Content      ..     14      15      16      17     ..

Extra 500. Maintenance Manual (2012) - page 16

Detail Steps/Work Items

Key Items

8

Apply Ottoseal S72 to the window in the

area of the frame as outlined on Figure 56-4.

9

Install frame.

10

Install the window attachment bolts and

tighten nuts to 3 thru 3.5 Nm (26 thru 31

in.lbs).

11

Complete Ottoseal S72 where necessary and

For curing time and

flatten with low surface tension water.

conditions refer to Ottoseal

S72 data sheet.

12

Apply 1 layer 92110 glass fiber to build new

Refer to Chapter 51

cover, if applicable.

13

Apply paint, if applicable.

Refer to Chapter 51

14

Install paneling,

Refer to Chapter 25 or 52

Page Date:9. August 2013

56 Page 13

57-10-00

CENTER WING

Description

The wing fuselage attachment fittings are a conventional steel design. Two

fittings are bolted to a forward fuselage frame , another two fittings are bolted

to an aft fuselage frame providing four wing attachment lugs. These lugs match

four bushings, two in the main spar and two in the aft spar of the wing. The

connection is completed by four high strength corrosion resistant steel bolts

installed against flight direction. The lugs of the fuselage fittings feature a high

quality thermoplastic liner for bolt surface protection. The design satisfies fail

safe requirements, any single bolt may fail.

Removal

Refer to Figure 57-1 and Figure 57-2. Wing removal is done by hoisting the

wing, removing the fuselage beneath it and lowering the wing on suitable

supports. The weight of the (dry) wing including flaps and ailerons is less than

300kg. Be sure that your hoist assembly and lifting straps provide enough load

bearing capacity.

Special tools required for wing removal:

EA-15001.2w

(bolt extractor, drawing or tool itself available from EXTRA)

Detail Steps/Work Items

Key Items

1

Ensure BATT switch is OFF and no external

power connected.

2

Drain all fuel

3

Remove two avionic bay access panels, the

Refer to Chapter 51-00-01

wing center fairing. and the fuel sump

access panels.

4

Remove all screws attaching the fuselage

Don’t forget the two screws

skin to the wing.

underneath the flaps.

5

Disconnect all electric connectors in the

Required tools are available

avionic bay and center wing nose section.

at a standard avionic shop.

6

Disconnect the main bonding connection in

Hex nut on stud bolt

the left forward section of the avionic bay

7

Disconnect tubing for pitot static system and

de-ice boots, protect open lines against

FOD.

8

Disconnect aileron control cables.

Three turnbuckles in wing

nose section

refer to Chapter 27

9

Disconnect all fuel supply lines (one on

Refer to Chapter 28-20-06

each side).

Page 4 57

Page Date:

10

Disconnect fuel lines running from and to

Accessible after removal of

the jet pumps.

avionic bay access panels

11

Carefully separate the silicone sealing

between fuselage and wing with a sharp

knife.

12

Sling two industrial hoisting straps (at least

It is helpful to use specially

2” wide) around the wing center section.

bended welding wire or

similar to get the straps

through the gap between

wing and fuselage.

13

Install the hoisting assembly and relieve the

wing fuselage connection. Take care of the

attachment flange of the center panel when

loading the straps, use wooden blocks or

similar to protect the flange. Be sure to

attach the hoisting assembly above the

wings center of gravity to avoid a nose or

tail heavy condition when lifting it. The

wing weight is approx. 250 kg (551 lbs). Be

sure to provide a lifting force appropriate to

this weight to avoid damage to the remai-

ning attachment points by uncontrolled wing

movement. This is likely to occur when the

attachment bolts are fix, but the wing

connections are not fix in all directions any

more.

14

Remove safety plates at main spar bolts

(also removes electric bonding strips) and

safety wire at rear spar securing bolts.

Remove rear spar securing washers and

bolts (concentric bolt M10)

NOTE

Be sure to have at least one person on suitable supports at each wing tip

before extracting the second bolt to counteract any undesirable

movement of the wing.

NOTE

It is advisable to begin with both bolts on one side to get a feel for the

proper relief tension of the hoist assembly while the wing is able to

swivel around the remaining bolts.

