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Extra 300/SC Maintenance Manual

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MAINTENANCE MANUAL EXTRA 300/SC
Dates of issue for original and revised pages:
1st Edition .............................................. 16. June 2008
1. Revision ............................................. 29. May 2009
2. Revision ........................................... 1. August 2014
3. Revision ............................................ 4. March 2016
4. Revision ...................................... 12. February 2019
PAGE DATE: 12. February 2019
Log of Revisions
Date and sign of approval:
EASA MAJOR CHANGE APPROVAL
N° EASA.A.C.08679 ................................ 17. July 2008
Approved under the authority of DOA
N° EASA.21J.073 ................................... 29. May 2009
The technical content of this document is approved
under the authority of DOA
ref. EASA.21J.073. ......................... 19. December 2014
The technical content of this document is approved
under the authority of DOA
ref. EASA.21J.073. .............................. 23. March 2016
The technical content of this document is approved
under the authority of DOA
ref. EASA.21J.073. ................................ 19. April 2019
PAGE A

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  • Page 1 MAINTENANCE MANUAL EXTRA 300/SC Log of Revisions Dates of issue for original and revised pages: Date and sign of approval: 1st Edition ..........16. June 2008 EASA MAJOR CHANGE APPROVAL N° EASA.A.C.08679 ........ 17. July 2008 1. Revision ..........29. May 2009 Approved under the authority of DOA N°...
  • Page 2 MAINTENANCE MANUAL EXTRA 300/SC List of Effective Pages Chapter Page Date of Issue Chapter Page Date of Issue Chapter Page Date of Issue Cover sheet 16. June 2008 1. August 2014 12. February 2019 12. February 2019 12. February 2019 16.
  • Page 3 MAINTENANCE MANUAL EXTRA 300/SC List of Effective Pages Chapter Page Date of Issue Chapter Page Date of Issue Chapter Page Date of Issue 12. February 2019 12. February 2019 1. August 2014 1. August 2014 12. February 2019 1. August 2014 29.
  • Page 4 MAINTENANCE MANUAL EXTRA 300/SC List of Effective Pages Chapter Page Date of Issue Chapter Page Date of Issue Chapter Page Date of Issue 12. February 2019 12. February 2019 1. August 2014 12. February 2019 1. August 2014 1. August 2014 12.
  • Page 5 MAINTENANCE MANUAL EXTRA 300/SC List of Effective Pages Chapter Page Date of Issue Chapter Page Date of Issue Chapter Page Date of Issue EA-9C102.10A 19.12.2008 EA-9C102.10B 19.03.2016 EA-9C102.11 05.05.2008 EA-94102.14C 25.02.2011 EA-9C102.15 11.04.2011 EA-9C102.15A 03.12.2016 EA-9C102.16 05.05.2008 EA-9C102.16B 05.08.2010 EA-93102.18A 13.07.2005...
  • Page 6 MAINTENANCE MANUAL EXTRA 300/SC Artex ME406 ELT Description, Operation, Installation and Maintenance • Manual ME406 and ME406HM ELT (P/N: 570-1600) Manufacturer: Artex Aircraft Supplies P.O. Box 1270 Canby, Oregon 97013 Kannad 406 AF ELT Installation and Operation Manual 406 AF-COMPACT •...
  • Page 7 MAINTENANCE MANUAL EXTRA 300/SC 01-00-01 Trade Marks Even when the ware or brand names used in this manual are not marked as registered trade-marks, this does not mean, that these names are free in the sens of trademark legislation. PAGE DATE: 12. February 2019...
  • Page 8 MAINTENANCE MANUAL EXTRA 300/SC 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 9 MAINTENANCE MANUAL EXTRA 300/SC Table of Contents Chapter 02 Chapter/Figure Title 02-00-00 GENERAL ........3 02-10-00 MANUAL DESCRIPTION .
  • Page 10 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. Orders can be placed by contacting Extra Aircraft at e-mail: ExtraAircraft@ExtraAircraft.com or facsimile: +49-(0) 2858-9137-30.
  • Page 11 HANDLING MAINTENANCE MANUAL EXTRA 300/SC 02-20-02 Service Bulletin The Service Bulletins describe which procedures and how and when they are to be carried out. Enter the receipt of each Service Bulletin in the Service Bulletin List (page E). N O T E...
  • Page 12 MAINTENANCE MANUAL EXTRA 300/SC Record of Revisions Chapter 04 EASA Approval Date and Rev. Date of Revision Revised Pages Description of Revision Sign of Approval 17. July 2008; Original 16. June 2008 EASA.A.C.08679 reference corrected 12. February 2019 PAGE DATE: 12. February 2019...
  • Page 13 GENERAL MAINTENANCE MANUAL EXTRA 300/SC Operating Time The reliability of the composite primary parts has been convincingly demonstrated by fatique testing (Two times design life 2x6000 = 12000 hrs). I M P O R T A N T Every 1000 flight hours the "Significant Items Inspec- tion"...
  • Page 14 TIME LIMIT COMPONENTS MAINTENANCE MANUAL EXTRA 300/SC 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 modificated by the respective national authorities. Item Replace...
  • Page 15 TIME LIMIT COMPONENTS MAINTENANCE MANUAL EXTRA 300/SC 05-10-04 Time Between Inspection Inspect these equipment items at the times shown: e t t r e f i c i i t c y t i c i t h t i...
  • Page 16 SCHEDULED MAINTENANCE CHECKS MAINTENANCE MANUAL EXTRA 300/SC Figure 2 Lubrication Chart 25 hours PAGE DATE: 12. February 2019 CHAPTER 05 PAGE...
  • Page 17 SCHEDULED MAINTENANCE CHECKS MAINTENANCE MANUAL EXTRA 300/SC Figure 3 Lubrication Chart 50 hours PAGE DATE: 12. February 2019 CHAPTER 05 PAGE...
  • Page 18 SCHEDULED MAINTENANCE CHECKS MAINTENANCE MANUAL EXTRA 300/SC Figure 4 Lubrication Chart 100 hours PAGE DATE: 12. February 2019 CHAPTER 05 PAGE...
  • Page 19 SCHEDULED MAINTENANCE CHECKS MAINTENANCE MANUAL EXTRA 300/SC Maintenance Checks Schedule Date: Inspector: Mechanic: Serial No.: Inspections O 23 Inspect ignition harness for general condition, free from fraying or chafing and insulators for high tension leakage and continuity. O 24 Inspect SlickSTART, refer to Unison Operation, Maintenance, and Troubleshooting Manual.
  • Page 20 If the stop is reached the control system indicates a too high flexibility which needs to be traced. In this case contact EXTRA for advice. O O 12 Inspect all flight control ventilation holes for obstruction.
  • Page 21 SCHEDULED MAINTENANCE CHECKS MAINTENANCE MANUAL EXTRA 300/SC Maintenance Checks Schedule Date: Inspector: Mechanic: Serial No.: Inspections O 14 Visually inspect fiber composite push/pull control rods for cracks, impacts or other visible damage, especially at their end fittings. No gap between aluminum head and rod is allowed.
  • Page 22 SCHEDULED MAINTENANCE CHECKS MAINTENANCE MANUAL EXTRA 300/SC Maintenance Checks Schedule Date: Inspector: Mechanic: Serial No.: Inspections 4 Inspect tail wheel fork and steering arm attachment stopnut for security. 5 Check for general condition and function. Pay attention to the free movement of the rudder.
  • Page 23 SCHEDULED MAINTENANCE CHECKS MAINTENANCE MANUAL EXTRA 300/SC Maintenance Checks Schedule 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 24 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 "EA300SC 1000 Std.Insp" is available from EXTRA. Inspector: Date: Mechanic: Serial No.:...
  • Page 25 SCHEDULED MAINTENANCE CHECKS MAINTENANCE MANUAL EXTRA 300/SC Significant Items Inspection Inspector: Date: Mechanic: Serial No.: Inspections Engine compartment O 1 Remove engine cowling halves. O 2 Check firewall for dents, cracks and deformation. Visual inspection of firewall sealant for porosity and general condition.
  • Page 26 UNSCHEDULED MAINTENANCE CHECKS MAINTENANCE MANUAL EXTRA 300/SC 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. Date: Inspector: Mechanic: Serial No.:...

  • Page 27: Table Of Contents

    MAINTENANCE MANUAL EXTRA 300/SC Chapter 12 Table of Contents Chapter/Figure Title 12-00-00 GENERAL ........3 12-10-00 REPLENISHING .

