Chapter 05 Time Limits/Maintenance Checks
Contents
1. O 7 Clean suction oil strainer at oil change check strainer for foreign particles 07 0 O 8 Change full flow cartridge type AEIO 360 A1E type en gine oil filter element check element for foreign particles 9 Inspect oil temperature sender unit for leaks and security 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 condition of fire sleeves 11 Clean and inspect oil radiator and attachment o 12 Remove and flush oil radiator 1 at10 and 25 hours and then each 25 hours 2 at 10 and 25 hours 3 each 500 hours PAGE DATE 15 December 1999 CHAPTER 05 PAGE 12 EXTRA FLUGZEUGBAU GmbH SCHEDULED MAINTENANCE CHECKS SERVICE MANUAL EXTRA 200 Maintenance Checks Schedule gt ae Date Inspector ey Serial No Mechanic Inspections OJO Inspect Christen Inverted Oil System for general condition leaks secure mounting and tight connections o 13 Clean and flush the Inverted Oil System with a suitable petroleum solvent such as varsol according to Lycoming Operator 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 Lycoming2. O Visual check of painting for deteriorated paint PAGE DATE 1 July 1996 CHAPTER 05 PAGE 31 EXTRA FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 200 05 50 00 IMPORTANT 05 50 01 05 50 02 UNSCHEDULED MAINTENANCE CHECKS Unscheduled checks are only performed after abnormal events which could possibly have caused damage to the aircraft or impaired the airworthiness In case of abnormal events or any exceedance of given limitations load factor never exceed speed etc the manufacturer has to be contacted to find appropriate maintenance procedures Therefore the procedures de scribed in the following could be subjected to changes In case of doubt or visible damage perform a 100 hour check per Chapter 05 20 03 in addition to the checks presented below Violent Stopping of the Engine Propeller Strike In a case where the propeller has struck the ground or the engine has been stopped violently shock loading the complete engine has to be disassembled and checked by an authorized company The crankshaft might be damaged Also refer to the latest issue of the Lycoming SB 201 The propeller has to be checked and repaired by an authorized company according to MT propeller instruction Refer to MT propeller Operation and Installation Manual E 124 Hard Landing After an extremely hard landing or other unusual loads on the landing gear perform a check as described in the following even when
3. ing to CHRISTEN 80linstruction Refer to CHRISTEN Product Manual P N 70047 001 or to TEXTRON LYCOMING Operator s Manual P N 60297 21 9 Carry out general engine check as instructed by TEXTRON LYCOMING Operator s Manual P N 60297 21 10 Visualinspectionofcowling for dents cracks delamination and smoke marks Hardware 1 Magnaflux or fluorescent dye check of the wing main spar bolts by authorized personnel is required Remove only one bolt at a time Inspect for security of the spar bolts and safety screws 2 Check harness attachment fittings for cracks deformations and corrosion 3 Check bolts and nuts in critical areas for fretting wear damage stretch proper torque and safety 4 Visual inspection of center tank fastening straps for cracks damage and corrosion O5 Visual inspection of battery fastening straps for cracks damage and corrosion 6 Check the quick pins of the seat adjustment for cracks deforma tions and corrosion Inspect wear and proper function PAGE DATE 1 July 1996 CHAPTER 05 PAGE 30 EXTRA FLUGZEUGBAU GmbH SCHEDULED MAINTENANCE CHECKS SERVICE MANUAL EXTRA 200 Significant Items Inspection A Date Inspector N Serial No Mechanic S S S Inspections 7 Visual inspection of rudder pedal mounting to the attachment fittings Check bolts for security Surface general
4. 200 Wing Leading edge 1 Detailed visual inspection on the surface for erosion scratches stone nicks and impact damages O 2 Detailed visual inspection on the bonding top bottom for dents cracks and delaminations O 3 Inspect grounding rivets visually Main spar section O 4 Check bonding skin spar for delaminations by coin tapping Refer to Chapter 20 10 05 5 Detailed visual inspection on the sparweb for dents cracks and delaminations by visual inspection through wing access holes using a boroscope Auxiliary spar section O 6 Check bonding skin spar for delamination by coin tapping 7 Detailed visual inspection on the aux spar web for dents cracks and delaminations Pay particular attention to the cutout for aileron cantilever 8 Inspect attachment fitting for damage corrosion and link bolts security Spar carry through 9 Remove spar cap paint by a solvent Perform visual inspection for dents and cracks Check for delaminations by coin tapping Restore finish in accordance with Chapter 51 70 05 10 Remove spar web paint by a solvent Perform visual inspection for dents and cracks Check for delaminations by coin tapping Restore finish in accordance with Chapter 51 70 05 PAGE DATE 15 December 1999 CHAPTER 05 PAGE 24 EXTRA FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 200 SCHEDULED MAINTENANCE CHECKS Significant
