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Maintenance Manual
EXTRA 500 Doc.- No. EA-0B702
Schwarze Heide 21
D - 46569 Hünxe
Tel.: + 49 28 58 / 91 37 - 0
Fax: + 49 28 58 / 91 37 - 30
Germany
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Maintenance Manual Extra 500
Log of Revision Issue
Date
Sign of approval
Date
1st Edition (Chapter 4 & 5 only)
31. March 2011
EASA Major Change Approval N° 10035367
17. June 2011
2nd Edition (Complete Manual except Chapter 4)
30. March 2012
The technical content of this document is approved under the authority of DOA N° EASA.21J.073
30. March 2012
Page Date: 30. March 2012
Page A
Maintenance Manual Extra 500
List of Effective Page A thru F............................... 30. March 2012
74-1 thru 4 ...........................30. March 2012
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Page C
Maintenance Manual Extra 500
List of Service Bulletins SB No.
Page D
Issue Date
Subject
Ser - No. German AD aff. (LTA)
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Maintenance Manual Extra 500
CONTENTS Title ....................................................................................................................................Page Log of Revisions ..................................................................................................................... A List of Effective Pages ........................................................................................................ B-C List of Service Bulletins ......................................................................................................... D
Group/Chapter Title....................................................................................................Chapter
GENERAL Introduction ........................................................................................................................... 01 How to Use the Service Manual ............................................................................................ 02
AIRCRAFT General Description ............................................................................................................... 03 Airworthiness Limitations ..................................................................................................... 04 Time Limits/Maintenance Checks ......................................................................................... 05 Dimensions and Areas ........................................................................................................... 06 Lifting and Shoring ................................................................................................................ 07 Leveling and Weighing ......................................................................................................... 08 Towing and Taxiing ............................................................................................................... 09 Parking, Mooring, Storage and Return to Service ................................................................. 10 Placards and Markings........................................................................................................... 11 Servicing ................................................................................................................................ 12 Standard Practices - Airframe ................................................................................................ 20
AIRFRAME SYSTEMS Air Conditioning .................................................................................................................... 21 Auto Flight ............................................................................................................................. 22 Communications .................................................................................................................... 23 Electrical Power ..................................................................................................................... 24 Equipment/Furnishings .......................................................................................................... 25 Flight Controls ....................................................................................................................... 27 Page Date: 30. March 2012
Page E
Maintenance Manual Extra 500
Group/Chapter Title.................................................................................................... Chapter Fuel ........................................................................................................................................ 28 Hydraulic Power .................................................................................................................... 29 Ice and Rain Protection.......................................................................................................... 30 Indication/Recording Systems ............................................................................................... 31 Landing Gear ......................................................................................................................... 32 Lights ..................................................................................................................................... 33 Navigation ............................................................................................................................. 34
STRUCTURES Standard Practices and Structures - General ......................................................................... 51 Doors...................................................................................................................................... 52 Stabilizers .............................................................................................................................. 55 Windows ................................................................................................................................ 56 Wings..................................................................................................................................... 57
PROPELLER Propeller ................................................................................................................................ 61
POWER PLANT Power Plant............................................................................................................................ 71 Engine Fuel and Control........................................................................................................ 73 Ignition................................................................................................................................... 74 Engine Controls ..................................................................................................................... 76 Engine Indicating................................................................................................................... 77 Exhaust .................................................................................................................................. 78 Oil .......................................................................................................................................... 79 Starting................................................................................................................................... 80
MISCELLANEOUS Charts ..................................................................................................................................... 91
Page F
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Maintenance Manual EXTRA 500
Chapter 01 General
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Table of Contents
01-00-00
GENERAL ........................................................................................................ 3 Address ............................................................................................................... 3 Contact................................................................................................................ 3
01-00-01
Documents ......................................................................................................... 3 Aircraft: .............................................................................................................. 3 Equipment:.......................................................................................................... 3
01-00-02 Figure 01-1 Figure 01-2 Figure 01-3 Figure 01-4
Special Tools...................................................................................................... 4 Main Gear Bolt Extracting Tool......................................................................... 4 Flap Track Snap Gauge...................................................................................... 5 Front Wing Main Bolt Extracting Tool .............................................................. 6 Rear Wing Main Bolt Extracting Tool................................................................ 6
01-00-03
Trade Marks ..................................................................................................... 7
01-00-04
Safety.................................................................................................................. 7
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01
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01-00-00
GENERAL According to the regulations of the FAR/JAR part 23, this Maintenance Manual provides educated maintenance staff with information necessary for servicing, maintaining and repairing the EXTRA 500. This Manual contains a detailed description of systems including time limits for the particular components, troubleshooting and instructions for the performance of inspection and maintenance work. The instructions that are necessary for disassembly, check, repair, maintenance or overhaul of vendor equipment are not incorporated in this manual.
Address EXTRA Flugzeugproduktions- und Vertriebs- GmbH Schwarze Heide 21 46569 Hünxe Germany
Contact Email: [email protected] Phone: +49 2858-9137-0 Fax: +49 2858-9137-30
01-00-01
Documents Use the following documents in connection with this Maintenance Manual:
Aircraft: 1 EXTRA 500 Pilot’s Operating Handbook and Airplane Flight Manual, Doc. No.: EA-0B701 most current revision 2 Service Bulletins 3 Aircraft Record 4 Airplane Log Book and Engine Log Book Note
Check the Airplane Log Book documents are up-to-date and in accordance with current applicable aviation authority regulations. Since the regulations may require different documents and data, owner of exported airplanes should check with their own aviation officials to determine their individual requirements.
Equipment: Applicable Instructions of Continuous Airworthiness for equipment installed. Refer to the List of Applicable Publications (LOAP), Doc. No.: EA-0B710.00 most current revision, provided by EXTRA. Page Date: 30. March 2012
01
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01-00-02
Special Tools Generally, for maintenance tasks no special tools are necessary. However, there are a few exceptions as listed below. These items are available at EXTRA. Alternatively, they can be crafted per instruction of Figures 01-1 through 01-4, using standard shop practices. Description
Extra Part No.
Subject
Chapter
Main gear bolt extracting tool
n/a
Main gear strut removal
32-10-10
Flap track snap gauge EA – 15182W10
Flap guidance check
27-50
Front wing main bolt extracting tool
EA – 15001.1W
Wing removal
57-10
Rear wing main bolt extracting tool
EA – 15001.2W
Wing removal
57-10
Stroke bushing
Threaded rod M 10
Figure 01-1
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01
Nut and counter nut
Main Gear Bolt Extracting Tool
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Maintenance Manual EXTRA 500
Figure 01-2
Flap Track Snap Gauge
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Maintenance Manual EXTRA 500
Figure 01-3
Front Wing Main Bolt Extracting Tool
Figure 01-4
Rear Wing Main Bolt Extracting Tool
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01
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01-00-03
Trade Marks Even when the ware or brand names used in this manual are not marked as registered trade-marks, this does not mean, that these names are free in the sense of trademark legislation.
01-00-04
Safety To keep the security risks during the execution of the inspection and maintenance work as low as possible, observe the following points: 1 Inspection and maintenance work has to be carried out only by qualified and authorized personnel. 2 The execution has to be in accordance with the respective national safety requirements. 3 Before beginning any work, this service manual has to be read and understood. In case of doubt or lack of information the manufacturer has to be contacted for advice. 4 The safety notes given in this manual are to be observed unconditionally. Refer to Chapter 02 for information concerning safety notes.
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Maintenance Manual EXTRA 500
Chapter 02 How to Use the Maintenance Manual
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Table of Contents
02-00-00
GENERAL ........................................................................................................ 3
02-10-00
MANUAL DESCRIPTION ............................................................................. 4
02-10-01
Manual Set-Up .................................................................................................. 4
02-10-02
Chapter Set-Up ................................................................................................. 4
02-10-03
Page Numbering ............................................................................................... 4
02-10-04
Figure Numbering ............................................................................................ 4
02-10-05
Layout ................................................................................................................ 5
02-10-06
Notes/Safety Notes ............................................................................................ 5
02-20-00
HANDLING ...................................................................................................... 6
02-20-01
Revisions ............................................................................................................ 6
02-20-02
Service Bulletin ................................................................................................. 6
02-20-03
Checklists........................................................................................................... 7
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02
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02-00-00
GENERAL The set-up of the manual, the chapters and the handling correspond to the regulations of the Air Transport Association of America, ATA Specification No. 100. However, the numbering of the pages and the layout have been changed to make working with this manual easier.
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02-10-00
MANUAL DESCRIPTION
02-10-01
Manual Set-Up The manual consists of groups, which are subdivided in chapters. Additionally there are preceding pages, which contain the List of Effective Pages, the Lists of Service Bulletins and the Record of Revisions. In the list of chapters the groups are marked by capital characters.
02-10-02
Chapter Set-Up The chapter numbering system used in this manual represents the chapter setup. It is a conventional dash-number breakdown. The number is composed of three elements which consist of two digits each:
02-10-02 chapter - section - subject The first element shows the chapter (here: "How to Use the Service Manual"). The second element shows the first subdivision, which is called "section" (here: "MANUAL DESCRIPTION"). The third element shows the "subject", which is handled within the respective section (here: "Chapter Set-Up"). The first three digits refer to the definitions of the ATA Specification 100, where they exist; the other digits are defined by the manufacturer. If a more detailed breakdown is necessary, bold faced headlines like the following are used: Powerplant When headlines are referenced in the text they are presented in italic letters. E.g.: see Powerplant paragraph.
02-10-03
Page Numbering The page numbering begins at the coversheet of each chapter with "Page 1". In contrast to the ATA Specification 100, the particular sections and subjects don't start with a new numbering.
02-10-04
Figure Numbering The figures are numbered in such a way that the first figure in each chapter starts at "Figure XX-1".
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02
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02-10-05
Layout Apart from the headers and footers the layout consists of two columns. The right column contains text, titles, tables, schedules and figures (figures also can fill the whole page); the left column contains the chapter numbering, boxed textmarkers for notes and safety notes as well as explanations.
02-10-06
Notes/Safety Notes Safety notes in this manual are marked by a boxed textmarker in the margin column and written in semi-bold characters. This manual distinguishes three warning levels:
DANGER
Represents any threatening danger for the personnel. The non-observation of this safety note will result in death or serious injuries.
Represents a possibly dangerous situation for the personnel. The nonWARNING observation of this safety note may result in injuries. CAUTION
Represents a danger to equipment. The non-observation of this safety note results in destruction of equipment. This safety note does not exclude a possible danger for the personnel. Additional information given in this manual are also marked by boxed textmarkers in the left column and are written in semi-bold characters:
IMPORTANT NOTE
Represents an important hint. Often used when the non-observation could endanger pilot or passengers during flight. Represents a useful or remarkable hint.
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02-20-00
HANDLING
02-20-01
Revisions Maintenance Manuals and other technical publications in current revision status are available over the World Wide Web direct link: http://www.extraaircraft.com/techservice.php Cross-check your documents against these publications and replace pages as necessary. Paper copies of publications will continue to be available if this is your preferred format of publications. Orders can be placed by contacting EXTRA.
NOTE
Pages of this Manual may not be exchanged and no alterations of or additions to the approved contents may be made without the EXTRA approval. If revision of pages will be necessary, observe the following steps:
NOTE
Change revised pages immediately upon receipt. 1 Take out the old pages and destroy them. 2 Insert the new pages following the chapter and page numbers. 3 Replace the old pages "List of Effective Pages". 4 Enter the date on page "Record of Revision" and on page "2 = Record of Revision" of Ch 04 if necessary. Each revised page is marked at the bottom by the date of revision; revised parts of the new page are marked by a bar on the left margin.
02-20-02
Service Bulletin The Service Bulletins describe which procedures and how and when they are to be carried out. Enter the receipt of each Service Bulletin in the Service Bulletin List.
NOTE
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02
The owner is responsible for incorporating Service Bulletins to the above mentioned Service Bulletins List.
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02-20-03
Checklists Observe the following steps when working with checklists: 1 Copy the respective check list for performing a check.
X1
50 hours
100 hours
1000 hours
as specified
2 Enter the date at the top of the table. Date:
Inspector
Serial No.:
Mechanic
X
X
X
Text
Description Text
3 Select the items to be worked out. The "X" at the beginning of the line is written in the column which indicates the point of time when an item has to be worked out. Specification for the first column is given by footnotes. 4 Work out the particular items and sign after execution (responsible mechanic and inspector) using the respective boxes behind the item. 5 After completion of the inspection check file the list with entries in the Aircraft Records. 6 Certify the completion of the check in the Aircraft Log Book.
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Chapter 03 General Description
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Table of Contents 03-00-00
Page 2
03
GENERAL ........................................................................................................ 3
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03-00-00
GENERAL
The EXTRA 500 is designed as a six-place, single engine, high-wing, full composite airplane. The fuselage consists of a skin with integrated longerons and frames. The wing uses a double front spar and a rear spar interconnected by ribs. The stabilizers use a front and a rear spar. In general the skins of fuselage, wing, stabilizers and control surfaces consist of carbon fiber facings and honeycomb. The supporting structures such as longerons, frames, spars and ribs consist of carbon fiber with foam core. Only the D-section of the wing consists of glass fiber with honey comb and glass fiber ribs. The EXTRA 500 has a hydraulically operated retractable tricycle landing gear with a controllable nose wheel.
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Chapter 04 Airworthiness Limitations
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Record of Revisions Chapter 04 Rev. No.
Date of Revision
Revised Pages
Description of Revision
—
4. June 2004
—
First edition
—
31. March 2011
—
Second edition
Page 2
04
EASA Approval Date and Sign of Approval
N° 10035367 17. June 2011
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Maintenance Manual Extra 500 Airworthiness Limitations
Table of Contents
04-00-00
GENERAL .........................................................................................................4
04-00-01
Temperature Limit............................................................................................4
04-00-02
Operating Time .................................................................................................4
04-10-00
LIFE LIMITED COMPONENTS ...................................................................5
04-10-01
General ...............................................................................................................5
04-10-02
Replacement Time.............................................................................................5
04-10-03
Service Life Limited Components ...................................................................5
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GENERAL For each inspection listed here, refer to the applicable chapter in this manual.
IMPORTANT
It is the operator's responsibility to make sure that time limits or life limits for items in this chapter are not exceeded. The airworthiness limitations items include mandatory replacement times and structural inspection intervals which may only be changed with permission of the applicable airworthiness authority. The Airworthiness Limitation section is FAA approved and specifies maintenance required under paragraphs 43.16 and 91.403 of the Federal Aviation Regulations, unless an alternative program has been FAA approved. *) *)
Legible statement pertaining to non US registered airplanes: The Airworthiness Limitation section is approved by the regulatory authority and specifies maintenance required under paragraphs 43.16 and 91.403 of the Federal Aviation Regulations, unless an alternative program has been approved by the regulatory authority.
04-00-01
Temperature Limit The composite material used to manufacture the Extra EA 400-500 is qualified for service temperatures up to 72° C (162° F) under load. As such, any surface repainting or surface repair paint finish must be accomplished with white color paint only. Contact manufacturer directly for approved paint brands and formulas.
04-00-02
Operating Time Only the airframe and components as listed in Chapter 04-10-00 are subject to a permissible operating time; concerning all other components recommended replacement times are given in Chapter 05.
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Maintenance Manual Extra 500 Airworthiness Limitations
04-10-00
LIFE LIMITED COMPONENTS
04-10-01
General The replacement time of the life limited components listed in Chapter 04-10-02 must be accomplished not later than the specified period of operation for that component or in accordance with the manufacturer's service data or airworthiness directives.
04-10-02
Replacement Time Items shown here must be replaced during the regular maintenance periods. Item
04-10-03
Replace after
Fuselage
20,000 h
Wing
20,000 h
Wing Flap
20,000 h
Aileron
20,000 h
Vertical Stabilizer
20,000 h
Rudder
20,000 h
Horizontal Stabilizer
20,000 h
Elevator
20,000 h
Service Life Limited Components The service lives of the EA 400-500 composite structure components as listed in Section 04-10-02 have been demonstrated up to 20,000 flight hours, up to 30,000 take-off and landing operations.
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Chapter 05 Time Limits/Maintenance Checks
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Table of Contents
05-00-00
GENERAL ........................................................................................................ 5
05-00-01
Chapter Configuration..................................................................................... 5
05-00-02
Words with Special Meanings ......................................................................... 6
05-10-00
TIME LIMITS .................................................................................................. 7
05-10-01
General .............................................................................................................. 7
05-10-02
Certification Authorities .................................................................................. 7
05-10-03
Scheduled Maintenance Time Limits ............................................................. 7
05-10-04
Component Time Limits .................................................................................. 8 Time Between Overhaul ..................................................................................... 8 Time Between Replacement ............................................................................... 8 Time Between Inspection ................................................................................... 9
05-20-00
SCHEDULED MAINTENANCE CHECKS................................................ 10
05-20-01
General ............................................................................................................ 10
05-20-02
Maintenance Checks Schedule ...................................................................... 10
05-20-03
Scheduled Maintenance Charts..................................................................... 11 Operational Checks........................................................................................... 11 Miscellaneous ................................................................................................... 13 Fuel System ...................................................................................................... 14 Oil System ........................................................................................................ 15 Bleed Air System.............................................................................................. 16 Air Inlet and Exhaust System ........................................................................... 17 Engine and Accessories .................................................................................... 18 Propeller and Governors ................................................................................... 19 Cabin and Equipment ....................................................................................... 20 Fuselage ............................................................................................................ 23 Wing Assembly ................................................................................................ 24 Control Systems and Surfaces .......................................................................... 26 Landing Gear .................................................................................................... 28 Wheels and Brakes ........................................................................................... 32 Completion ....................................................................................................... 34
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05-30-00
FLIGHTLINE INSPECTIONS .....................................................................35
05-30-01
General .............................................................................................................35
05-30-02
Pre - Flight Check ...........................................................................................35
05-30-03
Post - Flight Check ..........................................................................................35
05-50-00
UNSCHEDULED MAINTENANCE CHECKS...........................................36
05-50-01
General .............................................................................................................36
05-50-02
50 Hours – Inspection of Engine ....................................................................36
05-50-03
Hard Landing ..................................................................................................36
05-50-04
Engine Fire.......................................................................................................37
05-50-05
Propeller Strike, Sudden Stoppage and Violent Engine Stoppage ............37
05-50-06
Lightning Strike ..............................................................................................37
05-50-07
Engine Overspeed............................................................................................38
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05-00-00
GENERAL This chapter is a guide. It will help you to perform the maintenance correctly. You must perform the scheduled maintenance checks given in this chapter at the recommended time. These checks are minimum requirements for keeping the aircraft in a good technical condition. The aircraft manufacturer can change the time between maintenance actions and scheduled checks. If this happens, the aircraft manufacturer will supply the data by Service Bulletins or Service Letters. You can shorten the time between scheduled maintenance checks if the aircraft operation makes it necessary. You must not extend the time between scheduled maintenance checks without the aircraft manufacturer’s approval. The aircraft manufacturer must give approval to any change to the aircraft or to the maintenance checks schedule.
05-00-01
Chapter Configuration Section 05-10-00 contains the time limits for maintenance actions and checks. It also contains the time limits for components. Use the data in section 05-1000 to find out when to perform maintenance actions and checks. Section 05-20-00 contains the scheduled maintenance checks to be performed on different time intervals. It also contains data for the annual inspection if required due to national regulations. Section 05-30-00 contains data for flight line checks. Do a pre-flight check before each flight. And do a post-flight check after each flight. Section 05-40-00 is reserved. Section 05-50-00 contains the unscheduled maintenance checks. Do these checks after heavy landings, engine fire and propeller damage, or if the aircraft has been operated outside the flight envelope.
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05-00-02
Words with Special Meanings In this Maintenance Manual, the words that follow have special meanings :
Adjust To put to a specified position or condition. For example, adjust the clearance to 1 mm. Check A technical name for a group of maintenance tasks. For example, the 100 hour check. Examine To look carefully at an item. It includes steps such as these: Make sure that the item: 1 Is complete. 2 Is correctly attached. 3 Has no loose parts. 4 Shows no signs of leaks. 5 Is not cracked or damaged. 6 Is not worn. Make sure that: 1 The surface protection is not damaged. 2 All locking devices are installed correctly. Make sure that items such as pipes and cables (see also Chapter 20-10-09): 1 Look serviceable. 2 Do not rub against other items (chafing marks). Inspection The procedure, which compares an object with its standard or specification. Measure To find out the dimensions, capacity or quantity of something. Monitor To look at something during a time. For example, monitor the engine speed indicator. Record Technical name for something that shows what was done. For example, write the result of the test in the engine record. Replace To remove an unserviceable item and install a serviceable item in the same location. Set To put equipment into a given adjustment, condition or mode. For example, set the altimeter scale to 1013 mbar. Task An assigned work or procedure. For example, each step of the task has an identification letter. Test That what you do when you operate or examine an item to make sure that it agrees with the applicable specifications. For example, disconnect the systems, which are not necessary for the test.
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05-10-00
TIME LIMITS
05-10-01
General Various equipment and components of the aircraft (e.g. engine, propeller) are only cleared for a certain time of operation. After the permissible time of operation has expired they have to be replaced or overhauled (TBO - Time Between Overhaul). The respective TBO intervals are listed in the aircraft record sheets. For monitoring the permissible time of operation, this time should also be entered into the aircraft records when removing and installing such a part including full part and serial numbers.
05-10-02
Certification Authorities The time limits given in this chapter are recommended by the manufacturer. These time limits may be superseded by the regulatory authority.
05-10-03
Scheduled Maintenance Time Limits The following components listed in Chapter 05-14-00 have to be overhauled, replaced or inspected periodically, i.e. within fixed calendar periods or after appearance of a certain amount of flight hours. Do scheduled maintenance at these times: Scheduled Maintenance
Do at these times
100 hours check
At 100 FH. Or 100 hours after the last 100 hours or larger check. Tolerance +/- 10 hours.
1000 hours check
At 1000 FH. Or 100 hours after the last 100 hours or larger check. Tolerance +/- 10 hours.
In addition scheduled engine maintenance according to Rolls Royce 250-B17F Series Operation and Maintenance Manual (LOAP 1) has to be performed at the time intervals given there.
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Component Time Limits Time Between Overhaul These components have a TBO - Time Between Overhaul: Components
Time Between Overhaul
Turboprop Engine Rolls Royce 250-B17F/2.
Refer to the latest Rolls Royce 250-B17F Series Operation and Maintenance Manual (LOAP 1)
Engine accessories.
Refer to the latest Rolls Royce 250-B17F Series Operation and Maintenance Manual (LOAP 1)
Propeller Governors
Refer to the latest Rolls Royce 250-B17F Series Operation and Maintenance Manual (LOAP 1)
Aircraft Parts Corps 200SGL Starter Generator
Every 1000 hours.
BC410 Stand-by Alternator system
Every 1700 hours
Passenger seat belt webbing.
After 12 years.
MT-Propeller MTV-5-1-D-C-F-R(A) CFR210-56.
Refer to the latest MT-Propeller Service Bulletin (LOAP 5).
Time Between Replacement Replace these components at the times shown:
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Components Purolator Facet Scavenge lube oil filter Pierburg Motive flow fuel pump
Time Between Replacement 200 hours or 6 months which ever comes first 2000 hours
Integral Hydraulic Hydraulic accumulator
10 years
Rubber type hoses wing fuel tank pick up to fuselage connection and within wing fuel tank of SN 1002 and 1003
First 7, then 5 years.
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Maintenance Manual Extra 500 Time Limits and Maintenance Checks
Components
Time Between Replacement
Batteries of Emergency Locator Transmitter (ELT).
Every 2 years during shelf or service life, or after 1 hour of cumulative use (e.g. testing), or after operation in an emergency situation, or before battery replacement date. Battery replacement date is marked on the battery pack and the label at the end of transmitter. For battery replacement see ARTEX Description, Operation, Installation and Maintenance Manual for the ME406 ELT (LOAP 30)
Batteries of emergency torch.
Annually or after each use.
Time Between Inspection Inspect these equipment items at the times shown: Components
Time Between Inspection
Battery
Refer to CONCORDE Component Maintenance Manual (LOAP 27)
Static pressure system.
Every 2 years in accordance with 14 CFR Ch. 1 Part 43 App. E. Every 12 months in accordance with 14 CFR Ch. 1 Part 43 Apps. F Par. C and F.
ATC transponder.
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Maintenance Manual Extra 500 Time Limits and Maintenance Checks
05-20-00
SCHEDULED MAINTENANCE CHECKS
05-20-01
General Regular inspections must be carried out every 100 or 1000 operating hours. Annual inspections (ANI) must be performed according to the national requirements.
NOTE
The scope of an Annual Inspection and a 100 hour inspection is the same. However, the manufacturer may recommend to perform additional checks in the course of an Annual Inspection. If applicable, these checks are identified in the Maintenance Check Schedule with the abbreviation "ANI". All inspections must be executed by a designated representative of the Aviation Authority of the country in which the aircraft is registered.
05-20-02
Maintenance Checks Schedule The maintenance and control work given in the following tables has to be carried out within the given time intervals. The proper execution of the checks and maintenance actions has to be certified in the maintenance records and log books. Faults as well as their repairs have to be entered in an inspection report filed together with the check list in the aircraft records.
Page 10
05
Page Date: 30. March 2012
Maintenance Manual Extra 500 Time Limits and Maintenance Checks
05-20-03
Scheduled Maintenance Charts The maintenance checks described in this section include all the scheduled checks, which must be performed. Maintenance checks must be accomplished in accordance with CFR 14 P 43 App. D. Use the following schedule and the lubrication charts presented in Chapter 1220-04. Prior to inspection, the aircraft and engine should be thoroughly cleaned, all inspection panels, access doors or fairings should be removed.
Serial No.: Description:
Inspector
Date:
Mechanic
1000
Flight Hours
100
as specified
Operational Checks
05
Page 11
Rotating propeller can cause death or injuries! WARNING Do not allow anyone to stay in the propeller area. Perform an inspection operational run-up. Refer to the latest Rolls Royce 250-B17F Series Operation and Maintenance Manual (LOAP 1). Record and verify the engine operating parameters.
X
X
X
X
Start engine (in accordance with the EXTRA 500 Pilot's Operating Handbook).
X
X
Check the parking brake and toe brakes.
X
X
Check the fuel flow, fuel pressure and fuel quantity indication.
X
X
Check the function of fuel pumps by monitoring fuel pressure indication when running a single pump.
X
X
Check fuel selector valve for proper operation and pointer indication.
X
X
Check the oil pressure and oil temperature.
X
X
Check the generator output.
X
X
Check the stand-by alternator output with generator off. Then generator on.
X
X
Check the cabin pressurizing operation.
X
X
Check the air condition operation.
X
X
Check the de-ice system operation.
X
X
Check the windshield heater operation.
X
X
Check flight idle speed (N1: 65%).
X
X
Check response of the engine by power setting changes.
Page Date: 30. March 2012
Serial No.:
X
X
Check the propeller overspeed governor at 1800 RPM (N2 RPM) by pressing ENGINE OVSPD TEST button switch. Monitor RPM drop. After release of the ENGINE OVSPD TEST button switch Prop RPM should return to the above setting. Then return to idle.
X
X
Check temperature regulation. Actuate WARM/COOL switch in manual mode and check response. Return to automatic mode.
X
X
Check the annunciator light panel.
X
X
Check the radio and the other electronic equipment.
Description:
Inspector
Mechanic
Date:
1000
Flight Hours
100
as specified
Maintenance Manual Extra 500 Time Limits and Maintenance Checks
Function test of flaps only with upper door closed. CAUTION
Page 12
X
X
Check operation of controls and flaps.
X
X
Shut down engine. Condition lever at cut-off position. Check immediate PNEUMATIC LOW annunciation and interruption of cabin heat air flow. (bleed air distribution valves function check)
X
X
Check gyros for noise and roughness.
X
X
Change power lever position and check illumination of LOW PITCH annunciator light.
X
X
Check the generator/alternator warning light or ammeter.
X
X
BATT switch OFF.
05
T
Page Date: 30. March 2012
Maintenance Manual Extra 500 Time Limits and Maintenance Checks
X
Clean and inspect the cowling intakes and outlets for damage, cracks, distortion and overheat areas.
X
Inspect engine mount for cracks, corrosion, looseness of mountings and overheated areas. Inspect engine shock mount isolators for deterioration, improper assembly and insecurity. Replace as required.
X
X
Inspect engine controls for security, defects, improper travel and improper safetying. Lubricate as per Chapter 12-20-04 Lubrication Chart.
X
X
Inspect engine bonding for improper installation and poor condition.
X
X
Inspect firewall and seals for improper condition, insecurity and improper fire resistant sealing.
X
X
Inspect battery and attachment for corrosion, etching, poor condition and insecurity. (Charge battery if required.)
X
X
Inspect battery ventilation hose and attachment for chafing, leakage, poor condition and insecurity.
Inspector
X
Description:
Mechanic
Serial No.:
X
05
Page 13
Perform battery capacity test according to CONCORDE Component Maintenance Manual (LOAP 27)
1
X
X
Inspect external power supply receptacle, battery relay and fuses for cleanliness, corrosion, poor condition and insecurity.
X
X
Inspect electrical leads, lines, ceramics and attaching for chafing, deterioration, improper routing, wear, insecure installation and obvious defects.
DANGER
X
1
Date:
1000
Flight Hours
100
as specified
Miscellaneous
Nose gear and main gear extends and retracts under high pressure. Operation of the landing gear can cause death or injuries in its working area! Before beginning any work in the landing gear working area, pull OFF the GEAR CTRL circuit breaker located on the left side panel. Inspect nose wheel box for cracks, poor general condition and improper fire resistant sealing.
Refer to CONCORDE Component Maintenance Manual (LOAP 27)
Page Date: 30. March 2012
Maintenance Manual Extra 500 Time Limits and Maintenance Checks
Serial No.:
X
X
Inspect lines, hoses and clamps for leaks, improper condition and looseness.
X
X
Inspect fuel pumps for leaks, poor general condition, insecure attachment.
X
X
Inspect fuel collector block and check valves for leaks, improper condition, insecurity and insecure attachment.
X
X
Inspect fuel filter for leaks, improper condition, insecurity and insecure attachment.
X
X
Check function of red fuel filter bypass button (monitor annunciator panel).
Description:
Inspector
Mechanic
Date:
1000
Flight Hours
100
as specified
Fuel System
Check function of fuel selector valve. Ensure both wing tanks contain fuel. Place suitable container below fuel drain. Open fuel drain. Select various positions of fuel selector valve and monitor fuel flow. Close fuel drain
1
2
Change fuel filter element and O-rings.
1
Together with engine fuel maintenance. Refer to latest Rolls Royce 250-B17F Series Operation and Maintenance Manual (LOAP 1).
2
See prior footnote
Page 14
05
Page Date: 30. March 2012
Maintenance Manual Extra 500 Time Limits and Maintenance Checks
Serial No.: Description:
Inspector
Date:
Mechanic
1000
Flight Hours
100
as specified
Oil System
05
Page 15
Drain engine oil system. Refer to Rolls Royce 250-B17F Series Operation and Maintenance Manual (LOAP 1). To completely drain the oil system, also disconnect the outgoing oil line at the bottom of the oil tank.
1
X
X
Inspect oil tank for insecurity of attachment, leaks and cracks.
X
X
Inspect oil system lines, hoses, fittings and clamps for leaks, chafing, improper condition and looseness.
X
X
Clean and inspect oil cooler and fins for leaks, deterioration, distortion, insecure attachment, loose or missing fasteners and other evidence of failure.
X
X
Inspect temperature regulator for leaks, insecurity of attachment and poor condition.
X
X
Inspect oil tank vent valves for insecurity of attachment and poor condition.
1
together witch engine lubrication system maintenance Refer to Rolls Royce 250-B17F Series Operation and Maintenance Manual (LOAP 1)
Page Date: 30. March 2012
Maintenance Manual Extra 500 Time Limits and Maintenance Checks
Page 16
Serial No.: Description:
X
X
Inspect bleed air lines, hoses, fittings and clamps for leaks, chafing, improper condition and looseness. Use clean filtered compressed shop air with a pressure not exceeding 10 PSI.
X
X
Inspect valves for insecurity of mounting, poor condition and improper electrical connections.
X
X
Inspect ejectors for insecurity of mounting, leaks and poor condition.
X
X
Inspect pressure switch for insecurity of mounting, poor condition and improper electrical connections.
X
X
Inspect air flow sensor for insecurity of mounting and improper electrical connection.
X
X
Inspect acoustical muffler for insecurity of mounting, leaks and poor condition.
X
Perform temperature switch function test (Refer to Chapter 2160-01).
05
Inspector
Date:
Mechanic
1000
Flight Hours
100
as specified
Bleed Air System
Page Date: 30. March 2012
Maintenance Manual Extra 500 Time Limits and Maintenance Checks
X
X
Inspect air inlet and inlet heat ducts for leaks, cracks and poor condition.
X
Check mechanic and electric (annunciation) function of inlet heat. Lubricate as per Chapter 12-20-04 Lubrication Chart. Check function of engine internal solenoid valve (“click” when switched).
X
Inspect the exhaust pipes for burned areas, cracks, leakage, deterioration, loose and missing brackets, clamps and hardware.
X
Inspect induction and exhaust components for worn or damaged areas, loose clamps, cracks and leaks.
X
X
Description:
Page Date: 30. March 2012
Inspector
Serial No.:
Mechanic
Date:
1000
Flight Hours
100
as specified
Air Inlet and Exhaust System
05
Page 17
Maintenance Manual Extra 500 Time Limits and Maintenance Checks
Serial No.: Description: Perform complete engine inspection according to the latest edition of Rolls Royce 250-B17F Series Operation and Maintenance Manual (LOAP 1).
1
2
Complete overhaul of engine or parts X
X
Inspect oil temperature sensor unit for leaks and insecurity.
X
X
Inspect all wiring, fluid lines, hoses and electrical connections for improper routing, improper support and evidence of deterioration. Replace damaged wires, hoses, lines and clamps if required.
X
X
Visually inspect accessory to engine attaching hardware for insecurity. Visually inspect airframe to engine connections for insecurity and corrosion.
X
X
Inspect all accessories for poor condition, insecurity of mounting and improper operation. Refer to component manufacturer's Maintenance Manual.
X
Inspect and test the starter generator. Remove starter generator. Check brush length and condition. Clean brushes by clean filtered compressed shop air. Refer to the applicable starter generator manufacturer's instructions. Reinstall starter generator and ventilation. Inspect ventilation hose and attachment for leaks, chafing, looseness and poor condition.
X
X
Inspect and test the stand-by alternator. Check alternator externally for security of mounting and wiring. Refer to the applicable alternator manufacturer's instructions.
X
X
Inspect firewall mounted equipment for insecurity of mounting, improper electrical connections and poor general condition.
X
X
Inspect bleed air and pneumatic hoses and tubing for deterioration, chafing, wear and insecurity.
X
1
refer to Rolls Royce 250-B17F Series Operation and Maintenance Manual (LOAP 1)
2
see prior footnote
Page 18
Inspector
Date:
Mechanic
1000
Flight Hours
100
as specified
Engine and Accessories
05
Page Date: 30. March 2012
Maintenance Manual Extra 500 Time Limits and Maintenance Checks
X
X
1
2
Serial No.: Description:
Inspector
Date:
Mechanic
1000
Flight Hours
100
as specified
Propeller and Governors
Perform propeller check according to the latest edition of MTPropeller Operation and Installation Manual E-610 (LOAP 3) and Service Bulletin No 1 (LOAP 5). Perform propeller-power turbine governor functional feather check according to the latest edition of Rolls Royce 250-B17F Series Operation and Maintenance Manual (LOAP 1) Perform propeller overspeed governor functional check according to the latest edition of Rolls Royce 250-B17F Series Operation and Maintenance Manual (LOAP 1)
1
together with engine maintenance. Refer to Rolls Royce 250-B17F Series Operation and Maintenance Manual (LOAP 1). 2
see prior footnote
Page Date: 30. March 2012
05
Page 19
Maintenance Manual Extra 500 Time Limits and Maintenance Checks
X
X
Description:
Inspector
Serial No.: Remove inspection covers, door covering and panels (seats and carpet must be removed for access to inspection covers on the cabin floor). Inspect cabin and cockpit for uncleanliness and loose equipment that might foul the controls.
X X
X
Inspect cabin entrance door and emergency exit for improper rigging. Check retainer pins and striking parts for bending, cracks, improper engagement, pulled or sheared fasteners.
X
X
Inspect cabin entrance door and emergency exit door seals for folding and damage.
X
X
Check the door hinges for cracks and sideplay.
X
X
Check the door locking bolts for wear and improper adjustment.
X
X
Check the door locking fittings for wear.
X
X
Examine the door connecting rod geometry for cracks, bending and loose parts.
X
X
Check the door locking mechanism for improper operation.
X
Perform a teardown inspection of the central door operating device.
X
X
Perform a door pressure test. Inspect the sealing surfaces for leakage 1 .
X
X
Lubricate doors as per Chapter 12-20-04 Lubrication Chart.
X
X
Inspect crew seats for improper horizontal and vertical operation and insecure locking function.
CAUTION
1
Date:
Mechanic
1000
Flight Hours
100
as specified
Cabin and Equipment
Check crew seats for improper engagement of pins to seat track with occupied crew seat at the lowest vertical position.
X
X
Inspect seats and upholstery for tears and poor condition.
X
X
Inspect seat belts for insecurity of attachment and improper operation.
X
X
Inspect seat belts as per SCHROTH Abbreviated Component Maintenance Manuals for Restraint Systems Models 1-08-() (LOAP 32) and 5-02-() (LOAP 33)
For localizing leakage easily examine door seals for dust particles.
Page 20
05
Page Date: 30. March 2012
X
X
Inspect seats, seat belts, security brackets and bolts for poor condition and apparent defects.
X
X
Check operation of cabin and instrument lights.
X
X
Inspect instruments, lines, wiring and attachments for poor condition.
X
Inspect electric gyro instruments for poor condition, insecure mounting, marking and improper operation. Overhaul or replace as required. (Refer to the components manufacturer's instruction.)
X
Test pressure regulator setting and pressure switch setting.
X
X
Inspect avionics and radio equipment for poor condition, improper installation and insecure mounting.
X
X
Check electric trim operation and rigging.
X
X
Check operation of rudder pedals and toe brakes.
X
X
Check operation of parking brake.
X
X
Inspect control wheels, column and switches for poor condition.
X
X
Inspect cables, pulleys and connections for poor condition and insecurity.
X
X
Check operation of strobe, landing, navigation lights.
X
X
Check pitot/static air pressure operation.
X
X
Inspect pitot/static hoses, lines for poor condition and insecurity.
X
X
Inspect altimeter and ATC transponder for improper condition.
X
Description:
1
Check that altimeter and transponder comply with latest revision of 14 CFR Chapter 1 Part 43 Appendixes E and F.
2
Inspect compass and compass deviation card for improper indication and compensation.
3
Inspector
Serial No.:
Mechanic
Date:
1000
Flight Hours
100
as specified
Maintenance Manual Extra 500 Time Limits and Maintenance Checks
05
Page 21
Check magnetic compass compensation. X
X
Inspect all knobs, switches and levers and their mounting for insecurity of attachment and poor condition.
X
X
Inspect engine controls for improper installation and improper operation.
1
Every two years
2
Annually
3
Annually
Page Date: 30. March 2012
X
X
Inspect flight controls for improper installation and improper operation.
X
X
Check operation of fuel selector valve.
X
X
Check operation of cabin heat and defrost controls.
X
X
Inspect circuit breaker mounting and wiring for poor condition and insecurity.
X
X
Inspect environmental system ducts for poor condition.
X
X
Check cabin pressurization system and pressure controller operation.
X
X
Check electrical panel components for poor condition and insecurity.
X
X
Check forward side of outflow and safety valves for poor condition and insecurity. Remove and clean as shown in Chapter 21.
X
X
Inspect filters on control and safety valve for contamination. Clean or replace as required (see Chapter 21).
X
X
Inspect control cable boots for poor condition and insecurity.
X
X
Inspect air condition evaporators, drain valves and mounting for poor condition and insecurity.
X
X
Drain air condition evaporators.
X
X
Inspect portable fire extinguisher for improper service and poor condition. Check inspection date.
Description:
Inspector
Mechanic
Serial No.:
1
Change batteries of emergency torch. X
1
Date:
1000
Flight Hours
100
as specified
Maintenance Manual Extra 500 Time Limits and Maintenance Checks
X
Reinstall inspection covers and panels.
Annually or after each use.
Page 22
05
Page Date: 30. March 2012
Maintenance Manual Extra 500 Time Limits and Maintenance Checks
X
X
Remove access panels.
X
X
Inspect structure and exterior surfaces for deterioration, distortion, cracks, dents, other evidence of failure, uncleanliness and defective or insecure attachment of fittings.
X
X
Inspect windshield and windows for deterioration, nicks, scratches, cracks and crazing.
Description:
Inspector
Serial No.:
Mechanic
Date:
1000
Flight Hours
100
as specified
Fuselage
05
Page 23
Pressurized flight is prohibited with cracks and crazing. CAUTION X
X
Inspect electric windshield de-ice system for poor condition, insecurity and improper operation.
X
X
Inspect environmental system ducts for poor condition.
X
X
Inspect air condition compressor and mounting for poor condition and insecurity. Check condition and tension of compressor drive belt.
X
X
Inspect air condition hoses and clamps for poor condition, chafing and leaks.
X
X
Inspect air condition system wiring for fraying or cracks.
X
Inspect electrical leads, lines, radio antenna leads and attaching for chafing, deterioration, improper routing, wear, insecure installation and obvious defects.
X
X
Inspect antennas and coaxial cables for poor condition, insecure mounting and improper operation. (Refer to Figure23-01 in Chapter 23-60-00.)
X
X
Inspect ELT, trim servo and attachment for poor condition and insecurity.
X
X
X
Check ELT battery replacement date. (Refer to ARTEX Description, Operation, Installation and Maintenance Manual for the ME406 ELT (LOAP 30).)
X
X
Perform a cabin pressure test. Inspect the former joints for cracks and damage.
X
X
Reinstall access panels.
X
X
Inspect engine mounts for cracks.
Page Date: 30. March 2012
Maintenance Manual Extra 500 Time Limits and Maintenance Checks
X
X
Remove access panels from horizontal stabilizer and wing root avionics compartment.
X
X
Inspect wings for dents, cracks and delaminations.
X
X
Inspect wing ventilation holes for obstruction.
Description
Inspector
Mechanic
Serial No.:
Inspect wing spar main bolts and fittings for poor general condition, distortion, and insecurity of attachment.
1
Extract wing spar main bolts in sequence (refer to Chapter 5710-00). Inspect bolt shanks for cracks, wear, corrosion and insecurity. Install each bolt before extracting the next one.
2
3
Date:
1000
Flight Hours
100
as specified
Wing Assembly
X
X
Inspect inside wing structure in the area of access panels for deterioration, delamination, distortion and poor general condition.
X
X
Inspect wing tanks and lines for leaks, poor condition and evidence of fungus. If contamination with fungus is detected, contact the manufacturer.
X
X
Inspect tank bonding for improper installation and poor condition.
X
Drain wing fuel tanks.
X
Inspect fuel transmitter and electrical connectors for uncleanliness, poor condition and insecurity.
X
X
Clean motive flow filters.
X
X
Inspect motive flow pumps for insecurity of attachment and poor condition. Inspect electrical connectors for uncleanliness, poor condition and insecurity.
X
X
Inspect fuel transfer system lines for leaks and poor condition.
X
X
Inspect fuel filler caps and flapper valves for poor condition.
X
X
Inspect fuel tank breather and vent system for poor condition and insecurity. Function test of flaps only with upper door closed.
CAUTION
1
Annually
2
Every 5000 flight hours
3
Together with engine fuel system maintenance
Page 24
05
Page Date: 30. March 2012
X
X
Inspect landing flaps and attachment for dents, cracks, delaminations and improper operation.
X
X
Inspect flap ventilation holes for obstruction.
X
X
Inspect landing flaps gear drive, flap position transmitter and flap control switch for damage and improper operation.
X
X
Check and adjust flap guidance, flap actuation system, flap limit switches and flap asymmetry senders. Refer to Chapter 27-50-00.
X
X
Lubricate flap track mechanism as per Chapter 12-20-04 Lubrication Chart.
X
X
Inspect navigation lights, recognition lights, wingtip strobe lights for broken lenses, insecurity, improper wiring and operation.
X
X
Inspect electrical leads, radio antenna leads, pneumatic lines and attachment for improper routing, deterioration and incorrect installation.
X
X
Inspect pitot tubes and static pressure ports for poor condition, obstruction and damages. Inspect pitot and static heat for poor condition and improper operation.
X
X
Inspect pitot and static lines and attaching for improper routing, deterioration, poor condition and leaks. Drain pitot and static lines.
X
X
Inspect stall warning system for poor condition and insecurity of installation. Perform operational check including stall warn heat.
X
X
Inspect de-icer system (wing and control surfaces) for poor condition and improper operation.
Description
Inspector
Serial No.:
Mechanic
1
Date:
1000
1
Flight Hours
100
as specified
Maintenance Manual Extra 500 Time Limits and Maintenance Checks
05
Page 25
as specified in Chapter 12-20-04 Lubrication Chart
Page Date: 30. March 2012
Maintenance Manual Extra 500 Time Limits and Maintenance Checks
X
X
Remove access panels on horizontal stabilizer, tailcone, wing center fairing and wing root avionic bay.
X
X
Inspect control and stabilizer ventilation holes for obstruction.
X
X
Inspect stabilizer surfaces for dents, cracks, nicks and delaminations.
X
X
Inspect rudder for insecurity of attachment, free movement, dents, cracks and delaminations.
X
X
Inspect rudder hinges, attachment and bearings, stops, centering spring for cracks, excessive wear, insecurity and improper operation.
X
X
Inspect elevator surface for dents, cracks, nicks and delaminations.
X
X
Inspect elevator hinges, elevator trim tab hinges, attachment and bearing for poor condition, cracks, excessive wear, insecurity and improper operation.
Description
Inspector
Serial No.:
Inspect horizontal stabilizer main bolts for poor general condition, distortion and insecure attachment.
1
Extract horizontal stabilizer main bolts in sequence. Inspect bolt shanks for cracks, wear, corrosion and insecurity. Install each bolt before extracting the next one.
2
X
X
Check elevator trim system for improper operation and rigging.
X
X
Inspect elevator balance weight for looseness and poor condition.
X
X
Inspect aileron, rudder, elevator and elevator trim cable systems including turnbuckles, sleeves, fair leads, pulleys, cable retracting springs and push pull rods per FAA-AC1 43.13-1B for lack of safetying, damage and improper operation.
X
X
Check all cable tensions using a tensiometer.
X
Inspect rudder control torque tubes, bottom panel, shelf, linkage, control cable, sprocket wheel and interconnection for poor condition, distortion and insecurity. Inspect control cable connections for poor condition, chafing, distortion and insecurity.
X
1
Annually
2
Every 5000 flight hours
Page 26
Mechanic
Date:
1000
Flight Hours
100
as specified
Control Systems and Surfaces
05
Page Date: 30. March 2012
Description
Inspector
Serial No.:
05
Page 27
Examine control springs for mechanical damage, corrosion, and wear at the clevisses. Refer to Chapter 27-00-10.
1
Lubricate control system components as per Chapter 12-20-04 Lubrication Chart
X X
1
Date:
Mechanic
1000
Flight Hours
100
as specified
Maintenance Manual Extra 500 Time Limits and Maintenance Checks
X
Reinstall access panels.
Annually
Page Date: 30. March 2012
Maintenance Manual Extra 500 Time Limits and Maintenance Checks
DANGER
Serial No.: Description
Inspector
Date:
Mechanic
1000
Flight Hours
100
as specified
Landing Gear
Nose gear and main gear extends and retracts under high pressure. Operation of the landing gear can cause death or injuries in its working area ! Before beginning any work in the landing gear working area, pull OFF the electric circuit breaker located on the left side panel and marked GEAR CTRL. In case of intentional gear operation by switch or circuit breaker handling make sure, that neither a person nor material is in the landing gear working area.
NOTE
With the aircraft being airborne or jacked with retracted landing gear and battery switch OFF, the hot bus feeds an AUX circuit, which supplies the directional valves with electrical power to keep the landing gear in the up-position. The AUX circuit is protected by the GEAR AUX 1 (left side panel) and GEAR AUX 2 (E-box, engine compartment) circuit breakers. However, the nose gear and main gear will slowly extend due to valve oil leakage, if the hydraulic pump is not being activated temporarily to maintain hydraulic pressure. If retracted landing gear position is intended, turn BATT switch ON and push circuit breakers GEAR CTRL (left side panel) to the ON position, while the landing gear switch (left main panel) is in the UP position. If the aircraft is jacked with landing gear retracted and external power not connected, the battery will be discharged within approx. 2 days.
Page 28
X
X
Place the airplane on jacks.
X
X
Inspect the main gear struts for poor condition, cracks, bending, distortion and insecurity.
X
X
Inspect the main gear and nose gear shock absorber for oilleakage and scoring.
X
X
Check the main gear struts for maximum extension and overcentering of the radius struts.
X
X
Inspect the main gear bolts, bearings for lack of safety and poor condition, cracks, excessive wear and insecurity.
X
X
Clean and lubricate main gear bearings. Use AEROSHELL 22C spec. MIL-G-81322.
X
X
Inspect the web plate at the main landing gear frame for cracks.
X
X
Check the parallel strut and axle bar for vertical clearance.
X
X
Inspect all actuator brackets for cracks.
05
Page Date: 30. March 2012
X
Inspect main gear struts attachments for poor condition and insecurity.
X
X
Inspect track rods and attaching for poor condition, distortion and insecurity.
X
X
Inspect rear preloaded axle stop for poor condition.
X
X
Check the nitrogen inflation of the main gear-shock absorber (57 bar/827 psi ).
X
X
Inspect all wiring for poor condition, chafing and insecurity.
X
X
Inspect nose gear struts, trunnion pins and attachments for poor condition and insecurity.
X
X
Inspect the nose gear trunnion for poor condition, cracks and distortion.
X
X
Check the nose gear strut for maximum extension and overcenter of the radius strut.
X
X
Check the nitrogen inflation of the nose gear shock absorber (15 bar/218 psi ).
X
X
Inspect the nose wheel steering arm and its thrust bearing for poor condition and any damage.
X
X
Clean and lubricate nose gear bearings. Use AEROSHELL 22C spec. MIL-G-81322.
X
X
Inspect the fixing nose of the steering arm guide block for poor condition, cracks and bending.
X
X
Inspect the spring device assembly of the nose wheel steering and its attaching for looseness and any damage.
X
X
Inspect the nose wheel steering cables for wear and any damage.
X
X
Inspect shimmy damper and attaching for poor condition.
X
X
Inspect the gas springs of the nose gear strut and attaching for poor condition and insecurity. Perform Test Procedure as per Chapter 32-30-25.
X
X
Inspect all wiring for poor condition, chafing and insecurity.
Inspector
X
Description
Mechanic
Serial No.:
05
Page 29
Remove hydraulic sump. Clean filter and change hydraulic fluid (see Chapter 32-30-11).
1
X
1
Date:
1000
Flight Hours
100
as specified
Maintenance Manual Extra 500 Time Limits and Maintenance Checks
X
Inspect the hydraulic lines for leakage, poor condition, chafing, bulges and insecurity. Replace hoses and fittings as required.
Every 5 years.
Page Date: 30. March 2012
Serial No.:
X
X
Inspect the power pack and the distributor block for leakage, poor condition and insecurity.
X
X
Check the hydraulic fluid level of the hydraulic power pack (see Chapter 32-30-11) Refill as required.
X
X
Inspect the main and nose gear doors, door hinges and levers for cracks, distortion, insecurity and freedom of movement.
X
X
Inspect the main and nose gear door actuation mechanism for poor condition, deformation, excessive free play and excessive wear.
X
X
Inspect the hydraulic actuators and attachment for poor condition and insecurity.
X
X
Check the main gear-interlocking actuator for locking.
X
X
Loosen the door hinges. Fasten the door by means of tapes.
DANGER
Description
Inspector
Mechanic
Date:
1000
Flight Hours
100
as specified
Maintenance Manual Extra 500 Time Limits and Maintenance Checks
Nose gear and main gear extends and retracts under high pressure. Operation of the landing gear can cause death or injuries in its working area ! In case of intentional gear operation by switch or circuit breaker handling make sure, that neither a person nor material is located in the landing gear working area. Before beginning any work in the landing gear operating area, esp. any adjustment after performing test procedures, pull OFF the electric circuit breaker located on the left side panel and marked GEAR CTRL.
X
X
X
Lift the aircraft on jacks. Operate the landing gear (see Ch. 32-00-00 Operation). Inspect the hydraulic hoses and track rods for freedom of movement, chafing and distortion in extended and retracted position.
X
Perform gear up procedure (refer to Ch. 32-00-00 Operation). Inspect the main and nose gear door actuation mechanism for incorrect adjustment in the closed position. In case of doors closing with too much play or tension, adjust length of respective push rods (refer to Ch. 32-10-20/32-20-20). Perform test procedures in accordance with Ch. 32-00-00 and 32-30-25 Test Procedures.
1
1
X
X
Clean the position switches; inspect for poor operation, insecure seat and incorrect adjustment.
X
X
Inspect position switch wiring and harness for poor condition, chafing, any damage and insecurity.
Annually
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Page Date: 30. March 2012
X
X
Check the gear position lights on the panel for operation.
X
X
Reinstall the door hinges.
X
X
Clean and lubricate landing gear according to Chapter 12-2004 Lubrication Chart.
X
Replace all NMB M81935/1–6 rod ends (i.e. piston rod ends of the short main hydraulic cylinders as well as the track rod ends, refer to Figure 32-8 in Chapter 32-30-00).
Description
Page Date: 30. March 2012
Inspector
Serial No.:
Mechanic
Date:
1000
Flight Hours
100
as specified
Maintenance Manual Extra 500 Time Limits and Maintenance Checks
05
Page 31
Maintenance Manual Extra 500 Time Limits and Maintenance Checks
NOTE
Serial No.: Description
Inspector
Date:
Mechanic
1000
Flight Hours
100
as specified
Wheels and Brakes
Refer to on-aircraft inspections presented in the latest edition of Cleveland Technician’s Service Guide (LOAP 34) and Component Maintenance Manual (LOAP 35) for wheel, tire and break inspections.
DANGER
Nose gear and main gear extends and retracts under high pressure. Operation of the landing gear can cause death or injuries in its working area ! Before beginning any work in the landing gear working area, pull OFF the electric circuit breaker located on the left side panel and marked GEAR CTRL. In case of intentional gear operation by switch or circuit breaker handling make sure, that neither a person nor material is in the landing gear working area.
NOTE
With the aircraft being airborne or jacked with retracted landing gear and battery switch OFF, the hot bus feeds an AUX circuit, which supplies the directional valves with electrical power to keep the landing gear in the up-position. The AUX circuit is protected by the GEAR AUX 1 (left side panel) and GEAR AUX 2 (E-box, engine compartment) circuit breakers. However, the nose gear and main gear will slowly extend due to valve oil leakage, if the hydraulic pump is not being activated temporarily to maintain hydraulic pressure. If retracted landing gear position is intended, turn battery switch ON and push circuit breaker GEAR CTRL (left side panel) to the ON position, while the landing gear switch (left main panel) is in the UP position. If the aircraft is jacked with landing gear retracted and external power not connected, the battery will be discharged within approx. 2 days.
Page 32
X
X
Place the airplane on jacks.
X
X
Check the brake fluid level.
X
X
Inspect the brake assemblies for poor general condition.
X
X
Inspect the brakes and the master cylinder for leakage.
X
X
Inspect the brake lines and fittings for leakage and the hoses for bulges. Replace hoses as required.
X
X
Inspect the parking brake valve for poor condition and improper operation.
X
X
Inspect the brakes for corrosion, cracks and visible damage. Inspect inlet fitting bosses and anchor bolt lugs for cracks.
05
Page Date: 30. March 2012
Serial No.: Description
X
X
Inspect fit of brake cylinder anchor bolts in torque plate bushings for sloppiness. Excessive movement is cause for removal and detailed inspection.
X
X
Inspect the lining for wear ( min. thickness 2.54 mm/0.1 inch. ). Replace if required.
X
X
Lubricate the brake guide pins using silicone - base lubricant.
X
X
Inspect the wheels for corrosion, cracks, loosen or broken bolts and any damage.
X
X
Inspect the wheel nuts for improper installation and insecurity.
X
X
Check the wheel bearing clearance and wheels for free rotation.
X
X
Inspect the brake disc for rust, grooves, coning, cracks, wear and visible damage. Check disc thickness (min. 8.25 mm/0.325inch.). Replace if required. (Refer to Cleveland Technician’s Service Guide (LOAP 34) and Component Maintenance Manual (LOAP 35).
X
X
Inspect the brakes for improper adjustment.
X
X
Remove the wheels and wheel bearings. Inspect wheel bearings for excessive wear or damage. Replace on condition.
X
X
Inspect the snap rings for distortion and wear. Inspect grease for contamination and solidification.
X
X
Repack the bearings with AEROSHELL 22C (per MIL-G81322).
X
X
Visually inspect the tires for wear, cuts, flat spots, and tread or side wall damage. For tire changing refer to Cleveland Technician’s Service Guide (LOAP 34) and Component Maintenance Manual (LOAP 35).
X
X
Reinstall the wheels and safety.
X
X
Check tire inflation pressure. Main wheels 5.1 bar/74 psi ; nose wheel 3.5 bar/51 psi.
X
X
Inspect the wheels for improper alignment.
X
X
Lubricate as per Chapter 12-20-04 Lubrication Chart.
CAUTION X
X
Inspector
Date:
Mechanic
1000
Flight Hours
100
as specified
Maintenance Manual Extra 500 Time Limits and Maintenance Checks
Do not remove jacks before the landing gear is down and locked and the anti - retraction system has been checked. Operate the ON GROUND switch at nose gear strut. Check anti-retraction system by gear lever operation. Ensure that all gears are extended and locked.
CAUTION X
X
Remove the jacks.
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05
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Maintenance Manual Extra 500 Time Limits and Maintenance Checks
1
Serial No.:
1
X
X
Perform Flight Test.
1
X
X
Perform checks given for special equipment installed.
1
X
X
Reinstall upper and lower cowling, panels and doors as appropriate.
1
X
X
Aircraft conforms to specification of respective Authority.
1
X
X
All required Airworthiness Directives complied with.
1
X
X
All EXTRA mandatory Service Bulletins complied with.
1
X
X
All vendor Service Bulletins and Service Letters complied with.
1
X
X
Check for proper Flight Manual.
1
X
X
Aircraft papers in order.
Description
Inspector
Mechanic
Date:
1000
Flight Hours
100
as specified
Completion
As required.
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Maintenance Manual Extra 500 Time Limits and Maintenance Checks
05-30-00
FLIGHTLINE INSPECTIONS
05-30-01
General These checks include pre-flight and post-flight checks. When the aircraft is in operation, these checks have to be performed daily.
05-30-02
Pre - Flight Check This check must be carried out before the first flight of the day and serves as a guideline for the pilot to check the general condition of the aircraft and the engine. The pre-flight check is fundamental for the flight safety and has to be performed thoroughly in all details. The schedule for the pre-flight check is in the EXTRA 500 Pilot's Operating Handbook, Section 4.
05-30-03
Post - Flight Check This post-flight inspection has to be performed after the last flight of the day and consists of some visual checks. The post-flight inspection should include all steps of the pre-flight check. Additional measures: 1 Re-fuelling of the aircraft (refer to Chapter 12-10). 2 Reviewing of the entries in the log book for open discrepancies and correct entries of the landings and the flight hours. 3 If necessary, mooring of the aircraft (refer to Chapter 10-20).
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05
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Maintenance Manual Extra 500 Time Limits and Maintenance Checks
05-50-00
UNSCHEDULED MAINTENANCE CHECKS
05-50-01
General Unscheduled checks are exceptional and have to be performed only after abnormal events which are unusual at normal operating conditions and which could possibly have caused damage to the aircraft or impaired the airworthiness. The 50 hours - Inspection for new, repaired or overhold engines is categorized as an unscheduled check, since it has to be performed only once after the first 50 h of operation of the engine.
05-50-02
50 Hours – Inspection of Engine If a new, repaired or overhauled engine is installed, perform a 50 hours – inspection following the instructions of Rolls Royce 250-B17F Series Operation and Maintenance Manual (LOAP 1).
05-50-03
Hard Landing After an extremely hard landing or other unusual loads on the landing gear, a thorough check of the respective components and their attachment points is necessary. Even, when there are no obvious signs of damage, a visual check has to be performed. The check has to be carried out as follows: 1 The landing gear attachment area has to be examined for defects (e.g. cracks) using a mirror and a torch, check the outer laminate for delamination (press onto the laminate with your thumb). Furthermore, the struts have to be checked for deformations and cracks.
IMPORTANT
Examine wheel track The tires have to be checked for cuts in the side wall and the brake discs for impacts. 2 In the area of the nose gear, the belly of the fuselage should be checked for cracks. Delaminations in the bonding area of the fire wall frame may also occur. The condition (cracks, deformations) of the complete nose gear has to be checked.
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Maintenance Manual Extra 500 Time Limits and Maintenance Checks
3 After hard landings with damage observed, the attachment bolts of the landing gear have to be examined for cracks (magnaflux or x-ray; dye-check is not suitable in this case) or must be replaced. 4 In addition to the landing gear, all control surfaces (hinges, mass balance) and the complete engine mount (engine truss, attachment points of the engine truss at the fire-wall, shock mounts) have to be checked. 5 In addition, the wing structure has to be checked the main spar area plus the shear force fittings and particularly the spar connection. Also the wing-to-fuselage connection bolts have to be examined. 6 The same inspection has to be performed on the elevator. IMPORTANT
If there are indications that structural parts are damaged, the manufacturer has to be consulted for possible and suitable repair methods. 7 If any damage of landing gear or aircraft structure is detected, perform an engine special inspection. Refer to the applicable chapter of Rolls Royce 250B17F Series Operation and Maintenance Manual (LOAP 1).
05-50-04
Engine Fire After an engine fire, all hoses and cables have to be checked and if necessary replaced. A check of the engine has to be carried out according to the procedures in the applicable chapter Rolls Royce 250-B17F Series Operation and Maintenance Manual (LOAP 1). If parts of the airframe or the engine cowlings are suspected of being damaged by high temperatures (sign of blister on the protective paint), the manufacturer has to be consulted for assistance in damage evaluation before the aircraft is returned into service.
05-50-05
Propeller Strike, Sudden Stoppage and Violent Engine Stoppage Refer to applicable Maintenance Instructions of MT-Propeller (LOAP 3-5) and Rolls Royce (LOAP 1).
05-50-06
Lightning Strike Contact the manufacturer.
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05
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Maintenance Manual Extra 500 Time Limits and Maintenance Checks
05-50-07
Engine Overspeed Refer to applicable Maintenance Instructions of MT-Propeller (LOAP 3-5) and Rolls Royce (LOAP 1).
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Maintenance Manual EXTRA 500
Chapter 06 Dimensions and Areas
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06
Page 1
Maintenance Manual EXTRA 500
Table of Contents 06-10-00
MAIN DATA..................................................................................................... 3
06-10-01
Main Dimensions .............................................................................................. 3
06-10-02
Wing................................................................................................................... 3
06-10-03
Horizontal Tail .................................................................................................. 3
06-10-04
Elevator.............................................................................................................. 3
06-10-05
Vertical Tail....................................................................................................... 4
06-10-06
Rudder ............................................................................................................... 4
06-10-07
Ailerons.............................................................................................................. 4
06-10-08
Settings and Deflections ................................................................................... 4
Page 2
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Maintenance Manual EXTRA 500
06-10-00
MAIN DATA
06-10-01
Main Dimensions Length:
10.13 m
(33.23 ft)
Height:
3.37 m
(11.06 ft)
11.60 m
(38.06 ft)
Wheelbase:
2.65 m
(8.69 ft)
Wheel-track:
2.20 m
(7.22 ft)
2,130 kg
(4,696 lbs.)
Span:
11.60 m
(38.06 ft)
Area:
2
Span:
MTOW:
06-10-02
Wing 14.265 m (153.55 sq.ft.)
Airfoil: Root: NLF 22 - .05, 16.5 % Tip:
06-10-03
06-10-04
NLF 23 - .05, 13 %
Horizontal Tail Span:
3.80 m (12.47 ft)
Airfoil:
NACA 0012
Elevator Total projected nested area:
Page Date: 30. March 2012
1.13 m2 (12.16 sq.ft.)
06
Page 3
Maintenance Manual EXTRA 500
06-10-05
Vertical Tail Airfoil: Root: NACA 2412 Tip:
06-10-06
NACA 0012
Rudder Total projected nested area:
06-10-07
Ailerons Total projected nested area:
06-10-08
0.633 m2 (6.81 sq.ft.)
0.617 m2 (6.64 sq.ft.)
Settings and Deflections Flaps Take-off: Landing: Ailerons:
27° up, tolerance + 0°/-2° 19° down, tolerance + 2°/-0°
Rudder:
25° left/right, tolerance + 0°/-2°
Elevator:
33° up, tolerance + 0°/-2° 18° down, tolerance + 2°/-0°
Trim tab (at 0° elevator deflection):
Page 4
06
15°, tolerance ± 3° 30°, tolerance + 1°/-2°
20° up (nose down), tolerance ± 2° 30° down (nose up), tolerance ± 2°
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Maintenance Manual EXTRA 500
Chapter 07 Lifting and Shoring
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07
Page 1
Maintenance Manual EXTRA 500
Table of Contents 07-10-00
Page 2
07
JACKING.......................................................................................................... 3
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Maintenance Manual EXTRA 500
07-10-00
JACKING Jacking of the EXTRA 500 will be necessary for tire replacement, landing gear operation on ground or if either the main landing gear or the nose gear has to be removed or installed. Perform the following steps, if it is necessary to lift the aircraft off the ground:
CAUTION
Do not raise the aircraft on jacks out of doors when wind velocity is above 10 MPH. Jacks should be placed on hard and even surface.
1 Install jack points to the tie-down eyebolt receptacles in the middle of each wing and at the bottom of the fuselage, between nose gear and main gear (thread-diameter M8). Make sure jack points are fully screwed in. 2 Use standard aircraft jacks at both wing hoist points and behind the nose gear (tie-down eyebolt receptacles). While holding jack point in place, raise jack up to firmly contact with jack point.
CAUTION
When raising the aircraft, apply pressure on all jacks simultaneously and evenly to keep the aircraft leveled as it is raised. Otherwise the aircraft could slip from the jacks!
3 Raise the aircraft, keeping wings as level as possible. 4 Secure safety locks on each jack. Check landing gear three greens before lowering the aircraft. CAUTION CAUTION
When lowering the aircraft, bleed off pressure on all jacks simultaneously and evenly to keep the aircraft leveled as it is lowered.
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Maintenance Manual EXTRA 500
Intentionally left blank
Page 4
07
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Maintenance Manual EXTRA 500
Chapter 08 Leveling and Weighing
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08
Page 1
Maintenance Manual EXTRA 500
Table of Contents
08-10-00
WEIGHING AND BALANCING ................................................................... 3
08-20-00
LEVELING ....................................................................................................... 4
08-20-01
Longitudinal Leveling ...................................................................................... 4
08-20-02
Lateral Leveling................................................................................................ 4
Page 2
08
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Maintenance Manual EXTRA 500
08-10-00
WEIGHING AND BALANCING For detailed weighing procedure and related forms refer to Section 6 of the EXTRA 500 Pilot’s Operating Handbook.
Page Date: 30. March 2012
08
Page 3
Maintenance Manual EXTRA 500
08-20-00
LEVELING
08-20-01
Longitudinal Leveling Place a spirit level on the upper edge of the lower cabin door in closed position for longitudinal leveling. Check with indication of spirit level installed in the door. Level the aircraft by increasing or decreasing air pressure in the nose wheel tire.
08-20-02
Lateral Leveling Place a spirit level on the inner front seat rails for lateral leveling. Level the aircraft by inflating or deflating the main wheel tires
Page 4
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Maintenance Manual EXTRA 500
Chapter 09 Towing and Taxiing
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09
Page 1
Maintenance Manual EXTRA 500
Table of Contents
09-00-00
GENERAL ........................................................................................................ 3
09-10-00
TOWING ........................................................................................................... 4
09-20-00
TAXIING........................................................................................................... 5
Page 2
09
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Maintenance Manual EXTRA 500
09-00-00
GENERAL This chapter describes the procedures and precautions necessary for proper ground handling of the EXTRA 500. Minimum turning radius is 20.8 m [68.2 ft].
CAUTION
Exercise care not to turn the nose wheel past its normal swivel angle of 30° to each side of center. Exceeding the turn limits will cause structural damage.
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09
Page 3
Maintenance Manual EXTRA 500
09-10-00 DANGER
TOWING When preparing for ground handling operation ensure that the battery switch is OFF. Use a tow-bar to move the aircraft on ground. The tow-bar attaches to the nose gear fork, just above the nose wheel.
CAUTION
Moving the aircraft with a vehicle, especially when pushing in backward direction or moving on rough ground, may cause substantial damage to the nose gear strut. On smooth ground surfaces the aircraft may be towed carefully by coupling a vehicle to the tow-bar, but only in forward direction at low driving speed. Do not handle the aircraft at the end of the propeller blades.
CAUTION If no tow-bar is available, or when assistance in moving the aircraft is required, push the aircraft by hand on the inboard portion of the propeller blades, adjacent to the propeller hub and/or doorframe.
Page 4
09
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Maintenance Manual EXTRA 500
09-20-00
TAXIING Before attempting to warm up or taxi the aircraft, ground procedures should be checked by qualified pilots or other responsible personnel. All taxiing should be done at slow speed, and the controls should be set to appropriate positions in order to minimize the effects of gusty wind.
CAUTION
Taxiing over loose gravel or cinders should be done at low engine speed to minimize damage to the airframe surfaces due to stone impact. To taxi the aircraft, proceed as follows:
1 Start and warm up engine in accordance with the applicable paragraphs in Section 4 of the EXTRA 500 Pilot's Operating Handbook. Operate only with the engine in GROUND IDLE. CAUTION 2 Taxi forward a few feet and check brake effectiveness. 3 While taxiing, make shallow turns to test nose gear steering.
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09
Page 5
Maintenance Manual and Illustrated Parts Catalogue Extra EA-400 Towing & Taxiing
Left blank intentionally
Page 6
09
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Maintenance Manual EXTRA 500
Chapter 10 Parking, Mooring, Storage and Return to Service
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10
Page 1
Maintenance Manual EXTRA 500
Table of Contents
10-00-00
GENERAL ........................................................................................................ 3
10-10-00
PARKING/STORAGE..................................................................................... 4
10-10-01
Short - term Parking ........................................................................................ 4
10-10-02
Long - term Parking ......................................................................................... 4
10-10-03
Outdoor Storage ............................................................................................... 4 Aircraft................................................................................................................ 5 Engine ................................................................................................................. 5
10-20-00
MOORING........................................................................................................ 6
10-30-00
RETURN TO SERVICE.................................................................................. 7
Page 2
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Maintenance Manual EXTRA 500
10-00-00
GENERAL This chapter provides the procedures recommended to park or to moor the EXTRA 500 so that the likelihood of ground damage is minimized. Additionally, it describes precautions for protecting the engine during periods of storage.
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10
Page 3
Maintenance Manual EXTRA 500
10-10-00
PARKING/STORAGE When parking the aircraft, head the nose in the wind.
10-10-01
Short - term Parking The parking brakes may be used for short-term parking. To set the parking brakes at both main wheels, operate as follows: 1 Press both rudder pedals from either pilot's or copilot's seat. 2 Pull the parking brake control on the middle console. To release the parking brakes, push the parking brake control forward.
CAUTION
Do not set the parking brakes, when they are overheated or during cold weather conditions when moisture and slush accumulation could freeze in the brake mechanism. When using the parking brakes for an extended period of time an air temperature rise could cause the hydraulic fluid to expand, which may result in brake system damage and / or difficulties in releasing the brakes. Additionally place wheel chocks fore and aft both main wheels to prevent movement of the aircraft.
10-10-02
Long - term Parking For parking the aircraft over a longer period of time, proper mooring and tiedown is recommended. Refer to Chapter 10-20-00.
10-10-03
Outdoor Storage Outdoor storage requires adequate mooring and tie-down facilities. Refer to Chapter 10-20-00 for mooring instructions. The following precautionary measures are recommended for keeping the aircraft serviceable:
Page 4
10
Page Date: 30. March 2012
Maintenance Manual EXTRA 500
Aircraft 1 Keep the fuel tanks filled at least one-half full to minimize moisture condensation. 2 Keep the battery fully charged. 3 Install protective covers over pitot tube, engine cowling openings, canopy, etc. 4 Maintain a good wax finish on all exterior surfaces. 5 Check tire pressure each 30 days.
Engine Refer to the Rolls Royce 250-B17F Series Operation and Maintenance Manual (LOAP 1).
Page Date: 30. March 2012
10
Page 5
Maintenance Manual EXTRA 500
10-20-00
MOORING Careful tie-down proceeding is the best precaution against damage to the aircraft caused by gusty or strong winds. To tie-down the aircraft securely, carry out the following steps (Also refer to Subject 10-10-03): 1 Head the aircraft into the wind. 2 Place chocks fore and aft each main wheel. 3 Install tie-down eyebolts to the respective receptacles in the middle of each wing and at the bottom of the fuselage, between nose gear and main gear. 4 Drive stakes into the ground below each wing tip and next to each main wheel. 5 Tie sufficiently strong ropes or chains to the wing and bottom tie-down eyes and anchor to the ground stakes. Allow a little slack in each tie-down rope.
NOTE
Page 6
10
During severe weather conditions and strong winds, hangar the aircraft for maximum protection.
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Maintenance Manual EXTRA 500
10-30-00
RETURN TO SERVICE If the aircraft has been stored for an extended period of time, it is advisable to perform a 50-hour periodic inspection. Refer to Chapter 05-20 Scheduled Maintenance Checks. To return the engine to service refer to the Rolls Royce 250-B17F Series Operation and Maintenance Manual (LOAP 1).
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10
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Maintenance Manual EXTRA 500
Intentionally left blank
Page 8
10
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Maintenance Manual EXTRA 500
Chapter 11 Placards and Markings
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11
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Maintenance Manual EXTRA 500
Table of Contents
11-00-00
Page 2
11
GENERAL ........................................................................................................ 3
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Maintenance Manual EXTRA 500
11-00-00 NOTE
GENERAL All placards should be inspected for proper location, readability and security during maintenance actions. When an airplane has been painted inspect all placards to assure that they are not obscured by paint. The required placards installed on this airplane contain operating limitations and instructions. All placards and their locations, both interior and exterior, are listed in Section 2 of the EXTRA 500 Pilot's Operating Handbook.
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11
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Maintenance Manual EXTRA 500
Intentionally left blank
Page 4
11
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Maintenance Manual EXTRA 500
Chapter 12 Servicing
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12
Page 1
Maintenance Manual EXTRA 500
Table of Contents 12-00-00
GENERAL ........................................................................................................ 3
12-10-00
REPLENISHING.............................................................................................. 4
12-10-01
Refueling............................................................................................................ 4 Fuel Grade .......................................................................................................... 4 Fuel System Capacities....................................................................................... 4
12-10-02
Draining ............................................................................................................. 5
12-10-03
Fuel Drains ........................................................................................................ 5
12-10-04
Replenishment of Engine Oil ........................................................................... 6 Oil Grades........................................................................................................... 6 Oil System Capacities......................................................................................... 6
12-10-05
Oil Change......................................................................................................... 7
12-10-06
Replenishment of Brake Fluid......................................................................... 7
12-10-07
Brake Bleeding Procedure ............................................................................... 7
12-10-08
Tire Inflation ..................................................................................................... 8
12-10-09
Main Gear Shock Absorber Oil Draining/Refilling ...................................... 9
12-20-00
SCHEDULED SERVICING.......................................................................... 10
12-20-01
Exterior Cleaning ........................................................................................... 10
12-20-02
Interior Cleaning ............................................................................................ 11
12-20-03
Engine Cleaning .............................................................................................. 11
12-20-04
Lubrication Chart........................................................................................... 12
12-30-00
UNSCHEDULED SERVICING .................................................................... 14
12-30-01
Removal of Snow and Ice ............................................................................... 14
Page 2
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Maintenance Manual EXTRA 500
12-00-00
GENERAL This chapter describes the procedures and precautions necessary for proper servicing of the EXTRA 500. The specified intervals (refer to Chapter 5) are considered adequate to meet average requirements under normal operating conditions. It is advisable, however, to shorten service and maintenance intervals when operating under abnormal conditions, such as extreme temperature ranges, dusty atmospheric conditions, high humidity and moisture, unimproved airport facilities, or unusual operating requirements.
Page Date: 30. March 2012
12
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Maintenance Manual EXTRA 500
12-10-00
REPLENISHING The replenishing procedures contained in this section provide the proper methods for replenishing consumed fuel, engine oil and brake fluid. Also included are methods for inflation of tires.
12-10-01
Refueling Refueling is accomplished by pumping or pouring fuel into the main and auxiliary compartment of each wing tank through their respective filler caps. When fueling the aircraft, the following safety precautions must be followed:
DANGER
If the fuel system has been completely drained, the fuel system bleeding procedure must be performed (see Chapter 28-20-00). If the fuel system is not free of air, an engine flame out may be the result. Never refuel the aircraft with the engine running. Always ensure that the aircraft is grounded before refueling. Ensure that no one is smoking within 100 feet of the aircraft. Ensure that all aircraft electrical systems are deenergized while refueling. Ensure that no aircraft radar or powerful transmitters are operating within 100 feet of the aircraft during fueling. If fuel is spilled, ensure that the area of spillage is thoroughly flushed with water and that all residual fuel and vapor have dissipate or neutralized prior to starting the aircraft engine.
IMPORTANT
To prevent lateral fuel unbalance, make sure the left and right collector and main compartments are full before filling any auxiliary compartment. Maximum permissible fuel unbalance in flight is 106 liter (one auxiliary tank). After refueling, it has to be ensured that all four fuel tank caps are securely installed prior to flight. Wait at least five minutes after refueling for moisture and sediment to settle before draining and checking the fuel drain valves.
Fuel Grade For fuel grades (also temperature dependent) refer to Section 2 of the EXTRA 500 Pilot’s Operating Handbook.
Fuel System Capacities For the fuel system capacities refer to the Limitation Section of the EXTRA 500 Pilot’s Operating Handbook.
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Maintenance Manual EXTRA 500
12-10-02
Draining
DANGER
During the aircraft defueling observe the safety precautions specified in Section 12-10-01.
DANGER
Do not drain the fuel system when the engine or the exhaust is hot or while the wind is strong.
Even after completely draining the fuel system fuel may rest inside the WARNING engine and in the fuel lines downstream the check valves; which are located next to the fuel pumps. This fuel may be pressurized. The fuel system can be completely or partly drained. When fuel system shall be completely drained ensure fuel selector valve is set to BOTH. Drain at all fuel drains (for locations refer to Subject 12-10-03). When fuel system shall be partly drained ensure fuel selector valve is set to OFF. Then the individual fuel compartments and the area downstream the fuel selector valve can be drained over their respective drain valves. Consider that the collector and main compartments are connected by a check valve. So draining the collector compartment will also reduce fuel quantity in the main compartment. A quantity of fuel must be drained prior to the first flight of the day and at least five min. after refueling to inspect for water and/or contamination. Continue draining until free of water or contamination. IMPORTANT
12-10-03
After draining, make sure the fuel drain valve is returned to the closed position and the valve is not leaking.
Fuel Drains The EXTRA 500 is equipped with 12 fuel drains on the locations as given in the following table: Designation
Location
Inner and outer auxiliary compartment Each outboard wing drains Inner and outer main compartment drains
Each center wing
Collector compartment drains
Fuel sump next to each root rib
Lowest point drain
Down stream of the fuel selector valve, accessible by an opening in the forward keel beam access panel.
Fuel filter drain
Next to the fuel filter, accessible by an opening in the fuel filter access panel.
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Maintenance Manual EXTRA 500
12-10-04
Replenishment of Engine Oil The engine oil replenishment is accomplishment by pouring oil into the oil filler spout. The oil quantity can be conveniently checked by use of the dipstick attached to the oil filler spout cap. If larger quantity of oil has to be filled in (e.g. if oil system has been partly drained), follow the replenishment section of the Oil Change procedure of Subject 12-10-05, which incorporates engine motoring (refer to Chapter 80-1000, Motoring and to the EXTRA 500 Pilot’s Operating Handbook).
Oil Grades For oil grades (also temperature dependent) refer to Section 2 of the EXTRA 500 Pilot’s Operating Handbook.
Oil System Capacities For the oil system capacity refer to Section 1 of the EXTRA 500 Pilot’s Operating Handbook.
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12-10-05
Oil Change The engine oil must in accordance with the Rolls Royce 250-B17F Series Operation and Maintenance Manual (LOAP 1). Follow the instructions in the Oil Change paragraph of this Manual observing the following additions: 1 Remove engine cowlings of the aircraft (see Chapter 71-10-02). 2 Follow the respective drain procedures in Chapter 79. 3 For motoring and starting procedures refer to Chapter 80-10-00, Motoring and to the EXTRA 500 Pilot’s Operating Handbook. 4 Check oil level once more after motoring the engine. 5 Refill engine oil as necessary before starting the engine. 6 Reinstall cowlings after completion of oil change.
12-10-06
Replenishment of Brake Fluid In order to assure proper brake action, it is necessary to have positive transfer of hydraulic pressure through the system. Any air trapped in the system must be removed by following the bleeding procedure described below. The brake fluid reservoir is installed at the left side of the firewall. Brake fluid is toxic and can cause disease!
WARNING
Do not allow brake fluid to come in contact with your skin. In case of accidental contact flush with cold water immediately.
Brake bleeding procedure must be followed very carefully. Especially the WARNING connection between the pilot’s and copilot’s master brake cylinders has the tendency to carry air bubbles. Assure that bleeding equipment to be used for refilling is absolutely clean WARNING and is filled with uncontaminated brake fluid that conforms to Specification MIL-H-5606. Brake fluid can damage paint and other material! CAUTION
NOTE
12-10-07
Use a bleeding tank under the RH and LH break cylinder housing. Clean up immediately spilt brake fluid. Two mechanics are needed to carry out the bleeding procedure.
Brake Bleeding Procedure 1 Remove upper left engine cowling. 2 Remove fluid reservoir filler plug. 3 Ensure that pilot’s and copilot’s brake pedals and parking brake are released. 4 Remove bleed valve cap of the RH wheel brake assembly.
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5 Attach the bleeding equipment connector hose to the bleed valve. 6 Turn the bleeder fitting 1/2 rotation to the left for opening. 7 Slowly pump clean hydraulic fluid in the system (min. 0.33 L / 0.1 U.S. Gal). 8 Close bleed valve. 9 Disconnect bleeding equipment. 10 Install plastic hose to bleed valve. 11 Repeat steps 4 to 10 for the LH side accordingly. 12 Sit in the cockpit in a position that you can reach the right brake pedal of the pilot’s and copilot’s side simultaneously. NOTE
Maintain an adequate supply of fluid during the entire operation. Refill fluid reservoir if necessary. A low fluid supply will allow air to be drawn into the system. 13 Depress and hold the pilot’s right brake pedal. 14 Depress and hold the copilot’s right brake pedal. 15 Release the pilot’s brake pedal and depress and hold it again. 16 Release the copilot’s brake pedal and depress and hold it again. 17 Repeat steps 15 and 16 until a remarkable pressure is building up and then hold both pedals under pressure simultaneously. 18 Open the bleed valve on the RH brake cylinder housing. Both pedals must move foreward and fluid must come out of the brake cylinder housing. 19 Keeping the pedals pressed, close the bleed valve on the cylinder housing. 20 Release the pedals and repeat step 13 to 19 until the brake pressure is okay. A firm brake pedal must be obtained on pilot’s and copilot’s side. 21 Check the fluid level in the brake fluid reservoir. Fill up to full reservoir capacity. 22 Remove plastic hose from bleed valve and install cap. 23 Repeat step 13 to 22 for the LH brake system accordingly. 24 Reinstall fluid reservoir filler plug. 25 Check the brake operation. 26 Install upper engine cowling.
12-10-08
Tire Inflation Required tire pressure: Main wheels: 0.51 MPa (74 psi) Nose wheel:
0.35 MPa (51 psi)
When inflating tires, regulated air pressure through valve sems has to be used.
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12-10-09
Main Gear Shock Absorber Oil Draining/Refilling Detail Steps/Work Items
Key Items
High-pressure oil-jet damages eyes and limbs! WARNING
The shock absorber is under high pressure (827 psi/5.7 MPa). Expand the nitrogen gas-pressure before disassembly.
1 Remove the filling nipple − cover 2 Push the insert of the filling nipple to expand the nitrogen inflation 3 Remove the plug and O-ring from outer cylinder 4 Drain the hydraulic fluid completely in a sump 5 Replace O-rings and scraper ring
Chapter 32-10-13
6 Refill hydraulic fluid into the cylinder
Use only MIL−H−5606 Hydraulic Fluid 420 cm³/25.6 cu in
7 Replace the O-ring on the plug 8 Screw the plug in the outer cylinder 9 Lock the plug by a safety wire 10 Connect a nitrogen charging apparatus at the filling nipple 11 Refill nitrogen
Till inflation pressure 5.7 MPa / 827 psi
12 Recover the cover-filling nipple
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12-20-00
SCHEDULED SERVICING
12-20-01
Exterior Cleaning The painted surfaces of the aircraft have a long lasting, all-weather finish and should require no buffing or rubbing out in normal conditions. However, it is desirable to wash and polish it to preserve the outstanding exterior. Cleaning is best accomplished with cool water, mixed with a mild aircraft detergent, if required.
CAUTION
Do not use so called "mild" household detergents to wash aircraft exterior. Such detergents may damage finish and corrode aluminum components. In order to remove especially heavy dirt from the wing leading edges due to insect splatter and the like, it is good practice to undertake cleaning immediately after the flight, since deposits of this kind are more difficult to remove when dry. All lubricated components are to be covered before cleaning. Roughly twice a year, the complete surface should be treated with a nonsilicone car polish and repolished to high gloss. But do not apply wax or use pre-wax cleaners during initial paint curing period. Use only mild aircraft detergent and cool water when washing exterior during the first 90 days after repainting. Never use cleaning agents containing silicone!
CAUTION In order to maintain good visibility at all times, the windshield should be given good care and kept clean at all times. Techniques and materials used to clean glass should be avoided since acrylic glass is softer than glass and subject to damage by solvents and abrasive glass cleaning agents. Therefore it should be paid particular attention to using ample water applied with clean sponges and leather, otherwise even the smallest dust particles will tend to scratch the glazing. Never polish acrylic glass dry! CAUTION Dull or scratched canopy sections can be returned to their transparent state by treating with especially formulated acrylic glass cleaning agents.
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12-20-02
Interior Cleaning Prior to the first flight of the day it is recommended to clean the interior with a vacuum cleaner to remove dust and loose dirt. If liquid is spilled on the cockpit floor, blot it up promptly with cleansing tissue or rags. Continue blotting until no more liquid is taken up.
CAUTION
12-20-03
Never use gasoline, benzine, alcohol, acetone, carbon tetrachloride, fire extinguisher fluid, anti-ice fluid, lacquer thinner, or glass cleaner to clean the windshield and cabin windows. These materials will damage the acrylic glass and may cause severe crazing.
Engine Cleaning Accumulation of dirt and oil within the engine compartment creates a fire hazard and hampers inspection. All cleaning operations have to be performed in well ventilated work areas, and it has to be ensured that adequate firefighting and safety equipment is available. Clean the engine in accordance with the Rolls Royce 250-B17F Series Operation and Maintenance Manual (LOAP 1). Follow the procedures given there after performing the following preparations: 1 After running, allow the engine to cool before cleaning. 2 Protect the alternator, starter-generator, other electrical components, the air inlets and the engine cowlings (the inside of the engine cowlings is covered with water soluble fire protection paint) against cleaning agents. 3 Do not to start the engine before the cleaning agent has been completely removed or has evaporated.
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Maintenance Manual EXTRA 500
12-20-04 Interval CAUTION
Lubrication Chart Item
Location
Lubricant
Do not lubricate TEFLON coated bearings and rod ends Engine Compartment
100 h
Engine Controls (Throttle, Cond. Lever) Fork Ends and Bearings
Engine compartment
MIL-L-7870 after disassembly: MIL-G-81322 (Aeroshell Grease 22c)
100 h
Engine anti-ice Bowden Cable Ends
Engine compartment
MIL-PRF-7808
Controls 100 h
Control Shafts
Below Instrument Panel
MIL-G-81322 (Aeroshell Grease 22c)
100 h
Cable Chain Coupling (between Control Wheels)
Below Instrument Panel close to the firewall
MIL-G-81322 (Aeroshell Grease 22c)
100 h
Chain Interconnection (Aileron/Rudder)
Below Instrument Panel close to the firewall
MIL-G-81322 (Aeroshell Grease 22c)
100 h
Pedal Bearings
Below Instrument Panel
MIL-L-7870 after disassembly: MIL-G-81322 (Aeroshell Grease 22c)
100 h
Control Cable Bolt Attachments
Pedal Torque Tube and Controls/Control Surfaces and Nose Wheel Steering
MIL-G-81322 (Aeroshell Grease 22c)
100 h
Pressure Dome Control Cable Bushing
Cabin Pressure Dome
MIL-G-21164 (Aeroshell Grease 17)
100 h
Trim Tab Hinge
Elevator
MIL-L-7870 after disassembly: MIL-G-81322 (Aeroshell Grease 22c)
100 h
Trim Servo Chain
Tail Cone
MIL-G-3278 or MIL-G-23827 (Aeroshell Grease 7)
100 h
Wing Flap Tracks
Wing
MIL-G-81322 (Aeroshell Grease 22c)
2000 h
Front and rear Track Rollers at middle Flap Tracks
Wing
MIL-G-81322 (Aeroshell Grease 22c)
2000 h
Rear Track Rollers at inner Flap Tracks
Wing
MIL-G-81322 (Aeroshell Grease 22c)
100 h
Wing Flap Spindles
Wing
MIL-G-81322 (Aeroshell Grease 22c)
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Interval
Item
Location
Lubricant
Engine Controls 100 h
Bowden Cable Fork End Attachments
Middle Console
MIL-L-7870 after disassembly: MIL-G-81322 (Aeroshell Grease 22c)
100 h
Control Lever Bearing
Middle Console
MIL-L-7870 after disassembly: MIL-G-81322 (Aeroshell Grease 22c)
100 h
Control Lever Guidance
Middle Console
MIL-G-81322 (Aeroshell Grease 22c)
Landing Gear 100 h
Main Gear Doors Hinges
RH and LH Main Gear
MIL-L-7870 after disassembly: MIL-G-81322 (Aeroshell Grease 22c)
100 h
Nose Gear Doors Hinges
Nose Gear
MIL-L-7870 after disassembly: MIL-G-81322 (Aeroshell Grease 22c)
100 h
Nose Gear Steering Arm Guide/Telescoping Rod
Nose Gear
MIL-G-81322 (Aeroshell Grease 22c)
100 h
Bearings with Lubrication Nipple
Nose and Main Gear
MIL-G-21164 (Aeroshell Grease 17)
Wheels and Brakes 100 h or annually 100 h
Wheel Bearings
Main Gear
MIL-G-81322 (Aeroshell Grease 22c)
Brake Guide Pins
Brakes
Copper paste Doors
100 h
Upper and Lower Door Hinges
Upper and Lower Door
MIL-L-7870 after disassembly: MIL-G-81322 (Aeroshell Grease 22c)
100 h
Locking Mechanism
Upper and Lower Door
MIL-G-81322 (Aeroshell Grease 22c)
100 h
Locking Pivots
Upper and Lower Door
MIL-G-81322 (Aeroshell Grease 22c)
100 h
Rod Ends of Telescopic Lift Cylinder
Upper Door
MIL-L-7870 after disassembly: MIL-G-81322 (Aeroshell Grease 22c)
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Maintenance Manual EXTRA 500
12-30-00
UNSCHEDULED SERVICING
12-30-01
Removal of Snow and Ice After snowfall, the snow should be removed immediately from surface of the aircraft. Otherwise the water formed from melted snow will freeze on the surface or in slots and gaps of fairings. Do not use sharp tools for removing the snow.
CAUTION If the aircraft shows signs of ice formation, it is recommended to defrost in a room. Remove as much snow as possible with a soft bristle boom, make sure the wheels and brakes are clear, and tow the aircraft into a room with elevated temperature. This method is particularly desirable, since it will melt any undetected ice and snow that could constitute a flight hazard.
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Maintenance Manual EXTRA 500
Chapter 20 Standard Practices Airframe
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Page 1
Maintenance Manual EXTRA 500
Table of Contents
20-00-00
GENERAL ........................................................................................................ 3
20-10-00
STANDARD PRACTICES AIRFRAME ....................................................... 4
20-10-01
Width Across Flats for Metric Bolts ............................................................... 4
20-10-02
Torque Values ................................................................................................... 4
20-10-04
Special Torque Values...................................................................................... 5
20-10-05
Measuring Techniques ..................................................................................... 6
20-10-06
Coin Tapping..................................................................................................... 6
20-10-07
Flexible Hoses.................................................................................................... 6 Replacement of Flexible Hoses .......................................................................... 6 Installation of Flexible Hose Assemblies ........................................................... 7
20-10-08
Fittings ............................................................................................................... 7
20-10-10
Bowden Cables .................................................................................................. 8 Inspections .......................................................................................................... 8
20-10-11 Figure 20-1
Engine Controls ................................................................................................ 8 Engine Control Bowden Cables Schematic ...................................................... 10
20-10-12
Rod Ends ......................................................................................................... 11
20-10-13
Fork Ends ........................................................................................................ 11
20-10-14
Installing Bolts to CFRP Structures ............................................................. 11
20-10-15
Connections of Lightning Protection System ............................................... 12
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20-00-00
GENERAL The design of the airframe is according to standard procedures and requires no special tools or procedures for maintenance. For that reason, only the bolts used with the EXTRA 500 with relevant torque values and measuring techniques are described in the following.
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Maintenance Manual EXTRA 500
20-10-00
STANDARD PRACTICES AIRFRAME
20-10-01
Width Across Flats for Metric Bolts Thread diameter
20-10-02
Width across flats
M4
7 mm
M5
8 mm
M6
10 mm
M8
13 mm
M10
17 mm
M12
19 mm
M16
24 mm
M20
30 mm
M24
36 mm
Torque Values Nuts, except of counter nuts are mainly stop nuts according to LN 9348 or selflocking nuts according to AN 363. a) Standard torque values allowed for bolts and nuts according to DIN and LN must be adhered to as follows: Metric thread size M4
20
1.8
Torque value (in.lbs) 16
M5
3.9 – 4.3
35 – 38
M6
6.2 – 6.8
55 – 60
M8
15.2 – 16.8
144 – 148
M10
29.5 – 32.5
261 – 287
51 – 57
452 – 504
M12 x 1.5
Page 4
Torque value (Nm)
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Maintenance Manual EXTRA 500
b) Standard torque values allowed for bolts and nuts according to AN and MS must be adhered to as follows: Inch thread size
IMPORTANT
20-10-04
Torque value (Nm)
Torque value (in.lbs)
1/4 -28
3.5 – 4.5
30 – 40
5/16 -24
6.7 – 9.5
60 – 85
3/8 -24
10.7 – 12.5
95 – 110
7/16 -20
30.5 – 33.9
270 – 300
1/2 -20
32.8 – 46.3
290 – 410
9/16 -18
58.1 – 67.8
480 – 600
On all bolt connections, the specified torque and locking method must be observed. Do not reuse stop nuts if they can be run up finger tight!
Special Torque Values Special torque values for the following items must be adhered to: Item
Torque value (Nm)
(in.lbs)
Propeller flange bolt Mühlbauer
112
990
Bolt nose wheel tire
11
90 – 100
Bolt main wheel tire
17
150
Engine mount to fuselage (Bolts DIN 912 M12/12.9)
75 – 80
664 – 708
Engine mount to fuselage (Bolts LN 9037 x 08)
15.2 – 16.8
135 – 149
32
283
11.9 – 13.0
105 – 115
Engine mounting (Bolts AN 7 - 44A) Engine shock mount
IMPORTANT
Torque value
Wing bolt retaining sheets front (M5 bolts)
4
36
Wing bolts rear (M10 bolts)
16
140
Fuselage joints (M6)
6.5
57.5
Fuselage joints (M8)
16
142
Wing fittings (M8)
16
142
Wing fittings (M10)
30
265
Main gear former connection bolts (M10)
25
200
Valve cover
7
60
On all bolt connections, the specified torque and locking method must be observed. Do not reuse stop nuts if they can be run up finger tight!
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Maintenance Manual EXTRA 500
20-10-05
Measuring Techniques When using stop nuts, the safety torque (friction torque or braking torque) should be added to the table standard values. This value is indicated on the dial of the torquemeter, before the nut contacts the attachment surface. Always torque nuts for fastening, if possible. When bolts are torqued there might be an additional torque value due to shaft friction. This torque can be determined by a torquemeter before the bolt head contacts the attachment surface and should be added to the table value.
20-10-06
Coin Tapping Inspection for damage is more critical for composite structure than for conventional structures. A large washer or similar object is a valuable tool for detecting debonds in the airframe surface. When a large washer is lightly bounced against a solid structure, a clear metallic ring should be heard. If delamination is present, a dull thud will be heard.
20-10-07
Flexible Hoses The EXTRA 500 is equipped for the oil, fuel, and sensing lines with standard "STRATOFLEX-hoses, Aerospace Connectors Division" or equivalent "AEROQUIP-hoses, Aerospace Division", according to MIL-DTL-25579 and 27267 specification. For the bleed air system SCEET hoses are installed. For brake and hydraulic lines KRONTEC PTFE-Hoses 6000 are used. Maintenance work or overhaul of these hoses requires the attention to the manufacturer's information and bulletins. The hoses inside the engine compartment are covered with appropriate fire sleeves (integrated or slip-over type). Hoses and hose assemblies should be checked for deterioration at each inspection period. Leakage, separation of the cover or braid from the inner tube, cracks, hardening, lack of flexibility, and excessive "cold flow" are apparent signs of deterioration and reason for replacement. The term "cold flow" describes the deep, permanent impressions in the hose produced by pressure of hose clamps or supports.
Replacement of Flexible Hoses For the replacement of hoses and hose assemblies the EXTRA should be contacted. Any of the following conditions require replacement of the hose assembly: • Fitting slippage on hose, • Damaged, cracked, cut or abraded cover (any reinforcement exposed); • Hard, stiff, heat cracked, or charred hose; Page 6
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Maintenance Manual EXTRA 500
• Cracked or damaged fittings; • Leaks at fitting or in hose; • Kinked, crushed, flattened or twisted hose • Bent to a radius smaller than the minimum bend radius • Blistered, soft, degraded, or loose cover. The entire assembly must be replaced, if failure occurs in a flexible hose assembly. Obtain a new hose assembly of the correct size and length, complete with factory-installed end fittings.
Installation of Flexible Hose Assemblies External forces can significantly reduce hose life or cause failure. Mechanical loads which must be considered include tensile or side loads and vibration. In general hose assemblies should be handled with care to prevent excessive bending, twisting and kinking. Particular attention must be given to preclude hoses from wear, snagging, kinking, bending smaller that minimum bend radius and cutting, any of which can cause premature hose failure. The minimum bend radius for flexible hoses varies according to size and construction of the hose and the pressure under which the hose is to operate. Bends that are too sharp will reduce the bursting pressure of flexible hose considerably below its rated value. Large diameter hoses and very short hose assemblies are more prone to kinking. Twisting of the hose can be determined from the identification markings running along its length. The flexible hose should be installed so that it will be subject to a minimum of flexing during operation.
20-10-08
Fittings For the oil, fuel, bleed air, and brake system only AN-fittings are used in the EXTRA 500. In some areas of the hydraulic system special fittings are used (metric thread). For the assembly of PTFE-hoses and reusable fittings follow the standard practices for such combinations. All these fittings are made of aluminum alloy or stainless steel and are bluecolored or clear for identification purposes. The dash number following the AN number indicates the size of the hose for which the fitting is made, in 16ths of an inch. This size measures the inner diameter (I.D.) of the hose. The material code letter (Aluminum alloy: code D) follows the dash number. Example:
NOTE
Elbow AN 822-8D
Clean removed fittings from sealing, sealing tape, etc. and apply FUELUBE on the thread before installation (except ventilation system). Don't use sealing tape for sealing.
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Maintenance Manual EXTRA 500
20-10-10
Bowden Cables Bowden cables are used for the following systems of the EXTRA 500: • Engine Controls (High performance Push-pull Bowden cable, stainless steel) • Air Inlet Heating (Button lock dash control, solid wire end) • Parking Brake (Ratchet control, solid wire end) • Windshield Heating (solid wire end) • Trim Control (Special TLS III cable system) Minimum bend radius: 65 mm. Refer to Triumph Controls Germany GmbH Installation Instructions TLE10 (LOAP 36) • Seat adjustment locking mechanism • Aft passenger seat back rest swivel mechanism
Inspections Observe the following hints when performing inspections on the Bowden cables: A cable must be replaced whenever: • excessive free play is felt at the control even after all cable connections have been verified as in good working order. • visual inspection shows chafing, breakage or bent, loose or worn parts. • evidence of moisture is found inside (or Bowden cable has frozen). • a gradual or sudden decrease in the stroke (travel) length of the Bowden cable has been detected. • a gradual or sudden increase in the no-load (cable free and unattached) friction of a Bowden cable has been detected. Correct routing of the Bowden cable whenever: • misalignment, unacceptable high internal friction due to bends below minimum radius or malfunction of sliding elements has been detected. • the usable stroke is not centered within the available travel. • the swivel angle is not centered within the available angle (if applicable).
20-10-11
Engine Controls Consider the following information when working on engine Bowden cables. Refer to Figure 20-1: Hard and abrupt control inputs may impose high dynamic peak loads to the related sliding parts at reaching the travel stops. A bent swivel sleeve as well as wear and excessive free play at the pivot (swivel) points and sliding parts are an indication of misalignment and/or hard
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Maintenance Manual EXTRA 500
and abrupt control inputs. Those signs should be found early within the regular maintenance. This is a clear indication of an unacceptable Bowden cable condition, which might result in a malfunction. As soon as a Bowden cable becomes difficult to operate, the reason should be identified. An increase in no-load (cable free and unattached) friction or an increase in travel length of a Bowden cable are a good indication of pending performance problems and/or Bowden cable failure. The following notes, cautions and warnings describe application and installation information: Protect the cable from contaminants such as fuel, oil, water, dirt and CAUTION chemicals, which may damage the Bowden cable. Protect the cable from physical damage by paint, kinking, vibration, etc., which may damage the Bowden cable. IMPORTANT
A gradual or sudden increase in the no-load (cable free and unattached) friction of a Bowden cable is a good indication of pending performance problems and/or Bowden cable failure. Serious injury or death may result. Replacement is required. A gradual or sudden decrease in the stroke (travel) length of the Bowden cable is a good indication of pending performance problems and/or Bowden cable failure. Serious injury or death may result. Replacement is required. Bowden cables, which have moisture inside of them or have frozen, must be replaced. Do not apply heat to attempt to remove the moisture. Applying heat will not remove the moisture. Serious injury or death may result. Replacement is required.
NOTES
Installation should be accomplished by a licensed “A” and/or “P” mechanic. Bowden cables are designed to be non-repairable. Do not perform any repairs to this Bowden cable. Cables are designed to be contaminant resistant; not contaminant proof. The usable stroke must be centered within the available travel. The swivel angle must be centered within the available swivel angle. The minimum bend radius is 4". Bowden cables are lubricated for the life of the Bowden cable. Do not remove the seals or lubricate the Bowden cable.
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20
Page 9
NOT TO SCALE
Figure 20-1
Page 10
20
OUTER LINER (JACKET)
PIVOT POINT
EXTENDED POSITION
USABLE STROKE
RETRACTED POSITION MID-TRAVEL POSITION
OVER TRAVEL
BOTTOMED
FORK END
OVER TRAVEL
BOTTOMED
10° MAX. CONICAL SWIVEL
Maintenance Manual EXTRA 500
Engine Control Bowden Cables Schematic
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Maintenance Manual EXTRA 500
20-10-12
Rod Ends Two different kinds of rod ends are used for the EXTRA 500: • Teflon coated • stainless steel The Teflon coated rod ends have to be installed dry and require no maintenance. The stainless steel rod ends and attachment bolts shall be lubricated with MILG-81322 (Aeroshell Grease 22c) when newly installed or reinstalled. For lubrication during scheduled maintenance (without removal/reinstallation) MIL-PRF-7870 shall be used.
20-10-13
Fork Ends Generally fork ends and attachment bolts shall be lubricated with MIL-G81322 (Aeroshell Grease 22c) when newly installed or reinstalled. For lubrication during scheduled maintenance (without removal/reinstallation) MIL-PRF-7870 shall be used.
20-10-14
Installing Bolts to CFRP Structures To avoid electrochemical corrosion all non-stainless bolts and screws must be sealed independent from their surface protection. This does not apply to corrosion resistant steel (CRES). Detail Steps/Work Items
Key Items
1 Remove old sealant. 2 Install bolts with epoxy resin.
Hardening as per manufacturer information
PR 1750 accelerator contains harmful vapors and is readily absorbed WARNING through the skin. Avoid all contact with the skin and ingestion. Always wash hands before eating or smoking. Use adequate ventilation, hand protection and chemical-type goggles when working with this product. If accelerator contacts skin, flush area with warm water. Obtain medical attention in cases of extreme exposure or ingestion.
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Maintenance Manual EXTRA 500
Detail Steps/Work Items
Key Items
PR 1750 sealant contains solvents. WARNING Use adequate ventilation or air-supplied respirators during application. Avoid repeated or prolonged breathing of vapors. In case of extreme vapor exposure, remove affected personnel to fresh air immediately and obtain medical attention. For complete health and safety information, a refer to Le Joint Francais Material Safety Data Sheet PR 1750 (LOAP 41) 3 After final torquing apply PR 1750 sealant to both the head and nut side of the bolt including washer and thread end.
20-10-15
For mixing and application of PR 1750 sealant refer to manufacturer's instructions.
Connections of Lightning Protection System Prior to joining or riveting prepare contact surfaces as follows: Material
Action
Aluminum
Remove oxide film
Steel
Remove paint
Stainless steel
Degrease
Titanium
Degrease
After connection of parts seal gaps and connecting elements from all sides to avoid ingression of moisture:
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Connection
Action
Aluminum – Steel
Apply PR 1750A
All other
Apply Nycote 7-11
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Maintenance Manual EXTRA 500
Chapter 21 Air Conditioning
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21
Page 1
Maintenance Manual EXTRA 500
Table of Contents
21-00-00
DESCRIPTION ................................................................................................ 5 Troubleshooting.................................................................................................. 7
21-00-01
SCEET Hoses .................................................................................................... 8 Replacement ....................................................................................................... 8
21-10-00
COMPRESSION .............................................................................................. 9 Description.......................................................................................................... 9
21-10-01
Primary Shut-off Valve .................................................................................... 9 Removal/Installation........................................................................................... 9
21-10-02
Mass Flow Control Valve............................................................................... 10 Removal/Installation......................................................................................... 10
21-10-03
Mass Flow Sensor ........................................................................................... 10 Removal/Installation......................................................................................... 10 Check ................................................................................................................ 10
21-10-04
Mass Flow Controller..................................................................................... 11 Removal/Installation......................................................................................... 11
21-10-05
Muffler ............................................................................................................. 11 Removal/Installation......................................................................................... 11
21-20-00
DISTRIBUTION............................................................................................. 12 Description........................................................................................................ 12
21-20-01
Panel Vent Fans .............................................................................................. 12 Removal/Installation......................................................................................... 12
21-30-00
PRESSURIZATION CONTROL ................................................................. 14 Description........................................................................................................ 14 Operation .......................................................................................................... 14
21-30-01
Cabin Outflow Control Valve Filter ............................................................. 17 Replacement ..................................................................................................... 17
21-30-02
Cabin Outflow Control Valve........................................................................ 17 Removal/Installation......................................................................................... 17
21-30-03
Safety Valve..................................................................................................... 18 Removal/Installation......................................................................................... 18
21-50-00
COOLING ....................................................................................................... 19 Description........................................................................................................ 19 Service and Maintenance.................................................................................. 19
21-50-01
Compressor/Condenser.................................................................................. 20 Removal/Installation......................................................................................... 20
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21
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21-50-02
Evaporator .......................................................................................................20 Removal/Installation .........................................................................................20
21-50-03
Soft Start Module ............................................................................................21 Removal/Installation .........................................................................................21
21-60-00
TEMPERATURE CONTROL ......................................................................22 Description ........................................................................................................22
21-60-01
Temperature Switch........................................................................................23 Removal/Installation .........................................................................................23 Function Test.....................................................................................................23
21-60-02
Duct Temperature Sensor ..............................................................................24 Removal/Installation .........................................................................................24
21-60-03
Cabin Temperature Sensor ............................................................................24 Removal/Installation .........................................................................................24
21-60-04
Temperature Controller .................................................................................25 Removal/Installation .........................................................................................25
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Left blank intentionally
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Maintenance Manual EXTRA 500
21-00-00
DESCRIPTION Refer to Figure 21-1. The following systems are installed in the EXTRA 500 to cope with the various tasks of air conditioning: • Bleed air system with mass flow control • Ram air system • Distribution system • Pressurization system • Temperature regulation system • Cooling system For ventilation either ram or pressurized (bleed) air is used. Before entering the cabin bleed air is mass flow controlled and temperature can be modified by the temperature regulation. The airflow is then ducted to the legroom and/or to the windshield. The cabin air additionally can be cooled by the cooling system. Pressurization is done by the bleed air system in combination with a controllable outflow valve. Generally air is routed through SCEET hoses. On some locations T- or Ydistributors are connected to the hoses with worm drive hose clamps.
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Maintenance Manual EXTRA 500
Figure 21-1
Page 6
21
Cabin Air Condition and Pressurization Scheme
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Maintenance Manual EXTRA 500
Troubleshooting Complaint No or inadequate pressurization
Possible Cause
Remedy
Pressurization system inactive
Switch pressurization system ON
Excessive cabin leakage
Identify and seal
Excessive door seal leakage
Replace door seal
Excessive emergency exit seal leakage
Replace emergency exit seal
Bleed air system leakage
Identify and seal
Pneumatic system leakage
Identify and seal
Dump solenoid energized (safety valve open)
Check dump switch and squat switch
Pressure controller failure
Replace controller
Cabin control outflow valve failure
Replace control outflow valve
Safety valve failure
Replace safety valve
Mass flow sensor failure
Replace mass flow sensor
Mass flow valve failure
Replace mass flow valve
Mass flow controller failure
Replace mass flow controller
Pressurization system inactive
Switch pressurization system ON
Bleed air system leakage
Identify and seal
Pneumatic system leakage
Identify and seal
Cabin control outflow valve static reference blocked
Clean static reference connection
Cabin control outflow valve filter blocked
Replace filter
Pressure controller defective
Replace controller
Mass flow sensor failure
Replace mass flow sensor
Mass flow valve failure
Replace mass flow valve
Mass flow controller failure
Replace mass flow controller
Incorrect pressurization or pressurization rate control
Cabin control outflow valve defective
Replace control valve
Pressure differential exceeding 5.5 psi
Cabin control outflow valve static reference blocked
Clean static reference connection
Cabin control outflow valve differential failure
Replace control valve
Incorrect pressurization or pressurization rate control
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Maintenance Manual EXTRA 500
Complaint No dump
Erroneous warning
Possible Cause
Remedy
Pressurization system inactive
Switch pressurization system ON
Squat switch setting incorrect
Correct squat switch setting
Safety valve static reference blocked
Clean static reference connection
Dump switch defective
Replace dump switch
Squat switch defective
Replace squat switch
Safety valve solenoid failure
Replace safety valve
Safety valve blind plug at vacuum port not installed
Install blind plug
Temperature switch defective
Replace temperature switch
Differential pressure switch (5.65 psig) defective
Replace differential pressure switch
Absolute pressure switch (10,000 ft) defective
Replace absolute pressure switch
BLEED OVERTEMP
Erroneous warning CABIN PRESSURE
21-00-01
SCEET Hoses The worm drive hose clamps of the bleed air system are secured with a safety wire.
Replacement Detail Steps/Work Items
Key Items
1 Remove both upper engine cowlings.
Refer to Ch. 71-10-01/02.
2 Remove hose.
worm drive hose clamps, (safety wire)
3 Cut new SCEET hose to length. 4 Slip the worm drive hose clamps over the hose. 5 Slip both hose layers over the fittings. 6 Fasten worm drive hose clamps on both sides.
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21
Apply safety wire to all bleed air hose clamps.
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Maintenance Manual EXTRA 500
21-10-00
COMPRESSION Description Refer to Figure 21-1. The system consists of the engine compressor, bleed ports, a bleed air manifold, a shut-off valve, a mass flow control valve, a mass flow controller, a mass flow sensor, hoses, and the ENV AIR switch on the left side panel. Engine bleed air is used for cabin pressurization. Bleed air is taken from the engine compressor by means of two bleed ports. A forward-facing port is located on the right top of the engine compressor scroll. On its left bottom another downward-looking port is located. The bleed ports incorporate orifices (sonic venturi) which are installed with special O-rings. Bleed air is then routed through pressure hoses to the bleed air manifold located on the left engine side. Just above the primary shut-off valve is installed, which allows switching on or off cabin pressurization (and also heating) by means of the ENV AIR switch. The mass flow control valve is installed above the shut-off valve. It takes bleed air and/or ram air tapped from the left air-to-air cooler inlet to control the mass flow. The valve is governed by a computerized mass flow controller installed inside the cabin behind the side paneling between the cabin door and the pilot’s seat. The controller receives mass flow data from the mass flow sensor installed to a flange downstream the bleed air muffler.
21-10-01
Primary Shut-off Valve Removal/Installation The primary shut-off valve is screwed to the mass flow control valve. For this reason it is advisable to firstly remove both valves together and to disconnect them later by turning the shut-off valve. Detail Steps/Work Items 1 Remove LH engine cowling.
Key Items Refer to Chapter 71-10-01.
2 Disconnect bleed air manifold from shut-off the valve. 3 Cut the electrical wiring from the shut-off valve.
Reconnect later by splicing.
4 Disconnect the SCEET hoses from the mass flow control valve. 5 Disconnect the electrical wiring from the mass flow control valve. 6 Disconnect the mass flow control valve from the engine mount and remove both valves together. Page Date: 30. March 2012
4 bolts
21
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Maintenance Manual EXTRA 500
Detail Steps/Work Items
Key Items
7 Loosen counter nut between the two valves. 8 Unscrew the shut-off valve from the mass flow control valve.
Turn the complete shut-off valve. Watch the copper Oring.
9 Install in reverse sequence of removal.
21-10-02
Mass Flow Control Valve Removal/Installation Follow the procedure given in Section 21-10-01.
21-10-03
Mass Flow Sensor The mass flow sensor is electrically connected to its control box located on the nose gear firewall.
Removal/Installation Detail Steps/Work Items 1 Remove LH engine cowling.
Key Items Refer to Chapter 71-10-01.
2 Remove cable straps and tie tool wraps from the electrical wiring between sensor and control box. 2 Remove sensor.
4 bolts on muffler flange
3 Remove control box.
4 screws, 3 else connections
4 Install in reverse sequence of removal.
Check Detail Steps/Work Items
Key Items
1 Remove LH engine cowling.
Refer to Chapter 71-10-01.
2 Remove sensor from muffler.
4 screws
3 Check 2 wires in sensor are intact.
Replace sensor if wires are broken.
4 Install in reverse sequence of removal.
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21-10-04
Mass Flow Controller Removal/Installation Detail Steps/Work Items 1 Remove left side armrest paneling.
Key Items Refer to Chapter 25-20-21.
2 Disconnect the electrical connector from the mass flow controller. 2 Remove mass flow controller.
4 attachment nuts
5 Install in reverse sequence of removal.
21-10-05
Muffler The muffler is directly mounted to a flange providing a holding fixture for the mass flow sensor.
Removal/Installation Detail Steps/Work Items
Key Items
1 Remove LH engine cowling.
Refer to Chapter 71-10-01.
2 Remove mass flow sensor.
Remove 4 screws.
3 Disconnect SCEET hoses from muffler and flange. 4 Remove attachment bolts of hose clip and hose clamp carrying muffler and flange. 5 Remove muffler with flange. 6 Install in reverse sequence of removal.
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Maintenance Manual EXTRA 500
21-20-00
DISTRIBUTION Description Refer to Figure 21-1. The system consists of a valve box, SCEET hoses, a distribution valve, a Bowden cable with a handle on the center console panel and the panel vent fans. Ram air or bleed air is ducted into the cabin (refer to Section 21-10 for the bleed air system). Ram air is taken from the oil cooler inlet on the right engine side and routed through SCEET hoses to a valve box on the firewall. 2 check valves are mounted to the valve box (ram air and bleed air side). Additionally the valve box has a holding fixture for the duct temperature sensor. The cabin inflow check valve is mounted between the valve box and the firewall. Inside the cabin a valvular operated air distributor guides the air stream to the windshield and/or legroom dispensers. The air distributor has also a holding fixture for the temperature switch. For better ventilation in the forward cabin section two vent fans are installed in the LH and RH side of the instrument panel. Each vent fan sucks air from behind the panel. On the discharge side each vent fan is connected to an eyeball vent, which can be adjusted to direct or shut off the airflow. Two switches, placed on the instrument panel near the resp. air outlet, control the vent fans. The electric fan motors are protected by a 2 A - fuse. The evaporators (refer to Section 21-50) also work as cabin fans. Both evaporator blowers work with different power settings in low or high mode.
21-20-01
Panel Vent Fans Removal/Installation Detail Steps/Work Items
Key Items
1 a (RH vent fan) Remove RH IFD and right main panel.
Refer to Chapters 31-60-01 and 31-10-03
1 b (LH vent fan) Remove LH and RH IFD and analogue engine indicator.
Refer to Chapter 31-60-01 and Chapter 77-40-01
2 Loosen worm drive hose clamp on vent fan casing. 3 Disconnect electrical wiring. 4 Remove vent fan with casing.
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21
5 Disassemble vent fan and casing if applicable.
4 bolts
6 Remove eyeball vent.
1 nut
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Maintenance Manual EXTRA 500
Detail Steps/Work Items
Key Items
7 Reverse procedure for installation. 8 Perform pitot/static test.
Page Date: 30. March 2012
According to FAR 43, Appendix E and AC 43.131B CHG1 (or later) § 12-59
21
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21-30-00
PRESSURIZATION CONTROL Description Refer to Figure 21-1. The system consists of the engine compressor, two sonic venturi (flow limiters), a cabin control outflow valve, an unregulated safety valve, the cabin pressurization/dump switch, the cabin pressure controller, the landing gear squat switch, and two indicators, one for cabin altitude and differential pressure and one for cabin rate-of-climb. Pressurized air is supplied from the engine bleed air through the sonic venturi and then through a check valve into the cabin. Adequate flow to maintain pressurization up to the maximum differential pressure of 5.5 PSI is provided by the engine at normal power setting. Power changes should be made smoothly to prevent sudden changes in pressurization air inflow resulting in cabin pressure transients.
Operation The airplane may be operated in either the pressurized or depressurized mode. The mode selection is made with the cabin pressurization switch, which either activates the cabin control outflow valve or leaves it open. Mode operation should be selected prior to takeoff. If a change from pressurized to depressurized mode must be made while airborne, depressurize the cabin following the procedure given below before turning the dump switch as otherwise a rapid decompression occurs, which would cause discomfort to the passengers. When changing from unpressurized to pressurized mode, the cabin altitude rate of change will be limited by the pressurization controller. The valves are also opened by the landing gear squat switch assuring depressurized mode when aircraft is on ground to avoid bursting the cabin door due to cabin pressure when opening. In the pressurized mode cabin pressure is regulated by the cabin control outflow valve allowing air to exhaust either to the pressure level preselected by the cabin pressure controller or to maximum differential pressure level. Setting the center dial (identified as “Flight Level”) of the cabin pressure controller will suggest the system being at a certain flight altitude. So the system will maintain the corresponding cabin altitude (about 5.5 PSI above static pressure of flight level) or reach it with the rate set by the rate control knob located on the lower left corner of the pressurization controller. Only in case of maximum differential pressure is reached or flight level is below the selected cabin altitude, cabin altitude changes with the same rate the flight altitude does. In case of failure of the cabin outflow control valve the safety valve will open at a differential pressure of slightly above 5.5 PSI to avoid structure damage. Handling Use the cabin pressure controller as follows. Also refer to the sample chart (Figure 21-1). 1 Activate the pressurization controller by turning on the cabin pressurization switch. Make sure the ENV AIR switch is ON. Page 14
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2 Set the published official airport altitude (such as shown on flight charts) under the index arrow by turning the center control knob. 3 Turn the index arrow of the rate control knob (lower left corner of the control) to the 12 o’clock position (approx. 500 fpm). These steps set the system to pressurize at approximately 700 feet above the runway after takeoff. The system will hold this cabin altitude until the maximum differential altitude is reached (see “Cabin Altitude with minimum Flight Level Setting” line of Figure 21-1) or a different cabin pressure is selected. 4 After having cleared the airport area and established the climb and being on course to the destination (see “a” on 0), select the flight level corresponding to the intended cruise altitude in the center dial and align that with the index arrow. This alignment also indicates the approximate cabin altitude (within approx. 700 feet) at the index on the larger numbers marked “Airport Alt.”. 5 Increase or decrease the rate at which the cabin changes altitude for the best comfort level from normally 500 fpm by turning the rate knob counter clockwise for decreasing or clockwise for increasing the rate. Usually it is the best method to set the rate to reach the changed cabin pressure (referenced from the “Airport Alt.”) slightly ahead of reaching the cruising altitude (550 fpm in the sample of Figure 21-1). This selected altitude will be maintained until the aircraft changes altitude sufficiently to reach the max. differential pressure or descends sufficiently to go below the selected airport altitude. 6 When the aircraft reaches the proximity of the destination and starts to descent (see “b” on 0), set the selector knob to the published airport altitude. 7 Set the rate so that the selected airport altitude is reached in the cabin prior to descending to that altitude (650 fpm in the sample of Figure 21-1). When approaching the runway, the pressurization will cease approximately 700 feet above the landing prior to landing. Should any slight pressure remain, the remainder will dump when the squat switch closes. However, this is an additionally safety device, because landing with cabin pressurized is not allowed. CAUTION
If pressurization mode shall be terminated during flight, follow the procedure above, setting the airport altitude equal to the momentary flight altitude. Do not switch to the depressurized mode before the selected airport altitude has been reached.
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Page 15
Figure 21-1
Page 16
21
0
5
10
15
20
0
a
feet x 1,000
5
650 fpm
10
climb 1200 fpm
15
max. diff. pressure
20
Flight Altitude Cabin Altitude Cabin Altitude with Minimum Flight Level Setting
b 25
30
650 fpm
descent 1500 fpm
35
min
Maintenance Manual EXTRA 500
Cabin Pressurization Sample Chart
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Maintenance Manual EXTRA 500
21-30-01
Cabin Outflow Control Valve Filter Replacement Detail Steps/Work Items
Key Items
1 Remove upper half of rear baggage compartment wall.
Machine screws AN 526 10-32
2 Loosen the filter retention screw on the control outflow valve housing until the filter flange is free to rotate.
It is not necessary to remove the screw entirely.
3 Rotate the filter until the flat on the filter clears the screw head. 4 Remove the filter cartridge and replace with new one. 5 Rotate the filter so filter flange is captured by the screw head. 6 Tighten filter retaining screw.
21-30-02
Cabin Outflow Control Valve The valve is attached to the LH side of the pressure dome.
Removal/Installation Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. T
2 Remove upper half of rear baggage compartment wall.
Machine screws AN 526 10-32
3 Remove tail cone access panel on LH fuselage side. 4 Remove valve flange from pressure dome.
8 stop nuts MS 21044 AN3 with washers AN960 – 10L (3/8 inch.)
5 Remove overflow tube.
9/16 fitting; retain with 11/16 wrench at pressure dome fitting
6 Disconnect electrical connector. 7 Lift up valve from pressure dome 8 Install in reverse sequence of removal
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21-30-03
Safety Valve The valve is attached to the RH side of the pressure dome.
Removal/Installation Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. T
2 Remove upper half compartment wall.
of
rear
baggage Machine screws AN 526 10-32
3 Remove tail cone access panel on LH fuselage side. 4 Remove valve flange from pressure dome.
8 stop nuts MS 21044 AN3 with washers AN960 – 10L (3/8 inch.)
5 Remove overflow tube.
9/16 fitting; retain with 11/16 wrench at pressure dome fitting
6 Remove electrical connector 7 Lift up valve from pressure dome 8 Install in reverse sequence of removal NOTE
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21
Observe the following hint
Verify that blind plug at vacuum port is installed correctly. With installed valve, the vacuum port is accessible behind the rear baggage compartment wall.
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Maintenance Manual EXTRA 500
21-50-00
COOLING Description Refer to Figure 21-1. The aircraft is standard equipped with an electrically driven vapor cycle air conditioning system. The system consists of a compressor condenser module, two evaporators and the switches in the CABIN section of the left side panel. The electrically driven compressor condenser module is installed in the unpressurized part of the tail cone aft of the rear pressure dome. Cooling air for the condenser (circulated by the condenser fan) is taken from an inlet in the left fuselage side aft of the cabin door and dumped overboard through an outlet on the same side. The cabin recirculation air is cooled by means of two evaporators. The front evaporator is installed behind the co-pilot seat and the aft evaporator in the aft pressure dome area. Condensation at the evaporators is drained by means of a float type check valve for each evaporator. The air condition system is activated by the AIR CON switch located in the left side panel. The air-condition will only operate effectively with the cabin blower VENT switch at least in LOW position. The electric air-condition provides the ability to operate the system on ground using ground power without the necessity to run the aircraft engine.
NOTE
It is not possible to operate the air condition on battery power as the high current draw would shortly lead to a depleted battery. Therefore for operation either the aircrafts generator (engine running) or a sufficient external power source (capacity min. 100 A at 28 VDC) has to be connected to the aircraft bus system. 125 A is recommended for maximum cooling capacity. When using external power the battery must be off.
Service and Maintenance Servicing of the air-conditioning unit shall be performed by an approved airconditioning service station; only R-134a type refrigerant must be used. The air-conditioning compressor condenser module is equipped with conventional evacuating and charging connections. After new system plumbing installation, component replacement or line or hose rupture, a leak check is required, see Enviro Systems General Operating, Servicing and Maintenance Manual for Airborne R-134a Air-conditioning Systems (LOAP 13) for leak check and general charging procedures. Refer to this Manual also for component maintenance procedures. Access to the compressor condenser module is gained through the tailcone access hatch. Both low and high pressure service ports are located at this unit. Charging quantity of the installation is 0.650 kg +/- 0.050 kg, proper charging can be verified at the sight glass on the receiver dryer. With the system fully charged and operating, observe the suction and discharge pressures. Typical values at various ambient temperatures, with hot cabins are shown below: Page Date: 30. March 2012
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21-50-01
OAT (°C)
Suction pressure (psig)
Discharge pressure (psig)
20
28
112
25
30
133
30
31
156
35
32
180
Compressor/Condenser Removal/Installation Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. T
2 Remove tail cone access panel.
Refer to Chapter 51-00-01
3 Remove the refrigerant from the air conditioning system
Refer to Enviro Systems General Operating, Servicing and Maintenance Manual for Airborne R-134a Airconditioning Systems (LOAP 13)
4 Remove all avionic boxes, which may block removal of compressor/condenser.
XPDR, DME, amplifier
5 Remove refrigerant hoses. 6 Remove air hoses. 7 Remove compressor/condenser.
4 mounting screws
8 Reverse procedure for installation.
21-50-02
Evaporator Removal/Installation Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. T
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21
2 Remove tail cone access panel.
Refer to Chapter 51-00-01
3 Remove the refrigerant from the air conditioning system
Refer to Enviro Systems General Operating, Servicing and Maintenance Manual for Airborne R-134a AirPage Date: 30. March 2012
Maintenance Manual EXTRA 500
Detail Steps/Work Items
Key Items conditioning Systems (LOAP 13)
4 (front Set the co-pilot seat in the most forward evaporator only) position. 5 a (front Remove side paneling. evaporator)
Refer to Chapter 25-00-01
5 b (aft Remove aft paneling. evaporator)
Refer to Chapter 25-00-01
6 Remove refrigerant hoses. 7 Remove air hoses. 8 Cut electrical wires.
Reconnect later by splicing.
9 Remove mounting screws and remove evaporator. 10 Reverse procedure for installation.
21-50-03
Soft Start Module Removal/Installation Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. T
2 Remove tail cone access panel.
Refer to Chapter 51-00-01
3 Disconnect 3 power lines. 4 Cut control line.
Reconnect later by splicing.
5 Remove soft start module.
4 mounting bolts
6 Install in reverse sequence of removal.
Ensure cable clamps are installed.
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21-60-00
TEMPERATURE CONTROL Description Refer to Figure 21-1. The system consists of a temperature controller, a cabin temperature sensor, a duct temperature sensor, a temperature modulating valve, a temperature switch, the BLEED OVERTEMP warning light and the TEMP CTRL switches and rheostat on the left side panel. With the ENV AIR switch ON environmental bleed air is provided for cabin heating purposes. The bleed air, exiting the engine is too hot to be used for cabin heating without prior cooling. The amount of cooling required is dependent on ambient temperature, airspeed, engine power setting, desired cabin temperature and adequate changes if these parameters change. Cooling effectiveness is controlled by routing the environmental bleed air through the air-to-air cooler or directly (bypass) to the cabin by means of the temperature modulating valve. Operating mode of this valve is selected by the controls grouped in the CABIN section of the left side panel. With the TEMP CTRL switch being set to the AUTO position the computerized cabin temperature controller compares the actual cabin temperature (measured by a sensor in the cockpit ceiling) to the selected temperature. The temperature controller is installed inside the cabin behind the side paneling between the cabin door and the pilot’s seat. Selection is being done by means of the cabin temperature rheostat also located in the left side panel CABIN section. Adjustment range is between 13 °C and 30 °C (55 °F to 86 °F). Depending on the difference between actual cabin temperature and selected cabin temperature the controller determines a desirable cabin inflow temperature for the environmental bleed air. The actual inflow temperature is measured by a sensor located within the bleed ducting prior to cabin entry through the front pressure bulkhead. The temperature controller compares this actual inflow temperature to the desired inflow temperature and adjusts the temperature modulating valve to match this desired inflow temperature. It is within the nature of this design (bleed air cooling by means of an air to air heat exchanger) that cabin bleed air cannot be cooled below ambient temperature before entering the cabin. Therefore a vapor cycle air conditioning system (refer to Section 21-50) provides additional cooling capacity for hot ambient conditions. The automatic temperature control limits cabin inflow temperatures to values below 72 °C. An additional independent thermal switch installed in the cabin distribution valve activates the red BLEED OVERTEMP warning light located on the annunciator panel in case the cabin inflow temperature exceeds 85 °C. In case, the BLEED OVERTEMP warning light on the annunciator panel illuminates, indicating a temperature controller failure, the temperature can be manually controlled by switching the TEMP CTRL switch, to the MANUAL position.
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Selected and held in COOL or WARM position activates the temperature modulating valve manually (overrides the controller) causing warm up or cool down of incoming bleed air.
21-60-01
Temperature Switch Removal/Installation Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. T
2 Remove RH IFD and RH part of main panel.
Refer to Chapter 31
3 Remove attachment bolts of distribution valve.
To allow moving the distribution valve.
4 Move the distribution valve up some centimeters. 5 Cut the electrical wiring from the temperature switch
Reconnect later by splicing.
6 Remove temperature switch from the distribution valve. 7 Install in reverse sequence of removal.
Function Test Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. T
2 Remove RH IFD.
Refer to Chapter 31-60-01
3 Disconnect LH SCEET hose from the cabin distribution valve.
Worm drive hose clamp
4 Place BATT switch to ON position. T
5 Place NIGHT/DAY switch to TEST position.
To ensure annunciator lights are OK.
6 Apply hot air to the temperature switch.
More than 85 °C. Use a blow dryer.
7 Check BLEED OVERTEMP illuminates.
Replace temperature switch if necessary.
8 Place BATT switch to OFF position. T
9 Reinstall SCEET hose. Page Date: 30. March 2012
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Detail Steps/Work Items 9 Reinstall RH IFD. 10 Perform pitot/static test.
21-60-02
Key Items Refer to Chapter 31-60-01 According to FAR 43, Appendix E and AC 43.131B CHG1 (or later) § 12-59
Duct Temperature Sensor Removal/Installation The duct temperature sensor is attached to the valve box on the RH upper firewall with 4 bolts and nuts. To make the nuts accessible the forward hose and the flange have to be removed. Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. T
2 Remove LH and RH engine cowling.
Refer to Ch. 71-10-01/02
3 Disconnect the forward SCEET hose from the valve box.
Worm drive hose clamp, safety wire
4 Remove flange from the valve box.
4 nuts
5 Disconnect electrical connector from the temperature sensor.
Bayonet nut
6 Remove temperature sensor.
4 bolts and nuts
7 Install in reverse sequence of removal.
Observe the following step.
Refer to Product Label and Material Safety Data Sheet for health and WARNING safety information before using PR812. 8 Seal flange with PR812.
21-60-03
Cabin Temperature Sensor Removal/Installation Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. T
2 Remove paneling above pilot seat.
Refer to Chapter 25
3 Disconnect electrical wiring from the cabin temperature sensor. Page 24
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Detail Steps/Work Items 4 Remove sensor.
Key Items 4 nuts
5 Install in reverse sequence of removal.
21-60-04
Temperature Controller Removal/Installation Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. T
2 Remove left side cabin paneling.
Refer to Chapter 25.
3 Disconnect the electrical wiring from the temperature controller. 4 Remove temperature controller.
4 attachment screws
5 Install in reverse sequence of removal.
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Intentionally left blank
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Maintenance Manual EXTRA 500
Chapter 22 Auto Flight
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22
Page 1
Maintenance Manual EXTRA 500
Table of Contents 22-00-00
GENERAL ........................................................................................................ 5
22-10-00
AUTOPILOT .................................................................................................... 6 Description.......................................................................................................... 6 Autopilot Installation.......................................................................................... 8 System Components ........................................................................................... 9 Troubleshooting................................................................................................ 11 Heading Calibration.......................................................................................... 12
Figure 22-1
22-10-01 Figure 22-2
22-10-02 Figure 22-3
22-10-03 Figure 22-4
22-10-04
Figure 22-5
Roll Servo ........................................................................................................ 13 Removal............................................................................................................ 13 Roll Servo Installation ...................................................................................... 14 Installation ........................................................................................................ 15 Function Test .................................................................................................... 15 Pitch Servo....................................................................................................... 16 Removal............................................................................................................ 16 Pitch Servo Installation .................................................................................... 17 Installation ........................................................................................................ 18 Function Test .................................................................................................... 19 Yaw Servo........................................................................................................ 19 Removal............................................................................................................ 19 Yaw Servo Installation...................................................................................... 21 Installation ........................................................................................................ 22 Function Test .................................................................................................... 22 Clutches (Pitch, Roll and Yaw Servo)........................................................... 23 Torque Settings................................................................................................. 23 Torque Adjustment ........................................................................................... 24 Clutch Torque Adjustment ................................................................................ 24
22-10-05
Driving Wheels................................................................................................ 25 Removal/Installation......................................................................................... 25
22-10-06
Bridle Cables ................................................................................................... 25 Removal/Installation......................................................................................... 25 Tension Settings ............................................................................................... 26 Tensioning ........................................................................................................ 26
22-10-07 Figure 22-6
Cable Clamps .................................................................................................. 27 Cable Clamp Torquing ..................................................................................... 27
22-10-08
Trim Servo....................................................................................................... 27 Removal/ Installation........................................................................................ 27 Function Test .................................................................................................... 27
22-10-09
Trim Servo Clutch .......................................................................................... 28 Torque Settings................................................................................................. 28 Torque Adjustment ........................................................................................... 28
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22-10-10
Pressure Transducer.......................................................................................29 Removal/Installation .........................................................................................29
22-10-11
Yaw Amplifier .................................................................................................30 Removal/Installation .........................................................................................30
22-10-12
Programmer/Computer..................................................................................30 Removal/Installation .........................................................................................30
22-10-13
Turn Coordinator............................................................................................30 Removal/Installation .........................................................................................30
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22-00-00
GENERAL This chapter describes the features and functions of the System 55X Two and a half Axis Autopilot and gives information on basically required maintenance practices as well as related system components.
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22-10-00
AUTOPILOT Description Refer to Figure 22-1. The S-TEC System 55X autopilot system is a rate based autopilot. Internal signal processing for regulating purposes is mainly analog, whereas digital electronics is used for the pilot interface and for controlling the mode of operation. Pitch and Roll Axis The signal for the roll servo is generated using the following inputs: 1 Rate of turn information heading bug determined by the Turn Coordinator. 2 Navigation avionics (VOR / LOC, GPS; via IFD). The signal for the pitch servo is generated using the following inputs: 1 Static pressure (via remote mounted Absolute Pressure Transducer). 2 Sensitive Accelerometer (contained in the Programmer / Computer unit). 3 Altitude Selector (via IFD, key pad or vertical speed knob on A/P computer). 4 Glide Slope Receiver (via IFD). The autopilot can be activated by means of the 3-position AUTOPILOT MASTER/FD switch located in the right lower side of the pilot's instrument panel. Switching it from the OFF-position to the first stage (FD) energizes the autopilot system. The autopilot will start its self-test routine ending up in a ready mode if performed successfully. This allows the pilot to select the different operating modes. If appropriate modes are activated set-point steering commands are shown by the Flight Director symbol displayed in the LH IFD. The pitch and roll servos are not engaged. Pitch and roll still have to be controlled by normal steering, using the data provided by the IFD as a setactual comparison. In the second stage (MASTER) the servos are energized and the autopilot controls pitch and roll axis according to the operating mode(s) selected (refer to POH). One possibility to engage the autopilot (both axis) is given by the CWS switch (control wheel steering) located on top of the right horn of the pilot's control yoke. This mode engages the autopilot in a way which maintains the actual pitch and roll attitude (refer to POH).
NOTE
Operation in a pitch mode is possible only if a roll mode is activated. As a safety device an autopilot quick disconnect switch (AP DISC, red) is also located in the left horn of the pilot's control wheel to enable the pilot to disengage the autopilot quickly. Additionally, servo transmissions are designed as slip clutches, which can be overpowered in any case of failure or malfunction. The operation mode selection is done via the autopilot main unit and the IFD or the related keyboard. Indication is made on the autopilot main unit and the upper LH IFD.
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Trim System The EXTRA 500 uses a tab at the elevator's trailing edge for pitch trim. This tab is actuated by a Bowden cable with a special gear located in the horizontal stabilizer transforming the long travel of the cable into the shorter travel finally used for tab actuation. The Bowden cable itself may be actuated either by the pilot using the trim wheel or by the trim servo located on the floor of the tail cone compartment. The electric trim system may be operated independently from the autopilot. When an autopilot pitch mode is active and the electric trim system is switched on by the TRIM master switch in the pilot's instrument panel, the trim system operates in the auto trim mode. The pitch servo continuously senses the force necessary to maintain the assigned pitch attitude and transmits the signal to the autopilot main unit. This computes a signal to actuate the trim servo. By this mechanism the force the pitch servo has to apply on the elevator is minimized. When the autopilot is active (in a pitch mode) and the electric trim servo (TRIM master switch) is switched off a visual and audible annunciation to the pilot is provided by the autopilot system asking him to trim the airplane manually by means of the trim wheel. With autopilot switched off or no pitch mode engaged, but electric trim servo (TRIM master switch) on, the longitudinal trim may be adjusted by the pilot using the momentary split rocker switch on top of the left horn of the pilot's control yoke. Yaw Damper The yaw damper system consists of two units, the yaw servo actuating the rudder control cables and the yaw amplifier, which generates the signal for the servo. The amplifier is installed behind the aft pressure dome in the tail cone compartment. The amplifier features an integrated lateral acceleration sensor. This sensor detects lateral components of the gravity vector, which corresponds to the “ball not being centered”. Based on this input signal the yaw amplifier derives the control signal for the yaw servo. To allow for a fine adjustment of slip/skid angle, a yaw trim potentiometer allows the pilot to adjust (“trim”) the zero yaw angle based on a slip/skid indicator. In the OFF position of the yaw damper control switch the yaw damper is not engaged and the yaw servo clutch remains open. With the switch in ON position the yaw damper remains engaged as long as the autopilot is engaged in a roll mode. A roll signal from the autopilot main unit is provided to the yaw amplifier as an additional input (to the lateral acceleration sensed internally). Yaw damper disconnect is provided by the same means as the autopilot disconnect as the autopilot main unit provides a yaw damper enable signal to the yaw amplifier as long a roll mode is active. As soon as the autopilot disconnects the yaw damper follows therefore.
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Figure 22-1
Page 8
22 Trim Wheel
IFDs
CWS Switch (control wheel steering)
AP Disconnect Switch
Split Trim Rocker Switch
Roll Servo
Trim Wheel
Autopilot Switch Panel
Programmer/Computer Turn Coordinator
Trim Servo
3rd Static Port
Yaw Amplifier Absolute Pressure Transducer
Yaw Servo
Pitch Servo
Maintenance Manual EXTRA 500
Autopilot Installation
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Maintenance Manual EXTRA 500
System Components The following components are used in the S-TEC 55 installation of the EXTRA 500: Unit Designation
Location
Function
Autopilot Components Programmer/Computer (P/C) (special configuration for EXTRA 500)
Instr. Panel
Pilot interface signal generation for roll, pitch and pitch trim servo
Yaw amplifier
Tail cone equipment Yaw sensor & signal generation for yaw rack servo
Turn Coordinator
Instr. Panel
Sensing rate of turn, input signal for P/C, indication to pilot
Absolute pressure Transducer Tail cone equipment Converting static pressure => electric signal rack Roll Servo
Front wing compartment
Pitch Servo
Tail cone equipment Elevator actuation, force sensing for trim rack system
Pitch Trim Servo
Tail cone floor
Yaw Servo
Tail cone equipment Rudder actuation rack
Autopilot Relay
behind instrument panel
Connecting inputs to A/P computer from either IFD 1 or IFD 2
Autopilot Master Switch
Autopilot Panel (Pilot Instrument Panel)
Activation of autopilot and / or flight director
Pitch Trim Switch
Autopilot Panel (Pilot Instrument Panel)
Activation of electric pitch trim System
Yaw Damper Master Switch
Autopilot Panel (Pilot Instrument Panel)
Activation of yaw damper
Yaw Trim Knob (rotary Potentiometer)
Autopilot Panel (Pilot Instrument Panel)
Adjustment of zero jaw attitude
Trim command Switch (split switch)
Control Wheel
Change of aircraft pitch trim
CWS-Switch
Control Wheel
Engaging CWS-mode
Autopilot disconnect / trim interrupt switch
Control Wheel
Disengaging autopilot, interruption of electric trim actuation
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Aileron actuation
Trim tab actuation
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Unit Designation
Location
Function
Closely related systems/components Audio Panel
Instrument panel
Audible warnings from P/C
IFD 1
Instrument panel
Source for heading and course, vertical speed command, Flight Director display
IFD 2
Instrument panel
Source for heading and course, vertical speed command, flight director display
Keypad
Center console
Altitude and heading selection, inputs to IFDs
Stall warning switch (“Lift Detector”)
LH wing leading edge
Disconnect of A/P when stall warning becomes active
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Troubleshooting Complaint Autopilot will not engage in any mode
Possible Cause
Remedy
Autopilot has no power
Check AUTOPILOT MASTER switch FD or MASTER.
Autopilot has no power
Check AVIONICS switch ON.
No valid signals from turn coordinator
Check turn coordinator no flag.
AP disconnect switch struck/defective
Check AP disconnect switch continuity.
Pitch trim switch stuck/defective
Check pitch trim switch stuck.
Computer defective
Replace computer.
No roll mode engaged
A roll mode MUST be selected first
Computer defective
Replace computer.
No valid signal from absolute pressure transducer
Replace absolute pressure transducer.
Autopilot not coupled in both axes
An altitude and roll mode must be engaged previously.
Switch defective
Replace CWS switch.
Computer defective
Replace computer.
AP disconnect switch does not work
Switch defective
Replace AP disconnect switch.
Computer defective
Replace computer.
Mode engages, but servo does not couple
AP in FD mode
Check AUTOPILOT MASTER switch in MASTER position (not FD)
Servo defective
Replace servo.
Pitch system has no power
Check battery bus power.
Pitch system has no power
Check pitch trim switch ON.
Pitch trim switch defective
Replace pitch trim switch.
Computer defective
Replace computer.
Pitch trim servo defective
Replace pitch trim servo.
Will not engage in any altitude mode
CWS does not work
Electrical Pitch trim does not work
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Complaint Yaw trim does not work
Possible Cause
Remedy
No power to yaw amplifier
Check battery bus power
YAW DAMPER switch OFF.
YAW DAMPER switch ON.
Yaw damper switch defective
Replace yaw damper switch.
No roll mode enabled
Engage roll mode first.
Yaw amplifier defective
Replace yaw amplifier.
Yaw servo defective
Replace yaw servo.
Yaw trim poti defective
Replace yaw trim potentiometer.
Heading Calibration Detail Steps/Work Items
Key Items
1 Attach external power. 2 Check all switches OFF, A/P CMPTR CB IN, Turn-Coord CB IN, A/P SERVO CB IN, All IFD CB-s IN 3 Switch on EXT PWR 4 Switch on AUTOPILOT - MASTER 5 Check turn coordinator runs up, off-flag disappears, Autopilot display shows 7 on display, Autopilot display shows rdy, LH IFD shows AP RDY 6 Wait for 2 minutes
to let turn coordinator run up
7 Set IFD to NAV I 8 Tune NAV I to a frequency that has no reception 9 Set heading bug to current heading
push heading knob on keypad
10 Select NAV mode on autopilot
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11 Adjust the potentiometer between the REV and ALT buttons in small increments until the yoke stops turning
use miniature flat screwdriver
12 Make sure in the end the AP is in SOFT mode
indicated on IFD
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22-10-01
Roll Servo Removal Refer to Figure 22-2. Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. T
2 Remove wing center fairing.
Refer to Chapter 51-00-01
3 Disconnect electrical connector from roll servo. 4 Loosen bridle cable clamps. 5 Remove 3 bolts and nuts securing roll servo to support bracket. 6 Remove roll servo from support bracket. 7 Remove cable guard, cover and bridle cable from servo capstan, if required.
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Top View Upper control cable
fwd
bridle cable center ball
bridle cable bridle cable
Attachment bolts
Lower control cable
Roll Servo
Front View Upper control cable
Attachment bolts Cable clamp
Cable clamp
bridle cable end
bridle cable end bridle cable bridle cable Roll Servo
Figure 22-2
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Lower control cable
Roll Servo Installation
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Installation Detail Steps/Work Items
Key Items
IMPORTANT
Prior to installing roll servo, adjust clutch torque and determine proper direction of capstan rotation. See Section 22-10-04 for clutch torque settings.
IMPORTANT
Prior to installing roll servo, check aileron control system travels. Check aileron cable tension in accordance with Chapter 27-00-01.
IMPORTANT
Removal of servo requires disconnecting the bridle cable. Consequently, bridle cable tensioning is required upon reinstallation of the servo. 1 Ensure BATT switch is OFF and no external power connected. T
2 Attach roll servo with 3 screws to support bracket. 3 Insert bridle cable center ball into leading hole in capstan. 4 Adjust position of center ball with aileron controls in neutral position.
12 o’clock position. See Figure 22-2
5 Wrap bridle cable around capstan 1.5 turns each direction from center ball.
Cable clamps will be positively guided to correct position
6 Install cable guards and cover with 4 screws and washers.
Tighten screws only snugly against servo base plate Apply tension by hand before tightening the cable clamps. See 22-10-07Figure 22-6 for clamp torquing. Cable clamps may be rotated on aileron cable to align bridle cable with capstan grooves.
7 Install cable clamps. Adjust bridle cable tension to the value given in Subject 22-10-06.
8 Connect electrical connector. 9 Install wing center fairing.
Refer to Chapter 51-00-01
Function Test Detail Steps/Work Items
Key Items
1 Attach external power to the aircraft. 2 Check all switches off. 3 Switch EXT PWR on. 4 Switch AUTOPILOT MASTER to MASTER. 5 Check AP RDY on IFD. 6 Check RDY on autopilot computer. Page Date: 30. March 2012
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Detail Steps/Work Items
Key Items
7 Switch on HDG mode. 8 Check HDG is displayed on autopilot computer. 9 Check HDG bug is fully filled and magenta on IFD. 10 Turn HDG knob to the left. 10 Check control wheel turns CCW. 11 Turn HDG knob to the right. 12 Check control wheel turns CW. 13 Press AP DISC switch on LH control wheel.
Aural warning can be heard.
14 Switch AUTOPILOT MASTER off. 15 Switch EXT PWR off. 16 Disconnect external power.
22-10-02
Pitch Servo Removal Refer to Figure 22-3. Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. T
2 Remove tail cone access panel. 3 Disconnect electrical connector from roll servo. 4 Loosen bridle cable clamps. 5 Remove return pulley. 6 Remove 4 bolts and nuts securing pitch servo to support bracket. 7 Remove pitch servo from support bracket. 8 Remove cable guard, cover and bridle cable from servo capstan, if required.
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Top View bridle cable longer end
fwd
Cable clamps
bridle cable shorter end
Pulley
bridle cable
Attachment bolts
bridle cable center ball
Pitch servo
Control cable
Figure 22-3
Pitch Servo Installation
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Installation Detail Steps/Work Items
Key Items
IMPORTANT
Prior to installing pitch servo, adjust clutch torque and determine proper direction of capstan rotation. See Section 22-10-04 for clutch torque settings.
IMPORTANT
Prior to installing pitch servo, check elevator control system travels. Check elevator cable tension in accordance with Ch. 27-00-01.
IMPORTANT
Removal of servo requires disconnecting the bridle cable. Consequently, bridle cable tensioning is required upon reinstallation of the servo. 1 Ensure BATT switch is OFF and no external power connected. T
2 Attach pitch servo with 4 screws to support bracket. 3 Insert bridle cable center ball into leading hole in capstan. 4 Adjust position of center ball with elevator controls in neutral position.
11 o’clock position. See Figure 22-3
5 Wrap bridle cable around capstan 1 turn (360°) CW and 1.5 turns (540°) CCW from center ball.
Cable clamps will be positively guided to correct position
6 Install cable guards and cover with 4 screws and washers.
Tighten screws only snugly against servo base plate
7 Install return pulley. 8 Lead upper bridle cable segment around pulley and pre-install cable clamps. Tension bridle cable by hand before fastening the cable clamps.
See 22-10-07Figure 22-6 for clamp torquing. Cable clamps may be rotated on elevator cable to align bridle cable with capstan grooves
9 Connect electrical connector. 10 Adjust correct bridle cable tension.
Refer to the Tension Settings and the Tensioning procedure presented in Subject 22-10-06.
11 Install tail cone access panel.
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Function Test Detail Steps/Work Items
Key Items
1 Attach external power to the aircraft. 2 Check all switches off. 3 Switch EXT PWR on. 4 Switch AUTOPILOT MASTER to MASTER. 5 Check AP RDY on IFD. 6 Check RDY on autopilot computer. 7 Set heading bug to current heading
push heading knob on keypad
8 Switch on HDG mode. 9 Switch on VS mode. 10 Check ALT bug is open. 11 Check VS bug is filled and magenta on IFD. 12 Check control wheel moves forward. 13 Set VS bug to +1000 ft. 14 Control wheel moves aft or at least tries.
On the ground the servo does not have enough power.
15 Press AP DISC switch on LH control wheel.
Aural warning can be heard.
16 Switch AUTOPILOT MASTER off. 17 Switch EXT PWR off. 18 Disconnect external power.
22-10-03
Yaw Servo Removal Refer to Figure 22-4. Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. T
2 Remove tail cone access panel. 3 Disconnect electrical connector from roll servo. Page Date: 30. March 2012
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Detail Steps/Work Items
Key Items
4 Loosen bridle cable clamps. 5 Remove 4 bolts and nuts securing yaw servo to support bracket. 6 Remove yaw servo from support bracket. 7 Remove cable guard, cover and bridle cable from servo capstan, if required.
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Top View Bridle cable end fwd
Control cable Cable clamp
Attachment bolts Bridle cable
Bridle cable center ball
Yaw servo Bridle cable
Cable clamp
Bridle cable end Figure 22-4
Yaw Servo Installation
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Installation Detail Steps/Work Items
Key Items
IMPORTANT
Prior to installing yaw servo, adjust clutch torque and determine proper direction of capstan rotation. See Section 22-10-04 for clutch torque settings.
IMPORTANT
Prior to installing yaw servo, check elevator control system travels. Check elevator cable tension in accordance with Ch. 27-00-01.
IMPORTANT
Removal of servo requires disconnecting the bridle cable. Consequently, bridle cable tensioning is required upon reinstallation of the servo. 1 Ensure BATT switch is OFF and no external power connected. T
2 Attach yaw servo with 4 screws to support bracket. 3 Insert bridle cable center ball into leading hole in capstan. 4 Adjust position of center ball with rudder controls in neutral position.
12 o’clock position See Figure 22-4
5 Wrap bridle cable around capstan 1.5 turns each direction from center ball.
Cable clamps will be positively guided to correct position
6 Install cable guards and cover with 4 screws and washers.
Tighten screws only snugly against servo base plate
7 Lead upper bridle cable segment around pulley and install cable clamps Adjust bridle cable tension to the value given in Subject 22-10-06.
See Figure 22-6 for clamp torquing. Cable clamps may be rotated on elevator cable to align bridle cable with capstan grooves
8 Connect electrical connector. 9 Install tail cone access panel.
Function Test Detail Steps/Work Items
Key Items
1 Attach external power to the aircraft. 2 Check all switches off. 3 Switch EXT PWR on. 4 Switch AUTOPILOT MASTER to MASTER. 5 Engage heading mode 6 Switch AUTOPILOT YAW DAMPER on. 7 Turn YAW TRIM potentiometer to the left. Page 22
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Detail Steps/Work Items
Key Items
8 Check rudder pulses to the left. 9 Turn YAW TRIM potentiometer to the right. 10 Check rudder pulses to the right. 11 Press AP DISC switch on LH control wheel. 12 Switch AUTOPILOT YAW DAMPER off. 13 Switch EXT PWR off. 14 Disconnect external power.
22-10-04
Clutches (Pitch, Roll and Yaw Servo) Torque Settings The following torque settings must be checked and adjusted: Servo P/N
Clutch Torque setting
Servo RPM @24VDC (fixed, not adjustable)
Pitch S-TEC 0108-P4
29 ± 2 inlbs
1.08
Roll
S-TEC 0106-R2
36 ± 2 inlbs
2.40
Yaw
S-TEC 0106-6-Y9
73 ± 2 inlbs
3.59
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Torque Adjustment Before re-installation of a servo, perform the following steps to check and adjust clutch torque value in accordance with the Torque Settings given above.
Dial Torque Wrench Capstan Cover
Shim Washer
Tool S-TEC P/N 6622-1
Tension Washer
Cable Guard
Figure 22-5
Clutch Torque Adjustment
Detail Steps/Work Items
Key Items
1 Remove capstan cover from servo with 4 screws and washers. 2 Draw cotter pin from castle nut. 3 Insert adapter tool (S-TEC P/N 6622-1) into leading holes in servo capstan. 4 Bear dial torque wrench. 5 Connect servo motor to 28 VDC power source.
Servo shaft rotates
6 Read torque value.
See Torque Settings chart of Subject 22-10-04 for appropriate settings. Perform clutch torque adjustment as per step 7 - 8, if necessary
7 Remove torque wrench and adapter tool. 8 Align torque value with castle nut - turn CW to increase and CCW to decrease torque. 9 Repeat steps 3 to 8, until read torque setting (step 6) matches value given in Torque Settings chart of Subject 22-10-04. Page 24
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Detail Steps/Work Items
Key Items
10 Disconnect servo motor. 11 Re-install cotter pin. NOTE
To align cotter pin with shaft hole, use shim washers S - TEC P/N 1205 S 5 - 005, 007, 010, 031 in any combination (min. 1 required). 12 Re-install capstan cover.
NOTE
22-10-05
After capstan cover has been installed, determine that there is no interference between capstan and cover.
Driving Wheels Removal/Installation Detail Steps/Work Items
Key Items
1 Draw cotter pin from castle nut. 2 Remove castle nut. 3 Remove 2 tension washers. 4 Remove driving wheel. IMPORTANT
After removal of driving wheel, clutch torque adjustment is required.
Refer to Section 22-10-04 for torque settings.
5 Install in reverse order of removal.
22-10-06
Bridle Cables Removal/Installation Detail Steps/Work Items 1 Unfasten cable clamp bolts as far as necessary to unthread the bridle cable.
Key Items On both ends
2 Uncoil the bridle cable from the servo. 3 Install in reverse order of removal.
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Observe correct position of bridle cable center ball. Refer to applicable servo Installation Procedure.
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Tension Settings The following tension settings must be checked (cable tensiometer) and adjusted: Bridle Cable
Tension Setting
Pitch
32 ± 2 lbs
Roll
15 ± 2 lbs
Yaw
15 ± 2 lbs
Tensioning Generally the necessary tension can be applied by hand to the bridle cables before tightening the cable clamp bolts. However for tensioning the pitch servo bridle cable the power of the pitch servo itself is necessary to receive the correct tension values. Proceed as follows (refer to Figure 22-3): Detail Steps/Work Items
Key Items
1 Install the bridle cables as per Subject 2210-02. 2 Fix control wheel in neutral position by hand. 3 Switch on AUTOPILOT MASTER. 4 Switch on the VS Mode on the Autopilot Programmer/Computer. 5 Position VS bug to +1000 ft.
Control wheel tries to move aft. Counteract by hand. The pitch servo now tensions the longer bridle cable end.
6 Loosen cable clamp of the shorter bridle cable end, tension by hand, and retighten cable clamp bolts.
The tension applied here by hand allows adjusting the bridle cable to the desired tension.
7 Switch off AUTOPILOT MASTER. 8 Check bridle cable tension.
Use a conventional cable tensiometer.
9 Repeat procedure if necessary varying tension on step 6.
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22-10-07
Cable Clamps Observe the following values when installing/fastening the cable clamps.
Figure 22-6
22-10-08
Cable Clamp Torquing
Trim Servo Removal/ Installation Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. T
2 Remove tail cone access panel. 3 Disconnect electrical connector from trim servo. 4 Remove swivel from transmission chain. 5 Remove transmission chain. 6 Remove 4 bolts and nuts securing servo support bracket to GFK base. 7 Remove 4 bolts and nuts securing trim servo to support bracket. 8 Move trim servo with driving wheel to the right fuselage side out of support bracket. 9 Remove trim servo in forward direction. IMPORTANT
Prior to installing trim servo, check and adjust clutch torque and determine proper direction of driving wheel rotation. See Section 22-1004 for clutch torque settings.
IMPORTANT
Prior to installing trim servo, check trim tab control system.
10 Install in reverse order of removal.
Function Test Detail Steps/Work Items
Key Items
1 Attach external power to the aircraft. Page Date: 30. March 2012
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Detail Steps/Work Items
Key Items
2 Check all switches off. 3 Switch EXT PWR on. 4 Switch AUTOPILOT PITCH TRIM on. 5 Move (complete) TRIM switch on the LH control wheel forward. 6 Check trim wheel (upper part) turns forward. 7 Move (complete) TRIM switch on the LH control wheel aft. 8 Check trim wheel (upper part) turns aft. 9 Press AP DISC switch on LH control wheel. 10 Switch AUTOPILOT PITCH TRIM off. 11 Switch EXT PWR off. 12 Disconnect external power.
22-10-09
Trim Servo Clutch Torque Settings The following torque setting must be checked and adjusted: Servo P/N Trim S-TEC 0106-2-T3
Clutch Torque setting 36 ± 2 inlbs
Servo RPM @24VDC (fixed, not adjustable) 11.03
Torque Adjustment Before re-installation, perform the following steps to check and adjust clutch torque value given above. Detail Steps/Work Items
Key Items
Measuring 1 Draw cotter pin from castle nut. 2 Insert adapter tool (S-TEC P/N 6622-1) into leading holes in driving wheel. 3 Bear dial torque wrench.
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Detail Steps/Work Items
Key Items
4 Connect servo motor to 28 VDC power source.
Servo shaft rotates
5 Read torque value.
See above for appropriate torque settings. Perform clutch torque adjustment as per step 6 - 7, if necessary
Adjustment 6 Remove torque wrench and adapter tool. 7 Align torque value with castle nut - turn CW to increase and CCW to decrease torque. 8 Repeat steps 2 to 7, until read torque setting (step 5) matches value given above. 9 Disconnect servo motor. 10 Re-install cotter pin. NOTE
22-10-10
To align cotter pin with shaft hole, use shim washers S - TEC P/N 1205 S 5 - 005, 007, 010, 031 in any combination (min. 1 required).
Pressure Transducer Removal/Installation Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. T
2 Remove tail cone access panel.
Refer to Chapter 51-00-01.
3 Disconnect electrical connector from pressure transducer. 4 Disconnect pressure hose from pressure transducer.
Cut cable tie
5 Remove pressure transducer.
2 bolts
6 Install in reverse sequence of removal.
Fasten pressure hose with new cable tie.
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22-10-11
Yaw Amplifier Removal/Installation Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. T
2 Remove tail cone access panel. 3 Disconnect electrical connector from yaw amplifier. 4 Remove pressure yaw amplifier.
4 bolts
5 Install in reverse sequence of removal.
22-10-12
Programmer/Computer Removal/Installation Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. 2 Place a Allen key in hole between REV Computer will come out. and ALT key, rotate CCW. 3 Pull out rest of the way.
Do not pull on VS knob!
4 Remove programmer/computer
22-10-13
5 Install in reverse sequence of removal.
Use Allen key, rotate CW until computer sits firmly in rack, flush with panel.
6 Perform heading calibration procedure
Refer to Subject 22-10-00 Heading Calibration
Turn Coordinator Removal/Installation Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. Page 30
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Detail Steps/Work Items 2 Remove RH IFD.
Key Items Refer to Chapter 31-60-01.
3 Disconnect electrical wiring. 4 Remove turn coordinator.
4 screws
5 Install in reverse sequence of removal. 6 Perform heading calibration procedure
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Refer to Subject 22-10-00 Heading Calibration
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Chapter 23 Communications
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Table of Contents
23-00-00
GENERAL ........................................................................................................ 3 Description.......................................................................................................... 3 Troubleshooting.................................................................................................. 3
23-10-00
SPEECH COMMUNICATION ...................................................................... 5 Description.......................................................................................................... 5 Operation ............................................................................................................ 5
23-50-00
AUDIO INTEGRATING ................................................................................. 6
23-50-01
Intercom System PS Engineering PMA8000B(-T) ........................................ 6 Description.......................................................................................................... 6 Operation ............................................................................................................ 6 Removal.............................................................................................................. 6 Installation .......................................................................................................... 6 Tests and Checks ................................................................................................ 7
23-50-02
Antennas ............................................................................................................ 8 Description.......................................................................................................... 8 Removal/Installation........................................................................................... 8
23-60-00
STATIC DISCHARGING ............................................................................... 9 General................................................................................................................ 9 Description.......................................................................................................... 9 Lightning Protection/Static Discharging System ............................................. 10
Figure 23-01
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Maintenance Manual EXTRA 500
23-00-00
GENERAL Description The EXTRA 500 is equipped with a speech and entertainment communication system, consisting of the following devices: 1 Avidyne Entegra Release 9 IFD System 2 PS Engineering PMA8000B(-T) Stereo Intercom System 3 COM 1, 2, and Marker Antennas The system units (1 and 2) are mounted to the instrument panel, the antennas as shown on Figure 23-01. In Chapter 23-10-00 Speech Communication you will find information about Avidyne Entegra Release 9 IFD System. The related PS Engineering PM8000B(-T) devices and the COM antennas are subject to Chapter 23-50-00 Audio Integrating. Chapter 23-60-00 Static Discharging contains a description of the EXTRA 500 bonding system.
Troubleshooting Complaint Unable to transmit or receive
Possible Cause
Remedy
No power on load bus
Switch on starter/generator or external power.
Defective AUDIO-MRK breaker
Replace
Unable to transmit or receive COM I
Defective LH IFD
Replace LH IFD
Unable to transmit or receive COM II
Defective RH IFD
Replace RH IFD
Unable to transmit with IFD indication
No or defective antenna cable connections
Check antenna cable connections
Unable to transmit from the pilot's side (missing transmit mode indicator on display)
Defective transmit button on pilot's side
Replace
Defective wiring between pilot's transmit button and radio unit
Repair
Unable to transmit from the co-pilot's side (missing transmit mode indicator on display)
Defective transmit button on co-pilot's side
Replace
Defective wiring between copilot's transmit button and radio unit
Repair
No modulation when transmitting from pilot's seat
Defective pilot's headset
Replace
Defective wiring
Repair
COM [1/2] TX Fault
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Maintenance Manual EXTRA 500
Complaint
Possible Cause
Remedy
No modulation when transmitting from co-pilot's seat
Defective co-pilot's headset
Replace
Defective wiring
Repair
Short range in transmit mode; reception without problems
Defective radio unit
Repair
Short range in receive mode; signal noise in reception
Defective radio unit
Repair
Short range in transmit and receive mode; signal noise in reception
Defective COMM antenna, coaxial cable and plug
Repair or replace
Speaker silent, headsets operation normal
Defective speaker
Replace
Defective wiring
Repair
Defective intercom unit
Replace
Transmit button stuck
Replace
Defective intercom unit
Replace
Defective wiring
Repair
Transmit mode indicator on display is always visible COM [1/2] Stuck TX
Intercom system inoperative, transmit mode O.K.
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Maintenance Manual EXTRA 500
23-10-00
SPEECH COMMUNICATION Description The EXTRA 500 airplane is equipped with an Avidyne 700-00083-000 Integrated Flight Display (IFD) in the left (PFD) position and either another 700-00083-000 IFD in the right (MFD) position. A Control Display Unit (CDU) p/n 700-00150-002 is also installed as part of the Entegra Release 9 IFD System and located on the middle console. Refer to Chapter 31-60 for more information. The system is integrated to: • S-TEC System 55X Autopilot • Audio panel • Remote transponder • DME (optional) • Weather detection (optional) • Traffic advisory (optional)
Operation Refer to POH EXTRA 500.
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Maintenance Manual EXTRA 500
23-50-00
AUDIO INTEGRATING
23-50-01
Intercom System PS Engineering PMA8000B(-T) Description The PMA8000B and PMA8000BT are audio isolation amplifier and audio selector that contain an automatic voice activated (VOX) intercom system and integral marker beacon receiver. They can switch two transceivers (Com 1, Com 2) and six receivers (Com 1, Com 2, Nav 1, Nav 2, DME, and MKR).
Operation Refer to EXTRA 500 Pilot's Operating Handbook.
Removal Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. T
2 Put a 3/32 Allen wrench into the center access hole between the Com2 and Mon1 push buttons for the locking screw in the front panel. Engage the screw. 3 Turn the screw counter-clockwise until the unit disengages from the mounting rack. CAUTION
Do not pull on the knobs. Do not pry the face plate. You can damage the unit.
CAUTION
Do not touch the connector card at the rear of the unit. The electrostatic charge on your body can damage the unit.
4 Pull the sides of the unit gently to remove it from the mounting rack. 5 Install the protective covers on the rear connectors of the unit.
Installation Detail Steps/Work Items
Key Items
1 Remove the protective covers from the rear connectors of the unit. 2 Slide the unit into the rack. 3 Engage the locking screw so that the latch front lobe touches the rack. Page 6
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Detail Steps/Work Items
Key Items
4 Turn the locking screw clockwise so that the rear lobe engages the mounting rack. CAUTION
Do not over-tighten the locking screw. You can damage the locking mechanism.
5 Continue to turn the screw until the unit is fully installed in the mounting rack. 6 Perform a function test.
See Tests and Checks below.
Tests and Checks Perform the applicable operational checkout presented in the Avidyne System Installation and Operation Manual (LOAP 37) or (LOAP 38) whenever the unit has been reinstalled.
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Maintenance Manual EXTRA 500
23-50-02
Antennas Description For communication transmitting and receiving conventional antennas (COM 1, 2, and Marker) are used (refer to Figure 23-01). The antennas are attached to the fuselage by a ground plate. The lightning protection sheet is placed between the ground plate and the fuselage structure and thus ensures bonding. Connection is made via conventional BNC plugs and sockets. The Marker and COM 2 antenna is integrated in the structure of the ventral fin. Maintenance should not be required. In case access to this antenna is required, contact EXTRA.
Removal/Installation Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. T
2 Disconnect BNC plug. 3 Remove attachment nuts. 4 Remove antenna. 5 Install in reverse sequence of removal.
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Ensure lightning protection sheet is placed between fuselage structure and ground plate.
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Maintenance Manual EXTRA 500
23-60-00
STATIC DISCHARGING General A special bonding system is necessary for the composite structure of the EXTRA 500. The composite structure does not sufficiently conduct electricity. Lightning protection aluminium sheets are attached to the inner fuselage skin to make a conduct path. Attachment is made by fabric layers and interconnections between sheets are made by rivets. All metal components are bonded to the aluminium sheets by copper leads. Some components are directly connected to the aluminium sheets when attached (so as the COM 1, 2, and Marker antenna).
Description A main aluminium sheet is routed from the firewall to the right side of the inner fuselage and then to the rear. Several extensions are routed to the wing, landing gear, antennas and other equipment as shown on Figure 23-01 (Figure 23-01 only shows the lightning protection system and equipment as far as applicable for communication system static discharging).
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Page 9
NAV Antenna
COM 1 Antenna
Strobe Light Power Supply
COM 2 Antenna
Strobe Light
Maintenance Manual EXTRA 500
Figure 23-01 Page 10
23
Lightning Protection/Static Discharging System Page Date: 30. March 2012
Maintenance Manual EXTRA 500
Chapter 24 Electrical Power
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Table of Contents
24-00-00 Figure 24-1 Figure 24-2 Figure 24-3
GENERAL ........................................................................................................ 3 Description.......................................................................................................... 3 Electrical System Schematic............................................................................... 4 Left Side Panel Switches..................................................................................... 5 Left Side Panel Circuit breakers ........................................................................ 6 Troubleshooting.................................................................................................. 7
24-30-00
DC GENERATION .......................................................................................... 9
24-30-10
Starter-Generator............................................................................................. 9 Removal/Installation........................................................................................... 9
24-30-11
Generator Control Unit (GCU) ....................................................................... 9 Removal/Installation......................................................................................... 10
24-30-20
Standby Alternator......................................................................................... 10 Removal/Installation......................................................................................... 10
24-30-21
Alternator Regulator ...................................................................................... 10 Removal/Installation......................................................................................... 11
24-30-30
Battery ............................................................................................................. 11 Charging with external power .......................................................................... 11 Charging over charger plug .............................................................................. 12 Removal/Installation......................................................................................... 12
24-30-40
Indication......................................................................................................... 12
24-30-41
Indicator Cluster............................................................................................. 12 Removal/Installation......................................................................................... 13
24-40-00
EXTERNAL POWER .................................................................................... 14 Description........................................................................................................ 14
24-60-00
DISTRIBUTION............................................................................................. 15 Description........................................................................................................ 15
24-60-01
E-box ................................................................................................................ 16 Removal/Installation......................................................................................... 16
24-60-02
Switches ........................................................................................................... 16 Removal/Installation......................................................................................... 16
24-60-03
Circuit Breakers ............................................................................................. 17 Removal/Installation......................................................................................... 17
24-60-04
Relays ............................................................................................................... 17
24-60-05
Shunts .............................................................................................................. 17
24-60-06
Fuses................................................................................................................. 17
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24-00-00
GENERAL Description Refer to Figure 24-1. The electrical system is a 28 VDC system with negative ground. The primary DC power source is an engine driven 28 V/200 A startergenerator. It is backed up by an engine driven 26 V/20 A standby alternator. In addition a lead acid battery (24 V/28 Ah) is installed in the engine compartment. Normal battery power is sufficient to start engine or for ground check operation. An external 28 VDC power receptacle and its circuit breaker are installed in a hatch right hand at fixed portion of the cowling.
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Page 3
C EM B E G E RGE N N ST TE S C Y AR T GE T N EX T AV PW IO R ST NIC DB S YA LT
RC
BA TT
Maintenance Manual EXTRA 500
y
Generator control unit
r y
Alternator control unit
Bus voltage Battery current Generator current
External power
Battery 24 VDC
Standby alternator 20 A Starter/generator 200 A
Hot bus
Load bus
Emerg. bus
Batt. bus AV bus
Legend:
y
Hot bus
Figure 24-1
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Switch
Shunt
Annunciator light
Circuit breaker
Electrical bus
Fuse
Relay
Gauge
Electrical System Schematic
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CABIN
DEICE
LIGHTS
AVIONIC MASTER
MAIN
Maintenance Manual EXTRA 500
Figure 24-2
Left Side Panel Switches
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Maintenance Manual EXTRA 500
Figure 24-3
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24
Left Side Panel Circuit breakers
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Troubleshooting The following paragraph tabulates the trouble shooting procedures relevant to the battery system. Complaint System not energized when battery switch is turned on
Possible Cause
Remedy
Depleted or dead battery
Recharge or replace.
Defective wiring
With BATT switch OFF, check entire DC power system, accessible from plane fire wall resp. lower tail cone access panel, for an open circuit with a continuity tester
Defective battery relay
With BATT switch ON, connect a voltmeter to the main battery bus and check voltage. If no voltage is indicated, check and/or replace relay
Defective BATT switch
Remove switch and check with continuity tester. Replace switch if defective.
Charging rate too low
Check generator
Battery has been left standing too long without recharging
Recharge or replace
Equipment has been left on accidentally
Replace battery
Short circuit in wiring
Check wiring, replace battery.
Low charging rate
Check generator voltage
Corroded or loose battery connections
Clean and tighten, recharge battery.
Reduced battery capacity
Replace battery.
Battery polarity reversed
Connected backwards on airplane or charger
Battery should be slowly discharged completely, then charged correctly and tested
Battery freezes
Undercharged or overcharged battery
Replace battery
Battery discharged
Short battery life
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Maintenance Manual EXTRA 500
Complaint Starter-generator does not produce current when switched on.
Possible Cause
Remedy
Starter-generator defective
Replace starter-generator.
Generator control unit defective
Replace generator control unit.
GEN switch defective
Replace GEN switch.
Generator relay defective
Replace generator relay (Ebox).
Current indication defective
Replace shunt. Replace indicator. Repair wiring.
Standby alternator does not produce power when switched on
Bus voltage above 26.5 V
Normal, no action required.
Alternator defective
Replace alternator.
Alternator controller defective
Replace alternator controller.
Wiring defective
Repair wiring.
STDBY ALT switch defective
Replace STDBY ALT switch.
Alternator relay defective
Replace alternator relay (Ebox).
Alternator fuse defective
Examine reason and replace alternator fuse (E-box).
Current indication defective
Replace shunt.
T
Replace indicator. Repair wiring. Load bus without power
Starter-generator or external power not on.
Normal, no action required.
Load bus fuse defective
Replace fuse (E-box).
Battery bus without power
Battery bus fuse defective
Replace fuse (E-box).
Avionic bus without power
Battery bus without power
See above.
AVIONICS switch defective
Replace AVIONICS switch (left side panel).
Avionic bus relay defective
Replace avionic bus relay (left side panel).
AV BUS circuit breaker
Replace AV BUS circuit breaker (left side panel).
defective
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24-30-00
DC GENERATION Refer to Figure 24-1. DC generation is done by the following devices: • Starter-generator • Standby Alternator • Battery
24-30-10
Starter-Generator A starter-generator is mounted on the accessory gearbox of the engine. It is a direct driven starter during engine start and a DC generator driven by the engine during engine operation. Its rated capacity is 200 A maximum for continuous operation.
Removal/Installation Remove the LH upper engine cowling to get access to the starter-generator. Refer to AIRCRAFT PARTS CORP. Installation Instructions 200SGL Series Starter-Generators (LOAP 39) for further information.
24-30-11
Generator Control Unit (GCU) The starter-generator is regulated by the GCU (Generator Control Unit) to provide an output voltage of 28.5 V DC. The GCU is installed to the fuselage structure behind the left legroom side paneling. The GCU is controlled by the GEN and GEN TEST switches located on the MAIN section of the left side panel. Following engine start, the generator delivers electrical power when the GEN switch is switched to ON position. In case the generator is not switched on or has failed the red GENERATOR FAIL warning light on the annunciator panel illuminates. With the generator test switch (GEN TEST, left side panel) the overvoltage protection function of the GCU can be tested (switch position: OV-TEST). The TRIP position of this switch gives the possibility to “trip” the generator by momentarily interrupting its excitation. Both test functions lead to disengagement of the generator from the aircraft bus system. The momentary RESET position of the GEN switch serves to energize the generator field in case problems have occurred trying to connect the generator to the aircraft bus system (switching the generator ON). Resetting the generator is recommended in that case before trying to switch the generator on again.
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Maintenance Manual EXTRA 500
Removal/Installation Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. T
2 Remove left legroom side paneling.
Refer to Chapter 25-00-01.
3 Remove electrical connector. 4 Remove GCU.
4 bolts
5 Install in reverse order of removal.
24-30-20
Standby Alternator In case of a starter-generator failure a gear driven standby alternator provides an additional power source in excess to the aircraft battery. The standby alternator is controlled by the STDBY ALT switch in the MAIN section of the left side panel. Switching it to the ON position will command the alternator regulating unit to regulate an alternator output voltage of 26 VDC. Therefore as long as bus voltage is higher caused by an active generator the alternator load will be zero. As soon as bus voltage drops below the regulation voltage of the standby alternator the alternator feeds to the bus system. Max. rated current is 20 A which is available with N1 being at approx 92 %. At 78 % N1 about 10 A are available. Below 70 % N1 the standby alternator isn’t able to provide a relevant current. Operation of the standby alternator is indicated by a yellow STANDBY ALTERN ON caution light on the annunciator panel. Continuous illumination of this light signals operation below the 20 A output limitation.
CAUTION
If the STANDBY ALTERN ON caution light starts blinking, the load on the alternator exceeds its rated capacity. Reduce consumption of electrical consumers within 5 minutes to 20 A or less.
Removal/Installation Remove the upper engine cowlings to get access to the stand-by alternator. Refer to B & C SPECIALTY PRODUCTS Installation Instructions for BC410 Alternators (LOAP 40) for further information.
24-30-21
Alternator Regulator The alternator regulator is mounted to the cabin side of the firewall. Refer to B & C SPECIALTY PRODUCTS B & C SPECIALTY PRODUCTS Troubleshooting Guide (LOAP 28) for further information.
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Maintenance Manual EXTRA 500
Removal/Installation Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. T
2 Remove RH and LH IFD.
Refer to Chapter 31-60-01.
3 Remove electrical connection. 4 Remove 2 nuts. 5 Remove regulator. 6 Install in reverse order of removal.
24-30-30
Battery The 24 VDC/28 Ah valve regulated lead acid battery is located in the engine compartment, mounted to the pressure bulkhead and protected by a vented aluminum case. The battery is directly connected to the hot bus. The battery supplies power to the electrical system when BATT switch is switched to ON position. Recharging the battery may be done with battery installed. There are two procedures:
Charging with external power Detail Steps/Work Items
Key Items
Always keep sparks or any form of ignition away from the battery being WARNING charged. Explosive gases are being generated during the charging process. 1 Set external power unit to 28 VDC. 2 Connect external power. 3 Switch on BATT. 4 Switch on EXT PWR.
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Maintenance Manual EXTRA 500
Charging over charger plug Detail Steps/Work Items
Key Items
Always keep sparks or any form of ignition away from the battery being WARNING charged. Explosive gases are being generated during the charging process. Do not charge with more than 5 A. Use only supplied unit or equivalent. 1 Connect the charger to the charger plug. 2 Connect the charger to the wall socket.
Removal/Installation Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. T
2 Remove upper engine cowlings.
Refer to Ch. 71-10-01/02.
3 Disconnect the quick connect plug. 4 Disconnect the 2 retainers. 5 Remove battery from aircraft. 6 Install in reverse order of removal
24-30-40
Indication Electric system relevant indication is made by the digital indicator cluster installed in the left side of the main panel and the following lights in the annunciator panel: GENERATOR FAIL (red), see Subject 24-30-10. LO VOLTAGE (yellow), illuminates as soon as bus voltage drops below 25.5 V. STANDBY ALTERN ON (yellow), see Subject 24-30-20. EXTERNAL POWER (green), see Subject 24-40-00.
24-30-41
Indicator Cluster The digital indicator cluster installed in the left side of the main panel indicates three electric system parameters among other engine parameters (also refer to Chapter 77-40-02):
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Maintenance Manual EXTRA 500
VDC (bus voltage) During normal operation (generator active) a voltage of approx 28 V should be indicated. With standby alternator the indication should be about 26 V. Battery nominal voltage is 24 V. GEN AMPS (Generator Load) Generator load is indicated on this indicator as long as the generator is active (GENERATOR FAIL warning light off). Generator Load should be kept below 200 A. In case the generator is offline this indicator automatically displays the standby alternator load. The standby alternator load has to stay below 20 A (see also Subject 24-30-20). BAT AMPS The battery amp indicator shows load or charging current on the battery. A negative indication means battery is being charged, a positive indication means battery is discharged (load on battery).
Removal/Installation For removal/installation procedures refer to Chapter 77-40-02.
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Maintenance Manual EXTRA 500
24-40-00
EXTERNAL POWER Description An external power receptacle is installed under an access door on the right side of the engine compartment. The use of external power is recommended for engine starting in case aircraft battery is weak, for ground operation of the vapor cycle air condition system or for any prolonged ground operation of aircraft systems. An external power source being connected with the external power receptacle and switched on will be indicated by a green EXTERNAL POWER annunciation light in the annunciator panel. To enable the external power source to supply power to the aircraft the EXT PWR switch on the MAIN section of the left side panel has to be switched on.
CAUTION NOTE
Do not connect ground power units with a capacity greater than 1200 A for engine start. It is not possible to connect the starter-generator and an external power source simultaneously to the aircraft bus system. This is to avoid any uncontrolled currents between these units. Additionally a battery charger plug is installed at the external power receptacle. The battery may be charged with 29.0 V and 5 A.
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Maintenance Manual EXTRA 500
24-60-00
DISTRIBUTION Description Electrical power from the various power sources is supplied to the E-box. The E-box incorporates the main devices of the distribution system such as fuses, circuit breakers, relays, and shunts and is installed on the engine side of the firewall. From there power is distributed partly through individual fuses to the following buses: • Hot Bus, • Emergency Bus, • Battery Bus and Avionic Bus • Load Bus, The battery directly feeds the hot bus supplying power for equipment, which has to be independent from the battery switch position (e.g. ELT; see Figure 24-2 for location of battery switch). Turning the battery switch to the ON-position will activate a relay connecting the battery to the battery bus and further to the emergency bus. This allows starting the engine and feeding the other equipment and, if engine is running, recharging the battery with the starter/generator. The generator is activated by turning GEN switch to the ON-position (see Figure 24-2). So the generator is activated and the generator relay connects the generator to the load, battery and emergency bus. From the main bus electrical power is distributed to the various busses as outlined on Figure 24-1. The avionic bus can be disconnected by the AVIONICS switch. The main control switches of the electrical power system are located on the MAIN section of the left side panel (see Figure 24-2) and are marked EXT PWR, BATT, STBY ALT, GEN and GEN TEST. T
Push-pull circuit breakers automatically break the current if an overload occurs to prevent damage to the electrical wiring and equipment. The most circuit breakers are installed to the left side panel (see Figure 24-3). A single circuit breaker is installed on the upper LH engine mount (GCU) and under the external power hatch (EXT PWR) respectively. All other circuit breakers are installed to the E-box located on the engine side of the firewall and are labeled GEAR AUX 2, BATT CHARGE, SPARE, ALT FIELD 2, COURTESY LT, and ELT. Generally where exclusively wiring shall be protected poly switches are used. They are installed on different locations of the electrical system.
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Maintenance Manual EXTRA 500
24-60-01
E-box Removal/Installation Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. T
2 Remove upper engine cowlings.
Refer to Ch. 71-10-01/02.
3 Disconnect the SCEET hoses from the oil cooler inlet. 4 Remove 10 attachment screws of the oil cooler inlet. 5 Remove oil cooler inlet. 6 Remove 8 oil cooler outlet attachment screws. 7 Move oil cooler and outlet some centimeters forward.
To get access to the E-box.
8 Disconnect electrical connector 9 Disconnect power lines 10 Remove upper E-box cover.
1 screw
11 Disconnect 3 main power bulkhead feedthroughs.
Hold threaded rod in place by means of an Allen wrench.
12 Remove 3 attachment screws. 13 Remove E-box. 14 Remove cover plate and shell plate.
Plates are screwed on.
15 Install in reverse sequence of removal.
24-60-02
Switches Removal/Installation The switches on the instrument panel are accessible from the backside after removal of the RH IFD. The LANDING GEAR, FLAP, and ELT switch backsides are directly accessible from the legroom. The backsides of the left side panel switches are accessible when the upper and lower part of the left side panel has been removed. Generally conventional switches are used, so that removal is done by disconnecting the electrical wiring and removing attachment screws or nuts. Installation is vice versa.
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24-60-03
Circuit Breakers Removal/Installation The circuit breakers on the left side panel are accessible from the backside when the upper and lower part of the left side panel has been removed. To get access to the E-box circuit breakers the E-box must be removed (refer to Subject 24-60-01). Generally conventional circuit breakers are used, so that removal is done by disconnecting the electrical wiring (busses) and removing attachment screws or nuts. Installation is vice versa.
24-60-04
Relays Relays are installed in the left side panel, in the E-box and behind the RH IFD. To get access to the relays either the E-box (see Subject 24-60-01), the left side panel (see Chapter 31-10-01) or the RH IFD (see Chapter 31-60-01) must be removed Electrical wiring is generally connected to the relays by means of relay sockets. The relays are mounted to the sockets with bolts.
24-60-05
Shunts Shunts are installed in the E-box. To get access to the shunts the E-box must be removed (refer to Subject 24-6001). Electrical wiring is generally connected to the shunts by means of screws. The shunts are mounted to the supports with bolts.
24-60-06
Fuses The main fuses are installed in the E-box with bolts. They are accessible after removal of the upper E-box cover.
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Maintenance Manual EXTRA 500
Chapter 25 Equipment and Furnishing
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TABLE OF CONTENTS
25-00-00
GENERAL ........................................................................................................ 5
25-10-01
Paneling ............................................................................................................. 5 Description.......................................................................................................... 5 Removal/Installation........................................................................................... 5
25-10-00
FLIGHT COMPARTMENT ........................................................................... 6
25-10-10
Seats, Seat Belts, and Shoulder Harnesses ..................................................... 6 Description.......................................................................................................... 6
25-10-11
Pilot's Seat ......................................................................................................... 6 Removal/Installation........................................................................................... 6
25-10-12
Copilot's Seat..................................................................................................... 7 Removal/Installation........................................................................................... 7
25-10-21
LH Side Armrest Paneling............................................................................... 7 Removal/Installation........................................................................................... 7
25-10-22
RH Side Armrest Paneling............................................................................... 8 Removal/Installation........................................................................................... 8
25-10-23
Front Ceiling Paneling ..................................................................................... 8 Removal/Installation........................................................................................... 8
25-10-24
Upper Side Paneling LH/RH Side................................................................... 9 Removal/Installation........................................................................................... 9
25-10-25
Windshield Middle Strut Paneling.................................................................. 9 Removal/Installation........................................................................................... 9
25-10-26
Middle Console Paneling Upper Part ............................................................. 9 Description.......................................................................................................... 9 Removal/Installation........................................................................................... 9
25-10-27
Middle Console Paneling Lower Part........................................................... 10 Description........................................................................................................ 10 Removal/Installation......................................................................................... 10
25-20-00
PASSENGER COMPARTMENT................................................................. 11
25-20-10
Seats ................................................................................................................. 11
25-20-11
Front Passenger Seats .................................................................................... 11 Removal/Installation......................................................................................... 11
25-20-12
Aft Passenger Seats......................................................................................... 11 Removal............................................................................................................ 11 Installation ........................................................................................................ 12
25-20-21
LH Side Armrest Paneling............................................................................. 12 Removal/Installation ......................................................................................... 12
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25-20-22
RH Side Armrest Paneling .............................................................................13 Removal/Installation..........................................................................................13
25-20-31
Storage Boxes LH/RH.....................................................................................13 Description ........................................................................................................13 Removal/Installation .........................................................................................13
25-20-32
Table .................................................................................................................14 Removal/Installation .........................................................................................14
25-50-00
BAGGAGE COMPARTMENT.....................................................................15 Description ........................................................................................................15
25-50-01
Tie Down Belts.................................................................................................15 Removal/Installation .........................................................................................15
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25-00-00
GENERAL
25-10-01
Paneling Description If not described in another way paneling is generally mounted to the aircraft structure with Phillips screws.
Removal/Installation Take care of the paneling installations such as switches, sockets, lights etc. when removing. Ensure BATT switch is OFF and no external power connected, when electrical devices are involved. Sometimes the paneling overlaps. Then it is necessary to remove also the adjacent paneling. Move paneling some centimeters inboard after removal of Philips screws to get access to the paneling backsides. Then disconnect electrical wiring. Installing is vice versa. T
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25-10-00
FLIGHT COMPARTMENT
25-10-10
Seats, Seat Belts, and Shoulder Harnesses Description The pilot's and copilot's seats are one piece, four-way adjustable seats incorporating energy absorbers which reduce forces working on the occupants in case of crash. The seats may be moved forward, aft, up, and down. The adjustment is made by pulling a handle located at the right respective left forward underside of the seat to release the fixing mechanism. The horizontal adjustment range is 152 mm, 5 fixed positions are provided. The vertical adjustment range is 80 mm, 5 fixed positions are provided. Telescopic cylinders support the pilot during the vertical adjustment. The seat belts and the shoulder harnesses with inertia reels used for the pilot and copilot are attached to the seats. The seat belts provide a conventional adjustment. Shoulder harness adjustment is not necessary due to the inertia reels, which allow straps to extend and retract as required under normal movement. However the reels will lock in place in the event of a sudden deceleration.
25-10-11
Pilot's Seat Removal/Installation Detail Steps/Work Items
Key Items
1 Remove front roll from RH seat track.
2 screws
2 Remove mounting bracket and roll as a unit from back RH seat track.
2 screws
3 Pull off bracket from back LH seat track.
2 screws
4 Pull adjusting handle to release bolt at longitudinal adjusting device. 5 Slide seat out of mounting console in forward direction. 6 Install in reverse order of removal.
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25-10-12
Copilot's Seat Removal/Installation Detail Steps/Work Items
Key Items
1 Remove front roll from LH seat track.
2 screws
2 Remove mounting bracket and roll as a unit from back LH seat track.
2 screws
3 Pull off bracket from back RH seat track.
2 screws
4 Pull adjusting handle to release bolt at longitudinal adjusting device. 5 Slide seat out of mounting console in forward direction. 6 Install in reverse order of removal.
25-10-21
LH Side Armrest Paneling Removal/Installation Detail Steps/Work Items 1 Remove left side panel.
Key Items Refer to Chapter 31-10-01.
2 Remove screw fastening microphone twin socket on rear top of panel. 3 Remove screw at lower front panel side. 4 Remove screw at lower rear panel side. 5 Slightly lift panel and remove it against flight direction. 6 Install in reverse sequence of removal.
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25-10-22
RH Side Armrest Paneling Removal/Installation Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. T
2 Remove microphone socket cover on rear top of panel. 3 Remove screw at lower front panel side. 4 Remove screw at lower rear panel side. 5 Slightly lift panel and remove it against flight direction. 6 Install in reverse sequence of removal.
25-10-23
Front Ceiling Paneling Removal/Installation Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. T
CAUTION
Take care not to damage sunblinds. Swivel sunblinds up before removing ceiling panel
2 Remove 4 screws around upper windshield frame. 3 Remove 4 screws near panel edges. 4 Disconnect plug for dome light/speaker wiring. 5 Carefully remove adhesive tape at panel back side. 6 Remove front ceiling paneling. 7 Install in reverse sequence of removal.
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25-10-24
Upper Side Paneling LH/RH Side Removal/Installation Detail Steps/Work Items
Key Items
1 Remove 2 screws in windshield frame area. 2 Remove 2 screws in front cabin window contour area. 3 Remove upper side paneling. 4 Install in reverse sequence of removal.
25-10-25
Windshield Middle Strut Paneling Removal/Installation Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. T
2 Remove 2 screws at compass. 3 Disconnect wiring for compass lighting. 4 Remove compass. 5 Remove 4 screws at paneling. 6 Remove windshield middle strut paneling. 7 Install in reverse sequence of removal.
25-10-26
Middle Console Paneling Upper Part Description The middle console paneling consists of an upper and lower part. The upper part is screwed on the lower part and on the middle console structure.
Removal/Installation Detail Steps/Work Items 1 Remove trim wheel.
Key Items 1 Phillips screw
2 Remove the back-up microphone from the middle console. Page Date: 30. March 2012
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Detail Steps/Work Items 3 Remove the upper part of middle console paneling.
Key Items 24 Phillips screws
4 Install in reverse sequence of removal. 5 Check the function of the back-up microphone.
25-10-27
Middle Console Paneling Lower Part Description The lower part of the middle console paneling is aligned by 4 guiding pins in the fuselage frame and fixed by the upper part of the paneling.
Removal/Installation Detail Steps/Work Items
Key Items
1 Remove upper part of the middle console paneling.
Refer to Subject 25-12-06
2 Disconnect air hoses from the legroom dispensers.
1 worm drive hose clamp each side
3 Move lower part paneling some centimeter aft and remove. 4 Install in reverse sequence of removal.
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Insert guide pins to the related holes in the forward paneling edges.
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25-20-00
PASSENGER COMPARTMENT
25-20-10
Seats The passenger seats are one piece seats as well but are placed on a fix position. However the backrest of both aft seats can be swiveled forward allowing easy access to the baggage compartment. For this purpose a release handle located on the inner side of the backrest has to be pulled up.
Ensure backrest is locked by checking the down position of the release WARNING handle before using the seat. The seat belts provide a conventional adjustment however the locking mechanism is placed on the inner side of the seat providing a lock for the shoulder strap, which is equipped with inertia reels. The attachments of the seat belts and shoulder harnesses are integrated in the seat.
25-20-11
Front Passenger Seats Removal/Installation Detail Steps/Work Items 1 Remove screws at mounting console.
Key Items 4 Allen screws LN 29952-0615M
2 Remove seat. 3 Install in reverse order of removal.
25-20-12
If necessary, use mounting template at landing gear attachment for front side screws.
Aft Passenger Seats Removal Detail Steps/Work Items
Key Items
1 Remove front paneling of baggage compartment from seat assembly.
To get access to the mounting consoles.
2 Remove back side screws at inner and outer seat mounting console.
4 Allen screws LN 9037 - 06018
3 Remove front side screws at inner and outer seat mounting console.
1 Allen screw LN 9037 - 06016 and 2 Allen screws LN 9037 - 06018
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4 Remove screws at higher angle bracket.
6 Allen screws AN 5260 - 1032
Installation 1 Insert front side screws at inner and outer seat mounting console.
1 Allen screw LN 9037 - 06016 and 2 Allen screws LN 9037 - 06018
2 Before tightening front side screws completely, adjust seat from rear side and install back side screws at inner and outer seat mounting console.
4 Allen screws LN 9037 - 06018
3 Tighten front side screws at inner and outer seat mounting console. 4 Install screws at higher angle bracket.
6 Allen screws AN 5260 - 1032
5 Reinstall front paneling of baggage compartment..
25-20-21
LH Side Armrest Paneling Removal/Installation Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. T
2 Remove microphone socket cover on front top of panel. 3 Remove microphone socket cover on rear top of panel. 4 Remove 5 screws at entrance bottom panel sheet. 5 Loosen screws at door sealing frame in armrest area. NOTE
On some aircraft, the armrest is fixed with additional latches to the door frame. In this case remove the screws and the latches completely. 6 Remove screw at lower front panel side. 7 Remove screw at lower rear panel side. 8 Pull armrest together with frame floor finishing inboard and remove it against flight direction. 9 Install in reverse sequence of removal.
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25-20-22
RH Side Armrest Paneling Removal/Installation Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. T
2 Remove microphone socket cover on front top of panel. 3 Remove microphone socket cover on rear top of panel. 4 Remove table.
Refer to Subject 0.
5 Remove screw at lower front panel side. 6 Pull back frame floor finishing. 7 Slightly lift panel and remove it against flight direction. 8 Install in reverse sequence of removal.
25-20-31
Storage Boxes LH/RH Description Storage boxes are located between LH and RH side pilot’s/copilot’s and front passenger seats. They provide a place for depositing especially the emergency torch, first aid kit and the aircraft documentation material.
Removal/Installation Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. T
2 Slide pilot’s and co-pilot’s seat into most forward position. 3 Remove 2 screws at front and back bottom side. 4 LH box Remove screws at floor and back wall of upper and lower storage compartments. 4 RH box Take out fire extinguisher, remove bolts holding extinguisher support bracket. 5 Install in reverse sequence of removal.
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25-20-32
Table Removal/Installation Detail Steps/Work Items
Key Items
1 Remove 2 screws at table underside. 2 Remove 2 sheatings. 3 Remove table. 4 Install in reverse sequence of removal.
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25-50-00
BAGGAGE COMPARTMENT Description The baggage compartment is located behind the aft passenger seats. To get access the backrest of both aft seats can be swiveled forward. The release handle is placed on the left side of the backrest. The baggage can be secured by tie down belts, which are to be fastened on eyes located on two compartment sides.
25-50-01
Tie Down Belts Removal/Installation Detail Steps/Work Items
Key Items
1 Release the handles at aft passenger seat backrests and swivel backrests forward. 2 Remove 2 Phillips screws AN 526 C .1032 R8 securing front belt brackets to LH and RH side console. 3 Remove front belt. Remove 2 Phillips screws AN 526 C .1032 R8 securing aft belt brackets to LH and RH side console. Remove aft belt. 4 Install in reverse sequence of removal.
Page Date: 30. March 2012
Install screws just so tight, that belt brackets can be rotated freely, but without play.
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Maintenance Manual EXTRA 500
Chapter 27 Flight Controls
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TABLE OF CONTENTS 27-00-00
GENERAL ........................................................................................................ 5 Description.......................................................................................................... 5
27-00-01
Control Cable .................................................................................................... 5 Tensions.............................................................................................................. 5 Control System Surview...................................................................................... 6
Figure 27-01 27-00-10
CONTROL SPRINGS...................................................................................... 7 Location .............................................................................................................. 7
27-00-11
Down-Spring ..................................................................................................... 7 Description.......................................................................................................... 7
27-00-12
Interconnection Aileron/Rudder ..................................................................... 7 Description.......................................................................................................... 7
27-00-13
Centering Rudder ............................................................................................. 8 Description.......................................................................................................... 8
27-00-14
Nose Gear Steering ........................................................................................... 8 Description.......................................................................................................... 8
27-00-15
Nose Gear Control Cable ................................................................................. 8 Description.......................................................................................................... 8
27-10-00
AILERONS ....................................................................................................... 9 Description.......................................................................................................... 9 Troubleshooting.................................................................................................. 9 Removal/Installation......................................................................................... 10
27-10-01
Aileron Cables................................................................................................. 10 Removal/Installation......................................................................................... 10
27-20-00
RUDDER ......................................................................................................... 11 Description........................................................................................................ 11 Troubleshooting................................................................................................ 11 Removal/Installation......................................................................................... 12
27-20-01
Rudder Cables................................................................................................. 12 Removal/Installation......................................................................................... 12
27-30-00
ELEVATOR AND TAB................................................................................. 14 Description........................................................................................................ 14 Troubleshooting................................................................................................ 14 Removal/Installation......................................................................................... 16
27-30-01
Elevator Cables ............................................................................................... 16 Removal/Installation......................................................................................... 16
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FLAP SYSTEM ...............................................................................................18 Description ........................................................................................................18 Rigging and Adjustment ...................................................................................18 Track Adjustment..............................................................................................19 Guidance Checks and Adjustment ....................................................................19 Actuation Adjustment .......................................................................................20
27-50-01
Flap Drive Motor.............................................................................................21 Description ........................................................................................................21
27-50-02
Inboard Power Transmission Flexible Shaft ................................................22 Description ........................................................................................................22
27-50-03
Outboard Power Transmission Flexible Shaft .............................................22 Description ........................................................................................................22
27-50-04
Power Transmission Screw Jacks..................................................................23 Description ........................................................................................................23
27-50-05
Flap Control Box .............................................................................................23 Description ........................................................................................................23
27-50-06
Flap Limit Switches.........................................................................................24 Description ........................................................................................................24 Adjustment ........................................................................................................24
27-50-07
Flap Asymmetry Senders ...............................................................................26 Adjustment ........................................................................................................26
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27-00-00
GENERAL Description The flight controls consist of the ailerons, rudder and elevators. The right elevator is equipped with a trim system. All these control surfaces are constructed of composite material. The primary control system is a conventional cable-system consisting of a double control wheel (pitch and roll) with respective coupling systems, hanging control pedals (yaw), tubes, levers, pulleys and push-pull rods. Between ailerons and rudder controls an interconnection which is made via springs is installed. However, the coupling can easily be overpowered (e.g. in side slipping).
27-00-01
Control Cable Tensions The control cable systems generally use cable of 3.2 mm diameter. However the aileron control uses cables of 4 mm diameter in the wing region. System
Cable Diameter
Cable Tension
Tolerance
Ailerons
3.2 mm/4 mm
220 N/49.5 lbs
± 20 N/4.5 lbs
Rudder
3.2 mm
220 N/49.5 lbs
± 20 N/4.5 lbs
Elevator
3.2 mm
300 N/67.4 lbs
± 20 N/4.5 lbs
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Side View Pulley Segment
Aileron Control Elevator Control
Rudder Control
Top View Turnbuckles
Pulleys Rudder and Elevator Control
Top View
Pulleys Aileron Control Pulley Segment
Left Wing symmetrically
Turnbuckles
Figure 27-01 Page 6
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Control System Surview Page Date: 30. March 2012
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27-00-10
CONTROL SPRINGS Location The following springs are incorporated in the control system of the EXTRA 500: Application
27-00-11
Location
Down-spring
Cockpit, instrument shelf
Interconnection aileron/rudder
Cockpit, bulkhead
Centering rudder
Tail fairing
Nose gear steering
Nose wheel dome
Nose gear control cable
Cockpit
Down-Spring Description Safety spring, affecting the pulley segment of the elevator control, to create a nose-down pitching control force. The down-spring is located on the LH side, below the instrument shelf. In case of down-spring failure the amount of steering force required will rise when pushing the control yoke. Trimming "nose down" will compensate this effect. Malfunction of the down-spring will not cause further reductions of flight performance or any unsafe flight conditions.
27-00-12
Interconnection Aileron/Rudder Description To reduce tendency to raise the low wing, esp. during low speed flight (landing approach), the EXTRA 500 is furnished with an interconnection between the aileron and the rudder control. When activating the rudder, the coupling correspondingly actuates the aileron control. When moving the aileron, the rudder — as long as being free of any control forces — remains in neutral position. The coupling is being accomplished by means of a pair of safety springs, located at the LH foot compartment. The control force is conducted from the shafts of the rudder control to the safety springs by levers and cables, including the pulleys. Once the friction inside the control system has been overcome, a rudder control input is led to the LH control column by a chain drive.
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Failure of an interconnection spring will cause an additional force in one direction at the aileron control, which is rated below the tolerated amount.
27-00-13
Centering Rudder Description Within the lower rudder bearing a spring-loaded pulley strains a steel plate attached to the rudder, thus centering the rudder in neutral position and providing a defined rising of control forces while moving the rudder. Malfunction of the centering spring will disengage the centering and reduce the control force rise. Unsafe flight conditions are excluded.
27-00-14
Nose Gear Steering Description The pivoting of the nose gear is part of the rudder control system, completing the control cable arrangement. To de-couple the nose gear steering from the rudder control, two safety springs are incorporated into the nose gear pivoting. The springs will transmit the control force forward after having reached a defined travel. Malfunction of the nose gear steering springs will abolish pretension of the control cables. With a 16° play arising inside the nose gear steering, reduction of max. angular movement from ± 30° to approx. 10° in one direction will occur, whereas control force at the rudder pedals will slightly increase.
27-00-15
Nose Gear Control Cable Description These additional springs will stretch the nose gear control cables, when one of the springs at the nose gear pivoting has been lengthened due to a rudder movement against the locked nose wheel. Malfunction of one or both springs will not affect normal control functions.
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27-10-00
AILERONS Description The coupling between the two control wheels of the main control system is realized by a direct cable-chain coupling. The cables are connected to the control wheels by means of a longitudinal toothed wheel and run through the windshield center strut to the wing nose and move outboard. Outside the tank area they cross the front spar. Then they are connected to a cable segment which actuates the aileron via lever and push-rod. Each aileron is attached to the rear spar of the wing by two hinges.
Troubleshooting Complaint Lost motion in control wheel.
Resistance to control wheel movement.
Control wheels not level with ailerons neutral
Possible Cause
Remedy
Loose control cables.
Check cable tension. Adjust cables to proper tension.
Broken pulley or braket, cable of pulley or worn rod end bearings.
Check visually. Replace worn or broken parts, install cables correctly.
Cables too tight.
Check cable tension. Adjust cables to proper tension.
Pulleys binding or cable off.
Observe motion of the pulleys. Check cables visually. Replace defective pulleys. Install cables correctly.
Defective quadrant assembly.
Check visually. Replace defective quadrant.
Clevis bolts in system too tight.
Check connections where used. Loosen, then tighten properly and safety.
Improper adjustment of cables. Adjust turnbuckle to obtain proper alignment. Improper adjustment of aileron push-pull rods.
Adjust push-pull rods to obtain proper alignment.
Dual control wheels not coordinated.
Cables improperly adjusted.
Adjust cables.
Chain improperly adjusted.
Adjust chain.
Incorrect aileron travel.
Push-pull rod not adjusted properly.
Adjust rod.
Incorrect adjustment of travel stop bolts.
Adjust bolts.