  • Page 28: Fuel Drains

    MAINTENANCE MANUAL EXTRA 300/SC 12-10-03 Fuel Drains The EXTRA 300/SC has three fuel drain valves to provide for drainage of moisture and sediment. The center- and acro tank drain valve is located at the RH bottom of the fuselage behind the landing gear, the wing tank drain is located at the left side.
  • Page 29 MAINTENANCE MANUAL EXTRA 300/SC Return oil filler cap with dipstick into filler tube and tighten finger tight. Unscrew and remove oil filler cap with dipstick. Check oil level on dipstick versus the markings stamped on the dip- stick. If replenishment is required see "Replenishment of Engine Oil"...
  • Page 30 MAINTENANCE MANUAL EXTRA 300/SC 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. If the engine is in an extremely dirty condition, the switch to additive oil should be deferred until after engine has been overhauled.
  • Page 31 MAINTENANCE MANUAL EXTRA 300/SC 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) SAE 60 SAE 60 Above 16°C (60°F)

  • Page 32: Oil Change

    MAINTENANCE MANUAL EXTRA 300/SC Oil System Capacities: U.S. Imp. Liters Quarts Quarts Total Engine Capacitiy 15.18 13.32 Minimum Safe 8.53 7.49 Quantity: 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"...
  • Page 33 MAINTENANCE MANUAL EXTRA 300/SC Cut the safety wire and remove the hex sump plug with oil suction sump fitting. Remove oil suction screen from sump, inspect for metal particles and clean. N O T I C E When the oil suction screen is removed, extreme care...

  • Page 34: Replenishment Of Brake Fluid

    MAINTENANCE MANUAL EXTRA 300/SC 12-10-06 Replenishment of Brake Fluid In order to assure proper brake action, it is necessary to have positive transfer of hydraulic pressure through the system. Any air trapped in the system must be removed. Follow the procedure described below using a bleed tank (1, Figure 1): Remove engine cowlings as per Chapter 71-10-00.

  • Page 35: Tire Inflation

    Check the brake operation. Reinstall engine cowlings as per Chapter 71-10-00. 12-10-07 Tire Inflation For the EXTRA 300/SC the required tire pressure is 2620 hPa (38 Psi) for both main wheels. Use regulated air pressure to inflate tires. PAGE DATE: 12. February 2019...

  • Page 36: Scheduled Servicing

    MAINTENANCE MANUAL EXTRA 300/SC 12-20-00 SCHEDULED SERVICING 12-20-01 Exterior Cleaning The painted surface of the aircraft features 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 37: Interior Cleaning

    MAINTENANCE MANUAL EXTRA 300/SC Therefore one should pay particular attention to using ample water applied with clean sponges and leather, while even the smallest dust partiles will tend to scratch the glazing. N O T I C E Never dry polish plexiglass or polycarbonate!
  • Page 38 MAINTENANCE MANUAL EXTRA 300/SC The engine is cleaned as follows: After running, allow the engine to cool before cleaning. N O T I C E The magnetos, magneto start booster, alternator, starter, the air inlets, and the engine cowling (the inside of the...

  • Page 39: Unscheduled Servicing

    MAINTENANCE MANUAL EXTRA 300/SC 12-30-00 UNSCHEDULED SERVICING 12-30-01 Removal of Snow and Ice After snowfall, the snow should be removed immediately from the surface of the aircraft. Otherwise the water formed from melted snow will freeze on the surface or in slots and gaps of fairings.
  • Page 40 MAINTENANCE MANUAL EXTRA 300/SC Table of Contents Chapter 20 Chapter/Figure Title 20-00-00 GENERAL ........3 20-10-00 STANDARD PRACTICES AIRFRAME .
  • Page 41 STANDARD PRACTICES AIRFRAME ANDARD PRACTICES AIRFRAME Type of Bolts MAINTENANCE MANUAL EXTRA 300/SC 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:...
  • Page 42 MAINTENANCE MANUAL EXTRA 300/SC • Damaged, cracked, cut or abraded cover (any reinforcement exposed); • Blistered, soft, degraded, or loose cover. Installation of Flexible PTFE Hose Assemblies In general hose assemblies should be handled with care to prevent excessive bending, twisting and kinking since this reduces the life of the hose assembly considerably.
  • Page 43 MAINTENANCE MANUAL EXTRA 300/SC 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 44: Standard Practices Airframe

    STANDARD PRACTICES AIRFRAME MAINTENANCE MANUAL EXTRA 300/SC Flexible Hose Figure 2, Sheet 1 Connection Types PA Hoses PAGE DATE: 12. February 2019 CHAPTER PAGE...

  • Page 45: Connection Types Pa Hoses

    MAINTENANCE MANUAL EXTRA 300/SC Figure 2, Sheet 2 Connection Types PA Hoses PAGE DATE: 12. February 2019 CHAPTER PAGE...

  • Page 46: Fittings

    20-10-08 Fittings For the oil lubrication and the fuel system only AN-fittings are used in the EXTRA 300/SC. Generally these fittings are made of aluminium alloy and are colored blue for identifica- tion purposes. For firewall penetration special fittings made of stainless steel are used.
  • Page 47 MAINTENANCE MANUAL EXTRA 300/SC A bent nickel-plated brass swivel sleeve as well as wear and excessive free play at the pivot (swivel) points and sliding parts are an indication of misalignment and/or hard and abrupt control inputs. Those signs should be found early within the regular maintenance.
  • Page 48 MAINTENANCE MANUAL EXTRA 300/SC NOTES Installation should be accomplished by a licensed “A” and/or “P” mechanic. Control cables are designed to be non-repairable. Do not perform any repairs to this control cable. Cables are designed to be contaminant resistant; not contaminant proof.
  • Page 49 MAINTENANCE MANUAL EXTRA 300/SC a gradual or sudden increase in the no-load (cable free and • unattached) friction of a control cable has been detected. Correct routing of the control cable whenever: misalignment, unacceptable high internal friction due to •...

  • Page 50: Control Cables

    MAINTENANCE MANUAL EXTRA 300/SC Figure 3 Control Cables PAGE DATE: 12. February 2019 CHAPTER PAGE...

  • Page 51: Firewall Sealant

    MAINTENANCE MANUAL EXTRA 300/SC 20-10-10 Firewall Sealant For firewall sealing various products can be used (refer to Chapter 51-30-04). Replacement Before using any product, read and understand the applicable Technical Data Sheet (TDS) and Material Safety Data Sheet (MSDS). To ensure proper sealing and to avoid unintended chemical reactions with other products always remove old firewall sealant completely prior to application of new sealant.

  • Page 52: Assembly Instruction

    MAINTENANCE MANUAL EXTRA 300/SC 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 53 ASSEMBLY INSTRUCTION Assembly Instruction after Container Shipping MAINTENANCE MANUAL EXTRA 300/SC Remove the aircraft components out of the container. Small parts, hardware, spinner dome and the wheel fairings you find in the cockpit. Inspect all removed items for damage prior to assembly.
  • Page 54 ASSEMBLY INSTRUCTION Assembly Instruction after Container Shipping MAINTENANCE MANUAL EXTRA 300/SC Remove tail weight. Check if all switches are in Off-position and connect bat- tery. Perform operational check of electrical equipment. Inspect trim tab for full travel and deflection in relation to the trim indication.
  • Page 55 MAINTENANCE MANUAL EXTRA 330/SC Remove clamp sheet (9, 11) attachment bolts on the fire- wall. Loosen hose clamp (8). Mark Bowden cable (2) routing and remove the attachment self-clinching plastic straps (3). Remove attachment nut and washer (5) of the control handle (1).
  • Page 56 MAINTENANCE MANUAL EXTRA 300/SC Chapter 24 Table of Contents Chapter Title 24-00-00 GENERAL ........3 24-30-00 DC-GENERATION .

  • Page 57: Dc-Generation

    DC-GENERATION MAINTENANCE MANUAL EXTRA 300/SC Maintenance Practices I M P O R T A N T If replacement of wiring passing the firewall is neces- sary, renew the sealing of the bushing grooves and gaps at the engine side of the firewall. Use firewall sealant as presented in Chapter 51-30-04.

  • Page 58: Dc Electrical Load Distribution

    MAINTENANCE MANUAL EXTRA 300/SC 24-60-00 DC ELECTRICAL LOAD DISTRIBUTION (Refer to Figure 0 of Chapter 91) 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 lower rear instrument panel so as the lever switches.

  • Page 59: Lever Switch

    MAINTENANCE MANUAL EXTRA 300/SC 24-60-02 Lever Switch Removal/Installation N O T I C E Disconnect battery Remove the Main fuselage cover as per Chapter 51. Disconnect wiring from the switch. Remove the attachment nut at the front side of the instru- ment panel.
  • Page 60 MAINTENANCE MANUAL EXTRA 300/SC N O T I C E Possible damage of internal relay mechanism due to rotational displacement of contact and coil eletrical terminals. Use a back-up wrench to hold the bottom nut stationary when applying/releasing the outer nut.
  • Page 61 MAINTENANCE MANUAL EXTRA 300/SC Chapter 27 Table of Contents Chapter/Figure Title 27-00-00 GENERAL ........4 Figure 1 Controls .
  • Page 62 MAINTENANCE MANUAL EXTRA 300/SC Chapter/Figure Title 27-30-02 Trim Tab ........32 Figure 21 Trim Tab Rigging .

  • Page 63: General

    MAINTENANCE MANUAL EXTRA 300/SC 27-00-00 GENERAL (Refer to Figure 1) The EXTRA 300/SC is standard equipped with a conventional control stick and adjustable rudder pedals. The control surfaces are operated by a direct me- chanical linkage. The control surface deflections are shown in Figure 2.

  • Page 64: Control Surface Deflections

    MAINTENANCE MANUAL EXTRA 300/SC Figure 2 Control Surface Deflections PAGE DATE: 12. February 2019 CHAPTER PAGE...

