Extra 500. Maintenance Manual (2012)

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.

52-20-01

Emergency Exit Seal

Removal/Installation

Detail Steps/Work Items

Key Items

Remove emergency exit.

Remove seal frame.

11 screws

Remove seal from frame.

Install in reverse sequence of removal.

Install safety wire to emergency exit handle.

Cu/Cu 0.25 x 0.25

Page 18 52

Page Date:

Table of Contents

55-00-00

GENERAL

Description

55-10-00

HORIZONTAL STABILIZER

Description

Figure 55-1

Overview Horizontal Stabilizer

Removal

Installation

Figure 55-2

Trim Control Box

55-10-01

Horizontal Stabilizer Main Bolts

Inspection

55-20-00

ELEVATOR

Description

Figure 55-3

Elevator Control Surface (LH)

Figure 55-4

Elevator Control Surface (RH)

Figure 55-5

Elevator Trim Tab, (on RH elev. only)

55-30-00

VERTICAL STABILIZER

Description

55-30-01

Fin Tip

Removal/Installation

Figure 55-6

Fin Tip

55-40-00

RUDDER

Description

Figure 55-7

Overview Rudder Mounting

Figure 55-8

Bottom Rudder Mounting (including bell crank and centering device)

Figure 55-9

Middle and Upper Rudder Mounting

Page 2 55

Page Date: 9. August 2013

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.

Page 4 55

Removal

Refer to Figure 55-2.

Detail Steps/Work Items

Key Items

Remove fin tip.

Refer to Chapter 55-30-01

Remove elevator.

Refer to Chapter 27-30-00

Remove central horizontal stabilizer access

Refer to Chapter 51-00-01

panel

Remove pitch trim access panel

Refer to Chapter 51-00-01

Adjust pitch trim to N-position.

Remove upper part of middle console

Refer to Chapter 25-10-26

paneling.

Mark N-position of pitch trim indicator (6)

on the pitch trim control box (1) with tape.

Remove set screw (2).

Reinstall trim wheel (4) and screw (5).

Rotate trim wheel to the nose down

Observe movement of trim

direction until trim cable core is

tab actuator.

disconnected from the trim tab actuator in

the horizontal stabilizer.

Rotate a half turn further (to make sure trim

cable end is inside the trim cable flex

casing).

Disconnect trim cable flex casing from

actuator. Plug openings.

Disconnect de-icing boot pressure lines.

Plug holes.

CAUTION

Risk of main bolt thread ends damage due to hammer stroke.

Drive out main bolts using a short steel tube.

Remove horizontal stabilizer main bolts.

4 bolts, washers and nuts

Remove horizontal stabilizer.

Weight approx. 20 kg

Installation

Refer to Figure 55-2.

Detail Steps/Work Items

Key Items

Position horizontal stabilizer on the top of

the vertical stabilizer.

Install main bolts with MIL-PRF-81322.

Secure with safety wire.

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Page Date: 9. August 2013

Detail Steps/Work Items

Key Items

Connect trim cable flex casing to actuator.

Secure with safety wire.

Install central horizontal stabilizer access

Refer to Chapter 51-00-01

panel

Connect de-icing boot pressure lines.

Install elevator.

Refer to Chapter 27-30-00

Adjust elevator to neutral.

Rotate trim wheel to the nose up direction

until trim tab is in straight line with elevator

and horizontal stabilizer.

Adjust trim indicator (6) until the N-position

match the mark on the pitch trim control box

(1).

Rotate round nut (3) until thread hole is

visible in the guide slot.

Install set screw (2) with Loctite 243.

Install upper part of middle console

Refer to Chapter 25-10-26

paneling.

Install pitch trim access panel

Refer to Chapter 51-00-01

Install fin tip.

Refer to Chapter 55-30-01

Page Date:9. August 2013

55 Page 7

55-10-01

Horizontal Stabilizer Main Bolts

Inspection

Detail Steps/Work Items

Key Items

Remove fin tip.

Refer to Chapter 55-30-01

Remove central horizontal stabilizer access

Refer to Chapter 51-00-01

panel

CAUTION

Risk of main bolt thread ends damage due to hammer stroke.

Drive out main bolts using a short steel tube.