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Removal/Installation Detail Steps/Work Items
Key Items
1 Loosen push rod from central part of aileron 2 Remove cotter pin and bolt from each of the two hinges 3 Remove aileron backwards 4 Install in reverse order of removal
27-10-01
Aileron Cables Removal/Installation Detail Steps/Work Items
Key Items
1 Remove center cover of wing root section 2 Remove turnbuckle below cover Perform steps No 3 – 9 at LH and RH side wing each 3 Remove turnbuckle at outer wing rib 4 Remove rigging clamps of role servo at inner wing rib 5 Remove recognition light at outer wing nose section 6 Remove outer side pulley 7 Push up inner side pulley 8 Remove teflon guiding bushings at outer wing rib 9 Loosen return cable segment at outer wing rib for removal of 3.6 mm cable
Remove bolt and push segment sideways
10 Remove 2 pulleys at windshield center strut 11 Remove teflon guiding bushings at windshield center strut 12 Remove avionic panel 13 Remove LH and RH side return brackets 14 Remove LH and RH cable safety brackets below instrument shelf 15 Loosen return cable segments at steering column
Remove bolts and push segments sideways
16 Install in reverse order of removal
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27-20-00
RUDDER Description The rudder pedals are placed hanging on two tubes which have a lever arm at the right side of the cabin. From there the cables are led along the cabin right side armrest panel to the empennage around pulleys positioned in groups. Here a direct connection to the lever arms of the rudder follows. The connection points lay inside the tail cone adjacent to the lower rudder bearing. The rudder is connected to the rear fin spar at three points.
Troubleshooting Complaint
Possible Cause
Remedy
Play between pedals and rudder.
Insufficient cable tension.
Rig the system.
Rudder does not respond to pedal movement.
Broken or disconnected cables.
Open armrest panel, access doors and tailcone and check visually. Connect or replace cables.
Excessive resistance against pedal movement, binding or jumpy movement of pedals.
Cables too tight.
Rig the system.
Cables not running properly on pulleys.
Open armrest panel, access doors and tailcone and check visually. Lay cables correctly over pulleys.
Binding, broken or defective pulleys or cable guards.
Check visually. Replace defective pulleys and install guards properly.
Pedal torque-tube bearings need lubrication.
Lubricate pedal bearings.
Defective pedal torque-tube bearings.
Check visually. Replace bearings.
Defective rudder hinge bearings.
Check visually. Replace defective bearings.
Clevis bolts too tight.
Check and readjust bolts to eliminate binding.
Incorrect rudder travel.
Incorrect rigging.
Rig the system.
Excessive resistance against pedal movement only while gear is extended
Worn or defective nosewheel steering bearings
Check visually. Replace defective bearings.
Nosewheel does not respond to pedal movement.
Broken or disconnected cables.
Check visually. Connect or replace cables.
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Complaint
Possible Cause
Remedy
Reduced nosewheel steering travel on one side
One steering cable spring broken
Check visually. Replace spring
Incorrect nosewheel steering travel / aircraft not rolling straightly with pedals neutral.
Incorrect rigging.
Rig the system.
Removal/Installation Detail Steps/Work Items
Key Items
1 Remove right aft passenger seat
Refer to Chapter 25-20-13
2 Remove RH side paneling
Refer to Chapter 25-20-22
3 Loosen two turnbuckles of rudder cables, located at RH wall adjacent to right aft seat and baggage compartment 4 Loosen rudder cables at lower rudder bearing 5 Remove bolt at LH side of central rudder bearing 6 Remove lower rudder bearing
5 screws M5
7 Remove cotter pin and nut at lower rudder bearing 8 Slightly lift rudder above higher bearing and remove rudder backwards 9 Install in reverse order of removal
27-20-01
Rudder Cables Removal/Installation Detail Steps/Work Items
Key Items
1 Remove lower RH side panels in flight, passenger and baggage compartments 2 Remove upper rear wall of baggage compartment 3 Remove instrument shelf 4 Remove turnbuckle below RH side of instrument shelf 5 Remove 2 turnbuckles at RH side wall in baggage compartment Page 12
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6 Remove turnbuckle at rear wall of baggage compartment 7 Remove 2 pulleys below instrument shelf
Remove safety pin from smaller pulley
8 Remove 2 pulleys from RH side wall in flight compartment
Remove bolts
9 Remove 2 pulleys from RH side wall in rear passenger compartment
Remove bolts
10 Remove teflon guiding bushings at rear wall of baggage compartment 11 Remove LH access panel at rear fin 12 Remove 2 smaller pulleys 13 Remove 2 pulleys at LH and RH side each below instrument shelf 14 Remove teflon guiding bushings to nose wheel well
Remove safety sheet
15 Remove nose gear cable control springs 16 Install in reverse order of removal
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27-30-00
ELEVATOR AND TAB Description A lever system transfers elevator control movement from each of the two steering wheels by a respective carrier bolt bushing to a cable segment. From this cable segment the elevator cables run horizontally to the right cabin side to a 90° pulley and parallel to the rudder cables to the empennage. They are led to the elevator in front of the front fin spar and are attached to a lever positioned in front of the horizontal stabilizer front spar, which actuates the two elevator sides separately by means of push pull rods. Each elevator is attached to the respective horizontal stabilizer by three bearings. The mechanical pitch trim is actuated through a trim wheel in the pedestal. The pitch trim tab is located in the right elevator and is linked over a 'redundant' cable-lever system to the trim wheel. The trim Bowden cables run from the middle console down crossing the cabin floor and are then directed rearwards to the empennage following the nose section of the fin to the right side elevator. Pitch trim can be actuated electrically also by means of switches located on the pilot's control wheel. The system can be overpowered by pilot's hand forces in case of system failure.
Troubleshooting Complaint Play in control column.
Excessive resistance to control column movement.
Possible Cause Loose control cables.
Check cable tension. Adjust cables to proper tension.
Broken pulley or bracket, cable off pulley, or worn rod end bearings.
Check visually. Replace worn or broken parts, install cables correctly.
Cables too tight.
Check cable tension. Adjust cables to proper tension.
Pulleys binding or cable off.
Observe motion of the pulleys. Check cables visually. Replace defective pulleys. Install cables correctly.
Defective pulley quadrant assembly.
Check visually. Replace defective quadrant.
No nose down force on control Down-spring disconnected. column.
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Remedy
Check visually. Attach downspring correctly.
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Complaint Binding or jumpy motion felt in movement of elevator system.
Possible Cause
Remedy
Cables too tight.
Check and adjust tension.
Cables not riding correctly on pulleys.
Check visually. Replace defective pulleys.
Defective control column bearings.
Check visually. Replace defective bearings.
Control guide on aft end of control square tube adjusted too tightly.
Loosen screw and tapered plug in end of control tube enough to eliminate binding.
Defective elevator hinges.
Disconnect push-pull rods and move elevators by hand. Replace defective hinge bearings.
Stops set incorrectly.
Rig the system.
Cables tightened unevenly.
Rig the system.
Defective cable or deformed tube.
Check visually and replace defective parts.
Trim tab hinge binding.
Disconnect actuator and move tab up and down to check hinge resistance. Lubricate or replace hinge as necessary.
Defective trim tab actuator.
Disconnect cable from actuator and operate actuator manually. Replace defective actuator.
Stick-slip effect between cable and tube.
Lubricate all moving parts.
Control wheel does not move trim tab.
Disconnected or broken cable.
Check visually and connect or replace cable as necessary.
Play between control wheel and trim tab.
Parts worn out
Check visually and replace parts as necessary.
False reading on trim position indicator.
Indicator incorrectly engaged on wheel axis.
Check visually. Adjust indicator.
Worn, bent or disconnected linkage.
Check visually. Repair or replace parts as necessary.
Stop blocks loose or incorrectly adjusted.
Adjust stop blocks on cables.
Incorrect rigging.
Rig the system.
Elevator fails to attain prescribed travel.
Trim control wheel moves with excessive resistance.
Incorrect trim tab travel.
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Removal/Installation Detail Steps/Work Items
Key Items
RH elevator 1 Loosen push rod at trimming tab
8 hollow core bolts LN4
2 Continue as per step 1 to 5, LH elevator LH elevator 1 Loosen control lever 2 Swivel up elevator 3 Remove socket pins from central and outer bearings
2 socket pins LN6
4 Turn elevator horizontally backwards around inner bearing 5 Remove elevator 6 Install in reverse order of removal
27-30-01
Elevator Cables Removal/Installation Detail Steps/Work Items
Key Items
1 Remove lower RH side panels in flight, passenger and baggage compartments 2 Remove upper rear wall of baggage compartment 3 Remove instrument shelf 4 Remove turnbuckle below RH side of instrument shelf 5 Remove 2 turnbuckles at RH side wall in baggage compartment 6 Remove turnbuckle at rear wall of baggage compartment
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7 Remove 2 pulleys below instrument shelf
Remove safety pin from smaller pulley
8 Remove 2 pulleys from RH side wall in flight compartment
Remove bolts
9 Remove 2 pulleys from RH side wall in rear passenger compartment
Remove bolts
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10 Remove teflon guiding bushings at rear wall of baggage compartment 11 Remove LH tailcone access panel 12 Remove 2 clamps of pitch servo 13 Remove LH access panel at rear fin 14 Remove 2 larger pulleys 15 Remove linkage between cable and aileron
Remove bolt
16 Remove push rod 17 Install in reverse order of removal
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27-50-00
FLAP SYSTEM Description The wing flaps are of the Fowler type. Each wing flap (two per side) is attached to the rear wing spar and guided during its movement by three wing tracks. Actuation is by means of two spindles, which are connected to the central electrical flap motor by flexible shafts. The flap motor is located in front of the rear spar in the fuselage area of the wing and is controlled by the wing flap position switch in the cockpit. This switch incorporates a preselect feature which allows the pilot to select the amount of flap extension desired. When the UP/0°- , 15°- or 30°- position is selected, the flap motor is electrically actuated and drives the flaps toward the selected position. When the actual flap position equals the selected position, limit switches located at the wing tracks respective the outer spindles de-energize the flap motor. The actual flap position will be indicated by green lights at the left side of the wing flap position switch. When flaps are moving the yellow light will be illuminated. If the 0°-position is reached all lights are off. As the flaps move an electrical circuit compares the movement of the left and right wing flaps. If the wing flap positions differ by more than 7° ± 3°, the flap motor will be automatically switched off to prevent asymmetric conditions. This will be indicated by the flap error warning light located on the warning light panel. This light indicates also a failure of the complete flap control.
NOTE
In case of the wing flaps being unbalanced, they rest in the position they have reached when failing and cannot be actuated until airplane has been in maintenance. However in this case the airplane can be easily balanced by slight aileron and/or rudder input. Setting the wing flaps will cause a decrease of airspeed and a moderate nose down moment. Bring wing flaps to 0°-position before opening the cabin door
CAUTION
Rigging and Adjustment This section describes the procedure for correct adjustment of the defined flap settings as well as the maximum flap asymmetric limits. Due to the local chord of the flaps (30 % of the wing) and positioning the 15° and 30° DOWN extension relative to the local chord the travel of the flaps depends on the lateral station. CAUTION NOTE
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All adjustment must be made with the motor power OFF (pulled circuit breaker FLAP). Rigging of the flap system requires a flap track snap gauge (Extra PartNo. EA-15182W10). This will be available at EXTRA. See also Chapter 01-00-02.
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Track Adjustment Perform the following adjustment checks as long as the flaps are not installed. For flap installation, refer to Chapter 57-50-01: 1 Check of spanwise adjustment Check distance between flap tracks at their rear end. Distance between inner and middle track is 1989 ± 2 mm (78.31 ± 0.08 in.) and between middle and outer track 1827.5 ± 2 mm (71.95 ± 0.08 in.). If further details of flap track positioning are required, contact EXTRA. 2 Check of twist between tracks Check flap tracks for proper torsional alignment (cord over all three lower keyways). Max. permissible distance of lower keyway centerline at the middle flap track is 2mm (0.08 in.), when cord is aligned with outer and inner flap track keyway.
Guidance Checks and Adjustment Check the following items after flap installation: 1 Minimum gap between flap and aileron While pulling the flaps outboard against the stop, check width of gap between aileron and outer flap segment. The stop is reached, when one of the sliding surfaces on the outboard end of the inner or outer flap segment contacts the middle or outer flap track. Minimum gap width is 8 mm (0.31 in.). Check the following items after flap installation and after each 100 hours of operation: 2 Spanwise flap rigging Check whether any guidance roller on the inner track protrudes more than 3 mm (0.12 in.) outside the inner track when flaps are pulled outboard against the stop. The stop is reached, when one of the sliding surfaces on the outboard end of the inner or outer flap segment contacts the middle or outer flap track. Repeat the check for the rollers in the outer flap track while pushing the flaps inboard. Verify visually that stops are definitely reached. 3 Flap guidance rollers twist rigging Minimum play in guidance keyways: Check all flap segments for minimum free play of rollers in keyways. Lift each flap segment manually at trailing edge and observe for positive free play of flap segment at trailing edge. Check this for all four flap segments and for flap positions 0° and 30°. The SKF track rollers (forward roller on inner track and both rollers on outer track) feature an eccentric bushing to provide a means of adjustment in this respect. 4 Flap guidance rollers functional check Check whether the rollers are rolling but not slipping by performing the following test: Extend flaps to their 30° position and retract them while manually applying a load of about 200 N (45.0 lbs.) upwards at the trailing edge of the flaps near the respective track. If a roller is slipping identify cause and replace roller as necessary.
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5 Inspection of roller contact areas Inspect rear side of lower keyway on inner flap tracks for signs of axial contact with mushroom head of roller. Contact Extra Flugzeugbau GmbH if marks are found. Inspect guidance roller tracks for wear and permanent deformation. For wear and deformation the following service limits are defined: Max. increase of track width due to deformation: 0.6 mm (0.024 in.) per side. Width of guidance slot between 16.3 mm and 16.8 mm (0.64 in. and 0.66 in.). Check with flap track snap gauge (see Chapter 01-00-02).
Actuation Adjustment 1 Ascertain that both inner flex drive shafts are disconnected from the electric drive motor and that the flap motor and flap control circuit breakers are pulled. 2 Make sure for both LH and RH side flap that the respective asymmetry detection mechanisms are not mounted yet. If they are already mounted, make sure that the ball joint connection between linkage rod and bracket is disconnected and the linkage rod is taped to the spar. CAUTION
If this is not done, parts of the mechanism may be destroyed while moving the flaps.
3 Lower both (LH and RH) flaps to their fully extended stop position. This can be done by turning the hex socket coupling of the RH flex shaft CCW and the LH flex shaft CW respectively, with view of the coupling. Use a battery hand held drill with fine speed control and reverse feature, equipped with a 3/16 “ (4.7 mm) Allen key tip. CAUTION
Do not run flaps to their extreme position (end of trackslots) with electric drill to avoid damage. Turn flex shafts by hand to reach the end of the tracks.
4 If the roller on one flap end rib reaches the outer end of its track slot while the roller on the other flap end rib is 2 mm or more away from its track slot end, an adjustment is necessary. This is done at one of the two transmission screw jacks. 5 Disconnect the flap bracket from the rod end of its transmission actuator, then move the rod into the proper direction by rotating it in steps of 180°-turns, then reconnect. A 180°-turn of the inner transmission’s rod in CCW direction or of the outer transmission’s rod in CW direction will move the adjacent roller about 2 mm towards the extended position. NOTE
The screw of the inboard transmission rod features a RH thread whereas the outboard one features a LH thread 6 Raise both (LH and RH) flaps from their extended stop positions by rotating the hex socket coupling of the flex drive shafts 2.5 turns in reverse direction to secure a gap between rollers and track slot ends about 1.5 mm (.06"). This will give the 30° position. Use a 3/16" (4.7 mm) Allen key and turn by hand. 7 The basic adjustment dimensions at the transmission actuators (measured from the center of the mounting pin of the screw jack to the center of the rod end) are:
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Position Inner actuator Outer actuator
0° Retracted
15° Intermediate
30° Extended
58 + 3/- 0 mm
152 + 3/- 0 mm
270 + 3/- 0 mm
2.28 + .12/-0 inches
5.98 + .12/-0 inches
10.63+ .12/-0 inches
68 + 3/- 0 mm
135 + 3/- 0 mm
219 + 3/- 0 mm
2.68 + .12/-0 inches
5.31 + .12/-0 inches
8.62 + .12/-0 inches
8 If the rod end at the transmission screw and the respective flap bracket do not align, disconnect the rod end from the bracket and loosen the two bolts securing the bracket to the flap. This will allow the bracket to be moved by tapping. Connect the rod end to the bracket and tap the bracket to achieve a satisfactory alignment. Disconnect the rod end from the bracket and torque the bracket attachment bolts. With the transmission screw and flap bracket aligned, finally connect the rod end to the bracket with the bolt assy. 9 When measuring flap deflection angles, lift the trailing edge of the flap to eliminate play between rollers and track slots.
27-50-01
Flap Drive Motor Description Brush type bidirectional permanent magnet motor, positioned in the wing center box at the front web of the rear spar Characteristics: 1 Hex shafts on both sides 2 Capability of dynamic braking 3 Max. ambient temperature: + 40 °C 4 Voltage: 24 to 30 VDC, 24 VDC nominal 5 Torque at output shaft: 50.7 Ncm nominal at 24 VDC, 1,600 RPM, 4.5 amps 6 Power output: 85 W 7 Ratio RPM/Torque: 5.1 (Ncm ⋅ min) -1 8 Voltage factor: 0.013 V ⋅ min 9 Efficiency: 78 % 10 Insulation class IP 54 according DIN 40050 (protected against dirt, dust and ingressed water)
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27-50-02
Inboard Power Transmission Flexible Shaft Description The inboard flexible shaft has a female 3/16" hex drive at motor side and a DIN 75532 E1 for the screw jack side. LH and RH flex shaft are different in main rotation due to the musk wire: CW or CCW for main rotation. Characteristics: 1 Length: 1,400 mm 2 Core: Carbon steel musk wire φ 6 mm 3 Casing and end fittings in CRES 4 Shrink sleeve on casing 5 Minimum installation bend radius: 300 mm 6 Coupling nut 2024-T4 blue anodized or CRES with hole for safety wire 7 Min. static torque : 300 Ncm
27-50-03
Outboard Power Transmission Flexible Shaft Description The outboard flexible shaft is a standard type DIN 75532 E1. As for the inboard shaft LH and RH flex shafts are different in main rotation due to the musk wire: CW or CCW for main rotation. Characteristics: 1 Length: 2,000 mm 2 Core: Carbon steel musk wire φ 4 mm 3 Steel casing 4 End fitting in steel zinc - plated galvanically 5 Shrink sleeve on casing 6 Minimum installation bend radius: 55 mm 7 Coupling nut aluminium with hole for safety wire 8 Min. static torque: RH 104 Ncm (CCW)/49 Ncm (CW) LH 104 Ncm (CW)/49 Ncm (CCW)
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27-50-04
Power Transmission Screw Jacks Description The in- an outboard screw jacks consists of a reduction worm gear and machine screw nut with trapezoid thread (irreversible by choice of pitch). The inboard screw jacks have right hand threads, the outboard screw jacks left hand threads. The worm shaft and the screw nut are equipped with ball bearings. Characteristics: 1 Worm gear ratio: inboard 5:1 outboard 7:1 2 Efficiency of worm gear: inboard 0.7 outboard 0.65 3 Pitch of screw nut: 3 mm stroke per revolution 4 Number of revolutions for full stroke of screw jack (30° flap setting): inboard 70 revolutions outboard 50 revolutions 5 Stopping accuracy: ± 3 % of full stroke 6 The unit is sealed 7 All external parts are protected against corrosion 8 Periodic lubrication is not required 9 Output shaft splines: According DIN 75532 E2 for connection to the flexible drive shafts
27-50-05
Flap Control Box Description A Flap Control Box providing the flap control functions is fixed into the avionic bay with an adapted bracket, using 4 AN bolts with AN washers. The Flap Control Box performs the following functions: 1 Controlling the motor for the 3 intended flap - positions (retracted, 15° intermediate and 30° fully extended) 2 Activating the flap position signals 15°, 30° or "flaps in transition" and: Asymmetry detection by controlling the rheostats fitted at the outboard flaps on the LH and RH, thus activating: 1 Motor shut-off 2 Signalisation to the warning panel inside the cockpit Wing flap asymmetric tolerances are adjustable at the trimmer of the watchdog box. Refer to Subject 27-50-07.
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27-50-06
Flap Limit Switches Description The 0° and 30° flap positions are detected by four limit switches, every two of them attached to a mounting bracket positioned on the LH and RH side wing’s rear spar web. If one DOWN or UP limit switch related to any of these flap positions fails, the remaining one on the opposite side will still detect the desired flap position. The extended flap position is detected by the DOWN limit switch on the LH flap (backup switch on the RH side) and the retracted flap position is detected by the UP limit switch on the RH flap (backup switch on the LH side). The switches are operated by the same linkage mechanism that is used for asymmetry detection. The 15° flap position is detected by two limit switches at the LH outboard screw jack.
Adjustment DOWN Limit Switch 1 Run the flaps to the 30° position determined before. If not present yet, mount both asymmetry detection potentiometers and put the lever arm on the potentiometer shafts, but do not tighten their clamping screws yet. CAUTION
Tightening of the clamping screws may destroy parts of the mechanism while moving the flaps.
2 At the LH side wing flap, determine the axial and the angular position of the arm on the potentiometer shaft so that it contacts the 30° limit switch in the center of the arm. 3 With the positions of the potentiometer arm and flap bracket given, adjust the linkage rod until it fits. The start value is 66 mm (2.6”) between the ball joint centers. The length adjustment is done by loosening the nuts and rotating the rod, which features one LH side and one RH side thread. Tighten the rod nuts and the ball joint nuts after the adjustment is completed, but do not tighten the potentiometer arm clamping screw. 4 Manually move the flaps up to the retracted position as described in step 3 of the Guidance Check and Adjustment Paragraph of Section 27-50-00. With the flaps on retracted position the gap between the flap and the wing, measured at the lower side, should be 4 mm (.16”).
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UP Limit Switch 1 Perform the same way as with the DOWN limit switch, but with the rod linkage of the RH flap accordingly. Stop the flaps in retracted position just before any of the flap rollers reach the end of the track slots (approximately 1.5 mm (.06") space should remain between the end of the track slot and the closer roller of both flaps). Ascertain at least 1.5 mm (.06") clearance between the tip of the potentiometer arm and the spar. NOTE
Flaps must stop prior to rollers making contact with the end of the trackslots. 2 Turn one drive shaft coupling (RH or LH side) manually as far as necessary to give the right flap the same angular setting as the left flap. 3 Connect and safety-wire the flexible drive shafts to the electric drive motor. 4 Move the selector switch to position RETRACTED and engage the flap motor circuit breaker. Run the flaps from the retracted position to the fully extended position. When the actual flap position reaches the selected position, the appropriate limit switch must deenergize the flap motor. Otherwise parts may be destroyed.
CAUTION 15° Limit Switch 1 Run the flaps by moving the selector to the 15° position. Install the flap rigging tool, if not previously accomplished. Rigging the flaps to the defined 15° setting max require fine adjustment at the LH outboard screw jack. This can be accomplished by readjusting the nylon bushing positioned at the end of the transmission screw that actuates both 15° limit switches. 2 Run the flaps to the 30° setting for removal of the LH outboard screw jack. Disconnect the outer flex drive shaft from the LH outboard screw jack. Disconnect the transmission from the flap bracket. Remove the screw jack from the rear spar. Loosen the counter stop nut of the nylon bushing. Rotating the nylon bushing in CW direction will shift the 15° detection to the retracted position, rotating in CCW direction will shift it to the extended position. Adjust as required and tighten the counter stop nut. Reinstall transmission unit to the rear spar. Reinstall the transmission unit to the rear spar. Connect the flex drive shaft to the transmission actuator. 3 Check that all bolts and joints are secured where necessary. 4 Check function of the position indicator. Green lights indicate the 15° and 30° position and an additional yellow light indicating "flaps in transition". The retracted position is indicated by the fact that no light is on. 5 Check the flap operation.
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27-50-07
Flap Asymmetry Senders Adjustment This adjustment is required after the flaps have been rigged and checked for normal operation. The asymmetry senders, one potentiometer at the LH side and one at the RH side flap, are part of an electric system, the so-called watchdog. The watchdog shuts off the flap motor when the difference between the LH and RH side flap angular positions exceeds 7° ± 3°. 1 Lower the flaps by moving the selector to the 15° position. 2 Pull the flap motor circuit breaker. Ascertain that the flap control circuit breaker is engaged. Turn the sensitivity control potentiometer of the watchdog box towards maximum sensitivity. 3 Adjust the LH asymmetry detection potentiometer. Make sure that the arm is loose on the shaft, then rotate the shaft to find out the potentiometer’s center position between its two internal stops. The angular range of the potentiometer is ± 170 °. Then tighten the arm’s clamping screw. 4 Adjust the RH asymmetry detection potentiometer to ensure that the angular travel to engage the watchdog is the same when retracting as when extending the flaps. Make sure that the arm is loose on the shaft, then rotate the shaft in CW direction until the red asymmetry indicator light on the watchdog box appears (simultaneously the red light on the warning panel in the cockpit appears). Mark this angular shaft position. Rotate the shaft in CCW direction. The red indicator light will turn off, then light up again after rotating a few degrees. Mark this position, too. 5 Finally rotate the sender shaft to the middle between the two marks and tighten the arm’s clamping screw. Now the two potentiometers feature the same resistance value at a given flap position. After adjusting, check for correct alignment of asymmetry detection sensitivity: 6 With the flaps in 15° position disconnect the RH flex drive shaft from the electric drive motor. Engage the flap motor circuit breaker and move the selector switch to the UP position. The LH flap will move up while the RH flap will stay in the 15° position. After a certain difference in RH and LH flap angular positions is reached the watchdog shuts off the flap motor. 7 Measure the flap travel. If it is within the limit of 7° ± 3° , proceed with step 11. If it is outside that limit, proceed with step 8. 8 In order to drive the LH flap back to its 15° position, disconnect the watchdog box from the flap control box, pull the flap motor circuit breaker, move the selector switch to the 15° position and engage the flap motor circuit breaker.
CAUTION
The flap starts to move back to the 15° position immediately after engaging the circuit breaker.
9 Reconnect the watchdog box to the flap control box.
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10 Adjust the sensitivity control potentiometer by turning it in the proper direction, then repeat steps 6 to 7. After asymmetry has been adjusted for UP motion repeat this procedure for DOWN motion: 11 Move the selector switch to the DOWN position. The LH flap will move down while the RH flap will stay in the 15° position. When a certain difference in RH and LH flap angular positions is reached the watchdog shuts off the flap motor. 12 Measure the flap travel. If it is within the limit of 7° ± 3° , proceed with step 16. If it is outside that limit, proceed with step 13. 13 In order to drive the LH flap back to its 15° position, disconnect the watchdog box from the flap control box, pull the flap motor circuit breaker, move the selector switch to the 15° position and engage the flap motor circuit breaker. CAUTION
The flap starts to move back to the 15° position immediately after engaging the circuit breaker.
14 Reconnect the watchdog box to the flap control box. 15 Adjust the sensitivity control potentiometer by turning it in the proper direction, but do not turn it in a way that would compromise the setting found in step 7. Then repeat steps 11 to 12. 16 Connect and safety-wire the RH flexible drive shaft to the electric drive motor.
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Chapter 28 Fuel
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Page 1
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Table of Contents
28-00-00
GENERAL ........................................................................................................ 5 Description.......................................................................................................... 5 Figure 28-1, Sheet 1 Fuel System Schematic ....................................................................................... 6 Figure 28-1, Sheet 2 Fuel System Schematic ....................................................................................... 7 Troubleshooting.................................................................................................. 8 Reduction of Fuel Tank Vapor Hazards ............................................................. 9 28-10-00
STORAGE....................................................................................................... 10 Description........................................................................................................ 10
28-10-01
Tank ................................................................................................................. 11 Sealant Repair................................................................................................... 11 Draining ............................................................................................................ 11 Leakage Test..................................................................................................... 12
28-10-02
Drain (Curtis).................................................................................................. 12 Removal/Installation......................................................................................... 12
28-10-03
Flush Drain Valve ........................................................................................... 13 Removal/Installation......................................................................................... 13
28-10-04
Pressure Relief Valve...................................................................................... 13 Removal/Installation......................................................................................... 13
28-10-05
Pressure Relief Valve O-ring ......................................................................... 14 Replacement ..................................................................................................... 14
28-10-06
Float Valve....................................................................................................... 14 Removal/Installation......................................................................................... 14
28-10-07
Fuel Transfer Filter ........................................................................................ 15 Removal/Installation......................................................................................... 15 Cleaning............................................................................................................ 15
28-10-08
Fuel Transfer Pump ....................................................................................... 15 Removal/Installation......................................................................................... 15
28-10-09
Jet Pump.......................................................................................................... 16 Removal/Installation......................................................................................... 16
28-10-10
Jet Pump Filter Element ................................................................................ 16 Cleaning............................................................................................................ 16
28-10-11
Rubber Hose.................................................................................................... 17 Removal/Installation......................................................................................... 17
28-10-12
Pressure Switch............................................................................................... 17 Removal/Installation......................................................................................... 17
28-20-00
DISTRIBUTION............................................................................................. 18 Description........................................................................................................ 18
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Bleeding Procedure ...........................................................................................19 28-20-01
Check Valves (wing to selector valve) ...........................................................19 Removal/Installation .........................................................................................19
28-20-02
Check Valves (downstream electrical fuel pumps) ......................................20 Removal/Installation .........................................................................................20
28-20-03
Fuel Selector Valve..........................................................................................20 Removal/Installation .........................................................................................20
28-20-04
Fuel Filter Element .........................................................................................21 Exchange ...........................................................................................................21
28-20-05
Electrical Fuel Pump.......................................................................................21 Removal/Installation .........................................................................................21
28-20-06
Rubber Hose ....................................................................................................22 Removal/Installation .........................................................................................22
28-40-00
INDICATION..................................................................................................23 Description ........................................................................................................23
28-40-01
Fuel Quantity Sensor (collector compartment) ............................................23 Removal ............................................................................................................23 Installation.........................................................................................................23
28-40-02
Fuel Quantity Sensor (main or auxiliary compartment).............................25 Removal ............................................................................................................25 Installation.........................................................................................................25
28-40-03
Fuel Quantity Gauge.......................................................................................26 Removal/Installation .........................................................................................26 Calibration.........................................................................................................26
28-40-04
Fuel Flow Indicator.........................................................................................27 Removal/Installation .........................................................................................27 K-Factor Setting ................................................................................................27
28-40-05
Pressure Transducer .......................................................................................27
28-40-06
Pressure Gauge................................................................................................27
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28-00-00
GENERAL Description The next paragraph contains the general description and operation of the fuel system. The following paragraph contains information about Troubleshooting. The specified descriptions of the systems, sub-systems and units can be found in the respective chapters. The fuel system (refer to Figure 28-01) of the aircraft is a gravity assisted, pump fed system, supplying fuel to the engine driven fuel pump. The fuel system consists of: • Two integral main tank compartments (one each wing) • Two integral collector compartments (one each wing) with strainer, sump, drain and pick-up point • Two integral auxiliary compartments (one each wing) • A vent system for each tank • Two fuel transfer systems (left and right) for pumping fuel from the auxiliary tank into the main tank and to keep the collector compartment full (motive flow electrical pumps with jet pumps). • A fuel selector valve (LEFT – BOTH – RIGHT – OFF) located under the cockpit floor • A fuel filter in the engine compartment • 2 parallel, redundant electrical fuel pumps mounted on the firewall. • A fuel quantity indication system with 6 probes in the tanks and 6 indicators in the cockpit. • A fuel flow transducer mounted on the battery mount in the engine compartment. • A total of 12 drains (refer to Chapter 12-10-03 for locations)
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Page 5
Figure 28-1, Sheet 1
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Auxiliary
Main
Collector
Left
Right
Fuel quantity
Fuel flow
Fuel temperature
Fuel pressure
Fuel transfer right Fuel transfer left
Fuel pump 1
Fuel pump 2
Wing tank sump
Engine internal bypass
Overflow line
Auxiliary compartment
Vent line to left tank Collector compartment Main compartment
Only right tank shown, left tank symmetric
Firewall
Engine
Vent line
Fuel control unit
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Fuel System Schematic
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Legend:
Switch Unit Annunciator light Gauge Selector valve Check valve Overpressure relief valve Float valve Drain valve Fuel pressure accumulator Filter (with drain valve) Fuel transfer filter Pump Jet pump with filter at inlet Nozzle Filler neck Low fuel level switch Fuel level sensor Pressure switch Pressure transducer Electric wiring Flow direction
Figure 28-1, Sheet 2
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Fuel System Schematic
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Troubleshooting Complaint
Possible Cause
Fuel tank leakage
Remedy
Tank sealant damage
Identify and seal
Sump drain leakage
Inspect drain line plumbing and seal if necessary, or replace drain
Outer wing flush drain leakage Replace drain valve. Relief valve leakage
Replace relief valve/O-ring
Ventline leakage
Inspect float valves, replace if necessary, seal vent line connections
Fuel filler leakage
Filler cap O-ring damaged
Replace filler cap O-ring
Fuel line leakage
Line fittings loose
Tighten fittings
Collector compartment not full, auxiliary tank does not empty fast enough, FUEL TRANS LEFT/RIGHT ON in flight
Fuel transfer filter blocked
Clean filter
Loss of fuel supply
T
Insufficient fuel supply pressure reading
Incorrect fuel quantity reading
Incorrect fuel flow indication
Low fuel warning defective
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Electrical transfer fuel pump Replace pump defective Transfer fuel pick-up blocked
Remove blockage
Leaking transfer fuel line
Replace fitting or line
Strainer blocked (tank)
Clean strainer
Check valve (one of four) blocked
Replace check valve
Selector valve blocked
Replace selector valve
Fuel line blocked
Identify and clean or replace fuel line
Filter blocked
Replace filter element.
Fuel pressure indication defective
Replace sensor/indicator
Electrical fuel pump failure
Replace fuel pump
Float sensor defective
Repair or replace float sensor
Gauge defective
Replace gauge
Fuel flow sensor defective
Replace sensor
Fuel flow indicator defective
Replace indicator
Wrong K-factor set
Adjust K-factor at indicator
Fuel low level sensor failure
Replace fuel low level sensor
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Reduction of Fuel Tank Vapor Hazards General Precautions During all ventilation or maintenance procedures involving the fuel system, observe the following general precautions. • Defueling should be outdoors with the aircraft at least 100 feet from hangars or other aircraft. • No smoking should be allowed within 100 feet of the aircraft. • Suitable fire fighting equipment should be available. Foam or soda type extinguishing agents are recommended. • Ground the aircraft to prevent static electricity from causing sparks. If a ramp ground is available it should be connected to exhaust stack. If a ramp ground is not provided, a temporary ground can be obtained by driving a metal rod into the ground and attaching a ground wire between the rod and the aircraft exhaust stack. • Flame and spark producing equipment should not be operated within 100 feet of the aircraft. • Only personnel working on the aircraft should be allowed in the immediate area, and no other maintenance should be performed while the tanks are being worked on. • When a fuel tank is opened for repair, air ventilation (refer to Page 7) should be started immediately to reduce vapor concentrations. • When draining fuel, ensure that suitable containers are available and that drained fuel is stored safely. Do not allow fuel to drip to the ground and form pools. • If it is necessary to ventilate a tank when the aircraft is in hangar, ensure that vapors do not accumulate to explosive or toxic levels in the hangar. When fuel is being drained, there is little control over the release of fuel WARNING vapor. This vapor should be dissipated as quickly as possible by smoothly blowing shop air into the tank. Air Ventilation • Completely drain the fuel system per Chapter 12-10-02. • Remove inspection doors (refer to Chapter 28-11-03) and tank caps. • Use compressed air or an explosion-proof blower to blow air into the tank until tank interior is dry and free of vapor. • Continue ventilation whenever tank is open and being worked on. If flammable vapors from cleaning solvents are allowed in the tank WARNING increase air circulation to dissipate them.
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28-10-00
STORAGE Description The aircraft has six integral wing tanks between the wing spars. Each wing side has a main, auxiliary, and collector compartment. The latter is kept full by a jet pump driven fuel transfer system in flight. The collector compartment features a fuel level sensor, a sump with drain, a strainer and a pick-up tube behind it. The low fuel sensor is also located here. Three flapper type check valves separate the collector compartment from the main compartment to make sure fuel cannot flow out, but can flow in, in case of a fuel transfer system failure. The collector compartment can be inspected from the main compartment by opening the rib in which these valves are mounted or from the avionic compartment (center wing) by removing the inspection door on which the fuel quantity probe is installed. The main compartment has its own fuel level sensor mounted on the inner wing inspection door. The vent system has two float valves and an outlet. The vent systems of the two main tanks are interconnected. Each tank has a 1psi overpressure relief valve in the aft spar for the case the normal vent system fails. The main tanks have a Ø 75mm filler cap for JET-A1 with a titanium ring around it for static bonding. The auxiliary compartment also has a filler cap, vent system (including overpressure relief valve) and fuel level sensor, but is not directly connected to the fuel distribution system. As long as the auxiliary compartment is filled fuel is pumped from there into the main compartment by means of the fuel transfer system. Observe the safety notes given in Chapter 12-10-01.
DANGER WARNING
For all maintenance work on the tanks, drain them completely and appropriate open tank hatches on top of the wing. Be aware of fuel fumes and fuel stained cloth: highly inflammable! Power must be off, no external power connected, room well ventilated.
NOTE
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If the tank has been opened, a tank leakage test is mandatory. Refer to Subject 28-10-01 Leakage Test.
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28-10-01
Tank Sealant Repair Detail Steps/Work Items 1 Drain the fuel system.
Key Items Refer to Chapter 12-10-02
2 Observe precautions concerning Reduction Refer to Subject 28-00-00 of Fuel Tank Vapor Hazards. 3 Remove applicable fuel compartment access Refer to Chapter 51-00-01 panels. 4 Clean area. 5 Sand the area to be repaired.
Only ruff it up
PR 1750 accelerator contains harmful vapors and is readily absorbed WARNING through the skin. Avoid all contact with the skin and ingestion. Always wash hands before eating or smoking. Use adequate ventilation, hand protection and chemical-type goggles when working with this product. If accelerator contacts skin, flush area with warm water. Obtain medical attention in cases of extreme exposure or ingestion. PR 1750 sealant contains solvents. WARNING Use adequate ventilation or air-supplied respirators during application. Avoid repeated or prolonged breathing of vapors. In case of extreme vapor exposure, remove affected personnel to fresh air immediately and obtain medical attention. For complete health and safety information, refer to Le Joint Francais material safety data sheet PR 1750 (LOAP 41). 6 Apply PR 1750 tank sealant.
For mixing and application of PR 1750 sealant refer to manufacturer's instructions.
7 Perform a fuel tank leakage test.
See Leakage Test below.
8 Wait for at least 3 hours before filling the tank.
An absolute humidity of at least 10g/m3 is needed for curing. This corresponds with 35% relative humidity at 23°C and 78% at 10°C.
Draining Refer to Chapter 12-10-02.
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Leakage Test After opening a fuel tank (except the avionic bay access panels) or a tank repair, the tank shall undergo a leakage test. It is recommended to test all tanks together or LH and RH individually. The LH and RH tanks are connected by an interconnecting vent line, located in the avionic bay. It needs to be removed and the fittings in the root ribs plugged if the LH or RH should be tested individually. Furthermore, the four overpressure valves in the aft spar must be plugged or held shut as they have a lower cracking pressure as the required test pressure. Detail Steps/Work Items 1 Make sure aircraft is completely drained.
Key Items Refer to Chapter 12-10-02.
2 Observe precautions concerning Reduction Refer to Subject 28-00-00 of Fuel Tank Vapor Hazards. 3 Remove interconnecting vent line between LH and RH wing tank.
If one tank shall be tested individually.
4 Plug the appropriate fitting. Make sure the upper door is closed before extending flaps. CAUTION 5 Extend flaps to 30°.
To gain access to the overpressure valves from the outside.
6 Plug or hold shut the overpressure valves. 7 Plug vent system. 8 Turn fuel selector valve to OFF-position. 9 Pressurize the tanks slowly to 120 mbar (1.74 psig).
Tanks pressure shall be steady for min. of 10 minutes.
10 Return aircraft to normal.
28-10-02
Drain (Curtis) Removal/Installation Detail Steps/Work Items 1 Drain collector and main compartment.
Key Items Refer to Chapter 12-10-02
2 Observe precautions concerning Reduction Refer to Subject 28-00-00 of Fuel Tank Vapor Hazards. 3 Remove fuel sump access panel.
Refer to Chapter 51-00-01
4 Carefully screw drain out of fitting. 5 Install in reverse sequence of removal.
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Use Loctite 577
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28-10-03
Flush Drain Valve Removal/Installation Detail Steps/Work Items 1 Drain fuel system.
Key Items Refer to Chapter 12-10-02
2 Observe precautions concerning Reduction Refer to Subject 28-00-00 of Fuel Tank Vapor Hazards. 3 Remove applicable fuel compartment access Refer to Chapter 51-00-01 panels. 4 Loosen nut on tank inside. 5 Install vice versa.
Use Loctite 577
6 Perform tank leakage test.
Refer to Subject 28-10-01
28-10-04
Pressure Relief Valve Removal/Installation Detail Steps/Work Items
Key Items
Ensure cabin door is closed before extending wing flaps. CAUTION 1 Place wing flaps to the 30° position.
Refer to EXTRA 500 Pilot’s Operating Handbook
2 Drain fuel system.
Refer to Chapter 12-10-02
3 Observe precautions concerning Reduction Refer to Subject 28-00-00 of Fuel Tank Vapor Hazards. 4 Remove applicable fuel compartment access panel. 5 Screw out while holding plastic fitting from inside of tank to keep it from turning. 6 Install vice versa.
Use Loctite 577
7 Perform tank leakage test.
Refer to Subject 28-10-01
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28-10-05
Pressure Relief Valve O-ring Replacement Detail Steps/Work Items
Key Items
Ensure cabin door is closed before extending wing flaps. CAUTION 1 Place wing flaps to the 30° position.
Refer to EXTRA 500 Pilot’s Operating Handbook
2 Drain related fuel compartment.
Refer to Chapter 12-10-02
3 Observe precautions concerning Reduction Refer to Subject 28-00-00 of Fuel Tank Vapor Hazards. 4 Pull pressure relief valve poppet. 5 Replace O-ring
28-10-06
Float Valve Removal/Installation Detail Steps/Work Items 1 Drain fuel system.
Key Items Refer to Chapter 12-10-02
2 Observe precautions concerning Reduction Refer to Subject 28-00-00 of Fuel Tank Vapor Hazards. 3 Remove applicable fuel compartment access Refer to Chapter 51-00-01 panels. 4 Disconnect vent line. 5 Remove vent float valve from mounting.
2 screws
6 Install in reverse sequence of removal. 7 Perform tank leakage test.
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Refer to Subject 28-10-01
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28-10-07
Fuel Transfer Filter Removal/Installation Detail Steps/Work Items 1 Drain collector and main compartment.
Key Items Refer to Chapter 12-10-02
2 Observe precautions concerning Reduction Refer to Subject 28-00-00 of Fuel Tank Vapor Hazards. 3 Open wing center fairing.
Refer to Chapter 51-00-01.
4 Disconnect fittings from filter. 5 Remove fuel transfer filter from aircraft.
Notice flow direction
8 Reinstall in reverse sequence of removal.
Make sure flow direction is correct and bonding is attached.
Cleaning Detail Steps/Work Items 1 Remove fuel transfer filter.
Key Items See above
2 Open filter. 3 Clean with Jet-A1. 4 Reinstall fuel transfer filter.
28-10-08
See above
Fuel Transfer Pump Removal/Installation Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. T
2 Drain collector and main compartment.
Refer to Chapter 12-10-02
3 Observe precautions concerning Reduction Refer to Subject 28-00-00 of Fuel Tank Vapor Hazards 4 Open wing center fairing.
Refer to Chapter 51-00-01.
5 Disconnect electrical wiring. 6 Disconnect fuel hoses. 7 Remove fuel pump. 8 Install in reverse sequence of removal.
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Make sure flow direction is correct.
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28-10-09
Jet Pump The jet pumps incorporate a filter element (refer to Subject 28-10-10).
Removal/Installation Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. T
2 Drain related fuel compartment.
Refer to Chapter 12-10-02
3 Observe precautions concerning Reduction Refer to Subject 28-00-00 of Fuel Tank Vapor Hazards 4 Open related fuel compartment access panel. Refer to Chapter 51-00-01. 5 Disconnect motive flow and transfer fuel lines. 6 Remove jet pump
2 bolts
7 Install in reverse sequence of removal. 8 Perform tank leakage test.
28-10-10
Refer to Subject 28-10-01
Jet Pump Filter Element Cleaning Detail Steps/Work Items
Key Items
1 Remove jet pump.
Refer to Subject 28-10-09
2 Remove filter element.
Retaining ring
3 Clean with Jet-A1. 4 Reinstall filter element. 5 Reinstall jet pump.
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Refer to Subject 28-10-09
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28-10-11
Rubber Hose On the outflow side of the fuel transfer pumps rubber type hoses are installed (SN 1002 and 1003 only).
Removal/Installation Detail Steps/Work Items 1 Drain fuel system.
Key Items Refer to Chapter 12-10-02
2 Observe precautions concerning Reduction Refer to Subject 28-00-00 of Fuel Tank Vapor Hazards 3 Remove the applicable inner fuel compartment access panel
Refer to Chapter 51-00-01.
4 Remove hose clamps from hose end. 5 Remove fuel hose. 6 Install in reverse sequence of removal. 7 Perform tank leakage test.
28-10-12
Refer to Subject 28-10-01
Pressure Switch Removal/Installation Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. T
2 Drain collector and main compartment.
Refer to Chapter 12-10-02
3 Observe precautions concerning Reduction Refer to Subject 28-00-00 of Fuel Tank Vapor Hazards 4 Open avionic bay access panel.
Refer to Chapter 51-00-01.
5 Disconnect electrical connector. 6 Remove pressure switch. 7 Install in reverse sequence of removal.
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28-20-00
DISTRIBUTION Description Fuel runs from the LH and RH pick-up point at the bottom of the wing tank collector compartments through fuel lines via check valves down to the fuel selector valve. The check valves prevent cross flow between the left and right tanks. The fuel selector valve is located under the cockpit floor and direct mechanically linked to the fuel selector handle between the pilot's and the copilot's seat. Just downstream the fuel selector valve an aluminum block is installed which incorporates the fuel temperature sensor and a drain valve. This drain is the lowest point of the fuel system and is accessible by a panel in the right underside of the fuselage between the main and nose gear doors. The drain provides a means to remove moisture and sediment from the fuel system. Fuel lines are of aluminum tubing 5052-0 but in the engine compartment fire resistant PTFE hoses are installed. The hoses in the engine compartment are made fire resistant by means of red silicone fiberglass sleeves or brown integrated fire sleeves. The hose assemblies meet the requirements of MIL-DTL-27267 and MIL-DTL-25579 as well as the fire-resistance requirements of AS1055. Fire-sleeves meet TSO c53a requirements. The pick-up point fuselage connection fuel supply hoses are conforming to MIL-H-5593. From the firewall break-through the fuel is sucked though the aircraft fuel filter. Aft of the filter, a manifold splits to the two parallel electrical fuel pumps. Another manifold joins the fuel lines again though check valves. The single line continues through the fuel flow transducer to the engine inlet.
For all maintenance work on the tanks, drain them completely. Be aware WARNING of fuel fumes and fuel stained cloth: highly inflammable! Observe the safety notes given in Chapter 12-10-01, Refueling. Power must be off, no external power connected, room well ventilated.
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Bleeding Procedure Detail Steps/Work Items
Key Items
1 Make sure tanks are not empty. 2 Disconnect fuel hose from engine and hold in appropriate container. 3 Turn fuel selector valve to LEFT 4 Both fuel pumps ON
Until no more air bubbles
5 Both fuel pumps OFF 6 Turn fuel selector valve to RIGHT T
7 Both fuel pumps ON
Until no more air bubbles
8 Both fuel pumps OFF 9 Reinstall fuel hose to the engine. 10 Turn fuel selector valve to BOTH
28-20-01
Check Valves (wing to selector valve) Check valves are installed in front of the main gear bays.
Removal/Installation Detail Steps/Work Items 1 Drain fuel system.
Key Items Refer to Chapter 12-10-02
2 Observe precautions concerning Reduction Refer to Subject 28-00-00 of Fuel Tank Vapor Hazards. 3 Remove LH/RH front fuselage access panels.
Refer to Chapter 51-00-01.
4 Disconnect fuel hose. 5 Disconnect check valve from fitting. 6 Install in reverse sequence of removal.
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Make sure flow direction is correct.
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28-20-02
Check Valves (downstream electrical fuel pumps) The check valves are installed in the fuel manifold on the aft engine fireshield.
Removal/Installation Detail Steps/Work Items
Key Items
1 Set fuel selector valve to OFF. 2 Drain fuel at the lowest point drain and the fuel filter drain.
Refer to Chapter 12-10-02
3 Remove both upper cowlings.
Refer to Ch. 71-10-01/02.
Fuel may be pressurized (30 psi max). Fuel may spill. Protect yourself WARNING and catch spilling fuel. 4 Disconnect fuel hose. 5 Remove lock wire. 6 Screw check valve out of manifold. 7 Install in reverse sequence of removal.
28-20-03
Make sure flow direction is correct. Use new o-ring when necessary (MS29512-08).
Fuel Selector Valve The fuel selector valve is installed in the floor between the pilot and co-pilot seat and in the compartment below.
Removal/Installation Detail Steps/Work Items
Key Items
1 Drain fuel system completely.
Refer to Chapter 12-10-02
1 Remove forward keel beam access panel.
Refer to Chapter 51-00-01.
2 Disconnect the three fuel lines from the fuel selector valve. 3 Remove the screws on the fuel selector handle.
4 screws, in the cabin
4 Remove handle. 5 Unscrew the bolts on the bottom of the cup.
2 bolts
6 Remove the selector valve from the structure.
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7 Remove the spacer from selector valve.
2 screws
8 Install in reverse sequence of removal.
Selector valve can be mounted in one way only Page Date: 30. March 2012
Maintenance Manual EXTRA 500
28-20-04
Fuel Filter Element The fuel filter is installed in the engine compartment in front of the nose gear bay.
Exchange Detail Steps/Work Items
Key Items
1 Set fuel selector valve to OFF. 2 Drain fuel at the lowest point drain and the fuel filter drain.
Refer to Chapter 12-10-02
3 Remove fuel filter access panel.
Refer to Chapter 51-00-01.
4 Remove lock wire and unscrew lower boll of fuel filter. 5 Replace filter element in boll. 6 Screw boll into filter.
torque 100-150 lbs-inch (11.3 – 16.9 Nm)
7 Lock wire. 8 Re-install fuel filter access panel.
28-20-05
Electrical Fuel Pump The electrical fuel pumps are installed in the engine compartment on the firewall, below the battery.
Removal/Installation Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. T
2 Set fuel selector valve to OFF. 3 Drain fuel at the lowest point drain and the fuel filter drain.
Refer to Chapter 12-10-02
4 Remove upper left cowling.
Refer to Chapter 71-10-01.
5 Disconnect electrical connection. 6 Disconnect fuel hoses. 7 Loosen worm-drive hose clamps.
(2)
8 Remove pump. 9 Install in reverse sequence of removal. 10 Perform Bleeding Procedure. Page Date: 30. March 2012
Refer to Subject 28-20-00
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28-20-06
Rubber Hose For connection of the wing tip pick-up to the fuselage a rubber type hoses are installed.
Removal/Installation Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. T
2 Remove respective fuel sump access panel
Refer to Chapter 51-00-01.
3 Disconnect copper braid bond from fuselage side of hose connection.
Notice copper braid bond position.
4 Disconnect fuselage side fitting. 5 Remove hose clamps and copper braid bond. 6 Remove hose. 7 Install in reverse sequence of removal.
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Ensure correct copper braid bond position
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28-40-00
INDICATION Description The fuel system indication system displays the following parameter: • Left and right fuel quantity collector compartment • Left and right fuel quantity main compartment • Left and right fuel quantity auxiliary compartment • Fuel flow • Fuel pressure • Fuel temperature
28-40-01
Fuel Quantity Sensor (collector compartment) The fuel quantity probe is installed in the collector compartment on the root rib.
Removal Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. T
2 Open avionic bay access panels.
Refer to Chapter 51-00-01
3 Disconnect electrical connector from sensor. 4 Remove root rib inspection door.
14 bolts
5 Remove sensor from inspection door.
Installation 1 Ensure BATT switch is OFF and no external power connected. T
2 Clean root rib inspection door and sensor surfaces with solvents to remove dirt and grease.
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PR 1750 accelerator contains harmful vapors and is readily absorbed WARNING through the skin. Avoid all contact with the skin and ingestion. Always wash hands before eating or smoking. Use adequate ventilation, hand protection and chemical-type goggles when working with this product. If accelerator contacts skin, flush area with warm water. Obtain medical attention in cases of extreme exposure or ingestion. PR 1750 sealant contains solvents. WARNING Use adequate ventilation or air-supplied respirators during application. Avoid repeated or prolonged breathing of vapors. In case of extreme vapor exposure, remove affected personnel to fresh air immediately and obtain medical attention. For complete health and safety information, refer to Le Joint Francais material safety data sheet PR 1750 (LOAP 41). 3 Install sensor on root rib inspection door with PR 1750 tank sealant.
For mixing and application of PR 1750 sealant refer to manufacturer's instructions.
4 Check the float points in the direction of flight. NOTE
If the hatch seal has become partly clear instead of white, slightly pull those patches apart. Clear patches are NOT a sign that the seal is defective! 5 Install root rib inspection door, torque bolts 3-5 Nm (26-44inch-lbs). 6 After at least one half hour re-torque the bolts. 7 Connect electrical connector. 8 Make a tank leakage test.
Refer to Subject 28-10-01
9 Close avionic bay access panels.
Refer to Chapter 51-00-01
10 Recalibrate quantity indicator.
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28-40-02
Fuel Quantity Sensor (main or auxiliary compartment) The fuel quantity sensor is installed on the inner tank inspection door of the appropriate tank.
Removal Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. T
2 Open appropriate tank access panel.
Sensor is on the inner tank inspection door of the corresponding compartment.
3 Remove inspection door. 4 Remove sensor from inspection door.
5 bolts
5 Disconnect electrical connector from sensor.
Installation 1 Ensure BATT switch is OFF and no external power connected. T
2 Connect electrical connector. NOTE
When attaching sensor to hatch observe correct direction. For main compartment: Make sure the float is pointing inboard For auxiliary compartment: Make sure the float is pointing outboard 3 Attach sensor to inspection door.
NOTE
If the hatch seal has become partly clear instead of white, slightly pull those patches apart. Clear patches are NOT a sign that the seal is defective! 4 Install inspection door, torque bolts 3-5 Nm (26-44 inch-lbs). 5 After at least one half hour re-torque the bolts. 6 Recalibrate quantity indicator. 7 Reinstall appropriate tank access panel.
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28-40-03
Fuel Quantity Gauge The fuel quantity gauges are installed in the RH instrument panel.
Removal/Installation Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. T
2 Remove RH IFD.
Refer to Chapter 31-60-01.
3 Disconnect electrical connector from fuel quantity gauge. 4 Unscrew attachment .
4 screws
5 Install in reverse order of removal. 6 If more than one gauge is replaced, check if indicator shows proper tank.
Calibration The calibration potentiometers are installed on PCB installed behind the LH IFD. Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. T
2 Remove RH IFD.
Refer to Chapter 31-60-01.
3 Disconnect electrical connector from fuel quantity gauge. 4 Make sure the fuel quantity sensor is installed and laying on the bottom of the compartment (compartment is empty). 5 Measure with a calibrated, digital ohmmeter the resistance between pins 5 and 8.
For collector and main comp: The value must be 50.0 Ohm For auxiliary compartment: The value must be 80.0 Ohm
6 If value is not correct, follow the steps below. 7a Remove LH IFD.
Refer to Chapter 31-60-01.
7b Use the potentiometer on the PCB behind the RH IFD to bring the resistance value to the required value. 7c Reinstall the LH IFD. 8 Connect electrical connector. 9 Re-install the RH IFD. Page 26
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Maintenance Manual EXTRA 500
28-40-04
Fuel Flow Indicator The fuel flow indicator is installed in the RH instrument panel.
Removal/Installation Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. T
2 Remove RH IFD.
Refer to Chapter 31-60-01.
3 Disconnect electrical connector from fuel flow indicator. 4 Unscrew attachment.
4 screws
5 Install in reverse sequence of removal.
K-Factor Setting Refer to Shadin Avionics Miniflo-L Operating Manual (LOAP 42).
28-40-05
Pressure Transducer For description and maintenance practices refer to Chapter 73-30-01.
28-40-06
Pressure Gauge The fuel pressure gauge is integrated in the Digital Instrument Package (refer to Chapter 77-40-02).
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Intentionally left blank.
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Maintenance Manual EXTRA 500
Chapter 29 Hydraulic Power
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Maintenance Manual EXTRA 500
Table of Contents
29-00-00
Page 2
29
GENERAL ........................................................................................................ 3
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Maintenance Manual EXTRA 500
29-00-00
GENERAL The hydraulic system of the EXTRA 500 is used to operate the landing gear exclusively. Therefore all information concerning hydraulics is incorporated in Chapter 32-30 Extension and Retraction.
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Intentionally left blank
Page 4
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Maintenance Manual EXTRA 500
Chapter 30 Ice and Rain Protection
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TABLE OF CONTENTs 30-00-00
Figure 30-1
GENERAL ........................................................................................................ 5 Description.......................................................................................................... 5 Removal/Installation/Repair............................................................................... 5 De-Icing System Shematic .................................................................................. 6 Troubleshooting.................................................................................................. 7
30-10-00
AIRFOIL ......................................................................................................... 10 Description........................................................................................................ 10
30-10-01
Pressure Regulator ......................................................................................... 10 Removal/Installation......................................................................................... 10
30-10-02
Ejector Valve................................................................................................... 10 Removal/Installation......................................................................................... 10
30-10-03
Boots Timer ..................................................................................................... 11 Removal/Installation......................................................................................... 11
30-20-00
AIR INTAKES ................................................................................................ 12 Description........................................................................................................ 12
30-20-01
Bowden Cable ................................................................................................. 12 Removal/Installation......................................................................................... 12 Rigging ............................................................................................................. 13
30-20-02
Micro Switch ................................................................................................... 14 Removal/Installation......................................................................................... 14 Rigging ............................................................................................................. 14
30-20-03
Helical Metallic Hoses .................................................................................... 14 Removal/Installation......................................................................................... 14
30-30-00
PITOT, STATIC AND STALL WARNING ................................................ 15 Description........................................................................................................ 15
30-30-01
Current Sensor (Avionic Bay) ....................................................................... 15 Removal/Installation......................................................................................... 16
30-30-02
Current Sensor (Tail Cone) ........................................................................... 16 Removal/Installation......................................................................................... 16
30-40-00
WINDSHIELD................................................................................................ 17
30-40-01
Windshield Heat Controller .......................................................................... 17 Removal/Installation......................................................................................... 17
30-40-02
Windshield Heat Current Sensor .................................................................. 18 Removal/Installation......................................................................................... 18
30-60-00
PROPELLER.................................................................................................. 19 Description........................................................................................................ 19
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30-60-01
Propeller Ammeter..........................................................................................19 Removal/Installation .........................................................................................19
30-70-00
WATER LINES...............................................................................................20
30-80-00
DETECTION...................................................................................................21
30-80-01
Ice Light ...........................................................................................................21 Removal/Installation .........................................................................................21
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Intentionally left blank
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Maintenance Manual EXTRA 500
30-00-00
GENERAL Description The following icing protection systems are standard equipment on the EXTRA 500 (refer to Figure 30-1): 1 Pneumatic de-ice boots for wing and empennage 2 Heated Pitot tubes and heated static ports 3 Heated stall warning sensor 4 Heated windshield 5 Heated engine inlet 6 Heated propeller blades
Removal/Installation/Repair For respective information see manufacturers BF Goodrich publications concerning “Estane De-Icers” as listed in the LOAP 18-22.
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Maintenance Manual EXTRA 500
Figure 30-1
Page 6
30
De-Icing System Shematic
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Maintenance Manual EXTRA 500
Troubleshooting Complaint Deice boots fail to inflate completely
De-ice boots inflate only partially (low inflation pressure, no DEICE BOOTS safe operation light)
One of the two inflation sections (inner wing, outer wing and tail surfaces) fails to inflate
Possible Cause
Remedy
Leakage in pressure system upstream ejector valves
Identify leak, seal or replace defective part
Electric failure
Check wiring
Failure of: timer, pressure regulating valve, ejector valves, pressure manifold
Identify defective component(s) and replace
Leakage in pressure lines
Identify leak, seal or replace defective part
Kinked pressure tube
Replace defective tube
Failure of pressure regulating valve
Replace valve
Electric failure
Check pressure sensors, wiring and indication light
Failure of:
Identify defective component and replace
Timer, ejector valve, electric wiring Leakage of pressure lines downstream ejector valve
Check for leaks in pressure lines and boots, repair or replace defective parts
Blockage downstream distributing valve
Check for kinks in tubing, replace
Time intervals out of tolerances
Failure of timer (or false timer)
Replace timer
Boot evacuation fails
Timer, ejector valve, or switch failure
Identify and replace or repair
Electric failure
Check and repair wiring
Boot or line leakage
Identify and replace or repair
Bowden cable broken
Replace
Bowden cable loose
Rig Bowden cable
Exhaust ‘ashtray’ broken
Replace
Exhaust is leaking
Replace
Exhaust helical metallic hose disconnected or leaking
replace
Inlet heating defect
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Maintenance Manual EXTRA 500
Complaint
Possible Cause
Remedy
INTAKE HEAT safe operation
Wiring defective
Replace
light does not illuminate on activation
Microswitch defective
Replace
Bowden cable mis-rigged
Rig Bowden cable
Microswitch mis-aligned
Rig microswitch
Wiring defective
Replace
Microswitch defective
Replace
Bowden cable mis-rigged
Rig Bowden cable
Microswitch mis-aligned
Rig microswitch
Water separator drain line blocked
Remove drain line blockage
Orifice in water separator blocked
Remove blockage from and clean (inside of) water separator.
Pitot tube does not heat, no PITOT HEAT LEFT/RIGHT indication
Wiring defective
Check and repair wiring
Pitot tube heat defective
Replace Pitot tube
Static port does not heat
Wiring defective
Check and repair wiring
indication
Static port heat defective
Replace static port
Lift detector (3 heating circuits) does not heat
Wiring defective
Check and repair wiring
Current sensor defective
Replace current sensor.
Lift detector heat defective
Replace lift detector
High ambient temperature (windshield above 40°C)
Normal system function
Wiring to one temperature sensor in windshield defective
Check and repair
One windshield temperature sensor defective
Replace windshield
Respective circuit in controller defective
Replace controller
Wiring to or both temperature sensors in windshield defective
Check and repair
Windshield controller defective
Replace controller
Engine inlet anti ice system does not activate
Water in boots system
STATIC HEAT LEFT/RIGHT
Windshield heat inactive, no WINDSHIELD HEAT ON
indication WINDSHIELD HEAT FAIL
active, WINDSHIELD HEAT ON still
active
WINDSHIELD HEAT FAIL
active, WINDSHIELD HEAT ON
inactive
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Maintenance Manual EXTRA 500
Complaint WINDSHIELD HEAT ON
inactive
Prop Ammeter shows zero
Prop Ammeter shows low current (below green arc)
Ammeter shows excess current (above green arc)
Radio noise
Rapid brush wear and frequent breakage
Page Date: 30. March 2012
Possible Cause
Remedy
Wiring to heated area defective
Check and repair
Heated area in windshield defective
Replace windshield
Windshield controller defective
Replace controller
No power from aircraft to brushes
Check wiring, circuit breaker and switch, repair or replace defective part
Open circuit brushes to heater boots
Repair wiring (check when stretching and flexing the leads) or replace propeller in case of heater element failure
Ammeter shunt defective
Replace shunt
Ammeter wiring defective
Repair wiring
Ammeter defective
Replace ammeter
Open circuit (or high resistance) to at least one of the blade heating elements
Identify whether wiring or heater element itself is defective. Repair wiring or replace propeller
Ammeter defective
Replace ammeter
Power lead shorted to ground
Check insulation and replace defective lead
Ammeter defective
Replace ammeter
Brushes arcing
Check for brush alignment, dirty or rough slip rings and slip ring alignment
Loose connection
Check wiring connections
Brush assembly out of alignment
Check and adjust brush alignment
Slip ring wobbles
Check slip ring alignment, replace slip ring
Rough slip rings
Replace (or refinish) slip ring
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30-10-00
AIRFOIL Description The leading edges of the airfoils (wing, horizontal and vertical stabilizer) are protected against icing by inflatable rubber boots. The pressurized air for boot inflation is supplied by engine bleed air. Nominal inflation pressure of the system is 18 psig (1.25 bar). A system surview is given in Figure 30-1. The system, when activated, inflates two leading edge boots groups in sequence for ice shedding. Boot cycle A incorporates the inner wing boots, cycle B the outer wing and empennage. When not inflated, suction will keep the boots on the wing and empennage surfaces. The switching from underpressure to pressure is done by an ejector valve (one for each group), which is commanded by the boots timer. The boots timer is activated with the BOOTS switch on the left side panel.
30-10-01
Pressure Regulator The pressure regulator is located in the engine compartment, on the LH upper engine mount tube.
Removal/Installation Detail Steps/Work Items 1 Remove LH upper cowling.
Key Items Refer to Chapter 71-10-01.
2 Disconnect pneumatic lines. 3 Remove mounting plate from engine mount.
2 screws
4 Remove pressure regulator from mounting plate.
4 screws, lockwire
5 Install in reverse sequence of removal.
30-10-02
Ejector Valve Two ejector valves (one for boot cycle A and one for boot cycle B) are installed in the engine compartment. They are mounted on the firewall, left of the nose gear bay firewall.
Removal/Installation Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. Page 10
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Maintenance Manual EXTRA 500
Detail Steps/Work Items 2 Remove LH upper cowling.
Key Items Refer to Chapter 71-10-01.
3 Disconnect electrical connector. 4 Disconnect pneumatic lines. 5 Remove ejector valve.
4 bolts
6 Install in reverse sequence of removal.
30-10-03
Boots Timer The boots timer is installed in the avionics compartment in the center wing section.
Removal/Installation Detail Steps/Work Items 1 Remove LH avionic bay access panel on top of the wing.
Key Items Refer to Chapter 51-00-01.
2 Disconnect electrical connector. 3 Remove boots timer
4 bolts
4 Install in reverse sequence of removal.
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Maintenance Manual EXTRA 500
30-20-00
AIR INTAKES Description The EXTRA 500 is equipped with an exhaust heated engine inlet. Pulling the INTAKE ANTI ICE Bowden cable opens the “ashtray” in the LH exhaust stack which routes hot exhaust air into the double walled engine air inlet. The air flows out on the RH side to the RH exhaust stack. Pulling the Bowden cable will also throw a microswitch on the LH exhaust stack to illuminate the INTAKE HEAT safe operation light and to activate the engine compressor inlet anti ice system (Rolls Royce 250-B17F Series Operation and Maintenance Manual, LOAP 1).
30-20-01
Bowden Cable The Engine anti-ice Bowden cable is installed in the middle console in the cockpit and goes through the front pressure bulkhead/firewall to the LH engine exhaust stack in the engine compartment.
Removal/Installation Detail Steps/Work Items 1 Remove LH upper cowling.
Key Items Refer to Chapter 71-10-01.
2 Disconnect cable of Bowden cable on LH exhaust stack. 3 Disconnect Jacket of Bowden cable on LH exhaust stack. 4 Disconnect any tie-raps in engine compartment that hold the Bowden cable. 5 Remove upper paneling part of middle console in which the Bowden cable holding plate is mounted. NOTE
Refer to Chapter 25-10-26.
Do not pull the cable from the jacket. There is a very small metal ball that will fall out. 6 Remove Bowden cable from mounting plate. 7 With a firm pull, break the pressure cabin/firewall sealing and remove Bowden cable. 8 Install in reverse sequence of removal.
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Detail Steps/Work Items
Key Items
Refer to Product Label and Material Safety Data Sheet for health and WARNING safety information before using PR812. 9 Seal the Bowden cable from the firewall side with PR812 PR 1750 accelerator contains harmful vapors and is readily absorbed WARNING through the skin. Avoid all contact with the skin and ingestion. Always wash hands before eating or smoking. Use adequate ventilation, hand protection and chemical-type goggles when working with this product. If accelerator contacts skin, flush area with warm water. Obtain medical attention in cases of extreme exposure or ingestion. PR 1750 sealant contains solvents. WARNING Use adequate ventilation or air-supplied respirators during application. Avoid repeated or prolonged breathing of vapors. In case of extreme vapor exposure, remove affected personnel to fresh air immediately and obtain medical attention. For complete health and safety information, a material safety data sheet is available from the manufacturer. 10 Seal the Bowden cable from the inside with PR 1750.
For mixing and application of PR 1750 sealant refer to manufacturer's instructions.
11 Rig the Bowden cable.
See paragraph Rigging below.
Rigging Detail Steps/Work Items 1 Remove the LH upper cowling to gain access to the LH exhaust stack
Key Items Refer to Chapter 71-10-01.
2 Push the INTAKE ANTI ICE knob fully in. 3 Set the upper set screw that the ‘ashtray’ is fully closed when the lever is set against it. 4 Clamp the Bowden cable jacket so the jacket protrudes 4 mm +/- 1 mm from clamp. 5 Attach cable to lever while lever is at upper set screw. 6 Pull the INTAKE ANTI ICE knob fully out. 7 Make sure that the ‘ashtray’ is fully out.
20° travel
8 Set the lower set screw accordingly. 9 Perform micro switch rigging. Page Date: 30. March 2012
Refer to Subject 30-20-02.
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30-20-02
Micro Switch The engine anti-ice micro switch is located on the LH exhaust stack.
Removal/Installation Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. 2 Remove the LH upper cowling
Refer to Chapter 71-10-01.
3 Mark and cut wiring of the micro switch.
Connect later by splicing.
4 Remove micro switch.
2 screws
5 Install in reverse sequence of removal. 6 Perform micro switch rigging.
See paragraph Rigging below.
Rigging Detail Steps/Work Items 1 Remove the LH upper cowling
Key Items Refer to Chapter 71-10-01.
2 Pull the INTAKE ANTI ICE knob fully out. 3 Make sure the micro switch is activated, loosen, adjust and retighten at set and/or bend micro switch lever if needed.
30-20-03
Helical Metallic Hoses There are two helical metallic hoses installed in engine compartment for exhaust air routing from the LH exhaust stack to the inlet and from the inlet to the RH exhaust stack
Removal/Installation Detail Steps/Work Items 1 Remove exhaust stacks
Key Items Refer to Ch. 78-00-01/02
2 Unscrew helical metallic hose from inlet 3 Install in reverse sequence of removal. IMPORTANT
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30
Make sure while setting the length of the helical metallic hose that the forces on the engine flange while attaching the exhaust stack must be minimal. Screw in the helical metallic hose minimum one full turn on each side. Maximum two full turns each side are possible.
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Maintenance Manual EXTRA 500
30-30-00
PITOT, STATIC AND STALL WARNING Description The EXTRA 500 is equipped with two heated Pitot tubes, one underneath each wing. Standard AN-type (AN 5812-1) Pitot tubes are used. The electric Pitot heat is activated by switching the L-PITOT-R switches to the ON position. As long as the aircraft is on ground the heating of the Pitot tubes is avoided by means of a squat switch installed at the nose gear strut. To provide a means for checking the system on ground the switches can be set to a momentary TEST position to override the squat switch. Avoid operating the system in this mode longer than 10 sec. on ground to avoid an overheat condition. The current consumption of the heating elements is monitored by current sensors during operation. If an open circuit causes the Pitot tube heaters to fail, the PITOT HEAT LEFT/RIGHT illuminates in the annunciator panel. The two dual static ports installed in the aft fuselage sides are equipped with electric heater elements to prevent icing. They are also activated by the LPITOT-R switches. Heating is disabled on ground by means of a squat switch and current sensors generate the STATIC HEAT LEFT/RIGHT annunciation in case of malfunction. Temperature rise after activation of the test mode on ground is much slower than for the Pitot heat. Be aware of this behavior when checking the system on ground. The Stall detector installed in the left wing leading edge within the access panel for the recognition lights features three electric circuits for icing protection. The movable sensing vane, the mounting plate and the case itself are heated by electric heating elements. The heatings are activated by the PITOT-R switch and protected by the squat switch against inadvertent operation on ground. The TEST position of the switch overrides this protection to allow system checks on the ground (time limited up to max. 10 sec). The main heating circuits (vane and mounting plate) are monitored by a current sensor, generating the STALL HEAT warning indication in the annunciator panel in case of an open circuit.
NOTE
30-30-01
In case of defective Pitot tube, static port or stall detector heat elements, the respective components have to be replaced as a whole (refer to Chapter 34-10).
Current Sensor (Avionic Bay) Three current sensors are installed in the avionic bay and are accessible by the LH avionic bay access panel. The sensors are labeled 3HG, 5HG and 7HG. The following table shows to which systems they are related.
Page Date: 30. March 2012
Label
System
3HG
Stall heat
5HG
Pitot heat RH
7HG
Pitot heat LH
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Maintenance Manual EXTRA 500
Removal/Installation Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. 2 Remove LH avionic bay access panel.
Refer to Chapter 51-00-01.
3 Remove the wiring from the respective current sensor.
30-30-02
4 Remove the mounting plate.
4 bolts To get access to the underside of the current sensor. Notice ground bonding.
5 Remove current sensor.
2 bolts
6 Install in reverse sequence of removal.
Ensure mounting plate is correctly grounded and cable loom cable clamp is installed.
Current Sensor (Tail Cone) Two current sensors are installed in the aircraft tailcone on the underside of the air condition soft start module. The sensors are labeled 1HS and 4HS. The following table shows to which systems they are related. Label
System
1HS
Static heat RH
4HS
Static heat LH
Removal/Installation Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. 2 Remove tailcone access panel.
Refer to Chapter 51-00-01.
3 Remove the air condition soft start module.
Refer to Chapter 21-50-03 Disconnecting the electrical wiring is not necessary.
4 Disconnect the electrical connector.
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30
5 Remove the mounting plate.
4 bolts
5 Remove current sensor.
2 Allen screws
6 Install in reverse sequence of removal.
Ensure mounting plate is correctly grounded.
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Maintenance Manual EXTRA 500
30-40-00
WINDSHIELD An electric windshield heat for the pilot’s side of the windshield is part of the standard icing protection system. Also refer to Chapter 56-10. The system consists of three wire circuits bonded between the inner and outer windshield layer, one for the heating itself and two for the redundant temperature sensing. The heating current is switched by a special heat controller regulating the windshield temperature between 20°C and 40°C in case the system is active. The system may be activated by means of the WINDSH switch located in the DEICE group within the left side panel. In case of malfunction of the system, this condition is indicated by a red WINDSHIELD HEAT FAIL annunciator light. The following failure conditions cause a warning indication: • One or both temperature sensing circuits open or shorted • Overheat signal from at least one of the sensing circuits (more than 50°C) An additional means for monitoring the function of the windshield is provided by a green WINDSHIELD HEAT ON annunciator light (controlled by a current sensor in the heating circuit) illuminating when the heating current flows. This light is cycling during normal windshield heat operation. The system remains operative (green light cycling) as long as one of the two sensing circuits is functioning although the red WINDSHIELD HEAT FAIL warning annunciates one defective temperature sensing circuit. If both sensing circuits are defective the windshield controller inhibits any further windshield heating.
30-40-01
Windshield Heat Controller The windshield heat controller is installed beside the pilot seat, behind the pilot’s legroom LH paneling.
Removal/Installation Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. 2 Remove pilot seat.
Refer to Chapter 25-10-11.
3 Remove all LH forward lower paneling screws.
Refer to Chapter 25-00-01.
4 Carefully swivel the paneling forward to gain access from behind. 5 Remove electrical connector. 6 Remove windshield heat controller.
2 nuts
7 Install in reverse sequence of removal. Page Date: 30. March 2012
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Maintenance Manual EXTRA 500
30-40-02
Windshield Heat Current Sensor The windshield heat current sensor is installed beside the pilot seat, behind the pilot’s legroom LH paneling.
Removal/Installation Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. 2 Remove pilot seat.
Refer to Chapter 25-10-11.
3 Remove all LH forward lower paneling screws.
Refer to Chapter 25-00-01.
4 Carefully swivel the paneling forward to gain access from behind. 5 Remove electrical connections.
4 screws
6 Remove windshield heat current sensor including mounting plate.
2 nuts
7 Remove current sensor from mounting plate. 2 bolts 8 Install in reverse sequence of removal.
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Maintenance Manual EXTRA 500
30-60-00
PROPELLER Description The propeller of the EXTRA 500 is equipped with electrically heated boots at the blades for icing protection. All blades are heated continuously when switched on. All necessary information for repair and maintenance of the system is contained in BF Goodrich Aerospace publications as listed in the LOAP 14-17.
30-60-01
Propeller Ammeter The propeller ammeter is installed in the upper left corner of the instrument panel.
Removal/Installation Detail Steps/Work Items 1 Remove RH and LH IFD.
Key Items Refer to Chapter 31-60-01.
2 Disconnect electrical connector ammeter. 3 Remove propeller ammeter.
4 screws
4 Install in reverse sequence of removal.
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Maintenance Manual EXTRA 500
30-70-00
WATER LINES The pneumatic boot system incorporates a water separator to prevent water to enter boot lines and the boots themselves as water may freeze and render the system inoperative. The water separator is installed downstream of the pressure regulator and upstream of the ejector valves. A water drain line it routed to the exterior.
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30-80-00
DETECTION
30-80-01
Ice Light An ice light is installed on the forward left side of the fuselage. It is accessible from inside the engine compartment when the LH upper cowling is removed.
Removal/Installation Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. 2 Remove upper LH cowling.
Refer to Chapter 71-10-01
3 Disconnect electrical connection. 4 Remove ice light cover and window.
3 bolts
5 Disassemble ice light.
4 bolts
6 Install in reverse sequence of removal
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Maintenance Manual EXTRA 500
Chapter 31 Indication & Recording Systems
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Page 1
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TABLE OF CONTENTS
31-00-00
GENERAL ........................................................................................................ 3 Description.......................................................................................................... 3
31-10-00
INSTRUMENT & CONTROL PANELS....................................................... 4
31-10-01
Left Side Panel .................................................................................................. 4 Description.......................................................................................................... 4 Removal/Installation........................................................................................... 4
31-10-02
Left Main Panel ................................................................................................ 4 Removal/Installation........................................................................................... 4
31-10-03
Right Main Panel .............................................................................................. 5 Removal/Installation........................................................................................... 5
31-10-04
Lower Main Panel ............................................................................................ 5 Removal/Installation........................................................................................... 5
31-10-05
Glare Shield....................................................................................................... 6 Removal/Installation........................................................................................... 6
31-10-06
Control Display Unit ........................................................................................ 6 Removal/Installation........................................................................................... 6 Tests and Checks ................................................................................................ 6
31-50-00
CENTRAL WARNING SYSTEMS................................................................ 7 Description.......................................................................................................... 7 Annunciator Panel .............................................................................................. 7
Figure 31-1 31-50-01
Annunciator Panel (Westcoast Specialties) .................................................... 7 Removal/Installation........................................................................................... 7 Lamp Replacement ............................................................................................. 8
31-60-00
CENTRAL DISPLAY SYSTEMS .................................................................. 9 Description.......................................................................................................... 9
31-60-01
Integrated Flight Display (IFD)....................................................................... 9 Removal/Installation........................................................................................... 9 Tests and Checks ................................................................................................ 9
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31-00-00
GENERAL Description The EXTRA 500 is equipped with several indication systems: • The left and right main panel • The left side panel • The annunciator panel (part of the right main panel) • The LH Integrated Flight Display (IFD) • The RH Integrated Flight Display (IFD) • The Control Display Unit (CDU)
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Maintenance Manual EXTRA 500
31-10-00
INSTRUMENT & CONTROL PANELS
31-10-01
Left Side Panel Description On the LH of the pilot, most of the switches and circuit breakers are installed in a switch board assembly, the left side panel. This assembly contains all electrical busses excluding the hot bus. This assembly can be taken out of the aircraft as a whole.
Removal/Installation Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. 2 Remove pilot’s seat.
Refer to Chapter 25-10-11.
2 Remove left legroom side paneling.
Refer to Chapter 25-00-01.
3 Remove 6 screws of the upper part of the left side panel.
2 screws on the top 4 screws on the side
4 Remove 3 screws of the lower part of the left side panel. 5 Disconnect the 3 electrical connectors and the power connector. Take care not to damage luminescent foil connections CAUTION 6 Remove the two parts of the left side panel. 7 Install in reverse sequence of removal.
31-10-02
Left Main Panel Removal/Installation Detail Steps/Work Items 1 Remove IFDs.
Key Items Refer to Subject 31-60-01
2 Disconnect wiring/piping from back-up flight instruments and propeller ammeter. 3 Remove left main panel. Page 4
31
8 Phillips screws Page Date: 30. March 2012
Maintenance Manual EXTRA 500
Detail Steps/Work Items
Key Items
4 Install in reverse sequence of removal.
31-10-03
Right Main Panel Removal/Installation Detail Steps/Work Items 1 Remove RH IFD.
Key Items Refer to Subject 31-60-01
2 Remove 10 Phillips screws around right main panel. 2 Slightly swivel down right main panel
Take care not to damage electrical wiring
3 Disconnect electrical wiring from annunciator panel 4 Disconnect wiring from fuel gauges. 5 Disconnect wiring from fuel flow indicator. 6 Disconnect wiring from turn coordinator. 7 Install in reverse sequence of removal.
31-10-04
Lower Main Panel Removal/Installation Detail Steps/Work Items
Key Items
1 Remove LH and RH main panel
Refer to Subject 31-10-02/03
2 Remove engine indicators.
Refer to Chapter 77-40
3 Disconnect electrical wiring from ELT switch. 4 Disconnect electrical wiring from LANDING GEAR switch. 5 Disconnect electrical wiring from FLAP switch. 6 Remove attachment nuts from the other switches. 7 Disconnect electrical wiring from dimming potentiometers. Page Date: 12.April 2000
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Detail Steps/Work Items 8 Remove lower main panel.
Key Items 14 bolts
9 Install in reverse sequence of removal.
31-10-05
Glare Shield Removal/Installation Detail Steps/Work Items 1 Remove main panels.
Key Items Refer to Subjects 31-60-02 thru 04
2 Disconnect wiring from autopilot. 3 Remove glare shield.
4 screws
4 Install in reverse sequence of removal.
31-10-06
Control Display Unit Removal/Installation Follow the ACD215 Removal and Installation procedure presented in the Entegra Integrated Flight Display System Product Maintenance Manual (LOAP 24).
Tests and Checks Perform the applicable Return to Service Tests and Checks presented in the Entegra Integrated Flight Display System Product Maintenance Manual (LOAP 24). whenever the unit has been reinstalled.
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Maintenance Manual EXTRA 500
31-50-00
CENTRAL WARNING SYSTEMS Description The central warning system in the EXTRA 500 consists of an annunciator panel. The annunciator panel is located on the top RH instrument panel. (Refer to the Emergency Procedures (Amplified) part of Section 3 in the EXTRA 500 Pilot's Operating Handbook for further information to the particular caution and warning lights.)
r
r
r
r
y
y
r
r
r
r
y
y
r
r
r
y
y
y
y
y
g
g
y
y
y
g
g
y
y
y
g
g
g
r = red, y = yellow, g = green Figure 31-1
Annunciator Panel
31-50-01
Annunciator Panel (Westcoast Specialties) The annunciator panel is located on the top RH instrument panel.
Removal/Installation Detail Steps/Work Items
1 Remove RH IFD.
Key Items
Refer to Subject 31-60-01
2 Disconnect electrical wiring from annunciator panel. 3 Remove panel.
4 screws
4 Install in reverse sequence of removal. 5 Check if all lamps work by placing the NIGHT/DAY switch located on the left side panel in the TEST position.
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Maintenance Manual EXTRA 500
Lamp Replacement Each annunciator light (lamp module) is illuminated by two lamps. Relamp by pushing in lamp module approximately 1/16th of an inch and release. The lamp module will partially eject. Pull to disengage, then rotate downward to expose the lamps. When reinserting lamp modules ensure both latching springs engage cap assy by slowly pushing cap with equal force on both sides.
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Maintenance Manual EXTRA 500
31-60-00
CENTRAL DISPLAY SYSTEMS Description The central display system of the EXTRA 500 contains 2 Avidyne Integrated Flight Displays (IFDs).
31-60-01
Integrated Flight Display (IFD) Removal/Installation Follow the IFD5000i Removal and Installation procedure presented in the Entegra Integrated Flight Display System Product Maintenance Manual (LOAP 24) observing the following aircraft specific hints: Ensure BATT switch is OFF and no external power connected. The wiring and piping for the RH IFD is dimensioned in the way that it can be disconnected/connected when the IFD is removed from and held next to the instrument panel. The wiring and piping for the LH IFD is shorter so that connecting/disconnecting has to be done with IFD installed. For that reason the RH IFD must be removed to get access to the wiring/piping connectors. The wiring is marked conforming to the designations on the IFD backsides. However the piping (Pitot/static) is colored as shown in the following:
IMPORTANT
The colors of pitot/static lines do not match with the port markings on the backside of the IFDs. Piping Colors PITOT STATIC
LH IFD
RH IFD
white
blue
red
green
Tests and Checks Perform the applicable Return to Service Tests and Checks presented in the Entegra Integrated Flight Display System Product Maintenance Manual (LOAP 24) whenever the unit has been reinstalled. Pitot/Static Check Perform applicable Return to Service Pitot/static Check according to FAR 43, Appendix E and AC 43.13-1B CHG1 (or later) Ch. 12-59 whenever the unit has been reinstalled.
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Maintenance Manual EXTRA 500
Chapter 32 Landing Gear
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32
Page 1
Maintenance Manual EXTRA 500
Table of Contents
32-00-00
GENERAL ........................................................................................................ 5 Introduction ........................................................................................................ 5 Description.......................................................................................................... 5 Operation ............................................................................................................ 6 Troubleshooting.................................................................................................. 7 Operational Test Procedures............................................................................... 8 Gear Up Procedure ............................................................................................. 9 Gear Down Procedure ...................................................................................... 10 Emergency Extension Test ............................................................................... 10 Gear Up Cycle Test .......................................................................................... 11 Wheels Up Landing Test .................................................................................. 12 Gear Down Cycle Test ..................................................................................... 12 Gear Up Cycle Test With Rudder Full Left/Full Right .................................... 12 Leakage and Accumulator Function Test ......................................................... 13
32-10-00
MAIN GEAR AND DOORS.......................................................................... 14
32-10-10
Main Gear Strut Assembly ............................................................................ 14 Description........................................................................................................ 14 LH Main Gear Strut Assembly.......................................................................... 15 Removal............................................................................................................ 16 Installation ........................................................................................................ 17 Disassembly/Assembly..................................................................................... 17
Figure 32-1
32-10-11 Figure 32-2
32-10-12 Figure 32-3
32-10-13 Figure 32-4
32-10-20
Page 2
32
Parallel Strut ................................................................................................... 19 Description........................................................................................................ 19 Parallel Strut .................................................................................................... 20 Removal/Installation......................................................................................... 20 Disassembly/Assembly..................................................................................... 20 Adjustment of Vertical Play ............................................................................. 21 Axle Bar ........................................................................................................... 21 Description........................................................................................................ 21 Axle Bar ............................................................................................................ 22 Removal/Installation......................................................................................... 22 Disassembly/Assembly..................................................................................... 22 Adjustment of Vertical Play ............................................................................. 23 Shock Absorber............................................................................................... 23 Description........................................................................................................ 23 Shock absorber ................................................................................................. 24 Removal/Installation......................................................................................... 24 Disassembly/Assembly..................................................................................... 24 Main Gear Doors ............................................................................................ 25 Description........................................................................................................ 25 Page Date: 30. March 2012
Maintenance Manual EXTRA 500
32-10-21
Upper Doors.....................................................................................................26 Removal/Installation .........................................................................................26 Door Actuation Length Adjustment..................................................................26
32-10-22
Lower Doors ....................................................................................................26 Removal/Installation .........................................................................................26 Door Actuation Length Adjustment..................................................................27
32-20-00
NOSE GEAR AND DOORS ..........................................................................28 Description ........................................................................................................28
32-20-10
Nose Gear Strut Assembly..............................................................................28 Description ........................................................................................................28 Nose Gear..........................................................................................................29
Figure 32-5 32-20-20
Figure 32-6 32-30-00 Figure 32-7 Figure 32-8
Nose Gear Doors..............................................................................................30 Description ........................................................................................................30 Door Actuation Length Adjustment..................................................................30 Nose Gear Doors Actuation Mechanism...........................................................31 EXTENSION AND RETRACTION .............................................................32 Description ........................................................................................................32 Landing Gear Schematic...................................................................................34 Main Gear Actuators.........................................................................................35
32-30-10
Hydraulic System ............................................................................................36 Bleeding ............................................................................................................36 Hydraulic Fluid Change ....................................................................................37
32-30-11
Hydraulic Power Pack ....................................................................................39 Removal/Installation .........................................................................................39 Cleaning ............................................................................................................40
32-30-12
Distributor Block.............................................................................................40 Removal/Installation .........................................................................................40 Disassembly/Assembly .....................................................................................41
32-30-20
Actuators..........................................................................................................42
32-30-21
Main Gear Actuators ......................................................................................42 Removal/Installation .........................................................................................42
32-30-22
Upper Doors Actuator ....................................................................................44 Removal/Installation .........................................................................................44
32-30-23
Lower Doors Actuator ....................................................................................45 Removal/Installation .........................................................................................45
32-30-24
Nose Gear Actuator.........................................................................................46 Removal/Installation .........................................................................................46
32-30-25
Nose Gear Gas Pressurized Springs ..............................................................47 Removal/Installation .........................................................................................47 Test Procedure...................................................................................................48 Minimum Tension Forces .................................................................................49
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Maintenance Manual EXTRA 500
32-30-30
Hydraulic Lines............................................................................................... 49 Description........................................................................................................ 49
32-30-40
Torque Link Rod and Track Rods................................................................ 50 Removal/Installation......................................................................................... 50
32-30-50
Drive Mechanism Nose Doors ....................................................................... 51 Removal/Installation......................................................................................... 51
32-40-00
WHEELS AND BRAKES.............................................................................. 52 Description........................................................................................................ 52
32-40-01
Main Wheels.................................................................................................... 52 Removal/Installation......................................................................................... 52
32-40-02
Nose Wheel ...................................................................................................... 53 Removal/Installation......................................................................................... 53
32-40-03
Brake................................................................................................................ 54 Removal/Installation......................................................................................... 54
32-50-00
STEERING...................................................................................................... 56 Description........................................................................................................ 56 Removal/Installation......................................................................................... 56
32-60-00 Figure 32-9
POSITION AND WARNING........................................................................ 57 Description........................................................................................................ 57 Main Gear Switches (LH)................................................................................. 58
32-60-01
Main Gear Extended Switches ...................................................................... 58
32-60-02
Main Gear Retracted Switches...................................................................... 58
32-60-03
Upper Main Door Opened Switch................................................................. 59
32-60-04
Upper Main Door Closed Switch .................................................................. 59
32-60-05
Lower Main Door Closed Switch .................................................................. 59
32-60-06
Ground Safety Switch .................................................................................... 59
32-60-07
Nose Gear Extended Switch........................................................................... 59
32-60-08
Nose Gear Retracted Switch .......................................................................... 60
32-60-09
Operation and Indication............................................................................... 60
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Maintenance Manual EXTRA 500
32-00-00
GENERAL Introduction The next paragraph contains the general description and operation of the landing gear. The following paragraph contains information about troubleshooting. The specified descriptions of the systems, sub-systems and units can be found in the respective chapters.
Description The EXTRA 500 has a hydraulically operated retractable tricycle landing gear with a steerable nose wheel. Each landing gear strut has a single wheel carrying tube-type tires. The main gear is designed as a parallel guide strut construction. Each strut has an oleo shock absorber and retracts against flight direction after turning the wheel by 90° in plane with the strut. The upper and lower doors fair the main gear struts in flight. Main gear struts and doors are separately actuated by hydraulic cylinders. The nose gear is designed as an oleo leg strut with a steerable nose wheel and retracts aft in the nose gear compartment. The rudder pedals on both pilot sides operate the nose wheel while taxiing. Components and System Features The main wheels have hydraulically actuated single-disk brakes on the inside. The toe-brake pedals on the rudder pedals operate the brakes. While parking, the brakes can be set on by the parking brake valve, which is located in the middle-console. Two hydraulic actuators drive each main gear strut. The interlocking actuator fixes the extended main gear strut for landing and ground operation. While retracting the main-wheel is turned by the torque link rod and the track rods and then placed in the wheel bay. During this cycle the torque link rod also shortens the main gear strut. In case of hydraulic or electric failure the main gear extends and locks gravity assisted by air flow. One hydraulic actuator drives the nose gear strut. The nose gear strut positively guides the nose doors. In case of hydraulic or electric failure, the nose gear extends and locks by the elastic force of two gas springs. The hydraulic power system provides a flow of pressurized hydraulic fluid to operate the landing gear system as well as the respective landing gear doors. Hydraulic pressure is maintained while the battery-bus is powered. The system is equipped with a pressure sensor, which will switch the pump on once the pressure drops. The constant system pressure is needed to hold the gears and doors safely in place.
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Controls and Monitoring Devices (For detailed description, refer to Section 32-60) The landing gear action is controlled by the LANDING GEAR switch on the L/H instrument panel. The extended and retracted position of each landing gear strut is monitored by position switches and indicated by signal lights: 1 The downlock information for the extended wheel position is given for each wheel separately by three green lights, located near the selector switch. 2 The red GEAR WARN light on the annunciator panel indicates that the landing gear is not completely retracted or extended and locked. In combination with the GEAR WARN light a gear up warning horn is activated. When landing gear is in transition hydraulic pump operation is necessary indicated by the yellow HYDRAULIC PUMP annunciation light. During ground operation, the double ground safety switch on the nose gear strut just above torque link prevents accidental gear retraction, regardless of the LANDING GEAR switch position. The electric circuits of the landing gear equipment are protected by circuit breakers. They are located on the left side panel and in the E-box (refer to Chapter 24-60).
Operation The LANDING GEAR switch has a guard to prevent inadvertent operation. The switch has the positions UP for retracting and DN for extending. The operation of the hydraulic system is divided in three hydraulic circuits, actuating the following devices: 1 Lower main gear doors 2 Upper main gear doors 3 Main landing gear struts and nose gear strut (incl. nose gear doors) The GEAR DOWN cycle is: 1 Opening of the lower main gear doors, the upper main gear doors and the nose gear doors and extension of the main gear and nose gear 2 Closing of the upper main gear doors The GEAR UP cycle is: 1 Opening of the upper main gear doors 2 Main and nose gear retraction (incl. nose gear doors) 3 Closing of the upper main gear doors 4 Closing of lower main gear doors Changing from gear up to gear down and vice versa is possible at any time.
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Nose gear and main gear extends and retracts under high pressure. Operation of the landing gear can cause death or injuries in its working area!
DANGER
Before beginning any work in the landing gear working area, pull the electric circuit breaker located on the left side panel and marked GEAR-CTRL. In case of intentional gear operation by switch or circuit breaker handling make sure, that neither a person nor any object is located in the upper landing gear doors travel area. NOTE
With the aircraft being airborne or jacked and BATT and EXT PWR switch OFF, the hot bus feeds an AUX circuit, which supplies the directional valves with electrical power to keep the landing gear in the up-position. The AUX circuit is protected by the GEAR AUX 1 (left side panel) and GEAR AUX 2 (E-box) circuit breakers. Push these circuit breakers in. However, the nose gear and main gear will slowly extend due to valve oil leakage, if the hydraulic pump is not being activated temporarily to maintain hydraulic pressure. If retracted landing gear position is intended, turn BATT switch ON (left side panel, toggle switch) and push circuit breakers GEAR-CTRL and HYDR (left side panel) in, while the landing gear switch (left main panel) is in the UP position. If the aircraft is jacked with landing gear retracted and external power not connected, the battery will be discharged within approx. 2 days.
Troubleshooting The following paragraph tabulates the troubleshooting procedures relevant to the landing gear system. The complaints are classified in order to the landing gear sub-systems. Complaint
Possible Cause
Remedy
Main Gear and Doors
Refer to Section 32-10
Wings are not level
Main gear struts bent or damaged
Inspect the main gear struts for cracks and bending
Drag brace is not locked in overcenter position
Inspect the drag brace, the torque link rod and the main gear-attachment frame for cracks and bending. Check the length of the torque link rod.
Gas-leakage by worn O-ring sealing of the shock absorber.
Check the nitrogen gas pressure and inflate if required
Main gear rattles while taxiing
Worn collar bushings
Replace
Oil stains beneath the shock absorber
Leakage by worn ore damaged O-ring and scraper rings
Replace
Nose Gear and Doors
Refer to Section 32-20
Oil stains beneath the nose
Leakage by worn ore damaged
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Replace O-ring, refill
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Complaint gear oleo-strut
Possible Cause O-ring and scraper rings
Remedy Aeroshell Fluid 4 as needed
Nose wheel wobbles while taxiing
Shimmy damper mechanical damage
Replace damaged parts
Leakage by worn ore damaged O-ring and scraper rings
Replace O-ring, refill Aeroshell Fluid 4 as needed
Extension and Retraction
refer to Section 32-30
Oil stains beneath the nose gear actuator and hydraulic lines
Leakage by worn ore damaged O-rings, fittings, hoses or tubes
Replace damaged parts
Oil stains beneath the main gear actuator and hydraulic lines
Leakage by worn ore damaged O-rings, fittings, hoses or tubes
Replace damaged parts
Continued hydraulic pump operation exceeds 3 seconds and/or periods of rest shorter than 2 minutes.
Abnormal hydraulic internal Detect leak and seal system leakage. Pressure switch
Adjust or replace
Pump bypass valve
Adjust or replace
Wheels and Breaks
refer to Section 32-40
Wings are not level
Incorrect wheel tube pressure
Check the tube pressure and inflate to max. pressure if required
Too much tire wear
Incorrect toe-in
Check and adjust the toe-in
Wheel track out of tolerance
Correct the wheel track
Too much axial play in wheel
Defective wheel bearing
Replace the wheel bearings
Brake disk deformed
Excessive hard braking
Replace brake disk
Dragging brakes
Worn or broken piston return spring in master cylinder
Repair or replace master cylinder
Brake does not operate
Brake fluid level low
Inspect master cylinder, fittings and linings for leakage. Refill brake fluid
Air in the brake system
Bleed the brake system
Defective master cylinder
Replace the master cylinder. Then bleed the brake system
Defective fittings or lines
Replace the fitting or line. Then bleed the brake system
Worn brake lining
Replace the brake lining
Operational Test Procedures For ground testing the landing gear functions the aircraft must be lifted at the three jack points (see Ch. 07-10-00). When aircraft is on jacks and landing gear Page 8
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shall be driven to another status as it is, follow the Gear Up Procedure or Gear Down Procedure given in the following. DANGER
Nose gear and main gear extends and retracts under high pressure. Operation of the landing gear can cause death or injuries in its working area ! Before beginning any work in the landing gear working area, pull the electric circuit breaker located on the left side panel and marked GEAR-CTRL. In case of intentional gear operation by switch or circuit breaker handling make sure, that neither a person nor any object is located in the upper landing gear doors travel area.
NOTE
With the aircraft being airborne or jacked and BATT and EXT PWR switch OFF OFF, the hot bus feeds an AUX circuit, which supplies the directional valves with electrical power to keep the landing gear in the up-position. The AUX circuit is protected by the GEAR AUX 1 (left side panel) and GEAR AUX 2 (E-box) circuit breakers. Push these circuit breakers in. However, the nose gear and main gear will slowly extend due to valve oil leakage, if the hydraulic pump is not being activated temporarily to maintain hydraulic pressure. If retracted landing gear position is intended, turn BATT switch ON (left side panel, toggle switch) and push circuit breaker GEAR-CTRL (left side panel) in, while the landing gear switch (left main panel) is in the UP position. If the aircraft is jacked with landing gear retracted and external power not connected, the battery will be discharged within approx. 2 days.
Gear Up Procedure 1 Lift the aircraft on jacks (refer to Chapter 07-10-00). DANGER
Upper landing gear doors will close immediately, when BATT or EXT PWR switch is turned to ON and GEAR-CTRL circuit breaker is in. Make sure, that neither a person nor any object is located in the upper landing gear doors travel area.
2 Turn BATT and EXT PWR switch ON (left side panel, toggle switch). 3 Push circuit breaker GEAR-CTRL in (left side panel). DANGER
Make sure, that neither a person nor any object is located in the landing gear travel area.
4 Pull and move LANDING GEAR switch UP (left main panel, below RH side of control yoke). 5 Wait until HYDRAULIC PUMP light is off indicating that the gear up procedure is completed. However GEAR WARN remains illuminated and aural warning is still active. This is normal as engine power is below approach setting (35% torque).
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Gear Down Procedure It is assumed aircraft is on jacks, the gear is up, BATT and/or EXT PWR switch is ON, and GEAR-CTRL circuit breaker is in. Perform Gear Up Procedure if applicable. DANGER
Make sure, that neither a person nor any object is located in the landing gear travel area.
1 Pull and move LANDING GEAR switch DN (left main panel, below RH side of control yoke). 2 Wait until three green down and locked lights are illuminated, indicating that the gear down procedure is completed.
Emergency Extension Test 1 Perform Gear Up Procedure (see above) DANGER
Landing gear will immediately slam down after GEAR-CTRL circuit breaker handling. Make sure, that neither a person nor any object is located in the landing gear travel area.
2 Pull circuit breaker GEAR-CTRL. IMPORTANT
Setting the LANDING GEAR switch to the DN position does not affect the operation of the landing gear as long as the GEAR-CTRL circuit breaker is pulled. This action shall prevent an unintentional landing gear retraction after completion of this test procedure when resetting the GEAR-CTRL circuit breaker. 3 Pull and move LANDING GEAR switch DN. 4 Verify the nose gear to extend and reach its down and locked position. 5 Main gear is not required to extend completely. A force of approx. 100 N (22.5 lbs.) simulating air loads at each wheel must be sufficient to reach the down and locked position.
NOTE
Spilling of 200 - 300 ml (12.2 - 18.3 cu inch) of hydraulic fluid at vent of reservoir is normal. 6 Check oil level at middle of side view glass → Aeroshell Fluid 4 (1.83 l/111.7 cu inch). 7 For confirming minimum nose gear extending force, test gas pressurized springs. See Subject 32-30-25 for test procedure.
NOTE
Check activated switches acoustically or by observing the related green gear down and locked indicator lights. 8 Check gear extended switch activating points are within 2 mm to 5 mm (0.079 in. to 0.197 in.) travel at wheel axle indicating the down and locked position before gear is fully extended. 9 Return aircraft to normal observing respective procedures and warnings
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Gear Up Cycle Test 1 Lift the aircraft on jacks (see Chapter 07-10-00). DANGER
Upper landing gear doors will close immediately, when BATT or EXT PWR switch is turned to ON and GEAR-CTRL circuit breaker is in. Make sure, that neither a person nor any object is located in the upper landing gear doors travel area.
2 Turn BATT and EXT PWR switch ON (left side panel, toggle switch). 3 Push circuit breaker GEAR-CTRL in (left side panel). 4 Ensure wing flaps are in 0° position. 5 Measure gear up cycle with a stop watch. DANGER
Make sure, that neither a person nor any object is located in the landing gear travel area.
6 Pull and move LANDING GEAR switch UP (left main panel, below RH side of control yoke). 7 Check acoustic gear warning function on horn, speaker and headset. 8 Press GEAR WARNING MUTE button on power lever. 9 Check mute function. 10 Check GEAR WARN annunciator light remains on. 11 Check HYDRAULIC PUMP annunciator light is on. 12 Check upper doors opening. 13 Check gear retracting and nose doors closing. 14 Check upper doors closing. 15 Check lower doors closing. 16 After gear up cycle is completed: Check performance time for a complete gear up cycle is between 11 and 15 seconds (LH and RH gears are not required to retract simultaneously). 17 Check if the red GEAR WARN and HYDRAULIC PUMP light extinguish. Ensure cabin door is closed before actuating the flaps. CAUTION 18 Set wing flaps to 15° 19 No warning should come. 20 Set wing flaps to 30° 21 Check acoustic gear warning active and GEAR WARN annunciator light illuminating. 22 Press GEAR WARNING MUTE button on power lever. 23 Check acoustic gear warning still active and GEAR WARN annunciator light still illuminating. 24 Set wing flaps to 0°. 25 Press GEAR WARNING MUTE button on power lever when flaps are passing the 15° setting. Page Date: 30. March 2012
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26 Perform Leakage and Accumulator Function Test (see below). 27 Perform further tests or Gear Down Procedure and return aircraft to normal observing respective procedures and warnings.
Wheels Up Landing Test It is assumed aircraft is on jacks, the gear is up, BATT and/or EXT PWR switch is ON, and GEAR-CTRL circuit breaker is in. Perform Gear Up Procedure if applicable. Make sure, that neither a person nor any object is located in the landing DANGER gear travel area. 1 Shut OFF BATT and EXT PWR switch. 2 Check gear position. The undercarriage must remain in retracted position. 3 Perform Gear Down Cycle Test Procedure or Gear Down Procedure and return aircraft to normal observing respective procedures and warnings.
Gear Down Cycle Test It is assumed aircraft is on jacks, the gear is up, BATT and/or EXT PWR switch is ON, and GEAR-CTRL circuit breaker is in. Perform Gear Up Procedure if applicable. 1 Measure gear down cycle with a stop watch. Make sure, that neither a person nor any object is located in the landing DANGER gear travel area. 2 Pull and move LANDING GEAR switch DN. 3 Check gear extending and opening of all doors. 4 Check if the following lights illuminate during gear transition: The red GEAR WARN annunciator light The yellow HYDRAULIC PUMP annunciator light 5 After landing gear is down and locked check if performance time for a complete gear down cycle is between 11 and 15 seconds (LH and RH gears must not extend simultaneously). 6 Check if upper doors are closed. 7 Check if the red GEAR WARN and HYDRAULIC PUMP lights extinguish. 8 Check the three green lights for nose gear, LH and RH gear illuminating. 9 Return aircraft to normal observing respective procedures and warnings.
Gear Up Cycle Test With Rudder Full Left/Full Right 1 Lift the aircraft on jacks (see Chapter 07-10-00). Upper landing gear doors will close immediately, when BATT or EXT PWR DANGER switch is turned to ON and GEAR-CTRL circuit breaker is in. Make sure, that neither a person nor any object is located in the upper landing gear doors travel area. Page 12
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2 Turn BATT and EXT PWR switch ON (left side panel, toggle switch). 3 Push circuit breaker GEAR-CTRL in (left side panel). 4 Apply full left rudder pedal control input. Make sure, that neither a person nor any object is located in the landing DANGER gear travel area. 5 Pull and move LANDING GEAR switch UP. 6 Check if nose gear retracts without jamming in the nose wheel bay. 7 Perform Gear Down Procedure. 8 Apply full right rudder pedal control input. Make sure, that neither a person nor any object is located in the landing DANGER gear travel area. 9 Pull and move LANDING GEAR switch UP. 10 Check if nose gear retracts without jamming in the nose wheel bay. 11 Perform further tests or Gear Down Procedure and return aircraft to normal observing respective procedures and warnings.
Leakage and Accumulator Function Test After two accumulator recharge cycles, the time before the third and the following recharging actions has to be at least 2 minutes. Recharging action can be heard as a short operation of the hydraulic power pack and is indicated by the HYDRAULIC PUMP annuciator light.
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32-10-00
MAIN GEAR AND DOORS
32-10-10
Main Gear Strut Assembly Description The main gear has two hydraulically actuated main gear strut assemblies with the following components (refer to Figure 32-1): • Undercarriage leg • Drag brace (upper and lower part) • Parallel strut • Upper guide strut • Lower guide strut • Axle bar • Shock absorber The main gear bolt attaches the steel designed main gear strut assembly to the main gear attachment frame. The parallel strut, the upper and lower guide struts and the axle bar shape a parallelogram (parallel guide strut construction). The drag brace locks the extended main gear strut. The upper and lower part are kept in overcenter position and fix the parallel strut in vertical. The bearings above and below the parallel strut are the axle for the upper and lower guide struts. The vertical movement of the guide struts is absorbed by the shock absorber, which is attached between them. The axle bar carries the main wheel and is attached to the upper and lower guide struts by bearings.
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Figure 32-1
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Wheel rim
Tyre
Aft View
Brake disk
Axle bar
Shock absorber
Upper guide strut
Parallel strut
Undercarriage leg
Main gear bolt
Extended limit switch
Drag brace (upper and lower part)
Track rod (upper and lower)
Lower guide strut
Torque link rod
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LH Main Gear Strut Assembly
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Removal Detail Steps/Work Items
Key Items
1 Lift the aircraft on jacks
Chapter 07-10
2 Remove aft keel beam access panel
Refer to Chapter 51-00-01
DANGER
Landing gear extends and retracts under high pressure. Operation of the landing gear can cause death or injuries in its working area! Before beginning any work in the landing gear working area, pull the electric circuit breaker located on the left side panel and marked GEAR-CTRL. In case of intentional gear operation by switch or circuit breaker handling make sure, that neither a person nor any object is located in the landing gear travel area.
3 Remove the bolt from the push pull rod upper door 4 Lift the upper door and fasten by means of a tape 5 Remove the clevis pin from the hinge joint lower door 6 Remove the bolt between the torque link rod and the main gear strut assembly 7 Remove the bolt between the short actuator main gear and the main gear strut assembly 8 Unlock the mechanism of the interlocking actuator.
Apply shop air momentarily on the rod side fitting of the interlocking actuator.
9 Remove the bolt between the interlocking actuator and the main gear strut assembly. Brake fluid can cause disease! WARNING Do not allow brake fluid to come in contact with your skin. CAUTION
Brake fluid can damage paint and other material! Clean up immediately spilt brake fluid
10 Remove the brake
Chapter 32-40-03
11 Disconnect reusable fitting of the brake hose. 12 Remove brake line from main gear strut 13 Remove the main wheel
Chapter 32-40-01
14 Remove the limit switch
Chapter 32-60-01
15 Cut off the safety wires on both main gear bolt nuts 16 Remove the lower nut completely from the thread. Page 16
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Detail Steps/Work Items 17 Remove the upper nut.
Key Items While pulling the main gear bolt with an extracting tool (refer to Chapter 01-00-02)
18 Remove the main gear bolt and the lower nut from the main gear attachment frame 19 Remove the assembled main gear 20 Remove the collar bushings in the main gear strut assembly
Installation 1 Lubricate the fitting surface and thread of the main gear bolt before installation
Use only MIL−G−81322D Grease
2 Install in reverse sequence of removal
Use new stop nuts and new brake line with crimped fitting on inboard side.
3 Bleed the brake system
Refer to Chapter 12-10-07
Disassembly/Assembly Detail Steps/Work Items 1 The track rods have to be removed CAUTION
Key Items Chapter 32-30-40
False reassembled bolted connections can damage the gear struts and doors. Before removal of bolts and nuts, notice their position. It can be different from the respective figure for geometric reasons.
2 Remove the bolts, stop nuts and washers from the undercarriage leg 3 Remove the undercarriage leg from the assembled strut structure 4 Remove the bolts, stop nuts and washers from the upper part of the drag brace 5 Remove the upper part of the drag brace from the assembled strut structure 6 Remove the collar bushings in the upper part of the drag brace 7 Remove the bolts, stop nuts and washers from the lower part of the drag brace. 8 Remove the lower part of the drag brace and the parallel strut from the assembled strut structure
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Detail Steps/Work Items
Key Items
9 Remove the collar bushings and shims in the parallel strut Tensioned construction due to nitrogen inflation damages hands and WARNING limbs! The shock absorber is under high pressure (827 psi/57 bar)! 10 Relieve nitrogen pressure. 11 Remove the bolts, stop nuts and shims between the shock absorber and the upper and lower guide strut 12 Remove the shock absorber from the upper and lower guide strut 13 Remove the bolt, stop nut and washer between the upper guide strut and axle bar 14 Remove the upper guide strut from the axle bar 15 Remove bolts, stop nuts and washers between the lower guide strut and axle bar 16 Remove the lower guide strut from the axle bar 17 Remove the collar bushings in the axle bar 18 Install in reverse sequence of removal
Use new stop nuts.
19 Check the toe-in whenever any part of the main gear strut has been changed
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32-10-11
Parallel Strut Description The steel designed parallel strut has the following components (refer to Figure 32-2): Upper and lower T-strut Rotary bushing with guide brackets Jam nut with set screw Adjusting nut with set screw Inner and outer joint Collar bushings in the rotary bushing Collar bushings in the joints Grease nipples Attaching parts like bolts, stop nuts and washers The parallel strut is steel designed. It is linked with the under-carriage leg, the lower part of the drag brace and the upper and lower guide strut by the bearings in the upper and lower T-strut. When the landing gear is extended, the parallel strut is vertically fixed by the undercarriage leg and the upper and lower part of the drag brace. The upper T-strut is threaded and carries the adjusting nut and the jam nut, which are for adjusting to avoid any vertical play. The components with collar bushings inside like the axle guide bracket and the upper and lower T-strut are equipped with grease nipples.
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Grease nipple Upper T-strut
Set screw Set screw
Jam nut
Upper guide bracket Grease nipple
Adjusting nut Collar bushing
Outer joint Grease nipple
Inner joint
Rotary bushing Collar bushing
Grease nipple Lower guide bracket
Lower T-strut Grease nipple Figure 32-2
Parallel Strut
Removal/Installation For removal of the parallel strut from the main gear strut assembly perform as described in step 1 to 3 and 7 to 9 (refer to Subject 32-10-10 Main Gear Strut Disassembly).
Disassembly/Assembly Detail Steps/Work Items 1 Remove the lower T-strut from upper Tstrut with rotary bushing.
Key Items Turn lower T-strut counterclockwise
2 Remove the rotary bushing with its collar bushings. 3 Loosen the jam nut and adjusting nut set screws. 4 Loosen the jam nut from the adjusting nut Page 20
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Detail Steps/Work Items
Key Items
5 Remove the adjusting nut. 6 Remove the jam nut. 7 Remove the bolts, stop nuts and washers from the inner and outer joint. 8 Remove the inner and outer joint. 9 Remove the joint collar bushings. 10 Install in reverse sequence of removal
Use new stop nuts
Adjustment of Vertical Play Detail Steps/Work Items NOTE
Key Items
This procedure does not require jacking the aircraft 1 Loosen the jam nut and adjusting nut set screws. 2 Loosen the jam nut. 3 Tighten the collar bushings to the rotary bushing by clockwise turning the adjusting nut.
As long as any clearance occurs
4 Tighten the adjusting nut set screw. 5 Counter the adjusting nut by the jam nut. 6 Tighten the jam nut set screw. NOTE
32-10-12
Replace the collar bushings when their collar thickness is less then 3/64" (1 mm)
Axle Bar Description The steel designed axle bar has the following components (see Figure 32-3): Upper and lower T-strut Rotary bushing with axle and axle guide bracket Joint Collar bushings in the joint Grease nipples Attaching parts like bolts, stop nuts and washers The axle bar is linked with the upper and lower guide strut by the bearings in the upper and lower T-strut.
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The axle carries the main wheel. The rotary bushing and the upper and lower T-strut are equipped with grease nipples. Upper T-strut Grease nipple
Rotary bushing
Grease nipple
Axle guide bracket Collar bushing
Joint
Collar bushing
Grease nipple Lower T-strut
Figure 32-3
Axle Bar
Removal/Installation For removal of the axle bar from the main gear strut assembly follow step 1 and 13 to 17 (refer to Subject 32-10-10 Main Gear Strut Disassembly)
Disassembly/Assembly Detail Steps/Work Items
Key Items
1 Remove the upper T-strut from lower Tstrut and the rotary bushing 2 Remove the collar bushing in rotary bushing 3 Remove the bolts, stop nuts and washers from joint Page 22
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Detail Steps/Work Items
Key Items
4 Remove the joint 5 Remove the collar bushing in the joint 6 Install in reverse sequence of removal
Use new stop nuts
Adjustment of Vertical Play For disassembly follow step 12 to 16 (Subject 32-10-10 Main Gear Disassembly) Detail Steps/Work Items
NOTE
32-10-13
Key Items
1 The axle bar has to be removed
Follow step 1 and 13 to 17 (32-10-10 Main Gear Strut Disassembly)
2 Tighten the collar bushings in the rotary bushing by turning the upper T-strut (full turns only) against the lower T-strut clockwise.
As long as any clearance occurs
Replace the collar bushings when their collar thickness is less then 3/64"/ 1 mm
Shock Absorber Description The steel designed shock absorber has the following components (refer to Figure 32-4): Outer cylinder Inner cylinder Slide bearing Piston Throttle with disk and support Seals like O-rings and scraper ring Valves Hinge bearings Attaching parts like back up rings, safety pin and locking ring The shock absorber is connected to the upper and lower guide strut by bolts. The shock absorber is designed as oil/nitrogen filled cylinder. The lower outer cylinder is filled with hydraulic oil; the upper inner cylinder is nitrogen inflated. The piston in the upper inner cylinder separates the hydraulic oil from
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nitrogen inflation. The grounded and hardened surfaces of the inner cylinder and the piston are sealed by O-rings. Hinge bearing Valve
Outer cylinder
Throttle with disk and support
Piston Scraper ring
O-ring Locking wire
Slide bearing Inner cylinder
Valve Hinge bearing Figure 32-4
Shock absorber
Removal/Installation For removal of the shock absorber from the main gear strut assembly follow step 10 to 12 (refer to Subject 32-10-10 Main Gear Strut Disassembly)
Disassembly/Assembly Detail Steps/Work Items
Key Items
High-pressure oil-jet damages eyes and limbs! WARNING
The shock absorber is under high pressure (827 psi/57 bar)
1 Release nitrogen pressure and drain the hydraulic fluid completely in a sump
Refer to Chapter 12-10-09
2 Remove the locking wire from the outer cylinder. Page 24
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Detail Steps/Work Items
Key Items
3 Remove the outer cylinder from the slide bearing 4 Remove the O-ring and the back up-ring from the outer cylinder 5 Remove the safety pin from the slide bearing and the inner cylinder 6 Remove the support throttle, the disc and the throttle from inner cylinder 7 Remove the inner cylinder from the slide bearing 8 Remove the O-ring, the back up-rings and the scraper ring from the slide bearing 9 Push the piston out of the inner cylinder 10 Remove the O-ring and the back up-rings 11 Install in reverse sequence of removal
Use new stop nuts
12 Seal locking wire.
Elastosil E14, GE RTV 159 or equivalent
13 Refill hydraulic fluid into the cylinder and apply nitrogen pressure.
Refer to Chapter 12-10-09
14 Check the wheel track
32-10-20
Main Gear Doors Description The carbon fiber designed upper and lower doors fair the retracted main gears. The hinges are integrated in the door lamination. The upper doors are connected to the fuselage by two hinges each. Hydraulic actuators drive the upper doors by levers with push pull rod. The lower doors are connected to the fuselage by three hinges each. An hydraulic actuator drives both lower doors by levers with cardan hinge joint.
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32-10-21
Upper Doors Removal/Installation Detail Steps/Work Items
DANGER
Key Items
Landing gear extends and retracts under high pressure. Operation of the landing gear can cause death or injuries in its working area! Before beginning any work in the landing gear working area, pull the electric circuit breaker located on the left side panel and marked GEAR-CTRL. In case of intentional gear operation by switch or circuit breaker handling make sure, that neither a person nor any object is located in the landing gear travel area.
1 Remove the bolt between the upper door and the push pull rod. 2 Remove the bolts from both hinges.
Hold the door
3 Remove the upper door. 4 Install in reverse sequence of removal.
Use new stop nuts
Door Actuation Length Adjustment The outer push-pull rods for the upper doors are attached to the resp. door front section. For adjusting LH resp. RH push-pull rod, loosen upper and lower locknut and turn threaded rod. Re-tighten and torque locknuts with 4 Nm ± 0.2 Nm (35.4 inch.lbf. ± 1.8 inch.lbf.). Perform gear up procedure (refer to Subject 32-31-01) and check that doors are closing correctly. Repeat adjustment as necessary.
32-10-22
Lower Doors Removal/Installation Detail Steps/Work Items
DANGER
Key Items
Landing gear extends and retracts under high pressure. Operation of the landing gear can cause death or injuries in its working area! Before beginning any work in the landing gear working area, pull the electric circuit breaker located on the left side panel and marked GEAR-CTRL. In case of intentional gear operation by switch or circuit breaker handling make sure, that neither a person nor any object is located in the landing gear travel area.
1 Remove the clevis pin from hinge joint of the lower door Page 26
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Detail Steps/Work Items 2 Remove the bolts, stop nuts and washers from the hinge
Key Items Hold the door
3 Remove the lower door 4 Install in reverse sequence of removal
Use new stop nuts
Door Actuation Length Adjustment The inner push-pull rods for the lower doors are located about half door length below the wheel well. For adjusting LH resp. RH push-pull rod, loosen upper stop nut LN 9348-06 and turn threaded rod. Re-tighten and torque upper stop nuts with 6.5 Nm ± 0.3 Nm (57.5 inch.lbf. ± 2.5 inch.lbf.). CAUTION
Detach the upper doors to prevent them from damage during the following test in case the adjustment is not yet correct. Remove the bolt from the push pull rod upper door. Lift upper door and fasten with tape. Perform Gear Up Procedure (refer to Subject 32-00-00) and check that doors are closing correctly. Repeat adjustment as necessary. Reattach upper doors.
NOTE
Do not re-tighten lower stop nuts, but leave nuts ¼ - turn unlocked. This will allow threaded rods to turn in case both doors are not actuated evenly, thus reducing tension in the actuation mechanism.
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32-20-00
NOSE GEAR AND DOORS Description Two trunnion bolts attach the nose gear oleo leg strut to the engine mounting. The nose strut, using an oleo-hydraulic shock absorber, is operated by a hydraulic actuator and retracts aft in the nose gear compartment. In case of hydraulic system failure, the nose gear extends by two gas pressurized springs against air loads. A ground safety switch, located at the drag brace of the nose gear, prevents accidental nose gear retraction during ground operation. In flight the nose doors fair the nose gear strut.
32-20-10
Nose Gear Strut Assembly Description The nose gear consists of the following parts (see Figure 32-5) • Trunnion • Drag brace • Steering arm assembly • Oleo leg (upper and lower strut) • Torque link • Shimmy damper assembly The trunnion assembly carries the drag brace and the steering arm assembly. The support tubes and tubes for the RH and LH pivot bearings are welded to the trunnion. The upper strut of the Oleo leg fits inside the trunnion. The torque link is bolted to the upper strut and the lower strut of the Oleo leg. It prevents the lower strut from turning inside the upper strut. The drag brace is attached to the trunnion and the engine mounting. It locks the extended Oleo leg. In case of hydraulic system failure, the drag brace is locked in extended position by two gas pressurized springs, which are pivoted at the upper part of the drag brace. The shimmy damper assembly dampens lateral moving of the nose gear while taxiing. It is attached to the trunnion.
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Side View
Gas pressurized springs
Shimmy damper Hydraulic actuator
Trunnion
Upper strut
Nose gear extended switch
Oleo leg Ground safety switches Torque link
Drag brace (upper and lower part)
Lower strut
Wheel
Figure 32-5
Nose Gear
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32-20-20
Nose Gear Doors Description The carbon fibre nose gear doors are attached to the fuselage by aft and forward door hinges. The nose gear doors are operated by the nose gear door actuation mechanism, which is linked to the trunnion (refer to Figure 32-6). The actuation mechanism consists of the following parts: • Spring • Telescope guide rod • Push-pull rod (one each side) • Two-armed rocker lever incl. stop The doors are closed in the last part of the nose gear retraction phase. Then the telescope guide rod is fully extended and begins to drive the actuation mechanism. The spring presses the rocker lever against the stop thus keeping the actuation mechanism in the over-centered position and the doors open.
Door Actuation Length Adjustment The push-pull rods for the nose gear doors are attached to the resp. door front section. For adjusting LH resp. RH push-pull rod, loosen upper and lower locknut and turn threaded rod. Re-tighten and torque locknuts with 4 Nm ± 0.2 Nm (35.4 inch.lbf. ± 1.8 inch.lbf.). Perform gear up procedure (refer to Subject 32-31-01) and check that doors are closing correctly. Repeat adjustment as necessary.
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Figure 32-6
Nose gear retracted switch
Telescope guide rod
fwd
Push-pull rod
Spring
Stop
Page Date: 30. March 2012
Movement when retracting
RH nose gear door
Two-armed rocker lever
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Nose Gear Doors Actuation Mechanism
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32-30-00
EXTENSION AND RETRACTION Description Refer to Figures 32-7 and 32-8. Extension and retraction of main gear and nose gear is controlled by hydraulic actuators. The main landing gear doors are also hydraulically actuated. Nose landing gear doors are mechanically linked to the trunnion of the nose gear. The equipment for extension and retraction consists of the following components: 1 Hydraulic system components with the items: a Power pack, consisting of: Hydraulic pump with geared electric motor By-pass valve Strainer Reservoir b Distributor block, consisting of: 3 directional valves Pressure switch Diaphragm pressure accumulator 2 Hydraulic actuators for gears and doors 4 Main gear actuators (1 short actuator and 1 interlocking actuator each side) 2 Actuators for upper doors Actuator for lower doors Nose gear actuator 3 Hydraulic lines Part 1 Gear actuation Part 2 Main gear lower and upper doors actuation Part 3 Power supply 4 Torque link and track rods 5 Drive mechanism nose doors The hydraulic power pack together with the distributor block provide the landing gear system as well as the respective landing gear doors with a flow of pressurized hydraulic fluid (operation-pressure 100-120 bar/1,450-1,740 PSI). Hydraulic pressure is maintained throughout ground and flight operation as long as the electric battery bus is powered. An external, adjustable pressure switch, mounted to the distributor block, cuts off electric power as soon as 120 bar (1,740 PSI) are reached. The pressure switch will return power to the hydraulic pump when pressure drops below below 100 ± 5 bar (1,450 ± 2.5 PSI). As an additional safety device the equipment chassis of the power pack carries a pressure relief valve which will open the bypass above the pump once the pressure would exceed 130 bar (1,885 PSI). The hydraulic power pack with pump, strainer and reservoir as well as the distributor block with control valves and pressure switch are built into the hydraulic power compartment in front of the main gear attachment frame between the keelbeams.
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The hydraulic fluid level can be checked any time by means of an inspection glass on the hydraulic power pack reservoir, visible behind an opening in the keelbeam. It is accessible from the R/H main wheel bay. Just above the L/H side of the inspection glass is the filling cap for the hydraulic fluid. A small nitrogen diaphragm accumulator is used to eliminate the necessity of frequent hydraulic pack activation due to small internal system leakage. This accumulator is located underneath the passenger cabin floor within the pressurized (and heated) vessel to avoid embrittlement of the diaphragm during high altitude low temperature operation. A yellow HYDRAULIC PUMP caution light is included into the annunciator panel, which indicates hydraulic pump activity and normally shall illuminate for not more than 2 or 3 seconds after periods of several minutes of rest, or during landing gear operation. (See Subject 32-00-00 Leaks and Accumulator Function Test.) If longer constant pump action or shorter periods of rest are observed, refer to Troubleshooting Paragraph in this Chapter. Prolonged pump operation for more than 2 minutes will cause pump or electric motor to overheat. The distributor block is equipped with three solenoid directional control valves and the pressure switch. The hydraulic fluid is directed by the control valves; these are spring loaded and will automatically switch into the gear down position once electric power is lost. The hydraulic system is separated in three circuits to actuate the respective devices: 1 Extension/retraction of main gear and nose gear 2 Opening/closing of the lower main gear doors 3 Opening/closing of the upper main gear doors The main and nose gear struts and doors are separately actuated by hydraulic cylinders. Two hydraulic actuators drive each main gear strut. One of the cylinders (the interlocking actuator) is designed to carry the breaking loads and has a mechanical locking mechanism. The torque link rod tows and unlocks the drag brace when the actuators start retracting. It shortens the main gear strut while retracting to fit it into the wheel bay. The track rods turn and push the coupled axle bar together with its wheel forward to drive it into the wheel bay. The nose gear strut is driven by one hydraulic actuator. For emergency extending the nose gear strut is equipped with two gas pressurized springs. They push the nose gear out in case of hydraulic system failure. The nose gear has a positive downlock by an overcenter device (drag brace). The upper main gear doors are driven by a hydraulic actuator each. The lower main gear doors are driven by one common hydraulic actuator. The nose gear doors are positively guided by the nose gear strut. All parts of the hydraulic system are hydraulically connected by lines. They consist of aluminum tubes and braided reinforced Teflon hoses. The actuators are connected by the Teflon hoses.
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GEAR WARN MUTE
L/N/R DOWN Three Green Lights
GEAR AUX 1 Circuit Breaker
Gear Warning Circuit Board
GEAR AUX 2 Circuit Breaker
Gear Warning Horn
GEAR CTRL Circuit Breaker HYDR Circuit Breaker
Annunciator Panel
Landing Gear Switch Ground Safety Switch Diaphragm Accumulator Hydraulic Pump (driven by electric motor)
Reservoir Limit Switch(es)
Valve
Main Gear Lower Doors Limit Switch(es)
Valve
Main Gear Upper Doors Limit Switch(es)
Valve
Main Gear Struts and Nose Gear Strut & Doors Legend: Electrical Wiring Hydraulic Lines Figure 32-7 Page 34
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Hydraulic Cylinder(s)
Landing Gear Schematic Page Date: 30. March 2012
Figure 32-8
Lower door
fwd
Interlocking actuator
Short actuator
Torque link rod
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Lower track rod
Upper track rod
Piston rod end
LH main gear
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Main Gear Actuators
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32-30-10
Hydraulic System Bleeding This procedure describes bleeding the hydraulic system by operating the landing gear and then refilling hydraulic fluid. Follow this procedure when smaller works with little loss of hydraulic fluid have been performed on the hydraulic system such as removal and installation procedures of single components. Generally, when hydraulic lines have been plugged during these procedures and the respective components have been pre-filled with hydraulic fluid before reinstallation this bleeding procedure shall be sufficient. Detail Steps/Work Items
DANGER
Key Items
Landing gear extends and retracts under high pressure. Operation of the landing gear can cause death or injuries in its working area! Before beginning any work in the landing gear working area, pull the electric circuit breaker located on the left side panel and marked GEAR-CTRL. In case of intentional gear operation by switch or circuit breaker handling make sure, that neither a person nor any object is located in the landing gear travel area. Hydraulic fluid can cause disease!
WARNING
Do not allow hydraulic fluid to come in contact with your skin. Hydraulic fluid can damage paint and other material!
CAUTION
Clean up immediately spilt hydraulic fluid.
1 Lift the aircraft on jacks. DANGER
Chapter 07-10-00
Upper landing gear doors will close immediately, when BATT or EXTR PWR switch is turned to ON and GEAR-CTRL circuit breaker is in. Make sure, that neither a person nor any object is located in the upper landing gear doors travel area.
2 Turn BATT and EXT PWR switch ON. 3 Push circuit breaker GEAR-CTRL in. DANGER
Landing gear extends and retracts under high pressure. Operation of the landing gear can cause death or injuries in its working area! Make sure, that neither a person nor any object is located in the landing gear travel area.
4 Operate the landing gear: 1 Retraction cycle 1 Extension cycle 5 Turn BATT and EXT PWR switch OFF. 6 Pull circuit breaker GEAR-CTRL. 7 Check hydraulic fluid level; if necessary, refill hydraulic fluid until the oil level just covers the center line of the gauge glass. Page 36
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Use MIL−H−5606 Hydraulic Fluid
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Detail Steps/Work Items NOTE
Key Items
Pay attention to noise in the restrictor nozzles to localize trapped air in the system. Drive maximum 5 cycles; then allow power pack to cool down.
CAUTION 8 Repeat steps 2 to 7, until correct fluid level remains constant. 9 Remove the tape from RH upper door and re-install the bolt to the push pull rod.
Hydraulic Fluid Change Detail Steps/Work Items DANGER
Key Items
Landing gear extends and retracts under high pressure. Operation of the landing gear can cause death or injuries in its working area! Before beginning any work in the landing gear working area, pull the electric circuit breaker located on the left side panel and marked GEAR-CTRL. In case of intentional gear operation by switch or circuit breaker handling make sure, that neither a person nor any object is located in the landing gear travel area. Hydraulic fluid can cause disease!
WARNING
Do not allow hydraulic fluid to come in contact with your skin. Hydraulic fluid can damage paint and other material!
CAUTION
Clean up immediately spilt hydraulic fluid.
1 Lift the aircraft on jacks
Chapter 07-10-00
2 Remove the hydraulic power pack
Refer to Chapter 32-30-11 Removal/Installation
3 Clean hydraulic power pack and filter.
Refer to Chapter 32-30-11 Cleaning
4 Remove the oil vent plug from the reservoir. 5 Refill hydraulic fluid through vent plug opening of the reservoir up to maximum level.
Use MIL−H−5606 Hydraulic Fluid
6 Plug a temporary breather hose (diameter 6 mm/1/4 inch) with fitting into the vent plug opening. 7 Re-install the hydraulic power pack. Let upper RH door in lifted position.
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Refer to Chapter 32-30-11 Removal/Installation omitting steps 2 and 3.
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Detail Steps/Work Items
Key Items
8 Lead breather hose through free opening in keel beam to RH access compartment in front of main wheel bay During gear retraction, high pressure oil jet from the return line WARNING damages eyes and limbs! Cover return line in the sump with mesh gate to retain spilling fluid. DANGER
Upper landing gear doors will close immediately, when BATT or EXT PWR switch is turned to ON and GEAR-CTRL circuit breaker is in. Make sure, that neither a person nor any object is located in the upper landing gear doors travel area.
8 Turn BATT and EXT PWR switch ON (left side panel, toggle switch) 9 Push circuit breaker GEAR-CTRL in (left side panel) DANGER
Landing gear extends and retracts under high pressure. Operation of the landing gear can cause death or injuries in its working area! Make sure, that neither a person nor any object is located in the upper landing gear doors travel area.
10 Pull and move LANDING GEAR switch UP (left main panel, below RH side of control yoke) NOTE
Assure adequate fluid volume to avoid trapped air in the system 11 Refill reservoir through breather hose with hydraulic fluid up to maximum level.
DANGER
read out 1100 cm³ (67 cu in) or refill until fluid runs out
Landing gear extends and retracts under high pressure. Operation of the landing gear can cause death or injuries in its working area! Make sure, that neither a person nor any object is located in the upper landing gear doors travel area.
12 Pull and move LANDING GEAR switch DN. 13 Turn BATT and EXT PWR switch OFF.
When landing gear is down and locked.
14 Pull circuit breaker GEAR-CTRL. 15 Remove breather hose. 16 Screw the oil vent plug to the reservoir. 17 Remove the tape from RH upper door and re-install the bolt to the push pull rod 18 Return aircraft to normal observing respective procedures and warnings.
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32-30-11
Hydraulic Power Pack Removal/Installation Detail Steps/Work Items
DANGER
Key Items
Landing gear extends and retracts under high pressure. Operation of the landing gear can cause death or injuries in its working area! Before beginning any work in the landing gear working area, pull the electric circuit breaker located on the left side panel and marked GEAR-CTRL. In case of intentional gear operation by switch or circuit breaker handling make sure, that neither a person nor any object is located in the landing gear travel area.
1 Ensure BATT switch is OFF and no external power connected. 2 Remove the aft keel beam access panel.
Refer to Chapter 51-00-01
3 Remove the bolt from the push pull rod upper door RH. 4 Lift the upper door RH and fasten it by means of a tape. 5 Disconnect the electric power supply from the hydraulic power pack. Hydraulic fluid can cause disease! WARNING
Do not allow hydraulic fluid to come in contact with your skin. Hydraulic fluid can damage paint and other material!
CAUTION
Clean up immediately spilt hydraulic fluid
6 Disconnect the hydraulic lines from the inlet and outlet fitting of the hydraulic power pack.
Refer to Chapter 32-30-30
7 Install blind plugs to the disconnected lines to avoid trapped air in the system. NOTE
For identification, tag each hydraulic line. The line connecting the sump to the hydraulic pump is identified as return line, the line leading directly to the control valve is the pressure line. 8 Remove 2 attachment bolts of the power pack.
Hold unit
9 Drain the hydraulic fluid 10 Install in reverse sequence of removal 11 Perform Bleeding procedure.
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Refer to Subject 32-30-10
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Cleaning This procedure describes cleaning the interior of the hydraulic power pack and the incorporated suction filter. It is assumed that the hydraulic power pack is removed from aircraft. Detail Steps/Work Items
Key Items
1 Place the power pack in upright position.
Electric motor up
2 Remove the 4 bolts from the reservoir sump
Catch spilling hydraulic fluid
3 Remove the hydraulic power pack from the reservoir. 4 Pour hydraulic fluid of the reservoir completely in an external suitable container. 5 Clean the inside of the reservoir sump from sludge
By means of lint-free rags
6 Pull off the suction filter from the suction line 7 Dry and clean the suction filter carefully
By means of lint-free rags
8 Place the hydraulic power pack to the reservoir.
Check the sealing ring for proper arrangement
9 Reinstall the 4 reservoir attaching bolts. 10 Refill hydraulic fluid.
32-30-12
Use MIL−H−5606 Hydraulic Fluid 1100 cm³ (67 cu in)
Distributor Block Removal/Installation Detail Steps/Work Items
DANGER
Key Items
Landing gear extends and retracts under high pressure. Operation of the landing gear can cause death or injuries in its working area! Before beginning any work in the landing gear working area, pull the electric circuit breaker located on the left side panel and marked GEAR-CTRL. In case of intentional gear operation by switch or circuit breaker handling make sure, that neither a person nor any object is located in the landing gear travel area.
1 Ensure BATT switch is OFF and no external power connected. 2 Remove the aft keel beam access panel.
Refer to Chapter 51-00-01
3 Remove the bolts from the push pull rods of the upper doors. Page 40
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Detail Steps/Work Items
Key Items
4 Lift the upper doors and fasten them by means of a tape. 5 Disconnect the electrical plug of the control cables from the directional valves and from the pressure switch. Hydraulic fluid can cause disease! WARNING Do not allow hydraulic fluid to come in contact with your skin. CAUTION
Hydraulic fluid can damage paint and other material! Clean up immediately spilt hydraulic fluid.
6 Remove the hydraulic lines from the fittings of the distributor block.
Chapter 32-30-30
7 Install blind plugs to the disconnected lines to avoid trapped air in the system. 8 Remove the bolts, washers and spacer sleeves from the distributor block.
Hold the unit
9 Remove the distributor block10 Drain the hydraulic fluid of the distributor block in a sump. 11 Cover all hydraulic inlets and outlets by plastic caps. 12 Install in reverse sequence of removal 13 Perform Bleeding procedure.
Refer to Subject 32-30-10
Disassembly/Assembly Detail Steps/Work Items
Key Items
1 Cut off the safety wire on the top side of the directional valves. 2 Remove the Allen bolts and lock washers from the directional valves. 3 Remove the directional valves from the distributor block.
Valve solenoids are “spot” connected to each other with silicone. Catch the O-ring from the directional valves
4 Unscrew and remove the pressure switch from the distributor block.
Catch the O-ring from the pressure switch
5 Remove the nipples and elbows from the distributor block.
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Detail Steps/Work Items NOTE
Key Items
Sign the elbows with a tag to ensure re-assembly at the original position on the distributor block. The original position is required for the proper fitting and mounting of the distributor block on its place between the keel beams. 6 Install in reverse sequence of removal.
32-30-20
Actuators
32-30-21
Main Gear Actuators
Lock up the Allen bolts of the directional valves by safety wire and “spot” fix solenoids with Elastosil E14, GE RTV 159 or equivalent
Each side of the main landing gear is driven by two hydraulic actuators (see Figure 32-8): • Short actuator • Interlocking actuator
Removal/Installation The following procedure applies for both actuators. However the interlocking actuator has to be unlocked before removal as described in step 6. Detail Steps/Work Items DANGER
Key Items
Landing gear extends and retracts under high pressure. Operation of the landing gear can cause death or injuries in its working area! Before beginning any work in the landing gear working area, pull the electric circuit breaker located on the left side panel and marked GEAR-CTRL. In case of intentional gear operation by switch or circuit breaker handling make sure, that neither a person nor any object is located in the landing gear travel area.
1 Lift the aircraft on jacks
Chapter 07-10-00
2 Remove the bolt from the push pull rod upper doors. 3 Lift the upper doors and fasten them by means of a tape.
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Detail Steps/Work Items
Key Items
Hydraulic fluid can cause disease! WARNING
Do not allow hydraulic fluid to come in contact with your skin. Hydraulic fluid can damage paint and other material!
CAUTION
Clean up immediately spilt hydraulic fluid.
4 Remove the hydraulic lines from the hydraulic actuator fittings.
Chapter 32-30-30
5 Install blind plugs to the disconnected lines to avoid trapped air in the system. CAUTION
False reassembled bolted connections can damage the gear struts and doors. Before removal of bolts and nuts, notice their position.
6 (interlocking Momentarily apply shop air to the fitting at actuator only) the rod end side of the hydraulic cylinder.
To release the down locked position.
7 Remove the bolt, the stop nut and the washers between the rod end of the hydraulic actuator and the main gear strut assembly. 8 Remove the bolt, the stop nut and the washers between the cylinder side of the hydraulic actuator and the bracket on the keel beam.
Hold the hydraulic actuator
9 Remove the hydraulic actuator. 10 Measure the fully extended actuator length. 11 Install in reverse sequence of removal
Use new stop nuts
12 Check actuator for length.
Set the fully extended length to the previously measured length.
13 Perform Bleeding procedure.
Refer to Subject 32-30-10
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32-30-22
Upper Doors Actuator Removal/Installation Detail Steps/Work Items
DANGER
Key Items
Landing gear extends and retracts under high pressure. Operation of the landing gear can cause death or injuries in its working area! Before beginning any work in the landing gear working area, pull the electric circuit breaker located on the left side panel and marked GEAR-CTRL. In case of intentional gear operation by switch or circuit breaker handling make sure, that neither a person nor any object is located in the upper landing gear doors travel area. Hydraulic fluid can cause disease!
WARNING
Do not allow hydraulic fluid to come in contact with your skin. Hydraulic fluid can damage paint and other material!
CAUTION
Clean up immediately spilt hydraulic fluid.
1 Remove the respective front fuselage access panel.
Refer to Chapter 51-00-01
2 Remove the hydraulic lines from the fittings of the hydraulic actuator.
Chapter 32-31-00
3 Install blind plugs to the disconnected lines to avoid trapped air in the system. 4 Remove the bolt, the stop nut and the washers between the rod end of the hydraulic actuator and the torque tube. 5 Remove the cotter pin from the clevis pin 6 Remove the washer and clevis pin between the cylinder side of the hydraulic actuator and the support
Hold the hydraulic actuator
7 Remove the hydraulic actuator 8 Remove the bolts, the stop nuts and the washers between the torque tube and the cardan joint 9 Remove the torque tube 10 Remove the bolts, the stop nuts and the washers between the cardan joint and the shaft
Hold the cardan joint
11 Remove the cardan joint 12 Remove the bolts, the stop nut and the washers from the push pull rod
Hold the push pull rod
13 Remove the push pull rod Page 44
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Detail Steps/Work Items
Key Items
14 Remove the bolt, the stop nut and the washer from the lever 15 Pull off the lever from the shaft 16 Pull out the shaft of the bearing 17 Remove the collar bushing 18 Install in reverse sequence of removal
Use new stop nuts
19 Perform Bleeding procedure.
Refer to Subject 32-30-10
32-30-23
Lower Doors Actuator Removal/Installation Detail Steps/Work Items
DANGER
Key Items
Landing gear extends and retracts under high pressure. Operation of the landing gear can cause death or injuries in its working area! Before beginning any work in the landing gear working area, pull the electric circuit breaker located on the left side panel and marked GEAR-CTRL. In case of intentional gear operation by switch or circuit breaker handling make sure, that neither a person nor any object is located in the upper landing gear doors travel area. Hydraulic fluid can cause disease!
WARNING
Do not allow hydraulic fluid to come in contact with your skin. Hydraulic fluid can damage paint and other material!
CAUTION
Clean up immediately spilt hydraulic fluid.
1 Remove the aft keel beam access panel.
Refer to Chapter 51-00-01
2 Remove the hydraulic lines from the fittings of the hydraulic actuator.
Chapter 32-30-30
3 Install blind plugs to the disconnected lines to avoid trapped air in the system. 3 Remove the cotter pins from the clevis pins on the hydraulic actuator. 4 Remove the clevis pin between the rod end of the hydraulic actuator and the actuator lever. 5 Remove the clevis pin between the cylinder side of the hydraulic actuator and the support. Page Date: 30. March 2012
Hold the hydraulic actuator
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Detail Steps/Work Items
Key Items
6 Remove the hydraulic actuator 7 Remove the cotter pins from the clevis pins on the hinge joints 8 Remove the clevis pins and the washers from the hinge joints 9 Remove the hinge joints 10 Remove the bolts, the stop nuts and the washers between the actuator lever and both torque tubes 11 Pull out the torque tube LH of the actuator lever and the bearing
Hold the actuator lever
12 Remove the actuator lever from the torque tube RH
Hold the torque tube
13 Pull out the torque tube RH of the bearing 14 Remove the collar bushing from the keel beams 15 Install in reverse sequence of removal
Use new stop nuts
16 Perform Bleeding procedure.
Refer to Subject 32-30-10
32-30-24
Nose Gear Actuator Removal/Installation Detail Steps/Work Items
DANGER
Key Items
Landing gear extends and retracts under high pressure. Operation of the landing gear can cause death or injuries in its working area! Before beginning any work in the landing gear working area, pull the electric circuit breakers located on the left side panel and marked GEAR-CTRL. In case of intentional gear operation by switch or circuit breaker handling make sure, that neither a person nor any object is located in the upper landing gear doors travel area.
1 Lift the aircraft on jacks
Chapter 07-10-00
Hydraulic fluid can cause disease! WARNING
Do not allow hydraulic fluid to come in contact with your skin. Hydraulic fluid can damage paint and other material!
CAUTION
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Clean up immediately spilt hydraulic fluid.
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Detail Steps/Work Items 2 Remove the hydraulic lines from the fittings of the hydraulic actuator.
Key Items Chapter 32-30-30
3 Install blind plugs to the disconnected lines to avoid trapped air in the system. 4 Remove the bolt, the stop nut and the washer from the rod end of the hydraulic actuator. 5 Remove the bolt, the stop nut and the washer from the cylinder side of the hydraulic actuator.
Hold the hydraulic actuator
6 Remove the hydraulic actuator. 7 Measure the fully extended actuator length. 8 Install in reverse sequence of removal.
Use new stop nuts
9 Check actuator for length.
Set the fully extended length to the previously measured length.
10 Perform Bleeding procedure.
32-30-25
Refer to Subject 32-30-10
Nose Gear Gas Pressurized Springs Removal/Installation Detail Steps/Work Items
DANGER
Key Items
Landing gear extends and retracts under high pressure. Operation of the landing gear can cause death or injuries in its working area! Before beginning any work in the landing gear working area, pull the electric circuit breaker located on the left side panel and marked GEAR-CTRL. In case of intentional gear operation by switch or circuit breaker handling make sure, that neither a person nor any object is located in the upper landing gear doors travel area.
1 Lift the aircraft on jacks
Chapter 07-10-00
Preload of the gas pressurized spring damages limbs! WARNING 2 Remove cotter pin, washer and castle nut from the connection between drag brace and trunnion.
Counteract spring forces at lower drag brace.
3 Remove the bolt (AN 6) from the drag brace sheathing at trunnion.
Slowly move down drag brace and thus release gas spring.
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Detail Steps/Work Items
Key Items
4 Remove the cotter pin and the outside washer from the clevis pin on the rod end of the gas pressurized springs. 5 Remove the cotter pin, washer and castle nut on the cylinder side of the gas pressurized springs. 6 Remove the bolt of the gas pressurized springs. 7 Remove the gas pressurized springs. 8 Install in reverse sequence of removal
Test Procedure Detail Steps/Work Items 1 Lift the aircraft on jacks NOTE
Key Items Chapter 07-10-00
Landing gear must remain extended for testing.
Landing gear extends and retracts under high pressure. Operation of the DANGER landing gear can cause death or injuries in its working area! Make sure, that neither a person nor any object is located in the landing gear travel area. 2 Turn BATT switch OFF. Ensure external power is not connected. 3 Pull circuit breaker GEAR-CTRL. 4 Attach a strap connecting both main gear legs. 5 Attach a strap on the nose-wheel axis. 6 Connect the nose-wheel strap with the main gear strap using a tensiometer.
Tensiometer: 100- 120 N, (1 N resolution and accuracy)
7 Pull the nose gear back while manually unlocking the drag brace. Set the nose gear at 20 degrees retracted.
With the ratchet of the strap (242 mm nose gear axle travel; the upper part of the drag brace should be horizontal)
8 Pull the nose gear back by hand another 100mm and release slowly to the 20 degree position. 9 Read the strap tension; depending on the temperature, the tension should be at least as depicted in the table below.
Refer to Minimum Tension Forces table
10 If tensiometer reads lower than applicable chart value: a With actuators and springs disconnected, Page 48
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Detail Steps/Work Items check trunnion bearing and drag brace bearings for excessive friction.
Key Items
b Check for freedom of excessive friction or jamming after connecting the locking strut to the nose gear leg. c Replace both gas-pressurized springs if lack of extension force is not caused by friction. 11 Release nose gear, ensure nose gear is locked, remove straps and put aircraft back to normal.
Minimum Tension Forces
32-30-30
Temperature [°C]
Tension [N]
Temperature [°F]
Tension [lbs]
0
105
32
24
10
108
50
24
20
113
68
25
30
116
86
26
40
120
104
27
Hydraulic Lines Description The hydraulic devices are connected by aluminum tubes and PTFE hoses. All actuators are generally connected by flexible PTFE hoses: • The main gear actuators and the nose gear actuators are connected by PTFE hoses size 04. • The upper and lower door actuators of the main gear are connected by PTFE hoses size 03. The supply systems, the hydraulic power pack and the hydraulic control unit are connected by aluminum tubes and PTFE hoses: • The connection from the hydraulic control unit to the respective main gear actuator, up to the tee type or cross type fitting on the keel beam, is composed of aluminum tube size 04. • The connection from the hydraulic control unit to the upper door actuators of the main gear, up to the tee type fitting between the keel beams, is composed of aluminum tube size 03. • The connection from the hydraulic control unit to the nose gear actuators, up to the elbow fitting on the keel beam, is composed of PTFE hose size 04. From
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the elbow fitting to the tee type fitting in the nose gear compartment the connection is composed of aluminum tube size 04. • The connection from the hydraulic control unit to the lower door actuator of the main gear is composed of PTFE hose size 03. • The connection from the hydraulic control unit to the hydraulic power pack is composed of PTFE hoses size 04. The hydraulic system is separated in three circuits to actuate the respective devices: 1 Extension/retraction of main gear and nose gear 2 Opening/closing of the lower main gear doors 3 Opening/closing of the upper main gear doors
32-30-40
Torque Link Rod and Track Rods Removal/Installation This procedure applies for all kind of rods used in the landing gear. Detail Steps/Work Items 1 Lift the aircraft on jacks
DANGER
CAUTION
Key Items Chapter 07-10
Landing gear extends and retracts under high pressure. Operation of the landing gear can cause death or injuries in its working area! Before beginning any work in the landing gear working area, pull the electric circuit breaker located on the left side panel and marked GEAR-CTRL. In case of intentional gear operation by switch or circuit breaker handling make sure, that neither a person nor any object is located in the upper landing gear doors travel area. False reassembled bolted connections can damage the gear struts and doors. Before removal of bolts and nuts, notice their position.
2 Remove the bolts, the stop nuts and the washers connecting the respective rod to the main gear strut assembly. 3 Install in reverse sequence of removal
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Use new stop nuts
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32-30-50
Drive Mechanism Nose Doors Removal/Installation Detail Steps/Work Items
DANGER
Key Items
Landing gear extends and retracts under high pressure. Operation of the landing gear can cause death or injuries in its working area! Before beginning any work in the landing gear working area, pull the electric circuit breaker located on the left side panel and marked GEAR-CTRL. In case of intentional gear operation by switch or circuit breaker handling make sure, that neither a person nor any object is located in the upper landing gear doors travel area.
CAUTION
False reassembled bolted connections can damage the gear struts and doors. Before removal of bolts and nuts, notice their position.
1 Remove the bolts, the stop nuts and the washers from the push pull rods.
Hold the push pull rod
2 Remove the push-pull rods. 3 Remove bolts of telescope guide rod. 4 Remove telescope guide rod. 5 Remove bolt of nose gear door spring. 6 Remove nose gear door spring. 7 Install in reverse sequence of removal.
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32-40-00
WHEELS AND BRAKES Description The nose gear and the main gear struts have single wheels carrying lowpressure tube-type tires. The nose wheel has a 5.00-5, ply. 6 tire with an inner tube. The nose wheel hub has two aluminum alloy halves. Three bolts hold the halves together. The main wheels, being similar constructed as the nose wheel, have 15x6.00-6 tube tires. Each main wheel hub carries a hydraulically actuated single-disk brake on the inside. The toe-brake pedals on the rudder pedals operate the brakes by the hydraulic master cylinder. Hydraulic lines and hoses are routed from each master cylinder to the wheel cylinder on each brake assembly. The brakes can be actuated from either the pilot's or copilot's seat. The parking brake valve system consists of a manually operated control assembly located on the middle console and connected to the parking brake valve. Applying pressure to the brake system by pressing the toe pedals and pulling the parking brake control sets the parking brake. Pushing the parking brake control forward releases the brakes.
Do not set the parking brake when brakes are overheated after heavy CAUTION braking or when outside temperatures are unusually high. Trapped hydraulic fluid may expand with heat and damage the system.
32-40-01
Main Wheels Removal/Installation Detail Steps/Work Items 1 Lift the aircraft on jacks.
DANGER
Key Items Chapter 07-10
Landing gear extends and retracts under high pressure. Operation of the landing gear can cause death or injuries in its working area! Before beginning any work in the landing gear working area, pull the electric circuit breakers located on the left side panel and marked GEAR-CTRL. In case of intentional gear operation by switch or circuit breaker handling, make sure that neither a person nor any object is located in the upper landing gear doors travel area. The inflated tube tenses the wheel rim construction!
WARNING
Before working deflate the tire by the valve completely.
2 Remove the brake without disconnecting the brake hose. Page 52
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Detail Steps/Work Items
Key Items
3 Remove the cotter pins from the hub nut. 4 Remove the hub nut. 5 Remove the rim from the main gear strut. 6 Remove the stop nuts and the washer from the bolts. 7 Remove the bolts from both wheel halves and the brake disk. 8 Remove both wheel halves from the tire. 9 For removing of the cup and cone bearing in both wheel halves perform as described in Cleveland Maintenance Manual. 10 Remove the tube from the tire. 11 Install in reverse sequence of removal.
32-40-02
Use new stop nuts
Nose Wheel Removal/Installation Detail Steps/Work Items 1 Lift the aircraft on jacks.
DANGER
Key Items Chapter 07-10-00
Landing gear extends and retracts under high pressure. Operation of the landing gear can cause death or injuries in its working area! Before beginning any work in the landing gear working area, pull the electric circuit breaker located on the left side panel and marked GEAR-CTRL. In case of intentional gear operation by switch or circuit breaker handling, make sure that neither a person nor any object is located in the upper landing gear doors travel area. The inflated tube tenses the wheel rim construction!
WARNING
Before working deflate the tire by the valve completely.
2 Remove the cotter pin on one side of the through bolt. 3 Remove the castle nut and the washer from the through bolt. 4 Remove the through bolt from the rim nose gear. 5 Remove the spacer sleeves from the rim.
Hold the rim
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Detail Steps/Work Items
Key Items
7 Remove the stop nuts and the washer from the bolts. 8 Remove the bolts and the washer from both wheel halves. 9 Remove both wheel halves from the tire. 10 For removing of the cup and cone bearing in both wheel halves perform as in Cleveland Maintenance Manual described. 11 Remove the tube from the tire. 12 Install in reverse sequence of removal.
32-40-03
Use new stop nuts
Brake Removal/Installation Detail Steps/Work Items 1 Lift the aircraft on jacks.
DANGER
Key Items Chapter 07-10-00
Landing gear extends and retracts under high pressure. Operation of the landing gear can cause death or injuries in its working area! Before beginning any work in the landing gear working area, pull the electric circuit breaker located on the left side panel and marked GEAR-CTRL. In case of intentional gear operation by switch or circuit breaker handling, make sure that neither a person nor material is located in the landing gear working area.
Brake fluid can cause disease! WARNING Do not allow brake fluid to come in contact with your skin. CAUTION
Brake fluid can damage paint and other material! Clean up immediately spilt brake fluid.
2 Disconnect the brake hose from the elbow fitting of the brake.
Catch the brake fluid. Put caps on the opened lines and fittings
3 Install blind plug to the disconnected line to avoid trapped air in the system. 4 Cut off the safety wire on the bolts. 5 Remove the bolts from the brake. 6 Remove the brake from the axle bar.
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Fasten the brake at the main gear strut with a tape to protect the brake hose
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Detail Steps/Work Items
Key Items
7 Remove the cotter pins from the hub nut. 8 Remove the hub nut. 9 Remove the rim from the main gear strut. 10 Remove the stop nuts and the washer from the bolts. 11 Remove the bolts from both wheel halves and the brake disk. 12 Remove both wheel halves from the tire. 13 For removing of the cup and cone bearing in both wheel halves perform as described in Cleveland Maintenance Manual. 14 Remove the tube from the tire. 15 Install in reverse sequence of removal.
Use new stop nuts
16 Bleed the brake line.
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32-50-00
STEERING Description The EXTRA 500 has a controllable nose wheel. The steering arm of the extended nose wheel is linked to the rudder pedals by springs and control cables. The control cables are tightened by additional springs (mounted beneath the shelf) to prevent them from coming-off from the pulley. Nose gear retraction automatically disengages the steering mechanism from the nose wheel. The steering arm aligns the nose wheel for entry into the wheel bay and, during flight, fixes it in the center nose of the guide block. Nose wheel steering is accomplished through the use of the rudder pedals. Pushing on one rudder pedal steers the aircraft to that side. The maximum nose gear turning angle is 300 to either side while taxiing. During standstill the rudder pedals control only the rudder.
Removal/Installation Removal/Installation of the steering control cable is described in Chapter 27 Flight Controls.
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32-60-00
POSITION AND WARNING Description The LANDING GEAR switch is located on the L/H instrument panel and has the positions UP and DN for retracting and extending the landing gear. It is necessary first to pull out the selector switch handle prior to moving it up or down. The switch is fitted with a small wheel for easy identification and assisting in moving the switch in rough air. The downlock information, for each wheel separately, is given by three green lights located near the LANDING GEAR switch. The red GEAR WARN light on the annunciator panel indicates that the landing gear is not completely retracted or extended. The entire electric control processes signals from limit switches, indicating the completion of actions of the respective hydraulic circuits, and from the landing gear switches. In emergency case it can be deactivated by pulling the GEAR-CTRL circuit breaker. The directional valves are spring-loaded and will automatically switch in the GEAR DOWN position once electrical power is lost. As long as the LANDING GEAR switch is in DN-position the gear downlock indication will still be operative, however the prescribed reclosing of the upper main doors will not happen. A warning horn is furnished on the EXTRA 500 in combination with the red GEAR WARN light on the annunciator panel to caution the pilot against landing with the landing gear being retracted. A respective acoustic warning signal is heard on the headphones simultaneously. Firstly, the warning light and horn will be activated in case of the landing gear being still retracted, while engine torque is below 35 % for descent or landing approach and with wing flaps being in 0°- or 15°- position. If landing is not intended pressing the gear warning mute button located on the left side of the power lever will switch off the horn and the warning light. Secondly, if engine torque is below 35 % for normal landing approach and wing flaps are in landing position (30°), the warning light will illuminate and the warning horn will sound independently from the gear warning mute button until the landing gear will be completely extended. The function of the red GEAR WARN light and the aural warning can be tested switching the NIGHT/DAY switch on the left side panel to the TEST position. Separate position switches monitor the landing gear struts and doors: • Extending and retracting of each main gear strut and the nose gear strut • Opened and closed position of the upper and lower main gear doors Generally micro switches are used. During ground operation, a ground safety switch prevents accidental gear retraction by disconnecting the main valve from DC, regardless of LANDING GEAR switch position. It is located on the nose landing gear just above the torque link.
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fwd
Main gear retracted switch
Main gear attachment frame
Main gear extended switch
Undercarriage leg
Torque link rod
Figure 32-9
32-60-01
Main Gear Switches (LH)
Main Gear Extended Switches The main gear extended switches are located on the undercarriage leg of the LH and RH main gear as shown on Figure 32-9.
32-60-02
Main Gear Retracted Switches The main gear retracted switches are located at the main gear attachment frame next to the upper torque link attachment as shown on Figure 32-9. When the left and right gear retracted switches are reached, the upper door valve is powered to close the upper doors. The closing of the upper doors then causes the two upper door closed switches (see below) to power the lower door valve, which closes the lower doors.
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The closed upper doors are held in place not only by hydraulic power, but also by the lower doors overlapping them. Therefore the upper doors need to be closed first.
32-60-03
Upper Main Door Opened Switch The upper door opened switches are operated by the rod of the hydraulic actuator upper door. When the upper main doors are fully opened, the two upper main door opened switches will power the main valve which will retract the main gear strut.
32-60-04
Upper Main Door Closed Switch The upper main door closed switches are operated by the rod of the hydraulic actuator upper door.
32-60-05
Lower Main Door Closed Switch The lower main door closed switch is operated by the actuator lower door, opening circuit when the lower doors are closed completely. After all doors are closed the door closed switches upper/lower door cut off the power from the gear in-transition information. In case of wheel bay doors being opened during flight due to reduced system pressure, the gear intransition information will warn the pilot from abnormal system state by the red gear warning light in the instrument panel. At the same time the hydraulic pump will be activated to reclose the door accordingly.
32-60-06
Ground Safety Switch The function is realized by two switches. They are installed on the nose gear just above the torque link (refer to Figure 32-5).
32-60-07
Nose Gear Extended Switch The nose gear extended switch is mounted to the nose gear drag brace and is operated when the drag brace is in the over-centered position. It controls the green nose gear downlock light in the instrument panel (refer to Figure 32-5).
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32-60-08
Nose Gear Retracted Switch The nose gear retracted switch is located in the front part of the nose gear wheel well (refer to Figure 32-6) and operated by a bracket attached to the trunnion. It is used for the red GEAR WARN light to signal if the nose gear is fully retracted or not.
32-60-09
Operation and Indication The operation and indication assembly has the following components: Indication lights - Gear extended (three greens) LANDING GEAR switch
Annunciator light – GEAR WARN Annunciator light – HYDRAULIC PUMP
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Chapter 33 Lights
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Table of Contents
33-00-00
GENERAL ........................................................................................................ 3 Description.......................................................................................................... 3
33-10-00
FLIGHT COMPARTMENT ........................................................................... 4 Description.......................................................................................................... 4
33-20-00
PASSENGER COMPARTMENT................................................................... 5 Description.......................................................................................................... 5
33-40-00
EXTERIOR ....................................................................................................... 6 Description.......................................................................................................... 6
33-40-01
Wing Tip Navigation/Strobe Lights ................................................................ 6 Removal/Installation........................................................................................... 6
33-40-02
Tail Navigation/Strobe Light........................................................................... 7 Removal/Installation........................................................................................... 7
33-40-03
Strobe Light Power Supply (Wing)................................................................. 7 Removal/Installation........................................................................................... 7
33-40-04
Strobe Light Power Supply (Tail) ................................................................... 8 Removal/Installation........................................................................................... 8
33-40-05
Landing Light ................................................................................................... 9 Removal/Installation........................................................................................... 9
33-40-06
Recognition Light ............................................................................................. 9 Removal/Installation........................................................................................... 9
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33-00-00
GENERAL Description The EXTRA 500 is equipped with lights in the flight compartment for proper instrument and label reading in reduced ambient light conditions. The passenger compartment is also lighted for passenger comfort, but those lights can be switched off by the pilot at any time for safety reasons. External lighting is provided to ‘see and to be seen’.
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33-10-00
FLIGHT COMPARTMENT Description The cockpit is lighted with the following lights: • Instrument lights, including switches backlighting • Lights in the glareshield • Two dome lights in the ceiling • Two map lights in the ceiling • And for emergencies a flash light behind the co-pilot seat The instrument lights, switches backlighting, annunciator lights, lights in the glare shield and keypad/IFD backlighting are all dimmable by their respective potentiometer on the instrument panel. Dimming is activated by the NIGHT/DAY switch in the left side panel. The instrument lights and switches backlighting (INSTR), glareshield lights (GLARE), and the map lights (MAP) have their individual switches on the left side panel. The dome light switch is located adjacent to the dome light.
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33-20-00
PASSENGER COMPARTMENT Description The passenger compartment lighting consists of: • Ambient lighting on the central air-conditioning channel • A reading light for each passenger in the side walls These can be switched on and off by the passenger individually, but the CABIN LIGHT switch in the left side panel has priority to switch all passenger lighting off.
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33-40-00
EXTERIOR Description Exterior lights consist of: • Strobe lights at the wing tips and the fin tip (also refer to Whelen AntiCollision Light Systems Installation and Service Manual, LOAP 43) • Navigation lights at the wing tips • Landing light in the lower RH cowling • Two recognition lights, also used for taxiing, installed in the wing leading edge on both sides. • Ice light (described in Chapter 30-80-01) Each light (-group) has its own switch and circuit breaker in the left side panel (CABIN/CABIN-LT, RECO/RECO-LT NAV/NAV-LT, LDG/LDG-LT). The strobe light power supply for the wing mounted strobes is installed in the wing nose, just right of the forward-middle wing compartment. The tail power supply is installed in the vertical tail tip.
33-40-01
Wing Tip Navigation/Strobe Lights Removal/Installation Detail Steps/Work Items
Key Items
High voltage can cause injuries! WARNING
Let power supply stand for 5-10 minutes after disconnecting from power source to allow power to bleed off capacitors before beginning any work on the strobe light systems. Even after 5-10 minutes, care should be taken when handling components as electrical shock can result.
1 Pull the STROBE-LT circuit breaker.
Let power supply stand for 510 minutes.
2 Also pull the NAV-LT circuit breaker. 3 Remove the Phillips screws from the wing tip glass cover.
Hold the wing tip glass cover
4 Remove the wing tip glass cover 5 Remove the lens retainer mounting Phillips screw and retainer. 6 Remove counter-sunk screws and base assembly from wingtip. 7 Disconnect electrical connectors.
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Detail Steps/Work Items
Key Items
8 Install in reverse sequence of removal
33-40-02
Tail Navigation/Strobe Light Removal/Installation Detail Steps/Work Items
Key Items
High voltage can cause injuries! WARNING
Let power supply stand for 5-10 minutes after disconnecting from power source to allow power to bleed off capacitors before beginning any work on the strobe light systems. Even after 5-10 minutes, care should be taken when handling components as electrical shock can result.
1 Pull the STROBE-LT circuit breaker.
Let power supply stand for 510 minutes.
2 Also pull the NAV-LT circuit breaker. 3 Remove the retainer mask Phillips screws. Remove the unit. 4 Disconnect electrical connector. 5 Install in reverse sequence of removal
33-40-03
Strobe Light Power Supply (Wing) Removal/Installation Detail Steps/Work Items
Key Items
High voltage can cause injuries! WARNING
Let power supply stand for 5-10 minutes after disconnecting from power source to allow power to bleed off capacitors before beginning any work on the strobe light systems. Even after 5-10 minutes, care should be taken when handling components as electrical shock can result.
1 Pull the STROBE-LT circuit breaker.
Let power supply stand for 510 minutes.
2 Remove the wing center fairing.
Refer to Chapter 51-00-01
3 Disconnect the electrical wiring of the power supply 4 Disconnect the ground bonding lead
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Detail Steps/Work Items
Key Items
5 Remove the Phillips screws from the power supply unit 6 Pull out the power supply unit and remove from the attaching plate CAUTION
Reverse polarity of the input power, for just an instant, will permanently damage power supply. This damage is sometimes not immediately apparent, but will cause failure later on. Black lead is negative.
7 Install in reverse sequence of removal
33-40-04
Strobe Light Power Supply (Tail) Removal/Installation Detail Steps/Work Items
Key Items
High voltage can cause injuries! WARNING
Let power supply stand for 5-10 minutes after disconnecting from power source to allow power to bleed off capacitors before beginning any work on the strobe light systems. Even after 5-10 minutes, care should be taken when handling components as electrical shock can result.
1 Pull the STROBE-LT circuit breaker.
Let power supply stand for 510 minutes.
2 Remove fin tip.
Refer to Charter 55-30-01
3 Disconnect the ground bonding lead 4 Remove the Phillips screws from the power supply unit 5 Pull out the power supply unit and remove from the attaching plate CAUTION
Reverse polarity of the input power, for just an instant, will permanently damage power supply. This damage is sometimes not immediately apparent, but will cause failure later on. Black lead is negative.
6 Install in reverse sequence of removal
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33-40-05
Landing Light Removal/Installation Detail Steps/Work Items
Key Items
1 Pull LDG-LT circuit breaker. 2 Remove upper cowlings.
Refer to Chapter 71-10-01/02
3 Remove external landing light glass.
8 screws
4 Remove landing light cover.
2 screws
5 Disconnect electrical connection. 6 Remove lamp with igniter.
Retainer clip
7 Remove reflector with frame.
2 screws
8 Install in reverse sequence of removal
33-40-06
Recognition Light Removal/Installation Detail Steps/Work Items
Key Items
1 Pull RECO-LT circuit breaker. 2 Remove respective wing nose access panel.
Refer to Chapter 51-00-01
3 Remove baffle with recognition light.
3 screws
4 Disconnect electrical connector. 5 Remove recognition light from baffle.
2 screws
6 Install in reverse sequence of removal
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Chapter 34 Navigation
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Table of Contents
34-00-00
Figure 34-1
GENERAL ........................................................................................................ 5 Pitot/Static Pressure Systems.............................................................................. 5 Avionics.............................................................................................................. 5 Pitot Static System Schematic............................................................................. 6
34-10-00
FLIGHT ENVIRONMENTAL DATA ........................................................... 7
34-10-01
Altimeter (2” type)............................................................................................ 7 Troubleshooting.................................................................................................. 7 Removal/Installation........................................................................................... 8
34-10-02
Airspeed Indicator (2” type)............................................................................ 8 Troubleshooting.................................................................................................. 8 Removal/Installation........................................................................................... 8
34-10-11
Pitot Head.......................................................................................................... 9 Removal/Installation (LH/RH Side) ................................................................... 9 Pitot Head......................................................................................................... 10
Figure 34-2 34-10-12
Figure 34-3
Static Port ........................................................................................................ 10 Removal (LH/RH Side) .................................................................................... 10 Installation (LH/RH Side) ................................................................................ 11 Static Port ......................................................................................................... 11
34-10-13
Stall Warning Sensor...................................................................................... 12 Removal/Installation (LH/RH Side) ................................................................. 12
34-20-00
ATTITUDE AND DIRECTION.................................................................... 13
34-20-01
Attitude Indicator ........................................................................................... 13 Removal/Installation......................................................................................... 13
34-20-02
Magnetic Compass.......................................................................................... 13 Removal/Installation......................................................................................... 13 Bulb Replacement............................................................................................. 13
34-40-00
INDEPENDENT POSITIONING DETERMINING .................................. 14 Description........................................................................................................ 14 Troubleshooting................................................................................................ 14
34-40-01
TAS Processor................................................................................................. 14 Removal/Installation......................................................................................... 14
34-40-02
TWX Processor ............................................................................................... 15 Removal/Installation......................................................................................... 15
34-50-00
DEPENDENT POSITIONING DETERMINING ....................................... 16 Description........................................................................................................ 16
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34-50-01
Transponder ....................................................................................................16 Removal/Installation .........................................................................................16
34-50-02
DME Processor................................................................................................16 Removal/Installation .........................................................................................16
34-50-03
DME Indicator ................................................................................................17 Removal/Installation .........................................................................................17
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34-00-00
GENERAL Pitot/Static Pressure Systems Providing pitot and static pressure for the pilot's and copilot's instruments two independent systems are installed (refer to Figure 34-1). Each system consists of a heated pitot head located at about 3/4 of the wing span, the tubing including a drain and the respective instruments. The heated static ports are located on both sides of the rear fuselage. The two toggle-type drains are located at the fuselage underside, between the keel beams. They are accessible by the RH side, round cover plate between nose gear and main gear doors. When the pitot heat switches are placed in the ON position, the heating elements in the pitot heads and the static port for the autopilot are electrically energized to maintain proper operation of the systems during icing conditions. Normally, the heating elements can only be activated when airborne. On ground the system is deactivated by the squat switch, which detects aircraft being on ground. For testing on ground, pitot heat switches provide a TEST position (momentary ON).
CAUTION
In testing mode, do not operate pitot & static heat longer than 10 seconds to prevent overheating of the heating elements.
CAUTION
Care should be taken when an operational check of the heated pitot heads is being performed on the ground. The units become very hot.
Avionics The EXTRA 500 is equipped with Avidyne Entegra equipment. Please refer to Chapter 31. This chapter will deal with other avionics apart from Back-up altimeter and airspeed indicator: • Back-up attitude indicator • Magnetic compass • XPDR • DME (option) • TAS (option) • TWX (option) IMPORTANT
Avionics service and repair work requires special skills, tools and test equipment. In case of instrument failure or malfunction contact manufacturer or authorized service center.
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Page 5
LH
Figure 34-1
Page 6
34
red
white
Pitot LH
LH IFD ADAHRS
white
red
red
white
white
red
open
Back-up airspeed indicator
red
Cabin altimeter
red
Back-up altimeter
red
green
Static port LH red
RH
green
green
red
green
Static port RH
Pitot RH blue
RH IFD ADAHRS
blue
blue
green
Static port vertical tail
blue
blue
Transducer P550-5070
Autopilot
Maintenance Manual EXTRA 500
Pitot Static System Schematic
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34-10-00 NOTE
34-10-01
FLIGHT ENVIRONMENTAL DATA When any connections in the static system are opened for checking, a static leak check per FAR 23.1325 must be performed.
Altimeter (2” type) Troubleshooting
Complaint
Possible Cause
Remedy
Excessive scale error
Improper calibration adjustment
Contact manufacturer
Excessive pointer oscillation
Defective mechanism
Contact manufacturer
High or low reading
Improper venting
Eliminate leak in static pressure system
Setting knob is hard to turn
Wrong lubrication or lack of lubrication
Contact manufacturer
Inner reference marker fails to move when setting knob is rotated
Out of engagement
Contact manufacturer
Setting knob set screw loose or missing
Not tight when altimeter was reset
Tighten instrument screw, if loose. Contact manufacturer, if screw is missing
Cracked or loose cover glass
Case gasket hardened
Contact manufacturer
Dull or discolored markings
Age
Barometric scale and reference Slippage of mating parts markers out of synchronism
Contact manufacturer
Barometric scale and reference Drift in mechanism markers out of synchronism with pointers
Contact manufacturer
Altimeter sticks at altitude or does not change with change of altitude
Water or restriction in static line
Remove static lines from all instruments; blow line clear from cockpit to static ports
Altimeter changes reading as aircraft is banked
Water in static line
Remove static lines from all instruments; blow lines clear from cockpit to static ports
Altimeter requires resetting frequently
Temperature compensator inoperative
Contact manufacturer
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Removal/Installation Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. 2 Remove RH and LH IFD
Refer to Chapter 31
3 Disconnect (red) static pressure hose 4 Remove altimeter
3 screws
5 Disconnect electrical connector 6 Install in reverse sequence of removal 7 Perform Pitot/static check
34-10-02
According to FAR 43, Appendix E and AC 43.131B CHG1 (or later) § 12-59
Airspeed Indicator (2” type) Troubleshooting
Complaint
Possible Cause
Remedy
Pointer does not indicate properly
Leak in instrument case, in Pitot or static lines
Check for leak and seal
Pointer of instrument oscillates
Defective mechanism
Replace instrument
Instrument reads high
Pointer not on zero
Replace instrument
Leaking static system
Find leak and correct
Pointer not on zero
Replace instrument
Leaking Pitot system
Find leak and correct
Water in pitot line
Remove line from all instruments and blow out line from cockpit to Pitot head
Instrument reads low Airspeed changes as aircraft is banked
Removal/Installation Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. 2 Remove RH and LH IFD
Refer to Chapter 31
3 Disconnect (red) static pressure hose and (white) Pitot hoses 4 Remove airspeed indicator.
4 screws
5 Disconnect electrical connector. Page 8
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Detail Steps/Work Items
Key Items
6 Install in reverse sequence of removal. 7 Perform Pitot/static check
34-10-11
According to FAR 43, Appendix E and AC 43.131B CHG1 (or later) § 12-59
Pitot Head Removal/Installation (LH/RH Side) Refer to Figure 34-2. Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. 2 Remove outer wing access panel.
Refer to Chapter 51-00-01
3 Disconnect plug from sensor heat element. 4 Disconnect Pitot pressure line nut. 5 Remove 4 Phillips screws from Pitot tube shaft at bracket. 6 Remove Pitot tube from bracket downwards. 7 Install in reverse sequence of removal.
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Pitot line
Nut
Bracket
Attachment screws
Pitot head Figure 34-2
34-10-12
Pitot Head
Static Port Removal (LH/RH Side) Refer to Figure 34-3. Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. 2 Remove tail cone access panel
Refer to Chapter 51-00-01
3 Disconnect 2 static pressure hoses from static port at LH/RH fuselage 4 Cut tie-wrap and wiring to heat element on both sides of splice. Page 10
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Detail Steps/Work Items
Key Items
5 Remove static port fastening nut and strain relief. 6 Remove static port
Sensor is fitted with silicon
Installation (LH/RH Side) Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. 2 Install static port.
Apply silicon between outside part of sensor and fuselage
3 Install strain relief and static port fastening nut
Secure sensor fastening nut with Loctite 243.
4 Re-establish splice at wiring to heat element. 5 Fasten wiring with tie-wrap. 6 Connect 2 static pressure hoses to static port
red upper, green lower
7 Install tail cone access panel
Refer to Chapter 51-00-01
Wiring
Tie wrap
Strain relief Static hoses
Nut Static port Figure 34-3
Page Date: 30. March 2012
Static Port
34
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Maintenance Manual EXTRA 500
34-10-13
Stall Warning Sensor Removal/Installation (LH/RH Side) Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. 2 Remove LH wing nose access panel.
Refer to Chapter 51-00-01
3 Disconnect electrical connector from sensor. 4 Remove 4 bolts and nuts at sensor mounting plate. 5 Remove sensor. 6 Install in reverse sequence of removal
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34-20-00
ATTITUDE AND DIRECTION
34-20-01
Attitude Indicator Removal/Installation Detail Steps/Work Items 1 Remove RH and LH IFD
Key Items Refer to Chapter 31
2 Disconnect electrical connector. 3 Remove attitude indicator.
4 screws
4 Install in reverse sequence of removal.
34-20-02
Magnetic Compass Removal/Installation Detail Steps/Work Items 1 Remove compass
Key Items 2 screws
2 Disconnect electrical connector. 3 Install in reverse sequence of removal. 4 Make compass swing, if new unit is installed. 5 Replace deviation card if necessary.
Bulb Replacement Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. 2 Lift cap on upper front surface. 3 Remove bulb. 4 Insert new bulb.
24 VDC
5 Refit cap.
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34
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Maintenance Manual EXTRA 500
34-40-00
INDEPENDENT POSITIONING DETERMINING Description The EXTRA 500 can be equipped with the following optional equipment: • TAS (Traffic Avoidance System) • TWX (Lightning detection system)
Troubleshooting Complaint
Possible Cause
Remedy
TAS shows aircraft on the wrong side (left or right)
Antenna cables of upper antenna swapped
Swap antenna cables
TAS shows aircraft on the wrong side (front or aft)
Antenna cables of lower antenna swapped
Swap antenna cables
34-40-01
TAS Processor The TAS processor is installed on the back of the aft baggage compartment paneling.
Removal/Installation Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. 2 Remove aft baggage compartment paneling.
Refer to Chapter 25-00-01
3 Disconnect electrical connectors and antenna cables from TAS processor. 4 Unscrew the locking screws of the TAS processor mounting tray. 5 Slide the TAS processor out of the tray. 6 Install in reverse sequence of removal. CAUTION
Page 14
34
Observe the following hint
Make sure all antenna cables are connected to both antennas and TAS processor before applying power to the processor. Failing to do so may damage the processor.
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Maintenance Manual EXTRA 500
34-40-02
TWX Processor The TWX processor is installed beneath the armrest of the second seat row, LH seat.
Removal/Installation Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. 2 Remove LH front passenger seat.
Refer to Chapter 25-20-11
3 Remove LH side armrest paneling.
Refer to Chapter 25-20-21
4 Disconnect electrical connectors and antenna cable from TWX processor 5 Remove TWX processor from tray 6 Install in reverse sequence of removal.
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34
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Maintenance Manual EXTRA 500
34-50-00
DEPENDENT POSITIONING DETERMINING Description The EXTRA 500 has the following equipment installed: • Transponder In addition the following optional equipment may be installed: • DME (Distance Measuring Equipment)
34-50-01
Transponder The transponder is installed in the tail cone compartment.
Removal/Installation Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. 2 Remove the tailcone access panel
Refer to Chapter 51-00-01
3 Disconnect electrical connectors and antenna cables 4 Remove transponder from its tray
2 screws
5 Install in reverse sequence of removal.
34-50-02
DME Processor The DME processor is installed in the tail cone compartment
Removal/Installation Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. 2 Remove the tailcone access panel
Refer to Chapter 51-00-01
3 Disconnect electrical connectors and antenna cables 4 Remove DME processor from its tray
2 screws
5 Install in reverse sequence of removal.
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34-50-03
DME Indicator The DME indicator is installed on the instrument panel on the left lower edge.
Removal/Installation Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. 2 Disconnect electrical connector
Accessible from the bottom
3 Remove DME indicator
4 screws
4 Install in reverse sequence of removal.
Page Date: 30. March 2012
34
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Page 18
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Maintenance Manual EXTRA 500
Chapter 51 Standard Practices and Structures General
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Page 1
Maintenance Manual EXTRA 500
Table of Contents
51-00-00
GENERAL ........................................................................................................ 5
51-00-01 Access Panel Identification .............................................................................. 5 Figure 51-1, Sheet 1 Access Panel Identification ................................................................................ 6 Figure 51-1, Sheet 2 Access Panel Identification ................................................................................ 7 Figure 51-1, Sheet 3 Access Panel Identification ................................................................................ 8 51-10-00
INVESTIGATION............................................................................................ 9
51-10-01
Damage Classification ...................................................................................... 9
51-10-02
Repair Criteria and Limits ............................................................................ 10
51-30-00
MATERIALS .................................................................................................. 11
51-30-01
Composite Parts .............................................................................................. 11 Epoxy System ................................................................................................... 11 Glass Fibre Fabrics ........................................................................................... 11 Carbon Fibre Fabrics ........................................................................................ 12 Carbon Fibre Rovings....................................................................................... 12 UD Carbon Fibre Tape ..................................................................................... 12 Core Material .................................................................................................... 12 Filler Material for Resin ................................................................................... 14 Coating.............................................................................................................. 14
51-30-02
Metal Components.......................................................................................... 15 Round Seamless Steel Tubing .......................................................................... 15 Steel Sheet Metal .............................................................................................. 16 Coating.............................................................................................................. 16
51-30-03
Aluminium Components ................................................................................ 17 Aluminium Sheet Metal.................................................................................... 17 Tubings ............................................................................................................. 17 Coating.............................................................................................................. 18
51-30-04
Titanium Components.................................................................................... 18 Titanium Sheet Metal ....................................................................................... 18
51-30-05
Various Components ...................................................................................... 19 Sealant .............................................................................................................. 19 Silicon Adhesive............................................................................................... 19 Adhesive ........................................................................................................... 20 Corrosion Preventive Compound ..................................................................... 20 Sealing Material for Lightning Protection........................................................ 20 Release Agent ................................................................................................... 20
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51-60-00
CONTROL SURFACE BALANCING .........................................................21
51-60-01 Figure 51-2 Figure 51-3 Figure 51-4
Weighing and Determination of Control Surface Moments ......................21 Balancing Mandrels ..........................................................................................21 Procedure...........................................................................................................22 Control Surface Balancing................................................................................23 Permissible Weights and Moments ...................................................................24
51-70-00
REPAIRS .........................................................................................................25
51-70-01
Repair of Reinforced Glass and Carbon Fibre Components ......................25
51-70-02 Figure 51-5 Figure 51-6 Figure 51-7
Repair of Sandwich Material .........................................................................27 Minor Surface Damage .....................................................................................27 Curing Cycle Resin L 20 / SL............................................................................28 Damage of Complete Sandwich ........................................................................29
51-70-03
Repair of Laminates........................................................................................31 Minor Damage ..................................................................................................31 Repair of Minor Damage ..................................................................................32 Large Damage ...................................................................................................32
Figure 51-8 51-70-04
Repair of Spars and Elements of the Pressure Cabin..................................34 Structural elements of the pressure cabin..........................................................34 Spars of Wing and Empennage .........................................................................34
51-70-05
Structural Repair of Steel Components ........................................................34
51-70-06
Painting of Composite Parts...........................................................................35
51-70-07
Aluminium and Steel Components Refinishing ...........................................36 Degreasing.........................................................................................................36 Paint Removal ...................................................................................................36 Repainting .........................................................................................................37
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51-00-00
GENERAL
51-00-01
Access Panel Identification Refer to Figure 1 for identification of access panels. Generally all access panels (and fairings) are screwed on the respective structure or surface. However for the access to the oil filler and the external power receptacle hatches are used featuring a hinge and a latching mechanism. The LH wing nose access panel carries the stall sensor. So refer to Chapter 3410-13 for removal. To get access to the passenger compartment floor access panels the carpet has to be removed. To get access to the central horizontal stabilizer access panel the fin tip has to be removed (refer to Chapter 55-30-01).
Page Date: 30. March 2012
51
Page 5
Page 6
Tail fairing
Side Views
Figure 51-1, Sheet 1
51 RH front fuselage access panel Fuel filter access panel
External power hatch
Tailcone access panel
Door hinge access panel
Fuel sump access panel (RH)
LH front fuselage access panel
Fuel sump access panel (LH)
Landing light access panel
Oil filler hatch
Fin access panel
Tail fairing
Maintenance Manual EXTRA 500
Access Panel Identification
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Maintenance Manual EXTRA 500
Bottom View
Fuel filter access panel
RH front fuselage access panel
Forward keel beam access panel
LH front fuselage access panel
Aft keel beam access panel
RH gap fairing
LH gap fairing
Pitch trim access panel
Figure 51-1, Sheet 2
Access Panel Identification
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Top View
Oil filler hatch
Wing nose access panel
Inner and outer fuel main compartment access panels
External power hatch Avionic bay access panel
Wing center fairing
Inner and outer fuel auxiliary compartment access panels
Right wing symmetrically
Inspection doors Outer wing access panel Passenger compartment floor access panels (LH, middle, RH)
Central horizontal stabilizer access panel Figure 51-1, Sheet 3 Page 8
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Access Panel Identification Page Date: 30. March 2012
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51-10-00
INVESTIGATION
51-10-01
Damage Classification
All damage of composite parts must first be classified by qualified WARNING personnel. In case of doubt regarding the classification of damage, if a clear definition of the extent of damage is not possible, or if a repair of damage despite the consideration of the valid manufacturer documentation is doubtful, contact EXTRA. Only the Damages Classes 2, 3 and 4 may be repaired by qualified WARNING personnel. In case of Damage Class 1 EXTRA has to be contacted. Following to the Luftfahrt Bundesamt (Federal German Aviation Authority) four damage classes are defined: Damage Class 1: Large scale destruction requiring a partial reconstruction of the component or large scale repair. Each destruction over 300 mm diameter and each damage of a spar is a large scale destruction. EXTRA has to be contacted prior to repair. Damage Class 2: Damage to primary structures and to secondary structures to the following extent: Holes and fractures extending through a sandwich component and a scale under 300 mm diameter. Damage Class 3: Damage to primary structures and to secondary structures to the following extent: Small holes or fractures in the external covering layers, if not accompanied by damage to supporting layers or internal covering layers. Damage Class 4: Erosion, scratches or nicks not accompanied by fractures or break-ups. Damage to fairings belong to this class.
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51-10-02
Repair Criteria and Limits
IMPORTANT
Any damage of composite parts must first be classified prior to repair. Refer to Subject 51-10-01 Damage Classification.
IMPORTANT
Only the Damages Classes 2, 3 and 4 may be repaired by qualified personnel. In case of Damage Class 1 EXTRA has to be contacted. The decision whether to repair or replace a major unit of structure will be influenced by factors such as time and labor available, and by comparison of labor costs with the price of replacement assemblies. Past experiences indicate that replacement, in many cases, is less expensive than major repair. Certainly, when the aircraft must be restored to its airworthy condition within limited time, replacement is preferable.
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51-30-00
MATERIALS This Section describes metallic and non-metallic materials used in repairing the EXTRA 500 and gives the sources of supply (manufacturers and suppliers).
IMPORTANT
Only approved materials have to be used for repair. Materials not listed here are generally used for parts, which are not intended for repair. Contact EXTRA for advice.
51-30-01
Composite Parts Epoxy System Manufacturer: Momentive Varzinerstr. 49, D-47138 Duisburg, Germany Supplier:
Brenntag GmbH Stinnes Platz 1, D-45472 Mühlheim, Germany
Resin:
Epikote L20 / Rütapox L20
Hardener:
Epikure Curing Agent 960 / Rütapox SL
Ratio of comp.: 100 parts L20 / 34 parts SL (weight ratio)
Glass Fibre Fabrics Manufacturer: P-D Interglas Technologie GmbH Benzstraße 14, D-89155 Erbach, Germany
Page Date: 30. March 2012
Style Interglas
WLB-No.* LN 9169
US-style
Weave Patterns
Weight g/m2
90070
8.4505.60
1610
plain
80
92110
8.4548.60
none
2/2 twill
163
92125
8.4551.60
none
2/2 twill
280
92140
8.4554.60
none
2/2 twill
390
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Carbon Fibre Fabrics Manufacturer: C. Cramer GmbH & Co. KG Division ECC Weberstr. 21, D-48619 Heek-Nienborg, Germany Style ECC/CCC
WLB-No.* DIN 65147
US-style
Weave Patterns
Weight g/m2
447
8.3507.80
None
plain
160
452
8.3520.80
None
2/2 twill
204
459
-
None
2/2 twill
220
*WLB: Werkstoff Leistungsblatt, according to German standard DIN-WL
Carbon Fibre Rovings Manufacturer: Toho Tenax Europe GmbH Kasinostr. 19-21 D-42103 Wuppertal Type:
TENAX HTS5631 1600tex f24000 t 0 (WLB: 8.3614.1)
UD Carbon Fibre Tape Manufacturer: J.H.vom Baur Sohn GmbH & Co. KG Marktstraße 34 D-42396 Wuppertal, Germany Type:
CF UD tape 30 mm & 50 mm according material spec. Doc. N° EA-05803.1 & .2
Core Material PVC (Polyvinylchloride) Foam Manufacturer: Airex AG Industrie Nord 26 CH-5643 Sins, Switzerland
Page 12
51
Supplier:
Gaugler & Lutz OHG Habsburger Str. 12 D-73432 Aalen-Ebnat, Germany
Type:
Airex C 71.55
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Maintenance Manual EXTRA 500
PMI (Polymethacrylimide) Foam Manufacturer: Evonik Röhm GmbH Kirschenallee D-64293 Darmstadt, Germany Supplier:
Gaugler & Lutz OHG Habsburger Str. 12 D-73432 Aalen-Ebnat, Germany
Type:
Rohacell 51 A (WLB*: 5.1460.1)
*WLB: Werkstoff Leistungsblatt, according to German standard DIN-WL Honeycomb Manufacturer: Euro Composites S.A. B.P.95, Zone Industrielle L-6401 Echternach / Luxembourg or : Manufacturer: Schütz GmbH & Co. KGaA: Schützstr. 21 D-56242 Selters, Germany Honeycomb
Density Tolerance
Manufacturer
Specification
Cormaster C1-4,8-29 OX
+15%/-0%
Schütz
EA-03512.02
ECA-R-4.8-29
+13%/-0% Euro Composites
EA-03512.02
ECA-I-R-4.8-29
+16%/-0% Euro Composites
EA-03512.02
Cormaster C1-4,8-48 OX
±10%
Schütz
WLB5.3653.1*
ECA-R-4.8-48
±10%
Euro Composites
WLB5.3653.1*
ECA-I-R-4.8-48
±16%
Euro Composites
ECSS 704
Cormaster C1-3.2-48
±10%
Schütz
WLB5.3650.4*
ECA-I-3.2-48
±16%
Euro Composites
ECSS 704
*WLB: Werkstoff Leistungsblatt, according to German standard DIN-WL Plywood Manufacturer: For example: Mahogany Oy, Finnland Supplier:
For example: La Boisserolle 71960 Prissé-Lès-Mâcon, France
Type:
Aircraft grade Birch produced to German Lloyd GL-I & -II, t = 2 mm, 6 mm, 8 mm (WLB*: 6.1013.0) Okoume t = 4 mm, t = 6 mm**
*WLB: Werkstoff Leistungsblatt, according to German standard DIN-WL **Aircraft Grade acc. to French Standard
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Filler Material for Resin Manufacturer: STW Schwarzwälder Textilwerke Heinrich Kaukmann GmbH Aue 3 D-77773 Schenkenzell, Germany Supplier:
same
Type:
Cotton flakes FB1/035
Manufacturer: Malayan Adhesives & Chemicals Sdn Bhd No. 9 Jalan Utas 15/7, 40200 Shah Alam Selangor Darul Ehsan, Malaysia Supplier:
Brenntag GmbH Stinnes-Platz 1 D-45472 Mühlheim, Germany
Type:
Microballoons BJO - 0930
Coating Manufacturer: BASF Coatings GmbH Glasuritstr. 1, D-48165 Münster/Hiltrup, Germany Supplier:
Wessels & Müller AG Pagenstecherstraße 121, D-49090 Osnabrück, Germany
Type:
22
Glasurit HS-2K-Decklack
929-91/93/94 Glasurit HS Decklackhärter 352-50/91/216 Glasurit Einstellzusatz 55
Glasurit Zweischicht-Decklack Metallic/Uni/Perleffekt
352-50/91/216 Glasurit Einstellzusatz 90
Glasurit Zweischicht-Decklack Metallic/Uni/Perleffekt
93-E3
Glasurit Einstellzusatz
923-155
Glasurit MS-Klarlack
929-91/93/94 Glasurit HS Decklackhärter 352-50/91/216 Glasurit Einstellzusatz 285-100 VOC Glasurit Rapidfüller VOC, weiß
Page 14
51
929-55/56
Glasurit HS Füllerhärter
352-91
Glasurit Einstellzusatz
1006-26
Glasurit UP Spritzfüller, grau
948-22
Glasurit Härter
839-53
Glasurit UP-Schnellspachtel Page Date: 30. March 2012
Maintenance Manual EXTRA 500
948-36
Glasurit Härterpaste
293-10
Glasurit Einstellzusatz
934-0
Glasurit 1K-Kunststoffhaftprimer
Manufacturer: MOTIP DUPLI GmbH Kurt-Vogelsang-Straße 6 D-74855 Haßmersheim, Germany Supplier:
Wessels & Müller AG Pagenstecherstraße 121, D-49090 Osnabrück, Germany
Type:
presto Leichtspachtel prestolith easy
Manufacturer: PPG Aerospace PRC-DeSoto
51-30-02
Supplier:
Röder Präzision GmbH Am Flugplatz D-63329 Egelsbach, Germany
Type:
Fire protective coating N56582/T508 Clearcoat 4232-0303 Activator N39/1327 Thinner N39/3091
Metal Components Round Seamless Steel Tubing Manufacturer: MHP Mannesmann Hoesch Präzisrohr GmbH Postfach 1713, D-59061 Hamm, Germany Supplier:
Heggemann Autosport GmbH Zeppelinring 1 - 6, D-33142 Büren, Germany
Type:
WLB* 1.7734.4 various diameters and wall dimensions (for example: engine mount)
*WLB: Werkstoff Leistungsblatt, according to German standard DIN-WL Manufacturer: Pacific Tube Company 5710 Smithway Street Los Angeles, California 90040, USA Supplier:
Page Date: 30. March 2012
Wicks Aircraft Supply, Co. 410 Pine Street Highland, Illinois 62249, USA
51
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Type:
AISI 4130 N (MIL-T-6736) various diameters and wall dimensions (for example: support structure inside cabin)
Steel Sheet Metal Manufacturer: BÖHLER Edelstahl GmbH München, Germany Supplier:
BÖHLER Edelstahl GmbH Hansa Allee 321 D-40549 Düsseldorf, Germany
Type:
according to WLB* 1.7734.4 various dimensions
*WLB: Werkstoff Leistungsblatt, according to German standard DIN-WL Manufacturer: Cold Metal Products, Inc. 2301 So. Holt Road Indianapolis, In. 46241, USA Supplier:
Wicks Aircraft Supply, Co. 410 Pine Street Highland, Illinois 62249, USA
Type:
AISI 4130 N (MIL-S-18729) various dimensions
Coating Manufacturer: BASF Coatings GmbH Glasuritstr. 1, D-48165 Münster/Hiltrup, Germany Supplier:
Wessels & Müller AG Pagenstecherstraße 121, D-49090 Osnabrück, Germany
Type:
801-72 VOC
Glasurit Grundfüller EP VOC, grau
965-60
Glasurit Härter EP
352-91/216
Glasurit Einstellzusatz
22
Glasurit HS-2K-Decklack
929-91/93/94 Glasurit HS Decklackhärter 352-50/91/216 Glasurit Einstellzusatz
Page 16
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51-30-03
Aluminium Components Aluminium Sheet Metal Manufacturer: Kaiser Aluminium & Chem. Corp. Spokane, Washington Supplier:
Westdeutscher Metallhandel Friedrich W. Hermann GmbH Manderscheidtstr. 76-78, Postfach 104245 45141 Essen
Type:
WLB* 3.1364 T3 (2024 T3) various dimensions WLB* 3.3214 T6 (6061 T6) various dimensions
*WLB: Werkstoff Leistungsblatt, according to German standard DIN-WL Manufacturer: various Supplier:
Westdeutscher Metallhandel Friedrich W. Hermann GmbH Manderscheidtstr. 76-78, Postfach 104245 45141 Essen
Type:
AlMg3hh (EN-AW-5754 H24) various dimensions (also band)
Tubings Manufacturer: Aluminium AG CH-5737 Menziken, Swiss Supplier:
Westdeutscher Metallhandel Friedrich W. Hermann GmbH Manderscheidtstr. 76-78, Postfach 104245 45141 Essen
Type:
WLB* 3.1354 T3 various dimensions WLB* 3.3214 T4 various dimensions
*WLB: Werkstoff Leistungsblatt, according to German standard DIN-WL Manufacturer: various Supplier:
Wicks Aircraft Supply, Co. 410 Pine Street Highland, Illinois 62249, USA
Type:
5052-0 various dimensions
Page Date: 30. March 2012
51
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Maintenance Manual EXTRA 500
2024 T3 various dimensions Manufacturer: various Supplier:
Westdeutscher Metallhandel Friedrich W. Hermann GmbH Manderscheidtstr. 76-78, Postfach 104245 45141 Essen
Type:
AlMgSi 0.5 F22 (EN-AW 6060 T6) various dimensions
Coating Manufacturer: BASF Coatings GmbH Glasuritstr. 1, D-48165 Münster/Hiltrup, Germany Supplier:
Wessels & Müller AG Pagenstecherstraße 121, D-49090 Osnabrück, Germany
Type:
283-150 VOC Glasurit Grundfüller EP VOC 352-228 Glasurit Zusatzlösung 352-50/91 Glasurit Einstellzusatz 22 Glasurit HS-2K-Decklack 929-91/93/94 Glasurit HS Decklackhärter 352-50/91/216 Glasurit Einstellzusatz
Manufacturer: Parker & Anchem, Ambler, PA 19002 Supplier:
Aircraft Spruce
Chem. coating: for aluminium hardware metal (brackets, pedestals etc.) Type: Alodine No. 1201 (MIL-C-5541) Lacquer:
51-30-04
see above
Titanium Components Titanium Sheet Metal Manufacturer: Timet United Kingdom Supplier:
Tisto Titan und Sonderlegierungen GmbH Dinnendahlstraße 31 40235 Düsseldorf, Germany
Type:
WLB* 3.7034.1 and 3.7024.1 (firewall, nose gear box, lightning protection tank filler caps)
*WLB: Werkstoff Leistungsblatt, according to German standard DIN-WL Page 18
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51-30-05
Various Components Sealant Manufacturer: Le Joint Français Supplier:
Deutsche Hutchinson GmbH Rudolf-Diesel-Str. 20B 65760 Eschborn, Germany
Type:
PR 148 AF PR 1750 S PR 1750 A2 PR 1750 B2 PR 1829 B PR 812
Activator (for metal surfaces) Integral tank sealant sprayable Integral tank sealant, bolt sealing Sealant (tank, pressure cabin, fittings etc.) Window sealant Firewall sealant
Manufacturer: FLEET SUPPLIES, INC 215 Mahoning Avenue Cleveland, OH 44113, USA Supplier:
Aircraft Spruce and Speciality Co.
Type:
FUELUBE
Silicon Adhesive Manufacturer: Herrman Otto GmbH Krankenhausstr. 14 D-83413 Fridolfing, Germany Supplier:
same
Type:
Ottoseal S72
Manufacturer: Dow Corning GmbH Postfach 13 03 32 65201 Wiesbaden,Germany Supplier:
Brammer GmbH Daimlerstraße 51 76185 Karlsruhe, Germany
Type:
Dow Corning 732 white or clear (MIL-A-46106)
Manufacturer: Wacker Chemie AG Hannes-Seidel-Platz 4 81737 München, Germany Supplier:
Wacker Chemie AG Verkaufsbüro Stuttgart Sophienstr. 41 70178 Stuttgart, Germany
Type:
Elastosil E14 (RTV 1)
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51
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Maintenance Manual EXTRA 500
Manufacturer: Momentive (formerly GE Silicones) 22 Corporate Woods Boulevard Albany, NY 12211, USA Supplier:
diverse
Type:
RTV 159 (high temperature & high strength Silicone)
Adhesive Manufacturer: Henkel AG & Co. KGaA Henkelstr. 67 D-40589 Düsseldorf, Germany Supplier:
Wessels & Müller AG Pagenstecherstraße 121, D-49090 Osnabrück, Germany
Type:
Loctite 243 Loctite 401 Loctite 406 Loctite 577 Loctite 601
Threadlocker Instant adhesive Instant adhesive Thread sealing Small gaps retainer
Corrosion Preventive Compound Manufacturer: LEAR CHEMICAL RESEARCH P.O. Box 1040, Mississauga L4Y 3W3 Ontario, Canada Supplier:
Global Aviation & Piper Parts GmbH Flughafen Kassel, D-34379 Calden
Type:
ACF-50
Sealing Material for Lightning Protection Manufacturer: Nycote Laboratoires 12750 Raymer Street North Hollywood, CA 91605 Supplier:
Aero Consultants PO Box 35, Grabenstrasse 8 CH-8606 Nänikon/Uster, Switzerland
Type:
Nycote 7-11 (MIL-S-4383)
Release Agent Manufacturer: CIBA Speciality Chemicals Inc. CH-4002 Basel, Switzerland
Page 20
51
Supplier:
Schurg GmbH Industriestr. 12 D-34537 Bad Wildungen, Germany
Type:
QV 5110 Page Date: 30. March 2012
Maintenance Manual EXTRA 500
51-60-00
CONTROL SURFACE BALANCING
51-60-01
Weighing and Determination of Control Surface Moments Weighing and determination of control surface moments is necessary after repairs or painting. All weighing of control surfaces is performed with surfaces removed from aircraft. Weigh the control surfaces including mass balances and brackets but without control rods. The RH elevator weight includes the trim tab installed and provisionally held in elevator surface plane by means of tape (see also Figure 51-3). Copy Figure 51-4, enter the values (W, m, r) and check whether the surface weights and moments are within the given tolerances. If they are not, contact the EXTRA for advice. For the determination of control surface moments follow the steps as described below and use two balancing mandrels like shown in the Figure 51-2:
A
B
(for outboard aileron hinge) Ø
Figure 51-2
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Balancing Mandrels
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Procedure Detail Steps/Work Items
Key Items
1 Remove the control surface.
Refer to Chapter 27
2 Reinstall the bolts in the brackets where applicable.
Aileron inboard hinge Elevator outboard hinge
3 When weighing RH elevator fix trim tab with tape. 4 Put the control surface on the balancing mandrels (use a wire for the trim tab).
Refer to Figure 51-3
5 Level control surfaces and weigh by means of a conventional spring balance (kg/gindication) at the given weighing points and enter the weight (m) in figure 4.
Refer to Figure 51-3
6 Measure distance of hinge center line to weighing point (r) and enter the value in Figure 51-4. 7 Calculate the control surface moment (M) in Figure 51-4. IMPORTANT
If values exceed the given tolerances in Figure 51-4 contact EXTRA before modifying of control surfaces. 8 If necessary modify control surface under EXTRA’s guidance. 9 Reinstall the control surfaces.