5. Check landing gear spring for dents and cracks O 3 Inspect landing gear spring mounting clamps and bolts for security 4 Lubricate landing gear center bolt and landing gear bearings 5 Check wheel rake 10 0 5 and toe in 1 5 0 5 per Chapter 32 Fairings Disassemble fairings JO 2 Check fairings dents and cracks 3 Check fairing ventilation hole for obstruction PAGE DATE 1 July 1996 CHAPTER 05 PAGE 18 EXTRA FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 200 SCHEDULED MAINTENANCE CHECKS Maintenance Checks Schedule Date Inspector Serial No Mechanic Inspections Wheels refer to on aircraft inspections presented in the latest edition of Cleveland Wheels amp Brakes Maintenance Manual and Service Bulletins for wheel tire and break inspections Visually inspect the wheels for corrosion cracks or other visible damage 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 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 5 Remove wheels
6. Items Inspection Date Inspector Serial No Mechanic Inspections O 11 Check main bolt sleeves for secure bonding to the spar Wing trailing edge O 12 Check bonding top bottom for cracks and delaminations by coin tapping Refer to Chapter 20 10 05 Root and Tip Check root rib for cracks delaminations and secure bonding to skin and spars by coin tapping Refer to Chapter 20 10 05 Inspect tip rib visually for general condition Check metall fittings power supply support for secure bonding to the carbon laminate Aileron O Check root and tip rib bonding to the skin laminate by coin tapping Check bonding skin spar for delaminations by coin tapping Checkbonding top bottom for cracks and delaminations by coin tapping Refer to Chapter 20 10 05 Check hinge points mounting brackets and actuator for damages and cracks Ensure proper attachment Inspect spades visually for general condition Check spade support for corrosion cracks and deformations Ensure proper attachment to aileron Inspect ventilation holes for obstruction Surface general Check painting visually for general condition blisters etc Check laminate for erosion scratches and nicks Control system Inspect bell cranks for damage corrosion security of mounting and link bolts through wing access holes Inspect control rods fo
7. lever Check the alternator warning light or ammeter PAGE DATE 1 July 1996 CHAPTER 05 PAGE 10 EXTRA FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 200 SCHEDULED MAINTENANCE CHECKS Maintenance Checks Schedule gt Date Inspector S Q Serial No Mechanic DAIA Inspections 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 18 Ignition OFF main switch OFF remove ignition key 19 Check ifignition 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 1 DANGER Ground magneto primary circuit before working on propeller Remove spinner and check for cracks Check blade shake max 3 mm or 1 8 inch Check blade angle play max 2 Inspect outside condition of hub and parts for cracks corrosion deterioration Inspect check nut for high pitch stop for tightness Check all safety means to be intact Check flange bolts or stopnuts for tightness Check front and rear spinner plate for cracks and fixing Inspect blade root and hub fo
8. 100 hours Figure 3 PAGE DATE 1 July 1996 EXTRA FLUGZEUGBAU GmbH SCHEDULED MAINTENANCE CHECKS SERVICE MANUAL EXTRA 200 05 20 03 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 3 A Date Inspector ty AS Serial No Mechanic n Inspections Operational Checks 1 Start engine in accordance with the Pilot s Operating Handbook 2 Check the fuel quantity indication 3 Check oil pressure and temperature OJOJ 4 Check generator output 5 Check magneto RPM drop at 1800 RPM Allowed drop is 175 RPM and no greater diff between L from 50 RPM 6 Check ignition OFF function at 1000 RPM for a short moment 7 Check response of the engine by power setting changes OJOJ 8 Check the Propeller response at 1800 RPM when changing pitch 9 Check idle speed is between 650 and 750 RPM 10 Check the fuel flow and manifold pressure indicator 11 Check the EGT and CHT indicator 12 Check mixer function per CHT EGT indication 13 Check idle mixture 14 Check function of the fuel selector valve 15 Check the radio and the other electronic equipment 10 16 Shutdown engine using mixture
