Extra 500. Maintenance Manual (2012)

Permissible Weights and Moments

5.53

4.5

5.5

5.6

6.5

6.8

7.13

450

440

400

Rudder

350

300

290

250

Elevator (LH)

Elevator (RH)

220

200

Aileron

-40

-50

4.0

4.5

5.0

5.5

6.0

6.5

7.0

7.5

0.37

0.50

Trim tab

0.30

0.35

0.40

0.45

0.50

0.55

0.60

0.65

Weights

Aileron LH:

(W)

Aileron RH:

(W)

Rudder:

(W)

Elevator LH:

(W)

Elevator RH:

(W)

Trim Tab:

(W)

Moments

Aileron LH:

(m:)

kg x 9.81m/s

(r:)

cm = (M:)

Ncm

Aileron RH:

(m:)

kg x 9.81m/s

(r:)

cm = (M:)

Ncm

Rudder:

(m:)

9.81m/s

(r:)

cm = (M:)

Ncm

Elevator LH:

(m:)

9.81m/s

(r:)

cm = (M:)

Ncm

Elevator RH:

(m:)

cm = (M:)

Ncm

Trim Tab:

(m:)

9.81m/s

(r:)

cm = (M:)

Ncm

Figure 51-4

Permissible Weights and Moments

Page Date:9. August 2013

51 Page 25

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.

Page 26 51

Page Date:

In order to shorten the curing time, a heater can be used to increase the ambient

temperature.

Too high temperature will cause large air bubbles in the laminate. Local

CAUTION 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.

Page Date:9. August 2013

51 Page 27

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.

Page 28 51

Page Date:

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

Page Date:9. August 2013

51 Page 29

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:

Remove the sanding dust with a pneumatic vacuum cleaner.

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.

Page 30 51

Page Date:

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

For painting of the repair area proceed like mentioned in

Chapter 51-70-06.

Page Date:9. August 2013

51 Page 31

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:

Remove the sanding dust with a pneumatic vacuum cleaner

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

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.

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:

Page 32 51

Page Date:

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.

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 Ratio (laminate thickness : scarf lenght) approx. 1: 50.

Page Date:9. August 2013

51 Page 33

Following the scarf procedure, clean the repair area thoroughly:

Remove the sanding dust with a pneumatic vacuum cleaner

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:

Apply nylon peel ply on the last repair fabric layer.

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.

Lay a jute cloth or equivalent bleeder cloth on this perforated plastic foil.

Lay an air tight plastic foil upon the jute weave and seal their edges to the

surrounding surface using an adhesive tape.

Apply suction with a vacuum pump (pressure approx. .7 bar/ 10 psi).

Apply the thermal curing cycle.

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.

Page 34 51

Page Date:

51-70-04

Repair of Spars and Elements of the Pressure Cabin

IMPORTANT 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 must be considered as a large-scale repair

with a Damage Class 1 (Refer to Chapter 51-10-01 Damage Classification).

EXTRA has to be contacted prior to repair!

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

30 mm (except shell below the wing). Longerons are

integrated in the skin sandwich.

Spars of Wing and Empennage

The spars consist of carbon fibre roving or UD-tape caps, carbon fibre webs

and PMI foam or plywood/honeycomb cores.

51-70-05

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 43.13-1B Chapter 4 (Metal

Structure, Welding and Brazing)" latest change.

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

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.

Page Date:9. August 2013

51 Page 35

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.

Page 36 51

Page Date:

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.

Before stripping parts, remove all fittings, O-rings, nuts, bolts, washers,

CAUTION

pistons, bearing cups, etc.

Clean all metal parts by immersing in a clean degreasing solution. An alkaline

based solution is recommended for aluminium and magnesium parts.

Hardened dirt or grease may be removed with soft bristle brush, or by soaking

in cleaning solution.

Where necessary clean bearing cones carefully in a separate container of clean

solvent.

Do not spin bearing cones with compressed air.

CAUTION

After cleaning, thoroughly dry all metal parts with filtered, dry compressed air.

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.

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.

Before stripping parts, remove all fittings, O-rings, nuts, bolts, washers,

CAUTION

pistons, bearing cups, etc. Parts must be totally immersed in solvent, to

maximize cleaning.

Degrease part as per degreasing paragraph.

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.

