Extra 300L Service Manual 1995-2019 EA-06702 – Complete Aerobatic Aircraft Workshop Guide

Description

Extra 300L Service Manual – Document EA-06702

This is the complete service manual for the Extra 300L aerobatic aircraft, published by Extra Flugzeugproduktions- und Vertriebs-GmbH under document number EA-06702. The manual spans from the first edition issued in June 1995 through the 11th revision dated 11 December 2019, with technical content approved under DOA reference EASA 21J.073. It is written for licensed maintenance personnel and covers the airframe, engine, propeller, systems, and structural repair procedures required to service and maintain the Extra 300L.

File Details

• Manual Type: Service Manual
• Brand: Extra Flugzeugproduktions- und Vertriebs-GmbH
• Model: Extra 300L
• Document Number: EA-06702
• Edition: 1st Edition, 1 June 1995
• Latest Revision: 11th Revision, 11 December 2019
• Language: English
• Page Count: 491 pages
• File Format: PDF

Chapters Covered

• Chapter 01 – Introduction
• Chapter 02 – How to Use the Service Manual
• Chapter 03 – General Description
• Chapter 04 – Airworthiness Limitations
• Chapter 05 – Time Limits / Maintenance Checks
• Chapter 06 – Dimensions and Areas
• Chapter 07 – Lifting and Shoring
• Chapter 08 – Leveling and Weighing
• Chapter 09 – Towing and Taxiing
• Chapter 10 – Parking, Mooring, Storage and Return to Service
• Chapter 12 – Servicing
• Chapter 20 – Standard Practices – Airframe
• Chapter 23 – Communications
• Chapter 24 – Electrical Power
• Chapter 25 – Equipment and Furnishings
• Chapter 27 – Flight Controls
• Chapter 28 – Fuel
• Chapter 31 – Indication / Recording Systems
• Chapter 32 – Landing Gear
• Chapter 33 – Lights
• Chapter 34 – Navigation
• Chapter 51 – Standard Practices and Structures – General
• Chapter 53 – Fuselage
• Chapter 55 – Stabilizers
• Chapter 57 – Wings
• Chapter 61 – Propeller
• Chapter 71 – Power Plant
• Chapter 72 – Engine
• Chapter 73 – Engine Fuel and Control
• Chapter 77 – Engine Indicating
• Chapter 78 – Exhaust
• Chapter 79 – Oil System
• Chapter 91 – Charts (Wiring Diagrams)

This Extra 300L service manual goes well beyond routine maintenance. It documents the aircraft’s construction in detail – steel tube fuselage covered with fabric and composite panels, fiber composite wings and stabilizers, and a fixed main landing gear with a full-swivel tail wheel. The General Description chapter gives a full survey of the aircraft’s systems, including the flight control system, brake system, powerplant, fuel system, electrical system, and standard instrument installations for both front and rear cockpits.

The manual provides a complete scheduled maintenance program with inspection intervals at 25, 50, 100, 200, 300, 400, 500, and 1000 hours, plus an annual inspection equal to the 100-hour check. Lubrication charts for 25, 50, and 100-hour intervals are included, along with a drain and vent hole chart. The 1000-hour Significant Items Inspection is documented in detail, covering the wing, ailerons, vertical stabilizer, rudder, horizontal stabilizer, elevator, fuselage, flight controls, landing gear, engine compartment, and hardware. Unscheduled maintenance checks are covered for propeller strikes, hard landings, engine fires, lightning strikes, and flightline inspections.

Structural Repair and Composite Work

Structural repair guidance covers reinforced glass and carbon fiber components, sandwich material, laminates, spars, and steel components, with specific damage classification criteria and repair limits. The manual includes detailed procedures for repairing minor surface damage, complete sandwich damage, and large laminate damage, including scarfing, vacuum bagging, and curing cycles. Re-bonding procedures for bushings in the empennage spars and wing main spar flange bushings are documented step by step. Repair of steel components includes TIG welding guidance and material specifications for both early and later serial number ranges.

