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Extra 500. Maintenance Manual (2012) - page 17

73-00-00

GENERAL

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

Series Engine Operation and Maintenance Manual (LOAP 1).

73-30-00

Indicating

Description

The fuel indication consists of fuel pressure and a low fuel pressure warning in

the annunciator panel. The fuel pressure indication is described in 77-40-02

73-30-01

Fuel Pressure Transducer

Description

The fuel pressure transducer is located in the engine compartment, in the

sensor block mounted on the LH side of the battery mount, the most forward

upper sensor (refer to Figure 77-1).

Removal/Installation

Detail Steps/Work Items

Key Items

1

Ensure BATT switch is OFF and no external

power connected.

2

Remove LH upper cowling.

Refer to Chapter 71-10-01

3

Disconnect electrical connector.

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

WARNING

and catch spilling fuel in a suitable container.

4

Remove transducer from fuel pressure

manifold.

5

Install in reverse sequence of removal.

Replace O-ring when

necessary.

73 Page 3

73-30-02

Low Fuel Pressure Switch

Description

The low fuel pressure switch is located in the engine compartment, in the

sensor block mounted on the LH side of the battery mount, the most forward

sideward sensor (refer to Figure 79-1).

Removal/Installation

Detail Steps/Work Items

Key Items

1

Ensure BATT switch is OFF and no external

power connected.

2

Remove LH upper cowling.

Refer to Chapter 71-10-01

3

Disconnect electrical connector.

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

WARNING

and catch spilling fuel in a suitable container.

Never force the body of the sensor to turn against friction. It may

CAUTION

change the set-point. Always use a key on the attachment fitting for

removal and installation

4

Remove sensor.

5

Install in reverse sequence of removal.

Page 4 73

76-00-00

GENERAL

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

Series Engine Operation and Maintenance Manual (LOAP 1).

Description

The EXTRA 500 engine is controlled with two levers located in the middle

console: The power lever and the condition lever. Two Bowden cables are

routed through the firewall to the engine coordinator.

On the engine control mounting bracket, two microswitches are mounted. The

upper microswitch signals that the engine fuel is shut-off and has the function

to shut-off the bleed air when the engine is shut down. The lower is connected

to the LOW PITCH caution light on the annunciator panel.

Rigging Check

Detail Steps/Work Items

Key Items

1

Remove LH upper cowling.

Refer to Chapter 71-10-01

2

Perform engine manufacturer prepared

Refer to Rolls-Royce 250-

rigging check.

B17F Series Engine

Operation and Maintenance

Manual (LOAP 1), Chapter

76-00-00, page 201.

3

Check that the upper microswitch switches

Adjust by bending the

2-3 mm before the cut-off position is

microswitch arm

reached.

4

Check that the lower microswitch switches

Adjust by bending the

the LOW PITCH caution light on at 37°-39°

microswitch arm

(as indicated on the engine coordinator)

moving to a lesser angle.

76 Page 3

Figure 76-1

Engine Control Lever Travel Schematic

Page 4 76

76-10-00

POWER CONTROL

76-10-01

Engine Control Mounting Bracket

Description

The engine control mounting bracket is installed on the engine coordinator and

holds both engine control Bowden cables and 2 microswitches (refer to Figure

76-2).

Removal/Installation

Detail Steps/Work Items

Key Items

1

Remove LH upper cowling.

Refer to Chapter 71-10-01

2

Disconnect electrical wiring of the

microswitches.

3

Remove the Bowden cable rod ends from

the engine control levers.

4

Remove Bowden cables from bracket

flange.

5

Remove the two side supports of the

2 screws

bracket.

6

Remove the bracket.

2 screws

7

Install in reverse sequence of removal.

8

Perform engine control rigging check.

Refer to Subject 76-00-00

76 Page 5

Figure 76-2

Engine Control Mounting Bracket

Page 6 76

76-10-02

Throttle Quadrant

Description

The throttle quadrant is installed in the cockpit middle console. It includes the

power and condition levers as well as the pitch trim wheel and indicator.

Removal

Detail Steps/Work Items

Key Items

1

Remove the trim wheel.

