RC Factory EXTRA 300L Service Manual

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SERVICE MANUAL

EXTRA 300L

Doc. No: EA-06702

EXTRA

FLUGZEUGPRODUKTIONS-

UND VERTRIEBS-GMBH

Schwarze Heide 21

D-46569 Hünxe, Germany

Tel: 49-28 58-91 37-0

Fax: 49-28 58-91 37-30

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Summary of Contents for RC Factory EXTRA 300L

Page 1 SERVICE MANUAL EXTRA 300L Doc. No: EA-06702 EXTRA FLUGZEUGPRODUKTIONS- UND VERTRIEBS-GMBH Schwarze Heide 21 D-46569 Hünxe, Germany Tel: 49-28 58-91 37-0 Fax: 49-28 58-91 37-30...
Page 2 EXTRA SERVICE MANUAL EXTRA 300L Log of Revisions Dates of issue for original and revised pages: Date and sign of approval: 1st Edition ..........1. June 1995 1. Revision ..........1. June 1996 2. Revision ..........1. June 1997 3. Revision ........15. December 1999 4.
Page 3 EXTRA SERVICE MANUAL EXTRA 300L List of Effective Pages Chapter Page Date of Issue Chapter Page Date of Issue Chapter Page Date of Issue Cover sheet 15. December 2005 26. October 2015 16. January 2009 11. December 2019 26. October 2015 16.
Page 4 EXTRA SERVICE MANUAL EXTRA 300L List of Effective Pages Chapter Page Date of Issue Chapter Page Date of Issue Chapter Page Date of Issue 26. October 2015 26. October 2015 1. June 1995 26. October 2015 26. October 2015 26. October 2015 1.
Page 5 EXTRA SERVICE MANUAL EXTRA 300L List of Effective Pages Chapter Page Date of Issue Chapter Page Date of Issue Chapter Page Date of Issue 26. October 2015 26. October 2015 4. June 2009 26. October 2015 26. October 2015 4. June 2009 26.
Page 6 EXTRA SERVICE MANUAL EXTRA 300L List of Effective Pages Chapter Page Date of Issue Chapter Page Date of Issue Chapter Page Date of Issue EA-9E102.53 10. December 2010 EA-93102.58 21. November 2011 EA-9C102.58 21. November 2011 EA-9D102.58A 29. July 2013 EA-93102.59...
Page 7 EXTRA SERVICE MANUAL EXTRA 300L List of Service Bulletins/Service Letters N° Date Subject EA-300/L Airworthiness Directive (AD) SB-300-2-95, 10.07.06 Upper Longeron 01 thru 71, 73 thru 77, 79 thru 83, EASA: AD N° 2006-0281, Issue F Insp. 85 thru 89, 91 and 92...
Page 8 EXTRA SERVICE MANUAL EXTRA 300L CONTENTS Title Page Log of Revisions ....................................
Page 9 EXTRA SERVICE MANUAL EXTRA 300L STRUCTURES Standard Practices and Structures - General ......................
Page 10 EXTRA SERVICE MANUAL EXTRA 300L Chapter 01 Introduction PAGE DATE:1. June 1995 CHAPTER PAGE...
Page 11 EXTRA Chapter 01 SERVICE MANUAL EXTRA 300L Table of Contents Chapter Title 01-00-00 GENERAL ........3 01-00-01 Trade Marks .
Page 12 EXTRA SERVICE MANUAL EXTRA 300L 01-00-00 GENERAL According to the regulations of the FAR part 23, this service manual provides educated maintenancestaff with information necessary for servicing, maintaining and repair of the EXTRA 300L. This manual contains a detailed description of systems...
Page 13 EXTRA GENERAL SERVICE MANUAL EXTRA 300L Engine: Lycoming AEIO-540-L1B5 Lycoming AEIO-540-L1B5/D Lycoming AEIO-580-B1A Operator´s Manual AEIO-540 (P/N:60297-21) Operaton and Installation Manual AEIO-580 (P/N:60297-32) Maintenance and Overhaul Man. AEIO-580 (P/N: LMO-AEIO-580) Service Letters, Bulletins and Instructions INDEX Service Letters, Bulletins and Instructions...
Page 14 EXTRA GENERAL SERVICE MANUAL EXTRA 300L Manufacturer: UNISON INDUSTRIES 530 Blackhawk Part Aveneue Rockford, IL 61104 , USA b) BENDIX Model No. D6LN-3000 (for Lycoming AEIO-540-L1B5/D) Service Bulletins (refer to Lycoming Service Letters, Bulletins and Instructions INDEX) Manufacturer: TELEDYNE CONTINENTAL MOTORS P.O.
Page 15 EXTRA SERVICE MANUAL EXTRA 300L Pointer 3000-10 ELT Operation and Installation Instructions Manufacturer: Pointer Avionics 76 Woolwich St. N. PO Box 271 Breslau, Ontario N0B 1M0, Canada Artex ME406 ELT Descriptioon, Operation, Installation and Maintenance Manual ME406 and ME406HM ELT (P/N: 570-1600)
Page 16 EXTRA SERVICE MANUAL EXTRA 300L 01-10-00 SAFETY To keep the security risks during the execution of the inspection and maintenance work as low as possible, observe the following points: Inspection and maintenance work has to be carried out only by qualified and authorized personnel.
Page 17 EXTRA SERVICE MANUAL EXTRA 300L Chapter 02 How to Use the Service Manual PAGE DATE: 1. June 1995 CHAPTER PAGE...
Page 18 EXTRA SERVICE MANUAL EXTRA 300L Table of Contents Chapter 02 Chapter/Figure Title 02-00-00 GENERAL ........3 02-10-00 MANUAL DESCRIPTION .
Page 19 EXTRA SERVICE MANUAL EXTRA 300L 02-00-00 GENERAL The set-up of the manual, the chapters and the handling correspond to the regulations of the Air Transport Associa- tion of America, ATA Specification No. 100. Only the num- bering of the pages and the layout have been changed to make working with this manual easier.
Page 20 EXTRA SERVICE MANUAL EXTRA 300L defined by the manufacturer. If a more detailed breakdown is necessary, bold faced headlines like the following are used: Powerplant 02-10-03 Page Numbering The page numbering begins at the coversheet of each chapter with "Page 1". In contrast to the ATA Specification 100, the particular sections and subjects don't start with a new numbering.
Page 21 EXTRA SERVICE MANUAL EXTRA 300L 02-10-05 Layout Apart from the headers and footers the layout consists of two columns. The right column contains text, titles, tables, schedules and figures (figures also can fill the whole page); the left column contains the chapter numbering, boxed textmarkers for notes and safety notes as well as explana- tions.
Page 22 EXTRA SERVICE MANUAL EXTRA 300L 02-10-06 Notes/Safety Notes Safety notes in this manual are marked by a boxed textmarker in the margin column and written in semi-bold characters. This manual distinguishes three warning levels: D A N G E R Indicates a hazardous situation which, if not avoided, will result in death or serious injury.
Page 23 EXTRA SERVICE MANUAL EXTRA 300L 02-20-00 HANDLING 02-20-01 Revisions Service/Maintenance Manuals and other Technical Publications in current revision status are available over the World Wide Web (direct link http://www.extraaircraft.com/ techserv.asp). Cross-check your documents against these publications and replace pages as necessary. Paper copies of publications will continue to be available if this is your preferred format of publications.
Page 24 EXTRA SERVICE MANUAL EXTRA 300L N O T E The owner is responsible for incorporating Service Bulletins to the above mentioned Service Bulletins List (page E). 02-20-03 Checklists Observe the following steps when working with checklists: 1 Copy the respective check list for performing a check.
Page 25 EXTRA SERVICE MANUAL EXTRA 300L Chapter 03 General Description PAGE DATE: 1. June 1995 CHAPTER PAGE...
Page 26 EXTRA Chapter 03 SERVICE MANUAL EXTRA 300L Table of Contents Chapter Title 03-00-00 GENERAL ........3 03-10 DESCRIPTION .
Page 27 A more detailed description of the systems you find in the respective chapters (see: CONTENTS). The Extra 300L (refer to Figure 1) is designed as a light weight, single-engine, two seat, low-wing monoplane using composite and steel materials. It has a fixed main landing gear and a tail wheel unit with full-swivel capability.
Page 28 EXTRA SERVICE MANUAL EXTRA 300L 03-10 DESCRIPTION 03-10-01 Construction Manufacturer: EXTRA-FLUGZEUGBAU GmbH Flugplatz Dinslaken D-46569 Hünxe, Germany Fuselage: steel tube design, covered with fabric, composite material resp. aluminium sheet metal, single piece canopy side hinged Wing: fibre composite design Stabilizers :...
Page 29 EXTRA DESCRIPTION DESCRIPTION SERVICE MANUAL EXTRA 300L 03-10-03 Brake System Main wheels: hydraulically operated disc brakes, hydraulic cylinders actuated by brake pedals Tail wheel: no brake 03-10-04 Powerplant Engine Manufacturer: TEXTRON LYCOMING Williamsport Division 652 Oliver Street Williamsport Plant 17 701...
Page 30 EXTRA DESCRIPTION DESCRIPTION Powerplant SERVICE MANUAL EXTRA 300L Propeller Manufacturer: MT Propeller Entwicklung GmbH & Co. KG Airport Straubing D-94348 Atting, Germany Type: MTV-9-B-C/C 200-15 (3-blade wood composite, hydraulic variable pitch with con- stant speed regulator, Propeller diameter: 200 cm)
Page 31 EXTRA DESCRIPTION DESCRIPTION SERVICE MANUAL EXTRA 300L 03-10-06 Electrical system Power supply: engine driven 12 V alternator, integrated DV converter, 28 Ah starter battery, master switch Circuits: equiped with automatic circuit breakers Ignition: magneto system, independent from electrical power supply...
Page 32 EXTRA - FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 300L Chapter 04 Airworthiness Limitations PAGE DATE: 31. January 1995 CHAPTER 04 PAGE...
Page 33 EXTRA SERVICE MANUAL EXTRA 300L Log of Revisions Chapter 4 Dates of issue for original and revised pages: Date and sign of approval: 1st Edition ......... 31. January 1995 1st Revision ........11. December 2019 The technical content of this document is approved under the authority of the DOA ref.
Page 34 Chapter 04 EXTRA SERVICE MANUAL EXTRA 300L Table of Contents Chapter 04 Chapter Title 04-00-00 GENERAL ........4 04-00-01 Temperature Limit .
Page 35 EXTRA SERVICE MANUAL EXTRA 300L 04-00-00 GENERAL For each inspection listed here, refer to the applicable chapter in this manual. I M P O R T A N T It is the operator's responsibility to make sure that time limits or life limits for items in this chapter are not exceeded.
Page 36 EXTRA SERVICE MANUAL EXTRA 300L Design Organization (EASA.21J.073) of EXTRA Flugzeugproduktions- und Vertriebs- GmbH under the procedure agreed with the EASA. EXTRA Flugzeugproduktions- und Vertriebs- GmbH may be contacted for engineering support. 04-00-02 Operating Time Only the airframe and components as listed in Chapter 04- 10-00 are subject to a permissible operating time;...
Page 37 La nding Ge a r S pring 6000 h 04-10-03 Service Life Limited Components The service life of the EXTRA 300L composite structure as listed in section 04-10-02 has been set to 6000 flight hours. PAGE DATE: 11. Dezember 2019 CHAPTER 04...
Page 38 EXTRA SERVICE MANUAL EXTRA 300L Chapter 05 Time Limits/Maintenance Checks PAGE DATE: 16. January 2009 CHAPTER 05 PAGE...
Page 39: Table Of Contents
EXTRA SERVICE MANUAL EXTRA 300L Table Chapter 05 Table of Contents Chapter/Figure Title 05-00-00 GENERAL ........3 05-10-00 TIME LIMIT COMPONENTS .
Page 40 EXTRA 300L. The periodic inspections and checks de- scribed and their recommended time intervals are minimum requirements for maintaining the aircraft in an airworthy condition.
Page 41: Time Limit Components
EXTRA SERVICE MANUAL EXTRA 300L 05-10-00 TIME LIMIT COMPONENTS 05-10-01 General All components not listed herein should be inspected as detailed in Chapter 05-20 „Maintenance Checks“ and re- paired, overhauled as required. It is recommended that overhaul or replacement of components should be accom-...
Page 42: Recommended Replacement Times
EXTRA SERVICE MANUAL EXTRA 300L 05-10-03 Recommended Replacement Times It is recommended to replace the items shown in the follow- ing schedule at the times indicated. The times may be modified by the respective national authorities. * on the recommendation...
Page 43: Time Between Inspection
EXTRA SERVICE MANUAL EXTRA 300L 05-10-04 Time Between Inspection Inspect these equipment items at the times shown: Item Time between Inspections Battery (Concorde) Refer to Concorde Servicing Instruction (capacity check) Static Pressure System Every 24 calendar months in accordance with 14 CFR Ch. 1 Part 43 App.
Page 44: Scheduled Maintenance Checks
EXTRA SERVICE MANUAL EXTRA 300L 05-20-00 SCHEDULED MAINTENANCE CHECKS 05-20-01 General Scheduled maintenance checks or tasks must be carried out at 25, 50, 100, 200, 300, 400, 500 and 1000 hour intervals. In addition an annual inspection equal to the 100 hour inspection has to be performed.
Page 45 EXTRA SERVICE MANUAL EXTRA 300L 1. Root Rib Aileron 2. Root Elevator 3. Root Horizontal Stabilizer 4. TrimTab (3 Holes) 5. Stall Warn Transducer 6. Lower Root Rudder Fin 7. Lower Root Rudder Horn 8. Wheel Fairing 9. Nose Ribs Aileron (Hinge Gaps)
Page 46 EXTRA SERVICE MANUAL EXTRA 300L Figure 2 Lubrication Chart 25 hours PAGE DATE: 26. October 2015 CHAPTER 05 PAGE...
Page 47 EXTRA SERVICE MANUAL EXTRA 300L Figure 3 Lubrication Chart 50 hours PAGE DATE: 26. October 2015 CHAPTER 05 PAGE...
Page 48 EXTRA SERVICE MANUAL EXTRA 300L Figure 4 Lubrication Chart 100 hours PAGE DATE: 26. October 2015 CHAPTER 05 PAGE...
Page 49 EXTRA SERVICE MANUAL EXTRA 300L 05-20-04 Maintenance Checks Schedule The maintenance checks described in this Chapter include all the scheduled checks which must be performed. Use the following schedule and the lubrication charts (Figures 2-4). Date: Inspector: Mechanic: Serial No.:...
Page 50 EXTRA SERVICE MANUAL EXTRA 300L Date: Inspector: Mechanic: Serial No.: Inspections O O 17 Check optional electronic g-meter for the maximum g- loading. If extreme value exceeds ±10 G, contact EXTRA- Flugzeugproduktions- und Vertriebs- GmbH. Correct date and time (refer to DSA-12 Manual).
Page 51 EXTRA SERVICE MANUAL EXTRA 300L Date: Inspector: Mechanic: Serial No.: Inspections Engine compartment (Refer to latest edition of Textron Lycoming Operator´s (AEIO 540), Operation & Installation and Maintenance & Overhaul Manuals (AEIO 580) and SB's, Christen Product Manual 801 Series and SB's, Slick Magneto Maintenance and Overhaul...
Page 52 EXTRA SERVICE MANUAL EXTRA 300L Date: Inspector: Mechanic: Serial No.: Inspections 9 Inspect oil temperature sensor unit for leaks and security. O O 10 Inspect flexible oil lines, oil return lines and fittings for leaks, security, chafing, dents, and cracks (ref: FAA AC 43.13-1A).
Page 53 EXTRA SERVICE MANUAL EXTRA 300L Date: Inspector: Mechanic: Serial No.: Inspections 22 Remove rocker box covers and check for freedom of valve rockers when valves are closed. Look for evidence of abnor- mal wear or broken parts in the area of valve tips, valve keeper, springs and spring seats.
Page 54 EXTRA SERVICE MANUAL EXTRA 300L Date: Inspector: Mechanic: Serial No.: Inspections O 30 Check fuel injector for general condition, clean fuel inlet screen. O O 31 Inspect air intake gaskets and seal rings for leaks and flanges for tightness. O O 32 Inspect flexible fuel lines, fuel injection lines and fittings for leaks, security, chafing, dents, and cracks (for AEIO 540 engine refer to Lycoming SB 342 each 100h;...
Page 55 EXTRA SERVICE MANUAL EXTRA 300L Date: Inspector: Mechanic: Serial No.: Inspections O 46 Inspect alternator, cable connections and accessories. O 47 Inspect condition and tension of alternator drive belt O 48 Inspect security of alternator mounting O 49 Inspect starter and starter drive O O 50 Check brake fluid level (fill as required).
Page 56 EXTRA SERVICE MANUAL EXTRA 300L Date: Inspector: Mechanic: Serial No.: Inspections Fuselage 1 Remove tail fairing, tail side skins, main fuselage cover and landing gear cuffs per Chapter 51. 2 Remove bottom fuselage cover including exhaust area cover- ing sheet per Chapter 51.
Page 57 EXTRA SERVICE MANUAL EXTRA 300L Date: Inspector: Mechanic: Serial No.: Inspections Seat belts 1 Check seat belts for security, attachment, proper operation, and condition. 2 Check webbing; inspect for fuzzy edges at the adjusters, inspect whether edges start to fray, inspect whether webbing lost its color (topside a different shade than the bottom side).
Page 58 EXTRA SERVICE MANUAL EXTRA 300L Date: Inspector: Mechanic: Serial No.: Inspections Flight controls 1 Remove wing access panels. 2 Inspect control surfaces for security of attachment, free movement, dents, delaminations and cracks. 3 Check spades visually for general condition. Inspect spade support for corrosion, cracks and deformations.
Page 59 EXTRA SERVICE MANUAL EXTRA 300L Date: Inspector: Mechanic: Serial No.: Inspections O 12 Rough check of safety stop clearance. With a force of approx. 90 kg (200 lbs) acting on the fully deflected rudder pedal the safety stop shall not be reached. If the stop is reached the control system indicates a too high flexibility which needs to be traced.
Page 60 EXTRA SERVICE MANUAL EXTRA 300L Date: Inspector: Mechanic: Serial No.: Inspections Wheels (refer to on-aircraft inspections presented in the latest edition of Cleveland Wheels & Brakes Maintenance Manual and Service Bulletins for wheel, tire and break inspections) 1 Visually inspect the wheels for corrosion, cracks, or other visible damage.
