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CHAPTER 78

PAGE 1

MAINTENANCE MANUAL EXTRA 300LT

PAGE DATE: 7. July 2010

Chapter 78

Exhaust

Table of Contents

Chapter 1 Introduction11
- General12
- Related Documents12
- Trade Marks16
- Safety17
Chapter 2 How to Use the Service Manual19
- Table of Contents19
- Chapter Set-Up20
- Manual Description20
- Manual Set-Up20
- Page Numbering21
- Layout22
- Notes/Safety Notes23
- Handling24
- Revisions24
- Checklists25
- Service Bulletin25
Chapter 3 General Description27
- General28
- View EXTRA 300LT28
- Construction29
- Description29
- Flight Control System29
- Brake System30
- Powerplant30
- Electrical System31
- Fuel System31
- Instruments32
Table of Contents35
- General36
- Operating Time36
- Temperature Limit36
- General38
- Life Limited Components38
- Replacement Time38
- Service Life Limited Components38
- Major Inspection39
Chapter 5 Time Limits/Maintenance Checks41
- General42
- General43
- Overhaul Schedule43
- Time Limit Components43
- Recommended Replacement Times44
- Time between Inspection45
- 25 Hour Inspection - Aircraft46
- 25 Hour Inspection - Engine46
- General46
- Scheduled Maintenance Checks46
- Drain and Vent Holes47
- Lubrication Chart 25 Hours48
- Lubrication Chart 50 Hours49
- Lubrication Chart 100 Hours50
- Maintenance Checks Schedule51
- Significant Items Inspection67
- Hard Landing76
- Unscheduled Maintenance Checks76
- Violent Stopping of the Engine (Propeller Strike)76
- Engine Fire78
- Flightline Inspections79
- Lightning Strike79
Chapter 6 Dimensions and Areas81
- Axes and Planes82
- General82
- Main Data83
- Main Dimensions83
- Wing83
- Elevator84
- Horizontal Tail84
- Rudder84
- Vertical Tail84
- Three-View EXTRA 300LT85
Chapter 7 Lifting and Shoring87
- Balance Weight88
- Jacking88
- Shoring89
- Shoring the Front89
- Shoring the Tail90
Chapter 12 Servicing109
- Refueling111
- Replenishing111
- Defueling113
- Fuel Drains113
- Replenishment of Engine Oil114
- Oil Change117
- Replenishment of Brake Fluid119
- Tire Inflation120
- Exterior Cleaning121
- Scheduled Servicing121
- Engine Cleaning122
- Interior Cleaning122
- Removal of Snow and Ice124
- Unscheduled Servicing124
Chapter 20 Standard Practices - Airframe126
- General127
- Standard Practices Airframe128
- Type of Bolts128
- Width Across Flats for Metric Bolts130
- Torque Values131
- Special Torque Values132
- Coin Tapping133
- Measuring Techniques133
- Flexible Hose134
- Connection Types PA Hoses136
- Control Cables137
- Fittings137
- Control Cables141
- Assembly Instruction142
- Assembly Instruction after Container Shipping142
- General142
Chapter 21 Air Conditioning146
- Heating147
- Heating System148
- Heating Boxes149
- Inlet Box149
- Distribution Box150
- Main Bowden Cable150
- Distribution Bowden Cable152
- Heating Bowden Cables155
Chapter 24 Electrical Power161
- Electrical Main Board163
- Electrical System Schematic164
- Battery System166
- DC-Generation166
- Battery167
- Alternator169
- Alternator System169
- Alternator and Accessories170
- Drive Belt172
- Alternator Pulley175
- System Ground175
- Circuit Breaker176
- DC Electrical Load Distribution176
- Relay177
- Subminiature Pushbutton Switch177
- Toggle Switch177
Chapter 25 Equipment and Furnishings180
- Flight Compartments181
- Front Seat181
- Rear Seat181
- Seat Belts183
- Strap Assembly183
- Shoulder Strap Attachment184
- Tubes for Shoulder Strap Attachment184
- Aircraft Document Bag185
Chapter 27 Flight Controls187
- Control Surface Deflections190
- Control Rods191
- Control Rod Identification192
- Control Rod Measurement192
