Page 1 SERVICE MANUAL EXTRA 200 Doc. No: EA-07702 EXTRA FLUGZEUGPRODUKTIONS- UND VERTRIEBS-GMBH Schwarze Heide 21 D-46569 Hünxe, Germany Tel: 49-28 58-91 37-0 Fax: 49-28 58-91 37-30...
Page 2 List of Effective Pages...
Page 3 List of Effective Pages...
Page 4 List of Effective Pages...
Page 5 Record of Revisions...
Page 6 List of Service Bulletins Serial N° German AD S.B. N° Issue Date Subject affected (LTA) SB-300-1-97 11.06.1997 Front seat belt safety cover installation 01 thr. 15 97-203...
Page 7 CONTENTS GENERAL AIRCRAFT AIRFRAME SYSTEMS...
Page 8 STRUCTURES PROPELLER POWER PLANT MISCELLANEOUS...
Page 9 FAX MESSAGE From: Aircraft Description: Detailed Description of Damage or Problem...
Page 10 FAX MESSAGE From: Aircraft Description: Existing Technical Documentation: Notice:...
Page 11 Chapter 01 Introduction...
Page 12 TABLE OF CONTENTS 01-00-00 GENERAL 01-10-00 SAFETY...
Page 13 01-00-00 GENERAL Aircraft: N O T E Check the following Airplane Log Book documents are up-to-date and in accordance with current LBA regu- lations. Since the regulations of other nations may re- quire other documents and data, owner of exported airplanes should check with their own aviation officials to determine their individual requirements.
Page 14 Engine: Lycoming AEIO-360-A1E Propeller: MTV-12-B-C/C 183-17e (3-blade) Magneto: SLICK No. 4370 and 4372 Inverted Oil System: CHRISTEN 801 Series (mod.)
Page 15 Cleveland Wheels & Brakes Other Vendor Equipment 01-00-01 Trade Marks...
Page 16 01-10-00 SAFETY...
Page 17 EXTRA - FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 200 Chapter 02 How to Use the Service Manual PAGE DATE: 1. July 1996 CHAPTER PAGE...
Page 18 EXTRA - FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 200 TABLE OF CONTENTS Chapter Title 02-00-00 GENERAL .......................
Page 19 EXTRA - FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 200 02-00-00 GENERAL The set-up of the manual, the chapters and the handling correspond to the regulations of the Air Transport Associa- tion of America, ATA Specification No. 100. Only the numbering of the pages and the layout have been changed to make working with this manual easier.
Page 20 EXTRA - FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 200 breakdown is necessary, bold faced headlines like the following are used: Powerplant 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.
Page 21 EXTRA - FLUGZEUGBAU GmbH MANUAL DESCRIPTION SERVICE MANUAL EXTRA 200 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);...
Page 22 EXTRA - FLUGZEUGBAU GmbH MANUAL DESCRIPTION SERVICE MANUAL EXTRA 200 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: D A N G E R Represents a threatening danger for the personnel.
Page 23 N O T E Pages of this SERVICE MANUAL may not be ex- changed and no alterations of or additions to the ap- proved contents may be made without the EXTRA Flugzeugbau GmbH/LBA approval. If revision of pages is necessary, observe the following...
Page 24 6 Certify the completion of check in the Aircraft Log Book. 02-20-04 Fax-Formats When contacting the EXTRA-FLUGZEUGBAU GmbH is advisable in case of questions and/or problems during maintenance of aircraft copy and use on of the Fax-formats You find on the preceding pages ("H-I") for correct identi- fication of aircraft, equipment and existing technical in- structions.
Page 25 Chapter 03 General Description...
Page 26 TABLE OF CONTENTS 03-00-00 GENERAL 03-10-00 DESCRIPTION...
Page 27 03-00-00 GENERAL 8EAM-:64) .ECKHA...
Page 28 03-10 DESCRIPTION 03-10-01 Construction Seats 03-10-02 Flight Control System...
Page 29 03-10-03 Brake System 03-10-04 Powerplant Engine Propeller...
Page 30 03-10-05 Fuel System 03-10-06 Electrical system...
Page 31 03-10-07 Instruments Instrument Panel rear front Air Speed Indicator Altimeter Magnetic Compass Compass Correction Card Tachometer Oil Pressure Indicator Oil Temperature Indicator Fuel Pressure Indicator Manifold Pressure Indicator CHT/EGT Indicator Ammeter Fuel Quantity Indicator (Center tank) Fuel Quantity Indicator (Wing tank) Acceleration Indicator (G-Meter) Radio...
Page 32 Chapter 04 Airworthiness Limitations...
Page 33 Record of Revisions Chapter 04...
Page 34 TABLE OF CONTENTS 04-00-00 GENERAL ....................
Page 35 04-00-00 GENERAL I M P O R T A N T It is the operator's responsibility to make sure that time limits or life limits for items in this chapter are not ex- ceeded. 04-00-01 Temperature Limit 04-00-02 Operating Time...
Page 36 I M P O R T A N T Every 1000 flight hours the "Significant Items Inspec- tion" contained in Chapter 05-30-00 of this manual must be performed. This 1000 hours inspection releases the aircraft for further 1000 hours operation, up to max. of 6000 hours.
Page 37 04-10-00 LIFE LIMITED COMPONENTS 04-10-01 General 04-10-02 Replacement Time Item Replace Wing 6000 h Aileron 6000 h Vertical Stabilizer 6000 h Rudder 6000 h Horizonal Stabilizer 6000 h Elevator 6000 h Landing Gear Spring 6000 h 04-10-03 Service Life Limited Components...
Page 38 04-20-00 MAJOR INSPECTION...
Page 39 Chapter 05 Time Limits/Maintenance Checks...
Page 40 Table of Contents 05-00-00 GENERAL ................05-10-00 TIME LIMIT COMPONENTS .
Page 41 05-00-00 GENERAL N O T E For working with checklists refer to Chapter 02-20-03. D A N G E R Do not rotate the propeller nor allow any person to stay in the propeller operating area when performing an in- spection or check with the master switch "ON"...
Page 42 05-10-00 TIME LIMIT COMPONENTS 05-10-01 General 05-10-02 Overhaul Schedule Item Overhaul * refer to latest issue of Engine Manufacturer´s Service Bulletin (Textron Lycoming) together with Engine accessories engine Magneto (Slick) Propeller (MT-Propeller) Governor (Woodward) All other components on Condition...
Page 43 05-10-03 Replacement Schedule Item Replace Battery ** on the recommendation 2 years ** of the manufacturer (Sonnenschein) Batteries of the ELT 2 years ** (Pointer) Wheels on Condition (Cleveland, Parker) Tires on Condition Fuel, oil & brake hoses after first 7 years, (Aeroquip) then 5 years Seat belts...
Page 44 05-20-00 SCHEDULED MAINTENANCE CHECKS 05-20-01 General 05-20-02 25 Hour Inspection - Aircraft...
Page 45 1. Root Rib Aileron 2. Root Elevator 3. Root Horizontal Stabilizer 4. Stall Warn Transducer 5. Lower Root Rudder Fin 6. Lower Root Rudder Horn 7. Wheel Fairing 8. Nose Ribs Aileron (Hinge Gaps) Drain and Vent Holes Figure 1...
