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

EXTRA - FLUGZEUGBAU GmbH
SERVICE MANUAL EXTRA 300
CHAPTER 05
PAGE 11
PAGE DATE: 31. January 1995
05-20-04 Maintenance Checks Schedule
The maintenance checks described in this Chapter include
all the scheduled checks which must be performed. Use the
following schedule and the lubrication charts (Figures 2-4).
Operational Checks
O O 1 Start engine (in accordance with the Pilot`s Operating Handbook)
O O 2 Check the fuel quantity indication.
O O 3 Check oil pressure and temperature.
O O 4 Check generator output.
O O 5 Check magneto RPM-drop at 1800 RPM. (Allowed drop is
175 RPM and no greater diff. between L + R from 50 RPM)
O O 6 Check ignition OFF function at 1000 RPM for a short
moment.
O O 7 Check response of the engine by power setting changes.
O O 8 Check the Propeller response at 1800 RPM when changing
pitch.
O O 9 Check idle speed is between 650 and 750 RPM.
O O 10 Check the fuel flow and manifold pressure indicator.
O O 11 Check the EGT and CHT indicator.
O O 12 Check mixer function per CHT/EGT indication.
O O 13 Check idle mixture.
O O 14 Check the function of the fuel selector valve.
O O 15 Check the radio and the other electronic equipment.
O O 16 Shut down engine using mixture lever. Check the alternator
warning light or ammeter.
Inspector:
Mechanic:
Date:
Serial No.:
Inspections
as specified
each 50 hours
each 100 hours
SCHEDULED MAINTENANCE CHECKS
PAGE DATE: 1. June 1996

EXTRA - FLUGZEUGBAU GmbH
SERVICE MANUAL EXTRA 300
CHAPTER 05
PAGE 12
PAGE DATE: 31. January 1995
Inspector:
Mechanic:
Inspections
Date:
Serial No.:
as specified
each 100 hours
each 50 hours
SCHEDULED MAINTENANCE CHECKS
Maintenance Checks Schedule
O O 17 Check the optional electronic g-meter for the maximum g-
loading. If extreme value exceeds ±10 G, contact EXTRA-
Flugzeugbau GmbH. Correct date and time of the g-meter
(refer to DSA-12 Manual).
O O 18 Ignition OFF, main switch OFF, remove ignition key.
O O 19 Check if ignition key is removable in OFF-position only, and
if key functions in accordance with the requirements of the
Teledyne Continental Service Bulletin No. 636.
Propeller
(refer to latest edition of MT-Propeller Operation and Instal-
lation Manual E-124 and Service Bulletins)
Ground magneto primary circuit before
working on propeller
O 1 Remove spinner and check for cracks.
O O 2 Check blade shake, max. 3 mm or 1/8 inch.
O O 3 Check blade angle play, max. 2°.
O 4 Inspect outside condition of the hub and parts for cracks,
corrosion, deterioration.
O 5 Inspect check nut for high pitch stop for tightness.
O O 6 Check all safety means to be intact.
O O 7 Check flange bolts or stopnuts for tightness.
O 8 Check front and rear spinnerplate for cracks and fixing.
O O 9 Inspect bladeroot and hub for oil- and grease leaks.
O 10 Check position and condition of counterweights.
O O 11 Check blades for cracks in the fibreglass-cover and blade
erosion sheet. No cracks allowed. Refer to MT-Propeller SB
No. 8
O112 Overhaul propeller or perform a tear-down inspection.
D A N G E R
1refer to MT-Propeller Service Bulletin No. 1
PAGE DATE: 1. June 1996