2

Remove the power lever handle.

3

Remove the condition lever handle.

4

Remove the upper part of the middle

Refer to Chapter 25-10-26

console paneling.

5

Remove the both Bowden cable rod-ends

and flanges from the quadrant

6

Remove static pressure hoses and cabin

pressure sensors from support rod.

7

Remove 4 screws on top of the quadrant

cover.

Do not bend or dent the trim tubing. Bending or denting it will increase

CAUTION

pitch trim friction to an unacceptable level.

8

Detach the trim controller.

9

Remove support tube.

10

Remove quadrant.

76 Page 7

Installation

Detail Steps/Work Items

Key Items

1

Reverse sequence of removal.

PR 1750 accelerator contains harmful vapors and is readily absorbed

WARNING

through the skin.

Avoid all contact with the skin and ingestion.

Always wash hands before eating or smoking.

Use adequate ventilation, hand protection and chemical-type goggles

when working with this product.

If accelerator contacts skin, flush area with warm water. Obtain medical

attention in cases of extreme exposure or ingestion.

PR 1750 sealant contains solvents.

WARNING

Use adequate ventilation or air-supplied respirators during application.

Avoid repeated or prolonged breathing of vapors.

In case of extreme vapor exposure, remove affected personnel to fresh

air immediately and obtain medical attention.

For complete health and safety information, a material safety data sheet

is available from the manufacturer.

2

If the lower bolts of the support tube have

been loosened or removed seal it with

PR1750.

3

Perform an engine control rigging check.

Refer to Subject 76-00-00

4

Check the function of the back-up

microphone.

76-10-03

Power Lever Bowden Cable

Description

The Power lever Bowden cable connects the power lever in the cabin with the

input power lever of the engine coordinator.

Removal

Detail Steps/Work Items

Key Items

1

Remove LH upper cowling.

Refer to Chapter 71-10-01

2

Remove upper part of the middle console

Refer to Chapter 25-10-26

paneling.

3

Remove the power Bowden cable (LH) rod-

ends and flanges from the quadrant.

Page 8 76

Detail Steps/Work Items

Key Items

4

Remove the Bowden cable rod-ends and

flanges from the input power lever of the

engine coordinator and engine control

mounting bracket.

5

With a firm pull, remove the Bowden cable

from the firewall.

Installation

Detail Steps/Work Items

Key Items

1

Reverse sequence of removal.

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

WARNING

safety information before using PR812.

2

Seal the Bowden cable firewall

breakthrough with PR812 from the engine

compartment side.

PR 1750 accelerator contains harmful vapors and is readily absorbed

WARNING

through the skin.

Avoid all contact with the skin and ingestion.

Always wash hands before eating or smoking.

Use adequate ventilation, hand protection and chemical-type goggles

when working with this product.

If accelerator contacts skin, flush area with warm water. Obtain medical

attention in cases of extreme exposure or ingestion.

PR 1750 sealant contains solvents.

WARNING

Use adequate ventilation or air-supplied respirators during application.

Avoid repeated or prolonged breathing of vapors.

In case of extreme vapor exposure, remove affected personnel to fresh

air immediately and obtain medical attention.

For complete health and safety information, a material safety data sheet

is available from the manufacturer.

3

Seal the Bowden cable firewall

breakthrough with PR1750 from the cabin

side.

4

Perform an engine control rigging check.

Refer to Subject 76-00-00

5

Check the function of the back-up

microphone.

76 Page 9

76-10-04

Condition Lever Bowden Cable

Description

The condition lever Bowden cable connects the condition lever in the cabin

with the condition lever of the engine coordinator.

Removal

Detail Steps/Work Items

Key Items

1

Remove LH upper cowling.

Refer to Chapter 71-10-01

2

Remove upper part of the middle console

Refer to Chapter 25-10-26

paneling.

3

Remove the condition Bowden cable (RH)

rod-ends and flanges from the quadrant.

4

Remove the Bowden cable rod-ends and

flanges from the condition lever of the

engine coordinator and engine control

mounting bracket.

5

With a firm pull, remove the Bowden cable

from the firewall.

