Temporary Revision N.03702-TR-02-20131015 [Last
Contents
1. o Inspections o Clean magnetos o Inspectball bearing assembly impulse coupling coil contact points condenser and carbon brush on 28 Replace ball bearings o 29 Lubricate magnetos Oo 30 Overhaul or replace magnetos 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 JO 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 JO 34 Check fuel system for leaks o o O 35 Remove clean and inspect gascolator screen and fuel filter bowl O JO 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 JO 39 Inspectexhaust system attachment O 40 Inspectcrankcase for cracks leaks and security of seam bolts O JO 41 Check engine mounted accessories such as pumps tempera ture and pressure sensing units for leaks secure mounting and tight connections 1 each 500 hours 2 each 1000 hours 3 together with engine 4 clean at least every 90 days PAGE DATE 25 Oktober 2013 TEMPORARY REVISION CHAPTER2. Slick Double magnetos Bendix Propeller MT Propeller Governor Woodward or MT Propeller All other components on Condition PAGE DATE 25 Oktober 2013 TEMPORARY REVISION N 03702 TR 02 20131025 CHAPTER 05 PAGE 4 EXTRA TIME LIMIT COMPONENTS SERVICEMANUAL EXTRA 300 05 10 03 Recommended Replacement Times on the recommendation of the manufacturer if not stated otherwise Itis recommended to replace the items shown in the follow ing schedule at the times indicated The times may be modified by the respective national authorities Item Replace Battery a Sonnenschein Battery b Concorde 2 years on condition Batteries of the ELT Pointer 2 years Wheek Cleveland Parken on condition Tires on condition Fuel oil sensing amp brake hoses I Rubber Type MS28741 after first 7 years then 5 years Fuel Oil amp Sensing hoses PTFE Type MIL DTL 25579 on condition but in engine comp at the latest together with engine removal Seat belts Hooker Rework or replace after a period of 6 years in use service life limit of national aviation authority must be considered Brake and Brake Assembly Cleveland Parker on condition Rudder control cable on condition mio on c
3. Brake Back Plate Bolts Cleveland Ref einem Wheel Assembly Bolts Cleveland Maintenance Manual Engine Mounting Bolts AN7 50A Metal Stop Nut NAS 363C 720 Engine Mount to Fuselage Bolt Din 912 M12 12 9 Stop Nut DIN 985 M12 8 B2C Longeron Cutout Bridge Bolt DIN 912 M8 8 8 Stop Nut LN 9348 08 Horizontal Stabilizer Rear Spar Bolts Bolt LN 9037 08042 Stop Nut LN 9348 08 S N 1 thru 66 Horizontal Stabilizer Rear Spar Bolts Bolt LN 9037 10054 Stop Nut LN 9348 10 S N 67 ff Vertical Stabilizer Rear Spar Bolt Bolt LN 9037 10054 Stop Nut LN 9348 10 Wing Main Spar Safety Bolts Bolt LN 9038 K 08020 Torque for Engine Refer to Lycoming Overhaul Manual Torque for Propeller HE Horizontal Stabilizer Front Spar Bolts Bolt LN 9037 10054 Be 292 Stop Nut LN 9348 10 efer to MT propeller Installation Manual E24 IMPORTANT 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 25 Oktober 2013 TEMPORARY REVISION CHARTERS 2 0 N 03702 TR 02 20131025 PAGE 8 SERVICEMANUAL EXTRA 300 STANDARD PRACTICES AIRFRAME 20 10 07 Flexible Hose The EXTRA 300 is equipped for the oil fuel and brake lines with AEROQUIP hoses Aerospace Division From Serial No 64 equivalent STRATOFLEX hoses Aerospace Con nectors Division are used KNAPP hoses also can be used for the brake
4. Paint Manufacturer Parker amp Anchem Ambler PA 19002 Supplier Aircraft Spruce Chem coating Alodine No 1201 MIL C 5541 Lacquer see above PAGE DATE 25 Oktober 2013 TEMPORARY REVISION CHAPTER 51 N 03702 TR 02 20131025 PAGE 13 EXTRA SERVICE MANUAL EXTRA 300 TABLE OF CONTENTS Chapter Title 53 00 00 GENERAL sani 3 53 00 01 Cip 11 53 01 02 E HDTS TI arin wen ony A E ner eel 53 00 03 BottomEuselaee ovr men gear 12 PAGE DATE 25 Oktober 2013 TEMPORARY REVISION CHAPTER 53 N 03702 TR 02 20131025 PAGE 2 SERVICEMANUAL EXTRA 300 GENERAL 53 00 00 GENERAL The fuselage structure consists of a TIG welded steel tube construction integrating the wing and empennage connec tions as well as the seats refer to Figure 1 The particular areas of the fuselage are covered with differ ent materials also refer to Chapter 51 00 01 Access Panel Identification Both halves of the engine cowling consist of glass fibre laminate and honeycomb They are coated with fire protec tion paint WIEDOFLUGAT N 56582 T508 with clear coat 4232 0303 or HENSOTHERM 410KS with clear coat Glasurit 923 335 refer Chapter 51 30 01 The front part of the fuselage behind the fire wall the lower side and the sides below the wing are faired with aluminium panels The lower rear part of the fuselage is covered with fabric The rear part of the upper fuselage surface turtle deck consists of an aramid laminate The
