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CHAPTER 51
PAGE 7

PAGE DATE: 7. July 2010

MAINTENANCE MANUAL EXTRA 300LT

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

All damage of composite parts must first be classified
prior to repair. Refer to chapter "51-10-01 Damage
Classification".

I M P O R T A N T

Only the Damage Classes 2, 3 and 4 may be repaired by
qualified personnel. In case of Damage Class 1 EXTRA
Flugzeugproduktions- und Vertriebs- GmbH has to be
contacted.

The decision whether to repair or replace a major unit of
structure will be influenced by factors such as time and labor
available, and by comparison of labor costs with the price of
replacement assemblies. Past experience indicates that
replacement, in many cases, is less costly than major repair.
Certainly, when the aircraft must be restored to its airworthy
condition within limited time, replacement is preferable.

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Summary of Contents for 300LT

Page 1: ...EXTRA FLUGZEUGPRODUKTIONS UND VERTRIEBS GMBH MAINTENANCE MANUAL EXTRA 300LT Doc No EA 0D702 Schwarze Heide 21 D 46569 Hünxe Germany Tel 49 28 58 91 37 0 Fax 49 28 58 91 37 30 ...

Page 2: ...nual except Chapter 4 12 June 2015 2nd Edition Revision 3 Complete Manual except Chapter 4 24 February2017 Dateand sign ofapproval EASAMAJORCHANGEAPPROVAL N 10030180 1 June 2010 Approved under the authority of DOA N EASA 21J 073 18 November 2010 Approved under the authority of DOA N EASA 21J 073 22 August 2014 The technical content of this document is approved under the authority of DOA N EASA 21J...

Page 3: ...13 7 July2010 14 7 July2010 15 21 March 2014 16 7 July2010 17 7 July2010 20 1 7 July2010 2 12 June 2015 3 7 July2010 4 7 July2010 5 7 July2010 6 7 July2010 7 7 July2010 8 12 June 2015 9 7 July2010 10 21 March 2014 11 12 June 2015 12 12 June 2015 13 12 June 2015 14 12 June 2015 15 12 June 2015 16 12 June 2015 17 12 June 2015 18 12 June 2015 19 12 June 2015 20 12 June 2015 21 1 7 July2010 2 7 July20...

Page 4: ...9 7 July2010 10 7 July2010 11 7 July2010 12 7 July2010 13 7 July2010 14 21 March 2014 15 21 March 2014 16 7 July2010 17 7 July2010 18 7 July2010 19 7 July2010 20 7 July2010 21 7 July2010 22 21 March 2014 23 7 July2010 24 7 July2010 25 7 July2010 26 12 June 2015 27 21 March 2014 28 7 July2010 31 1 7 July2010 2 24 February 2017 3 7 July2010 4 7 July2010 5 7 July2010 6 7 July2010 7 24 February 2017 8...

Page 5: ...1 7 July2010 2 24 February 2017 3 21 March 2014 4 24 February 2017 5 24 February 2017 6 24 February 2017 7 24 February 2017 8 24 February 2017 9 24 February 2017 10 24 February 2017 11 24 February 2017 72 1 7 July2010 2 7 July2010 3 7 July2010 4 7 July2010 5 7 July2010 6 7 July2010 7 7 July2010 8 7 July2010 73 1 7 July2010 2 12 June 2015 3 12 June 2015 4 12 June 2015 5 12 June 2015 6 12 June 2015 ...

Page 6: ...EA 94102 39 18 July2006 EA 94102 39A 21 February 2016 EA 9D102 42 23 March 2010 EA 9D102 42A 22 July2012 EA 9D102 42B 3 March 2016 EA 93102 43 24 October 2006 EA 9C102 44A 17 November2016 EA 9D102 46 21 April2010 EA 9D102 46A 20 October 2012 EA 9D102 47 14 April2010 EA 9D102 47A 20 October 2012 EA 9D102 48 25 April2012 EA 96102 49 7 November2013 EA 9D102 51 25 April2010 EA 9D102 51A 04 July2013 EA...

Page 7: ...PAGE F PAGEDATE 21 March2014 MAINTENANCEMANUALEXTRA300LT List of Service Bulletins Service Letters S B S L N Issue Date Subject Serial N affected German AD LTA ...

Page 8: ...AIRCRAFT General Description 3 Airworthiness Limitations 4 Time Limits Maintenance Checks 5 Dimensions andAreas 6 Lifting and Shoring 7 Levelling andWeighing 8 TowingandTaxiing 9 Parking Mooring Storage and Return to Service 10 Servicing 12 AIRFRAMESYSTEMS Standard Practices Airframe 20 Air Conditioning 21 Communications 23 Electrical Power 24 Equipment Furnishings 25 Flight Controls 27 Fuel 28 In...

Page 9: ...0LT STRUCTURES Standard Practices and Structures General 51 Fuselage 53 Stabilizers 55 Wings 57 PROPELLER Propeller 61 POWERPLANT Power Plant 71 Engine 72 Engine Fuel and Control 73 Engine Indicating 77 Exhaust 78 OilSystem 79 Charts 91 Smoke 96 CONTENTS ...

Page 10: ...CHAPTER 1 PAGE 1 PAGEDATE 7 July2010 MAINTENANCEMANUALEXTRA300LT Chapter 1 Introduction ...

Page 11: ...CHAPTER 1 PAGE 2 PAGEDATE 12 June2015 MAINTENANCEMANUALEXTRA300LT Table of Contents Chapter Title 01 00 00 GENERAL 3 01 00 01 Related Documents 3 01 00 02 Trade Marks 7 01 10 00 SAFETY 8 ...

Page 12: ...uments Theinstructions thatarenecessaryfordisassembly check repair maintenanceoroverhaulofvendorequipmentarenot incorporated in this manual Use the most current revisions of the following documents in connection with this maintenance manual Aircraft Pilot s Operating Handbook andAirplane Flight Manual Parts Catalogue Service Bulletins Aircraft Record Airplane Log Book and Engine Log Book N O T E C...

Page 13: ...ters Bulletins and Instructions Manufacturer LYCOMINGENGINES 652 Oliver Street Williamsport PA17 701 USA Propeller MTV 9 B C C 198 25 3 blade Operation and Installation Manual E 124 Overhaul Manual and Parts List E 220 Service Bulletins Manufacturer MT PropellerEntwicklungGmbH AirportStraubing 94348Atting Germany Governor P 880 5 and P 880 41 A 210988 Woodward Operation and Installation Manual E 1...

Page 14: ...ntenance and Troubleshooting Manual L 1492 Service Bulletins Manufacturer UNISONINDUSTRIES 530BlackhawkPartAvenue Rockford IL61104 USA Cleveland Wheels Brakes Maintenance ManualAWBCMM0001 Technician s Service GuideAWBTSG0001 Illustrated Parts List Service Bulletins Manufacturer ParkerHannifinCorporation 1160 Center Road Avon Ohio44011 USA Hooker Harness General Restraint System Installation Guidel...

Page 15: ...rer AspenAvionicsInc 5001 Indian School Rd NE Albuquerque NM87110 Electronics International MVP 50P Installation Instructions II 0425051 Rev I Operationg Instructions OI 1002051 Rev D Manufacturer Electronics International Inc 63296 Powell Butte Hwy Bend OR 97701 Kannad406AFELT Installation and Operation Manual 406AF COMPACT ELT P N DOC08038E Rev 04 Initial Installation Manual 406AF INTEGRA ELT P ...

Page 16: ...ternational Inc 1200 E 151st Street Olathe KS 66062 USA OtherVendor Equipment Vendor publication should be obtained directly from the vendor Operation and Installation Manuals Service Bulletins 01 00 02 Trade Marks Even when the brand names used in this manual are not marked as registered trade marks this does not mean that these names are free in the sense of trademark legislation ...

Page 17: ...e carried out only by qualified and authorized personnel The execution has to be in accordance with the respective national safety requirements Before beginning any work this maintenance manual has to be read and understood In case of doubt or lack of informa tion the manufacturer has to be contacted for advice The safety notes given in this manual are to be observed unconditionally Refer to Chapt...

Page 18: ...PAGEDATE 7 July2010 CHAPTER 2 PAGE 1 MAINTENANCEMANUALEXTRA300LT Chapter 2 How to Use the Service Manual ...

Page 19: ...e Title 02 10 00 MANUALDESCRIPTION 3 02 10 01 Manual Set Up 3 02 10 02 Chapter Set Up 3 02 10 03 Page Numbering 4 02 10 04 Figure Numbering 4 02 10 05 Layout 5 Figure 1 Layout 5 02 10 06 Notes Safety Notes 6 02 20 00 HANDLING 7 02 20 01 Revisions 7 02 20 02 Service Bulletin 8 02 20 03 Checklists 8 ...

Page 20: ...e Bulletins and the Record of Revisions In the List of Chapters the groups are markedbycapitalcharacters 02 10 02 Chapter Set Up The chapter numbering system used in this manual repre sents the chapter set up It is a conventional dash number breakdown The number is composed of three elements which consist of two digits each 02 10 02 chapter section subject The first element shows the chapter here ...

Page 21: ...ethefollowingareused Powerplant 02 10 03 Page Numbering Thepagenumberingbeginsatthecoversheetofeachchapter with Page 1 In contrast to theATASpecification 100 the particular sections and subjects don t start with a new numbering 02 10 04 Figure Numbering The figures are numbered in such a way that the first figure in each chapter starts at Figure 1 ...

Page 22: ... to tables 8 figure title and number 9 date of first issue resp last revision 10 chapter and page numbers 02 10 05 Layout Apartfromtheheadersandfootersthelayoutconsistsoftwo 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 tio...

Page 23: ...ation which if not avoided could result in death or serious injury CAU T I O N Indicates a hazardous situation which if not avoided could result in minor or moderate injury Additionalinformationgiveninthismanualarealsomarked by boxed textmarkers in the left column and are written in semi bold characters N O T I C E Is used to address practices not related to physical in jury I M PO R TAN T Represe...

Page 24: ...ft ExtraAircraft com or facsimile 49 0 2858 9137 30 N O T E Pages of this maintenance manual may not be exchanged and no alterations of or additions to the approved contents may be made without the EXTRA Flugzeug produktuions und Vertriebs GmbH EASAapproval Ifrevisionofpagesisnecessary observethefollowingsteps N O T E Change revised pages immediately upon receipt 1 Take out the old pages and destr...

Page 25: ...lists 1 Copy the respective check list for performing a check 2 Enter the date at the top of the table O 1 O O Text 3 Select the items to be worked out The O at the beginning of the line is written in the column which indicates the point of time when an item has to be worked out Specifications for the first column are given by footnotes 4 Work out the particular items and sign after execution re s...

Page 26: ...CHAPTER 3 PAGE 1 PAGEDATE 7 July2010 MAINTENANCEMANUALEXTRA300LT Chapter 3 General Description ...

Page 27: ...ontents Chapter Figure Title 03 00 00 GENERAL 3 Figure 1 View EXTRA 300LT 3 03 10 00 DESCRIPTION 4 03 10 01 Construction 4 03 10 02 Flight Control System 4 03 10 03 Brake System 5 03 10 04 Powerplant 5 03 10 05 Fuel System 6 03 10 06 Electrical system 6 03 10 07 Instruments 7 ...

Page 28: ...s A more detailed description of the systems you find in the respectivechapters see CONTENTS The Extra 300LT refer to figure 1 is designed as a light weight single engine twoseat low wingmonoplaneusing composite and steel materials It has a fixed main landing gearandatailwheelunitwithfull swivelcapability Figure 1 View EXTRA 300LT ...

Page 29: ...le piece canopy side hinged Wing fibre composite design Stabilizers fibre composite design Landinggear 2 main wheels 1tail wheel fibre composite strut design Seats Rear Seat Seat angle and seat back rest adjustable 5 piece harness Front seat non variable position 5 piece harness 03 10 02 Flight Control System Pitch control push pullrods Roll control push pullrods Yawcontrol cable system Pitch trim...

Page 30: ...er Street Williamsport Plant 17 701 USA Type AEIO 580 B1A 6 cyl air cooled fuel injection independentmagnetoignition system inverted flight oil system specialantivibrationcounter weights retardbreakermagneto Slick Start system Rated power 315 hp at 2700 rpm Propeller Manufacturer MTPropellerEntwicklungGmbH Co KG AirportStraubing D 94348Atting Germany Type MTV 9 B C C198 25 3 blade wood composite h...

Page 31: ...ewall cockpit side Fuelsupply mechanicalenginedrivenpump additional electrically operated boostpump 03 10 06 Electrical system Powersupply engine driven 12Valternator integrated DVconverter alternator switch 28Ah starter battery battery switch Circuits equippedwithautomaticcircuit breakers Ignition magneto system independent from electrical power supply ...

Page 32: ...CHAPTER 3 PAGE 7 PAGEDATE 7 July2010 MAINTENANCEMANUALEXTRA300LT 03 10 07 Instruments Standard minimum equipmentinstalled X ...

Page 33: ...CHAPTER 4 PAGE 1 PAGEDATE 30 April2010 MAINTENANCEMANUALEXTRA300LT Chapter 4 Airworthiness Limitations ...

Page 34: ...GE 2 PAGEDATE 30 April2010 MAINTENANCEMANUALEXTRA300LT Log of Revisions Chapter 4 Datesofissuefororiginalandrevisedpages 1st Edition 30 April2010 Dateandsignofapproval EASAMAJORCHANGEAPPROVAL N 10030180 1 June 2010 ...

Page 35: ...A300LT Table of Contents Chapter Title 04 00 00 GENERAL 4 04 00 01 Temperature Limit 4 04 00 02 OperatingTime 4 04 10 00 LIFELIMITEDCOMPONENTS 6 04 10 01 General 6 04 10 02 Replacement Time 6 04 10 03 Service Life Limited Components 6 04 20 00 MAJORINSPECTION 7 ...

Page 36: ...er paragraphs 43 16 and 91 403 of the FederalAviation Regulations unless an alternative program has been ap provedbytheregulatoryauthority 04 00 01 Temperature Limit Composite structure is qualified up to 72 C 162 F Struc ture temperatures above this limit are not approved Not to exceedthistemperaturelimit onlyappropriatecolourspeci fication for composite structure as given by the manufac turer do...

Page 37: ...he Significant Items Inspec tion contained in Chapter 05 30 00 of this manual must be performed This 1000 hours inspection releases the aircraft for further 1000 hours operation up to max of 6000 hours I M PO R TAN T Prior to 6000 flight hours the Major Inspection con tained in Chapter 04 20 00 must be performed This in spection may release the aircraft for further operation subject to approval of...

Page 38: ...4 10 02 Replacement Time Items shown here must be replaced during the regular maintenanceperiods Item Replace Wing 6000 h Aileron 6000 h Vertical Stabilizer 6000 h Rudder 6000 h Horizonal Stabilizer 6000 h Elevator 6000 h Landing Gear Spring 6000 h 04 10 03 Service Life Limited Components The service life of the EA 300LT composite structure as listed in section 04 10 02 has been set to 6000 flight...

Page 39: ...actured utilizing the latest knowledge of composite construction and requires newexperienceaboutthosepartssubjecttowear Untilnow insufficient experience about this point has been acquired When such information is available it will be accomodated in later revisions of this manual and will include a major inspection procedure ...

Page 40: ...CHAPTER 5 PAGE 1 PAGEDATE 7 July2010 MAINTENANCEMANUALEXTRA300LT Chapter 5 Time Limits Maintenance Checks ...

Page 41: ... General 7 05 20 02 25 Hour Inspection Engine 7 05 20 03 25 Hour Inspection Aircraft 7 Figure 1 Drain and Vent Holes 8 Figure 2 Lubrication Chart 25 hours 9 Figure 3 Lubrication Chart 50 hours 10 Figure 4 Lubrication Chart 100 hours 11 05 20 04 Maintenance Checks Schedule 12 05 20 05 Significant Items Inspection 28 05 50 00 UNSCHEDULEDMAINTENANCECHECKS 37 05 50 01 Violent Stopping of the Engine Pr...

Page 42: ...ormation can be taken from the vendor equipment maintenance instructions refer to chapter 1 However for practicability reasons most of the applicable vendor equipment inspections are incorporated in the following checklists But it has to be noted that the latest editions of inspections given by the vendors remain decisive So beforebeginninganinspection theinspections ofvendorequipmentpresentedhere...

Page 43: ... plished not later than the specified period of operation for that component or in accordance with the manufactures service data or airworthiness directives 05 10 02 Overhaul Schedule Itemsshownheremustbeoverhauledatthetimesindicated refer to latest issue of Manufacturer s Service Bulletin and Maintenance and Overhaul Manual Item Overhaul Engine Textron Lycoming Engine accessories together with en...

Page 44: ...dtoreplacetheitemsshowninthefollow ing schedule at the times indicated The times may be modified by the respective national authorities 1 on the recommendation of the manufacturer 5 if not stated otherwise 2 recommended replacement every 5 years to avoid unscheduled maintenance 4 reworking only by authorized services 3 refer to Chapter 01 00 01 ...

Page 45: ...CHAPTER 5 PAGE 6 PAGE DATE 24 February2017 MAINTENANCEMANUALEXTRA300LT 05 10 04 Time Between Inspection Inspect these equipment items at the times shown ...

Page 46: ...how a drain hole chart figure 1 and lubrication charts figures 2 4 which can be used in connection with the checklists 05 20 02 25 Hour Inspection Engine A25hourinspectionisnecessaryfortheengine becausethe engine is not equipped with an external oil filter Therefore the engine oil has to be changed and the oil screen cleaned afterevery25hours Refertofigure2 LubricationChart25 hours 05 20 03 25 Hou...

Page 47: ...elage cover central hole 5 Lower wing shell at stall warn transducer station in front of the main spar 6 Lower wing shell at root section 7 Wing tip trailing edge at aileron cutout 6 6 7 8 9 7 8 9 8 Nose rib web of aileron hinge gaps 1 hole each 9 Nose rib web of aileron hinge gaps 2 holes each 10 Aileron root rib at trailing edge 11 Horizontal stabilizer root rib web 12 Root rib of elevator 13 St...

Page 48: ...PTER 5 PAGE 9 PAGEDATE 21 March2014 MAINTENANCEMANUALEXTRA300LT Figure 2 Lubrication Chart 25 hours SCHEDULEDMAINTENANCECHECKS MIL PRF 81322F or later MIL PRF 81322F or later Mobil Aviation Grease SHC 100 ...

Page 49: ...50 hours SCHEDULEDMAINTENANCECHECKS Brake fluid reservoir Engine oil Engine controls Governor Mixer Throttle Landing gear centering pin Trim flap hinges Tail wheel steering Torque tube bearing Trim actuation lever bolts MIL PRF 81322F or later MIL PRF 81322F or later Mobil Aviation Grease SHC 100 ...

Page 50: ...l wheel 6 soft type Brake fluid reservoir Engine oil Engine controls Governor Mixer Throttle Landing gear centering pin Main wheel bearings Trim flap hinges Trim actuation lever bolts Tail wheel steering Torque tube bearing Canopy hinges and latching mechanism Brake anchor bolts MIL PRF 81322F or later MIL PRF 81322F or later Mobil Aviation Grease SHC 100 ...

Page 51: ...L R than 50 RPM O O 6 Check ignition OFF function at 1000 RPM for a short moment O O 7 Check response of the engine by power setting changes O O 8 Check the propeller response at 1800 RPM when changing pitch O O 9 Check idle rpm is between 650 and 750 O O 10 Check the fuel flow and manifold pressure indicaton O O 11 ChecktheEGTandCHTindicaton O O 12 CheckmixerfunctionperCHT EGTindication O O 13 Ch...

Page 52: ...d Installation ManualE 124 andService Bulletins Ground magneto primary circuit before working on propeller O 1 Remove spinner and inspect for cracks O O 2 Check blade shake max 3 mm or 1 8 inch O O 3 Checkbladeangleplay max 2 O 4 Inspect outside condition of the hub and parts for cracks corrosion deterioration O 5 Inspect high pitch stop check nut for tightness O O 6 Check all safety means to be i...

Page 53: ...ordance with Chapter 12 10 04 En gineOilReplenishing O1 O O 8 Clean oil suction screen at oil change check suction screen for metal particles shavings or flakes Consider Lyc SB N 480 latest issue O1 O O 9 Clean oil pressure screen at oil change check pressure screen for metal particles shavings or flakes Consider Lyc SB N 480 latest issue O 10 Inspect oil temperature sensor unit for leaks and secu...

Page 54: ...ds and ceramics for corrosion anddeposits O O 19 Perform a hot engine differential compression check in accordancewithFAAAC43 13 1A O 20 Inspect cylinders for cracked or broken fins O O 21 Check cylinders for evidence of excessive heat which is indicated by discoloration O 22 Check fuel injector nozzles for loseness Tighten to 6 8 Nm 60 inch pounds torque Check fuel lines for fuel stains which are...

Page 55: ... fuel injection lines and fittings for leaks security chafing dents andcracks replaceoroverhaul as requiredor at engine overhaul Check fire protection O O 33 Check fuel system for leaks O 3 O O 34 Remove clean and inspect gascolator screen and fuel filter bowl O O 35 Inspect throttle mixture and propeller governor controls for security travel and operating conditions Observe the hints given in the...

Page 56: ...g exhaust structures for heat damage or burning O 44 Inspect engine crankcase for cracks leaks and security of seam bolts O O 45 Check engine mounted accessories such as pumps tem perature and pressure sensing units for leaks secure mountingandtightconnections O O 46 Inspect engine mount for cracks and loose mountings O O 47 Inspect engine baffles for cracks and fraying O 48 Inspect all wiring con...

Page 57: ...ucture for cracks and damage O O 5 Inspect baggage net and tie down straps for security attachment proper operation and condition O O 6 Check installed parts for general condition and security of attachment O O 7 Inspect fuselage for foreign objects O 8 Inspect steel tube construction for general condition cor rosion and cracks above all in areas of load stress e g wing stabilizer engineandseatatt...

Page 58: ...spect for fuzzyedges at the adjusters inspect whether edges start to fray inspect whether webbing lost its color top and bottom sides have a different shades O 19 Check hardware inspect for corrosion check whether buckles mate properly Check the buckles for easy opening O 20 Check ratchet assembly inspect for corrosion loss of plating discoloration slippage and wear check for ease of operation If ...

Page 59: ...or security of attachment free movement dents delaminationsandcracks O O 3 Check spades visuallyfor general condition Inspect spade support for corrosion cracks and deformations Ensure proper attachment to aileron O O 4 Inspect elevator trim system for proper operation and rigging O O 5 Inspect hinges hinge bolts hinge bearings and selflocking nuts for condition cracks and security O O 6 Visual in...

Page 60: ... is reached the control system indicates too much flexibility which needs to be traced In this case contact EXTRA Flugzeugproduktions undVertriebs GmbHforadvice O O 14 Inspect all flight control surface ventilation holes for ob struction O 15 Inspect elevator balance weights for looseness clearance condition and interference with the composite structure O 16 Visual inspect push pull control rods f...

Page 61: ...s inspection caps and heat protection sheet for dents and cracks Wheels 9 Refer to on aircraft inspections presented in the latest edition of Cleveland Wheels Brakes Maintenance Manual and Service Bulletins for wheel tire and brake inspections O O 10 Visually inspect the wheels for slippage corrosion cracks or other visible damage O O 11 Check the four bolts attaching the wheel axis to the landing...

Page 62: ...seals for distortion or wear Replace grease seal felts if they are hard or contaminated Lightly saturated grease seals should be replaced if cracked dried out or distorted O 16 Inspect wheel bearings for excessive wear or damage Replace on condition O 17 Repack bearings with MIL PRF 81322F or later Mobil Aviation Grease SHC 100 or equivalent Reinstall wheels andsecure O O 18 Check wheel bearing cl...

Page 63: ...ake cylinder anchor bolts in torque plate bushings for sloppiness This can be accomplished bygrasp ing the cylinder and moving it slight movement is normal Excessive movement is cause for removal and detailed inspection O O 28 Visually inspect brake linings for extreme chipping on the edges Lining worn to a minimum thickness of 0 100 inch 2 54 mm must be replaced O O 29 Visually check torque plate...

Page 64: ...ecurity O 3 Check the safety wire and the safety screw of the wing main spar bolt O 4 Inspect wing spar flange bushing for looseness and bearing load bymoving the wing tip up and down to detect play No playallowed O 5 Inspectwingauxiliarysparattachment O 6 Inspect wing ventilation holes for obstruction O O 7 Check inside wing structure in the area of access panels and root rib openings Stabilizer ...

Page 65: ...tatic air pressure lines for condition and leaks perform operational check O1 9 CheckASPEN EFD1000 PFD and 1000 MFD reversion mode speed bands for compliance with instrument mark ings in the Pilot s Operating Handbook Correct data if necessary perASPENInstallationManual O 1 10 CheckASPENEFD s inaccordance withAspenICA Doc 900 00012 001 latest Revision O 1 O 11 Check MVP 50P perElectronics Internat...

Page 66: ... POH supplements O 3 O O 2 Perform checks and maintenance for the ELT Follow the applicable instructions prepared bythe respective ELT manufacturer Refer to chapter 1 O 3 O O 3 Reinstall access panels as per chapter 51 O O 4 Check landing light for function O 3 O O 5 Aircraft conforms to specifications of respective authority O3 O O 6 All required airworthiness directives complied with O3 O O 7 Al...

Page 67: ... 6 Detailed visual inspection on the surface for erosion scratches stonenicks andimpact damages O 7 Detailed visual inspection on the top to bottom shell bonding for dents cracksanddelaminations Main spar section O 8 Check skin to spar bonding for delaminations by coin tapping refer to chapter 20 10 05 O 9 Detailed visual inspection on the sparweb for dents cracks and delaminations byvisual inspec...

Page 68: ... rivets of electrical bonding visually O 21 Inspect root rib for cracks delaminations and insecure bonding to skin and spars by coin tapping refer to chapter 20 10 05 O 22 Check tip area visually for general condition inside by boroscope throughstrobe navigationlightopening Surface general O 23 Check paint visually for general condition blisters etc O 24 Check laminate for erosion scratches and ni...

Page 69: ...chapter 20 10 05 O 4 Detailed visual sheet metal attachment fitting for damage corrosion and link bolts security Rear spar section O 5 Check skin to spar bonding for delamination bycoin tapping O 6 Detailed visual inspection of rear spar web for dents cracks and delamination Pay particular attention to the cut out for rudder cantilever O 7 Inspect cantilever bearings for play Check for free moveme...

Page 70: ... bottom hinge for cracks anddelaminationbycointapping O 9 Reinstall bottom hinge bracket and bellcrank as per chapter 27 O 10 Check bellcrank for damage cracks and proper attachment O 11 Visually inspect ventilation holes for obstruction Refer to chapter 05 20 01 Figure 1 Drain andVent Holes O 12 Check paint visually for general condition blisters etc O 13 Check laminate for erosion scratches and ...

Page 71: ...in laminate bycoin tapping O 2 Checkbondingskin sparfordelaminationsbycointapping O 3 Check trailing edge bonding and trim tab cutout for cracks and delaminationbycointapping O 4 Detailed visual inspection of mounting brackets for damage cracks and proper attachment Replace stop nuts Check for proper torque in accordance with chapter 20 10 02 O 5 Check center section for delamination by coin tappi...