  • Page 65: Spacer Sleeve Displaced

    MAINTENANCE MANUAL EXTRA 300/SC Maintenance Practices N O T E When installing a bellcrank or control stick the spacer sleeve inside the bearing could be displaced as shown in Figure 3. Use a mandrel to adjust the spacer sleeve. Figure 3...

  • Page 66: Control Rods

    MAINTENANCE MANUAL EXTRA 300/SC 27-00-01 Control Rods Removal/Installation Refer to Figure 8. All control rods are attached to the control levers in the same way with LN bolts, washers and self- locking nuts. The control rods inside the wing are intercon- nected by ground bonding leads fastened to the rod ends by additional nuts.

  • Page 67: Control Rod Identification

    MAINTENANCE MANUAL EXTRA 300/SC Figure 6 Control Rod Identification g i l ° 0 ! t s ° 0 ° 0 ° 0 ° 0 Table 1 Control Rod Measurement & Rod End Alignment Length Adjustment I M P O R T A N T Do not adjust control rod No 0 (See Figure 6).

  • Page 68: Aluminium Control Rod Check Hole

    MAINTENANCE MANUAL EXTRA 300/SC I M P O R T A N T Ensure that the rod ends of each control rod are ex- actly aligned to each other (see Table 1) after adjust- ment. This particularly applies for the control rod (1, Figure 6), which must allow the torque tube to rotate.

  • Page 69: Bellcranks

    MAINTENANCE MANUAL EXTRA 300/SC 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 70: Control Stick

    MAINTENANCE MANUAL EXTRA 300/SC 27-00-03 Control Stick Removal/Installation Refer to Figure 9. 1 Remove the leather protection cuff. 2 Disconnect the electrical wiring. 3 Remove the control stick attachment bolt (1). 4 Disconnect the control stick from the control rod per Chap- ter 27-00-01.

  • Page 71: Torque Tube

    MAINTENANCE MANUAL EXTRA 300/SC 27-00-04 Torque Tube Removal/Installation 1 Remove the respective access panels. 2 Remove the control stick and the respective rod per Chap- ters 27-00-01 and 27-00-03. 3 Loosen the bolts of the front and rear bearing blocks.

  • Page 72: Ailerons

    MAINTENANCE MANUAL EXTRA 300/SC 27-10-00 AILERONS Description and Operation (Refer to Figure 10) The aileron (1) is direct mechanical linked to the control stick (3) by the aileron center linkage (7) with spade arm, push-pull rods (4), bellcranks (5-6) and the torque tube (2).

  • Page 73: Aileron Control

    MAINTENANCE MANUAL EXTRA 300/SC Figure 10 Aileron Control PAGE DATE: 12. February 2019 CHAPTER PAGE...

  • Page 74: Neutral Position Of Control Stick

    MAINTENANCE MANUAL EXTRA 300/SC Secure the control stick in the neutral position (Figure 11). neutral position equal Figure 11 Neutral Position of Control Stick Check if the control rods connecting the torque tube and the inner wing bellcranks have correct length (Refer to Chap- ter 27-00-01).

  • Page 75: Spades

    MAINTENANCE MANUAL EXTRA 300/SC Check if the movement of the control sticks is free over the whole travel range and check if the control stick travel is symmetrically to each side. If it is not contact the manufac- turer. 27-10-01...

  • Page 76: Rudder Control

    MAINTENANCE MANUAL EXTRA 300/SC 27-20-00 RUDDER CONTROL Description and Operation (Refer to Figure 14) The rudder pedals (1) are connected via a cable system (2) to the bottom hinge bellcrank (3). The cables are guided by fairleads. Pedal retracting springs keep the cables under tension when they are not operated.
  • Page 77 MAINTENANCE MANUAL EXTRA 300/SC Figure 14 Rudder Control PAGE DATE: 12. February 2019 CHAPTER PAGE...

  • Page 78: Rudder

    MAINTENANCE MANUAL EXTRA 300/SC 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 79: Bottom Hinge Bracket

    MAINTENANCE MANUAL EXTRA 300/SC 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 80 MAINTENANCE MANUAL EXTRA 300/SC For detailed explanations concerning control cables refer to AC 43.13-1B, chapter 7, section 8. Inspection and Repair of Control Cables and Turnbuckles. Inspection Procedure Refer to the Control Cable Replacement Criteria Paragraph. Visually inspect the structure and other components located next to fairleads for cracks and traces of lubrication splashes caused by control cable wires sticking out.
  • Page 81 MAINTENANCE MANUAL EXTRA 300/SC Visually inspect each flight control cable exterior and interior along its entire length for evidence of broken wires, corrosion, fraying or other damage. Visual inspection may be via direct sight, mirror and flashlight or borescope. Bend and twist cable for proper inspection.

  • Page 82: Cable Wear Patterns

    MAINTENANCE MANUAL EXTRA 300/SC Rudder Control Cable Replacement Criteria EXTRA has defined the following replacement criteria when inspecting the rudder control cables: · Any cable assembly that has one single broken wire must be replaced. · Replace cable when worn areas on the individual wires in each strand appear 40% or more (as depicted in Figure 15).

  • Page 83: Pedal Adjustment Position

    Remove the control cable by pulling it out to the back. Installation Refer to Figure 18. Use only control cables manufactured by EXTRA Flugzeugproduktions- und Vertriebs GmbH. Those cables are prepared for simple installation. Remove the respective access panels per Chapter 51.

  • Page 84: Pedal Fix Template

    MAINTENANCE MANUAL EXTRA 300/SC 230 mm (9.06”) 205 mm (8.07”) Figure 17 Pedal Fix Template Secure the rudder in 0°-position. Check that the 550 mm PTFE protective hose is placed on the pre-assembled control cable. Mount the shackle of the pre-assembled control cable end to the front cable attachment point.
  • Page 85 MAINTENANCE MANUAL EXTRA 300/SC I M P O R T A N T Clamping has to be performed in accordance with the Service Bulletin 300-1-93 and the Instruction No. 32 of the National Telephone Supply Co., Cleveland Ohio. Consider to let a distance of 1 mm between the thimble and the sleeve and clamp the sleeve.

  • Page 86: Control Cable Installation

    MAINTENANCE MANUAL EXTRA 300/SC Figure 18 Control Cable Installation PAGE DATE: 12. February 2019 CHAPTER PAGE...

  • Page 87: Fairleads

    MAINTENANCE MANUAL EXTRA 300/SC 27-20-05 Fairleads Removal/Installation Remove the fairlead retaining clip. Pull the fairlead halves out of the sleeve. Reverse procedure to install the fairlead. 27-20-06 Rudder Pedals Removal/Installation Remove control cable as per Chapter 27-20-04. Drain the brake system.

  • Page 88: Elevator And Tab

    MAINTENANCE MANUAL EXTRA 300/SC 27-30-00 ELEVATOR AND TAB Description and Operation Refer to Figure 19. The control movements are transferred from the control stick (1) to the elevator (9) by push-pull rods (2), a rocker type bellcrank (3) and an actuator arm (4).

  • Page 89: Elevator And Trim Tab Control

    MAINTENANCE MANUAL EXTRA 300/SC Figure 19 Elevator and Trim Tab Control PAGE DATE: 12. February 2019 CHAPTER PAGE...

  • Page 90: Neutral Position Of The Control Stick

    MAINTENANCE MANUAL EXTRA 300/SC 6 Loosen the hinge bolts and the ground bonding leads and remove the bolts. 7 Install in reverse sequence of removal. Observe the second Note of Chapter 27-00-00 and Figure 4. Rigging Remove the respective access panels.
  • Page 91 MAINTENANCE MANUAL EXTRA 300/SC 6 Check if the elevator travel is within the given tolerances (up/down 25°, ±1°). Use a conventional protractor. 7 Adjust the travel stops if necessary. 8 Check if the control stick travel is symmetrically. 9 If it is not, contact the manufacturer.
  • Page 92 MAINTENANCE MANUAL EXTRA 300/SC Figure 21 Trim Tab Rigging PAGE DATE: 12. February 2019 CHAPTER PAGE...
  • Page 93 MAINTENANCE MANUAL EXTRA 300/SC Table of Contents Chapter 28 Chapter Title 28-00-00 GENERAL ........4 Figure 1 Fuel System .

  • Page 94: Title

    MAINTENANCE MANUAL EXTRA 300/SC Chapter Title 28-40-03 Tubular Tank Unit (Center Tanks) ....35 28-40-04 Lever-type Tank Unit (Wing Tank) ....36 Figure 17 Lever-type Tank Unit (Wing Tank) .

  • Page 95: General

    MAINTENANCE MANUAL EXTRA 300/SC 28-00-00 GENERAL Description and Operation The fuel system (refer to Figure 1) consists of the front center tank (2), the rear center tank (4) an acro tank (6), two wing tanks (1&5), a fuel selector valve (3), a gascolator (9), an electric driven boost pump (7) and an engine driven rotary pump (8).

