Extra 500. Maintenance Manual (2012)

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.

Ensure BATT switch is OFF and no

external power connected.

Attach roll servo with 3 screws to

support bracket.

Insert bridle cable center ball into

leading hole in capstan.

Adjust position of center ball with

12 o’clock position.

aileron controls in neutral position.

See Figure 22-2

Wrap bridle cable around capstan 1.5

Cable clamps will be positively

turns each direction from center ball.

guided to correct position

Install cable guards and cover with 4

Tighten screws only snugly against

screws and washers.

servo base plate

Apply tension by hand before

Install cable clamps.

tightening the cable clamps.

Adjust bridle cable tension to the

See 22-10-07Figure 22-6 for clamp

value given in Subject 22-10-06.

torquing.

Cable clamps may be rotated on

aileron cable to align bridle cable

with capstan grooves.

Connect electrical connector.

Install wing center fairing.

Refer to Chapter 51-00-01

Function Test

Detail Steps/Work Items

Key Items

Attach external power to the aircraft.

Check all switches off.

Switch EXT PWR on.

Switch AUTOPILOT MASTER to

MASTER.

Check AP RDY on IFD.

Check RDY on autopilot computer.

22 Page 15

Detail Steps/Work Items

Key Items

Switch on HDG mode.

Check HDG is displayed on autopilot

computer.

Check HDG bug is fully filled and

magenta on IFD.

Turn HDG knob to the left.

Check control wheel turns CCW.

Turn HDG knob to the right.

Check control wheel turns CW.

Press AP DISC switch on LH control

Aural warning can be heard.

wheel.

Switch AUTOPILOT MASTER off.

Switch EXT PWR off.

Disconnect external power.

22-10-02

Pitch Servo

Removal

Refer to Figure 22-3.

Detail Steps/Work Items

Key Items

Ensure BATT switch is OFF and no

external power connected.

Remove tail cone access panel.

Disconnect electrical connector from

roll servo.

Loosen bridle cable clamps.

Remove return pulley.

Remove 4 bolts and nuts securing

pitch servo to support bracket.

Remove pitch servo from support

bracket.

Remove cable guard, cover and bridle

cable from servo capstan, if required.

Page 16 22

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.

Ensure BATT switch is OFF and no

external power connected.

Attach pitch servo with 4 screws to

support bracket.

Insert bridle cable center ball into

leading hole in capstan.

Adjust position of center ball with

11 o’clock position.

elevator controls in neutral position.

See Figure 22-3

Wrap bridle cable around capstan

Cable clamps will be positively

1 turn (360°) CW and 1.5 turns (540°)

guided to correct position

CCW from center ball.

Install cable guards and cover with 4

Tighten screws only snugly against

screws and washers.

servo base plate

Install return pulley.

See 22-10-07Figure 22-6 for clamp

Lead upper bridle cable segment

torquing.

around pulley and pre-install cable

Cable clamps may be rotated on

clamps.

elevator cable to align bridle cable

Tension bridle cable by hand before

with capstan grooves

fastening the cable clamps.

Connect electrical connector.

Adjust correct bridle cable tension.

Refer to the Tension Settings and

the Tensioning procedure presented

in Subject 22-10-06.

Install tail cone access panel.

Page 18 22

Function Test

Detail Steps/Work Items

Key Items

Attach external power to the aircraft.

Check all switches off.

Switch EXT PWR on.

Switch AUTOPILOT MASTER to

MASTER.

Check AP RDY on IFD.

Check RDY on autopilot computer.

Set heading bug to current heading

push heading knob on keypad

Switch on HDG mode.

Switch on VS mode.

Check ALT bug is open.

Check VS bug is filled and magenta on

IFD.

Check control wheel moves forward.

Set VS bug to +1000 ft.

Control wheel moves aft or at least

On the ground the servo does not

tries.

have enough power.

Press AP DISC switch on LH control

Aural warning can be heard.

wheel.

Switch AUTOPILOT MASTER off.

Switch EXT PWR off.

Disconnect external power.

22-10-03

Yaw Servo

Removal

Refer to Figure 22-4.

Detail Steps/Work Items

Key Items

Ensure BATT switch is OFF and no

external power connected.