5. 3 at 25 hours for new remanufactured or newly overhauled engines and for engines with any newly installed cylinders PAGE DATE 25 Oktober 2013 TEMPORARY REVISION CHAPTER 05 N 03702 TR 02 20131025 PAGE 13 EXTRA SERVICE MANUAL EXTRA 300 SCHEDULED MAINTENANCE CHECKS Maintenance Checks Schedule Inspections 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 11 Clean and inspect oil radiators and attachment 12 Remove and flush oil radiators Inspect Christen Inverted Oil System for general condition leaks secure mounting and tight connections 13 Clean and flush the Inverted Oil System with a suitable petro leum solvent such as varsol according to Lycoming Opera tor s Manual 14 Service engine with recommended lubricating oil in accord ance with Chapter 12 10 04 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 16 Inspect spark plug cable leads and ceramics for corrosion and deposits 17 Perform a hot engine differential compression check in accordance with FAAA
6. 01 Remove transponder following the Removal Installation Instructions of the respective manufacturer Install in reverse sequence of removal Perform an operation test PAGE DATE 25 Oktober 2013 TEMPORARY REVISION CHAPTER 34 N 03702 TR 02 20131025 PAGE 10 EXTRA MATERIALS SERVICE MANUAL EXTRA 300 Composite Part Materials 1006 202 3 Glassit Spritzf ller SP 60 7023 948 36 Glassit H rterpaste rot SB 48 3360 21 Glassodur PUR Acryl LackAD AE2 929 73 Glassodur MS H rter SC 29 0173 352 9 Glassodur Einstellzusatz SV 41 0391 923 335 Glasurit Klarlack with Hensotherm 410KS Manufacturer Rudolf Hensel GmbH Lauenburger Landstra e 11 D 21039 B rnsen Type Fire protective coating Hensotherm 410KS with 923 335 Glasurit Klarlack 51 30 02 Metal Components IMPORTANT Only approved materials have to be used for the repair of metal components Steel tubing Manufacturer MHP Mannesmann Hoesch Pr zisrohr GmbH Postfach 1713 D 59061 Hamm Germany Supplier HEINE BEISSWENGER Stiftung CO Postfach 1510 D 70705 Fellbach Germany Type WLB 1 7734 4 18mm x 1 0mm 20mm x 1 0mm 22mm x 1 0mm 22mm x 1 5mm 25mm x 1 5mm PAGE DATE 25 Oktober 2013 TEMPORARY REVISION CHAPTER 51 N 03702 TR 02 20131025 PAGE 11 SERVICEMANUAL EXTRA 300 Metal Components Steel sheet metal Manufacturer BOHLER Edelstahl GmbH Miinchen Germany Supplier BOHLER Edelstahl GmbH Hansa Allee 321 D 40549 Diisseldorf Ge
7. evidence of this 7 Check fit of brake cylinder anchor bolts in torque plate bushings for sloppiness This can be accomplished by grasping the cylinder and moving it slight movement is normal Excessive movement is cause for removal and detailed inspection O 8 Linings should be visually checked for extreme chipping on the edges Lining worn to a minimum thickness of 0 100 inch 2 54 mm must be replaced O 9 Visually check torque plate for corrosion cracks loose an chor bolt bushings or other visible damage Anchor bolt bushings must be flat against torque plate surface 10 Check for any brake fluid leaks ego O 11 Check brake fluid level Tail wheel landing gear O 1 Checktail wheel landing gear for general condition O 2 Check tail wheel landing gear spring for dents cracks and delaminations O 3 Checktail wheel rubber tire condition O 4 Inspect tail wheel spring and swivel arm mounting bolts for security PAGE DATE 25 Oktober 2013 TEMPORARY REVISION CHAPTER 05 N 03702 TR 02 20131025 PAGE 22 EXTRA SERVICE MANUAL EXTRA 300 Inspector Mechanic Inspections a Standard Full
