Temporary Revision N.06702-TR-05-20131025
Contents
1. 47 Inspect firewall seals see EXTRA SB 300 6 94 48 Inspect alternator cable connections and accessories 49 Inspect condition and tension of alternator drive belt 50 Inspect security of alternator mounting S Inspect starter and starter drive 52 Check brake fluid level fill as required 53 Clean engine if necessary einer ler ee ee 54 Lubricate all controls per lubrication chart 55 Overhaul or replace propeller governor as required 56 Complete overhaul of engine or replace with factory rebuilt Reinstall engine cowling 1 refer to Woodward Service Bulletin No 33580 2 referto Lycoming Service Instruction No 1009 PAGE DATE 25 Oktober 2013 TEMPORARY REVISION CHAPTER 05 N 06702 TR 05 20131025 PAGE 18 EXIRA UNSCHEDULED MAINTENANCE CHECKS SERVICE MANUAL EXTRA300L 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 Inspector Serial No Mechanic Inspections 1 Check all cables and hoses replace when necessary O 2 Check engine according to the Lycoming Manual O 3 Check fire wall and engine cowling for damage by high temperatures e g signs of blister on2. 5 Remove the four landing gear attachment stop nuts LN9348 8 1 and the DIN 125 M8 washers 6 Removethe 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 Top Half of the Mounting Clamp Removal Installation Refer to Figure 1 Removethe 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 06702 TR 05 20131025 PAGE 4 EXTRA MATERIALS SERVICE MANUAL EXTRA 300L 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 91 Glassodur Einstellzusatz SV 41 0391 923 335 Glasurit Klarlack with Hensotherm 410KS Manufacturer Rudolf Hensel GmbH Lauenburger LandstraBe 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
3. of metal components Steel tubing except Serial No 45 thru 79 Manufacturer MHP Mannesmann Hoesch Prazisrohr GmbH Postfach 1713 D 59061 Hamm Germany Supplier HEINE BEISS WENGER 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 06702 TR 05 20131025 PAGE 11 SERVICE MANUAL EXTRA 300L Metal Components Steel sheet metal except Serial No 45 thru 79 Manufacturer B HLER Edelstahl GmbH Supplier Type M nchen Germany BOHLER Edelstahl GmbH Hansa Allee 321 D 40549 D sseldorf Germany WLB 1 7734 4 1 0mm 1 5mm 2 0mm 3 0mm Steel tubing Serial No 45 thru 79 Manufacturer Pacific Tube Company Supplier Type 5710 Smithway Street Los Angeles California 90040 USA Wicks Aircraft Supply Co 410 Pine Street Highland Illinois 62249 USA AISI4130 N MIL T 6736 Normalized 2 x 0 049 1 1 8 x 0 058 1 x 0 058 Sux 0 0581 7 8 x 0 0351 3 4 x 01035 50 8 x 00354 Steel sheet metal Serial No 45 thru 79 Manufacturer Cold Metal Products Inc Supplier Type 2301 So Holt Road Indianapolis In 46241 USA Wicks Aircraft Supply Co 410 Pine Street Highland Illinois 62249 USA AISI4130 N MIL S 18729 G Normal ized 0 04 0 063 0 08 0 1 0 125 PAGE DATE 25 Oktober 2013 TEMPORARY REVISI
4. TCM Bendix SB 643 27 Inspect magnetos equipped with snap ring impulse coupling Slick magnetos O 24 Adjust magneto to engine timing refer to Slick Magneto Maintenance and Overhaul Manual O25 Inspect wiring connections vent holes and P lead attachment referto Slick Magneto Maintenance and Overhaul Manual O 126 Inspect SlickSTART refer to Unison Operation Maintenance and Troubleshooting Manual AEIO 580 B 1 A engine only 1 each 400 hours 2 each 500 hours 3 atengine overhaul and at the expiration of 4 years PAGE DATE 25 Oktober 2013 TEMPORARY REVISION CHAPTER 0S N 06702 TR 05 20131025 PAGE 16 EXIRA SERVICE MANUAL EXTRA 300L Maintenance Checks Schedule Inspector Mechanic Inspections Inspect ball bearing assembly impulse coupling coil contact points condenser and carbon brush 20 Replace ball bearings 30 Lubricate magnetos 3 Overhaul or replace magnetos Check fuel injector for general condition clean fuel inlet screen O 33 Inspect intake seals and O rings for leaks and clamps for tightness Inspect flexible fuel lines fuel injection lines and fittings for leaks security chafing dents and cracks referto Lycoming SB 342 each 100h re
5. pedestals castings etc 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 06702 TR 05 20131025 PAGE 13A EXTRA SERVICE MANUAL EXTRA 300L REPAIRS 51 70 05 NOTE Structural Repair of Steel Components Restoration of a damaged fuselage to its original design strength shape and alignment involves careful evaluation of the damage followed by exacting workmanship in perform ing the repairs Should structural repairs practicable on the aircraft be necessary refer to Aircraft Inspection and Repair FAA AC 43 13 1A and Aircraft Alterations Accept able Methods Techniques and Practices FAA AC 43 13 2A Consult EXTRA in case of doubt about a repair not specifically mentioned there Alterations or repair of the airplane must be accom plished by icensed personnel Consider that except from Serial No 45 thru 79 WLB 1 7734 4 type steel has been used for the complete fuselage structure so as steel tubes brackets connections etc steel tubes arein mm measurements From Serial No 45 thru 79 AISI 4130 N type steel is used steel tubes are in inch measurements Also refer to Chapter 51 30 02 The two steel types shall not be mixed in repair If welding work must be performed use only the TIG procedure Tungsten Inert Gas Use steel we
