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Extra 300LX, Maintenance Manual

The Extra 300LX Maintenance Manual is essential for proper care of your aircraft. Ensure optimal performance by downloading the manual for free on manualshive.com. Retain your manual for future reference and keep your Extra 300LX in top condition. Get your copy now!

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1

1

2

2

3

3

4

4

D

D

C

C

B

B

A

A

EA 300/LT

PANELDOCK IPAD MINI

EA-9D102.68

05.10.14

HW

1

A4

1

EA3D0974

02

03

Benennung

Nr

01

Teilekennzeichen

ZF Werkstoff

Abmessungen

Menge

Gewicht

Einheit

MaWi-Nr.

1

PD 24

PANELDOCK

1

Die Gültigkeit szuordnung

von Version zu

dem jeweiligen Fertigungsauftrag
zu entnehmen.

Zuordnung links / rechts wird mit

*/* in allen Feldern angegeben.

04
03
02
01

Ver. Bezeic hnung

Nr.: Änderung/Mod. Nr.: Datum

Name

Letzte Bearbeitung:

Datum

Name

Bearb.:

Gepr.:

Maßstab
SI.-Klasse
Oberflächenschutz

Projektion
Freimaßtol eranz
Oberfläche

Schutzvermerk nach DIN 34 bea chten.

EDV-Kennun g:

auf

Blatt    von

Schwarze Heide 21

46569 Hünxe, Germany

Gepr.:

Flugzeugbaureihe

ist der Bauakte bzw.

2

3

4 12V TO 5V ADAPTER  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-

IDENT (CONTROL 0)

DATEN: LANE 0+

5

PHONEBUCHSE

J2

PHONE OUT LEFT
PHONE OUT RIGHT
PHONE GND

3

(Installed near mic/phone connectors)

MUSIC JACK STEREO

J2

1
2

3

4

USB 2.0

P3

P2

10A

12V

MAIN-BUS

Fa. Aircraft Spruce

4

P1

P3

Fa. CONRAD

12V/5V

see  12VDC OUTLET

EA-9D102.56

734136

734136

STEREO JACK

30362

Summary of Contents for 300LX

Page 1: ...EXTRA FLUGZEUGPRODUKTIONS UND VERTRIEBS GMBH MAINTENANCE MANUAL EXTRA 300LX Doc No EA 0E702 Schwarze Heide 21 D 46569 H nxe Germany Tel 49 28 58 91 37 0 Fax 49 28 58 91 37 30...

Page 2: ...nd Edition Revision 3 14 August 2015 Dateandsignofapproval EASAMAJORCHANGEAPPROVAL N 10034512 8 April2011 Approved under the authority of DOA N EASA 21J 073 20 May2011 EASAMAJORCHANGEAPPROVAL N 100466...

Page 3: ...1 March 2011 2 13 September2013 3 1 March 2011 4 1 March 2011 5 1 March 2011 6 1 March 2011 7 1 March 2011 8 14 August 2015 9 1 March 2011 10 13 September2013 11 14 August 2015 12 14 August 2015 13 14...

Page 4: ...21 1 March 2011 22 1 March 2011 23 1 March 2011 24 14 August 2015 25 1 March 2011 26 1 March 2011 27 1 March 2011 28 14 August 2015 29 14 August 2015 30 14 August 2015 31 1 1 March 2011 2 1 March 201...

Page 5: ...73 1 1 March 2011 2 14 August 2015 3 13 September2013 4 13 September2013 5 13 September2013 6 13 September2013 7 13 September2013 8 14 August 2015 9 14 August 2015 10 14 August 2015 11 14 August 2015...

Page 6: ...3 10 December2010 EA 9D102 54 27 April2011 EA 9D102 55 30 April2010 EA 9D102 56 27 April2010 EA 9D102 58A 29 July2013 EA 93102 59 9 May 2011 EA 9E102 60 19 May2011 EA 9E102 62A 23 June 2014 EA 9E102 6...

Page 7: ...PAGE F PAGE DATE 14 August 2015 MAINTENANCEMANUALEXTRA330LX List of Service Bulletins Service Letters S B S L N Issue Date Subject Serial N affected German AD LTA...

Page 8: ...IRCRAFT 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 Storag...

Page 9: ...URES 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...

Page 10: ...CHAPTER 1 PAGE 1 PAGE DATE 1 March 2011 MAINTENANCEMANUALEXTRA330LX Chapter 1 Introduction...

Page 11: ...CHAPTER 1 PAGE 2 PAGE DATE 14 August 2015 MAINTENANCEMANUALEXTRA330LX 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...

Page 13: ...and Instructions INDEX Service Letters Bulletins and Instructions Manufacturer LYCOMINGENGINES 652 Oliver Street Williamsport PA17 701 USA Propeller MTV 9 B C C 198 25 3 blade MTV 14 B C C190 130 4 bl...

Page 14: ...to Start Booster SlickSTART SS1001 Operation Maintenance and Troubleshooting Manual L 1492 Service Bulletins Manufacturer UNISONINDUSTRIES 530BlackhawkPartAvenue Rockford IL61104 USA Cleveland Wheels...

Page 15: ...spenAvionicsInc 5001 Indian School Rd NE Albuquerque NM87110 Electronics International MVP 50P Installation Instructions II 0425051 Rev I Operating Instructions OI 1002051 Rev D Manufacturer Electroni...

Page 16: ...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 regist...

Page 17: ...be carried out by qualified and authorized personnel only The execution has to be in accordance with the respective national safety requirements Before beginning any work this maintenance manual has t...

Page 18: ...PAGE DATE 1 March 2011 CHAPTER 2 PAGE 1 MAINTENANCEMANUALEXTRA330LX Chapter 2 How to Use the Service Manual...

Page 19: ...re 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...

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 chapte...

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...

Page 22: ...tions e g 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 Therightc...

Page 23: ...tuation 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 Additionalinformationgive...

Page 24: ...xtraAircraft 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 con tents may be made without the EXTRA...

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...

Page 26: ...CHAPTER 3 PAGE 1 PAGE DATE 1 March 2011 MAINTENANCEMANUALEXTRA330LX Chapter 3 General Description...

Page 27: ...f Contents Chapter Figure Title 03 00 00 GENERAL 3 Figure 1 EXTRA 330LX 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...

Page 28: ...ystems A more detailed description of the systems you find in the respectivechapters see CONTENTS The EXTRA 330LX refer to figure 1 is designed as a light weight single engine twoseat low wingmonoplan...

Page 29: ...le piece canopy side hinged Wing fibre composite design Stabilizers fibre composite design Landinggear 2 main wheels 1 tail wheel fibre composite strut design Seats Rear Seat Seat angle and seat back...

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 specialanti vibrationcounter weights retardbreake...

Page 31: ...ewall cockpit side Fuelsupply mechanicalenginedrivenpump additional electrically operated boostpump 03 10 06 Electrical system Powersupply engine driven 12Valternator integrated DC converter alternato...

Page 32: ...CHAPTER 3 PAGE 7 PAGE DATE 1 March 2011 MAINTENANCEMANUALEXTRA330LX 03 10 07 Instruments Standard minimum equipmentinstalled X...

Page 33: ...CHAPTER 4 PAGE 1 PAGE DATE 1 March 2011 MAINTENANCEMANUALEXTRA330LX Chapter 4 Airworthiness Limitations...

Page 34: ...andrevisedpages 1st Edition 1 March 2011 1st Edition 1st Revision 17 March 2014 Dateandsignofapproval EASAMAJORCHANGEAPPROVAL N 10034512 8 April2011 The technical content of this document is approved...

Page 35: ...NCEMANUALEXTRA330LX Table of Contents Chapter Title 04 00 00 GENERAL 4 04 00 01 Temperature Limit 4 04 00 02 OperatingTime 5 04 10 00 LIFELIMITEDCOMPONENTS 6 04 10 01 General 6 04 10 02 Replacement Ti...

Page 36: ...ible statement pertaining to non US registered air planes The Airworthiness Limitations section is approved by the regulatory authority and specifies maintenance required underSecs 43 16and91 403ofthe...

Page 37: ...10 00 are subject to a permissible operating time concern ing all other components recommended replacement times are given in Chapter 05 10 03 The reliability of the composite primary parts has been...

Page 38: ...ion for that component 04 10 02 Replacement Time Itemsshownheremustbereplacedduringtheregularmain tenance periods Item Replace after flight hours in service Wing 6000 h Aileron 6000 h Vertical Stabili...

Page 39: ...CHAPTER 5 PAGE 1 PAGEDATE 17 March2014 MAINTENANCEMANUALEXTRA330LX Chapter 5 Time Limits Maintenance Checks...

Page 40: ...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 Figu...

Page 41: ...an 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 followi...

Page 42: ...ed 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 Itemsshownheremustbeov...

Page 43: ...000 500 3 years or 2200 hours or on condition 5 years Wheels Cleveland Parker First aid pack on condition as stated on the pack Tires on condition Brake hoses PTFE type Wingtip position strobe light o...

Page 44: ...de Servicing Instruction capacity check Static Pressure System Every 24 calendar months in accordance with 14 CFR Ch 1 Part 43 App E ATC Transponder Aspen EFD1000 500 12 months EI MVP 50P 12 months or...

Page 45: ...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 becau...

Page 46: ...CHAPTER 5 PAGE 8 PAGE DATE 1 March 2011 MAINTENANCEMANUALEXTRA330LX Figure 1 Drain and Vent Holes SCHEDULEDMAINTENANCECHECKS...

Page 47: ...CHAPTER 5 PAGE 9 PAGE DATE 1 March 2011 MAINTENANCEMANUALEXTRA330LX Figure 2 Lubrication Chart 25 hours SCHEDULEDMAINTENANCECHECKS PAGEDATE 13 September2013...

Page 48: ...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 ac...

Page 49: ...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...

Page 50: ...ff between 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 w...

Page 51: ...ionManualE 124andServiceBulletins 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 Checkbladeangl...

Page 52: ...thefireprotectionpaint WIEDOFLUGAT N 56582 T508 with clear coat 4232 0303 or HENSOTHERM410KS withclearcoatGlasurit923 335 refer Chapter 51 30 01 O1 O2 O 6 Drain oil sump in accordance with chapter 12...