Page 61 EXTRA SERVICE MANUAL EXTRA 300L Date: Inspector: Mechanic: Serial No.: Inspections Tires 1 Visually inspect tires for cuts, flat spots, and tread or sidewall damage. If changing of tires is necessary follow the instruc- tions, including off-aircraft inspection of wheels, presented in the Cleveland Wheels &...
Page 62 EXTRA SERVICE MANUAL EXTRA 300L Date: Inspector: Mechanic: Serial No.: Inspections O O 10 Check for any brake fluid leaks. O O 11 Check brake fluid level. Tail-wheel landing gear 1 Check tail wheel landing gear for general condition and function.
Page 63 EXTRA SERVICE MANUAL EXTRA 300L Date: Inspector: Mechanic: Serial No.: Inspections Wing 1 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.
Page 64 EXTRA SERVICE MANUAL EXTRA 300L Date: Inspector: Mechanic: Serial No.: Inspections Instruments 1 Inspect panel mounting for security and safety. 2 Check operation, mounting, and wiring of switches for condi- tion and safety. 3 Check automatic circuit breaker mounting and wiring for condition and safety.
Page 65 EXTRA SERVICE MANUAL EXTRA 300L Date: Inspector: Mechanic: Serial No.: Inspections General 1 Perform checks given for special equipment installed. Refer to manufacturer instructions and the Handling, Servicing and Maintenance paragraphs of the related POH supplements. 2 Perform checks and maintenance for the ELT. Follow the applicable instructions prepared by the respective ELT manufacturer (Refer to Chapter 01).
Page 66 EXTRA SERVICE MANUAL EXTRA 300L 05-20-05 Significant Items Inspection Every 1000 flight hours the "Significant Items Inspection" must be performed in addition to the 100-hour inspection. It is recommended to replace all bolt connections, which are affected by this inspection. A complete inspection kit "EA300L 1000 Std.Insp"...
Page 67 EXTRA SERVICE MANUAL EXTRA 300L Inspector: Date: Mechanic: Serial No.: Inspections 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 O 13 Check root rib for cracks, delaminations and secure bonding to skin and spars by coin tapping (Refer to Chapter 20-10-05).
Page 68 EXTRA SERVICE MANUAL EXTRA 300L Inspector: Date: Mechanic: Serial No.: Inspections Front spar section O 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.
Page 69 EXTRA SERVICE MANUAL EXTRA 300L Inspector: Date: Mechanic: Serial No.: Inspections Horizontal Stabilizer Leading edge O 1 Check surface for erosion, scratches, stone nicks and impact damage. O 2 Check bonding top/bottom for dents, cracks and delamination. Front spar section O 3 Check bonding skin/spar for delamination by coin tapping.
Page 70 EXTRA SERVICE MANUAL EXTRA 300L Inspector: Date: Mechanic: Serial No.: Inspections O 6 Detailed visual of actuator lever for damage, cracks and proper attach- ment. O 7 Detailed visual of mass balance attachment and mounting boom for deformation, corrosion and cracks.
Page 71 EXTRA SERVICE MANUAL EXTRA 300L Inspector: Date: Mechanic: Serial No.: Inspections O 6 Detailed visual of trim actuator lever for damages and cracks. Ensure proper attachment and condition of friction. Main landing gear O 1 Inspect landing gear spring visually for dents, cracks and delaminations, especally at the axle attachment and the center bushing for wear and looseness.
Page 72 EXTRA SERVICE MANUAL EXTRA 300L Inspector: Date: Mechanic: Serial No.: Inspections O 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 73 EXTRA SERVICE MANUAL EXTRA 300L Inspector: Date: Mechanic: Serial No.: Inspections O 5 Visual inspection of battery fastening straps for cracks, damage and corrosion. O 6 Check the "quick pins" of the seat adjustment for cracks, deformations and corrosion. Inspect wear and proper function.
Page 74: Unscheduled Maintenance Checks
EXTRA SERVICE MANUAL EXTRA 300L 05-50-00 UNSCHEDULED MAINTENANCE CHECKS Unscheduled checks are only performed after abnormal events, which could possibly have caused damage to the aircraft or impaired the airworthiness. I M P O R T A N T In case of abnormal events or any exceedance of given limitations (load factor, never exceed speed, etc.) the...
Page 75 EXTRA SERVICE MANUAL EXTRA 300L Inspector: Date: Mechanic: Serial No.: Inspections Landing gear O 1 Examine landing gear mounting clamps for defects (e.g. cracks and deformed areas) O 2 Check clamp bolts of the landing gear for cracks, replace when...
Page 76: Engine Fire
EXTRA SERVICE MANUAL EXTRA 300L 05-50-03 Engine Fire After an engine fire, perform a check as described in the following: For damage evaluation consult the manufacturer, before the aircraft is put back into service. Inspector: Date: Mechanic: Serial No.: Inspections...
Page 77: Flightline Inspections
EXTRA SERVICE MANUAL EXTRA 300L 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 78 EXTRA SERVICE MANUAL EXTRA 300L Chapter 06 Dimensions and Areas PAGE DATE: 1. June 1995 CHAPTER PAGE...
Page 79 EXTRA Chapter 06 SERVICE MANUAL EXTRA 300L Table of Contents Chapter Title 06-00-00 GENERAL ........3 06-10-00 MAIN DATA .
Page 80: General
EXTRA SERVICE MANUAL EXTRA 300L 06-00-00 GENERAL The for measuring and weighing the aircraft relevant refer- ence planes are the following: Reference Planes Plane of upper longerons (horizontal plane) Plane of rudder (Vertical/symmetry plane) Fire wall plane (Vertical plane) The following figure1shows the aircraft planes :...
Page 81: Main Data
EXTRA SERVICE MANUAL EXTRA 300L 06-10-00 MAIN DATA 06-10-01 Main Dimensions (Refer to Figure 2 on page 6) Length: 6,96 m (22,83 ft) Height 1: 2.62 m (8.60 ft) Height 1 Height 2 : 2.59 m (8.45 ft) Height 2 Span: 8.00 m (26.25 ft)
Page 82: Horizontal Tail
EXTRA MAIN DATA SERVICE MANUAL EXTRA 300L 06-10-03 Horizontal Tail Span: 3.20 m (10.50 ft) Area: 2.56 m² (27.56 ft²) Airfoil: Wortmann FX 71-L-150/30 06-10-04 Elevator Area: 0.77 m² (8.29 ft²) Elevator-deflection: up -25°, down +25°, tolerance ± 2° Trim-tab-deflection: up -40°, down +50°, tolerance ± 5°...
Page 83 EXTRA MAIN DATA SERVICE MANUAL EXTRA 300L Three-View EXTRA 300L Figure 2 PAGE DATE: 1. June 1995 CHAPTER PAGE...
Page 84 EXTRA SERVICE MANUAL EXTRA 300L Chapter 07 Lifting and Shoring PAGE DATE: 1. June 1995 CHAPTER PAGE...
Page 85 EXTRA Chapter 07 SERVICE MANUAL EXTRA 300L Table of Contents Chapter 07 Chapter/Figure Title 07-10-00 JACKING ........3 07-10-01 Balance Weight .
Page 86: Jacking
EXTRA SERVICE MANUAL EXTRA 300L 07-10-00 JACKING 07-10-01 Balance Weight Prior to the removal of the horizontal and/or vertical stabilizer(s) or prior to shoring the aircraft as described in Chapter 07-20-00 it is necessary to weight the tail to prevent aircraft from tilting onto the nose.
Page 87: Shoring
EXTRA SERVICE MANUAL EXTRA 300L 07-20-00 SHORING Shoring the Extra 300L is necessary, when the main landing gear or the tail wheel has to be removed or installed. 07-20-01 Shoring the Front 1 Remove the fore access panels up to aft the main landing gear as per Chapter 51-00-01.
Page 88: Shoring The Front
EXTRA SERVICE MANUAL EXTRA 300L W A R N I N G Maintain hoisting strap as a security device to prevent nose over of the aircraft during maintenance work. Figure 3 Shoring the Front 07-20-02 Shoring the Tail Refer to Figure 4.
Page 89 EXTRA SERVICE MANUAL EXTRA 300L N O T I C E Don´t handle the elevator when lifting the tail. W A R N I N G Do not lift the tail higher than necessary for support- ing. The aircraft may tilt onto the nose.
Page 90 EXTRA SERVICE MANUAL EXTRA 300L Chapter 08 Leveling and Weighing PAGE DATE: 1. June 1995 CHAPTER PAGE...
Page 91 EXTRA Chapter 08 SERVICE MANUAL EXTRA 300L Table of Contents Chapter 08 Chapter/Figure Title 08-00-00 GENERAL ........3...
Page 92 08-00-00 GENERAL This chapter contains all information and procedures that are necessary for weighing and leveling the EXTRA 300L and for determining the Center of Gravity. Weigh the aircraft and determine the Center of Gravity each 5 years, after installation of additional equipment or after repairs.
Page 93 EXTRA SERVICE MANUAL EXTRA 300L 08-10-00 WEIGHING AND CALCULATION OF C OF G N O T E Weigh the aircraft only on even floor and in closed halls (wind protected). Use three identical scales. Ensure that the aircraft is fully equipped with equipment in locations according to the equipment list (PILOT´S...
Page 94 EXTRA WEIGHING SERVICE MANUAL EXTRA 300L Gross weight scale 1 ..kg Tare weight scale 1 (chocks) – ..kg Net weight scale 1 (W ..kg Gross weight scale 2 .
Page 95 EXTRA WEIGHING SERVICE MANUAL EXTRA 300L Empty Weight and Center of Gravity Position EXTRA 300L Data according to "TC Data-Sheet" and "Pilot´s Operating Handbook and LBA approved Airplane Flight Manual" Doc.-No.: EA - 06701 Equipment according to Equipment List dated: ... .
Page 96 EXTRA SERVICE MANUAL EXTRA 300L 08-20-00 LEVELING N O T E Level the aircraft only on even floor and in closed halls (wind protected). Secure each main wheel with two wheel chocks. W A R N I N G Do not lift tail wheel higher than necessary for leveling.
Page 97 EXTRA - FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 300L Chapter 09 Towing and Taxiing PAGE DATE: 1. June 1995 CHAPTER PAGE...
Page 98 EXTRA - FLUGZEUGBAU GmbH Chapter 09 SERVICE MANUAL EXTRA 300L Table of Contents Chapter Title 09-00-00 GENERAL ........3 09-10-00 TOWING .
Page 99 EXTRA - FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 300L 09-00-00 GENERAL This chapter describes the procedures and precautions nescessary for proper ground handling of the EXTRA 300L. 09-10-00 TOWING D A N G E R When preparing for ground handling operation ensure that the ignition switch is off.
Page 100 EXTRA - FLUGZEUGBAU GmbH TOWING AND TAXING SERVICE MANUAL EXTRA 300L 3 While taxiing, make shallow turns to test the brakes and the steerable tail wheel if installed. 4 Keep the Mixture in "FULL RICH" position. PAGE DATE: 1. June 1995...
Page 101 EXTRA - FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 300L Chapter 10 Parking, Mooring, Storage and Return to Service PAGE DATE: 1. June 1995 CHAPTER PAGE...
Page 102 EXTRA - FLUGZEUGBAU GmbH Chapter 10 SERVICE MANUAL EXTRA 300L Table of Contents Chapter Title 10-00-00 GENERAL ........3 10-10-00 PARKING / STORAGE .
Page 103: General
EXTRA - FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 300L 10-00-00 GENERAL This chapter provides the procedures recommended to park or to moor the aircraft so that the likelihood of ground damage is minimized. PAGE DATE: 1. June 1995 CHAPTER PAGE...
Page 104: Parking / Storage
EXTRA - FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 300L 10-10-00 PARKING / STORAGE When parking the aircraft, set the nose in the wind. Addition- ally both main wheels must be chocked fore and aft to prevent movement of the aircraft. C A U T I O N...
Page 105: Mooring
EXTRA - FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 300L 10-20-00 MOORING This section provides the procedures recommended for a normal tie-down of the aircraft. Proper tie-down procedure is the best precaution against damage to the aircraft by gusty or strong winds. To tie-down the aircraft securely, proceed as follows: 1.
Page 106: Return To Service
EXTRA - FLUGZEUGBAU GmbH SERVICE MANUAL EXTRA 300L 10-30-00 RETURN TO SERVICE If the aircraft has been storage for an extended period of time, it is advisable to perform a 50-hour periodic inspec- tion. Refer to Chapter "05-20-04 Scheduled Maintenance Checks"...
Page 107 EXTRA SERVICE MANUAL EXTRA 300L Chapter 12 Servicing PAGE DATE: 1. June 1995 PAGE DATE: 16. January 2009 CHAPTER PAGE...
Page 108 EXTRA SERVICE MANUAL EXTRA 300L Chapter 12 Table of Contents Chapter/Figure Title 12-00-00 GENERAL ........3 12-10-00 REPLENISHING .
Page 109: General
SERVICE MANUAL EXTRA 300L 12-00-00 GENERAL This chapter describes the procedures and precautions nescessary for proper servicing of the EXTRA 300L. The specified intervals (refer to chapter 5) are considered adequate to meet average requirements under normal oper- ating conditions.
Page 110: Replenishing
EXTRA SERVICE MANUAL EXTRA 300L 12-10-00 REPLENISHING The replenishing procedures contained in this section pro- vide the proper methods for replenishing consumed fuel, engine oil and brake fluid. Also included are methods for inflation of tires. 12-10-01 Refueling Refueling is accomplished by pumping or pouring fuel into the two wing tanks and the center tank through their respec- tive filler caps.
Page 111 EXTRA SERVICE MANUAL EXTRA 300L I M P O R T A N T Under no circumstances should fuel of lower octane rat- ing or automotive fuel (regardless of octane rating) be used. It is recommended that personnel be familiar with Service Instruction No.1070 regarding specified...
Page 112: Defueling
12-10-03 Fuel Drains The EXTRA 300L has three fuel drain valves to provide for drainage of moisture and sediment. Two fuel drain valves are located under the fuselage in the area of the landing gear; the third fuel drain which is interconnectecd to the fuel gascolator is located in the lowest point at the right side of the firewall.
Page 113 EXTRA SERVICE MANUAL EXTRA 300L Oil quantity The oil quantity is checked as follows: 1 Check oil level after engine has been stopped long enough for oil to drain back into sump. 2 Open the hatch on the upper part of the cowling.
Page 114 EXTRA SERVICE MANUAL EXTRA 300L Ashless Dispersant Oil MIL-L-22851 or SAE J1899 Ashless Dispersant Oil shall be used after the first 50 hours of the engine operation. Additive Oil If an engine has been operating on straight mineral oil for several hundred hours, a change to additive oil should be undertaken with caution.
Page 115 EXTRA SERVICE MANUAL EXTRA 300L Recommended Viscosity of Engine Oil: MIL-L-22851 or MIL-L-6082 or Average Ambient SAE J1899 Spec. SAE J1966 Spec. Air Temperature Ashless Dispersant Mineral Grades Grades SAE 15W50 or All Temperature ---------- SAE 20W50 Above 27°C (80°F)
Page 116: Oil Change
EXTRA SERVICE MANUAL EXTRA 300L Oil System Capacities: 12-10-05 Oil Change The engine oil must be changed after 25 hours of operation. It should be refilled in accordance with section "12-10-04 Engine Oil Replenishing" and the latest revision of Lycoming Service Instruction No.
Page 117: Replenishment Of Brake Fluid
EXTRA SERVICE MANUAL EXTRA 300L Remove, clean, inspect and reinstall engine oil strainers in accordance with Lycoming Operating Manual. Reinstall oil temp. sensor. Replenish engine oil as per Chapter 12-10-04. Reinstall the exhaust port of the second cylinder using new sealing rings.
Page 118 EXTRA SERVICE MANUAL EXTRA 300L Figure 1 Replenishment of Brake Fluid Be certain that the bleeding equipment to be used is abso- lutely clean and is filled with brake fluid that conforms to Specification MIL-H-5606, (refer to Chapter 05-20 Lubrication Charts) and is uncontaminated.
Page 119: Tire Inflation
Check the brake operation. 12-10-07 Tire Inflation For the EXTRA 300L the required tire pressure is 3.4 bar (49,3 Psi) for both main wheels. When inflating tires, it has to be used regulated air pressure through valve sems. PAGE DATE: 1. June 1995 CHAPTER PAGE DATE: 16.
Page 120: Scheduled Servicing
EXTRA SERVICE MANUAL EXTRA 300L 12-20-00 SCHEDULED SERVICING 12-20-01 Exterior Cleaning The painted surface of the aircraft have a long lasting, all- weather finish and should require no buffing or rubbing out in normal conditions. However, it is desirable to wash and polish it to preserve the outstanding exterior.
Page 121: Interior Cleaning
EXTRA SERVICE MANUAL EXTRA 300L Dull or scratched canopy sections can be returned to their transparent state by treating with especially formulated plexiglass cleaning agents. 12-20-02 Interior Cleaning Prior to the first acrobatic flight of the day it is recom- mended to clean the interior with a vacuum cleaner to remove dust and loose dirt.
Page 122 EXTRA SERVICE MANUAL EXTRA 300L 5 It is very important not to start the engine before the cleaning agent has been completely removed or has evaporated. PAGE DATE: 1. June 1995 CHAPTER PAGE DATE: 16. January 2009 PAGE...
Page 123: Unscheduled Servicing
EXTRA SERVICE MANUAL EXTRA 300L 12-30-00 UNSCHEDULED SERVICING 12-30-01 Removal of Snow and Ice After snowfall, the snow should be removed immediately from surface of the aircraft. Otherwise the water formed from melted snow will freeze on the surface or in slots and gaps of fairings.
Page 124 EXTRA SERVICE MANUAL EXTRA 300L Chapter 20 Standard practices - Airframe PAGE DATE: 1. June 1995 CHAPTER PAGE...
Page 125 EXTRA SERVICE MANUAL EXTRA 300L Chapter 20 Table of Contents Chapter/Figure Title 20-00-00 GENERAL ........3 20-10-00 STANDARD PRACTICES AIRFRAME .
Page 126: General