EXTRA - FLUGZEUGBAU GmbH
SERVICE MANUAL EXTRA 300
CHAPTER 05
PAGE 13
PAGE DATE: 31. January 1995
Inspector:
Mechanic:
Date:
Serial No.:
Inspections
as specified
each 50 hours
each 100 hours
Engine compartment
(Refer to latest edition of Textron Lycoming Operator´s
Manual and SB's, of Christen Product Manual 801 Series and
SB's, of Slick Magneto Maintenance and Overhaul Manual
and SB's and of TCM/Bendix Service Support Manual,
included in Form X40000 Master Service Manual and SB's)
Ground magneto primary circuit before
working on engine
O O 1 Remove engine cowling.
O O 2 Inspect cowling and air inlet screen for damage, cracks,
distortion, overheated areas and loose or missing blindnuts
and secure attachment of oil level access plate.
O O 3 After this inspection clean cowling.
O O 4 Check fire protection according to EXTRA Service Bulletin
300-6-94. If necessary repaint the fire protection paint
("WIEDOFLUGAT" Brandschutzfarbe N 56582 / T508).
O1O O 5 Drain oil sump in accordance with Chapter 12-10-04 En-
gine Oil Replenishing
O1O O 6 Clean and inspect oil screen filter
O1O O 7 Clean suction oil strainer at oil change (check strainer for
foreign particles).
O1O O 8 Clean pressure oil strainer (check for foreign particles)
O2O O 8a Change full flow (cartridge type, AEIO-540-L1B5/D en-
gine) oil filter element (check element for foreign particles).
O 9 Inspect oil temperature sensor unit for leaks and security.
O O 10 Inspect flexible oil lines, oil return lines and fittings for leaks,
security, chafing, dents, and cracks (ref: FAA AC 43.13-1A).
Replace flexible oil lines at engine TBO per Lyc. SB 240.
Check fire protection according to EXTRA SB 300-6-94.
O 11 Clean and inspect oil radiators and attachment.
O312 Remove and flush oil radiators.
SCHEDULED MAINTENANCE CHECKS
Maintenance Checks Schedule
D A N G E R
1 at 10 and 25 hours and then each 25 hours
2 at 10 and 25 hours
3 each 500 hours
PAGE DATE: 15. December 1999

EXTRA - FLUGZEUGBAU GmbH
SERVICE MANUAL EXTRA 300
CHAPTER 05
PAGE 14
PAGE DATE: 31. January 1995
Inspector:
Mechanic:
Date:
Serial No.:
Inspections
as specified
each 50 hours
each 100 hours
O O Inspect Christen Inverted Oil System for general condition,
leaks, secure mounting and tight connections.
O113 Clean and flush the Inverted Oil System with a suitable
petroleum solvent, such as varsol according to Lycoming
Operators Manual.
O2O O 14 Service engine with recommended lubricating oil in accord-
ance with Chapter 12-10-04.
O O 15 Inspect condition of spark plugs (Clean and adjust gap as
required, adjust per Lycoming Service Instruction 1042). If
fouling of spark plugs has been apparent, rotate buttom plugs
to upper plugs and vice versa.
O O 16 Inspect spark plug cable leads and ceramics for corrosion and
deposits.
O O 17 Perform a hot engine differential compression check in
accordance with FAA AC 43.13-1A.
O 18 Inspect cylinders for cracked or broken fins.
O O 19 Check cylinders for evidence of excessive heat which is
indicated by discoloration.
O 20 Check fuel injector nozzles for loseness. Tighten to 60 inch
pounds torque. Check fuel lines for fuel stains which are
indicative for fuel leaks.
O O 21 Inspect rocker box covers for evidence of oil leaks. If found,
replace gasket; torque cover screws 50 Inch-pounds.
O322 Remove rocker box covers and check for freedom of valve
rockers when valves are closed. Look for evidence of abnor-
mal wear or broken parts in the area of valve tips, valve
keeper, springs and spring seats.
O 23 Inspect ignition harness for general condition, free from
fraying or chafing and insulators for high tension leakage and
continuity.
SCHEDULED MAINTENANCE CHECKS
Maintenance Checks Schedule
1 each 300 hours
2 each 25 hours
3 each 400 hours
PAGE DATE: 1. June 1996