9. E CHECKS SERVICE MANUAL EXTRA 200 Maintenance Checks Schedule Date Inspector CAS 7 WALA Serial No Mechanic Inspections 39 Inspect exhaust system attachment 40 Inspect crankcase for cracks leaks and security of seam bolts JO 41 Check engine mounted accessories such as pumps tempera ture and pressure sensing units for leaks secure mounting and tight connections 42 Inspect all air inlet duct hoses replace as required 43 Inspect engine mount for cracks and loose mountings 44 Inspect engine baffles free from cracks and fraying 45 Inspect all wiring connected to the engine or accessories o ported cde 46 Inspect engine shock mounts for deterioration replace as required O 47 CheckPRCPR 812 firewall sealantatall firewall penetrations bowden cables around firewall fittings etc Refer to PRC product information if replacement is necessary 48 Inspect alternator cable connections and accessories 49 Inspect condition and tension of alternator drive belt 50 Inspect security of alternator mounting 5 Inspect starter and starter drive 52 Lubricate starter drive 53 Check brake fluid level fill as required 54 Clean engine if necessary 55 Lubricate all controls per lubrication chart o 56 Overhaul or replace propeller governor as required o 56 Complete overhaul of engine or replac
10. EXTRA FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 200 Chapter 05 Time Limits Maintenance Checks PAGE DATE 1 July 1996 CHAPTER 05 PAGE 1 EXTRA FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 200 Chapter 05 00 00 05 10 00 05 10 01 05 10 02 05 10 03 05 20 00 05 20 01 05 20 02 05 20 03 05 20 04 05 50 00 05 50 01 05 50 02 05 50 03 05 50 04 05 50 05 Table of Contents Title GENERAL oo iene i e deter 3 TIME LIMIT COMPONENTS 4 Generalerna tari dtr 4 Overhaul 4 Replacement Schedule sss 5 SCHEDULED MAINTENANCE CHECKS 6 General ast coe qeu ERE Sen EAR aS E 6 25 Hour Inspection Aircraft 6 Maintenance Checks Schedule 10 Significant Items Inspection 24 UNSCHEDULED MAINTENANCE CHECKS 32 Violent Stopping of the Engine Propeller Strike 32 Hard Landing 32 34 Lightning Strike iiec bi o rm RO thoro Ub 34 Flightline Inspections osse 35 PAGE DATE 1 July 1996 CHAPTER 05 PAGE 2 EXTRA FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 200 05 00 00 NOTE DANGER 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 200 The periodic inspections and checks de scribed and theirrecommended time intervals are minimum requirements for maintaining the aircraft
11. GBAU GmbH SCHEDULED MAINTENANCE CHECKS SERVICE MANUAL EXTRA 200 Maintenance Checks Schedule S Date A Re is ate Inspector S PARS Serial No Mechanic CII SS Inspections General 1 Perform checks given for special equipment installed refer to Chapter 95 Reinstall access panels per Ch 51 Aircraft conforms to Specifications of respective Authority required airworthiness directives complied with fam All EXTRA mandatory Service Bulletins complied with ololololo a Mc des Mao o vendor Service Bulletins and Service Letters complied with o 1 Check for proper flight manual 8 Aircraft papers in proper order B Min 3 5mm 1 8 Min 6 0mm 1 4 Rudder Pedal with newly installed rudder cables Safety Wire Hole Safety Sto ety p Minimum Clearance Check Figure 4 STRAIGHT EDGE OR SURFACE PLATE Coning Check Figure 5 1 as required PAGE DATE 1 July 1996 CHAPTER 05 PAGE 23 EXTRA FLUGZEUGBAU GmbH SCHEDULED MAINTENANCE CHECKS SERVICE MANUAL EXTRA 200 05 20 04 Significant Items Inspection Every 1000 flight hours the Significant Items Inspection must be performed in addition to the 100 hour inspection Ae Date Inspector z Serial No Mechanic S Inspections EXTRA
12. H SCHEDULED MAINTENANCE CHECKS SERVICE MANUAL EXTRA 200 Maintenance Checks Schedule A Date Inspector A Serial No Mechanic Inspections O O 4 Inspecttail wheel spring and swivel arm mounting bolts for security 5 Check for general condition and function Pay attention to the free movement of the rudder 6 Check the connector springs for light precompression 7 Check wheelfork for free rotation and steering function damage dents cracks and corrosion JO 8 Inspect wheelfork for damage dents cracks and corrosion 9 Inspect the axle bolt and nut for fretting wear damage and stretch JO 10 Lubricate tail wheel steering Wing I Check wing for dents cracks and delaminations 2 Inspect wing spar main bolts for looseness and security 3 Check the safety wire and the safety screw of the wing main spar bolt 4 Inspect wing spar main sleeves for looseness and bearing load 5 Inspect wing auxiliary spar attachment O 6 Inspect wing ventilation holes for obstruction JO 7 Check inside wing structure in the area of access panels Stabilizer 1 Check stabilizer for dents cracks stone nicks and delaminations O O 2 Inspectstabilizer spars main bolts for looseness and security O 3 Inspect stabilizer auxiliary spars attachm