8. landing gear cuffs for general condition dents cracks and loose screws and rivets Check installed parts for general condition and security of attachment 1 refer to Woodward Service Bulletin No 33580 2 refer to Lycoming Service Instruction No 1009 PAGE DATE 25 Oktober 2013 TEMPORARY REVISION CHARTERTOS N 03702 TR 02 20131025 PAGE ily EXTRA SCHEDULED MAINTENANCE CHECKS SERVICEMANUAL EXTRA 300 Maintenance Checks Schedule 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 7 Visually inspect steel tube construction in the area of horizon tal stabilizer attach brackets for cracks In case of doubt remove horizontal stabilizer and use a dye check penetrant In case of cracks are found contact EXTRA for repair advise 8 Inspect fabric cover for general condition 9 Inspect wooden longerons for damage 10 Clean and lubricate canopy hinge and latching mechanism ife ere 11 Inspect seats for security attachment proper operation and condition Inspect breather line for obstructions and security Inspect main and auxiliary wing spar connector for general condition a w Se
9. one piece canopy frame is built of carbon fibre laminate and rovings The window portion is made of acrylic glass The layer sequences of the engine cowlings the turtle deck and the tail fairing are shown in Figures 2 5 All composite parts as protection against moisture and UV radiation are coated with an unsaturated polyester gel coat an acrylic filler and finally with an acrylic paint For repair of composite parts and steel components refer to Chapter 51 The repair of fabric has to be executed in accordance to the FAA AC 43 13 1A PAGE DATE 25 Oktober 2013 TEMPORARY REVISION CHAPTER 53 N 03702 TR 02 20131025 PAGE 3 EXTRA SERVICE MANUAL EXTRA 300 53 00 03 Bottom Fuselage Cover Removal 1 Remove engine cowling the landing gear cuffs and turtle deck as per chapter 51 2 Pull the plug of the optional OAT sensor wiring if appli cable Disconnect the antenna wirings Remove bottom covering sheets and LEXAN window by re moving the attachment screws Installation The cockpit area must be thoroughly sealed and thus separated from the engine compartment Gases or flu ids could get into the cockpit area Critical areas to be observed are the following Position A and D of figure 6 where different parts converge firewall aluminium profile bottom covering sheet and exhaustarea covering sheet Position B and C where a bent corner ends in a bore hole Forward View on Bottom Side Firewal
10. swivel tailwheel Check swivel arm for dents and cracks Check tail wheel for free rotation and swivel feature Check swivel arm and wheel bearing clearance service b Optional Steerable tailwheel O JO 1 Check for general condition and function Pay attention to the free movement of the rudder O O 2 Check the connector springs for light precompression O JO 3 Check the wheelfork for free rotation and steering function damage dents cracks and corrosion O JO 4 Inspect wheelfork for damage dents cracks and corrosion o o 5 Inspect the axle bolt and nut for fretting wear damage and stretch O O 6 Lubricate tail wheel steering Wing O JO 1 Check wing for dents cracks and delaminations o Inspect wing spar main bolts for looseness and security O 3 Checkthe safety wire and the safety screw of the wing main spar bolt O 4 Inspect wing spar main sleeves for looseness and bearing load O 5 Inspect wing auxiliary spar attachment O 6 Inspect wing ventilation holes for obstruction O JO 7 Check inside wing structure in the area of access panels PAGE DATE 25 Oktober 2013 TEMPORARY REVISION CHAPTER 05 N 03702 TR 02 20131025 PAGE 22A EXTRA UNSCHEDULED MAINTENANCE CHECKS SERVICEMANUAL EXTRA 300 05 50 03 Engine Fire After an engine fire perform a check as described in the following Fordamage evaluation consultthe manufacturer before the aircraft is put back into service Date Inspect
11. 05 N 03702 TR 02 20131025 PAGE 16 EXTRA SERVICE MANUAL EXTRA 300 Inspections Inspect engine mount for cracks and loose mountings Inspect engine baffles free from cracks and fraying Inspect all wiring connected to the engine or accessories Inspect engine shock mounts for deterioration replace as required 46 Inspect firewall seals see EXTRA SB 300 6 94 47 Inspect alternator cable connections and accessories 48 Inspect condition and tension of alternator drive belt 49 Inspect security of alternator mounting 50 Inspect starter and starter drive S 52 Clean engine if necessary en B e Neal e e e O 53 Lubricate all controls per lubrication chart 54 Overhaul or replace propeller governor as required N SNe 59 Complete overhaul of engine or replace with factory rebuilt Reinstall engine cowling Check brake fluid level fill as required Fuselage Remove tail fairing tail side skins tank covering sheet turtle deck and landing gear cuffs per Chapter 51 Remove bottom covering window and sheets including ex haust area covering sheet per Chapter 51 Inspect tank covering sheet turtle deck bottom covering window and sheets including exhaust area covering sheet tail fairing tail side skins and
