Service and Repair Manual Experimental Aircraft
Contents
1. e axe e manua In addition to Rotax manual two stroke engines overhaul every 300 hours C four stroke engines overhaul every 1 500 hours from engine serial number 4404718 engine cover screws C C C engine mount SC engine mount dumpers and other C SC R every 500 hrs rubberparts 1 1 1 1 1 DEENEN 5 years _ air filters CL SC elect terminals joints and G C SC connectors hoses radiator mount exhaust muffler C C SG SC exhaust pipe springs and fire protect C SG R throttle choke propeller vvire drive SC R ENGINE CONTROL choke and throttle lever wire ropes C C SC R levers C SC PROPELLER AND SPINNER SC O surface condition C fastening bolts 1 1 R propeller bushings RF propeller pitch C SC propeller balance C SC FUEL SYSTEM O every 1000 hrs or 5 years generalleakage C C SC water inside gascolator C dirt and gascolator filter CL Wen R wing fuel tank caps C fuel tank caps o ring R every 500 hrs or 5 years fuel valves and leakage C ELECTRICAL WIRING se R battery C SC battery fluids C SC instr panel wires and connectors C C NAV AC and LDG lights C C fuses C pipistrel si Service manual 15 Servicing the aircraft first5 50 100 200 500 1 000 10 000 hours hours hours hours hours hours hours OIL AND WATER LINES O every 500 hrs or 5 years oil and cooling flui2. Epcot eti jo L 2sea16 sndind ninui Uses WAN 50 sp 16 052 05 enj6 y no 0 5109 5 5001030 01133011 SDIJELUDYIS Gc enue 83 185 sjepod sappny 76 WAN 9 2 lt dsui pueu x BVO PPPO UU 89 2 231320 llo t 250046 asndund 1jnw SNOILVIA3H388V oseoajb Sh amm 05 EE sa A de 5109 5 500 34 NOIL23dSNI 1 SDIJEWBUIS 315100 Jenueui 83 185 deu puey x 8y9 mmm 9 692 23120 6 osnd nd y nuu jo 5 aseal 1 10149 X9 0 SNOLLVIA3H388V oseo1jb V uy OO BOY s5ulM S108WAS 500 0304 NOIL23dSNI s neuieu s Z lenueul lAl s isrjansidid wings interior dsul puey x 85921220 mee Qvo EVT 9120 mem 6 osnd nd y nu o 5 SNOLLVIA3H388V oseojb V 052 05 y no KOM S108WAS 500 030 NOIL234SNI SDIJELUDYIS 6 Ienueuu 63 185 1 liods ayeiquiy 15 j943s d d sa2ey ns UEL RJUOZIJOU 7 S9IE INS 11 s neulau s SNOILVIA3H388V se 1 6 ve Ae 052 n 6 y 5109 5 500 34 NOIL23dSNI sq nsidid enueui 93 A19S OV 41 Service manual pipistrel si Schema
3. ADaAPOO JOE 2 uDokp009 07 1VS 91 6 Noo Lan 0692 0 015 7 01SV 8 PI 4904 9697 9001015 2 015 OI 92 N U01015 CZDISV 8 Pu xq 0597 ein DISV B PU i 1n84p003 00 3vs p 92 01815 OL DZ n fpooo ZMOP 1V5 91 S Mo SESS ei RR BU OGL X40045 ZZOISY 28 1034p009 wor 1V5 91 G A9 DRAI II 7 01SV 01 PZ L Du 1 109 00 ZMO 375 DU Mo sac TET D 1 n2JI u n321 Jonj 216 xe1ou Wia SAs janj SII EWU SUS Gy Ienueui 83 185 76 16 d Wd Z 901 16 d Jd 1 8 SAV 201 Bd Dd Clad B 83 upalpoo9 DC 1v5 91 6 7 2 EC 345 91 20n OUIUDM S DuegsD dD 50 64 aqn OUlUDY s DU97SD d0 0150 1 6 eqni wg 0022 X9U0104S 2 015 01 4094005 DC 3VS 91 sm ab 0607 9 0104 270157 Ol Loan ME 3Y5 91 6 som 12104 0G9Z X8JJ0 011S 7 015Y 01 lp lpoo2 M T 0 7 109 0009 OG 3 6 3 8m 19404 069 85 18 JD2hp009 0 3 5 90m 194104 OEY 901045 ZLOISV 8 upa 997 a ZLOISY 8 anakpoog LOE 3 5 1 24m h s bua D ww 170 Z8S xe1oy s neulau s 7606 jenuew 2214435 d JAd GS A SAYI 92 l LHEL NIG LEL NIO I LEZ NO sa 0217 Z DUDIUJD WWG7 P UN 0017 Z Dupjuun tuucge p tuupcg Q uuo 0212 Z DUD
4. 1 ug fury J ca rc SES e E x PP P PO ME 3 UW f I MOH 3100811 4 be 007 OE uu 7 uu DZ uunppe wuncgl d WOES Wg L I rs uu uugze 0006 01 ET 7 WL0GE WWQOL 9jqp2 uopadq 1649 s qoo 1ubus uopwoq b 286 Xe10y SIIJEWUBYIS 15 9 151014 LG Jenuew 33 185 IH IHL 1H9 IHL 34115100 a 23315 l Esch 00000 ZOd SOULS 5900115 AVN Wia SAs e514329 3 s2neulau s yenuew dS ZG n e214 2 SDIJEWBUIS EG jenueui 86 8 isrjansidid 54 Service manual pipistrel si PIPIETI zL This page is intentionally left blank pipistrel si Service manual 55 Schematics Repairs Elevator vertical pushrod replacement VARIO Propeller Assembly VARIO Propeller Drive Replacement VARIO Propeller Bearing Replacement 3 Bladed Fixed Pitch Propeller Airbrake Control s Drive Reinforcement 1 Airbrake Control s Drive Reinforcement 2 Flaperon Hinge Replacement Flaperon Lateral Drive Assembly Flaperon Mass Balance Weights Installation Wheel Brake cockpit side Assembly Hydraulic Fluid Lines Assembly wheel sid
5. 5952 iWNG 51 4 SMS JOJ onb Joj buius ubi NAZ SI ON 5905 Joj envoy buius JUDI INV L80dN apis 11041 UL Je 6X9N MOJIS pea JOJ SJ USPA 7 350 00 sufi Ajquiassy Jo odO1d u ild pope d si edoy sq nsidid Jenueui lAl s 09 sbumep buimoyo s s suu delj n ovd EN sbumep 0 s s p 07070 dvd MIN L 34ed JUaWIADIOJUIaY AHQ 5 104110007 7 si edoy L9 lenuew 0214405 isrjansidid pipistrel si Service manual Repairs 62 Wing Control s Drive Reinforcement part 2 Assembling the additional brace Screw M6x35 09 d For this screw use shorter spanner oe Screw M6x35 DIN 912 For this screw use longer spanner Additional brace Lock nut M6 Pay attention to the rotation of the brace DIN 985 Use LOCTITE 243 to lock the nut 344 490 04 E77 31101950 jobejasnj au sae uejd siy 00 0 842 JLLJOT 1 m J3YSEM MAN 22 86 N 94 111 30 bulu det Mau ay Duijquasse pue tuburu JUaWAaDIOJUIaY bu UoJadejJ siied u g9 enueui 83 1835 IS 11sidid 360 way fay V li WG p pt lg ue pue Jnu ay Joj day l b au lnolul ay uo uaas Se sJeg deJ ayy OU 0 Jeq de EJUOZIJOV 443 eq 0 deu 344 Jo Sajbue jeuoijeurpap 43534 0 AJessadau SI JI sJeq al Dur auasseaJ UN LNY L90dI qrui ZL UNG SI 9 SA3JS Joj anb sJn