EXTRA SERVICE MANUAL EXTRA 300L 20-00-00 GENERAL The design of the airframe is according to standard proce- dures and requires no special tools or procedures for main- tenance. For that reason, only the bolts used in the Extra 300L with relevant torque values and measuring techniques are described in the following.
Page 127: Standard Practices Airframe
STANDARD PRACTICES AIRFRAME 20-10-01 Type of Bolts For the Extra 300L, LN-bolts (LN="Luftfahrt Norm"), AN- bolts (AN="Army/Navy") and DIN-bolts (DIN="Deutsche Industrie Norm") are used. The type of bolt can be identified by the designation on bolt head and by the surface treatment.
Page 128 QQ-P-416A, Type II, Class 3. For the Extra 300L bolts with shank drilled for cotter pin or drilled head for safety wire are used. The adding letter "A" after the dash number specifies bolts with undrilled shank.
Page 129: Width Across Flats For Metric Bolts
EXTRA SERVICE MANUAL EXTRA 300L Example: DIN 931, M10 x 80 - 8.8 Bolt Head Identification Standard hex head bolt Metric thread size M10 Length 80mm (3.15") Strength type 8.8 Bolt Head: DIN 931: DIN 933: Identification of manufacturer (OEV) Strength type (8.8 resp.12.9)
Page 130: Torque Values
EXTRA SERVICE MANUAL EXTRA 300L 20-10-03 Torque Values Nuts, except of counter nuts are mainly stop nuts according to LN 9348 or selflocking nuts according to AN 363. a) Standard torque values allowed for bolts and nuts accord- ing to DIN and LN must be adhered to as follows:...
Page 131: Special Torque Values
EXTRA SERVICE MANUAL EXTRA 300L 20-10-04 Special Torque Values Special torque values for the following items must be adhered Torque value Item (Nm) (in.lbs) Top Half of the Main Landing Gear Mounting Clamp (Bolt LN 9037-10054) Brake Back Plate Bolts (Cleveland)
Page 132: Measuring Techniques
EXTRA SERVICE MANUAL EXTRA 300L 20-10-05 Measuring Techniques When using stop nuts, the safety torque (friction torque or braking torque) should be added to the table standard values. This value is indicated on the dial of the torquemeter, before the nut contacts the attachment surface.
Page 133: Flexible Hose
EXTRA SERVICE MANUAL EXTRA 300L 20-10-07 Flexible Hose The EXTRA 300L is equipped for the oil, fuel, and brake lines with "AEROQUIP-hoses Aerospace Division". From Serial No. 35 equivalent "STRATOFLEX-hoses Aerospace Connectors Division" are used. Later, from Serial No. 47 KNAPP hoses are used for the brake system in the cockpit area and for the flight instruments.
Page 134 EXTRA SERVICE MANUAL EXTRA 300L The flexible hose should be installed so that it will be subject to a minimum of flexing during operation. The AEROQUIP- hoses inside the engine compartment are to be covered with AEROQUIP AE102 fire sleeves. The...
Page 135 EXTRA SERVICE MANUAL EXTRA 300L Installation of PA Hose with Hoerbiger H31A Axial Plug Install the plug coupling M into the adapter (e.g. firewall, brake) (see Figure 2, Sheet 2). Insert the plug coupling W into plug coupling M until it is snapped as outlined in Figure 2, Sheet 2.
Page 136: Connection Types Pa Hoses
EXTRA SERVICE MANUAL EXTRA 300L Figure 2, Sheet 1 Connection Types PA Hoses PAGE DATE: 11. December 2019 CHAPTER PAGE...
Page 137 EXTRA SERVICE MANUAL EXTRA 300L Figure 2, Sheet 2 Connection Types PA Hoses PAGE DATE: 11. December 2019 CHAPTER PAGE...
Page 138: Fittings
SERVICE MANUAL EXTRA 300L 20-10-08 Fittings Generally AN-fittings are used in the Extra 300L for the oil lubrication, the fuel system, and the brake system (the latter up to Ser. No. 46). All these fittings are made of aluminium alloy and are colored blue for idendification purposes. The dash number following the AN number indicates the size of the hose for which the fitting is made, in 16ths of an inch.
Page 139: Control Cables
EXTRA SERVICE MANUAL EXTRA 300L 20-10-09 Control Cables Control cables are used for the following systems of the 300L: Engine (Throttle, Mixture and RPM) • Trim • Heating • Consider the following information when working on engine control cables. Refer to Figure 3:...
Page 140 EXTRA SERVICE MANUAL EXTRA 300L N O T I C E S Protect the cable from contaminants such as fuel, oil, water, dirt and chemicals, which may damage the control cable. Protect the control cable from physical damage by paint, kinking, vibration, etc., which may damage the control cable.
Page 141 EXTRA SERVICE MANUAL EXTRA 300L Inspections Observe the following hints when performing inspections on the control cables: A cable must be replaced whenever: excessive free play is felt at the control even after all cable • connections have been verified as in good working order.
Page 142: Control Cables
EXTRA SERVICE MANUAL EXTRA 300L Figure 3 Control Cables PAGE DATE: 11. December 2019 CHAPTER PAGE...
Page 143 EXTRA SERVICE MANUAL EXTRA 300L 20-10-10 PR-812 Application Also refer to PR-812 Technical Data Sheet available from PGG Aerospace. I M P O R T A N T Proper mixing and correct proportions are extremely important to obtain required results.
Page 144: Assembly Instruction
EXTRA SERVICE MANUAL EXTRA 300L 20-20-00 ASSEMBLY INSTRUCTION 20-20-01 General N O T E Make appropriate logbook entry of compliance with this Assembly Instruction after Container Shipping. In case of the aircraft is delivered in a container it has to be assembled on arrival.
Page 145 EXTRA SERVICE MANUAL EXTRA 300L Inspect all removed items for damage prior to assembly. Damaged items have to be replaced or if possible repaired according to Chapter 51. W A R N I N G In order to prevent the aircraft from nosing over the assembly always has to start with the empennage.
Page 146 EXTRA SERVICE MANUAL EXTRA 300L Remove tail weight. Check if all switches are in Off-position and connect battery. Perform operational check of electrical equipment. Shut- off master switch after completion. Perform operational check and rigging of control system. Inspect fluid filled lines for leaks.
Page 147 EXTRA SERVICE MANUAL EXTRA 300L Chapter 23 Communication PAGE DATE: 1. June 1995 CHAPTER PAGE...
Page 148 EXTRA Chapter 23 SERVICE MANUAL EXTRA 300L Table of Contents Chapter 23 Chapter/Figure Title 23-00-00 GENERAL ........3 23-10-00 Speech communication .
Page 149: General
EXTRA SERVICE MANUAL EXTRA 300L 23-00-00 GENERAL The aircraft is equipped with a BECKER communication system. Maintenance work or overhaul of the this system requires consultation of the manufacturer. (Refer to BECKER Flugfunkwerk GmbH). 23-10-00 Speech communication The VHF-communication system consists of: 1 transmitter/receiver, VHF radio BECKER AR 3201 2 circuit breaker 5Amp.
Page 150: Becker Ar 3201 Front View
EXTRA SPEECH COMMUNICATION SERVICE MANUAL EXTRA 300L BECKER AR 3201 Channel memories The AR 3201 is fitted with 4 non-volatile channel memo- ries, which can be programmed from the front panel. Channel storage Turn the channel selector in position "A".
Page 151: Circuit Breaker
EXTRA SPEECH COMMUNICATION SERVICE MANUAL EXTRA 300L BECKER AR 3201 Installation Instruction The AR 3201 VHF transceiver is installed in the rear instrument panel, rear mounted and secured with 4 M3- screws. For the electrical installation the AR 3201 is inter- connected through the wiring harness ref.431.001-950 fol-...
Page 152 EXTRA SPEECH COMMUNICATION SERVICE MANUAL EXTRA 300L VHF Whip antenna The VHF whip antenna is removed as follows: Assure the master switch is OFF Remove the main fuselage cover and the tail fairing (Refer to Chapter 05-00-01). Disconnect the antenna to the coaxial cable.
Page 153: Interphone (Intercom)
EXTRA SERVICE MANUAL EXTRA 300L 23-40-00 INTERPHONE (INTERCOM) The interphone (intercom) is useful in an aircraft with high noise level where headseats are used. When the IC-switch (located at the throttle lever) is pressed, the transceiver can simultaneously operated for radio communication by the PTT key.
Page 154 EXTRA SERVICE MANUAL EXTRA 300L Chapter 24 Electrical Power PAGE DATE: 1. June 1995 CHAPTER PAGE...
Page 155 EXTRA SERVICE MANUAL EXTRA 300L Chapter 24 Table of Contents Chapter/Figure Title 24-00-00 GENERAL ........3 24-30-00 DC-GENERATION .
Page 156: General
EXTRA SERVICE MANUAL EXTRA 300L 24-00-00 GENERAL This Chapter describes the electrical power system and its operation. This covers the battery system and the alternator system. The battery system consists of the dryfit A200 battery (Sonnenschein GmbH, Büdingen, Germany), the master relay and the associated wiring.
Page 157: Dc-Generation
EXTRA SERVICE MANUAL EXTRA 300L 24-30-00 DC-GENERATION (Refer to Figure 0 of Chapter 91) Power for the electrical system is provided by an alternator and/or the battery. The alternator serves as the main component to power the electrical system and charge the battery during normal conditions.
Page 158: Battery
EXTRA DC-GENERATION SERVICE MANUAL EXTRA 300L regulator. The voltage regulator will supply and regulate voltage to the alternator field and protects circuit against overvoltage. With the alternator operating (engine running) and the field energized, the alternator will develop electrical power. The alternator supplies power to the bus bar through the 60 amp alternator circuit breaker.
Page 159: Master Relay
EXTRA SERVICE MANUAL EXTRA 300L 24-30-02 Master Relay Removal/Installation N O T I C E Ensure the master switch is in Off-position. Remove the main fuselage cover as per Chapter 51. Disconnect electrical wiring. Remove the DIN933 M5x12 attachment bolts, the DIN9021 M5x20 washers and the LN9348-05 stopnuts.
Page 160: Alternator And Accessories
EXTRA MAINTENANCE PRACTICES SERVICE MANUAL EXTRA 300L Figure 1 Alternator and Accessories PAGE DATE: 26. October 2015 CHAPTER PAGE...
Page 161 EXTRA SERVICE MANUAL EXTRA 300L Removal Remove the upper and lower part of the cowling (ref. Chapter 71). Disconnect the wiring of the alternator. (Bosch) Remove cotter pins at castle nuts (2 & 3, Figure 1) and safety wire at bolt (1).
Page 162: Drive Belt
EXTRA SERVICE MANUAL EXTRA 300L Apply a proper tension to the drive belt by counter-clockwise rotating the alternator around bolt connection (3/6, Figure 1). Check tension of the drive belt and adjust if necessary per Chapter 24-30-04. 24-30-04 Drive Belt Replacement Remove cowling per Chapter 71.
Page 163 EXTRA SERVICE MANUAL EXTRA 300L Tension Check I M P O R T A N T An improperly tensioned alternator drive belt can slip, wear prematurely, and reduce electrical output of the alternator. Use the following simple method (Torque Method) to check proper tension of the drive belt.
Page 164: Alternator Pulley
EXTRA SERVICE MANUAL EXTRA 300L (Prestolite) Slightly loosen bolts (4 & 5) and castle nut (7) to release drive belt tension. Rotate the alternator counterclockwise around bolt connection (3/6) to increase the belt tension. Rotate the alternator clockwise around bolt connection (3/6) to decrease the belt tension.
Page 165: Dc Electrical Load Distribution
EXTRA SERVICE MANUAL EXTRA 300L 24-60-00 DC ELECTRICAL LOAD DISTRIBUTION From the main bus which physically corresponds to the bus bar the electrical load is distributed through circuit breakers and switches.The bus bar is located at the back side of the circuit breakers, the circuit breakers themselves are located at the rear instrument panel so as the lever switches.
Page 166: Lever Switch
EXTRA SERVICE MANUAL EXTRA 300L 24-60-02 Lever Switch Removal/Installation Disconnect battery Remove the instrument panel cover per Ch 31. Disconnect the tubings from the resp. instruments. Remove the instrument panel attachment screws. Turn down the panel. Disconnect wiring. Remove the attachment nut at the front side of the instru- ment panel.
Page 167: Relay
EXTRA SERVICE MANUAL EXTRA 300L 24-60-04 Relay Removal/Installation Disconnect battery and external power. Remove the LH cuff as per chapter 51. N O T I C E Possible damage of internal relay mechanism due to rotational displacement of contact and coil eletrical terminals.
Page 168 EXTRA SERVICE MANUAL EXTRA 300L Chapter 25 Equipment and Furnishings PAGE DATE: 1. June 1995 CHAPTER PAGE...
Page 169 EXTRA SERVICE MANUAL EXTRA 300L Chapter 25 Table of Contents Chapter/Figure Title 25-10-00 FLIGHT COMPARTMENTS ....3 25-10-01 Front Seat ........3 25-10-02 Rear Seat .
Page 170: Flight Compartments
SERVICE MANUAL EXTRA 300L 25-10-00 FLIGHT COMPARTMENTS The EXTRA 300L is standard equipped with a pilot and a co- pilot seat including special aerobatic seat belt / shoulder harnesses for both seats. An aircraft document bag is installed in the rear cockpit.
Page 171: Seat Belts
EXTRA SERVICE MANUAL EXTRA 300L Removal/Installation Loosen the leather protection cuff from the control stick. Remove quickpins of the backrest steel frame and the backrest-to-seat connection. Remove rear seat backrest. Disconnect backrest from the steel tubes if necessary by removing the resp. bolts.
Page 172: Strap Assembly
EXTRA SERVICE MANUAL EXTRA 300L Figure 1 Strap Assembly Up to Ser. No. 45 each strap end is fitted with LN 9037-0820 bolts , LN9348-08 stop nuts and DIN 125 M8 washers to its own fitting at the steel frame resp. at the underside of the seat.
Page 173: Shoulder Strap Attachment
EXTRA SERVICE MANUAL EXTRA 300L Figure 2 Shoulder Strap Attachment The shoulder harness shall be installed using the 3-bar slide as shown in figure 3. I M P O R T A N T Tuck excess webbing through the 3-bar slide. Failure to make this third pass through the 3-bar slide will cause the belt to slip under load.
Page 174: Aircraft Document Bag
SERVICE MANUAL EXTRA 300L 25-10-04 Aircraft Document Bag The rear cockpit of the EXTRA 300L is furnished with an aircraft document bag. This aircraft document bag is mounted with three AN 526 C 1032 R8 bolts and DIN 9021 M5x20 washers on the right inside of the cockpit frame.
Page 175 EXTRA SERVICE MANUAL EXTRA 300L Chapter 27 Flight Controls PAGE DATE: 1. June 1995 CHAPTER PAGE...
Page 176 EXTRA SERVICE MANUAL EXTRA 300L Chapter 27 Table of Contents Chapter/Figure Title 27-00-00 GENERAL ........3 Figure 1 Controls .
Page 177: General
SERVICE MANUAL EXTRA 300L 27-00-00 GENERAL (Refer to Figure 1) The EXTRA 300L is standard equipped with full dual primary flight controls including conventional control sticks and adjustable rudder pedals. The control surfaces are operated by a direct mechanical linkage. The control surface deflections are shown in Figure 2.
Page 178: Figure 2
EXTRA SERVICE MANUAL EXTRA 300L N O T E When installing a bellcrank or control stick the spacer sleeve inside the bearing could be displaced as shown in Figure 2. Use a mandrel to adjust the spacer sleeve. Figure 2...
Page 179: Figure 4
EXTRA SERVICE MANUAL EXTRA 300L Figure 4 Control Surface Deflections PAGE DATE: 26. October 2015 CHAPTER PAGE...
Page 180: Control Rods
EXTRA SERVICE MANUAL EXTRA 300L Free Play in the Control System With controls (stick and rudder pedals) locked, the free play measured at the control surfaces must not exceed the values listed: Aileron: ±1 mm * measured at the trailing edge and max.
Page 181: Figure 5
EXTRA SERVICE MANUAL EXTRA 300L Lengths The measurements given in this chapter refer to the dis- tances between the centers of the rod end bearings (see Figure 5). Figure 5 Control Rod Measurement Refer to the following Figure 6 for identification of the control rods.
Page 182: Figure 7
EXTRA SERVICE MANUAL EXTRA 300L Length Adjustment The standard measurements are given in Table 1. 1 Remove the respective access panels. 2 Disconnect one rod end from the respective bellcrank. 3 Loosen the check nut. N O T E It might be necessary to adjust both rod ends to get the correct length.
Page 183: Bellcranks
EXTRA SERVICE MANUAL EXTRA 300L 27-00-02 Bellcranks Removal/Installation Refer to Figure 8. 1 Remove the respective access panels. 2 Remove the adjacent control rods per Chapter 27-00-01. 3 Remove the M5 attachment bolt (2). 4 Remove the bellcrank. 5 Reverse procedure to install the bellcrank using sufficient washers (min.
Page 184: Front Control Stick
EXTRA SERVICE MANUAL EXTRA 300L 27-00-03 Front Control Stick Removal/Installation Refer to Figure 9. 1 Remove front seat per Chapter 25-10-01. 2 Disconnect the electrical wiring. 3 Remove the control stick attachment bolt (1). 4 Disconnect the control stick from the control rod per Chapter 27-00-01.
Page 185: Rear Control Stick
EXTRA SERVICE MANUAL EXTRA 300L 27-00-04 Rear Control Stick Removal/Installation 1 Remove rear seat per Chapter 25-10-02. 2 Disconnect the electrical wiring. 3 Bring the control stick in the foremost position and discon- nect the control stick from the control rods per Chapter 27-00-01.
Page 186: Aileron Control