12. 34 10 02 34 10 03 34 15 00 34 15 01 34 15 02 34 15 03 34 15 04 34 20 00 34 20 01 34 20 02 34 25 00 34 25 01 34 25 02 34 50 00 34 50 01 TABLE OF CONTENTS Title Pilot Stati Systemen en een een ene nen Altimeter ee ee eee Alrspecdiln dicato rer en Pressure Head Removal Installation Pitot Head Attachment Block Removal Installation Altimeter Raso Airspeed Indicator Remo nn ATTITUDEAND DIRECTION Masnese Compass ee TumandBankIndieaer nee Magnetic Compass Removal Installation Turn and Bank Indicator Removal Installation inn DEPENDENT POSITION DETERMINING Transponder ee n nen NN 10 10 PAGE DATE 25 Oktober 2013 TEMPORARY REVISION CHAPTER 34 N 03702 TR 02 20131025 PAGE 2 EXTRA SERVICEMANUAL EXTRA 300 34 50 00 DEPENDENT POSITION DETERMINING 34 50 01 Transponder Various transponders can be installed in the EXTRA 300 A transponder is a radio transmitter and receiver that fulfills the role of airborne beacon equipment according to the requirements of the Air Traffic Radar Beacon System ATCRBS Itoperates on radar frequencies receiving ground radar interrogations at 1030 MHz and transmitting a coded response of pulses to ground based radar on a frequency of 1090 MHz Removal Installation Remove Instrument Cover if transponder has to be installed from the rear Refer to Chapter 31 15
13. C 43 13 1A 18 Inspect cylinders for cracked or broken fins 19 Check cylinders for evidence of excessive heat which is indicated by discoloration 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 21 Inspect rocker box covers for evidence of oil leaks If found replace gasket torque cover screws 50 Inch pounds 1 each 500 hours 2 each 300 hours 3 each 25 hours PAGE DATE 25 Oktober 2013 TEMPORARY REVISION N 03702 TR 02 20131025 PAGE CHAPTER 05 14 EXTRA SCHEDULED MAINTENANCE CHECKS SERVICEMANUAL EXTRA 300 Maintenance Checks Schedule Inspections 22 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 Inspect ignition harness for general condition free from fraying or chafing and insulators for high tension leakage and continuity 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 I
14. G 8 1322 or equivalent Reinstall wheels and safety O JO 8 Check wheel bearing clearance and wheels for free rotation Tires damage If changing of tires is necessary follow the instruc tions including off aircraft inspection of wheels presented in the Cleveland Wheels amp Brakes Component Maintenance Manual OJO 2 Check inflation pressure 3 4 bar 49 3 psi Proper inflation will provide maximum tire and wheel life Brake system OJO 1 Inspect brake assemblies for general condition OJO 2 Inspect master cylinders for leaks OJO 1 Visually inspect tires for cuts flat spots and tread or sidewall PAGE DATE 25 Oktober 2013 TEMPORARY REVISION CHAPTER 05 N 03702 TR 02 20131025 PAGE 2 EXTRA SERVICE MANUAL EXTRA 300 SCHEDULED MAINTENANCE CHECKS Maintenance Checks Schedule Inspections 3 Inspect brake system plumbing for leaks and hoses for bulges and deterioration 4 Lubricate brake guide pins using Silicone base lubricant 5 Visually inspect the brakes for corrosion cracks or other visible damage Check inlet fitting bosses and anchor bolt lugs forcracks Check inlet flares on aircraft side of rigid hydraulic tubing for fatigue cracks 6 Check back plate attachment bolts to insure they are properly torqued and have not worked loose Gaps between the back plate and cylinder would be