Remove one main bolt.

Inspect bolt shanks for cracks, wear,

Replace if necessary

corrosion and insecurity.

Reinstall main bolt.

Follow steps 3 thru 5 for the other bolts.

Reinstall central horizontal stabilizer access

Refer to Chapter 51-00-01

panel.

Reinstall fin tip.

Refer to Chapter 55-30-01

Page Date:

55 Page 9

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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Page Date: 9. August 2013

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

Removal/Installation

Refer to Figure 55-6.

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.

Remove LH and RH gap fairing.

Refer to Chapter 51-00-01

Remove fin tip attaching bolts.

10 bolts

Lift fin tip some centimeters.

Disconnect strobe light power supply

In the front section

connectors.

Disconnect NAV antenna wiring BNC

From serial N° 1003

connector.

Remove fin tip.

Reverse polarity of the input power, for just an instant, will

CAUTION

permanently damage power supply. This damage is sometimes not

immediately apparent, but will cause failure later on. Black lead is

negative.

Install in reverse sequence of removal.

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Page Date: 9. August 2013

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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Page Date: 9. August 2013

Notes (∆) on Figure 55-8 and Figure 55-9:

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).

Page Date:

55 Page 19

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. If cracks are detected, the window has to be replaced

before the aircraft is operated in pressurized mode again.

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.

Page Date:

56 Page 3

56-10-00

FLIGHT COMPARTMENT

56-10-01

Windshield

Description

The EXTRA 500 is equipped with a two piece windshield divided by a

structural middle 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 again made from

stretched 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.

The windshield is attached to the fuselage structure with bolts. On the outside

of the windshield the bonding to the fuselage structure is realized by means of

an outer frame (refer to Figure 56-1). If the attachment bolts are to be covered

by paint, an optional outer frame cover consisting of one layer 92110 glass

fabric can be installed.

Removal

Refer to Figure 56-1.

Detail Steps/Work Items

Key Items

Remove front ceiling paneling, upper side

Refer to Chapter 25

paneling, LH and RH armrest paneling and

windshield middle strut paneling.

Remove main panels and glareshield.

Refer to Chapter 31

Remove windshield attachment nuts and

outer frame attachment nuts.

Peel off complete outer frame cover.

Remove respective windshield attachment

bolts and all outer frame attachment bolts.

Remove complete outer frame.

Remove residual PR1829B sealant.

Disconnect electrical wiring from

windshield heat (left side only).

Release windshield from Ottoseal S72 using

a cutter knife.

Remove windshield.

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Page Date: 9. August 2013

Sectional View Outer Windshield Attachment

Aluminum bushing

Rubber bushing

Outer frame cover

Outer frame

PR1829B

~2,5 mm

Fuselage

Windshield

structure

frame

Ottoseal S72

Silicone gasket seal

Outer frame attachment bolt

Windshield attachment bolt

Sectional View Middle Strut Windshield Attachment

Aluminum bushing

Outer frame cover

Rubber bushing

Outer frame

PR1829B

~3 mm

Windshield

Ottoseal S72

Silicone gasket seal

Middle strut

Windshield attachment bolt

Figure 56-1

Windshield Installation

Page 6 56

Page Date:9. August 2013

Installation

The new windshield is delivered without holes for bolt attachments. The holes

must be drilled to ensure matching the hole pattern of the structure and outer

frame. Refer to Figure 56-1.

Detail Steps/Work Items

Key Items

Place the windshield on the Silicone gasket

seal on the fuselage structure frame.

Adjust windshield position to receive

(~2,5 mm gap windshield to

minimum possible deviations from given

fuselage structure frame and

clearance.

~3 mm gap windshield to

windshield)

Place the outer frame on the windshields.

Prefix the windshield and the outer frame to

this position. Place shims to the gaps. Use

tape to fix the outer frame to the windshield.

Select 5 or 6 positions for pre-attachment of

the windshield.

Predrill 4 mm holes from both sides of the

Refer to Steps 1 and 2 of

windshield on selected positions. Drill with

Figure 56-2

reduced rotational speed. Plexiglass shall

not melt. Use a plexiglass-drill.

Pre-attach the windshield using 5 or 6

M4 bolts.