Page 53: ...gsandviceversa O O 17 Inspect spark plug cable leads and ceramics for corrosion anddeposits O O 18 Perform a hot engine differential compression check in accordancewithFAAAC43 13 1A O 19 Inspect cylin...

Page 54: ...t flexible fuel lines fuel injection lines and fittings for leaks security chafing dents and cracks replace or overhaul as required or at engine overhaul O O 32 Check fuel system for leaks O3 O O 33 R...

Page 55: ...ures for heat damage or burning O 43 Inspect engine crankcase for cracks leaks and security of seam bolts O O 44 Check engine mounted accessories such as pumps tem perature and pressure sensing units...

Page 56: ...5 Inspect fuselage for foreign objects O 6 Inspect steel tube construction for general condition cor rosion and cracks above all in areas of load stress e g wing stabilizer engineandseatattachments O...

Page 57: ...d wear check for ease of operation If the harness does not pass the check it has to be reworked or replaced Contact the harness manufacturer in case of doubt O 19 Check proper attachment of shoulder h...

Page 58: ...r condition cracks and security O O 6 Visual inspect bonding braid across the hinges for general condition O O 7 Check free play in control system torque tube control surfaces control sticks rod end b...

Page 59: ...ob struction O 15 Inspect elevator balance weights for looseness clearance condition and interference with the composite structure O 16 Visually inspect metal push pull control rods for corrosion loos...

Page 60: ...n 2 5 0 5 land ing gear not loaded as per chapter 32 Fairings O O 7 Disassemblefairings O O 8 Check fairings for dents and cracks O O 9 Check fairing ventilation hole for obstruction Wheels 10 Refer t...

Page 61: ...mage Check if disc thick ness is more than 0 325in 8 255mm Coning of disc in excess of 0 015 in 0 381 mm is cause for replacement O 15 Removewheelsandwheelbearings Inspectwheelbearing grease for conta...

Page 62: ...licone base lubricant O O 26 Visually inspect the brakes for corrosion cracks or other visible damage Inspect inlet fitting bosses and anchor bolt lugs for cracks O O 27 Check back plate attachment bo...

Page 63: ...Check the wheel fork for free rotation and steering func tion damage dents cracks and corrosion O O 39 Inspect axle bolt and nut for fretting wear damage and stretch O O 40 Lubricate tail wheel steeri...

Page 64: ...ck O O 5 Check wing tip position strobe lights for security and operation If any one LED fails the unit must be repaired or replaced Inspect the lens Replace if there is excessive scratching discolora...

Page 65: ...O O 2 Perform checks and maintenance for the ELT Follow the applicable instructions prepared by the respective ELT manufacturer Refer to chapter 1 O3 O O 3 Reinstall access panels as per chapter 51 O...

Page 66: ...g edge O 6 Detailed visual inspection on the surface for erosion scratches stonenicksandimpactdamages O 7 Detailed visual inspection on the top to bottom shell bonding for dents cracksanddelaminations...

Page 67: ...ct 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 fo...

Page 68: ...to 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 by coin tapping O...

Page 69: ...he 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 in...

Page 70: ...e skin laminate by coin tapping O 2 Checkbondingskin sparfordelaminationsbycointapping O 3 Check trailing edge bonding and trim tab cutout for cracks and delaminationbycointapping O 4 Detailed visual...

Page 71: ...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 torqu...

Page 72: ...deformations 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 w...

Page 73: ...r engine 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 hose...

Page 74: ...pedal adjustment for cracks deformations wear and corrosion Check proper function O 8 Visual inspection of rudder pedal mounting to the attachment fit tings Check bolts for security O 9 Inspect instr...

Page 75: ...d 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 r...

Page 76: ...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 f...

Page 77: ...form 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 firew...

Page 78: ...ctrical 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 OverhaulmagnetosaccordingtoM...

Page 79: ...CHAPTER 6 PAGE 1 PAGE DATE 1 March 2011 MAINTENANCEMANUALEXTRA330LX Chapter 6 Dimensions and Areas...

Page 80: ...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 0...

Page 81: ...Reference Planes Plane of upper longerons horizontal plane Plane of rudder Vertical symmetry plane Fire wall plane Vertical plane The following figure 1 shows the aircraft reference planes Figure 1 A...

Page 82: ...t Wheel base 5 12 m 16 80 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 2...

Page 83: ...tmann FX 71 L 150 30 06 10 04 Elevator Area 0 768 m 8 27 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 55 m 1...

Page 84: ...CHAPTER 6 PAGE 6 PAGE DATE 1 March 2011 MAINTENANCEMANUALEXTRA330LX Figure 2 Three View EXTRA 330LX 7 20 m 23 06 ft 1 80 m 5 91 ft 2 62 m 8 60 ft 8 0 m 26 25 ft 5 04 m 16 54 ft 5 12 m 16 80 ft...

Page 85: ...CHAPTER 7 PAGE 1 PAGE DATE 1 March 2011 MAINTENANCEMANUALEXTRA330LX Chapter 7 Lifting and Shoring...

Page 86: ...ALEXTRA330LX 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...

Page 87: ...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...

Page 88: ...he tail as per chap ter 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 Shor...

Page 89: ...wide 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 elev...

Page 90: ...CHAPTER 8 PAGE 1 PAGE DATE 1 March 2011 MAINTENANCEMANUALEXTRA330LX Chapter 8 Leveling and Weighing...

Page 91: ...PTER 8 PAGE 2 PAGE DATE 1 March 2011 MAINTENANCEMANUALEXTRA330LX Table of Contents Chapter Figure Title 08 00 00 GENERAL 3 08 10 00 WEIGHINGAND CALCULATIONOFCOFG 4 08 20 00 LEVELING 7 Figure 1 Levelin...

Page 92: ...hingandlevelingtheEXTRA330LXand for determining the Center of Gravity WeightheaircraftanddeterminetheCenterofGravityeach 5 years after installation of additional equipment or after repairs I M PO R TA...

Page 93: ...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 wh...

Page 94: ...LEXTRA330LX 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 w...

Page 95: ...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 Em...

Page 96: ...han necessary for level ing 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 w...

Page 97: ...CHAPTER 9 PAGE 1 PAGE DATE 1 March 2011 MAINTENANCEMANUALEXTRA330LX Chapter 9 Towing and Taxiing...

Page 98: ...CHAPTER 9 PAGE 2 PAGE DATE 1 March 2011 MAINTENANCEMANUALEXTRA330LX Table of Contents Chapter Figure Title 09 00 00 GENERAL 3 09 10 00 TOWING 3 09 20 00 TAXIING 3...

Page 99: ...orpullatthe inboard portion of the propeller blades 09 20 00 TAXIING Taxiing the aircraft shall be performed by qualified person nel only All taxiing should be done at slow speed and the controls shou...

Page 100: ...arch 2011 MAINTENANCEMANUALEXTRA330LX 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...

Page 101: ...CHAPTER 10 PAGE 1 PAGE DATE 1 March 2011 MAINTENANCEMANUALEXTRA330LX Chapter 10 Parking Mooring Storage and Return to Service...

Page 102: ...CHAPTER 10 PAGE 2 PAGE DATE 1 March 2011 MAINTENANCEMANUALEXTRA330LX 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 103: ...ER 10 PAGE 3 PAGE DATE 1 March 2011 MAINTENANCEMANUALEXTRA330LX 10 00 00 GENERAL Thischapterprovidestheproceduresrecommendedtopark or to moor the aircraft so that the likelihood of ground damageismini...

Page 104: ...ingprecautionarymeasuresarerecom mended for keeping the aircraft serviceable and ready to fly 1 Refer to chapter 10 20 00 Mooring for mooring i n structions DAN G E R Do not rotate the propeller with...

Page 105: ...When chocking the wheels ensure that the chocks used are not too large to come in contact with the wheel fair ings The use of chocks that are too large may damage the fairings 3 Drive stakes into the...

Page 106: ...2011 MAINTENANCEMANUALEXTRA330LX 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 0...

Page 107: ...CHAPTER 12 PAGE 1 PAGE DATE 1 March 2011 MAINTENANCEMANUALEXTRA330LX Chapter 12 Servicing...

Page 108: ...ing 6 12 10 03 Fuel Drains 6 12 10 04 Replenishment of Engine Oil 6 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...

Page 109: ...330LX The specified intervals refer to chapter 5 are considered ad equate to meet average requirements under normal operat ingconditions Itisadvisable however toshortenserviceandmaintenance intervals...

Page 110: ...GE R Never refuel the aircraft with the engine running Always ensure that the aircraft is grounded before re fueling Use the exhaust endpipe Ensure that no one is smoking within 100 feet of the aircr...

Page 111: ...H 60 L 15 9 US Gallons WingtankRH 60L 15 9 US Gallons Centertank 60 L 15 9 US Gallons Acrotank 9 L 2 3 US Gallons Totalfuelcapacity 189 L 49 9 US Gallons Usable fuel capacity 187 L 49 4 US Gallons Usa...

Page 112: ...ed to the fuel gascola tor is located in the lowest point at the right side of the firewall DAN G E R Do not drain the fuel system when the engine or the exhaust is hot or while the wind is strong A q...

Page 113: ...7 If replenishment is required see Replenishment of Engine Oil below 8 Return oil filler cap with dipstick into oil filler tube and tighten oil filler cap finger tight N O T I C E When tightening the...

Page 114: ...ution Iftheengineisinanextremelydirty condition theswitchtoadditiveoilshouldbedeferreduntil afterenginehasbeenoverhauled Whenchangingfromstraightmineraloiltoadditiveoiltake the following precautionary...

Page 115: ...W50 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...

Page 116: ...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 Remo...

Page 117: ...o ensure that the 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 oc...

Page 118: ...astic 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 certa...

Page 119: ...the sys tem with min 0 33 ltr 0 1 U S Gallons for complete change 11 Fill the fluid reservoir leaving 5 mm expansion space 12 Reinstall fluid reservoir filler plug 13 Close bleeder fitting 14 Disconne...

Page 120: ...sincedepositsofthiskindaremoredifficulttoremovewhen dry All lubricated components are to be covered before cleaning Roughlytwiceayear thecompletesurfaceshouldbetreated with a non silicone car polish...