6. the protective paint If necessary renew LJFPR 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 J Date Inspector Serial No Mechanic 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 ea eier A Io lwp fe Check the electrical system with running engine for correct opera tion o tA Check the avionic and antenna for correct operation O 6 Check the magnetic compass for correct readings PAGE DATE 25 Oktober 2013 TEMPORARY REVISION CHAPTERS 0S N 06702 TR 05 20131025 PAGE 39 EXTRA FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 300L 32 11 00 32 11 01 32 11 02 MAINTENANCE PRACTICES Main Landing Gear Removal Installation Refer to Figure 1 Removethe 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 4 Unfasten the ventilation tubings and brake lines and dis connect the brake lines from the brake assembly
7. 5 10 04 Time Between Inspection Inspect these equipment items at the times shown LEN co Battery Concorde Refer to Concorde Servicing Instruction capacity check Every 24 calendar months in accordance with 14 CFR Ch 1 Part 43 App E ATC Transponder 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 CHARTERTOS N 06702 TR 05 20131025 PAGE 6 EXIRA SERVICE MANUAL EXTRA 300L MODICO Giedo se Inspector Mechanic Inspections Engine compartment Refer to latest edition of Textron Lycoming Operator s and Maintenance Manual and SB s Christen Product Manual 801 Series and SB s Slick Magneto Maintenance and Overhaul Manual and SB s and TCM Bendix Service Support Manual included in Form X40000 Master Service Manual and SB s DANGER Ground magneto primary circuit before working on engine Removeengine cowling 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 Check optional landing light for dirt After this inspection clean cowling Check fire protection according to EXTRA Service Bulletin 300 6 94 On GFRP cowlings repaintthe fi
8. EXTRA TIMELIMIT COMPONENTS SERVICE MANUAL EXTRA 300L 05 10 03 Recommended Replacement Times 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 on the recommendation Battery a Sonnenschein of the manufacturer Battery b Concorde Battery of the Pointer ELT Battery of the Artex ELT Battery of Garmin GNC 420W on condition recommended replacement A Pun to avoid Internal Battery of 3 years 800 hours or unscheduled maintenance Aspen EFD Pilot PFD nconditien Wheels Cleveland Parker on condition Tires on condition Fuel oil sensing amp brake hoses after first 7 years Rubber Type MS28741 then 5 years Fuel Oil amp Sensing hoses on condition PTFE Type MIL DTL 25579 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 Brake and Brake Assembly on condition Cleveland Parker Rudder control cable on condition Fairleads on condition Shock mounts on condition Lord Kinematics Barry but at the latest at each Controls engine overhaul Bolts and Nuts on condition if not stated otherwise PAGE DATE 25 Oktober 2013 TEMPORARY REVISION CHAPTER 05 N 06702 TR 05 20131025 PAGE 3 SERVICE MANUAL EXTRA300L 0
9. ON CHAPTER 51 N 06702 TR 05 20131025 PAGE 112 SERVICE MANUAL EXTRA 300L Paint Manufacturer GLASURITGmbH Max Winkelmannstr 80 D 48165 M nster Hiltrup Germany Supplier WESSELSAG Pagenstecherstra e 121 D 49090 Osnabr ck Germany Type 801 1552 Glassofix Grundf ller EP AC 01 1492 965 32 2 Glassofix H rter EP SC 65 0322 21 Glassodur PUR Acryl Lack AD AE2 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 Control rod tubings Manufacturer AluminiumAG CH 5737 Menziken Supplier Karstens amp Knauer GmbH amp Co D 28865 Lilienthal Type WLB 3 1354 T3 25xImm PAGE DATE 25 Oktober 2013 TEMPORARY REVISION CHAPTER 51 N 06702 TR 05 20131025 PAGE 13 SERVICE MANUAL EXTRA 300L Aluminium Components Paint Manufacturer GLASURITGmbH Max Winkelmannstr 80 D 48165 M nster Hiltrup Germany Supplier WESSELSAG Pagenstecherstra e 121 D 49090 Osnabr ck Germany Type Primer 283 150 Glassofix Grundf ller AB83 1150 352 228 Glassofix Zusatzl sung SC12 0228 Lacquer 21 Glassodur PUR Acryl LackAD AE2 1929 73 Glassodur MS H rter SC 29 0173 352 91 Glassodur Einstellzusatz SV 41 0391 Aluminium hardware metal brackets
10. il in accord 1 each 500 hours 2 each 300 hours 3 each 25 hours PAGE DATE 25 Oktober 2013 TEMPORARY REVISION CHAPTERS 0S N 06702 TR 05 20131025 PAGE 15 SERVICE MANUAL EXTRA300L 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 wearor 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 theapplicable Support Manual O 26 Inspect magnetos with riveted impulse coupling for wear as specified in the latest revision of TCM Bendix SB 599D for wearasoutlinedinthe 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