- Control Rod Measurement & Rod End Alignment192
- Figure 5192
- Table 1192
- Control Rod Check Hole193
- Figure 7193
- Control Levers and Rods Removal/Installation194
- Figure 9195
- Front Control Stick195
- Front Control Stick Removal/Installation195
- Rear Control Stick196
- Torque Tube196
- Aileron Control197
- Aileron Control198
- Figure 10198
- Ailerons199
- Figure 11199
- Neutral Position of Rear Control Stick199
- Figure 12200
- Neutral Position of Aileron Bellcranks200
- Spade Rigging201
- Rudder Control202
- Figure 14203
- Rudder Control203
- Rudder204
- Bottom Hinge Bellcranks205
- Bottom Hinge Bracket205
- Control Cable205
- Figure 15206
- Rear Pedal Position and Template206
- Figure 16208
- Front Pedal Position and Template208
- Elevator Control210
- Elevator and Trim Tab Control211
- Figure 17211
- Elevator212
- Neutral Position of the Rear Control Stick213
- Trim Tab214
- Figure 19215
- Trim Tab Rigging215
Chapter 28 Fuel217
- General218
- Figure 1219
- Fuel System219
- Storage221
- Figure 2222
- Storage222
- Acro Tank223
- Center Tank223
- Acro Tank Flop Tube224
- Figure 3224
- Flop Tube Removal/Installation224
- Figure 4225
- Inspection Door Removal/Installation225
- Wing Tank Inspection Door225
- Center Tank Filler Neck226
- Figure 5226
- Wing Tank Outlets226
- Wing Tank Outlets Removal/Installation226
- Filler Neck Sealing Lip227
- Wing Tank Filler Neck227
- Figure 6228
- Filler Neck and Sealing Lip Removal/Installation228
- Ventilation Line228
- Distribution229
- Distribution230
- Figure 7230
- Fuel Selector Valve231
- Figure 8232
- Fuel Selector Valve and Control Rod232
- Figure 9234
- Gascolator234
- Gascolator Removal/Installation234
- Fuel Lines236
- Figure 11238
- Fuel Quantity Transducer (Center Tank)240
- Figure 12241
- Fuel Quantity Transducer (Wing Tank)241
- Removal/Installation241
- Figure 13242
- Float Wire242
- Float Wire Adjustment242
- Figure 14243
- Float Wire Installation243
Chapter 31 Indication/Recording System245
- Instrument and Control Panels247
- Rear Instrument Panel247
- Rear Switches & Circuit Breakers248
- Rear Instrument Cover Removal/Installation250
- Front Instrument Panel251
- Front Instrument Panel Support (for Garmin G5)255
- Removal/Installation255
- Typical Instrument Attachments257
- Typical Instruments257
- Central Warning Systems259
- Stall Warning System259
Chapter 32 Landing Gear261
- Landing Gear262
- Wheel Rake and Toe-In262
- Main Landing Gear263
- Top Half of the Mounting Clamp263
- Tail Wheel Fork265
- Wheels and Brakes267
- Brake System268
- Layer Sequence Wheel Fairing270
- Wheel Fairing270
Chapter 33 Lights273
- Flight Compartment274
- Low Voltage Monitor274
- Navigation/Strobe Light System276
- Landing Light279
- Landing Light System279
- Head Lamp281
- Landing Light Power Supply281
- LED Head Lamp282
- LED Landing Light282
- LED Landing Light System282
- LED Landing Light283
Chapter 34 Navigation285
- General286
- Flight Environment Data287
- Pitot/Static Drain287
- Pitot/Static System287
- Airspeed Indicator288
- Altimeter288
- Pitot-Static Tube289
- Pitot-Static Tube Attachment Block289
- Attitude and Direction291
- Magnetic Compass291
- Dependent Position Determining293
- Transponder293
Chapter 51 Standard Practices and Structures - General295
- Access Panel Identification296
- General296
- Access Panel Identification297
- Figure 1297
- Damage Classification299
- Investigation299
- Repair Criteria and Limits300
- Composite Parts301
- Materials301
- Metal Components306
- Aluminium Components307
- Various Components308
- Balancing Mandrels311
- Control Surface Balancing311