Page 121: ...he canopy These materials will damage the canopy and may cause se vere crazing 12 20 03 Engine Cleaning Accumulationofdirtandoilwithintheenginecompartment creates a fire hazard and hampers inspection...

Page 122: ...AGE 16 PAGE DATE 1 March 2011 MAINTENANCEMANUALEXTRA330LX 4 It is very important not to start the engine before the clean ing agent has been completely removed or has evaporated SCHEDULEDSERVICING Eng...

Page 123: ...ze 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 indoors Remove as...

Page 124: ...CHAPTER 20 PAGE 1 PAGE DATE 1 March 2011 MAINTENANCEMANUALEXTRA330LX Chapter 20 Standard Practices Airframe...

Page 125: ...0 03 TorqueValues 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...

Page 126: ...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 330LX with rele...

Page 127: ...nd 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 ac...

Page 128: ...the 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 a...

Page 129: ...andardhexheadbolt 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 1...

Page 130: ...saccordingtoMS 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...

Page 131: ...M12 12 9 Stop Nut DIN 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 H...

Page 132: ...ueduetoshaft 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 da...

Page 133: ...nsideredinclude excessive flexing twist kinking tensile or side loads bend radius andvibration Anyhosethathasbeenkinkedorbentto aradiussmallerthantheminimumbendradius andanyhose that has been cut or i...

Page 134: ...embliesthatdonotincorporateassembly fittings with spanner flats to counteract while the nut is turnedtotheconnectionfitting e g Parker Statoflex PTFE hosetype101 Twistingofthehosecanbedeterminedfrom t...

Page 135: ...Plug 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 a...

Page 136: ...Engine Throttle Mixture and RPM Trim Heating optional Considerthefollowinginformationwhenworkingonengine control cables Refer to Figure 3 Hard and abrupt power control inputs may impose high dynamicp...

Page 137: ...able with the power on or the engine running Serious injury or death could re sult N O T I C E S Protect the cable from contaminants such as fuel oil water dirt and chemicals which may damage the con...

Page 138: ...the 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...

Page 139: ...red 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...

Page 140: ...CHAPTER 20 PAGE 17 PAGE DATE 14 August 2015 MAINTENANCEMANUALEXTRA330LX Figure 3 Control Cables...

Page 141: ...contacted for advice Unlessotherwisespecifiedallboltsandconnectionsshould be torqued as listed in chapter 20 10 03 At some locations special torque values are considered necessary Refer to chapter 20...

Page 142: ...with elevator as per chapter 55 The procedure described there is also applicable to the in stallation of the complete horizontal tail Remember to con nect the ground bonding lead of the elevator too 9...

Page 143: ...opy engine 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 Inspec...

Page 144: ...CHAPTER 21 PAGE 1 PAGE DATE 1 March 2011 MAINTENANCEMANUALEXTRA330LX Chapter 21 Air Conditioning...

Page 145: ...330LX 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 0...

Page 146: ...From there fresh 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 a...

Page 147: ...CHAPTER 21 PAGE 4 PAGE DATE 1 March 2011 MAINTENANCEMANUALEXTRA330LX Figure 1 Heating System...

Page 148: ...ngine 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 D...

Page 149: ...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 bo...

Page 150: ...m 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 at tachment tube 6 2 Thread the...

Page 151: ...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 ac tuator 14 2 Place inlet box actuator to the closed position 3 Adj...

Page 152: ...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 cab...

Page 153: ...ble attachment 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 d...

Page 154: ...CHAPTER 21 PAGE 11 PAGE DATE 1 March 2011 MAINTENANCEMANUALEXTRA330LX Figure 3 Heating Bowden Cables...

Page 155: ...CHAPTER 23 PAGE 1 PAGE DATE 1 March 2011 MAINTENANCEMANUALEXTRA330LX Chapter 23 Communication...

Page 156: ...CHAPTER 23 PAGE 2 PAGE DATE 1 March 2011 MAINTENANCEMANUALEXTRA330LX Table of Contents Chapter Figure Title 23 10 00 SPEECH COMMUNICATION 3 23 10 01 VHFWhipAntenna 4...

Page 157: ...rmation Independentfromtheequipmentinstalled theelectrichard ware such as switches circuit breakers sockets and wiring is the same The control sticks and power levers for pilot and copilot featurePTTs...

Page 158: ...g the steel tube frame and connects this whip antenna directly to the respective transceiver Removal Installation 1 Assure the BATTERYswitch is OFF 2 Remove the front seat as per chapter 25 3 Disconne...

Page 159: ...CHAPTER 24 PAGE 1 PAGE DATE 1 March 2011 MAINTENANCEMANUALEXTRA330LX Chapter 24 Electrical Power...

Page 160: ...24 30 10 Battery System 5 24 30 11 Battery 6 24 30 20 Alternator System 6 24 30 21 Alternator 7 Figure 3 sheet 1 Alternator and Accessories 8 Figure 3 sheet 2 Alternator and Accessories 9 24 30 22 Dr...

Page 161: ...and its operation This covers the battery system and the alternator system Figure 1 shows the electrical main board with its various electrical devices It is attached to the lower left fuselage struct...

Page 162: ...CHAPTER 24 PAGE 4 PAGE DATE 1 March 2011 MAINTENANCEMANUALEXTRA330LX Figure 2 Electrical System Schematic...

Page 163: ...when alternator power is not available engine not running The battery also powers the electrical system in case of alternator failure The battery system consists of the battery the battery relay see f...

Page 164: ...g 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 24 30 20 Altern...

Page 165: ...oltage of the alternator constant under varying output cur rent requirements With the alternator power available the battery will be charged from the bus bar The ammeter which is in series withthebatt...

Page 166: ...CHAPTER 24 PAGE 8 PAGE DATE 1 March 2011 MAINTENANCEMANUALEXTRA330LX Figure 3 sheet 1 Alternator and Accessories...

Page 167: ...y wire 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 cas...

Page 168: ...alternator 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 fr...

Page 169: ...t tension 6 Rotate the alternator clockwise around bolt connection 3 6 10 7 Detach belt from the alternator pulley 8 Remove starter ring gear according to applicable Lycoming installation manual see C...

Page 170: ...follow ing for the new drive belt is to compensate for the ini tial stretch that takes place as soon as it is operated These higher tension values should not be applied to drive belts that have been u...

Page 171: ...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 5b Plane Power Install new safety wires at bolts...

Page 172: ...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 fire...

Page 173: ...sconnect 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 Inst...

Page 174: ...e 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 D...

Page 175: ...CHAPTER 25 PAGE 1 PAGE DATE 1 March 2011 MAINTENANCEMANUALEXTRA330LX Chapter 25 Equipment and Furnishings...

Page 176: ...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...

Page 177: ...Installation 1 Remove instrument panel 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...

Page 178: ...est 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...

Page 179: ...t shoulder harness two right and two left seat belts and a crotch strap Figure 1 Strap Assembly I M PO R TAN T Keep belts from contact with chemicals solvents degreaser battery acid and excessive expo...

Page 180: ...3 barslide as shown in figure 3 I M PO R TAN T Tuck excess webbing through the 3 bar slide Failure to make this third pass through the 3 bar slide will cause the belt to slip under load I M PO R TAN T...

Page 181: ...EMANUALEXTRA330LX 25 10 04 Aircraft Document Bag TherearcockpitoftheEXTRA330LXisfurnishedwithan aircraftdocumentbag Thisaircraftdocumentbagismounted with three AN 526 C 1032 R8 bolts and DIN 9021 M5x2...

Page 182: ...CHAPTER 27 PAGE 1 PAGE DATE 1 March 2011 MAINTENANCEMANUALEXTRA330LX Chapter 27 Flight Controls...

Page 183: ...llation 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...

Page 184: ...thfulldualprimaryflightcontrolsincludingconventional control sticks and adjustable rudder pedals The control surfaces are operated by a direct mechanical linkage The control surface deflections are sh...

Page 185: ...the 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 fo...

Page 186: ...CHAPTER 27 PAGE 5 PAGE DATE 1 March 2011 MAINTENANCEMANUALEXTRA330LX Figure 4 Control Surface Deflections 35 27...

Page 187: ...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...

Page 188: ...r identification of the control rods 0 1 2 6 6 7 7 8 8 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 1 2 8 0 2 m m 5...

Page 189: ...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 bell crank...

Page 190: ...se 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 selflo...

Page 191: ...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 Co...

Page 192: ...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 bott...

Page 193: ...s each hinge arm is electrically bonded to thecorrespondingattachmentbracketattheaileronbybond ingbraids Therodendbearingsofthepush pullrodslocated in the wing are also interconnected by bonding braid...

Page 194: ...1 MAINTENANCEMANUALEXTRA330LX Figure 10 Aileron Control 1 2 3 4 5 6 5 6 8 7 6 5 5 5 Legend 1 Front control stick 2 Rear control stick 3 Aileron LH outlined only 4 Aileron actuator arm 5 Control rods 6...

Page 195: ...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 Rigging Before beginning any adjustme...

Page 196: ...the length of the control rods connect ing the aileron actuator arm to the outer wing bellcrank per chapter 27 00 01 6 Check if the left aileron travel is within the given tolerances up 30 down 30 to...

Page 197: ...rim 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...

Page 198: ...arm isgroundedto thecorrespondingattachmentbracketattherudderbybond ing leads A travel stop plate is located at the bottom hinge bracket Asecond safety stop is located at the rudder pedal bearing hav...

Page 199: ...7 March2014 MAINTENANCEMANUALEXTRA330LX Figure 14 Rudder Control 1 2 3 4 5 6 5 7 6 7 8 9 9 Legend 1 rudder pedals 3 bottom hinge bellcrank 5 sleeves 8 cable fastening 9 spring 2 rudder control cable 4...

Page 200: ...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 p...

Page 201: ...the front shrinking sleeves and behind the cable to cable connection 5 Remove the control cable parts by pulling out to the back Installation UseonlycontrolcablesmanufacturedbyEXTRAFlugzeug produktio...

