chapter 05 time limits / maintenance checks - extra aircraft · and it contains data for a special...

Maintenance Manual and Illustrated Parts Catalogue

Extra EA -400

Page Date: 7. January 2000 05

Chapter 05 Time Limits / Maintenance Checks


Extra EA -400 Time Limits and Maintenance Checks

05 Page Date: 5. July 2002

Table of Contents

05-00-00 GENERAL .........................................................................................................4 05-00-01 Special Tools .......................................................................................................4

05-01-00 Chapter Configuration......................................................................................5 05-01-01 Section 05-10-00 .................................................................................................7 05-01-02 Section 05-20-00 .................................................................................................7 05-01-03 Section 05-30-00 .................................................................................................7 05-01-04 Section 05-40-00 .................................................................................................7 05-01-05 Section 05-50-00 .................................................................................................7

05-02-00 Words with Special Meanings ..........................................................................7

05-10-00 TIME LIMITS ...................................................................................................9

05-11-00 General ...............................................................................................................9

05-12-00 Certification Authorities...................................................................................9

05-13-00 Scheduled Maintenance Time Limits ..............................................................9

05-14-00 Component Time Limits .................................................................................10 05-14-01 Time Between Overhaul....................................................................................10 05-14-02 Time Between Replacement ..............................................................................10 05-14-03 Time Between Inspection..................................................................................11

05-20-00 SCHEDULED MAINTENANCE CHECKS.................................................13

05-21-00 General .............................................................................................................13

05-22-00 Maintenance Checks Schedule .......................................................................13



Page Date: 5. July 2002 05

05-23-00 Scheduled Maintenance Charts ..................................................................... 14 05-23-01 Operational Checks........................................................................................... 14 05-23-02 Miscellaneous .................................................................................................... 16 05-23-03 Fuel System....................................................................................................... 18 05-23-04 Oil System......................................................................................................... 19 05-23-05 Ignition System ................................................................................................. 20 05-23-06 Induction System............................................................................................... 21 05-23-07 Exhaust System / Turbocharger ........................................................................ 22 05-23-08 Accessories........................................................................................................ 24 05-23-09 Propeller............................................................................................................ 25 05-23-10 Cabin and Equipment........................................................................................ 26 05-23-11 Fuselage ............................................................................................................ 29 05-23-12 Wing Assembly................................................................................................. 31 05-23-13 Control Systems and Surfaces .......................................................................... 33 05-23-14 Landing Gear..................................................................................................... 34 05-23-15 Brakes and Wheels............................................................................................ 38 05-23-16 Completion........................................................................................................ 41

05-30-00 FLIGHTLINE INSPECTIONS ..................................................................... 42

05-31-00 General ............................................................................................................. 42

05-32-00 Pre - Flight Check .......................................................................................... 42

05-33-00 Post - Flight Check......................................................................................... 42

05-50-00 UNSCHEDULED MAINTENANCE CHECKS .......................................... 43

05-51-00 General ............................................................................................................. 43

05-52-00 Unscheduled Checks ....................................................................................... 43 05-52-01 25 h - Check ...................................................................................................... 43 05-52-02 Hard Landing .................................................................................................... 43 05-52-03 Engine Fire ........................................................................................................ 44 05-52-04 Propeller Strike and Violent Engine Stoppage ................................................. 44 05-52-05 Lightning Strike ................................................................................................ 44 05-52-06 Engine Overspeed ............................................................................................. 44




05-00-00 GENERAL

This chapter is a guide. It will help you to do the maintenance correctly.

You must do the scheduled maintenance checks given in this chapter at the recommended time. These checks are minimum requirements for keeping the aircraft in a good technical condition.

The aircraft manufacturer can change the time between checks. If this happens, the aircraft manufacturer will supply the data by Service Bulletins or Service Letters.

You can shorten the time between scheduled maintenance checks if the air-craft operation makes it necessary. You must not extend the time between scheduled maintenance checks without the aircraft manufacturer`s approval.

The aircraft manufacturer must give approval to any change to the aircraft or to the maintenance checks schedule.

05-00-01 Special Tools

Generally, for maintenance tasks no special tools are necessary. However, there are a few exceptions as listed below. These items are available at Extra Flugzeugbau GmbH. Alternatively, they can be crafted per instruction of Figures 05-01 through 05-03, using standard shop practices.

Description Extra Part No. Subject Chapter

Flap track snap gauge EA – 15182W10 Flap guidance check 27-53

Front bolt extracting tool

EA – 15001.1W Wing removal 57-10

Rear bolt extracting tool

EA – 15001.2W Wing removal 57-10




Figure 05-01 Flap track snap gauge




Figure 05-02 Front Bolt Extracting Tool

Figure 05-03 Rear Bolt Extracting Tool




05-01-00 Chapter Configuration

05-01-01 Section 05-10-00 Section 05-10-00 contains the time limits for maintenance checks. It also contains the time limits for components. Use the data in section 05-10-00 to find out when to do maintenance.

05-01-02 Section 05-20-00 Section 05-20-00 contains the maintenance checks for 50, 100 and 1000 FH checks. It also contains data for the annual check if necessary for national regulations. And it contains data for a special 25 hour check on new aircraft.

05-01-03 Section 05-30-00 Section 05-30-00 contains data for flight line checks. Do a pre-flight check before each flight. And do a post- flight check after each flight.

05-01-04 Section 05-40-00 Section 05-40-00 is reserved.

05-01-05 Section 05-50-00 Section 05-50-00 contains the unscheduled maintenance checks. Do these checks after heavy landings, engine fire and propeller damage, or if the aircraft has been operated outside the flight envelope.

05-02-00 Words with Special Meanings In this maintenance manual, the words that follow have special meanings :

Adjust To put to a specified position or condition. For example, adjust the clearance to 1 mm.

Check A technical name for a group of maintenance tasks. For example, the 100 hour check.