Page 46 Lubrication Chart 50 hours Figure 2...
Page 47 Lubrication Chart 100 hours Figure 3...
Page 48 05-20-03 Maintenance Checks Schedule Operational Checks...
Page 49 Propeller Ground magneto primary circuit before D A N G E R working on propeller refer to MT-Propeller Service Bulletin No. 1...
Page 50 Engine compartment Ground magneto primary circuit before D A N G E R working on engine 1 at 10 and 25 hours and then each 25 hours 2 at 10 and 25 hours 3 each 500 hours...
Page 51 1 each 300 hours 2 each 400 hours...
Page 52 1 each 500 hours 2 each 1000 hours 3 together with engine 4 clean at least every 90 days...
Page 53 1 refer to Woodward Service Bulletin No. 33580 refer to Lycoming Service Instruction No. 1009...
Page 54 Fuselage...
Page 55 Fuel system Flight controls...
Page 56 Landing gear Fairings:...
Page 57 Wheels Tires...
Page 58 Brake system Tail-wheel landing gear...
Page 59 Wing Stabilizer...
Page 60 Instruments Electrical system Annual, each twelve calendar month...
Page 61 General Minimum Clearance Check Figure 4 Coning Check Figure 5 1 as required...
Page 62 05-20-04 Significant Items Inspection 1000 flight in addition Wing Leading edge Main spar section Auxiliary spar section Spar carry-through...
Page 63 Wing trailing edge Root and Tip Aileron Surface general Control system...
Page 64 Vertical Stabilizer Leading edge Front spar section Rear spar section Root and Tip Rudder...
Page 65 Horizontal Stabilizer Leading edge Front spar section Rear spar section Spar carry-through Root and Tip Elevator...
Page 66 Surface general Fuselage Flight controls...
Page 67 Main landing gear Tail-wheel landing gear Steerable tail-wheel...
Page 68 Engine compartment Hardware...
Page 69 Surface general...
Page 70 05-50-00 UNSCHEDULED MAINTENANCE CHECKS I M P O R T A N T In case of abnormal events or any exceedance of given limitations (load factor, never exceed speed, etc.) the manufacturer has to be contacted to find appropriate maintenance procedures. Therefore the procedures de- scribed in the following could be subjected to changes.
Page 71 Landing gear Control surfaces Engine...
Page 72 05-50-03 Engine Fire 05-50-04 Lightning Strike...
Page 73 05-50-05 Flightline Inspections...
Page 74 Chapter 06 Dimensions and Areas...
Page 75 TABLE OF CONTENTS 06-00 -00 ....... . . GENERAL 06-10 -00 .
Page 76 06-00-00 GENERAL Reference Planes Axes and Planes Figure 1...
Page 77 06-10-00 MAIN DATA 06-10-01 Main Dimensions Height 1 Height 2 06-10-02 Wing...
Page 78 06-10-03 Horizontal Tail 06-10-04 Elevator 06-10-05 Vertical Tail 06-10-06 Rudder...
Page 79 Three-View EXTRA 200 Figure 2...
Page 80 Chapter 07 Lifting and Shoring...
Page 81 TABLE OF CONTENTS 07-10-00 JACKING ..................... . . 07-20-00 SHORING .
Page 82 07-10-00 JACKING 07-10-01 Balance Weight Balance Weight Figure 1...
Page 83 07-20-00 SHORING 07-20-01 Shoring the Front C A U T I O N Prevent damage of ventilation tubing, brake lines and drains, when shoring the aircraft. W A R N I N G Maintain hoisting strap as a security device to prevent nose over of the aircraft during maintenance work.
Page 84 07-20-02 Shoring the Tail C A U T I O N Don´t handle the elevator when lifting the tail. W A R N I N G Do not lift the tail higher than necessary for support- ing. The aircraft may tilt onto the nose. Shoring the Tail Figure 3...
Page 85 Chapter 08 Leveling and Weighing...
Page 86 TABLE OF CONTENTS 08-00-00 GENERAL 08-10-00 WEIGHING 08-20-00 LEVELING...
Page 87 08-00-00 GENERAL I M P O R T A N T Weigh, read the scales and calculate with carefulness. Incorrect weighing or determination of Center of Grav- ity endanger the pilot and the aircraft.
Page 88 08-10-00 WEIGHING AND CALCULATION OF C OF G N O T E Weigh the aircraft only on even floor and in closed halls (wind protected). Use three identical scales.
Page 89 ......
Page 90 Empty Weight and Center of Gravity Position EXTRA 200 Item Weight Moment Empty weight Total moment Empty weight ..Center of Gravity ..
Page 91 08-20-00 LEVELING N O T E Level the aircraft only on even floor and in closed halls (wind protected). W A R N I N G Do not lift tail wheel higher than necessary for leveling. The aircraft may tilt onto the nose. C A U T I O N Prior to levelling, ensure aircraft is clear of obstruc- tions.
Page 92 Chapter 09 Towing and Taxiing...
Page 93 TABLE OF CONTENTS 09-00-00 GENERAL ....................... . 09-10-00 TOWING .
Page 94 09-00-00 GENERAL 09-10-00 TOWING D A N G E R When preparing for ground handling operation ensure that the ignition switch is off. 09-20-00 TAXING C A U T I O N Taxiing over loose gravel or cinders should be done at low engine speed to minimize damage to the airframe surfaces due to stone damage.
Page 96 Chapter 10 Parking, Mooring, Storage and Return to Service...
Page 97 TABLE OF CONTENTS 10-00-00 GENERAL ....................... . 10-10-00 PARKING / STORAGE .
Page 98 10-00-00 GENERAL...
Page 99 10-10-00 PARKING / STORAGE C A U T I O N When chocking the wheels, ensure that the chocks used are not too large to come in contact with the wheel farings. The use of chocks that are too large may dam- age the farings.
Page 100 10-20-00 MOORING C A U T I O N When chocking the wheels, ensure that the chocks used are not too large to come in contact with the wheel fairings. The use of chocks that are too large may dam- age the fairings.
Page 101 10-30-00 RETURN TO SERVICE...
Page 102 Chapter 12 Servicing...
Page 103 TABLE OF CONTENTS 12-00-00 GENERAL 12-10-00 REPLENISHING 12-20-00 SCHEDULED SERVICING 12-30-00 UNSCHEDULED SERVICING...
Page 104 12-00-00 GENERAL...
Page 105 12-10-00 REPLENISHING 12-10-01 Refueling D AN G E R * 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.
Page 106 I M P O R T A N T Under no circumstances should fuel of lower octane rat- ing or automotive fuel (regardless of octane rating) be used. It is recommended that personnel be familiar with Service Instruction No.1070 regarding specified fuel for Lycoming engines.
Page 107 12-10-03 Fuel Drains D A N G E R Do not drain the fuel system when the engine or the exhaust is hot or while the wind is strong. I M P O R T A N T After draining, you have to be sure that the fuel drain valve is returned to the closed position and the valve is not leaking outside the aircraft.
Page 108 C A U T I O N When tightening the filler spout cap ensure that is se- cure. But do not overtighten, as this may damage the "O" ring seal in the cap. Replenish engine oil Aviation Grade Straight Mineral oil Ashless Dispersant Oil Additive Oil...