15. Oktober 2013 TEMPORARY REVISION CHAPTER 25 N 03702 TR 02 20131025 PAGE 9 SERVICEMANUAL EXTRA 300 32 11 00 MAINTENANCE PRACTICES 32 11 01 Main Landing Gear Removal Installation Refer to Figure 2 1 Removethe engine cowling the landing gear cuffs and the 1 bottom covering sheet as per chapter 51 00 01 2 Shore the aircraft as per Chapter 07 20 00 3 Drain brake system 4 Unfasten the ventilation tubings and disconnect the brake lines from the brake assembly 5 Remove the four landing gear attachment stop nuts LN9348 8 1 and the DIN 125 M8 washers 6 Remove the bottom halves of the mounting clamps 2 the anti abrasion strips 3 and the landing gear 4 7 Install in reverse sequence of removal using new stop nuts For correct position of landing gear the mandrel which is located at the bottom of the fuselage is to put into the respective sleeve at the top of the landing gear spring Replenish brake fluid per Chapter 12 32 11 02 Top Half of the Mounting Clamp Removal Installation Refer to Figure 2 1 Remove the main landing gear as per Chapter 32 11 01 2 Remove the LN9348 10 stop nuts the DIN125 M10 washers and the LN9037 10054 bolts 5 3 Remove the top half of the mounting clamp 6 4 Reverse procedure for installation PAGE DATE 25 Oktober 2013 TEMPORARY REVISION CHAPTER 32 N 03702 TR 02 20131025 PAGE 5 SERVICEMANUAL EXTRA 300 Chapter 34 00 00 34 10 00 34 10 01
16. SERVICEMANUAL EXTRA 300 Chapter 05 00 00 05 10 00 05 10 01 05 10 02 05 10 03 05 10 04 05 20 00 05 20 01 05 20 02 05 20 03 05 20 04 05 20 05 05 50 00 05 50 01 05 50 02 05 50 03 05 50 04 05 50 05 Table of Contents Title Overhaul Schaue 5 Recommended R T Time between Inspections SCHEDULED MAINTENANCE CHECKS 25 Hour Inspection Eiere ne 6 2 tioun nspecthion Air ee Maintenance Checks Schedule Significant Items Inspection UNSCHEDULED MAINTENAN CE CHECKS Ensine Bire ee Flightline Inspections 0 6 11 24 32 gt gt 3 34 34 PAGE DATE 25 Oktober 2013 TEMPORARY REVISION N 03702 TR 02 20131025 CHAPTER PAGE 05 2 SERVICEMANUAL EXTRA 300 05 10 00 05 10 01 05 10 02 refer to latest issue of Manufacturers Service Bulletin TIME LIMIT COMPONENTS 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 over haul or replacement of components should be accomplished not later than the specified period of operation for that componentor in accordance with the manufacturer s service data or airworthiness directives Overhaul Schedule Items shown here must be overhauled at the times indicated Item Engine Textron Lycoming Engine accessories together with engine Magneto
17. at belts O 1 Check seat belts for security attachment proper operation andcondition inspect whether edges start to fray inspect whether webbing lost its color top and bottom sides have a different shades O 3 Check hardware inspect for corrosion check whether buck les mate properly Check the buckles for easy opening O 4 Checkratchetassembly inspectfor corrosion loss of plating discoloration slippage and wear check for ease of operation If the harness does not pass the check it has to be reworked or replaced Contact the harness manufacturer in case of doubt 5 Check proper attachment of shoulder harness as per chapter 25 10 03 O 2 Check webbing inspect for fuzzy edges at the adjusters PAGE DATE 25 Oktober 2013 TEMPORARY REVISION CHAPTER 05 N 03702 TR 02 20131025 PAGE 18 EXTRA SERVICE MANUAL EXTRA 300 SCHEDULED MAINTENANCE CHECKS Maintenance Checks Schedule Inspections Fuel system Inspect the fuel lines for leaks security chafing dents and cracks Replace fuel lines as required Inspect fuel selector valve for operation and proper pointer indication Drain fuel system Check acro and center tank attachment Check acro center and both wingtanks for leaks Check bo
18. be installed using the 3 bar slide as shown in figure 6A Tuck excess webbing through the 3 bar slide Failure to make this third pass through the 3 bar slide will cause the belt to slip under load Make shure that after the proper length is determined the 3 bar slide is positioned as close to the structure as possible Shoulder Strap Attachment Figure 6A PAGE DATE 25 Oktober 2013 TEMPORARY REVISION CHARTERE 5 N 03702 TR 02 20131025 PAGE EXTRA SERVICEMANUAL EXTRA 300 25 10 04 Aircraft Document Bag Therearcockpitofthe Extra 300 is furnished with an aircraft document bag This aircraft document bag is mounted with three AN 526 C 1032 R8 bolts and DIN 9021 M5x20 washers on the right inside of the cockpit frame PAGE DATE 25 Oktober 2013 TEMPORARY REVISION CHAPTER 25 N 03702 TR 02 20131025 PAGE 8 EXTRA SERVICE MANUAL EXTRA 300 25 11 00 25 11 01 NOTE MAINTENANCE PRACTICES Reinforcement of Seat Attachment For the Serial No s V1 and 01 thru 63 it is advisable to strengthen the seat attachments Weld a reinforcement plate at the position as shown on Figure 7 Use steel grade 1 7734 4 or AN 4130 in conjunction with the TIG welding procedure Tungsten Inert Gas also called WIG welding thickness 1mm 0 04 Any welding needs to be done in accordance with FAA AC43 13 1A manual 7 Reinforcement of Seat Attachment Figure 7 PAGE DATE 25