- Figure 2311
- Moments311
- Weighing and Determination of Control Surface311
- Figure312
- Determination of Control Surface Moments313
- Figure 3313
- Control Surface Weights and Moments314
- Repair of Reinforced Glass and Carbon Fibre Components315
- Repairs315
- Figure 5317
- Minor Surface Damage317
- Repair of Sandwich Material317
- Curing Cycle Resin L20/SL319
- Figure 6319
- Level Sanding of Surrounding Area319
- Damage of Complete Sandwich321
- Figure 8321
- Repair of Laminates322
- Figure 9324
- Repair of Minor Damage324
- Repair of Spars326
- Structural Repair of Steel Components326
- Painting of Composite Parts327
- Aluminium and Steel Components Refinishing328
- Empennage Attachment Bushings331
- Figure 10331
- Re-Bonding of Bushings331
Chapter 53 Fuselage339
- Main Fuselage Cover345
- Layer Sequence Main Fuselage Cover346
- Bottom Fuselage Cover348
- Forward View on Bottom Side Firwall348
- Layer Sequence Bottom Fuselage Cover350
- Layer Sequence Cuffs351
- Layer Sequence Tail Fairing352
- Layer Sequence Top Half of the Engine Cowling353
- Up to SN LT040353
- From SN LT041354
- Layer Sequence Bottom Half of the Engine Cowling355
- Up to SN LT040355
- From SN LT041356
Chapter 55 Stabilizers358
- General359
- Horizontal Stabilizer360
- Layer Sequence Horizontal Stabilizer360
- Layer Sequence Horizontal Stabilizer361
- Horizontal Stabilizer Removal/Installation363
- Elevator364
- Layer Sequence Elevator364
- Layer Sequence Vertical Stabilizer365
- Vertical Stabilizer365
- Vertical Stabilizer Removal/Installation367
- Layer Sequence Rudder368
- Rudder368
Chapter 61 Propeller382
- General383
- Propeller384
- Controlling385
- RPM Vernier Control Cable Installation386
- Governor387
- RPM Vernier Control Cable387
Chapter 71 Power Plant391
- Cowling392
- Engine Cowling392
- Landing Light (LED) Disconnection Plug394
- Landing Light (Xenon) Disconnection Plug394
- Up to SN LT040394
- Engine Mount395
- Shock Mounts397
- Air Baffles399
Chapter 73410
- Throttle Control411
- Throttle Control Cable412
- Clamp Sheet to Clamp Block Distance413
- Rear Throttle Control Lever415
- Front Throttle Control Lever418
- Throttle Control Levers418
- Mixture Control419
- Mixture Vernier Control Cable420
- Clamp Sheet to Clamp Block Distance421
- Mixture Vernier Control Cable Rigging422
- Over-Travel at Mixture Control Unit422
- Fuel Pressure425
- Fuel Pressure Sense Line425
- Fuel Pressure Gauge426
- Sense Line426
Chapter 77 Engine Indicating428
- Manifold Pressure (MAP)431
- Sintered Bronze Filter Location431
- Manifold Pressure Gauge432
- Sense Line Engine Compartment432
- CHT Sensor433
- Cylinder Head Temperature (CHT)433
- Cylinder Head Temperature Gauge433
- EGT Sensor434
- Exhaust Gas Temperature (EGT)434
- Exhaust Gas Temperature Gauge434
- Electronics International MVP-50P435
- Integrated Engine Instrument Systems435
- Alternate Panel Layout437
- Electronic Data Converter439
- Mounting Sheet439
- Mounting Sheet and MVP-50P Components440
- Fuel Flow Transducer441
- Fuel Flow Transduver441
Chapter 79 Oil System451
- Christen Inverted Oil System452
- General452
- Inverted Oil System, Normal Flight453
- Inverted Oil System, Inverted Flight454
- Valve Balls455
- Distribution456
- Oil Cooler456
- Fittings457
- Flexible Hoses457
- Oil Cooling System457
- Indicating458
- Oil Pressure458
- Oil Pressure Sensor & Wet Line459
- Oil Pressure Wet Line459
- Engine Fitting460
- Oil Temperature460
- Oil Temperature Gauge460
- Oil Temperature Sensor460
- Oil Temperature Sensor Location461

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