Page 109 I M P O R T A N T 1 Do not mix additive oil and straight mineral oil. Drain straight mineral oil from engine and fill with addi- tive oil. 2 Do not operate engine longer than five hours before again changing oil.
Page 110 Oil System Capacities: U.S. Imp. Liters Quarts Quarts Total Engine Capacitiy Minimum Safe Quantity Acrobatic: Minimum Safe Quantity Normal: 12-10-05 Oil Change...
Page 111 12-10-06 Replenishment of Brake Fluid...
Page 112 Replenishment of Brake Fluid Figure 1...
Page 113 12-10-07 Tire Inflation...
Page 114 12-20-00 SCHEDULED SERVICING 12-20-01 Exterior Cleaning C A U T I O N Do not use so called "mild" household detergents to wash aircraft exterior. Such detergents may damage finish and corrode aluminum components. C A U T I O N Never use cleaning agents containing silicone!
Page 115 C A U T I O N Never polish plexiglass dry! 12-20-02 Interior Cleaning C A U T I O N Never use gasoline, benzine, alcohol, acetone, carbon tetracloride, fire extinguisher fluid, anti-ice fluid, lac- quer thinner, or glass cleaner to clean the canopy. These materials will damange the canopy and may cause se- vere crazing.
Page 117 12-30-00 UNSCHEDULED SERVICING 12-30-01 Removal of Snow and Ice C A U T I O N Do not use sharp tools for removing the snow.
Page 118 Chapter 20 Standard practices - Airframe...
Page 119 TABLE OF CONTENTS 20-00-00 GENERAL 20-10-00 STANDARD PRACTICES AIRFRAME 20-20-00 ASSEMBLY INSTRUCTION...
Page 120 20-00-00 GENERAL...
Page 121 20-10-00 STANDARD PRACTICES AIRFRAME 20-10-01 Type of Bolts LN-Bolts Example: LN 9037-08042...
Page 122 AN-Bolts Example: AN 3 - 5A DIN-Bolts...
Page 123 Example: DIN 931, M10 x 80 - 8.8 20-10-02 Width Across Flats for Metric Bolts Thread diameter Width across flats 7 mm 8 mm 10 mm 13 mm 17 mm 19 mm 24 mm 30 mm 36mm...
Page 124 20-10-03 Torque Values Metric thread size Torque value (Nm) (in.lbs) 3.9-4.3 35-38 6.2-6.8 55-60 15.2-16.8 144-148 29.5-32.5 261-287 M12x1.5 51-57 452-504 Inch thread size Torque value (Nm) (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...
Page 125 20-10-04 Special Torque Values Torque value Item (Nm) (in.lbs) Engine Mounting (Bolts AN7-36A / Metal Stop Nut NAS 363C-720) Engine Mount to Fuselage (Bolt Din 912, M12x160-12.9 Stop Nut DIN 985, M12-8-B2C) Longeron Cutout Bridge (Upper Bolts DIN 912 M8x180-8.8 Stop Nut LN 9348-08) (Lower Bolt DIN 912 M10x230-8.8 Stop Nut LN 9348-10)
Page 126 20-10-05 Measuring Techniques 20-10-06 Coin Tapping Coin Tapping Figure 1...
Page 127 20-10-07 Flexible Hose Replacement of Flexible Hose Overhaul Schedule Installation of Flexible Hose Assemblies...
Page 128 N O T E The STRATOFLEX-hoses used in the engine depart- ment are factory equipped with fire sleeves. Hose Fire sleeve AE303-4 AE102-10 AE303-6 AE102-12 AE303-8 AE102-16 AE303-10 AE102-18 20-10-08 Fittings N O T E Apply Loctite 577 on all National Pipe Threads (NPT) before installation.
Page 129 20-20-00 ASSEMBLY INSTRUCTION 20-20-01 General N O T E Make appropriate logbook entry of compliance with this Assembly Instruction after Container Shipping. 20-20-02 Assembly Instruction after Container Shipping...
Page 130 C A U T I O N In order to prevent the aircraft from nosing over the assembly has always to start with the empennage. N O T E In contrast to the instructions given in the respective Chapters don‘t reinstall these items before completion of the whole assembly.
Page 131 I M P O R T A N T After first flight check fuselage interior/exterior for fuel leaks. Check all bolts on fairings and cover sheets for tight fit.
Page 132 Chapter 24 Electrical Power...
Page 133 TABLE OF CONTENTS 24-00-00 GENERAL 24-30-00 DC-GENERATION 24-31-00 MAINTENANCE PRACTICES ..........................
Page 134 24-00-00 GENERAL...
Page 135 24-30-00 DC-GENERATION...
Page 137 24-31-00 MAINTENANCE PRACTICES I M P O R T A N T If replacement of wiring passing the firewall is neces- sary, renew the sealing of the bushing grooves and gaps at the engine side of the firewall. Use PRC-812 (Prod- ucts Research &...
Page 139 24-60-00 DC ELECTRICAL LOAD DISTRIBUTION...
Page 140 24-61-00 MAINTENANCE PRACTICES I M P O R T A N T If replacement of wiring passing the firewall is neces- sary, renew the sealing of the bushing grooves and gaps at the engine side of the firewall. Use PRC-812 (Prod- ucts Research &...
Page 141 24-61-02 Lever Switch Removal/Installation C A U T I O N Disconnect battery 24-61-03 Subminiature Pushbotton Switch Removal/Installation C A U T I O N Disconnect battery...
Page 142 Chapter 25 Equipment and Furnishings...
Page 143 TABLE OF CONTENTS 25-10-00 FLIGHTCOMPARTMENTS 25-15-00 MAINTENANCEPRACTICES...
Page 144 25-10-00 FLIGHT COMPARTMENTS 25-10-01 Front Seat 25-10-02 Rear Seat 25-10-03 Seat Belts...
Page 145 Strap Assembly Figure 1...
Page 146 Shoulder Strap Attachment Figure 2 25-10-04 Aircraft Document Bag...
Page 147 25-15-00 MAINTENANCE PRACTICES 25-15-01 Front Seat Removal/Installation 25-15-02 Rear Seat Removal/Installation...
Page 148 Chapter 27 Flight Controls...
Page 149 TABLE OF CONTENTS 27-00-00 GENERAL 27-01-00 MAINTENANCE PRACTICES 27-10-00 AILERONS 27-11-00 MAINTENANCE PRACTICES 27-20-00 RUDDER 27-21-00 MAINTENANCE PRACTICES 27-30-00 ELEVATOR AND TAB 27-31-00 MAINTENANCE PRACTICES...
Page 150 27-00-00 GENERAL Controls Figure 1 27-00-01 Free Play in the Control System * measured at the trailing edge and max. chord...
Page 151 Control Surface Deflections Figure 2...
Page 152 27-00-02 Control Rod Lengths Control Rod Measurement Figure 3 Control Rod Identification Figure 4 Control rod Measurements * clevis head at the rear control stick 801 mm 932 mm 520 mm 1884 mm 420 mm...
Page 153 27-01-00 MAINTENANCE PRACTICES N O T E When installing a bellcrank or control stick the spacer sleeve inside the bearing could be displaced as shown in Figure 5. Use a mandrel to adjust the spacer sleeve. Spacer Sleeve Displaced Figure 5 N O T E When installing a control surface use mandrels as shown in the following Figure 6 to preset the control surface.