  • Page 96: Figure 1

    MAINTENANCE MANUAL EXTRA 300/SC Figure 1 Fuel System PAGE DATE: 12. February 2019 CHAPTER PAGE...
  • Page 97 MAINTENANCE MANUAL EXTRA 300/SC Refueling/Defueling Refer to Chapter 12 for detailed refueling/defueling proce- dures. Reduction of Fuel Tank Vapor Hazards (General Precautions) During all ventilation or maintenance procedures involving the fuel system, observe the following general precautions. Defueling should be outdoors with the aircraft at least 100 feet from hangars or other aircraft.
  • Page 98 MAINTENANCE MANUAL EXTRA 300/SC W A R N I N G When fuel is being drained, there is little control over the release of fuel vapor. This vapor should be dissi- pated as quickly as possible. Compressed air or explo- sion-proof blowers may be used for the purpose.

  • Page 99: Storage

    MAINTENANCE MANUAL EXTRA 300/SC 28-10-00 STORAGE Description and Operation The EXTRA 300/SC is equipped with two independent fuel systems: The acro- and center tanks system and the wing tank system. The acro tank (1, Figure 2) incorporating an inverted flight fuel supply system is mounted in the fuselage just behind the firewall.

  • Page 100: Figure 2

    MAINTENANCE MANUAL EXTRA 300/SC Figure 2 Storage PAGE DATE: 12. February 2019 CHAPTER PAGE...

  • Page 101: Rear Center Tank

    MAINTENANCE MANUAL EXTRA 300/SC 28-10-01 Rear Center Tank Removal/Installation Remove the main and bottom fuselage cover and the cuffs as per Chapter 51. Drain the fuel system per Chapter 12. Remove smoke tank as per Chapter 96. Disconnect the electrical bonding and the fuel quantity trans- ducer wiring from the rear center tank.

  • Page 102: Acro Tank

    MAINTENANCE MANUAL EXTRA 300/SC Remove the bottom hose fitting from the front center tank. N O T I C E Prevent the drain tube of the GRP tank shell from breaking when handling the center tank. Remove the metal attachment belts with the rubber stripes.

  • Page 103: Flop Tube (Acro Tank)

    MAINTENANCE MANUAL EXTRA 300/SC 28-10-04 Flop Tube (Acro Tank) Removal/Installation Drain the fuel system per Chapter 12-10-02. Remove the acro tank per Chapter 28-10-03. Disconnect the hose (5, Figure 3) and the elbow fitting (4). Loosen the flop tube fitting (3) and take the flop tube as- sembly (2) out of the acro tank (1).

  • Page 104: Filler Neck (Center Tanks)

    MAINTENANCE MANUAL EXTRA 300/SC 28-10-05 Filler Neck (Center Tanks) Removal/Installation Remove the main fuselage cover as per Chapter 51. Completely drain the fuel system as per Chapter 12. Loosen the lower hose clip. Remove the filler neck. Install in reverse sequence of removal.

  • Page 105: Wing Tank

    MAINTENANCE MANUAL EXTRA 300/SC 28-10-10 Wing Tank Re-Sealing Procedure The first option to solve a fuel leakage problem is to re-seal the wing fuel tank compartment from the inside with Scotch Clad 776 (refer to Chapter 51-30-04). It is not necessary to remove existing Scotch Clad 776 prior to re-sealing.

  • Page 106: Figure 5

    MAINTENANCE MANUAL EXTRA 300/SC Side view Front view Figure 5 Wing Positions For totally drying the wing tank to be sealed and to eliminate any fuel vapor: Remove the fuel filler cap. Remove the wing tank inspection door as per Chapter 28- 10-11.
  • Page 107 MAINTENANCE MANUAL EXTRA 300/SC Apply a cohesive film of Scotch Clad 776 through the inspection hole of the tank root rib (Figure 6) by using the spray gun. Rotate the complete wing around its pitch and/or roll axis step by step to ensure that the Scotch Clad 776 is dispersed all-over the leak area.

  • Page 108: Wing Tank Inspection Door

    MAINTENANCE MANUAL EXTRA 300/SC 28-10-11 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 4).

  • Page 109: Wing Tank Outlets

    MAINTENANCE MANUAL EXTRA 300/SC 28-10-12 Wing Tank Outlets Removal/Installation Remove the inspection door (1, Figure 7) per Chapter 28- 10-11. Remove the union nuts (2) and the elbow tubes (3). Remove AN 924 nut and washers and remove AN 832 fit- ting.

  • Page 110: Filler Neck (Wing Tank)

    MAINTENANCE MANUAL EXTRA 300/SC 28-10-13 Filler Neck (Wing Tank) Removal/Installation Completely drain the fuel system as per Chapter 12. Remove wing tank inspection door as per Chapter 28-10- Unscrew filler neck lock ring (4, Figure 8) with sealing lip (5) using a tool as shown in Figure 8.

  • Page 111: Filler Neck Sealing Lip

    MAINTENANCE MANUAL EXTRA 300/SC 28-10-14 Filler Neck Sealing Lip Replacement Carefully drill out the body-bound rivets (7, Figure 8). Install the new sealing lip driving in new washers (6) and body-bound rivets. Figure 8 Filler Neck and Sealing Lip Removal/Installation...

  • Page 112: Distribution

    (Refer to Figure 9) Flexible hoses and aluminium tubes (5 & 6) connect the particular components of the fuel system. The wing tanks of the EXTRA 300/SC are equipped with a separate drain line. In addition to the engine driven fuel pump (3), an electrically...

  • Page 113: Figure 9

    MAINTENANCE MANUAL EXTRA 300/SC Figure 9 Distribution PAGE DATE: 12. February 2019 CHAPTER PAGE...

  • Page 114: Fuel Selector Valve And Control Rod

    MAINTENANCE MANUAL EXTRA 300/SC 28-20-01 Fuel Selector Valve and Control Rod Removal/Installation (Refer to Figure 10) 1 Drain the fuel system per Chapter 12-10-02. 2 Disconnect the fuel lines on the selector valve. 3 Loosen the control rod attachment bolt (5).

  • Page 115: Figure 10

    MAINTENANCE MANUAL EXTRA 300/SC Figure 10 Fuel Selector Valve and Control Rod PAGE DATE: 12. February 2019 CHAPTER PAGE...

  • Page 116: Gascolator

    MAINTENANCE MANUAL EXTRA 300/SC 28-20-02 Gascolator The gascolator (1, Figure 11) is positioned in the engine compartment, mounted with a bracket on the forward side of the firewall. It is installed in the fuel line between the fuel selector valve and the electric driven boost pump.
  • Page 117 MAINTENANCE MANUAL EXTRA 300/SC Loosen the bail nut (1, Figure 12), move the bail wire (2) to the side and remove the bowl (3). Remove the gasket (4) and screen (5) from the strainer housing (6). Clean and inspect the screen (5), gasket (4), bowl (3), strainer housing (6), bail wire (2) and bail nut (1).

  • Page 118: Figure 12

    MAINTENANCE MANUAL EXTRA 300/SC Removal/Installation 1 Position the fuel selector to "OFF". 2 Drain the forward fuel system using the gascolator drain. 3 Disconnect the fuel lines on the gascolator. 4 Loosen the knurled nut (1, Figure 12). 5 Remove the mounting bracket (2).

  • Page 119: Electric Driven Boost Pump

    MAINTENANCE MANUAL EXTRA 300/SC 28-20-03 Electric Driven Boost Pump Removal/Installation 1 Position the fuel selector to "OFF". 2 Drain the forward fuel system using the gascolator drain. Disconnect the plug and the fuel lines on the boost pump. 4 Loosen the clamping device screws (1, Figure 13).

  • Page 120: Fuel Lines

    MAINTENANCE MANUAL EXTRA 300/SC 28-20-04 Fuel Lines Replacement Ventilation lines are generally connected to the system components and to each other by fittings. General information concerning hoses and fittings you find in Chapter 20-10-07/08. I M P O R T A N T...

  • Page 121: Indicating

    MAINTENANCE MANUAL EXTRA 300/SC 28-40-00 INDICATING Description and Operation (Refer to Figure 14) For fuel contents indicating the center tanks are equipped with tubular tank units (1 & 2) and the left wing tank with a lever-type tank unit (4).

  • Page 122: Figure 14

    MAINTENANCE MANUAL EXTRA 300/SC Figure 14 Indicating PAGE DATE: 12. February 2019 CHAPTER PAGE...

  • Page 123: Fuel Quantity Indicator

    MAINTENANCE MANUAL EXTRA 300/SC 28-40-01 Fuel Quantity Indicator Removal/Installation Disconnect battery. Loosen the nuts, remove the mounting bracket and re- move the fuel quantity indi- cator. Disconnect the wiring (the lamp is not used). Install in reverse sequence of removal.

  • Page 124: Figure 15

    MAINTENANCE MANUAL EXTRA 300/SC Signal Stud Ground Stud = “S” = “G” Tubular Tank Unit Signal Stud Ground Stud “I” = Ignition Voltage (+12 VDC) Fuel Quantity Indicator Figure 15 Wiring Diagram Datcon System Tubular Tank Unit SEND (Ground) Figure 16 Wiring Diagram Centroid Products System PAGE DATE: 12.

  • Page 125: Fuel Quantity Indicator (Center Tanks)

    MAINTENANCE MANUAL EXTRA 300/SC 28-40-02 Fuel Quantity Indicator (Center Tanks) Calibration (VDO system only) 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“-posi- tion by turning the adjust- ment screw.