EXTRA SERVICE MANUAL EXTRA 300L 27-10-00 AILERON CONTROL (Refer to Figure 10) The aileron (1) is direct mechanical linked to the control sticks (6, 7) by the aileron center linkage (10) with spade arm, push-pull rods (8), bellcranks (9) and the torque tube (5). The bell cranks have two sealed ball bearings.
Page 187: Figure 10
EXTRA SERVICE MANUAL EXTRA 300L Figure 10 Aileron Control PAGE DATE: 26. October 2015 CHAPTER PAGE...
Page 188: Ailerons
EXTRA SERVICE MANUAL EXTRA 300L 27-10-01 Ailerons Removal/Installation Disconnect the actuator rod from the aileron center link- age. Disassemble the spade if necessary observing the quantity and location of washers. Loosen the hinge bolts and the ground bonding leads and remove the bolts.
Page 189: Figure 12
EXTRA SERVICE MANUAL EXTRA 300L Check if the control rods connecting the torque tube and the inner wing bellcranks have a length of 532 mm (Refer to Table 1). Adjust length if necessary per Chapter 27-00-01. Check if the ailerons are in 0°-position (The trailing edge bottom of the aileron is in alignment with the trailing edge bottom of the wing as shown in Figure 12).
Page 190: Spades
EXTRA SERVICE MANUAL EXTRA 300L 27-10-02 Spades Rigging For roll trim the spade rigging angle of incidence has to be changed. Insert washer(s) between the spade and the mount- ing plate (refer to Figure 13). For example: When the aircraft rolls to the left, insert washer(s) at the front attach- ment bolt of the right spade.
Page 191: Rudder Control
EXTRA SERVICE MANUAL EXTRA 300L 27-20-00 RUDDER CONTROL (Refer to Figure 14) The rudder pedals (4) are connected via a cable system (17) to the bottom hinge bellcrank (13). The cables are guided by fairleads (11). Springs (20) keep the cables under tension when they are not operated.
Page 192: Figure 14
EXTRA SERVICE MANUAL EXTRA 300L Figure 14 Rudder Control PAGE DATE: 26. October 2015 CHAPTER PAGE...
Page 193: Rudder
EXTRA SERVICE MANUAL EXTRA 300L 27-20-01 Rudder I M P O R T A N T Perform checks 10-11 of "Flight Controls" presented in Chapter 05-20-04 after each maintenance work af- fecting the rudder control cables. Removal/Installation Disconnect the rudder control cables from the bottom hinge bellcrank.
Page 194: Bottom Hinge Bracket
EXTRA SERVICE MANUAL EXTRA 300L 27-20-02 Bottom Hinge Bracket Removal/Installation Remove the rudder per Chapter 27-20-01. Loosen the attachment bolts. Remove the bottom hinge bracket with the travel stop plate. Install in reverse sequence of removal. 27-20-03 Bottom Hinge Bellcranks Removal/Installation Remove the rudder per Chapter 27-20-01.
Page 195: Figure 15
EXTRA SERVICE MANUAL EXTRA 300L Secure the rudder (3, Figure 14) in 0°-position. Mount the pre-assembled eye end of the longer control ca- ble to the LH cable fastening (20). Check that the 550 mm teflon protective hose is on the pre- assembled control cable.
Page 196 EXTRA SERVICE MANUAL EXTRA 300L Pre-install the LN9037-06030 bolt, the DIN 125-8,4 wash- ers (one on both sides of the thimble and one below the tailwheel steering attachment bracket), the DIN 125-6,3 washers, the bushing, the LN9348-06 nut and the thimble to the bottom hinge bellcrank.
Page 197: Figure 16
EXTRA SERVICE MANUAL EXTRA 300L Fix the front pedal in almost vertical position (97° relative to the footrest using the template as shown on Figure 16). Template Front pedal 97° 169 mm Figure 16 Front Pedal Template Stretch the shorter control cable with a force that is equivalent to the tractive effort of the front pedal retracting spring.
Page 198: Fairlead
EXTRA SERVICE MANUAL EXTRA 300L 27-20-05 Fairlead Removal/Installation Remove the fairlead retaining clip. Pull the fairlead halves out of the sleeve. Reverse procedure to install the fairlead. PAGE DATE: 26. October 2015 CHAPTER PAGE...
Page 199: Elevator Control
EXTRA SERVICE MANUAL EXTRA 300L 27-30-00 ELEVATOR CONTROL Refer to Figure 17. The two control sticks (6, 7) are con- nected by a push-pull rod (8) inside the torque tube (5). The control movements are transferred from the rear control stick (7) to the elevator (2) by push-pull rods (8) and bellcranks (9, 9a).
Page 200: Figure 17
EXTRA SERVICE MANUAL EXTRA 300L Figure 17 Elevator and Trim Tab Control PAGE DATE: 26. October 2015 CHAPTER PAGE...
Page 201: Elevator
EXTRA SERVICE MANUAL EXTRA 300L 27-30-01 Elevator Removal/Installation Before the removal of the elevator, the vertical stabilizer has to be disassembled. Remove the respective access panels. Remove the rudder per Chapter 27-20-01 Remove the vertical stabilizer per Chapter 55-30-00. Loosen the bowden cables from the trim tab. If a replace- ment is necessary order new cable.
Page 202: Neutral Position Of The Rear Control Stick
EXTRA SERVICE MANUAL EXTRA 300L Secure the rear control stick in the neutral position. (Verti- cal back edge of the torque tube parallel to the control stick like shown in Figure 18). Figure 18 Neutral Position of the Rear Control Stick Check if the elevator is in 0°-position.
Page 203: Trim Tab
EXTRA SERVICE MANUAL EXTRA 300L Adjust the travel stops if necessary. Check if the rear control stick travel is symmetrically. If it is not, contact the manufacturer. 27-30-02 Trim Tab Removal/Installation Loosen bowden cables. If a replacement is necessary order new cable.
Page 204 EXTRA SERVICE MANUAL EXTRA 300L vertical position. Ensure rod end is screwed in for min. 10 rotations. Renew locking varnish. d Reconnect the rod end. Repeat steps a thru d for the front rod end (2) if necessary. Bring the trim tab in 0°-position by replacing the selflocking nuts (6 and/or 7).
Page 205 EXTRA SERVICE MANUAL EXTRA 300L Chapter 28 Fuel PAGE DATE: 1. June 1995 PAGE DATE: 16. January 2009 CHAPTER PAGE...
Page 206 EXTRA SERVICE MANUAL EXTRA 300L Chapter 28 Table of Contents Chapter/Figure Title 28-00-00 GENERAL ........4 Figure 1, Sheet 1 Fuel System (Configuration 1) .
Page 207 EXTRA SERVICE MANUAL EXTRA 300L 28-40-05 Float Wire ........33 Figure 14 Float Wire Adjustment .
Page 208: General
(6) and an engine driven rotary pump (7). Concerning the fuel drains (5) also refer to Chapter 12-10-03. From serial number 1292 the EXTRA 300L is available ex factory in two different fuel tank system configurations. Configuration 1 is characterized by a center tank with 42 L capacity as it is used for the former serial numbers.
Page 209 EXTRA SERVICE MANUAL EXTRA 300L to exhaust stack. If a ramp ground is not provided, a temporary ground can be obtained by driving a metal rod into the ground and attaching a ground wire between the rod and the aircraft exhaust stack.
Page 210: Fuel System (Configuration 1)
EXTRA SERVICE MANUAL EXTRA 300L Figure 1, Sheet 1 Fuel System (Configuration 1) PAGE DATE: 26. October 2015 CHAPTER PAGE...
Page 211: Fuel System (Configuration 2)
EXTRA SERVICE MANUAL EXTRA 300L Figure 1, Sheet 2 Fuel System (Configuration 2) PAGE DATE: 26. October 2015 CHAPTER PAGE...
Page 212: Storage
EXTRA SERVICE MANUAL EXTRA 300L 28-10-00 STORAGE The EXTRA 300L is equipped with two independent fuel systems: The center- and acro tank system and the wing tank system. The acro tank (1, Figure 3) incorporating an inverted flight fuel supply system is mounted in the fuselage just behind the firewall.
Page 213: Center Tank
EXTRA SERVICE MANUAL EXTRA 300L 28-10-01 Center Tank Removal/Installation Remove the main fuselage cover (refer to Chapter 51). Remove the front seat per Chapter 25. Remove wing per Chapter 57 (60 L center tank only). Remove the front control stick per Chapter 27.
Page 214: Acro Tank Flop Tube
EXTRA SERVICE MANUAL EXTRA 300L 28-10-03 Acro Tank Flop Tube Removal/Installation Drain the fuel system per Chapter 12-10-02. Disconnect the hose (5, Figure 4) and the elbow fitting (4). Remove the acro tank per Chapter 28-10-02. Loosen the flop tube fitting (3) and take the flop tube as- sembly (2) out of the acro tank (1).
Page 215: Storage (Configuration 1)
EXTRA SERVICE MANUAL EXTRA 300L Figure 3, Sheet 1 Storage (Configuration 1) PAGE DATE: 26. October 2015 CHAPTER PAGE...
Page 216: Storage (Configuration 2)
EXTRA SERVICE MANUAL EXTRA 300L Figure 3, Sheet 2 Storage (Configuration 2) PAGE DATE: 26. October 2015 CHAPTER PAGE...
Page 217: Wing Tank Inspection Door
EXTRA SERVICE MANUAL EXTRA 300L 28-10-04 Wing Tank Inspection Door Removal/Installation 1 Drain the fuel system per Chapter 12-10-02. 2 Disconnect the ground bonding leads and if necessary (LH wing tank) the electrical wiring of the lever-type tank unit (3, Figure 5).
Page 218: Wing Tank Outlets
EXTRA SERVICE MANUAL EXTRA 300L 28-10-05 Wing Tank Outlets Removal/Installation Remove the inspection door (1) (refer to Figure 6) per Chapter 28-10-04. Remove the union nuts (2) and the elbow tubes (3). Remove AN 924 nut and washers and remove AN 832 fitting.
Page 219: Center Tank Filler Neck
EXTRA SERVICE MANUAL EXTRA 300L 28-10-06 Center Tank Filler Neck Removal/Installation Remove the main fuselage cover per Chapter 51. Completely drain the fuel system per Chapter 12. Loosen the lower hose clip. Remove the filler neck. Install in reverse sequence of removal.
Page 220: Filler Neck Sealing Lip
EXTRA SERVICE MANUAL EXTRA 300L 28-10-08 Filler Neck Sealing Lip Replacement Carefully drill out the body-bound rivets (7, Figure 7). Install the new sealing lip driving in new washers (6) and body-bound rivets. Figure 7 Filler Neck and Sealing Lip Removal/Installation PAGE DATE: 26.
Page 221: Ventilation Line
EXTRA SERVICE MANUAL EXTRA 300L 28-10-09 Ventilation Line Replacement General information concerning fittings is found in Chapter 20-10-08. PAGE DATE: 26. October 2015 CHAPTER PAGE...
Page 222: Distribution (Configuration 1)
EXTRA SERVICE MANUAL EXTRA 300L 28-20-00 DISTRIBUTION (Refer to Figure 8) Flexible hoses and aluminium tubes (A-K) connect the particular components of the fuel system. From Serial No. 1074 the drain line "L" has been added. The fuel lines connecting the wing tanks (D) meet at an alu- minium 3-port tee-block (7) in the bottom center of the fuselage.
Page 223 EXTRA SERVICE MANUAL EXTRA 300L Figure 8, Sheet 1 Distribution (Configuration 1) PAGE DATE: 26. October 2015 CHAPTER PAGE...
Page 224: Distribution (Configuration 2)
EXTRA SERVICE MANUAL EXTRA 300L Figure 8, Sheet 2 Distribution (Configuration 2) PAGE DATE: 26. October 2015 CHAPTER PAGE...
Page 225: Fuel Selector Valve And Control Rod
EXTRA SERVICE MANUAL EXTRA 300L 28-20-01 Fuel Selector Valve and Control Rod Removal/Installation (Refer to Figure 9 Sheet 1 resp. Sheet 2 from SN 1079) Drain the fuel system per Chapter 12-10-02. Disconnect the fuel lines on the selector valve.
Page 226: Fuel Selector Valve And Control Rod (Up To Sn 78)
EXTRA SERVICE MANUAL EXTRA 300L Figure 9, Sheet 1 Fuel Selector Valve and Control Rod (up to SN 78) PAGE DATE: 26. October 2015 CHAPTER PAGE...
Page 227: Fuel Selector Valve And Control Rod (From Sn 79)
EXTRA SERVICE MANUAL EXTRA 300L Figure 9, Sheet 2 Fuel Selector Valve and Control Rod (from SN 79) PAGE DATE: 26. October 2015 CHAPTER PAGE...
Page 228: Gascolator
EXTRA SERVICE MANUAL EXTRA 300L 28-20-03 Gascolator Removal/Installation 1 Drain the fuel system per Chapter 12-10-02. 2 Disconnect the fuel lines on the gascolator. 3 Loosen the knurled nut (1, Figure 10). 4 Remove the mounting bracket (2). 5 Remove the fuel reservoir (3) and the sealing ring (4).
Page 229: Electrical Boost Pump
EXTRA SERVICE MANUAL EXTRA 300L 28-20-04 Electrical Boost Pump Removal/Installation Drain the fuel system per Chapter 12-10-02. Disconnect the plug and the fuel lines on the boost pump. Loosen the screw clamps (1, Figure 11). Remove the boost pump (2).
Page 230: Fuel Line
EXTRA SERVICE MANUAL EXTRA 300L 28-20-05 Fuel Line Replacement General information concerning hoses and fittings you find in Chapter 20-10-07/08. I M P O R T A N T If replacement of fuel lines passing the firewall is nec- essary, renew the sealing of the rubber grommet grooves and gaps at the engine side of the firewall.
Page 231: Indicating (Configuration 1)
EXTRA SERVICE MANUAL EXTRA 300L 28-40-00 INDICATING (Refer to Figure 12) For fuel contents indicating the center tank is equipped with a tubular tank unit (1) and the left wing tank with a lever-type tank unit (2). They transmit the fuel levels to the respective fuel quantity indicators at the instrument panel (3).
Page 232 EXTRA SERVICE MANUAL EXTRA 300L Figure 12, Sheet 1 Indicating (Configuration 1) PAGE DATE: 26. October 2015 CHAPTER PAGE...
Page 233: Indicating (Configuration 2)
EXTRA SERVICE MANUAL EXTRA 300L Figure 12, Sheet 2 Indicating (Configuration 2) PAGE DATE: 26. October 2015 CHAPTER PAGE...
Page 234: Fuel Quantity Indicator
EXTRA SERVICE MANUAL EXTRA 300L 28-40-01 Fuel Quantity Indicator Removal/Installation Disconnect battery. Loosen the nuts, remove the mounting bracket and re- move the fuel quantity indicator. Disconnect the wiring (the lamp is not used). Install in reverse sequence of removal observing the wiring diagram.
Page 235: Fuel Quantity Indicator (Center Tank)
EXTRA SERVICE MANUAL EXTRA 300L 28-40-02 Fuel Quantity Indicator (Center Tank) Calibration Drain the fuel system (refer to Chapter 12-10-02). Remove the fuel quantity indicator following step 2 of Chap- ter 28-40-01. Bring indicator to „0“- position by turning the ad- justment screw.
Page 236: Lever-Type Tank Unit (Wing Tank)
EXTRA SERVICE MANUAL EXTRA 300L 6 Clean sealing surfaces mechanically and with Acetone. 7 Install in reverse sequence of removal after applying 3M Brand Fuel Resistant Coating 776 (3M, St. Paul, USA) for sealing to both sides of the sealing ring.
Page 237 EXTRA SERVICE MANUAL EXTRA 300L 5 Clean sealing surfaces mechanically and with Acetone. 6 Install in reverse sequence of removal after applying 3M Brand Fuel Resistant Coating 776 (3M, St. Paul, USA) for sealing to both sides of the sealing ring and the grooves inside the tank.
Page 238 EXTRA SERVICE MANUAL EXTRA 300L Figure 15 Float Wire Installation 4 Reinstall the lever-type tank unit per Chapter 28-40-04. PAGE DATE: 26. October 2015 CHAPTER PAGE...
Page 239 EXTRA SERVICE MANUAL EXTRA 300L Chapter 31 Indication \ Recording System PAGE DATE: 1. June 1995 CHAPTER PAGE...
Page 240 EXTRA SERVICE MANUAL EXTRA 300L TABLE OF CONTENTS Chapter 31 Chapter Title 31-00-00 GENERAL ........3 31-10-00 INSTRUMENT AND CONTROL PANELS .
Page 241: General
SERVICE MANUAL EXTRA 300L 31-00-00 GENERAL The Extra 300L is equipped with flight instruments in both cockpits. Instruments and placards can be provided with markings in either metric or English units (refer to Chapter11"Placards and Markings"). The colour markings in instruments follow US-FAR, part 23 recommendation.
Page 242: Instrument And Control Panels
EXTRA SERVICE MANUAL EXTRA 300L 31-10-00 INSTRUMENT AND CONTROL PANELS 31-10-01 Rear Instrument Panel The instrument panel of the rear cockpit consist of a top panel sheet (instrument panel) with an instrument cover and a center panel sheet (control switch and circuit breaker panel).
Page 243 EXTRA SERVICE MANUAL EXTRA 300L Figure1 Rear Instrument Panel Pos. Item Magneto Selector Switch & Starter Amperemeter Airspeed Indicator Magn. Direction Indicator Oil Pressure / Oil Temperature EGT / CHT RPM Indicator Circuit Breaker g-meter Manifold Pressure / Fuel Flow...
Page 244: Front Instrument Panel
EXTRA SERVICE MANUAL EXTRA 300L 31-10-02 Front Instrument Panel Up to Serial No. 26 an altimeter and an airspeed indicator are mounted in the main fuselage cover in front of the front pilot seat. From Serial No. 27 these instruments (2, 3, Figure 2) are installed on a separate removable instrument panel (1) in- corporating shock mounts.
Page 245: Front Instrument Panel Removal/Installation
EXTRA SERVICE MANUAL EXTRA 300L Figure 3 Front Instrument Panel Removal/Installation PAGE DATE: 1. June 1995 PAGE DATE: 4. June 2009 CHAPTER PAGE...
Page 246: Rear Instrument Cover
EXTRA SERVICE MANUAL EXTRA 300L 31-10-03 Rear Instrument Cover Removal/Installation 1 Remove the screws located at the top of the front seat back rest (1, Figure 4). 2 Remove the outer screws (2) of the rear instrument panel (the two inner screws connect the panel to the steelframe).
Page 247: Typical Instruments
EXTRA SERVICE MANUAL EXTRA 300L 31-10-04 Typical Instruments Removal/Installation In Figure 5 typical instrument attachments used in the EXTRA 300L are outlined. Switch off aircraft power Remove main fuselage cover per Chapter 53. Remove rear instrument panel cover if applicable per Chapter 31-10-03.
Page 248: Central Warning Systems
CENTRAL WARNING SYSTEMS 31-50-01 Stall Warning System The EXTRA 300L is equipped with a stall warning system as standard. This system is designed to warn the pilot by an audible alarm horn, which is fitted in the back of the front seat.