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

Page Date:9. August 2013

51 Page 37

entrapment might occur.

Thoroughly dry part with filtered, dry compressed air.

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:

Parts to be repainted should be cleaned and stripped as per instruction in

degreasing and paint removal paragraphs.

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.

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.

Remove excess coating by flushing with clean water.

Paint parts with one coat of wash primer. Allow to dry thoroughly.

Paint parts with one coat of lacquer listed in Section 51-30. Allow to dry

thoroughly before reassembly.

Page 38 51

Page Date:

Table of Contents

52-00-00

GENERAL

Troubleshooting

52-10-00

PASSENGER/CREW

Description

52-10-01

Upper Door Paneling

Removal/Installation

52-10-02

Lower Door Paneling

Removal/Installation

52-10-03

Central Door Operating Device

Removal/Disassembly

Inspection (After Teardown)

Installation/Assembly

52-10-04

Lower Door Operating Device

Removal/Disassembly

Inspection

Installation/Assembly

52-10-05

Door Locking Mechanism

Disassembly/Assembly

Rigging

52-10-06

Door Seal

Removal/Installation

52-10-07

Sill Seal

Removal

Installation

52-10-08

Door Switch

Removal/Installation

Adjustment

52-20-00

EMERGENCY EXIT

Description

52-20-01

Emergency Exit Seal

Removal/Installation

Page 2 52

Page Date: 9. August 2013

52-00-00

GENERAL

Troubleshooting

Complaint

Possible Cause

Remedy

Pressure cabin leakage

Erroneous cabin door or

Check seals for damages and

emergency exit seal

correct installation. If seal is

installation or damaged seal

damaged replace it as per

Section 52-10-06 and 52-20-

Exterior door locking

Rotation of outer door handle

Replace central door operating

mechanism damaged

without previously pulling it

device as per Section 52-10-03

against its stop

Unusual high operating forces

Misadjusted locking

Perform Door Locking

or lacking ability to reach the

mechanism

Mechanism Rigging as per

fully open or closed position

Section 52-10-05

of actuation handles

Lacking lubrication

Remove door paneling, clean

and lubricate mechanism

Damaged or worn locking

Replace damaged or worn

mechanism

parts. Perform Door Locking

Mechanism Rigging. Refer to

Section 52-10-05

Faultive mechanical locking

Mechanically damaged

Replace damaged or worn

indication (8 sight glasses)

indication or locking

parts. Perform Door Locking

mechanism

Mechanism Rigging. Refer to

Section 52-10-05

Door warning light does not

Light, wiring or switch

Identify and replace

illuminate with door open

defective

component as per Section 52-

10-07.

Door switch misadjusted

Perform Door Switch

Adjustment as per Section 52-

10-07.

Door warning light illuminates

Wiring or switch defective

Identify and replace

in spite of closed door

component as per Section 52-

10-07.

Door switch misadjusted

Perform Door Switch

Adjustment as per Section 52-

10-07.

Page Date:

52 Page 3

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.

Upper door could damage the left wing flap.

CAUTION Ensure wing flaps are retracted before opening the door.

For opening the door from outside, pull outer handle completely out, 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 inner 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.

Door locking pins could damage the door frame.

CAUTION Ensure handles are in the open position before closing upper or 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.

Page 4 52

Page Date: 9. August 2013

52-10-01

Upper Door Paneling

Removal/Installation

Refer to Figure 52-1

Detail Steps/Work Items

Key Items

Open door completely.

Remove button housing, safety button (4),

4 bolts

inner handle (3) and spring.

see also Figure 52-2

Not supported upper door could cause injuries by lodging.

WARNING

Let a helping person hold the upper door in open position.

Close upper door with care.

Disconnect telescopic (2) lift cylinder from

the door.

Remove the upper door paneling (1).

9 screws

Install in reverse sequence of removal.

52-10-02

Lower Door Paneling

Removal/Installation

Refer to Figure 52-1

Detail Steps/Work Items

Key Items

Open door completely.

Remove sill lever handle doubler (10) from

2 bolts

lower door actuator lever.

Remove the clamping strip (11).

Not arrested lower door could damage aircraft structure and lower door

CAUTION

hinges.

Support lower door at sufficient height, when removing the arresting

cables.

Disconnect arresting cables (6) from door

frame.

Remove the lower door paneling (7).

