Service and Repair manual - scuola di volo advanced aviation
Contents
1. NU 944 430 OF Eu 31 100 JUN 5 anbuoy 11 1 000080 1 106 uo 0 5 0 344 WEN Ajquiassy 13113001 0 OIHWA 74606 MIDS duu UN 9 nbio 0010310 DAN 4190104 6 V 7 5 ayy osje 3261091 Big 001 SI 221434 au J 10 92 913 911 M N E duu cc UN nbio uiua ubi LOAN ES 900 190001 au UJIM 25 3 0SJe 08 sapejq 19 90010 1101 uo g 3 5 3201091 nok J 7 JAUSEM 1601 WU 9 7 e 950 001516 ay gcc 0 D SI 3206150 ul JI 7 9221031 JOUSEM 650 0 WU 51 8 e JJOSUI LaCH uu SI Y 32006150 31 JI 1 y 32001510 30583 2007 Und 7 144 J 6 716 1031336113 3 110 131134010 OIHVA s edayy 6 jenuew 821 188 6 ud q ss li 105 310 01 JI burquesseaJ usuM jue jJodur SI SIY SOJ0Ud ayy WOU das ue nol se syed au yew Jajjadoud ayy BUNQUISSESIP 90 291392 aq UP milf ayy 50001830 ti 00 Ag 84 41X14 pue J gled qin 5011030 ayy ufi i nias su Aq pajeaji Axoda ayy ur ap P DSJE eq JSI aJay 3104 aues 344 OUI V Jed MONS 6 Dunquassesip 340400 SEM 11 SE 0111500 ales au Ul Jed 31014 9 sbuiJeoq Mau BUISN Aq 000 ay ajquasseay Jo adoJd ay UOJ y 0011638 pue USN DulJe3q 3AQUI AL 10 4 JJed 010104 g Jed 3 0081 J Ue nod 1 MI DSU2. s ur1 9519 2 s edayy 74606 jenuew 1760171 sasodund JO JOU DJE Jeds Von pue dul 077 4 ION 308 214 44D Japun o 3 210 ayy y nd pue 350 ay 3 0134 Ad Dululof MISUNA 1 Sued Isay 3150355251 40u 0 opp ay Up 133 au 0 pue 19402 BuLJeag pue JNU YO RO 05 3900 IY 3 003 1 ATU 09 UNL SI XSW 10 310101 01511 GUO AJU IYJ ISIP 3818 ay 9201020 pue 5113115 33 01 9594 BADWAY 7 1031 1 0 Z lenuew 8 5 74606 pipistrel si Service manual Repairs 12 Nose Wheel Strut Assembly Remove the nut washer rt ne upper side of the leg Engine holder nu 9 MN Remove the steering yoke Z Ls 5 Y S Remove the two screws Noseleq When removing all described parts pull the noseleg out of the engine holder PIPIETI L 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 pipistrel siol net www pipistrel si
3. 99 67 Service manual pipistrel si Repairs Hydraulic Fluid Lines Assembly wheel side Reassembling procedure Put part A on the hose 1 Put parts B and on the hose J Put the larger D ring on part D and smaller O ring on part E For easier assembling use SOME grease 4 Insert part E into part D 5 Screw parts E and D into the brake cylinder Use one 16mm and one 14mm wrench Dart 6 Connect parts A and D WARNING The larger O ring and the groove on part must face the brake cylinder Larger O ring x 2 de A Part D 5 Smaller ring Dart E Note Pneumatic tire and wheel spat are not drawn for visibility purposes apii uo 118 0 aj ay BU 0 ayy uo aseg aJ 5 2104 ayy 01 buds ay pue 32001110 Buds s H su 4 32uepIn 0 0 5 au JOJ 3704 uu g e JUL se r Jes au UO au aE 9 Mojag 1 3 au aas aseajaJ 9165 au aowa pue JaJoq WUE P YIM aXuepinb bulJds ayy Jo arejd ayy 5 XE ISPIJA 1915 ay SUN pue 3100 Gg P 310 Buimeup ayy 995 30 031730007 ave uid 85 pue aseajasAyajes Ip OS WW 7 Joy aseajaJ ALI aurpu c 3000110 001105 ayy JO 0 ud Ajnyas Jaddn ayy ayquassy 0 9 PUR 32060170 Buds JosUl pue bi URA WI aseapu jajgs ay uo pou jou 71 LLL 56 E qu su 1 ju uu cy 3 8 359313 0010
4. Repairs 53 70 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 PIPISTI L This page is intentionally left blank pipistrel si Service manua Table of contents General Servicing the aircraft Schematics 6 Service manual pipistrel si PIPISTI L This page is intentionally left blank pipistrel si General Service manual 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 IT IS MANDATORY TO CAREFULLY STUDY THIS MANUAL PRIOR TO USE OF AIRCRAFT Notes and remarks Safety definitions used in the manual WARNING Disregarding the following instructions leads to severe dete
5. Servicing the aircraft Fibre reinforced plastic repairs WARNING Do 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 Horiz ontal stablizer 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 tent using plastic film or Styrofoam plates Filler For gluing the resin hardener mix should be thickened with chopped cotton fi
6. i ndition clean firml C C hole pitatestatic lini C se Spoilers airbrakes drive fine adjustment CAUTION Perform this operation only once after first 50 flight hours Check spoilers thoroughly for unobstructed smooth and even extention 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 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 Unscrew and remove the bolt attaching the rod end bearing to the airbrake s plate lever Do not lose any parts YOO 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 5 Grease the drive around the rubber sleave 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 Loctite 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 sta