Page 249 EXTRA SERVICE MANUAL EXTRA 300L Chapter 32 Landing gear PAGE DATE: 1. June 1995 CHAPTER PAGE...
Page 250 EXTRA SERVICE MANUAL EXTRA 300L Chapter 32 Table of Contents Chapter/Figure Title 32-10-00 LANDING GEAR ......3 Figure 1 Wheel Rake and Toe-in.
Page 251: Landing Gear
EXTRA SERVICE MANUAL EXTRA 300L 32-10-00 LANDING GEAR The EXTRA 300L is designed as a conventional tail wheel airplane, with an unretractable landing gear. The landing gear consists of a 2 wheel main landing gear and a tail wheel. The main wheels are interconnected and attached to the fuselage by means of an U-shaped carrier.
Page 252: Main Landing Gear
EXTRA SERVICE MANUAL EXTRA 300L 32-10-01 Main Landing Gear Removal/Installation Refer to Figure 2 Remove the engine cowling, the landing gear cuffs and the bottom covering sheet as per chapter 51-00-01. Shore the aircraft as per Chapter 07-20-00 Drain brake system.
Page 253: Main Landing Gear Mounting
EXTRA SERVICE MANUAL EXTRA 300L Figure 2 Main Landing Gear Mounting 32-10-03 Wheel Axis Removal/Installation Remove wheel fairing as per chapter 32-40-02. Remove wheel. Remove the four wheel axis attachment bolts and remove the axis, the reinforcement plate and the wheel fairing holder plate.
Page 254: Tail Wheel Fork Assembly
EXTRA SERVICE MANUAL EXTRA 300L Remove the tail spring attachment bolts (1-3). Remove the tail spring (4). Reverse procedure for installation; consider to fasten the breather line using the MS21919-DG12 clamp (5). 32-10-05 Tail Wheel Fork Assembly Disassembly/Assembly Refer to Figure 3.
Page 255: Tail Wheel, Fork And Spring
EXTRA SERVICE MANUAL EXTRA 300L Note: From Serial N° 21 the tail spring consist of a compos- ite part and a steel shoe connected by two bolts. Figure 3 Tail Wheel, Fork and Spring PAGE DATE: 26. October 2015 CHAPTER...
Page 256: Wheels And Brakes
EXTRA SERVICE MANUAL EXTRA 300L 32-40-00 WHEELS AND BRAKES General This Chapter provides maintenance personnel with neces- sary procedures to accomplish both on-aircraft and off- aircraft maintenance of Cleveland design wheel and brake assemblies. Such maintenance shall include inspection, removal, servicing, refinishing, and installation of assem- blies.
Page 257 EXTRA SERVICE MANUAL EXTRA 300L N O T E For further information concerning main wheels and brakes refer to Cleveland Wheels and Brakes Compo- nent Maintenance Manual AWBCMM0001 and Techni- cian’s Service Guide AWBTSG0001. PAGE DATE: 26. October 2015 CHAPTER...
Page 258: Brake System
EXTRA SERVICE MANUAL EXTRA 300L Figure 4 Brake System PAGE DATE: 1. June 1995 CHAPTER PAGE...
Page 259: Master Cylinder
EXTRA SERVICE MANUAL EXTRA 300L 32-40-01 Master Cylinder Removal/Installation Drain the brake system. Disconnect the brake lines. Fix the master cylinder spring using a mounting aid as shown in Figure 5 (Cleveland master cylinder only). Remove the attachment bolts. Remove the master cylinder.
Page 260: Wheel Fairing
EXTRA SERVICE MANUAL EXTRA 300L 32-40-02 Wheel Fairing Removal/Installation The wheel fairings are screwed on. When installing the wheel fairing ensure a gap of minimum 1.5 mm from the fairing surface to the landing gear spring. Correct position if necessary prior to fastening the fairings.
Page 261 EXTRA SERVICE MANUAL EXTRA 300L Figure 6, Sheet 2 Layer Sequence Wheel Fairing from Ser. No. 50 PAGE DATE: 26. October 2015 CHAPTER PAGE...
Page 262: Tail Wheel
EXTRA SERVICE MANUAL EXTRA 300L 32-40-03 Tail Wheel Disassembly/Assembly Refer to Figure 3. Shore the tail as per Chapter 07-20-02. Remove the attachment bolt, washers, and stopnut (10). Remove the tailwheel. Disassemble the bearings (11), the wheel halves (12), the spacer sleeve (13), and the solid ruber tire (14).
Page 263 EXTRA SERVICE MANUAL EXTRA 300L Chapter 33 Lights PAGE DATE: 1. June 1995 CHAPTER PAGE...
Page 264 EXTRA SERVICE MANUAL EXTRA 300L Table of Contents Chapter/Figure Title 33-10-00 FLIGHT COMPARTMENT ....3 33-10-01 Low Voltage Monitor......3 33-40-00 EXTERIOR .
Page 265: Flight Compartment
EXTRA SERVICE MANUAL EXTRA 300L 33-10-00 FLIGHT COMPARTMENT 33-10-01 Low Voltage Monitor For monitoring the generator function a low voltage monitor is installed on the rear instrument panel (see Figure 2 of Chapter 31). The indicator is dimmable and has a built-in bulb testing device („press to test“).
Page 266 EXTRA SERVICE MANUAL EXTRA 300L Turn the indicator to the 2 o'clock position. Fasten the attachment nut. Turn the indicator to the 12 o'clock position. Reinstall the instrument cover per chapter 31-10-03. PAGE DATE: 26. October 2015 CHAPTER PAGE...
Page 267: Exterior
EXTRA SERVICE MANUAL EXTRA 300L 33-40-00 EXTERIOR 33-40-10 Navigation/Strobe Light System Refer to figure 1. The lighting units (1) installed at the wing tips incorporate the red or green navigation lights on the forward section, a strobe light in the center and a clear tail position light on the aft section.
Page 268: Navigation/Strobe Lights Removal/Installation
EXTRA SERVICE MANUAL EXTRA 300L Remove the lighting unit. Install in reverse sequence of removal after applying Sili- con between the wing tip fairing and the lighting unit. Figure 1 Navigation/Strobe Lights Removal/Installation PAGE DATE: 26. October 2015 CHAPTER PAGE...
Page 269: Strobe Light Power Supply
EXTRA SERVICE MANUAL EXTRA 300L 33-40-12 Strobe Light Power Supply Removal/Installation Refer to Figure 1. W A R N I N G High Voltage! Wait 5 minutes after shutting off before starting any work on the strobe light system. Remove the wing tip attachment plate with the lighting unit per Chapter 57-30-01.
Page 270: Landing Light
EXTRA SERVICE MANUAL EXTRA 300L 33-40-21 Landing Light Removal/Installation BATTERY switch OFF. Remove engine cowlings as per Chapter 71. Disconnect the plug (2, Figure 2) from the head lamp (8). Remove the attachment bolts (6) and remove the hood (9) and the glass (10) which is located under the hood.
Page 271: Landing Light
EXTRA SERVICE MANUAL EXTRA 300L Top View Side View Firewall Figure 2 Landing Light PAGE DATE: 26. October 2015 CHAPTER PAGE...
Page 272 EXTRA SERVICE MANUAL EXTRA 300L Chapter 34 Navigation PAGE DATE: 1. June 1995 CHAPTER PAGE...
Page 273 EXTRA Chapter 34 SERVICE MANUAL EXTRA 300L Table of Contents Chapter 34 Chapter Title 34-00-00 GENERAL ........3 34-10-00 FLIGHT ENVIRONMENT DATA .
Page 274: General
SERVICE MANUAL EXTRA 300L 34-00-00 GENERAL The Extra 300L is equipped with an altimeter, an airspeed indicator and a magnetic compass in the rear cockpit. Optional a turn and bank indicator is obtainable; in the front cockpit additionally a second airspeed indicator and altimeter are installed.
Page 275: Flight Environment Data
EXTRA SERVICE MANUAL EXTRA 300L 34-10-00 FLIGHT ENVIRONMENT DATA This Section describes that portion of the system which senses the environmental conditions and uses the data to influence navigation. 34-10-01 Pitot/Static System The pitot/static tube is designed to pick up pitot pressure and static pressure.
Page 276: Pitot Tube
EXTRA SERVICE MANUAL EXTRA 300L 34-10-02 Pitot Tube Removal/Installation The Pitot tube consists of an inner steel tube, an outer aluminium tube and a top cap which are screwed together. 1 Unscrew the top cap. 2 Unscrew the outer aluminium tube.
Page 277: Altimeter
EXTRA SERVICE MANUAL EXTRA 300L 34-10-04 Altimeter The altimeter is designed to measure pressure changes of the atmosphere by means of an aneroid capsule, the pressure changes corresponding to changes in altitude. In this instrument the shaft of pinion drives via gearwheels the pointer shaft of the large pointer.
Page 278: Airspeed Indicator
EXTRA SERVICE MANUAL EXTRA 300L 34-10-05 Airspeed Indicator The airspeed indicator shows the speed of the aircraft relative to the atmosphere. The pitot airspeed indicator measures the difference between pitot pressure and static pressure, the former being picked up by the pitot head at the pitot location of the air flow and applied to the airspeed indicator via tubing, the latter also being picked up by the pitot head.
Page 279: Attitude And Direction
EXTRA SERVICE MANUAL EXTRA 300L 34-20-00 ATTITUDE AND DIRECTION This Section describes that portion of the system which uses magnetic or inertia forces to sense and display the direction or attitude of the aircraft. 34-20-01 Magnetic Compass The magnetic compass shows the course of the aircraft in relation to magnetic north.
Page 280: Turn And Bank Indicator
EXTRA SERVICE MANUAL EXTRA 300L 34-20-02 Turn and Bank Indicator The turn and bank indicator indicates the turning rate of the aircraft about its vertical axis. This instrument comprises an electrically driven gyro, suspended in a gimbal system and whose spin axis is parallel to the lateral axis of the aircraft.
Page 281: Dependent Position Determining
DEPENDENT POSITION DETERMINING 34-50-01 Transponder Divers transponders can be installed in the EXTRA 300L. A Transponder is a radio transmitter and receiver that fulfills the role of the airborne beacon equipment according to the requirements of the Air Traffic Radar Beacon System (ATCRBS).
Page 282 EXTRA SERVICE MANUAL EXTRA 300L Chapter 51 Standard Practices and Structures - General PAGE DATE: 1. June 1995 CHAPTER PAGE...
Page 283 EXTRA SERVICE MANUAL EXTRA 300L Table of Contents Chapter 51 Chapter/Figure Title 51-00-00 GENERAL ........3 51-00-01 Access Panel Identification .
Page 284: General
GENERAL 51-00-01 Access Panel Identification For the Extra 300L all removable covers and fairings are defined as access panels (refer to Figure 1 and the adjacent chart). If maintenance or repair is not restricted to a small area it is advisable to remove all access panels before beginning work or checks.
Page 285: Figure 1
EXTRA SERVICE MANUAL EXTRA 300L Figure 1 Access Panel Identification PAGE DATE: 1. June 1995 CHAPTER PAGE...
Page 286 EXTRA SERVICE MANUAL EXTRA 300L Position Item Top half of the engine cowling Oil filler access door Main fuselage cover Instrument cover Tail fairing Tail cone access panel (RH) Tail side skin (LH/RH) Cuff (LH/RH) Wheel speed fairing (LH/RH) Bottom half of the engine cowling...
Page 287: Investigation
EXTRA SERVICE MANUAL EXTRA 300L 51-10-00 INVESTIGATION 51-10-01 Damage Classification W A R N I N G All damage of composite parts must first be classified by qualified personnel. In case of doubt with regard to the classification of damage, if a clear definition of the...
Page 288: Repair Criteria And Limits
EXTRA SERVICE MANUAL EXTRA 300L Damage Class 4: Erosion, scratches or nicks not accompanied by fractures or breakages. Damage to fairings belong to this class. 51-10-02 Repair Criteria and Limits I M P O R T A N T ll damage of composite parts must first be classified prior to repair.
Page 289: Materials
SERVICE MANUAL EXTRA 300L 51-30-00 MATERIALS This Section describes metallic and non-metallic materials used in the repair of the Extra 300L and gives the sources of supply (manufacturers and supplier). 51-30-01 Composite Parts I M P O R T A N T Only approved materials have to be used for the repair of composite parts.
Page 290 EXTRA SERVICE MANUAL EXTRA 300L Carbon fibre fabrics Manufacturer: CCC, C. Cramer GmbH & Co. KG Postfach 209, D-48619 Heek-Nienborg, Germany WLB-No.* weave weight Style CCC US-style DIN 65147 patterns g/m² 8,3507;80 none plain 8,3520;80 none twill 2/2 none cross-twi...
Page 291 EXTRA SERVICE MANUAL EXTRA 300L Core material a) PVC Foam: Manufacturer: DIAB Divincell International Gmbh Max-von-Laue-Straße 7 D-30966 Hemmingen, Germany Supplier: see above Type: Divinycell HT 50 b) Honeycomb: Manufacturer: EURO COMPOSITES S.A: B.P.95, Zone Industrielle, L-6401 Echternach / Luxembourg Type: ECA-I-R 4.8-29-R...
Page 292: Metal Components
EXTRA SERVICE MANUAL EXTRA 300L 1006-202/3 Glassit Spritzfüller SP 60-7023 948-36 Glassit Härterpaste, rot SB 48-3360 Glassodur-PUR-Acryl-Lack AD/AE 2 929-73 Glassodur-MS-Härter SC 29-0173 352-91 Glassodur-Einstellzusatz SV 41-0391 923-335 Glasurit Klarlack (with Hensotherm 410KS) Manufacturer: Rudolf Hensel GmbH Lauenburger Landstraße 11 D-21039 Börnsen...
Page 293 EXTRA SERVICE MANUAL EXTRA 300L Steel sheet metal (except Serial No. 45 thru 79): Manufacturer: BÖHLER Edelstahl GmbH München, Germany Supplier: BÖHLER Edelstahl GmbH Hansa Allee 321, D-40549 Düsseldorf, Germany Type: WLB 1.7734.4 1.0mm, 1.5mm, 2.0mm, 3.0mm Steel tubing (Serial No. 45 thru 79):...
Page 294: Aluminium Components
EXTRA SERVICE MANUAL EXTRA 300L Paint: Manufacturer: GLASURITGmbH Max-Winkelmannstr. 80, D-48165 Münster / Hiltrup, Germany Supplier: WESSELS AG Pagenstecherstraße 121, D-49090 Osnabrück, Germany Type: 801-1552 Glassofix Grundfüller-EP AC 01-1492 965-32/2 Glassofix Härter-EP SC 65-0322 Glassodur-PUR-Acryl-Lack AD/AE 2 1929-73 Glassodur-MS-Härter SC 29-0173...
Page 295 EXTRA SERVICE MANUAL EXTRA 300L Paint: Manufacturer: GLASURIT GmbH Max-Winkelmannstr. 80, D-48165 Münster / Hiltrup, Germany Supplier: WESSELS AG Pagenstecherstraße 121, D-49090 Osnabrück, Germany Type: Primer: 283-150 Glassofix-Grundfüller AB83-1150 352-228 Glassofix-Zusatzlösung SC12-0228 Lacquer: Glassodur-PUR-Acryl-Lack AD/AE 2 1929-73 Glassodur-MS-Härter SC 29-0173...
Page 296: Control Surface Balancing
EXTRA SERVICE MANUAL EXTRA 300L 51-60-00 CONTROL SURFACE BALANCING 51-60-01 Weighing and Determination of Control Surface Moments All weighing of control surfaces is performed with surface removed from aircraft. Weighing and determination of con- trol surfaces moments is necessary after repairs or painting.
Page 297 EXTRA SERVICE MANUAL EXTRA 300L 2 Reinstall the bolts in two brackets. 3 Put the control surfaces on the balancing mandrels (use a wire for the trim tab). 4 Weigh by means of a conventional spring balance (kg/g- indication) at the given weighing points (Figure 3) and enter the weight (m) in Figure 4.
Page 298: Figure 3
EXTRA SERVICE MANUAL EXTRA 300L Figure 3 Determination of Control Surface Moments PAGE DATE: 26. October 2015 CHAPTER PAGE...
Page 299 EXTRA SERVICE MANUAL EXTRA 300L Permissible Weights and Moments Elevator (incl. mass balance) Rudder (incl. mass balance) Aileron (incl. mass balance and spade) Mass (kg) Trim tab Mass (g) Weights Aileron LH: (W) ..kg Aileron RH: (W) .
Page 300: Repairs
EXTRA SERVICE MANUAL EXTRA 300L 51-70-00 REPAIRS 51-70-01 Repair of Reinforced Glass and Carbon Fibre Components I M P O R T A N T Repair of composite parts has to be carried out only by qualified and authorized personnel.
Page 301 EXTRA SERVICE MANUAL EXTRA 300L The number of layers required to restore the stability in the damaged area can be taken from the layer sequence/place- ment plan.(Refer to the respective Chapters) It is necessary to know the number and direction of layers in the damaged area, in order to be able to replace them with the original number.
Page 302: Repair Of Sandwich Material
EXTRA SERVICE MANUAL EXTRA 300L 51-70-02 Repair of Sandwich Material Two types of core materials are used for sandwich on the EXTRA 300L: - PVC hard foam - Honeycomb both with glass or carbon fibre shells The following section describes the repair of both types of sandwich.
Page 303 EXTRA SERVICE MANUAL EXTRA 300L to the repair area and lay on fabric in accordance to the layer sequence plans. Ensure to use correct style and direction of fabric. I M P O R T A N T Repair area must be clean of dirt, dust and grease!
Page 304: Figure 6
EXTRA SERVICE MANUAL EXTRA 300L Figure 6 Curing cycle resin L20/SL After the curing process is completed, the repair area can be sand level to the surrounding area. N O T I C E Sand only the edge thickness of repair laminate (refer...
Page 305 EXTRA SERVICE MANUAL EXTRA 300L The damaged area of the inner laminate has to be taken out as well. Make sure not to increase the disbond area by preparing the hole. Preferably use a hand held milling machine. In case of cutting with a saw, the pulsation stress may peel of the inner laminate (secondary damage).
Page 306 EXTRA SERVICE MANUAL EXTRA 300L Figure 8 Damage of Complete Sandwich Lay out the required number and size of fabric pieces on a piece of plastic foil and wet them with resin mixture. Subsequently position them on the repair area.
Page 307: Repair Of Laminates
EXTRA SERVICE MANUAL EXTRA 300L I M P O R T A N T Sand only the edge thickness of repair laminate! For painting of the repair area proceed like mentioned in Chapter 51-70-06. 51-70-03 Repair of Laminates a) Minor damage Scarf the edges of the minor damage area with sandpaper.