Page 72: ...ction of the sheet metal of the wing auxiliary spar attachment for damage corrosion Inspect the sheet metal supports using a fluorescent dye penetrant to insure no cracks are evident Control system O 1 Detailed visual inspection of torque tube for damages cracks free play especially in the rear torque tube bearing Check travel stop adjustments O 2 Inspect bell cranks for damage corrosion security ...

Page 73: ...eformations especially in the area of mounting clamps and the axleattachments O 4 Inspect main landing gear spring in the area of brakes for damage of overheating O 5 Inspect the center bushing for wear and looseness O 6 Check mounting clamps for damage and corrosion Inspect for dents andcracks O 7 Inspect mounting clamp bolts and nuts for fretting wear damage and stretch Check for proper torque r...

Page 74: ...ngine mount for dents cracks and corrosion Check all bolts for security and condition O 4 Visual inspection of rubber mounts shock mounts for porosity and generalcondition O 5 Inspect flexible hoses for damage and leakage O 6 Check electric wiring for proper connection O 7 If Plane Power alternator installed Remove alt field brush assem bly and inspect brushes for excess wear Replace brush assembl...

Page 75: ...wear and proper function O 7 Visual inspection of rudder pedal mounting to the attachment fittings Check bolts for security O 8 Inspect instrument panel for cracks and damaged screw holes Checkproperattachmentandsupport O 9 Check instrument cover for dents cracks delamination damaged screw holes and tearing of edges Surface general O 1 Visual check of paint for deteriorated paint General O 1 Reins...

Page 76: ...ng could be subject to changes 05 50 01 Violent Stopping of the Engine Propeller Strike Refer to Lycoming SB 533 latest approved issue if a propeller strike has occurred The propeller has to be checked and repaired by an author izedcompanyaccordingtoMT propellerinstruction Refer to MT propeller Operation and Installation Manual E 124 MagnetosmustbeoverhauledaccordingtoMagnetoMain tenanceandOverhau...

Page 77: ...nd spring to fuselage attachment O 6 Check fuselage structure in the area of landing gear attachment for deformationandcracks O 7 Examine wheel base and check if measurement corresponds to the value given in chapter 06 10 01 O 8 Check tires for cuts in the side wall O 9 Check wheel rim halves and brake discs for impacts cracks and distortionaccordingtoCLEVELANDinstruction O 10 Check tail wheel for...

Page 78: ...acturer beforethe aircraft is put back into service After an engine fire perform a check as described in the following O 1 Check all cables and hoses replace when necessary O 2 Cleanengineandenginecompartment O 3 Check engine according to the Lycoming Manual O 4 Inspect firewall and engine cowling for damage byhigh tempera tures e g signs of blisters on the protective paint If necessary renew LJF ...

Page 79: ...4 Check the electrical system with running engine for correct opera tion O 5 Check the avionics and antennas for correct operation O 6 Check the magnetic compass for correct readings O 7 OverhaulmagnetosaccordingtoMagnetoMaintenanceandOver haul Manual see Chapter 1 05 50 05 Flightline Inspections These checks include pre flight and postflight checks as they are described in Sections 3 and 4 EMERGE...

Page 80: ...CHAPTER 6 PAGE 1 PAGEDATE 7 July2010 MAINTENANCEMANUALEXTRA300LT Chapter 6 Dimensions and Areas ...

Page 81: ...ble of Contents Chapter Figure Title 06 00 00 GENERAL 3 Figure 1 Axes and Planes 3 06 10 00 MAINDATA 4 06 10 01 Main Dimensions 4 06 10 02 Wing 4 06 10 03 Horizontal Tail 5 06 10 04 Elevator 5 06 10 05 Vertical Tail 5 06 10 06 Rudder 5 Figure 2 Three View EXTRA 300LT 6 ...

Page 82: ... Reference Planes Plane of upper longerons horizontal plane Plane of rudder Vertical symmetry plane Fire wall plane Vertical plane The following figure1shows the aircraft reference planes Figure 1 Axes and Planes Unless otherwise stated all measurements given in this manual are in metric additional in feet and are measured parallel to the corresponding reference planes ...

Page 83: ... base 5 07 m 16 63 ft Wheel track 1 80 m 5 91 ft MTOW Normal category AcroIIIcategory 950 kg 2095 lbs Acro II category 870 kg 1918 lbs Acro I category 820 kg 1808 lbs 06 10 02 Wing Span 8 0 m 26 25 ft Area 10 84 m 116 68 ft Airfoil Root NACA23015 mod Tip NACA23012 mod Chord Root 1 88 m 6 17 ft Tip 0 843 m 2 77 ft MAC 1 427 m 4 682 ft Aileron area 2 x 0 757 m 2 x 8 15 ft Aileron deflection up 30 do...

Page 84: ...FX 71 L 150 30 06 10 04 Elevator Area 0 772 m 7 77 ft Elevator deflection up 25 tolerance 2 down 25 tolerance 2 Trim tab deflection up 35 down 27 tolerance 2 06 10 05 Vertical Tail Area 1 38 m 14 85 ft Airfoil Wortmann FX 71 L 150 30 06 10 06 Rudder Area 0 52 m 5 60 ft Rudder deflection left 30 right 30 tolerance 2 MAIN DATA PAGEDATE 16 January2009 ...

Page 85: ...CHAPTER 6 PAGE 6 PAGEDATE 7 July2010 MAINTENANCEMANUALEXTRA300LT MAIN DATA Figure 2 Three View EXTRA 300LT ...

Page 86: ...CHAPTER 7 PAGE 1 PAGEDATE 7 July2010 MAINTENANCEMANUALEXTRA300LT Chapter 7 Lifting and Shoring ...

Page 87: ...LEXTRA300LT Table of Contents Chapter Figure Title 07 10 00 JACKING 3 07 10 01 Balance Weight 3 Figure 1 Balance Weight 3 07 20 00 SHORING 4 07 20 01 Shoring the Front 4 Figure 2 Shoring the Front 4 07 20 02 Shoring the Tail 5 Figure 3 Shoring the Tail 5 ...

Page 88: ...chapter07 20 00itisnecessarytoweightthetailtoprevent aircraft from tilting onto the nose In this case follow the steps described below refer to figure 1 1 Put a weight 1 of min 30 kg under the tail 2 Remove the RH tail side skin and the tail cone access panel as per chapter 51 3 Connect the weight with the now accessible steel tube 3 by means of a strap 2 Prevent damage of paint and control cables...

Page 89: ...the tail as per chapter 07 10 01 3 Hoist the aircraft by means of both engine hoisting points 1 N O T I C E Prevent damage of ventilation tubing brake lines and drains when shoring the aircraft 4 Shore the aircraft by means of two supports 2 which are to put under the left and right bottom longeron each in the area behind the landing gear as shown in figure 2 This is possible also when the landing...

Page 90: ...ide and approx 3 feet long supports 3 Cushion the supports WAR N I N G Do not lift the tail higher than necessary for support ing The aircraft may tilt onto the nose N O T I C E Don t handle the elevator when lifting the tail 4 Lift the tail some centimeters by handling carefully the hori zontal fins and put the cushioned supports under each side of the horizontal stabilizer Figure 3 Shoring the T...

Page 91: ...CHAPTER 8 PAGE 1 PAGEDATE 7 July2010 MAINTENANCEMANUALEXTRA300LT Chapter 8 Leveling and Weighing ...

Page 92: ...HAPTER 8 PAGE 2 PAGEDATE 7 July2010 MAINTENANCEMANUALEXTRA300LT Table of Contents Chapter Figure Title 08 00 00 GENERAL 3 08 10 00 WEIGHINGAND CALCULATIONOFCOFG 4 08 20 00 LEVELING 7 Figure 1 Leveling 7 ...

Page 93: ...hingandlevelingtheEXTRA300LTand for determining the Center of Gravity WeightheaircraftanddeterminetheCenterofGravityeach 5 years after installation of additional equipment or after repairs I M PO R TAN T Weigh read the scales and calculate with carefulness Incorrect weighing or determination of Center of Grav ity can endanger the pilot and the aircraft ...

Page 94: ...objects e g tools luggage parachutes 5 Clean and dry the aircraft 6 Put the rear seat to middle position and close canopy 7 Weigh two of those wheel chocks that will be used for se curing the main wheels Enter the weight below in Page 5 Tare weight scale 1 2 chocks 8 Weigh the jack that will be used for jacking the tail wheel EntertheweightbelowinPage5 Tareweightscale3 jack 9 Roll the main wheels ...

Page 95: ...LEXTRA300LT Gross weight scale 1 kg Tare weight scale 1 chocks kg Net weight scale 1 W1 kg Gross weight scale 2 kg Tare weight scale 2 chocks kg Net weight scale 2 W2 kg Gross weight scale 3 kg Tare weight scale 3 jack kg Net weight scale 3 W3 kg WEIGHING ...

Page 96: ... NetweightmainwheelLH W2 NetweightmainwheelRH W3 Net weight tail wheel W Emptyweight Item Weight Arm Moment Main wheel LH W1 kg X1 cm kgcm Main wheel RH W2 kg X1 cm kgcm Tail wheel W3 kg X2 cm kgcm Empty weight W kg Total moment kgcm W1 X1 W2 X1 W3 X2 W XG W W1 W2 W3 XG Total moment Empty weight Empty weight is W kg Center of Gravity is XG cm aft fire wall Weighing performed by Aircraft Inspector ...

Page 97: ...han necessary for leveling The aircraft may tilt onto the nose N O T I C E Prior to levelling ensure aircraft is clear of obstruc tions 2 Lift tail and put the jack height 90 cm 3 ft under the tail wheel which has to be in the rearmost position 3 Level the aircraft to its horizontal reference line using a spirit level 2 figure 1 which is to put under the bolts of the rear main fuselage cover 1 Adj...

Page 98: ...CHAPTER 9 PAGE 1 PAGEDATE 7 July2010 MAINTENANCEMANUALEXTRA300LT Chapter 9 Towing and Taxiing ...

Page 99: ...CHAPTER 9 PAGE 2 PAGEDATE 7 July2010 MAINTENANCEMANUALEXTRA300LT Table of Contents Chapter Figure Title 09 00 00 GENERAL 3 09 10 00 TOWING 3 09 20 00 TAXIING 3 ...

Page 100: ...rpullatthe inboard portion of the propeller blades 09 20 00 TAXIING Taxiingtheaircraftshallbeperformedbyqualifiedpersonnel only All taxiing should be done at slow speed and the controls should be positioned such that the effects of gusty windareminimized N O T I C E Taxiing over loose gravel or cinders should be done at low engine speed to minimize damage to the airframe surfaces due to stone dama...

Page 101: ...July2010 MAINTENANCEMANUALEXTRA300LT 2 Taxi forward a few feet and check brake effectiveness 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 102: ...CHAPTER 10 PAGE 1 PAGEDATE 7 July2010 MAINTENANCEMANUALEXTRA300LT Chapter 10 Parking Mooring Storage and Return to Service ...

Page 103: ...CHAPTER 10 PAGE 2 PAGEDATE 7 July2010 MAINTENANCEMANUALEXTRA300LT Table of Contents Chapter Figure Title 10 00 00 GENERAL 3 10 10 00 PARKING STORAGE 4 10 20 00 MOORING 5 10 30 00 RETURNTOSERVICE 6 ...

Page 104: ...PTER 10 PAGE 3 PAGEDATE 7 July2010 MAINTENANCEMANUALEXTRA300LT 10 00 00 GENERAL Thischapterprovidestheproceduresrecommendedtopark or to moor the aircraft so that the likelihood of ground damageisminimized ...

Page 105: ...ollowing precautionary measures are recommendedforkeepingtheaircraftserviceableandready to fly 1 Refer to chapter 10 20 00 Mooring for mooring instructions DAN GE R Do not rotate the propeller with the master switch on and the battery connected The engine could start unintenionally and may course serious injuries or death 2 Maintain an oil film on internal engine parts frequently rotate the propel...

Page 106: ...e in contact with the wheel fairings Theuseofchocksthataretoolargemaydamage the fairings 3 Drive stakes into the ground approximately three feet outboard of each wing tip and to either side of tail wheel 4 Install plastic washers and tie down rings to the rear attachment point of the wing tip if no sighting device is installed 5 Tie a sufficiently strong rope to each wing tie down ring and anchor ...

Page 107: ...010 MAINTENANCEMANUALEXTRA300LT 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 108: ...CHAPTER 12 PAGE 1 PAGEDATE 7 July2010 MAINTENANCEMANUALEXTRA300LT Chapter 12 Servicing ...

Page 109: ...ng 6 12 10 03 Fuel Drains 6 12 10 04 Replenishment of Engine Oil 7 12 10 05 Oil Change 10 12 10 06 Replenishment of Brake Fluid 11 Figure 1 Replenishment of Brake Fluid 12 12 10 07 Tire Inflation 13 12 20 00 SCHEDULEDSERVICING 14 12 20 01 Exterior Cleaning 14 12 20 02 Interior Cleaning 15 12 20 03 Engine Cleaning 15 12 30 00 UNSCHEDULEDSERVICING 17 12 30 01 Removal of Snow and Ice 17 ...

Page 110: ...A300LT The specified intervals refer to chapter 5 are considered adequate to meet average requirements under normal oper atingconditions Itisadvisable however toshortenserviceandmaintenance intervalswhenoperatingunderabnormalconditions suchas extremetemperatureranges dustyatmosphericconditions high humidity and moisture unimproved airport facilities orunusualoperatingrequirements ...

Page 111: ... GE R Never refuel the aircraft with the engine running Always ensure that the aircraft is grounded before refueling Use the exhaust endpipe Ensure that no one is smoking within 100 feet of the aircraft Ensure that all aircraft electrical systems are deenergized while refueling Ensure that no aircraft radar or powerful transmitters are operating within 100 feet of the aircraft during fueling If fu...

Page 112: ... 76 L 20 1 US Gallons WingtankRH 76 L 20 1 US Gallons Centertank 60 L 15 9 US Gallons Acrotank 9 L 2 3 US Gallons Totalfuelcapacity 221 L 58 4 US Gallons Usable fuel capacity 209 L 55 2 US Gallons Usable fuel capacity for acrobatic 67 L 17 7 US Gallon I M PO R TAN T For acrobatic flight wing tanks must be empty I M PO R TAN T After refueling it has to be ensured that both fuel tank caps are secure...

Page 113: ... the 3 port tee block fitting 3 Allow draining the fuel which remained in the fuel line 4 Reinstall the fuel line to the 3 port tee block fitting 12 10 03 Fuel Drains TheEXTRA300LThasfourfueldrainvalvesfordrainageof moisture and sediment One fuel drain valve labelled WING TANK DRAIN is located in the root section of the underside of each wing The fuel drain valve for the center and acro tank CENTE...

Page 114: ...ough for oil to drain back into sump 2 Open the hatch on the upper part of the cowling 3 Unscrew oil filler cap with dipstick from engine oil filler tube 4 Remove oil filler cap with dipstick from engine and wipe oil from dipstick with a clean cloth or paper towel 5 Return oil filler cap with dipstick into oil filler tube and tighten finger tight 6 Unscrew and remove oil filler cap with dipstick C...

Page 115: ... MIL L 6082 AviationGradeStraightMineraloil Ashless Dispersant Oil MIL L 22851orSAEJ1899AshlessDispersantOilshallbe 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 undertakenwithcaution Iftheengineisinanextremelydirty condition theswitchtoadditiveoilshouldbedeferr...

Page 116: ...SAE 30 SAE 40 or SAE 20W40 18 C 0 F to 32 C 90 F SAE 20W50 SAE 20W50 or SAE 15W50 Below 12 C 10 F SAE 20 SAE 30 or SAE 20W30 N O T E Refer to latest revision of Lycoming Service Instruc tion No 1014 for further information Replenish engine oil as follows 1 Open the hatch on the upper part of the cowling and unscrew oil filler cap 2 Using a clean paper towel wipe any oil foreign material from the e...

Page 117: ... cowling of the aircraft 2 Cut the safety wire securing the oil drain plug 3 Place a suitable container under the oil drain 4 Unscrew engine oil drain plug and allow the oil to drain thoroughly 5 Remove oil pressure screen housing from engine accessory housing 6 Remove oil pressure screen from its housing 7 Inspect oil pressure screen for metal particles and clean it 8 Reinstall oil pressure scree...

Page 118: ...he sump plug located in the extreme end of the scavenger oil chamber is not dis lodged from its location If this plug is not secure in its correct location a lubrication failure will occur with severe damage to the engine 13 Reinstall the oil suction screen 14 Reinstall hex sump plug using a new O ring and secure with wire 15 Connect oil hose with oil suction sump fitting Fitting can be alligned b...

Page 119: ... 3 Remove fluid reservoir filler plug and screw a clear plastic hose with appropriate fitting into the filler hole at the top of the fluid reservoir 4 Remove bleeder fitting cap 3 of the wheel brake assembly 2 Figure 1 Replenishment of Brake Fluid 5 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 ...

Page 120: ...the clear hose andafirmbrakepedalisobtained filleachsideofthesystem with min 0 33 ltr 0 1 U S Gallons for complete change 11 Fill the fluid reservoir up to full reservoir capacity 12 Reinstall fluid reservoir filler plug 13 Close bleeder fitting 14 Disconnect the connector hose 15 Reinstall bleeder fitting cap 16 Check the brake operation 17 Reinstall engine cowlings and wheel fairing cover plates...

Page 121: ...daremoredifficulttoremovewhen dry All lubricated components are to be covered before cleaning Roughlytwiceayear thecompletesurfaceshouldbetreated with a non silicone car polish and repolished to high gloss But do not apply wax or use pre wax cleaners during initial paint curing period Use only mild aircraft detergent and cool water when washing exterior during the first 90 days afterrepainting N O...

Page 122: ... cleaner to clean the canopy These materials will damange the canopy and may cause se vere crazing 12 20 03 Engine Cleaning Accumulationofdirtandoilwithintheenginecompartment creates a fire hazard and hampers inspection All cleaning operations have to be performed in well ventilated work areas anditisensuredthatadequatefire fightingandsafety equipmentisavaiable The engine is cleaned as follows 1 A...

Page 123: ...CHAPTER 12 PAGE 16 PAGEDATE 7 July2010 MAINTENANCEMANUALEXTRA300LT 5 It is very important not to start the engine before the clean ing agent has been completely removed or has evaporated ...

Page 124: ...e on the surface or in slots and gaps of fairings N O T I C E Do not use sharp tools for removing the snow If the aircraft shows sign of ice formation it is recom mended to defrost in a room Remove as much snow as possible with a soft bristle boom make sure the wheels and brakes are clear and tow the aircraft into a room with elevatedtemperature Thismethodisparticularlydesirable since it will melt...

Page 125: ...CHAPTER 20 PAGE 1 PAGEDATE 7 July2010 MAINTENANCEMANUALEXTRA300LT Chapter 20 Standard Practices Airframe ...

Page 126: ...lues 7 20 10 04 Special Torque Values 8 20 10 05 MeasuringTechniques 9 20 10 06 CoinTapping 9 Figure 1 Coin Tapping 9 20 10 07 Flexible Hose 10 Figure 2 Connection Types PA Hoses 12 20 10 08 Fittings 13 20 10 09 Control Cables 13 20 10 10 PR 812 16 Figure 3 Control Cables 17 20 20 00 ASSEMBLY INSTRUCTION 18 20 20 01 General 18 20 20 02 Assembly Instruction after Container Shipping 18 Table of Cont...

Page 127: ...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 300LTwithrelevanttorquevaluesandmeasuringtechniques are described in the following ...

Page 128: ... LN 9355 aircraft bolts are made of high strength type 1 7220 5 alloy steel The bolts are centerless ground threaded after heat treatment and cadmium plated per specification LN 9368 3000 2 Bolts according LN 9037 are standard aircraft bolts with undrilled shank The specification LN 9355 indicates bolts with shanks drilled for cotter pins The specification LN 9038 K indicates bolts with drilled he...

Page 129: ...e end of the shank Example AN 3 5A Bolt Head Identification ANhexheadbolt Diameter3 16 4 8 mm Length 5 8 15 9 mm Undrilledshank DIN Bolts Hex head DIN 931 DIN 933 and hex socket head DIN 912 bolts are standard bolts made of steel with undrilled shank The surface treatment is chromatized yellow UnliketheDIN931andDIN912theshankofaDIN933bolt goes up to the head The numerical code shown on the head of...

Page 130: ...ndardhexheadbolt Metric thread size M10 Length80mm 3 15 Strength type 8 8 DIN 931 DIN 933 20 10 02 Width Across Flats for Metric Bolts Thread diameter Width across flats M4 7 mm M5 8 mm M6 10 mm M8 13 mm M10 17 mm M12 19 mm M16 24 mm M20 30 mm M24 36mm Identification of manufacturer OEV Bolt Head Strengthtype 8 8 resp 12 9 ...

Page 131: ...accordingtoMS must be adhered to as follows I M PO R TAN T On all bolt connections the specified torque and lock ing method must be observed Do not reuse stop nuts if they can be run up finger tight Inch thread size Torque value Nm in lbs 1 4 28 3 5 4 5 30 40 5 16 24 6 7 9 5 60 85 3 8 24 10 7 12 5 95 110 7 16 20 30 5 33 9 270 300 1 2 20 32 8 46 3 290 410 9 16 18 88 1 67 8 480 600 Metric thread siz...

Page 132: ...985 M12 8 B2C 80 720 Longeron Cutout Bridge Bolt DIN 912 M8 8 8 Stop Nut LN 9348 08 18 160 Horizontal Stabilizer Front Spar Bolts Bolt LN 9037 10054 Stop Nut LN 9348 10 33 292 Horizontal Stabilizer Rear Spar Bolts Bolt LN 9037 10046 Stop Nut LN 9348 10 33 292 Vertical Stabilizer Rear Spar Bolt Bolt LN 9037 10065 Stop Nut LN 9348 10 38 336 Wing Main Spar Safety Bolts Drain Valve Nut Bolt LN 9038 K ...

Page 133: ...eduetoshaft friction This torque can be determined by a torquemeter before the bolt head contacts the attachment surface and should be added to the table value 20 10 06 Coin Tapping Inspection for damage is more critical for composite struc ture than for conventional structures A large washer or similarobjectisavaluabletoolfordetectingdebondsinthe airframe surface When a large washer is lightly bo...

Page 134: ...whichmustbeconsideredinclude excessive flexing twist kinking tensile or side loads bend radius andvibration Anyhosethathasbeenkinkedorbentto aradiussmallerthantheminimumbendradius andanyhose that has been cut or is cracked or is otherwise damaged shouldberemovedanddiscarded Theentirehoseassembly must be replaced if damage or failure occurs within a flexible hose assembly Visual Inspection Hose Fit...

Page 135: ...sembliesthatdonotincorporateassembly fittings with spanner flats to counteract while the nut is turnedtotheconnectionfitting e g Parker Statoflex PTFE hosetype101 Twistingofthehosecanbedeterminedfrom the identification markings running along its length Theflexiblehoseshouldbeinstalledsothatitwillbesubject to a minimum of flexing during operation Installation of PA Hose Axial Plug 1 Install the plu...

Page 136: ...lug before snapping snapped Type M Connection before installing installed sleeve insert to release Plug in screw Plug in screw Hollow bolt Banjo Sealing washer Sealing washer at firewall and brakes at firewall instruments and brake cylinders Figure 2 Connection Types PA Hoses ...

Page 137: ... for the following systems of the 300LT Engine Throttle Mixture and RPM Trim Heating Considerthefollowinginformationwhenworkingonengine control cables Refer to figure 2 Hard and abrupt power control inputs may impose high dynamicpeakloadstotherelatedslidingpartsatreachingthe travelstopsoftheenginefuelinjectorservo Repeatingpeak loads may result in unacceptable additional wear and free playatthepiv...

Page 138: ...trol cable with the power on or the engine running Serious injury or death could result 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 I M PO R TAN T A gradual or sudden increase in the no load cable free an...

Page 139: ...he following hints when performing inspections on the control cables Acablemustbereplacedwhenever excessive free play is felt at the control even after all cable connections have been verified as in good working order visual inspection shows chafing breakage or bent loose or worn parts evidence of moisture is found inside or control cable has frozen a gradual or sudden decrease in the stroke trave...

Page 140: ...ed results 1 PreparePR 812firewallsealantbymixingbrownpartAwith black part B with weight ratio 2 5 100 2 Clean the surfaces to be sealed with solvents 3 Immediately thereafter dry these areas with a new dry cloth 4 Seal the gap between the firewall and the respective com ponentwithPR 812firewallsealant Minimumsealantthick ness on firewall side is 3 mm 1 8 inch Cure time 25 C 77 F 50 RH for a fille...

Page 141: ...CHAPTER 20 PAGE 17 PAGEDATE 12 June2015 MAINTENANCEMANUALEXTRA300LT Figure 3 Control Cables ...

Page 142: ... contacted for advice Unlessotherwisespecifiedallboltsandconnectionsshould be torqued as listed in chapter 20 10 03 At some locations special torque values are considered necessary Refer to chapter20 10 04 Thestateddirection Front and Rear are to be considered in respect of pilot s seating direction 20 20 02 Assembly Instruction after Container Shipping Complete each step of the assembly procedure...

Page 143: ...with elevator as per chapter 55 The procedure described there is also applicable to the installation of the complete horizontal tail Remember to connect the ground bonding lead of the elevator too 9 Connect elevator push pull rod actuator lever as per chapter 27 00 01 10 Connect trim wire to the tab actuator lever using fitted clamp 11 Inspect for full travel and elevator deflection in relation to...

Page 144: ...ngine cowlings and access panels refer to chapter 51 00 01 and 53 26 Check all control surfaces for freedom of movement and security 27 Perform a compass compensation according to Aircraft Inspection and Repair FAAAC 43 13 28 Check correct servicing of aircraft 29 Perform an engine run up Refer to chapter 05 20 04 Scheduled Maintenance Checks Start the engine in accordance with the Pilot s Operati...

Page 145: ...CHAPTER 21 PAGE 1 PAGEDATE 7 July2010 MAINTENANCEMANUALEXTRA300LT Chapter 21 Air Conditioning ...

Page 146: ...00LT Table of Contents Chapter Figure Title 21 40 00 HEATING 3 Figure 1 Heating System 4 21 40 01 Inlet Box 5 Figure 2 Heating Boxes 5 21 40 02 Distribution Box 6 21 40 03 Main Bowden Cable 6 21 40 04 Distribution Bowden Cable 8 Figure 3 Heating Bowden Cables 11 ...

Page 147: ...h air is routed through a3 ducting 2 totheexhaustmufflerheatshroud 3 where it is heated up An inlet box 4 is placed on the engine side of the firewall Using the main handle 9 the warm air can there be guided into the cockpit or dumped overboard A distribution box 5 is located on the aft side of the firewall Usingthedistributionhandle 8 theratioofwarmairsupply betweenfrontandrearcanbecontrolled Tur...

Page 148: ...CHAPTER 21 PAGE 4 PAGEDATE 7 July2010 MAINTENANCEMANUALEXTRA300LT Figure 1 Heating System ...

Page 149: ...gine cowlings as per chapter 71 2 Remove bottom fuselage cover as per chapter 53 3 Loosen the hose clamp 10 4 Disconnect the hose 11 from the inlet box 5 Loosen the Bowden cable attachment bolt 8 6 Disconnect the Bowden cable 7 from the linkage NOTE When removing the inlet box the distribution box is also unfastened Both boxes are attached by the same bolts ...