13. I PIN 3111899 CHAPTER 05 PAGE Lubrication Chart 50 hours Figure 2 PAGE DATE 1 July 1996 SCHEDULED MAINTENANCE CHECKS uooq sued uou jueoriqng STU SMN x uoneonqn 9401494153 moj 2509409 eisuay IO 084 17 TIIIN X VIOT ON TS 21 Jo onsst 15978 29 510 18 A4ISOOSIA 918015 18 jutsjodsIp ssayyse 8 1827 11 sINoY 06 1511 18 8 C809 T IHA jueauqn peseq 4 p 909c H IHA W dure mo ased qzce18 D TIN uoneouqn esesi TIT 8 qn e 34149315 PM rep e 1349 WIL 5 x sosury dey EXTRA FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 200 KL s noy 001 sguieaq Jeos Surpue T suid 49 1109 1911899 4 9 S 0J3u0o JUTSU s epod PIPI eqni 1ueunsnfpy IIOAJIOSOI PIN eset 3111899 usrueqoour 914938 sosury Adour CHAPTER 05 PAGE Lubrication Chart
14. L EXTRA 200 LZ Ele x 2 B _ amp Root Rib Aileron Root Elevator Root Horizontal Stabilizer Stall Warn Transducer Lower Root Rudder Fin Lower Root Rudder Horn 0 Wheel Fairing Nose Ribs Aileron Hinge Gaps M Drain and Vent Holes Figure 1 PAGE DATE 1 July 1996 CHAPTER 05 PAGE 7 SCHEDULED MAINTENANCE CHECKS po quiossesip aavy syed ULIN STUL S x uoneonqn 94012494153 Mo 5509409 OL8L TIIN X ON TS 2 Jo onsst 15978 995 STIO 18 AJISODSTA 9181 18 jutsjodsIp ssayyse 182 11 sInoyY 06 1541 18 8 C809 T IHA jueauqn peseq 4 p onnejpH 9096 eusooy dure mo uoneoniqn qzce18 D TIIN uoneouqn eseai TI 8 KL SulJeaq qn e 31119315 1349 WIL 0 x soSurq dey z EXTRA FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 200 SJnOU 06 eyo uoneoriqn sguieaq Jeos Surpue T 49 1104 1911989 4 9 1003409 S 0J3u0o IIOAJOSO
15. Service Instruction 1042 If fouling of spark plugs has been apparent rotate bottom plugs to upper plugs and vice versa 16 Inspect spark plug cable leads and ceramics for corrosion and deposits JO 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 JO 19 Check cylinders for evidence of excessive heat which is indicated by discoloration 20 Check fuel injector nozzles for looseness 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 o 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 O 23 Inspect ignition harness for general condition free from fraying or chafing and insulators for high tension leakage and continuity 1 each 300 hours 2 each 400 hours PAGE DATE 1 July 1996 CHAPTER 05 PAGE 13 EXTRA FLUGZEUGBAU GmbH SCHEDULED MAINTENANCE CHECKS SERVICE MANUAL EXTRA 200 Maintenance Checks Schedule CAS Date Inspector ty Serial No Mechanic a Inspections 24 Adjust magneto to engine timing
16. and wheel bearings Inspect wheel bearing grease for contamination and solidification 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 Inspect wheel bearings for excessive wear or damage Re place on condition Repack bearings with AEROSHELL 22C per MIL G 81322 or equivalent Reinstall wheels and safety Check wheel bearing clearance and wheels for free rotation Tires Visually inspect tires for cuts flat sports and tread or side wall damage If changing of tires is necessary follow the instructions including off aircraft inspection of wheels presented in the Cleveland Wheels amp Brakes Component Maintenance Manual Check inflation pressure 2 6 bar 38 psi Proper inflation will provide maximum tire and wheel life PAGE DATE 1 July 1996 CHAPTER 05 PAGE 19 EXTRA FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 200 SCHEDULED MAINTENANCE CHECKS Maintenance Checks Schedule CAS Date Inspector 9 SK Serial No Mechanic a Inspections Brake system O O 1 Inspect brake assemblies for general condition O O 2 Inspect master cylinders for leaks 3 Inspectbrake system plumbing for leaks and hoses for bulges and deter
17. ating 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 July 1996 CHAPTER 05 PAGE 3 EXTRA FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 200 05 10 00 05 10 01 05 10 02 refer to latest issue of Manufacturer s Service Bulletin TIME LIMIT COMPONENTS General 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 Overhaul Schedule It is recommended to overhaul the items shown here at the times indicated The times may be modificated by the respective national authorities Engine Textron Lycoming together with Engine accessories engine Magneto Slick Propeller MT Propeller Governor Woodward other components on Condition PAGE DATE 1 July 1996 CHAPTER 05 PAGE 4 EXTRA FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 200 TIME LIMIT COMPONENTS 05 10 03 on the recommendation of the manufacturer if not stated otherwise Replacement Schedule It is recommended t
18. ch and proper torque Steerable tail wheel 1 Disassemble tail wheel per Ch 32 Inspect for signs of wear and damage Check general condition and proper function O 2 Check connector springs for signs of wear and light precompression Pay attention to the free movement of the rudder 3 Inspect wheelfork visually for damage dents cracks and corrosion O 4 Inspect axle bolt and nut for fretting wear damage and stretch O 5 Check rubber tire for general condition PAGE DATE 1 July 1996 CHAPTER 05 PAGE 29 EXTRA FLUGZEUGBAU GmbH SCHEDULED MAINTENANCE CHECKS SERVICE MANUAL EXTRA 200 Significant Items Inspection lt gt Date Inspector 9 oY Serial No Mechanic gt Inspections Engine compartment 1 Check firewall for dents cracks and deformation Visual inspection of PR 812 sealant for porosity and general condition O 2 Inspect tubular engine mount for dents cracks and corrosion Check all bolts for security and condition O gt Visual inspection of rubber mounts shock mounts for porosity and general condition Inspect flexible hoses for damage and leakage Visual inspection of fire sleeves for chaffing and general condition Check electric wiring for proper connection Check grounding straps for proper connection QUO eo t A Visual inspection of inverted oil system for general condition accord