6. The table below indicates recommended maintenance periods see Service manual for detailed in formation Table legend C Check up visual only check for free play and whether everything is in position DO IT YOURSELF CL Cleaning DO IT YOURSELF LO Lubricating oiling lubricate all designated parts and spots using proper lubricant DO IT YOURSELF R Replacement replace designated parts regardless of state and condition You are encouraged to DO undemanding replacements YOURSELF otherwise have replacements done by AUTHORISED SERVICE PERSONNEL SC Special check up measuring verifying tolerances and functionality DONE BY AUTHORISED SERVICE PERSONNEL ONLY O Overhaul daily first 5 50 100 200 500 1 000 10 000 hours hours hours hours hours hours _hours WING AND TAIL SURFACES s surface and structure condition C SC deflections without free play E bearings moving parts bushings C SC lights C self adhesive sealing tape C C SC horizontal tail mount C C SC drain holes CL pipistrel si Service manual 13 Servicing the aircraft dail fist 5 50 100 200 500 1 000 10 000 y hours hours hours hours hours hours hours FUSELAGE sc O SC surface and structure condition C elevator control tube bearing undercarriage struts attaching points C C SC doors hinges C C SC LO rudder contro
7. is the sum of both distances above Second determine the c g position in percentage 96 of Mean Aerodynamic Chord MAC with fol lowing the formula CG R 287mm 22mm CG x 100 x 100 28 4 MAC 908mm where CGmm is the position of CG in millimeters mm Risthe difference between wing s leading edge and MAC s leading edge 29 mm MAC is the Mean Aerodynamic Chord 908 mm for Sinus it is 869 mm pipistrel si Service manual 31 Schematics Control levers Wings Tail surfaces Undercarriage Brakes Fuel system Engine cooling system Engine lubrication system Throttle and choke drive Electrical system ajpuey deu SI A 01 U0 S2Ijeulau s 315100 Jenueui 83 82 ZE 33 Service manual pipistrel si Schematics SYMBOLS INSPECTION PERIODS o m pw glue am grease ABBEREVIATIONS O UMM multi purpuse grease d Loctite 243 Loctite 648 hand insp Y 243 handle 2 dsui puey x J llo L se 4B asndund njnuu mmm WAn SNOLLVIA3H388V 250916 ve 052 00 09 n 6 y rol KOM o 5109 5 5001030 NOLIDIdSNI 3215 01 UO0 SDI EWAYIS 31510 jenuew lAs s yE Sa dp dou pejboud ap l l G 032 Up JN 000 Du DAD UBUU 07 M 8921120 ens
8. Mrroballoon 7 HEREX 5mm Inner fabric Phase 111 Grinding You can grind only the surface ring around the damaged area This surface is shawn in previous drawing When done the surface is ready for painting 28 Service manual pipistrel si Weight and balance Weight and Balance This chapter provides information on aircraft s weight and balance which is essential for safe flying activity Procedure How to weigh the aircraft and later determine the CG correctly Make sure all listed aircraft parts and appliances are installed and in position Remove all other objects e g tools mops Empty fuel tanks except for the unusable fuel Fill up engine oil to the top marking Retract flaps and spoilers leave control surfaces centred Support fuselage at the rear and level the aircraft inside a closed space To do this use the provided airfoil template at lower side of the wing close to the wing root and make sure its straight edge is level horizontal Once leveled read the scale readings and subtract eventual tare weight Now measure and record all readings and fill out the bottom schematic Datum is wing s leading edge at wing root CG lever arm formula for Tail wheel aircraft Sinus TW Virus TW any model Lever arm of CG X G G xb a CG lever arm formula for Nose wheel aircraft Sinus NW Virus NW any model Lever arm of CG X G G xc a Weighing form TAILWHEEL Weighing point an
9. case you notice poor braking action even when hydraulic brake levers are depressed fully it is not necessary the air bubbles in the hydraulic lining which is causing the problem The main wheel s main axis nut especially after a wheel and or axis replacement nut may be tight ened incorrectly so that the brake shims do not make contact with the brake plate Please consult the manufacturer or authorised service personnel for further information Schematic of wheel and wheel brakes pipistrel si Service manual 19 Connecting Auxiliary power supplies Should you be unable to start the engine due to a weak battery auxiliary power supplies can be con nected to help starting the engine Battery s amp Relay s location Battery black amp Relay top right To connect an auxiliary power supply use battery connector cables with clamps at either ends Connect the negative wire to aircraft s exhaust sticking out below the engine cowlings The positive wire leads inside the cockpit to the relay mounted top right of the aircraft s battery on the firewall This relay has 3 nipples the positive wire must be connected to the upper left nipple the only one to which 2 cables are connected to After you have connected the wires correctly start the engine normally by pressing the starter but ton in the cockpit WARNING rne pilot must be in cockpit when starting the engine The person who will disconne
