Extra 500. Maintenance Manual (2012) - page 3
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:
Chapter 06
Dimensions and Areas
06 Page 1
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
06-10-00
MAIN DATA
06-10-01
Main Dimensions
Length:
10.13 m
(33.23 ft)
Height:
3.37 m
(11.06 ft)
Span:
11.60 m
(38.06 ft)
Wheelbase:
2.65 m
(8.69 ft)
Wheel-track:
2.20 m
(7.22 ft)
MTOW:
2,130 kg
(4,696 lbs.)
06-10-02
Wing
Span:
11.60 m
(38.06 ft)
Area:
14.265 m2 (153.55 sq.ft.)
Airfoil: Root: NLF 22 - .05, 16.5 %
Tip: NLF 23 - .05, 13 %
06-10-03
Horizontal Tail
Span:
3.80 m (12.47 ft)
Airfoil:
NACA 0012
06-10-04
Elevator
Total projected nested area:
1.13 m2 (12.16 sq.ft.)
06 Page 3
06-10-05
Vertical Tail
Airfoil: Root: NACA 2412
Tip: NACA 0012
06-10-06
Rudder
Total projected nested area:
0.633 m2 (6.81 sq.ft.)
06-10-07
Ailerons
Total projected nested area:
0.617 m2 (6.64 sq.ft.)
06-10-08
Settings and Deflections
Flaps
Take-off:
15°, tolerance ± 3°
Landing:
30°, tolerance + 1°/-2°
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):
20° up (nose down), tolerance ± 2°
30° down (nose up), tolerance ± 2°
Page 4 06
Chapter 07
Lifting and Shoring
07 Page 1
Table of Contents
07-10-00
JACKING
3
Page 2 07
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:
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.
CAUTION
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.
When raising the aircraft, apply pressure on all jacks simultaneously
and evenly to keep the aircraft leveled as it is raised. Otherwise the
CAUTION
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
When lowering the aircraft, bleed off pressure on all jacks
CAUTION simultaneously and evenly to keep the aircraft leveled as it is lowered.
07 Page 3
Chapter 08
Leveling and Weighing
08 Page 1
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
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.
08 Page 3
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
Chapter 09
Towing and Taxiing
09 Page 1
Table of Contents
09-00-00
GENERAL
3
09-10-00
TOWING
4
09-20-00
TAXIING
5
Page 2 09
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].
Exercise care not to turn the nose wheel past its normal swivel angle of 30°
CAUTION to each side of center. Exceeding the turn limits will cause structural
damage.
09 Page 3
09-10-00
TOWING
When preparing for ground handling operation ensure that the battery
DANGER 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.
Moving the aircraft with a vehicle, especially when pushing in backward
CAUTION 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
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.
Taxiing over loose gravel or cinders should be done at low engine speed to
CAUTION 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.
09 Page 5
Chapter 10
Parking, Mooring, Storage and
Return to Service
10 Page 1
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 10
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.
10 Page 3
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.
Do not set the parking brakes, when they are overheated or during cold
CAUTION 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 tie-
down 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
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).
10 Page 5
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
During severe weather conditions and strong winds, hangar the aircraft
for maximum protection.
Page 6 10
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).
10 Page 7
Chapter 11
Placards and Markings
11 Page 1
Table of Contents
11-00-00
GENERAL
3
Page 2 11
11-00-00
GENERAL
NOTE
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.
