0B702 Maintenance Manual Ed2 Rev2 20130809

Maintenance Manual
EXTRA 500
Doc.- No. EA-0B702
Schwarze Heide 21 D - 46569 Hünxe Germany

Tel.: + 49 28 58 / 91 37 - 0 Fax: + 49 28 58 / 91 37 - 30
Intentionally left blank
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Log of Revision
Issue Date Sign of approval Date
1st Edition 31. March 2011 EASA Major Change 17. June 2011
(Chapter 4 & 5 only) Approval N° 10035367
2nd Edition 30. March 2012 The technical content of this 30. March 2012
(Complete Manual document is approved
except Chapter 4) under the authority of
DOA N° EASA.21J.073
1st Revision, 2nd Edition 11. July 2012 The technical content of this 31. July 2012
document is approved
under the authority of
2nd Revision, 2nd Edition 9. August 2013 The technical content of this 9. August 2013
document is approved
under the authority of
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Ser - No. German AD
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CONTENTS
Title ....................................................................................................................................Page
Log of Revisions ..................................................................................................................... A

List of Effective Pages ........................................................................................................ B-C
List of Service Bulletins ......................................................................................................... D
Group/Chapter Title.....................................................................................................Chapter
GENERAL
Introduction ........................................................................................................................... 01
How to Use the Service Manual ............................................................................................ 02
AIRCRAFT
General Description ............................................................................................................... 03

Airworthiness Limitations ..................................................................................................... 04
Time Limits/Maintenance Checks ......................................................................................... 05
Dimensions and Areas ........................................................................................................... 06
Lifting and Shoring ................................................................................................................ 07
Leveling and Weighing ......................................................................................................... 08
Towing and Taxiing ............................................................................................................... 09
Parking, Mooring, Storage and Return to Service ................................................................. 10
Placards and Markings........................................................................................................... 11
Servicing ................................................................................................................................ 12
Standard Practices - Airframe ................................................................................................ 20
AIRFRAME SYSTEMS
Air Conditioning .................................................................................................................... 21

Auto Flight ............................................................................................................................. 22
Communications .................................................................................................................... 23
Electrical Power ..................................................................................................................... 24
Equipment/Furnishings .......................................................................................................... 25
Flight Controls ....................................................................................................................... 27

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Group/Chapter Title..................................................................................................... Chapter
Fuel ........................................................................................................................................ 28
Hydraulic Power .................................................................................................................... 29
Ice and Rain Protection.......................................................................................................... 30
Indication/Recording Systems ............................................................................................... 31
Landing Gear ......................................................................................................................... 32
Lights ..................................................................................................................................... 33
Navigation ............................................................................................................................. 34
STRUCTURES
Standard Practices and Structures - General ......................................................................... 51

Doors...................................................................................................................................... 52
Stabilizers .............................................................................................................................. 55
Windows ................................................................................................................................ 56
Wings..................................................................................................................................... 57
PROPELLER
Propeller ................................................................................................................................ 61
POWER PLANT
Power Plant............................................................................................................................ 71
Engine Fuel and Control........................................................................................................ 73
Ignition................................................................................................................................... 74
Engine Controls ..................................................................................................................... 76
Engine Indicating................................................................................................................... 77
Exhaust .................................................................................................................................. 78
Oil .......................................................................................................................................... 79
Starting................................................................................................................................... 80
MISCELLANEOUS
Charts ..................................................................................................................................... 91
Page H Page Date: 30. March 2012

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Chapter 01
General
Page Date: 30. March 2012 01 Page 1

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Table of Contents
01-00-00 GENERAL ........................................................................................................ 3

Address ............................................................................................................... 3
Contact ................................................................................................................ 3
01-00-01 Documents ......................................................................................................... 3
Aircraft: .............................................................................................................. 3
Equipment:.......................................................................................................... 3
01-00-02 Special Tools ...................................................................................................... 4
Figure 01-1 Main Gear Bolt Extracting Tool ......................................................................... 4
Figure 01-2 Flap Track Snap Gauge ...................................................................................... 5
Figure 01-3 Front Wing Main Bolt Extracting Tool .............................................................. 6
Figure 01-4 Rear Wing Main Bolt Extracting Tool ................................................................ 6
01-00-03 Trade Marks ..................................................................................................... 7
01-00-04 Safety.................................................................................................................. 7
Page 2 01 Page Date: 30. March 2012

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01-00-00 GENERAL
According to the regulations of the FAR/JAR part 23, this Maintenance
Manual provides educated maintenance staff with information necessary for
servicing, maintaining and repairing the EXTRA 500. This Manual contains a
detailed description of systems including time limits for the particular
components, troubleshooting and instructions for the performance of inspection
and maintenance work. The instructions that are necessary for disassembly,
check, repair, maintenance or overhaul of vendor equipment are not
incorporated in this manual.
Address
EXTRA Flugzeugproduktions- und Vertriebs- GmbH
Schwarze Heide 21
46569 Hünxe
Germany
Contact
Email: extraaircraft@extraaircraft.com
Phone: +49 2858-9137-0
Fax: +49 2858-9137-30
01-00-01 Documents
Use the following documents in connection with this Maintenance Manual:
Aircraft:
1 EXTRA 500 Pilot’s Operating Handbook and Airplane Flight Manual, Doc.
No.: EA-0B701 most current revision
2 Service Bulletins
3 Aircraft Record
4 Airplane Log Book and Engine Log Book
Note Check the Airplane Log Book documents are up-to-date and in
accordance with current applicable aviation authority regulations.
Since the regulations may require different documents and data, owner of
exported airplanes should check with their own aviation officials to
determine their individual requirements.
Equipment:
Applicable Instructions of Continuous Airworthiness for equipment installed.
Refer to the List of Applicable Publications (LOAP), Doc. No.: EA-0B710.00
most current revision, provided by EXTRA.

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01-00-02 Special Tools

Generally, for maintenance tasks no special tools are necessary. However,
there are a few exceptions as listed below. These items are available at
EXTRA. Alternatively, they can be crafted per instruction of Figures 01-1
through 01-4, using standard shop practices.
Description Extra Part No. Subject Chapter
Main gear bolt n/a Main gear strut 32-10-10
extracting tool removal
Flap track snap gauge EA – 15182W10 Flap guidance check 27-50
Front wing main bolt EA – 15001.1W Wing removal 57-10
extracting tool
Rear wing main bolt EA – 15001.2W Wing removal 57-10
extracting tool
Stroke bushing
Threaded rod M 10 Nut and counter nut
Figure 01-1 Main Gear Bolt Extracting Tool

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Figure 01-2 Flap Track Snap Gauge

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Figure 01-3 Front Wing Main Bolt Extracting Tool
Figure 01-4 Rear Wing Main Bolt Extracting Tool

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01-00-03 Trade Marks

Even when the ware or brand names used in this manual are not marked as
registered trade-marks, this does not mean, that these names are free in the
sense of trademark legislation.
01-00-04 Safety
To keep the security risks during the execution of the inspection and
maintenance work as low as possible, observe the following points:
1 Inspection and maintenance work has to be carried out only by qualified and
authorized personnel.
2 The execution has to be in accordance with the respective national safety
requirements.
3 Before beginning any work, this service manual has to be read and understood.
In case of doubt or lack of information the manufacturer has to be contacted for
advice.
4 The safety notes given in this manual are to be observed unconditionally.
Refer to Chapter 02 for information concerning safety notes.

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Chapter 02
How to Use the Maintenance Manual

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Table of Contents
02-00-00 GENERAL ........................................................................................................ 3
02-10-00 MANUAL DESCRIPTION ............................................................................. 4

02-10-01 Manual Set-Up .................................................................................................. 4
02-10-02 Chapter Set-Up ................................................................................................. 4
02-10-03 Page Numbering ............................................................................................... 4
02-10-04 Figure Numbering ............................................................................................ 4
02-10-05 Layout ................................................................................................................ 5
02-10-06 Notes/Safety Notes ............................................................................................ 5
02-20-00 HANDLING ...................................................................................................... 6

02-20-01 Revisions ............................................................................................................ 6
02-20-02 Service Bulletin ................................................................................................. 6
02-20-03 Checklists ........................................................................................................... 7

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02-00-00 GENERAL
The set-up of the manual, the chapters and the handling correspond to the
regulations of the Air Transport Association of America, ATA Specification
No. 100. However, the numbering of the pages and the layout have been
changed to make working with this manual easier.

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02-10-00 MANUAL DESCRIPTION
02-10-01 Manual Set-Up

The manual consists of groups, which are subdivided in chapters. Additionally
there are preceding pages, which contain the List of Effective Pages, the Lists
of Service Bulletins and the Record of Revisions. In the list of chapters the
groups are marked by capital characters.
02-10-02 Chapter Set-Up

The chapter numbering system used in this manual represents the chapter set-
up. It is a conventional dash-number breakdown. The number is composed of
three elements which consist of two digits each:
02-10-02
chapter - section - subject
The first element shows the chapter (here: "How to Use the Service Manual").
The second element shows the first subdivision, which is called "section"
(here: "MANUAL DESCRIPTION"). The third element shows the "subject",
which is handled within the respective section (here: "Chapter Set-Up"). The
first three digits refer to the definitions of the ATA Specification 100, where
they exist; the other digits are defined by the manufacturer. If a more detailed
breakdown is necessary, bold faced headlines like the following are used:
Powerplant
When headlines are referenced in the text they are presented in italic letters.
E.g.: see Powerplant paragraph.
02-10-03 Page Numbering

The page numbering begins at the coversheet of each chapter with "Page 1". In
contrast to the ATA Specification 100, the particular sections and subjects
don't start with a new numbering.
02-10-04 Figure Numbering

The figures are numbered in such a way that the first figure in each chapter
starts at "Figure XX-1".

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02-10-05 Layout
Apart from the headers and footers the layout consists of two columns. The
right column contains text, titles, tables, schedules and figures (figures also can
fill the whole page); the left column contains the chapter numbering, boxed
textmarkers for notes and safety notes as well as explanations.
02-10-06 Notes/Safety Notes

Safety notes in this manual are marked by a boxed textmarker in the margin
column and written in semi-bold characters. This manual distinguishes three
warning levels:
Represents any threatening danger for the personnel. The non-observation
DANGER of this safety note will result in death or serious injuries.
Represents a possibly dangerous situation for the personnel. The non-
WARNING observation of this safety note may result in injuries.
Represents a danger to equipment. The non-observation of this safety note
CAUTION results in destruction of equipment. This safety note does not exclude a
possible danger for the personnel.
Additional information given in this manual are also marked by boxed
textmarkers in the left column and are written in semi-bold characters:
IMPORTANT Represents an important hint. Often used when the non-observation could
endanger pilot or passengers during flight.
NOTE Represents a useful or remarkable hint.

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02-20-00 HANDLING
02-20-01 Revisions
Maintenance Manuals and other technical publications in current revision
status are available over the World Wide Web direct link:
http://www.extraaircraft.com/techservice.php
Cross-check your documents against these publications and replace pages as
necessary. Paper copies of publications will continue to be available if this is
your preferred format of publications. Orders can be placed by contacting
EXTRA.
NOTE Pages of this Manual may not be exchanged and no alterations of or
additions to the approved contents may be made without the EXTRA
approval.
If revision of pages will be necessary, observe the following steps:
NOTE Change revised pages immediately upon receipt.
1 Take out the old pages and destroy them.
2 Insert the new pages following the chapter and page numbers.
3 Replace the old pages "List of Effective Pages".
4 Enter the date on page "Record of Revision" and on page "2 = Record of
Revision" of Ch 04 if necessary.
Each revised page is marked at the bottom by the date of revision; revised parts
of the new page are marked by a bar on the left margin.
02-20-02 Service Bulletin

The Service Bulletins describe which procedures and how and when they are to
be carried out. Enter the receipt of each Service Bulletin in the Service Bulletin
List.
NOTE The owner is responsible for incorporating Service Bulletins to the above
mentioned Service Bulletins List.

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02-20-03 Checklists
Observe the following steps when working with checklists:
1 Copy the respective check list for performing a check.
2 Enter the date at the top of the table.
Date: Inspector
as specified
1000 hours
100 hours
50 hours
Serial No.: Mechanic

Description
X X X Text
X1 Text
3 Select the items to be worked out. The "X" at the beginning of the line is
written in the column which indicates the point of time when an item has to be
worked out. Specification for the first column is given by footnotes.
4 Work out the particular items and sign after execution (responsible mechanic
and inspector) using the respective boxes behind the item.
5 After completion of the inspection check file the list with entries in the Aircraft
Records.
6 Certify the completion of the check in the Aircraft Log Book.

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Chapter 03
General Description

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Table of Contents
03-00-00 GENERAL ........................................................................................................ 3

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03-00-00 GENERAL
The EXTRA 500 is designed as a six-place, single engine, high-wing, full

composite airplane.
The fuselage consists of a skin with integrated longerons and frames.
The wing uses a double front spar and a rear spar interconnected by ribs.
The stabilizers use a front and a rear spar.
In general the skins of fuselage, wing, stabilizers and control surfaces consist
of carbon fiber facings and honeycomb. The supporting structures such as
longerons, frames, spars and ribs consist of carbon fiber with foam core.
Only the D-section of the wing consists of glass fiber with honey comb and
glass fiber ribs.
The EXTRA 500 has a hydraulically operated retractable tricycle landing gear
with a controllable nose wheel.

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Chapter 04
Airworthiness Limitations

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Record of Revisions Chapter 04

Rev. Date of EASA Approval Date
Revised Pages Description of Revision
No. Revision and Sign of Approval
LBA (NAA),
1st Ed. 4. June 2004 — First edition
16. July 2004
N° 10035367
2nd Ed. 31. March 2011 — Second edition
17. June 2011
FAA AEG IP M-1

2nd Ed. 9. November N° 10044853
2, 4 thru 5 Comments
Rev. 1 2012 10. May 2013
Proj. N° AT00413 CE-A
List of Effective Pages

04-1 ..................................... 31. March 2011
04-2 ................................. 9. November 2012
04-3 ..................................... 31. March 2011
04-4 thru 5....................... 9. November 2012
04-6 ..................................... 31. March 2011
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04-00-00 GENERAL ......................................................................................................... 4

04-00-01 Temperature Limit............................................................................................ 4
04-00-02 Operating Time ................................................................................................. 4
04-10-00 LIFE LIMITED COMPONENTS ................................................................... 5

04-10-01 General ............................................................................................................... 5
04-10-02 Replacement Time ............................................................................................. 5
04-10-03 Service Life Limited Components ................................................................... 5

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04-00-00 GENERAL
IMPORTANT It is the operator's responsibility to make sure that time limits or life
limits for items in this chapter are not exceeded.
The airworthiness limitations items include mandatory replacement times
which may only be changed with permission of the applicable airworthiness
authority.
The Airworthiness Limitation section is FAA approved and specifies
maintenance required under paragraphs 43.16 and 91.403 of the Federal
Aviation Regulations, unless an alternative program has been FAA approved. *)
*)
Legible statement pertaining to non US registered airplanes:
The Airworthiness Limitation section is approved by the regulatory authority
and specifies maintenance required under paragraphs 43.16 and 91.403 of the
Federal Aviation Regulations, unless an alternative program has been approved
by the regulatory authority.
04-00-01 Temperature Limit

The composite material used to manufacture the Extra EA 400-500 is qualified
for service temperatures up to 72° C (162° F) under load. As such, any surface
repainting or surface repair paint finish must be accomplished with white color
paint only.
04-00-02 Operating Time

Only the airframe and components as listed in Chapter 04-10-00 are subject to
a permissible operating time; concerning all other components recommended
replacement times are given in Chapter 05.
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04-10-00 LIFE LIMITED COMPONENTS
04-10-01 General
The replacement time of the life limited components listed in Chapter 04-10-02
must be accomplished not later than the specified period of operation for that
component or airworthiness directives.
04-10-02 Replacement Time

Items shown here must be replaced during the regular maintenance periods.
Item Replace after
Fuselage 20,000 flight hours in service or
30,000 take-off and landing operations,
which ever comes first
Wing 20,000 flight hours in service
Wing Flap 20,000 flight hours in service
Aileron 20,000 flight hours in service
Vertical Stabilizer 20,000 flight hours in service
Rudder 20,000 flight hours in service
Horizontal Stabilizer 20,000 flight hours in service
Elevator 20,000 flight hours in service
04-10-03 Service Life Limited Components

The service lives of the EA 400-500 composite structure components as listed
in Section 04-10-02 have been demonstrated
up to 20,000 flight hours in service,
up to 30,000 take-off and landing operations (fuselage only).
Page Date: 9.
31.November 2012
March 2011 04 Page 5
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Chapter 05
Time Limits/Maintenance Checks

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Time Limits and Maintenance Checks
Table of Contents
05-00-00 GENERAL ........................................................................................................ 5

05-00-01 Chapter Configuration ..................................................................................... 5
05-00-02 Words with Special Meanings ......................................................................... 6
05-10-00 TIME LIMITS .................................................................................................. 7

05-10-01 General .............................................................................................................. 7
05-10-02 Certification Authorities .................................................................................. 7
05-10-03 Scheduled Maintenance Time Limits ............................................................. 7
05-10-04 Component Time Limits .................................................................................. 8
Time Between Overhaul ..................................................................................... 8
Time Between Replacement ............................................................................... 8
Time Between Inspection ................................................................................... 9
05-20-00 SCHEDULED MAINTENANCE CHECKS ................................................ 10

05-20-01 General ............................................................................................................ 10
05-20-02 Maintenance Checks Schedule ...................................................................... 10
05-20-03 Scheduled Maintenance Charts ..................................................................... 11
Operational Checks........................................................................................... 11
Miscellaneous ................................................................................................... 13
Fuel System ...................................................................................................... 14
Oil System ........................................................................................................ 15
Bleed Air System .............................................................................................. 16
Air Inlet and Exhaust System ........................................................................... 17
Engine and Accessories .................................................................................... 18
Propeller and Governors ................................................................................... 19
Cabin and Equipment ....................................................................................... 20
Fuselage ............................................................................................................ 23
Wing Assembly ................................................................................................ 24
Control Systems and Surfaces .......................................................................... 26
Landing Gear .................................................................................................... 28
Wheels and Brakes ........................................................................................... 32
Completion ....................................................................................................... 34

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05-30-00 FLIGHTLINE INSPECTIONS ..................................................................... 35

05-30-01 General ............................................................................................................. 35
05-30-02 Pre - Flight Check ........................................................................................... 35
05-30-03 Post - Flight Check .......................................................................................... 35
05-50-00 UNSCHEDULED MAINTENANCE CHECKS........................................... 36

05-50-01 General ............................................................................................................. 36
05-50-02 50 Hours – Inspection of Engine .................................................................... 36
05-50-03 Hard Landing .................................................................................................. 36
05-50-04 Engine Fire ....................................................................................................... 37
05-50-05 Propeller Strike, Sudden Stoppage and Violent Engine Stoppage ............ 37
05-50-06 Lightning Strike .............................................................................................. 37
05-50-07 Engine Overspeed............................................................................................ 38

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05-00-00 GENERAL
This chapter is a guide. It will help you to perform the maintenance correctly.
You must perform the scheduled maintenance checks given in this chapter at
the recommended time. These checks are minimum requirements for keeping
the aircraft in a good technical condition.
The aircraft manufacturer can change the time between maintenance actions
and scheduled checks. If this happens, the aircraft manufacturer will supply the
data by Service Bulletins or Service Letters.
You can shorten the time between scheduled maintenance checks if the air-
craft operation makes it necessary. You must not extend the time between
scheduled maintenance checks without the aircraft manufacturer’s approval.
The aircraft manufacturer must give approval to any change to the aircraft or to
the maintenance checks schedule.
05-00-01 Chapter Configuration

Section 05-10-00 contains the time limits for maintenance actions and checks.
It also contains the time limits for components. Use the data in section 05-10-
00 to find out when to perform maintenance actions and checks.
Section 05-20-00 contains the scheduled maintenance checks to be performed
on different time intervals. It also contains data for the annual inspection if
required due to national regulations.
Section 05-30-00 contains data for flight line checks. Do a pre-flight check
before each flight. And do a post-flight check after each flight.
Section 05-40-00 is reserved.
Section 05-50-00 contains the unscheduled maintenance checks. Do these
checks after heavy landings, engine fire and propeller damage, or if the aircraft
has been operated outside the flight envelope.

Maintenance Manual
Extra 500
05-00-02 Words with Special Meanings

In this Maintenance Manual, the words that follow have special meanings :
Adjust To put to a specified position or condition. For example, adjust the clearance
to 1 mm.
Check A technical name for a group of maintenance tasks. For example,
the 100 hour check.
Examine To look carefully at an item. It includes steps such as these:
Make sure that the item:
1 Is complete.
2 Is correctly attached.
3 Has no loose parts.
4 Shows no signs of leaks.
5 Is not cracked or damaged.
6 Is not worn.
Make sure that:
1 The surface protection is not damaged.
2 All locking devices are installed correctly.
Make sure that items such as pipes and cables (see also Chapter 20-10-09):
1 Look serviceable.
2 Do not rub against other items (chafing marks).
Inspection The procedure, which compares an object with its standard or specification.
Measure To find out the dimensions, capacity or quantity of something.
Monitor To look at something during a time. For example, monitor the engine speed
indicator.
Record Technical name for something that shows what was done. For example, write
the result of the test in the engine record.
Replace To remove an unserviceable item and install a serviceable item in the same
location.
Set To put equipment into a given adjustment, condition or mode. For example,
set the altimeter scale to 1013 mbar.
Task An assigned work or procedure. For example, each step of the task has an
identification letter.
Test That what you do when you operate or examine an item to make sure that it
agrees with the applicable specifications. For example, disconnect the
systems, which are not necessary for the test.

Maintenance Manual
Extra 500
05-10-00 TIME LIMITS
05-10-01 General
Various equipment and components of the aircraft (e.g. engine, propeller) are
only cleared for a certain time of operation. After the permissible time of
operation has expired they have to be replaced or overhauled (TBO - Time
Between Overhaul). The respective TBO intervals are listed in the aircraft
record sheets.
For monitoring the permissible time of operation, this time should also be
entered into the aircraft records when removing and installing such a part
including full part and serial numbers.
05-10-02 Certification Authorities

The time limits given in this chapter are recommended by the manufacturer.
These time limits may be superseded by the regulatory authority.
05-10-03 Scheduled Maintenance Time Limits

The following components listed in Chapter 05-14-00 have to be overhauled,
replaced or inspected periodically, i.e. within fixed calendar periods or after
appearance of a certain amount of flight hours. Do scheduled maintenance at
these times:
Scheduled Maintenance Do at these times

100 hours check At 100 FH. Or 100 hours after the last 100
hours or larger check. Tolerance +/- 10 hours.
1000 hours check At 1000 FH. Or 100 hours after the last 100
hours or larger check. Tolerance +/- 10 hours.
In addition scheduled engine maintenance according to Rolls Royce 250-B17F
Series Operation and Maintenance Manual (LOAP 1) has to be performed at
the time intervals given there.

Maintenance Manual
Extra 500
05-10-04 Component Time Limits
Time Between Overhaul

These components have a TBO - Time Between Overhaul:
Components Time Between Overhaul

Turboprop Engine Rolls Refer to the latest Rolls Royce 250-B17F
Royce 250-B17F/2. Series Operation and Maintenance Manual
(LOAP 1)
Engine accessories. Refer to the latest Rolls Royce 250-B17F
Series Operation and Maintenance Manual
(LOAP 1)
Propeller Governors Refer to the latest Rolls Royce 250-B17F
Series Operation and Maintenance Manual
(LOAP 1)
Aircraft Parts Corps 200SGL Every 1000 hours.
Starter Generator
BC410 Stand-by Alternator Every 1700 hours
system
Passenger seat belt webbing. After 12 years.
MT-Propeller Refer to the latest MT-Propeller Service
MTV-5-1-D-C-F-R(A) Bulletin (LOAP 5).
CFR210-56.
Time Between Replacement

Replace these components at the times shown:
Components Time Between Replacement

Purolator Facet 200 hours or 6 months which ever comes
Scavenge lube oil filter first
Pierburg 2000 hours
Motive flow fuel pump
Integral Hydraulic 10 years
Hydraulic accumulator
Rubber type hoses First 7, then 5 years.
wing fuel tank pick up to
fuselage connection
and
within wing fuel tank of SN
1002 and 1003

Maintenance Manual
Extra 500
Components Time Between Replacement

Batteries of Emergency Every 2 years during shelf or service life, or
Locator Transmitter (ELT). after 1 hour of cumulative use (e.g. testing),
or after operation in an emergency situation,
or before battery replacement date.
Battery replacement date is marked on the
battery pack and the label at the end of
transmitter.
For battery replacement see ARTEX
Description, Operation, Installation and
Maintenance Manual for the ME406 ELT
(LOAP 30)
Batteries of emergency torch. Annually or after each use.
Annunciator panel If any one lamp fails, defective lamp must
(Westcoast Specialties) be replaced.
Annunciator panel If any one LED fails, the unit must be
(EXTRA) repaired or replaced.
Windows If cracks are detected
Time Between Inspection

Inspect these equipment items at the times shown:
Components Time Between Inspection

Battery Refer to CONCORDE Component
Maintenance Manual (LOAP 27)
Static pressure system. Every 2 years in accordance with 14 CFR
Ch. 1 Part 43 App. E.
ATC transponder. Every 12 months in accordance with 14
CFR Ch. 1 Part 43 Apps. F Par. C and F.

9. August 2012 05 Page 9
Maintenance Manual
Extra 500
05-20-00 SCHEDULED MAINTENANCE CHECKS
05-20-01 General
Regular inspections must be carried out every 100 or 1000 operating hours.
Annual inspections (ANI) must be performed according to the national
requirements.
NOTE The scope of an Annual Inspection and a 100 hour inspection is the same.
However, the manufacturer may recommend to perform additional
checks in the course of an Annual Inspection. If applicable, these checks
are identified in the Maintenance Check Schedule with the abbreviation
"ANI".
All inspections must be executed by a designated representative of the Aviation
Authority of the country in which the aircraft is registered.
05-20-02 Maintenance Checks Schedule

The maintenance and control work given in the following tables has to be
carried out within the given time intervals. The proper execution of the checks
and maintenance actions has to be certified in the maintenance records and log
books.
Faults as well as their repairs have to be entered in an inspection report filed
together with the check list in the aircraft records.

Maintenance Manual
Extra 500
05-20-03 Scheduled Maintenance Charts

The maintenance checks described in this section include all the scheduled
checks, which must be performed. Maintenance checks must be accomplished
in accordance with CFR 14 P 43 App. D.
Use the following schedule and the lubrication charts presented in Chapter 12-
20-04.
Prior to inspection, the aircraft and engine should be thoroughly cleaned, all
inspection panels, access doors or fairings should be removed.
Operational Checks
Flight Hours Date:
as specified
Mechanic
Inspector
Serial No.:
1000
100
Description:
Rotating propeller can cause death or severe injuries!
DANGER Do not allow anyone to stay in the propeller area.
Risk of propeller shaft bending due to wind forces.
CAUTION High power ground runs are only permitted with aircraft nose turned
into wind.
Perform an inspection operational run-up. Refer to the latest
Rolls Royce 250-B17F Series Operation and Maintenance
Manual (LOAP 1), Ch. 72-00-00, ENGINE-
X X
ADJUSTMENT/TEST, Check Run, Operating Instructions &
Check Run Schedule. Record and verify the engine operating
parameters. Check the following items while engine is running.
X X Check the parking brake and toe brakes.
X X Check the fuel flow, fuel pressure and fuel quantity indication.
X X Check the function of fuel pumps by monitoring fuel pressure
indication when running a single pump.
X X Check fuel selector valve for proper operation and pointer
indication.
X X Check the oil pressure and oil temperature.
X X Check the generator output.
X X Reduce system electrical load to approx. 10 thru 15 A.
Check the stand-by alternator output with generator off.
Then generator on.
X X Check the cabin pressurizing operation.
X X Check the air condition operation.
X X Check the de-ice system operation.

Maintenance Manual
Extra 500
Flight Hours Date:

as specified
Mechanic
Inspector
Serial No.:
1000
100
Description:
X X Check the windshield heater operation.
X X Check flight idle speed (N1: 65%).
X X Check response of the engine by power setting changes.
X X Check the propeller overspeed governor at 1800 RPM (N2
RPM) by pressing ENGINE OVSPD TEST button switch.
Monitor RPM drop. After release of the ENGINE OVSPD TEST
button switch Prop RPM should return to the above setting.
Then return to idle.
X X Check temperature regulation. Actuate WARM/COOL switch in
manual mode and check response. Return to automatic mode.
X X Check the annunciator light panel.
1
Check the radio and the other electronic equipment.
Risk of damage to flaps or upper door.
CAUTION Function test of flaps only with upper door closed.
X X Check operation of controls and flaps.
X X Shut down engine. Condition lever at cut-off position. Check
immediate PNEUMATIC LOW annunciation and interruption of
cabin heat air flow. (bleed air distribution valves function check)
X X Change power lever position and check illumination of LOW

PITCH annunciator light.
X X Check the generator/alternator warning light or ammeter.

X X BATT switch OFF.
1
according to national regulations
9. August 2013
Maintenance Manual
Extra 500
Miscellaneous
Flight Hours Date:
as specified
Mechanic
Inspector
Serial No.:
1000
100
Description:
Clean and inspect the cowling intakes and outlets for damage,
X X
cracks, distortion and overheat areas.
Clean fire protective coating of oil cooler inlet & outlet duct. If
X X necessary repaint and add clear coat (refer to Chapter 51-30-01
Fire Protective Coating).
Inspect engine mount for cracks, corrosion, looseness of
mountings and overheated areas. Inspect engine shock mount
X X
isolators for deterioration, improper assembly and insecurity.
Replace as required.
Inspect engine controls for security, defects, improper travel
X X and improper safetying. Lubricate as per Chapter 12-20-04
Lubrication Chart.
Inspect engine bonding for improper installation and poor
X X
condition.
Inspect firewall and seals for improper condition, insecurity
X X
and improper fire resistant sealing.
Inspect battery and attachment for corrosion, etching, poor
X X
condition and insecurity. (Charge battery if required.)
Inspect battery ventilation hose and attachment for chafing,
X X
leakage, poor condition and insecurity.
1
Perform battery capacity test according to CONCORDE
Component Maintenance Manual (LOAP 27), Capacity Test
Procedure.
Inspect external power supply receptacle and fuses for
X X
cleanliness, corrosion, poor condition and insecurity.
Inspect electrical leads, lines, ceramics and attaching for
X X chafing, deterioration, improper routing, wear, insecure
installation and obvious defects.
Nose gear and main gear extends and retracts under high pressure.
DANGER Operation of the landing gear can cause death or injuries in its working
area!
Before beginning any work in the landing gear working area, pull OFF
the GEAR CTRL circuit breaker located on the left side panel.
X Inspect nose wheel box for cracks, poor general condition and
improper fire resistant sealing.
1
Refer to CONCORDE Component Maintenance Manual (LOAP 27)
Page Date: 30. March2013
Maintenance Manual
Extra 500
Fuel System
Flight Hours Date:
as specified
Mechanic
Inspector
Serial No.:
1000
100
Description:
Inspect lines, hoses and clamps for leaks, improper condition
X X
and looseness.
Inspect fuel pumps for leaks, poor general condition, and
X X
insecure attachment.
Inspect fuel collector block and check valves for leaks,
X X
improper condition, insecurity and insecure attachment.
Inspect fuel filter for leaks, improper condition, insecurity and
X X
insecure attachment.
Check function of red fuel filter bypass button (monitor
X X
annunciator panel).
1
Check function of fuel selector valve as per Chapter 28-20-03.
2
Change fuel filter element and O-rings.
1
Together with engine fuel maintenance. Refer to latest Rolls Royce 250-B17F Series Operation
and Maintenance Manual (LOAP 1).
2
Together with engine fuel pump filter replacement. Refer to latest Rolls Royce 250-B17F Series
Operation and Maintenance Manual (LOAP 1).
9. August 2013
Maintenance Manual
Extra 500
Oil System
Flight Hours Date:
as specified
Mechanic
Inspector
Serial No.:
1000
100
Description:
1
Change engine Oil. Refer to Rolls Royce 250-B17F Series
Operation and Maintenance Manual (LOAP 1), Ch. 72-00-00,
ENGINE-SERVICING, Lubrication System Servicing, Oil
Change.
X X Inspect oil tank for insecurity of attachment, leaks and cracks.
Inspect oil system lines, hoses, fittings and clamps for leaks,
X X
chafing, improper condition and looseness.
Remove foreign objects from inlet duct and inspect oil cooler
X X and fins for leaks, deterioration, distortion, insecure attachment,
loose or missing fasteners and other evidence of failure.
Inspect oil tank vent valves for insecurity of attachment and

X X
poor condition.
1
together witch engine lubrication system maintenance
Refer to Rolls Royce 250-B17F Series Operation and Maintenance Manual (LOAP 1)
Page Date: 9.
30.August
March2013
2012 05 Page 15
Maintenance Manual
Extra 500
Bleed Air System

Flight Hours Date:
as specified
Mechanic
Inspector
Serial No.:
1000
100
Description:
Inspect bleed air lines, pneumatic hoses, tubing, fittings and
clamps for leaks, chafing, improper condition and looseness.
X X
Use clean filtered compressed shop air with a pressure not
exceeding 10 PSI.
Inspect valves for insecurity of mounting, poor condition and
X X
improper electrical connections.
Inspect ejectors for insecurity of mounting, leaks and poor
X X
condition.
Inspect pressure switch for insecurity of mounting, poor
X X
condition and improper electrical connections.
Inspect air flow sensor for insecurity of mounting and improper
X X
electrical connection.
Inspect acoustical muffler for insecurity of mounting, leaks and
X X
poor condition.
Perform temperature switch function test (Refer to Chapter 21-
X
60-01).
Page 16 05 Page Date: 30.

9. August
March 2013
2012
Maintenance Manual
Extra 500
Air Inlet and Exhaust System

Flight Hours Date:
as specified
Mechanic
Inspector
Serial No.:
1000
100
Description:
Inspect air inlet and inlet heat ducts for leaks, cracks and poor
X X
condition.
Check mechanic and electric (annunciation) function of inlet
heat. Lubricate as per Chapter 12-20-04 Lubrication Chart.
X X
Check function of engine internal solenoid valve (“click” when
switched).
Inspect the exhaust pipes for burned areas, cracks, leakage,
X X deterioration, loose and missing brackets, clamps and
hardware.
Inspect induction and exhaust components for worn or
X
damaged areas, loose clamps, cracks and leaks.

Maintenance Manual
Extra 500
Engine and Accessories

Flight Hours Date:
as specified
Mechanic
Inspector
Serial No.:
1000
100
Description:
Perform complete engine inspection according to the latest
edition of Rolls Royce 250-B17F Series Operation and
1
Maintenance Manual (LOAP 1), Ch. 72-00-00, ENGINE-
INSPECTION/CHECK, Inspections, Scheduled Inspection &
Special Inspections.
2
Complete overhaul of engine or parts
X X Inspect oil temperature sensor unit for leaks and insecurity.
Inspect all wiring, fluid lines, hoses and electrical connections
X X for improper routing, improper support and evidence of
deterioration.
Visually inspect accessory to engine attaching hardware for
X X insecurity. Visually inspect airframe to engine connections for
insecurity and corrosion.
Inspect all accessories for poor condition, insecurity of
X X mounting and improper operation. Refer to component
manufacturer's Maintenance Manual.
Inspect and test the starter generator. Remove starter generator.
Check brush length and condition. Clean brushes by clean
3 filtered compressed shop air. Refer to the applicable starter
generator manufacturer's instructions. Reinstall starter
generator and ventilation. Inspect ventilation hose and
attachment for leaks, chafing, looseness and poor condition.
Inspect and test the stand-by alternator. Check alternator
X X externally for security of mounting and wiring. Refer to the
applicable alternator manufacturer's instructions.
Inspect firewall mounted equipment for insecurity of mounting,
X X
improper electrical connections and poor general condition.
1
refer to Rolls Royce 250-B17F Series Operation and Maintenance Manual (LOAP 1)
2
see prior footnote
3
every 300 flight hours
9. August 2013
Maintenance Manual
Extra 500
Propeller and Governors

Flight Hours Date:
as specified
Mechanic
Inspector
Serial No.:
1000
100
Description:
Perform propeller check according to the latest edition of MT-
X X Propeller Operation and Installation Manual E-610 (LOAP 3),
Section 6.2.1, and Service Bulletin No 1 (LOAP 5).
Perform Propeller-Power Turbine Governor Functional
Feather Check according to the latest edition of Rolls Royce
1
250-B17F Series Operation and Maintenance Manual
(LOAP 1), Ch. 72-00-00, ENGINE-DESCRIPTION AND
OPERATION, Operating Procedures.
Perform Propeller Overspeed Governor Functional Check
according to the latest edition of Rolls Royce 250-B17F Series
2
Operation and Maintenance Manual (LOAP 1) Ch. 72-00-00,
ENGINE-DESCRIPTION AND OPERATION, Operating
Procedures.
1
together with engine maintenance. Refer to Rolls Royce 250-B17F Series Operation and
Maintenance Manual (LOAP 1).
2
see prior footnote
Maintenance Manual
Extra 500
Cabin and Equipment

Flight Hours Date:
as specified
Mechanic
Inspector
Serial No.:
1000
100
Description:
Remove inspection covers, door covering and panels (carpet
X X must be removed for access to inspection covers on the cabin
floor).
Inspect cabin and cockpit for uncleanliness and loose
X X
equipment that might foul the controls.
Inspect door locking mechanism for bending, cracks, pulled or
X X
sheared fasteners, and loose parts.
Check upper and lower door for proper rigging. Refer to
X X
Chapter 52-10-05.
Inspect door handles for play with the locking mechanism
X X
fixed. No play allowed.
Check that the gas spring (10, Figure 52-4) connected to the
X X upper door handle axle pushes the locking mechanism to the
extreme positions (with door open).
X X Inspect the door locking pins and bushings for wear.
X X Inspect door seals for folding and damage.
X X Inspect the door hinges for cracks and side play.
Check upper door holding gas spring for general condition.
X X Spring must hold the upper door completely open. Max. 15 mm
static compression of spring allowed.
Check cables supporting the lower door for general condition
X X and correct length (tread must be horizontal). Check cable
joints and bolt connections for general condition.
1
Check emergency exit for general condition.
1
Check emergency exit locking mechanism for free movement.
Inspect for corrosion.
1
Inspect emergency exit door seals for folding, cracks and other
damage.
Perform a teardown inspection of the central door operating
X
device. Refer to Chapter 52-10-03.
X X Lubricate doors as per Chapter 12-20-04 Lubrication Chart.
Inspect crew seats for improper horizontal and vertical
X X
operation and insecure locking function.
1
every 5 years
9. August
March 2012
2013
Maintenance Manual
Extra 500
as specified
Flight Hours Date:
Mechanic
Inspector
Serial No.:
1000
100 Description:
Check crew seats for proper engagement of pins to seat track
X X
with occupied crew seat at the lowest vertical position.
X X Inspect seats and upholstery for tears and poor condition.
X X Inspect seat belts for insecurity of attachment.
Inspect seat belts as per SCHROTH Abbreviated Component
X X Maintenance Manuals for Restraint Systems Models 1-08-()
(LOAP 32) and 5-02-() (LOAP 33)
X X Check operation of cabin and instrument lights.
Inspect instruments, lines, wiring and attachments for poor
X X
condition.
Inspect electric gyro instruments for poor condition, insecure
mounting, marking and improper operation. Overhaul or
X X
replace as required. (Refer to the components manufacturer's
instruction.)
Test pneumatic system pressure regulator setting and pressure
X
switch setting as per Chapter 30-10-01.
Inspect avionics for improper installation and insecure
X X
mounting.
X X Check electric trim operation and rigging.
X X Check operation of rudder pedals.
Inspect control wheels, column and switches for poor
X X
condition.
1
Remove seats and paneling. Inspect control cables, pulleys and
connections for poor condition and insecurity.
X X Check operation of strobe, landing, navigation lights.
X X Inspect pitot/static system for leakage and obstruction.
X X Inspect altimeter and ATC transponder for improper condition.
2
Check that altimeter complies with latest revision of 14 CFR
Chapter 1 Part 43 Appendix E.
3 Check that transponder complies with latest revision of 14 CFR
Chapter 1 Part 43 Appendix F.
1
2
every two years
3
annually
Page Date: 9.
30.August
March2013
2012 05 Page 21
Maintenance Manual
Extra 500
Flight Hours Date:

as specified
Mechanic
Inspector
Serial No.:
1000
100
Description:
1 Inspect compass and compass deviation card for improper
indication and compensation. Refer to Chapter 34-20-02.
1
Perform IFD Magnetometer Check procedure as per Chapter
31-60-01.
Inspect all knobs, switches and levers and their mounting for
X X
insecurity of attachment and poor condition.
Inspect engine controls for improper installation and improper
X X
operation.
Inspect flight controls for improper installation and improper
X X
operation.
X X Check operation of cabin heat and defrost controls.
2 Inspect circuit breaker mounting and wiring for poor condition
and insecurity.
X X Inspect environmental system ducts for poor condition.
3 Perform Blead Air System Leak Test, Cabin Leak Test and
Dump Test as per Ch. 21-00-00.
Inspect electrical panel components for poor condition and
X X
insecurity.
Inspect forward side of pressure cabin outflow and safety
X X valves for poor condition and insecurity. Remove and clean as
shown in Chapter 21.
Inspect filter on cabin control outflow valve for contamination.
X X
Clean or replace as required (see Chapter 21).
Inspect air condition evaporators, drain valves and mounting

X X
for poor condition and insecurity.
X X Drain air condition evaporators.
Inspect portable fire extinguisher for improper service and poor
X X
condition. Check inspection date.
4
Change batteries of emergency torch.
X X Reinstall inspection covers, panels and carpet.
1
Reinstall seats and paneling.
1
annually
2
3
4
annually or after each use
9. August 2013
Maintenance Manual
Extra 500
Fuselage
Flight Hours Date:
as specified
Mechanic
Inspector
Serial No.:
1000
100
Description:
X X Remove exterior access panels from fuselage.
Inspect structure and exterior surfaces for deterioration,
X X distortion, cracks, dents, other evidence of failure,
uncleanliness and defective or insecure attachment of fittings.
Inspect windshield and windows for deterioration, nicks,
X X
scratches, cracks and crazing.
Inspect electric windshield de-ice system for poor condition,
X X
insecurity and improper operation.
X X Inspect environmental system ducts for poor condition.
Inspect air condition compressor and mounting for poor
X X condition and insecurity. Check condition and tension of
compressor drive belt.
Inspect air condition hoses and clamps for poor condition,
X X
chafing and leaks.
X X Inspect air condition system wiring for fraying.
Inspect electrical leads, lines, radio antenna leads and attaching
X X for chafing, deterioration, improper routing, wear, insecure
installation and obvious defects.
Inspect antennas and coaxial cables for poor condition, insecure
X X
mounting and improper operation. Refer to Figure 23-01.
Inspect static pressure ports for poor condition, obstruction and
X X damages. Inspect static heat for poor condition and improper
operation.
Inspect static lines and attaching for improper routing,
X X deterioration, poor condition and leaks. Drain static lines as per
Chapter 34-00-00.
Inspect ELT, trim servo and attachment for poor condition and
X X
insecurity.
Check ELT battery replacement date. Refer to ARTEX
X X Description, Operation, Installation and Maintenance Manual
for the ME406 ELT (LOAP 30).
2
Perform a Cabin Leak Test and Dump Test. Dust particles on
door seals may indicate leakage position. Refer to Chapter 21.
X X Reinstall access panels (except every 300 flight hours).
1
2
Page Date: 9.
30.August
March2013
2012 05 Page 23
Maintenance Manual
Extra 500
Wing Assembly
Flight Hours Date:
as specified
Mechanic
Inspector
Serial No.:
1000
100
Description
X X Remove avionic bay access panels and wing center fairing.
1 Remove fuselage access panels and all fuel compartment
access panels.
X X Inspect wings for dents, cracks and delaminations.
X X Inspect wing ventilation holes for obstruction.
2 Inspect wing spar main bolts and fittings for poor general
condition, distortion, and insecurity of attachment.
Extract wing spar main bolts in sequence (refer to Chapter 57-
3
10-00). Inspect bolt shanks for cracks, wear, corrosion and
insecurity. Install each bolt before extracting the next one.
Inspect inside wing structure in the area of access panels for
X X deterioration, delamination, distortion and poor general
condition.
4
Drain wing fuel tanks.
Inspect the inside of the wing tanks and lines for leaks, poor
4 condition and evidence of fungus. If contamination with fungus
is detected, contact the manufacturer.
Inspect tank bonding for improper installation and poor
X X
condition.
4 Inspect fuel transmitter and electrical connectors for
uncleanliness, poor condition and insecurity.
4
Clean motive flow filters.
Inspect motive flow pumps for insecurity of attachment and
X X poor condition. Inspect electrical connectors for uncleanliness,
poor condition and insecurity.
4 Inspect fuel transfer system lines for leaks and poor condition.
Inspect fuel filler caps and flapper and float valves for poor
X X
condition.
1
2
annually
3
4
9. August 2013
Maintenance Manual
Extra 500
as specified
Flight Hours Date:
Mechanic
Inspector
Serial No.:
1000
100 Description
Inspect external fuel tank vent system for poor condition and
X X
insecurity.
1 Inspect vent system inside the fuel tank for poor condition and
insecurity.
Risk of damage to flaps or upper door.
CAUTION Function test of flaps only with upper door closed.
Inspect landing flaps and attachment for dents, cracks, de-
X X
laminations and improper operation.
X X Inspect flap ventilation holes for obstruction.
Inspect landing flaps gear drive, flap position transmitter and
X X
FLAPS switch for damage and improper operation.
Check flap guidance, flap actuation system, flap limit switches

X X
and flap asymmetry senders. Refer to Chapter 27-50-00.
Lubricate flap track mechanism as per Chapter 12-20-04
2
X X
Lubrication Chart.
Inspect navigation lights, recognition lights, wingtip strobe
X X lights for broken lenses, insecurity, improper wiring and
operation.
Inspect electrical leads, radio antenna leads, pneumatic lines
X X and attachment for improper routing, deterioration and
incorrect installation.
Inspect pitot tubes for poor condition, obstruction and damages.
X X
Inspect pitot heat for poor condition and improper operation.
Inspect pitot lines and attaching for improper routing,
X X
deterioration, poor condition and leaks. Drain pitot lines.
Inspect stall warning system for poor condition and insecurity
of installation. Perform operational check including stall warn
X X
heat (Refer to POH, Section 4, Normal Procedures (Amplified),
Preflight Inspection).
Inspect de-icer system (wing and control surfaces) for poor
X X
condition and improper operation.
1
2
as specified in Chapter 12-20-04 Lubrication Chart
Page Date: 9.
30.August
March2013
2012 05 Page 25
Maintenance Manual
Extra 500
Control Systems and Surfaces

Flight Hours Date:
as specified
Mechanic
Inspector
Serial No.:
1000
100
Description
Remove outer wing access panel, fin access panel, tail fairing,
X X
fin tip and central horizontal stabilizer access panel.
X X Inspect control and stabilizer ventilation holes for obstruction.
Inspect stabilizer surfaces for dents, cracks, nicks and
X X
delaminations.
Inspect rudder for insecurity of attachment, free movement,
X X
dents, cracks and delaminations.
Inspect rudder hinges, attachment and bearings, stops,
X X centering spring for cracks, excessive wear, insecurity and
improper operation.
Inspect elevator surface for dents, cracks, nicks and
X X
delaminations.
Inspect elevator hinges, elevator trim tab hinges, attachment
X X and bearing for poor condition, cracks, excessive wear,
insecurity and improper operation.
1 Inspect horizontal stabilizer main bolts for poor general
condition, distortion and insecure attachment.
2 Perform Horizontal Stabilizer Main Bolts Inspection as per
Chapter 55-10-01.
X X Check elevator trim system for improper operation and rigging.
Inspect elevator balance weight for looseness and poor
X X
condition.
Inspect aileron, rudder, elevator and elevator trim cable
systems including turnbuckles, sleeves, fair leads, pulleys,
X X
cable retracting springs and push pull rods per FAA-AC1
43.13-1B for lack of safetying, damage and improper operation.
X X Check all cable tensions using a tensiometer.
X Inspect rudder control torque tubes, bottom panel, shelf,
linkage, control cable, sprocket wheel and interconnection for
X poor condition, distortion and insecurity. Inspect control cable
connections for poor condition, chafing, distortion and
insecurity.
1
Annually
2
Every 5000 flight hours
9. August 2012
Maintenance Manual
Extra 500
as specified
Flight Hours Date:
Mechanic
Inspector
Serial No.:
1000
100 Description
1 Examine control springs for mechanical damage, corrosion, and
wear at the clevisses. Refer to Chapter 27-00-10.
Lubricate control system components as per Chapter 12-20-04
X
Lubrication Chart
X X Reinstall access panels.
1
Annually
Maintenance Manual
Extra 500
Landing Gear
Flight Hours Date:
as specified
Mechanic
Inspector
Serial No.:
1000
100
Description
area !
the electric circuit breaker located on the left side panel and marked
GEAR CTRL.
In case of intentional gear operation by switch or circuit breaker
handling make sure, that neither a person nor material is in the landing
gear working area.
NOTE With the aircraft being airborne or jacked with retracted landing gear
and BATT switch OFF, the hot bus feeds an AUX circuit, which supplies
the directional valves with electrical power to keep the landing gear in
the up-position. The AUX circuit is protected by the GEAR
AUX 1 (left side panel) and GEAR AUX 2 (E-box, engine compartment)
circuit breakers.
However, the nose gear and main gear will slowly extend due to valve oil
leakage, if the hydraulic pump is not being activated temporarily to
maintain hydraulic pressure. If retracted landing gear position is in-
tended, turn BATT switch ON and push circuit breakers GEAR CTRL (left
side panel) to the ON position, while the LANDING GEAR switch (left
main panel) is in the UP position.
If the aircraft is jacked with landing gear retracted and external power
not connected, the battery will be discharged within approx. 2 days.
X X Place the airplane on jacks.
Inspect the main gear struts for poor condition, cracks,
X X
bending, distortion and insecurity.
Inspect the main gear and nose gear shock absorber for oil-
X X
leakage and scoring.
Check the main gear struts for maximum extension and
X X
overcentering of the radius struts.
Inspect the main gear bolts, bearings for lack of safety and poor
X X
condition, cracks, excessive wear and insecurity.
X X Inspect the web plate at the main landing gear frame for cracks.
X X Check the parallel strut and axle bar for vertical clearance.
X X Inspect all actuator brackets for cracks.
X Inspect main gear struts attachments for poor condition and
X
insecurity.

9. August 2013
Maintenance Manual
Extra 500
as specified
Flight Hours Date:
Mechanic
Inspector
Serial No.:
1000
100 Description
Inspect track rods and attaching for poor condition, distortion
X X
and insecurity.
X X Inspect rear preloaded axle stop for poor condition.
Check the nitrogen inflation of the main gear-shock absorber
X X
(57 bar/827 psi ).
X X Inspect all wiring for poor condition, chafing and insecurity.
Inspect nose gear struts, trunnion pins and attachments for poor
X X
condition and insecurity.
Inspect the nose gear trunnion for poor condition, cracks and
X X
distortion.
Check the nose gear strut for maximum extension and
X X
overcenter of the radius strut.
Check the nitrogen inflation of the nose gear shock absorber
X X
(15 bar/218 psi ).
Inspect the nose wheel steering arm and its thrust bearing for
X X
poor condition and any damage.
Inspect the fixing nose of the steering arm guide block for poor
X X
condition, cracks and bending.
Inspect the spring device assembly of the nose wheel steering
X X
and its attaching for looseness and any damage.
Inspect the nose wheel steering cables for wear and any
X X
damage.
X X Inspect shimmy damper and attaching for poor condition.
Inspect the gas springs of the nose gear strut and attaching for
1
poor condition and insecurity. Perform Test Procedure as per
Chapter 32-30-25.
X X Inspect all wiring for poor condition, chafing and insecurity.
2 Remove hydraulic sump. Clean filter and change hydraulic
fluid (see Chapter 32-30-11).
Inspect the hydraulic lines for leakage, poor condition, chafing,
X X
bulges and insecurity. Replace hoses and fittings as required.
Inspect the power pack and the distributor block for leakage,
X X
poor condition and insecurity.
1
2
every 5 years.
Page Date: 9.
30.August
March2013
2012 05 Page 29
Maintenance Manual
Extra 500
Flight Hours Date:

as specified
Mechanic
Inspector
Serial No.:
1000
100
Description
Check the hydraulic fluid level of the hydraulic power pack
X X
(see Chapter 32-30-11) Refill as required.
Inspect the main and nose gear doors, door hinges and levers
X X
for cracks, distortion, insecurity and freedom of movement.
Inspect the main and nose gear door actuation mechanism for
X X poor condition, deformation, excessive free play and excessive
wear.
Inspect the hydraulic actuators and attachment for poor
X X
condition and insecurity.
X X Check the main gear-interlocking actuator for locking.
Remove the push-pull rods from the upper main gear doors.
X X
Fasten the doors in the open position by means of tapes.
area !
handling make sure, that neither a person nor material is located in the
landing gear working area.
Before beginning any work in the landing gear operating area, esp. any
adjustment after performing test procedures, pull OFF the electric
circuit breaker located on the left side panel and marked GEAR CTRL.
Lift the aircraft on jacks. Operate the landing gear
(see Ch. 32-00-00 Operation). Inspect the hydraulic hoses and
X X
track rods for freedom of movement, chafing and distortion in
extended and retracted position.
Perform gear up procedure (refer to Ch. 32-00-00 Operation).
Inspect the main and nose gear door actuation mechanism for
X X incorrect adjustment in the closed position. In case of doors
closing with too much play or tension, adjust length of
respective push rods (refer to Ch. 32-10-20/32-20-20).
1 Perform test procedures in accordance with Ch. 32-00-00 and
32-30-25 Test Procedures.
Clean the position switches; inspect for poor operation,
X X
insecure seat and incorrect adjustment.
Inspect position switch wiring and harness for poor condition,
X X
chafing, any damage and insecurity.
X X Check the gear position lights on the panel for operation.
1
Annually
9. August 2013
Maintenance Manual
Extra 500
as specified
Flight Hours Date:
Mechanic
Inspector
Serial No.:
1000
100 Description
X X Reinstall push-pull rods to the upper main gear doors.
Clean and lubricate landing gear according to Chapter 12-20-
X X
04 Lubrication Chart.
Replace all NMB M81935/1–6 rod ends (i.e. piston rod ends of
X the short main hydraulic cylinders as well as the track rod ends,
refer to Figure 32-8 in Chapter 32-30-00).
Page Date: 9.
30.August
March2013
2012 05 Page 31
Maintenance Manual
Extra 500
Wheels and Brakes

Flight Hours Date:
as specified
Mechanic
Inspector
Serial No.:
1000
100
Description
NOTE Refer to on-aircraft inspections presented in the latest edition of
Cleveland Technician’s Service Guide (LOAP 34) and Component
Maintenance Manual (LOAP 35) for wheel, tire and break inspections.
area!
the electric circuit breaker located on the left side panel and marked
GEAR CTRL.
handling make sure, that neither a person nor material is in the landing
gear working area.
NOTE With the aircraft being airborne or jacked with retracted landing gear
and BATT switch OFF, the hot bus feeds an AUX circuit, which supplies
the directional valves with electrical power to keep the landing gear in
the up-position. The AUX circuit is protected by the GEAR
AUX 1 (left side panel) and GEAR AUX 2 (E-box, engine compartment)
circuit breakers.
maintain hydraulic pressure. If retracted landing gear position is in-
tended, turn battery switch ON and push circuit breaker GEAR CTRL
(left side panel) to the ON position, while the LANDING GEAR switch (left
main panel) is in the UP position.
X X Place the airplane on jacks.
X X Check the brake fluid level.
X X Inspect the brake assemblies for poor general condition.
X X Inspect the brakes and the master cylinder for leakage.
Inspect the brake lines and fittings for leakage and the hoses for
X X
bulges. Replace hoses as required.
Inspect the brakes for corrosion, cracks and visible damage.

X X
Inspect inlet fitting bosses and anchor bolt lugs for cracks.
X Inspect fit of brake cylinder anchor bolts in torque plate
X bushings for sloppiness. Excessive movement is cause for
removal and detailed inspection.

9. August 2013
Maintenance Manual
Extra 500
as specified
Flight Hours Date:
Mechanic
Inspector
Serial No.:
1000
100 Description
Inspect the lining for wear (min. thickness 2.54 mm/0.1 inch.).
X X
Replace if required.
X X Lubricate the brake guide pins using silicone - base lubricant.
Inspect the wheels for corrosion, cracks, loosen or broken bolts
X X
and any damage.
X X Inspect the wheel nuts for improper installation and insecurity.
X X Check the wheel bearing clearance and wheels for free rotation.
Inspect the brake disc for rust, grooves, coning, cracks, wear
and visible damage. Check disc thickness (min. 8.25
X X mm/0.325inch.). Replace if required. (Refer to Cleveland
Technician’s Service Guide (LOAP 34) and Component
X X Inspect the brakes for improper adjustment.
Remove the wheels and wheel bearings. Inspect wheel bearings
X X
for excessive wear or damage. Replace on condition.
Inspect the snap rings for distortion and wear. Inspect grease
X X
for contamination and solidification.
Repack the bearings with AEROSHELL 22C (per MIL-G-
X X
81322).
Visually inspect the tires for wear, cuts, flat spots, and tread or
side wall damage. For tire changing refer to Cleveland
X X
Technician’s Service Guide (LOAP 34) and Component
X X Reinstall the wheels and secure.
Check tire inflation pressure. Main wheels 5.1 bar/74 psi, nose
X X
wheel 3.5 bar/51 psi.
X X Inspect the wheels for improper alignment.
X X Lubricate as per Chapter 12-20-04 Lubrication Chart.
Depress ground safety switches by removing them from nose
1
gear torque link (See Figure 32-5). Check anti-retraction
system by gear lever operation. Reinstall switches.
Do not remove jacks before the landing gear is complete extended and
CAUTION locked and the anti - retraction system has been checked.
Lower the aircraft as per Chapter 7 and remove the jacks and
X X
jack points.
1
Page Date: 9.
30.August
March2013
2012 05 Page 33
Maintenance Manual
Extra 500
Completion
Flight Hours Date:
as specified
Mechanic
Inspector
Serial No.:
1000
100
Description
1
X X Perform Flight Test.
1
X X Perform checks given for special equipment installed.
1 Reinstall upper and lower cowling, panels and doors as
X X
appropriate.
1
X X Aircraft conforms to specification of respective Authority.
1
X X All required Airworthiness Directives complied with.
1
X X All EXTRA mandatory Service Bulletins complied with.
1 All vendor Service Bulletins and Service Letters complied
X X
with.
1
X X Check for proper Flight Manual.
1
X X Aircraft papers in order.
1
As required.
Maintenance Manual
Extra 500
05-30-00 FLIGHTLINE INSPECTIONS
05-30-01 General
These checks include pre-flight and post-flight checks. When the aircraft is in
operation, these checks have to be performed daily.
05-30-02 Pre - Flight Check

This check must be carried out before the first flight of the day and serves as a
guideline for the pilot to check the general condition of the aircraft and the
engine.
The pre-flight check is fundamental for the flight safety and has to be
performed thoroughly in all details.
The schedule for the pre-flight check is in the EXTRA 500 Pilot's Operating
Handbook, Section 4.
05-30-03 Post - Flight Check

This post-flight inspection has to be performed after the last flight of the day
and consists of some visual checks.
The post-flight inspection should include all steps of the pre-flight check.
Additional measures:
1 Re-fuelling of the aircraft (refer to Chapter 12-10).
2 Reviewing of the entries in the log book for open discrepancies and correct
entries of the landings and the flight hours.
3 If necessary, mooring of the aircraft (refer to Chapter 10-20).

Maintenance Manual
Extra 500
05-50-00 UNSCHEDULED MAINTENANCE CHECKS
05-50-01 General
Unscheduled checks are exceptional and have to be performed only after
abnormal events which are unusual at normal operating conditions and which
could possibly have caused damage to the aircraft or impaired the
airworthiness.
The 50 hours - Inspection for new, repaired or overhold engines is categorized
as an unscheduled check, since it has to be performed only once after the first
50 h of operation of the engine.
05-50-02 50 Hours – Inspection of Engine

If a new, repaired or overhauled engine is installed, perform a 50 hours –
inspection following the instructions of Rolls Royce 250-B17F Series
05-50-03 Hard Landing

After an extremely hard landing or other unusual loads on the landing gear, a
thorough check of the respective components and their attachment points is
necessary. Even, when there are no obvious signs of damage, a visual check
has to be performed.
The check has to be carried out as follows:
1 The landing gear attachment area has to be examined for defects (e.g. cracks)
using a mirror and a torch, check the outer laminate for delamination (press
onto the laminate with your thumb).
Furthermore, the struts have to be checked for deformations and cracks.
IMPORTANT Examine wheel track
The tires have to be checked for cuts in the side wall and the brake discs for
impacts.
2 In the area of the nose gear, the belly of the fuselage should be checked for
cracks. Delaminations in the bonding area of the fire wall frame may also
occur.
The condition (cracks, deformations) of the complete nose gear has to be
checked.

Maintenance Manual
Extra 500
3 After hard landings with damage observed, the attachment bolts of the landing
gear have to be examined for cracks (magnaflux or x-ray; dye-check is not
suitable in this case) or must be replaced.
4 In addition to the landing gear, all control surfaces (hinges, mass balance) and
the complete engine mount (engine truss, attachment points of the engine truss
at the fire-wall, shock mounts) have to be checked.
5 In addition, the wing structure has to be checked the main spar area plus the
shear force fittings and particularly the spar connection.
Also the wing-to-fuselage connection bolts have to be examined.
6 The same inspection has to be performed on the elevator.
IMPORTANT If there are indications that structural parts are damaged, the
manufacturer has to be consulted for possible and suitable repair
methods.
7 If any damage of landing gear or aircraft structure is detected, perform an
engine special inspection. Refer to the applicable chapter of Rolls Royce 250-
B17F Series Operation and Maintenance Manual (LOAP 1).
05-50-04 Engine Fire

After an engine fire, all hoses and cables have to be checked and if necessary
replaced. A check of the engine has to be carried out according to the
procedures in the applicable chapter Rolls Royce 250-B17F Series Operation
and Maintenance Manual (LOAP 1).
If parts of the airframe or the engine cowlings are suspected of being damaged
by high temperatures (sign of blister on the protective paint, signs of resin
brown coloration or delamination), the manufacturer has to be consulted for
assistance in damage evaluation before the aircraft is returned into service.
05-50-05 Propeller Strike, Sudden Stoppage

and Violent Engine Stoppage
Refer to applicable Maintenance Instructions of MT-Propeller (LOAP 3-5) and
Rolls Royce (LOAP 1).
05-50-06 Lightning Strike

Contact the manufacturer.
Page Date: 9.
30.August
March2013
2012 05 Page 37
Maintenance Manual
Extra 500
05-50-07 Engine Overspeed

Refer to applicable Maintenance Instructions of MT-Propeller (LOAP 3-5) and
Rolls Royce (LOAP 1).

Maintenance Manual
EXTRA 500
Chapter 06
Dimensions and Areas

Maintenance Manual
EXTRA 500
Table of Contents
06-10-00 MAIN DATA ..................................................................................................... 3

06-10-01 Main Dimensions .............................................................................................. 3
06-10-02 Wing ................................................................................................................... 3
06-10-03 Horizontal Tail .................................................................................................. 3
06-10-04 Elevator.............................................................................................................. 3
06-10-05 Vertical Tail....................................................................................................... 4
06-10-06 Rudder ............................................................................................................... 4
06-10-07 Ailerons .............................................................................................................. 4
06-10-08 Settings and Deflections ................................................................................... 4

Maintenance Manual
EXTRA 500
06-10-00 MAIN DATA
06-10-01 Main Dimensions

Length: 10.13 m (33.23 ft)
Height: 3.37 m (11.06 ft)
Span: 11.60 m (38.06 ft)
Wheelbase: 2.65 m (8.69 ft)
Wheel-track: 2.20 m (7.22 ft)
MTOW: 2,130 kg (4,696 lbs.)
06-10-02 Wing
Span: 11.60 m (38.06 ft)
2
Area: 14.265 m (153.55 sq.ft.)
Airfoil: Root: NLF 22 - .05, 16.5 %
Tip: NLF 23 - .05, 13 %
06-10-03 Horizontal Tail

Span: 3.80 m (12.47 ft)
Airfoil: NACA 0012
06-10-04 Elevator
Total projected nested area: 1.13 m2 (12.16 sq.ft.)

Maintenance Manual
EXTRA 500
06-10-05 Vertical Tail

Airfoil: Root: NACA 2412
Tip: NACA 0012
06-10-06 Rudder
06-10-07 Ailerons
06-10-08 Settings and Deflections

Flaps
Take-off: 15°, tolerance ± 3°
Landing: 30°, tolerance + 1°/-2°
Ailerons: 27° up, tolerance + 0°/-2°
19° down, tolerance + 2°/-0°
Rudder: 25° left/right, tolerance + 0°/-2°
Elevator: 33° up, tolerance + 0°/-2°
18° down, tolerance + 2°/-0°
Trim tab
(at 0° elevator deflection): 20° up (nose down), tolerance ± 2°
30° down (nose up), tolerance ± 2°

Maintenance Manual
EXTRA 500
Chapter 07
Lifting and Shoring

Maintenance Manual
EXTRA 500
Table of Contents
07-10-00 JACKING .......................................................................................................... 3

Maintenance Manual
EXTRA 500
07-10-00 JACKING
Jacking of the EXTRA 500 will be necessary for tire replacement, landing gear
operation on ground or if either the main landing gear or the nose gear has to
be removed or installed.
Perform the following steps, if it is necessary to lift the aircraft off the ground:
Do not raise the aircraft on jacks out of doors when wind velocity is
CAUTION above 10 MPH. Jacks should be placed on hard and even surface.
1 Install jack points to the tie-down eyebolt receptacles in the middle of each
wing and at the bottom of the fuselage, between nose gear and main gear
(thread-diameter M8). Make sure jack points are fully screwed in.
2 Use standard aircraft jacks at both wing hoist points and behind the nose
gear (tie-down eyebolt receptacles). While holding jack point in place, raise
jack up to firmly contact with jack point.
When raising the aircraft, apply pressure on all jacks simultaneously
CAUTION and evenly to keep the aircraft leveled as it is raised. Otherwise the
aircraft could slip from the jacks!
3 Raise the aircraft, keeping wings as level as possible.
4 Secure safety locks on each jack.
Check landing gear three greens before lowering the aircraft.
CAUTION
When lowering the aircraft, bleed off pressure on all jacks
CAUTION simultaneously and evenly to keep the aircraft leveled as it is lowered.

Maintenance Manual
EXTRA 500

Maintenance Manual
EXTRA 500
Chapter 08
Leveling and Weighing

Maintenance Manual
EXTRA 500
Table of Contents
08-10-00 WEIGHING AND BALANCING ................................................................... 3
08-20-00 LEVELING ....................................................................................................... 4

08-20-01 Longitudinal Leveling ...................................................................................... 4
08-20-02 Lateral Leveling ................................................................................................ 4

Maintenance Manual
EXTRA 500
08-10-00 WEIGHING AND BALANCING

For detailed weighing procedure and related forms refer to Section 6 of the
EXTRA 500 Pilot’s Operating Handbook.

Maintenance Manual
EXTRA 500
08-20-00 LEVELING
08-20-01 Longitudinal Leveling

Place a spirit level on the upper edge of the lower cabin door in closed position
for longitudinal leveling. Check with indication of spirit level installed in the
door. Level the aircraft by increasing or decreasing air pressure in the nose
wheel tire.
08-20-02 Lateral Leveling

Place a spirit level on the inner front seat rails for lateral leveling. Level the
aircraft by inflating or deflating the main wheel tires

Maintenance Manual
EXTRA 500
Chapter 09
Towing and Taxiing

Maintenance Manual
EXTRA 500
Table of Contents
09-00-00 GENERAL ........................................................................................................ 3
09-10-00 TOWING ........................................................................................................... 4
09-20-00 TAXIING ........................................................................................................... 5

Maintenance Manual
EXTRA 500
09-00-00 GENERAL
This chapter describes the procedures and precautions necessary for proper
ground handling of the EXTRA 500.
Minimum turning radius is 20.8 m [68.2 ft].
Exercise care not to turn the nose wheel past its normal swivel angle of 30°
CAUTION to each side of center. Exceeding the turn limits will cause structural
damage.

Maintenance Manual
EXTRA 500
09-10-00 TOWING
When preparing for ground handling operation ensure that the battery
DANGER switch is OFF.
Use a tow-bar to move the aircraft on ground. The tow-bar attaches to the nose
gear fork, just above the nose wheel.
Moving the aircraft with a vehicle, especially when pushing in backward
CAUTION direction or moving on rough ground, may cause substantial damage to
the nose gear strut.
On smooth ground surfaces the aircraft may be towed carefully by coupling a
vehicle to the tow-bar, but only in forward direction at low driving speed.
Do not handle the aircraft at the end of the propeller blades.
CAUTION
If no tow-bar is available, or when assistance in moving the aircraft is required,
push the aircraft by hand on the inboard portion of the propeller blades,
adjacent to the propeller hub and/or doorframe.

Maintenance Manual
EXTRA 500
09-20-00 TAXIING
Before attempting to warm up or taxi the aircraft, ground procedures should be
checked by qualified pilots or other responsible personnel. All taxiing should
be done at slow speed, and the controls should be set to appropriate positions in
order to minimize the effects of gusty wind.
Taxiing over loose gravel or cinders should be done at low engine speed to
CAUTION minimize damage to the airframe surfaces due to stone impact.
To taxi the aircraft, proceed as follows:
1 Start and warm up engine in accordance with the applicable paragraphs in
Section 4 of the EXTRA 500 Pilot's Operating Handbook.
Operate only with the engine in GROUND IDLE.
CAUTION
2 Taxi forward a few feet and check brake effectiveness.
3 While taxiing, make shallow turns to test nose gear steering.

Maintenance Manual and Illustrated Parts Catalogue
Extra EA-400
Towing & Taxiing

Maintenance Manual
EXTRA 500
Chapter 10
Parking, Mooring, Storage and
Return to Service

Maintenance Manual
EXTRA 500
Table of Contents
10-00-00 GENERAL ........................................................................................................ 3
10-10-00 PARKING/STORAGE ..................................................................................... 4

10-10-01 Short - term Parking ........................................................................................ 4
10-10-02 Long - term Parking ......................................................................................... 4
10-10-03 Outdoor Storage ............................................................................................... 4
Aircraft................................................................................................................ 5
Engine ................................................................................................................. 5
10-20-00 MOORING ........................................................................................................ 6
10-30-00 RETURN TO SERVICE .................................................................................. 7

Maintenance Manual
EXTRA 500
10-00-00 GENERAL
This chapter provides the procedures recommended to park or to moor the
EXTRA 500 so that the likelihood of ground damage is minimized.
Additionally, it describes precautions for protecting the engine during periods
of storage.

Maintenance Manual
EXTRA 500
10-10-00 PARKING/STORAGE
When parking the aircraft, head the nose in the wind.
10-10-01 Short - term Parking

The parking brakes may be used for short-term parking. To set the parking
brakes at both main wheels, operate as follows:
1 Press both rudder pedals from either pilot's or copilot's seat.
2 Pull the parking brake control on the middle console.
To release the parking brakes, push the parking brake control forward.
Do not set the parking brakes, when they are overheated or during cold
CAUTION weather conditions when moisture and slush accumulation could freeze in
the brake mechanism.
When using the parking brakes for an extended period of time an air
temperature rise could cause the hydraulic fluid to expand, which may
result in brake system damage and / or difficulties in releasing the
brakes.
Additionally place wheel chocks fore and aft both main wheels to prevent
movement of the aircraft.
10-10-02 Long - term Parking

For parking the aircraft over a longer period of time, proper mooring and tie-
down is recommended. Refer to Chapter 10-20-00.
10-10-03 Outdoor Storage

Outdoor storage requires adequate mooring and tie-down facilities. Refer to
Chapter 10-20-00 for mooring instructions.
The following precautionary measures are recommended for keeping the
aircraft serviceable:

Maintenance Manual
EXTRA 500
Aircraft
1 Keep the fuel tanks filled at least one-half full to minimize moisture
condensation.
2 Keep the battery fully charged.
3 Install protective covers over pitot tube, engine cowling openings, canopy,
etc.
4 Maintain a good wax finish on all exterior surfaces.
5 Check tire pressure each 30 days.
Engine
Refer to the Rolls Royce 250-B17F Series Operation and Maintenance Manual
(LOAP 1).

Maintenance Manual
EXTRA 500
10-20-00 MOORING
Careful tie-down proceeding is the best precaution against damage to the
aircraft caused by gusty or strong winds. To tie-down the aircraft securely,
carry out the following steps (Also refer to Subject 10-10-03):
1 Head the aircraft into the wind.
2 Place chocks fore and aft each main wheel.
3 Install tie-down eyebolts to the respective receptacles in the middle of each
wing and at the bottom of the fuselage, between nose gear and main gear.
4 Drive stakes into the ground below each wing tip and next to each main
wheel.
5 Tie sufficiently strong ropes or chains to the wing and bottom tie-down eyes
and anchor to the ground stakes. Allow a little slack in each tie-down rope.
NOTE During severe weather conditions and strong winds, hangar the aircraft
for maximum protection.

Maintenance Manual
EXTRA 500
10-30-00 RETURN TO SERVICE

If the aircraft has been stored for an extended period of time, it is advisable to
perform a 50-hour periodic inspection. Refer to Chapter 05-20 Scheduled
Maintenance Checks.
To return the engine to service refer to the Rolls Royce 250-B17F Series

Maintenance Manual
EXTRA 500

Maintenance Manual
EXTRA 500
Chapter 11
Placards and Markings

Maintenance Manual
EXTRA 500
Table of Contents
11-00-00 GENERAL ........................................................................................................ 3

Maintenance Manual
EXTRA 500
11-00-00 GENERAL
NOTE All placards should be inspected for proper location, readability and
security during maintenance actions. When an airplane has been painted
inspect all placards to assure that they are not obscured by paint.
The required placards installed on this airplane contain operating limitations

and instructions. All placards and their locations, both interior and exterior, are
listed in Section 2 of the EXTRA 500 Pilot's Operating Handbook.

Maintenance Manual
EXTRA 500

Maintenance Manual
EXTRA 500
Chapter 12
Servicing

Maintenance Manual
EXTRA 500
Table of Contents
12-00-00 GENERAL ........................................................................................................ 3
12-10-00 REPLENISHING.............................................................................................. 4
12-10-01 Refueling ............................................................................................................ 4
Fuel Grade .......................................................................................................... 4
Fuel System Capacities ....................................................................................... 5
12-10-02 Draining ............................................................................................................. 6
12-10-03 Fuel Drains ........................................................................................................ 6
12-10-04 Replenishment of Engine Oil ........................................................................... 7
Oil Grades ........................................................................................................... 7
Oil System Capacities ......................................................................................... 7
12-10-05 Oil Change ......................................................................................................... 8
12-10-06 Replenishment of Brake Fluid ......................................................................... 8
Brake Fluid Grade .............................................................................................. 8
Brake Fluid System Capacity ............................................................................. 8
12-10-07 Brake Bleeding Procedure ............................................................................... 9
12-10-08 Tire Inflation ................................................................................................... 10
12-10-09 Main Gear Shock Absorber ........................................................................... 11
Oil Draining/Refilling....................................................................................... 11
Hydraulic Fluid Grade ...................................................................................... 11
Hydraulic Fluid Capacity.................................................................................. 11
Nitrogen Inflation Pressure ............................................................................... 11
12-10-10 Nose Gear Shock Absorber ............................................................................ 12
Oil Draining/Refilling....................................................................................... 12
Hydraulic Fluid Grade ...................................................................................... 13
Hydraulic Fluid Capacity.................................................................................. 13
Nitrogen Inflation Pressure ............................................................................... 13
12-20-00 SCHEDULED SERVICING .......................................................................... 14

12-20-01 Exterior Cleaning ........................................................................................... 14
12-20-02 Interior Cleaning ............................................................................................ 15
12-20-03 Engine Cleaning .............................................................................................. 15
12-20-04 Lubrication Chart........................................................................................... 16
12-30-00 UNSCHEDULED SERVICING .................................................................... 18

12-30-01 Removal of Snow and Ice ............................................................................... 18

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Maintenance Manual
EXTRA 500
12-00-00 GENERAL
This chapter describes the procedures and precautions necessary for proper
servicing of the EXTRA 500. The specified intervals (refer to Chapter 5) are
considered adequate to meet average requirements under normal operating
conditions.
It is advisable, however, to shorten service and maintenance intervals when
operating under abnormal conditions, such as extreme temperature ranges,
dusty atmospheric conditions, high humidity and moisture, unimproved airport
facilities, or unusual operating requirements.

Maintenance Manual
EXTRA 500
12-10-00 REPLENISHING
The replenishing procedures contained in this section provide the proper
methods for replenishing consumed fuel, engine oil and brake fluid. Also
included are methods for inflation of tires.
12-10-01 Refueling
Refueling is accomplished by pumping or pouring fuel into the main and
auxiliary compartment of each wing tank through their respective filler caps.
When fueling the aircraft, the following safety precautions must be followed:
If the fuel system has been completely drained, the fuel system bleeding
DANGER procedure must be performed (see Chapter 28-20-00). If the fuel system is
not free of air, an engine flame out may be the result.
Never refuel the aircraft with the engine running.
Always ensure that the aircraft is grounded before refueling.
Ensure that no one is smoking within 100 feet of the aircraft.
Ensure that all aircraft electrical systems are deenergized while refueling.
Ensure that no aircraft radar or powerful transmitters are operating
within 100 feet of the aircraft during fueling.
If fuel is spilled, ensure that the area of spillage is thoroughly flushed with
water and that all residual fuel and vapor have dissipate or neutralized
prior to starting the aircraft engine.
IMPORTANT To prevent lateral fuel unbalance, make sure the left and right collector
and main compartments are full before filling any auxiliary compartment.
Maximum permissible fuel unbalance in flight is 106 liter (one auxiliary
tank).
After refueling, it has to be ensured that all four fuel tank caps are
securely installed prior to flight.
Wait at least five minutes after refueling for moisture and sediment to
settle before draining and checking the fuel drain valves.
Fuel Grade
Fuel confirming the following commercial specifications are approved for
unrestricted use:
Primary Fuel
ASTM D 1655-03 or later, grade JET A or A-1
Cold Weather Fuel

ASTM D 1655-03 or later, grade JET A or A-1 with anti ice additive MIL-
DTL-85470B or later

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When adding anti-icing additive into the fuel during refueling.

CAUTION
Proper mixing of anti icing additive with fuel is extremely important,
because concentration in excess of the recommended (0.10 % up to 0.15
% by volume) will result in detrimental effects to the fuel tanks.
NOTE JET A and JET A-1 fuels are not restricted from use at ambient
temperatures below –18 °C (0 °F); however, special provisions for
starting (preheat to the engine fuel control area) must be made. Once
started, engine operation will be satisfactory in outside temperatures
down to –32 °C (-25 °F) for JET A and JET A-1.
Use of Fuel Grades Temperature Dependent

Starting and operating temperature ranges:
Fuel grade for
Ambient temperature
Starting Operating
at +38 °C(+100 °F) Primary
down to +4 °C (+40 °F)
below +4 °C (+40 °F) Cold weather
down to-18 °C (+0 °F)
below -18 °C(+0 °F) Cold weather Cold weather
down to -32 °C (-25 °F) preheated
Fuel System Capacities

Fuel quantity is based on fuel grade JET A-1 at 15 °C (59 °F) with specific
gravity 0.814 kg/l and shown in table below:
IMPORTANT The maximum allowable fuel unbalance is 106 liters (28 U.S. Gallons).
The left and right wing are subdivided in three compartments each; the
collector, main and auxiliary compartment.
Wing Tank Liter lbs Kg US Gal. Remark
Collector 2 x 37.4 2 x 67.1 2 x 30.4 2 x 9.9 One indicator
Compartment each side
Main 2 x 196.6 2 x 352.9 2 x 160.0 2 x 51.9 One indicator
Auxiliary 2 x 106.0 2 x 190.3 2 x 86.3 2 x 28.0 One indicator
Total
680.0 1220.5 553.5 179.7
Capacity
Unusable Fuel 2 x 14.0 2 x 25.1 2 x 11.4 2 x 3.7
Usable Fuel 652.0 1170.3 530.7 172.3

Maintenance Manual
EXTRA 500
12-10-02 Draining
During the aircraft defueling observe the safety precautions specified in
DANGER Section 12-10-01.
Do not drain the fuel system when the engine or the exhaust is hot or while
DANGER the wind is strong.
Even after completely draining the fuel system fuel may rest inside the
WARNING engine and in the fuel lines downstream the check valves; which are
located next to the fuel pumps. This fuel may be pressurized.
The fuel system can be completely or partly drained.
When fuel system shall be completely drained ensure fuel selector valve is set
to BOTH. Drain at all fuel drains (for locations refer to Subject 12-10-03).
When fuel system shall be partly drained ensure fuel selector valve is set to
OFF. Then the individual fuel compartments and the area downstream the fuel
selector valve can be drained over their respective drain valves. Consider that
the collector and main compartments are connected by a check valve. So
draining the collector compartment will also reduce fuel quantity in the main
compartment.
A quantity of fuel must be drained prior to the first flight of the day and at least
five min. after refueling to inspect for water and/or contamination. Continue
draining until free of water or contamination.
IMPORTANT After draining, make sure the fuel drain valve is returned to the closed
position and the valve is not leaking.
12-10-03 Fuel Drains

The EXTRA 500 is equipped with 12 fuel drains on the locations as given in
the following table:
Designation Location
Inner and outer auxiliary compartment Each outboard wing
drains
Inner and outer main compartment drains Each center wing
Collector compartment drains Fuel sump next to each root rib
Lowest point drain Down stream of the fuel selector
valve, accessible by an opening in
the forward keel beam access
panel.
Fuel filter drain Next to the fuel filter, accessible
by an opening in the fuel filter
access panel.

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EXTRA 500
12-10-04 Replenishment of Engine Oil

The engine oil replenishment is accomplishment by pouring oil into the oil
filler spout. The oil quantity can be conveniently checked by use of the dipstick
attached to the oil filler spout cap.
If larger quantity of oil has to be filled in (e.g. if oil system has been partly
drained), follow the replenishment section of the Oil Change procedure of
Subject 12-10-05, which incorporates engine motoring (refer to Chapter 80-10-
00, Motoring and to the EXTRA 500 Pilot’s Operating Handbook).
Oil Grades
At oil temperature –54 °C (-65 °F) or above: MIL-PRF-7808L or later
At oil temperature –40 °C (-40 °F) or above: MIL-PRF-23699F or later
Minimum Starting
MIL-PRF-7808L or later -54 °C (-65 °F)
MIL-PRF-23699F or later -40 °C (-40 °F)
Only discretionary mixing of oil series is permitted without time penalty.
CAUTION If brands of oils are changed, it is recommended this change be
accomplished gradually using a "TOP-OFF" method or by draining and
refilling.
NOTE Oil series and brand used shall be recorded in engine module logbook.
Oil System Capacities

Total Oil Capacity: 7.10 l (7.49 US Quarts)
Oil Tank Capacity: 5.18 l (5.47 US Quarts)

Maintenance Manual
EXTRA 500
12-10-05 Oil Change

The engine oil must in accordance with the Rolls Royce 250-B17F Series
Operation and Maintenance Manual (LOAP 1) Ch. 72-00-00, ENGINE-
SERVICING, Lubrication System Servicing, Oil Change. Follow the
instructions in this paragraph observing the following additions:
1 Remove engine cowlings of the aircraft (see Chapter 71-10-02).
2 Follow the respective drain procedures in Chapter 79.
3 For motoring and starting procedures refer to Chapter 80-10-00, Motoring and
to the EXTRA 500 Pilot’s Operating Handbook.
4 Check oil level once more after motoring the engine.
5 Refill engine oil as necessary before starting the engine.
6 Reinstall cowlings after completion of oil change.
12-10-06 Replenishment of Brake Fluid

In order to assure proper brake action, it is necessary to have positive transfer
of hydraulic pressure through the system. Any air trapped in the system must
be removed by following the bleeding procedure described below.
The brake fluid reservoir is installed at the left side of the firewall.
Brake fluid is toxic and can cause disease!
WARNING
Do not allow brake fluid to come in contact with your skin.
In case of accidental contact flush with cold water immediately.
Brake fluid can damage paint and other material!
CAUTION
Use a bleeding tank under the RH and LH break cylinder housing.
Clean up immediately spilt brake fluid.
IMPORTANT Brake bleeding procedure must be followed very carefully. Especially the
connection between the pilot’s and copilot’s master brake cylinders has
the tendency to carry air bubbles.
IMPORTANT Assure that bleeding equipment to be used for refilling is absolutely clean
and is filled with uncontaminated brake fluid.
NOTE Two mechanics are needed to carry out the bleeding procedure.
Brake Fluid Grade

Brake fluid must conform to Specification MIL-H-5606.
Brake Fluid System Capacity

min. 0.33 L / 0.1 U.S. Gal

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EXTRA 500
12-10-07 Brake Bleeding Procedure

1 Remove upper left engine cowling.
2 Remove fluid reservoir filler plug.
3 Ensure that pilot’s and copilot’s brake pedals and parking brake are released.
4 Remove bleed valve cap of the RH wheel brake assembly.
5 Attach the bleeding equipment connector hose to the bleed valve.
6 Turn the bleeder fitting 1/2 rotation to the left for opening.
7 Slowly pump clean hydraulic fluid in the system (min. 0.33 L / 0.1 U.S. Gal).
8 Close bleed valve.
9 Disconnect bleeding equipment.
10 Install plastic hose to bleed valve.
11 Repeat steps 4 to 10 for the LH side accordingly.
12 Sit in the cockpit in a position that you can reach the right brake pedal of the
pilot’s and copilot’s side simultaneously.
NOTE Maintain an adequate supply of fluid during the entire operation. Refill
fluid reservoir if necessary. A low fluid supply will allow air to be drawn
into the system.
13 Depress and hold the pilot’s right brake pedal.
14 Depress and hold the copilot’s right brake pedal.
15 Release the pilot’s brake pedal and depress and hold it again.
16 Release the copilot’s brake pedal and depress and hold it again.
17 Repeat steps 15 and 16 until a remarkable pressure is building up and then hold
both pedals under pressure simultaneously.
18 Open the bleed valve on the RH brake cylinder housing. Both pedals must
move foreward and fluid must come out of the brake cylinder housing.
19 Keeping the pedals pressed, close the bleed valve on the cylinder housing.
20 Release the pedals and repeat step 13 to 19 until the brake pressure is okay.
A firm brake pedal must be obtained on pilot’s and copilot’s side.
21 Check the fluid level in the brake fluid reservoir. Fill up to full reservoir
capacity.
22 Remove plastic hose from bleed valve and install cap.
23 Repeat step 13 to 22 for the LH brake system accordingly.
24 Reinstall fluid reservoir filler plug.
25 Check the brake operation.
26 Install upper engine cowling.
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12-10-08 Tire Inflation

Required tire pressure:
Main wheels: 0.51 MPa (74 psi)
Nose wheel: 0.35 MPa (51 psi)
When inflating tires, regulated air pressure through valve sems has to be used.

