Chapter 20 Standard practices - Airframe
Contents
1. after heat treatment and cadmium plated per speci fication QQ P 416A Type II Class 3 For the Extra 200 bolts with shank drilled for cotter pin or drilled head for safety wire are used The adding letter A after the dash number specifies bolts with undrilled shank For bolts with drilled head a letter H is added after the AN number The length of AN aircraft bolts is measured from under the head to the end of the shank Example AN3 5A Bolt Head Identification AN hex head bolt Diameter 4 8 mm Length 15 9 mm Undrilled shank Letter Identification of Manufacturer not always given Cross Alloy Steel Letter also adjected DIN Bolts Hex head DIN 931 DIN 933 and hex socket head DIN 912 bolts are standard bolts made of steel with undrilled shank The surface treatment is chromatized yellow Unlike the DIN 931 and DIN 912 the shank ofa DIN 933 bolt goes up to the head The numerical code shown on the head of a DIN bolt specifies the strength type Also most bolts will beara wide variety of finitials or symbols which identify the manufacturer Measure the diameter and length to specify the type dimension of the DIN bolt The length of DIN bolt is measured from under the head to the end of the shank PAGE DATE 1 July 1996 CHAPTER 20 PAGE 5 EXTRA FLUGZEUGBAU GmbH STANDARD PRACTICES AIRFRAME SERVICE MANUAL EXTRA 200 Type of Bolts Example DIN 931 M10 x 80 8 8 a i Bolt Head Id2. covered with AEROQUIP AE102 fire sleeves The correct size of fire sleeves can be taken from the following table 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 Fittings Generally AN fittings are used in the Extra 200 for the oil lubrication the fuel system and the brake system the latter up to Ser No 21 All these fittings are made of aluminium alloy and are colored blue 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 hose The material code letter Aluminum alloy code D follows the dash number Example Elbow AN 822 8D Apply Loctite 577 on all National Pipe Threads NPT before installation PAGE DATE 15 December 1999 CHAPTER 20 PAGE 11 EXTRA FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 200 20 20 00 20 20 01 NOTE 20 20 02 ASSEMBLY INSTRUCTION General Make appropriate logbook entry of compliance with this Assembly Instruction after Container Shipping In case of the aircraft is delivered in a container it has to be assembled on arrival For assembly of aircraft main components follow the instructions as outlined in the Chapter 20 20 02 These instructions can not replace the skill craftsmans
3. EXTRA FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 200 Chapter 20 Standard practices Airframe PAGE DATE 1 July 1996 CHAPTER 20 PAGE 1 EXTRA FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 200 Chapter 20 00 00 20 10 00 20 10 01 20 10 02 20 10 03 20 10 04 20 10 05 20 10 06 20 10 07 20 10 08 20 20 00 20 20 01 20 20 02 TABLE OF CONTENTS Title GENE RAG eneas E OS EES 3 STANDARD PRACTICES AIRFRAME 4 TYPEOF BOLS kerensa IE 4 Width Across Flats for Metric Bolts 6 ROP GIGS Vale Se ir r TTE E 7 Special Torque Values ec ccres ace tinscnircnecstsnanen mccain 8 Measuring Techniques 2 0 9 Coin 2 0 0 101 searen e n eee E ee 9 FleXIDIE HOSE seen Rea ere e A oO ER ere 10 Fittings tier ae et een oe eT eee 11 ASSEMBLY INSTRUCTION 12 General 12 Assembly Instruction after Container Shipping 12 PAGE DATE 1 July 1996 CHAPTER 20 PAGE 2 EXTRA FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 200 20 00 00 GENERAL The design of the airframe is according to standard proce dures and requires no special tools or procedures for main tenance For that reason only the bolts used in the Extra 200 with relevant torque values and measuring techniques are described in the following PAGE DATE 1 July 1996 CHAPTER 20 PAGE 3 EXTRA FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 200 20 10 00 20 10 01 STANDARD PRACTICES AIRFRAME Type of Bolts For the Extra 200 LN bolts LN Luftfahrt Norm AN bol
4. ance with MT Propeller in stallation instructions E 124 latest revision Remove tail weight Check if all switches are in Off position and connect battery Perform operational check of electrical equipment Shut off master switch after completion Perform operational check and rigging of control sys tem Inspect fluid filled lines for leaks Check security of main spar bolts Install wheel fairings main fuselage cover and rear sup port angle canopy engine cowlings and access pan els Refer to Chapter 51 00 01 and 53 Check all control surfaces for freedom of movement and security Perform a compass compensation according to Air craft Inspection and Repair FAA AC 43 13 Check correct servicing of aircraft Perform an engine run up Refer to Chapter 05 20 04 Scheduled Maintenance Checks Start the engine in accordance with the Pilot s Operating Handbook and Airplane Flight Manual POH Inspect aircraft for foreign objects Final inspection by licensed aircraft inspector After first flight check fuselage interior exterior for fuel leaks Check all bolts on fairings and cover sheets for tight fit PAGE DATE 1 July 1996 CHAPTER 20 PAGE 14