Page 150: ...from the distribution box 5 Loosen the Bowden cable attachment bolt 4 6 Disconnect the Bowden cable 5 from the linkage NOTE When removing the distribution box the inlet box is also unfastened Both boxes are attached by the same bolts 7 Remove the four heating boxes attachment bolts 6 8 Remove the distribution box 2 9 Install in reverse sequence of removal Seal contact areas of boxes with firewall ...

Page 151: ... aircraft Secure label plate 8 clamp sheets 12 15 and attachment nut and washer 7 Installation Refer to figure 3 1 Thread the Bowden cable 4 end through the respective attachment tube 6 2 Thread the attachment nut and washer 7 on the Bowden cable 3 Ensure nut 9 is fastened 4 Place label plate 8 and align 5 Attach the main control unit 1 and the label plate 8 by means of its attachment nut and wash...

Page 152: ...le to the inlet box actuator 14 16 Check full travel Rigging Refer to figure 3 1 Loosen Bowden cable attachment bolt on the inlet box actuator 14 2 Place inlet box actuator to the closed position 3 Adjust main handle 1 to the full forward minus 5 mm position refer to detail A of figure 1 4 Fasten Bowden cable attachment bolt on the inlet box actuator 14 5 Check full travel 21 40 04 Distribution Bo...

Page 153: ...Bowden cable 3 Ensure nut 9 is fastened 4 Place label plate 8 and align 5 Attach the distribution control unit 1 and the label plate 8 by means of its attachment nut and washer 7 6 Lay the Bowden cable 3 along the prior marked routing 7 Fasten the Bowden cable 3 with self clinching plastic straps 5 in place 8 Thread the Bowden cable end through the hoseclamp 13 NOTE Ensure distance of cable housin...

Page 154: ...ble attachmant bolt on the distribution box actuator 10 2 Place distribution box actuator in the upmost position 3 Push distribution handle 1 to the full forward position Then pull aft 5 mm refer to detail A of figure 3 4 Fasten Bowden cable attachmant bolt on the distribution box actuator 14 5 Check full travel ...

Page 155: ...CHAPTER 21 PAGE 11 PAGEDATE 7 July2010 MAINTENANCEMANUALEXTRA300LT Figure 3 Heating Bowden Cables ...

Page 156: ...CHAPTER 23 PAGE 1 PAGEDATE 7 July2010 MAINTENANCEMANUALEXTRA300LT Chapter 23 Communication ...

Page 157: ...CHAPTER 23 PAGE 2 PAGEDATE 7 July2010 MAINTENANCEMANUALEXTRA300LT Table of Contents Chapter Figure Title 23 10 00 SPEECH COMMUNICATION 3 23 10 01 VHFWhipAntenna 4 Figure 1 Whip Antenna 4 ...

Page 158: ...tion Independent from the equipment installed the electric hardware such as switches circuit breakers sockets and wiring is the same The control sticks and power levers for pilot and copilot featurePTTswitches Thesocketsforconnectingtheheadsets are located on the right side of the respective cockpit The related wiring is generally fastened to the sticks levers torque tube or steel tubes with cable...

Page 159: ...beframe and connects this whip antenna directly to the respective transceiver Removal Installation 1 Assure the BATTERYswitch is OFF 2 Remove the main fuselage cover and the tail fairing Re fer to chapter 05 00 01 3 Disconnect the antenna to the coaxial cable 4 Remove the nut holding the antenna to the grounding plate 5 Pull the antenna carefully out of the rudder fin 6 Install in reverse sequence...

Page 160: ...CHAPTER 24 PAGE 1 PAGEDATE 7 July2010 MAINTENANCEMANUALEXTRA300LT Chapter 24 Electrical Power ...

Page 161: ...eet 2 Electrical System Schematic 6 24 30 00 DC GENERATION 7 24 30 10 Battery System 7 24 30 11 Battery 8 24 30 20 Alternator System 10 24 30 21 Alternator 10 Figure 3 Sheet 1 Alternator and Accessories 11 Figure 3 sheet 2 Alternator and Accessories 12 24 30 22 Drive Belt 13 24 30 23 Alternator Pulley 16 24 30 30 System Ground 16 24 60 00 DCELECTRICALLOADDISTRIBUTION 17 24 60 01 Circuit Breaker 17...

Page 162: ... the battery system and the alternator system The electrical installations on the firewall are shown on Figure 1 Sheet 1 up to SN LT004 From SN LT005 these installations are combined in the electrical main board Figure 1 Sheet 2 which is attached to the lower left fuselage structure just behind the firewall Figure 1 Sheet 1 Electrical Installations in Firewall Area ...

Page 163: ...d Legend 1 Spare 2 Alternator relay 3 External power relay 4 Starter relay 5 Battery fuse 6 Shunt 7 Battery relay Figure 1 Sheet 2 Electrical Main Board A functional schematic of the complete electrical system is shown on Figure 2 Sheet 1 up to SN LT004 Sheet 2 applies from SN LT005 ...

Page 164: ...CHAPTER 24 PAGE 5 PAGEDATE 21 March2014 MAINTENANCEMANUALEXTRA300LT Figure 2 Sheet 1 Electrical System Schematic ...

Page 165: ... V A Indicator Fuel QTTY Indicators rpm Indicator Oil temp press Indicator ELT Boost pump NAV light MVP 50 alt Strobe light Pedal adjust Electric trim AVIONIC MAIN BUS AVIOINIC BUS ALTERNATOR BATTERY STARTER Stall warning Landing light MVP 50 alt Figure 2 Sheet 2 Electrical System Schematic ...

Page 166: ...y System The battery is used for starting the engine and powering the electrical system when alternator power is not available engine not running The battery also powers the electrical system in case of alternator failure Up to SN LT004 and for SN LT009 and LT010 the battery system consists of the battery 8 Figure 1 Sheet 1 the battery relay 7 a 60Afuse 5 the battery switch and the associatedwirin...

Page 167: ... external power theBATTERYswitchmustbeinON position The battery can also be charged via the direct charge socket locatedontheleftforwardsideofthebottomfuselagecover In this case the BATTERY switch should be in the OFF position 24 30 11 Battery Removal Installation Up to SN LT004 N O T I C E Ensure the BATTERY switch is in Off position 1 Remove the engine cowling the main fuselage cover and the LH ...

Page 168: ...ch is in Off position 1 Remove the rear instrument panel cover as per chapter 31 2 Remove the front seat as per chapter 25 3 Disconnect the electrical wiring from the battery 4 Remove the 4 attachment nuts LN9348 06 and the top at tachment frame 5 Lift the battery out of its bottom frame and remove 6 Install in reverse sequence of removal ...

Page 169: ...or relay 2 Figure 1 Sheet 2 is part of the electrical main board The optional fuse is now obsolete TheALTERNATORswitch allSN islocatedontheleftside oftherearinstrumentpanel ThetoggletypeALTERNATOR switch features a red cap Placing the ALTERNATOR switch to the ON position will energize the alternator solenoid which provides a circuit fromthebusbartothealternator Thevoltageregulatorwill supply and c...

Page 170: ...CHAPTER 24 PAGE 11 PAGEDATE 21 March2014 MAINTENANCEMANUALEXTRA300LT Figure 3 Sheet 1 Alternator and Accessories ...

Page 171: ...ire at bolt 1 3b Prestolite Remove cotter pin at castle nut 7 Figure 3 and safety wires at bolts 4 5 3c Plane Power Remove safety wires at bolts 8 9 Figure 3 4a Bosch Slightly loosen bolt 1 and castle nuts at bolts 2 3 to release drive belt tension 4b Prestolite Slightly loosen bolts 4 5 and castle nut 7 to release drive belt tension 4c Plane Power Slightly loosen bolts 8 9 and stop nut at bolt 10...

Page 172: ...ernator lugs Thus do not torque castle nut 7 Figure 3 to the standard value for M8 bolts Hand tighten castle nut 7 followed by max one half 1 2 turn using a wrench just enough to eliminate axial free play of the bolt 6 and align nut and bolt for the clevis pin position As a final check try to turn the bolt 6 at its head If the bolt 6 turns easily it may be presumed to be tight ened correctly 1 Ins...

Page 173: ...tension 6 Rotate the alternator clockwise around bolt connection 3 6 or 10 7 Detach belt from the alternator pulley 8 Remove starter ring gear according to applicable Lycoming installation manual see Chapter 1 9 Remove belt 10 Install in reverse sequence of removal Refer to Chapter 20 10 03 for torque values of bolt connections 11 Apply a proper tension to the drive belt by counter clockwise rotat...

Page 174: ...e following for the new drive belt is to compensate for the initial stretch that takes place as soon as it is operated These higher tension values should not be applied to drive belts that have been used previously Condition Torque indicated at alternator pulley Newdrivebelt 15 to 18 Nm 10 to 13 ft lbs Used drive belt 10 to 12 Nm 7 to 9 ft lbs 4 Adjust belt tension accordingly TensionAdjustment 1a...

Page 175: ...all new cotter pins at castle nuts of bolts 2 3 and safety wire at bolt 1 5b Prestolite Install new cotter pins at castle nut 7 and safety wires at bolts 4 5 5c Plane Power Install new safety wires at bolts 8 9 24 30 23 Alternator Pulley Removal 1 Remove the nut from the alternator drive shaft 2 Remove the pulley from the alternator drive shaft Installation 1 Install in reverse sequence of removal...

Page 176: ...d on the control sticks and the throttle controls I M PO R TAN 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 PRC 812 Prod ucts Research Chemical Corporation USA firewall sealant 24 60 01 Circuit Breaker Removal Installation N O T I C E Disconnect battery 1 Remove the instrument panel cover per ...

Page 177: ...Rotate the panel 5 Disconnect wiring 6 Remove the attachment nut at the front side of the instru ment panel 7 Remove the switch 8 Install in reverse sequence of removal 24 60 03 Subminiature Pushbutton Switch Removal Installation N O T I C E Disconnect battery 1 Remove the attachment nut 2 Pull out the switch some centimeters 3 Loosen the soldered connections 4 Remove the switch 5 Install in rever...

Page 178: ...nut stationary when applying releasing the outer nut 3 Disconnect electrical wiring 4 Remove the DIN933 M5x12 attachment bolts the DIN9021 M5x20 washers and the LN9348 05 stopnuts 5 Remove the relay 6 Install in reverse sequence of removal DAN G E R Serious injuries or death due to unintentional rotating of the propeller when switching on the master switch with defective starter relay Do not allow...

Page 179: ...CHAPTER 25 PAGE 1 PAGEDATE 7 July2010 MAINTENANCEMANUALEXTRA300LT Chapter 25 Equipment and Furnishings ...

Page 180: ...e of Contents Chapter Figure Title 25 10 00 FLIGHTCOMPARTMENTS 3 25 10 01 Front Seat 3 25 10 02 Rear Seat 3 25 10 03 Seat Belts 5 Figure 1 Strap Assembly 5 Figure 2 Tubes for Shoulder Strap Attachment 6 Figure 3 Shoulder Strap Attachment 6 25 10 04 Aircraft Document Bag 7 ...

Page 181: ...ach seat to pedal connection Removal Installation 1 Remove rear instrument cover as per Chapter 31 2 Loosen the leather protection cuff from the control stick 3 Remove front seat attachment screws 4 Remove front seat 5 Disconnect crotch strap from seat if necessary 6 Install in reverse sequence of removal 25 10 02 Rear Seat Therearseatassemblyconsistsoftwoparts Theseatandthe backrest are composite...

Page 182: ...eat connection 3 Remove rear seat backrest 4 Disconnect backrest from the steel tubes if necessary by removing the resp bolts 5 Remove the seat attachment bolts front side of the rear seat and the quickpins of the seat steel frame 6 Remove the seat 7 Disconnect the seat from the steel frame and the crotch strap if necessary by removing the resp bolts 8 Assemble and install in reverse sequence of d...

Page 183: ...left shoulder harness two right and two left seat belts and a crotch strap Figure 1 Strap Assembly IMPORTANT Keep belts from contact with chemicals solvents degreaser battery acid and excessive exposure to direct sunlight Installation Each strap end is fitted with bolts stop nuts and washers to its own fitting at the steel frame resp at the underside of the seat The shoulder strap loops of the fro...

Page 184: ...ngthe3 barslide as shown in figure 3 IMPORTANT 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 IMPORTANT Make shure that after the proper length is determined the 3 bar slide is positioned as close to the structure as possible Figure 3 Shoulder Strap Attachment ...

Page 185: ...ALEXTRA300LT 25 10 04 Aircraft Document Bag The rear cockpit of the EXTRA300LT is furnished with an aircraftdocumentbag Thisaircraftdocumentbagismounted with three AN 526 C 1032 R8 bolts and DIN 9021 M5x20 washers to the right inside of the cockpit frame ...

Page 186: ...CHAPTER 27 PAGE 1 PAGEDATE 7 July2010 MAINTENANCEMANUALEXTRA300LT Chapter 27 Flight Controls ...

Page 187: ... Removal Installation 10 27 00 04 Rear Control Stick 11 27 00 05 TorqueTube 11 27 10 00 AILERONCONTROL 12 Figure 10 Aileron Control 13 27 10 01 Ailerons 14 Figure 11 Neutral Position of Rear Control Stick 14 Figure 12 Neutral Position of Aileron Bellcranks 15 27 10 02 Spades 16 Figure 13 Spade Rigging 16 27 20 00 RUDDERCONTROL 17 Figure 14 Rudder Control 18 27 20 01 Rudder 19 27 20 02 Bottom Hinge...

Page 188: ...withfulldualprimaryflightcontrolsincludingconventional 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 For rear torque tube bearing lubrication there is a rubber plugged hole in the bottom fuselage cover Figure 1 Controls ...

Page 189: ...he bearing could be displaced as shown in Figure 2 Use a mandrel to adjust the spacer sleeve Figure 2 Spacer Sleeve Displaced N O T E When installing a control surface use mandrels as shown in the following Figure 3 to preset the control surface Then press out each mandrel by pushing a bolt into the bearing Figure 3 Control Surface Mounting Aid ...

Page 190: ...CHAPTER 27 PAGE 5 PAGEDATE 7 July2010 MAINTENANCEMANUALEXTRA300LT Figure 4 Control Surface Deflections ...

Page 191: ...nside the wing are intercon nected by ground bonding leads fastened to the rod ends by additional nuts So the rod ends have to be disassembled whenthegroundbondingleadsshallbedisconnected Inthis case also refer to Chapter 27 00 01 1 Remove the respective access panels as per Chapter 51 N O T E In case of removal of the control rod connecting the control sticks also observe the instructions given i...

Page 192: ...6 for identification of the control rods 0 2 1 3 4 7 8 6 Figure 6 Control Rod Identification d o R l o r t n o C t n e m e r u s a e M t n e m n g i l a d n e d o R 0 m m 0 2 0 1 0 1 m m 9 0 8 0 2 m m 5 4 6 0 3 m m 7 3 7 0 4 m m 4 6 7 0 6 m m 2 3 5 0 9 7 m m 7 8 0 1 0 2 8 m m 5 9 1 0 Table 1 Control Rod Measurement Rod End Alignment ...

Page 193: ...e 1 after adjust ment This particularly applies for the control rod 1 Figure 6 which must allow the torque tube to rotate I M PO R TAN T Observe that the rod ends joined to the rocker type bellcrank should be adjusted long enough not to ob struct the travel I M PO R TAN T Ensure that the threaded rod is visible in the check hole Figure 7 in any case Figure 7 Control Rod Check Hole 4 Turn the rod e...

Page 194: ...erse procedure to install the bellcrank using sufficient washers min 2 at the nut side of the bolt to cover the shank except the rocker type bellcrank use only one washer on each side Replace the selflocking nuts Observe the first note of Chapter 27 00 00 To ensure installation of the el evator rocker type bellcrank in correct direction this bellcrank is marked by an F which indicates the front si...

Page 195: ...achment bolt 1 4 Disconnect the control stick from the control rod per Chap ter 27 00 01 Use the control stick to move the control rod attachment bolt within the mounting hole area 2 Figure 9 Front Control Stick Removal Installation 5 Remove the control stick 6 Reverse procedure to install the control stick Replace the selflocking nuts Observe the first note of Chapter 27 00 00 7 Check for potenti...

Page 196: ...ick Replace the selflocking nuts Observe the first note of Chapter 27 00 00 7 Inspect for potential chafing of the wiring after installation 27 00 05 Torque Tube Removal Installation 1 Remove the bottom fuselage cover as per Chapter 51 2 Remove the control sticks and rods as per Chapters 27 00 01 and 27 00 03 04 3 Loosen the bolts of the front and rear bearing blocks 4 Disassemble the bearing bloc...

Page 197: ...iumhingearms Forlightningprotection reasons each hinge arm is electrically bonded to the corre spondingattachmentbracketattheaileronbybondingbraids Therodendbearingsofthepush pullrodslocatedinthewing are also interconnected by bonding braids The travel stops 7 arelocatedatthetorquetubenexttotherearcontrolstick 8 Toreducepilot shandforces theaileronsareequippedwith spades To prevent flutter the ail...

Page 198: ...CHAPTER 27 PAGE 13 PAGEDATE 7 July2010 MAINTENANCEMANUALEXTRA300LT Figure 10 Aileron Control ...

Page 199: ...se sequence of removal Ensure that the spade is installed with the same quantity and location of shimming washers refer to Figure 12 Observe the second note of Chapter 27 00 00 Apply new 3M Scotch 8671 PU tape Rigging Before beginning any adjustments inspect control rods levers and hinges for signs of wear or damage For new control rods check if lengths correspond to the measure mentsgiveninChapte...

Page 200: ... outboard bellcranks using the respective check hole refer to Figure 12 6 Adjust length of control rods 7 Figure 6 if necessary per Chapter 27 00 01 7 Check if the ailerons are in 0 position 8 Adjust length of control rods 8 Figure 6 if necessary per Chapter 27 00 01 9 Release the control stick 10 Check if the left aileron travel is within the given tolerances up 30 down 20 tol 2 Use a conventiona...

Page 201: ...symmetrically to each side 14 Contact the manufacturer when detecting faulty results 15 Reinstall wing access panels 27 10 02 Spades Rigging For roll trim the spade rigging angle of incidence has to be changed Insertwasher s betweenthespadeandthemount 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 Figure...

Page 202: ... is grounded to the correspondingattachmentbracketattherudderbybonding leads A travel stop plate is located at the bottom hinge bracket Asecond safety stop is located at the rudder pedal bearing having the only purpose of protecting the lower brake system fitting in case of rudder cable failure I M PO R TAN T This second stop must not be reached under normal operation conditions Misallignment or e...

Page 203: ...1 March 2014 MAINTENANCEMANUALEXTRA300LT Figure 14 Rudder Control 1 2 3 4 5 6 5 7 6 7 8 9 9 2 Legend 1 rudder pedals 3 bottom hinge bellcrank 5 sleeves 8 cable fastening 9 spring 2 rudder control cable 4 rudder 6 fairleads 7 pulley ...

Page 204: ...econd note of Chapter 27 00 00 Rigging N O T E Inspect the control cables the pulleys the fairleads and the bottom hinge assembly with the travel stop plate for signs of wear or damage before beginning any ad justments Replace parts if necessary 1 Secure the rudder pedals in neutral position 2 Check if the rudder is in 0 position Rudder horn leading edge in alignment with the leading edge of the v...

Page 205: ...20 01 2 Loosen the attachment bolts 3 Remove the bottom hinge bellcranks 4 Install in reverse sequence of removal 27 20 04 Control Cable Removal 1 Remove the respective access panels 2 Remove the cable to fuselage attachment bolts 3 Remove the cable to rudder bellcrank attachment bolts 4 Cut the control cables behind the front shrinking sleeves and behind the cable to cable connection 5 Remove the...

Page 206: ...o 20 mm in front of the pedal S tube 8 Slip 2 NICOPRESS NationalTelephone Supply Co Cleve land Ohio 18 3 M or 28 3 M sleeves 5 and 100 mm 771095 shrinking sleeve on the control cable 9 Thread the free end of the control cable through the rear fairleads 6 and the hole in the fabric to the tail 10 Slip 80 mm 771095 shrinking sleeve and 850 mm teflon protective hose on the control cable end The prote...

Page 207: ...truction No 32 of the National Telephone Supply Co Cleveland Ohio 16 Consider to let a distance of 1 mm between the thimble and the sleeve and clamp the sleeve 17 Cut the free end of the cable 20 mm in front of the sleeve 18 Slip the 80 mm 771095 shrinking sleeve on the cable end and the protective hose center on the protective hose end and heat up with a heat gun 19 Slip the other 80 mm 771095 sh...

Page 208: ...ational Telephone Supply Co Cleveland Ohio I M PO R TAN T To prevent the cables from twisting clamp the sleeves in the same plane 25 Consider that the clamping area shall be 195 mm aft of the rear pulley and clamp the sleeves 26 Cut the free end of the cable 20 mm behind the sleeve 27 Slip the shrinking sleeve on the rear sleeve and heat up with a heat gun the front sleeve can be left free for vis...

Page 209: ...4 PAGE DATE 21 March 2014 MAINTENANCEMANUALEXTRA300LT 27 20 05 Fairlead Removal Installation 1 Remove the fairlead retaining clip 2 Pull the fairlead halves out of the sleeve 3 Reverse procedure to install the fairlead ...

Page 210: ...vator by bonding leads The travel stops 15 are located at the torque tube Mass balance weights 9 are mounted on the elevator tips extending into the horizontal stabilizer when the elevator is inneutralordownwardposition Anadditionaloptionalmass balanceweight 9a canbeinstalledontheelevatoractuator arm An access panel is located at the right side of the rear fuselage TrimTab Pitch trim is done by me...

Page 211: ... 2 torque tube 3 push pull rod 4 control stick rear seat 4a handle incl trim control switch 5 trim lever 6 trim servo rod 7 trim servo 8 trim control bowden cable dual 9 mass balance weight standard 9a additional mass balance weight optional 10 trim tab 11 elevator 12 elevator actuation arm 13 bellcrank 14 rocker type bellcrank 15 travel stops 3 3 13 13 9 10 6 9 9a 7 8 11 ...

Page 212: ...oosen 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 Rigging I M PO R TAN T Before beginning any adjustments inspect control rods levers and hinges for signs of wear or damage and check if control rod lengths correspond with the measure ments given in Chapter 27 00 02 Replace parts and correct l...

Page 213: ...g edge aligned to the stabilizer tip trailing edge 4 If necessary adjust the length of the middle tail control rod as per Chapter 27 00 01 5 Check if the elevator travel is within the given tolerances up 25 2 down 25 2 Use a conventional protractor 6 Adjust the travel stops if necessary 7 Check if the rear control stick travel is symmetrical 8 If it is not contact the manufacturer ...

Page 214: ... is not proceed as follows a Remove the trim servo rod 2 from the trim servo 3 and the trim lever 4 by removing the clevis pins with cotter pins and washers b Loosen the counternut from the adjustable rod end and screw the rod end out or in as necessary to adjust the fuselage bellcrank in neutral position default measure ment is 147 mm Ensure rod end is screwed in for min 10 mm c Fasten the counte...

Page 215: ...CHAPTER 27 PAGE 30 PAGE DATE 21 March 2014 MAINTENANCEMANUALEXTRA300LT Figure 19 Trim Tab Rigging ...

Page 216: ...CHAPTER 28 PAGE 1 PAGEDATE 7 July2010 MAINTENANCEMANUALEXTRA300LT Chapter 28 Fuel ...

Page 217: ...12 Figure 6 Filler Neck and Sealing Lip Removal Installation 13 28 10 09 Ventilation Line 13 28 20 00 DISTRIBUTION 14 Figure 7 Distribution 15 28 20 01 Fuel Selector Valve 16 Figure 8 Fuel Selector Valve and Control Rod 17 28 20 02 Selector Valve Control Rod 18 28 20 03 Gascolator 19 Figure 9 Gascolator Removal Installation 19 28 20 04 Electrical Boost Pump 20 Figure 10 Boost Pump Removal Installa...

Page 218: ...outdoors with the aircraft at least 100 feet from hangars or other aircraft 2 No smoking should be allowed within 100 feet of the aircraft 3 Suitable fire fighting equipment should be available Foam or soda type extinguishing agents are recommended 4 Ground the aircraft to prevent static electricity from causing sparks If a ramp ground is available it should be connected to the exhaust If a ramp g...

Page 219: ...CHAPTER 28 PAGE 4 PAGEDATE 7 July2010 MAINTENANCEMANUALEXTRA300LT Figure 1 Fuel System ...

Page 220: ...ve or toxic levels in the hangar WAR 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 Air Ventilation 1 Completely drain the fuel system as per chapter 12 10 02 2 Remove inspection doors refer to chapter 28 11 04 and tank caps 3 Use...

Page 221: ...tankdeaerates a into the center tank that itself deaerates by a ventilation tube b ending at the right side of the main landing gear spring The root section of each wing behind the main spars forms an integral fuel tank 4 Each wing tank has a 2 diameter filler cap 5 for gravity fueling Sealing lips are installed at the filler necks inside the wing tank For sealing 3M Brand Fuel Resistant Coating 7...

Page 222: ...CHAPTER 28 PAGE 7 PAGEDATE 7 July2010 MAINTENANCEMANUALEXTRA300LT Figure 2 Storage ...

Page 223: ...ixtures 6 Loosen and remove the metal attachment belts including the rubber strips 7 Remove the center tank 8 Install in reverse sequence of removal 28 10 02 Acro Tank Removal Installation 1 Remove the main fuselage cover and the bottom fuselage cover as per chapter 53 00 03 53 00 04 respectively 2 Remove the front seat as per chapter 25 10 01 3 Drain the fuel system as per chapter 12 10 02 4 Loos...

Page 224: ...ube as sembly 2 out of the acro tank 1 WAR 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 containers covered when not in use 5 Clean the sealing surfaces mechanically and withAcetone N O T E If the flop tube assembly has to be replaced install a complete new assembly 6 Install in rever...

Page 225: ...n door flange 3 5 Push the inspection door 4 into the tank then turn and remove WAR 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 containers covered when not in use 6 Clean the sealing surfaces mechanically and withAcetone 7 Install in reverse sequence of removal after applying 3M Bra...

Page 226: ...ventilated areas Avoid physical contact with solvent and do not inhale vapors Keep solvent containers covered when not in use 4 Clean sealing surfaces mechanically and withAcetone 5 Install in reverse sequence of removal after applying 3M Brand Fuel Resistant Coating 776 3M St Paul USA to the sealing surfaces fitting to tank root rib Ensure that the outlet end positions are as shown in figure 5 be...

Page 227: ...ng 4 figure 6 with sealing lip 5 using a tool as shown in figure 6 4 Remove filler neck 3 with filler cap 1 and O ring 2 WAR 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 containers covered when not in use 5 Clean all sealing surfaces withAcetone 6 Install in reverse sequence of remov...

Page 228: ...ANUALEXTRA300LT 2 Install the new sealing lip using new washers 6 and body bound rivets Figure 6 Filler Neck and Sealing Lip Removal Installation 28 10 09 Ventilation Line Replacement General information concerning fittings is given in chapter 20 10 08 ...

Page 229: ...lector valve and the auxiliary fuel pump at the firewall engine side An Allen 6S122 type 1 fuel selec tor valve is located at the right side of the front cockpit behind the main spar on a separate support A control rod connects the selector valve to the control handles 2 The fuel selector valve is marked by the letters WT Wing Tank E Engine and CT CenterTank toensurecorrect installation of fuel li...

Page 230: ...CHAPTER 28 PAGE 15 PAGEDATE 21 March2014 MAINTENANCEMANUALEXTRA300LT Figure 7 Distribution ...