9. August 2013
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EXTRA 500
12-10-09 Main Gear Shock Absorber
Oil Draining/Refilling
Detail Steps/Work Items Key Items
1 Place aircraft on jacks. Refer to Chapter 07-10-00.
2 Keep landing gear down and locked.
3 Ensure BATT switch is off and no
external power attached.
4 Remove the filling nipple  cover.
High-pressure oil-jet damages eyes and limbs!
WARNING The shock absorber is under high pressure (see below).
Protect yourself when expanding the nitrogen gas-pressure.
5 Push the insert of the filling nipple to
expand the nitrogen inflation.
6 Remove the plug and O-ring from outer
cylinder.
7 Drain the hydraulic fluid completely in a
sump.
8 Replace O-rings and scraper ring. Chapter 32-10-13
9 Refill hydraulic fluid into the cylinder. For hydrauliuc fluid grade and
capacity see below
10 Replace the O-ring on the plug.
11 Screw the plug in the outer cylinder.
12 Lock the plug by a safety wire.
13 Connect a nitrogen charging apparatus at
the filling nipple.
14 Refill nitrogen. Till inflation pressure as shown
below
15 Recover the cover-filling nipple.
16 Lower the aircraft. Refer to Chapter 07-10-00.
Hydraulic Fluid Grade

Use only MILH5606 hydraulic fluid
Hydraulic Fluid Capacity

420 cm/25.6 cu in
Nitrogen Inflation Pressure

5.7 MPa / 827 psi (unloaded)
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12-10-10 Nose Gear Shock Absorber
Oil Draining/Refilling
It is not possible to completely drain the nose gear shock absorber hydraulic
fluid without removal of the nose gear. However the following procedure
allows minimizing the amount of used hydraulic fluid and obtaining a
reasonable mixing.
1 Place aircraft on jacks. Refer to Chapter 07-10-00.
2 Keep landing gear down and locked.
3 Ensure BATT switch is off and no
external power attached.
4 Remove the filling nipple  cover.
WARNING The shock absorber is under high pressure (see below).
Protect yourself when expanding the nitrogen gas-pressure.
5 Push the insert of the filling nipple and
completely expand the nitrogen inflation.
6 Remove the filling nipple.
7 Drain hydraulic fluid in a sump by
completely compressing the nose gear by
hand.
8 Install a ~1.5 m transparent hose to the
nipple housing.
9 Immerse hose in a container with fresh
hydraulic fluid.
10 Slowly decompress the nose gear by hand
and thus allow hydraulic fluid to be
sucked in.
11 Repeat compression and decompression
of nose gear until hydraulic fluid is clear
and free from air bubbles.
12 Compress nose gear by hand up to
20 mm (3/4 inch) below topmost position
and hold.
13 Remove transparent hose.
14 Slowly decompress the nose gear by
hand.
15 Install filling nipple to the housing.
16 Refill nitrogen. Till inflation pressure as shown
below.

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Maintenance Manual
EXTRA 500
17 Install filling nipple cover.

18 Lower the aircraft. Refer to Chapter 07-10-00.
Hydraulic Fluid Grade

Use only MILH5606 hydraulic fluid
Hydraulic Fluid Capacity

Determined by the procedure outlined above.
Nitrogen Inflation Pressure

1.5 MPa / 218 psi (unloaded)
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12-20-00 SCHEDULED SERVICING
12-20-01 Exterior Cleaning

The painted surfaces of the aircraft have a long lasting, all-weather finish and
should require no buffing or rubbing out in normal conditions. However, it is
desirable to wash and polish it to preserve the outstanding exterior. Cleaning is
best accomplished with cool water, mixed with a mild aircraft detergent, if
required.
Do not use so called "mild" household detergents to wash aircraft exterior.
CAUTION Such detergents may damage finish and corrode aluminum components.
In order to remove especially heavy dirt from the wing leading edges due to
insect splatter and the like, it is good practice to undertake cleaning
immediately after the flight, since deposits of this kind are more difficult to
remove when dry. All lubricated components are to be covered before
cleaning.
Roughly twice a year, the complete surface should be treated with a non-
silicone car polish and repolished to high gloss. But do not apply wax or use
pre-wax cleaners during initial paint curing period. Use only mild aircraft
detergent and cool water when washing exterior during the first 90 days after
repainting.
Never use cleaning agents containing silicone!
CAUTION
In order to maintain good visibility at all times, the windshield should be given
good care and kept clean at all times. Techniques and materials used to clean
glass should be avoided since acrylic glass is softer than glass and subject to
damage by solvents and abrasive glass cleaning agents.
Therefore it should be paid particular attention to using ample water applied
with clean sponges and leather, otherwise even the smallest dust particles will
tend to scratch the glazing.
Never polish acrylic glass dry!
CAUTION
Dull or scratched canopy sections can be returned to their transparent state by
treating with especially formulated acrylic glass cleaning agents.

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Maintenance Manual
EXTRA 500
12-20-02 Interior Cleaning

Prior to the first flight of the day it is recommended to clean the interior with a
vacuum cleaner to remove dust and loose dirt. If liquid is spilled on the cockpit
floor, blot it up promptly with cleansing tissue or rags. Continue blotting until
no more liquid is taken up.
Never use gasoline, benzine, alcohol, acetone, carbon tetrachloride, fire
CAUTION extinguisher fluid, anti-ice fluid, lacquer thinner, or glass cleaner to clean
the windshield and cabin windows. These materials will damage the
acrylic glass and may cause severe crazing.
12-20-03 Engine Cleaning

Accumulation of dirt and oil within the engine compartment creates a fire
hazard and hampers inspection. All cleaning operations have to be performed
in well ventilated work areas, and it has to be ensured that adequate fire-
fighting and safety equipment is available.
Clean the engine in accordance with the Rolls Royce 250-B17F Series
Operation and Maintenance Manual (LOAP 1). Follow the procedures given
there after performing the following preparations:
1 After running, allow the engine to cool before cleaning.
2 Protect the alternator, starter-generator, other electrical components, the air
inlets and the engine cowlings against cleaning agents.
3 Do not to start the engine before the cleaning agent has been completely
removed or has evaporated.

Maintenance Manual
EXTRA 500
12-20-04 Lubrication Chart

Interval Item Location Lubricant
CAUTION Do not lubricate TEFLON coated bearings and rod ends
Engine Compartment
100 h Engine Controls Engine compartment MIL-PRF-7870
(Throttle, Cond. Lever) after disassembly:
Fork Ends and Bearings MIL-PRF-81322
100 h Engine anti-ice Engine compartment MIL-PRF-7808
Bowden Cable Ends
Controls
100 h Control Shafts Below Instrument Panel MIL-PRF-81322
100 h Cable Chain Coupling Below Instrument Panel MIL-PRF-81322
(between Control Wheels) close to the firewall
100 h Chain Interconnection Below Instrument Panel MIL-PRF-81322
(Aileron/Rudder) close to the firewall
100 h Pedal Bearings Below Instrument Panel MIL-PRF-7870
after disassembly:
MIL-PRF-81322
100 h Control Cable Bolt Pedal Torque Tube and MIL-PRF-81322
Attachments Controls/Control Surfaces
and Nose Wheel Steering
100 h Pressure Dome Control Cabin Pressure Dome MIL-G-21164
Cable Bushing
100 h Trim Tab Hinge Elevator MIL-PRF-7870
after disassembly:
MIL-PRF-81322
100 h Trim Servo Chain Tail Cone MIL-PRF-23827
100 h Wing Flap Tracks Wing MIL-PRF-81322
2000 h Front and rear Track Wing MIL-PRF-81322
Rollers at middle Flap
Tracks
2000 h Rear Track Rollers at Wing MIL-PRF-81322
inner Flap Tracks
100 h Wing Flap Spindles Wing MIL-PRF-81322
Engine Controls
100 h Bowden Cable Fork End Middle Console MIL-PRF-7870
Attachments after disassembly:
MIL-PRF-81322
100 h Control Lever Bearing Middle Console MIL-PRF-7870
after disassembly:
MIL-PRF-81322

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EXTRA 500
Interval Item Location Lubricant

100 h Control Lever Guidance Middle Console MIL-PRF-81322
Landing Gear
100 h Nose Gear Steering Arm Nose Gear Steering MIL-PRF-81322
100 h Bearings with Lubrication Nose and Main Gear MIL-G-21164
Nipple
Landing Gear Doors
100 h Upper and Lower Door LH and RH Main Gear MIL-PRF-7870
Hinges after disassembly:
MIL-PRF-81322
100 h Nose Gear Door Hinges Nose Gear MIL-PRF-7870
after disassembly:
MIL-PRF-81322
100 h Rod Ends of Telescope Nose Gear MIL-PRF-7870
Guide Rod after disassembly:
MIL-PRF-81322
100 h Rod Ends of Push-Pull Nose Gear MIL-PRF-7870
Rods after disassembly:
MIL-PRF-81322
100 h Fork Ends and Universal LH and RH Main Gear MIL-PRF-7870
Joint of Lower Doors after disassembly:
Actuating Mechanism MIL-PRF-81322
100 h Fork Ends and End Fitting Main Gear between Keel MIL-PRF-7870
of Lower Doors Actuating Beams after disassembly:
Cylinders MIL-PRF-81322
100 h End Fitting of Upper Compartment in front of MIL-PRF-7870
Doors Actuating Cylinders Main Gear after disassembly:
MIL-PRF-81322
Wheels and Brakes
100 h or Wheel Bearings Main Gear MIL-PRF-81322
annually
100 h Brake Guide Pins Brakes Copper paste

Maintenance Manual
EXTRA 500
12-30-00 UNSCHEDULED SERVICING
12-30-01 Removal of Snow and Ice

After snowfall, the snow should be removed immediately from surface of the
aircraft. Otherwise the water formed from melted snow will freeze on the
surface or in slots and gaps of fairings.
Do not use sharp tools for removing the snow.
CAUTION
If the aircraft shows signs of ice formation, it is recommended to defrost in a
room. Remove as much snow as possible with a soft bristle boom, make sure
the wheels and brakes are clear, and tow the aircraft into a room with elevated
temperature. This method is particularly desirable, since it will melt any
undetected ice and snow that could constitute a flight hazard.

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Maintenance Manual
EXTRA 500
Chapter 20
Standard Practices
Airframe

Maintenance Manual
EXTRA 500
Table of Contents
20-00-00 GENERAL ........................................................................................................ 3
20-10-00 STANDARD PRACTICES AIRFRAME ....................................................... 4

20-10-01 Width Across Flats for Metric Bolts ............................................................... 4
20-10-02 Torque Values ................................................................................................... 4
20-10-04 Special Torque Values ...................................................................................... 5
20-10-05 Measuring Techniques ..................................................................................... 6
20-10-06 Coin Tapping..................................................................................................... 6
20-10-07 Flexible Hoses .................................................................................................... 6
Replacement of Flexible Hoses .......................................................................... 6
Installation of Flexible Hose Assemblies ........................................................... 7
20-10-08 Fittings ............................................................................................................... 7
20-10-10 Bowden Cables .................................................................................................. 8
Inspections .......................................................................................................... 8
20-10-11 Engine Controls ................................................................................................ 8
Figure 20-1 Engine Control Bowden Cables Schematic ...................................................... 10
20-10-12 Rod Ends ......................................................................................................... 11
20-10-13 Fork Ends ........................................................................................................ 11
20-10-14 Installing Bolts to CFRP Structures ............................................................. 11
20-10-15 Connections of Lightning Protection System ............................................... 12

Maintenance Manual
EXTRA 500
20-00-00 GENERAL
The design of the airframe is according to standard procedures and requires no
special tools or procedures for maintenance. For that reason, only the bolts
used with the EXTRA 500 with relevant torque values and measuring
techniques are described in the following.

Maintenance Manual
EXTRA 500
20-10-00 STANDARD PRACTICES AIRFRAME
20-10-01 Width Across Flats for Metric Bolts

Thread diameter Width across flats
M4 7 mm
M5 8 mm
M6 10 mm
M8 13 mm
M10 17 mm
M12 19 mm
M16 24 mm
M20 30 mm
M24 36 mm
20-10-02 Torque Values

Nuts, except of counter nuts are mainly stop nuts according to LN 9348 or
selflocking nuts according to AN 363.
a) Standard torque values allowed for bolts and nuts according to DIN and LN
must be adhered to as follows:
Metric thread size Torque value (Nm) Torque value (in.lbs)
M4 1.8 16
M5 3.9 – 4.3 35 – 38
M6 6.2 – 6.8 55 – 60
M8 15.2 – 16.8 144 – 148
M10 29.5 – 32.5 261 – 287
M12 x 1.5 51 – 57 452 – 504

Maintenance Manual
EXTRA 500
b) Standard torque values allowed for bolts and nuts according to AN and MS
must be adhered to as follows:
Inch thread size Torque value (Nm) Torque value (in.lbs)
1/4 -28 3.5 – 4.5 30 – 40
5/16 -24 6.7 – 9.5 60 – 85
3/8 -24 10.7 – 12.5 95 – 110
7/16 -20 30.5 – 33.9 270 – 300
1/2 -20 32.8 – 46.3 290 – 410
9/16 -18 58.1 – 67.8 480 – 600
IMPORTANT On all bolt connections, the specified torque and locking method must be
observed. Do not reuse stop nuts if they can be run up finger tight!
20-10-04 Special Torque Values

Special torque values for the following items must be adhered to:
Item Torque value Torque value
(Nm) (in.lbs)
Propeller flange bolt Mühlbauer 112 990
Bolt nose wheel tire 11 90 – 100
Bolt main wheel tire 17 150
Engine mount to fuselage 75 – 80 664 – 708
(Bolts DIN 912 M12/12.9)
Engine mount to fuselage 15.2 – 16.8 135 – 149
(Bolts LN 9037 x 08)
Engine mounting (Bolts AN 7 - 44A) 32 283
Engine shock mount 11.9 – 13.0 105 – 115
Wing bolt retaining sheets front (M5 bolts) 4 36
Wing bolts rear (M10 bolts) 16 140
Fuselage joints (M6) 6.5 57.5
Fuselage joints (M8) 16 142
Wing fittings (M8) 16 142
Wing fittings (M10) 30 265
Main gear former connection bolts (M10) 25 200
Valve cover 7 60
IMPORTANT On all bolt connections, the specified torque and locking method must be
observed. Do not reuse stop nuts if they can be run up finger tight!

Maintenance Manual
EXTRA 500
20-10-05 Measuring Techniques

When using stop nuts, the safety torque (friction torque or braking torque)
should be added to the table standard values. This value is indicated on the dial
of the torquemeter, before the nut contacts the attachment surface.
Always torque nuts for fastening, if possible. When bolts are torqued there
might be an additional torque value due to shaft friction. This torque can be
determined by a torquemeter before the bolt head contacts the attachment
surface and should be added to the table value.
20-10-06 Coin Tapping

Inspection for damage is more critical for composite structure than for
conventional structures. A large washer or similar object is a valuable tool for
detecting debonds in the airframe surface. When a large washer is lightly
bounced against a solid structure, a clear metallic ring should be heard. If
delamination is present, a dull thud will be heard.
20-10-07 Flexible Hoses

The EXTRA 500 is equipped for the oil, fuel, and sensing lines with standard
"STRATOFLEX-hoses, Aerospace Connectors Division" or equivalent
"AEROQUIP-hoses, Aerospace Division", according to MIL-DTL-25579 and -
27267 specification. For the bleed air system SCEET hoses are installed. For
brake and hydraulic lines KRONTEC PTFE-Hoses 6000 are used. Maintenance
work or overhaul of these hoses requires the attention to the manufacturer's
information and bulletins.
The hoses inside the engine compartment are covered with appropriate fire
sleeves (integrated or slip-over type).
Hoses and hose assemblies should be checked for deterioration at each
inspection period. Leakage, separation of the cover or braid from the inner
tube, cracks, hardening, lack of flexibility, and excessive "cold flow" are
apparent signs of deterioration and reason for replacement. The term "cold
flow" describes the deep, permanent impressions in the hose produced by
pressure of hose clamps or supports.
Replacement of Flexible Hoses

For the replacement of hoses and hose assemblies the EXTRA should be
contacted.
Any of the following conditions require replacement of the hose assembly:
• Fitting slippage on hose,
• Damaged, cracked, cut or abraded cover (any reinforcement exposed);
• Hard, stiff, heat cracked, or charred hose;

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• Cracked or damaged fittings;

• Leaks at fitting or in hose;
• Kinked, crushed, flattened or twisted hose
• Bent to a radius smaller than the minimum bend radius
• Blistered, soft, degraded, or loose cover.
The entire assembly must be replaced, if failure occurs in a flexible hose
assembly. Obtain a new hose assembly of the correct size and length, complete
with factory-installed end fittings.
Installation of Flexible Hose Assemblies

External forces can significantly reduce hose life or cause failure. Mechanical
loads which must be considered include tensile or side loads and vibration.
In general hose assemblies should be handled with care to prevent excessive
bending, twisting and kinking. Particular attention must be given to preclude
hoses from wear, snagging, kinking, bending smaller that minimum bend
radius and cutting, any of which can cause premature hose failure.
The minimum bend radius for flexible hoses varies according to size and
construction of the hose and the pressure under which the hose is to operate.
Bends that are too sharp will reduce the bursting pressure of flexible hose
considerably below its rated value.
Large diameter hoses and very short hose assemblies are more prone to
kinking. Twisting of the hose can be determined from the identification
markings running along its length.
The flexible hose should be installed so that it will be subject to a minimum of
flexing during operation.
20-10-08 Fittings
For the oil, fuel, bleed air, and brake system only AN-fittings are used in the
EXTRA 500. In some areas of the hydraulic system special fittings are used
(metric thread).
For the assembly of PTFE-hoses and reusable fittings follow the standard
practices for such combinations.
All these fittings are made of aluminum alloy or stainless steel and are blue-
colored or clear for identification purposes. The dash number following the AN
number indicates the size of the hose for which the fitting is made, in 16ths of
an inch. This size measures the inner diameter (I.D.) of the hose. The material
code letter (Aluminum alloy: code D) follows the dash number.
Example: Elbow AN 822-8D
NOTE Clean removed fittings from sealing, sealing tape, etc. and apply
FUELUBE on the thread before installation (except ventilation system).
Don't use sealing tape for sealing.

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20-10-10 Bowden Cables

Bowden cables are used for the following systems of the EXTRA 500:
• Engine Controls (High performance Push-pull Bowden cable, stainless steel)
• Air Inlet Heating (Button lock dash control, solid wire end)
• Parking Brake (Ratchet control, solid wire end)
• Windshield Heating (solid wire end)
• Trim Control (Special TLS III cable system)
Minimum bend radius: 65 mm.
Refer to Triumph Controls Germany GmbH Installation Instructions TLE10
(LOAP 36)
• Seat adjustment locking mechanism
• Aft passenger seat back rest swivel mechanism
Inspections
Observe the following hints when performing inspections on the Bowden
cables:
A cable must be replaced whenever:
• excessive free play is felt at the control even after all cable connections have
been verified as in good working order.
• visual inspection shows chafing, breakage or bent, loose or worn parts.
• evidence of moisture is found inside (or Bowden cable has frozen).
• a gradual or sudden decrease in the stroke (travel) length of the Bowden cable
has been detected.
• a gradual or sudden increase in the no-load (cable free and unattached) friction
of a Bowden cable has been detected.
Correct routing of the Bowden cable whenever:
• misalignment, unacceptable high internal friction due to bends below minimum
radius or malfunction of sliding elements has been detected.
• the usable stroke is not centered within the available travel.
• the swivel angle is not centered within the available angle (if applicable).
20-10-11 Engine Controls

Consider the following information when working on engine Bowden cables.
Refer to Figure 20-1:
Hard and abrupt control inputs may impose high dynamic peak loads to the
related sliding parts at reaching the travel stops.
A bent swivel sleeve as well as wear and excessive free play at the pivot
(swivel) points and sliding parts are an indication of misalignment and/or hard
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and abrupt control inputs. Those signs should be found early within the regular
maintenance. This is a clear indication of an unacceptable Bowden cable
condition, which might result in a malfunction.
As soon as a Bowden cable becomes difficult to operate, the reason should be
identified. An increase in no-load (cable free and unattached) friction or an
increase in travel length of a Bowden cable are a good indication of pending
performance problems and/or Bowden cable failure.
The following notes, cautions and warnings describe application and
installation information:
Protect the cable from contaminants such as fuel, oil, water, dirt and
CAUTION chemicals, which may damage the Bowden cable.
Protect the cable from physical damage by paint, kinking, vibration, etc.,
which may damage the Bowden cable.
IMPORTANT A gradual or sudden increase in the no-load (cable free and unattached)
friction of a Bowden cable is a good indication of pending performance
problems and/or Bowden cable failure. Serious injury or death may result.
Replacement is required.
A gradual or sudden decrease in the stroke (travel) length of the Bowden
cable is a good indication of pending performance problems and/or
Bowden cable failure. Serious injury or death may result. Replacement is
required.
Bowden cables, which have moisture inside of them or have frozen, must
be replaced. Do not apply heat to attempt to remove the moisture.
Applying heat will not remove the moisture. Serious injury or death may
result. Replacement is required.
NOTES Installation should be accomplished by a licensed “A” and/or “P”
mechanic.
Bowden cables are designed to be non-repairable. Do not perform any
repairs to this Bowden cable.
Cables are designed to be contaminant resistant; not contaminant proof.
The usable stroke must be centered within the available travel.
The swivel angle must be centered within the available swivel angle.
The minimum bend radius is 4".
Bowden cables are lubricated for the life of the Bowden cable. Do not
remove the seals or lubricate the Bowden cable.

Page 10
Figure 20-1
EXTRA 500
20
Maintenance Manual
10° MAX. CONICAL SWIVEL
NOT TO SCALE
BOTTOMED USABLE BOTTOMED
STROKE
OVER TRAVEL OVER TRAVEL
Engine Control Bowden Cables Schematic

RETRACTED POSITION
MID-TRAVEL POSITION EXTENDED
POSITION
PIVOT POINT FORK END
OUTER LINER (JACKET)

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20-10-12 Rod Ends

Two different kinds of rod ends are used for the EXTRA 500:
• Teflon coated
• stainless steel
The Teflon coated rod ends have to be installed dry and require no
maintenance.
The stainless steel rod ends and attachment bolts shall be lubricated with MIL-
G-81322 (Aeroshell Grease 22c) when newly installed or reinstalled. For
lubrication during scheduled maintenance (without removal/reinstallation)
MIL-PRF-7870 shall be used.
20-10-13 Fork Ends

Generally fork ends and attachment bolts shall be lubricated with MIL-G-
81322 (Aeroshell Grease 22c) when newly installed or reinstalled. For
lubrication during scheduled maintenance (without removal/reinstallation)
MIL-PRF-7870 shall be used.
20-10-14 Installing Bolts to CFRP Structures

To avoid electrochemical corrosion all non-stainless bolts and screws must be
sealed independent from their surface protection. This does not apply to
corrosion resistant steel (CRES).
1 Remove old sealant.
2 Install bolts with epoxy resin. Hardening as per
manufacturer information
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.

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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 refer to Le Joint Francais
Material Safety Data Sheet PR 1750 (LOAP 41)
3 After final torquing apply PR 1750 sealant For mixing and application of
to both the head and nut side of the bolt PR 1750 sealant refer to
including washer and thread end. manufacturer's instructions.
20-10-15 Connections of Lightning Protection System

Prior to joining or riveting prepare contact surfaces as follows:
Material Action
Aluminum Remove oxide film
Steel Remove paint
Stainless steel Degrease
Titanium Degrease
After connection of parts seal gaps and connecting elements from all sides to
avoid ingression of moisture:
Connection Action
Aluminum – Steel Apply PR 1750A
All other Apply Nycote 7-11

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Chapter 21
Air Conditioning

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Table of Contents
21-00-00 DESCRIPTION ................................................................................................ 5

Troubleshooting .................................................................................................. 7
Bleed Air System Leak Test ............................................................................... 8
Cabin Leak Test .................................................................................................. 9
Dump Test ........................................................................................................ 10
21-00-01 Sceet Hoses ...................................................................................................... 12
Replacement ..................................................................................................... 12
21-10-00 COMPRESSION ............................................................................................ 13

Description........................................................................................................ 13
21-10-01 Primary Shut-off Valve .................................................................................. 13
Removal/Installation ......................................................................................... 13
21-10-02 Mass Flow Control Valve ............................................................................... 14
21-10-03 Mass Flow Sensor ........................................................................................... 14
Check ................................................................................................................ 14
21-10-04 Mass Flow Controller ..................................................................................... 15
21-10-05 Muffler ............................................................................................................. 15
21-20-00 DISTRIBUTION............................................................................................. 16
Description........................................................................................................ 16
21-20-01 Panel Vent Fans .............................................................................................. 16
21-30-00 PRESSURIZATION CONTROL ................................................................. 18

Description........................................................................................................ 18
Operation .......................................................................................................... 18
21-30-01 Cabin Outflow Control Valve Filter ............................................................. 21
Replacement ..................................................................................................... 21
21-30-02 Cabin Outflow Control Valve ........................................................................ 21
21-30-03 Safety Valve ..................................................................................................... 22
21-50-00 COOLING ....................................................................................................... 23

Description........................................................................................................ 23
Service and Maintenance .................................................................................. 23

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21-50-01 Compressor/Condenser .................................................................................. 24

21-50-02 Evaporator ....................................................................................................... 24
21-50-03 Soft Start Module ............................................................................................ 25
21-60-00 TEMPERATURE CONTROL ...................................................................... 26

Description ........................................................................................................ 26
21-60-01 Temperature Switch........................................................................................ 27
Function Test ..................................................................................................... 27
21-60-02 Duct Temperature Sensor .............................................................................. 28
21-60-03 Cabin Temperature Sensor ............................................................................ 28
21-60-04 Temperature Controller ................................................................................. 29

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21-00-00 DESCRIPTION
Refer to Figure 21-1.
The following systems are installed in the EXTRA 500 to cope with the
various tasks of air conditioning:
• Bleed air system with mass flow control
• Ram air system
• Distribution system
• Pressurization system
• Temperature regulation system
• Cooling system
For ventilation either ram or pressurized (bleed) air is used. Before entering the
cabin bleed air is mass flow controlled and temperature can be modified by the
temperature regulation. The airflow is then ducted to the legroom and/or to the
windshield. The cabin air additionally can be cooled by the cooling system.
Pressurization is done by the bleed air system in combination with a
controllable outflow valve.
Generally air is routed through SCEET hoses. On some locations T- or Y-
distributors are connected to the hoses with worm drive hose clamps.

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Compressure/condenser module
Safety valve
Static reference port

Cabin control outflow valve
Evaporator (aft) Static reference port
Aft pressure dome
Evaporator drain float valve
High pressure refrigerant

(isolated)
Low pressure refrigerant
(return flow) Overhead channel
Temperature controller
Evaporator (front)
Mass flow controller
Evaporator drain valve
Cabin temperature sensor
Panel vent fan

Panel vent outlet
Defog/cabin distribution valve
Legroom dispenser
Temperature switch Windshield dispenser
Cabin inflow box Pressure bulkhead and firewall
with check valves
Duct temperature sensor Muffler
Mass flow sensor Air-to-air cooler
Air Inlet
Oil cooler
Temperature modulating valve

Sonic venturi Bleed air manifold
Primary shut-off valve

Engine compressor
Mass flow control valve
Figure 21-1 Cabin Air Condition and Pressurization Scheme

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Troubleshooting
Complaint Possible Cause Remedy
No or inadequate Pressurization system inactive Switch pressurization system
pressurization ON
Excessive cabin leakage Identify and seal
Excessive door seal leakage Replace door seal
Excessive emergency exit seal Replace emergency exit seal
leakage
Bleed air system leakage Perform Bleed Air System
Leak Test procedure
Dump solenoid energized Check dump switch and squat
(safety valve open) switch
Pressure controller failure Replace controller
Cabin control outflow valve Replace control outflow valve
failure
Safety valve failure Replace safety valve
Mass flow sensor failure Replace mass flow sensor
Mass flow valve failure Replace mass flow valve
Mass flow controller failure Replace mass flow controller
Incorrect pressurization or Pressurization system inactive Switch pressurization system
pressurization rate control ON
Bleed air system leakage Identify and seal
Pneumatic system leakage Identify and seal
Cabin control outflow valve Clean static reference
static reference blocked connection
Cabin control outflow valve Replace filter
filter blocked
Pressure controller defective Replace controller
Mass flow sensor failure Replace mass flow sensor
Mass flow valve failure Replace mass flow valve
Mass flow controller failure Replace mass flow controller
Incorrect pressurization or Cabin control outflow valve Replace control valve
pressurization rate control defective
Pressure differential exceeding Cabin control outflow valve Clean static reference
5.5 psi static reference blocked connection
Cabin control outflow valve Replace control valve
differential failure

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No dump Pressurization system inactive Switch pressurization system
ON
Squat switch setting incorrect Correct squat switch setting
Safety valve static reference Clean static reference
blocked connection
Dump switch defective Replace dump switch
Squat switch defective Replace squat switch
Safety valve solenoid failure Replace safety valve
Safety valve blind plug at Install blind plug
vacuum port not installed
Erroneous warning Temperature switch defective Replace temperature switch
BLEED OVERTEMP
Erroneous warning Differential pressure switch Replace differential pressure
CABIN PRESSURE (5.65 psig) defective switch
Absolute pressure switch Replace absolute pressure
(10,000 ft) defective switch
Bleed Air System Leak Test

1 Remove both upper engine cowlings. Refer to Ch. 71-10-01/02.
2 Remove bleed air hose from cabin inflow
box.
3 Install a cabin pressurization unit or
equivalent to the bleed air hose.
Risk of injury due to flying parts when pressurizing the bleed air
Warning system.
Follow cabin pressurization unit safety instructions before installing the
unit.
Apply Max. 5.5 psig air to the bleed air system.
Protect your eyes with safety glasses.
4 Inspect bleed air system for leaks using leak Seal or replace parts if
detection spray. necessary.
5 Reinstall bleed air hose to the cabin inflow
box.
6 Reinstall both upper engine cowlings. Refer to Ch. 71-10-01/02.

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Cabin Leak Test

It is advisable to integrate the Dump Test in this test, because the necessary
preparations are very similar. Refer to Figure 21-1.
2 Remove tail cone access panel. Refer to Chapter 51-00-01
3 Plug the static reference port of the cabin
control outflow valve with tape.
4 Place an altimeter in the cabin, readable
from a window.
5 Set altimeter to 1013 mbar and note altitude.
6 Close the cabin door.
7 Remove inlet hose from the cabin inflow
box on the upper right firewall.
Risk of injury due to flying parts when pressurizing the cabin.
Warning Follow cabin pressurization unit safety instructions before installing the
unit.
Apply Max. 5.5 psig air to the cabin.
8 Install a cabin pressurization unit or
equivalent to the cabin inflow box.
9 Let a helping person shut the cabin control
outflow valve by hand. Gently pull the valve
piston in its seat.
10 Pressurize cabin until altimeter reads Tolerance +/− 500 ft
−3000 ft.
11 Switch off external pressurization unit,
engage stop watch and note altimeter
reading. Stop the time when altimeter
reaches the prior noted value.
Risk of injury when opening the door with cabin pressurized. Door
Warning could open with force.
Do not open the door until cabin has reached ambient pressure.
12 Calculate altitude difference and check if Refer to Figure 21-2
time stopped is within limit.
13 Perform Dump Test if applicable.
14 Disconnect cabin pressurization unit from
cabin inflow box.
15 Re-install inlet hose to cabin inflow box.
16 Remove plug from static reference port of
the cabin control outflow valve.
17 Re-install access panels. Refer to Chapter 51-00-01

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e
Tim
s ec
30
ec
40 s Upper Limit
Leakage
ec
50 s
ec
60 s
ec
70 s
c
80 s e
1500 2000 2500 3000 3500 4000

Altitude Difference (ft)
Figure 21-2 Cabin Leakage Chart
Dump Test
It is advisable to combine this test with the Cabin Leak Test.
3 Plug the static reference port of the cabin
control outflow valve with tape.
4 Let a helping person enter the cabin with an
additional altimeter.
5 Set altimeter to 1013 mbar and note altitude.
6 Switch BATT on.
7 Close the cabin door.
8 Remove inlet hose from the cabin inflow
box on the upper right firewall.
Risk of injury due to flying parts when pressurizing the cabin.
Warning Follow cabin pressurization unit safety instructions before installing the
unit.
Apply Max. 5.5 psig air to the cabin.
9 Temporarily attach a cabin pressurization
unit or equivalent to the cabin inflow box.

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10 Let a helping person shut the cabin control
outflow valve by hand. Gently pull the valve
piston in its seat.
11 Pressurize cabin until altimeter reads Tolerance +/− 500 ft
−3000 ft.
12 Engage RH (outside) squat switch by hand.
Check if safety valve clicks and cabin
pressure drops.
13 Release squat switch.
14 Pressurize cabin again until altimeter reads Tolerance +/− 500 ft
−3000 ft.
15 Position PRESS-switch to DUMP.
Check if safety valve clicks and cabin
pressure drops.
16 Switch off external pressurization unit.
17 Switch BATT off.
Risk of injury when opening the door with cabin pressurized. Door
Warning could open with force.
Do not open the door until cabin has reached ambient pressure.
18 Disconnect cabin pressurization unit from
cabin inflow box.
19 Re-install inlet hose to cabin inflow box.
20 Remove plug from static reference port of
the cabin control outflow valve.
21 Re-install access panels.

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21-00-01 Sceet Hoses

The worm drive hose clamps of the bleed air system are secured with a safety
wire.
Replacement
2 Remove hose. worm drive hose clamps,
(safety wire)
3 Cut new SCEET hose to length.
4 Slip the worm drive hose clamps over the
hose.
5 Slip both hose layers over the fittings.
6 Fasten worm drive hose clamps on both Apply safety wire to all bleed
sides. air hose clamps.

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21-10-00 COMPRESSION
Description
The system consists of the engine compressor, bleed ports, a bleed air
manifold, a shut-off valve, a mass flow control valve, a mass flow controller, a
mass flow sensor, hoses, and the ENV AIR switch on the left side panel.
Engine bleed air is used for cabin pressurization. Bleed air is taken from the
engine compressor by means of two bleed ports. A forward-facing port is
located on the right top of the engine compressor scroll. On its left bottom
another downward-looking port is located. The bleed ports incorporate orifices
(sonic venturi) which are installed with special O-rings. Bleed air is then routed
through pressure hoses to the bleed air manifold located on the left engine side.
Just above the primary shut-off valve is installed, which allows switching on or
off cabin pressurization (and also heating) by means of the ENV AIR switch.
The mass flow control valve is installed above the shut-off valve. It takes bleed
air and/or ram air tapped from the left air-to-air cooler inlet to control the mass
flow. The valve is governed by a computerized mass flow controller installed
inside the cabin behind the side paneling between the cabin door and the pilot’s
seat. The controller receives mass flow data from the mass flow sensor
installed to a flange downstream the bleed air muffler.
21-10-01 Primary Shut-off Valve
Removal/Installation
The primary shut-off valve is screwed to the mass flow control valve. For this
reason it is advisable to firstly remove both valves together and to disconnect
them later by turning the shut-off valve.
1 Remove LH engine cowling. Refer to Chapter 71-10-01.
2 Disconnect bleed air manifold from shut-off
the valve.
3 Cut the electrical wiring from the shut-off Reconnect later by splicing.
valve.
4 Disconnect the SCEET hoses from the mass
flow control valve.
5 Disconnect the electrical wiring from the
mass flow control valve.
6 Disconnect the mass flow control valve 4 bolts
from the engine mount and remove both
valves together.

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7 Loosen counter nut between the two valves.
8 Unscrew the shut-off valve from the mass Turn the complete shut-off
flow control valve. valve. Watch the copper O-
ring.
9 Install in reverse sequence of removal.
21-10-02 Mass Flow Control Valve
Follow the procedure given in Section 21-10-01.
21-10-03 Mass Flow Sensor

The mass flow sensor is electrically connected to its control box located on the
nose gear firewall.
2 Remove cable straps and tie tool wraps from
the electrical wiring between sensor and
control box.
2 Remove sensor. 4 bolts on muffler flange
3 Remove control box. 4 screws, 3 else connections
Check
2 Remove sensor from muffler. 4 screws
3 Check 2 wires in sensor are intact. Replace sensor if wires are
broken.
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21-10-04 Mass Flow Controller
1 Remove left side armrest paneling. Refer to Chapter 25-20-21.
2 Disconnect the electrical connector from the
mass flow controller.
2 Remove mass flow controller. 4 attachment nuts
21-10-05 Muffler
The muffler is directly mounted to a flange providing a holding fixture for the
mass flow sensor.
2 Remove mass flow sensor. Remove 4 screws.
3 Disconnect SCEET hoses from muffler and
flange.
4 Remove attachment bolts of hose clip and
hose clamp carrying muffler and flange.
5 Remove muffler with flange.

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21-20-00 DISTRIBUTION
Description
The system consists of a valve box, SCEET hoses, a distribution valve, a
Bowden cable with a handle on the center console panel and the panel vent
fans.
Ram air or bleed air is ducted into the cabin (refer to Section 21-10 for the
bleed air system).
Ram air is taken from the oil cooler inlet on the right engine side and routed
through SCEET hoses to a valve box on the firewall. 2 check valves are
mounted to the valve box (ram air and bleed air side). Additionally the valve
box has a holding fixture for the duct temperature sensor. The cabin inflow
check valve is mounted between the valve box and the firewall.
Inside the cabin a valvular operated air distributor guides the air stream to the
windshield and/or legroom dispensers. The air distributor has also a holding
fixture for the temperature switch.
For better ventilation in the forward cabin section two vent fans are installed in
the LH and RH side of the instrument panel. Each vent fan sucks air from
behind the panel. On the discharge side each vent fan is connected to an
eyeball vent, which can be adjusted to direct or shut off the airflow. Two
switches, placed on the instrument panel near the resp. air outlet, control the
vent fans. The electric fan motors are protected by a 2 A - fuse.
The evaporators (refer to Section 21-50) also work as cabin fans. Both
evaporator blowers work with different power settings in low or high mode.
21-20-01 Panel Vent Fans

1 a (RH vent fan) Remove RH IFD and right main panel. Refer to Chapters 31-60-01
and 31-10-03
1 b (LH vent fan) Remove LH and RH IFD and analogue Refer to Chapter 31-60-01
engine indicator. and Chapter 77-40-01
2 Loosen worm drive hose clamp on vent fan
casing.
3 Disconnect electrical wiring.
4 Remove vent fan with casing.
5 Disassemble vent fan and casing if 4 bolts
applicable.
6 Remove eyeball vent. 1 nut

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7 Reverse procedure for installation.
8 Perform pitot/static test. According to FAR 43,
Appendix E and AC 43.13-
1B CHG1 (or later) § 12-59

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21-30-00 PRESSURIZATION CONTROL
Description
The system consists of the engine compressor, two sonic venturi (flow
limiters), a cabin control outflow valve, an unregulated safety valve, the cabin
pressurization/dump switch, the cabin pressure controller, the landing gear
squat switch, and two indicators, one for cabin altitude and differential pressure
and one for cabin rate-of-climb.
Pressurized air is supplied from the engine bleed air through the sonic venturi
and then through a check valve into the cabin. Adequate flow to maintain
pressurization up to the maximum differential pressure of 5.5 PSI is provided
by the engine at normal power setting. Power changes should be made
smoothly to prevent sudden changes in pressurization air inflow resulting in
cabin pressure transients.
Operation
The airplane may be operated in either the pressurized or depressurized mode.
The mode selection is made with the cabin pressurization switch, which either
activates the cabin control outflow valve or leaves it open. Mode operation
should be selected prior to takeoff. If a change from pressurized to
depressurized mode must be made while airborne, depressurize the cabin
following the procedure given below before turning the dump switch as
otherwise a rapid decompression occurs, which would cause discomfort to the
passengers. When changing from unpressurized to pressurized mode, the cabin
altitude rate of change will be limited by the pressurization controller. The
valves are also opened by the landing gear squat switch assuring depressurized
mode when aircraft is on ground to avoid bursting the cabin door due to cabin
pressure when opening.
In the pressurized mode cabin pressure is regulated by the cabin control
outflow valve allowing air to exhaust either to the pressure level preselected by
the cabin pressure controller or to maximum differential pressure level. Setting
the center dial (identified as “Flight Level”) of the cabin pressure controller
will suggest the system being at a certain flight altitude. So the system will
maintain the corresponding cabin altitude (about 5.5 PSI above static pressure
of flight level) or reach it with the rate set by the rate control knob located on
the lower left corner of the pressurization controller. Only in case of maximum
differential pressure is reached or flight level is below the selected cabin
altitude, cabin altitude changes with the same rate the flight altitude does.
In case of failure of the cabin outflow control valve the safety valve will open
at a differential pressure of slightly above 5.5 PSI to avoid structure damage.
Handling
Use the cabin pressure controller as follows. Also refer to the sample chart
(Figure 21-1).
1 Activate the pressurization controller by turning on the cabin pressurization
switch. Make sure the ENV AIR switch is ON.

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2 Set the published official airport altitude (such as shown on flight charts) under
the index arrow by turning the center control knob.
3 Turn the index arrow of the rate control knob (lower left corner of the control)
to the 12 o’clock position (approx. 500 fpm).
These steps set the system to pressurize at approximately 700 feet above the
runway after takeoff. The system will hold this cabin altitude until the
maximum differential altitude is reached (see “Cabin Altitude with minimum
Flight Level Setting” line of Figure 21-1) or a different cabin pressure is
selected.
4 After having cleared the airport area and established the climb and being on
course to the destination (see “a” on 0), select the flight level corresponding to
the intended cruise altitude in the center dial and align that with the index
arrow. This alignment also indicates the approximate cabin altitude (within
approx. 700 feet) at the index on the larger numbers marked “Airport Alt.”.
5 Increase or decrease the rate at which the cabin changes altitude for the best
comfort level from normally 500 fpm by turning the rate knob counter
clockwise for decreasing or clockwise for increasing the rate.
Usually it is the best method to set the rate to reach the changed cabin pressure
(referenced from the “Airport Alt.”) slightly ahead of reaching the cruising
altitude (550 fpm in the sample of Figure 21-1). This selected altitude will be
maintained until the aircraft changes altitude sufficiently to reach the max.
differential pressure or descends sufficiently to go below the selected airport
altitude.
6 When the aircraft reaches the proximity of the destination and starts to descent
(see “b” on 0), set the selector knob to the published airport altitude.
7 Set the rate so that the selected airport altitude is reached in the cabin prior to
descending to that altitude (650 fpm in the sample of Figure 21-1).
When approaching the runway, the pressurization will cease approximately 700
feet above the landing prior to landing. Should any slight pressure remain, the
remainder will dump when the squat switch closes. However, this is an
additionally safety device, because landing with cabin pressurized is not
allowed.
If pressurization mode shall be terminated during flight, follow the
CAUTION procedure above, setting the airport altitude equal to the momentary flight
altitude. Do not switch to the depressurized mode before the selected
airport altitude has been reached.
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Page 20
Figure 21-1
EXTRA 500
21
Flight Altitude
Maintenance Manual
Cabin Altitude
Cabin Altitude with Minimum Flight Level Setting
feet x 1,000
20
Cabin Pressurization Sample Chart

climb
15 1200 fpm descent
1500 fpm
max. diff.
10 pressure
650 fpm
5 650 fpm
0
0 a 10 20 b 25 30 35 min
5 15
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21-30-01 Cabin Outflow Control Valve Filter

Replacement
1 Remove upper half of rear baggage Machine screws AN 526
compartment wall. 10-32
2 Loosen the filter retention screw on the It is not necessary to remove
control outflow valve housing until the filter the screw entirely.
flange is free to rotate.
3 Rotate the filter until the flat on the filter
clears the screw head.
4 Remove the filter cartridge and replace with
new one.
5 Rotate the filter so filter flange is captured
by the screw head.
6 Tighten filter retaining screw.
21-30-02 Cabin Outflow Control Valve

The valve is attached to the LH side of the pressure dome.
1 Ensure BATT switch is OFF and no external
power connected.
3 Remove tail cone access panel on LH
fuselage side.
4 Remove valve flange from pressure dome. 8 stop nuts MS 21044 AN3
with washers AN960 – 10L
(3/8 inch.)
5 Remove overflow tube. 9/16 fitting; retain with 11/16
wrench at pressure dome
fitting
6 Disconnect electrical connector.
7 Lift up valve from pressure dome
8 Install in reverse sequence of removal

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21-30-03 Safety Valve

The valve is attached to the RH side of the pressure dome.
power connected.
3 Remove tail cone access panel on LH
fuselage side.
4 Remove valve flange from pressure dome. 8 stop nuts MS 21044 AN3
with washers AN960 – 10L
(3/8 inch.)
5 Remove overflow tube. 9/16 fitting; retain with 11/16
wrench at pressure dome
fitting
6 Remove electrical connector
7 Lift up valve from pressure dome
8 Install in reverse sequence of removal Observe the following hint
NOTE Verify that blind plug at vacuum port is installed correctly. With
installed valve, the vacuum port is accessible behind the rear baggage
compartment wall.

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21-50-00 COOLING
Description
The aircraft is standard equipped with an electrically driven vapor cycle air
conditioning system. The system consists of a compressor condenser module,
two evaporators and the switches in the CABIN section of the left side panel.
The electrically driven compressor condenser module is installed in the
unpressurized part of the tail cone aft of the rear pressure dome. Cooling air for
the condenser (circulated by the condenser fan) is taken from an inlet in the left
fuselage side aft of the cabin door and dumped overboard through an outlet on
the same side.
The cabin recirculation air is cooled by means of two evaporators. The front
evaporator is installed behind the co-pilot seat and the aft evaporator in the aft
pressure dome area. Condensation at the evaporators is drained by means of a
float type check valve for each evaporator.
The air condition system is activated by the AIR CON switch located in the left
side panel. The air-condition will only operate effectively with the cabin
blower VENT switch at least in LOW position.
The electric air-condition provides the ability to operate the system on ground
using ground power without the necessity to run the aircraft engine.
NOTE It is not possible to operate the air condition on battery power as the high
current draw would shortly lead to a depleted battery. Therefore for
operation either the aircrafts generator (engine running) or a sufficient
external power source (capacity min. 100 A at 28 VDC) has to be
connected to the aircraft bus system. 125 A is recommended for maximum
cooling capacity. When using external power the battery must be off.
Service and Maintenance

Servicing of the air-conditioning unit shall be performed by an approved air-
conditioning service station; only R-134a type refrigerant must be used.
The air-conditioning compressor condenser module is equipped with
conventional evacuating and charging connections.
After new system plumbing installation, component replacement or line or
hose rupture, a leak check is required, see Enviro Systems General Operating,
Servicing and Maintenance Manual for Airborne R-134a Air-conditioning
Systems (LOAP 13) for leak check and general charging procedures.
Refer to this Manual also for component maintenance procedures.
Access to the compressor condenser module is gained through the tailcone
access hatch. Both low and high pressure service ports are located at this unit.
Charging quantity of the installation is 0.650 kg +/- 0.050 kg, proper charging
can be verified at the sight glass on the receiver dryer. With the system fully
charged and operating, observe the suction and discharge pressures. Typical
values at various ambient temperatures, with hot cabins are shown below:

Maintenance Manual
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OAT Suction pressure Discharge pressure

(°C) (psig) (psig)
20 28 112
25 30 133
30 31 156
35 32 180
21-50-01 Compressor/Condenser
power connected.
3 Remove the refrigerant from the air Refer to Enviro Systems
conditioning system General Operating, Servicing
and Maintenance Manual for
Airborne R-134a Air-
conditioning Systems
(LOAP 13)
4 Remove all avionic boxes, which may block XPDR, DME, amplifier
removal of compressor/condenser.
5 Remove refrigerant hoses.
6 Remove air hoses.
7 Remove compressor/condenser. 4 mounting screws
21-50-02 Evaporator
power connected.
3 Remove the refrigerant from the air Refer to Enviro Systems
conditioning system General Operating, Servicing
and Maintenance Manual for
Airborne R-134a Air-

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conditioning Systems
(LOAP 13)
4 (front Set the co-pilot seat in the most forward
evaporator only) position.
5 a (front Remove side paneling. Refer to Chapter 25-00-01
evaporator)
5 b (aft Remove aft paneling. Refer to Chapter 25-00-01
evaporator)
6 Remove refrigerant hoses.
7 Remove air hoses.
8 Cut electrical wires. Reconnect later by splicing.
9 Remove mounting screws and remove
evaporator.
21-50-03 Soft Start Module

power connected.
3 Disconnect 3 power lines.
4 Cut control line. Reconnect later by splicing.
5 Remove soft start module. 4 mounting bolts
6 Install in reverse sequence of removal. Ensure cable clamps are
installed.
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21-60-00 TEMPERATURE CONTROL
Description
The system consists of a temperature controller, a cabin temperature sensor, a
duct temperature sensor, a temperature modulating valve, a temperature switch,
the BLEED OVERTEMP warning light and the TEMP CTRL switches and rheostat
on the left side panel.
With the ENV AIR switch ON environmental bleed air is provided for cabin
heating purposes. The bleed air, exiting the engine is too hot to be used for
cabin heating without prior cooling. The amount of cooling required is
dependent on ambient temperature, airspeed, engine power setting, desired
cabin temperature and adequate changes if these parameters change.
Cooling effectiveness is controlled by routing the environmental bleed air
through the air-to-air cooler or directly (bypass) to the cabin by means of the
temperature modulating valve. Operating mode of this valve is selected by the
controls grouped in the CABIN section of the left side panel. With the TEMP
CTRL switch being set to the AUTO position the computerized cabin
temperature controller compares the actual cabin temperature (measured by a
sensor in the cockpit ceiling) to the selected temperature. The temperature
controller is installed inside the cabin behind the side paneling between the
cabin door and the pilot’s seat. Selection is being done by means of the cabin
temperature rheostat also located in the left side panel CABIN section.
Adjustment range is between 13 °C and 30 °C (55 °F to 86 °F). Depending on
the difference between actual cabin temperature and selected cabin temperature
the controller determines a desirable cabin inflow temperature for the
environmental bleed air. The actual inflow temperature is measured by a sensor
located within the bleed ducting prior to cabin entry through the front pressure
bulkhead.
The temperature controller compares this actual inflow temperature to the
desired inflow temperature and adjusts the temperature modulating valve to
match this desired inflow temperature.
It is within the nature of this design (bleed air cooling by means of an air to air
heat exchanger) that cabin bleed air cannot be cooled below ambient
temperature before entering the cabin. Therefore a vapor cycle air conditioning
system (refer to Section 21-50) provides additional cooling capacity for hot
ambient conditions.
The automatic temperature control limits cabin inflow temperatures to values
below 72 °C. An additional independent thermal switch installed in the cabin
distribution valve activates the red BLEED OVERTEMP warning light located on
the annunciator panel in case the cabin inflow temperature exceeds 85 °C. In
case, the BLEED OVERTEMP warning light on the annunciator panel
illuminates, indicating a temperature controller failure, the temperature can be
manually controlled by switching the TEMP CTRL switch, to the MANUAL
position.

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Selected and held in COOL or WARM position activates the temperature

modulating valve manually (overrides the controller) causing warm up or cool
down of incoming bleed air.
21-60-01 Temperature Switch
power connected.
2 Remove RH IFD and RH part of main Refer to Chapter 31
panel.
3 Remove attachment bolts of distribution To allow moving the
valve. distribution valve.
4 Move the distribution valve up some
centimeters.
5 Cut the electrical wiring from the Reconnect later by splicing.
temperature switch
6 Remove temperature switch from the
distribution valve.
Function Test
power connected.
2 Remove RH IFD. Refer to Chapter 31-60-01
3 Disconnect LH SCEET hose from the cabin Worm drive hose clamp
distribution valve.
4 Place BATT switch to ON position.
5 Place NIGHT/DAY switch to TEST position. To ensure annunciator lights
are OK.
6 Apply hot air to the temperature switch. More than 85 °C.
Use a blow dryer.
7 Check BLEED OVERTEMP illuminates. Replace temperature switch if
necessary.
8 Place BATT switch to OFF position.
9 Reinstall SCEET hose.

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9 Reinstall RH IFD. Refer to Chapter 31-60-01
10 Perform pitot/static test. According to FAR 43,
21-60-02 Duct Temperature Sensor
The duct temperature sensor is attached to the valve box on the RH upper
firewall with 4 bolts and nuts. To make the nuts accessible the forward hose
and the flange have to be removed.
power connected.
2 Remove LH and RH engine cowling. Refer to Ch. 71-10-01/02
3 Disconnect the forward SCEET hose from Worm drive hose clamp,
the valve box. safety wire
4 Remove flange from the valve box. 4 nuts
5 Disconnect electrical connector from the Bayonet nut
temperature sensor.
6 Remove temperature sensor. 4 bolts and nuts
7 Install in reverse sequence of removal. Observe the following step.
Refer to Product Label and Material Safety Data Sheet for health and
WARNING safety information before using PR812.
8 Seal flange with PR812.
21-60-03 Cabin Temperature Sensor
power connected.
2 Remove paneling above pilot seat. Refer to Chapter 25
3 Disconnect electrical wiring from the cabin
temperature sensor.

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4 Remove sensor. 4 nuts
21-60-04 Temperature Controller
power connected.
2 Remove left side cabin paneling. Refer to Chapter 25.
temperature controller.
4 Remove temperature controller. 4 attachment screws

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Chapter 22
Auto Flight

Maintenance Manual
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Table of Contents
22-00-00 GENERAL ........................................................................................................ 5
22-10-00 AUTOPILOT .................................................................................................... 6

Description.......................................................................................................... 6
Figure 22-1 Autopilot Installation .......................................................................................... 8
System Components ........................................................................................... 9
Troubleshooting ................................................................................................ 11
Heading Calibration .......................................................................................... 12
22-10-01 Roll Servo ........................................................................................................ 13
Removal ............................................................................................................ 13
Figure 22-2 Roll Servo Installation ...................................................................................... 14
Installation ........................................................................................................ 15
Function Test .................................................................................................... 15
22-10-02 Pitch Servo....................................................................................................... 16
Removal ............................................................................................................ 16
Figure 22-3 Pitch Servo Installation .................................................................................... 17
Installation ........................................................................................................ 18
Function Test .................................................................................................... 19
22-10-03 Yaw Servo ........................................................................................................ 19
Removal ............................................................................................................ 19
Figure 22-4 Yaw Servo Installation ...................................................................................... 21
Installation ........................................................................................................ 22
Function Test .................................................................................................... 22
22-10-04 Clutches (Pitch, Roll and Yaw Servo) ........................................................... 23
Torque Settings ................................................................................................. 23
Torque Adjustment ........................................................................................... 24
Figure 22-5 Clutch Torque Adjustment ................................................................................ 24
22-10-05 Driving Wheels ................................................................................................ 25
22-10-06 Bridle Cables ................................................................................................... 25
Tension Settings ............................................................................................... 26
Tensioning ........................................................................................................ 26
22-10-07 Cable Clamps .................................................................................................. 27
Figure 22-6 Cable Clamp Torquing ..................................................................................... 27
22-10-08 Trim Servo....................................................................................................... 27
Removal/ Installation ........................................................................................ 27
Function Test .................................................................................................... 27
22-10-09 Trim Servo Clutch .......................................................................................... 28
Torque Settings ................................................................................................. 28
Torque Adjustment ........................................................................................... 28

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22-10-10 Pressure Transducer ....................................................................................... 29

22-10-11 Yaw Amplifier ................................................................................................. 30
22-10-12 Programmer/Computer .................................................................................. 30
22-10-13 Turn Coordinator............................................................................................ 30

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Maintenance Manual
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22-00-00 GENERAL
This chapter describes the features and functions of the System 55X Two and a
half Axis Autopilot and gives information on basically required maintenance
practices as well as related system components.

Maintenance Manual
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22-10-00 AUTOPILOT
Description
Refer to Figure 22-1. The S-TEC System 55X autopilot system is a rate based
autopilot. Internal signal processing for regulating purposes is mainly analog,
whereas digital electronics is used for the pilot interface and for controlling the
mode of operation.
Pitch and Roll Axis

The signal for the roll servo is generated using the following inputs:
1 Rate of turn information heading bug determined by the Turn Coordinator.
2 Navigation avionics (VOR / LOC, GPS; via IFD).
The signal for the pitch servo is generated using the following inputs:
1 Static pressure (via remote mounted Absolute Pressure Transducer).
2 Sensitive Accelerometer (contained in the Programmer / Computer unit).
3 Altitude Selector (via IFD, key pad or vertical speed knob on A/P computer).
4 Glide Slope Receiver (via IFD).
The autopilot can be activated by means of the 3-position AUTOPILOT
MASTER/FD switch located in the right lower side of the pilot's instrument
panel.
Switching it from the OFF-position to the first stage (FD) energizes the
autopilot system. The autopilot will start its self-test routine ending up in a
ready mode if performed successfully. This allows the pilot to select the
different operating modes. If appropriate modes are activated set-point steering
commands are shown by the Flight Director symbol displayed in the LH IFD.
The pitch and roll servos are not engaged. Pitch and roll still have to be
controlled by normal steering, using the data provided by the IFD as a set-
actual comparison.
In the second stage (MASTER) the servos are energized and the autopilot
controls pitch and roll axis according to the operating mode(s) selected (refer to
POH).
One possibility to engage the autopilot (both axis) is given by the CWS switch
(control wheel steering) located on top of the right horn of the pilot's control
yoke. This mode engages the autopilot in a way which maintains the actual
pitch and roll attitude (refer to POH).
NOTE Operation in a pitch mode is possible only if a roll mode is activated.
As a safety device an autopilot quick disconnect switch (AP DISC, red) is also
located in the left horn of the pilot's control wheel to enable the pilot to
disengage the autopilot quickly. Additionally, servo transmissions are designed
as slip clutches, which can be overpowered in any case of failure or
malfunction. The operation mode selection is done via the autopilot main unit
and the IFD or the related keyboard. Indication is made on the autopilot main
unit and the upper LH IFD.

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Trim System
The EXTRA 500 uses a tab at the elevator's trailing edge for pitch trim. This
tab is actuated by a Bowden cable with a special gear located in the horizontal
stabilizer transforming the long travel of the cable into the shorter travel finally
used for tab actuation. The Bowden cable itself may be actuated either by the
pilot using the trim wheel or by the trim servo located on the floor of the tail
cone compartment. The electric trim system may be operated independently
from the autopilot.
When an autopilot pitch mode is active and the electric trim system is switched
on by the TRIM master switch in the pilot's instrument panel, the trim system
operates in the auto trim mode. The pitch servo continuously senses the force
necessary to maintain the assigned pitch attitude and transmits the signal to the
autopilot main unit. This computes a signal to actuate the trim servo. By this
mechanism the force the pitch servo has to apply on the elevator is minimized.
When the autopilot is active (in a pitch mode) and the electric trim servo (TRIM
master switch) is switched off a visual and audible annunciation to the pilot is
provided by the autopilot system asking him to trim the airplane manually by
means of the trim wheel.
With autopilot switched off or no pitch mode engaged, but electric trim servo
(TRIM master switch) on, the longitudinal trim may be adjusted by the pilot
using the momentary split rocker switch on top of the left horn of the pilot's
control yoke.
Yaw Damper
The yaw damper system consists of two units, the yaw servo actuating the
rudder control cables and the yaw amplifier, which generates the signal for the
servo. The amplifier is installed behind the aft pressure dome in the tail cone
compartment. The amplifier features an integrated lateral acceleration sensor.
This sensor detects lateral components of the gravity vector, which corresponds
to the “ball not being centered”. Based on this input signal the yaw amplifier
derives the control signal for the yaw servo.
To allow for a fine adjustment of slip/skid angle, a yaw trim potentiometer
allows the pilot to adjust (“trim”) the zero yaw angle based on a slip/skid
indicator.
In the OFF position of the yaw damper control switch the yaw damper is not
engaged and the yaw servo clutch remains open. With the switch in ON
position the yaw damper remains engaged as long as the autopilot is engaged in
a roll mode. A roll signal from the autopilot main unit is provided to the yaw
amplifier as an additional input (to the lateral acceleration sensed internally).
Yaw damper disconnect is provided by the same means as the autopilot
disconnect as the autopilot main unit provides a yaw damper enable signal to
the yaw amplifier as long a roll mode is active. As soon as the autopilot
disconnects the yaw damper follows therefore.

Page 8
Pitch Servo
Figure 22-1
22
EXTRA 500
Yaw Servo
Yaw Amplifier
Maintenance Manual
Absolute Pressure Transducer
Roll Servo
Autopilot Installation
Trim Servo
Trim Wheel
3rd Static Port
IFDs Programmer/Computer
Turn Coordinator
Split Trim Rocker Switch

Autopilot Switch Panel
AP Disconnect Switch
Trim Wheel
CWS Switch
(control wheel steering)

Maintenance Manual
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System Components
The following components are used in the S-TEC 55 installation of the
EXTRA 500:
Unit Designation Location Function
Autopilot Components
Programmer/Computer Instr. Panel Pilot interface
(P/C) signal generation for roll, pitch and pitch
(special configuration for trim servo
EXTRA 500)
Yaw amplifier Tail cone equipment Yaw sensor & signal generation for yaw
rack servo
Turn Coordinator Instr. Panel Sensing rate of turn,
input signal for P/C,
indication to pilot
Absolute pressure Transducer Tail cone equipment Converting static pressure => electric signal
rack
Roll Servo Front wing Aileron actuation
compartment
Pitch Servo Tail cone equipment Elevator actuation, force sensing for trim
rack system
Pitch Trim Servo Tail cone floor Trim tab actuation
Yaw Servo Tail cone equipment Rudder actuation
rack
Autopilot Relay behind instrument Connecting inputs to A/P computer from
panel either IFD 1 or IFD 2
Autopilot Master Switch Autopilot Panel Activation of autopilot and / or flight
(Pilot Instrument director
Panel)
Pitch Trim Switch Autopilot Panel Activation of electric pitch trim System
(Pilot Instrument
Panel)
Yaw Damper Master Switch Autopilot Panel Activation of yaw damper
(Pilot Instrument
Panel)
Yaw Trim Knob (rotary Autopilot Panel Adjustment of zero jaw attitude
Potentiometer) (Pilot Instrument
Panel)
Trim command Switch Control Wheel Change of aircraft pitch trim
(split switch)
CWS-Switch Control Wheel Engaging CWS-mode
Autopilot disconnect / trim Control Wheel Disengaging autopilot, interruption of
interrupt switch electric trim actuation

Maintenance Manual
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Unit Designation Location Function
Closely related systems/components

Audio Panel Instrument panel Audible warnings from P/C
IFD 1 Instrument panel Source for heading and course, vertical
speed command, Flight Director display
IFD 2 Instrument panel Source for heading and course, vertical
speed command, flight director display
Keypad Center console Altitude and heading selection, inputs to
IFDs
Stall warning switch LH wing leading Disconnect of A/P when stall warning
(“Lift Detector”) edge becomes active

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Troubleshooting
Autopilot will not engage in Autopilot has no power Check AUTOPILOT MASTER
any mode switch FD or MASTER.
Autopilot has no power Check AVIONICS switch ON.
No valid signals from turn Check turn coordinator no
coordinator flag.
AP disconnect switch Check AP disconnect switch
struck/defective continuity.
Pitch trim switch Check pitch trim switch stuck.
stuck/defective
Computer defective Replace computer.
Will not engage in any altitude No roll mode engaged A roll mode MUST be
mode selected first
No valid signal from absolute Replace absolute pressure
pressure transducer transducer.
CWS does not work Autopilot not coupled in both An altitude and roll mode
axes must be engaged previously.
Switch defective Replace CWS switch.
AP disconnect switch does not Switch defective Replace AP disconnect switch.
work
Mode engages, but servo does AP in FD mode Check AUTOPILOT MASTER
not couple switch in MASTER position
(not FD)
Servo defective Replace servo.
Electrical Pitch trim does not Pitch system has no power Check battery bus power.
work
Pitch system has no power Check pitch trim switch ON.
Pitch trim switch defective Replace pitch trim switch.
Pitch trim servo defective Replace pitch trim servo.

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Yaw trim does not work No power to yaw amplifier Check battery bus power
YAW DAMPER switch OFF. YAW DAMPER switch ON.
Yaw damper switch defective Replace yaw damper switch.
No roll mode enabled Engage roll mode first.
Yaw amplifier defective Replace yaw amplifier.
Yaw servo defective Replace yaw servo.
Yaw trim poti defective Replace yaw trim
potentiometer.
Heading Calibration
1 Attach external power.
2 Check all switches OFF,
A/P CMPTR CB IN,
Turn-Coord CB IN,
A/P SERVO CB IN,
All IFD CB-s IN
3 Switch on EXT PWR
4 Switch on AUTOPILOT - MASTER
5 Check turn coordinator runs up,
off-flag disappears,
Autopilot display shows 7 on display,
Autopilot display shows rdy,
LH IFD shows AP RDY
6 Wait for 2 minutes to let turn coordinator run up
7 Set IFD to NAV I
8 Tune NAV I to a frequency that has no
reception
9 Set heading bug to current heading push heading knob on keypad
10 Select NAV mode on autopilot
11 Adjust the potentiometer between the REV use miniature flat screwdriver
and ALT buttons in small increments until
the yoke stops turning
12 Make sure in the end the AP is in SOFT indicated on IFD
mode

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22-10-01 Roll Servo
Removal
power connected.
2 Remove wing center fairing. Refer to Chapter 51-00-01
3 Disconnect electrical connector from roll
servo.
4 Loosen bridle cable clamps.
5 Remove 3 bolts and nuts securing roll servo
to support bracket.
6 Remove roll servo from support bracket.
7 Remove cable guard, cover and bridle cable
from servo capstan, if required.

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Top View
Upper control cable
fwd
bridle cable center ball
bridle cable
bridle cable
Attachment bolts
Lower control cable
Roll Servo
Front View
Attachment bolts Upper control cable
Cable clamp
Cable clamp
bridle cable end
bridle cable end

bridle cable
bridle cable
Roll Servo Lower control cable
Figure 22-2 Roll Servo Installation

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Installation

IMPORTANT Prior to installing roll servo, adjust clutch torque and determine proper
direction of capstan rotation. See Section 22-10-04 for clutch torque
settings.
IMPORTANT Prior to installing roll servo, check aileron control system travels. Check
aileron cable tension in accordance with Chapter 27-00-01.
IMPORTANT Removal of servo requires disconnecting the bridle cable. Consequently,
bridle cable tensioning is required upon reinstallation of the servo.
1 Ensure BATT switch is OFF and no
external power connected.
2 Attach roll servo with 3 screws to
support bracket.
3 Insert bridle cable center ball into
leading hole in capstan.
4 Adjust position of center ball with 12 o’clock position.
aileron controls in neutral position. See Figure 22-2
5 Wrap bridle cable around capstan 1.5 Cable clamps will be positively
turns each direction from center ball. guided to correct position
6 Install cable guards and cover with 4 Tighten screws only snugly against
screws and washers. servo base plate
7 Install cable clamps. Apply tension by hand before
Adjust bridle cable tension to the tightening the cable clamps.
value given in Subject 22-10-06. See 22-10-07Figure 22-6 for clamp
torquing.
Cable clamps may be rotated on
aileron cable to align bridle cable
with capstan grooves.
8 Connect electrical connector.
9 Install wing center fairing. Refer to Chapter 51-00-01
Function Test
1 Attach external power to the aircraft.
2 Check all switches off.
3 Switch EXT PWR on.
4 Switch AUTOPILOT MASTER to
MASTER.
5 Check AP RDY on IFD.

6 Check RDY on autopilot computer.

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7 Switch on HDG mode.
8 Check HDG is displayed on autopilot
computer.
9 Check HDG bug is fully filled and
magenta on IFD.
10 Turn HDG knob to the left.
10 Check control wheel turns CCW.
11 Turn HDG knob to the right.
12 Check control wheel turns CW.
13 Press AP DISC switch on LH control Aural warning can be heard.
wheel.
14 Switch AUTOPILOT MASTER off.
15 Switch EXT PWR off.
16 Disconnect external power.
22-10-02 Pitch Servo
Removal
2 Remove tail cone access panel.
3 Disconnect electrical connector from
roll servo.
5 Remove return pulley.
6 Remove 4 bolts and nuts securing
pitch servo to support bracket.
7 Remove pitch servo from support
bracket.
8 Remove cable guard, cover and bridle
cable from servo capstan, if required.

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Top View
fwd bridle cable

longer end
Cable clamps
bridle cable
shorter end
Pulley
bridle cable
Attachment bolts
bridle cable
center ball
Pitch servo
Control cable
Figure 22-3 Pitch Servo Installation

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Installation

IMPORTANT Prior to installing pitch servo, adjust clutch torque and determine
proper direction of capstan rotation. See Section 22-10-04 for clutch
torque settings.
IMPORTANT Prior to installing pitch servo, check elevator control system travels.
Check elevator cable tension in accordance with Ch. 27-00-01.
2 Attach pitch servo with 4 screws to
support bracket.
4 Adjust position of center ball with 11 o’clock position.
elevator controls in neutral position. See Figure 22-3
5 Wrap bridle cable around capstan Cable clamps will be positively
1 turn (360°) CW and 1.5 turns (540°) guided to correct position
CCW from center ball.
7 Install return pulley.
8 Lead upper bridle cable segment See 22-10-07Figure 22-6 for clamp
around pulley and pre-install cable torquing.
clamps. Cable clamps may be rotated on
Tension bridle cable by hand before elevator cable to align bridle cable
fastening the cable clamps. with capstan grooves
10 Adjust correct bridle cable tension. Refer to the Tension Settings and
the Tensioning procedure presented
in Subject 22-10-06.
11 Install tail cone access panel.

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Function Test
MASTER.
5 Check AP RDY on IFD.

6 Check RDY on autopilot computer.
7 Set heading bug to current heading push heading knob on keypad
8 Switch on HDG mode.
9 Switch on VS mode.
10 Check ALT bug is open.
11 Check VS bug is filled and magenta on
IFD.
12 Check control wheel moves forward.
13 Set VS bug to +1000 ft.
14 Control wheel moves aft or at least On the ground the servo does not
tries. have enough power.
15 Press AP DISC switch on LH control Aural warning can be heard.
wheel.
16 Switch AUTOPILOT MASTER off.
22-10-03 Yaw Servo
Removal
roll servo.

Maintenance Manual
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5 Remove 4 bolts and nuts securing yaw
servo to support bracket.
6 Remove yaw servo from support
bracket.
7 Remove cable guard, cover and bridle
cable from servo capstan, if required.

Maintenance Manual
EXTRA 500
Top View
Bridle cable end
fwd Control cable
Cable clamp
Attachment bolts
Bridle cable
Bridle cable
center ball
Yaw servo
Bridle cable
Cable clamp
Bridle cable end
Figure 22-4 Yaw Servo Installation

Maintenance Manual
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Installation

IMPORTANT Prior to installing yaw servo, adjust clutch torque and determine proper
direction of capstan rotation. See Section 22-10-04 for clutch torque
settings.
IMPORTANT Prior to installing yaw servo, check elevator control system travels.
Check elevator cable tension in accordance with Ch. 27-00-01.
2 Attach yaw servo with 4 screws to
support bracket.
4 Adjust position of center ball with 12 o’clock position
rudder controls in neutral position. See Figure 22-4
5 Wrap bridle cable around capstan 1.5 Cable clamps will be positively
turns each direction from center ball. guided to correct position
7 Lead upper bridle cable segment See Figure 22-6 for clamp torquing.
around pulley and install cable clamps Cable clamps may be rotated on
Adjust bridle cable tension to the elevator cable to align bridle cable
value given in Subject 22-10-06. with capstan grooves
9 Install tail cone access panel.
Function Test
MASTER.
5 Engage heading mode

6 Switch AUTOPILOT YAW DAMPER on.
7 Turn YAW TRIM potentiometer to the
left.

Maintenance Manual
EXTRA 500

8 Check rudder pulses to the left.
9 Turn YAW TRIM potentiometer to the
right.
10 Check rudder pulses to the right.
11 Press AP DISC switch on LH control
wheel.
12 Switch AUTOPILOT YAW DAMPER off.
22-10-04 Clutches (Pitch, Roll and Yaw Servo)
Torque Settings
The following torque settings must be checked and adjusted:
Servo P/N Clutch Torque Servo RPM @24VDC
setting (fixed, not adjustable)
Pitch S-TEC 0108-P4 29 ± 2 inlbs 1.08
Roll S-TEC 0106-R2 36 ± 2 inlbs 2.40
Yaw S-TEC 0106-6-Y9 73 ± 2 inlbs 3.59

Maintenance Manual
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Torque Adjustment
Before re-installation of a servo, perform the following steps to check and
adjust clutch torque value in accordance with the Torque Settings given above.
Dial Torque Wrench
Capstan Cover
Shim Washer Tool S-TEC P/N 6622-1
Cable Guard Tension Washer
Figure 22-5 Clutch Torque Adjustment

1 Remove capstan cover from servo with 4
screws and washers.
2 Draw cotter pin from castle nut.
3 Insert adapter tool (S-TEC P/N 6622-1) into
leading holes in servo capstan.
4 Bear dial torque wrench.
5 Connect servo motor to 28 VDC power Servo shaft rotates
source.
6 Read torque value. See Torque Settings chart of
Subject 22-10-04 for
appropriate settings. Perform
clutch torque adjustment as
per step 7 - 8, if necessary
7 Remove torque wrench and adapter tool.
8 Align torque value with castle nut - turn CW
to increase and CCW to decrease torque.
9 Repeat steps 3 to 8, until read torque setting
(step 6) matches value given in Torque
Settings chart of Subject 22-10-04.

Maintenance Manual
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10 Disconnect servo motor.
11 Re-install cotter pin.
NOTE To align cotter pin with shaft hole, use shim washers S - TEC
P/N 1205 S 5 - 005, 007, 010, 031 in any combination (min. 1 required).
12 Re-install capstan cover.
NOTE After capstan cover has been installed, determine that there is no
interference between capstan and cover.
22-10-05 Driving Wheels
2 Remove castle nut.
3 Remove 2 tension washers.
4 Remove driving wheel.
IMPORTANT After removal of driving wheel, clutch Refer to Section 22-10-04 for
torque adjustment is required. torque settings.
5 Install in reverse order of removal.
22-10-06 Bridle Cables
1 Unfasten cable clamp bolts as far as On both ends
necessary to unthread the bridle cable.
2 Uncoil the bridle cable from the servo.
3 Install in reverse order of removal. Observe correct position of
bridle cable center ball. Refer
to applicable servo
Installation Procedure.

Maintenance Manual
EXTRA 500
Tension Settings
The following tension settings must be checked (cable tensiometer) and
adjusted:
Bridle Cable Tension Setting
Pitch 32 ± 2 lbs
Roll 15 ± 2 lbs
Yaw 15 ± 2 lbs
Tensioning
Generally the necessary tension can be applied by hand to the bridle cables
before tightening the cable clamp bolts.
However for tensioning the pitch servo bridle cable the power of the pitch
servo itself is necessary to receive the correct tension values. Proceed as
follows (refer to Figure 22-3):
1 Install the bridle cables as per Subject 22-
10-02.
2 Fix control wheel in neutral position by
hand.
3 Switch on AUTOPILOT MASTER.
4 Switch on the VS Mode on the Autopilot
Programmer/Computer.
5 Position VS bug to +1000 ft. Control wheel tries to move
aft. Counteract by hand. The
pitch servo now tensions the
longer bridle cable end.
6 Loosen cable clamp of the shorter bridle The tension applied here by
cable end, tension by hand, and retighten hand allows adjusting the
cable clamp bolts. bridle cable to the desired
tension.
7 Switch off AUTOPILOT MASTER.
8 Check bridle cable tension. Use a conventional cable
tensiometer.
9 Repeat procedure if necessary varying
tension on step 6.

Maintenance Manual
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22-10-07 Cable Clamps

Observe the following values when installing/fastening the cable clamps.
Figure 22-6 Cable Clamp Torquing
22-10-08 Trim Servo
Removal/ Installation
power connected.
3 Disconnect electrical connector from trim
servo.
4 Remove swivel from transmission chain.
5 Remove transmission chain.
6 Remove 4 bolts and nuts securing servo
support bracket to GFK base.
7 Remove 4 bolts and nuts securing trim servo
to support bracket.
8 Move trim servo with driving wheel to the
right fuselage side out of support bracket.
9 Remove trim servo in forward direction.
IMPORTANT Prior to installing trim servo, check and adjust clutch torque and
determine proper direction of driving wheel rotation. See Section 22-10-
04 for clutch torque settings.
IMPORTANT Prior to installing trim servo, check trim tab control system.
Function Test

Maintenance Manual
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4 Switch AUTOPILOT PITCH TRIM on.
5 Move (complete) TRIM switch on the
LH control wheel forward.
6 Check trim wheel (upper part) turns
forward.
7 Move (complete) TRIM switch on the
LH control wheel aft.
8 Check trim wheel (upper part) turns
aft.
9 Press AP DISC switch on LH control
wheel.
10 Switch AUTOPILOT PITCH TRIM off.
22-10-09 Trim Servo Clutch
Torque Settings
The following torque setting must be checked and adjusted:
Servo P/N Clutch Torque Servo RPM @24VDC
setting (fixed, not adjustable)
Trim S-TEC 0106-2-T3 36 ± 2 inlbs 11.03
Torque Adjustment
Before re-installation, perform the following steps to check and adjust clutch
torque value given above.
Measuring
2 Insert adapter tool (S-TEC P/N 6622-1) into
leading holes in driving wheel.
3 Bear dial torque wrench.

Maintenance Manual
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4 Connect servo motor to 28 VDC power Servo shaft rotates
source.
5 Read torque value. See above for appropriate
torque settings. Perform
clutch torque adjustment as
per step 6 - 7,
if necessary
Adjustment
6 Remove torque wrench and adapter tool.
7 Align torque value with castle nut - turn CW
to increase and CCW to decrease torque.
8 Repeat steps 2 to 7, until read torque setting
(step 5) matches value given above.
9 Disconnect servo motor.
10 Re-install cotter pin.
NOTE To align cotter pin with shaft hole, use shim washers S - TEC
P/N 1205 S 5 - 005, 007, 010, 031 in any combination (min. 1 required).
22-10-10 Pressure Transducer
2 Remove tail cone access panel. Refer to Chapter 51-00-01.
pressure transducer.
4 Disconnect pressure hose from Cut cable tie
5 Remove pressure transducer. 2 bolts
6 Install in reverse sequence of removal. Fasten pressure hose with new
cable tie.

Maintenance Manual
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22-10-11 Yaw Amplifier
yaw amplifier.
4 Remove pressure yaw amplifier. 4 bolts
22-10-12 Programmer/Computer
2 Place a Allen key in hole between REV Computer will come out.
and ALT key, rotate CCW.
3 Pull out rest of the way. Do not pull on VS knob!
4 Remove programmer/computer
5 Install in reverse sequence of removal. Use Allen key, rotate CW until
computer sits firmly in rack, flush
with panel.
6 Perform heading calibration procedure Refer to Subject 22-10-00 Heading
Calibration
22-10-13 Turn Coordinator

Maintenance Manual
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2 Remove RH IFD. Refer to Chapter 31-60-01.
4 Remove turn coordinator. 4 screws
6 Perform heading calibration procedure Refer to Subject 22-10-00 Heading
Calibration

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Maintenance Manual
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Chapter 23
Communications

Maintenance Manual
EXTRA 500
Table of Contents
23-00-00 GENERAL ........................................................................................................ 3

Description.......................................................................................................... 3
23-10-00 SPEECH COMMUNICATION ...................................................................... 5

Description.......................................................................................................... 5
Operation ............................................................................................................ 5
23-50-00 AUDIO INTEGRATING ................................................................................. 6

23-50-01 Intercom System PS Engineering PMA8000B(-T) ........................................ 6
Description.......................................................................................................... 6
Operation ............................................................................................................ 6
Removal .............................................................................................................. 6
Installation .......................................................................................................... 6
Tests and Checks ................................................................................................ 7
23-50-02 COM Antennas ................................................................................................. 8
Description.......................................................................................................... 8
Removal/Installation ........................................................................................... 8
23-50-03 NAV Antenna .................................................................................................... 9
Description.......................................................................................................... 9
23-60-00 STATIC DISCHARGING ............................................................................. 10

General.............................................................................................................. 10
Description........................................................................................................ 10
Figure 23-01 Lightning Protection/Static Discharging System ............................................. 11
Page 2 23 Page Date: 30.11.

March
July 2012
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EXTRA 500
23-00-00 GENERAL
Description
The EXTRA 500 is equipped with a speech and entertainment communication
system, consisting of the following devices:
1 Avidyne Entegra Release 9 IFD System
2 PS Engineering PMA8000B(-T) Stereo Intercom System
3 COM 1, 2, and Marker Antennas
The system units (1 and 2) are mounted to the instrument panel, the antennas as
shown on Figure 23-01.
In Chapter 23-10-00 Speech Communication you will find information about
Avidyne Entegra Release 9 IFD System.
The related PS Engineering PM8000B(-T) devices and the COM antennas are
subject to Chapter 23-50-00 Audio Integrating.
Chapter 23-60-00 Static Discharging contains a description of the EXTRA 500
bonding system.
Troubleshooting
Unable to transmit or receive No power on load bus Switch on starter/generator or
external power.
Defective AUDIO-MRK breaker Replace
Unable to transmit or receive Defective LH IFD Replace LH IFD
COM I
Unable to transmit or receive Defective RH IFD Replace RH IFD
COM II
Unable to transmit with IFD No or defective antenna cable Check antenna cable
indication connections connections
COM [1/2] TX Fault
Unable to transmit from the Defective transmit button on Replace

pilot's side (missing transmit pilot's side
mode indicator on display)
Defective wiring between Repair
pilot's transmit button and
radio unit
Unable to transmit from the Defective transmit button on Replace
co-pilot's side (missing co-pilot's side
transmit mode indicator on
Defective wiring between co- Repair
display)
pilot's transmit button and
radio unit
No modulation when Defective pilot's headset Replace
transmitting from pilot's seat
Defective wiring Repair

Maintenance Manual
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No modulation when Defective co-pilot's headset Replace
transmitting from co-pilot's
seat
Short range in transmit mode; Defective radio unit Repair
reception without problems
Short range in receive mode; Defective radio unit Repair
signal noise in reception
Short range in transmit and Defective COMM antenna, Repair or replace
receive mode; signal noise in coaxial cable and plug
reception
Speaker silent, headsets Defective speaker Replace
operation normal
Defective intercom unit Replace
Transmit mode indicator on Transmit button stuck Replace
display is always visible
COM [1/2] Stuck TX
Intercom system inoperative, Defective intercom unit Replace

transmit mode O.K.

Maintenance Manual
EXTRA 500
23-10-00 SPEECH COMMUNICATION
Description
The EXTRA 500 airplane is equipped with an Avidyne 700-00083-000
Integrated Flight Display (IFD) in the left (PFD) position and either another
700-00083-000 IFD in the right (MFD) position. A Control Display Unit
(CDU) p/n 700-00150-002 is also installed as part of the Entegra Release 9
IFD System and located on the middle console. Refer to Chapter 31-60 for
more information.
The system is integrated to:
• S-TEC System 55X Autopilot
• Audio panel
• Remote transponder
• DME (optional)
• Weather detection (optional)
• Traffic advisory (optional)
Operation
Refer to POH EXTRA 500.

Maintenance Manual
EXTRA 500
23-50-00 AUDIO INTEGRATING
23-50-01 Intercom System PS Engineering PMA8000B(-T)
Description
The PMA8000B and PMA8000BT are audio isolation amplifier and audio
selector that contain an automatic voice activated (VOX) intercom system and
integral marker beacon receiver. They can switch two transceivers (Com 1,
Com 2) and six receivers (Com 1, Com 2, Nav 1, Nav 2, DME, and MKR).
Operation
Refer to EXTRA 500 Pilot's Operating Handbook.
Removal
power connected.
2 Put a 3/32 Allen wrench into the center access
hole between the Com2 and Mon1 push
buttons for the locking screw in the front
panel. Engage the screw.
3 Turn the screw counter-clockwise until the
unit disengages from the mounting rack.
Do not pull on the knobs. Do not pry the face plate. You can damage the
CAUTION unit.
Do not touch the connector card at the rear of the unit. The electrostatic
CAUTION charge on your body can damage the unit.
4 Pull the sides of the unit gently to remove it
from the mounting rack.
5 Install the protective covers on the rear
connectors of the unit.
Installation
1 Remove the protective covers from the rear
connectors of the unit.
2 Slide the unit into the rack.
3 Engage the locking screw so that the latch
front lobe touches the rack.

Maintenance Manual
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4 Turn the locking screw clockwise so that the
rear lobe engages the mounting rack.
Do not over-tighten the locking screw. You can damage the locking
CAUTION mechanism.
5 Continue to turn the screw until the unit is
fully installed in the mounting rack.
6 Perform a function test. See Tests and Checks
below.
Tests and Checks

Perform the applicable operational checkout presented in the Avidyne System
Installation and Operation Manual (LOAP 37) or (LOAP 38) whenever the unit
has been reinstalled.

Maintenance Manual
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23-50-02 COM Antennas
Description
For communication transmitting and receiving conventional antennas
(COM 1, 2, and Marker) are used (refer to Figure 23-01).
The antennas are attached to the fuselage by a ground plate. The lightning
protection sheet is placed between the ground plate and the fuselage structure
and thus ensures bonding. Connection is made via conventional BNC plugs and
sockets.
The Marker and COM 2 antenna is integrated in the structure of the ventral fin.
Maintenance should not be required. In case access to these antennas is
required, contact EXTRA.
power connected.
2 Disconnect BNC plug.
3 Remove attachment nuts.
4 Remove antenna.
5 Install in reverse sequence of removal. Ensure lightning protection
sheet is placed between
fuselage structure and ground
plate.
Page 8 23 Page Date: 30.11. July 2012

March
Maintenance Manual
EXTRA 500
23-50-03 NAV Antenna
Description
From serial N° 1003 the NAV antenna is installed on the fin tip.
power connected.
2 Remove NAV antenna access panel. Refer to Chapter 51-00-01
3 Remove attachment bolts.
4 Remove antenna.
5 Disconnect BNC plug.
Page Date: 30.

11. March 2012
July 2012 23 Page 9
Maintenance Manual
EXTRA 500
23-60-00 STATIC DISCHARGING
General
A special bonding system is necessary for the composite structure of the
EXTRA 500. The composite structure does not sufficiently conduct electricity.
Lightning protection aluminium sheets are attached to the inner fuselage skin
to make a conduct path. Attachment is made by fabric layers and
interconnections between sheets are made by rivets.
All metal components are bonded to the aluminium sheets by copper leads.
Some components are directly connected to the aluminium sheets when
attached (so as the COM 1, 2, and Marker antenna).
Description
A main aluminium sheet is routed from the firewall to the right side of the
inner fuselage and then to the rear. Several extensions are routed to the wing,
landing gear, antennas and other equipment as shown on Figure 23-01
(Figure 23-01 only shows the lightning protection system and equipment as far
as applicable for communication system static discharging).

March
July 2012
Figure 23-01
Page Date: 11.

30. July
March2012
NAV
2012
Antenna*
Strobe Light
Power Supply
COM 1
Antenna
Strobe Light
Lightning Protection/Static Discharging System

COM 2 NAV
Antenna Antenna*
23
*) NAV antenna installed on fin tip from serial N° 1003
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Page 11
Maintenance Manual
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March
July 2012
Maintenance Manual
EXTRA 500
Chapter 24
Electrical Power

Maintenance Manual
EXTRA 500
Table of Contents
24-00-00 GENERAL ........................................................................................................ 3

Description.......................................................................................................... 3
Figure 24-1 Electrical System Schematic ............................................................................... 4
Figure 24-2 Left Side Panel Switches ..................................................................................... 5
Figure 24-3 Left Side Panel Circuit breakers ........................................................................ 6
24-30-00 DC GENERATION .......................................................................................... 9

24-30-10 Starter-Generator ............................................................................................. 9
24-30-11 Generator Control Unit (GCU) ....................................................................... 9
24-30-20 Standby Alternator ......................................................................................... 10
24-30-21 Alternator Regulator ...................................................................................... 10
24-30-30 Battery ............................................................................................................. 11
Charging with external power .......................................................................... 11
Charging over charger plug .............................................................................. 12
24-30-40 Indication ......................................................................................................... 12
24-30-41 Indicator Cluster............................................................................................. 12
24-40-00 EXTERNAL POWER .................................................................................... 14

Description........................................................................................................ 14
24-60-00 DISTRIBUTION............................................................................................. 15
Description........................................................................................................ 15
24-60-01 E-box ................................................................................................................ 16
24-60-02 Switches ........................................................................................................... 16
24-60-03 Circuit Breakers ............................................................................................. 17
24-60-04 Relays ............................................................................................................... 17
24-60-05 Shunts .............................................................................................................. 17
24-60-06 Fuses ................................................................................................................. 17

Maintenance Manual
EXTRA 500
24-00-00 GENERAL
Description
Refer to Figure 24-1. The electrical system is a 28 VDC system with negative
ground. The primary DC power source is an engine driven 28 V/200 A starter-
generator. It is backed up by an engine driven 26 V/20 A standby alternator. In
addition a lead acid battery (24 V/28 Ah) is installed in the engine
compartment. Normal battery power is sufficient to start engine or for ground
check operation.
An external 28 VDC power receptacle and its circuit breaker are installed in a
hatch right hand at fixed portion of the cowling.