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13. ALAZ PIPISTI ZL Ss Service and Repair manual applies to Sinus 503 Sinus 582 in 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 updated in August 2005 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 Hint Online readers press F5 to see table of contents if it is not already displayed on the left hand side of the screen Use full option smoothing display in Adobe Acrobat family for best results Edit Preferences General Display All schematics and pictures can be zoomed for detailed look use Adobe Acrobat family zoom tool 2 Service manual pipistrel si 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 Name of Rev no revision date Signature date Description pipistrel si Service manual 3 List of valid pages This manual contains original and revised pages listed below Page numbering Index of revised pages List of valid pages Table of contents Servicing the aircraft 11 27 2
14. 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 Assemby wheel side Airbrake Handle Assembly Airbrake Guidance Installation Venting the Hydraulic Brake Lines Wheel Brake Repair Nose Wheel Strut Assembly JU 2500 pue 3110 aDuly ayy 1 nu 344 430 04 42 3111907 en Y 0011830 J3ddn 344 01 Ma DS 01101 UOJ 01808 34 3 WES ayy UCU 1574 auo ayy se aues ayy aq SMW Jeq mau ayy JO DUO Wy i 1 300 MAU ayy Jeq ay dun po 0 70 Jed SIU 3 01091 JOU OG E17 3111301 6 2003003210311 polusnd 2211136 3 s edayy jenuew 32 136 74606 S enueui 5 Dunquassesip aJoJaq S4Jed 6 uo 5 JUDIJ 344 26 WAN DUIME Jp J9UJ0 306 90080 8 igual ua 1300101 Bulu JUDI 0 ikay Ua JE uus e 350 9175 siu 9 0 m Dune dp 13440 39S tE 0 sped nay lt N 2 SI UNIX WAN 60003 340j3q 0 1109 uo UoLJE 04 JUBIJ au xuej
15. LO spoiler extension undisr m C SC LO flap handl C SC LO elevator trim _ S LO rings fl r r el trim lizer main fastening bol LO C R ilers ai dri j see page 15 for detailed description 14 Service manual pipistrel si Servicing the aircraft first5 50 100 250 500 1 000 10 000 daily hours hours 3 ENGINE ncl Rotax engine manual for il ngine maintenance information In addition to Rotax manual two stroke engines overhaul every 300 hours C four stroke engines overhaul every 1 500 hours C reduction gearbox oil R R cylinder head and exhaust pipe bolts C C two stroke engines gt 60 020U0 00944h8x engine cover screvvs C C 5 engine bearer C C SC engine bearer shk absorber and C SC R other rubber parts air filters C C CL R elect terminals joints and C C SC connectors hoses radiator mount rroroo manifold and exhaust silencer C C SC R exhaust pipe springs and fire protect C C SC f nin 5 R propeller pitch C C SC propeller balance C A e FUEL LINES O general leakage sle R water insi lator C C C ELECTRICAL WIRING 5C R battery C SC R ry flui C C SC C C instr panel wir n nn r NAV AC and LDG ligh C C fuses C C R pipistrel si Service manual 15 Servicing the aircraft first5 50 100 250 500 1 000 10 000 hours hours hours hours hours hours hour hermal switch pr re ctrl cover C SC C R PITOT STATIC LININ SC O instrumen i linin C SC instrument setting C C
16. N Y Jed MSN 1043 ay ul 3oy e Aq 390008 3y uo uoLJISOd 5 su V 5 ua qub 7 17 g Led up y masas Ja 10111501 ayy 120301321031 Duugag 13130010 s edayy 6S enuew 5 74606 NIC OSX9W 06 NI 9W NIC 06X84 5220 7 GZ 9 586 NIC SW NG SI ON 5 1325 J0 3010 00103110 UNZ SI IN 9125 Joj anbuo buius ubi INVLGDAN apis 110 1 JUL JE GG YJET JOJ 7 esf SC NIC ipi ap Ajquiassy 00 Yd popejg e s edayy jenueui 21135 09 74806 0110210 DUIMOJJOJ 33S hut dei MAN 0 501010 0 5 Je 0 1 MAN Te L Wed 103003210101311 3 0 S 011U0 7 s edayy 9 000 565 74606 pipistrel si Service manual Repairs 62 Wing Control s Drive Reinforcement part 2 Assembling the additional brace Screw Mbx35 DIN 912 For this screw use shorter spanner D LOCTITE 243 Lock nut M6 Pay attention to the rotation of the brace DIN 905 Y Use LOCTITE 243 fo lock the nut A Screw M6x35 DIN 912 Far this screw use longer spanner Additional brace a44 40 04 77 31110707186 jobejasnj au Saves 30611 SIYJ UN 17 311101 i 1 MON 7 86 N 9 0 abuiu dej mau ou buijquasse pue ulburu Juawa2 oyuray