Examine To look carefully at an item. It includes steps such as these :

Make sure that the item :

1 Is complete.

2 Is correctly attached.

3 Has no loose parts.

4 Shows no signs of leaks.

5 Is not cracked or damaged.

6 Is not worn.

Make sure that :

1 The surface protection is not damaged.




2 All locking devices are installed correctly.

Make sure that items such as pipes and cables :

1 Look serviceable.

2 Do not rub against other items (chafing marks).

Inspection The procedure, which compares an object with its standard or specification.

Measure To find out the dimensions, capacity or quantity of something.

Monitor To look at something during a time. For example, monitor the engine speed indicator.

Record Technical name for something that shows what was done. For example, write the result of the test in the engine record.

Replace To remove an unserviceable item and install a serviceable item in the same location.

Set To put equipment into a given adjustment, condition or mode. For example, set the altimeter scale to 1013 mbar.

Task An assigned work or procedure. For example, each step of the task has an identification letter.

Test That what you do when you operate or examine an item to make sure that it agrees with the applicable specifications. For example, disconnect the systems which are not necessary for the test.




05-10-00 TIME LIMITS

05-11-00 General Various equipment and components of the aircraft (e.g. engine, propeller) are only cleared for a certain time of operation. After the permissible time of operation has expired they have to be replaced or overhauled (TBO - Time Between Overhaul). The respective TBO times are listed in the aircraft record sheets.

For monitoring the permissible time of operation, this time should also be entered into the aircraft records when removing and installing such a part.

05-12-00 Certification Authorities The time limits given in this chapter are recommended by the manufacturer. These time limits may be superseded by the regulatory authority.

05-13-00 Scheduled Maintenance Time Limits The following components listed in Chapter 05-14-00 have to be overhauled, replaced or inspected periodically, i.e. within fixed calendar periods or after appearance of a certain amount of flight hours. Do scheduled maintenance at these times:

Scheduled Maintenance Do at these times

25 hours check At 25 FH from new only. Do the work of a 100 FH check. Tolerance +/- 2.5 hours.

50 hours check At 50 FH. Or 50 hours after the last scheduled maintenance check. Tolerance +/- 5 hours.

100 hours check At 100 FH. Or 100 hours after the last 100 hours or larger check. Tolerance +/- 10 hours.

1000 hours check At 1000 FH. Or 100 hours after the last 100 hours or larger check. Tolerance +/- 10 hours.




05-14-00 Component Time Limits

05-14-01 Time Between Overhaul These components have a TBO - Time Between Overhaul :

Components Time Between Overhaul

Engine Teledyne Continental TSIOL 550-C.

Refer to the latest Service Instruction.

Engine accessories. Overhaul with the engine.

Coolant. Change every 200 hours / annually.

Fuel nozzles cleaning. Every 300 hours / annually.

TCM magnetos overhaul. 4 years / 500 hours.

Other magnetos overhaul / inspection.

With the engine / every 500 hours.

TCM gear driven alternator. Inspection and testing every 500 hours.

Seat belts. After 12 years.

Propeller Mühlbauer MTV-14-D / 195-30a.

Refer to the latest Service Bulletin.

05-14-02 Time Between Replacement Replace these components at the times shown :

Components Time Between Replacement

Air filter. Every 100 hours or earlier on condition.

Vacuum system inlet filter. Every 500 hours or annually, whichever comes first, and each pump replacement.

Vacuum regulator filter. Every 100 hours or annually, whichever comes first, and each pump replacement.

Oil and fuel hoses (engine compartment).

First 7, then 5 years.

1

Vacuum suction pumps:

Airborne A/M 442CW-6

(2 pcs., type alternatively)

Every 400 hours or 6 years from date of manufacture, whichever comes first.

2 Aero Accessories CH 442CW-6 Every 500 hours or 6 years from date of manufacture, whichever comes first.




Components Time Between Replacement

Drive clutches of the engine- driven vacuum - pump.

Every 6 years (see the manufacturer´s Service Bulletins).

Vacuum check valve manifold. 10 years from date of manufacture.

Pressure check valve manifold. 10 years from date of manufacture.

Hydraulic hoses landing gear/ brake.

First 7, then 5 years.

Batteries of Emergency Locator Transmitter (ELT).

Every 2 years during shelf or service life, or after 1 hour of cumulative use (e.g. testing), or after operation in an emergency situation, or on or before battery replacement date.

Battery replacement date is marked on the battery pack and the label at the end of transmitter.

For battery replacement see Pointer Service Instructions.

Batteries of hand held NAV / COM receiver.12

Annually or after each use.

Batteries of emergency torch. Annually or after each use.

Main gear

Change oil, replace O-ring and scraper ring of shock absorber.

Every 4 years or after occurred oil leakage.

Actuators. After 500 hours or 5 years. Which ever comes first.

Torque link rod. After 500 hours or 5 years. Which ever comes first.

05-14-03 Time Between Inspection Inspect these equipment items at the times shown :

Components Time Between Inspection

Static pressure system. Every 2 years in accordance with 14 CFR Ch. 1 Part 43 App. E.

Vacuum check valve manifold. 5 years from date of manufacture, every 12 months thereafter until 10 years.

12 NAV / COM receiver not required for U.S. registered aircraft.




Components Time Between Inspection

Pressure check valve manifold. 5 years from date of manufacture, every 12 months thereafter until 10 years.

ATC transponder. Every 2 years in accordance with 14 CFR Ch. 1 Part 43 Apps. E Par. C and F.




05-20-00 SCHEDULED MAINTENANCE CHECKS

05-21-00 General Regular inspections must be carried out every 50, 100 or 1000 operating hours. In addition, a 100 hour inspection is necessary after the first 25 hours of opera-tion. Annual inspections (ANI) must be performed according to the national requirements.

Note The scope of an Annual Inspection and a 100 hour inspection is the same. However, the manufacturer may recommend to perform additional checks in the course of an Annual Inspection. If applicable, these checks are identified in the Maintenance Check Schedule with the abbreviation "ANI".

All inspections must be executed by a designated representative of the FAA or the Aviation Authority of the country in which the aircraft is licensed.

05-22-00 Maintenance Checks Schedule

The maintenance and control work given in the following tables has to be carried out within the given time intervals. The proper execution of the checks has to be certified in the maintenance records.