EXTRA - FLUGZEUGBAU GmbH
SERVICE MANUAL EXTRA 300
CHAPTER 05
PAGE 15
PAGE DATE: 31. January 1995
TCM/Bendix magnetos
O 24 Check magneto-to-engine timing.
O 25 Remove all ignition harness spark plug terminals from spark
plugs, clean and inspect following the respective sections of
the applicable Support Manual.
O 26 Inspect magnetos with riveted impulse coupling for wear as
specified in the latest revision of TCM/Bendix SB 599D.
O127 Inspect magnetos equipped with snap-ring impulse coupling
for wear as outlined in the PERIODIC MAINTENANCE
Section of the applicable Support Manual, Paragraph 6.2.2.
O128 Inspect magnetos as outlined in the PERIODIC MAINTE-
NANCE Section of the applicable Support Manual, Para-
graph 6.2.3. Clean and inspect all ignition harness outlet
plates, covers or cap assemblies and grommets following the
respective sections of the Manual mentioned above.
O229 Overhaul or replace magnetos acc. to TCM/Bendix SB 643.
Slick magnetos
O 24 Adjust magneto to engine timing, refer to Slick Magneto
Maintenance and Overhaul Manual
O 25 Inspect wiring connections, vent holes and P-lead
attachment, refer to Slick Magneto Maintenance and Over-
haul Manual.
O126 Clean magnetos.
O127 Inspect ball bearing assembly, impulse coupling, coil, con-
tact points, condenser and carbon brush.
O328 Replace ball bearings.
O129 Lubricate magnetos.
O430 Overhaul or replace magnetos.
Inspector:
Mechanic:
Date:
Serial No.:
Inspections
as specified
each 50 hours
each 100 hours
SCHEDULED MAINTENANCE CHECKS
Maintenance Checks Schedule
1 each 500 hours
2 at engine overhaul and at the expiration of 4 years
3 each 1000 hours
4 together with engine
PAGE DATE: 1. June 1996

EXTRA - FLUGZEUGBAU GmbH
SERVICE MANUAL EXTRA 300
CHAPTER 05
PAGE 16
PAGE DATE: 31. January 1995
Inspector:
Mechanic:
Date:
Serial No.:
Inspections
as specified
each 50 hours
each 100 hours
O 31 Check fuel injector for general condition, clean fuel inlet
screen.
O O 32 Inspect intake seals and O-rings for leaks and clamps for
tightness.
O O 33 Inspect flexible fuel lines, fuel injection lines and fittings for
leaks, security, chafing, dents, and cracks (refer to Lycoming
SB 342 each 100h; replace or overhaul as required or at
engine overhaul). Check fire protection according to EXTRA
SB 300-6-94.
O O 34 Check fuel system for leaks.
O1O O 35 Remove, clean and inspect gascolator screen and fuel filter
bowl.
O O 36 Inspect throttle, mixture, and propeller governor controls for
security, travel, and operating conditions.
O O 37 Inspect exhaust stacks, connections and gaskets (replace
gaskets as required).
O O 38 Inspect exhaust slipjoints for general condition.
O O 39 Inspect exhaust system attachment.
O 40 Inspect crankcase for cracks, leaks, and security of seam
bolts.
O O 41 Check engine mounted accessories such as pumps, tempera-
ture and pressure sensing units for leaks, secure mounting
and tight connections.
O O 42 Inspect engine mount for cracks and loose mountings.
O O 43 Inspect engine baffles free from cracks and fraying.
O 44 Inspect all wiring connected to the engine or accessories
O O 45 Inspect engine shock mounts for deterioration (replace as
required).
O 46 Inspect firewall seals (see EXTRA SB 300-6-94).
O 47 Inspect alternator, cable connections and accessories.
SCHEDULED MAINTENANCE CHECKS
Maintenance Checks Schedule
PAGE DATE: 1. June 1996
1 clean at least every 90 days