15

Extract the attachment bolts with special

Extracting tool EA-15001.2w

tool.

required

(See Chapter 01-00-02)

16

Slowly lift the wing from the fuselage and

take care of the electric wiring.

57 Page 5

17

As soon as the wing is completely free

remove the fuselage underneath the wing

and lower the wing on suitable supports

with protective lining. (Foam, carpet or

similar). The wing should be supported

underneath structural ribs, preferably the

ribs in front of the gap between the inner

and outer flap.

Installation

Install in reverse order of removal

Install wing attachment bolts with grease.

Aeroshell Grease 22c

Observe special torque values for:

Refer to chapter 20-10-04

Securing bolt rear bolts (Bolt M10)

retaining sheets front bolts (two Bolts M5)

Side view

Wing hoisting straps

approximate location of CG for lifting wing

Top view

wing attachment bolts

Figure 57-1

Hoisting the Wing

Page 6 57

Page Date:

Figure 57-2

Wing to Fuselage Attachment

57 Page 7

57-50-00

TRAILING EDGE AND TRAILING EDGE DEVICES

57-50-01

Flaps

Description

Refer to Figure 57-3 and Figure 57-4.The flaps are of one spar dual torsion box

all-CFRP-composite construction. For structural reason each flap is divided in

two parts. The inboard part extends from Y ± 550 to Y ± 2550, the outboard

from Y ± 2550 to Y ± 4400.

For adjustment of flap actuation, guidance and position indicating refer to

Chapter 27.

Removal/Installation

Move flaps to 30° position (wing flap position switch at right main panel).

Perform the following steps for LH and RH side flaps each.

Detail Steps/Work Items

Key Items

Pull circuit breakers FLAP and FLAP CTRL at left side circuit breaker

WARNING

panel

1

Remove safety wire from ball at connection

rod to watchdog potentiometer

2

Disconnect ball from connecting rod

Take care not to move or loosen arm from shaft. Otherwise

CAUTION

readjustment will be required as per Ch. 27-50-00

3

Disconnect bolts connecting inner and outer

1 hex bolt each

transmission rod to flap bracket

4

Disconnect 2 hex bolts at middle flap track

5

Remove inner flap segment from inboard

It is recommended to get

guidance keyway

some assistance

6

Remove outer flap segment from outboard

It is recommended to get

guidance keyway

some assistance

Before re-installation, perform flap track adjustment as per

CAUTION

Ch. 27-50-00

Install in reverse sequence of removal

57 Page 9

Figure 57-3

Inner Flap Structure

Page 10 57

Page Date:

Figure 57-4

Outer Flap Structure

57 Page 11

Figure 57-5

Aileron Structure

57 Page 13

Troubleshooting

Complaint

Possible Cause

Remedy

Excessive vibration, rough

Propeller unbalanced

Dynamically balance propeller

running

according to engine

manufacturer’s information

Icing

Switch on propeller de-icing

Blade damage

Foreign object damage

Repair or replace propeller

according to propeller

manufacturer’s instruction

Spinner or backplate damage

Foreign object or handling

Replace by airworthy parts

damage

Blade play

Blade bearing loose

Refer to propeller

manufacturer’s instruction

Hub damage

Propeller loose on crankshaft

Refer to engine and propeller

manufacturer’s instruction

Improper RPM

Propeller pitch setting out of

Adjust propeller governor

limits

speed stop acc. to engine

manufacturer's instruction

(LOAP 1), Chapter 73-20-01,

Page 203.

Governor setting out of limits

Refer to engine

manufacturer’s instruction

Malfunctioning propeller

Replace governor, for

governor

adjustment see engine

manufacturer’s instruction

Sluggish RPM change

Cold oil

Run engine until normal

operating oil temperature is

reached

Propeller pitch control

Refer to propeller

mechanism defective on

manufacturer’s instruction

Surging RPM

Trapped air in propeller piston

Cycle propeller control to

bleed trapped air

Engine power surge

Refer to engine section,

chapter 72

Abrupt control movement

Move controls carefully

Propeller pitch control

Refer to propeller

mechanism defective

manufacturer’s instruction

Governor defective

Replace governor

Page 4 61

Page Date:

Complaint

Possible Cause

Remedy

RPM changes at constant

Excessive hub friction

Refer to propeller

propeller setting

manufacturer’s instruction

Excessive governor friction

Replace governor

Oil leakage or hot oil

Check for leaks, replace

gasket, decrease oil

temperature

Propeller pitch control

Refer to propeller

mechanism defective

manufacturer’s instruction

Oil leakage

Damaged gasket

Replace gasket or repair

propeller

Loss of blade bearing grease

Refer to propeller

manufacturer’s instruction

No effect of condition lever

Connection detached

Restore connection

control

RPM control bracket defective

Restore or replace bracket

Bowden cable broken

Replace Bowden cable

Bowden cable binding

Replace Bowden cable

61 Page 5

71-00-00

GENERAL

For specific repair and replacement information refer to Rolls-Royce 250-B17F

Series Engine Operation and Maintenance Manual (LOAP 1).

Troubleshooting

For troubleshooting refer to Table 101 of the above-mentioned Manual.

71-10-01

Engine

Removal

Detail Steps/Work Items

Key Items

1

Set FUEL SELECTOR VALVE to OFF.

2

Switch off all electrical power, disconnect

battery.

3

As the balance of the aircraft will

dramatically change, put a support under the

tail.

4

Remove upper and lower cowlings.

Refer to subjects 71-10-01, -

02, -03

5

Remove propeller.

Refer to MT - Propeller

Operation and Installation

Manual E-610 (LOAP 3)

6

Remove beta-valve.

Refer to Rolls-Royce 250-

B17F Series Engine

Operation and Maintenance

Manual (LOAP 1), Chapter

76-10-02

7

Remove brush-block including mounting

from engine.

8

Remove engine inlet.

Refer to Subject 71-60-01

9

Remove exhaust stacks.

Refer to Ch. 78-00-01/02

10

Remove bleed air hoses.

11

Remove two sonic venturis. Plug holes.

12

Remove starter generator.

Refer to Chapter 24-30-10

13

Disconnect power line ignition.

14

Disconnect the bonding braid on the ignition

exciter attachment bolt.

71 Page 3

Detail Steps/Work Items

Key Items

15

Disconnect the electrical wiring from the

chip detection sensors.

Fuel may be pressurized (30 psi max). Fuel may spill. Protect yourself

WARNING

and catch spilling fuel in a suitable container.

16

Disconnect fuel hose at engine fuel inlet.

Plug hole and line.

17

Remove fuel manifold from aft engine fire-

shield.

18

Disconnect the fuel pressure sense line and

fitting. Plug hole and line.

19

Remove fuel drain lines from engine fire-

shield.

20

Remove fuel drain hose from combustion

chamber. Plug fitting.

21

Remove engine control mounting bracket

Refer to Chapter 76-10-01

22

Remove gearbox vent line and fitting from

engine. Plug hole and line.

23

Disconnect thermocouple wiring from

Refer to Chapter 77-20-01

terminal block on RH engine fire-shield.

24

Remove terminal block from RH engine

Refer to Chapter 77-20-02

fire-shield.

25

Remove oil vent line and fitting from

engine. Plug hole and line.

26

Remove oil vent ‘check valve T’ and

connecting hoses.

27

Remove TRQ sense line and fitting. Plug

RH forward gearbox

hole and line.

28

Remove oil pressure sense line and fitting.

LH forward gearbox

Plug hole and line.

29

Drain oil system.

Refer to Chapter 79-00-00

30

Remove ‘oil in’ hose.

31

Disconnect electrical connector oil

temperature sensor.

32

Loosen counter nut of ‘oil in’ fitting,

remove fitting. Plug hole and line.

33

Remove ‘oil out’ tube and fitting. Plug

check valve and line.

34

Remove external scavenge oil filter.

Refer to Chapter 79-20-01

35

Disconnect electrical connectors of engine

above engine fire-shield

anti-ice and propeller overspeed test.

Page 4 71

Detail Steps/Work Items

Key Items

36

Disconnect electrical wiring standby

alternator.

37

Disconnect lightning cable and bonding

braid from standby alternator RH

attachment stud.

38

Check engine is fully disconnected except

main attachment points.

39

Remove upper main attachment bolt.

Mark bolts and nuts as used.