  • Page 126: Tubular Tank Unit (Center Tanks)

    MAINTENANCE MANUAL EXTRA 300/SC 28-40-03 Tubular Tank Unit (Center Tanks) For VDO-System: The ground wire is connected to one attachment bolt of the tubular tank unit . For Datcon-System: The ground wire is connected to the ground stud (also refer...

  • Page 127: Lever-Type Tank Unit (Wing Tank)

    MAINTENANCE MANUAL EXTRA 300/SC 6 Clean sealing surfaces mechanically and with Acetone. 7 Install in reverse sequence of removal after applying Scotch Clad 776 (see Chapter 51-30-04) for sealing to both sides of the sealing ring. For the Datcon system: Torque sealing screws to 9-12 in.lbs.

  • Page 128: Float Wire

    MAINTENANCE MANUAL EXTRA 300/SC 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. Keep solvent contain- ers covered when not in use.

  • Page 129: Float Wire Installation

    MAINTENANCE MANUAL EXTRA 300/SC Reinstall the float wire observing the distances shown in Figure 19, pay attention to a proper alignment and tighten well the attachment bolt. Figure 19 Float Wire Installation Reinstall the lever-type tank unit per Chapter 28-40-04.
  • Page 130 MAINTENANCE MANUAL EXTRA 300/SC 31-10-00 INSTRUMENT PANEL Description and Operation The instrument panel consists of an aluminium sheet which is canted several times. It is fastened to the main fuselage cover and the steel frame with machine screws, bolts and special washers.
  • Page 131 MAINTENANCE MANUAL EXTRA 300/SC Chapter 32 Table of Contents Chapter/Figure Title 32-10-00 LANDING GEAR ......3 Figure 1 Wheel Rake and Toe-in .

  • Page 132: Main Landing Gear

    MAINTENANCE MANUAL EXTRA 300/SC 32-10-01 Main Landing Gear Removal/Installation Refer to Figure 2 Remove the engine cowling, the landing gear cuffs and fairings, and the bottom fuselage cover per Chapter 51. Shore the aircraft as per Chapter 07-20-00 Drain brake system.

  • Page 133: Main Landing Gear Mounting

    MAINTENANCE MANUAL EXTRA 300/SC Figure 2 Main Landing Gear Mounting 32-10-03 Wheel Axle Removal/Installation Remove wheel fairing as per chapter 32-40-02. Remove wheel. Remove the four wheel axle attachment bolts and remove the axle, the reinforcement plate and the wheel fairing holder plate.

  • Page 134: Tail Spring

    MAINTENANCE PRACTICES Top Half of the Mounting Clamp MAINTENANCE MANUAL EXTRA 300/SC 32-10-04 Tail spring Removal/Installation Refer to Figure 3. Shore the tail as per Chapter 07-20-02. Remove the tail cone access panel as per Chapter 51-00- Remove the tail spring attachment bolts (1-3).

  • Page 135: Main Wheel

    MAINTENANCE MANUAL EXTRA 300/SC 32-40-01 Main Wheel Removal Refer to Figure 4. Shore the aircraft as per Chapter 07-20-01. Remove bolts (6) with washers (7), brake back plate (4) with lining, and insulator shim (5). Remove cotter pin and axle nut (1).

  • Page 136: Main Wheel Fairing

    MAINTENANCE MANUAL EXTRA 300/SC Install the outer spacer ring (2), place the rounded edge (8) inboard). Install the axle nut with cotter pin (1). Install brake back plate (4) with lining, insulator shim (5), and bolts (6) with washers (7). Secure bolts with safety wire.

  • Page 137: Layer Sequence Wheel Fairing

    MAINTENANCE MANUAL EXTRA 300/SC Figure 5 Layer Sequence Wheel Fairing PAGE DATE: 12. February 2019 CHAPTER PAGE...

  • Page 138: Brake System

    MAINTENANCE MANUAL EXTRA 300/SC Figure 6 Brake System PAGE DATE: 12. February 2019 CHAPTER PAGE...

  • Page 139: Master Cylinder

    MAINTENANCE MANUAL EXTRA 300/SC 32-40-04 Master Cylinder Removal/Installation Drain the brake system. Disconnect the brake lines. Remove the attachment bolts. Remove the master cylinder. Install in reverse sequence of removal. PAGE DATE: 12. February 2019 CHAPTER PAGE...
  • Page 140 MAINTENANCE MANUAL EXTRA 300/SC Chapter 51 Table of Contents Chapter/Figure Title 51-00-00 GENERAL ........3 51-00-01 Access Panel Identification .

  • Page 141: Investigation

    N O T E Only the Damages Classes 2, 3 and 4 may be repaired by qualified personnel. In case of Damage Class 1 it has to be contacted EXTRA-Flugzeugproduktions- und Vertriebs- GmbH. According to the Luftfahrt-Bundesamt (Federal German Aviation Authority) four damage classes are defined:...

  • Page 142: Materials

    MAINTENANCE MANUAL EXTRA 300/SC 51-30-00 MATERIALS This Section describes metallic and non-metallic materials used in the repair of the EXTRA 300/SC 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 143 MATERIALS MAINTENANCE MANUAL EXTRA 300/SC Composite Parts Carbon fibre fabrics Manufacturer: CCC, C. Cramer GmbH & Co. KG Postfach 209, D-48619 Heek-Nienborg, Germany Style WLB-No.* weave weight US-style DIN 65147 patterns g/m² 8.3507.80 none plain 8.3520.80 none twill 2/2 cross-...

  • Page 144: Metal Components

    MATERIALS MAINTENANCE MANUAL EXTRA 300/SC Composite Part Materials 929-73 Glassodur-MS-Härter SC 29-0173 352-91 Glassodur-Einstellzusatz SV 41-0391 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 51-30-02 Metal Components...

  • Page 145: Various Components

    MAINTENANCE MANUAL EXTRA 300/SC 51-30-04 Various Components Fabric Manufacturer: CECONITE 4343 Fort Drive PO Box 3129 Riverside, CA 92519 800-362-3490 Email: info@ceconite.com Supplier: SIEBERT LUFTFAHRTBEDARD GmbH Rektoratsweg 40 D-48159 Münster Germany 49-251-92459-3 www.siebert-luftfahrbedard.de Type: CECONITE 102 Firewall Sealant Observe Chapter 20-10-10 when working with firewall sealant.
  • Page 146 MAINTENANCE MANUAL EXTRA 300/SC Manufacturer: Chem Seal Products Manuf. By The Flamemaster Corporation 13576 Desmond Street, Pacoima, CA 91331-2315 www.the flamemaster.com Supplier: NSL Aerospace 33110 Old Hempstead Rd. Magnolia, TX 77355 www.nslaerospace.com Type: CS 1900 Manufacturer: Cytec Engineered Materials Inc.

  • Page 147: Control Surface Balancing

    MAINTENANCE MANUAL EXTRA 300/SC 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 148 CONTROL SURFACE BALANCING MAINTENANCE MANUAL EXTRA 300/SC Weighing and Determination of Control Surface Moments Balancing Mandrels Prepare mandrels as shown on detail A in Figure 2 for balancing the rudder and the elevator. Prepare mandrels shaped as shown on detail B for balancing the ailerons.

  • Page 149: Figure 3

    CONTROL SURFACE BALANCING MAINTENANCE MANUAL EXTRA 300/SC Weighing and Determination of Control Surface Moments Figure 3 Determination of Control Surface Moments PAGE DATE: 12. February 2019 CHAPTER PAGE...

  • Page 150: Figure 4

    CONTROL SURFACE BALANCING MAINTENANCE MANUAL EXTRA 300/SC Weighing and Determination of Control Surface Moments Permissible Weights and Moments Aileron (one control surface) incl. mass balance, without spades Mass: 4.6 - 5.3 kg Moment: 135 - 169 Ncm incl. mass balance, with spades Mass: 5.1 - 5.8 kg...

  • Page 151: Repairs

    MAINTENANCE MANUAL EXTRA 300/SC 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. If the aircraft is damaged, proceed as follows. First conduct a careful visual inspection of the surface and the damaged area.
  • Page 152 REPAIRS MAINTENANCE MANUAL EXTRA 300/SC Repair of Reinforced Glass and Carbon Fibre Components 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 153: Repair Of Sandwich Material

    REPAIRS MAINTENANCE MANUAL EXTRA 300/SC 51-70-02 Repair of Sandwich Material Two types of core materials are used for sandwich on the EXTRA 300/SC: - PVC hard foam - Honeycomb both with glass or carbon fibre shells The following section describes the repair of both types of sandwich.
  • Page 154 REPAIRS MAINTENANCE MANUAL EXTRA 300/SC Repair of Sandwich Material 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...

  • Page 155: Figure 6

    REPAIRS MAINTENANCE MANUAL EXTRA 300/SC Repair of Sandwich Material 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 156 REPAIRS MAINTENANCE MANUAL EXTRA 300/SC Repair of Sandwich Material 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 157: Figure 8

    REPAIRS MAINTENANCE MANUAL EXTRA 300/SC Repair of Sandwich Material 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. Subse- quently position them on the repair area.