19. cks and proper attachment O 7 Detailed visual of mass balance attachment and mounting boom for deformation corrosion and cracks 8 Detailed visual of trim tab hinges actuator lever for damage cracks excessive wear and proper bonding to the laminate Detailed visual for delamination O 9 Inspect ventilation holes for obstruction Surface general 10 Check painting for general condition blisters etc 11 Check laminate for erosion scratches stone nicks and impact dam ages Fuselage O 1 Inspect tubular steel frame visually for corrosion scratches and damages O 2 Check wing main spar attachment for damage and corrosion Inspect for dents and cracks 3 Detailed visual of the sheet metal of the wing auxiliary spar attach ment for damage corrosion Inspect the sheet metal supports using a fluorescent dye penetrant to insure no cracks are evident O 4 Detailed visual of cockpit frame visually for dents cracks and delaminations 5 Inspect main fuselage cover visually for dents cracks and delamination Flight controls O 1 Detailed visual of torque tube for damages cracks free play and stop adjustments O 2 Detailed visual of bell cranks for damage cracks corrosion security of mounting and link bolts 3 Inspect control rods for loose or popped rivets and general condition O 4 Inspect sticks rear amp front for full travel proper rigging free play security of mounting and d
20. curity Inspect main and auxiliary wing spar connector for general condition PAGE DATE 1 July 1996 CHAPTER 05 PAGE 16 EXTRA FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 200 SCHEDULED MAINTENANCE CHECKS Maintenance Checks Schedule CAS Date Inspector CAS AS Serial No Mechanic Inspections Fuel system 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 3 Drain fuel system 4 Check acro and center tank attachment 5 Check acro center and both wing tanks for leaks O IO 6 Check boost pump JO 7 Check fuel filler caps for security and proper operation JO 8 Check proper seat and condition of sealing lip Flight controls 1 Remove wing access panels O O 2 Inspect control surfaces for security of attachment free movement dents delaminations and cracks O 3 Inspectelevator trim system for proper operation andrigging 4 Inspecthinges for condition cracks and security hinge bolts hinge bearings self locking nuts 5 Check free play in control system torque tube control surfaces control sticks rod end bearing deflector limiter 6 Lubricate reartorque tube bearing Remove bolt fo
21. e with factory rebuilt 1 refer to Woodward Service Bulletin No 33580 2 refer to Lycoming Service Instruction No 1009 PAGE DATE 1 July 1996 CHAPTER 05 PAGE 15 EXTRA FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 200 Date Inspector ty Sy Serial No Mechanic oo AS Inspections Fuselage Remove tail fairing tail side skins main fuselage cover and landing gear cuffs per Chapter 51 Remove bottom fuselage cover including exhaust area cov ering sheet per Chapter 51 Inspect main fuselage cover bottom fuselage cover including exhaust area covering sheet tail fairing tail side skins and landing gear cuffs for general condition dents cracks and loose screws Check installed parts for general condition and security of attachment Inspect fuselage for foreign matters O ON 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 Inspect fabric cover for general condition Inspect wooden longerons for damage Clean and lubricate canopy hinge and latching mechanism 10 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 11 Inspect breather line for obstructions and se
22. ent O 4 Inspect stabilizer ventilation holes for obstruction PAGE DATE 1 July 1996 CHAPTER 05 PAGE 21 EXTRA FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 200 SCHEDULED MAINTENANCE CHECKS Maintenance Checks Schedule Date Inspector eG 6 N Serial No Mechanic oY S s Inspections Instruments 1 Check front and rear panel mounting for security and safety Check shock mounts for general condition 2 Check operation mounting and wiring of switches for condition and safety 3 Check automatic circuit breaker mounting and wiring for condition and safety O 4 Inspect stall warner system for condition and security of installation perform operational check 5 Check wing tip position strobe lights or single strobe light for security and operation O O 6 Inspect compass and compass deviation card for proper indication and compensation o 7 Magnetic compass compensation 8 Check pitot static air pressure lines for condition and leaks perform operational check Electrical system O JO 1 Check engine bonding JO 2 Check tank bonding wing and center tank 3 Check system wiring free from fraying or cracks O 4 Inspect battery and attachment 5 Charge battery 1 Annual each twelve calendar month PAGE DATE 1 July 1996 CHAPTER 05 PAGE 22 EXTRA FLUGZEU