Page 202: ...ead inside the fuselage 11 Adjust rear pedals 78 mm aft of the foremost position 12 Fix rear pedals in neutral position 80 relative to the foot rest using a template as shown in Figure 15 78 mm 2 3 0...

Page 203: ...heat gun 19 Slip the other 80 mm 771095 shrinking sleeve on the front end of the protective hose center on the protective hose end and heat up with a heat gun 20 Remove the rear pedal template 21 Moun...

Page 204: ...t 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...

Page 205: ...ator by bonding leads The travel stops 15 are located at the torque tube Mass balance weights 9 are mounted to the elevator tips extending into the horizontal stabilizer when the elevator is inneutral...

Page 206: ...que tube 3 push pull rod 5 trim lever 6 trim servo rod 7 trim servo 15 travel stops 1 front seat stick 4 rear seat stick 8 trim control bowden cable mechanism 9 mass balance weights 10 trim tab 11 ele...

Page 207: ...e 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 adjustm...

Page 208: ...bilizer tip trailing edge 4 If necessary adjust the length of the aft 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 conventi...

Page 209: ...If it 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 adju...

Page 210: ...CHAPTER 27 PAGE 29 PAGEDATE 17 March2014 MAINTENANCEMANUALEXTRA330LX Figure 19 Trim Tab Rigging...

Page 211: ...CHAPTER 28 PAGE 1 PAGEDATE 1 March 2011 MAINTENANCEMANUALEXTRA330LX Chapter 28 Fuel...

Page 212: ...lacement 14 Figure 6 Filler Neck and Sealing Lip Removal Installation 14 28 10 09 Ventilation Line 14 28 20 00 DISTRIBUTION 15 Figure 7 Distribution 16 28 20 01 Fuel Selector Valve 17 Figure 8 Fuel Se...

Page 213: ...CHAPTER 28 PAGE 3 PAGEDATE 1 March 2011 MAINTENANCEMANUALEXTRA330LX 28 40 05 Float Wire 29 Figure 14 Float Wire Adjustment 29 Figure 15 Float Wire Installation 30...

Page 214: ...h the aircraft at least 100 feet from hangars or other aircraft 2 No smoking should be allowed within 100 feet of the air craft 3 Suitable fire fighting equipment should be available Foam or soda type...

Page 215: ...CHAPTER 28 PAGE 5 PAGEDATE 1 March 2011 MAINTENANCEMANUALEXTRA330LX Figure 1 Fuel System...

Page 216: ...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...

Page 217: ...nk are electrically bonded The acro tankdeaerates a intothecentertankthatitselfdeaeratesby a ventilation tube b ending at the right side of the main landinggearspring The root section of each wing in...

Page 218: ...CHAPTER 28 PAGE 8 PAGEDATE 1 March 2011 MAINTENANCEMANUALEXTRA330LX Figure 2 Storage...

Page 219: ...oosen 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 fuse...

Page 220: ...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...

Page 221: ...door flange 1 5 Push the inspection door 2 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 sol...

Page 222: ...c and volatile Use only in well ventilated areas Avoid physical contact with solvent and do not inhale vapors Keep solvent contain ers covered when not in use 4 Clean sealing surfaces mechanically and...

Page 223: ...er Chapter 12 2 Remove wing tank inspection door per Chapter 28 11 04 3 Unscrew filler neck lock ring 4 Figure 6 with sealing lip 5 using a tool as shown in Figure 6 4 Remove filler neck 3 with filler...

Page 224: ...lacement 1 Carefully drill out the body bound rivets 7 Figure 6 2 Install the new sealing lip driving in new washers 6 and body bound rivets Figure 6 Filler Neck and Sealing Lip Removal Installation 2...

Page 225: ...and the auxiliary fuel pump at the firewall engine side A fuel selector valve of an Allen 6S122 type 1 is located at the right side of the front cockpit behind the main spar on a separate support Acon...

Page 226: ...INTENANCEMANUALEXTRA330LX Figure 7 Distribution Legend 1 Fuel selector valve 2 Control rod and handles 3 Gascolator 4 Drain 5 Electric driven aux pump 6 engine driven rotary pump 7 T fitting A M Fuel...

Page 227: ...not more than 15 psi hydraulic or pneumatic pres sure Integrity Test 1 Completely drain wing tanks 2 Fuel selector position WING TANKS 3 Completely fill center tank 4 Leave aircraft stationary for a...

Page 228: ...rol Rod Legend 1 Selector valve 2 Selector valve attachment bolts 3 Controlbracket 4 Attachment screw 5 Control rod attachment bolts 6 Front control rod 7 Front control rod connection bolt 8 Washers 9...

Page 229: ...the selector valve attachment bolts 2 and the attachment screw 4 28 20 02 Selector Valve Control Rod Removal Installation Refer to figure 8 1 Remove the rear control rod connection bolt 11 2 Pull the...

Page 230: ...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 Re...

Page 231: ...p Removal Installation 1 Drain the fuel system as per chapter 12 10 02 2 Disconnect the plug 1 figure 10 and the fuel lines from the boost pump 3 Loosen the screw clamps 2 4 Remove the boost pump 3 5...

Page 232: ...p Removal Installation 1 Drain the fuel system as per chapter 12 10 02 2 Disconnect the plug 1 figure 10 and the fuel lines from the boost pump 3 Remove theAllen screws 2 4 Remove the boost pump 3 5 I...

Page 233: ...formationconcerninghosesandfittingsyoufind in chapter 20 10 07 08 I M P O R TAN T If replacement of fuel lines passing the firewall is nec essary renew the sealing of the rubber grommet grooves and ga...

Page 234: ...l quantity trans ducer 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 th...

Page 235: ...CHAPTER 28 PAGE 25 PAGEDATE 1 March 2011 MAINTENANCEMANUALEXTRA330LX Figure 12 Indicating...

Page 236: ...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 u...

Page 237: ...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 th...

Page 238: ...nsducer Wing Tank Removal Installation refer to figure 13 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 th...

Page 239: ...e sealing ring and the grooves in side the tank 7 Check proper shape and 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 c...

Page 240: ...ANUALEXTRA330LX 3 Reinstall the float wire observing the dimensions shown in figure 15 pay attention to a proper alignment and tighten well the attachment bolt Figure 15 Float Wire Installation 4 Rein...

Page 241: ...CHAPTER 31 PAGE 1 PAGE DATE 1 March 2011 MAINTENANCEMANUALEXTRA330LX Chapter 31 Indication Recording System...

Page 242: ...ar Instrument Panel 4 Figure 1 Rear Instrument Panel 5 Figure 2 Rear Switches Circuit Breakers 5 31 10 02 Front Instrument Panel 7 Figure 3 Front Instrument Panel 7 Figure 4 Front Instrument Panel Rem...

Page 243: ...EXTRA 330LX is equipped with flight instruments in both cockpits Instruments and placards can feature mark ings in either metric or US Standard units refer to Pilot s Operating Handbook Section 2 Mark...

Page 244: ...enterpanel sheet When the MVP 50 is installed generally the center panel is enlarged refer to Chapter 77 40 00 As an option an additional sub panel can be installed Thepanelsandthecoveraremountedonthe...

Page 245: ...CHAPTER 31 PAGE 5 PAGE DATE 1 March 2011 MAINTENANCEMANUALEXTRA330LX Figure 1 Rear Instrument Panel Figure 2 Rear Switches Circuit Breakers...

Page 246: ...sible 16 PTT switch 17 Fuel quantity center tank 18 Fuel quantity wing tank 19 Circuit breaker 20 Switches Position Item Fig 2 1 Alternator warning light incl press to test feature 2 Battery switch re...

Page 247: ...nel by hand to prevent from falling down when removing the instrument panel at tachment screws 1 RemovetheAN526C 1032 R6instrumentpanelattachment screws 3 figure 4 2 Disconnect the Pitot resp static l...

Page 248: ...CHAPTER 31 PAGE 8 PAGE DATE 1 March 2011 MAINTENANCEMANUALEXTRA330LX Figure 4 Front Instrument Panel Removal Installation...

Page 249: ...at the top of the front seat back rest 1 figure 5 2 Remove the outer screws 2 of the rear instrument panel The two inner screws connect the panel to the steel frame 3 Remove the cockpit corner cover s...

Page 250: ...X are outlined 1 Switch off aircraft power 2 Remove main fuselage cover per chapter 53 3 Remove rear instrument panel cover if applicable per chap ter 31 10 03 4 Disconnect cable and or sense line fro...

Page 251: ...CHAPTER 32 PAGE 1 PAGE DATE 1 March 2011 MAINTENANCEMANUALEXTRA330LX Chapter 32 Landing Gear...

Page 252: ...in 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 Sp...

Page 253: ...eansofthe landing gear U spring This spring is of integral glass fibre designandincorporateswheelalignment springanddamp eningaction I M PO R TAN T New bolts are to be used when the wheel axles are re...

Page 254: ...g gear 4 7 Install in reverse sequence of removal using new stop nuts For correctly positioning the landing gear the centering pin which is located at the bottom of the fuselage is to put into the res...

Page 255: ...pter 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 n...

Page 256: ...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 Installa...

Page 257: ...CHAPTER 32 PAGE 7 PAGE DATE 1 March 2011 MAINTENANCEMANUALEXTRA330LX 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 258: ...per 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 bra...

Page 259: ...CHAPTER 32 PAGE 9 PAGE DATE 1 March 2011 MAINTENANCEMANUALEXTRA330LX Figure 4 Brake System...

Page 260: ...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 32 40 02 Wheel Fairing The wheel fairings are...

Page 261: ...ntation 0 90 First Reinforcement Layer 1 Layer CCC447 Measurements see sketch Orientation 0 90 Second Reinforcement Layer 1 Layer CCC447 Measurements see sketch Orientation 0 90 Second Reinforcement L...

Page 262: ...Disassembly Assembly Refer to figure 3 1 Shore the tail as per chapter 07 20 02 2 Remove the attachment bolt washers and stopnut 10 3 Remove the tailwheel 4 Disassemble the bearings 11 the wheel halv...

Page 263: ...CHAPTER 33 PAGE 1 PAGE DATE 1 March 2011 MAINTENANCEMANUALEXTRA330LX Chapter 33 Lights...