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Hinge center axis
Rudder
r -m Weighing point
r
Weighing point
m Aileron
Hinge center axis
Hinge center axis
Elevator (RH) Wire
r Weighing point m
Trim tab
Tape r Weighing point m
Hinge center axis
Figure 51-3
Control Surface Balancing
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Permissible Weights and Moments 5.53 5.5 5.6
4.5
6.5
7.13
6.8
450
440
Rudder
400
350
350 300
290
Elevator (LH)
250
Elevator (RH) 220
200 50 0
0
Aileron -40
-50 4.0
4.5
5.0
5.5
6.0
7.0
6.5
7.5
0.50
0.37 50 25
30
Trim tab
15
0 0.30
0.35
0.40
Weights Aileron LH:
(W) . . . . . . . . . . kg
Aileron RH:
(W) . . . . . . . . . . kg
Rudder:
(W) . . . . . . . . . . kg
0.45
0.50
0.60
0.55
0.65
Elevator LH: (W) . . . . . . . . . . kg Elevator RH: (W) . . . . . . . . . . kg
x
x
Trim Tab:
(W) . . . . . . . . . . kg
Moments Aileron LH:
(m:) . . . . . . . . . kg x 9.81m/s x (r:) . . . . . . . . . cm = (M:) . . . . . . . . . . . . Ncm
Aileron RH:
(m:) . . . . . . . . . kg x 9.81m/s2 x (r:) . . . . . . . . . cm = (M:) . . . . . . . . . . . . Ncm
Rudder:
(m:) . . . . . . . . . kg x 9.81m/s2 x (r:) . . . . . . . . . cm = (M:) . . . . . . . . . . . . Ncm
2
Elevator LH: (m:) . . . . . . . . . kg x 9.81m/s2 x (r:) . . . . . . . . . cm = (M:) . . . . . . . . . . . . Ncm Elevator RH: (m:) . . . . . . . . . kg x 9.81m/s2 x (r:) . . . . . . . . . cm = (M:) . . . . . . . . . . . . Ncm Trim Tab: Figure 51-4 Page 24
51
(m:) . . . . . . . . . kg x 9.81m/s2 x (r:) . . . . . . . . . cm = (M:) . . . . . . . . . . . . Ncm Permissible Weights and Moments Page Date: 30. March 2012
Maintenance Manual EXTRA 500
51-70-00
REPAIRS
51-70-01
Repair of Reinforced Glass and Carbon Fibre Components
IMPORTANT
Repair of composite parts has to be carried out only by qualified and authorized personnel. If the aircraft is damaged, proceed as follows. First conduct a careful visual inspection of the surface and the damaged area. Frequently, the damage extends to further components, sometimes a fracture will continue invisible beneath the surface. Perform the repair work with utmost care. The external shell of the wing and empennage as well as all structural parts including the fuselage are stressed; a failure of this bonded structure can lead to an aircraft crash. In order to eliminate dangerous stress concentrations, avoid changes in cross-sectional areas.
IMPORTANT
The resin-hardener mixture ratio must be precisely maintained (± 0.5 %). Clean cups and tools must be used. The weight ratio of fabric to resin mixture should be approximately 50:50. Immediately prior to applying the wet laminate, sand and vacuum clean the repair area, so that no dirt and dust is involved which could prevent a secure adhesion.
Sanding carbon and glass fibre laminates gives off a fine dust that may WARNING cause skin and/or respiratory irritation unless suitable skin and respiration protection is used. Carbon-tetracloride or Acetone used for cleaning repair areas are WARNING flammable liquids and should be used with proper ventilation and safety equipment. IMPORTANT
As with plywood grain, the direction of the various fibres (longitudinal or diagonal) is of great importance for the stability. The number of layers required to restore the stability in the damaged area can be taken from the layer sequence / placement plan. (Refer to the respective Chapters) It is necessary to know the number and direction of layers in the damaged area, in order to be able to replace them with the original number. In all cases, the thickness of the laminate has to be measured with a vernier calliper for the exact determination of the laminate thickness. One technique to learn about the number of layers is to burn a small piece taken from the damaged area. The resin will burn off, leaving the glass and/or carbon fabric to be inspected for the number of layers and the type of fabric. Creating a scarfed overlap takes time. Sand away as much of the old material, so that the new fabric patches do not project beyond the contour.
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In order to shorten the curing time, a heater can be used to increase the ambient temperature. CAUTION
Too high temperature will cause large air bubbles in the laminate. Local overtemperature can be prevented by using a foil tent which leads the hot air stream. The curing cycle must be maintained as stated. Use a thermometer to monitor the temperature.
IMPORTANT
After repair of control surfaces, check for proper balance (Manufacturer will provide service instructions to manufacturer authorized repair stations). It is recommended to prepare test specimen at the same time as the actual repair is accomplished. These can then be subject to a material test to establish the quality of the laminate in the repaired part. To make this determination valid, the specimen must be assembled with the same style of fabric and resin mixture. Subsequently the specimen must be subject to the curing pressure, temperature and time identical with those in the actual repair.
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51-70-02
Repair of Sandwich Material Three types of core materials are used for sandwich on the EXTRA 500: 1 PMI or PVC hard foam, 2 Honeycomb 3 Plywood, with carbon fibre shells. The following section describes the repair of these types of sandwich. Different processing techniques for these materials, if necessary, are also described. a) Minor Surface Damage Around a visible crack, the laminate may be separated from the core material. Determine the extent of this area by coin tapping. Remove the separated laminate carefully using a sanding disk, sanding block or a sharp knife. Prepare a scarfed overlap of the laminate around the damaged area. Overlap lenght per fabric layer min. 20 mm.
IMPORTANT
Ratio (laminate thickness : overlay lenght) min. 1 : 50
Figure 51-5
Minor Surface Damage
After preparing the scarfed overlap, clean the repair area thoroughly as follows: 1 Remove the sanding dust with a pneumatic vacuum cleaner 2 Clean the scarfed overlaps with carbon-tetrachloride or acetone in case of dirt or grease was trapped during the preparation Damaged core material has to refilled with a mixture of resin and microballoons (weight ratio 100:15). Apply resin mixture to the repair area and lay on fabric in accordance to the layer sequence plans. Ensure to use correct style and direction of fabric. IMPORTANT
Repair area must be clean of dirt, dust and grease! Lay out the required number and size of fabric pieces on a piece of colored plastic foil and soak (wet) them with resin mixture; subsequently position them on the repair area.
IMPORTANT
Remove the plastic foil after each positioning process. For a repair of honeycomb sandwich parts you have to observe the following: The repair area has to be cured under condition of vacuum bagging. For vacuum bagging, proceed as follows: 1 Apply nylon peel ply on the last repair fabric layer.
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2 Perforate a clean, thin plastic foil with a thick needle (max.spacing of holes: 20 mm x 20 mm) - mainly in the area of the honeycomb - and lay it on the repair area. 3 Lay a jute cloth (weave) or equivalent bleeder cloth on this perforated plastic foil. 4 Lay an air tight plastic foil upon the jute weave and seal their edges to the surrounding surface using an adhesive tape. 5 Apply suction with a vacuum pump (pressure approx. .7 bar/ 10 psi). 6 Apply the thermal curing cycle. 7 Following the curing cycle remove vacuum bagging material and nylon peel ply. NOTE
After the pre-curing period at room temperature, the repaired area has to be cured according to the temperature cycle as showed below.
Figure 51-6
Curing Cycle Resin L 20 / SL
After the curing process is completed, the repair area can be sand leveled to the surrounding area. Sand only the edge thickness of repair laminate. CAUTION NOTE
For painting of the repair area refer to Chapter 51-70-06. b) Damage of Complete Sandwich If the inner laminate is also damaged, first remove the upper laminate within the area, where no secure bond connection to the core material is suspected. Trim out the complete damaged portion of core material to a circular or elliptical shape. The damaged area of the inner laminate has to be taken out as well. Make sure not to increase the disbond area by preparing the hole. Preferably use a hand held milling machine. In case of cutting with a saw, the pulsation stress may
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peel off the inner laminate (secondary damage). If the extent of the disbonded area on the inner laminate exceeds the prepared cut out, increase the cut out of material and upper laminate. Prepare a scarfed overlap of laminate around the circular cut out. Overlap lenght of inner laminate should not be less than 20 mm. IMPORTANT
Ratio (laminate thickness : overlay lenght) min. 1 : 50 Prepare a replacement block of core material (foam or honeycomb) with equivalent diameter and thickness. Cut it to fit snuggly in the trimed hole. In case of foam core, coat one side with a mixture of resin and microballoons (ratio 100:15). Apply prelaminated fabric layers required for the inner laminate on this side of the core filler block. Ensure correct style and direction of fabric. After precuring the laminate at elevated room temperature (30°C), scarf the overlap and sand the upper overlapping core material down, up to the surrounding core material. Subsequently clean the repair area thoroughly as follows: 1 Remove the sanding dust with a pneumatic vacuum cleaner. 2 Clean the scarfed overlaps with carbon-tetrachloride or acetone in case of dirt or grease was trapped during the preparation.
Carbon-tetrachloride or acetone used for cleaning repair areas are WARNING flammable liquids and should be used with proper ventilation and safety equipment. IMPORTANT
Repair area must be free of dirt and grease. Wet all surfaces of the backing plate and the scarfed area with resin mixture. Lay on prelaminated fabric layer in accordance to the layer sequence plan. Ensure correct style and direction of fabric.
Figure 51-7
Damage of Complete Sandwich
Lay out the required number and size of fabric pieces on a piece of plastic foil and wet them with resin mixture. Subsequently position them on the repair area. IMPORTANT
Remove the plastic foil after each positioning process. The repair area has to be cured under condition of vacuum bagging. Proceed as follows: 1 Apply nylon peel ply on the last repair fabric layer. 2 Perforate a clean, thin plastic foil with a thick needle (max.spacing of holes: 20 mm x 20 mm) - mainly in the area of the honeycomb - and lay it on the repair area.
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3 Lay a jute cloth (weave) or equivalent bleeder cloth on this perforated plastic foil. 4 Lay a second plastic foil upon the jute weave and seal their edges to the surrounding surface using an adhesive tape. 5 Apply suction with a vacuum pump (pressure approx. .7 bar/ 10 psi). 6 Apply the thermal curing cycle. 7 Following the curing cycle carefully remove vacuum bagging material and nylon peel ply. NOTE
After the pre-curing period at room temperature, the repaired area has to be cured according to the temperature cycle as given by the laminate's manufacturer. After the curing process is completed, remove the nylon peel ply. The repaired area can be sand leveled with the surrounding area. Sand only the edge thickness of repair laminate!
CAUTION NOTE
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For painting of Chapter 51-70-06.
the
repair
area
proceed
like
mentioned
in
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51-70-03
Repair of Laminates Minor Damage Scarf the edges of the minor damage area with sandpaper. Minimum lenght of scarf per fabric layer approx. 20 mm; ratio (laminate thickness : scarf lenght) approx. 1: 50. Following the scarf procedure, clean the repair area thoroughly: 1 Remove the sanding dust with a pneumatic vacuum cleaner 2 Clean the scarfed overlaps with carbon-tetrachloride or acetone in case of dirt or grease was introdued during the preparation. Repair area must be free of dirt, dust and grease.
CAUTION Wet the prepared scarfed areas with resin mixture. Lay on prelaminated fabric layer in accordance to the layer sequence plan. Ensure correct style and direction of fabric. Apply nylon peel ply on the last repair fabric layer. NOTE
IMPORTANT
Lay out the required number and size of fabric pieces on a piece of colored plastic foil and wet them with resin mixture. Subsequently position them on the repair area. Remove the plastic foil after each positioning process. After the curing process has been completed, remove the nylon peel ply. The repair area can be sand leveled with the surrounding area. Sand only the edge thickness of repair laminate!
CAUTION Refinish the surface according Chapter 51-70-06 (Painting). If the extent of the damaged area exceeds 10 cm (4 inches) a large damage repair is required. Carefully trim out the damaged portion to a circular or oval shape. Prelaminate a backing plate from two layers of glass fibre fabric and resin mixture, which must be approx. 20 mm larger than the damaged area. Apply nylon peel ply as external layer. Sandwich the resin wetted layers between two sheets of plastic foil. Work the excess resin out and allow the plate to cure at elevated room temperature for 8 hours on a flat surface or a plasticfoil-covered surface of the proper curvature near the damaged area, or the same location on a comparable undamaged part. Following the curing cycle remove plastic foil and nylon peel ply. Bond the backing plate to the inside using a mixture of resin and cotton flocks, and adapt to the contour. Cure the bonding at elevated room temperature for 8 hours. Subsequently scarf the edges of the damaged portion with sandpaper. Minimum lenght of scarf per fabric layer approx. 20 mm. IMPORTANT
Ratio (laminate thickness : scarf lenght) approx. 1: 50. Following the scarf procedure, clean the repair area thoroughly:
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1 Remove the sanding dust with a pneumatic vacuum cleaner 2 Clean the scarfed overlaps with carbon-tetrachloride or acetone in case of dirt or grease was trapped during the preparation of the overlap. IMPORTANT
Repair area must be free of dirt, dust and grease. Wet all surfaces of the backing plate and the scarfed area with resin mixture. Lay on prelaminated fabric layer in accordance to the layer sequence plan. Ensure correct style and direction of fabric.
NOTE
IMPORTANT
Lay out the required number and size of fabric pieces on a piece of colored plastic foil and wet them with resin mixture. Subsequently position them on the repair area. Remove the plastic foil after each positioning process. The repair area has to be cured under condition of vacuum bagging. Proceed as follows: 1 Apply nylon peel ply on the last repair fabric layer 2 Perforate a clean, thin plastic foil with a thick needle (max. spacing of holes: 20 mm x 20 mm) - mainly in the area of the honeycomb - and lay it on the repair area.
Figure 51-8
Repair of Minor Damage
Large Damage If the extent of the damaged area exceeds 100 mm (4 inches) a large damage repair is required. Carefully trim out the damaged portion to a circular or oval shape. Prelaminate a backing plate from two layers of glass fibre fabric and resin mixture, which must be approx. 20 mm larger than the damaged area. Apply nylon peel ply as external layer. Sandwich the resin wetted layers between two sheets of plastic foil. Work the excess resin out and allow the plate to cure at elevated room temperature for 8 hours on a flat surface or a plasticfoil-covered surface of the proper curvature near the damaged area, or the same location on a comparable undamaged part. Following the curing cycle remove plastic foil and nylon peel ply. Bond the backing plate to the inside using a mixture of resin and cotton flocks, and adapt to the contour. Cure the bonding at elevated room temperature for 8 hours. Subsequently scarf the edges of the damaged portion with sandpaper. Minimum lenght of scarf per fabric layer approx. 20 mm. IMPORTANT Page 32
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Ratio (laminate thickness : scarf lenght) approx. 1: 50. Page Date: 30. March 2012
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Following the scarf procedure, clean the repair area thoroughly: 1 Remove the sanding dust with a pneumatic vacuum cleaner 2 Clean the scarfed overlaps with carbon-tetrachloride or acetone in case of dirt or grease was trapped during the preparation of the overlap. IMPORTANT
Repair area must be free of dirt, dust and grease. Wet all surfaces of the backing plate and the scarfed area with resin mixture. Lay on prelaminated fabric layer in accordance to the layer sequence plan. Ensure correct style and direction of fabric.
NOTE
Lay out the required number and size of fabric pieces on a piece of colored plastic foil and wet them with resin mixture. Subsequently position them on the repair area.
IMPORTANT
Remove the plastic foil after each positioning process. The repair area has to be cured under condition of vacuum bagging. Proceed as follows: 1 Apply nylon peel ply on the last repair fabric layer. 2 Perforate a clean, thin plastic foil with a thick needle (max.spacing of holes: 20 mm x 20 mm) - mainly in the area of the honeycomb - and lay it on the repair area. 3 Lay a jute cloth or equivalent bleeder cloth on this perforated plastic foil. 4 Lay an air tight plastic foil upon the jute weave and seal their edges to the surrounding surface using an adhesive tape. 5 Apply suction with a vacuum pump (pressure approx. .7 bar/ 10 psi). 6 Apply the thermal curing cycle. 7 Following the curing cycle carefully remove vacuum bagging material and nylon peel ply.
NOTE
After the pre-curing period at room temperature, the repaired area has to be cured according to the temperature cycle as given by the laminate's manufacturer. After the curing process is completed, the repair area can be sand leveled to the surrounding area. Sand only the edge thickness of repair laminate!
CAUTION Refinish the surface according Chapter 51-70-06.
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51-70-04
Repair of Spars and Elements of the Pressure Cabin Structural elements of the pressure cabin The pressurized part of the fuselage runs from the front bulkhead (firewall position) to the rear pressure dome positioned at X6125. Main structure elements are: Flat front bulkhead, skin, frames, longerons, keel beams and the rear pressure dome (GRP). The height of the honeycomb core in the pressurized part is 30mm (except shell below the wing). Longerons are integrated in the skin sandwich.
Spars of Wing and Empennage The spars consists of carbon fibre roving or UD-tape caps, carbon fibre webs and PMI foam or plywood/honeycomb cores. IMPORTANT
51-70-05
The spars and structural elements of the pressure cabin are highly stressed; a failure of this bonded structure can result in loss of the aircraft! In all cases, the repair of a spar must be considered as a largescale repair with a Damage Class 1 (Refer to Chapter 51-10-01 Damage Classification). EXTRA has to be contacted prior to repair!
Structural Repair of Steel Components Restoration of damaged steel designed structures to their original design strength, shape and alignment involves careful evaluation of the damage, followed by exacting workmenship in performing the repairs.
IMPORTANT
Should structural repairs practicable on the aircraft be necessary, refer to "Aircraft Inspection and Repair FAA AC 43.13-1A" and "Aircraft Alterations Acceptable Methods, Techniques and Practices FAA AC 43.13-2A".
IMPORTANT
Alterations or repair of the airplane must be accomplished by licensed personnel. Consult EXTRA in case of doubt about a repair not specifically mentioned there. Consider, that different types of steel are being used on the aircraft structures, so as steel tubes, brackets, connections etc. (WLB 1.7734.4 and AISI 4130 N type steel). The two steel types shall not be mixed in repair. Also refer to Chapter 51-30-02.
NOTE
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If welding work must be performed, use only the TIG procedure (Tungsten Inert Gas). Use welding wire 1.7734.2 for 1.7734.4 and AISI 4130 N or equivalent, depending on the respective steel type, for welding additive.
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51-70-06
Painting of Composite Parts
Coating materials may cause sensitization by inhalation and skin contact. WARNING Hardeners and coating materials ready for use can have an irritant and sensitizing effect upon the skin and respiratory tracts and cause allergic reactions. Provide for a continuous supply of fresh air during and also after the WARNING application, do not inhale the vapors and wear a breathing mask during the spray application of these materials. Persons suffering from an allergy or being prone to diseases of the respiratory tracts must not get in contact with coating materials. Refer to the manufacturer technical information sheet! After curing cycle the surface of repared area can be sanded with sandpaper (80 grade). Indentations are filled with Presto putty light. Subsequently achieve a surface as uniformly rough as possible using a finer dry sandpaper (150 or 320 grade). Prior to paint application, the surface of the repair area must be cleaned thoroughly of all sanding dust, separation compounds and other foreign materials. Subsequently apply 285-100 VOC Glassodur Rapidfüller with a spray gun. NOTE
The Rapidfüller (rapidfiller) must be completely dry before the covering paint can be applied. For the final sanding, use 400 grade wet sandpaper to achieve a smooth clean surface. Allow surface to dry. Paint application of 22, 55 or 90 Glassodur Decklack is performed with a spray gun. Paint can be mixed with small quantities of reducer. After completion of the painting, polish the repair area.
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51-70-07
Aluminium and Steel Components Refinishing Complete procedure necessary to remove existing paint from aluminium and steel components and then to repaint them as described in the following paragraphs.
Degreasing Cleaning solvents can be toxic and volatile. Use only in well ventilated WARNING areas. Avoid physical contact with solvent and do not inhale vapors. Keep solvent containers covered when not in use. CAUTION
Before stripping parts, remove all fittings, O-rings, nuts, bolts, washers, pistons, bearing cups, etc.
1 Clean all metal parts by immersing in a clean degreasing solution. An alkaline based solution is recommended for aluminium and magnesium parts. 2 Hardened dirt or grease may be removed with soft bristle brush, or by soaking in cleaning solution. 3 Where necessary clean bearing cones carefully in a separate container of clean solvent. Do not spin bearing cones with compressed air. CAUTION 4 After cleaning, thoroughly dry all metal parts with filtered, dry compressed air. 5 It is recommended that all O-rings, backup rings, and wipers be replaced at each overhaul. However, if necessary, O-rings may be reused, but should be put back into that position from which they had been removed. 6 Wipe down O-rings, backup rings, wipers, or other rubber parts with a clean dry cloth. Lubricate with a suitable O-ring lubricant prior to installation.
Paint Removal Disassemble components to the level required for repainting, then proceed as follows. Stripping solvents can be toxic and volatile. Use only in well ventilated WARNING areas. Avoid physical contact with solvent and do not inhale vapors. Keep solvent containers covered when not in use. CAUTION
Before stripping parts, remove all fittings, O-rings, nuts, bolts, washers, pistons, bearing cups, etc. Parts must be totally immersed in solvent, to maximize cleaning.
1 Degrease part as per degreasing paragraph. 2 Totally immerse part in paint removing solvent. Portions not totally covered by solvent will begin to corrode. NOTE
Stripping agents are commercially available for removing topcoat and primer. Follow manufacturer's recommendations for use and disposal of stripping solutions. 3 Remove part from solvent and rinse thoroughly with water heated to 160° to 180°F (71° to 82° C). Flush solvent from all cavities and threaded holes where
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entrapment might occur. 4 Thoroughly dry part with filtered, dry compressed air. 5 Where applicable refer to inspection procedures given in the respective chapters for specific parts to locate possible defects. NOTE
Refinishing should be completed as soon as possible; unprotected parts will begin to corrode.
Repainting Paint all surfaces except those which are subjected to friction (bearing surfaces, anchor bolt bores, etc.). Proceed as follows: 1 Parts to be repainted should be cleaned and stripped as per instruction in degreasing and paint removal paragraphs. 2 Aluminium parts should have a protective barrier between the topcoat and base metal. It is recommended that they are treated with solutions listed in Chapter 51-30. 3 Apply solution liberally and evenly. Allow solution to set from 1 to 5 minutes. The solution must completely wet the surface and overlap onto the adjoining anodize. 4 Remove excess coating by flushing with clean water. 5 Paint parts with one coat of wash primer. Allow to dry thoroughly. 6 Paint parts with one coat of lacquer listed in Section 51-30. Allow to dry thoroughly before reassembly.
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Chapter 52 Doors
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Table of Contents
52-00-00
GENERAL ........................................................................................................ 3 Troubleshooting.................................................................................................. 3
52-10-00
PASSENGER/CREW....................................................................................... 4 Description.......................................................................................................... 4
52-20-00
EMERGENCY EXIT ....................................................................................... 5 Description.......................................................................................................... 5
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52-00-00 NOTE
GENERAL For replacement and adjustment of door bolts and fittings contact EXTRA
Troubleshooting Complaint
Possible Cause
Remedy
Pressure cabin leakage
Erroneous cabin door or emergency exit seal installation or damaged seal
Check seals for damages and correct installation. If seal is damaged replace it.
Exterior door locking mechanism damaged
Rotation of outer door handle without previously pulling it against its stop
Replace central door actuating mechanism
Unusual high operating forces or lacking ability to reach the fully open or closed position of actuation handles
Misadjusted locking mechanism
Remove interior panel, check mechanism for proper adjustment
Lacking lubrication
Remove interior panel, clean and lubricate mechanism
Damaged or worn locking mechanism
Remove interior panel, replace damaged or worn parts, readjust mechanism
Faultive mechanical locking indication (8 sight glasses)
Mechanically damaged indication or locking mechnism
Remove interior panel, check locking mechanism and position indication
Door warning light does not illuminate with door open
Light, wiring or switch defective
Identify and replace component
Door switch misadjusted
Remove interior panel, adjust switch actuation
Wiring or switch defective
Identify and replace component
Door switch misadjusted
Remove interior panel, adjust switch actuation
Door warning light illuminates in spite of closed door
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52-10-00
PASSENGER/CREW Description The entry door at the left side of the fuselage is a two-section, outward opening door. The upper part folds up held in upper position by a telescopic lift cylinder, and the lower part folds down, limited by two cables and provides a step for easy in boarding and deplaning passengers. Ensure wing flaps are retracted before opening the door.
CAUTION For opening the door from outside, pull handle out completely, turn handle clockwise and deploy upper door. Then rotate up the sill lever which is now accessible on the lower door, stand clear and deploy the lower door. For opening the door from inside, press safety button, turn handle counterclockwise and deploy upper door. Then rotate up the sill lever which is now accessible on the lower door, stand clear and deploy the lower door. For closing the doors reverse the above given procedure. Ensure that outer handle is sunk, inner handle is locked and all eight inspection glasses inside show green color.
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52-20-00
EMERGENCY EXIT Description In emergency case the upper door can be opened even with wing flaps down. The upper door shall then be strongly pressed against the wing flap edge, which will bend and thus increasing the upper door opening angle. This allows deploying the lower part. The middle RH side window opposite to the passenger entry door is built as an emergency exit window. For opening the emergency exit window from outside remove the clear plastic cover, turn the handle clockwise as marked and then push window inside and down. For opening the emergency exit window from inside swivel up the handle, turn the handle counterclockwise as marked and then pull window inside and down.
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Chapter 55 Stabilizers
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Table of Contents
55-00-00
GENERAL ........................................................................................................ 3 Description.......................................................................................................... 3
55-10-00
HORIZONTAL STABILIZER ....................................................................... 4 Description.......................................................................................................... 4 Overview Horizontal Stabilizer .......................................................................... 5
Figure 55-1 55-20-00 Figure 55-2 Figure 55-3 Figure 55-4
ELEVATOR...................................................................................................... 6 Description.......................................................................................................... 6 Elevator Control Surface (LH) ........................................................................... 7 Elevator Control Surface (RH)........................................................................... 8 Elevator Trim Tab, (on RH elev. only) ............................................................... 9
55-30-00
VERTICAL STABILIZER............................................................................ 10 Description........................................................................................................ 10
55-30-01 Figure 55-5
Fin Tip ............................................................................................................. 10 Fin Tip .............................................................................................................. 10 Removal/Installation......................................................................................... 11
55-40-00
RUDDER ......................................................................................................... 12 Description........................................................................................................ 12 Overview Rudder Mounting.............................................................................. 13 Bottom Rudder Mounting (including bell crank and centering device) ........... 14 Middle and Upper Rudder Mounting ............................................................... 14
Figure 55-6 Figure 55-7 Figure 55-8
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55-00-00
GENERAL Description The empennage is the element which controls the aircraft around the pitch and yaw axis. It is a T-tail design with extended fin and fixed straight main elements. The empennage is composed of the following elements: • Horizontal stabilizer • Elevator • Vertical stabilizer • Rudder
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55-10-00
HORIZONTAL STABILIZER Description The fixed straight tapered horizontal stabilizer has 2° anhedral. The NACA 0012 airfoil section is chosen for the horizontal stabilizer. The elevator hinge line is positioned at 62% of the horizontal stabilizer chord. The entire horizontal stabilizer structure is of CFRP sandwich construction with two CFRP spars. The horizontal stabilizer is attached to both vertical stabilizer front and rear spar.
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Figure 55-1
Overview Horizontal Stabilizer
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55-20-00
ELEVATOR Description Elevator The elevator is divided in the LH & RH elevator control surface due to the anhedral of the horizontal stabilizer and sweep back angle of the elevator hinge line. Each elevator control surface is attached separately to the rear spar of the horizontal stabilizer at three points. All attachment points incorporate spherical bearings. For aerodynamical reasons the elevator control surface itself features an shielded horn balance at the tip which incorporates the necessary mass balance to prevent flutter. Each elevator control surface is actuated by a push pull rod which is connected to the central cable quadrant mounted at the front spar of the vertical stabilizer. For elevator deflection refer to Chapter 06-10-08. Each entire elevator control surface structure is of one spar dual torsion box all-CFRP-composite construction. Elevator Tab The elevator trim is achieved by an elevator trim tab attached to the inboard trailing edge of the right elevator with a full length piano-type hinge. The trim tab is actuated by a fail safe push pull rod which is attached to a jack screw type actuator in the horizontal stabilizer. For elevator trim tab deflection refer to Chapter 06-10-08.
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Figure 55-2
Elevator Control Surface (LH)
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Figure 55-3
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Elevator Control Surface (RH)
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Figure 55-4
Elevator Trim Tab, (on RH elev. only)
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55-30-00
VERTICAL STABILIZER Description The vertical stabilizer consists of two parts. The lower part reaches to the horizontal stabilizer and is structurally integrated with the fuselage. The upper part (fin tip) is attached to the lower part with bolts. The vertical fin has the cambered NACA 2412 profile at the root gradually changing in the NACA 0012 airfoil section at the horizontal stabilizer. This is to counter the propeller induced cross flow. The fin tip is a NACA 0012 airfoil. The entire vertical stabilizer structure is of CFRP sandwich construction with two CFRP spars. The shell of the lower part of the vertical stabilizer is a part of the fuselage shell.
55-30-01
Fin Tip Side View
LN bolts
MS bolts
Strobe light
Top View
Figure 55-5 Page 10
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Removal/Installation Detail Steps/Work Items
Key Items
High voltage can cause injuries! WARNING
Pull out the STROBE-LT circuit breaker and let bleed down power supply for 10 minutes after shutting off before beginning any work on the strobe light systems.
2 Remove LH and RH gap fairing.
Refer to Chapter 51-00-01
3 Remove fin tip attaching bolts.
10 bolts
4 Lift fin tip some centimeters. 5 Disconnect strobe light power supply connectors.
In the front section
6 Remove fin tip. CAUTION
Reverse polarity of the input power, for just an instant, will permanently damage power supply. This damage is sometimes not immediately apparent, but will cause failure later on. Black lead is negative.
7 Install in reverse sequence of removal.
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55-40-00
RUDDER Description The rudder hinge line is positioned at 73% of the vertical stabilizer chord. To prevent flutter the rudder is mass balanced at the upper overhanging circular nose section. The entire rudder structure is of one spar dual torsion box all-CFRP-composite construction. The rudder is attached to the vertical stabilizer rear spar at three points. All hinges incorporate ball bearings. It is actuated by a bell crank attached to the bottom. A spring loaded centering device is located at the rudder actuation bell crank, which keeps the rudder in the neutral position and enlarges the control forces. For rudder deflection refer to Chapter 06-10-08.
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Figure 55-6
Overview Rudder Mounting
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* *
*) For rudder deflection refer to Chapter 06-10-08 Figure 55-7
Bottom Rudder Mounting (including bell crank and centering device)
Figure 55-8
Middle and Upper Rudder Mounting
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Notes on figures 55-06 and 55-07: Note 1: Install bushings EA-35020.01 and -45441.01 as well as pin of 35631.00 and -35633 with grease according MIL-G-81322D (e.g. Aeroshell Grease 22C) Note 2: Install spherical bearings and retaining rings with corrosion protectant according LN9368-5903 (e.g. Mastinox 6856H) Note 3: deleted in drawing Note 4: Adjust bolts DIN933-M5x25 for correct rudder deflection (refer to Chapter 06-10-08).
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Chapter 56 Windows
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TABLE OF CONTENTS
56-00-00
GENERAL ........................................................................................................ 3 Description.......................................................................................................... 3
56-10-00
FLIGHT COMPARTMENT ........................................................................... 4
56-10-01
Windshield......................................................................................................... 4 Description.......................................................................................................... 4
56-20-00
CABIN ............................................................................................................... 5
56-20-10
Cabin Windows................................................................................................. 5 Description.......................................................................................................... 5
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GENERAL Description For the EXTRA 500 windows two materials are used for the windows of the pressure cabin: Stretched acrylic material (MIL-P-25690) Cast acrylic material (MIL-P-8184) The windows are highly stressed members of the pressure vessel. Scratches have to be avoided, any crack in a window has to be repaired before the aircraft is operated in pressurized mode again. For repair, removal and installation procedures contact EXTRA. The middle window on the right side of the passenger compartment is designed as emergency exit. Refer to Chapter 52-20-00 for further information.
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56-10-00
FLIGHT COMPARTMENT
56-10-01
Windshield Description The EXTRA 500 is equipped with a two piece windshield divided by a structural strut between the pilot’s and copilot’s side. The pilot’s windshield is a laminated design consisting of an inner layer of stretched acrylic material followed by a layer with an integrated electric windshield heat (refer to chapter 30). The outer layer is made from cast acrylic material. The copilot’s windshield consists of a monolithic acrylic pane consisting of stretched acrylic material. The copilot’s side does not include an electric windshield heat.
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56-20-00
CABIN
56-20-10
Cabin Windows Description The cabin windows feature double panes for redundancy in case of structural failure of the outer pane. The outer pane is carrying the pressurization loads during normal operation and consist of stretched acrylic material. The inner pane is consisting of cast acrylic material and does not carry any load in normal operation. The room between the two panes is connected to the pressure vessel by a small orifice during normal pressurization. In case of structural failure of the outer pane the inner pane takes the pressurization loads and the orifice limits the leakage. The middle windows on both sides are integrated in either the normal door on the left side or into the emergency exit panel on the right side. Structurally they are identical to the fixed windows. All 6 cabin windows are contoured to match the fuselage shape individually.
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Chapter 57 Wings
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TABLE OF CONTENTS 57-00-00
GENERAL ........................................................................................................ 3 Description.......................................................................................................... 3
57-10-00
CENTER WING ............................................................................................... 4 Description.......................................................................................................... 4 Removal.............................................................................................................. 4 Installation .......................................................................................................... 6 Hoisting the Wing ............................................................................................... 6 Wing to Fuselage Attachment............................................................................. 7
Figure 57-1 Figure 57-2 57-30-00
WING TIPS....................................................................................................... 8 Description.......................................................................................................... 8
57-50-00
TRAILING EDGE AND TRAILING EDGE DEVICES.............................. 9
57-50-01
Flaps ................................................................................................................... 9 Description.......................................................................................................... 9 Removal/Installation........................................................................................... 9 Inner Flap Structure ......................................................................................... 10 Outer Flap Structure ........................................................................................ 11
Figure 57-3 Figure 57-4 57-60-00
Figure 57-5
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AILERONS AND ELEVONS........................................................................ 12 Description........................................................................................................ 12 Removal/Installation......................................................................................... 12 Aileron Structure .............................................................................................. 13
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57-00-00
GENERAL Description The EXTRA 500 features a straight tapered all composite cantilever wing. The one piece wing consists of a CFRP wing-box serving as structure for the bending and torsional loads. The GFRP nose section equipped with the de-ice boots (=> ref. to Chapter 30) is part of the aerodynamic wing section and carries shear due to aerodynamic lift forces into the wing box structure. To achieve minimum drag natural laminar flow wing sections have been designed specially for the EXTRA 500. Wing relative thickness is 16,5% at the root section gradually changing into the 12% wing section used at the tip. Wing twist distribution is selected to keep the wing sections within the low drag bucket in cruise flight. Wing-Structure Spars: The wing uses 1 double cell front spar at 22.6% chord and 1 single cell rear spar at 68.6% chord (carry-thru) to 60% chord (tip). Caps and webs are made of CFRP with PMI foam core. The tiplets are not part of the primary wing structure. Skin: The wing skin is a composite sandwich structure with CFRP facing layers and honeycomb core. Ribs: In the torsion wing box 7 CFRP ribs are used each side: structural root and fuel tank rib at Y±550, slosh rib with flapper valves at Y±800, slosh rib at Y±1550, structural and fuel tank rib at Y±2550, fuel tank end rib (long range) at Y±4300, structural rib at Y±4400 and the structural tip rip at Y±5500, which extends to the nose section. In addition 5 GFRP ribs are used in the D-nose section each side at Y± 550, Y±1550, Y±2550, Y±3400, Y±3600, Y±4400. Fuel tank: The wing fuel tank is an integral part of the wingbox between the main spars, the root rib at Y±550 and Y±4300. Flaps: => refer to section 57-50 Ailerons: => refer to section 57-60 Nose section: The nose skin is a composite sandwich structure with GFRP facing layers and honeycomb core. It incorporates the pneumatic de-icing boots.
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57-10-00
CENTER WING Description The wing fuselage attachment fittings are a conventional steel design. Two fittings are bolted to a forward fuselage frame , another two fittings are bolted to an aft fuselage frame providing four wing attachment lugs. These lugs match four bushings, two in the main spar and two in the aft spar of the wing. The connection is completed by four high strength corrosion resistant steel bolts installed against flight direction. The lugs of the fuselage fittings feature a high quality thermoplastic liner for bolt surface protection. The design satisfies fail safe requirements, any single bolt may fail.
Removal Refer to Figure 57-1 and Figure 57-2. Wing removal is done by hoisting the wing, removing the fuselage beneath it and lowering the wing on suitable supports. The weight of the (dry) wing including flaps and ailerons is less than 300kg. Be sure that your hoist assembly and lifting straps provide enough load bearing capacity. Special tools required for wing removal: EA-15001.2w (bolt extractor, drawing or tool itself available from EXTRA) Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. T
2 Drain all fuel 3 Remove two avionic bay access panels, the wing center fairing. and the fuel sump access panels.
Refer to Chapter 51-00-01
4 Remove all screws attaching the fuselage skin to the wing.
Don’t forget the two screws underneath the flaps.
5 Disconnect all electric connectors in the avionic bay and center wing nose section.
Required tools are available at a standard avionic shop.
6 Disconnect the main bonding connection in the left forward section of the avionic bay
Hex nut on stud bolt
7 Disconnect tubing for pitot static system and de-ice boots, protect open lines against FOD.
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8 Disconnect aileron control cables.
Three turnbuckles in wing nose section refer to Chapter 27
9 Disconnect all fuel supply lines (one on each side).
Refer to Chapter 28-20-06
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10 Disconnect fuel lines running from and to the jet pumps.
Accessible after removal of avionic bay access panels
11 Carefully separate the silicone sealing between fuselage and wing with a sharp knife. 12 Sling two industrial hoisting straps (at least 2” wide) around the wing center section.
It is helpful to use specially bended welding wire or similar to get the straps through the gap between wing and fuselage.
13 Install the hoisting assembly and relieve the wing fuselage connection. Take care of the attachment flange of the center panel when loading the straps, use wooden blocks or similar to protect the flange. Be sure to attach the hoisting assembly above the wings center of gravity to avoid a nose or tail heavy condition when lifting it. The wing weight is approx. 250 kg (551 lbs). Be sure to provide a lifting force appropriate to this weight to avoid damage to the remaining attachment points by uncontrolled wing movement. This is likely to occur when the attachment bolts are fix, but the wing connections are not fix in all directions any more. 14 Remove safety plates at main spar bolts (also removes electric bonding strips) and safety wire at rear spar securing bolts. Remove rear spar securing washers and bolts (concentric bolt M10) NOTE
Be sure to have at least one person on suitable supports at each wing tip before extracting the second bolt to counteract any undesirable movement of the wing.
NOTE
It is advisable to begin with both bolts on one side to get a feel for the proper relief tension of the hoist assembly while the wing is able to swivel around the remaining bolts. 15 Extract the attachment bolts with special tool.
Extracting tool EA-15001.2w required (See Chapter 01-00-02)
16 Slowly lift the wing from the fuselage and take care of the electric wiring.
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17 As soon as the wing is completely free remove the fuselage underneath the wing and lower the wing on suitable supports with protective lining. (Foam, carpet or similar). The wing should be supported underneath structural ribs, preferably the ribs in front of the gap between the inner and outer flap.
Installation Install in reverse order of removal Install wing attachment bolts with grease.
Aeroshell Grease 22c
Observe special torque values for: Securing bolt rear bolts (Bolt M10) retaining sheets front bolts (two Bolts M5)
Refer to chapter 20-10-04
Side view
Wing hoisting straps
approximate location of CG for lifting wing
Top view
wing attachment bolts
Figure 57-1
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Hoisting the Wing
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Figure 57-2
Wing to Fuselage Attachment
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57-30-00
WING TIPS Description The wing tips are non structural CFRP parts attached to a flange along the wing tip rib. Removing the wing tips gives access to the outer compartment of the wing between the main and aft spar. A transparent polycarbonate cover at the leading edge of the wing tip aerodynamically integrates the Navigation StrobeLight Combination. The wing tips are lightning protected by an outer CFRP layer incorporating a metallic mesh.
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57-50-00
TRAILING EDGE AND TRAILING EDGE DEVICES
57-50-01
Flaps Description Refer to Figure 57-3 and Figure 57-4.The flaps are of one spar dual torsion box all-CFRP-composite construction. For structural reason each flap is divided in two parts. The inboard part extends from Y ± 550 to Y ± 2550, the outboard from Y ± 2550 to Y ± 4400. For adjustment of flap actuation, guidance and position indicating refer to Chapter 27.
Removal/Installation Move flaps to 30° position (wing flap position switch at right main panel). Perform the following steps for LH and RH side flaps each. Detail Steps/Work Items
Key Items
Pull circuit breakers FLAP and FLAP CTRL at left side circuit breaker WARNING panel 1 Remove safety wire from ball at connection rod to watchdog potentiometer 2 Disconnect ball from connecting rod CAUTION
Take care not to move or loosen arm from shaft. Otherwise readjustment will be required as per Ch. 27-50-00
3 Disconnect bolts connecting inner and outer transmission rod to flap bracket
1 hex bolt each
4 Disconnect 2 hex bolts at middle flap track 5 Remove inner flap segment from inboard guidance keyway
It is recommended to get some assistance
6 Remove outer flap segment from outboard guidance keyway
It is recommended to get some assistance
CAUTION
Before re-installation, perform flap track adjustment as per Ch. 27-50-00 Install in reverse sequence of removal
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Figure 57-3
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Inner Flap Structure
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Figure 57-4
Outer Flap Structure
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57-60-00
AILERONS AND ELEVONS Description Refer to Figure 57-5. The ailerons are of one spar dual torsion box all-CFRPcomposite construction. The aileron hinge line is positioned 70% of the wing chord. To prevent flutter they are mass balanced in the overhanging leading edge.
Removal/Installation For removal and installation refer to Chapter 27
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Figure 57-5
Aileron Structure
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Chapter 61 Propeller
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Table of Contents
61-00-00
Page 2
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GENERAL ........................................................................................................ 3 Description.......................................................................................................... 3 Troubleshooting.................................................................................................. 4
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61-00-00
GENERAL Description The EXTRA 500 is equipped with a MTV-5-1-D-C-F-R(A)/CFR210-56 5-blade propeller. The MTV-propeller has a laminated wood composite structure encased by an epoxy-fiber glass cover with metal tipping. The governor regulates the blade pitch for a constant RPM. Internal springs and counter-weights push the blades in high pitch (feather position). Oil pressure pushes them in low pitch and reverse position. Thus in case of an engine failure the propeller will be in a low drag configuration. The propeller is equipped with electrically heated de-icers, bonded to the blades. The electric power is provided by slip rings and a stationary brush assembly. Refer to Chapter 30-60 for further information concerning propeller icing protection. Control, operation and maintenance of the propeller is described in the MT Propeller Operation and Installation Manual E-610 (LOAP 3). The parts and overhaul works are listed and described in the MT - Propeller Overhaul and Parts List E-220 (LOAP 5) For more information consult the propeller manufacturer. For dynamically balancing the propeller refer to Rolls-Royce 250-B17F Series Engine Operation and Maintenance Manual (LOAP 1)
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Troubleshooting Complaint Excessive vibration, rough running
Possible Cause
Remedy
Propeller unbalanced
Dynamically balance propeller according to engine manufacturer’s information
Icing
Switch on propeller de-icing
Blade damage
Foreign object damage
Repair or replace propeller according to propeller manufacturer’s instruction
Spinner or backplate damage
Foreign object or handling damage
Replace by airworthy parts
Blade play
Blade bearing loose
Refer to propeller manufacturer’s instruction
Hub damage
Propeller loose on crankshaft
Refer to engine and propeller manufacturer’s instruction
Improper RPM
Propeller pitch setting out of limits
Refer to propeller manufacturer’s instruction
Governor setting out of limits
Refer to engine manufacturer’s instruction
Malfunctioning propeller governor
Replace governor, for adjustment see engine manufacturer’s instruction
Cold oil
Run engine until normal operating oil temperature is reached
Propeller pitch control mechanism defective on
Refer to propeller manufacturer’s instruction
Trapped air in propeller piston
Cycle propeller control to bleed trapped air
Engine power surge
Refer to engine section, chapter 72
Abrupt control movement
Move controls carefully
Propeller pitch control mechanism defective
Refer to propeller manufacturer’s instruction
Governor defective
Replace governor
Sluggish RPM change
Surging RPM
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Complaint RPM changes at constant propeller setting
Oil leakage
No effect of condition lever control
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Possible Cause
Remedy
Excessive hub friction
Refer to propeller manufacturer’s instruction
Excessive governor friction
Replace governor
Oil leakage or hot oil
Check for leaks, replace gasket, decrease oil temperature
Propeller pitch control mechanism defective
Refer to propeller manufacturer’s instruction
Damaged gasket
Replace gasket or repair propeller
Loss of blade bearing grease
Refer to propeller manufacturer’s instruction
Connection detached
Restore connection
RPM control bracket defective
Restore or replace bracket
Bowden cable broken
Replace Bowden cable
Bowden cable binding
Replace Bowden cable
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Chapter 71 Power Plant
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Table of Contents 71-00-00
GENERAL ........................................................................................................ 3 Troubleshooting.................................................................................................. 3
71-10-01
Engine ................................................................................................................ 3 Removal.............................................................................................................. 3 Installation .......................................................................................................... 5
71-10-00
Cowling .............................................................................................................. 6
71-10-01
Upper Left Cowling .......................................................................................... 6 Removal.............................................................................................................. 6 Installation .......................................................................................................... 6
71-10-02
Upper Right Cowling........................................................................................ 7 Removal.............................................................................................................. 7 Installation .......................................................................................................... 7
71-10-03
Lower Cowling .................................................................................................. 7 Removal/Installation........................................................................................... 7
71-20-00
ENGINE MOUNT ............................................................................................ 8 Description.......................................................................................................... 8
71-20-01
Shock-Mount ..................................................................................................... 8 Removal.............................................................................................................. 8 Installation .......................................................................................................... 9
71-60-00
AIR INTAKES ................................................................................................ 10 Description........................................................................................................ 10
71-60-01
Engine Inlet ..................................................................................................... 10 Removal/Installation......................................................................................... 10
71-70-00
ENGINE DRAINS .......................................................................................... 11 Description........................................................................................................ 11
71-70-01
Engine Fire-Shield Drains.............................................................................. 11 Description........................................................................................................ 11 Removal/Installation......................................................................................... 11
71-70-02
Engine Combustion Chamber Drain ............................................................ 11 Description........................................................................................................ 11 Removal/Installation......................................................................................... 11
71-70-03
Engine Drain Manifold .................................................................................. 12 Description........................................................................................................ 12 Removal/Installation......................................................................................... 12
71-70-04
Overboard Line............................................................................................... 12 Description........................................................................................................ 12 Removal/Installation......................................................................................... 12
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71-00-00
GENERAL For specific repair and replacement information refer to Rolls-Royce 250-B17F Series Engine Operation and Maintenance Manual (LOAP 1).
Troubleshooting For troubleshooting refer to Table 101 of the above-mentioned Manual.
71-10-01
Engine Removal Detail Steps/Work Items
Key Items
1 Set FUEL SELECTOR VALVE to OFF. 2 Switch off all electrical power, disconnect battery. 3 As the balance of the aircraft will dramatically change, put a support under the tail. 4 Remove upper and lower cowlings.
Refer to subjects 71-10-01, 02, -03
5 Remove propeller.
Refer to MT - Propeller Operation and Installation Manual E-610 (LOAP 3)
6 Remove beta-valve.
Refer to Rolls-Royce 250B17F Series Engine Operation and Maintenance Manual (LOAP 1), Chapter 76-10-02
7 Remove brush-block including mounting from engine. 8 Remove engine inlet.
Refer to Subject 71-60-01
9 Remove exhaust stacks.
Refer to Ch. 78-00-01/02
10 Remove bleed air hoses. 11 Remove two sonic venturis. Plug holes. 12 Remove starter generator.
Refer to Chapter 24-30-10
13 Disconnect power line ignition. 14 Disconnect the bonding braid on the ignition exciter attachment bolt.
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Detail Steps/Work Items
Key Items
15 Disconnect the electrical wiring from the chip detection sensors. Fuel may be pressurized (30 psi max). Fuel may spill. Protect yourself WARNING and catch spilling fuel in a suitable container. 16 Disconnect fuel hose at engine fuel inlet. Plug hole and line. 17 Remove fuel manifold from aft engine fireshield. 18 Disconnect the fuel pressure sense line and fitting. Plug hole and line. 19 Remove fuel drain lines from engine fireshield. 20 Remove fuel drain hose from combustion chamber. Plug fitting. 21 Remove engine control mounting bracket
Refer to Chapter 76-10-01
22 Remove gearbox vent line and fitting from engine. Plug hole and line. 23 Disconnect thermocouple wiring from terminal block on RH engine fire-shield.
Refer to Chapter 77-20-01
24 Remove terminal block from RH engine fire-shield.
Refer to Chapter 77-20-02
25 Remove oil vent line and fitting from engine. Plug hole and line. 26 Remove oil vent ‘check valve T’ and connecting hoses. 27 Remove TRQ sense line and fitting. Plug hole and line.
RH forward gearbox
28 Remove oil pressure sense line and fitting. Plug hole and line.
LH forward gearbox
29 Drain oil system.
Refer to Chapter 79-00-00
30 Remove ‘oil in’ hose. 31 Disconnect electrical connector oil temperature sensor. 32 Loosen counter nut of ‘oil in’ fitting, remove fitting. Plug hole and line. 33 Remove ‘oil out’ tube and fitting. Plug check valve and line.
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34 Remove external scavenge oil filter.
Refer to Chapter 79-20-01
35 Disconnect electrical connectors of engine anti-ice and propeller overspeed test.
above engine fire-shield
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Detail Steps/Work Items
Key Items
36 Disconnect electrical wiring standby alternator. 37 Disconnect lightning cable and bonding braid from standby alternator RH attachment stud. 38 Check engine is fully disconnected except main attachment points. 39 Remove upper main attachment bolt.
Mark bolts and nuts as used.
40 Hoist engine slightly though upper shockmount bolt hole.
Hoisting structure must be able to carry at least 150 kg (300 lbs). Align hoist exactly above shock-mount.
41 Support the engine at the combustion chamber. 42 Remove both side main attachment bolts.
Mark bolts and nuts as used.
43 Lower engine 5-10cm (2-4 inch) and pull the engine out straight forward. 44 Remove the side shock-mounts.
Refer to Subject 71-20-01
45 Perform preservation and storage precautions.
Refer to Rolls-Royce 250B17F Series Engine Operation and Maintenance Manual (LOAP 1)
46 Remove upper shock-mount when engine is securely stored.
Refer to Subject 71-20-01
47 Remove standby alternator from engine
Refer to Chapter 24-30-20
48 Remove gas generator turbine tachometer
Refer to Chapter 77-00-01
49 Remove propeller/power turbine RPM sensor.
Refer to Chapter 77-10-02
Installation Detail Steps/Work Items
Key Items
1 Remove engine from container.
Refer to Engine Maintenance Manual
2 Install in reverse sequence of removal.
Observe the following steps.
3 Torque main attachment bolts 32 Nm (283 lbs-inch), use new bolts and nuts 4 Use new packings where necessary. 5 Perform engine control rigging check
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Refer to Chapter 76-00-00
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Detail Steps/Work Items NOTE
Key Items
The propeller must be dynamically balanced if a new engine or new propeller is installed. Refer to Rolls-Royce 250-B17F Series Engine Operation and Maintenance Manual (LOAP 1) 6 Perform applicable engine run tests.
Refer to Rolls-Royce 250B17F Series Engine Operation and Maintenance Manual (LOAP 1), Chapter 72-00-00
7 Perform engine indication check (TOT only) Refer to Chapter 77-00-00
71-10-00
Cowling The EXTRA 500 cowling consists of three parts: • Upper left cowling • Upper right cowling • Lower cowling The upper cowlings are attached by means of cam-locks. The lower cowling is attached with bolts.
71-10-01
Upper Left Cowling Removal Detail Steps/Work Items 1 Unlock all cam-locks.
Key Items 24 cam-locks
2 Raise and remove cowling.
Installation Detail Steps/Work Items
Key Items
1 Set cowling aircraft. 2 Fasten all cam-locks. 3 Check all cam-locks are engaged by firmly hitting the cowling near attachments.
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71-10-02
Upper Right Cowling Removal Detail Steps/Work Items
Key Items
1 Remove upper left cowling first. 2 Remove all cam-locks.
14 cam-locks
3 Raise and remove cowling
Installation Detail Steps/Work Items
Key Items
1 Set cowling aircraft. 2 Fasten all cam-locks.
14 cam-locks
3 Check all cam-locks are engaged by firmly hitting the cowling near attachments.
71-10-03
Lower Cowling Removal/Installation Detail Steps/Work Items 1 Remove upper cowlings first.
Key Items Refer to Subj. 71-10-01/02
2 Disconnect landing light bulkhead connector. 3 Remove bridge tube on forward part of cowling.
4 bolts
4 Remove lower cowling aft attaching bolts.
7 bolts
5 Remove lower cowling as one piece. 6 Disassemble lower cowling if applicable.
4 bolts
7 Install in reverse order of removal.
Make sure that all rubber seals fit properly at intake.
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71-20-00
ENGINE MOUNT Description The steel tube designed engine mount supports the engine and attaches it to the airframe. It is mounted to the airframe at six points with mount supports, using bolts, washers and self-locking type nuts.
71-20-01
Shock-Mount The engine is attached to the engine mount at three points. Each point incorporates a vibration isolator type shock mount assembly capable of sustaining operational loads and providing absorption of engine vibrations. They use the upper and side mounting pads of the engine. For humidity & corrosion prevention MASTINOX is applied to the lower shock-mount surface (contact area to the engine mounting pad).
Removal It is assumed that the engine is not installed in the aircraft (otherwise refer to Subject 71-00-01). Never remove a shock-mount while the engine is installed. CAUTION
Detail Steps/Work Items
Key Items
MASTINOX is highly flammable, toxic and dangerous for the WARNING environment. It may cause cancer and is harmful by inhalation, in contact with skin and if swallowed. Toxic to aquatic organisms, may cause long-term adverse effects in the aquatic environment. Use applicable gloves and respirator mask. 1 Remove lock-wire. 2 Unscrew bolts.
3 bolts
3 Remove shock-mount.
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Installation Detail Steps/Work Items
Key Items
MASTINOX is highly flammable, toxic and dangerous for the WARNING environment. May cause cancer. Harmful by inhalation, in contact with skin and if swallowed. Toxic to aquatic organisms, may cause long-term adverse effects in the aquatic environment. Use applicable gloves and respirator mask. 1 Apply MASTINOX on the lower surface of the shock-mount. 2 Place the shock-mount in position, hand tighten bolts.
3 bolts
3 Torque all three bolts
11.9- 13.0 Nm (105-115 lbs-inch)
4 Lock-wire bolts against each other.
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71-60-00
AIR INTAKES Description The EXTRA 500 has an exhaust heated engine air inlet. It is mounted on the engine compressor flange.
71-60-01
Engine Inlet Removal/Installation Detail Steps/Work Items 1 Remove the RH exhaust stack.
Key Items Refer to Chapter 78-00-02.
2 Unscrew the RH helical metal hose from the inlet. 3 Remove inlet.
12 bolts
4 Unscrew the inlet from the LH helical metal hose. 5 Install in reverse sequence of removal. IMPORTANT
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71
Observe the following hint.
Make sure while setting the length of the helical metallic hose that the forces on the engine flange while attaching the exhaust stack must be minimal. Screw in the helical metallic hose minimum one full turn on each side. Maximum two full turns each side are possible.
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Maintenance Manual EXTRA 500
71-70-00
ENGINE DRAINS Description The EXTRA 500 engine has 5 drain fittings. Fuel, oil or other fluids are collected in the engine manifold and drained overboard.
71-70-01
Engine Fire-Shield Drains Description The engine fire-shield drains are located on the left and right side (two each) of the engine fire-shield. They are connected by aluminum tubing and connected to the drain manifold by hoses.
Removal/Installation Detail Steps/Work Items 1 Remove LH and RH upper cowling.
Key Items Refer to Chapter 71-10-01/02
2 Disconnect hoses from drain manifold. 3 Disconnect drain lines from engine fireshield. 4 Install in reverse sequence of removal.
71-70-02
Make sure all lines are clean
Engine Combustion Chamber Drain Description In case of a false engine start, fuel may collect at the bottom of the combustion chamber. This fuel will be drained through the combustion chamber drain hose to the drain manifold.
Removal/Installation Detail Steps/Work Items 1 Remove LH upper cowling.
Key Items Refer to Chapter 71-10-01
2 Disconnect fittings of the combustion chamber drain hose. Plug fitting. 3 Install in reverse sequence of removal.
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71-70-03
Engine Drain Manifold Description The engine drain manifold is installed at the bottom of the cowling, left forward of the nose gear firewall.
Removal/Installation Detail Steps/Work Items 1 Remove LH upper cowling.
Key Items Refer to Chapter 71-10-01
2 Disconnect all hoses from engine drain manifold. 3 Disconnect engine drain manifold from overboard line and remove. 4 Install in reverse sequence of removal.
71-70-04
Overboard Line Description The overboard line is installed to the left side of the nose gear firewall.
Removal/Installation Detail Steps/Work Items 1 Remove LH upper cowling.
Key Items Refer to Chapter 71-10-01
2 Disconnect overboard line from engine drain manifold. 3 Remove the two hose clamps at the nose wheel bay firewall LH side. 4 Remove overboard line. 5 Install in reverse sequence of removal.
Observe the following
Refer to Product Label and Material Safety Data Sheet for health and WARNING safety information before using PR812. 6 Seal any opening in the firewall with PR812.
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Chapter 73 Engine Fuel and Control
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Page 1
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Table of Contents
73-00-00
GENERAL ........................................................................................................ 3
73-30-00
Indicating........................................................................................................... 3 Description.......................................................................................................... 3
73-30-01
Fuel Pressure Transducer................................................................................ 3 Description.......................................................................................................... 3 Removal/Installation........................................................................................... 3
73-30-02
Low Fuel Pressure Switch................................................................................ 4 Description.......................................................................................................... 4 Removal/Installation........................................................................................... 4
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73-00-00
GENERAL For specific repair and replacement information refer to Rolls-Royce 250-B17F Series Engine Operation and Maintenance Manual (LOAP 1).
73-30-00
Indicating Description The fuel indication consists of fuel pressure and a low fuel pressure warning in the annunciator panel. The fuel pressure indication is described in 77-40-02
73-30-01
Fuel Pressure Transducer Description The fuel pressure transducer is located in the engine compartment, in the sensor block mounted on the LH side of the battery mount, the most forward upper sensor (refer to Figure 77-1).
Removal/Installation Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. 2 Remove LH upper cowling.
Refer to Chapter 71-10-01
3 Disconnect electrical connector. Fuel may be pressurized (30 psi max). Fuel may spill. Protect yourself WARNING and catch spilling fuel in a suitable container. 4 Remove transducer from fuel pressure manifold. 5 Install in reverse sequence of removal.
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Replace O-ring when necessary.
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73-30-02
Low Fuel Pressure Switch Description The low fuel pressure switch is located in the engine compartment, in the sensor block mounted on the LH side of the battery mount, the most forward sideward sensor (refer to Figure 79-1).
Removal/Installation Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. 2 Remove LH upper cowling.
Refer to Chapter 71-10-01
3 Disconnect electrical connector. Fuel may be pressurized (30 psi max). Fuel may spill. Protect yourself WARNING and catch spilling fuel in a suitable container. CAUTION
Never force the body of the sensor to turn against friction. It may change the set-point. Always use a key on the attachment fitting for removal and installation
4 Remove sensor. 5 Install in reverse sequence of removal.
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Chapter 74 Ignition
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Page 1
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Table of Contents
74-00-00
Page 2
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GENERAL ........................................................................................................ 3
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Maintenance Manual EXTRA 500
74-00-00
GENERAL Ignition on the EXTRA 500 is only needed at engine start. For safety reasons it is also switched on at take-off and landing and in severe weather conditions (heavy rain, icing etc). The ignition switch is integrated in the start switch (refer to Chapter 80-00-00). For specific repair and replacement information refer to Rolls-Royce 250-B17F Series Engine Operation and Maintenance Manual (LOAP 1).
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Maintenance Manual EXTRA 500
Chapter 76 Engine Controls
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Page 1
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Table of Contents
76-00-00
Figure 76-1
GENERAL ........................................................................................................ 3 Description.......................................................................................................... 3 Rigging Check .................................................................................................... 3 Engine Control Lever Travel Schematic ............................................................ 4
76-10-00
POWER CONTROL ........................................................................................ 5
76-10-01
Engine Control Mounting Bracket ................................................................. 5 Description.......................................................................................................... 5 Removal/Installation........................................................................................... 5 Engine Control Mounting Bracket ..................................................................... 6
Figure 76-2 76-10-02
Throttle Quadrant ............................................................................................ 7 Description.......................................................................................................... 7 Removal.............................................................................................................. 7 Installation .......................................................................................................... 8
76-10-03
Power Lever Bowden Cable............................................................................. 8 Description.......................................................................................................... 8 Removal.............................................................................................................. 8 Installation .......................................................................................................... 9
76-10-04
Condition Lever Bowden Cable .................................................................... 10 Description........................................................................................................ 10 Removal............................................................................................................ 10 Installation ........................................................................................................ 10
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76-00-00
GENERAL For specific repair and replacement information refer to Rolls-Royce 250-B17F Series Engine Operation and Maintenance Manual (LOAP 1).
Description The EXTRA 500 engine is controlled with two levers located in the middle console: The power lever and the condition lever. Two Bowden cables are routed through the firewall to the engine coordinator. On the engine control mounting bracket, two microswitches are mounted. The upper microswitch signals that the engine fuel is shut-off and has the function to shut-off the bleed air when the engine is shut down. The lower is connected to the LOW PITCH caution light on the annunciator panel.
Rigging Check Detail Steps/Work Items
Key Items
1 Remove LH upper cowling.
Refer to Chapter 71-10-01
2 Perform engine manufacturer prepared rigging check.
Refer to Rolls-Royce 250B17F Series Engine Operation and Maintenance Manual (LOAP 1), Chapter 76-00-00, page 201.
3 Check that the upper microswitch switches 2-3 mm before the cut-off position is reached.
Adjust by bending the microswitch arm
4 Check that the lower microswitch switches the LOW PITCH caution light on at 37°-39° (as indicated on the engine coordinator) moving to a lesser angle.
Adjust by bending the microswitch arm
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Condition Lever
Power Lever
Maintenance Manual EXTRA 500
Figure 76-1 Page 4
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Engine Control Lever Travel Schematic Page Date: 30. March 2012
Maintenance Manual EXTRA 500
76-10-00
POWER CONTROL
76-10-01
Engine Control Mounting Bracket Description The engine control mounting bracket is installed on the engine coordinator and holds both engine control Bowden cables and 2 microswitches (refer to Figure 76-2).
Removal/Installation Detail Steps/Work Items 1 Remove LH upper cowling.
Key Items Refer to Chapter 71-10-01
2 Disconnect electrical wiring of the microswitches. 3 Remove the Bowden cable rod ends from the engine control levers. 4 Remove Bowden cables from bracket flange. 5 Remove the two side supports of the bracket.
2 screws
6 Remove the bracket.
2 screws
7 Install in reverse sequence of removal. 8 Perform engine control rigging check.
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Refer to Subject 76-00-00
76
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Figure 76-2
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Rear View
Screws
0° position (reverse)
Side support
Low pitch switch
Bleed air shut off switch
Side View Cut off position
Screws
Flange
Engine control mounting bracket
Power lever Bowden cable
Condition lever Bowden cable
Maintenance Manual EXTRA 500
Engine Control Mounting Bracket
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Maintenance Manual EXTRA 500
76-10-02
Throttle Quadrant Description The throttle quadrant is installed in the cockpit middle console. It includes the power and condition levers as well as the pitch trim wheel and indicator.
Removal Detail Steps/Work Items
Key Items
1 Remove the trim wheel. 2 Remove the power lever handle. 3 Remove the condition lever handle. 4 Remove the upper part of the middle console paneling.
Refer to Chapter 25-10-26
5 Remove the both Bowden cable rod-ends and flanges from the quadrant 6 Remove static pressure hoses and cabin pressure sensors from support rod. 7 Remove 4 screws on top of the quadrant cover. CAUTION
Do not bend or dent the trim tubing. Bending or denting it will increase pitch trim friction to an unacceptable level.
8 Detach the trim controller. 9 Remove support tube. 10 Remove quadrant.
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Installation Detail Steps/Work Items
Key Items
1 Reverse sequence of removal. PR 1750 accelerator contains harmful vapors and is readily absorbed WARNING through the skin. Avoid all contact with the skin and ingestion. Always wash hands before eating or smoking. Use adequate ventilation, hand protection and chemical-type goggles when working with this product. If accelerator contacts skin, flush area with warm water. Obtain medical attention in cases of extreme exposure or ingestion. PR 1750 sealant contains solvents. WARNING Use adequate ventilation or air-supplied respirators during application. Avoid repeated or prolonged breathing of vapors. In case of extreme vapor exposure, remove affected personnel to fresh air immediately and obtain medical attention. For complete health and safety information, a material safety data sheet is available from the manufacturer. 2 If the lower bolts of the support tube have been loosened or removed seal it with PR1750. 3 Perform an engine control rigging check.
Refer to Subject 76-00-00
4 Check the function of the back-up microphone.
76-10-03
Power Lever Bowden Cable Description The Power lever Bowden cable connects the power lever in the cabin with the input power lever of the engine coordinator.
Removal Detail Steps/Work Items
Key Items
1 Remove LH upper cowling.
Refer to Chapter 71-10-01
2 Remove upper part of the middle console paneling.
Refer to Chapter 25-10-26
3 Remove the power Bowden cable (LH) rodends and flanges from the quadrant.
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Detail Steps/Work Items
Key Items
4 Remove the Bowden cable rod-ends and flanges from the input power lever of the engine coordinator and engine control mounting bracket. 5 With a firm pull, remove the Bowden cable from the firewall.
Installation Detail Steps/Work Items
Key Items
1 Reverse sequence of removal. Refer to Product Label and Material Safety Data Sheet for health and WARNING safety information before using PR812. 2 Seal the Bowden cable firewall breakthrough with PR812 from the engine compartment side. PR 1750 accelerator contains harmful vapors and is readily absorbed WARNING through the skin. Avoid all contact with the skin and ingestion. Always wash hands before eating or smoking. Use adequate ventilation, hand protection and chemical-type goggles when working with this product. If accelerator contacts skin, flush area with warm water. Obtain medical attention in cases of extreme exposure or ingestion. PR 1750 sealant contains solvents. WARNING Use adequate ventilation or air-supplied respirators during application. Avoid repeated or prolonged breathing of vapors. In case of extreme vapor exposure, remove affected personnel to fresh air immediately and obtain medical attention. For complete health and safety information, a material safety data sheet is available from the manufacturer. 3 Seal the Bowden cable firewall breakthrough with PR1750 from the cabin side. 4 Perform an engine control rigging check.
Refer to Subject 76-00-00
5 Check the function of the back-up microphone.
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76-10-04
Condition Lever Bowden Cable Description The condition lever Bowden cable connects the condition lever in the cabin with the condition lever of the engine coordinator.
Removal Detail Steps/Work Items
Key Items
1 Remove LH upper cowling.
Refer to Chapter 71-10-01
2 Remove upper part of the middle console paneling.
Refer to Chapter 25-10-26
3 Remove the condition Bowden cable (RH) rod-ends and flanges from the quadrant. 4 Remove the Bowden cable rod-ends and flanges from the condition lever of the engine coordinator and engine control mounting bracket. 5 With a firm pull, remove the Bowden cable from the firewall.
Installation Detail Steps/Work Items
Key Items
1 Reverse sequence of removal. Refer to Product Label and Material Safety Data Sheet for health and WARNING safety information before using PR812. 2 Seal the Bowden cable firewall breakthrough with PR812 from the engine compartment side. PR 1750 accelerator contains harmful vapors and is readily absorbed WARNING through the skin. Avoid all contact with the skin and ingestion. Always wash hands before eating or smoking. Use adequate ventilation, hand protection and chemical-type goggles when working with this product. If accelerator contacts skin, flush area with warm water. Obtain medical attention in cases of extreme exposure or ingestion.
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Detail Steps/Work Items
Key Items
PR 1750 sealant contains solvents. WARNING Use adequate ventilation or air-supplied respirators during application. Avoid repeated or prolonged breathing of vapors. In case of extreme vapor exposure, remove affected personnel to fresh air immediately and obtain medical attention. For complete health and safety information, refer to Le Joint Francais material safety data sheet PR 1750 (LOAP 41). 3 Seal the Bowden cable firewall breakthrough with PR1750 from the cabin side.
For mixing and application of PR 1750 sealant refer to manufacturer's instructions.
4 Perform an engine control rigging check.
Refer to Subject 76-00-00
5 Check the function of the back-up microphone.
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Maintenance Manual EXTRA 500
Chapter 77 Engine Indicating
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Page 1
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Table of Contents
77-00-00
GENERAL ........................................................................................................ 3 Description.......................................................................................................... 3 Engine Indication Check .................................................................................... 4 Normal Ground Idle Engine Indication .............................................................. 4
77-00-01
Gas Generator Turbine Tachometer (N1)...................................................... 4 Removal.............................................................................................................. 4 Installation .......................................................................................................... 5
77-10-00
POWER ............................................................................................................. 6
77-10-01 Figure 77-1
Torque Transducer........................................................................................... 6 Engine Indication Transducers and Switches .................................................... 6 Removal.............................................................................................................. 6 Installation .......................................................................................................... 7
77-10-02
Torque Switch ................................................................................................... 7 Removal/Installation........................................................................................... 7
77-10-03
Propeller/Power Turbine RPM Sensor (N2) .................................................. 7 Removal.............................................................................................................. 7 Installation .......................................................................................................... 8
77-20-00
TEMPERATURE ............................................................................................. 9
77-20-01
Thermocouple Wiring ...................................................................................... 9
77-20-02
Thermocouple Terminal Block........................................................................ 9
77-40-00
INTEGRATED ENGINE INSTRUMENT SYSTEMS............................... 10
77-40-01
Analog Engine Indicator Cluster .................................................................. 10 Removal/Installation......................................................................................... 10
77-40-02
Digital Engine Indicator Cluster ................................................................... 10 Removal/Installation......................................................................................... 10
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77-00-00
GENERAL For specific repair and replacement information refer to Rolls-Royce 250-B17F Series Engine Operation and Maintenance Manual (LOAP 1).
Description The indication of engine parameters is presented on two integrated engine instruments in the LH instrument panel. The upper unit is an analog-digital unit which displays: • TRQ in percent • TOT in degree Celcius • N1 (compressor) in percent • N2 (propeller) in RPM • Oil pressure in psig • Oil temperature in degree Celcius Although these parameters are displayed in one unit, they all have their separate modules and are independent of each other. The same is valid for the lower display unit which displays digital values only: • Bus voltage • Generator current in ampere • Battery current in ampere • Indicated outside air temperature in degree Celcius • Fuel temperature in degree Celcius • Fuel pressure in psig
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Engine Indication Check The engine indication check consists of a engine run test in which the plausibility of the indications are checked apart from obvious things like oil system leakage if the oil pressure sensor has been exchanged. Detail Steps/Work Items
Key Items
1 Before the engine run, check that all pressure and RPM indications are zero and temperature indications in line with the OAT. 2 Start the engine.
Follow EXTRA 500 Pilot’s Operating Handbook procedures.
3 Set in ground idle. 4 Check engine indication is around the values Refer to Normal Ground Idle given in the following table. Engine Indication table
Normal Ground Idle Engine Indication
77-00-01
TRQ
~10%
TOT
~540°C
N1
~65%
N2
~1750 RPM
OP
~90 psig
OT
In green area
FP
>10 psig
Gas Generator Turbine Tachometer (N1) The gas generator turbine tachometer is installed on the LH forward engine gearbox.
Removal Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. 2 Remove LH upper cowling.
Refer to Chapter 71-10-01
3 Disconnect electrical connector.
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Detail Steps/Work Items
Key Items
4 Remove tachometer
Installation Detail Steps/Work Items
Key Items
1 Reverse sequence of removal.
Apply some engine oil to the drive-spline before installing.
2 Perform engine indication check.
Refer to Subject 77-00-00
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77-10-00
POWER
77-10-01
Torque Transducer The torque transducer is located in the engine compartment, on the LH side of the battery, the aft sensor.
Side View fwd
Transducers
Battery attachment frame Switches
OIL
T RQ
FUEL
Sensing lines
To accumulator
Firewall Figure 77-1
Engine Indication Transducers and Switches
Removal Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. 2 Remove LH upper cowling.
Refer to Chapter 71-10-01
3 Disconnect electrical connector. Page 6
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Detail Steps/Work Items
Key Items
4 Remove lock-wire. 5 Remove torque transducer
Installation Detail Steps/Work Items
Key Items
1 Reverse sequence of removal.
Replace o-ring when necessary.
2 Perform engine indication check.
Refer to Subject 77-00-00
77-10-02
Torque Switch The torque switch is located in the engine compartment, on the LH side of the battery, the aft sideward sensor (refer to Figure 79-1).
Removal/Installation Detail Steps/Work Items 1 Remove LH upper cowling.
Key Items Refer to Chapter 71-10-01
2 Disconnect electrical connector. CAUTION
Never force the body of the sensor to turn against friction. It may change the set-point. Always use a wrench on the spanner flats of the attachment fitting for removal and installation.
3 Remove torque switch. 4 Reverse sequence of removal.
77-10-03
Apply Loctite 577 to torque switch thread
Propeller/Power Turbine RPM Sensor (N2) The propeller tachometer is installed on the RH forward engine gearbox.
Removal Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. 2 Remove upper cowlings.
Refer to Ch. 71-10-01/02
3 Disconnect electrical connector.
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Detail Steps/Work Items
Key Items
4 Remove tachometer.
Installation Detail Steps/Work Items
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Key Items
1 Reverse sequence of removal.
Apply some engine oil to the drive-spline before installing.
2 Perform engine indication check.
Refer to Subject 77-00-00
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77-20-00
TEMPERATURE Engine temperature is measured using K-type thermocouples and indicated as TOT to the pilot.
77-20-01
Thermocouple Wiring The thermocouple wiring from the terminal block (77-20-02) to the indicator is Chromel – Alumel for the entire length, including connector pins. If any of this wiring is to be replaced, wiring of the same material shall be used. Perform engine indication check as per Subject 77-00-00.
77-20-02
Thermocouple Terminal Block Engine thermocouple wiring and aircraft thermocouple wiring is connected at the thermocouple terminal block. It is installed in the engine compartment on the RH engine fire-shield. It is crucial that the Chromel and Alumel wires from the engine are correctly connected to those of the aircraft. Observe the following table: Material Chromel Pos (+) Alumel
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Neg (-)
Aircraft wiring
Engine wiring
Yellow
White
Small diameter stud
Red
Green
Large diameter stud
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77-40-00
INTEGRATED ENGINE INSTRUMENT SYSTEMS
77-40-01
Analog Engine Indicator Cluster The analog engine indicator cluster is installed in the LH instrument panel.
Removal/Installation Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. 2 Remove the RH and LH IFD.
Refer to Chapter 31-60-01
3 Disconnect both electrical connectors 4 Remove indicator cluster. 5 Install in reverse sequence of removal. 6 Perform engine indication check.
77-40-02
Refer to Subject 77-00-00
Digital Engine Indicator Cluster The digital engine indicator cluster is installed in the LH instrument panel just below the analog engine indicator cluster.
Removal/Installation Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. 2 Remove the RH and LH IFD.
Refer to Chapter 31-60-01
3 Disconnect electrical connector. 4 Remove 4 bolts
Use a ratchet with adequate prolongation for holding nuts in place.
5 Remove indicator. 6 Install in reverse sequence of removal. 7 Perform engine indication check.
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Refer to Subject 77-00-00
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Chapter 78 Exhaust
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Page 1
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Table of Contents
78-00-00
GENERAL ........................................................................................................ 3 Description.......................................................................................................... 3
78-00-01
LH Exhaust Stack............................................................................................. 3 Removal/Installation........................................................................................... 3
78-00-02
RH Exhaust Stack............................................................................................. 3 Removal/Installation........................................................................................... 3
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78-00-00
GENERAL Description The exhaust system of the EXTRA 500 consists of two exhaust stacks, which flanged to the engine with a V-band clamp.
78-00-01
LH Exhaust Stack Removal/Installation Detail Steps/Work Items
Key Items
1 Remove the LH and RH upper cowlings.
Refer to Chapter 71-10-01/02
2 Remove the lower cowling.
Refer to Chapter 71-10-03
3 Remove engine anti-ice Bowden cable (from exhaust stack only) and micro switch.
Refer to Chapter 30-20-01/02
4 Remove the V-band clamp. 5 Remove engine gear box vent line from exhaust stack. 6 Unscrew the LH exhaust stack from the helical metal hose. 7 Install in reverse sequence of removal. IMPORTANT
78-00-02
Observe the following hint.
Make sure while setting the length of the helical metallic hose that the forces on the engine flange while attaching the exhaust stack must be minimal. Screw in the helical metallic hose minimum one full turn on each side. Maximum two full turns each side are possible.
RH Exhaust Stack Removal/Installation Detail Steps/Work Items
Key Items
1 Remove the LH and RH upper cowlings.
Refer to Chapter 71-10-01/02
2 Remove the lower cowling.
Refer to Chapter 71-10-03
3 Remove the V-band clamp. 4 Unscrew the RH exhaust stack from the helical metal hose. 5 Install in reverse sequence of removal. Page Date: 30. March 2012
Observe the following hint.
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Detail Steps/Work Items IMPORTANT
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Key Items
Make sure while setting the length of the helical metallic hose that the forces on the engine flange while attaching the exhaust stack must be minimal. Screw in the helical metallic hose minimum one full turn on each side. Maximum two full turns each side are possible.
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Maintenance Manual EXTRA 500
Chapter 79 Oil
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Table of Contents
79-00-00
GENERAL ........................................................................................................ 3 Description.......................................................................................................... 3 Troubleshooting.................................................................................................. 3 Oil System Draining ........................................................................................... 3
79-10-00
STORAGE......................................................................................................... 4 Description.......................................................................................................... 4
79-10-01
Engine Oil Supply Tank................................................................................... 4 Draining .............................................................................................................. 4 Removal/Installation........................................................................................... 4
79-10-02
Overpressure Valve .......................................................................................... 5 Removal.............................................................................................................. 5 Installation .......................................................................................................... 5
79-20-00
DISTRIBUTION............................................................................................... 6
79-20-01
External Scavenge Oil Filter............................................................................ 6 Filter Element Replacement ............................................................................... 6 Removal/Installation........................................................................................... 6
79-20-02
Engine Oil Cooler ............................................................................................. 7 Draining .............................................................................................................. 7 Removal/Installation........................................................................................... 7
79-20-03
Oil Thermostat .................................................................................................. 7 Removal/Installation........................................................................................... 7
79-20-04
Oil Lines............................................................................................................. 8 Draining .............................................................................................................. 8
79-30-00
INDICATION ................................................................................................... 9
79-30-01
Oil Pressure Transducer .................................................................................. 9 Removal.............................................................................................................. 9 Installation ........................................................................................................ 10
79-30-02
Oil Temperature Sensor................................................................................. 10 Removal............................................................................................................ 10 Installation ........................................................................................................ 10
79-30-03
Oil Pressure Switch ........................................................................................ 10 Removal............................................................................................................ 10 Installation ........................................................................................................ 11
Page 2
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Maintenance Manual EXTRA 500
79-00-00
GENERAL For specific repair and replacement information refer to Rolls-Royce 250-B17F Series Engine Operation and Maintenance Manual (LOAP 1).
Description The EXTRA 500 oil system includes the following external components that do not belong to the engine. • Engine oil supply tank • Oil vent system • External scavenge oil filter • Engine oil cooler
Troubleshooting Complaint
Possible Cause
Remedy
Oil pressure at high altitude too low
Oil tank not pressurized
Check oil vent system, Refer to Subject 79-10-00
Excessive oil consumption
3 psi overpressure vent valve open
Replace valve, Refer to Subject 79-10-02
External oil filter pin popped
External oil filter element clogged
Exchange external oil filter element, Refer to Subject 79-20-01
Oil System Draining The complete oil system can be drained using the following procedure. Detail Steps/Work Items
Key Items
1 Drain engine oil supply tank.
Refer to Subject 79-10-01
2 Drain engine oil cooler.
Refer to Subject 79-20-02
3 Drain oil lines.
Refer to Subject 79-20-04
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79
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Maintenance Manual EXTRA 500
79-10-00
STORAGE Description The engine oil supply tank is located in the engine compartment, mounted on the RH engine mount. The oil supply tank is vented to the engine gearbox over a 2 psid overpressure valve. In case this valve fails to open, the tank is vented overboard through a 3 psid overpressure valve. The reason for the oil tank pressurization is to prevent too low oil pressure in high altitude. Both overpressure valves are installed in the engine compartment on the RH side of the engine mount ring. They are directly connected to the vent line Tfitting.
79-10-01
Engine Oil Supply Tank Draining Detail Steps/Work Items 1 Remove upper cowlings.
Key Items Refer to Chapter 71-10-01/02
2 Place an ‘oil slide’ under the lower engine oil supply tank fitting to an appropriate canister. 3 Disconnect the lower engine oil supply tank fitting and drain the oil from the tank. 4 Drain hose if applicable.
Refer to Subject 79-20-04
Removal/Installation Detail Steps/Work Items
Key Items
1 Drain oil supply tank.
Refer to Draining Paragraph
2 Disconnect upper hoses. Plug hose fittings.
2 hoses
3 Remove oil supply tank.
2 worm drive hose clamps and 1 bolt
4 Install in reverse sequence of removal. 5 Re-fill tank with oil to the appropriate level.
Page 4
79
Refer to Chapter 12-10-04
Page Date: 30. March 2012
Maintenance Manual EXTRA 500
79-10-02
Overpressure Valve Removal Detail Steps/Work Items 1 Remove upper cowlings.
Key Items Refer to Chapter 71-10-01/02
2 Disconnect hose from overpressure valve. 3 Unscrew valve from T-fitting.
Installation Detail Steps/Work Items 1 Reverse sequence of removal.
Key Items Replace O-ring when necessary.
2 Check the 2 psi valve is connected to the hose routed to the engine gearbox. 3 Check the 3 psi valve is connected to the hose routed overboard. 4 Check the arrows on both valves point away from the T-fitting.
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79
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Maintenance Manual EXTRA 500
79-20-00
DISTRIBUTION
79-20-01
External Scavenge Oil Filter The external oil filter is located in the engine compartment, on the lower mount pad of the engine.
Filter Element Replacement Detail Steps/Work Items 1 Disconnect oil lines from external oil filter.
Key Items Use a funnel to collect oil from lines in a suitable container.
2 Remove lock-wire upper body – lower body. 3 Unscrew the lower part of the filter body. 4 Replace filter element. 5 Lubricate o-ring with engine oil. 6 Install lower filter body.
Hand tighten only
7 Lock-wire upper body against lower body. 8 Re-fill tank with oil to the appropriate level.
Removal/Installation Detail Steps/Work Items
Key Items
1 Disconnect oil lines from external oil filter.
Use a funnel to collect oil from lines in a suitable container.
2 Disconnect hoses from oil filter.
Plug ends.
3 Remove oil filter. 4 Install in reverse sequence of removal. 5 Refill tank with oil to the appropriate level.
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Maintenance Manual EXTRA 500
79-20-02
Engine Oil Cooler The oil cooler is installed in the engine compartment on the RH side
Draining Detail Steps/Work Items
Key Items
1 Remove upper cowlings.
Refer to Chapter 71-10-01/02
2 Remove lower cowling.
Refer to Chapter 71-10-03
3 Place an “oil slide” under the lower engine oil cooler fitting to an appropriate canister. 4 Disconnect the lower engine oil cooler fitting and drain the oil from the oil cooler. 5 Drain hose if applicable.
Refer to Subject 79-20-04
Removal/Installation Detail Steps/Work Items 1 Drain engine oil cooler.
Key Items Refer to Draining Paragraph
2 Disconnect upper hose. 3 Remove forward air duct. 4 Remove cooler from aft airduct.
The aft airduct can be removed from the structure to gain better access to the aft airduct to cooler mounting bolts.
5 Install in reverse sequence of removal.
79-20-03
Oil Thermostat The oil thermostat is mounted in the oil cooler housing at outlet to oil tank.
Removal/Installation Detail Steps/Work Items 1 Remove upper cowlings.
Key Items Refer to Chapter 71-10-01/02
2 Remove lock-wire. 3 Unscrew oil thermostat. 4 Install in reverse sequence of removal.
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Maintenance Manual EXTRA 500
79-20-04
Oil Lines Draining Detail Steps/Work Items
Key Items
1 Remove upper cowlings.
Refer to Chapter 71-10-01/02
2 Remove lower cowling.
Refer to Chapter 71-10-03
3 Place suitable “oil slides” and/or canisters under the lower oil line fittings. 4 Disconnect hoses or tubes on lower fittings and drain.
Page 8
79
Hold open hose end downward where necessary.
Page Date: 30. March 2012
Maintenance Manual EXTRA 500
79-30-00
INDICATION Top View fwd
Transducers
Spanner flats
FUEL
OIL
TRQ
Switches
Figure 79-1
79-30-01
Engine Indication Transducers and Switches
Oil Pressure Transducer The oil pressure transducer is located in the engine compartment, on the LH side of the battery, the middle sensor on top (refer to Figure 77-1 and 79-1).
Removal Detail Steps/Work Items 1 Remove LH upper cowling.
Key Items Refer to Chapter 71-10-01
2 Disconnect electrical connector. 3 Remove lock-wire. 4 Remove oil pressure transducer. Page Date: 30. March 2012
79
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Maintenance Manual EXTRA 500
Installation Detail Steps/Work Items
79-30-02
Key Items
1 Reverse sequence of removal.
Replace o-ring when necessary.
2 Perform engine indication check
Refer to Chapter 77-00-01
Oil Temperature Sensor The oil temperature sensor is installed in the engine compartment on the LH forward engine gearbox, at oil-in-connection fitting.
Removal Detail Steps/Work Items 1 Remove LH upper cowling.
Key Items Refer to Chapter 71-10-01
2 Disconnect electrical connector. 3 Remove lock-wire. 4 Remove oil temperature sensor from fitting.
Use a funnel to collect oil from line in a suitable container.
5 Plug oil temperature sensor fitting.
Installation Detail Steps/Work Items
79-30-03
Key Items
1 Reverse sequence of removal.
Replace o-ring when necessary.
2 Perform engine indication check
Refer to Chapter 77-00-01
Oil Pressure Switch The oil pressure switch is located in the engine compartment, on the LH side of the battery, the middle sideward sensor (refer to Figure 79-1).
Removal Detail Steps/Work Items 1 Remove LH upper cowling.
Key Items Refer to Chapter 71-10-01
2 Disconnect electrical connector.
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Maintenance Manual EXTRA 500
Detail Steps/Work Items CAUTION
Key Items
Never force the body of the sensor to turn against friction. It may change the set-point. Always use a wrench on the spanner flats of the attachment fitting for removal and installation.
3 Remove oil pressure switch.
Installation Detail Steps/Work Items
Key Items
1 Reverse sequence of removal.
Apply Loctite 577 to pressure switch thread
2 Perform engine indication check
Refer to Chapter 77-00-01
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Intentionally left blank
Page 12
79
Page Date: 30. March 2012
Maintenance Manual EXTRA 500
Chapter 80 Starting
Page Date: 30. March 2012
80
Page 1
Maintenance Manual EXTRA 500
Table of Contents
80-00-00
GENERAL ........................................................................................................ 3 Description.......................................................................................................... 3
80-10-00
CRANKING ...................................................................................................... 4 Motoring ............................................................................................................. 4
Page 2
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Maintenance Manual EXTRA 500
80-00-00
GENERAL For specific repair and replacement information refer to Rolls-Royce 250-B17F Series Engine Operation and Maintenance Manual (LOAP 1).
Description The ENGINE START switch is located on the instrument panel and has three positions: • START • IGN • IGN OFF
Engine starting on the EXTRA 500 is semi-automatic. The start switch is shortly set at START and automatically falls back in the IGN setting. This will initiate the start cycle directed by the Generator Control Unit and performed by the starter generator. The condition lever must be set during the cycle to add fuel. See EXTRA 500 Pilot’s Operating Handbook for exact procedure. When the engine has reached a certain RPM (N1), the starter will automatically switch off. Ignition must be switched off manually to prevent excessive spark plug wear.
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80
Page 3
Maintenance Manual EXTRA 500
80-10-00
CRANKING Cranking may be accomplished with the ENGINE MOTORING switch, located next to the ENGINE START switch. The ENGINE MOTORING switch has three positions: • MOTORING • ABORT • NORMAL
NOTE
For a normal engine start, the ENGINE MOTORING switch MUST be in the NORMAL position. Always return the switch in the NORMAL position. The ABORT position is to abort a normal engine start. It will immediately switch off the electrical starter and ignition. It does not cut the fuel.
Motoring Do not motor the engine while aircraft jacked. CAUTION Motoring may be used for maintenance and to cool down the engine prior to engine start to prevent a hot start. Normally, a TOT of below 100°C and a good battery will produce a start within limits. Detail Steps/Work Items
Key Items
1 Secure aircraft with wheel chocks. 2 Perform Before Starting Engine procedure.
Refer to EXTRA 500 Pilot’s Operating Handbook, Section 4
3 Check condition lever in CUT OFF. During motoring the propeller will turn and exhaust gasses will be hot. WARNING Make sure no one or nothing can be struck by a propeller blade or is in the propeller/exhaust jet stream. CAUTION
Motoring is the same as starting for the starter generator. Apply the normal starter limits to motoring also: Three times 30 seconds max. with a 60 second cool down period. After the third time, wait at least one half hour.
4 Switch and hold MOTORING. 5 Check oil pressure indication. 6 Return the switch to ABORT. 7 After motoring switch to NORMAL.
Page 4
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Maintenance Manual EXTRA 500
Chapter 91 Charts
Page Date: 30. March 2012
91
Page 1
Maintenance Manual EXTRA 500
Table of Contents EA-9B213.30A EA-9B215.10B EA-9B215.20A EA-9B235.17 EA-9B243.10A EA-9B243.20A EA-9B243.40A EA-9B243.41A EA-9B244.10A EA-9B244.20 EA-9B246.10A EA-9B252.10A EA-9B252.11A EA-9B256.11 EA-9B271.17B EA-9B271.18A EA-9B273.30A EA-9B275.20A EA-9B276.10A EA-9B284.10A EA-9B284.13A EA-9B284.30 EA-9B303.10A EA-9B304.10A EA-9B304.20A EA-9B310.10A EA-9B314.30B EA-9B315.80B EA-9B315.81 EA-9B315.90B EA-9B316.40A EA-9B316.50A EA-9B317.10A EA-9B323.10A EA-9B323.20A EA-9B334.10A EA-9B334.20A EA-9B334.35A EA-9B334.40A EA-9B334.50A EA-9B334.55A EA-9B334.60A EA-9B334.75A EA-9B334.81A EA-9B334.90A EA-9B334.91A EA-9B342.65 EA-9B342.66 EA-9B342.67 Page 2
91
Cabin Pressure Control, HP Air Condition, HB Bleed Air System MKR / Audio, RM DC Generation I, PP DC Generation II, PR E-Box PCB Board E-Box External Power, PD Battery charge, PL DC Distribution 12V Power receptacle (Cigar Lighter), MM 12V Sockets,TH ELT ARTEX ME 406, DA AutoPilot-STEC-55X, CA Yoke (Control stick) Left, Right Stall Warning, WH Flap-System, CG Prop Overspeed, ES Fuel QTY Indication, QX PCB-Board 1 Low Fuel Warning, WW Pitot-Static-Stall-Heat, HG Anti ICE Intake, HM Windshield Heat, HF Boots, HH Airspeed Warning, WV Annunciator Panel, WW PCB-Board Warning/Annunciator Low Voltage Monitor, WL Digital Instrument Package, EY Engine Instrument Package, EZ Engine Warning, LW Landing Gear Control, GA Gear Warning, GA Strobe Light, LB NAV Light, LC Landing Light, LA Cabin-Dome-MAP Light, LJ Courtesy Light, LY Ice Light, LN Recognition Lights, LF Glare Light Luminiszenz-Backlighting Dimming, LH Dimming IFD LH, FG IFD RH, FG Keypad, FG Page Date: 30. March 2012
Maintenance Manual EXTRA 500
EA-9B342.73 EA-9B344.14 EA-9B344.15 EA-9B344.16 EA-9B344.17 EA-9B345.47 EA-9B345.58 EA-9B360.11 EA-9B527.10 EA-9B731.10A EA-9B731.30A EA-9B731.40A EA-9B743.10A EA-9B752.15A
Attitude Gyro, FM Weather Detec TWX-670, SS Traffic System TAS-610, SD Broadcast MLB-700, TL Datalink 2-way MLX-770, TS DME KDM 706A, SN ATC BXP6402-1R, SH Prop Heat, HI Door Warning Fuel Pump / Filter, QB Fuel Trans, QF Fuel Flow, QY Start / Ignition, JB Panel Fan, HK
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Left blank intentionally
Page 4
91
Page Date: 30. March 2012
D
C
B
LK
-X2
1 2 3 4 5 6 7 8 9 10 11
Aft Door
Stall-Warn
Cab-Press
Gen-Fail
Gear Warn
Flaps
P/N 5111-00-3
Motor Motor + +12V DIAL LITES +28V DIAL LITES
+5V DIAL LITES GND 18-32,5VDC + POTENTIOMETER POTENTIOMETER POTENTIOMETER
COMMEN DIAL LITES
LG15E-22
HP15E-22
HP14E-22
MS27473E10A35S MIL-C-38999-II
ws org bl ws bl
HP2F-22
VV88 HP8E-22N
WW1-20
WW16-22
LG15E-22
100
LG16E-22N
10 1 9 11 2 3 8 13 12 4 7 5 6 4HP-A
4HP-A
HP9F-22
R C S
56k 0.25W
1k2 4W
1A
F3 Lumi Dimm
15 24 25
1
2
3
31
ST1
ANNUNCIATOR BOARD EA-9B315.81 see EA-9B315.80 ANNUNCIATOR PANEL
+ VOLT DIMM
LIGHT TEST (GND)
ANNUNCIATOR BOARD D15 5WW
4
5
LH2-22
LH4-22
5
VV91 VV92
108
3 4 5 6 7 8 9 12 13
EDV-Kennung:
9B21330T 6
Zuordnung links / rechts wird mit */* in allen Feldern angegeben.
MOTOR
6HP
16.09.10
Nr.: Änderung/Mod. Nr.: Datum
ÄM-400-09-01
18.02.11
VV90
C
7
8
Name
PB
Datum
Blatt 1
A von 1
8
Schutzvermerk nach DIN 34 beachten.
A3
EA-9B213.30
CABIN PRESSURE, HP
EA 400-500
Maßstab auf SI.-Klasse Oberflächenschutz
Projektion Freimaßtoleranz Oberfläche
Muß auf 12830 ft eingestellt werden!
27.04.04
Schwarze Heide 21
Gepr.:
Gepr.:
Bearb.:
Anschluß offen
8HP
HW Name 46569 Hünxe, Germany
HW
HP11E-22 HP12E-22
MPL500
AV1 NO
12830 ft SW
DRUCKSCHOTT
DRUCKSCHOTT
Anschluß an Static Press
Differenzdruck
P/N 5112-00-3
+
VACUUM VALVE VACUUM VALVE POTENTIOMETER POTENTIOMETER POTENTIOMETER
10000ft SW
Letzte Bearbeitung:
A
P/N 5113-00-3
DUMP SOLENOID
5HP
Absolutdruck
HP11G-22 HP12F-22N
VV89
7HP
001758_212_02 3VN-A
G
2A
DUMP
CABIN CONTROL OUTFLOW VALVE
D E
A B
SAFTY VALVE
see EA-9B334.90 DIMMING SYSTEM
SWITCHES
ws org bl ws bl
MS27473E10A35S MIL-C-38999-II 6HP 10 1 9 11 2 3 8 13 12 4 7 5 6
HP15E-22
HP14E-22
6HP-A
9HP
7
see EA-9B246.10 DC-DISTRIBUTION
3A
C-PRESS
EMERGENCY BUS PP4 1HP
HP1E-22
5HPA HP3G-22 HP9J-22
Die Gültigkeitszuordnung von Version zu Flugzeugbaureihe ist der Bauakte bzw. dem jeweiligen Fertigungsauftrag zu entnehmen.
cw
4.7k 24LH
04 03 02 01 Ver. Bezeichnung
HP11G-22
5WW-D
47
7
4
2
2HP:1
2HP:2 5
PRESS
DIM CONTROL
SIM
5
HP3F-22 HP9H-22
3 HP3E-22
3 HP9G-22
1 HP9E-22
1
3
DUMP 4
OFF 6
PRESS
3 HP10E-22N
2 HP2E-22
07.2.1.15L
CIRCUIT BREAKER/SWITCH PANEL
6
DRUCKSCHOTT HINTEN MS3116F106S ST14-B MIL-C-26482-I HP13-F22N HP13-E22N
A:2
A:3
D:13
A:4
A:10
27LH-A
19VN-A 001758 212 02
B
HP3F-22
HP9H-22
HP9F-22
HP10F-22N
HP2F-22
DIMMING BOARD EA-9B334.91 see EA-9B334.90 DIMMING SYSTEM
INV
DIMMING BOARD
1VN-E 001758 212 02
5WW-B
26 31
ST1
4
Maintenance Manual EXTRA 500 Chapter 91 30. March 2012
1WW
P/N 90-4219X-1
Annunciator Panel left
+X1
1A 3 1B 3 1C 3 1D
3
see EA-9B323.10 GEAR CONTROL
CABIN PRESSURE CONTROLLER
4HP
2
2
2
2
35GA
M220-B4N Schalterstellung A/C on Air
001758_212_02
1VN-E
VV189
GROUND RELAYS
GA32-22N
A
3
LG16E-22N HP8E-22N HP10F-22N
2
HP11F-22 HP12B-22
1
HP3E-22
D
C
B
A
D
C
7HB
6HB
9HB:2
VENT
:1
100A
VENT
2A
8HB
AIR CON
AIR-CTRL
30A
K4
BATTERY
ST1
m
1
1
HB17E-22
HB18E-22 C:20
C:19
D:2
D:19
C
21 22
HB18F-22
HB17F-22
HB7F-12
HB16F-22
HB2F-4
m n
HB15F-22 HB16F-22
FILTER-1
HB5F-4N
GND-Bolzen Firewall 1VN
HB15G-22 HB16G-22
ST1
FIREWALL
3
1
3
M320
low
M320
X2
3HB
1
2
3
4
D
A
BM-
17HB
B+
HB8F-12
HB8E-12
HB9F-12
HB9E-12
5
001758 212 02 8VN-F
M
B
HB5E-4N
sw/wht
12HB rt/wht
Binary Pressure Switch 1250232-4
rt
4HB Kompressor TEMP. SW. Kondenser Enviro Systems 1134410-5
grn
HB2G-4
P/N: 1240160-5 SOFT START MODULE
red-low
orange-high
14HB
rt
9B21510T 6
ÄM-400-09-02 ÄM-400-09-01 ÄM-400-04-02
Datum
27.04.04
PB
Name
7
PB Name 46569 Hünxe, Germany
16.09.10
Schwarze Heide 21
Gepr.:
Gepr.:
Bearb.:
GROUNDING POINTS
HB10E-12N
8
Blatt 1
B von 1
8
Schutzvermerk nach DIN 34 beachten.
A3
EA-9B215.10
AIR CONDITION 20A, HB
EA 400-500
Projektion Freimaßtoleranz Oberfläche
001458 212 02 8VN
LM
Maßstab auf SI.-Klasse Oberflächenschutz
HB23E-22N
blk
Enviro Systems 1134200-80
1134200-80
HW
HW
13HB
CABIN BLOWER AFT
orange-high red-low
7
17.09.10
23.02.11
Nr.: Änderung/Mod. Nr.: Datum
A
B
Letzte Bearbeitung:
001758 212 02 8VN
HJ
VV94
rt
1134200-81
HB9E-12
HB8E-12 VV93org
MOTOR CONTROL
HB13E-12N HB22E-22N
blk
Zuordnung links / rechts wird mit */* in allen Feldern angegeben.
EDV-Kennung:
C
Enviro Systems 1134200-81
Die Gültigkeitszuordnung von Version zu Flugzeugbaureihe ist der Bauakte bzw. dem jeweiligen Fertigungsauftrag zu entnehmen.
rt
org
6
CABIN BLOWER FO
04 03 02 01 Ver. Bezeichnung
org
VV100
VV97
COMPRESSOR AND CONDENSER FAN
3 1 2
Timer 18HB
HB19E-22N
VV99
5
SOFT START CONTROL
HB14E-22N
2 HB9G-12
X2
2HB VV98
2 HB8G-12
HB15E-22
HB2G-4
am Halteblech Blower Front
HB18F-22X1
HB6F-12
VENT
HB17F-22X1
HB6E-12 1
high
14
SIM
HB15F-22
ST13-D
Bolzen
HB2F-4
Bolzen
HB5E-4N
19VN
DRUCKSCHOTT HINTEN HB5F-4N
4
Maintenance Manual EXTRA 500 Chapter 91 30. March 2012
see EA-9B246.10 DC-DISTRIBUTION
3
1
5
n
HB7E-12
HB16E-22
HB2E-4
E-BOX EA-9B243.40 see EA-9B243.40 E-BOX
HB7E-12
AIR-CON
LOAD BUS PP3
1HB
3
2
LOW1
B
OFF
HB2E-4
CIRCUIT BREAKER/SWITCH PANEL
HI
A
K1
EXT POWER
HB3E-20
3
HB6F-12
K3
2
wht
GENERATOR
ON
HB20E-4 red
E-BOX
1
OFF
5 HB4E-20
4 6
07.2.1.40 901
3
07.1.1.13
HB21E-4 black
2
HB19E-22N HB14E-22N
HB15E-22 HB22E-22N HB13E-12N
1
HB23E-22N HB10E-12N
D
C
B
A
A
B
C
D
1
25 37 35
29 5 31
23 2 22 1
13
10 32
12 33
36 8
Pilot Control +VA Pilot Control Pilot Control GND
Bypass +28V Bypass GND H.Exchanger +28V H.Exchanger GND
Stadby ON
Duct Sensor pos. Duct Sensor GND
Cabin Sensor Pos Cabin Sensor GND
Chassis GND Power GND
3 6
Manual Bypass Man H. Exchanger
Auto/Manual SW Switch GND Switch Power +15VDC
27 9 20
28VDC 28VDC Overtemp Ind Light
+15V GND Input GND
Power GND Logic GND Power GND
Sensor Sensor Sensor Sensor
8 26 36
24 31 5 7
2
37pol DSub
ws bl ws bl
ws bl ws bl
3HA-A VV101
ws bl
ws bl
ws bl ws bl
ws org bl
org bl ws
ws bl
N/C
HA3E-22
HA1G-22
HA19E-22N
HA18E-22
HA17E-22
HA16E-22
HA15E-22
HA14E-22
HA12E-22
HA13E-22
001758 212 02 3VN-A
VV102
S
T
D:10
D:8
D:9
HA22G-22 HA23E-22N
BYW56
2VN-D C 001758 212 02
VV104
D1
66 67 43 68 69 42 70 71 41
20
2
D12
12 24 25
5WW-C
J4
ST4
1 bl
1
1
ws bl
14HA-A A B
HA18F-22
HA17F-22
HA16F-22
HA15F-22
5
2
HA4G-22 16HA:1
ws bl ws bl
9HA-A
HA8E-22 HA10F-22N HA2G-22
Annunciator Panel left
HA18F-22
HA17F-22
HA16F-22
HA15F-22
VV108
Splice
1
HA34E-22N NC HA33E-22 21HA VV109 EA-0B833-09 21544-3-60-2
Temp Sensor
Env. Bleed Temp
A
39
5WW-D
001758 212 02 2VN-D
44
2
BYW56
D38
+VDCII
G6A-234P
3
ANNUNCIATOR BOARD EA-9B315.81
K2
+ VOLT DIMM
LIGHT TEST (GND)
ANNUNCIATOR BOARD 5WW
9
WW39-20N
5WW-A
WW1-20
WW13-22
4
Bleed Overt
Stall-Warn
Cab-Press
Stall-Heat
Windsh-Heat
Aft Door
B D A C
Exch + Exch Bypass + Bypass -
Sensor + Sensor GND 28VDC
10HA
A C B D
Open + Open Close + Close -
11HA
VALVE-FLOW CONTROL
A B D C
9HA
Temp. Modulating Valve
Oil-Press
Fuel-Press
A B C D E F G H
5
1WW
ws bl ws bl
Sens Sens Sens Sens
+ In Gnd
EA-0B833.06
SN 1300464-15
Triebwerkraum links
EA-0B836.33
SN 1300490-13
Co Pilot overhead
SN 1300440 EA-0B833.08
Triewerkraum links
SN 1300330 EA-0B836.26
1
1
EDV-Kennung:
9B21520T 6
Zuordnung links / rechts wird mit */* in allen Feldern angegeben.
04 03 02 01 Ver. Bezeichnung
D:14
C:10
HA1F-22
HA21F-22
ÄM-400-09-01
06.10.10
Name
HW
7
Name
PB
Datum
17.02.04
HA21G-22
7
46569 Hünxe, Germany
Schwarze Heide 21
Gepr.:
Gepr.:
Bearb.:
21 22
ST4
Trennstecker FIREWALL
HA20F-22 HA21F-22
Nr.: Änderung/Mod. Nr.: Datum
A
Letzte Bearbeitung:
CB-Trennstecker
6
Die Gültigkeitszuordnung von Version zu Flugzeugbaureihe ist der Bauakte bzw. dem jeweiligen Fertigungsauftrag zu entnehmen.
P/N 90-42192-1 geändert
12HA Bugfahrwerkkasten
Flow Flow Flow Flow N/C N/C N/C N/C
12HA-A MASS FLOW SENSOR
ws bl ws bl
11HA-A
HA21G-22
HA1E-22
ENV-BLEED 5A
Temp. Poti. Ansicht von hinten.
10HA-A Cabin Temp. Sensor
Triebwerkraum 14HA Brandspant rechts
3 2
P16NM103KA
4
1HA
BATTERY BUS PP2
see EA-9B246.10 DC-DISTRIBUTION
07.2.1.13 5 HA21G-22
2
ENV BLEED
10k
TEMP
5AH:1 07.2.1.13
AUTO/MANUAL
2 07.1.1.17
7HA
:2
5
MAN CONTROL
SN 1300450-1 EA-0B833.07
6
4
C15P see EA-9B334.40 CABIN-DOME-LIGHT & EA-9B235.17 MKR-AUDIO
1 2 3 4
ST12
Sensor + Sensor -
Duct Temp Sensor
ON
3
OFF 1
6
4
AUTO 3
HA5F-22
HA22E-22
3
4HA 1
MAN 1
HA3F-22
HA28E-22
bl
1 1
org
ws
1
1
1
1 ws
1 bl
1 org
1
2HA-A C50C
CIRCUIT BREAKER/SWITCH PANEL 1 ws
ws HA8E-22 bl HA10E-22N HA2F-22
HA27F-22
HA7F-22
HA6F-22
A
D:15
B:2
B:13
B:12
B:11
B:10
B:9
B:6
B:8
B:7
B:5
B:4
B:3
4
CB-Trennstecker
HA22F-22
HA28F-22
001758 212 02
8VN-A
ST4
HA5E-22
HA4E-22
HA3E-22
FIREWALL
38 76 77 78 79 37
40 72 73 74 75 39
2 see EA-9B246.10 DC-DISTRIBUTION
2
CB-Trennstecker
HA11G-22
3VN-A 001758 212 02
HA9E-22N
VV100
HA8E-22
HA27E-22
VV99
HA7E-22
HA6E-22
15HA an 11HA Flow Valve EA-0B836.32
Prim. Bleed N/C
VV103
PRIM. SHUT OFF VALVE Splice
HA5E-22
Airframe Ground
Airframe Ground
HA4E-22
Airframe Ground
VV98
3
Maintenance Manual EXTRA 500 Chapter 91 30. March 2012
3HA
Flow Flow Flow Flow
35 23 2 22 1
18 30
Low High
Hi/Low Switch GND Open +28VDC Open GND Close +28VDC Close GND
27 9 13
28VDC 28VDC Standby ON
MASS FLOW CONTROLLER
2HA
KABINE
Cabin leftside
VV97 2HA-A
HA4F-22
CABIN TEMPERATUR CONTROLLER
SN 1300350-27 EA-0B836.31
SN 1300360-17 EA-0B836.30
HA28F-22
HA28G-22
HA1F-22 HA1G-22 HA2G-22 HA11F-22 HA20F-22
Microswitch am Condition-Lever
A Blatt1
von 1
8
Schutzvermerk nach DIN 34 beachten.
A3
EA-9B215.20
BLEED AIR, HA
EA 400-500
Projektion Freimaßtoleranz Oberfläche
Turbine leftside
334-870
18HA
Maßstab auf SI.-Klasse Oberflächenschutz
NO
NC
Cut Off
HA20G-22
8
A
B
C
D
D
C
B
A
HI LO HI LO
AUDIO AUDIO AUDIO AUDIO
HI LO HI LO
6 5
41 42
35 36
37 38
PASS4 MIC PASS4 MIC GND
PASS1 MIC PASS1 MIC GND
PASS2 MIC PASS2 MIC GND
27
25
23
COMMON
ENT INPUT 1 LT
28
COMMON
24
26
ENT INPUT 2 LT
ENTINPUT 1 RT
16 31 1
PILOT HEADSET L PILOT HEADSET R PILOT HEADSET GND
ENTINPUT 2 RT
32 33 34
COPILOT MIC IN COPILOT MIC KEY COPILOT MIC GND
3 4 2
39 40
PASS3 MIC PASS3 MIC GND
COPILOT HEADSET L COPILOT HEADSET R COPILOT HEADSET GND
20
8 9
27,5 VDC 27,5 VDC
COM SWAP
7
INSTR. LIGHT
Light GND Light GND
MKR ANTENNE MKR ANTENNE GND
ALT WRN GND
ADF ADF DME DME
PASS HEADSET GND PASS HEADSET L PASS HEADSET R
1 2
32
7 8 21 22
42 40 41
44 43 31 35 33 34
19 20 13 14
RZ2E-24S
C
U
RM15E-22N
ws bl
org ws bl
RM14E-22S
RZ4E-24S
ws bl
BYW-56
SS9E-24 D2
RZ13E-24S
org ws bl
RZ8E-24S
ws bl
RZ5E-24S
TZ7E-24S
ws bl
org ws bl
RZ10E-24S
ws bl
RV1F-24
RZ11E-24S
1
RZ1F-22
ws bl
VV145
see EA-9B284.13 PC-BOARD 1 Pin 8
G
2RM
CI118-5
2SN
Audio Hi Audio Lo
KDM 706A
MKR Ant.
DME
11 8
ST12
SPKR
see EA-9B344.14 WEATHER DETECTION
VV334905 Pin G
see EA-9B334.90 Dimming
RS 477-012
2RM-A
001758-212-02
SS7E-24
24
1VN
17
ws 21 bl
2SN-A
RM12F-24S
Druckspant
ws bl
Durchbruch
RM4E-RG400
LG3E-22
20 14 15
ST13-1B
SS7E-24 BYW-56
1VN-C
RZ9E-24S
001758_212_02
VV10
P3402 1RM-B
1VN-D
31
RZ9E-24S
1
org bl
ws
A F bl B G
VV235161
Module Pilot links
2RV2E-24S
WH12E-22S
2RM1E-24S
2RV2E-24S
2RV1E-24S
RM1F-24 RM2F-24 RM3F-24
RV1F-24
1RV4F-24 1RV5F-24 RV1E-24
1
1RV4E-24 1RV5E-24 RV1E-24 1RV5F-24 1RV4F-24
1
RM1E-24 RM2E-24 RM3E-24
1RV3E-24S
1RV2E-24S
1RM1E-24S
1RV1E-24S
2RM1E-24S
2RV1E-24S
SS8E-24 D1
1
RM1F-24 RM2F-24 RM3F-24
RM1E-24 RM2E-24 RM3E-24 1RV4E-24 1RV5E-24
1RV3E-24S
1RV2E-24S
RM12E-24S
WH13-22N
ws bl
N/C
bl ws org
bl org ws
ws bl ws bl
ws bl
bl ws bl ws bl
1RM1E-24S
1RV1E-24S
1
62 63 82
62 63 82
RZ2J-24S
ws bl ws bl
ws bl
P2144
J2121
P2122
P1122
J1121
ws bl ws bl ws bl
ws bl
P1144
13 29 44 30 43 28
11 5
38 37 21
#2 #2 LO #1 #1 LO #3 #3 LO
IFD-5000i
IFD-5000i
F G J
bl
G K J
C org E org
ws H K ws
E
C bl
bl ws
14RZ-A
F G H J K
1 2 3
14RZ-a
RZ16F-22 RZ16G-24 RZ16H-24 RZ16J-24 RZ16K-24
RZ9G-24S
1 2
grün gelb
Spiralkabel
1
13 14
10 11
GND GND
44 43
ICS MUTE INHIBIT ICS MUTE INHIBIT RETURN
SPEAKER OUT SPEAKER GND
2
VV11
RZ17E-22N RZ18E-22N RZ19E-22N
C15P
001758 212 02 1VN-D
AKF
3
see EA-9B215.20 BLEED AIR see EA-9B334.50 COURTESY LIGHT see EA-9B334.40 CABIN-DOME-LIGHT
5RM
bl
ws ws
C H D J E K
A F bl B G
C H D J E K
VV235162
bl
ws ws
RZ2G-24S
4
2x 001115 204 03
RZ2F-24S
12CA-A
ws bl
11 12
Spiralkabel
RZ2H-24S
RZ2G-24S
12CA-a
11 6
rt ws/grün
ws bl
ws bl
Pilot PTT
Copilot PTT
5
PTT MIC HANDMIKE
Mittelkosole
13RZ
5
PTT MIC Pilot MIKE
6RZ
LH Armrest
rt ws/grün
5RZ
4RZ
Steuerhorn-Steckerleiste
RZ9H-24S
RZ9F-24S
see EA-9B271.17 AUTOPILOT
RZ13F-24S
A B C D E
VV235164 001115-202-02
H
F
org A org B org D
ws ws ws
A B D
VV235163 2x 001115 208 02 bl bl bl
7FG see EA-9B342.66 IFD RIGHT
#2 #2 LO #1 #1 LO #3 #3 LO
MICROPHONE #1 TX KEY #1
CFG DISCRETE IN 0 CFG DISCRETE IN 1 CFG DISCRETE IN 2
DISCRETE IN 7 DISCRETE IN 6 DISCRETE OUT 10
HEADPHONE HEADPHONE HEADPHONE HEADPHONE HEADPHONE HEADPHONE
3FG see EA-9B342.65 IFD LEFT
DISCRETE IN 7 DISCRETE IN 6 DISCRETE OUT 10
CFG DISCRETE IN 0 CFG DISCRETE IN 1 CFG DISCRETE IN 2
HEADPHONE HEADPHONE HEADPHONE HEADPHONE HEADPHONE HEADPHONE
MICROPHONE #1 TX KEY #1
IFD RIGHT
38 37 21
13 29 44 30 43 28
11 5
IFD LEFT
4
Maintenance Manual EXTRA 500 Chapter 91 30. March 2012
1RM
RX RX RX RX
TEL RINGER IN TEL RINGER GND ALT WRN IN PILOT MIC GND PILOT MIC IN PILOT MIC KEY
#2 #2 #2 #2
15 30
COM 2 MIK AUDIO OUT COM 2 MIK KEY OUT
NAV NAV COM COM
27 28
COM 2 SPKR LOAD COM 2 SPKR LOAD GND
17 18 9 10 7 8
25 26
HI LO HI LO HI LO
COM 1 SPKR LOAD COM 1 SPKR LOAD GND
RX RX RX RX RX RX
37 38 36 24 25
#1 #1 #1 #1 #1 #1
11 12
ws bl
1RM-A
P3401
EXT BLUE LAMP (O) EXT AMBER LAMP (M) EXT WHITE LAMP (A) ACTIVE COM SELECTED COM SPLIT SELECTED
NAV NAV COM COM MONITOR MONITOR
COM 1 MIK AUDIO OUT COM 1 MIK KEY OUT
PMA8000B oder PMA8000BT
RZ9K-24S
AUDIO & MARKER
RZ16N-24 RZ16M-24
3
RZ2E-24S RZ2H-24S
Modul 2 Modul 3 Modul 4
2
Modul 5
Modul 6
F G H J K
001758-212-02
1VN-C, 1VN-C
001115-204-03
A B C D E
VV235151-2
RZ16F-22
RZ1F-22
2
2
F G H J K
001115-208-02
A B C D E
6
RZ16E-22
RZ1E-22
VV235153-4
D:4
D:3
CB Trennstecker
A B C D E
F G H J K
001115-202-02
VV
1A
2RZ
PP3
5A
AUDIO-MRK
VV21 bl VV23
Zuordnung links / rechts wird mit */* in allen Feldern angegeben.
EDV-Kennung:
9B23517T
04 03 02 01 Ver. Bezeichnung
bl
7
1 2 3 4 5 6 7 8 9
org ws ws bl
20RZ-A
ws bl
18RZ-a
1 2 3 4 5 6 7 8 9
20RZ-a
1 2 3 4 5 6 7 8 9
RIGHT EAR LEFT EAR MIC HI MIC LO
7
Nr.: Änderung/Mod. Nr.: Datum
19.01.11
HW
Name
Schwarze Heide 21
Gepr.:
Gepr.:
Bearb.: 29.11.10
Datum
Name 46569 Hünxe, Germany
HW
optical coverage minimal 98 - 100% Letzte Bearbeitung:
ws bl
7RZ BOSE
1
1
1
1
1
3RZ
6
6
6
6
6
PILOT
COPILOT
PASS 2
PASS 1
PASS 4
PASS 3
Blatt 1
8
Schutzvermerk nach DIN 34 beachten.
A2
EA-9B235.17 von 1
Projektion Freimaßtoleranz Oberfläche
EA 400-500 MKR/AUDIO, RM
Maßstab auf SI.-Klasse Oberflächenschutz
Pilot PHONE
PHONEBUCHSE
12RZ BOSE
11RZ BOSE
10RZ BOSE
9RZ BOSE
8RZ BOSE
6
LH Armrest
ws sw ws ws/bl
rt sw
ws sw ws ws/bl
RIGHT EAR LEFT EAR MIC HI MIC LO
V+ GND
rt sw
ws sw ws ws/bl
RIGHT EAR LEFT EAR MIC HI MIC LO
V+ GND
rt sw
ws sw ws ws/bl
RIGHT EAR LEFT EAR MIC HI MIC LO
V+ GND
rt sw
ws sw ws ws/bl
RIGHT EAR LEFT EAR MIC HI MIC LO
V+ GND
rt sw
V+ GND
ws sw ws ws/bl
RIGHT EAR LEFT EAR MIC HI MIC LO
36 AWG Tinned copper per ASTM-B-33
RZ4F-24S
VV24 VV25
org
1 2 3 4 5 6 7 8 9
18RZ-A bl ws org
17RZ-A 17RZ-a
ws bl
16RZ-a 1 2 3 4 5 6 7 8 9
rt sw
V+ GND
PASS 4
1
COPILOT
Copilot PTT
PASS 3
Pilot MIKE Pilot PHONE
HANDMIKE
Pilot
PASS 2
PILOT
Pilot PTT
8
PASS 1
16RZ-A bl ws org
15RZ-a 1 2 3 4 5 6 7 8 9
19RZ-A 19RZ-a
ws bl
bl ws org
ws bl
bl ws org
15RZ-A
bl org ws
OVERBRAID
Die Gültigkeitszuordnung von Version zu Flugzeugbaureihe ist der Bauakte bzw. dem jeweiligen Fertigungsauftrag zu entnehmen.
1
RZ13F-24S
RZ2J-24S
RZ4E-24S
RZ16N-24
VV22
RZ13E-24S
RZ5E-24S
RZ16M-24
RZ8E-24S
RZ9K-24S
RZ16K-24
RZ7E-24S
RZ9H-24S
RZ16J-24
RZ10E-24S
RZ9G-24S
RZ16H-24
RZ11E-24S
RZ9F-24S
RZ16G-24
see EA-9B246.10 DC-DISTRIBUTION
1RZ
LOAD BUS
CIRCUIT BREAKER/SWITCH PANEL
6
ws bl
1
C B A
F E D
J H G
M L K
R P N
U T S
bl ws
D
C
B
A
A
B
C
D
Z W C F R L G B A J U T E D H V X Y M
bl ws
A B C
7PR
GCU
OFF
3
07.1.1.13
2
EMERGENCY
ON
E
B
10A
B:10
B:5
B:6
D:13
PR16F-20
2
PR4F-20
3
PR5F-20
PR6F-20
3
3
2
2
D:15
D:14
1VN SCHRAUB-BOLZEN
D
A
2PR
PR7F-16
3x AWG18 PR13F-16
ST3 MS 27615-K14T7P
MS 27613-K14T7S
PR13E-16
PP6E-22
PP5E-22N
TRIP
7PR:2
:1
PP1E-2/0
LA2G-18 Landing Light Zündbox EA-9B334.35
LA2F-18
3
Note 1
001758 212 02 C 3VN-A
PP5F-22N
PP3F-22
2
07.1.1.17
GEN
3
07.2.1.16
RESET
OFF
ON
OFF PR10F-20 OV-TEST
PR11F-20
CB Trennstecker
ON PP3G-22
07.2.1.13
19PP OFF 1
PR07E-16 PR09E-16
PP4E-22
STARTER/GENERATOR 200SGL
2PR-A MS3126F8-3S
bl ws
ST2
:1
18PP:2
BATT
PR16E-20
PR4E-20
PR5E-20
3
PR6E-20
B:7
B:8 3
B:9
3
PR10E-20
PR11E-20
8PR 1
GEN TEST
PR16G-20
Bolzen
Kabel nach MIL-W 25038
see EA-9B244.10 EXT POWER 206PR Pin 3
see EA-9B246-10 DC DISTRIBUTION
see EA-9B244.10 EXT POWER see EA-9B334.50 COURTESY LIGHT
Bolzen
ST1
EMERGENCY BUS PP2 CB 9PR GEN RESET see EA-9B246.10
P R S T U V
see EA-9B743.10 Start/Ignition see EA-9B743.10 Start/Ignition
see EA-9B334.50 COURTESY LIGHT see EA-9B323.10 GEAR CONTROL see EA-9B256.10 ELT
PR19E-20
51 52
Starter/Generator
see EA-9B334.50 COURTESY LIGHT see EA-9B334.50 COURTESY LIGHT PR3E-20 PR2E-20 PR1E-20 PR15E-20 PR14E-20 JB4E-18 JB3E-18
ST1 E F G H J K L M N
PA1E-2/0 PA2E-2/0N
GND BOLD 1VN
*
PP6F-22
ST1
VV242
LY4E-22
LY3E-22
VV241
Bolzen
VV240
LY13E-22 LY14E-22
E-BOX
+ -
20PP-A
MS3349-2
Note 1
WX Y Z A b c d e f g h i j
EA-9B243.10
20PP
+ 28Ah
BATTERY RG-390E
4
PR206F-22 PL1G-20 PR203F-22
PR211F-22S
PR201F-20 ws bl org
Bolzen
VV246
10
i
N
h
U
M
r g
j
V
f
s
W
L
e
q
A
t
k
X
K
1
D
H
b
G
F
a E
C
Z
c
J
n
m
d
p
B
Y
MS 38999III 21-41
P
T
R
S
ST1
2
3
4
or MIL-W-22759/16 + Firesleeve (TSO-C53a)
Alle anderen nicht geschirmten nach MIL-W 22759 Alle geschirmten nach MIL-W 27500
PA01E-2/0 PA02E-2/0N
Maintenance Manual EXTRA 500 * 30. March 2012 Chapter 91
ST4
PR204E-22
PR8E-20 PR12E-20
Speed Sensor
PR17E-22
PR15E-20 PR14E-20 PR13E-16 PR12E-20 PR11E-20 PR10E-20 PR8E-20 PR7E-16 PR9E-16 PR6E-20 PR5E-20 PR4E-20 PR3E-20 PR2E-20 PR1E-20 PR16E-20
PR205F-22
Trenn-Stecker am Brandspant
FIREWALL
SWITCH 206PR "STDBY ALT" Pin 2 SWITCH 206PR "STDBY ALT" Pin 2
see EA-9B243.20 DC-GENERATION II
DIODE 205PR & Pin 2 D-17 Pin 6
Bei 58% schaltet die GCU aus!
START CONTACTOR CONT START POWER FIELD RETURN CIRCUIT GND REMOTE TRIP OVER VOLTAGE SELF TEST INTERPOLE GEN. FIELD GEN. OUT GEN. CONTROL SWITCH RESET ANTI CYCLE LOAD BUS P.O.R. LINE CONTACTOR COIL GENERATOR OUTPUT GENERATOR SPEED SENSOR GENERATOR SPEED SENSOR CHASSIS GROUND
PR18E-22N
PR17E-22
49 ws 53 bl 54
ws bl
1PR
MS3106F24-28S-F80 1PR-A
PR9F-16
GCSG 505-21 GENERATOR CONTROL UNIT
3x AWG18
1 2 3 4 5 6 7
PR20-2/0N
PR17F-22
2
F G
5
PR8F-20 PR12F-20
1
3
4
6
2
PR7F-16 PR8F-20 PR12F-20 PR13F-16 PP6F-22
1
3
4
6
1
org bl ws
5
EA-9B243.20 DC-GENERATION II, STANDBY ALTERNATOR SW 206PR Pin 4 EA-9B243.20 DC-GENERATION II, REGULATOR 203PR Pin 7 EA-9B243.20 DC-GENERATION II, REGULATOR 203PR Pin 3 EA-9B243.20 DC-GENERATION II, REGULATOR 203PR Pin 4 EA-9B243.20 DC-GENERATION II, REGULATOR 203PR Pin 1 EA-9B244.20 EXT LADER, ST2 Pin A EA-9B243.20 DC GENERATION II, STANDBY ALTERNATOR SW 206PR Pin 3
EA-9B243.20
204PR Alternator 2, Anschluss B
5
6
6
Platine Fuse/Relay E-Box EA-9B243.41
Platine Fuse EA-9B243.47
Bolzen
VV245
EDV-Kennung:
9B24310T
04 03 02 01 Ver. Bezeichnung
Zuordnung links / rechts wird mit */* in allen Feldern angegeben.
Die Gültigkeitszuordnung von Version zu Flugzeugbaureihe ist der Bauakte bzw. dem jeweiligen Fertigungsauftrag zu entnehmen.
Platine Fuse Shunt spezial EA-9B243.45
Platine Fuse Shunt gross EA-9B243.43
Platine Fuse Shunt klein EA-9B243.42
Bolzen
VV244
Bolzen
VV243
PP32E-10
PP31E-2
ST1 Pin D
5
5
7
ÄM-400-09-01
2
D
Nr.: Änderung/Mod. Nr.:
A
A
Cab-Press
Flaps
Datum
01.09.10
HW
Name
11.02.04
PB
Name
46569 Hünxe, Germany
Schwarze Heide 21
Gepr.:
Gepr.:
Datum
PP4
Bearb.:
EMERGENCY BUS
3EY-A Pin 16 3EY-A Pin 19 3EY-A Pin 8 3EY-A Pin 6
A Blatt 1
von 1
8
Schutzvermerk nach DIN 34 beachten.
A2
EA-9B243.10
DC GENERATION I, PP
EA 400-500
Projektion Freimaßtoleranz Oberfläche
CB im CB Panel
5PP 1A
D:17 1
D:16 1
PR101F-22
RCCB-CTRL
Maßstab auf SI.-Klasse Oberflächenschutz
U
3VN-A
001758 212 02
see EA-9B246-10 DC DISTRIBUTION
DIP EA-9B316.40 DIP EA-9B316.40 DIP EA-9B316.40 DIP EA-9B316.40
EA-9B215.10, AIR CONDITION EA-9B215.10, AIR CONDITION
5WW-D
48
ANNUNCIATOR BOARD EA-9B315.81 see EA-9B315.80 ANNUNCIATOR PANEL
+ VOLT DIMM
LIGHT TEST (GND)
ANNUNCIATOR BOARD D16 5WW
Aft Door Stall-Warn
Gen-Fail Gear Warn
BATTERY BUS PP2
25 26 24 23
41 21 22
16 24 25
8
see EA-9B246-10 DC DISTRIBUTION
Annunciator Panel left
LOAD BUS PP3
1WW
5WW-B
EZ63E-22 HB15F-22 HB16F-22 PR101F-22 ws EY9E-22 bl ws EY8E-22 bl
5
Letzte Bearbeitung:
k m n p q r s t
WW1-20
WW17-22
PP30E-2
ST1
7
PR102F-22N PR102E-22
PR101G-22
2
5
A
B
C
D
A
B
C
3
PLatine EA-9B243.41
B
F1 40A
50A
26.72.03
STBY. Alternator BC410-1 (26VDC 20A) 204PR
VV246
001758 212 02 A 2VN-C
K7
86
87a
88
85
87
50A
K10
88a
F10 2A
ALT CHARGE
CB4 2A
6
4
3
PR202E-22
K4
PP6H-22
F4 40A
50mV 200A
BATTERY SHUNT2
K5
VV244 F3 150A
P600M
205PR
PR201E-20
PR203E-22
PR204E-22
BATTERY BUS PP2
ON
1 OFF
07.2.1.13
:2 5
F5 30A
VV242
Hot Bus PP1 PP1 HOT BUS
26.73.04
ALT SENS
ws/org ws/bl ws
F16 1A
P600M
D1
ALT FIELD 2
VV245
PR200E-20
BATTERY
2A
ALT
206PR:1 2
STDBY ALT
3
K3
sse EA-9B243.40 E-BOX
PR201G-20
PR210E-22 PR211E-22 PR212E-22
PP6G-22 PP3E-22 PR203G-22 PR206E-22
EMG-Rel. K9 Pin X2 EMG-Rel. K9 Pin X1
GENERATOR
ETA 4930-04
SHUNT1 50mV 200A
150A
F2
6
4
3 ON
1 OFF
3
ON
2 07.1.1.13
19PP 1
OFF
PP3G-22
2 2 3
PR203E-22 PR201E-20
2
2
2
PR205E-22
PP6E-22
PP5E-22N
EMERGENCY
07.2.1.13 PR205F-22
:2 5
18PP:1 2
BATT
j
g h i
e T W f
B
B:11
D:16
D:17
D:15
D:14
D:13
PR211F-22S
PR201F-20
PR209F-20
org bl ws
PP6F-22 PP3F-22 PR203F-22 PR206F-22
GENERATOR
VV240
ST2
ST1
LOAD BUS PP3
VV243
1
B
GND
2
Field
204PR-A
F
PR209E-20
3
4
Plug with Shield MS 38999 III 26K F 32 SN (32 X #20)
5
5
PP6F-22
C
21
001758 212 02
PR212G-20N
PR209F-20
PR211F-22S
PR205G-22
PR213E-22
PR206F-22
PR213E-22
2VN-C
100
5WW-D
EDV-Kennung:
9B24320T
04 03 02 01 Ver. Bezeichnung
6
Zuordnung links / rechts wird mit */* in allen Feldern angegeben.
2WW
D25
15 24 25
5WW
7
Field
Ground
Sensor Analog
Sensor +10 Volts
Bus
ÄM-400-09-01
15.09.10
Nr.: Änderung/Mod. Nr.: Datum
A
5
7
3
4
6
Alt Loaded Lamp
HW
Name
Datum
13.04.04
WW20-20
WW32-22
7
46569 Hünxe, Germany
PB
Projektion Freimaßtoleranz Oberfläche
A Blatt 1
von 1
8
Schutzvermerk nach DIN 34 beachten.
A3
EA-9B243.20
DC-GENERATION II, PR
EA 400-500
Maßstab auf SI.-Klasse Oberflächenschutz
203PR
Name
Schwarze Heide 21
Gepr.:
Gepr.:
Bearb.:
Ringösen werden im Kit mitgeliefert.
Letzte Bearbeitung:
ws
bl
org
2
Ignition
8
Prop Low Pitch External Power
Low Voltage
Standby Alt On
STANDBY ALTERNATOR REGULATOR 1 Bus Sense BC203-2D
5WW-B
Fuel Low R
Pneumatic
Fuel Trans R
ANNUNCIATOR BOARD EA-9B315.81 see Annunciator-Panel EA-9B315.80
+ VOLT DIMM
LIGHT TEST (GND)
ANNUNCIATOR BOARD
P/N 90-42192-2 geändert
Annunciator Panel right
6
Die Gültigkeitszuordnung von Version zu Flugzeugbaureihe ist der Bauakte bzw. dem jeweiligen Fertigungsauftrag zu entnehmen.
F
001758 212 02 3VN-A
PP5F-22N
CB Trennstecker
see EA-9B246.10 DC-DISTRIBUTION
VV27
4
PP4E-22
Maintenance Manual EXTRA 500 ChapterG91 30. March 2012
202PR
SENSOR
50mV 200A
2
SHUNT 3
Platine EA-9B243.41
E-BOX
EMERGENCY BUS PP4
5
200PR
EMERGENCY BUS PP4
PP32E-10
D
CIRCUIT BREAKER/SWITCH PANEL
2
RCCB 4930-4 ETA
1
A2 5B
3
A1
4
PP211F-10
PP211E-10
PR102E-10
PR102E-10
PR101E-10
PR100F-10
-
+
PR100E-10
+
-
PR208E-20N
+
FIREWALL
-
A
B
C
D
VV242
J14
* P600M
D1
J37
* P600M
J36
D10
5A
efg hij
A
5A
W
5A
GEAR AUX 2
1A
CB5
ELT
CB1
ST1
PR201G-20
*
J30 J31 J32 J33 J34 J35
F5 30A 2
HOT BUS PP1
1 EA-9B243.46
F10 2A
5A
COURTESY LT
M210-B4M S210-A5A1
D8 BYW56 LY1E-22
X1
BATT CHARGE
CB6
CB2
ALT FIELD 2
J13
CB4
LY3E-22 GA34E-22 DA2E22 PP3E-22 PD5G-22 LY4E-22
3 1
Bolzen
S
T
ST1
VV246
40A
F1
85
87z 88y
86
88y
88b
U
86
87
V
s
W
K7
q
A
85
p
87a
ALTERNATOR
ws/org ws/bl ws
J15
86
87z
87a
85
88
88a
BATTERY
K4
26.57.73
88a 87a 88b
88
PR210E-22 PR211E-22 PR212E-22
*
D5
J12
F9 4A
K1
B
EXT POWER
JB4F-20
4
J4
BC218-1
J5
C
D
J6
J2 J1
*
1
J25
* D9
J19 J20
2
1A
J7
1A
ALT SENS
F15 4 F16
J23
REL MT4 K6
Spare Pins
88y
J22
J21
J26
J24
D7 BYW56
J18
87a 88b
87z 88y
85
88a
88
86
BYW56
K3 GENERATOR
+ SHUNT 3 50mV 200A EA-9B243.45
1A
F14
ST1
B C
J8
J17
D2
EA-9B243.45
PR206E-22
J3
STROM SENSOR 202PR PR206E-20N
*
D6
J11
F13 4A
26.57.73
START
F17
GCU 1
EA-9B243.46
1
* Bauteile sind auf einer Platine integriert!
*
Platine EA-9B243.41A
2
3
P
N
i
M
r g
f
L
e
k
t
K
d
m
Z
c
J
n
Y
MS 38999III 21-41
R
h
j
X
H
b
G
F
a E
4
c d
b
a
Z
Y
X
88b
87a
5
KISSLING RELAY 26.57.71X Hilsfanschlüsse
87z
1
SHUNT1 50mV 200A
K8 X2
X1
4
BYW56
D3
K10
EDV-Kennung:
9B24340T
04 03 02 01 Ver. Bezeichnung
6
150A
F3
ÄM-400-09-01
Bolzen
ST1 Pin D
EZ63E-22 HB15F-22 HB16F-22 PR101F-22 ws EY9E-22 bl ws EY8E-22 bl
BATTERY BUS PP2
k m n p q r s t
ST1
Datum
13.02.04
PB
Name
Schwarze Heide 21
Gepr.:
Gepr.:
Bearb.:
EMERGENCY BUS PP4
7
U
A von 1
8
Schutzvermerk nach DIN 34 beachten.
A3
Blatt 1
E-BOX EA-9B243.40
D:17
1
1A
Projektion Freimaßtoleranz Oberfläche
EA 400-500
Maßstab auf SI.-Klasse Oberflächenschutz
1
5PP
3VN-A 001758 212 02
RCCB-CTRL
CB im CB Panel
see EA-9B316.40, DIP 3EY-A Pin 16 see EA-9B316.40, DIP 3EY-A Pin 19 see EA-9B316.40, DIP 3EY-A Pin 8 see EA-9B316.40, DIP 3EY-A Pin 6
25 26 24 23
D:16
see EA-9B315.80, ANNUNCIATOR, GEN FAIL seeEA-9B215.10, AIR CONDITION see EA-9B215.10, AIR CONDITION
D16
LIGHT TEST
8
41 21 22
WW1 GEN FAIL
LOAD BUS PP3
7
+ V Dim
HW Name 46569 Hünxe, Germany
VV245
Nr.: Änderung/Mod. Nr.: Datum
A
Bolzen
VV244
Bolzen
VV243
16.09.10
M210-B4N_1
Letzte Bearbeitung:
PP6G-22
EZ63F-22 HB15E-22 HB16G-22 PR101E-22 EY9F-22 EY9G-22 EY8F-22 EY8G-22
K12
ETA 4930-04
K5
150A
F2
F4 40A
A2
A1
Zuordnung links / rechts wird mit */* in allen Feldern angegeben.
Die Gültigkeitszuordnung von Version zu Flugzeugbaureihe ist der Bauakte bzw. dem jeweiligen Fertigungsauftrag zu entnehmen.
2VN-C 001758 212 02
26.72.03 50A
5B
GND
ALT CHARGE
1A 1A 5A 3 1
GCU 2
F12 F11 F18
PP211E-10
2
3
3
CB
ETA RCCB 4930-4
4 Alt Power
5A 2
B
SHUNT2 50mV 200A
2
A
S210-A5A1 1 3 1
M210-B4M
PR100E-22
J16
*
D4
BYW56
2A
1A
1A 2
F8
F7
F6
J9 J10
EA-9B243.45
AB C DE F G HJ K
Maintenance Manual EXTRA 500 Chapter 91 30. March 2012
ELT
COURTESY LT
ALT FIELD 2
SPARE
BATT CHARGE
GEAR AUX 2
Bolzen BATTERY
P R S T U V
Bolzen
3 1
B
LY2E-22
K2
5A
1
6
2
A
B
C
EA-9B334.50 Courtesy Light EA-9B323.10 Gear Control EA-9B256.10 ELT EA-9B243.10 DC Generation EA-9B243.10 DC Generation
ST1
EXT. POWER
VV241
A
PP6G-22 PR206E-22 PR210E-22 PR211E-22 PR212E-22
K11
X2
P600M
2
447-0863
2
P600M
LY1F-22
26.57.71
88 88a
JB3F-20 87z 88y 87a 88b
447-0863
Bolzen
13
GENERATOR
12
PR15F-20 86 85
10
VV240
14
JB3F-20 JB4F-20
9 7
D
11
PR16E-22N LY13E-22 LY12E-22 PR1F-20
PR2F-20 8 5
PR14F-20
4
6
LY13E-22 LY12E-22 PR3F-20 PR2F-20 PR1F-20 PR15F-20
3
26.57.710
1 16
D E F G H J K L M N
PP100E-22N
EA-9B334.50 Courtesy Light EA-9B334.50 Courtesy Light
PR16E-22N PP103E-22N PP102E-22N PP101E-22N
PP100E-22N
ST1
PR3F-20
Shield für EY8 & EY9
5
88 87 88a
4
86 85
3
-
-
2
87a
PR101G-22 PR102E-22 PR102F-22N
+
+
1
X2
PR203G-22
X1
PL1G-20
1 A
EA-9B243.20 DC-GENERATION II
2
EA-9B244.20 BATTERY CHARGE
3
STBY ALTERNATOR
1 B
EA-9B243.10 EMERGENCY 19PP EA-9B243.20 DC-GENERATION II EA-9B243.20 DC-GENERATION II EA-9B243.20 DC-GENERATION II EA-9B243.20 DC-GENERATION II EA-9B243.20 DC-GENERATION II
3
A
B
C
D
A
B
C
ST1
ST1
J8
J17
J18
J9
J16
J10
J11
J15
J12
J14
1
CON1
1
CON1
1
CON1
1
CON1
1
CON1
1
CON1
1
CON1
1
CON1
1
CON1
1
CON1
1
CON1
1
CON1
BYW56
D2
BYW56
D9
BYW56
D3
BYW56
P600M D4
D6
P600M
D5
P600M
D1
P600M
D10
BYW56
D7
K6:1
t
ST1
J22 CON1
J7 CON1
MT4
ws
ws/bl
ws/org
s
ST1
J21 CON1
Maintenance Manual EXTRA 500 Chapter 91 30. March 2012
k
W
J13
J36
CON1
1
1 16
202 PR 6
J37
5
K6:2 4
D
7
ST1
8
1
11 K6:4 12 13 1
K6:3 3 1
9 K6:5 10 14
E
ST1
J5 CON1
1
A
1
J2 CON1
EDV-Kennung:
ST1
ST1
ST1
ST1
ST1
ÄM-400-09-01
F
J
i
h
g
14.10.10
Nr.: Änderung/Mod. Nr.: Datum
A
Letzte Bearbeitung:
J1 1 CON1
9B24341T
04 03 02 01 Ver. Bezeichnung
J3
J25
J26
J23
J24
J19
J20
J34 CON1 J35 CON1 J32 CON1 J33 CON1
J30 CON1 J31 CON1
J4 1 CON1
CON1
1
CON1
1
CON1
1
CON1
1
CON1
1
CON1
1
CON1
1
1
1
1
1
1
1
Die Gültigkeitszuordnung von Version zu Flugzeugbaureihe ist der Bauakte bzw. dem jeweiligen Fertigungsauftrag zu entnehmen. Zuordnung links / rechts wird mit */* in allen Feldern angegeben.
J6 CON1
1
Name
HW
HW
46569 Hünxe, Germany
Schwarze Heide 21
Gepr.:
Gepr.:
Name
Datum
Bearb.: 16.09.05
Projektion Freimaßtoleranz Oberfläche
A Blatt 1
von 1 Schutzvermerk nach DIN 34 beachten.
A3
EA-9B243.41
PCB Board E-Box
EA 400-500
Maßstab auf SI.-Klasse Oberflächenschutz
A
B
C
D
A
B
C
D
PD4E-22
ST4
Brandspant
VV186
VV186
23
7
PD5G-22
E-BOX
5WW
+ +
-
r g
j
V
s
W
q
A
k
X
2A
2PD
p
B
m
n
Y
Z
D
a E
C
3
ON
07.1.1.13
2
5PD
2
1
PD4H-22
PD5E-22
2
PD4G-22
see EA-9B246.10 DC-DISTRIBUTION
1
OFF
EXT PWR
CIRCUIT BREAKER/SWITCH PANEL
PD1E-22
PD5F-22
PD4J-22
PD4F-22
PD4F-22
CB Panel Trennstecker
D:12
D:11
D:11
34
U
ST1
Schraube
MS38999III
PD5F-22
PD3E-2/0
1
R
S
P
N
L
e
K
d
J
c
MS 38999III 21-41
M
f
t
H
b
G
F
2
3
4
Maintenance Manual EXTRA 500 Chapter 91 30. March 2012
i
U
ST1
h
EXT PWR
1VN Brandspant
WW40-22
WW27-22
5WW-C
K1
D46
BYW56
K3
K4
87z 88b
85
86
5
87a 88b
87z 88y
26.57.710
BYW56
EDV-Kennung:
3 4 9
9B24410T 6
A
ÄM-400-09-01
01.07.10
Nr.: Änderung/Mod. Nr.: Datum
Letzte Bearbeitung:
HW
Name
2
48
26
8
m
Datum
19.10.04
Name
PB
7
46569 Hünxe, Germany
49
108
41
EA-9B334.90
8
A Blatt 1
von 1
8
Schutzvermerk nach DIN 34 beachten.
A3
EA-9B244.10
EXTERNAL POWER, PD
EA 400-500
Projektion Freimaßtoleranz Oberfläche
+ Light-Test
28VDC CB 1LH2
Maßstab auf SI.-Klasse Oberflächenschutz
HP11G-22 MS38999III 17-26
ST1
PD4J-22
Schwarze Heide 21
Gepr.:
Gepr.:
VV161
LH3G-20
HP11G-22
5WW-D
5WW-A
7
Bearb.:
see EA-9B243.10 DC GENERATION I
E-BOX EA-9B243.40
Air Condition
Platine innerhalb der E-Box EA-9B243.41
DC Generation I REL K8 Air Condition
see EA-9B315.80 ANNUNCIATOR PANEL
Zuordnung links / rechts wird mit */* in allen Feldern angegeben.
04 03 02 01 Ver. Bezeichnung
GEN-FAIL
ANNUNCIATOR BOARD EA-9B315.81
6
Die Gültigkeitszuordnung von Version zu Flugzeugbaureihe ist der Bauakte bzw. dem jeweiligen Fertigungsauftrag zu entnehmen.
88a
88
Battery Relay
87a 88y
GEN RELAY
85
87a 88b
87z 88y
86
88a
88
D2
LIGHT TEST (GND)
D45
D37
291-9726
D30
ANNUNCIATOR BOARD
5
K1
Kleiner Pin vorne Flugrichtung!
T
Deice Boots
Intake Heat
4
EXT. POWER RELAY
PD3E-2/0
Ignition
Prop Low Pitch External Power Windshield On
Low Voltage
Standby Alt On
3
1PD
PD2E-2/0N
2WW
2
EXT POWER
P/N 90-42192-2
Annunciator Panel right
1
A
B
C
D
A
B
C
+
J1
02636
PL 1
PL1E-20 PL2E-20N
BATTERY CHARGE
PA1E-2/0 PA2E-2/0N
MS3349-2
+ -
20PP-A
EA-9B334.50 Courtesy Light EA-9B323.10 Gear Control EA-9B256.10 ELT EA-9B243.10 DC Generation EA-9B243.10 DC Generation
Masse auf Rahmen
PL1E-20 C1P
ST2 A
FIREWALL
KABINE
PL1F-20
A
P R S T U V
ST-1 #20
1
2
3
4
5
Bolzen
VV241
Bolzen
PL1G-20
J37
5A
ELT
COURTESY LT
ALT FIELD 2
SPARE
BATT CHARGE
GEAR AUX 2
EA-9B243.46
J14
*
J36
D10
EDV-Kennung:
9B24420T
04 03 02 01 Ver. Bezeichnung
M210-B4M S210-A5A1
5A
6
F5 30A
2
F9 4A
Name
HOT BUS PP1
Nr.: Änderung/Mod. Nr.: Datum
Letzte Bearbeitung:
F10 2A
5A
COURTESY LT
LY2E-22
1 EA-9B243.46
GEAR AUX 2
CB5
D8 BYW56 LY1E-22
X1
X2
LY1F-22
BATT CHARGE
1A
P600M
5A
CB1 ELT
P600M
*
D1
CB2
CB6
B 3 1
A
2
3 1
ALT FIELD 2
J13
CB4
K11
2
Die Gültigkeitszuordnung von Version zu Flugzeugbaureihe ist der Bauakte bzw. dem jeweiligen Fertigungsauftrag zu entnehmen. Zuordnung links / rechts wird mit */* in allen Feldern angegeben.
VV242
LY3E-22 GA34E-22 DA2E22 PP3E-22 PD5G-22 LY4E-22
Bolzen BATTERY
A
P R S T U V
ST1-A
EXT. POWER
ST1-A
PA1E-2/0
#20 #20 #20 #20 #20 #20
ST1-A
FIREWALL
GENERATOR
VV240
E-BOX
6
7
K1
88b
85
87z 88y
86
88y 88b
Name
HW
Datum
Bearb.: 14.09.10
7
46569 Hünxe, Germany
Schwarze Heide 21
Gepr.:
Gepr.:
4
E-BOX EA-9B243.40
F13 4A
26.57.73
START
K2
Projektion Freimaßtoleranz Oberfläche
8
Blatt 1
von 1
8
Schutzvermerk nach DIN 34 beachten.
A3
EA-9B244.20
BATTERY CHARGE, PL
EA 400-500
Maßstab auf SI.-Klasse Oberflächenschutz
see EA-9B243.10 DC GENERATION I
86
87z
87a
85
88
88a
BATTERY
K4
26.57.73
88a 87a
88
EXT POWER
88 88a
5
87z 87a
4
1VN see 9B243.10 DC GENERATION I GND BOLD
BATTERY RG-390E
28Ah
20PP +
3
Maintenance Manual EXTRA 500 Chapter 91 30. March 2012
GND
+28V
2
PL2E-20N
88y 88b
D
1
26.57.71
86 85
A
B
C
D
D
1
5A
CB2 CB4
2A
CB5
1 2
3 4
1 2 3 4 5
5A
6
F10 2A
PP32E-10
5A
F5 30A
5A
2
1
PP36E-16N
1
1
C:3 C:4
1
2A
C:7 B:5
Option
2
3
10A
DAY
2
3
A:4 D:13 A:3 A:2
A:10
3
3
2
A:1
3
1
2A
4
C:16
2
2
D:19 D:20
1
1A
C:12
1
1
A:3 A:4
1
1A
B:4
3
ICE-LT
2LA
1LA
7.5A
2
5LA 1A
1
5
7.5A
2LJ
1LR
1LR
6
EDV-Kennung:
9B24610T
04 03 02 01 Ver. Bezeichnung
ÄM-400-09-01
HW
7
HW
Name
11.10.10
A
02.02.11 PB
46569 Hünxe, Germany
Name
Datum
8
Blatt 1
A von 1
Projektion Freimaßtoleranz Oberfläche
1
C:18
Schutzvermerk nach DIN 34 beachten.
A2
EA-9B246.10
3
5A
T&B
EA 400-500 DC-DISTRIBUTION
Maßstab auf SI.-Klasse Oberflächenschutz
A:5 A:6
19.10.04
3
3CA
PP5
AP-CMPTR
5A
A:1
2CA
K
1VN-A
3
001758_212_02
3
1
TAS
3A
D:20
D:16 B:11
2
PR203E-22 3
201PR:2
DC-GEN 2
ON
PR201E-20 4
5
07.2.1.13
PR202E-22 6
8
PP44F-22N
2
243.20
STDBY ALT
C:4
IFD RH B
1SD
1
PP44E-22N
1
:1
AVIONICS BUS
10A
ON
OFF
1A
FLAP-UNB
P600M
205PR
A:3 D:10
2
2
A:2
27CG
D:17
PR205F-22
OFF 1
PR204E-22
2
3
1
6FG
Schwarze Heide 21
Gepr.:
Gepr.:
Bearb.:
2 PP48E-16
D:17
1
1A
5
PR205E-22 6
2
RCCB-CTRL
5PP
1
D:16
18PP:2
ON
BATT
AVIONIC 31PP
:1
PR19E-20
07.1.1.13
X2 PP43E-22 2
D:13
D:15
M320-B4N S320-A7-A10 25A
3
1
X1
30PP
2
2
Nr.: Änderung/Mod. Nr.: Datum
2A
ALT
EMGC-2
D:14
50A
2
19PP
EMERGENCY
B:10
PP35E-12
PP47E-16
Letzte Bearbeitung:
5A
200PR
4PP
30A
AV BUS
30A
GEN-RESET
Zuordnung links / rechts wird mit */* in allen Feldern angegeben.
A:11
D:1
C:7
C:4
3
3A
ATC
9PR
33PP CR1/1
OV-TEST
3
3PP
CR1/2
3
201CNQ045
EMGC-1
1
2A
B:9 B:8
3
GEN TEST
8PR
SIRIUS
3
B:3
3
1TL
B:6 B:7
3
Die Gültigkeitszuordnung von Version zu Flugzeugbaureihe ist der Bauakte bzw. dem jeweiligen Fertigungsauftrag zu entnehmen.
2
3
1
1A
KEYPAD
1SH
1
1
2A
7PR:2
VNE-WARN
1A
2
3
GEN
IRIDIUM
B:2
3
:1
1TS
3
C:13
1WV
D:18
10A
IFD LH A
9FG
IFD LH B
10A
C:3
2
2FG
C:3
3
10A
1
12-VDC
1
2A
1FG
STBY GYRO
1FM
A:7
3
AP-SERVO
5A
D:4
D:3
D:1 D:2
1CA
2
1A
1TH
2
2RZ
5A
AUDIO-MRK
1RZ
2
2
1
2A
DME
1SN D:11 D:11 B:5
2
A:9
2A
INTAKE-A/I
D:7
C:14
1HM
1
1
2HH
2A
BOOTS
1HH
1
2A
WTHR DET
B:1
3
1SS D:12
2
5PD
EXT PWR
3
ON
OFF
5 6
PR6F-20
2
OFF
PR10F-20 3
2
ON
3
PP3G-22
7
DC-GEN 2
6
2
1A
2
GLARE-LT
2
10A
IFD RH A
D:3
3
INST-LT
10k
HA5F-22
1
5FG
7.5A
1
3
A:9 A:8 A:7
1
1LH1
C:9
1
WARN-LT
A:8
1
1LH2
C:5 B:1
3
10A
1
A:12 A:11
LDG-LT
2LB
STROBE-LT
1
2A
2
4
TEMP
O-SP-TEST
1
1
1ES
7HA
4
P16NM103KA
2 3
A:6 D:5
2
5A
1
HA21E-22
ws org bl
1
2
PD4G-22 PD4H-22
RESET1
PR04F-20
4
PR5F-20
07.2.1.16
PR11F-20TRIP 1
07.1.1.17
PR16F-20
1 3
PP6E-22
2
PR101G-22
5
PR102E-22
CG50G-20
Poti. Ansicht von hinten.
RECO-LT
HA22E-22 6
1
7.5A
2LF
5
D:15 D:14 B:13 B:10 B:11 B:12
1LF
1LB
1
B:2
1
16HA:1
D:3 D:4
1
5A
2 3
ENV BLEED
NAV-LT
VOLT-MON
7EY
1LN
2LN
FUEL FLOW
1A
STALL-WARN
1QY
C:15
1A
LOW-VOLT
1WH
C:6
3
FLAP
7.5A
D:1
2LC
1LC
1
B:6 B:9
D:2
1
1
16LJ
5
ws
HA4F-22
ENV BLEED
HA4G-22
1
5A
B:8
CABIN-LT
1
1
2A
1LW
FUEL-QTY
1QX
DUMP
3
9HP
C:11
1
1CG
EMERGENCY BUS PP4
C:10
1
5A
FLAP-CTRL
25CG
ENV-BLEED
5A
C:2 C:1 C:8
1
3
5AH:1
15LJ
2
1LJ
B:14
1
2A
P-VENT
B:7
1
1
6HK
07.1.1.17 1
AUTO/MANUAL
1
5A
2
COLD
1
FUEL-TR-R
2QF
1
BATTERY BUS PP2
1HA
5A
1
4HA
LOAD BUS PP3
2
FUEL-TR-L
B:1
1
1
2HP
3A
C-PRESS
IGN
5A
A:6
1
1JB
A:12
2
2A
ENG-INS-2
1QF
2
HA12F-22 HA14F-22
MAN CONTROL
D:9 D:8 D:10 B:3 B:4 B:5
C:5
2A
ENG-INS-1
1HP
A:5
1
START
5A
C:6
1
1A
DIP-2
2EZ HA13F-22
2
BLEED AIR
SCHALTER ENTFÄLLT
1
1A
DIP-1
1EZ
1
A:7
1
1A
3HI 7.5A
4JB
FUEL-P-2
2QB
C:1
3
10A
2EY
CIGA-LTR
1MM
C:2 A:2
2
2
15A
PROP-HT
5
LH3E-20N
3
PITOT-R
20A
2
2HG
2HI
4 6
LT2E-20
3
1HG
A:8 A:9 A:10
3
1HI
NIGHT
LT1E-20
:2
D:19 B:2 B:3
1
1EY
PITOT-L
1
A:1
10HG
7.5A
1
D:12 D:6
9HG
FUEL-P-1
C:1
2
3HF:2
WSH-CTRL
2A
1 WV8E-22 TEST
07.2.1.16
DIMMING
NIGHT
8HB
2
AIR-CTRL
2A
2HF
WSH-HT
20A
1
9HB:2
HB4E-20
7HB
A:5 A:4
2
2
:1
1QB
GEAR-WARN
5
HYDR
LG52E-22S
1
1HF
1
ws org bl
WV9E-22 (TONE)
2HB3E-20
334.90
3LJ:1
VMO WARN
VV203
D:2 C:20 C:19
3
:1
30A
VENT
50A
D:7 F
2
1A
23GA
1GW
44GA
100A
5
125A
6HB
1
LUMI FOLIE
1
B:15 B:16 B:17 B:18
334.81
314.30
1
AIR-CON
C
1HB
C:8
GEAR-CTRL
PP30E-2
3
D:8 D:9
1
1GA
3GA-1
GEAR-AUX-1
D:6
2
39GA
3GA-2 DIODE
Stift FE 4198 Buchse FE 4199
4 X 12
1 Stück
Modul 0412
Stift FE 4196 Buchse FE 4197
8 X 16
3 Stück
Modul 0816
Stift FE 4192 Buchse FE 4193
12 X 20
6 Stück
Modul 1222
20 X 22
5 Stück
E
Stift FE 4194 5 Buchse FE 4195 A
C #4
#4
5
Modul 2022
1A
5
CB6
B
5
D:5
2
D
#0
D
B
2
3
A
20
E
5 8
#4
HOT BUS PP1
D
C
B
A 3 5 7
MS3106F 36-6P Stecker MS3100F 36-6S Dose
2
6
EA-9B243.10
HB2E-4
HB7E-12 OFF
HB18E-22 LOW1
5
VENT
1 3
HB16E-22
AIR CON
ON
2HG1E-16
#4
BATTERY, VV242 EA-9B243.10
D:7 D:18
20 AWG 22 2 2
4 AWG 12
B:6 B:7 B:8
B:4 2 2 2
8 AWG 16 2
12 AWG 20
2
E-Box, EA-9B243.40
5A
CB1
20 AWG 22
C:17
20 AWG 22 1
B:19 B:20
20 AWG 22 1 1
A:10
12 AWG 20 1
1 D
C
B
A
Kabel über Shelf
D:4
3
4 AWG 12
C:2
8 AWG 16 3
B:12
12 AWG 20 3
3
A:11 A:12
3
1
4
1617
AIR CON
1 HG2E-16 TEST
215.20
WARM1
ws
HA3F-22 3
bl
MAN
org
AUTO
07.2.1.134
bl
6
215.20
OFF 1
HA28E-22 ON
07.2.1.13 4
GENERATOR
GENERATOR
EMERGENCY
243.10
PP4E-22
RCCB
CG51G-20 CG51H-22
4
Maintenance Manual EXTRA 500 Chapter 91 30. March 2012
C
B
A 12 AWG 20
2
4 3
PP31E-2
DC GENERATION 1, VV243
BUS-TIE-NORMALLY-OUT
AIR CON
215.10
CABIN VENT
215.10
CABIN VENT
215.10
HB17E-22 HI
07.2.1.40 901 4 6 OFF
07.1.1.13 215.10
PITOT HEAT R/H
PITOT-R
SN2E-22
VV202
2HI1E-12
303.10
3
MAP
CABIN
ON
NAV
ON
2LF1E-20
ES1E-22
2FG1E-14
SS1E-20
SN1E-22
PD5E-22 OFF
07.1.1.13 244.10 EXT POWER
243.10
ON
243.10
PP33E-12
PP5E-22N OFF
07.1.1.13
DC-GEN I
243.10
OFF 1
243.10
FLAP SYSTEM
4 07.2.1.13
243.20
275.20
LUMI FOLIEN
1 3
OFF
HG3E-16
07.1.1.16 ON MM1E-18
EY2E-22
EZ2E-20
QF1E-22
QF4E-22
HK1F-22
1
2LJ1F-22
3
LJ5E-22
1
2LJ1E-22
3
LJ2E-22
1
2 LC1E-20
3
LC2E-22 LC2F-22
1 3
LF2E-20
RECO
ON
LF2J-22
#0
GA40F-22
HI2E-12
PROP
ON
#8
#8
5HF1E-22
6
HF3F-22
WINDSH
HF3E-22
HI4E-22
CIGAR LIGHTER
252.10
DIP 2
TRANSFER PUMP 1
TRANSFER PUMP 2
VENT LEFT
752.15
HK1E-22 LJ1G-22 OFF
MAP LIGHT
334.40
ON OFF
07.1.1.13
OVERSPEED TEST
RH IFD
WEATHER DETEC
(KDM 706A)
RZ1E-22 RZ16E-22
TH1E-18
TS1E-20
TL1E-20
5
GA37E-22
GA40E-22
GA1E-22
3
HF4EF-12 ON
07.2.1.13 4
PROP HEAT
QB1E-20
316.40
EIP 2
316.50
731.30
731.30
VENT RIGHT
752.15
DOME LIGHT
334.40
07.1.1.13
CABIN LIGHT
334.40
OFF
07.1.1.13 NAV LIGHT
334.20
OFF
07.1.1.13
276.10
344.14
DME
12V SOCKETS
BROADCAST(MLX770)
DATA LINK(MLB700)
F
GEAR CONTR
GEAR CONTR
323.10
GA3E-22 GA54E-22 GA6J-8
1
2HF2E-12
WINDSHIELD HEAT
FUEL PUMP 2
JB1E-20
JB2E-20
2LN1E-20
ICE
ON
STROBE
ON
2HH1H-22
3
1
E-BOX, VV244 EA-9B243.10
E-BOX, VV245 EA-9B243.20 323.10
GEAR AUX I
323.10
HYDR CAUTION
323.10
GEAR HYDRAULIC
323.10
OFF
304.20
WINDSHIELD CNTRL
304.20
OFF
07.1.1.13 360.11
731.10
IGNITION
743.10
HA1E-22
CG1E-22
CG8E-16
QY1E-22
1 3
LN2E-20
1
2LB1E-20
3
LB10E-20 LB2E-20
INSTR
ON
RECO LIGHT
334.60
2LG4G-20
3
LG116E-20
342.66
1
BOOTS
ON
345.47
344.16
VV201
2HG4E-18
PITOT-L
HP1E-22
5
ON
CABIN PRESS(IN FLOW)
FLAP CNTR
ICE LIGHT
INSTRUMENT LIGHT
LH116G-20 LH4E-20 HH1E-22 OFF
3
HH2E-22
CA3E-20
235.17 AUDIO/MKR (PM8300)
252.11
344.17
PP34E-12
XXX X X XX
6
START
07.1.1.15L 1 HP9E-22
215.20
275.20
FLAPS
275.20
FUEL FLOW
731.40
OFF
07.1.1.13 334.55
OFF
STROBE LIGHT
OFF1
07.1.1.13 334.90
BOOTS
310.10
07.1.1.13
A/P SERVOS (TRIM)
1FG3E-14
WV1E-22
Anzahl ETA-483 klein 1 - 35A ETA-482 mittel 0.1 - 50A ETA-452 gross 50 - 100A Anzahl Lochpositionen XX Kabel über Shelf
GW1E-22 GW1G-22
QB4E-20
HG5E-18 TEST1 OFF
3
ON
EY1E-22
EZ1E-20
OFF
743.10
2
HP10E-22N
HP9G-22 HP3E-22
QX1E-22
WL1F-22
2LA1E-18
LDG
07.1.1.13 334.10
2LR5E-20
DAY-NIGHT
334.90
BOOTS TIMER
310.10
271.17
2FG3E-14
SD1E-20
3
EIP 1
316.50
HP2E-22 PRESS
PRESS
3
LOW VOLTAGE MONITOR
315.90
WH1E-22 WH1G-22
EY3F-20S
1 3
LA2E-18 ON
LA7E-22
LG119E-20
1 3
LR6E-20
GLARE
ON
HM1E-22
FM1E-22
1FG1E-14
LH IFD
342.65
Vmo WARNING
314.30
IFD RH
342.66
(TAS610)
2
GEAR WARNING
323.20
CABIN PRESS
213.30
DUMP 4
STALL WARNING
273.30
GLARE LIGHT
334.90
LH IFD
342.65
FG16E20
SH1E-18
TAS
344.15
CA1E-20
1
EXT-LADER
EXT-LADER
ALTERNATOR 2 FIELD COURTESY LT
334.50
ELT
FUEL PUMP 1
731.10
HG6E-18
07.1.1.16 DIP 1
CABIN PRESS
213.30
DUMP
213.30
VOLT MONITORING
316.40
OFF
07.1.1.13
INTAKE ANTI-ICE
304.10
KEYPAD
342.67
(BXP6402R)
PP47E-16
A/P COMPTR
271.17
CA1F-20
CA2E-22
AUTOMATEN
GEAR-AUX-2
323.10
GEAR AUX 2
244.20
ALT-FIELD
243.20
COURTESY LT
ELT
256.11
EMGC RELAY
EMGC-2
EMERGENCY RELAY
PITOT/STATIC L/H
303.10
316.40
CABIN PRESS
213.30
FUEL INDICATION
284.10
LANDING-LIGHT
334.35
DIMMIMG
334.90
OFF
07.1.1.13
STBY GYRO
342.73
ATC
345.57
PR19E-20
PR200E-20 ALTERNATOR FEELD 2 243.20
TURN COORDINATOR
271.17
PR200E-20
D
C
B
A
A
B
C
D
2
001758_212_02
1VN-E
B
MM2-18N
MM1G-18
2
1
2MM
Zigarettenanzünder
3
4
C:1
3
1
2
3
4
Maintenance Manual EXTRA 500 Chapter 91 30. March 2012
1
5
MM1E-18
EDV-Kennung:
9B25210T
04 03 02 01 Ver. Bezeichnung
6
Zuordnung links / rechts wird mit */* in allen Feldern angegeben.
A
ÄM-400-09-01
01.07.10
Nr.: Änderung/Mod. Nr.: Datum
Letzte Bearbeitung:
see EA-9B246.10 DC-DISTRIBUTION
LOAD BUS PP3
6
Die Gültigkeitszuordnung von Version zu Flugzeugbaureihe ist der Bauakte bzw. dem jeweiligen Fertigungsauftrag zu entnehmen.
10A
1MM
CIGA-LTR
CIRCUIT BREAKER/SWITCH PANEL
5
HW
Name
Name
PB
Datum
16.12.02
7
46569 Hünxe, Germany
Schwarze Heide 21
Gepr.:
Gepr.:
Bearb.:
7
Projektion Freimaßtoleranz Oberfläche
A Blatt 1
von 1
8
Schutzvermerk nach DIN 34 beachten.
A3
EA-9B252.10
CIGAR LIGHTER, MM
EA 400-500
Maßstab auf SI.-Klasse Oberflächenschutz
8
A
B
C
D
A
B
C
D
TH3E-18N
TH3E-18N
TH2E-18
3 2
1
2TH
Mittelkonsole
Steckdose 1
2
H TG
3 2
1
1VN-F 001758_212_02
TH5E-18N
TH4E-18N
TH2F-18
Co-Pilot
3THM
Steckdose 2
3
TH5E-18N
TH2G-18
Tisch
2
3
1
F G H J K
001115-202-02
A B C D E
4TH
Steckdose 3
TH2E-18 TH2F-18 TH2G-18 TH2H-18
4
violet
1
2
3
4
5
black
24V TO 12V Converter
yellow
5
black
red
Converter SM 2430
Maintenance Manual EXTRA 500 Chapter 91 30. March 2012
1
E
TH6E-18N
C:3
EDV-Kennung:
9B25211T
04 03 02 01 Ver. Bezeichnung
Die Gültigkeitszuordnung von Version zu Flugzeugbaureihe ist der Bauakte bzw. dem jeweiligen Fertigungsauftrag zu entnehmen. Zuordnung links / rechts wird mit */* in allen Feldern angegeben.
3VN-A 001758 212 02
VV26
TH1F-18
6
3
ÄM-400-09-01
01.07.10
Nr.: Änderung/Mod. Nr.: Datum
A
10A
12-VDC
LOAD BUS
PP3
7
HW
Name
PB
7
46569 Hünxe, Germany
Schwarze Heide 21
Gepr.:
Gepr.:
Name
Datum
Bearb.: 20.12.04
see EA-9B246.10 DC-DISTRIBUTION
TH1E-18
1TH
CIRCUIT BREAKER/SWITCH PANEL
Letzte Bearbeitung:
CB Trennstecker
6
A Blatt 1
8
Schutzvermerk nach DIN 34 beachten.
A3
EA-9B252.11
12V SOCKETS. TH
von 1
Projektion Freimaßtoleranz Oberfläche
EA 400-500
Maßstab auf SI.-Klasse Oberflächenschutz
8
A
B
C
D
A
B
C
D
L2
L1
345-6196
3
2
1
4
6
5
2
5
8
3
6
9
7
4
1
1 3 8 5 2 7 6 4 9
3
151-5009
Molex
2DA-A
Auf Kabelseite gesehen
2DA
+28 VDC
ELT REMOTE SWITCH
2
001758_212_02 1VN-C
DA3E-22N
DA2F-22 DA11F-22 DA12F-22 DA13F-22 DA14F-22
H
DA2F-22
17 18 19 20
SIM
ST13-D
DRUCKSCHOTT HINTEN
DA11F-22 DA12F-22 DA13F-22 DA14F-22
4
2
1
2
3
4
Maintenance Manual EXTRA 500 Chapter 91 30. March 2012
1
S
5
RG 142 C/U
RG 142 C/U
611-6013-04
red + blk -
110-773
4DA
ELT ANTENNA
+
3DA
6
453-6603 (MOUNTING 452-3034)
Nr.: Änderung/Mod. Nr.: Datum
Letzte Bearbeitung:
452-6505
1DA
452-6504
EXCHANGE BATTERY
ARTEX ME 406 ELT
Light Reset 1 Reset 2 External On Horn Power G-Switch Loop G-Switch Loop Ground
9B25611T
04 03 02 01 Ver. Bezeichnung EDV-Kennung:
E-BOX EA-9B-243.40
HOT BUS PP1
AUDIO INDICATOR
2 6 13 14 8 5 12 7
ELT
1A
ELT
6
see EA-9B246.10 DC-DISTRIBUTION
CB6
Die Gültigkeitszuordnung von Version zu Flugzeugbaureihe ist der Bauakte bzw. dem jeweiligen Fertigungsauftrag zu entnehmen. Zuordnung links / rechts wird mit */* in allen Feldern angegeben.
DA15E-22 DA5E-22N
4DA-A
1DA-B
150-1130
SUBD 15S
1DA-A
DA2E-22
E-BOX
DA4E-22N
VV242
ST1
DA11E-22 DA12E-22 DA13E-22 DA14E-22 DA15E-22
BATTERY
Bolzen
5
ELT
COURTESY LT
ALT FIELD 2
SPARE
BATT CHARGE
GEAR AUX 2
Name
HW
Name
7
46569 Hünxe, Germany
Schwarze Heide 21
Gepr.:
Gepr.:
Bearb.: 17.09.10
Datum
Projektion Freimaßtoleranz Oberfläche
8
Blatt 1
von 1
8
Schutzvermerk nach DIN 34 beachten.
A3
EA-9B256.11
ELT ARTEX ME 406, DA
EA 400-500
Maßstab auf SI.-Klasse Oberflächenschutz
ONLY FOR EXCHANGE
7
A
B
C
D
D
C
B
A
4CA
8
43 38
27 43
16 15 46 5 6 45
28 30 31
10 11 44
14 41 34 35 40 4 12 13 24 25 26 7 19
49
18 22
36 37 46 1 2 39 20 21
29 12 31
15
34 17
5 6 24 41
16 33 50 46 7 8 13 14 45 32 28 11 44 30
9 10 48 37
42 26 27 2 21
4 20
3 22 23 40
FD Enable
GND GPSS
Audio Output GND
Manual UP SW Manual Down SW SHIELD GROUND CWS CWS GND Shield GND
Pitch Flap Pot. Signal Reference Trim FlaP Pot
10 VDC Paralax Pot. Pitch Str. Centering FD Pot. GND
Trim Interrupt SHIELD GROUND Roll Sign. Roll Sign. Ref. SHIELD GROUND FD LOGIC ROLL STR SIG PITCH STR SIG ANNUN LOAD ANNUN CLOCK ANNUN DATA SIG REF G/S DOWN -
SHIELD GROUND
G/S UP + VS SIGNAL
ROLL STEERING 429A ROLL STEERING 429B SHIELD GROUND G/S FLAG + G/S FLAG SHIELD GROUND ALT ENGAGE SIGNAL ALT SEL CONTROL
HDG RETURN CRS RETURN L-R -RT
Lights
A/P A+ A/P Disconnect
Rate Gyro Tach. Rate Gyro Ref. Rate Gyro Signal Shield Gnd.
Transducer Ground 10 VDC Transducer Signal Shield Gnd. AC Heading AC Course NAV FLAG + NAV FLAG SHIELD GROUND LOC SWITCH DC HDG HI (KCS 55) DC CRS HI (KCS 55) SHIELD GROUND L-R +RT
Ground for DG Ground 429 TX+ 429 TX-
Shield Gnd. Exitation Ref. Signal Ref. Pitch Solonoid GND Pitch Motor
Trim Switch DN Pitch Solonoid
Pitch Motor Trim Switch UP Trim Switch Com. Shield Gnd.
CA5E-24S
ws bl
CA5F-24S
CA4F-24S
ws bl
ws bl
E
CA39E-24S
rt ws/grün
CA26E-24S
CA25E-24S
1VN-B
CA37F-24S
ws org bl
ws bl
ws bl
11 12 13 14 15 20 16 17 18 19
ws org bl
ws bl
ws bl
ST14-A
6CA-A
CA26F-24S
CA25F-24S
ws org * bl *
ws * bl *
ws bl 2 3
6CA-a
PITCH SERVO P/N 001008-P4
4 8 7
6 1
7CA-a
ROLL SERVO
6CA
1
CA19E-24S
CA19E-24S
CA37E-24S
CA9E-24S
CA9E-24S
ws bl
ws org bl
CA24F-24S
1VN-B
001758_212_02
5CA
CA21E-24
3 2 1
8CA Transducer
GND
28 VDC
5CA-a
CA22E-24S
DRUCKSCHOTT HINTEN
SIM
ws org bl
A E D C B
CA21E-24
6 7 8 9
8CA-A ws 2 org 3 bl 1
TRANSDUCER P550-5017
CA29E-22N
CA23E-24S
ws org bl
CA22E-24S
ws org bl
ST14-A
DRUCKSCHOTT HINTEN
CA24E-24S
ws bl ws bl
1
CA20E-24S
CA23E-24S
CA15G-22 CA16E-24
ws bl
ws bl
ws bl
ws org bl
ws org bl
4CA-A
P2 39122
CA40E-24S
CA42E-24 CA43E-24
13 14 11 12
ws/rt blau grau grün braun sw gelb lila ws org
25CA-a 4 5 3 2 6 9 10 8 1 7
CA42E-24 CA43E-24
P/N 6405-28L
rt ws/grün
blau grau grün braun sw gelb lila ws org
ws/rt
25CA-A
CA41E-24S
11 6
9 19 13 16 12 17 20 10 18
12CA-a
Steckerleiste im Steuerhorn
CA41E-24S
CA2F-22
ws bl
ws bl
ws bl
TURN COORDINATOR
RZ2F-24S
CA13E-24S CA15F-22 CA8E-22 CA18E-24
CA7E-24S CA33E-22N
CA3F-20
12CA-A
Trennstecker Pilot
ws bl
5CA-A
see EA-9B235.17 MKR-AUDIO
10CA
TRIM SERVO
CA40E-24S
see EA-9B334.90 DIMMING
CA38E-24S
B
1VN-B 001115_1758_212_02
VV39
1 2
4 3
ws bl
LG8E-22
SIM
ws bl
ws bl
see EA-9B284.13 PCB-BOARD 1 Pin 25
4 5 10
3 1 2
CA39E-24S
1
bl
CA31E-24S CA32E-24S CA33E-24S CA34E-24S CA35E-24S CA36E-24S
25
ws bl
ws bl
10CA-a
ws bl
ws
CA13E-24S
ws bl
CA6E-22
CA7E-24S
ws bl
CA12E-24S
CA67E-22
CA14E-22S CA30E-22
CA4E-24S
ws bl
10CA-A
1
1
50
16
55
ws 54 bl
44
ws 5 bl
9 48
47
ws 46 bl
42
12
ws 43 bl
ws 13 bl
9CA-A 72
UP
PTT Pilot PTT Pilot
E
15CA
B
DN
C
A
F
D
2
25 39 43
19 18 1 36 39
35
Exitation EXC. + 10 V EXC. Ground
Roll Motor Roll Solonoid Roll Motor Roll Solonoid GND Shield Gnd.
Airframe Ground
P1 (39123)
ws bl ws bl
1
CA17E-20N
D
CA28E-24S
CA27E-24S
SIM
001758_212_02
ws bl ws bl
b d f h g c
ws bl ws bl
ST5
TRENNSTECKER OVERHEAD
CA28F-24S
CA27F-24S
ws bl ws bl
7CA-A
4 1 3 2
2
7CA
P/N 0106-2-T3
6
4
3
16CA:2
CA68-22N
CA1G-20
1 16CA:1
17CA
CWS
AIS 240-35
13CA
CA8F-22
CA18F-22
optical coverage minimal 98 - 100%
C
CA18E-24 CA8E-22
001758_212-02
1VN-B
K3D-NO K3B-NO K2A-NO
K2B-NO K1A-NO
K2D-NO K2C-NO
K1C-NO K1D-NO
9CA
K2B-NC K1A-NC
K2D-NC K2C-NC
K1C-NC K1D-NC
K4D-NC K4C-NC K4A-NC K4B-NC K3A-NC
K3D-NC K3B-NC K2A-NC
K4D-NO K4C-NO K4A-NO K4B-NO K3A-NO AI ENERGIZE
36 AWG Tinned copper per ASTM-B-33
K4A-W
K3D-W K4D-W K4C-W
K2B-W K1A-W
K3B-W K2A-W
K2D-W K2C-W
K1C-W K1D-W
K4B-W K3A-W
14CA CA3G-22
A/P DISCONNECT
5
07.2.1.23
28V RELAY POWER
A/P RELAY
2 07.1.1.13
A/P MASTER
3
1
TRIM
see EA-9B235.17 MKR-AUDIO
OVERBRAID
CA15H-22
see Detail A
TRIM COMMAND SW
CA67E-22
CA15E-20
CA14E-22S
Maintenance Manual EXTRA 500 Chapter 91 30. March 2012
29 9
Sig. Ref. FD. Flag
39 50 3
Shield GND 28 VDC Trim Roll Sol. Logic YD.
42 23
33 48 47
Trim Solonoid GND Solonoid Shield GND
GND Alt. Sel. Jumper
17 32
Trim Motor + Down Trim Motor + UP
4CA-B
CA15E-20
CA15G-22 CA15H-22
ST14-A
B3
DRUCKSCHOTT HINTEN
C
B
A
CA16E-24 A2
3
ws bl
ws bl
ws bl
ws bl
ws bl
ws bl
9CA-A
A1
3
F
E
D
Detail A
25 4
26 27
23 22
34 35 36 33 32
30 29 8
14 15 56 53 52 71
10 49 28
45 24
6 7
3 2
B1 A3
STEC 55X
CA6E-22 B2
CA1H-20 X1 X2
2
1
1
3
07.1.1.13
2
1K
107-9518
18CA 1 2K0 R2 2K0 0,25W
3 R1
YAW TRIM
3
17CA 2
CA46E-24S
CA45E-24S
E UP
15CA
DN
CA66E-24S
CA65E-24S
CA64E-24S
CA59E-24S CA60E-24S CA61E-24S CA62E-24S CA63E-24S
CA56E-24 CA57E-24 CA58E-24
CA50E-24S CA51E-24S CA52E-24S CA53E-24S CA54E-24S CA55E-24
CA47E-24 CA48E-24 CA49E-24
B
100
CA44E-24S
WH10E-22
REL M210B4N
55CA
C
F A
D
20CA-A
4 2 3 1
20CA-a
3 CA3E-20
3 CA1F-20
3 CA1E-20
1 CA2E-22
CA3H-22
A:7
A:6
A:5
C:18
CA3H-22
CA72E-22
CA70E-22
Zuordnung links / rechts wird mit */* in allen Feldern angegeben.
EDV-Kennung:
9B27117T
ws bl
CA46E-24S CA37E-24S
ws bl
CA50E-24S CA51E-24S CA52E-24S CA53E-24S CA54E-24S CA55E-24
ÄM-400-09-01 ÄM-400-04-02
07.10.10 09.09.04
19.01.11
Nr.: Änderung/Mod. Nr.: Datum
B A
Letzte Bearbeitung:
ws bl
CA37F-24S
ws bl
ws bl
P2121
ws bl
1
ws bl
CA66E-24S
CA65E-24S
CA64E-24S
CA59E-24S CA60E-24S CA61E-24S CA62E-24S CA63E-24S
CA56E-24 CA57E-24 CA58E-24
P2122
J2122
P1122
ws bl
CA47E-24 CA48E-24 CA49E-24
ws bl
CA45E-24S
P1121
J1122
ws bl
1
CA76E-22 CA75E-22 CA74E-22 CA73E-22
12CA-A
CA77E-22N CA73E-22 CA74E-22 CA75E-22 CA76E-22
CA72F-22
CA70F-22
CA69F-22 CA71F-22
10CA-A
2CA
CA3J-22
5A
CA44E-24S
CA31F-24S CA32F-24S CA33F-24S CA34F-24S CA35F-24S CA36F-24S
Die Gültigkeitszuordnung von Version zu Flugzeugbaureihe ist der Bauakte bzw. dem jeweiligen Fertigungsauftrag zu entnehmen.
04 03 02 01 Ver. Bezeichnung
19VN-A
SIM
SIM ST13-D
ST14-B
SIM
ST13-D
001758 212 02
A
13
12
7 6
11
PP5
AP COMPTR
AVIONICS BUS
DRUCKSCHOTT HINTEN
5A
T&B
CA69E-22 CA71E-22
3CA
CA38E-24S
CA31E-24S CA32E-24S CA33E-24S CA34E-24S CA35E-24S CA36E-24S
see EA-9B273.30 STALL WARNING AP-Disconnect bei Stall Warning
Montieren auf Platinen-Blech Instrumentenbrett mittig
YAW- Poti
1
2
Off Auto
CA30E-22
1
YAW DAMPER
CA3G-22
CA3F-20
CA1H-20
CA1G-20
CA2F-22
CIRCUIT BREAKER/SWITCH PANEL
CA36F-24S CA35F-24S CA34F-24S CA33F-24S CA32F-24S CA31F-24S
1
ws bl
CA38F-24S
GND Y Motor 2 Y Motor 1 Y Solenoid
51 72
10 31 14 20 41 60 19 40
25 39 2 3 4 15 12 13 27 26 10
3FG
IFD-5000i 700-00083-()
12 CA
Name
PB
Projektion Freimaßtoleranz Oberfläche
B Blatt 1
von 1 Schutzvermerk nach DIN 34 beachten.
A2
EA-9B271.17
EA 400-500 AP-STEC-55X, CA
Maßstab auf SI.-Klasse Oberflächenschutz
see EA-9B342.66 IFD RIGHT
7FG
IFD-5000i 700-00083-()
see EA-9B342.65 IFD LEFT
Datum
4
11 CA
Einstellen auf 73 IN/LBS
08.09.04
OUT 0+ OUT 0-
OUT 1+ OUT 1-
Schwarze Heide 21
Gepr.:
Gepr.:
Bearb.:
429 RX0+ 429 RX0-
429 TX0+ 429 TX0+ GROUND DISCRETE DISCRETE GROUND DISCRETE DISCRETE
Name 46569 Hünxe, Germany
HW PB
2 0 1
3
ANALOG REF ANALOG GROUND DISCRETE OUT DISCRETE OUT 1 DISCRETE OUT 2 GROUND ANALOG OUT 2 ANALOG OUT 3 ANALOG OUT 6 ANALOG OUT 5 ANALOG OUT 0
DISCRETE IN ANALOG IN 1 ANALOG IN 0 DISCRETE IN DISCRETE IN DISCRETE IN GROUND
IFD RIGHT
4 ANALOG REF ANALOG GROUND
25 39
0 1 2
OUT 0+ OUT 0-
OUT 1+ OUT 1-
DISCRETE OUT DISCRETE OUT DISCRETE OUT GROUND ANALOG OUT 2 ANALOG OUT 3 ANALOG OUT 6 ANALOG OUT 5 ANALOG OUT 0 DISCRETE OUT
429 RX0+ 429 RX0-
429 TX0+ 429 TX0+ GROUND DISCRETE DISCRETE GROUND DISCRETE DISCRETE
2 0 1
3
2 3 4 15 12 13 27 26 10 6
51 72
10 31 14 20 41 60 19 40
DISCRETE IN ANALOG IN 1 ANALOG IN 0 DISCRETE IN DISCRETE IN DISCRETE IN GROUND
IFD LEFT
2 4 3 1
HW
23 41 40 22 7 8 15
23 41 40 22 7 8 15
GND Y Solenoid Y Motor 1 Y Motor 2 GND
10 VDC out
Y CTR
YD ON / OFF GND
A+
YAW SERVO
19 3 1 2 6
8
10
13 7
4
YAW DAMPER
5A see EA-9B246.10 DC-DISTRIBUTION
1CA
AP-SERVO
BATTERY BUS PP2
4
D
C
B
A
A
B
C
D
see EA-9B235.17 MKR-AUDIO
see EA-9B235.17 MKR-AUDIO
Kabel im Flugzeug see EA-9B271.17 AP-STEC-55
Steckerleiste
2
ws grün grau ws/rt blau braun org lila sw glb rt ws/grün
1 2
STEUERHORN RECHTS
1 2 3 4 5 6 7 8 9 10 11 12 13 14
STEUERHORN LINKS
3
Verwendetes Kabel liegt im Lager auf Rolle
4
grün gelb
5RZ
rt ws/grün
6RZ
1
2
3
4
5
B
DN
UP
COPILOT PTT
PILOT PTT
E
15CA C
F A
D
5
TRIM COMMAND SW
Maintenance Manual EXTRA 500 Chapter 91 30. March 2012
1
13CA
EDV-Kennung:
9B27118T
04 03 02 01 Ver. Bezeichnung
Die Gültigkeitszuordnung von Version zu Flugzeugbaureihe ist der Bauakte bzw. dem jeweiligen Fertigungsauftrag zu entnehmen. Zuordnung links / rechts wird mit */* in allen Feldern angegeben.
1PST-MMPS
CWS
MPG206R
17CA
A/P DISCONNECT
6
6
ÄM-400-09-01
05.10.10
Nr.: Änderung/Mod. Nr.: Datum
A
Letzte Bearbeitung:
F
E
B C
D
A
Name
HW
E
B
Datum
C
F A
D
PB
Name
7
46569 Hünxe, Germany
Schwarze Heide 21
Gepr.:
Gepr.:
Bearb.: 01.06.04
UP
15CA
DN
7
Projektion Freimaßtoleranz Oberfläche
A Blatt 1
von 1
8
Schutzvermerk nach DIN 34 beachten.
A3
EA-9B271.18
CONTROL STICK LEFT/RIGHT
EA 400-500
Maßstab auf SI.-Klasse Oberflächenschutz
8
A
B
C
D
A
B
C
D
2WH
LIFT TRANSDUSER
15
12
39GA
13
14
org grün lila weiß/rot blau gelb
GEAR WARNING
2
2WH-A
1 5 10 12 6 2
2WH-a
Horn R1-1101 75 40 13-66
5WH
AP EA-9B271.17 55CA Pin X2
WH3E-22N
HG16G-16 HG17E-16N
WH2E-22
ST5
55CA
X2
13VN
see EA-9B303.10 PITOT-STALL HEAT
B
WH2F-22
see EA-9B315.80 ANNUNCIATOR PANEL
100
Trennstecker Overhead
40
CG37E-22
WH10E-22
3
AP X1
WV1F-22
GW1F-22
WH1H-22
WH1F-22
CA1H-20
WH11E-22
5WW-D
WH11E-22
WH2F-22
WH1H-22
CG37E-22
GW1F-22
WV1F-22
WH10E-22
WH1F-22
4
D33
D12
D32
1WH
46
1
STALL
1
2
3
Ground an Seilrollenbeschlag
4
K10
100
R40
5
OVERBRAID
13
8
1GW 2A
100
R41
1A
VNE WARN
K1
D13
14
31
35
ANNUNC
EA-9B315.81 STEUERPLATINE
+ VOLT DIMM
see EA-9B284.13 PCB-BOARD 1
EA-9B284.13b PCB-BOARD 1
VMO-Test
9B27330T 6
HW
Name
01.07.10
ÄM-400-09-01
Nr.: Änderung/Mod. Nr.: Datum
A
Letzte Bearbeitung:
25 24 14
1
8
see EA-9B314.30 AIRSPEED WARNING (TONE TEST)
7
46569 Hünxe, Germany
PB
Name
Cab-Press
Stall-Warn
Aft Door
Projektion Freimaßtoleranz Oberfläche
1WW
A Blatt 1
von 1
8
Schutzvermerk nach DIN 34 beachten.
A3
EA-9B273.30
STALL WARNING, WH
EA 400-500
Maßstab auf SI.-Klasse Oberflächenschutz
Flaps
Gear Warn
Gen-Fail
Annunciator Panel left
Schwarze Heide 21
Gepr.:
Gepr.:
Bearb.: 18.08.04
Datum
WW15-22
WW1-20
WH3E-22N
5WW-B
7
WV3E-22 see EA-9B314.30 AIRSPEED WARNING (IFD LEFT)
WV8F22
see EA-9B246.10 DC-DISTRIBUTION
1WV
see EA-9B315.80 ANNUNCIATOR PANEL
04 03 02 01 Ver. Bezeichnung EDV-Kennung:
6
BATTERY BUS PP2
Die Gültigkeitszuordnung von Version zu Flugzeugbaureihe ist der Bauakte bzw. dem jeweiligen Fertigungsauftrag zu entnehmen. Zuordnung links / rechts wird mit */* in allen Feldern angegeben.
LIGHT TEST (GND)
TONE-GENERATOR
9
K30
STALL
TONE-GENERATOR
K20
GEAR
TONE-GENERATOR
VNE
D11
D21
D31
5A
STALL-WARN
GEAR WARN
PP5
EMERGENCY BUS PP4
5A
AP-CMPTR
AVIONICS BUS 2CA
STEUERPLATINE ANNUNCIATOR 5WW D14
6
26
27
30
12
13
17
16
GW1E-22
WV1E-22
GW1G-22
1
WH1G-22
1
2
WH1E-22
CA1E-20
3
2
CA1F-20
3
C:13 1
C:3
C:4
D:20
D:19
A:5
A:6
5
CIRCUIT BREAKER/SWITCH PANEL
Maintenance Manual EXTRA 500 Chapter 91 30. March 2012
GND
GND
EA-9B323.20 Gear Warning EZ27E-22N
1
A
B
C
D
D
C
B
A
D
C
A
B
1 2 3 4 5
1 2 3 4 5
1 2 3 4 5
6
F
J
M
R
U
E
H
L
P
T
D
G
K
N
S
F G H J K
VV275207
Modul 1a
Modul entfällt !
CG17F-22N
C
H
001115_201_03
VV275204
AD J
J K
F G H J K
001115-209-02
A B C D E
Modul 6a
G
B
Modul 6a
1
2
CG23E-22N
VV275204
001115_201_03
VV275204
001115_201_03 A F
L POTI
17CG
1
5VDC
15° LIMIT B
3 4 5 6 7 8 9 10
FTS D436-37
C
11CG
NC
NO
VV124
VV123
WING L Y=4400 L DOWN LIMIT SW
VV122
VV121
NO
NC
13CG
C
CG30E-22
A2
B2
D2
A1
B1
B3
D1
CG15F-22
bl or ws
VV120
C G
J
VV275206
D
Modul 8a 001115_207_03
B
VV275206
CG19E-22
CG15G-22
001115_207_03
D E
VV275205
C
001115_209_02
VV275205
Modul 7A
CG21F-22 CG21H-22
Module Avionic-Bay
CG19F-22
18CG R POTI 1
3
Modul 8a
2
20VN-A
P600M
12LY
H
CG15E-22
CG30F-22
CG21H-22
AB
FG
X1
A1
X1
A1
FLAPBOX
4CG-A
VV130
VV129
VV128
CG24E-22
NO
NC
CG25E-22
CG41E-22
C
C
85
87
88 88a
16CG
Modul 8a
CG43E-22
BYW 56 BYW 56
R DOWN LIMIT SW
15CG
VV275206
1
CG22E-22N
2
VV125
12CG
C
NC
NO
VV126
VV127
L UP LIMIT SW
CG26E-22
CG20E-22
J K
3
Modul 7A
H
001115_209_02
A
B
G
Modul 7a VV275205
F
001115_209_03
Modul 7a VV275205
CG26F-22
CG20F-22
4
VV133
VV132
VV131
NO
NC
R UP LIMIT SW WING R Y=4400
blau
E
VV275206
001115_207_03
K
5
CG24F-22
Cab-Press
UP-Relais
CG42E-22
85
23CG
Aft Door Stall-Warn
LY10F-22
P600M
5LY
86
87
88
26.72.03 87a
88a
Flaps
Gear Warn
Gen-Fail
CG43E-22
CG8F-20
CG8G-16
CG16F-22
CG14E-16N
Annunciator Panel left
34CG
GNM 4175A
10CG
1WW
P/N 90-4219X-1 geändert
33CG
braun
Modul 8a 001115_207_03
86
22CG
87a
26.72.03
Down Relais
RELAY BOARD
Modul 5a VV275203 001115_211_03
15pol DSub Pin
4CG
Einbau BOTTOM
CG1G-22
X2
A2
X2
A2
3 9 5 7 1011 2 1 8 1413 6
X2
A3
B3
D3
EA-95275.23
15
X1
A2
B2
D2
001115_209_03
01758 212 02
Messen zwischen 1 und 2
001578_212_02
20VN-A
15pol DSub
4CG-B
Doc. EA-05856.054
BOX EA-85411.00
14CG CG17E-22N
C
CG12E-22
E
15
2
CG21E-22
NO
NC
VV119
Krimp-Splice blau
14° LIMIT A
rechts
Q?
Kabel anlöten
CG9E-22
links
CG17E-22N
ws or bl
Messen zwischen 2 und 3
3
>7°
Einbau TOP
Q2
EA-95275.22
Maintenance Manual EXTRA 500 Chapter 91 30. March 2012
001758_212_02
20VN-A
H
03.06.2004
35CG BYW 56
Entfernt:
001115-207-02
A B C D E
Modul 7a
F G H J K
Modul 8a
A B C D E
Modul 3a, 4a, 5a
001758-212-02
C
B
A
001115-211-02
F G H J K
A
B
C
D
001115-201-02
A B C D E
Modul 6a
001115 211 03
1 2 3 4 5
6
6
6
3
2
1
8
7
20
1617
20
16 17
3 4
1 2
2
1
1 2 3 4 5
5
4
5
6
6
4
3
20
16 17
20
1617
20
1617
FLAP ZUSATZBOX
Flap Inhibit
CG31E-22
20VN-A, 2VN-B, 1VN-C
GND
CG1E-22N
30CG
GND
5
H
29CG-C
6
29CG-D ST 6
LY10F-22
CG34E-22 CG32F-22 CG33E-22
CG15G-22
ST 6 29CG-D
CG8G-16
ST 7 30CG-D
CG39E-22
CG36E-22
CG40E-22
CG1G-22
SIM_M_2022
CG51E-22
ST 6
X2
S210-A5-A1
X1
A1
B1 A3
B3
M210-B4N
VV135
33CG
20
16 18 17
19
15
14
13
12
7
29CG-D
20
19
LY10E-22
CG33F-22
CG32G-22
CG34F-22
EDV-Kennung:
1
RZ2E-24S
CG52E-22
CG39G-22
CG36G-22
60
42
15°
30°
9B27520T
7CG-A
6CG-A
1 2
1 2
1 2
CG37G-22 CG33G-22
CG37F-22 CG32H-22
CG37E-22
ÄM-400-09-01
7
14.10.10
10
24
28
30°
11
9 7
HW
Name
HW
D4
D3
D2
D1
D8
18.08.04
PB
Name
46569 Hünxe, Germany
Blatt 1
A von 1
8
Schutzvermerk nach DIN 34 beachten.
A2
EA-9B275.20
FLAP SYSTEM, CG
EA 400-500
Projektion Freimaßtoleranz Oberfläche
DIMMING
see EA-9B334.90
Maßstab auf SI.-Klasse Oberflächenschutz
MODUL 1 Pin D 5lh-a Pin-23
5LH see EA-9B334.90 DIMMING
BYW-56
LAMP TEST GND
see EA-9B284.13B PCB-BOARD 1
BYW-56
BYW-56
BYW-56
BYW-56
DIMMING BOARD EA-9B410.30C
29
24
11
10
7
2SS see EA-9B344.14 WEATHER DEDECTION
MIC INHIBIT INPUT
MODUL 1 Pin E 5lh-a Pin-5
Datum
RS 321-379 FE4252 EA-75112.60 EA-75112.60.KBS
PC-BOARD 1 EA-9B411.50A
54
Schwarze Heide 21
Gepr.:
Gepr.:
Bearb.:
11 6
3CG
WEATHER DETECTION TWX-670
MODUL1 Pin C
LED 590-244 green
7CG
17.02.11
8
CG34H-22
5LH-A
CG34H-22
LED 590-244 green
6CG
Nr.: Änderung/Mod. Nr.: Datum
A
Letzte Bearbeitung:
P1
GA53H-22
SS9E-24
SS8E-24
SS7E-24
SS7E-24
P1
15°
Mittelabgriff
0°
9 10
FLAP CONTROL SWITCH
see EA-9B246.10 DC-DISTRIBUTION
FLAP 7.5A
3A
8
FLAP-CTRL
1CG
BATTERY BUS PP2 25CG
LED 590-250 amber
8CG
see EA-9B334.50 COURTESY LIGHT
VV138
VV137
VV136
8CG-A
CG34G-22
Platine GEAR WARNING, EA-9B323.20 39GA-A Pin 4
see EA-9B315.80 ANNUNCIATOR PANEL [HYDR]
see EA-9B344.14 WEATHER DETECTION RZ13E-24S see EA-9B235.16 MKR-AUDIO
Zuordnung links / rechts wird mit */* in allen Feldern angegeben.
04 03 02 01 Ver. Bezeichnung
2
3
4
3
2
1
CG40G-22
CG1E-22 CG8E-16
1A
FLAP-UNB
3 C:6
32CG-A
4
CG51G-20
2
32CG
CG50G-20 2
CG51H-22 27CG
C:11 1
A:3
A:2
1
CIRCUIT BREAKER/SWITCH PANEL
see EA-9B344.14 WEATHER DETECTION
In Transition
CG15H-22
N
D:10
7
see EA-9B235.16 MKR-AUDIO
1VN-C
001758_212_02
CG39F-22
CG36F-22
CG40F-22
CG8F-16
CG1F-22
CG51F-22
CG50F-22
CG51K-22
CG47E-22
42
5WW-D
50
CG52F-22N Die Gültigkeitszuordnung von Version zu Flugzeugbaureihe ist der Bauakte bzw. dem jeweiligen Fertigungsauftrag zu entnehmen.
STECKER AVIONIC BAY
CG50E-22
ST 6
3VN-A
REL M320A1N
36CG
CG53E-22N
A2
B2
see EA-9B315.80 ANNUNCIATOR PANEL
ANNUNCIATOR BOARD EA-9B315.81
+ VOLT DIMM
LIGHT TEST (GND)
ANNUNCIATOR BOARD D14 5WW
6
001758_212_02
18 24 25
5WW-B
An Punkt 20VN anschrauben
WW1-20
WW19-22
1
Flugrichtung
CG22F-22N
CG9E-22
4
3
29CG
CG23F-22N
5V Out Balanced GND 5V Out Balanced GND 28VDC
ws or bl ws or bl
CG12E-22 CG1J-22
14° Position 15° Position Pos. Switch 30° Pos. Switch 0° 28VDC Power In
15° LED Pos. Switch 15° Flap Inhibit/28V
CG35E-22N
Annunciator
NC
Up Relay Down Relay
CG33E-22 CG36E-22 CG31E-22 CG51E-22 CG19E-22 CG15E-22 CG39E-22 CG40E-22 CG1H-22 CG50E-22 CG42E-22 CG41E-22
3
2
2
CG25F-22 F A
X1 X2
CB Trennstecker
1
CG27E-22
16
D
C
B
A
A
B
C
C:9
1
see EA-9B246.10 DC-DISTRIBUTION
LOAD BUS PP3
ES1G-22
1 2
Taster Spörle 220678
P1
J1 MOLEX Mikro Fit 3
ES3G-22
TEST
Instrument-Panel left
2ES
OVERSPEED TEST
2A
3
ES3E-22
35 ES2E-22N
001758 212 02 2VN-C
J
ES3F-22
ST4
FIREWALL
4
1
2
3
4
Maintenance Manual EXTRA 500 Chapter 91 30. March 2012
ES1E-22
O-SP-TEST 1ES
CIRCUIT BREAKER/SWITCH PANEL
2
ES1F-22
D
1
ES1F-22 ES3E-22
5
5
EDV-Kennung:
9B27610T
04 03 02 01 Ver. Bezeichnung
A B
6
HW
Name
01.07.10
ÄM-400-09-01
An Turbine integriert
Nr.: Änderung/Mod. Nr.: Datum
A
Letzte Bearbeitung:
Stecker MS3106F10SL-4S
VV140
3ES
Propeller Overspeed Govenor Reset Solenoid 3ES-A
Die Gültigkeitszuordnung von Version zu Flugzeugbaureihe ist der Bauakte bzw. dem jeweiligen Fertigungsauftrag zu entnehmen. Zuordnung links / rechts wird mit */* in allen Feldern angegeben.
VV139
ES3F-22 ES2E-22N
Jiffi Diode
4ES
6
Datum
PB
Name
7
46569 Hünxe, Germany
Schwarze Heide 21
Gepr.:
Gepr.:
Bearb.: 19.08.04
7
Projektion Freimaßtoleranz Oberfläche
A Blatt 1
von 1
8
Schutzvermerk nach DIN 34 beachten.
A3
EA-9B276.10
PROP OVERSPEED, ES
EA 400-500
Maßstab auf SI.-Klasse Oberflächenschutz
8
A
B
C
D
A
1 2 3 4 5 6 7 8 9
7QX-A
6QX-A
5QX-A
QX13H-22 QX14F-22 QX14G-22 QX13J-22 QX4S-22
QX1R-22
QX11H-22 QX12F-22 QX12G-22 QX11J-22 QX4P-22
QX1Q-22
QX5H-22 QX6F-22 QX6G-22 QX5J-22 QX4L-22
QX1N-22
QX1P-22 QX7H-22 QX8F-22 QX8G-22 QX7J-22 QX4M-22 QX1P-22 QX9H-22 QX10F-22 QX10G-22 QX9J-22 QX4N-22
37pol DSub
1 20 2 21 3 22 4 23 5 24 6 25 7 26 8 27 9 28 10 29 11 30 12 31 13 32 14 33 15 34 16 35 17 36 18 37 19
ws ws bl bl
ws ws bl bl
ws ws bl bl
ws ws bl bl
ws ws bl bl
ws ws bl bl
9QX-A 9QX-a
QX4K-22
QX14E-22S
QX4J-22 QX1M-22 QX13E-22S
QX12E-22S
QX4H-22 QX1L-22 QX11E-22S
QX10E-22S
QX4G-22 QX1K-22 QX9E-22S
QX8E-22S
QX4F-22 QX1J-22 QX7E-22S
QX6E-22S
QX4E-22 QX1H-22 QX5E-22S
QX3E-22S
QX1G-22 QX2E-22S
F G H J K
001115-202-02
A B C D E
VV284101
001758 212 02 1VN-G
QX8-A
A B
F G H J K
001115-202-02
A B C D E
VV284102
1
14 2
15 3
16 4
17 5
18 6
19 7
20 8
21 9
22
10
23
11
24
12
25
13
QX15E-22S
R6 22R
8QX
25pol DSub
QX2F-22S
001758 212 02 1VN-G
C
QX16E-20N
7
QX3E-22S
1
2
3
R1 22R
right mid
right outside
right center
50R
T3
R3 22R
4
Von 0 Ohm bis 30 Ohm je nach Schwimmer ausmessen!
50R
50R
*
T2
*
T1
R2 22R
left center
50R
T4
R4 22R
see EA-9B284.13 PCB-BOARD 1
PCB-BOARD 1 EA-9B284.13B
left outside
50R
50R
left mid
T6
T5
R5 22R
Maintenance Manual EXTRA 500 Chapter 91 30. March 2012
7QX
Gnd
28VDC N/C N/C Input Resistive Float Light Light
Right outside A1026
Gnd
1 2 3 4 5 6 7 8 9
1 2 3 4 5 6 7 8 9
1 2 3 4 5 6 7 8 9
4QX-A
3QX-A
QX2H-22 QX3E-22 QX3F-22 QX2J-22 QX4L-22
QX1N-22
*
B
6QX
28VDC N/C N/C Input Resistive Float Light Light
Right mid A1024
5QX
N/C N/C Input Resistive Float Light Light Gnd
28VDC
Right center A1022
4QX
N/C N/C Input Resistive Float Light Light Gnd
28VDC
Left center A1021
3QX
Gnd
N/C N/C Input Resistive Float Light Light
28VDC
1 2 3 4 5 6 7 8 9
1 2 3 4 5 6 7 8 9
AC DIM-VOLTAGE see EA-9B334.90 DIMMING SYSTEM
*
C
Gnd
Left mid A1023
2QX
N/C N/C Input Resistive Float Light Light
28VDC
Left outside A1025
QX1E-22 QX1F-22 QX1G-22 QX1H-22 QX1J-22
QX17E-22N
QX1K-22 QX1L-22 QX1M-22
2QX-A
see EA-9B246.10 DC-DISTRIBUTION
QX13F-22S
C:15
QX11E-22S
1
QX11F-22S
FUEL-QTY 2A
QX9E-22S
Fuel Indication
1QX
QX7E-22S
EMERGENCY BUS PP4
QX7F-22S
CIRCUIT BREAKER/SWITCH PANEL
QX4H-22 QX4J-22 QX4K-22 QX9F-22S
QX4L-20N QX4E-22 QX4F-22 QX4G-22 QX13E-22S
4
QX5E-22S
3
QX5F-22S
D
2
QX2E-22S
ws bl ws bl ws bl ws bl ws bl ws bl ws bl ws bl ws bl ws bl ws bl ws bl
*
QX6E-22S
1
*
5
5
bl bl bl
ws ws ws
F G H J K
F G H J K
001115-202-02
A B C D E
VV284104
001115-202-02
A B C D E
VV284103
bl bl bl
bl
ws ws ws
ws
ws bl ws bl
QX9F-22S QX7F-22S QX5F-22S
A
B
C
20
16 11 6
20
16 11 6
20
16 11 6
20
5
1
5
1
5
1
5
1
9
5
20
16 11 6
3
4
5
4
2
1
30CG
12
8
7
6
Einpinseite
29CG 16 11 6
5
1
4
1
1
6
A
B
C
D
SIM M 2022
SIM_M_XXXX_SN(PN) D
8 9
QX2G-22S
QX5G-22S
QX7G-22S
QX9G-22S
QX11G-22S
QX13G-22
Zuordnung links / rechts wird mit */* in allen Feldern angegeben.