4 screws

Install in reverse sequence of removal.

2 bolts of step 2 must be

installed with Loctite 243

Page 6 52

Page Date:

52-10-03

Central Door Operating Device

Removal/Disassembly

Refer to Figure 52-2

Detail Steps/Work Items

Key Items

Remove the upper door paneling.

Refer to Chapter 52-10-01

Disconnect pushrods and gas spring from

actuator (11) and inner handle bearer (6).

Remove slotted spring pin (7) holding the

Relieve spring by pulling at

spring (8).

the spring eye with a bent

wire.

Remove inner handle bearer (6).

Remove slotted spring pin (9).

Remove inner guide pin (10).

Remove actuator (11).

Remove slotted set screw (15).

Remove outer guide pin (16).

Remove shafting axle (18) including outer

handle (20).

Remove collar bushing (17).

Remove dowel pin (19) to take out the

Dowel pin is glued in with

spring (8).

Loctite 243

Remove flange bushings (12).

Remove outer handle bearing (13)

4 bolts

Separate outer handle (20) from shafting

4 bolts

axle (18).

Remove slotted spring pin (3) from safety

button (2).

Inspection (After Teardown)

Refer to Figure 52-2

Detail Steps/Work Items

Key Items

Inspect sliding surfaces for damage and

Replace parts if necessary

cracks.

Inspect the shafting axle (18) slot for burrs

and torsional bending.

Inspect guide pins (10/16) for wear.

Replace parts if necessary

Inspect slotted spring pins (3/7/9) for

Replace parts if necessary

bending or other damage.

Page Date:

52 Page 7

Detail Steps/Work Items

Key Items

Check springs (5/8) for general condition

Replace parts if necessary

Installation/Assembly

Refer to Figure 52-2

Detail Steps/Work Items

Key Items

Install/assemble in reverse sequence of

Observe the following items.

removal/disassembly

Clean all parts (incl. rod ends and ball joint

bearings) and mount with MIL-PRF-81322.

Glue in dowel pin (19) with Loctite 243.

When installing the inner guide pin (10) let

the related slotted spring pin (9) protrude

6 mm from the actuator (11) flange plane to

allow later removal.

Page 8 52

Page Date: 9. August 2013

52-10-04

Lower Door Operating Device

Removal/Disassembly

Refer to Figure 52-3

Detail Steps/Work Items

Key Items

Open lower door completely.

Remove handle from actuator lever

2 bolts

Remove the clamping strip.

Not arrested lower door could damage aircraft structure and lower door

CAUTION

hinges.

Support lower door at sufficient height, when removing the arresting

cables.

Disconnect arresting cables (7) from door

frame.

Remove the lower door paneling.

4 screws

Disconnect pushrods (1) from actuator (5).

Remove shims (4).

Lift actuator (5) from bearing bolt (7) and

remove, while guiding actuator lever

through the slot.

Disassemble actuator parts (9, 10) by

removing the slotted spring pin (8).

Inspection

Refer to Figure 52-3.

Replace 2.5 x 12 slotted spring pin (8) with 3 x 12 when play is detected.

Installation/Assembly

Detail Steps/Work Items

Key Items

Install/assemble in reverse sequence of

Observe the following item2.

removal/disassembly

Clean all parts (incl. rod ends and ball joint

bearings) and mount with MIL-PRF-81322.

Install 2 bolts of removal/disassembly with

Loctite 243

Page 10 52

Page Date: 9. August 2013

52-10-05

Door Locking Mechanism

Refer to Figure 52-4

Disassembly/Assembly

Disconnect the pushpull rods (2) from bellcranks (1) using standard practices.

Remove bellcranks (1), locking pin guidance (5), and door safety indicators (8)

by removing respective attaching bolts. Assemble in reverse sequence of

disassembly. Install safety wire where necessary.

Rigging

The general procedure begins with the respective door handle, which has to be

placed to the closed position. Then the following items have to be checked and

adjusted in the given sequence:

• bellcrank (1) installation angles

• gaps between locking pin linkage (9) and locking pin guidance (5)

• mounting of the door safety indicators (8)

• hook (4) position

Detail Steps/Work Items

Key Items

Close door from inside and check hooks (4)

Notice deviation from correct

lock completely. Check hole (5, Figure 52-

hook or safety indicator

1) must be visible. Check proper indication

position for later adjustment.