Page 154 27-01-01 Control Rod Removal/Installation N O T E In case of removal of the control rod connecting the con- trol sticks also observe the instructions given in the Chapters 27-01-03 and -04. 27-01-02 Bellcrank Removal/Installation...
Page 155 Control Levers and Rods Removal/Installation Figure 7 27-01-03 Front Control Stick Removal/Installation...
Page 156 Front Control Stick Removal/Installation Figure 8 27-01-04 Rear Control Stick Removal/Installation...
Page 157 27-01-05 Torque Tube Removal/Installation 27-01-06 Control Rod Length Adjustment N O T E It might be necessary to adjust both rod ends to get the correct length. In this case the free thread of both rod ends should have the same length. I M P O R T A N T Observe that the rod ends joined to the rocker type bellcrank should be adjusted long enough not to obstruct...
Page 158 Control Rod Check Hole Figure 9...
Page 159 27-10-00 AILERONS...
Page 160 Aileron Control Figure 10...
Page 161 27-11-00 MAINTENANCE PRACTICES 27-11-01 Aileron Removal/Installation 27-11-02 Aileron Rigging...
Page 162 Trailing Edge Alignment Figure 11...
Page 163 27-11-03 Spade Rigging Spade Rigging Figure 12...
Page 164 27-20-00 RUDDER I M P O R T A N T This second stop must not be reached under normal operation conditions. Missallignment or exessive elon- gation of the rudder cabels will result in misuse of this second stop and a subsequent overload of the rudder bearing.
Page 165 Rudder Control Figure 13...
Page 166 27-21-00 MAINTENANCE PRACTICES I M P O R T A N T Perform checks 10-11 of "Flight Controls" presented in Chapter 05-20-04 after each maintenance work affect- ing the rudder control cables. 27-21-01 Rudder Removal/Installation 27-21-02 Bottom Hinge Bracket Removal/Installation 27-21-03 Bottom Hinge Bellcranks Removal/ Installation...
Page 167 27-21-04 Control Cable Removal 27-21-05 Control Cable Installation...
Page 168 I M P O R T A N T Clamping has to be performed in accordance with the Service Bulletin 300-1-93 and the Instruction No. 32 of the National Telephone Supply Co., Cleveland Ohio.
Page 169 I M P O R T A N T Clamping has to be performed in accordance with the Service Bulletin 300-1-93 and the Instruction No. 32 of the National Telephone Supply Co., Cleveland Ohio. I M P O R T A N T To prevent twisting the cables clamp the sleeves in the same plane.
Page 171 27-30-00 ELEVATOR AND TAB Trim Tab...
Page 173 27-31-00 MAINTENANCE PRACTICES 27-31-01 Elevator Removal/Installation 27-31-02 Trim Tab Removal/Installation 27-31-03 Elevator Rigging I M P O R T A N T Before beginning any adjustments, inspect control rods, levers and hinges for signs of wear or damage and check if control rod lengths correspond with the measurements given in Chapter 27-00-02.
Page 174 Lath on Chord Line Figure 15...
Page 175 27-31-04 Trim Tab Rigging Trim Tab Rigging Figure 16...
Page 176 Chapter 28 Fuel...
Page 177 TABLE OF CONTENTS 28-00-00 GENERAL 28-01-00 MAINTENANCE PRACTICES ................... .
Page 178 28-00-00 GENERAL...
Page 179 lö ösgsödfg dsfgdfg sdf fg sdfgs fdg s df s df sdfgsdfg sfdg s dfg s dfg s sdf sd Fuel System Figure 1...
Page 180 28-01-00 MAINTENANCE PRACTICES 28-01-01 Refueling/Defueling 28-01-02 Reduction of Fuel Tank Vapor Hazards General Precautions...
Page 181 W A R N I N G When fuel is being drained, there is little control over the release of fuel vapor. This vapor should be dissi- pated as quickly as possible. Compressed air or explo- sion-proof blowers may be used for the purpose. Air Ventilation W A R N I N G If flammable vapors from cleaning solvents are allowed...
Page 182 28-10-00 STORAGE...
Page 183 Storage Figure 2...
Page 184 28-11-00 MAINTENANCE PRACTICES 28-11-01 Center and Acro Tank Removal/Installation...
Page 185 28-11-02 Acro Tank Flop Tube Removal/Installation W A R N I N G Stripping solvents can be toxic and volatile. Use only in well ventilated areas. Avoid physical contact with sol- vent and do not inhale vapors. Keep solvent containers covered when not in use.
Page 186 28-11-03 Wing Tank Inspection Door Removal/Installation W A R N I N G Stripping solvents can be toxic and volatile. Use only in well ventilated areas. Avoid physical contact with sol- vent and do not inhale vapors. Keep solvent containers covered when not in use.
Page 187 28-11-04 Wing Tank Outlets Removal/Installation W A R N I N G Stripping solvents can be toxic and volatile. Use only in well ventilated areas. Avoid physical contact with sol- vent and do not inhale vapors. Keep solvent containers covered when not in use. Wing Tank Outlets Removal/Installation Figure 5...
Page 188 28-11-05 Center Tank Filler Neck Removal/Installation 28-11-06 Wing Tank Filler Neck Removal/Installation W A R N I N G Stripping solvents can be toxic and volatile. Use only in well ventilated areas. Avoid physical contact with sol- vent and do not inhale vapors. Keep solvent containers covered when not in use.
Page 189 28-11-07 Filler Neck Sealing Lip Replacement Filler Neck and Sealing Lip Removal/Installation Figure 6 28-11-08 Ventilation Line Replacement N O T E Use only, tubes and fittings as listed in the following.
Page 190 28-20-00 DISTRIBUTION...
Page 191 Distribution Figure 7...
Page 192 28-21-00 MAINTENANCE PRACTICES 28-21-01 Fuel Selector Valve Removal/Installation 28-21-02 Fuel Selector Valve Control Rod Removal/Installation...
Page 193 lö ösgsödfg dsfgdfg sdf fg sdfgs fdg s df s df sdfgsdfg sfdg s dfg s dfg s sdfgsfdgsdfg sdfgsfdg sdfgsdfg sdfgs sfdgggggggggggggggggggggggggggggggggggggggggggggggggggggggdfg sdf sd Fuel Selector Valve and Control Rod Figure 8...
Page 194 28-21-03 Gascolator Removal/Installation Gascolator Removal/Installation Figure 9...
Page 195 28-21-04 Electrical Boost Pump Removal/Installation Boost Pump Removal/Installation Figure 10...
Page 196 28-21-05 Fuel Line Replacement I M P O R T A N T If replacement of fuel lines passing the firewall is neces- sary, renew the sealing of the rubber grommet grooves and gaps at the engine side of the firewall. Use PRC- 812 (Products Research &...
Page 197 28-40-00 INDICATING...
Page 198 Indicating Figure 11...
Page 199 28-41-00 MAINTENANCE PRACTICES 28-41-01 Fuel Quantity Indicator Removal/Installation...
Page 200 28-41-02 Fuel Quantity Indicator Calibration (Center Tank) 28-41-03 Tubular Tank Unit (Center Tank) Removal/Installation W A R N I N G Stripping solvents can be toxic and volatile. Use only in well ventilated areas. Avoid physical contact with sol- vent and do not inhale vapors. Keep solvent containers covered when not in use.
