Flugzeugbau Extra 300 User manual
EXTRA - FLUGZEUGBAU GmbH
SERVICE MANUAL EXTRA 300
CHAPTER 05
PAGE 1
PAGE DATE: 31. January 1995
Chapter 05
Time Limits/Maintenance Checks
EXTRA - FLUGZEUGBAU GmbH
SERVICE MANUAL EXTRA 300
CHAPTER 05
PAGE 2
PAGE DATE: 31. January 1995
Table of Contents
Chapter Title
05-00-00 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
05-10-00 TIME LIMIT COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
05-10-01 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
05-10-02 Overhaul Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
05-10-03 Recommended Replacement Times . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
05-20-00 SCHEDULED MAINTENANCE CHECKS . . . . . . . . . . . . . . . . . . . . . . . 6
05-20-01 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
05-20-02 25 Hour Inspection - Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
05-20-03 25 Hour Inspection - Aircraft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
05-20-04 Maintenance Checks Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
05-20-05 Significant Items Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
05-50-00 UNSCHEDULED MAINTENANCE CHECKS . . . . . . . . . . 32
05-50-01 Violent Stopping of the Engine (Propeller Strike) . . . . . . . . . . . . . 32
05-50-02 Hard Landing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
05-50-03 Engine Fire. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
05-50-04 Lightning Strike . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
05-50-05 Flightline Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
EXTRA - FLUGZEUGBAU GmbH
SERVICE MANUAL EXTRA 300
CHAPTER 05
PAGE 3
PAGE DATE: 31. January 1995
05-00-00 GENERAL
This chapter contains charts for time limits, scheduled
maintenance and unscheduled maintenance, and enables
licensed personnel to carry out correct inspections on the
EXTRA 300. The periodic inspections and checks de-
scribed and their recommended time intervals are minimum
requirements for maintaining the aircraft in an airworthy
condition. Further information will be given by the infor-
mation service (Service Bulletins, Service Letters, etc.).
If operation of aircraft requires more frequent servicing, the
check intervals may be shortened. However the check
intervals must not be exceeded without explicit permission
from the regulatory authority. Additional checks as well as
changes must also be agreed by the regulatory authority.
In general this Manual does not give any information about
vendor equipment. Such information can be taken from the
vendor equipment maintenance instructions (refer to Chap-
ter 01). However for practicability reason most of the
applicable vendor equipment inspections are incorporated
in the following checklists. But it has to be noted that the
latest editions of inspections given by the vendors remain
decisive. So, before beginning an inspection, the inspec-
tions of vendor equipment presented here must be com-
pared with the originals referenced under the respective
headlines of the checklists, and, in case of doubt (e.g. if
originals have changed before changes could be transferred
to this Manual by the Revision Service), contact EXTRA-
FLUGZEUGBAU GmbH for advice. The maintenance
instructions referenced in the checklists are also valid if
further inspection of vendor equipment is necessary.
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" and the
battery connected. The engine may be started un-
intentionally and may cause serious injuries or death.
PAGE DATE: 1. June 1996
EXTRA - FLUGZEUGBAU GmbH
SERVICE MANUAL EXTRA 300
CHAPTER 05
PAGE 4
PAGE DATE: 31. January 1995
05-10-00 TIME LIMIT COMPONENTS
05-10-01 General
All components not listed herein should be inspected as
detailed in Chapter 05-20 Maintenance Checks and re-
paired, overhauled as required. It is recommended that
overhaul or replacement of components should be accom-
plished not later than the specified period of operation for
that component or in accordance with the manufactures
service data or airworthiness directives.
05-10-02 Overhaul Schedule
Items shown here must be overhauled at the times indi-
cated.
Item
Overhaul
E
n
g
i
n
e
(
T
e
x
t
r
o
n
L
y
c
o
m
i
n
g
)
*
Engine accessories
t
o
g
e
t
h
e
r
w
i
t
h
e
n
g
i
n
e
M
a
g
n
e
t
o
(Slick)
*
D
o
u
b
l
e
m
a
g
n
e
t
o
s
(
B
e
n
d
i
x
)
*
Propeller
(MT-Propeller)
*
G
o
v
e
r
n
e
r
(
W
o
o
d
w
a
r
d
)
*
All other components
o
n
C
o
n
d
i
t
i
o
n
* refer to latest issue of
Manufacturer´s Service Bulletin
PAGE DATE: 1. June 1996
EXTRA - FLUGZEUGBAU GmbH
SERVICE MANUAL EXTRA 300
CHAPTER 05
PAGE 5
PAGE DATE: 31. January 1995
TIME LIMIT COMPONENTS
05-10-03 Recommended Replacement Times
It is recommended to replace the items shown in the
following schedule at the times indicated. The times may be
modificated by the respective national authorities.