Predrill 4 mm holes on the remaining

Refer to Steps 1 and 2 of

attachment points.

Figure 56-2

Remove pre-attaching bolts and remove

outer frame and windshield.

Place the windshield on a cushioned surface

Drill in two phases. Refer to

and drill the remaining final 12 mm holes.

Step 3 of Figure 56-2

Add a 45° 1 mm chamfer on both sides of

Refer to Step 4 of Figure 56-2

each bore hole.

Install aluminum and rubber bushings.

Place the windshield to the fuselage

structure frame.

Adjust windshield as before and place the

outer frame on the windshield to check if

holes match.

Remove outer frame.

Note

Surfaces are difficult to clean from PR1829B.

Apply tape to windshield and structure parts where PR1829B shall not

adhere.

Page Date:9. August 2013

56 Page 7

Detail Steps/Work Items

Key Items

Apply PR1829B to the windshield in the

Refer to PR1829B data and

area of outer frame. Outer frame shall

safety sheet especially for

slightly swim on the PR1829B before

curing time and conditions.

fastening the bolts.

Work in several phases when applying

PR1829B to avoid drying before attachment

of outer frame. Begin in the area of middle

strut. Then work towards the sides. Refer to

Figure 56-3.

Place the outer frame on the windshield.

Bend the outer frame to allow application of

PR1829B in later phases.

Install the attachment bolts in the area where

PR1829B is applied and tighten nuts to 3

thru 3.5 Nm (26 thru 31 in.lbs).

Remove projecting PR1829B after complete

Clean with isopropyl alcohol

installation of outer frame.

as long PR1829B is not yet

hardened.

Connect electrical wiring

Apply Ottoseal S72 to the gap between

Refer to Ottoseal S72 data

inner side of windshield and fuselage

and safety sheet especially for

structure frame/middle strut.

curing time and conditions.

Apply 1 layer 92110 glass fiber to build new

Refer to Chapter 51

outer frame cover.

Apply paint.

Refer to Chapter 51

Install glarshield and main panels.

Refer to Chapter 31

Install windshield middle strut paneling, LH

Refer to Chapter 25

and RH armrest paneling, upper side

paneling and front ceiling paneling.

Page 8 56

Page Date: 9. August 2013

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.

To adjust the windows relative to the aircraft contour, spacers

(GFK or

equivalent) are used (refer to Figure 56-4).

If the attachment bolts are to be covered by paint, an optional cover consisting

of one layer 92110 glass fabric can be installed.

Removal

Refer to Figure 56-4.

Detail Steps/Work Items

Key Items

Remove respective paneling.

Refer to Chapter 25 or 52

Remove window attachment nuts.

Release frame from Ottoseal S72 using a

cutter knife.

Remove frame.

Peel off cover (if installed).

Remove window attachment bolts.

Release window from Ottoseal S72 using a

cutter knife.

Remove window.

Remove residual Ottoseal S72 sealant.

Replace damaged spacers

Remove aluminum and rubber bushings

Replace damaged bushings.

from old window for later transfer to the

new window.

Page Date:

56 Page 11

Sectional View Window Attachment

Aluminum bushing

Spacer

Rubber bushing

Frame

Ottoseal S72

Fuselage

1-3 mm

structure

Window

1-3 mm

Ottoseal S72

Spacer

Cover

Window attachment bolt

Figure 56-4

Window Installation

Installation

Refer to Figure 56-4.

Detail Steps/Work Items

Key Items

Install aluminum and rubber bushings to the

new window.

Place the window to the fuselage structure.

Adjust window position to match the

existing hole pattern.

Check if the outer window contour follows

Minimum spacer thickness:

the fuselage shape. Change spacers if

1 mm

necessary.

Apply Ottoseal S72 to the fuselage structure

Refer to Ottoseal S72 data

frame as outlined on Figure 56-4.

and safety sheet.

Place the window to the fuselage structure

and adjust window as before.

Place spacers on the windshield in the area

Minimum spacer thickness:

of frame. Spacer thickness shall match the

1 mm

vertical extension of aluminum bushings.

Page 12 56

Page Date: 9. August 2013

Extra 500. Maintenance Manual (2012) - page 15