Page 264: ...ation Strobe Light System 5 33 40 11 Navigation Strobe Light 6 Figure 1 Navigation Strobe Lights Removal Installation 7 33 40 12 Strobe Light Power Supply 8 33 40 20 LED Navigation Strobe Light System...

Page 265: ...dicator 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 Thelowvoltagemonito...

Page 266: ...CHAPTER 33 PAGE 4 PAGE DATE 1 March 2011 MAINTENANCEMANUALEXTRA330LX 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 267: ...nterandacleartail position LED light on the aft section They are mounted at the wing tip fairing 6 The strobe light power supplies 8 aremountedonspecialattachmentplates 9 insidethewing The wiring is r...

Page 268: ...or glass the removal of the Phillips screws 1 is sufficient for access 2 Remove wing tip fairing attachment bolts 5 3 Remove wing tip fairing 6 4 Remove electrical wiring from cable retainer inside th...

Page 269: ...CHAPTER 33 PAGE 7 PAGE DATE 1 March 2011 MAINTENANCEMANUALEXTRA330LX Figure 1 Navigation Strobe Lights Removal Installation...

Page 270: ...ve the wing tip fairing with the lighting unit per Chap ter 57 30 01 2 Disconnect the electrical wiring of the power supply 3 Remove the power supply attachment bolts 7 and discon nect the ground bond...

Page 271: ...rear instrument panel Ground bonding leads are installed be tweenthefuselage thepitottubemount andthealuminium tube The switches and circuit breakers are located on the rear instrument panel see figur...

Page 272: ...INTENANCEMANUALEXTRA330LX 1 2 3 4 3 5 Legend 1 Lighting unit attachment bolt 2 LED NAV Strobe light 3 Wing tip fairing attachment bolts 4 Wing tip fairing 5 Electrical connector left wing Figure 2 LED...

Page 273: ...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 31 Lan...

Page 274: ...CHAPTER 33 PAGE 12 PAGE DATE 14 August 2015 MAINTENANCEMANUALEXTRA330LX Top View Side View 1 3 3 7 8 7 4 5 5 Firewall 9 10 2 2 5 4 6 4 Figure 3 Landing Light...

Page 275: ...CHAPTER 34 PAGE 1 PAGE DATE 1 March 2011 MAINTENANCEMANUALEXTRA330LX Chapter 34 Navigation...

Page 276: ...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 Mag...

Page 277: ...nal airspeed indicator and altimeter are installed Refer to the Equipment List of the Pilot s Operating Hand book for installed optional equipment ThecolormarkingsontheinstrumentsfollowUS FAR Part 23...

Page 278: ...is screwed through the L H outboard leadingedgeintoanattachmentblocklocatedattherearweb ofthemainspar Fromtherethepressuresaretransmittedby meansofavinyltubewhichisroutedthroughanaluminium tube inside...

Page 279: ...essary 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 The airspeed indicator shows...

Page 280: ...itot Static Tube Removal Installation Thepitot statictubeconsistsofaninneraluminiumtube an outer aluminium tube and a top cap which are screwed together 1 Unscrew the top cap 2 Unscrew the outer alumi...

Page 281: ...EXTRA330LX 4 Remove the attachment block and disconnect the ground bonding leads 5 Loosen clamps and disconnect the tubing 6 Remove the fittings if necessary 7 Install in reverse sequence of removal U...

Page 282: ...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...

Page 283: ...th It indicates pitch fore and aft tilt and bank side to side tilt TheincorporatedAttitudeandHeadingReferenceSystems AHRS actuates a display that has two dimensions of free dom simultaneouslydisplayin...

Page 284: ...instrument cover if transponder has to be installed from the rear Refer to chapter 31 10 03 2 Remove transponder following the Removal Installation Instructions of the respective manufacturer 3 Insta...

Page 285: ...onnect the hose 5 from the digitizer static port 4 Remove the safety wire of the knurled screw 6 5 Loosen the knurled screw and remove the digitizer 1 6 Install in reverse sequence of removal Use new...

Page 286: ...CHAPTER 51 PAGE 1 PAGE DATE 1 March 2011 MAINTENANCEMANUALEXTRA330LX Chapter 51 Standard Practices and Structures General...

Page 287: ...drels 18 Figure 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 Compo nents 22 51...

Page 288: ...all access panels before beginningworkorchecks Withtheexceptionoftheoilfilleraccessdoorallpanelsare screwed on The following list shows where detailed removal installa tion information for the respec...

Page 289: ...CHAPTER 51 PAGE 4 PAGE DATE 1 March 2011 MAINTENANCEMANUALEXTRA330LX 1 2 3 5 6 7 8 9 10 11 12 15 16 17 17 16 15 13 14 4 Figure 1 Access Panel Identification...

Page 290: ...r 3 Main fuselage cover 4 Instrument cover 5 Tail fairing 6 Tail cone access panel RH 7 Tail side skin RH LH 8 Cuff 9 Wheel fairing 10 Bottom half of the engine cowling 11 Air inlet screen 12 Spinner...

Page 291: ...EXTRA Flugzeugproduktions und Vertriebs GmbH According to the Luftfahrt Bundesamt Federal German AviationAuthority four damage classes are defined Damage Class 1 Largescaledestructionrequiringapartia...

Page 292: ...O 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 re...

Page 293: ...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 S...

Page 294: ...hVolan 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...

Page 295: ...Postfach 426 D 5100Aachen Germany Supplier Lange Ritter GmbH Dieselstra e 25 D 70839 Gerlingen Germany Type Vetrotex EC14 2400 P185 Carbon rovings Manufacturer TohoTenaxEuropeGmbH Kasinostr 19 21 D 4...

Page 296: ...r Sch tzGmbH Co KGaA Sch tzstr 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 Stra e 405 D 51109 K ln...

Page 297: ...larlack 929 91 93 94 GlasuritHSDecklackh rter 352 50 91 216 GlasuritEinstellzusatz 923 335 GlasuritKlarlack with Hensotherm 410KS 285 100 VOC GlasuritRapidf llerVOC wei 929 55 56 Glasurit HS F llerh r...

Page 298: ...repair of metal components Steel tubing Manufacturer MHP MannesmannHoeschPr zisrohrGmbH Postfach 1713 D 59061Hamm Germany Supplier HeggemannAutosportGmbH Zeppelinring 1 6 D 33142 B ren Germany Type WL...

Page 299: ...br ck Germany Type 801 72 VOC GlasuritGrundf llerEPVOC grau 965 60 Glasurit H rter EP 352 91 216 GlasuritEinstellzusatz 22 GlasuritHS 2K Decklack 929 91 93 94 GlasuritHSDecklackh rter 352 50 91 216 Gl...

Page 300: ...ermany Supplier Wessels M ller AG Pagenstecherstra e 121 D 49090Osnabr ck Germany Type 283 150 VOC GlasuritGrundf llerEPVOC 352 228 GlasuritZusatzl sung 352 50 91 GlasuritEinstellzusatz 22 GlasuritHS...

Page 301: ...ductsEuropeGmbH Redcarstr 44a 53842 Troisdorf Spich Type Scotch Weld Urethane 3549 B A Manufacturer degussa Evonic Supplier MecaplexAG Solothurnstr 138 CH 2540 Grenchen Type ACRIFIX190 KATALYSATOR20 S...

Page 302: ...oductsEuropeGmbH Redcarstr 44a 53842 Troisdorf Spich Type Polyurethan PU tape Scotch 8671 Corrosion Preventive Compound Manufacturer LEARCHEMICALRESEARCH P O Box 1040 Mississauga L4Y3W3Ontario Canada...

Page 303: ...is necessary after repairs or painting Weigh the control surfaces including the mass balances in disassembled condition The aileron weight includes the spade Copy page 21 enter the values W m r and c...

Page 304: ...rol surfaces and weigh by means of a conven tional spring balance kg g indication at the given weigh ing points figure 3 and enter the weight m in figure 4 5 Measure distance of hinge center line to w...

Page 305: ...CHAPTER 51 PAGE 20 PAGE DATE 1 March 2011 MAINTENANCEMANUALEXTRA330LX Figure 3 Determination of Control Surface Moments...

Page 306: ...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 5 5 5 6 6 5 7 8 7 5...

Page 307: ...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...

Page 308: ...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...

Page 309: ...he 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 length per fabric layer min 20 mm I M PO R...

Page 310: ...uumbagging 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 t...

Page 311: ...dge 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 Iftheinner...

Page 312: ...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...

Page 313: ...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 pe...

Page 314: ...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...

Page 315: ...undam agedpart 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 bo...

Page 316: ...f 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...

Page 317: ...nated fabric layer in accor dance to the layer sequence plan Ensure correct style and direction of fabric N O T E Lay out the required number and size of fabric pieces on a piece of colored plastic fo...

Page 318: ...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 high...

Page 319: ...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...

Page 320: ...ocedure necessary to remove existing 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 a...

Page 321: ...ts can be toxic and volatile Use only in well ventilated areas Avoid physical contact with solvent and do not inhale vapors Keep solvent contain ers covered when not in use N O T I C E Before strippin...

Page 322: ...hose which are subjected to fric tion bearing surfaces anchor bolt bores etc Proceed as follows 1 Parts to be repainted should be cleaned and stripped per in struction in degreasing and paint removal...

Page 323: ...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 i...

Page 324: ...the 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...

Page 325: ...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...

Page 326: ...fafrontandarearflangebushing Thefront andrearflangebushingwillbere bondedoneafteranother Thereisadefinedbondgapbetweentheflangebushingsand the hole in the main spar web Re bondingofmainattachmentflang...

Page 327: ...ng 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 debri...

Page 328: ...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...

Page 329: ...GE DATE 14 August 2015 MAINTENANCEMANUALEXTRA330LX 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 the applicable Ch...

Page 330: ...CHAPTER 53 PAGE 1 PAGE DATE 1 March 2011 MAINTENANCEMANUALEXTRA330LX Chapter 53 Fuselage...

Page 331: ...esive Remainders 7 53 00 03 Main Fuselage Cover 8 Figure 6 Sheet 1 Layer Sequence Main Fuselage Cover 9 Figure 6 Sheet 2 Layer Sequence Main Fuselage Cover 10 53 00 04 Bottom Fuselage Cover 11 Figure...