Maintenance Manual
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S T T ES C Y
LT
N
T
DB S
IO R
GE R G E
YA
S T N IC
AV PW
GE R T
EM B
TT
C
E
N
N
T
A
RC
BA
EX
y
Alternator
r Generator control
control unit
y unit
Bus voltage
Battery current
Generator current
Battery External power

24 VDC
Standby alternator
20 A
Starter/generator
200 A
Hot Load Batt. Emerg.
bus bus bus bus
AV
bus
Legend:
Switch Shunt
y Annunciator light Circuit breaker

Hot bus Electrical bus Fuse
Relay Gauge
Figure 24-1 Electrical System Schematic

Maintenance Manual
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MAIN
AVIONIC MASTER
LIGHTS
DEICE
CABIN
Figure 24-2 Left Side Panel Switches

Maintenance Manual
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Figure 24-3 Left Side Panel Circuit breakers

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EXTRA 500
Troubleshooting
The following paragraph tabulates the trouble shooting procedures relevant to
the battery system.

System not energized when Depleted or dead battery Recharge or replace.
battery switch is turned on
Defective wiring With BATT switch OFF, check
entire DC power system,
accessible from plane fire wall
resp. lower tail cone access
panel, for an open circuit with
a continuity tester
Defective battery relay With BATT switch ON,
connect a voltmeter to the
main battery bus and check
voltage. If no voltage is
indicated, check and/or replace
relay
Defective BATT switch Remove switch and check
with continuity tester. Replace
switch if defective.
Battery discharged Charging rate too low Check generator
Battery has been left standing Recharge or replace
too long without recharging
Equipment has been left on Replace battery
accidentally
Short circuit in wiring Check wiring, replace battery.
Short battery life Low charging rate Check generator voltage
Corroded or loose battery Clean and tighten, recharge
connections battery.
Reduced battery capacity Replace battery.
Battery polarity reversed Connected backwards on Battery should be slowly
airplane or charger discharged completely, then
charged correctly and tested
Battery freezes Undercharged or overcharged Replace battery
battery

Maintenance Manual
EXTRA 500

Starter-generator does not Starter-generator defective Replace starter-generator.
produce current when
Generator control unit Replace generator control unit.
switched on.
defective
GEN switch defective Replace GEN switch.
Generator relay defective Replace generator relay (E-
box).
Current indication defective Replace shunt.
Replace indicator.
Repair wiring.
Standby alternator does not Bus voltage above 26.5 V Normal, no action required.
produce power when switched
Alternator defective Replace alternator.
on
Alternator controller defective Replace alternator controller.
Wiring defective Repair wiring.
STDBY ALT switch defective Replace STDBY ALT switch.
Alternator relay defective Replace alternator relay (E-
box).
Alternator fuse defective Examine reason and replace
alternator fuse (E-box).
Current indication defective Replace shunt.
Replace indicator.
Repair wiring.
Load bus without power Starter-generator or external Normal, no action required.
power not on.
Load bus fuse defective Replace fuse (E-box).
Battery bus without power Battery bus fuse defective Replace fuse (E-box).
Avionic bus without power Battery bus without power See above.
AVIONICS switch defective Replace AVIONICS switch (left
side panel).
Avionic bus relay defective Replace avionic bus relay (left
side panel).
AV BUS circuit breaker Replace AV BUS circuit
defective breaker (left side panel).

Maintenance Manual
EXTRA 500
24-30-00 DC GENERATION
DC generation is done by the following devices:
• Starter-generator
• Standby Alternator
• Battery
24-30-10 Starter-Generator
A starter-generator is mounted on the accessory gearbox of the engine. It is a
direct driven starter during engine start and a DC generator driven by the
engine during engine operation. Its rated capacity is 200 A maximum for
continuous operation.
Remove the LH upper engine cowling to get access to the starter-generator.
Refer to AIRCRAFT PARTS CORP. Installation Instructions 200SGL Series
Starter-Generators (LOAP 39) for further information.
24-30-11 Generator Control Unit (GCU)

The starter-generator is regulated by the GCU (Generator Control Unit) to
provide an output voltage of 28.5 V DC. The GCU is installed to the fuselage
structure behind the left legroom side paneling. The GCU is controlled by the
GEN and GEN TEST switches located on the MAIN section of the left side panel.
Following engine start, the generator delivers electrical power when the GEN
switch is switched to ON position.
In case the generator is not switched on or has failed the red GENERATOR FAIL
warning light on the annunciator panel illuminates. With the generator test
switch (GEN TEST, left side panel) the overvoltage protection function of the
GCU can be tested (switch position: OV-TEST). The TRIP position of this
switch gives the possibility to “trip” the generator by momentarily interrupting
its excitation. Both test functions lead to disengagement of the generator from
the aircraft bus system. The momentary RESET position of the GEN switch
serves to energize the generator field in case problems have occurred trying to
connect the generator to the aircraft bus system (switching the generator ON).
Resetting the generator is recommended in that case before trying to switch the
generator on again.

Maintenance Manual
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power connected.
2 Remove left legroom side paneling. Refer to Chapter 25-00-01.
3 Remove electrical connector.
4 Remove GCU. 4 bolts
24-30-20 Standby Alternator

In case of a starter-generator failure a gear driven standby alternator provides
an additional power source in excess to the aircraft battery. The standby
alternator is controlled by the STDBY ALT switch in the MAIN section of the
left side panel. Switching it to the ON position will command the alternator
regulating unit to regulate an alternator output voltage of 26 VDC. Therefore as
long as bus voltage is higher caused by an active generator the alternator load
will be zero. As soon as bus voltage drops below the regulation voltage of the
standby alternator the alternator feeds to the bus system. Max. rated current is
20 A which is available with N1 being at approx 92 %. At 78 % N1 about 10 A
are available. Below 70 % N1 the standby alternator isn’t able to provide a
relevant current.
Operation of the standby alternator is indicated by a yellow STANDBY ALTERN
ON caution light on the annunciator panel. Continuous illumination of this light
signals operation below the 20 A output limitation.
If the STANDBY ALTERN ON caution light starts blinking, the load on the
CAUTION alternator exceeds its rated capacity. Reduce consumption of electrical
consumers within 5 minutes to 20 A or less.
Remove the upper engine cowlings to get access to the stand-by alternator.
Refer to B & C SPECIALTY PRODUCTS Installation Instructions for BC410
Alternators (LOAP 40) for further information.
24-30-21 Alternator Regulator

The alternator regulator is mounted to the cabin side of the firewall.
Refer to B & C SPECIALTY PRODUCTS B & C SPECIALTY PRODUCTS
Troubleshooting Guide (LOAP 28) for further information.

Maintenance Manual
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power connected.
2 Remove RH and LH IFD. Refer to Chapter 31-60-01.
3 Remove electrical connection.
4 Remove 2 nuts.
5 Remove regulator.
24-30-30 Battery
The 24 VDC/28 Ah valve regulated lead acid battery is located in the engine
compartment, mounted to the pressure bulkhead and protected by a vented
aluminum case. The battery is directly connected to the hot bus. The battery
supplies power to the electrical system when BATT switch is switched to ON
position.
Recharging the battery may be done with battery installed. There are two
procedures:
Charging with external power

Always keep sparks or any form of ignition away from the battery being
WARNING charged. Explosive gases are being generated during the charging
process.
1 Set external power unit to 28 VDC.
2 Connect external power.
3 Switch on BATT.
4 Switch on EXT PWR.

Maintenance Manual
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Charging over charger plug

Always keep sparks or any form of ignition away from the battery being
WARNING charged. Explosive gases are being generated during the charging
process.
Do not charge with more than 5 A.
Use only supplied unit or equivalent.
1 Connect the charger to the charger plug.
2 Connect the charger to the wall socket.
power connected.
2 Remove upper engine cowlings. Refer to Ch. 71-10-01/02.
3 Disconnect the quick connect plug.
4 Disconnect the 2 retainers.
5 Remove battery from aircraft.
6 Install in reverse order of removal
24-30-40 Indication
Electric system relevant indication is made by the digital indicator cluster
installed in the left side of the main panel and the following lights in the
annunciator panel:
GENERATOR FAIL (red), see Subject 24-30-10.
LO VOLTAGE (yellow), illuminates as soon as bus voltage drops below 25.5 V.
STANDBY ALTERN ON (yellow), see Subject 24-30-20.
EXTERNAL POWER (green), see Subject 24-40-00.
24-30-41 Indicator Cluster

The digital indicator cluster installed in the left side of the main panel indicates
three electric system parameters among other engine parameters (also refer to
Chapter 77-40-02):

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VDC (bus voltage)

During normal operation (generator active) a voltage of approx 28 V should be
indicated. With standby alternator the indication should be about 26 V. Battery
nominal voltage is 24 V.
GEN AMPS (Generator Load)

Generator load is indicated on this indicator as long as the generator is active
(GENERATOR FAIL warning light off). Generator Load should be kept below
200 A. In case the generator is offline this indicator automatically displays the
standby alternator load. The standby alternator load has to stay below 20 A (see
also Subject 24-30-20).
BAT AMPS
The battery amp indicator shows load or charging current on the battery. A
negative indication means battery is being charged, a positive indication means
battery is discharged (load on battery).
For removal/installation procedures refer to Chapter 77-40-02.

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24-40-00 EXTERNAL POWER
Description
An external power receptacle is installed under an access door on the right side
of the engine compartment. The use of external power is recommended for
engine starting in case aircraft battery is weak, for ground operation of the
vapor cycle air condition system or for any prolonged ground operation of
aircraft systems. An external power source being connected with the external
power receptacle and switched on will be indicated by a green EXTERNAL
POWER annunciation light in the annunciator panel. To enable the external
power source to supply power to the aircraft the EXT PWR switch on the MAIN
section of the left side panel has to be switched on.
Do not connect ground power units with a capacity greater than 1200 A
CAUTION for engine start.
NOTE It is not possible to connect the starter-generator and an external power
source simultaneously to the aircraft bus system. This is to avoid any
uncontrolled currents between these units.
Additionally a battery charger plug is installed at the external power receptacle.
The battery may be charged with 29.0 V and 5 A.

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Description
Electrical power from the various power sources is supplied to the E-box. The
E-box incorporates the main devices of the distribution system such as fuses,
circuit breakers, relays, and shunts and is installed on the engine side of the
firewall. From there power is distributed partly through individual fuses to the
following buses:
• Hot Bus,
• Emergency Bus,
• Battery Bus and Avionic Bus
• Load Bus,
The battery directly feeds the hot bus supplying power for equipment, which
has to be independent from the battery switch position (e.g. ELT; see Figure
24-2 for location of battery switch).
Turning the battery switch to the ON-position will activate a relay connecting
the battery to the battery bus and further to the emergency bus. This allows
starting the engine and feeding the other equipment and, if engine is running,
recharging the battery with the starter/generator.
The generator is activated by turning GEN switch to the ON-position (see
Figure 24-2). So the generator is activated and the generator relay connects the
generator to the load, battery and emergency bus.
From the main bus electrical power is distributed to the various busses as
outlined on Figure 24-1. The avionic bus can be disconnected by the AVIONICS
switch.
The main control switches of the electrical power system are located on the
MAIN section of the left side panel (see Figure 24-2) and are marked EXT PWR,
BATT, STBY ALT, GEN and GEN TEST.
Push-pull circuit breakers automatically break the current if an overload occurs
to prevent damage to the electrical wiring and equipment. The most circuit
breakers are installed to the left side panel (see Figure 24-3). A single circuit
breaker is installed on the upper LH engine mount (GCU) and under the
external power hatch (EXT PWR) respectively. All other circuit breakers are
installed to the E-box located on the engine side of the firewall and are labeled
GEAR AUX 2, BATT CHARGE, SPARE, ALT FIELD 2, COURTESY LT, and ELT.
Generally where exclusively wiring shall be protected poly switches are used.
They are installed on different locations of the electrical system.

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24-60-01 E-box
power connected.
2 Remove upper engine cowlings. Refer to Ch. 71-10-01/02.
3 Disconnect the SCEET hoses from the oil
cooler inlet.
4 Remove 10 attachment screws of the oil
cooler inlet.
5 Remove oil cooler inlet.
6 Remove 8 oil cooler outlet attachment
screws.
7 Move oil cooler and outlet some centimeters To get access to the E-box.
forward.
8 Disconnect electrical connector
9 Disconnect power lines
10 Remove upper E-box cover. 1 screw
11 Disconnect 3 main power bulkhead feed- Hold threaded rod in place by
throughs. means of an Allen wrench.
12 Remove 3 attachment screws.
13 Remove E-box.
14 Remove cover plate and shell plate. Plates are screwed on.
24-60-02 Switches
The switches on the instrument panel are accessible from the backside after
removal of the RH IFD. The LANDING GEAR, FLAP, and ELT switch
backsides are directly accessible from the legroom.
The backsides of the left side panel switches are accessible when the upper and
lower part of the left side panel has been removed.
Generally conventional switches are used, so that removal is done by
disconnecting the electrical wiring and removing attachment screws or nuts.
Installation is vice versa.

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24-60-03 Circuit Breakers
The circuit breakers on the left side panel are accessible from the backside
when the upper and lower part of the left side panel has been removed.
To get access to the E-box circuit breakers the E-box must be removed (refer to
Subject 24-60-01).
Generally conventional circuit breakers are used, so that removal is done by
disconnecting the electrical wiring (busses) and removing attachment screws or
nuts. Installation is vice versa.
24-60-04 Relays
Relays are installed in the left side panel, in the E-box and behind the RH IFD.
To get access to the relays either the E-box (see Subject 24-60-01), the left side
panel (see Chapter 31-10-01) or the RH IFD (see Chapter 31-60-01) must be
removed
Electrical wiring is generally connected to the relays by means of relay sockets.
The relays are mounted to the sockets with bolts.
24-60-05 Shunts
Shunts are installed in the E-box.
To get access to the shunts the E-box must be removed (refer to Subject 24-60-
01).
Electrical wiring is generally connected to the shunts by means of screws. The
shunts are mounted to the supports with bolts.
24-60-06 Fuses
The main fuses are installed in the E-box with bolts. They are accessible after
removal of the upper E-box cover.

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Chapter 25
Equipment and Furnishing

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TABLE OF CONTENTS
25-00-00 GENERAL ........................................................................................................ 5

25-10-01 Paneling ............................................................................................................. 5
Description.......................................................................................................... 5
25-10-00 FLIGHT COMPARTMENT ........................................................................... 6

25-10-10 Seats, Seat Belts, and Shoulder Harnesses ..................................................... 6
Description.......................................................................................................... 6
25-10-11 Pilot's Seat ......................................................................................................... 6
25-10-12 Copilot's Seat..................................................................................................... 7
25-10-21 LH Side Armrest Paneling ............................................................................... 7
25-10-22 RH Side Armrest Paneling............................................................................... 8
25-10-23 Front Ceiling Paneling ..................................................................................... 8
25-10-24 Upper Side Paneling LH/RH Side ................................................................... 9
25-10-25 Windshield Middle Strut Paneling .................................................................. 9
25-10-26 Middle Console Paneling Upper Part ............................................................. 9
Description.......................................................................................................... 9
25-10-27 Middle Console Paneling Lower Part ........................................................... 10
Description........................................................................................................ 10
25-20-00 PASSENGER COMPARTMENT................................................................. 11

25-20-10 Seats ................................................................................................................. 11
25-20-11 Front Passenger Seats .................................................................................... 11
25-20-12 Aft Passenger Seats ......................................................................................... 11
Removal ............................................................................................................ 11
Installation ........................................................................................................ 12
25-20-21 LH Side Armrest Paneling ............................................................................. 12

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25-20-22 RH Side Armrest Paneling ............................................................................. 13

Removal/Installation.......................................................................................... 13
25-20-31 Storage Boxes LH/RH ..................................................................................... 13
Description ........................................................................................................ 13
25-20-32 Table ................................................................................................................. 14
25-50-00 BAGGAGE COMPARTMENT ..................................................................... 15

Description ........................................................................................................ 15
25-50-01 Tie Down Belts ................................................................................................. 15

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25-00-00 GENERAL
25-10-01 Paneling
Description
If not described in another way paneling is generally mounted to the aircraft
structure with Phillips screws.
Take care of the paneling installations such as switches, sockets, lights etc.
when removing. Ensure BATT switch is OFF and no external power connected,
when electrical devices are involved. Sometimes the paneling overlaps. Then it
is necessary to remove also the adjacent paneling. Move paneling some
centimeters inboard after removal of Philips screws to get access to the
paneling backsides. Then disconnect electrical wiring. Installing is vice versa.

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25-10-00 FLIGHT COMPARTMENT
25-10-10 Seats, Seat Belts, and Shoulder Harnesses
Description
The pilot's and copilot's seats are one piece, four-way adjustable seats
incorporating energy absorbers which reduce forces working on the occupants
in case of crash. The seats may be moved forward, aft, up, and down. The
adjustment is made by pulling a handle located at the right respective left
forward underside of the seat to release the fixing mechanism. The horizontal
adjustment range is 152 mm, 5 fixed positions are provided. The vertical
adjustment range is 80 mm, 5 fixed positions are provided. Telescopic
cylinders support the pilot during the vertical adjustment.
The seat belts and the shoulder harnesses with inertia reels used for the pilot
and copilot are attached to the seats. The seat belts provide a conventional
adjustment. Shoulder harness adjustment is not necessary due to the inertia
reels, which allow straps to extend and retract as required under normal
movement. However the reels will lock in place in the event of a sudden
deceleration.
25-10-11 Pilot's Seat
1 Remove front roll from RH seat track. 2 screws
2 Remove mounting bracket and roll as 2 screws
a unit from back RH seat track.
3 Pull off bracket from back LH seat 2 screws
track.
4 Pull adjusting handle to release bolt at
longitudinal adjusting device.
5 Slide seat out of mounting console in
forward direction.

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25-10-12 Copilot's Seat
1 Remove front roll from LH seat track. 2 screws
2 Remove mounting bracket and roll as 2 screws
a unit from back LH seat track.
3 Pull off bracket from back RH seat 2 screws
track.
4 Pull adjusting handle to release bolt at
longitudinal adjusting device.
5 Slide seat out of mounting console in
forward direction.
25-10-21 LH Side Armrest Paneling
1 Remove left side panel. Refer to Chapter 31-10-01.
2 Remove screw fastening microphone twin

socket on rear top of panel.
3 Remove screw at lower front panel side.
4 Remove screw at lower rear panel side.
5 Slightly lift panel and remove it against
flight direction.

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25-10-22 RH Side Armrest Paneling
power connected.
2 Remove microphone socket cover on rear
top of panel.
flight direction.
25-10-23 Front Ceiling Paneling
power connected.
Take care not to damage sunblinds. Swivel sunblinds up before
CAUTION removing ceiling panel
2 Remove 4 screws around upper windshield
frame.
3 Remove 4 screws near panel edges.
4 Disconnect plug for dome light/speaker
wiring.
5 Carefully remove adhesive tape at panel
back side.
6 Remove front ceiling paneling.

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25-10-24 Upper Side Paneling LH/RH Side
1 Remove 2 screws in windshield frame area.
2 Remove 2 screws in front cabin window
contour area.
3 Remove upper side paneling.
25-10-25 Windshield Middle Strut Paneling
power connected.
2 Remove 2 screws at compass.
3 Disconnect wiring for compass lighting.
4 Remove compass.
5 Remove 4 screws at paneling.
6 Remove windshield middle strut paneling.
25-10-26 Middle Console Paneling Upper Part
Description
The middle console paneling consists of an upper and lower part. The upper
part is screwed on the lower part and on the middle console structure.
1 Remove trim wheel. 1 Phillips screw
2 Remove the back-up microphone from the
middle console.

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3 Remove the upper part of middle console 24 Phillips screws
paneling.
5 Check the function of the back-up
microphone.
25-10-27 Middle Console Paneling Lower Part
Description
The lower part of the middle console paneling is aligned by 4 guiding pins in
the fuselage frame and fixed by the upper part of the paneling.
1 Remove upper part of the middle console Refer to Subject 25-12-06
paneling.
2 Disconnect air hoses from the legroom 1 worm drive hose clamp
dispensers. each side
3 Move lower part paneling some centimeter
aft and remove.
4 Install in reverse sequence of removal. Insert guide pins to the
related holes in the forward
paneling edges.

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25-20-00 PASSENGER COMPARTMENT
25-20-10 Seats
The passenger seats are one piece seats as well but are placed on a fix position.
However the backrest of both aft seats can be swiveled forward allowing easy
access to the baggage compartment. For this purpose a release handle located
on the inner side of the backrest has to be pulled up.
Ensure backrest is locked by checking the down position of the release
WARNING handle before using the seat.
The seat belts provide a conventional adjustment however the locking
mechanism is placed on the inner side of the seat providing a lock for the
shoulder strap, which is equipped with inertia reels. The attachments of the seat
belts and shoulder harnesses are integrated in the seat.
25-20-11 Front Passenger Seats
1 Remove screws at mounting console. 4 Allen screws LN 29952-0615M
2 Remove seat.
3 Install in reverse order of removal. If necessary, use mounting template
at landing gear attachment for front
side screws.
25-20-12 Aft Passenger Seats
Removal
1 Remove front paneling of baggage To get access to the mounting
compartment from seat assembly. consoles.
2 Remove back side screws at inner and 4 Allen screws LN 9037 - 06018
outer seat mounting console.
3 Remove front side screws at inner and 1 Allen screw LN 9037 - 06016 and
outer seat mounting console. 2 Allen screws LN 9037 - 06018

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4 Remove screws at higher angle 6 Allen screws AN 5260 - 1032

bracket.
Installation
1 Insert front side screws at inner and 1 Allen screw LN 9037 - 06016 and
outer seat mounting console. 2 Allen screws LN 9037 - 06018
2 Before tightening front side screws 4 Allen screws LN 9037 - 06018
completely, adjust seat from rear side
and install back side screws at inner
and outer seat mounting console.
3 Tighten front side screws at inner and
outer seat mounting console.
4 Install screws at higher angle bracket. 6 Allen screws AN 5260 - 1032
5 Reinstall front paneling of baggage
compartment..
25-20-21 LH Side Armrest Paneling
power connected.
2 Remove microphone socket cover on front
top of panel.
top of panel.
4 Remove 5 screws at entrance bottom panel
sheet.
5 Loosen screws at door sealing frame in
armrest area.
NOTE On some aircraft, the armrest is fixed with additional latches to the door
frame. In this case remove the screws and the latches completely.
8 Pull armrest together with frame floor
finishing inboard and remove it against
flight direction.

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25-20-22 RH Side Armrest Paneling
power connected.
2 Remove microphone socket cover on front
top of panel.
top of panel.
4 Remove table. Refer to Subject 0.
6 Pull back frame floor finishing.
flight direction.
25-20-31 Storage Boxes LH/RH
Description
Storage boxes are located between LH and RH side pilot’s/copilot’s and front
passenger seats. They provide a place for depositing especially the emergency
torch, first aid kit and the aircraft documentation material.
power connected.
2 Slide pilot’s and co-pilot’s seat into most
forward position.
3 Remove 2 screws at front and back bottom
side.
4 LH box Remove screws at floor and back wall of
upper and lower storage compartments.
4 RH box Take out fire extinguisher, remove bolts
holding extinguisher support bracket.

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25-20-32 Table
1 Remove 2 screws at table underside.
2 Remove 2 sheatings.
3 Remove table.

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25-50-00 BAGGAGE COMPARTMENT
Description
The baggage compartment is located behind the aft passenger seats. To get
access the backrest of both aft seats can be swiveled forward. The release
handle is placed on the left side of the backrest.
The baggage can be secured by tie down belts, which are to be fastened on eyes
located on two compartment sides.
25-50-01 Tie Down Belts
1 Release the handles at aft passenger seat
backrests and swivel backrests forward.
2 Remove 2 Phillips screws AN 526 C .1032
R8 securing front belt brackets to LH and
RH side console.
3 Remove front belt.
Remove 2 Phillips screws AN 526 C .1032
R8 securing aft belt brackets to LH and RH
side console.
Remove aft belt.
4 Install in reverse sequence of removal. Install screws just so tight,
that belt brackets can be
rotated freely, but without
play.

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Chapter 27
Flight Controls

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TABLE OF CONTENTS
27-00-00 GENERAL ........................................................................................................ 5

Description.......................................................................................................... 5
27-00-01 Control Cable .................................................................................................... 5
Tensions .............................................................................................................. 5
Figure 27-01 Control System Surview ...................................................................................... 6
27-00-10 CONTROL SPRINGS ...................................................................................... 7

Location .............................................................................................................. 7
27-00-11 Down-Spring ..................................................................................................... 7
Description.......................................................................................................... 7
27-00-12 Interconnection Aileron/Rudder ..................................................................... 7
Description.......................................................................................................... 7
27-00-13 Centering Rudder ............................................................................................. 8
Description.......................................................................................................... 8
27-00-14 Nose Gear Steering ........................................................................................... 8
Description.......................................................................................................... 8
27-00-15 Nose Gear Control Cable ................................................................................. 8
Description.......................................................................................................... 8
27-10-00 AILERONS ....................................................................................................... 9

Description.......................................................................................................... 9
27-10-01 Aileron Cables ................................................................................................. 10
27-20-00 RUDDER ......................................................................................................... 11

Description........................................................................................................ 11
27-20-01 Rudder Cables................................................................................................. 12
27-30-00 ELEVATOR AND TAB ................................................................................. 14

Description........................................................................................................ 14
27-30-01 Elevator Cables ............................................................................................... 16

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27-50-00 FLAP SYSTEM ............................................................................................... 18

Description ........................................................................................................ 18
Rigging and Adjustment ................................................................................... 18
Track Adjustment .............................................................................................. 19
Guidance Checks and Adjustment .................................................................... 19
Actuation Adjustment ....................................................................................... 20
27-50-01 Flap Drive Motor............................................................................................. 21
Description ........................................................................................................ 21
27-50-02 Inboard Power Transmission Flexible Shaft ................................................ 22
Description ........................................................................................................ 22
27-50-03 Outboard Power Transmission Flexible Shaft ............................................. 22
Description ........................................................................................................ 22
27-50-04 Power Transmission Screw Jacks .................................................................. 23
Description ........................................................................................................ 23
27-50-05 Flap Control Box ............................................................................................. 23
Description ........................................................................................................ 23
27-50-06 Flap Limit Switches......................................................................................... 24
Description ........................................................................................................ 24
Adjustment ........................................................................................................ 24
27-50-07 Flap Asymmetry Senders ............................................................................... 26
Adjustment ........................................................................................................ 26

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27-00-00 GENERAL
Description
The flight controls consist of the ailerons, rudder and elevators. The right
elevator is equipped with a trim system. All these control surfaces are
constructed of composite material. The primary control system is a
conventional cable-system consisting of a double control wheel (pitch and roll)
with respective coupling systems, hanging control pedals (yaw), tubes, levers,
pulleys and push-pull rods. Between ailerons and rudder controls an
interconnection which is made via springs is installed. However, the coupling
can easily be overpowered (e.g. in side slipping).
27-00-01 Control Cable
Tensions
The control cable systems generally use cable of 3.2 mm diameter. However
the aileron control uses cables of 4 mm diameter in the wing region.
System Cable Diameter Cable Tension Tolerance
Ailerons 3.2 mm/4 mm 220 N/49.5 lbs  20 N/4.5 lbs
Rudder 3.2 mm 220 N/49.5 lbs  20 N/4.5 lbs
Elevator 3.2 mm 300 N/67.4 lbs  20 N/4.5 lbs

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Side View
Pulley
Segment
Aileron Control
Elevator Control
Rudder Control
Top View
Turnbuckles
Pulleys
Rudder and Elevator
Control
Top View
Pulleys
Aileron Control
Pulley
Left Wing Segment
symmetrically
Turnbuckles
Figure 27-01 Control System Surview

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27-00-10 CONTROL SPRINGS
Location
The following springs are incorporated in the control system of the
EXTRA 500:
Application Location
Down-spring Cockpit, instrument shelf
Interconnection aileron/rudder Cockpit, bulkhead
Centering rudder Tail fairing
Nose gear steering Nose wheel dome
Nose gear control cable Cockpit
27-00-11 Down-Spring
Description
Safety spring, affecting the pulley segment of the elevator control, to create a
nose-down pitching control force. The down-spring is located on the LH side,
below the instrument shelf.
In case of down-spring failure the amount of steering force required will rise
when pushing the control yoke. Trimming "nose down" will compensate this
effect. Malfunction of the down-spring will not cause further reductions of
flight performance or any unsafe flight conditions.
27-00-12 Interconnection Aileron/Rudder
Description
To reduce tendency to raise the low wing, esp. during low speed flight (landing
approach), the EXTRA 500 is furnished with an interconnection between the
aileron and the rudder control. When activating the rudder, the coupling
correspondingly actuates the aileron control. When moving the aileron, the
rudder — as long as being free of any control forces — remains in neutral
position.
The coupling is being accomplished by means of a pair of safety springs,
located at the LH foot compartment. The control force is conducted from the
shafts of the rudder control to the safety springs by levers and cables, including
the pulleys.
Once the friction inside the control system has been overcome, a rudder control
input is led to the LH control column by a chain drive.

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Failure of an interconnection spring will cause an additional force in one

direction at the aileron control, which is rated below the tolerated amount.
27-00-13 Centering Rudder
Description
Within the lower rudder bearing a spring-loaded pulley strains a steel plate
attached to the rudder, thus centering the rudder in neutral position and
providing a defined rising of control forces while moving the rudder.
Malfunction of the centering spring will disengage the centering and reduce the
control force rise. Unsafe flight conditions are excluded.
27-00-14 Nose Gear Steering
Description
The pivoting of the nose gear is part of the rudder control system, completing
the control cable arrangement. To de-couple the nose gear steering from the
rudder control, two safety springs are incorporated into the nose gear pivoting.
The springs will transmit the control force forward after having reached a
defined travel.
Malfunction of the nose gear steering springs will abolish pretension of the
control cables. With a 16° play arising inside the nose gear steering, reduction
of max. angular movement from ± 30° to approx. 10° in one direction will
occur, whereas control force at the rudder pedals will slightly increase.
27-00-15 Nose Gear Control Cable
Description
These additional springs will stretch the nose gear control cables, when one of
the springs at the nose gear pivoting has been lengthened due to a rudder
movement against the locked nose wheel.
Malfunction of one or both springs will not affect normal control functions.

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27-10-00 AILERONS
Description
The coupling between the two control wheels of the main control system is
realized by a direct cable-chain coupling. The cables are connected to the
control wheels by means of a longitudinal toothed wheel and run through the
windshield center strut to the wing nose and move outboard. Outside the tank
area they cross the front spar. Then they are connected to a cable segment
which actuates the aileron via lever and push-rod.
Each aileron is attached to the rear spar of the wing by two hinges.
Troubleshooting
Lost motion in control wheel. Loose control cables. Check cable tension. Adjust
cables to proper tension.
Broken pulley or braket, cable Check visually. Replace worn
of pulley or worn rod end or broken parts, install cables
bearings. correctly.
Resistance to control wheel Cables too tight. Check cable tension. Adjust
movement. cables to proper tension.
Pulleys binding or cable off. Observe motion of the pulleys.
Check cables visually. Replace
defective pulleys. Install
cables correctly.
Defective quadrant assembly. Check visually. Replace
defective quadrant.
Clevis bolts in system too Check connections where
tight. used. Loosen, then tighten
properly and safety.
Control wheels not level with Improper adjustment of cables. Adjust turnbuckle to obtain
ailerons neutral proper alignment.
Improper adjustment of Adjust push-pull rods to obtain
aileron push-pull rods. proper alignment.
Dual control wheels not Cables improperly adjusted. Adjust cables.
coordinated.
Chain improperly adjusted. Adjust chain.
Incorrect aileron travel. Push-pull rod not adjusted Adjust rod.
properly.
Incorrect adjustment of travel Adjust bolts.
stop bolts.

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1 Loosen push rod from central part of aileron
2 Remove cotter pin and bolt from each of the
two hinges
3 Remove aileron backwards
27-10-01 Aileron Cables
1 Remove center cover of wing root section
2 Remove turnbuckle below cover
Perform steps No 3 – 9 at LH and RH side wing each
3 Remove turnbuckle at outer wing rib
4 Remove rigging clamps of role servo at
inner wing rib
5 Remove recognition light at outer wing nose
section
6 Remove outer side pulley
7 Push up inner side pulley
8 Remove teflon guiding bushings at outer
wing rib
9 Loosen return cable segment at outer wing Remove bolt and push
rib for removal of 3.6 mm cable segment sideways
10 Remove 2 pulleys at windshield center strut
11 Remove teflon guiding bushings at
windshield center strut
12 Remove avionic panel
13 Remove LH and RH side return brackets
14 Remove LH and RH cable safety brackets
below instrument shelf
15 Loosen return cable segments at steering Remove bolts and push
column segments sideways

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27-20-00 RUDDER
Description
The rudder pedals are placed hanging on two tubes which have a lever arm at
the right side of the cabin. From there the cables are led along the cabin right
side armrest panel to the empennage around pulleys positioned in groups. Here
a direct connection to the lever arms of the rudder follows. The connection
points lay inside the tail cone adjacent to the lower rudder bearing.
The rudder is connected to the rear fin spar at three points.
Troubleshooting
Play between pedals and Insufficient cable tension. Rig the system.
rudder.
Rudder does not respond to Broken or disconnected Open armrest panel, access
pedal movement. cables. doors and tailcone and check
visually. Connect or replace
cables.
Excessive resistance against Cables too tight. Rig the system.
pedal movement, binding or
Cables not running properly Open armrest panel, access
jumpy movement of pedals.
on pulleys. doors and tailcone and check
visually. Lay cables correctly
over pulleys.
Binding, broken or defective Check visually. Replace
pulleys or cable guards. defective pulleys and install
guards properly.
Pedal torque-tube bearings Lubricate pedal bearings.
need lubrication.
Defective pedal torque-tube Check visually. Replace
bearings. bearings.
Defective rudder hinge Check visually. Replace
bearings. defective bearings.
Clevis bolts too tight. Check and readjust bolts to
eliminate binding.
Incorrect rudder travel. Incorrect rigging. Rig the system.

Excessive resistance against Worn or defective nosewheel Check visually. Replace
pedal movement only while steering bearings defective bearings.
gear is extended
Nosewheel does not respond Broken or disconnected Check visually. Connect or
to pedal movement. cables. replace cables.

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Reduced nosewheel steering One steering cable spring Check visually. Replace spring
travel on one side broken
Incorrect nosewheel steering Incorrect rigging. Rig the system.
travel / aircraft not rolling
straightly with pedals neutral.
1 Remove right aft passenger seat Refer to Chapter 25-20-13
2 Remove RH side paneling Refer to Chapter 25-20-22
3 Loosen two turnbuckles of rudder cables,
located at RH wall adjacent to right aft seat
and baggage compartment
4 Loosen rudder cables at lower rudder
bearing
5 Remove bolt at LH side of central rudder
bearing
6 Remove lower rudder bearing 5 screws M5
7 Remove cotter pin and nut at lower rudder
bearing
8 Slightly lift rudder above higher bearing and
remove rudder backwards
27-20-01 Rudder Cables
1 Remove lower RH side panels in flight,
passenger and baggage compartments
2 Remove upper rear wall of baggage
compartment
3 Remove instrument shelf
4 Remove turnbuckle below RH side of
instrument shelf
5 Remove 2 turnbuckles at RH side wall in
baggage compartment

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6 Remove turnbuckle at rear wall of baggage

compartment
7 Remove 2 pulleys below instrument shelf Remove safety pin from
smaller pulley
8 Remove 2 pulleys from RH side wall in Remove bolts
flight compartment
9 Remove 2 pulleys from RH side wall in rear Remove bolts
passenger compartment
10 Remove teflon guiding bushings at rear wall
of baggage compartment
11 Remove LH access panel at rear fin
12 Remove 2 smaller pulleys
13 Remove 2 pulleys at LH and RH side each
below instrument shelf
14 Remove teflon guiding bushings to nose Remove safety sheet
wheel well
15 Remove nose gear cable control springs

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27-30-00 ELEVATOR AND TAB
Description
A lever system transfers elevator control movement from each of the two
steering wheels by a respective carrier bolt bushing to a cable segment. From
this cable segment the elevator cables run horizontally to the right cabin side to
a 90° pulley and parallel to the rudder cables to the empennage. They are led to
the elevator in front of the front fin spar and are attached to a lever positioned
in front of the horizontal stabilizer front spar, which actuates the two elevator
sides separately by means of push pull rods. Each elevator is attached to the
respective horizontal stabilizer by three bearings.
The mechanical pitch trim is actuated through a trim wheel in the pedestal. The
pitch trim tab is located in the right elevator and is linked over a 'redundant'
cable-lever system to the trim wheel. The trim Bowden cables run from the
middle console down crossing the cabin floor and are then directed rearwards
to the empennage following the nose section of the fin to the right side
elevator. Pitch trim can be actuated electrically also by means of switches
located on the pilot's control wheel. The system can be overpowered by pilot's
hand forces in case of system failure.
Troubleshooting
Play in control column. Loose control cables. Check cable tension. Adjust
cables to proper tension.
Broken pulley or bracket, Check visually. Replace worn
cable off pulley, or worn rod or broken parts, install cables
end bearings. correctly.
Excessive resistance to control Cables too tight. Check cable tension. Adjust
column movement. cables to proper tension.
Pulleys binding or cable off. Observe motion of the pulleys.
Check cables visually. Replace
defective pulleys. Install
cables correctly.
Defective pulley quadrant Check visually. Replace
assembly. defective quadrant.
No nose down force on control Down-spring disconnected. Check visually. Attach down-
column. spring correctly.

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Binding or jumpy motion felt Cables too tight. Check and adjust tension.
in movement of elevator
Cables not riding correctly on Check visually. Replace
system.
pulleys. defective pulleys.
Defective control column Check visually. Replace
bearings. defective bearings.
Control guide on aft end of Loosen screw and tapered plug

control square tube adjusted in end of control tube enough
too tightly. to eliminate binding.
Defective elevator hinges. Disconnect push-pull rods and
move elevators by hand.
Replace defective hinge
bearings.
Elevator fails to attain Stops set incorrectly. Rig the system.
prescribed travel.
Cables tightened unevenly. Rig the system.
Trim control wheel moves Defective cable or deformed Check visually and replace
with excessive resistance. tube. defective parts.
Trim tab hinge binding. Disconnect actuator and move
tab up and down to check
hinge resistance. Lubricate or
replace hinge as necessary.
Defective trim tab actuator. Disconnect cable from
actuator and operate actuator
manually. Replace defective
actuator.
Stick-slip effect between cable Lubricate all moving parts.
and tube.
Control wheel does not move Disconnected or broken cable. Check visually and connect or
trim tab. replace cable as necessary.
Play between control wheel Parts worn out Check visually and replace
and trim tab. parts as necessary.
False reading on trim position Indicator incorrectly engaged Check visually. Adjust
indicator. on wheel axis. indicator.
Worn, bent or disconnected Check visually. Repair or
linkage. replace parts as necessary.
Incorrect trim tab travel. Stop blocks loose or Adjust stop blocks on cables.
incorrectly adjusted.
Incorrect rigging. Rig the system.

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RH elevator
1 Loosen push rod at trimming tab 8 hollow core bolts LN4
2 Continue as per step 1 to 5, LH elevator
LH elevator
1 Loosen control lever
2 Swivel up elevator
3 Remove socket pins from central and outer 2 socket pins LN6
bearings
4 Turn elevator horizontally backwards
around inner bearing
5 Remove elevator
27-30-01 Elevator Cables
1 Remove lower RH side panels in flight,
passenger and baggage compartments
2 Remove upper rear wall of baggage
compartment
3 Remove instrument shelf
4 Remove turnbuckle below RH side of
instrument shelf
5 Remove 2 turnbuckles at RH side wall in
baggage compartment
6 Remove turnbuckle at rear wall of baggage
compartment
7 Remove 2 pulleys below instrument shelf Remove safety pin from
smaller pulley
8 Remove 2 pulleys from RH side wall in Remove bolts
flight compartment
9 Remove 2 pulleys from RH side wall in rear Remove bolts
passenger compartment

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10 Remove teflon guiding bushings at rear wall

of baggage compartment
11 Remove LH tailcone access panel
12 Remove 2 clamps of pitch servo
13 Remove LH access panel at rear fin
14 Remove 2 larger pulleys
15 Remove linkage between cable and aileron Remove bolt
16 Remove push rod

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27-50-00 FLAP SYSTEM
Description
The wing flaps are of the Fowler type. Each wing flap (two per side) is
attached to the rear wing spar and guided during its movement by three wing
tracks. Actuation is by means of two spindles, which are connected to the
central electrical flap motor by flexible shafts. The flap motor is located in
front of the rear spar in the fuselage area of the wing and is controlled by the
wing flap position switch in the cockpit. This switch incorporates a preselect
feature which allows the pilot to select the amount of flap extension desired.
When the UP/0°- , 15°- or 30°- position is selected, the flap motor is
electrically actuated and drives the flaps toward the selected position. When the
actual flap position equals the selected position, limit switches located at the
wing tracks respective the outer spindles de-energize the flap motor. The actual
flap position will be indicated by green lights at the left side of the wing flap
position switch. When flaps are moving the yellow light will be illuminated. If
the 0°-position is reached all lights are off.
As the flaps move an electrical circuit compares the movement of the left and
right wing flaps. If the wing flap positions differ by more than 7° ± 3°, the flap
motor will be automatically switched off to prevent asymmetric conditions.
This will be indicated by the flap error warning light located on the warning
light panel. This light indicates also a failure of the complete flap control.
NOTE In case of the wing flaps being unbalanced, they rest in the position they
have reached when failing and cannot be actuated until airplane has been
in maintenance. However in this case the airplane can be easily balanced
by slight aileron and/or rudder input.
Setting the wing flaps will cause a decrease of airspeed and a moderate nose
down moment.
Bring wing flaps to 0°-position before opening the cabin door
CAUTION
Rigging and Adjustment

This section describes the procedure for correct adjustment of the defined flap
settings as well as the maximum flap asymmetric limits.
Due to the local chord of the flaps (30 % of the wing) and positioning the 15°
and 30° DOWN extension relative to the local chord the travel of the flaps
depends on the lateral station.
All adjustment must be made with the motor power OFF (pulled circuit
CAUTION breaker FLAP).
NOTE Rigging of the flap system requires a flap track snap gauge (Extra Part-
No. EA-15182W10). This will be available at EXTRA. See also Chapter
01-00-02.

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Track Adjustment
Perform the following adjustment checks as long as the flaps are not installed.
For flap installation, refer to Chapter 57-50-01:
1 Check of spanwise adjustment
Check distance between flap tracks at their rear end. Distance between inner
and middle track is 1989 ± 2 mm (78.31 ± 0.08 in.) and between middle and
outer track 1827.5 ± 2 mm (71.95 ± 0.08 in.). If further details of flap track
positioning are required, contact EXTRA.
2 Check of twist between tracks
Check flap tracks for proper torsional alignment (cord over all three lower
keyways). Max. permissible distance of lower keyway centerline at the middle
flap track is 2mm (0.08 in.), when cord is aligned with outer and inner flap
track keyway.
Guidance Checks and Adjustment

Check the following items after flap installation:
1 Minimum gap between flap and aileron
While pulling the flaps outboard against the stop, check width of gap between
aileron and outer flap segment. The stop is reached, when one of the sliding
surfaces on the outboard end of the inner or outer flap segment contacts the
middle or outer flap track. Minimum gap width is 8 mm (0.31 in.).
Check the following items after flap installation and after each 100 hours of
operation:
2 Spanwise flap rigging
Check whether any guidance roller on the inner track protrudes more than
3 mm (0.12 in.) outside the inner track when flaps are pulled outboard against
the stop. The stop is reached, when one of the sliding surfaces on the outboard
end of the inner or outer flap segment contacts the middle or outer flap track.
Repeat the check for the rollers in the outer flap track while pushing the flaps
inboard. Verify visually that stops are definitely reached.
3 Flap guidance rollers twist rigging
Minimum play in guidance keyways: Check all flap segments for minimum
free play of rollers in keyways. Lift each flap segment manually at trailing edge
and observe for positive free play of flap segment at trailing edge. Check this
for all four flap segments and for flap positions 0° and 30°. The SKF track
rollers (forward roller on inner track and both rollers on outer track) feature an
eccentric bushing to provide a means of adjustment in this respect.
4 Flap guidance rollers functional check
Check whether the rollers are rolling but not slipping by performing the
following test: Extend flaps to their 30° position and retract them while
manually applying a load of about 200 N (45.0 lbs.) upwards at the trailing
edge of the flaps near the respective track. If a roller is slipping identify cause
and replace roller as necessary.

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5 Inspection of roller contact areas

Inspect rear side of lower keyway on inner flap tracks for signs of axial contact
with mushroom head of roller. Contact Extra Flugzeugbau GmbH if marks are
found.
Inspect guidance roller tracks for wear and permanent deformation.
For wear and deformation the following service limits are defined:
Max. increase of track width due to deformation: 0.6 mm (0.024 in.) per side.
Width of guidance slot between 16.3 mm and 16.8 mm (0.64 in. and 0.66 in.).
Check with flap track snap gauge (see Chapter 01-00-02).
Actuation Adjustment
1 Ascertain that both inner flex drive shafts are disconnected from the electric
drive motor and that the flap motor and flap control circuit breakers are pulled.
2 Make sure for both LH and RH side flap that the respective asymmetry
detection mechanisms are not mounted yet. If they are already mounted, make
sure that the ball joint connection between linkage rod and bracket is
disconnected and the linkage rod is taped to the spar.
If this is not done, parts of the mechanism may be destroyed while
CAUTION moving the flaps.
3 Lower both (LH and RH) flaps to their fully extended stop position. This can
be done by turning the hex socket coupling of the RH flex shaft CCW and the
LH flex shaft CW respectively, with view of the coupling. Use a battery hand
held drill with fine speed control and reverse feature, equipped with a 3/16 “
(4.7 mm) Allen key tip.
Do not run flaps to their extreme position (end of trackslots) with electric
CAUTION drill to avoid damage. Turn flex shafts by hand to reach the end of the
tracks.
4 If the roller on one flap end rib reaches the outer end of its track slot while the
roller on the other flap end rib is 2 mm or more away from its track slot end,
an adjustment is necessary. This is done at one of the two transmission screw
jacks.
5 Disconnect the flap bracket from the rod end of its transmission actuator, then
move the rod into the proper direction by rotating it in steps of 180°-turns,
then reconnect. A 180°-turn of the inner transmission’s rod in CCW direction
or of the outer transmission’s rod in CW direction will move the adjacent
roller about 2 mm towards the extended position.
NOTE The screw of the inboard transmission rod features a RH thread whereas
the outboard one features a LH thread
6 Raise both (LH and RH) flaps from their extended stop positions by rotating
the hex socket coupling of the flex drive shafts 2.5 turns in reverse direction to
secure a gap between rollers and track slot ends about 1.5 mm (.06"). This will
give the 30° position. Use a 3/16" (4.7 mm) Allen key and turn by hand.
7 The basic adjustment dimensions at the transmission actuators (measured from
the center of the mounting pin of the screw jack to the center of the rod end)
are:

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Position 0° Retracted 15° Intermediate 30° Extended

Inner actuator 58 + 3/- 0 mm 152 + 3/- 0 mm 270 + 3/- 0 mm
2.28 + .12/-0 inches 5.98 + .12/-0 inches 10.63+ .12/-0 inches
Outer actuator 68 + 3/- 0 mm 135 + 3/- 0 mm 219 + 3/- 0 mm

2.68 + .12/-0 inches 5.31 + .12/-0 inches 8.62 + .12/-0 inches
8 If the rod end at the transmission screw and the respective flap bracket do not
align, disconnect the rod end from the bracket and loosen the two bolts
securing the bracket to the flap. This will allow the bracket to be moved by
tapping. Connect the rod end to the bracket and tap the bracket to achieve a
satisfactory alignment. Disconnect the rod end from the bracket and torque the
bracket attachment bolts. With the transmission screw and flap bracket
aligned, finally connect the rod end to the bracket with the bolt assy.
9 When measuring flap deflection angles, lift the trailing edge of the flap to
eliminate play between rollers and track slots.
27-50-01 Flap Drive Motor
Description
Brush type bidirectional permanent magnet motor, positioned in the wing
center box at the front web of the rear spar
Characteristics:
1 Hex shafts on both sides
2 Capability of dynamic braking
3 Max. ambient temperature: + 40 °C
4 Voltage: 24 to 30 VDC, 24 VDC nominal
5 Torque at output shaft: 50.7 Ncm nominal at 24 VDC, 1,600 RPM, 4.5 amps
6 Power output: 85 W
7 Ratio RPM/Torque: 5.1 (Ncm ⋅ min) -1
8 Voltage factor: 0.013 V ⋅ min
9 Efficiency: 78 %
10 Insulation class IP 54 according DIN 40050 (protected against dirt, dust and
ingressed water)

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27-50-02 Inboard Power Transmission Flexible Shaft
Description
The inboard flexible shaft has a female 3/16" hex drive at motor side and a
DIN 75532 E1 for the screw jack side. LH and RH flex shaft are different in
main rotation due to the musk wire: CW or CCW for main rotation.
Characteristics:
1 Length: 1,400 mm
2 Core: Carbon steel musk wire φ 6 mm
3 Casing and end fittings in CRES
4 Shrink sleeve on casing
5 Minimum installation bend radius: 300 mm
6 Coupling nut 2024-T4 blue anodized or CRES with hole for safety wire
7 Min. static torque : 300 Ncm
27-50-03 Outboard Power Transmission Flexible Shaft
Description
The outboard flexible shaft is a standard type DIN 75532 E1. As for the
inboard shaft LH and RH flex shafts are different in main rotation due to the
musk wire: CW or CCW for main rotation.
Characteristics:
1 Length: 2,000 mm
2 Core: Carbon steel musk wire φ 4 mm
3 Steel casing
4 End fitting in steel zinc - plated galvanically
5 Shrink sleeve on casing
6 Minimum installation bend radius: 55 mm
7 Coupling nut aluminium with hole for safety wire
8 Min. static torque: RH 104 Ncm (CCW)/49 Ncm (CW)
LH 104 Ncm (CW)/49 Ncm (CCW)

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27-50-04 Power Transmission Screw Jacks
Description
The in- an outboard screw jacks consists of a reduction worm gear and
machine screw nut with trapezoid thread (irreversible by choice of pitch). The
inboard screw jacks have right hand threads, the outboard screw jacks left hand
threads. The worm shaft and the screw nut are equipped with ball bearings.
Characteristics:
1 Worm gear ratio: inboard 5:1
outboard 7:1
2 Efficiency of worm gear: inboard 0.7
outboard 0.65
3 Pitch of screw nut: 3 mm stroke per revolution
4 Number of revolutions for full stroke of screw jack (30° flap setting):
inboard 70 revolutions
outboard 50 revolutions
5 Stopping accuracy: ± 3 % of full stroke
6 The unit is sealed
7 All external parts are protected against corrosion
8 Periodic lubrication is not required
9 Output shaft splines: According DIN 75532 E2 for connection to the flexible
drive shafts
27-50-05 Flap Control Box
Description
A Flap Control Box providing the flap control functions is fixed into the
avionic bay with an adapted bracket, using 4 AN bolts with AN washers.
The Flap Control Box performs the following functions:
1 Controlling the motor for the 3 intended flap - positions (retracted, 15° inter-
mediate and 30° fully extended)
2 Activating the flap position signals 15°, 30° or "flaps in transition"
and:
Asymmetry detection by controlling the rheostats fitted at the outboard flaps
on the LH and RH, thus activating:
1 Motor shut-off
2 Signalisation to the warning panel inside the cockpit
Wing flap asymmetric tolerances are adjustable at the trimmer of the watchdog
box. Refer to Subject 27-50-07.

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27-50-06 Flap Limit Switches
Description
The 0° and 30° flap positions are detected by four limit switches, every two of
them attached to a mounting bracket positioned on the LH and RH side wing’s
rear spar web. If one DOWN or UP limit switch related to any of these flap
positions fails, the remaining one on the opposite side will still detect the
desired flap position.
The extended flap position is detected by the DOWN limit switch on the LH
flap (backup switch on the RH side) and the retracted flap position is detected
by the UP limit switch on the RH flap (backup switch on the LH side).
The switches are operated by the same linkage mechanism that is used for
asymmetry detection.
The 15° flap position is detected by two limit switches at the LH outboard
screw jack.
Adjustment
DOWN Limit Switch
1 Run the flaps to the 30° position determined before. If not present yet, mount
both asymmetry detection potentiometers and put the lever arm on the
potentiometer shafts, but do not tighten their clamping screws yet.
Tightening of the clamping screws may destroy parts of the mechanism
CAUTION while moving the flaps.
2 At the LH side wing flap, determine the axial and the angular position of the
arm on the potentiometer shaft so that it contacts the 30° limit switch in the
center of the arm.
3 With the positions of the potentiometer arm and flap bracket given, adjust the
linkage rod until it fits. The start value is 66 mm (2.6”) between the ball joint
centers. The length adjustment is done by loosening the nuts and rotating the
rod, which features one LH side and one RH side thread. Tighten the rod nuts
and the ball joint nuts after the adjustment is completed, but do not tighten the
potentiometer arm clamping screw.
4 Manually move the flaps up to the retracted position as described in step 3 of
the Guidance Check and Adjustment Paragraph of Section 27-50-00. With the
flaps on retracted position the gap between the flap and the wing, measured at
the lower side, should be 4 mm (.16”).

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UP Limit Switch
1 Perform the same way as with the DOWN limit switch, but with the rod
linkage of the RH flap accordingly. Stop the flaps in retracted position just
before any of the flap rollers reach the end of the track slots (approximately
1.5 mm (.06") space should remain between the end of the track slot and the
closer roller of both flaps). Ascertain at least 1.5 mm (.06") clearance bet-
ween the tip of the potentiometer arm and the spar.
NOTE Flaps must stop prior to rollers making contact with the end of the
trackslots.
2 Turn one drive shaft coupling (RH or LH side) manually as far as necessary to
give the right flap the same angular setting as the left flap.
3 Connect and safety-wire the flexible drive shafts to the electric drive motor.
4 Move the selector switch to position RETRACTED and engage the flap motor
circuit breaker. Run the flaps from the retracted position to the fully extended
position. When the actual flap position reaches the selected position, the
appropriate limit switch must deenergize the flap motor.
Otherwise parts may be destroyed.
CAUTION
15° Limit Switch

1 Run the flaps by moving the selector to the 15° position. Install the flap
rigging tool, if not previously accomplished. Rigging the flaps to the defined
15° setting max require fine adjustment at the LH outboard screw jack. This
can be accomplished by readjusting the nylon bushing positioned at the end of
the transmission screw that actuates both 15° limit switches.
2 Run the flaps to the 30° setting for removal of the LH outboard screw jack.
Disconnect the outer flex drive shaft from the LH outboard screw jack.
Disconnect the transmission from the flap bracket. Remove the screw jack
from the rear spar. Loosen the counter stop nut of the nylon bushing. Rotating
the nylon bushing in CW direction will shift the 15° detection to the retracted
position, rotating in CCW direction will shift it to the extended position.
Adjust as required and tighten the counter stop nut. Reinstall transmission unit
to the rear spar. Reinstall the transmission unit to the rear spar. Connect the
flex drive shaft to the transmission actuator.
3 Check that all bolts and joints are secured where necessary.
4 Check function of the position indicator. Green lights indicate the 15° and 30°
position and an additional yellow light indicating "flaps in transition". The
retracted position is indicated by the fact that no light is on.
5 Check the flap operation.

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27-50-07 Flap Asymmetry Senders
Adjustment
This adjustment is required after the flaps have been rigged and checked for
normal operation. The asymmetry senders, one potentiometer at the LH side
and one at the RH side flap, are part of an electric system, the so-called
watchdog. The watchdog shuts off the flap motor when the difference between
the LH and RH side flap angular positions exceeds 7° ± 3°.
1 Lower the flaps by moving the selector to the 15° position.
2 Pull the flap motor circuit breaker. Ascertain that the flap control circuit
breaker is engaged. Turn the sensitivity control potentiometer of the
watchdog box towards maximum sensitivity.
3 Adjust the LH asymmetry detection potentiometer. Make sure that the arm is
loose on the shaft, then rotate the shaft to find out the potentiometer’s center
position between its two internal stops. The angular range of the potentiometer
is ± 170 °. Then tighten the arm’s clamping screw.
4 Adjust the RH asymmetry detection potentiometer to ensure that the angular
travel to engage the watchdog is the same when retracting as when extending
the flaps. Make sure that the arm is loose on the shaft, then rotate the shaft in
CW direction until the red asymmetry indicator light on the watchdog box
appears (simultaneously the red light on the warning panel in the cockpit
appears). Mark this angular shaft position. Rotate the shaft in CCW direction.
The red indicator light will turn off, then light up again after rotating a few
degrees. Mark this position, too.
5 Finally rotate the sender shaft to the middle between the two marks and
tighten the arm’s clamping screw.
Now the two potentiometers feature the same resistance value at a given flap
position.
After adjusting, check for correct alignment of asymmetry detection
sensitivity:
6 With the flaps in 15° position disconnect the RH flex drive shaft from the
electric drive motor. Engage the flap motor circuit breaker and move the
selector switch to the UP position. The LH flap will move up while the RH
flap will stay in the 15° position. After a certain difference in RH and LH flap
angular positions is reached the watchdog shuts off the flap motor.
7 Measure the flap travel. If it is within the limit of 7° ± 3° , proceed with
step 11. If it is outside that limit, proceed with step 8.
8 In order to drive the LH flap back to its 15° position, disconnect the watchdog
box from the flap control box, pull the flap motor circuit breaker, move the
selector switch to the 15° position and engage the flap motor circuit breaker.
The flap starts to move back to the 15° position immediately after
CAUTION engaging the circuit breaker.
9 Reconnect the watchdog box to the flap control box.

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10 Adjust the sensitivity control potentiometer by turning it in the proper

direction, then repeat steps 6 to 7.
After asymmetry has been adjusted for UP motion repeat this procedure for
DOWN motion:
11 Move the selector switch to the DOWN position. The LH flap will move down
while the RH flap will stay in the 15° position. When a certain difference in RH
and LH flap angular positions is reached the watchdog shuts off the flap motor.
12 Measure the flap travel. If it is within the limit of 7° ± 3° , proceed with step
16. If it is outside that limit, proceed with step 13.
13 In order to drive the LH flap back to its 15° position, disconnect the watchdog
box from the flap control box, pull the flap motor circuit breaker, move the
selector switch to the 15° position and engage the flap motor circuit breaker.
The flap starts to move back to the 15° position immediately after engaging
CAUTION the circuit breaker.
14 Reconnect the watchdog box to the flap control box.
15 Adjust the sensitivity control potentiometer by turning it in the proper direction,
but do not turn it in a way that would compromise the setting found in step 7.
Then repeat steps 11 to 12.
16 Connect and safety-wire the RH flexible drive shaft to the electric drive motor.

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Chapter 28
Fuel

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Table of Contents
28-00-00 GENERAL ........................................................................................................ 5

Description.......................................................................................................... 5
Figure 28-1, Sheet 1 Fuel System Schematic ....................................................................................... 6
Figure 28-1, Sheet 2 Fuel System Schematic ....................................................................................... 7
Reduction of Fuel Tank Vapor Hazards ............................................................. 9
28-10-00 STORAGE ....................................................................................................... 10

Description........................................................................................................ 10
28-10-01 Tank ................................................................................................................. 11
Sealant Repair ................................................................................................... 11
Draining ............................................................................................................ 11
Leakage Test ..................................................................................................... 12
28-10-02 Drain (Curtis) .................................................................................................. 12
28-10-03 Flush Drain Valve ........................................................................................... 13
28-10-04 Pressure Relief Valve...................................................................................... 13
28-10-05 Pressure Relief Valve O-ring ......................................................................... 14
Replacement ..................................................................................................... 14
28-10-06 Float Valve....................................................................................................... 14
28-10-07 Fuel Transfer Filter ........................................................................................ 15
Cleaning ............................................................................................................ 15
28-10-08 Fuel Transfer Pump ....................................................................................... 15
28-10-09 Jet Pump .......................................................................................................... 16
28-10-10 Jet Pump Filter Element ................................................................................ 16
Cleaning ............................................................................................................ 16
28-10-11 Rubber Hose .................................................................................................... 17
28-10-12 Pressure Switch ............................................................................................... 17
28-20-00 DISTRIBUTION............................................................................................. 18
Description........................................................................................................ 18

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Bleeding Procedure ........................................................................................... 19

28-20-01 Check Valves (wing to selector valve) ........................................................... 19
28-20-02 Check Valves (downstream electrical fuel pumps) ...................................... 20
28-20-03 Fuel Selector Valve .......................................................................................... 20
Function Check ................................................................................................. 20
28-20-04 Fuel Filter Element ......................................................................................... 21
Exchange ........................................................................................................... 21
28-20-05 Electrical Fuel Pump....................................................................................... 22
28-20-06 Rubber Hose .................................................................................................... 22
28-40-00 INDICATION .................................................................................................. 23

Description ........................................................................................................ 23
28-40-01 Fuel Quantity Sensor (collector compartment) ............................................ 23
Removal ............................................................................................................ 23
Installation ......................................................................................................... 23
28-40-02 Fuel Quantity Sensor (main or auxiliary compartment) ............................. 25
Removal ............................................................................................................ 25
Installation ......................................................................................................... 25
28-40-03 Fuel Quantity Gauge ....................................................................................... 26
Calibration ......................................................................................................... 26
28-40-04 Fuel Flow Indicator ......................................................................................... 27
K-Factor Setting ................................................................................................ 27
28-40-05 Pressure Transducer ....................................................................................... 27
28-40-06 Pressure Gauge ................................................................................................ 27
Page Date: 9.
30.August
March2013
2012 28 Page 3
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28-00-00 GENERAL
Description
The next paragraph contains the general description and operation of the fuel
system. The following paragraph contains information about Troubleshooting.
The specified descriptions of the systems, sub-systems and units can be found
in the respective chapters.
The fuel system (refer to Figure 28-01) of the aircraft is a gravity assisted,
pump fed system, supplying fuel to the engine driven fuel pump. The fuel
system consists of:
• Two integral main tank compartments (one each wing)
• Two integral collector compartments (one each wing) with strainer, sump,
drain and pick-up point
• Two integral auxiliary compartments (one each wing)
• A vent system for each tank
• Two fuel transfer systems (left and right) for pumping fuel from the auxiliary
tank into the main tank and to keep the collector compartment full (motive
flow electrical pumps with jet pumps).
• A fuel selector valve (LEFT – BOTH – RIGHT – OFF) located under the cockpit
floor
• A fuel filter in the engine compartment
• 2 parallel, redundant electrical fuel pumps mounted on the firewall.
• A fuel quantity indication system with 6 probes in the tanks and 6 indicators in
the cockpit.
• A fuel flow transducer mounted on the battery mount in the engine
compartment.
• A total of 12 drains (refer to Chapter 12-10-03 for locations)

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Fuel control unit
28
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Figure 28-1, Sheet 1

Maintenance Manual
Fuel pump 2
Fuel pump 1 Engine
Fuel transfer right Engine internal bypass
Fuel System Schematic

Fuel transfer left
Fuel pressure Firewall

Vent line to left tank
Fuel temperature
Collector compartment
Vent line
Main compartment
Fuel flow Auxiliary compartment
Fuel quantity
Left Right
Collector
Main
Auxiliary Overflow line

Wing tank sump
Only right tank shown, left tank symmetric

Maintenance Manual
EXTRA 500
Legend: Switch
Unit
Annunciator light
Gauge
Selector valve
Check valve
Overpressure relief valve
Float valve
Drain valve
Fuel pressure accumulator
Filter (with drain valve)
Fuel transfer filter
Pump
Jet pump with filter at inlet
Nozzle
Filler neck
Low fuel level switch
Fuel level sensor
Pressure switch
Pressure transducer
Electric wiring
Flow direction
Figure 28-1, Sheet 2 Fuel System Schematic

Maintenance Manual
EXTRA 500
Troubleshooting
Fuel tank leakage Tank sealant damage Identify and seal
Sump drain leakage Inspect drain line plumbing
and seal if necessary, or
replace drain
Outer wing flush drain leakage Replace drain valve.
Relief valve leakage Replace relief valve/O-ring
Ventline leakage Inspect float valves, replace if
necessary, seal vent line
connections
Fuel filler leakage Filler cap O-ring damaged Replace filler cap O-ring
Fuel line leakage Line fittings loose Tighten fittings
Collector compartment not Fuel transfer filter blocked Clean filter
full,
Electrical transfer fuel pump Replace pump
auxiliary tank does not empty
defective
fast enough,
FUEL TRANS LEFT/RIGHT ON Transfer fuel pick-up blocked Remove blockage
in flight
Leaking transfer fuel line Replace fitting or line
Loss of fuel supply Strainer blocked (tank) Clean strainer
Check valve (one of four) Replace check valve
blocked
Selector valve blocked Replace selector valve
Fuel line blocked Identify and clean or replace
fuel line
Insufficient fuel supply Filter blocked Replace filter element.
pressure reading
Fuel pressure indication Replace sensor/indicator
defective
Electrical fuel pump failure Replace fuel pump
Incorrect fuel quantity reading Float sensor defective Repair or replace float sensor
Gauge defective Replace gauge
Incorrect fuel flow indication Fuel flow sensor defective Replace sensor
Fuel flow indicator defective Replace indicator
Wrong K-factor set Adjust K-factor at indicator
Low fuel warning defective Fuel low level sensor failure Replace fuel low level sensor

Maintenance Manual
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Reduction of Fuel Tank Vapor Hazards

General Precautions
During all ventilation or maintenance procedures involving the fuel system,
observe the following general precautions.
• Defueling should be outdoors with the aircraft at least 100 feet from hangars or
other aircraft.
• No smoking should be allowed within 100 feet of the aircraft.
• Suitable fire fighting equipment should be available. Foam or soda type
extinguishing agents are recommended.
• Ground the aircraft to prevent static electricity from causing sparks. If a ramp
ground is available it should be connected to exhaust stack. If a ramp ground is
not provided, a temporary ground can be obtained by driving a metal rod into
the ground and attaching a ground wire between the rod and the aircraft
exhaust stack.
• Flame and spark producing equipment should not be operated within 100 feet
of the aircraft.
• Only personnel working on the aircraft should be allowed in the immediate
area, and no other maintenance should be performed while the tanks are being
worked on.
• When a fuel tank is opened for repair, air ventilation (refer to Page 7) should be
started immediately to reduce vapor concentrations.
• When draining fuel, ensure that suitable containers are available and that
drained fuel is stored safely. Do not allow fuel to drip to the ground and form
pools.
• If it is necessary to ventilate a tank when the aircraft is in hangar, ensure that
vapors do not accumulate to explosive or toxic levels in the hangar.
When fuel is being drained, there is little control over the release of fuel
WARNING vapor. This vapor should be dissipated as quickly as possible by smoothly
blowing shop air into the tank.
Air Ventilation
• Completely drain the fuel system per Chapter 12-10-02.
• Remove inspection doors (refer to Chapter 28-11-03) and tank caps.
• Use compressed air or an explosion-proof blower to blow air into the tank until
tank interior is dry and free of vapor.
• Continue ventilation whenever tank is open and being worked on.
If flammable vapors from cleaning solvents are allowed in the tank
WARNING increase air circulation to dissipate them.

Maintenance Manual
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28-10-00 STORAGE
Description
The aircraft has six integral wing tanks between the wing spars. Each wing side
has a main, auxiliary, and collector compartment. The latter is kept full by a jet
pump driven fuel transfer system in flight.
The collector compartment features a fuel level sensor, a sump with drain, a
strainer and a pick-up tube behind it. The low fuel sensor is also located here.
Three flapper type check valves separate the collector compartment from the
main compartment to make sure fuel cannot flow out, but can flow in, in case
of a fuel transfer system failure. The collector compartment can be inspected
from the main compartment by opening the rib in which these valves are
mounted or from the avionic compartment (center wing) by removing the
inspection door on which the fuel quantity probe is installed.
The main compartment has its own fuel level sensor mounted on the inner
wing inspection door. The vent system has two float valves and an outlet. The
vent systems of the two main tanks are interconnected. Each tank has a 1psi
overpressure relief valve in the aft spar for the case the normal vent system
fails. The main tanks have a Ø 75mm filler cap for JET-A1 with a titanium ring
around it for static bonding.
The auxiliary compartment also has a filler cap, vent system (including
overpressure relief valve) and fuel level sensor, but is not directly connected to
the fuel distribution system. As long as the auxiliary compartment is filled fuel
is pumped from there into the main compartment by means of the fuel transfer
system.
Observe the safety notes given in Chapter 12-10-01.
DANGER
For all maintenance work on the tanks, drain them completely and
WARNING appropriate open tank hatches on top of the wing. Be aware of fuel fumes
and fuel stained cloth: highly inflammable!
Power must be off, no external power connected, room well ventilated.
NOTE If the tank has been opened, a tank leakage test is mandatory. Refer to
Subject 28-10-01 Leakage Test.

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28-10-01 Tank
Sealant Repair
1 Drain the fuel system. Refer to Chapter 12-10-02
2 Observe precautions concerning Reduction Refer to Subject 28-00-00
of Fuel Tank Vapor Hazards.
3 Remove applicable fuel compartment access Refer to Chapter 51-00-01
panels.
4 Clean area.
5 Sand the area to be repaired. Only ruff it up
For complete health and safety information, refer to Le Joint Francais
material safety data sheet PR 1750 (LOAP 41).
6 Apply PR 1750 tank sealant. For mixing and application of
PR 1750 sealant refer to
manufacturer's instructions.
7 Perform a fuel tank leakage test. See Leakage Test below.
8 Wait for at least 3 hours before filling the An absolute humidity of at
tank. least 10g/m3 is needed for
curing. This corresponds with
35% relative humidity at
23°C and 78% at 10°C.
Draining
Refer to Chapter 12-10-02.

Maintenance Manual
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Leakage Test
After opening a fuel tank (except the avionic bay access panels) or a tank
repair, the tank shall undergo a leakage test. It is recommended to test all tanks
together or LH and RH individually. The LH and RH tanks are connected by
an interconnecting vent line, located in the avionic bay. It needs to be removed
and the fittings in the root ribs plugged if the LH or RH should be tested
individually. Furthermore, the four overpressure valves in the aft spar must be
plugged or held shut as they have a lower cracking pressure as the required test
pressure.
1 Make sure aircraft is completely drained. Refer to Chapter 12-10-02.
3 Remove interconnecting vent line between If one tank shall be tested
LH and RH wing tank. individually.
4 Plug the appropriate fitting.
Make sure the upper door is closed before extending flaps.
CAUTION
5 Extend flaps to 30°. To gain access to the
overpressure valves from the
outside.
6 Plug or hold shut the overpressure valves.
7 Plug vent system.
8 Turn fuel selector valve to OFF-position.
9 Pressurize the tanks slowly to 120 mbar Tanks pressure shall be
(1.74 psig). steady for min. of 10 minutes.
10 Return aircraft to normal.
28-10-02 Drain (Curtis)
1 Drain collector and main compartment. Refer to Chapter 12-10-02
3 Remove fuel sump access panel. Refer to Chapter 51-00-01
4 Carefully screw drain out of fitting.
5 Install in reverse sequence of removal. Use Loctite 577

Maintenance Manual
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28-10-03 Flush Drain Valve
1 Drain fuel system. Refer to Chapter 12-10-02
panels.
4 Loosen nut on tank inside.
5 Install vice versa. Use Loctite 577
6 Perform tank leakage test. Refer to Subject 28-10-01
28-10-04 Pressure Relief Valve
Ensure cabin door is closed before extending wing flaps.
CAUTION
1 Place wing flaps to the 30° position. Refer to EXTRA 500 Pilot’s
Operating Handbook
4 Remove applicable fuel compartment access
panel.
5 Screw out while holding plastic fitting from
inside of tank to keep it from turning.
6 Install vice versa. Use Loctite 577

Maintenance Manual
EXTRA 500
28-10-05 Pressure Relief Valve O-ring
Replacement
Ensure cabin door is closed before extending wing flaps.
CAUTION
1 Place wing flaps to the 30° position. Refer to EXTRA 500 Pilot’s
Operating Handbook
2 Drain related fuel compartment. Refer to Chapter 12-10-02
4 Pull pressure relief valve poppet.
5 Replace O-ring
28-10-06 Float Valve
panels.
4 Disconnect vent line.
5 Remove vent float valve from mounting. 2 screws

Maintenance Manual
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28-10-07 Fuel Transfer Filter
3 Open wing center fairing. Refer to Chapter 51-00-01.
4 Disconnect fittings from filter.
5 Remove fuel transfer filter from aircraft. Notice flow direction
8 Reinstall in reverse sequence of removal. Make sure flow direction is
correct and bonding is
attached.
Cleaning
1 Remove fuel transfer filter. See above
2 Open filter.
3 Clean with Jet-A1.
4 Reinstall fuel transfer filter. See above
28-10-08 Fuel Transfer Pump
power connected.
of Fuel Tank Vapor Hazards
4 Open wing center fairing. Refer to Chapter 51-00-01.
6 Disconnect fuel hoses.
7 Remove fuel pump.
8 Install in reverse sequence of removal. Make sure flow direction is
correct.

Maintenance Manual
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28-10-09 Jet Pump

The jet pumps incorporate a filter element (refer to Subject 28-10-10).
power connected.
2 Drain related fuel compartment. Refer to Chapter 12-10-02
4 Open related fuel compartment access panel. Refer to Chapter 51-00-01.
5 Disconnect motive flow and transfer fuel
lines.
6 Remove jet pump 2 bolts
28-10-10 Jet Pump Filter Element
Cleaning
1 Remove jet pump. Refer to Subject 28-10-09
2 Remove filter element. Retaining ring
3 Clean with Jet-A1.
4 Reinstall filter element.
5 Reinstall jet pump. Refer to Subject 28-10-09

Maintenance Manual
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28-10-11 Rubber Hose

On the outflow side of the fuel transfer pumps rubber type hoses are installed
(SN 1002 and 1003 only).
3 Remove the applicable inner fuel Refer to Chapter 51-00-01.
compartment access panel
4 Remove hose clamps from hose end.
5 Remove fuel hose.
28-10-12 Pressure Switch
power connected.
4 Open avionic bay access panel. Refer to Chapter 51-00-01.
6 Remove pressure switch.

Maintenance Manual
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Description
Fuel runs from the LH and RH pick-up point at the bottom of the wing tank
collector compartments through fuel lines via check valves down to the fuel
selector valve.
The check valves prevent cross flow between the left and right tanks.
The fuel selector valve is located under the cockpit floor and direct
mechanically linked to the fuel selector handle between the pilot's and the
copilot's seat.
Just downstream the fuel selector valve an aluminum block is installed which
incorporates the fuel temperature sensor and a drain valve. This drain is the
lowest point of the fuel system and is accessible by a panel in the right
underside of the fuselage between the main and nose gear doors. The drain
provides a means to remove moisture and sediment from the fuel system.
Fuel lines are of aluminum tubing 5052-0 but in the engine compartment fire
resistant PTFE hoses are installed.
The hoses in the engine compartment are made fire resistant by means of red
silicone fiberglass sleeves or brown integrated fire sleeves. The hose
assemblies meet the requirements of MIL-DTL-27267 and MIL-DTL-25579 as
well as the fire-resistance requirements of AS1055. Fire-sleeves meet TSO
c53a requirements. The pick-up point fuselage connection fuel supply hoses
are conforming to MIL-H-5593.
From the firewall break-through the fuel is sucked though the aircraft fuel
filter. Aft of the filter, a manifold splits to the two parallel electrical fuel
pumps. Another manifold joins the fuel lines again though check valves. The
single line continues through the fuel flow transducer to the engine inlet.
For all maintenance work on the tanks, drain them completely. Be aware
WARNING of fuel fumes and fuel stained cloth: highly inflammable!
Observe the safety notes given in Chapter 12-10-01, Refueling.
Power must be off, no external power connected, room well ventilated.

Maintenance Manual
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Bleeding Procedure
1 Make sure tanks are not empty.
2 Disconnect fuel hose from engine and hold
in appropriate container.
3 Turn fuel selector valve to LEFT
4 Both fuel pumps ON Until no more air bubbles
5 Both fuel pumps OFF
6 Turn fuel selector valve to RIGHT
7 Both fuel pumps ON Until no more air bubbles
8 Both fuel pumps OFF
9 Reinstall fuel hose to the engine.
10 Turn fuel selector valve to BOTH
28-20-01 Check Valves (wing to selector valve)

Check valves are installed in front of the main gear bays.
3 Remove LH/RH front fuselage access Refer to Chapter 51-00-01.
panels.
4 Disconnect fuel hose.
5 Disconnect check valve from fitting.
correct.

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28-20-02 Check Valves (downstream electrical fuel pumps)

The check valves are installed in the fuel manifold on the aft engine fireshield.
1 Set fuel selector valve to OFF.
2 Drain fuel at the lowest point drain and the Refer to Chapter 12-10-02
fuel filter drain.
3 Remove both upper cowlings. Refer to Ch. 71-10-01/02.
Fuel may be pressurized (30 psi max). Fuel may spill. Protect yourself
WARNING and catch spilling fuel.
4 Disconnect fuel hose.
5 Remove lock wire.
6 Screw check valve out of manifold.
correct. Use new o-ring when
necessary (MS29512-08).
28-20-03 Fuel Selector Valve

The fuel selector valve is installed in the floor between the pilot and co-pilot
seat and in the compartment below.
Function Check
1 Ensure both wing tanks contain fuel.
2 Place suitable container below the lowest Refer to Chapter 12-10-03
point fuel drain.
3 Open fuel drain.
4 Select positions of fuel selector valve in the
following sequence and monitor fuel flow:
OFF: no fuel flow
LEFT: fuel flow
BOTH: fuel flow If the behavior outlined left
RIGHT: fuel flow applies, the fuel selector
OFF: no fuel flow works correctly.
5 Check blocker between LH and RH OFF-
position.
6 Close the lowest point fuel drain.

9. August 2012
Maintenance Manual
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1 Drain fuel system completely. Refer to Chapter 12-10-02
2 Remove forward keel beam access panel. Refer to Chapter 51-00-01.
3 Disconnect the three fuel lines from the fuel
selector valve.
4 Remove the screws on the fuel selector 4 screws, in the cabin
handle.
5 Remove handle.
6 Unscrew the bolts on the bottom of the cup. 2 bolts
7 Remove the selector valve from the
structure.
8 Remove the spacer from selector valve. 2 screws
9 Install in reverse sequence of removal. Selector valve can be
mounted in one way only
28-20-04 Fuel Filter Element

The fuel filter is installed in the engine compartment in front of the nose gear
bay.
Exchange
fuel filter drain.
3 Remove fuel filter access panel. Refer to Chapter 51-00-01.
4 Remove lock wire and unscrew lower bowl
of fuel filter.
5 Replace filter element in bowl.
6 Screw bowl into filter. torque 100-150 lbs-inch (11.3
– 16.9 Nm)
7 Lock wire.
8 Re-install fuel filter access panel.
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28-20-05 Electrical Fuel Pump

The electrical fuel pumps are installed in the engine compartment on the
firewall, below the battery.
power connected.
fuel filter drain.
4 Remove upper left cowling. Refer to Chapter 71-10-01.
5 Disconnect electrical connection.
6 Disconnect fuel hoses.
7 Loosen worm-drive hose clamps. (2)
8 Remove pump.
10 Perform Bleeding Procedure. Refer to Subject 28-20-00
28-20-06 Rubber Hose

For connection of the wing tip pick-up to the fuselage a rubber type hoses are
installed.
power connected.
2 Remove respective fuel sump access panel Refer to Chapter 51-00-01.
3 Disconnect copper braid bond from fuselage Notice copper braid bond
side of hose connection. position.
4 Disconnect fuselage side fitting.
5 Remove hose clamps and copper braid
bond.
6 Remove hose.
7 Install in reverse sequence of removal. Ensure correct copper braid
bond position

9. August 2012
Maintenance Manual
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28-40-00 INDICATION
Description
The fuel system indication system displays the following parameter:
• Left and right fuel quantity collector compartment
• Left and right fuel quantity main compartment
• Left and right fuel quantity auxiliary compartment
• Fuel flow
• Fuel pressure
• Fuel temperature
28-40-01 Fuel Quantity Sensor (collector compartment)

The fuel quantity probe is installed in the collector compartment on the root
rib.
Removal
power connected.
2 Open avionic bay access panels. Refer to Chapter 51-00-01
3 Disconnect electrical connector from sensor.
4 Remove root rib inspection door. 14 bolts
5 Remove sensor from inspection door.
Installation
power connected.
2 Clean root rib inspection door and sensor
surfaces with solvents to remove dirt and
grease.

Maintenance Manual
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3 Install sensor on root rib inspection door For mixing and application of
with PR 1750 tank sealant. PR 1750 sealant refer to
4 Check the float points in the direction of
flight.
NOTE If the hatch seal has become partly clear instead of white, slightly pull
those patches apart. Clear patches are NOT a sign that the seal is
defective!
5 Install root rib inspection door, torque bolts
3-5 Nm (26-44inch-lbs).
6 After at least one half hour re-torque the
bolts.
8 Make a tank leakage test. Refer to Subject 28-10-01
9 Close avionic bay access panels. Refer to Chapter 51-00-01
10 Recalibrate quantity indicator.

Maintenance Manual
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28-40-02 Fuel Quantity Sensor (main or auxiliary compartment)

The fuel quantity sensor is installed on the inner tank inspection door of the
appropriate tank.
Removal
power connected.
2 Open appropriate tank access panel. Sensor is on the inner tank
inspection door of the
corresponding compartment.
3 Remove inspection door.
4 Remove sensor from inspection door. 5 bolts
Installation
power connected.
NOTE When attaching sensor to hatch observe correct direction.
For main compartment: Make sure the float is pointing inboard
For auxiliary compartment: Make sure the float is pointing outboard
3 Attach sensor to inspection door.
NOTE If the hatch seal has become partly clear instead of white, slightly pull
those patches apart. Clear patches are NOT a sign that the seal is
defective!
4 Install inspection door, torque bolts 3-5 Nm
(26-44 inch-lbs).
5 After at least one half hour re-torque the
bolts.
6 Recalibrate quantity indicator.
7 Reinstall appropriate tank access panel.

Maintenance Manual
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28-40-03 Fuel Quantity Gauge

The fuel quantity gauges are installed in the RH instrument panel.
power connected.
3 Disconnect electrical connector from fuel
quantity gauge.
4 Unscrew attachment . 4 screws
6 If more than one gauge is replaced, check if
indicator shows proper tank.
Calibration
The calibration potentiometers are installed on PCB installed behind the LH
IFD.
power connected.
quantity gauge.
4 Make sure the fuel quantity sensor is
installed and laying on the bottom of the
compartment (compartment is empty).
5 Measure with a calibrated, digital ohmmeter For collector and main comp:
the resistance between pins 5 and 8. The value must be 50.0 Ohm
For auxiliary compartment:
The value must be 80.0 Ohm
6 If value is not correct, follow the steps
below.
7a Remove LH IFD. Refer to Chapter 31-60-01.
7b Use the potentiometer on the PCB behind
the RH IFD to bring the resistance value to
the required value.
7c Reinstall the LH IFD.
9 Re-install the RH IFD.

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28-40-04 Fuel Flow Indicator

The fuel flow indicator is installed in the RH instrument panel.
power connected.
flow indicator.
4 Unscrew attachment. 4 screws
K-Factor Setting
Refer to Shadin Avionics Miniflo-L Operating Manual (LOAP 42).
28-40-05 Pressure Transducer

For description and maintenance practices refer to Chapter 73-30-01.
28-40-06 Pressure Gauge

The fuel pressure gauge is integrated in the Digital Instrument Package (refer
to Chapter 77-40-02).

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Intentionally left blank.

Maintenance Manual
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Chapter 29
Hydraulic Power

Maintenance Manual
EXTRA 500
Table of Contents
29-00-00 GENERAL ........................................................................................................ 3

Maintenance Manual
EXTRA 500
29-00-00 GENERAL
The hydraulic system of the EXTRA 500 is used to operate the landing gear
exclusively. Therefore all information concerning hydraulics is incorporated in
Chapter 32-30 Extension and Retraction.

Maintenance Manual
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Maintenance Manual
EXTRA 500
Chapter 30
Ice and Rain Protection

Maintenance Manual
EXTRA 500
TABLE OF CONTENTS
30-00-00 GENERAL ........................................................................................................ 5

Description.......................................................................................................... 5
Removal/Installation/Repair ............................................................................... 5
Figure 30-1 De-Icing System Shematic .................................................................................. 6
30-10-00 AIRFOIL ......................................................................................................... 10

Description........................................................................................................ 10
30-10-01 Pressure Regulator ......................................................................................... 10
Pressure Regulator Setting and Pressure Switch Check ................................... 10
Figure 30-2 Pressure Manifold ............................................................................................ 11
Figure 30-3 Pressure Regulator ........................................................................................... 12
30-10-02 Ejector Valve ................................................................................................... 13
30-10-03 Boots Timer ..................................................................................................... 13
30-10-04 Pressure Switch ............................................................................................... 13
30-20-00 AIR INTAKES ................................................................................................ 15

Description........................................................................................................ 15
30-20-01 Bowden Cable ................................................................................................. 15
Rigging ............................................................................................................. 16
30-20-02 Micro Switch ................................................................................................... 17
Rigging ............................................................................................................. 17
30-20-03 Helical Metallic Hoses .................................................................................... 17
30-30-00 PITOT, STATIC AND STALL WARNING ................................................ 18

Description........................................................................................................ 18
30-30-01 Current Sensor (Avionic Bay) ....................................................................... 18
30-30-02 Current Sensor (Tail Cone) ........................................................................... 19
30-40-00 WINDSHIELD ................................................................................................ 20

30-40-01 Windshield Heat Controller .......................................................................... 20
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30-40-02 Windshield Heat Current Sensor .................................................................. 21

30-60-00 PROPELLER .................................................................................................. 22

Description ........................................................................................................ 22
30-60-01 Propeller Ammeter.......................................................................................... 22
30-70-00 WATER LINES ............................................................................................... 23
30-80-00 DETECTION ................................................................................................... 24

30-80-01 Ice Light ........................................................................................................... 24
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Maintenance Manual
EXTRA 500
30-00-00 GENERAL
Description
The following icing protection systems are standard equipment on the
EXTRA 500 (refer to Figure 30-1):
1 Pneumatic de-ice boots for wing and empennage
2 Heated Pitot tubes and heated static ports
3 Heated stall warning sensor
4 Heated windshield
5 Heated engine inlet
6 Heated propeller blades
Removal/Installation/Repair
For respective information see manufacturers BF Goodrich publications
concerning “Estane De-Icers” as listed in the LOAP 18-22.