19. c Inspections 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 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 813 Inspect all flight control ventilation holes for obstruction O 14 Inspect elevator balance weight for looseness and condition O15 Landing gear Inspect push rods Check landing gear for general condition Check landing gear spring for dents and cracks ojo 1 o o 2 olo Inspect landing gear spring mounting clamps and bolts for security 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 0101 2 Check fairings for dents and cracks O O 3 Checkfairing ventilation hole for obstruction Wheels refer to o
20. efore working on engine O O 1 Removeenginecowling 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 OJO 3 After this inspection clean cowling O O 4 Check fire protection according to EXTRA Service Bulletin 300 6 94 On GFRP cowlings repaint the fire protection paint WIEDOFLUGAT N 56582 T508 with clear coat 4232 0303 or HENSOTHERM 410KS with clear coat Glasurit 923 335 refer Chapter 51 30 01 if necessary o 0 0 5 Drain oil sump in accordance with Chapter 12 10 04 Engine Oil Replenishing oO oO 6 Clean oil suction screen at oil change check suction screen for metal particles shavings or flakes Consider Lyc SB N 480 latest issue 0 0 O 7 Cleanoil pressure screen atoil change check pressure screen for metal particles shavings or flakes Consider Lyc SB N 480 latest issue o o O 8 For engines using a full flow filtration system Replace oil filter Remove paper element from filter carefully unfold the paper element and examine the material trapped in the filter Con sider Lyc SB N 480 latest issue O 9 Inspect oil temperature sensor unit for leaks and security 1 each 25 hours for engines employing a pressure screen system 2 a spectrographic oil analysis is recommended at every 50 hours oil change
21. l Figure 6 1 Position aft bottom covering sheet in its original position 2 Plugthe optional OAT sensor wiring and or antenna wiring if applicable 3 Install aft bottom covering sheet attachment screws PAGE DATE 25 Oktober 2013 TEMPORARY REVISION CHAPTER 53 N 03702 TR 02 20131025 PAGE 112 SERVICEMANUAL EXTRA 300 Install LEXAN window 5 Repeat steps 1 thru 3 for the forward bottom covering sheets Install bottom cowling attachment screws one on either side without cowling present see two outer circles in fig ure 6 Loosen clamp screws on gascolator drain and fuel pump vent lines for easy access see inner dotted circles Prepare PR 812 firewall sealant by mixing brown part A with black part B with weight ratio 2 5 100 Clean areas from inside and outside with solvents at four positions pointed out by the arrows in figure 6 Immedi ately thereafter dry these areas with a new dry cloth 10 At the gascolator drain position A seal the remaining gap between firewall and bottom fuselage cover from inside and outside with PR 812 firewall sealant Minimum sealant thickness approximately 1 8 inch 3 mm 11 Repeat step 9 at positions B C and D 12 Cure time 77 F 25 C 50 RH for a fillet 1 8 inch thick tack free approx 24 hours to tough rubber approx 72 hours to performance properties approx 14 days 13 Fasten clamp screws on gascolator drain and fuel pump vent lines 14 Rem
22. n aircraft inspections presented in the latest edition of Cleveland Wheels amp Brakes Maintenance Manual and Service Bulletins for wheel tire and break inspections PAGE DATE 25 Oktober 2013 TEMPORARY REVISION CHAPTER N 03702 TR 02 20131025 PAGE EXTRA SCHEDULED MAINTENANCE CHECKS SERVICEMANUAL EXTRA 300 Maintenance Checks Schedule Inspections 1 Visually inspect the wheels for corrosion cracks or other visible damage 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 OJO 3 Inspectthe brake disc forrust excessive grooves large cracks coning or other visible damage Check if disc thickness 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 Replace on condition O 7 Repackbearings with AEROSHELL22C per MIL