EDV-Kennung:
9B28410T
04 03 02 01 Ver. Bezeichnung
Varistor
289-7569
15QX
Anschlußbolzen
Varistor
289-7569
+ -
11QX
7
ÄM-400-09-01
Nr.: Änderung/Mod. Nr.: Datum
A
Letzte Bearbeitung:
20.10.10
25.05.04
PB
Name
Schwarze Heide 21
Gepr.:
Gepr.:
Bearb.:
Datum
Name 46569 Hünxe, Germany
HW
Fuel Quantity left outside VDO 999.161.004
+ -
14QX
Fuel Quantity left mid VDO 999.161.004
+ -
13QX
Fuel Quantity left center VDO 999.161.004
+ -
12QX
Einbau siehe EA-1B050.10 Zsb. elektr. Holmdurchführung
ws bl
ws bl
16QX
Anschlußbolzen
ws Varistor bl 289-7569
17QX
+ -
10QX
Fuel Quantity right center VDO 999.161.004
Anschlußbolzen
ws Varistor bl 289-7569
18QX
+ -
9QX
Fuel Quantity right mid VDO 999.161.004
Anschlußbolzen
Die Gültigkeitszuordnung von Version zu Flugzeugbaureihe ist der Bauakte bzw. dem jeweiligen Fertigungsauftrag zu entnehmen.
Flugrichtung
19QX ws Varistor bl 289-7569
7
Fuel Quantity right outside VDO 999.161.004
Anschlußbolzen
ws Varistor bl 289-7569
20QX
Anschlußbolzen
see EA-9B334.90 DIMMING SYSTEM see EA-9B360.11 PROP HEAT
Stecker vom Hauptkabelbaum
SIM M 2022
ST 6
ws bl
ws bl
ws bl
ws bl
ws bl
8 ws 9 bl 10
4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
ST 6
HI9E-22S
6
STECKER AVIONIC BAY
ws bl
29CG-D
ws bl
QX11F-22S
QX2F-22S
ws bl
QX12E-22S
ws bl
QX10E-22S
QX13F-22S
29CG-C
QX14E-22S
QX8E-22S
Projektion Freimaßtoleranz Oberfläche
A Blatt 1
von 1
8
Schutzvermerk nach DIN 34 beachten.
A2
EA-9B284.10
FUEL QUANTITY, QX
EA 400-500
Maßstab auf SI.-Klasse Oberflächenschutz
8
A
B
C
D
D
C
B
A
right Outside
right Mid
right Center
left Center
left Mid
Audio out
Q30
Q20
Q10
10k
10k
10k
BC107
cw
TR30
R21 330
BC107
cw
TR20
R11 330
BC107
TR10 3 cw
50R 162-653
cw
TR56
50R 162-653
cw
TR55
50R 162-653
cw
TR54
50R 162-653
cw
TR53
50R 162-653
cw
TR52
50R 162-653
cw
TR51
2
1
R33 100k
R32 220k
R23 100k
R22 220k
R13 100k
R12 220k
R56 22R
R55 22R
R54 22R
R53 22R
R52 22R
R51 22R
C out
Vcc Q
C mod Gnd
Rt
3 4
1
Rt
C mod C out Gnd
Vcc Q
3 4
1
5
8 7
+ C21 22uF
C out
C mod Gnd
Rt
3 4
1
+ C31 10uF
Stall-Warning
Vcc Q
U30
C20ZSD 100 SOUND 39n
5
8 7
10n
C32
10n
C22
10n
C12
DB25P 259-3071
J51
+ C11 22uF
Gear-Warning U20
C10ZSD 100 SOUND 10n
5
8 7
1 14 2 15 3 16 4 17 5 18 6 19 7 20 8 21 9 22 10 23 11 24 12 25 13
3
Vout
1uF
Vout
U31 L7815C
C33 +
3
1uF
Vout
U21 L7815C
C23 +
3
1uF
C13 +
3
U11 L7815C
GND
Vin
GND
Vin
GND
Vin
1
1
1
0,1uF
C34 +
0,1uF
C24 +
0,1uF
C14 +
K10
K20
REL G6A
+Gear
cw
TR3
cw
cw
TR2
BYW56
BYW56
BYW56
BYW56
BYW56
10REL TN2 113-8875
9 K1:3 7
BYW56
10 REL TN2 113-8875
BYW56
D31
RS 162-647
25Ohm
Oil "0" adjust
Torque "0" adjust
25Ohm
BYW56
D21
TR1 1 Paralax Poti
BYW56
D11
5k
3
D1
D2
D3
D4
D1
K1:1 1
8
D2
K2:1 1
3
2 K2:2 4
EA-9B316.50 Engine Instrument Package
Abgleichpotis für Tourqe-und Oil Press Sensor
Vmo TEST
4
OVERBRAID
+Stall -Stall
1
8
9 6
11
D30 BYW56
16
4
13
1
8
9 6
11
+Vmod
BYW56-Gear
K30
D20
1
8
9 6
11
BYW56
REL G6A
16
4
13
D10
REL G6A
16
4
13
see EA-9B284.10 FUEL QUANTITY
Fuel calibration
Vmo-Warning U10
2
330
1
R31 330
C30ZSD 100 SOUND 20n
2
3
1
4
BYW56
D13
Sense
R5 330
R6
GND
Torque 0 T-O GND Oil 0
+Gear -Gear Stall -Stall -Stalld
Audio out +Vmo
330
-Vmo
14
2 20 1
12 30 27 26 17 6
16 33 15 25 28 9 8 13
5 23 4
7
10
11
24
29
31
35
34 32
19
36
18
37
3
22
21
J1
EDV-Kennung:
9B28413T
04 03 02 01 Ver. Bezeichnung
Die Gültigkeitszuordnung von Version zu Flugzeugbaureihe ist der Bauakte bzw. dem jeweiligen Fertigungsauftrag zu entnehmen. Zuordnung links / rechts wird mit */* in allen Feldern angegeben.
bestückt -9B411.50A
optical coverage minimal 98 - 100%
5
330
R9
L-Gnd
Out
Sense
-Vmo test
black
3 green
red
PC-BORD -9B411.51A
D33 BYW56 D32 BYW56
D12 BYW56
330
R8
Out
36 AWG Tinned copper per ASTM-B-33
330
R7
R40 100 R41 100
1
5
U60 LOW VOLTAGE
Maintenance Manual EXTRA 500 Chapter 91 30. March 2012
R30
330
R20
R10 330
left Outside
1
GND
2 GND
2 GND
2
2
Gnd 2
J1 DB37P
6
7
1 20 2 21 3 22 4 23 5 24 6 25 7 26 8 27 9 28 10 29 11 30 12 31 13 32 14 33 15 34 16 35 17 36 18 37 19
6
ws bl org
WV8F-22
WH3E-22N
EZ15E-22S
GW1F-22 CG37E-22 WH1H-22 WH2F-22 WH10E-22 WH11E-22
SD9E-24SS WH12E-22S WV1F-22
SS6E-24S CA12E-24S
WH1F-22
SS7E-24
SS8E-24
SS9E-24
GA53H-22
CG34H-22
WV3E-22
ÄM-400-09-01
1
1VN-G 001758 212 02
Datum
HW
Name
Schwarze Heide 21
Gepr.:
Gepr.:
Bearb.: 06.06.05
7
Name 46569 Hünxe, Germany
HW
HW
Blatt 1
von 1
8
Schutzvermerk nach DIN 34 beachten.
A3
EA-9B284.13
PCB-BOARD 1 A
Projektion Freimaßtoleranz Oberfläche
EA 400-500
Maßstab auf SI.-Klasse Oberflächenschutz
GEAR WARNING (GEAR-WARN 1GW EMERG BUS) GEAR WARNING (9GA-A Pin 14) STALL WARNING (STALL-WARN 1WH EMERG BUS) STALL WARNING (VV172) AP-RELAY (55CA Pin X2) ANNUNCIATOR PANEL (5WW-D Pin 46) see EA-9B316.50 EIP (VV171 ) see EA-9B316.50 EIP (VV169) see EA-9B316.50 EIP (VV168 )
see EA-9B323.10 see EA-9B323.20 see EA-9B273.30 see EA-9B273.30 see EA-9B271.17 see EA-9B315.80
see EA-9B344.15 TRAFFIC TAS-610 see EA-9B235.17 AUDIO/MARKER PMA-8000B (1RM-A Pin 31) see EA-9B314.80 AIRSPEED WARNING (VNE-WARN 1WV BATTERY BUS)
see EA-9B344.14 W-DETECTION TWX-670 see EA-9B271.17 AP-STEC-55X
see EA-9B273.30 STALL WARNING HORN
see EA-9B344.14 W-DETECTION TWX-670
see EA-9B344.14 W-DETECTION TWX-670
see EA-9B344.14 W-DETECTION TWX-670
see EA-9B344.14 W-DETECTION TWX-670
see EA-9B344.14 W-DETECTION TWX-670
see EA-9B342.65&66 IFD (Px122 Pin 16)
see EA-9B334.90 DIMMING (SWITCH 3LJ-1 (1) Vmo Test)
see EA-9B304.20 WINDSHIELD HEAT
see EA-9B304.20 WINDSHIELD HEAT
see EA-9B304.20 WINDSHIELD HEAT
see EA-9B304.20 WINDSHIELD HEAT
D
see EA-9B315.80 ANNUNCIATOR PANEL (5WW-D Pin 22)
1VN-F
05.09.10
8
see EA-9B246.10 DC-DISTRIBUTION (LOW VOLT 1LW EMERG BUS)
001758_212_02
17.02.11
U
1 C:4 66 2 D:20 11 100 35
5 31
X 25
31
X
X
X
12
35
108
C:16
Nr.: Änderung/Mod. Nr.: Datum
A =
Letzte Bearbeitung:
1
HF3J-22
HF7E-22
HF17E-22N
HF16E-22
WL3E-22N
WL1E-22
WL2F-22
CB Trennstecker
1 20 2 21 3 22 4 23 5 24 6 25 7 26 8 27 9 28 10 29 11 30 12 31 13 32 14 33 15 34 16 35 17 36 18 37 19
D
C
B
A
A
B
C
D
2WW
Pneumatic
Fuel Low R
Fuel Low L
Prop Low Pitch
Low Voltage
Fuel Trans R Standby Alt On
Fuel Filter
Fuel Trans L
2
3
WW20-20
WW33-22 WW36-22
5WW-C
24 25
13 16
LIGHT TEST (GND) 5WW-D 20 17
see EA-9B315.80 ANNUNCIATOR PANEL
ANNUNCIATOR BOARD EA-9B315.81
+ VOLT DIMM
D21
ANNUNCIATOR BOARD D24 5WW
4
1
2
3
4
5
5
106 105
Maintenance Manual EXTRA 500 Chapter 91 30. March 2012
geändert
P/N 90-42192-2
Annunciator Panel right
1
EZ64E-22 EZ66E-22
EDV-Kennung:
9B28430T
04 03 02 01 Ver. Bezeichnung
6
EZ66F-22
EZ64F-22
Die Gültigkeitszuordnung von Version zu Flugzeugbaureihe ist der Bauakte bzw. dem jeweiligen Fertigungsauftrag zu entnehmen. Zuordnung links / rechts wird mit */* in allen Feldern angegeben.
29CG-D
6 7
ST 6
STECKER AVIONIC BAY
6
14.10.10
Nr.: Änderung/Mod. Nr.: Datum
Letzte Bearbeitung:
RS 289-7569
7WW1
LOW FUEL LEFT
RS 339-730
5WW1
RS 289-7569
6WW1
LOW FUEL RIGHT
RS 339-730
4WW1
4mm Ringösen
Name
HW
B
PB
Name
7
46569 Hünxe, Germany
A
8
Blatt 1
von 1
8
Schutzvermerk nach DIN 34 beachten.
A3
EA-9B284.30
LOW FUEL WARNING, WW
EA 400-500
Projektion Freimaßtoleranz Oberfläche
20VN-B 001758 212 02
Maßstab auf SI.-Klasse Oberflächenschutz
20VN-B 001758 212 02
Schwarze Heide 21
Gepr.:
Gepr.:
Bearb.: 16.11.02
Datum
EZ67E-22N
AVIONIC BAY
EZ65E-22N
7
A
B
C
D
1
3
A
6
see EA-9B323.10 GEAR CONTROL
M220-B4N
2
34GA
12VN-A
HG7E-20
HG8E-20
3
B:5 C:7
2
13VN-A 20VN-A
Brücke AWG18
M320-B4N
X2
13HG 2
Brücke AWG18
M320-B4N
X2
12HG 2
E F G H
1
001115-302-02
A B C D
001115-302-02
F G H J K
001115-201-02
A B C D E
VV303101
2
001758-212-02
B
A
C
E
F
H
G
D
A
A
5
PITOT-L
B:3
B:2
VV141
X1 VV142
A 3 1
X1
A 1 HG9E-16
3
HG3F-16
HG2F-16
SIM
5 4
ST13-C
SIM
13 11
HG23F-22 HG25F-22
HS8G-22 HS7G-22
E F G H
K
HG28E-18
E F G H
001115-302-02
A B C D
X1
A1
B 1 3
M220-B4N HG9G-20
1
X2
M210-B4N
B 3
A 3 1
15HG
HG17E-18
001758 212 02 1VN-G
VV303102
J
2
2
VV146
HG27G-20 X1
3 C 1 3
Relais auf Relayhalter 7B251.60 Instrument Shelf
HG27E-18
HG9G-20
2
2
2
14HG
HG12E-16
HG23H-22 HG23G-22 HG24H-22 HG24G-22 HG24F-22
X2
001115-302-02
A B C D
VV303101
001758 212 02
1VN-G
HG11E-16 HG2F-16 HG9F-16 HG13E-16
F G H J K
001115-211-02
A B C D E
VV303103
HS8G-22 HS7G-22
4
HG23G-22
HG25G-22
HG17E-18
HG13E-16
HG12E-16
HG23E-22 HG24E-22 HG25E-22
HS25F-22 HS23F-22 HG24F-22 HS8F-22 HS7F22
HG12F-16
HG13F-16
6
SIM_M_0816_SN(PN)
HG17F-18
30CG-D
SIM_M_0816_SN(PN)
5
30CG-D
SIM_M_0816_SN(PN)
4
30CG-D
SIM_M_2022_SN(PN)
1 2 3
AVIONIC BAY 29CG-C
HG24H-22
HG23H-22
HS8F-22 HS7F-22
53 54 52 50 51
3
4
5
5WW-D
5
+ VOLT DIMM
D3
20A 1A
C
A GND
STROMSENSOR 3HG
C
A GND
N
C
A GND
R
Pitot Heat R
D5
5WW
HG14E-16
EDV-Kennung:
9B30310T 6
Zuordnung links / rechts wird mit */* in allen Feldern angegeben.
04 03 02 01 Ver. Bezeichnung
m k n
ÄM-400-09-01
04.10.10
Name
HW
WH3E-22N
1 2
Name
PB
Datum
14.09.04
AN3115-1
8HG-A
46569 Hünxe, Germany
7
Static Heat L
Hydraulic
Static Heat R
Pitot Heat R
2WH
LIFT TRANSDUSER
6HG
PITOT HEAT R
see EA-9B273.30 STALL WARNING
org grün lila weiß/rot blau gelb
2WH-A
Projektion Freimaßtoleranz Oberfläche
A Blatt 1
von
8
Schutzvermerk nach DIN 34 beachten.
A3
EA-9B303.10
1
PITOT-STATIC-STALL-HEAT, HG
EA 400-500
Maßstab auf SI.-Klasse Oberflächenschutz
8HG
PITOT HEAT L
Mit M4 am Seilrollenbeschlag
12VN
Schwarze Heide 21
Gepr.:
Gepr.:
Bearb.:
HG18G-18 HG19E-18
1 2 AN3115-1
6HG-A HG14G-16
Chip Pitot Heat L
8
see EA-9B273.30 STALL WARNING
1 5 10 12 6 2
Mit M4 am Seilrollenbeschlag
HG19E-18
13VN
HG16G-16
2WH-a
WH2E-22
Bleed Overt
Oil-Press Fuel-Press
Windsh-Heat
Annunciator Panel left Stall-Heat
03-06-2122 Pin 02-06-2103
ST5
Tragfläche overhead
Nr.: Änderung/Mod. Nr.: Datum
A
7
P/N 90-4219X-1
WW1-20
WW6-22 WW11-22 WW3-22 WW7-22 WW4-22
Trennstecker
Letzte Bearbeitung:
001758_212_02 20VN-A
HG18E-18
Pitot Heat L
5WW-B
1WW
HG16F-16 HG14F-16 HG18F-18
5 10 2 6 3 24 25
SIM M 0816
1 2 3
30CG-D
AVIONIC BAY
001758_212_02 20VN-A
Stall Heat
Die Gültigkeitszuordnung von Version zu Flugzeugbaureihe ist der Bauakte bzw. dem jeweiligen Fertigungsauftrag zu entnehmen.
20A 1A
STROMSENSOR 7HG
001758_212_02 P 20VN-A
HG24E-22
20A 1A
STROMSENSOR 5HG
HG25E-22
D2
D10
6
ANNUNCIATOR BOARD EA-9B315.81 see Annunciator-Panel EA-9B315.80
HG23E-22
37 42 34 38 35
D6
LIGHT TEST (GND)
ANNUNCIATOR BOARD
SIM_M_XXXX_SN(PN)
Maintenance Manual EXTRA 500 Chapter 91 30. March 2012
1VN-E
1
3
M220-B4N
2
35GA
HG2E-16 2
HG11F-16 HG28F-18
HS3E-22N
3 OFF HG3E-16 2 ON 1 TEST HG5E-18
1 TEST
D-SUB 9
HS2F-22
PITOT-L 9HG HG4E-18 2 OFF 3 HG6E-18 10A 07.1.1.16 10HG ON
see EA-9B246.10 DC-DISTRIBUTION
EMERGENCY BUS PP4
LOAD BUS BUS PP3
PITOT-R
2HG PITOT-R 1HG HG1E-16 2 07.1.1.16 15A
CIRCUIT BREAKER/SWITCH PANEL
HS7H-22
STATIC HEAT RIGHT 3HS
L
KL
5
1
HS6E-22N
ST14-B
7
B
2HS
HS7J-22
HS5F-22
STATIC HEAT LEFT 6HS
HS8H-22
P
N
K
1
5
C
1HS
HS2E-22 LOAD 4 HS1E-22 6,8 Ohm / 15 Watt HG11G-16 3 HG28G-18
A1
A3
see EA-7B233.00 & EA-7B233.10
BUS
A2 HS9F-22N
5HS
2
HS5E-22 LOAD 6 HS4E-22 6,8 Ohm 15 Watt
STATIC-SENSOR R
BUS
4HS
HS8J-22
T
S
1
4
D
6
16 11 6
30CG
29CG
1
4
1
D
2
3
D
A1
A3
20
9
1
16 11 6
C
12
5
20
1
16 11 6
B
1
GA32-22N GA31-22N
HG6F-18
A2 HS9E-22N
HG5F-18 HG3F-16
DRUCKSCHOTT HINTEN
R
HS9H-22N
J
HG28E-18 HG11E-16 HG9F-16
7
M
HG25G-22 HG25H-22 HG5F-18 HG27F-18
HS9G-22N
HG26E-20N
STATIC-SENSOR L
HG6F-18
U
HG10E-22 HG27F-18
5
KFG
8
HS7E-22
ST15
5
HG24G-22
3
B
19VN-A 001758_212_02
A
2
C
HS7E-22 HS8E-22 HS8E-22 4
HG25H-22 5
20
16 11 6
1
16 11 6
A
HG16E-16
1
Einpinseite
HG16E-16 HG18E-18
HG20E-16N HG21E-16N HG22E-18N
HG16G-16 HG18G-18
HG17E-16N
CURRENT SENSOR LeeAir 76390-401C101 400mA pull in curent 100mA drop out
5
20
5
20
HG15E-16N
A
B
C
D
A
B
C
D
HM1G-22
Splice
c
VV149
2HM
nc
no
OFF
ON
Microswitch
RS334-870
(FE4107)
2
VV151
VV150
HM2E-22
HM1G-22
ST4
ST4
24
23 D:18
1
HM2F-22
K
5
11
27
4
2A
HM3E-22 HM4E-22N
5 INV
K5
1
2
3
4
D14
9
6 24 25 5WW-A
5WW-C
WW39-20N
WW20-20
WW26-22
6
5
3HM
2300 7828
EDV-Kennung:
9B30410T
04 03 02 01 Ver. Bezeichnung
6
Zuordnung links / rechts wird mit */* in allen Feldern angegeben.
Die Gültigkeitszuordnung von Version zu Flugzeugbaureihe ist der Bauakte bzw. dem jeweiligen Fertigungsauftrag zu entnehmen.
Am Triebwerk installiert
1 2 3
Anti Icing Solenoid Valve
Intake Heat
ÄM-400-09-01
01.07.10
Windshield On
Nr.: Änderung/Mod. Nr.: Datum
A
Reco Light
HW
Name
7
Name
PB
Datum
07.4.04
2WW
7
46569 Hünxe, Germany
Projektion Freimaßtoleranz Oberfläche
8
A Blatt 1
von 1
8
Schutzvermerk nach DIN 34 beachten.
A3
EA-9B304.10
ANTI ICE INTAKE, HM
EA 400-500
Maßstab auf SI.-Klasse Oberflächenschutz
P/N 90-42192-2 geändert
Annunciator Panel right
Schwarze Heide 21
Gepr.:
Gepr.:
Bearb.:
Deice Boots Landing Light
Letzte Bearbeitung:
Diode direkt hinter dem Stecker 3HM-A installieren!
3HM-A
VV152 VV153
Jiffi Diode 4HM
see EA-9B315.80 ANNUNCIATOR PANEL
ANNUNCIATOR BOARD EA-9B315.81
291-9726
+ VOLT DIMM
LIGHT TEST (GND)
see EA-9B246.10 DC-DISTRIBUTION
EMERGENCY BUS PP4
5
(Stecker M83723/75R-08-03-6)
BYW56
D41
ANNUNCIATOR BOARD 5WW
HM1E-22
INTAKE-A/I 1HM
CIRCUIT BREAKER/SWITCH PANEL
001758 212 02 2VN-C
44
5WW-D
CB-Trennstaecker
HM1F-22
Brandspant Trennstecker
3
Maintenance Manual EXTRA 500 Chapter 91 30. March 2012
1
A
B
C
D
A
B
C
EA-9B284.13b
BYW56
D39
291-9726
GND
28VDC Fail
1 2 3 4 5 6 7 8
HF8E-22 HF9E-22 HF10E-22N
HF3G-22 HF5E-22 HF7E-22
VV239
HF7E-22
HF16E-22
HF17E-22N
15polDSub
4HF-A
19
36
37
18
ST-A
001758_212_02
AB
3VN-A
HF5E-22
HF4F-12
5HF
X1
1
3
an 1VN
4
HF3H-22
HF6E-12
HF3E-22
HF3F-22
HF4E-12
6
HF14E-12N
HF15E-22N
HF8E-22 HF9E-22
5
5
2 4 3
29
43
20A
WSH-HT 1HF
1 2 3 4
5
Windshield Heater
T
TEMP Sensor
1
1
2
3
4
D33
D15
4 24 25
HF6E-12 HF11E-12
5
001758_212_02 3VN-A
D
A514.2076
Stromsensor Kissling
5WW-C
5WW-B
7HF
15 24 25
EDV-Kennung:
9B30420T 6
Zuordnung links / rechts wird mit */* in allen Feldern angegeben.
04 03 02 01 Ver. Bezeichnung
Oil-Press Fuel-Press
Name
Nr.: Änderung/Mod. Nr.: Datum
Name
PB
Datum
25.08.04
Windshield On
7
46569 Hünxe, Germany
Schwarze Heide 21
Gepr.:
Gepr.:
Bearb.:
Reco Light
Projektion Freimaßtoleranz Oberfläche
8
A Blatt 1
von 1
8
Schutzvermerk nach DIN 34 beachten.
A3
EA-9B304.20
WINDSHIELD HEAT, HF
EA 400-500
Maßstab auf SI.-Klasse Oberflächenschutz
Deice Boots Landing Light
Intake Heat
Annunciator Panel right
Bleed Overt
Cab-Press
Stall-Heat Windsh-Heat
Aft Door Stall-Warn
HW
ÄM-400-09-01
7
Annunciator Panel left
04.10.10
A
2WW
P/N 90-42192-2 geändert
Letzte Bearbeitung:
WW20-20
WW26-22
WW1-20
WW16-22
1WW
P/N 90-42192-1
6
Die Gültigkeitszuordnung von Version zu Flugzeugbaureihe ist der Bauakte bzw. dem jeweiligen Fertigungsauftrag zu entnehmen.
Anschlüsse mit Kabelschuh
20A C A 1A GND
see EA-9B315.80 ANNUNCIATOR PANEL
ANNUNCIATOR BOARD EA-9B315.81
+ VOLT DIMM
LIGHT TEST (GND)
Anschlußschema
6HF
2A
WSH-CTRL 2HF
BATTERY BUS PP2
5
see EA-9B246.10 DC-DISTRIBUTION
ANNUNCIATOR BOARD 5WW
HF1E-22
HF2E-12
07.2.1.13
:2
2
5WW-D
HF12E-22
Massebolzen
1VN
3 4
HF16E-22
ON
OFF 1
3HF:1
WINDSH
CIRCUIT BREAKER/SWITCH PANEL
Befestigen mit Mutter und Schraube
M320-B4N
X2
2
1
D:6
HF3H-22
2
D:12 1
C:1
HF3G-22
HF4F-12
3
Maintenance Manual EXTRA 500 Chapter 91 30. March 2012
4HF
AT15.2121
Kissling
05856.12
TEMP CONTROLER
see EA-9B284.13B PC-BOARD 1
K2
PC-BOARD 1
2
HF11E-12 HF8E-22 HF15E-22N HF9E-22
D
HF3J-22
HF3J-22
1
HF14E-12N
HF13E-22N
A
B
C
D
A
B
C
D
2
Pneumatic
Fuel Low R
Fuel Filter
Fuel Low L
Ignition
Reco Light
Deice Boots Landing Light
Intake Heat
Prop Low Pitch External Power Windshield On
Low Voltage
Standby Alt On
WW20-20
WW28-22 WW34-22
H D B C E F A
24 25
3HH-A
4
1
2
3
28 19
see EA-9B315.80 ANNUNCIATOR PANEL
4
HH3F-22 HH4F-22
HH2F-22
38 43
5WW-D
5
HH6F-22 HH10F-22
J4
30 29
51 52
1
1
6
HH2E-22
EDV-Kennung:
9B31010T 6
Zuordnung links / rechts wird mit */* in allen Feldern angegeben.
04 03 02 01 Ver. Bezeichnung
J
G H
MS3470L10-6S
6HH-A
ÄM-400-09-01
Nr.: Änderung/Mod. Nr.: Datum
01.07.10
Name
HW
MS27467T9B98S
HH10E-22 HH9E-22N
Letzte Bearbeitung:
A
5HH-A
VV156 2VN-D 001758 212 02
HH8E-22N
HH4E-22
4HH-A
2A
1HH
BOOTS
VV154
VV155
HH7E-22N
HH3E-22 HH6E-22
HH1G-22
001758 212 02 2VN-D
Die Gültigkeitszuordnung von Version zu Flugzeugbaureihe ist der Bauakte bzw. dem jeweiligen Fertigungsauftrag zu entnehmen.
HH6E-22 HH10E-22
2 07.1.1.13
3
1
2HH
BOOTS
HH1E-22
CIRCUIT BREAKER/SWITCH PANEL
HH3E-22 HH4E-22
ST 4
FIREWALL
D:7
C:14
Stecker CB-Panel HH1F-22
5
MS 38999 III 20K G 35 PN (79 X #22D)
HH1F-22 HH2F-22 HH3F-22 HH4F-22
ANNUNCIATOR BOARD EA-9B315.81
+ VOLT DIMM
D32
?VN-A 001758 212 02
?
8 9 10 11
30CG-C
Stecker Avionikbay
LIGHT TEST (GND)
HH1G-22 HH2G-22 HH3G-22 HH4G-22 HH5E-22N
ANNUNCIATOR BOARD D23 5WW
Avionikbay
5 14
5WW-C
2WW
3HH
28 VDC POWER TIMER 1Min FLOW CONTROL FLOW CONTROL GND
TIMER
3
Maintenance Manual EXTRA 500 Chapter 91 30. March 2012
Fuel Trans R
P/N 90-42192-2 geändert
Annunciator Panel right
Fuel Trans L
1
31.10.02
PB
Name
C
46569 Hünxe, Germany
7
5HH
6HH
8
Blatt 1
von 1
8
Schutzvermerk nach DIN 34 beachten.
A3
EA-9B310.10
BOOTS, HH A
Projektion Freimaßtoleranz Oberfläche
EA 400-500
Maßstab auf SI.-Klasse Oberflächenschutz
NO
NC
P
PNEUMATIC LOW
3D3556-03
OUTBOARD WING DE-ICER
Datum
NO
NC
4HH EJECTOR VALVE 2
3D3556-03
Schwarze Heide 21
Gepr.:
Gepr.:
Bearb.:
A B C
A F E C
A F E C
INBOARD WING DE-ICER
EJECTOR VALVE 1
see EA-9B246.10 DC-DISTRIBUTION
BATTERY BUS PP2
7
Firewall Engine Compartement leftside
A
B
C
D
K10
BYW56
BYW56
1
7
9
+Vmo
14
31
35
13
16
EA-9B284.13a
GND
-Vmo
-Vmo test
BYW56
D12
R40 100
R41 100
8
see EA-9B284.13b PC-Board 1
D11
D31 D21
Audio out
31
1VN-C
1
WH3E-22N
WV3E-22
WV8F-22
WV1F-22
5WH
WH12E-22S
U
WH12E-22S
4
31
X
U
Horn
001758_212_02
1VN-F
2 A:4
2
07.2.1.16
3LJ:1
D:19 D:20
2
5A
STALL-WARN
WH1G-22
:2
NIGHT
3
3
3
1
2
3
4
2
5
5
A:8 A:9 A:10 A:5
3
LH3E-20N
Maintenance Manual EXTRA 500 Chapter 91 30. March 2012
D13
D1
K1:1 10
1
8
9 6
11
BYW56
K1:3 8
D10
REL G6A
16
4
13
Vmo TEST
REL TN2 113-8875
Audio
PC-BOARD 1
1RM
see EA-9B235.17 MKR-Audio
ALT WRN IN
1RM-A
1WH
WH1E-22
EMERGENCY BUS PP4
CIRCUIT BREAKER/SWITCH PANEL
DAY
(TONE) TEST
LT1E-20
4
2
A
B
C
AUDIO & MARKER PM8000B
3
NIGHT
D
2
1WV
C:13
1
6
EDV-Kennung:
9B31430T
04 03 02 01 Ver. Bezeichnung
Die Gültigkeitszuordnung von Version zu Flugzeugbaureihe ist der Bauakte bzw. dem jeweiligen Fertigungsauftrag zu entnehmen. Zuordnung links / rechts wird mit */* in allen Feldern angegeben.
1
1
WV3E-22
16
6
Vmo ALERT
Overspeed Contact closed at 207 Knots
7
HW PB
Name
01.07.10 09.09.04
Nr.: Änderung/Mod. Nr.: Datum
ÄM-400-09-01 ÄM-400-04-02
PB
Name
7
46569 Hünxe, Germany
Schwarze Heide 21
Gepr.:
Gepr.:
Bearb.: 06.09.04
Datum
optical coverage minimal 98 - 100%
8
B Blatt 1
von 1
8
Schutzvermerk nach DIN 34 beachten.
A3
EA-9B314.30
AIRSPEED WARNING, WV
EA 400-500
Projektion Freimaßtoleranz Oberfläche
+6/-0 Knots
Maßstab auf SI.-Klasse Oberflächenschutz
36 AWG Tinned copper per ASTM-B-33
Letzte Bearbeitung:
B A
3FG
700-00083-()
see EA-9B342.65 IFD-LEFT
OVERBRAID
P1122
IFD LEFT IFD-5000i
see EA-9B246.10 DC-DISTRIBUTION
1A
VNE-WARN
BATTERY BUS PP2
WV1E-22
1
WV8E-22
WH1F-22
WV9E-22N WV9F-22N
1 WV8F-22
4 LT2E-20
6 WV1F-22
5
A
B
C
D
D
C
B
A
Fuel Low L
Fuel Filter
Fuel Low R
Pneumatic
Fuel Trans R
Cab-Press
Flaps
Fuel Trans L
Aft Door
Stall-Warn
Gen-Fail
Gear Warn
Ignition
Chip
Hydraulic
Reco Light
3
5WW-C DB25RA/M
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
5WW-B DB25RA/F
4 38
EA-9B304.20 EA-9B310.10
Windshield Heat ON Boots
101 102 50 53 103
42 40 41 108 35 107 39 21 54
C 18 C 17 C 16 C 15 C 14 C 13 C 12 C 11 C 10 C9 C8 C7 C6 C5 C4 C3 C2 C1
51 52 46 00
EA-9B317.10 EA-9B317.10 EA-9B303.10 EA-9B303.10 EA-9B317.10
E-W Low Fuel Press E-W Oil Press P/Static/S Heat left Pitot/S/S Heat left E-W Chip Detect
25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
B1 B2 B3 B4 B5 B6 B7 B8 B9 B 10 B 11 B 12 B 13 B 14 B 15 B 16 B 17 B 18
P/Static/S Heat rightEA-9B303.10 Pitot/S/S Heat right EA-9B303.10 Gear Control System EA-9B323.10 Spare
EA-9B275.20 EA-9B323.20 EA-9B243.10 EA-9B213.30 EA-9B273.30 EA-9B527.10 EA-9B215.20 EA-9B304.20 EA-9B303.10
Flap System Gear Warning DC Generation I Cabin-Press Stall Warning Door Warning Bleed Air System Windshield Heat P/S/Stall Heat
GND CONTROLED
WW38-22 WW37-22 WW36-22 WW35-22 WW34-22 WW33-22 WW32-22 WW31-22 WW30-22 WW29-22 WW28-22 WW27-22 WW26-22 WW25-22 WW24-22 WW23-22 WW22-22 WW21-22
WW40-22
WW20-20
WW1-20
WW2-22 WW3-22 WW4-22 WW5-22 WW6-22 WW7-22 WW8-22 WW9-22 WW10-22 WW11-22 WW12-22 WW13-22 WW14-22 WW15-22 WW16-22 WW17-22 WW18-22 WW19-22
Static Heat R
Pitot Heat R
Deice Boots Landing Light
Intake Heat
Static Heat L
Pitot Heat L
Prop Low Pitch External Power Windshield On
Low Voltage
Standby Alt On
Bleed Overt
Oil-Press
Fuel-Press
Stall-Heat
Windsh-Heat
2
HF12E-22 HH6F-22
HS-7F-22 HG24F-22 GA53E-22 Spare 5WW32-22
LW1E-22 LW3E-22 HS-8F-22 HG25F-22 LW5E-22
CG47F-22 EZ65E-22 EZ63E-22 HP11G-22 WH11E-22 MC1E-22 HA33E-22 HF16E-22 HG23F-22
DB50SLE 5WW-B
+VDC II S
+VDC I S
4
F2
F1
5A
5A
+VDC II
+VDC I
1
2
EA-9B284.30 EA-9B310.10 EA-9B731.30 EA-9B284.30 EA-9B731.10
EA-9B731.30
Low Fuel Warning Pneumatic (Boots) Fuel Trans Right Low Fuel Warning Fuel Pump / Filter
Fuel Trans Left
3
EA-9B317.10 EA-9B315.90 EA-9B243.20
E-W Prop Low Pitch Low Voltage Monitor DC Generation II
Spare
47
106 43 48 105 1
104 108 100
00
QF10F-22
EZ64E-22 HH10F-22 QF9F-22 EZ66E-22 QW1F-22
LW6E-22 WL1E-22 PR213E-22
Spare 5WW25-22
4
Maintenance Manual EXTRA 500 Chapter 91 30. March 2012
P/N 90-42192-2 geändert
Annunciator Panel right
2WW
1WW
P/N 90-42192-1 geändert
Annunciator Panel left
1
D35
D33
D31
D29
D27
D25
D23
D21
D19
D17
D15
D13
D11
D9
D7
D5
D3
D1
D36
D34
D32
D30
D28
D26
D24
D22
D20
D18
D16
D14
D12
D10
D8
D6
D4
D2
3 INV 4 INV 5 INV 6 INV 1 INV 3 PLUS 7 INV 4 PLUS 5 PLUS 6 PLUS 7 PLUS 1 PLUS
36x BYW56
5
5
4
6
BYW56
G6A-234P
6
D43
K7
D42
K6
D41
K5
D40
K4
D39
K3
BYW56
291-9726
BYW56
291-9726
BYW56
291-9726
BYW56
291-9726
BYW56
291-9726
SIG IN 1 16 1 D38 BYW56
K2 16
4
D37
K1 291-9726
BYW56
G2RL-24
K8
D44
6
GND
DIM
+28V Test +28V
GND Test
5WW
RZ2E-24S
PD4J-22 LA7F-22 LF2K-22 HM2F-22 WL5E-22
Spare 5WW7-22 Spare 5WW13-22
see EA-9B275.20 FLAP SYSTEM [IN TRANSM]
see EA-9B344.14 WEATHER DEDECTION RZ13E-24S see EA-9B235.16 MKR-AUDIO
P1
P1
6
CG34H-22
GA53H-22
SS9E-24
SS8E-24
SS7E-24
SS7E-24
49 45 50 44 24
00 00
1 6 3 4 5 2 7 8 9
EA-9B244.10 EA-9B334.35 EA-9B334.60 EA-9B304.10 EA-9B743.10
7
D4
D3
D2
D1
9B31580T
04 03 02 01 Ver. Bezeichnung EDV-Kennung:
2SS
ÄM-400-09-01 ÄM-400-09-01
7
Nr.: Änderung/Mod. Nr.: Datum
B A
Letzte Bearbeitung:
17.02.11 06.10.10
WW39-20N
LG109E-20
see EA-9B284.13B PCB-BOARD 1
BYW-56
BYW-56
BYW-56
BYW-56
Die Gültigkeitszuordnung von Version zu Flugzeugbaureihe ist der Bauakte bzw. dem jeweiligen Fertigungsauftrag zu entnehmen. Zuordnung links / rechts wird mit */* in allen Feldern angegeben.
29
24
11
10
VV162
see EA-9B344.14 WEATHER DEDECTION
MIC INHIBIT INPUT
PC-BOARD 1 EA-9B411.50A
54
WEATHER DETECTION TWX-670
External Power Landing Light Reco Light Anti Ice Intake Ignition System
LH3G-20
LH4E-20
7
VV161 WW41E-20
VV160
5WW-A DB9RA/M
+28VDC CONTROLED INPUT
Spare Spare
Steuer-Platine EA-9B411.70
D46
D45
G2RL - 8A 365-0591
see EA-9B344.14 WEATHER DEDECTION
see EA-9B235.16 MKR-AUDIO
50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
J
Name
HW HW
16
41
40
Über 5LH-A Pin 20/1 K1 EA-9B334.90
Name
PB
Datum
46569 Hünxe, Germany
Schwarze Heide 21
Gepr.:
Gepr.:
Bearb.: 05.03.04
001758 212 02 1VN-E
Projektion Freimaßtoleranz Oberfläche
DIM Voltage
+ 28V Power
+ Light-Test
- Light-Test
B Blatt 1
von 1
8
Schutzvermerk nach DIN 34 beachten.
A2
EA-9B315.80
EA 400-500 ANNUNCIATOR PANEL, WW
Maßstab auf SI.-Klasse Oberflächenschutz
Über 5LH-A Pin 13/14 F6 EA-9B334.90
Über 5LH-A Pin 9 an F1 EA-9B334.90
Über 5LH-A Pin 7/8 F2 EA-9B334.90
8
D
C
B
A
A
B
C
D
25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
J5WW-C DB25RA/M
C 18 C 17 C 16 C 15 C 14 C 13 C 12 C 11 C 10 C9 C8 C7 C6 C5 C4 C3 C2 C1
B1 B2 B3 B4 B5 B6 B7 B8 B9 B 10 B 11 B 12 B 13 B 14 B 15 B 16 B 17 B 18
J5WW-D DB50SLE
+VDC II S
+VDC I S
3
CB2
CB1
5A
5A +VDC I
+VDC II
4
D35
D33
D31
D29
D27
D25
D23
D21
D19
D17
D15
D13
D11
D9
D7
D5
D3
D1
D36
D34
D32
D30
D28
D26
D24
D22
D20
D18
D16
D14
D12
D10
D8
D6
D4
D2
+VDC II
1
2
3
4
5
5
3 INV 4 INV 5 INV 6 INV 1 INV 3 PLUS 7 INV 4 PLUS 5 PLUS 6 PLUS 7 PLUS 1 PLUS
36x BYW56
Maintenance Manual EXTRA 500 Chapter 91 30. March 2012
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
J5WW-B DB25RA/F
2
50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
1
1
:2
D43
K7
D42
K6
D41
K5
D40
K4
D39
K3
D38
K2:1
4
D37
K1
G2RL-8A 365-0591
K8
D44
SIG IN
BYW56
BYW56
291-9726
BYW56
291-9726
BYW56
291-9726
BYW56
291-9726
BYW56
J5WW-A DB9RA/M
5WW
DIM
+28V Test
GND Test
GND
G6A-234P
BYW56
291-9726
16
8
6
291-9726
BYW56
6
EDV-Kennung:
9B31581T
04 03 02 01 Ver. Bezeichnung
Die Gültigkeitszuordnung von Version zu Flugzeugbaureihe ist der Bauakte bzw. dem jeweiligen Fertigungsauftrag zu entnehmen. Zuordnung links / rechts wird mit */* in allen Feldern angegeben.
6
14.10.10
1 6 3 4 5 2 7 8 9
Nr.: Änderung/Mod. Nr.: Datum
Letzte Bearbeitung:
Steuer-Platine EA.9B315.81
D46
BYW56
D45
BYW56
Name
HW
HW
7
46569 Hünxe, Germany
Schwarze Heide 21
Gepr.:
Gepr.:
Name
Datum
Bearb.: 15.03.04
7
Projektion Freimaßtoleranz Oberfläche
Blatt 1
von 1
8
Schutzvermerk nach DIN 34 beachten.
A3
EA-9B315.81
WARNING BOARD 55
EA 400-500
Maßstab auf SI.-Klasse Oberflächenschutz
8
A
B
C
D
A
B
C
D
2WW
2
Fuel Low R
Pneumatic
Fuel Trans R
Ignition
Prop Low Pitch External Power
Low Voltage
Standby Alt On
3
WW31-22
5WW-C
1A
1LW
D26
+ VOLT DIMM
LIGHT TEST (GND)
1
2
3
4
5
ANNUNCIATOR BOARD EA-9B315.81 see EA-9B315.80 ANNUNCIATOR PANEL
5WW
ANNUNCIATOR BOARD
11 24 25
WL2E-22
LOW-VOLT
5
1
22 108
5WW-D
6
J1A
6
DB37S
WL1E-22 WL2F-22 WL3E-22N
Die Gültigkeitszuordnung von Version zu Flugzeugbaureihe ist der Bauakte bzw. dem jeweiligen Fertigungsauftrag zu entnehmen. Zuordnung links / rechts wird mit */* in allen Feldern angegeben. 04 03 02 01 Ver. Bezeichnung EDV-Kennung: 9B31590T
001758 212 02 1VN-G
D
WL1E-22
CB Trennstecker C:16
see EA-9B246.10 DC-DISTRIBUTION
EMERGENCY BUS PP4
CIRCUIT BREAKER/SWITCH PANEL
4
Maintenance Manual EXTRA 500 Chapter 91 30. March 2012
P/N 90-42192-2 geändert
Annunciator Panel right
1
ÄM-400-09-01 ÄM-400-04-02
Name
HW PB
PB
Name
7
46569 Hünxe, Germany
Schwarze Heide 21
Gepr.:
Gepr.:
Datum Bearb.: 20.09.04
Projektion Freimaßtoleranz Oberfläche
8
B Blatt1 von
8
Schutzvermerk nach DIN 34 beachten.
A3
EA-9B315.90
1
LOW VOLTAGE MONITOR, WL
EA 400-500
Maßstab auf SI.-Klasse Oberflächenschutz
see EA-9B284.13b PC-BOARD 1
EA-9B284.13
Out L-Gnd Aircraft Spruce B00378-5
Lamar Low Voltage Monitor U60 Sense
01.07.10 09.09.04
red green black
Nr.: Änderung/Mod. Nr.: Datum
B A
Letzte Bearbeitung:
22 21 3
J1
PC-BOARD 1
7
A
B
C
D
A
B
C
D
13 12 17 18 9 16 19 20 11 8 6 25
+28VDC Lighting Power Input High Lighting Power low Fuel Temp Signal Input High Fuel Temp Signal Input Return Spare Bat Ameter Signal Input Low Bat Ameter Signal Input High Spare Case Ground Gen Amp Input high Gen Amp Input low Spare
G
001758 212 02 1VN-G
1
2
25 26
Trennstecker FIREWALL
EY4F-22S
EY8E-22S EY10E-22N
EY9E-22S
ws bl
3
4
5
24 23
N
r D s t
ws bl
N L M P R S
ws q bl
ws bl
R S
ws L bl M ws P bl
ws bl
EDV-Kennung:
VOLT-MON 1A
ws bl ws bl
ST2
ws bl
6
ST2
ws bl
ws bl
ST1
EY7F-22S
EY6F-22S
EY5F-22S
EY4E-22S
Output High Output Low Exitation +10VDC Exitation Return 4EY
r D s t
6EY
Name
Nr.: Änderung/Mod. Nr.: Datum
PB
7
46569 Hünxe, Germany
Schwarze Heide 21
Gepr.:
Gepr.:
Name
Datum
Bearb.: 26.08.04
HKM-186-375-50psi G
Output High Output Low Exitation 10-40VDC Exitation Return 4EY
Fuel Press Sensor
ws EY8F-22 bl EY8G-22
A Blatt 1
von 1
8
Schutzvermerk nach DIN 34 beachten.
A3
EA-9B316.40
DIGITAL INSTRUMENT, EY
EA 400-500
Maßstab auf SI.-Klasse Oberflächenschutz
EA-9B243.40
PCB EA-9B243.41b J21 PCB EA-9B243.41b J22
PCB EA-9B243.45 F11 PCB EA-9B243.45 F12
8
Projektion Freimaßtoleranz Oberfläche
0B823.03 Stecker MS3126F8-4S
05835.25 MS28034-3 102-00002 Stecker MS3106F12S-3S
ws EY9F-22 bl EY9G-22
E-BOX
HW
ÄM-400-10-01 ÄM-400-09-01
5EY
05835.25 MS28034-3 102-00002
Fuel Temp Sensor
Alternativ:
green white red black
ws bl
A B
IAT-Sensor
7
Fuel Press Sensor
ws q bl
ST1A
MS33678 6EY-A
B C A D
4EY-A
MS33678 5EY-A
13.09.10
A
Letzte Bearbeitung:
ST10-A
ws 18 bl 19 20
Y W X
ST5-A
see EA-9B246.10 DC-DISTRIBUTION
DIP-2 1A
9B31640T
04 03 02 01 Ver. Bezeichnung
7EY
LOAD BUS PP3
DIP-1 1A
Die Gültigkeitszuordnung von Version zu Flugzeugbaureihe ist der Bauakte bzw. dem jeweiligen Fertigungsauftrag zu entnehmen. Zuordnung links / rechts wird mit */* in allen Feldern angegeben.
EY8E-22S
EY9E-22S
Trennstecker FIREWALL
EY7E-22S
Trennstecker BODEN
EY6E-22S
LG101E-22S
J5
2EY
Trennstecker FLÜGELNASE
EY2E-22
EY3F-20S
EY1E-22
EY6E-22S
EY7E-22S
ws bl
1
1
1
1
Pilot left side
001758 212 02 3VN-A
L P
C:6
A:4
A:3
C:5
see EA-9B334.90 DIMMING SYSTEM
VV167
VV166 EY11E-22N EY12E-22N
EY2F-22
EY3E-20S
EY1F-22
CB-Trennstecker
1EY
6
EMERGENCY BUS PP4
CIRCUIT BREAKER/SWITCH PANEL
5
EY5E-22S
33 34
4
EY5E-22S
EY4F-22S
EY2F-22S EY3E-20S
EY1F-22S
ws bl ws bl
ws bl ws bl ws bl
ws bl
3EY-A J1
3
Maintenance Manual EXTRA 500 Chapter 91 30. March 2012
3EY
1 2 7 5 3 4 14 15 23 24 21 22 10
2
+28VDC Power Input High (Cannel A) Power Input Gnd Ch A & B & VDC +28VDC Power Input High (Cannel B) Power GND (Ch A & B) Voltmeter Signal Input High Spare IAT Signal Input high IAT Signal Input low Fuel Press Signal Input High Fuel Press Signal Input Low Fuel Press Sensor Exitation Output (+10VDC) Fuel Press Sensor Exitation Return Spare
Digital Instrument Package
1
A
B
C
D
A
B
C
D
21 22 23
16 17 24
6
N1 SIGNAL INPUT N1 RETURN CASE GROUND SPARE
OIL TEMP INPUT HIGH OIL TEMP INPUT RETURN CASE GROUND SPARE
CASE GROUND SPARE
3EZ
#
G
31
EZ13E-20N EZ14E-20N
Alumel, red (-) Chromel, yellow (+)
EZ9E-22S
EZ8E-22S
EZ7E-22S
EZ6E-22S
8.0 - 28 VDC Dimming < 8.0 VDC Day Mode
EZ4E-22S
EZ5E-22S
EZ3E-22S
R K
4
ws bl ws bl
ws bl
ws bl
ws bl ws bl
ws bl
h j
45 62 63 60 61 46
e c d
58 59 47
Y W X Z a b
T U V
*
ST2
A:12
A:1
ST4
EZ4F-22S
EZ5F-22S
EZ9F-22S
EZ8F-22S
Alumel: M39029/87-475 Cromel: M39029/87-476
EZ9F-22S
EZ8F-22S
Alumel: M39029/88-487 Cromel: M39029/88-488
1
2
Buchse Alumel: 8500-2055 Cromel: 8500-2054
3
4
A D B C
Exitation 10-40VDC Exitation Return Output High Output Low
VV178
VV177
8EZ
EZ15E-22S
7EZ
EDV-Kennung:
9B31650T
04 03 02 01 Ver. Bezeichnung
6
Zuordnung links / rechts wird mit */* in allen Feldern angegeben.
Die Gültigkeitszuordnung von Version zu Flugzeugbaureihe ist der Bauakte bzw. dem jeweiligen Fertigungsauftrag zu entnehmen.
Alumel, green (-) Chromel, white (+)
KM005-150G-8-1 & Stecker MS3126F8-4S
Ringöse Chromel
5
A B
8EZ-A Oil Press Sensor
Ringöse Alumel EZ11F-20 EZ12F-20
ws bl
7EZ-A
Oil Temp Sensor
ws bl
5EZ-A
8EZ
Exitation 10-40VDC Exitation Return Output High Output Low
8EZ-A Oil Press Sensor
A D B C
25Ohm
TR3
TR2
TOT PROBS
HW
Name
Nr.: Änderung/Mod. Nr.: Datum
ÄM-400-10-01 ÄM-400-09-01
1VE
EA-9B284.13
cw
25Ohm
RS 162-647
MS25038-4 32005-023
Name
PB
Datum
17.06.04
7
46569 Hünxe, Germany
Schwarze Heide 21
Gepr.:
Gepr.:
Bearb.:
Projektion Freimaßtoleranz Oberfläche
8
A Blatt 1
von 1
8
Schutzvermerk nach DIN 34 beachten.
A3
EA-9B316.50
ENGINE INSTRUMENT, EZ
EA 400-500
Maßstab auf SI.-Klasse Oberflächenschutz
see EA-9B284.13 PC-BOARD 1
Oil "0" adjust
Tourqe "0" adjust
5EZ
IPS1525-150PSI-7/16-20UNF-SW27-MIL-C26484 & Stecker MS3476W10-6S & Clamp M85049/52-1-10W
2 20 1
1VE-a
13.09.10
A
A B
RPM Sensor N1
PC-BOARD 1
Letzte Bearbeitung:
Alternativ:
MS25038-4 32005-023
Exitation 10-40VDC Exitation Return Output High Output Low 6EZ
Torque Sensor
4EZ
7
IPS1525-150PSI-7/16-20UNF-SW27-MIL-C26484 & Stecker MS3476W10-6S & Clamp M85049/52-1-10W
A D B C
6EZ-a
A B
RPM Sensor N2
PC 06E 8-2S (SR)
EZ6F-22S
Alternativ:
ws bl org
ws bl
4EZ-A
PC 06E 8-2S (SR)
EZ3F-22S
MS28034-3 102-00002
Exitation 10-40VDC Exitation Return Output High Output Low 6EZ
Torque Sensor
KM005-150G-8-1 & Stecker MS3126F8-4S
A D B C
MS3106F12S-3S
ws bl ws bl
6
see EA-9B246.10 DC-DISTRIBUTION
ENG-INS2 2A
LOAD BUS PP3
6EZ-A
EZ7F-22S
EZ4F-22S
EZ5F-22S
ws bl ws bl
2EZ
ENG-INS1 2A
EMERGENCY BUS PP4
Terminal am Triebwerk
EZ7F-22S
EZ6F-22S
Alumel, red (-) Chromel, yellow (+)
ST2
ws bl ws bl
ST4
ws bl
ST2
ws bl
1EZ
EZ2E-20
EZ1E-20
EZ3F-22S
2
1
MS38999III (23-54)
ws bl ws bl
ws bl
FIREWALL
ws
ws
5
CIRCUIT BREAKER/SWITCH PANEL
und Pinne aus Cromel und Alumel verwenden! * Buchsen Pinne Buchse
MS38999III (23-54)
EA-9B334.90
Dimming
VV174
bl bl
VV173
3VN-A Splice 001758 212 02
ALCOR P/N 42526
1VN-D 001758 212 02
EZ10E-20N
EZ9E-22S
EZ8E-22S
Alumel, red (-) EZ11E-22 Chromel, yellow (+) EZ12E-22
MS3126F10-6S
3EZ-B
D-SUB 25S
ws bl
VV168
EZ15E-22S
EZ7E-22S
ws bl
VV171
LG100E-22S
EZ4E-22S
EZ5E-22S
bl 32 ws
EZ2F-20S
EZ2F-20S
EZ3E-22S
EZ1F-20S
3
EZ1F-20S
EZ6E-22S
ws bl org
ws bl
D1 BYW56 D2 BYW56
VV172
ws bl
bl ws
ws bl
ws bl
ws bl bl ws
3EZ-A
VV170
VV169
Splice
# Buchsen und Pinne aus Cromel und Alumel verwenden!
A B C D E F
11 12 13
LIGHT GND 28 VDC LIGHT CASE GROUND SPARE
SPARE TOT - ALUMEL, RED (-) TOT - CHROMEL, YELLOW (+) SPARE SPARE SPARE
8 9 10
TRQ SIGNAL INPUT HIGH TRQ SIGNAL INPUT LOW CASE GROUND SPARE
18 19 20 25
14 15 5
N2 SIGNAL INPUT N2 RETURN CASE GROUND SPARE
OIL PRESS INPUT HIGH OIL PRESS RETURN CASE GROUND SPARE CASE GROUND
1 2 3 7 4
28 VDC POWER (Channel A) GROUND GROUND 28 VDC POWER (Channel B) CASE GROUND SPARE
Moritz A1270
Engine Instrument Package
2
Maintenance Manual EXTRA 500 Chapter 91 30. March 2012
1
cw
A
B
C
D
A
B
C
D
1
Engine Compartement
Turbine
9LW
NO
8LW
C3C
1
2
VV39
LW5F-22
LW1F-22 LW4E-22N
3
K
001758 212 02 2VN-D
NO
NC
VV184
19LW
LW6F-22
SW am Gestänge im Triebwerkraum
BAS4028U
334-870
L
Anschlüsse mit Gummitülle abdecken
1 3 2
LW3F-22 LW2E-22N
001758 212 02 2VN-D Gehäuse P 1-0480305-0 FE4308 Pin 163558-2 FE4306
U?
LOW PITCH
U?
LW7E-22N VV183 C
001758 212 02 2VN-D
E
Chip 3
12LW
GND Motorblock
Chip 2
Chip 1
11LW
10LW
CHIP DETECTOR
PCI P60
2
NC
C
1
LOW FUEL PRESS
Turbine
1 3 2
Gehäuse B 1-0480303-0 FE4307 Buchse 163557-2 FE4305
PCI P110
2
NO
C
1
NC
LOW OIL PRESS
2
LW3F-22 LW1F-22 LW5F-22 LW6F-22
ST4 27 28 26 25
FIREWALL
3
LW3E-22 LW1E-22 LW5E-22 LW6E-22 102 101 103 104
5WW-D 39 40 36 23
5WW
LIGHT TEST (GND)
ANNUNCIATOR BOARD
4
1
2
3
4
5
D4
D8
D27
D7
10 24 25
5
8 7 4 24 25 5WW-C
5WW-B
EDV-Kennung:
9B31710T 6
Zuordnung links / rechts wird mit */* in allen Feldern angegeben.
04 03 02 01 Ver. Bezeichnung
2WW
1WW
ÄM-400-09-01
04.10.10
Chip
Static Heat L
Pitot Heat L
Name
HW
Name
PB
Datum
09.02.04
7
46569 Hünxe, Germany
Schwarze Heide 21
Gepr.:
Gepr.:
Bearb.:
Hydraulic
8
A Blatt 1
von 1
8
Schutzvermerk nach DIN 34 beachten.
A3
EA-9B317.10
ENGINE WARNING, LW
EA 400-500
Projektion Freimaßtoleranz Oberfläche
Static Heat R
Pitot Heat R
Maßstab auf SI.-Klasse Oberflächenschutz
Prop Low Pitch External Power
Low Voltage
geändert
Fuel Low R
Pneumatic
Ignition
Annunciator Panel right
Fuel-Press
Fuel Trans R Standby Alt On
P/N 90-42192-2
Nr.: Änderung/Mod. Nr.: Datum
A
Bleed Overt
Windsh-Heat
Oil-Press
Annunciator Panel left
7
Stall-Heat
P/N 90-4219X-1
Letzte Bearbeitung:
WW20-20
WW30-22
WW1-20
WW5-22 WW8-22 WW9-22
6
Die Gültigkeitszuordnung von Version zu Flugzeugbaureihe ist der Bauakte bzw. dem jeweiligen Fertigungsauftrag zu entnehmen.
see Annunciator-Panel EA-9B315.80
ANNUNCIATOR BOARD EA-9B315.81
+ VOLT DIMM
Maintenance Manual EXTRA 500 Chapter 91 30. March 2012
Power Lever
A
B
C
D
A
B
C
13
14
DIMMING
DIMMING
F G H J K
GA1F-22
07.1.1.13 D927
C
001115-208-02
F G H J K
VV323103
A B C D E
GA26H-22 GA25G-22 GA24H-22
2
VV187
VV185
GA08E-22
VV186
F G H J K
001115-209-02
A B C D E
VV323104
SIM E-2022
GA37F-22 GA34F-22 GA30F-22
1 GA09E-22 AUS
EIN 3
62
30GA
FAHRWERKSHEBEL
3 2 1
ST10-A
GA30E-22
VV323106
001115-201-02
Modul 7
GA09F-22
GA08F-22
ST10-A
10 9 8
4
3
GA24F-22 GA25F-22 GA26F-22
F
G
B
H
G
F
A
C
B
A
J
D
J
D
VV323101
K
H
G
B F
A
GA10A-22
ge
bl
sw
bl
G 12.221.M.15 AUSGEFAHREN
org
ws
rt
ge
org
EINGEFAHREN G 12.221.M.15 rt sw ws
NOSE GEAR
5GA
4GA
VV323101
001115_201_02
Modul 9
bl
sw
D J
C H
B
G
A
F
36GA
G 12.221.M.15
glb
org
ws
rt
K
E
DUMP SWITCH SQUAT SWITCH NOSE GEAR
001115_201_02
VV323102
bl
sw
G 12.221.M.15
glb
rt
2GA
SQUAT SWITCH Nose Gear
E
C
K
E
C
H
D
J
K
E
GA8A-22 GA08D-22
Modul 8
GA3C-22
E
Zustand Flugzeug am Boden
GA16A-22
GA16C-22
GA26G-22
SD14H-22
GA17-22N
17GA
GA27-22
rt
GA24G-22
1
ge
bl
8GA
G 12.221.M.15
bl
9GA
AUSGEFAHREN
sw
GND
GND
GA14B-22
5VN-A
5VN-A
Modul 4
001758_212_02
KL MP C R
19GA
Lower & Nose Door Valve
SD16E-22N
GA16C-22N GA14C-22N GA17C-22N GA16C-22 GQ14C-22 GA17C-22 GA16D-22N GA14D-22N GA17D-22N
EINGEFAHREN
sw
7GA
GA9G-22
GA28-22N
SD15E-22N
GA8B-22
Uper Door Valve
18GA
G 12.221.M.15
org
ws
rt
ge
org
ws
rt
bl
33GA-a
LEFT GEAR
6GA
AUSGEFAHREN
sw
G 12.221.M.15
11 10 9 8 7 6 5 4 3
33GA-A
bl
sw
G12.221.M.15
15pol DSUB
GA14-22N GA16A-22N GA17A-22 GA14A-22 GA16-22 GA17B-22N GA14B-22N GA16B-22N
2
Main Valve
ge
org
ws
ge
org
ws
rt
SD14G-22
GA19-22
RIGHT GEAR
Schalter am Boden entlastet, im Flug belastet.
H J K
GA14-22 GA14C-22 GA14F-22
GA27-22 GA27A-22 GA19-22 GA19A-22
GA11-22N
H
L
P
T
G
K
N
S
001758-212-02
E
B
D
A
U
R
M
J
F
1
2
H
G
F
3
C
B
A
J
D
K
Fahrwerkschacht
VV323102
001115_201_02
Modul 2
4
001758_212_02
S DE F GH J T U
VV323106
001115_209_02
Modul 3 001115_208_02 VV323103
GA14D-22 GA14B-22
F GHJ K
A B C DE
Maintenance Manual EXTRA 500 Chapter 91 30. March 2012
20VN-A
001115-201-02
A B C D E
VV323101-2+5-6
41GA-A
40GA-A
LED 29GA 42GA-a Left Gear 42GA-A 1 2 GA26C-22
LED 28GA 41GA-a Nose Gear 1 2 GA25C-22
see EA-9B323.20 GEAR WARNING CIRCUIT BOARD
DIMMING (TEST) DIMMING (TEST) DIMMING (TEST)
12
DIMMING
1 2
40GA-a
27GA
GA24C-22
LED Right Gear
7 6 5
GA24J-22
GA25H-22
GA24J-22
GA24-22
GA26-22
GA3B-22
see EA-9B323.20 GEAR WARNING CIRCUIT BOARD
GA10B-22
5
GA41B-22
UPPER DOOR RIGHT
GA08B-22 GA08-22 GA08A-22 GA08C-22 GA08E-22
001115_201_02
GA34G-22
GA26F-22
GA37G-22
GA25F-22
GA24F-22
GA30E22
5
E
C D
GA17C-22 GA17A-22 GA17B-22
61 63 64
GA42-22
GA43-22
B
A
B
A
G
F
bl
zu
sw
VV323104
001115_209_02
Modul 4
G 12.221.M.30 16GA
org ge
auf bl
15GA
13GA
11GA
10GA
sw
G 12.221.M.15
ws
rt
ge
org
ws
rt
X2
10A
F300-B4N
zu bl
G 12.221.M.15
UPPER DOOR LEFT
X1
14GA
ge
org
ws
rt sw
bl
zu
sw
G 12.221.M.30
LOWER DOOR
ge
bl
auf
sw
G 12.221.M.15
org
ws
rt
ge
org
ws
rt
GA34F-22
ST1 R
1
J
K
6
D
E
ST10-A
H
G
F
GA3F-22
GA37F-22
GA1F-22
Modul 5
2
13
11
D:7
D:6
D:9
D:5
D:8
ST1
2
2
1
2
1
R
Hydr Caut
3GA-2
1
1 3
1 3
1 3
3
-X2
1
1 3
1 3
1 3
1
+X1
D
C
B
+X1
D
C
B
A
M220-B4N
2
2
2
2
85
GA4-22
EDV-Kennung:
9B32310T
04 03 02 01 Ver. Bezeichnung
Zuordnung links / rechts wird mit */* in allen Feldern angegeben.
SD14E-22
01.09.10
Datum
ÄM-400-09-01
7
5VN-A
33CG-a
15pol D-Sub
33CG-A
see EA-9B213.30, DUMP SWITCH, 3HP Pin 2
see EA-9B303.10 PITOT-STALL-HEAT, 11HG Pin X2
see EA-9B334.50 COURTESY LIGHT
see EA-9B345.58 XPDR BXP6402, ST14-A Pin 8
see EA-9B303.10 PITOT-STALL-HEAT, 12HG Pin X2
see EA-9B334.50 COURTESY LIGHT
2 1
001578_212_02
HW
Name
20GA
HYDRAULIC PUMP
An GND Anschluß Pumpe
GA51-22N
GA6H-8
GA7A-8
Zentraler Massepunkt
1VN
see EA-9B315.80 ANNUNCIATOR PANEL
001758 212 02
Schalterstellung A/C on Air
100
5
7
6
GA5-22
GA04A-22
C H VV323106
46
Brandschott
H
Datum
06.09.04
PB
Name
46569 Hünxe, Germany
Schwarze Heide 21
Gepr.:
Gepr.:
Bearb.:
Projektion Freimaßtoleranz Oberfläche
A Blatt 1
von 1
8
Schutzvermerk nach DIN 34 beachten.
A2
EA-9B323.10
LANDING GEAR CONTROL, GA
EA 400-500
Maßstab auf SI.-Klasse Oberflächenschutz
see EA-9B344.15 TRAFFIC SYSTEM TAS-610
z. B. PITOT aktiv bei abgefallenem Relay
HP9F-22
HG8E-20
VV
VV
001115_201_03
Nr.: Änderung/Mod. Nr.:
A
GA7F-8N
GA53E-22
1VN-G
see EA-9B246.10 DC-DISTRIBUTION
BATTERY BUS PP2
GA54G-22N
Modul 6
GA40-22
LY13F-22
SH5E-24
HG7E-20
LY4G-22
3
2
VV190
22GA
A
M220-B4N 35GA 3
-X2
GA3C-22
VV189
2
2
2
2
LY4G-22
VV188
34GA
86
Druckschalter
Hydraulic Motor Relais
GA3A-22
87a 88b
87z 88y
F
5
50A
GA6J-8
1
2
5A
1GA
CAPTOR CORP. RF Filter 23939/A-7464 2x 75A DC Filter 32GA GA6G-8
1A
23GA
HYDR
3GA-1
5A
37GA
8
see EA-9B243.40 E-BOX
HOT BUS PP1
GEAR-AUX-1 GEAR-CTRL
44GA
26.57.73
88a
88
21GA
ST11-A GA7E-8N
ST11-B
SIM 1
1
GA6F-8
B2
A2
M210-B4N
X2
45GA
4 GA40F-22
Bodenstecker
GA7F-8N
B3
A3 B1
GA53F-22 A1
GA54F-22 X1
GA54E-22
GA40E-22
GA3E-22
GA37E-22 3
GA1E-22
5A
GEAR AUX 2 CB1
Letzte Bearbeitung: Die Gültigkeitszuordnung von Version zu Flugzeugbaureihe ist der Bauakte bzw. dem jeweiligen Fertigungsauftrag zu entnehmen.
SD14E-22
GA34E-22
7
CIRCUIT BREAKER/SWITCH PANEL
E-BOX
001758_212_02 1VN-E L K
VV323105
ST10-A
SD14F-22
ST10-A
12
001115_201_02
ST10-A GA43-22
C
B
A
Bodenstecker
#22
GA53F-22 GA3F-22
Trennstecker Firewall
6
GA41B-22
4
GA13-22
EZ49E-22 EZ48E-22 EZ47E-22
GA41A-22N
GA41-22N
GA40-22
D
GA22A-22N GA22-22N
GA13A-22
GA10-22 GA41-22 GA41A-22
GA12A-22 GA12-22
GA11A-22N SD14G-22
GA11-22 GA11A-22
GA6E-8
3
GA22-22N GA11-22N GA20-22N GA21-22N GA28-22N GA29-22N SD16E-22N SD15E-22N
GA10B-22 GA10A-22
GA41A-22
2
SD14H-22 SD14F-22
GA50-22 GA50A-22 GA3F-22 GA03A-22
GA4B-22 GA5-22N
1
26GA AirLB Jiffi GA14G-22
GA31-22N GA32-22N
BN
A
B
C
D
D
C
B
A
2
3
20VN-A
40GA
Stall-Warn
Cab-Press
Gear Warn
Flaps
+Vmo
U?
GW9F22 GW9A-22N
NO
NC
F
EA-9B284.13B
14
30
12
CG19-22
CG15F-22
G C C
10 11
4CG-A
NO
NC
CG15G-22
1WW
P/N 90-4219X-1 geändert
U
DIMMING 14 DIMMING (TEST) 3
ST4
1VN-F
33
GW9E-22
rechts
14° LIMIT A
P600M
60
EZ65E-22
CG15H-22
5WW-D
19
29CG-D
STECKER AVIONIKBAY
12LY
Left Gear
DIMMING 13 DIMMING (TEST) 2
001758_212_02
LED
1
2
WW1-20
WW18-22
+ VOLT DIMM
LIGHT TEST (GND)
ANNUNCIATOR BOARD D14 5WW
3
ANNUNCIATOR BOARD EA-9B315.81 see EA-9B315.80 ANNUNCIATOR PANEL
17 24 25
5WW-B
49
4
49
1 2
1 2
1 2
42GA-a
29GA
GA27G-22 GA26H-22
LED
GA27F-22 GA25G-22
28GA
GA27E-22 GA24H-22
Nose Gear
DIMMING 12 DIMMING (TEST) 1
STECKER FIREWALL
66
6
4
GW9F-22
WH3E-22N
CG37E-22
GW1F-22
WH12E-22
Annunciator Panel left
see EA-9B275.20 FLAP SYSTEM
14° Position 15° Position
13CG
CG19A-22
B
VV275206
001115_207_03
001758 212 02 2VN-D
14CG
C
C CG43E-22
VV119
GND
-Vmo
+Vmo
8
see EA-9B284.13 PC-BOARD 1
Gehäuse B 1-0480303-0 FE4307 Buchse 163557-2 FE4305
FLAP BOX
Aft Door
1
8
9 6
11
BYW56 -Vmo
Spörle 220678
Gen-Fail
ADJ
NC
NO
15° LIMIT B
CG17-22N
D20
CLEAR HORN
1 3 2
links
2
1
K20
Audio out
REL G6A
16
4
13
1RM
see EA-9B235.17 MKR-AUDIO
31
1RM-A
27GA
Maintenance Manual EXTRA 500 Chapter 91 30. March 2012
001758_212_02
J
2CG
C
CG44E-22N
PCI P110
NO
NC
LOW TORQUE PRESS
1VN-F 001758 212 02
Batt. leftside
1
Gehäuse P 1-0480305-0 FE4308 Pin 163558-2 FE4306
Audio
PC-BOARD 1
PMA8000B oder PMA8000BT
Right Gear
LED
GA24H-22
GA24J-22
GA25G-22
5
EDV-Kennung:
04 03 02 01 Ver. Bezeichnung
GA26H-22
GA26J-22
VV187
VV186
VV185
9B32320T
ST10-A
5 6 7 8
Stecker Boden
6
C:3
ÄM-400-09-01
7
01.07.10
11.01.11
8 5 3 6 10 14 1 2 4 13 7 9 11 15 12
Datum
Gepr.:
Schwarze Heide 21
PB
Name
7
A Blatt 1
von 1
8
Schutzvermerk nach DIN 34 beachten.
A3
EA-9B323.20
GEAR WARNING, GA
EA 400-500
Maßstab auf SI.-Klasse Oberflächenschutz
EA-9B284.14 see EA-9B284.14 PC-BOARD 2
GEAR WARNING
Bearb.: 02.09.04 Gepr.:
EMERGENCY BUS PP4
HW Name 46569 Hünxe, Germany
HW
GND GND
2A
1GW
see EA-9B246.10 DC-DISTRIBUTION
LEFT GEAR NOSE GEAR RIGHT GEAR GEAR HORN PWR IDLE CLEAR HORN 15° FLAP GEAR WARN LIGHT
+28VDC DOOR CLOSED
PC-BOARD 2
GW1G-22
GW1E-22
GEAR-WARN
8
Projektion Freimaßtoleranz Oberfläche
see EA-9B323.10 GEAR CONTROL
CIRCUIT BREAKER/SWITCH PANEL
RIGHT-GEAR NOSE-GEAR LEFT-GEAR DOOR CLOSED
LANDING GEAR
Nr.: Änderung/Mod. Nr.: Datum
A
1
1
15pol D-sub
39GA-A
C:4
Letzte Bearbeitung:
EZ27E-22N
GW1H-22 GA30F-22 EZ49E-22 EZ48E-22 EZ47E-22 CG37E-22 GW9E-22 CG43E-22 CG15H-22 EZ65E-22
GW1H-22
GW1F-22
CB Trennstecker
1VN-B 001758 212 02
G
6
GA24E-22 GA25E-22 GA26E-22 GA30F-22
Die Gültigkeitszuordnung von Version zu Flugzeugbaureihe ist der Bauakte bzw. dem jeweiligen Fertigungsauftrag zu entnehmen. Zuordnung links / rechts wird mit */* in allen Feldern angegeben.
GA25H-22
42GA-A
41GA-A
41GA-a
40GA-A
40GA-a
5
EZ47E-22
64
4
EZ48E-22
63
3
EZ49E-22
61
AUDIO & MARKER
2
CG19-22 CG15E-22
1
62
D
C
B
A
A
B
C
D
red blk wht
red blk wht
1 2 3
4LB-A
6LB-A
LB13E-20
LB4E-20
AMP Stecker 1-0480305-0 AMP Buchse 1-0480305-0 AMP Crimpkontakt Buchse 163557-2 AMP Crimpcontakt Pin 163558-2
1 2 3
4LB-a
6LB-a
7LB
STROBE LIGHT POWER SUPPLY REAR A490-T-CF-14/28V GND 28VDC
2
1
8LB-A
LB20E-20
blk wht
LB20-20N
1 2
LB2F-20
F G H J K
1115_201_03
A B C D E
1
2
LB10G-20 LC2J-22
ST5
G
8VN
LB2G-22
STECKER OVERHEAD
AMP Stecker 180923-0 AMP Buchse 180924-0 AMP Flachstecker 6,3 mm 42565-2 AMP Flachhülse 6,3 mm 42282
LB10H-20 LC2H-22
Blitzschutz 7LB-B
17VN
DRUCKSCHOTT HINTEN
Maintenance Manual EXTRA 500 Chapter 91 30. March 2012
VV343101
4LB
A650-PR-28V
STROBE LIGHT LEFT
6LB
A650-PG-28V
STROBE LIGHT RIGHT
1
6
A:12
A:11
LB2E-20 LB10E-20
1 1
LB13E-20
Brücke VV193
LB4E-20
3
EDV-Kennung:
04 03 02 01 Ver. Bezeichnung
1 2 3
LB20F-20
5LB-a
9B33410T
3
red 1 blk 2 wht
C3C 3LB-C
1 2 3
3LB-B
3
red 1 blk 2 wht
3LB-A
2
red 1 blk
3LB-D
A
ÄM-400-09-01
01.08.10
Nr.: Änderung/Mod. Nr.: Datum
Letzte Bearbeitung:
Strobe Light left
Trigger Select
Strobe Light right
PN 01-0770028-05
HW
Datum
46569 Hünxe, Germany
Schwarze Heide 21
Gepr.:
Gepr.:
Name
PB
Projektion Freimaßtoleranz Oberfläche
A Blatt 1
von 1
4
Schutzvermerk nach DIN 34 beachten.
A3
EA-9B334.10
EA 400-500 STROBE LIGHT, LB
Maßstab auf SI.-Klasse Oberflächenschutz
3LB
A413A-HDA-CF-14/28V
5LB
STROBE LIGHT REAR A500-A-28V
Bearb.: 30.08.04
blk wht
red
Name
Power Input
STROBE LIGHT POWER SUPPLY
28 VDC GND
4
see EA-9B246.10 DC-DISTRIBUTION
AMP Stecker 1-0480305-0 AMP Buchse 1-0480305-0 AMP Crimpkontakt Buchse 163557-2 AMP Crimpcontakt Pin 163558-2
red blk wht
Die Gültigkeitszuordnung von Version zu Flugzeugbaureihe ist der Bauakte bzw. dem jeweiligen Fertigungsauftrag zu entnehmen. Zuordnung links / rechts wird mit */* in allen Feldern angegeben.
AMP Stecker 1-0480305-0 AMP Crimpcontakt Pin 163558-2
Massebolzen 8mm
LB2G-22 LB3E-20N LB14E-20N
LB20E-20
BATTERY BUS PP2
STROBE STROBE-LT 2LB 1LB OFF 1 2 LB1E-20 3 7.5A 07.1.1.13 ON
CIRCUIT BREAKER/SWITCH PANEL
see EA-9B334.20 NAV-LIGHT 5LB-A
ST13-C SIM
LB10F-20
LB2F-20
3
A
B
C
D
A
B
C
D
2
LC2K-22
15
DRUCKSCHOTT HINTEN
MS 347X-L22-41SN (27 X #20 / 14X#16)
LC2H-22
LB10F-20 LC2J-22
VV175
ST13-D
A
ST5
TRENNSTECKER OVERHEAD
MS 347X-L22-41SN (27 X #20 / 14X#16)
3
LC2K-22
LC2H-22 D:4
D:3 1
1
7LB-B 1 2
Modul 1
LB10G-20
Module Spaltverkleidung
4
F G H J K
1
001115-209-02
A B C D E
2
3
4
5
LC2M-22 LC5E-22N
15VN
8VN
5
Blitzschutz
LC2K-22
5A
1 2
3LC-a
1 2
blau blau
4LC-a
1 2
5LC-a
EDV-Kennung:
9B33410T 6
Zuordnung links / rechts wird mit */* in allen Feldern angegeben.
Die Gültigkeitszuordnung von Version zu Flugzeugbaureihe ist der Bauakte bzw. dem jeweiligen Fertigungsauftrag zu entnehmen.
4LC-A
5LC-A
Flachhülsengehäuse 2pol.
3LC-A
LOAD BUS PP3
6
5LC
BLITZROHR HECK
HW
Name
01.08.10
ÄM-400-09-01
Nr.: Änderung/Mod. Nr.: Datum
4LC
A500-AV28
NAV LIGHT REAR
BLITZROHR FLÜGEL
Letzte Bearbeitung:
A
3LC
A650PR-28
NAV LIGHT LEFT
BLITZROHR FLÜGEL
A650PG-28
NAV LIGHT RIGHT
see EA-9B246.10 DC-DISTRIBUTION
NAV-LT 1LC
Flachhülsengehäuse 2pol.
LC1E-20
04 03 02 01 Ver. Bezeichnung
LC4E-22N
see EA-9B334.10 STROB-LIGHT
Blitzschutz
07.1.1.13
2
LC2L-22 LC3E-22N
3
14VN
ON
Blitzschutz
LC2F-22
LC2E-22
OFF 1
NAV 2LC
CIRCUIT BREAKER/SWITCH PANEL
Maintenance Manual EXTRA 500 Chapter 91 30. March 2012
VV334201
1
Name
PB
Datum
30.08.04
7
46569 Hünxe, Germany
Schwarze Heide 21
Gepr.:
Gepr.:
Bearb.:
7
A Blatt 1
8
Schutzvermerk nach DIN 34 beachten.
A3
EA-9B334.20
NAV LIGHT, LC
von 1
Projektion Freimaßtoleranz Oberfläche
EA 400-500
Maßstab auf SI.-Klasse Oberflächenschutz
8
A
B
C
D
A
B
C
D
10A
LDG-LT 1LA
07.1.1.13
2
LDG 2LA
3
ON
1 OFF
1A LA2E-18
5LA
LA7E-22
3
see EA-9B246.10 DC-DISTRIBUTION
LA1E-18
2
3
2
C:5
B:1
CB Trennstecker 45
3
LA2G-18
5 INV
K5
1
2
3
4
5
4LA
red
ZÜNDBOX XV-1A-50
KABELSCHUH
C2C
J1
D35
ANNUNCIATOR BOARD EA-9B315.81
291-9726
+ VOLT DIMM
LIGHT TEST (GND)
5
blk
9
EDV-Kennung:
9B33435T
blk wht red
5LA-A
6
blk wht red
HW
Name
01.07.10
ÄM-400-09-01
Nr.: Änderung/Mod. Nr.: Datum
A
Letzte Bearbeitung:
MS3126F-8-3P
A C B
Name
PB
7
46569 Hünxe, Germany
P/N 90-42192-2 geändert
Projektion Freimaßtoleranz Oberfläche
A Blatt 1
von 1
8
Schutzvermerk nach DIN 34 beachten.
A3
EA-9B334.35
LANDING LIGHT, LA
EA 400-500
Maßstab auf SI.-Klasse Oberflächenschutz
blk
3LA
D1 50WATT
LAANDING LIGHT XV-19
wht
Datum
n/c
30.08.04
red
J1
C4C
red
blk wht
8
Annunciator Panel right
2WW
Schwarze Heide 21
Gepr.:
Gepr.:
Bearb.:
LA3F-18
Windshield On
5LA-a
Reco Light
7
Deice Boots Landing Light
Intake Heat
COWLING TRENNSTECKER
WW39-20N
MS3124F-8-3S
Zuordnung links / rechts wird mit */* in allen Feldern angegeben.
04 03 02 01 Ver. Bezeichnung
WW20-20
WW22-22
5WW-A
LA3E-18
2 24 25
5WW-C
6
Die Gültigkeitszuordnung von Version zu Flugzeugbaureihe ist der Bauakte bzw. dem jeweiligen Fertigungsauftrag zu entnehmen.
wht
n/c
C4C
red
blk wht
J2
see EA-9B315.80 ANNUNCIATOR PANEL
BYW56
D41
Kabelschuh an 5VN-A schrauben
LA4E-18
MS 27615-K14T7P
7
ST3
FIREWALL
MS 27613-K14T7S
LA2F-18
LA7F-22
9
31
ANNUNCIATOR BOARD 5WW-D 5WW
4
Maintenance Manual EXTRA 500 Chapter 91 30. March 2012
EMERGENCY BUS PP4
CIRCUIT BREAKER/SWITCH PANEL
1
A
B
C
D
A
B
C
D
2
1
2
1LJ
LJ1F-22
LJ1E-22
2
2
15LJ
3 LJ5E-22 ON
1 OFF
LJ1G-22
3 LJ2E-22 ON
1 OFF
MAP
16LJ
see EA-9B246.10 DC-DISTRIBUTION
1LJ
CABIN-LT
CABIN
3
1
1
1
D:2
C:8
D:1
LJ5F-22
LJ1H-22
LJ2F-22
2LJ-A
1 2 3
LJ3F-22N LJ2F-22 LY5E-22
2 1 3
LJ3E-22N LJ2G-22 LY5H-22
2LJ-a
001758_212_02
L
6 7
9
10
5
LJ4E-22N LJ6F-22N
LJ5G-22
LJ1K-22
LY5G-22
COCKPIT
1
PN. : 11-07800
(30531)
2
3
4
1 2
5
OUT
GND
M7815CV
TO220
OUT
EDV-Kennung:
04 03 02 01 Ver. Bezeichnung
9B33440T
Die Gültigkeitszuordnung von Version zu Flugzeugbaureihe ist der Bauakte bzw. dem jeweiligen Fertigungsauftrag zu entnehmen. Zuordnung links / rechts wird mit */* in allen Feldern angegeben.
GND
IN
IN
18LJ
Spannungsregler
Länge 200 cm = 20 Einheiten
B
+
B
W G R
+ G R
18LJ2-a
W
OS-LM10A-W1-847
OS-LM10A-W1-847
+
B
W
B
+ G R
W
OS-LM10A-W1-847
G R
see EA-9B235.17 MKR-AUDIO & EA-9B215.20 BLEED AIR & EA-9B334.50 COURTESY LIGHT
LJ4G-22N LJ6H-22N
LJ5F-22
LJ1H-22
LY5E-22
ST12
5
OS-LM10A-W1-847
CABIN
Gehäuse P 1-0480305-0 FE4308 Pin 163558-2 FE4306
see EA-9B334.50 COURTESY LIGHT
001758_212_02
Gehäuse B 1-0480303-0 FE4307 Buchse 163557-2 FE4305
4
Maintenance Manual EXTRA 500 Chapter 91 30. March 2012
(33260)
LOAD BUS PP3
CIRCUIT BREAKER/SWITCH PANEL
WATSKI 101727
1
6
6
DOME LIGHT
1 2
HW
Name
Nr.: Änderung/Mod. Nr.: Datum
Gepr.:
Datum
PILOT
PB
46569 Hünxe, Germany
7
2
1
12LJ
11LJ
LJ 1:2
Projektion Freimaßtoleranz Oberfläche
1
1
8
A Blatt 1
von 1
8
Schutzvermerk nach DIN 34 beachten.
A3
EA-9B334.40
CABIN-DOME-MAP-LIGHT, LJ
EA 400-500
Maßstab auf SI.-Klasse Oberflächenschutz
COPILOT
14V 0,08A
Name
19LJ
17LJ
Schwarze Heide 21
Gepr.:
6LJ
COPILOT
14LJ
10LJ
CABIN LIGHT 5LJ
13LJ PILOT
1:1
LJ
4LJ
9LJ
CABIN LIGHT 3LJ
MAP LIGHT
5LY
22LJ
VV195
Bearb.: 31.08.04
8LJ
VV197 7LJ
P600M
23LJ CABIN
LJ2G-22
LY5H-22
20.10.10
ÄM-400-09-01
Letzte Bearbeitung:
A
B
G R
+
B
18LJ1-A
W
+ G R
OS-LM10A-W1-847
W
OS-LM10A-W1-847
LJ3E-22N
7
VV198
VV196
A
B
C
D
1
2
3
001758_212_02 8VN-A
LJ6H-22N
(1LY or 8LY on)
LJ3F-22N
1
LY5E-22
7
10
5
C15P
LY5F-22 see EA-9B215.20 BLEED AIR see EA-9B235.17 MKR-AUDIO see EA-9B334.40 CABIN-DOME-LIGHTLY5E-22
ST12
1
9
PC-BOARD 2
BYW56
D19
K14:1 10
3
P600M
D11
P600M
D12
J2
1
4
2
T1
12
D20
(delay 100sec) (batt "off" + T1 "tast")
21 22 23
24
K11 16
12 3 4 6 H3FA-AU
9
13
BYW56
P600M
K13:2
2
green
L1
4
D14
K13
11
BYW56
D18
BYW56
15
(delay 100sec after batt "off")
21 22 23
24
16
13
P600M
D13
10
12 3 4 6 H3FA-AU
K12 9
12
3
20
1
OSRAM 5637 24V 10W (0,42A)
2
3
4
E
1
3
29CG-D ST6
D16 BYW56
BYW56
D17
EA-9B284.14-b
47-63
K15:1
BYW56
D15
K
5
1LY
001115_207_03
CG24F-22
Modul 8a
CG22E-22N
cycle 5Hz (delay 100sec after batt off + flap not up) or (batt on + aircraft on ground + flaps not up)
1LY-A
3LY-A
3LY-a
C1
10
4
2
red
L2
3LY
cycle 5Hz (batt on + aircraft on Ground + generator off + flap not up) or (8LY on) (batt off + flap not up)
Stecker Avionikbay
FLAP UP-RELAIS
CG27E-22
5LY
see EA-9B275.20 FLAP SYSTEM
TS2-b-24V-25S
14
7
3
1
5
2
TASTER 1241.6403 CONRAD 70 43 76-07
LIGHT ON
DOOR SWITCH
+
23CG 26.72.03
CG22E-22N
Maintenance Manual EXTRA 500 Chapter 91 30. March 2012
FE4305
Gehäuse B 1-0480303-0 FE4307 Buchse 163557-2
ST?
W
W
5LJ
P600M
4LY
11LJ
+
A
VV195
Gehäuse P 1-0480305-0 FE4308 Pin 163558-2 FE4306
W
W
P600M
23LJ
LJ
1:1
LJ1K-22
24V 10W (0,42A) OSRAM 5637
+
Text
B
C
22LJ
CABIN
3LJ
OS-LM10A-W1-847
OS-LM10A-W1-847
4LJ
+
+
D
+
+
OS-LM10A-W1-847
OS-LM10A-W1-847
LJ
LY5G-22
LY5G-22
10LJ
LY10E-22
LY10F-22
LY10E-22
9LJ
13 6
12
4
8
E-BOX
LEFT UP LIMIT 12CG
CG24E-22
CG26E-22
(Position NOT up) CG20E-22
F
E
F
E
EDV-Kennung:
04 03 02 01 Ver. Bezeichnung
9B33450T
T
V
P
SQUAT RELAY I
34GA
6
A
ÄM-400-09-01
20.10.10
Nr.: Änderung/Mod. Nr.: Datum
Letzte Bearbeitung:
19PP
EMERGENCY
:1
18PP:2
BATT
EA-9B243.10 DC DISTRIBUTION
CIRCUIT BREAKER/SWITCH PANEL
2 D:17
2 D:18
2 D:15
D:14
Datum
Gepr.:
7
HW Name 46569 Hünxe, Germany
Schwarze Heide 21
HW
Name
see EA-9B246.10 DC-DISTRIBUTION Projektion Freimaßtoleranz Oberfläche
A Blatt 1
von 1
8
Schutzvermerk nach DIN 34 beachten.
A3
EA-9B334.50
COURTESY LIGH, LY
EA 400-500
Maßstab auf SI.-Klasse Oberflächenschutz
Schalterstellung A/C on Ground
Gepr.:
8
2
Bearb.: 21.06.05
Brandspannt
ST1
ST1A
see EA-9B243.40 E-BOX
26.57.710
BATTERY RELAY
K4
RELAY BRACKET
T
V
P
LY2E-22
D
D8 BYW56
5A
7
EA-9B243.40 E-BOX
COURTESY LT
see EA-9B323.10 GEAR CONTROL
REL MT4
K11
LY1F-22
CB5
HOT BUS PP1
M210-B4M S210-A5A1
GENERATOR RELAY K6:4 K6:1
RIGHT UP LIMIT 16CG
Die Gültigkeitszuordnung von Version zu Flugzeugbaureihe ist der Bauakte bzw. dem jeweiligen Fertigungsauftrag zu entnehmen. Zuordnung links / rechts wird mit */* in allen Feldern angegeben.
LY4F-22 LY4G-22
LY3F-22
LY12F-22
LY12E-22
VV196
LY6E-22
(gen off) 12
DOME LIGHT PILOT
LY9E-22N
11
1:2
LY8E-22N
1
LY11E-22
13 LY13E-22
16
1
(5LJ on or 100sec delay 1LY or 8LY on)
LY7E-22 3
LY3F-22
6
LY3E-22 LY3F-22
LY4F-22
LJ3E-22N LJ3E-22N LY5H-22
EA-9B334.40 CABIN-DOME LIGHT
LY4E-22 LY4F-22
CABIN LIGHT
3 (on air)
LY1E-22
(7LJ on or 100sec delay 1LY or 8LY on)
2
LJ3E-22N LJ3E-22N LY5H-22
1 2 3
LJ2F-22 LJ3F-22N
PP5E-22N
5
OFF
LJ6F-22N
LJ6F-22N
LJ6H-22N
ON
LY12F-22 LY13F-22 LY12F-22 LY13F-22 LY13F-22
LJ1K-22
LJ1H-22
PP6E-22
4
07.1.1.13
243.10 EMERGENCY
C
3
PP4E-22
NC
NO
2
OFF
DC-GEN-I 243.10
C
EA-9B334.40 CABIN-DOME LIGHT
ON
1
PP3G-22
3
(aircraft on ground) 1
2
243.20 DC-GEN II
NC
NO
1
1
2
2
D
4 07.2.1.13
3
PR205F-22
6 PR205E-22
5
A
B
C
D
A
B
C
D
2
BATTERY BUS PP2
7.5A
1LN
ICE-LT
CIRCUIT BREAKER/SWITCH PANEL
3
07.1.1.13
2 3 ON
1 OFF LN2E-20
see EA-9B246.10 DC-DISTRIBUTION
LN1E-20
2LN
ICE
DC-DISTRIBUTION EA-9B246.10
4
B:4
LN2F-20
1
2
3
4
D
ST2
(E-Box)
TRENNSTECKER FIREWALL
5
B
5
EDV-Kennung:
04 03 02 01 Ver. Bezeichnung
9B33455T
Die Gültigkeitszuordnung von Version zu Flugzeugbaureihe ist der Bauakte bzw. dem jeweiligen Fertigungsauftrag zu entnehmen. Zuordnung links / rechts wird mit */* in allen Feldern angegeben.
6
3LN-a
ICE LIGHT 3LN
HW
Name
01.08.10
ÄM-400-09-01
Nr.: Änderung/Mod. Nr.: Datum
A
Letzte Bearbeitung:
1 2
3LN-A
6
2VN-D 001758 212 02
LN2G-20 LN3E-20N
Plug with Shield MS 38999 III 26K F 32 SN (32 X #20)
CB Trennstecker
3
Maintenance Manual EXTRA 500 Chapter 91 30. March 2012
1
Datum
PB
Name
7
46569 Hünxe, Germany
Schwarze Heide 21
Gepr.:
Gepr.:
Bearb.: 01.09.04
7
A Blatt 1
8
Schutzvermerk nach DIN 34 beachten.
A3
EA-9B334.55
ICE-LIGHT, LN
von 1
Projektion Freimaßtoleranz Oberfläche
EA 400-500
Maßstab auf SI.-Klasse Oberflächenschutz
8
A
B
C
D
A
B
C
D
Reco Light
Windshield On
Deice Boots Landing Light
Intake Heat
2
5WW-A
3 25 25
5WW-C
WW39-20N
WW20-20
WW23-22
2WW
5A
1LF
9
D35
3 ON
1 OFF
LF2J-22
LF2E-22
K5
BYW56
D34 5 INV
5WW
see EA-9B315.80 ANNUNCIATOR PANEL
ANNUNCIATOR BOARD EA-9B315.81
291-9726
+ VOLT DIMM
07.1.1.13
2
2LF
RECO
4
4
10
30
see EA-9B246.10 DC-DISTRIBUTION
LF1E-22
LIGHT TEST (GND)
ANNUNCIATOR BOARD
P/N 90-42192-2 geändert
Annunciator Panel right
LOAD BUS PP3
RECO-LT
CIRCUIT BREAKER/SWITCH PANEL
3
D:5
A:6
50
5WW-D
1
2
LF2K-22
LF2K-22
LF2F-22
1
2
3
4
Maintenance Manual EXTRA 500 Chapter 91 30. March 2012
1
5
5
VV158
12VN
13VN
EDV-Kennung:
LF4E-22N
LF2H-22
6
HW
Name
Nr.: Änderung/Mod. Nr.: Datum
ÄM-400-09-01
Datum
Gepr.:
7
46569 Hünxe, Germany
Schwarze Heide 21
Gepr.:
PB
Name
RECHTE FLÄCHE
01-0771125-(XX) r. Fläche
4LF
LINKE FLÄCHE
01-0771125-(XX)
3LF
Bearb.: 01.09.04
4LF-A
Flachhülsengehäuse von AMP Flachhülse 6,3mm
1 2
3LF-A
20.10.10
A
Letzte Bearbeitung:
7
Flachhülsengehäuse von AMP Flachhülse 6,3mm
12VN-C Lagerbock
9B33460T
04 03 02 01 Ver. Bezeichnung
LF3E-22N
LF2G-22
13VN-C Lagerbock
Die Gültigkeitszuordnung von Version zu Flugzeugbaureihe ist der Bauakte bzw. dem jeweiligen Fertigungsauftrag zu entnehmen. Zuordnung links / rechts wird mit */* in allen Feldern angegeben.
Z
ST5
TRENNSTECKER FLÜGELNASE
6
Projektion Freimaßtoleranz Oberfläche
A Blatt 1
von 1
8
Schutzvermerk nach DIN 34 beachten.
A3
EA-9B334.60
RECOGNITION LIGHTS, LF
EA 400-500
Maßstab auf SI.-Klasse Oberflächenschutz
8
A
B
C
D
25LH
2
A:9
ON
cw
4.7k
FM
LR9E-22
see EA-9B246.10 DC-DISTRIBUTION
12 11 24 16
GND GND
night
1A
Glare 1A
5LH
1
2
5
D7
D3
1
6LR
D10
D8
D9
3LR
D10
OS-LM10A-W1-847
D2
D9
D4
OS-LM10A-W1-847
D1
D8
+
B
G R
+
1,5k
3
4
D5
EDV-Kennung:
9B33475T
04 03 02 01 Ver. Bezeichnung
Die Gültigkeitszuordnung von Version zu Flugzeugbaureihe ist der Bauakte bzw. dem jeweiligen Fertigungsauftrag zu entnehmen. Zuordnung links / rechts wird mit */* in allen Feldern angegeben.
B
R2 1,5k
D6
VV334903 001758-212-02
1,5k
R1
D7
G R
D5
LR8G-22N
D6
B
D4
G R B
+
LR7G-22
R2 1,5k
G R
D3
D5
LR8H-22N
R1
D2
LR7E-20
D4
4
+
12
D3
5LH-A
D2
5
LR7H-22
D1
see EA-9B334.90 DIMMING SYSTEM
Dimming Platine, EA-9B334.91-b
Glare Dim
K2 SP4P
F5
LR8F-22N B
G R
1,5k
D1
LR8F-22N
Maintenance Manual EXTRA 500 Chapter 91 30. March 2012
7
4
5LH-C
5LH-B
LH5E-22N
1VN-E (3) 001758 212 02
LH7-22N LG110-22N
LR6E-20
GLARE-LT
see EA-9B334.90 DIMMING SYSTEM
GLARE
DIM CONTROL
OFF
2LR GLARE
1A
1LR
EMERGENCY BUS PP4
CIRCUIT BREAKER/SWITCH PANEL
+
LR7F-22
R1
LR7F-22
4
LR8E-20N
3
F G H J K
A
B
C
D
LR5E-20
LR6E-20 07.1.1.13
LR6F-20
2
day
1
LR7E-20
1 LR7H-22
3 LR8H-22N
2 A B C D E 6
D2
D6
D1
D2
LEFT SIDE
R2 1,5k
ÄM-400-09-01
20.10.10
D3
D7
D3
Nr.: Änderung/Mod. Nr.: Datum
A
Letzte Bearbeitung:
1,5k
R1
D1
RIGHT SIDE
1,5k
R1
6
D5
3
R2 1,5k
R2 1,5k
Datum
5LR
D10
PB
Name
7
46569 Hünxe, Germany
Schwarze Heide 21
Gepr.:
Gepr.:
Bearb.: 04.12.02
D5
D9
Name
HW
D4
D8
OS-LM10A-W1-847
D4
7
D7
5
2
7LR
D10
D8
4LR
D10
A Blatt 1
von 1
8
Schutzvermerk nach DIN 34 beachten.
A3
EA-9B334.75
GLARE-LIGHT, LR
EA 400-500
Projektion Freimaßtoleranz Oberfläche
D9
OS-LM10A-W1-847
D9
OS-LM10A-W1-847 D8
CENTER
D7
Maßstab auf SI.-Klasse Oberflächenschutz
D6
D6
8
A
B
C
D
A
B
C
D
OFF
2LJ
ON
LG116E-20
LH116G-20
07.1.1.13
LH4G-20
LH4E-20
INST-LT
1
2
2
2LG
cw
4.7k
3LG 820r
9 8
4
1LG-a
CONTROL SOURCE (5V) CONTROL 0 - 5V +28 VDC INPUT 0 - 115 VAC OUTPUT OUTPUT AC RETURN INPUT DC RETURN
LG118E-22
LH2E-22
LH5E-22N
5LH-C
3A
F4
night
E F A D C B
ws bl
1LG-A
LG52E-22S LG103E-20N
LG106E-22 LG109E-22 LG102E-20
see EA-95334.90 DIMMING
5LH
Lumi Plus
SP4P
K2
Dimming Platine, EA-9B334.91-b
Lumi Dimm
Lumi Plus
24 GND 16 GND
3
3
LG110E-22
LG102E-20
1VN-B 001758 212 02
LG52E-22S
5LH-A
37 LG106E-22
11
10
4
ws org
LG52F-22S
ws org
ws org
ws org
bl
bl
bl
bl
LG52F-22S
S
1
2
3
4
5
ws org bl
VV201 VV202 VV203
ws org bl
bl
bl
bl
LG5F-24S
LG54G-24S
LG54H-24S
ws org bl ws org bl ws org bl
1VN-B 001758_212_02
LG52H-24S
EDV-Kennung:
04 03 02 01 Ver. Bezeichnung
9B34481T
Die Gültigkeitszuordnung von Version zu Flugzeugbaureihe ist der Bauakte bzw. dem jeweiligen Fertigungsauftrag zu entnehmen. Zuordnung links / rechts wird mit */* in allen Feldern angegeben.
6
Name
Nr.: Änderung/Mod. Nr.: Datum
12LG-A ws org
HW
ÄM-400-09-01
bl
bl
11LG-A ws org
10LG-A ws org
ws org
9LG-A
8LG-A ws org
7LG-A ws org
6LG-A ws org
ws org
5LG-A
ws org
4LG-A
7
46569 Hünxe, Germany
Schwarze Heide 21
12LG
11LG
10LG
9LG
A Blatt 1
8
Schutzvermerk nach DIN 34 beachten.
A3
EA-9B334.81
LUMI FOLIE, LG
von 1
Projektion Freimaßtoleranz Oberfläche
EA 400-500
Maßstab auf SI.-Klasse Oberflächenschutz
Panel Switches
Gear Switch
Flap Switch
Center Console
LEUCHTFOLIEN
PB
Gepr.:
8LG
7LG
6LG
5LG
8
see EA-9B246.10 DC-DISTRIBUTION
Circuit Breaker
Circuit Breaker
Circuit Breaker
Circuit Breaker
Name
Gepr.:
4LG
LEUCHTFOLIEN
Switches
Datum
7
Bearb.: 04.02.04
RS 472-922
11.10.10
A
Letzte Bearbeitung:
LG58E-24S
LG57E-24S
bl
bl
bl
LG54E-24S
bl
ws org bl
ws org LG53E-24S bl
LG56E-24S
ws org bl
Splice
LG52G-22S
LG56E-24S
ws 1 org bl 1
1
1
CIRCUIT BREAKER/SWITCH PANEL
6
LG55E-24S
B:18
B:17
B:16
5
LG55E-24S
ws org bl
B:15
Maintenance Manual EXTRA 500 Chapter 91 30. March 2012
1LG
KGS SD-3
INVERTER
see EA-95334.90 DIMMING
SWITCHES
DIM CONTROL
5LH-B
LH7-22N LG110-22N
LH116H-20
1VN-E (3) 001758 212 02
FM
A:9
A:8
A:7
see EA-9B246.10 DC-DISTRIBUTION
INST
7,5A
1LH1
BATTERY BUS PP2
CIRCUIT BREAKER/SWITCH PANEL
2
day
1
LG103E-20N
1 ws org
3 LG57E-22N
2
A
B
C
D
D
C
B
A
CB TRENNSTECKER
1LR GLARE
A:8
ON
OFF
1
ON
A:9 A:8
2
3LJ:1 NIGHT
2
A:4
3
2
?
G
26LH
3LG 8,2k 25LH
2LG
FM
4.7k
cw
LH2E-22
LG108E-22
LR9E-22
LG118E-22 see EA-9B334.81 LUMI FOLIE
4.7k
LG107E-22
5
7
9 8
1
LH7-22N LG110-22N
4
24 GND 16 GND
LG119F-20
5LH-C
14 1
LR6E-20
X1
D17
X2
LIGHT TEST 3 2 B1 3 2 A1
Annunciator Dim
Glare Dim
Lumi Dim
Lumi Plus
Instr. Dim
D18
X2
NIGHT X1
K2 SP4P
12 11
LH5E-22N
K1 SP2P
DAY /
25 13
23 22 20 19 17 15 7 5 4 2
10
3
9
LG116F-20
5LH-B
LT2F-20
see EA-9B284.13 1VE
4.7k
cw
LT1F-20
LH116H-20
EA-9B284.13
1VN-E (3) 001758 212 02
cw
H
1VN-E (2) 001758 212 02
A:7
Vmo Tone Test
PC-BOARD 1
23LH
35
J1
3
A:8 A:9 A:10 A:5
3
:2
2
18 6 21 8
2
3A
3A
3A
F4
F9
F8
D10
D8
D6
D4
Dimming Platine, EA-9B410.30C
K3 TN2
DAY/NIGHT
IFD´s 1A
Annunciator 7,5A
Glare 1A
Instruments 7,5A
AC OUT INVERTER
1k2 4W
D9
D7
D5
D3
D1
5LH
Lumi Plus
AC 2 OUT
AC 1 OUT
DC 1 OUT
BYW56
D16
Dioden BYW 56
56k 0.25W
1A
F3
1A
Spare D2
BYW56
D15
F5
Lumi out Instruments out Glare out Annunciator out
AC RET
3A
F7
IN
1A
5A
F6 F1
5A
F2
CG34H-22
LG2E-20
37
33 32
36 35
16
CG34H-22
5LH-A
LG106E-22
LG11E-22 LG9E-22
QX15E-22S
LG17E-22S
F G H J K
F G H J K
LG13E-22 LG26E-22 LG3E-22
7
29
GND / 2 - 28 VDC
AVIDYNE IFD >O.8 - 28 VDC Dimming <0.8 VDC Day Mode
MORITZ 8.0 - 28 VDC Dimming < 8.0 VDC Day Mode
VV334904
A B C D E
VV-10
MODUL 3
001115 202 03
A B C D E
MODUL 2
VV334902
CG37G-22 CG37E-22
VV334901 CG37F-22
1 6 3 4 2 7 5 35 1 2 3 6 7 8
1
IFD
ANNUNCIATOR
27LH
4.7k
cw
4.7k
cw
LG121E-22
2
2
3
6
IFD Dim
3
4
D3
7
5
Flap System EA-9B275.20, LED 6CG Flap System EA-9B275.20, LED 7CG Flap System EA-9B275.20, LED 8CG
Gear Warning EA-9B323.20, LED 27GA Gear Warning EA-9B323.20, LED 28GA Gear Warning EA-9B323.20, LED 29GA
BYW-56
BYW-56
BYW-56
see EA-9B284.10
Flap Indikation
Gear Warn
EA-9B411.50A 5LH see EA-9B284.13B PCB-BOARD 1
D1
D2
12 13 14
BYW-56
DME-HOLD EA-9B345.47, 5SN
9 11 10
+
-
EA-9B411.70
15
D4
K8
5
see EA-9B315.80 ANNUNCIATOR PANEL DME-HOLD EA-9B345.47, 5SN Gear Warning EA-9B323.20 27GA Gear Warning EA-9B323.20 28GA Gear Warning EA-9B323.20 29GA Test Flap System EA-9B275.20, LED 7CG Flap System EA-9B275.20, LED 6CG Flap System EA-9B275.20, LED 8CG
+28V POWER
DIM Voltage
+ Light-Test
- Light-Test
PC-BOARD 1
LG24-22
P1
FG101E-22 GA24H-22 GA25G-22 GA26H-22 CG33G-22 CG32H-22 CG34G-22
VV162 WW41E-20
5WWA
MODUL 1 001115_202_03 LH8E-20 FG1-73-22 A F GA27E-22 LG21E-22 B G GA27F-22 C H GA27G-22 D J E K
LG15E-22S
LG110E-22
LH9E-20
LG102E-20
30 26 27 Spare
29
31
15
11
19
10
LR7E-20
17 Spare
18 Spare
34 LH8E-20 16
12
LG109E-20
LH3G-20
VV161
VV160
see EA-9B344.14 WEATHER DEDECTION
6 Spare 25 Spare
28
20 1 7 8 13 14 WW41E-20 9 2 Spare FG101E-22 21 GA24H-22 3 GA25G-22 22 GA26H-22 4 CG33G-22 23 CG32H-22 5 CG34G-22 24
LH4E-20
ANNUNCIATOR STEUER-PLATINE
Maintenance Manual EXTRA 500 Chapter 91 30. March 2012
GLARE
SWITCHES
PANEL
DIM CONTROL
A:9
2
OFF
2 LH4G-20
2LJ INST
2
INST-LT LH4E-20
1
GLARE-LT
07.2.1.16 3
7,5A
5
WARN-LT
1
1LH1
6
1A
2 LR5E-20
1
7.5A
1
LG119E-20
LG119F-20
3
07.1.1.13
3
07.1.1.13
LR6E-20
LR6F-20
NIGHT
1LR
see EA-9B246.10 DC-DISTRIBUTION
1LH2
LT1F-20
LH116G-20
LH116H-20
4
(TONE) TEST
LT1E-20
DAY
LT2E-20
LT2F-20
LG116E-20
LG116F-20
LH3E-20N
LH3F-20N
WV8E-22
WV8F-22
WV8F-22
WV9E-22N
WV9F-22N
LH7E-20N
LH7E-20N
BATTERY BUS PP2
2
EMERGENCY BUS PP4
2
4
LG8E-22 LG35E-22
3
1LG-A
9
LG110E-22 LG106E-22
LG103E-20N LG102E-20
F E
B A
VV334903 001758-212-02
6
CONTROL 0 - 5V CONTROL SOURCE (5V)
INPUT DC RETURN +28 VDC INPUT
1LG
C D
ws org bl
1LG-A
ws bl
ws bl
EDV-Kennung:
9B33490T
04 03 02 01 Ver. Bezeichnung
Zuordnung links / rechts wird mit */* in allen Feldern angegeben.
S
bl
org
ws
ws 1 org bl 1
1
1
7
Name
HW
Nr.: Änderung/Mod. Nr.: Datum
22.02.11
1VN-B 001758_212_02
LG52H-24S
LG56E-24S
HW
ÄM-400-09-01
B:18
B:17
B:16
B:15
7 6 5
1 2
PM8000B
7WW2
Fuel 6 Stück
17WW2
16WW2
4HP
PROP HEAT
ATTITUDE
DIP
ENG INST
Altimeter
Airspeed
IFD-5000i
IFD-5000i
STEC 55X
LED 5 Stück
10WW3
EA-9B334.75
EA-9B271.17
PB
46569 Hünxe, Germany
RIGHT PANEL
EA-9B235.17
5-8LG-A ws 1 org 2 bl
4LG-A ws 1 org 2 bl
CENTER PANEL
Lumi 4X C-Breaker
Lumi Switches
AUDIO/MARKER
TURN COORDINATOR
EA-9B284.10
12LG-A ws 1 org 2 bl
11LG-A ws 1 org 2 bl
10LG-A ws 1 org 2 bl
9LG-A ws 1 org 2 bl
A Blatt 1
von
8
Schutzvermerk nach DIN 34 beachten.
A2
EA-9B334.90
DIMMING, LH
EA 400-500
Projektion Freimaßtoleranz Oberfläche
1
see EA-9B334.81 LUMI FOLIE
Lumi Panel Switches
Lumi Gear Switch
Lumi Flap Switch
Lumi Center Console
Maßstab auf SI.-Klasse Oberflächenschutz
LG58E-24S
LG57E-24S
LG56E-24S
Name
PEDESTAL
FUEL INSTRUMENTS
CABIN ALTITUDE
CABIN PRESS
EA-9B213.30
CABIN PRESS CONTROL
EA-9B360.11
PROP HEAT
ATTITUDE GYRO
EA-9B316.40
DIGITAL INSTRUMENTS
EA-9B316.50
see EA-9B246.10 DC-DISTRIBUTION LG55E-24S
Datum
LEFT PANEL
ENGINE INSTRUMENTS
ALTIMETER
AIRSPEED
EA-9B342.66
IFD RH
EA-9B342.65
IFD LH
LG54E-24S
20.09.02
GLARE AUTOPILOT COMPUTER
LG53E-24S
Schwarze Heide 21
Gepr.:
Gepr.:
Bearb.:
LG52G-22S
8
GLARE LIGHTS
AIRPATH
CIRCUIT BREAKER/SWITCH PANEL
IRM-B
7WW2-A
7
1 2
1 2
1 11
6 7
B A
13 12 9
12 11 13
2 1
-QX-A QX_E-22 6 QX_F-22
LG55E-24S
VV10
9QX-A
VV225
17WW2-A
16WW2-A
4HP-A
PHI-A
1FM-A
3EY-A
ws 3EZ-A bl ws bl
2 1
7 20
7 20
15 35
1 2
11WW2-A
?WV
P2101
P1101
P1
?
10WW3-A
20.10.10
A
2 1
18WW2-A 1 2
?
VV224
7
Letzte Bearbeitung:
ws org bl
LG3E-22 RM15E-22N
LG26E-22 LG25-22N
QX_E-22S
9QX-a
LG17E-22S LG47E-22N
LG15E-22S
LG16E-22N
HI9E-22S
LG13E-22 FM2A-22N
LG101E-22S
LG100E-22S
LG24-22 LG30-22N
LG35E-22 LG36-22N
LG9E-22 LG10E-22N
LG11E-22 LG12E-22N
LG8E-22 CA17E-20N
LR7E-20 LR8E-20N
LG21E-22 LG22E-22N
LG52E-22S
33 34
31 32
Die Gültigkeitszuordnung von Version zu Flugzeugbaureihe ist der Bauakte bzw. dem jeweiligen Fertigungsauftrag zu entnehmen.
see EA-9B334.81 LUMI FOLIE
0 - 115 VAC OUTPUT OUTPUT AC RETURN
DC / AC CONVERTER
QX_E-22S
1VN
6
E D C B A K J H G F
2
1
night
2
A 3 1 B 3 1 C 3 1 D 3
day
E D C B A K J H G F
1
8 F G H J K A B C D E F G H J K A B C D E
E D C B A K J H G F
CIRCUIT BREAKER/SWITCH PANEL
LG52F-22S
LH4H-20
D
C
B
A
A
B
3-5 3-9 3-4 3-8 3-3 3-7 3-2 3-6 3-1
3-4 3-2
3-7
3-6
3-1
GND IFD Dimm
2-24 2-16
Glare Dimm
2-12 2-11
Annun Dimm
2-14 2-1
Instr. Dimm
2-25 2-13
2-2
2-4
U2 reg
I2
GND
4in
3in
U1 reg
U4 reg
U3 reg
A1
I2
A4
I4
A3
I3
A2
1A
3A
3A
1A
3A
3A
5A
5A
7,5A
3in
U1 reg
2in
U4 reg
4in
U3 reg 7,5A
GND
1out
GND
4out
GND
3out
GND
O1
GND
O4
O3
O2
GND lila/gnd
AC lila
F3
F3
D16 BYW56
1A Lumi out 1out
IFD´s
1A
Glare
D15
2out 4out 3out
2out
Annunciator
U2 reg
2in
Instruments
D1 D2 D3 D4 D5 D6 D7 D8 D9 D10
IFD IFD
AC
AC
DC1
F8
D14
F9
F5
F4
D16
D15
F7
F6
1-36
1-27
1-26
1-30
1-29
1-31
1-15
1-11
1-19
1-12
1-10
1-17
1-18
1-13 1-14 1-34 1-16
1-2 1-21 1-3 1-22 1-4 1-23 1-5 1-24 1-6 1-25
1-7 1-8
F2 D1 D2 D3 D4 D5 D6 D7 D8 D9 D10
1-20 1-1
GNDt
Dioden BYW 56
BYW56
AC INVERTER
1k2 4W
R11
4k7 4W
R12
F3
F8
F9
F5
F4
F7
F6
F2
Instruments out Glare out Annunciator out
DC2 yel
GND blk
2in
D14
D12
D13
D11
2-5
K2
15
2-7
2-15
2-17
2-19
2-20
2-22
2-23
2-10
D18
SP4P
K2:1
DAY / NIGHT
16
U4 reg
4in
4out
GND
U3 reg
3in
3out
GND
U2 reg
2in
2out
GND
U1 reg
2in
1out
GND
IFD IFD
1
3
Poti 0 = kleinste Ausgangsspannung Poti 4k7 = gröste Ausgangsspannung
Spare
5LH
4
Inverter
AC
AC
1VE20
1
3-9
3-3
3-5
3-8
LUMI Plus
Lumi Dimm
2
K3s
LUMI Plus
3
Dimming Platine, EA-9B334.91-b
BYW56
D19
K3:1 TN2
1-37
1-33 1-32
1-9
1-28
1-35
4
5
5
+ C1 1uF
+ C8 1uF
+ C2 1uF
470
R7
470
R5
470
R3
470
R1
A1
330
R6
330
R4
Vout
cw
330
ADJ A44adj R8
I3 A3
3in 3adj
EDV-Kennung:
9B33491T 6
Zuordnung links / rechts wird mit */* in allen Feldern angegeben.
04 03 02 01 Ver. Bezeichnung
6
5
4
3
2
1
P4
U3 adj
U3in
U3out
U2 adj
U2in
U2out
ADJ
ÄM-400-09-01
14.10.10
Nr.: Änderung/Mod. Nr.: Datum
A
Letzte Bearbeitung:
Vout
LT 1038 CK
7
Vin ADJ
Name
HW
Name
PB
Datum
09.09.04
A von 1
8
Schutzvermerk nach DIN 34 beachten.
A2
DB37S
Blatt 1
PCB DIMMER EA-9B334.91
J1 1 20 2 21 3 22 4 23 5 24 6 25 7 26 8 27 9 28 10 29 11 30 12 31 13 32 14 33 15 34 16 35 17 36 18 37 19
Projektion Freimaßtoleranz Oberfläche
1-1 1-20 1-2 1-21 1-3 1-22 1-4 1-23 1-5 1-24 1-6 1-25 1-7 1-26 1-8 1-27 1-9 1-28 1-10 1-29 1-11 1-30 1-12 1-31 1-13 1-32 1-14 1-33 1-15 1-34 1-16 1-35 1-17 1-36 1-18 1-37 1-19
8
EA 400-500
Maßstab auf SI.-Klasse Oberflächenschutz
10,0 - 26 VDC
GLARE
10,0 - 26 VDC
ANNUNCIATOR
MORITZ 8.0 - 28 VDC Dimming < 8.0 VDC Day Mode
10,0 - 26 VDC
INSTRUMENTS
46569 Hünxe, Germany
7
IFD 6,8 - 26 VDC ab Mittelstellung volle Helligkeit
Schwarze Heide 21
Gepr.:
Gepr.:
Bearb.:
Vout
U3 LT 1038 CK
Vin
U2
Instrument Light < 2A, min 15V max 24V Map Light ~200mA, min 10V max 24V Annunciator Panel 2,88A Lumifolien Warning Light < 300mA, min 12V max 24V
+ C5 1uF
O4
+ C4 1uF
O3
+ C6 1uF
A2
I2
O2
J4
4out
1out
+ C3 1uF
O1
3out
2adj
2in
2out
1adj
330
R2
LT 1038 CK
cw
cw
cw
ADJ
Vout
LT 1038 CK
6
Die Gültigkeitszuordnung von Version zu Flugzeugbaureihe ist der Bauakte bzw. dem jeweiligen Fertigungsauftrag zu entnehmen.
GND
2
TR4 4k7
Vin
U4
TR3 4k7
TR2 4k7
TR1 4k7
Vin
U1
einstellen !
28 VDC
+ C7 1uF
I4 4in
Inverter 28 VDC 115VAC
Maintenance Manual EXTRA 500 Chapter 91 30. March 2012
5 9 4 8 3 7 2 6 1
DB9S 259-3071
J3
DB25P 259-3071
2-13 2-25 2-12 2-24 2-11 2-23 2-10 2-22 2-9 2-21 2-8 2-20 2-7 2-19 2-6 2-18 2-5 2-17 2-4 2-16 2-3 2-15 2-2 2-14 2-1
K2s
Instt
7
C
13 25 12 24 11 23 10 22 9 21 8 20 7 19 6 18 5 17 4 16 3 15 2 14 1
BYW56
D17
2
9
1
10
J2
2-3
2-9
K1
SP2P
1
8
6
3
9
D
K1:1
Inst2
2-21 2-8
5
7
night
1
2
7 10
9
GND2
10 13
2-18 2-6
12
LIGHT TEST
11 14
2
6
5 8
day
1
8
A
B
C
D
D
C
B
A
13 12 25
21 38 37
62 63 82
GROUND BYTE FLIGHT BUS 1+ BYTE FLIGHT BUS 1-
DISCRETE OUT 10 DISCRETE IN 7 DISCRETE IN 6
CFG DISCRETE 0 CFG DISCRETE 1 CFG DISCRETE 2
see EA-9B342.66 IFD RIGHT
7 14 15
GROUND BYTE FLIGHT BUS 2+ BYTE FLIGHT BUS 2-
32 31
429 RX1+ 429 RX1-
AUDIO/MARKER
PMA-8000B
WEIGHT ON WEELS
429 RX1+ 429 RX1RS422-232 TX2 RS232 COMMON RS422-232 RX2
31
31
24 25
37 38 36
11 12
17 18
9 10
OUTER MARKER MIDDLE MARKER INNER MARKER
COM 1 MIK AUDIO OUT COM 1 MIK KEY OUT
NV #1 RX HI NV #1 RX LO
COM #1 RX HI COM #1 RX LO
20
ACTIVE COM SECECTED COM SPLIT SECECTED
COM SWAP
see EA-284.13a PCB-BOARD 1
Vmo ALERT P1
see EA-9B344.15 TRAFFIC ADVISORY
PCB-BOARD 1
TAS-610
10 11 17 18 19
see EA-9B344.14 WEATHER DETECTION
20 18 19
RS232 TX1 RS232 RX1 RS232 COMMON
TRAFFIC ADVISORY SYSTEM
TWX-670
14
14 1
BYTE FLIGHT BUS + BYTE FLIGHT BUS -
see EA-9B342.67 KEYBOARD
21 22
SS12E-24S
SS13E-24S
ws bl
SD6E-24S
ws bl org
1RV2E-24S
ws bl
1RV3E-24S
1RM1E-24S
ws bl
ws bl
1RV1E-24S
RM1E-24 RM2E-24 RM3E-24
1RV4E-24 1RV5E-24
1
RV1F-24
1
WV3E-22
ws bl
1RM-A
1RM-B
P1
1
SD13E-22
1
SS13F-24S
1
FG15E-TC746
1
1
1RV4E-24 1RV5E-24
1RV4F-24 1RV5F-24
RV1F-24
RV1E-24
WV3E-22
SD13E-22
1 RM1E-24 RM2E-24 RM3E-24
FG14E-TC746 Thermax TC746 120Ohm
FG15E-TC746
RM1F-24 RM2F-24 RM3F-24
1
FG19-22 FG20E-22
1
1FG8E-24S
ws bl
1
1FG7E-24S
ws bl
FG21E-22 FG22E-22
1FG6E-24S
ws bl
1
FG15F-TC746 Thermax TC746, 120 Ohm
H J K L M N P R S
1 RV1E-24 1RV4F-24 1RV5F-24
1
1
1
ws bl
ws bl
ws bl
ST5
ws org bl
1
ws bl
J1
P1
Px
P2121
P2122
ws bl
P2101
ws bl
P2102
ws bl
J3010
1FG8F-24S
ws bl
USB + USB -
WEATHER DETECTION
7FG
IFD-5000i 700-00083-()
IFD RIGHT
10FG
ACD-215 700-00150-()
1FG7F-24S
ws bl
9 10
H B
28V MAG POWER + 28V MAG POWER -
1FG6F-24S
ws bl
1
USB VCC +5V USB GROUND (DRAIN)
D C
MAG RS422 TX+ MAG RS422 TX-
KEYBOARD
F G
MAG RS422 RX+ MAG RS422 RX-
P13001 1
ws bl org
ws bl
ws bl
ws bl
ws bl
J1144
P1122
P1122
P1121
ws bl
ws org bl
P1121
ws bl
P1102
ws bl
ws bl
ws bl
ws bl
ws bl
ws bl
P1101
3
43 28
44 30
13 29
11 5
38 37
21
16
18
24 46 66 5
15 36
17 38
HEADPHONE #3 HEADPHONE #3 LO
HEADPHONE #1 HEADPHONE #1 LO
HEADPHONE #2 HEADPHONE #2 LO
MICROPHONE #1 TX KEY #1
DISCRETE IN 7 DISCRETE IN 6
DISCRETE OUT 10
Vmo ALERT
DISCRETE OUT 7
RS422-232 RX2 TX2-RX2 COMMON RS422-232 TX2 SHIELD GROUND
ARINC 429 TX4+ ARINC 429 TX4-
ARINC 429 TX6+ ARINC 429 TX6-
RS422-232 RX0 RS422-232 TX0 TX0-RX0 COMMON
ARINC 429 RX7+ ARINC 429 RX7-
59 80
22 64 61
CFG DISCRETE IN 0 CFG DISCRETE IN 1 CFG DISCRETE IN 2
ARINC 429 RX5+ ARINC 429 RX5SHIELD GROUND
GROUND BYTE FLIGHT BUS 2+ BYTE FLIGHT BUS 2-
USB + USB GROUND BYTE FLIGHT BUS 1+ BYTE FLIGHT BUS 1-
USB VCC +5V USB GROUND(DRAIN)
28V MAG POWER + 28V MAG POWER -
MAG RS422 RX+ MAG RS422 RX-
MAG RS422 TX+ MAG RS422 TX-
62 63 82
57 78 76
7 14 15
11 24 13 12 25
10 23
4 17
1 14
2 15
IFD-5000i
IFD LEFT
J103
2 0 1
3
GS ANTENNA
VOR / LOC ANTENNA
DISCRETE IN ANALOG IN 1 ANALOG IN 0 DISCRETE IN DISCRETE IN DISCRETE IN
ANALOG REF ANALOG GROUND
GROUND ANALOG OUT 2 ANALOG OUT 3 ANALOG OUT 6 ANALOG OUT 5 ANALOG OUT 0 DISCRETE OUT 4
DISCRETE OUT 0 DISCRETE OUT 1 DISCRETE OUT 2
DISCRETE OUT 0+ DISCRETE OUT 0GROUND
RS422 TX3+ RS422 TX3RS422 RX3+ RS422 RX3SCHIELD 429 RX0+ 429 RX0429 TX0+ 429 TX0+ GROUND DISCRETE OUT 1+ DISCRETE OUT 1-
RS232 RX0 TX0-RX0 COMMON RS232 TX0
RS232 RX2 TX0-RX0 COMMON RS232 TX2
RS232 RX1 RS232 COMMON RS232 TX1
28V POWER BUS B 28V POWER BUS RETURN B CHANNEL ID 0 GROUND CHANNEL ID 1 GROUND
DIM BUS COMMON
28V POWER BUS RETURN A
28V POWER BUS A
BEZEL DIMMING
23 41 40 22 7 8
25 39
15 12 13 27 26 10 6
2 3 4
19 40 60
85 86 4 25 67 51 72 10 31 14 20 41
89 87 88
23 67 65
91 96 44
A1 A2 4 11 5 12
20
A2
A1
7
3FG
700-00083-()
4
LG12E-22N
1FG2E-14
1FG1F-14
LG11E-22
P1142
P1141
P1122
ws bl
P1122
P1121
ws bl
ws bl
ws bl ws bl
ws bl ws bl
1
1FG12E-RG400
1FG11E-RG400
18FG-B
16FG-B
CA31E-24S CA32E-24S CA33E-24S CA34E-24S CA35E-24S CA36E-24S
CA38E-24S
CA37E-24S
SH8E-24S
SH7E-24S
TL9E-24S
ws bl org
QY4E-24S
TS3F-24S
1
1FG3F-14 1FG4E-14
ws bl org
ws bl
P1121
P1102
1
10FG
CI 428-200
GPS-1 ANTENNA
9FG
DM C70-1A
COM-1 ANTENNA
2
see EA-9B235.16 MKR-AUDIO
MONITOR #1 RX HI MONITOR #1 RX LO
7 8
10FG-A
9FG-A
1FG10E-RG400
1FG9E-RG400
3
P1131
P1145
J1144
GPS ANTENNA
COM ANTENNA
4
1
5
5
OVERBRAID
1
43 42
ws bl ws bl
ST13-A
ws bl org
18FG-C
18G-A
16FG-A
16FG-C
13 12
K4B-W K3A-W
FG13F-RG400
2FG12E-RG400
19FG see EA-9B342.66 IFD RIGHT
COCKPIT OVERHEAD
CI-193
GS ANTENNA
C:3
D:1
6
1
17FG-A
9CA-A
ws bl
ws bl
ws bl
CA41E-24S
CA40E-24S
CA31E-24S CA32E-24S CA33E-24S CA34E-24S CA35E-24S CA36E-24S
CA38E-24S
CA39E-24S
CA42E-24 CA43E-24
CA19E-24S
CA9E-24S
CA21E-24
CA22E-24S
SH8F-24S
SH7F-24S
TL9E-24S
15FG-A
EDV-Kennung:
04 03 02 01 Ver. Bezeichnung
9B34265T
Die Gültigkeitszuordnung von Version zu Flugzeugbaureihe ist der Bauakte bzw. dem jeweiligen Fertigungsauftrag zu entnehmen. Zuordnung links / rechts wird mit */* in allen Feldern angegeben.
FG13E-RG400
1
1
1
1
TS3E-24S
1
1
ws bl
ws bl
ws bl
ws bl
QY4E-24S
CA37E-24S
SH8F-24S
SH7F-24S
TS3E-24S
ws bl
1
10A
QY4F-24S
1FG3E-14
1FG1E-14
see EA-9B271.17 AP-STEC-55X
1
1
2
3
7
P2
2 3 24 40
2 24 3
RS-232 RX
9
GND SIG REF G/S DOWN SHIELD GROUND SHIELD GROUND FD LOGIC ROLL STR SIG PITCH STR SIG ANNUN LOAD ANNUN CLOCK ANNUN DATA SHIELD GROUND
43 7 19 41 39 4 12 13 24 25 26 40
7
Nr.: Änderung/Mod. Nr.: Datum
Letzte Bearbeitung:
15FG
S-TEC 55X
Datum
HW
46569 Hünxe, Germany
Schwarze Heide 21
Gepr.:
Gepr.:
OPTION
OPTION
8
rechts
Blatt 1
von 1
8
Schutzvermerk nach DIN 34 beachten.
A3
EA-9B342.65
IFD LEFT, FG
EA 400-500
Projektion Freimaßtoleranz Oberfläche
C1120-1
links
C1120-2
Maßstab auf SI.-Klasse Oberflächenschutz
14FG
13FG
VOR/LOC ANTENNA SET
Name
14FG-A
13FG-A
Bearb.: 24.02.11
51351-CI120-2
Name
BXP-6402-1R-(01)
see EA-9B271.17 AP-STEC-55X
51351-CI120-2
G/S UP + VS SIGNAL SHIELD GROUND
ALT ENGAGE SIGNAL ALT SEL CONTROL
429 TX+ 429 TXNAV FLAG + NAV FLAG SHIELD GROUND LOC SWITCH DC HDG HI DC CRS HI SHIELD GROUND L-R +RT HDG RETURN CRS RETURN L-R -RT
15FG-C
MLB-700
see EA-9B345.58 TRANSPONDER
RX+ RXTX+ TX-
ROLL STEERING 429A ROLL STEERING 429B SHIELD GROUND G/S FLAG + G/S FLAG SHIELD GROUND
TIS TIS TIS TIS
18 22 49
20 21
48 37 13 14 45 32 28 11 44 30 29 12 31
36 37 46 1 2 39
AUTOPILOT
RS-422 RS-422 RS-422 RS-422
TRANSPONDER
COM1 TX COM1 RX GND GROUND
see EA-9B344.16 DATA LINK BROADCAST
RS-232 RS-232 RS-232 SIGNAL
MLX-770
see EA-9B344.17 DATA LINK 2 WAY
SATELLITE WX
2QY
912041T-D
see EA-9B731.40 FUEL FLOW
SIGNAL RS-232 TX1 SIGNAL RS-232 GND SIGNAL RS-232 RX1
DATA LINK 2 WAY
RS-232 TX
6
15 14 18 17
IFD LH B
2FG
see EA-9B246.10 DC-DISTRIBUTION
10A
BATTERY BUS PP2
SHADIN MINIFLOW L
POWER COMBINER 15FG-B C1120-3
ws bl
4CA-B
P1
ws bl
ws bl ws bl
4CA-A
P2
ws bl
ws bl
4CA-B
ws bl ws bl
P8
ws org bl
J1
ws bl org
J1-A
Px
IFD LH A
1FG
EMERGEMCY BUS PP4
CIRCUIT BREAKER/SWITCH PANEL
CA37F-24S see EA-9B271.17 AP-STEC-55X
CA15H-22
ws bl
DRUCKSPANNT HINTEN
17FG-B
17FG-a
see EA-9B342.66 IFD RIGHT
see EA-9B342.66 IFD RIGHT
see EA-9B271.17 AP-STEC-55X
9CA
9 48
16
50 54 55
K3B-W K2A-W
K4A-W
K3D-W K4D-W K4C-W
5 44
72
28V RELAY POWER
K2B-W K1A-W
46 47
K2D-W K2C-W
K4D-NO K4C-NO K4A-NO K4B-NO K3A-NO AI ENERGIZE
K3D-NO K3B-NO K2A-NO
K2B-NO K1A-NO
K2D-NO K2C-NO
2FG11E-RG400
14 15 56 53 52 71
10 49 28
45 24
6 7
19FG-A FG14E-RG400
9CA-A
ws bl
ws bl
ws bl
K1C-W K1D-W
20 11 12 13 14 15
1 3 2 16
ws bl
AIS 240-35
ws bl ws bl
SIM
ws bl org
SIM
ST13-A
DRUCKSCHOTT HINTEN
9CA-A K1C-NO K1D-NO
A/P RELAY
SH8E-24S
1FG3F-14
1FG1F-14
see EA-9B342.66 IFD RIGHT
6
9CA-A 3 2
1
1
SH7E-24S
TS3F-24S
see EA-9B334.90 Dimming MODUL 2 Pin F
36 AWG Tinned copper per ASTM-B-33 optical coverage minimal 98 - 100%
HINTER I-BRETT
18FG
GS DUPLEXER CI-503
HINTER I-BRETT
16FG
NAV DUPLEXER CI-502
CA50E-24S CA51E-24S CA52E-24S CA53E-24S CA54E-24S CA55E-24
CA47E-24 CA48E-24 CA49E-24
CA46E-24S
CA45E-24S
CA44E-24S
700-00156-()
CONFIGURATION MODULE ACM-100
P1101
Maintenance Manual EXTRA 500 Chapter 91 30. March 2012
OPTION
OPTION
4FG
MAG-300 700-00011-()
MAG/OAT LH
RM1E-24 RM2E-24 RM3E-24
2
CA38F-24S
1
CA36F-24S CA35F-24S CA34FF-24S CA33FF-24S CA32F-24S CA31F-24S
D
C
B
A
D
C
B
A
H B
28V MAG POWER + 28V MAG POWER -
7 14 15
21 38 37
GROUND BYTE FLIGHT BUS 2+ BYTE FLIGHT BUS 2-
DISCRETE OUT 10 DISCRETE IN 7 DISCRETE IN 6
see EA-9B342.65 IFD LEFT
CFG DISCRETE 0 CFG DISCRETE 1 CFG DISCRETE 2
13 12 25
GROUND BYTE FLIGHT BUS 1+ BYTE FLIGHT BUS 1-
30 29
429 RX2+ 429 RX2-
AUDIO/MARKER PMA-8000B
KDI 574
TAS MUTE
429 RX2+ 429 RX2RS422-232 TX3 RS232 COMMON RS422-232 RX3
5
35 39 38 20 37 41 42 43 44 48
24 25
37 38 36
15 30
19 20
13 14
21 22
OUTER MARKER MIDDLE MARKER INNER MARKER
COM 2 MIK AUDIO OUT COM 2 MIK KEY OUT
NV #2 RX HI NV #2 RX LO
COM #2 RX HI COM #12RX LO
MONITOR #2 RX HI MONITOR #2 RX LO
20
62 63 82
ACTIVE COM SECECTED COM SPLIT SECECTED
COM SWAP
see EA-9B345.47 DME
1 MA 1 ME 1 MC 1 MD #NAME? #NAME? #NAME? #NAME? #NAME? NAV 1 COMMON Select 2X5 Code
see EA-9B344.15 TRAFFIC ADVISORY
DME INDICATOR
TAS-610
12 13 20 21 22
see EA-9B344.14 WEATHER DETECTION
14 12 13
RS232 TX2 RS232 RX2 RS232 COMMON
TRAFFIC ADVISORY SYSTEM
TWX-670
2FG8F-24S
ws bl
14 1
2FG7F-24S
ws bl
RV1F-24 1RV4E-24 1RV5E-24
2RM1E-24S
2RV2E-24S
ws bl
ws bl
RM1F-24 RM2F-24 RM3F-24
1RV4E-24 1RV5E-24
RV1E-24
2RV1E-24S
1
ws bl
1RM-A
1RM-B
1
SD8E-24S
ws bl org
SD11E-22
SS15F-24S
ws bl
SS15E-24S
1
1
2FG8E-24S
1RV4E-24 1RV5E-24
RV1E-24
RV1F-24
SD11E-22
1 RM1F-24 RM2F-24 RM3F-24
1
1
1
ws bl org
ws bl
ws bl
ws bl
J2144
P2122
P2121 P2122
ws bl
ws bl
ws org bl
P2121
ws bl
P2102
ws bl
ws bl
1
ws bl
2FG7E-24S
P2101 ws bl
1
2FG6E-24S
1RV4E-24 1RV5E-24
FG14E-TC746 Thermax TC746, 120 Ohm
FG15F-TC746
FG15F-TC746
ws bl
1
1
ws bl
ws bl
ws bl
FG15E-TC746 Thermax TC746, 120 Ohm
T U V i j p q r s
RM1E-24 RM2E-24 RM3E-24
1
1
1
1
ws bl
ws bl
ws bl
ST5
SS14E-24S
1
ws org bl
P7041
P1
Px
P1121
P1122
ws bl
P1102
ws bl
P1101
ws bl
ws bl
J3010
2FG6F-24S
1
ws bl
P23001
see EA-9B342.67 KEYBOARD
WEATHER DETECTION
3FG
IFD-5000i 700-00083-()
IFD LEFT
10FG
ACD-215 700-00150-()
BYTE FLIGHT BUS + BYTE FLIGHT BUS -
D C
MAG RS422 TX+ MAG RS422 TX-
KEYBOARD
F G
MAG RS422 RX+ MAG RS422 RX-
3
44 30
13 29
11 5
38 37
21
5 6 16 17 20 31 32 33 34
19
24 46 66 5
15 36
22 64 61
OUT OUT OUT OUT OUT OUT OUT OUT OUT
3 4 5 6 9 11 12 13 14
HEADPHONE #1 HEADPHONE #1 LO
HEADPHONE #2 HEADPHONE #2 LO
MICROPHONE #1 TX KEY #1
DISCRETE IN 7 DISCRETE IN 6
DISCRETE OUT 10
DISCRETE DISCRETE DISCRETE DISCRETE DISCRETE DISCRETE DISCRETE DISCRETE DISCRETE
DISCRETE OUT 8
RS422-232 RX2 TX2-RX2 COMMON RS422-232 TX2 SHIELD GROUND
ARINC 429 TX4+ ARINC 429 TX4-
RS422-232 RX0 RS422-232 TX0 TX0-RX0 COMMON
CFG DISCRETE IN 0 CFG DISCRETE IN 1 CFG DISCRETE IN 2
ARINC 429 RX7+ ARINC 429 RX7-
59 80
62 63 82
ARINC 429 TX6+ ARINC 429 TX6-
ARINC 429 RX5+ ARINC 429 RX5SHIELD GROUND
GROUND BYTE FLIGHT BUS 2+ BYTE FLIGHT BUS 2-
GROUND BYTE FLIGHT BUS 1+ BYTE FLIGHT BUS 1-
28V MAG POWER + 28V MAG POWER -
MAG RS422 RX+ MAG RS422 RX-
17 38
57 78 76
7 14 15
13 12 25
4 17
1 14
MAG RS422 TX+ MAG RS422 TX-
IFD-5000i 2 15 A1
7
20
11 24
10 23
2 0 1
3
VOR / LOC ANTENNA
DISCRETE IN ANALOG IN 1 ANALOG IN 0 DISCRETE IN DISCRETE IN DISCRETE IN
ANALOG REF ANALOG GROUND
2 3 6 5 0
23 41 40 22 7 8
25 39
15 12 13 27 26 10
GROUND ANALOG ANALOG ANALOG ANALOG ANALOG OUT OUT OUT OUT OUT
2 3 4
19 40 60
10 31 14 20 41
DISCRETE OUT DISCRETE OUT 1 DISCRETE OUT 2
DISCRETE OUT 0+ DISCRETE OUT 0GROUND
429 TX0+ 429 TX0+ GROUND DISCRETE OUT 1+ DISCRETE OUT 1-
85 86 4 25 51 72 67
89 87 88
RS232 RX0 TX0-RX0 COMMON RS232 TX0
RS422 TX3+ RS422 TX3RS422 RX3+ RS422 RX3429 RX0+ 429 RX0SCHIELD
23 67 65
91 96 44
RS232 RX2 TX0-RX0 COMMON RS232 TX2
RS232 RX1 RS232 COMMON RS232 TX1
A1 28V POWER BUS B 28V POWER BUS RETURN B A2 6 CHANNEL ID 2 13 GROUND 5 CHANNEL ID 1 12 GROUND
DIM BUS COMMON
USB + USB -
USB VCC +5V USB GROUND(DRAIN)
28V POWER BUS RETURN A A2
28V POWER BUS A
BEZEL DIMMING
700-00083-()
4
P2142
P2141
P2122
ws bl
P2121 P2122
ws bl
ws bl
ws bl
ws bl ws bl ws bl
ws bl org
ws bl org
ws bl
P2121
P2102
P2101
CA38F-24S
CA37F-24S
SH4E-24S
SH3E-24S
TL10E-24S
TS4F-24S
QY4F-24S
2FG11E-RG400
18FG-C
16FG-C
CA31F-24S CA32F-24S CA33F-24S CA34F-24S CA35F-24S CA36F-24S
1
1
2FG3F-14 2FG4E-14
LG10E-22N
2FG2E-14
2FG1F-14
LG9E-22
1
12FG
CI 428-200
GPS-2 ANTENNA
11FG
DM C70-4
COM-2 ANTENNA
2
see EA-9B235.17 MKR-AUDIO
12FG-A
11FG-A
2FG10E-RG400
2FG9E-RG400
3
P2131
P2145
J2144
43 28
GPS ANTENNA
COM ANTENNA
HEADPHONE #3 HEADPHONE #3 LO
4
GS ANTENNA
7FG 1
2FG12E-RG400
5
5
OVERBRAID
1
18FG-B
18G-A
16FG-A
16FG-B
FG13F-RG400
1FG12E-RG400
17FG see EA-9B342.65 IFD LEFT
COCKPIT OVERHEAD
CI-193
GS ANTENNA
6
DRUCKSPANNT HINTEN
17FG-B
17FG-a
see EA-9B342.65 IFD LEFT
see EA-9B342.65 IFD LEFT
1
1
1
CA41E-24S
CA40E-24S
9CA-A
ws bl
ws bl
ws bl
#22
04 03 02 01 Ver. Bezeichnung
5 26 6 40
5 26 6
ws bl
P1
4CA-B
P2
ws bl
ws bl ws bl
P1 4CA-A
ws bl
ws bl
4CA-B
ws bl ws bl
P9
ws bl org
J1
ws bl org
J1-A
Px
15FG
RS-232 RX
9
9B34266T
=
7
RX+ RXTX+ TX-
GND G/S UP + VS SIGNAL SHIELD GROUND
SIG REF G/S DOWN SHIELD GROUND SHIELD GROUND FD LOGIC ROLL STR SIG PITCH STR SIG ANNUN LOAD ANNUN CLOCK ANNUN DATA SHIELD GROUND
43 18 22 49
7 19 41 39 4 12 13 24 25 26 40
=
Name
=
51351-CI120-2
S-TEC 55X
HW
46569 Hünxe, Germany
Schwarze Heide 21
Gepr.:
Gepr.:
Name
OPTION
rechts
links
C1120-2
Blatt 1
8
Schutzvermerk nach DIN 34 beachten.
A2
EA-9B342.66 von 1
Projektion Freimaßtoleranz Oberfläche
EA 400 - 500 IFD RIGHT, FG
Maßstab auf SI.-Klasse Oberflächenschutz
see EA-9B342.65 IFD LEFT
14FG
13FG
8
OPTION
VOR/LOC ANTENNA SET
Bearb.: 24.02.11
Datum
14FG-A
13FG-A
see EA-9B271.17 AP-STEC-55X
ALT ENGAGE SIGNAL ALT SEL CONTROL
HDG RETURN CRS RETURN L-R -RT SHIELD GROUND 29 12 31 39
20 21
DC HDG HI DC CRS HI SHIELD GROUND L-R +RT
429 TX+ 429 TXNAV FLAG + NAV FLAG SHIELD GROUND LOC SWITCH
ROLL STEERING 429A ROLL STEERING 429B SHIELD GROUND G/S FLAG + G/S FLAG SHIELD GROUND
51351-CI120-2
BXP-6402-1R-(01)
see EA-9B345.58 TRANSPONDER
28 11 44 30
48 37 13 14 45 32
36 37 46 1 2 39
Nr.: Änderung/Mod. Nr.: Datum
=
RS422 RS422 RS422 RS422
AUTOPILOT
8 9 21 22
MLB-700
see EA-9B344.16 DATA LINK BROADCAST
COM2 TX GND COM 2RX GROUND
TRANSPONDER
RS-232 RS-232 RS-232 SIGNAL
MLX-770
see EA-9B344.17 DATA LINK 2 WAY
SATELLITE WX
2QY
912041T-D
see EA-9B731.40 FUEL FLOW
SIGNAL RS-232 TX2 SIGNAL RS-232 GND SIGNAL RS-232 RX2
DATA LINK 2 WAY
RS-232 TX
6
15FG-C
Letzte Bearbeitung:
IFD RH B
6FG
see EA-9B246.10 DC-DISTRIBUTION
10A
AVIONICS BUS PP5
SHADIN MINIFLOW L
IFD RH A
7
POWER COMBINER 15FG-B C1120-3
Die Gültigkeitszuordnung von Version zu Flugzeugbaureihe ist der Bauakte bzw. dem jeweiligen Fertigungsauftrag zu entnehmen. Zuordnung links / rechts wird mit */* in allen Feldern angegeben.
EDV-Kennung:
1
ws bl
ws bl
15FG-A
1
1
CA38F-24S
CA31F-24S CA32F-24S CA33F-24S CA34F-24S CA35F-24S CA36F-24S
FG13E-RG400
1
CA39E-24S
CA42E-24 CA43E-24
CA19E-24S
CA9E-24S
CA21E-24
1 TL10E-24S
CA37E-24S CA22E-24S
see EA-9B271.17 AP-STEC-55X ws bl
1
QY4F-24S
TS4E-24S
ws bl
1
ws bl
1
10A
QY4E-24S
2FG3E-14
CA37F-24S
SH4F-24S
SH3F-24S
TS4E-24S
2
2FG1E-14
see EA-9B271.17 AP-STEC-55X
CA15H-22
ws bl
ws bl
9CA-A
17FG-A
13 12
K4B-W K3A-W
9CA
9 48
16
K3B-W K2A-W
K4A-W
54 55
50 K4D-W K4C-W
K3D-W
72
46 47
43 42
ws bl ws bl
ST13-A
ws bl org
ST13-A
5 44
18 4 5 9 10 19
6 8 7 17
K2B-W K1A-W
28V RELAY POWER
K2D-W K2C-W
K1C-W K1D-W
AIS 240-35
ws bl ws bl
SIM
ws bl org
SIM
C:4
D:3
3
5FG
LOAD BUS PP3
CIRCUIT BREAKER/SWITCH PANEL
see EA-9B342.65 IFD LEFT
2FG3F-14
2FG1F-14
6
DRUCKSCHOTT HINTEN
see EA-9B271.17 AP-STEC-55X
K4D-NC K4C-NC K4A-NC K4B-NC K3A-NC
K3D-NC K3B-NC K2A-NC
K2B-NC K1A-NC
K2D-NC K2C-NC
K1C-NC K1D-NC
1FG11E-RG400
34 35 36 33 32
30 29 8
25 4
26 27
23 22
A/P RELAY
SH4E-24S
17FG-A FG14E-RG400
9CA-A
ws bl
ws bl
ws bl
9CA-A
1 SH3E-24S
TS4F-24S
1
see EA-9B334.90 Dimming MODUL 2 Pin G
36 AWG Tinned copper per ASTM-B-33 optical coverage minimal 98 - 100%
HINTER I-BRETT
18FG
GS DUPLEXER CI-503
HINTER I-BRETT
16FG
NAV DUPLEXER CI-502
CA59E-24S CA60E-24S CA61E-24S CA62E-24S CA63E-24S
CA56E-24 CA57E-24 CA58E-24
CA66E-24S
CA65E-24S
CA64E-24S
Maintenance Manual EXTRA 500 Chapter 91 30. March 2012
OPTION
OPTION
OPTION
8FG
MAG-300 700-00011-()
MAG/OAT II
RM1E-24 RM2E-24 RM3E-24
2
CA38E-24S
1
CA36E-24S CA35E-24S CA34E-24S CA33E-24S CA32E-24S CA31E-24S
D
C
B
A
A
B
C
D
2
6 8
9 10
21 22
14 1
7 20
28V IN #1FD 28V IN # 2FD
USB VCC +5V USB GROUND (DRAIN)
USB + USB -
BYTE FLIGHT BUS + BYTE FLIGHT BUS -
POWER GROUND # 1FD POWER GROUND # 2FD
ws bl
J3010
SPLICE NO FARTHER THEN 2 INCH (50mm) FROM PINS
10FG
ACD-215 700-00150-()
KEYBOARD
2
FG17E-20N FG18E-20N
1
FG15E-TC746
FG14E-TC746
FG14E-TC746 Thermax TC746, 120 Ohm
FG15E-TC746 Thermax TC746, 120 Ohm 1
FG19-22 FG20E-22
FG19-22 FG20E-22 FG15F-TC746
FG21E-22 FG22E-22
FG21E-22 FG22E-22
FG15F-TC746
FG16F-20
Thermax TC746, 120 Ohm
4
FG16F-20
3
1
1
OVERBRAID
2
optical coverage minimal 98 - 100%
36 AWG Tinned copper per ASTM-B-33
3
4
Maintenance Manual EXTRA 500 Chapter 91 30. March 2012
1
5
ws bl
P2102
ws bl
P2101
ws bl
P1102
ws bl
ws bl
2
A:11
P1101
5
2
GROUND BYTE FLIGHT BUS 2+ BYTE FLIGHT BUS 2-
USB + USB GROUND BYTE FLIGHT BUS 1+ BYTE FLIGHT BUS 1-
7 14 15
13 12 25
EDV-Kennung:
04 03 02 01 Ver. Bezeichnung
9B34267T
Die Gültigkeitszuordnung von Version zu Flugzeugbaureihe ist der Bauakte bzw. dem jeweiligen Fertigungsauftrag zu entnehmen. Zuordnung links / rechts wird mit */* in allen Feldern angegeben.
GROUND BYTE FLIGHT BUS 2+ BYTE FLIGHT BUS 2-
GROUND BYTE FLIGHT BUS 1+ BYTE FLIGHT BUS 1-
IFD-5000i
KEYPAD
9FG
6
.
Nr.: Änderung/Mod. Nr.: Datum
.
7FG
700-00083-()
Name
.
see EA-9B342.66 IFD RIGHT
Letzte Bearbeitung:
.
3FG
700-00083-()
see EA-9B342.65 IFD LEFT
see EA-9B246.10 DC-DISTRIBUTION
USB VCC +5V USB GROUND(DRAIN)
IFD RIGHT
7 14 15
11 24 13 12 25
10 23
IFD-5000i
IFD LEFT
FG16E-20
1A
EMERGENCY BUS PP4
CIRCUIT BREAKER/SWITCH PANEL
6
.
Datum
HW
Name
7
46569 Hünxe, Germany
Schwarze Heide 21
Gepr.:
Gepr.:
Bearb.: 01,08,10
7
Projektion Freimaßtoleranz Oberfläche
Blatt 1
von 1
8
Schutzvermerk nach DIN 34 beachten.
A2
EA-9B342.67
EA 400 - 500 KEYPAD, FG
Maßstab auf SI.-Klasse Oberflächenschutz
.
8
A
B
C
D
A
B
C
D
28V LIGHTING
+10 to 32VDC POWER LIGHTING (+) POWER/LIGHTING RETURN NC
C B A D
MS3112E8-4S
FM1F-22 LG13E-22 FM2E-22N
2FM-A
2
E
1
2
EDV-Kennung:
9B34273T
04 03 02 01 Ver. Bezeichnung
1
FM1E-22 2A
STBY-GYRO 1FM
3
Nr.: Änderung/Mod. Nr.: Datum
Letzte Bearbeitung:
HW
Name 46569 Hünxe, Germany
Schwarze Heide 21
Gepr.:
Gepr.:
Name
Datum
Bearb.: 01.09.10
4
Projektion Freimaßtoleranz Oberfläche
Blatt 1
von 1
4
Schutzvermerk nach DIN 34 beachten.
A3
EA-9B342.73
ATTITUDE GYRO, FM
EA 400-500
Maßstab auf SI.-Klasse Oberflächenschutz
see EA-9B246.10 DC-DISTRIBUTION
EMERGENCY BUS PP4
CIRCUIT BREAKER/SWITCH PANEL
3
see EA-9B334.90 DIMMING SYSTEM
C:7
Die Gültigkeitszuordnung von Version zu Flugzeugbaureihe ist der Bauakte bzw. dem jeweiligen Fertigungsauftrag zu entnehmen. Zuordnung links / rechts wird mit */* in allen Feldern angegeben.
1VN-G 001758 212 02
FM1F-22
Maintenance Manual EXTRA 500 Chapter 91 30. March 2012
2FM
4200-11
ATTITUDE GYRO
1
FM2E-22N
A
B
C
D
D
C
B
A
32 31
17 15 16
30 29
9 10
6 7
3 4
37 38
429 RX1+ 429 RX1-
RS232 TX2 RS232 RX2 RX2 COMMON
429 RX2+ 429 RX2-
RS232 RX4 RX2 COMMON
RS232 RX5 RX2 COMMON
RS232 RX6 RX2 COMMON
RS232 RX7 RX2 COMMON
2
SS14E-24S
ws org bl
SS5E-22N SS4E-22N SS3E-20N
SS15E-24S
SS13E-24S
ws bl
ws bl
SS12E-24S
SS11E-24
1VN-E
001758_212_02
SS6E-24S bl
SS7E-24
P1
ws
see EA-9B246.10 DC-DISTRIBUTION
BYW-56
D3
B:1
ws org bl
1
SS10E-24
SS6E-24S
SS1F-20
SS7E-24
560uH
L1
ws bl
P1
3
WTHR DET
1SS
BYW-56
D1 R8 330 R7 330 R6 330
BYW-56
D2
BYW-56
BYW-56
8
10
11
24
29
SS16E-24S
P1
SS8E-24
SS9E-24
1
2SS
ANTENNA SENSE IN
VERTICAL LOOP VERTICAL LOOP +
HORIZONTAL LOOP + HORIZONTAL LOOP -
2
60 61
63 62
BNC
SS18E-RG178
SS17E-24S
bl ws
P2
SS16E-24S
ws bl
SS17E-24S
3
4
12
GA53F-221
X1
8
45GA 5WW-B 2 GA53E-22
X2
CG34H-22
CG34G-22
C11C
3SS
5
ws bl
SS13F-24S
ws bl
SS15F-24S
ws org bl
15 36
22 64 61
15 36
22 64 61
EDV-Kennung:
9B34414T
04 03 02 01 Ver. Bezeichnung
6
D8
BYW-56
BYW-56
ALT WRN IN
PILOT MIC KEY
COPILOT MIC KEY
L217
L117
IFD-5000i
Nr.: Änderung/Mod. Nr.: Datum
22.02.11
Datum
HW
Schwarze Heide 21
Gepr.:
Bearb.: 01.08.10 Gepr.:
Name
700-00083-()
700-00083-()
7
Name 46569 Hünxe, Germany
HW
1RM
70-2420-x TAS-610
optical coverage minimal 98 - 100%
Letzte Bearbeitung:
5LWW
PMA-8000B
36 AWG Tinned copper per ASTM-B-33
ARINC 429 TX4+ ARINC 429 TX4-
RS422-232 RX0 RS422-232 TX0 TX0-RX0 COMMON
IFD RIGHT
ARINC 429 TX4+ ARINC 429 TX4-
RS422-232 RX0 RS422-232 TX0 TX0-RX0 COMMON
IFD-5000i
SWITCH ANNUNCIATOR GND
IFD LEFT
6
EA-9B411.70
+ DIMM VOLT I HYDRAULIC + DIMM VOLT II
LAMP TEST GND
TRAFFIC ADVISORY SYSTEM
31
34
33
AUDIO/MARKER
14
D17
5LH
EA-9B410.30C
[+ DIMMING VOLTAGE] LAMP TEST GND
ANNUNCIATOR BOARD 33
7
FLAP [IN TRANSITION] amber
8CG 10 MODUL1 Pin C DIMMING BOARD
aus EMI Kit P/N 800-00035-000
OVERBRAID
ws bl
SS15E-24S
1
ws org bl
P2121
ws bl
SS14E-24S
P1
P1121 P2121
SS13E-24S
1
SS12E-24S
28
24
1RM-A
1RM-B
Die Gültigkeitszuordnung von Version zu Flugzeugbaureihe ist der Bauakte bzw. dem jeweiligen Fertigungsauftrag zu entnehmen. Zuordnung links / rechts wird mit */* in allen Feldern angegeben.
2
1
RZ2E-24S
6
CG37E-22
1 2
5LH-A
8CG-A
RZ13E-24S
SS11E-24
WH12E-22S
see EA-9B235.16 MKR-AUDIO
see EA-9B235.16 MKR-AUDIO
see EA-9B344.15 TRAFFIC ADVISORY
C D B A E H F G K J
LOOP ANTENNA S72-1715-1
2
X2 ST10-A
BODENSTECKER
16
VV136
CG34G-22
3 26.57.73 M210-B4N GA53H-22 see EA-9B323.10 GEAR CONTROL GA53H-22
3
1
X1
21GA
29CG-D
CG34E-22
CG34H-22
5
STECKER AVIONIC BAY ST 6
see EA-9B344.15 TRAFFIC ADVISORY
P1
X1
1
3
M320A1N
36CG X2
CG16F-222
EA-9B284.13B PCB-BOARD 1
15
7
D3
D4
PCB-BOARD 1 EA-9B411.50A
GND
4
Maintenance Manual EXTRA 500 Chapter 91 30. March 2012
22 23 2 78
20 18 19
RS232 TX1 RS232 RX1 RS232 COMMON
BOTTOM MOUNTED ANTENNA CONFIG TOP MOUNTED ANTENNA CONFIG POWER SWITCH AIRCRAFT GND
41
12 13
RS232 RX3 RS232 COMMON
AUDIO SUPPRESION OUTPUT
75 77
AUDIO OUT MONO AUDIO OUT GROUND
40
54
MIC INHIBIT INPUT
AUDIO SUPPRESION INPUT
59
TWX-670
28 VDC
WEATHER DETECTION
SS1E-20
PP3
D
2A
LOAD BUS
CIRCUIT BREAKER/SWITCH PANEL
3
ws bl
2
bl ws
1
SS18E-RG178
CG34FG-22
Projektion Freimaßtoleranz Oberfläche
Blatt 1
von 1
8
Schutzvermerk nach DIN 34 beachten.
A3
EA-9B344.14
WEATHER DETEC TWX-670, SS
EA 400-500
Maßstab auf SI.-Klasse Oberflächenschutz
see EA-9B342.66 IFD RIGHT
see EA-9B342.65 IFD LEFT
see EA-9B344.15 TRAFFIC ADVISORY
see EA-9B235.16 MKR-AUDIO
see EA-9B315.80 ANNUNCIATOR PANEL
see EA-9B334.90 DIMMING
see EA-9B275.20 FLAP SYSTEM
8
D
C
B
A
D
C
B
A
TOP ANTENNA
3 5 2
11 15
GEAR POSITION NO RYAN DISPLAY
232 TX1 232 RTN 232 RX1
14
COM 1
7
WEIGHT ON WEELS
COUPLER
SUPPRESSION
BNC
P2
TNC
P4
9 S (61-2006)
COM 1
15 S
J1
25 S
ws
#22 #22
ws bl
ws bl org
ws bl
ws bl org
ws bl
SD10E-24S
SD3E-20
SD9E-24S
SD12E-22N
SD6E-24S
SS13F-24S
SS11E-24
SD-P4E-RG400
SD-P2E-RG400
SD14E-22
SD13E-22
1
SD-C1E-G400
1
1
SD11E-22
SD8E-24S
SS15F-24S
SIM
ST10-a
3
3
6SD-a
5SD-a
6SD-A
TNC
SIM
SIM
11 12 13
SD-C1E-RG400
ws bl
ST13-B
SD4F-20N
ST13-C
SD14H-22
SD14G-22
Zustand Flugzeug am Boden
ws bl
SIM
7
4
SD12F-22N
ST14-B
DRUCKSCHOTT HINTEN
SD4E-20N
5VN-A
TAS
6GA
SD-P4F-RG400
SD-P2F-RG400
TNC
P4
TNC
P2
TAS TWIN-BLADE 3SD
TAS TOP ANTENNA S72-1750-32L
see EA-9B323.10 GEAR CONTROL
N
1
BOTTOM ANTENNA
2
TNC
P3
TNC
P1
TNC
SD-P3E-RG400
SD-P1E-RG400
3
3
zur Avionic-Bay
3
TNC
SD-P3E-RG400
SD-P1E-RG400
TNC
P3
TNC
P1
4
4SD
TAS SINGLE BLADE
TAS BOTTOM ANTENNA S72-1750-31L
5
SD9E-24S
5SD
5
ANT
XPDR
TCAD
XPDR COUPLER 70-2040
ws bl
P1 8
bl
ws
BNC
BNC
BNC
BNC
BODENSTECKER 6SH-B 6SH-C 6SH-A
BNC
DISCRETE OUT 7
RS422-232 RX2 TX2-RX2 COMMON RS422-232 TX2 SHIELD GROUND
ARINC 429 TX4+ ARINC 429 TX4-
ALT WRN IN
SUPPRESSION GND
BNC
3SH-A
ANTENNA
SUPPRESSION
TRANSPONDER
25 19
2SH
BXP-6402-1R
3SN
KDM-706A
1RM
PMA-8000B
3FG
IFD-5000i 700-00083-()
3SH
8
see EA-9B345.58 ATC
see EA-9B345.47 DME
OPTION
see EA-9B235.16 MKR-AUDIO
see EA-9B342.65 IFD LEFT
see EA-9B344.14 WETHER DETEC
OPTION
see EA-9B342.66 IFD RIGHT
see EA-9B345.57 ATC
TRANSPONDER ANTENNA KA-60
DME TRANSCEIVER
31
AUDIO/MARKER
24 46 66 5
15 36
2SS
TWX-670
7FG
IFD-5000i 700-00083-()
AUDIO SUPPRESION INPUT
IFD LEFT
40
SH26E-RG400
TNC
5
P3301 2SH-A
bl
DISCRETE OUT 8
RS422-232 RX2 TX2-RX2 COMMON RS422-232 TX2 SHIELD GROUND
ARINC 429 TX4+ ARINC 429 TX4-
WEATHER DETECTION
24 46 66 5
15 36
IFD RIGHT
7
EDV-Kennung:
9B34415T
04 03 02 01 Ver. Bezeichnung
6
21.02.11
Nr.: Änderung/Mod. Nr.: Datum
Letzte Bearbeitung:
Datum
HW
Name
Schwarze Heide 21
Gepr.:
Gepr.:
Bearb.: 12.09.10
7
Name 46569 Hünxe, Germany
HW
OVERBRAID 36 AWG Tinned copper per ASTM-B-33 optical coverage minimal 98 - 100%
aus EMI Kit P/N 62-2003
All antenna cables must be of the same lenght. ( +- 25 mm)
Projektion Freimaßtoleranz Oberfläche
Blatt 1
von 1
8
Schutzvermerk nach DIN 34 beachten.
A3
EA-9B344.15
TRAFFIC SYSTEM TAS-610, SD
EA 400-500
Maßstab auf SI.-Klasse Oberflächenschutz
Applying power to the TAS-610 transceiver without an antenna connected to the BNC connector may damage the TAS-610 transceiver.
SD-C3E-RG393
BNC
Die Gültigkeitszuordnung von Version zu Flugzeugbaureihe ist der Bauakte bzw. dem jeweiligen Fertigungsauftrag zu entnehmen. Zuordnung links / rechts wird mit */* in allen Feldern angegeben.
1
2
3
!
N
5SD-C
N
SD10H-24S
ws
P3401
18
D1 P7061 MUR120
WH12E-22S
ws bl org
DRUCKSCHOTT HINTEN 5SH-C 5SH-B 2SH-B 5SH-A SD-C2E-RG400 RG400
P1
SD13E-22
19
P1121
P1
P1122
ws bl
SS13F-24S
SD6E-24S
ws bl
1
SS10E-24
*
P2122
SS13E-24S
BYW-56
D1
1
ws bl org
ws bl
SS15F-24S
SD8E-24S
ws P2121 bl
SS15E-24S
6
SD11E-22
EA-9B284.13 PCB-BOARD 1
5SD-B
9
R6 330 R5 330 R7 330
PCB-BOARD 1
see EA-9B344.14 WEATHER DETECTION TWX-670
SS11E-24
see EA-9B344.14 WEATHER DETECTION TWX-670
19VN-E 001758_212_02
5SD-A
Schalter am Boden entlastet, im Flug belastet.
SD16E-22N SD15E-22N
8GA
D SD10F-24S
see EA-9B246.10 DC-DISTRIBUTION
SD1E-20
SD12E-22N
3
SD10E-24S
A:1
SD14F-22
SD10-A
5SD-A
13
SD4E-20N
BODENSTECKER
2
SPULE
L2
SD1F-20
1SD
Maintenance Manual EXTRA 500 Chapter 91 30. March 2012
2SD
3 4
AUDIO AUDIO GND
J1
16
TCAD ON
15 14
23 24 25
232 TX4 232 RTN 232 RX4
GND GND
17 18 19
232 TX2 232 RTN 232 RX2
8 9
10 11
A B
6
5
20 21 22
12 13
429 RX1 A 429 RX1 B
429 TX 429 TX
SWITCH ANNUNCIATOR GND
REMOTE MUTE
232 TX3 232 RTN 232 RX3
429 RX2 A 429 RX2 B
L1
F G
SPULE
A B
SD2E-20
ge
#22 #22
org
1 2
bl
28 VDC 28 VDC
3A
ws
2
rt
P1
LEFT GEAR
J1
AVIONICS BUS PP5
ge
70-2420-x TAS-610
org
TRAFFIC ADVISORY SYSTEM
4
rt
bl
CIRCUIT BREAKER/SWITCH PANEL
sw
3
ws
2
bl
SD10F-24S
1
UT
RIGHT GEAR
SD12F-22N sw
SD10GF-24S ws bl
D
C
B
A
A
B
C
D
55
14
15
16
17
18
2 3 24
4
25
45
5 6 26
MUTE INPUT
MUTE INPUT
VOLUME UP
VOLUME DOWN
TUNE UP
TUNE DOWN
SIGNAL 232 TX1 SIGNAL 232 RX1 SIGNAL 232 GND
SIGNAL 232 RTS
SIGNAL 232 GND
SIGNAL 232 CTS
SIGNAL 232 TX2 SIGNAL 232 RX2 SIGNAL 232 GND
J4
J3
51
54
STANDBY
27
53
AUDIO SUPPRESSION
SIGNAL 232 RX
43 44
RS 422 COM1 Rx+ RS 422 COM1 Rx-
SIGNAL 232 GND
22 23
RS 422 COM1 Tx+ RS 422 COM1 Tx-
50
21
SIGNAL 232 TX
42
AUDIO GND
AUDIO OUT RIGHT
P1
P4
P3
J1
ws org bl
ws org bl
#22 #22 #22 #22 #22 #22
2
1
TL11E-RG400
TL10E-24S
TL9E-24S
3SN-A
TL2E-20N
TL2E-20N
S67-1575-650
SIRIUS SATELLITE ANTENNA
DRUCKSCHOTT HINTEN
TL1F-20
2A
3
B:3
3
PP3
001758_212_02
19VN-E
ST13-C
SIM
1
REMOTE ANTENNA
SIRIUS ANTENNA
J2
J1
TNC
2
3
TNC
4
3TL
200-00176-000
5
5
001758_212_02
1VN-E
see EA-9B246.10 DC-DISTRIBUTION
SIRIUS
1TL
TL13E-20N
LOAD BUS
CIRCUIT BREAKER/SWITCH PANEL
4
TL1F-20
3
Maintenance Manual EXTRA 500 Chapter 91 30. March 2012
2TL
20
AUDIO OUT LEFT
P1
10 11 32 12 13 33 1
D.C. POWER INPUT D.C. POWER INPUT D.C. POWER INPUT BATTERY GROUND BATTERY GROUND BATTERY GROUND CHASSIS GND.
BROADCAST DATA LINK RECEIVER MLB-700 700-00159-xxx
1
TL1E-20 TL2F-20N
EDV-Kennung:
04 03 02 01 Ver. Bezeichnung
9B34416T 6
Zuordnung links / rechts wird mit */* in allen Feldern angegeben.
1
1
ws org bl
P2121
ws org bl
P1121
89 88 87
89 88 87
Nr.: Änderung/Mod. Nr.: Datum
Name
Datum
27.09.10
7
46569 Hünxe, Germany
HW
Name
Schwarze Heide 21
Gepr.:
Gepr.:
Bearb.:
7FG
IFD-5000i 700-00083-()
Projektion Freimaßtoleranz Oberfläche
8
Blatt 1
von 1
8
Schutzvermerk nach DIN 34 beachten.
A3
EA-9B344.16
BROADCAST MLB-700, TL
EA 400-500
Maßstab auf SI.-Klasse Oberflächenschutz
see EA-9B342.66 IFD RIGHT
optical coverage minimal 98 - 100% Letzte Bearbeitung:
3FG
IFD-5000i 700-00083-()
see EA-9B342.65 IFD LEFT
RS232 RX0 RS232 TX0 TX0-RX0 COMMON
IFD RIGHT
RS232 RX0 RS232 TX0 TX0-RX0 COMMON
IFD LEFT
7
36 AWG Tinned copper per ASTM-B-33
TL10E-24S
TL9E-24S
OVERBRAID
Die Gültigkeitszuordnung von Version zu Flugzeugbaureihe ist der Bauakte bzw. dem jeweiligen Fertigungsauftrag zu entnehmen.
1
6
A
B
C
D
A
B
C
D
2TS
43 44
54
COM1 RS-422 Rx+ COM1 RS-422 Rx-
STANDBY
SAT ANTENNA
USB
ETH
22 23
COM1 RS-422 Tx+ COM1 RS-422 Tx-
J1
J3
J2
P1
5 26 6
SIGNAL RS-232 TX2 SIGNAL RS-232 GND SIGNAL RS-232 RX2
51
DIAGNOSTIC RS-232 RX
2 24 3
27
SIGNAL RS-232 TX1 SIGNAL RS-232 GND SIGNAL RS-232 RX1
50
DIAGNOSTIC RS-232 TX
DIAGNOSTIC RS-232 GND
10 11 32 12 13 33
MLX-770
D.C. INPUT POWER D.C. INPUT POWER D.C. INPUT POWER AIRCRAFT GROUND AIRCRAFT GROUND AIRCRAFT GROUND
DATALINK 2-WAY
2
P1-A
J3-A
TS5E-RG400
TS4E-24S
ws bl org
J2-A
TS3E-24S
1
TS1G-20 TS2E-20N
ws bl org
#22 #22 #22 #22 #22 #22
J1-A
3
3TS-A
TS4E-24S
TS3E-24S
1
7 17
ws bl 6 org 8
2 16
ws bl 1 org 3
ST13-A
1 2
SAT ANTENNA
TS1G-20 TS2E-20N
ST13-C
1
3TS
TS4F-24S
TS3F-24S
TS1F-20 TS2F-20N
S67-1575-109
ws bl org
ws bl org
SIM
SIM
DRUCKSCHOTT HINTEN
4
1
2
3
4
5
5
TS1F-20 TS2F-20N
2A
6
OVERBRAID
EDV-Kennung:
04 03 02 01 Ver. Bezeichnung
9B34417T 6
Zuordnung links / rechts wird mit */* in allen Feldern angegeben.
Die Gültigkeitszuordnung von Version zu Flugzeugbaureihe ist der Bauakte bzw. dem jeweiligen Fertigungsauftrag zu entnehmen.
1
!
TS4F-24S
TS3F-24S
1
1
65
65
ws bl 23 org 67
P2121
ws bl 23 org 67
P1121
RS232 RX2 TX0-RX0 COMMON RS232 TX2
IFD-RIHT
RS232 RX2 TX0-RX0 COMMON RS232 TX2
IFD-LEFT
7
see EA-9B342.66 IFD RIGHT
7FG
IFD-5000i 700-00083-()
see EA-9B342.65 IFD LEFT
3FG
IFD-5000i 700-00083-()
8
Nr.: Änderung/Mod. Nr.: Datum
Letzte Bearbeitung:
Name
Datum
12.09.10
HW
Name
7
46569 Hünxe, Germany
Schwarze Heide 21
Gepr.:
Gepr.:
Bearb.:
optical coverage minimal 98 - 100%
36 AWG Tinned copper per ASTM-B-33
Projektion Freimaßtoleranz Oberfläche
Blatt 1
von 1
8
Schutzvermerk nach DIN 34 beachten.
A3
EA-9B344.17
DATALINK 2-WAY MLX-770, TS
EA 400-500
Maßstab auf SI.-Klasse Oberflächenschutz
Applying power to the MLX770 transceiver without an antenna connected to the SMA connector may damage the MLX770 transceiver.
see EA-9B246.10 DC-DISTRIBUTION
001758_212_02 19VN-E
D
B:2
3
PP3
IRIDIUM
1TS
LOAD BUS
CIRCUIT BREAKER/SWITCH PANEL
Maintenance Manual EXTRA 500 Chapter 91 30. March 2012
1
TS1E-20
A
B
C
D
D
C
B
A
5
2SN
KDM706A
8
1 14
CLOCK BUS
A/C GROUND A/C GROUND
2SN-C
2SN-A
ws bl
R U
SN10F-24S
SN23E-RG400
9 10
4 5
SN2E-22
2
6
8
blau
grün
VV60
4 5
DME HOLD
7 9
DME HOLD
D C B A 1 2 3 5
8
4
6
7
9
3SN
5SN
VV59
D3
C3
B3
A3
D1
D2
C1
C2
B1
B2
A1
DME HOLD Displ.
Normal
1
OVERBRAID
2
optical coverage minimal 98 - 100%
3
D
4
5
EDV-Kennung:
9B34547T
04 03 02 01 Ver. Bezeichnung
Die Gültigkeitszuordnung von Version zu Flugzeugbaureihe ist der Bauakte bzw. dem jeweiligen Fertigungsauftrag zu entnehmen. Zuordnung links / rechts wird mit */* in allen Feldern angegeben.
001758 212 02 1VN-C
bl
ws bl
1RM-A
ws
P1
21 22
7 14 15
SN11E-24S
SN7E-22 SN8E-22
SN5E-22 SN6E-24
6
1
P2122
7
DME INDICATOR
34 33 32 31 20 17 16 6 5
Nr.: Änderung/Mod. Nr.: Datum
Datum
Bearb.: 01.09.10 Gepr.:
HW
Name
Schwarze Heide 21
Gepr.:
7
7FG
Projektion Freimaßtoleranz Oberfläche
8
Blatt 1
von 1
8
Schutzvermerk nach DIN 34 beachten.
A3
EA-9B345.47
DME KDM 706A, SN
EA 400-500
Maßstab auf SI.-Klasse Oberflächenschutz
see EA-9B342.66 IFD RIGHT
14 13 12 11 9 6 5 4 3
4SN
KDI 574
IFD-5000i
Name 46569 Hünxe, Germany
HW
DISCRETE DISCRETE DISCRETE DISCRETE DISCRETE DISCRETE DISCRETE DISCRETE DISCRETE
OUT OUT OUT OUT OUT OUT OUT OUT OUT
1 MA 1 ME 1 MC 1 MD .1 MA .1 ME .1 MC .1 MD .01 MC NAV 1 COMMON
IFD RIGHT
35 39 38 20 37 41 42 43 44 48
NAV 1 COMMON 10MA
NAV 1 CODE SELECT 2 X 5 CODE PROGRAMM 47 30
N1 50 7
CLOCK BUS
DME REQUEST
NC(KEY)
DATA BUS
10
12
15
5
11
GROUND HOLD ON +9,25V +192V
1RM
PMA 8000B
see EA-9B235.17 MKR/AUDIO
DME AUDIO HI DME AUDIO LO
AUDIO & MARKER
40 2 19 3 1
2SD see EA-9B344.15 TRAFFIC SYSTEM TAS-610
SUPPRESSION GND GND
TRAFFIC ADVISORY SYSTEM 70-2420-x TAS-610
16.02.11
4SN-A
Letzte Bearbeitung:
SN22E-24 SN21E-24 SN20E-24 SN19E-24 SN18E-24 SN17E-24 SN16E-24 SN15E-24 SN14E-24 SN13E-24
SN13E-24 SN14E-24 SN15E-24 SN16E-24 SN17E-24 SN18E-24 SN19E-24 SN20E-24 SN21E-24 SN22E-24
SN12E-24
1
Gehäuse 11D-50-000-G-VL P7041
RM12E-24S
SD10E-24S
SN10E-24S
SN23E-24N
see EA-9B246.10 DC-DISTRIBUTION
2A
DME
PP3
6
SN10E-24S
A2
SN1E-22
2
1SN
LOAD BUS
CIRCUIT BREAKER/SWITCH PANEL
5
SN9E-24S
Anschlußschema
VV58
D:2
D:1
SN12E-24
SN2F-22
SN1F-22
4
SN9E-24S
SN11E-24S
DME ANTENNA KA 60
SIM
SN7E-22 SN8E-22
SN5E-22 SN6E-24
3SN-A
FG1-73-22 FG101E-22
001758_212_02 19VN-A
see EA-9B334.90 DIMMING VV334901 Pin F 15 Test 5LH-A Pin 21 35
SN3E-22N SN4E-22N
SN9F-24S
7 8
5 6
ST13-B
SN7F-22 SN8F-22
3 4
ST13-D
14 15 20
SIM
RM12E-24S
ws bl
ws bl
SD10E-24S
SN7E-22 SN8E-22
RM12F-24S
SD10F-24S
ws bl
11 12 13
SIM
SN2F-22
ws bl
2
1
SN1F-22
SIM
ST13-B
SN2G-22
SN1G-22
ST13-D
DRUCKSCHOTT HINTEN
SN5F-22 SN6F-24
SN11F-24S
ws bl
SN5E-22 SN6E-24
RM12F-24S
D1 SN24E-24 ws bl MUR120
SN2G-22
SN1G-22
P7061
SD10H-24S
36 AWG Tinned copper per ASTM-B-33
DME ANTENNE
24
DME REQ IN
9
DATA BUS
18
22 4
+9,25 VDC +192 VDC
20
16 12
GND HOLD
ON
21 17
AUDIO HI AUDIO LO
GND
25 19
3
A/C 28 VDC POWER
SUPPRESSION GND
2
A/C 28 VDC POWER
DME TRANSCEIVER
ws bl
2SH-A
3
Maintenance Manual EXTRA 500 Chapter 91 30. March 2012
1
SUPPRESSION
see EA-9B345.58 TRANSPONDER BXP-6402R
2SN
TRANSPONDER BXP-6402-1R-()
2
ws bl
SD10G-24S
1
SD10F-24S
D
C
B
A
D
C
B
A
2SH
25 19
see EA-9B345.47 DME
7
REPLAY OUT
3 21
GND GND
CHASSIS STUD
ANTENNA
1
PSEL
J7
ws bl ws bl
#16
TNC
2SH-B
15 14 18 17
P8
ws bl ws bl
VV63
1
bl
SD10H-24S
1
SD10F-24S
BNC
AIRFRAME GROUND
BNC
BNC
5SH-C
BNC
2
SH26F-RG393
4
BNC
5SD-B
ST13-A
ws bl ws bl
SIM
ws bl ws bl
SIM
ws bl ws bl
1
N
5SD-A
N
5SD-C
SH8E-24S
1
2
3
1
2
OVERBRAID
optical coverage minimal 98 - 100% 4
SH4E-24S
SH3E-24S
1
SD10E-24S
ws bl ws bl
P2121
ws bl
2
5
BNC
85 86 4 25 67
BNC
6SH-B
RS422 TX3+ RS422 TX3RS422 RX3+ RS422 RX3SCHIELD
EDV-Kennung:
9B34558T
04 03 02 01 Ver. Bezeichnung
6
Zuordnung links / rechts wird mit */* in allen Feldern angegeben.
3FG
IFD-5000i 700-00083-()
XPDR ANTENNA
Nr.: Änderung/Mod. Nr.: Datum
21.02.11
Name
HW
Datum
12.09.10
OPTION
OPTION
Schwarze Heide 21
Gepr.:
Gepr.:
Bearb.:
7
7
Name 46569 Hünxe, Germany
HW
see EA-9B344.15 TAS
2SD
70-2420-x TAS-610
4SH
KA-60
see EA-9B342.65 IFD LEFT
Letzte Bearbeitung:
COUPLER
7FG
IFD-5000i 700-00083-()
see EA-9B342.66 IFD RIGHT
TRAFFIC ADVISORY SYSTEM
SH26E-RG400
3SH-A
RS422 TX3+ RS422 TX3RS422 RX3+ RS422 RX3SCHIELD
IFD LEFT
2SD see EA-9B344.15 TRAFFIC SYSTEM TAS-610
SUPPRESSION GND GND
IFD RIGHT
COUPLER
BNC
6SH-C
ATC
1SH
see EA-9B246.10 DC-DISTRIBUTION
3A
EMERGENCY BUS PP4
TRAFFIC ADVISORY SYSTEM 70-2420-x TAS-610
SH1E-18
Die Gültigkeitszuordnung von Version zu Flugzeugbaureihe ist der Bauakte bzw. dem jeweiligen Fertigungsauftrag zu entnehmen.
BNC
6SH-A
SD-C1E-G400
SH26F-RG393
ws bl ws bl
P1121
85 86 4 25 67
7 14 15
BODENSTECKER 6SH-A
SH8E-24S*
SH7E-24S
1
P1
6
CIRCUIT BREAKER/SWITCH PANEL
C:4 3
CB Trennstecker
SH1F-18
see EA-9B323.10 GEAR CONTROL
5
SD-C3E-RG393
36 AWG Tinned copper per ASTM-B-33
Coupler only installed when Option TAS is used.
7
SH4E-24S
SH3E-24S
SH7E-24S
see EA-9B344.15 TAS
2
ohne Option TAS
5SD
TCAD
XPDR
ANT
1
SD10E-24S
SH5E-24
TCAD COUPLER 70-2040
20 11 12 13 14 15
8 3
ST14-B
ws bl ws bl
18 4 5 9 10 19
ST13-A SIM
bl
11 12 13
ws bl
SH1F-18
SIM
SIM
8
ST13-B
SH1G-18
ST13-C
DRUCKSCHOTT HINTEN
SH5F-24
SD-C2E-RG400
19VN 001758 212 02
DRUCKSCHOTT HINTEN 5SH-B 5SH-C
5SH-A
AM 6400-1-(01)
SH10E-20N
SH9E-20N
SH8F-24S
1
SH8F-24S
E F
SH4F-24S
SH3F-24S
19VN 001758 212 02
ws bl
SH7F-24S
ws bl
SH7F-24S
SH11E-20N SH12E-20N
SH4F-24S
SH25E-RG400
3SH
1
SH5F-24
ws
3
SD10G-24S
SH3F-24S
ws bl
SH1G-18
MUR120
P7061 D1
J9 2SH-A
RX+ RXTX+ TX-
TIS TIS TIS TIS
12 13
ALT S ALT S +
RS422 RS422 RS422 RS422
11
24
25 13
GROUND SWITCH
GROUND GROUND ON
9 21 22
8
5
SUPPRESSION
RX+ RXTX+ TX-
17 18 19 20 4
C1 C2 C4 D4 EXT. IDENT
RS422 RS422 RS422 RS422
1 2 3 14 15 16
6
SWITCHED POWER OUTPUT
A1 A2 A4 B1 B2 B4
11 12
POWER IN POWER IN
BXP-6402-1R-()
TRANSPONDER
3SN
SUPPRESSION GND
DME TRANSCEIVER KDM-706A
2
Maintenance Manual EXTRA 500 Chapter 91 30. March 2012
1
SD10G-24S ws bl
Projektion Freimaßtoleranz Oberfläche
Blatt 1
von 1
8
Schutzvermerk nach DIN 34 beachten.
A3
EA-9B345.58
ATC BXP6402-1R, SH
EA 400-500
Maßstab auf SI.-Klasse Oberflächenschutz
8
D
C
B
A
#20
A
B
C
2
ON
Instrument Panel leftside
28VDC N/C Positiv Input Negativ Input Light Light GND
1 2 3 5 4 6 7 8 9
9HI-A
ws bl
see EA-9B246.10 DC-DISTRIBUTION
HI4E-22
HI2E-12
3
HI4F-22
HI2F-12
CB Trennstecker
A:2
C:2
HI5E-22N
QX3E-22
HI9E-22S
HI8E-22 HI7E-22
HI4F-22
1
2
4
1
2
3
4
5
8 9
8HI
2A
7HI
EA-9B243.42
5
EDV-Kennung:
04 03 02 01 Ver. Bezeichnung
9B36011T 6
Zuordnung links / rechts wird mit */* in allen Feldern angegeben.
Die Gültigkeitszuordnung von Version zu Flugzeugbaureihe ist der Bauakte bzw. dem jeweiligen Fertigungsauftrag zu entnehmen.
HI6E-12N
B
5HI
Name
Kohleschleifer Halterung
Nr.: Änderung/Mod. Nr.: Datum
Letzte Bearbeitung:
Blech am External Power Stecker
HI3F-12
TRENNSTECKER FIREWALL
6
TRIEBWERKSTRAEGER LINKS
see EA-9B334.90 DIMMING SYSTEM see EA-9B284.10 FUEL QUANTITY
2A
HI3E-12
50mV 30A
SHUNT
4HI
6HI
HI2F-12
Achtung: Polarität beachten !
Maintenance Manual EXTRA 500 Chapter 91 30. March 2012
9HI
3
1 OFF
FUSE 1 RUE30V
3HI
07.1.1.13
2HI
PROP
PROP-HT
20A
ELECTRONIC AMMETER N15 1120 030P 01W
1HI
HI1E-12
BATTERY BUS PP2
CIRCUIT BREAKER/SWITCH PANEL
2
HI8E-22 HI7E-22
D
1
- +
Name
HW
Datum
PROP DE-ICER
04.10.10
A
7
46569 Hünxe, Germany
Schwarze Heide 21
Gepr.:
Gepr.:
Bearb.:
7
Projektion Freimaßtoleranz Oberfläche
Blatt 1
von 1
8
Schutzvermerk nach DIN 34 beachten.
A3
EA-9B360.11
PROP HEAT UMA, HI
EA 400-500
Maßstab auf SI.-Klasse Oberflächenschutz
8
A
B
C
D
A
B
C
D
8VN-A 001758 212 02
D
MC2E-22N
2
DC-1
2
Art.Nr. 01738
1
6WW2 3
DOOR
MC1E-22
3
107
5WW-D 45
D15
1
2
3
4
5
5
see EA-9B315.80 ANNUNCIATOR PANEL
+ VOLT DIMM
LIGHT TEST (GND)
ANNUNCIATOR BOARD 5WW
4
Maintenance Manual EXTRA 500 Chapter 91 30. March 2012
1
13 24 25 WW1-20
WW14-22
EDV-Kennung:
9B52710T
04 03 02 01 Ver. Bezeichnung
6
7
Flaps
Nr.: Änderung/Mod. Nr.: Datum
Name
HW
Datum
Bleed Overt
Windsh-Heat
Stall-Heat
PB
Name
7
46569 Hünxe, Germany
Schwarze Heide 21
Gepr.:
Gepr.:
Bearb.: 11.02.04
Cab-Press
Stall-Warn
Aft Door
01.09.10
Gear Warn
Gen-Fail
Annunciator Panel left
Letzte Bearbeitung:
1WW
Die Gültigkeitszuordnung von Version zu Flugzeugbaureihe ist der Bauakte bzw. dem jeweiligen Fertigungsauftrag zu entnehmen. Zuordnung links / rechts wird mit */* in allen Feldern angegeben.
5WW-B
P/N 90-4219X-1 geändert
Annunciator Panel left
6
Projektion Freimaßtoleranz Oberfläche
Blatt 1
von 1
8
Schutzvermerk nach DIN 34 beachten.
A3
EA-9B527.10
DOOR WARNING, WW
EA 400-500
Maßstab auf SI.-Klasse Oberflächenschutz
8
A
B
C
D
A
B
C
D
Fuel Low L
Fuel Filter
3
1
Fuel Low R
Pneumatic
Prop Low Pitch
Low Voltage
Standby Alt On
7.5A
A:1
2
4
QB4F-20
WW37-22
5WW-C
3
1 ON
OFF
QB5E-20
3
1 ON
OFF
QB2E-20
+ VOLT DIMM
LIGHT TEST (GND)
see EA-9B315.80 ANNUNCIATOR PANEL
ANNUNCIATOR BOARD EA-9B315.81
17 24 25
5WW
D20
ANNUNCIATOR BOARD
Instrument-Panel left
07.1.1.13
3QB 2
FUEL PUMP 2
07.1.1.13
4QB 2
FUEL PUMP 1
see EA-9B246.10 DC-DISTRIBUTION
QB1F-20
7.5A
FUEL-P-1
EMERGENCY BUS PP4
FUEL-P-2 1QB
CB Trennstecker A:7
2QB
QB1E-20
BATTERY BUS PP2
CIRCUIT BREAKER/SWITCH PANEL
Fuel Trans L Fuel Trans R
2
QB4E-20
1
2
3
4
Maintenance Manual EXTRA 500 Chapter 91 30. March 2012
2WW
P/N 90-42192-2 geändert
Annunciator Panel right
1
16
5
5WW-D
5
QW1F-22
P
EDV-Kennung:
9B73110T 6
Zuordnung links / rechts wird mit */* in allen Feldern angegeben.
04 03 02 01 Ver. Bezeichnung
31 32
E
g
HW
Name
01.09.10
ÄM-400-09-01
QW1E-22 QW2E-22N
6QB
7QB
Name
PB
Datum
A Blatt 1
von 1
8
Schutzvermerk nach DIN 34 beachten.
A3
EA-9B731.10
FUEL PUMP / FILTER, QB
EA 400-500
Projektion Freimaßtoleranz Oberfläche
FUEL PUMP 2
Maßstab auf SI.-Klasse Oberflächenschutz
Engine Compartment
8
FUEL PUMP 1 Fa. Parker
5QB
PN 1743640-06
46569 Hünxe, Germany
7
P
2.15 PSID
02.09.04
A B C
FUEL FILTER
Schwarze Heide 21
Gepr.:
Gepr.:
Bearb.:
7QB-A
NEG
POS
NEG
POS
Anschluss mir Ringöse MXX
QB2F-20
QB5F-20 QB6E-20N
7
2VN-D 001758 212 02
N M
Nr.: Änderung/Mod. Nr.: Datum
A
Letzte Bearbeitung:
ST4
QB2F-20
QB5F-20
FIREWALL ST2
MS38999III (13-35)
QW1F-22 QW2F-22N
Die Gültigkeitszuordnung von Version zu Flugzeugbaureihe ist der Bauakte bzw. dem jeweiligen Fertigungsauftrag zu entnehmen.
001758 212 02 2VN-D
1
QB2E-20
QB5E-20
6
QB6E-20N QB3E-20N
A
B
C
D
A
B
C
D
2WW
3
Pneumatic
Fuel Low R
Fuel Low L
Prop Low Pitch
Low Voltage
Fuel Trans R Standby Alt On
ON
1 OFF
07.1.1.13
4QF 2
Fuel Filter
Fuel Trans L
QF1F-22
FUEL TRANSFER 2
ON
1
QF5E-22 QF2E-22
WW20-20
WW35-22 WW38-22
5WW-C
QF4E-22
QF1E-22
5A
FUEL-TR-R
24 25
15 18
LIGHT TEST (GND)
ANNUNCIATOR BOARD EA-9B315.81 see EA-9B315.80 ANNUNCIATOR PANEL
+ VOLT DIMM
D19
ANNUNCIATOR BOARD D22 5WW
see EA-9B246.10 DC-DISTRIBUTION
2QF
18 15
5WW-D 48 47
Maintenance Manual EXTRA 500 Chapter 91 30. March 2012
geändert
P/N 90-42192-2
Annunciator Panel right
3
1 OFF
07.1.1.13
3QF 2
B:14
B:1
1
CB Trennstecker
FUEL TRANSFER 1
QF4F-22
QF1F-22
5A
FUEL-TR-L
LOAD BUS PP3
QF5F-22 QF2F-22 QF6F-22N QF3F-22N
KOPF
6 7
30CG-C
EDV-Kennung:
9B73130T
7.21440.68.0
Ringösen 5mm
right
QF8E-22N
right
2x Type P110
8QF 3
PCI
ÄM-400-09-01
14.10.10
1
2
Name
HW
PB
Gepr.:
Name
46569 Hünxe, Germany
Schwarze Heide 21
Gepr.:
T S
A Blatt 1
Schutzvermerk nach DIN 34 beachten.
A3
EA-9B731.30
FUEL TRANS, QF
von 1
Projektion Freimaßtoleranz Oberfläche
EA 400-500
Maßstab auf SI.-Klasse Oberflächenschutz
001758 212 02 20VN-A
Datum
QF7E-22N
left
Bearb.: 07.09.04
3
7QF
FUEL PRESSURE SWITCH MOTIVE FLOW
1
2
FUEL PRESSURE SWITCH MOTIVE FLOW
left
WING CENTER COMPARTEMENT (front)
Einbau im Avionic-Bay, left and right
6QF
Letzte Bearbeitung:
A
Ringösen 5mm
MOTIVE FLOW FUEL PUMP
5QF
MOTIVE FLOW FUEL PUMP
Nr.: Änderung/Mod. Nr.: Datum
QF9E-22 QF10E-22
Die Gültigkeitszuordnung von Version zu Flugzeugbaureihe ist der Bauakte bzw. dem jeweiligen Fertigungsauftrag zu entnehmen. Zuordnung links / rechts wird mit */* in allen Feldern angegeben. 04 03 02 01 Ver. Bezeichnung
QF9F-22 QF10F-22
ST 7
STECKER AVIONIC BAY
Copilot overhead
001758 212 02 8VN-A
B C
C D E F
MS 347X-L22-41SN (27 X #20 / 14X#16)
QF5E-22 QF2E-22 QF6E-22N QF3E-22N
ST5
STECKER OVERHEAD
+ +
1QF
-
CIRCUIT BREAKER/SWITCH PANEL
-
A
B
C
D
A
B
C
D
see EA-9B342.66 IFD RIGHT
700-00083-()
IFD-5000i
IFD RIGHT
RS232 RX1 RS232 COMMON RS232 TX1
RS232 RX1 RS232 COMMON RS232 TX1
28VDC POWER Instrument GND NC Flow Transducer Power Transducer GND Flow Transducer Signal NC RS-232 In RS-232 Out
see EA-9B342.65 IFD LEFT
700-00083-()
IFD-5000i
IFD LEFT
2QY
912041T-D
SHADIN MINIFLOW L
2
91 96 44
ws bl or
ws bl
P2121
ws bl
ws bl ws bl
1
1
QY1F-22 QY2E-22N
P1121
D-SUB 9
91 96 44
1 2 4 3 5 7 8 9 6
2QY-A
1
QY4E-24S
QY4F-24S
QY5E-22N
QY3E-22S
QY4F-24S
QY4E-24S
3
LM
001758 212 02 1VN-G
4
QY3E-22S
ws bl or
C:12
J4 55 56 57 48
1
912041T-D = GPS & Gal 912047T-D = GPS & Lit
2
3
4
1
5
5
red blk wht
QY1E-22
6
EDV-Kennung:
9B73110T
04 03 02 01 Ver. Bezeichnung
6
HW
Name
12.09.10
ÄM-400-09-01
PB
Name
7
46569 Hünxe, Germany
Schwarze Heide 21
Gepr.:
Gepr.:
Bearb.: 06.09.04
Datum
optical coverage minimal 98 - 100%
Nr.: Änderung/Mod. Nr.: Datum
A
7
36 AWG Tinned copper per ASTM-B-33
Letzte Bearbeitung:
OVERBRAID
Shadin P/N 66050X
3QY
TRANSDUSER
see EA-9B246.10 DC-DISTRIBUTION
BATTERY BUS PP2
Die Gültigkeitszuordnung von Version zu Flugzeugbaureihe ist der Bauakte bzw. dem jeweiligen Fertigungsauftrag zu entnehmen. Zuordnung links / rechts wird mit */* in allen Feldern angegeben.
1
QY3F-22S
1A
FUEL FLOW 1QY
CIRCUIT BREAKER/SWITCH PANEL
ST4
FIREWALL
QY1F-22
Maintenance Manual EXTRA 500 Chapter 91 30. March 2012
1
QY5E-22N QY2E-22N
A Blatt 1
8
Schutzvermerk nach DIN 34 beachten.
A3
EA-9B731.40
FUEL FLOW, QY
von 1
Projektion Freimaßtoleranz Oberfläche
EA 400-500
Maßstab auf SI.-Klasse Oberflächenschutz
8
A
B
C
D
A
B
C
PT 6
Starter/Generator
4JB
3JB
A B
JB5F-20 JB6E-18N
3JB-A
TGLN-28 IGNITION EXCITER
IGNITION PLUG
TURBINE
A:6
JB2F-20
JB1F-20
VV234
ABORT NORMAL
JB2G-20
6 WL5-22 08.2.1.16 JB5E-20 Nut oben
4
3
1 MOTORING
4
3 IGN OFF
IGN
1 START
C
JB5E-20
MS38999 III 26K F 32 SN
ST2
FIREWALL
6 08.2.1.25 Nut oben
5
:2
2
26PP:1
I-Panel left 1 START
5
:2
2
5JB:1
I-Panel left 2 MOTORING
JB3F-20
WL5-22
52
51
1PR-A
24
5WW-D
PR15E-20 PR14E-20 PR18E-22N
PR14E-20 PR15E-20
JB4E-20
JB3E-20
6
12
24
L K
M
N
1
2
3
4
5
START
5 INV
D40
291-9726
5
BYW56
D28
EDV-Kennung:
9B74310T
04 03 02 01 Ver. Bezeichnung
6
Zuordnung links / rechts wird mit */* in allen Feldern angegeben.
Die Gültigkeitszuordnung von Version zu Flugzeugbaureihe ist der Bauakte bzw. dem jeweiligen Fertigungsauftrag zu entnehmen.
5WW-A
5WW-C
HW
Name
01.09.10
ÄM-400-09-01
WW39-20N
WW20-20
WW29-22
Ignition
Intake Heat Deice Boots
PB
7
46569 Hünxe, Germany
Schwarze Heide 21
Gepr.:
Gepr.:
Name
Datum
08.09.04
Projektion Freimaßtoleranz Oberfläche
8
A Blatt 1
von 1
8
Schutzvermerk nach DIN 34 beachten.
A3
EA-9B743.10
START/IGNITION, JB
EA 400-500
Maßstab auf SI.-Klasse Oberflächenschutz
Prop Low Pitch External Power Windshield On
Low Voltage
P/N 90-42192-2 geändert
Annunciator Panel right
Standby Alt On
7
Bearb.:
2WW
Nr.: Änderung/Mod. Nr.: Datum
A
Letzte Bearbeitung:
see EA-9B315.80 ANNUNCIATOR PANEL
9
9 24 25
5WW
ANNUNCIATOR BOARD EA-9B315.81
Annunciator Panel EA-9B315.80
K4
+ VOLT DIMM
LIGHT TEST (GND)
see EA-9B243.10 DC-GENERATION I
1PR
see EA-9B243.40 E-BOX
26.57.73
K2
6
START CONTACTOR CONT START POWER CHASSIS GROUND Bei 58% schaltet die GCU aus!
ANNUNCIATOR BOARD
Z W M
GENERATOR CONTROL UNIT GCSG 505-21
ST1
FIREWALL
E-BOX
Maintenance Manual EXTRA 500 Chapter 91 30. March 2012
Allison
1
JB2E-20
A:5
CB Trennstecker
1
5A
5A
JB1E-20
START
4JB
IGN
see EA-9B246.10 DC-DISTRIBUTION
1JB
BATTERY BUS PP2
JB4F-20
CIRCUIT BREAKER/SWITCH PANEL
4
88
3
87z
88a
2
88b 88y
87a
D
1
Fertig konfektioniert
85 86
A
B
C
D
D
C
B
A
HK1F-22
HK1E-22
3
see EA-9B246.10 DC-DISTRIBUTION
2A
LOAD BUS PP3 6HK
P-VENT
CIRCUIT BREAKER/SWITCH PANEL
2
1
1
C:2
C:1
HK1H-22
HK1G-22
32CG-A
4
HK3F-22N
HK1H-22
HK2F-22N
HK1G-22
001758_212_02 3VN-A
J
HK2F-22N
2
1
2
1
P2
P1
MOLEX
MOLEX
1
2
3
4
Maintenance Manual EXTRA 500 Chapter 91 30. March 2012
1
HK3F-22N
2
5
HK3E-22N
HK1K-22
HK2E-22N
HK1J-22
5
1
2HK
4HK 1
EDV-Kennung:
9B75215T
04 03 02 01 Ver. Bezeichnung
6
HK2E-22
A
3HK
M
ÄM-400-09-01
05.10.10
5HK
M
7
HK2E-22N
Datum
18.08.04
PB
Name
7
HW Name 46569 Hünxe, Germany
Schwarze Heide 21
Gepr.:
Gepr.:
Bearb.:
9G0624G1021
HK3E-22N
9G0624G1021
VENT FAN right
Letzte Bearbeitung:
VV237
VV236
VENT FAN left
Nr.: Änderung/Mod. Nr.: Datum
HK1H-22
Die Gültigkeitszuordnung von Version zu Flugzeugbaureihe ist der Bauakte bzw. dem jeweiligen Fertigungsauftrag zu entnehmen. Zuordnung links / rechts wird mit */* in allen Feldern angegeben.
AV1611A240K
2
1
FAN RIGHT
AV1611A240K
2
FAN LEFT
6
Blatt 1
A
8
Schutzvermerk nach DIN 34 beachten.
A3
EA-9B752.15
PANEL FAN, HK
von 1
Projektion Freimaßtoleranz Oberfläche
EA 400-500
Maßstab auf SI.-Klasse Oberflächenschutz
8
D
C
B
A
Intentionally left blank
EXTRA 500 Doc.- No. EA-0B702
Schwarze Heide 21
D - 46569 Hünxe
Tel.: + 49 28 58 / 91 37 - 0
Fax: + 49 28 58 / 91 37 - 30
Germany
Intentionally left blank
Maintenance Manual Extra 500
Log of Revision Issue
Date
Sign of approval
Date
1st Edition (Chapter 4 & 5 only)
31. March 2011
EASA Major Change Approval N° 10035367
17. June 2011
2nd Edition (Complete Manual except Chapter 4)
30. March 2012
The technical content of this document is approved under the authority of DOA N° EASA.21J.073
30. March 2012
Page Date: 30. March 2012
Page A
Maintenance Manual Extra 500
List of Effective Page A thru F............................... 30. March 2012
74-1 thru 4 ...........................30. March 2012
01-1 thru 8........................... 30. March 2012
76-1 thru 12 .........................30. March 2012
02-1 thru 8........................... 30. March 2012
77-1 thru 10 .........................30. March 2012
03-1 thru 4........................... 30. March 2012
78-1 thru 4 ...........................30. March 2012
04-1 thru 6........................... 31. March 2011
79-1 thru 12 .........................30. March 2012
05-1 thru 38......................... 30. March 2012
80-1 thru 4 ...........................30. March 2012
06-1 thru 4........................... 30. March 2012
91-1 thru 67 .........................30. March 2012
07-1 thru 4........................... 30. March 2012 08-1 thru 4........................... 30. March 2012 09-1 thru 6........................... 30. March 2012 10-1 thru 8........................... 30. March 2012 11-1 thru 4........................... 30. March 2012 12-1 thru 14......................... 30. March 2012 20-1 thru 12......................... 30. March 2012 21-1 thru 26......................... 30. March 2012 22-1 thru 32......................... 30. March 2012 23-1 thru 10......................... 30. March 2012 24-1 thru 18......................... 30. March 2012 25-1 thru 16......................... 30. March 2012 27-1 thru 28......................... 30. March 2012 28-1 thru 28......................... 30. March 2012 29-1 thru 4........................... 30. March 2012 30-1 thru 22......................... 30. March 2012 31-1 thru 10......................... 30. March 2012 32-1 thru 60......................... 30. March 2012 33-1 thru 10......................... 30. March 2012 34-1 thru 18......................... 30. March 2012 51-1 thru 38......................... 30. March 2012 52-1 thru 6........................... 30. March 2012 55-1 thru 16......................... 30. March 2012 56-1 thru 6........................... 30. March 2012 57-1 thru 14......................... 30. March 2012 61-1 thru 6........................... 30. March 2012 71-1 thru 12......................... 30. March 2012 73-1 thru 4........................... 30. March 2012 Page B
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Maintenance Manual Extra 500
Intentionally left blank
Page Date: 30. March 2012
Page C
Maintenance Manual Extra 500
List of Service Bulletins SB No.