Page 201 28-41-04 Lever-type Tank Unit (Wing Tank) Removal/Installation Lever-type Tank Unit (Wing Tank) Removal/Installation Figure 12 W A R N I N G Stripping solvents can be toxic and volatile. Use only in well ventilated areas. Avoid physical contact with sol- vent and do not inhale vapors.
Page 202 28-41-05 Float Wire Adjustment Float Wire Adjustment Figure 13 Float Wire Installation Figure 14...
Page 203 Fittings and washers Tubes Ventilation lines Figure 6A...
Page 204 Fittings and washers Hoses* Tubes Valves * Refer to Ch. 20-10-07 Fuel Lines Airframe Department Figure 10A, Sheet 1...
Page 205 Fittings and washers Hoses * Tubes Valves * Refer to Ch. 20-10-07 Fuel Lines Airframe Department Figure 10A, Sheet 2...
Page 206 EXTRA - FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 200 Chapter 31 Indication \ Recording System PAGE DATE: 1. July 1996 CHAPTER PAGE...
Page 207 EXTRA - FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 200 TABLE OF CONTENTS Chapter Title 31-00-00 GENERAL ................
Page 208 EXTRA - FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 200 31-00-00 GENERAL The Extra 200 is equipped with flight instruments in both cockpits. Instruments and placards can be provided with markings in either metric or English units (refer to Chapter11"Placards and Markings"). The colour markings in instruments follow US-FAR, part 23 recommendation.
Page 209 EXTRA - FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 200 31-10-00 INSTRUMENT AND CONTROL PANELS 31-10-01 Rear Instrument Panel The instrument panel of the rear cockpit carries the instru- ments, control switches and circuit breakers and is covered by a composite part. The panel and the cover are mounted on the steel frame with AN 526 C 1032 R8 bolts.
Page 210 EXTRA - FLUGZEUGBAU GmbH INSTRUMENT AND CONTROL PANELS SERVICE MANUAL EXTRA 200 Rear Instrument Panel Figure1 Pos. Item Starter Ammeter Air Speed Indicator " Magnetic Compass Acceleration Indicator (G-Meter) * CHT/EGT Indicator * Radio * & Oil Temperature Indicator Oil Pressure Indicator...
Page 211 EXTRA - FLUGZEUGBAU GmbH INSTRUMENT AND CONTROL PANELS SERVICE MANUAL EXTRA 200 31-10-02 Front Instrument Panel The front instrument panel (1, Figure 2) incorporates shock mounts and carries an altimeter (2) and an air speed indicator (3). Front Instrument Panel Figure 2 PAGE DATE: 1.
Page 212 EXTRA - FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 200 31-15-00 MAINTENANCE PRACTICES I M P O R T A N T If replacement of the manifold, fuel, and oil pressure lines inside the engine department is necessary, cover the pressure lines with AEROQUIP AE102 fire sleeves as per Chapter 20-10-07 in case of AEROQUIP hoses are used.
Page 213 EXTRA - FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 200 31-15-02 Front Instrument Panel Removal/Installation C A U T I O N Hold instruments and panel by hand to prevent from falling down when removing the instrument panel at- tachment screws. 1 Remove the AN526 C-1032-R6 instrument panel at- tachment screws (3, Figure 4).
Page 214 EXTRA - FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 200 Front Instrument Panel Removal/Installation Figure 4 PAGE DATE: 1. July 1996 CHAPTER PAGE...
Page 215 CENTRAL WARNING SYSTEMS 31-50-01 Stall Warning System The EXTRA 200 is equipped with a stall warning system as standard. This system is designed to warn the pilot by an audible alarm horn, which is fitted in the back of the front seat.
Page 216 EXTRA - FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 200 Chapter 32 Landing gear PAGE DATE: 1. July 1996 CHAPTER PAGE...
Page 217 EXTRA - FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 200 TABLE OF CONTENTS Chapter Title 32-10-00 LANDING GEAR ................... . .
Page 218 EXTRA - FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 200 32-10-00 LANDING GEAR The EXTRA 200 is designed as a conventional tail wheel airplane, with an unretractable landing gear. The landing gear consists of a 2 wheel main landing gear and a tail wheel.
Page 219 EXTRA - FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 200 32-11-00 MAINTENANCE PRACTICES 32-11-01 Main Landing Gear Removal/Installation Refer to Figure 2 1 Remove the engine cowling, the landing gear cuffs and the bottom covering sheet as per chapter 51-00-01. 2 Shore the aircraft as per Chapter 07-20-00 3 Drain brake system.
Page 220 EXTRA - FLUGZEUGBAU GmbH MAINTENANCE PRACTICES SERVICE MANUAL EXTRA 200 Top Half of the Mounting Clamp Main Landing Gear Mounting Figure 2 32-11-03 Tail spring Removal/Installation 1 Shore the tail as per Chapter 07-20-02. 2 Remove the tail cone access panel per Ch. 51-00-01.
Page 221 EXTRA - FLUGZEUGBAU GmbH MAINTENANCE PRACTICES SERVICE MANUAL EXTRA 200 32-11-04 Tail Wheel Fork Assembly Removal/Installation 1 Shore the tail as per Chapter 07-20-02. 2 Disconnect the connector spring kit (7, Figure 3) from the rudder bootom hinge bellcrank by removing the attachment bolts (8).
Page 222 EXTRA - FLUGZEUGBAU GmbH MAINTENANCE PRACTICES SERVICE MANUAL EXTRA 200 Tail Wheel, Fork and Spring Figure 3 PAGE DATE: 1. July 1996 CHAPTER PAGE...
Page 223 EXTRA - FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 200 32-40-00 WHEELS AND BRAKES 32-40-01 General The main wheels have standard brand 500x5 rims, six-ply rated 5.00-5-tyres with tubes, according to FAA Standard TSO-C62. Cleveland 40-151 wheels with 30-164 brake assemblies are used. The main wheels are covered with glas fibre designed fairings of which Figure 4 shows the layer sequence.
Page 224 EXTRA - FLUGZEUGBAU GmbH WHEELS AND BRAKES SERVICE MANUAL EXTRA 200 General Layer Sequence Wheel Fairing up to Ser. No. 16 Figure 4 PAGE DATE: 1. July 1996 PAGE DATE: 15. December 1999 CHAPTER PAGE DATE: 1. June 1996 PAGE...
Page 225 EXTRA - FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 200 Brake System Figure 5 PAGE DATE: 1. July 1996 CHAPTER PAGE...
Page 226 EXTRA - FLUGZEUGBAU GmbH WHEELS AND BRAKES SERVICE MANUAL EXTRA 200 General 32-41-00 MAINTENANCE PRACTICIES 32-41-01 Master Cylinder Removal/Installation 1 Drain the brake system. 2 Disconnect the fuel lines. 3 Fix the master cylinder spring using a mounting aid as shown in Figure 6 (Cleveland master cylinder only).
Page 227 EXTRA - FLUGZEUGBAU GmbH WHEELS AND BRAKES SERVICE MANUAL EXTRA 200 G e n e r a l Layer Sequence Wheel Fairing from Ser. No. 17 Figure 3, Sheet 2 PAGE DATE: 1. July 1996 CHAPTER CHAPTER 32 PAGE DATE: 15. December 1999...