17. 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 airbubbles Apply outer layers Special hints for processing aramidfibres The difficulties processing aramidfibre 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 formation of fluff or fuzz Only wet sanding is feasible After sanding the area must be dried with a fan heater Aramidfibre has the tendency to take up humidit
18. bres FL I 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 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 Carbonfibre is the same as for glasfibre except that the carbonfibres should not be kinked and only the specified resins are used WARNING ai 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 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
19. e area is located on the flap hinge the fabric used there is carbon fibre black colour 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 Phase Il 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 Do 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 diagonaly 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 Flight direction pipistrel si Service manual 25 Drawing of skin final repair Inner fabric 1x90070 dass 70q m2 X T umo 5 7177 a Quther fabric 1x90070 glass 709 m2 IxGGI6D carbon 160q m2 1 HEREX 3mm nev 1x90070 gloss 101 7 Paint 135 100160 carbon 1600 02 X Grind off 26 Service manual pipistrel si Example of wing FRP repair WARNING Do not under any circumstances attempt to repair damages greater than 50 mm in size on wing and or 20 mm in
20. e 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 Z pura A M htm 72 WV pipistrel si Service manual 19 Connecting Auxilliary power supplies Should you be unable to start the engine due to a weak battery auxilliary power supplies can be connected to help starting the engine Battery s amp Relay s location Battery black amp Relay top right wi wr 1 ADU a M d S c 1 D ha K Pi 35 Top left ni To connect an auxilliary 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 nip ple 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 The pilot must be in cockpit when starting the engine The person who will disconnect the cables after the engine has started must be aware of the danger of spinning propeller nearby 20 Service manual pipistrel si
21. erials 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 PIPISTI L This page is intentionally left blank pipistrel si Service manual 1 1 Servicing the aircraft _Servicing the aircraft HX m x i 1 3 Introduction Repairs and spare part replacements Inspection periods Special check ups Fibre reinforced plastic repairs Example of flapperon FRP repair Example of wing FRP repair 12 Service manual pipistrel si Servicing the aircraft Introduction This chapter provides information on servicing all models of Sinus ultralight motorglider and Virus 912 Repairs and spare part replacements 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 re placement light bulb replacements fuel hose replacements battery servicing and replacement sparks and spark plugs replacements and air filter replacements The table below indicates recommended maintenance periods see Service manual for detailed in
22. formation Inspection periods Table legend C Check up visual only check for free play and whether everything is in position DO IT YOURSELF SC Special check up measuring verifying tolerances and functionality DONE BY AUTHORISED SERVICE PERSONNEL LO Lubricating oiling lutbirace all designated parts and spots using proper lubricant DO IT YOURSELF CL Cleaning 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 O Overhaul first 5 50 100 250 500 1 000 10 000 hours hours hours hours hours hours hours WING AND TAIL SURFACES SC 0 rf n 1 1 ndition C SC daily pipistrel si Service manual 13 Servicing the aircraft dail fist 5 50 100 250 500 1 000 10 000 2 hours 5 hours hours hours hours hours FUSELAGE SC O rf nd str re condition C SC levator control rin SC SC ndercarri hin in a C SC 1 2 OIA C UN C UN C c D Lo e rf clean fety harn n h poin SC rach r ivation handl SEE SC C C SC se win nn rs fuel electrical C C brake wires 0000606747 SR brake drums 4 Rh J 4 wheel bearin C SC R il wheel main bol C R wheel fairings KKK il wheel mountin check and fasten every 50 landings ifficult to reach rings win nder in floor LO ileron elevator and r r hin SC