Page 332: ...35 referChapter51 30 01 Themainfuselagecoverconsistsofglassfibre carbonfibre andaramidlaminate refertofigure6 Thebottomfuselage cover is made of carbon fibre and aramid fibre laminate refer to figure...

Page 333: ...CHAPTER 53 PAGE 4 PAGE DATE 1 March 2011 MAINTENANCEMANUALEXTRA330LX Figure 1 Fuselage Steel Tube Design...

Page 334: ...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 Sanddownthebondin...

Page 335: ...ve 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 Fo...

Page 336: ...product to both canopy glass and canopy frame 15 Place canopy glass in canopy frame Observe correct posi tion using position markings 16 Apply pressure on canopy glass using tightener to hold it in pl...

Page 337: ...r 51 30 and refinish the area 53 00 03 Main Fuselage Cover Removal Installation 1 Remove the canopy per chapter 53 00 01 2 Disconnect the pitot hoses from the front instruments 3 Remove the instrument...

Page 338: ...CHAPTER 53 PAGE 9 PAGE DATE 1 March 2011 MAINTENANCEMANUALEXTRA330LX Figure 6 Sheet 1 Layer Sequence Main Fuselage Cover detail A detail B detail C detail D detail E detail F...

Page 339: ...ramid fabric CCC 502 0 90 0 90 A 0 90 detail A 5 Carbon fabric CCC 452 0 90 detail A 6 Aramid fabric CCC 502 0 90 on the whole plane except air hoods detail B 7 Aramid fabric CCC 502 0 90 detail C 8 G...

Page 340: ...s Installation I M PO R TAN T The cockpit area must be thoroughly sealed and thus separated from the engine compartment Gases or flu ids could get into the cockpit area Critical areas to be observed a...

Page 341: ...and outside with solvents at four positions pointed out by the arrows in figure 7 Immedi ately thereafter dry these areas with a new dry cloth 9 At the gascolator drain positionA seal the remaining g...

Page 342: ...CHAPTER 53 PAGE 13 PAGE DATE 1 March 2011 MAINTENANCEMANUALEXTRA330LX Figure 8 Sheet 1 Layer Sequence Bottom Fuselage Cover...

Page 343: ...CHAPTER 53 PAGE 14 PAGE DATE 1 March 2011 MAINTENANCEMANUALEXTRA330LX Figure 8 Sheet 2 Layer Sequence Bottom Fuselage Cover...

Page 344: ...ence Cuffs Carbon fabric CCC 452 whole plane Glass fabric Interglas 92140 60 mm wide tape along edges Glass fabric Interglas 92140 40 mm wide tape along edges 5 4 3 whole plane 30 mm wide tape along e...

Page 345: ...CHAPTER 53 PAGE 16 PAGE DATE 1 March 2011 MAINTENANCEMANUALEXTRA330LX Figure 11 Layer Sequence Top Half of the Engine Cowling...

Page 346: ...CHAPTER 53 PAGE 17 PAGE DATE 1 March 2011 MAINTENANCEMANUALEXTRA330LX Figure 12 Layer Sequence Bottom Half of the Engine Cowling...

Page 347: ...CHAPTER 55 PAGE 1 PAGE DATE 1 March 2011 MAINTENANCEMANUALEXTRA330LX Chapter 55 Stabilizers...

Page 348: ...BILIZER 4 Figure 1 Horizontal Stabilizer Removal Installation 5 Figure 2 Layer Sequence Horizontal Stabilizer 6 55 20 00 ELEVATOR 7 Figure 3 Layer Sequence Elevator 7 55 30 00 VERTICALSTABILIZER 8 Fig...

Page 349: ...tal and vertical tail are built of honeycomb sandwich with carbon fibre laminate Also bucklingispreventedbyplywoodribs OntheR Helevator half a trim tab is fitted by means of two hinges The layer seque...

Page 350: ...he attach brackets 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 addi tional washe...

Page 351: ...CHAPTER 55 PAGE 5 PAGE DATE 1 March 2011 MAINTENANCEMANUALEXTRA330LX Figure 1 Horizontal Stabilizer Removal Installation...

Page 352: ...C452 45 3 Reinforcements nose and aux spar 1 x CCC452 45 4 2 x CCC452 45 Reinforcements root 5 Honeycomb ECA R4 8 29 6 1 x CCC490 45 7 1 x CCC452 45 Reinforcement spar and area of mass balance Layer s...

Page 353: ...H upper and lower shell RH upper and lower shell LH upper and lower shell RH upper and lower shell RH upper and lower shell RH upper shell RH lower shell 1 Vorgelat Scheufler T35 2 1 x CCC452 whole pl...

Page 354: ...3 with the washers and the stop nut 6 Move the fin backward and remove Installation 1 Position the vertical stabilizer over the aircraft tail 2 Slide the auxiliary spar attachment sheet 1 figure 4 of...

Page 355: ...CHAPTER 55 PAGE 9 PAGE DATE 1 March 2011 MAINTENANCEMANUALEXTRA330LX Figure 4 Vertical Stabilizer Removal Installation...

Page 356: ...2011 MAINTENANCEMANUALEXTRA330LX Figure 5 Layer Sequence Vertical Stabilizer 1 Vorgelat T35 2 1 x CCC452 45 3 Reinforcement 1 x CCC452 45 4 Honeycomb 5 Reinforcement 1 x CCC490 45 6 1 x CCC490 45 RH...

Page 357: ...11 MAINTENANCEMANUALEXTRA330LX Figure 6 Layer Sequence Rudder 1 Vorgelat T35 2 1 x CCC452 45 3 Reinforcement 1 x CCC452 45 5 Honeycomb 4 Reinforcement 1 x CCC452 0 90 6 1 x CCC490 45 RH shell shown LH...

Page 358: ...CHAPTER 57 PAGE 1 PAGE DATE 1 March 2011 MAINTENANCEMANUALEXTRA330LX Chapter 57 Wings...

Page 359: ...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 30 00 WINGT...

Page 360: ...The wing shells are a honey combsandwichconstructionwithcarbonfibrelaminates To prevent buckling of the shells plywood and composite ribs are used The layer sequence of the wing is shown in figure 1 F...

Page 361: ...CHAPTER 57 PAGE 4 PAGE DATE 1 March 2011 MAINTENANCEMANUALEXTRA330LX Figure 1 Sheet 1 Layer Sequence Wing...

Page 362: ...CHAPTER 57 PAGE 5 PAGE DATE 1 March 2011 MAINTENANCEMANUALEXTRA330LX Figure 1 Sheet 2 Layer Sequence Wing...

Page 363: ...CHAPTER 57 PAGE 6 PAGE DATE 1 March 2011 MAINTENANCEMANUALEXTRA330LX Figure 1 Sheet 3 Layer Sequence Wing...

Page 364: ...lever and control sticks in rearmost position 5 Remove RPM vernier control cable 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 fuselag...

Page 365: ...washers Torque security 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 nut...

Page 366: ...17 Connect fuel system tubes and vent lines pitot static sys tem navigation strobe light wires ground bonding leads and fuel indicator wires with prefitted connectors per respec tive Chapters Connect...

Page 367: ...CHAPTER 57 PAGE 10 PAGE DATE 14 August 2015 MAINTENANCEMANUALEXTRA330LX A Figure 3 Wing Removal Installation...

Page 368: ...ENANCEMANUALEXTRA330LX 57 30 00 WING TIP 57 30 01 Wing Tip Fairing Removal Installation Referto LED Navigation StrobeLightRemoval Installa tion instructions of Chapter 33 40 The wing tip fairing instr...

Page 369: ...res a shieldedhornbalance Furthermoretheaileronsareequipped with spades to decrease pilots forces To prevent flutter the aileronsaremassbalancedintheoverhangingleadingedge as well as in the horn balan...

Page 370: ...CHAPTER 57 PAGE 13 PAGE DATE 1 March 2011 MAINTENANCEMANUALEXTRA330LX AILERONS Figure 4 Sheet 1 Layer Sequence Ailerons...

Page 371: ...CHAPTER 57 PAGE 14 PAGE DATE 1 March 2011 MAINTENANCEMANUALEXTRA330LX Figure 4 Sheet 2 Layer Sequence Ailerons...

Page 372: ...CHAPTER 61 PAGE 1 SERVICEMANUAL EXTRA330LX PAGE DATE 1 March 2011 Chapter 61 Propeller...

Page 373: ...ATE 1 March 2011 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...

Page 374: ...lade 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...

Page 375: ...eller govenor Natural composite blades using high compressed wood in the root and lightweight wood in the remaining body with fiber reinforced Epoxy cover and metal leading edge protection are used to...

Page 376: ...s 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 cont...

Page 377: ...PAGE 6 SERVICEMANUAL EXTRA330LX PAGE DATE 1 March 2011 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 PAGEDATE 13 Sep...

Page 378: ...ontrol cables 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...

Page 379: ...s Installation Installinreversesequenceofremovalobservingthefollowing items 1 Thread the respective clamp sheets and plastic guidance on the vernier control cable before penetrating the firewall and t...

Page 380: ...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 inspect...

Page 381: ...CHAPTER 71 PAGE 1 MAINTENANCEMANUAL EXTRA330LX PAGE DATE 1 March 2011 Chapter 71 Power Plant...

Page 382: ...2011 Table of Contents Chapter Figure Title 71 10 00 COWLING 3 Figure 1 Engine Cowling 3 Figure 2 Landing Light Connector 4 71 20 00 ENGINEMOUNT 5 Figure 3 Engine Mount Shock Mount Installation 6 71 2...

Page 383: ...flush type Camloc retainers The bottom half features an optional landing light 6 Its electrical connec tor 7 is installed on the left aft inside Both cowling halves are attached to each other and the...

Page 384: ...russ head screws 4 5 of top cowl ing half see figure 1 3 Remove top half of the engine cowling 4 If landing light installed Disconnect the landing light wir ing using the connector shown in figure 2 5...

Page 385: ...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...

Page 386: ...CHAPTER 71 PAGE 6 MAINTENANCEMANUAL EXTRA330LX PAGE DATE 1 March 2011 Figure 3 Engine Mount Shock Mount Installation Removal This paragraph describes the removal of the engine mount from the engine...