Faults as well as their repairs have to be entered in an inspection report filed together with the check list in the aircraft records.

Additional information for the maintenance of the engine is included in the Teledyne Continental Operation and Maintenance Instructions (Form OMI-15), in the Teledyne Service Bulletins (SB), Service Instructions (SI) and Service Letters (SL).

CAUTION On new aircraft, the first inspection is necessary after 25 operating hours. This inspection corresponds to a 100 hour inspection.




05-23-00 Scheduled Maintenance Charts The maintenance checks described in this section include all the scheduled checks, which must be performed. Maintenance checks must be accomplished in accordance with CFR 14 P 43 App. D.

Use the following schedule and the lubrication charts.

Prior to inspection, the aircraft and engine should be thoroughly cleaned, all inspection panels, access doors or fairings should be removed.

05-23-01 Operational Checks

Flight Hours Date: Inspector

Serial No.: Mechanic

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WARNING Rotating propeller can cause death or injuries! Ground magneto primary circuit before working on engine.

X X X Perform an inspection operational run-up. Refer to the latest TCM Operation and Maintenance Instructions (Form OMI-15), Section 2. Record and verify the engine operating parameters.

X X X Start engine (in accordance with the Pilot's Operating Handbook).

X X X Check the parking brake and toe brakes.

X X X Check the fuel flow, fuel pressure and fuel quantity indication.

X X X Check the fuel pump and fuel selector valve.

X X X Check the oil pressure and oil temperature.

X X X Check the alternator 1 + 2 output.

X X X Check the manifold pressure indicator.

X X X Check the cabin heater operation.

X X X Check the cabin pressurizing operation.

X X X Check the aircon operation.

X X X Check the de-ice system operation.

X X X Check the windshield heater operation.

X X X Check magneto RPM drop at 1700 RPM (allowed drop is 150 RPM and no greater difference between L + R than 50 RPM).

X X X Check idle speed (between 600 and 750 RPM).

X X X Check response of the engine by power setting changes.

X X X Check the propeller response at 1700 RPM when changing pitch.






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Operational Checks (cont.)

X X X Check the EGT and CHT indicator.

X X X Check the mixture function per CHT / EGT indication.

X X X Check the annunciator light panel.

X X X Check the radio and the other electronic equipment.

X X X Check operation of controls and flaps.

X X X Shut down engine using mixture lever. Check the alternator warning light or ammeter.

X X X Magnetos OFF, main switch OFF.

X X X Check gyros for noise and roughness.

Refer to the latest edition of Teledyne Continental Motors Operation and Maintenance Instructions (Form OMI-15):

WARNING Rotating propeller can cause death or injuries! Ground magneto primary circuit before working on engine.

X1

With a new, rebuilt or overhauled engine perform a complete 100 hours inspection. Drain the oil used for engine break-in and replace the filter. Replenish with TCM approved oil. Refer to latest Teledyne Continental Motors Operation and Maintenance Instructions (Form OMI-15), Section 2.

X1 X X X Remove the engine cowling and inspect the engine, accessory section and cowling for fuel, oil leaks, overheating, coolant and other discrepancies.

X X Inspect studs and nuts for proper torquing and obvious defects.

CAUTION Fasten and secure oil cooler and intercooler while cowlings are removed. 1 After the first 25 hours of operation or 6 months, whichever comes first.




05-23-02 Miscellaneous



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X X X Clean and inspect the cowling intakes and outlets for damage, cracks, distortion and overheat areas.

X X X Clean the engine with a suitable solvent. Refer to latest Teledyne Continental Motors Operation and Maintenance Instructions (Form OMI-15), Section 2.

X X X Inspect oil cooler, intercooler, cabin cooler and air filter for insecure attachment and loose or missing fasteners.

X X X Inspect cylinders for leaks in cooling system and poor general condition.

X X X Clean and inspect oil, water, intercooler and cabin cooler radiator, fins for deterioration, distortion, insecure attachment and other evidence of failure.

X X

Inspect the cylinder barrels and heads for cracks, leakage, rust. Check cylinder compression while engine is warm. Refer to latest Teledyne Continental Motors Operation and Maintenance Instructions (Form OMI-15). If there is weak cylinder com-pression, inspect for improper internal condition and improper internal tolerances.

X X Inspect internal engine for metal particles or foreign matter on screens and sump drain plugs.

X X X

Inspect engine mount for cracks, corrosion, looseness of mountings and overheated areas. Inspect engine shock mount isolators for deterioration, improper assembly and insecurity. Replace as required.

X X Inspect engine mount heat shield for cracks, corrosion and improper condition.

X X X Inspect throttle, mixture and propeller governor controls for security, defects, improper travel and improper safetying.

X X Inspect crankcase for cracks, leaks and insecurity of seam bolts.

X X Inspect engine bonding for improper installation and poor condition.

X X Inspect firewall and seals for improper condition, insecurity and improper fire resistant sealing.






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Miscellaneous (cont.)

X16 Inspect engine driven vacuum pumps for oil contamination. Replace vacuum pumps subjected to oil contamination. Refer to Airborne Service Letter No.43, latest edition.

X X Inspect alternator mounts or brackets for cracks, improper condition and insecurity.

X X Inspect alternator drive belt for improper condition and improper tension.

DANGER Nose gear and main gear extends and retracts under high pressure. Operation of the landing gear can cause death or injuries in its working area !

Before beginning any work in the landing gear working area, pull OFF the electric circuit breakers located on the left side panel and marked GEAR CTRL and HYDR.

X X Inspect nose wheel box for cracks, poor general condition and improper fire resistant sealing.

X2 Complete overhaul of engine or replacement with factory rebuilt one.

2 Overhaul period 2,000 hours. 16 Every 100 hours or annually, whichever comes first.




05-23-03 Fuel System



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X X

Inspect fuel nozzles, upper deck and fuel injection nozzle reference lines, hoses, manifolds and fittings for improper routing, support and signs of fuel stains. Inspect manifold valve for insecurity of installation, improper venting and signs of fuel stains.

X X Inspect lines, hoses and clamps for leaks, improper condition and looseness.