Page 228 EXTRA - FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 200 Chapter 33 Lights PAGE DATE: 1. July 1996 CHAPTER PAGE...
Page 229 EXTRA - FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 200 TABLE OF CONTENTS Chapter Title 33-10-00 FLIGHT COMPARTMENT ..............
Page 230 EXTRA - FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 200 33-10-00 FLIGHT COMPARTMENT For controlling the generator function a low voltage moni- tor is optionally installed at the rear instrument panel. The indicator is dimmable and has a built-in bulb testing device („press to test“).
Page 231 From the rear instrument panel the wiring follows the respective steel tubes of the fuselage. As an option the Extra 200 is equipped with a dual strobe light combined with a navigation light system. The lighting units (1, Figure 1) installed at the wing tips incorporate the...
Page 232 EXTRA - FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 200 33-41-00 MAINTENANCE PRACTICES 33-41-01 Navigation/Strobe Lights Removal/Installation W A R N I N G High Voltage! Wait 5 minutes after shutting off before starting any work on the strobe light system. 1 Disconnect the battery and wait 5 minutes.
Page 233 EXTRA - FLUGZEUGBAU GmbH MAINTENANCE PRACTICES SERVICE MANUAL EXTRA 200 3 Remove the AN 526 C 1032 R8 bolts (9, Figure 1) and disconnect the ground bonding lead. 4 Pull out the power supply (10) 2 centimetres and re- move.
Page 234 EXTRA - FLUGZEUGBAU GmbH MAINTENANCE PRACTICES SERVICE MANUAL EXTRA 200 Navigation/Strobe Lights Removal/Installation Figure 1 PAGE DATE: 1. July 1996 CHAPTER PAGE...
Page 235 Chapter 34 Navigation...
Page 236 TABLE OF CONTENTS 34-00-00 GENERAL 34-10-00 FLIGHT ENVIRONMENT DATA ....................
Page 237 34-00-00 GENERAL...
Page 238 34-10-00 FLIGHT ENVIRONMENT DATA 34-10-01 Pitot/Static System Pitot/Static Drain Figure 1...
Page 239 34-10-02 Altimeter 34-10-03 Airspeed Indicator...
Page 240 34-15-00 MAINTENANCE PRACTICES 34-15-01 Pressure Head Removal/Installation 34-15-02 Pitot Head Attachment Block Removal/Installation...
Page 241 34-15-03 Altimeter Removal/Installation N O T E For removal/installation of the front altimeter refer to Chapter 31. 34-15-04 Airspeed Indicator Removal/Installation N O T E For removal/installation of the front airspeed indicator refer to Chapter 31.
Page 242 34-20-00 ATTITUDE AND DIRECTION 34-20-01 Magnetic Compass 34-20-02 Turn and Bank Indicator...
Page 243 34-25-00 MAINTENANCE PRACTICES 34-25-01 Magnetic Compass Removal/Installation 34-25-02 Turn and Bank Indicator Removal/Installation...
Page 244 Chapter 51 Standard Practices and Structures - General...
Page 245 TABLE OF CONTENTS 51-00-00 GENERAL 51-10-00 INVESTIGATION 51-30-00 MATERIALS 51-60-00 CONTROL SURFACE BALANCING 51-70-00 REPAIRS...
Page 246 51-00-00 GENERAL 51-00-01 Access Panel Identification N O T E Access panels partly overlap. Remove the front panels first. Main Fuselage Cover Removal/Installation...
Page 247 Access Panel Identification Figure 1...
Page 248 Position Item Top half of the engine cowling Oil filler access door (non-removable) Main fuselage cover Instrument cover Tail fairing Tail cone access panel (RH) Tail side skin (LH/RH) Cuff (LH/RH) Wheel speed fairing (LH/RH) Bottom half of the engine cowling Air inlet screen Spinner From Ser.
Page 249 W A R N I N G Only the Damages Classes 2, 3 and 4 may be repaired by qualified personnel. In case of Damage Class 1 it has to be contacted EXTRA-FLUGZEUGBAU GmbH. Damage Class 1: Damage Class 2:...
Page 250 Refer to Chapter "51-10-01 Damage Classification". I M P O R T A N T Only the Damages Classes 2, 3 and 4 may be repaired by qualified personnel. In case of Damage Class 1 it has to be contacted EXTRA-FLUGZEUGBAU GmbH.
Page 251 51-30-00 MATERIALS 51-30-01 Composite Parts I M P O R T A N T Only approved materials have to be used for the repair of composite parts. Epoxy-system Glass fibre fabrics WLB-No.* weave weigh Style US-style LN 9169 patterns g/m² 90070 8.4505.60 1610...
Page 252 Carbon fibre fabrics WLB-No.* weave weight Style CCC US-style DIN 65147 patterns g/m² 8,3507;80 none plain 8,3520;80 none twill 2/2 none cross-twil Glass rovings: Carbon rovings:...
Page 253 Core material Filler material for resin: Paint:...
Page 254 51-30-02 Metal Components I M P O R T A N T Only approved materials have to be used for the repair of metal components. Steel tubing: Steel sheet metal :...
Page 255 Paint: 51-30-03 Aluminium Components Aluminium sheet metal: Control rod tubings:...
Page 256 Paint: Aluminium hardware metal (brackets, pedestals, castings, etc.): Paint:...
Page 257 51-60-00 CONTROL SURFACE BALANCING 51-60-01 Weighing and Determination of Control Surface Moments Balancing Mandrels Figure 2 Procedure...
Page 258 I M P O R T A N T If values exceed the given tolerances in Figure 4 contact the manufacturer before beginning any changes of con- trol surfaces.
Page 259 Determination of Control Surface Moments Figure 3...
Page 260 EA 200 Permissible Permissible Item Weight (W) Moment (M) from / to from / to Aileron 5.4 / 6.55 0 / 68 (incl. mass balance and spade) Rudder 4.5 / 6.55 45 / 135 (incl. mass balance) Elevator 6.2 / 7.2 140 / 225 (incl.
Page 261 51-70-00 REPAIRS 51-70-01 Repair of Reinforced Glass and Carbon Fibre Components I M P O R T A N T Repair of composite parts has to be carried out only by qualified and authorized personnel. I M P O R T A N T The resin-hardener mixture ratio must be precisely maintained (+0.5%).
Page 262 C A U T I O N Too high temperature will cause large air bubbles in the laminate. Local overtemperature can be prevented by using a foil tent which leads the hot air stream. I M P O R T A N T After repair of control surfaces, check for proper bal- ance ( refer to chapter 27, Flight Controls).
Page 263 51-70-02 Repair of Sandwich Material a) Minor surface damage Ratio (laminate thickness : overlay length) min. 1: 50 (refer to Figure 5). Minor surface damage Figure 5...
Page 264 I M P O R T A N T Repair area must be clean of dirt, dust and grease! I M P O R T A N T Remove the plastic foil after each positioning process.
Page 265 Curing cycle resin L20/SL Figure 6 C A U T I O N Sand only the edge thickness of repair laminate Level Sanding of Surrounding Area Figure 7 N O T E For painting of the repair area refer to Chapter 51-70- b) Damage of complete sandwich...