10. 030 1 aUo Jabuo 344 J Ma DS ay Ose sapejq JajadoJd yjog uo g sJaysem azeda nok J 7 q JALJSEM 5600 WU 4 7 e JIM Jausen Buijsixa au eda L t uu 6 SI axuejsip au JI 71 JOUSEM 6671 UU GI e H sul La 0 WU SI v 3208510 aul 1 V 30UEJSIp aly aunseay 1 lt gt 0 1448 68 sbureag 7 jueuue2e day 3 1 0 J j doid si edoy s nsidid Jenueui 83 185 ui Usa JID usasid 0 JI DUIJ U9SSE3J gin jue Uu A12 SI SIY S0J0Ud AU UOJ das Ve nol ep Sued au yew au Durquassesip 300 ipapajJe aq UP l ay s ulJe q au Bunquassesip Ag y N 3 A xoda au 1 Jed JA p1 pue 4 jed YUM sfuueaq ayy quf 0i nas siy Aq paypasa Axoda ay ur aqoy e osje aq Jsnu aayy ajo aues AU OJU Y JJed M S G auajaq sem ji SE UDLJISOA aues au ui g gJed 136 sbuijeog Mau Buisn q 404 ayy ajquasseay 1 Jajadoud ay wos 3 Mupat pue q YSN 3 0 03 A Joj 4 ued 240401 g Jed IAOU J ver nod g Jed 325000 4 V Lied M3 DSW oda ui 30 e q japgdoud 3y uo uoi jsod sj Jeu 04 V Mads ua ub NV 4 Z q ped uo y masis JA tost ayy 4JeW 1 jueuje e dey Pu ieog 1311340 OIHVA siied u 65 lenuew 0214405 IS 11sidid 16 NIC 074 SMIDS 986 NIQ 166 NIC 06484 05 686 1081 Sadajd Z i NIQ
11. 160 carbon 1609 m2 X HEREX 3mm Inner fabric 1x90070 glass 71g m2 X 182125 glass 280g m2 4 1x90070 glass 70g m2 X WARNING ifthe damage area is located on the flap hinge the fabric used there is carbon fibre black color you must laminate using one ply of GG160 fabric oriented diagonally to the flight direction Also you must apply Peel Ply on top of GG160 24 Service manual pipistrel si Phasell Remove the Peel Ply and adapt a new piece of foam Herex 3 mm as accurately as you possibly can and glue it with microballoons WARNING po not apply too much pressure anywhere HEREX 3mm Phase li Grind the foam if its level is too high Also grind the external laminate around the cut out for about 25 mm in a conical shape see next drawing When done laminate as follows Place one 1 piece of GG160 diagonally and One 1 piece of 90070 perpendicular to the flight direction Phase IV Grind only the outer edge of the new fabric When done the new surface is ready to be painted Hight direction pipistrel si Service manual 25 Drawing of skin final repair inner fabric 1190070 gass Juin X E om HEREX Som 5m Em HERE 3mm nev Outher fabric 1x90070 glass 70g m2 190070 gloss 101 n2 F 1xCG160 carbon 1604 m2 X Pont 135 1x66160 carbon 160g m2 X ji 26 Service manual pipistrel si Example of wing FRP repair WARNIN
12. 553 e ou MO J10 auj pue puno Je SUR Y UN U9 S S ayy Jo JNO Jie ti e 495 abus au unu qo ayy Bui 41245 pue sjepad a isoddo au ua SXUE 344 usdo VIUM 9 ayy bul polu vaya sjepad ayy dund nok Jey papuswworsy OSIE SI J 00 au 00 pJEMJOJ al Ae pue SYUEJ JNO M 5300 ti sepad au Uo sbuuds au aou jio bui pefur 6 lt P d 504 aj uo J gnd pue yo Un alle au 14 4 1193 a Uo JI X1 pue pd H b Ue nof se 405 Se asoy Duo mut e 400 soaubap 196 VEJ 100 JUBA JIE BY 7 uy 1909 42 gie ale e Jo dund jio ue 20 1 JUDA Ip vai alu Jo dund 0 WAJSAS out 40 NO ayy Job 01 MOH sourj exeJg 2IJNEJPAH eu 7 si edoy 7606 jenuew 7 741 sasodund lu gg JO UMEJP 0U Jeds JOYA pue 301 2I jeurnsug 3JON au 440 Japuryo ayeug ayy ynd pue asoy 344 aola adaid DVIUIO ayy 3250 jslJed 39JU asa a quassesim 0u ag ht au Up joa at m pue J9A02 DULJEDJ pue Jnu p0 app 05 133 ayy 2 0031 Grut 09 UNL Si XSW 104 andoy buet 27 UO MAU IYJ UJIA ISIP 290 244 370108 pue SN2J25 3S3 3 07 Jredey 100 si edoy LZ enueui a iA48S 76 pipistrel si Repairs Nose Wheel Strut Assembly Remove the nut washer off the upper side of the leg Engine holder Remove the screw M6x10 Remove the filler plug Remove the two screws 2 Noseleq When removing all described pa
13. G DISREGARDING THE FOLLOWING INSTRUCTIONS LEADS TO SEVERE DETERIORATION OF FLIGHT SAFETY AND HAZARDOUS SITUATIONS INCLUDING SUCH RESULTING IN INJURY AND LOSS OF LIFE CAUTION DISREGARDING THE FOLLOWING INSTRUCTIONS LEADS TO SERIOUS DETERIORATION OF FLIGHT SAFETY pipistrel si Service manual 9 General Materials used in manufacturing process Composite parts are made of fabric GG160 GG200 90070 92110 92120 91125 92140 92145 KHW200 roving NF24 foam 75 kg m3 PVC 3mm PVC 5 mm PVC 8mm GFK 3 mm 5 mm 7 mm of thickness paint gelcoat heat resistant protection glass aluminium sandwich Metal parts used are tubes materials Fe0146 Fe 0147 Fe0545 Fe1430 AC 100 CR41 in LN9369 sheet metal materials Fe0147 in Al 3571 rods materials Fe 1221 Fe 4732 C4130 Al 6082 CR41 in Al 6362 cable AISI 316 bolts and nuts 8 8 steel All composite parts are made of glass carbon and kevlar fiber manufactured by Interglas GmbH All parts have been tested at safety factor 1 8 meaning stressed to 7 2 G All parts are made in moulds therefore no shape or structural differences can occur All designing manufacturing and testing complies with following regulations Bauvorschriften f r Ultraleichtflugzeuge des Deutschen Aero Club e V Beauftragter des Bundes ministeriums f r Verkehr e JAR 1 microlight definition EASA CS 22 certain sections EASA CS VLA certain sections for Slovenia