X3

Remove and clean all fuel injection nozzles by soaking in lacquer thinner, acetone or methylethylketone (MEK). Refer to latest TCM Operation and Maintenance Instructions (Form OMI-15), 300 hour inspection.

X X X Inspect gascolator for water, sediments and improper operation.

X X X Inspect fuel selector valve for improper operation and improper pointer indication. Remove, clean and inspect gascolator screen and fuel filter bowl.

X X X Check fuel pump for operation and pressure. Perform ground run : 1. Electrical boost pump

2. Mechanical fuel pump

X X Electrical boost pump / mechanical fuel pump and fittings: Inspect for leaks, poor general condition, insecure attachment.

3 Every 300 hours or annually, whichever comes first.




05-23-02 Oil System



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X X X

Drain engine oil while engine is warm. Refer to latest Teledyne Continental Motors Operation and Maintenance Instructions (Form OMI-15), Section 2. Reinstall oil drain plug with new gasket, torque and safety wire.

X X X Replenish oil cooler, hoses etc. with TCM approved oil. Refer to latest Teledyne Continental Motors Operation and Maintenance Instructions (Form OMI-15), Section 2.

X X X Remove oil filter. Inspect filter element for foreign particles. Refer to latest Teledyne Continental Motors Operation and Maintenance Instructions (Form OMI-15), Section 2.

X X X Install new oil filter. Place a thin film of Dow Corning DC-4 compound on new filter gasket. Torque filter to values as directed by filter manufacturer and safety wire.




05-23-05 Ignition System



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X X X Inspect spark plug cable leads and ceramics for chafing, corrosion, deterioration, improper routing and deposits.

X X Inspect condition of spark plugs (clean and adjust gap as required, adjust per TCM Service Bulletin). If fouling of spark plugs has been apparent, rotate bottom plugs to upper plugs and vice versa.

X4 X X X Visually inspect magnetos for poor condition. Inspect, repair and adjust as required if magneto drop or spread was not within published limits.

X X Ensure magneto timing is within specification. Refer to latest Teledyne Continental Motors Operation and Maintenance Instructions (Form OMI-15).

X X

Visually inspect magneto pressurization filter for contamination. If there is visible moisture present in the filter canister the magneto must be removed from the engine, disassembled and inspected for possible internal contamination and corrosion.

4 Inspect magnetos every 500 hours according to Slick Master Manual.




05-23-06 Induction System



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X X X Inspect all induction system or cylinder drain for clogging, leaks or restriction.

X X X Remove and inspect induction air filter. Clean or replace as instructed every 100 hours.

X X Inspect alternate air system, alternate air box and attaching for deterioration, cracks and poor condition.




05-23-07 Exhaust System / Turbocharger



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X X X

Inspect the exhaust system for burned areas, cracks, leakage, deterioration, loose and missing brackets, clamps and hardware. Visually inspect turbocharger and associated system components for evidence of oil or exhaust leakage.

X X X Inspect system for oil leakage, exhaust system leaks and poor general condition.

X X X Inspect induction and exhaust components for worn or damaged areas, loose clamps, cracks and leaks.

X X X Inspect turbo and controller system oil lines for leaks and insecurity.

X X

Visually inspect the turbocharger center housing for poor general condition. Inspect the compressor housing V-band clamp for insecurity. Inspect the exhaust housing bolts and lock tabs for cracks, corrosion, clearance and insecurity. Inspect the oil inlet and outlet ports in center housing and surrounding area for leaks.

X X

Remove the induction air supply duct to the turbocharger compressor and inspect the compressor blades for evidence of foreign object damage. Turn compressor wheel by hand, check freedom of rotation. Inspect the interior of the air supply duct for poor general condition.

X X

Remove the turbocharger exhaust stack and inspect the turbine wheel for nicks, cracks, broken blades, freedom of rotation and evidence of oil. For installation, refer to Teledyne Continental Motors Operation and Maintenance Instructions (Form OMI-15).

X X Visually inspect the exhaust system transition unit at the turbocharger for poor general condition and evidence of exhaust leaks, cracks and distortion.

X X

Remove the turbocharger compressor discharge duct and inspect the interior for evidence of oil. If there is evidence of oil in the duct, further inspection of the turbocharger is required to determine cause and source of oil. Refer to the turbocharger manufacturer's information for specific instructions.






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Exhaust System / Turbocharger (cont.)

X X

Inspect waste gate actuator and butterfly valve for poor general condition and freedom of movement. Check linkage, rod ends, springs, levers and bushing for poor condition and wear. Lubricate waste gate butterfly valve with "Mouse Milk" (see Chapter 12 Servicing).

X X X Check connection and routing of all hoses and attachment of coolers.

X X Verify operation and accuracy of EGT / TIT system.

X X

Inspect turbine inlet temperature probe / TIT and wires for insecurity. For replacement and depth of insertion see Ch 81-20 (Turbo Supercharger).




05-23-08 Accessories



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X X Inspect oil temperature sensor unit for leaks and insecurity.

X X Inspect cylinder head temperature probe / EGT and wires for insecurity.

X X Inspect all wiring, fluid lines, hoses and electrical connections for improper routing, improper support and evidence of deterioration. Replace damaged wires, hoses, lines and clamps if required.

X X Visually inspect all cylinder and accessory to engine attaching hardware for insecurity. Visually inspect airframe to engine connections for insecurity and corrosion.

X X Inspect all accessories for poor condition, insecurity of mounting and improper operation. Refer to component manufacturer's Maintenance Manual.

X X Inspect the belt driven alternator, electric connection and air cooling parts for poor general condition and insecurity. Refer to the applicable alternator manufacturer's instructions.

X5 X X Inspect and test the gear driven alternator. Refer to the applicable alternator manufacturer's instructions.

X X Inspect vacuum pumps and firewall mounted equipment for poor general condition.

X X Inspect pneumatic and vacuum hoses for deterioration, chafing, wear and insecurity.

X X Inspect starter for improper connection and insecurity. 5 Every 500 hours.




05-23-09 Propeller



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Refer to the latest edition of MT-Propeller Operation and Installation Manual E-124 and Service Bulletin No.1.