11. l The layer sequences of the composite parts are shown in Figures 2 6 Allcomposite 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 06702 TR 05 20131025 PAGE 3 SERVICE MANUAL EXTRA300L Minimum sealant thickness approximately 1 8 inch 23mm Repeat step 6 at positions B C and D Cure time 77 F 25 C 5096 RH for a fillet 1 8 inch thick tack free approx 24 hours to tough rubber approx y hours to performance properties approx 14 days Fasten clamp screws on gascolator drain and fuel pump vent lines 10 Remove the two bottom cowling attachment screws 11 Reinstall main fuselage cover as per Chapter 53 00 03 12 Reinstall landing gear cuffs and engine cowling as per Chapter 51 00 01 PAGE DATE 25 Oktober 2013 TEMPORARY REVISION CHAPTER 53 N 06702 TR 05 20131025 PAGE 16
12. lding wire 1 7734 2 except from Serial No 45 thru 79 or 1 7324 1 7734 2 or equivalent from Serial No 45 thru 79 for welding additive PAGE DATE 25 Oktober 2013 TEMPORARY REVISION CHAPTER 51 N 06702 TR 05 20131025 PAGE 30 SERVICE MANUAL EXTRA300L 53 00 00 GENERAL The fuselage structure of the EXTRA 300L consists of a TIG welded steel tube construction integrating the wing and empennage connections refer to Figure 1 The particular areas ofthe fuselage are covered with different 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 IWIEDOFLUGAT N 56582 T508 with clear coat 4232 0303 or HENSOTHERM 410KS with clear coat Glasurit 923 335 refer Chapter 51 30 01 The optional carbon cowlings have been coated with fire protection paint up to serial number 1323 The fire protec tion paint for carbon cowlings does not need to be renewed when uncomplete or worn out The main fuselage cover consists of glass fibre carbon fibre and aramid laminate The bottom fuselage cover is made of carbon fibre and aramid fibre laminate the cuffs of carbon fibre laminate The lower rear part of the fuselage is covered with fabric The window portion is of acrylic glass The tail fairing consists of glas fibre laminate and the tail side skins are made of aluminium sheet meta
13. place or overhaul as required or at engine overhaul Check fire protection according to EXTRA SB 300 6 94 O 35 Check fuel system for leaks O 36 Remove clean and inspect gascolator screen and fuel filter bowl Inspect throttle mixture and propeller governor controls for security travel and operating conditions 38 ei Inspect exhaust stacks connections and gaskets replace gaskets as required 39 Inspect exhaust slipjoints for general condition 40 Inspectexhaust system attachment 41 Inspectcrankcase for cracks leaks and security of seam bolts cox eie tee 42 Check engine mounted accessories such as pumps tempera ture and pressure sensing units for leaks secure mounting and tight connections each 500 hours each 1000 hours 4A UC bh m together with engine clean at least every 90 days PAGE DATE 25 Oktober 2013 TEMPORARY REVISION CHARTER 0S N 06702 TR 05 20131025 PAGE Ny EXIRA SERVICE MANUAL EXTRA 300L 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 mount for deterioration replace as required
14. re 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 Drain oil sump in accordance with Chapter 12 10 04 Engine Oil Replenishing Clean oil suction screen at oil change check suction screen for metal particles shavings or flakes Consider Lyc SB N 480 latest issue Clean oil pressure screen at oil change check pressure screen for metal particles shavings or flakes Consider Lyc SB N 480 latest issue 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 1 each 25 hours for engines employing a pressure screen system 2 aspectrographic oil analysis is recommended at every 50 hours oil change 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 06702 TR 05 20131025 PAGE 14 EXIRA SERVICE MANUAL EXTRA 300L Verne timed e eres Inspections Inspect oil temperature sensor unit for leaks and security Inspect flexible oil lines oil return lines and fittings for leaks security chafing dents and crack
15. s 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 Clean and inspect oil radiators and attachment Remove and flush oil radiators Inspect Christen Inverted Oil System for general condition leaks secure mounting and tight connections Clean and flush the Inverted Oil System with a suitable petro leum solvent such as varsol according to Lycoming Opera tor sand Maintenance Manual ance with Chapter 12 10 04 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 Inspect spark plug cable leads and ceramics for corrosion and deposits Perform a hot engine differential compression check in accordance with FAA AC 43 13 1A Inspect cylinders for cracked or broken fins Check cylinders for evidence of excessive heat which is indicated by discoloration Check fuel injector nozzles for loseness Tighten to 60 inch pounds torque Check fuel lines for fuel stains which are indicative for fuel leaks Inspect rocker box covers for evidence of oil leaks If found replace gasket torque cover screws 50 Inch pounds Service engine with recommended lubricating o
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