Page 231: ... three hours 5 If fuel is found in the wing tanks the fuel selector valve must be repaired or replaced Removal Installation Refer to figure 8 1 Drain the fuel system as per chapter 12 10 02 2 Disconnect the fuel lines on the selector valve 3 Remove the control rod attachment bolts 5 4 Remove the attachment screw 4 if reasonable 5 Remove the control bracket 3 6 Remove the selector valve attachment ...

Page 232: ...l Rod Legend 1 Selector valve 2 Selector valve attachment bolts 3 Control bracket 4 Attachment screw 5 Control rod attachment bolts 6 Front control rod 7 Front control rod connection bolt 8 Washers 9 Spring 10 Middle control rod with handle 11 Rear control rod connection bolt 12 Rear control rod with handle ...

Page 233: ...on Refer to figure 8 1 Remove the rear control rod connection bolt 11 2 Pull the control rod 12 to the rear 3 Remove the control rod attachment bolts 5 4 Remove the front control rod connection bolt 7 5 Remove the washers 8 and the spring 9 the front 6 and the middle control rod 10 6 Install in reverse sequence of removal ...

Page 234: ...ystem per chapter 12 10 02 2 Disconnect the fuel lines from the gascolator 3 Loosen the knurled nut 1 figure 9 4 Remove the mounting bracket 2 5 Remove the fuel reservoir 3 and the sealing ring 4 6 Remove the strainer 5 and the gascolator cover 6 7 Install in reverse sequence of removal Figure 9 Gascolator Removal Installation ...

Page 235: ... Boost Pump Removal Installation 1 Drain the fuel system as per chapter 12 10 02 2 Disconnect the plug and the fuel lines from the boost pump 3 Loosen the screw clamps 1 figure 10 4 Remove the boost pump 2 5 Install in reverse sequence of removal Figure 10 Boost Pump Removal Installation ...

Page 236: ...formationconcerninghosesandfittingsyoufind in chapter 20 10 07 08 I M PO R TAN 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 Use PRC 812 Products Research Chemical Cor poration USA firewall sealant ...

Page 237: ...antitytransducer 2 If the optional MVP 50P is installed the right wing tank is also equipped with a lever type fuel quantity transducer refer to chapter 77 40 They transmit the fuel levels to the respective fuel quantity indicators at the instrument panel 3 In contrast to the fuel quantityindicatorofthecentertanktheoneofthewingtank isnotadjustable Iftheindicationisinexactthefloatwireof the tank un...

Page 238: ...CHAPTER 28 PAGE 23 PAGEDATE 7 July2010 MAINTENANCEMANUALEXTRA300LT Figure 11 Indicating ...

Page 239: ...40 01 Fuel Quantity Indicator Removal Installation 1 Disconnect battery 2 Loosen the nuts remove the mounting bracket and re move the fuel quantity indi cator 3 Disconnect the wiring the lamp is not used 4 Install in reverse sequence of removal observing the wiringdiagram ...

Page 240: ...r Tank Removal Installation 1 Drain the fuel system as per chapter 12 10 02 2 Loosen one bolt and replace by a M5 threaded rod 1 for securing the slotted retainer ring 2 3 Remove the other bolts and the ground bonding lead 3 4 Remove the transducer and the sealing ring while holding the threaded rod 5 Removethethreadedrodand turn out the slotted retainer ring 2 WAR N I N G Stripping solvents can b...

Page 241: ...nsducer Wing Tank Removal Installation refer to figure 12 1 Disconnect the electrical wiring 2 Remove inspection door as per chapter 28 10 04 3 Remove tank unit bolts 1 4 Remove the retainer ring 3 the tank unit 4 and the seal ing ring 2 Figure 12 Fuel Quantity Transducer Wing Tank Removal Installation WAR N I N G Stripping solvents can be toxic and volatile Use only in well ventilated areas Avoid...

Page 242: ... installation of float wire as per para graph 28 40 05 28 40 05 Float Wire Adjustment 1 Remove the lever type tank unit as per chapter 28 40 04 N O T E Figures 13 and 14 are mirror inverted also valid for the float wire in the RH wing tank if the optional MVP 50P is installed 2 Remove the float wire and bend it in form like shown in the following figure 13 Figure 13 Float Wire Adjustment 3 Reinsta...

Page 243: ...CHAPTER 28 PAGE 28 PAGEDATE 7 July2010 MAINTENANCEMANUALEXTRA300LT Figure 14 Float Wire Installation 4 Reinstall the lever type tank unit as per chapter 28 40 04 ...

Page 244: ...CHAPTER 31 PAGE 1 PAGEDATE 7 July2010 MAINTENANCEMANUALEXTRA300LT Chapter 31 Indication Recording System ...

Page 245: ...el 8 Figure 4 Front Instrument Panel 8 31 10 04 Front Instrument Panel Frame 9 Figure 5 Front Instrument Panel Removal Installation 10 31 10 05 Front Instrument Panel with Garmin G5 11 Figure 6 Front Instrument Panel with Garmin G5 11 31 10 06 Front Instrument Panel Support for Garmin G5 12 Figure 7 Front Instrument Panel Support for Garmin G5 Removal Installation 13 31 10 07 Typical Instruments 1...

Page 246: ...RAL TheExtra300LTisequippedwithflightinstrumentsinboth cockpits Instruments and placards can feature markings in either metric or English units refer to Pilot s Operating Handbook Section2 MarkingsandPlacards Thecolour markings in instruments follow US FAR part 23 recommendations ...

Page 247: ...verand a center panel sheet control switch and circuit breaker panel WhentheMVP 50isinstalledgenerallyanadditional sub panel is installed refer to Chapter 77 40 00 Thepanelsandthecoveraremountedonthesteelframewith AN 526 C 1032 R8 bolts Forthestandardpanelarrangementoftherearcockpitrefer to Figure 1 and 2 and the adjacent charts N O T E The charts may be modified by the minimum equipment requireme...

Page 248: ...CHAPTER 31 PAGE 5 PAGEDATE 7 July2010 MAINTENANCEMANUALEXTRA300LT Figure 1 Rear Instrument Panel Figure 2 Rear Switches Circuit Breakers ...

Page 249: ...tches Position Item Fig 2 1 Alternatorwarninglightincl press to testfeature 2 Batteryswitch redcap 3 Alternatorswitch redcap 4 Boostpumpswitch 5 Strobelightswitch 6 NAVlightswitch 7 Avionicswitch circuitbreaker 8 Leftpedaladjustmentswitch 9 Rightpedaladjustmentswitch 10 Landinglightswitch 11 Stallwarningcircuitbreaker 12 Spare 13 Startercircuitbreaker 14 Alternatorfieldcircuitbreaker 15 Boostpumpc...

Page 250: ...at the top of the front seat back rest 1 Figure 3 2 Remove the outer screws 2 of the rear instrument panel The two inner screws connect the panel to the steelframe 3 Remove the cockpit corner cover screws 3 4 Remove the instrument and the cockpit corner covers 5 Install in reverse sequence of removal Figure 3 Rear Instrument Cover Removal Installation ...

Page 251: ...trument Panel Removal Installation N O T I C E Hold instruments and panel by hand to prevent from falling down when removing the instrument panel at tachment bolts 1 RemoveDIN912M4x5bolts 2 Figure5 andshockmounts 1 with LN 9348 M4 stop nuts 2 Pull the front instrument panel with instruments aft some centimeter 3 Disconnect the Pitot resp static lines from the instruments 7 Mark lines for later ide...

Page 252: ... front instrument panel is installed in frame which is connected to the main fuselage cover Removal Installation 1 Remove front instrument panel as per Chapter 31 10 03 2 Remove the AN526 C 1032 R6 frame attachment screws 3 Figure 5 3 Remove the front instrument panel frame 6 4 Reverse procedure for installation ...

Page 253: ...CHAPTER 31 PAGE 10 PAGEDATE 24 February2017 MAINTENANCEMANUALEXTRA300LT Figure 5 Front Instrument Panel and Frame Removal Installation ...

Page 254: ...t Instrument Panel with Garmin G5 Removal Installation N O T I C E Hold Garmin G5 and panel by hand to prevent from falling down when removing the instrument panel at tachment screws 1 RemovetheAN526C 1032 R6instrumentpanelattachment screws 3 Figure 7 2 Pull the front instrument panel with instruments aft some centimeter 3 Disconnect the pitot resp static lines from the Garmin G5 4 Mark lines for ...

Page 255: ...emove the front instrument panel as per Chapter 31 10 04 3 Hoist the aircraft front by means of both engine hoisting points just enough to relieve the bolts 5 and 6 Figure 7 Refer to Chapter 07 20 01 4 Loosen the cutout bridge attachment bolts 5 on each fuselage side Turn maximum 2 rotations 5 Remove DIN 912 M12x220 bolts 6 6 Remove front instrument panel support 1 N O T I C E Damage to the fusela...

Page 256: ...CHAPTER 31 PAGE 13 PAGEDATE 24 February2017 MAINTENANCEMANUALEXTRA300LT Figure 7 Front Instrument Panel Support for Garmin G5 Removal Installation ...

Page 257: ...00LTare outlined 1 Switch off aircraft power 2 Remove main fuselage cover per Chapter 53 3 Remove rear instrument panel cover if applicable per Chapter 31 10 02 4 Disconnect cable and or sense line from the instrument 5 Remove screws nuts or clipnuts as applicable 6 Remove instrument from panel 7 Install in reverse sequence of removal Figure 8 Typical Instrument Attachments ...

Page 258: ...val Installation G5 Battery Removal Installation if optional backup battery installed and G5 Mounting Ring Replacement Test and Calibration Procedures 1 Perform a Pitot static system Leak Check per Garmin G5 Maintenance Manual see Chapter 1 whenever the system is opened up 2 Perform Garmin G5 Calibration Procedures per Garmin G5 Maintenance Manual see Chapter 1 after maintenance ...

Page 259: ...rm horn which is fitted in the back of the front seat The stall warning switch is located at the RH wing leading edge The electrical circuit of the stall warner is independentlyprotectedwithanautomatic1amperecircuit breaker in the rear instrument panel Thestallwarningswitchhasbeenadjustedatthefactoryafter atestflight Itissettotriggerthewarningapprox 5 10knots prior to stalling in normal flight The...

Page 260: ...CHAPTER 32 PAGE 1 PAGEDATE 7 July2010 MAINTENANCEMANUALEXTRA300LT Chapter 32 Landing Gear ...

Page 261: ...n Landing Gear 4 32 10 02 Top Half of the Mounting Clamp 4 Figure 2 Main Landing Gear Mounting 5 32 10 03 WheelAxis 5 32 10 04 Tail Spring 5 32 10 05 Tail Wheel Fork 6 Figure 3 Tail Wheel Fork and Spring 7 32 40 00 WHEELSANDBRAKES 8 Figure 4 Brake System 9 32 40 01 Master Cylinder 10 32 40 02 Wheel Fairing 11 Figure 5 Layer Sequence Wheel Fairing 11 32 40 03 Tail Wheel 12 ...

Page 262: ...eansofthe landing gear U spring This spring is of integral glasfibre design and incorporates wheel alignement spring and dampeningaction IMPORTANT New bolts are to be used when the wheel axles are replaced or refitted Thetailwheelissteerableandfeaturesfullswivelcapability Thetailwheelsteeringisattachedtotherudderbottomhinge bellcranks using the same bolts as the control cables Thevaluesforwheelrak...

Page 263: ...anding gear 4 7 Install in reverse sequence of removal using new stop nuts For correct position of landing gear the mandrel which is located at the bottom of the fuselage is to put into the respective sleeve at the top of the landing gear spring Use 3M Scotch 8671 PU tape to fasten the ventilation tubings and brake lines Replenish brake fluid 32 10 02 Top Half of the Mounting Clamp Removal Install...

Page 264: ...ter 32 40 02 2 Remove wheel 3 Remove the four wheel axis attachment bolts and remove the axis the reinforcement plate and the wheel fairing holder plate 4 Install in reverse sequence of removal Use new nuts and bolts 32 10 04 Tail Spring Removal Installation Refer to figure 3 1 Shore the tail as per chapter 07 20 02 2 Remove the tail cone access panel as per chapter 51 00 01 ...

Page 265: ...ing 4 6 Remove bolts 6 for disassembly if appropriate 7 Reverse procedure for installation consider to fasten the breather line using the MS21919 DG12 clamp 5 32 10 05 Tail Wheel Fork Removal Installation Refer to figure 3 1 Shore the tail as per chapter 07 20 02 2 Remove the attachment stopnut 7 and washer 3 Remove the steering arm 8 and the tail wheel fork 9 4 Reverse procedure for assembly ...

Page 266: ...CHAPTER 32 PAGE 7 PAGEDATE 21 March2014 MAINTENANCEMANUALEXTRA300LT Figure 3 Tail Wheel Fork and Spring Top View 1 2 3 4 4 5 6 7 8 9 9 10 11 12 13 11 12 14 14 7 8 10 15 15 ...

Page 267: ... the brake caliper floating over the disc The brake system refer to figure 4 consists of a brake assembly located at the inner side of the wheel a master cylinder 1 at the front and rear rudder pedals each and a brake fluid reservoir 2 mounted at the engine side of the firewall Themastercylindersaremountedinline sothatthe front cylinder looses his efficiency when the rear cylinder has been actuate...

Page 268: ...CHAPTER 32 PAGE 9 PAGEDATE 7 July2010 MAINTENANCEMANUALEXTRA300LT Figure 4 Brake System ...

Page 269: ...ly2010 MAINTENANCEMANUALEXTRA300LT 32 40 01 Master Cylinder Removal Installation 1 Drain the brake system 2 Disconnect the brake lines 3 Remove the attachment bolts 4 Remove the master cylinder 5 Install in reverse sequence of removal ...

Page 270: ...nsists of the fairing body a brakeinspectionpanelontheinboardsideandatireinflation access cap on the outboard side Figure 5 Layer Sequence Wheel Fairing Removal Installation The wheel fairings are screwed Wheninstallingthewheelfairingensureagapofminimum 1 5 mm from the fairing surface to the landing gear spring Correct position if necessary prior to fastening the fairings ...

Page 271: ...heel Disassembly Assembly Refer to figure 3 1 Shore the tail as per chapter 07 20 02 2 Remove the axle bolt washers and stopnut 10 3 Remove the tailwheel 4 Disassemble the bearings 11 the wheel halves 12 the spacer sleeve 13 and the solid rubber tire 14 5 Reverse procedure for assembly ...

Page 272: ...CHAPTER 33 PAGE 1 PAGEDATE 7 July2010 MAINTENANCEMANUALEXTRA300LT Chapter 33 Lights ...

Page 273: ... Navigation Strobe Light 6 Figure 1 Navigation Strobe Lights Removal Installation 6 33 40 12 Strobe Light Power Supply 7 Figure 2 Strobe Light Power Supply Removal Installation 7 33 40 20 Landing Light System 8 33 40 21 LandingLight 8 Figure 3 Landing Light 9 33 40 22 HeadLamp 10 33 40 23 Landing Light Power Supply 10 33 40 30 LED Landing Light System 11 33 40 31 LEDLandingLight 11 33 40 32 LEDHea...

Page 274: ...e indicator by turning the dimmer ring counter clockwise 4 Remove the attachment nut and washer 5 Disconnect wiring if appropriate 6 Remove the low voltage monitor housing Installation Thelowvoltagemonitorshallbeinstalledinsuchaway that the rightmost dimming position is at the 2 o clock position Thisensuresanindicationwhentheindicatoristurnedtothe normal position 1 BATTERYswitchOFF 2 Connect wirin...

Page 275: ...CHAPTER 33 PAGE 4 PAGEDATE 7 July2010 MAINTENANCEMANUALEXTRA300LT 7 Fasten the attachment nut 8 Turn the indicator to the 12 o clock position 9 Reinstall the instrument cover per Chapter 31 10 03 ...

Page 276: ...r ward section a strobe light in the center and a clear tail position LED light on the aft section They are mounted at thewingtip Thestrobelightpowersupplyismountedonthe left wing root rib The wiring is routed through an aluminium tube inside the wingandalongtheleftresp rightupperlongerontotherear instrument panel Ground bonding leads are installed be tween the fuselage the aluminium tube the pito...

Page 277: ...it 5 minutes N O T E To change a navigation LED light or glass the removal of the Phillips screws 1 is sufficient for access 2 Remove the lighting cover Phillips screws 6 3 Remove the lighting cover and pull out the strobe light 2 some centimetres 4 Remove the lighting unit attachment bolts 3 5 Remove the lighting unit 6 Install in reverse sequence of removal after applying Silicon between the win...

Page 278: ...er shutting off before starting any work on the strobe light system 1 Disconnect the electrical wiring of the power supply 1 2 Remove the attachment bolts 2 and disconnect the ground bonding lead 3 Remove the power supply N O T I C E DC units are polarity sensitive Black lead is negative 4 Install in reverse sequence of removal Figure 2 Strobe Light Power Supply Removal Installation ...

Page 279: ...connectiononeachside 8 13 Between firewallfeedthroughandthepowersupplythereisafurther plug and socket connection 14 15 N O T E When the cowling shall be removed the plug 15 must be disconnected The system is controlled by the LANDING LIGHT switch and is protected by the LANDING LIGHT circuit breaker both located on the aft right instrument panel see Chapter 31 10 00 33 40 21 Landing Light Removal ...

Page 280: ...CHAPTER 33 PAGE 9 PAGEDATE 7 July2010 MAINTENANCEMANUALEXTRA300LT Figure 3 Landing Light ...

Page 281: ...chment bolts 5 3 Remove the head lamp 6 from the hood 10 4 Install in reverse sequence of removal 33 40 23 Landing Light Power Supply Removal Installation 1 BATTERYswitchOFF 2 Remove engine cowlings as per Chapter 71 3 Disconnect the plugs 13 14 from the power supply 2 4 Remove the attachment bolts 12 and remove the power supply 2 5 Install in reverse sequence of removal ...

Page 282: ...must be disconnected The system is controlled by the LANDING LIGHT switch and is protected by the LANDING LIGHT circuit breaker both located on the rear instrument panel see Chapter 31 10 00 33 40 31 LED Landing Light Removal Installation 1 BATTERYswitchOFF 2 Remove engine cowlings as per Chapter 71 3 Disconnect the plug 2 Figure 4 from the LED head lamp 8 4 Remove the attachment bolts 6 and remov...

Page 283: ...CHAPTER 33 PAGE 12 PAGEDATE 21 March2014 MAINTENANCEMANUALEXTRA300LT Top View Side View 1 3 3 7 8 7 4 5 5 Firewall 9 10 2 2 5 4 6 4 Figure 4 LED Landing Light ...

Page 284: ...CHAPTER 34 PAGE 1 PAGEDATE 7 July2010 MAINTENANCEMANUALEXTRA300LT Chapter 34 Navigation ...

Page 285: ...NTDATA 4 34 10 01 Pitot Static System 4 Figure 1 Pitot Static Drain 4 34 10 02 Altimeter 5 34 10 03 Airspeed Indicator 5 34 10 04 Pitot Static Tube 6 34 10 05 Pitot Static TubeAttachment Block 6 34 20 00 ATTITUDEANDDIRECTION 8 34 20 01 Magnetic Compass 8 34 20 02 Attitude Indicator 9 34 50 00 DEPENDENTPOSITIONDETERMINING 10 34 50 01 Transponder 10 ...

Page 286: ...nal airspeed indicator and altimeter are installed Refer to the Equipment List of the Pilot s Operating Handbookforinstalledoptionalequipment The colour markings on the instruments follow US FAR part 23 recommendations To get the pitot and static pressure a pitot static tube is installed at the LH wing leading edge IMPORTANT Perform a leakage test on the pitot static system whenever working on the...

Page 287: ...is screwed through the L H outboard leadingedgeintoanattachmentblocklocatedattherearweb ofthemainspar Fromtherethepressuresaretransmittedby meansofavinyltubewhichisroutedthroughanaluminium tube inside the wing to the left side of the fuselage and furthertotheinstrumentpanels Theendsofeachvinyltube are marked with the letters P or S for pitot resp static pressure line The pitot static system can be...

Page 288: ...if necessary 3 Remove the attachment bolts and clip nuts 4 Remove the altimeter 5 Install in reverse sequence of removal 6 Perform an operation test 34 10 03 Airspeed Indicator Theairspeedindicatorshowsthespeedoftheaircraftrelative to the atmosphere The airspeed indicator measures the difference between pitot pressure and static pressure the formerbeingpickedupbythepitottubeatthepitotlocation of t...

Page 289: ...Installation Thepitot statictubeconsistsofaninneraluminiumtube an outer aluminium tube and a top cap which are screwed 1 Unscrew the top cap 2 Unscrew the outer aluminium tube 3 Unscrew the inner aluminium tube 4 Install in reverse sequence of removal applying silicone in the gap between the outer aluminium tube and the hole of the wing leading edge 34 10 05 Pitot Static Tube Attachment Block Remo...

Page 290: ...CHAPTER 34 PAGE 7 PAGEDATE 7 July2010 MAINTENANCEMANUALEXTRA300LT 5 Loosen clamps and disconnect the tubing 6 Remove the fittings if necessary 7 Install in reverse sequence of removal Use new stop nuts ...

Page 291: ...n increments of 5 Its case is filled with silicone oil to dampen the movements The compass correction card is located on the rear instrument panel The magnetic compass must be inspected as per chapter 5 andwhenevertheengine magnetizablemetalsorpartsofthe electricalresp ignitionsystemhavebeenreplaced changed oradded Removal Installation 1 Remove the instrument cover per chapter 31 10 03 2 Remove th...

Page 292: ...rth It indicates pitch fore and aft tilt and bank side to side tilt TheincorporatedAttitudeandHeadingReferenceSystems AHRS actuates a display that has two dimensions of freedom simultaneouslydisplayingpitchandbank Removal Installation 1 Remove the instrument cover per chapter 31 10 03 2 Disconnect the electrical wiring from the attitude indicator 3 Remove the attitude indicator attachment bolts an...

Page 293: ...f the Air Traffic Radar Beacon System ATCRBS Itoperatesonradarfrequencies receivingground radar interrogations at 1030 MHz and transmitting a coded response of pulses to ground based radar on a frequency of 1090 MHz Rermoval Installation 1 Remove instrument cover if transponder has to be installed from the rear Refer to chapter 31 10 03 2 Remove transponder following the Removal Installation Instr...

Page 294: ...CHAPTER 51 PAGE 1 PAGEDATE 7 July2010 MAINTENANCEMANUALEXTRA300LT Chapter 51 Standard Practices and Structures General ...

Page 295: ...e 3 Determination of Control Surface Moments 20 Figure 4 Control Surface Weights and Moments 21 51 70 00 REPAIRS 22 51 70 01 Repair of Reinforced Glass and Carbon Fibre Components 22 51 70 02 Repair of Sandwich Material 24 Figure 5 Minor surface damage 24 Figure 6 Curing cycle resin L20 SL 26 Figure 7 Level Sanding of Surrounding Area 26 Figure 8 Damage of Complete Sandwich 28 51 70 03 Repair of L...

Page 296: ...beginningworkorchecks With the exception of the oil filler access door the baggage compartment door and the wheel fairing inspection cap all panels are screwed Thefollowinglistshows wheredetailledremoval installation information for the respective parts can be found Part Chapter Enginecowlings 71 Fuselagecovers canopy 53 Instrumentcover 31 Wheel fairings 32 N O T E Access panels partly overlap Rem...

Page 297: ...CHAPTER 51 PAGE 4 PAGEDATE 7 July2010 MAINTENANCEMANUALEXTRA300LT Figure 1 Access Panel Identification ...

Page 298: ... Baggage compartment door 6 Tail fairing 7 Tail cone access panel RH 8 Tail side skin RH LH 9 Cuff 10 Wheel fairing 11 Wheel fairing inspection cap 12 Bottom half of the engine cowling 13 Air inlet screen 14 Spinner 15 Brake inspection panel 16 Bottom fuselage cover 17 Pitot static tube access panel 18 Wing outboard access panel 19 Wing inboard access panel 20 Wing gap cover ...

Page 299: ...ed EXTRA Flugzeugproduktions und Vertriebs GmbH According to the Luftfahrt Bundesamt Federal German AviationAuthority four damage classes are defined Damage Class 1 Largescaledestructionrequiringapartialreconstructionof the component or large scale repair Each destruction over 300 mm diameter and each damage of a spar is a large scale destruction EXTRAFlugzeugproduktions und Vertriebs GmbH has to ...

Page 300: ... M PO R TAN T Only the Damage Classes 2 3 and 4 may be repaired by qualified personnel In case of Damage Class 1 EXTRA Flugzeugproduktions und Vertriebs GmbH has to be contacted The decision whether to repair or replace a major unit of structurewillbeinfluencedbyfactorssuchastimeandlabor available andbycomparisonoflaborcostswiththepriceof replacement assemblies Past experience indicates that repla...

Page 301: ...R TAN T Only approved materials have to be used for the repair of composite parts Epoxy system Manufacturer HexionSpecialtyChemicalsGmbH Varzinerstr 49 D 47138Duisburg Germany Supplier BrenntagGmbH Stinnes Platz 1 D 45472Mühlheim Germany Resin Epikote L20 Rütapox L20 Hardener EpikureCuringAgent960 RütapoxSL Ratio of comp 100 parts L20 34 parts SL weight ratio Glass fibre fabrics Manufacturer P D I...

Page 302: ...olan A finish or with finish I 550 Carbon fibre fabrics Manufacturer C Cramer GmbH Co KG DivisionECC Weberstr 21 D 48619 Heek Nienborg Germany Style ECC CCC WLB No DIN 65147 US style weave patterns weight g m 447 490 8 3507 80 none none plain plain 160 120 452 495 8 3520 80 none none twill 2 2 5HS 204 120 459 none cross twill 220 WLB Werkstoff Leistungsblatt according to German standardDIN WL Aram...

Page 303: ...H Postfach 426 D 5100Aachen Germany Supplier Lange Ritter GmbH Dieselstraße 25 D 70839 Gerlingen Germany Type Vetrotex EC14 2400 P185 Carbon rovings Manufacturer TohoTenaxEuropeGmbH Kasinostr 19 21 D 42103 Wuppertal Type TENAX HTS5631 1600tex f24000 t 0 WLB 8 3614 1 CarbonUD Tape Manufacturer J H Vom Baur Sohn GmbH Co KG Marktstr 34 42369 Wuppertal Type CF UD tape 30 mm 50 mm Core material a PVCFo...

Page 304: ... SchützGmbH Co KGaA Schützstr 12 D 56242 Selters Germany Type Coremaster C1 4 8 29 OX Coremaster C1 4 8 48 OX Filler material for resin Manufacturer EBERHARDChemieGmbH Olpener Straße 405 D 51109 Köln 91 Merheim Germany Supplier STWSchwarzwälderTextilwerke HeinrichKaukmannGmbH Aue3 D 77773Schenkenzell Germany Type Cotton flakes Supplier BrenntagGmbH Stinnes Platz 1 D 45472Mühlheim Germany Type Micr...

Page 305: ...Einstellzusatz 923 155 GlasuritMS Klarlack 929 91 93 94 GlasuritHSDecklackhärter 352 50 91 216 GlasuritEinstellzusatz 285 100 VOC GlasuritRapidfüllerVOC weiß 929 55 56 Glasurit HS Füllerhärter 352 91 GlasuritEinstellzusatz 1006 26 GlasuritUPSpritzfüller grau 948 22 Glasurit Härter 839 53 GlasuritUP Schnellspachtel 948 36 Glasurit Härterpaste 293 10 GlasuritEinstellzusatz 934 0 Glasurit1K Kunststof...