WARNING Rotating prope ller can cause death or injuries! Ground magneto primary circuit before working on engine .

X X X Remove and inspect spinner and spinner bulkhead for cracks.

X X X Inspect blades for cracks, nicks and gouges. Check blades for cracks in the fiberglass cover.

X X X Inspect propeller for grease and oil leaks.

X X X Check track of the blades. Max. allowable is 3 mm / 1/8 inch, approx. 10 cm / 4 inch from the tip, on the trailing edge.

X X X Check blade angle play, max. 2°.

X X

Inspect propeller mounting bolts for improper torquing and lack of safetying. Check all safety means for improper condition.

X X X Inspect hub and parts for cracks, corrosion and wear.

X X X Rotate blades and check for tightness in hub pivot tube.

X X

Check propeller de- icer system for improper operation, poor condition and obvious defects.

X X Inspect propeller de- icer slip rings for wear, inspect brush block for poor condition and check brush length.

X X X Reinstall spinner.

X X Inspect MT- propeller. Refer to MT-Propeller Operation and Installation Manual E-124.

Overhaul or replace propeller governor. Refer to latest McCauley Service Bulletin 137.




05-23-10 Cabin and Equipment



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X X X Remove inspection covers, door covering and panels (seats and carpet must be removed for access to inspection covers on the cabin floor).

X X Inspect cabin and cockpit for uncleanliness and loose equipment that might foul the controls.

X X X Inspect cabin entrance door and emergency exit for improper rigging. Check retainer pins and striking parts for bending, cracks, improper engagement, pulled or sheared fasteners.

X X X Inspect cabin entrance door and emergency exit door seals for folding and damage.

X X X Check the door hinges for cracks and sideplay.

X X X Check the door locking bolts for wear and improper adjustment.

X X X Check the door locking fittings for wear.

X X Examine the door connecting rod geometry for cracks, bending and loose parts.

X X X Check the door locking mechanism for improper operation.

X Perform a teardown inspection of the central door operating device.

X X X Perform a door pressure test. Inspect the sealing surfaces for leakage 6.

X X X Inspect crew seats for improper horizontal and vertical operation and insecure locking function.

CAUTION Check crew seats for improper engagement of pins to seat track with occupied crew seat at the lowest vertical position.

X X X Inspect seats and upholstery for tears and poor condition.

X X X Inspect seat belts for insecurity of attachment and improper operation.

X X X Inspect seats, seat belts, security brackets and bolts for poor condition and apparent defects.

X X X Check operation of cabin and instrumentation lights.

6 For localizing leakage easily examine door seals for dust

particles.






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Cabin and Equipment (cont.)

X X X

Inspect instruments, lines, wiring and attachments for poor condition.

X X

Inspect pneumatic and electric gyro instruments for poor condition, insecure mounting, marking and improper operation. Overhaul or replace as required. (Refer to the components manufacturer's instruction.)

X X Inspect avionics and radio equipment for poor condition, improper installation and insecure mounting.

X X Check electric trim operation and rigging.

X X Check operation of rudder pedals and toe brakes.

X X Check operation of parking brake.

X X Inspect control wheels, column and switches for poor condition.

X X Inspect cables, pulleys and connections for poor condition and insecurity.

X X X Check operation of strobe, landing, navigation, cabin and instrument lights.

X X Check pitot / static air pressure operation.

X X

Inspect pitot / static hoses, lines, and alternate static lines for poor condition and insecurity.

X X Inspect altimeter and ATC transponder for improper condition.

X7 Check that altimeter and transponder comply with latest revision of 14 CFR Chapter 1 Part 43 Appendixes E and F.

X8 Inspect compass and compass deviation card for improper indication and compensation.

X8 Check magnetic compass compensation.

X X X

Inspect all knobs, switches and levers and their mounting for insecurity of attachment and poor condition.

X X X Inspect engine controls for improper installation and improper operation.

7 Every two years.

8 Annually.






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Cabin and Equipment (cont.)

X X X Inspect flight controls for improper installation and improper operation.

X X X Check operation of fuel selector valve.

X X Check operation of cabin heat and defrost controls.

X X X Inspect circuit breaker mounting and wiring for poor condition and insecurity.

X X Inspect environmental system ducts for poor condition.

X X Check cabin pressurization system and pressure controller operation.

X X X Check electrical panel components for poor condition and insecurity.

X X Check forward side of outflow and safety valves for poor con-dition and insecurity. Remove and clean as shown in Chapter 21.

X X Inspect filters on control and safety valve for contamination. Clean or replace as required (see Chapter 21).

X X Inspect control cable boots for poor condition and insecurity.

X X Inspect air condition evaporators, drain valve and mounting for poor condition and insecurity.

X X Drain air condition evaporators.

X X X Inspect heater elements and mounting for poor condition and insecurity.

X X Inspect heater ducting for obstruction, poor condition and insecurity.

X X X Inspect portable fire extinguisher for improper service and poor condition. Check inspection date.

X9 Change batteries of emergency torch.

X9 Change batteries of hand held NAV / COM receiver 12.

X X X Reinstall inspection covers and panels.

9 Annually or after each use.

12 NAV / COM receiver not required for U.S. registered aircraft.




05-23-11 Fuselage


Seria l No.: Mechanic

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X X X Remove access panels.

X X X

Inspect structure and exterior surfaces for deterioration, distortion, cracks, dents, other evidence of failure, uncleanliness and defective or insecure attachment of fittings.

X X X Inspect windshield and windows for deterioration, nicks, scratches, cracks and crazing.

CAUTION Pressurized flight is prohibited with cracks and crazing.

X X X

Inspect electric windshield de-ice system for poor condition, insecurity and improper operation.

X X X Inspect environmental system ducts for poor condition.

X Replace vacuum system inlet filter element. Refer to Ch. 37-10-01.

X X Inspect air condition compressor and mounting for poor condition and insecurity. Check condition and tension of compressor drive belt.

X X X Inspect air condition hoses and clamps for poor condition, chafing and leaks.

X X X Inspect air condition system wiring for fraying or cracks.