** on the recommendation
of the manufacturer
Item
Replace
Battery
(
S
o
n
n
e
n
s
c
h
e
i
n
)
2 years **
B
a
t
t
e
r
i
e
s
o
f
t
h
e
E
L
T
(Pointer)
2 years **
Wheels
(
C
l
e
v
e
l
a
n
d
,
P
a
r
k
e
r
)
o
n
C
o
n
d
i
t
i
o
n
T
i
r
e
s
o
n
C
o
n
d
i
t
i
o
n
F
u
e
l
,
o
i
l
&
b
r
a
k
e
h
o
s
e
s
(
A
e
r
o
q
u
i
p
)
after first 7 years,
t
h
e
n
5
y
e
a
r
s
Seat belts
(Hooker)
6 years **
B
r
a
k
e
a
n
d
B
r
a
k
e
A
s
s
e
m
b
l
y
(
C
l
e
v
e
l
a
n
d
,
P
a
r
k
e
r
)
o
n
C
o
n
d
i
t
i
o
n
R
u
d
d
e
r
c
o
n
t
r
o
l
c
a
b
l
e
o
n
C
o
n
d
i
t
i
o
n
F
a
i
r
l
e
a
d
s
o
n
C
o
n
d
i
t
i
o
n
S
h
o
c
k
m
o
u
n
t
s
(
L
o
r
d
Kinematics, Barry Controls)
o
n
C
o
n
d
i
t
i
o
n
B
o
l
t
s
a
n
d
N
u
t
s
on Condition ***
*** if not stated otherwise
PAGE DATE: 1. June 1997
EXTRA - FLUGZEUGBAU GmbH
SERVICE MANUAL EXTRA 300
CHAPTER 05
PAGE 6
PAGE DATE: 31. January 1995
05-20-00 SCHEDULED MAINTENANCE CHECKS
05-20-01 General
Scheduled maintenance checks or tasks must be carried out
at 25, 50, 100, 200, 300, 400, 500 and 1000 hour intervals.
In addition an annual inspection equal to the 100 hour
inspection has to be performed.
The following pages show a drain hole chart (Figure 1) and
lubrication charts (Figures 2 - 4) which can be used in
connection with the checklists.
05-20-02 25 Hour Inspection - Engine
A 25 hour inspection is necessary for the engine, because
the engine is not equipped with an external oil filter.
Therefore the engine oil has to be changed and the oil screen
cleaned after every 25 hours. Refer to Figure 2 "Lubrication
Chart 25 hours".
05-20-03 25 Hour Inspection - Aircraft
After the first 25 hours, a check equal to the 100-hour
maintenance check has to be performed. Refer to Chapter
05-20-04.
PAGE DATE: 1. June 1996
EXTRA - FLUGZEUGBAU GmbH
SERVICE MANUAL EXTRA 300
CHAPTER 05
PAGE 7
PAGE DATE: 31. January 1995
Drain and Vent Holes
Figure 1
SCHEDULED MAINTENANCE CHECKS
1. Root Rib Aileron
2. Root Elevator
3. Root Horizontal Stabilizer
4. TrimTab (3 Holes)
5. Stall Warn Transducer
6. Lower Root Rudder Fin
7. Lower Root Rudder Horn
8. Wheel Fairing
9. Nose Ribs Aileron (Hinge Gaps)
EXTRA - FLUGZEUGBAU GmbH
SERVICE MANUAL EXTRA 300
CHAPTER 05
PAGE 8
PAGE DATE: 31. January 1995
Lubrication Chart 25 hours
Figure 2
SCHEDULED MAINTENANCE CHECKS
PAGE DATE: 1. June 1996
EXTRA - FLUGZEUGBAU GmbH
SERVICE MANUAL EXTRA 300
CHAPTER 05
PAGE 9
PAGE DATE: 31. January 1995
Lubrication Chart 50 hours
Figure 3
SCHEDULED MAINTENANCE CHECKS
PAGE DATE: 1. June 1996
EXTRA - FLUGZEUGBAU GmbH
SERVICE MANUAL EXTRA 300
CHAPTER 05
PAGE 10
PAGE DATE: 31. January 1995
SCHEDULED MAINTENANCE CHECKS
Lubrication Chart 100 hours
Figure 4
PAGE DATE: 1. June 1996
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