Page 306: ...tosportGmbH Zeppelinring 1 6 D 33142 Büren Germany Type WLB 1 7734 4 18 mm x 1 0 mm 20 mm x 1 0 mm 22 mm x 1 0 mm 22 mm x 1 5 mm 25 mm x 1 5 mm Steel sheet metal Manufacturer BÖHLEREdelstahlGmbH München Germany Supplier Böhler UddeholmDeutschlandGmbH HansaAllee 321 D 40549 Düsseldorf Germany Type WLB 1 7734 4 1 0 mm 1 5 mm 2 0 mm 3 0 mm Coating Manufacturer BASFCoatingsGmbH Glasuritstr 1 D 48165 M...

Page 307: ...m Components Aluminium sheet metal Manufacturer KaiserAluminium Chem Corp Spokane Washington Supplier WestdeutscherMetallhandel FriedrichW HermannGmbH Manderscheidtstr 76 78 Postfach 104245 45141 Essen Type WLB 3 1364 T3511 or 2024 T3 0 6 mm 0 8 mm 1 2 mm Control rod tubings Manufacturer AluminiumAG CH 5737Menziken Supplier Karstens KnauerGmbH Co Hiligenwarf9 D 28865 Lilienthal Type WLB 3 1354 T3 ...

Page 308: ...HSDecklackhärter 352 50 91 216 GlasuritEinstellzusatz Aluminium hardware metal brackets pedestals castings etc Paint Manufacturer Parker Anchem Ambler PA19002 Supplier AircraftSpruce Chem coating Alodine No 1201 MIL C 5541 Lacquer seeabove 51 30 04 Various Components Adhesive Manufacturer Wacker Chemie Supplier DrawinVertriebsGmbH Rudolf Diesel Str 15 85521 Riemerling Ottobrunn Type Silikon Elasto...

Page 309: ...AIS Supplier AviationProductsEuropeGmbH Redcarstr 44a 53842 Troisdorf Spich Type PRC 812 Manufacturer 3M Supplier Otto Kerner Schleif Klebetechnik e K Ungelsheimer Weg 5 D 40472 Düsseldorf Type Scotch Clad 776 Tape Manufacturer 3M Supplier AviationProductsEuropeGmbH Redcarstr 44a 53842 Troisdorf Spich Type Polyurethan PU tape Scotch 8671 Corrosion Preventive Compound Manufacturer LEARCHEMICALRESEA...

Page 310: ...CHAPTER 51 PAGE 17 PAGEDATE 7 July2010 MAINTENANCEMANUALEXTRA300LT Supplier GlobalAviation Piper Parts GmbH FlughafenKassel D 34379 Calden Type ACF 50 ...

Page 311: ... is necessary after repairs or painting Weigh the control surfaces including the mass balances in disassembled condition The aileron weight includes the spade Copy Figure 4 enter the values W m r and check whether the surface weights and moments are within the given tolerances If they are not contact the manufacturer foradvice For the determination of control surface moments follow thestepsasdescr...

Page 312: ...rol surfaces and weigh by means of a con ventional spring balance kg g indication at the given weighing points figure 3 and enter the weight m in figure 4 5 Measure distance of hinge center line to weighing point r and enter the value in figure 4 6 Calculate the control surface moment M in figure 4 I M PO R TAN T If values exceed the given tolerances in figure 4 contact the manufacturer before mod...

Page 313: ...CHAPTER 51 PAGE 20 PAGEDATE 21 March2014 MAINTENANCEMANUALEXTRA300LT Figure 3 Determination of Control Surface Moments ...

Page 314: ... Surface Weights and Moments Weights AileronLH W kg AileronRH W kg Rudder W kg Elevator W kg TrimTab W kg Moments AileronLH m kg 9 81m s 2 r cm M Ncm AileronRH m kg 9 81m s 2 r cm M Ncm Rudder m kg 9 81m s2 r cm M Ncm Elevator m kg 9 81m s2 r cm M Ncm TrimTab m kg 9 81m s2 r cm M Ncm ...

Page 315: ...usstressconcentrations avoidchangesin cross sectional areas I M PO R TAN T The resin hardener mixture ratio must be precisely maintained 0 5 Clean cups and tools must be used The weight ratio of glass fabric to resin mixture should be approximately 50 50 Immediately prior to applying the wet laminate sand and vacuum clean the repair area so that no dirt and dust could prevent a secure adhesion WAR...

Page 316: ...rial sothatthenewfabricpatchesdonotproject beyond the contour In order to shorten the curing time a heater can be used to increase the ambient temperature N O T I C E Too high temperatures will cause large air bubbles in the laminate Local overtemperature can be prevented by using a foil tent which leads the hot air stream The curing cycle must be maintained as stated Use a thermometer to monitor ...

Page 317: ...move the separated laminate carefully using a sanding disk sanding block or a sharp knife Prepare a scarfed overlap of the laminate around the damaged area Overlap lenght per fabric layer min 20 mm I M PO R TAN T Ratio laminate thickness overlay lenght min 1 50 refer to Figure 5 Figure 5 Minor surface damage After preparing the scarfed overlap clean the repair area thoroughly as follows 1 Remove t...

Page 318: ...agging proceedasfollows 1 Apply peel nylon fabric on the last repair fabric layer 2 Perforate a clean thin plastic foil with a thick needle max spacing of holes 20mm x 20mm mainly in the area of the honeycomb and lay it on the repair area 3 Lay a jute cloth weave or equivalent bleeder cloth on this perforated plastic foil 4 Lay an air tight plastic foil upon the jute weave and seal their edges to ...

Page 319: ...ge thickness of repair laminate refer to figure 7 Figure 7 Level Sanding of Surrounding Area N O T E For painting of the repair area refer to chapter 51 70 06 b Damage of complete sandwich Iftheinnerlaminateisalsodamaged firstremovetheupper laminate within the area where no secure bond connection to the core material is suspected Trim out the complete damaged portion of core material to a circular...

Page 320: ... it tofitsnugglyinthetrimmedhole Incaseoffoamcore coat one side with a mixture of resin and microballoons ratio 100 15 Apply prelaminated fabric layers required for the inner laminate on this side of the core filler block Ensure correct style and direction of fabric After precuring the laminate at elevated room temperature 30 C scarf the overlapandsandtheupperoverlappingcorematerialdown up to the ...

Page 321: ... clean thin plastic foil with a thick needle max spacing of holes 20mm x 20mm mainly in the area of the honeycomb and lay it on the repair area 3 Lay a jute cloth or equivalent bleeder cloth on this perforated plastic foil 4 Lay a second plastic foil uppon the jute weave and seal their edges to the surrounding surface using an adhesive tape 5 Apply suction with a vacuum pump pressure approx 0 7bar...

Page 322: ... acetone in case dirt or grease was introduced during the preparation N O T I C E Repair area must be free of dirt dust and grease Wet the prepared scarfed areas with resin mixture Lay on prelaminated fabric layer in accordance to the layer se quence plan Ensure correct style and direction of fabric Apply peel nylon fabric on the last repair fabric layer N O T E Lay out the required number and siz...

Page 323: ...ble undamagedpart Following the curing cycle remove plastic foil and peel nylon fabric Bond the backing plate to the inside using a mixture of resin and cotton flocks and adapt to the contour Cure the bonding at elevated room temperature for 8 hours Subsequently scarf the edges of the damaged portion with sandpaper Minimumlenghtofscarfperfabriclayerapprox 20 mm I M PO R TAN T Ratio laminate thickn...

Page 324: ... the extent of the damaged area exceeds 10 cm 4 inches a large damage repair is required Carefully trim out the damaged portion to a circular or oval shape Prelaminate a backing plate from two layers of glass fibre fabric and resin mixture which must be approx 20 mm larger than the damaged area Apply peel nylon fabric as externallayer Sandwichtheresinwettedlayersbetweentwo sheetsofplasticfoil Work...

Page 325: ...elaminatedfabriclayerinaccordance tothelayersequenceplan Ensurecorrectstyleanddirection of fabric 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 PO R TAN T Remove the plastic foil after each positioning process The repair area has to be cured under condition of vacuum...

Page 326: ...minate Refinish the surface according chapter 51 10 06 51 70 04 Repair of Spars The spars consists of carbon roving caps glass or carbon fibre webs and PVC foam cores I M PO R TAN T The spars are higly stessed a failure of this bonded struc ture can result in loss of the aircraft In all cases the repair of a spar must be considered as a large scale re pair with a Damage Class 1 Refer to chapter 51...

Page 327: ...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 WAR N I N G Provide for a continuous supply of fresh air during and also after the application do not inhale the vapours and wear a breathing mask during the spray ...

Page 328: ...ting paint from aluminium and steel components and then to repaint them as described in the following paragraphs Degreasing WAR N I N G Cleaning solvents can be toxic and volatile Use only in well ventilated areas Avoid physical contact with sol vent and do not inhale vapors Keep solvent containers covered when not in use N O T I C E Before stripping parts remove all fittings O rings nuts bolts wa...

Page 329: ...Use only in well ventilated areas Avoid physical contact with solvent and do not inhale vapors Keep solvent containers covered when not in use N O T I C E Before stripping parts remove all fittings O rings nuts bolts washers pistons bearingcups etc Parts must be totally immersed in solvent to maximize cleaning 1 Degrease part per degreasing paragraph 2 Totally immerse part in paint removing solven...

Page 330: ...thosewhicharesubjectedtofriction bearing surfaces anchor bolt bores etc Proceed as follows 1 Parts to be repainted should be cleaned and stripped per instruction in degreasing and paint removal paragraphs 2 Aluminium parts should have a protective barrier between thetopcoatandbasemetal Itisrecommendedtheybetreated with solutions listed in chapter 51 30 3 For priming follow the procedures given by ...

Page 331: ...lstabilizerisonlypermissible if the hole in the related spar web is not elongated or has impermissible irregular wear which is evidence of bearing stress exceedance In case the bushing fits the hole in the spar web tightly use epoxy resin Epikote Resin L20 with Epikure CuringAgent 960 ref Chapter51 30 01 Ifthegapbetweenbushingand holeinthesparwebexceeds0 5mm 0 02 useamixtureof epoxy resin compound...

Page 332: ...he inner surface of bush ing and sandblast or use 80 grit sandpaper to rough the outer surface which will be bonded later on no remaining shiny areas are allowed Existing grooves on the outer surface if any must be free of residual resin 5 Solvent clean the bushing thoroughly with isopropyl alco hol carbon tetrachloride or acetone WAR N I N G Solvents used for cleaning re bond areas are flamma ble...

Page 333: ...and reapplying as this will cause air to become en trapped in the bonding gap 12 Verify epoxy resin compound at entire bond line is continu ous and free of gaps 13 Remove excessive resin compound with cloth damped with isopropyl alcohol 14 Apply mold release agent to the related surfaces of the sta bilizer mounting brackets of the fuselage and related mount ing bolts 15 Position the stabilizer to ...

Page 334: ...ebofthemain wingsparexistsofafrontandarearflangebushing Thefront andrearflangebushingwillbere bondedoneafteranother Thereisadefinedbondgapbetweentheflangebushingsand the hole in the main spar web Re bondingofmainattachmentflangebushingspositioned in the web of the main wing spar is only permissible if the holeintherelatedsparwebisnotelongatedorhasimpermis sible irregular wear which is evidence of ...

Page 335: ...adjacent composite structure The re maining flange bushing will be used to align the removed flange bushing during the re bonding process 3 Visually check the exposed surface area of the hole in the spar web for any damage 4 Remove any residual resin debris existing on the bonding surface of the flange bushing Protect the inner surface of bushing and sandblast or use 80 grit sandpaper to rough the...

Page 336: ...he spar Additionally apply HB15 com pound 11 Apply mold release agent to the surface of the related wing main bolt Insert the bolt to the flange bushing which is still fixed in the main spar opposite side to provide a guidance for the flange bushing to be bonded to the spar 12 Insert the flange bushing to the hole Slide on the main bolt and slightly rotate the bushing clockwise or counterclockwise...

Page 337: ...CEMANUALEXTRA300LT 18 Proceed with final curing at 60 C 140 F for at least 15h refer to Chapter 51 70 02 19 Repeat the procedure in case the flange bushing on the op posite side has to be re bonded as well 20 Reinstall the wing Refer to Chapter 57 0 01 ...

Page 338: ...CHAPTER 53 PAGE 1 PAGEDATE 7 July2010 MAINTENANCEMANUALEXTRA300LT Chapter 53 Fuselage ...

Page 339: ...uselage Cover 9 Figure 6 Sheet 2 Layer Sequence Main Fuselage Cover 10 53 00 04 Bottom Fuselage Cover 11 Figure 7 Forward View on Bottom Side Firwall 11 Figure 8 Layer Sequence Bottom Fuselage Cover 13 Figure 9 Layer Sequence Cuffs 14 Figure 10 Layer Sequence Tail Fairing 15 Figure 11 Layer Sequence Top Half of the Engine Cowling up to SN LT040 16 Figure 12 Layer Sequence Top Half of the Engine Co...

Page 340: ...er to figure 6 The bottom fuselage cover is made of carbon fibre and aramid fibre laminate refer to figure 8 the cuffs of carbon fibre laminate refer to figure 9 The lower rear part of the fuselage is covered with fabric The window portion is of acrylicglass Thetailfairingconsistsofcarbonfibrelaminate refer to figure 10 and the tail side skins are made of aluminiumsheetmetal Thelayersequencesofthe...

Page 341: ...CHAPTER 53 PAGE 4 PAGEDATE 7 July2010 MAINTENANCEMANUALEXTRA300LT Figure 1 Fuselage Steel Tube Design ...

Page 342: ... in reverse sequence of removal 53 00 02 Canopy Glass Replacement 1 Remove canopy as per Chapter 53 00 01 2 Remove the old canopy glass 3 Gently remove remaining glue with a chisel 4 Sanddownthebondingareaonthecanopyframecompletely sandpaper grit P120 Check that there are no reflecting areas left Canopy Frame 2 4 mm Canopy Glass Positioning Line Figure 2 Typical Cross Section of Canopy Bonding Are...

Page 343: ...e a strip width approx 50mm from the protective layer from the outside along the canopy glass bonding area 9 Place fine tape width 3mm on the outside opposing the positioning line on the inside 10 For protection purposes place 3 layers of tape as depicted in figure 4 11 Sand down the canopy glass up to the fine tape line use Scotch Brite Handpad Medium Check that there are no reflecting areas left...

Page 344: ... product to both canopy glass and canopy frame 15 Place canopy glass in canopy frame Observe correct position using position markings 16 Apply pressure on canopy glass using tightener to hold it in place 17 Remove adhesive remainders with wooden spatula 18 Curing time min 75 F 8h 68 F 15h 19 The next day Remove tightener and remove canopy from form 20 Sand down using Scotch Brite Handpad Fine a sm...

Page 345: ...0 and refinish the area 53 00 03 Main Fuselage Cover Removal Installation 1 Remove the canopy per chapter 53 00 01 2 Remove the front instrument panel per Chapter 31 10 03 31 10 05 3 Remove the rear instrument cover per Chapter 31 4 Remove the rear canopy hinge 5 Remove the filler neck attachment screws 6 Remove the main fuselage cover attachment screws 7 Remove the main fuselage cover 8 Install i...

Page 346: ...CHAPTER 53 PAGE 9 PAGEDATE 7 July2010 MAINTENANCEMANUALEXTRA300LT Figure 6 Sheet 1 Layer Sequence Main Fuselage Cover ...

Page 347: ...CHAPTER 53 PAGE 10 PAGEDATE 7 July2010 MAINTENANCEMANUALEXTRA300LT Figure 6 Sheet 2 Layer Sequence Main Fuselage Cover ...

Page 348: ...e 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 PositionAandDofFigure7 wheredifferentpartsconverge firewall aluminium profile bottom fuselage cover and exhaust area covering sheet Position B and C where a bent corner ends in a bore hole Figure 7 Forward View on Bo...

Page 349: ...s at four positions pointed out by the arrows in figure 7 Immediately thereafter dry these areas with a new dry cloth 9 At the gascolator drain positionA seal the remaining gap between firewall and bottom fuselage cover from inside and outside with PR 812 firewall sealant Minimum sealant thickness approximately 1 8 inch 3 mm 10 Repeat step 9 at positions B C and D 11 Cure for at least 24 hours at ...

Page 350: ...CHAPTER 53 PAGE 13 PAGEDATE 7 July2010 MAINTENANCEMANUALEXTRA300LT Figure 8 Layer Sequence Bottom Fuselage Cover ...

Page 351: ...CHAPTER 53 PAGE 14 PAGEDATE 7 July2010 MAINTENANCEMANUALEXTRA300LT Figure 9 Layer Sequence Cuffs ...

Page 352: ...CHAPTER 53 PAGE 15 PAGEDATE 7 July2010 MAINTENANCEMANUALEXTRA300LT Figure 10 Layer Sequence Tail Fairing ...

Page 353: ...CHAPTER 53 PAGE 16 PAGEDATE 24 February2017 MAINTENANCEMANUALEXTRA300LT Figure 11 Layer Sequence Top Half of the Engine Cowling up to SN LT040 ...

Page 354: ...CHAPTER 53 PAGE 17 PAGEDATE 24 February2017 MAINTENANCEMANUALEXTRA300LT Figure 12 Layer Sequence Top Half of the Engine Cowling from SN LT041 ...

Page 355: ...CHAPTER 53 PAGE 18 PAGEDATE 24 February2017 MAINTENANCEMANUALEXTRA300LT Figure 13 Layer Sequence Bottom Half of the Engine Cowling up to SN LT040 ...

Page 356: ...CHAPTER 53 PAGE 19 PAGEDATE 24 February2017 MAINTENANCEMANUALEXTRA300LT Figure 14 Layer Sequence Bottom Half of the Engine Cowling from SN LT041 ...

Page 357: ...CHAPTER 55 PAGE 1 PAGEDATE 7 July2010 MAINTENANCEMANUALEXTRA300LT Chapter 55 Stabilizers ...

Page 358: ...Figure 1 Sheet 2 Layer Sequence Horizontal Stabilizer S N LT021 and up 5 Figure 2 Horizontal Stabilizer Removal Installation 7 55 20 00 ELEVATOR 8 Figure 3 Layer Sequence Elevator 8 55 30 00 VERTICALSTABILIZER 9 Figure 4 Layer Sequence Vertical Stabilizer 9 Figure 5 Vertical Stabilizer Removal Installation 11 55 40 00 RUDDER 12 Figure 6 Layer Sequence Rudder 12 Table of Contents Chapter Figure Tit...

Page 359: ...ycombsandwichwithcarbonfibrelaminate Thevertical stabilizer shell is a glas fibre sandwich Also buckling is prevented by plywood ribs On the R H elevator half a trim tab is fitted by means of two hinges The layer sequences of the stabilizers the elevator and the rudder are shown in Figures 1 3 4 and 6 For protection against moisture and UV radiation all composite parts are coated with an unsaturat...

Page 360: ...CHAPTER 55 PAGE 4 PAGEDATE 12 June2015 MAINTENANCEMANUALEXTRA300LT 55 10 00 HORIZONTALSTABILIZER Figure 1 Sheet 1 Layer Sequence Horizontal Stabilizer up to S N LT020 ...

Page 361: ...CHAPTER 55 PAGE 5 PAGEDATE 12 June2015 MAINTENANCEMANUALEXTRA300LT Figure 1 Sheet 2 Layer Sequence Horizontal Stabilizer S N LT021 and up ...

Page 362: ...ckets 4 on fuselage The rear spar 2 is positioned behind the rear attachment bracket 5 trim tab is on the right side 2 Slide in the front spar attachment bolts 8 with an additional washer under the bolt head from the front to the rear These bolts are also used for the vertical stabilizer attachment Therefore do not apply stop nuts before the vertical stabilizer is fitted to the fuselage 3 Slide in...

Page 363: ...CHAPTER 55 PAGE 7 PAGEDATE 12 June2015 MAINTENANCEMANUALEXTRA300LT Figure 2 Horizontal Stabilizer Removal Installation ...

Page 364: ...CHAPTER 55 PAGE 8 PAGEDATE 12 June2015 MAINTENANCEMANUALEXTRA300LT 55 20 00 ELEVATOR Figure 3 Layer Sequence Elevator ...

Page 365: ...CHAPTER 55 PAGE 9 PAGEDATE 12 June2015 MAINTENANCEMANUALEXTRA300LT 55 30 00 VERTICALSTABILIZER Figure 4 Layer Sequence Vertical Stabilizer ...

Page 366: ... be damaged 6 Move the fin backward and lift the fin over the antenna Installation 1 Put the vertical stabilizer leading edge over the antenna N O T I C E Do not move the fin too far backward the antenna could be damaged 2 Slide the auxiliary spar attachment sheet 1 figure 5 of the vertical stabilizer from the rear over the preinstalled horizontal stabilizer front spar bolts and install the washer...

Page 367: ...CHAPTER 55 PAGE 11 PAGEDATE 12 June2015 MAINTENANCEMANUALEXTRA300LT Figure 5 Vertical Stabilizer Removal Installation ...

Page 368: ...CHAPTER 55 PAGE 12 PAGEDATE 12 June2015 MAINTENANCEMANUALEXTRA300LT Figure 6 Layer Sequence Rudder 55 40 00 RUDDER ...

Page 369: ...CHAPTER 57 PAGE 1 PAGEDATE 7 July2010 MAINTENANCEMANUALEXTRA300LT Chapter 57 Wings ...

Page 370: ...r Figure Title 57 00 00 GENERAL 3 Figure 1 Sheet 1 Layer Sequence Wing 4 Figure 1 Sheet 2 Layer Sequence Wing 5 Figure 1 Sheet 3 Layer Sequence Wing 6 57 00 01 Wing 7 Figure 2 Shims Installation 8 Figure 3 Wing Removal Installation 10 57 60 00 AILERONS 11 Figure 4 Layer Sequence Ailerons 12 ...

Page 371: ...hewingshellsareahoneycomb sandwich construction with carbon fibre laminates To pre vent buckling of the shells plywood ribs are used The layer sequence of the wing D section is shown in figure 1 For protection against moisture and UV radiation all composite parts are coated with an unsaturated polyester gel coat an acrylic filler and finally with an acrylic paint For repair of composite parts refe...

Page 372: ...CHAPTER 57 PAGE 4 PAGEDATE 7 July2010 MAINTENANCEMANUALEXTRA300LT Figure 1 Sheet 1 Layer Sequence Wing GENERAL ...

Page 373: ...CHAPTER 57 PAGE 5 PAGEDATE 7 July2010 MAINTENANCEMANUALEXTRA300LT Figure 1 Sheet 2 Layer Sequence Wing GENERAL ...

Page 374: ...CHAPTER 57 PAGE 6 PAGEDATE 7 July2010 MAINTENANCEMANUALEXTRA300LT GENERAL Figure 1 Sheet 3 Layer Sequence Wing ...

Page 375: ...ottle lever and control sticks in rearmost position 5 Remove the provisionally installed RPM Vernier control as per Chapter 61 and bring cable out of the main spar area WAR N I N G Beware not to get jammed between wing and fuselage N O T I C E Ensure that areas in which the wing shall be slided are clear of obstructions N O T I C E Prevent cables and pitot static lines from being damaged Keep them...

Page 376: ...curity bolts for fastening and subsequently safety wire 10 Install upper longeron cutout bridges 7 using at each side 3x DIN912 M8 x 180 3x DIN125 M8 washers and 3x LN9348 08 stop nuts at the top and 1x DIN912 M10 x 230 bolt DIN125 M10 washer and LN9348 10 stop nut at the bottom 6 Check cutout bridges for RH and LH marking Install the bolts except the upper outer bolts see figure 3 detailA from fr...

Page 377: ...7 10 02 17 Connect fuel system fuel lines and vent lines pitot static system stall warner navigation strobe light ground bonding leads and wing fuel indicator with prefitted plugs per respective chapters Connect instrument wet lines if MVP 50 is not installed 18 Reinstall breather line main fuselage cover engine cowlings and canopy as per chapter 51 MAINTENANCEPRACTICES Wing ...

Page 378: ...CHAPTER 57 PAGE 10 PAGEDATE 21 March2014 MAINTENANCEMANUALEXTRA300LT MAINTENANCEPRACTICES Wing A Figure 3 Wing Removal Installation ...

Page 379: ...bearings pressed into aluminium brack ets Furthermore the ailerons are equipped with glass fibre laminate spades to decrease pilots forces The layer sequence of the ailerons is shown in figure 4 For protection against moisture and UV radiation all composite parts are coated with an unsaturated polyester gel coat an acrylic filler and finally with an acrylic paint For repair of composite parts refe...

Page 380: ...CHAPTER 57 PAGE 12 PAGEDATE 7 July2010 MAINTENANCEMANUALEXTRA300LT Figure 4 Layer Sequence Ailerons AILERONS ...

Page 381: ...CHAPTER 61 PAGE 1 SERVICEMANUAL EXTRA300LT PAGEDATE 7 July2010 Chapter 61 Propeller ...

Page 382: ...EDATE 7 July2010 Table of Contents Chapter Figure Title 61 00 00 GENERAL 3 61 10 00 PROPELLER 4 61 20 00 CONTROLLING 5 Figure 1 Controlling 5 Figure 2 RPM Vernier Control Cable Installation 6 61 20 01 Governor 7 61 20 02 RPM Vernier Control Cable 7 ...

Page 383: ...pedwith MTV 9 B C C198 25 3 blade propeller Maintenance work or overhaul of the propeller requires consultation of the propeller manufac turer MT Propeller Proper control operation and maintenance of the propeller is described in the Operation and Installation Overhaul Manual E 124 of the manufacturer ...

Page 384: ...uly2010 61 10 00 PROPELLER TheMTV Propellersaremadeoflaminatedwoodencasedin 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 385: ...baffles and is then routed to the governor The cable is attachedatitsfrontendtotheenginebyaclampblockandin the cockpit area to the steel tube structure by self clinching plastic tiedown straps The RPM vernier control unit is mountedtoafuselagebracket Thefirewallandenginebaffle penetrations are covered with clamp sheets The firewall penetration 2 figure 1 is additionally sealed with PRC 812 Product...

Page 386: ...CHAPTER 61 PAGE 6 SERVICEMANUAL EXTRA300LT PAGEDATE 12 June2015 Figure 2 RPM Vernier Control Cable Installation Left View Engine Cockpit 5 mm 1 2 3 4 5 6 6 7 9 8 or Firewall 10 11 Engine Baffle ...

Page 387: ...les Removal 1 Ensure master switch is off 2 Remove engine upper cowling per Chapter 71 3 Remove main and bottom fuselage cover per Chapter 53 4 Remove cotter pin castle nut washers and bolt from the rod end 1 Figure 2 to governor actuator 2 attachment 5 Loosen counter nut and remove the rod end 1 from the vernier control cable 6 6 Remove rod end counter nut and vernier control cable protective swi...

Page 388: ... outside direction 14 Pull complete vernier control cable 6 aft to remove from aircraft Secure clamp sheets Installation Installinreversesequenceofremovalobservingthefollowing items 1 Thread the respective clamp sheets and plastic guidance on the vernier control cable before penetrating the firewall and the rear engine baffle 2 Distance between clamp sheet and clamp block is 755 mm 3 Install rod e...