EXTRA - FLUGZEUGBAU GmbH
SERVICE MANUAL EXTRA 300
CHAPTER 05
PAGE 17
PAGE DATE: 31. January 1995
Inspector:
Mechanic:
Date:
Serial No.:
Inspections
as specified
each 50 hours
each 100 hours
O 48 Inspect condition and tension of alternator drive belt
O 49 Inspect security of alternator mounting
O 50 Inspect starter and starter drive
O O 51 Check brake fluid level (fill as required).
O O 52 Clean engine if necessary.
O O 53 Lubricate all controls per lubrication chart.
O154 Overhaul or replace propeller governor as required.
O255 Complete overhaul of engine or replace with factory rebuilt
O O 56 Reinstall engine cowling.
Fuselage
O O 1 Remove tail fairing, tail side skins, tank covering sheet, turtle
deck and landing gear cuffs per Chapter 51.
O 2 Remove bottom covering window and sheets including ex-
haust area covering sheet per Chapter 51.
O O 3 Inspect tank covering sheet, turtle deck, bottom covering
window and sheets including exhaust area covering sheet,
tail fairing, tail side skins and landing gear cuffs for general
condition, dents, cracks and loose screws and rivets.
O O 4 Check installed parts for general condition and security of
attachment.
O O 5 Inspect fuselage for foreign matters.
O 6 Inspect steel tube construction for general condition, corro-
sion and cracks, above all in areas of load stress (e.g. wing,
stabilizer, engine and seat attachments).
O O 7 Visually inspect steel tube construction in the area of hori-
zontal stabilizer attach brackets for cracks. In case of doubt
remove horizontal stabilizer and use a dye check penetrant.
Incaseofcracksarefound contact EXTRA-FLUGZEUGBAU
GmbH for repair advise.
O O 8 Inspect fabric cover for general condition.
1 refer to Woodward Service Bulletin No. 33580
2refer to Lycoming Service Instruction No. 1009
PAGE DATE: 1. June 1996

EXTRA - FLUGZEUGBAU GmbH
SERVICE MANUAL EXTRA 300
CHAPTER 05
PAGE 18
PAGE DATE: 31. January 1995
Inspector:
Mechanic:
Date:
Serial No.:
Inspections
as specified
each 50 hours
each 100 hours
O 9 Inspect wooden longerons for damage.
O 10 Clean and lubricate canopy hinge and latching mechanism.
O O 11 Inspect seats and seat belts for security, attachment, proper
operation, and condition. Control the time limit of the seat
belts. Refer to Chapter 05-10-02 "Overhaul Schedule".
O 12 Inspect breather line for obstructions and security.
O 13 Inspect main and auxiliary wing spar connector for general
condition.
Fuel system
O O 1 Inspect the fuel lines for leaks, security, chafing, dents and
cracks. Replace fuel lines as required.
O O 2 Inspect fuel selector valve for operation and proper pointer
indication
O O 3 Drain fuel system
O O 4 Check acro- and center tank attachment
O O 5 Check acro-, center- and both wingtanks for leaks
O O 6 Check boost pump
O O 7 Check fuel filler caps for security and proper operation
O O 8 Check proper seat and condition of sealing lip (from S.No 59)
Flight controls
O O 1 Remove wing access panels.
O O 2 Inspect control surfaces for security of attachment, free
movement, dents, delaminations and cracks.
O O 3 Inspect elevator trim system for proper operation and rigging.
O O 4 Inspect hinges for condition, cracks and security; hinge bolts,
hinge bearings, selflocking nuts.
O O 5 Check free play in control system: torque tube, control
surfaces, control sticks, rod end bearing, deflector limiter.
O1O O 6 Lubricate rear torque tube bearing.
SCHEDULED MAINTENANCE CHECKS
Maintenance Checks Schedule
1 each 25 hours
PAGE DATE: 1. June 1996