Installation

Detail Steps/Work Items

Key Items

1

Reverse sequence of removal.

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

WARNING

safety information before using PR812.

2

Seal the Bowden cable firewall

breakthrough with PR812 from the engine

compartment side.

PR 1750 accelerator contains harmful vapors and is readily absorbed

WARNING

through the skin.

Avoid all contact with the skin and ingestion.

Always wash hands before eating or smoking.

Use adequate ventilation, hand protection and chemical-type goggles

when working with this product.

If accelerator contacts skin, flush area with warm water. Obtain medical

attention in cases of extreme exposure or ingestion.

Page 10 76

Detail Steps/Work Items

Key Items

PR 1750 sealant contains solvents.

WARNING

Use adequate ventilation or air-supplied respirators during application.

Avoid repeated or prolonged breathing of vapors.

In case of extreme vapor exposure, remove affected personnel to fresh

air immediately and obtain medical attention.

For complete health and safety information, refer to Le Joint Francais

material safety data sheet PR 1750 (LOAP 41).

3

Seal the Bowden cable firewall

For mixing and application of

breakthrough with PR1750 from the cabin

PR 1750 sealant refer to

side.

manufacturer's instructions.

4

Perform an engine control rigging check.

Refer to Subject 76-00-00

5

Check the function of the back-up

microphone.

76 Page 11

Engine Indication Check

The engine indication check consists of a engine run test in which the

plausibility of the indications are checked apart from obvious things like oil

system leakage if the oil pressure sensor has been exchanged.

Detail Steps/Work Items

Key Items

1

Before the engine run, check that all

pressure and RPM indications are zero and

temperature indications in line with the

OAT.

2

Start the engine.

Follow EXTRA 500 Pilot’s

Operating Handbook

procedures.

3

Set in ground idle.

4

Check engine indication is around the values

Refer to Normal Ground Idle

given in the following table.

Engine Indication table

Normal Ground Idle Engine Indication

TRQ

~10%

TOT

~540°C

N1

~65%

N2

~1750 RPM

OP

~90 psig

OT

In green area

FP

>10 psig

77-00-01

Gas Generator Turbine Tachometer (N1)

The gas generator turbine tachometer is installed on the LH forward engine

gearbox.

Removal

Detail Steps/Work Items

Key Items

1

Ensure BATT switch is OFF and no external

power connected.

2

Remove LH upper cowling.

Refer to Chapter 71-10-01

3

Disconnect electrical connector.

Page 4 77

Detail Steps/Work Items

Key Items

4

Remove tachometer

Installation

Detail Steps/Work Items

Key Items

1

Reverse sequence of removal.

Apply some engine oil to the

drive-spline before installing.

2

Perform engine indication check.

Refer to Subject 77-00-00

77 Page 5

77-10-00

POWER

77-10-01

Torque Transducer

The torque transducer is located in the engine compartment, on the LH side of

the battery, the aft sensor.

Side View

fwd

Transducers

Battery attachment frame

Switches

Sensing lines

To accumulator

Firewall

Figure 77-1

Engine Indication Transducers and Switches

Removal

Detail Steps/Work Items

Key Items

1

Ensure BATT switch is OFF and no external

power connected.

2

Remove LH upper cowling.

Refer to Chapter 71-10-01

3

Disconnect electrical connector.

Page 6 77

Detail Steps/Work Items

Key Items

4

Remove lock-wire.

5

Remove torque transducer

Installation

Detail Steps/Work Items

Key Items

1

Reverse sequence of removal.

Replace o-ring when

necessary.

2

Perform engine indication check.

Refer to Subject 77-00-00

77-10-02

Torque Switch

The torque switch is located in the engine compartment, on the LH side of the

battery, the aft sideward sensor (refer to Figure 79-1).

Removal/Installation

Detail Steps/Work Items

Key Items

1

Remove LH upper cowling.

Refer to Chapter 71-10-01

2

Disconnect electrical connector.

Never force the body of the sensor to turn against friction. It may change the

CAUTION

set-point. Always use a wrench on the spanner flats of the attachment fitting

for removal and installation.

3

Remove torque switch.

4

Reverse sequence of removal.