Page 308 EXTRA SERVICE MANUAL EXTRA 300L Refinish the surface according chapter 51-70-05 Painting. If the extent of the damaged area exceed 10 cm (4 inches) a large damage repair is required. Carefully trim out the damaged portion to a circular or oval shape.
Page 309: Figure 9
EXTRA SERVICE MANUAL EXTRA 300L N O T E Lay out the required number and size of fabric pieces on a piece of colored plastic foil and wet them with resin mixture. Subsequently position them on the repair area. I M P O R T A N T Remove the plastic foil after each positioning process.
Page 310 EXTRA SERVICE MANUAL EXTRA 300L Subsequently scarf the edges of the damaged portion with sandpaper. Minimum lenght of scarf per fabric layer approx. 20 mm; I M P O R T A N T ratio (laminate thickness : scarf lenght) approx. 1: 50.
Page 311: Repair Of Spars
EXTRA SERVICE MANUAL EXTRA 300L - Perforate a clean, thin plastic foil with a coarse needle (max. spacing of holes: 20mm x 20mm) - mainly in the area of the honeycomb - and lay it on to the repair area.
Page 312: Structural Repair Of Steel Components
EXTRA SERVICE MANUAL EXTRA 300L 51-70-05 Structural Repair of Steel Components Restoration of a damaged fuselage to its original design strength, shape and alignment involves careful evaluation of the damage, followed by exacting workmanship in perform- ing the repairs. I M P O R T A N T Should structural repairs practicable on the aircraft be necessary, refer to "Aircraft Inspection and Repair...
Page 313: Painting Of Composite Parts
EXTRA SERVICE MANUAL EXTRA 300L 51-70-06 Painting of Composite Parts W A R N I N G Coating materials may cause sensitization by inhala- tion and skin contact. Hardeners and coating materials ready for use can have an irritant and sensitizing effect upon the skin and respiratory tracts and cause allergic reactions.
Page 314: Aluminium And Steel Components Refinishing
EXTRA SERVICE MANUAL EXTRA 300L 51-70-07 Aluminium and Steel Components Refinishing Complete procedure necessary to remove existing paint from aluminium and steel components and then to repaint them as described in the following paragraphs. Degreasing W A R N I N G Cleaning solvents can be toxic and volatile.
Page 315 EXTRA SERVICE MANUAL EXTRA 300L Paint Removal Disassemble components to the level required for repaint- ing, then proceed as follows. W A R N I N G Stripping solvents can be toxic and volatile. Use only in well ventilated areas. Avoid physical contact with solvent and do not inhale vapors.
Page 316 EXTRA SERVICE MANUAL EXTRA 300L Repainting Paint all surfaces exept those which are subjected to friction (bearing surfaces, anchor bolt bores, etc.). Proceed as follows: Parts to be repainted should be cleaned and stripped per in- struction in degreasing and paint removal paragraphs.
Page 317: Re-Bonding Of Bushings
EXTRA SERVICE MANUAL EXTRA 300L 51-70-08 Re-Bonding of Bushings a) Re-bonding of loose bushings in empennage spars Figure 10 Empennage attachment bushings Re-bonding of main attachment bushings positioned in the web of the front and rear spar in the horizontal tail as well as...
Page 318 EXTRA SERVICE MANUAL EXTRA 300L For re-bonding of bushings the related stabilizer has to be removed from the fuselage first. To prevent misalignment, reinstallation is needed at the end of the re-bonding process of the bushings. Remove stabilizer from the fuselage. Refer to the applica- ble Chapter of this Manual.
Page 319 EXTRA SERVICE MANUAL EXTRA 300L (ref. Chapter 51-30-01). Record quantities of parts to be mixed, ambient air temperature and humidity. Apply a sufficient amount of epoxy resin compound L20/ 960 to the surface area of the hole in the spar web. Remain- ing small cavities within the area should be filled with "HB20".
Page 320: Figure 11
EXTRA SERVICE MANUAL EXTRA 300L b) Re-bonding of loose main wing spar flange bushings Figure 11 Wing main spar attachment flange bushings Main attachment bushings positioned in the web of the main wing spar exists of a front and a rear flange bushing. The front and rear flange bushing will be re-bonded one after another.
Page 321 EXTRA SERVICE MANUAL EXTRA 300L There is a defined bond gap between the flange bushings and the hole in the main spar web. Re-bonding of main attachment flange bushings positioned in the web of the main wing spar is only permissible if the...
Page 322 EXTRA SERVICE MANUAL EXTRA 300L Take 80-grit sandpaper and sand the exposed surface area of the hole in the spar web where the bushing will be placed later on smooth. Any remaining material from the initial bond within the hole must be removed. Use 120-grit sandpaper to rough the ring surface area of the main spar web where the flange of the bushing will be bonded to later on.
Page 323 EXTRA SERVICE MANUAL EXTRA 300L Do not apply any pressure on the flange bushing prior to complete curing cycle. Disturbing the flange bushing may create bonding voids. Apply curing procedure (specified time and temperature): At elevated room temperature 25°C (77°F) for 10h.
Page 324 EXTRA SERVICE MANUAL EXTRA 300L Chapter 53 Fuselage PAGE DATE: 1. June 1995 CHAPTER PAGE...
Page 325 EXTRA SERVICE MANUAL EXTRA 300L Chapter 53 Table of Contents Chapter/Figure Title 53-00-00 GENERAL ........3 Figure 1, Sheet 1 Fuselage Steel Tube Design up to Ser.
Page 326 SERVICE MANUAL EXTRA 300L 53-00-00 GENERAL The fuselage structure of the EXTRA 300L consists of a TIG-welded steel tube construction integrating the wing and empennage connections (refer to Figure 1). The particular areas of the fuselage are covered with different materials (also refer to Chapter 51-00-01 "Access Panel...
Page 327 EXTRA SERVICE MANUAL EXTRA 300L Figure 1, Sheet 1 Fuselage Steel Tube Design up to Ser. N° 13 PAGE DATE: 26. October 2015 CHAPTER PAGE...
Page 328 EXTRA SERVICE MANUAL EXTRA 300L Figure 1, Sheet 2 Fuselage Steel Tube Design from Ser. N° 14 PAGE DATE: 26. October 2015 CHAPTER PAGE...
Page 329 EXTRA SERVICE MANUAL EXTRA 300L Figure 2 Layer Sequence Top Half of the Engine Cowling PAGE DATE: 26. October 2015 CHAPTER PAGE...
Page 330 EXTRA SERVICE MANUAL EXTRA 300L Figure 3 Layer Sequence Bottom Half of the Engine Cowling PAGE DATE: 26. October 2015 CHAPTER PAGE...
Page 331 EXTRA SERVICE MANUAL EXTRA 300L Figure 4, Sheet 1 Layer Sequence Main Fuselage Cover up to Ser. N° 10 PAGE DATE: 26. October 2015 CHAPTER PAGE...
Page 332 EXTRA SERVICE MANUAL EXTRA 300L Figure 4, Sheet 2 Layer Sequence Main Fuselage Cover from Ser. N° 11 PAGE DATE: 26. October 2015 CHAPTER PAGE...
Page 333 EXTRA SERVICE MANUAL EXTRA 300L Figure 5 Layer Sequence Bottom Fuselage Cover and Cuffs PAGE DATE: 26. October 2015 CHAPTER PAGE...
Page 334 EXTRA SERVICE MANUAL EXTRA 300L Figure 6, Sheet 1 Layer Sequence Tail Fairing up to Ser. No. 51 Figure 6, Sheet 2 Layer Sequence Tail Fairing from Ser. No. 52 PAGE DATE: 26. October 2015 CHAPTER PAGE...
Page 335 EXTRA SERVICE MANUAL EXTRA 300L 53-00-01 Canopy Removal/Installation Open canopy. N O T I C E Support the canopy by hand before disconnecting the opening limiter strap. Remove the attachment bolt of the opening limiter strap. Push canopy to front and remove.
Page 336 EXTRA SERVICE MANUAL EXTRA 300L Position markings Position markings Figure 8 Canopy Position Markings Secure the canopy glass in the frame. Draw a positioning line (see figure 7) and position markings on the inside (see figure 8). Prepare canopy glass for bonding.
Page 337 EXTRA SERVICE MANUAL EXTRA 300L Filler Figure 10 Canopy adhesive remainders Remove the fine tape. Prepare adhesive (3M Scotch-Weld Urethane Adhesives 3549 B/A): Thoroughly mix approx. 300 g (approx. 10.6 oz.) adhesive (weight ratio white base : brown accelerator - 100 : 109, 40-70 minutes application time at RT).
Page 338 EXTRA SERVICE MANUAL EXTRA 300L Sand down (using Scotch Brite Handpad Fine) the overlap- ping part between canopy glass and canopy frame on the inside (Area B in figure 10). Apply primer (Glasurit 934-0) and refinish the area (Nextel). 53-00-03...
Page 339 EXTRA SERVICE MANUAL EXTRA 300L Installation I M P O R T A N T The cockpit area must be thoroughly sealed and thus separated from the engine compartment. Gases or fluids could get into the cockpit area. Critical areas to be observed are the following:...
Page 340 EXTRA SERVICE MANUAL EXTRA 300L Minimum sealant thickness approximately 1/8 inch (= 3 mm). Repeat step 6 at positions B, C and D. Cure time @77°F (25°C), 50%RH for a fillet 1/8 inch thick: tack free approx. 24 hours to tough rubber approx.
Page 341 EXTRA SERVICE MANUAL EXTRA 300L Chapter 55 Stabilizers PAGE DATE: 1. June 1995 CHAPTER PAGE...
Page 342 EXTRA Chapter 55 SERVICE MANUAL EXTRA 300L Table of Contents Chapter 55 Chapter Title 55-00-00 GENERAL ........3 55-10-00 HORIZONTAL STABILIZER .
Page 343: General
SERVICE MANUAL EXTRA 300L 55-00-00 GENERAL The EXTRA 300L has a conventional empennage with stabi- lizers and moveable control surfaces. The spars consist of carbon roving caps, glass fibre webs and PVC foam cores. The shells are built of honeycomb sandwich with glass fibre laminate.
Page 344: Horizontal Stabilizer
EXTRA SERVICE MANUAL EXTRA 300L 55-10-00 HORIZONTAL STABILIZER Figure 1 Layer Sequence Horizontal Stabilizer PAGE DATE: 26. October 2015 CHAPTER PAGE...
Page 345 EXTRA SERVICE MANUAL EXTRA 300L Removal Remove elevator and rudder per Chapter 27-30-01, remove the vertical stabilizer per Chapter 55-30-00 and then reverse procedure of installation. Installation N O T I C E Make shure that the trim bowden cable will not be dam- aged when installing the horizontal stabilizer.
Page 346 EXTRA SERVICE MANUAL EXTRA 300L Figure 2 Horizontal Stabilizer Removal/Installation PAGE DATE: 26. October 2015 CHAPTER PAGE...
Page 347: Elevator
EXTRA SERVICE MANUAL EXTRA 300L 55-20-00 ELEVATOR Figure 3 Layer Sequence Elevator PAGE DATE: 26. October 2015 CHAPTER PAGE...
Page 348: Vertical Stabilizer
EXTRA SERVICE MANUAL EXTRA 300L 55-30-00 VERTICAL STABILIZER Figure 4 Layer Sequence Vertical Stabilizer PAGE DATE: 26. October 2015 CHAPTER PAGE...
Page 349 EXTRA SERVICE MANUAL EXTRA 300L Removal Remove the tail fairing and the tail cone access panel per Chapter 51-00-01. Remove the rudder per Chapter 27-20-01. Remove the bottom hinge bracket assembly per Chapter 27- 20-02. Remove the two LN 9348-10 stop nuts (2, Figure 6) and DIN 125 M10 washers of the front main bolts.
Page 350 EXTRA SERVICE MANUAL EXTRA 300L Figure 5 Vertical Stabilizer Removal/Installation PAGE DATE: 26. October 2015 CHAPTER PAGE...
Page 351: Rudder
EXTRA SERVICE MANUAL EXTRA 300L 55-40-00 RUDDER Figure 6 Layer Sequence Rudder PAGE DATE: 26. October 2015 CHAPTER PAGE...
Page 352 EXTRA SERVICE MANUAL EXTRA 300L Chapter 57 Wings PAGE DATE: 1. June 1995 CHAPTER PAGE...
Page 353 EXTRA Chapter 57 SERVICE MANUAL EXTRA 300L Table of Contents Chapter 57 Chapter Title 57-00-00 GENERAL ........3 Figure 1, Sheet 1 Layer Sequence Wing .
Page 354: General
EXTRA SERVICE MANUAL EXTRA 300L 57-00-00 GENERAL The wing consists of a one-piece, dual chamber main spar with carbon fibre roving caps and carbon fibre webs. For the spar core PVC foam is used. The wing shells are a honeycomb sandwich construction with carbon fibre laminates.
Page 355: Layer Sequence Wing
EXTRA GENERAL SERVICE MANUAL EXTRA 300L Figure 1, Sheet 1 Layer Sequence Wing PAGE DATE: 1. June 1995 PAGE DATE: 15. December 1999 CHAPTER PAGE...
Page 356 EXTRA GENERAL SERVICE MANUAL EXTRA 300L Figure 1, Sheet 2 Layer Sequence Wing PAGE DATE: 1. June 1995 PAGE DATE: 15. December 1999 CHAPTER PAGE...
Page 357: Layer Sequence Wing
EXTRA GENERAL SERVICE MANUAL EXTRA 300L Figure 1, Sheet 3 Layer Sequence Wing PAGE DATE: 15. December 1999 PAGE DATE: 1. June 1995 CHAPTER PAGE...
Page 358: Wing
EXTRA SERVICE MANUAL EXTRA 300L 57-00-01 Wing Removal Reverse procedure of installation omitting step 16. Installation Remove the canopy per Chapter 53, the engine cowlings and the main fuselage cover per Chapter 51. Remove the right front canopy hinge. Loosen the breather line clamps located at the engine side...
Page 359 EXTRA SERVICE MANUAL EXTRA 300L I M P O R T A N T If there is clearance between the main spar and the at- tachment brackets (1, Figure 2), use shims (3) like shown below which are to be slided in the front gaps (2).
Page 360 EXTRA SERVICE MANUAL EXTRA 300L Install short aileron push pull rods per Ch. 27-00-01. Perform an aileron rigging per Chapter 27-10-01. Connect fuel system (tubes and vent lines), pitot/static system, stall warner, navigation/strobe light wires, ground bonding leads and fuel indicator wires with prefitted plugs per respective Chapters.
Page 361 EXTRA SERVICE MANUAL EXTRA 300L Figure 3 Wing Removal/Installation PAGE DATE: 26. October 2015 CHAPTER PAGE...
Page 362: Wing Tip
EXTRA SERVICE MANUAL EXTRA 300L 57-30-00 WING TIP 57-30-01 Wing Tip Attachment Plate Removal/Installation Refer to Figure 1 of Chapter 33. W A R N I N G High Voltage! Wait 5 minutes after shutting off before starting any work on the strobe light system.
Page 363: Ailerons
EXTRA SERVICE MANUAL EXTRA 300L 57-60-00 AILERONS The ailerons are constructed in the same manner as the wing but with single chamber spar. They are supported at three points in spherical bearings pressed into aluminium brack- ets. Furthermore the ailerons are equipped with "glass fibre laminate spades"...
Page 364 EXTRA SERVICE MANUAL EXTRA 300L Note: Measurements are given in mm Figure 4 Layer Sequence Ailerons PAGE DATE: 1. June 1997 PAGE DATE: 1. June 1995 CHAPTER PAGE...
Page 365 EXTRA SERVICE MANUAL EXTRA 300L Chapter 61 Propeller PAGE DATE: 4. June 2009 CHAPTER PAGE...
Page 366 EXTRA SERVICE MANUAL EXTRA 300L Table of Contents Chapter 61 Chapter Title 61-00-00 GENERAL ........3 61-10-00 PROPELLER .
Page 367 EXTRA SERVICE MANUAL EXTRA 300L 61-00-00 GENERAL The EXTRA 300L can be equipped with either a MTV-9-B-C/ C 200-15 (3-blade), MTV-14-B-C/C 190-17 (4-blade) or MTV-9-B-C/C 198-25 (3-blade) propeller. Maintenance work or overhaul of the propeller requires consultation of the propeller manufacturer MT-Propeller.
Page 368 EXTRA SERVICE MANUAL EXTRA 300L 61-10-00 PROPELLER The MTV-Propellers are made of laminated wood encased in glass-fiber reinforced plastic, which is painted to make it waterproof. N O T E For more information about the propeller refer to MT- Propeller Operation- and Installation Manual E-124.
Page 369 EXTRA SERVICE MANUAL EXTRA 300L 61-20-00 CONTROLLING The pitch change is conducted by a propeller governor (refer to Figure 1). Once an engine rotational speed is selected it will be held constant at variations of airspeed and power. The governor itself is actuated via a vernier control cable ending on the left side of the rear cockpit.
Page 370 EXTRA SERVICE MANUAL EXTRA 300L Figure 2 RPM Vernier Control Cable Installation PAGE DATE: 4. June 2009 CHAPTER PAGE...
Page 371 EXTRA SERVICE MANUAL EXTRA 300L 61-20-01 Governor One of the following governors is installed: MT-Propeller P-880-5, preset for a max. 2700 rpm MT-Propeller P-880-41, preset for a max. 2600 rpm Refer to the MT-Propeller Operation- and Installation Manual E-1048 for further information.
Page 372 EXTRA SERVICE MANUAL EXTRA 300L Remove attachment nut (9) and washer of the vernier control unit (7). Pull the vernier control unit aft (about 15 cm) and then inside the cockpit to remove. Pull complete vernier control cable (6) aft to remove from aircraft.
Page 373 EXTRA SERVICE MANUAL EXTRA 300L b Loosen the counter nut and adjust rod end by turning. Ensure thread is visible in the inspection hole when fastening. Apply inspection lacquer on the counter nut. Reinstall the rod end to the governor actuator (2).
Page 374 EXTRA SERVICE MANUAL EXTRA 300L Chapter 71 Power Plant PAGE DATE: 4. June 2009 CHAPTER PAGE...
Page 375 EXTRA SERVICE MANUAL EXTRA 300L Table of Contents Chapter Title 71-10-00 COWLING ........3 71-20-00 ENGINE MOUNT .
Page 376: Cowling
EXTRA SERVICE MANUAL EXTRA 300L 71-10-00 COWLING Description The engine cowling is divided into two parts: The upper (1, Figure 1) and lower (2) cowling made of GFRP or CFRP honeycomb sandwich. The top half of the engine cowling features a hinged hatch (3) for access to the oil dip stick.
Page 377 EXTRA SERVICE MANUAL EXTRA 300L Removal/Installation N O T E It is favourable to remove the cowling with two persons. W A R N I N G Before rotating the propeller in the most convenient position for removal of the cowling, make sure that the ignition switch is in the “OFF”...
Page 378: Engine Mount
EXTRA SERVICE MANUAL EXTRA 300L 71-20-00 ENGINE MOUNT Description The engine is mounted on the airframe via the engine mount. The engine mount is constructed of welded steel tubes and is bolted to the firewall at 4 attachment points. The tubes of the engine mount structure are provided with an internal anti corrosion treatment.