  • Page 158: Repair Of Laminates

    REPAIRS MAINTENANCE MANUAL EXTRA 300/SC 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. Minimum lenght of scarf per fabric layer approx. 20 mm;...
  • Page 159 REPAIRS MAINTENANCE MANUAL EXTRA 300/SC Repair of Laminates 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 160: Figure 9

    REPAIRS MAINTENANCE MANUAL EXTRA 300/SC Repair of Laminates 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 re- pair area.
  • Page 161 REPAIRS MAINTENANCE MANUAL EXTRA 300/SC Repair of Laminates 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 162: Repair Of Spars

    REPAIRS MAINTENANCE MANUAL EXTRA 300/SC Repair of Laminates - 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 163: Structural Repair Of Steel Components

    Practices – Aircraft Alterations FAA AC 43.13-2B". I M P O R T A N T Alterations or repair of the airplane must be accom- plished by licensed personnel. Consult EXTRA- FLUGZEUGPRODUKTIONS- UND VERTRIEBS- GmbH in case of doubt about a repair not specifically mentioned there.

  • Page 164: Repair Of Fabric

    Repair of Fabric I M P O R T A N T Alterations or repair of the airplane must be accom- plished by licensed personnel. Consult EXTRA- FLUGZEUGPRODUKTIONS- UND VERTRIEBS- GmbH in case of doubt about a repair not specifically mentioned there.

  • Page 165: Aluminium And Steel Components Refinishing

    REPAIRS MAINTENANCE MANUAL EXTRA 300/SC N O T E The Rapid Filler must be completely dry before the cov- ering paint can be applied. For the final sanding, use 400 grade wet sandpaper to achieve a smooth clean surface. Allow surface to dry. Paint applica- tion of Glassodur-Pur-Acryl-Lack AD/AE 21 two compo- nent acryl paint is performed with a spray gun.
  • Page 166 REPAIRS MAINTENANCE MANUAL EXTRA 300/SC Aluminium and Steel Components Refinishing After cleaning, thoroughly dry all metal parts with filtered, dry compressed air. It is recommended that all O-rings, backup rings, and wip- ers be replaced at each overhaul. However, if necessary, O- rings may be reused, but should be put back into position from which removed.
  • Page 167 REPAIRS MAINTENANCE MANUAL EXTRA 300/SC Aluminium and Steel Components Refinishing Where applicable refer to inspections procedures given in the respective chapters for specific parts to locate possible defects. N O T E Refinishing should be completed as soon as possible;...

  • Page 168: Re-Bonding Of Bushings

    MAINTENANCE MANUAL EXTRA 300/SC 51-70-09 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 169 Contact Extra Flugzeugproduktions- und Vertriebs GmbH for advice and repair instructions. Remove any residual resin debris existing on the outer bond- ing surface of the bushing.
  • Page 170 MAINTENANCE MANUAL EXTRA 300/SC (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 171: Figure 11

    MAINTENANCE MANUAL EXTRA 300/SC 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 172 MAINTENANCE MANUAL EXTRA 300/SC identified, oversized flange bushing are needed. Contact Extra Flugzeugproduktions- und Vertriebs GmbH for advice and repair instructions. Use a mixture of epoxy-resign Epikote Resin L20 with Epikure Curing Agent 960 (for mixing ratio ref. Chapter 51- 30-01) and cotton flocks.
  • Page 173 MAINTENANCE MANUAL EXTRA 300/SC Remove sanding dust with a pneumatic vacuum cleaner and solvent clean the surface area of the hole in the spar web with isopropyl alcohol, carbon-tetrachloride or acetone in case dirt or grease was introduced during the preparation.
  • Page 174 MAINTENANCE MANUAL EXTRA 300/SC Repeat the procedure in case the flange bushing on the op- posite side has to be re-bonded as well. Reinstall the wing. Refer to the applicable Chapter of this Manual. PAGE DATE: 12. February 2019 CHAPTER...
  • Page 175 MAINTNANCE MANUAL EXTRA 300/SC Table of Contents Chapter 53 Chapter Title 53-00-00 GENERAL ........3 Figure 1 Fuselage Steel Tube Design .

  • Page 176: General

    GENERAL MAINTNANCE MANUAL EXTRA 300/SC Figure 2 Layer Sequence Top Half of the Engine Cowling up to SN SC059 PAGE DATE: 12. February 2019 CHAPTER PAGE...

  • Page 177: Layer Sequence Top Half Of The Engine Cowling

    MAINTNANCE MANUAL EXTRA 300/SC Figure 3 Layer Sequence Top Half of the Engine Cowling from SN SC060 PAGE DATE: 12. February 2019 CHAPTER PAGE...

  • Page 178: Layer Sequence Bottom Half Of The Engine Cowling

    GENERAL MAINTNANCE MANUAL EXTRA 300/SC Figure 4 Layer Sequence Bottom Half of the Engine Cowling up to SN SC059 PAGE DATE: 12. February 2019 CHAPTER PAGE...

  • Page 179: Layer Sequence Bottom Half Of The Engine Cowling

    MAINTNANCE MANUAL EXTRA 300/SC Figure 5 Layer Sequence Bottom Half of the Engine Cowling from SN SC060 PAGE DATE: 12. February 2019 CHAPTER PAGE...

  • Page 180: Layer Sequence Main Fuselage Cover

    GENERAL MAINTNANCE MANUAL EXTRA 300/SC Figure 6, Sheet 1 Layer Sequence Main Fuselage Cover PAGE DATE: 12. February 2019 CHAPTER PAGE...
  • Page 181 MAINTNANCE MANUAL EXTRA 300/SC Figure 6, Sheet 2 Layer Sequence Main Fuselage Cover PAGE DATE: 12. February 2019 CHAPTER PAGE...

  • Page 182: Layer Sequence Side Cover

    GENERAL MAINTNANCE MANUAL EXTRA 300/SC Figure 7 Layer Sequence Side Cover PAGE DATE: 12. February 2019 CHAPTER PAGE...
  • Page 183 MAINTNANCE MANUAL EXTRA 300/SC Figure 8 Layer Sequence Side Cover PAGE DATE: 12. February 2019 CHAPTER PAGE...

  • Page 184: Canopy

    MAINTNANCE MANUAL EXTRA 300/SC 53-00-10 Canopy Removal/Installation Open canopy. C A U T I O N 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 185: Canopy Position Markings

    MAINTNANCE MANUAL EXTRA 300/SC Position markings Position markings Figure 10 Canopy position markings Secure the canopy glass in the frame. Draw a positioning line (see Figure 9) and position markings on the inside (see Figure 10). Prepare canopy glass for bonding.

  • Page 186: Canopy Adhesive Remainders

    MAINTNANCE MANUAL EXTRA 300/SC Filler Figure 12 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). Mix ap- proximately 15 seconds after a uniform color is obtained.
  • Page 187 MAINTNANCE MANUAL EXTRA 300/SC Sand down (using Scotch Brite Handpad Fine) the overlap- ping part between canopy glass and canopy frame on the in- side (Area B in Figure 12). Apply primer (Glasurit 934-0) and refinish the area (Nextel). PAGE DATE: 12. February 2019...

  • Page 188: Bottom Fuselage Cover

    MAINTNANCE MANUAL EXTRA 300/SC 53-00-04 Bottom Fuselage Cover Removal Remove engine cowling as per Chapter 71, the landing gear cuffs and main fuselage cover in accordance with this chap- ter. Pull the plug of the optional OAT sensor wiring, if appli- cable.
  • Page 189 MAINTNANCE MANUAL EXTRA 300/SC Install bottom fuselage cover attachment screws. Install bottom cowling attachment screws (one on either side) without cowling present (see two outer circles in Fig- ure 13). Loosen clamp screws on gascolator drain and fuel pump vent lines for easy access (see inner dotted circles).
  • Page 190 MAINTENANCE MANUAL EXTRA 300/SC 57-00-00 GENERAL Description and Operation 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 honey- comb sandwich construction with carbon fibre laminates.
  • Page 191 MAINTENANCE PRACTICES MAINTENANCE MANUAL EXTRA 300/SC Wing Figure 2 Shims Installation Slide in shims if necessary and install the main spar tubular bolts (4, Figure 3) to the wing flange bushings (11) from front to rear. Secure main spar tubular bolts with LN 9038-08020K (2) bolts or LN 9037-08020K (2), DIN912 M8 washers and special aluminum washers (30x11x4).
  • Page 192 MAINTENANCE PRACTICES MAINTENANCE MANUAL EXTRA 300/SC Wing prefitted plugs per respective Chapters. Connect instrument wet lines (except when MVP-50P is installed). Reinstall breather line, canopy, engine cowlings and main fuselage cover. Figure 3 Wing Removal/Installation PAGE DATE: 12. February 2019...
  • Page 193 MAINTENANCE MANUAL EXTRA 300/SC 61-20-00 CONTROLLING The propeller blade pitch change is conducted by a governor (refer to Figure 1). Once an engine rotational speed is selected it will be held constant independent of airspeed or power variations. Mechanical stops for low pitch and high pich within the hub limit the pitch change level.
  • Page 194 MAINTENANCE MANUAL EXTRA 300/SC clamp sheets and contained plastic guidance from the en- gine baffle. Remove 2 bolts of the clamp sheet attachment positioned at the firewall break through (10). Disconnect clamp sheet and contained plastic guidance from the rear side of the firewall.
  • Page 195 MAINTENANCE MANUAL EXTRA 300/SC Oil temperature is limited by installation of a single oil cooler. Ignition is a magneto type with 2 independent systems. The complete power plant is attached to the fuselage struc- ture using 4 mounting points and rubber vibration absorbers.
  • Page 196 MAINTENANCE MANUAL EXTRA 300SC Chapter 73 Table of Contents Chapter, Figure Title 73-20-00 CONTROLLING ......3 73-20-10 Throttle .