23. nspect magnetos with riveted impulse coupling for wear as specified in the latest revision of TCM Bendix SB 599D 27 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 28 Inspect magnetos as outlined in the PERIODIC MAINTE NANCE Section of the applicable Support Manual Paragraph 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 29 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 Overhaul Manual 1 each 400 hours 2 each 500 hours 3 at engine overhaul and at the expiration of 4 years PAGE DATE 25 Oktober 2013 TEMPORARY REVISION CHAPTER 05 N 03702 TR 02 20131025 PAGE 15 SERVICEMANUAL SCHEDULED MAINTENANCE CHECKS EXTRA 300 Maintenance Checks Schedule Inspector Mechanic
24. of the hose and the pressure under which the hose is to operate Bends that are too sharp will reduce the bursting pressure of flexible hose considerably below its rated value PAGE DATE 25 Oktober 2013 TEMPORARY REVISION CHAPTER 20 N 03702 TR 02 20131025 PAGE 10 EXTRA SERVICEMANUAL EXTRA 300 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 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 compart ment are factory equipped with fire sleeves MIL H 8794 4 AE303 4 111 4 AE102 10 MIL H 8794 6 AE303 6 111 6 AE102 12 MIL H 8794 8 AE303 8 111 8 AE102 16 MIL H 8794 10 AE303 10 111 10 AE102 18 Fittings For the oil lubrication the fuel system and the brake system only AN fittings are used in the Extra 300 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 the hose The material code letter Aluminum alloy code D follows the dash number Example Elbow AN 822 8D Appl
25. ondition Shock mounts Lord Kinematics Barry Controls on condition but at the latest at each engine overhaul Bolts and Nuts on condition PAGE DATE 25 Oktober 2013 TEMPORARY REVISION N 03702 TR 02 20131025 CHAPTER 05 PAGE 5 EXTRA TIME LIMIT COMPONENTS SERVICE MANUAL EXTRA 300 05 10 04 Time Between Inspections Inspect these equipment items at the times shown Static Pressure System ATC Transponder fen prec Battery Concorde Refer to Concorde Servicing Instruction capacity check Every 24 calendar months in accordance with 14 CFR Ch 1 Part 43 App E For US registered airplanes Every 24 calendar months in accordance with 14 CFR Ch 1 Part 43 App F Par C and F For airplanes registered in other countries Observe the latest national aviation regulations PAGE DATE 25 Oktober 2013 TEMPORARY REVISION N 03702 TR 02 20131025 CHAPTER 05 PAGE SA EXTRA SCHEDULED MAINTENANCE CHECKS SERVICE MANUAL EXTRA 300 Maintenance Checks Schedule Date Inspector Serial No Mechanic Inspections 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 DANGER Ground magneto primary circuit b
26. or Serial No Mechanic Inspections O 1 Checkall cables and hoses replace when necessary O 2 Checkengine according to the Lycoming Manual O 3 Inspectfirewall andengine cowling for damage by high temperatures e g signs of blisters on the protective paint If necessary renew LJF PR 812 seals and on GFRP cowlings reapply the fire protection paint N56582 T508 and the lacquer 4243 0303 or HENSOTHERM 410KS with clear coat Glasurit 923 335 refer Chapter 51 30 01 05 50 04 Lightning Strike In the event of a lightning strike in flight or on ground check the following Serial No Inspections Check engine according to Lycoming Service Bulletin 401 Check the skin of the strike area for burns and melting Inspect bolts and fasteneners for burns and melting A Io lwp fe Check the electrical system with running engine for correct opera tion Check the avionic and antenna for correct operation Lh O 6 Check the magnetic compass for correct readings PAGE DATE 25 Oktober 2013 TEMPORARY REVISION CHAPTER 05 N 03702 TR 02 20131025 PAGE 34 EXTRA STANDARD PRACTICES AIRFRAME SERVICEMANUAL EXTRA 300 20 10 04 Special Torque Values Special torque values for the following items must be ad hered to in Torque value Nm in lbs
27. ost pump Check fuel filler caps for security and proper operation elven Reser Reiko a re fe Fee olny Gl ny AJO Check proper seat and condition of sealing lip from S No 59 Flight controls Remove wing access panels Inspect control surfaces for security of attachment free movement dents delaminations and cracks support for corrosion cracks and deformations Ensure proper attachment to aileron Inspect elevator trim system for proper operation and rigging Inspect hinges for condition cracks and security hinge bolts hinge bearings selflocking nuts Check free play in control system torque tube control surfaces control sticks rod end bearing deflector limiter Lubricate rear torque tube bearing Lubricate aileron rodend bearings trim flap hinges and trim lever bolt Check spades visually for general condition Inspect spade Lubricate adjustment tube of electrical pedal adjustment Check rudder cable system including sleeves fairleads pulleys and cable retracting springs per FAA AC 43 13 1A 1 each 25 hours PAGE DATE 25 Oktober 2013 TEMPORARY REVISION CHAPTER 05 N 03702 TR 02 20131025 PAGE 10 EXTRA SERVICE MANUAL EXTRA 300 SCHEDULED MAINTENANCE CHECKS Maintenance Checks Schedule 11 Inspector Mechani