14. G po not under any circumstances attempt to repair damages greater than 50 mm in size on wing and or 20 mm in size on any control circumstances These require a treatment by a FRP professional Phase Preparing the surface Carefully clean the damaged foam and check if there is also a damage on the inner fabric Carefully clean the foam Flight direction If the inner fabric in not damaged fill the hole with microballoons as you can see on the drawing be low In case the hole is through the inner fabric as well you have to repair the inner fabric too The new patch must be at least 20mm bigger than the damaged area You also have to replace glue the missing foam with a new one Gap filling drawing N Microballoon nw HEREX Smm Outher fabric Inner fabric pipistrel si Service manual 27 Phasell Laminating Grind the outer fabric in a shape of a cone at least 25mm around the damaged area see drawing below and laminate only the ground surface with fabrics as follows Two 2 pieces of 92110 and One 1 piece of 90070 Flight direction When laminating be careful about the orientation of the fibres The fibres of 92110 must be put di agonally to the flight direction the fibres of 90070 must be put perpendicular to this direction The directions are also shown in the drawing below 1x92110 glass 1634 X 19001 glass 10g m2 grind of Duther fabric N
15. HUHD juug p WW g ww 021 Z DUDHUHD UUGZ lt P uupcg Q mn ougoP To CL6 Xejoy ul 3s4s Buijoo3 ul5uq SDIJEWAYIS y jenuew 214425 76 p3l5 UJM D2J0JUS1 Pays WU oU p315 UIW DOJOJUJI up 7606 AUUG7 P Uuyp WG pua Du 0 Wb joy pQ4 Und TANIDA 0 Z8S xe1oy S neulau s enueui 33 1385 ST 3M Zel SAVI AM uw L T sdysz iqc z NG 9 oan dba 4 f 00 10 SA T SMO HOL IN ep 00 10 4017 SMO FOL UNO Wee 1 6 unu SDIJEWAYIS lenuew 0214435 216 XEJ0Y 5 5 uone iiqn ulbuq IS 11sidid pipistrel si O Service manual Schematics Throttle and choke drive Rotax 912 bowden cable za plet 1 2mm 21 2mm za plet 1 2mm 61 2mm za plet 1707 1600m m 1670mm bowden lenght cable lenght les f j ZA NI 22 2 PLIN CP 1 d T I 1 el 1 FT O L Il 1 5 1 1 E 2130mm 2280mm 4 8 1200mm 1400mm 2 SC N wem m X N g 7 d V I j GA 07 I j i U WW WDE J
16. ct the cables after the engine has started must be aware of the danger of spinning propeller nearby 20 Service manual pipistrel si Servicing the aircraft Fibre reinforced plastic repairs WARNING po not under any circumstances attempt to repair damages greater than 50 mm in size on wing and or 20 mm in size on any control circumstances These require a treatment by a FRP professional Definition of minor damage Only the damage listed below can be considered as minor damage repairable by oneself Any damage limited to gelcoat or filler Holes in the fuselage underside where the average diameter does not exceed Forward fuselage 50 mm Rear fuselage 50 mm Cracks in fuselage underside max Forward fuselage 50 mm Rear fuselage 50 mm The fuselage glued joint rear fuselage should not be damaged Holes cracks and tears bubbles etc in the wings horizontal stabilizer and control surfaces skins where the damage does not exceed average diameter crack length Wings 50 mm 50 mm Horizontal stabilizer 20 mm 20 mm Rudder 20 mm 20 mm Flaperon Elevator 20 mm 20 mm The above parts should not be damaged in the spar area Damaged fittings should not be repaired but replaced Facilities To insure proper curing the room temperature during repair work and at least 12 hours afterwards should be maintained at 21 C 70 F After that the repaired parts are to be tempered Therefore you may construct a tempering ten
17. d symbol Scale reading Tare Nett right main wheel Gp left main wheel GL tail wheel G2 total G Gp GL G2 se 02 kg d G kg kg Je kg pipistrel si Service manual 29 Weight and balance kg 15 cl ka Gb kg kg 02 Determination of CG Weight kg Weights lever Torque kg cm Remarks arm cm Basic cfg empty weight CAUTION Each newly installed part or appliance must be registered in the upper table Also new total weight and lever arm of CG values must be entered and position of CG re determined Furthermore the momentum must be recalculated This is rather easy to do First multiply the new part s weight by it s lever arm measured from the reference point wing s trailing edge Then sum up all moments and divide the sum by the new total weight WARNING Regard to the Flight manual and Maintenance manual for allowable C G limita tions 30 Service manual pipistrel si Sample c g calculation Guidelines Gtotal is the total mass of empty aircraft All calculations can be performed with aircraft empty weight and empty weight centre of gravity c g as the pilots sits directly below the centre of gravity and do not cause the c g to be shifted The amount of fuel quantity also has no impact on the c g WARNING Both pilots we
18. ds level oil and cooling fluids leakage four stroke engine oil and engine filter f refer to engine manual cooling fluid level refer to engine manual hoses C C R Tadiators C C water radiator pressure cap refer to engine manual daily G C PITOT STATIC LINING SC O be lini Rate O y Gy iyi Spoilers airbrakes drive fine adjustment CAUTION Perform this operation only once after first 50 flight hours Check spoilers thoroughly for unobstructed smooth and even extension every 200 flight hours Schematic of spoilers airbrakes drive fine adjustment see next page for detailed description 16 Service manual pipistrel si Perform the adjustment as follows 1 Unscrew and remove the inner horizontal bolt of the airbrake s plate Do not lose any parts Lift the airbrake in order to make room for further operation 3 Unscrew and remove the bolt attaching the rod end bearing to the airbrake s plate lever Do not lose any parts Rotate the rod end bearing fine setting nut 360 so that the rod end moves towards the other end of the airbrake s box length of rod increases Make sure you secure this nut after turning it for 360 Grease the drive around the rubber sleeve inside the airbrake s box using rubber non agressive lubricant spray Once you have accomplished this repeat steps 1 3 in opposite order 3 2 1 Make sure you apply ad hesive e g Loc