Page 389: ...is ensured at the rpm control knob see figure 2 3 Check full travel 4 If necessary adjust rod end 1 figure 2 by the following steps a Remove cotter pin castle nut washers and bolt from the rod end 1 to governor control lever 2 attachment b Loosen the counter nut and adjust rod end 1 by turning Ensure thread is visible in the inspection hole when fastening Apply inspection lacquer on the counter nu...

Page 390: ...CHAPTER 71 PAGE 1 SERVICEMANUAL EXTRA300LT PAGEDATE 7 July2010 Chapter 71 Power Plant ...

Page 391: ...wling 3 Figure 2 Sheet 1 Landing Light Xenon Disconnection Plug up to SN LT040 5 Figure 2 Sheet 2 Landing Light LED Disconnection Plug 5 71 20 00 ENGINEMOUNT 6 Figure 3 Engine Mount Shock Mount Installation 7 71 20 01 Shock Mounts 8 71 60 00 AIRBAFFLES 10 Figure 4 Air Baffles 10 Table of Contents Chapter Figure Title ...

Page 392: ...o slotted head flush type Camloc retainers The bottom half featuresaXenonorLEDlandinglight 6 TheXenonpower supply 7 and the electrical connector are installed on the left aft inside Both cowling halves are attached to each other and the airframe by means of truss head screws 4 and special washers 5 The interior surface of both cowling halves is coated with a fireprotectionpaintwhichissealedbyvarni...

Page 393: ...enient position 2 Remove the related truss head screws 4 5 of top cowling half see Figure 1 3 Remove top half of the engine cowling 4 Disconnect the landing light wiring using the plug shown in Figure 2 Sheet 1 Xenon or Sheet 2 LED 5 Remove the remaining truss head screws 4 5 of the bottom cowling half see Figure 1 6 Remove the bottom half of the cowling N O T I C E Pay attention to the rubber fla...

Page 394: ...E 5 SERVICEMANUAL EXTRA300LT PAGEDATE 24 February2017 Figure 2 Sheet 1 Landing Light Xenon Disconnection Plug up to SN LT040 Side View Firewall Connector Cowling Figure 2 Sheet 2 Landing Light LED Disconnection Plug ...

Page 395: ...he engine mount structure are provided with an internal anti corrosion treatment The engine mount itself carries the oil cooler and is used as a support for various hoses of the oil system as well as electrical wiring The engine is nested into the engine mount on a system of rubber shock mounts each of which comprises two rubber elements and one tubular spacer ref figure 2 The shock mounts reduce ...

Page 396: ...CHAPTER 71 PAGE 7 SERVICEMANUAL EXTRA300LT PAGEDATE 24 February2017 Figure 3 Engine Mount Shock Mount Installation ...

Page 397: ...s outwards for removal Installation Install in reverse sequence of removal Torque locknutsofconnectionboltstoengineshockmounts with 55 Nm 40 5 ft lbs 71 20 01 Shock Mounts Description Theshockmountsserveasdamperstoreducethetransmission of vibrations induced by the engine to the airframe Theshockmountsconsistof bondedrubbermaterialwitha metal spacer at the center Eachofthe4shockmountsconsistsof two...

Page 398: ...wards to remove it 4 Remove forward half of the shock mount 5 Remove tubular spacer 6 Extract aft half of the shock mount If necessary lower respectively lift the engine a little to get the needed clearance for removal of the aft shock mount half Installation Install in reverse sequence of removal Torque locknuts of connection bolts with 55 Nm 40 5 ft lbs ...

Page 399: ... the engine cowling is sealed by rubber strips whicharerivetedtotheouteredgeofthebaffles Furthermore the forward LH baffle has a circular cutout serving as a cooling air inlet that is connected with the exhaust s heat exchangerairintakeviaanairducting Single oil cooler system TheaftRHbafflehasarectangularcutouttoprovideairflow to the oil cooler Figure 4 Air Baffles Removal Refer to figure 4 1 Disc...

Page 400: ...H baffle 5 Unscrew grommets for ignition harness and RPM bowden cable from their cutouts and pull out ignition harness and RPM bowden cable 6 Unscrew baffle plates Installation Install in reverse sequence of removal N O T E Minor cracks in the plating can be stopped by drilling a hole at the end of the crack Serious damage requires replacement of the baffle concerned ...

Page 401: ...CHAPTER 72 PAGE 1 PAGEDATE 7 July2010 MAINTENANCEMANUALEXTRA300LT Chapter 72 Engine ...

Page 402: ...CHAPTER 72 PAGE 2 PAGEDATE 7 July2010 MAINTENANCEMANUALEXTRA300LT Table of Contents Chapter Figure Title 72 00 00 GENERAL 3 72 10 00 ENGINE 5 Figure 1 Lycoming Engine 5 ...

Page 403: ... people to assist you in narrowing down the causes 2 Review maintenance logs and use appropriate diagnostic tools to eliminate simple and inexpensive solutions before proceeding to more complicated and expensive remedies Often a quick visual inspection of the engine will provide evidence of obvious problems such as intake and exhaust leaks physical damage to ignition harness blocked breathers gas ...

Page 404: ...ler adjustedproperly Document E 1048 Muffler s internal baffles Strike muffler with a rubber are broken and blocking the mallet or soft object and exhaust outlet Note listen for a rattle A rattle Broken baffles are free to indicates loose baffles Re move around in the muffler move muffler for thorough The engine may turn static inspection Replace as rpm sintermittently necessary per Ch 78 Throttle...

Page 405: ...ture control is proportional to the intake air flow A manual mixture adjustment as an overriding system is provided Thepowersettingisdonemanuallybymeansofa butterfly valve in the air induction tube The engine is air cooled Baffles are provided to build up pressure and to force the air through the cylinder fins The cooling air flow is dependent on engine speed and dynamic air pressure The engine is...

Page 406: ...partment Removal N O T E In many cases it is favourable to remove the complete engine incl engine mount and all components of the inverted oil system from the firewall Then remove the engine mount the exhaust and engine accessories as necessary After disconnection of lines and fittings protect related inlet by appropriate plug or cap Cut self clinching plastic straps used for routing of lines and ...

Page 407: ...ntrol at the control levers of the fuel control servo Disconnect Bowden cable attachment to the engine 12 Detach the rod end of Bowden cables for RPM control at the control levers of the propeller governor Disconnect Bowden cable attachment to the engine and related fairlead at the LH aft engine cooling baffle 13 Disconnect the GND cable from the engine accessory housing 14 Remove the oil temperat...

Page 408: ...d oil pressure 23 Unbolt the complete engine with engine mount from the airframe at the four attachments points 24 Lift the complete engine from the airframe 25 Refer to 71 20 00 for removal of the engine mount from the engine Installation 1 Install in reverse sequence Refer to Chapter 20 10 04 for torque values specified for the mount to the engine and mount to the airframe connection 2 Apply fir...

Page 409: ...CHAPTER 73 PAGE 1 MAINTENANCEMANUALEXTRA300LT PAGEDATE 7 July2010 Chapter 73 Engine Fuel and Control ...

Page 410: ...e 4 Throttle Control Cable Rigging 9 73 20 13 Front Throttle Control Lever 10 73 20 20 Mixture 11 Figure 5 Mixture Control 11 73 20 21 Mixture Vernier Control Cable 12 Figure 6 Clamp Sheet to Clamp Block Distance 13 Figure 7 Over travel at Mixture Control Unit 14 Figure 8 Mixture Vernier Control Cable Rigging 15 73 30 00 INDICATING 16 73 30 10 Fuel Pressure 17 Figure 9 Fuel Pressure Sense Line 17 ...

Page 411: ...etratesthe firewall and is then routed centrally below the exhaust muffler tothethrottle Intheenginecompartmentthiscable is covered with a 690 mm fire sleeve The cable is attached to the fuselage using clamp blocks at its ends cable ties in the cockpit area and a cushioned clamp at the exhaust muffler Rod ends at both terminals of the control cable serve as a means for rigging The fire wall penetr...

Page 412: ...lock from the throttle control cable 9 Remove cushioned clamp 4 10 Cut safety wires and remove fire sleeve from the throttle control cable 11 Remove 4 bolts and firewall sealant of the clamp sheets Figure 2 positioned at the firewall break through 12 Mark throttle control cable routing and positions of the cable ties and remove the cable ties in the cabin area 13 Remove cotter pin castle nut washe...

Page 413: ...SA firewall sealant as outlined in Chapter 20 10 10 3 Let the sealant slightly cure before thightening the clamp sheet attachment bolts This will strengthen the clamping 4 Install the clamp sheets 5 Install the cable ties in the cockpit area on positions as marked before 6 Install the 690 mm firesleeve to the throttle control cable and secure with safety wire at both ends refer to Figure 2 7 Insta...

Page 414: ...ure4 Tightenthecastlenutslightly Ensure movability of actuator 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 12 Screw the rod end onto the threaded terminal on the throttle control lever side of the throttle control cable 13 Tighten the counternut to prevent rod end from loose...

Page 415: ...move main fuselage cover per chapter 53 4 Remove cotter pin castle nut washers and bolt 6 figure 3 and the throttle control linkage 3 from the throttle control lever 5 5 Pull the smoke switch 5a if installed out of the throttle lever handle and disconnect switch wiring 6 Remove intercom switch 5b attachment nut Remove self clinching plastic tiedown straps of related wiring Pull the intercom switch...

Page 416: ...t 7 Remove throttle control lever Installation Installinreversesequenceofremovalobservingthefollowing items 1 Thread the intercom switch 5b Figure 3 and the smoke switch 5a wiring through the throttle control lever 5 before mounting the lever to the attachment bracket 2 Tighten the throttle control lever castle nut 7 slightly Ensure movability of control levers 1 5 ...

Page 417: ...d extended position shall be 8 to 13 mm 5 16 1 2 Ref to figure 2 of Chap 20 10 09 1 2 4 3 Figure 4 Throttle Control Cable Rigging 4 If necessary adjust rod ends 2 Figure 4 6 Figure 3 to ensure correct over travel by the following steps a Remove cotter pin castle nut washers and bolt of the rod end from throttle lever 1 Figure 4 and rear throttle control lever 6 Figure 3 b Loosen the counter nut at...

Page 418: ...ter 53 4 Disconnect the throttle control linkage 3 Figure 3 from the front throttle control lever 1 5 Disconnect the throttle control handle 2 from the front throttle control lever 1 6 Disconnect throttle control lever attachment by removing cotterpin castlenut washersandbolt 9 andremovethrottle control lever 7 Install in reverse sequence of removal Tighten the throttle control lever castle nut 9 ...

Page 419: ...selage penetrates the firewall and is then routed to the mixture control lever In the engine compartment this cable is covered with a 540 mm firesleeve The cable is attached to the fuselage using a clamp block at its front end and cable ties The mixture vernier control unit 1 is mounted to a fuselage bracket The fire wall penetration is sealed with PR 812 ProductsResearch ChemicalCorp USA firewall...

Page 420: ...ective swivel and wiper seal 8 Remove clamp block 1 attachment bolt 9 Remove clamp block 1 from the vernier mixture control cable 10 Cut safety wires and remove fire sleeve from vernier mixture control cable 11 Remove 2 bolts of the clamp sheet attachment positioned at the firewall break through 2 Figure 5 Remove firewall sealing and disconnect clamp sheet and contained plastic guidance from the r...

Page 421: ... 6 Clamp Sheet to Clamp Block Distance 5 Renew the sealing of the firewall breakthrough at the engine side of the firewall Use PR 812 Products Research ChemicalCorp USA firewallsealantasoutlinedinChapter 20 10 10 6 Let the sealant slightly cure before thightening the clamp sheet attachment bolts This will strengthen the clamping 7 Install the clamp sheet 8 Install the cable ties in the cockpit are...

Page 422: ...ctuator position Tighten the counternut 13 Install rod end to mixture actuator with bolt washers castle nut and cotter pin Tighten the castle nut slightly Ensure movability of actuator 14 Install the firewall forward cable ties on positions as marked before 15 Perform Mixture Vernier Control Cable Rigging Rigging 1 Move mixture control knob to the foremost position 2 Check that the travel stop at ...

Page 423: ...e 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 Ensure thread is visible in the inspection hole when fastening Apply inspection lacquer on the counter nut c Reconnect the rod end 2 to the mixture control actuator 3 or 1 2 3 Figure 8 Mixture Vernier Control Cable Rigging ...

Page 424: ...and is indicated to the pilot in command Refer to chapter 77 40 if an integrated engine instrument system is installed Trouble Shooting Trouble Possible Cause Remedy No fuel pressure indication Gaugedefective Replacegauge Fuel pressure low Orifice in engine fuel pressure fitting defective Cleanfitting Sense line leakage Replace sense line ...

Page 425: ... Because the fuel flow to the engine cylinders is restricted thereisadirectrelationbetweenfuelpressureandfuelflow ThisrelationisshownontheLycomingcurveN 13011 Fuel Flowvs NozzlePressure Sothefuelpressuregaugeindicates fuel pressure but on a scale which is converted to fuel flow values generally the fuel flow value is more useful for the pilot The red line however shows a pressure value Figure 9 Fu...

Page 426: ... E Pick up spilling fluid when disconnecting a sense line 3 Disconnect the sense line from the fitting 4 Remove the sense line 5 Install in reverse sequence of removal Torque sense line fittings with 15 3 16 9Nm 135 150lbs inch and apply inspection lacquer 73 30 15 Fitting Removal Installation 1 Remove cowling per Chapter 71 2 Disconnect the sense line as per Chapter 73 30 12 3 Remove the fitting ...

Page 427: ...CHAPTER 77 PAGE 1 MAINTENANCEMANUALEXTRA300LT PAGEDATE 7 July2010 Chapter 77 Engine Indicating ...

Page 428: ... Gauge 7 77 20 12 CHT Sensor 7 77 20 20 Exhaust GasTemperature EGT 8 77 20 21 Exhaust Gas Temperature Gauge 8 77 20 22 EGT Sensor 8 77 40 00 INTEGRATEDENGINEINSTRUMENTSYSTEMS 9 77 41 00 Electronics International MVP 50P 9 Figure 3 Alternate Panel Layout 11 77 41 01 Main Engine Screen 12 Figure 4 MVP 50P with Main Engine Screen 12 77 41 02 Mounting Sheet 13 77 41 03 Electronic Data Converter 13 77 ...

Page 429: ...00LT 1 tachometer 2 manifold pressure gauge 3 cylinder head temperature gauge 4 exhaust gas temperature gauge Generallyenginedataisroutedelectricallyfromtheengine sensors refer to Figure 1 to the instruments However the manifold pressure line is routed through the firewall and directlyfittedtotheinstrument Theenginedataareindicated to the pilot in command Figure 1 Engine Sensor Locations ...

Page 430: ...hometer NoMAPindication Gaugedefective Replacegauge NoMAPvariation Sense line leakage Replace sense line withpowersetting NoCHTindication Sensor or cable defective Replace sensor Repair cable defect CHTgaugedefective Replacegauge No or incorrect EGT Sensor defective Replace sensor with cable indication Cabledefective Replace cable with sensor Gaugedefective Replacegauge ...

Page 431: ...oltage 77 10 11 Tachometer Removal Installation Refer to Chapter 31 77 10 20 Manifold Pressure MAP Themanifoldpressuresenselineisconnectedtotheairinlet of cylinder no 5 rear right hand refer to Figure 1 It is a wet line consisting of two parts divided by the firewall To protect the instrument from fuel vapor a sintered bronze filter is placed in the hose connection to the MAP gauge as outlined in ...

Page 432: ...apter 31 77 10 22 Sense Line Engine Compartment Removal Installation 1 Remove cowling per Chapter 71 2 Remove clamps if applicable 3 Disconnect the sense line from the fittings 4 Remove the sense line 5 Install in reverse sequence of removal Torque sense line fittings with 15 3 to 16 9Nm 135 to 150 inch lbs and apply inspection lacquer ...

Page 433: ... Chapter 31 77 20 12 CHT Sensor ThesensorisabayonettypeJthermocoupleandisconnected directly with the overbraided wiring This wiring cannot be disconnected from the sensor and must not be shortened Removal Installation 1 Remove cowling per Chapter 71 2 Disconnect overbraided wires from the instrument 3 Note correct wiring 4 Remove sensor with mounting fitting and complete overbraided wires from eng...

Page 434: ...oming Service Instruction No 1094 77 20 21 Exhaust Gas Temperature Gauge Removal Installation Refer to Chapter 31 77 20 22 EGT Sensor The sensor is a type K thermocouple and is connected directly with the overbraided wiring This wiring cannot be disconnected from the sensor and must not be shortened Removal 1 Remove cowling per Chapter 71 2 Disconnect overbraided wires from instrument 3 Note corre...

Page 435: ...antityTransducers Wing root ribs Manifold PressureTransducer Mountingsheet Oil Pressure Transducer Firewall Fuel Pressure Transducer Firewall FuelFlowTransducer Left side engine OATProbe Bottom fuselage cover Oil Temperature Sensor Aftengine EGTProbes Exhaustpipes CHTProbes Cylinderheads RelatedWiringandTubing Cockpit enginecomp An additional fuel quantity transducer identical to the standardoneis...

Page 436: ...MVP 50P documentation of Electronics Inter national Inc see Chapter 1 for detailed information about features Thefollowingfeaturesarenotavailableintheconfiguration installedintheEXTRA300LT External dimmer potentiometer External warning and caution light Voice alarm System Screen Weight and Balance not applicable do not use Checklists 1 3 not applicable do not use Gear warning andTAS Setup Screen P...

Page 437: ...ing light incl press to test feature located in the switch row if sub panel is not used 2 Alternator field circuit breaker 3 Boost pump circuit breaker 4 Strobe light circuit breaker 5 NAVlight circuit breaker 6 Electrical pedal adjustment circuit breaker 7 Landinglightcircuitbreaker 8 Stallwarningcircuitbreaker 9 MVP 50 circuit breaker 10 Electrical trim system circuit breaker 11 COM circuit brea...

Page 438: ...e monitored for most of the flight Figure 4 MVP 50P with Main Engine Screen Buttons operate as follows Push Select Moves the cursor selects functions and changesdigits Exit Exits out of a field or screen and returns the display to the Main Engine Screen Screens Switches the display between screens as selected in the Screens Button Setup Menu Displays a menu if available for the current screen Remo...

Page 439: ...shock mounts 9 and remove the mounting sheet 10 4 Reverse procedure for installation 77 41 03 Electronic Data Converter Removal Installation 1 Remove main fuselage cover as per Chapter 53 2 Disconnect the electrical wiring 8 from the electronic data converter 1 Figure 5 3 Remove the attachment bolts 11 and remove the electronic data converter 1 4 Reverse procedure for installation 77 41 04 Module ...

Page 440: ...CHAPTER 77 PAGE 14 MAINTENANCEMANUALEXTRA300LT PAGEDATE 24 February2017 Figure 5 Mounting Sheet and MVP 50P Components ...

Page 441: ...xhaust is cool 1 BATTERYswitchoff 2 Remove engine cowlings as per Chapter 71 3 Remove the fire sleeve 6 Figure 6 4 Disconnect the fuel hoses 3 from the transducer 4 5 Disconnect the electrical wiring 1 from the transducer 6 Remove the attachment bolts 2 and remove the transducer from the mounting sheet 5 7 Reverse procedure for installation Figure 6 Fuel Flow Transduver ...

Page 442: ... see Figure 6 of Chapter 79 The oil 4 Figure 5 and fuel 5 pressure transducers are screwed to the respective fittings on the firewall Refer to Chapter 28 for fuel contents transmitters TheMAPtransducerismodule3ofFigure4 Thetubing 7 isroutedfromthemodulethroughabulkeadfitting 6 inthe firewall to the engine see also Figure 1 The rpm signals are taken directly from the magnetos The OAT probe is faste...

Page 443: ...CHAPTER 78 PAGE 1 MAINTENANCEMANUALEXTRA300LT PAGEDATE 7 July2010 Chapter 78 Exhaust ...

Page 444: ...AGEDATE 7 July2010 Table of Contents Chapter Figure Title 78 00 00 GENERAL 3 Figure 1 Exhaust System 3 78 10 00 COLLECTOR NOZZLE 4 78 10 01 Exhaust Pipe 6 78 10 02 Muffler 6 78 10 03 Gasket 7 78 10 04 Heat Shield 7 Figure 2 Heat Shield Replacement 7 ...

Page 445: ... 3 MAINTENANCEMANUALEXTRA300LT PAGEDATE 7 July2010 78 00 00 GENERAL The EXTRA300LTis generally equipped with a Gomolzig 6 in 1 exhaust system refer to figure 1 with integrated silencer muffler Figure 1 Exhaust System ...

Page 446: ...reofweldedstainlesssteel Thesepipes are routed from the cylinders down to the muffler under the engine The muffler comprises an inner pipe which is perforated and an outer pipe to form a welded sealed structure Themuffleriscooledusingasurroundingheatshroud which isfedwithfreshairfromtheforwardLHbafflewhichisthen discharged to the athmosphere or to the heating system Trouble Shooting Trouble Possib...

Page 447: ...apter 73 4 Removethecoolingairductingonbothforwardandrearward flanges on the muffler 5 In case a smoke system is installed remove the smoke oil hose from the smoke oil injector nozzle on the exhaust end pipe 6 Loosen the nuts on the exhaust flanges and remove the exhaust system Installation Installinreversesequenceofremovalobservingthefollowing items 1 Use new gaskets 2 Use new toothed lock washer...

Page 448: ...78 10 00 2 For cylinders 1 2 replace entire collector tube 3 For cylinders 3 4 pull the exhaust pipe out of the slip joint and replace the exhaust pipe 4 For cylinder 5 6 loosen the clamps on the slip joints and replace the exhaust pipe 5 Drill 4 8 mm 3 16 hole for EGT sensor s at identical location 6 Reinstall exhaust system in reverse sequence of re moval 78 10 02 Muffler Replacement 1 Remove ex...

Page 449: ...per chapter 78 10 00 2 Replace gaskets 3 Reinstall exhaust system in reverse sequence of removal 78 10 04 Heat Shield Replacement Refer to figure 2 1 Remove cowling per chapter 71 2 Remove heat shield worm drive hose clips 3 Replace heat shield 4 Reinstall in reverse sequence of removal Figure 2 Heat Shield Replacement ...

Page 450: ...CHAPTER 79 PAGE 1 MAINTENANCEMANUALEXTRA300LT PAGEDATE 7 July2010 Chapter 79 Oil System ...

Page 451: ...01 01 Valve Balls 6 79 20 00 DISTRIBUTION 7 79 20 01 Oil Cooler 7 Figure 3 Oil Cooling System 8 79 20 02 Fittings 8 79 20 03 Flexible Hoses 8 79 30 00 INDICATING 9 79 30 10 Oil Pressure 9 Figure 4 Oil Pressure Sensor Wet Line 10 79 30 11 Oil Pressure Gauge 10 79 30 12 Oil Pressure Wet Line 10 79 30 13 Engine Fitting 11 79 30 20 Oil Temperature 11 79 30 21 Oil Temperature Gauge 11 79 30 22 Oil Temp...

Page 452: ... Operation ThestandardChristen801InvertedOilSystemisakit form accessory for Lycoming aircraft engines which permits normal engine lubrication with minimal oil loss during aerobaticflight Wheninstalled itbecomesaself contained extension of the normal aircraft engine oil and breather systems Asthesystemcontrolvalvesaregravity operated no connection to aircraft power sources is required refer to figu...

Page 453: ...ingtotheoilpumpandouttotheenginelubrication points Figure 1 Inverted Oil System Normal Flight Inverted flight Whentheaircraftisinverted engineoilfallstothetopofthe crankcase The weighted ball valve in the oil seperator closes preventing overboard loss of oil through the top of theoilseparator Blow bygassesfromtheenginecrankcase are vented from the sump to the bottom of the oil separator and out th...

Page 454: ...l system normally requires no maintenance During major overhauls or when repairs require sump removal inspect sump for excessive deposits of sludge varnish or foreign material If sump is dirty remove and thoroughly clean all hoses and components then use com pressedairblastfordryingandcleanoutbeforereassembly Cleaning The inverted oil system must be flushed with a suitable petroleumsolvent suchasv...

Page 455: ...mnicks inthevalveseatswhichcauseleakagewhenthevalveshould 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 overhauledengine Formoreinformationofthevalvesrefer to Lycoming Operaton and Installation Manual see chapter 1 ...

Page 456: ...tionangles Maintenance Practices Before making installations and repairs to the aircraft plumbing it is important to make accurate identification of plumbingmaterials 79 20 01 Oil Cooler Description and Operation Thelubricationsystemofthe EXTRA300LThasasingleoil cooler which is mounted on the aft right hand side of the engine It is connected to the engine by hoses Duringoperationthehotlubricatingo...

Page 457: ...GEDATE 7 July2010 79 20 02 Fittings GeneralinformationconcerningfittingsusedintheEXTRA 300LT can be found in chapter 20 10 08 79 20 03 Flexible Hoses Generalinformationconcerningflexiblehosescanbefound in chapter 20 10 07 Figure 3 Oil Cooling System ...

Page 458: ...oil pressure withcalibratedequipment Orifice engine fitting Cleanfitting blocked Sense line leakage Replace sense line Oil temperature high Sensor or cable defective Replace sensor Repair cable defect Gaugedefective Replacegauge Incorrect engine oil Perform engine oil change 79 30 10 Oil Pressure The oil pressure gauge is located in the rear instrument panel Thegaugereceivesitsdataelectricallyfrom...

Page 459: ... a single unit Removal Installation Refer to chapter 31 79 30 12 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 4 3 Install in reverse sequence of removal Torque sense line fittings with 15 3 to 16 9Nm 135 to 150 in lbs and apply inspection lacquer PAGEDATE 4 June200...

Page 460: ...0 Oil Temperature The oil temperature gauge is located in the rear instrument panel Thegaugereceivesitsdataelectricallyfromasensor located on the engine in front of the oil filter screen refer to figure 5 79 30 21 Oil Temperature Gauge Oiltemperatureindicationiscombinedwiththeoilpressure indication in a single unit 79 30 22 Oil Temperature Sensor Removal Installation The sensor can be easily remov...

Page 461: ...CHAPTER 79 PAGE 12 MAINTENANCEMANUALEXTRA300LT PAGEDATE 7 July2010 Figure 5 Oil Temperature Sensor Location ...

Page 462: ...PAGEDATE 24 September2012 CHAPTER 91 PAGE 1 MAINTENANCEMANUALEXTRA300LT Chapter 91 Charts ...

Page 463: ...SN LT041 EA 9E102 1E Sheet 2 Electrical System from SN LT041 EA 9D102 3 Nav Strobe Light Sys up to SN LT007 EA 9D102 3A Nav Strobe Light Sys from SN LT008 EA 93102 4A Fuel Gages up to SN LT039 EA 93102 4B Fuel Gages from SN LT040 EA 9E102 5 COMS EGERÄT EA 93102 6B Audio Switches Jacks EA 93102 11B Fuel Boost Pump EA 9E102 11 Fuel Boost Pump EA 9D102 12 Stall Warning System EA 94102 14C PedalAdjust...

Page 464: ...rcom NATAA83 from SN LT020 thru SN LT038 EA 9D102 51C Intercom NATAA83 from SN LT039 EA 9D102 52 Sheet 1 Digital Indication MVP 50P up to SN LT019 EA 9D102 52A Sheet 1 Digital Indication MVP 50P from SN LT020 EA 9D102 52 Sheet 2 Digital Indication MVP 50P up to SN LT019 EA 9D102 52A Sheet 2 Digital Indication MVP 50P from SN LT020 EA 9D102 53 LandingLight EA 9E102 53 LandingLight EA 9D102 54 Garmi...