Page D
Issue Date
Subject
Ser - No. German AD aff. (LTA)
Page Date: 30. March 2012
Maintenance Manual Extra 500
CONTENTS Title ....................................................................................................................................Page Log of Revisions ..................................................................................................................... A List of Effective Pages ........................................................................................................ B-C List of Service Bulletins ......................................................................................................... D
Group/Chapter Title....................................................................................................Chapter
GENERAL Introduction ........................................................................................................................... 01 How to Use the Service Manual ............................................................................................ 02
AIRCRAFT General Description ............................................................................................................... 03 Airworthiness Limitations ..................................................................................................... 04 Time Limits/Maintenance Checks ......................................................................................... 05 Dimensions and Areas ........................................................................................................... 06 Lifting and Shoring ................................................................................................................ 07 Leveling and Weighing ......................................................................................................... 08 Towing and Taxiing ............................................................................................................... 09 Parking, Mooring, Storage and Return to Service ................................................................. 10 Placards and Markings........................................................................................................... 11 Servicing ................................................................................................................................ 12 Standard Practices - Airframe ................................................................................................ 20
AIRFRAME SYSTEMS Air Conditioning .................................................................................................................... 21 Auto Flight ............................................................................................................................. 22 Communications .................................................................................................................... 23 Electrical Power ..................................................................................................................... 24 Equipment/Furnishings .......................................................................................................... 25 Flight Controls ....................................................................................................................... 27 Page Date: 30. March 2012
Page E
Maintenance Manual Extra 500
Group/Chapter Title.................................................................................................... Chapter Fuel ........................................................................................................................................ 28 Hydraulic Power .................................................................................................................... 29 Ice and Rain Protection.......................................................................................................... 30 Indication/Recording Systems ............................................................................................... 31 Landing Gear ......................................................................................................................... 32 Lights ..................................................................................................................................... 33 Navigation ............................................................................................................................. 34
STRUCTURES Standard Practices and Structures - General ......................................................................... 51 Doors...................................................................................................................................... 52 Stabilizers .............................................................................................................................. 55 Windows ................................................................................................................................ 56 Wings..................................................................................................................................... 57
PROPELLER Propeller ................................................................................................................................ 61
POWER PLANT Power Plant............................................................................................................................ 71 Engine Fuel and Control........................................................................................................ 73 Ignition................................................................................................................................... 74 Engine Controls ..................................................................................................................... 76 Engine Indicating................................................................................................................... 77 Exhaust .................................................................................................................................. 78 Oil .......................................................................................................................................... 79 Starting................................................................................................................................... 80
MISCELLANEOUS Charts ..................................................................................................................................... 91
Page F
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Maintenance Manual EXTRA 500
Chapter 01 General
Page Date: 30. March 2012
01
Page 1
Maintenance Manual EXTRA 500
Table of Contents
01-00-00
GENERAL ........................................................................................................ 3 Address ............................................................................................................... 3 Contact................................................................................................................ 3
01-00-01
Documents ......................................................................................................... 3 Aircraft: .............................................................................................................. 3 Equipment:.......................................................................................................... 3
01-00-02 Figure 01-1 Figure 01-2 Figure 01-3 Figure 01-4
Special Tools...................................................................................................... 4 Main Gear Bolt Extracting Tool......................................................................... 4 Flap Track Snap Gauge...................................................................................... 5 Front Wing Main Bolt Extracting Tool .............................................................. 6 Rear Wing Main Bolt Extracting Tool................................................................ 6
01-00-03
Trade Marks ..................................................................................................... 7
01-00-04
Safety.................................................................................................................. 7
Page 2
01
Page Date: 30. March 2012
Maintenance Manual EXTRA 500
01-00-00
GENERAL According to the regulations of the FAR/JAR part 23, this Maintenance Manual provides educated maintenance staff with information necessary for servicing, maintaining and repairing the EXTRA 500. This Manual contains a detailed description of systems including time limits for the particular components, troubleshooting and instructions for the performance of inspection and maintenance work. The instructions that are necessary for disassembly, check, repair, maintenance or overhaul of vendor equipment are not incorporated in this manual.
Address EXTRA Flugzeugproduktions- und Vertriebs- GmbH Schwarze Heide 21 46569 Hünxe Germany
Contact Email: [email protected] Phone: +49 2858-9137-0 Fax: +49 2858-9137-30
01-00-01
Documents Use the following documents in connection with this Maintenance Manual:
Aircraft: 1 EXTRA 500 Pilot’s Operating Handbook and Airplane Flight Manual, Doc. No.: EA-0B701 most current revision 2 Service Bulletins 3 Aircraft Record 4 Airplane Log Book and Engine Log Book Note
Check the Airplane Log Book documents are up-to-date and in accordance with current applicable aviation authority regulations. Since the regulations may require different documents and data, owner of exported airplanes should check with their own aviation officials to determine their individual requirements.
Equipment: Applicable Instructions of Continuous Airworthiness for equipment installed. Refer to the List of Applicable Publications (LOAP), Doc. No.: EA-0B710.00 most current revision, provided by EXTRA. Page Date: 30. March 2012
01
Page 3
Maintenance Manual EXTRA 500
01-00-02
Special Tools Generally, for maintenance tasks no special tools are necessary. However, there are a few exceptions as listed below. These items are available at EXTRA. Alternatively, they can be crafted per instruction of Figures 01-1 through 01-4, using standard shop practices. Description
Extra Part No.
Subject
Chapter
Main gear bolt extracting tool
n/a
Main gear strut removal
32-10-10
Flap track snap gauge EA – 15182W10
Flap guidance check
27-50
Front wing main bolt extracting tool
EA – 15001.1W
Wing removal
57-10
Rear wing main bolt extracting tool
EA – 15001.2W
Wing removal
57-10
Stroke bushing
Threaded rod M 10
Figure 01-1
Page 4
01
Nut and counter nut
Main Gear Bolt Extracting Tool
Page Date: 30. March 2012
Maintenance Manual EXTRA 500
Figure 01-2
Flap Track Snap Gauge
Page Date: 30. March 2012
01
Page 5
Maintenance Manual EXTRA 500
Figure 01-3
Front Wing Main Bolt Extracting Tool
Figure 01-4
Rear Wing Main Bolt Extracting Tool
Page 6
01
Page Date: 30. March 2012
Maintenance Manual EXTRA 500
01-00-03
Trade Marks Even when the ware or brand names used in this manual are not marked as registered trade-marks, this does not mean, that these names are free in the sense of trademark legislation.
01-00-04
Safety To keep the security risks during the execution of the inspection and maintenance work as low as possible, observe the following points: 1 Inspection and maintenance work has to be carried out only by qualified and authorized personnel. 2 The execution has to be in accordance with the respective national safety requirements. 3 Before beginning any work, this service manual has to be read and understood. In case of doubt or lack of information the manufacturer has to be contacted for advice. 4 The safety notes given in this manual are to be observed unconditionally. Refer to Chapter 02 for information concerning safety notes.
Page Date: 30. March 2012
01
Page 7
Maintenance Manual EXTRA 500
Intentionally left blank
Page 8
01
Page Date: 30. March 2012
Maintenance Manual EXTRA 500
Chapter 02 How to Use the Maintenance Manual
Page Date: 30. March 2012
02
Page 1
Maintenance Manual EXTRA 500
Table of Contents
02-00-00
GENERAL ........................................................................................................ 3
02-10-00
MANUAL DESCRIPTION ............................................................................. 4
02-10-01
Manual Set-Up .................................................................................................. 4
02-10-02
Chapter Set-Up ................................................................................................. 4
02-10-03
Page Numbering ............................................................................................... 4
02-10-04
Figure Numbering ............................................................................................ 4
02-10-05
Layout ................................................................................................................ 5
02-10-06
Notes/Safety Notes ............................................................................................ 5
02-20-00
HANDLING ...................................................................................................... 6
02-20-01
Revisions ............................................................................................................ 6
02-20-02
Service Bulletin ................................................................................................. 6
02-20-03
Checklists........................................................................................................... 7
Page 2
02
Page Date: 30. March 2012
Maintenance Manual EXTRA 500
02-00-00
GENERAL The set-up of the manual, the chapters and the handling correspond to the regulations of the Air Transport Association of America, ATA Specification No. 100. However, the numbering of the pages and the layout have been changed to make working with this manual easier.
Page Date: 30. March 2012
02
Page 3
Maintenance Manual EXTRA 500
02-10-00
MANUAL DESCRIPTION
02-10-01
Manual Set-Up The manual consists of groups, which are subdivided in chapters. Additionally there are preceding pages, which contain the List of Effective Pages, the Lists of Service Bulletins and the Record of Revisions. In the list of chapters the groups are marked by capital characters.
02-10-02
Chapter Set-Up The chapter numbering system used in this manual represents the chapter setup. It is a conventional dash-number breakdown. The number is composed of three elements which consist of two digits each:
02-10-02 chapter - section - subject The first element shows the chapter (here: "How to Use the Service Manual"). The second element shows the first subdivision, which is called "section" (here: "MANUAL DESCRIPTION"). The third element shows the "subject", which is handled within the respective section (here: "Chapter Set-Up"). The first three digits refer to the definitions of the ATA Specification 100, where they exist; the other digits are defined by the manufacturer. If a more detailed breakdown is necessary, bold faced headlines like the following are used: Powerplant When headlines are referenced in the text they are presented in italic letters. E.g.: see Powerplant paragraph.
02-10-03
Page Numbering The page numbering begins at the coversheet of each chapter with "Page 1". In contrast to the ATA Specification 100, the particular sections and subjects don't start with a new numbering.
02-10-04
Figure Numbering The figures are numbered in such a way that the first figure in each chapter starts at "Figure XX-1".
Page 4
02
Page Date: 30. March 2012
Maintenance Manual EXTRA 500
02-10-05
Layout Apart from the headers and footers the layout consists of two columns. The right column contains text, titles, tables, schedules and figures (figures also can fill the whole page); the left column contains the chapter numbering, boxed textmarkers for notes and safety notes as well as explanations.
02-10-06
Notes/Safety Notes Safety notes in this manual are marked by a boxed textmarker in the margin column and written in semi-bold characters. This manual distinguishes three warning levels:
DANGER
Represents any threatening danger for the personnel. The non-observation of this safety note will result in death or serious injuries.
Represents a possibly dangerous situation for the personnel. The nonWARNING observation of this safety note may result in injuries. CAUTION
Represents a danger to equipment. The non-observation of this safety note results in destruction of equipment. This safety note does not exclude a possible danger for the personnel. Additional information given in this manual are also marked by boxed textmarkers in the left column and are written in semi-bold characters:
IMPORTANT NOTE
Represents an important hint. Often used when the non-observation could endanger pilot or passengers during flight. Represents a useful or remarkable hint.
Page Date: 30. March 2012
02
Page 5
Maintenance Manual EXTRA 500
02-20-00
HANDLING
02-20-01
Revisions Maintenance Manuals and other technical publications in current revision status are available over the World Wide Web direct link: http://www.extraaircraft.com/techservice.php Cross-check your documents against these publications and replace pages as necessary. Paper copies of publications will continue to be available if this is your preferred format of publications. Orders can be placed by contacting EXTRA.
NOTE
Pages of this Manual may not be exchanged and no alterations of or additions to the approved contents may be made without the EXTRA approval. If revision of pages will be necessary, observe the following steps:
NOTE
Change revised pages immediately upon receipt. 1 Take out the old pages and destroy them. 2 Insert the new pages following the chapter and page numbers. 3 Replace the old pages "List of Effective Pages". 4 Enter the date on page "Record of Revision" and on page "2 = Record of Revision" of Ch 04 if necessary. Each revised page is marked at the bottom by the date of revision; revised parts of the new page are marked by a bar on the left margin.
02-20-02
Service Bulletin The Service Bulletins describe which procedures and how and when they are to be carried out. Enter the receipt of each Service Bulletin in the Service Bulletin List.
NOTE
Page 6
02
The owner is responsible for incorporating Service Bulletins to the above mentioned Service Bulletins List.
Page Date: 30. March 2012
Maintenance Manual EXTRA 500
02-20-03
Checklists Observe the following steps when working with checklists: 1 Copy the respective check list for performing a check.
X1
50 hours
100 hours
1000 hours
as specified
2 Enter the date at the top of the table. Date:
Inspector
Serial No.:
Mechanic
X
X
X
Text
Description Text
3 Select the items to be worked out. The "X" at the beginning of the line is written in the column which indicates the point of time when an item has to be worked out. Specification for the first column is given by footnotes. 4 Work out the particular items and sign after execution (responsible mechanic and inspector) using the respective boxes behind the item. 5 After completion of the inspection check file the list with entries in the Aircraft Records. 6 Certify the completion of the check in the Aircraft Log Book.
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Maintenance Manual EXTRA 500
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Page 8
02
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Maintenance Manual EXTRA 500
Chapter 03 General Description
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03
Page 1
Maintenance Manual EXTRA 500
Table of Contents 03-00-00
Page 2
03
GENERAL ........................................................................................................ 3
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Maintenance Manual EXTRA 500
03-00-00
GENERAL
The EXTRA 500 is designed as a six-place, single engine, high-wing, full composite airplane. The fuselage consists of a skin with integrated longerons and frames. The wing uses a double front spar and a rear spar interconnected by ribs. The stabilizers use a front and a rear spar. In general the skins of fuselage, wing, stabilizers and control surfaces consist of carbon fiber facings and honeycomb. The supporting structures such as longerons, frames, spars and ribs consist of carbon fiber with foam core. Only the D-section of the wing consists of glass fiber with honey comb and glass fiber ribs. The EXTRA 500 has a hydraulically operated retractable tricycle landing gear with a controllable nose wheel.
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03
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Page 4
03
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Maintenance Manual Extra 500
Chapter 04 Airworthiness Limitations
Page Date: 31. March 2011
04
Page 1
Maintenance Manual Extra 500
Record of Revisions Chapter 04 Rev. No.
Date of Revision
Revised Pages
Description of Revision
—
4. June 2004
—
First edition
—
31. March 2011
—
Second edition
Page 2
04
EASA Approval Date and Sign of Approval
N° 10035367 17. June 2011
Page Date: 31. March 2011
Maintenance Manual Extra 500 Airworthiness Limitations
Table of Contents
04-00-00
GENERAL .........................................................................................................4
04-00-01
Temperature Limit............................................................................................4
04-00-02
Operating Time .................................................................................................4
04-10-00
LIFE LIMITED COMPONENTS ...................................................................5
04-10-01
General ...............................................................................................................5
04-10-02
Replacement Time.............................................................................................5
04-10-03
Service Life Limited Components ...................................................................5
Page Date: 31. March 2011
04
Page 3
Maintenance Manual Extra 500
04-00-00
GENERAL For each inspection listed here, refer to the applicable chapter in this manual.
IMPORTANT
It is the operator's responsibility to make sure that time limits or life limits for items in this chapter are not exceeded. The airworthiness limitations items include mandatory replacement times and structural inspection intervals which may only be changed with permission of the applicable airworthiness authority. The Airworthiness Limitation section is FAA approved and specifies maintenance required under paragraphs 43.16 and 91.403 of the Federal Aviation Regulations, unless an alternative program has been FAA approved. *) *)
Legible statement pertaining to non US registered airplanes: The Airworthiness Limitation section is approved by the regulatory authority and specifies maintenance required under paragraphs 43.16 and 91.403 of the Federal Aviation Regulations, unless an alternative program has been approved by the regulatory authority.
04-00-01
Temperature Limit The composite material used to manufacture the Extra EA 400-500 is qualified for service temperatures up to 72° C (162° F) under load. As such, any surface repainting or surface repair paint finish must be accomplished with white color paint only. Contact manufacturer directly for approved paint brands and formulas.
04-00-02
Operating Time Only the airframe and components as listed in Chapter 04-10-00 are subject to a permissible operating time; concerning all other components recommended replacement times are given in Chapter 05.
Page 4
04
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Maintenance Manual Extra 500 Airworthiness Limitations
04-10-00
LIFE LIMITED COMPONENTS
04-10-01
General The replacement time of the life limited components listed in Chapter 04-10-02 must be accomplished not later than the specified period of operation for that component or in accordance with the manufacturer's service data or airworthiness directives.
04-10-02
Replacement Time Items shown here must be replaced during the regular maintenance periods. Item
04-10-03
Replace after
Fuselage
20,000 h
Wing
20,000 h
Wing Flap
20,000 h
Aileron
20,000 h
Vertical Stabilizer
20,000 h
Rudder
20,000 h
Horizontal Stabilizer
20,000 h
Elevator
20,000 h
Service Life Limited Components The service lives of the EA 400-500 composite structure components as listed in Section 04-10-02 have been demonstrated up to 20,000 flight hours, up to 30,000 take-off and landing operations.
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Maintenance Manual EXTRA 500
Chapter 05 Time Limits/Maintenance Checks
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Page 1
Maintenance Manual Extra 500 Time Limits and Maintenance Checks
Table of Contents
05-00-00
GENERAL ........................................................................................................ 5
05-00-01
Chapter Configuration..................................................................................... 5
05-00-02
Words with Special Meanings ......................................................................... 6
05-10-00
TIME LIMITS .................................................................................................. 7
05-10-01
General .............................................................................................................. 7
05-10-02
Certification Authorities .................................................................................. 7
05-10-03
Scheduled Maintenance Time Limits ............................................................. 7
05-10-04
Component Time Limits .................................................................................. 8 Time Between Overhaul ..................................................................................... 8 Time Between Replacement ............................................................................... 8 Time Between Inspection ................................................................................... 9
05-20-00
SCHEDULED MAINTENANCE CHECKS................................................ 10
05-20-01
General ............................................................................................................ 10
05-20-02
Maintenance Checks Schedule ...................................................................... 10
05-20-03
Scheduled Maintenance Charts..................................................................... 11 Operational Checks........................................................................................... 11 Miscellaneous ................................................................................................... 13 Fuel System ...................................................................................................... 14 Oil System ........................................................................................................ 15 Bleed Air System.............................................................................................. 16 Air Inlet and Exhaust System ........................................................................... 17 Engine and Accessories .................................................................................... 18 Propeller and Governors ................................................................................... 19 Cabin and Equipment ....................................................................................... 20 Fuselage ............................................................................................................ 23 Wing Assembly ................................................................................................ 24 Control Systems and Surfaces .......................................................................... 26 Landing Gear .................................................................................................... 28 Wheels and Brakes ........................................................................................... 32 Completion ....................................................................................................... 34
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Maintenance Manual Extra 500 Time Limits and Maintenance Checks
05-30-00
FLIGHTLINE INSPECTIONS .....................................................................35
05-30-01
General .............................................................................................................35
05-30-02
Pre - Flight Check ...........................................................................................35
05-30-03
Post - Flight Check ..........................................................................................35
05-50-00
UNSCHEDULED MAINTENANCE CHECKS...........................................36
05-50-01
General .............................................................................................................36
05-50-02
50 Hours – Inspection of Engine ....................................................................36
05-50-03
Hard Landing ..................................................................................................36
05-50-04
Engine Fire.......................................................................................................37
05-50-05
Propeller Strike, Sudden Stoppage and Violent Engine Stoppage ............37
05-50-06
Lightning Strike ..............................................................................................37
05-50-07
Engine Overspeed............................................................................................38
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Maintenance Manual Extra 500 Time Limits and Maintenance Checks
05-00-00
GENERAL This chapter is a guide. It will help you to perform the maintenance correctly. You must perform the scheduled maintenance checks given in this chapter at the recommended time. These checks are minimum requirements for keeping the aircraft in a good technical condition. The aircraft manufacturer can change the time between maintenance actions and scheduled checks. If this happens, the aircraft manufacturer will supply the data by Service Bulletins or Service Letters. You can shorten the time between scheduled maintenance checks if the aircraft operation makes it necessary. You must not extend the time between scheduled maintenance checks without the aircraft manufacturer’s approval. The aircraft manufacturer must give approval to any change to the aircraft or to the maintenance checks schedule.
05-00-01
Chapter Configuration Section 05-10-00 contains the time limits for maintenance actions and checks. It also contains the time limits for components. Use the data in section 05-1000 to find out when to perform maintenance actions and checks. Section 05-20-00 contains the scheduled maintenance checks to be performed on different time intervals. It also contains data for the annual inspection if required due to national regulations. Section 05-30-00 contains data for flight line checks. Do a pre-flight check before each flight. And do a post-flight check after each flight. Section 05-40-00 is reserved. Section 05-50-00 contains the unscheduled maintenance checks. Do these checks after heavy landings, engine fire and propeller damage, or if the aircraft has been operated outside the flight envelope.
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Maintenance Manual Extra 500 Time Limits and Maintenance Checks
05-00-02
Words with Special Meanings In this Maintenance Manual, the words that follow have special meanings :
Adjust To put to a specified position or condition. For example, adjust the clearance to 1 mm. Check A technical name for a group of maintenance tasks. For example, the 100 hour check. Examine To look carefully at an item. It includes steps such as these: Make sure that the item: 1 Is complete. 2 Is correctly attached. 3 Has no loose parts. 4 Shows no signs of leaks. 5 Is not cracked or damaged. 6 Is not worn. Make sure that: 1 The surface protection is not damaged. 2 All locking devices are installed correctly. Make sure that items such as pipes and cables (see also Chapter 20-10-09): 1 Look serviceable. 2 Do not rub against other items (chafing marks). Inspection The procedure, which compares an object with its standard or specification. Measure To find out the dimensions, capacity or quantity of something. Monitor To look at something during a time. For example, monitor the engine speed indicator. Record Technical name for something that shows what was done. For example, write the result of the test in the engine record. Replace To remove an unserviceable item and install a serviceable item in the same location. Set To put equipment into a given adjustment, condition or mode. For example, set the altimeter scale to 1013 mbar. Task An assigned work or procedure. For example, each step of the task has an identification letter. Test That what you do when you operate or examine an item to make sure that it agrees with the applicable specifications. For example, disconnect the systems, which are not necessary for the test.
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Maintenance Manual Extra 500 Time Limits and Maintenance Checks
05-10-00
TIME LIMITS
05-10-01
General Various equipment and components of the aircraft (e.g. engine, propeller) are only cleared for a certain time of operation. After the permissible time of operation has expired they have to be replaced or overhauled (TBO - Time Between Overhaul). The respective TBO intervals are listed in the aircraft record sheets. For monitoring the permissible time of operation, this time should also be entered into the aircraft records when removing and installing such a part including full part and serial numbers.
05-10-02
Certification Authorities The time limits given in this chapter are recommended by the manufacturer. These time limits may be superseded by the regulatory authority.
05-10-03
Scheduled Maintenance Time Limits The following components listed in Chapter 05-14-00 have to be overhauled, replaced or inspected periodically, i.e. within fixed calendar periods or after appearance of a certain amount of flight hours. Do scheduled maintenance at these times: Scheduled Maintenance
Do at these times
100 hours check
At 100 FH. Or 100 hours after the last 100 hours or larger check. Tolerance +/- 10 hours.
1000 hours check
At 1000 FH. Or 100 hours after the last 100 hours or larger check. Tolerance +/- 10 hours.
In addition scheduled engine maintenance according to Rolls Royce 250-B17F Series Operation and Maintenance Manual (LOAP 1) has to be performed at the time intervals given there.
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05-10-04
Component Time Limits Time Between Overhaul These components have a TBO - Time Between Overhaul: Components
Time Between Overhaul
Turboprop Engine Rolls Royce 250-B17F/2.
Refer to the latest Rolls Royce 250-B17F Series Operation and Maintenance Manual (LOAP 1)
Engine accessories.
Refer to the latest Rolls Royce 250-B17F Series Operation and Maintenance Manual (LOAP 1)
Propeller Governors
Refer to the latest Rolls Royce 250-B17F Series Operation and Maintenance Manual (LOAP 1)
Aircraft Parts Corps 200SGL Starter Generator
Every 1000 hours.
BC410 Stand-by Alternator system
Every 1700 hours
Passenger seat belt webbing.
After 12 years.
MT-Propeller MTV-5-1-D-C-F-R(A) CFR210-56.
Refer to the latest MT-Propeller Service Bulletin (LOAP 5).
Time Between Replacement Replace these components at the times shown:
Page 8
05
Components Purolator Facet Scavenge lube oil filter Pierburg Motive flow fuel pump
Time Between Replacement 200 hours or 6 months which ever comes first 2000 hours
Integral Hydraulic Hydraulic accumulator
10 years
Rubber type hoses wing fuel tank pick up to fuselage connection and within wing fuel tank of SN 1002 and 1003
First 7, then 5 years.
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Maintenance Manual Extra 500 Time Limits and Maintenance Checks
Components
Time Between Replacement
Batteries of Emergency Locator Transmitter (ELT).
Every 2 years during shelf or service life, or after 1 hour of cumulative use (e.g. testing), or after operation in an emergency situation, or before battery replacement date. Battery replacement date is marked on the battery pack and the label at the end of transmitter. For battery replacement see ARTEX Description, Operation, Installation and Maintenance Manual for the ME406 ELT (LOAP 30)
Batteries of emergency torch.
Annually or after each use.
Time Between Inspection Inspect these equipment items at the times shown: Components
Time Between Inspection
Battery
Refer to CONCORDE Component Maintenance Manual (LOAP 27)
Static pressure system.
Every 2 years in accordance with 14 CFR Ch. 1 Part 43 App. E. Every 12 months in accordance with 14 CFR Ch. 1 Part 43 Apps. F Par. C and F.
ATC transponder.
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Maintenance Manual Extra 500 Time Limits and Maintenance Checks
05-20-00
SCHEDULED MAINTENANCE CHECKS
05-20-01
General Regular inspections must be carried out every 100 or 1000 operating hours. Annual inspections (ANI) must be performed according to the national requirements.
NOTE
The scope of an Annual Inspection and a 100 hour inspection is the same. However, the manufacturer may recommend to perform additional checks in the course of an Annual Inspection. If applicable, these checks are identified in the Maintenance Check Schedule with the abbreviation "ANI". All inspections must be executed by a designated representative of the Aviation Authority of the country in which the aircraft is registered.
05-20-02
Maintenance Checks Schedule The maintenance and control work given in the following tables has to be carried out within the given time intervals. The proper execution of the checks and maintenance actions has to be certified in the maintenance records and log books. Faults as well as their repairs have to be entered in an inspection report filed together with the check list in the aircraft records.
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Maintenance Manual Extra 500 Time Limits and Maintenance Checks
05-20-03
Scheduled Maintenance Charts The maintenance checks described in this section include all the scheduled checks, which must be performed. Maintenance checks must be accomplished in accordance with CFR 14 P 43 App. D. Use the following schedule and the lubrication charts presented in Chapter 1220-04. Prior to inspection, the aircraft and engine should be thoroughly cleaned, all inspection panels, access doors or fairings should be removed.
Serial No.: Description:
Inspector
Date:
Mechanic
1000
Flight Hours
100
as specified
Operational Checks
05
Page 11
Rotating propeller can cause death or injuries! WARNING Do not allow anyone to stay in the propeller area. Perform an inspection operational run-up. Refer to the latest Rolls Royce 250-B17F Series Operation and Maintenance Manual (LOAP 1). Record and verify the engine operating parameters.
X
X
X
X
Start engine (in accordance with the EXTRA 500 Pilot's Operating Handbook).
X
X
Check the parking brake and toe brakes.
X
X
Check the fuel flow, fuel pressure and fuel quantity indication.
X
X
Check the function of fuel pumps by monitoring fuel pressure indication when running a single pump.
X
X
Check fuel selector valve for proper operation and pointer indication.
X
X
Check the oil pressure and oil temperature.
X
X
Check the generator output.
X
X
Check the stand-by alternator output with generator off. Then generator on.
X
X
Check the cabin pressurizing operation.
X
X
Check the air condition operation.
X
X
Check the de-ice system operation.
X
X
Check the windshield heater operation.
X
X
Check flight idle speed (N1: 65%).
X
X
Check response of the engine by power setting changes.
Page Date: 30. March 2012
Serial No.:
X
X
Check the propeller overspeed governor at 1800 RPM (N2 RPM) by pressing ENGINE OVSPD TEST button switch. Monitor RPM drop. After release of the ENGINE OVSPD TEST button switch Prop RPM should return to the above setting. Then return to idle.
X
X
Check temperature regulation. Actuate WARM/COOL switch in manual mode and check response. Return to automatic mode.
X
X
Check the annunciator light panel.
X
X
Check the radio and the other electronic equipment.
Description:
Inspector
Mechanic
Date:
1000
Flight Hours
100
as specified
Maintenance Manual Extra 500 Time Limits and Maintenance Checks
Function test of flaps only with upper door closed. CAUTION
Page 12
X
X
Check operation of controls and flaps.
X
X
Shut down engine. Condition lever at cut-off position. Check immediate PNEUMATIC LOW annunciation and interruption of cabin heat air flow. (bleed air distribution valves function check)
X
X
Check gyros for noise and roughness.
X
X
Change power lever position and check illumination of LOW PITCH annunciator light.
X
X
Check the generator/alternator warning light or ammeter.
X
X
BATT switch OFF.
05
T
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Maintenance Manual Extra 500 Time Limits and Maintenance Checks
X
Clean and inspect the cowling intakes and outlets for damage, cracks, distortion and overheat areas.
X
Inspect engine mount for cracks, corrosion, looseness of mountings and overheated areas. Inspect engine shock mount isolators for deterioration, improper assembly and insecurity. Replace as required.
X
X
Inspect engine controls for security, defects, improper travel and improper safetying. Lubricate as per Chapter 12-20-04 Lubrication Chart.
X
X
Inspect engine bonding for improper installation and poor condition.
X
X
Inspect firewall and seals for improper condition, insecurity and improper fire resistant sealing.
X
X
Inspect battery and attachment for corrosion, etching, poor condition and insecurity. (Charge battery if required.)
X
X
Inspect battery ventilation hose and attachment for chafing, leakage, poor condition and insecurity.
Inspector
X
Description:
Mechanic
Serial No.:
X
05
Page 13
Perform battery capacity test according to CONCORDE Component Maintenance Manual (LOAP 27)
1
X
X
Inspect external power supply receptacle, battery relay and fuses for cleanliness, corrosion, poor condition and insecurity.
X
X
Inspect electrical leads, lines, ceramics and attaching for chafing, deterioration, improper routing, wear, insecure installation and obvious defects.
DANGER
X
1
Date:
1000
Flight Hours
100
as specified
Miscellaneous
Nose gear and main gear extends and retracts under high pressure. Operation of the landing gear can cause death or injuries in its working area! Before beginning any work in the landing gear working area, pull OFF the GEAR CTRL circuit breaker located on the left side panel. Inspect nose wheel box for cracks, poor general condition and improper fire resistant sealing.
Refer to CONCORDE Component Maintenance Manual (LOAP 27)
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Maintenance Manual Extra 500 Time Limits and Maintenance Checks
Serial No.:
X
X
Inspect lines, hoses and clamps for leaks, improper condition and looseness.
X
X
Inspect fuel pumps for leaks, poor general condition, insecure attachment.
X
X
Inspect fuel collector block and check valves for leaks, improper condition, insecurity and insecure attachment.
X
X
Inspect fuel filter for leaks, improper condition, insecurity and insecure attachment.
X
X
Check function of red fuel filter bypass button (monitor annunciator panel).
Description:
Inspector
Mechanic
Date:
1000
Flight Hours
100
as specified
Fuel System
Check function of fuel selector valve. Ensure both wing tanks contain fuel. Place suitable container below fuel drain. Open fuel drain. Select various positions of fuel selector valve and monitor fuel flow. Close fuel drain
1
2
Change fuel filter element and O-rings.
1
Together with engine fuel maintenance. Refer to latest Rolls Royce 250-B17F Series Operation and Maintenance Manual (LOAP 1).
2
See prior footnote
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05
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Maintenance Manual Extra 500 Time Limits and Maintenance Checks
Serial No.: Description:
Inspector
Date:
Mechanic
1000
Flight Hours
100
as specified
Oil System
05
Page 15
Drain engine oil system. Refer to Rolls Royce 250-B17F Series Operation and Maintenance Manual (LOAP 1). To completely drain the oil system, also disconnect the outgoing oil line at the bottom of the oil tank.
1
X
X
Inspect oil tank for insecurity of attachment, leaks and cracks.
X
X
Inspect oil system lines, hoses, fittings and clamps for leaks, chafing, improper condition and looseness.
X
X
Clean and inspect oil cooler and fins for leaks, deterioration, distortion, insecure attachment, loose or missing fasteners and other evidence of failure.
X
X
Inspect temperature regulator for leaks, insecurity of attachment and poor condition.
X
X
Inspect oil tank vent valves for insecurity of attachment and poor condition.
1
together witch engine lubrication system maintenance Refer to Rolls Royce 250-B17F Series Operation and Maintenance Manual (LOAP 1)
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Maintenance Manual Extra 500 Time Limits and Maintenance Checks
Page 16
Serial No.: Description:
X
X
Inspect bleed air lines, hoses, fittings and clamps for leaks, chafing, improper condition and looseness. Use clean filtered compressed shop air with a pressure not exceeding 10 PSI.
X
X
Inspect valves for insecurity of mounting, poor condition and improper electrical connections.
X
X
Inspect ejectors for insecurity of mounting, leaks and poor condition.
X
X
Inspect pressure switch for insecurity of mounting, poor condition and improper electrical connections.
X
X
Inspect air flow sensor for insecurity of mounting and improper electrical connection.
X
X
Inspect acoustical muffler for insecurity of mounting, leaks and poor condition.
X
Perform temperature switch function test (Refer to Chapter 2160-01).
05
Inspector
Date:
Mechanic
1000
Flight Hours
100
as specified
Bleed Air System
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Maintenance Manual Extra 500 Time Limits and Maintenance Checks
X
X
Inspect air inlet and inlet heat ducts for leaks, cracks and poor condition.
X
Check mechanic and electric (annunciation) function of inlet heat. Lubricate as per Chapter 12-20-04 Lubrication Chart. Check function of engine internal solenoid valve (“click” when switched).
X
Inspect the exhaust pipes for burned areas, cracks, leakage, deterioration, loose and missing brackets, clamps and hardware.
X
Inspect induction and exhaust components for worn or damaged areas, loose clamps, cracks and leaks.
X
X
Description:
Page Date: 30. March 2012
Inspector
Serial No.:
Mechanic
Date:
1000
Flight Hours
100
as specified
Air Inlet and Exhaust System
05
Page 17
Maintenance Manual Extra 500 Time Limits and Maintenance Checks
Serial No.: Description: Perform complete engine inspection according to the latest edition of Rolls Royce 250-B17F Series Operation and Maintenance Manual (LOAP 1).
1
2
Complete overhaul of engine or parts X
X
Inspect oil temperature sensor unit for leaks and insecurity.
X
X
Inspect all wiring, fluid lines, hoses and electrical connections for improper routing, improper support and evidence of deterioration. Replace damaged wires, hoses, lines and clamps if required.
X
X
Visually inspect accessory to engine attaching hardware for insecurity. Visually inspect airframe to engine connections for insecurity and corrosion.
X
X
Inspect all accessories for poor condition, insecurity of mounting and improper operation. Refer to component manufacturer's Maintenance Manual.
X
Inspect and test the starter generator. Remove starter generator. Check brush length and condition. Clean brushes by clean filtered compressed shop air. Refer to the applicable starter generator manufacturer's instructions. Reinstall starter generator and ventilation. Inspect ventilation hose and attachment for leaks, chafing, looseness and poor condition.
X
X
Inspect and test the stand-by alternator. Check alternator externally for security of mounting and wiring. Refer to the applicable alternator manufacturer's instructions.
X
X
Inspect firewall mounted equipment for insecurity of mounting, improper electrical connections and poor general condition.
X
X
Inspect bleed air and pneumatic hoses and tubing for deterioration, chafing, wear and insecurity.
X
1
refer to Rolls Royce 250-B17F Series Operation and Maintenance Manual (LOAP 1)
2
see prior footnote
Page 18
Inspector
Date:
Mechanic
1000
Flight Hours
100
as specified
Engine and Accessories
05
Page Date: 30. March 2012
Maintenance Manual Extra 500 Time Limits and Maintenance Checks
X
X
1
2
Serial No.: Description:
Inspector
Date:
Mechanic
1000
Flight Hours
100
as specified
Propeller and Governors
Perform propeller check according to the latest edition of MTPropeller Operation and Installation Manual E-610 (LOAP 3) and Service Bulletin No 1 (LOAP 5). Perform propeller-power turbine governor functional feather check according to the latest edition of Rolls Royce 250-B17F Series Operation and Maintenance Manual (LOAP 1) Perform propeller overspeed governor functional check according to the latest edition of Rolls Royce 250-B17F Series Operation and Maintenance Manual (LOAP 1)
1
together with engine maintenance. Refer to Rolls Royce 250-B17F Series Operation and Maintenance Manual (LOAP 1). 2
see prior footnote
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05
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Maintenance Manual Extra 500 Time Limits and Maintenance Checks
X
X
Description:
Inspector
Serial No.: Remove inspection covers, door covering and panels (seats and carpet must be removed for access to inspection covers on the cabin floor). Inspect cabin and cockpit for uncleanliness and loose equipment that might foul the controls.
X X
X
Inspect cabin entrance door and emergency exit for improper rigging. Check retainer pins and striking parts for bending, cracks, improper engagement, pulled or sheared fasteners.
X
X
Inspect cabin entrance door and emergency exit door seals for folding and damage.
X
X
Check the door hinges for cracks and sideplay.
X
X
Check the door locking bolts for wear and improper adjustment.
X
X
Check the door locking fittings for wear.
X
X
Examine the door connecting rod geometry for cracks, bending and loose parts.
X
X
Check the door locking mechanism for improper operation.
X
Perform a teardown inspection of the central door operating device.
X
X
Perform a door pressure test. Inspect the sealing surfaces for leakage 1 .
X
X
Lubricate doors as per Chapter 12-20-04 Lubrication Chart.
X
X
Inspect crew seats for improper horizontal and vertical operation and insecure locking function.
CAUTION
1
Date:
Mechanic
1000
Flight Hours
100
as specified
Cabin and Equipment
Check crew seats for improper engagement of pins to seat track with occupied crew seat at the lowest vertical position.
X
X
Inspect seats and upholstery for tears and poor condition.
X
X
Inspect seat belts for insecurity of attachment and improper operation.
X
X
Inspect seat belts as per SCHROTH Abbreviated Component Maintenance Manuals for Restraint Systems Models 1-08-() (LOAP 32) and 5-02-() (LOAP 33)
For localizing leakage easily examine door seals for dust particles.
Page 20
05
Page Date: 30. March 2012
X
X
Inspect seats, seat belts, security brackets and bolts for poor condition and apparent defects.
X
X
Check operation of cabin and instrument lights.
X
X
Inspect instruments, lines, wiring and attachments for poor condition.
X
Inspect electric gyro instruments for poor condition, insecure mounting, marking and improper operation. Overhaul or replace as required. (Refer to the components manufacturer's instruction.)
X
Test pressure regulator setting and pressure switch setting.
X
X
Inspect avionics and radio equipment for poor condition, improper installation and insecure mounting.
X
X
Check electric trim operation and rigging.
X
X
Check operation of rudder pedals and toe brakes.
X
X
Check operation of parking brake.
X
X
Inspect control wheels, column and switches for poor condition.
X
X
Inspect cables, pulleys and connections for poor condition and insecurity.
X
X
Check operation of strobe, landing, navigation lights.
X
X
Check pitot/static air pressure operation.
X
X
Inspect pitot/static hoses, lines for poor condition and insecurity.
X
X
Inspect altimeter and ATC transponder for improper condition.
X
Description:
1
Check that altimeter and transponder comply with latest revision of 14 CFR Chapter 1 Part 43 Appendixes E and F.
2
Inspect compass and compass deviation card for improper indication and compensation.
3
Inspector
Serial No.:
Mechanic
Date:
1000
Flight Hours
100
as specified
Maintenance Manual Extra 500 Time Limits and Maintenance Checks
05
Page 21
Check magnetic compass compensation. X
X
Inspect all knobs, switches and levers and their mounting for insecurity of attachment and poor condition.
X
X
Inspect engine controls for improper installation and improper operation.
1
Every two years
2
Annually
3
Annually
Page Date: 30. March 2012
X
X
Inspect flight controls for improper installation and improper operation.
X
X
Check operation of fuel selector valve.
X
X
Check operation of cabin heat and defrost controls.
X
X
Inspect circuit breaker mounting and wiring for poor condition and insecurity.
X
X
Inspect environmental system ducts for poor condition.
X
X
Check cabin pressurization system and pressure controller operation.
X
X
Check electrical panel components for poor condition and insecurity.
X
X
Check forward side of outflow and safety valves for poor condition and insecurity. Remove and clean as shown in Chapter 21.
X
X
Inspect filters on control and safety valve for contamination. Clean or replace as required (see Chapter 21).
X
X
Inspect control cable boots for poor condition and insecurity.
X
X
Inspect air condition evaporators, drain valves and mounting for poor condition and insecurity.
X
X
Drain air condition evaporators.
X
X
Inspect portable fire extinguisher for improper service and poor condition. Check inspection date.
Description:
Inspector
Mechanic
Serial No.:
1
Change batteries of emergency torch. X
1
Date:
1000
Flight Hours
100
as specified
Maintenance Manual Extra 500 Time Limits and Maintenance Checks
X
Reinstall inspection covers and panels.
Annually or after each use.
Page 22
05
Page Date: 30. March 2012
Maintenance Manual Extra 500 Time Limits and Maintenance Checks
X
X
Remove access panels.
X
X
Inspect structure and exterior surfaces for deterioration, distortion, cracks, dents, other evidence of failure, uncleanliness and defective or insecure attachment of fittings.
X
X
Inspect windshield and windows for deterioration, nicks, scratches, cracks and crazing.
Description:
Inspector
Serial No.:
Mechanic
Date:
1000
Flight Hours
100
as specified
Fuselage
05
Page 23
Pressurized flight is prohibited with cracks and crazing. CAUTION X
X
Inspect electric windshield de-ice system for poor condition, insecurity and improper operation.
X
X
Inspect environmental system ducts for poor condition.
X
X
Inspect air condition compressor and mounting for poor condition and insecurity. Check condition and tension of compressor drive belt.
X
X
Inspect air condition hoses and clamps for poor condition, chafing and leaks.
X
X
Inspect air condition system wiring for fraying or cracks.
X
Inspect electrical leads, lines, radio antenna leads and attaching for chafing, deterioration, improper routing, wear, insecure installation and obvious defects.
X
X
Inspect antennas and coaxial cables for poor condition, insecure mounting and improper operation. (Refer to Figure23-01 in Chapter 23-60-00.)
X
X
Inspect ELT, trim servo and attachment for poor condition and insecurity.
X
X
X
Check ELT battery replacement date. (Refer to ARTEX Description, Operation, Installation and Maintenance Manual for the ME406 ELT (LOAP 30).)
X
X
Perform a cabin pressure test. Inspect the former joints for cracks and damage.
X
X
Reinstall access panels.
X
X
Inspect engine mounts for cracks.
Page Date: 30. March 2012
Maintenance Manual Extra 500 Time Limits and Maintenance Checks
X
X
Remove access panels from horizontal stabilizer and wing root avionics compartment.
X
X
Inspect wings for dents, cracks and delaminations.
X
X
Inspect wing ventilation holes for obstruction.
Description
Inspector
Mechanic
Serial No.:
Inspect wing spar main bolts and fittings for poor general condition, distortion, and insecurity of attachment.
1
Extract wing spar main bolts in sequence (refer to Chapter 5710-00). Inspect bolt shanks for cracks, wear, corrosion and insecurity. Install each bolt before extracting the next one.
2
3
Date:
1000
Flight Hours
100
as specified
Wing Assembly
X
X
Inspect inside wing structure in the area of access panels for deterioration, delamination, distortion and poor general condition.
X
X
Inspect wing tanks and lines for leaks, poor condition and evidence of fungus. If contamination with fungus is detected, contact the manufacturer.
X
X
Inspect tank bonding for improper installation and poor condition.
X
Drain wing fuel tanks.
X
Inspect fuel transmitter and electrical connectors for uncleanliness, poor condition and insecurity.
X
X
Clean motive flow filters.
X
X
Inspect motive flow pumps for insecurity of attachment and poor condition. Inspect electrical connectors for uncleanliness, poor condition and insecurity.
X
X
Inspect fuel transfer system lines for leaks and poor condition.
X
X
Inspect fuel filler caps and flapper valves for poor condition.
X
X
Inspect fuel tank breather and vent system for poor condition and insecurity. Function test of flaps only with upper door closed.
CAUTION
1
Annually
2
Every 5000 flight hours
3
Together with engine fuel system maintenance
Page 24
05
Page Date: 30. March 2012
X
X
Inspect landing flaps and attachment for dents, cracks, delaminations and improper operation.
X
X
Inspect flap ventilation holes for obstruction.
X
X
Inspect landing flaps gear drive, flap position transmitter and flap control switch for damage and improper operation.
X
X
Check and adjust flap guidance, flap actuation system, flap limit switches and flap asymmetry senders. Refer to Chapter 27-50-00.
X
X
Lubricate flap track mechanism as per Chapter 12-20-04 Lubrication Chart.
X
X
Inspect navigation lights, recognition lights, wingtip strobe lights for broken lenses, insecurity, improper wiring and operation.
X
X
Inspect electrical leads, radio antenna leads, pneumatic lines and attachment for improper routing, deterioration and incorrect installation.
X
X
Inspect pitot tubes and static pressure ports for poor condition, obstruction and damages. Inspect pitot and static heat for poor condition and improper operation.
X
X
Inspect pitot and static lines and attaching for improper routing, deterioration, poor condition and leaks. Drain pitot and static lines.
X
X
Inspect stall warning system for poor condition and insecurity of installation. Perform operational check including stall warn heat.
X
X
Inspect de-icer system (wing and control surfaces) for poor condition and improper operation.
Description
Inspector
Serial No.:
Mechanic
1
Date:
1000
1
Flight Hours
100
as specified
Maintenance Manual Extra 500 Time Limits and Maintenance Checks
05
Page 25
as specified in Chapter 12-20-04 Lubrication Chart
Page Date: 30. March 2012
Maintenance Manual Extra 500 Time Limits and Maintenance Checks
X
X
Remove access panels on horizontal stabilizer, tailcone, wing center fairing and wing root avionic bay.
X
X
Inspect control and stabilizer ventilation holes for obstruction.
X
X
Inspect stabilizer surfaces for dents, cracks, nicks and delaminations.
X
X
Inspect rudder for insecurity of attachment, free movement, dents, cracks and delaminations.
X
X
Inspect rudder hinges, attachment and bearings, stops, centering spring for cracks, excessive wear, insecurity and improper operation.
X
X
Inspect elevator surface for dents, cracks, nicks and delaminations.
X
X
Inspect elevator hinges, elevator trim tab hinges, attachment and bearing for poor condition, cracks, excessive wear, insecurity and improper operation.
Description
Inspector
Serial No.:
Inspect horizontal stabilizer main bolts for poor general condition, distortion and insecure attachment.
1
Extract horizontal stabilizer main bolts in sequence. Inspect bolt shanks for cracks, wear, corrosion and insecurity. Install each bolt before extracting the next one.
2
X
X
Check elevator trim system for improper operation and rigging.
X
X
Inspect elevator balance weight for looseness and poor condition.
X
X
Inspect aileron, rudder, elevator and elevator trim cable systems including turnbuckles, sleeves, fair leads, pulleys, cable retracting springs and push pull rods per FAA-AC1 43.13-1B for lack of safetying, damage and improper operation.
X
X
Check all cable tensions using a tensiometer.
X
Inspect rudder control torque tubes, bottom panel, shelf, linkage, control cable, sprocket wheel and interconnection for poor condition, distortion and insecurity. Inspect control cable connections for poor condition, chafing, distortion and insecurity.
X
1
Annually
2
Every 5000 flight hours
Page 26
Mechanic
Date:
1000
Flight Hours
100
as specified
Control Systems and Surfaces
05
Page Date: 30. March 2012
Description
Inspector
Serial No.:
05
Page 27
Examine control springs for mechanical damage, corrosion, and wear at the clevisses. Refer to Chapter 27-00-10.
1
Lubricate control system components as per Chapter 12-20-04 Lubrication Chart
X X
1
Date:
Mechanic
1000
Flight Hours
100
as specified
Maintenance Manual Extra 500 Time Limits and Maintenance Checks
X
Reinstall access panels.
Annually
Page Date: 30. March 2012
Maintenance Manual Extra 500 Time Limits and Maintenance Checks
DANGER
Serial No.: Description
Inspector
Date:
Mechanic
1000
Flight Hours
100
as specified
Landing Gear
Nose gear and main gear extends and retracts under high pressure. Operation of the landing gear can cause death or injuries in its working area ! Before beginning any work in the landing gear working area, pull OFF the electric circuit breaker located on the left side panel and marked GEAR CTRL. In case of intentional gear operation by switch or circuit breaker handling make sure, that neither a person nor material is in the landing gear working area.
NOTE
With the aircraft being airborne or jacked with retracted landing gear and battery switch OFF, the hot bus feeds an AUX circuit, which supplies the directional valves with electrical power to keep the landing gear in the up-position. The AUX circuit is protected by the GEAR AUX 1 (left side panel) and GEAR AUX 2 (E-box, engine compartment) circuit breakers. However, the nose gear and main gear will slowly extend due to valve oil leakage, if the hydraulic pump is not being activated temporarily to maintain hydraulic pressure. If retracted landing gear position is intended, turn BATT switch ON and push circuit breakers GEAR CTRL (left side panel) to the ON position, while the landing gear switch (left main panel) is in the UP position. If the aircraft is jacked with landing gear retracted and external power not connected, the battery will be discharged within approx. 2 days.
Page 28
X
X
Place the airplane on jacks.
X
X
Inspect the main gear struts for poor condition, cracks, bending, distortion and insecurity.
X
X
Inspect the main gear and nose gear shock absorber for oilleakage and scoring.
X
X
Check the main gear struts for maximum extension and overcentering of the radius struts.
X
X
Inspect the main gear bolts, bearings for lack of safety and poor condition, cracks, excessive wear and insecurity.
X
X
Clean and lubricate main gear bearings. Use AEROSHELL 22C spec. MIL-G-81322.
X
X
Inspect the web plate at the main landing gear frame for cracks.
X
X
Check the parallel strut and axle bar for vertical clearance.
X
X
Inspect all actuator brackets for cracks.
05
Page Date: 30. March 2012
X
Inspect main gear struts attachments for poor condition and insecurity.
X
X
Inspect track rods and attaching for poor condition, distortion and insecurity.
X
X
Inspect rear preloaded axle stop for poor condition.
X
X
Check the nitrogen inflation of the main gear-shock absorber (57 bar/827 psi ).
X
X
Inspect all wiring for poor condition, chafing and insecurity.
X
X
Inspect nose gear struts, trunnion pins and attachments for poor condition and insecurity.
X
X
Inspect the nose gear trunnion for poor condition, cracks and distortion.
X
X
Check the nose gear strut for maximum extension and overcenter of the radius strut.
X
X
Check the nitrogen inflation of the nose gear shock absorber (15 bar/218 psi ).
X
X
Inspect the nose wheel steering arm and its thrust bearing for poor condition and any damage.
X
X
Clean and lubricate nose gear bearings. Use AEROSHELL 22C spec. MIL-G-81322.
X
X
Inspect the fixing nose of the steering arm guide block for poor condition, cracks and bending.
X
X
Inspect the spring device assembly of the nose wheel steering and its attaching for looseness and any damage.
X
X
Inspect the nose wheel steering cables for wear and any damage.
X
X
Inspect shimmy damper and attaching for poor condition.
X
X
Inspect the gas springs of the nose gear strut and attaching for poor condition and insecurity. Perform Test Procedure as per Chapter 32-30-25.
X
X
Inspect all wiring for poor condition, chafing and insecurity.
Inspector
X
Description
Mechanic
Serial No.:
05
Page 29
Remove hydraulic sump. Clean filter and change hydraulic fluid (see Chapter 32-30-11).
1
X
1
Date:
1000
Flight Hours
100
as specified
Maintenance Manual Extra 500 Time Limits and Maintenance Checks
X
Inspect the hydraulic lines for leakage, poor condition, chafing, bulges and insecurity. Replace hoses and fittings as required.
Every 5 years.
Page Date: 30. March 2012
Serial No.:
X
X
Inspect the power pack and the distributor block for leakage, poor condition and insecurity.
X
X
Check the hydraulic fluid level of the hydraulic power pack (see Chapter 32-30-11) Refill as required.
X
X
Inspect the main and nose gear doors, door hinges and levers for cracks, distortion, insecurity and freedom of movement.
X
X
Inspect the main and nose gear door actuation mechanism for poor condition, deformation, excessive free play and excessive wear.
X
X
Inspect the hydraulic actuators and attachment for poor condition and insecurity.
X
X
Check the main gear-interlocking actuator for locking.
X
X
Loosen the door hinges. Fasten the door by means of tapes.
DANGER
Description
Inspector
Mechanic
Date:
1000
Flight Hours
100
as specified
Maintenance Manual Extra 500 Time Limits and Maintenance Checks
Nose gear and main gear extends and retracts under high pressure. Operation of the landing gear can cause death or injuries in its working area ! In case of intentional gear operation by switch or circuit breaker handling make sure, that neither a person nor material is located in the landing gear working area. Before beginning any work in the landing gear operating area, esp. any adjustment after performing test procedures, pull OFF the electric circuit breaker located on the left side panel and marked GEAR CTRL.
X
X
X
Lift the aircraft on jacks. Operate the landing gear (see Ch. 32-00-00 Operation). Inspect the hydraulic hoses and track rods for freedom of movement, chafing and distortion in extended and retracted position.
X
Perform gear up procedure (refer to Ch. 32-00-00 Operation). Inspect the main and nose gear door actuation mechanism for incorrect adjustment in the closed position. In case of doors closing with too much play or tension, adjust length of respective push rods (refer to Ch. 32-10-20/32-20-20). Perform test procedures in accordance with Ch. 32-00-00 and 32-30-25 Test Procedures.
1
1
X
X
Clean the position switches; inspect for poor operation, insecure seat and incorrect adjustment.
X
X
Inspect position switch wiring and harness for poor condition, chafing, any damage and insecurity.
Annually
Page 30
05
Page Date: 30. March 2012
X
X
Check the gear position lights on the panel for operation.
X
X
Reinstall the door hinges.
X
X
Clean and lubricate landing gear according to Chapter 12-2004 Lubrication Chart.
X
Replace all NMB M81935/1–6 rod ends (i.e. piston rod ends of the short main hydraulic cylinders as well as the track rod ends, refer to Figure 32-8 in Chapter 32-30-00).
Description
Page Date: 30. March 2012
Inspector
Serial No.:
Mechanic
Date:
1000
Flight Hours
100
as specified
Maintenance Manual Extra 500 Time Limits and Maintenance Checks
05
Page 31
Maintenance Manual Extra 500 Time Limits and Maintenance Checks
NOTE
Serial No.: Description
Inspector
Date:
Mechanic
1000
Flight Hours
100
as specified
Wheels and Brakes
Refer to on-aircraft inspections presented in the latest edition of Cleveland Technician’s Service Guide (LOAP 34) and Component Maintenance Manual (LOAP 35) for wheel, tire and break inspections.
DANGER
Nose gear and main gear extends and retracts under high pressure. Operation of the landing gear can cause death or injuries in its working area ! Before beginning any work in the landing gear working area, pull OFF the electric circuit breaker located on the left side panel and marked GEAR CTRL. In case of intentional gear operation by switch or circuit breaker handling make sure, that neither a person nor material is in the landing gear working area.
NOTE
With the aircraft being airborne or jacked with retracted landing gear and battery switch OFF, the hot bus feeds an AUX circuit, which supplies the directional valves with electrical power to keep the landing gear in the up-position. The AUX circuit is protected by the GEAR AUX 1 (left side panel) and GEAR AUX 2 (E-box, engine compartment) circuit breakers. However, the nose gear and main gear will slowly extend due to valve oil leakage, if the hydraulic pump is not being activated temporarily to maintain hydraulic pressure. If retracted landing gear position is intended, turn battery switch ON and push circuit breaker GEAR CTRL (left side panel) to the ON position, while the landing gear switch (left main panel) is in the UP position. If the aircraft is jacked with landing gear retracted and external power not connected, the battery will be discharged within approx. 2 days.
Page 32
X
X
Place the airplane on jacks.
X
X
Check the brake fluid level.
X
X
Inspect the brake assemblies for poor general condition.
X
X
Inspect the brakes and the master cylinder for leakage.
X
X
Inspect the brake lines and fittings for leakage and the hoses for bulges. Replace hoses as required.
X
X
Inspect the parking brake valve for poor condition and improper operation.
X
X
Inspect the brakes for corrosion, cracks and visible damage. Inspect inlet fitting bosses and anchor bolt lugs for cracks.
05
Page Date: 30. March 2012
Serial No.: Description
X
X
Inspect fit of brake cylinder anchor bolts in torque plate bushings for sloppiness. Excessive movement is cause for removal and detailed inspection.
X
X
Inspect the lining for wear ( min. thickness 2.54 mm/0.1 inch. ). Replace if required.
X
X
Lubricate the brake guide pins using silicone - base lubricant.
X
X
Inspect the wheels for corrosion, cracks, loosen or broken bolts and any damage.
X
X
Inspect the wheel nuts for improper installation and insecurity.
X
X
Check the wheel bearing clearance and wheels for free rotation.
X
X
Inspect the brake disc for rust, grooves, coning, cracks, wear and visible damage. Check disc thickness (min. 8.25 mm/0.325inch.). Replace if required. (Refer to Cleveland Technician’s Service Guide (LOAP 34) and Component Maintenance Manual (LOAP 35).
X
X
Inspect the brakes for improper adjustment.
X
X
Remove the wheels and wheel bearings. Inspect wheel bearings for excessive wear or damage. Replace on condition.
X
X
Inspect the snap rings for distortion and wear. Inspect grease for contamination and solidification.
X
X
Repack the bearings with AEROSHELL 22C (per MIL-G81322).
X
X
Visually inspect the tires for wear, cuts, flat spots, and tread or side wall damage. For tire changing refer to Cleveland Technician’s Service Guide (LOAP 34) and Component Maintenance Manual (LOAP 35).
X
X
Reinstall the wheels and safety.
X
X
Check tire inflation pressure. Main wheels 5.1 bar/74 psi ; nose wheel 3.5 bar/51 psi.
X
X
Inspect the wheels for improper alignment.
X
X
Lubricate as per Chapter 12-20-04 Lubrication Chart.
CAUTION X
X
Inspector
Date:
Mechanic
1000
Flight Hours
100
as specified
Maintenance Manual Extra 500 Time Limits and Maintenance Checks
Do not remove jacks before the landing gear is down and locked and the anti - retraction system has been checked. Operate the ON GROUND switch at nose gear strut. Check anti-retraction system by gear lever operation. Ensure that all gears are extended and locked.
CAUTION X
X
Remove the jacks.
Page Date: 30. March 2012
05
Page 33
Maintenance Manual Extra 500 Time Limits and Maintenance Checks
1
Serial No.:
1
X
X
Perform Flight Test.
1
X
X
Perform checks given for special equipment installed.
1
X
X
Reinstall upper and lower cowling, panels and doors as appropriate.
1
X
X
Aircraft conforms to specification of respective Authority.
1
X
X
All required Airworthiness Directives complied with.
1
X
X
All EXTRA mandatory Service Bulletins complied with.
1
X
X
All vendor Service Bulletins and Service Letters complied with.
1
X
X
Check for proper Flight Manual.
1
X
X
Aircraft papers in order.
Description
Inspector
Mechanic
Date:
1000
Flight Hours
100
as specified
Completion
As required.
Page 34
05
Page Date: 30. March 2012
Maintenance Manual Extra 500 Time Limits and Maintenance Checks
05-30-00
FLIGHTLINE INSPECTIONS
05-30-01
General These checks include pre-flight and post-flight checks. When the aircraft is in operation, these checks have to be performed daily.
05-30-02
Pre - Flight Check This check must be carried out before the first flight of the day and serves as a guideline for the pilot to check the general condition of the aircraft and the engine. The pre-flight check is fundamental for the flight safety and has to be performed thoroughly in all details. The schedule for the pre-flight check is in the EXTRA 500 Pilot's Operating Handbook, Section 4.
05-30-03
Post - Flight Check This post-flight inspection has to be performed after the last flight of the day and consists of some visual checks. The post-flight inspection should include all steps of the pre-flight check. Additional measures: 1 Re-fuelling of the aircraft (refer to Chapter 12-10). 2 Reviewing of the entries in the log book for open discrepancies and correct entries of the landings and the flight hours. 3 If necessary, mooring of the aircraft (refer to Chapter 10-20).
Page Date: 30. March 2012
05
Page 35
Maintenance Manual Extra 500 Time Limits and Maintenance Checks
05-50-00
UNSCHEDULED MAINTENANCE CHECKS
05-50-01
General Unscheduled checks are exceptional and have to be performed only after abnormal events which are unusual at normal operating conditions and which could possibly have caused damage to the aircraft or impaired the airworthiness. The 50 hours - Inspection for new, repaired or overhold engines is categorized as an unscheduled check, since it has to be performed only once after the first 50 h of operation of the engine.
05-50-02
50 Hours – Inspection of Engine If a new, repaired or overhauled engine is installed, perform a 50 hours – inspection following the instructions of Rolls Royce 250-B17F Series Operation and Maintenance Manual (LOAP 1).
05-50-03
Hard Landing After an extremely hard landing or other unusual loads on the landing gear, a thorough check of the respective components and their attachment points is necessary. Even, when there are no obvious signs of damage, a visual check has to be performed. The check has to be carried out as follows: 1 The landing gear attachment area has to be examined for defects (e.g. cracks) using a mirror and a torch, check the outer laminate for delamination (press onto the laminate with your thumb). Furthermore, the struts have to be checked for deformations and cracks.
IMPORTANT
Examine wheel track The tires have to be checked for cuts in the side wall and the brake discs for impacts. 2 In the area of the nose gear, the belly of the fuselage should be checked for cracks. Delaminations in the bonding area of the fire wall frame may also occur. The condition (cracks, deformations) of the complete nose gear has to be checked.
Page 36
05
Page Date: 30. March 2012
Maintenance Manual Extra 500 Time Limits and Maintenance Checks
3 After hard landings with damage observed, the attachment bolts of the landing gear have to be examined for cracks (magnaflux or x-ray; dye-check is not suitable in this case) or must be replaced. 4 In addition to the landing gear, all control surfaces (hinges, mass balance) and the complete engine mount (engine truss, attachment points of the engine truss at the fire-wall, shock mounts) have to be checked. 5 In addition, the wing structure has to be checked the main spar area plus the shear force fittings and particularly the spar connection. Also the wing-to-fuselage connection bolts have to be examined. 6 The same inspection has to be performed on the elevator. IMPORTANT
If there are indications that structural parts are damaged, the manufacturer has to be consulted for possible and suitable repair methods. 7 If any damage of landing gear or aircraft structure is detected, perform an engine special inspection. Refer to the applicable chapter of Rolls Royce 250B17F Series Operation and Maintenance Manual (LOAP 1).
05-50-04
Engine Fire After an engine fire, all hoses and cables have to be checked and if necessary replaced. A check of the engine has to be carried out according to the procedures in the applicable chapter Rolls Royce 250-B17F Series Operation and Maintenance Manual (LOAP 1). If parts of the airframe or the engine cowlings are suspected of being damaged by high temperatures (sign of blister on the protective paint), the manufacturer has to be consulted for assistance in damage evaluation before the aircraft is returned into service.
05-50-05
Propeller Strike, Sudden Stoppage and Violent Engine Stoppage Refer to applicable Maintenance Instructions of MT-Propeller (LOAP 3-5) and Rolls Royce (LOAP 1).
05-50-06
Lightning Strike Contact the manufacturer.
Page Date: 30. March 2012
05
Page 37
Maintenance Manual Extra 500 Time Limits and Maintenance Checks
05-50-07
Engine Overspeed Refer to applicable Maintenance Instructions of MT-Propeller (LOAP 3-5) and Rolls Royce (LOAP 1).
Page 38
05
Page Date: 30. March 2012
Maintenance Manual EXTRA 500
Chapter 06 Dimensions and Areas
Page Date: 30. March 2012
06
Page 1
Maintenance Manual EXTRA 500
Table of Contents 06-10-00
MAIN DATA..................................................................................................... 3
06-10-01
Main Dimensions .............................................................................................. 3
06-10-02
Wing................................................................................................................... 3
06-10-03
Horizontal Tail .................................................................................................. 3
06-10-04
Elevator.............................................................................................................. 3
06-10-05
Vertical Tail....................................................................................................... 4
06-10-06
Rudder ............................................................................................................... 4
06-10-07
Ailerons.............................................................................................................. 4
06-10-08
Settings and Deflections ................................................................................... 4
Page 2
06
Page Date: 30. March 2012
Maintenance Manual EXTRA 500
06-10-00
MAIN DATA
06-10-01
Main Dimensions Length:
10.13 m
(33.23 ft)
Height:
3.37 m
(11.06 ft)
11.60 m
(38.06 ft)
Wheelbase:
2.65 m
(8.69 ft)
Wheel-track:
2.20 m
(7.22 ft)
2,130 kg
(4,696 lbs.)
Span:
11.60 m
(38.06 ft)
Area:
2
Span:
MTOW:
06-10-02
Wing 14.265 m (153.55 sq.ft.)
Airfoil: Root: NLF 22 - .05, 16.5 % Tip:
06-10-03
06-10-04
NLF 23 - .05, 13 %
Horizontal Tail Span:
3.80 m (12.47 ft)
Airfoil:
NACA 0012
Elevator Total projected nested area:
Page Date: 30. March 2012
1.13 m2 (12.16 sq.ft.)
06
Page 3
Maintenance Manual EXTRA 500
06-10-05
Vertical Tail Airfoil: Root: NACA 2412 Tip:
06-10-06
NACA 0012
Rudder Total projected nested area:
06-10-07
Ailerons Total projected nested area:
06-10-08
0.633 m2 (6.81 sq.ft.)
0.617 m2 (6.64 sq.ft.)
Settings and Deflections Flaps Take-off: Landing: Ailerons:
27° up, tolerance + 0°/-2° 19° down, tolerance + 2°/-0°
Rudder:
25° left/right, tolerance + 0°/-2°
Elevator:
33° up, tolerance + 0°/-2° 18° down, tolerance + 2°/-0°
Trim tab (at 0° elevator deflection):
Page 4
06
15°, tolerance ± 3° 30°, tolerance + 1°/-2°
20° up (nose down), tolerance ± 2° 30° down (nose up), tolerance ± 2°
Page Date: 30. March 2012
Maintenance Manual EXTRA 500
Chapter 07 Lifting and Shoring
Page Date: 30. March 2012
07
Page 1
Maintenance Manual EXTRA 500
Table of Contents 07-10-00
Page 2
07
JACKING.......................................................................................................... 3
Page Date: 30. March 2012
Maintenance Manual EXTRA 500
07-10-00
JACKING Jacking of the EXTRA 500 will be necessary for tire replacement, landing gear operation on ground or if either the main landing gear or the nose gear has to be removed or installed. Perform the following steps, if it is necessary to lift the aircraft off the ground:
CAUTION
Do not raise the aircraft on jacks out of doors when wind velocity is above 10 MPH. Jacks should be placed on hard and even surface.
1 Install jack points to the tie-down eyebolt receptacles in the middle of each wing and at the bottom of the fuselage, between nose gear and main gear (thread-diameter M8). Make sure jack points are fully screwed in. 2 Use standard aircraft jacks at both wing hoist points and behind the nose gear (tie-down eyebolt receptacles). While holding jack point in place, raise jack up to firmly contact with jack point.
CAUTION
When raising the aircraft, apply pressure on all jacks simultaneously and evenly to keep the aircraft leveled as it is raised. Otherwise the aircraft could slip from the jacks!
3 Raise the aircraft, keeping wings as level as possible. 4 Secure safety locks on each jack. Check landing gear three greens before lowering the aircraft. CAUTION CAUTION
When lowering the aircraft, bleed off pressure on all jacks simultaneously and evenly to keep the aircraft leveled as it is lowered.
Page Date: 30. March 2012
07
Page 3
Maintenance Manual EXTRA 500
Intentionally left blank
Page 4
07
Page Date: 30. March 2012
Maintenance Manual EXTRA 500
Chapter 08 Leveling and Weighing
Page Date: 30. March 2012
08
Page 1
Maintenance Manual EXTRA 500
Table of Contents
08-10-00
WEIGHING AND BALANCING ................................................................... 3
08-20-00
LEVELING ....................................................................................................... 4
08-20-01
Longitudinal Leveling ...................................................................................... 4
08-20-02
Lateral Leveling................................................................................................ 4
Page 2
08
Page Date: 30. March 2012
Maintenance Manual EXTRA 500
08-10-00
WEIGHING AND BALANCING For detailed weighing procedure and related forms refer to Section 6 of the EXTRA 500 Pilot’s Operating Handbook.
Page Date: 30. March 2012
08
Page 3
Maintenance Manual EXTRA 500
08-20-00
LEVELING
08-20-01
Longitudinal Leveling Place a spirit level on the upper edge of the lower cabin door in closed position for longitudinal leveling. Check with indication of spirit level installed in the door. Level the aircraft by increasing or decreasing air pressure in the nose wheel tire.
08-20-02
Lateral Leveling Place a spirit level on the inner front seat rails for lateral leveling. Level the aircraft by inflating or deflating the main wheel tires
Page 4
08
Page Date: 30. March 2012
Maintenance Manual EXTRA 500
Chapter 09 Towing and Taxiing
Page Date: 30. March 2012
09
Page 1
Maintenance Manual EXTRA 500
Table of Contents
09-00-00
GENERAL ........................................................................................................ 3
09-10-00
TOWING ........................................................................................................... 4
09-20-00
TAXIING........................................................................................................... 5
Page 2
09
Page Date: 30. March 2012
Maintenance Manual EXTRA 500
09-00-00
GENERAL This chapter describes the procedures and precautions necessary for proper ground handling of the EXTRA 500. Minimum turning radius is 20.8 m [68.2 ft].
CAUTION
Exercise care not to turn the nose wheel past its normal swivel angle of 30° to each side of center. Exceeding the turn limits will cause structural damage.
Page Date: 30. March 2012
09
Page 3
Maintenance Manual EXTRA 500
09-10-00 DANGER
TOWING When preparing for ground handling operation ensure that the battery switch is OFF. Use a tow-bar to move the aircraft on ground. The tow-bar attaches to the nose gear fork, just above the nose wheel.
CAUTION
Moving the aircraft with a vehicle, especially when pushing in backward direction or moving on rough ground, may cause substantial damage to the nose gear strut. On smooth ground surfaces the aircraft may be towed carefully by coupling a vehicle to the tow-bar, but only in forward direction at low driving speed. Do not handle the aircraft at the end of the propeller blades.
CAUTION If no tow-bar is available, or when assistance in moving the aircraft is required, push the aircraft by hand on the inboard portion of the propeller blades, adjacent to the propeller hub and/or doorframe.
Page 4
09
Page Date: 30. March 2012
Maintenance Manual EXTRA 500
09-20-00
TAXIING Before attempting to warm up or taxi the aircraft, ground procedures should be checked by qualified pilots or other responsible personnel. All taxiing should be done at slow speed, and the controls should be set to appropriate positions in order to minimize the effects of gusty wind.
CAUTION
Taxiing over loose gravel or cinders should be done at low engine speed to minimize damage to the airframe surfaces due to stone impact. To taxi the aircraft, proceed as follows:
1 Start and warm up engine in accordance with the applicable paragraphs in Section 4 of the EXTRA 500 Pilot's Operating Handbook. Operate only with the engine in GROUND IDLE. CAUTION 2 Taxi forward a few feet and check brake effectiveness. 3 While taxiing, make shallow turns to test nose gear steering.
Page Date: 30. March 2012
09
Page 5
Maintenance Manual and Illustrated Parts Catalogue Extra EA-400 Towing & Taxiing
Left blank intentionally
Page 6
09
Page Date: 30. March 2012
Maintenance Manual EXTRA 500
Chapter 10 Parking, Mooring, Storage and Return to Service
Page Date: 30. March 2012
10
Page 1
Maintenance Manual EXTRA 500
Table of Contents
10-00-00
GENERAL ........................................................................................................ 3
10-10-00
PARKING/STORAGE..................................................................................... 4
10-10-01
Short - term Parking ........................................................................................ 4
10-10-02
Long - term Parking ......................................................................................... 4
10-10-03
Outdoor Storage ............................................................................................... 4 Aircraft................................................................................................................ 5 Engine ................................................................................................................. 5
10-20-00
MOORING........................................................................................................ 6
10-30-00
RETURN TO SERVICE.................................................................................. 7
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10-00-00
GENERAL This chapter provides the procedures recommended to park or to moor the EXTRA 500 so that the likelihood of ground damage is minimized. Additionally, it describes precautions for protecting the engine during periods of storage.
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10-10-00
PARKING/STORAGE When parking the aircraft, head the nose in the wind.
10-10-01
Short - term Parking The parking brakes may be used for short-term parking. To set the parking brakes at both main wheels, operate as follows: 1 Press both rudder pedals from either pilot's or copilot's seat. 2 Pull the parking brake control on the middle console. To release the parking brakes, push the parking brake control forward.
CAUTION
Do not set the parking brakes, when they are overheated or during cold weather conditions when moisture and slush accumulation could freeze in the brake mechanism. When using the parking brakes for an extended period of time an air temperature rise could cause the hydraulic fluid to expand, which may result in brake system damage and / or difficulties in releasing the brakes. Additionally place wheel chocks fore and aft both main wheels to prevent movement of the aircraft.
10-10-02
Long - term Parking For parking the aircraft over a longer period of time, proper mooring and tiedown is recommended. Refer to Chapter 10-20-00.
10-10-03
Outdoor Storage Outdoor storage requires adequate mooring and tie-down facilities. Refer to Chapter 10-20-00 for mooring instructions. The following precautionary measures are recommended for keeping the aircraft serviceable:
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Aircraft 1 Keep the fuel tanks filled at least one-half full to minimize moisture condensation. 2 Keep the battery fully charged. 3 Install protective covers over pitot tube, engine cowling openings, canopy, etc. 4 Maintain a good wax finish on all exterior surfaces. 5 Check tire pressure each 30 days.
Engine Refer to the Rolls Royce 250-B17F Series Operation and Maintenance Manual (LOAP 1).
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10-20-00
MOORING Careful tie-down proceeding is the best precaution against damage to the aircraft caused by gusty or strong winds. To tie-down the aircraft securely, carry out the following steps (Also refer to Subject 10-10-03): 1 Head the aircraft into the wind. 2 Place chocks fore and aft each main wheel. 3 Install tie-down eyebolts to the respective receptacles in the middle of each wing and at the bottom of the fuselage, between nose gear and main gear. 4 Drive stakes into the ground below each wing tip and next to each main wheel. 5 Tie sufficiently strong ropes or chains to the wing and bottom tie-down eyes and anchor to the ground stakes. Allow a little slack in each tie-down rope.
NOTE
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During severe weather conditions and strong winds, hangar the aircraft for maximum protection.
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10-30-00
RETURN TO SERVICE If the aircraft has been stored for an extended period of time, it is advisable to perform a 50-hour periodic inspection. Refer to Chapter 05-20 Scheduled Maintenance Checks. To return the engine to service refer to the Rolls Royce 250-B17F Series Operation and Maintenance Manual (LOAP 1).
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Chapter 11 Placards and Markings
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Table of Contents
11-00-00
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11
GENERAL ........................................................................................................ 3
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11-00-00 NOTE
GENERAL All placards should be inspected for proper location, readability and security during maintenance actions. When an airplane has been painted inspect all placards to assure that they are not obscured by paint. The required placards installed on this airplane contain operating limitations and instructions. All placards and their locations, both interior and exterior, are listed in Section 2 of the EXTRA 500 Pilot's Operating Handbook.
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Chapter 12 Servicing
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Table of Contents 12-00-00
GENERAL ........................................................................................................ 3
12-10-00
REPLENISHING.............................................................................................. 4
12-10-01
Refueling............................................................................................................ 4 Fuel Grade .......................................................................................................... 4 Fuel System Capacities....................................................................................... 4
12-10-02
Draining ............................................................................................................. 5
12-10-03
Fuel Drains ........................................................................................................ 5
12-10-04
Replenishment of Engine Oil ........................................................................... 6 Oil Grades........................................................................................................... 6 Oil System Capacities......................................................................................... 6
12-10-05
Oil Change......................................................................................................... 7
12-10-06
Replenishment of Brake Fluid......................................................................... 7
12-10-07
Brake Bleeding Procedure ............................................................................... 7
12-10-08
Tire Inflation ..................................................................................................... 8
12-10-09
Main Gear Shock Absorber Oil Draining/Refilling ...................................... 9
12-20-00
SCHEDULED SERVICING.......................................................................... 10
12-20-01
Exterior Cleaning ........................................................................................... 10
12-20-02
Interior Cleaning ............................................................................................ 11
12-20-03
Engine Cleaning .............................................................................................. 11
12-20-04
Lubrication Chart........................................................................................... 12
12-30-00
UNSCHEDULED SERVICING .................................................................... 14
12-30-01
Removal of Snow and Ice ............................................................................... 14
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12-00-00
GENERAL This chapter describes the procedures and precautions necessary for proper servicing of the EXTRA 500. The specified intervals (refer to Chapter 5) are considered adequate to meet average requirements under normal operating conditions. It is advisable, however, to shorten service and maintenance intervals when operating under abnormal conditions, such as extreme temperature ranges, dusty atmospheric conditions, high humidity and moisture, unimproved airport facilities, or unusual operating requirements.
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12-10-00
REPLENISHING The replenishing procedures contained in this section provide the proper methods for replenishing consumed fuel, engine oil and brake fluid. Also included are methods for inflation of tires.
12-10-01
Refueling Refueling is accomplished by pumping or pouring fuel into the main and auxiliary compartment of each wing tank through their respective filler caps. When fueling the aircraft, the following safety precautions must be followed:
DANGER
If the fuel system has been completely drained, the fuel system bleeding procedure must be performed (see Chapter 28-20-00). If the fuel system is not free of air, an engine flame out may be the result. Never refuel the aircraft with the engine running. Always ensure that the aircraft is grounded before refueling. Ensure that no one is smoking within 100 feet of the aircraft. Ensure that all aircraft electrical systems are deenergized while refueling. Ensure that no aircraft radar or powerful transmitters are operating within 100 feet of the aircraft during fueling. If fuel is spilled, ensure that the area of spillage is thoroughly flushed with water and that all residual fuel and vapor have dissipate or neutralized prior to starting the aircraft engine.
IMPORTANT
To prevent lateral fuel unbalance, make sure the left and right collector and main compartments are full before filling any auxiliary compartment. Maximum permissible fuel unbalance in flight is 106 liter (one auxiliary tank). After refueling, it has to be ensured that all four fuel tank caps are securely installed prior to flight. Wait at least five minutes after refueling for moisture and sediment to settle before draining and checking the fuel drain valves.
Fuel Grade For fuel grades (also temperature dependent) refer to Section 2 of the EXTRA 500 Pilot’s Operating Handbook.
Fuel System Capacities For the fuel system capacities refer to the Limitation Section of the EXTRA 500 Pilot’s Operating Handbook.
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12-10-02
Draining
DANGER
During the aircraft defueling observe the safety precautions specified in Section 12-10-01.
DANGER
Do not drain the fuel system when the engine or the exhaust is hot or while the wind is strong.
Even after completely draining the fuel system fuel may rest inside the WARNING engine and in the fuel lines downstream the check valves; which are located next to the fuel pumps. This fuel may be pressurized. The fuel system can be completely or partly drained. When fuel system shall be completely drained ensure fuel selector valve is set to BOTH. Drain at all fuel drains (for locations refer to Subject 12-10-03). When fuel system shall be partly drained ensure fuel selector valve is set to OFF. Then the individual fuel compartments and the area downstream the fuel selector valve can be drained over their respective drain valves. Consider that the collector and main compartments are connected by a check valve. So draining the collector compartment will also reduce fuel quantity in the main compartment. A quantity of fuel must be drained prior to the first flight of the day and at least five min. after refueling to inspect for water and/or contamination. Continue draining until free of water or contamination. IMPORTANT
12-10-03
After draining, make sure the fuel drain valve is returned to the closed position and the valve is not leaking.
Fuel Drains The EXTRA 500 is equipped with 12 fuel drains on the locations as given in the following table: Designation
Location
Inner and outer auxiliary compartment Each outboard wing drains Inner and outer main compartment drains
Each center wing
Collector compartment drains
Fuel sump next to each root rib
Lowest point drain
Down stream of the fuel selector valve, accessible by an opening in the forward keel beam access panel.
Fuel filter drain
Next to the fuel filter, accessible by an opening in the fuel filter access panel.
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12-10-04
Replenishment of Engine Oil The engine oil replenishment is accomplishment by pouring oil into the oil filler spout. The oil quantity can be conveniently checked by use of the dipstick attached to the oil filler spout cap. If larger quantity of oil has to be filled in (e.g. if oil system has been partly drained), follow the replenishment section of the Oil Change procedure of Subject 12-10-05, which incorporates engine motoring (refer to Chapter 80-1000, Motoring and to the EXTRA 500 Pilot’s Operating Handbook).
Oil Grades For oil grades (also temperature dependent) refer to Section 2 of the EXTRA 500 Pilot’s Operating Handbook.
Oil System Capacities For the oil system capacity refer to Section 1 of the EXTRA 500 Pilot’s Operating Handbook.
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12-10-05
Oil Change The engine oil must in accordance with the Rolls Royce 250-B17F Series Operation and Maintenance Manual (LOAP 1). Follow the instructions in the Oil Change paragraph of this Manual observing the following additions: 1 Remove engine cowlings of the aircraft (see Chapter 71-10-02). 2 Follow the respective drain procedures in Chapter 79. 3 For motoring and starting procedures refer to Chapter 80-10-00, Motoring and to the EXTRA 500 Pilot’s Operating Handbook. 4 Check oil level once more after motoring the engine. 5 Refill engine oil as necessary before starting the engine. 6 Reinstall cowlings after completion of oil change.
12-10-06
Replenishment of Brake Fluid In order to assure proper brake action, it is necessary to have positive transfer of hydraulic pressure through the system. Any air trapped in the system must be removed by following the bleeding procedure described below. The brake fluid reservoir is installed at the left side of the firewall. Brake fluid is toxic and can cause disease!
WARNING
Do not allow brake fluid to come in contact with your skin. In case of accidental contact flush with cold water immediately.
Brake bleeding procedure must be followed very carefully. Especially the WARNING connection between the pilot’s and copilot’s master brake cylinders has the tendency to carry air bubbles. Assure that bleeding equipment to be used for refilling is absolutely clean WARNING and is filled with uncontaminated brake fluid that conforms to Specification MIL-H-5606. Brake fluid can damage paint and other material! CAUTION
NOTE
12-10-07
Use a bleeding tank under the RH and LH break cylinder housing. Clean up immediately spilt brake fluid. Two mechanics are needed to carry out the bleeding procedure.
Brake Bleeding Procedure 1 Remove upper left engine cowling. 2 Remove fluid reservoir filler plug. 3 Ensure that pilot’s and copilot’s brake pedals and parking brake are released. 4 Remove bleed valve cap of the RH wheel brake assembly.
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5 Attach the bleeding equipment connector hose to the bleed valve. 6 Turn the bleeder fitting 1/2 rotation to the left for opening. 7 Slowly pump clean hydraulic fluid in the system (min. 0.33 L / 0.1 U.S. Gal). 8 Close bleed valve. 9 Disconnect bleeding equipment. 10 Install plastic hose to bleed valve. 11 Repeat steps 4 to 10 for the LH side accordingly. 12 Sit in the cockpit in a position that you can reach the right brake pedal of the pilot’s and copilot’s side simultaneously. NOTE
Maintain an adequate supply of fluid during the entire operation. Refill fluid reservoir if necessary. A low fluid supply will allow air to be drawn into the system. 13 Depress and hold the pilot’s right brake pedal. 14 Depress and hold the copilot’s right brake pedal. 15 Release the pilot’s brake pedal and depress and hold it again. 16 Release the copilot’s brake pedal and depress and hold it again. 17 Repeat steps 15 and 16 until a remarkable pressure is building up and then hold both pedals under pressure simultaneously. 18 Open the bleed valve on the RH brake cylinder housing. Both pedals must move foreward and fluid must come out of the brake cylinder housing. 19 Keeping the pedals pressed, close the bleed valve on the cylinder housing. 20 Release the pedals and repeat step 13 to 19 until the brake pressure is okay. A firm brake pedal must be obtained on pilot’s and copilot’s side. 21 Check the fluid level in the brake fluid reservoir. Fill up to full reservoir capacity. 22 Remove plastic hose from bleed valve and install cap. 23 Repeat step 13 to 22 for the LH brake system accordingly. 24 Reinstall fluid reservoir filler plug. 25 Check the brake operation. 26 Install upper engine cowling.
12-10-08
Tire Inflation Required tire pressure: Main wheels: 0.51 MPa (74 psi) Nose wheel:
0.35 MPa (51 psi)
When inflating tires, regulated air pressure through valve sems has to be used.
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12-10-09
Main Gear Shock Absorber Oil Draining/Refilling Detail Steps/Work Items
Key Items
High-pressure oil-jet damages eyes and limbs! WARNING
The shock absorber is under high pressure (827 psi/5.7 MPa). Expand the nitrogen gas-pressure before disassembly.
1 Remove the filling nipple − cover 2 Push the insert of the filling nipple to expand the nitrogen inflation 3 Remove the plug and O-ring from outer cylinder 4 Drain the hydraulic fluid completely in a sump 5 Replace O-rings and scraper ring
Chapter 32-10-13
6 Refill hydraulic fluid into the cylinder
Use only MIL−H−5606 Hydraulic Fluid 420 cm³/25.6 cu in
7 Replace the O-ring on the plug 8 Screw the plug in the outer cylinder 9 Lock the plug by a safety wire 10 Connect a nitrogen charging apparatus at the filling nipple 11 Refill nitrogen
Till inflation pressure 5.7 MPa / 827 psi
12 Recover the cover-filling nipple
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12-20-00
SCHEDULED SERVICING
12-20-01
Exterior Cleaning The painted surfaces of the aircraft have a long lasting, all-weather finish and should require no buffing or rubbing out in normal conditions. However, it is desirable to wash and polish it to preserve the outstanding exterior. Cleaning is best accomplished with cool water, mixed with a mild aircraft detergent, if required.
CAUTION
Do not use so called "mild" household detergents to wash aircraft exterior. Such detergents may damage finish and corrode aluminum components. In order to remove especially heavy dirt from the wing leading edges due to insect splatter and the like, it is good practice to undertake cleaning immediately after the flight, since deposits of this kind are more difficult to remove when dry. All lubricated components are to be covered before cleaning. Roughly twice a year, the complete surface should be treated with a nonsilicone car polish and repolished to high gloss. But do not apply wax or use pre-wax cleaners during initial paint curing period. Use only mild aircraft detergent and cool water when washing exterior during the first 90 days after repainting. Never use cleaning agents containing silicone!
CAUTION In order to maintain good visibility at all times, the windshield should be given good care and kept clean at all times. Techniques and materials used to clean glass should be avoided since acrylic glass is softer than glass and subject to damage by solvents and abrasive glass cleaning agents. Therefore it should be paid particular attention to using ample water applied with clean sponges and leather, otherwise even the smallest dust particles will tend to scratch the glazing. Never polish acrylic glass dry! CAUTION Dull or scratched canopy sections can be returned to their transparent state by treating with especially formulated acrylic glass cleaning agents.
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12-20-02
Interior Cleaning Prior to the first flight of the day it is recommended to clean the interior with a vacuum cleaner to remove dust and loose dirt. If liquid is spilled on the cockpit floor, blot it up promptly with cleansing tissue or rags. Continue blotting until no more liquid is taken up.
CAUTION
12-20-03
Never use gasoline, benzine, alcohol, acetone, carbon tetrachloride, fire extinguisher fluid, anti-ice fluid, lacquer thinner, or glass cleaner to clean the windshield and cabin windows. These materials will damage the acrylic glass and may cause severe crazing.
Engine Cleaning Accumulation of dirt and oil within the engine compartment creates a fire hazard and hampers inspection. All cleaning operations have to be performed in well ventilated work areas, and it has to be ensured that adequate firefighting and safety equipment is available. Clean the engine in accordance with the Rolls Royce 250-B17F Series Operation and Maintenance Manual (LOAP 1). Follow the procedures given there after performing the following preparations: 1 After running, allow the engine to cool before cleaning. 2 Protect the alternator, starter-generator, other electrical components, the air inlets and the engine cowlings (the inside of the engine cowlings is covered with water soluble fire protection paint) against cleaning agents. 3 Do not to start the engine before the cleaning agent has been completely removed or has evaporated.
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12-20-04 Interval CAUTION
Lubrication Chart Item
Location
Lubricant
Do not lubricate TEFLON coated bearings and rod ends Engine Compartment
100 h
Engine Controls (Throttle, Cond. Lever) Fork Ends and Bearings
Engine compartment
MIL-L-7870 after disassembly: MIL-G-81322 (Aeroshell Grease 22c)
100 h
Engine anti-ice Bowden Cable Ends
Engine compartment
MIL-PRF-7808
Controls 100 h
Control Shafts
Below Instrument Panel
MIL-G-81322 (Aeroshell Grease 22c)
100 h
Cable Chain Coupling (between Control Wheels)
Below Instrument Panel close to the firewall
MIL-G-81322 (Aeroshell Grease 22c)
100 h
Chain Interconnection (Aileron/Rudder)
Below Instrument Panel close to the firewall
MIL-G-81322 (Aeroshell Grease 22c)
100 h
Pedal Bearings
Below Instrument Panel
MIL-L-7870 after disassembly: MIL-G-81322 (Aeroshell Grease 22c)
100 h
Control Cable Bolt Attachments
Pedal Torque Tube and Controls/Control Surfaces and Nose Wheel Steering
MIL-G-81322 (Aeroshell Grease 22c)
100 h
Pressure Dome Control Cable Bushing
Cabin Pressure Dome
MIL-G-21164 (Aeroshell Grease 17)
100 h
Trim Tab Hinge
Elevator
MIL-L-7870 after disassembly: MIL-G-81322 (Aeroshell Grease 22c)
100 h
Trim Servo Chain
Tail Cone
MIL-G-3278 or MIL-G-23827 (Aeroshell Grease 7)
100 h
Wing Flap Tracks
Wing
MIL-G-81322 (Aeroshell Grease 22c)
2000 h
Front and rear Track Rollers at middle Flap Tracks
Wing
MIL-G-81322 (Aeroshell Grease 22c)
2000 h
Rear Track Rollers at inner Flap Tracks
Wing
MIL-G-81322 (Aeroshell Grease 22c)
100 h
Wing Flap Spindles
Wing
MIL-G-81322 (Aeroshell Grease 22c)
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Interval
Item
Location
Lubricant
Engine Controls 100 h
Bowden Cable Fork End Attachments
Middle Console
MIL-L-7870 after disassembly: MIL-G-81322 (Aeroshell Grease 22c)
100 h
Control Lever Bearing
Middle Console
MIL-L-7870 after disassembly: MIL-G-81322 (Aeroshell Grease 22c)
100 h
Control Lever Guidance
Middle Console
MIL-G-81322 (Aeroshell Grease 22c)
Landing Gear 100 h
Main Gear Doors Hinges
RH and LH Main Gear
MIL-L-7870 after disassembly: MIL-G-81322 (Aeroshell Grease 22c)
100 h
Nose Gear Doors Hinges
Nose Gear
MIL-L-7870 after disassembly: MIL-G-81322 (Aeroshell Grease 22c)
100 h
Nose Gear Steering Arm Guide/Telescoping Rod
Nose Gear
MIL-G-81322 (Aeroshell Grease 22c)
100 h
Bearings with Lubrication Nipple
Nose and Main Gear
MIL-G-21164 (Aeroshell Grease 17)
Wheels and Brakes 100 h or annually 100 h
Wheel Bearings
Main Gear
MIL-G-81322 (Aeroshell Grease 22c)
Brake Guide Pins
Brakes
Copper paste Doors
100 h
Upper and Lower Door Hinges
Upper and Lower Door
MIL-L-7870 after disassembly: MIL-G-81322 (Aeroshell Grease 22c)
100 h
Locking Mechanism
Upper and Lower Door
MIL-G-81322 (Aeroshell Grease 22c)
100 h
Locking Pivots
Upper and Lower Door
MIL-G-81322 (Aeroshell Grease 22c)
100 h
Rod Ends of Telescopic Lift Cylinder
Upper Door
MIL-L-7870 after disassembly: MIL-G-81322 (Aeroshell Grease 22c)
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12-30-00
UNSCHEDULED SERVICING
12-30-01
Removal of Snow and Ice After snowfall, the snow should be removed immediately from surface of the aircraft. Otherwise the water formed from melted snow will freeze on the surface or in slots and gaps of fairings. Do not use sharp tools for removing the snow.
CAUTION If the aircraft shows signs of ice formation, it is recommended to defrost in a room. Remove as much snow as possible with a soft bristle boom, make sure the wheels and brakes are clear, and tow the aircraft into a room with elevated temperature. This method is particularly desirable, since it will melt any undetected ice and snow that could constitute a flight hazard.
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Chapter 20 Standard Practices Airframe
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Table of Contents
20-00-00
GENERAL ........................................................................................................ 3
20-10-00
STANDARD PRACTICES AIRFRAME ....................................................... 4
20-10-01
Width Across Flats for Metric Bolts ............................................................... 4
20-10-02
Torque Values ................................................................................................... 4
20-10-04
Special Torque Values...................................................................................... 5
20-10-05
Measuring Techniques ..................................................................................... 6
20-10-06
Coin Tapping..................................................................................................... 6
20-10-07
Flexible Hoses.................................................................................................... 6 Replacement of Flexible Hoses .......................................................................... 6 Installation of Flexible Hose Assemblies ........................................................... 7
20-10-08
Fittings ............................................................................................................... 7
20-10-10
Bowden Cables .................................................................................................. 8 Inspections .......................................................................................................... 8
20-10-11 Figure 20-1
Engine Controls ................................................................................................ 8 Engine Control Bowden Cables Schematic ...................................................... 10
20-10-12
Rod Ends ......................................................................................................... 11
20-10-13
Fork Ends ........................................................................................................ 11
20-10-14
Installing Bolts to CFRP Structures ............................................................. 11
20-10-15
Connections of Lightning Protection System ............................................... 12
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20-00-00
GENERAL The design of the airframe is according to standard procedures and requires no special tools or procedures for maintenance. For that reason, only the bolts used with the EXTRA 500 with relevant torque values and measuring techniques are described in the following.
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20-10-00
STANDARD PRACTICES AIRFRAME
20-10-01
Width Across Flats for Metric Bolts Thread diameter
20-10-02
Width across flats
M4
7 mm
M5
8 mm
M6
10 mm
M8
13 mm
M10
17 mm
M12
19 mm
M16
24 mm
M20
30 mm
M24
36 mm
Torque Values Nuts, except of counter nuts are mainly stop nuts according to LN 9348 or selflocking nuts according to AN 363. a) Standard torque values allowed for bolts and nuts according to DIN and LN must be adhered to as follows: Metric thread size M4
20
1.8
Torque value (in.lbs) 16
M5
3.9 – 4.3
35 – 38
M6
6.2 – 6.8
55 – 60
M8
15.2 – 16.8
144 – 148
M10
29.5 – 32.5
261 – 287
51 – 57
452 – 504
M12 x 1.5
Page 4
Torque value (Nm)
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b) Standard torque values allowed for bolts and nuts according to AN and MS must be adhered to as follows: Inch thread size
IMPORTANT
20-10-04
Torque value (Nm)
Torque value (in.lbs)
1/4 -28
3.5 – 4.5
30 – 40
5/16 -24
6.7 – 9.5
60 – 85
3/8 -24
10.7 – 12.5
95 – 110
7/16 -20
30.5 – 33.9
270 – 300
1/2 -20
32.8 – 46.3
290 – 410
9/16 -18
58.1 – 67.8
480 – 600
On all bolt connections, the specified torque and locking method must be observed. Do not reuse stop nuts if they can be run up finger tight!
Special Torque Values Special torque values for the following items must be adhered to: Item
Torque value (Nm)
(in.lbs)
Propeller flange bolt Mühlbauer
112
990
Bolt nose wheel tire
11
90 – 100
Bolt main wheel tire
17
150
Engine mount to fuselage (Bolts DIN 912 M12/12.9)
75 – 80
664 – 708
Engine mount to fuselage (Bolts LN 9037 x 08)
15.2 – 16.8
135 – 149
32
283
11.9 – 13.0
105 – 115
Engine mounting (Bolts AN 7 - 44A) Engine shock mount
IMPORTANT
Torque value
Wing bolt retaining sheets front (M5 bolts)
4
36
Wing bolts rear (M10 bolts)
16
140
Fuselage joints (M6)
6.5
57.5
Fuselage joints (M8)
16
142
Wing fittings (M8)
16
142
Wing fittings (M10)
30
265
Main gear former connection bolts (M10)
25
200
Valve cover
7
60
On all bolt connections, the specified torque and locking method must be observed. Do not reuse stop nuts if they can be run up finger tight!
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20-10-05
Measuring Techniques When using stop nuts, the safety torque (friction torque or braking torque) should be added to the table standard values. This value is indicated on the dial of the torquemeter, before the nut contacts the attachment surface. Always torque nuts for fastening, if possible. When bolts are torqued there might be an additional torque value due to shaft friction. This torque can be determined by a torquemeter before the bolt head contacts the attachment surface and should be added to the table value.
20-10-06
Coin Tapping Inspection for damage is more critical for composite structure than for conventional structures. A large washer or similar object is a valuable tool for detecting debonds in the airframe surface. When a large washer is lightly bounced against a solid structure, a clear metallic ring should be heard. If delamination is present, a dull thud will be heard.
20-10-07
Flexible Hoses The EXTRA 500 is equipped for the oil, fuel, and sensing lines with standard "STRATOFLEX-hoses, Aerospace Connectors Division" or equivalent "AEROQUIP-hoses, Aerospace Division", according to MIL-DTL-25579 and 27267 specification. For the bleed air system SCEET hoses are installed. For brake and hydraulic lines KRONTEC PTFE-Hoses 6000 are used. Maintenance work or overhaul of these hoses requires the attention to the manufacturer's information and bulletins. The hoses inside the engine compartment are covered with appropriate fire sleeves (integrated or slip-over type). Hoses and hose assemblies should be checked for deterioration at each inspection period. Leakage, separation of the cover or braid from the inner tube, cracks, hardening, lack of flexibility, and excessive "cold flow" are apparent signs of deterioration and reason for replacement. The term "cold flow" describes the deep, permanent impressions in the hose produced by pressure of hose clamps or supports.
Replacement of Flexible Hoses For the replacement of hoses and hose assemblies the EXTRA should be contacted. Any of the following conditions require replacement of the hose assembly: • Fitting slippage on hose, • Damaged, cracked, cut or abraded cover (any reinforcement exposed); • Hard, stiff, heat cracked, or charred hose; Page 6
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• Cracked or damaged fittings; • Leaks at fitting or in hose; • Kinked, crushed, flattened or twisted hose • Bent to a radius smaller than the minimum bend radius • Blistered, soft, degraded, or loose cover. The entire assembly must be replaced, if failure occurs in a flexible hose assembly. Obtain a new hose assembly of the correct size and length, complete with factory-installed end fittings.
Installation of Flexible Hose Assemblies External forces can significantly reduce hose life or cause failure. Mechanical loads which must be considered include tensile or side loads and vibration. In general hose assemblies should be handled with care to prevent excessive bending, twisting and kinking. Particular attention must be given to preclude hoses from wear, snagging, kinking, bending smaller that minimum bend radius and cutting, any of which can cause premature hose failure. The minimum bend radius for flexible hoses varies according to size and construction of the hose and the pressure under which the hose is to operate. Bends that are too sharp will reduce the bursting pressure of flexible hose considerably below its rated value. Large diameter hoses and very short hose assemblies are more prone to kinking. Twisting of the hose can be determined from the identification markings running along its length. The flexible hose should be installed so that it will be subject to a minimum of flexing during operation.
20-10-08
Fittings For the oil, fuel, bleed air, and brake system only AN-fittings are used in the EXTRA 500. In some areas of the hydraulic system special fittings are used (metric thread). For the assembly of PTFE-hoses and reusable fittings follow the standard practices for such combinations. All these fittings are made of aluminum alloy or stainless steel and are bluecolored or clear for identification purposes. The dash number following the AN number indicates the size of the hose for which the fitting is made, in 16ths of an inch. This size measures the inner diameter (I.D.) of the hose. The material code letter (Aluminum alloy: code D) follows the dash number. Example:
NOTE
Elbow AN 822-8D
Clean removed fittings from sealing, sealing tape, etc. and apply FUELUBE on the thread before installation (except ventilation system). Don't use sealing tape for sealing.
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Maintenance Manual EXTRA 500
20-10-10
Bowden Cables Bowden cables are used for the following systems of the EXTRA 500: • Engine Controls (High performance Push-pull Bowden cable, stainless steel) • Air Inlet Heating (Button lock dash control, solid wire end) • Parking Brake (Ratchet control, solid wire end) • Windshield Heating (solid wire end) • Trim Control (Special TLS III cable system) Minimum bend radius: 65 mm. Refer to Triumph Controls Germany GmbH Installation Instructions TLE10 (LOAP 36) • Seat adjustment locking mechanism • Aft passenger seat back rest swivel mechanism
Inspections Observe the following hints when performing inspections on the Bowden cables: A cable must be replaced whenever: • excessive free play is felt at the control even after all cable connections have been verified as in good working order. • visual inspection shows chafing, breakage or bent, loose or worn parts. • evidence of moisture is found inside (or Bowden cable has frozen). • a gradual or sudden decrease in the stroke (travel) length of the Bowden cable has been detected. • a gradual or sudden increase in the no-load (cable free and unattached) friction of a Bowden cable has been detected. Correct routing of the Bowden cable whenever: • misalignment, unacceptable high internal friction due to bends below minimum radius or malfunction of sliding elements has been detected. • the usable stroke is not centered within the available travel. • the swivel angle is not centered within the available angle (if applicable).
20-10-11
Engine Controls Consider the following information when working on engine Bowden cables. Refer to Figure 20-1: Hard and abrupt control inputs may impose high dynamic peak loads to the related sliding parts at reaching the travel stops. A bent swivel sleeve as well as wear and excessive free play at the pivot (swivel) points and sliding parts are an indication of misalignment and/or hard
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20
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Maintenance Manual EXTRA 500
and abrupt control inputs. Those signs should be found early within the regular maintenance. This is a clear indication of an unacceptable Bowden cable condition, which might result in a malfunction. As soon as a Bowden cable becomes difficult to operate, the reason should be identified. An increase in no-load (cable free and unattached) friction or an increase in travel length of a Bowden cable are a good indication of pending performance problems and/or Bowden cable failure. The following notes, cautions and warnings describe application and installation information: Protect the cable from contaminants such as fuel, oil, water, dirt and CAUTION chemicals, which may damage the Bowden cable. Protect the cable from physical damage by paint, kinking, vibration, etc., which may damage the Bowden cable. IMPORTANT
A gradual or sudden increase in the no-load (cable free and unattached) friction of a Bowden cable is a good indication of pending performance problems and/or Bowden cable failure. Serious injury or death may result. Replacement is required. A gradual or sudden decrease in the stroke (travel) length of the Bowden cable is a good indication of pending performance problems and/or Bowden cable failure. Serious injury or death may result. Replacement is required. Bowden cables, which have moisture inside of them or have frozen, must be replaced. Do not apply heat to attempt to remove the moisture. Applying heat will not remove the moisture. Serious injury or death may result. Replacement is required.
NOTES
Installation should be accomplished by a licensed “A” and/or “P” mechanic. Bowden cables are designed to be non-repairable. Do not perform any repairs to this Bowden cable. Cables are designed to be contaminant resistant; not contaminant proof. The usable stroke must be centered within the available travel. The swivel angle must be centered within the available swivel angle. The minimum bend radius is 4". Bowden cables are lubricated for the life of the Bowden cable. Do not remove the seals or lubricate the Bowden cable.
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20
Page 9
NOT TO SCALE
Figure 20-1
Page 10
20
OUTER LINER (JACKET)
PIVOT POINT
EXTENDED POSITION
USABLE STROKE
RETRACTED POSITION MID-TRAVEL POSITION
OVER TRAVEL
BOTTOMED
FORK END
OVER TRAVEL
BOTTOMED
10° MAX. CONICAL SWIVEL
Maintenance Manual EXTRA 500
Engine Control Bowden Cables Schematic
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Maintenance Manual EXTRA 500
20-10-12
Rod Ends Two different kinds of rod ends are used for the EXTRA 500: • Teflon coated • stainless steel The Teflon coated rod ends have to be installed dry and require no maintenance. The stainless steel rod ends and attachment bolts shall be lubricated with MILG-81322 (Aeroshell Grease 22c) when newly installed or reinstalled. For lubrication during scheduled maintenance (without removal/reinstallation) MIL-PRF-7870 shall be used.
20-10-13
Fork Ends Generally fork ends and attachment bolts shall be lubricated with MIL-G81322 (Aeroshell Grease 22c) when newly installed or reinstalled. For lubrication during scheduled maintenance (without removal/reinstallation) MIL-PRF-7870 shall be used.
20-10-14
Installing Bolts to CFRP Structures To avoid electrochemical corrosion all non-stainless bolts and screws must be sealed independent from their surface protection. This does not apply to corrosion resistant steel (CRES). Detail Steps/Work Items
Key Items
1 Remove old sealant. 2 Install bolts with epoxy resin.
Hardening as per manufacturer information
PR 1750 accelerator contains harmful vapors and is readily absorbed WARNING through the skin. Avoid all contact with the skin and ingestion. Always wash hands before eating or smoking. Use adequate ventilation, hand protection and chemical-type goggles when working with this product. If accelerator contacts skin, flush area with warm water. Obtain medical attention in cases of extreme exposure or ingestion.
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Maintenance Manual EXTRA 500
Detail Steps/Work Items
Key Items
PR 1750 sealant contains solvents. WARNING Use adequate ventilation or air-supplied respirators during application. Avoid repeated or prolonged breathing of vapors. In case of extreme vapor exposure, remove affected personnel to fresh air immediately and obtain medical attention. For complete health and safety information, a refer to Le Joint Francais Material Safety Data Sheet PR 1750 (LOAP 41) 3 After final torquing apply PR 1750 sealant to both the head and nut side of the bolt including washer and thread end.
20-10-15
For mixing and application of PR 1750 sealant refer to manufacturer's instructions.
Connections of Lightning Protection System Prior to joining or riveting prepare contact surfaces as follows: Material
Action
Aluminum
Remove oxide film
Steel
Remove paint
Stainless steel
Degrease
Titanium
Degrease
After connection of parts seal gaps and connecting elements from all sides to avoid ingression of moisture:
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20
Connection
Action
Aluminum – Steel
Apply PR 1750A
All other
Apply Nycote 7-11
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Maintenance Manual EXTRA 500
Chapter 21 Air Conditioning
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21
Page 1
Maintenance Manual EXTRA 500
Table of Contents
21-00-00
DESCRIPTION ................................................................................................ 5 Troubleshooting.................................................................................................. 7
21-00-01
SCEET Hoses .................................................................................................... 8 Replacement ....................................................................................................... 8
21-10-00
COMPRESSION .............................................................................................. 9 Description.......................................................................................................... 9
21-10-01
Primary Shut-off Valve .................................................................................... 9 Removal/Installation........................................................................................... 9
21-10-02
Mass Flow Control Valve............................................................................... 10 Removal/Installation......................................................................................... 10
21-10-03
Mass Flow Sensor ........................................................................................... 10 Removal/Installation......................................................................................... 10 Check ................................................................................................................ 10
21-10-04
Mass Flow Controller..................................................................................... 11 Removal/Installation......................................................................................... 11
21-10-05
Muffler ............................................................................................................. 11 Removal/Installation......................................................................................... 11
21-20-00
DISTRIBUTION............................................................................................. 12 Description........................................................................................................ 12
21-20-01
Panel Vent Fans .............................................................................................. 12 Removal/Installation......................................................................................... 12
21-30-00
PRESSURIZATION CONTROL ................................................................. 14 Description........................................................................................................ 14 Operation .......................................................................................................... 14
21-30-01
Cabin Outflow Control Valve Filter ............................................................. 17 Replacement ..................................................................................................... 17
21-30-02
Cabin Outflow Control Valve........................................................................ 17 Removal/Installation......................................................................................... 17
21-30-03
Safety Valve..................................................................................................... 18 Removal/Installation......................................................................................... 18
21-50-00
COOLING ....................................................................................................... 19 Description........................................................................................................ 19 Service and Maintenance.................................................................................. 19
21-50-01
Compressor/Condenser.................................................................................. 20 Removal/Installation......................................................................................... 20
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Maintenance Manual EXTRA 500
21-50-02
Evaporator .......................................................................................................20 Removal/Installation .........................................................................................20
21-50-03
Soft Start Module ............................................................................................21 Removal/Installation .........................................................................................21
21-60-00
TEMPERATURE CONTROL ......................................................................22 Description ........................................................................................................22
21-60-01
Temperature Switch........................................................................................23 Removal/Installation .........................................................................................23 Function Test.....................................................................................................23
21-60-02
Duct Temperature Sensor ..............................................................................24 Removal/Installation .........................................................................................24
21-60-03
Cabin Temperature Sensor ............................................................................24 Removal/Installation .........................................................................................24
21-60-04
Temperature Controller .................................................................................25 Removal/Installation .........................................................................................25
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Left blank intentionally
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Maintenance Manual EXTRA 500
21-00-00
DESCRIPTION Refer to Figure 21-1. The following systems are installed in the EXTRA 500 to cope with the various tasks of air conditioning: • Bleed air system with mass flow control • Ram air system • Distribution system • Pressurization system • Temperature regulation system • Cooling system For ventilation either ram or pressurized (bleed) air is used. Before entering the cabin bleed air is mass flow controlled and temperature can be modified by the temperature regulation. The airflow is then ducted to the legroom and/or to the windshield. The cabin air additionally can be cooled by the cooling system. Pressurization is done by the bleed air system in combination with a controllable outflow valve. Generally air is routed through SCEET hoses. On some locations T- or Ydistributors are connected to the hoses with worm drive hose clamps.
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Page 5
Maintenance Manual EXTRA 500
Figure 21-1
Page 6
21
Cabin Air Condition and Pressurization Scheme
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Maintenance Manual EXTRA 500
Troubleshooting Complaint No or inadequate pressurization
Possible Cause
Remedy
Pressurization system inactive
Switch pressurization system ON
Excessive cabin leakage
Identify and seal
Excessive door seal leakage
Replace door seal
Excessive emergency exit seal leakage
Replace emergency exit seal
Bleed air system leakage
Identify and seal
Pneumatic system leakage
Identify and seal
Dump solenoid energized (safety valve open)
Check dump switch and squat switch
Pressure controller failure
Replace controller
Cabin control outflow valve failure
Replace control outflow valve
Safety valve failure
Replace safety valve
Mass flow sensor failure
Replace mass flow sensor
Mass flow valve failure
Replace mass flow valve
Mass flow controller failure
Replace mass flow controller
Pressurization system inactive
Switch pressurization system ON
Bleed air system leakage
Identify and seal
Pneumatic system leakage
Identify and seal
Cabin control outflow valve static reference blocked
Clean static reference connection
Cabin control outflow valve filter blocked
Replace filter
Pressure controller defective
Replace controller
Mass flow sensor failure
Replace mass flow sensor
Mass flow valve failure
Replace mass flow valve
Mass flow controller failure
Replace mass flow controller
Incorrect pressurization or pressurization rate control
Cabin control outflow valve defective
Replace control valve
Pressure differential exceeding 5.5 psi
Cabin control outflow valve static reference blocked
Clean static reference connection
Cabin control outflow valve differential failure
Replace control valve
Incorrect pressurization or pressurization rate control
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Maintenance Manual EXTRA 500
Complaint No dump
Erroneous warning
Possible Cause
Remedy
Pressurization system inactive
Switch pressurization system ON
Squat switch setting incorrect
Correct squat switch setting
Safety valve static reference blocked
Clean static reference connection
Dump switch defective
Replace dump switch
Squat switch defective
Replace squat switch
Safety valve solenoid failure
Replace safety valve
Safety valve blind plug at vacuum port not installed
Install blind plug
Temperature switch defective
Replace temperature switch
Differential pressure switch (5.65 psig) defective
Replace differential pressure switch
Absolute pressure switch (10,000 ft) defective
Replace absolute pressure switch
BLEED OVERTEMP
Erroneous warning CABIN PRESSURE
21-00-01
SCEET Hoses The worm drive hose clamps of the bleed air system are secured with a safety wire.
Replacement Detail Steps/Work Items
Key Items
1 Remove both upper engine cowlings.
Refer to Ch. 71-10-01/02.
2 Remove hose.
worm drive hose clamps, (safety wire)
3 Cut new SCEET hose to length. 4 Slip the worm drive hose clamps over the hose. 5 Slip both hose layers over the fittings. 6 Fasten worm drive hose clamps on both sides.
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Apply safety wire to all bleed air hose clamps.
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Maintenance Manual EXTRA 500
21-10-00
COMPRESSION Description Refer to Figure 21-1. The system consists of the engine compressor, bleed ports, a bleed air manifold, a shut-off valve, a mass flow control valve, a mass flow controller, a mass flow sensor, hoses, and the ENV AIR switch on the left side panel. Engine bleed air is used for cabin pressurization. Bleed air is taken from the engine compressor by means of two bleed ports. A forward-facing port is located on the right top of the engine compressor scroll. On its left bottom another downward-looking port is located. The bleed ports incorporate orifices (sonic venturi) which are installed with special O-rings. Bleed air is then routed through pressure hoses to the bleed air manifold located on the left engine side. Just above the primary shut-off valve is installed, which allows switching on or off cabin pressurization (and also heating) by means of the ENV AIR switch. The mass flow control valve is installed above the shut-off valve. It takes bleed air and/or ram air tapped from the left air-to-air cooler inlet to control the mass flow. The valve is governed by a computerized mass flow controller installed inside the cabin behind the side paneling between the cabin door and the pilot’s seat. The controller receives mass flow data from the mass flow sensor installed to a flange downstream the bleed air muffler.
21-10-01
Primary Shut-off Valve Removal/Installation The primary shut-off valve is screwed to the mass flow control valve. For this reason it is advisable to firstly remove both valves together and to disconnect them later by turning the shut-off valve. Detail Steps/Work Items 1 Remove LH engine cowling.
Key Items Refer to Chapter 71-10-01.
2 Disconnect bleed air manifold from shut-off the valve. 3 Cut the electrical wiring from the shut-off valve.
Reconnect later by splicing.
4 Disconnect the SCEET hoses from the mass flow control valve. 5 Disconnect the electrical wiring from the mass flow control valve. 6 Disconnect the mass flow control valve from the engine mount and remove both valves together. Page Date: 30. March 2012
4 bolts
21
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Maintenance Manual EXTRA 500
Detail Steps/Work Items
Key Items
7 Loosen counter nut between the two valves. 8 Unscrew the shut-off valve from the mass flow control valve.
Turn the complete shut-off valve. Watch the copper Oring.
9 Install in reverse sequence of removal.
21-10-02
Mass Flow Control Valve Removal/Installation Follow the procedure given in Section 21-10-01.
21-10-03
Mass Flow Sensor The mass flow sensor is electrically connected to its control box located on the nose gear firewall.
Removal/Installation Detail Steps/Work Items 1 Remove LH engine cowling.
Key Items Refer to Chapter 71-10-01.
2 Remove cable straps and tie tool wraps from the electrical wiring between sensor and control box. 2 Remove sensor.
4 bolts on muffler flange
3 Remove control box.
4 screws, 3 else connections
4 Install in reverse sequence of removal.
Check Detail Steps/Work Items
Key Items
1 Remove LH engine cowling.
Refer to Chapter 71-10-01.
2 Remove sensor from muffler.
4 screws
3 Check 2 wires in sensor are intact.
Replace sensor if wires are broken.
4 Install in reverse sequence of removal.
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Maintenance Manual EXTRA 500
21-10-04
Mass Flow Controller Removal/Installation Detail Steps/Work Items 1 Remove left side armrest paneling.
Key Items Refer to Chapter 25-20-21.
2 Disconnect the electrical connector from the mass flow controller. 2 Remove mass flow controller.
4 attachment nuts
5 Install in reverse sequence of removal.
21-10-05
Muffler The muffler is directly mounted to a flange providing a holding fixture for the mass flow sensor.
Removal/Installation Detail Steps/Work Items
Key Items
1 Remove LH engine cowling.
Refer to Chapter 71-10-01.
2 Remove mass flow sensor.
Remove 4 screws.
3 Disconnect SCEET hoses from muffler and flange. 4 Remove attachment bolts of hose clip and hose clamp carrying muffler and flange. 5 Remove muffler with flange. 6 Install in reverse sequence of removal.
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Maintenance Manual EXTRA 500
21-20-00
DISTRIBUTION Description Refer to Figure 21-1. The system consists of a valve box, SCEET hoses, a distribution valve, a Bowden cable with a handle on the center console panel and the panel vent fans. Ram air or bleed air is ducted into the cabin (refer to Section 21-10 for the bleed air system). Ram air is taken from the oil cooler inlet on the right engine side and routed through SCEET hoses to a valve box on the firewall. 2 check valves are mounted to the valve box (ram air and bleed air side). Additionally the valve box has a holding fixture for the duct temperature sensor. The cabin inflow check valve is mounted between the valve box and the firewall. Inside the cabin a valvular operated air distributor guides the air stream to the windshield and/or legroom dispensers. The air distributor has also a holding fixture for the temperature switch. For better ventilation in the forward cabin section two vent fans are installed in the LH and RH side of the instrument panel. Each vent fan sucks air from behind the panel. On the discharge side each vent fan is connected to an eyeball vent, which can be adjusted to direct or shut off the airflow. Two switches, placed on the instrument panel near the resp. air outlet, control the vent fans. The electric fan motors are protected by a 2 A - fuse. The evaporators (refer to Section 21-50) also work as cabin fans. Both evaporator blowers work with different power settings in low or high mode.
21-20-01
Panel Vent Fans Removal/Installation Detail Steps/Work Items
Key Items
1 a (RH vent fan) Remove RH IFD and right main panel.
Refer to Chapters 31-60-01 and 31-10-03
1 b (LH vent fan) Remove LH and RH IFD and analogue engine indicator.
Refer to Chapter 31-60-01 and Chapter 77-40-01
2 Loosen worm drive hose clamp on vent fan casing. 3 Disconnect electrical wiring. 4 Remove vent fan with casing.
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21
5 Disassemble vent fan and casing if applicable.
4 bolts
6 Remove eyeball vent.
1 nut
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Maintenance Manual EXTRA 500
Detail Steps/Work Items
Key Items
7 Reverse procedure for installation. 8 Perform pitot/static test.
Page Date: 30. March 2012
According to FAR 43, Appendix E and AC 43.131B CHG1 (or later) § 12-59
21
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Maintenance Manual EXTRA 500
21-30-00
PRESSURIZATION CONTROL Description Refer to Figure 21-1. The system consists of the engine compressor, two sonic venturi (flow limiters), a cabin control outflow valve, an unregulated safety valve, the cabin pressurization/dump switch, the cabin pressure controller, the landing gear squat switch, and two indicators, one for cabin altitude and differential pressure and one for cabin rate-of-climb. Pressurized air is supplied from the engine bleed air through the sonic venturi and then through a check valve into the cabin. Adequate flow to maintain pressurization up to the maximum differential pressure of 5.5 PSI is provided by the engine at normal power setting. Power changes should be made smoothly to prevent sudden changes in pressurization air inflow resulting in cabin pressure transients.
Operation The airplane may be operated in either the pressurized or depressurized mode. The mode selection is made with the cabin pressurization switch, which either activates the cabin control outflow valve or leaves it open. Mode operation should be selected prior to takeoff. If a change from pressurized to depressurized mode must be made while airborne, depressurize the cabin following the procedure given below before turning the dump switch as otherwise a rapid decompression occurs, which would cause discomfort to the passengers. When changing from unpressurized to pressurized mode, the cabin altitude rate of change will be limited by the pressurization controller. The valves are also opened by the landing gear squat switch assuring depressurized mode when aircraft is on ground to avoid bursting the cabin door due to cabin pressure when opening. In the pressurized mode cabin pressure is regulated by the cabin control outflow valve allowing air to exhaust either to the pressure level preselected by the cabin pressure controller or to maximum differential pressure level. Setting the center dial (identified as “Flight Level”) of the cabin pressure controller will suggest the system being at a certain flight altitude. So the system will maintain the corresponding cabin altitude (about 5.5 PSI above static pressure of flight level) or reach it with the rate set by the rate control knob located on the lower left corner of the pressurization controller. Only in case of maximum differential pressure is reached or flight level is below the selected cabin altitude, cabin altitude changes with the same rate the flight altitude does. In case of failure of the cabin outflow control valve the safety valve will open at a differential pressure of slightly above 5.5 PSI to avoid structure damage. Handling Use the cabin pressure controller as follows. Also refer to the sample chart (Figure 21-1). 1 Activate the pressurization controller by turning on the cabin pressurization switch. Make sure the ENV AIR switch is ON. Page 14
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Maintenance Manual EXTRA 500
2 Set the published official airport altitude (such as shown on flight charts) under the index arrow by turning the center control knob. 3 Turn the index arrow of the rate control knob (lower left corner of the control) to the 12 o’clock position (approx. 500 fpm). These steps set the system to pressurize at approximately 700 feet above the runway after takeoff. The system will hold this cabin altitude until the maximum differential altitude is reached (see “Cabin Altitude with minimum Flight Level Setting” line of Figure 21-1) or a different cabin pressure is selected. 4 After having cleared the airport area and established the climb and being on course to the destination (see “a” on 0), select the flight level corresponding to the intended cruise altitude in the center dial and align that with the index arrow. This alignment also indicates the approximate cabin altitude (within approx. 700 feet) at the index on the larger numbers marked “Airport Alt.”. 5 Increase or decrease the rate at which the cabin changes altitude for the best comfort level from normally 500 fpm by turning the rate knob counter clockwise for decreasing or clockwise for increasing the rate. Usually it is the best method to set the rate to reach the changed cabin pressure (referenced from the “Airport Alt.”) slightly ahead of reaching the cruising altitude (550 fpm in the sample of Figure 21-1). This selected altitude will be maintained until the aircraft changes altitude sufficiently to reach the max. differential pressure or descends sufficiently to go below the selected airport altitude. 6 When the aircraft reaches the proximity of the destination and starts to descent (see “b” on 0), set the selector knob to the published airport altitude. 7 Set the rate so that the selected airport altitude is reached in the cabin prior to descending to that altitude (650 fpm in the sample of Figure 21-1). When approaching the runway, the pressurization will cease approximately 700 feet above the landing prior to landing. Should any slight pressure remain, the remainder will dump when the squat switch closes. However, this is an additionally safety device, because landing with cabin pressurized is not allowed. CAUTION
If pressurization mode shall be terminated during flight, follow the procedure above, setting the airport altitude equal to the momentary flight altitude. Do not switch to the depressurized mode before the selected airport altitude has been reached.
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21
Page 15
Figure 21-1
Page 16
21
0
5
10
15
20
0
a
feet x 1,000
5
650 fpm
10
climb 1200 fpm
15
max. diff. pressure
20
Flight Altitude Cabin Altitude Cabin Altitude with Minimum Flight Level Setting
b 25
30
650 fpm
descent 1500 fpm
35
min
Maintenance Manual EXTRA 500
Cabin Pressurization Sample Chart
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Maintenance Manual EXTRA 500
21-30-01
Cabin Outflow Control Valve Filter Replacement Detail Steps/Work Items
Key Items
1 Remove upper half of rear baggage compartment wall.
Machine screws AN 526 10-32
2 Loosen the filter retention screw on the control outflow valve housing until the filter flange is free to rotate.
It is not necessary to remove the screw entirely.
3 Rotate the filter until the flat on the filter clears the screw head. 4 Remove the filter cartridge and replace with new one. 5 Rotate the filter so filter flange is captured by the screw head. 6 Tighten filter retaining screw.
21-30-02
Cabin Outflow Control Valve The valve is attached to the LH side of the pressure dome.
Removal/Installation Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. T
2 Remove upper half of rear baggage compartment wall.
Machine screws AN 526 10-32
3 Remove tail cone access panel on LH fuselage side. 4 Remove valve flange from pressure dome.
8 stop nuts MS 21044 AN3 with washers AN960 – 10L (3/8 inch.)
5 Remove overflow tube.
9/16 fitting; retain with 11/16 wrench at pressure dome fitting
6 Disconnect electrical connector. 7 Lift up valve from pressure dome 8 Install in reverse sequence of removal
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Maintenance Manual EXTRA 500
21-30-03
Safety Valve The valve is attached to the RH side of the pressure dome.
Removal/Installation Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. T
2 Remove upper half compartment wall.
of
rear
baggage Machine screws AN 526 10-32
3 Remove tail cone access panel on LH fuselage side. 4 Remove valve flange from pressure dome.
8 stop nuts MS 21044 AN3 with washers AN960 – 10L (3/8 inch.)
5 Remove overflow tube.
9/16 fitting; retain with 11/16 wrench at pressure dome fitting
6 Remove electrical connector 7 Lift up valve from pressure dome 8 Install in reverse sequence of removal NOTE
Page 18
21
Observe the following hint
Verify that blind plug at vacuum port is installed correctly. With installed valve, the vacuum port is accessible behind the rear baggage compartment wall.
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Maintenance Manual EXTRA 500
21-50-00
COOLING Description Refer to Figure 21-1. The aircraft is standard equipped with an electrically driven vapor cycle air conditioning system. The system consists of a compressor condenser module, two evaporators and the switches in the CABIN section of the left side panel. The electrically driven compressor condenser module is installed in the unpressurized part of the tail cone aft of the rear pressure dome. Cooling air for the condenser (circulated by the condenser fan) is taken from an inlet in the left fuselage side aft of the cabin door and dumped overboard through an outlet on the same side. The cabin recirculation air is cooled by means of two evaporators. The front evaporator is installed behind the co-pilot seat and the aft evaporator in the aft pressure dome area. Condensation at the evaporators is drained by means of a float type check valve for each evaporator. The air condition system is activated by the AIR CON switch located in the left side panel. The air-condition will only operate effectively with the cabin blower VENT switch at least in LOW position. The electric air-condition provides the ability to operate the system on ground using ground power without the necessity to run the aircraft engine.
NOTE
It is not possible to operate the air condition on battery power as the high current draw would shortly lead to a depleted battery. Therefore for operation either the aircrafts generator (engine running) or a sufficient external power source (capacity min. 100 A at 28 VDC) has to be connected to the aircraft bus system. 125 A is recommended for maximum cooling capacity. When using external power the battery must be off.
Service and Maintenance Servicing of the air-conditioning unit shall be performed by an approved airconditioning service station; only R-134a type refrigerant must be used. The air-conditioning compressor condenser module is equipped with conventional evacuating and charging connections. After new system plumbing installation, component replacement or line or hose rupture, a leak check is required, see Enviro Systems General Operating, Servicing and Maintenance Manual for Airborne R-134a Air-conditioning Systems (LOAP 13) for leak check and general charging procedures. Refer to this Manual also for component maintenance procedures. Access to the compressor condenser module is gained through the tailcone access hatch. Both low and high pressure service ports are located at this unit. Charging quantity of the installation is 0.650 kg +/- 0.050 kg, proper charging can be verified at the sight glass on the receiver dryer. With the system fully charged and operating, observe the suction and discharge pressures. Typical values at various ambient temperatures, with hot cabins are shown below: Page Date: 30. March 2012
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Maintenance Manual EXTRA 500
21-50-01
OAT (°C)
Suction pressure (psig)
Discharge pressure (psig)
20
28
112
25
30
133
30
31
156
35
32
180
Compressor/Condenser Removal/Installation Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. T
2 Remove tail cone access panel.
Refer to Chapter 51-00-01
3 Remove the refrigerant from the air conditioning system
Refer to Enviro Systems General Operating, Servicing and Maintenance Manual for Airborne R-134a Airconditioning Systems (LOAP 13)
4 Remove all avionic boxes, which may block removal of compressor/condenser.
XPDR, DME, amplifier
5 Remove refrigerant hoses. 6 Remove air hoses. 7 Remove compressor/condenser.
4 mounting screws
8 Reverse procedure for installation.
21-50-02
Evaporator Removal/Installation Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. T
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2 Remove tail cone access panel.
Refer to Chapter 51-00-01
3 Remove the refrigerant from the air conditioning system
Refer to Enviro Systems General Operating, Servicing and Maintenance Manual for Airborne R-134a AirPage Date: 30. March 2012
Maintenance Manual EXTRA 500
Detail Steps/Work Items
Key Items conditioning Systems (LOAP 13)
4 (front Set the co-pilot seat in the most forward evaporator only) position. 5 a (front Remove side paneling. evaporator)
Refer to Chapter 25-00-01
5 b (aft Remove aft paneling. evaporator)
Refer to Chapter 25-00-01
6 Remove refrigerant hoses. 7 Remove air hoses. 8 Cut electrical wires.
Reconnect later by splicing.
9 Remove mounting screws and remove evaporator. 10 Reverse procedure for installation.
21-50-03
Soft Start Module Removal/Installation Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. T
2 Remove tail cone access panel.
Refer to Chapter 51-00-01
3 Disconnect 3 power lines. 4 Cut control line.
Reconnect later by splicing.
5 Remove soft start module.
4 mounting bolts
6 Install in reverse sequence of removal.
Ensure cable clamps are installed.
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21-60-00
TEMPERATURE CONTROL Description Refer to Figure 21-1. The system consists of a temperature controller, a cabin temperature sensor, a duct temperature sensor, a temperature modulating valve, a temperature switch, the BLEED OVERTEMP warning light and the TEMP CTRL switches and rheostat on the left side panel. With the ENV AIR switch ON environmental bleed air is provided for cabin heating purposes. The bleed air, exiting the engine is too hot to be used for cabin heating without prior cooling. The amount of cooling required is dependent on ambient temperature, airspeed, engine power setting, desired cabin temperature and adequate changes if these parameters change. Cooling effectiveness is controlled by routing the environmental bleed air through the air-to-air cooler or directly (bypass) to the cabin by means of the temperature modulating valve. Operating mode of this valve is selected by the controls grouped in the CABIN section of the left side panel. With the TEMP CTRL switch being set to the AUTO position the computerized cabin temperature controller compares the actual cabin temperature (measured by a sensor in the cockpit ceiling) to the selected temperature. The temperature controller is installed inside the cabin behind the side paneling between the cabin door and the pilot’s seat. Selection is being done by means of the cabin temperature rheostat also located in the left side panel CABIN section. Adjustment range is between 13 °C and 30 °C (55 °F to 86 °F). Depending on the difference between actual cabin temperature and selected cabin temperature the controller determines a desirable cabin inflow temperature for the environmental bleed air. The actual inflow temperature is measured by a sensor located within the bleed ducting prior to cabin entry through the front pressure bulkhead. The temperature controller compares this actual inflow temperature to the desired inflow temperature and adjusts the temperature modulating valve to match this desired inflow temperature. It is within the nature of this design (bleed air cooling by means of an air to air heat exchanger) that cabin bleed air cannot be cooled below ambient temperature before entering the cabin. Therefore a vapor cycle air conditioning system (refer to Section 21-50) provides additional cooling capacity for hot ambient conditions. The automatic temperature control limits cabin inflow temperatures to values below 72 °C. An additional independent thermal switch installed in the cabin distribution valve activates the red BLEED OVERTEMP warning light located on the annunciator panel in case the cabin inflow temperature exceeds 85 °C. In case, the BLEED OVERTEMP warning light on the annunciator panel illuminates, indicating a temperature controller failure, the temperature can be manually controlled by switching the TEMP CTRL switch, to the MANUAL position.
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Selected and held in COOL or WARM position activates the temperature modulating valve manually (overrides the controller) causing warm up or cool down of incoming bleed air.
21-60-01
Temperature Switch Removal/Installation Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. T
2 Remove RH IFD and RH part of main panel.
Refer to Chapter 31
3 Remove attachment bolts of distribution valve.
To allow moving the distribution valve.
4 Move the distribution valve up some centimeters. 5 Cut the electrical wiring from the temperature switch
Reconnect later by splicing.
6 Remove temperature switch from the distribution valve. 7 Install in reverse sequence of removal.
Function Test Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. T
2 Remove RH IFD.
Refer to Chapter 31-60-01
3 Disconnect LH SCEET hose from the cabin distribution valve.
Worm drive hose clamp
4 Place BATT switch to ON position. T
5 Place NIGHT/DAY switch to TEST position.
To ensure annunciator lights are OK.
6 Apply hot air to the temperature switch.
More than 85 °C. Use a blow dryer.
7 Check BLEED OVERTEMP illuminates.
Replace temperature switch if necessary.
8 Place BATT switch to OFF position. T
9 Reinstall SCEET hose. Page Date: 30. March 2012
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Detail Steps/Work Items 9 Reinstall RH IFD. 10 Perform pitot/static test.
21-60-02
Key Items Refer to Chapter 31-60-01 According to FAR 43, Appendix E and AC 43.131B CHG1 (or later) § 12-59
Duct Temperature Sensor Removal/Installation The duct temperature sensor is attached to the valve box on the RH upper firewall with 4 bolts and nuts. To make the nuts accessible the forward hose and the flange have to be removed. Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. T
2 Remove LH and RH engine cowling.
Refer to Ch. 71-10-01/02
3 Disconnect the forward SCEET hose from the valve box.
Worm drive hose clamp, safety wire
4 Remove flange from the valve box.
4 nuts
5 Disconnect electrical connector from the temperature sensor.
Bayonet nut
6 Remove temperature sensor.
4 bolts and nuts
7 Install in reverse sequence of removal.
Observe the following step.
Refer to Product Label and Material Safety Data Sheet for health and WARNING safety information before using PR812. 8 Seal flange with PR812.
21-60-03
Cabin Temperature Sensor Removal/Installation Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. T
2 Remove paneling above pilot seat.
Refer to Chapter 25
3 Disconnect electrical wiring from the cabin temperature sensor. Page 24
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Detail Steps/Work Items 4 Remove sensor.
Key Items 4 nuts
5 Install in reverse sequence of removal.
21-60-04
Temperature Controller Removal/Installation Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. T
2 Remove left side cabin paneling.
Refer to Chapter 25.
3 Disconnect the electrical wiring from the temperature controller. 4 Remove temperature controller.
4 attachment screws
5 Install in reverse sequence of removal.
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Intentionally left blank
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Chapter 22 Auto Flight
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Page 1
Maintenance Manual EXTRA 500
Table of Contents 22-00-00
GENERAL ........................................................................................................ 5
22-10-00
AUTOPILOT .................................................................................................... 6 Description.......................................................................................................... 6 Autopilot Installation.......................................................................................... 8 System Components ........................................................................................... 9 Troubleshooting................................................................................................ 11 Heading Calibration.......................................................................................... 12
Figure 22-1
22-10-01 Figure 22-2
22-10-02 Figure 22-3
22-10-03 Figure 22-4
22-10-04
Figure 22-5
Roll Servo ........................................................................................................ 13 Removal............................................................................................................ 13 Roll Servo Installation ...................................................................................... 14 Installation ........................................................................................................ 15 Function Test .................................................................................................... 15 Pitch Servo....................................................................................................... 16 Removal............................................................................................................ 16 Pitch Servo Installation .................................................................................... 17 Installation ........................................................................................................ 18 Function Test .................................................................................................... 19 Yaw Servo........................................................................................................ 19 Removal............................................................................................................ 19 Yaw Servo Installation...................................................................................... 21 Installation ........................................................................................................ 22 Function Test .................................................................................................... 22 Clutches (Pitch, Roll and Yaw Servo)........................................................... 23 Torque Settings................................................................................................. 23 Torque Adjustment ........................................................................................... 24 Clutch Torque Adjustment ................................................................................ 24
22-10-05
Driving Wheels................................................................................................ 25 Removal/Installation......................................................................................... 25
22-10-06
Bridle Cables ................................................................................................... 25 Removal/Installation......................................................................................... 25 Tension Settings ............................................................................................... 26 Tensioning ........................................................................................................ 26
22-10-07 Figure 22-6
Cable Clamps .................................................................................................. 27 Cable Clamp Torquing ..................................................................................... 27
22-10-08
Trim Servo....................................................................................................... 27 Removal/ Installation........................................................................................ 27 Function Test .................................................................................................... 27
22-10-09
Trim Servo Clutch .......................................................................................... 28 Torque Settings................................................................................................. 28 Torque Adjustment ........................................................................................... 28
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22-10-10
Pressure Transducer.......................................................................................29 Removal/Installation .........................................................................................29
22-10-11
Yaw Amplifier .................................................................................................30 Removal/Installation .........................................................................................30
22-10-12
Programmer/Computer..................................................................................30 Removal/Installation .........................................................................................30
22-10-13
Turn Coordinator............................................................................................30 Removal/Installation .........................................................................................30
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22-00-00
GENERAL This chapter describes the features and functions of the System 55X Two and a half Axis Autopilot and gives information on basically required maintenance practices as well as related system components.
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22-10-00
AUTOPILOT Description Refer to Figure 22-1. The S-TEC System 55X autopilot system is a rate based autopilot. Internal signal processing for regulating purposes is mainly analog, whereas digital electronics is used for the pilot interface and for controlling the mode of operation. Pitch and Roll Axis The signal for the roll servo is generated using the following inputs: 1 Rate of turn information heading bug determined by the Turn Coordinator. 2 Navigation avionics (VOR / LOC, GPS; via IFD). The signal for the pitch servo is generated using the following inputs: 1 Static pressure (via remote mounted Absolute Pressure Transducer). 2 Sensitive Accelerometer (contained in the Programmer / Computer unit). 3 Altitude Selector (via IFD, key pad or vertical speed knob on A/P computer). 4 Glide Slope Receiver (via IFD). The autopilot can be activated by means of the 3-position AUTOPILOT MASTER/FD switch located in the right lower side of the pilot's instrument panel. Switching it from the OFF-position to the first stage (FD) energizes the autopilot system. The autopilot will start its self-test routine ending up in a ready mode if performed successfully. This allows the pilot to select the different operating modes. If appropriate modes are activated set-point steering commands are shown by the Flight Director symbol displayed in the LH IFD. The pitch and roll servos are not engaged. Pitch and roll still have to be controlled by normal steering, using the data provided by the IFD as a setactual comparison. In the second stage (MASTER) the servos are energized and the autopilot controls pitch and roll axis according to the operating mode(s) selected (refer to POH). One possibility to engage the autopilot (both axis) is given by the CWS switch (control wheel steering) located on top of the right horn of the pilot's control yoke. This mode engages the autopilot in a way which maintains the actual pitch and roll attitude (refer to POH).
NOTE
Operation in a pitch mode is possible only if a roll mode is activated. As a safety device an autopilot quick disconnect switch (AP DISC, red) is also located in the left horn of the pilot's control wheel to enable the pilot to disengage the autopilot quickly. Additionally, servo transmissions are designed as slip clutches, which can be overpowered in any case of failure or malfunction. The operation mode selection is done via the autopilot main unit and the IFD or the related keyboard. Indication is made on the autopilot main unit and the upper LH IFD.
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Trim System The EXTRA 500 uses a tab at the elevator's trailing edge for pitch trim. This tab is actuated by a Bowden cable with a special gear located in the horizontal stabilizer transforming the long travel of the cable into the shorter travel finally used for tab actuation. The Bowden cable itself may be actuated either by the pilot using the trim wheel or by the trim servo located on the floor of the tail cone compartment. The electric trim system may be operated independently from the autopilot. When an autopilot pitch mode is active and the electric trim system is switched on by the TRIM master switch in the pilot's instrument panel, the trim system operates in the auto trim mode. The pitch servo continuously senses the force necessary to maintain the assigned pitch attitude and transmits the signal to the autopilot main unit. This computes a signal to actuate the trim servo. By this mechanism the force the pitch servo has to apply on the elevator is minimized. When the autopilot is active (in a pitch mode) and the electric trim servo (TRIM master switch) is switched off a visual and audible annunciation to the pilot is provided by the autopilot system asking him to trim the airplane manually by means of the trim wheel. With autopilot switched off or no pitch mode engaged, but electric trim servo (TRIM master switch) on, the longitudinal trim may be adjusted by the pilot using the momentary split rocker switch on top of the left horn of the pilot's control yoke. Yaw Damper The yaw damper system consists of two units, the yaw servo actuating the rudder control cables and the yaw amplifier, which generates the signal for the servo. The amplifier is installed behind the aft pressure dome in the tail cone compartment. The amplifier features an integrated lateral acceleration sensor. This sensor detects lateral components of the gravity vector, which corresponds to the “ball not being centered”. Based on this input signal the yaw amplifier derives the control signal for the yaw servo. To allow for a fine adjustment of slip/skid angle, a yaw trim potentiometer allows the pilot to adjust (“trim”) the zero yaw angle based on a slip/skid indicator. In the OFF position of the yaw damper control switch the yaw damper is not engaged and the yaw servo clutch remains open. With the switch in ON position the yaw damper remains engaged as long as the autopilot is engaged in a roll mode. A roll signal from the autopilot main unit is provided to the yaw amplifier as an additional input (to the lateral acceleration sensed internally). Yaw damper disconnect is provided by the same means as the autopilot disconnect as the autopilot main unit provides a yaw damper enable signal to the yaw amplifier as long a roll mode is active. As soon as the autopilot disconnects the yaw damper follows therefore.
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Page 7
Figure 22-1
Page 8
22 Trim Wheel
IFDs
CWS Switch (control wheel steering)
AP Disconnect Switch
Split Trim Rocker Switch
Roll Servo
Trim Wheel
Autopilot Switch Panel
Programmer/Computer Turn Coordinator
Trim Servo
3rd Static Port
Yaw Amplifier Absolute Pressure Transducer
Yaw Servo
Pitch Servo
Maintenance Manual EXTRA 500
Autopilot Installation
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Maintenance Manual EXTRA 500
System Components The following components are used in the S-TEC 55 installation of the EXTRA 500: Unit Designation
Location
Function
Autopilot Components Programmer/Computer (P/C) (special configuration for EXTRA 500)
Instr. Panel
Pilot interface signal generation for roll, pitch and pitch trim servo
Yaw amplifier
Tail cone equipment Yaw sensor & signal generation for yaw rack servo
Turn Coordinator
Instr. Panel
Sensing rate of turn, input signal for P/C, indication to pilot
Absolute pressure Transducer Tail cone equipment Converting static pressure => electric signal rack Roll Servo
Front wing compartment
Pitch Servo
Tail cone equipment Elevator actuation, force sensing for trim rack system
Pitch Trim Servo
Tail cone floor
Yaw Servo
Tail cone equipment Rudder actuation rack
Autopilot Relay
behind instrument panel
Connecting inputs to A/P computer from either IFD 1 or IFD 2
Autopilot Master Switch
Autopilot Panel (Pilot Instrument Panel)
Activation of autopilot and / or flight director
Pitch Trim Switch
Autopilot Panel (Pilot Instrument Panel)
Activation of electric pitch trim System
Yaw Damper Master Switch
Autopilot Panel (Pilot Instrument Panel)
Activation of yaw damper
Yaw Trim Knob (rotary Potentiometer)
Autopilot Panel (Pilot Instrument Panel)
Adjustment of zero jaw attitude
Trim command Switch (split switch)
Control Wheel
Change of aircraft pitch trim
CWS-Switch
Control Wheel
Engaging CWS-mode
Autopilot disconnect / trim interrupt switch
Control Wheel
Disengaging autopilot, interruption of electric trim actuation
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Aileron actuation
Trim tab actuation
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Unit Designation
Location
Function
Closely related systems/components Audio Panel
Instrument panel
Audible warnings from P/C
IFD 1
Instrument panel
Source for heading and course, vertical speed command, Flight Director display
IFD 2
Instrument panel
Source for heading and course, vertical speed command, flight director display
Keypad
Center console
Altitude and heading selection, inputs to IFDs
Stall warning switch (“Lift Detector”)
LH wing leading edge
Disconnect of A/P when stall warning becomes active
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Troubleshooting Complaint Autopilot will not engage in any mode
Possible Cause
Remedy
Autopilot has no power
Check AUTOPILOT MASTER switch FD or MASTER.
Autopilot has no power
Check AVIONICS switch ON.
No valid signals from turn coordinator
Check turn coordinator no flag.
AP disconnect switch struck/defective
Check AP disconnect switch continuity.
Pitch trim switch stuck/defective
Check pitch trim switch stuck.
Computer defective
Replace computer.
No roll mode engaged
A roll mode MUST be selected first
Computer defective
Replace computer.
No valid signal from absolute pressure transducer
Replace absolute pressure transducer.
Autopilot not coupled in both axes
An altitude and roll mode must be engaged previously.
Switch defective
Replace CWS switch.
Computer defective
Replace computer.
AP disconnect switch does not work
Switch defective
Replace AP disconnect switch.
Computer defective
Replace computer.
Mode engages, but servo does not couple
AP in FD mode
Check AUTOPILOT MASTER switch in MASTER position (not FD)
Servo defective
Replace servo.
Pitch system has no power
Check battery bus power.
Pitch system has no power
Check pitch trim switch ON.
Pitch trim switch defective
Replace pitch trim switch.
Computer defective
Replace computer.
Pitch trim servo defective
Replace pitch trim servo.
Will not engage in any altitude mode
CWS does not work
Electrical Pitch trim does not work
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Complaint Yaw trim does not work
Possible Cause
Remedy
No power to yaw amplifier
Check battery bus power
YAW DAMPER switch OFF.
YAW DAMPER switch ON.
Yaw damper switch defective
Replace yaw damper switch.
No roll mode enabled
Engage roll mode first.
Yaw amplifier defective
Replace yaw amplifier.
Yaw servo defective
Replace yaw servo.
Yaw trim poti defective
Replace yaw trim potentiometer.
Heading Calibration Detail Steps/Work Items
Key Items
1 Attach external power. 2 Check all switches OFF, A/P CMPTR CB IN, Turn-Coord CB IN, A/P SERVO CB IN, All IFD CB-s IN 3 Switch on EXT PWR 4 Switch on AUTOPILOT - MASTER 5 Check turn coordinator runs up, off-flag disappears, Autopilot display shows 7 on display, Autopilot display shows rdy, LH IFD shows AP RDY 6 Wait for 2 minutes
to let turn coordinator run up
7 Set IFD to NAV I 8 Tune NAV I to a frequency that has no reception 9 Set heading bug to current heading
push heading knob on keypad
10 Select NAV mode on autopilot
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11 Adjust the potentiometer between the REV and ALT buttons in small increments until the yoke stops turning
use miniature flat screwdriver
12 Make sure in the end the AP is in SOFT mode
indicated on IFD
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22-10-01
Roll Servo Removal Refer to Figure 22-2. Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. T
2 Remove wing center fairing.
Refer to Chapter 51-00-01
3 Disconnect electrical connector from roll servo. 4 Loosen bridle cable clamps. 5 Remove 3 bolts and nuts securing roll servo to support bracket. 6 Remove roll servo from support bracket. 7 Remove cable guard, cover and bridle cable from servo capstan, if required.
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Top View Upper control cable
fwd
bridle cable center ball
bridle cable bridle cable
Attachment bolts
Lower control cable
Roll Servo
Front View Upper control cable
Attachment bolts Cable clamp
Cable clamp
bridle cable end
bridle cable end bridle cable bridle cable Roll Servo
Figure 22-2
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Lower control cable
Roll Servo Installation
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Installation Detail Steps/Work Items
Key Items
IMPORTANT
Prior to installing roll servo, adjust clutch torque and determine proper direction of capstan rotation. See Section 22-10-04 for clutch torque settings.
IMPORTANT
Prior to installing roll servo, check aileron control system travels. Check aileron cable tension in accordance with Chapter 27-00-01.
IMPORTANT
Removal of servo requires disconnecting the bridle cable. Consequently, bridle cable tensioning is required upon reinstallation of the servo. 1 Ensure BATT switch is OFF and no external power connected. T
2 Attach roll servo with 3 screws to support bracket. 3 Insert bridle cable center ball into leading hole in capstan. 4 Adjust position of center ball with aileron controls in neutral position.
12 o’clock position. See Figure 22-2
5 Wrap bridle cable around capstan 1.5 turns each direction from center ball.
Cable clamps will be positively guided to correct position
6 Install cable guards and cover with 4 screws and washers.
Tighten screws only snugly against servo base plate Apply tension by hand before tightening the cable clamps. See 22-10-07Figure 22-6 for clamp torquing. Cable clamps may be rotated on aileron cable to align bridle cable with capstan grooves.
7 Install cable clamps. Adjust bridle cable tension to the value given in Subject 22-10-06.
8 Connect electrical connector. 9 Install wing center fairing.
Refer to Chapter 51-00-01
Function Test Detail Steps/Work Items
Key Items
1 Attach external power to the aircraft. 2 Check all switches off. 3 Switch EXT PWR on. 4 Switch AUTOPILOT MASTER to MASTER. 5 Check AP RDY on IFD. 6 Check RDY on autopilot computer. Page Date: 30. March 2012
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Detail Steps/Work Items
Key Items
7 Switch on HDG mode. 8 Check HDG is displayed on autopilot computer. 9 Check HDG bug is fully filled and magenta on IFD. 10 Turn HDG knob to the left. 10 Check control wheel turns CCW. 11 Turn HDG knob to the right. 12 Check control wheel turns CW. 13 Press AP DISC switch on LH control wheel.
Aural warning can be heard.
14 Switch AUTOPILOT MASTER off. 15 Switch EXT PWR off. 16 Disconnect external power.
22-10-02
Pitch Servo Removal Refer to Figure 22-3. Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. T
2 Remove tail cone access panel. 3 Disconnect electrical connector from roll servo. 4 Loosen bridle cable clamps. 5 Remove return pulley. 6 Remove 4 bolts and nuts securing pitch servo to support bracket. 7 Remove pitch servo from support bracket. 8 Remove cable guard, cover and bridle cable from servo capstan, if required.
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Top View bridle cable longer end
fwd
Cable clamps
bridle cable shorter end
Pulley
bridle cable
Attachment bolts
bridle cable center ball
Pitch servo
Control cable
Figure 22-3
Pitch Servo Installation
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Installation Detail Steps/Work Items
Key Items
IMPORTANT
Prior to installing pitch servo, adjust clutch torque and determine proper direction of capstan rotation. See Section 22-10-04 for clutch torque settings.
IMPORTANT
Prior to installing pitch servo, check elevator control system travels. Check elevator cable tension in accordance with Ch. 27-00-01.
IMPORTANT
Removal of servo requires disconnecting the bridle cable. Consequently, bridle cable tensioning is required upon reinstallation of the servo. 1 Ensure BATT switch is OFF and no external power connected. T
2 Attach pitch servo with 4 screws to support bracket. 3 Insert bridle cable center ball into leading hole in capstan. 4 Adjust position of center ball with elevator controls in neutral position.
11 o’clock position. See Figure 22-3
5 Wrap bridle cable around capstan 1 turn (360°) CW and 1.5 turns (540°) CCW from center ball.
Cable clamps will be positively guided to correct position
6 Install cable guards and cover with 4 screws and washers.
Tighten screws only snugly against servo base plate
7 Install return pulley. 8 Lead upper bridle cable segment around pulley and pre-install cable clamps. Tension bridle cable by hand before fastening the cable clamps.
See 22-10-07Figure 22-6 for clamp torquing. Cable clamps may be rotated on elevator cable to align bridle cable with capstan grooves
9 Connect electrical connector. 10 Adjust correct bridle cable tension.
Refer to the Tension Settings and the Tensioning procedure presented in Subject 22-10-06.
11 Install tail cone access panel.
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Function Test Detail Steps/Work Items
Key Items
1 Attach external power to the aircraft. 2 Check all switches off. 3 Switch EXT PWR on. 4 Switch AUTOPILOT MASTER to MASTER. 5 Check AP RDY on IFD. 6 Check RDY on autopilot computer. 7 Set heading bug to current heading
push heading knob on keypad
8 Switch on HDG mode. 9 Switch on VS mode. 10 Check ALT bug is open. 11 Check VS bug is filled and magenta on IFD. 12 Check control wheel moves forward. 13 Set VS bug to +1000 ft. 14 Control wheel moves aft or at least tries.
On the ground the servo does not have enough power.
15 Press AP DISC switch on LH control wheel.
Aural warning can be heard.
16 Switch AUTOPILOT MASTER off. 17 Switch EXT PWR off. 18 Disconnect external power.
22-10-03
Yaw Servo Removal Refer to Figure 22-4. Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. T
2 Remove tail cone access panel. 3 Disconnect electrical connector from roll servo. Page Date: 30. March 2012
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Detail Steps/Work Items
Key Items
4 Loosen bridle cable clamps. 5 Remove 4 bolts and nuts securing yaw servo to support bracket. 6 Remove yaw servo from support bracket. 7 Remove cable guard, cover and bridle cable from servo capstan, if required.
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Top View Bridle cable end fwd
Control cable Cable clamp
Attachment bolts Bridle cable
Bridle cable center ball
Yaw servo Bridle cable
Cable clamp
Bridle cable end Figure 22-4
Yaw Servo Installation
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Installation Detail Steps/Work Items
Key Items
IMPORTANT
Prior to installing yaw servo, adjust clutch torque and determine proper direction of capstan rotation. See Section 22-10-04 for clutch torque settings.
IMPORTANT
Prior to installing yaw servo, check elevator control system travels. Check elevator cable tension in accordance with Ch. 27-00-01.
IMPORTANT
Removal of servo requires disconnecting the bridle cable. Consequently, bridle cable tensioning is required upon reinstallation of the servo. 1 Ensure BATT switch is OFF and no external power connected. T
2 Attach yaw servo with 4 screws to support bracket. 3 Insert bridle cable center ball into leading hole in capstan. 4 Adjust position of center ball with rudder controls in neutral position.
12 o’clock position See Figure 22-4
5 Wrap bridle cable around capstan 1.5 turns each direction from center ball.
Cable clamps will be positively guided to correct position
6 Install cable guards and cover with 4 screws and washers.
Tighten screws only snugly against servo base plate
7 Lead upper bridle cable segment around pulley and install cable clamps Adjust bridle cable tension to the value given in Subject 22-10-06.
See Figure 22-6 for clamp torquing. Cable clamps may be rotated on elevator cable to align bridle cable with capstan grooves
8 Connect electrical connector. 9 Install tail cone access panel.
Function Test Detail Steps/Work Items
Key Items
1 Attach external power to the aircraft. 2 Check all switches off. 3 Switch EXT PWR on. 4 Switch AUTOPILOT MASTER to MASTER. 5 Engage heading mode 6 Switch AUTOPILOT YAW DAMPER on. 7 Turn YAW TRIM potentiometer to the left. Page 22
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Detail Steps/Work Items
Key Items
8 Check rudder pulses to the left. 9 Turn YAW TRIM potentiometer to the right. 10 Check rudder pulses to the right. 11 Press AP DISC switch on LH control wheel. 12 Switch AUTOPILOT YAW DAMPER off. 13 Switch EXT PWR off. 14 Disconnect external power.
22-10-04
Clutches (Pitch, Roll and Yaw Servo) Torque Settings The following torque settings must be checked and adjusted: Servo P/N
Clutch Torque setting
Servo RPM @24VDC (fixed, not adjustable)
Pitch S-TEC 0108-P4
29 ± 2 inlbs
1.08
Roll
S-TEC 0106-R2
36 ± 2 inlbs
2.40
Yaw
S-TEC 0106-6-Y9
73 ± 2 inlbs
3.59
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Torque Adjustment Before re-installation of a servo, perform the following steps to check and adjust clutch torque value in accordance with the Torque Settings given above.
Dial Torque Wrench Capstan Cover
Shim Washer
Tool S-TEC P/N 6622-1
Tension Washer
Cable Guard
Figure 22-5
Clutch Torque Adjustment
Detail Steps/Work Items
Key Items
1 Remove capstan cover from servo with 4 screws and washers. 2 Draw cotter pin from castle nut. 3 Insert adapter tool (S-TEC P/N 6622-1) into leading holes in servo capstan. 4 Bear dial torque wrench. 5 Connect servo motor to 28 VDC power source.
Servo shaft rotates
6 Read torque value.
See Torque Settings chart of Subject 22-10-04 for appropriate settings. Perform clutch torque adjustment as per step 7 - 8, if necessary
7 Remove torque wrench and adapter tool. 8 Align torque value with castle nut - turn CW to increase and CCW to decrease torque. 9 Repeat steps 3 to 8, until read torque setting (step 6) matches value given in Torque Settings chart of Subject 22-10-04. Page 24
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Detail Steps/Work Items
Key Items
10 Disconnect servo motor. 11 Re-install cotter pin. NOTE
To align cotter pin with shaft hole, use shim washers S - TEC P/N 1205 S 5 - 005, 007, 010, 031 in any combination (min. 1 required). 12 Re-install capstan cover.
NOTE
22-10-05
After capstan cover has been installed, determine that there is no interference between capstan and cover.
Driving Wheels Removal/Installation Detail Steps/Work Items
Key Items
1 Draw cotter pin from castle nut. 2 Remove castle nut. 3 Remove 2 tension washers. 4 Remove driving wheel. IMPORTANT
After removal of driving wheel, clutch torque adjustment is required.
Refer to Section 22-10-04 for torque settings.
5 Install in reverse order of removal.
22-10-06
Bridle Cables Removal/Installation Detail Steps/Work Items 1 Unfasten cable clamp bolts as far as necessary to unthread the bridle cable.
Key Items On both ends
2 Uncoil the bridle cable from the servo. 3 Install in reverse order of removal.
Page Date: 30. March 2012
Observe correct position of bridle cable center ball. Refer to applicable servo Installation Procedure.
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Tension Settings The following tension settings must be checked (cable tensiometer) and adjusted: Bridle Cable
Tension Setting
Pitch
32 ± 2 lbs
Roll
15 ± 2 lbs
Yaw
15 ± 2 lbs
Tensioning Generally the necessary tension can be applied by hand to the bridle cables before tightening the cable clamp bolts. However for tensioning the pitch servo bridle cable the power of the pitch servo itself is necessary to receive the correct tension values. Proceed as follows (refer to Figure 22-3): Detail Steps/Work Items
Key Items
1 Install the bridle cables as per Subject 2210-02. 2 Fix control wheel in neutral position by hand. 3 Switch on AUTOPILOT MASTER. 4 Switch on the VS Mode on the Autopilot Programmer/Computer. 5 Position VS bug to +1000 ft.
Control wheel tries to move aft. Counteract by hand. The pitch servo now tensions the longer bridle cable end.
6 Loosen cable clamp of the shorter bridle cable end, tension by hand, and retighten cable clamp bolts.
The tension applied here by hand allows adjusting the bridle cable to the desired tension.
7 Switch off AUTOPILOT MASTER. 8 Check bridle cable tension.
Use a conventional cable tensiometer.
9 Repeat procedure if necessary varying tension on step 6.
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22-10-07
Cable Clamps Observe the following values when installing/fastening the cable clamps.
Figure 22-6
22-10-08
Cable Clamp Torquing
Trim Servo Removal/ Installation Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. T
2 Remove tail cone access panel. 3 Disconnect electrical connector from trim servo. 4 Remove swivel from transmission chain. 5 Remove transmission chain. 6 Remove 4 bolts and nuts securing servo support bracket to GFK base. 7 Remove 4 bolts and nuts securing trim servo to support bracket. 8 Move trim servo with driving wheel to the right fuselage side out of support bracket. 9 Remove trim servo in forward direction. IMPORTANT
Prior to installing trim servo, check and adjust clutch torque and determine proper direction of driving wheel rotation. See Section 22-1004 for clutch torque settings.
IMPORTANT
Prior to installing trim servo, check trim tab control system.
10 Install in reverse order of removal.
Function Test Detail Steps/Work Items
Key Items
1 Attach external power to the aircraft. Page Date: 30. March 2012
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Detail Steps/Work Items
Key Items
2 Check all switches off. 3 Switch EXT PWR on. 4 Switch AUTOPILOT PITCH TRIM on. 5 Move (complete) TRIM switch on the LH control wheel forward. 6 Check trim wheel (upper part) turns forward. 7 Move (complete) TRIM switch on the LH control wheel aft. 8 Check trim wheel (upper part) turns aft. 9 Press AP DISC switch on LH control wheel. 10 Switch AUTOPILOT PITCH TRIM off. 11 Switch EXT PWR off. 12 Disconnect external power.
22-10-09
Trim Servo Clutch Torque Settings The following torque setting must be checked and adjusted: Servo P/N Trim S-TEC 0106-2-T3
Clutch Torque setting 36 ± 2 inlbs
Servo RPM @24VDC (fixed, not adjustable) 11.03
Torque Adjustment Before re-installation, perform the following steps to check and adjust clutch torque value given above. Detail Steps/Work Items
Key Items
Measuring 1 Draw cotter pin from castle nut. 2 Insert adapter tool (S-TEC P/N 6622-1) into leading holes in driving wheel. 3 Bear dial torque wrench.
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Detail Steps/Work Items
Key Items
4 Connect servo motor to 28 VDC power source.
Servo shaft rotates
5 Read torque value.
See above for appropriate torque settings. Perform clutch torque adjustment as per step 6 - 7, if necessary
Adjustment 6 Remove torque wrench and adapter tool. 7 Align torque value with castle nut - turn CW to increase and CCW to decrease torque. 8 Repeat steps 2 to 7, until read torque setting (step 5) matches value given above. 9 Disconnect servo motor. 10 Re-install cotter pin. NOTE
22-10-10
To align cotter pin with shaft hole, use shim washers S - TEC P/N 1205 S 5 - 005, 007, 010, 031 in any combination (min. 1 required).
Pressure Transducer Removal/Installation Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. T
2 Remove tail cone access panel.
Refer to Chapter 51-00-01.
3 Disconnect electrical connector from pressure transducer. 4 Disconnect pressure hose from pressure transducer.
Cut cable tie
5 Remove pressure transducer.
2 bolts
6 Install in reverse sequence of removal.
Fasten pressure hose with new cable tie.
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22-10-11
Yaw Amplifier Removal/Installation Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. T
2 Remove tail cone access panel. 3 Disconnect electrical connector from yaw amplifier. 4 Remove pressure yaw amplifier.
4 bolts
5 Install in reverse sequence of removal.
22-10-12
Programmer/Computer Removal/Installation Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. 2 Place a Allen key in hole between REV Computer will come out. and ALT key, rotate CCW. 3 Pull out rest of the way.
Do not pull on VS knob!
4 Remove programmer/computer
22-10-13
5 Install in reverse sequence of removal.
Use Allen key, rotate CW until computer sits firmly in rack, flush with panel.
6 Perform heading calibration procedure
Refer to Subject 22-10-00 Heading Calibration
Turn Coordinator Removal/Installation Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. Page 30
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Detail Steps/Work Items 2 Remove RH IFD.
Key Items Refer to Chapter 31-60-01.
3 Disconnect electrical wiring. 4 Remove turn coordinator.
4 screws
5 Install in reverse sequence of removal. 6 Perform heading calibration procedure
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Refer to Subject 22-10-00 Heading Calibration
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Intentionally left blank
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Chapter 23 Communications
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Page 1
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Table of Contents
23-00-00
GENERAL ........................................................................................................ 3 Description.......................................................................................................... 3 Troubleshooting.................................................................................................. 3
23-10-00
SPEECH COMMUNICATION ...................................................................... 5 Description.......................................................................................................... 5 Operation ............................................................................................................ 5
23-50-00
AUDIO INTEGRATING ................................................................................. 6
23-50-01
Intercom System PS Engineering PMA8000B(-T) ........................................ 6 Description.......................................................................................................... 6 Operation ............................................................................................................ 6 Removal.............................................................................................................. 6 Installation .......................................................................................................... 6 Tests and Checks ................................................................................................ 7
23-50-02
Antennas ............................................................................................................ 8 Description.......................................................................................................... 8 Removal/Installation........................................................................................... 8
23-60-00
STATIC DISCHARGING ............................................................................... 9 General................................................................................................................ 9 Description.......................................................................................................... 9 Lightning Protection/Static Discharging System ............................................. 10
Figure 23-01
Page 2
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23-00-00
GENERAL Description The EXTRA 500 is equipped with a speech and entertainment communication system, consisting of the following devices: 1 Avidyne Entegra Release 9 IFD System 2 PS Engineering PMA8000B(-T) Stereo Intercom System 3 COM 1, 2, and Marker Antennas The system units (1 and 2) are mounted to the instrument panel, the antennas as shown on Figure 23-01. In Chapter 23-10-00 Speech Communication you will find information about Avidyne Entegra Release 9 IFD System. The related PS Engineering PM8000B(-T) devices and the COM antennas are subject to Chapter 23-50-00 Audio Integrating. Chapter 23-60-00 Static Discharging contains a description of the EXTRA 500 bonding system.
Troubleshooting Complaint Unable to transmit or receive
Possible Cause
Remedy
No power on load bus
Switch on starter/generator or external power.
Defective AUDIO-MRK breaker
Replace
Unable to transmit or receive COM I
Defective LH IFD
Replace LH IFD
Unable to transmit or receive COM II
Defective RH IFD
Replace RH IFD
Unable to transmit with IFD indication
No or defective antenna cable connections
Check antenna cable connections
Unable to transmit from the pilot's side (missing transmit mode indicator on display)
Defective transmit button on pilot's side
Replace
Defective wiring between pilot's transmit button and radio unit
Repair
Unable to transmit from the co-pilot's side (missing transmit mode indicator on display)
Defective transmit button on co-pilot's side
Replace
Defective wiring between copilot's transmit button and radio unit
Repair
No modulation when transmitting from pilot's seat
Defective pilot's headset
Replace
Defective wiring
Repair
COM [1/2] TX Fault
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Maintenance Manual EXTRA 500
Complaint
Possible Cause
Remedy
No modulation when transmitting from co-pilot's seat
Defective co-pilot's headset
Replace
Defective wiring
Repair
Short range in transmit mode; reception without problems
Defective radio unit
Repair
Short range in receive mode; signal noise in reception
Defective radio unit
Repair
Short range in transmit and receive mode; signal noise in reception
Defective COMM antenna, coaxial cable and plug
Repair or replace
Speaker silent, headsets operation normal
Defective speaker
Replace
Defective wiring
Repair
Defective intercom unit
Replace
Transmit button stuck
Replace
Defective intercom unit
Replace
Defective wiring
Repair
Transmit mode indicator on display is always visible COM [1/2] Stuck TX
Intercom system inoperative, transmit mode O.K.
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Maintenance Manual EXTRA 500
23-10-00
SPEECH COMMUNICATION Description The EXTRA 500 airplane is equipped with an Avidyne 700-00083-000 Integrated Flight Display (IFD) in the left (PFD) position and either another 700-00083-000 IFD in the right (MFD) position. A Control Display Unit (CDU) p/n 700-00150-002 is also installed as part of the Entegra Release 9 IFD System and located on the middle console. Refer to Chapter 31-60 for more information. The system is integrated to: • S-TEC System 55X Autopilot • Audio panel • Remote transponder • DME (optional) • Weather detection (optional) • Traffic advisory (optional)
Operation Refer to POH EXTRA 500.
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Maintenance Manual EXTRA 500
23-50-00
AUDIO INTEGRATING
23-50-01
Intercom System PS Engineering PMA8000B(-T) Description The PMA8000B and PMA8000BT are audio isolation amplifier and audio selector that contain an automatic voice activated (VOX) intercom system and integral marker beacon receiver. They can switch two transceivers (Com 1, Com 2) and six receivers (Com 1, Com 2, Nav 1, Nav 2, DME, and MKR).
Operation Refer to EXTRA 500 Pilot's Operating Handbook.
Removal Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. T
2 Put a 3/32 Allen wrench into the center access hole between the Com2 and Mon1 push buttons for the locking screw in the front panel. Engage the screw. 3 Turn the screw counter-clockwise until the unit disengages from the mounting rack. CAUTION
Do not pull on the knobs. Do not pry the face plate. You can damage the unit.
CAUTION
Do not touch the connector card at the rear of the unit. The electrostatic charge on your body can damage the unit.
4 Pull the sides of the unit gently to remove it from the mounting rack. 5 Install the protective covers on the rear connectors of the unit.
Installation Detail Steps/Work Items
Key Items
1 Remove the protective covers from the rear connectors of the unit. 2 Slide the unit into the rack. 3 Engage the locking screw so that the latch front lobe touches the rack. Page 6
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Detail Steps/Work Items
Key Items
4 Turn the locking screw clockwise so that the rear lobe engages the mounting rack. CAUTION
Do not over-tighten the locking screw. You can damage the locking mechanism.
5 Continue to turn the screw until the unit is fully installed in the mounting rack. 6 Perform a function test.
See Tests and Checks below.
Tests and Checks Perform the applicable operational checkout presented in the Avidyne System Installation and Operation Manual (LOAP 37) or (LOAP 38) whenever the unit has been reinstalled.
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23-50-02
Antennas Description For communication transmitting and receiving conventional antennas (COM 1, 2, and Marker) are used (refer to Figure 23-01). The antennas are attached to the fuselage by a ground plate. The lightning protection sheet is placed between the ground plate and the fuselage structure and thus ensures bonding. Connection is made via conventional BNC plugs and sockets. The Marker and COM 2 antenna is integrated in the structure of the ventral fin. Maintenance should not be required. In case access to this antenna is required, contact EXTRA.
Removal/Installation Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. T
2 Disconnect BNC plug. 3 Remove attachment nuts. 4 Remove antenna. 5 Install in reverse sequence of removal.
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Ensure lightning protection sheet is placed between fuselage structure and ground plate.
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Maintenance Manual EXTRA 500
23-60-00
STATIC DISCHARGING General A special bonding system is necessary for the composite structure of the EXTRA 500. The composite structure does not sufficiently conduct electricity. Lightning protection aluminium sheets are attached to the inner fuselage skin to make a conduct path. Attachment is made by fabric layers and interconnections between sheets are made by rivets. All metal components are bonded to the aluminium sheets by copper leads. Some components are directly connected to the aluminium sheets when attached (so as the COM 1, 2, and Marker antenna).
Description A main aluminium sheet is routed from the firewall to the right side of the inner fuselage and then to the rear. Several extensions are routed to the wing, landing gear, antennas and other equipment as shown on Figure 23-01 (Figure 23-01 only shows the lightning protection system and equipment as far as applicable for communication system static discharging).
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Page 9
NAV Antenna
COM 1 Antenna
Strobe Light Power Supply
COM 2 Antenna
Strobe Light
Maintenance Manual EXTRA 500
Figure 23-01 Page 10
23
Lightning Protection/Static Discharging System Page Date: 30. March 2012
Maintenance Manual EXTRA 500
Chapter 24 Electrical Power
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Page 1
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Table of Contents
24-00-00 Figure 24-1 Figure 24-2 Figure 24-3
GENERAL ........................................................................................................ 3 Description.......................................................................................................... 3 Electrical System Schematic............................................................................... 4 Left Side Panel Switches..................................................................................... 5 Left Side Panel Circuit breakers ........................................................................ 6 Troubleshooting.................................................................................................. 7
24-30-00
DC GENERATION .......................................................................................... 9
24-30-10
Starter-Generator............................................................................................. 9 Removal/Installation........................................................................................... 9
24-30-11
Generator Control Unit (GCU) ....................................................................... 9 Removal/Installation......................................................................................... 10
24-30-20
Standby Alternator......................................................................................... 10 Removal/Installation......................................................................................... 10
24-30-21
Alternator Regulator ...................................................................................... 10 Removal/Installation......................................................................................... 11
24-30-30
Battery ............................................................................................................. 11 Charging with external power .......................................................................... 11 Charging over charger plug .............................................................................. 12 Removal/Installation......................................................................................... 12
24-30-40
Indication......................................................................................................... 12
24-30-41
Indicator Cluster............................................................................................. 12 Removal/Installation......................................................................................... 13
24-40-00
EXTERNAL POWER .................................................................................... 14 Description........................................................................................................ 14
24-60-00
DISTRIBUTION............................................................................................. 15 Description........................................................................................................ 15
24-60-01
E-box ................................................................................................................ 16 Removal/Installation......................................................................................... 16
24-60-02
Switches ........................................................................................................... 16 Removal/Installation......................................................................................... 16
24-60-03
Circuit Breakers ............................................................................................. 17 Removal/Installation......................................................................................... 17
24-60-04
Relays ............................................................................................................... 17
24-60-05
Shunts .............................................................................................................. 17
24-60-06
Fuses................................................................................................................. 17
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24-00-00
GENERAL Description Refer to Figure 24-1. The electrical system is a 28 VDC system with negative ground. The primary DC power source is an engine driven 28 V/200 A startergenerator. It is backed up by an engine driven 26 V/20 A standby alternator. In addition a lead acid battery (24 V/28 Ah) is installed in the engine compartment. Normal battery power is sufficient to start engine or for ground check operation. An external 28 VDC power receptacle and its circuit breaker are installed in a hatch right hand at fixed portion of the cowling.
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Page 3
C EM B E G E RGE N N ST TE S C Y AR T GE T N EX T AV PW IO R ST NIC DB S YA LT
RC
BA TT
Maintenance Manual EXTRA 500
y
Generator control unit
r y
Alternator control unit
Bus voltage Battery current Generator current
External power
Battery 24 VDC
Standby alternator 20 A Starter/generator 200 A
Hot bus
Load bus
Emerg. bus
Batt. bus AV bus
Legend:
y
Hot bus
Figure 24-1
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Switch
Shunt
Annunciator light
Circuit breaker
Electrical bus
Fuse
Relay
Gauge
Electrical System Schematic
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CABIN
DEICE
LIGHTS
AVIONIC MASTER
MAIN
Maintenance Manual EXTRA 500
Figure 24-2
Left Side Panel Switches
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Maintenance Manual EXTRA 500
Figure 24-3
Page 6
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Left Side Panel Circuit breakers
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Maintenance Manual EXTRA 500
Troubleshooting The following paragraph tabulates the trouble shooting procedures relevant to the battery system. Complaint System not energized when battery switch is turned on
Possible Cause
Remedy
Depleted or dead battery
Recharge or replace.
Defective wiring
With BATT switch OFF, check entire DC power system, accessible from plane fire wall resp. lower tail cone access panel, for an open circuit with a continuity tester
Defective battery relay
With BATT switch ON, connect a voltmeter to the main battery bus and check voltage. If no voltage is indicated, check and/or replace relay
Defective BATT switch
Remove switch and check with continuity tester. Replace switch if defective.
Charging rate too low
Check generator
Battery has been left standing too long without recharging
Recharge or replace
Equipment has been left on accidentally
Replace battery
Short circuit in wiring
Check wiring, replace battery.
Low charging rate
Check generator voltage
Corroded or loose battery connections
Clean and tighten, recharge battery.
Reduced battery capacity
Replace battery.
Battery polarity reversed
Connected backwards on airplane or charger
Battery should be slowly discharged completely, then charged correctly and tested
Battery freezes
Undercharged or overcharged battery
Replace battery
Battery discharged
Short battery life
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Complaint Starter-generator does not produce current when switched on.
Possible Cause
Remedy
Starter-generator defective
Replace starter-generator.
Generator control unit defective
Replace generator control unit.
GEN switch defective
Replace GEN switch.
Generator relay defective
Replace generator relay (Ebox).
Current indication defective
Replace shunt. Replace indicator. Repair wiring.
Standby alternator does not produce power when switched on
Bus voltage above 26.5 V
Normal, no action required.
Alternator defective
Replace alternator.
Alternator controller defective
Replace alternator controller.
Wiring defective
Repair wiring.
STDBY ALT switch defective
Replace STDBY ALT switch.
Alternator relay defective
Replace alternator relay (Ebox).
Alternator fuse defective
Examine reason and replace alternator fuse (E-box).
Current indication defective
Replace shunt.
T
Replace indicator. Repair wiring. Load bus without power
Starter-generator or external power not on.
Normal, no action required.
Load bus fuse defective
Replace fuse (E-box).
Battery bus without power
Battery bus fuse defective
Replace fuse (E-box).
Avionic bus without power
Battery bus without power
See above.
AVIONICS switch defective
Replace AVIONICS switch (left side panel).
Avionic bus relay defective
Replace avionic bus relay (left side panel).
AV BUS circuit breaker
Replace AV BUS circuit breaker (left side panel).
defective
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24-30-00
DC GENERATION Refer to Figure 24-1. DC generation is done by the following devices: • Starter-generator • Standby Alternator • Battery
24-30-10
Starter-Generator A starter-generator is mounted on the accessory gearbox of the engine. It is a direct driven starter during engine start and a DC generator driven by the engine during engine operation. Its rated capacity is 200 A maximum for continuous operation.
Removal/Installation Remove the LH upper engine cowling to get access to the starter-generator. Refer to AIRCRAFT PARTS CORP. Installation Instructions 200SGL Series Starter-Generators (LOAP 39) for further information.
24-30-11
Generator Control Unit (GCU) The starter-generator is regulated by the GCU (Generator Control Unit) to provide an output voltage of 28.5 V DC. The GCU is installed to the fuselage structure behind the left legroom side paneling. The GCU is controlled by the GEN and GEN TEST switches located on the MAIN section of the left side panel. Following engine start, the generator delivers electrical power when the GEN switch is switched to ON position. In case the generator is not switched on or has failed the red GENERATOR FAIL warning light on the annunciator panel illuminates. With the generator test switch (GEN TEST, left side panel) the overvoltage protection function of the GCU can be tested (switch position: OV-TEST). The TRIP position of this switch gives the possibility to “trip” the generator by momentarily interrupting its excitation. Both test functions lead to disengagement of the generator from the aircraft bus system. The momentary RESET position of the GEN switch serves to energize the generator field in case problems have occurred trying to connect the generator to the aircraft bus system (switching the generator ON). Resetting the generator is recommended in that case before trying to switch the generator on again.
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Removal/Installation Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. T
2 Remove left legroom side paneling.
Refer to Chapter 25-00-01.
3 Remove electrical connector. 4 Remove GCU.
4 bolts
5 Install in reverse order of removal.
24-30-20
Standby Alternator In case of a starter-generator failure a gear driven standby alternator provides an additional power source in excess to the aircraft battery. The standby alternator is controlled by the STDBY ALT switch in the MAIN section of the left side panel. Switching it to the ON position will command the alternator regulating unit to regulate an alternator output voltage of 26 VDC. Therefore as long as bus voltage is higher caused by an active generator the alternator load will be zero. As soon as bus voltage drops below the regulation voltage of the standby alternator the alternator feeds to the bus system. Max. rated current is 20 A which is available with N1 being at approx 92 %. At 78 % N1 about 10 A are available. Below 70 % N1 the standby alternator isn’t able to provide a relevant current. Operation of the standby alternator is indicated by a yellow STANDBY ALTERN ON caution light on the annunciator panel. Continuous illumination of this light signals operation below the 20 A output limitation.
CAUTION
If the STANDBY ALTERN ON caution light starts blinking, the load on the alternator exceeds its rated capacity. Reduce consumption of electrical consumers within 5 minutes to 20 A or less.
Removal/Installation Remove the upper engine cowlings to get access to the stand-by alternator. Refer to B & C SPECIALTY PRODUCTS Installation Instructions for BC410 Alternators (LOAP 40) for further information.
24-30-21
Alternator Regulator The alternator regulator is mounted to the cabin side of the firewall. Refer to B & C SPECIALTY PRODUCTS B & C SPECIALTY PRODUCTS Troubleshooting Guide (LOAP 28) for further information.
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Maintenance Manual EXTRA 500
Removal/Installation Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. T
2 Remove RH and LH IFD.
Refer to Chapter 31-60-01.
3 Remove electrical connection. 4 Remove 2 nuts. 5 Remove regulator. 6 Install in reverse order of removal.
24-30-30
Battery The 24 VDC/28 Ah valve regulated lead acid battery is located in the engine compartment, mounted to the pressure bulkhead and protected by a vented aluminum case. The battery is directly connected to the hot bus. The battery supplies power to the electrical system when BATT switch is switched to ON position. Recharging the battery may be done with battery installed. There are two procedures:
Charging with external power Detail Steps/Work Items
Key Items
Always keep sparks or any form of ignition away from the battery being WARNING charged. Explosive gases are being generated during the charging process. 1 Set external power unit to 28 VDC. 2 Connect external power. 3 Switch on BATT. 4 Switch on EXT PWR.
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Maintenance Manual EXTRA 500
Charging over charger plug Detail Steps/Work Items
Key Items
Always keep sparks or any form of ignition away from the battery being WARNING charged. Explosive gases are being generated during the charging process. Do not charge with more than 5 A. Use only supplied unit or equivalent. 1 Connect the charger to the charger plug. 2 Connect the charger to the wall socket.
Removal/Installation Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. T
2 Remove upper engine cowlings.
Refer to Ch. 71-10-01/02.
3 Disconnect the quick connect plug. 4 Disconnect the 2 retainers. 5 Remove battery from aircraft. 6 Install in reverse order of removal
24-30-40
Indication Electric system relevant indication is made by the digital indicator cluster installed in the left side of the main panel and the following lights in the annunciator panel: GENERATOR FAIL (red), see Subject 24-30-10. LO VOLTAGE (yellow), illuminates as soon as bus voltage drops below 25.5 V. STANDBY ALTERN ON (yellow), see Subject 24-30-20. EXTERNAL POWER (green), see Subject 24-40-00.
24-30-41
Indicator Cluster The digital indicator cluster installed in the left side of the main panel indicates three electric system parameters among other engine parameters (also refer to Chapter 77-40-02):
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VDC (bus voltage) During normal operation (generator active) a voltage of approx 28 V should be indicated. With standby alternator the indication should be about 26 V. Battery nominal voltage is 24 V. GEN AMPS (Generator Load) Generator load is indicated on this indicator as long as the generator is active (GENERATOR FAIL warning light off). Generator Load should be kept below 200 A. In case the generator is offline this indicator automatically displays the standby alternator load. The standby alternator load has to stay below 20 A (see also Subject 24-30-20). BAT AMPS The battery amp indicator shows load or charging current on the battery. A negative indication means battery is being charged, a positive indication means battery is discharged (load on battery).
Removal/Installation For removal/installation procedures refer to Chapter 77-40-02.
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24-40-00
EXTERNAL POWER Description An external power receptacle is installed under an access door on the right side of the engine compartment. The use of external power is recommended for engine starting in case aircraft battery is weak, for ground operation of the vapor cycle air condition system or for any prolonged ground operation of aircraft systems. An external power source being connected with the external power receptacle and switched on will be indicated by a green EXTERNAL POWER annunciation light in the annunciator panel. To enable the external power source to supply power to the aircraft the EXT PWR switch on the MAIN section of the left side panel has to be switched on.
CAUTION NOTE
Do not connect ground power units with a capacity greater than 1200 A for engine start. It is not possible to connect the starter-generator and an external power source simultaneously to the aircraft bus system. This is to avoid any uncontrolled currents between these units. Additionally a battery charger plug is installed at the external power receptacle. The battery may be charged with 29.0 V and 5 A.
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24-60-00
DISTRIBUTION Description Electrical power from the various power sources is supplied to the E-box. The E-box incorporates the main devices of the distribution system such as fuses, circuit breakers, relays, and shunts and is installed on the engine side of the firewall. From there power is distributed partly through individual fuses to the following buses: • Hot Bus, • Emergency Bus, • Battery Bus and Avionic Bus • Load Bus, The battery directly feeds the hot bus supplying power for equipment, which has to be independent from the battery switch position (e.g. ELT; see Figure 24-2 for location of battery switch). Turning the battery switch to the ON-position will activate a relay connecting the battery to the battery bus and further to the emergency bus. This allows starting the engine and feeding the other equipment and, if engine is running, recharging the battery with the starter/generator. The generator is activated by turning GEN switch to the ON-position (see Figure 24-2). So the generator is activated and the generator relay connects the generator to the load, battery and emergency bus. From the main bus electrical power is distributed to the various busses as outlined on Figure 24-1. The avionic bus can be disconnected by the AVIONICS switch. The main control switches of the electrical power system are located on the MAIN section of the left side panel (see Figure 24-2) and are marked EXT PWR, BATT, STBY ALT, GEN and GEN TEST. T
Push-pull circuit breakers automatically break the current if an overload occurs to prevent damage to the electrical wiring and equipment. The most circuit breakers are installed to the left side panel (see Figure 24-3). A single circuit breaker is installed on the upper LH engine mount (GCU) and under the external power hatch (EXT PWR) respectively. All other circuit breakers are installed to the E-box located on the engine side of the firewall and are labeled GEAR AUX 2, BATT CHARGE, SPARE, ALT FIELD 2, COURTESY LT, and ELT. Generally where exclusively wiring shall be protected poly switches are used. They are installed on different locations of the electrical system.
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24-60-01
E-box Removal/Installation Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. T
2 Remove upper engine cowlings.
Refer to Ch. 71-10-01/02.
3 Disconnect the SCEET hoses from the oil cooler inlet. 4 Remove 10 attachment screws of the oil cooler inlet. 5 Remove oil cooler inlet. 6 Remove 8 oil cooler outlet attachment screws. 7 Move oil cooler and outlet some centimeters forward.
To get access to the E-box.
8 Disconnect electrical connector 9 Disconnect power lines 10 Remove upper E-box cover.
1 screw
11 Disconnect 3 main power bulkhead feedthroughs.
Hold threaded rod in place by means of an Allen wrench.
12 Remove 3 attachment screws. 13 Remove E-box. 14 Remove cover plate and shell plate.
Plates are screwed on.
15 Install in reverse sequence of removal.
24-60-02
Switches Removal/Installation The switches on the instrument panel are accessible from the backside after removal of the RH IFD. The LANDING GEAR, FLAP, and ELT switch backsides are directly accessible from the legroom. The backsides of the left side panel switches are accessible when the upper and lower part of the left side panel has been removed. Generally conventional switches are used, so that removal is done by disconnecting the electrical wiring and removing attachment screws or nuts. Installation is vice versa.
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24-60-03
Circuit Breakers Removal/Installation The circuit breakers on the left side panel are accessible from the backside when the upper and lower part of the left side panel has been removed. To get access to the E-box circuit breakers the E-box must be removed (refer to Subject 24-60-01). Generally conventional circuit breakers are used, so that removal is done by disconnecting the electrical wiring (busses) and removing attachment screws or nuts. Installation is vice versa.
24-60-04
Relays Relays are installed in the left side panel, in the E-box and behind the RH IFD. To get access to the relays either the E-box (see Subject 24-60-01), the left side panel (see Chapter 31-10-01) or the RH IFD (see Chapter 31-60-01) must be removed Electrical wiring is generally connected to the relays by means of relay sockets. The relays are mounted to the sockets with bolts.
24-60-05
Shunts Shunts are installed in the E-box. To get access to the shunts the E-box must be removed (refer to Subject 24-6001). Electrical wiring is generally connected to the shunts by means of screws. The shunts are mounted to the supports with bolts.
24-60-06
Fuses The main fuses are installed in the E-box with bolts. They are accessible after removal of the upper E-box cover.
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Chapter 25 Equipment and Furnishing
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TABLE OF CONTENTS
25-00-00
GENERAL ........................................................................................................ 5
25-10-01
Paneling ............................................................................................................. 5 Description.......................................................................................................... 5 Removal/Installation........................................................................................... 5
25-10-00
FLIGHT COMPARTMENT ........................................................................... 6
25-10-10
Seats, Seat Belts, and Shoulder Harnesses ..................................................... 6 Description.......................................................................................................... 6
25-10-11
Pilot's Seat ......................................................................................................... 6 Removal/Installation........................................................................................... 6
25-10-12
Copilot's Seat..................................................................................................... 7 Removal/Installation........................................................................................... 7
25-10-21
LH Side Armrest Paneling............................................................................... 7 Removal/Installation........................................................................................... 7
25-10-22
RH Side Armrest Paneling............................................................................... 8 Removal/Installation........................................................................................... 8
25-10-23
Front Ceiling Paneling ..................................................................................... 8 Removal/Installation........................................................................................... 8
25-10-24
Upper Side Paneling LH/RH Side................................................................... 9 Removal/Installation........................................................................................... 9
25-10-25
Windshield Middle Strut Paneling.................................................................. 9 Removal/Installation........................................................................................... 9
25-10-26
Middle Console Paneling Upper Part ............................................................. 9 Description.......................................................................................................... 9 Removal/Installation........................................................................................... 9
25-10-27
Middle Console Paneling Lower Part........................................................... 10 Description........................................................................................................ 10 Removal/Installation......................................................................................... 10
25-20-00
PASSENGER COMPARTMENT................................................................. 11
25-20-10
Seats ................................................................................................................. 11
25-20-11
Front Passenger Seats .................................................................................... 11 Removal/Installation......................................................................................... 11
25-20-12
Aft Passenger Seats......................................................................................... 11 Removal............................................................................................................ 11 Installation ........................................................................................................ 12
25-20-21
LH Side Armrest Paneling............................................................................. 12 Removal/Installation ......................................................................................... 12
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25-20-22
RH Side Armrest Paneling .............................................................................13 Removal/Installation..........................................................................................13
25-20-31
Storage Boxes LH/RH.....................................................................................13 Description ........................................................................................................13 Removal/Installation .........................................................................................13
25-20-32
Table .................................................................................................................14 Removal/Installation .........................................................................................14
25-50-00
BAGGAGE COMPARTMENT.....................................................................15 Description ........................................................................................................15
25-50-01
Tie Down Belts.................................................................................................15 Removal/Installation .........................................................................................15
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25-00-00
GENERAL
25-10-01
Paneling Description If not described in another way paneling is generally mounted to the aircraft structure with Phillips screws.
Removal/Installation Take care of the paneling installations such as switches, sockets, lights etc. when removing. Ensure BATT switch is OFF and no external power connected, when electrical devices are involved. Sometimes the paneling overlaps. Then it is necessary to remove also the adjacent paneling. Move paneling some centimeters inboard after removal of Philips screws to get access to the paneling backsides. Then disconnect electrical wiring. Installing is vice versa. T
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25-10-00
FLIGHT COMPARTMENT
25-10-10
Seats, Seat Belts, and Shoulder Harnesses Description The pilot's and copilot's seats are one piece, four-way adjustable seats incorporating energy absorbers which reduce forces working on the occupants in case of crash. The seats may be moved forward, aft, up, and down. The adjustment is made by pulling a handle located at the right respective left forward underside of the seat to release the fixing mechanism. The horizontal adjustment range is 152 mm, 5 fixed positions are provided. The vertical adjustment range is 80 mm, 5 fixed positions are provided. Telescopic cylinders support the pilot during the vertical adjustment. The seat belts and the shoulder harnesses with inertia reels used for the pilot and copilot are attached to the seats. The seat belts provide a conventional adjustment. Shoulder harness adjustment is not necessary due to the inertia reels, which allow straps to extend and retract as required under normal movement. However the reels will lock in place in the event of a sudden deceleration.
25-10-11
Pilot's Seat Removal/Installation Detail Steps/Work Items
Key Items
1 Remove front roll from RH seat track.
2 screws
2 Remove mounting bracket and roll as a unit from back RH seat track.
2 screws
3 Pull off bracket from back LH seat track.
2 screws
4 Pull adjusting handle to release bolt at longitudinal adjusting device. 5 Slide seat out of mounting console in forward direction. 6 Install in reverse order of removal.
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25-10-12
Copilot's Seat Removal/Installation Detail Steps/Work Items
Key Items
1 Remove front roll from LH seat track.
2 screws
2 Remove mounting bracket and roll as a unit from back LH seat track.
2 screws
3 Pull off bracket from back RH seat track.
2 screws
4 Pull adjusting handle to release bolt at longitudinal adjusting device. 5 Slide seat out of mounting console in forward direction. 6 Install in reverse order of removal.
25-10-21
LH Side Armrest Paneling Removal/Installation Detail Steps/Work Items 1 Remove left side panel.
Key Items Refer to Chapter 31-10-01.
2 Remove screw fastening microphone twin socket on rear top of panel. 3 Remove screw at lower front panel side. 4 Remove screw at lower rear panel side. 5 Slightly lift panel and remove it against flight direction. 6 Install in reverse sequence of removal.
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25-10-22
RH Side Armrest Paneling Removal/Installation Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. T
2 Remove microphone socket cover on rear top of panel. 3 Remove screw at lower front panel side. 4 Remove screw at lower rear panel side. 5 Slightly lift panel and remove it against flight direction. 6 Install in reverse sequence of removal.
25-10-23
Front Ceiling Paneling Removal/Installation Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. T
CAUTION
Take care not to damage sunblinds. Swivel sunblinds up before removing ceiling panel
2 Remove 4 screws around upper windshield frame. 3 Remove 4 screws near panel edges. 4 Disconnect plug for dome light/speaker wiring. 5 Carefully remove adhesive tape at panel back side. 6 Remove front ceiling paneling. 7 Install in reverse sequence of removal.
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25-10-24
Upper Side Paneling LH/RH Side Removal/Installation Detail Steps/Work Items
Key Items
1 Remove 2 screws in windshield frame area. 2 Remove 2 screws in front cabin window contour area. 3 Remove upper side paneling. 4 Install in reverse sequence of removal.
25-10-25
Windshield Middle Strut Paneling Removal/Installation Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. T
2 Remove 2 screws at compass. 3 Disconnect wiring for compass lighting. 4 Remove compass. 5 Remove 4 screws at paneling. 6 Remove windshield middle strut paneling. 7 Install in reverse sequence of removal.
25-10-26
Middle Console Paneling Upper Part Description The middle console paneling consists of an upper and lower part. The upper part is screwed on the lower part and on the middle console structure.
Removal/Installation Detail Steps/Work Items 1 Remove trim wheel.
Key Items 1 Phillips screw
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Detail Steps/Work Items 3 Remove the upper part of middle console paneling.
Key Items 24 Phillips screws
4 Install in reverse sequence of removal. 5 Check the function of the back-up microphone.
25-10-27
Middle Console Paneling Lower Part Description The lower part of the middle console paneling is aligned by 4 guiding pins in the fuselage frame and fixed by the upper part of the paneling.
Removal/Installation Detail Steps/Work Items
Key Items
1 Remove upper part of the middle console paneling.
Refer to Subject 25-12-06
2 Disconnect air hoses from the legroom dispensers.
1 worm drive hose clamp each side
3 Move lower part paneling some centimeter aft and remove. 4 Install in reverse sequence of removal.
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Insert guide pins to the related holes in the forward paneling edges.
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25-20-00
PASSENGER COMPARTMENT
25-20-10
Seats The passenger seats are one piece seats as well but are placed on a fix position. However the backrest of both aft seats can be swiveled forward allowing easy access to the baggage compartment. For this purpose a release handle located on the inner side of the backrest has to be pulled up.
Ensure backrest is locked by checking the down position of the release WARNING handle before using the seat. The seat belts provide a conventional adjustment however the locking mechanism is placed on the inner side of the seat providing a lock for the shoulder strap, which is equipped with inertia reels. The attachments of the seat belts and shoulder harnesses are integrated in the seat.
25-20-11
Front Passenger Seats Removal/Installation Detail Steps/Work Items 1 Remove screws at mounting console.
Key Items 4 Allen screws LN 29952-0615M
2 Remove seat. 3 Install in reverse order of removal.
25-20-12
If necessary, use mounting template at landing gear attachment for front side screws.
Aft Passenger Seats Removal Detail Steps/Work Items
Key Items
1 Remove front paneling of baggage compartment from seat assembly.
To get access to the mounting consoles.
2 Remove back side screws at inner and outer seat mounting console.
4 Allen screws LN 9037 - 06018
3 Remove front side screws at inner and outer seat mounting console.
1 Allen screw LN 9037 - 06016 and 2 Allen screws LN 9037 - 06018
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4 Remove screws at higher angle bracket.
6 Allen screws AN 5260 - 1032
Installation 1 Insert front side screws at inner and outer seat mounting console.
1 Allen screw LN 9037 - 06016 and 2 Allen screws LN 9037 - 06018
2 Before tightening front side screws completely, adjust seat from rear side and install back side screws at inner and outer seat mounting console.
4 Allen screws LN 9037 - 06018
3 Tighten front side screws at inner and outer seat mounting console. 4 Install screws at higher angle bracket.
6 Allen screws AN 5260 - 1032
5 Reinstall front paneling of baggage compartment..
25-20-21
LH Side Armrest Paneling Removal/Installation Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. T
2 Remove microphone socket cover on front top of panel. 3 Remove microphone socket cover on rear top of panel. 4 Remove 5 screws at entrance bottom panel sheet. 5 Loosen screws at door sealing frame in armrest area. NOTE
On some aircraft, the armrest is fixed with additional latches to the door frame. In this case remove the screws and the latches completely. 6 Remove screw at lower front panel side. 7 Remove screw at lower rear panel side. 8 Pull armrest together with frame floor finishing inboard and remove it against flight direction. 9 Install in reverse sequence of removal.
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25-20-22
RH Side Armrest Paneling Removal/Installation Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. T
2 Remove microphone socket cover on front top of panel. 3 Remove microphone socket cover on rear top of panel. 4 Remove table.
Refer to Subject 0.
5 Remove screw at lower front panel side. 6 Pull back frame floor finishing. 7 Slightly lift panel and remove it against flight direction. 8 Install in reverse sequence of removal.
25-20-31
Storage Boxes LH/RH Description Storage boxes are located between LH and RH side pilot’s/copilot’s and front passenger seats. They provide a place for depositing especially the emergency torch, first aid kit and the aircraft documentation material.
Removal/Installation Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. T
2 Slide pilot’s and co-pilot’s seat into most forward position. 3 Remove 2 screws at front and back bottom side. 4 LH box Remove screws at floor and back wall of upper and lower storage compartments. 4 RH box Take out fire extinguisher, remove bolts holding extinguisher support bracket. 5 Install in reverse sequence of removal.
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25-20-32
Table Removal/Installation Detail Steps/Work Items
Key Items
1 Remove 2 screws at table underside. 2 Remove 2 sheatings. 3 Remove table. 4 Install in reverse sequence of removal.
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25-50-00
BAGGAGE COMPARTMENT Description The baggage compartment is located behind the aft passenger seats. To get access the backrest of both aft seats can be swiveled forward. The release handle is placed on the left side of the backrest. The baggage can be secured by tie down belts, which are to be fastened on eyes located on two compartment sides.
25-50-01
Tie Down Belts Removal/Installation Detail Steps/Work Items
Key Items
1 Release the handles at aft passenger seat backrests and swivel backrests forward. 2 Remove 2 Phillips screws AN 526 C .1032 R8 securing front belt brackets to LH and RH side console. 3 Remove front belt. Remove 2 Phillips screws AN 526 C .1032 R8 securing aft belt brackets to LH and RH side console. Remove aft belt. 4 Install in reverse sequence of removal.
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Install screws just so tight, that belt brackets can be rotated freely, but without play.
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Chapter 27 Flight Controls
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TABLE OF CONTENTS 27-00-00
GENERAL ........................................................................................................ 5 Description.......................................................................................................... 5
27-00-01
Control Cable .................................................................................................... 5 Tensions.............................................................................................................. 5 Control System Surview...................................................................................... 6
Figure 27-01 27-00-10
CONTROL SPRINGS...................................................................................... 7 Location .............................................................................................................. 7
27-00-11
Down-Spring ..................................................................................................... 7 Description.......................................................................................................... 7
27-00-12
Interconnection Aileron/Rudder ..................................................................... 7 Description.......................................................................................................... 7
27-00-13
Centering Rudder ............................................................................................. 8 Description.......................................................................................................... 8
27-00-14
Nose Gear Steering ........................................................................................... 8 Description.......................................................................................................... 8
27-00-15
Nose Gear Control Cable ................................................................................. 8 Description.......................................................................................................... 8
27-10-00
AILERONS ....................................................................................................... 9 Description.......................................................................................................... 9 Troubleshooting.................................................................................................. 9 Removal/Installation......................................................................................... 10
27-10-01
Aileron Cables................................................................................................. 10 Removal/Installation......................................................................................... 10
27-20-00
RUDDER ......................................................................................................... 11 Description........................................................................................................ 11 Troubleshooting................................................................................................ 11 Removal/Installation......................................................................................... 12
27-20-01
Rudder Cables................................................................................................. 12 Removal/Installation......................................................................................... 12
27-30-00
ELEVATOR AND TAB................................................................................. 14 Description........................................................................................................ 14 Troubleshooting................................................................................................ 14 Removal/Installation......................................................................................... 16
27-30-01
Elevator Cables ............................................................................................... 16 Removal/Installation......................................................................................... 16
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27-50-00
FLAP SYSTEM ...............................................................................................18 Description ........................................................................................................18 Rigging and Adjustment ...................................................................................18 Track Adjustment..............................................................................................19 Guidance Checks and Adjustment ....................................................................19 Actuation Adjustment .......................................................................................20
27-50-01
Flap Drive Motor.............................................................................................21 Description ........................................................................................................21
27-50-02
Inboard Power Transmission Flexible Shaft ................................................22 Description ........................................................................................................22
27-50-03
Outboard Power Transmission Flexible Shaft .............................................22 Description ........................................................................................................22
27-50-04
Power Transmission Screw Jacks..................................................................23 Description ........................................................................................................23
27-50-05
Flap Control Box .............................................................................................23 Description ........................................................................................................23
27-50-06
Flap Limit Switches.........................................................................................24 Description ........................................................................................................24 Adjustment ........................................................................................................24
27-50-07
Flap Asymmetry Senders ...............................................................................26 Adjustment ........................................................................................................26
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27-00-00
GENERAL Description The flight controls consist of the ailerons, rudder and elevators. The right elevator is equipped with a trim system. All these control surfaces are constructed of composite material. The primary control system is a conventional cable-system consisting of a double control wheel (pitch and roll) with respective coupling systems, hanging control pedals (yaw), tubes, levers, pulleys and push-pull rods. Between ailerons and rudder controls an interconnection which is made via springs is installed. However, the coupling can easily be overpowered (e.g. in side slipping).
27-00-01
Control Cable Tensions The control cable systems generally use cable of 3.2 mm diameter. However the aileron control uses cables of 4 mm diameter in the wing region. System
Cable Diameter
Cable Tension
Tolerance
Ailerons
3.2 mm/4 mm
220 N/49.5 lbs
± 20 N/4.5 lbs
Rudder
3.2 mm
220 N/49.5 lbs
± 20 N/4.5 lbs
Elevator
3.2 mm
300 N/67.4 lbs
± 20 N/4.5 lbs
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Side View Pulley Segment
Aileron Control Elevator Control
Rudder Control
Top View Turnbuckles
Pulleys Rudder and Elevator Control
Top View
Pulleys Aileron Control Pulley Segment
Left Wing symmetrically
Turnbuckles
Figure 27-01 Page 6
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27-00-10
CONTROL SPRINGS Location The following springs are incorporated in the control system of the EXTRA 500: Application
27-00-11
Location
Down-spring
Cockpit, instrument shelf
Interconnection aileron/rudder
Cockpit, bulkhead
Centering rudder
Tail fairing
Nose gear steering
Nose wheel dome
Nose gear control cable
Cockpit
Down-Spring Description Safety spring, affecting the pulley segment of the elevator control, to create a nose-down pitching control force. The down-spring is located on the LH side, below the instrument shelf. In case of down-spring failure the amount of steering force required will rise when pushing the control yoke. Trimming "nose down" will compensate this effect. Malfunction of the down-spring will not cause further reductions of flight performance or any unsafe flight conditions.
27-00-12
Interconnection Aileron/Rudder Description To reduce tendency to raise the low wing, esp. during low speed flight (landing approach), the EXTRA 500 is furnished with an interconnection between the aileron and the rudder control. When activating the rudder, the coupling correspondingly actuates the aileron control. When moving the aileron, the rudder — as long as being free of any control forces — remains in neutral position. The coupling is being accomplished by means of a pair of safety springs, located at the LH foot compartment. The control force is conducted from the shafts of the rudder control to the safety springs by levers and cables, including the pulleys. Once the friction inside the control system has been overcome, a rudder control input is led to the LH control column by a chain drive.
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Failure of an interconnection spring will cause an additional force in one direction at the aileron control, which is rated below the tolerated amount.
27-00-13
Centering Rudder Description Within the lower rudder bearing a spring-loaded pulley strains a steel plate attached to the rudder, thus centering the rudder in neutral position and providing a defined rising of control forces while moving the rudder. Malfunction of the centering spring will disengage the centering and reduce the control force rise. Unsafe flight conditions are excluded.
27-00-14
Nose Gear Steering Description The pivoting of the nose gear is part of the rudder control system, completing the control cable arrangement. To de-couple the nose gear steering from the rudder control, two safety springs are incorporated into the nose gear pivoting. The springs will transmit the control force forward after having reached a defined travel. Malfunction of the nose gear steering springs will abolish pretension of the control cables. With a 16° play arising inside the nose gear steering, reduction of max. angular movement from ± 30° to approx. 10° in one direction will occur, whereas control force at the rudder pedals will slightly increase.
27-00-15
Nose Gear Control Cable Description These additional springs will stretch the nose gear control cables, when one of the springs at the nose gear pivoting has been lengthened due to a rudder movement against the locked nose wheel. Malfunction of one or both springs will not affect normal control functions.
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27-10-00
AILERONS Description The coupling between the two control wheels of the main control system is realized by a direct cable-chain coupling. The cables are connected to the control wheels by means of a longitudinal toothed wheel and run through the windshield center strut to the wing nose and move outboard. Outside the tank area they cross the front spar. Then they are connected to a cable segment which actuates the aileron via lever and push-rod. Each aileron is attached to the rear spar of the wing by two hinges.
Troubleshooting Complaint Lost motion in control wheel.
Resistance to control wheel movement.
Control wheels not level with ailerons neutral
Possible Cause
Remedy
Loose control cables.
Check cable tension. Adjust cables to proper tension.
Broken pulley or braket, cable of pulley or worn rod end bearings.
Check visually. Replace worn or broken parts, install cables correctly.
Cables too tight.
Check cable tension. Adjust cables to proper tension.
Pulleys binding or cable off.
Observe motion of the pulleys. Check cables visually. Replace defective pulleys. Install cables correctly.
Defective quadrant assembly.
Check visually. Replace defective quadrant.
Clevis bolts in system too tight.
Check connections where used. Loosen, then tighten properly and safety.
Improper adjustment of cables. Adjust turnbuckle to obtain proper alignment. Improper adjustment of aileron push-pull rods.