X X X Inspect battery and attachment for corrosion, etching, poor condition and insecurity. (Charge battery if required.)

X X Inspect external power supply receptacle, battery relay and fuses for cleanliness, corrosion, poor condition and insecurity.

X X X Inspect electrical leads, lines, radio antenna leads and attaching for chafing, deterioration, improper routing, wear, insecure installation and obvious defects.

X X Inspect antennas and coaxial cables for poor condition, insecure mounting and improper operation. (Refer to Figure 23-01.)

X X X Inspect ELT, trimming servo and attaching for poor condition and insecurity.

X X Check ELT battery replacement date. (Refer to the ELT manu-facturer's instructions.)

13 Every 500 flight hours or annually.

13






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Fuselage (cont.)

X X Perform a cabin pressure test. Inspect the former joints for cracks and damage.

X X X Reinstall access panels.

X X Inspect engine mounts for cracks.




05-23-12 Wing Assembly



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X X X Remove access panels from horizontal stabilizer and wing root avionics compartment.

X X X Inspect wings for dents, cracks and delaminations.

X X X Inspect wing ventilation holes for obstruction.

X Inspect wing spar main bolts and fittings for poor general condition, distortion, and insecurity of attachment.

X Extract wing spar main bolts in sequence (refer to Ch. 57-10-00). Inspect bolt shanks for cracks, wear, corrosion and insecurity. Install each bolt before extracting the next one.

X X X Inspect inside wing structure in the area of access panels for deterioration, delamination, distortion and poor general condition.

X X X Inspect wing tanks and lines for leaks and poor condition.

X X Inspect tank bonding for improper installation and poor condition.

X Drain wing fuel tanks.

X

Inspect fuel transmitter and electrical connectors for uncleanliness, poor condition and insecurity.

X X Inspect fuel filler cap and flapper valve for poor condition.

X X Inspect fuel tank breather and vent system for poor condition and insecurity.

CAUTION Function test of flaps only with upper door closed.

X X X

Inspect landing flaps and attachment for dents, cracks, delamina-tions and improper operation.

X X X Inspect flap ventilation holes for obstruction.

X X

Inspect landing flaps gear drive, flap position transmitter and flap control switch for damage and improper operation.

X X Check and adjust flap guidance, flap actuation system, flap limit switches and flap asymmetry senders. Refer to Chapter 27-53-00.

X X X

Inspect navigation lights, recognition lights, wingtip strobe lights for broken lenses, insecurity, improper wiring and operation.

8 Annually.

10 Every 5000 flight hours.

10

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Wing Assembly (cont.)

X X Inspect electrical leads, radio antenna leads, pneumatic and vacuum lines and attaching for improper routing, deterioration and incorrect installation.

X X X Inspect pitot and static head for poor condition, obstruction and damages. Inspect pitot heater for poor condition and improper operation.

X X Inspect pitot and static lines and attaching for improper routing, deterioration, poor condition and leaks. Drain pitot and static lines.

X X X Inspect stall warner system for poor condition and insecurity of installation. Perform operational check.

X X X

Inspect de- icer system (wing and control surfaces) for poor condition and improper operation.

X Replace vacuum system inlet filter element. Refer to Ch. 37-10-01.

13 Every 500 flight hours or annually.

13




05-23-13 Control Systems and Surfaces Flight Hours Date: Inspector


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X X X Remove access panels on horizontal stabilizer, tailcone, wing center fairing and wing root avionic bay.

X X X Inspect control and stabilizer ventilation holes for obstruction.

X X X Inspect stabilizer surfaces for dents, cracks, nicks and delaminations.

X X X

Inspect rudder for insecurity of attachment, free movement, dents, cracks and delaminations.

X X Inspect rudder hinges, attachment and bearings, stops, centering spring for cracks, excessive wear, insecurity and improper operation.

X X X Inspect elevator surface for dents, cracks, nicks and delaminations.

X X

Inspect elevator hinges, elevator trim tab hinges, attachment and bearing for poor condition, cracks, excessive wear, insecurity and improper operation.

X8 Inspect horizontal stabilizer main bolts for poor general condition, distortion and insecure attachment.

X10 Extract horizontal stabilizer main bolts in sequence. Inspect bolt shanks for cracks, wear, corrosion and insecurity. Install each bolt before extracting the next one.

X X X Check elevator trim system for improper operation and rigging.

X X Inspect elevator balance weight for looseness and poor condition.

X X X

Inspect aileron, rudder, elevator and elevator trim cable systems including turnbuckles, sleeves, fair leads, pulleys, cable retracting springs and push pull rods per FAA-AC1 43.13-1B for lack of safetying, damage and improper operation.

X X Check all cable tensions using a tensiometer.

X X X

Inspect rudder control torque tubes, bottom panel, shelf, linkage, control cable, sprocket wheel and interconnection for poor condition, distortion and insecurity. Inspect control cable connections for poor condition, chafing, distortion and insecurity.

X8 Examine control springs for mechanical damage, corrosion, and wear at the clevisses. Refer to Chapter 27-00 (Flight Controls).

X X X Reinstall access panels.

8 Annually. 10 Every 5000 flight hours.




05-23-14 Landing Gear



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In case of intentional gear operation by switch or circuit breaker handling make sure, that neither a person nor material is in the landing gear working area.

NOTE With the aircraft being airborne or jacked with retracted landing gear and battery switch OFF, the hot bus feeds an AUX circuit, which supplies the directional valves with electrical power to keep the landing gear in the up-position. The AUX circuit is protected by the GEAR AUX 1 (left side panel) and GEAR AUX 2 (tail cone panel) circuit breakers.

However, the nose gear and main gear will slowly extend due to valve oil leakage, if the hydraulic pump is not being activated temporarily to maintain hydraulic pressure. If retracted landing gear position is in-tended, turn battery switch ON and push circuit breakers GEAR CTRL and HYDR (left side panel) to the ON position, while the landing gear switch (left main panel) is in the UP position.

If the aircraft is jacked with landing gear retracted and external power not connected, the battery will be discharged within approx. 2 days.