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Page 470: ...HOLDER 02 00301 03 00360 FUSE 60A 01602 SWITCH SPST MS35058 22 mtr MIL W 22759 16 4 WIRE AWG 4 200005 31763 CAP RED 11 00815 11 12 PIPER SOCKET 11 00500 31731 PLASTI GRIP 130008 02198 RECTIFIER FE4292 BYW56 FA3008 S 50 SHUNT FUSE PCB 4F 00775 MIL W 22759 16 20 WIRE AWG 20 EA 9B243 45 FT0001 BOSCH ALTERNATOR K1 14V23 65A 0120 489 935 CAPACITOR 2 2uF 250V 31608 0 290 800 052 31505 7277 2 10 CIRCUIT ...

Page 471: ...WIRE AWG 18 SHIELDED MIL C 27500 18TG1 mtr MAGNETO LEFT 6393 SLICK START SS 1001 6350 MAGNETO RIGHT 27 28 29 1 W31X2M1G 40 CIRCUIT BREAKER SWITCH 40A mtr see DIGITAL INDICATION EA 9D102 52 see DIGITAL INDICATION EA 9D102 52 MIL W 22759 16 18 WIRE AWG 18 mtr 30033 FUSEHOLDER 414 601 FUSE 2A 5 x 20mm flink 00140 PRESS TO TEST INDICATOR red GE330 MS25041 2 BULB 14V 0 08A 01569 R1 68R 30 30 31 32 Fa M...

Page 472: ...TAL INDICATION EA 9E102 52 ALTERNATOR D B 2 2uF 250V 20 F8 2A 18 K4 6 20 39 29 30 R1 68R 41 6 L1 LOW VOLTAGE 1 2 3 20 27 28 34 20 6 K4 20 36 18 BOSCH 55A 20 20 B 42 2 2uF 250V 39 43 44 6 ALTERNATOR D B GND B PRESTOLITE 65A 70A B 2 4 OPTION 05 06 11 12 10 10 MAIN BUS SH 1 100mV 100A 1A F5 1A F6 19 5A F7 5A F4 20 37 K4 6 6 34 6 20 18 20 20 EA 9E102 1 EA3E0900b EA 300 LC 10 02 11 HW L R GRD S BAT PR ...

Page 473: ...UMFIELD Fa TELEDYNE CONTINENTAL Fa UNISON 32598 13 SWITCH SPST 07 1 1 13 920 Fa KISSLING 1 35 X mtr MIL W 22759 16 10 WIRE AWG 10 X 2 1 5 1 2 2 1 5 2 1 X 1 1 1 X X X 1 1 1 1 1 1 1 X 1 1 1 1 1 2 2 1 5 1 2 1 5 2 1 X 1 1 1 X X X 1 1 1 1 1 1 1 X 1 1 1 1 1 2 Fa AMP Fa AMP 7E291 010 520 620 Fa ESKA 00776 33081 FE 0003 01168 926474 1 33 1 1 7277 2 5 CIRCUIT BREAKER 5A Fa KLIXON FE 4028 03618 31506 1 1 38...

Page 474: ...N EA 9E102 52 ALTERNATOR D B 2 2uF 250V 20 F8 2A 18 K4 6 20 39 29 30 R1 68R 41 6 L1 LOW VOLTAGE 1 2 3 20 27 28 34 20 6 K4 20 36 18 BOSCH 55A 20 20 B 42 2 2uF 250V 39 43 44 6 ALTERNATOR D B GND B PRESTOLITE 65A 70A B 2 4 OPTION 05 06 11 12 10 10 MAIN BUS SH 1 100mV 100A 1A F5 1A F6 19 5A F7 5A F4 20 37 K4 6 6 34 6 20 18 20 20 EA 9E102 1 EA3E0900c EA 300 LC 10 02 11 HW L R GRD S BAT PR ZUENDSCHLOSS ...

Page 475: ...R BRUMFIELD Fa TELEDYNE CONTINENTAL Fa UNISON 32598 13 SWITCH SPST 07 1 1 13 920 Fa KISSLING 1 35 X mtr MIL W 22759 16 10 WIRE AWG 10 X 2 1 5 1 2 2 1 5 2 1 X 1 1 1 X X X 1 1 1 1 1 1 1 X 1 1 1 1 1 2 2 1 5 1 2 1 5 2 1 X 1 1 1 X X X 1 1 1 1 1 1 1 X 1 1 1 1 1 2 Fa AMP Fa AMP 7E291 010 520 620 Fa ESKA 00776 33081 FE 0003 01168 926474 1 33 1 1 7277 2 5 CIRCUIT BREAKER 5A Fa KLIXON FE 4028 03618 31506 1 ...

Page 476: ...ATOR D B 2 2uF 250V 20 F8 2A 18 K4 6 20 39 29 30 R1 68R 41 6 L1 LOW VOLTAGE 1 2 3 20 27 28 34 20 6 K4 20 36 18 BOSCH 55A 20 20 B 42 2 2uF 250V 39 43 44 6 ALTERNATOR D B GND B PRESTOLITE 65A 70A B 2 4 OPTION 05 06 11 12 10 10 MAIN BUS SH 1 100mV 100A 1A F5 1A F6 19 5A F7 5A F4 20 37 K4 6 6 34 6 20 18 20 20 EA 9E102 1 EA3E0900d EA 300 LC 10 02 11 HW L R GRD S BAT PR ZUENDSCHLOSS OFF R L BOTH START L...

Page 477: ...ER Fa KLIXON Fa POTTER BRUMFIELD Fa TELEDYNE CONTINENTAL Fa UNISON 32598 13 SWITCH SPST 07 1 1 13 920 Fa KISSLING 1 35 X mtr MIL W 22759 16 10 WIRE AWG 10 X 2 1 5 1 2 2 1 5 2 1 X 1 1 1 X X X 1 1 1 1 1 1 1 X 1 1 1 1 1 1 2 1 5 1 2 1 5 2 1 X 1 1 1 X X X 1 1 1 1 1 1 1 X 1 1 1 1 1 1 Fa AMP Fa AMP 7E291 010 520 620 Fa ESKA 00776 33081 FE 0003 01168 926474 1 33 1 1 7277 2 5 CIRCUIT BREAKER 5A Fa KLIXON F...

Page 478: ...ION EA 9E102 52 ALTERNATOR D B 2 2uF 250V 20 F8 2A 18 K4 6 20 39 29 30 R1 68R 41 6 L1 LOW VOLTAGE 1 2 3 20 27 28 34 20 6 K4 20 36 18 BOSCH 55A 20 20 B 42 2 2uF 250V 39 43 44 6 ALTERNATOR D B GND B PRESTOLITE 65A 70A B 2 4 OPTION 05 06 11 12 10 10 MAIN BUS SH 1 100mV 100A 1A F5 1A F6 19 5A F7 5A F4 20 37 K4 6 6 34 6 20 18 20 20 EA 9E102 1 EA3E0900e1 EA 300 LC 10 02 11 HW L R GRD S BAT PR ZUENDSCHLO...

Page 479: ...Fa TELEDYNE CONTINENTAL Fa UNISON 32598 13 SWITCH SPST 07 1 1 13 920 Fa KISSLING 1 35 X mtr MIL W 22759 16 10 WIRE AWG 10 X 2 1 5 1 2 2 1 5 2 1 X 1 1 1 X X X 1 1 1 1 1 1 1 X 1 1 1 1 1 1 2 1 5 1 2 1 5 2 1 X 1 1 1 X X X 1 1 1 1 1 1 1 X 1 1 1 1 1 1 Fa AMP Fa AMP 7E291 010 520 620 Fa ESKA 00776 33081 FE 0003 01168 926474 1 33 1 1 7277 2 5 CIRCUIT BREAKER 5A Fa KLIXON FE 4028 03618 31506 1 1 38 20 3355...

Page 480: ...TROBE L ON OFF 3 2 3 P10 J10 15 7 8 9 10 7 8 9 10 9 10 7 8 P11 J11 18 18 18 18 18 18 18 18 18 13 14 13 14 18 18 2 1 bonding of strobe lights refer to drawing EA 10101 0 2 bonding of lighting protection tube refer to drawing EA 10101 0 1 2 1 7 8 9 10 16 18 Benennung Nr Teilekennzeichen ZF Werkstoff Abmessungen Menge Gewicht Einheit MaWi Nr 1 CIRCUIT BREAKER 10A 7277 2 10 POWER SUPPLY A413A HDACF 01...

Page 481: ...13 14 13 14 18 18 1 bonding of strobe lights refer to drawing EA 1D101 0 1 1 7 8 9 10 18 19 Benennung Nr Teilekennzeichen ZF Werkstoff Abmessungen Menge Gewicht Einheit MaWi Nr 1 CIRCUIT BREAKER 2A 7277 2 2 POWER SUPPLY A413A HDACF 01 0770028 05 2 7277 2 5 CIRCUIT BREAKER 5A 1 3 LAMP ASSY L H 90340 01 0790340 02 5 4 01 0790340 01 LAMP ASSY R H 90340 6 8 7 12 11 13 PIN PIN GEHÄUSE 3 POLIG 1 0480305...

Page 482: ...leranz Oberfläche Schutzvermerk nach DIN 34 beachten EDV Kennung auf Blatt von Schwarze Heide 21 46569 Hünxe Germany Gepr Flugzeugbaureihe ist der Bauakte bzw EA 300 FUEL GAGES EA 93102 4 30 10 90 KHP 1 A4 1 EA300908 ÄM 300 05 18 INSTR CB10 5A S S 1 2 R R FUSELAGE WING FUEL FUEL FUSELAGE WING INDICATOR INDICATOR 301030 001G 301030 002G 3 180Ohm 20 20 20 20 20 20 20 20 MAIN BUS 1 2 3 4 9 10 8 11 5 ...

Page 483: ... Gepr Maßstab SI Klasse Oberflächenschutz Projektion Freimaßtoleranz Oberfläche Schutzvermerk nach DIN 34 beachten EDV Kennung auf Blatt von Schwarze Heide 21 46569 Hünxe Germany Gepr Flugzeugbaureihe ist der Bauakte bzw EA 300 FUEL GAGES EA 93102 4 30 10 90 KHP 1 A4 1 EA300908b ÄM 300 05 18 INSTR CB10 5A S S R R FUSELAGE WING FUEL FUEL FUSELAGE WING INDICATOR INDICATOR 301030 001G 301030 002G 3 1...

Page 484: ...02 6 AUDIO JACKS SWITCHES OPTION 01 04 OPTION 02 BECKER COM AR 6201 mit POTTER BRUMFIELD CB OPTION 01 BECKER COM AR 6201 mit KLIXON CB Lighting 10 20 GND GND 13 75 VDC 13 75 VDC Lighting Mic GND IC Control PTT Mic Hi Phone Hi 13 25 12 11 23 17 7 14 18 2 Speaker 1 Lighting 10 Phone Lo 3 Phone Lo 3 bl bl FE4006 MIL C 27500 24TG2 WIRE 2xAWG24 7 A8 A6 A4 A3 A2 A1 COM S E GERÄT Die Gültigkeitszuordnung...

Page 485: ...PHONE JACK FE4301 00196 00195 1174599 PUSH BUTTON JJ 034 MIC JACK JJ 033 PUSH BUTTON 01430 701548 FE4006 MIL C 27500 24TG2 WIRE 2xAWG24 2 4 2 2 X 4 1 WASHER 31381 31382 04 00975 WASHER 04 00976 2 4 mtr FE4256 BUCHSENGEHÄUSE 43025 0400 FE4079 43030 0007 BUCHSE 15 02 06 HW B ÄM 300 05 18 Wegfall Audiobox Wegfall NAV 9 9 EA 76291 1 PTT KABELBAUM 1 25 04 96 MB A ÄM 300 96 06 Die Gültigkeitszuordnung v...

Page 486: ...18 red blk 18 18 BOOST PUMP M4 8120 M MAIN BUS MAIN BUS 18 red blk 18 18 BOOST PUMP M4 8120 M OPTION 01 02 OPTION 03 18 1 1 8 6 5 7 3 4 2 6 5 2 FLACHSTECKER PIN 6 3mm PIN GEHÄUSE 2 POLIG 00099 00103 00097 180924 0 180923 0 BUCHSEN GEHÄUSE 2 POLIG FLACHSTECKER BUCHSE 6 3mm 0042282 2 00093 42565 2 8 7 1 1 2 2 1 1 2 2 1 1 2 3 1 2 1 2 2 MS35058 22 SWITCH SPST 1 01602 ÄM 300 05 18 Die Gültigkeitszuordn...

Page 487: ...PTION 01 02 18 1 8 6 5 7 3 4 2 6 5 2 FLACHSTECKER PIN 6 3mm PIN GEHÄUSE 2 POLIG 00099 00103 00097 180924 0 180923 0 BUCHSEN GEHÄUSE 2 POLIG FLACHSTECKER BUCHSE 6 3mm 0042282 2 00093 42565 2 8 7 1 1 2 2 1 1 2 1 2 2 MS35058 22 SWITCH SPST 1 01602 Die Gültigkeitszuordnung von Version zu dem jeweiligen Fertigungsauftrag zu entnehmen Zuordnung links rechts wird mit in allen Feldern angegeben 04 03 02 0...

Page 488: ...y Gepr Flugzeugbaureihe ist der Bauakte bzw EA 300 LT STALL WARNING SYSTEM EA 9D102 12 27 02 10 hw 1 A4 1 EA3D0904 02 04 03 Benennung Nr 01 Teilekennzeichen ZF Werkstoff Abmessungen Menge Gewicht Einheit MaWi Nr 1 31526 7277 2 1 CIRCUIT BREAKER 1A 1 3 STALL WARNER EA 7D106 1 1 2 EM S 110P BUZZER 1 01600 01694 4 WIRE AWG 22 MIL W 22759 16 22 mtr X 1A STALL MAIN BUS 1 8 6 5 7 4 2 6 5 6 FLACHSTECKER ...

Page 489: ... 92 NH 1 A4 1 29 11 05 HW 02 04 03 Benennung Nr 01 Teilekennzeichen ZF Werkstoff Abmessungen Menge Gewicht Einheit MaWi Nr 1 2 3 4 PEDALMOTOR FLACHSTECKER PIN 6 3mm PIN GEHÄUSE 2 POLIG CARR 20X20X1 00099 00103 00097 01996 180924 0 180923 0 1 3 4 5 7 8 9 10 5 6 7 8 BUCHSEN GEHÄUSE 2 POLIG FLACHSTECKER BUCHSE 6 3mm MICROSCHALTER BUCHSEN GEHÄUSE 4 POLIG 0042282 2 01170 01171 33626 00093 180900 1 1809...

Page 490: ...00097 01996 180924 0 180923 0 1 3 4 5 7 9 11 12 5 6 7 8 BUCHSEN GEHÄUSE 2 POLIG FLACHSTECKER BUCHSE 6 3mm MICROSCHALTER Burgess PIN 0042282 2 FE4306 FE4308 33626 00093 1 0480305 0 163558 2 PIN GEHÄUSE 3 POLIG 07 2 1 22 2 8 10 6 V4NCSK2A7 0 5M 42565 2 12 7277 2 7 5 31506 CIRCUIT BREAKER 7 5A 2 1 2 4 2 2 4 4 4 12 11 SCHALTER 2 POLIG TAST ON TAST EA3E0920 P2 J2 P1 J1 J5 20 20 20 20 20 20 20 20 20 20 ...

Page 491: ... D 9S 1 5 9 6 PC CONNECTION L1 LED G METER EA 93102 6 see AUDIO JACKS SWITCHES ws bl ws bl ws bl or bl ws or bl ws 1 2 3 4 5 7 6 8 9 10 1 J1 24 24 22 22 22 22 22 22 MIL C 27500 24TG2 FE4006 WIRE 2xAWG24 MIL C 27500 24TG3 WIRE 3xAWG24 MIL W 22759 16 22 01694 WIRE AWG22 X 1 X CONNECTOR SUBD 9S 2 24 24 24 22 22 ws bl INPUT GND PWR GND OUT Hi OUT Lo K4900 mod AMPLIFIER 1 ws bl WARNING R3 330R 4 2 5 AM...

Page 492: ...7500 24TG3 WIRE 3xAWG24 MIL W 22759 16 22 01694 WIRE AWG22 X X X CONNECTOR SUBD9S 2 24 24 24 22 22 ws bl INPUT GND PWR GND OUT Hi OUT Lo K4900 mod AMPLIFIER 1 ws bl WARNING 330R R3 4 2 AMPLIFIER OPTIONEN P1 7 19 P4002 2 3 COM SYSTEM AR 4201 6201 EA 9E102 05 Option COM 32 3 INTERCOM AUDIO SYSTEM AA 83 001 P1 EA 9D102 51 Option INTERCOM NAT AA 83 001 18 COMM AUDIO HI COMM AUDIO LO Phone Hi Phone Lo ...

Page 493: ...ws bl INPUT GND PWR GND OUT Hi OUT Lo K4900 mod AMPLIFIER 1 ws bl WARNING R3 330R 4 2 AMPLIFIER OPTIONEN P1 7 19 P4002 2 3 COM SYSTEM AR 4201 6201 EA 9E102 05 Option COM 32 3 INTERCOM AUDIO SYSTEM AA 83 001 P1 EA 9D102 51 Option INTERCOM NAT AA 83 001 18 COMM AUDIO HI COMM AUDIO LO Phone Hi Phone Lo Music Input Right Music Input Left Music Input Lo PHONE BUCHSE PILOT ws bl ws bl ws bl ws bl ws bl ...

Page 494: ...3 52 133 MIL W 22759 16 20 WIRE AWG20 WIRE RG400 RG 400 FE4111 11TNC 50 3 177 133 1 4 7 3 2 5 7 8 6 X X X X X X X X X X X X X X X 2 ANTENNA COMANT CI 105 1 Stueck 30336 010 10160 00 X OPTION 02 TRT 800 mit KING KA 60 ANTENNE OPTION 03 TRT 800H mit COMANT CI 105 ANTENNE für EA 300 SC EA 300 LC 2SH 3SH in Pos 1 FE4242 Die Gültigkeitszuordnung von Version zu dem jeweiligen Fertigungsauftrag zu entneh...

Page 495: ...IRE AWG20 WIRE RG400 RG 400 00775 X X X X X X X X X X X X X X ANTENNA COMANT CI 105 1 Stueck 30336 010 10160 00 1 2 3 4 5 6 7 8 2 3SH A ATC ANTENNA 2 5 6 5 EA300930a 1 9 7 4 11 to GPS ws bl ws bl ws bl ws bl ws bl to GPS and EFIS to AUDIO 8 10 3 mtr WIRE AWG24 MIL W 22759 16 24 FE4011 X X 9 Stueck 1 CONNECTOR SUBD 62P KIT X X 10 Stueck 1 CONNECTOR SUBD 25S X X green white light brown blue yellow o...

Page 496: ...00 RG 400 00775 X X X X X X X X X X X X X X ANTENNACOMANT CI 105 1 Stueck 30336 010 10160 00 1 2 3 4 5 6 7 8 2 3SH A ATC ANTENNA 2 5 6 5 EA300930 1 9 7 4 11 to GPS ws bl ws bl ws bl ws bl ws bl to GPS and EFIS to AUDIO 8 10 3 mtr WIRE AWG24 MIL W 22759 16 24 FE4011 X X 9 Stueck 1 CONNECTOR SUBD 62P KIT X X 10 Stueck 1 CONNECTOR SUBD 25S X X green white light brown blue yellow orange pink violet gr...

Page 497: ... 13 6 SWITCHED POWER OUTPUT D4 20 14 VDC POWER IN 11 green white light brown blue yellow orange pink violet gray 5 11 12 A C GND 10 4 Option RG 400 4SH ACK A 30 5SH A BLIND ENCODER GROUND 14VDC A1 A2 A4 B1 B2 B4 C1 C2 C4 2 3 4 5 9 10 11 12 13 15 8 6 STROBE 5SH 2SH A 7 REPLAY OUT 20 28V LIGHT 23 J8 TIS RX 14 17 18 TIS RX TIS TX TIS TX 15 GROUND SWITCH 11 ws to GPS Option 24 24 ALT S 12 ALT S 13 bl ...

Page 498: ...range pink violet gray 4 8 10 A C GND 7 3 Option RG 400 CIRCUIT BREAKER 3A 1 1 Stueck Stueck Stueck 31507 04108 002239 7277 2 3 BLIND ENCODER A 30 1 2 Stueck mtr 3 5 mtr A 30 ANTENNA KING KA 60 071 01591 0001 CONNECTOR BNC FE4111 30705 11BNC 50 3 52 133 MIL W 22759 16 20 WIRE AWG20 WIRE RG400 RG 400 00775 X X X X X X X X X X X X ANTENNA COMANT CI 105 1 Stueck 30336 010 10160 00 2 3 4 5 6 7 8 2 mtr...

Page 499: ...2 OUT B 20 28V LIGHT 23 red 02 04 03 Benennung Nr 01 Teilekennzeichen ZF Werkstoff Abmessungen Menge Gewicht Einheit MaWi Nr TRANSPONDER ATC 4401 1 CIRCUIT BREAKER 3A 1 1 1 Stueck Stueck Stueck Stueck ATC 4401 1 175 04108 31508 31002 1 1 Stueck mtr 0 7 mtr 2 9 7277 2 3 ANTENNA KING KA 60 071 01591 0001 CONNECTOR TNC 31633 11TNC 50 3 117 133 MIL W 22759 16 20 WIRE AWG20 WIRE RG400 RG 400 FE4111 X X...

Page 500: ...he Schutzvermerk nach DIN 34 beachten EDV Kennung auf Blatt von Schwarze Heide 21 46569 Hünxe Germany Gepr Flugzeugbaureihe ist der Bauakte bzw A4 1 1 EA3D0936 02 03 Benennung Nr 01 Teilekennzeichen ZF Werkstoff Abmessungen Menge Gewicht Einheit MaWi Nr 1 DIGITAL AMPERE METER FA3007 2 VA 1A 50 CONNECTOR KIT FA3007 KIT VA 1A XX 1 VOLT AMP INDICATOR red wht brn I1B 4 1 wht yel 3 VA 1A 50 SH 1 100mV ...

Page 501: ...etzte Bearbeitung Datum Name Bearb Gepr Maßstab SI Klasse Oberflächenschutz Projektion Freimaßtoleranz Oberfläche Schutzvermerk nach DIN 34 beachten EDV Kennung auf Blatt von Schwarze Heide 21 46569 Hünxe Germany Gepr Flugzeugbaureihe ist der Bauakte bzw EA 300 LT RPM INDICATION EA 9D102 30 21 04 10 HW 1 A4 1 EA3D0939 DIG RPM blk left Magn right Magn ws B C A E D F INDICATOR TIMER 22 5A INSTR MAIN...

Page 502: ...2735 149 12LS 8 MAIN BUS F3 40A L2 STARTER ENGAGED 1 3 2 18 INSTR CB10 5A MAIN BUS see FUEL GAGES EA 93102 4 to SHUNT see EA 93102 9 to BATTERY RELAY see EA 93102 9 see MAGNETO SYSTEM EA 93102 2 D E see BATTERY CIRCUIT EA 93102 9 F G 20 20 20 4 4 1 2 3 1A F4 5A F5 EA 83290 1 4 18 Die Gültigkeitszuordnung von Version zu dem jeweiligen Fertigungsauftrag zu entnehmen Zuordnung links rechts wird mit i...

Page 503: ... nach DIN 34 beachten EDV Kennung auf Blatt von Schwarze Heide 21 46569 Hünxe Germany Gepr Flugzeugbaureihe ist der Bauakte bzw 14 GND 29 07 13 HW see conforming ELEKTRIK SYSTEM EA 9__102 1 red blk wht A A ÄM 300 13 07 11 14 12 1 15 4 5 INDICATOR 22 22 1 2 4 3 5 11 14VDC GND GAUGE 2 IN GAUGE 2 IN GAUGE 1 IN GAUGE 1 IN 4 1 15 5 6 3 22 red blk wht see conforming OIL TEMP PRESS EA 9__102 34 22 02 03 ...

Page 504: ... 22 1 2 4 3 5 11 14VDC GND GAUGE 2 IN GAUGE 2 IN GAUGE 1 IN GAUGE 1 IN 4 1 15 5 6 3 22 or blu wht see conforming OIL TEMP PRESS EA 9__102 34 22 02 03 Benennung Nr 01 Teilekennzeichen ZF Werkstoff Abmessungen Menge Gewicht Einheit MaWi Nr 2 in Pos 1 CONNECTOR DSUB 15 4 OIL PRESS SENSOR N1EU150G T1EU150G 3 1B3A OIL TEMP SENSOR 00775 WIRE AWG 20 MIL W 22759 16 20 mtr 1 1 1 X 1 D2 OP130U 0T300U 00 IND...

Page 505: ...a K5 8 10 9 10 FLACHSTECKER BUCHSE 6 3mm 42282 1 2 FLACHSTECKER BUCHSE 5 6 3mm VCF4 1001 2 10 2 10 Die Gültigkeitszuordnung von Version zu dem jeweiligen Fertigungsauftrag zu entnehmen Zuordnung links rechts wird mit in allen Feldern angegeben 04 03 02 01 Ver Bezeichnung Nr Änderung Mod Nr Datum Name Letzte Bearbeitung Datum Name Bearb Gepr Maßstab SI Klasse Oberflächenschutz Projektion Freimaßtol...

Page 506: ... 1 2 2 2 1 2 1 1 1 2 1 1 2 2 OPTION 01 STANDARDPANEL OPTION 02 KOHLEPANEL 1 2 1 3 SMOKE REFILL ON OFF S5 2 1 3 SMOKE ARM ON OFF S6 16 16 16 16 11 MS35058 23 07 1 1 13 16 21 02 16 HW A ÄM 300 15 07 07006 FE4025 9 12V 40A Wechsler 30 85 86 87 87a K4 12V 40A Wechsler 30 85 86 87 87a K5 8 10 9 10 FLACHSTECKER BUCHSE 6 3mm 42282 1 2 FLACHSTECKER BUCHSE 5 6 3mm VCF4 1001 2 10 2 10 Die Gültigkeitszuordnu...

Page 507: ...ound 5 8 12 8 1 2 5 7 9 14 VDC 8 3 452 6505 ALERT BUZZER 1 9 5g 3DA ALLERT BUZZER 3 114g 142g 1 2 3 4 5 6 7 8 9 Auf Kabelseite gesehen 1DA Die Gültigkeitszuordnung von Version zu dem jeweiligen Fertigungsauftrag zu entnehmen Zuordnung links rechts wird mit in allen Feldern angegeben 04 03 02 01 Ver Bezeichnung Nr Änderung Mod Nr Datum Name Letzte Bearbeitung Datum Name Bearb Gepr Maßstab SI Klasse...

Page 508: ... 1DA Die Gültigkeitszuordnung von Version zu dem jeweiligen Fertigungsauftrag zu entnehmen Zuordnung links rechts wird mit in allen Feldern angegeben 04 03 02 01 Ver Bezeichnung Nr Änderung Mod Nr Datum Name Letzte Bearbeitung Datum Name Bearb Gepr Maßstab SI Klasse Oberflächenschutz Projektion Freimaßtoleranz Oberfläche Schutzvermerk nach DIN 34 beachten EDV Kennung auf Blatt von Schwarze Heide 2...