Remove tail cone access panel.

Disconnect electrical connector from

roll servo.

22 Page 19

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.

Ensure BATT switch is OFF and no

external power connected.

Attach yaw servo with 4 screws to

support bracket.

Insert bridle cable center ball into

leading hole in capstan.

Adjust position of center ball with

12 o’clock position

rudder controls in neutral position.

See Figure 22-4

Wrap bridle cable around capstan 1.5

Cable clamps will be positively

turns each direction from center ball.

guided to correct position

Install cable guards and cover with 4

Tighten screws only snugly against

screws and washers.

servo base plate

Lead upper bridle cable segment

See Figure 22-6 for clamp torquing.

around pulley and install cable clamps

Cable clamps may be rotated on

Adjust bridle cable tension to the

elevator cable to align bridle cable

value given in Subject 22-10-06.

with capstan grooves

Connect electrical connector.

Install tail cone access panel.

Function Test

Detail Steps/Work Items

Key Items

Attach external power to the aircraft.

Check all switches off.

Switch EXT PWR on.

Switch AUTOPILOT MASTER to

MASTER.

Engage heading mode

Switch AUTOPILOT YAW DAMPER on.

Turn YAW TRIM potentiometer to the

left.

Page 22 22

Detail Steps/Work Items

Key Items

Check rudder pulses to the left.

Turn YAW TRIM potentiometer to the

right.

Check rudder pulses to the right.

Press AP DISC switch on LH control

wheel.

Switch AUTOPILOT YAW DAMPER off.

Switch EXT PWR off.

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

Servo RPM @24VDC

setting

(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

22 Page 23

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

Cable Guard

Tension Washer

Figure 22-5

Clutch Torque Adjustment

Detail Steps/Work Items

Key Items

Remove capstan cover from servo with 4

screws and washers.

Draw cotter pin from castle nut.

Insert adapter tool (S-TEC P/N 6622-1) into

leading holes in servo capstan.

Bear dial torque wrench.

Connect servo motor to 28 VDC power

Servo shaft rotates

source.

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

Remove torque wrench and adapter tool.

Align torque value with castle nut - turn CW

to increase and CCW to decrease torque.

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 22

Detail Steps/Work Items

Key Items

Disconnect servo motor.

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).

Re-install capstan cover.

NOTE

After capstan cover has been installed, determine that there is no

interference between capstan and cover.

22-10-05

Driving Wheels

Removal/Installation

Detail Steps/Work Items

Key Items

Draw cotter pin from castle nut.

Remove castle nut.

Remove 2 tension washers.

Remove driving wheel.

IMPORTANT

After removal of driving wheel, clutch

Refer to Section 22-10-04 for

torque adjustment is required.

torque settings.

Install in reverse order of removal.

22-10-06

Bridle Cables

Removal/Installation

Detail Steps/Work Items

Key Items

Unfasten cable clamp bolts as far as

On both ends

necessary to unthread the bridle cable.

Uncoil the bridle cable from the servo.

Install in reverse order of removal.

Observe correct position of

bridle cable center ball. Refer

to applicable servo

Installation Procedure.

22 Page 25

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

Install the bridle cables as per Subject 22-

10-02.

Fix control wheel in neutral position by

hand.

Switch on AUTOPILOT MASTER.

Switch on the VS Mode on the Autopilot

Programmer/Computer.

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.

Loosen cable clamp of the shorter bridle

The tension applied here by

cable end, tension by hand, and retighten

hand allows adjusting the

cable clamp bolts.

bridle cable to the desired

tension.

Switch off AUTOPILOT MASTER.

Check bridle cable tension.

Use a conventional cable

tensiometer.

Repeat procedure if necessary varying

tension on step 6.

Page 26 22

22-10-07

Cable Clamps

Observe the following values when installing/fastening the cable clamps.

Figure 22-6

Cable Clamp Torquing

22-10-08

Trim Servo

Removal/ Installation

Detail Steps/Work Items

Key Items

Ensure BATT switch is OFF and no external

power connected.

Remove tail cone access panel.

Disconnect electrical connector from trim

servo.

Remove swivel from transmission chain.

Remove transmission chain.