Maintenance Manual
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Figure 30-1 De-Icing System Shematic

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Troubleshooting
Deice boots fail to inflate Leakage in pressure system Identify leak, seal or replace
completely upstream ejector valves defective part
Electric failure Check wiring
Failure of: Identify defective
timer, pressure regulating component(s) and replace
valve, ejector valves, pressure
manifold
De-ice boots inflate only Leakage in pressure lines Identify leak, seal or replace
partially (low inflation defective part
pressure, no DEICE BOOTS
Kinked pressure tube Replace defective tube
safe operation light)
Failure of pressure regulating Replace valve
valve
Electric failure Check pressure sensors, wiring
and indication light
One of the two inflation Failure of: Identify defective component
sections (inner wing, outer and replace
Timer, ejector valve, electric
wing and tail surfaces) fails to wiring
inflate
Leakage of pressure lines Check for leaks in pressure
downstream ejector valve lines and boots, repair or
replace defective parts
Blockage downstream Check for kinks in tubing,
distributing valve replace
Time intervals out of Failure of timer (or false Replace timer
tolerances timer)
Boot evacuation fails Timer, ejector valve, or switch Identify and replace or repair
failure
Electric failure Check and repair wiring
Boot or line leakage Identify and replace or repair
Inlet heating defect Bowden cable broken Replace
Bowden cable loose Rig Bowden cable
Exhaust ‘ashtray’ broken Replace
Exhaust is leaking Replace
Exhaust helical metallic hose replace
disconnected or leaking

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INTAKE HEAT safe operation Wiring defective Replace
light does not illuminate on
Microswitch defective Replace
activation
Bowden cable mis-rigged Rig Bowden cable
Microswitch mis-aligned Rig microswitch
Engine inlet anti ice system Wiring defective Replace
does not activate
Microswitch defective Replace
Bowden cable mis-rigged Rig Bowden cable
Microswitch mis-aligned Rig microswitch
Water in boots system Water separator drain line Remove drain line blockage
blocked
Orifice in water separator Remove blockage from and
blocked clean (inside of) water
separator.
Pitot tube does not heat, Wiring defective Check and repair wiring
no PITOT HEAT LEFT/RIGHT
Pitot tube heat defective Replace Pitot tube
indication
Static port does not heat Wiring defective Check and repair wiring
STATIC HEAT LEFT/RIGHT
indication Static port heat defective Replace static port
Lift detector (3 heating Wiring defective Check and repair wiring

circuits) does not heat
Current sensor defective Replace current sensor.
Lift detector heat defective Replace lift detector
Windshield heat inactive, no High ambient temperature Normal system function
WINDSHIELD HEAT ON (windshield above 40°C)
indication
WINDSHIELD HEAT FAIL Wiring to one temperature Check and repair
active, sensor in windshield defective
WINDSHIELD HEAT ON still
active One windshield temperature Replace windshield
sensor defective
Respective circuit in Replace controller
controller defective
WINDSHIELD HEAT FAIL Wiring to or both temperature Check and repair
active, sensors in windshield
WINDSHIELD HEAT ON defective
inactive
Windshield controller Replace controller
defective

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WINDSHIELD HEAT ON Wiring to heated area Check and repair
inactive defective
Heated area in windshield Replace windshield
defective
Windshield controller Replace controller
defective
Prop Ammeter shows zero No power from aircraft to Check wiring, circuit breaker
brushes and switch, repair or replace
defective part
Open circuit brushes to heater Repair wiring (check when
boots stretching and flexing the
leads) or replace propeller in
case of heater element failure
Ammeter shunt defective Replace shunt
Ammeter wiring defective Repair wiring
Ammeter defective Replace ammeter
Prop Ammeter shows low Open circuit (or high Identify whether wiring or
current (below green arc) resistance) to at least one of heater element itself is
the blade heating elements defective. Repair wiring or
replace propeller
Ammeter shows excess Power lead shorted to ground Check insulation and replace
current (above green arc) defective lead
Radio noise Brushes arcing Check for brush alignment,
dirty or rough slip rings and
slip ring alignment
Loose connection Check wiring connections
Rapid brush wear and frequent Brush assembly out of Check and adjust brush
breakage alignment alignment
Slip ring wobbles Check slip ring alignment,
replace slip ring
Rough slip rings Replace (or refinish) slip ring

Maintenance Manual
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30-10-00 AIRFOIL
Description
The leading edges of the airfoils (wing, horizontal and vertical stabilizer) are
protected against icing by inflatable rubber boots. The pressurized air for boot
inflation is supplied by engine bleed air. Nominal inflation pressure of the
system is 18 psig (1.25 bar). A system surview is given in Figure 30-1.
The system, when activated, inflates two leading edge boots groups in
sequence for ice shedding. Boot cycle A incorporates the inner wing boots,
cycle B the outer wing and empennage. When not inflated, suction will keep
the boots on the wing and empennage surfaces. The switching from under-
pressure to pressure is done by an ejector valve (one for each group), which is
commanded by the boots timer. The boots timer is activated with the BOOTS
switch on the left side panel.
30-10-01 Pressure Regulator

The pressure regulator is located in the engine compartment, on the LH upper
engine mount tube.
Pressure Regulator Setting and Pressure Switch Setting Check

Refer to Figure 30-2 and Figure 30-3.
1 Remove LH upper cowling. Refer to Chapter 71-10-01.
2 Remove tubes (2 + 3, Figure 30-2) from
pressure manifold.
3 Plug one open fitting of the pressure
manifold.
4 Install a pressure indicator with an
indication range from minimum 0 thru
25 psig on the other fitting.
5 Disconnect the tube (3, Figure 30-3) from
the pressure regulator.
6 Connect 40 psig regulated shop air to the
open pressure regulator fitting.
7 Check pressure indication 19 psig. tolerance: +/- 1 psig.
If reading out of tolerance:
a Loosen counter nut (7, Figure 30-3).
b Adjust pressure using the Allen set screw (8,
Figure 30-3).

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c Fasten counter nut (7, Figure 30-3).
8 Slowly reduce shop air pressure and check tolerance: +/- 0.5 psig.
PNEUMATIC LOW illuminates when pressure
drops below 15 psig.
If reading out of tolerance:
a Replace pressure switch. Refer to Section 30-10-04
9 Remove regulated shop air from pressure
regulator inlet fitting.
10 Connect the tube (3, Figure 30-3) to the
pressure regulator.
11 Remove pressure indicator and plug from
pressure manifold.
12 Reinstall tubes (2 + 3, Figure 30-2) to
pressure manifold.
from pressure regulator
Firewall
2
Legend:
1 pressure manifold
2 tube
5 3 tube
4 pressure switch
5 hose clamp
Figure 30-2 Pressure Manifold
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fwd 2
3
to
pressure
manifold
5
Legend:
1 pressure regulator
2 tube
3 tube 6
4 bolt
5 mounting plate
6 bolt 8
7 counter nut
8 Allen set screw 7
Figure 30-3 Pressure Regulator
2 Disconnect pneumatic lines (2 + 3).
3 Remove mounting plate (5) from engine 2 bolts (4 + 6)
mount.
4 Remove pressure regulator (1) from 4 screws, lockwire
mounting plate.

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30-10-02 Ejector Valve

Two ejector valves (one for boot cycle A and one for boot cycle B) are
installed in the engine compartment. They are mounted on the firewall, left of
the nose gear bay firewall.
power connected.
4 Disconnect pneumatic lines.
5 Remove ejector valve. 4 bolts
30-10-03 Boots Timer

The boots timer is installed in the avionics compartment in the center wing
section.
1 Remove LH avionic bay access panel on top Refer to Chapter 51-00-01.
of the wing.
3 Remove boots timer 4 bolts
30-10-04 Pressure Switch

The pressure switch is installed on the left hand front side of the firewall. Also
refer to Figure 30-2.
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3 Remove pressure switch (4, Figure 30-2) hose clamp (5, Figure 30-2)

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30-20-00 AIR INTAKES
Description
The EXTRA 500 is equipped with an exhaust heated engine inlet. Pulling the
INTAKE ANTI ICE Bowden cable opens the “ashtray” in the LH exhaust stack
which routes hot exhaust air into the double walled engine air inlet. The air
flows out on the RH side to the RH exhaust stack.
Pulling the Bowden cable will also throw a microswitch on the LH exhaust
stack to illuminate the INTAKE HEAT safe operation light and to activate the
engine compressor inlet anti ice system (Rolls Royce 250-B17F Series
Operation and Maintenance Manual, LOAP 1).
30-20-01 Bowden Cable

The Engine anti-ice Bowden cable is installed in the middle console in the
cockpit and goes through the front pressure bulkhead/firewall to the LH engine
exhaust stack in the engine compartment.
2 Disconnect cable of Bowden cable on LH
exhaust stack.
3 Disconnect Jacket of Bowden cable on LH
exhaust stack.
4 Disconnect any tie-raps in engine
compartment that hold the Bowden cable.
5 Remove upper paneling part of middle Refer to Chapter 25-10-26.
console in which the Bowden cable holding
plate is mounted.
NOTE Do not pull the cable from the jacket. There is a very small metal ball
that will fall out.
6 Remove Bowden cable from mounting
plate.
7 With a firm pull, break the pressure
cabin/firewall sealing and remove Bowden
cable.
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9 Seal the Bowden cable from the firewall
side with PR812
For complete health and safety information, a material safety data sheet
is available from the manufacturer.
10 Seal the Bowden cable from the inside with For mixing and application of
PR 1750. PR 1750 sealant refer to
11 Rig the Bowden cable. See paragraph Rigging below.
Rigging
1 Remove the LH upper cowling to gain Refer to Chapter 71-10-01.
access to the LH exhaust stack
2 Push the INTAKE ANTI ICE knob fully in.
3 Set the upper set screw that the ‘ashtray’ is
fully closed when the lever is set against it.
4 Clamp the Bowden cable jacket so the
jacket protrudes 4 mm +/- 1 mm from
clamp.
5 Attach cable to lever while lever is at upper
set screw.
6 Pull the INTAKE ANTI ICE knob fully out.
7 Make sure that the ‘ashtray’ is fully out. 20° travel
8 Set the lower set screw accordingly.
9 Perform micro switch rigging. Refer to Subject 30-20-02.
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30-20-02 Micro Switch

The engine anti-ice micro switch is located on the LH exhaust stack.
power connected.
2 Remove the LH upper cowling Refer to Chapter 71-10-01.
3 Mark and cut wiring of the micro switch. Connect later by splicing.
4 Remove micro switch. 2 screws
6 Perform micro switch rigging. See paragraph Rigging below.
Rigging
1 Remove the LH upper cowling Refer to Chapter 71-10-01.
2 Pull the INTAKE ANTI ICE knob fully out.
3 Make sure the micro switch is activated,
loosen, adjust and retighten at set and/or
bend micro switch lever if needed.
30-20-03 Helical Metallic Hoses

There are two helical metallic hoses installed in engine compartment for
exhaust air routing from the LH exhaust stack to the inlet and from the inlet to
the RH exhaust stack
1 Remove exhaust stacks Refer to Ch. 78-00-01/02
2 Unscrew helical metallic hose from inlet
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.
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30-30-00 PITOT, STATIC AND STALL WARNING
Description
The EXTRA 500 is equipped with two heated Pitot tubes, one underneath each
wing. Standard AN-type (AN 5812-1) Pitot tubes are used. The electric Pitot
heat is activated by switching the L-PITOT-R switches to the ON position. As
long as the aircraft is on ground the heating of the Pitot tubes is avoided by
means of a squat switch installed at the nose gear strut. To provide a means for
checking the system on ground the switches can be set to a momentary TEST
position to override the squat switch. Avoid operating the system in this mode
longer than 10 sec. on ground to avoid an overheat condition. The current
consumption of the heating elements is monitored by current sensors during
operation. If an open circuit causes the Pitot tube heaters to fail, the PITOT
HEAT LEFT/RIGHT illuminates in the annunciator panel.
The two dual static ports installed in the aft fuselage sides are equipped with
electric heater elements to prevent icing. They are also activated by the L-
PITOT-R switches. Heating is disabled on ground by means of a squat switch
and current sensors generate the STATIC HEAT LEFT/RIGHT annunciation in
case of malfunction. Temperature rise after activation of the test mode on
ground is much slower than for the Pitot heat. Be aware of this behavior when
checking the system on ground.
The Stall detector installed in the left wing leading edge within the access
panel for the recognition lights features three electric circuits for icing
protection. The movable sensing vane, the mounting plate and the case itself
are heated by electric heating elements. The heatings are activated by the
PITOT-R switch and protected by the squat switch against inadvertent operation
on ground. The TEST position of the switch overrides this protection to allow
system checks on the ground (time limited up to max. 10 sec). The main
heating circuits (vane and mounting plate) are monitored by a current sensor,
generating the STALL HEAT warning indication in the annunciator panel in case
of an open circuit.
NOTE In case of defective Pitot tube, static port or stall detector heat elements,
the respective components have to be replaced as a whole (refer to
Chapter 34-10).
30-30-01 Current Sensor (Avionic Bay)

Three current sensors are installed in the avionic bay and are accessible by the
LH avionic bay access panel. The sensors are labeled 3HG, 5HG and 7HG. The
following table shows to which systems they are related.
Label System
3HG Stall heat
5HG Pitot heat RH
7HG Pitot heat LH

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power connected.
2 Remove LH avionic bay access panel. Refer to Chapter 51-00-01.
3 Remove the wiring from the respective
current sensor.
4 Remove the mounting plate. 4 bolts
To get access to the underside
of the current sensor. Notice
ground bonding.
5 Remove current sensor. 2 bolts
6 Install in reverse sequence of removal. Ensure mounting plate is
correctly grounded and cable
loom cable clamp is installed.
30-30-02 Current Sensor (Tail Cone)

Two current sensors are installed in the aircraft tailcone on the underside of the
air condition soft start module. The sensors are labeled 1HS and 4HS. The
following table shows to which systems they are related.
Label System
1HS Static heat RH
4HS Static heat LH
power connected.
2 Remove tailcone access panel. Refer to Chapter 51-00-01.
3 Remove the air condition soft start module. Refer to Chapter 21-50-03
Disconnecting the electrical
wiring is not necessary.
4 Disconnect the electrical connector.
5 Remove the mounting plate. 4 bolts
5 Remove current sensor. 2 Allen screws
6 Install in reverse sequence of removal. Ensure mounting plate is
correctly grounded.
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30-40-00 WINDSHIELD
An electric windshield heat for the pilot’s side of the windshield is part of the
standard icing protection system. Also refer to Chapter 56-10.
The system consists of three wire circuits bonded between the inner and outer
windshield layer, one for the heating itself and two for the redundant
temperature sensing. The heating current is switched by a special heat
controller regulating the windshield temperature between 20°C and 40°C in
case the system is active. The system may be activated by means of the
WINDSH switch located in the DEICE group within the left side panel. In case of
malfunction of the system, this condition is indicated by a red WINDSHIELD
HEAT FAIL annunciator light. The following failure conditions cause a warning
indication:
• One or both temperature sensing circuits open or shorted
• Overheat signal from at least one of the sensing circuits (more than 50°C)
An additional means for monitoring the function of the windshield is provided
by a green WINDSHIELD HEAT ON annunciator light (controlled by a current
sensor in the heating circuit) illuminating when the heating current flows. This
light is cycling during normal windshield heat operation.
The system remains operative (green light cycling) as long as one of the two
sensing circuits is functioning although the red WINDSHIELD HEAT FAIL
warning annunciates one defective temperature sensing circuit. If both sensing
circuits are defective the windshield controller inhibits any further windshield
heating.
30-40-01 Windshield Heat Controller

The windshield heat controller is installed beside the pilot seat, behind the
pilot’s legroom LH paneling.
power connected.
2 Remove pilot seat. Refer to Chapter 25-10-11.
3 Remove all LH forward lower paneling Refer to Chapter 25-00-01.
screws.
4 Carefully swivel the paneling forward to
gain access from behind.
5 Remove electrical connector.
6 Remove windshield heat controller. 2 nuts

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30-40-02 Windshield Heat Current Sensor

The windshield heat current sensor is installed beside the pilot seat, behind the
pilot’s legroom LH paneling.
power connected.
2 Remove pilot seat. Refer to Chapter 25-10-11.
3 Remove all LH forward lower paneling Refer to Chapter 25-00-01.
screws.
4 Carefully swivel the paneling forward to
gain access from behind.
5 Remove electrical connections. 4 screws
6 Remove windshield heat current sensor 2 nuts
including mounting plate.
7 Remove current sensor from mounting plate. 2 bolts
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30-60-00 PROPELLER
Description
The propeller of the EXTRA 500 is equipped with electrically heated boots at
the blades for icing protection. All blades are heated continuously when
switched on. All necessary information for repair and maintenance of the
system is contained in BF Goodrich Aerospace publications as listed in the
LOAP 14-17.
30-60-01 Propeller Ammeter

The propeller ammeter is installed in the upper left corner of the instrument
panel.
1 Remove RH and LH IFD. Refer to Chapter 31-60-01.
2 Disconnect electrical connector ammeter.
3 Remove propeller ammeter. 4 screws

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30-70-00 WATER LINES

The pneumatic boot system incorporates a water separator to prevent water to
enter boot lines and the boots themselves as water may freeze and render the
system inoperative. The water separator is installed downstream of the pressure
regulator and upstream of the ejector valves. A water drain line is routed to the
exterior.
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30-80-00 DETECTION
30-80-01 Ice Light

An ice light is installed on the forward left side of the fuselage. It is accessible
from inside the engine compartment when the LH upper cowling is removed.
power connected.
2 Remove upper LH cowling. Refer to Chapter 71-10-01
4 Remove ice light cover and window. 3 bolts
5 Disassemble ice light. 4 bolts

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Chapter 31
Indication & Recording Systems

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TABLE OF CONTENTS
31-00-00 GENERAL ........................................................................................................ 3

Description.......................................................................................................... 3
31-10-00 INSTRUMENT & CONTROL PANELS ....................................................... 4

31-10-01 Left Side Panel .................................................................................................. 4
Description.......................................................................................................... 4
31-10-02 Left Main Panel ................................................................................................ 4
31-10-03 Right Main Panel .............................................................................................. 5
31-10-04 Lower Main Panel ............................................................................................ 5
31-10-05 Glare Shield ....................................................................................................... 6
31-10-06 Control Display Unit ........................................................................................ 6
Tests and Checks ................................................................................................ 6
31-50-00 CENTRAL WARNING SYSTEMS ................................................................ 7

Description.......................................................................................................... 7
31-50-01 Annunciator Panel (Westcoast Specialties) .................................................... 7
Figure 31-1 Annunciator Panel (Westcoast Specialties) ........................................................ 7
Lamp Replacement ............................................................................................. 8
31-50-02 Annunciator Panel (EXTRA) .......................................................................... 8
Figure 31-2 Annunciator Panel (EXTRA) .............................................................................. 8
31-60-00 CENTRAL DISPLAY SYSTEMS .................................................................. 9

Description.......................................................................................................... 9
31-60-01 Integrated Flight Display (IFD)....................................................................... 9
Tests and Checks ................................................................................................ 9
Magnetometer Calibration .................................................................................. 9
Magnetometer Check ........................................................................................ 11

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31-00-00 GENERAL
Description
The EXTRA 500 is equipped with several indication systems:
• The left and right main panel
• The left side panel
• The annunciator panel (part of the right main panel)
• The LH Integrated Flight Display (IFD)
• The RH Integrated Flight Display (IFD)
• The Control Display Unit (CDU)

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31-10-00 INSTRUMENT & CONTROL PANELS
31-10-01 Left Side Panel
Description
On the LH of the pilot, most of the switches and circuit breakers are installed in
a switch board assembly, the left side panel. This assembly contains all
electrical busses excluding the hot bus. This assembly can be taken out of the
aircraft as a whole.
power connected.
2 Remove pilot’s seat. Refer to Chapter 25-10-11.
2 Remove left legroom side paneling. Refer to Chapter 25-00-01.
3 Remove 6 screws of the upper part of the 2 screws on the top
left side panel. 4 screws on the side
4 Remove 3 screws of the lower part of the
left side panel.
5 Disconnect the 3 electrical connectors and
the power connector.
Take care not to damage luminescent foil connections
CAUTION
6 Remove the two parts of the left side panel.
31-10-02 Left Main Panel
1 Remove IFDs. Refer to Subject 31-60-01
2 Disconnect wiring/piping from back-up
flight instruments and propeller ammeter.
3 Remove left main panel. 8 Phillips screws

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31-10-03 Right Main Panel
1 Remove RH IFD. Refer to Subject 31-60-01
2 Remove 10 Phillips screws around right
main panel.
2 Slightly swivel down right main panel Take care not to damage
electrical wiring
3 Disconnect electrical wiring from
annunciator panel
4 Disconnect wiring from fuel gauges.
5 Disconnect wiring from fuel flow indicator.
6 Disconnect wiring from turn coordinator.
31-10-04 Lower Main Panel
1 Remove LH and RH main panel Refer to Subject 31-10-02/03
2 Remove engine indicators. Refer to Chapter 77-40
3 Disconnect electrical wiring from ELT
switch.
4 Disconnect electrical wiring from LANDING
GEAR switch.
5 Disconnect electrical wiring from FLAP

switch.
6 Remove attachment nuts from the other
switches.
7 Disconnect electrical wiring from dimming
potentiometers.

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8 Remove lower main panel. 14 bolts
31-10-05 Glare Shield
1 Remove main panels. Refer to Subjects 31-60-02
thru 04
2 Disconnect wiring from autopilot.
3 Remove glare shield. 4 screws
31-10-06 Control Display Unit
Follow the ACD215 Removal and Installation procedure presented in the
Entegra Integrated Flight Display System Product Maintenance Manual (LOAP
24).
Tests and Checks

Perform the applicable Return to Service Tests and Checks presented in the
24). whenever the unit has been reinstalled.

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31-50-00 CENTRAL WARNING SYSTEMS
Description
The central warning system in the EXTRA 500 consists of an annunciator
panel. The annunciator panel is located on the top RH instrument panel. (Refer
to the Emergency Procedures (Amplified) part of Section 3 in the EXTRA 500
Pilot's Operating Handbook for further information to the particular caution
and warning lights.)
31-50-01 Annunciator Panel (Westcoast Specialties)

The annunciator panel is located on the top RH instrument panel.
r r r r y y
r r r r y y
r r r y y
y y y g g g
y y y g g
y y y g g
r = red, y = yellow, g = green

Figure 31-1 Annunciator Panel (Westcoast Specialties)
1 Remove RH IFD. Refer to Subject 31-60-01
annunciator panel.
3 Remove panel. 4 screws
5 Check if all lamps work by placing the
NIGHT/DAY switch located on the left side
panel in the TEST position.
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Lamp Replacement
Each annunciator light (lamp module) is illuminated by two lamps. Relamp by
pushing in lamp module approximately 1/16th of an inch and release. The lamp
module will partially eject. Pull to disengage, then rotate downward to expose
the lamps. When reinserting lamp modules ensure both latching springs engage
cap assy by slowly pushing cap with equal force on both sides.
31-50-02 Annunciator Panel (EXTRA)

The annunciator panel is located on the top RH instrument panel.
r = red, y = yellow, g = green

Figure 31-2 Annunciator Panel (EXTRA)
1 Unscrew the four inner bolts.
2 Pull the panel out.
3 Disconnect electrical connectors.
5 Check if all lamps work by placing the
NIGHT/DAY switch located on the left side
panel in the TEST position.

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31-60-00 CENTRAL DISPLAY SYSTEMS
Description
The central display system of the EXTRA 500 contains 2 Avidyne Integrated
Flight Displays (IFDs).
31-60-01 Integrated Flight Display (IFD)
Follow the IFD5000i Removal and Installation procedure presented in the
24) observing the following aircraft specific hints:
Ensure BATT switch is OFF and no external power connected.
The wiring and piping for the RH IFD is dimensioned in the way that it can be
disconnected/connected when the IFD is removed from and held next to the
instrument panel. The wiring and piping for the LH IFD is shorter so that
connecting/disconnecting has to be done with IFD installed. For that reason the
RH IFD must be removed to get access to the wiring/piping connectors.
The wiring is marked conforming to the designations on the IFD backsides.
However the piping (Pitot/static) is colored as shown in the following:
IMPORTANT The colors of pitot/static lines do not match with the port markings on the
backside of the IFDs.
Piping Colors
LH IFD RH IFD
PITOT white blue
STATIC red green
Tests and Checks

Perform the applicable Return to Service Tests and Checks presented in the
24) whenever the unit has been reinstalled.
Pitot/Static Check
Perform applicable Return to Service Pitot/static Check according to FAR 43,
Appendix E and AC 43.13-1B CHG1 (or later) Ch. 12-59 whenever the unit
has been reinstalled.
Magnetometer Calibration
It is advisable to integrate the Compass Swing procedure outlined in Chapter
34-20-02 in this calibration procedure.
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It is recommended to perform the calibration with a mobile external power

unit.
1 Place the aircraft in a magnetically clean area
2 Attach external power
3 Switch on BATT, EXT PWR, and AVIONICS
4 Wait, until both IFD-s have aligned
5 Wait additional 10 minutes.
6 Press ‘SYS’ and select ‘setup’ on both IFD-s
7 Press ‘Update Databases’ L(ine) S(elect) K(ey)
8 Press ‘Confirm’ LSK
9 Simultaneously hold the LH upper and third
LSK for 5 seconds
10 Press ‘Proceed’ LSK
11 Check ‘Technician maintenance mode’
indication
12 Press ‘SYS’ and select ‘cal’
13 Press ‘Cal select – select Magnetometer
calibration’
14 Check ‘Calibrate Heading’ indication
IMPORTANT Place the ailerons to neutral and do not move them during calibration
and verification.
Calibration
15 Place the aircraft to the magnetic north
360°+/−1°
16 Switch on STROBE
17 Follow the procedure as displayed on IFD-s
18 After the heading point (330°):
19 Check ‘Magnetometer Calibration Complete’
indication.
20 Wait 10 seconds
21 Press ‘Done’
22 Wait until IFD-s to reboot.
23 Switch off EXT PWR
24 Switch off BATT
25 Wait one minute
26 Verify neither “Mag CAL 1 required” or
“Mag CAL 2 required” appears.
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Magnetometer Check

1 Place the aircraft in a magnetically clean area
2 Attach external power
3 Switch on BATT
4 Switch on EXT PWR
5 Wait until IFD-s to reboot and are aligned
6 Check ‘Mag Cal 1 (or 2) Required’ Caution
does NOT appear.
7 Place the aircraft to the given directions. If values are out of limit
Check if reading in limits and note values. perform Magnetometer
Calibration Procedure
8 Heading accuracy each IFD at 0°true within or True: LH: RH:
at 356 to 004°
9 LH and RH IFD-s at 0°true within or at 2° of
each other
10 Heading accuracy each IFD at 90°true within True: LH: RH:
or at 86 to 94 °
each other
or at 176 to 184°
each other
or at 266 to 274°
each other
16 Switch off EXT PWR
17 Switch off BATT
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Chapter 32
Landing Gear

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Table of Contents
32-00-00 GENERAL ........................................................................................................ 5

Introduction ........................................................................................................ 5
Description.......................................................................................................... 5
Operation ............................................................................................................ 6
Operational Test Procedures ............................................................................... 8
Gear Up Procedure ............................................................................................. 9
Gear Down Procedure ...................................................................................... 10
Emergency Extension Test ............................................................................... 10
Gear Up Cycle Test .......................................................................................... 11
Wheels Up Landing Test .................................................................................. 12
Gear Down Cycle Test ..................................................................................... 12
Gear Up Cycle Test With Rudder Full Left/Full Right .................................... 12
Leakage and Accumulator Function Test ......................................................... 13
32-10-00 MAIN GEAR AND DOORS .......................................................................... 14

32-10-10 Main Gear Strut Assembly ............................................................................ 14
Description........................................................................................................ 14
Figure 32-1 LH Main Gear Strut Assembly.......................................................................... 15
Removal ............................................................................................................ 16
Installation ........................................................................................................ 17
Disassembly/Assembly..................................................................................... 17
32-10-11 Parallel Strut ................................................................................................... 19
Description........................................................................................................ 19
Figure 32-2 Parallel Strut .................................................................................................... 20
Adjustment of Vertical Play ............................................................................. 21
32-10-12 Axle Bar ........................................................................................................... 21
Description........................................................................................................ 21
Figure 32-3 Axle Bar ............................................................................................................ 22
Adjustment of Vertical Play ............................................................................. 23
32-10-13 Shock Absorber............................................................................................... 23
Description........................................................................................................ 23
Figure 32-4 Shock absorber ................................................................................................. 24
32-10-20 Main Gear Doors ............................................................................................ 25
Description........................................................................................................ 25

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32-10-21 Upper Doors ..................................................................................................... 26

Door Actuation Length Adjustment .................................................................. 26
32-10-22 Lower Doors .................................................................................................... 26
32-20-00 NOSE GEAR AND DOORS .......................................................................... 28

Description ........................................................................................................ 28
32-20-10 Nose Gear Strut Assembly.............................................................................. 28
Description ........................................................................................................ 28
Figure 32-5 Nose Gear.......................................................................................................... 29
32-20-20 Nose Gear Doors .............................................................................................. 30
Description ........................................................................................................ 30
Figure 32-6 Nose Gear Doors Actuation Mechanism........................................................... 31
32-30-00 EXTENSION AND RETRACTION ............................................................. 32

Description ........................................................................................................ 32
Figure 32-7 Landing Gear Schematic ................................................................................... 34
Figure 32-8 Main Gear Actuators......................................................................................... 35
32-30-10 Hydraulic System ............................................................................................ 36
Bleeding ............................................................................................................ 36
Hydraulic Fluid Change .................................................................................... 37
32-30-11 Hydraulic Power Pack .................................................................................... 39
Cleaning ............................................................................................................ 40
32-30-12 Distributor Block ............................................................................................. 40
Disassembly/Assembly ..................................................................................... 41
32-30-20 Actuators .......................................................................................................... 42
32-30-21 Main Gear Actuators ...................................................................................... 42
32-30-22 Upper Doors Actuator .................................................................................... 44
32-30-23 Lower Doors Actuator .................................................................................... 45
32-30-24 Nose Gear Actuator......................................................................................... 46
32-30-25 Nose Gear Gas Pressurized Springs .............................................................. 47
Test Procedure ................................................................................................... 48
Minimum Tension Forces ................................................................................. 49

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32-30-30 Hydraulic Lines............................................................................................... 49

Description........................................................................................................ 49
32-30-40 Torque Link Rod and Track Rods ................................................................ 50
32-30-50 Drive Mechanism Nose Doors ....................................................................... 51
32-40-00 WHEELS AND BRAKES .............................................................................. 52

Description........................................................................................................ 52
32-40-01 Main Wheels .................................................................................................... 52
32-40-02 Nose Wheel ...................................................................................................... 53
32-40-03 Brake ................................................................................................................ 54
32-50-00 STEERING...................................................................................................... 56
Description........................................................................................................ 56
32-60-00 POSITION AND WARNING ........................................................................ 57

Description........................................................................................................ 57
Figure 32-9 Main Gear Switches (LH) ................................................................................. 58
32-60-01 Main Gear Extended Switches ...................................................................... 58
32-60-02 Main Gear Retracted Switches ...................................................................... 58
32-60-03 Upper Main Door Opened Switch ................................................................. 59
32-60-04 Upper Main Door Closed Switch .................................................................. 59
32-60-05 Lower Main Door Closed Switch .................................................................. 59
32-60-06 Ground Safety Switch .................................................................................... 59
32-60-07 Nose Gear Extended Switch........................................................................... 59
32-60-08 Nose Gear Retracted Switch .......................................................................... 60
32-60-09 Operation and Indication ............................................................................... 60

Maintenance Manual
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32-00-00 GENERAL
Introduction
The next paragraph contains the general description and operation of the
landing gear. The following paragraph contains information about trouble-
shooting.
The specified descriptions of the systems, sub-systems and units can be found
in the respective chapters.
Description
The EXTRA 500 has a hydraulically operated retractable tricycle landing gear
with a steerable nose wheel. Each landing gear strut has a single wheel carrying
tube-type tires.
The main gear is designed as a parallel guide strut construction. Each strut has
an oleo shock absorber and retracts against flight direction after turning the
wheel by 90° in plane with the strut. The upper and lower doors fair the main
gear struts in flight. Main gear struts and doors are separately actuated by
hydraulic cylinders.
The nose gear is designed as an oleo leg strut with a steerable nose wheel and
retracts aft in the nose gear compartment. The rudder pedals on both pilot sides
operate the nose wheel while taxiing.
Components and System Features

The main wheels have hydraulically actuated single-disk brakes on the inside.
The toe-brake pedals on the rudder pedals operate the brakes. While parking,
the brakes can be set on by the parking brake valve, which is located in the
middle-console.
Two hydraulic actuators drive each main gear strut. The interlocking actuator
fixes the extended main gear strut for landing and ground operation. While
retracting the main-wheel is turned by the torque link rod and the track rods
and then placed in the wheel bay. During this cycle the torque link rod also
shortens the main gear strut. In case of hydraulic or electric failure the main
gear extends and locks gravity assisted by air flow.
One hydraulic actuator drives the nose gear strut. The nose gear strut positively
guides the nose doors. In case of hydraulic or electric failure, the nose gear
extends and locks by the elastic force of two gas springs.
The hydraulic power system provides a flow of pressurized hydraulic fluid to
operate the landing gear system as well as the respective landing gear doors.
Hydraulic pressure is maintained while the battery-bus is powered. The system
is equipped with a pressure sensor, which will switch the pump on once the
pressure drops. The constant system pressure is needed to hold the gears and
doors safely in place.

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Controls and Monitoring Devices

(For detailed description, refer to Section 32-60)
The landing gear action is controlled by the LANDING GEAR switch on the L/H
instrument panel.
The extended and retracted position of each landing gear strut is monitored by
position switches and indicated by signal lights:
1 The downlock information for the extended wheel position is given for each
wheel separately by three green lights, located near the selector switch.
2 The red GEAR WARN light on the annunciator panel indicates that the landing
gear is not completely retracted or extended and locked.
In combination with the GEAR WARN light a gear up warning horn is activated.
When landing gear is in transition hydraulic pump operation is necessary
indicated by the yellow HYDRAULIC PUMP annunciation light.
During ground operation, the double ground safety switch on the nose gear
strut just above torque link prevents accidental gear retraction, regardless of the
LANDING GEAR switch position.
The electric circuits of the landing gear equipment are protected by circuit
breakers. They are located on the left side panel and in the E-box (refer to
Chapter 24-60).
Operation
The LANDING GEAR switch has a guard to prevent inadvertent operation. The
switch has the positions UP for retracting and DN for extending.
The operation of the hydraulic system is divided in three hydraulic circuits,
actuating the following devices:
1 Lower main gear doors
2 Upper main gear doors
3 Main landing gear struts and nose gear strut (incl. nose gear doors)
The GEAR DOWN cycle is:
1 Opening of the lower main gear doors, the upper main gear doors and the nose
gear doors and extension of the main gear and nose gear
2 Closing of the upper main gear doors
The GEAR UP cycle is:
1 Opening of the upper main gear doors
2 Main and nose gear retraction (incl. nose gear doors)
3 Closing of the upper main gear doors
4 Closing of lower main gear doors
Changing from gear up to gear down and vice versa is possible at any time.

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DANGER Operation of the landing gear can cause death or injuries in its
working area!
Before beginning any work in the landing gear working area, pull the
electric circuit breaker located on the left side panel and marked
GEAR-CTRL.
handling make sure, that neither a person nor any object is located in
the upper landing gear doors travel area.
NOTE With the aircraft being airborne or jacked and BATT and EXT PWR
switch OFF, the hot bus feeds an AUX circuit, which supplies the
directional valves with electrical power to keep the landing gear in the
up-position. The AUX circuit is protected by the GEAR AUX 1 (left side
panel) and GEAR AUX 2 (E-box) circuit breakers. Push these circuit
breakers in.
However, the nose gear and main gear will slowly extend due to valve
oil leakage, if the hydraulic pump is not being activated temporarily to
maintain hydraulic pressure. If retracted landing gear position is
intended, turn BATT switch ON (left side panel, toggle switch) and push
circuit breakers GEAR-CTRL and HYDR (left side panel) in, while the
landing gear switch (left main panel) is in the UP position.
Troubleshooting
The following paragraph tabulates the troubleshooting procedures relevant to
the landing gear system. The complaints are classified in order to the landing
gear sub-systems.
Main Gear and Doors Refer to Section 32-10
Wings are not level Main gear struts bent or Inspect the main gear struts for
damaged cracks and bending
Drag brace is not locked in Inspect the drag brace, the
overcenter position torque link rod and the main
gear-attachment frame for
cracks and bending. Check the
length of the torque link rod.
Gas-leakage by worn O-ring Check the nitrogen gas
sealing of the shock absorber. pressure and inflate if required
Main gear rattles while taxiing Worn collar bushings Replace
Oil stains beneath the shock Leakage by worn ore damaged Replace
absorber O-ring and scraper rings
Nose Gear and Doors Refer to Section 32-20
Oil stains beneath the nose Leakage by worn ore damaged Replace O-ring, refill

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gear oleo-strut O-ring and scraper rings Aeroshell Fluid 4 as needed
Nose wheel wobbles while Shimmy damper mechanical Replace damaged parts
taxiing damage
Leakage by worn ore damaged Replace O-ring, refill
O-ring and scraper rings Aeroshell Fluid 4 as needed
Extension and Retraction refer to Section 32-30
Oil stains beneath the nose Leakage by worn ore damaged Replace damaged parts
gear actuator and hydraulic O-rings, fittings, hoses or
lines tubes
Oil stains beneath the main Leakage by worn ore damaged Replace damaged parts
gear actuator and hydraulic O-rings, fittings, hoses or
lines tubes
Continued hydraulic pump Abnormal hydraulic internal Detect leak and seal
operation exceeds 3 seconds system leakage.
and/or periods of rest shorter
Pressure switch Adjust or replace
than 2 minutes.
Pump bypass valve Adjust or replace
Wheels and Breaks refer to Section 32-40
Wings are not level Incorrect wheel tube pressure Check the tube pressure and
inflate to max. pressure if
required
Too much tire wear Incorrect toe-in Check and adjust the toe-in
Wheel track out of tolerance Correct the wheel track
Too much axial play in wheel Defective wheel bearing Replace the wheel bearings
Brake disk deformed Excessive hard braking Replace brake disk
Dragging brakes Worn or broken piston return Repair or replace master
spring in master cylinder cylinder
Brake does not operate Brake fluid level low Inspect master cylinder,
fittings and linings for
leakage. Refill brake fluid
Air in the brake system Bleed the brake system
Defective master cylinder Replace the master cylinder.
Then bleed the brake system
Defective fittings or lines Replace the fitting or line.
Then bleed the brake system
Worn brake lining Replace the brake lining
Operational Test Procedures

For ground testing the landing gear functions the aircraft must be lifted at the
three jack points (see Ch. 07-10-00). When aircraft is on jacks and landing gear

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shall be driven to another status as it is, follow the Gear Up Procedure or Gear
Down Procedure given in the following.
area !
GEAR-CTRL.
NOTE With the aircraft being airborne or jacked and BATT and EXT PWR
switch OFF OFF, the hot bus feeds an AUX circuit, which supplies the
directional valves with electrical power to keep the landing gear in the
up-position. The AUX circuit is protected by the GEAR AUX 1 (left side
panel) and GEAR AUX 2 (E-box) circuit breakers. Push these circuit
breakers in.
maintain hydraulic pressure. If retracted landing gear position is
intended, turn BATT switch ON (left side panel, toggle switch) and push
circuit breaker GEAR-CTRL (left side panel) in, while the landing gear
switch (left main panel) is in the UP position.
Gear Up Procedure
1 Lift the aircraft on jacks (refer to Chapter 07-10-00).
Upper landing gear doors will close immediately, when BATT or EXT PWR
DANGER switch is turned to ON and GEAR-CTRL circuit breaker is in. Make sure,
that neither a person nor any object is located in the upper landing gear
doors travel area.
2 Turn BATT and EXT PWR switch ON (left side panel, toggle switch).
3 Push circuit breaker GEAR-CTRL in (left side panel).
Make sure, that neither a person nor any object is located in the landing
DANGER gear travel area.
4 Pull and move LANDING GEAR switch UP (left main panel, below RH side of
control yoke).
5 Wait until HYDRAULIC PUMP light is off indicating that the gear up procedure
is completed. However GEAR WARN remains illuminated and aural warning is
still active. This is normal as engine power is below approach setting (35%
torque).

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Gear Down Procedure

It is assumed aircraft is on jacks, the gear is up, BATT and/or EXT PWR switch
is ON, and GEAR-CTRL circuit breaker is in. Perform Gear Up Procedure if
applicable.
1 Pull and move LANDING GEAR switch DN (left main panel, below RH side of
control yoke).
2 Wait until three green down and locked lights are illuminated, indicating that
the gear down procedure is completed.
Emergency Extension Test

1 Perform Gear Up Procedure (see above)
Landing gear will immediately slam down after GEAR-CTRL circuit
DANGER breaker handling. Make sure, that neither a person nor any object is
located in the landing gear travel area.
2 Pull circuit breaker GEAR-CTRL.
IMPORTANT Setting the LANDING GEAR switch to the DN position does not affect the
operation of the landing gear as long as the GEAR-CTRL circuit breaker is
pulled. This action shall prevent an unintentional landing gear retraction
after completion of this test procedure when resetting the GEAR-CTRL
circuit breaker.
3 Pull and move LANDING GEAR switch DN.
4 Verify the nose gear to extend and reach its down and locked position.
5 Main gear is not required to extend completely. A force of approx. 100 N
(22.5 lbs.) simulating air loads at each wheel must be sufficient to reach the
down and locked position.
NOTE Spilling of 200 - 300 ml (12.2 - 18.3 cu inch) of hydraulic fluid at vent of
reservoir is normal.
6 Check oil level at middle of side view glass → Aeroshell Fluid 4
(1.83 l/111.7 cu inch).
7 For confirming minimum nose gear extending force, test gas pressurized
springs. See Subject 32-30-25 for test procedure.
NOTE Check activated switches acoustically or by observing the related green
gear down and locked indicator lights.
8 Check gear extended switch activating points are within 2 mm to 5 mm (0.079
in. to 0.197 in.) travel at wheel axle indicating the down and locked position
before gear is fully extended.
9 Return aircraft to normal observing respective procedures and warnings

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Gear Up Cycle Test

1 Lift the aircraft on jacks (see Chapter 07-10-00).
doors travel area.
4 Ensure wing flaps are in 0° position.
5 Measure gear up cycle with a stop watch.
6 Pull and move LANDING GEAR switch UP (left main panel, below RH side of
control yoke).
7 Check acoustic gear warning function on horn, speaker and headset.
8 Press GEAR WARNING MUTE button on power lever.
9 Check mute function.
10 Check GEAR WARN annunciator light remains on.
11 Check HYDRAULIC PUMP annunciator light is on.
12 Check upper doors opening.
13 Check gear retracting and nose doors closing.
14 Check upper doors closing.
15 Check lower doors closing.
16 After gear up cycle is completed:
Check performance time for a complete gear up cycle is between 11 and 15
seconds (LH and RH gears are not required to retract simultaneously).
17 Check if the red GEAR WARN and HYDRAULIC PUMP light extinguish.
Ensure cabin door is closed before actuating the flaps.
CAUTION
18 Set wing flaps to 15°
19 No warning should come.
20 Set wing flaps to 30°
21 Check acoustic gear warning active and GEAR WARN annunciator light
illuminating.
22 Press GEAR WARNING MUTE button on power lever.
23 Check acoustic gear warning still active and GEAR WARN annunciator light
still illuminating.
24 Set wing flaps to 0°.
25 Press GEAR WARNING MUTE button on power lever when flaps are passing the
15° setting.

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26 Perform Leakage and Accumulator Function Test (see below).

27 Perform further tests or Gear Down Procedure and return aircraft to normal
observing respective procedures and warnings.
Wheels Up Landing Test

applicable.
1 Shut OFF BATT and EXT PWR switch.
2 Check gear position. The undercarriage must remain in retracted position.
3 Perform Gear Down Cycle Test Procedure or Gear Down Procedure and
return aircraft to normal observing respective procedures and warnings.
Gear Down Cycle Test

applicable.
1 Measure gear down cycle with a stop watch.
3 Check gear extending and opening of all doors.
4 Check if the following lights illuminate during gear transition:
The red GEAR WARN annunciator light
The yellow HYDRAULIC PUMP annunciator light
5 After landing gear is down and locked check if performance time for a
complete gear down cycle is between 11 and 15 seconds (LH and RH gears
must not extend simultaneously).
6 Check if upper doors are closed.
7 Check if the red GEAR WARN and HYDRAULIC PUMP lights extinguish.
8 Check the three green lights for nose gear, LH and RH gear illuminating.
9 Return aircraft to normal observing respective procedures and warnings.
Gear Up Cycle Test With Rudder Full Left/Full Right

1 Lift the aircraft on jacks (see Chapter 07-10-00).
doors travel area.

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4 Apply full left rudder pedal control input.
5 Pull and move LANDING GEAR switch UP.
6 Check if nose gear retracts without jamming in the nose wheel bay.
7 Perform Gear Down Procedure.
8 Apply full right rudder pedal control input.
9 Pull and move LANDING GEAR switch UP.
10 Check if nose gear retracts without jamming in the nose wheel bay.
11 Perform further tests or Gear Down Procedure and return aircraft to normal
observing respective procedures and warnings.
Leakage and Accumulator Function Test

After two accumulator recharge cycles, the time before the third and the
following recharging actions has to be at least 2 minutes. Recharging action
can be heard as a short operation of the hydraulic power pack and is indicated
by the HYDRAULIC PUMP annuciator light.

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32-10-00 MAIN GEAR AND DOORS
32-10-10 Main Gear Strut Assembly
Description
The main gear has two hydraulically actuated main gear strut assemblies with
the following components (refer to Figure 32-1):
• Undercarriage leg
• Drag brace (upper and lower part)
• Parallel strut
• Upper guide strut
• Lower guide strut
• Axle bar
• Shock absorber
The main gear bolt attaches the steel designed main gear strut assembly to the
main gear attachment frame.
The parallel strut, the upper and lower guide struts and the axle bar shape a
parallelogram (parallel guide strut construction).
The drag brace locks the extended main gear strut. The upper and lower part
are kept in overcenter position and fix the parallel strut in vertical.
The bearings above and below the parallel strut are the axle for the upper and
lower guide struts. The vertical movement of the guide struts is absorbed by the
shock absorber, which is attached between them.
The axle bar carries the main wheel and is attached to the upper and lower
guide struts by bearings.

Aft View
Figure 32-1
Torque link rod Extended limit switch
Main gear bolt

Undercarriage leg

Parallel strut
Upper guide strut
Shock absorber
LH Main Gear Strut Assembly

Axle bar
Tyre Drag brace
(upper and lower part)
Track rod (upper and lower)
Lower guide strut
Wheel rim
32
Brake disk
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Page 15
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Removal
1 Lift the aircraft on jacks Chapter 07-10
2 Remove aft keel beam access panel Refer to Chapter 51-00-01
Landing gear extends and retracts under high pressure. Operation of
DANGER the landing gear can cause death or injuries in its working area!
GEAR-CTRL.
the landing gear travel area.
3 Remove the bolt from the push pull rod
upper door
4 Lift the upper door and fasten by means of a
tape
5 Remove the clevis pin from the hinge joint
lower door
6 Remove the bolt between the torque link rod
and the main gear strut assembly
7 Remove the bolt between the short actuator
main gear and the main gear strut assembly
8 Unlock the mechanism of the interlocking Apply shop air momentarily
actuator. on the rod side fitting of the
interlocking actuator.
9 Remove the bolt between the interlocking
actuator and the main gear strut assembly.
Brake fluid can cause disease!
WARNING Do not allow brake fluid to come in contact with your skin.
CAUTION Clean up immediately spilt brake fluid
10 Remove the brake Chapter 32-40-03
11 Disconnect reusable fitting of the brake
hose.
12 Remove brake line from main gear strut
13 Remove the main wheel Chapter 32-40-01
14 Remove the limit switch Chapter 32-60-01
15 Cut off the safety wires on both main gear
bolt nuts
16 Remove the lower nut completely from the Hold the main gear strut until
thread. completely removed.

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17 Remove the upper nut. While pulling the main gear
bolt with an extracting tool
(refer to Chapter 01-00-02)
18 Remove the main gear bolt and the lower
nut from the main gear attachment frame
19 Remove the assembled main gear
20 Remove the collar bushings in the main gear
strut assembly
Installation
1 Lubricate the fitting surface and thread of Use only MILG81322D
the main gear bolt before installation Grease
2 Install in reverse sequence of removal Use new stop nuts and new
brake line with crimped
fitting on inboard side.
3 Bleed the brake system Refer to Chapter 12-10-07
Disassembly/Assembly
1 The track rods have to be removed Chapter 32-30-40
False reassembled bolted connections can damage the gear struts and
CAUTION doors.
Before removal of bolts and nuts, notice their position. It can be
different from the respective figure for geometric reasons.
2 Remove the bolts, stop nuts and washers
from the undercarriage leg
3 Remove the undercarriage leg from the
assembled strut structure
from the upper part of the drag brace
5 Remove the upper part of the drag brace
from the assembled strut structure
6 Remove the collar bushings in the upper
part of the drag brace
from the lower part of the drag brace.
8 Remove the lower part of the drag brace and
the parallel strut from the assembled strut
structure

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9 Remove the collar bushings and shims in the
parallel strut
Tensioned construction due to nitrogen inflation damages hands and
WARNING limbs!
The shock absorber is under high pressure (827 psi/57 bar)!
10 Relieve nitrogen pressure.
11 Remove the bolts, stop nuts and shims
between the shock absorber and the upper
and lower guide strut
12 Remove the shock absorber from the upper
and lower guide strut
13 Remove the bolt, stop nut and washer
between the upper guide strut and axle bar
14 Remove the upper guide strut from the axle
bar
15 Remove bolts, stop nuts and washers
between the lower guide strut and axle bar
16 Remove the lower guide strut from the axle
bar
17 Remove the collar bushings in the axle bar
18 Install in reverse sequence of removal Use new stop nuts.
19 Check the toe-in whenever any part of the
main gear strut has been changed

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32-10-11 Parallel Strut
Description
The steel designed parallel strut has the following components (refer to Figure
32-2):
Upper and lower T-strut
Rotary bushing with guide brackets
Jam nut with set screw
Adjusting nut with set screw
Inner and outer joint
Collar bushings in the rotary bushing
Collar bushings in the joints
Grease nipples
Attaching parts like bolts, stop nuts and washers
The parallel strut is steel designed. It is linked with the under-carriage leg, the
lower part of the drag brace and the upper and lower guide strut by the bearings
in the upper and lower T-strut.
When the landing gear is extended, the parallel strut is vertically fixed by the
undercarriage leg and the upper and lower part of the drag brace.
The upper T-strut is threaded and carries the adjusting nut and the jam nut,
which are for adjusting to avoid any vertical play.
The components with collar bushings inside like the axle guide bracket and the
upper and lower T-strut are equipped with grease nipples.

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Grease nipple
Upper T-strut
Set screw
Set screw
Jam nut
Adjusting nut Upper guide bracket
Grease nipple
Collar bushing
Outer joint
Grease nipple
Inner joint
Rotary bushing
Collar bushing
Grease nipple
Lower guide bracket
Lower T-strut
Grease nipple
Figure 32-2 Parallel Strut
For removal of the parallel strut from the main gear strut assembly perform as
described in step 1 to 3 and 7 to 9 (refer to Subject 32-10-10 Main Gear Strut
Disassembly).
1 Remove the lower T-strut from upper T- Turn lower T-strut
strut with rotary bushing. counterclockwise
2 Remove the rotary bushing with its collar
bushings.
3 Loosen the jam nut and adjusting nut set
screws.
4 Loosen the jam nut from the adjusting nut

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5 Remove the adjusting nut.
6 Remove the jam nut.
from the inner and outer joint.
8 Remove the inner and outer joint.
9 Remove the joint collar bushings.
10 Install in reverse sequence of removal Use new stop nuts
Adjustment of Vertical Play

NOTE This procedure does not require jacking the aircraft
1 Loosen the jam nut and adjusting nut set
screws.
2 Loosen the jam nut.
3 Tighten the collar bushings to the rotary As long as any clearance
bushing by clockwise turning the adjusting occurs
nut.
4 Tighten the adjusting nut set screw.
5 Counter the adjusting nut by the jam nut.
6 Tighten the jam nut set screw.
NOTE Replace the collar bushings when their collar thickness is less then 3/64"
(1 mm)
32-10-12 Axle Bar
Description
The steel designed axle bar has the following components (see Figure 32-3):
Upper and lower T-strut
Rotary bushing with axle and axle guide bracket
Joint
Collar bushings in the joint
Grease nipples
Attaching parts like bolts, stop nuts and washers
The axle bar is linked with the upper and lower guide strut by the bearings in
the upper and lower T-strut.

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The axle carries the main wheel.

The rotary bushing and the upper and lower T-strut are equipped with grease
nipples.
Upper T-strut
Grease nipple
Rotary bushing
Axle guide bracket
Collar bushing
Grease nipple
Joint
Collar bushing
Grease nipple
Lower T-strut
Figure 32-3 Axle Bar
For removal of the axle bar from the main gear strut assembly follow step 1
and 13 to 17 (refer to Subject 32-10-10 Main Gear Strut Disassembly)
1 Remove the upper T-strut from lower T-
strut and the rotary bushing
2 Remove the collar bushing in rotary bushing
from joint

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4 Remove the joint
5 Remove the collar bushing in the joint
Adjustment of Vertical Play

For disassembly follow step 12 to 16 (Subject 32-10-10 Main Gear
Disassembly)
1 The axle bar has to be removed Follow step 1 and 13 to 17
(32-10-10 Main Gear Strut
Disassembly)
2 Tighten the collar bushings in the rotary As long as any clearance
bushing by turning the upper T-strut (full occurs
turns only) against the lower T-strut
clockwise.
NOTE Replace the collar bushings when their collar thickness is less then
3/64"/ 1 mm
32-10-13 Shock Absorber
Description
The steel designed shock absorber has the following components (refer to
Figure 32-4):
Outer cylinder
Inner cylinder
Slide bearing
Piston
Throttle with disk and support
Seals like O-rings and scraper ring
Valves
Hinge bearings
Attaching parts like back up rings, safety pin and locking ring
The shock absorber is connected to the upper and lower guide strut by bolts.
The shock absorber is designed as oil/nitrogen filled cylinder. The lower outer
cylinder is filled with hydraulic oil; the upper inner cylinder is nitrogen
inflated. The piston in the upper inner cylinder separates the hydraulic oil from

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nitrogen inflation. The grounded and hardened surfaces of the inner cylinder
and the piston are sealed by O-rings.
Hinge bearing
Valve
Outer cylinder
Throttle with disk and support
Piston
Scraper ring
O-ring
Locking wire
Slide bearing
Inner cylinder
Valve
Hinge bearing
Figure 32-4 Shock absorber
For removal of the shock absorber from the main gear strut assembly follow
step 10 to 12 (refer to Subject 32-10-10 Main Gear Strut Disassembly)
WARNING
The shock absorber is under high pressure (827 psi/57 bar)
1 Release nitrogen pressure and drain the Refer to Chapter 12-10-09
hydraulic fluid completely in a sump
2 Remove the locking wire from the outer
cylinder.

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3 Remove the outer cylinder from the slide
bearing
4 Remove the O-ring and the back up-ring
from the outer cylinder
5 Remove the safety pin from the slide
bearing and the inner cylinder
6 Remove the support throttle, the disc and the
throttle from inner cylinder
7 Remove the inner cylinder from the slide
bearing
8 Remove the O-ring, the back up-rings and
the scraper ring from the slide bearing
9 Push the piston out of the inner cylinder
10 Remove the O-ring and the back up-rings
12 Seal locking wire. Elastosil E14, GE RTV 159
or equivalent
13 Refill hydraulic fluid into the cylinder and Refer to Chapter 12-10-09
apply nitrogen pressure.
14 Check the wheel track
32-10-20 Main Gear Doors
Description
The carbon fiber designed upper and lower doors fair the retracted main gears.
The hinges are integrated in the door lamination.
The upper doors are connected to the fuselage by two hinges each. Hydraulic
actuators drive the upper doors by levers with push pull rod.
The lower doors are connected to the fuselage by three hinges each. An
hydraulic actuator drives both lower doors by levers with cardan hinge joint.

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32-10-21 Upper Doors
GEAR-CTRL.
1 Remove the bolt between the upper door
and the push pull rod.
2 Remove the bolts from both hinges. Hold the door
3 Remove the upper door.
4 Install in reverse sequence of removal. Use new stop nuts
Door Actuation Length Adjustment

The outer push-pull rods for the upper doors are attached to the resp. door front
section. For adjusting LH resp. RH push-pull rod, loosen upper and lower
locknut and turn threaded rod. Re-tighten and torque locknuts with
4 Nm ± 0.2 Nm (35.4 inch.lbf. ± 1.8 inch.lbf.). Perform gear up procedure
(refer to Subject 32-31-01) and check that doors are closing correctly. Repeat
adjustment as necessary.
32-10-22 Lower Doors
GEAR-CTRL.
1 Remove the clevis pin from hinge joint of
the lower door

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2 Remove the bolts, stop nuts and washers Hold the door
from the hinge
3 Remove the lower door

The inner push-pull rods for the lower doors are located about half door length
below the wheel well. For adjusting LH resp. RH push-pull rod, loosen upper
stop nut LN 9348-06 and turn threaded rod. Re-tighten and torque upper stop
nuts with 6.5 Nm ± 0.3 Nm (57.5 inch.lbf. ± 2.5 inch.lbf.).
Detach the upper doors to prevent them from damage during the
CAUTION following test in case the adjustment is not yet correct. Remove the bolt
from the push pull rod upper door. Lift upper door and fasten with tape.
Perform Gear Up Procedure (refer to Subject 32-00-00) and check that doors
are closing correctly. Repeat adjustment as necessary. Reattach upper doors.
NOTE Do not re-tighten lower stop nuts, but leave nuts ¼ - turn unlocked. This
will allow threaded rods to turn in case both doors are not actuated evenly,
thus reducing tension in the actuation mechanism.

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32-20-00 NOSE GEAR AND DOORS
Description
Two trunnion bolts attach the nose gear oleo leg strut to the engine mounting.
The nose strut, using an oleo-hydraulic shock absorber, is operated by a
hydraulic actuator and retracts aft in the nose gear compartment. In case of
hydraulic system failure, the nose gear extends by two gas pressurized springs
against air loads. A ground safety switch, located at the drag brace of the nose
gear, prevents accidental nose gear retraction during ground operation.
In flight the nose doors fair the nose gear strut.
32-20-10 Nose Gear Strut Assembly
Description
The nose gear consists of the following parts (see Figure 32-5)
• Trunnion
• Drag brace
• Steering arm assembly
• Oleo leg (upper and lower strut)
• Torque link
• Shimmy damper assembly
The trunnion assembly carries the drag brace and the steering arm assembly.
The support tubes and tubes for the RH and LH pivot bearings are welded to
the trunnion.
The upper strut of the Oleo leg fits inside the trunnion.
The torque link is bolted to the upper strut and the lower strut of the Oleo leg.
It prevents the lower strut from turning inside the upper strut.
The drag brace is attached to the trunnion and the engine mounting. It locks
the extended Oleo leg. In case of hydraulic system failure, the drag brace is
locked in extended position by two gas pressurized springs, which are pivoted
at the upper part of the drag brace.
The shimmy damper assembly dampens lateral moving of the nose gear while
taxiing. It is attached to the trunnion.

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Side View Gas pressurized springs
Shimmy damper
Hydraulic actuator
Trunnion
Nose gear extended

Upper strut switch
Oleo leg
Ground safety switches

Drag brace
Torque link (upper and lower part)
Lower strut
Wheel
Figure 32-5 Nose Gear

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32-20-20 Nose Gear Doors
Description
The carbon fibre nose gear doors are attached to the fuselage by aft and
forward door hinges. The nose gear doors are operated by the nose gear door
actuation mechanism, which is linked to the trunnion (refer to Figure 32-6).
The actuation mechanism consists of the following parts:
• Spring
• Telescope guide rod
• Push-pull rod (one each side)
• Two-armed rocker lever incl. stop
The doors are closed in the last part of the nose gear retraction phase. Then the
telescope guide rod is fully extended and begins to drive the actuation
mechanism. The spring presses the rocker lever against the stop thus keeping
the actuation mechanism in the over-centered position and the doors open.

The push-pull rods for the nose gear doors are attached to the resp. door front
section. For adjusting LH resp. RH push-pull rod, loosen upper and lower
locknut and turn threaded rod. Re-tighten and torque locknuts with
4 Nm ± 0.2 Nm (35.4 inch.lbf. ± 1.8 inch.lbf.). Perform gear up procedure
(refer to Subject 32-31-01) and check that doors are closing correctly. Repeat
adjustment as necessary.

fwd
Figure 32-6
Stop
Spring
Telescope guide rod

Nose gear
retracted switch Two-armed rocker lever
Nose Gear Doors Actuation Mechanism

RH nose gear door
Push-pull rod
32
Movement when retracting
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32-30-00 EXTENSION AND RETRACTION

Description
Refer to Figures 32-7 and 32-8. Extension and retraction of main gear and nose
gear is controlled by hydraulic actuators. The main landing gear doors are also
hydraulically actuated. Nose landing gear doors are mechanically linked to the
trunnion of the nose gear. The equipment for extension and retraction consists
of the following components:
1 Hydraulic system components with the items:
a Power pack, consisting of:
Hydraulic pump with geared electric motor
By-pass valve
Strainer
Reservoir
b Distributor block, consisting of:
3 directional valves
Pressure switch
Diaphragm pressure accumulator
2 Hydraulic actuators for gears and doors
4 Main gear actuators (1 short actuator and 1 interlocking actuator each side)
2 Actuators for upper doors
Actuator for lower doors
Nose gear actuator
3 Hydraulic lines
Part 1 Gear actuation
Part 2 Main gear lower and upper doors actuation
Part 3 Power supply
4 Torque link and track rods
5 Drive mechanism nose doors
The hydraulic power pack together with the distributor block provide the
landing gear system as well as the respective landing gear doors with a flow of
pressurized hydraulic fluid (operation-pressure 100-120 bar/1,450-1,740 PSI).
Hydraulic pressure is maintained throughout ground and flight operation as
long as the electric battery bus is powered. An external, adjustable pressure
switch, mounted to the distributor block, cuts off electric power as soon as
120 bar (1,740 PSI) are reached. The pressure switch will return power to the
hydraulic pump when pressure drops below below 100 ± 5 bar (1,450 ± 2.5
PSI). As an additional safety device the equipment chassis of the power pack
carries a pressure relief valve which will open the bypass above the pump once
the pressure would exceed 130 bar (1,885 PSI). The hydraulic power pack with
pump, strainer and reservoir as well as the distributor block with control valves
and pressure switch are built into the hydraulic power compartment in front of
the main gear attachment frame between the keelbeams.

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The hydraulic fluid level can be checked any time by means of an inspection
glass on the hydraulic power pack reservoir, visible behind an opening in the
keelbeam. It is accessible from the R/H main wheel bay. Just above the L/H
side of the inspection glass is the filling cap for the hydraulic fluid.
A small nitrogen diaphragm accumulator is used to eliminate the necessity of
frequent hydraulic pack activation due to small internal system leakage. This
accumulator is located underneath the passenger cabin floor within the
pressurized (and heated) vessel to avoid embrittlement of the diaphragm during
high altitude low temperature operation.
A yellow HYDRAULIC PUMP caution light is included into the annunciator
panel, which indicates hydraulic pump activity and normally shall illuminate
for not more than 2 or 3 seconds after periods of several minutes of rest, or
during landing gear operation. (See Subject 32-00-00 Leaks and Accumulator
Function Test.) If longer constant pump action or shorter periods of rest are
observed, refer to Troubleshooting Paragraph in this Chapter. Prolonged pump
operation for more than 2 minutes will cause pump or electric motor to
overheat.
The distributor block is equipped with three solenoid directional control valves
and the pressure switch. The hydraulic fluid is directed by the control valves;
these are spring loaded and will automatically switch into the gear down
position once electric power is lost. However, when selecting LANDING GEAR
DN, de-energizing the main gear control valve is slightly time delayed by
means of a capacitor. This allows the main gear doors to open first (to prevent
contact to the main landing gear strut).
The hydraulic system is separated in three circuits to actuate the respective
devices:
1 Extension/retraction of main gear and nose gear
2 Opening/closing of the lower main gear doors
3 Opening/closing of the upper main gear doors
The main and nose gear struts and doors are separately actuated by hydraulic
cylinders. Two hydraulic actuators drive each main gear strut. One of the
cylinders (the interlocking actuator) is designed to carry the breaking loads and
has a mechanical locking mechanism.
The torque link rod tows and unlocks the drag brace when the actuators start
retracting. It shortens the main gear strut while retracting to fit it into the wheel
bay. The track rods turn and push the coupled axle bar together with its wheel
forward to drive it into the wheel bay.
The nose gear strut is driven by one hydraulic actuator. For emergency
extending the nose gear strut is equipped with two gas pressurized springs.
They push the nose gear out in case of hydraulic system failure. The nose gear
has a positive downlock by an overcenter device (drag brace).
The upper main gear doors are driven by a hydraulic actuator each. The lower
main gear doors are driven by one common hydraulic actuator. The nose gear
doors are positively guided by the nose gear strut.
All parts of the hydraulic system are hydraulically connected by lines. They
consist of aluminum tubes and braided reinforced Teflon hoses. The actuators
are connected by the Teflon hoses.
Page Date: 9.
30.August
March2013
2012 32 Page 33
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GEAR WARN MUTE L/N/R DOWN

Three Green Lights
GEAR AUX 1 Circuit Breaker
Gear Warning
Circuit Board
GEAR AUX 2 Circuit Breaker
GEAR CTRL Circuit Breaker Gear Warning Horn
HYDR Circuit Breaker Annunciator Panel
Landing Gear Switch

Ground Safety Switch
Diaphragm
Accumulator
Hydraulic Pump
(driven by electric motor)
Reservoir
Limit
Valve Switch(es)
Main Gear Lower Doors
Limit
Valve Switch(es)
Main Gear Upper Doors
Limit
Valve Switch(es)
Main Gear Struts and

Nose Gear Strut & Doors
Legend:
Electrical Wiring Diode
Hydraulic Lines Capacitor Hydraulic Cylinder(s)
Figure 32-7 Landing Gear Schematic
Page 34 32 Page Date: 9. August

30. 2013
March 2012
fwd
Figure 32-8
Short actuator
Piston rod end

LH main gear
Main Gear Actuators

Lower door
Torque link rod

Interlocking actuator
Upper track rod
Lower track rod
32
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32-30-10 Hydraulic System
Bleeding
This procedure describes bleeding the hydraulic system by operating the
landing gear and then refilling hydraulic fluid. Follow this procedure when
smaller works with little loss of hydraulic fluid have been performed on the
hydraulic system such as removal and installation procedures of single
components. Generally, when hydraulic lines have been plugged during these
procedures and the respective components have been pre-filled with hydraulic
fluid before reinstallation this bleeding procedure shall be sufficient.
GEAR-CTRL.
Hydraulic fluid can cause disease!
WARNING
Do not allow hydraulic fluid to come in contact with your skin.
Hydraulic fluid can damage paint and other material!
CAUTION
Clean up immediately spilt hydraulic fluid.
1 Lift the aircraft on jacks. Chapter 07-10-00
Upper landing gear doors will close immediately, when BATT or
DANGER EXTR PWR switch is turned to ON and GEAR-CTRL circuit breaker is in.
Make sure, that neither a person nor any object is located in the upper
landing gear doors travel area.
2 Turn BATT and EXT PWR switch ON.
3 Push circuit breaker GEAR-CTRL in.
gear travel area.
4 Operate the landing gear:
1 Retraction cycle
1 Extension cycle
5 Turn BATT and EXT PWR switch OFF.
7 Check hydraulic fluid level; if necessary, Use MILH5606 Hydraulic
refill hydraulic fluid until the oil level just Fluid
covers the center line of the gauge glass.

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NOTE Pay attention to noise in the restrictor nozzles to localize trapped air in
the system.
Drive maximum 5 cycles; then allow power pack to cool down.
CAUTION
8 Repeat steps 2 to 7, until correct fluid level
remains constant.
9 Remove the tape from RH upper door and
re-install the bolt to the push pull rod.
Hydraulic Fluid Change

GEAR-CTRL.
WARNING
CAUTION
1 Lift the aircraft on jacks Chapter 07-10-00
2 Remove the hydraulic power pack Refer to Chapter 32-30-11
3 Clean hydraulic power pack and filter. Refer to Chapter 32-30-11
Cleaning
4 Remove the oil vent plug from the
reservoir.
5 Refill hydraulic fluid through vent plug Use MILH5606 Hydraulic
opening of the reservoir up to maximum Fluid
level.
6 Plug a temporary breather hose (diameter 6
mm/1/4 inch) with fitting into the vent plug
opening.
7 Re-install the hydraulic power pack. Let Refer to Chapter 32-30-11
upper RH door in lifted position. Removal/Installation omitting
steps 2 and 3.

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8 Lead breather hose through free opening in
keel beam to RH access compartment in
front of main wheel bay
During gear retraction, high pressure oil jet from the return line
WARNING damages eyes and limbs!
Cover return line in the sump with mesh gate to retain spilling fluid.
Upper landing gear doors will close immediately, when BATT or
DANGER EXT PWR switch is turned to ON and GEAR-CTRL circuit breaker is in.
8 Turn BATT and EXT PWR switch ON (left side panel, toggle switch)
9 Push circuit breaker GEAR-CTRL in (left side panel)
10 Pull and move LANDING GEAR switch UP
(left main panel, below RH side of control
yoke)
NOTE Assure adequate fluid volume to avoid trapped air in the system
11 Refill reservoir through breather hose with read out 1100 cm (67 cu in)
hydraulic fluid up to maximum level. or refill until fluid runs out
13 Turn BATT and EXT PWR switch OFF. When landing gear is down
and locked.
15 Remove breather hose.
16 Screw the oil vent plug to the reservoir.
17 Remove the tape from RH upper door and
re-install the bolt to the push pull rod
18 Return aircraft to normal observing
respective procedures and warnings.

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32-30-11 Hydraulic Power Pack
GEAR-CTRL.
power connected.
2 Remove the aft keel beam access panel. Refer to Chapter 51-00-01
upper door RH.
4 Lift the upper door RH and fasten it by
means of a tape.
5 Disconnect the electric power supply from
the hydraulic power pack.
WARNING
CAUTION
Clean up immediately spilt hydraulic fluid
6 Disconnect the hydraulic lines from the inlet Refer to Chapter 32-30-30
and outlet fitting of the hydraulic power
pack.
7 Install blind plugs to the disconnected lines
to avoid trapped air in the system.
NOTE For identification, tag each hydraulic line. The line connecting the sump
to the hydraulic pump is identified as return line, the line leading
directly to the control valve is the pressure line.
8 Remove 2 attachment bolts of the power Hold unit
pack.
9 Drain the hydraulic fluid
11 Perform Bleeding procedure. Refer to Subject 32-30-10

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Cleaning
This procedure describes cleaning the interior of the hydraulic power pack and
the incorporated suction filter. It is assumed that the hydraulic power pack is
removed from aircraft.
1 Place the power pack in upright position. Electric motor up
2 Remove the 4 bolts from the reservoir sump Catch spilling hydraulic fluid
3 Remove the hydraulic power pack from the
reservoir.
4 Pour hydraulic fluid of the reservoir
completely in an external suitable container.
5 Clean the inside of the reservoir sump from By means of lint-free rags
sludge
6 Pull off the suction filter from the suction
line
7 Dry and clean the suction filter carefully By means of lint-free rags
8 Place the hydraulic power pack to the Check the sealing ring for
reservoir. proper arrangement
9 Reinstall the 4 reservoir attaching bolts.
10 Refill hydraulic fluid. Use MILH5606 Hydraulic
Fluid 1100 cm (67 cu in)
32-30-12 Distributor Block
GEAR-CTRL.
power connected.
3 Remove the bolts from the push pull rods of
the upper doors.

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4 Lift the upper doors and fasten them by
means of a tape.
5 Disconnect the electrical plug of the control
cables from the directional valves and from
the pressure switch.
WARNING Do not allow hydraulic fluid to come in contact with your skin.
CAUTION Clean up immediately spilt hydraulic fluid.
6 Remove the hydraulic lines from the fittings Chapter 32-30-30
of the distributor block.
8 Remove the bolts, washers and spacer Hold the unit
sleeves from the distributor block.
9 Remove the distributor block-
10 Drain the hydraulic fluid of the distributor
block in a sump.
11 Cover all hydraulic inlets and outlets by
plastic caps.
1 Cut off the safety wire on the top side of the
directional valves.
2 Remove the Allen bolts and lock washers
from the directional valves.
3 Remove the directional valves from the Valve solenoids are “spot”
distributor block. connected to each other with
silicone.
Catch the O-ring from the
directional valves
4 Unscrew and remove the pressure switch Catch the O-ring from the
from the distributor block. pressure switch
5 Remove the nipples and elbows from the
distributor block.

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NOTE Sign the elbows with a tag to ensure re-assembly at the original position
on the distributor block. The original position is required for the proper
fitting and mounting of the distributor block on its place between the
keel beams.
6 Install in reverse sequence of removal. Lock up the Allen bolts of the
directional valves by safety
wire and “spot” fix solenoids
with Elastosil E14, GE RTV
159 or equivalent
32-30-20 Actuators
32-30-21 Main Gear Actuators

Each side of the main landing gear is driven by two hydraulic actuators (see
Figure 32-8):
• Short actuator
• Interlocking actuator
The following procedure applies for both actuators. However the interlocking
actuator has to be unlocked before removal as described in step 6.
GEAR-CTRL.
upper doors.
3 Lift the upper doors and fasten them by
means of a tape.

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WARNING
CAUTION
4 Remove the hydraulic lines from the Chapter 32-30-30
hydraulic actuator fittings.
CAUTION doors.
Before removal of bolts and nuts, notice their position.
6 (interlocking Momentarily apply shop air to the fitting at To release the down locked
actuator only) the rod end side of the hydraulic cylinder. position.
7 Remove the bolt, the stop nut and the
washers between the rod end of the
hydraulic actuator and the main gear strut
assembly.
8 Remove the bolt, the stop nut and the Hold the hydraulic actuator
washers between the cylinder side of the
hydraulic actuator and the bracket on the
keel beam.
9 Remove the hydraulic actuator.
10 Measure the fully extended actuator length.
12 Check actuator for length. Set the fully extended length
to the previously measured
length.

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32-30-22 Upper Doors Actuator
GEAR-CTRL.
WARNING
CAUTION
1 Remove the respective front fuselage access Refer to Chapter 51-00-01
panel.
of the hydraulic actuator.
washers between the rod end of the
hydraulic actuator and the torque tube.
5 Remove the cotter pin from the clevis pin
6 Remove the washer and clevis pin between Hold the hydraulic actuator
the cylinder side of the hydraulic actuator
and the support
7 Remove the hydraulic actuator
8 Remove the bolts, the stop nuts and the
washers between the torque tube and the
cardan joint
9 Remove the torque tube
10 Remove the bolts, the stop nuts and the Hold the cardan joint
washers between the cardan joint and the
shaft
11 Remove the cardan joint
12 Remove the bolts, the stop nut and the Hold the push pull rod
washers from the push pull rod
13 Remove the push pull rod

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washer from the lever
15 Pull off the lever from the shaft
16 Pull out the shaft of the bearing
17 Remove the collar bushing
32-30-23 Lower Doors Actuator
GEAR-CTRL.
WARNING
CAUTION
3 Remove the cotter pins from the clevis pins
on the hydraulic actuator.
4 Remove the clevis pin between the rod end
of the hydraulic actuator and the actuator
lever.
5 Remove the clevis pin between the cylinder Hold the hydraulic actuator
side of the hydraulic actuator and the
support.

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6 Remove the hydraulic actuator
7 Remove the cotter pins from the clevis pins
on the hinge joints
8 Remove the clevis pins and the washers
from the hinge joints
9 Remove the hinge joints
washers between the actuator lever and both
torque tubes
11 Pull out the torque tube LH of the actuator Hold the actuator lever
lever and the bearing
12 Remove the actuator lever from the torque Hold the torque tube
tube RH
13 Pull out the torque tube RH of the bearing
14 Remove the collar bushing from the keel
beams
32-30-24 Nose Gear Actuator
electric circuit breakers located on the left side panel and marked
GEAR-CTRL.
WARNING
CAUTION

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washer from the rod end of the hydraulic
actuator.
5 Remove the bolt, the stop nut and the Hold the hydraulic actuator
washer from the cylinder side of the
hydraulic actuator.
6 Remove the hydraulic actuator.
7 Measure the fully extended actuator length.
9 Check actuator for length. Set the fully extended length
to the previously measured
length.
32-30-25 Nose Gear Gas Pressurized Springs
GEAR-CTRL.
Preload of the gas pressurized spring damages limbs!
WARNING
2 Remove cotter pin, washer and castle nut Counteract spring forces at
from the connection between drag brace and lower drag brace.
trunnion.
3 Remove the bolt (AN 6) from the drag brace Slowly move down drag
sheathing at trunnion. brace and thus release gas
spring.

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4 Remove the cotter pin and the outside
washer from the clevis pin on the rod end of
the gas pressurized springs.
5 Remove the cotter pin, washer and castle nut
on the cylinder side of the gas pressurized
springs.
6 Remove the bolt of the gas pressurized
springs.
7 Remove the gas pressurized springs.
Test Procedure
NOTE Landing gear must remain extended for testing.
Landing gear extends and retracts under high pressure. Operation of the
DANGER landing gear can cause death or injuries in its working area! Make sure,
that neither a person nor any object is located in the landing gear travel
area.
2 Turn BATT switch OFF.
Ensure external power is not connected.
4 Attach a strap connecting both main gear legs.
5 Attach a strap on the nose-wheel axis.
6 Connect the nose-wheel strap with the main Tensiometer: 100- 120 N,
gear strap using a tensiometer. (1 N resolution and accuracy)
7 Pull the nose gear back while manually With the ratchet of the strap
unlocking the drag brace. Set the nose gear at (242 mm nose gear axle
20 degrees retracted.
travel; the upper part of the
drag brace should be
horizontal)
8 Pull the nose gear back by hand another
100mm and release slowly to the 20 degree
position.
9 Read the strap tension; depending on the Refer to Minimum Tension
temperature, the tension should be at least as Forces table
depicted in the table below.
10 If tensiometer reads lower than applicable
chart value:
a With actuators and springs disconnected,

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check trunnion bearing and drag brace
bearings for excessive friction.
b Check for freedom of excessive friction or
jamming after connecting the locking strut to
the nose gear leg.
c Replace both gas-pressurized springs if lack
of extension force is not caused by friction.
11 Release nose gear, ensure nose gear is locked,
remove straps and put aircraft back to normal.
Minimum Tension Forces

Temperature Tension Temperature Tension
[°C] [N] [°F] [lbs]
0 105 32 24
10 108 50 24
20 113 68 25
30 116 86 26
40 120 104 27
32-30-30 Hydraulic Lines
Description
The hydraulic devices are connected by aluminum tubes and PTFE hoses.
All actuators are generally connected by flexible PTFE hoses:
• The main gear actuators and the nose gear actuators are connected by PTFE
hoses size 04.
• The upper and lower door actuators of the main gear are connected by PTFE
hoses size 03.
The supply systems, the hydraulic power pack and the hydraulic control unit
are connected by aluminum tubes and PTFE hoses:
• The connection from the hydraulic control unit to the respective main gear
actuator, up to the tee type or cross type fitting on the keel beam, is composed
of aluminum tube size 04.
• The connection from the hydraulic control unit to the upper door actuators of
the main gear, up to the tee type fitting between the keel beams, is composed of
aluminum tube size 03.
• The connection from the hydraulic control unit to the nose gear actuators, up to
the elbow fitting on the keel beam, is composed of PTFE hose size 04. From

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the elbow fitting to the tee type fitting in the nose gear compartment the
connection is composed of aluminum tube size 04.
• The connection from the hydraulic control unit to the lower door actuator of
the main gear is composed of PTFE hose size 03.
• The connection from the hydraulic control unit to the hydraulic power pack is
composed of PTFE hoses size 04.
The hydraulic system is separated in three circuits to actuate the respective
devices:
1 Extension/retraction of main gear and nose gear
2 Opening/closing of the lower main gear doors
3 Opening/closing of the upper main gear doors
32-30-40 Torque Link Rod and Track Rods
This procedure applies for all kind of rods used in the landing gear.
1 Lift the aircraft on jacks Chapter 07-10
GEAR-CTRL.
CAUTION doors.
washers connecting the respective rod to the
main gear strut assembly.

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32-30-50 Drive Mechanism Nose Doors
GEAR-CTRL.
CAUTION doors.
1 Remove the bolts, the stop nuts and the Hold the push pull rod
washers from the push pull rods.
2 Remove the push-pull rods.
3 Remove bolts of telescope guide rod.
4 Remove telescope guide rod.
5 Remove bolt of nose gear door spring.
6 Remove nose gear door spring.

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32-40-00 WHEELS AND BRAKES
Description
The nose gear and the main gear struts have single wheels carrying low-
pressure tube-type tires.
The nose wheel has a 5.00-5, ply. 6 tire with an inner tube. The nose wheel hub
has two aluminum alloy halves. Three bolts hold the halves together.
The main wheels, being similar constructed as the nose wheel, have 15x6.00-6
tube tires.
Each main wheel hub carries a hydraulically actuated single-disk brake on the
inside. The toe-brake pedals on the rudder pedals operate the brakes by the
hydraulic master cylinder. Hydraulic lines and hoses are routed from each
master cylinder to the wheel cylinder on each brake assembly. The brakes can
be actuated from either the pilot's or copilot's seat.
The parking brake valve system consists of a manually operated control
assembly located on the middle console and connected to the parking brake
valve. Applying pressure to the brake system by pressing the toe pedals and
pulling the parking brake control sets the parking brake. Pushing the parking
brake control forward releases the brakes.
Do not set the parking brake when brakes are overheated after heavy
CAUTION braking or when outside temperatures are unusually high. Trapped
hydraulic fluid may expand with heat and damage the system.
32-40-01 Main Wheels
1 Lift the aircraft on jacks. Chapter 07-10
electric circuit breakers located on the left side panel and marked
GEAR-CTRL.
handling, make sure that neither a person nor any object is located in
The inflated tube tenses the wheel rim construction!
WARNING
Before working deflate the tire by the valve completely.
2 Remove the brake without disconnecting the Refer to Subject 32-40-03
brake hose. omitting steps 2 and 3

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3 Remove the cotter pins from the hub nut.
4 Remove the hub nut.
5 Remove the rim from the main gear strut.
6 Remove the stop nuts and the washer from
the bolts.
7 Remove the bolts from both wheel halves
and the brake disk.
8 Remove both wheel halves from the tire.
9 For removing of the cup and cone bearing in
both wheel halves perform as described in
Cleveland Maintenance Manual.
10 Remove the tube from the tire.
32-40-02 Nose Wheel
GEAR-CTRL.
handling, make sure that neither a person nor any object is located in
The inflated tube tenses the wheel rim construction!
WARNING
Before working deflate the tire by the valve completely.
2 Remove the cotter pin on one side of the
through bolt.
3 Remove the castle nut and the washer from
the through bolt.
4 Remove the through bolt from the rim nose
gear.
5 Remove the spacer sleeves from the rim. Hold the rim
6 Remove the axle from the rim.

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the bolts.
8 Remove the bolts and the washer from both
wheel halves.
both wheel halves perform as in Cleveland
Maintenance Manual described.
32-40-03 Brake
GEAR-CTRL.
handling, make sure that neither a person nor material is located in the
landing gear working area.
Brake fluid can cause disease!
WARNING Do not allow brake fluid to come in contact with your skin.
CAUTION Clean up immediately spilt brake fluid.
2 Disconnect the brake hose from the elbow Catch the brake fluid. Put
fitting of the brake. caps on the opened lines and
fittings
3 Install blind plug to the disconnected line to
avoid trapped air in the system.
4 Cut off the safety wire on the bolts.
5 Remove the bolts from the brake.
6 Remove the brake from the axle bar. Fasten the brake at the main
gear strut with a tape to
protect the brake hose

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7 Remove the cotter pins from the hub nut.
8 Remove the hub nut.
9 Remove the rim from the main gear strut.
the bolts.
11 Remove the bolts from both wheel halves
and the brake disk.
both wheel halves perform as described in
Cleveland Maintenance Manual.
16 Bleed the brake line.

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32-50-00 STEERING
Description
The EXTRA 500 has a controllable nose wheel. The steering arm of the
extended nose wheel is linked to the rudder pedals by springs and control
cables. The control cables are tightened by additional springs (mounted
beneath the shelf) to prevent them from coming-off from the pulley.
Nose gear retraction automatically disengages the steering mechanism from the
nose wheel. The steering arm aligns the nose wheel for entry into the wheel
bay and, during flight, fixes it in the center nose of the guide block.
Nose wheel steering is accomplished through the use of the rudder pedals.
Pushing on one rudder pedal steers the aircraft to that side. The maximum nose
gear turning angle is 300 to either side while taxiing. During standstill the
rudder pedals control only the rudder.
Removal/Installation of the steering control cable is described in Chapter 27
Flight Controls.

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32-60-00 POSITION AND WARNING
Description
The LANDING GEAR switch is located on the L/H instrument panel and has the
positions UP and DN for retracting and extending the landing gear. It is
necessary first to pull out the selector switch handle prior to moving it up or
down. The switch is fitted with a small wheel for easy identification and
assisting in moving the switch in rough air.
The downlock information, for each wheel separately, is given by three green
lights located near the LANDING GEAR switch. The red GEAR WARN light on
the annunciator panel indicates that the landing gear is not completely retracted
or extended.
The entire electric control processes signals from limit switches, indicating the
completion of actions of the respective hydraulic circuits, and from the landing
gear switches.
In emergency case it can be deactivated by pulling the GEAR-CTRL circuit
breaker. The directional valves are spring-loaded and will automatically switch
in the GEAR DOWN position once electrical power is lost. As long as the
LANDING GEAR switch is in DN-position the gear downlock indication will still
be operative, however the prescribed reclosing of the upper main doors will not
happen.
A warning horn is furnished on the EXTRA 500 in combination with the red
GEAR WARN light on the annunciator panel to caution the pilot against landing
with the landing gear being retracted. A respective acoustic warning signal is
heard on the headphones simultaneously.
Firstly, the warning light and horn will be activated in case of the landing gear
being still retracted, while engine torque is below 35 % for descent or landing
approach and with wing flaps being in 0°- or 15°- position. If landing is not
intended pressing the gear warning mute button located on the left side of the
power lever will switch off the horn and the warning light.
Secondly, if engine torque is below 35 % for normal landing approach and
wing flaps are in landing position (30°), the warning light will illuminate and
the warning horn will sound independently from the gear warning mute button
until the landing gear will be completely extended. The function of the red
GEAR WARN light and the aural warning can be tested switching the
NIGHT/DAY switch on the left side panel to the TEST position.
Separate position switches monitor the landing gear struts and doors:
• Extending and retracting of each main gear strut and the nose gear strut
• Opened and closed position of the upper and lower main gear doors
Generally micro switches are used.
During ground operation, a ground safety switch prevents accidental gear
retraction by disconnecting the main valve from DC, regardless of LANDING
GEAR switch position. It is located on the nose landing gear just above the
torque link.

Maintenance Manual
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fwd
Main gear retracted switch

Main gear attachment frame
Main gear extended switch
Undercarriage leg
Torque link rod
Figure 32-9 Main Gear Switches (LH)
32-60-01 Main Gear Extended Switches

The main gear extended switches are located on the undercarriage leg of the
LH and RH main gear as shown on Figure 32-9.
32-60-02 Main Gear Retracted Switches

The main gear retracted switches are located at the main gear attachment frame
next to the upper torque link attachment as shown on Figure 32-9.
When the left and right gear retracted switches are reached, the upper door
valve is powered to close the upper doors. The closing of the upper doors then
causes the two upper door closed switches (see below) to power the lower door
valve, which closes the lower doors.

Maintenance Manual
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The closed upper doors are held in place not only by hydraulic power, but also
by the lower doors overlapping them. Therefore the upper doors need to be
closed first.
32-60-03 Upper Main Door Opened Switch

The upper door opened switches are operated by the rod of the hydraulic
actuator upper door.
When the upper main doors are fully opened, the two upper main door opened
switches will power the main valve which will retract the main gear strut.
32-60-04 Upper Main Door Closed Switch

The upper main door closed switches are operated by the rod of the hydraulic
actuator upper door.
32-60-05 Lower Main Door Closed Switch

The lower main door closed switch is operated by the actuator lower door,
opening circuit when the lower doors are closed completely.
After all doors are closed the door closed switches upper/lower door cut off the
power from the gear in-transition information. In case of wheel bay doors
being opened during flight due to reduced system pressure, the gear in-
transition information will warn the pilot from abnormal system state by the
red gear warning light in the instrument panel. At the same time the hydraulic
pump will be activated to reclose the door accordingly.
32-60-06 Ground Safety Switch

The function is realized by two switches. They are installed on the nose gear
just above the torque link (refer to Figure 32-5).
32-60-07 Nose Gear Extended Switch

The nose gear extended switch is mounted to the nose gear drag brace and is
operated when the drag brace is in the over-centered position. It controls the
green nose gear downlock light in the instrument panel (refer to Figure 32-5).