Page 266 I M P O R T A N T Overlap length of the upper laminate should not be less than 1/50; (ratio: laminate thickness / overlap length). W A R N I N G Carbon-tetracloride or Acetone used for cleaning re- pair areas are flammable liquids and should be used with proper ventilation and safety equipment.
Page 267 Damage of Complete Sandwich Figure 8 I M P O R T A N T Remove the plastic foil after each positioning process. N O T E After the pre-curing period at room temperature, the repaired area has to be cured according the tempera- ture cycle as shown on Figure 6.
Page 268 51-70-03 Repair of Laminates a) Minor damage (laminate thickness : scarf length) approx. 1: 50. C A U T I O N Repair area must be free of dirt, dust and grease. N O T E Lay out the required number and size of fabric pieces on a piece of colored plastic foil and wet them with resin mixture.
Page 269 I M P O R T A N T Ratio (laminate thickness : scarf length) approx. 1: 50. I M P O R T A N T Repair area must be free of dirt, dust and grease.
Page 270 N O T E 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. I M P O R T A N T Remove the plastic foil after each positioning process.
Page 271 I M P O R T A N T ratio (laminate thickness : scarf length) approx. 1: 50. I M P O R T A N T Repair area must be free of dirt, dust and grease. N O T E Lay out the required number and size of fabric pieces on a piece of colored plastic foil and wet them with resin mixture.
Page 272 In all cases, the repair of a spar must be considered as a large-scale repair with a Damage Class 1 (Refer to Chapter 51-10- 01 Damage Classification"). EXTRA-FLUGZEUGBAU GmbH has to be contacted prior to repair!
Page 273 2A". I M P O R T A N T Alterations or repair of the airplane must be accom- plished by licensed personnel. Consult EXTRA- FLUGZEUGBAU GmbH in case of doubt about a re- pair not specifically mentioned there. N O T E If welding work must be performed, use only the TIG procedure (Tungsten Inert Gas).
Page 274 51-70-06 Painting of Composite Parts W A R N I N G Coating materials may cause sensitization by inhala- tion and skin contact. Hardeners and coating materials ready for use can have an irritant and sensitizing effect upon the skin and respiratory tracts and cause allergic reactions.
Page 275 51-70-07 Aluminium and Steel Components Refinishing Degreasing W A R N I N G Cleaning solvents can be toxic and volatile. Use only in well ventilated areas. Avoid physical contact with sol- vent and do not inhale vapors. Keep solvent containers covered when not in use.
Page 276 Paint Removal W A R N I N G Stripping solvents can be toxic and volatile. Use only in well ventilated areas. Avoid physical contact with solvent and do not inhale vapors. Keep solvent containers covered when not in use. C A U T I O N Before stripping parts, remove all fittings, O-rings, nuts, bolts, washers, pistons, bearing cups, etc.
Page 277 Repainting...
Page 278 EXTRA - FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 200 Chapter 53 Fuselage PAGE DATE: 1. July 1996 CHAPTER PAGE...
Page 279 EXTRA - FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 200 TABLE OF CONTENTS Chapter Title 53-00-00 GENERAL ....................... .
Page 280 EXTRA - FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 200 53-00-00 GENERAL The fuselage structure of the EXTRA 200 consists of a TIG- welded steel tube construction integrating the wing and empennage connections (refer to Figure 1). The firewall consisting of stainless steel separates the fuselage from the engine compartment.
Page 281 EXTRA - FLUGZEUGBAU GmbH GENERAL SERVICE MANUAL EXTRA 200 Fuselage Steel Tube Design Figure 1 PAGE DATE: 1. July 1996 CHAPTER PAGE...
Page 282 EXTRA - FLUGZEUGBAU GmbH GENERAL SERVICE MANUAL EXTRA 200 Layer Sequence Top Half of the Engine Cowling Figure 2 PAGE DATE: 1. July 1996 CHAPTER PAGE...
Page 283 EXTRA - FLUGZEUGBAU GmbH GENERAL SERVICE MANUAL EXTRA 200 Layer Sequence Bottom Half of the Engine Cowling Figure 3 PAGE DATE: 1. July 1996 CHAPTER PAGE...
Page 284 EXTRA - FLUGZEUGBAU GmbH GENERAL SERVICE MANUAL EXTRA 200 Layer Sequence Main Fuselage Cover Figure 4 PAGE DATE: 1. July 1996 CHAPTER PAGE...
Page 285 EXTRA - FLUGZEUGBAU GmbH GENERAL SERVICE MANUAL EXTRA 200 Layer Sequence Bottom Fuselage Cover and Cuffs Figure 5 PAGE DATE: 1. July 1996 CHAPTER PAGE...
Page 286 EXTRA - FLUGZEUGBAU GmbH GENERAL SERVICE MANUAL EXTRA 200 Layer Sequence Tail Fairing up to Ser. No. 20 Figure 6, Sheet 1 Layer Sequence Tail Fairing from Ser. No. 21 Figure 6, Sheet 2 PAGE DATE: 15. December 1999 PAGE DATE: 1. July 1996...
Page 287 EXTRA - FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 200 53-01-00 MAINTENANCE PRACTICES 53-01-01 Canopy Removal/Installation 1 Open canopy. C A U T I O N Support the canopy by hand before disconnecting the opening limiter strap. 2 Remove the attachment bolt of the opening limiter strap.
Page 288 Chapter 55 Stabilizers...
Page 289 Table of Contents 55-00-00 GENERAL 55-21-00 MAINTENANCE PRACTICES ...................
Page 290 55-00-00 GENERAL...
Page 291 Layer Sequence Horizontal Tail Figure 1, Sheet 1...
Page 292 Layer Sequence Horizontal Tail Figure 1, Sheet 2...
Page 293 Layer Sequence Vertical Tail Figure 2, Sheet 1...
Page 294 Layer Sequence Vertical Tail Figure 2, Sheet 2...
Page 295 55-21-00 MAINTENANCE PRACTICES 55-21-01 Horizontal Stabilizer Removal Installation C A U T I O N Make shure that the trim bowden cable will not be dam- aged when installing the horizontal stabilizer.
Page 296 Horizontal Stabilizer Removal/Installation Figure 3...
Page 297 55-21-02 Vertical Stabilizer Removal C A U T I O N Do not put the fin too far backward, the antenna could be damaged. Installation C A U T I O N Do not put the fin too far backward, the antenna could be damaged.
Page 298 Vertical Stabilizer Removal/Installation Figure 4...
Page 299 EXTRA - FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 200 Chapter 57 Wings PAGE DATE: 1. July 1996 CHAPTER PAGE...
Page 300 EXTRA - FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 200 TABLE OF CONTENTS Chapter Title 57-00-00 GENERAL ....................... .
Page 301 EXTRA - FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 200 57-00-00 GENERAL The wing consists of a one-piece, dual chamber main spar with carbon fibre roving caps and carbon fibre webs. For the spar core PVC foam is used. The wing shells are a honeycomb sandwich construction with carbon fibre lami- nates.
Page 302 EXTRA - FLUGZEUGBAU GmbH GENERAL SERVICE MANUAL EXTRA 200 Layer Sequence Wing Figure 1, Sheet 1 PAGE DATE: 1. July 1996 PAGE DATE: 15. December 1999 CHAPTER PAGE...