(green) of door safety indicators (8).

Remove door paneling.

Refer to Chapter 52-10-01/02

Damage to the door frame by the door locking pins (3) may occur, when

CAUTION

placing the door handle to the closed position and when moving the

door.

Observe the locking pins when working on the door.

Place upper door handle resp. sill lever to

If closed position cannot be

the closed position.

reached, adjust adjacent

pushrods.

Check gap between locking pin linkage (9,

If gap is detected, follow

Figure 52-4) and locking pin guidance (5) at

steps a and b.

all locking pins (3). No gap allowed.

Adjust pushrods to correct bellcrank (1)

Bellcrank angles on Figure

installation angles as per Figure 52-4, if

52-4 are given for the closed

applicable.

position.

Adjust pushrods (2) between bellcranks (1)

to minimize gap.

Check mounting of safety indicators (8).

Correct, if necessary

Adjust pushrods (2) to correct hook (4)

position, if necessary.

Reinstall door paneling.

Refer to Chapter 52-10-01/02

Page 12 52

Page Date: 9. August 2013

52-10-06

Door Seal

Up to serial number 1002 the cable of the door switch has to be disconnected

prior to removal of the door seal frame. Follow the Door Switch

Removal/Installation procedure as far as necessary to disconnect the cable.

Removal/Installation

Detail Steps/Work Items

Key Items

Not supported upper door could cause injuries by lodging.

WARNING

Let a helping person hold the upper door in open position.

Close upper door with care.

Disconnect telescopic (2, Figure 52-1) lift

cylinder from the door.

Not arrested lower door could damage aircraft structure and lower door

CAUTION

hinges.

Support lower door at sufficient height, when removing the arresting

cables.

Disconnect arresting cables (7, Figure 52-1)

from door frame.

Remove door threshold plate.

5 screws, hook-and-loop

fastener

Remove door seal frame.

34 screws

Remove door seal from frame.

Mark seal position on frame

Install in reverse sequence of removal.

Provisionally fix the seal to

the frame with tape. Remove

tape after frame installation.

Page 14 52

Page Date: 9. August 2013

52-10-07

Sill Seal

The gap between upper and lower door is sealed by means of the sill seal.

Removal

Refer to Figure 52-5.

Detail Steps/Work Items

Key Items

Open upper and lower door

Remove handle doubler (10, Figure 52-1)

from sill lever.

Remove sill seal frame (2, Figure 52-5).

5 bolts (1)

Remove sill seal (3) and corner seals (6).

Installation

Xdate

Refer to Figure 52-5.

Detail Steps/Work Items

Key Items

Cut the sill seal (3) to the shape and length

as outlined on Figure 52-5. Ensure that the

curve on the sill seal ends match the shape

of the door seal (8). Refer to Detail A.

Cut a foam rubber plug (4) of 35 mm length

Refer to Chapter 51-30-05

and glue into the ends of the sill seal (3).

Foam Rubber

Dow Corning 732. Follow the

instructions of the data and

safety sheet.

Place the sill seal (3) to the sill (5).

Install the sill seal frame (2).

5 bolts (1)

Clean the adherent surfaces of the corner

seals (6) with Aceton.

Glue the corner seals (6) on the door seam

Dow Corning 732. Follow the

(7) and on the sill seal (3).

instructions of the data and

safety sheet.

Install the handle doubler (10, Figure 52-1)

to the sill lever.

Page Date:9. August 2013

52 Page 15

52-10-08

Door Switch

The door switch (6, Figure 52-4) is located on the upper door next to the upper

left door safety indicator. Electrical connectors are located next to the switch

and/or under the upper side paneling.

Removal/Installation

Detail Steps/Work Items

Key Items

Remove upper door paneling.

Refer to Section 52-10-01

Disconnect wiring from door switch.

Remove the switch.

2 bolts

Install in reverse sequence of removal.

Adjustment

Detail Steps/Work Items

Key Items

Remove upper door paneling.

Refer to Section 52-10-01

Adjust the door switch (6) by bending the

The switch shall trigger

trigger sheet (7, Figure 52-4).

(“click”) just before the door

handle locks.

Reinstall upper door paneling.

Page Date:9. August 2013

52 Page 17

Extra 500. Maintenance Manual (2012) - page 14