Maintenance Manual
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32-60-08 Nose Gear Retracted Switch

The nose gear retracted switch is located in the front part of the nose gear
wheel well (refer to Figure 32-6) and operated by a bracket attached to the
trunnion. It is used for the red GEAR WARN light to signal if the nose gear is
fully retracted or not.
32-60-09 Operation and Indication

The operation and indication assembly has the following components:
Indication lights - Gear extended (three greens)
LANDING GEAR switch
Annunciator light – GEAR WARN
Annunciator light – HYDRAULIC PUMP

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Chapter 33
Lights

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Table of Contents
33-00-00 GENERAL ........................................................................................................ 3

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

Description.......................................................................................................... 4
33-20-00 PASSENGER COMPARTMENT................................................................... 5

Description.......................................................................................................... 5
33-40-00 EXTERIOR ....................................................................................................... 6

Description.......................................................................................................... 6
33-40-01 Wing Tip Navigation/Strobe Lights ................................................................ 6
33-40-02 Tail Navigation/Strobe Light ........................................................................... 7
33-40-03 Strobe Light Power Supply (Wing)................................................................. 7
33-40-04 Strobe Light Power Supply (Tail) ................................................................... 8
33-40-05 Landing Light ................................................................................................... 9
33-40-06 Recognition Light ............................................................................................. 9

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33-00-00 GENERAL
Description
The EXTRA 500 is equipped with lights in the flight compartment for proper
instrument and label reading in reduced ambient light conditions. The
passenger compartment is also lighted for passenger comfort, but those lights
can be switched off by the pilot at any time for safety reasons. External lighting
is provided to ‘see and to be seen’.

Maintenance Manual
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Description
The cockpit is lighted with the following lights:
• Instrument lights, including switches backlighting
• Lights in the glareshield
• Two dome lights in the ceiling
• Two map lights in the ceiling
• And for emergencies a flash light behind the co-pilot seat
The instrument lights, switches backlighting, annunciator lights, lights in the
glare shield and keypad/IFD backlighting are all dimmable by their respective
potentiometer on the instrument panel.
Dimming is activated by the NIGHT/DAY switch in the left side panel. The
instrument lights and switches backlighting (INSTR), glareshield lights
(GLARE), and the map lights (MAP) have their individual switches on the left
side panel.
The dome light switch is located adjacent to the dome light.

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33-20-00 PASSENGER COMPARTMENT
Description
The passenger compartment lighting consists of:
• Ambient lighting on the central air-conditioning channel
• A reading light for each passenger in the side walls
These can be switched on and off by the passenger individually, but the CABIN
LIGHT switch in the left side panel has priority to switch all passenger lighting
off.

Maintenance Manual
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33-40-00 EXTERIOR
Description
Exterior lights consist of:
• Strobe lights at the wing tips and the fin tip (also refer to Whelen Anti-
Collision Light Systems Installation and Service Manual, LOAP 43)
• Navigation lights at the wing tips
• Landing light in the lower RH cowling
• Two recognition lights, also used for taxiing, installed in the wing leading edge
on both sides.
• Ice light (described in Chapter 30-80-01)
Each light (-group) has its own switch and circuit breaker in the left side panel
(CABIN/CABIN-LT, RECO/RECO-LT NAV/NAV-LT, LDG/LDG-LT).
The strobe light power supply for the wing mounted strobes is installed in the
wing nose, just right of the forward-middle wing compartment. The tail power
supply is installed in the vertical tail tip.
33-40-01 Wing Tip Navigation/Strobe Lights
High voltage can cause injuries!
WARNING
Let power supply stand for 5-10 minutes after disconnecting from power
source to allow power to bleed off capacitors before beginning any work
on the strobe light systems. Even after 5-10 minutes, care should be
taken when handling components as electrical shock can result.
1 Pull the STROBE-LT circuit breaker. Let power supply stand for 5-
10 minutes.
2 Also pull the NAV-LT circuit breaker.
3 Remove the Phillips screws from the wing Hold the wing tip glass cover
tip glass cover.
4 Remove the wing tip glass cover
5 Remove the lens retainer mounting Phillips
screw and retainer.
6 Remove counter-sunk screws and base
assembly from wingtip.
7 Disconnect electrical connectors.

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33-40-02 Tail Navigation/Strobe Light
WARNING
10 minutes.
2 Also pull the NAV-LT circuit breaker.
3 Remove the retainer mask Phillips screws.
Remove the unit.
33-40-03 Strobe Light Power Supply (Wing)
WARNING
10 minutes.
2 Remove the wing center fairing. Refer to Chapter 51-00-01
3 Disconnect the electrical wiring of the
power supply
4 Disconnect the ground bonding lead

Maintenance Manual
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5 Remove the Phillips screws from the power
supply unit
6 Pull out the power supply unit and remove
from the attaching plate
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.
33-40-04 Strobe Light Power Supply (Tail)
WARNING
10 minutes.
2 Remove fin tip. Refer to Charter 55-30-01
3 Disconnect the ground bonding lead
4 Remove the Phillips screws from the power
supply unit
5 Pull out the power supply unit and remove
from the attaching plate
negative.

Maintenance Manual
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33-40-05 Landing Light
1 Pull LDG-LT circuit breaker.
2 Remove upper cowlings. Refer to Chapter 71-10-01/02
3 Remove external landing light glass. 8 screws
4 Remove landing light cover. 2 screws
6 Remove lamp with igniter. Retainer clip
7 Remove reflector with frame. 2 screws
33-40-06 Recognition Light
1 Pull RECO-LT circuit breaker.
2 Remove respective wing nose access panel. Refer to Chapter 51-00-01
3 Remove baffle with recognition light. 3 screws
5 Remove recognition light from baffle. 2 screws

Maintenance Manual
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Chapter 34
Navigation

Maintenance Manual
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Table of Contents
34-00-00 GENERAL ........................................................................................................ 5

Pitot/Static Pressure Systems.............................................................................. 5
Avionics .............................................................................................................. 5
Figure 34-1 Pitot Static System Schematic ............................................................................. 6
34-10-00 FLIGHT ENVIRONMENTAL DATA ........................................................... 7

34-10-01 Altimeter (2” type) ............................................................................................ 7
34-10-02 Airspeed Indicator (2” type) ............................................................................ 8
34-10-11 Pitot Head .......................................................................................................... 9
Removal/Installation (LH/RH Side) ................................................................... 9
Figure 34-2 Pitot Head ......................................................................................................... 10
34-10-12 Static Port ........................................................................................................ 10
Removal (LH/RH Side) .................................................................................... 10
Installation (LH/RH Side) ................................................................................ 11
Figure 34-3 Static Port ......................................................................................................... 11
34-10-13 Stall Warning Sensor...................................................................................... 12
Removal/Installation (LH/RH Side) ................................................................. 12
34-20-00 ATTITUDE AND DIRECTION.................................................................... 13

34-20-01 Attitude Indicator ........................................................................................... 13
34-20-02 Magnetic Compass .......................................................................................... 13
Bulb Replacement............................................................................................. 13
Compass Swing ................................................................................................ 13
34-40-00 INDEPENDENT POSITIONING DETERMINING .................................. 14

Description........................................................................................................ 14
34-40-01 TAS Processor ................................................................................................. 14
34-40-02 TWX Processor ............................................................................................... 15
34-50-00 DEPENDENT POSITIONING DETERMINING ....................................... 16

Description........................................................................................................ 16

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34-50-01 Transponder .................................................................................................... 16

34-50-02 DME Processor ................................................................................................ 16
34-50-03 DME Indicator ................................................................................................ 17

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34-00-00 GENERAL
Pitot/Static Pressure Systems

Providing pitot and static pressure for the pilot's and copilot's instruments two
independent systems are installed (refer to Figure 34-1). Each system consists
of a heated pitot head located at about 3/4 of the wing span, the tubing
including a drain and the respective instruments. The heated static ports are
located on both sides of the rear fuselage. The two toggle-type drains are
located at the fuselage underside, between the keel beams. They are accessible
by the forward keel beam access panel.
When the pitot heat switches are placed in the ON position, the heating
elements in the pitot heads and the static port for the autopilot are electrically
energized to maintain proper operation of the systems during icing conditions.
Normally, the heating elements can only be activated when airborne. On
ground the system is deactivated by the squat switch, which detects aircraft
being on ground.
For testing on ground, pitot heat switches provide a TEST position (momentary
ON).
In testing mode, do not operate pitot & static heat longer than 10 seconds
CAUTION to prevent overheating of the heating elements.
Care should be taken when an operational check of the heated pitot heads
WARNING is being performed on the ground. The units become very hot.
An additional static system is installed in the tail cone for the autopilot. The
static port is located on the lower aft part of the vertical stabilizer. The static
line is routed from there to the bottom of the tail cone compartment. There, on
the lowest point of the system a plugged hose serves as a drain. Remove the
plug for draining. The static line is further routed via T-fitting to the autopilot
Avionics
The EXTRA 500 is equipped with Avidyne Entegra equipment. Please refer to
Chapter 31. This chapter will deal with other avionics apart from Back-up
altimeter and airspeed indicator:
• Back-up attitude indicator
• Magnetic compass
• XPDR
• DME (option)
• TAS (option)
• TWX (option)
IMPORTANT Avionics service and repair work requires special skills, tools and test
equipment. In case of instrument failure or malfunction contact manu-
facturer or authorized service center.
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Figure 34-1
34
EXTRA 500
LH RH Autopilot
Maintenance Manual
white
blue green Transducer
red P550-5070
blue
white red red red white blue green
Pitot Static System Schematic

Back-up
LH IFD Back-up airspeed RH IFD
ADAHRS altimeter indicator ADAHRS
Pitot RH
Static port LH
blue
open red
red
green green
red blue
Cabin
altimeter
Static port RH
Pitot LH
red red Static port
white green
vertical tail

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34-10-00 FLIGHT ENVIRONMENTAL DATA

NOTE When any connections in the static system are opened for checking, a static
leak check per AC 43-6C §9a must be performed.
34-10-01 Altimeter (2” type)
Troubleshooting
Excessive scale error Improper calibration Contact manufacturer
adjustment
Excessive pointer oscillation Defective mechanism Contact manufacturer
High or low reading Improper venting Eliminate leak in static
pressure system
Setting knob is hard to turn Wrong lubrication or lack of Contact manufacturer
lubrication
Inner reference marker fails to Out of engagement Contact manufacturer
move when setting knob is
rotated
Setting knob set screw loose Not tight when altimeter was Tighten instrument screw, if
or missing reset loose. Contact manufacturer, if
screw is missing
Cracked or loose cover glass Case gasket hardened Contact manufacturer
Dull or discolored markings Age
Barometric scale and reference Slippage of mating parts Contact manufacturer
markers out of synchronism
Barometric scale and reference Drift in mechanism Contact manufacturer
markers out of synchronism
with pointers
Altimeter sticks at altitude or Water or restriction in static Remove static lines from all
does not change with change line instruments; blow line clear
of altitude from cockpit to static ports
Altimeter changes reading as Water in static line Remove static lines from all
aircraft is banked instruments; blow lines clear
from cockpit to static ports
Altimeter requires resetting Temperature compensator Contact manufacturer
frequently inoperative
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power connected.
2 Remove RH and LH IFD Refer to Chapter 31
3 Disconnect (red) static pressure hose
4 Remove altimeter 3 screws
5 Disconnect electrical connector
7 Perform Pitot/static check According to FAR 43,
34-10-02 Airspeed Indicator (2” type)
Troubleshooting
Pointer does not indicate Leak in instrument case, in Check for leak and seal
properly Pitot or static lines
Pointer of instrument oscillates Defective mechanism Replace instrument
Instrument reads high Pointer not on zero Replace instrument
Leaking static system Find leak and correct
Instrument reads low Pointer not on zero Replace instrument
Leaking Pitot system Find leak and correct
Airspeed changes as aircraft is Water in pitot line Remove line from all
banked instruments and blow out line
from cockpit to Pitot head
power connected.
3 Disconnect (red) static pressure hose and
(white) Pitot hoses
4 Remove airspeed indicator. 4 screws

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7 Perform Pitot/static check According to FAR 43,
34-10-11 Pitot Head

Removal/Installation (LH/RH Side)
power connected.
2 Remove outer wing access panel. Refer to Chapter 51-00-01
3 Disconnect plug from sensor heat element.
4 Disconnect Pitot pressure line nut.
5 Remove 4 Phillips screws from Pitot tube
shaft at bracket.
6 Remove Pitot tube from bracket downwards.

Maintenance Manual
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Pitot line
Nut
Bracket
Attachment screws
Pitot head
Figure 34-2 Pitot Head
34-10-12 Static Port

Removal (LH/RH Side)
power connected.
2 Remove tail cone access panel Refer to Chapter 51-00-01
3 Disconnect 2 static pressure hoses from
static port at LH/RH fuselage
4 Cut tie-wrap and wiring to heat element on
both sides of splice.

Maintenance Manual
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5 Remove static port fastening nut and strain
relief.
6 Remove static port Sensor is fitted with silicon
Installation (LH/RH Side)

power connected.
2 Install static port. Apply silicon between
outside part of sensor and
fuselage
3 Install strain relief and static port fastening Secure sensor fastening nut
nut with Loctite 243.
4 Re-establish splice at wiring to heat
element.
5 Fasten wiring with tie-wrap.
6 Connect 2 static pressure hoses to static port red upper, green lower
7 Install tail cone access panel Refer to Chapter 51-00-01
Wiring
Tie wrap
Strain relief
Static hoses
Nut
Static port
Figure 34-3 Static Port

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34-10-13 Stall Warning Sensor
Removal/Installation (LH/RH Side)

power connected.
2 Remove LH wing nose access panel. Refer to Chapter 51-00-01
4 Remove 4 bolts and nuts at sensor mounting
plate.
5 Remove sensor.

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34-20-00 ATTITUDE AND DIRECTION
34-20-01 Attitude Indicator

3 Remove attitude indicator. 4 screws
34-20-02 Magnetic Compass

1 Remove compass 2 screws
4 Make compass swing, if new unit is
installed.
5 Replace deviation card if necessary.
Bulb Replacement
power connected.
2 Lift cap on upper front surface.
3 Remove bulb.
4 Insert new bulb. 24 VDC
5 Refit cap.
Compass Swing
Refer to the Compensation Instructions of Airpath Instrument Company
(LOAP 40). It is advisable to perform this compass swing simultaneously with
the IFD Magnetometer Calibration outlined in Chapter 31-60-01.
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34-40-00 INDEPENDENT POSITIONING DETERMINING
Description
The EXTRA 500 can be equipped with the following optional equipment:
• TAS (Traffic Avoidance System)
• TWX (Lightning detection system)
Troubleshooting
TAS shows aircraft on the Antenna cables of upper Swap antenna cables
wrong side (left or right) antenna swapped
TAS shows aircraft on the Antenna cables of lower Swap antenna cables
wrong side (front or aft) antenna swapped
34-40-01 TAS Processor

The TAS processor is installed on the back of the aft baggage compartment
paneling.
power connected.
2 Remove aft baggage compartment paneling. Refer to Chapter 25-00-01
3 Disconnect electrical connectors and
antenna cables from TAS processor.
4 Unscrew the locking screws of the TAS
processor mounting tray.
5 Slide the TAS processor out of the tray.
6 Install in reverse sequence of removal. Observe the following hint
Make sure all antenna cables are connected to both antennas and TAS
CAUTION processor before applying power to the processor. Failing to do so may
damage the processor.

Maintenance Manual
EXTRA 500
34-40-02 TWX Processor

The TWX processor is installed beneath the armrest of the second seat row, LH
seat.
power connected.
2 Remove LH front passenger seat. Refer to Chapter 25-20-11
3 Remove LH side armrest paneling. Refer to Chapter 25-20-21
antenna cable from TWX processor
5 Remove TWX processor from tray

Maintenance Manual
EXTRA 500
34-50-00 DEPENDENT POSITIONING DETERMINING
Description
The EXTRA 500 has the following equipment installed:
• Transponder
In addition the following optional equipment may be installed:
• DME (Distance Measuring Equipment)
34-50-01 Transponder
The transponder is installed in the tail cone compartment.
power connected.
2 Remove the tailcone access panel Refer to Chapter 51-00-01
antenna cables
4 Remove transponder from its tray 2 screws
34-50-02 DME Processor

The DME processor is installed in the tail cone compartment
power connected.
2 Remove the tailcone access panel Refer to Chapter 51-00-01
antenna cables
4 Remove DME processor from its tray 2 screws

Maintenance Manual
EXTRA 500
34-50-03 DME Indicator

The DME indicator is installed on the instrument panel on the left lower edge.
power connected.
2 Disconnect electrical connector Accessible from the bottom
3 Remove DME indicator 4 screws

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Chapter 51
Standard Practices and Structures
General

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Table of Contents
51-00-00 GENERAL ........................................................................................................ 5

51-00-01 Access Panel Identification .............................................................................. 5
Figure 51-1, Sheet 1 Access Panel Identification ................................................................................ 6
51-10-00 INVESTIGATION............................................................................................ 9
51-10-01 Damage Classification ...................................................................................... 9
51-10-02 Repair Criteria and Limits .............................................................................. 9
51-10-02 Repair Criteria and Limits ............................................................................ 10
51-30-00 MATERIALS .................................................................................................. 11

51-30-01 Composite Parts .............................................................................................. 11
Epoxy System ................................................................................................... 11
Glass Fibre Fabrics ........................................................................................... 11
Carbon Fibre Fabrics ........................................................................................ 12
Carbon Fibre Rovings ....................................................................................... 12
UD Carbon Fibre Tape ..................................................................................... 12
Core Material .................................................................................................... 12
Filler Material for Resin ................................................................................... 14
Coating.............................................................................................................. 14
51-30-02 Metal Components .......................................................................................... 15
Round Seamless Steel Tubing .......................................................................... 15
Steel Sheet Metal .............................................................................................. 16
Coating.............................................................................................................. 16
51-30-03 Aluminium Components ................................................................................ 17
Aluminium Sheet Metal.................................................................................... 17
Tubings ............................................................................................................. 17
Coating.............................................................................................................. 18
51-30-04 Titanium Components .................................................................................... 18
Titanium Sheet Metal ....................................................................................... 18
51-30-05 Various Components ...................................................................................... 19
Sealant .............................................................................................................. 19
Silicon Adhesive ............................................................................................... 19
Adhesive ........................................................................................................... 20
Corrosion Preventive Compound ..................................................................... 20
Sealing Material for Lightning Protection ........................................................ 20
Release Agent ................................................................................................... 20
Foam Rubber .................................................................................................... 21

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51-60-00 CONTROL SURFACE BALANCING ......................................................... 22

51-60-01 Weighing and Determination of Control Surface Moments ...................... 22
Figure 51-2 Balancing Mandrels .......................................................................................... 22
Procedure........................................................................................................... 23
Figure 51-3 Control Surface Balancing ................................................................................ 24
Figure 51-4 Permissible Weights and Moments ................................................................... 25
51-70-00 REPAIRS ......................................................................................................... 26

51-70-01 Repair of Reinforced Glass and Carbon Fibre Components ...................... 26
51-70-02 Repair of Sandwich Material ......................................................................... 28
Figure 51-5 Minor Surface Damage ..................................................................................... 28
Figure 51-6 Curing Cycle Resin L 20 / SL ............................................................................ 29
Figure 51-7 Damage of Complete Sandwich ........................................................................ 30
51-70-03 Repair of Laminates ........................................................................................ 32
Minor Damage .................................................................................................. 32
Figure 51-8 Repair of Minor Damage .................................................................................. 33
Large Damage ................................................................................................... 33
51-70-04 Repair of Spars and Elements of the Pressure Cabin .................................. 35
Structural elements of the pressure cabin .......................................................... 35
Spars of Wing and Empennage ......................................................................... 35
51-70-05 Structural Repair of Steel Components ........................................................ 35
51-70-06 Painting of Composite Parts ........................................................................... 36
51-70-07 Aluminium and Steel Components Refinishing ........................................... 37
Degreasing......................................................................................................... 37
Paint Removal ................................................................................................... 37
Repainting ......................................................................................................... 38
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51-00-00 GENERAL
51-00-01 Access Panel Identification

Refer to Figure 1 for identification of access panels.
Generally all access panels (and fairings) are screwed on the respective
structure or surface. However for the access to the oil filler and the external
power receptacle hatches are used featuring a hinge and a latching mechanism.
The LH wing nose access panel carries the stall sensor. So refer to Chapter 34-
10-13 for removal.
To get access to the passenger compartment floor access panels the carpet has
to be removed.
To get access to the central horizontal stabilizer access panel the fin tip has to
be removed (refer to Chapter 55-30-01).

Side Views
Page 6
NAV antenna access panel*
51
EXTRA 500
Fuel sump access panel (LH) Door hinge access panel
Figure 51-1, Sheet 1

Maintenance Manual
Tail fairing
Fin access panel
Tailcone access panel
Access Panel Identification

LH front fuselage
access panel
NAV antenna access panel*
Fuel sump access panel (RH) External power hatch Oil filler hatch
Page Date:
Tail fairing
30.11.
RH front fuselage
access panel
Landing light
March
*) from serial N° 1003 access panel
July 2012
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Bottom View
Fuel filter access panel
RH front fuselage
access panel
LH front fuselage
access panel
Forward keel beam
access panel
Aft keel beam

access panel
RH gap fairing LH gap fairing
Pitch trim
access panel
Figure 51-1, Sheet 2 Access Panel Identification
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Top View
Oil filler hatch
Inner and outer External power

fuel main compartment hatch
access panels
Wing nose
access panel Avionic bay
access panel
Wing center
Inner and outer fairing
fuel auxiliary compartment
access panels
Right wing
symmetrically
Inspection doors
Outer wing
access panel
Passenger compartment floor
access panels (LH, middle, RH)
Central horizontal stabilizer

access panel
NAV antenna access panel

from serial N° 1003
Figure 51-1, Sheet 3 Access Panel Identification

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July 2012
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51-10-00 INVESTIGATION
51-10-01 Damage Classification

All damage of composite parts must first be classified by qualified
WARNING personnel. In case of doubt regarding the classification of damage, if a
clear definition of the extent of damage is not possible, or if a repair of
damage despite the consideration of the valid manufacturer
documentation is doubtful, contact EXTRA.
Only the Damages Classes 2, 3 and 4 may be repaired by qualified
WARNING personnel. In case of Damage Class 1 EXTRA has to be contacted.
Following to the Luftfahrt Bundesamt (Federal German Aviation Authority)
four damage classes are defined:
Damage Class 1:
Large scale destruction requires a partial reconstruction of the component or
large scale repair. Each destruction over 300 mm diameter and each damage of
a spar or the pressure cabin is a “large scale destruction”. EXTRA has to be
contacted prior to repair.
Damage Class 2:
Damage to primary structures and to secondary structures to the following
extent: Holes and fractures extending through a sandwich component and a
scale under 300 mm diameter.
Damage Class 3:
Damage to primary structures and to secondary structures to the following
extent: Small holes or fractures in the external covering layers, if not
accompanied by damage to supporting layers or internal covering layers.
Damage Class 4:
Erosion, scratches or nicks not accompanied by fractures or break-ups. Damage
to fairings belong to this class.
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51-10-02Repair Criteria and Limits

IMPORTANT Any damage of composite parts must first be classified prior to repair.
Refer to Subject 51-10-01 Damage Classification.
IMPORTANT Only the Damages Classes 2, 3 and 4 may be repaired by qualified
personnel. In case of Damage Class 1 EXTRA has to be contacted.
The decision whether to repair or replace a major unit of structure will be

influenced by factors such as time and labor available, and by comparison of
labor costs with the price of replacement assemblies. Past experiences indicate
that replacement, in many cases, is less expensive than major repair. Certainly,
when the aircraft must be restored to its airworthy condition within limited
time, replacement is preferable.

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EXTRA 500
51-30-00 MATERIALS
This Section describes metallic and non-metallic materials used in repairing the
EXTRA 500 and gives the sources of supply (manufacturers and suppliers).
IMPORTANT Only approved materials have to be used for repair.
Materials not listed here are generally used for parts, which are not intended for
repair. Contact EXTRA for advice.
Observe the data and safety sheets when working with auxiliary materials such
as sealants, adhesives, solvents, agents and the like. However, if not stated
otherwise, aircraft parts must not be heated to more than 80 °C (176 °F) for
example in curing processes.
51-30-01 Composite Parts
Epoxy System
Manufacturer: Momentive
Varzinerstr. 49,
D-47138 Duisburg, Germany
Supplier: Brenntag GmbH
Stinnes Platz 1,
D-45472 Mühlheim, Germany
Resin: Epikote L20 / Rütapox L20
Hardener: Epikure Curing Agent 960 / Rütapox SL
Ratio of comp.: 100 parts L20 / 34 parts SL (weight ratio)
Glass Fibre Fabrics

Manufacturer: P-D Interglas Technologie GmbH
Benzstraße 14,
D-89155 Erbach, Germany
Style WLB-No.* US-style Weave Weight
Interglas LN 9169 Patterns g/m2
90070 8.4505.60 1610 plain 80
92110 8.4548.60 none 2/2 twill 163
92125 8.4551.60 none 2/2 twill 280
92140 8.4554.60 none 2/2 twill 390
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Carbon Fibre Fabrics

Manufacturer: C. Cramer GmbH & Co. KG
Division ECC
Weberstr. 21,
D-48619 Heek-Nienborg, Germany
Style WLB-No.* US-style Weave Weight
ECC/CCC DIN 65147 Patterns g/m2
447 8.3507.80 None plain 160
452 8.3520.80 None 2/2 twill 204
459 - None 2/2 twill 220
*WLB: Werkstoff Leistungsblatt, according to German standard DIN-WL
Carbon Fibre Rovings

Manufacturer: Toho Tenax Europe GmbH
Kasinostr. 19-21
D-42103 Wuppertal
Type: TENAX HTS5631 1600tex f24000 t 0
(WLB: 8.3614.1)
UD Carbon Fibre Tape

Manufacturer: J.H.vom Baur Sohn GmbH & Co. KG
Marktstraße 34
D-42396 Wuppertal, Germany
Type: CF UD tape 30 mm & 50 mm
according material spec. Doc. N° EA-05803.1 & .2
Core Material
PVC (Polyvinylchloride) Foam
Manufacturer: Airex AG
Industrie Nord 26
CH-5643 Sins, Switzerland
Supplier: Gaugler & Lutz OHG
Habsburger Str. 12
D-73432 Aalen-Ebnat, Germany
Type: Airex C 71.55

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PMI (Polymethacrylimide) Foam

Manufacturer: Evonik Röhm GmbH
Kirschenallee
D-64293 Darmstadt, Germany
Supplier: Gaugler & Lutz OHG
Habsburger Str. 12
D-73432 Aalen-Ebnat, Germany
Type: Rohacell 51 A
(WLB*: 5.1460.1)
Honeycomb
Manufacturer: Euro Composites S.A.
B.P.95, Zone Industrielle
L-6401 Echternach / Luxembourg
or :
Manufacturer: Schütz GmbH & Co. KGaA:
Schützstr. 21
D-56242 Selters, Germany
Honeycomb Density Manufacturer Specification
Tolerance
Cormaster C1-4,8-29 OX +15%/-0% Schütz EA-03512.02
ECA-R-4.8-29 +13%/-0% Euro Composites EA-03512.02
ECA-I-R-4.8-29 +16%/-0% Euro Composites EA-03512.02
Cormaster C1-4,8-48 OX ±10% Schütz WLB5.3653.1*
ECA-R-4.8-48 ±10% Euro Composites WLB5.3653.1*
ECA-I-R-4.8-48 ±16% Euro Composites ECSS 704
Cormaster C1-3.2-48 ±10% Schütz WLB5.3650.4*
ECA-I-3.2-48 ±16% Euro Composites ECSS 704
Plywood
Manufacturer: For example: Mahogany Oy, Finnland
Supplier: For example: La Boisserolle
71960 Prissé-Lès-Mâcon, France
Type: Aircraft grade Birch produced to German Lloyd GL-I & -II,
t = 2 mm, 6 mm, 8 mm (WLB*: 6.1013.0)
Okoume t = 4 mm, t = 6 mm**
**Aircraft Grade acc. to French Standard

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EXTRA 500
Filler Material for Resin

Manufacturer: STW Schwarzwälder Textilwerke
Heinrich Kaukmann GmbH
Aue 3
D-77773 Schenkenzell, Germany
Supplier: same
Type: Cotton flakes FB1/035
Manufacturer: Malayan Adhesives & Chemicals Sdn Bhd
No. 9 Jalan Utas 15/7,
40200 Shah Alam Selangor Darul Ehsan, Malaysia
Supplier: Brenntag GmbH
Stinnes-Platz 1
D-45472 Mühlheim, Germany
Type: Microballoons BJO - 0930
Coating
Manufacturer: BASF Coatings GmbH
Glasuritstr. 1,
D-48165 Münster/Hiltrup, Germany
Supplier: Wessels & Müller AG
Pagenstecherstraße 121,
D-49090 Osnabrück, Germany
Type: 22 Glasurit HS-2K-Decklack
929-91/93/94 Glasurit HS Decklackhärter
352-50/91/216 Glasurit Einstellzusatz
55 Glasurit Zweischicht-Decklack
Metallic/Uni/Perleffekt
90 Glasurit Zweischicht-Decklack
Metallic/Uni/Perleffekt
93-E3 Glasurit Einstellzusatz
923-155 Glasurit MS-Klarlack
285-100 VOC Glasurit Rapidfüller VOC, weiß
929-55/56 Glasurit HS Füllerhärter
352-91 Glasurit Einstellzusatz
1006-26 Glasurit UP Spritzfüller, grau
948-22 Glasurit Härter
839-53 Glasurit UP-Schnellspachtel

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948-36 Glasurit Härterpaste

293-10 Glasurit Einstellzusatz
934-0 Glasurit 1K-Kunststoffhaftprimer
Manufacturer: MOTIP DUPLI GmbH
Kurt-Vogelsang-Straße 6
D-74855 Haßmersheim, Germany
Type: presto Leichtspachtel prestolith easy
Fire Protective Coating

Manufacturer: PPG Aerospace, PRC-DeSoto
Supplier: Röder Präzision GmbH
Am Flugplatz
D-63329 Egelsbach, Germany
Type: Fire protective coating N56582/T508
with clear coat:
Clearcoat 4232-0303
Hardener N39/1327
Reducer N39/3091
Manufacturer: Rudolf Hensel GmbH
Lauenburger Landstraße 11
D-21039 Börnsen, Germany
Supplier: same
Type: Fire protective coating Hensotherm 410KS
with clear coat (see Manufacturer above):
923-335 Glasurit HS-Multi-Klarlack VOC (clear coat)
929-31/33/34 Glasurit HS Decklackhärter (hardener)
51-30-02 Metal Components
Round Seamless Steel Tubing

Manufacturer: MHP Mannesmann Hoesch Präzisrohr GmbH
Postfach 1713,
D-59061 Hamm, Germany
Supplier: Heggemann Autosport GmbH
Zeppelinring 1 - 6,
D-33142 Büren, Germany
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Type: WLB* 1.7734.4

various diameters and wall dimensions
(for example: engine mount)
Manufacturer: Pacific Tube Company
5710 Smithway Street
Los Angeles, California 90040, USA
Supplier: Wicks Aircraft Supply, Co.
410 Pine Street
Highland, Illinois 62249, USA
Type: AISI 4130 N (MIL-T-6736)
various diameters and wall dimensions
(for example: support structure inside cabin)
Steel Sheet Metal

Manufacturer: BÖHLER Edelstahl GmbH
München, Germany
Supplier: BÖHLER Edelstahl GmbH
Hansa Allee 321
D-40549 Düsseldorf, Germany
Type: according to WLB* 1.7734.4, various dimensions
Manufacturer: Cold Metal Products, Inc.
2301 So. Holt Road
Indianapolis, In. 46241, USA
410 Pine Street
Type: AISI 4130 N (MIL-S-18729)
various dimensions
Coating
Glasuritstr. 1,
Type: 801-72 VOC Glasurit Grundfüller EP VOC, grau
965-60 Glasurit Härter EP
352-91/216 Glasurit Einstellzusatz
22 Glasurit HS-2K-Decklack

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51-30-03 Aluminium Components
Aluminium Sheet Metal

Manufacturer: Kaiser Aluminium & Chem. Corp.
Spokane, Washington
Supplier: Westdeutscher Metallhandel
Friedrich W. Hermann GmbH
Manderscheidtstr. 76-78,
Postfach 104245
45141 Essen
Type: WLB* 3.1364 T3 (2024 T3)
various dimensions
WLB* 3.3214 T6 (6061 T6)
various dimensions
Manufacturer: various
Postfach 104245
45141 Essen
Type: AlMg3hh (EN-AW-5754 H24)
various dimensions (also band)
Tubings
Manufacturer: Aluminium AG
CH-5737 Menziken, Swiss
Postfach 104245
45141 Essen
Type: WLB* 3.1354 T3
various dimensions
WLB* 3.3214 T4
various dimensions
410 Pine Street
Type: 5052-0
various dimensions

Maintenance Manual
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2024 T3
various dimensions
Postfach 104245
45141 Essen
Type: AlMgSi 0.5 F22 (EN-AW 6060 T6)
various dimensions
Coating
Glasuritstr. 1,
Type: 283-150 VOC Glasurit Grundfüller EP VOC
352-228 Glasurit Zusatzlösung
352-50/91 Glasurit Einstellzusatz
22 Glasurit HS-2K-Decklack
Manufacturer: Parker & Anchem, Ambler, PA 19002
Supplier: Aircraft Spruce
Chem. coating: for aluminium hardware metal (brackets, pedestals etc.)
Type: Alodine No. 1201 (MIL-C-5541)
Lacquer: see above
51-30-04 Titanium Components
Titanium Sheet Metal

Manufacturer: Timet
United Kingdom
Supplier: Tisto Titan und Sonderlegierungen GmbH
Dinnendahlstraße 31
40235 Düsseldorf, Germany
Type: WLB* 3.7034.1 and 3.7024.1
(firewall, nose gear box, lightning protection tank filler caps)

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51-30-05 Various Components
Sealant
Manufacturer: Le Joint Français
Supplier: Deutsche Hutchinson GmbH
Rudolf-Diesel-Str. 20B
65760 Eschborn, Germany
Type: PR 148 AF Activator (for metal surfaces)
PR 1750 S Integral tank sealant sprayable
PR 1750 A2 Integral tank sealant, bolt sealing
PR 1750 B2 Sealant (tank, pressure cabin, fittings etc.)
PR 1829 B Window sealant
PR 812 Firewall sealant
Manufacturer: FLEET SUPPLIES, INC
215 Mahoning Avenue
Cleveland, OH 44113, USA
Supplier: Aircraft Spruce and Speciality Co.
Type: FUELUBE
Silicon Adhesive
Manufacturer: Herrman Otto GmbH
Krankenhausstr. 14
D-83413 Fridolfing, Germany
Supplier: same
Type: Ottoseal S72
Manufacturer: Dow Corning GmbH
Postfach 13 03 32
65201 Wiesbaden,Germany
Supplier: Brammer GmbH
Daimlerstraße 51
76185 Karlsruhe, Germany
Type: Dow Corning 732 white or clear (MIL-A-46106)
Manufacturer: Wacker Chemie AG
Hannes-Seidel-Platz 4
81737 München, Germany
Supplier: Wacker Chemie AG
Verkaufsbüro Stuttgart
Sophienstr. 41
70178 Stuttgart, Germany
Type: Elastosil E14 (RTV 1)

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Manufacturer: Momentive (formerly GE Silicones)

22 Corporate Woods Boulevard
Albany, NY 12211, USA
Supplier: diverse
Type: RTV 159 (high temperature & high strength Silicone)
Adhesive
Manufacturer: Henkel AG & Co. KGaA
Henkelstr. 67
D-40589 Düsseldorf, Germany
Type: Loctite 243 Threadlocker
Loctite 401 Instant adhesive
Loctite 406 Instant adhesive
Loctite 577 Thread sealing
Loctite 601 Small gaps retainer
Corrosion Preventive Compound

Manufacturer: LEAR CHEMICAL RESEARCH
P.O. Box 1040, Mississauga
L4Y 3W3 Ontario, Canada
Supplier: Global Aviation & Piper Parts GmbH
Flughafen Kassel, D-34379 Calden
Type: ACF-50
Sealing Material for Lightning Protection

Manufacturer: Nycote Laboratoires
12750 Raymer Street
North Hollywood, CA 91605
Supplier: Aero Consultants
PO Box 35, Grabenstrasse 8
CH-8606 Nänikon/Uster, Switzerland
Type: Nycote 7-11 (MIL-S-4383)
Release Agent
Manufacturer: CIBA Speciality Chemicals Inc.
CH-4002 Basel, Switzerland
Supplier: Schurg GmbH
Industriestr. 12
D-34537 Bad Wildungen, Germany
Type: QV 5110

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Foam Rubber
Manufacturer: JPR Espace Industriel Nord
Rue André Durouchez
BP 1561
80015 Amiens cedex 02 - France
Supplier: same
Type: Silicone D563, colour grey, Ø 15 mm
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51-60-00 CONTROL SURFACE BALANCING
51-60-01 Weighing and Determination of

Control Surface Moments
Weighing and determination of control surface moments is necessary after
repairs or painting. All weighing of control surfaces is performed with surfaces
removed from aircraft. Weigh the control surfaces including mass balances and
brackets but without control rods.
The RH elevator weight includes the trim tab installed and provisionally held
in elevator surface plane by means of tape (see also Figure 51-3).
Copy Figure 51-4, enter the values (W, m, r) and check whether the surface
weights and moments are within the given tolerances. If they are not, contact
the EXTRA for advice.
For the determination of control surface moments follow the steps as described
below and use two balancing mandrels like shown in the Figure 51-2:
A B (for outboard aileron hinge)
Figure 51-2 Balancing Mandrels

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Procedure
1 Remove the control surface. Refer to Chapter 27
2 Reinstall the bolts in the brackets where Aileron inboard hinge
applicable. Elevator outboard hinge
3 When weighing RH elevator fix trim tab
with tape.
4 Put the control surface on the balancing Refer to Figure 51-3
mandrels (use a wire for the trim tab).
5 Level control surfaces and weigh by means Refer to Figure 51-3
of a conventional spring balance (kg/g-
indication) at the given weighing points and
enter the weight (m) in figure 4.
6 Measure distance of hinge center line to
weighing point (r) and enter the value in
Figure 51-4.
7 Calculate the control surface moment (M) in
Figure 51-4.
IMPORTANT If values exceed the given tolerances in Figure 51-4 contact EXTRA
before modifying of control surfaces.
8 If necessary modify control surface under
EXTRA’s guidance.
9 Reinstall the control surfaces.

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Hinge center axis
Rudder
r
-m
Weighing point r
Weighing point
m
Aileron
Hinge center axis

Hinge center axis
Elevator (RH)
Wire
r
Weighing point
m Tape Trim tab
r
Weighing point
m
Hinge center axis
Figure 51-3 Control Surface Balancing

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Permissible Weights and Moments

5.53
4.5 5.5 5.6 6.5 6.8 7.13
450
440
400 Rudder
350 350
300
290
250 Elevator (LH) Elevator (RH)

220
200
50
0 0
Aileron
-40
-50
4.0 4.5 5.0 5.5 6.0 6.5 7.0 7.5
0.37 0.50
50
30
25 Trim tab 15
0
0.30 0.35 0.40 0.45 0.50 0.55 0.60 0.65
Weights
Aileron LH: (W) . . . . . . . . . . kg
Aileron RH: (W) . . . . . . . . . . kg
Rudder: (W) . . . . . . . . . . kg
Elevator LH: (W) . . . . . . . . . . kg
Elevator RH: (W) . . . . . . . . . . kg
Trim Tab: (W) . . . . . . . . . . kg x x

Moments
2
Aileron LH: (m:) . . . . . . . . . kg x 9.81m/s x (r:) . . . . . . . . . cm = (M:) . . . . . . . . . . . . Ncm
Aileron RH: (m:) . . . . . . . . . kg x 9.81m/s2 x (r:) . . . . . . . . . cm = (M:) . . . . . . . . . . . . Ncm
Rudder: (m:) . . . . . . . . . kg x 9.81m/s2 x (r:) . . . . . . . . . cm = (M:) . . . . . . . . . . . . Ncm

2
Elevator LH: (m:) . . . . . . . . . kg x 9.81m/s x (r:) . . . . . . . . . cm = (M:) . . . . . . . . . . . . Ncm
Elevator RH: (m:) . . . . . . . . . kg x 9.81m/s2 x (r:) . . . . . . . . . cm = (M:) . . . . . . . . . . . . Ncm
Trim Tab: (m:) . . . . . . . . . kg x 9.81m/s2 x (r:) . . . . . . . . . cm = (M:) . . . . . . . . . . . . Ncm

Figure 51-4 Permissible Weights and Moments
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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.

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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.
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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.

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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
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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:
1 Remove the sanding dust with a pneumatic vacuum cleaner.
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.
The repair area has to be cured under condition of vacuum bagging. Proceed as
follows:
repair area.

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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
7 Following the curing cycle carefully remove vacuum bagging material and
nylon peel ply.
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.
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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:
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.
After the curing process has been completed, remove the nylon peel ply. The
repair area can be sand leveled with the surrounding area.
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.

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or grease was trapped during the preparation of the overlap.
IMPORTANT Repair area must be free of dirt, dust and grease.
on the repair area.
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:
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.
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or grease was trapped during the preparation of the overlap.
IMPORTANT Repair area must be free of dirt, dust and grease.
on the repair area.
follows:
repair area.
3 Lay a jute cloth 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
7 Following the curing cycle carefully remove vacuum bagging material and
nylon peel ply.
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.
CAUTION
Refinish the surface according Chapter 51-70-06.

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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.
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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.

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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.
1 Clean all metal parts by immersing in a clean degreasing solution. An alkaline
based solution is recommended for aluminium and magnesium parts.
2 Hardened dirt or grease may be removed with soft bristle brush, or by soaking
in cleaning solution.
3 Where necessary clean bearing cones carefully in a separate container of clean
solvent.
Do not spin bearing cones with compressed air.
CAUTION
4 After cleaning, thoroughly dry all metal parts with filtered, dry compressed air.
5 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.
6 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.
1 Degrease part as per degreasing paragraph.
2 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.
3 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
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entrapment might occur.

4 Thoroughly dry part with filtered, dry compressed air.
5 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:
1 Parts to be repainted should be cleaned and stripped as per instruction in
degreasing and paint removal paragraphs.
2 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.
3 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.
4 Remove excess coating by flushing with clean water.
5 Paint parts with one coat of wash primer. Allow to dry thoroughly.
6 Paint parts with one coat of lacquer listed in Section 51-30. Allow to dry
thoroughly before reassembly.

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Chapter 52
Doors

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Table of Contents
52-00-00 GENERAL ........................................................................................................ 3

52-10-00 PASSENGER/CREW ....................................................................................... 4

Description.......................................................................................................... 4
52-10-01 Upper Door Paneling ........................................................................................ 6
52-10-02 Lower Door Paneling........................................................................................ 6
52-10-03 Central Door Operating Device....................................................................... 7
Removal/Disassembly ........................................................................................ 7
Inspection (After Teardown) .............................................................................. 7
Installation/Assembly ......................................................................................... 8
52-10-04 Lower Door Operating Device....................................................................... 10
Removal/Disassembly ...................................................................................... 10
Inspection.......................................................................................................... 10
Installation/Assembly ....................................................................................... 10
52-10-05 Door Locking Mechanism .............................................................................. 12
Rigging ............................................................................................................. 12
52-10-06 Door Seal ......................................................................................................... 14
52-10-07 Sill Seal............................................................................................................. 15
Removal ............................................................................................................ 15
Installation ........................................................................................................ 15
52-10-08 Door Switch ..................................................................................................... 17
Adjustment........................................................................................................ 17
52-20-00 EMERGENCY EXIT ..................................................................................... 18

Description........................................................................................................ 18
52-20-01 Emergency Exit Seal ....................................................................................... 18
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52-00-00 GENERAL
Troubleshooting
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-
01
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.

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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.

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View from inside 1

8
5 8
11
10
9
5
6 6
Legend:
1 upper door paneling 7 lower door paneling
2 telescopic lift cylinder 8 inspection glas
3 upper door inner handle 9 foot step
4 safety button 10 sill lever handle doubler
5 check hole 11 clamping strip
6 arresting cable
Figure 52-1 Door

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52-10-01 Upper Door Paneling
Refer to Figure 52-1
1 Open door completely.
2 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.
3 Disconnect telescopic (2) lift cylinder from
the door.
4 Remove the upper door paneling (1). 9 screws
52-10-02 Lower Door Paneling
1 Open door completely.
2 Remove sill lever handle doubler (10) from 2 bolts
lower door actuator lever.
3 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.
4 Disconnect arresting cables (6) from door
frame.
5 Remove the lower door paneling (7). 4 screws
6 Install in reverse sequence of removal. 2 bolts of step 2 must be
installed with Loctite 243

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52-10-03 Central Door Operating Device
Removal/Disassembly
1 Remove the upper door paneling. Refer to Chapter 52-10-01
2 Disconnect pushrods and gas spring from
actuator (11) and inner handle bearer (6).
3 Remove slotted spring pin (7) holding the Relieve spring by pulling at
spring (8). the spring eye with a bent
wire.
4 Remove inner handle bearer (6).
5 Remove slotted spring pin (9).
6 Remove inner guide pin (10).
7 Remove actuator (11).
8 Remove slotted set screw (15).
9 Remove outer guide pin (16).
10 Remove shafting axle (18) including outer
handle (20).
11 Remove collar bushing (17).
12 Remove dowel pin (19) to take out the Dowel pin is glued in with
spring (8). Loctite 243
13 Remove flange bushings (12).
14 Remove outer handle bearing (13) 4 bolts
15 Separate outer handle (20) from shafting 4 bolts
axle (18).
16 Remove slotted spring pin (3) from safety
button (2).
Inspection (After Teardown)

1 Inspect sliding surfaces for damage and Replace parts if necessary
cracks.
2 Inspect the shafting axle (18) slot for burrs
and torsional bending.
3 Inspect guide pins (10/16) for wear. Replace parts if necessary
4 Inspect slotted spring pins (3/7/9) for Replace parts if necessary
bending or other damage.

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5 Check springs (5/8) for general condition Replace parts if necessary
Installation/Assembly
1 Install/assemble in reverse sequence of Observe the following items.
removal/disassembly
2 Clean all parts (incl. rod ends and ball joint
bearings) and mount with MIL-PRF-81322.
3 Glue in dowel pin (19) with Loctite 243.
4 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.
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shown in open position
fwd
Figure 52-2
1
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4
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8
11
12
13
12
17
Central Door Operating Device

18
2 19
3
5
6
9
10
14 15
Legend: 16
1 button housing 11 actuator
2 safety button 12 flange bushing
3 slotted spring pin 13 outer handle bearing 20
4 inner handle 14 stop pin
5 spring 15 slotted set screw
6 inner handle bearer 16 outer guide pin
7 slotted spring pin 17 collar bushing
8 spring 18 shafting axle
52
9 slotted spring pin 19 dowel pin
10 inner guide pin 20 outer handle
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52-10-04 Lower Door Operating Device
Removal/Disassembly
1 Open lower door completely.
2 Remove handle from actuator lever 2 bolts
3 Remove the clamping strip.
CAUTION hinges.
cables.
4 Disconnect arresting cables (7) from door
frame.
5 Remove the lower door paneling. 4 screws
6 Disconnect pushrods (1) from actuator (5).
7 Remove shims (4).
8 Lift actuator (5) from bearing bolt (7) and
remove, while guiding actuator lever
through the slot.
9 Disassemble actuator parts (9, 10) by
removing the slotted spring pin (8).
Inspection
Replace 2.5 x 12 slotted spring pin (8) with 3 x 12 when play is detected.
Installation/Assembly
1 Install/assemble in reverse sequence of Observe the following item2.
removal/disassembly
2 Clean all parts (incl. rod ends and ball joint
bearings) and mount with MIL-PRF-81322.
3 Install 2 bolts of removal/disassembly with
Loctite 243

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2 3
4
1
Legend:
1 pushrods
2 sill lever handle doubler
3 bolts
4 shims
5 actuator
6 lower door structure
7 bearing bolt
Actuator (5) Section Drawing 8 slotted spring pin
9 actuator, upper part
10 actuator, lower part
8 9
10
7 lift
Figure 52-3 Lower Door Operating Device

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52-10-05 Door Locking Mechanism

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
1 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).
2 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.
3 Place upper door handle resp. sill lever to If closed position cannot be
the closed position. reached, adjust adjacent
pushrods.
4 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.
a 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.
b Adjust pushrods (2) between bellcranks (1)
to minimize gap.
5 Check mounting of safety indicators (8). Correct, if necessary
6 Adjust pushrods (2) to correct hook (4)
position, if necessary.
7 Reinstall door paneling. Refer to Chapter 52-10-01/02

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fwd
6
6 7
5
3 3 3
8
1
1
9
no gap
2 2
1 49° 64°
1
3 3
2 2
4 10 4
2 2
3
3
1
1
Legend: 13°
66.5°
1 bellcrank 2
2 2 push-pull rod
3 locking pin
4 hook
1
5 locking pin guidance
1 6 door switch
7 trigger sheet
8 safety indicator
3 9 locking pin linkage 3
10 gas spring
Figure 52-4 Door Locking Mechanism

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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.
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.
1 Disconnect telescopic (2, Figure 52-1) lift
cylinder from the door.
CAUTION hinges.
cables.
2 Disconnect arresting cables (7, Figure 52-1)
from door frame.
3 Remove door threshold plate. 5 screws, hook-and-loop
fastener
4 Remove door seal frame. 34 screws
5 Remove door seal from frame. Mark seal position on frame
6 Install in reverse sequence of removal. Provisionally fix the seal to
the frame with tape. Remove
tape after frame installation.
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52-10-07 Sill Seal

The gap between upper and lower door is sealed by means of the sill seal.
Removal
1 Open upper and lower door
2 Remove handle doubler (10, Figure 52-1)
from sill lever.
3 Remove sill seal frame (2, Figure 52-5). 5 bolts (1)
4 Remove sill seal (3) and corner seals (6).
Installation
Xdate
1 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.
2 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.
3 Place the sill seal (3) to the sill (5).
4 Install the sill seal frame (2). 5 bolts (1)
5 Clean the adherent surfaces of the corner
seals (6) with Aceton.
6 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.
7 Install the handle doubler (10, Figure 52-1)
to the sill lever.
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Detail A
fwd
1 fwd
6
3
lower door shut
Legend:
1 bolt
2 sill seal frame
3 sill seal
4 foam rubber plug
5 sill
6 corner seal 7
7 door seam
8 door seal
Figure 52-5 Sill Seal
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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.
1 Remove upper door paneling. Refer to Section 52-10-01
2 Disconnect wiring from door switch.
3 Remove the switch. 2 bolts
Adjustment
1 Remove upper door paneling. Refer to Section 52-10-01
2 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.
3 Reinstall upper door paneling.
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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
1 Remove emergency exit.
2 Remove seal frame. 11 screws
3 Remove seal from frame.
5 Install safety wire to emergency exit handle. Cu/Cu 0.25 x 0.25

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Chapter 55
Stabilizers

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Table of Contents
55-00-00 GENERAL ........................................................................................................ 3

Description.......................................................................................................... 3
55-10-00 HORIZONTAL STABILIZER ....................................................................... 4

Description.......................................................................................................... 4
Figure 55-1 Overview Horizontal Stabilizer .......................................................................... 5
Removal .............................................................................................................. 6
Installation .......................................................................................................... 6
Figure 55-2 Trim Control Box ................................................................................................ 8
55-10-01 Horizontal Stabilizer Main Bolts..................................................................... 9
Inspection............................................................................................................ 9
55-20-00 ELEVATOR .................................................................................................... 10

Description........................................................................................................ 10
Figure 55-3 Elevator Control Surface (LH) ......................................................................... 11
Figure 55-4 Elevator Control Surface (RH) ......................................................................... 12
Figure 55-5 Elevator Trim Tab, (on RH elev. only) ............................................................. 13
55-30-00 VERTICAL STABILIZER ............................................................................ 14

Description........................................................................................................ 14
55-30-01 Fin Tip ............................................................................................................. 14
Figure 55-6 Fin Tip .............................................................................................................. 15
55-40-00 RUDDER ......................................................................................................... 16

Description........................................................................................................ 16
Figure 55-7 Overview Rudder Mounting.............................................................................. 17
Figure 55-8 Bottom Rudder Mounting (including bell crank and centering device) ........... 18
Figure 55-9 Middle and Upper Rudder Mounting ............................................................... 18

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55-00-00 GENERAL
Description
The empennage is the element which controls the aircraft around the pitch and
yaw axis. It is a T-tail design with extended fin and fixed straight main
elements. The empennage is composed of the following elements:
• Horizontal stabilizer
• Elevator
• Vertical stabilizer
• Rudder

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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.

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Figure 55-1 Overview Horizontal Stabilizer

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Removal
1 Remove fin tip. Refer to Chapter 55-30-01
2 Remove elevator. Refer to Chapter 27-30-00
3 Remove central horizontal stabilizer access Refer to Chapter 51-00-01
panel
4 Remove pitch trim access panel Refer to Chapter 51-00-01
5 Adjust pitch trim to N-position.
6 Remove upper part of middle console Refer to Chapter 25-10-26
paneling.
7 Mark N-position of pitch trim indicator (6)
on the pitch trim control box (1) with tape.
8 Remove set screw (2).
9 Reinstall trim wheel (4) and screw (5).
10 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.
11 Rotate a half turn further (to make sure trim
cable end is inside the trim cable flex
casing).
12 Disconnect trim cable flex casing from
actuator. Plug openings.
13 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.
14 Remove horizontal stabilizer main bolts. 4 bolts, washers and nuts
15 Remove horizontal stabilizer. Weight approx. 20 kg
Installation
1 Position horizontal stabilizer on the top of
the vertical stabilizer.
2 Install main bolts with MIL-PRF-81322.
Secure with safety wire.

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3 Connect trim cable flex casing to actuator.
Secure with safety wire.
4 Install central horizontal stabilizer access Refer to Chapter 51-00-01
panel
5 Connect de-icing boot pressure lines.
6 Install elevator. Refer to Chapter 27-30-00
7 Adjust elevator to neutral.
8 Rotate trim wheel to the nose up direction
until trim tab is in straight line with elevator
and horizontal stabilizer.
9 Adjust trim indicator (6) until the N-position
match the mark on the pitch trim control box
(1).
10 Rotate round nut (3) until thread hole is
visible in the guide slot.
11 Install set screw (2) with Loctite 243.
12 Install upper part of middle console Refer to Chapter 25-10-26
paneling.
13 Install pitch trim access panel Refer to Chapter 51-00-01
14 Install fin tip. Refer to Chapter 55-30-01
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Aft View
6
2
4
3 2
Side View (without trim wheel)
2
Legend:
1 Pitch trim control box
2 Set screw
3 Round nut
4 Trim wheel
5 Screw 3
6 Pitch trim indicator
Figure 55-2 Trim Control Box

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55-10-01 Horizontal Stabilizer Main Bolts
Inspection
1 Remove fin tip. Refer to Chapter 55-30-01
2 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.
3 Remove one main bolt.
4 Inspect bolt shanks for cracks, wear, Replace if necessary
corrosion and insecurity.
5 Reinstall main bolt.
6 Follow steps 3 thru 5 for the other bolts.
7 Reinstall central horizontal stabilizer access Refer to Chapter 51-00-01
panel.
8 Reinstall fin tip. Refer to Chapter 55-30-01

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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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Figure 55-3 Elevator Control Surface (LH)
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Figure 55-4 Elevator Control Surface (RH)

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Figure 55-5 Elevator Trim Tab, (on RH elev. only)
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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
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.
2 Remove LH and RH gap fairing. Refer to Chapter 51-00-01
3 Remove fin tip attaching bolts. 10 bolts
4 Lift fin tip some centimeters.
5 Disconnect strobe light power supply In the front section
connectors.
6 Disconnect NAV antenna wiring BNC From serial N° 1003
connector.
7 Remove fin tip.
negative.

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Side View NAV antenna*
LN bolts
MS bolts Strobe light
Top View
NAV antenna*
*) NAV antenna installed on fin tip from serial N° 1003

Figure 55-6 Fin Tip

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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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Figure 55-7 Overview Rudder Mounting
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*) For rudder deflection refer to Chapter 06-10-08

Figure 55-8 Bottom Rudder Mounting (including bell crank and centering device)
Figure 55-9 Middle and Upper Rudder Mounting

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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).
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Chapter 56
Windows

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TABLE OF CONTENTS
56-00-00 GENERAL ........................................................................................................ 3

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

56-10-01 Windshield ......................................................................................................... 4
Description.......................................................................................................... 4
Removal .............................................................................................................. 4
Installation .......................................................................................................... 7
56-20-00 CABIN ............................................................................................................. 11

56-20-10 Cabin Windows ............................................................................................... 11
Description........................................................................................................ 11
Removal ............................................................................................................ 11
Installation ........................................................................................................ 12

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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.

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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
1 Remove front ceiling paneling, upper side Refer to Chapter 25
paneling, LH and RH armrest paneling and
windshield middle strut paneling.
2 Remove main panels and glareshield. Refer to Chapter 31
3 Remove windshield attachment nuts and
outer frame attachment nuts.
4 Peel off complete outer frame cover.
5 Remove respective windshield attachment
bolts and all outer frame attachment bolts.
6 Remove complete outer frame.
7 Remove residual PR1829B sealant.
windshield heat (left side only).
9 Release windshield from Ottoseal S72 using
a cutter knife.
10 Remove windshield.

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11 Remove residual Ottoseal S72 sealant.

12 Clean Silicone gasket seal surface.
13 Remove aluminum and rubber bushings Replace damaged bushings.
from windshield.

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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 Aluminum bushing
Outer frame cover Rubber bushing Rubber bushing

Outer frame ~3 mm PR1829B
Windshield Windshield
Ottoseal S72
Ottoseal S72
Silicone gasket seal
Middle strut
Windshield attachment bolt
Figure 56-1 Windshield Installation

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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.
1 Place the windshield on the Silicone gasket
seal on the fuselage structure frame.
2 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)
3 Place the outer frame on the windshields.
4 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.
5 Select 5 or 6 positions for pre-attachment of
the windshield.
6 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.
7 Pre-attach the windshield using 5 or 6
M4 bolts.
8 Predrill 4 mm holes on the remaining Refer to Steps 1 and 2 of
attachment points. Figure 56-2
9 Remove pre-attaching bolts and remove
outer frame and windshield.
10 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
11 Add a 45° 1 mm chamfer on both sides of Refer to Step 4 of Figure 56-2
each bore hole.
12 Install aluminum and rubber bushings.
13 Place the windshield to the fuselage
structure frame.
14 Adjust windshield as before and place the
outer frame on the windshield to check if
holes match.
15 Remove outer frame.
Note Surfaces are difficult to clean from PR1829B.
Apply tape to windshield and structure parts where PR1829B shall not
adhere.
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16 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.
17 Place the outer frame on the windshield.
Bend the outer frame to allow application of
PR1829B in later phases.
18 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).
19 Remove projecting PR1829B after complete Clean with isopropyl alcohol
installation of outer frame. as long PR1829B is not yet
hardened.
20 Connect electrical wiring
21 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.
22 Apply 1 layer 92110 glass fiber to build new Refer to Chapter 51
outer frame cover.
23 Apply paint. Refer to Chapter 51
24 Install glarshield and main panels. Refer to Chapter 31
25 Install windshield middle strut paneling, LH Refer to Chapter 25
and RH armrest paneling, upper side
paneling and front ceiling paneling.

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ø 4 mm
Outer frame
Step 1
Fuselage Windshield
structure
frame
Outer frame
Fuselage Windshield
Step 2 structure
frame
ø 4 mm
ø 8 mm
Step 3
Windshield
phase 1
ø 12 mm
phase 2 Windshield
Step 4
45°
Windshield
1 mm
Figure 56-2 Drilling Plexiglass

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Sectional drawing
Outer frame
Aircraft contour
PR1829B application phases Middle strut PR1829B
Figure 56-3 Work in Phases

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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
1 Remove respective paneling. Refer to Chapter 25 or 52
2 Remove window attachment nuts.
3 Release frame from Ottoseal S72 using a
cutter knife.
4 Remove frame.
5 Peel off cover (if installed).
6 Remove window attachment bolts.
7 Release window from Ottoseal S72 using a
cutter knife.
8 Remove window.
9 Remove residual Ottoseal S72 sealant. Replace damaged spacers
10 Remove aluminum and rubber bushings Replace damaged bushings.
from old window for later transfer to the
new window.

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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
1 Install aluminum and rubber bushings to the
new window.
2 Place the window to the fuselage structure.
3 Adjust window position to match the
existing hole pattern.
4 Check if the outer window contour follows Minimum spacer thickness:
the fuselage shape. Change spacers if 1 mm
necessary.
5 Apply Ottoseal S72 to the fuselage structure Refer to Ottoseal S72 data
frame as outlined on Figure 56-4. and safety sheet.
6 Place the window to the fuselage structure
and adjust window as before.
7 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.

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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
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Chapter 57
Wings

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TABLE OF CONTENTS
57-00-00 GENERAL ........................................................................................................ 3

Description.......................................................................................................... 3
57-10-00 CENTER WING ............................................................................................... 4

Description.......................................................................................................... 4
Removal .............................................................................................................. 4
Installation .......................................................................................................... 6
Figure 57-1 Hoisting the Wing ............................................................................................... 6
Figure 57-2 Wing to Fuselage Attachment ............................................................................. 7
57-30-00 WING TIPS ....................................................................................................... 8

Description.......................................................................................................... 8
57-50-00 TRAILING EDGE AND TRAILING EDGE DEVICES.............................. 9

57-50-01 Flaps ................................................................................................................... 9
Description.......................................................................................................... 9
Figure 57-3 Inner Flap Structure ......................................................................................... 10
Figure 57-4 Outer Flap Structure ........................................................................................ 11
57-60-00 AILERONS ..................................................................................................... 12

Description........................................................................................................ 12
Figure 57-5 Aileron Structure .............................................................................................. 13

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57-00-00 GENERAL
Description
The EXTRA 500 features a straight tapered all composite cantilever wing. The
one piece wing consists of a CFRP wing-box serving as structure for the
bending and torsional loads. The GFRP nose section equipped with the de-ice
boots
(=> ref. to Chapter 30) is part of the aerodynamic wing section and carries
shear due to aerodynamic lift forces into the wing box structure. To achieve
minimum drag natural laminar flow wing sections have been designed
specially for the EXTRA 500. Wing relative thickness is 16,5% at the root
section gradually changing into the 12% wing section used at the tip. Wing
twist distribution is selected to keep the wing sections within the low drag
bucket in cruise flight.
Wing-Structure
Spars: The wing uses 1 double cell front spar at 22.6% chord and 1 single
cell rear spar at 68.6% chord (carry-thru) to 60% chord (tip). Caps and webs
are made of CFRP with PMI foam core. The tiplets are not part of the primary
wing structure.
Skin: The wing skin is a composite sandwich structure with CFRP facing
layers and honeycomb core.
Ribs: In the torsion wing box 7 CFRP ribs are used each side: structural root
and fuel tank rib at Y±550, slosh rib with flapper valves at Y±800, slosh rib at
Y±1550, structural and fuel tank rib at Y±2550, fuel tank end rib (long range)
at Y±4300, structural rib at Y±4400 and the structural tip rip at Y±5500, which
extends to the nose section.
In addition 5 GFRP ribs are used in the D-nose section each side at Y± 550,
Y±1550, Y±2550, Y±3400, Y±3600, Y±4400.
Fuel tank: The wing fuel tank is an integral part of the wingbox between
the main spars, the root rib at Y±550 and Y±4300.
Flaps: => refer to section 57-50
Ailerons: => refer to section 57-60
Nose section: The nose skin is a composite sandwich structure with GFRP
facing layers and honeycomb core. It incorporates the pneumatic de-icing
boots.

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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)
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).

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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.

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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

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Figure 57-2 Wing to Fuselage Attachment

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57-30-00 WING TIPS
Description
The wing tips are non structural CFRP parts attached to a flange along the wing
tip rib. Removing the wing tips gives access to the outer compartment of the
wing between the main and aft spar. A transparent polycarbonate cover at the
leading edge of the wing tip aerodynamically integrates the Navigation Strobe-
Light Combination. The wing tips are lightning protected by an outer CFRP
layer incorporating a metallic mesh.

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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.
Move flaps to 30° position (wing flap position switch at right main panel).
Perform the following steps for LH and RH side flaps each.

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

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Figure 57-3 Inner Flap Structure

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Figure 57-4 Outer Flap Structure

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57-60-00 AILERONS
Description
Refer to Figure 57-5. The ailerons are of one spar dual torsion box all-CFRP-
composite construction. The aileron hinge line is positioned 70% of the wing
chord. To prevent flutter they are mass balanced in the overhanging leading
edge.
For removal and installation refer to Chapter 27

30. March 2013
2012
Maintenance Manual
EXTRA 500
Figure 57-5 Aileron Structure

Maintenance Manual
EXTRA 500

Maintenance Manual
EXTRA 500
Chapter 61
Propeller

Maintenance Manual
EXTRA 500
Table of Contents
61-00-00 GENERAL ........................................................................................................ 3

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

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61-00-00 GENERAL
Description
The EXTRA 500 is equipped with a MTV-5-1-D-C-F-R(A)/CFR210-56
5-blade propeller. The MTV-propeller has a laminated wood composite
structure encased by an epoxy-fiber glass cover with metal tipping.
The governor regulates the blade pitch for a constant RPM.
Internal springs and counter-weights push the blades in high pitch (feather
position). Oil pressure pushes them in low pitch and reverse position. Thus in
case of an engine failure the propeller will be in feather position (low drag
configuration).
The propeller is equipped with electrically heated de-icers, bonded to the
blades. The electric power is provided by slip rings and a stationary brush
assembly.
Refer to Chapter 30-60 for further information concerning propeller icing
protection.
Control, operation and maintenance of the propeller is described in the MT -
Propeller Operation and Installation Manual E-610 (LOAP 3). Some of the
control aspects and rigging (propeller beta control, propeller blade angle
adjust) are described in the Rolls-Royce 250-B17F Series Engine Operation
and Maintenance Manual (LOAP 1), Chapters 76-00-00 and 76-10-02.
The parts and overhaul works are listed and described in the MT - Propeller
Overhaul and Parts List E-220 (LOAP 5).
For more information consult the propeller manufacturer.
For dynamically balancing the propeller refer to Rolls-Royce 250-B17F Series
Engine Operation and Maintenance Manual (LOAP 1), Chapter 72-00-00,
Page 503.
Page Date: 9.
30.August
March2013
2012 61 Page 3
Maintenance Manual
EXTRA 500
Troubleshooting
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
Hub damage Propeller loose on crankshaft Refer to engine and propeller
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
Malfunctioning propeller Replace governor, for
governor adjustment see engine
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
mechanism defective manufacturer’s instruction
Governor defective Replace governor

9. August 2013
Maintenance Manual
EXTRA 500

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
mechanism defective manufacturer’s instruction
Oil leakage Damaged gasket Replace gasket or repair
propeller
Loss of blade bearing grease Refer to propeller
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

Maintenance Manual
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Maintenance Manual
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Chapter 71
Power Plant

Maintenance Manual
EXTRA 500
Table of Contents
71-00-00 GENERAL ........................................................................................................ 3

71-10-01 Engine ................................................................................................................ 3
Removal .............................................................................................................. 3
Installation .......................................................................................................... 5
71-10-00 Cowling .............................................................................................................. 6
71-10-01 Upper Left Cowling .......................................................................................... 6
Removal .............................................................................................................. 6
Installation .......................................................................................................... 6
71-10-02 Upper Right Cowling........................................................................................ 7
Removal .............................................................................................................. 7
Installation .......................................................................................................... 7
71-10-03 Lower Cowling .................................................................................................. 7
71-20-00 ENGINE MOUNT ............................................................................................ 8

Description.......................................................................................................... 8
71-20-01 Shock-Mount ..................................................................................................... 8
Removal .............................................................................................................. 8
Installation .......................................................................................................... 9
71-60-00 AIR INTAKES ................................................................................................ 10

Description........................................................................................................ 10
71-60-01 Engine Inlet ..................................................................................................... 10
71-70-00 ENGINE DRAINS .......................................................................................... 11

Description........................................................................................................ 11
71-70-01 Engine Fire-Shield Drains.............................................................................. 11
Description........................................................................................................ 11
71-70-02 Engine Combustion Chamber Drain ............................................................ 11
Description........................................................................................................ 11
71-70-03 Engine Drain Manifold .................................................................................. 12
Description........................................................................................................ 12
71-70-04 Overboard Line............................................................................................... 12
Description........................................................................................................ 12

Maintenance Manual
EXTRA 500
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
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.

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chip detection sensors.
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.

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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
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
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

Maintenance Manual
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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
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
1 Unlock all cam-locks. 24 cam-locks
2 Raise and remove cowling.
Installation
1 Set cowling aircraft.
2 Fasten all cam-locks.
3 Check all cam-locks are engaged by firmly
hitting the cowling near attachments.

Maintenance Manual
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71-10-02 Upper Right Cowling
Removal
1 Remove upper left cowling first.
2 Remove all cam-locks. 14 cam-locks
3 Raise and remove cowling
Installation
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
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.

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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

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.

Maintenance Manual
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Installation
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.

Maintenance Manual
EXTRA 500
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
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.

Maintenance Manual
EXTRA 500
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.
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.
1 Remove LH upper cowling. Refer to Chapter 71-10-01
2 Disconnect fittings of the combustion
chamber drain hose. Plug fitting.

Maintenance Manual
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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.
2 Disconnect all hoses from engine drain
manifold.
3 Disconnect engine drain manifold from
overboard line and remove.
71-70-04 Overboard Line
Description
The overboard line is installed to the left side of the nose gear firewall.
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
6 Seal any opening in the firewall with
PR812.

Maintenance Manual
EXTRA 500
Chapter 73
Engine Fuel and Control

Maintenance Manual
EXTRA 500
Table of Contents
73-00-00 GENERAL ........................................................................................................ 3

73-30-00 Indicating........................................................................................................... 3
Description.......................................................................................................... 3
73-30-01 Fuel Pressure Transducer ................................................................................ 3
Description.......................................................................................................... 3
73-30-02 Low Fuel Pressure Switch ................................................................................ 4
Description.......................................................................................................... 4

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73-00-00 GENERAL
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).
power connected.
4 Remove transducer from fuel pressure
manifold.
5 Install in reverse sequence of removal. Replace O-ring when
necessary.

Maintenance Manual
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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).
power connected.
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.

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Chapter 74
Ignition

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Table of Contents
74-00-00 GENERAL ........................................................................................................ 3

Maintenance Manual
EXTRA 500
74-00-00 GENERAL
Ignition on the EXTRA 500 is only needed at engine start. For safety reasons it
is also switched on at take-off and landing and in severe weather conditions
(heavy rain, icing etc). The ignition switch is integrated in the start switch
(refer to Chapter 80-00-00).

Maintenance Manual
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Maintenance Manual
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Chapter 76
Engine Controls

Maintenance Manual
EXTRA 500
Table of Contents
76-00-00 GENERAL ........................................................................................................ 3

Description.......................................................................................................... 3
Rigging Check .................................................................................................... 3
Figure 76-1 Engine Control Lever Travel Schematic ............................................................ 4
76-10-00 POWER CONTROL ........................................................................................ 5

76-10-01 Engine Control Mounting Bracket ................................................................. 5
Description.......................................................................................................... 5
Figure 76-2 Engine Control Mounting Bracket ..................................................................... 6
76-10-02 Throttle Quadrant ............................................................................................ 7
Description.......................................................................................................... 7
Removal .............................................................................................................. 7
Installation .......................................................................................................... 8
76-10-03 Power Lever Bowden Cable............................................................................. 8
Description.......................................................................................................... 8
Removal .............................................................................................................. 8
Installation .......................................................................................................... 9
76-10-04 Condition Lever Bowden Cable .................................................................... 10
Description........................................................................................................ 10
Removal ............................................................................................................ 10
Installation ........................................................................................................ 10

Maintenance Manual
EXTRA 500
76-00-00 GENERAL
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
2 Perform engine manufacturer prepared Refer to Rolls-Royce 250-
rigging check. B17F Series Engine
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.

Maintenance Manual
EXTRA 500
Power Lever
Condition Lever
Figure 76-1 Engine Control Lever Travel Schematic

Maintenance Manual
EXTRA 500
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).
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
8 Perform engine control rigging check. Refer to Subject 76-00-00

Side View
Page 6
Cut off
position
Figure 76-2
76
EXTRA 500
Bleed air shut off switch Condition lever

Bowden cable
Maintenance Manual
Low pitch switch Flange
Rear View 0° position
Engine Control Mounting Bracket

(reverse)
Power lever
Bowden cable
Side support
Screws
Engine control mounting bracket
Screws

Maintenance Manual
EXTRA 500
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
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.

Maintenance Manual
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Installation
1 Reverse sequence of removal.
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
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
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.

Maintenance Manual
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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
2 Seal the Bowden cable firewall
breakthrough with PR812 from the engine
compartment side.
breakthrough with PR1750 from the cabin
side.
microphone.

Maintenance Manual
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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
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
breakthrough with PR812 from the engine
compartment side.

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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.
microphone.

Maintenance Manual
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Maintenance Manual
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Chapter 77
Engine Indicating

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EXTRA 500
Table of Contents
77-00-00 GENERAL ........................................................................................................ 3

Description.......................................................................................................... 3
Engine Indication Check .................................................................................... 4
Normal Ground Idle Engine Indication .............................................................. 4
77-00-01 Gas Generator Turbine Tachometer (N1) ...................................................... 4
Removal .............................................................................................................. 4
Installation .......................................................................................................... 5
77-10-00 POWER ............................................................................................................. 6

77-10-01 Torque Transducer........................................................................................... 6
Figure 77-1 Engine Indication Transducers and Switches .................................................... 6
Removal .............................................................................................................. 6
Installation .......................................................................................................... 7
77-10-02 Torque Switch ................................................................................................... 7
77-10-03 Propeller/Power Turbine RPM Sensor (N2) .................................................. 7
Removal .............................................................................................................. 7
Installation .......................................................................................................... 8
77-20-00 TEMPERATURE ............................................................................................. 9

77-20-01 Thermocouple Wiring ...................................................................................... 9
77-20-02 Thermocouple Terminal Block........................................................................ 9
77-40-00 INTEGRATED ENGINE INSTRUMENT SYSTEMS ............................... 10

77-40-01 Analog Engine Indicator Cluster .................................................................. 10
77-40-02 Digital Engine Indicator Cluster ................................................................... 10

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77-00-00 GENERAL
Description
The indication of engine parameters is presented on two integrated engine
instruments in the LH instrument panel. The upper unit is an analog-digital unit
which displays:
• TRQ in percent
• TOT in degree Celcius
• N1 (compressor) in percent
• N2 (propeller) in RPM
• Oil pressure in psig
• Oil temperature in degree Celcius
Although these parameters are displayed in one unit, they all have their
separate modules and are independent of each other. The same is valid for the
lower display unit which displays digital values only:
• Bus voltage
• Generator current in ampere
• Battery current in ampere
• Indicated outside air temperature in degree Celcius
• Fuel temperature in degree Celcius
• Fuel pressure in psig

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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.
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
power connected.

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4 Remove tachometer
Installation
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

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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
TRQ
OIL
FUEL
Sensing lines
To accumulator
Firewall
Figure 77-1 Engine Indication Transducers and Switches
Removal
power connected.

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4 Remove lock-wire.
5 Remove torque transducer
Installation
1 Reverse sequence of removal. Replace o-ring when
necessary.
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).
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
power connected.
2 Remove upper cowlings. Refer to Ch. 71-10-01/02

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4 Remove tachometer.
Installation
1 Reverse sequence of removal. Apply some engine oil to the
drive-spline before installing.

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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

Maintenance Manual
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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.
power connected.
2 Remove the RH and LH IFD. Refer to Chapter 31-60-01
3 Disconnect both electrical connectors
4 Remove indicator cluster.
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.
power connected.
2 Remove the RH and LH IFD. Refer to Chapter 31-60-01
4 Remove 4 bolts Use a ratchet with adequate
prolongation for holding nuts
in place.
5 Remove indicator.

Maintenance Manual
EXTRA 500
Chapter 78
Exhaust

Maintenance Manual
EXTRA 500
Table of Contents
78-00-00 GENERAL ........................................................................................................ 3

Description.......................................................................................................... 3
78-00-01 LH Exhaust Stack ............................................................................................. 3
78-00-02 RH Exhaust Stack ............................................................................................. 3

Maintenance Manual
EXTRA 500
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
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.
78-00-02 RH Exhaust Stack
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.

Maintenance Manual
EXTRA 500


Maintenance Manual
EXTRA 500
Chapter 79
Oil

Maintenance Manual
EXTRA 500
Table of Contents
79-00-00 GENERAL ........................................................................................................ 3

Description.......................................................................................................... 3
Oil System Draining ........................................................................................... 3
79-10-00 STORAGE ......................................................................................................... 4

Description.......................................................................................................... 4
79-10-01 Engine Oil Supply Tank ................................................................................... 4
Draining .............................................................................................................. 4
79-10-02 Overpressure Valve .......................................................................................... 5
Removal .............................................................................................................. 5
Installation .......................................................................................................... 5
79-20-00 DISTRIBUTION............................................................................................... 6
79-20-01 External Scavenge Oil Filter ............................................................................ 6
Filter Element Replacement ............................................................................... 6
79-20-02 Engine Oil Cooler ............................................................................................. 7
Draining .............................................................................................................. 7
79-20-03 Oil Thermostat .................................................................................................. 7
79-20-04 Oil Lines............................................................................................................. 8
Draining .............................................................................................................. 8
79-20-05 Fire Protection Box ........................................................................................... 8
79-30-00 INDICATION ................................................................................................. 10

79-30-01 Oil Pressure Transducer ................................................................................ 10
Removal ............................................................................................................ 10
Installation ........................................................................................................ 11
79-30-02 Oil Temperature Sensor ................................................................................. 11
Removal ............................................................................................................ 11
Installation ........................................................................................................ 11
79-30-03 Oil Pressure Switch ........................................................................................ 11
Removal ............................................................................................................ 11
Installation ........................................................................................................ 12
Page 2 79 9. August
2012
Maintenance Manual
EXTRA 500
79-00-00 GENERAL
Description
The EXTRA 500 oil system includes the following external components that
do not belong to the engine.
• Engine oil supply tank
• Oil vent system
• External scavenge oil filter
• Engine oil cooler
Troubleshooting
Oil pressure at high altitude Oil tank not pressurized Check oil vent system,
too low Refer to Subject 79-10-00
Excessive oil consumption 3 psi overpressure vent valve Replace valve,
open Refer to Subject 79-10-02
External oil filter pin popped External oil filter element Exchange external oil filter
clogged element,
Refer to Subject 79-20-01
Oil System Draining

The complete oil system can be drained using the following procedure.
1 Drain engine oil supply tank. Refer to Subject 79-10-01
2 Drain engine oil cooler. Refer to Subject 79-20-02
3 Replace external scavenge oil filter element. Refer to Subject 79-20-01
Page Date: 9.
30.August
March2013
2012 79 Page 3
Maintenance Manual
EXTRA 500
79-10-00 STORAGE
Description
The engine oil supply tank is located in the engine compartment, mounted on
the RH engine mount.
The oil supply tank is vented to the engine gearbox over a 2 psid overpressure
valve. In case this valve fails to open, the tank is vented overboard through a
3 psid overpressure valve. The reason for the oil tank pressurization is to
prevent too low oil pressure in high altitude.
Both overpressure valves are installed in the engine compartment on the RH
side of the engine mount ring. They are directly connected to the vent line T-
fitting.
79-10-01 Engine Oil Supply Tank
Draining
2 Place an ‘oil slide’ under the lower engine
oil supply tank fitting to an appropriate
canister.
3 Disconnect the engine oil supply tank outlet
fitting and drain the oil from the tank.
4 Drain hose if applicable. Refer to Subject 79-20-04
1 Drain oil supply tank. Refer to Draining Paragraph
2 Disconnect upper hoses. Plug hose fittings. 2 hoses
3 Remove oil supply tank. 2 worm drive hose clamps
and 1 bolt
5 Re-fill tank with oil to the appropriate level. Refer to Chapter 12-10-04

Maintenance Manual
EXTRA 500
79-10-02 Overpressure Valve
Removal
2 Disconnect hose from overpressure valve.
3 Unscrew valve from T-fitting.
Installation
1 Reverse sequence of removal. Replace O-ring when
necessary.
2 Check the 2 psi valve is connected to the
hose routed to the engine gearbox.
3 Check the 3 psi valve is connected to the
hose routed overboard.
4 Check the arrows on both valves point away
from the T-fitting.

Maintenance Manual
EXTRA 500
79-20-01 External Scavenge Oil Filter

The external oil filter is located in the engine compartment, on the lower mount
pad of the engine. It is housed in a fire protection box and accessible after
removal of its cover. Refer to Figure 79-1.
Filter Element Replacement

2 Remove lower cowling. Refer to Chapter 71-10-03
3 Remove fire protection box cover. 23 Phillips screws (2, Figure
79-1)
4 Place a suitable container under the oil filter
element.
5 Remove lock-wire and unscrew filter bowl.
6 Remove dirty element.
7 Remove O-ring and Back-up ring from filter
head.
8 Install new seal kit. Purolator P/N 1741125
9 Install new element. Purolator P/N 038088-08
10 Hand tighten filter bowl until tight against
head and lockwire.
NOTE Only Purolator approved replacement parts may be used to maintain
warranty. Differential pressure bypass indicators and bowls are
matched assemblies and are not field replaceable.
11 Install fire protection box cover. 23 Phillips screws and clip
nuts (2 + 3, Figure 79-1)
12 Install cowlings Refer to Chapter 71
3 Remove fire protection box cover. 23 Phillips screws and clip
nuts (2 + 3, Figure 79-1)

9. August 2013
Maintenance Manual
EXTRA 500

4 Disconnect oil lines from external oil filter. Use a funnel to collect oil
Plug ends. from lines in a suitable
container.
5 Remove oil filter. 2 bolts (9, Figure 79-1)
7 Refill tank with oil to the appropriate level.
79-20-02 Engine Oil Cooler

The oil cooler is installed in the engine compartment on the RH side
Draining
3 Place an “oil slide” under the lower engine
oil cooler fitting to an appropriate canister.
4 Disconnect the lower engine oil cooler
fitting and drain the oil from the oil cooler.
5 Drain hose if applicable. Refer to Subject 79-20-04
1 Drain engine oil cooler. Refer to Draining Paragraph
2 Disconnect upper hose.
3 Remove forward air duct.
4 Remove cooler from aft airduct. The aft airduct can be
removed from the structure to
gain better access to the aft
airduct to cooler mounting
bolts.
79-20-03 Oil Thermostat

The oil thermostat is mounted in the oil cooler housing at outlet to oil tank.
Page Date: 9.
30.August
March2013
2012 79 Page 7
Maintenance Manual
EXTRA 500
2 Remove oil cooler. From serial N 1003
Refer to Subject 79-20-02
3 Remove lock-wire.
4 Unscrew oil thermostat.
79-20-04 Oil Lines
Draining
3 Place suitable “oil slides” and/or canisters
under the lower oil line fittings.
4 Disconnect hoses or tubes on lower fittings Hold open hose end
and drain. downward where necessary.
79-20-05 Fire Protection Box

A fire protection box is installed to house the external oil filter. Refer to Figure
79-1.
1 Remove external oil filter. Refer to Subject 79-00-01
2 Disconnect air hose from fire protection box
(4).
3 Remove carrier (7) and fire protection box 3 bolts (8)
(4).
4 Remove bracket (6) if applicable. 3 bolts (5)

9. August 2012
Maintenance Manual
EXTRA 500
6
fwd
9
1
10
Legend:
1 cover
2 Phillips screw (x23)
3 clip nut (x23)
4 fire protection box
5 bolt
6 bracket
7 carrier
8 bolt
9 bolt
10 oil filter
Figure 79-1 Fire Protection Oil Filter
Page Date: 9.
30.August
March2013
2012 79 Page 9
Maintenance Manual
EXTRA 500
79-30-00 INDICATION
Top View
fwd Transducers
Spanner flats
FUEL OIL TRQ
Switches
Figure 79-2 Engine Indication Transducers and Switches
79-30-01 Oil Pressure Transducer

The oil pressure transducer is located in the engine compartment, on the LH
side of the battery, the middle sensor on top (refer to Figure 77-1 and 79-1).
Removal
3 Remove lock-wire.
4 Remove oil pressure transducer.

9. August 2013
Maintenance Manual
EXTRA 500
Installation
necessary.
2 Perform engine indication check. Refer to Chapter 77-00-01
79-30-02 Oil Temperature Sensor

The oil temperature sensor is installed in the engine compartment on the LH
forward engine gearbox, at oil-in-connection fitting.
Removal
3 Remove lock-wire.
4 Remove oil temperature sensor from fitting. Use a funnel to collect oil
from line in a suitable
container.
5 Plug oil temperature sensor fitting.
Installation
necessary.
2 Perform engine indication check Refer to Chapter 77-00-01
79-30-03 Oil Pressure Switch

The oil pressure switch is located in the engine compartment, on the LH side of
the battery, the middle sideward sensor (refer to Figure 79-1).
Removal

Maintenance Manual
EXTRA 500

Never force the body of the sensor to turn against friction. It may
CAUTION change the set-point. Always use a wrench on the spanner flats of the
attachment fitting for removal and installation.
3 Remove oil pressure switch.
Installation
1 Reverse sequence of removal. Apply Loctite 577 to pressure
switch thread
2 Perform engine indication check Refer to Chapter 77-00-01

9. August 2012
Maintenance Manual
EXTRA 500
Chapter 80
Starting

Maintenance Manual
EXTRA 500
Table of Contents
80-00-00 GENERAL ........................................................................................................ 3

Description.......................................................................................................... 3
80-10-00 CRANKING ...................................................................................................... 4

Motoring ............................................................................................................. 4

Maintenance Manual
EXTRA 500
80-00-00 GENERAL
Description
The ENGINE START switch is located on the instrument panel and has three
positions:
• START
• IGN
• IGN OFF
Engine starting on the EXTRA 500 is semi-automatic. The start switch is
shortly set at START and automatically falls back in the IGN setting. This will
initiate the start cycle directed by the Generator Control Unit and performed by
the starter generator. The condition lever must be set during the cycle to add
fuel. See EXTRA 500 Pilot’s Operating Handbook for exact procedure. When
the engine has reached a certain RPM (N1), the starter will automatically
switch off. Ignition must be switched off manually to prevent excessive spark
plug wear.

Maintenance Manual
EXTRA 500
80-10-00 CRANKING
Cranking may be accomplished with the ENGINE MOTORING switch, located
next to the ENGINE START switch. The ENGINE MOTORING switch has three
positions:
• MOTORING
• ABORT
• NORMAL
NOTE For a normal engine start, the ENGINE MOTORING switch MUST be in the
NORMAL position. Always return the switch in the NORMAL position.
The ABORT position is to abort a normal engine start. It will immediately
switch off the electrical starter and ignition. It does not cut the fuel.
Motoring
Do not motor the engine while aircraft jacked.
CAUTION
Motoring may be used for maintenance and to cool down the engine prior to
engine start to prevent a hot start. Normally, a TOT of below 100°C and a good
battery will produce a start within limits.
1 Secure aircraft with wheel chocks.
2 Perform Before Starting Engine procedure. Refer to EXTRA 500
Pilot’s Operating Handbook,
Section 4
3 Check condition lever in CUT OFF.
During motoring the propeller will turn and exhaust gasses will be hot.
WARNING Make sure no one or nothing can be struck by a propeller blade or is in
the propeller/exhaust jet stream.
Motoring is the same as starting for the starter generator. Apply the
CAUTION normal starter limits to motoring also: Three times 30 seconds max.
with a 60 second cool down period. After the third time, wait at least one
half hour.
4 Switch and hold MOTORING.
5 Check oil pressure indication.
6 Return the switch to ABORT.
7 After motoring switch to NORMAL.