Page 387: ...ltstoengineshockmounts with 55 Nm 40 5 ft lbs 71 20 01 Shock Mounts Description The shock mounts serve as dampers to reduce the transmis sion of vibrations induced by the engine to the airframe Thesho...

Page 388: ...mount 5 Remove tubular spacer 6 Extract aft half of the shock mount If necessary lower re spectively lift the engine a little to get the needed clearance for removal of the aft shock mount half Instal...

Page 389: ...he engine cowling is sealed by rubber strips which are riveted to the outer edge of the baffles Further moretheforwardLHbafflehasacircularcutout servingas a cooling air inlet that is connected with th...

Page 390: ...ard LH 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...

Page 391: ...CHAPTER 72 PAGE 1 PAGE DATE 1 March 2011 MAINTENANCEMANUALEXTRA330LX Chapter 72 Engine...

Page 392: ...CHAPTER 72 PAGE 2 PAGE DATE 1 March 2011 MAINTENANCEMANUALEXTRA330LX Table of Contents Chapter Figure Title 72 00 00 GENERAL 3 72 10 00 ENGINE 5 Figure 1 Lycoming Engine 5...

Page 393: ...nt 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...

Page 394: ...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 Brok...

Page 395: ...control is proportional to the intake air flow A manual mixture adjustment as an overriding system is pro vided The power setting is done manually by means of a butterfly valve in the air induction tu...

Page 396: ...epartment 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 th...

Page 397: ...nd of Bowden cables for throttle and mix ture control 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 co...

Page 398: ...all connection for engine manifold pressure fuel pressure and oil pres sure 23 Unbolt the complete engine with engine mount from the airframe at the four attachments points 24 Lift the complete engine...

Page 399: ...CHAPTER 73 PAGE 1 MAINTENANCEMANUALEXTRA330LX PAGE DATE 1 March 2011 Chapter 73 Engine Fuel and Control...

Page 400: ...ttle Control Cable Rigging 7 73 20 13 Front Throttle Control Lever 8 73 20 20 Mixture 9 Figure 5 Mixture Control 9 73 20 21 Mixture Vernier Control Cable 10 Figure 6 Clamp Sheet to Clamp Block Distanc...

Page 401: ...ll and is then routed centrally below the exhaust muffler tothethrottle Intheenginecompartmentthiscable is covered with a fire sleeve The cable is attached to the fuselageusingclampblocksatitsends sel...

Page 402: ...he 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 posi...

Page 403: ...f the firewall break through at the en gine side of the firewall Use PRC 812 Products Research Chemical Corp USA firewall sealant Let the sealant slightly cure before thightening the clamp sheet attac...

Page 404: ...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...

Page 405: ...7 slightly Ensure movability of control levers 1 5 Rigging 1 Move the rear throttle control lever 5 figure 3 in idle position parallel to the adjoining fuselage structure steel tube as shown in figur...

Page 406: ...astening Apply inspection lacquer on the counter nut c Reconnect the rod ends 73 20 13 Front Throttle Control Lever Removal Installation 1 Ensure master switch is off 2 Remove engine cowling per chapt...

Page 407: ...the firewall and is then routed to the mixture control lever In the engine compartment this cable is covered with a fire sleeve The cable is attached to the fuselage using a clamp block at its front e...

Page 408: ...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 contro...

Page 409: ...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 firewallsealantasoutlinedinChap...

Page 410: ...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...

Page 411: ...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...

Page 412: ...tting defective Cleanfitting Sense line leakage Replace sense line 73 30 10 Fuel Pressure The fuel pressure gauge is located in the rear instrument panel Theinstrumenttakesfuelpressurefromthesenseline...

Page 413: ...essure Sense Line 73 30 11 Fuel Pressure Gauge Removal Installation Refer to Chapter 31 73 30 12 Sense Line Removal Installation 1 Remove cowling per Chapter 71 2 Remove clamps N O T I C E Pick up spi...

Page 414: ...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 Disconn...

Page 415: ...CHAPTER 77 PAGE 1 MAINTENANCEMANUALEXTRA330LX PAGE DATE 1 March 2011 Chapter 77 Engine Indicating...

Page 416: ...re 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...

Page 417: ...1 tachometer 2 manifold pressure gauge 3 cylinder head temperature gauge 4 exhaust gas temperature gauge Generallyenginedataisroutedelectricallyfromtheengine sensors refer to Figure 1 to the instrumen...

Page 418: ...chometer NoMAPindication Gaugedefective Replacegauge NoMAPvariation Sense line leakage Replace sense line withpowersetting NoCHTindication Sensor or cable defective Replace sensor Repair cable defect...

Page 419: ...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...

Page 420: ...pter 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...

Page 421: ...ter 31 77 20 12 CHT Sensor The sensor is a bayonet type J thermocouple and is con nected directly with the overbraided wiring This wiring cannot be disconnected from the sensor and must not be shorten...

Page 422: ...coming 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 wit...

Page 423: ...ransducers Wing tank Center tank Manifold PressureTransducer Mountingsheet Oil Pressure Transducer Firewall Fuel Pressure Transducer Firewall FuelFlowTransducer Left side engine OATProbe Bottom fusela...

Page 424: ...MVP 50P documentation of Electronics Inter national Inc see Chapter 1 for detailed information about features Thefollowingfeaturesarenotavailableintheconfiguration installedintheEXTRA330LX External d...

Page 425: ...ng 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...

Page 426: ...ld be monitoredduringflight 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...

Page 427: ...k mounts 9 and re move 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 00 03 2 Disconn...

Page 428: ...CHAPTER 77 PAGE 14 MAINTENANCEMANUALEXTRA330LX PAGE DATE 14 August 2015 Figure 5 Mounting Sheet and MVP 50P Components...

Page 429: ...ld inflame 1 BATTERYswitchoff 2 Remove engine cowlings as per Chapter 71 10 00 3 Remove the fire sleeve 6 4 Disconnect the fuel hoses 3 Figure 6 from the transducer 4 5 Disconnect the electrical wirin...

Page 430: ...pter 79 30 20 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 TheMAPtransducerismodule3ofFi...

Page 431: ...CHAPTER 78 PAGE 1 MAINTENANCEMANUALEXTRA330LX PAGE DATE 1 March 2011 Chapter 78 Exhaust...

Page 432: ...DATE 1 March 2011 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...

Page 433: ...MAINTENANCEMANUALEXTRA330LX PAGE DATE 1 March 2011 78 00 00 GENERAL The EXTRA 330LX is generally equipped with a Gomolzig 6 in 1 exhaust system refer to figure 1 with integrated silencer muffler Figur...

Page 434: ...pesareofweldedstainlesssteel Thesepipes are routed from the cylinders down to the muffler under the engine Themufflercomprisesaninnerpipe whichisperfo rated and an outer pipe to form a welded sealed s...

Page 435: ...73 4 Remove the cooling air ducting on both forward and rear ward 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 exha...

Page 436: ...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...

Page 437: ...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...

Page 438: ...CHAPTER 79 PAGE 1 MAINTENANCEMANUALEXTRA330LX PAGE DATE 1 March 2011 Chapter 79 Oil System...

Page 439: ...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...

Page 440: ...ation ThestandardChristen801InvertedOilSystemisakit form accessory for Lycoming aircraft engines which permits normal engine lubrication with minimal oil loss during aerobaticflight Wheninstalled itbe...

Page 441: ...ngtotheoilpumpandouttotheenginelubrication points Figure 1 Inverted Oil System Normal Flight Inverted flight Whentheaircraftisinverted engineoilfallstothetopofthe crankcase Theweightedballvalveintheoi...

Page 442: ...l system normally requires no maintenance During major overhauls or when repairs require sump re moval inspect sump for excessive deposits of sludge var nish or foreign material If sump is dirty remov...

Page 443: ...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...

Page 444: ...connectionangles Maintenance Practices Beforemakinginstallationsandrepairstotheaircraftplumb ing itisimportanttomakeaccurateidentificationofplumb ingmaterials 79 20 01 Oil Cooler Description and Oper...

Page 445: ...DATE 1 March 2011 79 20 02 Fittings GeneralinformationconcerningfittingsusedintheEXTRA 330LX can be found in chapter 20 10 08 79 20 03 Flexible Hoses Generalinformationconcerningflexiblehosescanbefou...

Page 446: ...ent 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 Inco...

Page 447: ...ication in 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...

Page 448: ...20 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 fig...

Page 449: ...CHAPTER 79 PAGE 12 MAINTENANCEMANUALEXTRA330LX PAGE DATE 1 March 2011 Figure 5 Oil Temperature Sensor Location...

Page 450: ...PAGE DATE 1 March 2011 CHAPTER 91 PAGE 1 MAINTENANCEMANUALEXTRA330LX Chapter 91 Charts...

Page 451: ...0 H EA 93102 21B Transponder GTX328 330 EA 93102 22 Transponder BXP6401 EA 93102 25 Transponder GTX327 EA 93102 26 TransponderATC4401 EA 9D102 27 Volt Ampere Indication EA 93102 28 Fuel Flow EDM700 EA...

Page 452: ...Clock EA 9D102 56 12VDC Outlet EA 9D102 58A EGT CHT Indication EA 93102 59 FLIGHTTIMER EA 9E102 60 GPSMAP 695 EA 9E102 62A Garmin GTN 635 EA 9E102 63A Garmin GTN 650 750 EA 9D102 64A Garmin GTX 33 EA...

Page 453: ......

Page 454: ...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...

Page 455: ...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...

Page 456: ...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 PREST...

Page 457: ...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...

Page 458: ...BUCHSEN GEH USE 2 POLIG FLACHSTECKER BUCHSE 6 3mm BUCHSEN GEH USE 4 POLIG 0042282 2 01170 01171 00093 180900 1 180900 0 PIN GEH USE 4 POLIG 42565 2 11 2 2 4 10 4 4 4 16 16 1 1 2 2 MS35058 22 SWITCH S...

Page 459: ...ng Nr nderung Mod Nr Datum Name Letzte Bearbeitung Datum Name Bearb Gepr Ma stab SI Klasse Oberfl chenschutz Projektion Freima toleranz Oberfl che Schutzvermerk nach DIN 34 beachten EDV Kennung auf Bl...