Control surface balancing is covered with weighing and moment determination procedures, including permissible weights and moments for the ailerons, elevator, rudder, and trim tab. The manual also details the materials used in repairs, including epoxy systems, glass and carbon fiber fabrics, core materials, paints, steel tubing, and aluminum components, with manufacturer and supplier information.

Systems and Components

Flight control systems are covered in depth, including aileron, elevator, and rudder rigging procedures, control rod lengths, bellcrank installation, and free play limits. The fuel system chapter details the wing tanks, center tank, acro tank with flop tube, fuel selector valve, gascolator, and electrical boost pump, including both 42 L and 60 L center tank configurations. Electrical power covers the battery, master relay, alternator, and drive belt. Landing gear, wheels, and brakes are documented with Cleveland wheel and brake assemblies, master cylinder, and tail wheel procedures.

Communications and navigation equipment includes the Becker AR 3201 VHF radio, intercom systems, transponder installations, pitot/static system, altimeter, airspeed indicator, magnetic compass, and turn and bank indicator. Chapter 91 provides wiring diagrams for power generation, magneto systems, nav/strobe lights, fuel gauges, COM equipment, alternators, fuel boost pumps, stall warning, transponders, ELT systems, and more.

For the powerplant, the manual covers the Lycoming AEIO-540-L1B5, AEIO-540-L1B5D, and AEIO-580-B1A engines, including the Christen inverted oil system that allows sustained inverted flight. Engine removal and installation procedures, fuel system servicing, exhaust system maintenance, and engine indicating system troubleshooting are all documented. The propeller section covers the MT-Propeller MTV-9-B-C/C 200-15, MTV-14-B-C/C 190-17, and MTV-9-B-C/C 198-25 models, with governor and RPM vernier control cable rigging procedures.

Specifications and Operating Limits

The manual includes dimensions and areas data: length 6.96 m, height 2.62 m, span 8.00 m, wheelbase 5.00 m, and wheel track 1.80 m. Wing area is 10.7 m² with a root chord of 1.85 m and tip chord of 0.87 m. Maximum takeoff weight is 950 kg in normal category, 820 kg for single-seat acrobatic, and 870 kg for two-seat acrobatic. Fuel capacities are 171 L total for Configuration 1 and 189 L total for Configuration 2. Engine oil capacity is 16 U.S. quarts (15.18 L). Tire pressure is 3.4 bar (49.3 psi) for both main wheels.

Airworthiness limitations include a 6000-flight-hour life limit for the wing, aileron, vertical stabilizer, rudder, horizontal stabilizer, elevator, and landing gear spring. The composite structure is qualified to a maximum temperature of 72°C (162°F). Recommended replacement times are given for batteries, hoses, seat belts, and other components. Torque values are provided for standard metric and AN hardware, plus special torque values for critical airframe connections.

What You Can Do With This Manual

With the Extra 300L service manual, you can perform scheduled inspections, troubleshoot systems, remove and install major components, rig flight controls, repair composite structures, service the fuel and oil systems, maintain the landing gear and brakes, and perform engine-related maintenance tasks. The manual includes torque values, rigging dimensions, control surface deflection tolerances, fluid capacities, tire pressures, and other specifications needed to work on the aircraft correctly.

The flight control rigging procedures are especially valuable, covering neutral position setup, control rod lengths, aileron and elevator deflection tolerances, rudder cable installation with clamping specifications, and trim tab rigging. The manual also documents the free play limits for aileron, elevator, and trim tab, which are critical for safe operation of an aerobatic aircraft.

Correct procedures and specifications matter on an aerobatic aircraft like the Extra 300L, where control system rigging, structural integrity, and engine reliability are critical. This manual gives you the manufacturer’s guidance directly, so you can work with confidence rather than guesswork. Whether you are an owner performing routine maintenance or a shop undertaking major repairs, the procedures and specifications in this manual are the authoritative reference for the Extra 300L.

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