23. 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 For working with checklists refer to Chapter 02 20 03 Do not rotate the propeller nor allow any person to stay in the propeller oper
24. ioration 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 for cracks Check inlet flares on aircraft side of rigid hydraulic tubing for fatigue cracks JO 6 Checkback plate attachment bolts to insure they are properly torqued and have not worked loose Gaps between the back plate and cylinder would be evidence of this JO 7 Check fit of brake cylinder anchor bolts in torque plate bushings for sloppiness This can be accomplished by grasp ing the cylinder and moving it slight movement is normal Excessive movement is cause for removal and detailed inspection JO 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 9 Visually check torque plate for corrosion cracks loose anchor bolt bushings or other visible damage Anchor bolt bushings must be flat against torque plate surface JO 10 Check for any brake fluid leaks O JO 11 Check brake fluid level Tail wheel landing gear O JO 1 Check tail wheel landing gear for general condition JO 2 Check tail wheel landing gear spring for dents cracks and delaminations O JO 3 Check tail wheel rubber tire condition PAGE DATE 1 July 1996 CHAPTER 05 PAGE 20 EXTRA FLUGZEUGBAU Gmb
25. irection of control surface movement with relation to stick movement PAGE DATE 1 July 1996 CHAPTER 05 PAGE 28 EXTRA FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 200 SCHEDULED MAINTENANCE CHECKS Significant Items Inspection e Date Inspector Serial No Mechanic S S Inspections O 5 Check rod end bearings for free movement and cleanliness O 6 Detailed visual oftrim actuator lever for damages and cracks Ensure proper attachment and condition of friction Main landing gear 1 Inspectlandinggear spring visually for dents cracks and delaminations especally at the axle attachment and the center bushing for wear and looseness O 2 Check mounting clamp for damage and corrosion Inspect for dents and cracks 3 Inspect mounting clamp bolts and nuts for fretting wear damage stretch and proper torque refer to Chapter 20 10 03 4 Check brakes discs for warping and wear Inspect wheel brake cylinder mounting bracket for wear O 5 Inspect brake lines for leakage dents cracks chaffing kinks and security of anchorage O 6 Inspectaxle attachment bolts and nuts for fretting wear damage and stretch O 7 Check tires for general condition Tail wheel landing gear O 1 Inspectglass fibre spring visually for dents cracks and delaminations O 2 Inspect mounting bolts and nuts for fretting wear damage stret
26. o replace the items shown in the following schedule at the times indicated The times may be modificated by the respective national authorities Battery Sonnenschein Batteries of the ELT Pointer 2 years 2 years Wheels Cleveland Parker on Condition Tires Fuel oil amp brake hoses on Condition after first 7 years Aeroquip then 5 years Seat belts Hooker Brake and Brake Assembly Cleveland Parker Rudder control cable on Condition 6 years on Condition Fairleads on Condition Shock mounts Lord Kinematics Barry Controls Bolts and Nuts on Condition on Condition PAGE DATE 1 June 1997 CHAPTER 05 PAGE 5 EXTRA FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 200 05 20 00 SCHEDULED MAINTENANCE CHECKS 05 20 01 General Scheduled maintenance checks or tasks must be carried out at 50 100 200 300 400 500 and 1000 hour intervals In addition an annual inspection equal to the 100 hour inspec tion has to be performed The following pages show a drain hole chart Figure 1 and lubrication charts Figures 2 3 which can be used in connection with the checklists 05 20 02 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 03 PAGE DATE 1 July 1996 CHAPTER 05 PAGE 6 EXTRA FLUGZEUGBAU GmbH SCHEDULED MAINTENANCE CHECKS SERVICE MANUA
27. on 5 Check the avionic and antenna for correct operation O 6 Check the magnetic compass for correct readings PAGE DATE 1 July 1996 CHAPTER 05 PAGE 34 EXTRA FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 200 UNSCHEDULED MAINTENANCE CHECKS 05 50 05 Flightline Inspections These checks include pre flight and postflight checks as they are described in Sections 3 and 4 EMERGENCY PROCEDURES and NORMAL PROCEDURES of the PILOT S OPERATING HANDBOOK When the aircraft is in operation perform these checks daily PAGE DATE 1 July 1996 CHAPTER 05 PAGE 35