19. e Airbrake Handle Assembly Airbrake Guidance Installation Venting the Hydraulic Brake Lines Wheel Brake Repair Nose Wheel Strut Assembly JEG 34 Wd Dei pue aJe d abuly au 3 008 inu 24 320 01 42 311001 951 V LE 9 28 upon Jaddn au 0 Wo Jog WO DL aWeS a44 UPUOJ JSNU UOI JEUIDU Di 111001 9 AO 10 aj se aues 344 aq JSNU JE Mau 344 JO JUDUA au Mau 344 UJIM Jed au OBUPU No 00 P SIYI 940191 JOU Og 711 jueuje e day po4usng 21 49A 4035A l4 si edoy Ienueuu IS oA1sidid si edoy Z S lenuew o gt 14405 Dunqu ssesp aJ0Jaq s Jed 1100 uo UOLJISOG WU ayy YJeW WAT Pd mE EENHEETEN bumesp au aac abuey 0 s Jed Nay mud Oe SI onbJoj Duiua ubi NV OdAl bumep 10410 aac abuey 01 sjJed MaN il uajje WW e st MAIS SILI U8JUBIJ WAN es WAN Durnquassesip aJojag s Jed um uo uorje40J JUDIU ay MU 344 430 04 E77 3101 951 Uyg 5 andso 00 03 ubt NY 10 buljquassesip 3036 51 yjog uo uoiJisod 344 6 Ajquiassy Jo odOld isjansidid MDS J Mads d cc WN 9 onbo4 Duiua ub Nv LY0dHI 11990 04 OLZ 3111 01 asn pue J M i ayy ose adejdo Big 00 SI 3214342 24 1 J MAIS UO 321494 2 2094 f J ro cc WN 9 0 3 0 0
20. e J siied u S9 Ienueui 83 185 IS 11sidid ESL 7 3S0U au 0 86 NIG SW PO CEG NIQ HAH 582 08 JnJ 3p0 04 7 01 2500 3 qru 09 UNL S S 5081 5 10 3000 00080 70 AOGE faq osa se Jnpa oJd JO UJ0J 95J9N9J e Duisn epad ayy pue sapuljAd ayy ojguasseoy 7 T Xa GUIMRJP UL PAGIISIP se suorpauuo 2 ejquiasseag 1 Val MOJISUN Of VVO UY IUO pue WUY IUO s AUNG ayy 440 SU011J3UU03 9504 10 90 3 003 7 ON SMOJIS aU Buinous q jepad au 440 dund apuro ayy aroway D M D5 JOU pue pa U sU Si yeys ay dund arne p i dy jo evs v Ua pue 25 a 440 dip Ayajes ay 07 SUOLJISO JRUJ Dun JOJ Je SJOJIAUUO at JJ0 S S0U at 34009 aJnpa oJd 0 N I K quuessy apis 11d 02 ayeig dund 2ijne apk 227 350 dU 0 JM DA 2 y DD d m Ayayes si edoy 7606 jenuew 2214435 99 67 Service manual pipistrel si Repairs Hydraulic Fluid Lines Assembly wheel side Reassembling procedure 1 Put part A on fhe hose 1 Put parts B and C on the hose J Put the larger O ring on part D and smaller O ring on part E Part B Far easier assembling use some grease l nsert part E into part D 5 Screw parts E and D into the brake cylinder Use one 16mm and one 14mm wrench Part C 6 Connect parts A and D WARNING The larger O ring and the groove on part D must fac
21. e the brake cylinder Larger 0 ring AA Ba Part D Smaller 0 ring Part E Note Pneumatic tire and wheel spat are not drawn for visibility purposes APPLY Wo aj yu 0 ay BU Cd e 6 app ayy Uo aseayes ayes ay 3714 6 lu 104 ayy Oui buds au pue goen Huds IY 20 apuepinh Bus ayy Joy ajo uu gg e 10 ase ayes au uo AY SEN 9 mapa BUIMEJP at aas aseaja aJes au aNouiaJ pue JaJoq c P UJIM axuepinb uk ayy Jo arejd aui e G iy DSPOJAJ AjajPS ayy k sil pu 291 GG L 7 Janoge Bumesp 344 395 pajquassy Dotaug aje uid quas pue aseaauAjajes pH OS wu Z JOJ aspayad Kjajes ay ap Ss esi I NT 9 UPDInD Duud ay Jo UOI ISO uid Ajunoas Jaddn ayy a quiassy 1 0 pu jou Bunquassy suen Huds e pue ajo uiu e 0 LI Y NDA 310 U 6 JU suits JANU ayxe aseajal Ajajes aJuepin6 Buds Uid Hum jed May bE NIQ 00 inu 344 0 171 SCHER Ajquiassy pueH 7 si edoy 7606 enueui 331 185 89 RT UMA SJ MJ UN XJ pue SOJU MUTE 6 geg M8J S au UO BUS VIPI ayy X14 HE AR eyuepinb ayini jeumpppe au 80 80 uone ei1su 33026110 si edoy 69 Ienueuu 0214435 IS 11sidid yo ypa dn uou IY 7 100 10 E 70 pue uoijisod jeuibiJo sil 0 peq sue ayy tin a WaJSAS ai U I0 OU SI 213 Jeu IOU NO U9UM 9 fl Japun 4nd GACY n l Jey 3
22. g the aircraft 11 27 Original Schematics 29 52 Original Repairs 53 70 Original Caution This manual is valid only if it contains all of the original and revised pages listed above Each page to be revised must be removed shredded and later replaced with the new revised page in the exact same place in the manual 4 Service manual pipistrel si PIPIETI zL This page is intentionally left blank pipistrel si Service manua Table of contents LGeneral Servicing the aircraft Schematics 6 Service manual pipistrel si PIPIETI zL This page is intentionally left blank pipistrel si Service manual 7 General General Introduction Notes and remarks Materials used in manufacturing process 8 Service manual pipistrel si General Introduction This manual contains all information needed for appropriate and safe servicing of Sinus ultralight motorglider models 503 582 912 and Virus 912 In case of aircraft damage or people injury resulting form disobeying instructions in the manual PIPISTREL d o o denies any responsibility All text design layout and graphics are owned by PIPISTREL d o o Therefore this manual and any of its contents may not be copied or distributed in any manner electronic web or printed without the prior consent of PIPISTREL d o o ITIS MANDATORY TO CAREFULLY STUDY THIS MANUAL PRIOR TO USE OF AIRCRAFT Notes and remarks Safety definitions used in the manual WARNIN