Maintenance Manual
EXTRA 500
Chapter 91
Charts

Maintenance Manual
EXTRA 500
Table of Contents
EA-9B213.30A Cabin Pressure Control, HP up to serial N° 1002

EA-9B213.30B Cabin Pressure Control, HP from serial N° 1003
EA-9B215.10B Air Condition, HB
EA-9B215.20A Bleed Air System up to serial N° 1002
EA-9B215.20B Bleed Air System from serial N° 1003
EA-9B235.17 MKR / Audio, RM
EA-9B243.10A DC Generation I, PP up to serial N° 1002
EA-9B243.10B DC Generation I, PP from serial N° 1003
EA-9B243.20A DC Generation II, PR up to serial N° 1002
EA-9B243.20B DC Generation II, PR from serial N° 1003
EA-9B243.40A E-Box
EA-9B243.41A PCB Board E-Box
EA-9B244.10A External Power, PD up to serial N° 1002
EA-9B244.10B External Power, PD from serial N° 1003
EA-9B244.20 Battery charge, PL
EA-9B246.10A DC Distribution
EA-9B246.10B DC Distribution from serial N° 1003
EA-9B252.10A 12V Power receptacle (Cigar Lighter), MM
EA-9B252.11A 12V Sockets,TH
EA-9B256.11 ELT ARTEX ME 406, DA
EA-9B271.17B AutoPilot-STEC-55X, CA
EA-9B271.18A Yoke (Control stick) Left, Right
EA-9B273.30A Stall Warning, WH up to serial N° 1002
EA-9B273.30B Stall Warning, WH from serial N° 1003
EA-9B275.20A Flap-System, CG up to serial N° 1002
EA-9B275.20B Flap-System, CG from serial N° 1003
EA-9B276.10A Prop Overspeed, ES
EA-9B284.10A Fuel QTY Indication, QX
EA-9B284.13A PCB-Board 1
EA-9B284.30 Low Fuel Warning, WW up to serial N° 1002
EA-9B284.30A Low Fuel Warning, WW from serial N° 1003
EA-9B303.10A Pitot-Static-Stall-Heat, HG up to serial N° 1002
EA-9B303.10B Pitot-Static-Stall-Heat, HG from serial N° 1003
EA-9B304.10A Anti ICE Intake, HM up to serial N° 1002
EA-9B304.10B Anti ICE Intake, HM from serial N° 1003
EA-9B304.20A Windshield Heat, HF up to serial N° 1002
EA-9B304.20B Windshield Heat, HF from serial N° 1003
EA-9B310.10A Boots, HH up to serial N° 1002
EA-9B310.10B Boots, HH from serial N° 1003
EA-9B314.30B Airspeed Warning, WV
EA-9B315.80B Annunciator Panel, WW up to serial N° 1002
EA-9B315.80C Annunciator Panel, WW from serial N° 1003
EA-9B315.81 PCB-Board Warning/Annunciator up to serial N° 1002
EA-9B315.90B Low Voltage Monitor, WL up to serial N° 1002
EA-9B315.90C Low Voltage Monitor, WL from serial N° 1003
EA-9B316.40A Digital Instrument Package, EY
EA-9B316.50A Engine Instrument Package, EZ
EA-9B317.10A Engine Warning, LW up to serial N° 1002
EA-9B317.10B Engine Warning, LW from serial N° 1003

March
July 2012
Maintenance Manual
EXTRA 500
EA-9B323.10A-1 Landing Gear Control, GA up to serial N° 1002

EA-9B323.10C Landing Gear Control, GA from serial N° 1003
EA-9B323.20A Gear Warning, GA up to serial N° 1002
EA-9B323.20B Gear Warning, GA from serial N° 1003
EA-9B334.10A Strobe Light, LB
EA-9B334.20A NAV Light, LC
EA-9B334.35A Landing Light, LA up to serial N° 1002
EA-9B334.35B Landing Light, LA from serial N° 1003
EA-9B334.40A Cabin-Dome-MAP Light, LJ
EA-9B334.50A Courtesy Light, LY
EA-9B334.55A Ice Light, LN
EA-9B334.60A Recognition Lights, LF up to serial N° 1002
EA-9B334.60B Recognition Lights, LF from serial N° 1003
EA-9B334.75A Glare Light
EA-9B334.81A Luminiszenz-Backlighting
EA-9B334.90A Dimming, LH
EA-9B334.91A Dimming
EA-9B342.65 IFD LH, FG up to serial N° 1002
EA-9B342.65A IFD LH, FG from serial N° 1003
EA-9B342.66 IFD RH, FG up to serial N° 1002
EA-9B342.66A IFD RH, FG from serial N° 1003
EA-9B342.67 Keypad, FG
EA-9B342.73 Attitude Gyro, FM
EA-9B344.14 Weather Detec TWX-670, SS
EA-9B344.15 Traffic System TAS-610, SD
EA-9B344.16 Broadcast MLB-700, TL
EA-9B344.17 Datalink 2-way MLX-770, TS
EA-9B345.47 DME KDM 706A, SN
EA-9B345.58 ATC BXP6402-1R, SH up to serial N° 1002
EA-9B345.58A ATC BXP6402-1R, SH from serial N° 1003
EA-9B360.11 Prop Heat, HI
EA-9B360.11A Prop Heat, HI from serial N° 1003
EA-9B411.70A_1 PCB Annunciator from serial N° 1003
EA-9B411.70A_2 PCB Annunciator from serial N° 1003
EA-9B527.10 Door Warning up to serial N° 1002
EA-9B527.10A Door Warning from serial N° 1003
EA-9B731.10A Fuel Pump / Filter, QB up to serial N° 1002
EA-9B731.10B Fuel Pump / Filter, QB from serial N° 1003
EA-9B731.30A Fuel Trans, QF up to serial N° 1002
EA-9B731.30B Fuel Trans, QF from serial N° 1003
EA-9B731.40A Fuel Flow, QY
EA-9B743.10A Start / Ignition, JB up to serial N° 1002
EA-9B743.10B Start / Ignition, JB from serial N° 1003
EA-9B752.15A Panel Fan, HK
Page Date: 30.

11. March 2012
July 2012 91 Page 3
Maintenance Manual
EXTRA 500

1 2 3 4 5 6 7 8
CIRCUIT BREAKER/SWITCH PANEL
EMERGENCY BUS PP4

1HP 9HP
C-PRESS DUMP
07.2.1.15L 3A 2A
HP2F-22 2 HP2E-22 PRESS
A:10 2HP:2
OFF 6 HP1E-22
A GROUND RELAYS 5 A
DUMP 4
HP3E-22
2HP:1
35GA 3 3
VV189 HP10F-22N A:4 3 HP10E-22N 2
2 1
1A
3 PRESS
2
1B HP9F-22 HP9F-22 1 HP9E-22
100 D:13
3
GA32-22N
2 HP9H-22 3 HP9G-22
1C A:3
1VN-E LK 3 HP3F-22 3 HP3E-22
2 A:2
1D
001758_212_02 see EA-9B246.10 DC-DISTRIBUTION
-X2 +X1
M220-B4N
Schalterstellung A/C on Air SAFTY VALVE
5HPA
5HP
VV91
see EA-9B323.10 GEAR CONTROL HP3F-22 HP3G-22 A DUMP
HP9H-22 HP9J-22 B SOLENOID
DRUCKSCHOTT
VV92
D
LG16E-22N
HP8E-22N
HP10F-22N
B E B
4HP-A
DRUCKSCHOTT HINTEN
10 1 R C S MS3116F106S P/N 5113-00-3
9 11 2 ST14-B MIL-C-26482-I
3
8 13 12 HP13-F22N HP13-E22N
4 5
7 5 1VN-E
CABIN PRESSURE CONTROLLER 6
4HP-A 001758 212 02 SIM
B CABIN CONTROL OUTFLOW VALVE
COMMEN DIAL LITES
LG16E-22N
1 6HP-A
+5V DIAL LITES 2 VV88 HP8E-22N 19VN-A 6HP
GND - 3 001758 212 02 3 VACUUM VALVE
18-32,5VDC + 4
HP2F-22 4 VACUUM VALVE
POTENTIOMETER 5
ws ws 5 POTENTIOMETER
POTENTIOMETER 6 org HP14E-22 HP14E-22 org 6 POTENTIOMETER DRUCKSCHOTT
bl bl
POTENTIOMETER 7 7 POTENTIOMETER
ws ws -
Motor - 8 8
bl HP15E-22 HP15E-22 bl MOTOR
Motor + 9 9 +
+12V DIAL LITES 10 12
LG15E-22
DIMMING BOARD DIM CONTROL P/N 5112-00-3
MS27473E10A35S 27LH-A
4HP P/N 5111-00-3 MIL-C-38999-II MS27473E10A35S
ST1 LH4-22 MIL-C-38999-II
INV 4
1k2 4W 4.7k 6HP
24LH 10 1
26 56k 0.25W F3 Lumi
Gen-Fail Aft Door LG15E-22 LH2-22 9 11 2
Annunciator Panel left 31 Dimm 7 3 Absolutdruck Differenzdruck
1A cw
SWITCHES 8 13 12
C Gear Warn Stall-Warn 10000ft SW 12830 ft SW C
P/N 90-4219X-1 ST1 7 5 4
6
Flaps Cab-Press Muß auf 12830 ft eingestellt werden!
AV1 MPL500
31 Anschluß an Static Press
see EA-9B334.90 DIMMING SYSTEM
DIMMING BOARD EA-9B334.91 7HP 8HP
1WW NO C
ANNUNCIATOR BOARD
5WW D15 VV89
HP11F-22
HP12B-22
5WW-B 5WW-D
LIGHT TEST (GND)
WW16-22 HP11G-22 108
HP11G-22 HP11E-22
15 47 HP12F-22N HP12E-22
24 + VOLT DIMM
WW1-20
25 VV90
Anschluß offen
G
ANNUNCIATOR BOARD EA-9B315.81
see EA-9B315.80 ANNUNCIATOR PANEL 001758_212_02
3VN-A
Die Gültigkeitszuordnung Letzte Bearbeitung: 18.02.11 HW Datum Name Maßstab auf Projektion
von Version zu Bearb.: 27.04.04 PB SI.-Klasse Freimaßtoleranz
Flugzeugbaureihe Oberflächenschutz Oberfläche
D ist der Bauakte bzw. Gepr.: D
dem jeweiligen Fertigungsauftrag Gepr.: EA 400-500
zu entnehmen.
Maintenance Manual EXTRA 500
Zuordnung links / rechts wird mit CABIN PRESSURE, HP
*/* in allen Feldern angegeben.
04
03
EA-9B213.30 A
02 Schwarze Heide 21 A3 Blatt 1 von 1
01 A ÄM-400-09-01 16.09.10 HW
Chapter 91 30. March 2012 Ver. Bezeichnung Nr.: Änderung/Mod. Nr.: Datum Name 46569 Hünxe, Germany Schutzvermerk nach DIN 34 beachten.
EDV-Kennung: 9B21330T
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
EMERGENCY BUS PP4

1HP 9HP
C-PRESS DUMP
07.2.1.15L 3A 2A
HP2F-22 2 HP2E-22 PRESS
A:10 2HP:2
OFF 6 HP1E-22
A 5 A
GROUND RELAYS DUMP 4
HP3E-22
2HP:1
35GA 3 3
VV189 2 HP10F-22N A:4 3 HP10E-22N 2
1A 1
3 PRESS
2
1B HP9F-22 HP9F-22 1 HP9E-22
100 D:13
3
GA32-22N
2 HP9H-22 3 HP9G-22
1C A:3
1VN-E LK 3 HP3F-22 3 HP3E-22
2 A:2
1D
001758_212_02 see EA-9B246.10 DC-DISTRIBUTION
-X2 +X1
M220-B4N
Schalterstellung A/C on Air SAFTY VALVE
5HPA
5HP
VV91
see EA-9B323.10 GEAR CONTROL HP3F-22 HP3G-22 A DUMP
HP9H-22 HP9J-22 B SOLENOID
DRUCKSCHOTT
VV92
D
LG16E-22N
HP8E-22N
HP10F-22N
B E B
4HP-A
DRUCKSCHOTT HINTEN
10 1 K PK P/N 5113-00-3
ST14-B MS3116F106S
9 11 2 MIL-C-26482-I
3
8 13 12 1VN-2 1VN-3 HP13E-F22N HP13E-E22N
4 5
7 5 001758 212 02
CABIN PRESSURE CONTROLLER 6
4HP-A SIM
B CABIN CONTROL OUTFLOW VALVE
COMMEN DIAL LITES
LG16E-22N
1 6HP-A
+5V DIAL LITES 2 VV88 HP8E-22N 19VN-A
6HP
GND - 3 001758 212 02 3 VACUUM VALVE
18-32,5VDC + 4
HP2F-22 4 VACUUM VALVE
POTENTIOMETER 5
ws ws 5 POTENTIOMETER
POTENTIOMETER 6 org HP14E-22 HP14E-22 org 6 POTENTIOMETER DRUCKSCHOTT
bl bl
POTENTIOMETER 7 7 POTENTIOMETER
ws ws -
Motor - 8 8
bl HP15E-22 HP15E-22 bl MOTOR
Motor+ 9 9 +
LG15E-22 DIMMING BOARD DIM CONTROL
5LH
MS27473E10A35S 5LH-C P/N 5112-00-3
4HP P/N 5111-00-3 MIL-C-38999-II MS27473E10A35S
5LH-A LH5E-22N MIL-C-38999-II
INV 4 6HP
1k2 4W
23LH 4.7k 10 1
26 56k 0.25W F3 INSTR.
LG15E-22 LG107E-22 9 11 2
31 Dimm 1 3
1A cw 8 13 12
C 7 5 4 C
5LH-B INSTRUMENTS 6
AC OUT Absolutdruck Differenzdruck
13
10000ft SW 12830 ft SW
LG107E-22
25 see EA-9B334.90 DIMMING SYSTEM Muß auf 12830 ft eingestellt werden!
DIMMING BOARD EA-9B410.30
AV1 MPL500 Anschluß an Static Press
7HP NO C
8HP
ANNUNCIATOR PANEL
5WW L106 L206 D06 VV89
Annunciator Panel
HP11F-22
HP12B-22
5WW-D
LIGHT TEST (GND)
Stall-Warn Flaps Cab-Press
47 HP11G-22 108 HP11G-22 HP11E-22
Windsh-Heat Gear Warn Aft Door HP12F-22N HP12E-22
+ VOLT DIMM
VV90
Pitot Heat R Hydraulik Pneumatic Anschluß offen
P
1VN-5
see EA-9B315.80 ANNUNCIATOR PANEL 001758 212 02
Die Gültigkeitszuordnung Letzte Bearbeitung: Datum Name Maßstab auf Projektion

zu entnehmen.
Zuordnung links / rechts wird mit CABIN PRESSURE, HP
Maintenance Manual EXTRA 500 */* in allen Feldern angegeben.
04
03
EA-9B213.30 B
02 B ÄM-400-10-04 08.09.11 HW Schwarze Heide 21 A3 Blatt 1 von 1
01 A ÄM-400-09-01 16.09.10 HW
Nr.: Änderung/Mod. Nr.: Datum Name 46569 Hünxe, Germany
Ver. Bezeichnung
Chapter 91 11. July 2012 Schutzvermerk nach DIN 34 beachten.
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
E-BOX
GENERATOR EXT POWER BATTERY
K3 K1 K4
A FIREWALL A
ST1 ST1
m HB15G-22 m HB15F-22
21
n
HB16G-22 n
HB16F-22
22
E-BOX EA-9B243.40
see EA-9B243.40 E-BOX GND-Bolzen Firewall DRUCKSCHOTT HINTEN
1VN
19VN
HB5F-4N HB5F-4N HB5E-4N
CIRCUIT BREAKER/SWITCH PANEL Bolzen P/N: 1240160-5

SOFT START MODULE
HB2E-4 5 HB2F-4 HB2F-4 HB2G-4 HB2G-4 HB5E-4N
C B+ B-
grn M-
Bolzen
HB2E-4
17HB
1HB
AIR-CON
wht
HB20E-4
HB21E-4
100A SOFT START CONTROL
Timer D A B
B LOAD BUS PP3 B
18HB
red
6HB
black
VENT 3
30A 1
HB7E-12 2 4HB
7HB
AIR-CTRL Kompressor
2A TEMP. SW.
Kondenser
Enviro Systems 1134410-5
VENT AIR CON
12HB
rt sw/wht MOTOR CONTROL
C
2
5 HB4E-20
2
rt/wht rt
:1 9HB:2 8HB
HB3E-20
1
3
3
6
4
OFF
HI
LOW1
ON
OFF
Binary Pressure Switch 1250232-4
ST13-D
HB15E-22
COMPRESSOR AND CONDENSER FAN

HB16E-22 1 HB16F-22 HB15F-22 HB15E-22
D:19 14
07.1.1.13
07.2.1.40 901
SIM
CABIN BLOWER AFT
13HB
Enviro Systems 1134200-80
high HB8E-12 HB8E-12 VV93org
3 VV97 blk HB10E-12N
FILTER-1 2 HB8G-12 HB8F-12 org
C HB7E-12 3 HB7F-12 HB6E-12 1 C
D:2 2HB VV98 HB9E-12 rt
HB23E-22N
HB17E-22 1 HB17F-22 HB17F-22X1 X2 HB14E-22N VV94 orange-high
C:19
red-low
M320 CABIN BLOWER FO
VENT 14HB
HB6F-12
low HB9E-12 Enviro Systems 1134200-81
3 org 1134200-81 1134200-80
2 HB9G-12 HB9F-12 rt blk HB13E-12N
HB6F-12 1 VV99
3HB VV100
HB18E-22 1 HB18F-22 HB18F-22X1 X2 HB19E-22N orange-high HB22E-22N
C:20
red-low
M320
see EA-9B246.10 DC-DISTRIBUTION am Halteblech Blower Front
HB22E-22N
HB13E-12N
HB23E-22N
HB10E-12N
HB19E-22N
HB14E-22N
GROUNDING POINTS
M HJ LM
001758 212 02 001758 212 02 001458 212 02

8VN-F 8VN 8VN
von Version zu Bearb.: SI.-Klasse Freimaßtoleranz
27.04.04 PB
D Gepr.: D
ist der Bauakte bzw.
Maintenance Manual EXTRA 500 dem jeweiligen Fertigungsauftrag Gepr.:
EA 400-500
zu entnehmen.
Zuordnung links / rechts wird mit AIR CONDITION 20A, HB
04
03 B ÄM-400-09-02 17.09.10 HW
EA-9B215.10 B
02 ÄM-400-09-01 Schwarze Heide 21 A3 Blatt 1 von 1
01 A ÄM-400-04-02 16.09.10 PB
1 2 3 4 5 6 7 8
2HA-A
1 2 3 4 C50C 5 6 7 8
VV97
CABIN TEMPERATUR CONTROLLER
2HA-A
VV98
28VDC 27
HA1G-22
28VDC 9 CIRCUIT BREAKER/SWITCH PANEL
Overtemp Ind Light 20 N/C
4HA
ws 1 ws 1 MAN CONTROL
Manual Bypass 3 B:3 BATTERY BUS PP2
Man H. Exchanger 6
bl HA3E-22 HA3E-22 1 bl HA3F-22 2
B:4 3 07.1.1.17 1HA
Airframe Ground ENV-BLEED
1
B:5 5A
D 1 org MAN 1 AUTO/MANUAL D
25
org B:7 HA1E-22 1 HA1F-22
Auto/Manual SW 2 C:10
37
bl HA4E-22 HA4E-22 1 bl
Switch GND B:8 AUTO 3 5AH:1
Switch Power +15VDC 35
ws
1 ws
B:6 4 07.2.1.13
Airframe Ground
1 5
B:9
6
HA4F-22
HA1F-22
HA1G-22
3 2
4
Temp. Poti. Ansicht
Airframe Ground 1 ws
7HA TEMP von hinten.
Pilot Control +VA 29
ws B:10
Pilot Control 5
org HA5E-22 HA5E-22 1 org HA5F-22
B:11 10k P16NM103KA
31
bl
Pilot Control GND 1 bl
B:12
1 HA20G-22
EA-0B836.31
B:13 OFF 1 ENV BLEED
SN 1300350-27
2 HA4G-22 Microswitch am
HA2G-22
HA11F-22
HA20F-22
HA28F-22 1 HA28E-22 3 ST4 Cut Off Condition-Lever
B:2 16HA:1
D1 NC
ON 18HA
BYW56 4 :2 07.2.1.13 HA20F-22
PRIM. SHUT OFF VALVE Splice 21 NO
ST4 5 HA21G-22 HA21G-22 1 HA21F-22 HA21F-22 HA21G-22
VV103 D:14 22
HA22G-22 HA22F-22 1 HA22E-22 6
Prim. Bleed N/C 20 D:15
HA23E-22N
CB-Trennstecker Trennstecker 334-870
15HA VV104 CB-Trennstecker see EA-9B246.10 DC-DISTRIBUTION
an 11HA Flow Valve FIREWALL
HA28F-22
2VN-D C
ws EA-0B836.32 001758 212 02 Temp. Modulating Valve Turbine leftside
Bypass +28V 23 9HA-A
Bypass GND 2
bl HA6E-22
H.Exchanger +28V 22 ws SN 1300330
ws Exch +
H.Exchanger GND 1
bl HA7E-22 66 B EA-0B836.26
HA6F-22 bl Exch -
C 67 D C
ws
43 A Bypass +
Stadby ON 13 VV99 bl
68 C Bypass -
HA7F-22 14HA-A Triewerkraum
Duct Sensor pos. 10
ws 69 Duct Temp Sensor SN 1300450-1 9HA links
Duct Sensor GND 32
bl HA27E-22 42 ws A Sensor + EA-0B833.07
70 HA27F-22 bl
71 B Sensor - Triebwerkraum
Cabin Sensor Pos 12
ws 41 14HA Brandspant
rechts
Cabin Sensor GND 33
bl HA8E-22
10HA-A Cabin Temp. Sensor
VV100 ST12
Chassis GND 36 ws SN 1300440
HA9E-22N 1 A Sensor + EA-0B833.08
Power GND 8 HA8E-22 bl HA8E-22
2 B Sensor -
HA10E-22N HA10F-22N D GND
3VN-A HA2F-22 3 HA2G-22
2HA 001758 212 02
S 8VN-A C 28VDC Co Pilot
4 overhead
C15P
A 10HA
see EA-9B334.40 CABIN-DOME-LIGHT
HA28G-22
MASS FLOW CONTROLLER 3HA-A
& EA-9B235.17 MKR-AUDIO
VV101 HA11G-22 001758 212 02
Cabin leftside
28VDC 27
28VDC 9 CB-Trennstecker
Standby ON 13
HA13E-22 2
D:9
Low 18
HA12E-22 2 see EA-9B246.10 DC-DISTRIBUTION
High 30 D:8 VALVE-FLOW CONTROL
11HA-A
Hi/Low Switch GND
HA14E-22 2
35 D:10 40 SN 1300490-13
ws ws Open +
Open +28VDC 23 72 A EA-0B836.33
B bl HA15E-22 HA15F-22 HA15F-22 bl Open -
B
Open GND 2 73 C
Close +28VDC
ws ws Close +
22 74 B Triebwerkraum
Close GND
bl HA16E-22 HA16F-22 HA16F-22 bl Close -
1 75 D links
39
11HA
EA-0B836.30
12HA-A MASS FLOW SENSOR
SN 1300360-17
ws 38 ws
Flow Sensor +15V 24 76 A Flow Sens + SN 1300464-15
Flow Sensor GND
bl HA17E-22 HA17F-22 HA17F-22 bl Flow Sens - EA-0B833.06
31 77 B
Flow Sensor Input
ws ws Flow Sens In
5 78 C
Flow Sensor GND
bl HA18E-22 HA18F-22 HA18F-22 bl Flow Sens Gnd
7 79 D
37 E N/C
Power GND 8 VV102 F N/C
Logic GND 26 G N/C
Power GND
HA19E-22N J4 ST4 N/C
36 H
3HA
37pol DSub 001758 212 02 12HA
3VN-A T
Bugfahrwerkkasten
Annunciator Panel left
FIREWALL
Aft Door Stall-Heat Oil-Press P/N 90-42192-1
geändert
Stall-Warn Windsh-Heat Fuel-Press
ANNUNCIATOR BOARD Die Gültigkeitszuordnung Letzte Bearbeitung: Datum Name Maßstab auf Projektion
5WW-C von Version zu 17.02.04 PB SI.-Klasse Freimaßtoleranz
001758 212 02 5WW D12 Cab-Press Bleed Overt Bearb.:
A
Maintenance Manual EXTRA 500 2VN-D LIGHT TEST (GND)
WW13-22
Flugzeugbaureihe
Gepr.:
Oberflächenschutz Oberfläche
A
12 dem jeweiligen Fertigungsauftrag EA 400-500
+ VOLT DIMM 24 Gepr.:
KABINE A WW1-20 zu entnehmen.
K2 25 1WW BLEED AIR, HA
Zuordnung links / rechts wird mit
Env. Bleed Temp Splice */* in allen Feldern angegeben.
Temp Sensor VV108 5WW-D G6A-234P 5WW-A 04
Chapter 91 30. March 2012
HA34E-22N 03
EA-9B215.20 A
NC D38
HA33E-22 WW39-20N 02 Schwarze Heide 21
39 44 +VDCII 9 A3 Blatt1 von 1
21HA VV109 01 A ÄM-400-09-01 06.10.10 HW
BYW56 Nr.: Änderung/Mod. Nr.: Datum Name 46569 Hünxe, Germany
EA-0B833-09 Ver. Bezeichnung Schutzvermerk nach DIN 34 beachten.
21544-3-60-2 ANNUNCIATOR BOARD EA-9B315.81
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
CABIN TEMPERATUR CONTROLLER 2HA-A

VV98
28VDC 27
HA1G-22
28VDC 9 CIRCUIT BREAKER/SWITCH PANEL
Overtemp Ind Light 20 N/C CB-Trennstecker
ws 4HA
ws 1 1 MAN CONTROL
Manual Bypass 3 B:3 BATTERY BUS PP2
Man H. Exchanger 6
bl HA3E-22 HA3E-22 1 bl HA3F-22 2
B:4 3 07.1.1.17 1HA
Airframe Ground ENV-BLEED
1
B:5 5A
A 1 org MAN 1 AUTO/MANUAL A
org B:7 HA1E-22 1 HA1F-22
Switch Power +15VDC 25 2 C:10
37
bl HA4E-22 HA4E-22 1 bl
Auto/Manual SW B:8 AUTO 3 5AH:1
ws
Switch GND 35 1 ws
B:6 4 07.2.1.13 org
Airframe Ground bl 3 ws
1 5
HA1F-22
HA1G-22
B:9 4 2
6
HA4F-22
Temp. Poti. Ansicht
1 ws TEMP von hinten.
ws B:10 2 4
A
B
E
C
D
Pilot Control +VA 29 Modul 1
Pilot Control 5
org HA5E-22 HA5E-22 1 org HA5F-22
B:11
J
3 10k 7HA
F
K
P16NM103KA
G
Pilot Control GND 31
bl 001115-202-02
1 bl
B:12
Airframe Ground
1 ENV BLEED FIREWALL
B:13 OFF1
2 HA4G-22
EA-0B836.31
SN 1300350-27
HA28F-22 1 HA28E-22 3 16HA:1 ST4 Microswitch am
B:2 Condition-Lever
HA2F-22
HA11F-22
HA20F-22
ON 18HA
4 :2 07.2.1.13 HA20F-22 HA20G-22
21 NC
5 HA21E-22 HA21E-22 1 HA21F-22 HA21F-22 HA21G-22
D:14 22
HA22F-22 1 HA22E-22 6 C HA20G-22
D:15 NO
FIREWALL
see EA-9B246.10 DC-DISTRIBUTIONCB-Trennstecker Cut Off
J4 ST4
Splice PRIM. SHUT OFF VALVE 334-870
HA28F-22
HA22F-22 HA22G-22 VV104 VV103
20 Prim. Bleed N/C an 11HA Flow Valve
Bypass +28V 23
ws HA23E-22N
Turbine leftside
Bypass GND 2
bl HA6E-22 D1 15HA Temp. Modulating Valve
ws 2VN-A EA-0B836.32 9HA-A
H.Exchanger +28V 22 C
H.Exchanger GND 1
bl HA7E-22 001758 212 02
B ws ws BYW56 ws SN 1300330 B
B Exch + EA-0B836.26
HA6E-22 bl 66 bl HA6F-22 HA6F-22 bl Exch -
67 D
ws Bypass +
A
Duct Sensor pos. 10
ws ws 43 ws HA7F-22 bl Bypass -
C
Duct Sensor GND 32
bl HA27E-22 HA7E-22 bl 68 bl HA7F-22 Triewerkraum
69 DUCT TEMP SENSOR
14HA-A 9HA links
ws 42 ws ws A Sensor +
Cabin Sensor Pos 12
ws HA27E-22 bl 70 bl HA27F-22 bl Triebwerkraum
Sensor -
71 B Brandspant
Cabin Sensor GND 33
bl HA8E-22
41 14HA rechts Cabin Temp. Sensor
OVERHEAD 10HA-A
SN 1300450-1
VV100 ST12 EA-0B833.07
Chassis GND 36 ws HA24E-22 HA24E-22 SN 1300440
HA9E-22N 1 A Sensor + EA-0B833.08
Power GND 8 HA8E-22 bl HA8F-22 HA8F-22
2 B Sensor -
Stadby ON 13 VV99 HA10E-22N HA10F-22N HA10F-22N
3 D GND
T 8VN-A HA2F-22 HA2G-22 HA2G-22 C 28VDC Co Pilot
2HA 4 Overhead
50pol DSub
A 10HA
3HA-A 1VN-3 see EA-9B334.40 CABIN-DOME-LIGHT
MASS FLOW CONTROLLER 001758 212 02 & EA-9B235.17 MKR-AUDIO
HA28G-22
VV101 001758 212 02
HA11G-22
Cabin leftside
28VDC 27
28VDC 9
Standby ON
CB-Trennstecker
13
HA13E-22 2
D:9
Low 18
High
HA12E-22 2 see EA-9B246.10 DC-DISTRIBUTION
30 D:8 11HA-A VALVE-FLOW CONTROL
Hi/Low Switch GND
HA14E-22 2
35 D:10 40 SN 1300490-13
Open +28VDC
ws ws ws ws Open +
C 23 72 A EA-0B836.33 C
Open GND
bl HA15E-22 bl bl HA15F-22 HA15F-22 bl Open -
2 73 C
Close +28VDC
ws ws ws ws Close +
22 74 B Triebwerkraum
Close GND
bl HA16E-22 bl bl HA16F-22 HA16F-22 bl Close -
1 75 D links
39
11HA
MASS FLOW SENSOR
EA-0B836.30
SN 1300360-17
12HA-A
ws ws 38 ws ws
Flow Sensor +15V 24 76 A Flow Sens + SN 1300464-15
Flow Sensor GND
bl HA17E-22 bl bl HA17F-22 HA17F-22 bl Flow Sens - EA-0B833.06
31 77 B
Flow Sensor Input
ws ws ws ws Flow Sens In
5 78 C
Flow Sensor GND
bl HA18E-22 bl bl HA18F-22 HA18F-22 bl Flow Sens Gnd
7 79 D
37 E N/C
Power GND 8 VV102 F N/C
Logic GND 26 J4 ST4 G N/C
Power GND
HA19E-22N N/C
36 Annunciator Panel H
3HA
37pol DSub 12HA Bugfahrwerkkasten
D Oil Press Bleed Overt Stall-Warn
Fuel Press Stall Heat Windsh-Heat

1VN-3
001758 212 02 Prop Low Pitch Pitot Heat L Pitot Heat R
ANNUNCIATOR PANEL
5WW D03 von Version zu Bearb.: 17.02.04 PB SI.-Klasse Freimaßtoleranz
001758 212 02 L103 L203
LIGHT TEST (GND) Flugzeugbaureihe Oberflächenschutz Oberfläche
D 1VN-1 Gepr.: D
KABINE + VOLT DIMM
E K2 zu entnehmen.
5WW-A
Env. Bleed Temp Splice 1VN-5 Zuordnung links / rechts wird mit BLEED AIR, HA
Temp Sensor VV108 5WW-D G6A-234P WW39-20N
9 K 001758 212 02 04
HA34E-22N EA-9B215.20 B
NC D38 03
HA33E-22 + 28V Power WW41E-20
39 44 5 Über 5LH-A Pin 9 an F1 02 B ÄM-400-10-04 08.09.11 HW Schwarze Heide 21
21HA VV109 A3 Blatt1 von 1
BYW56 see EA-9B334.90 01 A ÄM-400-09-01 06.10.10 HW
46569 Hünxe, Germany
Chapter 91 11. July 2012
21544-3-60-2
EA-0B833-09 ANNUNCIATOR BOARD EA-9B411.70 Ver. Bezeichnung Nr.: Änderung/Mod. Nr.: Datum Name Schutzvermerk nach DIN 34 beachten.
see EA-9B315.80 ANNUNCIATOR PANEL EDV-Kennung: 9B21520T
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
AUDIO & MARKER

P3401 IFD LEFT CIRCUIT BREAKER/SWITCH PANEL
PMA8000B oder 1RM-A
PMA8000BT 1 P1144 IFD-5000i
ws ws
COM 1 MIK AUDIO OUT 11 1RV1E-24S 1RV1E-24S 11 MICROPHONE #1 LOAD BUS PP3
bl bl Pilot PTT Pilot Copilot PTT
COM 1 MIK KEY OUT 12 5 TX KEY #1
ws 1RZ AUDIO-MRK
NAV #1 RX HI 17 1RM1E-24S 1RM1E-24S 13 HEADPHONE #2 CB Trennstecker 5A
bl bl HANDMIKE
NAV #1 RX LO 18 29 HEADPHONE #2 LO
ws ws RZ1F-22 2 RZ1E-22
COM #1 RX HI 9 1RV2E-24S 1RV2E-24S 44 HEADPHONE #1 D:3
bl bl
COM #1 RX LO 10 30 HEADPHONE #1 LO
ws ws
MONITOR #1 RX HI 7 1RV3E-24S 1RV3E-24S 43 HEADPHONE #3
PILOT COPILOT
bl bl 2RZ
MONITOR #1 RX LO 8 28 HEADPHONE #3 LO
RZ16F-22 D:4 2 RZ16E-22
J1121
1A
RM1E-24 RM1E-24
A EXT BLUE LAMP (O) 37 62 CFG DISCRETE IN 0 A
RM2E-24 RM2E-24 Pilot MIKE
EXT AMBER LAMP (M) 38 63 CFG DISCRETE IN 1 see EA-9B246.10 DC-DISTRIBUTION
RM3E-24 RM3E-24
EXT WHITE LAMP (A) 36 82 CFG DISCRETE IN 2 Pilot PHONE
1RV4E-24
ACTIVE COM SELECTED 24
1RV5E-24 1
COM SPLIT SELECTED 25 P1122
RM1F-24 1RV4E-24
38 DISCRETE IN 7
RM2F-24 1RV5E-24 PASS 1 PASS 2
37 DISCRETE IN 6
RM3F-24 RV1E-24
21 DISCRETE OUT 10
1RV5F-24
3FG
1RV4F-24
see EA-9B342.65 IFD LEFT
IFD RIGHT
1 P2122
IFD-5000i
1RV4F-24
1 38 DISCRETE IN 7
1RV5F-24
37 DISCRETE IN 6
RV1E-24
21 DISCRETE OUT 10
RV1F-24 PASS 3 PASS 4
COM 1 SPKR LOAD 25 J2121
RM1F-24
COM 1 SPKR LOAD GND 26 62 CFG DISCRETE IN 0
RM2F-24
63 CFG DISCRETE IN 1
RM3F-24
COM 2 SPKR LOAD 27 82 CFG DISCRETE IN 2
COM 2 SPKR LOAD GND 28 P2144
1
ws ws
COM 2 MIK AUDIO OUT 15 2RV1E-24S 2RV1E-24S 11 MICROPHONE #1
bl bl
COM 2 MIK KEY OUT 30 5 TX KEY #1
ws ws
NAV #2 RX HI 19 2RM1E-24S 2RM1E-24S 13 HEADPHONE #2
bl bl
NAV #2 RX LO 20 29 HEADPHONE #2 LO
ws ws
COM #2 RX HI 13 2RV2E-24S 2RV2E-24S 44 HEADPHONE #1
bl bl
COM #2 RX LO 14 30 HEADPHONE #1 LO
43 HEADPHONE #3
28 HEADPHONE #3 LO
15RZ-A 15RZ-a 7RZ
7FG
TEL RINGER IN 44 BOSE
RZ16G-24 V+ rt
TEL RINGER GND 43 see EA-9B342.66 IFD RIGHT 1
WH12E-22S bl GND sw 1 6
ALT WRN IN 31 31 see EA-9B284.13 PC-BOARD 1 Pin 8 2
bl ws
PILOT MIC GND 35 3
org RZ2E-24S RZ9F-24S RZ9F-24S org RIGHT EAR ws PASS 3
B PILOT MIC IN 33 4 B
ws LEFT EAR sw
PILOT MIC KEY 34 5
VV235163 ws MIC HI ws
SS8E-24 D1 SS7E-24 6
2x 001115 208 02 bl MIC LO ws/bl
BYW-56 7
bl bl A C bl RZ11E-24S
PASS HEADSET GND 42 8
ws RZ9E-24S RZ9E-24S bl B RZ9G-24S
PASS HEADSET L 40 9 16RZ-A 16RZ-a 8RZ
org bl D E bl
PASS HEADSET R 41 BOSE
RZ16H-24 V+ rt
ST13-1B DME ws
1
ws F H bl GND sw 1 6
2
Modul 2
ADF AUDIO HI 7 2SN-A KDM 706A ws ws
N/C G K ws 3
ADF AUDIO LO 8 20 ws J RZ9G-24S org RIGHT EAR ws PASS 4
ws ws ws 4
DME AUDIO HI 21 14 21 Audio Hi LEFT EAR sw
bl RM12E-24S bl RM12F-24S bl 5
DME AUDIO LO 22 15 17 Audio Lo org A C org ws MIC HI ws
6
2SN org B E org bl MIC LO ws/bl
7
WH13-22N org D RZ10E-24S
ALT WRN GND 32 8
17RZ-A 17RZ-a 9 9RZ
C U F G BOSE
1VN-D 1VN-C
Modul 3
K RZ16J-24 V+ rt
1
MKR Ant. H J bl GND sw 1 6
001758_212_02 2
Druckspant ws
2RM-A CI118-5 3
RZ9H-24S RZ9H-24S org RIGHT EAR ws PASS 1
4
MKR ANTENNE RM4E-RG400 VV235164 LEFT EAR sw
1 5
001115-202-02 ws MIC HI ws
MKR ANTENNE GND 2 6
RZ16F-22 bl MIC LO ws/bl
RZ9K-24S
RS 477-012 A F 7
2RM B G RZ16G-24 RZ7E-24S
Durchbruch 8
C H RZ16H-24
9 18RZ-A 18RZ-a 10RZ
P3402 1VN D J RZ16J-24
BOSE
Modul 4
1RM-B E K RZ16K-24 RZ16K-24 V+ rt
001758-212-02 1
RM15E-22N bl GND sw 1 6
Light GND 6 G 2
see EA-9B334.90 Dimming ws
Light GND 5 VV10 3
RZ9K-24S org RIGHT EAR ws PASS 2
LG3E-22 4
INSTR. LIGHT 7 24 VV334905 Pin G LEFT EAR sw
5
RZ1F-22 ws MIC HI ws
27,5 VDC 8 6
bl MIC LO ws/bl
27,5 VDC 9 VV145 7
1 RZ8E-24S
RV1F-24 8
COM SWAP 20
9
RZ16N-24
RZ16M-24
ws
PASS3 MIC 39
bl RZ11E-24S
PASS3 MIC GND 40
ws
PASS4 MIC 41
C bl RZ10E-24S C
PASS4 MIC GND 42
ws
PASS1 MIC 35
bl TZ7E-24S
PASS1 MIC GND 36
19RZ-A 19RZ-a 11RZ
ws
PASS2 MIC 37 BOSE
bl RZ8E-24S V+ rt
PASS2 MIC GND 38 1
RZ16M-24 bl GND sw 1 6
2
org org COPILOT
COPILOT HEADSET L 3 3
ws RZ5E-24S RZ5E-24S ws RIGHT EAR ws
COPILOT HEADSET R 4 4
bl LEFT EAR sw
COPILOT HEADSET GND 2 5
org MIC HI ws
6
org MIC LO ws/bl
COPILOT MIC IN 32 7
ws RZ13E-24S RZ13E-24S VV21
COPILOT MIC KEY 33 8
bl bl VV23
COPILOT MIC GND 34 9
VV22 20RZ-A 20RZ-a 12RZ
SS9E-24 D2 SS7E-24
bl
ws
BOSE
RZ16N-24 V+ rt
BYW-56 see EA-9B344.14 WEATHER DETECTION 1
VV24 GND sw 1 6
2
org VV25 org PILOT
PILOT HEADSET L 16 3
ws RZ4E-24S RZ4E-24S ws RIGHT EAR ws
PILOT HEADSET R 31 4
bl bl LEFT EAR sw
PILOT HEADSET GND 1 5
ws MIC HI ws
6
bl MIC LO ws/bl
ENT INPUT 2 LT 26 7
bl
ws
RZ2J-24S
8
COMMON 28
9
RZ13F-24S
ENTINPUT 2 RT 27
3RZ
14RZ-A 14RZ-a Spiralkabel 5RZ
ENTINPUT 1 RT 24 PHONEBUCHSE
Copilot PTT ws
1
COMMON 25 bl 1
grün RZ4F-24S bl Pilot PHONE
Module Pilot links 2
RZ2E-24S
RZ13F-24S ws 2
gelb
ENT INPUT 1 LT 23 VV235161 3 VV
VV235151-2 VV235153-4
ST12 LH Armrest
org ws see EA-9B271.17 AUTOPILOT Steuerhorn-Steckerleiste
A F A F A F A F
ws ws bl bl RZ2J-24S 6RZ
SPEAKER OUT 44 11 SPKR B G B G B G B G 36 AWG Tinned copper per ASTM-B-33
bl RM14E-22S bl Pilot PTT
SPEAKER GND 43 8 C H C H C H OVERBRAID
C15P 5RM ws ws ws rt 11
rt 1
C H 11 D J D J D J optical coverage minimal 98 - 100%
ws ws RZ2F-24S bl ws/grün 12
ws/grün
Modul 5
see EA-9B215.20 BLEED AIR D J 6 E K E K E K
D ICS MUTE INHIBIT 13 see EA-9B334.50 COURTESY LIGHT E K D
ICS MUTE INHIBIT RETURN 14
VV11 Spiralkabel
see EA-9B334.40 CABIN-DOME-LIGHT bl bl 12CA-A 12CA-a
A F 2x 001115 204 03 Die Gültigkeitszuordnung Letzte Bearbeitung: 19.01.11 HW Datum Name Maßstab auf Projektion
RZ17E-22N bl 4RZ
B G 001115-204-03 001115-208-02 001115-202-02 von Version zu SI.-Klasse Freimaßtoleranz
RZ18E-22N ws
RZ2H-24S
Bearb.: 29.11.10 HW
Maintenance Manual EXTRA 500 GND
GND
10
11
RZ19E-22N RZ2G-24S RZ2G-24S bl
PTT
MIC Pilot MIKE
Flugzeugbaureihe
ist der Bauakte bzw. Gepr.:
C H 1VN-C, 1VN-C dem jeweiligen Fertigungsauftrag

Modul 6
Gepr.: EA 400-500
C
F
J
M
R
U
AKF D J LH Armrest zu entnehmen.

1RM
E K Zuordnung links / rechts wird mit MKR/AUDIO, RM
T
001758 212 02
B
E
H
L
P
VV235162 13RZ 04
1VN-D ws EA-9B235.17
PTT 03
RZ2H-24S bl
A
D
G
K
N
S
MIC HANDMIKE 02 Schwarze Heide 21 A2 Blatt 1 von 1

Chapter 91 30. March 2012 Mittelkosole
01
Ver. Bezeichnung Nr.: Änderung/Mod. Nr.: Datum Name 46569 Hünxe, Germany Schutzvermerk nach DIN 34 beachten.
001758-212-02 EDV-Kennung: 9B23517T
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
BATTERY RG-390E
GCSG 505-21 Note 1 20PP-A + 28Ah

MS3106F24-28S-F80
GENERATOR CONTROL UNIT * PA1E-2/0
1PR-A +
1PR PA2E-2/0N
-
PR15E-20 MS3349-2
START CONTACTOR CONT Z
W PR14E-20
START POWER PR13E-16 20PP VV243
FIELD RETURN C GND BOLD
PR12E-20 5
CIRCUIT GND F 1VN PP30E-2
PR11E-20 A LOAD BUS PP3 see EA-9B246-10 DC DISTRIBUTION
REMOTE TRIP R PR10E-20
D OVER VOLTAGE SELF TEST L GEN TEST D
PR8E-20 Bolzen
INTERPOLE G PR7E-16 8PR ST1
GEN. FIELD B
PR9E-16 PR11E-20 3 PR11F-20 TRIP 1
E-BOX EA-9B243.10
GEN. OUT A PR6E-20
B:9
2
GEN. CONTROL SWITCH J OFF
PR5E-20 PR10E-20 B:8 3 PR10F-20 3 see EA-9B334.50 COURTESY LIGHT
RESET U PR4E-20 07.1.1.17
E LY13E-22 Gen-Fail Aft Door
T OV-TEST see EA-9B334.50 COURTESY LIGHT F LY14E-22
ANTI CYCLE PR3E-20 PR3E-20
LOAD BUS E G Gear Warn Stall-Warn
PR2E-20 PR2E-20
P.O.R. D H
PR1E-20 PR1E-20
LINE CONTACTOR COIL H J Flaps Cab-Press
PR16E-20 PR15E-20
GENERATOR OUTPUT V K
X bl PR14E-20
GENERATOR SPEED SENSOR L
ws PR17E-22 JB4E-18
GENERATOR SPEED SENSOR Y M
GEN JB3E-18
CHASSIS GROUND M N
7PR:2
PR16G-20
PR6E-20 3 PR6F-20 ON
B:7 6
1WW
OFF 5 VV240
PR5E-20 3 PR5F-20
B:6 4
RESET Starter/Generator
Bei 58% schaltet die GCU aus!
PR18E-22N
3
2
PR4E-20 3 PR4F-20 Bolzen
B:5 1
:1 ANNUNCIATOR BOARD
PR16E-20 3 PR16F-20 07.2.1.16 51 see EA-9B743.10 Start/Ignition D16
B:10
see EA-9B743.10 Start/Ignition 5WW-B
5WW 5WW-D
52 LIGHT TEST (GND)
PR19E-20 EMERGENCY BUS PP2
WW17-22 48
CB 9PR GEN RESET 16
PR205F-22
DIODE 205PR & Pin 2 D-17 Pin 6 see EA-9B246.10 24 + VOLT DIMM
WW1-20
25
BATT VV241 3VN-A
see EA-9B243.20 DC-GENERATION II 18PP:2 Bolzen ANNUNCIATOR BOARD EA-9B315.81
6 ST1
PR204E-22
SWITCH 206PR "STDBY ALT" Pin 2 5 see EA-9B315.80 ANNUNCIATOR PANEL
SWITCH 206PR "STDBY ALT" Pin 2 4 U
EZ63E-22
2 ST1 k 41
:1 ON PP3G-22 PP3F-22 HB15F-22 001758 212 02
3 D:13 m 21 EA-9B215.10, AIR CONDITION
see EA-9B334.50 COURTESY LIGHT LY3E-22 HB16F-22
2 P n 22 EA-9B215.10, AIR CONDITION
PR101F-22 PR101F-22
see EA-9B323.10 GEAR CONTROL R
PR102F-22N
1
OFF p ws
see EA-9B256.10 ELT S q 25 DIP EA-9B316.40 3EY-A Pin 16
CB Trennstecker EY9E-22 bl
07.2.1.13 T r ws 26 DIP EA-9B316.40 3EY-A Pin 19
see EA-9B244.10 EXT POWER U s 24 DIP EA-9B316.40 3EY-A Pin 8
EMERGENCY LY4E-22 EY8E-22 bl D:17
see EA-9B334.50 COURTESY LIGHT V t 23 DIP EA-9B316.40 3EY-A Pin 6 D:16
PP4E-22
19PP
OFF 1 1 1
C 2 ST1 Pin D C
2 PP5E-22N PP5F-22N
D:14 001758 212 02 VV242 VV244
3
ON 07.1.1.13 Bolzen 5
C 3VN-A PP31E-2
PP6E-22 D BATTERY BUS PP2 see EA-9B246-10 DC DISTRIBUTION
D:15
PR102E-22
PR101G-22
2
PR07E-16 PR13E-16 Bolzen
PR09E-16 5PP
LA2F-18 see EA-9B246-10 DC DISTRIBUTION RCCB-CTRL 1A
PR17E-22
3x AWG18
PR8E-20
PR12E-20
MS 27613-K14T7S
see EA-9B244.10 EXT POWER CB im CB Panel
ws
bl
206PR Pin 3
49
53
54
F
G
FIREWALL
1
2
3
4
5
6
7
ST3
ST4 ST2
ws
bl
MS 27615-K14T7P
LA2G-18
3x AWG18 Landing Light Zündbox
PR13F-16 EA-9B334.35
PR8F-20
PR12F-20
PR9F-16
PR7F-16
PR17F-22
Platine Fuse/Relay E-Box EA-9B243.41
Platine Fuse Shunt klein EA-9B243.42
VV245
Platine Fuse Shunt gross EA-9B243.43 PP32E-10
5
2 EMERGENCY BUS PP4
PP1E-2/0 Platine Fuse Shunt spezial EA-9B243.45
Bolzen
Platine Fuse EA-9B243.47
7PR
10A
GCU
2PR
PR7F-16
PR8F-20
PR12F-20
PR13F-16
PP6F-22
bl B VV246
A
ws B A Bolzen
B Speed Sensor C B
2PR-A WX Y Z A b c d e f g h i j
ST1 204PR Alternator 2, Anschluss B
MS3126F8-3S D 10
bl
EA-9B243.20
ws
org
E PR201F-20
EA-9B243.20 DC-GENERATION II, STANDBY ALTERNATOR SW 206PR Pin 4
ws EA-9B243.20 DC-GENERATION II, REGULATOR 203PR Pin 7
PR211F-22S bl
STARTER/GENERATOR EA-9B243.20 DC-GENERATION II, REGULATOR 203PR Pin 3
PP6F-22 org
200SGL EA-9B243.20 DC-GENERATION II, REGULATOR 203PR Pin 4
PR206F-22
EA-9B243.20 DC-GENERATION II, REGULATOR 203PR Pin 1
PL1G-20
EA-9B244.20 EXT LADER, ST2 Pin A
PR20-2/0N
PR203F-22
EA-9B243.20 DC GENERATION II, STANDBY ALTERNATOR SW 206PR Pin 3
1VN
SCHRAUB-BOLZEN
Trenn-Stecker am Brandspant
A ST1 A
W A
V B
T
U
j X Y
C
D
k Z Die Gültigkeitszuordnung Letzte Bearbeitung: Datum Name Maßstab auf Projektion
i
s m von Version zu SI.-Klasse Freimaßtoleranz
S a E Bearb.: 11.02.04 PB
h t Flugzeugbaureihe Oberflächenschutz Oberfläche
r n
b F ist der Bauakte bzw. Gepr.:
R g p dem jeweiligen Fertigungsauftrag
q Note 1 Gepr.: EA 400-500
P f c G zu entnehmen.
e d
N H Kabel nach MIL-W 25038 Zuordnung links / rechts wird mit DC GENERATION I, PP
J
PA01E-2/0 */* in allen Feldern angegeben.
M K PA02E-2/0N
L or MIL-W-22759/16 + Firesleeve (TSO-C53a) 04
Chapter 91 * 30. March 2012
MS 38999III 21-41
03
02 Schwarze Heide 21
EA-9B243.10 A
A2 Blatt 1 von 1
Alle anderen nicht geschirmten nach MIL-W 22759 01 A ÄM-400-09-01 01.09.10 HW 46569 Hünxe, Germany
Ver. Bezeichnung Nr.: Änderung/Mod. Nr.: Datum Name Schutzvermerk nach DIN 34 beachten.
Alle geschirmten nach MIL-W 27500
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
BATTERY RG-390E
20PP-A
Note 1 + 28Ah
PA1E-2/0
* +
PA2E-2/0N
-
PA2F-3X90N 20PP
GROUND PLATE 1VN

BLITZSCHUTZ
PA2E-2/0N
A see EA-9B923.00 GROND PLANE GND BOLD A
C
F
J
M
R
U
MASSEBAND
PA2F-3X90N
GENERATOR CONTROL UNIT HB5F-4N 1VN-UP 1VN-DOWN
see EA-9B215.10 AIR CONDITION
B
E
H
L
P
1PR-A MS3106F24-28S-F80 PR20-2/0N PA2H-2/0N PA2G-3X90N
1PR
PD2E-2/0N
A
D
G
K
N
S
Z PR15E-20
START CONTACTOR CONT see EA-9B244.10 EXTERNAL POWER
W PR14E-20 GND BOLD
START POWER PR13E-16 001758-212-02
C
F
J
M
R
U
FIELD RETURN C STECKER AVIONIC BAY
see EA-2B951.00
B
E
H
L
P
GEN TEST PA2L-4N J 7a P 7A
PA2J-8N PA2J-8N PA2K-8N see EA-9B913.47 STECKER AVIONIKBAY ST 7
PR11E-20 PR11E-20 3 PR11F-20 TRIP 1 8PR 1 see EA-1B951.80 BLITZSCHUTZFLUEGELKASTEN
A
D
G
K
N
S
REMOTE TRIP R B:9
OFF 2 51 see EA-9B743.10 Start/Ignition 30CG-A
L PR10E-20 PR10E-20 B:8 3 PR10F-20 3 52 see EA-9B743.10 Start/Ignition
OVER VOLTAGE SELF TEST
OV-TEST GROUNDMODUL PILOT OVERHEAD
07.1.1.17
ST1
PR16G-20
PR3E-20 PR3E-20 PR3F-20 VV243
LOAD BUS E G
D PR2E-20 PR2E-20 PR2F-20 PP30E-2 9
P.O.R. H
H PR1E-20 PR1E-20
J
PR1F-20 A LOAD BUS PP3 see EA-9B246-10 DC DISTRIBUTION
LINE CONTACTOR COIL LY13E-22
see EA-9B334.50 COURTESY LIGHT E
GEN see EA-9B334.50 COURTESY LIGHT LY12E-22 Bolzen Annunciator Panel
ON F
PR6E-20 PR6E-20 3 PR6F-20 7PR:2 PR15E-20 PR15F-20
GEN. CONTROL SWITCH J B:7 K
PR5E-20 6 JB4E-18 JB3F-20 Gen-Fail Oil-Press
RESET U OFF M
T PR4E-20 PR5E-20 3 PR5F-20 5 JB3E-18 JB4F-20
ANTI CYCLE B:6 N
PR2F-20
V PR16E-20 RESET 4 PR14E-20 PR14F-20 EA-9B412.30 Fuel-Press
GENERATOR OUTPUT L
B PR7E-16
GEN. FIELD PR9E-16 3 1 EA-9B411.90 Standby Alt On Prop Low Pitch
GEN. OUT A GCU 1 K3
PR12E-20 3 PR4F-20 2 F2
CIRCUIT GND F PR4E-20 B:5 F17
PR8E-20 1 :1 VV240 GENERATOR SHUNT1 150A
PR15F-20
INTERPOLE G 5A 50mV 200A
bl 07.2.1.16
JB3F-20
GENERATOR SPEED SENSOR X Starter/Generator PP1E-2/0 88 88a
Y ws PR17E-22 PR16E-20 3 PR16F-20 - +
GENERATOR SPEED SENSOR B:10
87z 87a F6 F7 F8 ANNUNCIATOR PANEL
CHASSIS GROUND M
Bolzen 88y 88b
CB Trennstecker LY1F-22 1A 1A 5WW
GCSG 505-21 START 2A
88
87z
88y
LY2E-22 1 2 4 L101 L201 D01
PR19E-20
5WW-D
86
B2
A2
X2
BYW56 J9 22 LIGHT TEST (GND)
22
J10
PR18E-22N
Bei 58% schaltet die GCU aus! see EA-9B246.10 DC-DISTRIBUTION 4 A1 K5
85
K11 85
22
22
EMERGENCY BUS PP2 D4 D3 48
86
PR14F-20
JB4F-20
26.57.73 Alt Power
ETA 4930-04
88a
87a
88b
26.57.710
CB 9PR GEN RESET ETA
M210-B4N * RCCB 4930-4 + VOLT DIMM
U 1VN-4 K1 K2 BYW56 CB GND
VV241 S210-A5A1 J16 3 A2
5B 1VN-4
B3
B1
A3
A1
X1
LY5E-22 EXT POWER
see EA-9B244.10 EXT POWER PP3E-2/0 88 88a
B ST1 B
206PR Pin 3
22
87z 87a PR100E-22 see EA-9B315.80 ANNUNCIATOR PANEL M
PR205F-22 J 36
DIODE 205PR & Pin 2 D-17 Pin 6 Bolzen D10 88y 88b EZ63F-22 EZ63E-22
k 41
HB15E-22 m HB15F-22 001758 212 02
BATT 21 EA-9B215.10, AIR CONDITION
ST 1 * HB16G-22 HB16F-22
22
22
see EA-9B243.20 DC-GENERATION II 18PP:2 P600M n 22 EA-9B215.10, AIR CONDITION
PR101E-22 p PR101F-22 PR101F-22
J17
PR102F-22N
J 37 J18
X1
A1
A3
B1
B3
PR204E-22 6 see EA-9B334.50 COURTESY LIGHT P LY3E-22 K8 EY8F-22 s ws

SWITCH 206PR "STDBY ALT" Pin 2 LY1E-22 * 24 DIP EA-9B316.40 3EY-A Pin 8
5 LY4E-22 EY8G-22 EY8E-22 bl
LY13E-22
LY12E-22
see EA-9B334.50 COURTESY LIGHT V 85 D2 D9 t 23 DIP EA-9B316.40 3EY-A Pin 6
86 J8
4 U PD5G-22 22 EY9F-22 q ws
2 see EA-9B244.10 EXT POWER 25 DIP EA-9B316.40 3EY-A Pin 16
:1 ON PP3G-22 PP3F-22 T PP3E-22 EY9G-22 r EY9E-22 bl D:17
D:13 26.57.73 BYW56 26 DIP EA-9B316.40 3EY-A Pin 19 D:16
3 GA34E-22
PP100E-22N
see EA-9B323.10 GEAR CONTROL R PR1F-20 D

M210-B4N
2 S DA2E22 S210-A5A1 1 1
X2
A2
B2
1 OFF CB Trennstecker see EA-9B256.10 ELT

CB6 CB1 CB5 K4
VV242 ELT GEAR AUX 2 COURTESY LT BATTERY SHUNT2 VV244
07.2.1.13
1A 5A 5A HOT BUS PP1 50mV 200A F3 9
22
22
PA1E-2/0 88a 88 PP31E-2
22
20
EMERGENCY - + D BATTERY BUS PP2 see EA-9B246-10 DC DISTRIBUTION
PP4E-22
19PP CB4 CB2 CB3 EA-9B412.10
PR102E-22
87a 87z 150A

PR101G-22
ALT FIELD 2 BATT CHARGE SPARE F10 F5 F9 F13

OFF 1 Bolzen 5A 5A 7,5A 30A 4A 4A J4 J5 J6 J 20 J19 J21
F12 F11 F18 F4 Bolzen
2 2A 22 5PP
2 PP5E-22N PP5F-22N 2 1 88b 88y 4 GCU 2
D:14 40A
3 * REL MT4 J22 22 1A 1A 5A
20
EA-9B412.40 1A
PR3F-20
RCCB-CTRL
20
20
ON 07.1.1.13 K6 2 1 3
13
14
3
4
1
PP6E-22 2 C 1VN-4 J13 J12 J11
D:15 22
PL1G-20
26.57.71
D1 D5 D6 D7 22 CB im CB Panel
SPARE
85 86 BYW56
20
22
22
7
5
P600M
9
8
* 6
16
P600M
12
10
11
P600M * * J24
447-0863
J15
PP6F-22
J14
447-0863
J26
J3 J2 J1 J25 J23 J7
X1
A1
A3
B1
B3
K12
88
87
86
ALT CHARGE
22
22
22
LA2F-18 LA2F-18 K10
PR17E-22
PR09E-16
PR07E-16
PR13E-16
see EA-9B246-10 DC DISTRIBUTION M210-B4N
26.72.03
88a
85
87a
50A
X2
A2
B2
PP6G-22
3x AWG18
PR8E-20
PR12E-20
MS 27613-K14T7S PR206E-22
ws
bl
ws/org
49
53
54
F
G
J30 J31 PR210E-22
FIREWALL J32 J33 PR211E-22 ws/bl F14 1 2 F15 4 F16
1
2
3
4
5
6
7
J34 J35 PR212E-22 ws ALT SENS
ST4 ST2 ST3
1A 1A 1A VV245
MS 27615-K14T7P * F1 ALTERNATOR Comment: BC218-1
ws
bl
PP103E-22N
PP102E-22N
PP101E-22N
PR16E-22N
PP100E-22N
87 87a PP32E-10 9
- PP211E-10
+ B EMERGENCY BUS PP4 see EA-9B246-10 DC DISTRIBUTION
C C
40A STROM SENSOR SHUNT 3
Bolzen
PR8F-20
PR12F-20
202PR 50mV 200A
LA2G-18
LA2G-18 86 85 EA-9B412.20
see EA-9B334.35 LANDING LIGHT PR201G-20 PR208E-20N
Landing Light Zündbox
PR9F-16
3x AWG18
K7 3VN-A
PR17F-22
PR13F-16 AB C DE F G HJ K 001758 212 02
PP6G-22
PR206E-22
PR210E-22
PR211E-22
PR212E-22
PR203G-22
PL1G-20
PR7F-16
VV246
PP1E-2/0
W A e f g h i j
ST 1 Bolzen
bl
ws
org
7PR
GCU 10A
PP6F-22
PR203F-22
PL1G-20
PR206F-22
PR100E-10 204PR Alternator 2, Anschluss B
200SGL B 10
see EA-9B243.20 DC-GENERATION II
PR7F-16
2PR-A A
bl A PR201F-20
EA-9B243.20 DC-GENERATION II, STANDBY ALTERNATOR SW 206PR Pin 4
ws B
PR8F-20
C ws EA-9B243.20 DC-GENERATION II, REGULATOR 203PR Pin 7
PR211F-22S bl
MS3126F8-3S D org
Speed Sensor
E 2PR PR206F-22
PL1G-20
EA-9B244.20 EXT LADER, ST2 Pin A
PR12F-20 PR203F-22
EA-9B243.20 DC GENERATION II, STANDBY ALTERNATOR SW 206PR Pin 3
STARTER/GENERATOR
PR13F-16
PR20-2/0N
Trenn-Stecker am Brandspant
D ST1 D
W A
V B
U C
j X Y
T k D Letzte Bearbeitung: Datum Name Maßstab auf Projektion
i Z Die Gültigkeitszuordnung
s m von Version zu SI.-Klasse Freimaßtoleranz
S a E Bearb.: 11.02.04 PB
h t Flugzeugbaureihe Oberflächenschutz Oberfläche
r n
b F ist der Bauakte bzw. Gepr.:
R g p
q Note 1 dem jeweiligen Fertigungsauftrag Gepr.: EA 400-500
c G
Maintenance Manual
P
N
* f
EXTRA e
500 d
H Kabel nach MIL-W 25038
zu entnehmen.
Zuordnung links / rechts wird mit DC GENERATION I, PP
J
PA1E-2/0 */* in allen Feldern angegeben.
M PA2E-2/0N
L K or MIL-W-22759/16 + Firesleeve (TSO-C53a) 04
03 EA-9B243.10 B
MS 38999III 21-41 02 B ÄM-400-10-04 08.09.11 HW Schwarze Heide 21 A2 Blatt 1 von 1
Alle anderen nicht geschirmten nach MIL-W 22759 01 A ÄM-400-09-01 01.09.10 HW 46569 Hünxe, Germany
Alle geschirmten nach MIL-W 27500
Chapter 91
1
11. July 2012 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
BATT
18PP:1 1 OFF
2 CB Trennstecker
3 PP3G-22 2
ON D:13
STDBY ALT :2 4
PP4E-22
PR204E-22 5
D 6 D
206PR:1 1 OFF
EMERGENCY BUS PP4
2 07.2.1.13
200PR ALT 3 PR203E-22 PR205F-22
ON
2A :2 4 PR201E-20 EMERGENCY
PR200E-20 5 19PP
PP32E-10
205PR VV27
6 PR202E-22 OFF 1
5 2
2 PP5E-22N PP5F-22N
07.2.1.13 P600M D:14
B ON 3
001758 212 02
07.1.1.13 3VN-A C
PP6E-22 2 PP6F-22
D:15
PR205E-22 2
D:17
PP211F-10
EMERGENCY BUS PP4 BATTERY BATTERY BUS PP2 PR203E-22 2
D:16
VV245 VV242 VV244 PR201E-20 3 B:11

E-BOX
see EA-9B246.10 DC-DISTRIBUTION
K4 F3
BATTERY SHUNT2 150A K5 Fuel Trans R Standby Alt On Ignition
50mV 200A F2 Annunciator Panel right
A1
A2
- +
Hot Bus
HOT BUSPP1 PP1 LOAD BUS PP3 Pneumatic Low Voltage
F5 F4 150A VV243 P/N 90-42192-2
-
ALT FIELD 2 CB4 F10 40A Fuel Low R Prop Low Pitch External Power
30A
5B
C SHUNT1 geändert C
2A 2A 50mV 200A
ETA
PP211E-10
3
4
RCCB 4930-4
D1
P600M K10 ETA 4930-04 K3
88a 88
50A 2WW
87a 87
SHUNT 3 F16 GENERATOR
-
Platine EA-9B243.41 2 1A GENERATOR
VV240
86 85 PP6H-22
+
PLatine EA-9B243.41 3 EMG-Rel. K9 Pin X2 ST1
EMG-Rel. K9 Pin X1
50mV 200A ALT CHARGE ANNUNCIATOR BOARD
26.72.03 PP6G-22 PP6F-22
PP3E-22
e PP3F-22 D25 5WW
T 5WW-D 5WW-B
PR203G-22 PR203F-22 LIGHT TEST (GND)
PR206E-22 W PR206F-22
PR102E-10
f PR213E-22 WW32-22
100 21 15
ws/org PR210E-22 g org + VOLT DIMM 24
SENSOR WW20-20
ws/bl PR211E-22 bl PR211F-22S 25
202PR ws PR212E-22
h ws
i
ALT SENS
see Annunciator-Panel EA-9B315.80
PR201G-20 PR201F-20
j STANDBY ALTERNATOR REGULATOR
PR102E-10
B PR206F-22 1 Bus Sense B
26.73.04 BC203-2D
50A K7 PR213E-22 2 Alt Loaded Lamp
PR205G-22
6 Bus
org 4 Sensor +10 Volts
PR211F-22S
PR101E-10
bl 3 Sensor Analog
PR208E-20N
F1 ws
40A 001758 212 02 7 Ground
A 2VN-C
PR209F-20 5 Field
PR212G-20N
203PR
Ringösen werden im Kit mitgeliefert.

FIREWALL
F 2VN-C
PR100F-10
001758 212 02
sse EA-9B243.40 E-BOX
VV246
PR100E-10
STBY. Alternator Die Gültigkeitszuordnung Letzte Bearbeitung: Datum Name Maßstab auf Projektion
B BC410-1 (26VDC 20A) von Version zu Bearb.: SI.-Klasse Freimaßtoleranz
13.04.04 PB
204PR Flugzeugbaureihe Oberflächenschutz Oberfläche
A ST2 ist der Bauakte bzw. Gepr.: A
Maintenance Manual EXTRA 500 204PR-A zu entnehmen.
PR209E-20 PR209F-20
B Zuordnung links / rechts wird mit DC-GENERATION II, PR
F */* in allen Feldern angegeben.
Field 04
03 EA-9B243.20 A
ChapterG91 30. March 2012 Plug with Shield MS 38999 III 26K F 32 SN (32 X #20) 01 A ÄM-400-09-01 15.09.10 HW 46569 Hünxe, Germany
A3 Blatt 1 von 1
GND Ver. Bezeichnung Nr.: Änderung/Mod. Nr.: Datum Name Schutzvermerk nach DIN 34 beachten.
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
BATT
18PP:1 1 OFF
2 CB Trennstecker
3 PP3G-22 2
D:13
ON
STDBY ALT :2 4
PP4E-22
A PR204E-22 5 A
206PR:1 6
EMERGENCY BUS PP4 1 OFF
2 07.2.1.13
200PR ALT 3 PR203E-22 PR205F-22
ON
2A :2 4 PR201E-20 EMERGENCY
PR200E-20 5 19PP
PP32E-10
205PR VV27
6 PR202E-22 OFF 1
5 2
2 PP5E-22N PP5F-22N
07.2.1.13 P600M D:14
see EA-9B316.40, DIP 3EY-A B ON 3
001758 212 02
07.1.1.13 K
8
6
1VN-4
PP6E-22 2 PP6F-22
D:15
PR205E-22 2
D:17
PP211F-10
EY8E-22 bl
EMERGENCY BUS PP4 BATTERY BATTERY BUS PP2 PR203E-22 2
D:16
ST1 Pin D
ST1-A VV245 VV242 VV244 PR201E-20 3 B:11
E-BOX s t
K4 F3
BATTERY SHUNT2 150A K5
J21 J22
50mV 200A F2
A1
REL MT4
A2
K6 Hot Bus PP1 - + LOAD BUS PP3
3
4
HOT BUS PP1
1
F5 F4 150A VV243
-
D7 ALT FIELD 2 CB4 F10 40A
30A
5B
B SHUNT1 B
BYW56 5A 2A 50mV 200A
7
5
8
6
ETA
16
PP211E-10
3
4
Annunciator Panel
RCCB 4930-4
D1
J25 J23 P600M K10 Fuel-Press Stall-Heat
ETA 4930-04 K3
EA-9B411.80 88a 88
Standby Alt On Prop Low Pitch Pitot Heat L
SHUNT 3 50A
87a 87
50mV 200A Low Voltage Chip Static Heat L
F16 GENERATOR
2 F15 GENERATOR
1A
+
VV240
1A
1 F14 86 85 PP6H-22
-
EMG-Rel. K12 Pin X2 ST1-A ST1
1A 4
EMG-Rel. K12 Pin X1 ANNUNCIATOR PANEL
ALT CHARGE
EA-9B412.20 26.72.03 PP6G-22 PP6F-22 5WW
e e D13 L113 L213
PP3E-22 PP3F-22 5WW-D
PR203G-22 T T PR203F-22 LIGHT TEST (GND)
PR206E-22 W W PR206F-22
f f PR213E-22
PR102E-10
100 21
ws/org PR210E-22 ws/org g g org
SENSOR + VOLT DIMM
ws/bl PR211E-22 ws/bl h h bl PR211F-22S
202PR ws PR212E-22 ws i i ws
ALT SENS
see Annunciator-Panel EA-9B315.80
PR201G-20 PR201F-20
j j STANDBY ALTERNATOR REGULATOR
PR102E-10
C PR213E-22 2 Alt Loaded Lamp C
26.73.04 BC203-2D
50A K7 PR205G-22 6 Bus
PR206F-22
1 Bus Sense
org
4 Sensor +10 Volts
PR211F-22S bl
PR101E-10
3 Sensor Analog
PR208E-20N
F1 ws
40A 001758 212 02 7 Ground
A 3VN-A
PR209F-20
5 Field 203PR
PR212G-20N
Ringösen werden im Kit mitgeliefert.

FIREWALL
PR100F-10
S
sse EA-9B243.40 E-BOX
VV246
1VN-2
001758 212 02
PR100E-10
STBY. Alternator Die Gültigkeitszuordnung Letzte Bearbeitung: Datum Name Maßstab auf Projektion
B BC410-1 (26VDC 20A) von Version zu Bearb.: SI.-Klasse Freimaßtoleranz
13.04.04 PB
204PR Flugzeugbaureihe Oberflächenschutz Oberfläche
ST2
204PR-A zu entnehmen.
PR209E-20 PR209F-20 Zuordnung links / rechts wird mit DC-GENERATION II, PR
F B
Maintenance
G Manual EXTRA 500 Field 04
03 EA-9B243.20 B
02 B ÄM-400-10-04 20.09.11 HW Schwarze Heide 21
Plug with Shield MS 38999 III 26K F 32 SN (32 X #20) A3 Blatt 1 von 1
01 A ÄM-400-09-01 15.09.10 HW 46569 Hünxe, Germany
GND Ver. Bezeichnung Nr.: Änderung/Mod. Nr.: Datum Name Schutzvermerk nach DIN 34 beachten.
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
ST1
Shield für EY8 & EY9 D
LY13E-22
EA-9B334.50 Courtesy Light E
LY12E-22
EA-9B334.50 Courtesy Light F
PR3F-20
G
PR2F-20
H
PR1F-20
J
PR15F-20
K
PR14F-20
L JB3F-20
M
PR2F-20
D JB4F-20 EA-9B243.46 D
N
1 EA-9B243.45
GCU 1 K3
VV240 F17 VV243
GENERATOR SHUNT1
5A F2
JB4F-20
50mV 200A
PR15F-20
JB3F-20
88 88a - +
GENERATOR LOAD BUS PP3
87z 87a F6 F7 F8 150A
Bolzen LY1F-22 88y 88b Bolzen
+ V Dim
K2 1A 1A 2A
LY2E-22 1 2 4
START
88
87z
88y
2 2 X2 BYW56 J9
86
J10 WW1
4 A1 K5
26.57.710
85 D4 D3 LIGHT TEST
86 Alt Power
ETA 4930-04 GEN FAIL
85
K11 ETA
RCCB 4930-4
88a
87a
88b
A B M210-B4M 26.57.73
* D16
3 1 3 1 X1
K1 BYW56 CB GND
VV241 S210-A5A1 J16 3 5B A2
EXT POWER
88 88a
EXT. POWER ST1
87z 87a PR100E-22
ST1 Bolzen D8 88y 88b EZ63F-22 EZ63E-22
BYW56 k 41 see EA-9B315.80, ANNUNCIATOR, GEN FAIL
HB15E-22 HB15F-22
m 21 seeEA-9B215.10, AIR CONDITION
EA-9B334.50 Courtesy Light LY3E-22 LY1E-22 HB16G-22 HB16F-22
P n 22 see EA-9B215.10, AIR CONDITION
EA-9B323.10 Gear Control GA34E-22 M210-B4M PR101E-22 PR101F-22
R J17 J18 p
DA2E22 S210-A5A1 EY9F-22 ws
EA-9B256.10 ELT S * q 25 see EA-9B316.40, DIP 3EY-A Pin 16
PP3E-22 1 3 1 3 EY9G-22 EY9E-22 bl
PR16E-22N
LY13E-22
LY12E-22
PR1F-20
EA-9B243.10 DC Generation T 85 D2 D9 X1 r 26 see EA-9B316.40, DIP 3EY-A Pin 19
PD5G-22 86 J8 A B EY8F-22 ws
EA-9B243.10 DC Generation U s 24 see EA-9B316.40, DIP 3EY-A Pin 8
C LY4E-22 EY8G-22 EY8E-22 bl C
V 26.57.73 BYW56 K8 t 23 see EA-9B316.40, DIP 3EY-A Pin 6 D:16
5A
PP100E-22N
1
X2 2 2 ST1 Pin D
CB6 CB1 CB5 K4
VV242 ELT GEAR AUX 2 COURTESY LT BATTERY SHUNT2 VV244
Bolzen 1A 5A 5A HOT BUS PP1 50mV 200A F3
88a 88 - +
BATTERY BATTERY BUS PP2
CB4 CB2 87a 87z EA-9B243.45 150A
PR101G-22
ALT FIELD 2 BATT CHARGE F10 F5 F9 F13

5A 5A 30A 4A 4A F12 F11 F18 F4 Bolzen
2A J4 J5 J6 J19 J20 J21 5PP
1 2 88b 88y 4 GCU 2 CB im CB Panel
40A
EA-9B243.46 * REL MT4 J22 1A 1A 5A
PR3F-20 RCCB-CTRL 1A
13
14
3
4
3
1
K6 2 1
J13 J36 J12 J11
26.57.71
D1 D10 D5 D6 D7
85 86 BYW56
P600M
* *
7
5
9
8
6
P600M
16
P600M
12
10
P600M *
11
* J24
447-0863
J14 J37 J15
PR102E-22
447-0863
J26
J3 J2 J1 J25 J23 J7 1
K12
3
3
D:17
X1
88
87
86
1 B
1 A
ALT CHARGE
K10
88a
26.72.03
85
87a
2
2
X2
50A
PR206E-22 M210-B4N_1
PP6G-22
PR102F-22N
B GEAR AUX 2 J30 J31 PR210E-22 ws/org B

J32 J33 PR211E-22 ws/bl F14 1 2 F15 4 F16
BATT CHARGE
J34 J35 PR212E-22 ws ALT SENS 3VN-A U
SPARE 1A 1A 1A VV245 001758 212 02
* F1 ALTERNATOR BC218-1
ALT FIELD 2
PR16E-22N
PP103E-22N
PP102E-22N
PP101E-22N
PP100E-22N
87 87a PP211E-10
- + EMERGENCY BUS PP4
COURTESY LT
40A STROM SENSOR SHUNT 3
ELT 50mV 200A Bolzen
202PR
86 85 EA-9B243.45
PR201G-20 PR206E-20N
K7 2VN-C
AB C DE F G HJ K 001758 212 02
PP6G-22
PR206E-22
PR210E-22
PR211E-22
PR212E-22
PR203G-22
PL1G-20
VV246
Bolzen
W A efg hij
ST1
ST1 ST1
W A
V B
B Die Gültigkeitszuordnung Letzte Bearbeitung: Datum Name Maßstab auf Projektion
U X C
j Y C von Version zu Bearb.: 13.02.04 PB SI.-Klasse Freimaßtoleranz
T k Z D 88y 87a Flugzeugbaureihe Oberflächenschutz Oberfläche
STBY ALTERNATOR
A i X Gepr.:
A
s m ist der Bauakte bzw.
S t a E Y dem jeweiligen Fertigungsauftrag EA 400-500
Maintenance Manual EXTRA 500 h r n
b F
Spare Pins 87z 88b
zu entnehmen.
Gepr.:
Platine EA-9B243.41A R g Z E-BOX
q p Zuordnung links / rechts wird mit
P f c G a */* in allen Feldern angegeben.
e d
N H b 04
* J 03
EA-9B243.40 A
M K
L c KISSLING RELAY 26.57.71X 02 Schwarze Heide 21
Chapter 91 30. March 2012 A3 Blatt 1 von 1
EA-9B243.20 DC-GENERATION II
EA-9B244.20 BATTERY CHARGE
EA-9B243.10 EMERGENCY 19PP
Hilsfanschlüsse 01 A ÄM-400-09-01 16.09.10 HW
d
* Bauteile sind auf einer Platine integriert! MS 38999III 21-41 Ver. Bezeichnung Nr.: Änderung/Mod. Nr.: Datum Name 46569 Hünxe, Germany Schutzvermerk nach DIN 34 beachten.
1 2 3 4 5 6 7 8
ST1
A D10
J30
J37 1 1
D CON1 D
CON1 P600M J31
1
CON1
ws/org ST1
J36 1 g
CON1 ws/bl ST1 h
202 PR
D1 ws ST1
i
J13 1
J34
ST1 CON1 P600M 1 CON1
W J35
1 CON1
J14 1
J32
1
CON1 CON1
J33
1 CON1
D5
J12 1
1 J20
CON1 P600M
CON1
J15 1
1 J19
CON1
D6 CON1 ST1
J
J11 1
1 J24
CON1 P600M
C D4 CON1 C
J10 1
1 J23
CON1 BYW56
CON1
J16 1
1 J26
CON1
D3 CON1
J9 1
1 J25
CON1 BYW56
ST1 CON1
k D9
J18 1 1 J3
BYW56 CON1 ST1
CON1
D2
F
J17 1 1 J4
CON1 BYW56 CON1
K6:2
K6:3
K6:4
K6:5
J8 1 1 J1
6
8
11
9
5
7
12
10
1
D7 K6:1
CON1 CON1
MT4
4
3
BYW56
16
13
14
B B
1
1
1
1
1
1
J7 J22 J21 J5 J6 J2
CON1 CON1 CON1 CON1 CON1 CON1
ST1 ST1 ST1

t s E

von Version zu Bearb.: 16.09.05 HW SI.-Klasse Freimaßtoleranz
A
Maintenance Manual EXTRA 500 Flugzeugbaureihe
A
zu entnehmen.
Zuordnung links / rechts wird mit PCB Board E-Box
04
Chapter 91 30. March 2012 03
EA-9B243.41 A
01 A ÄM-400-09-01 14.10.10 HW
Ver. Bezeichnung Schutzvermerk nach DIN 34 beachten.
1 2 3 4 5 6 7 8
ANNUNCIATOR BOARD
D30
Standby Alt On Ignition Intake Heat LIGHT TEST (GND) 5WW-A
28VDC CB 1LH2 EA-9B334.90
Low Voltage Deice Boots 3 LH3G-20
291-9726 41 + Light-Test
4 VV161
Prop Low Pitch External Power Windshield On K1 9
D D
Annunciator Panel right BYW56 5WW-D

D37
P/N 90-42192-2 8
2WW 5WW-C 5WW
26
WW27-22 D45 48 HP11G-22 108
7 GEN-FAIL
WW40-22 D46 2 PD4J-22
23 49

see EA-9B315.80 ANNUNCIATOR PANEL
E-BOX
1VN Brandspant
PD2E-2/0N
EXT POWER K1
1PD VV186 EXT. POWER RELAY
C VV186 C
- PD3E-2/0 PD3E-2/0 88 88a
+ DC Generation I
+ Brandspant 87z 87a
EXT PWR 88y 88b
REL K8
Kleiner Pin vorne Flugrichtung! ST4 Schraube Air Condition
PD1E-22
2PD PD4E-22 PD4F-22
34
2A ST1 ST1
D2
PD5F-22 U PD5G-22 m HP11G-22
86 85 BYW56
CIRCUIT BREAKER/SWITCH PANEL MS38999III MS38999III 17-26
PD4G-22 2 PD4F-22
D:11 K3 Platine innerhalb der E-Box
1 GEN RELAY
PD4H-22 PD4J-22 EA-9B243.41
D:11
EXT PWR
87a 87z
OFF 1 5PD
88y 88b Air Condition
2 PD5E-22 2 PD5F-22
ON
D:12
3
CB Panel Trennstecker
07.1.1.13
B see EA-9B246.10 DC-DISTRIBUTION B
K4
Battery Relay
88 88a
87z 87a
88y 88b 26.57.710
86 85
E-BOX EA-9B243.40
see EA-9B243.10 DC GENERATION I
ST1
W A
V B
U X C
j Y
T k Z D
i
s m
S t a E
h r n
b F
R g p von Version zu Bearb.: 19.10.04 PB SI.-Klasse Freimaßtoleranz
q
P c G Flugzeugbaureihe Oberflächenschutz Oberfläche
A f Gepr.: A
e d ist der Bauakte bzw.
N H dem jeweiligen Fertigungsauftrag EA 400-500
Gepr.:
M
L K
J zu entnehmen.
Zuordnung links / rechts wird mit EXTERNAL POWER, PD
MS 38999III 21-41
04
03 EA-9B244.10 A
Chapter 91 30. March 2012 01 A ÄM-400-09-01 01.07.10 HW 46569 Hünxe, Germany
A3 Blatt 1 von 1
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
ANNUNCIATOR PANEL
5WW
Low Voltage Chip Static Heat L L125 L225
5WW-A
External Power Ignition Deice Boots
A VV161 see EA-9B334.90 28VDC CB 1LH2 A
LH3G-20
Reco Light Landing Light Intake Heat 3 41 + Light-Test
D37 4
Annunciator Panel WW39-20N
9
5WW-D K 001758 212 02
26 1VN-5
D50 HP11G-22 108
GEN-FAIL 48
D51 PD4J-22
2 49

E-BOX
1VN-UP
PD2E-2/0N
EXT POWER K1
1PD VV186 EXT. POWER RELAY
B B
- PD3E-2/0 PD3E-2/0 88 88a
+ DC Generation I
+ 87z 87a REL K8
FIREWALL Schraube 88y 88b
Kleiner Pin vorne Flugrichtung! Air Condition
EXT PWR FIREWALL FIREWALL
ST4
PD1E-22
2PD PD4E-22 PD4F-22
34 ST1 ST1-A ST1-A ST1
2A D2
PD5F-22 U U PD5G-22 m m HP11G-22
86 85 BYW56
CIRCUIT BREAKER/SWITCH PANEL MS38999III 17-26
MS38999III
PD4G-22 2 PD4F-22
D:11 K3 Platine innerhalb der E-Box
PD4H-22 1 PD4J-22 GEN RELAY EA-9B243.41
D:11
EXT PWR
87a 87z
OFF 1 5PD
88y 88b Air Condition
2 PD5E-22 2 PD5F-22
ON
D:12
3
CB Panel Trennstecker
07.1.1.13
86 85
C see EA-9B246.10 DC-DISTRIBUTION C
K4
Battery Relay
88 88a
87z 87a
88y 88b 26.57.710
86 85
E-BOX EA-9B243.40
see EA-9B243.10 DC GENERATION I
ST1
W A
V B
U X C
j Y
T k D
i Z
s m
S a E
h t
r n Letzte Bearbeitung: Datum Name Maßstab auf Projektion
b F Die Gültigkeitszuordnung
R g p von Version zu Bearb.: 19.10.04 PB SI.-Klasse Freimaßtoleranz
q
P c G Flugzeugbaureihe Oberflächenschutz Oberfläche
D f Gepr.: D
e d ist der Bauakte bzw.
N H dem jeweiligen Fertigungsauftrag
J Gepr.: EA 400-500
M K zu entnehmen.
L
Zuordnung links / rechts wird mit EXTERNAL POWER, PD
MS 38999III 21-41
Maintenance Manual EXTRA 500 04
03 EA-9B244.10 B
A3 Blatt 1 von 1
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
E-BOX
D D
VV240
GENERATOR
Bolzen LY1F-22
K2
LY2E-22
START
88
87z
88y
2 2 X2
86
85
K11
A B
88a
87a
88b
M210-B4M K1 26.57.73
VV241 3 1 3 1 X1 S210-A5A1
EXT POWER
88 88a
FIREWALL EXT. POWER
87z 87a
ST1-A ST1-A Bolzen D8 88y 88b
BYW56
EA-9B334.50 Courtesy Light #20 LY3E-22 LY1E-22
P P
EA-9B323.10 Gear Control #20 GA34E-22
R R
EA-9B256.10 ELT #20 DA2E22
S S
EA-9B243.10 DC Generation #20 PP3E-22
T T 86 85
EA-9B243.10 DC Generation #20 PD5G-22
U U
#20 LY4E-22
V V 26.57.73
C CB6 CB1 CB5 K4 C

20PP + 20PP-A VV242 ELT GEAR AUX 2 COURTESY LT BATTERY
Bolzen 1A 5A 5A HOT BUS PP1
PA1E-2/0 PA1E-2/0 88a 88
28Ah + PA2E-2/0N BATTERY
- CB4 CB2 87a 87z
ALT FIELD 2 BATT CHARGE F10 F5 F9 F13
5A 5A 2A 30A 4A 4A
1 2 88b 88y 4
BATTERY RG-390E MS3349-2 EA-9B243.46
1VN
see 9B243.10 DC GENERATION I J13 J36
26.57.71
GND BOLD D1 D10