28. r corrosion Check Rod end bearing for free movement and cleanliness PAGE DATE 1 July 1996 CHAPTER 05 PAGE 25 EXTRA FLUGZEUGBAU GmbH SCHEDULED MAINTENANCE CHECKS SERVICE MANUAL EXTRA 200 Significant Items Inspection lt gt Date Inspector 9 y oY Serial No Mechanic gt Inspections Vertical Stabilizer Leading edge O 1 Check surface for erosion scratches stone nicks and impact dam ages O 2 Check bonding left right for dents cracks and delamination Front spar section 3 Check bonding skin spar for delamination by coin tapping Refer to Chapter 20 10 05 O 4 Detailed visual sheet metal attachment fitting for damage corrosion and link bolts security Rear spar section 5 Check bonding skin spar for delamination by coin tapping O 6 Detailed visual rear spar web for dents cracks and delamination Pay particular attention to the cut out for rudder cantilever O 7 Check steel sleeve for secure bonding to the spar O 8 Replace attachment bolts and stop nuts Check for proper torque in accordance with Chapter 20 10 02 Root and Tip O 9 Check root rib for cracks delamination and secure bonding to skin and spars by coin tapping 10 Inspect tip rib visually for general condition Rudder o Check tip rib bonding to the skin laminate by coin tapping O 2 Check bonding skin
29. r greasing 7 Lubricate aileron rodend bearings trim flap hinges and trim lever bolt 8 Lubricate adjustment tube of electrical pedal adjustment 9 Check rudder cable system including sleeves fairleads pulleys and cable retracting springs per FAA AC 43 13 1A PAGE DATE 1 July 1996 CHAPTER 05 PAGE 17 EXTRA FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 200 SCHEDULED MAINTENANCE CHECKS Maintenance Checks Schedule Date Inspector Serial No Mechanic Inspections 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 Referto Figure 4 This check is to be performed with zero loading on the rudder pedals 11 Roughcheckofsafety stop clearance With a force of approx 90 kg 200 Ibs 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 JO 12 Inspect all flight control ventilation holes for obstruction O 13 Inspectelevator balance weight for looseness and condition 14 Inspect push rods Landing gear O JO 1 Check landing gear for general condition JO 2
30. r oil and grease leaks 10 Check position and condition of counterweights Check blades for cracks in fibreglass cover and blade erosion sheet No cracks allowed Refer to MT Propeller SB No 8 o 12 Overhaul propeller or perform a tear down inspection 1 refer to MT Propeller Service Bulletin No 1 PAGE DATE 1 July 1996 CHAPTER 05 PAGE EXTRA FLUGZEUGBAU GmbH SCHEDULED MAINTENANCE CHECKS SERVICE MANUAL EXTRA 200 Maintenance Checks Schedule 2 Date Inspector SS Serial No Mechanic e ON S eria O echanic S Inspections Engine compartment Refer to latest edition of Textron Lycoming Operator s Manual and SB s of Christen Product Manual 801 Series and SB sandofSlick Magneto Maintenance and Overhaul Manual and SB s DANGER Ground magneto primary circuit before working on engine O 1 Remove engine cowling O 2 Inspect cowling and air inlet screen for damage cracks distortion overheated areas and loose or missing blind nuts and secure attachment of oil level access plate O JO 3 After this inspection clean cowling 4 Check fire protection paint If necessary repaint the fire protection paint WIEDOFLUGAT Brandschutzfarbe 56582 T508 O 5 Drain oil sump in accordance with Chapter 12 10 04 En gine Oil Replenishing O 6 Clean and inspect oil screen filter
31. ree movement Check the balance weights of the elevator for security of attachment Q Qoo BR W Check the spades for security of attachment Engine Check engine mount PAGE DATE 1 July 1996 CHAPTER 05 PAGE 33 EXTRA FLUGZEUGBAU GmbH UNSCHEDULED MAINTENANCE CHECKS SERVICE MANUAL EXTRA 200 05 50 03 Engine Fire After an engine fire perform a check as described in the following For damage evaluation consultthe manufacturer before the aircraft is put back into service Date Inspector Serial No Mechanic Inspections O 1 Check all cables and hoses replace when necessary O 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 on the protective paint If necessary repaint the fire protection paint WIEDOFLUGAT Brandschutzfarbe 56582 T508 05 50 04 Lightning Strike In the event ofa lightning strike in flight or on ground check the following Date Inspector Serial No Mechanic Inspections O 1 Check engine according to Lycoming Service Bulletin 401 O gt Check the skin of the strike area for burns and melting O 3 Inspect bolts fasteners bearings and ground bonding leads for burns and melting O 4 Check the electrical system with running engine for correct opera ti