X X Place the airplane on jacks.

X X X Inspect the main gear struts for poor condition, cracks, bending, distortion and insecurity.

X X X Inspect the main gear and nose gear shock absorber for oil- leakage and scoring.

X X X Check the main gear struts for maximum extension and overcentering of the radius struts.

X X X Inspect the main gear bolts, bearings for lack of safety and poor condition, cracks, excessive wear and insecurity.

X X X Clean and lubricate the bearings. Use AEROSHELL 2 spec. MIL-G-81322.

X X X Inspect the web plate at the landing gear frame for cracks.






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Landing Gear (cont.)

X X X Check the parallel strut and axle bar for vertical clearance.

X X X Inspect all blocks for cracks.

X X X Inspect gear struts, trunnion pins and attachments for poor condition and insecurity.

X X X Check the nitrogen inflation of the main gear-shock absorber (57 bar / 827 psi ).

X X X Inspect the nose gear trunnion for poor condition, cracks and distortion.

X X X Check the nose gear strut for maximum extension and overcenter of the radius strut.

X X X Check the nitrogen inflation of the nose gear shock absorber (15 bar / 218 psi ).

X X X Inspect track rods and attaching for poor condition, distortion and insecurity.

X X X Inspect rear preloaded axle stop for poor condition.

X X X Inspect the nose wheel steering arm and its thrust bearing for poor condition and any damage.

X X X Inspect the fixing nose of the steering arm guide block for poor condition, cracks and bending.

X X X Inspect the spring device assembly of the nose wheel steering and its attaching for looseness and any damage.

X X X Inspect the nose wheel steering cables for wear and any damage.

X X Inspect shimmy damper and attaching for poor condition.

X X Inspect the gas springs of the nose gear strut and attaching for poor condition and insecurity.

X X Inspect all wiring for poor condition, chafing and insecurity.

X Remove hydraulic sump. Clean filter and change hydraulic fluid (see Ch. 32-30-11).

X X X Inspect the hydraulic lines for leakage, poor condition, chafing, bulges and insecurity. Replace hoses and fittings as required.

15 Every 5 years.

15






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X X X Inspect the power pack and the distributor block for leakage, poor condition and insecurity.

X X X Check the oil level of the hydraulic power pack (see Ch. 32-30-11) Replenish as required.

X X X Inspect the main and nose gear doors, door hinges and levers for cracks, distortion, insecurity and freedom of movement.

X X X Inspect the main and nose gear door actuation mechanism for poor condition, deformation, excessive free play and excessive wear.

X X Inspect the hydraulic actuators and attachment for poor condition and insecurity.

X X Check the main gear- interlocking actuator for locking.

X X Loosen the door hinges. Fasten the door by means of tapes.


In case of intentional gear operation by switch or circuit breaker handling make sure, that neither a person nor material is located in the landing gear working area.

Before beginning any work in the landing gear operating area, esp. any adjustment after performing test procedures, pull OFF the electric circuit breakers located on the left side panel and marked GEAR CTRL and HYDR.

X X

Lift the aircraft on jacks. Operate the landing gear (see Ch. 32-31-01/02 for gear up/down procedure). Inspect the hydraulic hoses and track rods for freedom of movement, chafing and distortion in extended and retracted position.

X X

Perform gear up procedure (refer to Ch. 32-31-01). Inspect the main and nose gear door actuation mechanism for maladjustment in the closed position. In case of doors closing with too much play or tension, adjust length of respective push rods (refer to Ch. 32-10-20 / 32-20-20).

X8 Perform test procedures in accordance with Ch. 32-31.

8 Annually.






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X X Clean the position switches; inspect for poor operation, insecure seat and maladjustment.

X X Inspect position switch wiring and harness for poor condition, chafing, any damage and insecurity.

X X Check the gear position lights on the panel for operation.

X X Reinstall the door hinges.

X X Clean and lubricate landing gear according to the lubrication chart (see Chapter 12-20-04).

X Replace all rodends (NMB M 81935/1 - 6).




05-23-15 Brakes and Wheels



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Refer to on-aircraft inspections presented in the latest edition of Cleveland Wheels & Brakes Maintenance Manual and Service Bulletins for wheel, tire and break inspections.



In case of intentional gear operation by switch or circuit breaker handling make sure, that neither a person nor material is in the landing gear working area.

NOTE With the aircraft being airborne or jacked with retracted landing gear and battery switch OFF, the hot bus feeds an AUX circuit, which supplies the directional valves with electrical power to keep the landing gear in the up-position. The AUX circuit is protected by the GEAR AUX 1 (left side panel) and GEAR AUX 2 (tail cone panel) circuit breakers.

However, the nose gear and main gear will slowly extend due to valve oil leakage, if the hydraulic pump is not being activated temporarily to maintain hydraulic pressure. If retracted landing gear position is in-tended, turn battery switch ON and push circuit breakers GEAR CTRL and HYDR (left side panel) to the ON position, while the landing gear switch (left main panel) is in the UP position.

If the aircraft is jacked with landing gear retracted and external power not connected, the battery will be discharged within approx. 2 days.

X X X Place the airplane on jacks.

X X X Check the brake fluid level.

X X X Inspect the brake assemblies for poor general condition.

X X X Inspect the brakes and the master cylinder for leakage.

X X X Inspect the brake lines and fittings for leakage and the hoses for bulges. Replace hoses as required.

X X Inspect the parking brake valve for poor condition and improper operation.






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Brakes and Wheels (cont.)

X X X Inspect the brakes for corrosion, cracks and visible damage. Inspect inlet fitting bosses and anchor bolt lugs for cracks.

X X X Inspect fit of brake cylinder anchor bolts in torque plate bushings for sloppiness. Excessive movement is cause for removal and detailed inspection.

X X X Inspect the lining for wear ( min. thickness 2.54 mm / 0.1 inch. ). Replace if required.

X X Lubricate the brake guide pins using silicone - base lubricant.

X X X Inspect the wheels for corrosion, cracks, loosen or broken bolts and any damage.

X X Inspect the wheel nuts for improper installation and insecurity.