23. ghten or loosen the screw inside Make sure tightening or loosing you apply equal number of screw rotations at both sides To check if the steering clutch is stiff enough lift the tail and rotate the fork left and right At the end reattach both springs to the tubes again see Service manual for photos Venting the hydraulic brakes lining In case you notice poor braking action even when hydraulic brake levers are depressed fully it is most definitely necessary to vent the hydraulic lining To do so first unscrew the caps of small fluid reservoirs behind rudder pedals on one side of the cockpit and remove the inner seal cap At the side where there are no fluid reservoirs grab the whole rudder pedal and deflect it back fully so that it becomes level with the cockpit s floor beneath Now at the side where there are fluid res ervoirs jerk brake levers back and forth a couple of times this will push air bubbles towards the reservoir and out of the lining When convinced air bubbles are no more put seal caps back onto the reservoirs and screw the caps on as well Repeat the procedure for the other brake lever WARNING should you encounter any difficulties during this procedure or the air bubbles would not vent please consult the manufacturer or authorised service personnel for further instructions 18 Service manual pipistrel si Schematic of hydraulic brakes lining amp R O LC Poor braking action In
24. ight and weight of fuel do not influence c g or their influence is insignificant However baggage can influence the c g severely and may cause the aircraft to become uncontrollable Basic CG formulas and calculation The below instructions are valid for Virus Tail Wheel and Nose Wheel editions Read thoroughly Note also that the basic c g at 287 mm will be used purely as an example First weigh the aircraft according to the procedure described in this chapter and write down values of G1 sum of scale readings at main wheels and G2 scale reading at tail front wheel Then calcu late the position of c g in millimeters mm from the datum wing s leading edge at wing root For Tail wheel edition of Virus use the following formula G2 X b G2 X 4300 mm mm OS 110mm 287mm G G CG total total where G2tail is the scale reading at the tail wheel Gtotal is the sum of G1 and G2tail G1 G2tail a k a aircraft empty weight ais the distance from main wheel axis to wing s leading edge b is the distance between main and tail wheel axis For Nose wheel edition of Virus use the following formula CG EU a 3000 1020mm 287mm Gitar Gu where G2back is the sum of scale readings at both main back wheels Gtotal is the sum of G1 and G2back G1 G2back a k a aircraft empty weight ais the distance from nose wheel axis to wing s leading edge b is the distance from main wheel axis to wing s leading edge c a b
25. ion of fluff or fuzz Only wet sanding is feasible After sanding the area must be dried with a fan heater Aramid fibre has the tendency to take up humidity Therefore dry storage and drying the fibres prior to processing is necessary Aramid must be protected against UV rays before and after processing An aramid repaired area must be protected by a paint with UV protection Thin aramid layers can t be scarfed Only overlapping is possible Repair of the carbon fibre aramid fibre hybrid fuselage shell With this construction the repair method see mentioned above is not applicable Contact the manu facturer 22 Service manual pipistrel si Repairing small dents in a sandwich panel skin no cracks in the gelcoat Small dents can usually be removed by heating up to 60 to 70 C 140 158 F Use a hot air blower to heat the area of the dent The crushed foam will then spring back to its original form so that the dent will hardly be seen Final sanding with wet sandpaper grade 600 should finish the job In more severe cases one coat of gelcoat will remove all trace of the dent Outer skin finish Repairs should be such that the area is exactly level or only slightly higher than the surrounding skin surfaces Sand the hardened repair surface with dry grade 80 sandpaper Fill with Polyester filler let dry and sand with dry sandpaper When the surface is smooth sand the repair area and at least 5 cm 2 in of the surrounding gelcoat
26. l wires and hinges C C SC CABIN sc MES control levers instr panel seats C SC control levers free play C C SC instruments and pitot static check yearly glass surfaces clean attached C C SC rivet condition C sc safety harnesses and attach points C SC parachute rescue sys activation handle C SC wing connectors fuel electrical C C SC bolts and spar pins C SE wing main bushings control connectors SC UNDERCARRIAGE o tires C replace on condition or every 5 years main strut tail nose wh strut condition C C SC wheel axis and wheels C hyd brake lines C SC R brake fluid C SC R 500 hrs or 5 years brake discs SC R on condition wheel bearings C SC R tail wheel main bolt C R wheel fairings C C C tail wheel mounting bolt C SC CONTROLS LO every 200 hrs or yearly R general free play C C SC control stick C LO SC rudder pedals damage centered paral C C C rudder wire rope C SC difficult to reach bearings wings under cabin floor ce aileron elevator and rudder hinges SC equal spoiler extension undistributed m SC spoiler plate springs stiffness flap handle G SC elevator trim R cable every 500 hrs inas fl id L tri bili in f ina bol LO C R spoilers airbrakes drive fine adjustment see page 15 for detailed description 14 Service manual pipistrel si Servicing the aircraft first5 50 100 200 500 1 000 10 000 daily pours hours hours hours HOE EEN lll