Apply Loctite 577 to torque

switch thread

77-10-03

Propeller/Power Turbine RPM Sensor (N2)

The propeller tachometer is installed on the RH forward engine gearbox.

Removal

Detail Steps/Work Items

Key Items

1

Ensure BATT switch is OFF and no external

power connected.

2

Remove upper cowlings.

Refer to Ch. 71-10-01/02

3

Disconnect electrical connector.

77 Page 7

Detail Steps/Work Items

Key Items

4

Remove tachometer.

Installation

Detail Steps/Work Items

Key Items

1

Reverse sequence of removal.

Apply some engine oil to the

drive-spline before installing.

2

Perform engine indication check.

Refer to Subject 77-00-00

Page 8 77

77-20-00

TEMPERATURE

Engine temperature is measured using K-type thermocouples and indicated as

TOT to the pilot.

77-20-01

Thermocouple Wiring

The thermocouple wiring from the terminal block (77-20-02) to the indicator is

Chromel - Alumel for the entire length, including connector pins. If any of this

wiring is to be replaced, wiring of the same material shall be used. Perform

engine indication check as per Subject 77-00-00.

77-20-02

Thermocouple Terminal Block

Engine thermocouple wiring and aircraft thermocouple wiring is connected at

the thermocouple terminal block. It is installed in the engine compartment on

the RH engine fire-shield.

It is crucial that the Chromel and Alumel wires from the engine are correctly

connected to those of the aircraft. Observe the following table:

Material

Aircraft wiring

Engine wiring

Chromel

Pos (+)

Yellow

White

Small diameter stud

Alumel

Neg (-)

Red

Green

Large diameter stud

77 Page 9

77-40-00

INTEGRATED ENGINE INSTRUMENT SYSTEMS

77-40-01

Analog Engine Indicator Cluster

The analog engine indicator cluster is installed in the LH instrument panel.

Removal/Installation

Detail Steps/Work Items

Key Items

1

Ensure BATT switch is OFF and no external

power connected.

2

Remove the RH and LH IFD.

Refer to Chapter 31-60-01

3

Disconnect both electrical connectors

4

Remove indicator cluster.

5

Install in reverse sequence of removal.

6

Perform engine indication check.

Refer to Subject 77-00-00

77-40-02

Digital Engine Indicator Cluster

The digital engine indicator cluster is installed in the LH instrument panel just

below the analog engine indicator cluster.

Removal/Installation

Detail Steps/Work Items

Key Items

1

Ensure BATT switch is OFF and no external

power connected.

2

Remove the RH and LH IFD.

Refer to Chapter 31-60-01

3

Disconnect electrical connector.

4

Remove 4 bolts

Use a ratchet with adequate

prolongation for holding nuts

in place.

5

Remove indicator.

6

Install in reverse sequence of removal.

7

Perform engine indication check.

Refer to Subject 77-00-00

Page 10 77

78-00-00

GENERAL

Description

The exhaust system of the EXTRA 500 consists of two exhaust stacks, which

flanged to the engine with a V-band clamp.

Repair of the exhaust stacks is allowed only at EXTRA.

78-00-01

LH Exhaust Stack

Removal/Installation

Detail Steps/Work Items

Key Items

1

Remove the LH and RH upper cowlings.

Refer to Chapter 71-10-01/02

2

Remove the lower cowling.

Refer to Chapter 71-10-03

3

Remove engine anti-ice Bowden cable

Refer to Chapter 30-20-01/02

(from exhaust stack only) and micro switch.

4

Remove the V-band clamp.

5

Remove engine gear box vent line from

exhaust stack.

6

Unscrew the LH exhaust stack from the

helical metal hose.

7

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.

78-00-02

RH Exhaust Stack

Removal/Installation

Detail Steps/Work Items

Key Items

1

Remove the LH and RH upper cowlings.

Refer to Chapter 71-10-01/02

2

Remove the lower cowling.

Refer to Chapter 71-10-03

3

Remove the V-band clamp.

4

Unscrew the RH exhaust stack from the

helical metal hose.

Page Date:

78 Page 3

Detail Steps/Work Items

Key Items

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 4 78

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