Adjust push-pull rods to obtain proper alignment.
Dual control wheels not coordinated.
Cables improperly adjusted.
Adjust cables.
Chain improperly adjusted.
Adjust chain.
Incorrect aileron travel.
Push-pull rod not adjusted properly.
Adjust rod.
Incorrect adjustment of travel stop bolts.
Adjust bolts.
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Removal/Installation Detail Steps/Work Items
Key Items
1 Loosen push rod from central part of aileron 2 Remove cotter pin and bolt from each of the two hinges 3 Remove aileron backwards 4 Install in reverse order of removal
27-10-01
Aileron Cables Removal/Installation Detail Steps/Work Items
Key Items
1 Remove center cover of wing root section 2 Remove turnbuckle below cover Perform steps No 3 – 9 at LH and RH side wing each 3 Remove turnbuckle at outer wing rib 4 Remove rigging clamps of role servo at inner wing rib 5 Remove recognition light at outer wing nose section 6 Remove outer side pulley 7 Push up inner side pulley 8 Remove teflon guiding bushings at outer wing rib 9 Loosen return cable segment at outer wing rib for removal of 3.6 mm cable
Remove bolt and push segment sideways
10 Remove 2 pulleys at windshield center strut 11 Remove teflon guiding bushings at windshield center strut 12 Remove avionic panel 13 Remove LH and RH side return brackets 14 Remove LH and RH cable safety brackets below instrument shelf 15 Loosen return cable segments at steering column
Remove bolts and push segments sideways
16 Install in reverse order of removal
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27-20-00
RUDDER Description The rudder pedals are placed hanging on two tubes which have a lever arm at the right side of the cabin. From there the cables are led along the cabin right side armrest panel to the empennage around pulleys positioned in groups. Here a direct connection to the lever arms of the rudder follows. The connection points lay inside the tail cone adjacent to the lower rudder bearing. The rudder is connected to the rear fin spar at three points.
Troubleshooting Complaint
Possible Cause
Remedy
Play between pedals and rudder.
Insufficient cable tension.
Rig the system.
Rudder does not respond to pedal movement.
Broken or disconnected cables.
Open armrest panel, access doors and tailcone and check visually. Connect or replace cables.
Excessive resistance against pedal movement, binding or jumpy movement of pedals.
Cables too tight.
Rig the system.
Cables not running properly on pulleys.
Open armrest panel, access doors and tailcone and check visually. Lay cables correctly over pulleys.
Binding, broken or defective pulleys or cable guards.
Check visually. Replace defective pulleys and install guards properly.
Pedal torque-tube bearings need lubrication.
Lubricate pedal bearings.
Defective pedal torque-tube bearings.
Check visually. Replace bearings.
Defective rudder hinge bearings.
Check visually. Replace defective bearings.
Clevis bolts too tight.
Check and readjust bolts to eliminate binding.
Incorrect rudder travel.
Incorrect rigging.
Rig the system.
Excessive resistance against pedal movement only while gear is extended
Worn or defective nosewheel steering bearings
Check visually. Replace defective bearings.
Nosewheel does not respond to pedal movement.
Broken or disconnected cables.
Check visually. Connect or replace cables.
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Complaint
Possible Cause
Remedy
Reduced nosewheel steering travel on one side
One steering cable spring broken
Check visually. Replace spring
Incorrect nosewheel steering travel / aircraft not rolling straightly with pedals neutral.
Incorrect rigging.
Rig the system.
Removal/Installation Detail Steps/Work Items
Key Items
1 Remove right aft passenger seat
Refer to Chapter 25-20-13
2 Remove RH side paneling
Refer to Chapter 25-20-22
3 Loosen two turnbuckles of rudder cables, located at RH wall adjacent to right aft seat and baggage compartment 4 Loosen rudder cables at lower rudder bearing 5 Remove bolt at LH side of central rudder bearing 6 Remove lower rudder bearing
5 screws M5
7 Remove cotter pin and nut at lower rudder bearing 8 Slightly lift rudder above higher bearing and remove rudder backwards 9 Install in reverse order of removal
27-20-01
Rudder Cables Removal/Installation Detail Steps/Work Items
Key Items
1 Remove lower RH side panels in flight, passenger and baggage compartments 2 Remove upper rear wall of baggage compartment 3 Remove instrument shelf 4 Remove turnbuckle below RH side of instrument shelf 5 Remove 2 turnbuckles at RH side wall in baggage compartment Page 12
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6 Remove turnbuckle at rear wall of baggage compartment 7 Remove 2 pulleys below instrument shelf
Remove safety pin from smaller pulley
8 Remove 2 pulleys from RH side wall in flight compartment
Remove bolts
9 Remove 2 pulleys from RH side wall in rear passenger compartment
Remove bolts
10 Remove teflon guiding bushings at rear wall of baggage compartment 11 Remove LH access panel at rear fin 12 Remove 2 smaller pulleys 13 Remove 2 pulleys at LH and RH side each below instrument shelf 14 Remove teflon guiding bushings to nose wheel well
Remove safety sheet
15 Remove nose gear cable control springs 16 Install in reverse order of removal
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27-30-00
ELEVATOR AND TAB Description A lever system transfers elevator control movement from each of the two steering wheels by a respective carrier bolt bushing to a cable segment. From this cable segment the elevator cables run horizontally to the right cabin side to a 90° pulley and parallel to the rudder cables to the empennage. They are led to the elevator in front of the front fin spar and are attached to a lever positioned in front of the horizontal stabilizer front spar, which actuates the two elevator sides separately by means of push pull rods. Each elevator is attached to the respective horizontal stabilizer by three bearings. The mechanical pitch trim is actuated through a trim wheel in the pedestal. The pitch trim tab is located in the right elevator and is linked over a 'redundant' cable-lever system to the trim wheel. The trim Bowden cables run from the middle console down crossing the cabin floor and are then directed rearwards to the empennage following the nose section of the fin to the right side elevator. Pitch trim can be actuated electrically also by means of switches located on the pilot's control wheel. The system can be overpowered by pilot's hand forces in case of system failure.
Troubleshooting Complaint Play in control column.
Excessive resistance to control column movement.
Possible Cause Loose control cables.
Check cable tension. Adjust cables to proper tension.
Broken pulley or bracket, cable off pulley, or worn rod end bearings.
Check visually. Replace worn or broken parts, install cables correctly.
Cables too tight.
Check cable tension. Adjust cables to proper tension.
Pulleys binding or cable off.
Observe motion of the pulleys. Check cables visually. Replace defective pulleys. Install cables correctly.
Defective pulley quadrant assembly.
Check visually. Replace defective quadrant.
No nose down force on control Down-spring disconnected. column.
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Remedy
Check visually. Attach downspring correctly.
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Complaint Binding or jumpy motion felt in movement of elevator system.
Possible Cause
Remedy
Cables too tight.
Check and adjust tension.
Cables not riding correctly on pulleys.
Check visually. Replace defective pulleys.
Defective control column bearings.
Check visually. Replace defective bearings.
Control guide on aft end of control square tube adjusted too tightly.
Loosen screw and tapered plug in end of control tube enough to eliminate binding.
Defective elevator hinges.
Disconnect push-pull rods and move elevators by hand. Replace defective hinge bearings.
Stops set incorrectly.
Rig the system.
Cables tightened unevenly.
Rig the system.
Defective cable or deformed tube.
Check visually and replace defective parts.
Trim tab hinge binding.
Disconnect actuator and move tab up and down to check hinge resistance. Lubricate or replace hinge as necessary.
Defective trim tab actuator.
Disconnect cable from actuator and operate actuator manually. Replace defective actuator.
Stick-slip effect between cable and tube.
Lubricate all moving parts.
Control wheel does not move trim tab.
Disconnected or broken cable.
Check visually and connect or replace cable as necessary.
Play between control wheel and trim tab.
Parts worn out
Check visually and replace parts as necessary.
False reading on trim position indicator.
Indicator incorrectly engaged on wheel axis.
Check visually. Adjust indicator.
Worn, bent or disconnected linkage.
Check visually. Repair or replace parts as necessary.
Stop blocks loose or incorrectly adjusted.
Adjust stop blocks on cables.
Incorrect rigging.
Rig the system.
Elevator fails to attain prescribed travel.
Trim control wheel moves with excessive resistance.
Incorrect trim tab travel.
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Removal/Installation Detail Steps/Work Items
Key Items
RH elevator 1 Loosen push rod at trimming tab
8 hollow core bolts LN4
2 Continue as per step 1 to 5, LH elevator LH elevator 1 Loosen control lever 2 Swivel up elevator 3 Remove socket pins from central and outer bearings
2 socket pins LN6
4 Turn elevator horizontally backwards around inner bearing 5 Remove elevator 6 Install in reverse order of removal
27-30-01
Elevator Cables Removal/Installation Detail Steps/Work Items
Key Items
1 Remove lower RH side panels in flight, passenger and baggage compartments 2 Remove upper rear wall of baggage compartment 3 Remove instrument shelf 4 Remove turnbuckle below RH side of instrument shelf 5 Remove 2 turnbuckles at RH side wall in baggage compartment 6 Remove turnbuckle at rear wall of baggage compartment
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7 Remove 2 pulleys below instrument shelf
Remove safety pin from smaller pulley
8 Remove 2 pulleys from RH side wall in flight compartment
Remove bolts
9 Remove 2 pulleys from RH side wall in rear passenger compartment
Remove bolts
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10 Remove teflon guiding bushings at rear wall of baggage compartment 11 Remove LH tailcone access panel 12 Remove 2 clamps of pitch servo 13 Remove LH access panel at rear fin 14 Remove 2 larger pulleys 15 Remove linkage between cable and aileron
Remove bolt
16 Remove push rod 17 Install in reverse order of removal
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27-50-00
FLAP SYSTEM Description The wing flaps are of the Fowler type. Each wing flap (two per side) is attached to the rear wing spar and guided during its movement by three wing tracks. Actuation is by means of two spindles, which are connected to the central electrical flap motor by flexible shafts. The flap motor is located in front of the rear spar in the fuselage area of the wing and is controlled by the wing flap position switch in the cockpit. This switch incorporates a preselect feature which allows the pilot to select the amount of flap extension desired. When the UP/0°- , 15°- or 30°- position is selected, the flap motor is electrically actuated and drives the flaps toward the selected position. When the actual flap position equals the selected position, limit switches located at the wing tracks respective the outer spindles de-energize the flap motor. The actual flap position will be indicated by green lights at the left side of the wing flap position switch. When flaps are moving the yellow light will be illuminated. If the 0°-position is reached all lights are off. As the flaps move an electrical circuit compares the movement of the left and right wing flaps. If the wing flap positions differ by more than 7° ± 3°, the flap motor will be automatically switched off to prevent asymmetric conditions. This will be indicated by the flap error warning light located on the warning light panel. This light indicates also a failure of the complete flap control.
NOTE
In case of the wing flaps being unbalanced, they rest in the position they have reached when failing and cannot be actuated until airplane has been in maintenance. However in this case the airplane can be easily balanced by slight aileron and/or rudder input. Setting the wing flaps will cause a decrease of airspeed and a moderate nose down moment. Bring wing flaps to 0°-position before opening the cabin door
CAUTION
Rigging and Adjustment This section describes the procedure for correct adjustment of the defined flap settings as well as the maximum flap asymmetric limits. Due to the local chord of the flaps (30 % of the wing) and positioning the 15° and 30° DOWN extension relative to the local chord the travel of the flaps depends on the lateral station. CAUTION NOTE
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All adjustment must be made with the motor power OFF (pulled circuit breaker FLAP). Rigging of the flap system requires a flap track snap gauge (Extra PartNo. EA-15182W10). This will be available at EXTRA. See also Chapter 01-00-02.
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Track Adjustment Perform the following adjustment checks as long as the flaps are not installed. For flap installation, refer to Chapter 57-50-01: 1 Check of spanwise adjustment Check distance between flap tracks at their rear end. Distance between inner and middle track is 1989 ± 2 mm (78.31 ± 0.08 in.) and between middle and outer track 1827.5 ± 2 mm (71.95 ± 0.08 in.). If further details of flap track positioning are required, contact EXTRA. 2 Check of twist between tracks Check flap tracks for proper torsional alignment (cord over all three lower keyways). Max. permissible distance of lower keyway centerline at the middle flap track is 2mm (0.08 in.), when cord is aligned with outer and inner flap track keyway.
Guidance Checks and Adjustment Check the following items after flap installation: 1 Minimum gap between flap and aileron While pulling the flaps outboard against the stop, check width of gap between aileron and outer flap segment. The stop is reached, when one of the sliding surfaces on the outboard end of the inner or outer flap segment contacts the middle or outer flap track. Minimum gap width is 8 mm (0.31 in.). Check the following items after flap installation and after each 100 hours of operation: 2 Spanwise flap rigging Check whether any guidance roller on the inner track protrudes more than 3 mm (0.12 in.) outside the inner track when flaps are pulled outboard against the stop. The stop is reached, when one of the sliding surfaces on the outboard end of the inner or outer flap segment contacts the middle or outer flap track. Repeat the check for the rollers in the outer flap track while pushing the flaps inboard. Verify visually that stops are definitely reached. 3 Flap guidance rollers twist rigging Minimum play in guidance keyways: Check all flap segments for minimum free play of rollers in keyways. Lift each flap segment manually at trailing edge and observe for positive free play of flap segment at trailing edge. Check this for all four flap segments and for flap positions 0° and 30°. The SKF track rollers (forward roller on inner track and both rollers on outer track) feature an eccentric bushing to provide a means of adjustment in this respect. 4 Flap guidance rollers functional check Check whether the rollers are rolling but not slipping by performing the following test: Extend flaps to their 30° position and retract them while manually applying a load of about 200 N (45.0 lbs.) upwards at the trailing edge of the flaps near the respective track. If a roller is slipping identify cause and replace roller as necessary.
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5 Inspection of roller contact areas Inspect rear side of lower keyway on inner flap tracks for signs of axial contact with mushroom head of roller. Contact Extra Flugzeugbau GmbH if marks are found. Inspect guidance roller tracks for wear and permanent deformation. For wear and deformation the following service limits are defined: Max. increase of track width due to deformation: 0.6 mm (0.024 in.) per side. Width of guidance slot between 16.3 mm and 16.8 mm (0.64 in. and 0.66 in.). Check with flap track snap gauge (see Chapter 01-00-02).
Actuation Adjustment 1 Ascertain that both inner flex drive shafts are disconnected from the electric drive motor and that the flap motor and flap control circuit breakers are pulled. 2 Make sure for both LH and RH side flap that the respective asymmetry detection mechanisms are not mounted yet. If they are already mounted, make sure that the ball joint connection between linkage rod and bracket is disconnected and the linkage rod is taped to the spar. CAUTION
If this is not done, parts of the mechanism may be destroyed while moving the flaps.
3 Lower both (LH and RH) flaps to their fully extended stop position. This can be done by turning the hex socket coupling of the RH flex shaft CCW and the LH flex shaft CW respectively, with view of the coupling. Use a battery hand held drill with fine speed control and reverse feature, equipped with a 3/16 “ (4.7 mm) Allen key tip. CAUTION
Do not run flaps to their extreme position (end of trackslots) with electric drill to avoid damage. Turn flex shafts by hand to reach the end of the tracks.
4 If the roller on one flap end rib reaches the outer end of its track slot while the roller on the other flap end rib is 2 mm or more away from its track slot end, an adjustment is necessary. This is done at one of the two transmission screw jacks. 5 Disconnect the flap bracket from the rod end of its transmission actuator, then move the rod into the proper direction by rotating it in steps of 180°-turns, then reconnect. A 180°-turn of the inner transmission’s rod in CCW direction or of the outer transmission’s rod in CW direction will move the adjacent roller about 2 mm towards the extended position. NOTE
The screw of the inboard transmission rod features a RH thread whereas the outboard one features a LH thread 6 Raise both (LH and RH) flaps from their extended stop positions by rotating the hex socket coupling of the flex drive shafts 2.5 turns in reverse direction to secure a gap between rollers and track slot ends about 1.5 mm (.06"). This will give the 30° position. Use a 3/16" (4.7 mm) Allen key and turn by hand. 7 The basic adjustment dimensions at the transmission actuators (measured from the center of the mounting pin of the screw jack to the center of the rod end) are:
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Position Inner actuator Outer actuator
0° Retracted
15° Intermediate
30° Extended
58 + 3/- 0 mm
152 + 3/- 0 mm
270 + 3/- 0 mm
2.28 + .12/-0 inches
5.98 + .12/-0 inches
10.63+ .12/-0 inches
68 + 3/- 0 mm
135 + 3/- 0 mm
219 + 3/- 0 mm
2.68 + .12/-0 inches
5.31 + .12/-0 inches
8.62 + .12/-0 inches
8 If the rod end at the transmission screw and the respective flap bracket do not align, disconnect the rod end from the bracket and loosen the two bolts securing the bracket to the flap. This will allow the bracket to be moved by tapping. Connect the rod end to the bracket and tap the bracket to achieve a satisfactory alignment. Disconnect the rod end from the bracket and torque the bracket attachment bolts. With the transmission screw and flap bracket aligned, finally connect the rod end to the bracket with the bolt assy. 9 When measuring flap deflection angles, lift the trailing edge of the flap to eliminate play between rollers and track slots.
27-50-01
Flap Drive Motor Description Brush type bidirectional permanent magnet motor, positioned in the wing center box at the front web of the rear spar Characteristics: 1 Hex shafts on both sides 2 Capability of dynamic braking 3 Max. ambient temperature: + 40 °C 4 Voltage: 24 to 30 VDC, 24 VDC nominal 5 Torque at output shaft: 50.7 Ncm nominal at 24 VDC, 1,600 RPM, 4.5 amps 6 Power output: 85 W 7 Ratio RPM/Torque: 5.1 (Ncm ⋅ min) -1 8 Voltage factor: 0.013 V ⋅ min 9 Efficiency: 78 % 10 Insulation class IP 54 according DIN 40050 (protected against dirt, dust and ingressed water)
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27-50-02
Inboard Power Transmission Flexible Shaft Description The inboard flexible shaft has a female 3/16" hex drive at motor side and a DIN 75532 E1 for the screw jack side. LH and RH flex shaft are different in main rotation due to the musk wire: CW or CCW for main rotation. Characteristics: 1 Length: 1,400 mm 2 Core: Carbon steel musk wire φ 6 mm 3 Casing and end fittings in CRES 4 Shrink sleeve on casing 5 Minimum installation bend radius: 300 mm 6 Coupling nut 2024-T4 blue anodized or CRES with hole for safety wire 7 Min. static torque : 300 Ncm
27-50-03
Outboard Power Transmission Flexible Shaft Description The outboard flexible shaft is a standard type DIN 75532 E1. As for the inboard shaft LH and RH flex shafts are different in main rotation due to the musk wire: CW or CCW for main rotation. Characteristics: 1 Length: 2,000 mm 2 Core: Carbon steel musk wire φ 4 mm 3 Steel casing 4 End fitting in steel zinc - plated galvanically 5 Shrink sleeve on casing 6 Minimum installation bend radius: 55 mm 7 Coupling nut aluminium with hole for safety wire 8 Min. static torque: RH 104 Ncm (CCW)/49 Ncm (CW) LH 104 Ncm (CW)/49 Ncm (CCW)
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27-50-04
Power Transmission Screw Jacks Description The in- an outboard screw jacks consists of a reduction worm gear and machine screw nut with trapezoid thread (irreversible by choice of pitch). The inboard screw jacks have right hand threads, the outboard screw jacks left hand threads. The worm shaft and the screw nut are equipped with ball bearings. Characteristics: 1 Worm gear ratio: inboard 5:1 outboard 7:1 2 Efficiency of worm gear: inboard 0.7 outboard 0.65 3 Pitch of screw nut: 3 mm stroke per revolution 4 Number of revolutions for full stroke of screw jack (30° flap setting): inboard 70 revolutions outboard 50 revolutions 5 Stopping accuracy: ± 3 % of full stroke 6 The unit is sealed 7 All external parts are protected against corrosion 8 Periodic lubrication is not required 9 Output shaft splines: According DIN 75532 E2 for connection to the flexible drive shafts
27-50-05
Flap Control Box Description A Flap Control Box providing the flap control functions is fixed into the avionic bay with an adapted bracket, using 4 AN bolts with AN washers. The Flap Control Box performs the following functions: 1 Controlling the motor for the 3 intended flap - positions (retracted, 15° intermediate and 30° fully extended) 2 Activating the flap position signals 15°, 30° or "flaps in transition" and: Asymmetry detection by controlling the rheostats fitted at the outboard flaps on the LH and RH, thus activating: 1 Motor shut-off 2 Signalisation to the warning panel inside the cockpit Wing flap asymmetric tolerances are adjustable at the trimmer of the watchdog box. Refer to Subject 27-50-07.
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27-50-06
Flap Limit Switches Description The 0° and 30° flap positions are detected by four limit switches, every two of them attached to a mounting bracket positioned on the LH and RH side wing’s rear spar web. If one DOWN or UP limit switch related to any of these flap positions fails, the remaining one on the opposite side will still detect the desired flap position. The extended flap position is detected by the DOWN limit switch on the LH flap (backup switch on the RH side) and the retracted flap position is detected by the UP limit switch on the RH flap (backup switch on the LH side). The switches are operated by the same linkage mechanism that is used for asymmetry detection. The 15° flap position is detected by two limit switches at the LH outboard screw jack.
Adjustment DOWN Limit Switch 1 Run the flaps to the 30° position determined before. If not present yet, mount both asymmetry detection potentiometers and put the lever arm on the potentiometer shafts, but do not tighten their clamping screws yet. CAUTION
Tightening of the clamping screws may destroy parts of the mechanism while moving the flaps.
2 At the LH side wing flap, determine the axial and the angular position of the arm on the potentiometer shaft so that it contacts the 30° limit switch in the center of the arm. 3 With the positions of the potentiometer arm and flap bracket given, adjust the linkage rod until it fits. The start value is 66 mm (2.6”) between the ball joint centers. The length adjustment is done by loosening the nuts and rotating the rod, which features one LH side and one RH side thread. Tighten the rod nuts and the ball joint nuts after the adjustment is completed, but do not tighten the potentiometer arm clamping screw. 4 Manually move the flaps up to the retracted position as described in step 3 of the Guidance Check and Adjustment Paragraph of Section 27-50-00. With the flaps on retracted position the gap between the flap and the wing, measured at the lower side, should be 4 mm (.16”).
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UP Limit Switch 1 Perform the same way as with the DOWN limit switch, but with the rod linkage of the RH flap accordingly. Stop the flaps in retracted position just before any of the flap rollers reach the end of the track slots (approximately 1.5 mm (.06") space should remain between the end of the track slot and the closer roller of both flaps). Ascertain at least 1.5 mm (.06") clearance between the tip of the potentiometer arm and the spar. NOTE
Flaps must stop prior to rollers making contact with the end of the trackslots. 2 Turn one drive shaft coupling (RH or LH side) manually as far as necessary to give the right flap the same angular setting as the left flap. 3 Connect and safety-wire the flexible drive shafts to the electric drive motor. 4 Move the selector switch to position RETRACTED and engage the flap motor circuit breaker. Run the flaps from the retracted position to the fully extended position. When the actual flap position reaches the selected position, the appropriate limit switch must deenergize the flap motor. Otherwise parts may be destroyed.
CAUTION 15° Limit Switch 1 Run the flaps by moving the selector to the 15° position. Install the flap rigging tool, if not previously accomplished. Rigging the flaps to the defined 15° setting max require fine adjustment at the LH outboard screw jack. This can be accomplished by readjusting the nylon bushing positioned at the end of the transmission screw that actuates both 15° limit switches. 2 Run the flaps to the 30° setting for removal of the LH outboard screw jack. Disconnect the outer flex drive shaft from the LH outboard screw jack. Disconnect the transmission from the flap bracket. Remove the screw jack from the rear spar. Loosen the counter stop nut of the nylon bushing. Rotating the nylon bushing in CW direction will shift the 15° detection to the retracted position, rotating in CCW direction will shift it to the extended position. Adjust as required and tighten the counter stop nut. Reinstall transmission unit to the rear spar. Reinstall the transmission unit to the rear spar. Connect the flex drive shaft to the transmission actuator. 3 Check that all bolts and joints are secured where necessary. 4 Check function of the position indicator. Green lights indicate the 15° and 30° position and an additional yellow light indicating "flaps in transition". The retracted position is indicated by the fact that no light is on. 5 Check the flap operation.
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27-50-07
Flap Asymmetry Senders Adjustment This adjustment is required after the flaps have been rigged and checked for normal operation. The asymmetry senders, one potentiometer at the LH side and one at the RH side flap, are part of an electric system, the so-called watchdog. The watchdog shuts off the flap motor when the difference between the LH and RH side flap angular positions exceeds 7° ± 3°. 1 Lower the flaps by moving the selector to the 15° position. 2 Pull the flap motor circuit breaker. Ascertain that the flap control circuit breaker is engaged. Turn the sensitivity control potentiometer of the watchdog box towards maximum sensitivity. 3 Adjust the LH asymmetry detection potentiometer. Make sure that the arm is loose on the shaft, then rotate the shaft to find out the potentiometer’s center position between its two internal stops. The angular range of the potentiometer is ± 170 °. Then tighten the arm’s clamping screw. 4 Adjust the RH asymmetry detection potentiometer to ensure that the angular travel to engage the watchdog is the same when retracting as when extending the flaps. Make sure that the arm is loose on the shaft, then rotate the shaft in CW direction until the red asymmetry indicator light on the watchdog box appears (simultaneously the red light on the warning panel in the cockpit appears). Mark this angular shaft position. Rotate the shaft in CCW direction. The red indicator light will turn off, then light up again after rotating a few degrees. Mark this position, too. 5 Finally rotate the sender shaft to the middle between the two marks and tighten the arm’s clamping screw. Now the two potentiometers feature the same resistance value at a given flap position. After adjusting, check for correct alignment of asymmetry detection sensitivity: 6 With the flaps in 15° position disconnect the RH flex drive shaft from the electric drive motor. Engage the flap motor circuit breaker and move the selector switch to the UP position. The LH flap will move up while the RH flap will stay in the 15° position. After a certain difference in RH and LH flap angular positions is reached the watchdog shuts off the flap motor. 7 Measure the flap travel. If it is within the limit of 7° ± 3° , proceed with step 11. If it is outside that limit, proceed with step 8. 8 In order to drive the LH flap back to its 15° position, disconnect the watchdog box from the flap control box, pull the flap motor circuit breaker, move the selector switch to the 15° position and engage the flap motor circuit breaker.
CAUTION
The flap starts to move back to the 15° position immediately after engaging the circuit breaker.
9 Reconnect the watchdog box to the flap control box.
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10 Adjust the sensitivity control potentiometer by turning it in the proper direction, then repeat steps 6 to 7. After asymmetry has been adjusted for UP motion repeat this procedure for DOWN motion: 11 Move the selector switch to the DOWN position. The LH flap will move down while the RH flap will stay in the 15° position. When a certain difference in RH and LH flap angular positions is reached the watchdog shuts off the flap motor. 12 Measure the flap travel. If it is within the limit of 7° ± 3° , proceed with step 16. If it is outside that limit, proceed with step 13. 13 In order to drive the LH flap back to its 15° position, disconnect the watchdog box from the flap control box, pull the flap motor circuit breaker, move the selector switch to the 15° position and engage the flap motor circuit breaker. CAUTION
The flap starts to move back to the 15° position immediately after engaging the circuit breaker.
14 Reconnect the watchdog box to the flap control box. 15 Adjust the sensitivity control potentiometer by turning it in the proper direction, but do not turn it in a way that would compromise the setting found in step 7. Then repeat steps 11 to 12. 16 Connect and safety-wire the RH flexible drive shaft to the electric drive motor.
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Intentionally left blank
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Chapter 28 Fuel
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Table of Contents
28-00-00
GENERAL ........................................................................................................ 5 Description.......................................................................................................... 5 Figure 28-1, Sheet 1 Fuel System Schematic ....................................................................................... 6 Figure 28-1, Sheet 2 Fuel System Schematic ....................................................................................... 7 Troubleshooting.................................................................................................. 8 Reduction of Fuel Tank Vapor Hazards ............................................................. 9 28-10-00
STORAGE....................................................................................................... 10 Description........................................................................................................ 10
28-10-01
Tank ................................................................................................................. 11 Sealant Repair................................................................................................... 11 Draining ............................................................................................................ 11 Leakage Test..................................................................................................... 12
28-10-02
Drain (Curtis).................................................................................................. 12 Removal/Installation......................................................................................... 12
28-10-03
Flush Drain Valve ........................................................................................... 13 Removal/Installation......................................................................................... 13
28-10-04
Pressure Relief Valve...................................................................................... 13 Removal/Installation......................................................................................... 13
28-10-05
Pressure Relief Valve O-ring ......................................................................... 14 Replacement ..................................................................................................... 14
28-10-06
Float Valve....................................................................................................... 14 Removal/Installation......................................................................................... 14
28-10-07
Fuel Transfer Filter ........................................................................................ 15 Removal/Installation......................................................................................... 15 Cleaning............................................................................................................ 15
28-10-08
Fuel Transfer Pump ....................................................................................... 15 Removal/Installation......................................................................................... 15
28-10-09
Jet Pump.......................................................................................................... 16 Removal/Installation......................................................................................... 16
28-10-10
Jet Pump Filter Element ................................................................................ 16 Cleaning............................................................................................................ 16
28-10-11
Rubber Hose.................................................................................................... 17 Removal/Installation......................................................................................... 17
28-10-12
Pressure Switch............................................................................................... 17 Removal/Installation......................................................................................... 17
28-20-00
DISTRIBUTION............................................................................................. 18 Description........................................................................................................ 18
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Bleeding Procedure ...........................................................................................19 28-20-01
Check Valves (wing to selector valve) ...........................................................19 Removal/Installation .........................................................................................19
28-20-02
Check Valves (downstream electrical fuel pumps) ......................................20 Removal/Installation .........................................................................................20
28-20-03
Fuel Selector Valve..........................................................................................20 Removal/Installation .........................................................................................20
28-20-04
Fuel Filter Element .........................................................................................21 Exchange ...........................................................................................................21
28-20-05
Electrical Fuel Pump.......................................................................................21 Removal/Installation .........................................................................................21
28-20-06
Rubber Hose ....................................................................................................22 Removal/Installation .........................................................................................22
28-40-00
INDICATION..................................................................................................23 Description ........................................................................................................23
28-40-01
Fuel Quantity Sensor (collector compartment) ............................................23 Removal ............................................................................................................23 Installation.........................................................................................................23
28-40-02
Fuel Quantity Sensor (main or auxiliary compartment).............................25 Removal ............................................................................................................25 Installation.........................................................................................................25
28-40-03
Fuel Quantity Gauge.......................................................................................26 Removal/Installation .........................................................................................26 Calibration.........................................................................................................26
28-40-04
Fuel Flow Indicator.........................................................................................27 Removal/Installation .........................................................................................27 K-Factor Setting ................................................................................................27
28-40-05
Pressure Transducer .......................................................................................27
28-40-06
Pressure Gauge................................................................................................27
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Intentionally left blank.
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Maintenance Manual EXTRA 500
28-00-00
GENERAL Description The next paragraph contains the general description and operation of the fuel system. The following paragraph contains information about Troubleshooting. The specified descriptions of the systems, sub-systems and units can be found in the respective chapters. The fuel system (refer to Figure 28-01) of the aircraft is a gravity assisted, pump fed system, supplying fuel to the engine driven fuel pump. The fuel system consists of: • Two integral main tank compartments (one each wing) • Two integral collector compartments (one each wing) with strainer, sump, drain and pick-up point • Two integral auxiliary compartments (one each wing) • A vent system for each tank • Two fuel transfer systems (left and right) for pumping fuel from the auxiliary tank into the main tank and to keep the collector compartment full (motive flow electrical pumps with jet pumps). • A fuel selector valve (LEFT – BOTH – RIGHT – OFF) located under the cockpit floor • A fuel filter in the engine compartment • 2 parallel, redundant electrical fuel pumps mounted on the firewall. • A fuel quantity indication system with 6 probes in the tanks and 6 indicators in the cockpit. • A fuel flow transducer mounted on the battery mount in the engine compartment. • A total of 12 drains (refer to Chapter 12-10-03 for locations)
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28
Page 5
Figure 28-1, Sheet 1
Page 6
28
Auxiliary
Main
Collector
Left
Right
Fuel quantity
Fuel flow
Fuel temperature
Fuel pressure
Fuel transfer right Fuel transfer left
Fuel pump 1
Fuel pump 2
Wing tank sump
Engine internal bypass
Overflow line
Auxiliary compartment
Vent line to left tank Collector compartment Main compartment
Only right tank shown, left tank symmetric
Firewall
Engine
Vent line
Fuel control unit
Maintenance Manual EXTRA 500
Fuel System Schematic
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Maintenance Manual EXTRA 500
Legend:
Switch Unit Annunciator light Gauge Selector valve Check valve Overpressure relief valve Float valve Drain valve Fuel pressure accumulator Filter (with drain valve) Fuel transfer filter Pump Jet pump with filter at inlet Nozzle Filler neck Low fuel level switch Fuel level sensor Pressure switch Pressure transducer Electric wiring Flow direction
Figure 28-1, Sheet 2
Page Date: 30. March 2012
Fuel System Schematic
28
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Maintenance Manual EXTRA 500
Troubleshooting Complaint
Possible Cause
Fuel tank leakage
Remedy
Tank sealant damage
Identify and seal
Sump drain leakage
Inspect drain line plumbing and seal if necessary, or replace drain
Outer wing flush drain leakage Replace drain valve. Relief valve leakage
Replace relief valve/O-ring
Ventline leakage
Inspect float valves, replace if necessary, seal vent line connections
Fuel filler leakage
Filler cap O-ring damaged
Replace filler cap O-ring
Fuel line leakage
Line fittings loose
Tighten fittings
Collector compartment not full, auxiliary tank does not empty fast enough, FUEL TRANS LEFT/RIGHT ON in flight
Fuel transfer filter blocked
Clean filter
Loss of fuel supply
T
Insufficient fuel supply pressure reading
Incorrect fuel quantity reading
Incorrect fuel flow indication
Low fuel warning defective
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28
Electrical transfer fuel pump Replace pump defective Transfer fuel pick-up blocked
Remove blockage
Leaking transfer fuel line
Replace fitting or line
Strainer blocked (tank)
Clean strainer
Check valve (one of four) blocked
Replace check valve
Selector valve blocked
Replace selector valve
Fuel line blocked
Identify and clean or replace fuel line
Filter blocked
Replace filter element.
Fuel pressure indication defective
Replace sensor/indicator
Electrical fuel pump failure
Replace fuel pump
Float sensor defective
Repair or replace float sensor
Gauge defective
Replace gauge
Fuel flow sensor defective
Replace sensor
Fuel flow indicator defective
Replace indicator
Wrong K-factor set
Adjust K-factor at indicator
Fuel low level sensor failure
Replace fuel low level sensor
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Maintenance Manual EXTRA 500
Reduction of Fuel Tank Vapor Hazards General Precautions During all ventilation or maintenance procedures involving the fuel system, observe the following general precautions. • Defueling should be outdoors with the aircraft at least 100 feet from hangars or other aircraft. • No smoking should be allowed within 100 feet of the aircraft. • Suitable fire fighting equipment should be available. Foam or soda type extinguishing agents are recommended. • Ground the aircraft to prevent static electricity from causing sparks. If a ramp ground is available it should be connected to exhaust stack. If a ramp ground is not provided, a temporary ground can be obtained by driving a metal rod into the ground and attaching a ground wire between the rod and the aircraft exhaust stack. • Flame and spark producing equipment should not be operated within 100 feet of the aircraft. • Only personnel working on the aircraft should be allowed in the immediate area, and no other maintenance should be performed while the tanks are being worked on. • When a fuel tank is opened for repair, air ventilation (refer to Page 7) should be started immediately to reduce vapor concentrations. • When draining fuel, ensure that suitable containers are available and that drained fuel is stored safely. Do not allow fuel to drip to the ground and form pools. • If it is necessary to ventilate a tank when the aircraft is in hangar, ensure that vapors do not accumulate to explosive or toxic levels in the hangar. When fuel is being drained, there is little control over the release of fuel WARNING vapor. This vapor should be dissipated as quickly as possible by smoothly blowing shop air into the tank. Air Ventilation • Completely drain the fuel system per Chapter 12-10-02. • Remove inspection doors (refer to Chapter 28-11-03) and tank caps. • Use compressed air or an explosion-proof blower to blow air into the tank until tank interior is dry and free of vapor. • Continue ventilation whenever tank is open and being worked on. If flammable vapors from cleaning solvents are allowed in the tank WARNING increase air circulation to dissipate them.
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Maintenance Manual EXTRA 500
28-10-00
STORAGE Description The aircraft has six integral wing tanks between the wing spars. Each wing side has a main, auxiliary, and collector compartment. The latter is kept full by a jet pump driven fuel transfer system in flight. The collector compartment features a fuel level sensor, a sump with drain, a strainer and a pick-up tube behind it. The low fuel sensor is also located here. Three flapper type check valves separate the collector compartment from the main compartment to make sure fuel cannot flow out, but can flow in, in case of a fuel transfer system failure. The collector compartment can be inspected from the main compartment by opening the rib in which these valves are mounted or from the avionic compartment (center wing) by removing the inspection door on which the fuel quantity probe is installed. The main compartment has its own fuel level sensor mounted on the inner wing inspection door. The vent system has two float valves and an outlet. The vent systems of the two main tanks are interconnected. Each tank has a 1psi overpressure relief valve in the aft spar for the case the normal vent system fails. The main tanks have a Ø 75mm filler cap for JET-A1 with a titanium ring around it for static bonding. The auxiliary compartment also has a filler cap, vent system (including overpressure relief valve) and fuel level sensor, but is not directly connected to the fuel distribution system. As long as the auxiliary compartment is filled fuel is pumped from there into the main compartment by means of the fuel transfer system. Observe the safety notes given in Chapter 12-10-01.
DANGER WARNING
For all maintenance work on the tanks, drain them completely and appropriate open tank hatches on top of the wing. Be aware of fuel fumes and fuel stained cloth: highly inflammable! Power must be off, no external power connected, room well ventilated.
NOTE
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28
If the tank has been opened, a tank leakage test is mandatory. Refer to Subject 28-10-01 Leakage Test.
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Maintenance Manual EXTRA 500
28-10-01
Tank Sealant Repair Detail Steps/Work Items 1 Drain the fuel system.
Key Items Refer to Chapter 12-10-02
2 Observe precautions concerning Reduction Refer to Subject 28-00-00 of Fuel Tank Vapor Hazards. 3 Remove applicable fuel compartment access Refer to Chapter 51-00-01 panels. 4 Clean area. 5 Sand the area to be repaired.
Only ruff it up
PR 1750 accelerator contains harmful vapors and is readily absorbed WARNING through the skin. Avoid all contact with the skin and ingestion. Always wash hands before eating or smoking. Use adequate ventilation, hand protection and chemical-type goggles when working with this product. If accelerator contacts skin, flush area with warm water. Obtain medical attention in cases of extreme exposure or ingestion. PR 1750 sealant contains solvents. WARNING Use adequate ventilation or air-supplied respirators during application. Avoid repeated or prolonged breathing of vapors. In case of extreme vapor exposure, remove affected personnel to fresh air immediately and obtain medical attention. For complete health and safety information, refer to Le Joint Francais material safety data sheet PR 1750 (LOAP 41). 6 Apply PR 1750 tank sealant.
For mixing and application of PR 1750 sealant refer to manufacturer's instructions.
7 Perform a fuel tank leakage test.
See Leakage Test below.
8 Wait for at least 3 hours before filling the tank.
An absolute humidity of at least 10g/m3 is needed for curing. This corresponds with 35% relative humidity at 23°C and 78% at 10°C.
Draining Refer to Chapter 12-10-02.
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Maintenance Manual EXTRA 500
Leakage Test After opening a fuel tank (except the avionic bay access panels) or a tank repair, the tank shall undergo a leakage test. It is recommended to test all tanks together or LH and RH individually. The LH and RH tanks are connected by an interconnecting vent line, located in the avionic bay. It needs to be removed and the fittings in the root ribs plugged if the LH or RH should be tested individually. Furthermore, the four overpressure valves in the aft spar must be plugged or held shut as they have a lower cracking pressure as the required test pressure. Detail Steps/Work Items 1 Make sure aircraft is completely drained.
Key Items Refer to Chapter 12-10-02.
2 Observe precautions concerning Reduction Refer to Subject 28-00-00 of Fuel Tank Vapor Hazards. 3 Remove interconnecting vent line between LH and RH wing tank.
If one tank shall be tested individually.
4 Plug the appropriate fitting. Make sure the upper door is closed before extending flaps. CAUTION 5 Extend flaps to 30°.
To gain access to the overpressure valves from the outside.
6 Plug or hold shut the overpressure valves. 7 Plug vent system. 8 Turn fuel selector valve to OFF-position. 9 Pressurize the tanks slowly to 120 mbar (1.74 psig).
Tanks pressure shall be steady for min. of 10 minutes.
10 Return aircraft to normal.
28-10-02
Drain (Curtis) Removal/Installation Detail Steps/Work Items 1 Drain collector and main compartment.
Key Items Refer to Chapter 12-10-02
2 Observe precautions concerning Reduction Refer to Subject 28-00-00 of Fuel Tank Vapor Hazards. 3 Remove fuel sump access panel.
Refer to Chapter 51-00-01
4 Carefully screw drain out of fitting. 5 Install in reverse sequence of removal.
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Use Loctite 577
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Maintenance Manual EXTRA 500
28-10-03
Flush Drain Valve Removal/Installation Detail Steps/Work Items 1 Drain fuel system.
Key Items Refer to Chapter 12-10-02
2 Observe precautions concerning Reduction Refer to Subject 28-00-00 of Fuel Tank Vapor Hazards. 3 Remove applicable fuel compartment access Refer to Chapter 51-00-01 panels. 4 Loosen nut on tank inside. 5 Install vice versa.
Use Loctite 577
6 Perform tank leakage test.
Refer to Subject 28-10-01
28-10-04
Pressure Relief Valve Removal/Installation Detail Steps/Work Items
Key Items
Ensure cabin door is closed before extending wing flaps. CAUTION 1 Place wing flaps to the 30° position.
Refer to EXTRA 500 Pilot’s Operating Handbook
2 Drain fuel system.
Refer to Chapter 12-10-02
3 Observe precautions concerning Reduction Refer to Subject 28-00-00 of Fuel Tank Vapor Hazards. 4 Remove applicable fuel compartment access panel. 5 Screw out while holding plastic fitting from inside of tank to keep it from turning. 6 Install vice versa.
Use Loctite 577
7 Perform tank leakage test.
Refer to Subject 28-10-01
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Maintenance Manual EXTRA 500
28-10-05
Pressure Relief Valve O-ring Replacement Detail Steps/Work Items
Key Items
Ensure cabin door is closed before extending wing flaps. CAUTION 1 Place wing flaps to the 30° position.
Refer to EXTRA 500 Pilot’s Operating Handbook
2 Drain related fuel compartment.
Refer to Chapter 12-10-02
3 Observe precautions concerning Reduction Refer to Subject 28-00-00 of Fuel Tank Vapor Hazards. 4 Pull pressure relief valve poppet. 5 Replace O-ring
28-10-06
Float Valve Removal/Installation Detail Steps/Work Items 1 Drain fuel system.
Key Items Refer to Chapter 12-10-02
2 Observe precautions concerning Reduction Refer to Subject 28-00-00 of Fuel Tank Vapor Hazards. 3 Remove applicable fuel compartment access Refer to Chapter 51-00-01 panels. 4 Disconnect vent line. 5 Remove vent float valve from mounting.
2 screws
6 Install in reverse sequence of removal. 7 Perform tank leakage test.
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Refer to Subject 28-10-01
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Maintenance Manual EXTRA 500
28-10-07
Fuel Transfer Filter Removal/Installation Detail Steps/Work Items 1 Drain collector and main compartment.
Key Items Refer to Chapter 12-10-02
2 Observe precautions concerning Reduction Refer to Subject 28-00-00 of Fuel Tank Vapor Hazards. 3 Open wing center fairing.
Refer to Chapter 51-00-01.
4 Disconnect fittings from filter. 5 Remove fuel transfer filter from aircraft.
Notice flow direction
8 Reinstall in reverse sequence of removal.
Make sure flow direction is correct and bonding is attached.
Cleaning Detail Steps/Work Items 1 Remove fuel transfer filter.
Key Items See above
2 Open filter. 3 Clean with Jet-A1. 4 Reinstall fuel transfer filter.
28-10-08
See above
Fuel Transfer Pump Removal/Installation Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. T
2 Drain collector and main compartment.
Refer to Chapter 12-10-02
3 Observe precautions concerning Reduction Refer to Subject 28-00-00 of Fuel Tank Vapor Hazards 4 Open wing center fairing.
Refer to Chapter 51-00-01.
5 Disconnect electrical wiring. 6 Disconnect fuel hoses. 7 Remove fuel pump. 8 Install in reverse sequence of removal.
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Make sure flow direction is correct.
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28-10-09
Jet Pump The jet pumps incorporate a filter element (refer to Subject 28-10-10).
Removal/Installation Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. T
2 Drain related fuel compartment.
Refer to Chapter 12-10-02
3 Observe precautions concerning Reduction Refer to Subject 28-00-00 of Fuel Tank Vapor Hazards 4 Open related fuel compartment access panel. Refer to Chapter 51-00-01. 5 Disconnect motive flow and transfer fuel lines. 6 Remove jet pump
2 bolts
7 Install in reverse sequence of removal. 8 Perform tank leakage test.
28-10-10
Refer to Subject 28-10-01
Jet Pump Filter Element Cleaning Detail Steps/Work Items
Key Items
1 Remove jet pump.
Refer to Subject 28-10-09
2 Remove filter element.
Retaining ring
3 Clean with Jet-A1. 4 Reinstall filter element. 5 Reinstall jet pump.
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Refer to Subject 28-10-09
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Maintenance Manual EXTRA 500
28-10-11
Rubber Hose On the outflow side of the fuel transfer pumps rubber type hoses are installed (SN 1002 and 1003 only).
Removal/Installation Detail Steps/Work Items 1 Drain fuel system.
Key Items Refer to Chapter 12-10-02
2 Observe precautions concerning Reduction Refer to Subject 28-00-00 of Fuel Tank Vapor Hazards 3 Remove the applicable inner fuel compartment access panel
Refer to Chapter 51-00-01.
4 Remove hose clamps from hose end. 5 Remove fuel hose. 6 Install in reverse sequence of removal. 7 Perform tank leakage test.
28-10-12
Refer to Subject 28-10-01
Pressure Switch Removal/Installation Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. T
2 Drain collector and main compartment.
Refer to Chapter 12-10-02
3 Observe precautions concerning Reduction Refer to Subject 28-00-00 of Fuel Tank Vapor Hazards 4 Open avionic bay access panel.
Refer to Chapter 51-00-01.
5 Disconnect electrical connector. 6 Remove pressure switch. 7 Install in reverse sequence of removal.
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Maintenance Manual EXTRA 500
28-20-00
DISTRIBUTION Description Fuel runs from the LH and RH pick-up point at the bottom of the wing tank collector compartments through fuel lines via check valves down to the fuel selector valve. The check valves prevent cross flow between the left and right tanks. The fuel selector valve is located under the cockpit floor and direct mechanically linked to the fuel selector handle between the pilot's and the copilot's seat. Just downstream the fuel selector valve an aluminum block is installed which incorporates the fuel temperature sensor and a drain valve. This drain is the lowest point of the fuel system and is accessible by a panel in the right underside of the fuselage between the main and nose gear doors. The drain provides a means to remove moisture and sediment from the fuel system. Fuel lines are of aluminum tubing 5052-0 but in the engine compartment fire resistant PTFE hoses are installed. The hoses in the engine compartment are made fire resistant by means of red silicone fiberglass sleeves or brown integrated fire sleeves. The hose assemblies meet the requirements of MIL-DTL-27267 and MIL-DTL-25579 as well as the fire-resistance requirements of AS1055. Fire-sleeves meet TSO c53a requirements. The pick-up point fuselage connection fuel supply hoses are conforming to MIL-H-5593. From the firewall break-through the fuel is sucked though the aircraft fuel filter. Aft of the filter, a manifold splits to the two parallel electrical fuel pumps. Another manifold joins the fuel lines again though check valves. The single line continues through the fuel flow transducer to the engine inlet.
For all maintenance work on the tanks, drain them completely. Be aware WARNING of fuel fumes and fuel stained cloth: highly inflammable! Observe the safety notes given in Chapter 12-10-01, Refueling. Power must be off, no external power connected, room well ventilated.
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Maintenance Manual EXTRA 500
Bleeding Procedure Detail Steps/Work Items
Key Items
1 Make sure tanks are not empty. 2 Disconnect fuel hose from engine and hold in appropriate container. 3 Turn fuel selector valve to LEFT 4 Both fuel pumps ON
Until no more air bubbles
5 Both fuel pumps OFF 6 Turn fuel selector valve to RIGHT T
7 Both fuel pumps ON
Until no more air bubbles
8 Both fuel pumps OFF 9 Reinstall fuel hose to the engine. 10 Turn fuel selector valve to BOTH
28-20-01
Check Valves (wing to selector valve) Check valves are installed in front of the main gear bays.
Removal/Installation Detail Steps/Work Items 1 Drain fuel system.
Key Items Refer to Chapter 12-10-02
2 Observe precautions concerning Reduction Refer to Subject 28-00-00 of Fuel Tank Vapor Hazards. 3 Remove LH/RH front fuselage access panels.
Refer to Chapter 51-00-01.
4 Disconnect fuel hose. 5 Disconnect check valve from fitting. 6 Install in reverse sequence of removal.
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Make sure flow direction is correct.
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Maintenance Manual EXTRA 500
28-20-02
Check Valves (downstream electrical fuel pumps) The check valves are installed in the fuel manifold on the aft engine fireshield.
Removal/Installation Detail Steps/Work Items
Key Items
1 Set fuel selector valve to OFF. 2 Drain fuel at the lowest point drain and the fuel filter drain.
Refer to Chapter 12-10-02
3 Remove both upper cowlings.
Refer to Ch. 71-10-01/02.
Fuel may be pressurized (30 psi max). Fuel may spill. Protect yourself WARNING and catch spilling fuel. 4 Disconnect fuel hose. 5 Remove lock wire. 6 Screw check valve out of manifold. 7 Install in reverse sequence of removal.
28-20-03
Make sure flow direction is correct. Use new o-ring when necessary (MS29512-08).
Fuel Selector Valve The fuel selector valve is installed in the floor between the pilot and co-pilot seat and in the compartment below.
Removal/Installation Detail Steps/Work Items
Key Items
1 Drain fuel system completely.
Refer to Chapter 12-10-02
1 Remove forward keel beam access panel.
Refer to Chapter 51-00-01.
2 Disconnect the three fuel lines from the fuel selector valve. 3 Remove the screws on the fuel selector handle.
4 screws, in the cabin
4 Remove handle. 5 Unscrew the bolts on the bottom of the cup.
2 bolts
6 Remove the selector valve from the structure.
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28
7 Remove the spacer from selector valve.
2 screws
8 Install in reverse sequence of removal.
Selector valve can be mounted in one way only Page Date: 30. March 2012
Maintenance Manual EXTRA 500
28-20-04
Fuel Filter Element The fuel filter is installed in the engine compartment in front of the nose gear bay.
Exchange Detail Steps/Work Items
Key Items
1 Set fuel selector valve to OFF. 2 Drain fuel at the lowest point drain and the fuel filter drain.
Refer to Chapter 12-10-02
3 Remove fuel filter access panel.
Refer to Chapter 51-00-01.
4 Remove lock wire and unscrew lower boll of fuel filter. 5 Replace filter element in boll. 6 Screw boll into filter.
torque 100-150 lbs-inch (11.3 – 16.9 Nm)
7 Lock wire. 8 Re-install fuel filter access panel.
28-20-05
Electrical Fuel Pump The electrical fuel pumps are installed in the engine compartment on the firewall, below the battery.
Removal/Installation Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. T
2 Set fuel selector valve to OFF. 3 Drain fuel at the lowest point drain and the fuel filter drain.
Refer to Chapter 12-10-02
4 Remove upper left cowling.
Refer to Chapter 71-10-01.
5 Disconnect electrical connection. 6 Disconnect fuel hoses. 7 Loosen worm-drive hose clamps.
(2)
8 Remove pump. 9 Install in reverse sequence of removal. 10 Perform Bleeding Procedure. Page Date: 30. March 2012
Refer to Subject 28-20-00
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Maintenance Manual EXTRA 500
28-20-06
Rubber Hose For connection of the wing tip pick-up to the fuselage a rubber type hoses are installed.
Removal/Installation Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. T
2 Remove respective fuel sump access panel
Refer to Chapter 51-00-01.
3 Disconnect copper braid bond from fuselage side of hose connection.
Notice copper braid bond position.
4 Disconnect fuselage side fitting. 5 Remove hose clamps and copper braid bond. 6 Remove hose. 7 Install in reverse sequence of removal.
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Ensure correct copper braid bond position
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Maintenance Manual EXTRA 500
28-40-00
INDICATION Description The fuel system indication system displays the following parameter: • Left and right fuel quantity collector compartment • Left and right fuel quantity main compartment • Left and right fuel quantity auxiliary compartment • Fuel flow • Fuel pressure • Fuel temperature
28-40-01
Fuel Quantity Sensor (collector compartment) The fuel quantity probe is installed in the collector compartment on the root rib.
Removal Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. T
2 Open avionic bay access panels.
Refer to Chapter 51-00-01
3 Disconnect electrical connector from sensor. 4 Remove root rib inspection door.
14 bolts
5 Remove sensor from inspection door.
Installation 1 Ensure BATT switch is OFF and no external power connected. T
2 Clean root rib inspection door and sensor surfaces with solvents to remove dirt and grease.
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Maintenance Manual EXTRA 500
PR 1750 accelerator contains harmful vapors and is readily absorbed WARNING through the skin. Avoid all contact with the skin and ingestion. Always wash hands before eating or smoking. Use adequate ventilation, hand protection and chemical-type goggles when working with this product. If accelerator contacts skin, flush area with warm water. Obtain medical attention in cases of extreme exposure or ingestion. PR 1750 sealant contains solvents. WARNING Use adequate ventilation or air-supplied respirators during application. Avoid repeated or prolonged breathing of vapors. In case of extreme vapor exposure, remove affected personnel to fresh air immediately and obtain medical attention. For complete health and safety information, refer to Le Joint Francais material safety data sheet PR 1750 (LOAP 41). 3 Install sensor on root rib inspection door with PR 1750 tank sealant.
For mixing and application of PR 1750 sealant refer to manufacturer's instructions.
4 Check the float points in the direction of flight. NOTE
If the hatch seal has become partly clear instead of white, slightly pull those patches apart. Clear patches are NOT a sign that the seal is defective! 5 Install root rib inspection door, torque bolts 3-5 Nm (26-44inch-lbs). 6 After at least one half hour re-torque the bolts. 7 Connect electrical connector. 8 Make a tank leakage test.
Refer to Subject 28-10-01
9 Close avionic bay access panels.
Refer to Chapter 51-00-01
10 Recalibrate quantity indicator.
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Maintenance Manual EXTRA 500
28-40-02
Fuel Quantity Sensor (main or auxiliary compartment) The fuel quantity sensor is installed on the inner tank inspection door of the appropriate tank.
Removal Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. T
2 Open appropriate tank access panel.
Sensor is on the inner tank inspection door of the corresponding compartment.
3 Remove inspection door. 4 Remove sensor from inspection door.
5 bolts
5 Disconnect electrical connector from sensor.
Installation 1 Ensure BATT switch is OFF and no external power connected. T
2 Connect electrical connector. NOTE
When attaching sensor to hatch observe correct direction. For main compartment: Make sure the float is pointing inboard For auxiliary compartment: Make sure the float is pointing outboard 3 Attach sensor to inspection door.
NOTE
If the hatch seal has become partly clear instead of white, slightly pull those patches apart. Clear patches are NOT a sign that the seal is defective! 4 Install inspection door, torque bolts 3-5 Nm (26-44 inch-lbs). 5 After at least one half hour re-torque the bolts. 6 Recalibrate quantity indicator. 7 Reinstall appropriate tank access panel.
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Maintenance Manual EXTRA 500
28-40-03
Fuel Quantity Gauge The fuel quantity gauges are installed in the RH instrument panel.
Removal/Installation Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. T
2 Remove RH IFD.
Refer to Chapter 31-60-01.
3 Disconnect electrical connector from fuel quantity gauge. 4 Unscrew attachment .
4 screws
5 Install in reverse order of removal. 6 If more than one gauge is replaced, check if indicator shows proper tank.
Calibration The calibration potentiometers are installed on PCB installed behind the LH IFD. Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. T
2 Remove RH IFD.
Refer to Chapter 31-60-01.
3 Disconnect electrical connector from fuel quantity gauge. 4 Make sure the fuel quantity sensor is installed and laying on the bottom of the compartment (compartment is empty). 5 Measure with a calibrated, digital ohmmeter the resistance between pins 5 and 8.
For collector and main comp: The value must be 50.0 Ohm For auxiliary compartment: The value must be 80.0 Ohm
6 If value is not correct, follow the steps below. 7a Remove LH IFD.
Refer to Chapter 31-60-01.
7b Use the potentiometer on the PCB behind the RH IFD to bring the resistance value to the required value. 7c Reinstall the LH IFD. 8 Connect electrical connector. 9 Re-install the RH IFD. Page 26
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Maintenance Manual EXTRA 500
28-40-04
Fuel Flow Indicator The fuel flow indicator is installed in the RH instrument panel.
Removal/Installation Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. T
2 Remove RH IFD.
Refer to Chapter 31-60-01.
3 Disconnect electrical connector from fuel flow indicator. 4 Unscrew attachment.
4 screws
5 Install in reverse sequence of removal.
K-Factor Setting Refer to Shadin Avionics Miniflo-L Operating Manual (LOAP 42).
28-40-05
Pressure Transducer For description and maintenance practices refer to Chapter 73-30-01.
28-40-06
Pressure Gauge The fuel pressure gauge is integrated in the Digital Instrument Package (refer to Chapter 77-40-02).
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Intentionally left blank.
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Maintenance Manual EXTRA 500
Chapter 29 Hydraulic Power
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29
Page 1
Maintenance Manual EXTRA 500
Table of Contents
29-00-00
Page 2
29
GENERAL ........................................................................................................ 3
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Maintenance Manual EXTRA 500
29-00-00
GENERAL The hydraulic system of the EXTRA 500 is used to operate the landing gear exclusively. Therefore all information concerning hydraulics is incorporated in Chapter 32-30 Extension and Retraction.
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Maintenance Manual EXTRA 500
Intentionally left blank
Page 4
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Maintenance Manual EXTRA 500
Chapter 30 Ice and Rain Protection
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30
Page 1
Maintenance Manual EXTRA 500
TABLE OF CONTENTs 30-00-00
Figure 30-1
GENERAL ........................................................................................................ 5 Description.......................................................................................................... 5 Removal/Installation/Repair............................................................................... 5 De-Icing System Shematic .................................................................................. 6 Troubleshooting.................................................................................................. 7
30-10-00
AIRFOIL ......................................................................................................... 10 Description........................................................................................................ 10
30-10-01
Pressure Regulator ......................................................................................... 10 Removal/Installation......................................................................................... 10
30-10-02
Ejector Valve................................................................................................... 10 Removal/Installation......................................................................................... 10
30-10-03
Boots Timer ..................................................................................................... 11 Removal/Installation......................................................................................... 11
30-20-00
AIR INTAKES ................................................................................................ 12 Description........................................................................................................ 12
30-20-01
Bowden Cable ................................................................................................. 12 Removal/Installation......................................................................................... 12 Rigging ............................................................................................................. 13
30-20-02
Micro Switch ................................................................................................... 14 Removal/Installation......................................................................................... 14 Rigging ............................................................................................................. 14
30-20-03
Helical Metallic Hoses .................................................................................... 14 Removal/Installation......................................................................................... 14
30-30-00
PITOT, STATIC AND STALL WARNING ................................................ 15 Description........................................................................................................ 15
30-30-01
Current Sensor (Avionic Bay) ....................................................................... 15 Removal/Installation......................................................................................... 16
30-30-02
Current Sensor (Tail Cone) ........................................................................... 16 Removal/Installation......................................................................................... 16
30-40-00
WINDSHIELD................................................................................................ 17
30-40-01
Windshield Heat Controller .......................................................................... 17 Removal/Installation......................................................................................... 17
30-40-02
Windshield Heat Current Sensor .................................................................. 18 Removal/Installation......................................................................................... 18
30-60-00
PROPELLER.................................................................................................. 19 Description........................................................................................................ 19
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30-60-01
Propeller Ammeter..........................................................................................19 Removal/Installation .........................................................................................19
30-70-00
WATER LINES...............................................................................................20
30-80-00
DETECTION...................................................................................................21
30-80-01
Ice Light ...........................................................................................................21 Removal/Installation .........................................................................................21
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30-00-00
GENERAL Description The following icing protection systems are standard equipment on the EXTRA 500 (refer to Figure 30-1): 1 Pneumatic de-ice boots for wing and empennage 2 Heated Pitot tubes and heated static ports 3 Heated stall warning sensor 4 Heated windshield 5 Heated engine inlet 6 Heated propeller blades
Removal/Installation/Repair For respective information see manufacturers BF Goodrich publications concerning “Estane De-Icers” as listed in the LOAP 18-22.
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Maintenance Manual EXTRA 500
Figure 30-1
Page 6
30
De-Icing System Shematic
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Maintenance Manual EXTRA 500
Troubleshooting Complaint Deice boots fail to inflate completely
De-ice boots inflate only partially (low inflation pressure, no DEICE BOOTS safe operation light)
One of the two inflation sections (inner wing, outer wing and tail surfaces) fails to inflate
Possible Cause
Remedy
Leakage in pressure system upstream ejector valves
Identify leak, seal or replace defective part
Electric failure
Check wiring
Failure of: timer, pressure regulating valve, ejector valves, pressure manifold
Identify defective component(s) and replace
Leakage in pressure lines
Identify leak, seal or replace defective part
Kinked pressure tube
Replace defective tube
Failure of pressure regulating valve
Replace valve
Electric failure
Check pressure sensors, wiring and indication light
Failure of:
Identify defective component and replace
Timer, ejector valve, electric wiring Leakage of pressure lines downstream ejector valve
Check for leaks in pressure lines and boots, repair or replace defective parts
Blockage downstream distributing valve
Check for kinks in tubing, replace
Time intervals out of tolerances
Failure of timer (or false timer)
Replace timer
Boot evacuation fails
Timer, ejector valve, or switch failure
Identify and replace or repair
Electric failure
Check and repair wiring
Boot or line leakage
Identify and replace or repair
Bowden cable broken
Replace
Bowden cable loose
Rig Bowden cable
Exhaust ‘ashtray’ broken
Replace
Exhaust is leaking
Replace
Exhaust helical metallic hose disconnected or leaking
replace
Inlet heating defect
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Maintenance Manual EXTRA 500
Complaint
Possible Cause
Remedy
INTAKE HEAT safe operation
Wiring defective
Replace
light does not illuminate on activation
Microswitch defective
Replace
Bowden cable mis-rigged
Rig Bowden cable
Microswitch mis-aligned
Rig microswitch
Wiring defective
Replace
Microswitch defective
Replace
Bowden cable mis-rigged
Rig Bowden cable
Microswitch mis-aligned
Rig microswitch
Water separator drain line blocked
Remove drain line blockage
Orifice in water separator blocked
Remove blockage from and clean (inside of) water separator.
Pitot tube does not heat, no PITOT HEAT LEFT/RIGHT indication
Wiring defective
Check and repair wiring
Pitot tube heat defective
Replace Pitot tube
Static port does not heat
Wiring defective
Check and repair wiring
indication
Static port heat defective
Replace static port
Lift detector (3 heating circuits) does not heat
Wiring defective
Check and repair wiring
Current sensor defective
Replace current sensor.
Lift detector heat defective
Replace lift detector
High ambient temperature (windshield above 40°C)
Normal system function
Wiring to one temperature sensor in windshield defective
Check and repair
One windshield temperature sensor defective
Replace windshield
Respective circuit in controller defective
Replace controller
Wiring to or both temperature sensors in windshield defective
Check and repair
Windshield controller defective
Replace controller
Engine inlet anti ice system does not activate
Water in boots system
STATIC HEAT LEFT/RIGHT
Windshield heat inactive, no WINDSHIELD HEAT ON
indication WINDSHIELD HEAT FAIL
active, WINDSHIELD HEAT ON still
active
WINDSHIELD HEAT FAIL
active, WINDSHIELD HEAT ON
inactive
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Maintenance Manual EXTRA 500
Complaint WINDSHIELD HEAT ON
inactive
Prop Ammeter shows zero
Prop Ammeter shows low current (below green arc)
Ammeter shows excess current (above green arc)
Radio noise
Rapid brush wear and frequent breakage
Page Date: 30. March 2012
Possible Cause
Remedy
Wiring to heated area defective
Check and repair
Heated area in windshield defective
Replace windshield
Windshield controller defective
Replace controller
No power from aircraft to brushes
Check wiring, circuit breaker and switch, repair or replace defective part
Open circuit brushes to heater boots
Repair wiring (check when stretching and flexing the leads) or replace propeller in case of heater element failure
Ammeter shunt defective
Replace shunt
Ammeter wiring defective
Repair wiring
Ammeter defective
Replace ammeter
Open circuit (or high resistance) to at least one of the blade heating elements
Identify whether wiring or heater element itself is defective. Repair wiring or replace propeller
Ammeter defective
Replace ammeter
Power lead shorted to ground
Check insulation and replace defective lead
Ammeter defective
Replace ammeter
Brushes arcing
Check for brush alignment, dirty or rough slip rings and slip ring alignment
Loose connection
Check wiring connections
Brush assembly out of alignment
Check and adjust brush alignment
Slip ring wobbles
Check slip ring alignment, replace slip ring
Rough slip rings
Replace (or refinish) slip ring
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30-10-00
AIRFOIL Description The leading edges of the airfoils (wing, horizontal and vertical stabilizer) are protected against icing by inflatable rubber boots. The pressurized air for boot inflation is supplied by engine bleed air. Nominal inflation pressure of the system is 18 psig (1.25 bar). A system surview is given in Figure 30-1. The system, when activated, inflates two leading edge boots groups in sequence for ice shedding. Boot cycle A incorporates the inner wing boots, cycle B the outer wing and empennage. When not inflated, suction will keep the boots on the wing and empennage surfaces. The switching from underpressure to pressure is done by an ejector valve (one for each group), which is commanded by the boots timer. The boots timer is activated with the BOOTS switch on the left side panel.
30-10-01
Pressure Regulator The pressure regulator is located in the engine compartment, on the LH upper engine mount tube.
Removal/Installation Detail Steps/Work Items 1 Remove LH upper cowling.
Key Items Refer to Chapter 71-10-01.
2 Disconnect pneumatic lines. 3 Remove mounting plate from engine mount.
2 screws
4 Remove pressure regulator from mounting plate.
4 screws, lockwire
5 Install in reverse sequence of removal.
30-10-02
Ejector Valve Two ejector valves (one for boot cycle A and one for boot cycle B) are installed in the engine compartment. They are mounted on the firewall, left of the nose gear bay firewall.
Removal/Installation Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. Page 10
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Maintenance Manual EXTRA 500
Detail Steps/Work Items 2 Remove LH upper cowling.
Key Items Refer to Chapter 71-10-01.
3 Disconnect electrical connector. 4 Disconnect pneumatic lines. 5 Remove ejector valve.
4 bolts
6 Install in reverse sequence of removal.
30-10-03
Boots Timer The boots timer is installed in the avionics compartment in the center wing section.
Removal/Installation Detail Steps/Work Items 1 Remove LH avionic bay access panel on top of the wing.
Key Items Refer to Chapter 51-00-01.
2 Disconnect electrical connector. 3 Remove boots timer
4 bolts
4 Install in reverse sequence of removal.
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Maintenance Manual EXTRA 500
30-20-00
AIR INTAKES Description The EXTRA 500 is equipped with an exhaust heated engine inlet. Pulling the INTAKE ANTI ICE Bowden cable opens the “ashtray” in the LH exhaust stack which routes hot exhaust air into the double walled engine air inlet. The air flows out on the RH side to the RH exhaust stack. Pulling the Bowden cable will also throw a microswitch on the LH exhaust stack to illuminate the INTAKE HEAT safe operation light and to activate the engine compressor inlet anti ice system (Rolls Royce 250-B17F Series Operation and Maintenance Manual, LOAP 1).
30-20-01
Bowden Cable The Engine anti-ice Bowden cable is installed in the middle console in the cockpit and goes through the front pressure bulkhead/firewall to the LH engine exhaust stack in the engine compartment.
Removal/Installation Detail Steps/Work Items 1 Remove LH upper cowling.
Key Items Refer to Chapter 71-10-01.
2 Disconnect cable of Bowden cable on LH exhaust stack. 3 Disconnect Jacket of Bowden cable on LH exhaust stack. 4 Disconnect any tie-raps in engine compartment that hold the Bowden cable. 5 Remove upper paneling part of middle console in which the Bowden cable holding plate is mounted. NOTE
Refer to Chapter 25-10-26.
Do not pull the cable from the jacket. There is a very small metal ball that will fall out. 6 Remove Bowden cable from mounting plate. 7 With a firm pull, break the pressure cabin/firewall sealing and remove Bowden cable. 8 Install in reverse sequence of removal.
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Detail Steps/Work Items
Key Items
Refer to Product Label and Material Safety Data Sheet for health and WARNING safety information before using PR812. 9 Seal the Bowden cable from the firewall side with PR812 PR 1750 accelerator contains harmful vapors and is readily absorbed WARNING through the skin. Avoid all contact with the skin and ingestion. Always wash hands before eating or smoking. Use adequate ventilation, hand protection and chemical-type goggles when working with this product. If accelerator contacts skin, flush area with warm water. Obtain medical attention in cases of extreme exposure or ingestion. PR 1750 sealant contains solvents. WARNING Use adequate ventilation or air-supplied respirators during application. Avoid repeated or prolonged breathing of vapors. In case of extreme vapor exposure, remove affected personnel to fresh air immediately and obtain medical attention. For complete health and safety information, a material safety data sheet is available from the manufacturer. 10 Seal the Bowden cable from the inside with PR 1750.
For mixing and application of PR 1750 sealant refer to manufacturer's instructions.
11 Rig the Bowden cable.
See paragraph Rigging below.
Rigging Detail Steps/Work Items 1 Remove the LH upper cowling to gain access to the LH exhaust stack
Key Items Refer to Chapter 71-10-01.
2 Push the INTAKE ANTI ICE knob fully in. 3 Set the upper set screw that the ‘ashtray’ is fully closed when the lever is set against it. 4 Clamp the Bowden cable jacket so the jacket protrudes 4 mm +/- 1 mm from clamp. 5 Attach cable to lever while lever is at upper set screw. 6 Pull the INTAKE ANTI ICE knob fully out. 7 Make sure that the ‘ashtray’ is fully out.
20° travel
8 Set the lower set screw accordingly. 9 Perform micro switch rigging. Page Date: 30. March 2012
Refer to Subject 30-20-02.
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30-20-02
Micro Switch The engine anti-ice micro switch is located on the LH exhaust stack.
Removal/Installation Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. 2 Remove the LH upper cowling
Refer to Chapter 71-10-01.
3 Mark and cut wiring of the micro switch.
Connect later by splicing.
4 Remove micro switch.
2 screws
5 Install in reverse sequence of removal. 6 Perform micro switch rigging.
See paragraph Rigging below.
Rigging Detail Steps/Work Items 1 Remove the LH upper cowling
Key Items Refer to Chapter 71-10-01.
2 Pull the INTAKE ANTI ICE knob fully out. 3 Make sure the micro switch is activated, loosen, adjust and retighten at set and/or bend micro switch lever if needed.
30-20-03
Helical Metallic Hoses There are two helical metallic hoses installed in engine compartment for exhaust air routing from the LH exhaust stack to the inlet and from the inlet to the RH exhaust stack
Removal/Installation Detail Steps/Work Items 1 Remove exhaust stacks
Key Items Refer to Ch. 78-00-01/02
2 Unscrew helical metallic hose from inlet 3 Install in reverse sequence of removal. IMPORTANT
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Make sure while setting the length of the helical metallic hose that the forces on the engine flange while attaching the exhaust stack must be minimal. Screw in the helical metallic hose minimum one full turn on each side. Maximum two full turns each side are possible.
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Maintenance Manual EXTRA 500
30-30-00
PITOT, STATIC AND STALL WARNING Description The EXTRA 500 is equipped with two heated Pitot tubes, one underneath each wing. Standard AN-type (AN 5812-1) Pitot tubes are used. The electric Pitot heat is activated by switching the L-PITOT-R switches to the ON position. As long as the aircraft is on ground the heating of the Pitot tubes is avoided by means of a squat switch installed at the nose gear strut. To provide a means for checking the system on ground the switches can be set to a momentary TEST position to override the squat switch. Avoid operating the system in this mode longer than 10 sec. on ground to avoid an overheat condition. The current consumption of the heating elements is monitored by current sensors during operation. If an open circuit causes the Pitot tube heaters to fail, the PITOT HEAT LEFT/RIGHT illuminates in the annunciator panel. The two dual static ports installed in the aft fuselage sides are equipped with electric heater elements to prevent icing. They are also activated by the LPITOT-R switches. Heating is disabled on ground by means of a squat switch and current sensors generate the STATIC HEAT LEFT/RIGHT annunciation in case of malfunction. Temperature rise after activation of the test mode on ground is much slower than for the Pitot heat. Be aware of this behavior when checking the system on ground. The Stall detector installed in the left wing leading edge within the access panel for the recognition lights features three electric circuits for icing protection. The movable sensing vane, the mounting plate and the case itself are heated by electric heating elements. The heatings are activated by the PITOT-R switch and protected by the squat switch against inadvertent operation on ground. The TEST position of the switch overrides this protection to allow system checks on the ground (time limited up to max. 10 sec). The main heating circuits (vane and mounting plate) are monitored by a current sensor, generating the STALL HEAT warning indication in the annunciator panel in case of an open circuit.
NOTE
30-30-01
In case of defective Pitot tube, static port or stall detector heat elements, the respective components have to be replaced as a whole (refer to Chapter 34-10).
Current Sensor (Avionic Bay) Three current sensors are installed in the avionic bay and are accessible by the LH avionic bay access panel. The sensors are labeled 3HG, 5HG and 7HG. The following table shows to which systems they are related.
Page Date: 30. March 2012
Label
System
3HG
Stall heat
5HG
Pitot heat RH
7HG
Pitot heat LH
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Removal/Installation Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. 2 Remove LH avionic bay access panel.
Refer to Chapter 51-00-01.
3 Remove the wiring from the respective current sensor.
30-30-02
4 Remove the mounting plate.
4 bolts To get access to the underside of the current sensor. Notice ground bonding.
5 Remove current sensor.
2 bolts
6 Install in reverse sequence of removal.
Ensure mounting plate is correctly grounded and cable loom cable clamp is installed.
Current Sensor (Tail Cone) Two current sensors are installed in the aircraft tailcone on the underside of the air condition soft start module. The sensors are labeled 1HS and 4HS. The following table shows to which systems they are related. Label
System
1HS
Static heat RH
4HS
Static heat LH
Removal/Installation Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. 2 Remove tailcone access panel.
Refer to Chapter 51-00-01.
3 Remove the air condition soft start module.
Refer to Chapter 21-50-03 Disconnecting the electrical wiring is not necessary.
4 Disconnect the electrical connector.
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30
5 Remove the mounting plate.
4 bolts
5 Remove current sensor.
2 Allen screws
6 Install in reverse sequence of removal.
Ensure mounting plate is correctly grounded.
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Maintenance Manual EXTRA 500
30-40-00
WINDSHIELD An electric windshield heat for the pilot’s side of the windshield is part of the standard icing protection system. Also refer to Chapter 56-10. The system consists of three wire circuits bonded between the inner and outer windshield layer, one for the heating itself and two for the redundant temperature sensing. The heating current is switched by a special heat controller regulating the windshield temperature between 20°C and 40°C in case the system is active. The system may be activated by means of the WINDSH switch located in the DEICE group within the left side panel. In case of malfunction of the system, this condition is indicated by a red WINDSHIELD HEAT FAIL annunciator light. The following failure conditions cause a warning indication: • One or both temperature sensing circuits open or shorted • Overheat signal from at least one of the sensing circuits (more than 50°C) An additional means for monitoring the function of the windshield is provided by a green WINDSHIELD HEAT ON annunciator light (controlled by a current sensor in the heating circuit) illuminating when the heating current flows. This light is cycling during normal windshield heat operation. The system remains operative (green light cycling) as long as one of the two sensing circuits is functioning although the red WINDSHIELD HEAT FAIL warning annunciates one defective temperature sensing circuit. If both sensing circuits are defective the windshield controller inhibits any further windshield heating.
30-40-01
Windshield Heat Controller The windshield heat controller is installed beside the pilot seat, behind the pilot’s legroom LH paneling.
Removal/Installation Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. 2 Remove pilot seat.
Refer to Chapter 25-10-11.
3 Remove all LH forward lower paneling screws.
Refer to Chapter 25-00-01.
4 Carefully swivel the paneling forward to gain access from behind. 5 Remove electrical connector. 6 Remove windshield heat controller.
2 nuts
7 Install in reverse sequence of removal. Page Date: 30. March 2012
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30-40-02
Windshield Heat Current Sensor The windshield heat current sensor is installed beside the pilot seat, behind the pilot’s legroom LH paneling.
Removal/Installation Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. 2 Remove pilot seat.
Refer to Chapter 25-10-11.
3 Remove all LH forward lower paneling screws.
Refer to Chapter 25-00-01.
4 Carefully swivel the paneling forward to gain access from behind. 5 Remove electrical connections.
4 screws
6 Remove windshield heat current sensor including mounting plate.
2 nuts
7 Remove current sensor from mounting plate. 2 bolts 8 Install in reverse sequence of removal.
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Maintenance Manual EXTRA 500
30-60-00
PROPELLER Description The propeller of the EXTRA 500 is equipped with electrically heated boots at the blades for icing protection. All blades are heated continuously when switched on. All necessary information for repair and maintenance of the system is contained in BF Goodrich Aerospace publications as listed in the LOAP 14-17.
30-60-01
Propeller Ammeter The propeller ammeter is installed in the upper left corner of the instrument panel.
Removal/Installation Detail Steps/Work Items 1 Remove RH and LH IFD.
Key Items Refer to Chapter 31-60-01.
2 Disconnect electrical connector ammeter. 3 Remove propeller ammeter.
4 screws
4 Install in reverse sequence of removal.
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30-70-00
WATER LINES The pneumatic boot system incorporates a water separator to prevent water to enter boot lines and the boots themselves as water may freeze and render the system inoperative. The water separator is installed downstream of the pressure regulator and upstream of the ejector valves. A water drain line it routed to the exterior.
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30-80-00
DETECTION
30-80-01
Ice Light An ice light is installed on the forward left side of the fuselage. It is accessible from inside the engine compartment when the LH upper cowling is removed.
Removal/Installation Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. 2 Remove upper LH cowling.
Refer to Chapter 71-10-01
3 Disconnect electrical connection. 4 Remove ice light cover and window.
3 bolts
5 Disassemble ice light.
4 bolts
6 Install in reverse sequence of removal
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Maintenance Manual EXTRA 500
Chapter 31 Indication & Recording Systems
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TABLE OF CONTENTS
31-00-00
GENERAL ........................................................................................................ 3 Description.......................................................................................................... 3
31-10-00
INSTRUMENT & CONTROL PANELS....................................................... 4
31-10-01
Left Side Panel .................................................................................................. 4 Description.......................................................................................................... 4 Removal/Installation........................................................................................... 4
31-10-02
Left Main Panel ................................................................................................ 4 Removal/Installation........................................................................................... 4
31-10-03
Right Main Panel .............................................................................................. 5 Removal/Installation........................................................................................... 5
31-10-04
Lower Main Panel ............................................................................................ 5 Removal/Installation........................................................................................... 5
31-10-05
Glare Shield....................................................................................................... 6 Removal/Installation........................................................................................... 6
31-10-06
Control Display Unit ........................................................................................ 6 Removal/Installation........................................................................................... 6 Tests and Checks ................................................................................................ 6
31-50-00
CENTRAL WARNING SYSTEMS................................................................ 7 Description.......................................................................................................... 7 Annunciator Panel .............................................................................................. 7
Figure 31-1 31-50-01
Annunciator Panel (Westcoast Specialties) .................................................... 7 Removal/Installation........................................................................................... 7 Lamp Replacement ............................................................................................. 8
31-60-00
CENTRAL DISPLAY SYSTEMS .................................................................. 9 Description.......................................................................................................... 9
31-60-01
Integrated Flight Display (IFD)....................................................................... 9 Removal/Installation........................................................................................... 9 Tests and Checks ................................................................................................ 9
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Maintenance Manual EXTRA 500
31-00-00
GENERAL Description The EXTRA 500 is equipped with several indication systems: • The left and right main panel • The left side panel • The annunciator panel (part of the right main panel) • The LH Integrated Flight Display (IFD) • The RH Integrated Flight Display (IFD) • The Control Display Unit (CDU)
Page Date: 12.April 2000
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Maintenance Manual EXTRA 500
31-10-00
INSTRUMENT & CONTROL PANELS
31-10-01
Left Side Panel Description On the LH of the pilot, most of the switches and circuit breakers are installed in a switch board assembly, the left side panel. This assembly contains all electrical busses excluding the hot bus. This assembly can be taken out of the aircraft as a whole.
Removal/Installation Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. 2 Remove pilot’s seat.
Refer to Chapter 25-10-11.
2 Remove left legroom side paneling.
Refer to Chapter 25-00-01.
3 Remove 6 screws of the upper part of the left side panel.
2 screws on the top 4 screws on the side
4 Remove 3 screws of the lower part of the left side panel. 5 Disconnect the 3 electrical connectors and the power connector. Take care not to damage luminescent foil connections CAUTION 6 Remove the two parts of the left side panel. 7 Install in reverse sequence of removal.
31-10-02
Left Main Panel Removal/Installation Detail Steps/Work Items 1 Remove IFDs.
Key Items Refer to Subject 31-60-01
2 Disconnect wiring/piping from back-up flight instruments and propeller ammeter. 3 Remove left main panel. Page 4
31
8 Phillips screws Page Date: 30. March 2012
Maintenance Manual EXTRA 500
Detail Steps/Work Items
Key Items
4 Install in reverse sequence of removal.
31-10-03
Right Main Panel Removal/Installation Detail Steps/Work Items 1 Remove RH IFD.
Key Items Refer to Subject 31-60-01
2 Remove 10 Phillips screws around right main panel. 2 Slightly swivel down right main panel
Take care not to damage electrical wiring
3 Disconnect electrical wiring from annunciator panel 4 Disconnect wiring from fuel gauges. 5 Disconnect wiring from fuel flow indicator. 6 Disconnect wiring from turn coordinator. 7 Install in reverse sequence of removal.
31-10-04
Lower Main Panel Removal/Installation Detail Steps/Work Items
Key Items
1 Remove LH and RH main panel
Refer to Subject 31-10-02/03
2 Remove engine indicators.
Refer to Chapter 77-40
3 Disconnect electrical wiring from ELT switch. 4 Disconnect electrical wiring from LANDING GEAR switch. 5 Disconnect electrical wiring from FLAP switch. 6 Remove attachment nuts from the other switches. 7 Disconnect electrical wiring from dimming potentiometers. Page Date: 12.April 2000
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Detail Steps/Work Items 8 Remove lower main panel.
Key Items 14 bolts
9 Install in reverse sequence of removal.
31-10-05
Glare Shield Removal/Installation Detail Steps/Work Items 1 Remove main panels.
Key Items Refer to Subjects 31-60-02 thru 04
2 Disconnect wiring from autopilot. 3 Remove glare shield.
4 screws
4 Install in reverse sequence of removal.
31-10-06
Control Display Unit Removal/Installation Follow the ACD215 Removal and Installation procedure presented in the Entegra Integrated Flight Display System Product Maintenance Manual (LOAP 24).
Tests and Checks Perform the applicable Return to Service Tests and Checks presented in the Entegra Integrated Flight Display System Product Maintenance Manual (LOAP 24). whenever the unit has been reinstalled.
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Maintenance Manual EXTRA 500
31-50-00
CENTRAL WARNING SYSTEMS Description The central warning system in the EXTRA 500 consists of an annunciator panel. The annunciator panel is located on the top RH instrument panel. (Refer to the Emergency Procedures (Amplified) part of Section 3 in the EXTRA 500 Pilot's Operating Handbook for further information to the particular caution and warning lights.)
r
r
r
r
y
y
r
r
r
r
y
y
r
r
r
y
y
y
y
y
g
g
y
y
y
g
g
y
y
y
g
g
g
r = red, y = yellow, g = green Figure 31-1
Annunciator Panel
31-50-01
Annunciator Panel (Westcoast Specialties) The annunciator panel is located on the top RH instrument panel.
Removal/Installation Detail Steps/Work Items
1 Remove RH IFD.
Key Items
Refer to Subject 31-60-01
2 Disconnect electrical wiring from annunciator panel. 3 Remove panel.
4 screws
4 Install in reverse sequence of removal. 5 Check if all lamps work by placing the NIGHT/DAY switch located on the left side panel in the TEST position.
Page Date: 12.April 2000
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Maintenance Manual EXTRA 500
Lamp Replacement Each annunciator light (lamp module) is illuminated by two lamps. Relamp by pushing in lamp module approximately 1/16th of an inch and release. The lamp module will partially eject. Pull to disengage, then rotate downward to expose the lamps. When reinserting lamp modules ensure both latching springs engage cap assy by slowly pushing cap with equal force on both sides.
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Maintenance Manual EXTRA 500
31-60-00
CENTRAL DISPLAY SYSTEMS Description The central display system of the EXTRA 500 contains 2 Avidyne Integrated Flight Displays (IFDs).
31-60-01
Integrated Flight Display (IFD) Removal/Installation Follow the IFD5000i Removal and Installation procedure presented in the Entegra Integrated Flight Display System Product Maintenance Manual (LOAP 24) observing the following aircraft specific hints: Ensure BATT switch is OFF and no external power connected. The wiring and piping for the RH IFD is dimensioned in the way that it can be disconnected/connected when the IFD is removed from and held next to the instrument panel. The wiring and piping for the LH IFD is shorter so that connecting/disconnecting has to be done with IFD installed. For that reason the RH IFD must be removed to get access to the wiring/piping connectors. The wiring is marked conforming to the designations on the IFD backsides. However the piping (Pitot/static) is colored as shown in the following:
IMPORTANT
The colors of pitot/static lines do not match with the port markings on the backside of the IFDs. Piping Colors PITOT STATIC
LH IFD
RH IFD
white
blue
red
green
Tests and Checks Perform the applicable Return to Service Tests and Checks presented in the Entegra Integrated Flight Display System Product Maintenance Manual (LOAP 24) whenever the unit has been reinstalled. Pitot/Static Check Perform applicable Return to Service Pitot/static Check according to FAR 43, Appendix E and AC 43.13-1B CHG1 (or later) Ch. 12-59 whenever the unit has been reinstalled.
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Chapter 32 Landing Gear
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Table of Contents
32-00-00
GENERAL ........................................................................................................ 5 Introduction ........................................................................................................ 5 Description.......................................................................................................... 5 Operation ............................................................................................................ 6 Troubleshooting.................................................................................................. 7 Operational Test Procedures............................................................................... 8 Gear Up Procedure ............................................................................................. 9 Gear Down Procedure ...................................................................................... 10 Emergency Extension Test ............................................................................... 10 Gear Up Cycle Test .......................................................................................... 11 Wheels Up Landing Test .................................................................................. 12 Gear Down Cycle Test ..................................................................................... 12 Gear Up Cycle Test With Rudder Full Left/Full Right .................................... 12 Leakage and Accumulator Function Test ......................................................... 13
32-10-00
MAIN GEAR AND DOORS.......................................................................... 14
32-10-10
Main Gear Strut Assembly ............................................................................ 14 Description........................................................................................................ 14 LH Main Gear Strut Assembly.......................................................................... 15 Removal............................................................................................................ 16 Installation ........................................................................................................ 17 Disassembly/Assembly..................................................................................... 17
Figure 32-1
32-10-11 Figure 32-2
32-10-12 Figure 32-3
32-10-13 Figure 32-4
32-10-20
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Parallel Strut ................................................................................................... 19 Description........................................................................................................ 19 Parallel Strut .................................................................................................... 20 Removal/Installation......................................................................................... 20 Disassembly/Assembly..................................................................................... 20 Adjustment of Vertical Play ............................................................................. 21 Axle Bar ........................................................................................................... 21 Description........................................................................................................ 21 Axle Bar ............................................................................................................ 22 Removal/Installation......................................................................................... 22 Disassembly/Assembly..................................................................................... 22 Adjustment of Vertical Play ............................................................................. 23 Shock Absorber............................................................................................... 23 Description........................................................................................................ 23 Shock absorber ................................................................................................. 24 Removal/Installation......................................................................................... 24 Disassembly/Assembly..................................................................................... 24 Main Gear Doors ............................................................................................ 25 Description........................................................................................................ 25 Page Date: 30. March 2012
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32-10-21
Upper Doors.....................................................................................................26 Removal/Installation .........................................................................................26 Door Actuation Length Adjustment..................................................................26
32-10-22
Lower Doors ....................................................................................................26 Removal/Installation .........................................................................................26 Door Actuation Length Adjustment..................................................................27
32-20-00
NOSE GEAR AND DOORS ..........................................................................28 Description ........................................................................................................28
32-20-10
Nose Gear Strut Assembly..............................................................................28 Description ........................................................................................................28 Nose Gear..........................................................................................................29
Figure 32-5 32-20-20
Figure 32-6 32-30-00 Figure 32-7 Figure 32-8
Nose Gear Doors..............................................................................................30 Description ........................................................................................................30 Door Actuation Length Adjustment..................................................................30 Nose Gear Doors Actuation Mechanism...........................................................31 EXTENSION AND RETRACTION .............................................................32 Description ........................................................................................................32 Landing Gear Schematic...................................................................................34 Main Gear Actuators.........................................................................................35
32-30-10
Hydraulic System ............................................................................................36 Bleeding ............................................................................................................36 Hydraulic Fluid Change ....................................................................................37
32-30-11
Hydraulic Power Pack ....................................................................................39 Removal/Installation .........................................................................................39 Cleaning ............................................................................................................40
32-30-12
Distributor Block.............................................................................................40 Removal/Installation .........................................................................................40 Disassembly/Assembly .....................................................................................41
32-30-20
Actuators..........................................................................................................42
32-30-21
Main Gear Actuators ......................................................................................42 Removal/Installation .........................................................................................42
32-30-22
Upper Doors Actuator ....................................................................................44 Removal/Installation .........................................................................................44
32-30-23
Lower Doors Actuator ....................................................................................45 Removal/Installation .........................................................................................45
32-30-24
Nose Gear Actuator.........................................................................................46 Removal/Installation .........................................................................................46
32-30-25
Nose Gear Gas Pressurized Springs ..............................................................47 Removal/Installation .........................................................................................47 Test Procedure...................................................................................................48 Minimum Tension Forces .................................................................................49
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32-30-30
Hydraulic Lines............................................................................................... 49 Description........................................................................................................ 49
32-30-40
Torque Link Rod and Track Rods................................................................ 50 Removal/Installation......................................................................................... 50
32-30-50
Drive Mechanism Nose Doors ....................................................................... 51 Removal/Installation......................................................................................... 51
32-40-00
WHEELS AND BRAKES.............................................................................. 52 Description........................................................................................................ 52
32-40-01
Main Wheels.................................................................................................... 52 Removal/Installation......................................................................................... 52
32-40-02
Nose Wheel ...................................................................................................... 53 Removal/Installation......................................................................................... 53
32-40-03
Brake................................................................................................................ 54 Removal/Installation......................................................................................... 54
32-50-00
STEERING...................................................................................................... 56 Description........................................................................................................ 56 Removal/Installation......................................................................................... 56
32-60-00 Figure 32-9
POSITION AND WARNING........................................................................ 57 Description........................................................................................................ 57 Main Gear Switches (LH)................................................................................. 58
32-60-01
Main Gear Extended Switches ...................................................................... 58
32-60-02
Main Gear Retracted Switches...................................................................... 58
32-60-03
Upper Main Door Opened Switch................................................................. 59
32-60-04
Upper Main Door Closed Switch .................................................................. 59
32-60-05
Lower Main Door Closed Switch .................................................................. 59
32-60-06
Ground Safety Switch .................................................................................... 59
32-60-07
Nose Gear Extended Switch........................................................................... 59
32-60-08
Nose Gear Retracted Switch .......................................................................... 60
32-60-09
Operation and Indication............................................................................... 60
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32-00-00
GENERAL Introduction The next paragraph contains the general description and operation of the landing gear. The following paragraph contains information about troubleshooting. The specified descriptions of the systems, sub-systems and units can be found in the respective chapters.
Description The EXTRA 500 has a hydraulically operated retractable tricycle landing gear with a steerable nose wheel. Each landing gear strut has a single wheel carrying tube-type tires. The main gear is designed as a parallel guide strut construction. Each strut has an oleo shock absorber and retracts against flight direction after turning the wheel by 90° in plane with the strut. The upper and lower doors fair the main gear struts in flight. Main gear struts and doors are separately actuated by hydraulic cylinders. The nose gear is designed as an oleo leg strut with a steerable nose wheel and retracts aft in the nose gear compartment. The rudder pedals on both pilot sides operate the nose wheel while taxiing. Components and System Features The main wheels have hydraulically actuated single-disk brakes on the inside. The toe-brake pedals on the rudder pedals operate the brakes. While parking, the brakes can be set on by the parking brake valve, which is located in the middle-console. Two hydraulic actuators drive each main gear strut. The interlocking actuator fixes the extended main gear strut for landing and ground operation. While retracting the main-wheel is turned by the torque link rod and the track rods and then placed in the wheel bay. During this cycle the torque link rod also shortens the main gear strut. In case of hydraulic or electric failure the main gear extends and locks gravity assisted by air flow. One hydraulic actuator drives the nose gear strut. The nose gear strut positively guides the nose doors. In case of hydraulic or electric failure, the nose gear extends and locks by the elastic force of two gas springs. The hydraulic power system provides a flow of pressurized hydraulic fluid to operate the landing gear system as well as the respective landing gear doors. Hydraulic pressure is maintained while the battery-bus is powered. The system is equipped with a pressure sensor, which will switch the pump on once the pressure drops. The constant system pressure is needed to hold the gears and doors safely in place.
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Controls and Monitoring Devices (For detailed description, refer to Section 32-60) The landing gear action is controlled by the LANDING GEAR switch on the L/H instrument panel. The extended and retracted position of each landing gear strut is monitored by position switches and indicated by signal lights: 1 The downlock information for the extended wheel position is given for each wheel separately by three green lights, located near the selector switch. 2 The red GEAR WARN light on the annunciator panel indicates that the landing gear is not completely retracted or extended and locked. In combination with the GEAR WARN light a gear up warning horn is activated. When landing gear is in transition hydraulic pump operation is necessary indicated by the yellow HYDRAULIC PUMP annunciation light. During ground operation, the double ground safety switch on the nose gear strut just above torque link prevents accidental gear retraction, regardless of the LANDING GEAR switch position. The electric circuits of the landing gear equipment are protected by circuit breakers. They are located on the left side panel and in the E-box (refer to Chapter 24-60).
Operation The LANDING GEAR switch has a guard to prevent inadvertent operation. The switch has the positions UP for retracting and DN for extending. The operation of the hydraulic system is divided in three hydraulic circuits, actuating the following devices: 1 Lower main gear doors 2 Upper main gear doors 3 Main landing gear struts and nose gear strut (incl. nose gear doors) The GEAR DOWN cycle is: 1 Opening of the lower main gear doors, the upper main gear doors and the nose gear doors and extension of the main gear and nose gear 2 Closing of the upper main gear doors The GEAR UP cycle is: 1 Opening of the upper main gear doors 2 Main and nose gear retraction (incl. nose gear doors) 3 Closing of the upper main gear doors 4 Closing of lower main gear doors Changing from gear up to gear down and vice versa is possible at any time.
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Nose gear and main gear extends and retracts under high pressure. Operation of the landing gear can cause death or injuries in its working area!
DANGER
Before beginning any work in the landing gear working area, pull the electric circuit breaker located on the left side panel and marked GEAR-CTRL. In case of intentional gear operation by switch or circuit breaker handling make sure, that neither a person nor any object is located in the upper landing gear doors travel area. NOTE
With the aircraft being airborne or jacked and BATT and EXT PWR switch OFF, the hot bus feeds an AUX circuit, which supplies the directional valves with electrical power to keep the landing gear in the up-position. The AUX circuit is protected by the GEAR AUX 1 (left side panel) and GEAR AUX 2 (E-box) circuit breakers. Push these circuit breakers in. However, the nose gear and main gear will slowly extend due to valve oil leakage, if the hydraulic pump is not being activated temporarily to maintain hydraulic pressure. If retracted landing gear position is intended, turn BATT switch ON (left side panel, toggle switch) and push circuit breakers GEAR-CTRL and HYDR (left side panel) in, while the landing gear switch (left main panel) is in the UP position. If the aircraft is jacked with landing gear retracted and external power not connected, the battery will be discharged within approx. 2 days.
Troubleshooting The following paragraph tabulates the troubleshooting procedures relevant to the landing gear system. The complaints are classified in order to the landing gear sub-systems. Complaint
Possible Cause
Remedy
Main Gear and Doors
Refer to Section 32-10
Wings are not level
Main gear struts bent or damaged
Inspect the main gear struts for cracks and bending
Drag brace is not locked in overcenter position
Inspect the drag brace, the torque link rod and the main gear-attachment frame for cracks and bending. Check the length of the torque link rod.
Gas-leakage by worn O-ring sealing of the shock absorber.
Check the nitrogen gas pressure and inflate if required
Main gear rattles while taxiing
Worn collar bushings
Replace
Oil stains beneath the shock absorber
Leakage by worn ore damaged O-ring and scraper rings
Replace
Nose Gear and Doors
Refer to Section 32-20
Oil stains beneath the nose
Leakage by worn ore damaged
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Replace O-ring, refill
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Complaint gear oleo-strut
Possible Cause O-ring and scraper rings
Remedy Aeroshell Fluid 4 as needed
Nose wheel wobbles while taxiing
Shimmy damper mechanical damage
Replace damaged parts
Leakage by worn ore damaged O-ring and scraper rings
Replace O-ring, refill Aeroshell Fluid 4 as needed
Extension and Retraction
refer to Section 32-30
Oil stains beneath the nose gear actuator and hydraulic lines
Leakage by worn ore damaged O-rings, fittings, hoses or tubes
Replace damaged parts
Oil stains beneath the main gear actuator and hydraulic lines
Leakage by worn ore damaged O-rings, fittings, hoses or tubes
Replace damaged parts
Continued hydraulic pump operation exceeds 3 seconds and/or periods of rest shorter than 2 minutes.
Abnormal hydraulic internal Detect leak and seal system leakage. Pressure switch
Adjust or replace
Pump bypass valve
Adjust or replace
Wheels and Breaks
refer to Section 32-40
Wings are not level
Incorrect wheel tube pressure
Check the tube pressure and inflate to max. pressure if required
Too much tire wear
Incorrect toe-in
Check and adjust the toe-in
Wheel track out of tolerance
Correct the wheel track
Too much axial play in wheel
Defective wheel bearing
Replace the wheel bearings
Brake disk deformed
Excessive hard braking
Replace brake disk
Dragging brakes
Worn or broken piston return spring in master cylinder
Repair or replace master cylinder
Brake does not operate
Brake fluid level low
Inspect master cylinder, fittings and linings for leakage. Refill brake fluid
Air in the brake system
Bleed the brake system
Defective master cylinder
Replace the master cylinder. Then bleed the brake system
Defective fittings or lines
Replace the fitting or line. Then bleed the brake system
Worn brake lining
Replace the brake lining
Operational Test Procedures For ground testing the landing gear functions the aircraft must be lifted at the three jack points (see Ch. 07-10-00). When aircraft is on jacks and landing gear Page 8
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shall be driven to another status as it is, follow the Gear Up Procedure or Gear Down Procedure given in the following. DANGER
Nose gear and main gear extends and retracts under high pressure. Operation of the landing gear can cause death or injuries in its working area ! Before beginning any work in the landing gear working area, pull the electric circuit breaker located on the left side panel and marked GEAR-CTRL. In case of intentional gear operation by switch or circuit breaker handling make sure, that neither a person nor any object is located in the upper landing gear doors travel area.
NOTE
With the aircraft being airborne or jacked and BATT and EXT PWR switch OFF OFF, the hot bus feeds an AUX circuit, which supplies the directional valves with electrical power to keep the landing gear in the up-position. The AUX circuit is protected by the GEAR AUX 1 (left side panel) and GEAR AUX 2 (E-box) circuit breakers. Push these circuit breakers in. However, the nose gear and main gear will slowly extend due to valve oil leakage, if the hydraulic pump is not being activated temporarily to maintain hydraulic pressure. If retracted landing gear position is intended, turn BATT switch ON (left side panel, toggle switch) and push circuit breaker GEAR-CTRL (left side panel) in, while the landing gear switch (left main panel) is in the UP position. If the aircraft is jacked with landing gear retracted and external power not connected, the battery will be discharged within approx. 2 days.
Gear Up Procedure 1 Lift the aircraft on jacks (refer to Chapter 07-10-00). DANGER
Upper landing gear doors will close immediately, when BATT or EXT PWR switch is turned to ON and GEAR-CTRL circuit breaker is in. Make sure, that neither a person nor any object is located in the upper landing gear doors travel area.
2 Turn BATT and EXT PWR switch ON (left side panel, toggle switch). 3 Push circuit breaker GEAR-CTRL in (left side panel). DANGER
Make sure, that neither a person nor any object is located in the landing gear travel area.
4 Pull and move LANDING GEAR switch UP (left main panel, below RH side of control yoke). 5 Wait until HYDRAULIC PUMP light is off indicating that the gear up procedure is completed. However GEAR WARN remains illuminated and aural warning is still active. This is normal as engine power is below approach setting (35% torque).
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Gear Down Procedure It is assumed aircraft is on jacks, the gear is up, BATT and/or EXT PWR switch is ON, and GEAR-CTRL circuit breaker is in. Perform Gear Up Procedure if applicable. DANGER
Make sure, that neither a person nor any object is located in the landing gear travel area.
1 Pull and move LANDING GEAR switch DN (left main panel, below RH side of control yoke). 2 Wait until three green down and locked lights are illuminated, indicating that the gear down procedure is completed.
Emergency Extension Test 1 Perform Gear Up Procedure (see above) DANGER
Landing gear will immediately slam down after GEAR-CTRL circuit breaker handling. Make sure, that neither a person nor any object is located in the landing gear travel area.
2 Pull circuit breaker GEAR-CTRL. IMPORTANT
Setting the LANDING GEAR switch to the DN position does not affect the operation of the landing gear as long as the GEAR-CTRL circuit breaker is pulled. This action shall prevent an unintentional landing gear retraction after completion of this test procedure when resetting the GEAR-CTRL circuit breaker. 3 Pull and move LANDING GEAR switch DN. 4 Verify the nose gear to extend and reach its down and locked position. 5 Main gear is not required to extend completely. A force of approx. 100 N (22.5 lbs.) simulating air loads at each wheel must be sufficient to reach the down and locked position.
NOTE
Spilling of 200 - 300 ml (12.2 - 18.3 cu inch) of hydraulic fluid at vent of reservoir is normal. 6 Check oil level at middle of side view glass → Aeroshell Fluid 4 (1.83 l/111.7 cu inch). 7 For confirming minimum nose gear extending force, test gas pressurized springs. See Subject 32-30-25 for test procedure.
NOTE
Check activated switches acoustically or by observing the related green gear down and locked indicator lights. 8 Check gear extended switch activating points are within 2 mm to 5 mm (0.079 in. to 0.197 in.) travel at wheel axle indicating the down and locked position before gear is fully extended. 9 Return aircraft to normal observing respective procedures and warnings
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Gear Up Cycle Test 1 Lift the aircraft on jacks (see Chapter 07-10-00). DANGER
Upper landing gear doors will close immediately, when BATT or EXT PWR switch is turned to ON and GEAR-CTRL circuit breaker is in. Make sure, that neither a person nor any object is located in the upper landing gear doors travel area.
2 Turn BATT and EXT PWR switch ON (left side panel, toggle switch). 3 Push circuit breaker GEAR-CTRL in (left side panel). 4 Ensure wing flaps are in 0° position. 5 Measure gear up cycle with a stop watch. DANGER
Make sure, that neither a person nor any object is located in the landing gear travel area.
6 Pull and move LANDING GEAR switch UP (left main panel, below RH side of control yoke). 7 Check acoustic gear warning function on horn, speaker and headset. 8 Press GEAR WARNING MUTE button on power lever. 9 Check mute function. 10 Check GEAR WARN annunciator light remains on. 11 Check HYDRAULIC PUMP annunciator light is on. 12 Check upper doors opening. 13 Check gear retracting and nose doors closing. 14 Check upper doors closing. 15 Check lower doors closing. 16 After gear up cycle is completed: Check performance time for a complete gear up cycle is between 11 and 15 seconds (LH and RH gears are not required to retract simultaneously). 17 Check if the red GEAR WARN and HYDRAULIC PUMP light extinguish. Ensure cabin door is closed before actuating the flaps. CAUTION 18 Set wing flaps to 15° 19 No warning should come. 20 Set wing flaps to 30° 21 Check acoustic gear warning active and GEAR WARN annunciator light illuminating. 22 Press GEAR WARNING MUTE button on power lever. 23 Check acoustic gear warning still active and GEAR WARN annunciator light still illuminating. 24 Set wing flaps to 0°. 25 Press GEAR WARNING MUTE button on power lever when flaps are passing the 15° setting. Page Date: 30. March 2012
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26 Perform Leakage and Accumulator Function Test (see below). 27 Perform further tests or Gear Down Procedure and return aircraft to normal observing respective procedures and warnings.
Wheels Up Landing Test It is assumed aircraft is on jacks, the gear is up, BATT and/or EXT PWR switch is ON, and GEAR-CTRL circuit breaker is in. Perform Gear Up Procedure if applicable. Make sure, that neither a person nor any object is located in the landing DANGER gear travel area. 1 Shut OFF BATT and EXT PWR switch. 2 Check gear position. The undercarriage must remain in retracted position. 3 Perform Gear Down Cycle Test Procedure or Gear Down Procedure and return aircraft to normal observing respective procedures and warnings.
Gear Down Cycle Test It is assumed aircraft is on jacks, the gear is up, BATT and/or EXT PWR switch is ON, and GEAR-CTRL circuit breaker is in. Perform Gear Up Procedure if applicable. 1 Measure gear down cycle with a stop watch. Make sure, that neither a person nor any object is located in the landing DANGER gear travel area. 2 Pull and move LANDING GEAR switch DN. 3 Check gear extending and opening of all doors. 4 Check if the following lights illuminate during gear transition: The red GEAR WARN annunciator light The yellow HYDRAULIC PUMP annunciator light 5 After landing gear is down and locked check if performance time for a complete gear down cycle is between 11 and 15 seconds (LH and RH gears must not extend simultaneously). 6 Check if upper doors are closed. 7 Check if the red GEAR WARN and HYDRAULIC PUMP lights extinguish. 8 Check the three green lights for nose gear, LH and RH gear illuminating. 9 Return aircraft to normal observing respective procedures and warnings.
Gear Up Cycle Test With Rudder Full Left/Full Right 1 Lift the aircraft on jacks (see Chapter 07-10-00). Upper landing gear doors will close immediately, when BATT or EXT PWR DANGER switch is turned to ON and GEAR-CTRL circuit breaker is in. Make sure, that neither a person nor any object is located in the upper landing gear doors travel area. Page 12
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2 Turn BATT and EXT PWR switch ON (left side panel, toggle switch). 3 Push circuit breaker GEAR-CTRL in (left side panel). 4 Apply full left rudder pedal control input. Make sure, that neither a person nor any object is located in the landing DANGER gear travel area. 5 Pull and move LANDING GEAR switch UP. 6 Check if nose gear retracts without jamming in the nose wheel bay. 7 Perform Gear Down Procedure. 8 Apply full right rudder pedal control input. Make sure, that neither a person nor any object is located in the landing DANGER gear travel area. 9 Pull and move LANDING GEAR switch UP. 10 Check if nose gear retracts without jamming in the nose wheel bay. 11 Perform further tests or Gear Down Procedure and return aircraft to normal observing respective procedures and warnings.
Leakage and Accumulator Function Test After two accumulator recharge cycles, the time before the third and the following recharging actions has to be at least 2 minutes. Recharging action can be heard as a short operation of the hydraulic power pack and is indicated by the HYDRAULIC PUMP annuciator light.
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32-10-00
MAIN GEAR AND DOORS
32-10-10
Main Gear Strut Assembly Description The main gear has two hydraulically actuated main gear strut assemblies with the following components (refer to Figure 32-1): • Undercarriage leg • Drag brace (upper and lower part) • Parallel strut • Upper guide strut • Lower guide strut • Axle bar • Shock absorber The main gear bolt attaches the steel designed main gear strut assembly to the main gear attachment frame. The parallel strut, the upper and lower guide struts and the axle bar shape a parallelogram (parallel guide strut construction). The drag brace locks the extended main gear strut. The upper and lower part are kept in overcenter position and fix the parallel strut in vertical. The bearings above and below the parallel strut are the axle for the upper and lower guide struts. The vertical movement of the guide struts is absorbed by the shock absorber, which is attached between them. The axle bar carries the main wheel and is attached to the upper and lower guide struts by bearings.
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Figure 32-1
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Wheel rim
Tyre
Aft View
Brake disk
Axle bar
Shock absorber
Upper guide strut
Parallel strut
Undercarriage leg
Main gear bolt
Extended limit switch
Drag brace (upper and lower part)
Track rod (upper and lower)
Lower guide strut
Torque link rod
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LH Main Gear Strut Assembly
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Removal Detail Steps/Work Items
Key Items
1 Lift the aircraft on jacks
Chapter 07-10
2 Remove aft keel beam access panel
Refer to Chapter 51-00-01
DANGER
Landing gear extends and retracts under high pressure. Operation of the landing gear can cause death or injuries in its working area! Before beginning any work in the landing gear working area, pull the electric circuit breaker located on the left side panel and marked GEAR-CTRL. In case of intentional gear operation by switch or circuit breaker handling make sure, that neither a person nor any object is located in the landing gear travel area.
3 Remove the bolt from the push pull rod upper door 4 Lift the upper door and fasten by means of a tape 5 Remove the clevis pin from the hinge joint lower door 6 Remove the bolt between the torque link rod and the main gear strut assembly 7 Remove the bolt between the short actuator main gear and the main gear strut assembly 8 Unlock the mechanism of the interlocking actuator.
Apply shop air momentarily on the rod side fitting of the interlocking actuator.
9 Remove the bolt between the interlocking actuator and the main gear strut assembly. Brake fluid can cause disease! WARNING Do not allow brake fluid to come in contact with your skin. CAUTION
Brake fluid can damage paint and other material! Clean up immediately spilt brake fluid
10 Remove the brake
Chapter 32-40-03
11 Disconnect reusable fitting of the brake hose. 12 Remove brake line from main gear strut 13 Remove the main wheel
Chapter 32-40-01
14 Remove the limit switch
Chapter 32-60-01
15 Cut off the safety wires on both main gear bolt nuts 16 Remove the lower nut completely from the thread. Page 16
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Detail Steps/Work Items 17 Remove the upper nut.
Key Items While pulling the main gear bolt with an extracting tool (refer to Chapter 01-00-02)
18 Remove the main gear bolt and the lower nut from the main gear attachment frame 19 Remove the assembled main gear 20 Remove the collar bushings in the main gear strut assembly
Installation 1 Lubricate the fitting surface and thread of the main gear bolt before installation
Use only MIL−G−81322D Grease
2 Install in reverse sequence of removal
Use new stop nuts and new brake line with crimped fitting on inboard side.
3 Bleed the brake system
Refer to Chapter 12-10-07
Disassembly/Assembly Detail Steps/Work Items 1 The track rods have to be removed CAUTION
Key Items Chapter 32-30-40
False reassembled bolted connections can damage the gear struts and doors. Before removal of bolts and nuts, notice their position. It can be different from the respective figure for geometric reasons.
2 Remove the bolts, stop nuts and washers from the undercarriage leg 3 Remove the undercarriage leg from the assembled strut structure 4 Remove the bolts, stop nuts and washers from the upper part of the drag brace 5 Remove the upper part of the drag brace from the assembled strut structure 6 Remove the collar bushings in the upper part of the drag brace 7 Remove the bolts, stop nuts and washers from the lower part of the drag brace. 8 Remove the lower part of the drag brace and the parallel strut from the assembled strut structure
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Detail Steps/Work Items
Key Items
9 Remove the collar bushings and shims in the parallel strut Tensioned construction due to nitrogen inflation damages hands and WARNING limbs! The shock absorber is under high pressure (827 psi/57 bar)! 10 Relieve nitrogen pressure. 11 Remove the bolts, stop nuts and shims between the shock absorber and the upper and lower guide strut 12 Remove the shock absorber from the upper and lower guide strut 13 Remove the bolt, stop nut and washer between the upper guide strut and axle bar 14 Remove the upper guide strut from the axle bar 15 Remove bolts, stop nuts and washers between the lower guide strut and axle bar 16 Remove the lower guide strut from the axle bar 17 Remove the collar bushings in the axle bar 18 Install in reverse sequence of removal
Use new stop nuts.
19 Check the toe-in whenever any part of the main gear strut has been changed
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32-10-11
Parallel Strut Description The steel designed parallel strut has the following components (refer to Figure 32-2): Upper and lower T-strut Rotary bushing with guide brackets Jam nut with set screw Adjusting nut with set screw Inner and outer joint Collar bushings in the rotary bushing Collar bushings in the joints Grease nipples Attaching parts like bolts, stop nuts and washers The parallel strut is steel designed. It is linked with the under-carriage leg, the lower part of the drag brace and the upper and lower guide strut by the bearings in the upper and lower T-strut. When the landing gear is extended, the parallel strut is vertically fixed by the undercarriage leg and the upper and lower part of the drag brace. The upper T-strut is threaded and carries the adjusting nut and the jam nut, which are for adjusting to avoid any vertical play. The components with collar bushings inside like the axle guide bracket and the upper and lower T-strut are equipped with grease nipples.
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Grease nipple Upper T-strut
Set screw Set screw
Jam nut
Upper guide bracket Grease nipple
Adjusting nut Collar bushing
Outer joint Grease nipple
Inner joint
Rotary bushing Collar bushing
Grease nipple Lower guide bracket
Lower T-strut Grease nipple Figure 32-2
Parallel Strut
Removal/Installation For removal of the parallel strut from the main gear strut assembly perform as described in step 1 to 3 and 7 to 9 (refer to Subject 32-10-10 Main Gear Strut Disassembly).
Disassembly/Assembly Detail Steps/Work Items 1 Remove the lower T-strut from upper Tstrut with rotary bushing.
Key Items Turn lower T-strut counterclockwise
2 Remove the rotary bushing with its collar bushings. 3 Loosen the jam nut and adjusting nut set screws. 4 Loosen the jam nut from the adjusting nut Page 20
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Detail Steps/Work Items
Key Items
5 Remove the adjusting nut. 6 Remove the jam nut. 7 Remove the bolts, stop nuts and washers from the inner and outer joint. 8 Remove the inner and outer joint. 9 Remove the joint collar bushings. 10 Install in reverse sequence of removal
Use new stop nuts
Adjustment of Vertical Play Detail Steps/Work Items NOTE
Key Items
This procedure does not require jacking the aircraft 1 Loosen the jam nut and adjusting nut set screws. 2 Loosen the jam nut. 3 Tighten the collar bushings to the rotary bushing by clockwise turning the adjusting nut.
As long as any clearance occurs
4 Tighten the adjusting nut set screw. 5 Counter the adjusting nut by the jam nut. 6 Tighten the jam nut set screw. NOTE
32-10-12
Replace the collar bushings when their collar thickness is less then 3/64" (1 mm)
Axle Bar Description The steel designed axle bar has the following components (see Figure 32-3): Upper and lower T-strut Rotary bushing with axle and axle guide bracket Joint Collar bushings in the joint Grease nipples Attaching parts like bolts, stop nuts and washers The axle bar is linked with the upper and lower guide strut by the bearings in the upper and lower T-strut.
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The axle carries the main wheel. The rotary bushing and the upper and lower T-strut are equipped with grease nipples. Upper T-strut Grease nipple
Rotary bushing
Grease nipple
Axle guide bracket Collar bushing
Joint
Collar bushing
Grease nipple Lower T-strut
Figure 32-3
Axle Bar
Removal/Installation For removal of the axle bar from the main gear strut assembly follow step 1 and 13 to 17 (refer to Subject 32-10-10 Main Gear Strut Disassembly)
Disassembly/Assembly Detail Steps/Work Items
Key Items
1 Remove the upper T-strut from lower Tstrut and the rotary bushing 2 Remove the collar bushing in rotary bushing 3 Remove the bolts, stop nuts and washers from joint Page 22
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Detail Steps/Work Items
Key Items
4 Remove the joint 5 Remove the collar bushing in the joint 6 Install in reverse sequence of removal
Use new stop nuts
Adjustment of Vertical Play For disassembly follow step 12 to 16 (Subject 32-10-10 Main Gear Disassembly) Detail Steps/Work Items
NOTE
32-10-13
Key Items
1 The axle bar has to be removed
Follow step 1 and 13 to 17 (32-10-10 Main Gear Strut Disassembly)
2 Tighten the collar bushings in the rotary bushing by turning the upper T-strut (full turns only) against the lower T-strut clockwise.
As long as any clearance occurs
Replace the collar bushings when their collar thickness is less then 3/64"/ 1 mm
Shock Absorber Description The steel designed shock absorber has the following components (refer to Figure 32-4): Outer cylinder Inner cylinder Slide bearing Piston Throttle with disk and support Seals like O-rings and scraper ring Valves Hinge bearings Attaching parts like back up rings, safety pin and locking ring The shock absorber is connected to the upper and lower guide strut by bolts. The shock absorber is designed as oil/nitrogen filled cylinder. The lower outer cylinder is filled with hydraulic oil; the upper inner cylinder is nitrogen inflated. The piston in the upper inner cylinder separates the hydraulic oil from
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nitrogen inflation. The grounded and hardened surfaces of the inner cylinder and the piston are sealed by O-rings. Hinge bearing Valve
Outer cylinder
Throttle with disk and support
Piston Scraper ring
O-ring Locking wire
Slide bearing Inner cylinder
Valve Hinge bearing Figure 32-4
Shock absorber
Removal/Installation For removal of the shock absorber from the main gear strut assembly follow step 10 to 12 (refer to Subject 32-10-10 Main Gear Strut Disassembly)
Disassembly/Assembly Detail Steps/Work Items
Key Items
High-pressure oil-jet damages eyes and limbs! WARNING
The shock absorber is under high pressure (827 psi/57 bar)
1 Release nitrogen pressure and drain the hydraulic fluid completely in a sump
Refer to Chapter 12-10-09
2 Remove the locking wire from the outer cylinder. Page 24
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Detail Steps/Work Items
Key Items
3 Remove the outer cylinder from the slide bearing 4 Remove the O-ring and the back up-ring from the outer cylinder 5 Remove the safety pin from the slide bearing and the inner cylinder 6 Remove the support throttle, the disc and the throttle from inner cylinder 7 Remove the inner cylinder from the slide bearing 8 Remove the O-ring, the back up-rings and the scraper ring from the slide bearing 9 Push the piston out of the inner cylinder 10 Remove the O-ring and the back up-rings 11 Install in reverse sequence of removal
Use new stop nuts
12 Seal locking wire.
Elastosil E14, GE RTV 159 or equivalent
13 Refill hydraulic fluid into the cylinder and apply nitrogen pressure.
Refer to Chapter 12-10-09
14 Check the wheel track
32-10-20
Main Gear Doors Description The carbon fiber designed upper and lower doors fair the retracted main gears. The hinges are integrated in the door lamination. The upper doors are connected to the fuselage by two hinges each. Hydraulic actuators drive the upper doors by levers with push pull rod. The lower doors are connected to the fuselage by three hinges each. An hydraulic actuator drives both lower doors by levers with cardan hinge joint.
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32-10-21
Upper Doors Removal/Installation Detail Steps/Work Items
DANGER
Key Items
Landing gear extends and retracts under high pressure. Operation of the landing gear can cause death or injuries in its working area! Before beginning any work in the landing gear working area, pull the electric circuit breaker located on the left side panel and marked GEAR-CTRL. In case of intentional gear operation by switch or circuit breaker handling make sure, that neither a person nor any object is located in the landing gear travel area.
1 Remove the bolt between the upper door and the push pull rod. 2 Remove the bolts from both hinges.
Hold the door
3 Remove the upper door. 4 Install in reverse sequence of removal.
Use new stop nuts
Door Actuation Length Adjustment The outer push-pull rods for the upper doors are attached to the resp. door front section. For adjusting LH resp. RH push-pull rod, loosen upper and lower locknut and turn threaded rod. Re-tighten and torque locknuts with 4 Nm ± 0.2 Nm (35.4 inch.lbf. ± 1.8 inch.lbf.). Perform gear up procedure (refer to Subject 32-31-01) and check that doors are closing correctly. Repeat adjustment as necessary.
32-10-22
Lower Doors Removal/Installation Detail Steps/Work Items
DANGER
Key Items
Landing gear extends and retracts under high pressure. Operation of the landing gear can cause death or injuries in its working area! Before beginning any work in the landing gear working area, pull the electric circuit breaker located on the left side panel and marked GEAR-CTRL. In case of intentional gear operation by switch or circuit breaker handling make sure, that neither a person nor any object is located in the landing gear travel area.
1 Remove the clevis pin from hinge joint of the lower door Page 26
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Detail Steps/Work Items 2 Remove the bolts, stop nuts and washers from the hinge
Key Items Hold the door
3 Remove the lower door 4 Install in reverse sequence of removal
Use new stop nuts
Door Actuation Length Adjustment The inner push-pull rods for the lower doors are located about half door length below the wheel well. For adjusting LH resp. RH push-pull rod, loosen upper stop nut LN 9348-06 and turn threaded rod. Re-tighten and torque upper stop nuts with 6.5 Nm ± 0.3 Nm (57.5 inch.lbf. ± 2.5 inch.lbf.). CAUTION
Detach the upper doors to prevent them from damage during the following test in case the adjustment is not yet correct. Remove the bolt from the push pull rod upper door. Lift upper door and fasten with tape. Perform Gear Up Procedure (refer to Subject 32-00-00) and check that doors are closing correctly. Repeat adjustment as necessary. Reattach upper doors.
NOTE
Do not re-tighten lower stop nuts, but leave nuts ¼ - turn unlocked. This will allow threaded rods to turn in case both doors are not actuated evenly, thus reducing tension in the actuation mechanism.
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32-20-00
NOSE GEAR AND DOORS Description Two trunnion bolts attach the nose gear oleo leg strut to the engine mounting. The nose strut, using an oleo-hydraulic shock absorber, is operated by a hydraulic actuator and retracts aft in the nose gear compartment. In case of hydraulic system failure, the nose gear extends by two gas pressurized springs against air loads. A ground safety switch, located at the drag brace of the nose gear, prevents accidental nose gear retraction during ground operation. In flight the nose doors fair the nose gear strut.
32-20-10
Nose Gear Strut Assembly Description The nose gear consists of the following parts (see Figure 32-5) • Trunnion • Drag brace • Steering arm assembly • Oleo leg (upper and lower strut) • Torque link • Shimmy damper assembly The trunnion assembly carries the drag brace and the steering arm assembly. The support tubes and tubes for the RH and LH pivot bearings are welded to the trunnion. The upper strut of the Oleo leg fits inside the trunnion. The torque link is bolted to the upper strut and the lower strut of the Oleo leg. It prevents the lower strut from turning inside the upper strut. The drag brace is attached to the trunnion and the engine mounting. It locks the extended Oleo leg. In case of hydraulic system failure, the drag brace is locked in extended position by two gas pressurized springs, which are pivoted at the upper part of the drag brace. The shimmy damper assembly dampens lateral moving of the nose gear while taxiing. It is attached to the trunnion.
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Side View
Gas pressurized springs
Shimmy damper Hydraulic actuator
Trunnion
Upper strut
Nose gear extended switch
Oleo leg Ground safety switches Torque link
Drag brace (upper and lower part)
Lower strut
Wheel
Figure 32-5
Nose Gear
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32-20-20
Nose Gear Doors Description The carbon fibre nose gear doors are attached to the fuselage by aft and forward door hinges. The nose gear doors are operated by the nose gear door actuation mechanism, which is linked to the trunnion (refer to Figure 32-6). The actuation mechanism consists of the following parts: • Spring • Telescope guide rod • Push-pull rod (one each side) • Two-armed rocker lever incl. stop The doors are closed in the last part of the nose gear retraction phase. Then the telescope guide rod is fully extended and begins to drive the actuation mechanism. The spring presses the rocker lever against the stop thus keeping the actuation mechanism in the over-centered position and the doors open.
Door Actuation Length Adjustment The push-pull rods for the nose gear doors are attached to the resp. door front section. For adjusting LH resp. RH push-pull rod, loosen upper and lower locknut and turn threaded rod. Re-tighten and torque locknuts with 4 Nm ± 0.2 Nm (35.4 inch.lbf. ± 1.8 inch.lbf.). Perform gear up procedure (refer to Subject 32-31-01) and check that doors are closing correctly. Repeat adjustment as necessary.
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Figure 32-6
Nose gear retracted switch
Telescope guide rod
fwd
Push-pull rod
Spring
Stop
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Movement when retracting
RH nose gear door
Two-armed rocker lever
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Nose Gear Doors Actuation Mechanism
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32-30-00
EXTENSION AND RETRACTION Description Refer to Figures 32-7 and 32-8. Extension and retraction of main gear and nose gear is controlled by hydraulic actuators. The main landing gear doors are also hydraulically actuated. Nose landing gear doors are mechanically linked to the trunnion of the nose gear. The equipment for extension and retraction consists of the following components: 1 Hydraulic system components with the items: a Power pack, consisting of: Hydraulic pump with geared electric motor By-pass valve Strainer Reservoir b Distributor block, consisting of: 3 directional valves Pressure switch Diaphragm pressure accumulator 2 Hydraulic actuators for gears and doors 4 Main gear actuators (1 short actuator and 1 interlocking actuator each side) 2 Actuators for upper doors Actuator for lower doors Nose gear actuator 3 Hydraulic lines Part 1 Gear actuation Part 2 Main gear lower and upper doors actuation Part 3 Power supply 4 Torque link and track rods 5 Drive mechanism nose doors The hydraulic power pack together with the distributor block provide the landing gear system as well as the respective landing gear doors with a flow of pressurized hydraulic fluid (operation-pressure 100-120 bar/1,450-1,740 PSI). Hydraulic pressure is maintained throughout ground and flight operation as long as the electric battery bus is powered. An external, adjustable pressure switch, mounted to the distributor block, cuts off electric power as soon as 120 bar (1,740 PSI) are reached. The pressure switch will return power to the hydraulic pump when pressure drops below below 100 ± 5 bar (1,450 ± 2.5 PSI). As an additional safety device the equipment chassis of the power pack carries a pressure relief valve which will open the bypass above the pump once the pressure would exceed 130 bar (1,885 PSI). The hydraulic power pack with pump, strainer and reservoir as well as the distributor block with control valves and pressure switch are built into the hydraulic power compartment in front of the main gear attachment frame between the keelbeams.
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The hydraulic fluid level can be checked any time by means of an inspection glass on the hydraulic power pack reservoir, visible behind an opening in the keelbeam. It is accessible from the R/H main wheel bay. Just above the L/H side of the inspection glass is the filling cap for the hydraulic fluid. A small nitrogen diaphragm accumulator is used to eliminate the necessity of frequent hydraulic pack activation due to small internal system leakage. This accumulator is located underneath the passenger cabin floor within the pressurized (and heated) vessel to avoid embrittlement of the diaphragm during high altitude low temperature operation. A yellow HYDRAULIC PUMP caution light is included into the annunciator panel, which indicates hydraulic pump activity and normally shall illuminate for not more than 2 or 3 seconds after periods of several minutes of rest, or during landing gear operation. (See Subject 32-00-00 Leaks and Accumulator Function Test.) If longer constant pump action or shorter periods of rest are observed, refer to Troubleshooting Paragraph in this Chapter. Prolonged pump operation for more than 2 minutes will cause pump or electric motor to overheat. The distributor block is equipped with three solenoid directional control valves and the pressure switch. The hydraulic fluid is directed by the control valves; these are spring loaded and will automatically switch into the gear down position once electric power is lost. The hydraulic system is separated in three circuits to actuate the respective devices: 1 Extension/retraction of main gear and nose gear 2 Opening/closing of the lower main gear doors 3 Opening/closing of the upper main gear doors The main and nose gear struts and doors are separately actuated by hydraulic cylinders. Two hydraulic actuators drive each main gear strut. One of the cylinders (the interlocking actuator) is designed to carry the breaking loads and has a mechanical locking mechanism. The torque link rod tows and unlocks the drag brace when the actuators start retracting. It shortens the main gear strut while retracting to fit it into the wheel bay. The track rods turn and push the coupled axle bar together with its wheel forward to drive it into the wheel bay. The nose gear strut is driven by one hydraulic actuator. For emergency extending the nose gear strut is equipped with two gas pressurized springs. They push the nose gear out in case of hydraulic system failure. The nose gear has a positive downlock by an overcenter device (drag brace). The upper main gear doors are driven by a hydraulic actuator each. The lower main gear doors are driven by one common hydraulic actuator. The nose gear doors are positively guided by the nose gear strut. All parts of the hydraulic system are hydraulically connected by lines. They consist of aluminum tubes and braided reinforced Teflon hoses. The actuators are connected by the Teflon hoses.
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GEAR WARN MUTE
L/N/R DOWN Three Green Lights
GEAR AUX 1 Circuit Breaker
Gear Warning Circuit Board
GEAR AUX 2 Circuit Breaker
Gear Warning Horn
GEAR CTRL Circuit Breaker HYDR Circuit Breaker
Annunciator Panel
Landing Gear Switch Ground Safety Switch Diaphragm Accumulator Hydraulic Pump (driven by electric motor)
Reservoir Limit Switch(es)
Valve
Main Gear Lower Doors Limit Switch(es)
Valve
Main Gear Upper Doors Limit Switch(es)
Valve
Main Gear Struts and Nose Gear Strut & Doors Legend: Electrical Wiring Hydraulic Lines Figure 32-7 Page 34
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Hydraulic Cylinder(s)
Landing Gear Schematic Page Date: 30. March 2012
Figure 32-8
Lower door
fwd
Interlocking actuator
Short actuator
Torque link rod
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Lower track rod
Upper track rod
Piston rod end
LH main gear
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Main Gear Actuators
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32-30-10
Hydraulic System Bleeding This procedure describes bleeding the hydraulic system by operating the landing gear and then refilling hydraulic fluid. Follow this procedure when smaller works with little loss of hydraulic fluid have been performed on the hydraulic system such as removal and installation procedures of single components. Generally, when hydraulic lines have been plugged during these procedures and the respective components have been pre-filled with hydraulic fluid before reinstallation this bleeding procedure shall be sufficient. Detail Steps/Work Items
DANGER
Key Items
Landing gear extends and retracts under high pressure. Operation of the landing gear can cause death or injuries in its working area! Before beginning any work in the landing gear working area, pull the electric circuit breaker located on the left side panel and marked GEAR-CTRL. In case of intentional gear operation by switch or circuit breaker handling make sure, that neither a person nor any object is located in the landing gear travel area. Hydraulic fluid can cause disease!
WARNING
Do not allow hydraulic fluid to come in contact with your skin. Hydraulic fluid can damage paint and other material!
CAUTION
Clean up immediately spilt hydraulic fluid.
1 Lift the aircraft on jacks. DANGER
Chapter 07-10-00
Upper landing gear doors will close immediately, when BATT or EXTR PWR switch is turned to ON and GEAR-CTRL circuit breaker is in. Make sure, that neither a person nor any object is located in the upper landing gear doors travel area.
2 Turn BATT and EXT PWR switch ON. 3 Push circuit breaker GEAR-CTRL in. DANGER
Landing gear extends and retracts under high pressure. Operation of the landing gear can cause death or injuries in its working area! Make sure, that neither a person nor any object is located in the landing gear travel area.
4 Operate the landing gear: 1 Retraction cycle 1 Extension cycle 5 Turn BATT and EXT PWR switch OFF. 6 Pull circuit breaker GEAR-CTRL. 7 Check hydraulic fluid level; if necessary, refill hydraulic fluid until the oil level just covers the center line of the gauge glass. Page 36
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Use MIL−H−5606 Hydraulic Fluid
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Detail Steps/Work Items NOTE
Key Items
Pay attention to noise in the restrictor nozzles to localize trapped air in the system. Drive maximum 5 cycles; then allow power pack to cool down.
CAUTION 8 Repeat steps 2 to 7, until correct fluid level remains constant. 9 Remove the tape from RH upper door and re-install the bolt to the push pull rod.
Hydraulic Fluid Change Detail Steps/Work Items DANGER
Key Items
Landing gear extends and retracts under high pressure. Operation of the landing gear can cause death or injuries in its working area! Before beginning any work in the landing gear working area, pull the electric circuit breaker located on the left side panel and marked GEAR-CTRL. In case of intentional gear operation by switch or circuit breaker handling make sure, that neither a person nor any object is located in the landing gear travel area. Hydraulic fluid can cause disease!
WARNING
Do not allow hydraulic fluid to come in contact with your skin. Hydraulic fluid can damage paint and other material!
CAUTION
Clean up immediately spilt hydraulic fluid.
1 Lift the aircraft on jacks
Chapter 07-10-00
2 Remove the hydraulic power pack
Refer to Chapter 32-30-11 Removal/Installation
3 Clean hydraulic power pack and filter.
Refer to Chapter 32-30-11 Cleaning
4 Remove the oil vent plug from the reservoir. 5 Refill hydraulic fluid through vent plug opening of the reservoir up to maximum level.
Use MIL−H−5606 Hydraulic Fluid
6 Plug a temporary breather hose (diameter 6 mm/1/4 inch) with fitting into the vent plug opening. 7 Re-install the hydraulic power pack. Let upper RH door in lifted position.
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Refer to Chapter 32-30-11 Removal/Installation omitting steps 2 and 3.
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Detail Steps/Work Items
Key Items
8 Lead breather hose through free opening in keel beam to RH access compartment in front of main wheel bay During gear retraction, high pressure oil jet from the return line WARNING damages eyes and limbs! Cover return line in the sump with mesh gate to retain spilling fluid. DANGER
Upper landing gear doors will close immediately, when BATT or EXT PWR switch is turned to ON and GEAR-CTRL circuit breaker is in. Make sure, that neither a person nor any object is located in the upper landing gear doors travel area.
8 Turn BATT and EXT PWR switch ON (left side panel, toggle switch) 9 Push circuit breaker GEAR-CTRL in (left side panel) DANGER
Landing gear extends and retracts under high pressure. Operation of the landing gear can cause death or injuries in its working area! Make sure, that neither a person nor any object is located in the upper landing gear doors travel area.
10 Pull and move LANDING GEAR switch UP (left main panel, below RH side of control yoke) NOTE
Assure adequate fluid volume to avoid trapped air in the system 11 Refill reservoir through breather hose with hydraulic fluid up to maximum level.
DANGER
read out 1100 cm³ (67 cu in) or refill until fluid runs out
Landing gear extends and retracts under high pressure. Operation of the landing gear can cause death or injuries in its working area! Make sure, that neither a person nor any object is located in the upper landing gear doors travel area.
12 Pull and move LANDING GEAR switch DN. 13 Turn BATT and EXT PWR switch OFF.
When landing gear is down and locked.
14 Pull circuit breaker GEAR-CTRL. 15 Remove breather hose. 16 Screw the oil vent plug to the reservoir. 17 Remove the tape from RH upper door and re-install the bolt to the push pull rod 18 Return aircraft to normal observing respective procedures and warnings.
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32-30-11
Hydraulic Power Pack Removal/Installation Detail Steps/Work Items
DANGER
Key Items
Landing gear extends and retracts under high pressure. Operation of the landing gear can cause death or injuries in its working area! Before beginning any work in the landing gear working area, pull the electric circuit breaker located on the left side panel and marked GEAR-CTRL. In case of intentional gear operation by switch or circuit breaker handling make sure, that neither a person nor any object is located in the landing gear travel area.
1 Ensure BATT switch is OFF and no external power connected. 2 Remove the aft keel beam access panel.
Refer to Chapter 51-00-01
3 Remove the bolt from the push pull rod upper door RH. 4 Lift the upper door RH and fasten it by means of a tape. 5 Disconnect the electric power supply from the hydraulic power pack. Hydraulic fluid can cause disease! WARNING
Do not allow hydraulic fluid to come in contact with your skin. Hydraulic fluid can damage paint and other material!
CAUTION
Clean up immediately spilt hydraulic fluid
6 Disconnect the hydraulic lines from the inlet and outlet fitting of the hydraulic power pack.
Refer to Chapter 32-30-30
7 Install blind plugs to the disconnected lines to avoid trapped air in the system. NOTE
For identification, tag each hydraulic line. The line connecting the sump to the hydraulic pump is identified as return line, the line leading directly to the control valve is the pressure line. 8 Remove 2 attachment bolts of the power pack.
Hold unit
9 Drain the hydraulic fluid 10 Install in reverse sequence of removal 11 Perform Bleeding procedure.
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Refer to Subject 32-30-10
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Cleaning This procedure describes cleaning the interior of the hydraulic power pack and the incorporated suction filter. It is assumed that the hydraulic power pack is removed from aircraft. Detail Steps/Work Items
Key Items
1 Place the power pack in upright position.
Electric motor up
2 Remove the 4 bolts from the reservoir sump
Catch spilling hydraulic fluid
3 Remove the hydraulic power pack from the reservoir. 4 Pour hydraulic fluid of the reservoir completely in an external suitable container. 5 Clean the inside of the reservoir sump from sludge
By means of lint-free rags
6 Pull off the suction filter from the suction line 7 Dry and clean the suction filter carefully
By means of lint-free rags
8 Place the hydraulic power pack to the reservoir.
Check the sealing ring for proper arrangement
9 Reinstall the 4 reservoir attaching bolts. 10 Refill hydraulic fluid.
32-30-12
Use MIL−H−5606 Hydraulic Fluid 1100 cm³ (67 cu in)
Distributor Block Removal/Installation Detail Steps/Work Items
DANGER
Key Items
Landing gear extends and retracts under high pressure. Operation of the landing gear can cause death or injuries in its working area! Before beginning any work in the landing gear working area, pull the electric circuit breaker located on the left side panel and marked GEAR-CTRL. In case of intentional gear operation by switch or circuit breaker handling make sure, that neither a person nor any object is located in the landing gear travel area.
1 Ensure BATT switch is OFF and no external power connected. 2 Remove the aft keel beam access panel.
Refer to Chapter 51-00-01
3 Remove the bolts from the push pull rods of the upper doors. Page 40
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Detail Steps/Work Items
Key Items
4 Lift the upper doors and fasten them by means of a tape. 5 Disconnect the electrical plug of the control cables from the directional valves and from the pressure switch. Hydraulic fluid can cause disease! WARNING Do not allow hydraulic fluid to come in contact with your skin. CAUTION
Hydraulic fluid can damage paint and other material! Clean up immediately spilt hydraulic fluid.
6 Remove the hydraulic lines from the fittings of the distributor block.
Chapter 32-30-30
7 Install blind plugs to the disconnected lines to avoid trapped air in the system. 8 Remove the bolts, washers and spacer sleeves from the distributor block.
Hold the unit
9 Remove the distributor block10 Drain the hydraulic fluid of the distributor block in a sump. 11 Cover all hydraulic inlets and outlets by plastic caps. 12 Install in reverse sequence of removal 13 Perform Bleeding procedure.
Refer to Subject 32-30-10
Disassembly/Assembly Detail Steps/Work Items
Key Items
1 Cut off the safety wire on the top side of the directional valves. 2 Remove the Allen bolts and lock washers from the directional valves. 3 Remove the directional valves from the distributor block.
Valve solenoids are “spot” connected to each other with silicone. Catch the O-ring from the directional valves
4 Unscrew and remove the pressure switch from the distributor block.
Catch the O-ring from the pressure switch
5 Remove the nipples and elbows from the distributor block.
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Detail Steps/Work Items NOTE
Key Items
Sign the elbows with a tag to ensure re-assembly at the original position on the distributor block. The original position is required for the proper fitting and mounting of the distributor block on its place between the keel beams. 6 Install in reverse sequence of removal.
32-30-20
Actuators
32-30-21
Main Gear Actuators
Lock up the Allen bolts of the directional valves by safety wire and “spot” fix solenoids with Elastosil E14, GE RTV 159 or equivalent
Each side of the main landing gear is driven by two hydraulic actuators (see Figure 32-8): • Short actuator • Interlocking actuator
Removal/Installation The following procedure applies for both actuators. However the interlocking actuator has to be unlocked before removal as described in step 6. Detail Steps/Work Items DANGER
Key Items
Landing gear extends and retracts under high pressure. Operation of the landing gear can cause death or injuries in its working area! Before beginning any work in the landing gear working area, pull the electric circuit breaker located on the left side panel and marked GEAR-CTRL. In case of intentional gear operation by switch or circuit breaker handling make sure, that neither a person nor any object is located in the landing gear travel area.
1 Lift the aircraft on jacks
Chapter 07-10-00
2 Remove the bolt from the push pull rod upper doors. 3 Lift the upper doors and fasten them by means of a tape.
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Detail Steps/Work Items
Key Items
Hydraulic fluid can cause disease! WARNING
Do not allow hydraulic fluid to come in contact with your skin. Hydraulic fluid can damage paint and other material!
CAUTION
Clean up immediately spilt hydraulic fluid.
4 Remove the hydraulic lines from the hydraulic actuator fittings.
Chapter 32-30-30
5 Install blind plugs to the disconnected lines to avoid trapped air in the system. CAUTION
False reassembled bolted connections can damage the gear struts and doors. Before removal of bolts and nuts, notice their position.
6 (interlocking Momentarily apply shop air to the fitting at actuator only) the rod end side of the hydraulic cylinder.
To release the down locked position.
7 Remove the bolt, the stop nut and the washers between the rod end of the hydraulic actuator and the main gear strut assembly. 8 Remove the bolt, the stop nut and the washers between the cylinder side of the hydraulic actuator and the bracket on the keel beam.
Hold the hydraulic actuator
9 Remove the hydraulic actuator. 10 Measure the fully extended actuator length. 11 Install in reverse sequence of removal
Use new stop nuts
12 Check actuator for length.
Set the fully extended length to the previously measured length.
13 Perform Bleeding procedure.
Refer to Subject 32-30-10
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32-30-22
Upper Doors Actuator Removal/Installation Detail Steps/Work Items
DANGER
Key Items
Landing gear extends and retracts under high pressure. Operation of the landing gear can cause death or injuries in its working area! Before beginning any work in the landing gear working area, pull the electric circuit breaker located on the left side panel and marked GEAR-CTRL. In case of intentional gear operation by switch or circuit breaker handling make sure, that neither a person nor any object is located in the upper landing gear doors travel area. Hydraulic fluid can cause disease!
WARNING
Do not allow hydraulic fluid to come in contact with your skin. Hydraulic fluid can damage paint and other material!
CAUTION
Clean up immediately spilt hydraulic fluid.
1 Remove the respective front fuselage access panel.
Refer to Chapter 51-00-01
2 Remove the hydraulic lines from the fittings of the hydraulic actuator.
Chapter 32-31-00
3 Install blind plugs to the disconnected lines to avoid trapped air in the system. 4 Remove the bolt, the stop nut and the washers between the rod end of the hydraulic actuator and the torque tube. 5 Remove the cotter pin from the clevis pin 6 Remove the washer and clevis pin between the cylinder side of the hydraulic actuator and the support
Hold the hydraulic actuator
7 Remove the hydraulic actuator 8 Remove the bolts, the stop nuts and the washers between the torque tube and the cardan joint 9 Remove the torque tube 10 Remove the bolts, the stop nuts and the washers between the cardan joint and the shaft
Hold the cardan joint
11 Remove the cardan joint 12 Remove the bolts, the stop nut and the washers from the push pull rod
Hold the push pull rod
13 Remove the push pull rod Page 44
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Detail Steps/Work Items
Key Items
14 Remove the bolt, the stop nut and the washer from the lever 15 Pull off the lever from the shaft 16 Pull out the shaft of the bearing 17 Remove the collar bushing 18 Install in reverse sequence of removal
Use new stop nuts
19 Perform Bleeding procedure.
Refer to Subject 32-30-10
32-30-23
Lower Doors Actuator Removal/Installation Detail Steps/Work Items
DANGER
Key Items
Landing gear extends and retracts under high pressure. Operation of the landing gear can cause death or injuries in its working area! Before beginning any work in the landing gear working area, pull the electric circuit breaker located on the left side panel and marked GEAR-CTRL. In case of intentional gear operation by switch or circuit breaker handling make sure, that neither a person nor any object is located in the upper landing gear doors travel area. Hydraulic fluid can cause disease!
WARNING
Do not allow hydraulic fluid to come in contact with your skin. Hydraulic fluid can damage paint and other material!
CAUTION
Clean up immediately spilt hydraulic fluid.
1 Remove the aft keel beam access panel.
Refer to Chapter 51-00-01
2 Remove the hydraulic lines from the fittings of the hydraulic actuator.
Chapter 32-30-30
3 Install blind plugs to the disconnected lines to avoid trapped air in the system. 3 Remove the cotter pins from the clevis pins on the hydraulic actuator. 4 Remove the clevis pin between the rod end of the hydraulic actuator and the actuator lever. 5 Remove the clevis pin between the cylinder side of the hydraulic actuator and the support. Page Date: 30. March 2012
Hold the hydraulic actuator
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Detail Steps/Work Items
Key Items
6 Remove the hydraulic actuator 7 Remove the cotter pins from the clevis pins on the hinge joints 8 Remove the clevis pins and the washers from the hinge joints 9 Remove the hinge joints 10 Remove the bolts, the stop nuts and the washers between the actuator lever and both torque tubes 11 Pull out the torque tube LH of the actuator lever and the bearing
Hold the actuator lever
12 Remove the actuator lever from the torque tube RH
Hold the torque tube
13 Pull out the torque tube RH of the bearing 14 Remove the collar bushing from the keel beams 15 Install in reverse sequence of removal
Use new stop nuts
16 Perform Bleeding procedure.
Refer to Subject 32-30-10
32-30-24
Nose Gear Actuator Removal/Installation Detail Steps/Work Items
DANGER
Key Items
Landing gear extends and retracts under high pressure. Operation of the landing gear can cause death or injuries in its working area! Before beginning any work in the landing gear working area, pull the electric circuit breakers located on the left side panel and marked GEAR-CTRL. In case of intentional gear operation by switch or circuit breaker handling make sure, that neither a person nor any object is located in the upper landing gear doors travel area.
1 Lift the aircraft on jacks
Chapter 07-10-00
Hydraulic fluid can cause disease! WARNING
Do not allow hydraulic fluid to come in contact with your skin. Hydraulic fluid can damage paint and other material!
CAUTION
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Clean up immediately spilt hydraulic fluid.
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Detail Steps/Work Items 2 Remove the hydraulic lines from the fittings of the hydraulic actuator.
Key Items Chapter 32-30-30
3 Install blind plugs to the disconnected lines to avoid trapped air in the system. 4 Remove the bolt, the stop nut and the washer from the rod end of the hydraulic actuator. 5 Remove the bolt, the stop nut and the washer from the cylinder side of the hydraulic actuator.
Hold the hydraulic actuator
6 Remove the hydraulic actuator. 7 Measure the fully extended actuator length. 8 Install in reverse sequence of removal.
Use new stop nuts
9 Check actuator for length.
Set the fully extended length to the previously measured length.
10 Perform Bleeding procedure.
32-30-25
Refer to Subject 32-30-10
Nose Gear Gas Pressurized Springs Removal/Installation Detail Steps/Work Items
DANGER
Key Items
Landing gear extends and retracts under high pressure. Operation of the landing gear can cause death or injuries in its working area! Before beginning any work in the landing gear working area, pull the electric circuit breaker located on the left side panel and marked GEAR-CTRL. In case of intentional gear operation by switch or circuit breaker handling make sure, that neither a person nor any object is located in the upper landing gear doors travel area.
1 Lift the aircraft on jacks
Chapter 07-10-00
Preload of the gas pressurized spring damages limbs! WARNING 2 Remove cotter pin, washer and castle nut from the connection between drag brace and trunnion.
Counteract spring forces at lower drag brace.
3 Remove the bolt (AN 6) from the drag brace sheathing at trunnion.
Slowly move down drag brace and thus release gas spring.
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Detail Steps/Work Items
Key Items
4 Remove the cotter pin and the outside washer from the clevis pin on the rod end of the gas pressurized springs. 5 Remove the cotter pin, washer and castle nut on the cylinder side of the gas pressurized springs. 6 Remove the bolt of the gas pressurized springs. 7 Remove the gas pressurized springs. 8 Install in reverse sequence of removal
Test Procedure Detail Steps/Work Items 1 Lift the aircraft on jacks NOTE
Key Items Chapter 07-10-00
Landing gear must remain extended for testing.
Landing gear extends and retracts under high pressure. Operation of the DANGER landing gear can cause death or injuries in its working area! Make sure, that neither a person nor any object is located in the landing gear travel area. 2 Turn BATT switch OFF. Ensure external power is not connected. 3 Pull circuit breaker GEAR-CTRL. 4 Attach a strap connecting both main gear legs. 5 Attach a strap on the nose-wheel axis. 6 Connect the nose-wheel strap with the main gear strap using a tensiometer.
Tensiometer: 100- 120 N, (1 N resolution and accuracy)
7 Pull the nose gear back while manually unlocking the drag brace. Set the nose gear at 20 degrees retracted.
With the ratchet of the strap (242 mm nose gear axle travel; the upper part of the drag brace should be horizontal)
8 Pull the nose gear back by hand another 100mm and release slowly to the 20 degree position. 9 Read the strap tension; depending on the temperature, the tension should be at least as depicted in the table below.
Refer to Minimum Tension Forces table
10 If tensiometer reads lower than applicable chart value: a With actuators and springs disconnected, Page 48
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Detail Steps/Work Items check trunnion bearing and drag brace bearings for excessive friction.
Key Items
b Check for freedom of excessive friction or jamming after connecting the locking strut to the nose gear leg. c Replace both gas-pressurized springs if lack of extension force is not caused by friction. 11 Release nose gear, ensure nose gear is locked, remove straps and put aircraft back to normal.
Minimum Tension Forces
32-30-30
Temperature [°C]
Tension [N]
Temperature [°F]
Tension [lbs]
0
105
32
24
10
108
50
24
20
113
68
25
30
116
86
26
40
120
104
27
Hydraulic Lines Description The hydraulic devices are connected by aluminum tubes and PTFE hoses. All actuators are generally connected by flexible PTFE hoses: • The main gear actuators and the nose gear actuators are connected by PTFE hoses size 04. • The upper and lower door actuators of the main gear are connected by PTFE hoses size 03. The supply systems, the hydraulic power pack and the hydraulic control unit are connected by aluminum tubes and PTFE hoses: • The connection from the hydraulic control unit to the respective main gear actuator, up to the tee type or cross type fitting on the keel beam, is composed of aluminum tube size 04. • The connection from the hydraulic control unit to the upper door actuators of the main gear, up to the tee type fitting between the keel beams, is composed of aluminum tube size 03. • The connection from the hydraulic control unit to the nose gear actuators, up to the elbow fitting on the keel beam, is composed of PTFE hose size 04. From
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the elbow fitting to the tee type fitting in the nose gear compartment the connection is composed of aluminum tube size 04. • The connection from the hydraulic control unit to the lower door actuator of the main gear is composed of PTFE hose size 03. • The connection from the hydraulic control unit to the hydraulic power pack is composed of PTFE hoses size 04. The hydraulic system is separated in three circuits to actuate the respective devices: 1 Extension/retraction of main gear and nose gear 2 Opening/closing of the lower main gear doors 3 Opening/closing of the upper main gear doors
32-30-40
Torque Link Rod and Track Rods Removal/Installation This procedure applies for all kind of rods used in the landing gear. Detail Steps/Work Items 1 Lift the aircraft on jacks
DANGER
CAUTION
Key Items Chapter 07-10
Landing gear extends and retracts under high pressure. Operation of the landing gear can cause death or injuries in its working area! Before beginning any work in the landing gear working area, pull the electric circuit breaker located on the left side panel and marked GEAR-CTRL. In case of intentional gear operation by switch or circuit breaker handling make sure, that neither a person nor any object is located in the upper landing gear doors travel area. False reassembled bolted connections can damage the gear struts and doors. Before removal of bolts and nuts, notice their position.
2 Remove the bolts, the stop nuts and the washers connecting the respective rod to the main gear strut assembly. 3 Install in reverse sequence of removal
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Use new stop nuts
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32-30-50
Drive Mechanism Nose Doors Removal/Installation Detail Steps/Work Items
DANGER
Key Items
Landing gear extends and retracts under high pressure. Operation of the landing gear can cause death or injuries in its working area! Before beginning any work in the landing gear working area, pull the electric circuit breaker located on the left side panel and marked GEAR-CTRL. In case of intentional gear operation by switch or circuit breaker handling make sure, that neither a person nor any object is located in the upper landing gear doors travel area.
CAUTION
False reassembled bolted connections can damage the gear struts and doors. Before removal of bolts and nuts, notice their position.
1 Remove the bolts, the stop nuts and the washers from the push pull rods.
Hold the push pull rod
2 Remove the push-pull rods. 3 Remove bolts of telescope guide rod. 4 Remove telescope guide rod. 5 Remove bolt of nose gear door spring. 6 Remove nose gear door spring. 7 Install in reverse sequence of removal.
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32-40-00
WHEELS AND BRAKES Description The nose gear and the main gear struts have single wheels carrying lowpressure tube-type tires. The nose wheel has a 5.00-5, ply. 6 tire with an inner tube. The nose wheel hub has two aluminum alloy halves. Three bolts hold the halves together. The main wheels, being similar constructed as the nose wheel, have 15x6.00-6 tube tires. Each main wheel hub carries a hydraulically actuated single-disk brake on the inside. The toe-brake pedals on the rudder pedals operate the brakes by the hydraulic master cylinder. Hydraulic lines and hoses are routed from each master cylinder to the wheel cylinder on each brake assembly. The brakes can be actuated from either the pilot's or copilot's seat. The parking brake valve system consists of a manually operated control assembly located on the middle console and connected to the parking brake valve. Applying pressure to the brake system by pressing the toe pedals and pulling the parking brake control sets the parking brake. Pushing the parking brake control forward releases the brakes.
Do not set the parking brake when brakes are overheated after heavy CAUTION braking or when outside temperatures are unusually high. Trapped hydraulic fluid may expand with heat and damage the system.
32-40-01
Main Wheels Removal/Installation Detail Steps/Work Items 1 Lift the aircraft on jacks.
DANGER
Key Items Chapter 07-10
Landing gear extends and retracts under high pressure. Operation of the landing gear can cause death or injuries in its working area! Before beginning any work in the landing gear working area, pull the electric circuit breakers located on the left side panel and marked GEAR-CTRL. In case of intentional gear operation by switch or circuit breaker handling, make sure that neither a person nor any object is located in the upper landing gear doors travel area. The inflated tube tenses the wheel rim construction!
WARNING
Before working deflate the tire by the valve completely.
2 Remove the brake without disconnecting the brake hose. Page 52
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Maintenance Manual EXTRA 500
Detail Steps/Work Items
Key Items
3 Remove the cotter pins from the hub nut. 4 Remove the hub nut. 5 Remove the rim from the main gear strut. 6 Remove the stop nuts and the washer from the bolts. 7 Remove the bolts from both wheel halves and the brake disk. 8 Remove both wheel halves from the tire. 9 For removing of the cup and cone bearing in both wheel halves perform as described in Cleveland Maintenance Manual. 10 Remove the tube from the tire. 11 Install in reverse sequence of removal.
32-40-02
Use new stop nuts
Nose Wheel Removal/Installation Detail Steps/Work Items 1 Lift the aircraft on jacks.
DANGER
Key Items Chapter 07-10-00
Landing gear extends and retracts under high pressure. Operation of the landing gear can cause death or injuries in its working area! Before beginning any work in the landing gear working area, pull the electric circuit breaker located on the left side panel and marked GEAR-CTRL. In case of intentional gear operation by switch or circuit breaker handling, make sure that neither a person nor any object is located in the upper landing gear doors travel area. The inflated tube tenses the wheel rim construction!
WARNING
Before working deflate the tire by the valve completely.
2 Remove the cotter pin on one side of the through bolt. 3 Remove the castle nut and the washer from the through bolt. 4 Remove the through bolt from the rim nose gear. 5 Remove the spacer sleeves from the rim.
Hold the rim
6 Remove the axle from the rim. Page Date: 30. March 2012
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Detail Steps/Work Items
Key Items
7 Remove the stop nuts and the washer from the bolts. 8 Remove the bolts and the washer from both wheel halves. 9 Remove both wheel halves from the tire. 10 For removing of the cup and cone bearing in both wheel halves perform as in Cleveland Maintenance Manual described. 11 Remove the tube from the tire. 12 Install in reverse sequence of removal.
32-40-03
Use new stop nuts
Brake Removal/Installation Detail Steps/Work Items 1 Lift the aircraft on jacks.
DANGER
Key Items Chapter 07-10-00
Landing gear extends and retracts under high pressure. Operation of the landing gear can cause death or injuries in its working area! Before beginning any work in the landing gear working area, pull the electric circuit breaker located on the left side panel and marked GEAR-CTRL. In case of intentional gear operation by switch or circuit breaker handling, make sure that neither a person nor material is located in the landing gear working area.
Brake fluid can cause disease! WARNING Do not allow brake fluid to come in contact with your skin. CAUTION
Brake fluid can damage paint and other material! Clean up immediately spilt brake fluid.
2 Disconnect the brake hose from the elbow fitting of the brake.
Catch the brake fluid. Put caps on the opened lines and fittings
3 Install blind plug to the disconnected line to avoid trapped air in the system. 4 Cut off the safety wire on the bolts. 5 Remove the bolts from the brake. 6 Remove the brake from the axle bar.
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Fasten the brake at the main gear strut with a tape to protect the brake hose
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Detail Steps/Work Items
Key Items
7 Remove the cotter pins from the hub nut. 8 Remove the hub nut. 9 Remove the rim from the main gear strut. 10 Remove the stop nuts and the washer from the bolts. 11 Remove the bolts from both wheel halves and the brake disk. 12 Remove both wheel halves from the tire. 13 For removing of the cup and cone bearing in both wheel halves perform as described in Cleveland Maintenance Manual. 14 Remove the tube from the tire. 15 Install in reverse sequence of removal.
Use new stop nuts
16 Bleed the brake line.
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32-50-00
STEERING Description The EXTRA 500 has a controllable nose wheel. The steering arm of the extended nose wheel is linked to the rudder pedals by springs and control cables. The control cables are tightened by additional springs (mounted beneath the shelf) to prevent them from coming-off from the pulley. Nose gear retraction automatically disengages the steering mechanism from the nose wheel. The steering arm aligns the nose wheel for entry into the wheel bay and, during flight, fixes it in the center nose of the guide block. Nose wheel steering is accomplished through the use of the rudder pedals. Pushing on one rudder pedal steers the aircraft to that side. The maximum nose gear turning angle is 300 to either side while taxiing. During standstill the rudder pedals control only the rudder.
Removal/Installation Removal/Installation of the steering control cable is described in Chapter 27 Flight Controls.
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32-60-00
POSITION AND WARNING Description The LANDING GEAR switch is located on the L/H instrument panel and has the positions UP and DN for retracting and extending the landing gear. It is necessary first to pull out the selector switch handle prior to moving it up or down. The switch is fitted with a small wheel for easy identification and assisting in moving the switch in rough air. The downlock information, for each wheel separately, is given by three green lights located near the LANDING GEAR switch. The red GEAR WARN light on the annunciator panel indicates that the landing gear is not completely retracted or extended. The entire electric control processes signals from limit switches, indicating the completion of actions of the respective hydraulic circuits, and from the landing gear switches. In emergency case it can be deactivated by pulling the GEAR-CTRL circuit breaker. The directional valves are spring-loaded and will automatically switch in the GEAR DOWN position once electrical power is lost. As long as the LANDING GEAR switch is in DN-position the gear downlock indication will still be operative, however the prescribed reclosing of the upper main doors will not happen. A warning horn is furnished on the EXTRA 500 in combination with the red GEAR WARN light on the annunciator panel to caution the pilot against landing with the landing gear being retracted. A respective acoustic warning signal is heard on the headphones simultaneously. Firstly, the warning light and horn will be activated in case of the landing gear being still retracted, while engine torque is below 35 % for descent or landing approach and with wing flaps being in 0°- or 15°- position. If landing is not intended pressing the gear warning mute button located on the left side of the power lever will switch off the horn and the warning light. Secondly, if engine torque is below 35 % for normal landing approach and wing flaps are in landing position (30°), the warning light will illuminate and the warning horn will sound independently from the gear warning mute button until the landing gear will be completely extended. The function of the red GEAR WARN light and the aural warning can be tested switching the NIGHT/DAY switch on the left side panel to the TEST position. Separate position switches monitor the landing gear struts and doors: • Extending and retracting of each main gear strut and the nose gear strut • Opened and closed position of the upper and lower main gear doors Generally micro switches are used. During ground operation, a ground safety switch prevents accidental gear retraction by disconnecting the main valve from DC, regardless of LANDING GEAR switch position. It is located on the nose landing gear just above the torque link.
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fwd
Main gear retracted switch
Main gear attachment frame
Main gear extended switch
Undercarriage leg
Torque link rod
Figure 32-9
32-60-01
Main Gear Switches (LH)
Main Gear Extended Switches The main gear extended switches are located on the undercarriage leg of the LH and RH main gear as shown on Figure 32-9.
32-60-02
Main Gear Retracted Switches The main gear retracted switches are located at the main gear attachment frame next to the upper torque link attachment as shown on Figure 32-9. When the left and right gear retracted switches are reached, the upper door valve is powered to close the upper doors. The closing of the upper doors then causes the two upper door closed switches (see below) to power the lower door valve, which closes the lower doors.
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The closed upper doors are held in place not only by hydraulic power, but also by the lower doors overlapping them. Therefore the upper doors need to be closed first.
32-60-03
Upper Main Door Opened Switch The upper door opened switches are operated by the rod of the hydraulic actuator upper door. When the upper main doors are fully opened, the two upper main door opened switches will power the main valve which will retract the main gear strut.
32-60-04
Upper Main Door Closed Switch The upper main door closed switches are operated by the rod of the hydraulic actuator upper door.
32-60-05
Lower Main Door Closed Switch The lower main door closed switch is operated by the actuator lower door, opening circuit when the lower doors are closed completely. After all doors are closed the door closed switches upper/lower door cut off the power from the gear in-transition information. In case of wheel bay doors being opened during flight due to reduced system pressure, the gear intransition information will warn the pilot from abnormal system state by the red gear warning light in the instrument panel. At the same time the hydraulic pump will be activated to reclose the door accordingly.
32-60-06
Ground Safety Switch The function is realized by two switches. They are installed on the nose gear just above the torque link (refer to Figure 32-5).
32-60-07
Nose Gear Extended Switch The nose gear extended switch is mounted to the nose gear drag brace and is operated when the drag brace is in the over-centered position. It controls the green nose gear downlock light in the instrument panel (refer to Figure 32-5).
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32-60-08
Nose Gear Retracted Switch The nose gear retracted switch is located in the front part of the nose gear wheel well (refer to Figure 32-6) and operated by a bracket attached to the trunnion. It is used for the red GEAR WARN light to signal if the nose gear is fully retracted or not.
32-60-09
Operation and Indication The operation and indication assembly has the following components: Indication lights - Gear extended (three greens) LANDING GEAR switch
Annunciator light – GEAR WARN Annunciator light – HYDRAULIC PUMP
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Chapter 33 Lights
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Table of Contents
33-00-00
GENERAL ........................................................................................................ 3 Description.......................................................................................................... 3
33-10-00
FLIGHT COMPARTMENT ........................................................................... 4 Description.......................................................................................................... 4
33-20-00
PASSENGER COMPARTMENT................................................................... 5 Description.......................................................................................................... 5
33-40-00
EXTERIOR ....................................................................................................... 6 Description.......................................................................................................... 6
33-40-01
Wing Tip Navigation/Strobe Lights ................................................................ 6 Removal/Installation........................................................................................... 6
33-40-02
Tail Navigation/Strobe Light........................................................................... 7 Removal/Installation........................................................................................... 7
33-40-03
Strobe Light Power Supply (Wing)................................................................. 7 Removal/Installation........................................................................................... 7
33-40-04
Strobe Light Power Supply (Tail) ................................................................... 8 Removal/Installation........................................................................................... 8
33-40-05
Landing Light ................................................................................................... 9 Removal/Installation........................................................................................... 9
33-40-06
Recognition Light ............................................................................................. 9 Removal/Installation........................................................................................... 9
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33-00-00
GENERAL Description The EXTRA 500 is equipped with lights in the flight compartment for proper instrument and label reading in reduced ambient light conditions. The passenger compartment is also lighted for passenger comfort, but those lights can be switched off by the pilot at any time for safety reasons. External lighting is provided to ‘see and to be seen’.
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33-10-00
FLIGHT COMPARTMENT Description The cockpit is lighted with the following lights: • Instrument lights, including switches backlighting • Lights in the glareshield • Two dome lights in the ceiling • Two map lights in the ceiling • And for emergencies a flash light behind the co-pilot seat The instrument lights, switches backlighting, annunciator lights, lights in the glare shield and keypad/IFD backlighting are all dimmable by their respective potentiometer on the instrument panel. Dimming is activated by the NIGHT/DAY switch in the left side panel. The instrument lights and switches backlighting (INSTR), glareshield lights (GLARE), and the map lights (MAP) have their individual switches on the left side panel. The dome light switch is located adjacent to the dome light.
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33-20-00
PASSENGER COMPARTMENT Description The passenger compartment lighting consists of: • Ambient lighting on the central air-conditioning channel • A reading light for each passenger in the side walls These can be switched on and off by the passenger individually, but the CABIN LIGHT switch in the left side panel has priority to switch all passenger lighting off.
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33-40-00
EXTERIOR Description Exterior lights consist of: • Strobe lights at the wing tips and the fin tip (also refer to Whelen AntiCollision Light Systems Installation and Service Manual, LOAP 43) • Navigation lights at the wing tips • Landing light in the lower RH cowling • Two recognition lights, also used for taxiing, installed in the wing leading edge on both sides. • Ice light (described in Chapter 30-80-01) Each light (-group) has its own switch and circuit breaker in the left side panel (CABIN/CABIN-LT, RECO/RECO-LT NAV/NAV-LT, LDG/LDG-LT). The strobe light power supply for the wing mounted strobes is installed in the wing nose, just right of the forward-middle wing compartment. The tail power supply is installed in the vertical tail tip.
33-40-01
Wing Tip Navigation/Strobe Lights Removal/Installation Detail Steps/Work Items
Key Items
High voltage can cause injuries! WARNING
Let power supply stand for 5-10 minutes after disconnecting from power source to allow power to bleed off capacitors before beginning any work on the strobe light systems. Even after 5-10 minutes, care should be taken when handling components as electrical shock can result.
1 Pull the STROBE-LT circuit breaker.
Let power supply stand for 510 minutes.
2 Also pull the NAV-LT circuit breaker. 3 Remove the Phillips screws from the wing tip glass cover.
Hold the wing tip glass cover
4 Remove the wing tip glass cover 5 Remove the lens retainer mounting Phillips screw and retainer. 6 Remove counter-sunk screws and base assembly from wingtip. 7 Disconnect electrical connectors.
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Detail Steps/Work Items
Key Items
8 Install in reverse sequence of removal
33-40-02
Tail Navigation/Strobe Light Removal/Installation Detail Steps/Work Items
Key Items
High voltage can cause injuries! WARNING
Let power supply stand for 5-10 minutes after disconnecting from power source to allow power to bleed off capacitors before beginning any work on the strobe light systems. Even after 5-10 minutes, care should be taken when handling components as electrical shock can result.
1 Pull the STROBE-LT circuit breaker.
Let power supply stand for 510 minutes.
2 Also pull the NAV-LT circuit breaker. 3 Remove the retainer mask Phillips screws. Remove the unit. 4 Disconnect electrical connector. 5 Install in reverse sequence of removal
33-40-03
Strobe Light Power Supply (Wing) Removal/Installation Detail Steps/Work Items
Key Items
High voltage can cause injuries! WARNING
Let power supply stand for 5-10 minutes after disconnecting from power source to allow power to bleed off capacitors before beginning any work on the strobe light systems. Even after 5-10 minutes, care should be taken when handling components as electrical shock can result.
1 Pull the STROBE-LT circuit breaker.
Let power supply stand for 510 minutes.
2 Remove the wing center fairing.
Refer to Chapter 51-00-01
3 Disconnect the electrical wiring of the power supply 4 Disconnect the ground bonding lead
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Detail Steps/Work Items
Key Items
5 Remove the Phillips screws from the power supply unit 6 Pull out the power supply unit and remove from the attaching plate CAUTION
Reverse polarity of the input power, for just an instant, will permanently damage power supply. This damage is sometimes not immediately apparent, but will cause failure later on. Black lead is negative.
7 Install in reverse sequence of removal
33-40-04
Strobe Light Power Supply (Tail) Removal/Installation Detail Steps/Work Items
Key Items
High voltage can cause injuries! WARNING
Let power supply stand for 5-10 minutes after disconnecting from power source to allow power to bleed off capacitors before beginning any work on the strobe light systems. Even after 5-10 minutes, care should be taken when handling components as electrical shock can result.
1 Pull the STROBE-LT circuit breaker.
Let power supply stand for 510 minutes.
2 Remove fin tip.
Refer to Charter 55-30-01
3 Disconnect the ground bonding lead 4 Remove the Phillips screws from the power supply unit 5 Pull out the power supply unit and remove from the attaching plate CAUTION
Reverse polarity of the input power, for just an instant, will permanently damage power supply. This damage is sometimes not immediately apparent, but will cause failure later on. Black lead is negative.
6 Install in reverse sequence of removal
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33-40-05
Landing Light Removal/Installation Detail Steps/Work Items
Key Items
1 Pull LDG-LT circuit breaker. 2 Remove upper cowlings.
Refer to Chapter 71-10-01/02
3 Remove external landing light glass.
8 screws
4 Remove landing light cover.
2 screws
5 Disconnect electrical connection. 6 Remove lamp with igniter.
Retainer clip
7 Remove reflector with frame.
2 screws
8 Install in reverse sequence of removal
33-40-06
Recognition Light Removal/Installation Detail Steps/Work Items
Key Items
1 Pull RECO-LT circuit breaker. 2 Remove respective wing nose access panel.
Refer to Chapter 51-00-01
3 Remove baffle with recognition light.
3 screws
4 Disconnect electrical connector. 5 Remove recognition light from baffle.
2 screws
6 Install in reverse sequence of removal
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Intentionally left blank
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Chapter 34 Navigation
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Table of Contents
34-00-00
Figure 34-1
GENERAL ........................................................................................................ 5 Pitot/Static Pressure Systems.............................................................................. 5 Avionics.............................................................................................................. 5 Pitot Static System Schematic............................................................................. 6
34-10-00
FLIGHT ENVIRONMENTAL DATA ........................................................... 7
34-10-01
Altimeter (2” type)............................................................................................ 7 Troubleshooting.................................................................................................. 7 Removal/Installation........................................................................................... 8
34-10-02
Airspeed Indicator (2” type)............................................................................ 8 Troubleshooting.................................................................................................. 8 Removal/Installation........................................................................................... 8
34-10-11
Pitot Head.......................................................................................................... 9 Removal/Installation (LH/RH Side) ................................................................... 9 Pitot Head......................................................................................................... 10
Figure 34-2 34-10-12
Figure 34-3
Static Port ........................................................................................................ 10 Removal (LH/RH Side) .................................................................................... 10 Installation (LH/RH Side) ................................................................................ 11 Static Port ......................................................................................................... 11
34-10-13
Stall Warning Sensor...................................................................................... 12 Removal/Installation (LH/RH Side) ................................................................. 12
34-20-00
ATTITUDE AND DIRECTION.................................................................... 13
34-20-01
Attitude Indicator ........................................................................................... 13 Removal/Installation......................................................................................... 13
34-20-02
Magnetic Compass.......................................................................................... 13 Removal/Installation......................................................................................... 13 Bulb Replacement............................................................................................. 13
34-40-00
INDEPENDENT POSITIONING DETERMINING .................................. 14 Description........................................................................................................ 14 Troubleshooting................................................................................................ 14
34-40-01
TAS Processor................................................................................................. 14 Removal/Installation......................................................................................... 14
34-40-02
TWX Processor ............................................................................................... 15 Removal/Installation......................................................................................... 15
34-50-00
DEPENDENT POSITIONING DETERMINING ....................................... 16 Description........................................................................................................ 16
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34-50-01
Transponder ....................................................................................................16 Removal/Installation .........................................................................................16
34-50-02
DME Processor................................................................................................16 Removal/Installation .........................................................................................16
34-50-03
DME Indicator ................................................................................................17 Removal/Installation .........................................................................................17
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34-00-00
GENERAL Pitot/Static Pressure Systems Providing pitot and static pressure for the pilot's and copilot's instruments two independent systems are installed (refer to Figure 34-1). Each system consists of a heated pitot head located at about 3/4 of the wing span, the tubing including a drain and the respective instruments. The heated static ports are located on both sides of the rear fuselage. The two toggle-type drains are located at the fuselage underside, between the keel beams. They are accessible by the RH side, round cover plate between nose gear and main gear doors. When the pitot heat switches are placed in the ON position, the heating elements in the pitot heads and the static port for the autopilot are electrically energized to maintain proper operation of the systems during icing conditions. Normally, the heating elements can only be activated when airborne. On ground the system is deactivated by the squat switch, which detects aircraft being on ground. For testing on ground, pitot heat switches provide a TEST position (momentary ON).
CAUTION
In testing mode, do not operate pitot & static heat longer than 10 seconds to prevent overheating of the heating elements.
CAUTION
Care should be taken when an operational check of the heated pitot heads is being performed on the ground. The units become very hot.
Avionics The EXTRA 500 is equipped with Avidyne Entegra equipment. Please refer to Chapter 31. This chapter will deal with other avionics apart from Back-up altimeter and airspeed indicator: • Back-up attitude indicator • Magnetic compass • XPDR • DME (option) • TAS (option) • TWX (option) IMPORTANT
Avionics service and repair work requires special skills, tools and test equipment. In case of instrument failure or malfunction contact manufacturer or authorized service center.
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34
Page 5
LH
Figure 34-1
Page 6
34
red
white
Pitot LH
LH IFD ADAHRS
white
red
red
white
white
red
open
Back-up airspeed indicator
red
Cabin altimeter
red
Back-up altimeter
red
green
Static port LH red
RH
green
green
red
green
Static port RH
Pitot RH blue
RH IFD ADAHRS
blue
blue
green
Static port vertical tail
blue
blue
Transducer P550-5070
Autopilot
Maintenance Manual EXTRA 500
Pitot Static System Schematic
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Maintenance Manual EXTRA 500
34-10-00 NOTE
34-10-01
FLIGHT ENVIRONMENTAL DATA When any connections in the static system are opened for checking, a static leak check per FAR 23.1325 must be performed.
Altimeter (2” type) Troubleshooting
Complaint
Possible Cause
Remedy
Excessive scale error
Improper calibration adjustment
Contact manufacturer
Excessive pointer oscillation
Defective mechanism
Contact manufacturer
High or low reading
Improper venting
Eliminate leak in static pressure system
Setting knob is hard to turn
Wrong lubrication or lack of lubrication
Contact manufacturer
Inner reference marker fails to move when setting knob is rotated
Out of engagement
Contact manufacturer
Setting knob set screw loose or missing
Not tight when altimeter was reset
Tighten instrument screw, if loose. Contact manufacturer, if screw is missing
Cracked or loose cover glass
Case gasket hardened
Contact manufacturer
Dull or discolored markings
Age
Barometric scale and reference Slippage of mating parts markers out of synchronism
Contact manufacturer
Barometric scale and reference Drift in mechanism markers out of synchronism with pointers
Contact manufacturer
Altimeter sticks at altitude or does not change with change of altitude
Water or restriction in static line
Remove static lines from all instruments; blow line clear from cockpit to static ports
Altimeter changes reading as aircraft is banked
Water in static line
Remove static lines from all instruments; blow lines clear from cockpit to static ports
Altimeter requires resetting frequently
Temperature compensator inoperative
Contact manufacturer
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Maintenance Manual EXTRA 500
Removal/Installation Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. 2 Remove RH and LH IFD
Refer to Chapter 31
3 Disconnect (red) static pressure hose 4 Remove altimeter
3 screws
5 Disconnect electrical connector 6 Install in reverse sequence of removal 7 Perform Pitot/static check
34-10-02
According to FAR 43, Appendix E and AC 43.131B CHG1 (or later) § 12-59
Airspeed Indicator (2” type) Troubleshooting
Complaint
Possible Cause
Remedy
Pointer does not indicate properly
Leak in instrument case, in Pitot or static lines
Check for leak and seal
Pointer of instrument oscillates
Defective mechanism
Replace instrument
Instrument reads high
Pointer not on zero
Replace instrument
Leaking static system
Find leak and correct
Pointer not on zero
Replace instrument
Leaking Pitot system
Find leak and correct
Water in pitot line
Remove line from all instruments and blow out line from cockpit to Pitot head
Instrument reads low Airspeed changes as aircraft is banked
Removal/Installation Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. 2 Remove RH and LH IFD
Refer to Chapter 31
3 Disconnect (red) static pressure hose and (white) Pitot hoses 4 Remove airspeed indicator.
4 screws
5 Disconnect electrical connector. Page 8
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Maintenance Manual EXTRA 500
Detail Steps/Work Items
Key Items
6 Install in reverse sequence of removal. 7 Perform Pitot/static check
34-10-11
According to FAR 43, Appendix E and AC 43.131B CHG1 (or later) § 12-59
Pitot Head Removal/Installation (LH/RH Side) Refer to Figure 34-2. Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. 2 Remove outer wing access panel.
Refer to Chapter 51-00-01
3 Disconnect plug from sensor heat element. 4 Disconnect Pitot pressure line nut. 5 Remove 4 Phillips screws from Pitot tube shaft at bracket. 6 Remove Pitot tube from bracket downwards. 7 Install in reverse sequence of removal.
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Maintenance Manual EXTRA 500
Pitot line
Nut
Bracket
Attachment screws
Pitot head Figure 34-2
34-10-12
Pitot Head
Static Port Removal (LH/RH Side) Refer to Figure 34-3. Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. 2 Remove tail cone access panel
Refer to Chapter 51-00-01
3 Disconnect 2 static pressure hoses from static port at LH/RH fuselage 4 Cut tie-wrap and wiring to heat element on both sides of splice. Page 10
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Maintenance Manual EXTRA 500
Detail Steps/Work Items
Key Items
5 Remove static port fastening nut and strain relief. 6 Remove static port
Sensor is fitted with silicon
Installation (LH/RH Side) Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. 2 Install static port.
Apply silicon between outside part of sensor and fuselage
3 Install strain relief and static port fastening nut
Secure sensor fastening nut with Loctite 243.
4 Re-establish splice at wiring to heat element. 5 Fasten wiring with tie-wrap. 6 Connect 2 static pressure hoses to static port
red upper, green lower
7 Install tail cone access panel
Refer to Chapter 51-00-01
Wiring
Tie wrap
Strain relief Static hoses
Nut Static port Figure 34-3
Page Date: 30. March 2012
Static Port
34
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Maintenance Manual EXTRA 500
34-10-13
Stall Warning Sensor Removal/Installation (LH/RH Side) Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. 2 Remove LH wing nose access panel.
Refer to Chapter 51-00-01
3 Disconnect electrical connector from sensor. 4 Remove 4 bolts and nuts at sensor mounting plate. 5 Remove sensor. 6 Install in reverse sequence of removal
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34-20-00
ATTITUDE AND DIRECTION
34-20-01
Attitude Indicator Removal/Installation Detail Steps/Work Items 1 Remove RH and LH IFD
Key Items Refer to Chapter 31
2 Disconnect electrical connector. 3 Remove attitude indicator.
4 screws
4 Install in reverse sequence of removal.
34-20-02
Magnetic Compass Removal/Installation Detail Steps/Work Items 1 Remove compass
Key Items 2 screws
2 Disconnect electrical connector. 3 Install in reverse sequence of removal. 4 Make compass swing, if new unit is installed. 5 Replace deviation card if necessary.
Bulb Replacement Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. 2 Lift cap on upper front surface. 3 Remove bulb. 4 Insert new bulb.
24 VDC
5 Refit cap.
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34
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Maintenance Manual EXTRA 500
34-40-00
INDEPENDENT POSITIONING DETERMINING Description The EXTRA 500 can be equipped with the following optional equipment: • TAS (Traffic Avoidance System) • TWX (Lightning detection system)
Troubleshooting Complaint
Possible Cause
Remedy
TAS shows aircraft on the wrong side (left or right)
Antenna cables of upper antenna swapped
Swap antenna cables
TAS shows aircraft on the wrong side (front or aft)
Antenna cables of lower antenna swapped
Swap antenna cables
34-40-01
TAS Processor The TAS processor is installed on the back of the aft baggage compartment paneling.
Removal/Installation Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. 2 Remove aft baggage compartment paneling.
Refer to Chapter 25-00-01
3 Disconnect electrical connectors and antenna cables from TAS processor. 4 Unscrew the locking screws of the TAS processor mounting tray. 5 Slide the TAS processor out of the tray. 6 Install in reverse sequence of removal. CAUTION
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34
Observe the following hint
Make sure all antenna cables are connected to both antennas and TAS processor before applying power to the processor. Failing to do so may damage the processor.
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Maintenance Manual EXTRA 500
34-40-02
TWX Processor The TWX processor is installed beneath the armrest of the second seat row, LH seat.
Removal/Installation Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. 2 Remove LH front passenger seat.
Refer to Chapter 25-20-11
3 Remove LH side armrest paneling.
Refer to Chapter 25-20-21
4 Disconnect electrical connectors and antenna cable from TWX processor 5 Remove TWX processor from tray 6 Install in reverse sequence of removal.
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Maintenance Manual EXTRA 500
34-50-00
DEPENDENT POSITIONING DETERMINING Description The EXTRA 500 has the following equipment installed: • Transponder In addition the following optional equipment may be installed: • DME (Distance Measuring Equipment)
34-50-01
Transponder The transponder is installed in the tail cone compartment.
Removal/Installation Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. 2 Remove the tailcone access panel
Refer to Chapter 51-00-01
3 Disconnect electrical connectors and antenna cables 4 Remove transponder from its tray
2 screws
5 Install in reverse sequence of removal.
34-50-02
DME Processor The DME processor is installed in the tail cone compartment
Removal/Installation Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. 2 Remove the tailcone access panel
Refer to Chapter 51-00-01
3 Disconnect electrical connectors and antenna cables 4 Remove DME processor from its tray
2 screws
5 Install in reverse sequence of removal.
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Maintenance Manual EXTRA 500
34-50-03
DME Indicator The DME indicator is installed on the instrument panel on the left lower edge.
Removal/Installation Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. 2 Disconnect electrical connector
Accessible from the bottom
3 Remove DME indicator
4 screws
4 Install in reverse sequence of removal.
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Maintenance Manual EXTRA 500
Chapter 51 Standard Practices and Structures General
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Page 1
Maintenance Manual EXTRA 500
Table of Contents
51-00-00
GENERAL ........................................................................................................ 5
51-00-01 Access Panel Identification .............................................................................. 5 Figure 51-1, Sheet 1 Access Panel Identification ................................................................................ 6 Figure 51-1, Sheet 2 Access Panel Identification ................................................................................ 7 Figure 51-1, Sheet 3 Access Panel Identification ................................................................................ 8 51-10-00
INVESTIGATION............................................................................................ 9
51-10-01
Damage Classification ...................................................................................... 9
51-10-02
Repair Criteria and Limits ............................................................................ 10
51-30-00
MATERIALS .................................................................................................. 11
51-30-01
Composite Parts .............................................................................................. 11 Epoxy System ................................................................................................... 11 Glass Fibre Fabrics ........................................................................................... 11 Carbon Fibre Fabrics ........................................................................................ 12 Carbon Fibre Rovings....................................................................................... 12 UD Carbon Fibre Tape ..................................................................................... 12 Core Material .................................................................................................... 12 Filler Material for Resin ................................................................................... 14 Coating.............................................................................................................. 14
51-30-02
Metal Components.......................................................................................... 15 Round Seamless Steel Tubing .......................................................................... 15 Steel Sheet Metal .............................................................................................. 16 Coating.............................................................................................................. 16
51-30-03
Aluminium Components ................................................................................ 17 Aluminium Sheet Metal.................................................................................... 17 Tubings ............................................................................................................. 17 Coating.............................................................................................................. 18
51-30-04
Titanium Components.................................................................................... 18 Titanium Sheet Metal ....................................................................................... 18
51-30-05
Various Components ...................................................................................... 19 Sealant .............................................................................................................. 19 Silicon Adhesive............................................................................................... 19 Adhesive ........................................................................................................... 20 Corrosion Preventive Compound ..................................................................... 20 Sealing Material for Lightning Protection........................................................ 20 Release Agent ................................................................................................... 20
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51-60-00
CONTROL SURFACE BALANCING .........................................................21
51-60-01 Figure 51-2 Figure 51-3 Figure 51-4
Weighing and Determination of Control Surface Moments ......................21 Balancing Mandrels ..........................................................................................21 Procedure...........................................................................................................22 Control Surface Balancing................................................................................23 Permissible Weights and Moments ...................................................................24
51-70-00
REPAIRS .........................................................................................................25
51-70-01
Repair of Reinforced Glass and Carbon Fibre Components ......................25
51-70-02 Figure 51-5 Figure 51-6 Figure 51-7
Repair of Sandwich Material .........................................................................27 Minor Surface Damage .....................................................................................27 Curing Cycle Resin L 20 / SL............................................................................28 Damage of Complete Sandwich ........................................................................29
51-70-03
Repair of Laminates........................................................................................31 Minor Damage ..................................................................................................31 Repair of Minor Damage ..................................................................................32 Large Damage ...................................................................................................32
Figure 51-8 51-70-04
Repair of Spars and Elements of the Pressure Cabin..................................34 Structural elements of the pressure cabin..........................................................34 Spars of Wing and Empennage .........................................................................34
51-70-05
Structural Repair of Steel Components ........................................................34
51-70-06
Painting of Composite Parts...........................................................................35
51-70-07
Aluminium and Steel Components Refinishing ...........................................36 Degreasing.........................................................................................................36 Paint Removal ...................................................................................................36 Repainting .........................................................................................................37
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51-00-00
GENERAL
51-00-01
Access Panel Identification Refer to Figure 1 for identification of access panels. Generally all access panels (and fairings) are screwed on the respective structure or surface. However for the access to the oil filler and the external power receptacle hatches are used featuring a hinge and a latching mechanism. The LH wing nose access panel carries the stall sensor. So refer to Chapter 3410-13 for removal. To get access to the passenger compartment floor access panels the carpet has to be removed. To get access to the central horizontal stabilizer access panel the fin tip has to be removed (refer to Chapter 55-30-01).
Page Date: 30. March 2012
51
Page 5
Page 6
Tail fairing
Side Views
Figure 51-1, Sheet 1
51 RH front fuselage access panel Fuel filter access panel
External power hatch
Tailcone access panel
Door hinge access panel
Fuel sump access panel (RH)
LH front fuselage access panel
Fuel sump access panel (LH)
Landing light access panel
Oil filler hatch
Fin access panel
Tail fairing
Maintenance Manual EXTRA 500
Access Panel Identification
Page Date: 30. March 2012
Maintenance Manual EXTRA 500
Bottom View
Fuel filter access panel
RH front fuselage access panel
Forward keel beam access panel
LH front fuselage access panel
Aft keel beam access panel
RH gap fairing
LH gap fairing
Pitch trim access panel
Figure 51-1, Sheet 2
Access Panel Identification
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Maintenance Manual EXTRA 500
Top View
Oil filler hatch
Wing nose access panel
Inner and outer fuel main compartment access panels
External power hatch Avionic bay access panel
Wing center fairing
Inner and outer fuel auxiliary compartment access panels
Right wing symmetrically
Inspection doors Outer wing access panel Passenger compartment floor access panels (LH, middle, RH)
Central horizontal stabilizer access panel Figure 51-1, Sheet 3 Page 8
51
Access Panel Identification Page Date: 30. March 2012
Maintenance Manual EXTRA 500
51-10-00
INVESTIGATION
51-10-01
Damage Classification
All damage of composite parts must first be classified by qualified WARNING personnel. In case of doubt regarding the classification of damage, if a clear definition of the extent of damage is not possible, or if a repair of damage despite the consideration of the valid manufacturer documentation is doubtful, contact EXTRA. Only the Damages Classes 2, 3 and 4 may be repaired by qualified WARNING personnel. In case of Damage Class 1 EXTRA has to be contacted. Following to the Luftfahrt Bundesamt (Federal German Aviation Authority) four damage classes are defined: Damage Class 1: Large scale destruction requiring a partial reconstruction of the component or large scale repair. Each destruction over 300 mm diameter and each damage of a spar is a large scale destruction. EXTRA has to be contacted prior to repair. Damage Class 2: Damage to primary structures and to secondary structures to the following extent: Holes and fractures extending through a sandwich component and a scale under 300 mm diameter. Damage Class 3: Damage to primary structures and to secondary structures to the following extent: Small holes or fractures in the external covering layers, if not accompanied by damage to supporting layers or internal covering layers. Damage Class 4: Erosion, scratches or nicks not accompanied by fractures or break-ups. Damage to fairings belong to this class.
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51-10-02
Repair Criteria and Limits
IMPORTANT
Any damage of composite parts must first be classified prior to repair. Refer to Subject 51-10-01 Damage Classification.
IMPORTANT
Only the Damages Classes 2, 3 and 4 may be repaired by qualified personnel. In case of Damage Class 1 EXTRA has to be contacted. The decision whether to repair or replace a major unit of structure will be influenced by factors such as time and labor available, and by comparison of labor costs with the price of replacement assemblies. Past experiences indicate that replacement, in many cases, is less expensive than major repair. Certainly, when the aircraft must be restored to its airworthy condition within limited time, replacement is preferable.
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51-30-00
MATERIALS This Section describes metallic and non-metallic materials used in repairing the EXTRA 500 and gives the sources of supply (manufacturers and suppliers).
IMPORTANT
Only approved materials have to be used for repair. Materials not listed here are generally used for parts, which are not intended for repair. Contact EXTRA for advice.
51-30-01
Composite Parts Epoxy System Manufacturer: Momentive Varzinerstr. 49, D-47138 Duisburg, Germany Supplier:
Brenntag GmbH Stinnes Platz 1, D-45472 Mühlheim, Germany
Resin:
Epikote L20 / Rütapox L20
Hardener:
Epikure Curing Agent 960 / Rütapox SL
Ratio of comp.: 100 parts L20 / 34 parts SL (weight ratio)
Glass Fibre Fabrics Manufacturer: P-D Interglas Technologie GmbH Benzstraße 14, D-89155 Erbach, Germany
Page Date: 30. March 2012
Style Interglas
WLB-No.* LN 9169
US-style
Weave Patterns
Weight g/m2
90070
8.4505.60
1610
plain
80
92110
8.4548.60
none
2/2 twill
163
92125
8.4551.60
none
2/2 twill
280
92140
8.4554.60
none
2/2 twill
390
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Carbon Fibre Fabrics Manufacturer: C. Cramer GmbH & Co. KG Division ECC Weberstr. 21, D-48619 Heek-Nienborg, Germany Style ECC/CCC
WLB-No.* DIN 65147
US-style
Weave Patterns
Weight g/m2
447
8.3507.80
None
plain
160
452
8.3520.80
None
2/2 twill
204
459
-
None
2/2 twill
220
*WLB: Werkstoff Leistungsblatt, according to German standard DIN-WL
Carbon Fibre Rovings Manufacturer: Toho Tenax Europe GmbH Kasinostr. 19-21 D-42103 Wuppertal Type:
TENAX HTS5631 1600tex f24000 t 0 (WLB: 8.3614.1)
UD Carbon Fibre Tape Manufacturer: J.H.vom Baur Sohn GmbH & Co. KG Marktstraße 34 D-42396 Wuppertal, Germany Type:
CF UD tape 30 mm & 50 mm according material spec. Doc. N° EA-05803.1 & .2
Core Material PVC (Polyvinylchloride) Foam Manufacturer: Airex AG Industrie Nord 26 CH-5643 Sins, Switzerland
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51
Supplier:
Gaugler & Lutz OHG Habsburger Str. 12 D-73432 Aalen-Ebnat, Germany
Type:
Airex C 71.55
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Maintenance Manual EXTRA 500
PMI (Polymethacrylimide) Foam Manufacturer: Evonik Röhm GmbH Kirschenallee D-64293 Darmstadt, Germany Supplier:
Gaugler & Lutz OHG Habsburger Str. 12 D-73432 Aalen-Ebnat, Germany
Type:
Rohacell 51 A (WLB*: 5.1460.1)
*WLB: Werkstoff Leistungsblatt, according to German standard DIN-WL Honeycomb Manufacturer: Euro Composites S.A. B.P.95, Zone Industrielle L-6401 Echternach / Luxembourg or : Manufacturer: Schütz GmbH & Co. KGaA: Schützstr. 21 D-56242 Selters, Germany Honeycomb
Density Tolerance
Manufacturer
Specification
Cormaster C1-4,8-29 OX
+15%/-0%
Schütz
EA-03512.02
ECA-R-4.8-29
+13%/-0% Euro Composites
EA-03512.02
ECA-I-R-4.8-29
+16%/-0% Euro Composites
EA-03512.02
Cormaster C1-4,8-48 OX
±10%
Schütz
WLB5.3653.1*
ECA-R-4.8-48
±10%
Euro Composites
WLB5.3653.1*
ECA-I-R-4.8-48
±16%
Euro Composites
ECSS 704
Cormaster C1-3.2-48
±10%
Schütz
WLB5.3650.4*
ECA-I-3.2-48
±16%
Euro Composites
ECSS 704
*WLB: Werkstoff Leistungsblatt, according to German standard DIN-WL Plywood Manufacturer: For example: Mahogany Oy, Finnland Supplier:
For example: La Boisserolle 71960 Prissé-Lès-Mâcon, France
Type:
Aircraft grade Birch produced to German Lloyd GL-I & -II, t = 2 mm, 6 mm, 8 mm (WLB*: 6.1013.0) Okoume t = 4 mm, t = 6 mm**
*WLB: Werkstoff Leistungsblatt, according to German standard DIN-WL **Aircraft Grade acc. to French Standard
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Maintenance Manual EXTRA 500
Filler Material for Resin Manufacturer: STW Schwarzwälder Textilwerke Heinrich Kaukmann GmbH Aue 3 D-77773 Schenkenzell, Germany Supplier:
same
Type:
Cotton flakes FB1/035
Manufacturer: Malayan Adhesives & Chemicals Sdn Bhd No. 9 Jalan Utas 15/7, 40200 Shah Alam Selangor Darul Ehsan, Malaysia Supplier:
Brenntag GmbH Stinnes-Platz 1 D-45472 Mühlheim, Germany
Type:
Microballoons BJO - 0930
Coating Manufacturer: BASF Coatings GmbH Glasuritstr. 1, D-48165 Münster/Hiltrup, Germany Supplier:
Wessels & Müller AG Pagenstecherstraße 121, D-49090 Osnabrück, Germany
Type:
22
Glasurit HS-2K-Decklack
929-91/93/94 Glasurit HS Decklackhärter 352-50/91/216 Glasurit Einstellzusatz 55
Glasurit Zweischicht-Decklack Metallic/Uni/Perleffekt
352-50/91/216 Glasurit Einstellzusatz 90
Glasurit Zweischicht-Decklack Metallic/Uni/Perleffekt
93-E3
Glasurit Einstellzusatz
923-155
Glasurit MS-Klarlack
929-91/93/94 Glasurit HS Decklackhärter 352-50/91/216 Glasurit Einstellzusatz 285-100 VOC Glasurit Rapidfüller VOC, weiß
Page 14
51
929-55/56
Glasurit HS Füllerhärter
352-91
Glasurit Einstellzusatz
1006-26
Glasurit UP Spritzfüller, grau
948-22
Glasurit Härter
839-53
Glasurit UP-Schnellspachtel Page Date: 30. March 2012
Maintenance Manual EXTRA 500
948-36
Glasurit Härterpaste
293-10
Glasurit Einstellzusatz
934-0
Glasurit 1K-Kunststoffhaftprimer
Manufacturer: MOTIP DUPLI GmbH Kurt-Vogelsang-Straße 6 D-74855 Haßmersheim, Germany Supplier:
Wessels & Müller AG Pagenstecherstraße 121, D-49090 Osnabrück, Germany
Type:
presto Leichtspachtel prestolith easy
Manufacturer: PPG Aerospace PRC-DeSoto
51-30-02
Supplier:
Röder Präzision GmbH Am Flugplatz D-63329 Egelsbach, Germany
Type:
Fire protective coating N56582/T508 Clearcoat 4232-0303 Activator N39/1327 Thinner N39/3091
Metal Components Round Seamless Steel Tubing Manufacturer: MHP Mannesmann Hoesch Präzisrohr GmbH Postfach 1713, D-59061 Hamm, Germany Supplier:
Heggemann Autosport GmbH Zeppelinring 1 - 6, D-33142 Büren, Germany
Type:
WLB* 1.7734.4 various diameters and wall dimensions (for example: engine mount)
*WLB: Werkstoff Leistungsblatt, according to German standard DIN-WL Manufacturer: Pacific Tube Company 5710 Smithway Street Los Angeles, California 90040, USA Supplier:
Page Date: 30. March 2012
Wicks Aircraft Supply, Co. 410 Pine Street Highland, Illinois 62249, USA
51
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Maintenance Manual EXTRA 500
Type:
AISI 4130 N (MIL-T-6736) various diameters and wall dimensions (for example: support structure inside cabin)
Steel Sheet Metal Manufacturer: BÖHLER Edelstahl GmbH München, Germany Supplier:
BÖHLER Edelstahl GmbH Hansa Allee 321 D-40549 Düsseldorf, Germany
Type:
according to WLB* 1.7734.4 various dimensions
*WLB: Werkstoff Leistungsblatt, according to German standard DIN-WL Manufacturer: Cold Metal Products, Inc. 2301 So. Holt Road Indianapolis, In. 46241, USA Supplier:
Wicks Aircraft Supply, Co. 410 Pine Street Highland, Illinois 62249, USA
Type:
AISI 4130 N (MIL-S-18729) various dimensions
Coating Manufacturer: BASF Coatings GmbH Glasuritstr. 1, D-48165 Münster/Hiltrup, Germany Supplier:
Wessels & Müller AG Pagenstecherstraße 121, D-49090 Osnabrück, Germany
Type:
801-72 VOC
Glasurit Grundfüller EP VOC, grau
965-60
Glasurit Härter EP
352-91/216
Glasurit Einstellzusatz
22
Glasurit HS-2K-Decklack
929-91/93/94 Glasurit HS Decklackhärter 352-50/91/216 Glasurit Einstellzusatz
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51-30-03
Aluminium Components Aluminium Sheet Metal Manufacturer: Kaiser Aluminium & Chem. Corp. Spokane, Washington Supplier:
Westdeutscher Metallhandel Friedrich W. Hermann GmbH Manderscheidtstr. 76-78, Postfach 104245 45141 Essen
Type:
WLB* 3.1364 T3 (2024 T3) various dimensions WLB* 3.3214 T6 (6061 T6) various dimensions
*WLB: Werkstoff Leistungsblatt, according to German standard DIN-WL Manufacturer: various Supplier:
Westdeutscher Metallhandel Friedrich W. Hermann GmbH Manderscheidtstr. 76-78, Postfach 104245 45141 Essen
Type:
AlMg3hh (EN-AW-5754 H24) various dimensions (also band)
Tubings Manufacturer: Aluminium AG CH-5737 Menziken, Swiss Supplier:
Westdeutscher Metallhandel Friedrich W. Hermann GmbH Manderscheidtstr. 76-78, Postfach 104245 45141 Essen
Type:
WLB* 3.1354 T3 various dimensions WLB* 3.3214 T4 various dimensions
*WLB: Werkstoff Leistungsblatt, according to German standard DIN-WL Manufacturer: various Supplier:
Wicks Aircraft Supply, Co. 410 Pine Street Highland, Illinois 62249, USA
Type:
5052-0 various dimensions
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Maintenance Manual EXTRA 500
2024 T3 various dimensions Manufacturer: various Supplier:
Westdeutscher Metallhandel Friedrich W. Hermann GmbH Manderscheidtstr. 76-78, Postfach 104245 45141 Essen
Type:
AlMgSi 0.5 F22 (EN-AW 6060 T6) various dimensions
Coating Manufacturer: BASF Coatings GmbH Glasuritstr. 1, D-48165 Münster/Hiltrup, Germany Supplier:
Wessels & Müller AG Pagenstecherstraße 121, D-49090 Osnabrück, Germany
Type:
283-150 VOC Glasurit Grundfüller EP VOC 352-228 Glasurit Zusatzlösung 352-50/91 Glasurit Einstellzusatz 22 Glasurit HS-2K-Decklack 929-91/93/94 Glasurit HS Decklackhärter 352-50/91/216 Glasurit Einstellzusatz
Manufacturer: Parker & Anchem, Ambler, PA 19002 Supplier:
Aircraft Spruce
Chem. coating: for aluminium hardware metal (brackets, pedestals etc.) Type: Alodine No. 1201 (MIL-C-5541) Lacquer:
51-30-04
see above
Titanium Components Titanium Sheet Metal Manufacturer: Timet United Kingdom Supplier:
Tisto Titan und Sonderlegierungen GmbH Dinnendahlstraße 31 40235 Düsseldorf, Germany
Type:
WLB* 3.7034.1 and 3.7024.1 (firewall, nose gear box, lightning protection tank filler caps)
*WLB: Werkstoff Leistungsblatt, according to German standard DIN-WL Page 18
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Maintenance Manual EXTRA 500
51-30-05
Various Components Sealant Manufacturer: Le Joint Français Supplier:
Deutsche Hutchinson GmbH Rudolf-Diesel-Str. 20B 65760 Eschborn, Germany
Type:
PR 148 AF PR 1750 S PR 1750 A2 PR 1750 B2 PR 1829 B PR 812
Activator (for metal surfaces) Integral tank sealant sprayable Integral tank sealant, bolt sealing Sealant (tank, pressure cabin, fittings etc.) Window sealant Firewall sealant
Manufacturer: FLEET SUPPLIES, INC 215 Mahoning Avenue Cleveland, OH 44113, USA Supplier:
Aircraft Spruce and Speciality Co.
Type:
FUELUBE
Silicon Adhesive Manufacturer: Herrman Otto GmbH Krankenhausstr. 14 D-83413 Fridolfing, Germany Supplier:
same
Type:
Ottoseal S72
Manufacturer: Dow Corning GmbH Postfach 13 03 32 65201 Wiesbaden,Germany Supplier:
Brammer GmbH Daimlerstraße 51 76185 Karlsruhe, Germany
Type:
Dow Corning 732 white or clear (MIL-A-46106)
Manufacturer: Wacker Chemie AG Hannes-Seidel-Platz 4 81737 München, Germany Supplier:
Wacker Chemie AG Verkaufsbüro Stuttgart Sophienstr. 41 70178 Stuttgart, Germany
Type:
Elastosil E14 (RTV 1)
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Maintenance Manual EXTRA 500
Manufacturer: Momentive (formerly GE Silicones) 22 Corporate Woods Boulevard Albany, NY 12211, USA Supplier:
diverse
Type:
RTV 159 (high temperature & high strength Silicone)
Adhesive Manufacturer: Henkel AG & Co. KGaA Henkelstr. 67 D-40589 Düsseldorf, Germany Supplier:
Wessels & Müller AG Pagenstecherstraße 121, D-49090 Osnabrück, Germany
Type:
Loctite 243 Loctite 401 Loctite 406 Loctite 577 Loctite 601
Threadlocker Instant adhesive Instant adhesive Thread sealing Small gaps retainer
Corrosion Preventive Compound Manufacturer: LEAR CHEMICAL RESEARCH P.O. Box 1040, Mississauga L4Y 3W3 Ontario, Canada Supplier:
Global Aviation & Piper Parts GmbH Flughafen Kassel, D-34379 Calden
Type:
ACF-50
Sealing Material for Lightning Protection Manufacturer: Nycote Laboratoires 12750 Raymer Street North Hollywood, CA 91605 Supplier:
Aero Consultants PO Box 35, Grabenstrasse 8 CH-8606 Nänikon/Uster, Switzerland
Type:
Nycote 7-11 (MIL-S-4383)
Release Agent Manufacturer: CIBA Speciality Chemicals Inc. CH-4002 Basel, Switzerland
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51
Supplier:
Schurg GmbH Industriestr. 12 D-34537 Bad Wildungen, Germany
Type:
QV 5110 Page Date: 30. March 2012
Maintenance Manual EXTRA 500
51-60-00
CONTROL SURFACE BALANCING
51-60-01
Weighing and Determination of Control Surface Moments Weighing and determination of control surface moments is necessary after repairs or painting. All weighing of control surfaces is performed with surfaces removed from aircraft. Weigh the control surfaces including mass balances and brackets but without control rods. The RH elevator weight includes the trim tab installed and provisionally held in elevator surface plane by means of tape (see also Figure 51-3). Copy Figure 51-4, enter the values (W, m, r) and check whether the surface weights and moments are within the given tolerances. If they are not, contact the EXTRA for advice. For the determination of control surface moments follow the steps as described below and use two balancing mandrels like shown in the Figure 51-2:
A
B
(for outboard aileron hinge) Ø
Figure 51-2
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Balancing Mandrels
51
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Maintenance Manual EXTRA 500
Procedure Detail Steps/Work Items
Key Items
1 Remove the control surface.
Refer to Chapter 27
2 Reinstall the bolts in the brackets where applicable.
Aileron inboard hinge Elevator outboard hinge
3 When weighing RH elevator fix trim tab with tape. 4 Put the control surface on the balancing mandrels (use a wire for the trim tab).