  • Page 197: Controlling

    MAINTENANCE MANUAL EXTRA 300SC 73-20-00 CONTROLLING 73-20-10 Throttle Refer to Figure 1. The throttle is controlled by means of the throttle control lever located on the left side of the cockpit. The throttle control lever transfers its movements to the throttle by means of the throttle control cable.

  • Page 198: Throttle Control Cable

    MAINTENANCE MANUAL EXTRA 300SC Remove rod end counter nut and throttle control cable pro- tective swivel and wiper seal. Remove clamp block (1, Figure 3) attachment bolt(s). Remove clamp block from the throttle control cable. Pull complete throttle control cable aft to remove from air- craft.
  • Page 199 MAINTENANCE MANUAL EXTRA 300SC Install cable ties in the cockpit area on positions as marked before. Install fire sleeve to the throttle control cable and secure with safety wires at both ends (refer to Figure 2). Install cushioned clamp (4, Figure 4) or cable ties.
  • Page 200 MAINTENANCE MANUAL EXTRA 300SC Screw the rod end onto the threaded terminal. Tighten the counternut to prevent rod end from loosening. Install the rod end to the throttle control lever with bolt, washers, castle nut and cotter pin (3, Figure 3). Tighten the castle nut slightly.

  • Page 201: Throttle Control Lever

    MAINTENANCE MANUAL EXTRA 300SC 73-20-12 Throttle Control Lever Figure 3, Sheet 1 Throttle Control Lever Figure 3, Sheet 2 Throttle Control Lever with Travel Stops PAGE DATE: 12. February 2019 CHAPTER PAGE...
  • Page 202 The spring-back is the small extra push that is needed for the throttle control lever to hit its mechanical stops. Refer to Figure 4, Sheet 1 or 2 depending on the exhaust system installed and Figure 3, Sheet 2.

  • Page 203: Throttle Control Cable Rigging Standard Exhaust

    MAINTENANCE MANUAL EXTRA 300SC 15° Figure 4, Sheet 1 Throttle Control Cable Rigging Standard Exhaust 15° 15° Figure 4, Sheet 2 Throttle Control Cable Rigging Option Exhaust PAGE DATE: 12. February 2019 CHAPTER PAGE...
  • Page 204 MAINTENANCE MANUAL EXTRA 300SC Place throttle actuator to full idle travel stop position. Check distance "d" (refer to Figure 4) between protektive wipper seal end and the beginning of the terminal thread depending on the configuration as outlined in the following table.
  • Page 205 MAINTENANCE MANUAL EXTRA 300SC " " ± ( ± ( Move the throttle control lever (4, Figure 3) in full WOT position (as shown in Figure 3). Check throttle actuator (1, Figure 4) of the fuel injector servo reached travel stop for full WOT position.

  • Page 206: Mixture Control

    MAINTENANCE MANUAL EXTRA 300SC Side View Figure 5 Mixture Control 73-20-21 Mixture Control Cable The mixture control cable is a Vernier type cable connecting the mixture control unit (1, Figure 5) with the mixture actuator (3). Refer to Chapter 20 for general information about handling control cables.
  • Page 207 MAINTENANCE MANUAL EXTRA 300SC Loosen counter nut and remove the rod end (2) from the mixture control cable. Remove rod end counter nut and mixture vernier control cable protective swivel and wiper seal. Remove clamp block (1) attachment bolt. Remove clamp block (1) from the vernier mixture control cable.

  • Page 208: Clamp Sheet To Clamp Block Distance

    MAINTENANCE MANUAL EXTRA 300SC Side View 555 mm Figure 6 Clamp Sheet to Clamp Block Distance Renew the sealing of the firewall breakthrough at the engine side of the firewall. Use firewall sealant as outlined in Chapter 51-30-04. Let the sealant slightly cure before thightening the clamp sheet attachment bolts.

  • Page 209: Over-Travel At Mixture Control Unit

    MAINTENANCE MANUAL EXTRA 300SC Install rod end to mixture actuator with bolt, washers, castle nut and cotter pin. Tighten the castle nut slightly. Ensure movability of actuator. Install the firewall forward cable ties on positions as marked before. Perform Mixture Vernier Control Cable Rigging.

  • Page 210: Mixture Control Cable Rigging

    MAINTENANCE MANUAL EXTRA 300SC Figure 8 Mixture Control Cable Rigging PAGE DATE: 12. February 2019 CHAPTER PAGE...

  • Page 211: Indicating

    MAINTENANCE MANUAL EXTRA 300SC 73-30-00 INDICATING Fuel pressure is sensed on the EXTRA 300SC 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 212: Fuel Pressure Sense Line

    MAINTENANCE MANUAL EXTRA 300SC Figure 9 Fuel Pressure Sense Line 73-30-11 Fuel Pressure Gauge Removal/Installation Refer to Chapter 31. PAGE DATE: 12. February 2019 CHAPTER PAGE...

  • Page 213: Sense Line

    MAINTENANCE MANUAL EXTRA 300SC 73-30-12 Sense Line Removal/Installation 1 Remove cowling per Chapter 71. 2 Remove clamps. N O T I C E Pick up spilling fluid, when disconnecting a sense line. 3 Disconnect the sense line from the fitting.
  • Page 214 MAINTENANCE MANUAL EXTRA 300SC Chapter 77 Table of Contents Chapter/Figure Title 77-00-00 GENERAL ........3 Figure 1 Engine Sensor Locations .

  • Page 215: General

    MAINTENANCE MANUAL EXTRA 300SC 77-00-00 GENERAL See Chapter 77-40 when MVP-50P is installed. The following engine instruments are installed in the EXTRA 300SC: 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 216: Power

    MAINTENANCE MANUAL EXTRA 300SC 77-10-00 POWER 77-10-10 Engine speed data in the EXTRA 300SC is obtained from the ignition switch. The tachometer is located in the rear instru- ment panel and requires electrical supply bus voltage. 77-10-11 Tachometer Removal/Installation Refer to Chapter 31.

  • Page 217: Sintered Bronze Filter Location (Mvp-50)

    MAINTENANCE MANUAL EXTRA 300SC Sense line Bulkhead fitting Filter Firewall Figure 2b Sintered Bronze Filter Location (MVP-50) 77-10-21 Manifold Pressure Gauge Removal/Installation Refer to Chapter 31. 77-10-22 Sense Line Engine Compartment Removal/Installation 1 Remove cowling per Chapter 71. 2 Remove clamps if applicable.
  • Page 218 MAINTENANCE MANUAL EXTRA 300SC 77-40-00 INTEGRATED ENGINE INSTRUMENT SYSTEMS 77-41-00 Electronics International MVP-50P The EXTRA 300SC can be equipped with the MVP-50P Glass Panel Engine Monitor. The system as installed in the EXTRA 300SC consists of: Item Location Main Engine Screen...
  • Page 219 Passwords The Level #1 password (for maintenance) is 00200. For system configurations requiring the Level #2 Password, contact Extra Flugzeugproduktions- & Vertriebs-GmbH. Features Refer to the MVP-50P documentation of Electronics Inter- national Inc. (see Chapter 1) for detailed information about features.

  • Page 220: Figure 3

    MAINTENANCE MANUAL EXTRA 300SC Instrument Panel Layout Generally an alternate panel is used to carry the MVP-50P as shown in Figure 3. Alt W Lt Master Boost Smoke OV Protect Alt Output Smoke Starter MVP-50 XPDR Trim 12 V Figure 3 Alternate Panel Layout Pos.
  • Page 221 MAINTENANCE MANUAL EXTRA 300SC 77-41-01 Main Engine Screen The MVP-50P Main Engine Screen (see Figure 4) displays the primary engine and aircraft instruments. This screen is displayed on power-up and is the screen that should be monitored during flight. Figure 4...

  • Page 222: Mounting Sheets

    MAINTENANCE MANUAL EXTRA 300SC 77-41-02 Mounting Sheets To carry the engine data converter (1, Figure 5) and two modules (9, 13) mounting sheets (12, 14) are installed on the right side of the fuselage just behind the firewall. Removal/Installation Remove main fuselage cover as per Chapter 53-00-03.

  • Page 223: Figure 5

    MAINTENANCE MANUAL EXTRA 300SC Firewall Legend: 1 engine data converter 2 attachment bolt 3 electrical wiring 4 shock mount and attachment bolt 5 oil pressure transducer 6 fuel pressure transducer 7 bulkhead fitting and filter 8 tubing 9 MAP transducer...