85 86
*
P600M
*
P600M
FIREWALL J14 J37
EA-9B243.46
+28V BATTERY CHARGE
ST2 ST-1
PL 1
J1 PL1E-20 PL1E-20 PL1F-20 #20 PL1G-20
+ A A A
PL2E-20N
02636 C1P
GND ST1-A
E-BOX EA-9B243.40
B see EA-9B243.10 DC GENERATION I B

KABINE
PL2E-20N
GEAR AUX 2
BATT CHARGE
SPARE
Masse auf Rahmen
ALT FIELD 2
COURTESY LT
ELT

A ist der Bauakte bzw. Gepr.: A
Maintenance Manual EXTRA 500 zu entnehmen.
Zuordnung links / rechts wird mit BATTERY CHARGE, PL
04
03 EA-9B244.20
Chapter 91 30. March 2012 01 46569 Hünxe, Germany
A3 Blatt 1 von 1
1 2 3 4 5 6 7 8
B
A
D
C
3
1
1
3
1
3
1
3
A:10
C:2
C:17
3
B:12
1
3
D:4
GEAR-AUX-2
CB1
8 AWG 16
12 AWG 20
12 AWG 20
4 AWG 12
20 AWG 22
12 AWG 20
20 AWG 22
20 AWG 22
B:19 B:20
323.10
5A
GEAR AUX 2
A:11 A:12
AUTOMATEN
Kabel über Shelf

XX
2
2
EXT-LADER
CB2
A
D
C
1
1
244.20 EXT-LADER
5A
B:4
2
Kabel über Shelf
Anzahl
2 2 2
D:7 D:18
ETA-483 klein 1 - 35A
8 AWG 16
Anzahl Lochpositionen
4 AWG 12
12 AWG 20
20 AWG 22
B:6 B:7 B:8
E-Box, EA-9B243.40
ETA-482 mittel 0.1 - 50A
ETA-452 gross 50 - 100A
CB4
ALT-FIELD
A
D
C
243.20
2A
ALTERNATOR 2 FIELD
1 2 1 2 3 1 2 3 4 1 2 3 4 5
E-BOX, VV245 E-BOX, VV244
CB5
COURTESY LT
EA-9B243.10
#4
#4
4 5 5 6
334.50 COURTESY LT
F
5A
E
EA-9B243.20 EA-9B243.10
X
X
3 4
BATTERY, VV242
6 7 8
XX
2
D
XXX
GA37E-22
5
323.10 GEAR CONTR

#0
D
A
#0
HOT BUS PP1
ELT
CB6
D:5
1617 20
5
5
256.11 ELT GA40F-22

1A
B
F10
#4
#4
MS3100F 36-6S Dose
EMGC RELAY PP31E-2

2
1 Stück
3 Stück
6 Stück
5 Stück
39GA
GA40E-22
3GA-2
4 X 12
8 X 16
MS3106F 36-6P Stecker
12 X 20
GEAR AUX I
20 X 22
323.10
2A
Modul 0412
Modul 0816
Modul 1222
Modul 2022
D:6
5
Stift FE 4198
Stift FE 4196
Stift FE 4192
Stift FE 4194
5A
E
PP32E-10
Buchse FE 4199
Buchse FE 4197
Buchse FE 4193
DIODE
Buchse FE 4195 A
F5
EMGC-2
GEAR-AUX-1
5
BUS-TIE-NORMALLY-OUT
DC GENERATION 1, VV243
3GA-1
EMERGENCY RELAY
1GA
GA1E-22 PP30E-2
Chapter 91
323.10 GEAR CONTR #8

EA-9B243.10
#8
30A
5A
3
PP36E-16N
1
GA3E-22
2
2
C:8
100A
D:8 D:9
5
1HB
HB2E-4
GEAR-CTRL
C
44GA
AIR CON
2
323.10
GA54E-22 215.10
HYDR CAUTION
1
1
1GW
GW1E-22
125A
323.20 GEAR WARNING

1A
23GA
5
AIR-CON
GA6J-8
1
2A
D:7 F
GW1G-22 323.10 GEAR HYDRAULIC

1
C:3 C:4
VV201
6HB
HB7E-12
50A
HYDR
215.10 CABIN VENT ws

1
OFF org LG52E-22S

GEAR-WARN
30A
VENT
:1
OFF 1 334.81 LUMI FOLIE

1
VV202
HB18E-22 LOW1 2 bl
:1
1QB
2
1HF
QB4E-20 2HF2E-12
1
731.10 FUEL PUMP 1 3

2
A:1
LUMI FOLIEN
HF4EF-12 3 215.10 CABIN VENT

1
304.20 WINDSHIELD HEAT HB17E-22 HI

B:15 B:16 B:17 B:18
20A
C:1
VV203
ON
7.5A
WSH-HT
D:2 C:20 C:19
Option
9HB:2
FUEL-P-1
HB4E-20
7HB
07.2.1.13 4 5
3
2
3HF:2
HG5E-18 TEST1 07.2.1.40 901 4 WV9E-22

2HF
10HG
5HF1E-22 6
9HG
2A
2HG4E-18 (TONE)
1
303.10 PITOT/STATIC L/H OFF HF3F-22 6 VENT 314.30 VMO WARN

2A
2
2
HG6E-18 3 WINDSH 1
WV8E-22 TEST
3LJ:1
304.20 WINDSHIELD CNTRL

10A
C:7 B:5
1
PITOT-L
A:5 A:4
AIR-CTRL
ON HF3E-22 OFF 1 2
8HB
PITOT-L
DAY
WSH-CTRL
07.1.1.16 07.1.1.13 2HB3E-20

D:12 D:6
07.2.1.16 3
1
1EY
EY1E-22 HB16E-22 3 NIGHT

3
316.40 DIP 1 OFF 1 215.10 AIR CON AIR CON LT1E-20 4

C:5
NIGHT
ON
:2
2HI
1HI
1A
07.1.1.13 2HI1E-12 5
DIP-1
2
1
HG2E-16 TEST 334.90 DIMMING
2HG
2
3
HI2E-12 3 303.10 PITOT HEAT R/H LT2E-20 6

1HG
2HG1E-16
1EZ
20A
EZ1E-20 ON PROP OFF

2
HG3E-16 3
PROP-HT
316.50 EIP 1 360.11 PROP HEAT HI4E-22

3
A:1
PITOT-R LH3E-20N
2A
15A
D:19 B:2 B:3
C:2 A:2
07.1.1.16 ON
PITOT-R
A:8 A:9 A:10
3
3
1A
3HI
1
2QB
QB1E-20
ENG-INS-1
2
3
HP2E-22 PRESS 731.10 FUEL PUMP 2 MM1E-18

1MM
A:7
213.30 CABIN PRESS 252.10 CIGAR LIGHTER

2HP
1HP
C:1
6 HP1E-22
A:10
OFF
7.5A
10A
5
FUEL-P-2
3A
DUMP 4
4JB
CIGA-LTR
JB1E-20
C-PRESS
PRESS 743.10 START

A:5
1
2EY
3 EY2E-22
5A
316.40 DIP 2
3
C:6
START
HP10E-22N 2
1A
DIP-2
213.30 CABIN PRESS

07.1.1.15L 1
1JB
2EZ
1
2
JB2E-20 EZ2E-20
1
HP9E-22 ON 743.10 IGNITION 316.50 EIP 2

A:6
A:12
5A
IGN
2A
213.30
3
CABIN PRESS HP9G-22

2
HA13F-22
ENG-INS-2
9HP
HP3E-22
1HA
213.30 DUMP HA1E-22 215.20 BLEED AIR

2
A:4 D:13 A:3 A:2

1
1QF
215.20 CABIN PRESS(IN FLOW) QF1E-22 HA12F-22

2A
C:10
731.30 TRANSFER PUMP 1

5A
DUMP
B:1
5A
ENTFÄLLT
SCHALTER
HA14F-22
1
1QX
QX1E-22
284.10 FUEL INDICATION
ENV-BLEED
FUEL-TR-L
C:15
2A
1
ws WARM1
1
25CG
1
2QF
CG1E-22 QF4E-22
4HA
275.20 FLAP CNTR 731.30 TRANSFER PUMP 2 2

FUEL-QTY
C:11
B:14
5A
5A
1
HA3F-22 3
bl
1
1LW
WL1F-22 COLD
1
1
315.90 LOW VOLTAGE MONITOR HK1F-22

FUEL-TR-R
FLAP-CTRL
752.15 VENT LEFT 07.1.1.17
C:16
1A
D:9 D:8 D:10 B:3 B:4 B:5
1
6HK
4
4
MAN CONTROL
HK1E-22
3
1CG
CG8E-16 VENT RIGHT

BATTERY BUS PP2
752.15
LOAD BUS PP3
275.20 FLAPS
2A
C:6
1
EMERGENCY BUS PP4
LOW-VOLT
org MAN 1
1
LJ1G-22
FLAP
B:7
P-VENT
334.40 DOME LIGHT 2
2
C:2 C:1 C:8
1WH
7.5A
WH1E-22
273.30 STALL WARNING OFF 1 3
1LJ
15LJ
1A
2
WH1G-22 07.1.1.13 2LJ1F-22 AUTO
1
1QY
QY1E-22
1
1
731.40 FUEL FLOW LJ5E-22 3 bl 07.2.1.134

5A
D:19 D:20
5AH:1
334.40 MAP LIGHT

B:8
MAP
C:12
1A
D:2
ON 5
STALL-WARN
OFF 1 6
CABIN-LT
AUTO/MANUAL
16LJ
07.1.1.13 2LJ1E-22
FUEL FLOW
1
ws
7EY
1
1
EY3F-20S OFF 1 LJ2E-22 3

2LN
316.40 VOLT MONITORING 334.40 CABIN LIGHT CABIN

1LN
D:1
07.1.1.13 2LN1E-20 ON
1A
1
1
215.20 ENV BLEED
3
LN2E-20 3 OFF 1
B:6 B:9
334.55
2LC
HA4F-22
A:3 A:4
ICE LIGHT
1LC
B:4
ON ICE 07.1.1.13
ICE-LT
2 LC1E-20 OFF 1
HA4G-22
7.5A
VOLT-MON
1
OFF 1 LC2E-22 3 2
5A
1LA
1
NAV
2LA
07.1.1.13 2LA1E-18 ON HA28E-22 3
1
NAV LIGHT
NAV-LT
334.20 LC2F-22
B:2
3
LA2E-18 3 OFF 1 ON
D:3 D:4
334.35 LANDING-LIGHT
10A
2LB
1LB
ON LDG 07.1.1.13 2LB1E-20 07.2.1.13 4
LDG-LT
OFF 1
16HA:1
2
1

LA7E-22 LB10E-20 3 5
1LF
2LF
ENV BLEED
07.1.1.13 2LF1E-20
30. March 2012

5LA
334.10 STROBE LIGHT
C:5 B:1
1
ON STROBE HA22E-22 6
2
7.5A
LB2E-20 LF2E-20 3
1A
5A
1
1
ON RECO
STROBE-LT
HA21E-22
1
1LH2
1
LG119E-20 334.60 RECO LIGHT LF2J-22

RECO-LT
A:12 A:11
DIMMIMG
A:8
3
A:6 D:5
334.90
4
2
OFF1 P16NM103KA
1ES
5
5
7.5A
1
ES1E-22
2LJ
07.1.1.13 2LG4G-20
WARN-LT
276.10 OVERSPEED TEST
C:9
1
7HA
2A
OFF 1 LG116E-20 3
1LH1
1LR
2
4
334.90 INSTRUMENT LIGHT ws
1LR
07.1.1.13 ON INSTR
Poti. Ansicht von hinten.
2LR5E-20
1
org
O-SP-TEST
2
3
2
LR6E-20 3 LH116G-20 10k
1A
334.90 GLARE LIGHT bl
A:9
7.5A
ON GLARE
INST-LT
TEMP
3
5FG
1
2FG1E-14
2
LH4E-20 342.66 RH IFD

HA5F-22
D:3
GLARE-LT
DAY-NIGHT
A:9 A:8 A:7
D:15 D:14 B:13 B:10 B:11 B:12
334.90
10A
1
1HM
HM1E-22
1
304.10 INTAKE ANTI-ICE HH1E-22

IFD RH A
310.10 BOOTS
2A
D:18
C:14 1
1SS
OFF
3
2HH
07.1.1.13 SS1E-20
1HH
2HH1H-22 344.14 WEATHER DETEC

B:1
INTAKE-A/I
2A
1
1
HH2E-22 3
2A
310.10 BOOTS TIMER BOOTS
D:7
ON
BOOTS
1
1FM
FM1E-22
2
WTHR DET
342.73 STBY GYRO SN1E-22
C:7
2A
2
1SN
3
1CA
CA3E-20 SN2E-22
271.17 A/P SERVOS (TRIM) 345.47 DME (KDM 706A)
D:1 D:2
A:7
2A
STBY GYRO
5A
DME
1FG
01
02
03
04
1FG1E-14
1RZ
342.65 LH IFD RZ1E-22

AP-SERVO
2
PD5E-22
D:1
D:3
5A
10A
D:12
235.17 AUDIO/MKR (PM8300)
2
2FG
2RZ
1FG3E-14 RZ16E-22 OFF 1
IFD LH A
342.65 LH IFD
C:3
5PD
07.1.1.13
D:4
2
AUDIO-MRK
1A
10A
2
2
9FG
zu entnehmen.
EDV-Kennung:
FG16E20 PD4G-22 3
6
6
von Version zu
1TH
342.67 KEYPAD IFD LH B

3
TH1E-18 ON
Flugzeugbaureihe
1A
A:11
244.10 EXT POWER
Ver. Bezeichnung
EXT PWR
C:3
252.11 12V SOCKETS

1
PD4H-22

10A
KEYPAD
1
WV1E-22
1WV
12-VDC
314.30 Vmo WARNING

3
C:13
RESET1
Die Gültigkeitszuordnung
3
1SH
1A
SH1E-18 243.10 GENERATOR
:1
3
D:11 D:11 B:5
1TS
345.57 ATC (BXP6402R) TS1E-20 PR04F-20 2
C:4
344.17 BROADCAST(MLX770) OFF
ATC
3A
B:2
9B24610T
3
2A
VNE-WARN
ON
9PR
dem jeweiligen Fertigungsauftrag

PR19E-20
IRIDIUM
GEN

3
PR5F-20 4
7PR:2
33PP
5A
PP47E-16 07.2.1.16 5
3
1TL
A
TL1E-20
3
344.16 DATA LINK(MLB700) PR6F-20 6

B:3
30A
2A
B:6 B:7
GEN-RESET
SIRIUS
AV BUS
200PR
4PP
3
30A
PR200E-20 1
PR11F-20TRIP
8PR
EMGC-1
07.1.1.17 2
2A
ALT
ALTERNATOR FEELD 2 PP34E-12 243.10 GENERATOR OFF
3
243.20 PR10F-20 3
B:9 B:8
CR1/2
OV-TEST
CR1/1
GEN TEST
ÄM-400-09-01
Letzte Bearbeitung:
201CNQ045
PP47E-16
PP35E-12
3PP
3
PP33E-12 PR16F-20
B:10
50A
EMGC-2
2
PP5E-22N
Nr.: Änderung/Mod. Nr.: Datum

11.10.10
02.02.11
X1
3
1
D:14
OFF 1
19PP
7
7
07.1.1.13 2
HW
HW
Name
2
25A
30PP
PP6E-22 3
243.10 EMERGENCY
ON
D:15
M320-B4N
S320-A7-A10
EMERGENCY
Gepr.:
Gepr.:
Bearb.:
PP4E-22
OFF
1
2 PP48E-16
:1
Datum
PR19E-20
X2 PP43E-22 2
2
19.10.04
1
1
2
5PP
07.1.1.13
PR102E-22 PR101G-22 DC-GEN I
PP3G-22 3
243.10 RCCB 243.10
Schwarze Heide 21
ON
D:16
31PP
D:17
1A
D:13

2
3
1
6FG
PB
AVIONIC
2FG3E-14 4
BATT
Name
18PP:2
342.66 IFD RH
C:4
07.2.1.13 5
ON
OFF
RCCB-CTRL
10A
2
PR205E-22 6
243.20 DC-GEN 2
IFD RH B
D:17
PR205F-22
1SD
3
SD1E-20
344.15 TAS (TAS610)
A:1
27CG
CG51G-20 CG50G-20
TAS
Maßstab
3A
275.20 FLAP SYSTEM
1
PP44E-22N
A:2
1
1A
SI.-Klasse
1
CG51H-22
A:3 D:10
FLAP-UNB
A2
3
2CA
D:20
CA1E-20
auf
205PR
271.17 A/P COMPTR

P600M
AVIONICS BUS
PR204E-22
OFF 1
5A
Oberflächenschutz
:1
3
CA1F-20
EA-9B246.10
2
A:5 A:6
2
PR203E-22 3
AP-CMPTR
243.20 DC-GEN 2
8
8
ON
PP44F-22N
PP5
3 PR201E-20 4
1
3CA
CA2E-22
201PR:2
EA 400-500
271.17 TURN COORDINATOR
K
07.2.1.13 5
D:16 B:11
1VN-A
STDBY ALT
Blatt 1
C:18
001758_212_02
5A
T&B
PR202E-22 6
Oberfläche
Projektion
A
DC-DISTRIBUTION
PR200E-20
Freimaßtoleranz
von 1
Schutzvermerk nach DIN 34 beachten.

B
A
D
C
B
A
D
C
2
1 2 3 4 5 2 1 3 2 1 3 4 1 2
2
2
A:2
2 3
2
2
1 4
2D:9
5 4 5
D:10
B:6
B:4
6 3 2 1 2 1
2
GE AR-AUX- 2
CB1
2
2
4 3
P 8A-2
8 7 6
323.10 GEAR AUX 2 5 4
5A
D:8 D:18
AUTOMATEN
B:8
B:7
20 16 17 6 5 4 3
XX
8 7 6
3
EX T-L ADER
CB2
1
1
2 1 3 2 1 3 4 1 2 3 4 1 2 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 3 4 1 2
244.20
C:2
EXT- LADER
1
5A
1
2 34 2 3
P 8A-3 Kennung - 3
P 8A-2 Kennung - 2
1 4
P 8A-1 Kennung - 1
5 4 5 5 6 6 6
Anzahl
5
3
1
Anzahl Lochpositionen
P 8A-3
3
1
1
1
ETA-483 klein 1 - 35A
2 34 4 3
Sicht Stecker "front"
4 X 12
1 2 34
2 Stück
2 Stück
1 2 34
8 X 16
1
P 8A-1
8 7 6
D:4
E-Box, EA-9B243.40
ETA-482 mittel 0.1 - 50A
A:10
C:17
ETA-452 gross 50 - 100A
B:20
B:18 B:19
6 5 5
A:12
3A:11
6
Modul 0 816
Modul 0 412
20 16 17 20 16 17 20 16 17
CB4
ALT-FIELD
Buchse FE 41 99
Buchse FE 4197
6 5 6 5 6 5
A
243.20
A
D
C
ALTE RNATOR 2 FIEL D

2A
B
D
C
CB5
EA-9B243.10
COURTE SY LT E-BOX, VV245 EA-9B243.10

#4
#4
1 2 3 4 5 3 4 1 2
334.50 COUR TESY L T
5A
F
E
E
X
X
BATTERY, VV242
EA-9B243.20
D
XX
6 5
XXX
GA37E-22
323. 10 GEAR CONTR
HOT BUS PP1
ELT
CB6
9
D:5
256.11 GA40F -22

#0 A
ELT
#0 D
1A
P 9A
20 16 17
B
F10
#4
#4
EMGC RELAY PP31E-2

2
39GA
GA40E-22
3GA-2
323. 10 GEAR AUX I

(MS3100F 36-6S Dose)
2A
4 Stück
4 Stück
MS3106F 36-6P Stecker
D:6
12 X 20
5A
20 X 22
Modul 2 022
Modul 1 222
Sicht Stecker Pin "front"

A
Buchse FE 41 93
Buchse FE 4195
EMGC-2
F5
DC GENERATION 1, VV243
GE AR-AUX-1
BUS-TIE-NORMALLY- OUT
STTA 5012 TV1
PP32E-1 0
3GA-1
EMER GENCY RELAY

1GA
GA1E-22 EA-9B243.10 PP30E-2

323.10 GEAR CONTR #8 #8
30A
5A
3
PP36E- 16N
1
GA3E-22
Chapter 91
2
2
C:8
100A
D:8 D:9
9
1HB
HB2E -4
44GA
GEAR-CTRL
C
215.10 AIR CON

2
GA54E-22
323.10 HYDR CAUTION
1
1
D:7
1GW
GW1E -22
100A
323.20 GEAR WARNING

1A
9
23GA
AIR-CON
GA6J-8
1
2A
F
GW1G-22 323.10 GEAR HYDRAULIC

1
ws
VV20 1
C:3 C:4
6HB
HB7E -12 334.81 LUMI FOLIE

50A
HYDR
215.10 CABIN VENT org LG52E-22S

D:2
1
OFF
30A
GE AR-WARN
VENT
:1
OFF
1
HB18E -22 LOW

B:15 B:16 B:17
1HF
2
LUMI FOLIEN
1QB
1
QB4E -20 HF2 E-12
731.10 FUEL PUMP 1
1 2
VV20 2
A:1
2
HF4E-12 215.10 CABIN VENT
1
3
304.20 WINDSHIELD HEAT HB17E -22 HI
20A
C:1
ON
3
7.5A
Option
WSH-HT
C:20 C:19
9HB:2
3HF:2
7HB
FUEL -P -1
HB4E-20
07.2. 1.13
3
2
HG5E-18 TEST 07.2.1. 40 901 WV9E -22N

2HF
4 4 5
HF1 E-22
10HG
9HG
2A
1
HG4E-18 VENT (TONE)
1
5 6
303.10 PITOT/STATIC L/H OFF HF3F-22 314.30 VMO WARN
2A
2
2
2
HG6E-18 6 WINDSH WV8E -22 TEST
304.20 WINDSHIELD CNTRL
3LJ:1
10A
PITOT-L
C:7 B:5
1
ON OFF
A:5 A:4
3 1
HF3E-22
AIR-CT RL
8HB
DAY
PI TOT- L
WSH-CTRL
1
07.1. 1. 16 07.1. 1.13 HB3E-20 07.2. 1.16
2
D:12 D:6
1
1
1EY
2
EY1E-22 OFF HB16E -22 NIGHT
3
2HI
3
316.40 DIP 1 HI 1E- 12 215.10 AIR CON AI R CON LT1E-20

NIGHT
ON
C:5
3
07.1. 1. 13
:2
1
1A
4
DI P-1
3
2
2
HI2E-22 HG2E-16 TEST 334.90 DIMMING
#12
2HG
1HI
3
5
PROP 303.10 PITOT HEAT R/H LT2E-20
1HG
3 1
HG1 E-16
1EZ
11HI ON
1
#12
4A
6
EZ1E-20 OFF
1
2
316.50 EIP 1 HI4E-22 HG3E-16

2
360.11 PROP HEAT
3
A:1
30A
PITOT-R LH3E-20N
2A
15A
D:19 B:2 B:3
3
07.1. 1.16 ON
3
3
1A
3HI
PROP -HT
2
A:8 A:9 A:10
HI1F-12
PI TOT-R
2
3
ENG-INS-1
HP2E-22 PRESS MM1E-18

1MM
213.30 CABIN PRESS CIGAR LIGHTER

1
QB1E -20 252.10

2HP
2QB
1HP
C:1
6
HP1E-2 2 731.10 FUEL PUMP 2
A:10
OFF
B:12 A:2 C:2 A:7
10A
5
3A
DUMP
4
7.5A
CIGA-L T R
FUEL-P -2
C-PRE SS
PRESS
1
4JB
2EY
3
EY2E-22
1
JB 1E-20 316.40 DIP 2

743.10 START
3
C:6
2
HP10E-22N
A:5
1A
5A
213.30 CABIN PRESS

DI P-2
1
ST ART
07.1.1. 15L
2
2EZ
EZ2E-20
1
HP9E-22 ON 316.50 EIP 2

1JB
1
A:12
JB 2E-20
2A
213.30 CABIN PRESS 743.10 IGNITION

3
HP9G-22
A:6
5A
IGN
9HP
ENG-IN S-2
HP3E-22
213.30 DUMP
1HA
A:4 D:13 A:3 A:2

1
1QF
HA1E-22 QF1E-22
2A
215.20 CABI N PRES S(IN FL OW) 731.30 TRANSFER PUMP 1

DUMP
B:1
C:10
5A
5A
1
1QX
QX1E-22
284.10 FUEL INDICATION
ENV- BL EED
FUEL -T R-L
2A
C:15
1
ws WARM
1
1
25CG
2QF
CG1E -22 QF4E-22 1

275.20 FLAP CNTR 731.30 TRANSFER PUMP 2
FUEL -QTY
HA3F-22S
B:14
5A
5A
C:11
1
2
bl
1
1LW
COLD
3
WL1F-22
1
1
4HA
315.90 LOW VOLTAGE MONITOR HK1F-22

FUEL -TR-R
VENT LEFT
FLAP-CTRL
752.15 07.1. 1.17

1A
C:16
B:3 B:4 B:5
4
4
1
6HK
HK1E-22
MAN CONTROL
BATTERY BUS PP2
3
1CG
CG8E -16 752.15 VENT RIGHT

LOAD BUS PP3
EMERGENCY BUS PP4
275.20 FLAPS
2A
C:6
1
org MAN
LOW- VOLT
1
LJ1G-22
FLAP
B:7
1
DOME LIGHT
P- VENT
334.40
2
1WH
C:2 C:1 C:8
7.5A
WH1E -22 2
273.30 STALL WARNING OFF
15LJ
1LJ
1A
2
WH1G-22 07.1. 1. 13 1
LJ1 F-22 AUTO
3
1
1QY
QY1E-22
1
1
07.2.1. 13
5AH:1
2
731.40 FUEL FLOW LJ5E-22 bl
5A
D:19 D:20
334.40 MAP LIGHT MAP
B:8
1A
C:12
ON
D:2
3 4
OFF
5
ST ALL-WARN
CABIN-L T
16LJ
AUTO/MANUAL
07.1. 1. 13 1
LJ1 E-22
6
1
FUEL FLOW
ws
11. July 2012

1
1
7EY
2LN
2
EY3F-20S OFF LJ2E-22
316.40 VOLT MONITORING 334.40 CABIN LIGHT ON CABIN
1LN
07.1. 1. 13
D:1
1 3
LN 1E- 20
1A
1
1
215.20 ENV BLEED
3
2
LN2E-20 OFF
B:6 B:9
334.55
2LC
ICE LIGHT
1LC
A:3 A:4
ICE
B:4
ON
3 07.1. 1. 13 1
LC1E-20 OFF
ICE- LT
HA4 F-22S

HA4G-22
7.5A
VOLT-MON
1
2 1
OFF LC2E-22
5A
1LA
NAV
1
2LA
07.1. 1.13 1 LA 1E- 18 ON
3
HA28E-22
2
1
334.20 NAV LIGHT

NAV-LT
LC2F-22
B:2
ON
3
2 3
LA2E-18
2LB
OFF
D:3 D:4
334.35 LANDING-LIGHT
10A
1LB
ON
3 LDG 07.1. 1. 13
1
LB1E-20 07.2.1.13
16HA:1
LDG-LT
OFF
2
1
2 4
LA7E-22 LB 10E-20
1LF
2LF
ENV BLEED
07.1. 1. 13 1
LF1E-20
5LA
334.10 STROBE LIGHT
C:5 B:1
1
ON
3 STROBE HA22E-22
5
2
7.5A
1A
LB 2E-20 LF2E -20
5A
6
1
RECO
1
ON
3
HA21E-22
STRO BE-LT
1LH2
RECO LIGHT
1
1
LG119E-20 334.60 LF2J-22

A:12 A:11
DIMMIMG
RECO-L T
3
334.90
A:8
A:6 D:5
4
2
P16N M103KA
2LJ
5
5
OFF
1ES
7.5A
1
1 ES1E -22
07.1.1. 13 LG 4G-20 OVERSPEED TEST
WARN-LT
276.10
C:9
1
7HA
2A
2
OFF LG116E-20
1LH1
1LR
2
4
334.90 INSTRUMENT LIGHT ws
1LR
07.1. 1.13 1 LR5E-2 0 ON 3 INSTR
Poti. Ansicht von hinten.
org
2
3
O-SP -TEST
2
LR6E-20
2 LH116G-20 10k
1A
334.90 GLARE LIGHT bl
7.5A
ON GLARE
A:9
3
TEMP
IN ST -LT
3
5FG
1
2FG1E-14
2
LH4E-20 342.66 IFD RH

HA5F-22S
D:3
GL ARE-LT
334.90 DAY-NIGHT
A:9 A:8 A:7
D:15 D:14 B:13 B:10 B:11 B:12
10A
1
1HM
HM1E-22
1
304.10 INTAKE ANTI-ICE HH1E-22

IFD RH A
310.10 BOOTS
2A
D:18
C:14 OFF
1SS
2HH
07.1.1. 13 SS1E-20
1HH
1
HH1H-22 344.14 WEATHER DETEC
B:1
IN TAKE-A/I
2A
1 2
HH2E-22
1
2A
310.10 BOOTS TIMER BOOTS
D:7
3
ON
BOOTS
1
1FM
FM1E -22
2
342.73 STBY GYRO SN1E-22

WTH R D ET
C:7
2A
2
PD5E-22
2
1SN
SN2E-22
3
1CA
CA3E -20 345.47 DME (KDM 706A)

271.17 A/P SERVOS (TRIM)
D:1 D:2
D:12
A:7
2A
5A
DME
STBY GYRO
1
OFF
07.1. 1.13 1
1FG
01
02
03
04
1FG1E-14
1RZ
342.65 IFD LH R Z1E-22

2
AP-SE RVO
2
2
PD4G-22
D:1
D:3
5A
ON
3
5PD
10A
235.17 AUDIO/MKR (PM8300) 244.10 EXT POWER
EXT PWR
2
2FG
2
1
1FG3E-14
2RZ
R Z16E-22 PD4H-22
IFD LH A
342.65 IFD LH
C:3
D:4
1A
10A
AUDIO -MRK
EDV-Kennung:
6
6
2
3
9FG
zu entnehmen.
FG16E-20 RESET
von Version zu
1TH
342.67 KEYPAD 243.10 GENERATOR

3
D:11 D:11 B:5
IFD LH B 1
TH1E-18 PR 4F-20
Flugzeugbaureihe
1A
Ver. Bezeichnung
A:11
OFF
C:3
252.11 12V SOCKETS 2

10A
KE YPAD
ON
1
3
WV1E -22
1WV
12-VDC
314.30 Vmo WARNING

3
7PR:2
PR5F-20
C:13
3
1SH
1A
SH1E-18
3
1TS
ATC (BXP6402R)
4
345.58 TS1E -20 07.2. 1.16
C:4
344.17 BROADCAST(MLX770)
3A
B:2
3
ATC
9B24610T
5
PR6F-20
2A
1
B:6 B:7
VNE- WARN
9PR

PR19E-20

IRI DIUM
3
PR11F-20TRIP
33PP
5A
PP47E-16
3
1TL
07.1. 1.17 1
TL1E-20
A
B
344.16 DATA LINK(MLB700) 243.10 GENERATOR OFF
B:3
3
2
PR10F-20
30A
2A
GE N-RESET
B:9 B:8
OV-TEST
3
AV BUS
SIRIU S
8PR
GEN PR19E-20 GEN TEST
200PR
4PP
30A
PR200E-20
3
PR16F-20
EMGC-1
2A
ALT
ALTERNATOR FEELD 2 PP34E- 12
B:10
243.20
CR1/2
CR1/1
ÄM-400-09-01
ÄM-400-12-12
2
PP5E-22N
Letzte Bearbeitung:
201C NQ045
PP47E-16
3PP
PP33E- 12
PP35E-1 2
2
PP6E-22 ON
243.10 EMERGENCY
50A
1
07.1.1. 13
D:14 D:15
EMGC-2
2
PP4E-22
Nr.: Änderung/Mod. Nr. : Datum

11.10.10
23.10.12
OFF
X1
3
3
1
19PP
EMERGENCY
7
7
HW
HW
Name
30PP
25A
M320-B4N
OFF
S320-A7-A10
1
Gepr.:
Gepr.:
1
1
5PP
Bearb.:
PR102E-22 PR101G-22N
2
2
243. 10 D C GEN 1 DC-GEN I
PP3G-22
243.10
D:16
ON
D:17
1A
3
D:13
18PP:2
BATT
2 PP48E-16
Datum
07.2. 1. 13
X2PP43E-2 2 2
4
19.10.04
RCCB-CT RL
2
5
PR205E-22
07.1. 1.13
243.20 DC-GEN 2
Schwarze Heide 21
6
31PP
D:17
PR205F-22

2
3
1
6FG
PB
AVIONIC
2FG3E-14
Name
2
342.66 IFD RH
2
27CG
CG51G- 20 CG50G- 20
C:4
ON
275. 20 FL AP SYST EM
OFF
A:2
10A
1A
1
CG51H- 22
IFD RH B
1SD
3
A:3 D:10
SD1E-20
FLAP- UNB
344.15 TAS (TAS610)
205PR
A:1
Maßstab
P600M
3A
TAS
OFF
1
PR2 04E -2 2
1
PP44E-2 2N
SI.-Klasse
1
2
2
PR203E-22
243.20 DC-GEN 2
A2
3
ON
D:20
2CA
3
CA1E -20
auf
271.17 A/P COMPTR
AVIONICS BUS
3
PR201E-20
Oberflächenschutz
5A
201PR:2
3
CA1F-20
EA-9B246.10
4
07.2. 1.13
D:16 B:11
STDBY ALT
A:5 A:6
5
PR202E-22
8
8
AP-CMPT R
6
PP5
PP44F-22N
1
3CA
CA2E -22
EA 400-500
271.17 TURN COORDINATOR
Blatt 1
C:18
1VN- 4
001758_212_02
5A
Oberfläche
Projektion
T&B
B
PR2 00E -20
DC-DISTRIBUTION
Freimaßtoleranz
Schutzvermerk nach DIN 34 beachten.

von 1
B
A
D
C
1 2 3 4 5 6 7 8
D D
CIGA-LTR
1MM LOAD BUS PP3
3 MM1E-18
C:1
C 10A C
Zigarettenanzünder
MM1G-18 2MM
1
MM2-18N
2
1VN-E
001758_212_02
B B

Zuordnung links / rechts wird mit CIGAR LIGHTER, MM
04
03 EA-9B252.10 A
A3 Blatt 1 von 1
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
D D
Converter SM 2430 LOAD BUS PP3

1TH 12-VDC
yellow
CB Trennstecker 10A
TH2E-18 A F TH2H-18 violet red TH1F-18 3 TH1E-18

24V TO 12V C:3
TH2F-18 B G
TH2G-18 C H Converter black
C C
D J
E K
black
VV26
001115-202-02
TH6E-18N
3VN-A
E 001758 212 02
Steckdose 1 Steckdose 2 Steckdose 3
Mittelkonsole Co-Pilot Tisch
TH2E-18 TH2F-18 TH2G-18

1 1 1
2TH 3THM 4TH
3 3 3
TH3E-18N TH4E-18N
2 2 TH5E-18N
2
TH3E-18N TH5E-18N
B H TG 1VN-F B
001758_212_02

Zuordnung links / rechts wird mit 12V SOCKETS. TH
04
03 EA-9B252.11 A
A3 Blatt 1 von 1
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
D D
E-BOX
ST1
DA2F-22 DA2E-22
2 S
GEAR AUX 2
BATT CHARGE
CB6 ELT SPARE
VV242 1A ALT FIELD 2
Bolzen HOT BUS PP1
BATTERY COURTESY LT
ELT
3 2 1
E-BOX EA-9B-243.40
C 6 5 4 C
9 8 7
Auf Kabelseite gesehen
ELT REMOTE SWITCH 2DA-A

DRUCKSCHOTT HINTEN ELT
ST13-D 1DA-A
1 ARTEX ME 406 ELT
DA2F-22
+28 VDC 3
DA11F-22 DA11F-22 DA11E-22
1 L1 4 8 17 2 Light
DA12F-22 DA12F-22 DA12E-22
5 18 6 Reset 1
DA13F-22 DA13F-22 DA13E-22
2 19 13 Reset 2
2 5 DA14F-22 DA14F-22 DA14E-22 External On
ONLY FOR EXCHANGE
7 20 14
DA15E-22
6 8 Horn Power
4 SIM 5 G-Switch Loop
3 L2 DA3E-22N EXCHANGE BATTERY
6 9 12 G-Switch Loop
DA4E-22N 452-6504
345-6196 2DA 7 Ground
Molex
151-5009 SUBD 15S
001758_212_02
H 150-1130
1VN-C
RG 142 C/U
611-6013-04 1DA
B 1DA-B 453-6603 B
(MOUNTING 452-3034)
4DA-A ELT ANTENNA

RG 142 C/U
4DA
110-773
AUDIO INDICATOR
3DA
DA15E-22 red + +
DA5E-22N blk - 452-6505

Zuordnung links / rechts wird mit ELT ARTEX ME 406, DA
04
03 EA-9B256.11
Chapter 91 30. March 2012 01 46569 Hünxe, Germany
1 2 3 4 5 6 7 8
1 2 3 4
STEC 55X DRUCKSCHOTT HINTEN T&B AVIONICS BUS PP5 BATTERY BUS PP2
3CA
ST14-A CA2F-22 1 CA2E-22
4CA-B 10CA-a C:18
10CA-A 5A
TRIM SERVO CA1G-20
A:5
3 CA1E-20 AP COMPTR
3
ws ws ws ws 2CA
Trim Motor + Down 17 1 4 AP-SERVO
bl CA4E-24S bl bl CA4F-24S bl CA1H-20 3 CA1F-20
Trim Motor + UP 32 2 3 A:6
5A 1CA
ws ws ws ws CA3F-20 3 CA3E-20
Trim Solonoid 33 4 1 A:7
bl CA5E-24S bl bl CA5F-24S bl
GND Solonoid 48 5 2 10CA TRIM 5A
Shield GND 47 10 14CA
1 see EA-9B246.10 DC-DISTRIBUTION
SIM 2 CA3G-22 CA3G-22 CA3H-22
Shield GND 39 DRUCKSCHOTT HINTEN
CA14E-22S CA14E-22S 3 10CA-A
YAW DAMPER
28 VDC Trim 50 07.1.1.13
CA30E-22 YAW DAMPER ST13-D
Roll Sol. Logic YD. 3
A 17CA CA3H-22 CA3J-22 A
A/P MASTER Off 1 11 4 A+
GND 42
1 16CA:1 2
Alt. Sel. Jumper 23 SIM
CA15E-20 2 CA30E-22 3
3 CA1G-20 Auto 07.1.1.13
Sig. Ref. 29 ST14-B
FD. Flag 9 07.2.1.23 CA69E-22 CA69F-22
4 CA68-22N 7 13 YD ON / OFF
20CA-A CA71E-22 CA71F-22
CA67E-22 CA67E-22 5 16CA:2 20CA-a 6 7 GND
FD Enable 8
6 1VN-B SIM
C
GND 43 YAW TRIM ST13-D
Trennstecker Pilot see Detail A A/P DISCONNECT 2 4
GPSS 38
TRIM COMMAND SW 18CA CA70E-22 CA70F-22
001758_212-02 2 2 12 10 Y CTR
Steckerleiste im Steuerhorn 1 3 R1
CA18F-22 2K0 3
1 3 CA72E-22 CA72F-22
12CA-A 12CA-a D 1 13 8 10 VDC out
CA12E-24S see EA-9B284.13 PCB-BOARD 1 Pin 25 25CA-A 25CA-a DN 17CA 107-9518 R2 2K0
Audio Output 27 25 B CA8F-22
0,25W
CA15E-20
GND 43 ws/rt ws/rt F 1K SIM
4 YAW- Poti CA77E-22N
CA3F-20 blau 5
blau 15CA 19 GND
9 CA73E-22
ws ws grau 3
grau A 3 Y Solenoid
Manual UP SW 16 19 CWS CA74E-22
bl CA7E-24S CA7E-24S bl grün 2
grün E 1 Y Motor 1
Manual Down SW 15 13 CA75E-22
CA33E-22N braun 6
braun UP C 13CA 2 Y Motor 2
SHIELD GROUND 46 16 CA76E-22
ws ws sw 9
sw CA18E-24 6 GND
CWS 5 12
bl CA13E-24S CA13E-24S bl gelb gelb CA8E-22
CA1H-20
CWS GND 6 17 10 Montieren auf Platinen-Blech
VV39
CA15F-22 lila lila Instrumentenbrett mittig 11 CA
Shield GND 45 20 8
CA8E-22 ws ws
B3
B1
A3
A1
X1
10 1
CA18E-24 org org 55CA YAW SERVO
18 7
B 12CA-A
Pitch Flap Pot. 28 REL M210B4N
13
Signal Reference 30
14 CA76E-22
Trim FlaP Pot 31 rt rt 2 GND
CA15G-22
CA15H-22
1VN-B ws
11 11 PTT Pilot CA75E-22 Einstellen auf 73 IN/LBS
see EA-9B235.17 MKR-AUDIO RZ2F-24S bl ws/grün ws/grün see EA-9B235.17 MKR-AUDIO 4 Y Motor 2
X2
10 VDC Paralax Pot. 10
001115_1758_212_02 6 12 PTT Pilot CA74E-22
3 Y Motor 1
Pitch Str. Centering 11 CA73E-22
WH10E-22 1 Y Solenoid
FD Pot. GND 44 100 see EA-9B273.30 STALL WARNING
AP-Disconnect bei Stall Warning 12 CA
CA6E-22 B2
CA6E-22 A 19VN-A
CA16E-24 A2
Trim Interrupt 14
SHIELD GROUND 41
IFD LEFT
Roll Sign. 34 001758 212 02
Roll Sign. Ref. 35
J1122 IFD-5000i
SHIELD GROUND 40
CA31E-24S CA31E-24S 700-00083-()
B FD LOGIC 4 23 DISCRETE IN 3 B
CA32E-24S CA32E-24S
ROLL STR SIG 12 41 ANALOG IN 1
CA33E-24S CA33E-24S
PITCH STR SIG 13 40 ANALOG IN 0
CA34E-24S CA34E-24S
ANNUN LOAD 24 22 DISCRETE IN 2
CA35E-24S CA35E-24S
ANNUN CLOCK 25 7 DISCRETE IN 0
CA36E-24S CA36E-24S
ANNUN DATA 26 8 DISCRETE IN 1
ws
SIG REF 7 CA38E-24S 15 GROUND
bl
G/S DOWN - 19
SHIELD GROUND 49 9CA-A A/P RELAY 9CA-A
1 P1121
1 CA15H-22 ws ws
72 28V RELAY POWER K1C-NO 3 CA44E-24S CA44E-24S 10 429 TX0+
CA36F-24S
CA35F-24S
CA34F-24S
CA33F-24S
CA32F-24S
CA31F-24S
bl bl
ws ws K1D-NO 2 31 429 TX0+
G/S UP + 18 CA39E-24S CA39E-24S 13 K4B-W
bl bl 14 GROUND
VS SIGNAL 22 12 K3A-W ws ws
K2D-NO 6 CA45E-24S CA45E-24S 20 DISCRETE OUT 1+
ws ws bl bl
ROLL STEERING 429A 36 CA40E-24S CA40E-24S 43 K1C-W K2C-NO 7 41 DISCRETE OUT 1-
bl bl
ROLL STEERING 429B 37 42 K1D-W 60 GROUND
ws ws
SHIELD GROUND 46 K2B-NO 45 CA46E-24S CA46E-24S 19 DISCRETE OUT 0+
ws ws bl bl
G/S FLAG + 1 CA41E-24S CA41E-24S 46 K2D-W K1A-NO 24 40 DISCRETE OUT 0-
bl bl
G/S FLAG - 2 47 K2C-W ws
CA37E-24S 51 429 RX0+
SHIELD GROUND 39 bl
CA42E-24 CA42E-24 72 429 RX0-
ALT ENGAGE SIGNAL 20 9 K3B-W
CA43E-24 CA43E-24
ALT SEL CONTROL 21 48 K2A-W
P1122
P2 39122 1 CA47E-24 CA47E-24
K3D-NO 10 2 DISCRETE OUT 0
CA48E-24 CA48E-24
K3B-NO 49 3 DISCRETE OUT 1
4CA-A CA49E-24 CA49E-24
K2A-NO 28 4 DISCRETE OUT 2
HDG RETURN 29 15 GROUND
CA50E-24S CA50E-24S
CRS RETURN 12 K4D-NO 14 12 ANALOG OUT 2
CA51E-24S CA51E-24S
L-R -RT 31 K4C-NO 15 13 ANALOG OUT 3
CA52E-24S CA52E-24S
LG8E-22 K4A-NO 56 27 ANALOG OUT 6
Lights 15 see EA-9B334.90 DIMMING CA53E-24S CA53E-24S
TURN COORDINATOR K4B-NO 53 26 ANALOG OUT 5
CA54E-24S CA54E-24S
CA15G-22 5CA-A K3A-NO 52 10 ANALOG OUT 0
A/P A+ 34 5CA-a CA55E-24 CA55E-24
CA16E-24 P/N 6405-28L AI ENERGIZE 71 6 DISCRETE OUT 4
A/P Disconnect 17
CA2F-22 ws
A 28 VDC CA38E-24S 25 ANALOG REF
ws ws bl
Rate Gyro Tach. 5 E 1 39 ANALOG GROUND
org CA23E-24S CA23E-24S org 3FG
Rate Gyro Ref. 6 D
ws
bl
bl bl
Rate Gyro Signal 24 C
C CA29E-22N see EA-9B342.65 IFD LEFT C
Shield Gnd. 41 DRUCKSCHOTT HINTEN B GND
IFD RIGHT
TRANSDUCER P550-5017
ST14-A 5CA AIS 240-35
8CA-A J2122
1VN-B IFD-5000i
ws ws ws ws 8CA E CA31F-24S
Transducer Ground 16 6 2 001758_212_02 23 DISCRETE IN 3
700-00083-()
org CA20E-24S org org org CA32F-24S
10 VDC 33 7 3 Transducer 41 ANALOG IN 1
bl bl bl bl CA33F-24S
Transducer Signal 50 8 1 40 ANALOG IN 0
CA34F-24S
Shield Gnd. 46 9 22 DISCRETE IN 2
3 2 1 CA35F-24S
AC Heading 7 7 DISCRETE IN 0
1 SIM CA36F-24S
AC Course 8 8 DISCRETE IN 1
ws ws
NAV FLAG + 13 CA22E-24S CA22E-24S 5 K2B-W 15 GROUND
bl bl
NAV FLAG - 14 44 K1A-W
SHIELD GROUND 45
CA21E-24 CA21E-24 P2122
LOC SWITCH 32 50 K3D-W
ws ws ws
DC HDG HI (KCS 55) 28 CA9E-24S CA9E-24S 54 K4D-W 25 ANALOG REF
CA38F-24S
bl bl bl
DC CRS HI (KCS 55) 11 55 K4C-W 39 ANALOG GROUND
CA56E-24 CA56E-24
SHIELD GROUND 44 K3D-NC 30 2 DISCRETE OUT
CA19E-24S CA19E-24S CA57E-24 CA57E-24
L-R +RT 30 16 K4A-W K3B-NC 29 3 DISCRETE OUT 1
CA58E-24 CA58E-24
K2A-NC 8 4 DISCRETE OUT 2
ws 15 GROUND
Ground for DG 9 CA37E-24S 1 CA59E-24S CA59E-24S
bl K4D-NC 34 12 ANALOG OUT 2
Ground 10 CA60E-24S CA60E-24S
ws K4C-NC 35 13 ANALOG OUT 3
429 TX+ 48 CA37F-24S CA61E-24S CA61E-24S
bl K4A-NC 36 27 ANALOG OUT 6
429 TX- 37 CA62E-24S CA62E-24S
DRUCKSCHOTT HINTEN K4B-NC 33 26 ANALOG OUT 5
CA63E-24S CA63E-24S
Shield Gnd. 42 K3A-NC 32 10 ANALOG OUT 0
Exitation Ref. 26 ST14-A 6CA-A 6CA-a PITCH SERVO
Signal Ref. 27 1 P2121
ws ws 11
ws ws
Pitch Solonoid GND 2 2 P/N 001008-P4
bl CA24E-24S bl 12
bl CA24F-24S bl ws ws
Pitch Motor 21 3 K1C-NC 23 CA64E-24S CA64E-24S 10 429 TX0+
13
bl bl
K1D-NC 22 31 429 TX0+
ws ws 14
ws ws *
Trim Switch DN 4 6 14 GROUND
bl CA25E-24S bl 15
bl CA25F-24S bl * ws ws
Pitch Solonoid 20 1 K2D-NC 26 CA65E-24S CA65E-24S 20 DISCRETE OUT 1+
20
bl bl
K2C-NC 27 41 DISCRETE OUT 1-
ws ws 16
ws ws
Pitch Motor 3 4 60 GROUND
org CA26E-24S org 17
org CA26F-24S org * ws ws
Trim Switch UP 22 8 K2B-NC 25 CA66E-24S CA66E-24S 19 DISCRETE OUT 0+
bl bl 18
bl bl * bl bl
Trim Switch Com. 23 7 6CA K1A-NC 4 40 DISCRETE OUT 0-
Shield Gnd. 40 19
ws
SIM 1 CA37F-24S 51 429 RX0+
bl
Exitation 25 9CA 72 429 RX0-
TRENNSTECKER OVERHEAD 7FG
D EXC. + 10 V 39 D
EXC. Ground 43 ST5 7CA-A 7CA-a ROLL SERVO see EA-9B342.66 IFD RIGHT
19
ws ws b
ws ws P/N 0106-2-T3 Letzte Bearbeitung:
Roll Motor 4 Die Gültigkeitszuordnung 19.01.11 HW Datum Name Maßstab auf Projektion
bl CA27E-24S bl d
bl CA27F-24S bl SI.-Klasse
Roll Solonoid 18 1 von Version zu Bearb.: 08.09.04 PB Freimaßtoleranz
ws ws f
ws ws Oberflächenschutz Oberfläche
Roll Motor 1 3 Flugzeugbaureihe
bl CA28E-24S bl h
bl CA28F-24S bl ist der Bauakte bzw. Gepr.:
Roll Solonoid GND 36 2 Detail A
7CA
Shield Gnd. 39 g
c
zu entnehmen.
Gepr.: EA 400-500
CA17E-20N DN D Zuordnung links / rechts wird mit
Airframe Ground 35 AP-STEC-55X, CA
1VN-B A D B */* in allen Feldern angegeben.
4CA P1 (39123) D 001758_212_02 B E F 04
36 AWG Tinned copper per ASTM-B-33 15CA A EA-9B271.17 B
03
1 OVERBRAID C F E 02 B ÄM-400-09-01 07.10.10 HW Schwarze Heide 21
A2 Blatt 1 von 1
optical coverage minimal 98 - 100% UP C 01 A ÄM-400-04-02 09.09.04 PB
EDV-Kennung:
Chapter 91 30. March 2012 9B27117T
1 2 3 4
1 2 3 4 5 6 7 8
D D
STEUERHORN LINKS
TRIM COMMAND SW A/P DISCONNECT

D
B
DN
F
15CA A
E 17CA
C MPG206R
UP
Steckerleiste
1
ws
2
grün
3
grau
4
ws/rt
5
blau
6
braun
Kabel im Flugzeug
7
org
C see EA-9B271.17 AP-STEC-55 C
8
lila CWS 13CA
9
sw
10
glb
11
rt DN D
1PST-MMPS A D
see EA-9B235.17 MKR-AUDIO ws/grün B
12
F
13 B E 15CA
6RZ A
14
PILOT PTT E
C F
rt UP C
ws/grün
STEUERHORN RECHTS
5RZ
COPILOT PTT
1
grün
see EA-9B235.17 MKR-AUDIO 2
gelb
B B
Verwendetes Kabel liegt im Lager auf Rolle

A
A
zu entnehmen.
Zuordnung links / rechts wird mit CONTROL STICK LEFT/RIGHT
04
EA-9B271.18 A
01 A ÄM-400-09-01 05.10.10 HW
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
AVIONICS BUS PP5

2CA
AP
AP-CMPTR
5A
X2 X1
WH10E-22 CA1H-20 3 CA1F-20
D 100 AP EA-9B271.17 55CA Pin X2 A:6 D
3 CA1E-20
55CA A:5
EMERGENCY BUS PP4

1WH 1GW
5WH STALL-WARN GEAR WARN
5A 2A
WH1F-22 2 WH1E-22
D:19
Horn
WH1H-22 2 WH1G-22
R1-1101 D:20
75 40 13-66
1 GW1G-22 BATTERY BUS PP2
C:4
GW1F-22 1 GW1E-22 1WV
C:3 VNE WARN
1A
WV1F-22 C:13 1 WV1E-22
WH1F-22
16
C D32 D31 R40 R41 C
WH10E-22
17
D21 100 100
D11
D12
WV1F-22
13
VMO-Test
VNE WV8F22
35 see EA-9B314.30 AIRSPEED WARNING (TONE TEST)
K10 K1
D13
WV3E-22 see EA-9B314.30 AIRSPEED WARNING (IFD LEFT)
31
TONE-GENERATOR
GW1F-22
GEAR WARNING 12 1
EA-9B323.20 Gear Warning CG37E-22 CG37E-22 GEAR
14 30
EZ27E-22N 12
K20
GND TONE-GENERATOR
see EA-9B315.80 ANNUNCIATOR PANEL D33 Annunciator Panel left
13 40 WH1H-22
15 27
Gen-Fail Aft Door
39GA
B STALL B
WH2F-22 WH2F-22 Gear Warn Stall-Warn
GND 26
K30 8 Flaps Cab-Press
1WW
13 WH3E-22N
Trennstecker Overhead 14
WH11E-22 9
B 6
TONE-GENERATOR
ST5
2WH-A 2WH-a
LIFT TRANSDUSER EA-9B284.13b PCB-BOARD 1
org WH2E-22
1 see EA-9B284.13 PCB-BOARD 1
grün
5
lila HG16G-16 STEUERPLATINE ANNUNCIATOR
10 5WW-B
weiß/rot HG17E-16N see EA-9B303.10 PITOT-STALL HEAT 5WW
12
blau D14
6
gelb 2 WH3E-22N 5WW-D WW1-20
2WH LIGHT TEST (GND) + VOLT DIMM 25
STALL ANNUNC 24
WH11E-22 WW15-22
46 14
13VN EA-9B315.81 STEUERPLATINE

Ground an Seilrollenbeschlag Die Gültigkeitszuordnung Letzte Bearbeitung: Datum Name Maßstab auf Projektion
Zuordnung links / rechts wird mit STALL WARNING, WH
04
1 OVERBRAID 03
EA-9B273.30 A
Chapter 91 30. March 2012 01 A ÄM-400-09-01 01.07.10 HW
A3 Blatt 1 von 1
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
AVIONICS BUS PP5

2CA
AP
AP-CMPTR
5A
X2 X1
A WH10E-22 CA1H-20 3 CA1F-20 A
100 AP EA-9B271.17 55CA Pin X2 A:6
3 CA1E-20
55CA A:5
EMERGENCY BUS PP4

1WH 1GW
5WH STALL-WARN GEAR WARN
5A 2A
red WH1F-22 WH1F-22 2 WH1E-22
D:19
Horn blk
WH1H-22 2 WH1G-22
D:20
R1-1101
75 40 13-66 1 GW1G-22 BATTERY BUS PP2
C:4
WH4E-22
GW1F-22 1 GW1E-22 1WV
C:3 VNE WARN
1A
WV1F-22 C:13 1 WV1E-22
PC-BOARD 1
P1
WH4E-22
16
B D32 D31 B
WH10E-22 R40 R41
17
D21 100 100
D11
D12
WV1F-22
13 P1
VMO-Test
VNE WV8F22
35 see EA-9B314.30 AIRSPEED WARNING (TONE TEST)
K10 K1
D13
WV3E-22 see EA-9B314.30 AIRSPEED WARNING (IFD LEFT)
31
TONE-GENERATOR
GEAR WARNING
GW1F-22
PC-BOARD 2 2GW 12 1
CG37E-22 CG37E-22 GEAR
14 30
EZ27E-22N
12
K20
TONE-GENERATOR
EZ65E-22 D33
13 40 see EA-9B315.80 ANNUNCIATOR PANEL
U WH1H-22
(GEAR WARNING) 27
C 1VN-3 STALL C
WH2F-22 WH2F-22
001758 212 02 EA-9B411.60 26
see EA-9B323.20 GEAR WARNING K30 8
13 WH5E-22N
Trennstecker Flügelnase 14
WH11E-22 9
B m 6
TONE-GENERATOR
ST5
C
LIFT TRANSDUSER 2WH-A 2WH-a PC-BOARD 1 EA-9B411.50
org WH2E-22 1VN-4
1 see EA-9B284.13 PCB-BOARD 1
grün
5 ANNUNCIATOR PANEL 001758 212 02
lila HG16G-16
10 see EA-9B303.10
weiß/rot HG17E-16N 5WW
12 PITOT-STALL HEAT + VOLT DIMM L104 L204
blau D04 Annunciator Panel
6
gelb 2 WH3E-22N 5WW-D
2WH LIGHT TEST (GND) Bleed Overt Stall-Warn Flaps
STALL
WH11E-22
46 Stall-Heat Windsh-Heat Gear Warn
ANNUNCIATOR BOARD EA-9B411.70 Pitot Heat L Pitot Heat R Hydraulic

13VN
Ground an Seilrollenbeschlag Die Gültigkeitszuordnung Letzte Bearbeitung: Datum Name Maßstab auf Projektion
zu entnehmen.
Zuordnung links / rechts wird mit STALL WARNING, WH
Maintenance Manual EXTRA 500 1 04
OVERBRAID 03
EA-9B273.30 B
01 A ÄM-400-09-01 01.07.10 HW
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
Flugrichtung FLAP ZUSATZBOX FLAPBOX

20VN-A, 2VN-B, 1VN-C EA-95275.22 EA-95275.23
29CG 30CG
D3
3
8
D
20
D Q2
D2 D2
5
D1
2
7
Gen-Fail Aft Door
A2
4
A1 P/N 90-4219X-1
1 2 3 4 5
1
6
1617
Gear Warn Stall-Warn ANNUNCIATOR BOARD
6
Q? geändert
B3 B3 X2 X1 5WW D14
C A B C 5WW-B 5WW-D
20
C Flaps Cab-Press LIGHT TEST (GND)
B2 B2
3 4
D E F B1
5VDC WW19-22
18 50 42
A A2 A2 24 + VOLT DIMM A
1 2 3 4 5
1 2
G H J
16 17
WW1-20
6
5
>7° A1 A3 25
B K L M A2
20
B
2
4
X1 X2 ANNUNCIATOR BOARD EA-9B315.81
A1
N P R
X2 X1
1WW
1
3
S T U
1 2 3 4 5
16 17
33CG
6
B3
20
20
A A B2
B1
A3 CG47E-22 CIRCUIT BREAKER/SWITCH PANEL
A2
1 2 3 4 5
1 2 3 4 5
1617
1617
6
6
A1
001758-212-02 BOX EA-85411.00 CG53E-22N X2 X1 CG51K-22 1 CG51H-22 BATTERY BUS PP2

D:10
GND
15° LED
Pos. Switch 15°
Flap Inhibit/28V
Pos. Switch 30°
Pos. Switch 0°
Up Relay
Down Relay
Einbau TOP Einbau BOTTOM
14° Position
15° Position
28VDC Power In
5V Out
Balanced
GND
5V Out
Balanced
GND
28VDC
Flap Inhibit
GND
Annunciator
VV135 27CG 25CG 1CG
H FLAP-UNB FLAP-CTRL FLAP
Modul 6a Modul 3a, 4a, 5a 15 3 9 5 7 1011 2 1 8 1413 6 4CG 1A 3A 7.5A
Doc. EA-05856.054 M210-B4N
001758_212_02 S210-A5-A1
1 3 4 5 6 7 8 9 10 2 15 4CG-B 4CG-A
A F A F 15pol DSub 15pol DSub Pin
3VN-A
or
bl
or
bl
ws
ws
B G B G
NC
C H C H
D J D J
E K E K STECKER AVIONIC BAY
CG33E-22
CG36E-22
CG31E-22
CG51E-22
CG19E-22
CG15E-22
CG39E-22
CG40E-22
CG1H-22
CG50E-22
CG42E-22
CG41E-22
CB Trennstecker
ST 6
CG35E-22N
29CG-C
CG9E-22
CG12E-22
CG1J-22
CG31E-22
CG1E-22N
001115-201-02 001115-211-02
CG50E-22 CG50F-22 2 CG50G-20
19 A:2
E 20VN-A 20VN-A H
Modul 8a Modul 7a 001578_212_02 01758 212 02 CG51E-22 CG51F-22 A:3 2 CG51G-20
20
Modul 5a SIM_M_2022
A F A F
B G B G FG VV275203 ST 6
C H C H AB 001115_211_03 29CG-D
D J D J
CG1G-22 CG1G-22 CG1F-22 CG1E-22
B E K E K 12 C:11 1 B
CG8F-16 3 CG8E-16
Messen zwischen 2 und 3 C:6
Messen zwischen 1 und 2
001115-207-02 001115-209-02
3 3 see EA-9B246.10 DC-DISTRIBUTION
17CG ws bl 18CG
2 or CG9E-22 CG12E-22 or 2
L POTI bl ws 1
R POTI
1 32CG
Entfernt: 32CG-A FLAP CONTROL SWITCH
CG40E-22 CG40F-22 CG40G-22 9 0° 3CG
35CG 13 1 RS 321-379
BYW 56 CG36E-22 CG36F-22 CG36G-22 10 15° FE4252
Kabel anlöten 14 2 EA-75112.60
CG39E-22 CG39F-22 CG39G-22 11 30° EA-75112.60.KBS
15 3
03.06.2004
CG52E-22 Mittelabgriff
4
CG52F-22N
WEATHER DETECTION
P1
Modul entfällt ! TWX-670
001758_212_02 4
3
RELAY BOARD N 2 SS7E-24 54 MIC INHIBIT INPUT
1VN-C 1
Modul 1a
H J CG14E-16N 2SS
VV275207 K
001115 211 03 see EA-9B344.14 WEATHER DEDECTION
An Punkt 20VN
Down Relais UP-Relais PC-BOARD 1
10CG anschrauben P1
26.72.03 GNM 4175A EA-9B411.50A
26.72.03 ST 7 RZ2E-24S SS7E-24
see EA-9B235.16 MKR-AUDIO
88 88 CG16F-22 30CG-D SS8E-24 7
D1 BYW-56
88a braun blau 88a
see EA-9B344.14 WEATHER DETECTION
10
SS9E-24 D2 BYW-56
87 87a 87a 87 CG8G-16 CG8G-16 see EA-9B344.14 WEATHER DETECTION
Modul 8a 7 RZ13E-24S 11
001115_207_03 23CG see EA-9B235.16 MKR-AUDIO
22CG 33CG 34CG CG8F-20
GA53H-22 D3 BYW-56
C VV275206 85 86 85 86 see EA-9B315.80 ANNUNCIATOR PANEL [HYDR] 24 C
12LY BYW 56 BYW 56 CG34H-22 D4 BYW-56
29
VV119 CG15E-22
CG15F-22 C CG15G-22
B G P600M
see EA-9B284.13B PCB-BOARD 1
X1
1
3
links NC 36CG
16
CG15H-22 Platine GEAR WARNING, EA-9B323.20 DIMMING BOARD

C CG41E-22 60
15° LIMIT B NO
39GA-A Pin 4 5LH-A
Modul 6a REL M320A1N ST 6 EA-9B410.30C LAMP TEST GND
001115_201_03 CG42E-22 29CG-D CG34H-22
2
28
CG17F-22N CG17E-22N 14CG CG17E-22N
X2
A F
VV120 CG34G-22 D8 BYW-56
CG15G-22 8 24
NC 19 In Transition 8CG-A
VV275204 8CG 5LH
C CG43E-22 CG43E-22 CG34E-22 CG34F-22
20VN-A 16 1
NO CG32F-22 LED 590-250 amber see EA-9B334.90 DIMMING
AD J rechts Modul 8a 18 VV136 2
001758_212_02 CG33E-22
CG25F-22
001115_207_03 17 CG37E-22
14° LIMIT A 13CG 10 MODUL1 Pin C
CG19F-22 CG19E-22 Modul 8a
F
D J 001115_207_03
VV121 30° 6CG-A
VV275206
A
VV275206 CG32G-22 VV137 6CG
1
CG22F-22N
CG23F-22N
2
LED 590-244 green
CG25E-22
Modul 6a CG37F-22 see EA-9B334.90
Krimp-Splice blau CG32H-22 9 MODUL 1 Pin E
7 5lh-a Pin-5 DIMMING
001115_201_03 C B 001115_201_03
FTS D436-37 7CG-A
CG27E-22
VV275204 VV275204 15° VV138 7CG

H G VV128 CG33F-22
Module Avionic-Bay NC 1
5LY 2
LED 590-244 green
Modul 7A
P600M CG37G-22
WING L Y=4400 VV275205 CG33G-22
11 MODUL 1 Pin D
001115_209_02 6 5lh-a Pin-23
L DOWN LIMIT SW
LY10F-22 LY10F-22 LY10E-22
VV123 CG21F-22 C 20 42 see EA-9B334.50 COURTESY LIGHT
11CG NO CG21E-22 D CG21H-22 CG21H-22 VV129 NO 15CG
VV122 C E
CG23E-22N C R DOWN LIMIT SW 29CG-D
001115_209_03 VV130
NC CG30E-22 CG30F-22
A B ST 6
VV124 Modul 7a
VV275205
D D
Modul 8a
CG24E-22 CG24F-22
VV275205 K E Letzte Bearbeitung:
Die Gültigkeitszuordnung 17.02.11 HW Datum Name Maßstab auf Projektion
L UP LIMIT SW 001115_209_02 VV131 001115_207_03 von Version zu SI.-Klasse Freimaßtoleranz
NC Bearb.: 18.08.04 PB
VV126 Flugzeugbaureihe Oberflächenschutz Oberfläche
Maintenance Manual EXTRA 500 CG22E-22N
VV125
C
NO CG20E-22
H J
CG20F-22 VV132 NO
C
16CG VV275206 ist der Bauakte bzw. Gepr.:
K dem jeweiligen Fertigungsauftrag Gepr.: EA 400-500
NC 001115_209_03 R UP LIMIT SW zu entnehmen.
CG26E-22 CG26F-22 VV133
F G WING R Y=4400 Zuordnung links / rechts wird mit FLAP SYSTEM, CG
12CG Modul 7A */* in allen Feldern angegeben.
VV127 Modul 7a 04
03
EA-9B275.20 A
VV275205
A2 Blatt 1 von 1
Chapter 91 30. March 2012 Ver. Bezeichnung
EDV-Kennung:
Nr.: Änderung/Mod. Nr.: Datum Name Schutzvermerk nach DIN 34 beachten.
9B27520T
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
AVIONIC BAY
FLAP BOX
D3
Q2 D2 D2 ANNUNCIATOR PANEL
FLUGRICHTUNG D1 Annunciator Panel 5WW L105 L205 D05 B3 33CG
RUMPF A2 5WW-D B2
LIGHT TEST (GND)
EINBAUDOSE SOCKET A1 Bleed Overt Flaps Cab-Press B1
AVIONIC BAY Q? 50 CG47E-22 A3
42
J 7a J 6a B3 B3 X2 X1 Stall-Heat Gear Warn Aft Door A2
STECKER PIN B2 B2 A1
30CG 29CG + VOLT DIMM
B1 Pitot Heat L Hydraulik Pneumatic
5VDC
P 6A P 7A CG51K-22 X1 X2 CG53E-22N
A 29CG 30CG A2 A2 ANNUNCIATOR BOARD EA-9B411.70 A
VV135
>7° A1 A3 see EA-9B315.80 ANNUNCIATOR PANEL
A2
M210-B4N
X1 X2 Sockel S210-A5-A1 T
A1
1 A 1
X2 X1 1VN-1
001758 212 02
B CIRCUIT BREAKER/SWITCH PANEL
5
4
5
5
4
4
BOX EA-85411.00 CG51K-22 1 CG51H-22 CG51G-20 BATTERY BUS PP2
D:10
GND
15° LED
Pos. Switch 15°
Flap Inhibit/28V
Pos. Switch 30°
Pos. Switch 0°
Up Relay
Down Relay
14° Position
15° Position
28VDC Power In
2 3
5V Out
Balanced
GND
5V Out
Balanced
GND
28VDC
Flap Inhibit
GND
Annunciator
2 3
2 3
27CG 25CG 1CG
12 34
1
1
FLAP-UNB FLAP-CTRL FLAP
20 6
20 6
1A 3A 7.5A
20 6
20 6
Doc. EA-05856.04 15 3 9 5 7 1011 2 1 8 1413 6 4CG
1 3 4 5 6 7 8 9 10 2 15
C Einbau TOP 4CG-B 4CG-A Einbau BOTTOM
1 2 3 4 5
1 2 3 4 5
1617
1617
1 2 3 4 5
1 2 3 4 5
or
bl
or
bl
ws
ws
16 17
16 17
6
6
6
6
15pol DSub 15pol DSub Pin
CG1E-22
CG8E-16
NC
CG50G-20
8
3
20
3
8
Schraubverschluss Schraubverschluss
20
5
5
STECKER AVIONIC BAY
7
2
2
7
CB Trennstecker
4
4
D
1 2 3 4 5
1
P 6A
6
16 17
1 2 3 4 5
1
CG9E-22S
CG12E-22S
CG1J-22
CG31E-22
CG4E-22N
CG35E-22N
CG33E-22
CG36E-22
CG31E-22
CG51E-22
CG19E-22
CG21E-22
CG39E-22
CG40E-22
CG1H-22
CG50E-22
CG42E-22
CG41E-22
1617
6
6
29CG-C J 6a-C
Sicht Stecker "front" CG50E-22 CG50F-22 2 CG50G-20
20VN-A 19 A:2
E 20VN-A H
001578 212 02 01758 212 02 CG51E-22 CG51F-22 A:3 2 CG51G-20
20
AUSSEN RECHTS
Sicht Dose "front"
Modul 22 P 6A
CG1H-22 29CG-D J 6a-D
E
CG1J-22 CG1G-22 CG1G-22 CG1F-22 CG1E-22
B C D 12 C:11 1 B
Module Avionic-Bay
Modul 20, 22 H
K J P 7A J 7a-D
30CG-D
A F CG8G-16 CG8F-16 C:6 3 CG8E-16
FLUEGEL G F 7
B G A B
C H see EA-9B246.10 DC-DISTRIBUTION
D J
E K
P 6A 32CG-A 32CG-a FLAP CONTROL SWITCH
Messen zwischen 2 und 3 J 6a-D
29CG-D
CG40E-22 13 CG40F-22 CG40G-22 9 0° 3CG
001115 211 02 3 1 RS 321-379
17CG ws CG36E-22 CG36F-22 CG36G-22 10 15° FE4252
Modul 21 2 CG9E-22S
14 2 EA-75112.60
or
L POTI bl CG39E-22 CG39F-22 CG39G-22 11 30° EA-75112.60.KBS
1 15 3
A F CG52E-22 Mittelabgriff
B G P 7A 4
C H RELAY BOARD 30CG-D J 7a-D
D J CG14E-16N CG14G-16N
E K 8
Kabel anlöten
CG52F-22N
DOWN RELAIS UP RELAIS

4
B 2
001115 209 02 26.72.03 GNM 4175A 26.72.03 G S 3
Messen zwischen 1 und 2 1
CG14F-16N
20VN-A WEATHER DETECTION
CG14F-16N
CG14E-16N
CG8G-16
88 88a braun blau 88a 88 P1 TWX-670
1 1VN-6 1VN-3
CG16E-22N
20VN-A, 3VN-A, 1VN-C 18CG 87 87a 87a 87 CG8H-16

ws 001758 212 02 SS7E-24 54 MIC INHIBIT INPUT
R POTI 2 or CG12E-22S
X1
A1
A3
B1
B3
22CG 10CG 23CG 2SS

3 bl
see EA-9B344.14 WEATHER DEDECTION
CG2E-16
CG3E-16
36CG REL M210B4N PC-BOARD 1
CG8H-16
CG8H-16
86 85 86 85 Sockel S210-A5A1 P1
EA-9B411.50A
X2
A2
B2
RZ2E-24S SS7E-24
A B C see EA-9B235.16 MKR-AUDIO
7
SS8E-24 D1 BYW-56
C see EA-9B344.14 WEATHER DETECTION C
D E F 10
SS9E-24 D2 BYW-56
see EA-9B344.14 WEATHER DETECTION
11
CG41E-22 RZ13E-24S
CG25F-22
CG2E-16
CG3E-16
CG42E-22
CG27E-22
G H J
CG43E-20
CG34E-22
CG21E-22
GA53H-22 D3 BYW-56
K L M see EA-9B315.80 ANNUNCIATOR PANEL [HYDR] 24
12LY 33CG 34CG 5LY CG34H-22 D4 BYW-56
15° LIMIT B 29
N P R
14CG NC
links Modul 20 P 6A
001119 702 02 2 X 001119 702 02 P600M 29CG-D J 6a-D see EA-9B284.13B PCB-BOARD 1
S T U CG15E-22 CG15E-22
16
G F Platine GEAR WARNING, EA-9B323.20 DIMMING BOARD

C NO VV119 CG15F-22 CG15F-22 CG15G-22 CG15G-22 CG15H-22
A B 19 60
39GA-A Pin 4 5LH-A EA-9B410.30C LAMP TEST GND
14° LIMIT A CG34H-22
CG43G-20 28
13CG NC links CG34G-22 D8 BYW-56
VV120 8 24
CG43F-20
CG24F-22
NO VV121 CG19E-22 CG43F-20

In Transition 8CG-A D7 BYW-56
C E 5
CG43G-20 CG43E-20 CG34E-22 CG34F-22
C D 16 1 8CG
2
D6 BYW-56
VV136 23
R DOWN LIMIT SW CG37G-22
LED 590-250 amber
10 34 DIMMING VOLT
Modul 21 CG32G-22
15CG NC VV128 CG25E-22 7
CG30F-22 30° 6CG-A 5LH
CG17E-22N
C NO VV130
VV129 CG32H-22 CG32H-22 CG32E-22 CG32E-22 CG32F-22 1
18 6CG see EA-9B334.90 DIMMING
LH8E-20
E D
CG32J-22
C VV137 2
CG30F-22 CG37E-22
LED 590-244 green
9
CG33G-22
L DOWN LIMIT SW 6 Modul 15
11CG VV123 CG32J-22 15° 7CG-A LH8E-20
VV122 C A F
CG23E-22N NO CG33E-22 CG33F-22 1
17 7CG B G
VV124 CG30E-22 CG30E-22 CG30F-22 CG37G-22
A B VV138 2 C H
NC CG37E-22
LED 590-244 green D J
CG37F-22 CG37F-22
11 E K
WING R Y=4400
R UP LIMIT SW CG24F-22
16CG NC VV131 CG24E-22 CG24E-22 H LY10F-22 LY10F-22 LY10E-22
CG26F-22
K J 20 42 see EA-9B334.50 COURTESY LIGHT
D C NO VV132 CG20F-22 29CG-D J 6aD D
VV133 CG26F-22 CG26F-22 CG26E-22 P 6A Letzte Bearbeitung:

F G Die Gültigkeitszuordnung Datum Name Maßstab auf Projektion
18.08.04 PB
L UP LIMIT SW ist der Bauakte bzw. Gepr.:
CG20F-22 dem jeweiligen Fertigungsauftrag EA 400-500
12CG K J Gepr.:
VV126 CG20E-22 CG20E-22 zu entnehmen.
VV125 C H
CG22E-22N NO Zuordnung links / rechts wird mit FLAP SYSTEM, CG
Krimp-Splice blau
Maintenance Manual EXTRA 500 NC
VV127 CG26E-22
20VN-A */* in allen Feldern angegeben.
04
WING L Y=4400 CG22E-22N EA-9B275.20 B
03
FTS D436-37 CG23E-22N
J
CG17E-22N
D A2 Blatt 1 von 1
01 A ÄM-400-09-01 14.10.10 HW
A Nr.: Änderung/Mod. Nr.: Datum Name 46569 Hünxe, Germany
Chapter 91
1
11. July 2012 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
D D
O-SP-TEST
1ES
ES1E-22
2A
LOAD BUS PP3
1 see EA-9B246.10 DC-DISTRIBUTION

C:9
ES1F-22
OVERSPEED TEST
2ES Taster Spörle 220678
C TEST C
Instrument-Panel left
ES1G-22 ES3G-22
J1
1 2 MOLEX
Mikro Fit 3
P1
FIREWALL Propeller Overspeed
Govenor Reset Solenoid
4ES
ES1F-22
ES3E-22
ST4 3ES-A
Jiffi Diode
ES3E-22 ES3F-22 ES3F-22
35 A An Turbine integriert
ES2E-22N ES2E-22N
B
VV139 VV140 3ES
J
Stecker MS3106F10SL-4S
001758 212 02
2VN-C
B B

Zuordnung links / rechts wird mit PROP OVERSPEED, ES
04
03
EA-9B276.10 A
Chapter 91 30. March 2012 01 A ÄM-400-09-01 01.07.10 HW
A3 Blatt 1 von 1
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
EMERGENCY BUS PP4

1QX FUEL-QTY
2A
QX1E-22
D
1 see EA-9B246.10 DC-DISTRIBUTION D
C:15
QX17E-22N
VV284103
Fuel Indication 2QX-A AC DIM-VOLTAGE
001758 212 02 QX15E-22S A F ws
A B see EA-9B334.90 DIMMING SYSTEM 7 8 see EA-9B334.90 DIMMING SYSTEM
1VN-G B G HI9E-22S
Left outside A1025 9 see EA-9B360.11 PROP HEAT
QX1N-22 ws C H ws
28VDC 1 ws ws
2 D J
ws E K ws
N/C 3 VV284101 VV284102
N/C 4
QX1F-22
QX2H-22
QX4L-20N
Input Resistive Float 5 QX3E-22 A F A F Anschlußbolzen 9QX
Light 6 QX3F-22 B G B G 001115-202-02
Light 7 QX2J-22 C H C H
Gnd 8 QX4L-22 VV284104 20QX
9 D J D J
E K E K ws Varistor +
2QX A F bl QX13G-22 bl 289-7569 -
QX16E-20N B G
3QX-A bl bl
001115-202-02 001115-202-02 C H
Left mid A1023 bl D J bl Fuel Quantity right outside
QX1N-22 bl E K bl VDO 999.161.004
28VDC 1
2
N/C 3 10QX
Anschlußbolzen
QX1G-22
QX1H-22
QX1J-22
QX1K-22
QX1L-22
QX1M-22
QX4E-22
QX4F-22
QX4G-22
QX4H-22
QX4J-22
QX4K-22
N/C 4 C
QX5H-22 001115-202-02
Input Resistive Float 5 QX6F-22
Light 6 QX6G-22 9QX-A 9QX-a 001758 212 02 19QX
Light 7 1VN-G
QX5J-22
QX3E-22S
QX6E-22S
QX8E-22S
QX12E-22S
QX14E-22S
QX10E-22S
8
ws Varistor +
Gnd QX4L-22 QX1G-22 QX11G-22S bl 289-7569 -
9 1
3QX ws QX2E-22S
20
ws
2
bl QX3E-22S Fuel Quantity right mid
4QX-A 21
bl VDO 999.161.004
3
Left center A1021 QX4E-22
22
QX1H-22
1 4 11QX
28VDC ws QX5E-22S Anschlußbolzen
2 23
ws
N/C 3 5
C bl QX6E-22S C
N/C 4 24
bl
18QX
Input Resistive Float 5 6
QX4F-22 ws Varistor +
Light 6 25
QX1P-22 QX1J-22 QX9G-22S bl 289-7569 -
Light 7 7
QX7H-22 ws QX7E-22S
8 26
Gnd QX8F-22 ws
9 8
QX8G-22 bl QX8E-22S Fuel Quantity right center
27
4QX QX7J-22 bl VDO 999.161.004
9
QX4M-22 QX4G-22
28
QX1P-22 QX1K-22
5QX-A 10
QX9H-22 ws QX9E-22S
29
Right center A1022 QX10F-22 ws
11
QX10G-22 bl QX10E-22S
1 30
28VDC QX9J-22 bl
2 12
QX4N-22 QX4H-22
N/C 3 31
QX1L-22
N/C 4 13
ws QX11E-22S
Input Resistive Float 5 32
ws
Light 6 14
bl QX12E-22S
Light 7 33 12QX
bl Anschlußbolzen
8 15
Gnd QX4J-22
9 34
QX1M-22
5QX 16
ws QX13E-22S
17QX
35
ws ws Varistor +
6QX-A 17 ST 6
bl QX14E-22S QX7G-22S bl 289-7569 -
36
Right mid A1024 bl
18 29CG-C
QX1Q-22 QX4K-22
1 37
28VDC ws ws Fuel Quantity left center
2 19 4
QX13F-22S bl bl VDO 999.161.004
N/C 3 5
N/C 4 6
QX11H-22 ws ws
Input Resistive Float 5 37pol DSub 7
Light QX12F-22 QX11F-22S bl
8 bl Anschlußbolzen 13QX
6 QX12G-22
Light 7 9
QX11J-22 ws ws
Gnd 8 QX4P-22 QX9F-22S bl
10
bl
16QX
9 11
ws +
12 289-7569
6QX ws ws QX5G-22S bl -
13
QX7F-22S bl bl
7QX-A 14
15 Varistor
Right outside A1026 ws ws Fuel Quantity left mid
16
B QX1R-22 QX5F-22S bl bl VDO 999.161.004 B
1 17
28VDC 18
2
N/C 3 SIM M 2022 14QX
Anschlußbolzen
N/C 4 QX13H-22
Input Resistive Float 5 ST 6
QX14F-22
Light 6 QX14G-22 29CG-D 15QX
Light 7 QX13J-22 ws ws +
8 8 ws 289-7569
Gnd QX4S-22 QX2F-22S QX2F-22S bl QX2G-22S bl -
9 9 bl
10
QX13E-22S
QX13F-22S
QX11E-22S
QX11F-22S
QX9E-22S
QX9F-22S
QX7E-22S
QX7F-22S
QX5E-22S
QX5F-22S
QX2E-22S
7QX Varistor
Fuel Quantity left outside
SIM M 2022 VDO 999.161.004
Einbau siehe EA-1B050.10
ws
bl
ws
bl
ws
bl
ws
bl
ws
bl
ws
bl
ws
bl
ws
bl
ws
bl
ws
bl
ws
bl
ws
bl
QX8-A Zsb. elektr. Holmdurchführung

STECKER AVIONIC BAY
25pol DSub
14 15 16 17 18 19 20 21 22 23 24 25
1 2 3 4 5 6 7 8 9 10 11 12 13
8QX SIM_M_XXXX_SN(PN)
29CG 30CG
D 16 11 6 6 D
1 4 1
7
5
8
5
20
16 11 6 9 5 1 Stecker vom Hauptkabelbaum
C 1 C
R1 R2 R3 R4 R5 R6 Flugrichtung
5
*
12
*
*
*
4
*
*
22R 22R 22R 22R 22R 22R 20

B 16 11 6 B
1
A 4 1 A
T1 T2 T3 T4 T5 T6 3 2
Letzte Bearbeitung:
Maintenance Manual EXTRA 500 50R 50R 50R 50R 50R 50R 20
5 Die Gültigkeitszuordnung
von Version zu Bearb.:
Datum
25.05.04
Name
PB
Maßstab
SI.-Klasse
auf Projektion
Freimaßtoleranz
16 11 6 16 11 6 Flugzeugbaureihe Oberflächenschutz Oberfläche
A 1 1 A Gepr.:
right outside right mid right center left center left mid left outside dem jeweiligen Fertigungsauftrag Gepr.: EA 400-500
zu entnehmen.
PCB-BOARD 1 EA-9B284.13B
Zuordnung links / rechts wird mit FUEL QUANTITY, QX
see EA-9B284.13 PCB-BOARD 1 5 5 */* in allen Feldern angegeben.
Von 0 Ohm bis 30 Ohm je nach Schwimmer ausmessen! 20 20
04
Einpinseite 03
EA-9B284.10 A
Chapter 91 30. March 2012 02 Schwarze Heide 21
A2 Blatt 1 von 1
01 A ÄM-400-09-01 20.10.10 HW
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
J1
DB37P
1
2
3
4
5
6
7
8
9
20
21
22
23
24
25
26
27
28
10
29
11
30
12
31
13
32
14
33
15
34
16
35
17
36
18
37
19
Fuel calibration
1
20
2
21
3
22
4
23
5
24
6
25
7
26
8
27
9
28
10
29
11
30
12
31
13
32
14
33
15
34
16
35
17
36
18
37
19
TR51
right Outside
A cw R51 J51 A
50R 22R
1
162-653
14
2 J1
15
TR52
3
right Mid
cw R52 CB Trennstecker
50R 22R 16 red Sense WL2F-22 1
21 C:16 see EA-9B246.10 DC-DISTRIBUTION (LOW VOLT 1LW EMERG BUS)
162-653 4
17 U60
5 LOW VOLTAGE
TR53 18 1 3 green Out WL1E-22
cw R53 Sense Out 22 108 see EA-9B315.80 ANNUNCIATOR PANEL (5WW-D Pin 22)
6
right Center
50R 22R
19
Gnd
162-653
7
see EA-9B284.10 FUEL QUANTITY
2
20
8 black L-Gnd WL3E-22N
TR54 3
cw R54 21
50R 22R 9 1VN-G
left Center
162-653 22 D 001758 212 02
10
23 HF16E-22
37 35 see EA-9B304.20 WINDSHIELD HEAT
TR55 11 2
cw R55 24 3
50R 22R K2:2
12 4 HF17E-22N
left Mid
162-653 K2:1 18 12 see EA-9B304.20 WINDSHIELD HEAT
25
13 1 10 REL TN2 HF7E-22
36 X see EA-9B304.20 WINDSHIELD HEAT
TR56 D2 113-8875
cw R56 DB25P BYW56
B 50R 22R HF3J-22 B
259-3071 19 X see EA-9B304.20 WINDSHIELD HEAT
162-653
left Outside
34
9 32
Vmo TEST
8 K1:3
K10 7
11 K1:1
13 1
1 10REL TN2 -Vmo test WV8F-22 see EA-9B334.90 DIMMING (SWITCH 3LJ-1 (1) Vmo Test)
U11 9 35 X
113-8875 D13
TR10 L7815C 6 D1 -Vmo WV3E-22
2
31 31 see EA-9B342.65&66 IFD (Px122 Pin 16)
3 cw 1 3 1 4 BYW56 BYW56
Vout Vin
8
10k R12 Vmo-Warning D4 BYW56 CG34H-22 see EA-9B344.14 W-DETECTION TWX-670
GND
220k U10 29
Q10 16 1
8 1 D3 BYW56 GA53H-22 see EA-9B344.14 W-DETECTION TWX-670
2
Vcc Rt 24
7 C12 C13 C14 REL G6A
Q +Vmod D2 BYW56 SS9E-24 see EA-9B344.14 W-DETECTION TWX-670
3 + + 11
C mod D10
R10 5 4 BYW56 D1 BYW56 SS8E-24 see EA-9B344.14 W-DETECTION TWX-670
BC107 C out Gnd 10n 1uF 0,1uF 10
330 + C11
C10ZSD 100 SOUND 22uF SS7E-24 see EA-9B344.14 W-DETECTION TWX-670
R11 R13 7
10n 3 TR1 1 Paralax Poti
330 100k 5
GND cw
2
5k 23
4
K20 11 WH1F-22
R40 100 R41 100
16 see EA-9B273.30 STALL WARNING HORN
13 R9
330 33
U21 9 D11 D21 D31 R8 SS6E-24S see EA-9B344.14 W-DETECTION TWX-670
330 15 X
TR20 L7815C 6 R7 CA12E-24S see EA-9B271.17 AP-STEC-55X
cw 330 25 25
C 3 1 4 BYW56 BYW56 BYW56 R6 C
Vout Vin 330 28
8 R5 SD9E-24SS see EA-9B344.15 TRAFFIC TAS-610
10k R22 Gear-Warning 330 9 5
Audio out WH12E-22S see EA-9B235.17 AUDIO/MARKER PMA-8000B (1RM-A Pin 31)
GND
220k U20 8 31
Q20 16 1 D12 +Vmo WV1F-22 see EA-9B314.80 AIRSPEED WARNING (VNE-WARN 1WV BATTERY BUS)
8 1 BYW56 13
2
Vcc Rt
7 C22 C23 C24 REL G6A
Q +Gear +Gear GW1F-22 1 see EA-9B323.10 GEAR WARNING (GEAR-WARN 1GW EMERG BUS)
3 + + 12 C:4
C mod D20 -Gear CG37E-22 see EA-9B323.20 GEAR WARNING (9GA-A Pin 14)
R20 5 4 30 66
BC107 C out Gnd 10n 1uF 0,1uF
BYW56-Gear D33 Stall WH1H-22 2 see EA-9B273.30 STALL WARNING (STALL-WARN 1WH EMERG BUS)
+ C21 BYW56 27 D:20
22uF -Stall WH2F-22 see EA-9B273.30 STALL WARNING (VV172)
330 R21 R23
C20ZSD 100 SOUND 26 11
39n D32 -Stalld WH10E-22 see EA-9B271.17 AP-RELAY (55CA Pin X2)
330 100k BYW56 17 100
WH11E-22 see EA-9B315.80 ANNUNCIATOR PANEL (5WW-D Pin 46)
GND 6 35
TR2 25Ohm
K30 Torque 0 ws see EA-9B316.50 EIP (VV171 )
11 2
cw T-O GND bl EZ15E-22S see EA-9B316.50 EIP (VV169)
Torque "0" adjust 20
Audio out
13
Oil 0 org see EA-9B316.50 EIP (VV168 )
U31 9 1
TR30 L7815C 6 GND WH3E-22N
cw
14
3 1 4 cw Oil "0" adjust
Vout Vin
8
10k R32 Stall-Warning TR3 25Ohm PC-BORD -9B411.51A 001758_212_02
GND
220k U30
Q30 16 1 RS 162-647 U 1VN-F
8 1 bestückt -9B411.50A
2
Vcc Rt Abgleichpotis für Tourqe-und
7 C32 C33 C34 REL G6A
Q +Stall Oil Press Sensor
3 + +
C mod
R30 5 4 D30 BYW56 EA-9B316.50
BC107 C out Gnd 10n 1uF 0,1uF -Stall
+ C31 Engine Instrument Package
10uF Die Gültigkeitszuordnung Letzte Bearbeitung: 17.02.11 HW Datum Name Maßstab auf Projektion
330 R31 R33
C30ZSD 100 SOUND
20n von Version zu Bearb.: 06.06.05 HW SI.-Klasse Freimaßtoleranz
330 100k Flugzeugbaureihe Oberflächenschutz Oberfläche
D GND Gepr.: D
zu entnehmen.
Maintenance Manual EXTRA 500 Zuordnung links / rechts wird mit PCB-BOARD 1
04
36 AWG Tinned copper per ASTM-B-33 03
EA-9B284.13 A
1 OVERBRAID 02 Schwarze Heide 21 A3 Blatt 1 von 1
optical coverage minimal 98 - 100% 01 A
= ÄM-400-09-01 05.09.10 HW
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
D D
Fuel Trans L Fuel Trans R Standby Alt On