Refer to Figure 51-3
5 Level control surfaces and weigh by means of a conventional spring balance (kg/gindication) at the given weighing points and enter the weight (m) in figure 4.
Refer to Figure 51-3
6 Measure distance of hinge center line to weighing point (r) and enter the value in Figure 51-4. 7 Calculate the control surface moment (M) in Figure 51-4. IMPORTANT
If values exceed the given tolerances in Figure 51-4 contact EXTRA before modifying of control surfaces. 8 If necessary modify control surface under EXTRA’s guidance. 9 Reinstall the control surfaces.
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Hinge center axis
Rudder
r -m Weighing point
r
Weighing point
m Aileron
Hinge center axis
Hinge center axis
Elevator (RH) Wire
r Weighing point m
Trim tab
Tape r Weighing point m
Hinge center axis
Figure 51-3
Control Surface Balancing
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Maintenance Manual EXTRA 500
Permissible Weights and Moments 5.53 5.5 5.6
4.5
6.5
7.13
6.8
450
440
Rudder
400
350
350 300
290
Elevator (LH)
250
Elevator (RH) 220
200 50 0
0
Aileron -40
-50 4.0
4.5
5.0
5.5
6.0
7.0
6.5
7.5
0.50
0.37 50 25
30
Trim tab
15
0 0.30
0.35
0.40
Weights Aileron LH:
(W) . . . . . . . . . . kg
Aileron RH:
(W) . . . . . . . . . . kg
Rudder:
(W) . . . . . . . . . . kg
0.45
0.50
0.60
0.55
0.65
Elevator LH: (W) . . . . . . . . . . kg Elevator RH: (W) . . . . . . . . . . kg
x
x
Trim Tab:
(W) . . . . . . . . . . kg
Moments Aileron LH:
(m:) . . . . . . . . . kg x 9.81m/s x (r:) . . . . . . . . . cm = (M:) . . . . . . . . . . . . Ncm
Aileron RH:
(m:) . . . . . . . . . kg x 9.81m/s2 x (r:) . . . . . . . . . cm = (M:) . . . . . . . . . . . . Ncm
Rudder:
(m:) . . . . . . . . . kg x 9.81m/s2 x (r:) . . . . . . . . . cm = (M:) . . . . . . . . . . . . Ncm
2
Elevator LH: (m:) . . . . . . . . . kg x 9.81m/s2 x (r:) . . . . . . . . . cm = (M:) . . . . . . . . . . . . Ncm Elevator RH: (m:) . . . . . . . . . kg x 9.81m/s2 x (r:) . . . . . . . . . cm = (M:) . . . . . . . . . . . . Ncm Trim Tab: Figure 51-4 Page 24
51
(m:) . . . . . . . . . kg x 9.81m/s2 x (r:) . . . . . . . . . cm = (M:) . . . . . . . . . . . . Ncm Permissible Weights and Moments Page Date: 30. March 2012
Maintenance Manual EXTRA 500
51-70-00
REPAIRS
51-70-01
Repair of Reinforced Glass and Carbon Fibre Components
IMPORTANT
Repair of composite parts has to be carried out only by qualified and authorized personnel. If the aircraft is damaged, proceed as follows. First conduct a careful visual inspection of the surface and the damaged area. Frequently, the damage extends to further components, sometimes a fracture will continue invisible beneath the surface. Perform the repair work with utmost care. The external shell of the wing and empennage as well as all structural parts including the fuselage are stressed; a failure of this bonded structure can lead to an aircraft crash. In order to eliminate dangerous stress concentrations, avoid changes in cross-sectional areas.
IMPORTANT
The resin-hardener mixture ratio must be precisely maintained (± 0.5 %). Clean cups and tools must be used. The weight ratio of fabric to resin mixture should be approximately 50:50. Immediately prior to applying the wet laminate, sand and vacuum clean the repair area, so that no dirt and dust is involved which could prevent a secure adhesion.
Sanding carbon and glass fibre laminates gives off a fine dust that may WARNING cause skin and/or respiratory irritation unless suitable skin and respiration protection is used. Carbon-tetracloride or Acetone used for cleaning repair areas are WARNING flammable liquids and should be used with proper ventilation and safety equipment. IMPORTANT
As with plywood grain, the direction of the various fibres (longitudinal or diagonal) is of great importance for the stability. The number of layers required to restore the stability in the damaged area can be taken from the layer sequence / placement plan. (Refer to the respective Chapters) It is necessary to know the number and direction of layers in the damaged area, in order to be able to replace them with the original number. In all cases, the thickness of the laminate has to be measured with a vernier calliper for the exact determination of the laminate thickness. One technique to learn about the number of layers is to burn a small piece taken from the damaged area. The resin will burn off, leaving the glass and/or carbon fabric to be inspected for the number of layers and the type of fabric. Creating a scarfed overlap takes time. Sand away as much of the old material, so that the new fabric patches do not project beyond the contour.
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In order to shorten the curing time, a heater can be used to increase the ambient temperature. CAUTION
Too high temperature will cause large air bubbles in the laminate. Local overtemperature can be prevented by using a foil tent which leads the hot air stream. The curing cycle must be maintained as stated. Use a thermometer to monitor the temperature.
IMPORTANT
After repair of control surfaces, check for proper balance (Manufacturer will provide service instructions to manufacturer authorized repair stations). It is recommended to prepare test specimen at the same time as the actual repair is accomplished. These can then be subject to a material test to establish the quality of the laminate in the repaired part. To make this determination valid, the specimen must be assembled with the same style of fabric and resin mixture. Subsequently the specimen must be subject to the curing pressure, temperature and time identical with those in the actual repair.
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51-70-02
Repair of Sandwich Material Three types of core materials are used for sandwich on the EXTRA 500: 1 PMI or PVC hard foam, 2 Honeycomb 3 Plywood, with carbon fibre shells. The following section describes the repair of these types of sandwich. Different processing techniques for these materials, if necessary, are also described. a) Minor Surface Damage Around a visible crack, the laminate may be separated from the core material. Determine the extent of this area by coin tapping. Remove the separated laminate carefully using a sanding disk, sanding block or a sharp knife. Prepare a scarfed overlap of the laminate around the damaged area. Overlap lenght per fabric layer min. 20 mm.
IMPORTANT
Ratio (laminate thickness : overlay lenght) min. 1 : 50
Figure 51-5
Minor Surface Damage
After preparing the scarfed overlap, clean the repair area thoroughly as follows: 1 Remove the sanding dust with a pneumatic vacuum cleaner 2 Clean the scarfed overlaps with carbon-tetrachloride or acetone in case of dirt or grease was trapped during the preparation Damaged core material has to refilled with a mixture of resin and microballoons (weight ratio 100:15). Apply resin mixture to the repair area and lay on fabric in accordance to the layer sequence plans. Ensure to use correct style and direction of fabric. IMPORTANT
Repair area must be clean of dirt, dust and grease! Lay out the required number and size of fabric pieces on a piece of colored plastic foil and soak (wet) them with resin mixture; subsequently position them on the repair area.
IMPORTANT
Remove the plastic foil after each positioning process. For a repair of honeycomb sandwich parts you have to observe the following: The repair area has to be cured under condition of vacuum bagging. For vacuum bagging, proceed as follows: 1 Apply nylon peel ply on the last repair fabric layer.
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2 Perforate a clean, thin plastic foil with a thick needle (max.spacing of holes: 20 mm x 20 mm) - mainly in the area of the honeycomb - and lay it on the repair area. 3 Lay a jute cloth (weave) or equivalent bleeder cloth on this perforated plastic foil. 4 Lay an air tight plastic foil upon the jute weave and seal their edges to the surrounding surface using an adhesive tape. 5 Apply suction with a vacuum pump (pressure approx. .7 bar/ 10 psi). 6 Apply the thermal curing cycle. 7 Following the curing cycle remove vacuum bagging material and nylon peel ply. NOTE
After the pre-curing period at room temperature, the repaired area has to be cured according to the temperature cycle as showed below.
Figure 51-6
Curing Cycle Resin L 20 / SL
After the curing process is completed, the repair area can be sand leveled to the surrounding area. Sand only the edge thickness of repair laminate. CAUTION NOTE
For painting of the repair area refer to Chapter 51-70-06. b) Damage of Complete Sandwich If the inner laminate is also damaged, first remove the upper laminate within the area, where no secure bond connection to the core material is suspected. Trim out the complete damaged portion of core material to a circular or elliptical shape. The damaged area of the inner laminate has to be taken out as well. Make sure not to increase the disbond area by preparing the hole. Preferably use a hand held milling machine. In case of cutting with a saw, the pulsation stress may
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peel off the inner laminate (secondary damage). If the extent of the disbonded area on the inner laminate exceeds the prepared cut out, increase the cut out of material and upper laminate. Prepare a scarfed overlap of laminate around the circular cut out. Overlap lenght of inner laminate should not be less than 20 mm. IMPORTANT
Ratio (laminate thickness : overlay lenght) min. 1 : 50 Prepare a replacement block of core material (foam or honeycomb) with equivalent diameter and thickness. Cut it to fit snuggly in the trimed hole. In case of foam core, coat one side with a mixture of resin and microballoons (ratio 100:15). Apply prelaminated fabric layers required for the inner laminate on this side of the core filler block. Ensure correct style and direction of fabric. After precuring the laminate at elevated room temperature (30°C), scarf the overlap and sand the upper overlapping core material down, up to the surrounding core material. Subsequently clean the repair area thoroughly as follows: 1 Remove the sanding dust with a pneumatic vacuum cleaner. 2 Clean the scarfed overlaps with carbon-tetrachloride or acetone in case of dirt or grease was trapped during the preparation.
Carbon-tetrachloride or acetone used for cleaning repair areas are WARNING flammable liquids and should be used with proper ventilation and safety equipment. IMPORTANT
Repair area must be free of dirt and grease. Wet all surfaces of the backing plate and the scarfed area with resin mixture. Lay on prelaminated fabric layer in accordance to the layer sequence plan. Ensure correct style and direction of fabric.
Figure 51-7
Damage of Complete Sandwich
Lay out the required number and size of fabric pieces on a piece of plastic foil and wet them with resin mixture. Subsequently position them on the repair area. IMPORTANT
Remove the plastic foil after each positioning process. The repair area has to be cured under condition of vacuum bagging. Proceed as follows: 1 Apply nylon peel ply on the last repair fabric layer. 2 Perforate a clean, thin plastic foil with a thick needle (max.spacing of holes: 20 mm x 20 mm) - mainly in the area of the honeycomb - and lay it on the repair area.
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3 Lay a jute cloth (weave) or equivalent bleeder cloth on this perforated plastic foil. 4 Lay a second plastic foil upon the jute weave and seal their edges to the surrounding surface using an adhesive tape. 5 Apply suction with a vacuum pump (pressure approx. .7 bar/ 10 psi). 6 Apply the thermal curing cycle. 7 Following the curing cycle carefully remove vacuum bagging material and nylon peel ply. NOTE
After the pre-curing period at room temperature, the repaired area has to be cured according to the temperature cycle as given by the laminate's manufacturer. After the curing process is completed, remove the nylon peel ply. The repaired area can be sand leveled with the surrounding area. Sand only the edge thickness of repair laminate!
CAUTION NOTE
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For painting of Chapter 51-70-06.
the
repair
area
proceed
like
mentioned
in
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Maintenance Manual EXTRA 500
51-70-03
Repair of Laminates Minor Damage Scarf the edges of the minor damage area with sandpaper. Minimum lenght of scarf per fabric layer approx. 20 mm; ratio (laminate thickness : scarf lenght) approx. 1: 50. Following the scarf procedure, clean the repair area thoroughly: 1 Remove the sanding dust with a pneumatic vacuum cleaner 2 Clean the scarfed overlaps with carbon-tetrachloride or acetone in case of dirt or grease was introdued during the preparation. Repair area must be free of dirt, dust and grease.
CAUTION Wet the prepared scarfed areas with resin mixture. Lay on prelaminated fabric layer in accordance to the layer sequence plan. Ensure correct style and direction of fabric. Apply nylon peel ply on the last repair fabric layer. NOTE
IMPORTANT
Lay out the required number and size of fabric pieces on a piece of colored plastic foil and wet them with resin mixture. Subsequently position them on the repair area. Remove the plastic foil after each positioning process. After the curing process has been completed, remove the nylon peel ply. The repair area can be sand leveled with the surrounding area. Sand only the edge thickness of repair laminate!
CAUTION Refinish the surface according Chapter 51-70-06 (Painting). If the extent of the damaged area exceeds 10 cm (4 inches) a large damage repair is required. Carefully trim out the damaged portion to a circular or oval shape. Prelaminate a backing plate from two layers of glass fibre fabric and resin mixture, which must be approx. 20 mm larger than the damaged area. Apply nylon peel ply as external layer. Sandwich the resin wetted layers between two sheets of plastic foil. Work the excess resin out and allow the plate to cure at elevated room temperature for 8 hours on a flat surface or a plasticfoil-covered surface of the proper curvature near the damaged area, or the same location on a comparable undamaged part. Following the curing cycle remove plastic foil and nylon peel ply. Bond the backing plate to the inside using a mixture of resin and cotton flocks, and adapt to the contour. Cure the bonding at elevated room temperature for 8 hours. Subsequently scarf the edges of the damaged portion with sandpaper. Minimum lenght of scarf per fabric layer approx. 20 mm. IMPORTANT
Ratio (laminate thickness : scarf lenght) approx. 1: 50. Following the scarf procedure, clean the repair area thoroughly:
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1 Remove the sanding dust with a pneumatic vacuum cleaner 2 Clean the scarfed overlaps with carbon-tetrachloride or acetone in case of dirt or grease was trapped during the preparation of the overlap. IMPORTANT
Repair area must be free of dirt, dust and grease. Wet all surfaces of the backing plate and the scarfed area with resin mixture. Lay on prelaminated fabric layer in accordance to the layer sequence plan. Ensure correct style and direction of fabric.
NOTE
IMPORTANT
Lay out the required number and size of fabric pieces on a piece of colored plastic foil and wet them with resin mixture. Subsequently position them on the repair area. Remove the plastic foil after each positioning process. The repair area has to be cured under condition of vacuum bagging. Proceed as follows: 1 Apply nylon peel ply on the last repair fabric layer 2 Perforate a clean, thin plastic foil with a thick needle (max. spacing of holes: 20 mm x 20 mm) - mainly in the area of the honeycomb - and lay it on the repair area.
Figure 51-8
Repair of Minor Damage
Large Damage If the extent of the damaged area exceeds 100 mm (4 inches) a large damage repair is required. Carefully trim out the damaged portion to a circular or oval shape. Prelaminate a backing plate from two layers of glass fibre fabric and resin mixture, which must be approx. 20 mm larger than the damaged area. Apply nylon peel ply as external layer. Sandwich the resin wetted layers between two sheets of plastic foil. Work the excess resin out and allow the plate to cure at elevated room temperature for 8 hours on a flat surface or a plasticfoil-covered surface of the proper curvature near the damaged area, or the same location on a comparable undamaged part. Following the curing cycle remove plastic foil and nylon peel ply. Bond the backing plate to the inside using a mixture of resin and cotton flocks, and adapt to the contour. Cure the bonding at elevated room temperature for 8 hours. Subsequently scarf the edges of the damaged portion with sandpaper. Minimum lenght of scarf per fabric layer approx. 20 mm. IMPORTANT Page 32
51
Ratio (laminate thickness : scarf lenght) approx. 1: 50. Page Date: 30. March 2012
Maintenance Manual EXTRA 500
Following the scarf procedure, clean the repair area thoroughly: 1 Remove the sanding dust with a pneumatic vacuum cleaner 2 Clean the scarfed overlaps with carbon-tetrachloride or acetone in case of dirt or grease was trapped during the preparation of the overlap. IMPORTANT
Repair area must be free of dirt, dust and grease. Wet all surfaces of the backing plate and the scarfed area with resin mixture. Lay on prelaminated fabric layer in accordance to the layer sequence plan. Ensure correct style and direction of fabric.
NOTE
Lay out the required number and size of fabric pieces on a piece of colored plastic foil and wet them with resin mixture. Subsequently position them on the repair area.
IMPORTANT
Remove the plastic foil after each positioning process. The repair area has to be cured under condition of vacuum bagging. Proceed as follows: 1 Apply nylon peel ply on the last repair fabric layer. 2 Perforate a clean, thin plastic foil with a thick needle (max.spacing of holes: 20 mm x 20 mm) - mainly in the area of the honeycomb - and lay it on the repair area. 3 Lay a jute cloth or equivalent bleeder cloth on this perforated plastic foil. 4 Lay an air tight plastic foil upon the jute weave and seal their edges to the surrounding surface using an adhesive tape. 5 Apply suction with a vacuum pump (pressure approx. .7 bar/ 10 psi). 6 Apply the thermal curing cycle. 7 Following the curing cycle carefully remove vacuum bagging material and nylon peel ply.
NOTE
After the pre-curing period at room temperature, the repaired area has to be cured according to the temperature cycle as given by the laminate's manufacturer. After the curing process is completed, the repair area can be sand leveled to the surrounding area. Sand only the edge thickness of repair laminate!
CAUTION Refinish the surface according Chapter 51-70-06.
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Maintenance Manual EXTRA 500
51-70-04
Repair of Spars and Elements of the Pressure Cabin Structural elements of the pressure cabin The pressurized part of the fuselage runs from the front bulkhead (firewall position) to the rear pressure dome positioned at X6125. Main structure elements are: Flat front bulkhead, skin, frames, longerons, keel beams and the rear pressure dome (GRP). The height of the honeycomb core in the pressurized part is 30mm (except shell below the wing). Longerons are integrated in the skin sandwich.
Spars of Wing and Empennage The spars consists of carbon fibre roving or UD-tape caps, carbon fibre webs and PMI foam or plywood/honeycomb cores. IMPORTANT
51-70-05
The spars and structural elements of the pressure cabin are highly stressed; a failure of this bonded structure can result in loss of the aircraft! In all cases, the repair of a spar must be considered as a largescale repair with a Damage Class 1 (Refer to Chapter 51-10-01 Damage Classification). EXTRA has to be contacted prior to repair!
Structural Repair of Steel Components Restoration of damaged steel designed structures to their original design strength, shape and alignment involves careful evaluation of the damage, followed by exacting workmenship in performing the repairs.
IMPORTANT
Should structural repairs practicable on the aircraft be necessary, refer to "Aircraft Inspection and Repair FAA AC 43.13-1A" and "Aircraft Alterations Acceptable Methods, Techniques and Practices FAA AC 43.13-2A".
IMPORTANT
Alterations or repair of the airplane must be accomplished by licensed personnel. Consult EXTRA in case of doubt about a repair not specifically mentioned there. Consider, that different types of steel are being used on the aircraft structures, so as steel tubes, brackets, connections etc. (WLB 1.7734.4 and AISI 4130 N type steel). The two steel types shall not be mixed in repair. Also refer to Chapter 51-30-02.
NOTE
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51
If welding work must be performed, use only the TIG procedure (Tungsten Inert Gas). Use welding wire 1.7734.2 for 1.7734.4 and AISI 4130 N or equivalent, depending on the respective steel type, for welding additive.
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Maintenance Manual EXTRA 500
51-70-06
Painting of Composite Parts
Coating materials may cause sensitization by inhalation and skin contact. WARNING Hardeners and coating materials ready for use can have an irritant and sensitizing effect upon the skin and respiratory tracts and cause allergic reactions. Provide for a continuous supply of fresh air during and also after the WARNING application, do not inhale the vapors and wear a breathing mask during the spray application of these materials. Persons suffering from an allergy or being prone to diseases of the respiratory tracts must not get in contact with coating materials. Refer to the manufacturer technical information sheet! After curing cycle the surface of repared area can be sanded with sandpaper (80 grade). Indentations are filled with Presto putty light. Subsequently achieve a surface as uniformly rough as possible using a finer dry sandpaper (150 or 320 grade). Prior to paint application, the surface of the repair area must be cleaned thoroughly of all sanding dust, separation compounds and other foreign materials. Subsequently apply 285-100 VOC Glassodur Rapidfüller with a spray gun. NOTE
The Rapidfüller (rapidfiller) must be completely dry before the covering paint can be applied. For the final sanding, use 400 grade wet sandpaper to achieve a smooth clean surface. Allow surface to dry. Paint application of 22, 55 or 90 Glassodur Decklack is performed with a spray gun. Paint can be mixed with small quantities of reducer. After completion of the painting, polish the repair area.
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Maintenance Manual EXTRA 500
51-70-07
Aluminium and Steel Components Refinishing Complete procedure necessary to remove existing paint from aluminium and steel components and then to repaint them as described in the following paragraphs.
Degreasing Cleaning solvents can be toxic and volatile. Use only in well ventilated WARNING areas. Avoid physical contact with solvent and do not inhale vapors. Keep solvent containers covered when not in use. CAUTION
Before stripping parts, remove all fittings, O-rings, nuts, bolts, washers, pistons, bearing cups, etc.
1 Clean all metal parts by immersing in a clean degreasing solution. An alkaline based solution is recommended for aluminium and magnesium parts. 2 Hardened dirt or grease may be removed with soft bristle brush, or by soaking in cleaning solution. 3 Where necessary clean bearing cones carefully in a separate container of clean solvent. Do not spin bearing cones with compressed air. CAUTION 4 After cleaning, thoroughly dry all metal parts with filtered, dry compressed air. 5 It is recommended that all O-rings, backup rings, and wipers be replaced at each overhaul. However, if necessary, O-rings may be reused, but should be put back into that position from which they had been removed. 6 Wipe down O-rings, backup rings, wipers, or other rubber parts with a clean dry cloth. Lubricate with a suitable O-ring lubricant prior to installation.
Paint Removal Disassemble components to the level required for repainting, then proceed as follows. Stripping solvents can be toxic and volatile. Use only in well ventilated WARNING areas. Avoid physical contact with solvent and do not inhale vapors. Keep solvent containers covered when not in use. CAUTION
Before stripping parts, remove all fittings, O-rings, nuts, bolts, washers, pistons, bearing cups, etc. Parts must be totally immersed in solvent, to maximize cleaning.
1 Degrease part as per degreasing paragraph. 2 Totally immerse part in paint removing solvent. Portions not totally covered by solvent will begin to corrode. NOTE
Stripping agents are commercially available for removing topcoat and primer. Follow manufacturer's recommendations for use and disposal of stripping solutions. 3 Remove part from solvent and rinse thoroughly with water heated to 160° to 180°F (71° to 82° C). Flush solvent from all cavities and threaded holes where
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entrapment might occur. 4 Thoroughly dry part with filtered, dry compressed air. 5 Where applicable refer to inspection procedures given in the respective chapters for specific parts to locate possible defects. NOTE
Refinishing should be completed as soon as possible; unprotected parts will begin to corrode.
Repainting Paint all surfaces except those which are subjected to friction (bearing surfaces, anchor bolt bores, etc.). Proceed as follows: 1 Parts to be repainted should be cleaned and stripped as per instruction in degreasing and paint removal paragraphs. 2 Aluminium parts should have a protective barrier between the topcoat and base metal. It is recommended that they are treated with solutions listed in Chapter 51-30. 3 Apply solution liberally and evenly. Allow solution to set from 1 to 5 minutes. The solution must completely wet the surface and overlap onto the adjoining anodize. 4 Remove excess coating by flushing with clean water. 5 Paint parts with one coat of wash primer. Allow to dry thoroughly. 6 Paint parts with one coat of lacquer listed in Section 51-30. Allow to dry thoroughly before reassembly.
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Chapter 52 Doors
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Table of Contents
52-00-00
GENERAL ........................................................................................................ 3 Troubleshooting.................................................................................................. 3
52-10-00
PASSENGER/CREW....................................................................................... 4 Description.......................................................................................................... 4
52-20-00
EMERGENCY EXIT ....................................................................................... 5 Description.......................................................................................................... 5
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52-00-00 NOTE
GENERAL For replacement and adjustment of door bolts and fittings contact EXTRA
Troubleshooting Complaint
Possible Cause
Remedy
Pressure cabin leakage
Erroneous cabin door or emergency exit seal installation or damaged seal
Check seals for damages and correct installation. If seal is damaged replace it.
Exterior door locking mechanism damaged
Rotation of outer door handle without previously pulling it against its stop
Replace central door actuating mechanism
Unusual high operating forces or lacking ability to reach the fully open or closed position of actuation handles
Misadjusted locking mechanism
Remove interior panel, check mechanism for proper adjustment
Lacking lubrication
Remove interior panel, clean and lubricate mechanism
Damaged or worn locking mechanism
Remove interior panel, replace damaged or worn parts, readjust mechanism
Faultive mechanical locking indication (8 sight glasses)
Mechanically damaged indication or locking mechnism
Remove interior panel, check locking mechanism and position indication
Door warning light does not illuminate with door open
Light, wiring or switch defective
Identify and replace component
Door switch misadjusted
Remove interior panel, adjust switch actuation
Wiring or switch defective
Identify and replace component
Door switch misadjusted
Remove interior panel, adjust switch actuation
Door warning light illuminates in spite of closed door
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52-10-00
PASSENGER/CREW Description The entry door at the left side of the fuselage is a two-section, outward opening door. The upper part folds up held in upper position by a telescopic lift cylinder, and the lower part folds down, limited by two cables and provides a step for easy in boarding and deplaning passengers. Ensure wing flaps are retracted before opening the door.
CAUTION For opening the door from outside, pull handle out completely, turn handle clockwise and deploy upper door. Then rotate up the sill lever which is now accessible on the lower door, stand clear and deploy the lower door. For opening the door from inside, press safety button, turn handle counterclockwise and deploy upper door. Then rotate up the sill lever which is now accessible on the lower door, stand clear and deploy the lower door. For closing the doors reverse the above given procedure. Ensure that outer handle is sunk, inner handle is locked and all eight inspection glasses inside show green color.
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52-20-00
EMERGENCY EXIT Description In emergency case the upper door can be opened even with wing flaps down. The upper door shall then be strongly pressed against the wing flap edge, which will bend and thus increasing the upper door opening angle. This allows deploying the lower part. The middle RH side window opposite to the passenger entry door is built as an emergency exit window. For opening the emergency exit window from outside remove the clear plastic cover, turn the handle clockwise as marked and then push window inside and down. For opening the emergency exit window from inside swivel up the handle, turn the handle counterclockwise as marked and then pull window inside and down.
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Chapter 55 Stabilizers
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Table of Contents
55-00-00
GENERAL ........................................................................................................ 3 Description.......................................................................................................... 3
55-10-00
HORIZONTAL STABILIZER ....................................................................... 4 Description.......................................................................................................... 4 Overview Horizontal Stabilizer .......................................................................... 5
Figure 55-1 55-20-00 Figure 55-2 Figure 55-3 Figure 55-4
ELEVATOR...................................................................................................... 6 Description.......................................................................................................... 6 Elevator Control Surface (LH) ........................................................................... 7 Elevator Control Surface (RH)........................................................................... 8 Elevator Trim Tab, (on RH elev. only) ............................................................... 9
55-30-00
VERTICAL STABILIZER............................................................................ 10 Description........................................................................................................ 10
55-30-01 Figure 55-5
Fin Tip ............................................................................................................. 10 Fin Tip .............................................................................................................. 10 Removal/Installation......................................................................................... 11
55-40-00
RUDDER ......................................................................................................... 12 Description........................................................................................................ 12 Overview Rudder Mounting.............................................................................. 13 Bottom Rudder Mounting (including bell crank and centering device) ........... 14 Middle and Upper Rudder Mounting ............................................................... 14
Figure 55-6 Figure 55-7 Figure 55-8
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55-00-00
GENERAL Description The empennage is the element which controls the aircraft around the pitch and yaw axis. It is a T-tail design with extended fin and fixed straight main elements. The empennage is composed of the following elements: • Horizontal stabilizer • Elevator • Vertical stabilizer • Rudder
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55-10-00
HORIZONTAL STABILIZER Description The fixed straight tapered horizontal stabilizer has 2° anhedral. The NACA 0012 airfoil section is chosen for the horizontal stabilizer. The elevator hinge line is positioned at 62% of the horizontal stabilizer chord. The entire horizontal stabilizer structure is of CFRP sandwich construction with two CFRP spars. The horizontal stabilizer is attached to both vertical stabilizer front and rear spar.
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Figure 55-1
Overview Horizontal Stabilizer
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55-20-00
ELEVATOR Description Elevator The elevator is divided in the LH & RH elevator control surface due to the anhedral of the horizontal stabilizer and sweep back angle of the elevator hinge line. Each elevator control surface is attached separately to the rear spar of the horizontal stabilizer at three points. All attachment points incorporate spherical bearings. For aerodynamical reasons the elevator control surface itself features an shielded horn balance at the tip which incorporates the necessary mass balance to prevent flutter. Each elevator control surface is actuated by a push pull rod which is connected to the central cable quadrant mounted at the front spar of the vertical stabilizer. For elevator deflection refer to Chapter 06-10-08. Each entire elevator control surface structure is of one spar dual torsion box all-CFRP-composite construction. Elevator Tab The elevator trim is achieved by an elevator trim tab attached to the inboard trailing edge of the right elevator with a full length piano-type hinge. The trim tab is actuated by a fail safe push pull rod which is attached to a jack screw type actuator in the horizontal stabilizer. For elevator trim tab deflection refer to Chapter 06-10-08.
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Figure 55-2
Elevator Control Surface (LH)
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Figure 55-3
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Elevator Control Surface (RH)
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Figure 55-4
Elevator Trim Tab, (on RH elev. only)
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55-30-00
VERTICAL STABILIZER Description The vertical stabilizer consists of two parts. The lower part reaches to the horizontal stabilizer and is structurally integrated with the fuselage. The upper part (fin tip) is attached to the lower part with bolts. The vertical fin has the cambered NACA 2412 profile at the root gradually changing in the NACA 0012 airfoil section at the horizontal stabilizer. This is to counter the propeller induced cross flow. The fin tip is a NACA 0012 airfoil. The entire vertical stabilizer structure is of CFRP sandwich construction with two CFRP spars. The shell of the lower part of the vertical stabilizer is a part of the fuselage shell.
55-30-01
Fin Tip Side View
LN bolts
MS bolts
Strobe light
Top View
Figure 55-5 Page 10
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Removal/Installation Detail Steps/Work Items
Key Items
High voltage can cause injuries! WARNING
Pull out the STROBE-LT circuit breaker and let bleed down power supply for 10 minutes after shutting off before beginning any work on the strobe light systems.
2 Remove LH and RH gap fairing.
Refer to Chapter 51-00-01
3 Remove fin tip attaching bolts.
10 bolts
4 Lift fin tip some centimeters. 5 Disconnect strobe light power supply connectors.
In the front section
6 Remove fin tip. CAUTION
Reverse polarity of the input power, for just an instant, will permanently damage power supply. This damage is sometimes not immediately apparent, but will cause failure later on. Black lead is negative.
7 Install in reverse sequence of removal.
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55-40-00
RUDDER Description The rudder hinge line is positioned at 73% of the vertical stabilizer chord. To prevent flutter the rudder is mass balanced at the upper overhanging circular nose section. The entire rudder structure is of one spar dual torsion box all-CFRP-composite construction. The rudder is attached to the vertical stabilizer rear spar at three points. All hinges incorporate ball bearings. It is actuated by a bell crank attached to the bottom. A spring loaded centering device is located at the rudder actuation bell crank, which keeps the rudder in the neutral position and enlarges the control forces. For rudder deflection refer to Chapter 06-10-08.
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Figure 55-6
Overview Rudder Mounting
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* *
*) For rudder deflection refer to Chapter 06-10-08 Figure 55-7
Bottom Rudder Mounting (including bell crank and centering device)
Figure 55-8
Middle and Upper Rudder Mounting
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Notes on figures 55-06 and 55-07: Note 1: Install bushings EA-35020.01 and -45441.01 as well as pin of 35631.00 and -35633 with grease according MIL-G-81322D (e.g. Aeroshell Grease 22C) Note 2: Install spherical bearings and retaining rings with corrosion protectant according LN9368-5903 (e.g. Mastinox 6856H) Note 3: deleted in drawing Note 4: Adjust bolts DIN933-M5x25 for correct rudder deflection (refer to Chapter 06-10-08).
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Chapter 56 Windows
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TABLE OF CONTENTS
56-00-00
GENERAL ........................................................................................................ 3 Description.......................................................................................................... 3
56-10-00
FLIGHT COMPARTMENT ........................................................................... 4
56-10-01
Windshield......................................................................................................... 4 Description.......................................................................................................... 4
56-20-00
CABIN ............................................................................................................... 5
56-20-10
Cabin Windows................................................................................................. 5 Description.......................................................................................................... 5
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56-00-00
GENERAL Description For the EXTRA 500 windows two materials are used for the windows of the pressure cabin: Stretched acrylic material (MIL-P-25690) Cast acrylic material (MIL-P-8184) The windows are highly stressed members of the pressure vessel. Scratches have to be avoided, any crack in a window has to be repaired before the aircraft is operated in pressurized mode again. For repair, removal and installation procedures contact EXTRA. The middle window on the right side of the passenger compartment is designed as emergency exit. Refer to Chapter 52-20-00 for further information.
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56-10-00
FLIGHT COMPARTMENT
56-10-01
Windshield Description The EXTRA 500 is equipped with a two piece windshield divided by a structural strut between the pilot’s and copilot’s side. The pilot’s windshield is a laminated design consisting of an inner layer of stretched acrylic material followed by a layer with an integrated electric windshield heat (refer to chapter 30). The outer layer is made from cast acrylic material. The copilot’s windshield consists of a monolithic acrylic pane consisting of stretched acrylic material. The copilot’s side does not include an electric windshield heat.
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56-20-00
CABIN
56-20-10
Cabin Windows Description The cabin windows feature double panes for redundancy in case of structural failure of the outer pane. The outer pane is carrying the pressurization loads during normal operation and consist of stretched acrylic material. The inner pane is consisting of cast acrylic material and does not carry any load in normal operation. The room between the two panes is connected to the pressure vessel by a small orifice during normal pressurization. In case of structural failure of the outer pane the inner pane takes the pressurization loads and the orifice limits the leakage. The middle windows on both sides are integrated in either the normal door on the left side or into the emergency exit panel on the right side. Structurally they are identical to the fixed windows. All 6 cabin windows are contoured to match the fuselage shape individually.
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Chapter 57 Wings
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TABLE OF CONTENTS 57-00-00
GENERAL ........................................................................................................ 3 Description.......................................................................................................... 3
57-10-00
CENTER WING ............................................................................................... 4 Description.......................................................................................................... 4 Removal.............................................................................................................. 4 Installation .......................................................................................................... 6 Hoisting the Wing ............................................................................................... 6 Wing to Fuselage Attachment............................................................................. 7
Figure 57-1 Figure 57-2 57-30-00
WING TIPS....................................................................................................... 8 Description.......................................................................................................... 8
57-50-00
TRAILING EDGE AND TRAILING EDGE DEVICES.............................. 9
57-50-01
Flaps ................................................................................................................... 9 Description.......................................................................................................... 9 Removal/Installation........................................................................................... 9 Inner Flap Structure ......................................................................................... 10 Outer Flap Structure ........................................................................................ 11
Figure 57-3 Figure 57-4 57-60-00
Figure 57-5
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AILERONS AND ELEVONS........................................................................ 12 Description........................................................................................................ 12 Removal/Installation......................................................................................... 12 Aileron Structure .............................................................................................. 13
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57-00-00
GENERAL Description The EXTRA 500 features a straight tapered all composite cantilever wing. The one piece wing consists of a CFRP wing-box serving as structure for the bending and torsional loads. The GFRP nose section equipped with the de-ice boots (=> ref. to Chapter 30) is part of the aerodynamic wing section and carries shear due to aerodynamic lift forces into the wing box structure. To achieve minimum drag natural laminar flow wing sections have been designed specially for the EXTRA 500. Wing relative thickness is 16,5% at the root section gradually changing into the 12% wing section used at the tip. Wing twist distribution is selected to keep the wing sections within the low drag bucket in cruise flight. Wing-Structure Spars: The wing uses 1 double cell front spar at 22.6% chord and 1 single cell rear spar at 68.6% chord (carry-thru) to 60% chord (tip). Caps and webs are made of CFRP with PMI foam core. The tiplets are not part of the primary wing structure. Skin: The wing skin is a composite sandwich structure with CFRP facing layers and honeycomb core. Ribs: In the torsion wing box 7 CFRP ribs are used each side: structural root and fuel tank rib at Y±550, slosh rib with flapper valves at Y±800, slosh rib at Y±1550, structural and fuel tank rib at Y±2550, fuel tank end rib (long range) at Y±4300, structural rib at Y±4400 and the structural tip rip at Y±5500, which extends to the nose section. In addition 5 GFRP ribs are used in the D-nose section each side at Y± 550, Y±1550, Y±2550, Y±3400, Y±3600, Y±4400. Fuel tank: The wing fuel tank is an integral part of the wingbox between the main spars, the root rib at Y±550 and Y±4300. Flaps: => refer to section 57-50 Ailerons: => refer to section 57-60 Nose section: The nose skin is a composite sandwich structure with GFRP facing layers and honeycomb core. It incorporates the pneumatic de-icing boots.
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57-10-00
CENTER WING Description The wing fuselage attachment fittings are a conventional steel design. Two fittings are bolted to a forward fuselage frame , another two fittings are bolted to an aft fuselage frame providing four wing attachment lugs. These lugs match four bushings, two in the main spar and two in the aft spar of the wing. The connection is completed by four high strength corrosion resistant steel bolts installed against flight direction. The lugs of the fuselage fittings feature a high quality thermoplastic liner for bolt surface protection. The design satisfies fail safe requirements, any single bolt may fail.
Removal Refer to Figure 57-1 and Figure 57-2. Wing removal is done by hoisting the wing, removing the fuselage beneath it and lowering the wing on suitable supports. The weight of the (dry) wing including flaps and ailerons is less than 300kg. Be sure that your hoist assembly and lifting straps provide enough load bearing capacity. Special tools required for wing removal: EA-15001.2w (bolt extractor, drawing or tool itself available from EXTRA) Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. T
2 Drain all fuel 3 Remove two avionic bay access panels, the wing center fairing. and the fuel sump access panels.
Refer to Chapter 51-00-01
4 Remove all screws attaching the fuselage skin to the wing.
Don’t forget the two screws underneath the flaps.
5 Disconnect all electric connectors in the avionic bay and center wing nose section.
Required tools are available at a standard avionic shop.
6 Disconnect the main bonding connection in the left forward section of the avionic bay
Hex nut on stud bolt
7 Disconnect tubing for pitot static system and de-ice boots, protect open lines against FOD.
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8 Disconnect aileron control cables.
Three turnbuckles in wing nose section refer to Chapter 27
9 Disconnect all fuel supply lines (one on each side).
Refer to Chapter 28-20-06
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10 Disconnect fuel lines running from and to the jet pumps.
Accessible after removal of avionic bay access panels
11 Carefully separate the silicone sealing between fuselage and wing with a sharp knife. 12 Sling two industrial hoisting straps (at least 2” wide) around the wing center section.
It is helpful to use specially bended welding wire or similar to get the straps through the gap between wing and fuselage.
13 Install the hoisting assembly and relieve the wing fuselage connection. Take care of the attachment flange of the center panel when loading the straps, use wooden blocks or similar to protect the flange. Be sure to attach the hoisting assembly above the wings center of gravity to avoid a nose or tail heavy condition when lifting it. The wing weight is approx. 250 kg (551 lbs). Be sure to provide a lifting force appropriate to this weight to avoid damage to the remaining attachment points by uncontrolled wing movement. This is likely to occur when the attachment bolts are fix, but the wing connections are not fix in all directions any more. 14 Remove safety plates at main spar bolts (also removes electric bonding strips) and safety wire at rear spar securing bolts. Remove rear spar securing washers and bolts (concentric bolt M10) NOTE
Be sure to have at least one person on suitable supports at each wing tip before extracting the second bolt to counteract any undesirable movement of the wing.
NOTE
It is advisable to begin with both bolts on one side to get a feel for the proper relief tension of the hoist assembly while the wing is able to swivel around the remaining bolts. 15 Extract the attachment bolts with special tool.
Extracting tool EA-15001.2w required (See Chapter 01-00-02)
16 Slowly lift the wing from the fuselage and take care of the electric wiring.
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17 As soon as the wing is completely free remove the fuselage underneath the wing and lower the wing on suitable supports with protective lining. (Foam, carpet or similar). The wing should be supported underneath structural ribs, preferably the ribs in front of the gap between the inner and outer flap.
Installation Install in reverse order of removal Install wing attachment bolts with grease.
Aeroshell Grease 22c
Observe special torque values for: Securing bolt rear bolts (Bolt M10) retaining sheets front bolts (two Bolts M5)
Refer to chapter 20-10-04
Side view
Wing hoisting straps
approximate location of CG for lifting wing
Top view
wing attachment bolts
Figure 57-1
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Hoisting the Wing
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Figure 57-2
Wing to Fuselage Attachment
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57-30-00
WING TIPS Description The wing tips are non structural CFRP parts attached to a flange along the wing tip rib. Removing the wing tips gives access to the outer compartment of the wing between the main and aft spar. A transparent polycarbonate cover at the leading edge of the wing tip aerodynamically integrates the Navigation StrobeLight Combination. The wing tips are lightning protected by an outer CFRP layer incorporating a metallic mesh.
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57-50-00
TRAILING EDGE AND TRAILING EDGE DEVICES
57-50-01
Flaps Description Refer to Figure 57-3 and Figure 57-4.The flaps are of one spar dual torsion box all-CFRP-composite construction. For structural reason each flap is divided in two parts. The inboard part extends from Y ± 550 to Y ± 2550, the outboard from Y ± 2550 to Y ± 4400. For adjustment of flap actuation, guidance and position indicating refer to Chapter 27.
Removal/Installation Move flaps to 30° position (wing flap position switch at right main panel). Perform the following steps for LH and RH side flaps each. Detail Steps/Work Items
Key Items
Pull circuit breakers FLAP and FLAP CTRL at left side circuit breaker WARNING panel 1 Remove safety wire from ball at connection rod to watchdog potentiometer 2 Disconnect ball from connecting rod CAUTION
Take care not to move or loosen arm from shaft. Otherwise readjustment will be required as per Ch. 27-50-00
3 Disconnect bolts connecting inner and outer transmission rod to flap bracket
1 hex bolt each
4 Disconnect 2 hex bolts at middle flap track 5 Remove inner flap segment from inboard guidance keyway
It is recommended to get some assistance
6 Remove outer flap segment from outboard guidance keyway
It is recommended to get some assistance
CAUTION
Before re-installation, perform flap track adjustment as per Ch. 27-50-00 Install in reverse sequence of removal
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Figure 57-3
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Inner Flap Structure
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Figure 57-4
Outer Flap Structure
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57-60-00
AILERONS AND ELEVONS Description Refer to Figure 57-5. The ailerons are of one spar dual torsion box all-CFRPcomposite construction. The aileron hinge line is positioned 70% of the wing chord. To prevent flutter they are mass balanced in the overhanging leading edge.
Removal/Installation For removal and installation refer to Chapter 27
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Figure 57-5
Aileron Structure
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Chapter 61 Propeller
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Table of Contents
61-00-00
Page 2
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GENERAL ........................................................................................................ 3 Description.......................................................................................................... 3 Troubleshooting.................................................................................................. 4
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61-00-00
GENERAL Description The EXTRA 500 is equipped with a MTV-5-1-D-C-F-R(A)/CFR210-56 5-blade propeller. The MTV-propeller has a laminated wood composite structure encased by an epoxy-fiber glass cover with metal tipping. The governor regulates the blade pitch for a constant RPM. Internal springs and counter-weights push the blades in high pitch (feather position). Oil pressure pushes them in low pitch and reverse position. Thus in case of an engine failure the propeller will be in a low drag configuration. The propeller is equipped with electrically heated de-icers, bonded to the blades. The electric power is provided by slip rings and a stationary brush assembly. Refer to Chapter 30-60 for further information concerning propeller icing protection. Control, operation and maintenance of the propeller is described in the MT Propeller Operation and Installation Manual E-610 (LOAP 3). The parts and overhaul works are listed and described in the MT - Propeller Overhaul and Parts List E-220 (LOAP 5) For more information consult the propeller manufacturer. For dynamically balancing the propeller refer to Rolls-Royce 250-B17F Series Engine Operation and Maintenance Manual (LOAP 1)
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Troubleshooting Complaint Excessive vibration, rough running
Possible Cause
Remedy
Propeller unbalanced
Dynamically balance propeller according to engine manufacturer’s information
Icing
Switch on propeller de-icing
Blade damage
Foreign object damage
Repair or replace propeller according to propeller manufacturer’s instruction
Spinner or backplate damage
Foreign object or handling damage
Replace by airworthy parts
Blade play
Blade bearing loose
Refer to propeller manufacturer’s instruction
Hub damage
Propeller loose on crankshaft
Refer to engine and propeller manufacturer’s instruction
Improper RPM
Propeller pitch setting out of limits
Refer to propeller manufacturer’s instruction
Governor setting out of limits
Refer to engine manufacturer’s instruction
Malfunctioning propeller governor
Replace governor, for adjustment see engine manufacturer’s instruction
Cold oil
Run engine until normal operating oil temperature is reached
Propeller pitch control mechanism defective on
Refer to propeller manufacturer’s instruction
Trapped air in propeller piston
Cycle propeller control to bleed trapped air
Engine power surge
Refer to engine section, chapter 72
Abrupt control movement
Move controls carefully
Propeller pitch control mechanism defective
Refer to propeller manufacturer’s instruction
Governor defective
Replace governor
Sluggish RPM change
Surging RPM
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Complaint RPM changes at constant propeller setting
Oil leakage
No effect of condition lever control
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Possible Cause
Remedy
Excessive hub friction
Refer to propeller manufacturer’s instruction
Excessive governor friction
Replace governor
Oil leakage or hot oil
Check for leaks, replace gasket, decrease oil temperature
Propeller pitch control mechanism defective
Refer to propeller manufacturer’s instruction
Damaged gasket
Replace gasket or repair propeller
Loss of blade bearing grease
Refer to propeller manufacturer’s instruction
Connection detached
Restore connection
RPM control bracket defective
Restore or replace bracket
Bowden cable broken
Replace Bowden cable
Bowden cable binding
Replace Bowden cable
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Chapter 71 Power Plant
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Maintenance Manual EXTRA 500
Table of Contents 71-00-00
GENERAL ........................................................................................................ 3 Troubleshooting.................................................................................................. 3
71-10-01
Engine ................................................................................................................ 3 Removal.............................................................................................................. 3 Installation .......................................................................................................... 5
71-10-00
Cowling .............................................................................................................. 6
71-10-01
Upper Left Cowling .......................................................................................... 6 Removal.............................................................................................................. 6 Installation .......................................................................................................... 6
71-10-02
Upper Right Cowling........................................................................................ 7 Removal.............................................................................................................. 7 Installation .......................................................................................................... 7
71-10-03
Lower Cowling .................................................................................................. 7 Removal/Installation........................................................................................... 7
71-20-00
ENGINE MOUNT ............................................................................................ 8 Description.......................................................................................................... 8
71-20-01
Shock-Mount ..................................................................................................... 8 Removal.............................................................................................................. 8 Installation .......................................................................................................... 9
71-60-00
AIR INTAKES ................................................................................................ 10 Description........................................................................................................ 10
71-60-01
Engine Inlet ..................................................................................................... 10 Removal/Installation......................................................................................... 10
71-70-00
ENGINE DRAINS .......................................................................................... 11 Description........................................................................................................ 11
71-70-01
Engine Fire-Shield Drains.............................................................................. 11 Description........................................................................................................ 11 Removal/Installation......................................................................................... 11
71-70-02
Engine Combustion Chamber Drain ............................................................ 11 Description........................................................................................................ 11 Removal/Installation......................................................................................... 11
71-70-03
Engine Drain Manifold .................................................................................. 12 Description........................................................................................................ 12 Removal/Installation......................................................................................... 12
71-70-04
Overboard Line............................................................................................... 12 Description........................................................................................................ 12 Removal/Installation......................................................................................... 12
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71-00-00
GENERAL For specific repair and replacement information refer to Rolls-Royce 250-B17F Series Engine Operation and Maintenance Manual (LOAP 1).
Troubleshooting For troubleshooting refer to Table 101 of the above-mentioned Manual.
71-10-01
Engine Removal Detail Steps/Work Items
Key Items
1 Set FUEL SELECTOR VALVE to OFF. 2 Switch off all electrical power, disconnect battery. 3 As the balance of the aircraft will dramatically change, put a support under the tail. 4 Remove upper and lower cowlings.
Refer to subjects 71-10-01, 02, -03
5 Remove propeller.
Refer to MT - Propeller Operation and Installation Manual E-610 (LOAP 3)
6 Remove beta-valve.
Refer to Rolls-Royce 250B17F Series Engine Operation and Maintenance Manual (LOAP 1), Chapter 76-10-02
7 Remove brush-block including mounting from engine. 8 Remove engine inlet.
Refer to Subject 71-60-01
9 Remove exhaust stacks.
Refer to Ch. 78-00-01/02
10 Remove bleed air hoses. 11 Remove two sonic venturis. Plug holes. 12 Remove starter generator.
Refer to Chapter 24-30-10
13 Disconnect power line ignition. 14 Disconnect the bonding braid on the ignition exciter attachment bolt.
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Detail Steps/Work Items
Key Items
15 Disconnect the electrical wiring from the chip detection sensors. Fuel may be pressurized (30 psi max). Fuel may spill. Protect yourself WARNING and catch spilling fuel in a suitable container. 16 Disconnect fuel hose at engine fuel inlet. Plug hole and line. 17 Remove fuel manifold from aft engine fireshield. 18 Disconnect the fuel pressure sense line and fitting. Plug hole and line. 19 Remove fuel drain lines from engine fireshield. 20 Remove fuel drain hose from combustion chamber. Plug fitting. 21 Remove engine control mounting bracket
Refer to Chapter 76-10-01
22 Remove gearbox vent line and fitting from engine. Plug hole and line. 23 Disconnect thermocouple wiring from terminal block on RH engine fire-shield.
Refer to Chapter 77-20-01
24 Remove terminal block from RH engine fire-shield.
Refer to Chapter 77-20-02
25 Remove oil vent line and fitting from engine. Plug hole and line. 26 Remove oil vent ‘check valve T’ and connecting hoses. 27 Remove TRQ sense line and fitting. Plug hole and line.
RH forward gearbox
28 Remove oil pressure sense line and fitting. Plug hole and line.
LH forward gearbox
29 Drain oil system.
Refer to Chapter 79-00-00
30 Remove ‘oil in’ hose. 31 Disconnect electrical connector oil temperature sensor. 32 Loosen counter nut of ‘oil in’ fitting, remove fitting. Plug hole and line. 33 Remove ‘oil out’ tube and fitting. Plug check valve and line.
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34 Remove external scavenge oil filter.
Refer to Chapter 79-20-01
35 Disconnect electrical connectors of engine anti-ice and propeller overspeed test.
above engine fire-shield
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Maintenance Manual EXTRA 500
Detail Steps/Work Items
Key Items
36 Disconnect electrical wiring standby alternator. 37 Disconnect lightning cable and bonding braid from standby alternator RH attachment stud. 38 Check engine is fully disconnected except main attachment points. 39 Remove upper main attachment bolt.
Mark bolts and nuts as used.
40 Hoist engine slightly though upper shockmount bolt hole.
Hoisting structure must be able to carry at least 150 kg (300 lbs). Align hoist exactly above shock-mount.
41 Support the engine at the combustion chamber. 42 Remove both side main attachment bolts.
Mark bolts and nuts as used.
43 Lower engine 5-10cm (2-4 inch) and pull the engine out straight forward. 44 Remove the side shock-mounts.
Refer to Subject 71-20-01
45 Perform preservation and storage precautions.
Refer to Rolls-Royce 250B17F Series Engine Operation and Maintenance Manual (LOAP 1)
46 Remove upper shock-mount when engine is securely stored.
Refer to Subject 71-20-01
47 Remove standby alternator from engine
Refer to Chapter 24-30-20
48 Remove gas generator turbine tachometer
Refer to Chapter 77-00-01
49 Remove propeller/power turbine RPM sensor.
Refer to Chapter 77-10-02
Installation Detail Steps/Work Items
Key Items
1 Remove engine from container.
Refer to Engine Maintenance Manual
2 Install in reverse sequence of removal.
Observe the following steps.
3 Torque main attachment bolts 32 Nm (283 lbs-inch), use new bolts and nuts 4 Use new packings where necessary. 5 Perform engine control rigging check
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Refer to Chapter 76-00-00
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Detail Steps/Work Items NOTE
Key Items
The propeller must be dynamically balanced if a new engine or new propeller is installed. Refer to Rolls-Royce 250-B17F Series Engine Operation and Maintenance Manual (LOAP 1) 6 Perform applicable engine run tests.
Refer to Rolls-Royce 250B17F Series Engine Operation and Maintenance Manual (LOAP 1), Chapter 72-00-00
7 Perform engine indication check (TOT only) Refer to Chapter 77-00-00
71-10-00
Cowling The EXTRA 500 cowling consists of three parts: • Upper left cowling • Upper right cowling • Lower cowling The upper cowlings are attached by means of cam-locks. The lower cowling is attached with bolts.
71-10-01
Upper Left Cowling Removal Detail Steps/Work Items 1 Unlock all cam-locks.
Key Items 24 cam-locks
2 Raise and remove cowling.
Installation Detail Steps/Work Items
Key Items
1 Set cowling aircraft. 2 Fasten all cam-locks. 3 Check all cam-locks are engaged by firmly hitting the cowling near attachments.
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71-10-02
Upper Right Cowling Removal Detail Steps/Work Items
Key Items
1 Remove upper left cowling first. 2 Remove all cam-locks.
14 cam-locks
3 Raise and remove cowling
Installation Detail Steps/Work Items
Key Items
1 Set cowling aircraft. 2 Fasten all cam-locks.
14 cam-locks
3 Check all cam-locks are engaged by firmly hitting the cowling near attachments.
71-10-03
Lower Cowling Removal/Installation Detail Steps/Work Items 1 Remove upper cowlings first.
Key Items Refer to Subj. 71-10-01/02
2 Disconnect landing light bulkhead connector. 3 Remove bridge tube on forward part of cowling.
4 bolts
4 Remove lower cowling aft attaching bolts.
7 bolts
5 Remove lower cowling as one piece. 6 Disassemble lower cowling if applicable.
4 bolts
7 Install in reverse order of removal.
Make sure that all rubber seals fit properly at intake.
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71-20-00
ENGINE MOUNT Description The steel tube designed engine mount supports the engine and attaches it to the airframe. It is mounted to the airframe at six points with mount supports, using bolts, washers and self-locking type nuts.
71-20-01
Shock-Mount The engine is attached to the engine mount at three points. Each point incorporates a vibration isolator type shock mount assembly capable of sustaining operational loads and providing absorption of engine vibrations. They use the upper and side mounting pads of the engine. For humidity & corrosion prevention MASTINOX is applied to the lower shock-mount surface (contact area to the engine mounting pad).
Removal It is assumed that the engine is not installed in the aircraft (otherwise refer to Subject 71-00-01). Never remove a shock-mount while the engine is installed. CAUTION
Detail Steps/Work Items
Key Items
MASTINOX is highly flammable, toxic and dangerous for the WARNING environment. It may cause cancer and is harmful by inhalation, in contact with skin and if swallowed. Toxic to aquatic organisms, may cause long-term adverse effects in the aquatic environment. Use applicable gloves and respirator mask. 1 Remove lock-wire. 2 Unscrew bolts.
3 bolts
3 Remove shock-mount.
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Installation Detail Steps/Work Items
Key Items
MASTINOX is highly flammable, toxic and dangerous for the WARNING environment. May cause cancer. Harmful by inhalation, in contact with skin and if swallowed. Toxic to aquatic organisms, may cause long-term adverse effects in the aquatic environment. Use applicable gloves and respirator mask. 1 Apply MASTINOX on the lower surface of the shock-mount. 2 Place the shock-mount in position, hand tighten bolts.
3 bolts
3 Torque all three bolts
11.9- 13.0 Nm (105-115 lbs-inch)
4 Lock-wire bolts against each other.
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71-60-00
AIR INTAKES Description The EXTRA 500 has an exhaust heated engine air inlet. It is mounted on the engine compressor flange.
71-60-01
Engine Inlet Removal/Installation Detail Steps/Work Items 1 Remove the RH exhaust stack.
Key Items Refer to Chapter 78-00-02.
2 Unscrew the RH helical metal hose from the inlet. 3 Remove inlet.
12 bolts
4 Unscrew the inlet from the LH helical metal hose. 5 Install in reverse sequence of removal. IMPORTANT
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Observe the following hint.
Make sure while setting the length of the helical metallic hose that the forces on the engine flange while attaching the exhaust stack must be minimal. Screw in the helical metallic hose minimum one full turn on each side. Maximum two full turns each side are possible.
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Maintenance Manual EXTRA 500
71-70-00
ENGINE DRAINS Description The EXTRA 500 engine has 5 drain fittings. Fuel, oil or other fluids are collected in the engine manifold and drained overboard.
71-70-01
Engine Fire-Shield Drains Description The engine fire-shield drains are located on the left and right side (two each) of the engine fire-shield. They are connected by aluminum tubing and connected to the drain manifold by hoses.
Removal/Installation Detail Steps/Work Items 1 Remove LH and RH upper cowling.
Key Items Refer to Chapter 71-10-01/02
2 Disconnect hoses from drain manifold. 3 Disconnect drain lines from engine fireshield. 4 Install in reverse sequence of removal.
71-70-02
Make sure all lines are clean
Engine Combustion Chamber Drain Description In case of a false engine start, fuel may collect at the bottom of the combustion chamber. This fuel will be drained through the combustion chamber drain hose to the drain manifold.
Removal/Installation Detail Steps/Work Items 1 Remove LH upper cowling.
Key Items Refer to Chapter 71-10-01
2 Disconnect fittings of the combustion chamber drain hose. Plug fitting. 3 Install in reverse sequence of removal.
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71-70-03
Engine Drain Manifold Description The engine drain manifold is installed at the bottom of the cowling, left forward of the nose gear firewall.
Removal/Installation Detail Steps/Work Items 1 Remove LH upper cowling.
Key Items Refer to Chapter 71-10-01
2 Disconnect all hoses from engine drain manifold. 3 Disconnect engine drain manifold from overboard line and remove. 4 Install in reverse sequence of removal.
71-70-04
Overboard Line Description The overboard line is installed to the left side of the nose gear firewall.
Removal/Installation Detail Steps/Work Items 1 Remove LH upper cowling.
Key Items Refer to Chapter 71-10-01
2 Disconnect overboard line from engine drain manifold. 3 Remove the two hose clamps at the nose wheel bay firewall LH side. 4 Remove overboard line. 5 Install in reverse sequence of removal.
Observe the following
Refer to Product Label and Material Safety Data Sheet for health and WARNING safety information before using PR812. 6 Seal any opening in the firewall with PR812.
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Maintenance Manual EXTRA 500
Chapter 73 Engine Fuel and Control
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Page 1
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Table of Contents
73-00-00
GENERAL ........................................................................................................ 3
73-30-00
Indicating........................................................................................................... 3 Description.......................................................................................................... 3
73-30-01
Fuel Pressure Transducer................................................................................ 3 Description.......................................................................................................... 3 Removal/Installation........................................................................................... 3
73-30-02
Low Fuel Pressure Switch................................................................................ 4 Description.......................................................................................................... 4 Removal/Installation........................................................................................... 4
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73-00-00
GENERAL For specific repair and replacement information refer to Rolls-Royce 250-B17F Series Engine Operation and Maintenance Manual (LOAP 1).
73-30-00
Indicating Description The fuel indication consists of fuel pressure and a low fuel pressure warning in the annunciator panel. The fuel pressure indication is described in 77-40-02
73-30-01
Fuel Pressure Transducer Description The fuel pressure transducer is located in the engine compartment, in the sensor block mounted on the LH side of the battery mount, the most forward upper sensor (refer to Figure 77-1).
Removal/Installation Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. 2 Remove LH upper cowling.
Refer to Chapter 71-10-01
3 Disconnect electrical connector. Fuel may be pressurized (30 psi max). Fuel may spill. Protect yourself WARNING and catch spilling fuel in a suitable container. 4 Remove transducer from fuel pressure manifold. 5 Install in reverse sequence of removal.
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Replace O-ring when necessary.
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73-30-02
Low Fuel Pressure Switch Description The low fuel pressure switch is located in the engine compartment, in the sensor block mounted on the LH side of the battery mount, the most forward sideward sensor (refer to Figure 79-1).
Removal/Installation Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. 2 Remove LH upper cowling.
Refer to Chapter 71-10-01
3 Disconnect electrical connector. Fuel may be pressurized (30 psi max). Fuel may spill. Protect yourself WARNING and catch spilling fuel in a suitable container. CAUTION
Never force the body of the sensor to turn against friction. It may change the set-point. Always use a key on the attachment fitting for removal and installation
4 Remove sensor. 5 Install in reverse sequence of removal.
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Maintenance Manual EXTRA 500
Chapter 74 Ignition
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Table of Contents
74-00-00
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GENERAL ........................................................................................................ 3
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74-00-00
GENERAL Ignition on the EXTRA 500 is only needed at engine start. For safety reasons it is also switched on at take-off and landing and in severe weather conditions (heavy rain, icing etc). The ignition switch is integrated in the start switch (refer to Chapter 80-00-00). For specific repair and replacement information refer to Rolls-Royce 250-B17F Series Engine Operation and Maintenance Manual (LOAP 1).
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Maintenance Manual EXTRA 500
Chapter 76 Engine Controls
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Table of Contents
76-00-00
Figure 76-1
GENERAL ........................................................................................................ 3 Description.......................................................................................................... 3 Rigging Check .................................................................................................... 3 Engine Control Lever Travel Schematic ............................................................ 4
76-10-00
POWER CONTROL ........................................................................................ 5
76-10-01
Engine Control Mounting Bracket ................................................................. 5 Description.......................................................................................................... 5 Removal/Installation........................................................................................... 5 Engine Control Mounting Bracket ..................................................................... 6
Figure 76-2 76-10-02
Throttle Quadrant ............................................................................................ 7 Description.......................................................................................................... 7 Removal.............................................................................................................. 7 Installation .......................................................................................................... 8
76-10-03
Power Lever Bowden Cable............................................................................. 8 Description.......................................................................................................... 8 Removal.............................................................................................................. 8 Installation .......................................................................................................... 9
76-10-04
Condition Lever Bowden Cable .................................................................... 10 Description........................................................................................................ 10 Removal............................................................................................................ 10 Installation ........................................................................................................ 10
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Maintenance Manual EXTRA 500
76-00-00
GENERAL For specific repair and replacement information refer to Rolls-Royce 250-B17F Series Engine Operation and Maintenance Manual (LOAP 1).
Description The EXTRA 500 engine is controlled with two levers located in the middle console: The power lever and the condition lever. Two Bowden cables are routed through the firewall to the engine coordinator. On the engine control mounting bracket, two microswitches are mounted. The upper microswitch signals that the engine fuel is shut-off and has the function to shut-off the bleed air when the engine is shut down. The lower is connected to the LOW PITCH caution light on the annunciator panel.
Rigging Check Detail Steps/Work Items
Key Items
1 Remove LH upper cowling.
Refer to Chapter 71-10-01
2 Perform engine manufacturer prepared rigging check.
Refer to Rolls-Royce 250B17F Series Engine Operation and Maintenance Manual (LOAP 1), Chapter 76-00-00, page 201.
3 Check that the upper microswitch switches 2-3 mm before the cut-off position is reached.
Adjust by bending the microswitch arm
4 Check that the lower microswitch switches the LOW PITCH caution light on at 37°-39° (as indicated on the engine coordinator) moving to a lesser angle.
Adjust by bending the microswitch arm
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Condition Lever
Power Lever
Maintenance Manual EXTRA 500
Figure 76-1 Page 4
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Engine Control Lever Travel Schematic Page Date: 30. March 2012
Maintenance Manual EXTRA 500
76-10-00
POWER CONTROL
76-10-01
Engine Control Mounting Bracket Description The engine control mounting bracket is installed on the engine coordinator and holds both engine control Bowden cables and 2 microswitches (refer to Figure 76-2).
Removal/Installation Detail Steps/Work Items 1 Remove LH upper cowling.
Key Items Refer to Chapter 71-10-01
2 Disconnect electrical wiring of the microswitches. 3 Remove the Bowden cable rod ends from the engine control levers. 4 Remove Bowden cables from bracket flange. 5 Remove the two side supports of the bracket.
2 screws
6 Remove the bracket.
2 screws
7 Install in reverse sequence of removal. 8 Perform engine control rigging check.
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Refer to Subject 76-00-00
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Figure 76-2
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Rear View
Screws
0° position (reverse)
Side support
Low pitch switch
Bleed air shut off switch
Side View Cut off position
Screws
Flange
Engine control mounting bracket
Power lever Bowden cable
Condition lever Bowden cable
Maintenance Manual EXTRA 500
Engine Control Mounting Bracket
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Maintenance Manual EXTRA 500
76-10-02
Throttle Quadrant Description The throttle quadrant is installed in the cockpit middle console. It includes the power and condition levers as well as the pitch trim wheel and indicator.
Removal Detail Steps/Work Items
Key Items
1 Remove the trim wheel. 2 Remove the power lever handle. 3 Remove the condition lever handle. 4 Remove the upper part of the middle console paneling.
Refer to Chapter 25-10-26
5 Remove the both Bowden cable rod-ends and flanges from the quadrant 6 Remove static pressure hoses and cabin pressure sensors from support rod. 7 Remove 4 screws on top of the quadrant cover. CAUTION
Do not bend or dent the trim tubing. Bending or denting it will increase pitch trim friction to an unacceptable level.
8 Detach the trim controller. 9 Remove support tube. 10 Remove quadrant.
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Installation Detail Steps/Work Items
Key Items
1 Reverse sequence of removal. PR 1750 accelerator contains harmful vapors and is readily absorbed WARNING through the skin. Avoid all contact with the skin and ingestion. Always wash hands before eating or smoking. Use adequate ventilation, hand protection and chemical-type goggles when working with this product. If accelerator contacts skin, flush area with warm water. Obtain medical attention in cases of extreme exposure or ingestion. PR 1750 sealant contains solvents. WARNING Use adequate ventilation or air-supplied respirators during application. Avoid repeated or prolonged breathing of vapors. In case of extreme vapor exposure, remove affected personnel to fresh air immediately and obtain medical attention. For complete health and safety information, a material safety data sheet is available from the manufacturer. 2 If the lower bolts of the support tube have been loosened or removed seal it with PR1750. 3 Perform an engine control rigging check.
Refer to Subject 76-00-00
4 Check the function of the back-up microphone.
76-10-03
Power Lever Bowden Cable Description The Power lever Bowden cable connects the power lever in the cabin with the input power lever of the engine coordinator.
Removal Detail Steps/Work Items
Key Items
1 Remove LH upper cowling.
Refer to Chapter 71-10-01
2 Remove upper part of the middle console paneling.
Refer to Chapter 25-10-26
3 Remove the power Bowden cable (LH) rodends and flanges from the quadrant.
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Detail Steps/Work Items
Key Items
4 Remove the Bowden cable rod-ends and flanges from the input power lever of the engine coordinator and engine control mounting bracket. 5 With a firm pull, remove the Bowden cable from the firewall.
Installation Detail Steps/Work Items
Key Items
1 Reverse sequence of removal. Refer to Product Label and Material Safety Data Sheet for health and WARNING safety information before using PR812. 2 Seal the Bowden cable firewall breakthrough with PR812 from the engine compartment side. PR 1750 accelerator contains harmful vapors and is readily absorbed WARNING through the skin. Avoid all contact with the skin and ingestion. Always wash hands before eating or smoking. Use adequate ventilation, hand protection and chemical-type goggles when working with this product. If accelerator contacts skin, flush area with warm water. Obtain medical attention in cases of extreme exposure or ingestion. PR 1750 sealant contains solvents. WARNING Use adequate ventilation or air-supplied respirators during application. Avoid repeated or prolonged breathing of vapors. In case of extreme vapor exposure, remove affected personnel to fresh air immediately and obtain medical attention. For complete health and safety information, a material safety data sheet is available from the manufacturer. 3 Seal the Bowden cable firewall breakthrough with PR1750 from the cabin side. 4 Perform an engine control rigging check.
Refer to Subject 76-00-00
5 Check the function of the back-up microphone.
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76-10-04
Condition Lever Bowden Cable Description The condition lever Bowden cable connects the condition lever in the cabin with the condition lever of the engine coordinator.
Removal Detail Steps/Work Items
Key Items
1 Remove LH upper cowling.
Refer to Chapter 71-10-01
2 Remove upper part of the middle console paneling.
Refer to Chapter 25-10-26
3 Remove the condition Bowden cable (RH) rod-ends and flanges from the quadrant. 4 Remove the Bowden cable rod-ends and flanges from the condition lever of the engine coordinator and engine control mounting bracket. 5 With a firm pull, remove the Bowden cable from the firewall.
Installation Detail Steps/Work Items
Key Items
1 Reverse sequence of removal. Refer to Product Label and Material Safety Data Sheet for health and WARNING safety information before using PR812. 2 Seal the Bowden cable firewall breakthrough with PR812 from the engine compartment side. PR 1750 accelerator contains harmful vapors and is readily absorbed WARNING through the skin. Avoid all contact with the skin and ingestion. Always wash hands before eating or smoking. Use adequate ventilation, hand protection and chemical-type goggles when working with this product. If accelerator contacts skin, flush area with warm water. Obtain medical attention in cases of extreme exposure or ingestion.
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Detail Steps/Work Items
Key Items
PR 1750 sealant contains solvents. WARNING Use adequate ventilation or air-supplied respirators during application. Avoid repeated or prolonged breathing of vapors. In case of extreme vapor exposure, remove affected personnel to fresh air immediately and obtain medical attention. For complete health and safety information, refer to Le Joint Francais material safety data sheet PR 1750 (LOAP 41). 3 Seal the Bowden cable firewall breakthrough with PR1750 from the cabin side.
For mixing and application of PR 1750 sealant refer to manufacturer's instructions.
4 Perform an engine control rigging check.
Refer to Subject 76-00-00
5 Check the function of the back-up microphone.
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Maintenance Manual EXTRA 500
Chapter 77 Engine Indicating
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Page 1
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Table of Contents
77-00-00
GENERAL ........................................................................................................ 3 Description.......................................................................................................... 3 Engine Indication Check .................................................................................... 4 Normal Ground Idle Engine Indication .............................................................. 4
77-00-01
Gas Generator Turbine Tachometer (N1)...................................................... 4 Removal.............................................................................................................. 4 Installation .......................................................................................................... 5
77-10-00
POWER ............................................................................................................. 6
77-10-01 Figure 77-1
Torque Transducer........................................................................................... 6 Engine Indication Transducers and Switches .................................................... 6 Removal.............................................................................................................. 6 Installation .......................................................................................................... 7
77-10-02
Torque Switch ................................................................................................... 7 Removal/Installation........................................................................................... 7
77-10-03
Propeller/Power Turbine RPM Sensor (N2) .................................................. 7 Removal.............................................................................................................. 7 Installation .......................................................................................................... 8
77-20-00
TEMPERATURE ............................................................................................. 9
77-20-01
Thermocouple Wiring ...................................................................................... 9
77-20-02
Thermocouple Terminal Block........................................................................ 9
77-40-00
INTEGRATED ENGINE INSTRUMENT SYSTEMS............................... 10
77-40-01
Analog Engine Indicator Cluster .................................................................. 10 Removal/Installation......................................................................................... 10
77-40-02
Digital Engine Indicator Cluster ................................................................... 10 Removal/Installation......................................................................................... 10
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77-00-00
GENERAL For specific repair and replacement information refer to Rolls-Royce 250-B17F Series Engine Operation and Maintenance Manual (LOAP 1).
Description The indication of engine parameters is presented on two integrated engine instruments in the LH instrument panel. The upper unit is an analog-digital unit which displays: • TRQ in percent • TOT in degree Celcius • N1 (compressor) in percent • N2 (propeller) in RPM • Oil pressure in psig • Oil temperature in degree Celcius Although these parameters are displayed in one unit, they all have their separate modules and are independent of each other. The same is valid for the lower display unit which displays digital values only: • Bus voltage • Generator current in ampere • Battery current in ampere • Indicated outside air temperature in degree Celcius • Fuel temperature in degree Celcius • Fuel pressure in psig
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Engine Indication Check The engine indication check consists of a engine run test in which the plausibility of the indications are checked apart from obvious things like oil system leakage if the oil pressure sensor has been exchanged. Detail Steps/Work Items
Key Items
1 Before the engine run, check that all pressure and RPM indications are zero and temperature indications in line with the OAT. 2 Start the engine.
Follow EXTRA 500 Pilot’s Operating Handbook procedures.
3 Set in ground idle. 4 Check engine indication is around the values Refer to Normal Ground Idle given in the following table. Engine Indication table
Normal Ground Idle Engine Indication
77-00-01
TRQ
~10%
TOT
~540°C
N1
~65%
N2
~1750 RPM
OP
~90 psig
OT
In green area
FP
>10 psig
Gas Generator Turbine Tachometer (N1) The gas generator turbine tachometer is installed on the LH forward engine gearbox.
Removal Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. 2 Remove LH upper cowling.
Refer to Chapter 71-10-01
3 Disconnect electrical connector.
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Detail Steps/Work Items
Key Items
4 Remove tachometer
Installation Detail Steps/Work Items
Key Items
1 Reverse sequence of removal.
Apply some engine oil to the drive-spline before installing.
2 Perform engine indication check.
Refer to Subject 77-00-00
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77-10-00
POWER
77-10-01
Torque Transducer The torque transducer is located in the engine compartment, on the LH side of the battery, the aft sensor.
Side View fwd
Transducers
Battery attachment frame Switches
OIL
T RQ
FUEL
Sensing lines
To accumulator
Firewall Figure 77-1
Engine Indication Transducers and Switches
Removal Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. 2 Remove LH upper cowling.
Refer to Chapter 71-10-01
3 Disconnect electrical connector. Page 6
77
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Maintenance Manual EXTRA 500
Detail Steps/Work Items
Key Items
4 Remove lock-wire. 5 Remove torque transducer
Installation Detail Steps/Work Items
Key Items
1 Reverse sequence of removal.
Replace o-ring when necessary.
2 Perform engine indication check.
Refer to Subject 77-00-00
77-10-02
Torque Switch The torque switch is located in the engine compartment, on the LH side of the battery, the aft sideward sensor (refer to Figure 79-1).
Removal/Installation Detail Steps/Work Items 1 Remove LH upper cowling.
Key Items Refer to Chapter 71-10-01
2 Disconnect electrical connector. CAUTION
Never force the body of the sensor to turn against friction. It may change the set-point. Always use a wrench on the spanner flats of the attachment fitting for removal and installation.
3 Remove torque switch. 4 Reverse sequence of removal.
77-10-03
Apply Loctite 577 to torque switch thread
Propeller/Power Turbine RPM Sensor (N2) The propeller tachometer is installed on the RH forward engine gearbox.
Removal Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. 2 Remove upper cowlings.
Refer to Ch. 71-10-01/02
3 Disconnect electrical connector.
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Maintenance Manual EXTRA 500
Detail Steps/Work Items
Key Items
4 Remove tachometer.
Installation Detail Steps/Work Items
Page 8
77
Key Items
1 Reverse sequence of removal.
Apply some engine oil to the drive-spline before installing.
2 Perform engine indication check.
Refer to Subject 77-00-00
Page Date: 30. March 2012
Maintenance Manual EXTRA 500
77-20-00
TEMPERATURE Engine temperature is measured using K-type thermocouples and indicated as TOT to the pilot.
77-20-01
Thermocouple Wiring The thermocouple wiring from the terminal block (77-20-02) to the indicator is Chromel – Alumel for the entire length, including connector pins. If any of this wiring is to be replaced, wiring of the same material shall be used. Perform engine indication check as per Subject 77-00-00.
77-20-02
Thermocouple Terminal Block Engine thermocouple wiring and aircraft thermocouple wiring is connected at the thermocouple terminal block. It is installed in the engine compartment on the RH engine fire-shield. It is crucial that the Chromel and Alumel wires from the engine are correctly connected to those of the aircraft. Observe the following table: Material Chromel Pos (+) Alumel
Page Date: 30. March 2012
Neg (-)
Aircraft wiring
Engine wiring
Yellow
White
Small diameter stud
Red
Green
Large diameter stud
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Maintenance Manual EXTRA 500
77-40-00
INTEGRATED ENGINE INSTRUMENT SYSTEMS
77-40-01
Analog Engine Indicator Cluster The analog engine indicator cluster is installed in the LH instrument panel.
Removal/Installation Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. 2 Remove the RH and LH IFD.
Refer to Chapter 31-60-01
3 Disconnect both electrical connectors 4 Remove indicator cluster. 5 Install in reverse sequence of removal. 6 Perform engine indication check.
77-40-02
Refer to Subject 77-00-00
Digital Engine Indicator Cluster The digital engine indicator cluster is installed in the LH instrument panel just below the analog engine indicator cluster.
Removal/Installation Detail Steps/Work Items
Key Items
1 Ensure BATT switch is OFF and no external power connected. 2 Remove the RH and LH IFD.
Refer to Chapter 31-60-01
3 Disconnect electrical connector. 4 Remove 4 bolts
Use a ratchet with adequate prolongation for holding nuts in place.
5 Remove indicator. 6 Install in reverse sequence of removal. 7 Perform engine indication check.
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77
Refer to Subject 77-00-00
Page Date: 30. March 2012
Maintenance Manual EXTRA 500
Chapter 78 Exhaust
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78
Page 1
Maintenance Manual EXTRA 500
Table of Contents
78-00-00
GENERAL ........................................................................................................ 3 Description.......................................................................................................... 3
78-00-01
LH Exhaust Stack............................................................................................. 3 Removal/Installation........................................................................................... 3
78-00-02
RH Exhaust Stack............................................................................................. 3 Removal/Installation........................................................................................... 3
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Maintenance Manual EXTRA 500
78-00-00
GENERAL Description The exhaust system of the EXTRA 500 consists of two exhaust stacks, which flanged to the engine with a V-band clamp.
78-00-01
LH Exhaust Stack Removal/Installation Detail Steps/Work Items
Key Items
1 Remove the LH and RH upper cowlings.
Refer to Chapter 71-10-01/02
2 Remove the lower cowling.
Refer to Chapter 71-10-03
3 Remove engine anti-ice Bowden cable (from exhaust stack only) and micro switch.
Refer to Chapter 30-20-01/02
4 Remove the V-band clamp. 5 Remove engine gear box vent line from exhaust stack. 6 Unscrew the LH exhaust stack from the helical metal hose. 7 Install in reverse sequence of removal. IMPORTANT
78-00-02
Observe the following hint.
Make sure while setting the length of the helical metallic hose that the forces on the engine flange while attaching the exhaust stack must be minimal. Screw in the helical metallic hose minimum one full turn on each side. Maximum two full turns each side are possible.
RH Exhaust Stack Removal/Installation Detail Steps/Work Items
Key Items
1 Remove the LH and RH upper cowlings.
Refer to Chapter 71-10-01/02
2 Remove the lower cowling.
Refer to Chapter 71-10-03
3 Remove the V-band clamp. 4 Unscrew the RH exhaust stack from the helical metal hose. 5 Install in reverse sequence of removal. Page Date: 30. March 2012
Observe the following hint.
78
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Maintenance Manual EXTRA 500
Detail Steps/Work Items IMPORTANT
Page 4
78
Key Items
Make sure while setting the length of the helical metallic hose that the forces on the engine flange while attaching the exhaust stack must be minimal. Screw in the helical metallic hose minimum one full turn on each side. Maximum two full turns each side are possible.
Page Date: 30. March 2012
Maintenance Manual EXTRA 500
Chapter 79 Oil
Page Date: 30. March 2012
79
Page 1
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Table of Contents
79-00-00
GENERAL ........................................................................................................ 3 Description.......................................................................................................... 3 Troubleshooting.................................................................................................. 3 Oil System Draining ........................................................................................... 3
79-10-00
STORAGE......................................................................................................... 4 Description.......................................................................................................... 4
79-10-01
Engine Oil Supply Tank................................................................................... 4 Draining .............................................................................................................. 4 Removal/Installation........................................................................................... 4
79-10-02
Overpressure Valve .......................................................................................... 5 Removal.............................................................................................................. 5 Installation .......................................................................................................... 5
79-20-00
DISTRIBUTION............................................................................................... 6
79-20-01
External Scavenge Oil Filter............................................................................ 6 Filter Element Replacement ............................................................................... 6 Removal/Installation........................................................................................... 6
79-20-02
Engine Oil Cooler ............................................................................................. 7 Draining .............................................................................................................. 7 Removal/Installation........................................................................................... 7
79-20-03
Oil Thermostat .................................................................................................. 7 Removal/Installation........................................................................................... 7
79-20-04
Oil Lines............................................................................................................. 8 Draining .............................................................................................................. 8
79-30-00
INDICATION ................................................................................................... 9
79-30-01
Oil Pressure Transducer .................................................................................. 9 Removal.............................................................................................................. 9 Installation ........................................................................................................ 10
79-30-02
Oil Temperature Sensor................................................................................. 10 Removal............................................................................................................ 10 Installation ........................................................................................................ 10
79-30-03
Oil Pressure Switch ........................................................................................ 10 Removal............................................................................................................ 10 Installation ........................................................................................................ 11
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Maintenance Manual EXTRA 500
79-00-00
GENERAL For specific repair and replacement information refer to Rolls-Royce 250-B17F Series Engine Operation and Maintenance Manual (LOAP 1).
Description The EXTRA 500 oil system includes the following external components that do not belong to the engine. • Engine oil supply tank • Oil vent system • External scavenge oil filter • Engine oil cooler
Troubleshooting Complaint
Possible Cause
Remedy
Oil pressure at high altitude too low
Oil tank not pressurized
Check oil vent system, Refer to Subject 79-10-00
Excessive oil consumption
3 psi overpressure vent valve open
Replace valve, Refer to Subject 79-10-02
External oil filter pin popped
External oil filter element clogged
Exchange external oil filter element, Refer to Subject 79-20-01
Oil System Draining The complete oil system can be drained using the following procedure. Detail Steps/Work Items
Key Items
1 Drain engine oil supply tank.
Refer to Subject 79-10-01
2 Drain engine oil cooler.
Refer to Subject 79-20-02
3 Drain oil lines.
Refer to Subject 79-20-04
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Maintenance Manual EXTRA 500
79-10-00
STORAGE Description The engine oil supply tank is located in the engine compartment, mounted on the RH engine mount. The oil supply tank is vented to the engine gearbox over a 2 psid overpressure valve. In case this valve fails to open, the tank is vented overboard through a 3 psid overpressure valve. The reason for the oil tank pressurization is to prevent too low oil pressure in high altitude. Both overpressure valves are installed in the engine compartment on the RH side of the engine mount ring. They are directly connected to the vent line Tfitting.
79-10-01
Engine Oil Supply Tank Draining Detail Steps/Work Items 1 Remove upper cowlings.
Key Items Refer to Chapter 71-10-01/02
2 Place an ‘oil slide’ under the lower engine oil supply tank fitting to an appropriate canister. 3 Disconnect the lower engine oil supply tank fitting and drain the oil from the tank. 4 Drain hose if applicable.
Refer to Subject 79-20-04
Removal/Installation Detail Steps/Work Items
Key Items
1 Drain oil supply tank.
Refer to Draining Paragraph
2 Disconnect upper hoses. Plug hose fittings.
2 hoses
3 Remove oil supply tank.
2 worm drive hose clamps and 1 bolt
4 Install in reverse sequence of removal. 5 Re-fill tank with oil to the appropriate level.
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Refer to Chapter 12-10-04
Page Date: 30. March 2012
Maintenance Manual EXTRA 500
79-10-02
Overpressure Valve Removal Detail Steps/Work Items 1 Remove upper cowlings.
Key Items Refer to Chapter 71-10-01/02
2 Disconnect hose from overpressure valve. 3 Unscrew valve from T-fitting.
Installation Detail Steps/Work Items 1 Reverse sequence of removal.
Key Items Replace O-ring when necessary.
2 Check the 2 psi valve is connected to the hose routed to the engine gearbox. 3 Check the 3 psi valve is connected to the hose routed overboard. 4 Check the arrows on both valves point away from the T-fitting.
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Maintenance Manual EXTRA 500
79-20-00
DISTRIBUTION
79-20-01
External Scavenge Oil Filter The external oil filter is located in the engine compartment, on the lower mount pad of the engine.
Filter Element Replacement Detail Steps/Work Items 1 Disconnect oil lines from external oil filter.
Key Items Use a funnel to collect oil from lines in a suitable container.
2 Remove lock-wire upper body – lower body. 3 Unscrew the lower part of the filter body. 4 Replace filter element. 5 Lubricate o-ring with engine oil. 6 Install lower filter body.
Hand tighten only
7 Lock-wire upper body against lower body. 8 Re-fill tank with oil to the appropriate level.
Removal/Installation Detail Steps/Work Items
Key Items
1 Disconnect oil lines from external oil filter.
Use a funnel to collect oil from lines in a suitable container.
2 Disconnect hoses from oil filter.
Plug ends.
3 Remove oil filter. 4 Install in reverse sequence of removal. 5 Refill tank with oil to the appropriate level.
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Maintenance Manual EXTRA 500
79-20-02
Engine Oil Cooler The oil cooler is installed in the engine compartment on the RH side
Draining Detail Steps/Work Items
Key Items
1 Remove upper cowlings.
Refer to Chapter 71-10-01/02
2 Remove lower cowling.
Refer to Chapter 71-10-03
3 Place an “oil slide” under the lower engine oil cooler fitting to an appropriate canister. 4 Disconnect the lower engine oil cooler fitting and drain the oil from the oil cooler. 5 Drain hose if applicable.
Refer to Subject 79-20-04
Removal/Installation Detail Steps/Work Items 1 Drain engine oil cooler.
Key Items Refer to Draining Paragraph
2 Disconnect upper hose. 3 Remove forward air duct. 4 Remove cooler from aft airduct.
The aft airduct can be removed from the structure to gain better access to the aft airduct to cooler mounting bolts.
5 Install in reverse sequence of removal.
79-20-03
Oil Thermostat The oil thermostat is mounted in the oil cooler housing at outlet to oil tank.
Removal/Installation Detail Steps/Work Items 1 Remove upper cowlings.
Key Items Refer to Chapter 71-10-01/02
2 Remove lock-wire. 3 Unscrew oil thermostat. 4 Install in reverse sequence of removal.
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Maintenance Manual EXTRA 500
79-20-04
Oil Lines Draining Detail Steps/Work Items
Key Items
1 Remove upper cowlings.
Refer to Chapter 71-10-01/02
2 Remove lower cowling.
Refer to Chapter 71-10-03
3 Place suitable “oil slides” and/or canisters under the lower oil line fittings. 4 Disconnect hoses or tubes on lower fittings and drain.
Page 8
79
Hold open hose end downward where necessary.
Page Date: 30. March 2012
Maintenance Manual EXTRA 500
79-30-00
INDICATION Top View fwd
Transducers
Spanner flats
FUEL
OIL
TRQ
Switches
Figure 79-1
79-30-01
Engine Indication Transducers and Switches
Oil Pressure Transducer The oil pressure transducer is located in the engine compartment, on the LH side of the battery, the middle sensor on top (refer to Figure 77-1 and 79-1).
Removal Detail Steps/Work Items 1 Remove LH upper cowling.
Key Items Refer to Chapter 71-10-01
2 Disconnect electrical connector. 3 Remove lock-wire. 4 Remove oil pressure transducer. Page Date: 30. March 2012
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Maintenance Manual EXTRA 500
Installation Detail Steps/Work Items
79-30-02
Key Items
1 Reverse sequence of removal.
Replace o-ring when necessary.
2 Perform engine indication check
Refer to Chapter 77-00-01
Oil Temperature Sensor The oil temperature sensor is installed in the engine compartment on the LH forward engine gearbox, at oil-in-connection fitting.
Removal Detail Steps/Work Items 1 Remove LH upper cowling.
Key Items Refer to Chapter 71-10-01
2 Disconnect electrical connector. 3 Remove lock-wire. 4 Remove oil temperature sensor from fitting.
Use a funnel to collect oil from line in a suitable container.
5 Plug oil temperature sensor fitting.
Installation Detail Steps/Work Items
79-30-03
Key Items
1 Reverse sequence of removal.
Replace o-ring when necessary.
2 Perform engine indication check
Refer to Chapter 77-00-01
Oil Pressure Switch The oil pressure switch is located in the engine compartment, on the LH side of the battery, the middle sideward sensor (refer to Figure 79-1).
Removal Detail Steps/Work Items 1 Remove LH upper cowling.
Key Items Refer to Chapter 71-10-01
2 Disconnect electrical connector.
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Maintenance Manual EXTRA 500
Detail Steps/Work Items CAUTION
Key Items
Never force the body of the sensor to turn against friction. It may change the set-point. Always use a wrench on the spanner flats of the attachment fitting for removal and installation.
3 Remove oil pressure switch.
Installation Detail Steps/Work Items
Key Items
1 Reverse sequence of removal.
Apply Loctite 577 to pressure switch thread
2 Perform engine indication check
Refer to Chapter 77-00-01
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Intentionally left blank
Page 12
79
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Maintenance Manual EXTRA 500
Chapter 80 Starting
Page Date: 30. March 2012
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Page 1
Maintenance Manual EXTRA 500
Table of Contents
80-00-00
GENERAL ........................................................................................................ 3 Description.......................................................................................................... 3
80-10-00
CRANKING ...................................................................................................... 4 Motoring ............................................................................................................. 4
Page 2
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Maintenance Manual EXTRA 500
80-00-00
GENERAL For specific repair and replacement information refer to Rolls-Royce 250-B17F Series Engine Operation and Maintenance Manual (LOAP 1).
Description The ENGINE START switch is located on the instrument panel and has three positions: • START • IGN • IGN OFF
Engine starting on the EXTRA 500 is semi-automatic. The start switch is shortly set at START and automatically falls back in the IGN setting. This will initiate the start cycle directed by the Generator Control Unit and performed by the starter generator. The condition lever must be set during the cycle to add fuel. See EXTRA 500 Pilot’s Operating Handbook for exact procedure. When the engine has reached a certain RPM (N1), the starter will automatically switch off. Ignition must be switched off manually to prevent excessive spark plug wear.
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Maintenance Manual EXTRA 500
80-10-00
CRANKING Cranking may be accomplished with the ENGINE MOTORING switch, located next to the ENGINE START switch. The ENGINE MOTORING switch has three positions: • MOTORING • ABORT • NORMAL
NOTE
For a normal engine start, the ENGINE MOTORING switch MUST be in the NORMAL position. Always return the switch in the NORMAL position. The ABORT position is to abort a normal engine start. It will immediately switch off the electrical starter and ignition. It does not cut the fuel.
Motoring Do not motor the engine while aircraft jacked. CAUTION Motoring may be used for maintenance and to cool down the engine prior to engine start to prevent a hot start. Normally, a TOT of below 100°C and a good battery will produce a start within limits. Detail Steps/Work Items
Key Items
1 Secure aircraft with wheel chocks. 2 Perform Before Starting Engine procedure.
Refer to EXTRA 500 Pilot’s Operating Handbook, Section 4
3 Check condition lever in CUT OFF. During motoring the propeller will turn and exhaust gasses will be hot. WARNING Make sure no one or nothing can be struck by a propeller blade or is in the propeller/exhaust jet stream. CAUTION
Motoring is the same as starting for the starter generator. Apply the normal starter limits to motoring also: Three times 30 seconds max. with a 60 second cool down period. After the third time, wait at least one half hour.
4 Switch and hold MOTORING. 5 Check oil pressure indication. 6 Return the switch to ABORT. 7 After motoring switch to NORMAL.
Page 4
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Maintenance Manual EXTRA 500
Chapter 91 Charts
Page Date: 30. March 2012
91
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Maintenance Manual EXTRA 500
Table of Contents EA-9B213.30A EA-9B215.10B EA-9B215.20A EA-9B235.17 EA-9B243.10A EA-9B243.20A EA-9B243.40A EA-9B243.41A EA-9B244.10A EA-9B244.20 EA-9B246.10A EA-9B252.10A EA-9B252.11A EA-9B256.11 EA-9B271.17B EA-9B271.18A EA-9B273.30A EA-9B275.20A EA-9B276.10A EA-9B284.10A EA-9B284.13A EA-9B284.30 EA-9B303.10A EA-9B304.10A EA-9B304.20A EA-9B310.10A EA-9B314.30B EA-9B315.80B EA-9B315.81 EA-9B315.90B EA-9B316.40A EA-9B316.50A EA-9B317.10A EA-9B323.10A EA-9B323.20A EA-9B334.10A EA-9B334.20A EA-9B334.35A EA-9B334.40A EA-9B334.50A EA-9B334.55A EA-9B334.60A EA-9B334.75A EA-9B334.81A EA-9B334.90A EA-9B334.91A EA-9B342.65 EA-9B342.66 EA-9B342.67 Page 2
91
Cabin Pressure Control, HP Air Condition, HB Bleed Air System MKR / Audio, RM DC Generation I, PP DC Generation II, PR E-Box PCB Board E-Box External Power, PD Battery charge, PL DC Distribution 12V Power receptacle (Cigar Lighter), MM 12V Sockets,TH ELT ARTEX ME 406, DA AutoPilot-STEC-55X, CA Yoke (Control stick) Left, Right Stall Warning, WH Flap-System, CG Prop Overspeed, ES Fuel QTY Indication, QX PCB-Board 1 Low Fuel Warning, WW Pitot-Static-Stall-Heat, HG Anti ICE Intake, HM Windshield Heat, HF Boots, HH Airspeed Warning, WV Annunciator Panel, WW PCB-Board Warning/Annunciator Low Voltage Monitor, WL Digital Instrument Package, EY Engine Instrument Package, EZ Engine Warning, LW Landing Gear Control, GA Gear Warning, GA Strobe Light, LB NAV Light, LC Landing Light, LA Cabin-Dome-MAP Light, LJ Courtesy Light, LY Ice Light, LN Recognition Lights, LF Glare Light Luminiszenz-Backlighting Dimming, LH Dimming IFD LH, FG IFD RH, FG Keypad, FG Page Date: 30. March 2012
Maintenance Manual EXTRA 500
EA-9B342.73 EA-9B344.14 EA-9B344.15 EA-9B344.16 EA-9B344.17 EA-9B345.47 EA-9B345.58 EA-9B360.11 EA-9B527.10 EA-9B731.10A EA-9B731.30A EA-9B731.40A EA-9B743.10A EA-9B752.15A
Attitude Gyro, FM Weather Detec TWX-670, SS Traffic System TAS-610, SD Broadcast MLB-700, TL Datalink 2-way MLX-770, TS DME KDM 706A, SN ATC BXP6402-1R, SH Prop Heat, HI Door Warning Fuel Pump / Filter, QB Fuel Trans, QF Fuel Flow, QY Start / Ignition, JB Panel Fan, HK
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Left blank intentionally
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D
C
B
LK
-X2
1 2 3 4 5 6 7 8 9 10 11
Aft Door
Stall-Warn
Cab-Press
Gen-Fail
Gear Warn
Flaps
P/N 5111-00-3
Motor Motor + +12V DIAL LITES +28V DIAL LITES
+5V DIAL LITES GND 18-32,5VDC + POTENTIOMETER POTENTIOMETER POTENTIOMETER
COMMEN DIAL LITES
LG15E-22
HP15E-22
HP14E-22
MS27473E10A35S MIL-C-38999-II
ws org bl ws bl
HP2F-22
VV88 HP8E-22N
WW1-20
WW16-22
LG15E-22
100
LG16E-22N
10 1 9 11 2 3 8 13 12 4 7 5 6 4HP-A
4HP-A
HP9F-22
R C S
56k 0.25W
1k2 4W
1A
F3 Lumi Dimm
15 24 25
1
2
3
31
ST1
ANNUNCIATOR BOARD EA-9B315.81 see EA-9B315.80 ANNUNCIATOR PANEL
+ VOLT DIMM
LIGHT TEST (GND)
ANNUNCIATOR BOARD D15 5WW
4
5
LH2-22
LH4-22
5
VV91 VV92
108
3 4 5 6 7 8 9 12 13
EDV-Kennung:
9B21330T 6
Zuordnung links / rechts wird mit */* in allen Feldern angegeben.
MOTOR
6HP
16.09.10
Nr.: Änderung/Mod. Nr.: Datum
ÄM-400-09-01
18.02.11
VV90
C
7
8
Name
PB
Datum
Blatt 1
A von 1
8
Schutzvermerk nach DIN 34 beachten.
A3
EA-9B213.30
CABIN PRESSURE, HP
EA 400-500
Maßstab auf SI.-Klasse Oberflächenschutz
Projektion Freimaßtoleranz Oberfläche
Muß auf 12830 ft eingestellt werden!
27.04.04
Schwarze Heide 21
Gepr.:
Gepr.:
Bearb.:
Anschluß offen
8HP
HW Name 46569 Hünxe, Germany
HW
HP11E-22 HP12E-22
MPL500
AV1 NO
12830 ft SW
DRUCKSCHOTT
DRUCKSCHOTT
Anschluß an Static Press
Differenzdruck
P/N 5112-00-3
+
VACUUM VALVE VACUUM VALVE POTENTIOMETER POTENTIOMETER POTENTIOMETER
10000ft SW
Letzte Bearbeitung:
A
P/N 5113-00-3
DUMP SOLENOID
5HP
Absolutdruck
HP11G-22 HP12F-22N
VV89
7HP
001758_212_02 3VN-A
G
2A
DUMP
CABIN CONTROL OUTFLOW VALVE
D E
A B
SAFTY VALVE
see EA-9B334.90 DIMMING SYSTEM
SWITCHES
ws org bl ws bl
MS27473E10A35S MIL-C-38999-II 6HP 10 1 9 11 2 3 8 13 12 4 7 5 6
HP15E-22
HP14E-22
6HP-A
9HP
7
see EA-9B246.10 DC-DISTRIBUTION
3A
C-PRESS
EMERGENCY BUS PP4 1HP
HP1E-22
5HPA HP3G-22 HP9J-22
Die Gültigkeitszuordnung von Version zu Flugzeugbaureihe ist der Bauakte bzw. dem jeweiligen Fertigungsauftrag zu entnehmen.
cw
4.7k 24LH
04 03 02 01 Ver. Bezeichnung
HP11G-22
5WW-D
47
7
4
2
2HP:1
2HP:2 5
PRESS
DIM CONTROL
SIM
5
HP3F-22 HP9H-22
3 HP3E-22
3 HP9G-22
1 HP9E-22
1
3
DUMP 4
OFF 6
PRESS
3 HP10E-22N
2 HP2E-22
07.2.1.15L
CIRCUIT BREAKER/SWITCH PANEL
6
DRUCKSCHOTT HINTEN MS3116F106S ST14-B MIL-C-26482-I HP13-F22N HP13-E22N
A:2
A:3
D:13
A:4
A:10
27LH-A
19VN-A 001758 212 02
B
HP3F-22
HP9H-22
HP9F-22
HP10F-22N
HP2F-22
DIMMING BOARD EA-9B334.91 see EA-9B334.90 DIMMING SYSTEM
INV
DIMMING BOARD
1VN-E 001758 212 02
5WW-B
26 31
ST1
4
Maintenance Manual EXTRA 500 Chapter 91 30. March 2012
1WW
P/N 90-4219X-1
Annunciator Panel left
+X1
1A 3 1B 3 1C 3 1D
3
see EA-9B323.10 GEAR CONTROL
CABIN PRESSURE CONTROLLER
4HP
2
2
2
2
35GA
M220-B4N Schalterstellung A/C on Air
001758_212_02
1VN-E
VV189
GROUND RELAYS
GA32-22N
A
3
LG16E-22N HP8E-22N HP10F-22N
2
HP11F-22 HP12B-22
1
HP3E-22
D
C
B
A
D
C
7HB
6HB
9HB:2
VENT
:1
100A
VENT
2A
8HB
AIR CON
AIR-CTRL
30A
K4
BATTERY
ST1
m
1
1
HB17E-22
HB18E-22 C:20
C:19
D:2
D:19
C
21 22
HB18F-22
HB17F-22
HB7F-12
HB16F-22
HB2F-4
m n
HB15F-22 HB16F-22
FILTER-1
HB5F-4N
GND-Bolzen Firewall 1VN
HB15G-22 HB16G-22
ST1
FIREWALL
3
1
3
M320
low
M320
X2
3HB
1
2
3
4
D
A
BM-
17HB
B+
HB8F-12
HB8E-12
HB9F-12
HB9E-12
5
001758 212 02 8VN-F
M
B
HB5E-4N
sw/wht
12HB rt/wht
Binary Pressure Switch 1250232-4
rt
4HB Kompressor TEMP. SW. Kondenser Enviro Systems 1134410-5
grn
HB2G-4
P/N: 1240160-5 SOFT START MODULE
red-low
orange-high
14HB
rt
9B21510T 6
ÄM-400-09-02 ÄM-400-09-01 ÄM-400-04-02
Datum
27.04.04
PB
Name
7
PB Name 46569 Hünxe, Germany
16.09.10
Schwarze Heide 21
Gepr.:
Gepr.:
Bearb.:
GROUNDING POINTS
HB10E-12N
8
Blatt 1
B von 1
8
Schutzvermerk nach DIN 34 beachten.
A3
EA-9B215.10
AIR CONDITION 20A, HB
EA 400-500
Projektion Freimaßtoleranz Oberfläche
001458 212 02 8VN
LM
Maßstab auf SI.-Klasse Oberflächenschutz
HB23E-22N
blk
Enviro Systems 1134200-80
1134200-80
HW
HW
13HB
CABIN BLOWER AFT
orange-high red-low
7
17.09.10
23.02.11
Nr.: Änderung/Mod. Nr.: Datum
A
B
Letzte Bearbeitung:
001758 212 02 8VN
HJ
VV94
rt
1134200-81
HB9E-12
HB8E-12 VV93org
MOTOR CONTROL
HB13E-12N HB22E-22N
blk
Zuordnung links / rechts wird mit */* in allen Feldern angegeben.
EDV-Kennung:
C
Enviro Systems 1134200-81
Die Gültigkeitszuordnung von Version zu Flugzeugbaureihe ist der Bauakte bzw. dem jeweiligen Fertigungsauftrag zu entnehmen.
rt
org
6
CABIN BLOWER FO
04 03 02 01 Ver. Bezeichnung
org
VV100
VV97
COMPRESSOR AND CONDENSER FAN
3 1 2
Timer 18HB
HB19E-22N
VV99
5
SOFT START CONTROL
HB14E-22N
2 HB9G-12
X2
2HB VV98
2 HB8G-12
HB15E-22
HB2G-4
am Halteblech Blower Front
HB18F-22X1
HB6F-12
VENT
HB17F-22X1
HB6E-12 1
high
14
SIM
HB15F-22
ST13-D
Bolzen
HB2F-4
Bolzen
HB5E-4N
19VN
DRUCKSCHOTT HINTEN HB5F-4N
4
Maintenance Manual EXTRA 500 Chapter 91 30. March 2012
see EA-9B246.10 DC-DISTRIBUTION
3
1
5
n
HB7E-12
HB16E-22
HB2E-4
E-BOX EA-9B243.40 see EA-9B243.40 E-BOX
HB7E-12
AIR-CON
LOAD BUS PP3
1HB
3
2
LOW1
B
OFF
HB2E-4
CIRCUIT BREAKER/SWITCH PANEL
HI
A
K1
EXT POWER
HB3E-20
3
HB6F-12
K3
2
wht
GENERATOR
ON
HB20E-4 red
E-BOX
1
OFF
5 HB4E-20
4 6
07.2.1.40 901
3
07.1.1.13
HB21E-4 black
2
HB19E-22N HB14E-22N
HB15E-22 HB22E-22N HB13E-12N
1
HB23E-22N HB10E-12N
D
C
B
A
A
B
C
D
1
25 37 35
29 5 31
23 2 22 1
13
10 32
12 33
36 8
Pilot Control +VA Pilot Control Pilot Control GND
Bypass +28V Bypass GND H.Exchanger +28V H.Exchanger GND
Stadby ON
Duct Sensor pos. Duct Sensor GND
Cabin Sensor Pos Cabin Sensor GND
Chassis GND Power GND
3 6
Manual Bypass Man H. Exchanger
Auto/Manual SW Switch GND Switch Power +15VDC
27 9 20
28VDC 28VDC Overtemp Ind Light
+15V GND Input GND
Power GND Logic GND Power GND
Sensor Sensor Sensor Sensor
8 26 36
24 31 5 7
2
37pol DSub
ws bl ws bl
ws bl ws bl
3HA-A VV101
ws bl
ws bl
ws bl ws bl
ws org bl
org bl ws
ws bl
N/C
HA3E-22
HA1G-22
HA19E-22N
HA18E-22
HA17E-22
HA16E-22
HA15E-22
HA14E-22
HA12E-22
HA13E-22
001758 212 02 3VN-A
VV102
S
T
D:10
D:8
D:9
HA22G-22 HA23E-22N
BYW56
2VN-D C 001758 212 02
VV104
D1
66 67 43 68 69 42 70 71 41
20
2
D12
12 24 25
5WW-C
J4
ST4
1 bl
1
1
ws bl
14HA-A A B
HA18F-22
HA17F-22
HA16F-22
HA15F-22
5
2
HA4G-22 16HA:1
ws bl ws bl
9HA-A
HA8E-22 HA10F-22N HA2G-22
Annunciator Panel left
HA18F-22
HA17F-22
HA16F-22
HA15F-22
VV108
Splice
1
HA34E-22N NC HA33E-22 21HA VV109 EA-0B833-09 21544-3-60-2
Temp Sensor
Env. Bleed Temp
A
39
5WW-D
001758 212 02 2VN-D
44
2
BYW56
D38
+VDCII
G6A-234P
3
ANNUNCIATOR BOARD EA-9B315.81
K2
+ VOLT DIMM
LIGHT TEST (GND)
ANNUNCIATOR BOARD 5WW
9
WW39-20N
5WW-A
WW1-20
WW13-22
4
Bleed Overt
Stall-Warn
Cab-Press
Stall-Heat
Windsh-Heat
Aft Door
B D A C
Exch + Exch Bypass + Bypass -
Sensor + Sensor GND 28VDC
10HA
A C B D
Open + Open Close + Close -
11HA
VALVE-FLOW CONTROL
A B D C
9HA
Temp. Modulating Valve
Oil-Press
Fuel-Press
A B C D E F G H
5
1WW
ws bl ws bl
Sens Sens Sens Sens
+ In Gnd
EA-0B833.06
SN 1300464-15
Triebwerkraum links
EA-0B836.33
SN 1300490-13
Co Pilot overhead
SN 1300440 EA-0B833.08
Triewerkraum links
SN 1300330 EA-0B836.26
1
1
EDV-Kennung:
9B21520T 6
Zuordnung links / rechts wird mit */* in allen Feldern angegeben.
04 03 02 01 Ver. Bezeichnung
D:14
C:10
HA1F-22
HA21F-22
ÄM-400-09-01
06.10.10
Name
HW
7
Name
PB
Datum
17.02.04
HA21G-22
7
46569 Hünxe, Germany
Schwarze Heide 21
Gepr.:
Gepr.:
Bearb.:
21 22
ST4
Trennstecker FIREWALL
HA20F-22 HA21F-22
Nr.: Änderung/Mod. Nr.: Datum
A
Letzte Bearbeitung:
CB-Trennstecker
6
Die Gültigkeitszuordnung von Version zu Flugzeugbaureihe ist der Bauakte bzw. dem jeweiligen Fertigungsauftrag zu entnehmen.
P/N 90-42192-1 geändert
12HA Bugfahrwerkkasten
Flow Flow Flow Flow N/C N/C N/C N/C
12HA-A MASS FLOW SENSOR
ws bl ws bl
11HA-A
HA21G-22
HA1E-22
ENV-BLEED 5A
Temp. Poti. Ansicht von hinten.
10HA-A Cabin Temp. Sensor
Triebwerkraum 14HA Brandspant rechts
3 2
P16NM103KA
4
1HA
BATTERY BUS PP2
see EA-9B246.10 DC-DISTRIBUTION
07.2.1.13 5 HA21G-22
2
ENV BLEED
10k
TEMP
5AH:1 07.2.1.13
AUTO/MANUAL
2 07.1.1.17
7HA
:2
5
MAN CONTROL
SN 1300450-1 EA-0B833.07
6
4
C15P see EA-9B334.40 CABIN-DOME-LIGHT & EA-9B235.17 MKR-AUDIO
1 2 3 4
ST12
Sensor + Sensor -
Duct Temp Sensor
ON
3
OFF 1
6
4
AUTO 3
HA5F-22
HA22E-22
3
4HA 1
MAN 1
HA3F-22
HA28E-22
bl
1 1
org
ws
1
1
1
1 ws
1 bl
1 org
1
2HA-A C50C
CIRCUIT BREAKER/SWITCH PANEL 1 ws
ws HA8E-22 bl HA10E-22N HA2F-22
HA27F-22
HA7F-22
HA6F-22
A
D:15
B:2
B:13
B:12
B:11
B:10
B:9
B:6
B:8
B:7
B:5
B:4
B:3
4
CB-Trennstecker
HA22F-22
HA28F-22
001758 212 02
8VN-A
ST4
HA5E-22
HA4E-22
HA3E-22
FIREWALL
38 76 77 78 79 37
40 72 73 74 75 39
2 see EA-9B246.10 DC-DISTRIBUTION
2
CB-Trennstecker
HA11G-22
3VN-A 001758 212 02
HA9E-22N
VV100
HA8E-22
HA27E-22
VV99
HA7E-22
HA6E-22
15HA an 11HA Flow Valve EA-0B836.32
Prim. Bleed N/C
VV103
PRIM. SHUT OFF VALVE Splice
HA5E-22
Airframe Ground
Airframe Ground
HA4E-22
Airframe Ground
VV98
3
Maintenance Manual EXTRA 500 Chapter 91 30. March 2012
3HA
Flow Flow Flow Flow
35 23 2 22 1
18 30
Low High
Hi/Low Switch GND Open +28VDC Open GND Close +28VDC Close GND
27 9 13
28VDC 28VDC Standby ON
MASS FLOW CONTROLLER
2HA
KABINE
Cabin leftside
VV97 2HA-A
HA4F-22
CABIN TEMPERATUR CONTROLLER
SN 1300350-27 EA-0B836.31
SN 1300360-17 EA-0B836.30
HA28F-22
HA28G-22
HA1F-22 HA1G-22 HA2G-22 HA11F-22 HA20F-22
Microswitch am Condition-Lever
A Blatt1
von 1
8
Schutzvermerk nach DIN 34 beachten.
A3
EA-9B215.20
BLEED AIR, HA
EA 400-500
Projektion Freimaßtoleranz Oberfläche
Turbine leftside
334-870
18HA
Maßstab auf SI.-Klasse Oberflächenschutz
NO
NC
Cut Off
HA20G-22
8
A
B
C
D
D
C
B
A
HI LO HI LO
AUDIO AUDIO AUDIO AUDIO
HI LO HI LO
6 5
41 42
35 36
37 38
PASS4 MIC PASS4 MIC GND
PASS1 MIC PASS1 MIC GND
PASS2 MIC PASS2 MIC GND
27
25
23
COMMON
ENT INPUT 1 LT
28
COMMON
24
26
ENT INPUT 2 LT
ENTINPUT 1 RT
16 31 1
PILOT HEADSET L PILOT HEADSET R PILOT HEADSET GND
ENTINPUT 2 RT
32 33 34
COPILOT MIC IN COPILOT MIC KEY COPILOT MIC GND
3 4 2
39 40
PASS3 MIC PASS3 MIC GND
COPILOT HEADSET L COPILOT HEADSET R COPILOT HEADSET GND
20
8 9
27,5 VDC 27,5 VDC
COM SWAP
7
INSTR. LIGHT
Light GND Light GND
MKR ANTENNE MKR ANTENNE GND
ALT WRN GND
ADF ADF DME DME
PASS HEADSET GND PASS HEADSET L PASS HEADSET R
1 2
32
7 8 21 22
42 40 41
44 43 31 35 33 34
19 20 13 14
RZ2E-24S
C
U
RM15E-22N
ws bl
org ws bl
RM14E-22S
RZ4E-24S
ws bl
BYW-56
SS9E-24 D2
RZ13E-24S
org ws bl
RZ8E-24S
ws bl
RZ5E-24S
TZ7E-24S
ws bl
org ws bl
RZ10E-24S
ws bl
RV1F-24
RZ11E-24S
1
RZ1F-22
ws bl
VV145
see EA-9B284.13 PC-BOARD 1 Pin 8
G
2RM
CI118-5
2SN
Audio Hi Audio Lo
KDM 706A
MKR Ant.
DME
11 8
ST12
SPKR
see EA-9B344.14 WEATHER DETECTION
VV334905 Pin G
see EA-9B334.90 Dimming
RS 477-012
2RM-A
001758-212-02
SS7E-24
24
1VN
17
ws 21 bl
2SN-A
RM12F-24S
Druckspant
ws bl
Durchbruch
RM4E-RG400
LG3E-22
20 14 15
ST13-1B
SS7E-24 BYW-56
1VN-C
RZ9E-24S
001758_212_02
VV10
P3402 1RM-B
1VN-D
31
RZ9E-24S
1
org bl
ws
A F bl B G
VV235161
Module Pilot links
2RV2E-24S
WH12E-22S
2RM1E-24S
2RV2E-24S
2RV1E-24S
RM1F-24 RM2F-24 RM3F-24
RV1F-24
1RV4F-24 1RV5F-24 RV1E-24
1
1RV4E-24 1RV5E-24 RV1E-24 1RV5F-24 1RV4F-24
1
RM1E-24 RM2E-24 RM3E-24
1RV3E-24S
1RV2E-24S
1RM1E-24S
1RV1E-24S
2RM1E-24S
2RV1E-24S
SS8E-24 D1
1
RM1F-24 RM2F-24 RM3F-24
RM1E-24 RM2E-24 RM3E-24 1RV4E-24 1RV5E-24
1RV3E-24S
1RV2E-24S
RM12E-24S
WH13-22N
ws bl
N/C
bl ws org
bl org ws
ws bl ws bl
ws bl
bl ws bl ws bl
1RM1E-24S
1RV1E-24S
1
62 63 82
62 63 82
RZ2J-24S
ws bl ws bl
ws bl
P2144
J2121
P2122
P1122
J1121
ws bl ws bl ws bl
ws bl
P1144
13 29 44 30 43 28
11 5
38 37 21
#2 #2 LO #1 #1 LO #3 #3 LO
IFD-5000i
IFD-5000i
F G J
bl
G K J
C org E org
ws H K ws
E
C bl
bl ws
14RZ-A
F G H J K
1 2 3
14RZ-a
RZ16F-22 RZ16G-24 RZ16H-24 RZ16J-24 RZ16K-24
RZ9G-24S
1 2
grün gelb
Spiralkabel
1
13 14
10 11
GND GND
44 43
ICS MUTE INHIBIT ICS MUTE INHIBIT RETURN
SPEAKER OUT SPEAKER GND
2
VV11
RZ17E-22N RZ18E-22N RZ19E-22N
C15P
001758 212 02 1VN-D
AKF
3
see EA-9B215.20 BLEED AIR see EA-9B334.50 COURTESY LIGHT see EA-9B334.40 CABIN-DOME-LIGHT
5RM
bl
ws ws
C H D J E K
A F bl B G
C H D J E K
VV235162
bl
ws ws
RZ2G-24S
4
2x 001115 204 03
RZ2F-24S
12CA-A
ws bl
11 12
Spiralkabel
RZ2H-24S
RZ2G-24S
12CA-a
11 6
rt ws/grün
ws bl
ws bl
Pilot PTT
Copilot PTT
5
PTT MIC HANDMIKE
Mittelkosole
13RZ
5
PTT MIC Pilot MIKE
6RZ
LH Armrest
rt ws/grün
5RZ
4RZ
Steuerhorn-Steckerleiste
RZ9H-24S
RZ9F-24S
see EA-9B271.17 AUTOPILOT
RZ13F-24S
A B C D E
VV235164 001115-202-02
H
F
org A org B org D
ws ws ws
A B D
VV235163 2x 001115 208 02 bl bl bl
7FG see EA-9B342.66 IFD RIGHT
#2 #2 LO #1 #1 LO #3 #3 LO
MICROPHONE #1 TX KEY #1
CFG DISCRETE IN 0 CFG DISCRETE IN 1 CFG DISCRETE IN 2
DISCRETE IN 7 DISCRETE IN 6 DISCRETE OUT 10
HEADPHONE HEADPHONE HEADPHONE HEADPHONE HEADPHONE HEADPHONE
3FG see EA-9B342.65 IFD LEFT
DISCRETE IN 7 DISCRETE IN 6 DISCRETE OUT 10
CFG DISCRETE IN 0 CFG DISCRETE IN 1 CFG DISCRETE IN 2
HEADPHONE HEADPHONE HEADPHONE HEADPHONE HEADPHONE HEADPHONE
MICROPHONE #1 TX KEY #1
IFD RIGHT
38 37 21
13 29 44 30 43 28
11 5
IFD LEFT
4
Maintenance Manual EXTRA 500 Chapter 91 30. March 2012
1RM
RX RX RX RX
TEL RINGER IN TEL RINGER GND ALT WRN IN PILOT MIC GND PILOT MIC IN PILOT MIC KEY
#2 #2 #2 #2
15 30
COM 2 MIK AUDIO OUT COM 2 MIK KEY OUT
NAV NAV COM COM
27 28
COM 2 SPKR LOAD COM 2 SPKR LOAD GND
17 18 9 10 7 8
25 26
HI LO HI LO HI LO
COM 1 SPKR LOAD COM 1 SPKR LOAD GND
RX RX RX RX RX RX
37 38 36 24 25
#1 #1 #1 #1 #1 #1
11 12
ws bl
1RM-A
P3401
EXT BLUE LAMP (O) EXT AMBER LAMP (M) EXT WHITE LAMP (A) ACTIVE COM SELECTED COM SPLIT SELECTED
NAV NAV COM COM MONITOR MONITOR
COM 1 MIK AUDIO OUT COM 1 MIK KEY OUT
PMA8000B oder PMA8000BT
RZ9K-24S
AUDIO & MARKER
RZ16N-24 RZ16M-24
3
RZ2E-24S RZ2H-24S
Modul 2 Modul 3 Modul 4
2
Modul 5
Modul 6
F G H J K
001758-212-02
1VN-C, 1VN-C
001115-204-03
A B C D E
VV235151-2
RZ16F-22
RZ1F-22
2
2
F G H J K
001115-208-02
A B C D E
6
RZ16E-22
RZ1E-22
VV235153-4
D:4
D:3
CB Trennstecker
A B C D E
F G H J K
001115-202-02
VV
1A
2RZ
PP3
5A
AUDIO-MRK
VV21 bl VV23
Zuordnung links / rechts wird mit */* in allen Feldern angegeben.
EDV-Kennung:
9B23517T
04 03 02 01 Ver. Bezeichnung
bl
7
1 2 3 4 5 6 7 8 9
org ws ws bl
20RZ-A
ws bl
18RZ-a
1 2 3 4 5 6 7 8 9
20RZ-a
1 2 3 4 5 6 7 8 9
RIGHT EAR LEFT EAR MIC HI MIC LO
7
Nr.: Änderung/Mod. Nr.: Datum
19.01.11
HW
Name
Schwarze Heide 21
Gepr.:
Gepr.:
Bearb.: 29.11.10
Datum
Name 46569 Hünxe, Germany
HW
optical coverage minimal 98 - 100% Letzte Bearbeitung:
ws bl
7RZ BOSE
1
1
1
1
1
3RZ
6
6
6
6
6
PILOT
COPILOT
PASS 2
PASS 1
PASS 4
PASS 3
Blatt 1
8
Schutzvermerk nach DIN 34 beachten.
A2
EA-9B235.17 von 1
Projektion Freimaßtoleranz Oberfläche
EA 400-500 MKR/AUDIO, RM
Maßstab auf SI.-Klasse Oberflächenschutz
Pilot PHONE
PHONEBUCHSE
12RZ BOSE
11RZ BOSE
10RZ BOSE
9RZ BOSE
8RZ BOSE
6
LH Armrest
ws sw ws ws/bl
rt sw
ws sw ws ws/bl
RIGHT EAR LEFT EAR MIC HI MIC LO
V+ GND
rt sw
ws sw ws ws/bl
RIGHT EAR LEFT EAR MIC HI MIC LO
V+ GND
rt sw
ws sw ws ws/bl
RIGHT EAR LEFT EAR MIC HI MIC LO
V+ GND
rt sw
ws sw ws ws/bl
RIGHT EAR LEFT EAR MIC HI MIC LO
V+ GND
rt sw
V+ GND
ws sw ws ws/bl
RIGHT EAR LEFT EAR MIC HI MIC LO
36 AWG Tinned copper per ASTM-B-33
RZ4F-24S
VV24 VV25
org
1 2 3 4 5 6 7 8 9
18RZ-A bl ws org
17RZ-A 17RZ-a
ws bl
16RZ-a 1 2 3 4 5 6 7 8 9
rt sw
V+ GND
PASS 4
1
COPILOT
Copilot PTT
PASS 3
Pilot MIKE Pilot PHONE
HANDMIKE
Pilot
PASS 2
PILOT
Pilot PTT
8
PASS 1
16RZ-A bl ws org
15RZ-a 1 2 3 4 5 6 7 8 9
19RZ-A 19RZ-a
ws bl
bl ws org
ws bl
bl ws org
15RZ-A
bl org ws
OVERBRAID
Die Gültigkeitszuordnung von Version zu Flugzeugbaureihe ist der Bauakte bzw. dem jeweiligen Fertigungsauftrag zu entnehmen.
1
RZ13F-24S
RZ2J-24S
RZ4E-24S
RZ16N-24
VV22
RZ13E-24S
RZ5E-24S
RZ16M-24
RZ8E-24S
RZ9K-24S
RZ16K-24
RZ7E-24S
RZ9H-24S
RZ16J-24
RZ10E-24S
RZ9G-24S
RZ16H-24
RZ11E-24S
RZ9F-24S
RZ16G-24
see EA-9B246.10 DC-DISTRIBUTION
1RZ
LOAD BUS
CIRCUIT BREAKER/SWITCH PANEL
6
ws bl
1
C B A
F E D
J H G
M L K
R P N
U T S
bl ws
D
C
B
A
A
B
C
D
Z W C F R L G B A J U T E D H V X Y M
bl ws
A B C
7PR
GCU
OFF
3
07.1.1.13
2
EMERGENCY
ON
E
B
10A
B:10
B:5
B:6
D:13
PR16F-20
2
PR4F-20
3
PR5F-20
PR6F-20
3
3
2
2
D:15
D:14
1VN SCHRAUB-BOLZEN
D
A
2PR
PR7F-16
3x AWG18 PR13F-16
ST3 MS 27615-K14T7P
MS 27613-K14T7S
PR13E-16
PP6E-22
PP5E-22N
TRIP
7PR:2
:1
PP1E-2/0
LA2G-18 Landing Light Zündbox EA-9B334.35
LA2F-18
3
Note 1
001758 212 02 C 3VN-A
PP5F-22N
PP3F-22
2
07.1.1.17
GEN
3
07.2.1.16
RESET
OFF
ON
OFF PR10F-20 OV-TEST
PR11F-20
CB Trennstecker
ON PP3G-22
07.2.1.13
19PP OFF 1
PR07E-16 PR09E-16
PP4E-22
STARTER/GENERATOR 200SGL
2PR-A MS3126F8-3S
bl ws
ST2
:1
18PP:2
BATT
PR16E-20
PR4E-20
PR5E-20
3
PR6E-20
B:7
B:8 3
B:9
3
PR10E-20
PR11E-20
8PR 1
GEN TEST
PR16G-20
Bolzen
Kabel nach MIL-W 25038
see EA-9B244.10 EXT POWER 206PR Pin 3
see EA-9B246-10 DC DISTRIBUTION
see EA-9B244.10 EXT POWER see EA-9B334.50 COURTESY LIGHT
Bolzen
ST1
EMERGENCY BUS PP2 CB 9PR GEN RESET see EA-9B246.10
P R S T U V
see EA-9B743.10 Start/Ignition see EA-9B743.10 Start/Ignition
see EA-9B334.50 COURTESY LIGHT see EA-9B323.10 GEAR CONTROL see EA-9B256.10 ELT
PR19E-20
51 52
Starter/Generator
see EA-9B334.50 COURTESY LIGHT see EA-9B334.50 COURTESY LIGHT PR3E-20 PR2E-20 PR1E-20 PR15E-20 PR14E-20 JB4E-18 JB3E-18
ST1 E F G H J K L M N
PA1E-2/0 PA2E-2/0N
GND BOLD 1VN
*
PP6F-22
ST1
VV242
LY4E-22
LY3E-22
VV241
Bolzen
VV240
LY13E-22 LY14E-22
E-BOX
+ -
20PP-A
MS3349-2
Note 1
WX Y Z A b c d e f g h i j
EA-9B243.10
20PP
+ 28Ah
BATTERY RG-390E
4
PR206F-22 PL1G-20 PR203F-22
PR211F-22S
PR201F-20 ws bl org
Bolzen
VV246
10
i
N
h
U
M
r g
j
V
f
s
W
L
e
q
A
t
k
X
K
1
D
H
b
G
F
a E
C
Z
c
J
n
m
d
p
B
Y
MS 38999III 21-41
P
T
R
S
ST1
2
3
4
or MIL-W-22759/16 + Firesleeve (TSO-C53a)
Alle anderen nicht geschirmten nach MIL-W 22759 Alle geschirmten nach MIL-W 27500
PA01E-2/0 PA02E-2/0N
Maintenance Manual EXTRA 500 * 30. March 2012 Chapter 91
ST4
PR204E-22
PR8E-20 PR12E-20
Speed Sensor
PR17E-22
PR15E-20 PR14E-20 PR13E-16 PR12E-20 PR11E-20 PR10E-20 PR8E-20 PR7E-16 PR9E-16 PR6E-20 PR5E-20 PR4E-20 PR3E-20 PR2E-20 PR1E-20 PR16E-20
PR205F-22
Trenn-Stecker am Brandspant
FIREWALL
SWITCH 206PR "STDBY ALT" Pin 2 SWITCH 206PR "STDBY ALT" Pin 2
see EA-9B243.20 DC-GENERATION II
DIODE 205PR & Pin 2 D-17 Pin 6
Bei 58% schaltet die GCU aus!
START CONTACTOR CONT START POWER FIELD RETURN CIRCUIT GND REMOTE TRIP OVER VOLTAGE SELF TEST INTERPOLE GEN. FIELD GEN. OUT GEN. CONTROL SWITCH RESET ANTI CYCLE LOAD BUS P.O.R. LINE CONTACTOR COIL GENERATOR OUTPUT GENERATOR SPEED SENSOR GENERATOR SPEED SENSOR CHASSIS GROUND
PR18E-22N
PR17E-22
49 ws 53 bl 54
ws bl
1PR
MS3106F24-28S-F80 1PR-A
PR9F-16
GCSG 505-21 GENERATOR CONTROL UNIT
3x AWG18
1 2 3 4 5 6 7
PR20-2/0N
PR17F-22
2
F G
5
PR8F-20 PR12F-20
1
3
4
6
2
PR7F-16 PR8F-20 PR12F-20 PR13F-16 PP6F-22
1
3
4
6
1
org bl ws
5
EA-9B243.20 DC-GENERATION II, STANDBY ALTERNATOR SW 206PR Pin 4 EA-9B243.20 DC-GENERATION II, REGULATOR 203PR Pin 7 EA-9B243.20 DC-GENERATION II, REGULATOR 203PR Pin 3 EA-9B243.20 DC-GENERATION II, REGULATOR 203PR Pin 4 EA-9B243.20 DC-GENERATION II, REGULATOR 203PR Pin 1 EA-9B244.20 EXT LADER, ST2 Pin A EA-9B243.20 DC GENERATION II, STANDBY ALTERNATOR SW 206PR Pin 3
EA-9B243.20
204PR Alternator 2, Anschluss B
5
6
6
Platine Fuse/Relay E-Box EA-9B243.41
Platine Fuse EA-9B243.47
Bolzen
VV245
EDV-Kennung:
9B24310T
04 03 02 01 Ver. Bezeichnung
Zuordnung links / rechts wird mit */* in allen Feldern angegeben.
Die Gültigkeitszuordnung von Version zu Flugzeugbaureihe ist der Bauakte bzw. dem jeweiligen Fertigungsauftrag zu entnehmen.
Platine Fuse Shunt spezial EA-9B243.45
Platine Fuse Shunt gross EA-9B243.43
Platine Fuse Shunt klein EA-9B243.42
Bolzen
VV244
Bolzen
VV243
PP32E-10
PP31E-2
ST1 Pin D
5
5
7
ÄM-400-09-01
2
D
Nr.: Änderung/Mod. Nr.:
A
A
Cab-Press
Flaps
Datum
01.09.10
HW
Name
11.02.04
PB
Name
46569 Hünxe, Germany
Schwarze Heide 21
Gepr.:
Gepr.:
Datum
PP4
Bearb.:
EMERGENCY BUS
3EY-A Pin 16 3EY-A Pin 19 3EY-A Pin 8 3EY-A Pin 6
A Blatt 1
von 1
8
Schutzvermerk nach DIN 34 beachten.
A2
EA-9B243.10
DC GENERATION I, PP
EA 400-500
Projektion Freimaßtoleranz Oberfläche
CB im CB Panel
5PP 1A
D:17 1
D:16 1
PR101F-22
RCCB-CTRL
Maßstab auf SI.-Klasse Oberflächenschutz
U
3VN-A
001758 212 02
see EA-9B246-10 DC DISTRIBUTION
DIP EA-9B316.40 DIP EA-9B316.40 DIP EA-9B316.40 DIP EA-9B316.40
EA-9B215.10, AIR CONDITION EA-9B215.10, AIR CONDITION
5WW-D
48
ANNUNCIATOR BOARD EA-9B315.81 see EA-9B315.80 ANNUNCIATOR PANEL
+ VOLT DIMM
LIGHT TEST (GND)
ANNUNCIATOR BOARD D16 5WW
Aft Door Stall-Warn
Gen-Fail Gear Warn
BATTERY BUS PP2
25 26 24 23
41 21 22
16 24 25
8
see EA-9B246-10 DC DISTRIBUTION
Annunciator Panel left
LOAD BUS PP3
1WW
5WW-B
EZ63E-22 HB15F-22 HB16F-22 PR101F-22 ws EY9E-22 bl ws EY8E-22 bl
5
Letzte Bearbeitung:
k m n p q r s t
WW1-20
WW17-22
PP30E-2
ST1
7
PR102F-22N PR102E-22
PR101G-22
2
5
A
B
C
D
A
B
C
3
PLatine EA-9B243.41
B
F1 40A
50A
26.72.03
STBY. Alternator BC410-1 (26VDC 20A) 204PR
VV246
001758 212 02 A 2VN-C
K7
86
87a
88
85
87
50A
K10
88a
F10 2A
ALT CHARGE
CB4 2A
6
4
3
PR202E-22
K4
PP6H-22
F4 40A
50mV 200A
BATTERY SHUNT2
K5
VV244 F3 150A
P600M
205PR
PR201E-20
PR203E-22
PR204E-22
BATTERY BUS PP2
ON
1 OFF
07.2.1.13
:2 5
F5 30A
VV242
Hot Bus PP1 PP1 HOT BUS
26.73.04
ALT SENS
ws/org ws/bl ws
F16 1A
P600M
D1
ALT FIELD 2
VV245
PR200E-20
BATTERY
2A
ALT
206PR:1 2
STDBY ALT
3
K3
sse EA-9B243.40 E-BOX
PR201G-20
PR210E-22 PR211E-22 PR212E-22
PP6G-22 PP3E-22 PR203G-22 PR206E-22
EMG-Rel. K9 Pin X2 EMG-Rel. K9 Pin X1
GENERATOR
ETA 4930-04
SHUNT1 50mV 200A
150A
F2
6
4
3 ON
1 OFF
3
ON
2 07.1.1.13
19PP 1
OFF
PP3G-22
2 2 3
PR203E-22 PR201E-20
2
2
2
PR205E-22
PP6E-22
PP5E-22N
EMERGENCY
07.2.1.13 PR205F-22
:2 5
18PP:1 2
BATT
j
g h i
e T W f
B
B:11
D:16
D:17
D:15
D:14
D:13
PR211F-22S
PR201F-20
PR209F-20
org bl ws
PP6F-22 PP3F-22 PR203F-22 PR206F-22
GENERATOR
VV240
ST2
ST1
LOAD BUS PP3
VV243
1
B
GND
2
Field
204PR-A
F
PR209E-20
3
4
Plug with Shield MS 38999 III 26K F 32 SN (32 X #20)
5
5
PP6F-22
C
21
001758 212 02
PR212G-20N
PR209F-20
PR211F-22S
PR205G-22
PR213E-22
PR206F-22
PR213E-22
2VN-C
100
5WW-D
EDV-Kennung:
9B24320T
04 03 02 01 Ver. Bezeichnung
6
Zuordnung links / rechts wird mit */* in allen Feldern angegeben.
2WW
D25
15 24 25
5WW
7
Field
Ground
Sensor Analog
Sensor +10 Volts
Bus
ÄM-400-09-01
15.09.10
Nr.: Änderung/Mod. Nr.: Datum
A
5
7
3
4
6
Alt Loaded Lamp
HW
Name
Datum
13.04.04
WW20-20
WW32-22
7
46569 Hünxe, Germany
PB
Projektion Freimaßtoleranz Oberfläche
A Blatt 1
von 1
8
Schutzvermerk nach DIN 34 beachten.
A3
EA-9B243.20
DC-GENERATION II, PR
EA 400-500
Maßstab auf SI.-Klasse Oberflächenschutz
203PR
Name
Schwarze Heide 21
Gepr.:
Gepr.:
Bearb.:
Ringösen werden im Kit mitgeliefert.
Letzte Bearbeitung:
ws
bl
org
2
Ignition
8
Prop Low Pitch External Power
Low Voltage
Standby Alt On
STANDBY ALTERNATOR REGULATOR 1 Bus Sense BC203-2D
5WW-B
Fuel Low R
Pneumatic
Fuel Trans R
ANNUNCIATOR BOARD EA-9B315.81 see Annunciator-Panel EA-9B315.80
+ VOLT DIMM
LIGHT TEST (GND)
ANNUNCIATOR BOARD
P/N 90-42192-2 geändert
Annunciator Panel right
6
Die Gültigkeitszuordnung von Version zu Flugzeugbaureihe ist der Bauakte bzw. dem jeweiligen Fertigungsauftrag zu entnehmen.
F
001758 212 02 3VN-A
PP5F-22N
CB Trennstecker
see EA-9B246.10 DC-DISTRIBUTION
VV27
4
PP4E-22
Maintenance Manual EXTRA 500 ChapterG91 30. March 2012
202PR
SENSOR
50mV 200A
2
SHUNT 3
Platine EA-9B243.41
E-BOX
EMERGENCY BUS PP4
5
200PR
EMERGENCY BUS PP4
PP32E-10
D
CIRCUIT BREAKER/SWITCH PANEL
2
RCCB 4930-4 ETA
1
A2 5B
3
A1
4
PP211F-10
PP211E-10
PR102E-10
PR102E-10
PR101E-10
PR100F-10
-
+
PR100E-10
+
-
PR208E-20N
+
FIREWALL
-
A
B
C
D
VV242
J14
* P600M
D1
J37
* P600M
J36
D10
5A
efg hij
A
5A
W
5A
GEAR AUX 2
1A
CB5
ELT
CB1
ST1
PR201G-20
*
J30 J31 J32 J33 J34 J35
F5 30A 2
HOT BUS PP1
1 EA-9B243.46
F10 2A
5A
COURTESY LT
M210-B4M S210-A5A1
D8 BYW56 LY1E-22
X1
BATT CHARGE
CB6
CB2
ALT FIELD 2
J13
CB4
LY3E-22 GA34E-22 DA2E22 PP3E-22 PD5G-22 LY4E-22
3 1
Bolzen
S
T
ST1
VV246
40A
F1
85
87z 88y
86
88y
88b
U
86
87
V
s
W
K7
q
A
85
p
87a
ALTERNATOR
ws/org ws/bl ws
J15
86
87z
87a
85
88
88a
BATTERY
K4
26.57.73
88a 87a 88b
88
PR210E-22 PR211E-22 PR212E-22
*
D5
J12
F9 4A
K1
B
EXT POWER
JB4F-20
4
J4
BC218-1
J5
C
D
J6
J2 J1
*
1
J25
* D9
J19 J20
2
1A
J7
1A
ALT SENS
F15 4 F16
J23
REL MT4 K6
Spare Pins
88y
J22
J21
J26
J24
D7 BYW56
J18
87a 88b
87z 88y
85
88a
88
86
BYW56
K3 GENERATOR
+ SHUNT 3 50mV 200A EA-9B243.45
1A
F14
ST1
B C
J8
J17
D2
EA-9B243.45
PR206E-22
J3
STROM SENSOR 202PR PR206E-20N
*
D6
J11
F13 4A
26.57.73
START
F17
GCU 1
EA-9B243.46
1
* Bauteile sind auf einer Platine integriert!
*
Platine EA-9B243.41A
2
3
P
N
i
M
r g
f
L
e
k
t
K
d
m
Z
c
J
n
Y
MS 38999III 21-41
R
h
j
X
H
b
G
F
a E
4
c d
b
a
Z
Y
X
88b
87a
5
KISSLING RELAY 26.57.71X Hilsfanschlüsse
87z
1
SHUNT1 50mV 200A
K8 X2
X1
4
BYW56
D3
K10
EDV-Kennung:
9B24340T
04 03 02 01 Ver. Bezeichnung
6
150A
F3
ÄM-400-09-01
Bolzen
ST1 Pin D
EZ63E-22 HB15F-22 HB16F-22 PR101F-22 ws EY9E-22 bl ws EY8E-22 bl
BATTERY BUS PP2
k m n p q r s t
ST1
Datum
13.02.04
PB
Name
Schwarze Heide 21
Gepr.:
Gepr.:
Bearb.:
EMERGENCY BUS PP4
7
U
A von 1
8
Schutzvermerk nach DIN 34 beachten.
A3
Blatt 1
E-BOX EA-9B243.40
D:17
1
1A
Projektion Freimaßtoleranz Oberfläche
EA 400-500
Maßstab auf SI.-Klasse Oberflächenschutz
1
5PP
3VN-A 001758 212 02
RCCB-CTRL
CB im CB Panel
see EA-9B316.40, DIP 3EY-A Pin 16 see EA-9B316.40, DIP 3EY-A Pin 19 see EA-9B316.40, DIP 3EY-A Pin 8 see EA-9B316.40, DIP 3EY-A Pin 6
25 26 24 23
D:16
see EA-9B315.80, ANNUNCIATOR, GEN FAIL seeEA-9B215.10, AIR CONDITION see EA-9B215.10, AIR CONDITION
D16
LIGHT TEST
8
41 21 22
WW1 GEN FAIL
LOAD BUS PP3
7
+ V Dim
HW Name 46569 Hünxe, Germany
VV245
Nr.: Änderung/Mod. Nr.: Datum
A
Bolzen
VV244
Bolzen
VV243
16.09.10
M210-B4N_1
Letzte Bearbeitung:
PP6G-22
EZ63F-22 HB15E-22 HB16G-22 PR101E-22 EY9F-22 EY9G-22 EY8F-22 EY8G-22
K12
ETA 4930-04
K5
150A
F2
F4 40A
A2
A1
Zuordnung links / rechts wird mit */* in allen Feldern angegeben.
Die Gültigkeitszuordnung von Version zu Flugzeugbaureihe ist der Bauakte bzw. dem jeweiligen Fertigungsauftrag zu entnehmen.
2VN-C 001758 212 02
26.72.03 50A
5B
GND
ALT CHARGE
1A 1A 5A 3 1
GCU 2
F12 F11 F18
PP211E-10
2
3
3
CB
ETA RCCB 4930-4
4 Alt Power
5A 2
B
SHUNT2 50mV 200A
2
A
S210-A5A1 1 3 1
M210-B4M
PR100E-22
J16
*
D4
BYW56
2A
1A
1A 2
F8
F7
F6
J9 J10
EA-9B243.45
AB C DE F G HJ K
Maintenance Manual EXTRA 500 Chapter 91 30. March 2012
ELT
COURTESY LT
ALT FIELD 2
SPARE
BATT CHARGE
GEAR AUX 2
Bolzen BATTERY
P R S T U V
Bolzen
3 1
B
LY2E-22
K2
5A
1
6
2
A
B
C
EA-9B334.50 Courtesy Light EA-9B323.10 Gear Control EA-9B256.10 ELT EA-9B243.10 DC Generation EA-9B243.10 DC Generation
ST1
EXT. POWER
VV241
A
PP6G-22 PR206E-22 PR210E-22 PR211E-22 PR212E-22
K11
X2
P600M
2
447-0863
2
P600M
LY1F-22
26.57.71
88 88a
JB3F-20 87z 88y 87a 88b
447-0863
Bolzen
13
GENERATOR
12
PR15F-20 86 85
10
VV240
14
JB3F-20 JB4F-20
9 7
D
11
PR16E-22N LY13E-22 LY12E-22 PR1F-20
PR2F-20 8 5
PR14F-20
4
6
LY13E-22 LY12E-22 PR3F-20 PR2F-20 PR1F-20 PR15F-20
3
26.57.710
1 16
D E F G H J K L M N
PP100E-22N
EA-9B334.50 Courtesy Light EA-9B334.50 Courtesy Light
PR16E-22N PP103E-22N PP102E-22N PP101E-22N
PP100E-22N
ST1
PR3F-20
Shield für EY8 & EY9
5
88 87 88a
4
86 85
3
-
-
2
87a
PR101G-22 PR102E-22 PR102F-22N
+
+
1
X2
PR203G-22
X1
PL1G-20
1 A
EA-9B243.20 DC-GENERATION II
2
EA-9B244.20 BATTERY CHARGE
3
STBY ALTERNATOR
1 B
EA-9B243.10 EMERGENCY 19PP EA-9B243.20 DC-GENERATION II EA-9B243.20 DC-GENERATION II EA-9B243.20 DC-GENERATION II EA-9B243.20 DC-GENERATION II EA-9B243.20 DC-GENERATION II
3
A
B
C
D
A
B
C
ST1
ST1
J8
J17
J18
J9
J16
J10
J11
J15
J12
J14
1
CON1
1
CON1
1
CON1
1
CON1
1
CON1
1
CON1
1
CON1
1
CON1
1
CON1
1
CON1
1
CON1
1
CON1
BYW56
D2
BYW56
D9
BYW56
D3
BYW56
P600M D4
D6
P600M
D5
P600M
D1
P600M
D10
BYW56
D7
K6:1
t
ST1
J22 CON1
J7 CON1
MT4
ws
ws/bl
ws/org
s
ST1
J21 CON1
Maintenance Manual EXTRA 500 Chapter 91 30. March 2012
k
W
J13
J36
CON1
1
1 16
202 PR 6
J37
5
K6:2 4
D
7
ST1
8
1
11 K6:4 12 13 1
K6:3 3 1
9 K6:5 10 14
E
ST1
J5 CON1
1
A
1
J2 CON1
EDV-Kennung:
ST1
ST1
ST1
ST1
ST1
ÄM-400-09-01
F
J
i
h
g
14.10.10
Nr.: Änderung/Mod. Nr.: Datum
A
Letzte Bearbeitung:
J1 1 CON1
9B24341T
04 03 02 01 Ver. Bezeichnung
J3
J25
J26
J23
J24
J19
J20
J34 CON1 J35 CON1 J32 CON1 J33 CON1
J30 CON1 J31 CON1
J4 1 CON1
CON1
1
CON1
1
CON1
1
CON1
1
CON1
1
CON1
1
CON1
1
1
1
1
1
1
1
Die Gültigkeitszuordnung von Version zu Flugzeugbaureihe ist der Bauakte bzw. dem jeweiligen Fertigungsauftrag zu entnehmen. Zuordnung links / rechts wird mit */* in allen Feldern angegeben.
J6 CON1
1
Name
HW
HW
46569 Hünxe, Germany
Schwarze Heide 21
Gepr.:
Gepr.:
Name
Datum
Bearb.: 16.09.05
Projektion Freimaßtoleranz Oberfläche
A Blatt 1
von 1 Schutzvermerk nach DIN 34 beachten.
A3
EA-9B243.41
PCB Board E-Box
EA 400-500
Maßstab auf SI.-Klasse Oberflächenschutz
A
B
C
D
A
B
C
D
PD4E-22
ST4
Brandspant
VV186
VV186
23
7
PD5G-22
E-BOX
5WW
+ +
-
r g
j
V
s
W
q
A
k
X
2A
2PD
p
B
m
n
Y
Z
D
a E
C
3
ON
07.1.1.13
2
5PD
2
1
PD4H-22
PD5E-22
2
PD4G-22
see EA-9B246.10 DC-DISTRIBUTION
1
OFF
EXT PWR
CIRCUIT BREAKER/SWITCH PANEL
PD1E-22
PD5F-22
PD4J-22
PD4F-22
PD4F-22
CB Panel Trennstecker
D:12
D:11
D:11
34
U
ST1
Schraube
MS38999III
PD5F-22
PD3E-2/0
1
R
S
P
N
L
e
K
d
J
c
MS 38999III 21-41
M
f
t
H
b
G
F
2
3
4
Maintenance Manual EXTRA 500 Chapter 91 30. March 2012
i
U
ST1
h
EXT PWR
1VN Brandspant
WW40-22
WW27-22
5WW-C
K1
D46
BYW56
K3
K4
87z 88b
85
86
5
87a 88b
87z 88y
26.57.710
BYW56
EDV-Kennung:
3 4 9
9B24410T 6
A
ÄM-400-09-01
01.07.10
Nr.: Änderung/Mod. Nr.: Datum
Letzte Bearbeitung:
HW
Name
2
48
26
8
m
Datum
19.10.04
Name
PB
7
46569 Hünxe, Germany
49
108
41
EA-9B334.90
8
A Blatt 1
von 1
8
Schutzvermerk nach DIN 34 beachten.
A3
EA-9B244.10
EXTERNAL POWER, PD
EA 400-500
Projektion Freimaßtoleranz Oberfläche
+ Light-Test
28VDC CB 1LH2
Maßstab auf SI.-Klasse Oberflächenschutz
HP11G-22 MS38999III 17-26
ST1
PD4J-22
Schwarze Heide 21
Gepr.:
Gepr.:
VV161
LH3G-20
HP11G-22
5WW-D
5WW-A
7
Bearb.:
see EA-9B243.10 DC GENERATION I
E-BOX EA-9B243.40
Air Condition
Platine innerhalb der E-Box EA-9B243.41
DC Generation I REL K8 Air Condition
see EA-9B315.80 ANNUNCIATOR PANEL
Zuordnung links / rechts wird mit */* in allen Feldern angegeben.
04 03 02 01 Ver. Bezeichnung
GEN-FAIL
ANNUNCIATOR BOARD EA-9B315.81
6
Die Gültigkeitszuordnung von Version zu Flugzeugbaureihe ist der Bauakte bzw. dem jeweiligen Fertigungsauftrag zu entnehmen.
88a
88
Battery Relay
87a 88y
GEN RELAY
85
87a 88b
87z 88y
86
88a
88
D2
LIGHT TEST (GND)
D45
D37
291-9726
D30
ANNUNCIATOR BOARD
5
K1
Kleiner Pin vorne Flugrichtung!
T
Deice Boots
Intake Heat
4
EXT. POWER RELAY
PD3E-2/0
Ignition
Prop Low Pitch External Power Windshield On
Low Voltage
Standby Alt On
3
1PD
PD2E-2/0N
2WW
2
EXT POWER
P/N 90-42192-2
Annunciator Panel right
1
A
B
C
D
A
B
C
+
J1
02636
PL 1
PL1E-20 PL2E-20N
BATTERY CHARGE
PA1E-2/0 PA2E-2/0N
MS3349-2
+ -
20PP-A
EA-9B334.50 Courtesy Light EA-9B323.10 Gear Control EA-9B256.10 ELT EA-9B243.10 DC Generation EA-9B243.10 DC Generation
Masse auf Rahmen
PL1E-20 C1P
ST2 A
FIREWALL
KABINE
PL1F-20
A
P R S T U V
ST-1 #20
1
2
3
4
5
Bolzen
VV241
Bolzen
PL1G-20
J37
5A
ELT
COURTESY LT
ALT FIELD 2
SPARE
BATT CHARGE
GEAR AUX 2
EA-9B243.46
J14
*
J36
D10
EDV-Kennung:
9B24420T
04 03 02 01 Ver. Bezeichnung
M210-B4M S210-A5A1
5A
6
F5 30A
2
F9 4A
Name
HOT BUS PP1
Nr.: Änderung/Mod. Nr.: Datum
Letzte Bearbeitung:
F10 2A
5A
COURTESY LT
LY2E-22
1 EA-9B243.46
GEAR AUX 2
CB5
D8 BYW56 LY1E-22
X1
X2
LY1F-22
BATT CHARGE
1A
P600M
5A
CB1 ELT
P600M
*
D1
CB2
CB6
B 3 1
A
2
3 1
ALT FIELD 2
J13
CB4
K11
2
Die Gültigkeitszuordnung von Version zu Flugzeugbaureihe ist der Bauakte bzw. dem jeweiligen Fertigungsauftrag zu entnehmen. Zuordnung links / rechts wird mit */* in allen Feldern angegeben.
VV242
LY3E-22 GA34E-22 DA2E22 PP3E-22 PD5G-22 LY4E-22
Bolzen BATTERY
A
P R S T U V
ST1-A
EXT. POWER
ST1-A
PA1E-2/0
#20 #20 #20 #20 #20 #20
ST1-A
FIREWALL
GENERATOR
VV240
E-BOX
6
7
K1
88b
85
87z 88y
86
88y 88b
Name
HW
Datum
Bearb.: 14.09.10
7
46569 Hünxe, Germany
Schwarze Heide 21
Gepr.:
Gepr.:
4
E-BOX EA-9B243.40
F13 4A
26.57.73
START
K2
Projektion Freimaßtoleranz Oberfläche
8
Blatt 1
von 1
8
Schutzvermerk nach DIN 34 beachten.
A3
EA-9B244.20
BATTERY CHARGE, PL
EA 400-500
Maßstab auf SI.-Klasse Oberflächenschutz
see EA-9B243.10 DC GENERATION I
86
87z
87a
85
88
88a
BATTERY
K4
26.57.73
88a 87a
88
EXT POWER
88 88a
5
87z 87a
4
1VN see 9B243.10 DC GENERATION I GND BOLD
BATTERY RG-390E
28Ah
20PP +
3
Maintenance Manual EXTRA 500 Chapter 91 30. March 2012
GND
+28V
2
PL2E-20N
88y 88b
D
1
26.57.71
86 85
A
B
C
D
D
1
5A
CB2 CB4
2A
CB5
1 2
3 4
1 2 3 4 5
5A
6
F10 2A
PP32E-10
5A
F5 30A
5A
2
1
PP36E-16N
1
1
C:3 C:4
1
2A
C:7 B:5
Option
2
3
10A
DAY
2
3
A:4 D:13 A:3 A:2
A:10
3
3
2
A:1
3
1
2A
4
C:16
2
2
D:19 D:20
1
1A
C:12
1
1
A:3 A:4
1
1A
B:4
3
ICE-LT
2LA
1LA
7.5A
2
5LA 1A
1
5
7.5A
2LJ
1LR
1LR
6
EDV-Kennung:
9B24610T
04 03 02 01 Ver. Bezeichnung
ÄM-400-09-01
HW
7
HW
Name
11.10.10
A
02.02.11 PB
46569 Hünxe, Germany
Name
Datum
8
Blatt 1
A von 1
Projektion Freimaßtoleranz Oberfläche
1
C:18
Schutzvermerk nach DIN 34 beachten.
A2
EA-9B246.10
3
5A
T&B
EA 400-500 DC-DISTRIBUTION
Maßstab auf SI.-Klasse Oberflächenschutz
A:5 A:6
19.10.04
3
3CA
PP5
AP-CMPTR
5A
A:1
2CA
K
1VN-A
3
001758_212_02
3
1
TAS
3A
D:20
D:16 B:11
2
PR203E-22 3
201PR:2
DC-GEN 2
ON
PR201E-20 4
5
07.2.1.13
PR202E-22 6
8
PP44F-22N
2
243.20
STDBY ALT
C:4
IFD RH B
1SD
1
PP44E-22N
1
:1
AVIONICS BUS
10A
ON
OFF
1A
FLAP-UNB
P600M
205PR
A:3 D:10
2
2
A:2
27CG
D:17
PR205F-22
OFF 1
PR204E-22
2
3
1
6FG
Schwarze Heide 21
Gepr.:
Gepr.:
Bearb.:
2 PP48E-16
D:17
1
1A
5
PR205E-22 6
2
RCCB-CTRL
5PP
1
D:16
18PP:2
ON
BATT
AVIONIC 31PP
:1
PR19E-20
07.1.1.13
X2 PP43E-22 2
D:13
D:15
M320-B4N S320-A7-A10 25A
3
1
X1
30PP
2
2
Nr.: Änderung/Mod. Nr.: Datum
2A
ALT
EMGC-2
D:14
50A
2
19PP
EMERGENCY
B:10
PP35E-12
PP47E-16
Letzte Bearbeitung:
5A
200PR
4PP
30A
AV BUS
30A
GEN-RESET
Zuordnung links / rechts wird mit */* in allen Feldern angegeben.
A:11
D:1
C:7
C:4
3
3A
ATC
9PR
33PP CR1/1
OV-TEST
3
3PP
CR1/2
3
201CNQ045
EMGC-1
1
2A
B:9 B:8
3
GEN TEST
8PR
SIRIUS
3
B:3
3
1TL
B:6 B:7
3
Die Gültigkeitszuordnung von Version zu Flugzeugbaureihe ist der Bauakte bzw. dem jeweiligen Fertigungsauftrag zu entnehmen.
2
3
1
1A
KEYPAD
1SH
1
1
2A
7PR:2
VNE-WARN
1A
2
3
GEN
IRIDIUM
B:2
3
:1
1TS
3
C:13
1WV
D:18
10A
IFD LH A
9FG
IFD LH B
10A
C:3
2
2FG
C:3
3
10A
1
12-VDC
1
2A
1FG
STBY GYRO
1FM
A:7
3
AP-SERVO
5A
D:4
D:3
D:1 D:2
1CA
2
1A
1TH
2
2RZ
5A
AUDIO-MRK
1RZ
2
2
1
2A
DME
1SN D:11 D:11 B:5
2
A:9
2A
INTAKE-A/I
D:7
C:14
1HM
1
1
2HH
2A
BOOTS
1HH
1
2A
WTHR DET
B:1
3
1SS D:12
2
5PD
EXT PWR
3
ON
OFF
5 6
PR6F-20
2
OFF
PR10F-20 3
2
ON
3
PP3G-22
7
DC-GEN 2
6
2
1A
2
GLARE-LT
2
10A
IFD RH A
D:3
3
INST-LT
10k
HA5F-22
1
5FG
7.5A
1
3
A:9 A:8 A:7
1
1LH1
C:9
1
WARN-LT
A:8
1
1LH2
C:5 B:1
3
10A
1
A:12 A:11
LDG-LT
2LB
STROBE-LT
1
2A
2
4
TEMP
O-SP-TEST
1
1
1ES
7HA
4
P16NM103KA
2 3
A:6 D:5
2
5A
1
HA21E-22
ws org bl
1
2
PD4G-22 PD4H-22
RESET1
PR04F-20
4
PR5F-20
07.2.1.16
PR11F-20TRIP 1
07.1.1.17
PR16F-20
1 3
PP6E-22
2
PR101G-22
5
PR102E-22
CG50G-20
Poti. Ansicht von hinten.
RECO-LT
HA22E-22 6
1
7.5A
2LF
5
D:15 D:14 B:13 B:10 B:11 B:12
1LF
1LB
1
B:2
1
16HA:1
D:3 D:4
1
5A
2 3
ENV BLEED
NAV-LT
VOLT-MON
7EY
1LN
2LN
FUEL FLOW
1A
STALL-WARN
1QY
C:15
1A
LOW-VOLT
1WH
C:6
3
FLAP
7.5A
D:1
2LC
1LC
1
B:6 B:9
D:2
1
1
16LJ
5
ws
HA4F-22
ENV BLEED
HA4G-22
1
5A
B:8
CABIN-LT
1
1
2A
1LW
FUEL-QTY
1QX
DUMP
3
9HP
C:11
1
1CG
EMERGENCY BUS PP4
C:10
1
5A
FLAP-CTRL
25CG
ENV-BLEED
5A
C:2 C:1 C:8
1
3
5AH:1
15LJ
2
1LJ
B:14
1
2A
P-VENT
B:7
1
1
6HK
07.1.1.17 1
AUTO/MANUAL
1
5A
2
COLD
1
FUEL-TR-R
2QF
1
BATTERY BUS PP2
1HA
5A
1
4HA
LOAD BUS PP3
2
FUEL-TR-L
B:1
1
1
2HP
3A
C-PRESS
IGN
5A
A:6
1
1JB
A:12
2
2A
ENG-INS-2
1QF
2
HA12F-22 HA14F-22
MAN CONTROL
D:9 D:8 D:10 B:3 B:4 B:5
C:5
2A
ENG-INS-1
1HP
A:5
1
START
5A
C:6
1
1A
DIP-2
2EZ HA13F-22
2
BLEED AIR
SCHALTER ENTFÄLLT
1
1A
DIP-1
1EZ
1
A:7
1
1A
3HI 7.5A
4JB
FUEL-P-2
2QB
C:1
3
10A
2EY
CIGA-LTR
1MM
C:2 A:2
2
2
15A
PROP-HT
5
LH3E-20N
3
PITOT-R
20A
2
2HG
2HI
4 6
LT2E-20
3
1HG
A:8 A:9 A:10
3
1HI
NIGHT
LT1E-20
:2
D:19 B:2 B:3
1
1EY
PITOT-L
1
A:1
10HG
7.5A
1
D:12 D:6
9HG
FUEL-P-1
C:1
2
3HF:2
WSH-CTRL
2A
1 WV8E-22 TEST
07.2.1.16
DIMMING
NIGHT
8HB
2
AIR-CTRL
2A
2HF
WSH-HT
20A
1
9HB:2
HB4E-20
7HB
A:5 A:4
2
2
:1
1QB
GEAR-WARN
5
HYDR
LG52E-22S
1
1HF
1
ws org bl
WV9E-22 (TONE)
2HB3E-20
334.90
3LJ:1
VMO WARN
VV203
D:2 C:20 C:19
3
:1
30A
VENT
50A
D:7 F
2
1A
23GA
1GW
44GA
100A
5
125A
6HB
1
LUMI FOLIE
1
B:15 B:16 B:17 B:18
334.81
314.30
1
AIR-CON
C
1HB
C:8
GEAR-CTRL
PP30E-2
3
D:8 D:9
1
1GA
3GA-1
GEAR-AUX-1
D:6
2
39GA
3GA-2 DIODE
Stift FE 4198 Buchse FE 4199
4 X 12
1 Stück
Modul 0412
Stift FE 4196 Buchse FE 4197
8 X 16
3 Stück
Modul 0816
Stift FE 4192 Buchse FE 4193
12 X 20
6 Stück
Modul 1222
20 X 22
5 Stück
E
Stift FE 4194 5 Buchse FE 4195 A
C #4
#4
5
Modul 2022
1A
5
CB6
B
5
D:5
2
D
#0
D
B
2
3
A
20
E
5 8
#4
HOT BUS PP1
D
C
B
A 3 5 7
MS3106F 36-6P Stecker MS3100F 36-6S Dose
2
6
EA-9B243.10
HB2E-4
HB7E-12 OFF
HB18E-22 LOW1
5
VENT
1 3
HB16E-22
AIR CON
ON
2HG1E-16
#4
BATTERY, VV242 EA-9B243.10
D:7 D:18
20 AWG 22 2 2
4 AWG 12
B:6 B:7 B:8
B:4 2 2 2
8 AWG 16 2
12 AWG 20
2
E-Box, EA-9B243.40
5A
CB1
20 AWG 22
C:17
20 AWG 22 1
B:19 B:20
20 AWG 22 1 1
A:10
12 AWG 20 1
1 D
C
B
A
Kabel über Shelf
D:4
3
4 AWG 12
C:2
8 AWG 16 3
B:12
12 AWG 20 3
3
A:11 A:12
3
1
4
1617
AIR CON
1 HG2E-16 TEST
215.20
WARM1
ws
HA3F-22 3
bl
MAN
org
AUTO
07.2.1.134
bl
6
215.20
OFF 1
HA28E-22 ON
07.2.1.13 4
GENERATOR
GENERATOR
EMERGENCY
243.10
PP4E-22
RCCB
CG51G-20 CG51H-22
4
Maintenance Manual EXTRA 500 Chapter 91 30. March 2012
C
B
A 12 AWG 20
2
4 3
PP31E-2
DC GENERATION 1, VV243
BUS-TIE-NORMALLY-OUT
AIR CON
215.10
CABIN VENT
215.10
CABIN VENT
215.10
HB17E-22 HI
07.2.1.40 901 4 6 OFF
07.1.1.13 215.10
PITOT HEAT R/H
PITOT-R
SN2E-22
VV202
2HI1E-12
303.10
3
MAP
CABIN
ON
NAV
ON
2LF1E-20
ES1E-22
2FG1E-14
SS1E-20
SN1E-22
PD5E-22 OFF
07.1.1.13 244.10 EXT POWER
243.10
ON
243.10
PP33E-12
PP5E-22N OFF
07.1.1.13
DC-GEN I
243.10
OFF 1
243.10
FLAP SYSTEM
4 07.2.1.13
243.20
275.20
LUMI FOLIEN
1 3
OFF
HG3E-16
07.1.1.16 ON MM1E-18
EY2E-22
EZ2E-20
QF1E-22
QF4E-22
HK1F-22
1
2LJ1F-22
3
LJ5E-22
1
2LJ1E-22
3
LJ2E-22
1
2 LC1E-20
3
LC2E-22 LC2F-22
1 3
LF2E-20
RECO
ON
LF2J-22
#0
GA40F-22
HI2E-12
PROP
ON
#8
#8
5HF1E-22
6
HF3F-22
WINDSH
HF3E-22
HI4E-22
CIGAR LIGHTER
252.10
DIP 2
TRANSFER PUMP 1
TRANSFER PUMP 2
VENT LEFT
752.15
HK1E-22 LJ1G-22 OFF
MAP LIGHT
334.40
ON OFF
07.1.1.13
OVERSPEED TEST
RH IFD
WEATHER DETEC
(KDM 706A)
RZ1E-22 RZ16E-22
TH1E-18
TS1E-20
TL1E-20
5
GA37E-22
GA40E-22
GA1E-22
3
HF4EF-12 ON
07.2.1.13 4
PROP HEAT
QB1E-20
316.40
EIP 2
316.50
731.30
731.30
VENT RIGHT
752.15
DOME LIGHT
334.40
07.1.1.13
CABIN LIGHT
334.40
OFF
07.1.1.13 NAV LIGHT
334.20
OFF
07.1.1.13
276.10
344.14
DME
12V SOCKETS
BROADCAST(MLX770)
DATA LINK(MLB700)
F
GEAR CONTR
GEAR CONTR
323.10
GA3E-22 GA54E-22 GA6J-8
1
2HF2E-12
WINDSHIELD HEAT
FUEL PUMP 2
JB1E-20
JB2E-20
2LN1E-20
ICE
ON
STROBE
ON
2HH1H-22
3
1
E-BOX, VV244 EA-9B243.10
E-BOX, VV245 EA-9B243.20 323.10
GEAR AUX I
323.10
HYDR CAUTION
323.10
GEAR HYDRAULIC
323.10
OFF
304.20
WINDSHIELD CNTRL
304.20
OFF
07.1.1.13 360.11
731.10
IGNITION
743.10
HA1E-22
CG1E-22
CG8E-16
QY1E-22
1 3
LN2E-20
1
2LB1E-20
3
LB10E-20 LB2E-20
INSTR
ON
RECO LIGHT
334.60
2LG4G-20
3
LG116E-20
342.66
1
BOOTS
ON
345.47
344.16
VV201
2HG4E-18
PITOT-L
HP1E-22
5
ON
CABIN PRESS(IN FLOW)
FLAP CNTR
ICE LIGHT
INSTRUMENT LIGHT
LH116G-20 LH4E-20 HH1E-22 OFF
3
HH2E-22
CA3E-20
235.17 AUDIO/MKR (PM8300)
252.11
344.17
PP34E-12
XXX X X XX
6
START
07.1.1.15L 1 HP9E-22
215.20
275.20
FLAPS
275.20
FUEL FLOW
731.40
OFF
07.1.1.13 334.55
OFF
STROBE LIGHT
OFF1
07.1.1.13 334.90
BOOTS
310.10
07.1.1.13
A/P SERVOS (TRIM)
1FG3E-14
WV1E-22
Anzahl ETA-483 klein 1 - 35A ETA-482 mittel 0.1 - 50A ETA-452 gross 50 - 100A Anzahl Lochpositionen XX Kabel über Shelf
GW1E-22 GW1G-22
QB4E-20
HG5E-18 TEST1 OFF
3
ON
EY1E-22
EZ1E-20
OFF
743.10
2
HP10E-22N
HP9G-22 HP3E-22
QX1E-22
WL1F-22
2LA1E-18
LDG
07.1.1.13 334.10
2LR5E-20
DAY-NIGHT
334.90
BOOTS TIMER
310.10
271.17
2FG3E-14
SD1E-20
3
EIP 1
316.50
HP2E-22 PRESS
PRESS
3
LOW VOLTAGE MONITOR
315.90
WH1E-22 WH1G-22
EY3F-20S
1 3
LA2E-18 ON
LA7E-22
LG119E-20
1 3
LR6E-20
GLARE
ON
HM1E-22
FM1E-22
1FG1E-14
LH IFD
342.65
Vmo WARNING
314.30
IFD RH
342.66
(TAS610)
2
GEAR WARNING
323.20
CABIN PRESS
213.30
DUMP 4
STALL WARNING
273.30
GLARE LIGHT
334.90
LH IFD
342.65
FG16E20
SH1E-18
TAS
344.15
CA1E-20
1
EXT-LADER
EXT-LADER
ALTERNATOR 2 FIELD COURTESY LT
334.50
ELT
FUEL PUMP 1
731.10
HG6E-18
07.1.1.16 DIP 1
CABIN PRESS
213.30
DUMP
213.30
VOLT MONITORING
316.40
OFF
07.1.1.13
INTAKE ANTI-ICE
304.10
KEYPAD
342.67
(BXP6402R)
PP47E-16
A/P COMPTR
271.17
CA1F-20
CA2E-22
AUTOMATEN
GEAR-AUX-2
323.10
GEAR AUX 2
244.20
ALT-FIELD
243.20
COURTESY LT
ELT
256.11
EMGC RELAY
EMGC-2
EMERGENCY RELAY
PITOT/STATIC L/H
303.10
316.40
CABIN PRESS
213.30
FUEL INDICATION
284.10
LANDING-LIGHT
334.35
DIMMIMG
334.90
OFF
07.1.1.13
STBY GYRO
342.73
ATC
345.57
PR19E-20
PR200E-20 ALTERNATOR FEELD 2 243.20
TURN COORDINATOR
271.17
PR200E-20
D
C
B
A
A
B
C
D
2
001758_212_02
1VN-E
B
MM2-18N
MM1G-18
2
1
2MM
Zigarettenanzünder
3
4
C:1
3
1
2
3
4
Maintenance Manual EXTRA 500 Chapter 91 30. March 2012
1
5
MM1E-18
EDV-Kennung:
9B25210T
04 03 02 01 Ver. Bezeichnung
6
Zuordnung links / rechts wird mit */* in allen Feldern angegeben.
A
ÄM-400-09-01
01.07.10
Nr.: Änderung/Mod. Nr.: Datum
Letzte Bearbeitung:
see EA-9B246.10 DC-DISTRIBUTION
LOAD BUS PP3
6
Die Gültigkeitszuordnung von Version zu Flugzeugbaureihe ist der Bauakte bzw. dem jeweiligen Fertigungsauftrag zu entnehmen.
10A
1MM
CIGA-LTR
CIRCUIT BREAKER/SWITCH PANEL
5
HW
Name
Name
PB
Datum
16.12.02
7
46569 Hünxe, Germany
Schwarze Heide 21
Gepr.:
Gepr.:
Bearb.:
7
Projektion Freimaßtoleranz Oberfläche
A Blatt 1
von 1
8
Schutzvermerk nach DIN 34 beachten.
A3
EA-9B252.10
CIGAR LIGHTER, MM
EA 400-500
Maßstab auf SI.-Klasse Oberflächenschutz
8
A
B
C
D
A
B
C
D
TH3E-18N
TH3E-18N
TH2E-18
3 2
1
2TH
Mittelkonsole
Steckdose 1
2
H TG
3 2
1
1VN-F 001758_212_02
TH5E-18N
TH4E-18N
TH2F-18
Co-Pilot
3THM
Steckdose 2
3
TH5E-18N
TH2G-18
Tisch
2
3
1
F G H J K
001115-202-02
A B C D E
4TH
Steckdose 3
TH2E-18 TH2F-18 TH2G-18 TH2H-18
4
violet
1
2
3
4
5
black
24V TO 12V Converter
yellow
5
black
red
Converter SM 2430
Maintenance Manual EXTRA 500 Chapter 91 30. March 2012
1
E
TH6E-18N
C:3
EDV-Kennung:
9B25211T
04 03 02 01 Ver. Bezeichnung
Die Gültigkeitszuordnung von Version zu Flugzeugbaureihe ist der Bauakte bzw. dem jeweiligen Fertigungsauftrag zu entnehmen. Zuordnung links / rechts wird mit */* in allen Feldern angegeben.
3VN-A 001758 212 02
VV26
TH1F-18
6
3
ÄM-400-09-01
01.07.10
Nr.: Änderung/Mod. Nr.: Datum
A
10A
12-VDC
LOAD BUS
PP3
7
HW
Name
PB
7
46569 Hünxe, Germany
Schwarze Heide 21
Gepr.:
Gepr.:
Name
Datum
Bearb.: 20.12.04
see EA-9B246.10 DC-DISTRIBUTION
TH1E-18
1TH
CIRCUIT BREAKER/SWITCH PANEL
Letzte Bearbeitung:
CB Trennstecker
6
A Blatt 1
8
Schutzvermerk nach DIN 34 beachten.
A3
EA-9B252.11
12V SOCKETS. TH
von 1
Projektion Freimaßtoleranz Oberfläche
EA 400-500
Maßstab auf SI.-Klasse Oberflächenschutz
8
A
B
C
D
A
B
C
D
L2
L1
345-6196
3
2
1
4
6
5
2
5
8
3
6
9
7
4
1
1 3 8 5 2 7 6 4 9
3
151-5009
Molex
2DA-A
Auf Kabelseite gesehen
2DA
+28 VDC
ELT REMOTE SWITCH
2
001758_212_02 1VN-C
DA3E-22N
DA2F-22 DA11F-22 DA12F-22 DA13F-22 DA14F-22
H
DA2F-22
17 18 19 20
SIM
ST13-D
DRUCKSCHOTT HINTEN
DA11F-22 DA12F-22 DA13F-22 DA14F-22
4
2
1
2
3
4
Maintenance Manual EXTRA 500 Chapter 91 30. March 2012
1
S
5
RG 142 C/U
RG 142 C/U
611-6013-04
red + blk -
110-773
4DA
ELT ANTENNA
+
3DA
6
453-6603 (MOUNTING 452-3034)
Nr.: Änderung/Mod. Nr.: Datum
Letzte Bearbeitung:
452-6505
1DA
452-6504
EXCHANGE BATTERY
ARTEX ME 406 ELT
Light Reset 1 Reset 2 External On Horn Power G-Switch Loop G-Switch Loop Ground
9B25611T
04 03 02 01 Ver. Bezeichnung EDV-Kennung:
E-BOX EA-9B-243.40
HOT BUS PP1
AUDIO INDICATOR
2 6 13 14 8 5 12 7
ELT
1A
ELT
6
see EA-9B246.10 DC-DISTRIBUTION
CB6
Die Gültigkeitszuordnung von Version zu Flugzeugbaureihe ist der Bauakte bzw. dem jeweiligen Fertigungsauftrag zu entnehmen. Zuordnung links / rechts wird mit */* in allen Feldern angegeben.
DA15E-22 DA5E-22N
4DA-A
1DA-B
150-1130
SUBD 15S
1DA-A
DA2E-22
E-BOX
DA4E-22N
VV242
ST1
DA11E-22 DA12E-22 DA13E-22 DA14E-22 DA15E-22
BATTERY
Bolzen
5
ELT
COURTESY LT
ALT FIELD 2
SPARE
BATT CHARGE
GEAR AUX 2
Name
HW
Name
7
46569 Hünxe, Germany
Schwarze Heide 21
Gepr.:
Gepr.:
Bearb.: 17.09.10
Datum
Projektion Freimaßtoleranz Oberfläche
8
Blatt 1
von 1
8
Schutzvermerk nach DIN 34 beachten.
A3
EA-9B256.11
ELT ARTEX ME 406, DA
EA 400-500
Maßstab auf SI.-Klasse Oberflächenschutz
ONLY FOR EXCHANGE
7
A
B
C
D
D
C
B
A
4CA
8
43 38
27 43
16 15 46 5 6 45
28 30 31
10 11 44
14 41 34 35 40 4 12 13 24 25 26 7 19
49
18 22
36 37 46 1 2 39 20 21
29 12 31
15
34 17
5 6 24 41
16 33 50 46 7 8 13 14 45 32 28 11 44 30
9 10 48 37
42 26 27 2 21
4 20
3 22 23 40
FD Enable
GND GPSS
Audio Output GND
Manual UP SW Manual Down SW SHIELD GROUND CWS CWS GND Shield GND
Pitch Flap Pot. Signal Reference Trim FlaP Pot
10 VDC Paralax Pot. Pitch Str. Centering FD Pot. GND
Trim Interrupt SHIELD GROUND Roll Sign. Roll Sign. Ref. SHIELD GROUND FD LOGIC ROLL STR SIG PITCH STR SIG ANNUN LOAD ANNUN CLOCK ANNUN DATA SIG REF G/S DOWN -
SHIELD GROUND
G/S UP + VS SIGNAL
ROLL STEERING 429A ROLL STEERING 429B SHIELD GROUND G/S FLAG + G/S FLAG SHIELD GROUND ALT ENGAGE SIGNAL ALT SEL CONTROL
HDG RETURN CRS RETURN L-R -RT
Lights
A/P A+ A/P Disconnect
Rate Gyro Tach. Rate Gyro Ref. Rate Gyro Signal Shield Gnd.
Transducer Ground 10 VDC Transducer Signal Shield Gnd. AC Heading AC Course NAV FLAG + NAV FLAG SHIELD GROUND LOC SWITCH DC HDG HI (KCS 55) DC CRS HI (KCS 55) SHIELD GROUND L-R +RT
Ground for DG Ground 429 TX+ 429 TX-
Shield Gnd. Exitation Ref. Signal Ref. Pitch Solonoid GND Pitch Motor
Trim Switch DN Pitch Solonoid
Pitch Motor Trim Switch UP Trim Switch Com. Shield Gnd.
CA5E-24S
ws bl
CA5F-24S
CA4F-24S
ws bl
ws bl
E
CA39E-24S
rt ws/grün
CA26E-24S
CA25E-24S
1VN-B
CA37F-24S
ws org bl
ws bl
ws bl
11 12 13 14 15 20 16 17 18 19
ws org bl
ws bl
ws bl
ST14-A
6CA-A
CA26F-24S
CA25F-24S
ws org * bl *
ws * bl *
ws bl 2 3
6CA-a
PITCH SERVO P/N 001008-P4
4 8 7
6 1
7CA-a
ROLL SERVO
6CA
1
CA19E-24S
CA19E-24S
CA37E-24S
CA9E-24S
CA9E-24S
ws bl
ws org bl
CA24F-24S
1VN-B
001758_212_02
5CA
CA21E-24
3 2 1
8CA Transducer
GND
28 VDC
5CA-a
CA22E-24S
DRUCKSCHOTT HINTEN
SIM
ws org bl
A E D C B
CA21E-24
6 7 8 9
8CA-A ws 2 org 3 bl 1
TRANSDUCER P550-5017
CA29E-22N
CA23E-24S
ws org bl
CA22E-24S
ws org bl
ST14-A
DRUCKSCHOTT HINTEN
CA24E-24S
ws bl ws bl
1
CA20E-24S
CA23E-24S
CA15G-22 CA16E-24
ws bl
ws bl
ws bl
ws org bl
ws org bl
4CA-A
P2 39122
CA40E-24S
CA42E-24 CA43E-24
13 14 11 12
ws/rt blau grau grün braun sw gelb lila ws org
25CA-a 4 5 3 2 6 9 10 8 1 7
CA42E-24 CA43E-24
P/N 6405-28L
rt ws/grün
blau grau grün braun sw gelb lila ws org
ws/rt
25CA-A
CA41E-24S
11 6
9 19 13 16 12 17 20 10 18
12CA-a
Steckerleiste im Steuerhorn
CA41E-24S
CA2F-22
ws bl
ws bl
ws bl
TURN COORDINATOR
RZ2F-24S
CA13E-24S CA15F-22 CA8E-22 CA18E-24
CA7E-24S CA33E-22N
CA3F-20
12CA-A
Trennstecker Pilot
ws bl
5CA-A
see EA-9B235.17 MKR-AUDIO
10CA
TRIM SERVO
CA40E-24S
see EA-9B334.90 DIMMING
CA38E-24S
B
1VN-B 001115_1758_212_02
VV39
1 2
4 3
ws bl
LG8E-22
SIM
ws bl
ws bl
see EA-9B284.13 PCB-BOARD 1 Pin 25
4 5 10
3 1 2
CA39E-24S
1
bl
CA31E-24S CA32E-24S CA33E-24S CA34E-24S CA35E-24S CA36E-24S
25
ws bl
ws bl
10CA-a
ws bl
ws
CA13E-24S
ws bl
CA6E-22
CA7E-24S
ws bl
CA12E-24S
CA67E-22
CA14E-22S CA30E-22
CA4E-24S
ws bl
10CA-A
1
1
50
16
55
ws 54 bl
44
ws 5 bl
9 48
47
ws 46 bl
42
12
ws 43 bl
ws 13 bl
9CA-A 72
UP
PTT Pilot PTT Pilot
E
15CA
B
DN
C
A
F
D
2
25 39 43
19 18 1 36 39
35
Exitation EXC. + 10 V EXC. Ground
Roll Motor Roll Solonoid Roll Motor Roll Solonoid GND Shield Gnd.
Airframe Ground
P1 (39123)
ws bl ws bl
1
CA17E-20N
D
CA28E-24S
CA27E-24S
SIM
001758_212_02
ws bl ws bl
b d f h g c
ws bl ws bl
ST5
TRENNSTECKER OVERHEAD
CA28F-24S
CA27F-24S
ws bl ws bl
7CA-A
4 1 3 2
2
7CA
P/N 0106-2-T3
6
4
3
16CA:2
CA68-22N
CA1G-20
1 16CA:1
17CA
CWS
AIS 240-35
13CA
CA8F-22
CA18F-22
optical coverage minimal 98 - 100%
C
CA18E-24 CA8E-22
001758_212-02
1VN-B
K3D-NO K3B-NO K2A-NO
K2B-NO K1A-NO
K2D-NO K2C-NO
K1C-NO K1D-NO
9CA
K2B-NC K1A-NC
K2D-NC K2C-NC
K1C-NC K1D-NC
K4D-NC K4C-NC K4A-NC K4B-NC K3A-NC
K3D-NC K3B-NC K2A-NC
K4D-NO K4C-NO K4A-NO K4B-NO K3A-NO AI ENERGIZE
36 AWG Tinned copper per ASTM-B-33
K4A-W
K3D-W K4D-W K4C-W
K2B-W K1A-W
K3B-W K2A-W
K2D-W K2C-W
K1C-W K1D-W
K4B-W K3A-W
14CA CA3G-22
A/P DISCONNECT
5
07.2.1.23
28V RELAY POWER
A/P RELAY
2 07.1.1.13
A/P MASTER
3
1
TRIM
see EA-9B235.17 MKR-AUDIO
OVERBRAID
CA15H-22
see Detail A
TRIM COMMAND SW
CA67E-22
CA15E-20
CA14E-22S
Maintenance Manual EXTRA 500 Chapter 91 30. March 2012
29 9
Sig. Ref. FD. Flag
39 50 3
Shield GND 28 VDC Trim Roll Sol. Logic YD.
42 23
33 48 47
Trim Solonoid GND Solonoid Shield GND
GND Alt. Sel. Jumper
17 32
Trim Motor + Down Trim Motor + UP
4CA-B
CA15E-20
CA15G-22 CA15H-22
ST14-A
B3
DRUCKSCHOTT HINTEN
C
B
A
CA16E-24 A2
3
ws bl
ws bl
ws bl
ws bl
ws bl
ws bl
9CA-A
A1
3
F
E
D
Detail A
25 4
26 27
23 22
34 35 36 33 32
30 29 8
14 15 56 53 52 71
10 49 28
45 24
6 7
3 2
B1 A3
STEC 55X
CA6E-22 B2
CA1H-20 X1 X2
2
1
1
3
07.1.1.13
2
1K
107-9518
18CA 1 2K0 R2 2K0 0,25W
3 R1
YAW TRIM
3
17CA 2
CA46E-24S
CA45E-24S
E UP
15CA
DN
CA66E-24S
CA65E-24S
CA64E-24S
CA59E-24S CA60E-24S CA61E-24S CA62E-24S CA63E-24S
CA56E-24 CA57E-24 CA58E-24
CA50E-24S CA51E-24S CA52E-24S CA53E-24S CA54E-24S CA55E-24
CA47E-24 CA48E-24 CA49E-24
B
100
CA44E-24S
WH10E-22
REL M210B4N
55CA
C
F A
D
20CA-A
4 2 3 1
20CA-a
3 CA3E-20
3 CA1F-20
3 CA1E-20
1 CA2E-22
CA3H-22
A:7
A:6
A:5
C:18
CA3H-22
CA72E-22
CA70E-22
Zuordnung links / rechts wird mit */* in allen Feldern angegeben.
EDV-Kennung:
9B27117T
ws bl
CA46E-24S CA37E-24S
ws bl
CA50E-24S CA51E-24S CA52E-24S CA53E-24S CA54E-24S CA55E-24
ÄM-400-09-01 ÄM-400-04-02
07.10.10 09.09.04
19.01.11
Nr.: Änderung/Mod. Nr.: Datum
B A
Letzte Bearbeitung:
ws bl
CA37F-24S
ws bl
ws bl
P2121
ws bl
1
ws bl
CA66E-24S
CA65E-24S
CA64E-24S
CA59E-24S CA60E-24S CA61E-24S CA62E-24S CA63E-24S
CA56E-24 CA57E-24 CA58E-24
P2122
J2122
P1122
ws bl
CA47E-24 CA48E-24 CA49E-24
ws bl
CA45E-24S
P1121
J1122
ws bl
1
CA76E-22 CA75E-22 CA74E-22 CA73E-22
12CA-A
CA77E-22N CA73E-22 CA74E-22 CA75E-22 CA76E-22
CA72F-22
CA70F-22
CA69F-22 CA71F-22
10CA-A
2CA
CA3J-22
5A
CA44E-24S
CA31F-24S CA32F-24S CA33F-24S CA34F-24S CA35F-24S CA36F-24S
Die Gültigkeitszuordnung von Version zu Flugzeugbaureihe ist der Bauakte bzw. dem jeweiligen Fertigungsauftrag zu entnehmen.
04 03 02 01 Ver. Bezeichnung
19VN-A
SIM
SIM ST13-D
ST14-B
SIM
ST13-D
001758 212 02
A
13
12
7 6
11
PP5
AP COMPTR
AVIONICS BUS
DRUCKSCHOTT HINTEN
5A
T&B
CA69E-22 CA71E-22
3CA
CA38E-24S
CA31E-24S CA32E-24S CA33E-24S CA34E-24S CA35E-24S CA36E-24S
see EA-9B273.30 STALL WARNING AP-Disconnect bei Stall Warning
Montieren auf Platinen-Blech Instrumentenbrett mittig
YAW- Poti
1
2
Off Auto
CA30E-22
1
YAW DAMPER
CA3G-22
CA3F-20
CA1H-20
CA1G-20
CA2F-22
CIRCUIT BREAKER/SWITCH PANEL
CA36F-24S CA35F-24S CA34F-24S CA33F-24S CA32F-24S CA31F-24S
1
ws bl
CA38F-24S
GND Y Motor 2 Y Motor 1 Y Solenoid
51 72
10 31 14 20 41 60 19 40
25 39 2 3 4 15 12 13 27 26 10
3FG
IFD-5000i 700-00083-()
12 CA
Name
PB
Projektion Freimaßtoleranz Oberfläche
B Blatt 1
von 1 Schutzvermerk nach DIN 34 beachten.
A2
EA-9B271.17
EA 400-500 AP-STEC-55X, CA
Maßstab auf SI.-Klasse Oberflächenschutz
see EA-9B342.66 IFD RIGHT
7FG
IFD-5000i 700-00083-()
see EA-9B342.65 IFD LEFT
Datum
4
11 CA
Einstellen auf 73 IN/LBS
08.09.04
OUT 0+ OUT 0-
OUT 1+ OUT 1-
Schwarze Heide 21
Gepr.:
Gepr.:
Bearb.:
429 RX0+ 429 RX0-
429 TX0+ 429 TX0+ GROUND DISCRETE DISCRETE GROUND DISCRETE DISCRETE
Name 46569 Hünxe, Germany
HW PB
2 0 1
3
ANALOG REF ANALOG GROUND DISCRETE OUT DISCRETE OUT 1 DISCRETE OUT 2 GROUND ANALOG OUT 2 ANALOG OUT 3 ANALOG OUT 6 ANALOG OUT 5 ANALOG OUT 0
DISCRETE IN ANALOG IN 1 ANALOG IN 0 DISCRETE IN DISCRETE IN DISCRETE IN GROUND
IFD RIGHT
4 ANALOG REF ANALOG GROUND
25 39
0 1 2
OUT 0+ OUT 0-
OUT 1+ OUT 1-
DISCRETE OUT DISCRETE OUT DISCRETE OUT GROUND ANALOG OUT 2 ANALOG OUT 3 ANALOG OUT 6 ANALOG OUT 5 ANALOG OUT 0 DISCRETE OUT
429 RX0+ 429 RX0-
429 TX0+ 429 TX0+ GROUND DISCRETE DISCRETE GROUND DISCRETE DISCRETE
2 0 1
3
2 3 4 15 12 13 27 26 10 6
51 72
10 31 14 20 41 60 19 40
DISCRETE IN ANALOG IN 1 ANALOG IN 0 DISCRETE IN DISCRETE IN DISCRETE IN GROUND
IFD LEFT
2 4 3 1
HW
23 41 40 22 7 8 15
23 41 40 22 7 8 15
GND Y Solenoid Y Motor 1 Y Motor 2 GND
10 VDC out
Y CTR
YD ON / OFF GND
A+
YAW SERVO
19 3 1 2 6
8
10
13 7
4
YAW DAMPER
5A see EA-9B246.10 DC-DISTRIBUTION
1CA
AP-SERVO
BATTERY BUS PP2
4
D
C
B
A
A
B
C
D
see EA-9B235.17 MKR-AUDIO
see EA-9B235.17 MKR-AUDIO
Kabel im Flugzeug see EA-9B271.17 AP-STEC-55
Steckerleiste
2
ws grün grau ws/rt blau braun org lila sw glb rt ws/grün
1 2
STEUERHORN RECHTS
1 2 3 4 5 6 7 8 9 10 11 12 13 14
STEUERHORN LINKS
3
Verwendetes Kabel liegt im Lager auf Rolle
4
grün gelb
5RZ
rt ws/grün
6RZ
1
2
3
4
5
B
DN
UP
COPILOT PTT
PILOT PTT
E
15CA C
F A
D
5
TRIM COMMAND SW
Maintenance Manual EXTRA 500 Chapter 91 30. March 2012
1
13CA
EDV-Kennung:
9B27118T
04 03 02 01 Ver. Bezeichnung
Die Gültigkeitszuordnung von Version zu Flugzeugbaureihe ist der Bauakte bzw. dem jeweiligen Fertigungsauftrag zu entnehmen. Zuordnung links / rechts wird mit */* in allen Feldern angegeben.
1PST-MMPS
CWS
MPG206R
17CA
A/P DISCONNECT
6
6
ÄM-400-09-01
05.10.10
Nr.: Änderung/Mod. Nr.: Datum
A
Letzte Bearbeitung:
F
E
B C
D
A
Name
HW
E
B
Datum
C
F A
D
PB
Name
7
46569 Hünxe, Germany
Schwarze Heide 21
Gepr.:
Gepr.:
Bearb.: 01.06.04
UP
15CA
DN
7
Projektion Freimaßtoleranz Oberfläche
A Blatt 1
von 1
8
Schutzvermerk nach DIN 34 beachten.
A3
EA-9B271.18
CONTROL STICK LEFT/RIGHT
EA 400-500
Maßstab auf SI.-Klasse Oberflächenschutz
8
A
B
C
D
A
B
C
D
2WH
LIFT TRANSDUSER
15
12
39GA
13
14
org grün lila weiß/rot blau gelb
GEAR WARNING
2
2WH-A
1 5 10 12 6 2
2WH-a
Horn R1-1101 75 40 13-66
5WH
AP EA-9B271.17 55CA Pin X2
WH3E-22N
HG16G-16 HG17E-16N
WH2E-22
ST5
55CA
X2
13VN
see EA-9B303.10 PITOT-STALL HEAT
B
WH2F-22
see EA-9B315.80 ANNUNCIATOR PANEL
100
Trennstecker Overhead
40
CG37E-22
WH10E-22
3
AP X1
WV1F-22
GW1F-22
WH1H-22
WH1F-22
CA1H-20
WH11E-22
5WW-D
WH11E-22
WH2F-22
WH1H-22
CG37E-22
GW1F-22
WV1F-22
WH10E-22
WH1F-22
4
D33
D12
D32
1WH
46
1
STALL
1
2
3
Ground an Seilrollenbeschlag
4
K10
100
R40
5
OVERBRAID
13
8
1GW 2A
100
R41
1A
VNE WARN
K1
D13
14
31
35
ANNUNC
EA-9B315.81 STEUERPLATINE
+ VOLT DIMM
see EA-9B284.13 PCB-BOARD 1
EA-9B284.13b PCB-BOARD 1
VMO-Test
9B27330T 6
HW
Name
01.07.10
ÄM-400-09-01
Nr.: Änderung/Mod. Nr.: Datum
A
Letzte Bearbeitung:
25 24 14
1
8
see EA-9B314.30 AIRSPEED WARNING (TONE TEST)
7
46569 Hünxe, Germany
PB
Name
Cab-Press
Stall-Warn
Aft Door
Projektion Freimaßtoleranz Oberfläche
1WW
A Blatt 1
von 1
8
Schutzvermerk nach DIN 34 beachten.
A3
EA-9B273.30
STALL WARNING, WH
EA 400-500
Maßstab auf SI.-Klasse Oberflächenschutz
Flaps
Gear Warn
Gen-Fail
Annunciator Panel left
Schwarze Heide 21
Gepr.:
Gepr.:
Bearb.: 18.08.04
Datum
WW15-22
WW1-20
WH3E-22N
5WW-B
7
WV3E-22 see EA-9B314.30 AIRSPEED WARNING (IFD LEFT)
WV8F22
see EA-9B246.10 DC-DISTRIBUTION
1WV
see EA-9B315.80 ANNUNCIATOR PANEL
04 03 02 01 Ver. Bezeichnung EDV-Kennung:
6
BATTERY BUS PP2
Die Gültigkeitszuordnung von Version zu Flugzeugbaureihe ist der Bauakte bzw. dem jeweiligen Fertigungsauftrag zu entnehmen. Zuordnung links / rechts wird mit */* in allen Feldern angegeben.
LIGHT TEST (GND)
TONE-GENERATOR
9
K30
STALL
TONE-GENERATOR
K20
GEAR
TONE-GENERATOR
VNE
D11
D21
D31
5A
STALL-WARN
GEAR WARN
PP5
EMERGENCY BUS PP4
5A
AP-CMPTR
AVIONICS BUS 2CA
STEUERPLATINE ANNUNCIATOR 5WW D14
6
26
27
30
12
13
17
16
GW1E-22
WV1E-22
GW1G-22
1
WH1G-22
1
2
WH1E-22
CA1E-20
3
2
CA1F-20
3
C:13 1
C:3
C:4
D:20
D:19
A:5
A:6
5
CIRCUIT BREAKER/SWITCH PANEL
Maintenance Manual EXTRA 500 Chapter 91 30. March 2012
GND
GND
EA-9B323.20 Gear Warning EZ27E-22N
1
A
B
C
D
D
C
B
A
D
C
A
B
1 2 3 4 5
1 2 3 4 5
1 2 3 4 5
6
F
J
M
R
U
E
H
L
P
T
D
G
K
N
S
F G H J K
VV275207
Modul 1a
Modul entfällt !
CG17F-22N
C
H
001115_201_03
VV275204
AD J
J K
F G H J K
001115-209-02
A B C D E
Modul 6a
G
B
Modul 6a
1
2
CG23E-22N
VV275204
001115_201_03
VV275204
001115_201_03 A F
L POTI
17CG
1
5VDC
15° LIMIT B
3 4 5 6 7 8 9 10
FTS D436-37
C
11CG
NC
NO
VV124
VV123
WING L Y=4400 L DOWN LIMIT SW
VV122
VV121
NO
NC
13CG
C
CG30E-22
A2
B2
D2
A1
B1
B3
D1
CG15F-22
bl or ws
VV120
C G
J
VV275206
D
Modul 8a 001115_207_03
B
VV275206
CG19E-22
CG15G-22
001115_207_03
D E
VV275205
C
001115_209_02
VV275205
Modul 7A
CG21F-22 CG21H-22
Module Avionic-Bay
CG19F-22
18CG R POTI 1
3
Modul 8a
2
20VN-A
P600M
12LY
H
CG15E-22
CG30F-22
CG21H-22
AB
FG
X1
A1
X1
A1
FLAPBOX
4CG-A
VV130
VV129
VV128
CG24E-22
NO
NC
CG25E-22
CG41E-22
C
C
85
87
88 88a
16CG
Modul 8a
CG43E-22
BYW 56 BYW 56
R DOWN LIMIT SW
15CG
VV275206
1
CG22E-22N
2
VV125
12CG
C
NC
NO
VV126
VV127
L UP LIMIT SW
CG26E-22
CG20E-22
J K
3
Modul 7A
H
001115_209_02
A
B
G
Modul 7a VV275205
F
001115_209_03
Modul 7a VV275205
CG26F-22
CG20F-22
4
VV133
VV132
VV131
NO
NC
R UP LIMIT SW WING R Y=4400
blau
E
VV275206
001115_207_03
K
5
CG24F-22
Cab-Press
UP-Relais
CG42E-22
85
23CG
Aft Door Stall-Warn
LY10F-22
P600M
5LY
86
87
88
26.72.03 87a
88a
Flaps
Gear Warn
Gen-Fail
CG43E-22
CG8F-20
CG8G-16
CG16F-22
CG14E-16N
Annunciator Panel left
34CG
GNM 4175A
10CG
1WW
P/N 90-4219X-1 geändert
33CG
braun
Modul 8a 001115_207_03
86
22CG
87a
26.72.03
Down Relais
RELAY BOARD
Modul 5a VV275203 001115_211_03
15pol DSub Pin
4CG
Einbau BOTTOM
CG1G-22
X2
A2
X2
A2
3 9 5 7 1011 2 1 8 1413 6
X2
A3
B3
D3
EA-95275.23
15
X1
A2
B2
D2
001115_209_03
01758 212 02
Messen zwischen 1 und 2
001578_212_02
20VN-A
15pol DSub
4CG-B
Doc. EA-05856.054
BOX EA-85411.00
14CG CG17E-22N
C
CG12E-22
E
15
2
CG21E-22
NO
NC
VV119
Krimp-Splice blau
14° LIMIT A
rechts
Q?
Kabel anlöten
CG9E-22
links
CG17E-22N
ws or bl
Messen zwischen 2 und 3
3
>7°
Einbau TOP
Q2
EA-95275.22
Maintenance Manual EXTRA 500 Chapter 91 30. March 2012
001758_212_02
20VN-A
H
03.06.2004
35CG BYW 56
Entfernt:
001115-207-02
A B C D E
Modul 7a
F G H J K
Modul 8a
A B C D E
Modul 3a, 4a, 5a
001758-212-02
C
B
A
001115-211-02
F G H J K
A
B
C
D
001115-201-02
A B C D E
Modul 6a
001115 211 03
1 2 3 4 5
6
6
6
3
2
1
8
7
20
1617
20
16 17
3 4
1 2
2
1
1 2 3 4 5
5
4
5
6
6
4
3
20
16 17
20
1617
20
1617
FLAP ZUSATZBOX
Flap Inhibit
CG31E-22
20VN-A, 2VN-B, 1VN-C
GND
CG1E-22N
30CG
GND
5
H
29CG-C
6
29CG-D ST 6
LY10F-22
CG34E-22 CG32F-22 CG33E-22
CG15G-22
ST 6 29CG-D
CG8G-16
ST 7 30CG-D
CG39E-22
CG36E-22
CG40E-22
CG1G-22
SIM_M_2022
CG51E-22
ST 6
X2
S210-A5-A1
X1
A1
B1 A3
B3
M210-B4N
VV135
33CG
20
16 18 17
19
15
14
13
12
7
29CG-D
20
19
LY10E-22
CG33F-22
CG32G-22
CG34F-22
EDV-Kennung:
1
RZ2E-24S
CG52E-22
CG39G-22
CG36G-22
60
42
15°
30°
9B27520T
7CG-A
6CG-A
1 2
1 2
1 2
CG37G-22 CG33G-22
CG37F-22 CG32H-22
CG37E-22
ÄM-400-09-01
7
14.10.10
10
24
28
30°
11
9 7
HW
Name
HW
D4
D3
D2
D1
D8
18.08.04
PB
Name
46569 Hünxe, Germany
Blatt 1
A von 1
8
Schutzvermerk nach DIN 34 beachten.
A2
EA-9B275.20
FLAP SYSTEM, CG
EA 400-500
Projektion Freimaßtoleranz Oberfläche
DIMMING
see EA-9B334.90
Maßstab auf SI.-Klasse Oberflächenschutz
MODUL 1 Pin D 5lh-a Pin-23
5LH see EA-9B334.90 DIMMING
BYW-56
LAMP TEST GND
see EA-9B284.13B PCB-BOARD 1
BYW-56
BYW-56
BYW-56
BYW-56
DIMMING BOARD EA-9B410.30C
29
24
11
10
7
2SS see EA-9B344.14 WEATHER DEDECTION
MIC INHIBIT INPUT
MODUL 1 Pin E 5lh-a Pin-5
Datum
RS 321-379 FE4252 EA-75112.60 EA-75112.60.KBS
PC-BOARD 1 EA-9B411.50A
54
Schwarze Heide 21
Gepr.:
Gepr.:
Bearb.:
11 6
3CG
WEATHER DETECTION TWX-670
MODUL1 Pin C
LED 590-244 green
7CG
17.02.11
8
CG34H-22
5LH-A
CG34H-22
LED 590-244 green
6CG
Nr.: Änderung/Mod. Nr.: Datum
A
Letzte Bearbeitung:
P1
GA53H-22
SS9E-24
SS8E-24
SS7E-24
SS7E-24
P1
15°
Mittelabgriff
0°
9 10
FLAP CONTROL SWITCH
see EA-9B246.10 DC-DISTRIBUTION
FLAP 7.5A
3A
8
FLAP-CTRL
1CG
BATTERY BUS PP2 25CG
LED 590-250 amber
8CG
see EA-9B334.50 COURTESY LIGHT
VV138
VV137
VV136
8CG-A
CG34G-22
Platine GEAR WARNING, EA-9B323.20 39GA-A Pin 4
see EA-9B315.80 ANNUNCIATOR PANEL [HYDR]
see EA-9B344.14 WEATHER DETECTION RZ13E-24S see EA-9B235.16 MKR-AUDIO
Zuordnung links / rechts wird mit */* in allen Feldern angegeben.
04 03 02 01 Ver. Bezeichnung
2
3
4
3
2
1
CG40G-22
CG1E-22 CG8E-16
1A
FLAP-UNB
3 C:6
32CG-A
4
CG51G-20
2
32CG
CG50G-20 2
CG51H-22 27CG
C:11 1
A:3
A:2
1
CIRCUIT BREAKER/SWITCH PANEL
see EA-9B344.14 WEATHER DETECTION
In Transition
CG15H-22
N
D:10
7
see EA-9B235.16 MKR-AUDIO
1VN-C
001758_212_02
CG39F-22
CG36F-22
CG40F-22
CG8F-16
CG1F-22
CG51F-22
CG50F-22
CG51K-22
CG47E-22
42
5WW-D
50
CG52F-22N Die Gültigkeitszuordnung von Version zu Flugzeugbaureihe ist der Bauakte bzw. dem jeweiligen Fertigungsauftrag zu entnehmen.
STECKER AVIONIC BAY
CG50E-22
ST 6
3VN-A
REL M320A1N
36CG
CG53E-22N
A2
B2
see EA-9B315.80 ANNUNCIATOR PANEL
ANNUNCIATOR BOARD EA-9B315.81
+ VOLT DIMM
LIGHT TEST (GND)
ANNUNCIATOR BOARD D14 5WW
6
001758_212_02
18 24 25
5WW-B
An Punkt 20VN anschrauben
WW1-20
WW19-22
1
Flugrichtung
CG22F-22N
CG9E-22
4
3
29CG
CG23F-22N
5V Out Balanced GND 5V Out Balanced GND 28VDC
ws or bl ws or bl
CG12E-22 CG1J-22
14° Position 15° Position Pos. Switch 30° Pos. Switch 0° 28VDC Power In
15° LED Pos. Switch 15° Flap Inhibit/28V
CG35E-22N
Annunciator
NC
Up Relay Down Relay
CG33E-22 CG36E-22 CG31E-22 CG51E-22 CG19E-22 CG15E-22 CG39E-22 CG40E-22 CG1H-22 CG50E-22 CG42E-22 CG41E-22
3
2
2
CG25F-22 F A
X1 X2
CB Trennstecker
1
CG27E-22
16
D
C
B
A
A
B
C
C:9
1
see EA-9B246.10 DC-DISTRIBUTION
LOAD BUS PP3
ES1G-22
1 2
Taster Spörle 220678
P1
J1 MOLEX Mikro Fit 3
ES3G-22
TEST
Instrument-Panel left
2ES
OVERSPEED TEST
2A
3
ES3E-22
35 ES2E-22N
001758 212 02 2VN-C
J
ES3F-22
ST4
FIREWALL
4
1
2
3
4
Maintenance Manual EXTRA 500 Chapter 91 30. March 2012
ES1E-22
O-SP-TEST 1ES
CIRCUIT BREAKER/SWITCH PANEL
2
ES1F-22
D
1
ES1F-22 ES3E-22
5
5
EDV-Kennung:
9B27610T
04 03 02 01 Ver. Bezeichnung
A B
6
HW
Name
01.07.10
ÄM-400-09-01
An Turbine integriert
Nr.: Änderung/Mod. Nr.: Datum
A
Letzte Bearbeitung:
Stecker MS3106F10SL-4S
VV140
3ES
Propeller Overspeed Govenor Reset Solenoid 3ES-A
Die Gültigkeitszuordnung von Version zu Flugzeugbaureihe ist der Bauakte bzw. dem jeweiligen Fertigungsauftrag zu entnehmen. Zuordnung links / rechts wird mit */* in allen Feldern angegeben.
VV139
ES3F-22 ES2E-22N
Jiffi Diode
4ES
6
Datum
PB
Name
7
46569 Hünxe, Germany
Schwarze Heide 21
Gepr.:
Gepr.:
Bearb.: 19.08.04
7
Projektion Freimaßtoleranz Oberfläche
A Blatt 1
von 1
8
Schutzvermerk nach DIN 34 beachten.
A3
EA-9B276.10
PROP OVERSPEED, ES
EA 400-500
Maßstab auf SI.-Klasse Oberflächenschutz
8
A
B
C
D
A
1 2 3 4 5 6 7 8 9
7QX-A
6QX-A
5QX-A
QX13H-22 QX14F-22 QX14G-22 QX13J-22 QX4S-22
QX1R-22
QX11H-22 QX12F-22 QX12G-22 QX11J-22 QX4P-22
QX1Q-22
QX5H-22 QX6F-22 QX6G-22 QX5J-22 QX4L-22
QX1N-22
QX1P-22 QX7H-22 QX8F-22 QX8G-22 QX7J-22 QX4M-22 QX1P-22 QX9H-22 QX10F-22 QX10G-22 QX9J-22 QX4N-22
37pol DSub
1 20 2 21 3 22 4 23 5 24 6 25 7 26 8 27 9 28 10 29 11 30 12 31 13 32 14 33 15 34 16 35 17 36 18 37 19
ws ws bl bl
ws ws bl bl
ws ws bl bl
ws ws bl bl
ws ws bl bl
ws ws bl bl
9QX-A 9QX-a
QX4K-22
QX14E-22S
QX4J-22 QX1M-22 QX13E-22S
QX12E-22S
QX4H-22 QX1L-22 QX11E-22S
QX10E-22S
QX4G-22 QX1K-22 QX9E-22S
QX8E-22S
QX4F-22 QX1J-22 QX7E-22S
QX6E-22S
QX4E-22 QX1H-22 QX5E-22S
QX3E-22S
QX1G-22 QX2E-22S
F G H J K
001115-202-02
A B C D E
VV284101
001758 212 02 1VN-G
QX8-A
A B
F G H J K
001115-202-02
A B C D E
VV284102
1
14 2
15 3
16 4
17 5
18 6
19 7
20 8
21 9
22
10
23
11
24
12
25
13
QX15E-22S
R6 22R
8QX
25pol DSub
QX2F-22S
001758 212 02 1VN-G
C
QX16E-20N
7
QX3E-22S
1
2
3
R1 22R
right mid
right outside
right center
50R
T3
R3 22R
4
Von 0 Ohm bis 30 Ohm je nach Schwimmer ausmessen!