27. n market also Pravilnik o ultralahkih napravah Republike Slovenije All parts and materials presented in all versions of Sinus ultralight motorglider and Virus 912 are also being used in glider and general aviation industry and all comply with aviation standards WARNING wHEN SERVICING OR REPLACING PARTS ALWAYS USE THE SAME MATERIAL AS USED ORIGINALLY SEE ABOVE 10 Service manual pipistrel si General PIPIETI zL This page is intentionally left blank pipistrel si Service manual 11 Servicing the aircraft Servicing the aircraft Introduction Repairs and spare part replacements Inspection periods Special check ups Fibre reinforced plastic repairs Example of flaperon FRP repair Example of wing FRP repair Weight and Balance 12 Service manual pipistrel si Servicing the aircraft Introduction This chapter determines handling and preventative maintenance terms Also recommended ground handling is presented Repairs spare part replacements and preventative maintenance All major repairs and spare part replacements MUST be done by authorised service personnel However you are encouraged to take care of preventative maintenance yourself This includes tire and wheel bearings replacements safety wire replacements door and safety harness replacement light bulb replacements fuel hose replacements battery servicing and replacement sparks and spark plugs replacements and air filter replacements
28. rts pull the noseleg out of the engine holder 72 Service manual ANLAR PIPIST L RA Pipistrel d o o Ajdov ina podjetje za alternativno letalstvo Gori ka cesta 50a 5270 Ajdov ina Slovenija tel 386 0 5 3663 873 fax 386 0 5 3661 263 e mail info pipistrel si www pipistrel si
29. skin of a sandwich panel Cut out the damaged area remove the gelcoat over the overlap area and 10 mm around the dam aged area Fill the damaged foam area with resin thickened with microballoons microballoons res in let harden Sand down With a round headed hammer tap the outer skin around the hole so that the foam is somewhat compressed therefore heat this area to ca 60 C 140 F Apply the new cloth Repair of outer and inner skin of a sandwich panel Additionally remove as much foam as is needed so that the entire damage to the inner skin can be seen plus enough undamaged inner skin as is required for overlapping If the inner skin still holds together sand properly and lay up the new cloth over it Insert a suitable cut piece of foam 1 2 mm thinner than the original glued in with microballoons resin Should the inner skin be so damaged that the above process cannot be use the inner skin fabric should be applied to the foam first and left to harden before inserting into the repair area Microballoons resin should once again be used For lay up of the fabric to the foam a layer of microballoons resin should be applied first to eliminate the formation of air bubbles Apply outer layers Special hints for processing aramid fibres The difficulties processing aramid fibre starts already when cutting the fabric Only with very sharp tools toothed scissors cutting the material is possible Sanding the fibres is not possible without format
30. t using plastic film or Styrofoam plates Filler For gluing the resin hardener mix should be thickened with chopped cotton fibres FL f add enough so that the resin no longer flows The surfaces to be glued should be wetted with non thick ened resin amp hardener before To glue foam pieces into place when repairing sandwich sections and to fill in irregularities and gaps etc around the repair Microballoons BJO 0930 can be used mixed with the resin hardener Application and mixing is the same as for the cotton flocks WARNING Only materials listed on page 9 should be used Only damage defined above should be repaired pipistrel si Service manual 21 Repair method for FRP Cut out damaged area roughen the surrounding area for the overlap required Repairs should be made such that bonding is wet over dry Specific details concerning handling and using fibre rein forced plastics can be obtained from various publications ie Petite Plane Patch Primer The use of Carbon fibre is the same as for glassfibre except that the carbon fibres should not be kinked and only the specified resins are used WARNING nil repairs should be tempered for 20 hours at 54 C before the next take off Repairs of the FRP shell Prepare the repair area as specified above Scarf the shell so that the individual layers of fabric can be seen like plywood layers Remove the gelcoat for at least 20 mm around the damaged area Repairing the outer
31. tics SYMBOLS glue am grease INSPECTION PERIODS o m pw ABBEREVIATIONS hand insp O Y 222 multi purpuse grease d Loctite 243 Loctite 648 UVM 243 648 vertical tail surfaces 71 deu puey x Se m 9 Jio t 2se916 sndund n nuu mm s gpouu IS snu s 300 re SNOLLVIA3H388V enj6 y KE KOM sel V 7 5001 030 NOLL2IdSNI 9 6 e E A 224 9 p u n s2ijeulau s 315100 jenuew 2214495 Zt WY Z i dan AN SSS NON Le Z SSSN SSS SS ASA RSS SS dsu puey x 89 213201 Erz 911901 6 osnd nd y nuu llo L 501 oseo1jb V ans o Ko 092 0 0 S1O8WAS SGOld3d NOLLD3dSNI SDIJEWAYIS Et lenuew 2 SS 2ALIP s yeiq 3I neip u 4 sayeig 176 16 d Id dled 8 SIM 16 d Md Zil 8 SAYO 195 16 d Wd L al poo9 02 1Y9 91 6 ei Bun 0697 HOPS 7 Ol waxpoog 7906 1VS 91 6 Mo 7606 meer amp o UJNJOJ n ou 216 xeyoy ul 3s42s janj SDIJEWAYIS jenuew 831 135 py BL d Od BG g SIAV M1 Iw B SAVO 2 76 d Md led B 253 E 16 d Ad 2142 A SVO e T 71 p 2