Page 460: ...I4 I5 I1 I2 I3 bl or bl ws ws or bl ws bl ws 24 24 EA 93102 6 AUDIO JACKS SWITCHES EA 93102 _ _ OPTION INTERCOM OPTION 01 04 OPTION 02 BECKER COM AR 6201 mit POTTER BRUMFIELD CB OPTION 01 BECKER COM...

Page 461: ...A2 A1 COM S E GER T oder INTERCOM 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 31...

Page 462: ...T ON OFF S2 BOOST CB6 10A 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 GEH...

Page 463: ...PTION 01 02 18 1 8 6 5 7 3 4 2 6 5 2 FLACHSTECKER PIN 6 3mm PIN GEH USE 2 POLIG 00099 00103 00097 180924 0 180923 0 BUCHSEN GEH USE 2 POLIG FLACHSTECKER BUCHSE 6 3mm 0042282 2 00093 42565 2 8 7 1 1 2...

Page 464: ...R 20X20X1 00099 00103 00097 01996 180924 0 180923 0 1 3 4 5 7 9 11 12 5 6 7 8 BUCHSEN GEH USE 2 POLIG FLACHSTECKER BUCHSE 6 3mm MICROSCHALTER Burgess PIN 0042282 2 FE4306 FE4308 33626 00093 1 0480305...

Page 465: ...ITCH OPTION 04 KISSLING SWITCH BURGESS MICRO SWITCH MICROSCHALTER Cherry 01738 DC1C C3LD 4 4 6 2 1 2 4 2 2 4 4 12 1 2 4 2 2 4 4 12 2 33581 33627 Fa CONRAD 702333 blue blue blue blue Fa ALDERS Fa KISSL...

Page 466: ...500 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 OPTION...

Page 467: ...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 80...

Page 468: ...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...

Page 469: ...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 A...

Page 470: ...brown blue yellow orange 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 ANTENN...

Page 471: ...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...

Page 472: ...Schutzvermerk nach DIN 34 beachten EDV Kennung auf Blatt von Schwarze Heide 21 46569 H nxe Germany Gepr Flugzeugbaureihe ist der Bauakte bzw A4 1 1 EA3D0936 02 03 Benennung Nr 01 Teilekennzeichen ZF...

Page 473: ...INDICATOR yel yel yel yel yel yel yel yel yel yel yel red red red red red red red red red red red red P2 1 2 3 4 5 6 7 8 9 10 11 12 14 15 16 17 18 19 20 21 22 23 24 25 yel CHT 1 CHT 2 CHT 3 CHT 4 CHT...

Page 474: ...15 OAT 14 OAT OIL TEMP PROBE OAT PROBE P6 FIRE WALL MAGNETO L H 2 1 3 FF ALL EGT S1 FUEL FLOW EGT 02 04 03 Benennung Nr 01 Teilekennzeichen ZF Werkstoff Abmessungen Menge Gewicht Einheit MaWi Nr 1 2...

Page 475: ...Name Letzte Bearbeitung Datum Name Bearb Gepr Ma stab SI Klasse Oberfl chenschutz Projektion Freima toleranz Oberfl che Schutzvermerk nach DIN 34 beachten EDV Kennung auf Blatt von Schwarze Heide 21...

Page 476: ...e Oberfl chenschutz Projektion Freima toleranz Oberfl che Schutzvermerk nach DIN 34 beachten EDV Kennung auf Blatt von Schwarze Heide 21 46569 H nxe Germany Gepr Flugzeugbaureihe ist der Bauakte bzw E...

Page 477: ...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 s...

Page 478: ...bmessungen Menge Gewicht Einheit MaWi Nr 1 2 3 30611 201 B 4 5 FLOW SENSOR FUEL FLOW INDICATOR FS 450 450000 CONNECTOR KIT CIRCUIT BREAKER 2A FE4086 31508 in Pos 1 7277 2 2 D 436 37 SPLICE 1 1 1 1 3 1...

Page 479: ...nach DIN 34 beachten EDV Kennung auf Blatt von Schwarze Heide 21 46569 H nxe Germany Gepr Flugzeugbaureihe ist der Bauakte bzw 14 GND 29 07 13 HW see conforming ELEKTRIK SYSTEM EA 9__102 1 red blk wh...

Page 480: ...UCHSEN GEH USE 2 POLIG FLACHSTECKER BUCHSE 6 3mm 0042282 2 00093 42565 2 16 16 16 16 16 11 SCHALTER 1 POLIG ON OFF 1 1 1 2 1 1 2 2 2 1 2 1 1 1 2 1 1 2 2 OPTION 01 STANDARDPANEL OPTION 02 KOHLEPANEL 1...

Page 481: ...1DA Die G ltigkeitszuordnung von Version zu dem jeweiligen Fertigungsauftrag zu entnehmen Zuordnung links rechts wird mit in allen Feldern angegeben 04 03 02 01 Ver Bezeichnung Nr nderung Mod Nr Datu...

Page 482: ...GROUND SUPPRESSION 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 2...

Page 483: ...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 BUCHS...

Page 484: ...EN 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 1 920 000...

Page 485: ...gen 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 CON...

Page 486: ...MFD requires GNC 420W or GNS 430W to be installed 3 optional MFD requires GTX 330 or GTX 328 to be installed 9 11 02 04 03 Benennung Nr 01 Teilekennzeichen ZF Werkstoff Abmessungen Menge Gewicht Einhe...

Page 487: ...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 Einhei...

Page 488: ...24 I3 I2 I1 I5 I4 24 24 24 24 24 24 24 ws bl bl ws bl ws bl bl bl ws ws ws ws ws PTT PILOT PTT COPILOT I C COPILOT I C PILOT PHONE BUCHSE PILOT PHONE BUCHSE COPILOT 24 24 24 24 24 24 MIC BUCHSE COPILO...

Page 489: ...2 Stueck 1 A B C D ATTITUDE GYRO POWER 9 32VDC POWER GROUND 20 20 see POWER DISTRIBUTION 8 5oz 16oz 5 Option INCLINOMETER OPTION 03 3 Inch VERSION with INCLOMETER 5 Stueck 1 INCLINOMETER RCA 444 0010...

Page 490: ...N 01430 701548 734136 STEREO JACK 2 4 2 2 1 4 1 WASHER 31381 31382 04 00975 WASHER 04 00976 2 4 mtr FE4256 BUCHSENGEH USE 43025 0400 FE4079 43030 0007 BUCHSE 13 EA 76291 1 PTT KABELBAUM 1 1 2 5 3 8 14...

Page 491: ...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...

Page 492: ...OR 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...

Page 493: ...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...

Page 494: ...HSE 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 762...

Page 495: ...tzte Bearbeitung Datum Name Bearb Gepr Ma stab SI Klasse Oberfl chenschutz Projektion Freima toleranz Oberfl che Schutzvermerk nach DIN 34 beachten EDV Kennung auf Blatt von Schwarze Heide 21 46569 H...

Page 496: ...Nr nderung Mod Nr Datum Name Letzte Bearbeitung Datum Name Bearb Gepr Ma stab SI Klasse Oberfl chenschutz Projektion Freima toleranz Oberfl che Schutzvermerk nach DIN 34 beachten EDV Kennung auf Blat...

Page 497: ...tab SI Klasse Oberfl chenschutz Projektion Freima toleranz Oberfl che Schutzvermerk nach DIN 34 beachten EDV Kennung auf Blatt von Schwarze Heide 21 46569 H nxe Germany Gepr Flugzeugbaureihe ist der B...

Page 498: ...zeichnung Nr nderung Mod Nr Datum Name Letzte Bearbeitung Datum Name Bearb Gepr Ma stab SI Klasse Oberfl chenschutz Projektion Freima toleranz Oberfl che Schutzvermerk nach DIN 34 beachten EDV Kennung...

Page 499: ...utz Projektion Freima toleranz Oberfl che Schutzvermerk nach DIN 34 beachten EDV Kennung auf Blatt von Schwarze Heide 21 46569 H nxe Germany Gepr Flugzeugbaureihe ist der Bauakte bzw 2 3 CIRCUIT BREAK...

Page 500: ...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...

Page 501: ...7 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 OU...

Page 502: ...R 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 R...

Page 503: ...T 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 O...

Page 504: ...auf Blatt von Schwarze Heide 21 46569 H nxe 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...

Page 505: ...MIL W 22759 16 20 mtr X 14 4 4 X KONTAKT PIN FE4306 1 0480303 0 1 0480305 0 KONTAKT BUCHSE 163557 2 FE4305 163558 2 11 4 4 2 10 2 2 2 6 6 1 1 MS35058 22 SWITCH SPST 01602 2 07 1 1 13 SWITCH SPST 2 FE4...

Page 506: ...henschutz Projektion Freima toleranz Oberfl che Schutzvermerk nach DIN 34 beachten EDV Kennung auf Blatt von Schwarze Heide 21 46569 H nxe Germany Gepr Flugzeugbaureihe ist der Bauakte bzw 2 3 4 12VTO...

Page 507: ...N 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...

Page 508: ...ng auf Blatt von Schwarze Heide 21 46569 H nxe 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...

Page 509: ...CHAPTER 96 PAGE 1 MAINTENANCEMANUAL EXTRA330LX PAGE DATE 1 March 2011 Chapter 96 Smoke...

Page 510: ...NANCEMANUAL EXTRA330LX PAGE DATE 1 March 2011 Table of Contents Chapter Title 96 00 00 GENERAL 3 Figure 1 Smoke System 4 96 10 00 STORAGE 5 96 10 01 Smoke Oil MainTank 5 96 10 02 Smoke OilAcro Tank 6...

Page 511: ...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 changeovercontactt...

Page 512: ...CHAPTER 96 PAGE 4 MAINTENANCEMANUAL EXTRA330LX PAGE DATE 1 March 2011 Figure 1 Smoke System 1 2 3 4 5 6 7 9 8 10 12 13 14 15 11...

Page 513: ...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 co...

Page 514: ...rain 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 N O T I C E Prevent the...

Page 515: ...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 sy...

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