Remove 4 bolts and nuts securing servo

support bracket to GFK base.

Remove 4 bolts and nuts securing trim servo

to support bracket.

Move trim servo with driving wheel to the

right fuselage side out of support bracket.

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 22-10-

04 for clutch torque settings.

IMPORTANT

Prior to installing trim servo, check trim tab control system.

Install in reverse order of removal.

Function Test

Detail Steps/Work Items

Key Items

Attach external power to the aircraft.

22 Page 27

Detail Steps/Work Items

Key Items

Check all switches off.

Switch EXT PWR on.

Switch AUTOPILOT PITCH TRIM on.

Move (complete) TRIM switch on the

LH control wheel forward.

Check trim wheel (upper part) turns

forward.

Move (complete) TRIM switch on the

LH control wheel aft.

Check trim wheel (upper part) turns

aft.

Press AP DISC switch on LH control

wheel.

Switch AUTOPILOT PITCH TRIM off.

Switch EXT PWR off.

Disconnect external power.

22-10-09

Trim Servo Clutch

Torque Settings

The following torque setting must be checked and adjusted:

Servo P/N

Clutch Torque

Servo RPM @24VDC

setting

(fixed, not adjustable)

Trim S-TEC 0106-2-T3

36 ± 2 inlbs

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

Draw cotter pin from castle nut.

Insert adapter tool (S-TEC P/N 6622-1) into

leading holes in driving wheel.

Bear dial torque wrench.

Page 28 22

Detail Steps/Work Items

Key Items

Connect servo motor to 28 VDC power

Servo shaft rotates

source.

Read torque value.

See above for appropriate

torque settings. Perform

clutch torque adjustment as

per step 6 - 7,

if necessary

Adjustment

Remove torque wrench and adapter tool.

Align torque value with castle nut - turn CW

to increase and CCW to decrease torque.

Repeat steps 2 to 7, until read torque setting

(step 5) matches value given above.

Disconnect servo motor.

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).

22-10-10

Pressure Transducer

Removal/Installation

Detail Steps/Work Items

Key Items

Ensure BATT switch is OFF and no

external power connected.

Remove tail cone access panel.

Refer to Chapter 51-00-01.

Disconnect electrical connector from

pressure transducer.

Disconnect pressure hose from

Cut cable tie

pressure transducer.

Remove pressure transducer.

2 bolts

Install in reverse sequence of removal.

Fasten pressure hose with new

cable tie.

22 Page 29

22-10-11

Yaw Amplifier

Removal/Installation

Detail Steps/Work Items

Key Items

Ensure BATT switch is OFF and no

external power connected.

Remove tail cone access panel.

Disconnect electrical connector from

yaw amplifier.

Remove pressure yaw amplifier.

4 bolts

Install in reverse sequence of removal.

22-10-12

Programmer/Computer

Removal/Installation

Detail Steps/Work Items

Key Items

Ensure BATT switch is OFF and no

external power connected.

Place a Allen key in hole between REV

Computer will come out.

and ALT key, rotate CCW.

Pull out rest of the way.

Do not pull on VS knob!

Remove programmer/computer

Install in reverse sequence of removal.

Use Allen key, rotate CW until

computer sits firmly in rack, flush

with panel.

Perform heading calibration procedure

Refer to Subject 22-10-00 Heading

Calibration

22-10-13

Turn Coordinator

Removal/Installation

Detail Steps/Work Items

Key Items

Ensure BATT switch is OFF and no

external power connected.

Page 30 22

Table of Contents

23-00-00

GENERAL

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

COM Antennas

................................................................................................. 8

Description.......................................................................................................... 8

Removal/Installation

........................................................................................... 8

23-50-03

NAV Antenna

.................................................................................................... 9

Description.......................................................................................................... 9

Removal/Installation

........................................................................................... 9

23-60-00

STATIC DISCHARGING

............................................................................. 10

General.............................................................................................................. 10

Description........................................................................................................ 10

Figure 23-01

Lightning Protection/Static Discharging System

Page 2 23

Page Date:

11. July 2012

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

Possible Cause

Remedy

Unable to transmit or receive

No power on load bus

Switch on starter/generator or

external power.