28. ove the two bottom cowling attachment screws 15 Reinstall turtle deck landing gear cuffs and engine cowling as per Chapter 51 PAGE DATE 25 Oktober 2013 TEMPORARY REVISION CHAPTER 53 N 03702 TR 02 20131025 PAGE 13
29. rmany Type WLB 1 7734 4 1 0mm 1 5mm 2 0mm 3 0mm Paint Manufacturer GLASURITGmbH Max Winkelmannstr 80 D 48165 Miinster Hiltrup Germany Supplier WESSELS AG PagenstecherstraBe 121 D 49090 Osnabriick Germany Type 801 1552 Glassofix Grundfiiller EP AC 01 1492 965 32 2 Glassofix H rter EP SC 65 0322 21 Glassodur PUR Acryl Lack AD AE 2 1929 73 Glassodur MS H rter SC 29 0173 352 91 Glassodur Einstellzusatz SV 41 0391 51 30 03 Aluminium Components Aluminium sheet metal Manufacturer Kaiser Aluminium amp Chem Corp Spokane Washington Supplier Westdeutscher Metallhandel Postfach 104245 45141 Essen Type WLB 3 1364 T3511 or 2024 T3 0 6mm 0 8mm 1 2mm PAGE DATE 25 Oktober 2013 TEMPORARY REVISION CHAPTER 51 N 03702 TR 02 20131025 PAGE 12 SERVICEMANUAL EXTRA 300 Aluminium Components Control rod tubings Manufacturer AluminiumAG CH 5737 Menziken Supplier Karstens amp Knauer GmbH amp Co D 28865 Lilienthal Type WLB 3 1354 T3 25xlmm Paint Manufacturer GLASURITGmbH Max Winkelmannstr 80 D 48165 Miinster Hiltrup Germany Supplier WESSELS AG PagenstecherstraBe 121 D 49090 Osnabriick Germany Type Primer 283 150 Glassofix Grundf ller AB83 1150 352 228 Glassofix Zusatzl sung SC 12 0228 Lacquer 21 Glassodur PUR Acryl Lack AD AE2 1929 73 Glassodur MS Harter SC 29 0173 357 91 Glassodur Einstellzusatz SV 41 0391 Aluminium hardware metal brackets pedestals castings etc
30. system in the cockpit area and for the flight instruments PARKER STRATOFLEX or AEROQUIPPTFE type hoses are alternatively used as fuel oil and sensing lines Maintenance work or overhaul of these hoses requires the attention of the manufacturer informations and bulletins For the replacement of hose and hose assemblies EXTRA Flugzeugproduktions und Vertriebs GmbH should be con tacted Replacement of Flexible Hose Hose and hose assemblies should be checked for deteriora tion at each inspection period Leakage separation of the cover or braid from the inner tube cracks hardening lack of flexibility and excessive cold flow are apparent 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 a failure occurs in a flexible hose before the time limit refer to Chapter 05 10 02 Overhaul Schedule of the hose is achieved Obtain anew 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 according to size and construction
31. y Loctite 577 on all National Pipe Threads NPT before installation PAGE DATE 25 Oktober 2013 TEMPORARY REVISION CHAPTER 20 N 03702 TR 02 20131025 PAGE 11 SERVICEMANUAL EXTRA 300 Chapter 25 10 00 25 10 01 25 10 02 25 10 03 25 10 04 25 11 00 25 11 01 TABLE OF CONTENTS Title Frontisca o gt e o ene ene ey RESA I RN Seat DELS eee Aincran Document Base een MAINTENANCE PRACTICES Reinforcement of Seat Attachment GO Lh E UL Ww PAGE DATE 25 Oktober 2013 TEMPORARY REVISION N 03702 TR 02 20131025 CHAPTER PAGE 25 2 EXTRA FLIGHT COMPARTMENTS SERVICEMANUAL EXTRA 300 Seat belts Each strap end is fitted with LN 9037 0820 bolts LN9348 08 stop nuts and DIN 125 M8 washers to its own fitting at the steel frame refer to Figures 4 5 Side view Front Seat Belt Attachment Figure 4 Side view seat belts attachment points Rear Seat Belt Attachment Figure 5 The shoulder strap loops of the front and rear seat are attached to horizontal steel tubes as shown in Figure 6 PAGE DATE 25 Oktober 2013 TEMPORARY REVISION CHAPTER 25 N 03702 TR 02 20131025 PAGE 6 EXTRA FLIGHT COMPARTMENTS SERVICE MANUAL EXTRA 300 Seat belts tubes for shoulder strap attachment rear seat front seat Shoulder Strap Attachment Figure 6 The shoulder harness shall
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