50R
50R
*
T2
*
T1
R2 22R
left center
50R
T4
R4 22R
see EA-9B284.13 PCB-BOARD 1
PCB-BOARD 1 EA-9B284.13B
left outside
50R
50R
left mid
T6
T5
R5 22R
Maintenance Manual EXTRA 500 Chapter 91 30. March 2012
7QX
Gnd
28VDC N/C N/C Input Resistive Float Light Light
Right outside A1026
Gnd
1 2 3 4 5 6 7 8 9
1 2 3 4 5 6 7 8 9
1 2 3 4 5 6 7 8 9
4QX-A
3QX-A
QX2H-22 QX3E-22 QX3F-22 QX2J-22 QX4L-22
QX1N-22
*
B
6QX
28VDC N/C N/C Input Resistive Float Light Light
Right mid A1024
5QX
N/C N/C Input Resistive Float Light Light Gnd
28VDC
Right center A1022
4QX
N/C N/C Input Resistive Float Light Light Gnd
28VDC
Left center A1021
3QX
Gnd
N/C N/C Input Resistive Float Light Light
28VDC
1 2 3 4 5 6 7 8 9
1 2 3 4 5 6 7 8 9
AC DIM-VOLTAGE see EA-9B334.90 DIMMING SYSTEM
*
C
Gnd
Left mid A1023
2QX
N/C N/C Input Resistive Float Light Light
28VDC
Left outside A1025
QX1E-22 QX1F-22 QX1G-22 QX1H-22 QX1J-22
QX17E-22N
QX1K-22 QX1L-22 QX1M-22
2QX-A
see EA-9B246.10 DC-DISTRIBUTION
QX13F-22S
C:15
QX11E-22S
1
QX11F-22S
FUEL-QTY 2A
QX9E-22S
Fuel Indication
1QX
QX7E-22S
EMERGENCY BUS PP4
QX7F-22S
CIRCUIT BREAKER/SWITCH PANEL
QX4H-22 QX4J-22 QX4K-22 QX9F-22S
QX4L-20N QX4E-22 QX4F-22 QX4G-22 QX13E-22S
4
QX5E-22S
3
QX5F-22S
D
2
QX2E-22S
ws bl ws bl ws bl ws bl ws bl ws bl ws bl ws bl ws bl ws bl ws bl ws bl
*
QX6E-22S
1
*
5
5
bl bl bl
ws ws ws
F G H J K
F G H J K
001115-202-02
A B C D E
VV284104
001115-202-02
A B C D E
VV284103
bl bl bl
bl
ws ws ws
ws
ws bl ws bl
QX9F-22S QX7F-22S QX5F-22S
A
B
C
20
16 11 6
20
16 11 6
20
16 11 6
20
5
1
5
1
5
1
5
1
9
5
20
16 11 6
3
4
5
4
2
1
30CG
12
8
7
6
Einpinseite
29CG 16 11 6
5
1
4
1
1
6
A
B
C
D
SIM M 2022
SIM_M_XXXX_SN(PN) D
8 9
QX2G-22S
QX5G-22S
QX7G-22S
QX9G-22S
QX11G-22S
QX13G-22
Zuordnung links / rechts wird mit */* in allen Feldern angegeben.
EDV-Kennung:
9B28410T
04 03 02 01 Ver. Bezeichnung
Varistor
289-7569
15QX
Anschlußbolzen
Varistor
289-7569
+ -
11QX
7
ÄM-400-09-01
Nr.: Änderung/Mod. Nr.: Datum
A
Letzte Bearbeitung:
20.10.10
25.05.04
PB
Name
Schwarze Heide 21
Gepr.:
Gepr.:
Bearb.:
Datum
Name 46569 Hünxe, Germany
HW
Fuel Quantity left outside VDO 999.161.004
+ -
14QX
Fuel Quantity left mid VDO 999.161.004
+ -
13QX
Fuel Quantity left center VDO 999.161.004
+ -
12QX
Einbau siehe EA-1B050.10 Zsb. elektr. Holmdurchführung
ws bl
ws bl
16QX
Anschlußbolzen
ws Varistor bl 289-7569
17QX
+ -
10QX
Fuel Quantity right center VDO 999.161.004
Anschlußbolzen
ws Varistor bl 289-7569
18QX
+ -
9QX
Fuel Quantity right mid VDO 999.161.004
Anschlußbolzen
Die Gültigkeitszuordnung von Version zu Flugzeugbaureihe ist der Bauakte bzw. dem jeweiligen Fertigungsauftrag zu entnehmen.
Flugrichtung
19QX ws Varistor bl 289-7569
7
Fuel Quantity right outside VDO 999.161.004
Anschlußbolzen
ws Varistor bl 289-7569
20QX
Anschlußbolzen
see EA-9B334.90 DIMMING SYSTEM see EA-9B360.11 PROP HEAT
Stecker vom Hauptkabelbaum
SIM M 2022
ST 6
ws bl
ws bl
ws bl
ws bl
ws bl
8 ws 9 bl 10
4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
ST 6
HI9E-22S
6
STECKER AVIONIC BAY
ws bl
29CG-D
ws bl
QX11F-22S
QX2F-22S
ws bl
QX12E-22S
ws bl
QX10E-22S
QX13F-22S
29CG-C
QX14E-22S
QX8E-22S
Projektion Freimaßtoleranz Oberfläche
A Blatt 1
von 1
8
Schutzvermerk nach DIN 34 beachten.
A2
EA-9B284.10
FUEL QUANTITY, QX
EA 400-500
Maßstab auf SI.-Klasse Oberflächenschutz
8
A
B
C
D
D
C
B
A
right Outside
right Mid
right Center
left Center
left Mid
Audio out
Q30
Q20
Q10
10k
10k
10k
BC107
cw
TR30
R21 330
BC107
cw
TR20
R11 330
BC107
TR10 3 cw
50R 162-653
cw
TR56
50R 162-653
cw
TR55
50R 162-653
cw
TR54
50R 162-653
cw
TR53
50R 162-653
cw
TR52
50R 162-653
cw
TR51
2
1
R33 100k
R32 220k
R23 100k
R22 220k
R13 100k
R12 220k
R56 22R
R55 22R
R54 22R
R53 22R
R52 22R
R51 22R
C out
Vcc Q
C mod Gnd
Rt
3 4
1
Rt
C mod C out Gnd
Vcc Q
3 4
1
5
8 7
+ C21 22uF
C out
C mod Gnd
Rt
3 4
1
+ C31 10uF
Stall-Warning
Vcc Q
U30
C20ZSD 100 SOUND 39n
5
8 7
10n
C32
10n
C22
10n
C12
DB25P 259-3071
J51
+ C11 22uF
Gear-Warning U20
C10ZSD 100 SOUND 10n
5
8 7
1 14 2 15 3 16 4 17 5 18 6 19 7 20 8 21 9 22 10 23 11 24 12 25 13
3
Vout
1uF
Vout
U31 L7815C
C33 +
3
1uF
Vout
U21 L7815C
C23 +
3
1uF
C13 +
3
U11 L7815C
GND
Vin
GND
Vin
GND
Vin
1
1
1
0,1uF
C34 +
0,1uF
C24 +
0,1uF
C14 +
K10
K20
REL G6A
+Gear
cw
TR3
cw
cw
TR2
BYW56
BYW56
BYW56
BYW56
BYW56
10REL TN2 113-8875
9 K1:3 7
BYW56
10 REL TN2 113-8875
BYW56
D31
RS 162-647
25Ohm
Oil "0" adjust
Torque "0" adjust
25Ohm
BYW56
D21
TR1 1 Paralax Poti
BYW56
D11
5k
3
D1
D2
D3
D4
D1
K1:1 1
8
D2
K2:1 1
3
2 K2:2 4
EA-9B316.50 Engine Instrument Package
Abgleichpotis für Tourqe-und Oil Press Sensor
Vmo TEST
4
OVERBRAID
+Stall -Stall
1
8
9 6
11
D30 BYW56
16
4
13
1
8
9 6
11
+Vmod
BYW56-Gear
K30
D20
1
8
9 6
11
BYW56
REL G6A
16
4
13
D10
REL G6A
16
4
13
see EA-9B284.10 FUEL QUANTITY
Fuel calibration
Vmo-Warning U10
2
330
1
R31 330
C30ZSD 100 SOUND 20n
2
3
1
4
BYW56
D13
Sense
R5 330
R6
GND
Torque 0 T-O GND Oil 0
+Gear -Gear Stall -Stall -Stalld
Audio out +Vmo
330
-Vmo
14
2 20 1
12 30 27 26 17 6
16 33 15 25 28 9 8 13
5 23 4
7
10
11
24
29
31
35
34 32
19
36
18
37
3
22
21
J1
EDV-Kennung:
9B28413T
04 03 02 01 Ver. Bezeichnung
Die Gültigkeitszuordnung von Version zu Flugzeugbaureihe ist der Bauakte bzw. dem jeweiligen Fertigungsauftrag zu entnehmen. Zuordnung links / rechts wird mit */* in allen Feldern angegeben.
bestückt -9B411.50A
optical coverage minimal 98 - 100%
5
330
R9
L-Gnd
Out
Sense
-Vmo test
black
3 green
red
PC-BORD -9B411.51A
D33 BYW56 D32 BYW56
D12 BYW56
330
R8
Out
36 AWG Tinned copper per ASTM-B-33
330
R7
R40 100 R41 100
1
5
U60 LOW VOLTAGE
Maintenance Manual EXTRA 500 Chapter 91 30. March 2012
R30
330
R20
R10 330
left Outside
1
GND
2 GND
2 GND
2
2
Gnd 2
J1 DB37P
6
7
1 20 2 21 3 22 4 23 5 24 6 25 7 26 8 27 9 28 10 29 11 30 12 31 13 32 14 33 15 34 16 35 17 36 18 37 19
6
ws bl org
WV8F-22
WH3E-22N
EZ15E-22S
GW1F-22 CG37E-22 WH1H-22 WH2F-22 WH10E-22 WH11E-22
SD9E-24SS WH12E-22S WV1F-22
SS6E-24S CA12E-24S
WH1F-22
SS7E-24
SS8E-24
SS9E-24
GA53H-22
CG34H-22
WV3E-22
ÄM-400-09-01
1
1VN-G 001758 212 02
Datum
HW
Name
Schwarze Heide 21
Gepr.:
Gepr.:
Bearb.: 06.06.05
7
Name 46569 Hünxe, Germany
HW
HW
Blatt 1
von 1
8
Schutzvermerk nach DIN 34 beachten.
A3
EA-9B284.13
PCB-BOARD 1 A
Projektion Freimaßtoleranz Oberfläche
EA 400-500
Maßstab auf SI.-Klasse Oberflächenschutz
GEAR WARNING (GEAR-WARN 1GW EMERG BUS) GEAR WARNING (9GA-A Pin 14) STALL WARNING (STALL-WARN 1WH EMERG BUS) STALL WARNING (VV172) AP-RELAY (55CA Pin X2) ANNUNCIATOR PANEL (5WW-D Pin 46) see EA-9B316.50 EIP (VV171 ) see EA-9B316.50 EIP (VV169) see EA-9B316.50 EIP (VV168 )
see EA-9B323.10 see EA-9B323.20 see EA-9B273.30 see EA-9B273.30 see EA-9B271.17 see EA-9B315.80
see EA-9B344.15 TRAFFIC TAS-610 see EA-9B235.17 AUDIO/MARKER PMA-8000B (1RM-A Pin 31) see EA-9B314.80 AIRSPEED WARNING (VNE-WARN 1WV BATTERY BUS)
see EA-9B344.14 W-DETECTION TWX-670 see EA-9B271.17 AP-STEC-55X
see EA-9B273.30 STALL WARNING HORN
see EA-9B344.14 W-DETECTION TWX-670
see EA-9B344.14 W-DETECTION TWX-670
see EA-9B344.14 W-DETECTION TWX-670
see EA-9B344.14 W-DETECTION TWX-670
see EA-9B344.14 W-DETECTION TWX-670
see EA-9B342.65&66 IFD (Px122 Pin 16)
see EA-9B334.90 DIMMING (SWITCH 3LJ-1 (1) Vmo Test)
see EA-9B304.20 WINDSHIELD HEAT
see EA-9B304.20 WINDSHIELD HEAT
see EA-9B304.20 WINDSHIELD HEAT
see EA-9B304.20 WINDSHIELD HEAT
D
see EA-9B315.80 ANNUNCIATOR PANEL (5WW-D Pin 22)
1VN-F
05.09.10
8
see EA-9B246.10 DC-DISTRIBUTION (LOW VOLT 1LW EMERG BUS)
001758_212_02
17.02.11
U
1 C:4 66 2 D:20 11 100 35
5 31
X 25
31
X
X
X
12
35
108
C:16
Nr.: Änderung/Mod. Nr.: Datum
A =
Letzte Bearbeitung:
1
HF3J-22
HF7E-22
HF17E-22N
HF16E-22
WL3E-22N
WL1E-22
WL2F-22
CB Trennstecker
1 20 2 21 3 22 4 23 5 24 6 25 7 26 8 27 9 28 10 29 11 30 12 31 13 32 14 33 15 34 16 35 17 36 18 37 19
D
C
B
A
A
B
C
D
2WW
Pneumatic
Fuel Low R
Fuel Low L
Prop Low Pitch
Low Voltage
Fuel Trans R Standby Alt On
Fuel Filter
Fuel Trans L
2
3
WW20-20
WW33-22 WW36-22
5WW-C
24 25
13 16
LIGHT TEST (GND) 5WW-D 20 17
see EA-9B315.80 ANNUNCIATOR PANEL
ANNUNCIATOR BOARD EA-9B315.81
+ VOLT DIMM
D21
ANNUNCIATOR BOARD D24 5WW
4
1
2
3
4
5
5
106 105
Maintenance Manual EXTRA 500 Chapter 91 30. March 2012
geändert
P/N 90-42192-2
Annunciator Panel right
1
EZ64E-22 EZ66E-22
EDV-Kennung:
9B28430T
04 03 02 01 Ver. Bezeichnung
6
EZ66F-22
EZ64F-22
Die Gültigkeitszuordnung von Version zu Flugzeugbaureihe ist der Bauakte bzw. dem jeweiligen Fertigungsauftrag zu entnehmen. Zuordnung links / rechts wird mit */* in allen Feldern angegeben.
29CG-D
6 7
ST 6
STECKER AVIONIC BAY
6
14.10.10
Nr.: Änderung/Mod. Nr.: Datum
Letzte Bearbeitung:
RS 289-7569
7WW1
LOW FUEL LEFT
RS 339-730
5WW1
RS 289-7569
6WW1
LOW FUEL RIGHT
RS 339-730
4WW1
4mm Ringösen
Name
HW
B
PB
Name
7
46569 Hünxe, Germany
A
8
Blatt 1
von 1
8
Schutzvermerk nach DIN 34 beachten.
A3
EA-9B284.30
LOW FUEL WARNING, WW
EA 400-500
Projektion Freimaßtoleranz Oberfläche
20VN-B 001758 212 02
Maßstab auf SI.-Klasse Oberflächenschutz
20VN-B 001758 212 02
Schwarze Heide 21
Gepr.:
Gepr.:
Bearb.: 16.11.02
Datum
EZ67E-22N
AVIONIC BAY
EZ65E-22N
7
A
B
C
D
1
3
A
6
see EA-9B323.10 GEAR CONTROL
M220-B4N
2
34GA
12VN-A
HG7E-20
HG8E-20
3
B:5 C:7
2
13VN-A 20VN-A
Brücke AWG18
M320-B4N
X2
13HG 2
Brücke AWG18
M320-B4N
X2
12HG 2
E F G H
1
001115-302-02
A B C D
001115-302-02
F G H J K
001115-201-02
A B C D E
VV303101
2
001758-212-02
B
A
C
E
F
H
G
D
A
A
5
PITOT-L
B:3
B:2
VV141
X1 VV142
A 3 1
X1
A 1 HG9E-16
3
HG3F-16
HG2F-16
SIM
5 4
ST13-C
SIM
13 11
HG23F-22 HG25F-22
HS8G-22 HS7G-22
E F G H
K
HG28E-18
E F G H
001115-302-02
A B C D
X1
A1
B 1 3
M220-B4N HG9G-20
1
X2
M210-B4N
B 3
A 3 1
15HG
HG17E-18
001758 212 02 1VN-G
VV303102
J
2
2
VV146
HG27G-20 X1
3 C 1 3
Relais auf Relayhalter 7B251.60 Instrument Shelf
HG27E-18
HG9G-20
2
2
2
14HG
HG12E-16
HG23H-22 HG23G-22 HG24H-22 HG24G-22 HG24F-22
X2
001115-302-02
A B C D
VV303101
001758 212 02
1VN-G
HG11E-16 HG2F-16 HG9F-16 HG13E-16
F G H J K
001115-211-02
A B C D E
VV303103
HS8G-22 HS7G-22
4
HG23G-22
HG25G-22
HG17E-18
HG13E-16
HG12E-16
HG23E-22 HG24E-22 HG25E-22
HS25F-22 HS23F-22 HG24F-22 HS8F-22 HS7F22
HG12F-16
HG13F-16
6
SIM_M_0816_SN(PN)
HG17F-18
30CG-D
SIM_M_0816_SN(PN)
5
30CG-D
SIM_M_0816_SN(PN)
4
30CG-D
SIM_M_2022_SN(PN)
1 2 3
AVIONIC BAY 29CG-C
HG24H-22
HG23H-22
HS8F-22 HS7F-22
53 54 52 50 51
3
4
5
5WW-D
5
+ VOLT DIMM
D3
20A 1A
C
A GND
STROMSENSOR 3HG
C
A GND
N
C
A GND
R
Pitot Heat R
D5
5WW
HG14E-16
EDV-Kennung:
9B30310T 6
Zuordnung links / rechts wird mit */* in allen Feldern angegeben.
04 03 02 01 Ver. Bezeichnung
m k n
ÄM-400-09-01
04.10.10
Name
HW
WH3E-22N
1 2
Name
PB
Datum
14.09.04
AN3115-1
8HG-A
46569 Hünxe, Germany
7
Static Heat L
Hydraulic
Static Heat R
Pitot Heat R
2WH
LIFT TRANSDUSER
6HG
PITOT HEAT R
see EA-9B273.30 STALL WARNING
org grün lila weiß/rot blau gelb
2WH-A
Projektion Freimaßtoleranz Oberfläche
A Blatt 1
von
8
Schutzvermerk nach DIN 34 beachten.
A3
EA-9B303.10
1
PITOT-STATIC-STALL-HEAT, HG
EA 400-500
Maßstab auf SI.-Klasse Oberflächenschutz
8HG
PITOT HEAT L
Mit M4 am Seilrollenbeschlag
12VN
Schwarze Heide 21
Gepr.:
Gepr.:
Bearb.:
HG18G-18 HG19E-18
1 2 AN3115-1
6HG-A HG14G-16
Chip Pitot Heat L
8
see EA-9B273.30 STALL WARNING
1 5 10 12 6 2
Mit M4 am Seilrollenbeschlag
HG19E-18
13VN
HG16G-16
2WH-a
WH2E-22
Bleed Overt
Oil-Press Fuel-Press
Windsh-Heat
Annunciator Panel left Stall-Heat
03-06-2122 Pin 02-06-2103
ST5
Tragfläche overhead
Nr.: Änderung/Mod. Nr.: Datum
A
7
P/N 90-4219X-1
WW1-20
WW6-22 WW11-22 WW3-22 WW7-22 WW4-22
Trennstecker
Letzte Bearbeitung:
001758_212_02 20VN-A
HG18E-18
Pitot Heat L
5WW-B
1WW
HG16F-16 HG14F-16 HG18F-18
5 10 2 6 3 24 25
SIM M 0816
1 2 3
30CG-D
AVIONIC BAY
001758_212_02 20VN-A
Stall Heat
Die Gültigkeitszuordnung von Version zu Flugzeugbaureihe ist der Bauakte bzw. dem jeweiligen Fertigungsauftrag zu entnehmen.
20A 1A
STROMSENSOR 7HG
001758_212_02 P 20VN-A
HG24E-22
20A 1A
STROMSENSOR 5HG
HG25E-22
D2
D10
6
ANNUNCIATOR BOARD EA-9B315.81 see Annunciator-Panel EA-9B315.80
HG23E-22
37 42 34 38 35
D6
LIGHT TEST (GND)
ANNUNCIATOR BOARD
SIM_M_XXXX_SN(PN)
Maintenance Manual EXTRA 500 Chapter 91 30. March 2012
1VN-E
1
3
M220-B4N
2
35GA
HG2E-16 2
HG11F-16 HG28F-18
HS3E-22N
3 OFF HG3E-16 2 ON 1 TEST HG5E-18
1 TEST
D-SUB 9
HS2F-22
PITOT-L 9HG HG4E-18 2 OFF 3 HG6E-18 10A 07.1.1.16 10HG ON
see EA-9B246.10 DC-DISTRIBUTION
EMERGENCY BUS PP4
LOAD BUS BUS PP3
PITOT-R
2HG PITOT-R 1HG HG1E-16 2 07.1.1.16 15A
CIRCUIT BREAKER/SWITCH PANEL
HS7H-22
STATIC HEAT RIGHT 3HS
L
KL
5
1
HS6E-22N
ST14-B
7
B
2HS
HS7J-22
HS5F-22
STATIC HEAT LEFT 6HS
HS8H-22
P
N
K
1
5
C
1HS
HS2E-22 LOAD 4 HS1E-22 6,8 Ohm / 15 Watt HG11G-16 3 HG28G-18
A1
A3
see EA-7B233.00 & EA-7B233.10
BUS
A2 HS9F-22N
5HS
2
HS5E-22 LOAD 6 HS4E-22 6,8 Ohm 15 Watt
STATIC-SENSOR R
BUS
4HS
HS8J-22
T
S
1
4
D
6
16 11 6
30CG
29CG
1
4
1
D
2
3
D
A1
A3
20
9
1
16 11 6
C
12
5
20
1
16 11 6
B
1
GA32-22N GA31-22N
HG6F-18
A2 HS9E-22N
HG5F-18 HG3F-16
DRUCKSCHOTT HINTEN
R
HS9H-22N
J
HG28E-18 HG11E-16 HG9F-16
7
M
HG25G-22 HG25H-22 HG5F-18 HG27F-18
HS9G-22N
HG26E-20N
STATIC-SENSOR L
HG6F-18
U
HG10E-22 HG27F-18
5
KFG
8
HS7E-22
ST15
5
HG24G-22
3
B
19VN-A 001758_212_02
A
2
C
HS7E-22 HS8E-22 HS8E-22 4
HG25H-22 5
20
16 11 6
1
16 11 6
A
HG16E-16
1
Einpinseite
HG16E-16 HG18E-18
HG20E-16N HG21E-16N HG22E-18N
HG16G-16 HG18G-18
HG17E-16N
CURRENT SENSOR LeeAir 76390-401C101 400mA pull in curent 100mA drop out
5
20
5
20
HG15E-16N
A
B
C
D
A
B
C
D
HM1G-22
Splice
c
VV149
2HM
nc
no
OFF
ON
Microswitch
RS334-870
(FE4107)
2
VV151
VV150
HM2E-22
HM1G-22
ST4
ST4
24
23 D:18
1
HM2F-22
K
5
11
27
4
2A
HM3E-22 HM4E-22N
5 INV
K5
1
2
3
4
D14
9
6 24 25 5WW-A
5WW-C
WW39-20N
WW20-20
WW26-22
6
5
3HM
2300 7828
EDV-Kennung:
9B30410T
04 03 02 01 Ver. Bezeichnung
6
Zuordnung links / rechts wird mit */* in allen Feldern angegeben.
Die Gültigkeitszuordnung von Version zu Flugzeugbaureihe ist der Bauakte bzw. dem jeweiligen Fertigungsauftrag zu entnehmen.
Am Triebwerk installiert
1 2 3
Anti Icing Solenoid Valve
Intake Heat
ÄM-400-09-01
01.07.10
Windshield On
Nr.: Änderung/Mod. Nr.: Datum
A
Reco Light
HW
Name
7
Name
PB
Datum
07.4.04
2WW
7
46569 Hünxe, Germany
Projektion Freimaßtoleranz Oberfläche
8
A Blatt 1
von 1
8
Schutzvermerk nach DIN 34 beachten.
A3
EA-9B304.10
ANTI ICE INTAKE, HM
EA 400-500
Maßstab auf SI.-Klasse Oberflächenschutz
P/N 90-42192-2 geändert
Annunciator Panel right
Schwarze Heide 21
Gepr.:
Gepr.:
Bearb.:
Deice Boots Landing Light
Letzte Bearbeitung:
Diode direkt hinter dem Stecker 3HM-A installieren!
3HM-A
VV152 VV153
Jiffi Diode 4HM
see EA-9B315.80 ANNUNCIATOR PANEL
ANNUNCIATOR BOARD EA-9B315.81
291-9726
+ VOLT DIMM
LIGHT TEST (GND)
see EA-9B246.10 DC-DISTRIBUTION
EMERGENCY BUS PP4
5
(Stecker M83723/75R-08-03-6)
BYW56
D41
ANNUNCIATOR BOARD 5WW
HM1E-22
INTAKE-A/I 1HM
CIRCUIT BREAKER/SWITCH PANEL
001758 212 02 2VN-C
44
5WW-D
CB-Trennstaecker
HM1F-22
Brandspant Trennstecker
3
Maintenance Manual EXTRA 500 Chapter 91 30. March 2012
1
A
B
C
D
A
B
C
EA-9B284.13b
BYW56
D39
291-9726
GND
28VDC Fail
1 2 3 4 5 6 7 8
HF8E-22 HF9E-22 HF10E-22N
HF3G-22 HF5E-22 HF7E-22
VV239
HF7E-22
HF16E-22
HF17E-22N
15polDSub
4HF-A
19
36
37
18
ST-A
001758_212_02
AB
3VN-A
HF5E-22
HF4F-12
5HF
X1
1
3
an 1VN
4
HF3H-22
HF6E-12
HF3E-22
HF3F-22
HF4E-12
6
HF14E-12N
HF15E-22N
HF8E-22 HF9E-22
5
5
2 4 3
29
43
20A
WSH-HT 1HF
1 2 3 4
5
Windshield Heater
T
TEMP Sensor
1
1
2
3
4
D33
D15
4 24 25
HF6E-12 HF11E-12
5
001758_212_02 3VN-A
D
A514.2076
Stromsensor Kissling
5WW-C
5WW-B
7HF
15 24 25
EDV-Kennung:
9B30420T 6
Zuordnung links / rechts wird mit */* in allen Feldern angegeben.
04 03 02 01 Ver. Bezeichnung
Oil-Press Fuel-Press
Name
Nr.: Änderung/Mod. Nr.: Datum
Name
PB
Datum
25.08.04
Windshield On
7
46569 Hünxe, Germany
Schwarze Heide 21
Gepr.:
Gepr.:
Bearb.:
Reco Light
Projektion Freimaßtoleranz Oberfläche
8
A Blatt 1
von 1
8
Schutzvermerk nach DIN 34 beachten.
A3
EA-9B304.20
WINDSHIELD HEAT, HF
EA 400-500
Maßstab auf SI.-Klasse Oberflächenschutz
Deice Boots Landing Light
Intake Heat
Annunciator Panel right
Bleed Overt
Cab-Press
Stall-Heat Windsh-Heat
Aft Door Stall-Warn
HW
ÄM-400-09-01
7
Annunciator Panel left
04.10.10
A
2WW
P/N 90-42192-2 geändert
Letzte Bearbeitung:
WW20-20
WW26-22
WW1-20
WW16-22
1WW
P/N 90-42192-1
6
Die Gültigkeitszuordnung von Version zu Flugzeugbaureihe ist der Bauakte bzw. dem jeweiligen Fertigungsauftrag zu entnehmen.
Anschlüsse mit Kabelschuh
20A C A 1A GND
see EA-9B315.80 ANNUNCIATOR PANEL
ANNUNCIATOR BOARD EA-9B315.81
+ VOLT DIMM
LIGHT TEST (GND)
Anschlußschema
6HF
2A
WSH-CTRL 2HF
BATTERY BUS PP2
5
see EA-9B246.10 DC-DISTRIBUTION
ANNUNCIATOR BOARD 5WW
HF1E-22
HF2E-12
07.2.1.13
:2
2
5WW-D
HF12E-22
Massebolzen
1VN
3 4
HF16E-22
ON
OFF 1
3HF:1
WINDSH
CIRCUIT BREAKER/SWITCH PANEL
Befestigen mit Mutter und Schraube
M320-B4N
X2
2
1
D:6
HF3H-22
2
D:12 1
C:1
HF3G-22
HF4F-12
3
Maintenance Manual EXTRA 500 Chapter 91 30. March 2012
4HF
AT15.2121
Kissling
05856.12
TEMP CONTROLER
see EA-9B284.13B PC-BOARD 1
K2
PC-BOARD 1
2
HF11E-12 HF8E-22 HF15E-22N HF9E-22
D
HF3J-22
HF3J-22
1
HF14E-12N
HF13E-22N
A
B
C
D
A
B
C
D
2
Pneumatic
Fuel Low R
Fuel Filter
Fuel Low L
Ignition
Reco Light
Deice Boots Landing Light
Intake Heat
Prop Low Pitch External Power Windshield On
Low Voltage
Standby Alt On
WW20-20
WW28-22 WW34-22
H D B C E F A
24 25
3HH-A
4
1
2
3
28 19
see EA-9B315.80 ANNUNCIATOR PANEL
4
HH3F-22 HH4F-22
HH2F-22
38 43
5WW-D
5
HH6F-22 HH10F-22
J4
30 29
51 52
1
1
6
HH2E-22
EDV-Kennung:
9B31010T 6
Zuordnung links / rechts wird mit */* in allen Feldern angegeben.
04 03 02 01 Ver. Bezeichnung
J
G H
MS3470L10-6S
6HH-A
ÄM-400-09-01
Nr.: Änderung/Mod. Nr.: Datum
01.07.10
Name
HW
MS27467T9B98S
HH10E-22 HH9E-22N
Letzte Bearbeitung:
A
5HH-A
VV156 2VN-D 001758 212 02
HH8E-22N
HH4E-22
4HH-A
2A
1HH
BOOTS
VV154
VV155
HH7E-22N
HH3E-22 HH6E-22
HH1G-22
001758 212 02 2VN-D
Die Gültigkeitszuordnung von Version zu Flugzeugbaureihe ist der Bauakte bzw. dem jeweiligen Fertigungsauftrag zu entnehmen.
HH6E-22 HH10E-22
2 07.1.1.13
3
1
2HH
BOOTS
HH1E-22
CIRCUIT BREAKER/SWITCH PANEL
HH3E-22 HH4E-22
ST 4
FIREWALL
D:7
C:14
Stecker CB-Panel HH1F-22
5
MS 38999 III 20K G 35 PN (79 X #22D)
HH1F-22 HH2F-22 HH3F-22 HH4F-22
ANNUNCIATOR BOARD EA-9B315.81
+ VOLT DIMM
D32
?VN-A 001758 212 02
?
8 9 10 11
30CG-C
Stecker Avionikbay
LIGHT TEST (GND)
HH1G-22 HH2G-22 HH3G-22 HH4G-22 HH5E-22N
ANNUNCIATOR BOARD D23 5WW
Avionikbay
5 14
5WW-C
2WW
3HH
28 VDC POWER TIMER 1Min FLOW CONTROL FLOW CONTROL GND
TIMER
3
Maintenance Manual EXTRA 500 Chapter 91 30. March 2012
Fuel Trans R
P/N 90-42192-2 geändert
Annunciator Panel right
Fuel Trans L
1
31.10.02
PB
Name
C
46569 Hünxe, Germany
7
5HH
6HH
8
Blatt 1
von 1
8
Schutzvermerk nach DIN 34 beachten.
A3
EA-9B310.10
BOOTS, HH A
Projektion Freimaßtoleranz Oberfläche
EA 400-500
Maßstab auf SI.-Klasse Oberflächenschutz
NO
NC
P
PNEUMATIC LOW
3D3556-03
OUTBOARD WING DE-ICER
Datum
NO
NC
4HH EJECTOR VALVE 2
3D3556-03
Schwarze Heide 21
Gepr.:
Gepr.:
Bearb.:
A B C
A F E C
A F E C
INBOARD WING DE-ICER
EJECTOR VALVE 1
see EA-9B246.10 DC-DISTRIBUTION
BATTERY BUS PP2
7
Firewall Engine Compartement leftside
A
B
C
D
K10
BYW56
BYW56
1
7
9
+Vmo
14
31
35
13
16
EA-9B284.13a
GND
-Vmo
-Vmo test
BYW56
D12
R40 100
R41 100
8
see EA-9B284.13b PC-Board 1
D11
D31 D21
Audio out
31
1VN-C
1
WH3E-22N
WV3E-22
WV8F-22
WV1F-22
5WH
WH12E-22S
U
WH12E-22S
4
31
X
U
Horn
001758_212_02
1VN-F
2 A:4
2
07.2.1.16
3LJ:1
D:19 D:20
2
5A
STALL-WARN
WH1G-22
:2
NIGHT
3
3
3
1
2
3
4
2
5
5
A:8 A:9 A:10 A:5
3
LH3E-20N
Maintenance Manual EXTRA 500 Chapter 91 30. March 2012
D13
D1
K1:1 10
1
8
9 6
11
BYW56
K1:3 8
D10
REL G6A
16
4
13
Vmo TEST
REL TN2 113-8875
Audio
PC-BOARD 1
1RM
see EA-9B235.17 MKR-Audio
ALT WRN IN
1RM-A
1WH
WH1E-22
EMERGENCY BUS PP4
CIRCUIT BREAKER/SWITCH PANEL
DAY
(TONE) TEST
LT1E-20
4
2
A
B
C
AUDIO & MARKER PM8000B
3
NIGHT
D
2
1WV
C:13
1
6
EDV-Kennung:
9B31430T
04 03 02 01 Ver. Bezeichnung
Die Gültigkeitszuordnung von Version zu Flugzeugbaureihe ist der Bauakte bzw. dem jeweiligen Fertigungsauftrag zu entnehmen. Zuordnung links / rechts wird mit */* in allen Feldern angegeben.
1
1
WV3E-22
16
6
Vmo ALERT
Overspeed Contact closed at 207 Knots
7
HW PB
Name
01.07.10 09.09.04
Nr.: Änderung/Mod. Nr.: Datum
ÄM-400-09-01 ÄM-400-04-02
PB
Name
7
46569 Hünxe, Germany
Schwarze Heide 21
Gepr.:
Gepr.:
Bearb.: 06.09.04
Datum
optical coverage minimal 98 - 100%
8
B Blatt 1
von 1
8
Schutzvermerk nach DIN 34 beachten.
A3
EA-9B314.30
AIRSPEED WARNING, WV
EA 400-500
Projektion Freimaßtoleranz Oberfläche
+6/-0 Knots
Maßstab auf SI.-Klasse Oberflächenschutz
36 AWG Tinned copper per ASTM-B-33
Letzte Bearbeitung:
B A
3FG
700-00083-()
see EA-9B342.65 IFD-LEFT
OVERBRAID
P1122
IFD LEFT IFD-5000i
see EA-9B246.10 DC-DISTRIBUTION
1A
VNE-WARN
BATTERY BUS PP2
WV1E-22
1
WV8E-22
WH1F-22
WV9E-22N WV9F-22N
1 WV8F-22
4 LT2E-20
6 WV1F-22
5
A
B
C
D
D
C
B
A
Fuel Low L
Fuel Filter
Fuel Low R
Pneumatic
Fuel Trans R
Cab-Press
Flaps
Fuel Trans L
Aft Door
Stall-Warn
Gen-Fail
Gear Warn
Ignition
Chip
Hydraulic
Reco Light
3
5WW-C DB25RA/M
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
5WW-B DB25RA/F
4 38
EA-9B304.20 EA-9B310.10
Windshield Heat ON Boots
101 102 50 53 103
42 40 41 108 35 107 39 21 54
C 18 C 17 C 16 C 15 C 14 C 13 C 12 C 11 C 10 C9 C8 C7 C6 C5 C4 C3 C2 C1
51 52 46 00
EA-9B317.10 EA-9B317.10 EA-9B303.10 EA-9B303.10 EA-9B317.10
E-W Low Fuel Press E-W Oil Press P/Static/S Heat left Pitot/S/S Heat left E-W Chip Detect
25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
B1 B2 B3 B4 B5 B6 B7 B8 B9 B 10 B 11 B 12 B 13 B 14 B 15 B 16 B 17 B 18
P/Static/S Heat rightEA-9B303.10 Pitot/S/S Heat right EA-9B303.10 Gear Control System EA-9B323.10 Spare
EA-9B275.20 EA-9B323.20 EA-9B243.10 EA-9B213.30 EA-9B273.30 EA-9B527.10 EA-9B215.20 EA-9B304.20 EA-9B303.10
Flap System Gear Warning DC Generation I Cabin-Press Stall Warning Door Warning Bleed Air System Windshield Heat P/S/Stall Heat
GND CONTROLED
WW38-22 WW37-22 WW36-22 WW35-22 WW34-22 WW33-22 WW32-22 WW31-22 WW30-22 WW29-22 WW28-22 WW27-22 WW26-22 WW25-22 WW24-22 WW23-22 WW22-22 WW21-22
WW40-22
WW20-20
WW1-20
WW2-22 WW3-22 WW4-22 WW5-22 WW6-22 WW7-22 WW8-22 WW9-22 WW10-22 WW11-22 WW12-22 WW13-22 WW14-22 WW15-22 WW16-22 WW17-22 WW18-22 WW19-22
Static Heat R
Pitot Heat R
Deice Boots Landing Light
Intake Heat
Static Heat L
Pitot Heat L
Prop Low Pitch External Power Windshield On
Low Voltage
Standby Alt On
Bleed Overt
Oil-Press
Fuel-Press
Stall-Heat
Windsh-Heat
2
HF12E-22 HH6F-22
HS-7F-22 HG24F-22 GA53E-22 Spare 5WW32-22
LW1E-22 LW3E-22 HS-8F-22 HG25F-22 LW5E-22
CG47F-22 EZ65E-22 EZ63E-22 HP11G-22 WH11E-22 MC1E-22 HA33E-22 HF16E-22 HG23F-22
DB50SLE 5WW-B
+VDC II S
+VDC I S
4
F2
F1
5A
5A
+VDC II
+VDC I
1
2
EA-9B284.30 EA-9B310.10 EA-9B731.30 EA-9B284.30 EA-9B731.10
EA-9B731.30
Low Fuel Warning Pneumatic (Boots) Fuel Trans Right Low Fuel Warning Fuel Pump / Filter
Fuel Trans Left
3
EA-9B317.10 EA-9B315.90 EA-9B243.20
E-W Prop Low Pitch Low Voltage Monitor DC Generation II
Spare
47
106 43 48 105 1
104 108 100
00
QF10F-22
EZ64E-22 HH10F-22 QF9F-22 EZ66E-22 QW1F-22
LW6E-22 WL1E-22 PR213E-22
Spare 5WW25-22
4
Maintenance Manual EXTRA 500 Chapter 91 30. March 2012
P/N 90-42192-2 geändert
Annunciator Panel right
2WW
1WW
P/N 90-42192-1 geändert
Annunciator Panel left
1
D35
D33
D31
D29
D27
D25
D23
D21
D19
D17
D15
D13
D11
D9
D7
D5
D3
D1
D36
D34
D32
D30
D28
D26
D24
D22
D20
D18
D16
D14
D12
D10
D8
D6
D4
D2
3 INV 4 INV 5 INV 6 INV 1 INV 3 PLUS 7 INV 4 PLUS 5 PLUS 6 PLUS 7 PLUS 1 PLUS
36x BYW56
5
5
4
6
BYW56
G6A-234P
6
D43
K7
D42
K6
D41
K5
D40
K4
D39
K3
BYW56
291-9726
BYW56
291-9726
BYW56
291-9726
BYW56
291-9726
BYW56
291-9726
SIG IN 1 16 1 D38 BYW56
K2 16
4
D37
K1 291-9726
BYW56
G2RL-24
K8
D44
6
GND
DIM
+28V Test +28V
GND Test
5WW
RZ2E-24S
PD4J-22 LA7F-22 LF2K-22 HM2F-22 WL5E-22
Spare 5WW7-22 Spare 5WW13-22
see EA-9B275.20 FLAP SYSTEM [IN TRANSM]
see EA-9B344.14 WEATHER DEDECTION RZ13E-24S see EA-9B235.16 MKR-AUDIO
P1
P1
6
CG34H-22
GA53H-22
SS9E-24
SS8E-24
SS7E-24
SS7E-24
49 45 50 44 24
00 00
1 6 3 4 5 2 7 8 9
EA-9B244.10 EA-9B334.35 EA-9B334.60 EA-9B304.10 EA-9B743.10
7
D4
D3
D2
D1
9B31580T
04 03 02 01 Ver. Bezeichnung EDV-Kennung:
2SS
ÄM-400-09-01 ÄM-400-09-01
7
Nr.: Änderung/Mod. Nr.: Datum
B A
Letzte Bearbeitung:
17.02.11 06.10.10
WW39-20N
LG109E-20
see EA-9B284.13B PCB-BOARD 1
BYW-56
BYW-56
BYW-56
BYW-56
Die Gültigkeitszuordnung von Version zu Flugzeugbaureihe ist der Bauakte bzw. dem jeweiligen Fertigungsauftrag zu entnehmen. Zuordnung links / rechts wird mit */* in allen Feldern angegeben.
29
24
11
10
VV162
see EA-9B344.14 WEATHER DEDECTION
MIC INHIBIT INPUT
PC-BOARD 1 EA-9B411.50A
54
WEATHER DETECTION TWX-670
External Power Landing Light Reco Light Anti Ice Intake Ignition System
LH3G-20
LH4E-20
7
VV161 WW41E-20
VV160
5WW-A DB9RA/M
+28VDC CONTROLED INPUT
Spare Spare
Steuer-Platine EA-9B411.70
D46
D45
G2RL - 8A 365-0591
see EA-9B344.14 WEATHER DEDECTION
see EA-9B235.16 MKR-AUDIO
50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
J
Name
HW HW
16
41
40
Über 5LH-A Pin 20/1 K1 EA-9B334.90
Name
PB
Datum
46569 Hünxe, Germany
Schwarze Heide 21
Gepr.:
Gepr.:
Bearb.: 05.03.04
001758 212 02 1VN-E
Projektion Freimaßtoleranz Oberfläche
DIM Voltage
+ 28V Power
+ Light-Test
- Light-Test
B Blatt 1
von 1
8
Schutzvermerk nach DIN 34 beachten.
A2
EA-9B315.80
EA 400-500 ANNUNCIATOR PANEL, WW
Maßstab auf SI.-Klasse Oberflächenschutz
Über 5LH-A Pin 13/14 F6 EA-9B334.90
Über 5LH-A Pin 9 an F1 EA-9B334.90
Über 5LH-A Pin 7/8 F2 EA-9B334.90
8
D
C
B
A
A
B
C
D
25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
J5WW-C DB25RA/M
C 18 C 17 C 16 C 15 C 14 C 13 C 12 C 11 C 10 C9 C8 C7 C6 C5 C4 C3 C2 C1
B1 B2 B3 B4 B5 B6 B7 B8 B9 B 10 B 11 B 12 B 13 B 14 B 15 B 16 B 17 B 18
J5WW-D DB50SLE
+VDC II S
+VDC I S
3
CB2
CB1
5A
5A +VDC I
+VDC II
4
D35
D33
D31
D29
D27
D25
D23
D21
D19
D17
D15
D13
D11
D9
D7
D5
D3
D1
D36
D34
D32
D30
D28
D26
D24
D22
D20
D18
D16
D14
D12
D10
D8
D6
D4
D2
+VDC II
1
2
3
4
5
5
3 INV 4 INV 5 INV 6 INV 1 INV 3 PLUS 7 INV 4 PLUS 5 PLUS 6 PLUS 7 PLUS 1 PLUS
36x BYW56
Maintenance Manual EXTRA 500 Chapter 91 30. March 2012
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
J5WW-B DB25RA/F
2
50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
1
1
:2
D43
K7
D42
K6
D41
K5
D40
K4
D39
K3
D38
K2:1
4
D37
K1
G2RL-8A 365-0591
K8
D44
SIG IN
BYW56
BYW56
291-9726
BYW56
291-9726
BYW56
291-9726
BYW56
291-9726
BYW56
J5WW-A DB9RA/M
5WW
DIM
+28V Test
GND Test
GND
G6A-234P
BYW56
291-9726
16
8
6
291-9726
BYW56
6
EDV-Kennung:
9B31581T
04 03 02 01 Ver. Bezeichnung
Die Gültigkeitszuordnung von Version zu Flugzeugbaureihe ist der Bauakte bzw. dem jeweiligen Fertigungsauftrag zu entnehmen. Zuordnung links / rechts wird mit */* in allen Feldern angegeben.
6
14.10.10
1 6 3 4 5 2 7 8 9
Nr.: Änderung/Mod. Nr.: Datum
Letzte Bearbeitung:
Steuer-Platine EA.9B315.81
D46
BYW56
D45
BYW56
Name
HW
HW
7
46569 Hünxe, Germany
Schwarze Heide 21
Gepr.:
Gepr.:
Name
Datum
Bearb.: 15.03.04
7
Projektion Freimaßtoleranz Oberfläche
Blatt 1
von 1
8
Schutzvermerk nach DIN 34 beachten.
A3
EA-9B315.81
WARNING BOARD 55
EA 400-500
Maßstab auf SI.-Klasse Oberflächenschutz
8
A
B
C
D
A
B
C
D
2WW
2
Fuel Low R
Pneumatic
Fuel Trans R
Ignition
Prop Low Pitch External Power
Low Voltage
Standby Alt On
3
WW31-22
5WW-C
1A
1LW
D26
+ VOLT DIMM
LIGHT TEST (GND)
1
2
3
4
5
ANNUNCIATOR BOARD EA-9B315.81 see EA-9B315.80 ANNUNCIATOR PANEL
5WW
ANNUNCIATOR BOARD
11 24 25
WL2E-22
LOW-VOLT
5
1
22 108
5WW-D
6
J1A
6
DB37S
WL1E-22 WL2F-22 WL3E-22N
Die Gültigkeitszuordnung von Version zu Flugzeugbaureihe ist der Bauakte bzw. dem jeweiligen Fertigungsauftrag zu entnehmen. Zuordnung links / rechts wird mit */* in allen Feldern angegeben. 04 03 02 01 Ver. Bezeichnung EDV-Kennung: 9B31590T
001758 212 02 1VN-G
D
WL1E-22
CB Trennstecker C:16
see EA-9B246.10 DC-DISTRIBUTION
EMERGENCY BUS PP4
CIRCUIT BREAKER/SWITCH PANEL
4
Maintenance Manual EXTRA 500 Chapter 91 30. March 2012
P/N 90-42192-2 geändert
Annunciator Panel right
1
ÄM-400-09-01 ÄM-400-04-02
Name
HW PB
PB
Name
7
46569 Hünxe, Germany
Schwarze Heide 21
Gepr.:
Gepr.:
Datum Bearb.: 20.09.04
Projektion Freimaßtoleranz Oberfläche
8
B Blatt1 von
8
Schutzvermerk nach DIN 34 beachten.
A3
EA-9B315.90
1
LOW VOLTAGE MONITOR, WL
EA 400-500
Maßstab auf SI.-Klasse Oberflächenschutz
see EA-9B284.13b PC-BOARD 1
EA-9B284.13
Out L-Gnd Aircraft Spruce B00378-5
Lamar Low Voltage Monitor U60 Sense
01.07.10 09.09.04
red green black
Nr.: Änderung/Mod. Nr.: Datum
B A
Letzte Bearbeitung:
22 21 3
J1
PC-BOARD 1
7
A
B
C
D
A
B
C
D
13 12 17 18 9 16 19 20 11 8 6 25
+28VDC Lighting Power Input High Lighting Power low Fuel Temp Signal Input High Fuel Temp Signal Input Return Spare Bat Ameter Signal Input Low Bat Ameter Signal Input High Spare Case Ground Gen Amp Input high Gen Amp Input low Spare
G
001758 212 02 1VN-G
1
2
25 26
Trennstecker FIREWALL
EY4F-22S
EY8E-22S EY10E-22N
EY9E-22S
ws bl
3
4
5
24 23
N
r D s t
ws bl
N L M P R S
ws q bl
ws bl
R S
ws L bl M ws P bl
ws bl
EDV-Kennung:
VOLT-MON 1A
ws bl ws bl
ST2
ws bl
6
ST2
ws bl
ws bl
ST1
EY7F-22S
EY6F-22S
EY5F-22S
EY4E-22S
Output High Output Low Exitation +10VDC Exitation Return 4EY
r D s t
6EY
Name
Nr.: Änderung/Mod. Nr.: Datum
PB
7
46569 Hünxe, Germany
Schwarze Heide 21
Gepr.:
Gepr.:
Name
Datum
Bearb.: 26.08.04
HKM-186-375-50psi G
Output High Output Low Exitation 10-40VDC Exitation Return 4EY
Fuel Press Sensor
ws EY8F-22 bl EY8G-22
A Blatt 1
von 1
8
Schutzvermerk nach DIN 34 beachten.
A3
EA-9B316.40
DIGITAL INSTRUMENT, EY
EA 400-500
Maßstab auf SI.-Klasse Oberflächenschutz
EA-9B243.40
PCB EA-9B243.41b J21 PCB EA-9B243.41b J22
PCB EA-9B243.45 F11 PCB EA-9B243.45 F12
8
Projektion Freimaßtoleranz Oberfläche
0B823.03 Stecker MS3126F8-4S
05835.25 MS28034-3 102-00002 Stecker MS3106F12S-3S
ws EY9F-22 bl EY9G-22
E-BOX
HW
ÄM-400-10-01 ÄM-400-09-01
5EY
05835.25 MS28034-3 102-00002
Fuel Temp Sensor
Alternativ:
green white red black
ws bl
A B
IAT-Sensor
7
Fuel Press Sensor
ws q bl
ST1A
MS33678 6EY-A
B C A D
4EY-A
MS33678 5EY-A
13.09.10
A
Letzte Bearbeitung:
ST10-A
ws 18 bl 19 20
Y W X
ST5-A
see EA-9B246.10 DC-DISTRIBUTION
DIP-2 1A
9B31640T
04 03 02 01 Ver. Bezeichnung
7EY
LOAD BUS PP3
DIP-1 1A
Die Gültigkeitszuordnung von Version zu Flugzeugbaureihe ist der Bauakte bzw. dem jeweiligen Fertigungsauftrag zu entnehmen. Zuordnung links / rechts wird mit */* in allen Feldern angegeben.
EY8E-22S
EY9E-22S
Trennstecker FIREWALL
EY7E-22S
Trennstecker BODEN
EY6E-22S
LG101E-22S
J5
2EY
Trennstecker FLÜGELNASE
EY2E-22
EY3F-20S
EY1E-22
EY6E-22S
EY7E-22S
ws bl
1
1
1
1
Pilot left side
001758 212 02 3VN-A
L P
C:6
A:4
A:3
C:5
see EA-9B334.90 DIMMING SYSTEM
VV167
VV166 EY11E-22N EY12E-22N
EY2F-22
EY3E-20S
EY1F-22
CB-Trennstecker
1EY
6
EMERGENCY BUS PP4
CIRCUIT BREAKER/SWITCH PANEL
5
EY5E-22S
33 34
4
EY5E-22S
EY4F-22S
EY2F-22S EY3E-20S
EY1F-22S
ws bl ws bl
ws bl ws bl ws bl
ws bl
3EY-A J1
3
Maintenance Manual EXTRA 500 Chapter 91 30. March 2012
3EY
1 2 7 5 3 4 14 15 23 24 21 22 10
2
+28VDC Power Input High (Cannel A) Power Input Gnd Ch A & B & VDC +28VDC Power Input High (Cannel B) Power GND (Ch A & B) Voltmeter Signal Input High Spare IAT Signal Input high IAT Signal Input low Fuel Press Signal Input High Fuel Press Signal Input Low Fuel Press Sensor Exitation Output (+10VDC) Fuel Press Sensor Exitation Return Spare
Digital Instrument Package
1
A
B
C
D
A
B
C
D
21 22 23
16 17 24
6
N1 SIGNAL INPUT N1 RETURN CASE GROUND SPARE
OIL TEMP INPUT HIGH OIL TEMP INPUT RETURN CASE GROUND SPARE
CASE GROUND SPARE
3EZ
#
G
31
EZ13E-20N EZ14E-20N
Alumel, red (-) Chromel, yellow (+)
EZ9E-22S
EZ8E-22S
EZ7E-22S
EZ6E-22S
8.0 - 28 VDC Dimming < 8.0 VDC Day Mode
EZ4E-22S
EZ5E-22S
EZ3E-22S
R K
4
ws bl ws bl
ws bl
ws bl
ws bl ws bl
ws bl
h j
45 62 63 60 61 46
e c d
58 59 47
Y W X Z a b
T U V
*
ST2
A:12
A:1
ST4
EZ4F-22S
EZ5F-22S
EZ9F-22S
EZ8F-22S
Alumel: M39029/87-475 Cromel: M39029/87-476
EZ9F-22S
EZ8F-22S
Alumel: M39029/88-487 Cromel: M39029/88-488
1
2
Buchse Alumel: 8500-2055 Cromel: 8500-2054
3
4
A D B C
Exitation 10-40VDC Exitation Return Output High Output Low
VV178
VV177
8EZ
EZ15E-22S
7EZ
EDV-Kennung:
9B31650T
04 03 02 01 Ver. Bezeichnung
6
Zuordnung links / rechts wird mit */* in allen Feldern angegeben.
Die Gültigkeitszuordnung von Version zu Flugzeugbaureihe ist der Bauakte bzw. dem jeweiligen Fertigungsauftrag zu entnehmen.
Alumel, green (-) Chromel, white (+)
KM005-150G-8-1 & Stecker MS3126F8-4S
Ringöse Chromel
5
A B
8EZ-A Oil Press Sensor
Ringöse Alumel EZ11F-20 EZ12F-20
ws bl
7EZ-A
Oil Temp Sensor
ws bl
5EZ-A
8EZ
Exitation 10-40VDC Exitation Return Output High Output Low
8EZ-A Oil Press Sensor
A D B C
25Ohm
TR3
TR2
TOT PROBS
HW
Name
Nr.: Änderung/Mod. Nr.: Datum
ÄM-400-10-01 ÄM-400-09-01
1VE
EA-9B284.13
cw
25Ohm
RS 162-647
MS25038-4 32005-023
Name
PB
Datum
17.06.04
7
46569 Hünxe, Germany
Schwarze Heide 21
Gepr.:
Gepr.:
Bearb.:
Projektion Freimaßtoleranz Oberfläche
8
A Blatt 1
von 1
8
Schutzvermerk nach DIN 34 beachten.
A3
EA-9B316.50
ENGINE INSTRUMENT, EZ
EA 400-500
Maßstab auf SI.-Klasse Oberflächenschutz
see EA-9B284.13 PC-BOARD 1
Oil "0" adjust
Tourqe "0" adjust
5EZ
IPS1525-150PSI-7/16-20UNF-SW27-MIL-C26484 & Stecker MS3476W10-6S & Clamp M85049/52-1-10W
2 20 1
1VE-a
13.09.10
A
A B
RPM Sensor N1
PC-BOARD 1
Letzte Bearbeitung:
Alternativ:
MS25038-4 32005-023
Exitation 10-40VDC Exitation Return Output High Output Low 6EZ
Torque Sensor
4EZ
7
IPS1525-150PSI-7/16-20UNF-SW27-MIL-C26484 & Stecker MS3476W10-6S & Clamp M85049/52-1-10W
A D B C
6EZ-a
A B
RPM Sensor N2
PC 06E 8-2S (SR)
EZ6F-22S
Alternativ:
ws bl org
ws bl
4EZ-A
PC 06E 8-2S (SR)
EZ3F-22S
MS28034-3 102-00002
Exitation 10-40VDC Exitation Return Output High Output Low 6EZ
Torque Sensor
KM005-150G-8-1 & Stecker MS3126F8-4S
A D B C
MS3106F12S-3S
ws bl ws bl
6
see EA-9B246.10 DC-DISTRIBUTION
ENG-INS2 2A
LOAD BUS PP3
6EZ-A
EZ7F-22S
EZ4F-22S
EZ5F-22S
ws bl ws bl
2EZ
ENG-INS1 2A
EMERGENCY BUS PP4
Terminal am Triebwerk
EZ7F-22S
EZ6F-22S
Alumel, red (-) Chromel, yellow (+)
ST2
ws bl ws bl
ST4
ws bl
ST2
ws bl
1EZ
EZ2E-20
EZ1E-20
EZ3F-22S
2
1
MS38999III (23-54)
ws bl ws bl
ws bl
FIREWALL
ws
ws
5
CIRCUIT BREAKER/SWITCH PANEL
und Pinne aus Cromel und Alumel verwenden! * Buchsen Pinne Buchse
MS38999III (23-54)
EA-9B334.90
Dimming
VV174
bl bl
VV173
3VN-A Splice 001758 212 02
ALCOR P/N 42526
1VN-D 001758 212 02
EZ10E-20N
EZ9E-22S
EZ8E-22S
Alumel, red (-) EZ11E-22 Chromel, yellow (+) EZ12E-22
MS3126F10-6S
3EZ-B
D-SUB 25S
ws bl
VV168
EZ15E-22S
EZ7E-22S
ws bl
VV171
LG100E-22S
EZ4E-22S
EZ5E-22S
bl 32 ws
EZ2F-20S
EZ2F-20S
EZ3E-22S
EZ1F-20S
3
EZ1F-20S
EZ6E-22S
ws bl org
ws bl
D1 BYW56 D2 BYW56
VV172
ws bl
bl ws
ws bl
ws bl
ws bl bl ws
3EZ-A
VV170
VV169
Splice
# Buchsen und Pinne aus Cromel und Alumel verwenden!
A B C D E F
11 12 13
LIGHT GND 28 VDC LIGHT CASE GROUND SPARE
SPARE TOT - ALUMEL, RED (-) TOT - CHROMEL, YELLOW (+) SPARE SPARE SPARE
8 9 10
TRQ SIGNAL INPUT HIGH TRQ SIGNAL INPUT LOW CASE GROUND SPARE
18 19 20 25
14 15 5
N2 SIGNAL INPUT N2 RETURN CASE GROUND SPARE
OIL PRESS INPUT HIGH OIL PRESS RETURN CASE GROUND SPARE CASE GROUND
1 2 3 7 4
28 VDC POWER (Channel A) GROUND GROUND 28 VDC POWER (Channel B) CASE GROUND SPARE
Moritz A1270
Engine Instrument Package
2
Maintenance Manual EXTRA 500 Chapter 91 30. March 2012
1
cw
A
B
C
D
A
B
C
D
1
Engine Compartement
Turbine
9LW
NO
8LW
C3C
1
2
VV39
LW5F-22
LW1F-22 LW4E-22N
3
K
001758 212 02 2VN-D
NO
NC
VV184
19LW
LW6F-22
SW am Gestänge im Triebwerkraum
BAS4028U
334-870
L
Anschlüsse mit Gummitülle abdecken
1 3 2
LW3F-22 LW2E-22N
001758 212 02 2VN-D Gehäuse P 1-0480305-0 FE4308 Pin 163558-2 FE4306
U?
LOW PITCH
U?
LW7E-22N VV183 C
001758 212 02 2VN-D
E
Chip 3
12LW
GND Motorblock
Chip 2
Chip 1
11LW
10LW
CHIP DETECTOR
PCI P60
2
NC
C
1
LOW FUEL PRESS
Turbine
1 3 2
Gehäuse B 1-0480303-0 FE4307 Buchse 163557-2 FE4305
PCI P110
2
NO
C
1
NC
LOW OIL PRESS
2
LW3F-22 LW1F-22 LW5F-22 LW6F-22
ST4 27 28 26 25
FIREWALL
3
LW3E-22 LW1E-22 LW5E-22 LW6E-22 102 101 103 104
5WW-D 39 40 36 23
5WW
LIGHT TEST (GND)
ANNUNCIATOR BOARD
4
1
2
3
4
5
D4
D8
D27
D7
10 24 25
5
8 7 4 24 25 5WW-C
5WW-B
EDV-Kennung:
9B31710T 6
Zuordnung links / rechts wird mit */* in allen Feldern angegeben.
04 03 02 01 Ver. Bezeichnung
2WW
1WW
ÄM-400-09-01
04.10.10
Chip
Static Heat L
Pitot Heat L
Name
HW
Name
PB
Datum
09.02.04
7
46569 Hünxe, Germany
Schwarze Heide 21
Gepr.:
Gepr.:
Bearb.:
Hydraulic
8
A Blatt 1
von 1
8
Schutzvermerk nach DIN 34 beachten.
A3
EA-9B317.10
ENGINE WARNING, LW
EA 400-500
Projektion Freimaßtoleranz Oberfläche
Static Heat R
Pitot Heat R
Maßstab auf SI.-Klasse Oberflächenschutz
Prop Low Pitch External Power
Low Voltage
geändert
Fuel Low R
Pneumatic
Ignition
Annunciator Panel right
Fuel-Press
Fuel Trans R Standby Alt On
P/N 90-42192-2
Nr.: Änderung/Mod. Nr.: Datum
A
Bleed Overt
Windsh-Heat
Oil-Press
Annunciator Panel left
7
Stall-Heat
P/N 90-4219X-1
Letzte Bearbeitung:
WW20-20
WW30-22
WW1-20
WW5-22 WW8-22 WW9-22
6
Die Gültigkeitszuordnung von Version zu Flugzeugbaureihe ist der Bauakte bzw. dem jeweiligen Fertigungsauftrag zu entnehmen.
see Annunciator-Panel EA-9B315.80
ANNUNCIATOR BOARD EA-9B315.81
+ VOLT DIMM
Maintenance Manual EXTRA 500 Chapter 91 30. March 2012
Power Lever
A
B
C
D
A
B
C
13
14
DIMMING
DIMMING
F G H J K
GA1F-22
07.1.1.13 D927
C
001115-208-02
F G H J K
VV323103
A B C D E
GA26H-22 GA25G-22 GA24H-22
2
VV187
VV185
GA08E-22
VV186
F G H J K
001115-209-02
A B C D E
VV323104
SIM E-2022
GA37F-22 GA34F-22 GA30F-22
1 GA09E-22 AUS
EIN 3
62
30GA
FAHRWERKSHEBEL
3 2 1
ST10-A
GA30E-22
VV323106
001115-201-02
Modul 7
GA09F-22
GA08F-22
ST10-A
10 9 8
4
3
GA24F-22 GA25F-22 GA26F-22
F
G
B
H
G
F
A
C
B
A
J
D
J
D
VV323101
K
H
G
B F
A
GA10A-22
ge
bl
sw
bl
G 12.221.M.15 AUSGEFAHREN
org
ws
rt
ge
org
EINGEFAHREN G 12.221.M.15 rt sw ws
NOSE GEAR
5GA
4GA
VV323101
001115_201_02
Modul 9
bl
sw
D J
C H
B
G
A
F
36GA
G 12.221.M.15
glb
org
ws
rt
K
E
DUMP SWITCH SQUAT SWITCH NOSE GEAR
001115_201_02
VV323102
bl
sw
G 12.221.M.15
glb
rt
2GA
SQUAT SWITCH Nose Gear
E
C
K
E
C
H
D
J
K
E
GA8A-22 GA08D-22
Modul 8
GA3C-22
E
Zustand Flugzeug am Boden
GA16A-22
GA16C-22
GA26G-22
SD14H-22
GA17-22N
17GA
GA27-22
rt
GA24G-22
1
ge
bl
8GA
G 12.221.M.15
bl
9GA
AUSGEFAHREN
sw
GND
GND
GA14B-22
5VN-A
5VN-A
Modul 4
001758_212_02
KL MP C R
19GA
Lower & Nose Door Valve
SD16E-22N
GA16C-22N GA14C-22N GA17C-22N GA16C-22 GQ14C-22 GA17C-22 GA16D-22N GA14D-22N GA17D-22N
EINGEFAHREN
sw
7GA
GA9G-22
GA28-22N
SD15E-22N
GA8B-22
Uper Door Valve
18GA
G 12.221.M.15
org
ws
rt
ge
org
ws
rt
bl
33GA-a
LEFT GEAR
6GA
AUSGEFAHREN
sw
G 12.221.M.15
11 10 9 8 7 6 5 4 3
33GA-A
bl
sw
G12.221.M.15
15pol DSUB
GA14-22N GA16A-22N GA17A-22 GA14A-22 GA16-22 GA17B-22N GA14B-22N GA16B-22N
2
Main Valve
ge
org
ws
ge
org
ws
rt
SD14G-22
GA19-22
RIGHT GEAR
Schalter am Boden entlastet, im Flug belastet.
H J K
GA14-22 GA14C-22 GA14F-22
GA27-22 GA27A-22 GA19-22 GA19A-22
GA11-22N
H
L
P
T
G
K
N
S
001758-212-02
E
B
D
A
U
R
M
J
F
1
2
H
G
F
3
C
B
A
J
D
K
Fahrwerkschacht
VV323102
001115_201_02
Modul 2
4
001758_212_02
S DE F GH J T U
VV323106
001115_209_02
Modul 3 001115_208_02 VV323103
GA14D-22 GA14B-22
F GHJ K
A B C DE
Maintenance Manual EXTRA 500 Chapter 91 30. March 2012
20VN-A
001115-201-02
A B C D E
VV323101-2+5-6
41GA-A
40GA-A
LED 29GA 42GA-a Left Gear 42GA-A 1 2 GA26C-22
LED 28GA 41GA-a Nose Gear 1 2 GA25C-22
see EA-9B323.20 GEAR WARNING CIRCUIT BOARD
DIMMING (TEST) DIMMING (TEST) DIMMING (TEST)
12
DIMMING
1 2
40GA-a
27GA
GA24C-22
LED Right Gear
7 6 5
GA24J-22
GA25H-22
GA24J-22
GA24-22
GA26-22
GA3B-22
see EA-9B323.20 GEAR WARNING CIRCUIT BOARD
GA10B-22
5
GA41B-22
UPPER DOOR RIGHT
GA08B-22 GA08-22 GA08A-22 GA08C-22 GA08E-22
001115_201_02
GA34G-22
GA26F-22
GA37G-22
GA25F-22
GA24F-22
GA30E22
5
E
C D
GA17C-22 GA17A-22 GA17B-22
61 63 64
GA42-22
GA43-22
B
A
B
A
G
F
bl
zu
sw
VV323104
001115_209_02
Modul 4
G 12.221.M.30 16GA
org ge
auf bl
15GA
13GA
11GA
10GA
sw
G 12.221.M.15
ws
rt
ge
org
ws
rt
X2
10A
F300-B4N
zu bl
G 12.221.M.15
UPPER DOOR LEFT
X1
14GA
ge
org
ws
rt sw
bl
zu
sw
G 12.221.M.30
LOWER DOOR
ge
bl
auf
sw
G 12.221.M.15
org
ws
rt
ge
org
ws
rt
GA34F-22
ST1 R
1
J
K
6
D
E
ST10-A
H
G
F
GA3F-22
GA37F-22
GA1F-22
Modul 5
2
13
11
D:7
D:6
D:9
D:5
D:8
ST1
2
2
1
2
1
R
Hydr Caut
3GA-2
1
1 3
1 3
1 3
3
-X2
1
1 3
1 3
1 3
1
+X1
D
C
B
+X1
D
C
B
A
M220-B4N
2
2
2
2
85
GA4-22
EDV-Kennung:
9B32310T
04 03 02 01 Ver. Bezeichnung
Zuordnung links / rechts wird mit */* in allen Feldern angegeben.
SD14E-22
01.09.10
Datum
ÄM-400-09-01
7
5VN-A
33CG-a
15pol D-Sub
33CG-A
see EA-9B213.30, DUMP SWITCH, 3HP Pin 2
see EA-9B303.10 PITOT-STALL-HEAT, 11HG Pin X2
see EA-9B334.50 COURTESY LIGHT
see EA-9B345.58 XPDR BXP6402, ST14-A Pin 8
see EA-9B303.10 PITOT-STALL-HEAT, 12HG Pin X2
see EA-9B334.50 COURTESY LIGHT
2 1
001578_212_02
HW
Name
20GA
HYDRAULIC PUMP
An GND Anschluß Pumpe
GA51-22N
GA6H-8
GA7A-8
Zentraler Massepunkt
1VN
see EA-9B315.80 ANNUNCIATOR PANEL
001758 212 02
Schalterstellung A/C on Air
100
5
7
6
GA5-22
GA04A-22
C H VV323106
46
Brandschott
H
Datum
06.09.04
PB
Name
46569 Hünxe, Germany
Schwarze Heide 21
Gepr.:
Gepr.:
Bearb.:
Projektion Freimaßtoleranz Oberfläche
A Blatt 1
von 1
8
Schutzvermerk nach DIN 34 beachten.
A2
EA-9B323.10
LANDING GEAR CONTROL, GA
EA 400-500
Maßstab auf SI.-Klasse Oberflächenschutz
see EA-9B344.15 TRAFFIC SYSTEM TAS-610
z. B. PITOT aktiv bei abgefallenem Relay
HP9F-22
HG8E-20
VV
VV
001115_201_03
Nr.: Änderung/Mod. Nr.:
A
GA7F-8N
GA53E-22
1VN-G
see EA-9B246.10 DC-DISTRIBUTION
BATTERY BUS PP2
GA54G-22N
Modul 6
GA40-22
LY13F-22
SH5E-24
HG7E-20
LY4G-22
3
2
VV190
22GA
A
M220-B4N 35GA 3
-X2
GA3C-22
VV189
2
2
2
2
LY4G-22
VV188
34GA
86
Druckschalter
Hydraulic Motor Relais
GA3A-22
87a 88b
87z 88y
F
5
50A
GA6J-8
1
2
5A
1GA
CAPTOR CORP. RF Filter 23939/A-7464 2x 75A DC Filter 32GA GA6G-8
1A
23GA
HYDR
3GA-1
5A
37GA
8
see EA-9B243.40 E-BOX
HOT BUS PP1
GEAR-AUX-1 GEAR-CTRL
44GA
26.57.73
88a
88
21GA
ST11-A GA7E-8N
ST11-B
SIM 1
1
GA6F-8
B2
A2
M210-B4N
X2
45GA
4 GA40F-22
Bodenstecker
GA7F-8N
B3
A3 B1
GA53F-22 A1
GA54F-22 X1
GA54E-22
GA40E-22
GA3E-22
GA37E-22 3
GA1E-22
5A
GEAR AUX 2 CB1
Letzte Bearbeitung: Die Gültigkeitszuordnung von Version zu Flugzeugbaureihe ist der Bauakte bzw. dem jeweiligen Fertigungsauftrag zu entnehmen.
SD14E-22
GA34E-22
7
CIRCUIT BREAKER/SWITCH PANEL
E-BOX
001758_212_02 1VN-E L K
VV323105
ST10-A
SD14F-22
ST10-A
12
001115_201_02
ST10-A GA43-22
C
B
A
Bodenstecker
#22
GA53F-22 GA3F-22
Trennstecker Firewall
6
GA41B-22
4
GA13-22
EZ49E-22 EZ48E-22 EZ47E-22
GA41A-22N
GA41-22N
GA40-22
D
GA22A-22N GA22-22N
GA13A-22
GA10-22 GA41-22 GA41A-22
GA12A-22 GA12-22
GA11A-22N SD14G-22
GA11-22 GA11A-22
GA6E-8
3
GA22-22N GA11-22N GA20-22N GA21-22N GA28-22N GA29-22N SD16E-22N SD15E-22N
GA10B-22 GA10A-22
GA41A-22
2
SD14H-22 SD14F-22
GA50-22 GA50A-22 GA3F-22 GA03A-22
GA4B-22 GA5-22N
1
26GA AirLB Jiffi GA14G-22
GA31-22N GA32-22N
BN
A
B
C
D
D
C
B
A
2
3
20VN-A
40GA
Stall-Warn
Cab-Press
Gear Warn
Flaps
+Vmo
U?
GW9F22 GW9A-22N
NO
NC
F
EA-9B284.13B
14
30
12
CG19-22
CG15F-22
G C C
10 11
4CG-A
NO
NC
CG15G-22
1WW
P/N 90-4219X-1 geändert
U
DIMMING 14 DIMMING (TEST) 3
ST4
1VN-F
33
GW9E-22
rechts
14° LIMIT A
P600M
60
EZ65E-22
CG15H-22
5WW-D
19
29CG-D
STECKER AVIONIKBAY
12LY
Left Gear
DIMMING 13 DIMMING (TEST) 2
001758_212_02
LED
1
2
WW1-20
WW18-22
+ VOLT DIMM
LIGHT TEST (GND)
ANNUNCIATOR BOARD D14 5WW
3
ANNUNCIATOR BOARD EA-9B315.81 see EA-9B315.80 ANNUNCIATOR PANEL
17 24 25
5WW-B
49
4
49
1 2
1 2
1 2
42GA-a
29GA
GA27G-22 GA26H-22
LED
GA27F-22 GA25G-22
28GA
GA27E-22 GA24H-22
Nose Gear
DIMMING 12 DIMMING (TEST) 1
STECKER FIREWALL
66
6
4
GW9F-22
WH3E-22N
CG37E-22
GW1F-22
WH12E-22
Annunciator Panel left
see EA-9B275.20 FLAP SYSTEM
14° Position 15° Position
13CG
CG19A-22
B
VV275206
001115_207_03
001758 212 02 2VN-D
14CG
C
C CG43E-22
VV119
GND
-Vmo
+Vmo
8
see EA-9B284.13 PC-BOARD 1
Gehäuse B 1-0480303-0 FE4307 Buchse 163557-2 FE4305
FLAP BOX
Aft Door
1
8
9 6
11
BYW56 -Vmo
Spörle 220678
Gen-Fail
ADJ
NC
NO
15° LIMIT B
CG17-22N
D20
CLEAR HORN
1 3 2
links
2
1
K20
Audio out
REL G6A
16
4
13
1RM
see EA-9B235.17 MKR-AUDIO
31
1RM-A
27GA
Maintenance Manual EXTRA 500 Chapter 91 30. March 2012
001758_212_02
J
2CG
C
CG44E-22N
PCI P110
NO
NC
LOW TORQUE PRESS
1VN-F 001758 212 02
Batt. leftside
1
Gehäuse P 1-0480305-0 FE4308 Pin 163558-2 FE4306
Audio
PC-BOARD 1
PMA8000B oder PMA8000BT
Right Gear
LED
GA24H-22
GA24J-22
GA25G-22
5
EDV-Kennung:
04 03 02 01 Ver. Bezeichnung
GA26H-22
GA26J-22
VV187
VV186
VV185
9B32320T
ST10-A
5 6 7 8
Stecker Boden
6
C:3
ÄM-400-09-01
7
01.07.10
11.01.11
8 5 3 6 10 14 1 2 4 13 7 9 11 15 12
Datum
Gepr.:
Schwarze Heide 21
PB
Name
7
A Blatt 1
von 1
8
Schutzvermerk nach DIN 34 beachten.
A3
EA-9B323.20
GEAR WARNING, GA
EA 400-500
Maßstab auf SI.-Klasse Oberflächenschutz
EA-9B284.14 see EA-9B284.14 PC-BOARD 2
GEAR WARNING
Bearb.: 02.09.04 Gepr.:
EMERGENCY BUS PP4
HW Name 46569 Hünxe, Germany
HW
GND GND
2A
1GW
see EA-9B246.10 DC-DISTRIBUTION
LEFT GEAR NOSE GEAR RIGHT GEAR GEAR HORN PWR IDLE CLEAR HORN 15° FLAP GEAR WARN LIGHT
+28VDC DOOR CLOSED
PC-BOARD 2
GW1G-22
GW1E-22
GEAR-WARN
8
Projektion Freimaßtoleranz Oberfläche
see EA-9B323.10 GEAR CONTROL
CIRCUIT BREAKER/SWITCH PANEL
RIGHT-GEAR NOSE-GEAR LEFT-GEAR DOOR CLOSED
LANDING GEAR
Nr.: Änderung/Mod. Nr.: Datum
A
1
1
15pol D-sub
39GA-A
C:4
Letzte Bearbeitung:
EZ27E-22N
GW1H-22 GA30F-22 EZ49E-22 EZ48E-22 EZ47E-22 CG37E-22 GW9E-22 CG43E-22 CG15H-22 EZ65E-22
GW1H-22
GW1F-22
CB Trennstecker
1VN-B 001758 212 02
G
6
GA24E-22 GA25E-22 GA26E-22 GA30F-22
Die Gültigkeitszuordnung von Version zu Flugzeugbaureihe ist der Bauakte bzw. dem jeweiligen Fertigungsauftrag zu entnehmen. Zuordnung links / rechts wird mit */* in allen Feldern angegeben.
GA25H-22
42GA-A
41GA-A
41GA-a
40GA-A
40GA-a
5
EZ47E-22
64
4
EZ48E-22
63
3
EZ49E-22
61
AUDIO & MARKER
2
CG19-22 CG15E-22
1
62
D
C
B
A
A
B
C
D
red blk wht
red blk wht
1 2 3
4LB-A
6LB-A
LB13E-20
LB4E-20
AMP Stecker 1-0480305-0 AMP Buchse 1-0480305-0 AMP Crimpkontakt Buchse 163557-2 AMP Crimpcontakt Pin 163558-2
1 2 3
4LB-a
6LB-a
7LB
STROBE LIGHT POWER SUPPLY REAR A490-T-CF-14/28V GND 28VDC
2
1
8LB-A
LB20E-20
blk wht
LB20-20N
1 2
LB2F-20
F G H J K
1115_201_03
A B C D E
1
2
LB10G-20 LC2J-22
ST5
G
8VN
LB2G-22
STECKER OVERHEAD
AMP Stecker 180923-0 AMP Buchse 180924-0 AMP Flachstecker 6,3 mm 42565-2 AMP Flachhülse 6,3 mm 42282
LB10H-20 LC2H-22
Blitzschutz 7LB-B
17VN
DRUCKSCHOTT HINTEN
Maintenance Manual EXTRA 500 Chapter 91 30. March 2012
VV343101
4LB
A650-PR-28V
STROBE LIGHT LEFT
6LB
A650-PG-28V
STROBE LIGHT RIGHT
1
6
A:12
A:11
LB2E-20 LB10E-20
1 1
LB13E-20
Brücke VV193
LB4E-20
3
EDV-Kennung:
04 03 02 01 Ver. Bezeichnung
1 2 3
LB20F-20
5LB-a
9B33410T
3
red 1 blk 2 wht
C3C 3LB-C
1 2 3
3LB-B
3
red 1 blk 2 wht
3LB-A
2
red 1 blk
3LB-D
A
ÄM-400-09-01
01.08.10
Nr.: Änderung/Mod. Nr.: Datum
Letzte Bearbeitung:
Strobe Light left
Trigger Select
Strobe Light right
PN 01-0770028-05
HW
Datum
46569 Hünxe, Germany
Schwarze Heide 21
Gepr.:
Gepr.:
Name
PB
Projektion Freimaßtoleranz Oberfläche
A Blatt 1
von 1
4
Schutzvermerk nach DIN 34 beachten.
A3
EA-9B334.10
EA 400-500 STROBE LIGHT, LB
Maßstab auf SI.-Klasse Oberflächenschutz
3LB
A413A-HDA-CF-14/28V
5LB
STROBE LIGHT REAR A500-A-28V
Bearb.: 30.08.04
blk wht
red
Name
Power Input
STROBE LIGHT POWER SUPPLY
28 VDC GND
4
see EA-9B246.10 DC-DISTRIBUTION
AMP Stecker 1-0480305-0 AMP Buchse 1-0480305-0 AMP Crimpkontakt Buchse 163557-2 AMP Crimpcontakt Pin 163558-2
red blk wht
Die Gültigkeitszuordnung von Version zu Flugzeugbaureihe ist der Bauakte bzw. dem jeweiligen Fertigungsauftrag zu entnehmen. Zuordnung links / rechts wird mit */* in allen Feldern angegeben.
AMP Stecker 1-0480305-0 AMP Crimpcontakt Pin 163558-2
Massebolzen 8mm
LB2G-22 LB3E-20N LB14E-20N
LB20E-20
BATTERY BUS PP2
STROBE STROBE-LT 2LB 1LB OFF 1 2 LB1E-20 3 7.5A 07.1.1.13 ON
CIRCUIT BREAKER/SWITCH PANEL
see EA-9B334.20 NAV-LIGHT 5LB-A
ST13-C SIM
LB10F-20
LB2F-20
3
A
B
C
D
A
B
C
D
2
LC2K-22
15
DRUCKSCHOTT HINTEN
MS 347X-L22-41SN (27 X #20 / 14X#16)
LC2H-22
LB10F-20 LC2J-22
VV175
ST13-D
A
ST5
TRENNSTECKER OVERHEAD
MS 347X-L22-41SN (27 X #20 / 14X#16)
3
LC2K-22
LC2H-22 D:4
D:3 1
1
7LB-B 1 2
Modul 1
LB10G-20
Module Spaltverkleidung
4
F G H J K
1
001115-209-02
A B C D E
2
3
4
5
LC2M-22 LC5E-22N
15VN
8VN
5
Blitzschutz
LC2K-22
5A
1 2
3LC-a
1 2
blau blau
4LC-a
1 2
5LC-a
EDV-Kennung:
9B33410T 6
Zuordnung links / rechts wird mit */* in allen Feldern angegeben.
Die Gültigkeitszuordnung von Version zu Flugzeugbaureihe ist der Bauakte bzw. dem jeweiligen Fertigungsauftrag zu entnehmen.
4LC-A
5LC-A
Flachhülsengehäuse 2pol.
3LC-A
LOAD BUS PP3
6
5LC
BLITZROHR HECK
HW
Name
01.08.10
ÄM-400-09-01
Nr.: Änderung/Mod. Nr.: Datum
4LC
A500-AV28
NAV LIGHT REAR
BLITZROHR FLÜGEL
Letzte Bearbeitung:
A
3LC
A650PR-28
NAV LIGHT LEFT
BLITZROHR FLÜGEL
A650PG-28
NAV LIGHT RIGHT
see EA-9B246.10 DC-DISTRIBUTION
NAV-LT 1LC
Flachhülsengehäuse 2pol.
LC1E-20
04 03 02 01 Ver. Bezeichnung
LC4E-22N
see EA-9B334.10 STROB-LIGHT
Blitzschutz
07.1.1.13
2
LC2L-22 LC3E-22N
3
14VN
ON
Blitzschutz
LC2F-22
LC2E-22
OFF 1
NAV 2LC
CIRCUIT BREAKER/SWITCH PANEL
Maintenance Manual EXTRA 500 Chapter 91 30. March 2012
VV334201
1
Name
PB
Datum
30.08.04
7
46569 Hünxe, Germany
Schwarze Heide 21
Gepr.:
Gepr.:
Bearb.:
7
A Blatt 1
8
Schutzvermerk nach DIN 34 beachten.
A3
EA-9B334.20
NAV LIGHT, LC
von 1
Projektion Freimaßtoleranz Oberfläche
EA 400-500
Maßstab auf SI.-Klasse Oberflächenschutz
8
A
B
C
D
A
B
C
D
10A
LDG-LT 1LA
07.1.1.13
2
LDG 2LA
3
ON
1 OFF
1A LA2E-18
5LA
LA7E-22
3
see EA-9B246.10 DC-DISTRIBUTION
LA1E-18
2
3
2
C:5
B:1
CB Trennstecker 45
3
LA2G-18
5 INV
K5
1
2
3
4
5
4LA
red
ZÜNDBOX XV-1A-50
KABELSCHUH
C2C
J1
D35
ANNUNCIATOR BOARD EA-9B315.81
291-9726
+ VOLT DIMM
LIGHT TEST (GND)
5
blk
9
EDV-Kennung:
9B33435T
blk wht red
5LA-A
6
blk wht red
HW
Name
01.07.10
ÄM-400-09-01
Nr.: Änderung/Mod. Nr.: Datum
A
Letzte Bearbeitung:
MS3126F-8-3P
A C B
Name
PB
7
46569 Hünxe, Germany
P/N 90-42192-2 geändert
Projektion Freimaßtoleranz Oberfläche
A Blatt 1
von 1
8
Schutzvermerk nach DIN 34 beachten.
A3
EA-9B334.35
LANDING LIGHT, LA
EA 400-500
Maßstab auf SI.-Klasse Oberflächenschutz
blk
3LA
D1 50WATT
LAANDING LIGHT XV-19
wht
Datum
n/c
30.08.04
red
J1
C4C
red
blk wht
8
Annunciator Panel right
2WW
Schwarze Heide 21
Gepr.:
Gepr.:
Bearb.:
LA3F-18
Windshield On
5LA-a
Reco Light
7
Deice Boots Landing Light
Intake Heat
COWLING TRENNSTECKER
WW39-20N
MS3124F-8-3S
Zuordnung links / rechts wird mit */* in allen Feldern angegeben.
04 03 02 01 Ver. Bezeichnung
WW20-20
WW22-22
5WW-A
LA3E-18
2 24 25
5WW-C
6
Die Gültigkeitszuordnung von Version zu Flugzeugbaureihe ist der Bauakte bzw. dem jeweiligen Fertigungsauftrag zu entnehmen.
wht
n/c
C4C
red
blk wht
J2
see EA-9B315.80 ANNUNCIATOR PANEL
BYW56
D41
Kabelschuh an 5VN-A schrauben
LA4E-18
MS 27615-K14T7P
7
ST3
FIREWALL
MS 27613-K14T7S
LA2F-18
LA7F-22
9
31
ANNUNCIATOR BOARD 5WW-D 5WW
4
Maintenance Manual EXTRA 500 Chapter 91 30. March 2012
EMERGENCY BUS PP4
CIRCUIT BREAKER/SWITCH PANEL
1
A
B
C
D
A
B
C
D
2
1
2
1LJ
LJ1F-22
LJ1E-22
2
2
15LJ
3 LJ5E-22 ON
1 OFF
LJ1G-22
3 LJ2E-22 ON
1 OFF
MAP
16LJ
see EA-9B246.10 DC-DISTRIBUTION
1LJ
CABIN-LT
CABIN
3
1
1
1
D:2
C:8
D:1
LJ5F-22
LJ1H-22
LJ2F-22
2LJ-A
1 2 3
LJ3F-22N LJ2F-22 LY5E-22
2 1 3
LJ3E-22N LJ2G-22 LY5H-22
2LJ-a
001758_212_02
L
6 7
9
10
5
LJ4E-22N LJ6F-22N
LJ5G-22
LJ1K-22
LY5G-22
COCKPIT
1
PN. : 11-07800
(30531)
2
3
4
1 2
5
OUT
GND
M7815CV
TO220
OUT
EDV-Kennung:
04 03 02 01 Ver. Bezeichnung
9B33440T
Die Gültigkeitszuordnung von Version zu Flugzeugbaureihe ist der Bauakte bzw. dem jeweiligen Fertigungsauftrag zu entnehmen. Zuordnung links / rechts wird mit */* in allen Feldern angegeben.
GND
IN
IN
18LJ
Spannungsregler
Länge 200 cm = 20 Einheiten
B
+
B
W G R
+ G R
18LJ2-a
W
OS-LM10A-W1-847
OS-LM10A-W1-847
+
B
W
B
+ G R
W
OS-LM10A-W1-847
G R
see EA-9B235.17 MKR-AUDIO & EA-9B215.20 BLEED AIR & EA-9B334.50 COURTESY LIGHT
LJ4G-22N LJ6H-22N
LJ5F-22
LJ1H-22
LY5E-22
ST12
5
OS-LM10A-W1-847
CABIN
Gehäuse P 1-0480305-0 FE4308 Pin 163558-2 FE4306
see EA-9B334.50 COURTESY LIGHT
001758_212_02
Gehäuse B 1-0480303-0 FE4307 Buchse 163557-2 FE4305
4
Maintenance Manual EXTRA 500 Chapter 91 30. March 2012
(33260)
LOAD BUS PP3
CIRCUIT BREAKER/SWITCH PANEL
WATSKI 101727
1
6
6
DOME LIGHT
1 2
HW
Name
Nr.: Änderung/Mod. Nr.: Datum
Gepr.:
Datum
PILOT
PB
46569 Hünxe, Germany
7
2
1
12LJ
11LJ
LJ 1:2
Projektion Freimaßtoleranz Oberfläche
1
1
8
A Blatt 1
von 1
8
Schutzvermerk nach DIN 34 beachten.
A3
EA-9B334.40
CABIN-DOME-MAP-LIGHT, LJ
EA 400-500
Maßstab auf SI.-Klasse Oberflächenschutz
COPILOT
14V 0,08A
Name
19LJ
17LJ
Schwarze Heide 21
Gepr.:
6LJ
COPILOT
14LJ
10LJ
CABIN LIGHT 5LJ
13LJ PILOT
1:1
LJ
4LJ
9LJ
CABIN LIGHT 3LJ
MAP LIGHT
5LY
22LJ
VV195
Bearb.: 31.08.04
8LJ
VV197 7LJ
P600M
23LJ CABIN
LJ2G-22
LY5H-22
20.10.10
ÄM-400-09-01
Letzte Bearbeitung:
A
B
G R
+
B
18LJ1-A
W
+ G R
OS-LM10A-W1-847
W
OS-LM10A-W1-847
LJ3E-22N
7
VV198
VV196
A
B
C
D
1
2
3
001758_212_02 8VN-A
LJ6H-22N
(1LY or 8LY on)
LJ3F-22N
1
LY5E-22
7
10
5
C15P
LY5F-22 see EA-9B215.20 BLEED AIR see EA-9B235.17 MKR-AUDIO see EA-9B334.40 CABIN-DOME-LIGHTLY5E-22
ST12
1
9
PC-BOARD 2
BYW56
D19
K14:1 10
3
P600M
D11
P600M
D12
J2
1
4
2
T1
12
D20
(delay 100sec) (batt "off" + T1 "tast")
21 22 23
24
K11 16
12 3 4 6 H3FA-AU
9
13
BYW56
P600M
K13:2
2
green
L1
4
D14
K13
11
BYW56
D18
BYW56
15
(delay 100sec after batt "off")
21 22 23
24
16
13
P600M
D13
10
12 3 4 6 H3FA-AU
K12 9
12
3
20
1
OSRAM 5637 24V 10W (0,42A)
2
3
4
E
1
3
29CG-D ST6
D16 BYW56
BYW56
D17
EA-9B284.14-b
47-63
K15:1
BYW56
D15
K
5
1LY
001115_207_03
CG24F-22
Modul 8a
CG22E-22N
cycle 5Hz (delay 100sec after batt off + flap not up) or (batt on + aircraft on ground + flaps not up)
1LY-A
3LY-A
3LY-a
C1
10
4
2
red
L2
3LY
cycle 5Hz (batt on + aircraft on Ground + generator off + flap not up) or (8LY on) (batt off + flap not up)
Stecker Avionikbay
FLAP UP-RELAIS
CG27E-22
5LY
see EA-9B275.20 FLAP SYSTEM
TS2-b-24V-25S
14
7
3
1
5
2
TASTER 1241.6403 CONRAD 70 43 76-07
LIGHT ON
DOOR SWITCH
+
23CG 26.72.03
CG22E-22N
Maintenance Manual EXTRA 500 Chapter 91 30. March 2012
FE4305
Gehäuse B 1-0480303-0 FE4307 Buchse 163557-2
ST?
W
W
5LJ
P600M
4LY
11LJ
+
A
VV195
Gehäuse P 1-0480305-0 FE4308 Pin 163558-2 FE4306
W
W
P600M
23LJ
LJ
1:1
LJ1K-22
24V 10W (0,42A) OSRAM 5637
+
Text
B
C
22LJ
CABIN
3LJ
OS-LM10A-W1-847
OS-LM10A-W1-847
4LJ
+
+
D
+
+
OS-LM10A-W1-847
OS-LM10A-W1-847
LJ
LY5G-22
LY5G-22
10LJ
LY10E-22
LY10F-22
LY10E-22
9LJ
13 6
12
4
8
E-BOX
LEFT UP LIMIT 12CG
CG24E-22
CG26E-22
(Position NOT up) CG20E-22
F
E
F
E
EDV-Kennung:
04 03 02 01 Ver. Bezeichnung
9B33450T
T
V
P
SQUAT RELAY I
34GA
6
A
ÄM-400-09-01
20.10.10
Nr.: Änderung/Mod. Nr.: Datum
Letzte Bearbeitung:
19PP
EMERGENCY
:1
18PP:2
BATT
EA-9B243.10 DC DISTRIBUTION
CIRCUIT BREAKER/SWITCH PANEL
2 D:17
2 D:18
2 D:15
D:14
Datum
Gepr.:
7
HW Name 46569 Hünxe, Germany
Schwarze Heide 21
HW
Name
see EA-9B246.10 DC-DISTRIBUTION Projektion Freimaßtoleranz Oberfläche
A Blatt 1
von 1
8
Schutzvermerk nach DIN 34 beachten.
A3
EA-9B334.50
COURTESY LIGH, LY
EA 400-500
Maßstab auf SI.-Klasse Oberflächenschutz
Schalterstellung A/C on Ground
Gepr.:
8
2
Bearb.: 21.06.05
Brandspannt
ST1
ST1A
see EA-9B243.40 E-BOX
26.57.710
BATTERY RELAY
K4
RELAY BRACKET
T
V
P
LY2E-22
D
D8 BYW56
5A
7
EA-9B243.40 E-BOX
COURTESY LT
see EA-9B323.10 GEAR CONTROL
REL MT4
K11
LY1F-22
CB5
HOT BUS PP1
M210-B4M S210-A5A1
GENERATOR RELAY K6:4 K6:1
RIGHT UP LIMIT 16CG
Die Gültigkeitszuordnung von Version zu Flugzeugbaureihe ist der Bauakte bzw. dem jeweiligen Fertigungsauftrag zu entnehmen. Zuordnung links / rechts wird mit */* in allen Feldern angegeben.
LY4F-22 LY4G-22
LY3F-22
LY12F-22
LY12E-22
VV196
LY6E-22
(gen off) 12
DOME LIGHT PILOT
LY9E-22N
11
1:2
LY8E-22N
1
LY11E-22
13 LY13E-22
16
1
(5LJ on or 100sec delay 1LY or 8LY on)
LY7E-22 3
LY3F-22
6
LY3E-22 LY3F-22
LY4F-22
LJ3E-22N LJ3E-22N LY5H-22
EA-9B334.40 CABIN-DOME LIGHT
LY4E-22 LY4F-22
CABIN LIGHT
3 (on air)
LY1E-22
(7LJ on or 100sec delay 1LY or 8LY on)
2
LJ3E-22N LJ3E-22N LY5H-22
1 2 3
LJ2F-22 LJ3F-22N
PP5E-22N
5
OFF
LJ6F-22N
LJ6F-22N
LJ6H-22N
ON
LY12F-22 LY13F-22 LY12F-22 LY13F-22 LY13F-22
LJ1K-22
LJ1H-22
PP6E-22
4
07.1.1.13
243.10 EMERGENCY
C
3
PP4E-22
NC
NO
2
OFF
DC-GEN-I 243.10
C
EA-9B334.40 CABIN-DOME LIGHT
ON
1
PP3G-22
3
(aircraft on ground) 1
2
243.20 DC-GEN II
NC
NO
1
1
2
2
D
4 07.2.1.13
3
PR205F-22
6 PR205E-22
5
A
B
C
D
A
B
C
D
2
BATTERY BUS PP2
7.5A
1LN
ICE-LT
CIRCUIT BREAKER/SWITCH PANEL
3
07.1.1.13
2 3 ON
1 OFF LN2E-20
see EA-9B246.10 DC-DISTRIBUTION
LN1E-20
2LN
ICE
DC-DISTRIBUTION EA-9B246.10
4
B:4
LN2F-20
1
2
3
4
D
ST2
(E-Box)
TRENNSTECKER FIREWALL
5
B
5
EDV-Kennung:
04 03 02 01 Ver. Bezeichnung
9B33455T
Die Gültigkeitszuordnung von Version zu Flugzeugbaureihe ist der Bauakte bzw. dem jeweiligen Fertigungsauftrag zu entnehmen. Zuordnung links / rechts wird mit */* in allen Feldern angegeben.
6
3LN-a
ICE LIGHT 3LN
HW
Name
01.08.10
ÄM-400-09-01
Nr.: Änderung/Mod. Nr.: Datum
A
Letzte Bearbeitung:
1 2
3LN-A
6
2VN-D 001758 212 02
LN2G-20 LN3E-20N
Plug with Shield MS 38999 III 26K F 32 SN (32 X #20)
CB Trennstecker
3
Maintenance Manual EXTRA 500 Chapter 91 30. March 2012
1
Datum
PB
Name
7
46569 Hünxe, Germany
Schwarze Heide 21
Gepr.:
Gepr.:
Bearb.: 01.09.04
7
A Blatt 1
8
Schutzvermerk nach DIN 34 beachten.
A3
EA-9B334.55
ICE-LIGHT, LN
von 1
Projektion Freimaßtoleranz Oberfläche
EA 400-500
Maßstab auf SI.-Klasse Oberflächenschutz
8
A
B
C
D
A
B
C
D
Reco Light
Windshield On
Deice Boots Landing Light
Intake Heat
2
5WW-A
3 25 25
5WW-C
WW39-20N
WW20-20
WW23-22
2WW
5A
1LF
9
D35
3 ON
1 OFF
LF2J-22
LF2E-22
K5
BYW56
D34 5 INV
5WW
see EA-9B315.80 ANNUNCIATOR PANEL
ANNUNCIATOR BOARD EA-9B315.81
291-9726
+ VOLT DIMM
07.1.1.13
2
2LF
RECO
4
4
10
30
see EA-9B246.10 DC-DISTRIBUTION
LF1E-22
LIGHT TEST (GND)
ANNUNCIATOR BOARD
P/N 90-42192-2 geändert
Annunciator Panel right
LOAD BUS PP3
RECO-LT
CIRCUIT BREAKER/SWITCH PANEL
3
D:5
A:6
50
5WW-D
1
2
LF2K-22
LF2K-22
LF2F-22
1
2
3
4
Maintenance Manual EXTRA 500 Chapter 91 30. March 2012
1
5
5
VV158
12VN
13VN
EDV-Kennung:
LF4E-22N
LF2H-22
6
HW
Name
Nr.: Änderung/Mod. Nr.: Datum
ÄM-400-09-01
Datum
Gepr.:
7
46569 Hünxe, Germany
Schwarze Heide 21
Gepr.:
PB
Name
RECHTE FLÄCHE
01-0771125-(XX) r. Fläche
4LF
LINKE FLÄCHE
01-0771125-(XX)
3LF
Bearb.: 01.09.04
4LF-A
Flachhülsengehäuse von AMP Flachhülse 6,3mm
1 2
3LF-A
20.10.10
A
Letzte Bearbeitung:
7
Flachhülsengehäuse von AMP Flachhülse 6,3mm
12VN-C Lagerbock
9B33460T
04 03 02 01 Ver. Bezeichnung
LF3E-22N
LF2G-22
13VN-C Lagerbock
Die Gültigkeitszuordnung von Version zu Flugzeugbaureihe ist der Bauakte bzw. dem jeweiligen Fertigungsauftrag zu entnehmen. Zuordnung links / rechts wird mit */* in allen Feldern angegeben.
Z
ST5
TRENNSTECKER FLÜGELNASE
6
Projektion Freimaßtoleranz Oberfläche
A Blatt 1
von 1
8
Schutzvermerk nach DIN 34 beachten.
A3
EA-9B334.60
RECOGNITION LIGHTS, LF
EA 400-500
Maßstab auf SI.-Klasse Oberflächenschutz
8
A
B
C
D
25LH
2
A:9
ON
cw
4.7k
FM
LR9E-22
see EA-9B246.10 DC-DISTRIBUTION
12 11 24 16
GND GND
night
1A
Glare 1A
5LH
1
2
5
D7
D3
1
6LR
D10
D8
D9
3LR
D10
OS-LM10A-W1-847
D2
D9
D4
OS-LM10A-W1-847
D1
D8
+
B
G R
+
1,5k
3
4
D5
EDV-Kennung:
9B33475T
04 03 02 01 Ver. Bezeichnung
Die Gültigkeitszuordnung von Version zu Flugzeugbaureihe ist der Bauakte bzw. dem jeweiligen Fertigungsauftrag zu entnehmen. Zuordnung links / rechts wird mit */* in allen Feldern angegeben.
B
R2 1,5k
D6
VV334903 001758-212-02
1,5k
R1
D7
G R
D5
LR8G-22N
D6
B
D4
G R B
+
LR7G-22
R2 1,5k
G R
D3
D5
LR8H-22N
R1
D2
LR7E-20
D4
4
+
12
D3
5LH-A
D2
5
LR7H-22
D1
see EA-9B334.90 DIMMING SYSTEM
Dimming Platine, EA-9B334.91-b
Glare Dim
K2 SP4P
F5
LR8F-22N B
G R
1,5k
D1
LR8F-22N
Maintenance Manual EXTRA 500 Chapter 91 30. March 2012
7
4
5LH-C
5LH-B
LH5E-22N
1VN-E (3) 001758 212 02
LH7-22N LG110-22N
LR6E-20
GLARE-LT
see EA-9B334.90 DIMMING SYSTEM
GLARE
DIM CONTROL
OFF
2LR GLARE
1A
1LR
EMERGENCY BUS PP4
CIRCUIT BREAKER/SWITCH PANEL
+
LR7F-22
R1
LR7F-22
4
LR8E-20N
3
F G H J K
A
B
C
D
LR5E-20
LR6E-20 07.1.1.13
LR6F-20
2
day
1
LR7E-20
1 LR7H-22
3 LR8H-22N
2 A B C D E 6
D2
D6
D1
D2
LEFT SIDE
R2 1,5k
ÄM-400-09-01
20.10.10
D3
D7
D3
Nr.: Änderung/Mod. Nr.: Datum
A
Letzte Bearbeitung:
1,5k
R1
D1
RIGHT SIDE
1,5k
R1
6
D5
3
R2 1,5k
R2 1,5k
Datum
5LR
D10
PB
Name
7
46569 Hünxe, Germany
Schwarze Heide 21
Gepr.:
Gepr.:
Bearb.: 04.12.02
D5
D9
Name
HW
D4
D8
OS-LM10A-W1-847
D4
7
D7
5
2
7LR
D10
D8
4LR
D10
A Blatt 1
von 1
8
Schutzvermerk nach DIN 34 beachten.
A3
EA-9B334.75
GLARE-LIGHT, LR
EA 400-500
Projektion Freimaßtoleranz Oberfläche
D9
OS-LM10A-W1-847
D9
OS-LM10A-W1-847 D8
CENTER
D7
Maßstab auf SI.-Klasse Oberflächenschutz
D6
D6
8
A
B
C
D
A
B
C
D
OFF
2LJ
ON
LG116E-20
LH116G-20
07.1.1.13
LH4G-20
LH4E-20
INST-LT
1
2
2
2LG
cw
4.7k
3LG 820r
9 8
4
1LG-a
CONTROL SOURCE (5V) CONTROL 0 - 5V +28 VDC INPUT 0 - 115 VAC OUTPUT OUTPUT AC RETURN INPUT DC RETURN
LG118E-22
LH2E-22
LH5E-22N
5LH-C
3A
F4
night
E F A D C B
ws bl
1LG-A
LG52E-22S LG103E-20N
LG106E-22 LG109E-22 LG102E-20
see EA-95334.90 DIMMING
5LH
Lumi Plus
SP4P
K2
Dimming Platine, EA-9B334.91-b
Lumi Dimm
Lumi Plus
24 GND 16 GND
3
3
LG110E-22
LG102E-20
1VN-B 001758 212 02
LG52E-22S
5LH-A
37 LG106E-22
11
10
4
ws org
LG52F-22S
ws org
ws org
ws org
bl
bl
bl
bl
LG52F-22S
S
1
2
3
4
5
ws org bl
VV201 VV202 VV203
ws org bl
bl
bl
bl
LG5F-24S
LG54G-24S
LG54H-24S
ws org bl ws org bl ws org bl
1VN-B 001758_212_02
LG52H-24S
EDV-Kennung:
04 03 02 01 Ver. Bezeichnung
9B34481T
Die Gültigkeitszuordnung von Version zu Flugzeugbaureihe ist der Bauakte bzw. dem jeweiligen Fertigungsauftrag zu entnehmen. Zuordnung links / rechts wird mit */* in allen Feldern angegeben.
6
Name
Nr.: Änderung/Mod. Nr.: Datum
12LG-A ws org
HW
ÄM-400-09-01
bl
bl
11LG-A ws org
10LG-A ws org
ws org
9LG-A
8LG-A ws org
7LG-A ws org
6LG-A ws org
ws org
5LG-A
ws org
4LG-A
7
46569 Hünxe, Germany
Schwarze Heide 21
12LG
11LG
10LG
9LG
A Blatt 1
8
Schutzvermerk nach DIN 34 beachten.
A3
EA-9B334.81
LUMI FOLIE, LG
von 1
Projektion Freimaßtoleranz Oberfläche
EA 400-500
Maßstab auf SI.-Klasse Oberflächenschutz
Panel Switches
Gear Switch
Flap Switch
Center Console
LEUCHTFOLIEN
PB
Gepr.:
8LG
7LG
6LG
5LG
8
see EA-9B246.10 DC-DISTRIBUTION
Circuit Breaker
Circuit Breaker
Circuit Breaker
Circuit Breaker
Name
Gepr.:
4LG
LEUCHTFOLIEN
Switches
Datum
7
Bearb.: 04.02.04
RS 472-922
11.10.10
A
Letzte Bearbeitung:
LG58E-24S
LG57E-24S
bl
bl
bl
LG54E-24S
bl
ws org bl
ws org LG53E-24S bl
LG56E-24S
ws org bl
Splice
LG52G-22S
LG56E-24S
ws 1 org bl 1
1
1
CIRCUIT BREAKER/SWITCH PANEL
6
LG55E-24S
B:18
B:17
B:16
5
LG55E-24S
ws org bl
B:15
Maintenance Manual EXTRA 500 Chapter 91 30. March 2012
1LG
KGS SD-3
INVERTER
see EA-95334.90 DIMMING
SWITCHES
DIM CONTROL
5LH-B
LH7-22N LG110-22N
LH116H-20
1VN-E (3) 001758 212 02
FM
A:9
A:8
A:7
see EA-9B246.10 DC-DISTRIBUTION
INST
7,5A
1LH1
BATTERY BUS PP2
CIRCUIT BREAKER/SWITCH PANEL
2
day
1
LG103E-20N
1 ws org
3 LG57E-22N
2
A
B
C
D
D
C
B
A
CB TRENNSTECKER
1LR GLARE
A:8
ON
OFF
1
ON
A:9 A:8
2
3LJ:1 NIGHT
2
A:4
3
2
?
G
26LH
3LG 8,2k 25LH
2LG
FM
4.7k
cw
LH2E-22
LG108E-22
LR9E-22
LG118E-22 see EA-9B334.81 LUMI FOLIE
4.7k
LG107E-22
5
7
9 8
1
LH7-22N LG110-22N
4
24 GND 16 GND
LG119F-20
5LH-C
14 1
LR6E-20
X1
D17
X2
LIGHT TEST 3 2 B1 3 2 A1
Annunciator Dim
Glare Dim
Lumi Dim
Lumi Plus
Instr. Dim
D18
X2
NIGHT X1
K2 SP4P
12 11
LH5E-22N
K1 SP2P
DAY /
25 13
23 22 20 19 17 15 7 5 4 2
10
3
9
LG116F-20
5LH-B
LT2F-20
see EA-9B284.13 1VE
4.7k
cw
LT1F-20
LH116H-20
EA-9B284.13
1VN-E (3) 001758 212 02
cw
H
1VN-E (2) 001758 212 02
A:7
Vmo Tone Test
PC-BOARD 1
23LH
35
J1
3
A:8 A:9 A:10 A:5
3
:2
2
18 6 21 8
2
3A
3A
3A
F4
F9
F8
D10
D8
D6
D4
Dimming Platine, EA-9B410.30C
K3 TN2
DAY/NIGHT
IFD´s 1A
Annunciator 7,5A
Glare 1A
Instruments 7,5A
AC OUT INVERTER
1k2 4W
D9
D7
D5
D3
D1
5LH
Lumi Plus
AC 2 OUT
AC 1 OUT
DC 1 OUT
BYW56
D16
Dioden BYW 56
56k 0.25W
1A
F3
1A
Spare D2
BYW56
D15
F5
Lumi out Instruments out Glare out Annunciator out
AC RET
3A
F7
IN
1A
5A
F6 F1
5A
F2
CG34H-22
LG2E-20
37
33 32
36 35
16
CG34H-22
5LH-A
LG106E-22
LG11E-22 LG9E-22
QX15E-22S
LG17E-22S
F G H J K
F G H J K
LG13E-22 LG26E-22 LG3E-22
7
29
GND / 2 - 28 VDC
AVIDYNE IFD >O.8 - 28 VDC Dimming <0.8 VDC Day Mode
MORITZ 8.0 - 28 VDC Dimming < 8.0 VDC Day Mode
VV334904
A B C D E
VV-10
MODUL 3
001115 202 03
A B C D E
MODUL 2
VV334902
CG37G-22 CG37E-22
VV334901 CG37F-22
1 6 3 4 2 7 5 35 1 2 3 6 7 8
1
IFD
ANNUNCIATOR
27LH
4.7k
cw
4.7k
cw
LG121E-22
2
2
3
6
IFD Dim
3
4
D3
7
5
Flap System EA-9B275.20, LED 6CG Flap System EA-9B275.20, LED 7CG Flap System EA-9B275.20, LED 8CG
Gear Warning EA-9B323.20, LED 27GA Gear Warning EA-9B323.20, LED 28GA Gear Warning EA-9B323.20, LED 29GA
BYW-56
BYW-56
BYW-56
see EA-9B284.10
Flap Indikation
Gear Warn
EA-9B411.50A 5LH see EA-9B284.13B PCB-BOARD 1
D1
D2
12 13 14
BYW-56
DME-HOLD EA-9B345.47, 5SN
9 11 10
+
-
EA-9B411.70
15
D4
K8
5
see EA-9B315.80 ANNUNCIATOR PANEL DME-HOLD EA-9B345.47, 5SN Gear Warning EA-9B323.20 27GA Gear Warning EA-9B323.20 28GA Gear Warning EA-9B323.20 29GA Test Flap System EA-9B275.20, LED 7CG Flap System EA-9B275.20, LED 6CG Flap System EA-9B275.20, LED 8CG
+28V POWER
DIM Voltage
+ Light-Test
- Light-Test
PC-BOARD 1
LG24-22
P1
FG101E-22 GA24H-22 GA25G-22 GA26H-22 CG33G-22 CG32H-22 CG34G-22
VV162 WW41E-20
5WWA
MODUL 1 001115_202_03 LH8E-20 FG1-73-22 A F GA27E-22 LG21E-22 B G GA27F-22 C H GA27G-22 D J E K
LG15E-22S
LG110E-22
LH9E-20
LG102E-20
30 26 27 Spare
29
31
15
11
19
10
LR7E-20
17 Spare
18 Spare
34 LH8E-20 16
12
LG109E-20
LH3G-20
VV161
VV160
see EA-9B344.14 WEATHER DEDECTION
6 Spare 25 Spare
28
20 1 7 8 13 14 WW41E-20 9 2 Spare FG101E-22 21 GA24H-22 3 GA25G-22 22 GA26H-22 4 CG33G-22 23 CG32H-22 5 CG34G-22 24
LH4E-20
ANNUNCIATOR STEUER-PLATINE
Maintenance Manual EXTRA 500 Chapter 91 30. March 2012
GLARE
SWITCHES
PANEL
DIM CONTROL
A:9
2
OFF
2 LH4G-20
2LJ INST
2
INST-LT LH4E-20
1
GLARE-LT
07.2.1.16 3
7,5A
5
WARN-LT
1
1LH1
6
1A
2 LR5E-20
1
7.5A
1
LG119E-20
LG119F-20
3
07.1.1.13
3
07.1.1.13
LR6E-20
LR6F-20
NIGHT
1LR
see EA-9B246.10 DC-DISTRIBUTION
1LH2
LT1F-20
LH116G-20
LH116H-20
4
(TONE) TEST
LT1E-20
DAY
LT2E-20
LT2F-20
LG116E-20
LG116F-20
LH3E-20N
LH3F-20N
WV8E-22
WV8F-22
WV8F-22
WV9E-22N
WV9F-22N
LH7E-20N
LH7E-20N
BATTERY BUS PP2
2
EMERGENCY BUS PP4
2
4
LG8E-22 LG35E-22
3
1LG-A
9
LG110E-22 LG106E-22
LG103E-20N LG102E-20
F E
B A
VV334903 001758-212-02
6
CONTROL 0 - 5V CONTROL SOURCE (5V)
INPUT DC RETURN +28 VDC INPUT
1LG
C D
ws org bl
1LG-A
ws bl
ws bl
EDV-Kennung:
9B33490T
04 03 02 01 Ver. Bezeichnung
Zuordnung links / rechts wird mit */* in allen Feldern angegeben.
S
bl
org
ws
ws 1 org bl 1
1
1
7
Name
HW
Nr.: Änderung/Mod. Nr.: Datum
22.02.11
1VN-B 001758_212_02
LG52H-24S
LG56E-24S
HW
ÄM-400-09-01
B:18
B:17
B:16
B:15
7 6 5
1 2
PM8000B
7WW2
Fuel 6 Stück
17WW2
16WW2
4HP
PROP HEAT
ATTITUDE
DIP
ENG INST
Altimeter
Airspeed
IFD-5000i
IFD-5000i
STEC 55X
LED 5 Stück
10WW3
EA-9B334.75
EA-9B271.17
PB
46569 Hünxe, Germany
RIGHT PANEL
EA-9B235.17
5-8LG-A ws 1 org 2 bl
4LG-A ws 1 org 2 bl
CENTER PANEL
Lumi 4X C-Breaker
Lumi Switches
AUDIO/MARKER
TURN COORDINATOR
EA-9B284.10
12LG-A ws 1 org 2 bl
11LG-A ws 1 org 2 bl
10LG-A ws 1 org 2 bl
9LG-A ws 1 org 2 bl
A Blatt 1
von
8
Schutzvermerk nach DIN 34 beachten.
A2
EA-9B334.90
DIMMING, LH
EA 400-500
Projektion Freimaßtoleranz Oberfläche
1
see EA-9B334.81 LUMI FOLIE
Lumi Panel Switches
Lumi Gear Switch
Lumi Flap Switch
Lumi Center Console
Maßstab auf SI.-Klasse Oberflächenschutz
LG58E-24S
LG57E-24S
LG56E-24S
Name
PEDESTAL
FUEL INSTRUMENTS
CABIN ALTITUDE
CABIN PRESS
EA-9B213.30
CABIN PRESS CONTROL
EA-9B360.11
PROP HEAT
ATTITUDE GYRO
EA-9B316.40
DIGITAL INSTRUMENTS
EA-9B316.50
see EA-9B246.10 DC-DISTRIBUTION LG55E-24S
Datum
LEFT PANEL
ENGINE INSTRUMENTS
ALTIMETER
AIRSPEED
EA-9B342.66
IFD RH
EA-9B342.65
IFD LH
LG54E-24S
20.09.02
GLARE AUTOPILOT COMPUTER
LG53E-24S
Schwarze Heide 21
Gepr.:
Gepr.:
Bearb.:
LG52G-22S
8
GLARE LIGHTS
AIRPATH
CIRCUIT BREAKER/SWITCH PANEL
IRM-B
7WW2-A
7
1 2
1 2
1 11
6 7
B A
13 12 9
12 11 13
2 1
-QX-A QX_E-22 6 QX_F-22
LG55E-24S
VV10
9QX-A
VV225
17WW2-A
16WW2-A
4HP-A
PHI-A
1FM-A
3EY-A
ws 3EZ-A bl ws bl
2 1
7 20
7 20
15 35
1 2
11WW2-A
?WV
P2101
P1101
P1
?
10WW3-A
20.10.10
A
2 1
18WW2-A 1 2
?
VV224
7
Letzte Bearbeitung:
ws org bl
LG3E-22 RM15E-22N
LG26E-22 LG25-22N
QX_E-22S
9QX-a
LG17E-22S LG47E-22N
LG15E-22S
LG16E-22N
HI9E-22S
LG13E-22 FM2A-22N
LG101E-22S
LG100E-22S
LG24-22 LG30-22N
LG35E-22 LG36-22N
LG9E-22 LG10E-22N
LG11E-22 LG12E-22N
LG8E-22 CA17E-20N
LR7E-20 LR8E-20N
LG21E-22 LG22E-22N
LG52E-22S
33 34
31 32
Die Gültigkeitszuordnung von Version zu Flugzeugbaureihe ist der Bauakte bzw. dem jeweiligen Fertigungsauftrag zu entnehmen.
see EA-9B334.81 LUMI FOLIE
0 - 115 VAC OUTPUT OUTPUT AC RETURN
DC / AC CONVERTER
QX_E-22S
1VN
6
E D C B A K J H G F
2
1
night
2
A 3 1 B 3 1 C 3 1 D 3
day
E D C B A K J H G F
1
8 F G H J K A B C D E F G H J K A B C D E
E D C B A K J H G F
CIRCUIT BREAKER/SWITCH PANEL
LG52F-22S
LH4H-20
D
C
B
A
A
B
3-5 3-9 3-4 3-8 3-3 3-7 3-2 3-6 3-1
3-4 3-2
3-7
3-6
3-1
GND IFD Dimm
2-24 2-16
Glare Dimm
2-12 2-11
Annun Dimm
2-14 2-1
Instr. Dimm
2-25 2-13
2-2
2-4
U2 reg
I2
GND
4in
3in
U1 reg
U4 reg
U3 reg
A1
I2
A4
I4
A3
I3
A2
1A
3A
3A
1A
3A
3A
5A
5A
7,5A
3in
U1 reg
2in
U4 reg
4in
U3 reg 7,5A
GND
1out
GND
4out
GND
3out
GND
O1
GND
O4
O3
O2
GND lila/gnd
AC lila
F3
F3
D16 BYW56
1A Lumi out 1out
IFD´s
1A
Glare
D15
2out 4out 3out
2out
Annunciator
U2 reg
2in
Instruments
D1 D2 D3 D4 D5 D6 D7 D8 D9 D10
IFD IFD
AC
AC
DC1
F8
D14
F9
F5
F4
D16
D15
F7
F6
1-36
1-27
1-26
1-30
1-29
1-31
1-15
1-11
1-19
1-12
1-10
1-17
1-18
1-13 1-14 1-34 1-16
1-2 1-21 1-3 1-22 1-4 1-23 1-5 1-24 1-6 1-25
1-7 1-8
F2 D1 D2 D3 D4 D5 D6 D7 D8 D9 D10
1-20 1-1
GNDt
Dioden BYW 56
BYW56
AC INVERTER
1k2 4W
R11
4k7 4W
R12
F3
F8
F9
F5
F4
F7
F6
F2
Instruments out Glare out Annunciator out
DC2 yel
GND blk
2in
D14
D12
D13
D11
2-5
K2
15
2-7
2-15
2-17
2-19
2-20
2-22
2-23
2-10
D18
SP4P
K2:1
DAY / NIGHT
16
U4 reg
4in
4out
GND
U3 reg
3in
3out
GND
U2 reg
2in
2out
GND
U1 reg
2in
1out
GND
IFD IFD
1
3
Poti 0 = kleinste Ausgangsspannung Poti 4k7 = gröste Ausgangsspannung
Spare
5LH
4
Inverter
AC
AC
1VE20
1
3-9
3-3
3-5
3-8
LUMI Plus
Lumi Dimm
2
K3s
LUMI Plus
3
Dimming Platine, EA-9B334.91-b
BYW56
D19
K3:1 TN2
1-37
1-33 1-32
1-9
1-28
1-35
4
5
5
+ C1 1uF
+ C8 1uF
+ C2 1uF
470
R7
470
R5
470
R3
470
R1
A1
330
R6
330
R4
Vout
cw
330
ADJ A44adj R8
I3 A3
3in 3adj
EDV-Kennung:
9B33491T 6
Zuordnung links / rechts wird mit */* in allen Feldern angegeben.
04 03 02 01 Ver. Bezeichnung
6
5
4
3
2
1
P4
U3 adj
U3in
U3out
U2 adj
U2in
U2out
ADJ
ÄM-400-09-01
14.10.10
Nr.: Änderung/Mod. Nr.: Datum
A
Letzte Bearbeitung:
Vout
LT 1038 CK
7
Vin ADJ
Name
HW
Name
PB
Datum
09.09.04
A von 1
8
Schutzvermerk nach DIN 34 beachten.
A2
DB37S
Blatt 1
PCB DIMMER EA-9B334.91
J1 1 20 2 21 3 22 4 23 5 24 6 25 7 26 8 27 9 28 10 29 11 30 12 31 13 32 14 33 15 34 16 35 17 36 18 37 19
Projektion Freimaßtoleranz Oberfläche
1-1 1-20 1-2 1-21 1-3 1-22 1-4 1-23 1-5 1-24 1-6 1-25 1-7 1-26 1-8 1-27 1-9 1-28 1-10 1-29 1-11 1-30 1-12 1-31 1-13 1-32 1-14 1-33 1-15 1-34 1-16 1-35 1-17 1-36 1-18 1-37 1-19
8
EA 400-500
Maßstab auf SI.-Klasse Oberflächenschutz
10,0 - 26 VDC
GLARE
10,0 - 26 VDC
ANNUNCIATOR
MORITZ 8.0 - 28 VDC Dimming < 8.0 VDC Day Mode
10,0 - 26 VDC
INSTRUMENTS
46569 Hünxe, Germany
7
IFD 6,8 - 26 VDC ab Mittelstellung volle Helligkeit
Schwarze Heide 21
Gepr.:
Gepr.:
Bearb.:
Vout
U3 LT 1038 CK
Vin
U2
Instrument Light < 2A, min 15V max 24V Map Light ~200mA, min 10V max 24V Annunciator Panel 2,88A Lumifolien Warning Light < 300mA, min 12V max 24V
+ C5 1uF
O4
+ C4 1uF
O3
+ C6 1uF
A2
I2
O2
J4
4out
1out
+ C3 1uF
O1
3out
2adj
2in
2out
1adj
330
R2
LT 1038 CK
cw
cw
cw
ADJ
Vout
LT 1038 CK
6
Die Gültigkeitszuordnung von Version zu Flugzeugbaureihe ist der Bauakte bzw. dem jeweiligen Fertigungsauftrag zu entnehmen.
GND
2
TR4 4k7
Vin
U4
TR3 4k7
TR2 4k7
TR1 4k7
Vin
U1
einstellen !
28 VDC
+ C7 1uF
I4 4in
Inverter 28 VDC 115VAC
Maintenance Manual EXTRA 500 Chapter 91 30. March 2012
5 9 4 8 3 7 2 6 1
DB9S 259-3071
J3
DB25P 259-3071
2-13 2-25 2-12 2-24 2-11 2-23 2-10 2-22 2-9 2-21 2-8 2-20 2-7 2-19 2-6 2-18 2-5 2-17 2-4 2-16 2-3 2-15 2-2 2-14 2-1
K2s
Instt
7
C
13 25 12 24 11 23 10 22 9 21 8 20 7 19 6 18 5 17 4 16 3 15 2 14 1
BYW56
D17
2
9
1
10
J2
2-3
2-9
K1
SP2P
1
8
6
3
9
D
K1:1
Inst2
2-21 2-8
5
7
night
1
2
7 10
9
GND2
10 13
2-18 2-6
12
LIGHT TEST
11 14
2
6
5 8
day
1
8
A
B
C
D
D
C
B
A
13 12 25
21 38 37
62 63 82
GROUND BYTE FLIGHT BUS 1+ BYTE FLIGHT BUS 1-
DISCRETE OUT 10 DISCRETE IN 7 DISCRETE IN 6
CFG DISCRETE 0 CFG DISCRETE 1 CFG DISCRETE 2
see EA-9B342.66 IFD RIGHT
7 14 15
GROUND BYTE FLIGHT BUS 2+ BYTE FLIGHT BUS 2-
32 31
429 RX1+ 429 RX1-
AUDIO/MARKER
PMA-8000B
WEIGHT ON WEELS
429 RX1+ 429 RX1RS422-232 TX2 RS232 COMMON RS422-232 RX2
31
31
24 25
37 38 36
11 12
17 18
9 10
OUTER MARKER MIDDLE MARKER INNER MARKER
COM 1 MIK AUDIO OUT COM 1 MIK KEY OUT
NV #1 RX HI NV #1 RX LO
COM #1 RX HI COM #1 RX LO
20
ACTIVE COM SECECTED COM SPLIT SECECTED
COM SWAP
see EA-284.13a PCB-BOARD 1
Vmo ALERT P1
see EA-9B344.15 TRAFFIC ADVISORY
PCB-BOARD 1
TAS-610
10 11 17 18 19
see EA-9B344.14 WEATHER DETECTION
20 18 19
RS232 TX1 RS232 RX1 RS232 COMMON
TRAFFIC ADVISORY SYSTEM
TWX-670
14
14 1
BYTE FLIGHT BUS + BYTE FLIGHT BUS -
see EA-9B342.67 KEYBOARD
21 22
SS12E-24S
SS13E-24S
ws bl
SD6E-24S
ws bl org
1RV2E-24S
ws bl
1RV3E-24S
1RM1E-24S
ws bl
ws bl
1RV1E-24S
RM1E-24 RM2E-24 RM3E-24
1RV4E-24 1RV5E-24
1
RV1F-24
1
WV3E-22
ws bl
1RM-A
1RM-B
P1
1
SD13E-22
1
SS13F-24S
1
FG15E-TC746
1
1
1RV4E-24 1RV5E-24
1RV4F-24 1RV5F-24
RV1F-24
RV1E-24
WV3E-22
SD13E-22
1 RM1E-24 RM2E-24 RM3E-24
FG14E-TC746 Thermax TC746 120Ohm
FG15E-TC746
RM1F-24 RM2F-24 RM3F-24
1
FG19-22 FG20E-22
1
1FG8E-24S
ws bl
1
1FG7E-24S
ws bl
FG21E-22 FG22E-22
1FG6E-24S
ws bl
1
FG15F-TC746 Thermax TC746, 120 Ohm
H J K L M N P R S
1 RV1E-24 1RV4F-24 1RV5F-24
1
1
1
ws bl
ws bl
ws bl
ST5
ws org bl
1
ws bl
J1
P1
Px
P2121
P2122
ws bl
P2101
ws bl
P2102
ws bl
J3010
1FG8F-24S
ws bl
USB + USB -
WEATHER DETECTION
7FG
IFD-5000i 700-00083-()
IFD RIGHT
10FG
ACD-215 700-00150-()
1FG7F-24S
ws bl
9 10
H B
28V MAG POWER + 28V MAG POWER -
1FG6F-24S
ws bl
1
USB VCC +5V USB GROUND (DRAIN)
D C
MAG RS422 TX+ MAG RS422 TX-
KEYBOARD
F G
MAG RS422 RX+ MAG RS422 RX-
P13001 1
ws bl org
ws bl
ws bl
ws bl
ws bl
J1144
P1122
P1122
P1121
ws bl
ws org bl
P1121
ws bl
P1102
ws bl
ws bl
ws bl
ws bl
ws bl
ws bl
P1101
3
43 28
44 30
13 29
11 5
38 37
21
16
18
24 46 66 5
15 36
17 38
HEADPHONE #3 HEADPHONE #3 LO
HEADPHONE #1 HEADPHONE #1 LO
HEADPHONE #2 HEADPHONE #2 LO
MICROPHONE #1 TX KEY #1
DISCRETE IN 7 DISCRETE IN 6
DISCRETE OUT 10
Vmo ALERT
DISCRETE OUT 7
RS422-232 RX2 TX2-RX2 COMMON RS422-232 TX2 SHIELD GROUND
ARINC 429 TX4+ ARINC 429 TX4-
ARINC 429 TX6+ ARINC 429 TX6-
RS422-232 RX0 RS422-232 TX0 TX0-RX0 COMMON
ARINC 429 RX7+ ARINC 429 RX7-
59 80
22 64 61
CFG DISCRETE IN 0 CFG DISCRETE IN 1 CFG DISCRETE IN 2
ARINC 429 RX5+ ARINC 429 RX5SHIELD GROUND
GROUND BYTE FLIGHT BUS 2+ BYTE FLIGHT BUS 2-
USB + USB GROUND BYTE FLIGHT BUS 1+ BYTE FLIGHT BUS 1-
USB VCC +5V USB GROUND(DRAIN)
28V MAG POWER + 28V MAG POWER -
MAG RS422 RX+ MAG RS422 RX-
MAG RS422 TX+ MAG RS422 TX-
62 63 82
57 78 76
7 14 15
11 24 13 12 25
10 23
4 17
1 14
2 15
IFD-5000i
IFD LEFT
J103
2 0 1
3
GS ANTENNA
VOR / LOC ANTENNA
DISCRETE IN ANALOG IN 1 ANALOG IN 0 DISCRETE IN DISCRETE IN DISCRETE IN
ANALOG REF ANALOG GROUND
GROUND ANALOG OUT 2 ANALOG OUT 3 ANALOG OUT 6 ANALOG OUT 5 ANALOG OUT 0 DISCRETE OUT 4
DISCRETE OUT 0 DISCRETE OUT 1 DISCRETE OUT 2
DISCRETE OUT 0+ DISCRETE OUT 0GROUND
RS422 TX3+ RS422 TX3RS422 RX3+ RS422 RX3SCHIELD 429 RX0+ 429 RX0429 TX0+ 429 TX0+ GROUND DISCRETE OUT 1+ DISCRETE OUT 1-
RS232 RX0 TX0-RX0 COMMON RS232 TX0
RS232 RX2 TX0-RX0 COMMON RS232 TX2
RS232 RX1 RS232 COMMON RS232 TX1
28V POWER BUS B 28V POWER BUS RETURN B CHANNEL ID 0 GROUND CHANNEL ID 1 GROUND
DIM BUS COMMON
28V POWER BUS RETURN A
28V POWER BUS A
BEZEL DIMMING
23 41 40 22 7 8
25 39
15 12 13 27 26 10 6
2 3 4
19 40 60
85 86 4 25 67 51 72 10 31 14 20 41
89 87 88
23 67 65
91 96 44
A1 A2 4 11 5 12
20
A2
A1
7
3FG
700-00083-()
4
LG12E-22N
1FG2E-14
1FG1F-14
LG11E-22
P1142
P1141
P1122
ws bl
P1122
P1121
ws bl
ws bl
ws bl ws bl
ws bl ws bl
1
1FG12E-RG400
1FG11E-RG400
18FG-B
16FG-B
CA31E-24S CA32E-24S CA33E-24S CA34E-24S CA35E-24S CA36E-24S
CA38E-24S
CA37E-24S
SH8E-24S
SH7E-24S
TL9E-24S
ws bl org
QY4E-24S
TS3F-24S
1
1FG3F-14 1FG4E-14
ws bl org
ws bl
P1121
P1102
1
10FG
CI 428-200
GPS-1 ANTENNA
9FG
DM C70-1A
COM-1 ANTENNA
2
see EA-9B235.16 MKR-AUDIO
MONITOR #1 RX HI MONITOR #1 RX LO
7 8
10FG-A
9FG-A
1FG10E-RG400
1FG9E-RG400
3
P1131
P1145
J1144
GPS ANTENNA
COM ANTENNA
4
1
5
5
OVERBRAID
1
43 42
ws bl ws bl
ST13-A
ws bl org
18FG-C
18G-A
16FG-A
16FG-C
13 12
K4B-W K3A-W
FG13F-RG400
2FG12E-RG400
19FG see EA-9B342.66 IFD RIGHT
COCKPIT OVERHEAD
CI-193
GS ANTENNA
C:3
D:1
6
1
17FG-A
9CA-A
ws bl
ws bl
ws bl
CA41E-24S
CA40E-24S
CA31E-24S CA32E-24S CA33E-24S CA34E-24S CA35E-24S CA36E-24S
CA38E-24S
CA39E-24S
CA42E-24 CA43E-24
CA19E-24S
CA9E-24S
CA21E-24
CA22E-24S
SH8F-24S
SH7F-24S
TL9E-24S
15FG-A
EDV-Kennung:
04 03 02 01 Ver. Bezeichnung
9B34265T
Die Gültigkeitszuordnung von Version zu Flugzeugbaureihe ist der Bauakte bzw. dem jeweiligen Fertigungsauftrag zu entnehmen. Zuordnung links / rechts wird mit */* in allen Feldern angegeben.
FG13E-RG400
1
1
1
1
TS3E-24S
1
1
ws bl
ws bl
ws bl
ws bl
QY4E-24S
CA37E-24S
SH8F-24S
SH7F-24S
TS3E-24S
ws bl
1
10A
QY4F-24S
1FG3E-14
1FG1E-14
see EA-9B271.17 AP-STEC-55X
1
1
2
3
7
P2
2 3 24 40
2 24 3
RS-232 RX
9
GND SIG REF G/S DOWN SHIELD GROUND SHIELD GROUND FD LOGIC ROLL STR SIG PITCH STR SIG ANNUN LOAD ANNUN CLOCK ANNUN DATA SHIELD GROUND
43 7 19 41 39 4 12 13 24 25 26 40
7
Nr.: Änderung/Mod. Nr.: Datum
Letzte Bearbeitung:
15FG
S-TEC 55X
Datum
HW
46569 Hünxe, Germany
Schwarze Heide 21
Gepr.:
Gepr.:
OPTION
OPTION
8
rechts
Blatt 1
von 1
8
Schutzvermerk nach DIN 34 beachten.
A3
EA-9B342.65
IFD LEFT, FG
EA 400-500
Projektion Freimaßtoleranz Oberfläche
C1120-1
links
C1120-2
Maßstab auf SI.-Klasse Oberflächenschutz
14FG
13FG
VOR/LOC ANTENNA SET
Name
14FG-A
13FG-A
Bearb.: 24.02.11
51351-CI120-2
Name
BXP-6402-1R-(01)
see EA-9B271.17 AP-STEC-55X
51351-CI120-2
G/S UP + VS SIGNAL SHIELD GROUND
ALT ENGAGE SIGNAL ALT SEL CONTROL
429 TX+ 429 TXNAV FLAG + NAV FLAG SHIELD GROUND LOC SWITCH DC HDG HI DC CRS HI SHIELD GROUND L-R +RT HDG RETURN CRS RETURN L-R -RT
15FG-C
MLB-700
see EA-9B345.58 TRANSPONDER
RX+ RXTX+ TX-
ROLL STEERING 429A ROLL STEERING 429B SHIELD GROUND G/S FLAG + G/S FLAG SHIELD GROUND
TIS TIS TIS TIS
18 22 49
20 21
48 37 13 14 45 32 28 11 44 30 29 12 31
36 37 46 1 2 39
AUTOPILOT
RS-422 RS-422 RS-422 RS-422
TRANSPONDER
COM1 TX COM1 RX GND GROUND
see EA-9B344.16 DATA LINK BROADCAST
RS-232 RS-232 RS-232 SIGNAL
MLX-770
see EA-9B344.17 DATA LINK 2 WAY
SATELLITE WX
2QY
912041T-D
see EA-9B731.40 FUEL FLOW
SIGNAL RS-232 TX1 SIGNAL RS-232 GND SIGNAL RS-232 RX1
DATA LINK 2 WAY
RS-232 TX
6
15 14 18 17
IFD LH B
2FG
see EA-9B246.10 DC-DISTRIBUTION
10A
BATTERY BUS PP2
SHADIN MINIFLOW L
POWER COMBINER 15FG-B C1120-3
ws bl
4CA-B
P1
ws bl
ws bl ws bl
4CA-A
P2
ws bl
ws bl
4CA-B
ws bl ws bl
P8
ws org bl
J1
ws bl org
J1-A
Px
IFD LH A
1FG
EMERGEMCY BUS PP4
CIRCUIT BREAKER/SWITCH PANEL
CA37F-24S see EA-9B271.17 AP-STEC-55X
CA15H-22
ws bl
DRUCKSPANNT HINTEN
17FG-B
17FG-a
see EA-9B342.66 IFD RIGHT
see EA-9B342.66 IFD RIGHT
see EA-9B271.17 AP-STEC-55X
9CA
9 48
16
50 54 55
K3B-W K2A-W
K4A-W
K3D-W K4D-W K4C-W
5 44
72
28V RELAY POWER
K2B-W K1A-W
46 47
K2D-W K2C-W
K4D-NO K4C-NO K4A-NO K4B-NO K3A-NO AI ENERGIZE
K3D-NO K3B-NO K2A-NO
K2B-NO K1A-NO
K2D-NO K2C-NO
2FG11E-RG400
14 15 56 53 52 71
10 49 28
45 24
6 7
19FG-A FG14E-RG400
9CA-A
ws bl
ws bl
ws bl
K1C-W K1D-W
20 11 12 13 14 15
1 3 2 16
ws bl
AIS 240-35
ws bl ws bl
SIM
ws bl org
SIM
ST13-A
DRUCKSCHOTT HINTEN
9CA-A K1C-NO K1D-NO
A/P RELAY
SH8E-24S
1FG3F-14
1FG1F-14
see EA-9B342.66 IFD RIGHT
6
9CA-A 3 2
1
1
SH7E-24S
TS3F-24S
see EA-9B334.90 Dimming MODUL 2 Pin F
36 AWG Tinned copper per ASTM-B-33 optical coverage minimal 98 - 100%
HINTER I-BRETT
18FG
GS DUPLEXER CI-503
HINTER I-BRETT
16FG
NAV DUPLEXER CI-502
CA50E-24S CA51E-24S CA52E-24S CA53E-24S CA54E-24S CA55E-24
CA47E-24 CA48E-24 CA49E-24
CA46E-24S
CA45E-24S
CA44E-24S
700-00156-()
CONFIGURATION MODULE ACM-100
P1101
Maintenance Manual EXTRA 500 Chapter 91 30. March 2012
OPTION
OPTION
4FG
MAG-300 700-00011-()
MAG/OAT LH
RM1E-24 RM2E-24 RM3E-24
2
CA38F-24S
1
CA36F-24S CA35F-24S CA34FF-24S CA33FF-24S CA32F-24S CA31F-24S
D
C
B
A
D
C
B
A
H B
28V MAG POWER + 28V MAG POWER -
7 14 15
21 38 37
GROUND BYTE FLIGHT BUS 2+ BYTE FLIGHT BUS 2-
DISCRETE OUT 10 DISCRETE IN 7 DISCRETE IN 6
see EA-9B342.65 IFD LEFT
CFG DISCRETE 0 CFG DISCRETE 1 CFG DISCRETE 2
13 12 25
GROUND BYTE FLIGHT BUS 1+ BYTE FLIGHT BUS 1-
30 29
429 RX2+ 429 RX2-
AUDIO/MARKER PMA-8000B
KDI 574
TAS MUTE
429 RX2+ 429 RX2RS422-232 TX3 RS232 COMMON RS422-232 RX3
5
35 39 38 20 37 41 42 43 44 48
24 25
37 38 36
15 30
19 20
13 14
21 22
OUTER MARKER MIDDLE MARKER INNER MARKER
COM 2 MIK AUDIO OUT COM 2 MIK KEY OUT
NV #2 RX HI NV #2 RX LO
COM #2 RX HI COM #12RX LO
MONITOR #2 RX HI MONITOR #2 RX LO
20
62 63 82
ACTIVE COM SECECTED COM SPLIT SECECTED
COM SWAP
see EA-9B345.47 DME
1 MA 1 ME 1 MC 1 MD #NAME? #NAME? #NAME? #NAME? #NAME? NAV 1 COMMON Select 2X5 Code
see EA-9B344.15 TRAFFIC ADVISORY
DME INDICATOR
TAS-610
12 13 20 21 22
see EA-9B344.14 WEATHER DETECTION
14 12 13
RS232 TX2 RS232 RX2 RS232 COMMON
TRAFFIC ADVISORY SYSTEM
TWX-670
2FG8F-24S
ws bl
14 1
2FG7F-24S
ws bl
RV1F-24 1RV4E-24 1RV5E-24
2RM1E-24S
2RV2E-24S
ws bl
ws bl
RM1F-24 RM2F-24 RM3F-24
1RV4E-24 1RV5E-24
RV1E-24
2RV1E-24S
1
ws bl
1RM-A
1RM-B
1
SD8E-24S
ws bl org
SD11E-22
SS15F-24S
ws bl
SS15E-24S
1
1
2FG8E-24S
1RV4E-24 1RV5E-24
RV1E-24
RV1F-24
SD11E-22
1 RM1F-24 RM2F-24 RM3F-24
1
1
1
ws bl org
ws bl
ws bl
ws bl
J2144
P2122
P2121 P2122
ws bl
ws bl
ws org bl
P2121
ws bl
P2102
ws bl
ws bl
1
ws bl
2FG7E-24S
P2101 ws bl
1
2FG6E-24S
1RV4E-24 1RV5E-24
FG14E-TC746 Thermax TC746, 120 Ohm
FG15F-TC746
FG15F-TC746
ws bl
1
1
ws bl
ws bl
ws bl
FG15E-TC746 Thermax TC746, 120 Ohm
T U V i j p q r s
RM1E-24 RM2E-24 RM3E-24
1
1
1
1
ws bl
ws bl
ws bl
ST5
SS14E-24S
1
ws org bl
P7041
P1
Px
P1121
P1122
ws bl
P1102
ws bl
P1101
ws bl
ws bl
J3010
2FG6F-24S
1
ws bl
P23001
see EA-9B342.67 KEYBOARD
WEATHER DETECTION
3FG
IFD-5000i 700-00083-()
IFD LEFT
10FG
ACD-215 700-00150-()
BYTE FLIGHT BUS + BYTE FLIGHT BUS -
D C
MAG RS422 TX+ MAG RS422 TX-
KEYBOARD
F G
MAG RS422 RX+ MAG RS422 RX-
3
44 30
13 29
11 5
38 37
21
5 6 16 17 20 31 32 33 34
19
24 46 66 5
15 36
22 64 61
OUT OUT OUT OUT OUT OUT OUT OUT OUT
3 4 5 6 9 11 12 13 14
HEADPHONE #1 HEADPHONE #1 LO
HEADPHONE #2 HEADPHONE #2 LO
MICROPHONE #1 TX KEY #1
DISCRETE IN 7 DISCRETE IN 6
DISCRETE OUT 10
DISCRETE DISCRETE DISCRETE DISCRETE DISCRETE DISCRETE DISCRETE DISCRETE DISCRETE
DISCRETE OUT 8
RS422-232 RX2 TX2-RX2 COMMON RS422-232 TX2 SHIELD GROUND
ARINC 429 TX4+ ARINC 429 TX4-
RS422-232 RX0 RS422-232 TX0 TX0-RX0 COMMON
CFG DISCRETE IN 0 CFG DISCRETE IN 1 CFG DISCRETE IN 2
ARINC 429 RX7+ ARINC 429 RX7-
59 80
62 63 82
ARINC 429 TX6+ ARINC 429 TX6-
ARINC 429 RX5+ ARINC 429 RX5SHIELD GROUND
GROUND BYTE FLIGHT BUS 2+ BYTE FLIGHT BUS 2-
GROUND BYTE FLIGHT BUS 1+ BYTE FLIGHT BUS 1-
28V MAG POWER + 28V MAG POWER -
MAG RS422 RX+ MAG RS422 RX-
17 38
57 78 76
7 14 15
13 12 25
4 17
1 14
MAG RS422 TX+ MAG RS422 TX-
IFD-5000i 2 15 A1
7
20
11 24
10 23
2 0 1
3
VOR / LOC ANTENNA
DISCRETE IN ANALOG IN 1 ANALOG IN 0 DISCRETE IN DISCRETE IN DISCRETE IN
ANALOG REF ANALOG GROUND
2 3 6 5 0
23 41 40 22 7 8
25 39
15 12 13 27 26 10
GROUND ANALOG ANALOG ANALOG ANALOG ANALOG OUT OUT OUT OUT OUT
2 3 4
19 40 60
10 31 14 20 41
DISCRETE OUT DISCRETE OUT 1 DISCRETE OUT 2
DISCRETE OUT 0+ DISCRETE OUT 0GROUND
429 TX0+ 429 TX0+ GROUND DISCRETE OUT 1+ DISCRETE OUT 1-
85 86 4 25 51 72 67
89 87 88
RS232 RX0 TX0-RX0 COMMON RS232 TX0
RS422 TX3+ RS422 TX3RS422 RX3+ RS422 RX3429 RX0+ 429 RX0SCHIELD
23 67 65
91 96 44
RS232 RX2 TX0-RX0 COMMON RS232 TX2
RS232 RX1 RS232 COMMON RS232 TX1
A1 28V POWER BUS B 28V POWER BUS RETURN B A2 6 CHANNEL ID 2 13 GROUND 5 CHANNEL ID 1 12 GROUND
DIM BUS COMMON
USB + USB -
USB VCC +5V USB GROUND(DRAIN)
28V POWER BUS RETURN A A2
28V POWER BUS A
BEZEL DIMMING
700-00083-()
4
P2142
P2141
P2122
ws bl
P2121 P2122
ws bl
ws bl
ws bl
ws bl ws bl ws bl
ws bl org
ws bl org
ws bl
P2121
P2102
P2101
CA38F-24S
CA37F-24S
SH4E-24S
SH3E-24S
TL10E-24S
TS4F-24S
QY4F-24S
2FG11E-RG400
18FG-C
16FG-C
CA31F-24S CA32F-24S CA33F-24S CA34F-24S CA35F-24S CA36F-24S
1
1
2FG3F-14 2FG4E-14
LG10E-22N
2FG2E-14
2FG1F-14
LG9E-22
1
12FG
CI 428-200
GPS-2 ANTENNA
11FG
DM C70-4
COM-2 ANTENNA
2
see EA-9B235.17 MKR-AUDIO
12FG-A
11FG-A
2FG10E-RG400
2FG9E-RG400
3
P2131
P2145
J2144
43 28
GPS ANTENNA
COM ANTENNA
HEADPHONE #3 HEADPHONE #3 LO
4
GS ANTENNA
7FG 1
2FG12E-RG400
5
5
OVERBRAID
1
18FG-B
18G-A
16FG-A
16FG-B
FG13F-RG400
1FG12E-RG400
17FG see EA-9B342.65 IFD LEFT
COCKPIT OVERHEAD
CI-193
GS ANTENNA
6
DRUCKSPANNT HINTEN
17FG-B
17FG-a
see EA-9B342.65 IFD LEFT
see EA-9B342.65 IFD LEFT
1
1
1
CA41E-24S
CA40E-24S
9CA-A
ws bl
ws bl
ws bl
#22
04 03 02 01 Ver. Bezeichnung
5 26 6 40
5 26 6
ws bl
P1
4CA-B
P2
ws bl
ws bl ws bl
P1 4CA-A
ws bl
ws bl
4CA-B
ws bl ws bl
P9
ws bl org
J1
ws bl org
J1-A
Px
15FG
RS-232 RX
9
9B34266T
=
7
RX+ RXTX+ TX-
GND G/S UP + VS SIGNAL SHIELD GROUND
SIG REF G/S DOWN SHIELD GROUND SHIELD GROUND FD LOGIC ROLL STR SIG PITCH STR SIG ANNUN LOAD ANNUN CLOCK ANNUN DATA SHIELD GROUND
43 18 22 49
7 19 41 39 4 12 13 24 25 26 40
=
Name
=
51351-CI120-2
S-TEC 55X
HW
46569 Hünxe, Germany
Schwarze Heide 21
Gepr.:
Gepr.:
Name
OPTION
rechts
links
C1120-2
Blatt 1
8
Schutzvermerk nach DIN 34 beachten.
A2
EA-9B342.66 von 1
Projektion Freimaßtoleranz Oberfläche
EA 400 - 500 IFD RIGHT, FG
Maßstab auf SI.-Klasse Oberflächenschutz
see EA-9B342.65 IFD LEFT
14FG
13FG
8
OPTION
VOR/LOC ANTENNA SET
Bearb.: 24.02.11
Datum
14FG-A
13FG-A
see EA-9B271.17 AP-STEC-55X
ALT ENGAGE SIGNAL ALT SEL CONTROL
HDG RETURN CRS RETURN L-R -RT SHIELD GROUND 29 12 31 39
20 21
DC HDG HI DC CRS HI SHIELD GROUND L-R +RT
429 TX+ 429 TXNAV FLAG + NAV FLAG SHIELD GROUND LOC SWITCH
ROLL STEERING 429A ROLL STEERING 429B SHIELD GROUND G/S FLAG + G/S FLAG SHIELD GROUND
51351-CI120-2
BXP-6402-1R-(01)
see EA-9B345.58 TRANSPONDER
28 11 44 30
48 37 13 14 45 32
36 37 46 1 2 39
Nr.: Änderung/Mod. Nr.: Datum
=
RS422 RS422 RS422 RS422
AUTOPILOT
8 9 21 22
MLB-700
see EA-9B344.16 DATA LINK BROADCAST
COM2 TX GND COM 2RX GROUND
TRANSPONDER
RS-232 RS-232 RS-232 SIGNAL
MLX-770
see EA-9B344.17 DATA LINK 2 WAY
SATELLITE WX
2QY
912041T-D
see EA-9B731.40 FUEL FLOW
SIGNAL RS-232 TX2 SIGNAL RS-232 GND SIGNAL RS-232 RX2
DATA LINK 2 WAY
RS-232 TX
6
15FG-C
Letzte Bearbeitung:
IFD RH B
6FG
see EA-9B246.10 DC-DISTRIBUTION
10A
AVIONICS BUS PP5
SHADIN MINIFLOW L
IFD RH A
7
POWER COMBINER 15FG-B C1120-3
Die Gültigkeitszuordnung von Version zu Flugzeugbaureihe ist der Bauakte bzw. dem jeweiligen Fertigungsauftrag zu entnehmen. Zuordnung links / rechts wird mit */* in allen Feldern angegeben.
EDV-Kennung:
1
ws bl
ws bl
15FG-A
1
1
CA38F-24S
CA31F-24S CA32F-24S CA33F-24S CA34F-24S CA35F-24S CA36F-24S
FG13E-RG400
1
CA39E-24S
CA42E-24 CA43E-24
CA19E-24S
CA9E-24S
CA21E-24
1 TL10E-24S
CA37E-24S CA22E-24S
see EA-9B271.17 AP-STEC-55X ws bl
1
QY4F-24S
TS4E-24S
ws bl
1
ws bl
1
10A
QY4E-24S
2FG3E-14
CA37F-24S
SH4F-24S
SH3F-24S
TS4E-24S
2
2FG1E-14
see EA-9B271.17 AP-STEC-55X
CA15H-22
ws bl
ws bl
9CA-A
17FG-A
13 12
K4B-W K3A-W
9CA
9 48
16
K3B-W K2A-W
K4A-W
54 55
50 K4D-W K4C-W
K3D-W
72
46 47
43 42
ws bl ws bl
ST13-A
ws bl org
ST13-A
5 44
18 4 5 9 10 19
6 8 7 17
K2B-W K1A-W
28V RELAY POWER
K2D-W K2C-W
K1C-W K1D-W
AIS 240-35
ws bl ws bl
SIM
ws bl org
SIM
C:4
D:3
3
5FG
LOAD BUS PP3
CIRCUIT BREAKER/SWITCH PANEL
see EA-9B342.65 IFD LEFT
2FG3F-14
2FG1F-14
6
DRUCKSCHOTT HINTEN
see EA-9B271.17 AP-STEC-55X
K4D-NC K4C-NC K4A-NC K4B-NC K3A-NC
K3D-NC K3B-NC K2A-NC
K2B-NC K1A-NC
K2D-NC K2C-NC
K1C-NC K1D-NC
1FG11E-RG400
34 35 36 33 32
30 29 8
25 4
26 27
23 22
A/P RELAY
SH4E-24S
17FG-A FG14E-RG400
9CA-A
ws bl
ws bl
ws bl
9CA-A
1 SH3E-24S
TS4F-24S
1
see EA-9B334.90 Dimming MODUL 2 Pin G
36 AWG Tinned copper per ASTM-B-33 optical coverage minimal 98 - 100%
HINTER I-BRETT
18FG
GS DUPLEXER CI-503
HINTER I-BRETT
16FG
NAV DUPLEXER CI-502
CA59E-24S CA60E-24S CA61E-24S CA62E-24S CA63E-24S
CA56E-24 CA57E-24 CA58E-24
CA66E-24S
CA65E-24S
CA64E-24S
Maintenance Manual EXTRA 500 Chapter 91 30. March 2012
OPTION
OPTION
OPTION
8FG
MAG-300 700-00011-()
MAG/OAT II
RM1E-24 RM2E-24 RM3E-24
2
CA38E-24S
1
CA36E-24S CA35E-24S CA34E-24S CA33E-24S CA32E-24S CA31E-24S
D
C
B
A
A
B
C
D
2
6 8
9 10
21 22
14 1
7 20
28V IN #1FD 28V IN # 2FD
USB VCC +5V USB GROUND (DRAIN)
USB + USB -
BYTE FLIGHT BUS + BYTE FLIGHT BUS -
POWER GROUND # 1FD POWER GROUND # 2FD
ws bl
J3010
SPLICE NO FARTHER THEN 2 INCH (50mm) FROM PINS
10FG
ACD-215 700-00150-()
KEYBOARD
2
FG17E-20N FG18E-20N
1
FG15E-TC746
FG14E-TC746
FG14E-TC746 Thermax TC746, 120 Ohm
FG15E-TC746 Thermax TC746, 120 Ohm 1
FG19-22 FG20E-22
FG19-22 FG20E-22 FG15F-TC746
FG21E-22 FG22E-22
FG21E-22 FG22E-22
FG15F-TC746
FG16F-20
Thermax TC746, 120 Ohm
4
FG16F-20
3
1
1
OVERBRAID
2
optical coverage minimal 98 - 100%
36 AWG Tinned copper per ASTM-B-33
3
4
Maintenance Manual EXTRA 500 Chapter 91 30. March 2012
1
5
ws bl
P2102
ws bl
P2101
ws bl
P1102
ws bl
ws bl
2
A:11
P1101
5
2
GROUND BYTE FLIGHT BUS 2+ BYTE FLIGHT BUS 2-
USB + USB GROUND BYTE FLIGHT BUS 1+ BYTE FLIGHT BUS 1-
7 14 15
13 12 25
EDV-Kennung:
04 03 02 01 Ver. Bezeichnung
9B34267T
Die Gültigkeitszuordnung von Version zu Flugzeugbaureihe ist der Bauakte bzw. dem jeweiligen Fertigungsauftrag zu entnehmen. Zuordnung links / rechts wird mit */* in allen Feldern angegeben.
GROUND BYTE FLIGHT BUS 2+ BYTE FLIGHT BUS 2-
GROUND BYTE FLIGHT BUS 1+ BYTE FLIGHT BUS 1-
IFD-5000i
KEYPAD
9FG
6
.
Nr.: Änderung/Mod. Nr.: Datum
.
7FG
700-00083-()
Name
.
see EA-9B342.66 IFD RIGHT
Letzte Bearbeitung:
.
3FG
700-00083-()
see EA-9B342.65 IFD LEFT
see EA-9B246.10 DC-DISTRIBUTION
USB VCC +5V USB GROUND(DRAIN)
IFD RIGHT
7 14 15
11 24 13 12 25
10 23
IFD-5000i
IFD LEFT
FG16E-20
1A
EMERGENCY BUS PP4
CIRCUIT BREAKER/SWITCH PANEL
6
.
Datum
HW
Name
7
46569 Hünxe, Germany
Schwarze Heide 21
Gepr.:
Gepr.:
Bearb.: 01,08,10
7
Projektion Freimaßtoleranz Oberfläche
Blatt 1
von 1
8
Schutzvermerk nach DIN 34 beachten.
A2
EA-9B342.67
EA 400 - 500 KEYPAD, FG
Maßstab auf SI.-Klasse Oberflächenschutz
.
8
A
B
C
D
A
B
C
D
28V LIGHTING
+10 to 32VDC POWER LIGHTING (+) POWER/LIGHTING RETURN NC
C B A D
MS3112E8-4S
FM1F-22 LG13E-22 FM2E-22N
2FM-A
2
E
1
2
EDV-Kennung:
9B34273T
04 03 02 01 Ver. Bezeichnung
1
FM1E-22 2A
STBY-GYRO 1FM
3
Nr.: Änderung/Mod. Nr.: Datum
Letzte Bearbeitung:
HW
Name 46569 Hünxe, Germany
Schwarze Heide 21
Gepr.:
Gepr.:
Name
Datum
Bearb.: 01.09.10
4
Projektion Freimaßtoleranz Oberfläche
Blatt 1
von 1
4
Schutzvermerk nach DIN 34 beachten.
A3
EA-9B342.73
ATTITUDE GYRO, FM
EA 400-500
Maßstab auf SI.-Klasse Oberflächenschutz
see EA-9B246.10 DC-DISTRIBUTION
EMERGENCY BUS PP4
CIRCUIT BREAKER/SWITCH PANEL
3
see EA-9B334.90 DIMMING SYSTEM
C:7
Die Gültigkeitszuordnung von Version zu Flugzeugbaureihe ist der Bauakte bzw. dem jeweiligen Fertigungsauftrag zu entnehmen. Zuordnung links / rechts wird mit */* in allen Feldern angegeben.
1VN-G 001758 212 02
FM1F-22
Maintenance Manual EXTRA 500 Chapter 91 30. March 2012
2FM
4200-11
ATTITUDE GYRO
1
FM2E-22N
A
B
C
D
D
C
B
A
32 31
17 15 16
30 29
9 10
6 7
3 4
37 38
429 RX1+ 429 RX1-
RS232 TX2 RS232 RX2 RX2 COMMON
429 RX2+ 429 RX2-
RS232 RX4 RX2 COMMON
RS232 RX5 RX2 COMMON
RS232 RX6 RX2 COMMON
RS232 RX7 RX2 COMMON
2
SS14E-24S
ws org bl
SS5E-22N SS4E-22N SS3E-20N
SS15E-24S
SS13E-24S
ws bl
ws bl
SS12E-24S
SS11E-24
1VN-E
001758_212_02
SS6E-24S bl
SS7E-24
P1
ws
see EA-9B246.10 DC-DISTRIBUTION
BYW-56
D3
B:1
ws org bl
1
SS10E-24
SS6E-24S
SS1F-20
SS7E-24
560uH
L1
ws bl
P1
3
WTHR DET
1SS
BYW-56
D1 R8 330 R7 330 R6 330
BYW-56
D2
BYW-56
BYW-56
8
10
11
24
29
SS16E-24S
P1
SS8E-24
SS9E-24
1
2SS
ANTENNA SENSE IN
VERTICAL LOOP VERTICAL LOOP +
HORIZONTAL LOOP + HORIZONTAL LOOP -
2
60 61
63 62
BNC
SS18E-RG178
SS17E-24S
bl ws
P2
SS16E-24S
ws bl
SS17E-24S
3
4
12
GA53F-221
X1
8
45GA 5WW-B 2 GA53E-22
X2
CG34H-22
CG34G-22
C11C
3SS
5
ws bl
SS13F-24S
ws bl
SS15F-24S
ws org bl
15 36
22 64 61
15 36
22 64 61
EDV-Kennung:
9B34414T
04 03 02 01 Ver. Bezeichnung
6
D8
BYW-56
BYW-56
ALT WRN IN
PILOT MIC KEY
COPILOT MIC KEY
L217
L117
IFD-5000i
Nr.: Änderung/Mod. Nr.: Datum
22.02.11
Datum
HW
Schwarze Heide 21
Gepr.:
Bearb.: 01.08.10 Gepr.:
Name
700-00083-()
700-00083-()
7
Name 46569 Hünxe, Germany
HW
1RM
70-2420-x TAS-610
optical coverage minimal 98 - 100%
Letzte Bearbeitung:
5LWW
PMA-8000B
36 AWG Tinned copper per ASTM-B-33
ARINC 429 TX4+ ARINC 429 TX4-
RS422-232 RX0 RS422-232 TX0 TX0-RX0 COMMON
IFD RIGHT
ARINC 429 TX4+ ARINC 429 TX4-
RS422-232 RX0 RS422-232 TX0 TX0-RX0 COMMON
IFD-5000i
SWITCH ANNUNCIATOR GND
IFD LEFT
6
EA-9B411.70
+ DIMM VOLT I HYDRAULIC + DIMM VOLT II
LAMP TEST GND
TRAFFIC ADVISORY SYSTEM
31
34
33
AUDIO/MARKER
14
D17
5LH
EA-9B410.30C
[+ DIMMING VOLTAGE] LAMP TEST GND
ANNUNCIATOR BOARD 33
7
FLAP [IN TRANSITION] amber
8CG 10 MODUL1 Pin C DIMMING BOARD
aus EMI Kit P/N 800-00035-000
OVERBRAID
ws bl
SS15E-24S
1
ws org bl
P2121
ws bl
SS14E-24S
P1
P1121 P2121
SS13E-24S
1
SS12E-24S
28
24
1RM-A
1RM-B
Die Gültigkeitszuordnung von Version zu Flugzeugbaureihe ist der Bauakte bzw. dem jeweiligen Fertigungsauftrag zu entnehmen. Zuordnung links / rechts wird mit */* in allen Feldern angegeben.
2
1
RZ2E-24S
6
CG37E-22
1 2
5LH-A
8CG-A
RZ13E-24S
SS11E-24
WH12E-22S
see EA-9B235.16 MKR-AUDIO
see EA-9B235.16 MKR-AUDIO
see EA-9B344.15 TRAFFIC ADVISORY
C D B A E H F G K J
LOOP ANTENNA S72-1715-1
2
X2 ST10-A
BODENSTECKER
16
VV136
CG34G-22
3 26.57.73 M210-B4N GA53H-22 see EA-9B323.10 GEAR CONTROL GA53H-22
3
1
X1
21GA
29CG-D
CG34E-22
CG34H-22
5
STECKER AVIONIC BAY ST 6
see EA-9B344.15 TRAFFIC ADVISORY
P1
X1
1
3
M320A1N
36CG X2
CG16F-222
EA-9B284.13B PCB-BOARD 1
15
7
D3
D4
PCB-BOARD 1 EA-9B411.50A
GND
4
Maintenance Manual EXTRA 500 Chapter 91 30. March 2012
22 23 2 78
20 18 19
RS232 TX1 RS232 RX1 RS232 COMMON
BOTTOM MOUNTED ANTENNA CONFIG TOP MOUNTED ANTENNA CONFIG POWER SWITCH AIRCRAFT GND
41
12 13
RS232 RX3 RS232 COMMON
AUDIO SUPPRESION OUTPUT
75 77
AUDIO OUT MONO AUDIO OUT GROUND
40
54
MIC INHIBIT INPUT
AUDIO SUPPRESION INPUT
59
TWX-670
28 VDC
WEATHER DETECTION
SS1E-20
PP3
D
2A
LOAD BUS
CIRCUIT BREAKER/SWITCH PANEL
3
ws bl
2
bl ws
1
SS18E-RG178
CG34FG-22
Projektion Freimaßtoleranz Oberfläche
Blatt 1
von 1
8
Schutzvermerk nach DIN 34 beachten.
A3
EA-9B344.14
WEATHER DETEC TWX-670, SS
EA 400-500
Maßstab auf SI.-Klasse Oberflächenschutz
see EA-9B342.66 IFD RIGHT
see EA-9B342.65 IFD LEFT
see EA-9B344.15 TRAFFIC ADVISORY
see EA-9B235.16 MKR-AUDIO
see EA-9B315.80 ANNUNCIATOR PANEL
see EA-9B334.90 DIMMING
see EA-9B275.20 FLAP SYSTEM
8
D
C
B
A
D
C
B
A
TOP ANTENNA
3 5 2
11 15
GEAR POSITION NO RYAN DISPLAY
232 TX1 232 RTN 232 RX1
14
COM 1
7
WEIGHT ON WEELS
COUPLER
SUPPRESSION
BNC
P2
TNC
P4
9 S (61-2006)
COM 1
15 S
J1
25 S
ws
#22 #22
ws bl
ws bl org
ws bl
ws bl org
ws bl
SD10E-24S
SD3E-20
SD9E-24S
SD12E-22N
SD6E-24S
SS13F-24S
SS11E-24
SD-P4E-RG400
SD-P2E-RG400
SD14E-22
SD13E-22
1
SD-C1E-G400
1
1
SD11E-22
SD8E-24S
SS15F-24S
SIM
ST10-a
3
3
6SD-a
5SD-a
6SD-A
TNC
SIM
SIM
11 12 13
SD-C1E-RG400
ws bl
ST13-B
SD4F-20N
ST13-C
SD14H-22
SD14G-22
Zustand Flugzeug am Boden
ws bl
SIM
7
4
SD12F-22N
ST14-B
DRUCKSCHOTT HINTEN
SD4E-20N
5VN-A
TAS
6GA
SD-P4F-RG400
SD-P2F-RG400
TNC
P4
TNC
P2
TAS TWIN-BLADE 3SD
TAS TOP ANTENNA S72-1750-32L
see EA-9B323.10 GEAR CONTROL
N
1
BOTTOM ANTENNA
2
TNC
P3
TNC
P1
TNC
SD-P3E-RG400
SD-P1E-RG400
3
3
zur Avionic-Bay
3
TNC
SD-P3E-RG400
SD-P1E-RG400
TNC
P3
TNC
P1
4
4SD
TAS SINGLE BLADE
TAS BOTTOM ANTENNA S72-1750-31L
5
SD9E-24S
5SD
5
ANT
XPDR
TCAD
XPDR COUPLER 70-2040
ws bl
P1 8
bl
ws
BNC
BNC
BNC
BNC
BODENSTECKER 6SH-B 6SH-C 6SH-A
BNC
DISCRETE OUT 7
RS422-232 RX2 TX2-RX2 COMMON RS422-232 TX2 SHIELD GROUND
ARINC 429 TX4+ ARINC 429 TX4-
ALT WRN IN
SUPPRESSION GND
BNC
3SH-A
ANTENNA
SUPPRESSION
TRANSPONDER
25 19
2SH
BXP-6402-1R
3SN
KDM-706A
1RM
PMA-8000B
3FG
IFD-5000i 700-00083-()
3SH
8
see EA-9B345.58 ATC
see EA-9B345.47 DME
OPTION
see EA-9B235.16 MKR-AUDIO
see EA-9B342.65 IFD LEFT
see EA-9B344.14 WETHER DETEC
OPTION
see EA-9B342.66 IFD RIGHT
see EA-9B345.57 ATC
TRANSPONDER ANTENNA KA-60
DME TRANSCEIVER
31
AUDIO/MARKER
24 46 66 5
15 36
2SS
TWX-670
7FG
IFD-5000i 700-00083-()
AUDIO SUPPRESION INPUT
IFD LEFT
40
SH26E-RG400
TNC
5
P3301 2SH-A
bl
DISCRETE OUT 8
RS422-232 RX2 TX2-RX2 COMMON RS422-232 TX2 SHIELD GROUND
ARINC 429 TX4+ ARINC 429 TX4-
WEATHER DETECTION
24 46 66 5
15 36
IFD RIGHT
7
EDV-Kennung:
9B34415T
04 03 02 01 Ver. Bezeichnung
6
21.02.11
Nr.: Änderung/Mod. Nr.: Datum
Letzte Bearbeitung:
Datum
HW
Name
Schwarze Heide 21
Gepr.:
Gepr.:
Bearb.: 12.09.10
7
Name 46569 Hünxe, Germany
HW
OVERBRAID 36 AWG Tinned copper per ASTM-B-33 optical coverage minimal 98 - 100%
aus EMI Kit P/N 62-2003
All antenna cables must be of the same lenght. ( +- 25 mm)
Projektion Freimaßtoleranz Oberfläche
Blatt 1
von 1
8
Schutzvermerk nach DIN 34 beachten.
A3
EA-9B344.15
TRAFFIC SYSTEM TAS-610, SD
EA 400-500
Maßstab auf SI.-Klasse Oberflächenschutz
Applying power to the TAS-610 transceiver without an antenna connected to the BNC connector may damage the TAS-610 transceiver.
SD-C3E-RG393
BNC
Die Gültigkeitszuordnung von Version zu Flugzeugbaureihe ist der Bauakte bzw. dem jeweiligen Fertigungsauftrag zu entnehmen. Zuordnung links / rechts wird mit */* in allen Feldern angegeben.
1
2
3
!
N
5SD-C
N
SD10H-24S
ws
P3401
18
D1 P7061 MUR120
WH12E-22S
ws bl org
DRUCKSCHOTT HINTEN 5SH-C 5SH-B 2SH-B 5SH-A SD-C2E-RG400 RG400
P1
SD13E-22
19
P1121
P1
P1122
ws bl
SS13F-24S
SD6E-24S
ws bl
1
SS10E-24
*
P2122
SS13E-24S
BYW-56
D1
1
ws bl org
ws bl
SS15F-24S
SD8E-24S
ws P2121 bl
SS15E-24S
6
SD11E-22
EA-9B284.13 PCB-BOARD 1
5SD-B
9
R6 330 R5 330 R7 330
PCB-BOARD 1
see EA-9B344.14 WEATHER DETECTION TWX-670
SS11E-24
see EA-9B344.14 WEATHER DETECTION TWX-670
19VN-E 001758_212_02
5SD-A
Schalter am Boden entlastet, im Flug belastet.
SD16E-22N SD15E-22N
8GA
D SD10F-24S
see EA-9B246.10 DC-DISTRIBUTION
SD1E-20
SD12E-22N
3
SD10E-24S
A:1
SD14F-22
SD10-A
5SD-A
13
SD4E-20N
BODENSTECKER
2
SPULE
L2
SD1F-20
1SD
Maintenance Manual EXTRA 500 Chapter 91 30. March 2012
2SD
3 4
AUDIO AUDIO GND
J1
16
TCAD ON
15 14
23 24 25
232 TX4 232 RTN 232 RX4
GND GND
17 18 19
232 TX2 232 RTN 232 RX2
8 9
10 11
A B
6
5
20 21 22
12 13
429 RX1 A 429 RX1 B
429 TX 429 TX
SWITCH ANNUNCIATOR GND
REMOTE MUTE
232 TX3 232 RTN 232 RX3
429 RX2 A 429 RX2 B
L1
F G
SPULE
A B
SD2E-20
ge
#22 #22
org
1 2
bl
28 VDC 28 VDC
3A
ws
2
rt
P1
LEFT GEAR
J1
AVIONICS BUS PP5
ge
70-2420-x TAS-610
org
TRAFFIC ADVISORY SYSTEM
4
rt
bl
CIRCUIT BREAKER/SWITCH PANEL
sw
3
ws
2
bl
SD10F-24S
1
UT
RIGHT GEAR
SD12F-22N sw
SD10GF-24S ws bl
D
C
B
A
A
B
C
D
55
14
15
16
17
18
2 3 24
4
25
45
5 6 26
MUTE INPUT
MUTE INPUT
VOLUME UP
VOLUME DOWN
TUNE UP
TUNE DOWN
SIGNAL 232 TX1 SIGNAL 232 RX1 SIGNAL 232 GND
SIGNAL 232 RTS
SIGNAL 232 GND
SIGNAL 232 CTS
SIGNAL 232 TX2 SIGNAL 232 RX2 SIGNAL 232 GND
J4
J3
51
54
STANDBY
27
53
AUDIO SUPPRESSION
SIGNAL 232 RX
43 44
RS 422 COM1 Rx+ RS 422 COM1 Rx-
SIGNAL 232 GND
22 23
RS 422 COM1 Tx+ RS 422 COM1 Tx-
50
21
SIGNAL 232 TX
42
AUDIO GND
AUDIO OUT RIGHT
P1
P4
P3
J1
ws org bl
ws org bl
#22 #22 #22 #22 #22 #22
2
1
TL11E-RG400
TL10E-24S
TL9E-24S
3SN-A
TL2E-20N
TL2E-20N
S67-1575-650
SIRIUS SATELLITE ANTENNA
DRUCKSCHOTT HINTEN
TL1F-20
2A
3
B:3
3
PP3
001758_212_02
19VN-E
ST13-C
SIM
1
REMOTE ANTENNA
SIRIUS ANTENNA
J2
J1
TNC
2
3
TNC
4
3TL
200-00176-000
5
5
001758_212_02
1VN-E
see EA-9B246.10 DC-DISTRIBUTION
SIRIUS
1TL
TL13E-20N
LOAD BUS
CIRCUIT BREAKER/SWITCH PANEL
4
TL1F-20
3
Maintenance Manual EXTRA 500 Chapter 91 30. March 2012
2TL
20
AUDIO OUT LEFT
P1
10 11 32 12 13 33 1
D.C. POWER INPUT D.C. POWER INPUT D.C. POWER INPUT BATTERY GROUND BATTERY GROUND BATTERY GROUND CHASSIS GND.
BROADCAST DATA LINK RECEIVER MLB-700 700-00159-xxx
1
TL1E-20 TL2F-20N
EDV-Kennung:
04 03 02 01 Ver. Bezeichnung
9B34416T 6
Zuordnung links / rechts wird mit */* in allen Feldern angegeben.
1
1
ws org bl
P2121
ws org bl
P1121
89 88 87
89 88 87
Nr.: Änderung/Mod. Nr.: Datum
Name
Datum
27.09.10
7
46569 Hünxe, Germany
HW
Name
Schwarze Heide 21
Gepr.:
Gepr.:
Bearb.:
7FG
IFD-5000i 700-00083-()
Projektion Freimaßtoleranz Oberfläche
8
Blatt 1
von 1
8
Schutzvermerk nach DIN 34 beachten.
A3
EA-9B344.16
BROADCAST MLB-700, TL
EA 400-500
Maßstab auf SI.-Klasse Oberflächenschutz
see EA-9B342.66 IFD RIGHT
optical coverage minimal 98 - 100% Letzte Bearbeitung:
3FG
IFD-5000i 700-00083-()
see EA-9B342.65 IFD LEFT
RS232 RX0 RS232 TX0 TX0-RX0 COMMON
IFD RIGHT
RS232 RX0 RS232 TX0 TX0-RX0 COMMON
IFD LEFT
7
36 AWG Tinned copper per ASTM-B-33
TL10E-24S
TL9E-24S
OVERBRAID
Die Gültigkeitszuordnung von Version zu Flugzeugbaureihe ist der Bauakte bzw. dem jeweiligen Fertigungsauftrag zu entnehmen.
1
6
A
B
C
D
A
B
C
D
2TS
43 44
54
COM1 RS-422 Rx+ COM1 RS-422 Rx-
STANDBY
SAT ANTENNA
USB
ETH
22 23
COM1 RS-422 Tx+ COM1 RS-422 Tx-
J1
J3
J2
P1
5 26 6
SIGNAL RS-232 TX2 SIGNAL RS-232 GND SIGNAL RS-232 RX2
51
DIAGNOSTIC RS-232 RX
2 24 3
27
SIGNAL RS-232 TX1 SIGNAL RS-232 GND SIGNAL RS-232 RX1
50
DIAGNOSTIC RS-232 TX
DIAGNOSTIC RS-232 GND
10 11 32 12 13 33
MLX-770
D.C. INPUT POWER D.C. INPUT POWER D.C. INPUT POWER AIRCRAFT GROUND AIRCRAFT GROUND AIRCRAFT GROUND
DATALINK 2-WAY
2
P1-A
J3-A
TS5E-RG400
TS4E-24S
ws bl org
J2-A
TS3E-24S
1
TS1G-20 TS2E-20N
ws bl org
#22 #22 #22 #22 #22 #22
J1-A
3
3TS-A
TS4E-24S
TS3E-24S
1
7 17
ws bl 6 org 8
2 16
ws bl 1 org 3
ST13-A
1 2
SAT ANTENNA
TS1G-20 TS2E-20N
ST13-C
1
3TS
TS4F-24S
TS3F-24S
TS1F-20 TS2F-20N
S67-1575-109
ws bl org
ws bl org
SIM
SIM
DRUCKSCHOTT HINTEN
4
1
2
3
4
5
5
TS1F-20 TS2F-20N
2A
6
OVERBRAID
EDV-Kennung:
04 03 02 01 Ver. Bezeichnung
9B34417T 6
Zuordnung links / rechts wird mit */* in allen Feldern angegeben.
Die Gültigkeitszuordnung von Version zu Flugzeugbaureihe ist der Bauakte bzw. dem jeweiligen Fertigungsauftrag zu entnehmen.
1
!
TS4F-24S
TS3F-24S
1
1
65
65
ws bl 23 org 67
P2121
ws bl 23 org 67
P1121
RS232 RX2 TX0-RX0 COMMON RS232 TX2
IFD-RIHT
RS232 RX2 TX0-RX0 COMMON RS232 TX2
IFD-LEFT
7
see EA-9B342.66 IFD RIGHT
7FG
IFD-5000i 700-00083-()
see EA-9B342.65 IFD LEFT
3FG
IFD-5000i 700-00083-()
8
Nr.: Änderung/Mod. Nr.: Datum
Letzte Bearbeitung:
Name
Datum
12.09.10
HW
Name
7
46569 Hünxe, Germany
Schwarze Heide 21
Gepr.:
Gepr.:
Bearb.:
optical coverage minimal 98 - 100%
36 AWG Tinned copper per ASTM-B-33
Projektion Freimaßtoleranz Oberfläche
Blatt 1
von 1
8
Schutzvermerk nach DIN 34 beachten.
A3
EA-9B344.17
DATALINK 2-WAY MLX-770, TS
EA 400-500
Maßstab auf SI.-Klasse Oberflächenschutz
Applying power to the MLX770 transceiver without an antenna connected to the SMA connector may damage the MLX770 transceiver.
see EA-9B246.10 DC-DISTRIBUTION
001758_212_02 19VN-E
D
B:2
3
PP3
IRIDIUM
1TS
LOAD BUS
CIRCUIT BREAKER/SWITCH PANEL
Maintenance Manual EXTRA 500 Chapter 91 30. March 2012
1
TS1E-20
A
B
C
D
D
C
B
A
5
2SN
KDM706A
8
1 14
CLOCK BUS
A/C GROUND A/C GROUND
2SN-C
2SN-A
ws bl
R U
SN10F-24S
SN23E-RG400
9 10
4 5
SN2E-22
2
6
8
blau
grün
VV60
4 5
DME HOLD
7 9
DME HOLD
D C B A 1 2 3 5
8
4
6
7
9
3SN
5SN
VV59
D3
C3
B3
A3
D1
D2
C1
C2
B1
B2
A1
DME HOLD Displ.
Normal
1
OVERBRAID
2
optical coverage minimal 98 - 100%
3
D
4
5
EDV-Kennung:
9B34547T
04 03 02 01 Ver. Bezeichnung
Die Gültigkeitszuordnung von Version zu Flugzeugbaureihe ist der Bauakte bzw. dem jeweiligen Fertigungsauftrag zu entnehmen. Zuordnung links / rechts wird mit */* in allen Feldern angegeben.
001758 212 02 1VN-C
bl
ws bl
1RM-A
ws
P1
21 22
7 14 15
SN11E-24S
SN7E-22 SN8E-22
SN5E-22 SN6E-24
6
1
P2122
7
DME INDICATOR
34 33 32 31 20 17 16 6 5
Nr.: Änderung/Mod. Nr.: Datum
Datum
Bearb.: 01.09.10 Gepr.:
HW
Name
Schwarze Heide 21
Gepr.:
7
7FG
Projektion Freimaßtoleranz Oberfläche
8
Blatt 1
von 1
8
Schutzvermerk nach DIN 34 beachten.
A3
EA-9B345.47
DME KDM 706A, SN
EA 400-500
Maßstab auf SI.-Klasse Oberflächenschutz
see EA-9B342.66 IFD RIGHT
14 13 12 11 9 6 5 4 3
4SN
KDI 574
IFD-5000i
Name 46569 Hünxe, Germany
HW
DISCRETE DISCRETE DISCRETE DISCRETE DISCRETE DISCRETE DISCRETE DISCRETE DISCRETE
OUT OUT OUT OUT OUT OUT OUT OUT OUT
1 MA 1 ME 1 MC 1 MD .1 MA .1 ME .1 MC .1 MD .01 MC NAV 1 COMMON
IFD RIGHT
35 39 38 20 37 41 42 43 44 48
NAV 1 COMMON 10MA
NAV 1 CODE SELECT 2 X 5 CODE PROGRAMM 47 30
N1 50 7
CLOCK BUS
DME REQUEST
NC(KEY)
DATA BUS
10
12
15
5
11
GROUND HOLD ON +9,25V +192V
1RM
PMA 8000B
see EA-9B235.17 MKR/AUDIO
DME AUDIO HI DME AUDIO LO
AUDIO & MARKER
40 2 19 3 1
2SD see EA-9B344.15 TRAFFIC SYSTEM TAS-610
SUPPRESSION GND GND
TRAFFIC ADVISORY SYSTEM 70-2420-x TAS-610
16.02.11
4SN-A
Letzte Bearbeitung:
SN22E-24 SN21E-24 SN20E-24 SN19E-24 SN18E-24 SN17E-24 SN16E-24 SN15E-24 SN14E-24 SN13E-24
SN13E-24 SN14E-24 SN15E-24 SN16E-24 SN17E-24 SN18E-24 SN19E-24 SN20E-24 SN21E-24 SN22E-24
SN12E-24
1
Gehäuse 11D-50-000-G-VL P7041
RM12E-24S
SD10E-24S
SN10E-24S
SN23E-24N
see EA-9B246.10 DC-DISTRIBUTION
2A
DME
PP3
6
SN10E-24S
A2
SN1E-22
2
1SN
LOAD BUS
CIRCUIT BREAKER/SWITCH PANEL
5
SN9E-24S
Anschlußschema
VV58
D:2
D:1
SN12E-24
SN2F-22
SN1F-22
4
SN9E-24S
SN11E-24S
DME ANTENNA KA 60
SIM
SN7E-22 SN8E-22
SN5E-22 SN6E-24
3SN-A
FG1-73-22 FG101E-22
001758_212_02 19VN-A
see EA-9B334.90 DIMMING VV334901 Pin F 15 Test 5LH-A Pin 21 35
SN3E-22N SN4E-22N
SN9F-24S
7 8
5 6
ST13-B
SN7F-22 SN8F-22
3 4
ST13-D
14 15 20
SIM
RM12E-24S
ws bl
ws bl
SD10E-24S
SN7E-22 SN8E-22
RM12F-24S
SD10F-24S
ws bl
11 12 13
SIM
SN2F-22
ws bl
2
1
SN1F-22
SIM
ST13-B
SN2G-22
SN1G-22
ST13-D
DRUCKSCHOTT HINTEN
SN5F-22 SN6F-24
SN11F-24S
ws bl
SN5E-22 SN6E-24
RM12F-24S
D1 SN24E-24 ws bl MUR120
SN2G-22
SN1G-22
P7061
SD10H-24S
36 AWG Tinned copper per ASTM-B-33
DME ANTENNE
24
DME REQ IN
9
DATA BUS
18
22 4
+9,25 VDC +192 VDC
20
16 12
GND HOLD
ON
21 17
AUDIO HI AUDIO LO
GND
25 19
3
A/C 28 VDC POWER
SUPPRESSION GND
2
A/C 28 VDC POWER
DME TRANSCEIVER
ws bl
2SH-A
3
Maintenance Manual EXTRA 500 Chapter 91 30. March 2012
1
SUPPRESSION
see EA-9B345.58 TRANSPONDER BXP-6402R
2SN
TRANSPONDER BXP-6402-1R-()
2
ws bl
SD10G-24S
1
SD10F-24S
D
C
B
A
D
C
B
A
2SH
25 19
see EA-9B345.47 DME
7
REPLAY OUT
3 21
GND GND
CHASSIS STUD
ANTENNA
1
PSEL
J7
ws bl ws bl
#16
TNC
2SH-B
15 14 18 17
P8
ws bl ws bl
VV63
1
bl
SD10H-24S
1
SD10F-24S
BNC
AIRFRAME GROUND
BNC
BNC
5SH-C
BNC
2
SH26F-RG393
4
BNC
5SD-B
ST13-A
ws bl ws bl
SIM
ws bl ws bl
SIM
ws bl ws bl
1
N
5SD-A
N
5SD-C
SH8E-24S
1
2
3
1
2
OVERBRAID
optical coverage minimal 98 - 100% 4
SH4E-24S
SH3E-24S
1
SD10E-24S
ws bl ws bl
P2121
ws bl
2
5
BNC
85 86 4 25 67
BNC
6SH-B
RS422 TX3+ RS422 TX3RS422 RX3+ RS422 RX3SCHIELD
EDV-Kennung:
9B34558T
04 03 02 01 Ver. Bezeichnung
6
Zuordnung links / rechts wird mit */* in allen Feldern angegeben.
3FG
IFD-5000i 700-00083-()
XPDR ANTENNA
Nr.: Änderung/Mod. Nr.: Datum
21.02.11
Name
HW
Datum
12.09.10
OPTION
OPTION
Schwarze Heide 21
Gepr.:
Gepr.:
Bearb.:
7
7
Name 46569 Hünxe, Germany
HW
see EA-9B344.15 TAS
2SD
70-2420-x TAS-610
4SH
KA-60
see EA-9B342.65 IFD LEFT
Letzte Bearbeitung:
COUPLER
7FG
IFD-5000i 700-00083-()
see EA-9B342.66 IFD RIGHT
TRAFFIC ADVISORY SYSTEM
SH26E-RG400
3SH-A
RS422 TX3+ RS422 TX3RS422 RX3+ RS422 RX3SCHIELD
IFD LEFT
2SD see EA-9B344.15 TRAFFIC SYSTEM TAS-610
SUPPRESSION GND GND
IFD RIGHT
COUPLER
BNC
6SH-C
ATC
1SH
see EA-9B246.10 DC-DISTRIBUTION
3A
EMERGENCY BUS PP4
TRAFFIC ADVISORY SYSTEM 70-2420-x TAS-610
SH1E-18
Die Gültigkeitszuordnung von Version zu Flugzeugbaureihe ist der Bauakte bzw. dem jeweiligen Fertigungsauftrag zu entnehmen.
BNC
6SH-A
SD-C1E-G400
SH26F-RG393
ws bl ws bl
P1121
85 86 4 25 67
7 14 15
BODENSTECKER 6SH-A
SH8E-24S*
SH7E-24S
1
P1
6
CIRCUIT BREAKER/SWITCH PANEL
C:4 3
CB Trennstecker
SH1F-18
see EA-9B323.10 GEAR CONTROL
5
SD-C3E-RG393
36 AWG Tinned copper per ASTM-B-33
Coupler only installed when Option TAS is used.
7
SH4E-24S
SH3E-24S
SH7E-24S
see EA-9B344.15 TAS
2
ohne Option TAS
5SD
TCAD
XPDR
ANT
1
SD10E-24S
SH5E-24
TCAD COUPLER 70-2040
20 11 12 13 14 15
8 3
ST14-B
ws bl ws bl
18 4 5 9 10 19
ST13-A SIM
bl
11 12 13
ws bl
SH1F-18
SIM
SIM
8
ST13-B
SH1G-18
ST13-C
DRUCKSCHOTT HINTEN
SH5F-24
SD-C2E-RG400
19VN 001758 212 02
DRUCKSCHOTT HINTEN 5SH-B 5SH-C
5SH-A
AM 6400-1-(01)
SH10E-20N
SH9E-20N
SH8F-24S
1
SH8F-24S
E F
SH4F-24S
SH3F-24S
19VN 001758 212 02
ws bl
SH7F-24S
ws bl
SH7F-24S
SH11E-20N SH12E-20N
SH4F-24S
SH25E-RG400
3SH
1
SH5F-24
ws
3
SD10G-24S
SH3F-24S
ws bl
SH1G-18
MUR120
P7061 D1
J9 2SH-A
RX+ RXTX+ TX-
TIS TIS TIS TIS
12 13
ALT S ALT S +
RS422 RS422 RS422 RS422
11
24
25 13
GROUND SWITCH
GROUND GROUND ON
9 21 22
8
5
SUPPRESSION
RX+ RXTX+ TX-
17 18 19 20 4
C1 C2 C4 D4 EXT. IDENT
RS422 RS422 RS422 RS422
1 2 3 14 15 16
6
SWITCHED POWER OUTPUT
A1 A2 A4 B1 B2 B4
11 12
POWER IN POWER IN
BXP-6402-1R-()
TRANSPONDER
3SN
SUPPRESSION GND
DME TRANSCEIVER KDM-706A
2
Maintenance Manual EXTRA 500 Chapter 91 30. March 2012
1
SD10G-24S ws bl
Projektion Freimaßtoleranz Oberfläche
Blatt 1
von 1
8
Schutzvermerk nach DIN 34 beachten.
A3
EA-9B345.58
ATC BXP6402-1R, SH
EA 400-500
Maßstab auf SI.-Klasse Oberflächenschutz
8
D
C
B
A
#20
A
B
C
2
ON
Instrument Panel leftside
28VDC N/C Positiv Input Negativ Input Light Light GND
1 2 3 5 4 6 7 8 9
9HI-A
ws bl
see EA-9B246.10 DC-DISTRIBUTION
HI4E-22
HI2E-12
3
HI4F-22
HI2F-12
CB Trennstecker
A:2
C:2
HI5E-22N
QX3E-22
HI9E-22S
HI8E-22 HI7E-22
HI4F-22
1
2
4
1
2
3
4
5
8 9
8HI
2A
7HI
EA-9B243.42
5
EDV-Kennung:
04 03 02 01 Ver. Bezeichnung
9B36011T 6
Zuordnung links / rechts wird mit */* in allen Feldern angegeben.
Die Gültigkeitszuordnung von Version zu Flugzeugbaureihe ist der Bauakte bzw. dem jeweiligen Fertigungsauftrag zu entnehmen.
HI6E-12N
B
5HI
Name
Kohleschleifer Halterung
Nr.: Änderung/Mod. Nr.: Datum
Letzte Bearbeitung:
Blech am External Power Stecker
HI3F-12
TRENNSTECKER FIREWALL
6
TRIEBWERKSTRAEGER LINKS
see EA-9B334.90 DIMMING SYSTEM see EA-9B284.10 FUEL QUANTITY
2A
HI3E-12
50mV 30A
SHUNT
4HI
6HI
HI2F-12
Achtung: Polarität beachten !
Maintenance Manual EXTRA 500 Chapter 91 30. March 2012
9HI
3
1 OFF
FUSE 1 RUE30V
3HI
07.1.1.13
2HI
PROP
PROP-HT
20A
ELECTRONIC AMMETER N15 1120 030P 01W
1HI
HI1E-12
BATTERY BUS PP2
CIRCUIT BREAKER/SWITCH PANEL
2
HI8E-22 HI7E-22
D
1
- +
Name
HW
Datum
PROP DE-ICER
04.10.10
A
7
46569 Hünxe, Germany
Schwarze Heide 21
Gepr.:
Gepr.:
Bearb.:
7
Projektion Freimaßtoleranz Oberfläche
Blatt 1
von 1
8
Schutzvermerk nach DIN 34 beachten.
A3
EA-9B360.11
PROP HEAT UMA, HI
EA 400-500
Maßstab auf SI.-Klasse Oberflächenschutz
8
A
B
C
D
A
B
C
D
8VN-A 001758 212 02
D
MC2E-22N
2
DC-1
2
Art.Nr. 01738
1
6WW2 3
DOOR
MC1E-22
3
107
5WW-D 45
D15
1
2
3
4
5
5
see EA-9B315.80 ANNUNCIATOR PANEL
+ VOLT DIMM
LIGHT TEST (GND)
ANNUNCIATOR BOARD 5WW
4
Maintenance Manual EXTRA 500 Chapter 91 30. March 2012
1
13 24 25 WW1-20
WW14-22
EDV-Kennung:
9B52710T
04 03 02 01 Ver. Bezeichnung
6
7
Flaps
Nr.: Änderung/Mod. Nr.: Datum
Name
HW
Datum
Bleed Overt
Windsh-Heat
Stall-Heat
PB
Name
7
46569 Hünxe, Germany
Schwarze Heide 21
Gepr.:
Gepr.:
Bearb.: 11.02.04
Cab-Press
Stall-Warn
Aft Door
01.09.10
Gear Warn
Gen-Fail
Annunciator Panel left
Letzte Bearbeitung:
1WW
Die Gültigkeitszuordnung von Version zu Flugzeugbaureihe ist der Bauakte bzw. dem jeweiligen Fertigungsauftrag zu entnehmen. Zuordnung links / rechts wird mit */* in allen Feldern angegeben.
5WW-B
P/N 90-4219X-1 geändert
Annunciator Panel left
6
Projektion Freimaßtoleranz Oberfläche
Blatt 1
von 1
8
Schutzvermerk nach DIN 34 beachten.
A3
EA-9B527.10
DOOR WARNING, WW
EA 400-500
Maßstab auf SI.-Klasse Oberflächenschutz
8
A
B
C
D
A
B
C
D
Fuel Low L
Fuel Filter
3
1
Fuel Low R
Pneumatic
Prop Low Pitch
Low Voltage
Standby Alt On
7.5A
A:1
2
4
QB4F-20
WW37-22
5WW-C
3
1 ON
OFF
QB5E-20
3
1 ON
OFF
QB2E-20
+ VOLT DIMM
LIGHT TEST (GND)
see EA-9B315.80 ANNUNCIATOR PANEL
ANNUNCIATOR BOARD EA-9B315.81
17 24 25
5WW
D20
ANNUNCIATOR BOARD
Instrument-Panel left
07.1.1.13
3QB 2
FUEL PUMP 2
07.1.1.13
4QB 2
FUEL PUMP 1
see EA-9B246.10 DC-DISTRIBUTION
QB1F-20
7.5A
FUEL-P-1
EMERGENCY BUS PP4
FUEL-P-2 1QB
CB Trennstecker A:7
2QB
QB1E-20
BATTERY BUS PP2
CIRCUIT BREAKER/SWITCH PANEL
Fuel Trans L Fuel Trans R
2
QB4E-20
1
2
3
4
Maintenance Manual EXTRA 500 Chapter 91 30. March 2012
2WW
P/N 90-42192-2 geändert
Annunciator Panel right
1
16
5
5WW-D
5
QW1F-22
P
EDV-Kennung:
9B73110T 6
Zuordnung links / rechts wird mit */* in allen Feldern angegeben.
04 03 02 01 Ver. Bezeichnung
31 32
E
g
HW
Name
01.09.10
ÄM-400-09-01
QW1E-22 QW2E-22N
6QB
7QB
Name
PB
Datum
A Blatt 1
von 1
8
Schutzvermerk nach DIN 34 beachten.
A3
EA-9B731.10
FUEL PUMP / FILTER, QB
EA 400-500
Projektion Freimaßtoleranz Oberfläche
FUEL PUMP 2
Maßstab auf SI.-Klasse Oberflächenschutz
Engine Compartment
8
FUEL PUMP 1 Fa. Parker
5QB
PN 1743640-06
46569 Hünxe, Germany
7
P
2.15 PSID
02.09.04
A B C
FUEL FILTER
Schwarze Heide 21
Gepr.:
Gepr.:
Bearb.:
7QB-A
NEG
POS
NEG
POS
Anschluss mir Ringöse MXX
QB2F-20
QB5F-20 QB6E-20N
7
2VN-D 001758 212 02
N M
Nr.: Änderung/Mod. Nr.: Datum
A
Letzte Bearbeitung:
ST4
QB2F-20
QB5F-20
FIREWALL ST2
MS38999III (13-35)
QW1F-22 QW2F-22N
Die Gültigkeitszuordnung von Version zu Flugzeugbaureihe ist der Bauakte bzw. dem jeweiligen Fertigungsauftrag zu entnehmen.
001758 212 02 2VN-D
1
QB2E-20
QB5E-20
6
QB6E-20N QB3E-20N
A
B
C
D
A
B
C
D
2WW
3
Pneumatic
Fuel Low R
Fuel Low L
Prop Low Pitch
Low Voltage
Fuel Trans R Standby Alt On
ON
1 OFF
07.1.1.13
4QF 2
Fuel Filter
Fuel Trans L
QF1F-22
FUEL TRANSFER 2
ON
1
QF5E-22 QF2E-22
WW20-20
WW35-22 WW38-22
5WW-C
QF4E-22
QF1E-22
5A
FUEL-TR-R
24 25
15 18
LIGHT TEST (GND)
ANNUNCIATOR BOARD EA-9B315.81 see EA-9B315.80 ANNUNCIATOR PANEL
+ VOLT DIMM
D19
ANNUNCIATOR BOARD D22 5WW
see EA-9B246.10 DC-DISTRIBUTION
2QF
18 15
5WW-D 48 47
Maintenance Manual EXTRA 500 Chapter 91 30. March 2012
geändert
P/N 90-42192-2
Annunciator Panel right
3
1 OFF
07.1.1.13
3QF 2
B:14
B:1
1
CB Trennstecker
FUEL TRANSFER 1
QF4F-22
QF1F-22
5A
FUEL-TR-L
LOAD BUS PP3
QF5F-22 QF2F-22 QF6F-22N QF3F-22N
KOPF
6 7
30CG-C
EDV-Kennung:
9B73130T
7.21440.68.0
Ringösen 5mm
right
QF8E-22N
right
2x Type P110
8QF 3
PCI
ÄM-400-09-01
14.10.10
1
2
Name
HW
PB
Gepr.:
Name
46569 Hünxe, Germany
Schwarze Heide 21
Gepr.:
T S
A Blatt 1
Schutzvermerk nach DIN 34 beachten.
A3
EA-9B731.30
FUEL TRANS, QF
von 1
Projektion Freimaßtoleranz Oberfläche
EA 400-500
Maßstab auf SI.-Klasse Oberflächenschutz
001758 212 02 20VN-A
Datum
QF7E-22N
left
Bearb.: 07.09.04
3
7QF
FUEL PRESSURE SWITCH MOTIVE FLOW
1
2
FUEL PRESSURE SWITCH MOTIVE FLOW
left
WING CENTER COMPARTEMENT (front)
Einbau im Avionic-Bay, left and right
6QF
Letzte Bearbeitung:
A
Ringösen 5mm
MOTIVE FLOW FUEL PUMP
5QF
MOTIVE FLOW FUEL PUMP
Nr.: Änderung/Mod. Nr.: Datum
QF9E-22 QF10E-22
Die Gültigkeitszuordnung von Version zu Flugzeugbaureihe ist der Bauakte bzw. dem jeweiligen Fertigungsauftrag zu entnehmen. Zuordnung links / rechts wird mit */* in allen Feldern angegeben. 04 03 02 01 Ver. Bezeichnung
QF9F-22 QF10F-22
ST 7
STECKER AVIONIC BAY
Copilot overhead
001758 212 02 8VN-A
B C
C D E F
MS 347X-L22-41SN (27 X #20 / 14X#16)
QF5E-22 QF2E-22 QF6E-22N QF3E-22N
ST5
STECKER OVERHEAD
+ +
1QF
-
CIRCUIT BREAKER/SWITCH PANEL
-
A
B
C
D
A
B
C
D
see EA-9B342.66 IFD RIGHT
700-00083-()
IFD-5000i
IFD RIGHT
RS232 RX1 RS232 COMMON RS232 TX1
RS232 RX1 RS232 COMMON RS232 TX1
28VDC POWER Instrument GND NC Flow Transducer Power Transducer GND Flow Transducer Signal NC RS-232 In RS-232 Out
see EA-9B342.65 IFD LEFT
700-00083-()
IFD-5000i
IFD LEFT
2QY
912041T-D
SHADIN MINIFLOW L
2
91 96 44
ws bl or
ws bl
P2121
ws bl
ws bl ws bl
1
1
QY1F-22 QY2E-22N
P1121
D-SUB 9
91 96 44
1 2 4 3 5 7 8 9 6
2QY-A
1
QY4E-24S
QY4F-24S
QY5E-22N
QY3E-22S
QY4F-24S
QY4E-24S
3
LM
001758 212 02 1VN-G
4
QY3E-22S
ws bl or
C:12
J4 55 56 57 48
1
912041T-D = GPS & Gal 912047T-D = GPS & Lit
2
3
4
1
5
5
red blk wht
QY1E-22
6
EDV-Kennung:
9B73110T
04 03 02 01 Ver. Bezeichnung
6
HW
Name
12.09.10
ÄM-400-09-01
PB
Name
7
46569 Hünxe, Germany
Schwarze Heide 21
Gepr.:
Gepr.:
Bearb.: 06.09.04
Datum
optical coverage minimal 98 - 100%
Nr.: Änderung/Mod. Nr.: Datum
A
7
36 AWG Tinned copper per ASTM-B-33
Letzte Bearbeitung:
OVERBRAID
Shadin P/N 66050X
3QY
TRANSDUSER
see EA-9B246.10 DC-DISTRIBUTION
BATTERY BUS PP2
Die Gültigkeitszuordnung von Version zu Flugzeugbaureihe ist der Bauakte bzw. dem jeweiligen Fertigungsauftrag zu entnehmen. Zuordnung links / rechts wird mit */* in allen Feldern angegeben.
1
QY3F-22S
1A
FUEL FLOW 1QY
CIRCUIT BREAKER/SWITCH PANEL
ST4
FIREWALL
QY1F-22
Maintenance Manual EXTRA 500 Chapter 91 30. March 2012
1
QY5E-22N QY2E-22N
A Blatt 1
8
Schutzvermerk nach DIN 34 beachten.
A3
EA-9B731.40
FUEL FLOW, QY
von 1
Projektion Freimaßtoleranz Oberfläche
EA 400-500
Maßstab auf SI.-Klasse Oberflächenschutz
8
A
B
C
D
A
B
C
PT 6
Starter/Generator
4JB
3JB
A B
JB5F-20 JB6E-18N
3JB-A
TGLN-28 IGNITION EXCITER
IGNITION PLUG
TURBINE
A:6
JB2F-20
JB1F-20
VV234
ABORT NORMAL
JB2G-20
6 WL5-22 08.2.1.16 JB5E-20 Nut oben
4
3
1 MOTORING
4
3 IGN OFF
IGN
1 START
C
JB5E-20
MS38999 III 26K F 32 SN
ST2
FIREWALL
6 08.2.1.25 Nut oben
5
:2
2
26PP:1
I-Panel left 1 START
5
:2
2
5JB:1
I-Panel left 2 MOTORING
JB3F-20
WL5-22
52
51
1PR-A
24
5WW-D
PR15E-20 PR14E-20 PR18E-22N
PR14E-20 PR15E-20
JB4E-20
JB3E-20
6
12
24
L K
M
N
1
2
3
4
5
START
5 INV
D40
291-9726
5
BYW56
D28
EDV-Kennung:
9B74310T
04 03 02 01 Ver. Bezeichnung
6
Zuordnung links / rechts wird mit */* in allen Feldern angegeben.
Die Gültigkeitszuordnung von Version zu Flugzeugbaureihe ist der Bauakte bzw. dem jeweiligen Fertigungsauftrag zu entnehmen.
5WW-A
5WW-C
HW
Name
01.09.10
ÄM-400-09-01
WW39-20N
WW20-20
WW29-22
Ignition
Intake Heat Deice Boots
PB
7
46569 Hünxe, Germany
Schwarze Heide 21
Gepr.:
Gepr.:
Name
Datum
08.09.04
Projektion Freimaßtoleranz Oberfläche
8
A Blatt 1
von 1
8
Schutzvermerk nach DIN 34 beachten.
A3
EA-9B743.10
START/IGNITION, JB
EA 400-500
Maßstab auf SI.-Klasse Oberflächenschutz
Prop Low Pitch External Power Windshield On
Low Voltage
P/N 90-42192-2 geändert
Annunciator Panel right
Standby Alt On
7
Bearb.:
2WW
Nr.: Änderung/Mod. Nr.: Datum
A
Letzte Bearbeitung:
see EA-9B315.80 ANNUNCIATOR PANEL
9
9 24 25
5WW
ANNUNCIATOR BOARD EA-9B315.81
Annunciator Panel EA-9B315.80
K4
+ VOLT DIMM
LIGHT TEST (GND)
see EA-9B243.10 DC-GENERATION I
1PR
see EA-9B243.40 E-BOX
26.57.73
K2
6
START CONTACTOR CONT START POWER CHASSIS GROUND Bei 58% schaltet die GCU aus!
ANNUNCIATOR BOARD
Z W M
GENERATOR CONTROL UNIT GCSG 505-21
ST1
FIREWALL
E-BOX
Maintenance Manual EXTRA 500 Chapter 91 30. March 2012
Allison
1
JB2E-20
A:5
CB Trennstecker
1
5A
5A
JB1E-20
START
4JB
IGN
see EA-9B246.10 DC-DISTRIBUTION
1JB
BATTERY BUS PP2
JB4F-20
CIRCUIT BREAKER/SWITCH PANEL
4
88
3
87z
88a
2
88b 88y
87a
D
1
Fertig konfektioniert
85 86
A
B
C
D
D
C
B
A
HK1F-22
HK1E-22
3
see EA-9B246.10 DC-DISTRIBUTION
2A
LOAD BUS PP3 6HK
P-VENT
CIRCUIT BREAKER/SWITCH PANEL
2
1
1
C:2
C:1
HK1H-22
HK1G-22
32CG-A
4
HK3F-22N
HK1H-22
HK2F-22N
HK1G-22
001758_212_02 3VN-A
J
HK2F-22N
2
1
2
1
P2
P1
MOLEX
MOLEX
1
2
3
4
Maintenance Manual EXTRA 500 Chapter 91 30. March 2012
1
HK3F-22N
2
5
HK3E-22N
HK1K-22
HK2E-22N
HK1J-22
5
1
2HK
4HK 1
EDV-Kennung:
9B75215T
04 03 02 01 Ver. Bezeichnung
6
HK2E-22
A
3HK
M
ÄM-400-09-01
05.10.10
5HK
M
7
HK2E-22N
Datum
18.08.04
PB
Name
7
HW Name 46569 Hünxe, Germany
Schwarze Heide 21
Gepr.:
Gepr.:
Bearb.:
9G0624G1021
HK3E-22N
9G0624G1021
VENT FAN right
Letzte Bearbeitung:
VV237
VV236
VENT FAN left
Nr.: Änderung/Mod. Nr.: Datum
HK1H-22
Die Gültigkeitszuordnung von Version zu Flugzeugbaureihe ist der Bauakte bzw. dem jeweiligen Fertigungsauftrag zu entnehmen. Zuordnung links / rechts wird mit */* in allen Feldern angegeben.
AV1611A240K
2
1
FAN RIGHT
AV1611A240K
2
FAN LEFT
6
Blatt 1
A
8
Schutzvermerk nach DIN 34 beachten.
A3
EA-9B752.15
PANEL FAN, HK
von 1
Projektion Freimaßtoleranz Oberfläche
EA 400-500
Maßstab auf SI.-Klasse Oberflächenschutz
8
D
C
B
A
Intentionally left blank
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