Defective AUDIO-MRK breaker

Replace

Unable to transmit or receive

Defective LH IFD

Replace LH IFD

COM I

Unable to transmit or receive

Defective RH IFD

Replace RH IFD

COM II

Unable to transmit with IFD

No or defective antenna cable

Check antenna cable

indication

connections

COM [1/2] TX Fault

Unable to transmit from the

Defective transmit button on

Replace

pilot's side (missing transmit

pilot's side

mode indicator on display)

Defective wiring between

Repair

pilot's transmit button and

radio unit

Unable to transmit from the

Defective transmit button on

Replace

co-pilot's side (missing

co-pilot's side

transmit mode indicator on

Defective wiring between co-

Repair

display)

pilot's transmit button and

radio unit

No modulation when

Defective pilot's headset

Replace

transmitting from pilot's seat

Defective wiring

Repair

23 Page 3

Complaint

Possible Cause

Remedy

No modulation when

Defective co-pilot's headset

Replace

transmitting from co-pilot's

Defective wiring

Repair

seat

Short range in transmit mode;

Defective radio unit

Repair

reception without problems

Short range in receive mode;

Defective radio unit

Repair

signal noise in reception

Short range in transmit and

Defective COMM antenna,

Repair or replace

receive mode; signal noise in

coaxial cable and plug

reception

Speaker silent, headsets

Defective speaker

Replace

operation normal

Defective wiring

Repair

Defective intercom unit

Replace

Transmit mode indicator on

Transmit button stuck

Replace

display is always visible

COM [1/2] Stuck TX

Intercom system inoperative,

Defective intercom unit

Replace

transmit mode O.K.

Defective wiring

Repair

Page 4 23

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.

23 Page 5

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

Ensure BATT switch is OFF and no external

power connected.

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.

Turn the screw counter-clockwise until the

unit disengages from the mounting rack.

Do not pull on the knobs. Do not pry the face plate. You can damage the

CAUTION

unit.

Do not touch the connector card at the rear of the unit. The electrostatic

CAUTION

charge on your body can damage the unit.

Pull the sides of the unit gently to remove it

from the mounting rack.

Install the protective covers on the rear

connectors of the unit.

Installation

Detail Steps/Work Items

Key Items

Remove the protective covers from the rear

connectors of the unit.

Slide the unit into the rack.

Engage the locking screw so that the latch

front lobe touches the rack.

Page 6 23

Detail Steps/Work Items

Key Items

Turn the locking screw clockwise so that the

rear lobe engages the mounting rack.

Do not over-tighten the locking screw. You can damage the locking

CAUTION

mechanism.

Continue to turn the screw until the unit is

fully installed in the mounting rack.

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.

23 Page 7

23-50-02

COM 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 these antennas is

required, contact EXTRA.

Removal/Installation

Detail Steps/Work Items

Key Items

Ensure BATT switch is OFF and no external

power connected.

Disconnect BNC plug.

Remove attachment nuts.

Remove antenna.

Install in reverse sequence of removal.

Ensure lightning protection

sheet is placed between

fuselage structure and ground

plate.

Page 8 23

Page Date:

11. July 2012

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).

Page 10 23

Page Date:

11. July 2012

Table of Contents

24-00-00

GENERAL

Description.......................................................................................................... 3

Figure 24-1

Electrical System Schematic

............................................................................... 4

Figure 24-2

Left Side Panel Switches

..................................................................................... 5

Figure 24-3

Left Side Panel Circuit breakers

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

24-30-20

Standby Alternator

Removal/Installation

24-30-21

Alternator Regulator

Removal/Installation

24-30-30

Battery

Charging with external power

Charging over charger plug

Removal/Installation

24-30-40

Indication

24-30-41

Indicator Cluster

Removal/Installation

24-40-00

EXTERNAL POWER

Description

24-60-00

DISTRIBUTION

Description

24-60-01

E-box

Removal/Installation

24-60-02

Switches

Removal/Installation

24-60-03

Circuit Breakers

Removal/Installation

24-60-04

Relays

24-60-05

Shunts

24-60-06

Fuses

Page 2 24

Extra 500. Maintenance Manual (2012) - page 6