EXTRA - FLUGZEUGBAU GmbH
SERVICE MANUAL EXTRA 300
CHAPTER 05
PAGE 19
PAGE DATE: 31. January 1995
Inspector:
Mechanic:
Date:
Serial No.:
Inspections
as specified
each 50 hours
each 100 hours
SCHEDULED MAINTENANCE CHECKS
Maintenance Checks Schedule
O O 7 Lubricate aileron rodend bearings, trim flap hinges and trim
lever bolt.
O 8 Lubricate adjustment tube of electrical pedal adjustment.
O O 9 Check rudder cable system including sleeves, fairleads,
pulleys and cable retracting springs per FAA-AC 43.13-1A.
O 10 Check for minimum 3.5 mm (1/8") clearance of rudder pedal
versus safety stop when fully deflected for rudder cables
having 50 h flight time minimum. On newly installed rudder
cables the minimum spacing is 6 mm (1/4"). Refer to Figure 5.
This check is to be performed with zero loading on the rudder
pedals.
O 11 Rough check of safety stop clearance. With a force of approx.
90 kg (200 lbs) acting on the fully deflected rudder pedal the
safety stop shall not be reached. If the stop is reached the
control system indicates a too high flexibility which needs to
be traced. In this case contact EXTRA for advice.
O O 12 Inspect all flight control ventilation holes for obstruction.
O 13 Inspect elevator balance weight for looseness and condition.
O 14 Inspect push rods.
Landing gear
O O 1 Check landing gear for general condition.
O O 2 Check landing gear spring for dents and cracks.
O O 3 Inspect landing gear spring mounting clamps and bolts for
security.
O 4 Lubricate landing gear center bolt and landing gear bearings.
O 5 Check wheel rake (10° ± 0.5°) and toe-in (1.5° ± 0.5°) per
Chapter 32.
Fairings:
O O 1 Disassemble fairings.
O O 2 Check fairings for dents and cracks.
O O 3 Check fairing ventilation hole for obstruction.
PAGE DATE: 1. June 1996

EXTRA - FLUGZEUGBAU GmbH
SERVICE MANUAL EXTRA 300
CHAPTER 05
PAGE 20
PAGE DATE: 31. January 1995
Wheels
(refer to on-aircraft inspections presented in the latest edition
of Cleveland Wheels & Brakes Maintenance Manual and
Service Bulletins for wheel, tire and break inspections)
O O 1 Visually inspect the wheels for corrosion, cracks, or other
visible damage.
O O 2 Check wheel nuts to be sure they are properly installed and
have not worked loose. Bolt threads should be flush to 1-1/2
threads extending beyond the nut. Nuts should be on the side
of wheel opposite the brake disc (outboard side of wheel).
O O 3 Inspect the brake disc for rust, excessive grooves, large
cracks, coning or other visible damage. Check if disc thick-
ness is more than 0.325in/8.255mm. Coning of disc in excess
of 0.015 in /0.381 mm is cause for replacement (see Fig. 6).
O 4 Remove wheels and wheel bearings. Inspect wheel bearing
grease for contamination and solidification.
O 5 Inspect snap rings and grease seals for distortion or wear.
Replace grease seal felts if they are hard or contaminated.
Lightly saturate grease seals should be replaced if cracked,
dried out, or distorted.
O 6 Inspect wheel bearings for excessive wear or damage. Re-
place on condition.
O 7 Repack bearings with AEROSHELL 22C (per MIL-G-81322),
or equivalent. Reinstall wheels and safety.
O O 8 Check wheel bearing clearance and wheels for free rotation.
Tires
O O 1 Visually inspect tires for cuts, flat spots, and tread or sidewall
damage. If changing of tires is necessary follow the instruc-
tions, including off-aircraft inspection of wheels, presented
in the Cleveland Wheels & Brakes Component Maintenance
Manual.
O O 2 Check inflation pressure (3.4 bar/49.3 psi). Proper inflation
will provide maximum tire and wheel life.
Inspector:
Mechanic:
Date:
Serial No.:
Inspections
as specified
each 50 hours
each 100 hours
SCHEDULED MAINTENANCE CHECKS
Maintenance Checks Schedule
PAGE DATE: 1. June 1996