Annunciator Panel right
P/N 90-42192-2 Fuel Filter Pneumatic Low Voltage
geändert Fuel Low L Fuel Low R Prop Low Pitch
2WW
C C
ANNUNCIATOR BOARD STECKER AVIONIC BAY 4mm Ringösen
5WW D24
LIGHT TEST (GND)
D21
5WW-C 5WW-D ST 6
4WW1
WW33-22 EZ64E-22 EZ64F-22 EZ65E-22N
WW36-22 13 20 106 EZ66E-22 6
16 17 105 7 RS 339-730
24 + VOLT DIMM LOW FUEL RIGHT

WW20-20
25 29CG-D 6WW1 AVIONIC BAY
RS 289-7569
5WW1
EZ66F-22 EZ67E-22N
RS 339-730 20VN-B 20VN-B
B 001758 212 02 A 001758 212 02
LOW FUEL LEFT
7WW1
RS 289-7569
B B
A
A
zu entnehmen.
Zuordnung links / rechts wird mit LOW FUEL WARNING, WW
04
EA-9B284.30
01 46569 Hünxe, Germany
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
B ANNUNCIATOR PANEL B
5WW STECKER AVIONIC BAY

D29
Static Heat R Fuel Trans L Fuel Trans R L129 L229 D130 L230 LIGHT TEST (GND)
D30 1EZ
Windshield On Fuel Low L Fuel Low R 5WW-D ST 6 1EZ-A
LOW FUEL RIGHT
Fuel Filter EZ64E-22 EZ64F-22 EZ64F-22
20 106 6 1
EZ66E-22 EZ66F-22 EZ65E-22N
Annunciator Panel 17 105 7 2
RS 339-730
+ VOLT DIMM AMP
29CG-D AVIONIC BAY
ANNUNCIATOR BOARD EA-9B411.70 2EZ
see EA-9B315.80 ANNUNCIATOR PANEL 2EZ-A
LOW FUEL LEFT
EZ66F-22
1
EZ67E-22N
2
RS 339-730
AMP
EZ65E-22N
EZ67E-22N
20VN-A
LM
C 001758 212 02 C

zu entnehmen.
Zuordnung links / rechts wird mit LOW FUEL WARNING, EZ
03
EA-9B284.30 A
01 A ÄM-400-10-04 12.09.11 HW
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
CURRENT SENSOR 19VN-A ANNUNCIATOR BOARD

001758_212_02
LeeAir D5 5WW
76390-401C101 ST15
400mA pull in curent LIGHT TEST (GND)
KFG
100mA drop out D3 D10 1WW
HS9G-22N HS9H-22N
7
STATIC-SENSOR L 5WW-D D6 D2 5WW-B
DRUCKSCHOTT HINTEN
A3 HS8J-22 HS8H-22
2 HS25F-22 5
WW6-22
A2 STATIC HEAT LEFT 53 HS23F-22 37
WW11-22
HS9E-22N A1 4HS ST14-B 54 42 10
6HS HG24F-22 WW3-22
52 34 2
5HS HS5E-22 HS5F-22 HS6E-22N
HS8G-22 HS8G-22 HS8F-22 HS8F-22 6
WW7-22
D BUS LOAD 13 50 38 D
6 HS7G-22 HS7G-22 HS7F-22 HS7F22 WW4-22
HS4E-22 6,8 Ohm 15 Watt 11 51 35 3
STATIC-SENSOR R + VOLT DIMM 24
WW1-20
A3 HS7J-22 HS7H-22 SIM AVIONIC BAY 25
A2 1 VV303103
STATIC HEAT RIGHT 29CG-C
HS7E-22
HS8E-22
HS9F-22N A1 ANNUNCIATOR BOARD EA-9B315.81 Annunciator Panel left
1HS 3HS A F HG23H-22 HG23H-22
2HS HG23F-22 HG23G-22 HG23E-22 see Annunciator-Panel EA-9B315.80
BUS LOAD HS2E-22 HS2F-22 HS3E-22N B G 1 Stall-Heat Oil-Press Chip Hydraulic
4 ST13-C
HG25F-22 C H HG24H-22 HG24H-22 HG24E-22
HS1E-22 6,8 Ohm / 15 Watt
HG24G-22 2 HG25E-22
D J 3 Windsh-Heat Fuel-Press Pitot Heat L Pitot Heat R
HG11G-16 HG11F-16 E K HG24F-22
3 5
HG28G-18 HG28F-18
5 4 Bleed Overt Static Heat L Static Heat R
SIM_M_2022_SN(PN)
D-SUB 9 STROMSENSOR
HG25H-22
001115-211-02 P/N 90-4219X-1
HG25G-22
HG25H-22
SIM 3HG
see EA-7B233.00 & EA-7B233.10
CIRCUIT BREAKER/SWITCH PANEL VV303101 WH2E-22
HG28E-18
HG11E-16
PITOT-R see EA-9B273.30 STALL WARNING
Stall Heat
PITOT-R 2HG HG11E-16 A E
LOAD BUS BUS PP3 1 TEST HG2E-16 2 HG2F-16 HG2F-16 30CG-D
1HG HG1E-16 2 B:2 B F 20A 1A C A GND
HG9F-16 C G 2WH-A
2WH-a
15A 07.1.1.16 3 OFF HG3E-16 2 HG3F-16 HG13E-16 D H HG12E-16 HG12E-16 HG12F-16 LIFT TRANSDUSER
ON
B:3 4 03-06-2122
EMERGENCY BUS PP4 PITOT-L HG23E-22 Pin 02-06-2103 org
1 TEST HG5E-18 1
9HG HG4E-18 2 5 grün
OFF HG16G-16
HS7E-22
3 HG6E-18 001115-302-02 14HG 3 SIM_M_0816_SN(PN) 10 lila
10A 07.1.1.16
HG20E-16N
10HG ON 2 12 weiß/rot
C C 1 blau C
HG16E-16
PITOT-L 001758_212_02 6
3 N 2 gelb
HG23G-22 20VN-A 2WH
see EA-9B246.10 DC-DISTRIBUTION 2 3 2
B:5 C:7 B 1
HG24G-22
3
HG10E-22
35GA 2
WH3E-22N
HG17E-16N
1VN-G K A1 see EA-9B273.30 STALL WARNING

STROMSENSOR
X2 X1 5HG
001758 212 02 13VN
HG6F-18
HG5F-18
HG3F-16
VV141
12HG 3 Pitot Heat R HG19E-18
HG9F-16
2 M220-B4N
A 1 HG9E-16 HG9G-20 HG9G-20
Mit M4 am Seilrollenbeschlag
3 HG8E-20 X2 X1 20A 1A C A GND AVIONIC BAY
5 Relais auf Relayhalter
2 7B251.60
A 30CG-D ST5
1 30CG-D HG24E-22
HG16G-16
M320-B4N Instrument Shelf

HG16E-16
6HG-A PITOT HEAT R

Brücke AWG18
HG13E-16 5 HG13F-16 HG16F-16
1 m
HG21E-16N
13HG HG14E-16 HG14F-16 HG14G-16

2 15HG 2 HG18F-18 k 1
M220-B4N A 3 3 n 2
1 HG27E-18 HG27G-20 X1 X2
SIM_M_0816_SN(PN) 001758_212_02 P
34GA 3 HG7E-20 X2 X1 VV142 1 20VN-A SIM M 0816 AN3115-1 6HG
2 6 2
A Trennstecker
HS8E-22
HG18G-18
1 A 3
HG18E-18
Tragfläche overhead
HG27F-18
HG15E-16N
M320-B4N 1 STROMSENSOR
B Brücke AWG18
VV146 2 7HG B
B 3 HG25G-22
HG6F-18
M210-B4N 12VN
Pitot Heat L Mit M4 am Seilrollenbeschlag
HG26E-20N
001758 212 02 20A 1A C A GND
J 1VN-G
GA32-22N
GA31-22N
1VN-E
VV303102 8HG-A PITOT HEAT L
KL M220-B4N HG25E-22
HG22E-18N
30CG-D HG18E-18 HG18G-18

1
HG27F-18
see EA-9B323.10 GEAR CONTROL A E HG19E-18
HG5F-18
B F 2
HG28E-18 C G HG17E-18 HG17E-18 HG17F-18
6 R 001758_212_02
D H AN3115-1 8HG
20VN-A
SIM_M_0816_SN(PN)
001115-302-02
D
C
B
A
13VN-A
5
1
1
4
1
001115-302-02 VV303101
1
2
20VN-A Letzte Bearbeitung:

12VN-A Die Gültigkeitszuordnung Datum Name Maßstab auf Projektion
5
4
5
C
F
J
M
R
U
14.09.04 PB
30CG
9
A E A F
12

4
3
6
7
8
16 11 6
20
A B F B G ist der Bauakte bzw. Gepr.: A
T
B
E
H
L
P
C G C H Gepr.: EA 400-500
5
5
5
1
5
1
1
D H D J zu entnehmen.
Einpinseite
E K Zuordnung links / rechts wird mit PITOT-STATIC-STALL-HEAT, HG
A
D
G
K
N
S
29CG */* in allen Feldern angegeben.
04
Chapter 91
001115-302-02
30. March 2012 16 11 6
20
16 11 6
20
16 11 6
20
16 11 6
20
001758-212-02 SIM_M_XXXX_SN(PN) 03 EA-9B303.10 A

001115-201-02
02 Schwarze Heide 21 von
A3 Blatt 1 1
D
C
B
A
01 A ÄM-400-09-01 04.10.10 HW
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
CURRENT SENSOR ANNUNCIATOR PANEL

19VN-A
LeeAir D15 L115 L215 L116 L216 5WW
76390-401C101 ST15
400mA pull in curent LIGHT TEST (GND)
KF G 001758 212 02 L109 L209
100mA drop out D22 D09
HS9G-22N HS9H-22N L121 L221 L122 L222
7
STATIC-SENSOR L 5WW-D D21 D16
DRUCKSCHOTT
A3 HS8J-22 HS8H-22
2 HS25F-22
A2 53 37
STATIC HEAT LEFT ST14-B HS23F-22
HS9E-22N A1 4HS 54 42
6HS HG24F-22
52 34
A 5HS HS8G-22 HS8G-22 HS8F-22 HS8F-22 A
BUS LOAD HS5E-22 HS5F-22 HS6E-22N 13 50 38
6 HS7G-22 HS7G-22 HS7F-22 HS7F22
HS4E-22 6,8 Ohm 15 Watt 11 51 35
STATIC-SENSOR R + VOLT DIMM
A3 HS7J-22 HS7H-22 SIM_M_2022_PN AVIONIC BAY
1 Modul 12
A2 ST6
STATIC HEAT RIGHT
HS7E-22
HS8E-22
HS9F-22N A1 ANNUNCIATOR BOARD EA-9B411.70
1HS 3HS HG23H-22 HG23H-22 29CG-C
A F see Annunciator-Panel EA-9B315.80
2HS HG23F-22 HG23G-22 HG23E-22
BUS LOAD HS2E-22 HS2F-22 HS3E-22N B G 1
4 HG25F-22 HG24H-22 HG24H-22 HG24E-22 Annunciator Panel
HS1E-22 6,8 Ohm / 15 Watt ST13-C C H 2
HG24G-22 HG25E-22
D J 3 Oil-Press Bleed Overt Stall-Warn Flaps
HG11G-16 HG11F-16 HG24F-22
3 5 E K
HG28G-18 HG28F-18
5 4 SIM_M_2022_PN Fuel-Press Stall-Heat Windsh-Heat Gear Warn
SUB-D 9S STROMSENSOR Prop Low Pitch Pitot Heat L Pitot Heat R Hydraulic
HG25H-22
SIM_M_0816_PN 001115-211-02
HG25G-22
HG25H-22
3HG
see EA-7B233.00 & EA-7B233.10 Chip Static Heat L Static Heat R Fuel Trans L
Stall Heat
HG28E-18
HG11E-16
Modul 13
PITOT-R
2HG HG11E-16
PITOT-R A E ST7
LOAD BUS BUS PP3 1 TEST HG2E-16 2 HG2F-16 HG2F-16
1HG HG1E-16 2 B:2 B F 30CG-D 20A 1A C A GND
HG9F-16
C G
03-06-2122 2WH-a
15A 07.1.1.16 3 OFF HG3E-16 2 HG3F-16 HG13E-16 HG12E-16 HG12E-16 HG12F-16 2WH-A LIFT TRANSDUSER
B:3 D H 4 Pin 02-06-2103
ON
EMERGENCY BUS PP4 PITOT-L HG23E-22 WH2E-22 org
1 TEST HG5E-18 1
9HG HG4E-18 2 grün
5
OFF HG16G-16 lila
HS7E-22
10A 07.1.1.16 3 HG6E-18 001115-302-0214HG 3 10
HG20E-22N
2 weiß/rot
10HG ON 12
B C 1 blau B
HG16E-16
PITOT-L 20VN-A 6
3 N gelb
HG23G-22 001758 212 02 2 2WH
see EA-9B246.10 DC-DISTRIBUTION 2 3 2
B:5 C:7 B 1
HG24G-22
3
HG10E-22
35GA 2
HG17E-16N
WH3E-22N
1VN-1 N
A1 see EA-9B273.30 STALL WARNING
STROMSENSOR
X2 X1 5HG
001758 212 02 13VN
HG6F-18
HG5F-18
HG3F-16
VV141
Pitot Heat R
see EA-9B273.30 STALL WARNING
12HG 3 HG19E-18N
HG9F-16
3 2 M220-B4N
2 A 1 HG9E-16 HG9G-20 HG9G-20
B Mit M4 am Seilrollenbeschlag
1 AVIONIC BAY OVERHEAD
3 AIR HG8E-20 X2 X1 20A 1A C A GND
5 Relais auf Relayhalter
2 ST5
A 7B251.60 ST7
WH2E-22
HG16G-16
1
M320-B4N Instrument Shelf HG24E-22
WOW B
HG16E-16
6HG-A PITOT HEAT R

GND=WOW Brücke AWG18
HG13E-16 HG13F-16 HG16F-16
5 1 m
HG21E-22N
13HG 3 HG14E-16 HG14F-16 HG14G-16

2 15HG 2 HG18F-18 k 1
M220-B4N 2
A HG27E-18 HG27G-20 X1 X2 3 n
1 20VN-A
34GA P
3 AIR HG7E-20 X2 X1 VV142 1 001758 212 02 30CG-D AN3115-1 6HG
6 2
2
HS8E-22
A A 3
1
HG18E-18
HG18G-18
HG15E-16N
M320-B4N 1 STROMSENSOR
HG27F-18
3 WOW
C 2 Brücke AWG18
VV146 2 7HG C
B
HG6F-18
1 B 3 HG25G-22 12VN
Pitot Heat L
M210-B4N
HG26E-20N
Mit M4 am Seilrollenbeschlag
1VN-4 20A 1A C A GND
N 001758 212 02
GA32-22N
GA31-22N
GND=WOW Modul 14
R S 1VN-4 8HG-A PITOT HEAT L
HG25E-22
M220-B4N HG27F-18
A E
HG22E-22N
HG5F-18 HG18E-18 HG18G-18

B F 1
001758 212 02 HG28E-18 HG17E-18 HG17E-18 HG17F-18 HG19E-18N
C G 6 2
see EA-9B323.10 GEAR CONTROL D H
20VN-A R
SIM_M_0816_SN SIM_M_0816_PN 001758 212 02 AN3115-1 8HG
001115-302-02
AVIONIC BAY DRUCKSCHOTT
D
C
B
A
Letzte Bearbeitung: Datum Name Maßstab auf Projektion
D
C
B
A
5
5
5
5
5
5
14.09.04 PB
1
1
1
4
1
1
1
1
1
1
2
D Gepr.: D
5
C
F
J
M
R
U
4
5
ST7 ST14 dem jeweiligen Fertigungsauftrag Gepr.: EA 400-500
30CG
9
1VN-E zu entnehmen.
4
3
6
7
8
16 11 6
2012
16 11 6
20
16 11 6
20
16 11 6
20
16 11 6
20
16 11 6
20
T
B
E
H
L
P
Zuordnung links / rechts wird mit PITOT-STATIC-STALL-HEAT, HG

1VN-G */* in allen Feldern angegeben.
5
5
5
5
5
5
1
5
1
1
1
1
1
1
1
A
D
G
K
N
S
Einpinseite
20VN-A
ST6 03 EA-9B303.10 B
4
ST13 5
29CG
02 B ÄM-400-10-04 12.09.11 HW Schwarze Heide 21 von
001758-212-02 A3 Blatt 1 1
6
7
8
01
16 11 6
20
16 11 6
20
16 11 6
20
16 11 6
20
16 11 6
20
16 11 6
20
A ÄM-400-09-01 04.10.10 HW
16 11 6
20
B
A
D
C
EDV-Kennung:
D
C
B
A
9B30310T
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
D D
Brandspant Trennstecker
ST4 INTAKE-A/I Intake Heat Reco Light

1HM EMERGENCY BUS PP4 Annunciator Panel right
Deice Boots Landing Light P/N 90-42192-2
HM1G-22 HM1F-22 1 HM1E-22
23 D:18
2A geändert
Windshield On
CB-Trennstaecker
see EA-9B246.10 DC-DISTRIBUTION 2WW

ANNUNCIATOR BOARD
5WW D14
5WW-D 5WW-C
LIGHT TEST (GND)
WW26-22
27 6
+ VOLT DIMM 24
K5 WW20-20
25
C 11 C
ST4 291-9726 5WW-A
D41
HM2E-22 HM2F-22 5 INV WW39-20N
24 44 5 9
BYW56

(FE4107)
RS334-870
Microswitch Diode direkt hinter dem Stecker 3HM-A installieren!
2HM Jiffi Diode
4HM Anti Icing
no ON VV150
HM1G-22
VV149 Solenoid Valve
c 3HM-A
HM3E-22 2300 7828
Splice nc 1
HM4E-22N
OFF VV151 2
VV152 VV153 3
K 001758 212 02 3HM
2VN-C (Stecker M83723/75R-08-03-6)
Am Triebwerk installiert
B B

Zuordnung links / rechts wird mit ANTI ICE INTAKE, HM
04
03
EA-9B304.10 A
A3 Blatt 1 von 1
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
FIREWALL
INTAKE-A/I
ST4
1HM EMERGENCY BUS PP4
HM1G-22 HM1F-22 1 HM1E-22
23 D:18
2A
CB-Trennstecker
Chip Static Heat L Static Heat R

ANNUNCIATOR PANEL
5WW L133 L233 Ignition Deice Boots Windshield On
D33
5WW-D
LIGHT TEST (GND) Landing Light Intake Heat
27 Annunciator Panel
K5 + VOLT DIMM
B 11 B
291-9726 5WW-A
HM2E-22 HM2F-22 5 INV WW39-20N

24 44 5 9
D5 BYW56

Microswitch Diode direkt hinter dem Stecker 3HM-A installieren!

2HM Jiffi Diode
4HM ANTI ICE
NO ON VV150 SOLENOID VALVE
HM1G-22 C 3HM-A
NC HM3E-22 2300 7828
VV149 1
HM4E-22N
OFF VV151 2
VV152 VV153 3
D 3HM
(Stecker M83723/75R-08-03-6)
2HM Am Triebwerk installiert
2VN-A
C 001758 212 02 C
C
NO
NC
(FE4107)

zu entnehmen.
Zuordnung links / rechts wird mit ANTI ICE INTAKE, HM
EA-9B304.10
03 B
A3 Blatt 1 von 1
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8

Aft Door Stall-Heat Oil-Press
CIRCUIT BREAKER/SWITCH PANEL P/N 90-42192-1
Stall-Warn Windsh-Heat Fuel-Press
WINDSH Cab-Press Bleed Overt

3HF:1 WSH-HT
D D
1HF BATTERY BUS PP2
OFF 1
2 HF2E-12
HF4F-12 2 HF4E-12 3 20A WSH-CTRL
C:1
ON 2HF
4 :2 1WW
5 HF1E-22
HF3G-22 HF3F-22 6 2A
D:12 1 07.2.1.13
HF3H-22 1 HF3E-22
D:6

PC-BOARD 1
Intake Heat Reco Light
ST-A ANNUNCIATOR BOARD P/N 90-42192-2
geändert Deice Boots Landing Light
5WW D15
HF17E-22N 5WW-D
18 LIGHT TEST (GND) 5WW-B Windshield On
K2 HF16E-22 HF16E-22 WW16-22
37 43 15
24
WW1-20
291-9726 25
C D39 2WW C
HF7E-22
36
BYW56 D33
5WW-C
19
HF12E-22 WW26-22
29 4
EA-9B284.13b + VOLT DIMM 24
WW20-20
25
see EA-9B284.13B PC-BOARD 1
HF3J-22
5HF 3
HF4F-12 2
1 HF6E-12 HF6E-12
HF3J-22
HF11E-12 20A
TEMP CONTROLER Stromsensor
4HF-A X2 X1 C Kissling
HF5E-22 HF3H-22
05856.12 VV239 A 7HF
HF3G-22 1A
Kissling 28VDC A514.2076
AT15.2121 1
HF5E-22 GND
Fail 2 M320-B4N
HF7E-22
3 TEMP
B 4 Sensor Anschlüsse mit Kabelschuh B
5 2
HF8E-22 HF8E-22
6
HF9E-22 HF9E-22
HF13E-22N
7
4 T
HF10E-22N
GND 8 3
4HF HF15E-22N 6HF
3VN-A D
15polDSub 5 1
HF14E-12N
AB 001758_212_02
3VN-A
001758_212_02
Windshield Heater
Befestigen mit Mutter und Schraube

1VN
an 1VN
Massebolzen
5
1 2 3 4
Anschlußschema
HF14E-12N

HF11E-12
HF8E-22
HF15E-22N
HF9E-22
A
A
zu entnehmen.
Zuordnung links / rechts wird mit WINDSHIELD HEAT, HF
04
Chapter 91 30. March 2012 03 EA-9B304.20 A
A3 Blatt 1 von 1
01 A ÄM-400-09-01 04.10.10 HW
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
WINDSH
A 3HF:1 WSH-HT A
1HF BATTERY BUS PP2
OFF 1
2 HF2E-12
HF4F-12 2 HF4E-12 3 20A WSH-CTRL
C:1
ON 2HF
4 :2
5 HF1E-22
HF3G-22 HF3F-22 6 2A
D:12 1 07.2.1.13
HF3H-22 1 HF3E-22
D:6
1VN-1
001758 212 02 B
PC-BOARD 1
ANNUNCIATOR PANEL Annunciator Panel
ST-A
L110 L210 Bleed Overt Stall-Warn Flaps
5WW-D 5WW D10
HF17E-22N
18 LIGHT TEST (GND) Stall-Heat Windsh-Heat Gear Warn
K2 HF16E-22 HF16E-22
37 43 Pitot Heat L Pitot Heat R Hydraulic
291-9726 L128 L228 Static Heat L Static Heat R Fuel Trans L

D28
B D39 Deice Boots Windshield On Fuel Low L B
HF7E-22
36
HF12E-22
BYW56 29 Intake Heat Fuel Filter
19
+ VOLT DIMM
EA-9B411.50
see EA-9B284.13 PC-BOARD 1
HF3J-22
5HF 3
HF4F-12 2
1 HF6E-12 HF6E-12
HF3J-22
20A
TEMP CONTROLER HF11E-12 Stromsensor
4HF-A X2 X1 C Kissling
HF5E-22 HF3H-22 HF12E-22
05856.12 VV239 A 7HF
1A
Kissling 28VDC
HF3G-22 A514.2076
1 M320-B4N GND
AT15.2121 Fail
HF5E-22
2
HF7E-22
3 TEMP
C 4 Sensor Anschlüsse mit Kabelschuh C
5
HF8E-22 HF8E-22 2
6
HF9E-22 HF9E-22
HF13E-22N
7 4 T
HF10E-22N
GND 8
4HF HF15E-22N 3 6HF
HF11E-12
A
15polDSub
U N HF14E-12N 5 1 1VN-2
001758 212 02
1VN-2 1VN-3
001758 212 02 001758 212 02 Windshield Heater
Befestigen mit Mutter und Schraube

1VN
an 1VN
Massebolzen
5
1 2 3 4
Anschlußschema
HF14E-12N

HF11E-12
HF8E-22
HF15E-22N
HF9E-22

25.08.04 PB
zu entnehmen.
Zuordnung links / rechts wird mit WINDSHIELD HEAT, HF
03 EA-9B304.20 B
A3 Blatt 1 von 1
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8

D D
Stecker CB-Panel BOOTS
1HH BATTERY BUS PP2
HH1F-22 1 HH1E-22
C:14
2A
BOOTS
2HH
1
2 HH1G-22
HH2F-22 1 HH2E-22 3
D:7
07.1.1.13
Stecker Avionikbay see EA-9B246.10 DC-DISTRIBUTION

3HH-A EJECTOR VALVE 1
TIMER FIREWALL 4HH-A
INBOARD WING DE-ICER
H 30CG-C
J4 ST 4 HH3E-22 VV154
D A
HH1G-22 HH1F-22 HH6E-22
28 VDC POWER B 8 F
HH2G-22 HH2F-22 3D3556-03
TIMER 1Min C 9 E
HH3G-22 HH3F-22 HH3F-22 51
HH3E-22 HH7E-22N
FLOW CONTROL E 10 C
HH4G-22 HH4F-22 HH4F-22 HH4E-22
FLOW CONTROL F 11 52 VV155
HH5E-22N 4HH
GND A
C
Annunciator Panel right C
P/N 90-42192-2 3HH MS3470L10-6S
geändert ? EJECTOR VALVE 2
Avionikbay 5HH-A
OUTBOARD WING DE-ICER
?VN-A
Fuel Trans L Fuel Trans R Standby Alt On Ignition Intake Heat Reco Light 001758 212 02 HH4E-22
A
F 3D3556-03
Fuel Filter Pneumatic Low Voltage Deice Boots Landing Light
E
HH8E-22N
C
Fuel Low L Fuel Low R Prop Low Pitch External Power Windshield On
2VN-D VV156
G H
001758 212 02
5HH
MS 38999 III 20K G 35 PN (79 X #22D)

2WW
ANNUNCIATOR BOARD
5WW D23
LIGHT TEST (GND) PNEUMATIC LOW
D32
5WW-C 5WW-D
6HH-A
Firewall Engine Compartement leftside
WW28-22 HH6F-22 HH6E-22

P
5 28 38 30
WW34-22 HH10F-22 29
HH10E-22 HH10E-22 NC
B 14 19 43 A NC B
HH9E-22N
B
24 + VOLT DIMM NO C NO
C
WW20-20
25 J
ANNUNCIATOR BOARD EA-9B315.81 001758 212 02 MS27467T9B98S 6HH
2VN-D

31.10.02 PB
Zuordnung links / rechts wird mit BOOTS, HH
04
03 EA-9B310.10 A
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8

A A
Stecker CB-Panel BOOTS

1HH BATTERY BUS PP2
HH1F-22 1 HH1E-22
C:14
2A
BOOTS
2HH
1
2 HH1G-22
HH2F-22 1 HH2E-22 3
D:7
07.1.1.13
AVIONIKBAY see EA-9B246.10 DC-DISTRIBUTION
3HH-A FIREWALL EJECTOR VALVE 1

TIMER 4HH-A
INBOARD WING DE-ICER
P7-A J7-a
H J4 ST 4
30CG-C HH3E-22 VV154
D A
HH1G-22 HH1F-22 HH6E-22
28 VDC POWER B 8 F
HH2G-22 HH2F-22 3D3556-03
TIMER 1Min C 9 E
HH3G-22 HH3F-22 HH3F-22 51
HH3E-22 HH7E-22N
FLOW CONTROL E 10 C
HH4G-22 HH4F-22 HH4F-22 HH4E-22
FLOW CONTROL F 11 52 VV155
HH5E-22N 4HH
GND A
B B
3HH MS3470L10-6S
C EJECTOR VALVE 2
Avionikbay 5HH-A
OUTBOARD WING DE-ICER
20VN-A
HH4E-22
001758 212 02 A
F 3D3556-03
E
Stall-Heat Windsh-Heat Gear Warn Aft Door HH8E-22N
C
Prop Low Pitch Pitot Heat L Pitot Heat R Hydraulic Pneumatic 2VN-A VV156
GH 001758 212 02
5HH
Chip Static Heat L Static Heat R Fuel Trans L Fuel Trans R
Ignition Deice Boots Windshield On Fuel Low L Fuel Low R MS 38999 III 20K G 35 PN (79 X #22D)
Landing Light Intake Heat Fuel Filter

Annunciator Panel
ANNUNCIATOR PANEL
5WW D27
L118 L218 L127 L227 LIGHT TEST (GND)
D18 PNEUMATIC LOW
5WW-D
6HH-A
Firewall Engine Compartement leftside
P
HH6F-22 HH6F-22 30
HH6E-22
28 38
HH10F-22 HH10F-22 29
HH10E-22 HH10E-22 NC
C 19 43 A NC C
HH9E-22N
B
C NO
C NO
+ VOLT DIMM
J
ANNUNCIATOR BOARD EA-9B411.70 6HH
2VN-A MS27467T9B98S
see EA-9B315.80 ANNUNCIATOR PANEL 001758 212 02

31.10.02 PB
zu entnehmen.
Zuordnung links / rechts wird mit BOOTS, HH
03 EA-9B310.10 B
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
D EMERGENCY BUS PP4 BATTERY BUS PP2 D

1WH NIGHT 1WV
3LJ:1 :2 VNE-WARN
2
5
STALL-WARN
5A 1A
1
3
4
6
07.2.1.16
DAY
NIGHT
AUDIO & MARKER
(TONE) TEST
PM8000B
1RM-A
WH12E-22S
WV8E-22
WV9E-22N
WH1E-22
WH1G-22
LH3E-20N
LT1E-20
LT2E-20
ALT WRN IN 31
WV1E-22
2 2 2 3 3 3 2 1 see EA-9B246.10 DC-DISTRIBUTION
1RM D:19 D:20 A:4 A:8 A:9 A:10 A:5 C:13
see EA-9B235.17 MKR-Audio
U 1VN-C
WH1F-22
WV8F-22
WV9F-22N
WV1F-22
C C
PC-BOARD 1
Audio out WH12E-22S

8 4
K10 11
13 R41
D31 D21
9
100 16
6
Audio 4 R40
8 5WH Horn
100
16 1 D11
REL G6A D12
+Vmo WV1F-22
13
D10
BYW56 BYW56
K1:3 9
8
7
REL TN2 K1:1
B 113-8875 10 1 B
D1
IFD LEFT
BYW56 -Vmo test WV8F-22
IFD-5000i
35 X P1122
700-00083-()
Overspeed
D13 -Vmo WV3E-22 WV3E-22 Contact closed at 207 Knots +6/-0 Knots
31 31 16 Vmo ALERT
Vmo TEST BYW56
GND WH3E-22N 1
14 3FG
EA-9B284.13a 1 see EA-9B342.65 IFD-LEFT

001758_212_02
see EA-9B284.13b PC-Board 1 U 1VN-F
36 AWG Tinned copper per ASTM-B-33

1 OVERBRAID
optical coverage minimal 98 - 100%

Zuordnung links / rechts wird mit AIRSPEED WARNING, WV
04
03
EA-9B314.30 B
Chapter 91 30. March 2012 01 A ÄM-400-04-02 09.09.04 PB
A3 Blatt 1 von 1
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
Gen-Fail Aft Door Stall-Heat Oil-Press Chip Hydraulic
Gear Warn Stall-Warn Windsh-Heat Fuel-Press Pitot Heat L Pitot Heat R

Flaps Cab-Press Bleed Overt Static Heat L Static Heat R
P/N 90-42192-1
geändert
1WW
5WW-B 5WW
A DB25RA/F 36x BYW56 A
WW2-22 B1 D1
1
WW3-22 B2 D2
2 5WW-A
WW4-22 B3 D3
3
WW5-22 B4 D4 DB9RA/M
4 D44 BYW56
WW6-22 B5 D5
5
WW7-22 B6 D6 K8
6 VV160
WW8-22 B7 D7 LH4E-20
7 1 40 Über 5LH-A Pin 20/1 K1 EA-9B334.90 - Light-Test
WW9-22 B8 D8 GND Test
8 6
WW10-22 B9 D9 LH3G-20
9 3 41 Über 5LH-A Pin 7/8 F2 EA-9B334.90 + Light-Test
WW11-22 B 10 D10 +28V Test
10 4 VV161
WW12-22 B 11 D11 +28V WW41E-20
11 G2RL - 8A 5 Über 5LH-A Pin 9 an F1 EA-9B334.90 + 28V Power
WW13-22 B 12 D12
12 365-0591 2
WW14-22 B 13 D13 DIM LG109E-20
13 7 16 Über 5LH-A Pin 13/14 F6 EA-9B334.90 DIM Voltage
WW15-22 B 14 D14 VV162
14 8
WW16-22 B 15 D15 WW39-20N
15 D45 9
WW17-22 B 16 D16 G2RL-24
16
WW18-22 B 17 D17
17
WW19-22 B 18 D18
18
19 001758 212 02
20 GND J
K1 1VN-E
21
22 291-9726
23
F1
24 5A +VDC I
WW1-20 +VDC I S D37
25 BYW56
6
6
4
4
K2 G6A-234P
16 1 SIG IN
16 1
F2
5A D38
WW20-20 +VDC II S +VDC II
25 BYW56
24
WW40-22
23
22
B 21 K3 B
20
19 291-9726
WW38-22 C 18 D19 D46
18
WW37-22 C 17 D20
17
WW36-22 C 16 D21 D39
16 BYW56
WW35-22 C 15 D22
15
WW34-22 C 14 D23
14 K4
WW33-22 C 13 D24
13
WW32-22 C 12 D25 291-9726
12
WW31-22 C 11 D26
11
WW30-22 C 10 D27
10
WW29-22 C9 D28 D40
9 BYW56
WW28-22 C8 D29
8
WW27-22 C7 D30
7 K5
WW26-22 C6 D31
6
WW25-22 C5 D32 291-9726
5
WW24-22 C4 D33
4
WW23-22 C3 D34
3
WW22-22 C2 D35 D41
2 BYW56
WW21-22 C1 D36
1
K6
5WW-C 3 INV 291-9726
2WW 4 INV
DB25RA/M 5 INV
6 INV D42
BYW56
1 INV
3 PLUS
7 INV K7
4 PLUS 291-9726
5 PLUS
6 PLUS
Fuel Trans L Fuel Trans R Standby Alt On Ignition Intake Heat Reco Light 7 PLUS D43
BYW56
1 PLUS
Annunciator Panel right Fuel Filter Pneumatic Low Voltage Deice Boots Landing Light
P/N 90-42192-2
Fuel Low L Fuel Low R Prop Low Pitch External Power Windshield On
geändert Steuer-Platine EA-9B411.70
C C
50
49
48
47
46
45
44
43
42
41
40
39
38
37
36
35
34
33
32
31
30
29
28
27
26
25
24
23
22
21
20
19
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
DB50SLE
5WW-B
GND CONTROLED
CG47F-22 Spare 5WW7-22
Flap System EA-9B275.20 42 00 Spare
EZ65E-22 Spare 5WW13-22
Gear Warning EA-9B323.20 40 00 Spare
EZ63E-22
DC Generation I EA-9B243.10 41
HP11G-22
Cabin-Press EA-9B213.30 108
WH11E-22
Stall Warning EA-9B273.30 35 +28VDC CONTROLED INPUT
MC1E-22
Door Warning EA-9B527.10 107
HA33E-22 PD4J-22
Bleed Air System EA-9B215.20 39 49 External Power EA-9B244.10
HF16E-22 LA7F-22
Windshield Heat EA-9B304.20 21 45 Landing Light EA-9B334.35
HG23F-22 LF2K-22
P/S/Stall Heat EA-9B303.10 54 50 Reco Light EA-9B334.60
HM2F-22
44 Anti Ice Intake EA-9B304.10
WL5E-22
24 Ignition System EA-9B743.10
LW1E-22
E-W Low Fuel Press EA-9B317.10 101
LW3E-22 WEATHER DETECTION
E-W Oil Press EA-9B317.10 102
HS-8F-22 P1
P/Static/S Heat left EA-9B303.10 50 TWX-670
HG25F-22
Pitot/S/S Heat left EA-9B303.10 53
LW5E-22 SS7E-24
E-W Chip Detect EA-9B317.10 103 54 MIC INHIBIT INPUT
51
HS-7F-22 2SS
P/Static/S Heat rightEA-9B303.10 HG24F-22
Pitot/S/S Heat right EA-9B303.10 52 see EA-9B344.14 WEATHER DEDECTION
GA53E-22
Gear Control System EA-9B323.10 46 PC-BOARD 1
Spare 5WW32-22
Spare 00 P1 EA-9B411.50A
RZ2E-24S SS7E-24
see EA-9B235.16 MKR-AUDIO 7
SS8E-24 D1 BYW-56
HF12E-22 see EA-9B344.14 WEATHER DEDECTION 10
Windshield Heat ON EA-9B304.20 4
HH6F-22 SS9E-24 D2 BYW-56
Boots EA-9B310.10 38 see EA-9B344.14 WEATHER DEDECTION 11
RZ13E-24S
Spare 5WW25-22
Spare 00 GA53H-22 D3 BYW-56
24
LW6E-22 CG34H-22 D4 BYW-56
E-W Prop Low Pitch EA-9B317.10 104 see EA-9B275.20 FLAP SYSTEM [IN TRANSM] 29
WL1E-22
D Low Voltage Monitor EA-9B315.90 108 D
PR213E-22
DC Generation II EA-9B243.20 100
see EA-9B284.13B PCB-BOARD 1
EZ64E-22
Low Fuel Warning EA-9B284.30 106 Die Gültigkeitszuordnung Letzte Bearbeitung: Datum Name Maßstab auf Projektion
HH10F-22
Maintenance Manual EXTRA 500 Pneumatic (Boots)
Fuel Trans Right
EA-9B310.10
EA-9B731.30
43
48
QF9F-22 von Version zu
Flugzeugbaureihe
Bearb.: 05.03.04 PB SI.-Klasse
Oberflächenschutz
Freimaßtoleranz
Oberfläche
EZ66E-22 Gepr.:
Low Fuel Warning EA-9B284.30 105 ist der Bauakte bzw.
QW1F-22 dem jeweiligen Fertigungsauftrag
Fuel Pump / Filter EA-9B731.10 1 Gepr.: EA 400-500
zu entnehmen.
QF10F-22
Fuel Trans Left EA-9B731.30 47 Zuordnung links / rechts wird mit ANNUNCIATOR PANEL, WW
04
03 EA-9B315.80 B
Chapter 91 30. March 2012 02 B
A
ÄM-400-09-01
ÄM-400-09-01
17.02.11
06.10.10
HW
HW
Schwarze Heide 21 A2 Blatt 1 von 1
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
Annunciator Panel
+VDC I S
5WW
+VDC II S
D01
D07
D13
F2 F1 D8 BYW56 5WW-A
A A
D02
16 1
VV160 LH4E-20
D08 1 40 Über 5LH-A Pin 20/1 K1 EA-9B334.90 - Light-Test
GND Test
6
D14 8 LH3G-20
K8:1 3 41 Über 5LH-A Pin 7/8 F2 EA-9B334.90 + Light-Test
+VDC I +28V Test
PICO II Slo-Blo 1,5AT

PICO II Slo-Blo 1,5AT
4 VV161
4
D03 6 +28V WW41E-20
5 Über 5LH-A Pin 9 an F1 EA-9B334.90 + 28V Power
REL G6A
D09 2
9 DIM LG109E-20
7 16 Über 5LH-A Pin 13/14 F6 EA-9B334.90 DIM Voltage
D15 +VDC II 13 VV162
8
11 GND WW39-20N
9
D04
D10
D50 DB9RA/M
D16 K 1VN-5
BYW56 K1 001758 212 02
D05
D11 291-9726
D17
EXT
D06 D1 BYW56
D12
6
D18 4
8
K2:1 REL G6A
D24
1 16 BLEED IN
D30
Gen-Fail Oil-Press Bleed Overt Stall-Warn Flaps Cab-Press D36
36x BYW56
D2 BYW56
Fuel-Press Stall-Heat Windsh-Heat Gear Warn Aft Door D23
D37
D29
Standby Alt On Prop Low Pitch Pitot Heat L Pitot Heat R Hydraulic Pneumatic
BYW56
D35
K3
Low Voltage Chip Static Heat L Static Heat R Fuel Trans L Fuel Trans R
D22 291-9726
External Power Ignition Deice Boots Windshield On Fuel Low L Fuel Low R
D28 D51
B Reco Light Landing Light Intake Heat Fuel Filter D34 B
BYW56 D3 BYW56
D21
D27
291-9726
D33 K4
D20
D4 BYW56
D26
D32
291-9726
D19 K5
D25
D31 D5 BYW56
3 INV
4 INV
6 INV 291-9726
K6
5 INV
1 INV
3 PLUS
D6 BYW56
4 PLUS
5 PLUS
7 INV
291-9726
6 PLUS K7
EXT IN
7 PLUS
1 PLUS D7 BYW56
PC-BORD -9B411.71A
50
49
48
47
46
45
44
43
42
41
40
39
38
37
36
35
34
33
32
31
30
29
28
27
26
25
24
23
22
21
20
19
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
bestückt -9B411.70A
DB50SLE
5WW-D
GND CONTROLED
CG47F-22
C Flap System EA-9B275.20 42 C
EZ65E-22
Gear Warning EA-9B323.20 40
EZ63E-22
DC Generation I EA-9B243.10 41
HP11G-22
Cabin-Press EA-9B213.30 108
WH11E-22 +28VDC CONTROLED INPUT
Stall Warning EA-9B273.30 35
MC1E-22
FLAPS
GEAR WARN
GEN- FAIL
CAB-PRESS
STALL-WARN
AFT DOOR
BLEED OVERT
WINDSH-HEAT
STALL-HEAT
BLANK 1 (1)
FUEL PRESS
OIL-PRESS
STATIC HEAT L
PITOT HEAT L
CHIP
STATC HEAT R
PITOT HEAT R
HYDRAULIC
BLANK 3 (36)
LANDING LIGHT
RECO LIGHT
WINDSHIELD ON
DEICE BOOTS
INTAKE HEAT
BLANK 2 (34)
IGNITION
PROP LOW PITCH
LOW VOLTAGE
STANDBY ALT ON
FUEL LOW R
PNEUMATIC
FUEL TRANS R
FUEL LOW L
FUEL FILTER
FUEL TRANS L
TWX INHIBIT
3 INV SPARE
4 INV
5 INV
6 INV
7 INV
1 INV SPARE
3 PLUS SPARE
IGNITION
INTAKE HEAT
RECO LIGHT
LANDING LIGHT
EXTERNAL POWER
1 PLUS SPARE
Door Warning EA-9B527.10 107

HA33E-22 PD4J-22
Bleed Air System EA-9B215.20 39 49 External Power EA-9B244.10
HF16E-22 LA7F-22
Windshield Heat EA-9B304.20 21 45 Landing Light EA-9B334.35
HG23F-22 LF2K-22
P/S/Stall Heat EA-9B303.10 54 50 Reco Light EA-9B334.60
HM2F-22
44 Anti Ice Intake EA-9B304.10
Spare 5WW41-22 WL5E-22
Spare 00 24 Ignition System EA-9B743.10
Spare 5WW1-22
LW1E-22 00 Spare
E-W Low Fuel Press EA-9B317.10 101
LW3E-22 Spare 5WW7-22
E-W Oil Press EA-9B317.10 102 00 Spare
HS-8F-22
P/Static/S Heat left EA-9B303.10 50 Spare 5WW8-22
HG25F-22 00 Spare
Pitot/S/S Heat left EA-9B303.10 53
LW5E-22 Spare 5WW13-22
E-W Chip Detect EA-9B317.10 103 00 Spare
HS-7F-22 WEATHER DETECTION
P/Static/S Heat rightEA-9B303.10 51
HG24F-22
Pitot/S/S Heat right EA-9B303.10 52 P1 TWX-670
GA53E-22
Gear Control System EA-9B323.10 46
Spare 5WW32-22
Spare 00 SS7E-24
54 MIC INHIBIT INPUT
2SS
HF12E-22 see EA-9B344.14 WEATHER DEDECTION
Windshield Heat ON EA-9B304.20 4
HH6F-22 PC-BOARD 1
Boots EA-9B310.10 38
P1 EA-9B411.50A
RZ2E-24S SS7E-24
Spare 5WW25-22 see EA-9B235.16 MKR-AUDIO 7
Spare 00
SS8E-24 D1 BYW-56
see EA-9B344.14 WEATHER DEDECTION 10
LW6E-22
E-W Prop Low Pitch EA-9B317.10 104 SS9E-24 D2 BYW-56
WL2E-22 see EA-9B344.14 WEATHER DEDECTION 11
Low Voltage Monitor EA-9B315.90 108
PR213E-22 RZ13E-24S
DC Generation II EA-9B243.20 100 see EA-9B235.16 MKR-AUDIO
EZ64E-22 GA53H-22 D3 BYW-56
Low Fuel Warning EA-9B284.30 106 24
HH10F-22
Pneumatic (Boots) EA-9B310.10 43 CG34H-22 D4 BYW-56
QF9F-22 see EA-9B275.20 FLAP SYSTEM [IN TRANSM] 29
Fuel Trans Right EA-9B731.30 48
EZ66E-22
Low Fuel Warning EA-9B284.30 105
QW1F-22
D Fuel Pump / Filter EA-9B731.10 1 see EA-9B284.13B PCB-BOARD 1 D
QF10F-22
Fuel Trans Left EA-9B731.30 47
Zuordnung links / rechts wird mit ANNUNCIATOR PANEL, WW
04
03 C ÄM-400-10-04 13.09.11 HW EA-9B315.80 C
01 A ÄM-400-09-01 06.10.10 HW
Chapter 91 11. July 2012 EDV-Kennung: 9B31580T
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
J5WW-B 5WW
DB25RA/F 36x BYW56
B1 D1
1
B2 D2
2
D B3 D3 J5WW-A D
3
B4 D4
4 D44 BYW56 DB9RA/M
B5 D5
5
B6 D6 K8
6
B7 D7
7 1
B8 D8 GND Test
8 G2RL-8A 6
B9 D9
9 365-0591 3
B 10 D10 +28V Test
10 4
B 11 D11
11 5
B 12 D12
12 2
B 13 D13 DIM
13 7
B 14 D14
14 8
B 15 D15
15 D45 9
B 16 D16
16
B 17 D17
17
B 18 D18
18
19 BYW56
20 GND
21
22 291-9726
K1
23
CB1
24 5A
+VDC I S +VDC I D37
25 BYW56
:2 6
4
8
K2:1 G6A-234P
C +VDC II 1 16 SIG IN C
CB2
5A
+VDC II S +VDC II BYW56
25
D38
24
23
22
21
20
19 291-9726
C 18 D19 K3
18 D46
C 17 D20
17
C 16 D21 D39
16 BYW56
C 15 D22
15
C 14 D23
14
BYW56
C 13 D24
13
C 12 D25 291-9726
12 K4
C 11 D26
11
C 10 D27
10
C9 D28 D40
9 BYW56
C8 D29
8
C7 D30
7
C6 D31
6
C5 D32 291-9726
5 K5
C4 D33
4
C3 D34
3
C2 D35 D41
2 BYW56
C1 D36
1
B B
J5WW-C 3 INV 291-9726
DB25RA/M 4 INV K6
5 INV
6 INV D42
BYW56
1 INV
3 PLUS
7 INV
4 PLUS 291-9726
5 PLUS K7
6 PLUS
7 PLUS D43
BYW56
1 PLUS
J5WW-D
DB50SLE Steuer-Platine EA.9B315.81
50
49
48
47
46
45
44
43
42
41
40
39
38
37
36
35
34
33
32
31
30
29
28
27
26
25
24
23
22
21
20
19
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
A
A
zu entnehmen.
Zuordnung links / rechts wird mit WARNING BOARD 55
04
EA-9B315.81
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
D D
LOW-VOLT
CB Trennstecker
EMERGENCY BUS PP4 1LW
WL2E-22 1 WL1E-22
C:16
1A
Fuel Trans R Standby Alt On Ignition

C Pneumatic Low Voltage C
P/N 90-42192-2
geändert Fuel Low R Prop Low Pitch External Power
PC-BOARD 1
2WW ANNUNCIATOR BOARD J1

J1A
D26 5WW-D
5WW-C 5WW Lamar Low Voltage Monitor
LIGHT TEST (GND)
WL1E-22 22 red Sense U60
WW31-22 WL2F-22 green Out
11 22 108 WL3E-22N
21
black
24 + VOLT DIMM 3 L-Gnd
25 Aircraft Spruce B00378-5
D
001758 212 02 DB37S
see EA-9B315.80 ANNUNCIATOR PANEL EA-9B284.13
1VN-G
see EA-9B284.13b PC-BOARD 1
B B

Zuordnung links / rechts wird mit LOW VOLTAGE MONITOR, WL
04
03 EA-9B315.90 B
Chapter 91 30. March 2012 01 A ÄM-400-04-02 09.09.04 PB 46569 Hünxe, Germany
A3 Blatt1 von 1
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
LOW-VOLT
1LW
CB Trennstecker
EMERGENCY BUS PP4
WL1F-22 1 WL1E-22
C:16
1A
B B
PC-BOARD 1
Annunciator Panel ANNUNCIATOR PANEL
5WW
Standby Alt On Prop Low Pitch L119 L219 D19 5WW-D P1 J1
LIGHT TEST (GND)
Lamar Low Voltage Monitor
Low Voltage Chip WL1E-22 21 red Sense U60
WL2E-22 green Out
22 108 22
External Power Ignition WL3E-22N black L-Gnd
3
Aircraft Spruce B00378-5
+ VOLT DIMM
ANNUNCIATOR BOARD EA-9B411.70 L DB37S

see EA-9B315.80 ANNUNCIATOR PANEL PC-BOARD 1 EA-9B411.50
1VN-1 see EA-9B284.13 PC-BOARD 1
001758 212 02
C C

zu entnehmen.
Zuordnung links / rechts wird mit LOW VOLTAGE MONITOR, WL
03 C ÄM-400-10-04 13.09.11 HW EA-9B315.90 C
02 B ÄM-400-09-01 01.07.10 HW Schwarze Heide 21 A3 Blatt1 von 1
01 A ÄM-400-04-02 09.09.04 PB
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
D EMERGENCY BUS PP4 D
1EY DIP-1 7EY VOLT-MON

1A 1A
CB-Trennstecker
EY1F-22 1 EY1E-22
C:5
EY3E-20S 1 EY3F-20S
A:3
1
A:4
LOAD BUS PP3
2EY DIP-2
1A
EY2F-22 1 EY2E-22
C:6
VV166 EY11E-22N
EY12E-22N see EA-9B246.10 DC-DISTRIBUTION
VV167
Digital Instrument Package 3EY-A L P Pilot left side

J1 J5
ST5-A
ws 001758 212 02 MS33678
+28VDC Power Input High (Cannel A) 1 Trennstecker FLÜGELNASE IAT-Sensor
bl EY1F-22S 3VN-A 5EY-A
C Power Input Gnd Ch A & B & VDC 2 Y C
ws ws 05835.25
+28VDC Power Input High (Cannel B) 7 W A
EY2F-22S EY4F-22S bl bl EY4E-22S MS28034-3
Power GND (Ch A & B) 5 X B
EY3E-20S 102-00002
Voltmeter Signal Input High 3
ST2 5EY
Spare 4
ws
IAT Signal Input high 14 Trennstecker FIREWALL
bl EY4F-22S 4EY-A
Fuel Press Sensor
IAT Signal Input low 15 N
ws ws ws B
0B823.03
Fuel Press Signal Input High 23 L Output High Stecker MS3126F8-4S
bl EY5E-22S EY5E-22S bl bl EY5F-22S C
Fuel Press Signal Input Low 24 M Output Low
ws ws ws A
Fuel Press Sensor Exitation Output (+10VDC) 21 P Exitation +10VDC
bl EY6E-22S EY6E-22S bl bl EY6F-22S D
Fuel Press Sensor Exitation Return 22 R Exitation Return 4EY
Spare 10 S
ws MS33678
+28VDC Lighting Power Input High 13 33 Fuel Temp Sensor
bl LG101E-22S see EA-9B334.90 DIMMING SYSTEM
Lighting Power low 12 34 Trennstecker BODEN 6EY-A
ws ws ws 05835.25
Fuel Temp Signal Input High 17 18
bl EY7E-22S EY7E-22S bl bl EY7F-22S MS28034-3
Fuel Temp Signal Input Return 18 19
102-00002
Spare 9 20
ws 6EY Stecker MS3106F12S-3S
Bat Ameter Signal Input Low 16
bl EY9E-22S ST10-A
Bat Ameter Signal Input High 19
Spare 20
Case Ground 11
ws
Gen Amp Input high 8 E-BOX
bl EY8E-22S
Gen Amp Input low 6 ST1 ST1A
EY10E-22N
Spare 25 Trennstecker FIREWALL
001758 212 02 ws ws ws ws EY9F-22
25 q q PCB EA-9B243.45 F11
3EY G 1VN-G EY9E-22S bl bl bl bl EY9G-22
26 r r PCB EA-9B243.45 F12
B D D B
ws ws ws ws EY8F-22
24 s s PCB EA-9B243.41b J21
EY8E-22S bl bl bl bl EY8G-22
23 t t PCB EA-9B243.41b J22
EA-9B243.40
ST2
Fuel Press Sensor
N
green
L Output High
white
M Output Low
red
P Exitation 10-40VDC
black
R Exitation Return 4EY
S
Alternativ: HKM-186-375-50psi G

Zuordnung links / rechts wird mit DIGITAL INSTRUMENT, EY
04
03
EA-9B316.40 A
02 A ÄM-400-10-01 13.09.10 HW Schwarze Heide 21
Chapter 91 30. March 2012 01 ÄM-400-09-01
A3 Blatt 1 von 1
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
EMERGENCY BUS PP4

1EZ ENG-INS1
Splice
2A
D
Engine Instrument Package VV169 LOAD BUS PP3 D
VV170 ws 1 EZ1E-20
Moritz A1270 A:1 2EZ ENG-INS2
3EZ-A
VV172 2A
ws 2 EZ2E-20
A:12
ws
28 VDC POWER (Channel A) 1 VV173
bl EZ1F-20S EZ1F-20S bl EZ13E-20N
GROUND 2
bl bl EZ14E-20N see EA-9B246.10 DC-DISTRIBUTION
GROUND 3
ws EZ2F-20S EZ2F-20S VV174
28 VDC POWER (Channel B) 7 3VN-A
CASE GROUND SPARE 4 Splice 001758 212 02 R K
D1
BYW56
D2
BYW56 FIREWALL
ST2 RPM Sensor N2
4EZ-A
ws ws ws ws A
N2 SIGNAL INPUT 14 T MS25038-4
bl EZ3E-22S EZ3E-22S bl bl EZ3F-22S EZ3F-22S bl B
N2 RETURN 15 U 4EZ 32005-023
CASE GROUND SPARE 5 V
PC 06E 8-2S (SR)
6EZ-A Torque Sensor 6EZ-a Torque Sensor

Y
ws ws ws ws A
W Exitation 10-40VDC A Exitation 10-40VDC
bl EZ5E-22S EZ5E-22S bl bl EZ5F-22S EZ5F-22S bl D
X Exitation Return D Exitation Return
ws ws ws ws B
TRQ SIGNAL INPUT HIGH 8 Z Output High B Output High
bl EZ4E-22S EZ4E-22S bl bl EZ4F-22S EZ4F-22S bl C
TRQ SIGNAL INPUT LOW 9 a Output Low 6EZ C Output Low 6EZ
C CASE GROUND SPARE 10 b C
KM005-150G-8-1 Alternativ: IPS1525-150PSI-7/16-20UNF-SW27-MIL-C26484
bl bl & Stecker MS3126F8-4S & Stecker MS3476W10-6S
LIGHT GND 11 32 Dimming 8.0 - 28 VDC Dimming MS38999III (23-54) & Clamp M85049/52-1-10W
ws LG100E-22S ws
28 VDC LIGHT 12 31 EA-9B334.90 < 8.0 VDC Day Mode
CASE GROUND SPARE 13 ST4 RPM Sensor N1
VV171 5EZ-A
ws ws ws ws A
N1 SIGNAL INPUT 21 58 MS25038-4
bl EZ6E-22S EZ6E-22S bl bl EZ6F-22S EZ6F-22S bl B
N1 RETURN 22 59 5EZ 32005-023
CASE GROUND SPARE 23 47 PC 06E 8-2S (SR)
ST2
Oil Temp Sensor
e 7EZ-A 7EZ PC-BOARD 1
ws ws ws ws
OIL TEMP INPUT HIGH 16 c A MS28034-3
bl EZ7E-22S EZ7E-22S bl bl EZ7F-22S EZ7F-22S bl RS 162-647 1VE
OIL TEMP INPUT RETURN 17 d B 102-00002 1VE-a
CASE GROUND SPARE 24 MS3106F12S-3S Tourqe "0" adjust 25Ohm TR2
ws ws
2
bl EZ15E-22S EZ15E-22S bl cw
20
org org
1 cw
CASE GROUND SPARE 6
Oil "0" adjust TR3
25Ohm
EA-9B284.13
see EA-9B284.13 PC-BOARD 1
ST4
VV168 8EZ-A Oil Press Sensor 8EZ-A Oil Press Sensor
45
ws ws ws A
B
62 Exitation 10-40VDC A Exitation 10-40VDC B
EZ8E-22S EZ8E-22S bl bl EZ8F-22S EZ8F-22S bl D
63 Exitation Return D Exitation Return
ws ws ws ws B
OIL PRESS INPUT HIGH 18 60 Output High B Output High
bl EZ9E-22S EZ9E-22S bl bl EZ9F-22S EZ9F-22S bl C
OIL PRESS RETURN 19 61 Output Low C Output Low
CASE GROUND SPARE 20 46
8EZ 8EZ
EZ10E-20N KM005-150G-8-1 Alternativ: IPS1525-150PSI-7/16-20UNF-SW27-MIL-C26484
CASE GROUND 25 & Stecker MS3476W10-6S
MS38999III (23-54) & Stecker MS3126F8-4S
& Clamp M85049/52-1-10W
G
D-SUB 25S
1VN-D
3EZ-B 001758 212 02 Terminal am Triebwerk
ST2 Ringöse Alumel
SPARE A VV177
Alumel, red (-) EZ11E-22 ALCOR P/N 42526 Alumel, red (-) Alumel, red (-) EZ11F-20 Alumel, green (-)
TOT - ALUMEL, RED (-) B h *
# Chromel, yellow (+) EZ12E-22 Chromel, yellow (+) Chromel, yellow (+) EZ12F-20 Chromel, white (+)
TOT - CHROMEL, YELLOW (+) C j
SPARE D VV178
SPARE E
Ringöse Chromel TOT PROBS
SPARE F und Pinne aus Cromel und Alumel verwenden!
3EZ MS3126F10-6S * Buchsen
Pinne Buchse
Alumel: M39029/87-475 Alumel: M39029/88-487
Cromel: M39029/87-476 Cromel: M39029/88-488
# Buchsen und Pinne aus Cromel und Alumel verwenden!
Buchse
Alumel: 8500-2055 Die Gültigkeitszuordnung Letzte Bearbeitung: Datum Name Maßstab auf Projektion
Cromel: 8500-2054 von Version zu Bearb.: 17.06.04 PB SI.-Klasse Freimaßtoleranz
dem jeweiligen Fertigungsauftrag EA 400-500
Gepr.:
Zuordnung links / rechts wird mit ENGINE INSTRUMENT, EZ

04
03
EA-9B316.50 A
02 A ÄM-400-10-01 13.09.10 HW Schwarze Heide 21
Chapter 91 30. March 2012 01 ÄM-400-09-01
A3 Blatt 1 von 1
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
D D
LOW OIL PRESS

U?
NC 1 LW3F-22
1 LW2E-22N Stall-Heat Chip
3 Oil-Press Hydraulic
NO C 2 2
Windsh-Heat Fuel-Press Pitot Heat L Pitot Heat R
L
9LW Bleed Overt Static Heat L Static Heat R
PCI P110 001758 212 02
2VN-D P/N 90-4219X-1
Gehäuse B 1-0480303-0 Gehäuse P 1-0480305-0
FE4307 FE4308
Buchse 163557-2 Pin 163558-2 ANNUNCIATOR BOARD
FE4305 FE4306
C D7 1WW C
LOW FUEL PRESS D8
Engine Compartement
U? 1 2 3 LIGHT TEST (GND)
D4
NC 1 LW1F-22
1 LW4E-22N
FIREWALL
2
3 5WW-D 5WW
NO C 5WW-B
2 ST4
K LW3F-22 LW3E-22 WW5-22
8LW 27 102 39 8
C3C LW1F-22 LW1E-22 WW8-22
001758 212 02 28 101 40 7 Annunciator Panel right
PCI P60 LW5F-22 LW5E-22 WW9-22
2VN-D 26 103 36 4
LW6F-22 LW6E-22
CHIP DETECTOR 25 104 23 24 Fuel Trans R Standby Alt On Ignition
WW1-20
25
Pneumatic Low Voltage
10LW LW5F-22 D27
Chip 1
VV39 5WW-C Fuel Low R Prop Low Pitch External Power
11LW Chip 2
WW30-22 P/N 90-42192-2 geändert
10
Turbine
12LW Chip 3 + VOLT DIMM 24
WW20-20
GND Motorblock Anschlüsse mit Gummitülle abdecken 25
Turbine
2WW
LOW PITCH see Annunciator-Panel EA-9B315.80
B B
NC
LW7E-22N VV183 C 19LW
NO LW6F-22
Power Lever
E 334-870 VV184
BAS4028U
001758 212 02 SW am Gestänge im Triebwerkraum
2VN-D

A
Gepr.:
A
zu entnehmen.
Zuordnung links / rechts wird mit ENGINE WARNING, LW
04
EA-9B317.10 A
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
LOW OIL PRESS

9LW-a 9LW-A
NC yel LW3F-22
1
red 3 LW2E-22N
NO C wht 2
L 2VN-A
9LW
PCI P110 001758 212 02
Gehäuse B 1-0480303-0 Gehäuse P 1-0480305-0

FE4307 FE4308
Buchse 163557-2 Pin 163558-2 ANNUNCIATOR PANEL
FE4305 FE4306
5WW
B B
D2
LOW FUEL PRESS D8 L102 L202
Engine Compartement
1 2 3
8LW-a 8LW-A LIGHT TEST (GND)
D27
NC yel 1 LW1F-22 FIREWALL
red LW4E-22N
wht
3 5WW-D Annunciator Panel
NO C L108 L208
2 ST4
K 2VN-A Gen-Fail Oil-Press Bleed Overt
LW3F-22 LW3E-22
8LW 27 102 39
LW1F-22 LW1E-22
28 101 40 Fuel-Press Stall-Heat
PCI P60 LW6F-22 LW6E-22
001758 212 02 25 104 23
LW5F-22 LW5E-22 L120 L220
26 103 36 D14 Standby Alt On Prop Low Pitch Pitot Heat L
LOW PITCH
19LW Low Voltage Chip Static Heat L
NC
LW7E-22N VV183 C L114 L214
NO LW6F-22
19LW
Power Lever
E 2VN-A VV184
BAS4028U
+ VOLT DIMM
SW am Gestänge im Triebwerkraum C
001758 212 02 ANNUNCIATOR BOARD EA-9B411.70
NO see Annunciator-Panel EA-9B315.80
NC
C C
CHIP DETECTOR
(FE4107)
10LW LW5F-22
Chip 1
VV39
11LW Chip 2
Turbine
12LW Chip 3
GND Motorblock Anschlüsse mit Gummitülle abdecken
Turbine

zu entnehmen.
Zuordnung links / rechts wird mit ENGINE WARNING, LW
03
EA-9B317.10 B
EDV-Kennung:
Chapter 91 11. July 2012 9B31710T
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
E-BOX
Trennstecker Firewall
ST1 ST1 GEAR AUX 2

CB1
GA34F-22 #22 GA34E-22
R R 5A HOT BUS PP1
see EA-9B243.40 E-BOX

CIRCUIT BREAKER /SWITCH PANEL
GA1F-22 1 GA1E-22
D:8
GEAR-AUX-1 GEAR-CTRL
3GA-2 37GA 1GA
GA37F-22 2 GA37E-22 3 4 GA40F-22
D:5
5A 5A
GA3F-22 1 GA3E-22
A D:9 A
EZ49E-22 2 GA40E-22
61 D:6
EZ48E-22 see EA- 9B323.20 GEAR WARNING CIRCUIT BOARD
63 2
EZ47E-22
64
Bodenstecker 3GA-1
GA40-22
1 ST10-A 1
HYDR
GA3C-22 23GA
44GA
2 GA54E-22
GA10A-22 D:7 BATTERY BUS PP2
1A 50 A
GA6J-8
Modul 8 5 see EA-9B246.10 DC-DISTRIBUTION
001115_201_02 E D C B A Zustand Flugzeug am Boden Hydr Caut F 1VN-G
VV323101 K J H G F Schalt er am Boden entlastet, im Flug belastet.
45GA
LED 27GA GA54F-22 X1 X2 GA54G-22N
Right Gear 40GA-a H 001758 212 02
40GA-A
GA24J-22
VV185
1 GA53F-22 A1 M210-B4N
GA11-22N
2 10GA A2 GA53E-22 see EA-9B315.80
GA24C-22 ST10-A GA10B- 22 rt 46 ANNUNCIATOR PANEL
DIMMING 12 A3
sw
B1
GA8A-22
GA08D-22
GA3B-22
GA10-22
2GA ws
GA11A-22N
LED 28GA rt B2
41GA-a GA24F-22
GA24-22
Nose Gear auf
VV186
41GA-A sw B3
GA25F-22 org
GA25H-22
1 RIGHT GEAR
2 GA26F-22 bl
7 6 5
GA25C-22 ge Brandschott
DIMMING 13 6GA UPPER DOOR RIGHT
GA19-22 rt
bl G 12.221.M.15 GA7F-8N GA7F-8N
LED 29GA glb sw GA8B-22 1VN
GA26-22
GA53F-22
Left Gear 42GA-a ws GA41B- 22 rt
GA6E-8
42GA-A
VV187
sw
GA24J-22
1 G 12.221.M.15 Zentraler Massepunkt
2 org ws
GA26C-22 DUMP SWITCH bl SD15E-22N zu Bodenstecker
DIMMING 14
SD14G-22 ge org
SQUAT SWITCH NOSE GEAR bl 12 1 1
SIM
G12.221.M.15
GA26H-22 ge CAPTOR CORP.
DIMMING (TEST) 3 ST10-A ST11-B ST11-A
GA25G-22 GA24G-22 rt RF Filter 23939/A-7464 2x 75A DC
DIMMING (TEST) 2 G 12.221.M.30
1
GA24H-22 sw GA28-22N 11GA GA7E-8N
DIMMING (TEST) ws Filter 32GA HYDRAULIC PUMP
AUSGEFAHREN 21GA GA7A-8 20GA
GA27-22 org VV
GA26F- 22
GA24F- 22
bl GA9G-22 GA6F-8 88 88a GA6G-8 GA6H-8
VV
FAHRWERKSHEBEL ge
B 87z 87a B
30GA A B C D E G 12.221.M.15 7GA
GA53G-22 88y 88b GA51-22N
F G H J K 001115_201_02
ST10-A VV323102
EIN
26.57.73
3 GA08E-22 GA08F-22
GA1F-22 2
3 001578_212_02
LOWER DOOR
GA10B-22
GA10A-22
GA13A-22
GA41B-22
GA12A-22
GA11-22
Modul6
GA3F-22
1 GA09E-22 GA09F-22 001115_201_03
07.1.1.13 D927 4 Main Valve Uper Door Valve Lower & Nose Door Valve rt GA3A-22 GA4-22
BN
AUS 13GA 86 85 C H
sw
GA37F-22 17GA 18GA 19GA ws Hydraulic Motor Relais VV323106
10 E D A B C Modul 5 5VN-A
GA34F-22 NOSE GEAR zu
GA30F-22
9 org K J F G H 001115_201_02 An GND Anschluß Pumpe
see EA- 9B323.20 GEAR WARNING CIRCUIT BOARD 62 Druckschalter
GA4B-22
GA5-22N
8 EINGEFAHREN bl VV323105
G 12.221.M.15 ge
SIM E-2022 rt GA17-22N 2 1 2 1
33CG-A
GA34G-22
GA37G-22
GA25F- 22
sw G 12.221.M.15 15pol D-Sub
GA30E-22
ws
GND GND
Modul 7 A B D C E GA14-22N
GA41A-22
GA13-22
GA12-22
2 GA04A-22
GA11A-22
001115-201-02 org 4GA GA16A-22N 33CG-a

VV323106 1
F G J H K bl GA17A-22 (GA36G-22)
3
ge GA14A-22
GA16-22 22GA
rt GA17B-22N 14GA 10A
sw GA14B-22N GA5-22
GA30E22
ws GA16B-22N A
5GA
org
bl B
ge 15pol DSUB
33GA-a X1 X2 LY4G-22 see EA-9B334.50 COURTESY LIGHT
G 12.221.M.15 33GA-A
AUSGEFAHREN 34GA HG7E-20
F300-B4N 3
GA16C-22N VV188 6 see EA-9B303.10 PITOT-STALL-HEAT, 12HG Pin X2
11 2
GA14C-22N A
10 1
GA17C-22N SH5E-24
9 3
GA16C-22 7 see EA-9B345.58 XP DR BXP 6402, ST14-A P in 8
8 2
GQ14C-22 25GA B
7 1
GA36K-22 GA36H-22 GA17C-22
6 3
SQUAT SWITCH Nose Gear GA16D-22N 24GA
5 P600A 2
GA14D-22N 6,8 uF 100V C
36GA 4 1
rt GA17D-22N AK-950-FTR1
sw 3 3
GA46E-22N
ws LY4G-22 2
ST10-A D
1 LY13F-22
KLMP C R AB see EA-9B334.50 COURTESY LIGHT
C org C
UPPER DOOR LEFT GA3C-22 -X2 +X1 VV190 GA40-22
bl 2
glb
001758 212 02 rt 15GA M220-B4N
G 12.221.M.15 LEFT GEAR sw 35GA 3 HG8E-20
ws VV189 2
5 see EA-9B303.10 PITOT-STALL-HEAT, 11HG Pi n X2
rt
8GA A
auf 1
sw GA14B-22 org
3
ws bl
2
EINGEFAHREN ge B HP9F-22
1 100
org see EA-9B213.30, DUMP SWITCH, 3HP Pin 2
3
GA31-22N
GA32-22N
bl SD16E-22N G 12.221.M.15
GA42-22
GA41A-22N
GA41-22
GA22A-22N
2
SD14H-22 ge rt 001758_212_02 C
1
G 12.221.M.15 sw
Modul 9 1VN-E L K 3
A B C D E rt ws
001115_201_02 2
sw zu ST10-A D
VV323101 1
F G H J K ws org Schalterstellung A/C on Air
AUSGEFAHREN bl
GA43-22 -X2 +X1
GA26G-22 org ge 11 z. B. PITOT aktiv bei abgefallenem Relay
bl
VV323101-2+5-6 VV323103 VV323104 ge G 12.221.M.30 16GA
M220-B4N
G 12.221.M.15 9GA SD14F-22 SD14E-22 SD14E-22
13 see EA-9B344.15 TRAFF IC SYSTEM TAS-610
GA22-22N
A F A F A F
GA43-22
GA41-22N
GA41A-22
B G B G B G
C H C H C H
D J D J D J
E K E K E K
26GA
001115-201-02 001115-208-02 001115- 209-02

GA16C-22
AirLB Jiffi
5VN-A GA16A-22
GA08-22
GA08A-22
GA27-22
GA27A-22
GA19-22
GA19A-22
GA14-22
GA14C-22
GA14F- 22
GA14G-22
GA14B-22
GA14D-22
GA08B-22
GA08C-22
GA08E- 22
GA17C-22
GA17A-22
GA17B-22
GA50-22
GA50A-22
GA3F -22
GA03A-22
SD14G-22
SD14H-22
A B C D E Modul 2
001115_201_02 Modul 4 AB C DE Modul 4
A B C F G H J K
VV323102 001115_209_02 A 001115_209_02
H J C D F
D D E F VV323106 K F GHJ K E VV323104 D
B G
SD16E- 22N
SD15E- 22N
GA22-22N
GA11-22N
GA20-22N
GA21-22N
GA28-22N
GA29-22N
G H J
K L M
Die Gül tigke itsz uordn ung Let zte Bearb eitu ng: D atum Na me M aßsta b a uf P roje ktio n
Modul 3 S I.-Kl asse
N P R S DE F GHJ T U 5VN-A von Ver sion zu Bea rb.: 06.09.04 PB F reim aßto lera nz
Fahrwerkschacht 001115_208_02 O berfl äche nsch utz O berf läch e
Flu gzeu gbaur eihe
S T
U VV323103 ist der Baua kte bzw. Gep r.:
SD14F-22
001758_212_02
dem jew eilig en F ertig ungs auftr ag Gep r.: EA 400-500
zu entn ehmen .
Zuo rdnu ng li nks / rec hts wird mit LANDING GEAR CONTROL, GA
*/* in allen Fel dern ange geben .
04
03 EA-9B323.10 A-1
02 A-1 ÄM-400-12-10 11. 09.12 HW Schwarze Heide 21 A2 B latt 1 von 1
001758- 212-02 01 A ÄM-400-09-01 01. 09.10 HW
Ve r. B ezei chnu ng Sc hu tz ve rm er k na ch D IN 3 4 be acht en.
Chapter 91 11. July 2012 E DV-K ennu ng: 9B32310T
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
E-BOX
Trennstecker Firewall
GEAR-AUX-2
ST 1 ST 1A CB1
GA34F-22 #22 GA34E-22
R R HOT BUS PP1
5A
see EA-9B243.40 E-BOX

GA1F-22 1 GA1E-22
DH
GEAR-AUX-1 GEAR-CTRL
37GA 1GA
GA37F-22 2 GA37E-22 3 4 GA40F-22
DE
DIMMING BOARD PC -BOARD 2 3GA-2 5A 2 5A
5LH-A
A P1 GEAR WARNING 3GA-1 A
GA26H-22 GA26K- 22 GA26K- 22 GA3F-22 1 GA3E-22 1
DIMMING ( TEST) 3 3 61 3 LE FT GEAR DI
GA25H-22 GA25K- 22 GA25K- 22 NO SE GEAR
DIMMING ( TEST) 22 2 63 6 GA40E-22 2 GA40F-22
GA24H-22 GA24K- 22 GA24K- 22 RI GHT GEA R
DF
DIMMING ( TEST) 4 1 64 10
GA30E-22 GA30E-22 DO OR CLOS ED
62 5 HYDR
DIMMING 34 23GA
5LH PC-BOARD 2 EA-9B411.60 44GA
GA54F-22 2 GA54E-22
see EA- 9B323.20 GEAR WARNING DG BATTERY BUS PP2
see EA-9B334.90 DIMMING RIGHT GEAR UPP ER DOOR R IGHT 1A 50A
LH8E-20 CB TRENNSTECKER
EINGEFAHREN AUF
GA6J-8
GA41E-22 UP rt GA27F-22 AUF rt
sw GA8H-22 sw GA11E-22 9 see EA-9B246.10 DC-DISTRIBUTION
ws INT ws
E
C
B
D
A
MODUL 15 F
Bode nstecker
J
001115 202 02 6GA 10GA
K
G
J 10a ST 10A org org
bl SD16E-22N bl HYDRAULIK CAUTION
SD14H-22 INT ge ge 1VN-4
GA30E-22 GA30F-22
GA6E-8
8
LED 27GA G12.221.M.15 G 12.221.M.15 GA54F-22 X1 X2 GA57E-22N
P
Right Gear 27GA-a
27GA-A
1 GA24J-22 GA24E-22 GA24F-22 GA24F-22 G 12.221.M.15 G 12.221.M.30 GA53F-22 A1 001758 212 02
5 INT GA8J-22 ZU see EA-9B315.80
GA27F-22
GA27E-22
ge rt A2 GA56E-22 GA56E-22
GA27G-22
2 VV185 46 ANNUNCIATOR PANEL
GA9F-22 GA44F-22 bl GA16E-22N sw GA12E-22 A3
GA27E-22
12 GA24G-22 DOWN org INT ws B1 1VN
B2 GA7E-8N
ws
7GA GA46E-22 ZU org
11GA B3
Brandschott
GA3F -22
GA53F- 22
LED 28GA Modul 30 Zentraler Massepunkt
sw GA9G-22 bl GA13E-22
28GA-a
GA6E-8
Nose Gear 28GA-A GA10E-22 DOWN rt ge 45GA J 11b J 11a

GA25J-22 GA25E-22 GA25F-22 A B C D E J 10a
1 6 M210-B4N
2 VV186 F G H J K ZU
GA27F-22
AUSGEFAHREN
13 1 12 Bodenstecker 1 1 Bodenstecker
GA24G-22 ST 10A ST 11B ST 11A
LED 29GA
Left Gear 29GA-a GA27F-22
29GA-A
GA9G-22
GA44E- 22
GA27E- 22
1 GA24J-22 GA26E-22 GA26F22
7
GA3G-22
GA53E-22
GA6F-8
GA7F-8N
2 VV187 GA53E-22
GA27G-22
14
HYDRAULIK RELAIS
GA12E- 22
GA11E- 22
GA13E-22
GA46E-22
87y
87z
88
GA3G-22 86
SQUAT SWITCH
FAHRWERKSHEBEL Modul 34 21GA
LOWER & NOSE DOOR UPPER DOOR MAIN REL 26.57.73 85
B Modul 32 A B C D E B
GA8G-22
GA8F -22
GA8H-22
GA8J-22
GA8K-22
rt VALVE VALVE VALVE
88b
87a
88a
30GA F G H J K DRUCKSCHALTER
sw
EIN Einfahr-
ws KJ H G F
3 GA8E-22 GA8F-22
19GA 18GA 17GA Modul + 22GA GA51E-22N
3 36GA
GA42E- 22
GA1F-22 2 AIR org Press = low

1 GA9E-22 GA9F-22 bl GA21E-22N
07.1.1.13 D927 4
GA5E-8
GA7F-8N
AUS GA45E-22 WOW ge 2 (<100 bar)

AB C DE 1
2 1 2 1 2 1
GA46F-22
GA13F-22
GA12F-22
GA11F-22
G 12.221.M.15 3 32GA
RF FILTER
GA8K-22
GA37F-22 GA37G-22 GA14G-22 Press = high
VV
VV
10 NOSE GEAR (>120bar) CAPTOR CORP.
GND
GND
GND
GA34F-22 GA34G-22 23939/A-7464 2x 75A DC
9
GA35G-22
GA33G-22
GA36G-22
GA38F-22N
GA14F-22
X1
A1
A3
B1
B3
GA14E- 22
GA14H-22
GA39F-22N
DUMP SWITCH
GA18F- 22N
GA19F- 22N
14GA
26GA
F300-B4N GA43F-22N GA42F-22
GA27E-22
GA28F-22N
GA29F-22N
GA4E-8
GA2E-8
2GA AIR rt 001119 702 02 10A

sw GA8G-22
ws GA14G-22
X2
A2
B2
33CG-a 20GA
GA33G-22
GA18F- 22N
GA19F- 22N
GA38F- 22N
GA39F- 22N
GA35G-22
GA36G-22
36GA org
2GA
8 5 11 4 10 3 9 7 6 1 2
FRONT GEAR bl GA20E-22N
15pol D- Sub
HYDRAULIK PUMPE
GA44E-22 WOW ge
4GA 33CG-A
G 12.221.M.15
GA2E-8
GA33F-22
GA34G-22
GA37G-22
GA30F-22
GA26F-22
GA25F-22
NOSE GEAR GA42E-22
Modul 35 25GA
SD14H- 22
SD14G- 22
GA10E- 22
GA41E- 22
GA36K-22
GA35H-22
GA17E-22N
GA36H-22
RIGHT LEFT GA36H-22 GA36F-22
GA35F-22
GA43E-22N
5GA A B C D E
Modul 31
F G H J K D P600A
A B C E 24GA
NOSE GEAR 6,8 uF
GA18E- 22N
GA19E- 22N
GA28E- 22N
GA29E- 22N
GA38E- 22N
GA39E- 22N
F G H J K 100V
EINGEFAHREN AK-950-FTR1
11GA 16GA
GA20E- 22N
GA21E- 22N
GA16E- 22N
SD16E- 22N
GA17E- 22N
org GA46E-22N
GA43E- 22N
GA51E- 22N
5VN-A An GND Anschluß Pumpe

bl
10GA 15GA ge A B C DE F G HJ U K L MN P R S T
GA37H-22
GA34H-22
GA30G-22
GA26G-22
GA25G-22
ST11 4GA
GA30G-22 UP rt
GA33E-22
SD14F- 22
GA10F- 22
GA41F- 22
B A sw GA46F-22
ST10 INT ws LY4G-22
6GA 8GA see EA-9B334.50 COURTESY LIGHT
G 12.221.M.15
G 12.221.M.15
LOWER DOOR
C 34GA 3 AIR HG7E-20 C
ge G 12.221.M.15 6 see EA-9B303.10 PITOT- STALL- HEAT, 12HG Pin X2
GA22E-22N
SD15E-22N
GA15E-22N
GA36F- 22
GA36H-22
bl GA22E-22N GA23F-22 ZU org A
GA45F- 22
GA35F- 22
GA35H-22
7GA 13GA 9GA 1
GA29E-22N
GA25G-22 DOWN org Modul 33 bl WOW

3
5GA AUF ge
2
GA37H-22 ws 13GA
A F 1
INT sw GA34H-22 K J C D rt
3
rt H E sw
B G 2
ws C
1
AUSGEFAHREN 3
ZU
Bode nstecker
LY4G-22 2
D
ST 10A J 10a 1 LY13F-22
see EA-9B334.50 COURTESY LIGHT
GEZEICHNETER ZUSTAND VV190
GA45E- 22
GA35E- 22
GA36E- 22
GA23E- 22
GA44F-22 GA44G-22 GND=WOW -X2

0B702 Maintenance Manual Ed2 Rev2 20130809

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0B702 Maintenance Manual Ed2 Rev2 20130809

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Maintenance Manual

Schwarze Heide 21 D - 46569 Hünxe Germany

Page Date: 30. March 2013

List of Effective Page

Page B Page Date: 30. March 2012

51-10....................................30. March 2012 91-4 ..................................... 30. March 2012

Page Date: 30. March 2013

91-75 thru 82....................... 30. March 2012

Page D Page Date: 30. March 2012

Left blank intentionally

Page Date: 30. March 2013

List of Service Bulletins

Page F Page Date: 30. March 2012

Log of Revisions ..................................................................................................................... A

General Description ............................................................................................................... 03

Air Conditioning .................................................................................................................... 21

Page Date: 30. March 2013

Group/Chapter Title..................................................................................................... Chapter

Standard Practices and Structures - General ......................................................................... 51

Page H Page Date: 30. March 2012

Page Date: 30. March 2012 01 Page 1

01-00-00 GENERAL ........................................................................................................ 3

Page 2 01 Page Date: 30. March 2012

Page Date: 30. March 2012 01 Page 3

01-00-02 Special Tools

Threaded rod M 10 Nut and counter nut

Figure 01-1 Main Gear Bolt Extracting Tool

Page 4 01 Page Date: 30. March 2012

Figure 01-2 Flap Track Snap Gauge

Page Date: 30. March 2012 01 Page 5

Figure 01-3 Front Wing Main Bolt Extracting Tool

Figure 01-4 Rear Wing Main Bolt Extracting Tool

Page 6 01 Page Date: 30. March 2012

01-00-03 Trade Marks

Refer to Chapter 02 for information concerning safety notes.

Page Date: 30. March 2012 01 Page 7

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Page 8 01 Page Date: 30. March 2012

Page Date: 30. March 2012 02 Page 1

02-00-00 GENERAL ........................................................................................................ 3

02-10-00 MANUAL DESCRIPTION ............................................................................. 4

02-20-00 HANDLING ...................................................................................................... 6

Page 2 02 Page Date: 30. March 2012

Page Date: 30. March 2012 02 Page 3

02-10-00 MANUAL DESCRIPTION

02-10-01 Manual Set-Up

02-10-02 Chapter Set-Up

02-10-03 Page Numbering

02-10-04 Figure Numbering

Page 4 02 Page Date: 30. March 2012

02-10-06 Notes/Safety Notes

Page Date: 30. March 2012 02 Page 5

02-20-02 Service Bulletin

Page 6 02 Page Date: 30. March 2012

Serial No.: Mechanic

Page Date: 30. March 2012 02 Page 7

Intentionally left blank

Page 8 02 Page Date: 30. March 2012

Page Date: 30. March 2012 03 Page 1

03-00-00 GENERAL ........................................................................................................ 3

Page 2 03 Page Date: 30. March 2012

The EXTRA 500 is designed as a six-place, single engine, high-wing, full

Page Date: 30. March 2012 03 Page 3

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