Page 303 EXTRA - FLUGZEUGBAU GmbH GENERAL SERVICE MANUAL EXTRA 200 Layer Sequence Wing Figure 1, Sheet 2 PAGE DATE: 15. December 1999 PAGE DATE: 1. July 1996 CHAPTER PAGE...
Page 304 EXTRA - FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 200 57-05-00 MAINTENANCE PRACTICES 57-05-01 Wing Removal Reverse procedure of installation omitting step 19. Installation 1 Remove the canopy per Chapter 53, the engine cowl- ings and the main fuselage cover per Chapter 51.
Page 305 EXTRA - FLUGZEUGBAU GmbH MAINTENANCE PRACTICES SERVICE MANUAL EXTRA 200 Wing W A R N I N G Beware not to get jammed between wing and fuselage. 7 Slide wing down into fuselage attachment brackets (3). 8 Preinstall LN 9037-08042 auxiliary spar attachment bolts (1) from front to rear.
Page 306 EXTRA - FLUGZEUGBAU GmbH MAINTENANCE PRACTICES SERVICE MANUAL EXTRA 200 Wing 12 Secure main spar tubular bolts with LN 9038-08020K bolts (2), DIN912 M8 and aluminum 30x11x4 wash- ers. Torque security bolts for fastening and subse- quently safety wire. 13 Fasten auxiliary spar attachment bolts.
Page 307 EXTRA - FLUGZEUGBAU GmbH MAINTENANCE PRACTICES SERVICE MANUAL EXTRA 200 Wing Wing Removal/Installation Figure 3 PAGE DATE: 1. July 1996 CHAPTER PAGE...
Page 308 EXTRA - FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 200 57-35-00 MAINTENANCE PRACTICES 57-35-01 Wing Tip Panel Removal/Installation (if dual strobe light and navigation light system is installed) . Refer to Figure 1 of Chapter 33. W A R N I N G High Voltage! Wait 5 minutes after shutting off before starting any work on the strobe light system.
Page 309 EXTRA - FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 200 57-60-00 AILERONS The ailerons are constructed in the same manner as the wing but with single chamber spar. They are supported at three points in spherical bearings pressed into aluminium brack- ets. Furthermore the ailerons are equipped with "glass fibre laminate spades"...
Page 310 EXTRA - FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 200 Note: measurements are given in mm Layer Sequence Ailerons Figure 4 PAGE DATE: 1. June 1997 PAGE DATE: 1. July 1996 CHAPTER PAGE...
Page 311 EXTRA - FLUGZEUGBAU GmbH GENERAL SERVICE MANUAL EXTRA 200 Layer Sequence Wing Figure 1, Sheet 3 PAGE DATE: 1. July 1996 PAGE DATE: 15. December 1999 CHAPTER CHAPTER 57 PAGE PAGE...
Page 312 EXTRA - FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 200 Chapter 61 Propeller PAGE DATE: 1. July 1996 CHAPTER PAGE...
Page 313 EXTRA - FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 200 TABLE OF CONTENTS Chapter Title 61-00-00 GENERAL .......................
Page 314 EXTRA - FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 200 61-00-00 GENERAL The EXTRA 200 is equipped with a MTV-12-B-C/C 183- 17e propeller. Maintenance work or overhaul of the propel- ler requires consultation of the propeller manufacturer MT- Propeller (refer to Chapter 01).
Page 315 Chapter 72 Engine...
Page 316 TABLE OF CONTENTS 72-00-00 GENERAL 72-10-00 ENGINE ........................
Page 317 72-00-00 GENERAL I M P O R T A N T If replacement of the engine control cables is necessary, renew the sealing of the bushing grooves and gaps at the engine side of the firewall. Use PRC-812 (Products Research & Chemical Corporation, USA) firewall seal- ant.
Page 318 72-10-00 ENGINE...
Page 319 Chapter 79 Oil System...
Page 320 Table of contents 79-00-00 GENERAL ....................... . 79-10-00 INVERTED OIL SYSTEM .
Page 321 79-00-00 GENERAL I M P O R T A N T Before making installations and repairs to the aircraft plumping, it is important to make accurate identifica- tion of plumping materials. Refer to the respective Fig- ures in this Chapter. I M P O R T A N T If replacement of oil lines is necessary, cover the oil lines of the engine department with AEROQUIP AE102 fire...
Page 322 79-10-00 INVERTED OIL SYSTEM 1 AEROQUIP 637/ MIL-H 6000+ Hose clips PN: PC-67207A1 hose lenght: 520mm 2 AEROQUIP 637/ MIL-H 6000+ Hose clips PN: PC-67207A2 hose lenght: 350mm 3 AEROQUIP* 303-10 + Hose Fittings 491-10D PN: PC-67207A3 hose lenght: 720mm 4 AEROQUIP* 303-10 + Hose Fittings 491-10D PN: PC-67207A4 hose lenght: 530mm...
Page 323 1 AN 842-12D PN: PC-00175 2 AN 844-12D PN: PC-00881 3 AN 823-10D PN: PC-00165 4 AN 823-10D PN: PC-00165 5 AN 816-10D PN: PC-00157 6 AN 816-10D PN: PC-00157 7 Christen 804-S PN: PC-700031 8 AN 823-10D PN: PC-00165 9 LW-14148 PN: PC-700030 10 AN 823-10D (mod.)
Page 324 79-20-00 OIL COOLER 1 AEROQUIP 303-8 + Hose Fittings 491-8D PN: PC-67207A7 hose lenght: 1080 mm 2 AEROQUIP 303-8 + Hose Fittings 491-8D PN: PC-67207A8 hose lenght: 1040 mm 3 AN 823-8D PN: PC-00869 4 AN 823-8D PN: PC-00869 5 AN 822-8D PN: PC-00163 6 AN 822-8D PN: PC-00163...
Page 325 EXTRA - FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 200 Chapter 91 Charts PAGE DATE: 1. July 1996 CHAPTER PAGE...
Page 326 EXTRA - FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 200 Table of Contents Chapter Title 91-00-00 GENERAL ....................... .
Page 327 EXTRA - FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 200 91-00-00 GENERAL This chapter provides an electrical wiring diagram neces- sary to maintain the aircraft electrical power sytem. PAGE DATE: 1. July 1996 CHAPTER PAGE...
Page 328 EXTRA - FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 200 91-10-00 ELECTRICAL WIRING DIAGRAMS Wire Table Figure 1 PAGE DATE: 1. July 1996 CHAPTER PAGE...
Page 329 EXTRA - FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 200 Chapter 95 Special Equipment PAGE DATE: 1. July 1996 CHAPTER PAGE...
Page 330 EXTRA - FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 200 TABLE OF CONTENTS Existing Title EXHAUST ENDPIPE SILENCER STEERABLE TAIL WHEEL ELECTRICAL ACTUATED RUDDER PEDAL ADJUSTMENT ELT POINTER 3000 P-1000 DIGITAL RPM INDICATOR EXTERNAL POWER SUPPLY HEATING SYSTEM AIR TOW RELEASE LONGE RANGE TANK PAGE DATE: 1.

Extra 200 Service Manual

Quick Links

Need help?

Questions and answers

Related Manuals for Extra 200

Summary of Contents for Extra 200