32. refer to Slick Magneto Maintenance and Overhaul Manual 25 Inspect wiring connections vent holes and P lead attachment refer to Slick Magneto Maintenance and Over haul Manual o 26 Clean magnetos o 27 Inspect ball bearing assembly impulse coupling coil con tact points condenser and carbon brush o 28 Replace ball bearings o 29 Lubricate magnetos o 30 Overhaul or replace magnetos O 31 Check fuel injector for general condition clean fuel inlet screen 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 condition of fire sleeves O 34 Check fuel system for leaks O O 35 Remove clean and inspect gascolator screen and fuel filter bowl 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 38 Inspect exhaust slip joints for general condition each 500 hours each 1000 hours together with engine clean at least every 90 days 4A M PAGE DATE 1 July 1996 CHAPTER 05 PAGE 14 EXTRA FLUGZEUGBAU GmbH SCHEDULED MAINTENANC
33. spar for delamination by coin tapping 3 Check bonding trailing edge for cracks and delaminations by coin tapping O 4 Detailed visual of mounting brackets for damages and cracks Ensure proper attachment Replace bolts and stop nuts for new ones in any case Check for proper torque in accordance with Chapter 20 10 02 5 Check actuator lever for damage cracks and proper attachment O 6 Inspect ventilation holes visually for obstruction Refer to Chapter 05 20 01 Figure 2 Drain and Vent Holes PAGE DATE 1 July 1996 CHAPTER 05 PAGE 26 EXTRA FLUGZEUGBAU GmbH SCHEDULED MAINTENANCE CHECKS SERVICE MANUAL EXTRA 200 Significant Items Inspection lt gt Date Inspector 8 7 oY Serial No Mechanic S Inspections O 7 Check painting visually for general condition blisters etc 8 Check laminate for erosion scratches and stone nicks Horizontal Stabilizer Leading edge O Check surface for erosion scratches stone nicks and impact damage O 2 Check bonding top bottom for dents cracks and delamination Front spar section 3 Check bonding skin spar for delamination by coin tapping Rear spar section O 4 Check bonding skin spar for delamination by coin tapping Spar carry through 5 Remove spar cap paint by a solvent Perform visual inspection for dents and cracks Check for delamination by coin
34. tapping Restore finish in accordance with Chapter 51 70 05 6 Remove Spar web paint by a solvent Perform visual inspection for dents and cracks Check for delaminations by coin tapping Restore finish in accordance with Chapter 51 70 05 7 Replace attachment bolts and stop nuts Check for proper torque in accordance with Chapter 20 10 02 O 8 Check steel sleeves for secure bonding to the spar Root and Tip 9 Check root rib for cracks delamination and secure bonding to skin and spars by coin tapping 10 Inspect tip rib visually for general condition Elevator e Check tip rib bonding to the skin laminate by coin tapping O 2 Check bonding skin spar for delaminations by coin tapping O 3 Check bonding trailing edge for cracks and delamination by coin tapping O 4 Detailed visual inspection of mounting brackets for damage cracks and proper attachment Replace bolts and stop nuts Check for proper torque in accordance with Chapter 20 10 02 PAGE DATE 15 December 1999 CHAPTER 05 PAGE 27 EXTRA FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 200 SCHEDULED MAINTENANCE CHECKS Significant Items Inspection e Date Inspector Serial No Mechanic S N Inspections O Check center section for delamination by coin tapping O 6 Detailed visual of actuator lever for damage cra
35. there areno obvious signs of damage Ifthere are indications that structural parts are damaged the manufacturer has to be consulted for possible and suitable repair methods PAGE DATE 1 July 1996 CHAPTER 05 PAGE 32 EXTRA FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 200 UNSCHEDULED MAINTENANCE CHECKS Hard Landing Date Inspector Serial No Mechanic Inspections Landing gear Examine landing gear mounting clamps for defects e g cracks and deformed areas Check clamp bolts of the landing gear for cracks replace when necessary Examine wheel track and wheel base and check if measurement correspond to the value given in Chapter 06 10 01 Remove and check the fairings for delamination deformations and cracks Check the landing gear spring for delamination deformations and cracks especially in the area of the axle attachment Check fuselage structure in the area of landing gear attachment for deformation and cracks Check tires for cuts in the side wall Check wheel halves and brake discs for impacts cracks and distortion according to CLEVELAND instruction Check tail wheel for deformation and cracks especially in the area of the axle attachment Check fuselage structure in the area of the tail wheel for deformation and cracks Control surfaces Check control surfaces for proper operation Check control surface hinges for cracks security and f
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