X X X Check the wheel bearing clearance and wheels for free rotation.

X X

Inspect the brake disc for rust, grooves, coning, cracks, wear and visible damage. Check disc thickness (min. 8.25 mm / 0.325inch.). Replace if required. ( Refer to Cleveland Wheels & Brakes Maintenance Manual and Service Bulletins. )

X X Inspect the brakes for improper adjustment.

X X Remove the wheels and wheel bearings. Inspect wheel bearings for excessive wear or damage. Replace on condition.

X X Inspect the snap rings for distortion and wear. Inspect grease for contamination and solidification.

X X Repack the bearings with AEROSHELL 22C (per MIL-G-81322).

X X X

Visually inspect the tires for wear, cuts, flat spots, and tread or side wall damage. For tire changing refer to Cleveland Wheels & Brakes maintenance instructions.

X X Reinstall the wheels and safety.

X X X Check tire inflation pressure. Main wheels 5.7 bar / 83 psi ; nose wheel 3.5 bar / 51 psi.

X X Inspect the wheels for improper alignment.

X X X Lubricate per lubrication chart.

CAUTION Do not remove jacks before the landing gear is down and locked and the anti - retraction system has been checked.






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Brakes and Wheels (cont.)

X X Operate the ON GROUND switch at nose gear strut resp. RH main gear strut. Check anti- retraction system by gear lever operation.

CAUTION Ensure that all gears are extended and locked.

X X X Remove the jacks.




05-23-16 Completion



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X11 X X X Perform Flight Test.

X11 X X X Perform checks given for special equipment installed.

X11 X X X Reinstall upper and lower cowling, panels and doors as appropriate.

X11 X X X Aircraft conforms to specification of respective Authority.

X11 X X X All required Airworthiness Directives complied with.

X11 X X X All EXTRA mandatory Service Bulletins complied with.

X11 X X All vendor Service Bulletins and Service Letters complied with.

X11 X X X Check for proper Flight Manual.

X11 X X X Aircraft papers in order.

11 As required.




05-30-00 FLIGHTLINE INSPECTIONS

05-31-00 General These checks include pre-flight and post- flight checks. When the aircraft is in operation, these checks have to be performed daily.

05-32-00 Pre - Flight Check This check must be carried out before the first flight of the day and serves as a guideline for the pilot to check the general condition of the aircraft and the engine.

The pre-flight check is fundamental for the flight safety and has to be performed thoroughly in all details.

The schedule for the pre-flight check is in the EXTRA EA-400 Pilot' s Operating Handbook, Section 4.

05-33-00 Post - Flight Check This post-flight inspection has to be performed after the last flight of the day and consists of some visual checks.

The post-flight inspection should include all steps of the pre-flight check.

Additional measures:

1 Refuelling of the aircraft (refer to Chapter 12-10).

2 Reviewing of the entries in the log book for open discrepancies and correct entries of the landings and the flight hours.

3 If necessary, mooring of the aircraft (refer to Chapter 10-20).




05-50-00 UNSCHEDULED MAINTENANCE CHECKS

05-51-00 General Unscheduled checks are exceptional and have to be performed only after abnormal events which are unusual under normal operating conditions and which could possibly have caused damage to the aircraft or impaired the airworthiness.

The 25 h - Check for new engines is categorized as an unscheduled check, since it has to be performed only once after the first 25 h of operation of the engine.

05-52-00 Unscheduled Checks

05-52-01 25 h - Check After the first 25 h of operation, a check with a schedule equivalent to a 100 h inspection has to be performed. Oil and oil filter have to be replaced.

The 25 h inspection does not postpone the first 50 h inspection which has to be performed after a total of 50 h of operation.

05-52-02 Hard Landing After an extremely hard landing or other unusual loads on the landing gear, a thorough check of the respective components and their attachment points is necessary. Even, when there are no obvious signs of damage, a visual check has to be performed.

The check has to be carried out as follows:

1 The landing gear attachment area has to be examined for defects (e.g. cracks) using a mirror and a torch, check the outer laminate for delamination (press onto the laminate with your thumb).

Furthermore, the struts have to be checked for deformations and cracks.

IMPORTANT Examine wheel track

The tires have to be checked for cuts in the side wall and the brake discs for impacts.

2 In the area of the nose gear, the belly of the fuselage should be checked for cracks. Delaminations in the bonding area of the fire wall frame may also occur.

The condition (cracks, deformations) of the complete nose gear has to be checked.




3 After hard landings with damage observed, the attachment bolts of the land ing gear have to be examined for cracks (magnaflux or x-ray; dye-check is not suitable in this case) or must be replaced.

4 In addition to the landing gear, all control surfaces (hinges, mass balance) and the complete engine mount (engine truss, attachment points of the engine truss at the fire-wall, shock mounts) have to be checked.

In addition, the wings have to be checked at the leading edge and the main spar area plus the shear force fittings and particularly the spar connection.

Also the wing- to-fuselage connection bolts have to be examined.

5 The same inspection has to be performed on the elevator.

IMPORTANT If there are indications that structural parts are damaged, the manufacturer has to be consulted for possible and suitable repair methods.

05-52-03 Engine Fire After an engine fire, all hoses and cables have to be checked and if necessary replaced. A check of the engine has to be carried out according to the procedures in the applicable Teledyne Continental Manual.

If parts of the airframe or the engine cowlings are suspected of being damaged by high temperatures (sign of blister on the protective paint), the manufacturer has to be consulted for assistance in damage evaluation before the aircraft is returned into service.

05-52-04 Propeller Strike and Violent Engine Stoppage In case the propeller has touched 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 or other components might be damaged.

Replace engine driven vacuum pumps (Airborne A/M 442CW-6). Refer to Airborne Service Letter No. 38, latest edition.

05-52-05 Lightning Strike If a lightning strike has occurred, refer to TCM SB M88-9 and McCauley SB 215 B. Additionally, contact the manufacturer.

05-52-06 Engine Overspeed In case of an engine overspeed, refer to MT Doc E-124 and TCM SB M85-15.

chapter 05 time limits / maintenance checks - extra aircraft · and it contains data for a special...

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