32. tite on all screws when reattaching Perform the procedure at the other airbrake as well In the end verify airbrakes for equal extension WARNING should the airbrakes not retract evenly apply step action 4 again for the air brake which remains higher when retracting Vital stages of spoilers airbrakes drive fine adjustment in pictures Spoiler s Airbrake s plate Horizontal bolt of the AB s plate Rod end bearin pipistrel si Service manual 17 Clicking noise overhead The wings are factory fitted to the fuselage to make a tight fit at approximately 20 Celsius When ex posed to low temperatures materials shrink Therefore flying in the winter or in cold temperatures you may encounter click clack like noises above your head The remedy for this unpleasant noises is to add washers typically of 0 5 mm thickness in between wing and fuselage Washers must be added both at rear and front bushings at one side of the fuselage only WARNING It is mandatory to consult the manufacturer or authorised service personnel before applying washers Adjustment of tail wheel steering clutch stiffness To adjust the stiffness of tail wheel steering clutch you need two allen keys a k a hex wrench inbus key On top of the wheel fork you will notice a ring with two tubes welded to each side with hex bolts inside First disconnect the springs at the tubes then stick an allen key into each of these tubes and ti
33. u 3 sJeq dei je juozuuou pue 7 ni inu 20 3001 04 111 1 41 Bun vey pue Jeg au 41 Ues o Jeu U9 V UWY papua xa Ue s IW PN lt Jeq de je uoziJou 1 2 081 199010 E17 110019 0 oy 25 at JO Us 02003 9 ue 0 080 1805 au uo Daul au DUE M HS au I 00 9 J9SU IQ JSNU ON Mo UP qil Ma DS all Jas SJE Uf h si wn Jeq deji qolla Wl 5 1 Ex a ER a 0010 0 Panel Juugz 7 Die 0 ue ous N 09 45 308 08 34 JO SJEG OPJ JE uoziJot au 0 008 23S ay Joj f U V WUG papua xe ue pue Nu au Joj fex Jet UWY Papua xa Ue ISN 3J0N sJeq de je uoziJot au UOJJ oj MAJIS DUE Qy NU at 2 0087 BENEKE JO Q 5285 PUL 0 SJNU 01 BU 2009 D vl t 006 AV ur JNU au up qi UY pue Jeg au OJULJUJJ SUL0 Kay jem uu pepuaJxe Ue 951 WW9E NEI 0 14005 ON 65 K quiessy 3 e193e1 uogede J si edoy jenuew e2lAJeS 179 Dun 443 3 ay saddo ayy 1511 si Dui JUDIJ 000 HMU au po 04 472 3101880 0 duu ai Jo JJ 0300 0 jobuelj de ay um ut du au 40 pauoyisag sapi UU 6 0 pue au 0 SJU JAM au pue OU A MA Et 01 IKS S86 NI 7001 abun uiu 7 rr H t yesi 5861 NI hans DUM H jo 38 ns adin uone eisu s1uBI AA 33102169 ssew uoJed
34. with wet sandpaper grade 400 Spray the repair area with 5 coats of gelcoat After the gelcoat has hardened sand with grade 400 600 and 800 wet sandpaper until the surface is smooth Polish with a power buffer electric drill or similar with cloth polishing wheel Apply a block of wax onto the rotating polishing wheel and then polish the repaired area Do not polish in only one direction and do not polish one spot for too long to prevent material overheating WARNING after repairing control surfaces the mass balance weights MUST be checked again with the values given in the maintenance manual Should the maximum values be exceed ed then the parts have to be replaced pipistrel si Service manual 23 Example of flaperon FRP repair WARNING po not under any circumstances attempt to repair damages greater than 50 mm in size on wing and or 20 mm in size on any control circumstances These require a treatment by a FRP professional Phase Carefully cut and remove the damaged foam Herex 3 mm in width of at least 20 mm around the damaged area Clean the area paying special attention that the inner fabric is immaculate This is of vital importance After you have cleaned and rinsed everything laminate the 20 mm area according to the laminate plan shown on the drawing below Flight direction Laminate plan for flaperon Cotton resin Microballoon resin Quther fabric 1x90070 glass 70g m2 1x66
35. x REV AS PIPIETI zL C Service and Repair Manual applies to Sinus 503 Sinus 582 and Sinus 912 equipped with Rotax 503 Rotax 582 and Rotax 912 engines all TW and NW versions and Virus 912 equipped with Rotax 912 engine all TW in NW versions Revision 1 updated 18th June 2012 This is the original manual of Pipistrel d o o Ajdov ina Should third party translations to other languages contain any inconsistencies Pipistrel d o o Ajdov ina denies all responsibility 2 Service manual Index of revisions Enter and sign the list of revised pages in the manual into the spaces provided below All revised pages should be clearly designated in the upper right corner of the page also any changes in page content should be clearly visible e g marked with a bold vertical line pipistrel si 2012 18th June 2012 Name of Revision no SN 2 Signature date Description revision date SE 1 18th June Tomazic Coates Checked all spelling in document Revision 1 US English pipistrel si List of valid pages This manual contains 74 original and revised pages listed below Service manual 3 Pages State Cover 1 Original Index of revised pages 2 Original List of valid pages 3 Original Table of contents 5 Original General 7 9 Original Servicin
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