Page 509: ... 01 Ver Bezeichnung Nr Änderung Mod Nr Datum Name Letzte Bearbeitung Datum Name Bearb Gepr Maßstab SI Klasse Oberflächenschutz Projektion Freimaßtoleranz Oberfläche Schutzvermerk nach DIN 34 beachten EDV Kennung auf Blatt von Schwarze Heide 21 46569 Hünxe Germany Gepr Flugzeugbaureihe ist der Bauakte bzw 6 12 V B1 BATTERIE 5A F1 CHARGE 18 18 1A F2 EA 83290 1 4 4 BATTERY RELAY K1 9 10 zwischen Rela...

Page 510: ...N 12 10 1 2 3 14 15 16 17 18 19 4 25 5 GROUND 13 6 SWITCHED POWER OUTPUT D4 20 14 VDC POWER IN 11 5 A C GND 10 4 RG 400 4SH BE 6400 01 BLIND ENCODER MODULE 5SH 2SH A 7 REPLAY OUT 20 28V LIGHT 23 J8 TIS RX 14 17 18 TIS RX TIS TX TIS TX 15 GROUND SWITCH 11 ALT S 12 ALT S 13 GND 3 GND 21 J7 ADDRESS MODULE AM 6400 1 01 2 10 Stueck 1 CONNECTOR CK 4401 C X X BLIND ENCODER MODULE BE 6400 01 00775 3SH TRA...

Page 511: ...ack orange blue green 1 2 1 2 3 1 2 3 1 2 1 2 1 2 PITCH TRIM SERVO TRIM INDICATOR TRIM SWITCH 31506 PIN MOLEX 43025 0200 BUCHSE Molex 43030 0007 7277 2 1 CIRCUIT BREAKER 1A 43031 0007 43025 0400 BUCHSEN GEHÄUSE 4 POLIG PIN GEHÄUSE 4 POLIG 43020 0400 BUCHSEN GEHÄUSE 2 POLIG 43020 0200 PIN GEHÄUSE 2 POLIG MIL W 22759 16 22 KABEL AWG 22 7 8 9 10 11 mtr 2 14 2 4 4 X 14 white 12V Light 12V Power Ground...

Page 512: ... 500 1000 MFD 24 24 24 24 ws bl ws bl ws bl ws bl 24 ws bl or OPTIONEN EA3D0955 02 04 03 Benennung Nr 01 Teilekennzeichen ZF Werkstoff Abmessungen Menge Gewicht Einheit MaWi Nr 1 2 3 4 CONFIGURATION MODULE PFD PIL 1 1 910 00003 001 5 REMOTE SENSOR MODULE 1 1 1 920 00004 001 EFD 1000 DISPLAY 910 00001 001 CIRCUIT BREAKER 7 5A 116 00022 002 CONNECTOR SUBD 44S 7277 2 7 5 6 7 8 CONNECTOR RSM CIRCULAR ...

Page 513: ...ngen Menge Gewicht Einheit MaWi Nr 1 2 3 4 CONFIGURATION MODULE PFD PIL 1 1 910 00003 001 5 REMOTE SENSOR MODULE 1 1 1 920 00004 001 EFD 1000 DISPLAY 910 00001 001 CIRCUITBREAKER 7 5A 116 00022 002 CONNECTOR SUBD44S 7277 2 7 5 6 7 8 CONNECTOR RSM CIRCULAR 1 1 MIL C 27500 18TG1 9 WIRE AWG18 SHIELD X 116 00020 001 CONNECTOR 5S WITHCABLE 412 00004 001 X mtr WIRE AWG18 MIL W 22759 16 18 3 2 7 1 5 8 4 ...

Page 514: ... 11 14 12 RS232_RX4 RS232_RX5 RS232_TX2 11 14 12 24 ws bl or 24 25 429 TAS RX5A 429 TAS RX5B ws bl 24 24 25 429 TAS RX5A 429 TAS RX5B P1 EFIS PFD EFD 1000 PFD 24 24 24 ws bl ws bl ws bl 24 ws bl or OPTIONEN 3 7 ARINC 429 IN 1 B 32 ARINC 429 IN 1 A 35 30 28 Arinc 429 Out 2 A Arinc 429 Out 2 B P1 TRANSPONDER GTX 330 328 24 24 ws bl ws bl 46 47 50 51 ARINC 429 IN 2 A ARINC 429 IN 2 B ARINC 429 OUT A ...

Page 515: ...t requires GNC 420W or GTN 635 to be installed 3 optional MFD requires GTX 330 328 or GTX 33 to be installed 9 11 02 04 03 Benennung Nr 01 Teilekennzeichen ZF Werkstoff Abmessungen Menge Gewicht Einheit MaWi Nr 1 2 3 4 CONFIGURATION MODULE 500MFD 1 1 910 00003 002 5 REMOTE SENSOR MODULE 1 1 920 00004 005 EFD 500 DISPLAY 910 00001 003 CIRCUITBREAKER 7 5A 116 00022 002 CONNECTOR SUBD44S 7277 2 7 5 6...

Page 516: ...E COPILOT 24 24 24 24 24 24 MIC BUCHSE COPILOT MIC BUCHSE PILOT J4 P4 1 2 3 4 ws bl ws bl ws bl ws bl ws bl ws bl ws bl bl bl ws bl ws bl ws bl ws bl ws bl bl bl bl ws bl ws ws ws ws ws 24 24 A16 A15 A14 A13 A12 A11 A10 A9 A8 A7 EA 76291 1 A6 A5 A4 A3 A2 A1 24 ws bl bl bl ws bl bl bl bl ws bl ws ws ws ws ws 24 24 EA 93102 6 AUDIO JACKS SWITCHES bl bl 11 A8 A6 A4 A3 A2 A1 I3 I2 I1 I5 I4 OPTION INTE...

Page 517: ...DC POWER GROUND 20 20 see POWER DISTRIBUTION 8 5oz 16oz 5 Option INCLINOMETER OPTION 04 3 Inch VERSION with INCLOMETER 5 Stueck 1 INCLINOMETER RCA444 0010 01 1 X X X 1 Die Gültigkeitszuordnung von Version zu dem jeweiligen Fertigungsauftrag zu entnehmen Zuordnung links rechts wird mit in allen Feldern angegeben 04 03 02 01 Ver Bezeichnung Nr Änderung Mod Nr Datum Name Letzte Bearbeitung Datum Name...

Page 518: ...nector INTERCOM ws ws blk ws bl blk 734136 PHONE COPILOT 1 PHONE PILOT 1 ws bl ws bl MIC COPILOT 1 ws bl MIC PILOT 1 ws bl EA3D0960 17 18 14 PTT PILOT PTT COPILOT J4 P4 1 2 3 4 ws bl ws bl ws bl ws bl 24 24 ws bl ws bl 10 9 7 7 EA 76291 1 11 02 03 Benennung Nr 01 Teilekennzeichen ZF Werkstoff Abmessungen Menge Gewicht Einheit MaWi Nr 6 7 8 9 10 11 12 14 5 STEREO PHONE JACK SWL 12B FE4301 00196 033...

Page 519: ...ON 01430 701548 734136 STEREO JACK 2 4 2 2 1 4 1 WASHER 31381 31382 04 00975 WASHER 04 00976 2 4 mtr FE4256 BUCHSENGEHÄUSE 43025 0400 FE4079 43030 0007 BUCHSE 13 EA 76291 1 PTT KABELBAUM 1 1 2 5 3 8 14 4 6 5 3 8 16 4 6 13 12 2 3 1 1 1 15 16 X X X NAT AA83 001 INTERCOM CONNECTOR KIT in Pos 2 WIRE AWG 20 00775 MIL W 22759 16 20 FE4006 MIL C 27500 24TG2 WIRE 2xAWG24 MIL C 27500 24TG3 WIRE 3xAWG24 mtr...

Page 520: ...T in Pos 2 WIRE AWG 20 00775 MIL W 22759 16 20 FE4006 MIL C 27500 24TG2 WIRE 2xAWG24 MIL C 27500 24TG3 WIRE 3xAWG24 mtr mtr 15 mtr X MIL C 27500 22TG2 WIRE 2xAWG22 Fa AIRCRAFT SPRUCE 6 6 SH 1 100mV 100A 5A 1A see DIGITAL INDICATION EA 9D102 52 see VOLT AMPERE INDICATION EA 9D102 27 OPTIONEN ANALOG OPTIONEN DIGITAL 1A 4 FE4009 FE4005 30362 31659 OPTIONEN 7 19 P4002 COMM AUDIO HI COMM AUDIO LO ws bl...

Page 521: ...EMP CH12 In TEMP CH13 In TEMP CH14 In TEMP CH15 In GND GND 1 2 3 4 5 6 7 8 9 10 11 12 14 15 16 17 18 19 20 21 22 23 24 25 13 26 27 28 29 30 31 32 33 34 35 36 37 FL CH 2 Cin FL CH 2 5V FL CH 2 GND FL CH 2 Rin GND 5V TEMP CH16 In TEMP CH17 In FL CH 4 Cin FL CH 4 5V FL CH 4 GND FL CH 4 Rin GND GND FL CH 1 Cin FL CH 1 5V FL CH 1 GND FL CH 1 Rin GND RPM CH 2 In RPM CH 1 In RPM 6 CYL Sel RPM 6 CYL GND G...

Page 522: ...7 FL CH 2 Cin FL CH 2 5V FL CH 2 GND FL CH 2 Rin GND 5V TEMP CH16 In TEMP CH17 In FL CH 4 Cin FL CH 4 5V FL CH 4 GND FL CH 4 Rin GND GND FL CH 1 Cin FL CH 1 5V FL CH 1 GND FL CH 1 Rin GND RPM CH 2 In RPM CH 1 In RPM 6 CYL Sel RPM 6 CYL GND GND 5V GND 5V GND GND TEMP CH16 In TEMP CH17 In FL CH 3 Cin FL CH 3 5V FL CH 3 Rin FL CH 3 GND GND GND Bottom Connector Middle Connector MVP 50P 4 6 EDC 33P 4 6...

Page 523: ...ITOR EDC 33P 4 6 CONNECTOR CONNECTOR EGT SENSORS P 110 P 100 CHT SENSORS OAT PROBE P 120 P 128 OIL TEMP PROBE TC CONNECTOR SOCKET TYP K mtr MANIFOLD PRESS SENSOR PT 30ABS OIL PRESS SENSOR PT 100GA FUEL PRESS SENSOR PT 30GA FLOW SENSOR FT 60 MIL W 22759 16 22 RESISTOR VI 221 79K RESISTOR 79K RFLM 4 12V ENGINE DATA CONVERTER MIL C 27500 20TG1 mtr WIRE AWG 22 WIRE AWG 20 SHIELDED CIRCULAR CONNECTOR 2...

Page 524: ...CTOR CONNECTOR EGT SENSORS P 110 P 100 CHT SENSORS OAT PROBE P 120 P 128 OIL TEMP PROBE TC CONNECTOR SOCKET TYP K mtr MANIFOLD PRESS SENSOR PT 30ABS OIL PRESS SENSOR PT 100GA FUEL PRESS SENSOR PT 30GA FLOW SENSOR FT 60 MIL W 22759 16 22 RESISTOR VI 221 79K RESISTOR 79K RFLM 4 12V ENGINE DATA CONVERTER MIL C 27500 20TG1 mtr WIRE AWG 22 WIRE AWG 20 SHIELDED CIRCULAR CONNECTOR 27 28 29 2 226 801 015 ...

Page 525: ...ANDING LIGHT 10A LDG LT 2 1 3 LDG LT ON OFF BALLAST 18 16 1 A4 1 see ELEKTRIK SYSTEM EA 9D102 1 P1 red red blk blk wht wht D1 50WATT XV 19 XV4D 12 35 blk wht red blk wht red n c n c EA3D0962 MAIN BUS 02 03 Benennung Nr 01 Teilekennzeichen ZF Werkstoff Abmessungen Menge Gewicht Einheit MaWi Nr 1 7277 2 10 CIRCUIT BREAKER 10A 1 33079 3 BALLAST XV4D XV4D 12 35 1 2 07 1 1 13 SWITCH 1 FE 4308 4 WIRE AW...

Page 526: ...2 EA3E0962 MAIN BUS 1 2 3 20 8 1 2 J1 P1 1 2 20 5 7 4 6 1 mechanical installation drawing EA 8E001 50 20 see conforming ELEKTRIK SYSTEM EA 9__102 1 L1 L2 L3 L4 L5 L6 red red black black 20 20 20 20 5 7 4 6 OPTION 02 MS SWITCH POTTER BRUMFIELD CB OPTION 01 KISSLING SWITCH KLIXON CB LAMP ASSY L H 7112512 01 0771125 12 Fa WHELEN 33588 02 04 03 Benennung Nr 01 Teilekennzeichen ZF Werkstoff Abmessungen...

Page 527: ...l ws bl ws bl ws bl ws bl ws bl ws bl bl bl ws bl ws bl ws bl ws bl ws bl bl bl bl ws bl ws ws ws ws ws 24 24 A16 A15 A14 A13 A12 A11 A10 A9 A8 A7 EA 76291 1 A6 A5 A4 A3 A2 A1 24 ws bl bl bl ws bl bl bl bl ws bl ws ws ws ws ws 24 24 EA 93102 6 AUDIO JACKS SWITCHES bl bl 14 A8 A6 A4 A3 A2 A1 I3 I2 I1 I5 I4 OPTION INTERCOM AUDIO JACKS SWITCHES P4002 TRANSPONDER GTX 330 328 P3301 P1 EFIS EFD 500 1000...

Page 528: ...l bl bl bl ws bl ws ws ws ws ws 24 24 A16 A15 A14 A13 A12 A11 A10 A9 A8 A7 EA 76291 1 A6 A5 A4 A3 A2 A1 24 ws bl bl bl ws bl bl bl bl ws bl ws ws ws ws ws 24 24 EA 93102 6 AUDIO JACKS SWITCHES bl bl 14 A8 A6 A4 A3 A2 A1 I3 I2 I1 I5 I4 OPTION INTERCOM AUDIO JACKS SWITCHES P4002 TRANSPONDER GTX 330 328 P3301 P1 EFIS EFD 500 1000 MFD P1 EFIS EFD 1000 PFD Pro OPTIONEN OPTIONEN 02 04 03 Benennung Nr 01...

Page 529: ...etzte Bearbeitung Datum Name Bearb Gepr Maßstab SI Klasse Oberflächenschutz Projektion Freimaßtoleranz Oberfläche Schutzvermerk nach DIN 34 beachten EDV Kennung auf Blatt von Schwarze Heide 21 46569 Hünxe Germany Gepr Flugzeugbaureihe ist der Bauakte bzw B1 BATTERIE 12 V Masse auf Rahmen 5A F1 CHARGE 18 18 1A F2 2 1 3 S1 MAIN BUS EA 83290 1 4 4 4 18 K1 BATTERY RELAY RG 25XC 4 1 2 3 zwischen Relais...

Page 530: ... Nr Änderung Mod Nr Datum Name Letzte Bearbeitung Datum Name Bearb Gepr Maßstab SI Klasse Oberflächenschutz Projektion Freimaßtoleranz Oberfläche Schutzvermerk nach DIN 34 beachten EDV Kennung auf Blatt von Schwarze Heide 21 46569 Hünxe Germany Gepr Flugzeugbaureihe ist der Bauakte bzw 1 3 4 5 GEHÄUSE STECKHÜLSE 1 POL 00093 FLACHSTECKHÜLSE 6 3mm 00098 925324 2 0042282 2 mtr 00776 MIL W 22759 16 18...

Page 531: ...tab SI Klasse Oberflächenschutz Projektion Freimaßtoleranz Oberfläche Schutzvermerk nach DIN 34 beachten EDV Kennung auf Blatt von Schwarze Heide 21 46569 Hünxe Germany Gepr Flugzeugbaureihe ist der Bauakte bzw see conforming VOLT AMPERE INDICATION EA 9__102 27 22 see conforming OIL TEMP PRESS EA 9__102 34 22 Typ K Typ J 29 07 13 HW A A ÄM 300 13 07 4 1 15 5 6 3 Opt 02 Verbindung für S N 2in1 206 ...

Page 532: ...zeichnung Nr Änderung Mod Nr Datum Name Letzte Bearbeitung Datum Name Bearb Gepr Maßstab SI Klasse Oberflächenschutz Projektion Freimaßtoleranz Oberfläche Schutzvermerk nach DIN 34 beachten EDV Kennung auf Blatt von Schwarze Heide 21 46569 Hünxe Germany Gepr Flugzeugbaureihe ist der Bauakte bzw EA 300 FLIGHT TIMER EA 93102 59 09 05 11 HW 1 A4 1 EA300927 INSTR 5A FLIGHT TIMER 20 20 20 MAIN BUS 1 3 ...

Page 533: ...chutz Projektion Freimaßtoleranz Oberfläche Schutzvermerk nach DIN 34 beachten EDV Kennung auf Blatt von Schwarze Heide 21 46569 Hünxe Germany Gepr Flugzeugbaureihe ist der Bauakte bzw 2 3 CIRCUIT BREAKER 5A 7277 2 5 010 11206 15 POWER DATA CABLE 1 1 GPS ANTENNA 5A GPS 20 red yel blu 14 VDC POWER 1 2 3 4 DATA IN blk 20 GPSMAP 696 PANEL DOCK GA 25 MCX 1 3 2 AVIONIC BUS GROUND DATA OUT 4 mtr 00775 M...

Page 534: ... GND 40 RS 232 GND 1 46 61 AIRCRAFT GROUND 60 AIRCRAFT GROUND P1004 P1003 P1001 59 43 FAN POWER OUT 12 VDC FAN GROUND CONFIG MODULE POWER 65 CONFIG MODULE GND CONFIG MODULE DATA 64 62 CONFIG MODULE CLOCK 63 red blk yel wht RS232 IN 1 RS232 IN 3 RS232 OUT 1 ARINC 429 OUT 1A ARINC 429 OUT 1B ARINC 429 IN 2A ARINC 429 IN 2B 8 27 25 10 29 47 66 RS232 OUT 4 24 RS232 IN 4 5 P1001 78 Pin 78 Pin ARINC 429...

Page 535: ...OWER OUT 12 VDC FAN GROUND CONFIG MODULE POWER 65 CONFIG MODULE GND CONFIG MODULE DATA 64 62 CONFIG MODULE CLOCK 63 red blk yel wht RS232 IN 1 RS232 IN 3 RS232 OUT 1 ARINC 429 OUT 1A ARINC 429 OUT 1B ARINC 429 IN 2A ARINC 429 IN 2B 8 27 25 10 29 47 66 RS232 OUT 4 24 RS232 IN 4 5 P1001 78 Pin 78 Pin ARINC 429 OUT 2A ARINC 429 OUT 2B 24 RS232 IN 2 30 28 high 24 30 28 INTERCOM RS 232 OUT 3 15 NAV GPS...

Page 536: ... RS232 IN 3 RS232 OUT 1 ARINC 429 OUT 1A ARINC 429 OUT 1B VOR ILS ARINC 429 OUT A VOR ILS ARINC 429 OUT B ARINC 429 IN 2A ARINC 429 IN 2B 8 27 25 10 29 23 24 47 66 RS232 OUT 4 24 RS232 IN 4 5 MAIN LEFT OUT 49 MAIN RIGHT OUT MAIN TO OUT 68 11 MAIN FROM OUT 30 MAIN LATERAL FLAG OUT MAIN LATERAL FLAG OUT 50 69 MAIN UP OUT 12 MAIN VERTICAL FLAG OUT MAIN DOWN OUT MAIN VERTICAL FLAG OUT MAIN OBS STATOR ...

Page 537: ...ER 5A 1 1 Stueck Stueck Stueck 31506 04108 33775 7277 2 5 1 2 Stueck mtr 4 0 mtr ANTENNA KING KA 60 071 01591 0001 CONNECTOR BNC WINKEL 33632 J01000A0031 MIL W 22759 16 20 WIRE AWG20 COAX WIRE RG 393 RG 393 00775 1 1 1 2 X X 1 1 1 2 X X ANTENNA COMANT CI 105 1 Stueck 30336 010 10160 00 1 2 4 5 5 6 6 2 mtr WIRE AWG24 MIL W 22759 16 24 FE4011 X X 3 Stueck 1 CONNECTOR SUBD 62P KIT 1 1 in Pos 1 mtr MI...

Page 538: ...OT MIC KEY IN 20 COPILOT MIC AUDIO IN LO 33 34 PILOT MIC AUDIO IN HI PILOT MIC KEY IN PILOT MIC AUDIO IN LO 4 31 34 bl ws ws bl ws bl ws bl ws bl 1 35 PILOT HEADSET AUDIO OUT LO COPILOT HEADSET AUDIO OUT L COPILOT HEADSET AUDIO OUT LO 2 blk ws bl PHONE COPILOT PHONE PILOT ws bl ws bl MIC COPILOT ws bl MIC PILOT ws bl PTT PILOT PTT COPILOT P4 J4 1 2 3 4 ws bl ws bl ws bl ws bl ws bl ws bl 9 8 7 7 E...

Page 539: ... auf Blatt von Schwarze Heide 21 46569 Hünxe Germany Gepr Flugzeugbaureihe ist der Bauakte bzw 2 3 CIRCUIT BREAKER 5A 7277 2 5 010 11756 01 POWER DATA CABLE 1 1 GPS ANTENNA 5A GPS 20 red yel blu 14 VDC POWER RX1 Data In org 20 GPSMAP 795 PANEL DOCK GA 25 MCX 1 3 2 AVIONIC BUS POWER GND DATA GND TX1 Data Out 4 mtr 00775 MIL W 22759 16 20 WIRE AWG 20 X 4 GPS ANTENNA GARMIN AERA 9 40 VDC POWER AERA 7...

Page 540: ...ächenschutz Projektion Freimaßtoleranz Oberfläche Schutzvermerk nach DIN 34 beachten EDV Kennung auf Blatt von Schwarze Heide 21 46569 Hünxe Germany Gepr Flugzeugbaureihe ist der Bauakte bzw 2 3 4 12VTO 5VADAPTER 68302111 PHONE CABLE 11 07783 856741 62 in POS 1 APPLE CABLE LIGHTNING 1 1 1 PANELDOCK POWER DATEN LANE 1 PD 24 1 2 IDENT CONTROL 1 DATEN LANE 1 P1 5 1 1 2 3 4 5 6 7 8 GND DATEN LANE 0 ID...

Page 541: ...ION 01 ELT KANNAD 406 AF COMPACT OPTION 02 ELT KANNAD 406 AF INTEGRA REMOTE SWITCH 02 04 03 Benennung Nr 01 Teilekennzeichen ZF Werkstoff Abmessungen Menge Gewicht Einheit MaWi Nr 1 1 3 5 6 S1820513 18 S1840501 01 ELT KANNAD 406 AF COMPACT REMOTE CONTROL Kit RC200 1 1 ANTENNA CABLE RG 400 2 1 1 WIRING 3 x AWG 24 S MIL C 27500 24TG3 7 REMOTE CONNECTOR D SUB 9P D SUB 9 Pin X mtr 8 ELT CONNECTOR Din ...

Page 542: ...ung auf Blatt von Schwarze Heide 21 46569 Hünxe Germany Gepr Flugzeugbaureihe ist der Bauakte bzw 2 3 MATING CONNECTOR KIT 9017960 6430102 1 DUAL USB CHARGER TA102 1 1 DUAL USB CHARGER 1 2 USB 2A MAIN BUS Fa MID CONTINENT 3 TA 102 in Pos 2 7277 2 2 CIRCUIT BREAKER 2A 31508 Fa MID CONTINENT A B P1 4 4 mtr 00775 2 MIL W 22759 16 20 KABEL AWG 20 X 20 20 1 2 3 4 J2 USB 2 0 1 2 3 4 J3 USB 2 0 DC IN 10 ...

Page 543: ... C GND 22 24 22 G5 1 2 5 3 MAIN BUS D SUB 9S P51 5 7 6 4 9 POWER 1 POWER GROUND COM NAV GPS SYSTEM GNS 430W EA 9D102 54 Option COM NAV GPS GTN 650 750 24 bl ws RS 232 IN 3 RS 232 OUT 3 42 41 P4001 2 RS 232 TX 1 RS 232 RX 1 SIGNAL GROUND EA 9_102 63 Option COM NAV GPS GNS 430W bl ws or 49 RS 232 5 GND RS 232 5 IN RS 232 5 OUT 29 8 P1005 1 GARMIN COM NAV GPS GTN 635 650 750 24 1 optional EFI require...

Page 544: ...CHAPTER 96 PAGE 1 MAINTENANCEMANUAL EXTRA300LT PAGEDATE 21 March2014 Chapter 96 Smoke ...

Page 545: ...1 March2014 Table of Contents Chapter Title 96 00 00 GENERAL 3 Figure 1 Sheet 1 Smoke System up to SN LT010 4 Figure 1 Sheet 2 Smoke System from SN LT011 5 96 10 00 STORAGE 6 96 10 01 Smoke Oil MainTank 6 96 10 02 Smoke OilAcro Tank 7 96 20 00 DISTRIBUTION 8 ...

Page 546: ...in the middle of the aircraft refer to Figure 1 Sheet 2 The system consists of refer to Figure 1 Main smoke oil tank 1 Smoke oil acro tank 7 Ventilation lines 9 Overpressure check valve in smoke oil supply line to the nozzle 3 Refill Injection pump 2 Tworelais changeovercontacttype forpumpcontrol 15 Smoke switch ON OFF type on the throttle lever 13 SMOKE REFILLswitch in the instrument panel 11 SMO...

Page 547: ...CHAPTER 96 PAGE 4 MAINTENANCEMANUAL EXTRA300LT PAGEDATE 21 March2014 Figure 1 Sheet 1 Smoke System up to SN LT010 1 2 3 4 5 6 7 9 8 10 12 13 14 15 11 ...

Page 548: ...CHAPTER 96 PAGE 5 MAINTENANCEMANUAL EXTRA300LT PAGEDATE 21 March2014 Figure 1 Sheet 2 Smoke System from SN LT011 1 2 3 4 5 6 7 9 8 10 12 13 14 15 11 ...

Page 549: ...heON position Filledsmokeoil tanks are detected by a float switch 10 placed in the main tank which shuts the pump off 96 10 01 Smoke Oil Main Tank Removal Installation 1 Remove canopy main fuselage cover instrument cover as per Chapter 51 2 Drain the smoke system 3 Disconnect the electrical facilities from the smoke oil main tank 4 Disconnect the smoke oil line from the smoke oil main tank 5 Disco...

Page 550: ...Drain the smoke system 3 Loosen the center fuel tank and move to the RH side 4 Remove the battery as per Chapter 24 5 Disconnect the smoke oil lines from the smoke oil acro tank CAU T I O N Prevent the drain tube of the GRP tank shell from breaking when handling the smoke oil acro tank 6 Remove the metal attachment belts with the rubber stripes 7 Remove the smoke tank through the cockpit 8 Install...

Page 551: ...e oil tanks through an overpressure check valve 3 and the injector nozzle 8 into the hot exhaust gas to generate smoke The pump is controlled by the SMOKE switches 11 12 and the relais 15 The smoke system is electrically protected by the SMOKE SYSTEM circuit breaker 14 ForsmokesystemactivationtheSMOKEARMswitch 12 hastobeswitchedtotheON position ThenthesmokeON OFF toggle switch 13 can be used to co...

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