11 Page 3
Chapter 12
Servicing
12 Page 1
Table of Contents
12-00-00
GENERAL
3
12-10-00
REPLENISHING.............................................................................................. 4
12-10-01
Refueling
............................................................................................................ 4
Fuel Grade
.......................................................................................................... 4
Fuel System Capacities
....................................................................................... 5
12-10-02
Draining
............................................................................................................. 6
12-10-03
Fuel Drains
........................................................................................................ 6
12-10-04
Replenishment of Engine Oil
........................................................................... 7
Oil Grades
........................................................................................................... 7
Oil System Capacities
......................................................................................... 7
12-10-05
Oil Change
......................................................................................................... 8
12-10-06
Replenishment of Brake Fluid
......................................................................... 8
Brake Fluid Grade
8
Brake Fluid System Capacity
............................................................................. 8
12-10-07
Brake Bleeding Procedure
............................................................................... 9
12-10-08
Tire Inflation
................................................................................................... 10
12-10-09
Main Gear Shock Absorber
........................................................................... 11
Oil Draining/Refilling....................................................................................... 11
Hydraulic Fluid Grade
...................................................................................... 11
Hydraulic Fluid Capacity.................................................................................. 11
Nitrogen Inflation Pressure
............................................................................... 11
12-10-10
Nose Gear Shock Absorber
............................................................................ 12
Oil Draining/Refilling....................................................................................... 12
Hydraulic Fluid Grade
...................................................................................... 13
Hydraulic Fluid Capacity.................................................................................. 13
Nitrogen Inflation Pressure
............................................................................... 13
12-20-00
SCHEDULED SERVICING
.......................................................................... 14
12-20-01
Exterior Cleaning
14
12-20-02
Interior Cleaning
............................................................................................ 15
12-20-03
Engine Cleaning
.............................................................................................. 15
12-20-04
Lubrication Chart........................................................................................... 16
12-30-00
UNSCHEDULED SERVICING
.................................................................... 18
12-30-01
Removal of Snow and Ice
............................................................................... 18
Page 2 12
Page Date: 9. August 2013
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.
12 Page 3
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:
If the fuel system has been completely drained, the fuel system bleeding
DANGER
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
Fuel confirming the following commercial specifications are approved for
unrestricted use:
Primary Fuel
ASTM D 1655-03 or later, grade JET A or A-1
Cold Weather Fuel
ASTM D 1655-03 or later, grade JET A or A-1 with anti ice additive MIL-
DTL-85470B or later
Page 4 12
Page Date: 9. August 2013
When adding anti-icing additive into the fuel during refueling.
CAUTION
Proper mixing of anti icing additive with fuel is extremely important,
because concentration in excess of the recommended (0.10 % up to 0.15
% by volume) will result in detrimental effects to the fuel tanks.
NOTE
JET A and JET A-1 fuels are not restricted from use at ambient
temperatures below
-18
°C (0 °F); however, special provisions for
starting (preheat to the engine fuel control area) must be made. Once
started, engine operation will be satisfactory in outside temperatures
down to -32 °C (-25 °F) for JET A and JET A-1.
Use of Fuel Grades Temperature Dependent
Starting and operating temperature ranges:
Fuel grade for
Ambient temperature
Starting
Operating
at +38 °C(+100 °F)
Primary
down to +4 °C (+40 °F)
below +4 °C (+40 °F)
Cold weather
down to-18 °C (+0 °F)
below -18 °C(+0 °F)
Cold weather
Cold weather
down to -32 °C (-25 °F)
preheated
Fuel System Capacities
Fuel quantity is based on fuel grade JET A-1 at 15 °C (59 °F) with specific
gravity 0.814 kg/l and shown in table below:
IMPORTANT
The maximum allowable fuel unbalance is 106 liters (28 U.S. Gallons).
The left and right wing are subdivided in three compartments each; the
collector, main and auxiliary compartment.
Wing Tank
Liter
lbs
Kg
US Gal.
Remark
Collector
2 x 37.4
2 x 67.1
2 x 30.4
2 x 9.9
One indicator
Compartment
each side
Main
2 x 196.6
2 x 352.9
2 x 160.0
2 x 51.9
One indicator
Compartment
each side
Auxiliary
2 x 106.0
2 x 190.3
2 x 86.3
2 x 28.0
One indicator
Compartment
each side
Total
680.0
1220.5
553.5
179.7
Capacity
Unusable Fuel
2 x 14.0
2 x 25.1
2 x 11.4
2 x 3.7
Usable Fuel
652.0
1170.3
530.7
172.3
Page Date:
12 Page 5