5. entification Standard hex head bolt Metric thread size M10 Length 80mm 3 15 Strength type 8 8 Bolt Head olt Head 931 DIN 933 Identification of manufacturer O Strength type 8 8 resp 12 9 20 10 02 Width Across Flats for Metric Bolts Thread diameter Width across flats PAGE DATE 1 July 1996 CHAPTER 20 PAGE 6 EXTRA FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 200 STANDARD PRACTICES AIRFRAME 20 10 03 IMPORTANT Torque Values Nuts except of counter nuts are mainly stop nuts according to LN 9348 or self locking nuts according to AN 363 a Standard torque values allowed for bolts and nuts accord ing to DIN and LN must be adhered to as follows Metric thread size Torque value in Ibs 144 148 M10 261 287 M12x1 5 452 504 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 in Ibs 9 16 18 88 1 67 8 270 300 290 410 480 600 On all bolt connections the specified torque and lock ing method must be observed Do not reuse stop nuts if they can be run up finger tight PAGE DATE 1 July 1996 CHAPTER 20 PAGE 7 EXTRA FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 200 STANDARD PRACTICES AIRFRAME 20 10 04 IMPORTANT Special Torque Values Special torque values for the following items must be adhered to Tor
6. hip and sound technical knowledge of qualified personnel In case of doubt or lack of information the manufacturer of the respective component should be contacted for advice Unless otherwise specified all bolts and connections should be torqued as listed in Chapter 20 10 03 At some locations special torque values considered necessary Refer to Chap ter 20 10 04 The stated direction Front and Rear are to be considered in respect of pilot s seating direction Assembly Instruction after Container Shipping Complete each step of the assembly procedure in the order shown below 1 Check the condition of fastening of the aircraft com ponents in the container Note any damage 2 Remove the fuselage engine assembly from the con tainer Prevent the aircraft from nosing over by keep ing down the tail 3 Weight the tail per Chapter 07 4 Remove the aircraft components out of the container Small parts hardware spinner dome and the wheel fairings You find in the cockpit PAGE DATE 1 July 1996 CHAPTER 20 PAGE 12 EXTRA FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 200 ASSEMBLY INSTRUCTION Assembly Instruction after Container Shipping CAUTION NOTE 5 Inspect all removed items for damage prior to assem bly Damaged items have to be replaced or if possible repaired according to Chapter 51 In order to prevent the aircraft from nosing over the assembly has always to start with the empennage 6 Prior to asse
7. mbly remove engine cowlings canopy main fuselage cover including the rear support angle per Chapters 51 and 53 In contrast to the instructions given in the respective Chapters don t reinstall these items before completion of the whole assembly 7 Remove provisional attached rudder and vertical sta bilizer per Chapters 27 and 55 Install horizontal stabilizer with elevator per Chapter 55 The procedure described there is also applicable to the installation of the complete horizontal tail Con sider to connect the ground bonding lead of the eleva tor too Connect elevator push pull rod actuator lever per Chap ter 27 01 01 Connect trim wire to the tab actuator lever using fitted clamp Inspect for full travel and elevator deflection in rela tion to stick movement Inspect for full travel and trim tab deflection in rela tion to trim handle movement Install the vertical stabilizer per Chapter 55 Reinstall rudder to the vertical stabilizer per Chapter 27 21 01 Inspect for full travel and rudder deflection in relation to rudder pedal movement Install the wing per Chapter 57 Install navigation strobe lights per Chapter 33 41 01 PAGE DATE 1 July 1996 CHAPTER 20 PAGE 13 EXTRA FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 200 ASSEMBLY INSTRUCTION Assembly Instruction after Container Shipping IMPORTANT 2 22 23 24 25 26 27 28 29 30 31 Install propeller in accord