Page 379 EXTRA SERVICE MANUAL EXTRA 300L Figure 3 Engine Mount & Shock Mount Installation PAGE DATE: 26. October 2015 CHAPTER PAGE...
Page 380: Shock Mounts
EXTRA SERVICE MANUAL EXTRA 300L Removal This paragraph describes the removal of the engine mount from the engine (instructions in brackets for double oil cooler system only!) Disconnect (aft) oil cooler assembly (and separator) from its supports at the engine mount by removing the connection bolts and nuts, remove baffles if necessary.
Page 381 EXTRA SERVICE MANUAL EXTRA 300L Removal N O T I C E Replace the extracted shock mount before proceeding with the removal of the next. Support engine at its designated lifting lugs (ref. Lycoming Maintenance Manual). Unscrew locknut of the mounting bolt at one shock mount (ref.
Page 382: Air Baffles
EXTRA SERVICE MANUAL EXTRA 300L 71-60-00 AIR BAFFLES Description Refer to Figure 4. Air baffles are screwed to the engine to achieve optimum engine cooling. These baffles are multi section items designed for separate removal of each section. They are manufactured of plated aluminium sheets. The interface to the engine cowling is sealed by rubber stripes, which are riveted to the outer edge of the baffles.
Page 383 EXTRA SERVICE MANUAL EXTRA 300L Figure 4 Air Baffles Removal Refer to Figure 4 (Instructions in brackets for dual oil cooler system only). Disconnect bowden cable of RPM-control from engine (refer to Chapter 61). Disconnect fuel pressure sensing line at bulkhead of aft RH baffle.
Page 384 EXTRA SERVICE MANUAL EXTRA 300L Disconnect air ducting to exhaust heat exchanger at air intake of forward LH baffle (to aft oil cooler at rear LH baffle). (Disconnect forward oil cooler assy at forward LH baffle). Unscrew grommets for ignition harness and RPM bowden cable from their cutouts and pull out ignition harness and RPM bowden cable.
Page 385 EXTRA SERVICE MANUAL EXTRA 300L Chapter 72 Engine PAGE DATE: 4. June 2009 CHAPTER PAGE...
Page 386 EXTRA SERVICE MANUAL EXTRA 300L Table of Contents Chapter 72 Chapter Title 72-00-00 GENERAL ........3 72-10-00 ENGINE .
Page 387 EXTRA SERVICE MANUAL EXTRA 300L 72-00-00 GENERAL This chapter describes the engine installed in the EXTRA 300L aircraft, together with its fitted assemblies. Operation and maintenance work of the engine requires consultation of the Lycoming Operator`s Manual (Refer to Chapter 01).
Page 388 EXTRA SERVICE MANUAL EXTRA 300L Trouble Possible Cause Remedy Engine will not start or is Defective battery Replace with a charged hard to start battery per Ch. 24. Rough idle Cracked engine mounts or Replace per Ch. 71. defective shock mounts Engine shock mount Install per Ch.
Page 389 300 HP @ 2700 RPM b) AEIO-540-L1B5D 300 HP @ 2700 RPM c) AEIO-580-B1A 315 HP @ 2700 RPM Figure 1 shows the Lycoming engine of the EXTRA 300L: Figure 1 Lycoming engine The induction system is equipped with a BENDIX RSA-10 fuel injection system which is attitude independent.
Page 390 EXTRA SERVICE MANUAL EXTRA 300L The engine is lubricated by means of an engine driven oil pump. The system uses an oil sump as reservoir. For acro- batic maneuvers, lubrication is assured via an inverted flight oil system (refer to CHRISTEN 801 Inverted Oil Sytem and Chapter 79).
Page 391 EXTRA SERVICE MANUAL EXTRA 300L Remove the upper and lower part of the cowling (ref. Chapter 71). Support the engine at its two lifting lugs (ref. Lycoming Maintenance Instructions). Remove the canopy and main fuselage cover (ref. Chapter 53). Remove the LH & RH cuff from bottom fuselage cover (ref.
Page 392 EXTRA SERVICE MANUAL EXTRA 300L Disconnect the exhaust gas and cylinder head tem-perature sensors located at cylinder N° 5. Disconnect the short-circuit and GND wire from engine magnetos. Disconnect the wire from retard connection of LH magneto (for AEIO-580-B1A engine only).
Page 393 EXTRA SERVICE MANUAL EXTRA 300L Chapter 73 Engine Fuel and Control PAGE DATE: 4. June 2009 CHAPTER PAGE...
Page 394 EXTRA SERVICE MANUAL EXTRA 300L Table of Contents Chapter 73 Chapter/Figure Title 73-20-00 CONTROLLING ......3 73-20-10 Throttle .
Page 395: Controlling
EXTRA SERVICE MANUAL EXTRA 300L 73-20-00 CONTROLLING 73-20-10 Throttle Refer to Figure 1. The throttle is controlled by means of the throttle control levers located in the left side of the cockpit. These levers are interconnected by the throttle control linkage.
Page 396: Throttle Control Cable
EXTRA SERVICE MANUAL EXTRA 300L 73-20-11 Throttle Control Cable Removal Ensure master switch is off. Remove engine cowling per Chapter 71. Remove main fuselage cover per Chapter 53. Remove cotter pin, castle nut, washers and bolt from the rod end (2, Figure 4) to throttle actuator (1) attachment.
Page 397: Firesleeve Length
EXTRA SERVICE MANUAL EXTRA 300L Installation Install in reverse sequence of removal observing the following items: Thread the respective clamp sheet on the throttle control cable before penetrating the firewall. Install both rod ends with 8 rotations to the throttle control cable.
Page 398: Rear Throttle Control Lever
EXTRA SERVICE MANUAL EXTRA 300L 73-20-12 Rear Throttle Control Lever Figure 3 Throttle Control Levers Removal Ensure master switch is off. Remove engine cowling per Chapter 71. Remove main fuselage cover per Chapter 53. Remove cotter pin, castle nut, washers and bolt and remove the control cable rod end (6, Figure 3) and the throttle control linkage (3) from the throttle control lever (5).
Page 399: Throttle Control Cable Rigging
EXTRA SERVICE MANUAL EXTRA 300L Installation Install in reverse sequence of removal observing the following items: Thread the intercom switch and the smoke switch wiring through the throttle control lever (5, Figure 3) before positioning it. Tighten the throttle control lever castle nut (7) slightly.
Page 400: Front Throttle Control Lever
EXTRA SERVICE MANUAL EXTRA 300L a Remove cotter pin, castle nut, washers and bolt from the rod end to throttle actuator (1) attachment. b Loosen the counter nut and adjust rod end by turning. Ensure thread is visible in the inspection hole when fastening. Apply inspection lacquer on the counter nut.
Page 401: Mixture
EXTRA SERVICE MANUAL EXTRA 300L 73-20-20 Mixture Refer to Figure 5. The mixture of the fuel injector servo is controlled by means of the vernier mixture control cable located on the left side of the cockpit (red control knob). This cable is routed on the left side of the fuselage, penetrates the firewall and is then routed to the mixture control lever.
Page 402: Mixture Vernier Control Cable
EXTRA SERVICE MANUAL EXTRA 300L 73-20-21 Mixture Vernier Control Cable Refer to chapter 20 for general information about handling of control cables. Removal Ensure master switch is off. Remove engine cowling per Chapter 71. Remove main and bottom fuselage cover per Chapter 53.
Page 403: Clamp Sheet To Clamp Block Distance
EXTRA SERVICE MANUAL EXTRA 300L Installation Install the mixture control unit. Move mixture control knob to the foremost position. Thread the rear clamp sheet and plastic guidance for the firewall break through on the mixture control cable. Install the mixture vernier control cable according to the previously marked routing.
Page 404: Over-Travel At Mixture Control Unit
EXTRA SERVICE MANUAL EXTRA 300L Push the mixture actuator (3, Figure 8) to the full forward position. N O T E It is essential that the rod end is screwed onto the threaded terminal until the inspection hole of the rod end is completely filled with thread (minimum 8 turns).
Page 405: Mixture Vernier Control Cable Rigging
EXTRA SERVICE MANUAL EXTRA 300L If necessary adjust rod end (2, Figure 8) by the following steps: a Remove cotter pin, castle nut, washers and bolt from the rod end (2) to mixer control actuator (3) attachment. b Loosen the counter nut and adjust rod end (2) by turning.
Page 406: Indicating
EXTRA SERVICE MANUAL EXTRA 300L 73-30-00 Indicating Fuel pressure is sensed on the EXTRA 300L engine and is indicated to the pilot in command. Trouble Shooting Trouble Possible Cause Remedy No fuel pressure indication Gauge defective Replace gauge Fuel pressure low...
Page 407: Fuel Pressure Wet Line From Sn 1303
EXTRA SERVICE MANUAL EXTRA 300L Top View Oil cooler Firewall Engine Legend: 1 Fuel pressure sens line 2 Fitting Figure 9, Sheet 2 Fuel Pressure Wet Line from SN 1303 PAGE DATE: 26. October 2015 CHAPTER PAGE...
Page 408: Fuel Pressure Gauge
EXTRA SERVICE MANUAL EXTRA 300L 73-30-11 Fuel Pressure Gauge Removal/Installation Refer to Chapter 31. 73-30-12 Sense Line Removal/Installation 1 Remove cowling per Chapter 71. 2 Remove clamps. 3 Disconnect the sense line from the fitting. 4 Remove the sense line.
Page 409 EXTRA SERVICE MANUAL EXTRA 300L Chapter 77 Engine Indicating PAGE DATE: 4. June 2009 CHAPTER PAGE...
Page 410 EXTRA SERVICE MANUAL EXTRA 300L TABLE OF CONTENTS Chapter 77 Chapter/Figure Title 77-00-00 GENERAL ........3 Figure 1 Engine Sensor Locations .
Page 411: General
EXTRA SERVICE MANUAL EXTRA 300L 77-00-00 GENERAL The following engine instruments are installed in the EXTRA 300L: 1 tachometer 2 manifold pressure gauge 3 cylinder head temperature gauge 4 exhaust gas temperature gauge Generally engine data is routed electrically from the engine sensors (refer to Figure 1) to the instruments.
Page 412 EXTRA SERVICE MANUAL EXTRA 300L Trouble Shooting Trouble Possible Cause Remedy No engine speed indication Tachometer defective Replace tachometer No MAP indication Gauge defective Replace gauge No MAP variation Sense line leakage Replace sense line with power setting No CHT indication...
Page 413: Power
EXTRA SERVICE MANUAL EXTRA 300L 77-10-00 POWER 77-10-10 Engine speed data in the EXTRA 300L is obtained from the magnetos. The tachometer is located in the rear instrument panel and requires electrical supply bus voltage. 77-10-11 Tachometer Removal/Installation Refer to Chapter 31.
Page 414: Manifold Pressure (Map)
EXTRA SERVICE MANUAL EXTRA 300L 77-10-20 Manifold Pressure (MAP) The manifold pressure sense line is connected to the air inlet of cylinder no. 5 (rear right-hand), refer to Figure 1. It is a wet line consisting of two parts divided by the firewall.
Page 415: Temperature
EXTRA SERVICE MANUAL EXTRA 300L 77-20-00 TEMPERATURE 77-20-10 Cylinder Head Temperature (CHT) The cylinder head temperature gauge is located in the rear instrument panel. The sensor is located in the rear right-hand cylinder (No. 5). For an installation with 2 oil coolers the CHT sensor is located in the middle right-hand cylinder (No.
Page 416: Exhaust Gas Temperature (Egt)
EXTRA SERVICE MANUAL EXTRA 300L 77-20-20 Exhaust Gas Temperature (EGT) The exhaust gas temperature gauge is located in the rear instrument panel. The temperature sensor is located on the rear exhaust pipe on the right-hand side (refer to Figure 1).
Page 417 EXTRA SERVICE MANUAL EXTRA 300L Chapter 78 Exhaust PAGE DATE: 4. June 2009 CHAPTER PAGE...
Page 418 EXTRA SERVICE MANUAL EXTRA 300L Table of Contents Chapter 78 Chapter Title 78-00-00 GENERAL ........3 Figure 1 Exhaust System .
Page 419: General
EXTRA SERVICE MANUAL EXTRA 300L 78-00-00 GENERAL The EXTRA 300L is generally equipped with a Gomolzig 6 in 1 exhaust system (refer to Figure 1) with integrated silencer (muffler). Figure 1 Exhaust System PAGE DATE: 4. June 2009 CHAPTER PAGE...
Page 420 EXTRA SERVICE MANUAL EXTRA 300L 78-10-00 COLLECTOR/NOZZLE Description Each engine cylinder has a separate exhaust pipe routed down merging in collector tubes with increasing diameter. The collector tubes are equipped with heat shields to protect the lower engine cowling against the heat. Several exhaust pipes feature slip joints to allow for thermal expansion.
Page 421: Exhaust System
EXTRA SERVICE MANUAL EXTRA 300L Removal Remove upper and lower engine cowling per Ch. 71. Remove EGT sensor on the right hand side rear cylinder (No.5) per Chapter 77. Remove throttle control cable at the injector, at the attachment clamp block near the injector and at the cushioned clamp on the muffler (refer to Chapter 73).
Page 422: Exhaust Pipe
EXTRA SERVICE MANUAL EXTRA 300L 78-10-01 Exhaust Pipe Replacement Remove exhaust system per Chapter 78-10-00. For cylinders 1-2 replace entire collector tube. For cylinders 3-4 pull the exhaust pipe out of the slip joint and replace the exhaust pipe. For cylinder 5 loosen the clamps on the slip joints, replace the exhaust pipe and drill 4,8 mm (3/16") hole for EGT sensor...
Page 423: Heat Shield
EXTRA SERVICE MANUAL EXTRA 300L 78-10-04 Heat Shield Replacement Refer to Figure 2 Remove cowling per Chapter 71. Remove heat shield worm drive hose clips. Replace heat shield. Reinstall in reverse sequence of removal. Figure 2 Heat Shield Replacement PAGE DATE: 4. June 2009...
Page 424 SERVICE MANUAL EXTRA 300L Chapter 79 Oil System PAGE DATE: 4. June 2009 CHAPTER PAGE...
Page 425 SERVICE MANUAL EXTRA 300L Chapter 79 TABLE OF CONTENTS Chapter/Figure Title 79-00-00 GENERAL ........3 79-00-10 Christen Inverted Oil System .
Page 426: General
GENERAL 79-00-10 Christen Inverted Oil System The EXTRA 300L is equipped with a modification of a Christen Inverted Oil System (CHRISTEN 801 series). The need for modification of the standard Christen 801 Inverted Oil System results from installation requirements of the Lycoming engine.
Page 427: Inverted Oil System, Normal Flight
INVERTED OIL SYSTEM SERVICE MANUAL EXTRA 300L Normal flight During normal flight, the weighted ball valve at the top of the oil separator is open, allowing blow-by gases from the engine crankcase to be vented from the breather port to the top of the oil separator and out through the overboard breather line.
Page 428: Inverted Oil System, Inverted Flight
INVERTED OIL SYSTEM SERVICE MANUAL EXTRA 300L Principles of Operation Any oil in the lines which fails to return to the sump during the transition between normal and inverted flight drains into the oil separator. This oil then returns to the sump from the bottom of the oil separator during periods of normal flight.
Page 429: Valve Balls
SERVICE MANUAL EXTRA 300L 79-00-11 Valve Balls Reseating Marginal oil loss of valve may result from nicks in the valve seats which cause leakage when the valve should be closed. Such nicks can be caused by mishandling or by small chips of metal being caught between the ball and the seat as the valve operates during initial run-in of a new or overhauled engine.
Page 430: Distribution
79-20-00 DISTRIBUTION Description and Operation The lubrication system of the EXTRA 300L features either a single or dual oil cooler system both using flexible tubing. The hose and fitting installation is modified with respect to the standard Christen Inverted Oil System. The connections of the Inverted Oil System however still consist of AN (Army/Navy) Standard fittings.
Page 431: Single Oil Cooler System
SERVICE MANUAL EXTRA 300L I M P O R T A N T If replacement of oil lines is necessary, cover the oil lines of the engine compartment with AEROQUIP AE102 fire sleeves as per Chapter 20-10-07 except the AEROQUIP 637/MIL-H 6000 hoses.
Page 432: Dual Oil Cooler System
SERVICE MANUAL EXTRA 300L 79-20-20 Dual Oil Cooler System Description and Operation When the dual oil cooler system is installed the oil coolers are mounted on the left front and left rear engine baffles and are connected to the engine by flexible hose (refer to Fig. 4).
Page 433: Indicating
SERVICE MANUAL EXTRA 300L 79-30-00 INDICATING Oil pressure and oil temperature are sensed on the EXTRA 300L engine and are indicated to the pilot in command. Trouble Shooting Trouble Possible Cause Remedy No oil pressure indication Sensor defective Replace sensor.
Page 434: Oil Pressure Sensor & Wet Line Up To Sn 1302
SERVICE MANUAL EXTRA 300L Figure 5, Sheet 1 Oil Pressure Sensor & Wet Line up to SN 1302 Top View Oil cooler Firewall Engine Legend: 1 Oil pressure sensor 2 Fitting 3 Sense line 4 Fitting Figure 5, Sheet 2 Oil Pressure Sensor &...
Page 435: Oil Pressure Gauge
SERVICE MANUAL EXTRA 300L 79-30-11 Oil Pressure Gauge Oil pressure indication is combined with the oil temperature indication in one single unit. Removal/Installation Refer to Chapter 31. 79-30-14 Oil Pressure Wet Line Removal/Installation 1 Remove upper cowling per Chapter 71 2 Disconnect the sense wet line at firewall bulkhead fitting and at engine fitting (refer to Figure 5).
Page 436: Oil Temperature
SERVICE MANUAL EXTRA 300L 79-30-20 Oil Temperature The oil temperature gauge is located in the rear instrument panel. The gauge receives its data electrically from a sensor located on the engine in front of the oil filter screen (refer to Figure 6).