40

Hoist engine slightly though upper shock-

Hoisting structure must be

mount bolt hole.

able to carry at least 150 kg

(300 lbs). Align hoist exactly

above shock-mount.

41

Support the engine at the combustion

chamber.

42

Remove both side main attachment bolts.

Mark bolts and nuts as used.

43

Lower engine 5-10cm (2-4 inch) and pull

the engine out straight forward.

44

Remove the side shock-mounts.

Refer to Subject 71-20-01

45

Perform preservation and storage

Refer to Rolls-Royce 250-

precautions.

B17F Series Engine

Operation and Maintenance

Manual (LOAP 1)

46

Remove upper shock-mount when engine is

Refer to Subject 71-20-01

securely stored.

47

Remove standby alternator from engine

Refer to Chapter 24-30-20

48

Remove gas generator turbine tachometer

Refer to Chapter 77-00-01

49

Remove propeller/power turbine RPM

Refer to Chapter 77-10-02

sensor.

Installation

Detail Steps/Work Items

Key Items

1

Remove engine from container.

Refer to Engine Maintenance

Manual

2

Install in reverse sequence of removal.

Observe the following steps.

3

Torque main attachment bolts 32 Nm

(283 lbs-inch), use new bolts and nuts

4

Use new packings where necessary.

5

Perform engine control rigging check

Refer to Chapter 76-00-00

71 Page 5

Detail Steps/Work Items

Key Items

NOTE

The propeller must be dynamically balanced if a new engine or new

propeller is installed. Refer to Rolls-Royce

250-B17F Series Engine

Operation and Maintenance Manual (LOAP 1)

6

Perform applicable engine run tests.

Refer to Rolls-Royce 250-

B17F Series Engine

Operation and Maintenance

Manual (LOAP 1), Chapter

72-00-00

7

Perform engine indication check (TOT only)

Refer to Chapter 77-00-00

71-10-00

Cowling

The EXTRA 500 cowling consists of three parts:

• Upper left cowling

• Upper right cowling

• Lower cowling

The upper cowlings are attached by means of cam-locks. The lower cowling is

attached with bolts.

71-10-01

Upper Left Cowling

Removal

Detail Steps/Work Items

Key Items

1

Unlock all cam-locks.

24 cam-locks

2

Raise and remove cowling.

Installation

Detail Steps/Work Items

Key Items

1

Set cowling aircraft.

2

Fasten all cam-locks.

3

Check all cam-locks are engaged by firmly

hitting the cowling near attachments.

Page 6 71

71-10-02

Upper Right Cowling

Removal

Detail Steps/Work Items

Key Items

1

Remove upper left cowling first.

2

Remove all cam-locks.

14 cam-locks

3

Raise and remove cowling

Installation

Detail Steps/Work Items

Key Items

1

Set cowling aircraft.

2

Fasten all cam-locks.

14 cam-locks

3

Check all cam-locks are engaged by firmly

hitting the cowling near attachments.

71-10-03

Lower Cowling

Removal/Installation

Detail Steps/Work Items

Key Items

1

Remove upper cowlings first.

Refer to Subj. 71-10-01/02

2

Disconnect landing light bulkhead

connector.

3

Remove bridge tube on forward part of

4 bolts

cowling.

4

Remove lower cowling aft attaching bolts.

7 bolts

5

Remove lower cowling as one piece.

6

Disassemble lower cowling if applicable.

4 bolts

7

Install in reverse order of removal.

Make sure that all rubber

seals fit properly at intake.

71 Page 7

71-20-00

ENGINE MOUNT

Description

The steel tube designed engine mount supports the engine and attaches it to the

airframe. It is mounted to the airframe at six points with mount supports, using

bolts, washers and self-locking type nuts.

71-20-01

Shock-Mount

The engine is attached to the engine mount at three points. Each point

incorporates a vibration isolator type shock mount assembly capable of

sustaining operational loads and providing absorption of engine vibrations.

They use the upper and side mounting pads of the engine.

For humidity & corrosion prevention MASTINOX is applied to the lower

shock-mount surface (contact area to the engine mounting pad).

Removal

It is assumed that the engine is not installed in the aircraft (otherwise refer to

Subject 71-00-01).

Never remove a shock-mount while the engine is installed.