8. of the cover or braid from the inner tube cracks hardening lack of flexibility and excessive cold flow are apparent sign 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 The entire assembly must be replaced if failure occurs in a flexible hose before the time limit refer to Chapter 05 10 02 Overhaul Schedule of the hose is achieved Obtain a new hose assembly of the correct size and length complete with factory installed end fittings Installation of Flexible Hose Assemblies The flexible hose must not be twisted on installation since this reduces the life of the hose considerably and may loosen the fittings Twisting of the hose can be determined from the identification stripe running along its length The minimum bend radius for flexible hose varies accord ing 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 consider ably below its rated value PAGE DATE 15 December 1999 CHAPTER 20 PAGE 10 EXTRA FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 200 STANDARD PRACTICES AIRFRAME Flexible Hose NOTE 20 10 08 NOTE The flexible hose should be installed so that it will be subject to a minimum of flexing during operation The AEROQUIP hoses inside the engine compartment are to be
9. que value Nm in Ibs Engine Mounting AN7 36A Metal Stop Nut NAS 363C 720 Engine Mount to Fuselage Din 912 M12x160 12 9 Longeron Cutout Bridge d Bolts DIN 912 M8x180 8 8 Stop Nut LN 9348 08 Lower Bolt DIN 912 M10x230 8 8 Stop Nut LN 9348 10 Horizontal Stabilizer Front Spar Bolts Bolt LN 9037 10054 Stop Nut LN 9348 10 Horizontal Stabilizer Rear Spar Bolts Bolt LN 9037 10042 Stop Nut LN 9348 08 Vertical Stabilizer Rear Spar Bolt Bol LN 9037 10042 Stop Nut LN 9348 10 Wing Main Spar Safety Bolts 15 Bolt LN 9038 K 08020 Brake Back Plate Bolts Cleveland 133 Refer to Cleveland Maintenance Manual Wheel Assembly Bolts Cleveland Torque for Engine Refer to Lycoming Overhaul Manual Torque for Propeller See MT propeller Installation Manual E 124 On all bolt connections the specified torque and lock ing method must be observed Do not reuse stop nuts PAGE DATE 1 July 1996 CHAPTER 20 PAGE 8 EXTRA FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 200 STANDARD PRACTICES AIRFRAME 20 10 05 20 10 06 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 torq
10. ts AN Army Navy and DIN bolts DIN Deutsche Industrie Norm are used The type of bolt can be identified by the designation on bolt head and by the surface treatment LN Bolts Hex head LN 9037 LN 9038 K and LN 9355 aircraft bolts are made of high strength type 1 7220 5 alloy steel The bolts are centerless ground threaded after heat treatment and cadmium plated per specification LN 9368 3000 2 Bolts according LN 9037 are standard aircraft bolts with undrilled shank The specification LN 9355 indicates bolts with shank drilled for cotter pin The specification LN 9038 K indicates bolts with drilled head for safety wire anda shank up to the head The adding numbers after the dash of bolt spec indicates the dimensions of the bolt These numbers are not marked on the head of the LN bolt Measure the diameter and length to specify the type dimension of the LN bolt The length of LN aircraft bolt is measured from under the head to the end of the shank Example LN 9037 08042 aa Bolt Head Identification Metricthreadsize M8 8 mm and Lenght 042 42mm 1 65 inch Bolt Head Letter R L P H Identification of Manufacturer LN Specification PAGE DATE 1 July 1996 CHAPTER 20 PAGE 4 EXTRA FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 200 STANDARD PRACTICES AIRFRAME Type of Bolts AN Bolts Hex head AN aircraft bolts are made of high strength type 4037 or 8740 alloy steel The bolts are centerless ground threaded
11. ue value due to shaft friction This torque can be determined by atorquemeter before the bolt head contacts the attachment surface and should be added to the table value Coin Tapping Inspection for damage is more critical for composite struc ture 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 This procedure is shown in the following Figure 1 Coin Tapping Figure 1 PAGE DATE 1 July 1996 CHAPTER 20 PAGE 9 EXTRA FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 200 STANDARD PRACTICES AIRFRAME 20 10 07 Flexible Hose The EXTRA 200 is equipped for the oil fuel and brake lines with AEROQUIP hoses Aerospace Division From Serial No 3 equivalent STRATOFLEX hoses Aerospace Connectors Division are used Later from Serial No 22 KNAPP hoses are used for the brake system in the cockpit area and for the flight instruments Maintenance work or overhaul of these hoses requires the attention of the manu facturer informations and bulletins For the replacement of hose and hose assemblies the EXTRA Flugzeugbau GmbH should be contacted Replacement of Flexible Hose Hose and hose assemblies should be checked for deteriora tion at each inspection period Leakage separation
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