  • Page 224: Fuel Flow Transducer

    MAINTENANCE MANUAL EXTRA 300SC 77-41-05 Fuel Flow Transducer Removal/Installation C A U T I O N Spilling fuel could inflame. Ensure exhaust is cool. BATTERY switch off. Remove engine cowlings as per Chapter 71-10-00. Remove the fire sleeve (6). Disconnect the fuel hoses (3, Figure 6) from the transducer (4).

  • Page 225: Probes And Transducers

    MAINTENANCE MANUAL EXTRA 300SC 77-41-06 Probes and Transducers The CHT probes are screwed to the respective ports on the engine (see Figure 7). The EGT probes are attached to the exhaust pipes with clamps (see Figure 7). The OT probe is screwed to the respective port on the aft engine side (see 79-30-20).
  • Page 226 MAINTENANCE MANUAL EXTRA 300/SC Table of Contents Chapter 91 Figure Title EA-9C102B POWER GENERATION/DISTRIBUTION (UP TO SN SC027) EA-9C102C POWER GENERATION/DISTRIBUTION (SN SC028 THRU SC039) EA-9C102D POWER GENERATION/DISTRIBUTION (FROM SN SC040 THRU SC041) EA-9C102E POWER GENERATION/DISTRIBUTION (FROM SN SC042) EA-9C102F...
  • Page 227 MAINTENANCE MANUAL EXTRA 300/SC EA-9C102.27A Ampere Indication (SN SC003 thru SC019 and SC022) EA-9C102.27B Ampere Indication (from SN SC020 exc. SC022) EA-93102.28 Fuel Flow EDM700 EA-93102.29 Fuel Flow EDM800 EA-9C102.30 RPM Indication (up to SN SC005) EA-9C102.30A RPM Indication (from SN SC006) EA-96102.31...
  • Page 230 Version zu Freimaßtoleranz Bearb.: 05.05.08 Flugzeugbaureihe Oberflächenschutz Oberfläche Gepr.: ist der Bauakte bzw. EA 300/SC dem jeweiligen Fertigungsauftrag Gepr.: zu entnehmen. FUEL GAGES Zuordnung links / rechts wird mit */* in allen Feldern angegeben. STUD # 8-32 EA-9C102.4 ÄM-300-15-07 27.02.16...
  • Page 231 05.05.08 Freimaßtoleranz von Version zu Bearb.: Oberflächenschutz Oberfläche Flugzeugbaureihe Gepr.: ist der Bauakte bzw. EA 300/SC dem jeweiligen Fertigungsauftrag Gepr.: zu entnehmen. COM S/E GERÄT Zuordnung links / rechts wird mit */* in allen Feldern angegeben. EA-9C102.5 Schwarze Heide 21 Blatt ÄM-300-11-08...
  • Page 232 Freimaßtoleranz von Version zu 05.05.08 Bearb.: Flugzeugbaureihe Oberflächenschutz Oberfläche Gepr.: ist der Bauakte bzw. EA 300/SC dem jeweiligen Fertigungsauftrag Gepr.: zu entnehmen. SMOKE SYSTEM Zuordnung links / rechts wird mit */* in allen Feldern angegeben. EA-9C102.8 Schwarze Heide 21 Blatt ÄM-300-15-07...
  • Page 233 SI.-Klasse Freimaßtoleranz von Version zu Bearb.: 05.05.08 Oberflächenschutz Oberfläche Flugzeugbaureihe Gepr.: ist der Bauakte bzw. EA 300/SC dem jeweiligen Fertigungsauftrag Gepr.: zu entnehmen. BATTERY CIRCUIT Zuordnung links / rechts wird mit */* in allen Feldern angegeben. ÄM-300-14-17 16.05.15 EA-9C102.9 ÄM-300-11-17 22.06.11...
  • Page 234 Version zu Freimaßtoleranz Bearb.: 05.05.08 Auf Masseschiene Flugzeugbaureihe Oberflächenschutz Oberfläche Gepr.: ist der Bauakte bzw. EA 300/SC dem jeweiligen Fertigungsauftrag Gepr.: zu entnehmen. ALTERNATOR SYSTEM Zuordnung links / rechts wird mit */* in allen Feldern angegeben. EA-9C102.10 Schwarze Heide 21 ÄM-300-15-07 19.03.16...
  • Page 235 SI.-Klasse von Version zu Freimaßtoleranz Bearb.: 05.05.08 Flugzeugbaureihe Oberflächenschutz Oberfläche Gepr.: ist der Bauakte bzw. EA 300/SC dem jeweiligen Fertigungsauftrag Gepr.: zu entnehmen. ACCELEROMETER Zuordnung links / rechts wird mit */* in allen Feldern angegeben. EA-9C102.15 Schwarze Heide 21 Blatt ÄM-300-15-07...
  • Page 236 Freimaßtoleranz von Version zu 05.05.08 Bearb.: Oberflächenschutz Oberfläche Flugzeugbaureihe Gepr.: ist der Bauakte bzw. EA 300/SC dem jeweiligen Fertigungsauftrag Gepr.: zu entnehmen. EXTERNAL POWER Zuordnung links / rechts wird mit */* in allen Feldern angegeben. EA-9C102.16 Schwarze Heide 21 ÄM-300-08-11 19.12.2008 HW...
  • Page 237 Zuordnung links / rechts wird mit */* in allen Feldern angegeben. EA-93102.20 Schwarze Heide 21 Blatt OPTION 03 = TRT-800H mit COMANT CI-105 ANTENNE (für EA 300/SC & EA 300/LC) ÄM-300-14-05 24.03.14 46569 Hünxe, Germany Nr.: Änderung/Mod. Nr.: Datum Name OPTION 02 = TRT-800 mit KING KA-60 ANTENNE Ver.
  • Page 238 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 239 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 240 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 241 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 242 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 243 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 Relay EA-83290.1 9/10 REMOTE SWITCH TRANSMITTER ASSY +14 VDC P1-A ARTEX ME 406 ELT Light ONLY FOR EXCHANGE Reset 1 Reset 2 External On Ground...
  • Page 244 Version zu Bearb.: 05.05.08 Flugzeugbaureihe Oberflächenschutz Oberfläche Gepr.: ist der Bauakte bzw. EA 300/SC dem jeweiligen Fertigungsauftrag Gepr.: zu entnehmen. NOTE ELECTRIC TRIM SYSTEM Zuordnung links / rechts wird mit Alternative zu Pos.-Nr. 5 - 10 */* in allen Feldern angegeben.
  • Page 245 see POWER DISTRIBUTION 14 VDC VOLTAGE GYRO ATTITUDE GYRO POWER 9 - 32VDC POWER GROUND Option INCLINOMETER INCLINOMETER Stueck 33529 RCA 444-0010-01 WIRE AWG20 MIL-W-22759/16-20 00775 CIRCUIT BREAKER 2A 7277-2-2 31508 Stueck in Pos. 1 CONNECTOR MS3116E-4S Stueck ATTITUDE GYRO 3" RCA 2610-3-G Stueck 191g...
  • Page 246 Version zu Freimaßtoleranz Bearb.: 14.07.16 Oberflächenschutz Oberfläche Flugzeugbaureihe Gepr.: ist der Bauakte bzw. EA 300/SC dem jeweiligen Fertigungsauftrag Gepr.: zu entnehmen. DIGITAL INDICATION MVP-50P Zuordnung links / rechts wird mit */* in allen Feldern angegeben. EA-9C102.52_1 Schwarze Heide 21 Blatt 46569 Hünxe, Germany...
  • Page 247 Freimaßtoleranz von Version zu Bearb.: 22.07.16 Oberflächenschutz Oberfläche Flugzeugbaureihe Gepr.: ist der Bauakte bzw. EA 300/SC dem jeweiligen Fertigungsauftrag Gepr.: zu entnehmen. DIGITAL INDICATION MVP-50P Zuordnung links / rechts wird mit */* in allen Feldern angegeben. EA-9C102.52_2 2700 RPM Schwarze Heide 21...
  • Page 248 Version zu Freimaßtoleranz Bearb.: 27.06.16 Flugzeugbaureihe Oberflächenschutz Oberfläche Gepr.: ist der Bauakte bzw. EA 300/SC dem jeweiligen Fertigungsauftrag Gepr.: zu entnehmen. 12VDC OUTLET Zuordnung links / rechts wird mit */* in allen Feldern angegeben. EA-9C102.56 Schwarze Heide 21 Blatt 46569 Hünxe, Germany...
  • Page 249 SI.-Klasse Freimaßtoleranz Bearb.: 07.12.18 Flugzeugbaureihe Oberflächenschutz Oberfläche Gepr.: ist der Bauakte bzw. EA 300/SC dem jeweiligen Fertigungsauftrag Gepr.: zu entnehmen. AvMap EKP V Cradle Zuordnung links / rechts wird mit */* in allen Feldern angegeben. EA-9C102.78 Schwarze Heide 21 Blatt 46569 Hünxe, Germany...
  • Page 250 MAINTENANCE MANUAL EXTRA 300/SC 96-00-01 Smoke Tank Removal/Installation Remove the main and bottom fuselage cover and cuffs as per Chapter 51. Remove the instrument panel attachment screws and tilt forward the instrument panel (also refer to Chapter 31). Remove the torque tube as per Chapter 27.

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