CAUTION

Detail Steps/Work Items

Key Items

MASTINOX is highly flammable, toxic and dangerous for the

WARNING

environment. It may cause cancer and is harmful by inhalation, in

contact with skin and if swallowed. Toxic to aquatic organisms, may

cause long-term adverse effects in the aquatic environment.

Use applicable gloves and respirator mask.

1

Remove lock-wire.

2

Unscrew bolts.

3 bolts

3

Remove shock-mount.

Page 8 71

Installation

Detail Steps/Work Items

Key Items

MASTINOX is highly flammable, toxic and dangerous for the

WARNING

environment. May cause cancer. Harmful by inhalation, in contact with

skin and if swallowed. Toxic to aquatic organisms, may cause long-term

adverse effects in the aquatic environment.

Use applicable gloves and respirator mask.

1

Apply MASTINOX on the lower surface of

the shock-mount.

2

Place the shock-mount in position, hand

3 bolts

tighten bolts.

3

Torque all three bolts

11.9- 13.0 Nm

(105-115 lbs-inch)

4

Lock-wire bolts against each other.

71 Page 9

71-60-00

AIR INTAKES

Description

The EXTRA 500 has an exhaust heated engine air inlet. It is mounted on the

engine compressor flange.

71-60-01

Engine Inlet

Removal/Installation

Detail Steps/Work Items

Key Items

1

Remove the RH exhaust stack.

Refer to Chapter 78-00-02.

2

Unscrew the RH helical metal hose from the

inlet.

3

Remove inlet.

12 bolts

4

Unscrew the inlet from the LH helical metal

hose.

5

Install in reverse sequence of removal.

Observe the following hint.

IMPORTANT

Make sure while setting the length of the helical metallic hose that the

forces on the engine flange while attaching the exhaust stack must be

minimal. Screw in the helical metallic hose minimum one full turn on

each side. Maximum two full turns each side are possible.

Page 10 71

71-70-00

ENGINE DRAINS

Description

The EXTRA 500 engine has 5 drain fittings. Fuel, oil or other fluids are

collected in the engine manifold and drained overboard.

71-70-01

Engine Fire-Shield Drains

Description

The engine fire-shield drains are located on the left and right side (two each) of

the engine fire-shield. They are connected by aluminum tubing and connected

to the drain manifold by hoses.

Removal/Installation

Detail Steps/Work Items

Key Items

1

Remove LH and RH upper cowling.

Refer to Chapter 71-10-01/02

2

Disconnect hoses from drain manifold.

3

Disconnect drain lines from engine fire-

shield.

4

Install in reverse sequence of removal.

Make sure all lines are clean

71-70-02

Engine Combustion Chamber Drain

Description

In case of a false engine start, fuel may collect at the bottom of the combustion

chamber. This fuel will be drained through the combustion chamber drain hose

to the drain manifold.

Removal/Installation

Detail Steps/Work Items

Key Items

1

Remove LH upper cowling.

Refer to Chapter 71-10-01

2

Disconnect fittings of the combustion

chamber drain hose. Plug fitting.

3

Install in reverse sequence of removal.

71 Page 11

71-70-03

Engine Drain Manifold

Description

The engine drain manifold is installed at the bottom of the cowling, left

forward of the nose gear firewall.

Removal/Installation

Detail Steps/Work Items

Key Items

1

Remove LH upper cowling.

Refer to Chapter 71-10-01

2

Disconnect all hoses from engine drain

manifold.

3

Disconnect engine drain manifold from

overboard line and remove.

4

Install in reverse sequence of removal.

71-70-04

Overboard Line

Description

The overboard line is installed to the left side of the nose gear firewall.

Removal/Installation

Detail Steps/Work Items

Key Items

1

Remove LH upper cowling.

Refer to Chapter 71-10-01

2

Disconnect overboard line from engine

drain manifold.

3

Remove the two hose clamps at the nose

wheel bay firewall LH side.

4

Remove overboard line.

5

Install in reverse sequence of removal.

Observe the following

Refer to Product Label and Material Safety Data Sheet for health and

WARNING

safety information before using PR812.

6

Seal any opening in the firewall with

PR812.

Page 12 71

Content      ..     14      15      16      17     ..