Page 437: Oil Temperature Sensor
SERVICE MANUAL EXTRA 300L 79-30-25 Oil Temperature Sensor Removal/Installation The sensor can be easily removed and installed without special equipment. 1 Remove upper cowling per Chapter 71. 2 Remove oil temperature sensor (refer to Figure 6). 3 Install in reverse sequence of removal.
Page 438 EXTRA SERVICE MANUAL EXTRA 300L Chapter 91 Charts PAGE DATE: 1. June 1995 CHAPTER PAGE...
Page 439 EXTRA SERVICE MANUAL EXTRA 300L Chapter 91 Table of Contents Figure Title EA-96102D Power Generation/Distribution EA-93102.02C Magneto System EA-9C102.02A Magneto System EA-93102.03A Nav/Strobe Light Sys. EA-93102.04A Fuel Gages EA-9E102.05 COM S/E Gerät EA-93102.06B Audio Switches & Jacks EA-93102.07D Low Voltage Warning EA-93102.08C...
Page 440 EXTRA SERVICE MANUAL EXTRA 300L EA-96102.46 Aspen EFD1000 PFD (P/N A-05-110-00) EA-96102.48 Garmin GNC 420W EA-96102.49 Attitude Gyro (RC Allen RCA2600) EA-9E102.53 Landing Light EA-93102.58 EGT & CHT Indication EA-9C102.58 EGT & CHT Indication EA-9D102.58A EGT & CHT Indication EA-93102.59 FLIGHT TIMER EA-9E102.62A...
Page 442 STARTER see ALTERNATOR WARNING EA-9C102.7 START RELAY see ALTERNATOR SYSTEM MAIN-BUS EA-9C102.10 see BATTERY CIRCUIT STARTER see BATTERY CIRCUIT EA-9C102.9 EA-9C102.9 see STARTER ENGAGE LIGHT (Option) EA-96102.31 MAGNETO SWITCH & Holder R L BOTH START left Magn see RPM INDICATION EA-9C102.30 right Magn MAGNETOS.
Page 443 START RELAY MAIN-BUS see BATTERY CIRCUIT EA-93102.9 START see LOW VOLTAGE WARNING EA-93102.7 ZUENDSCHLOSS R L BOTH START left Magn see RPM INDICATION EA-93102.30 right Magn or EA-97102.30 10-357200-1 MAGNETOS. R MAGNETOS. L 4 WIRE 1 x AWG 18 SHIELDED 02199 MIL-C-27500-18TG1 3 WIRE AWG 18...
Page 444 MAIN-BUS OPTION 01 & 02 MAIN-BUS OPTION 04 RIGHT WING RIGHT WING NAV-L STROBE-L NAV-L STROBE-L green green white white POWER POWER SUPPLY Strobe SUPPLY Strobe NAV-L STROBE A600PG A600PG A490T A490T POWER POWER SUPPLY Strobe SUPPLY Strobe A490T A490T white white A600PR...
Page 445 MAIN-BUS CB10 INSTR zu anderen Systemen FUEL FUEL WING FUSELAGE INDICATOR INDICATOR 301030-001G 301030-002G 3-180Ohm 60/90-0,5Ohm 00775 KABEL AWG 20 MIL-W-22759/16-20 02198 RINGÖSE ROT 5mm 130008 01417 RINGÖSE ROT 4mm 031890 FLACHSTECKER PIN 6,3mm 42565-2 00097 180924-0 00103 PIN GEHÄUSE 2 POLIG 180923-0 00099 BUCHSEN GEHÄUSE 2 POLIG...
Page 446 OPTION 01 - 04 14 VDC AVIONIC BUS 14 VDC AVIONIC BUS COM S/E GERÄT COM S/E GERÄT 13,75 VDC 13,75 VDC 13,75 VDC 13,75 VDC +Lighting +Lighting Speaker Speaker PHONE-BUCHSE COPILOT IC Control MIC- BUCHSE COPILOT Phone Hi # 24 I/C PILOT Phone Lo PTT COPILOT...
Page 447 PHONE-BUCHSE COPILOT MIC-BUCHSE COPILOT I/C PILOT COM S/E-GERÄT oder PTT COPILOT INTERCOM PTT PILOT EA-76291.1 I/C COPILOT MIC-BUCHSE PILOT PHONE-BUCHSE PILOT WIRE 2xAWG24 FE4006 MIL-C-27500-24TG2 PTT-KABELBAUM EA-76291.1 BUCHSE 43030-0007 FE4079 BUCHSENGEHÄUSE FE4256 43025-0400 PUSH BUTTON 701548 01430 1174599 FE4301 PUSH BUTTON 04-00975 WASHER 31382...
Page 448 OPTION 03 OPTION 02 BOSCH 55A & 65A PRESTOLITE 65A/70A & BOSCH 55A mit "W" ALTERNATOR ALTERNATOR nur bei BOSCH 0120 489 469 see RPM-INDICATOR EA-93102.30 Opt. 03 or EA-97102.30 Opt. 03 2,2uF / 250V 2,2uF / 250V Motorgehäuse see ALTERNATOR SYSTEM see ALTERNATOR SYSTEM EA-93102.10 EA-93102.10...
Page 449 MAIN-BUS SOLENOID CB11 CB12 SMOKE PUMP SMOKE CONTROL SMOKE PUMP 30/51 SMOKE ARM SMOKE POWERLEVER REFILL PUMP 30/51 SMOKE REFILL CIRCUIT BREAKER 5A 7277-2-5 31506 CIRCUIT BREAKER 5A W23X1A1G-5 31504 CIRCUIT BREAKER 15A 7277-2-15 31506 CIRCUIT BREAKER 15A W23X1A1G-15 00105 SCHALTER 1 POLIG ON-ON 07.1.1.13 FE4025...
Page 450 OPTION 03 & 04 OPTION 01 & 02 to VOLT/AMPERE INDICATION to VOLT/AMPERE INDICATION see EA-93102.27 see EA-93102.27 MAIN BUS MAIN BUS to STARTER ENGAGE LIGHT to STARTER ENGAGE LIGHT see EA-96102.31 see EA-96102.31 STARTER STARTER see BATTERIE LADEEINRICHTUNG see BATTERIE LADEEINRICHTUNG BATTERY RELAY BATTERY RELAY START RELAY...
Page 451 PRESTOLITE 65A/70A ELECTROSYSTEMS ALTERNATOR ALTERNATOR OPTION 01 OPTION 05 15/16 2,2uF / 250V Motorgehäuse 6/14 see MAGNETO SYSTEM EA-93102.2 GEN FAIL (LOW VOLTAGE) VOLTAGE REGULATOR blue PRESS TO TEST black ALT/FIELD ALT OUT INCREASE LOW VOLTAGE WARNING MS25041-X see EA-93102.7 + GE330 ALT OUT MAIN-BUS...
Page 452 MAIN-BUS OPTION 01 & 02 BOOST BOOST BOOST PUMP 8120-M MAIN-BUS OPTION 03 BOOST BOOST PUMP 8120-M BUCHSEN GEHÄUSE 2 POLIG 180923-0 00099 PIN GEHÄUSE 2 POLIG 180924-0 00103 FLACHSTECKER BUCHSE 6,3mm 0042282-2 00093 FLACHSTECKER PIN 6,3mm 42565-2 00097 4 WIRE AWG 18 MIL-W-22759/16-18 00776 3 FUEL PUMP...
Page 453 MAIN-BUS STALL BUZZER STALL WARNER grey BUCHSEN GEHÄUSE 2 POLIG 180923-0 00099 PIN GEHÄUSE 2 POLIG 180924-0 00103 FLACHSTECKER BUCHSE 6,3mm 0042282-2 00093 FLACHSTECKER PIN 6,3mm 42565-2 00097 4 WIRE AWG 22 01694 MIL-W-22759/16-22 3 STALL WARNER EA-73106.1 BUZZER EM-S 110P 01600 CIRCUIT BREAKER 1A W23X1A1G-1...
Page 454 BECKER TRANSPONDER 2SH-A 14 VDC RADIO BUS ATC-2000 J4204 XPDR 14V LIGHT BLIND ENCODER 4SH-A 13.75 VDC IN ACK A-30 13.75 VDC IN 13.75 VDC SWITCHED OUT 14VDC green green white white blue blue light/brown light/brown yellow yellow orange orange pink pink violet...
Page 455 MAIN-BUS CB10 7,5A PEDALS PEDAL-ADJUST END-SWITCHES PEDAL RIGHT S6:1 rück front gray gray S6:2 RIGHT black black rear Nut unten black GND Modul PEDAL LEFT S7:1 rück front gray gray S7:2 black black rear Nut unten black LEFT CIRCUIT BREAKER 7,5A 7277-2-7.5 32112 CIRCUIT BREAKER 7,5A...
Page 457 Minus am Rahmen EXT POWER RELAY AWG4 AWG4 START RELAY POWER CONTACT IN AWG18 AWG18 EXTERNAL POWER CONNECTOR PLASTI GRIP 130008 Stueck 02198 TERMINAL 0033470 01148 Stueck TERMINAL 160075-0 Stueck FE487 WIRE AWG 4 2,57 mtr 200005 22759-16-4 WIRE AWG 18 00776 22759-16-18 RELAY...
Page 458 zwischen Relaismutter und Kabelschuh montiert EA-83290.1 FUSE 2 Bat-Relay +12V OPTION CLOCK CHARGE FUSE 1 EDV EA300Z01 111-226 BATTERIE HAUPTSCHALTER 10PP Masse auf Rahmen Auf Masseschiene BATTERIE LADEKABEL 03543 KABEL AWG 18 MIL-C-27500-18TG1T14 02199 STECKDOSE 12 VOLT 146 19 20 02636 GEHÄUSE STECKHÜLSE 1 POL 925324-2...
Page 459 14 VDC RADIO BUS TRANSPONDER Mode S XPDR FILSER TRT 600 2SH-A 14 VDC Power not connected = Light on Light off Suppression input Suppression - I/O TXPC RXPC ON Ground Switch Power GND Power GND WIRE RG400 RG-400 FE4111 WIRE AWG20 in Pos.
Page 460 14 VDC BUS see conforming ELEKTRIK SYSTEM XPDR TRANSPONDER Mode S 2SH-A 14 VDC Power not connected = Light on Light off Suppression input Suppression - I/O TXPC RXPC ON Ground Switch Power GND Power GND WIRE RG400 RG-400 FE4111 WIRE AWG20 in Pos.
Page 461 14 VDC RADIO BUS GARMIN TRANSPONDER J3301 2SH-A GTX-330/328 XPDR BLIND ENCODER 4SH-A AIRCRAFT POWER ACK A-30 / -08 AIRCRAFT POWER Master ON 14 V LIGHT Switched Power Out 14VDC RS-232 IN 2 RS 232 Out 2 green green white white blue blue...
Page 462 BECKER TRANSPONDER MODE S 14 VDC RADIO BUS 2SH-A BXP 6401-X-(XX) XPDR BLIND ENCODER 14 VDC POWER IN 5SH-A 14 VDC POWER IN ACK A-30 14V LIGHT SWITCHED POWER OUTPUT 14VDC green green white white blue blue light/brown light/brown yellow yellow orange orange...
Page 463 14 VDC RADIO BUS BENDIX/KING TRANSPONDER 2SH-A KT-73 XPDR BLIND ENCODER 5SH-A 11-33 VDC IN ACK A-30 11-33 VDC IN 14V LIGHT 14VDC green green white white blue blue light/brown light/brown yellow yellow orange orange pink pink violet violet gray gray 9V SUPPRESSION IN ARINC SUPPRESSION I/O...
Page 464 14 VDC RADIO BUS KING TRANSPONDER 2SH-A KT-76A XPDR BLIND ENCODER 5SH-A ACK A-30 13.75 VDC IN 14V LIGHT 14VDC green green white white blue blue light/brown light/brown yellow yellow orange orange pink pink violet violet gray gray 9V SUPPRESSION IN green white blue...
Page 465 14 VDC RADIO BUS J3301 GARMIN TRANSPONDER 2SH-A GTX327 XPDR BLIND ENCODER 4SH-A RADIO MASTER IN ACK A-30 14 VDC POWER IN 14V LIGHT 14VDC green green white white blue blue light/brown light/brown yellow yellow orange orange pink pink violet violet gray gray...
Page 466 14 VDC RADIO BUS J3301 BECKER TRANSPONDER 2SH-A ATC-4401 XPDR BLIND ENCODER 14 VDC POWER IN 4SH-A 14 VDC POWER IN ACK A-30 14V LIGHT SWITCHED POWER OUTPUT 14VDC green green white white blue blue light/brown light/brown yellow yellow orange orange pink pink...
Page 467 OPTION 01 = ANALOG AMP-METER OPTION 02 = mit INTERNEM SHUNT OPTION 03 = mit EXTERNEM SHUNT Standard Analog Alternativ Digital Alternativ Digital S-50 FA3008 AMPERE METER SH 1 VOLT / AMP 100mV 100A INDICATOR MAIN BUS MAIN BUS MAIN BUS +/- 60A VA-1A EA-83290.2...
Page 468 see conforming ELEKTRIK SYSTEM MAIN BUS EA-9__102.1 SCANNER/INDICATOR FIRE WALL EGT-701-(6CF) TT-K-22S CHT-1 CHT-1 TT-K-22S CHT-2 CHT-2 TT-K-22S CHT-3 CHT-3 14-28 VDC TT-K-22S CHT-4 CHT-4 RS 232 DATA OUT DATA PORT TT-K-22S CHT-5 CHT-5 TT-K-22S CHT-6 CHT-6 TT-K-22S EGT-1 EGT-1 TT-K-22S EGT-2 EGT-2...
Page 469 FRONT UNTERPANZER see conforming ELEKTRIK SYSTEM MAIN BUS right Side EA-9__102.1 SCANNER/INDICATOR FIRE WALL EGT-701-(6COAF R/M) TT-K-22S DRAIN CHT-1 CHT-1 CENTER TANK TT-K-22S CHT-2 CHT-2 TT-K-22S CHT-3 CHT-3 14-28 VDC FIRE WALL OIL-TEMP PROBE TT-K-22S CHT-4 CHT-4 OIL-TEMP TT-K-22S OIL-TEMP TT-K-22S CHT-5 CHT-5...
Page 470 ZUENDSCHLOSS MAIN-BUS MAIN-BUS R L BOTH BOSCH START ALTERNATOR CB10 CB10 see START / MAGNETO EA-93102.2 see ALTERNATORSYSTEM Opt. 04 INSTR see FUEL GAGES see FUEL GAGES INSTR EA-93102.10 EA-93102.4 EA-93102.4 Motorgehäuse 10-357200-1 MAGNET MAGNETOS. R 6350 MAGNETOS. L ANALOG-RPM ANALOG-RPM INDICATOR INDICATOR...
Page 471 STARTER ENGAGED PRESS TO TEST see FUEL GAGES MS25041-X EA-93102.4 + GE330 CB10 INSTR to SHUNT MAIN BUS see EA-93102.9 STARTER MAIN BUS START START RELAY to BATTERY RELAY 149-12LS see EA-93102.9 see BATTERY CIRCUIT EA-93102.9 22735 see MAGNETO SYSTEM EA-93102.2 ZUENDSCHLOSS R L BOTH...
Page 472 MAIN BUS FUEL FLOW OPTION FUEL FLOW INDICATOR GARMIN GNC-420/GNS-430/GNS-530 FS-450 P4001 14-28 VDC RS 232 Out 1 RS 232 In RS 232 In 1 RS 232 Out schwarz Ground FLOW SENSOR orange orange Left (and Right) Transduser Power schwarz blau blau Left and Right Transducer Ground...
Page 473 MAIN-BUS CB10 INSTR see FUEL GAGES EA-93102.4 OIL PRESS OIL TEMP INDICATOR 2DA3-3KV TEMP PRESS SENS SENS 399S9 387-100KV 5 WIRE AWG 20 00775 MIL-W-22759/16-20 5 OIL PRESS SENSOR 387-100KV in Pos. 1 OIL TEMP SENSOR 399S9 in Pos. 1 CONNECTOR in Pos.
Page 474 see conforming ELEKTRIK SYSTEM 14V MAIN-BUS EA-9__102.1 INSTR see conforming FUEL GAGES EA-9__102.4 see conforming OIL TEMP/PRESS see conforming RPM INDICATION EA-9__102.34 EA-9__102.30 see conforming ACCELEROMETER (Option) EA-9__102.15 INDICATOR +14VDC GAUGE #2 IN - TEMP GAUGE #2 IN + SENS +12V PRESS GAUGE #1 IN -...
Page 475 Buchse aus PS Kit PN.: 200-000-0002 AUX PHONE RADIO PM 1200-R 11961 # 22 COM S/E GERÄT see VOLT AMPERE INDICATION SH 1 EA-93102.27 # 22 11-33 VDC Radio Phone Hi Aircraft RadioPhone Hi # 24 # 24 # 24 Aircraft Radio Phone Lo Radio Phone Lo Radio PTT...
Page 476 MAIN-BUS CB11 SMOKE PUMP 12V 40A Wechsler SMOKE PUMP SMOKE ARM SMOKE POWERLEVER SMOKE REFILL SMOKE REFILL 12V 40A Wechsler LEVEL SMOKETANK CIRCUIT BREAKER 15A 7277-2-15 31504 CIRCUIT BREAKER 15A W23X1A1G-15 30675 11 SCHALTER 1 POLIG ON-OFF 07.1.1.13 FE4025 SCHALTER 1 POLIG ON-OFF MS35058-23 07006 10 FLACHSTECKER BUCHSE 6,3mm...
Page 477 14VDC MAIN BUS 3DA-A 1,2k Pointer ELT P3000-10 ONLY FOR EXCHANGE Pointer ELT P3000-11 3DA-B RG 58 C/U Pointer 2020 02045 EXCHANGE BATTERY WIRING 3xAWG22 MIL-C-27500-22TG3 FE4009 WIRING AWG 22 MIL-W-22759/16-22 01694 REMOTE CONNECTOR Part of 2019-10 Kit Pointer 3002 ANTENNA CABLE W23X1A1G-1 00130...
Page 478 see conforming ELEKTRIK SYSTEM BATTERY RELAY EA-9__102.1 BATTERIE 12 V see conforming CHARGE ELEKTRIK SYSTEM EA-9__102.1 Kabelschuh montiert zwischen Relaismutter und EA-83290.1 9/10 REMOTE SWITCH TRANSMITTER ASSY 2DA-A 1DA-A ARTEX ME 406 ELT +14 VDC Light Reset 1 ONLY FOR EXCHANGE Reset 2 External On Ground...
Page 479 14 VDC RADIO BUS BECKER TRANSPONDER MODE S 2SH-A BXP 6401-X-(XX) XPDR 14 VDC POWER IN 14 VDC POWER IN 14V LIGHT SWITCHED POWER OUTPUT EXT. IDENT SUPPRESSION REPLAY OUT 28V LIGHT GROUND GROUND A/C GND BLIND ENCODER MODULE GROUND SWITCH BE 6400-01 ALT S - ALT S +...
Page 480 14VDC RADIO BUS EFD 1000 PDF A-05-110-00 7,5A DD44F10000 AIRCRAFT POWER AIRCRAFT POWER AIRCRAFT POWER AIRCRAFT GROUND AIRCRAFT GROUND AIRCRAFT GROUND CONFIGURATION MODULE PFD A/C GND A-05-113-00 DIGITAL_OUT CONFIG_A CONFIG_A CONFIG_B CONFIG_B A-08-144-00-A CONFIG_C CONFIG_C CONFIG_D CONFIG_D CONFIG_S OPTIONEN Molex 50-57-9045 TRANSPONDER GTX 330/328 REMOTE SENSOR PFD...
Page 481 OPTIONEN 14VDC RADIO BUS GARMIN COM - GPS P4001 PHONE-BUCHSE COPILOT GNC 420W OPTIONEN 14 VDC Aircraft Power 14 VDC Aircraft Power MIC-BUCHSE COPILOT TRANSPONDER Aircraft Ground GTX 330/328 Aircraft Ground P3301 Lighting Hi Lighting Lo nur bei GTX-330 I/C PILOT TIS CONNECT SELECT RS-232 OUT 2 A/C GND...
Page 482 see POWER DISTRIBUTION 14 VDC VOLTAGE GYRO ATTITUDE GYRO POWER 9 - 32VDC POWER GROUND Option INCLINOMETER INCLINOMETER RCA 444-0010-01 Stueck 33529 WIRE AWG20 MIL-W-22759/16-20 CIRCUIT BREAKER 2A 7277-2-2 31508 Stueck CONNECTOR MS3116E-4S Stueck ATTITUDE GYRO 3" RCA 2600-3 Stueck 16oz 33217/33882 33027/33881...
Page 483 see conforming ELEKTRIK SYSTEM MAIN BUS EA-9__102.1 LANDING LIGHT LED ASSY LANDING LIGHT (14V 0,9A) black black 7112512 WIRE AWG 20 MIL-W-22759/16-20 00776 BUCHSEN GEHÄUSE 2 POLIG 180923-0 00099 PIN GEHÄUSE 2 POLIG 180924-0 00103 FLACHSTECKER BUCHSE 6,3mm 0042282-2 00093 FLACHSTECKER PIN 6,3mm 42565-2 00097...
Page 484 BRANDSPANT EGT/CHT INDICATOR white Typ J CHT Sensor black white Typ K EGT Sensor black MIL-W-22759/16-20 00775 WIRE AWG 22 CHT TEMP SENSOR (J) 3/8-24 w/snap 712-7DK 3/8-24 Fa. WESTBERG 00835 EGT TEMP SENSOR (K) 1 5/8 - 2 1/2 712-2DWK Fa.
Page 485 BRANDSPANT EGT/CHT INDICATOR white Typ J CHT Sensor black white Typ K EGT Sensor black MIL-W-22759/16-20 00775 WIRE AWG 22 CHT TEMP SENSOR (J) 3/8-24 w/snap 712-7DK 3/8-24 Fa. WESTBERG 00835 EGT TEMP SENSOR (K) 1 5/8 - 2 1/2 712-2DWK Fa.
Page 486 see conforming ELEKTRIK SYSTEM 14V MAIN-BUS EA-9__102.1 INSTR see conforming VOLT AMPERE INDICATION see conforming FUEL GAGES EA-9__102.27 EA-9__102.4 see conforming OIL TEMP/PRESS see conforming RPM INDICATION EA-9__102.34 EA-9__102.30 see conforming ACCELEROMETER (Option) EA-9__102.15 INDICATOR +14VDC GAUGE #1 IN - Typ K GAUGE #1 IN + GAUGE #2 IN -...
Page 487 MAIN-BUS INSTR zu anderen Systemen FLIGHT TIMER FSZM OPTION KABEL AWG 20 00775 MIL-W-22759/16-20 30755 STECKER STECKER FÜR FSZM 01605 FLIGHT TIMER FSZM 1510 Benennung Teilekennzeichen ZF Werkstoff Abmessungen Menge Einheit Gewicht MaWi-Nr. Letzte Bearbeitung: Datum Name Maßstab Projektion Die Gültigkeitszuordnung SI.-Klasse von Version zu Freimaßtoleranz...
Page 488 GARMIN COM/GPS AVIONIC-BUS OPTIONEN GTN-635 NAV/GPS TRANSPONDER CONFIG MODULE 7,5A GTX-33 GTX 330/328 P1001 P1003 KIT 011-00979-00 P3301 P3301 ALERT AUDIO OUT HI CONFIG MODULE POWER AIRCRAFT POWER see Option TRANSPONDER ALERT AUDIO OUT LO CONFIG MODULE GND AIRCRAFT POWER CONFIG MODULE DATA AIRCRAFT POWER RS232 IN 1...
Page 489 GARMIN NAV INDICATOR GARMIN COM/NAV/GPS AVIONIC-BUS OPTIONEN GI-106A GTN-650/750 NAV/GPS TRANSPONDER 7,5A GTX-33 GTX 330/328 P1001 P1003 P3301 P3301 see Option TRANSPONDER ALERT AUDIO OUT HI AIRCRAFT POWER GPS ANNUNCIATE see Option GARMIN GMA 35 EA-9D102.65 GPS ANNUNCIATE ALERT AUDIO OUT LO AIRCRAFT POWER VLOC ANNUNCIATE VLOC ANNUNCIATE...
Page 490 AVIONIC-BUS XPDR GARMIN TRANSPONDER J3301 GTX-33 OPTIONEN AIRCRAFT POWER 1 AIRCRAFT POWER 1 COM/NAV/GPS & COM/GPS GTN-650/750 & GTN-635 P1001 RS232 OUT 1 RS232 IN 1 RS232 OUT 1 RS232 IN 1 GROUND RS-232 GND 1 ARINC 429 IN 1A ARINC 429 OUT 1A ARINC 429 IN 1B ARINC 429 OUT 1B...
Page 491 AVIONIC-BUS AUDIO AUDIO PANEL P3502 GMA-35 AIRCRAFT POWER AIRCRAFT POWER GARMIN COM/NAV/GPS AIRCRAFT GROUND P3502 AIRCRAFT GROUND A/C GND P1001 GTN-750 RS 232 OUT 2 RS232 IN RS 232 IN 2 RS232 OUT RS 232 GND 2 MUSIK 1 IN LO AUDIO OUT HI ALERT-2 AUDIO IN HI MUSIK 1 IN RIGHT...

RC Factory EXTRA 300L Service Manual

Chapter 05 Time Limits/Maintenance Checks

Chapter 06

Chapter 07

Chapter 10

Chapter 12

Chapter 20 Standard Practices - Airframe

Chapter 23

Chapter 24 Electrical Power

Chapter 25 Equipment and Furnishings

Chapter 27

Chapter 28 Fuel

Chapter 31 Indication \ Recording System

Chapter 32 Landing Gear

Chapter 33 Lights

Chapter 34

Chapter 51 Standard Practices and Structures - General

Chapter 55

Chapter 57

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Summary of Contents for RC Factory EXTRA 300L