23. fyums un 3102415 11131 9nj 216 4 5 5 any SDIJELUSUIS Gy enueu 565 74606 74606 16 did 8 1 ww 6 4 2 0 Zlal 8 SAYD C mp Ir Upehpo0 Aot 315 9 9 oum 0081 1051000 ZADE 1VS 91 S 1 p lpoo9 8 2 5 9qny 685 XEloq 53 60 956 JENUCW 2 135 OV d JAd 6 H SAYI 0 0096 WAN Ww ZN De 2 u ii 0212 Z DUDJIIUJD GZ4 pP 0 0 WOOL 021 Z DUDHUUD 0 0 0092 0917 Z DUDJIUJD WWOZ7 Pp 0 uup 021 Z DUDJJULJD ug uuppj wwgg 011310 PUZIOP 703 53 60 956 Ly lenueu 5 ULU CL6 UH 3S4S 201002 53 74606 d JAd 6 B SAYI 1 d JAd 6x3 B SV 1 n 00 0 aqm xvioy 6 PAS YIM DOJOJUGI PI UIN 00J0 U3 UU Pays UM eg E mi 74606 gt ee Y y 4 r Y Y Y LL 1 1 I Pur oL r Ni l N he K nud I A pc d I J I 6 A SEA EN N SEN l V 7 M d 57 NL I I I Den dund JOM 0 685 XEloq 53 60 956 JENUCW 2 35 QT 49 Service manual pipistrel si Schematics Eng
24. ges 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 1 7 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 tipically 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 tt 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 stearing 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 tighten or loosen the screw inside Make sure thightening or loosing you apply egual 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 ma
25. il 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 flapperon FRP repair WARNING Do 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 Laminate plan for flapperon Cotton resin Microballoon resin Duther fabric 1x90070 gloss 709 m2 1x66160 carbon 1609 m2 X HEREX 5mm Inner fabric 1290070 glass 709 02 XK 1x92125 gloss 2809 m2 b 1x90070 glass 70g m2 X WARNING if the damag
26. ine lubrication system Rotax 912 pipistrel si Service manual 50 Schematics Throttle and choke drive Rotax 912 El S SE E E E S 2 S PLIN 410mm 620mm 6 420mm aDDmm 3 E S o gt 1200mm 1400mm 2 5 EE s 1 1 uU 000 CIE Had oz ITA ACTIOUN 810 wwz LZ 860 Wor W L DICH 868 027 TA DI 60 oz Wt ug 860 oz uo u E uW Wu 1 0 07 UUOOZJ 3 090 090 jubuo 9409 0 3 9S XEJOH SDIJELUSUIS s enueu 9311195 74606 00000 080 Oar um a7 1 1H9N SOULS y 0 s k Tl A fil Om 149 70d 5300125 79 520 AVN 0095 5 53 SDIJEWAUIS 74606 Jenueuu 83 188 ZG lo P zm 1 gt 5 ne 5 ado T TH MN O MM O O puio O 1 R NAL ox N ans o o 2i 1 31 3 3 393 6 53 36 G Jenuew 565 74606 54 Service manual pipistrel si PIPISTI L 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
27. nual 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 reservoars behind rudder pedals on one side of the cockpit and remove the inner seal cap At the side where there are no fluid reservoars 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 flud reser voars jerk brake levers back and forth a couple of times this will push air bubbles towards the res ervoar and out of the lining When convinced air bubbles are no more put seal caps back onto the reservoars 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 R al Poor braking action In 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 replacementnut may be tight ened incorrectly so that the brak
28. rioration 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 roving foam GFK paint heat resistant protection Metal parts used are tubes sheet metal rods cable bolts and nuts GG160 GG200 90070 92110 92120 91125 92140 92145 KHW200 NF24 75 kg m3 PVC 3mm PVC 5 mm PVC 8mm 3 mm 5 mm 7 mm of thickness gelcoat glass aluminium sandwich materials Fe0146 Fe 0147 Fe0545 Fe1430 AC 100 CR41 in LN9369 materials Fe0147 in Al 3571 materials Fe 1221 Fe 4732 C4130 Al 6082 CR41 in Al 6362 AISI 316 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 desinging manufacturing and testing complies with following regulations Bauvorschriften f r Ultraleichtflugzeuge des Deutschen Aero Club e V Beauftragter des Bundes ministeriums f r Verkehr JAR 1 microlight definition e JAR VLA certain sections for Slovenian market also Pravilnik o ultralahkih napravah Republike Slovenije All parts and mat
29. 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 N N N N _ N N N N N N Dulher fabric NA Microballoon HERE X 5mm Inner fabric pipistrel si Service manual 7 Phase Il Laminating Grind the outher fabric in a shape of a cone at least 25mm around the damaged area see drawing below and laminate only the grinded surface with fabrics as follows Two 2 pieces of 92110 and One 1 piece of 90070 Flight direction Grngoff the paint around the damage 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 9 110 glass 163q m2 X 0 0 10 glass 09 0 nit 6 grind off Tzu LL hale 9 Du
30. ther fabric O Mecroballoon HEREX 5mm Inner fabric Phase III 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 Example of undercarriage strut FRP repair WARNING Do 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 pipistrel si Service manual 29 30 Service manual pipistrel si PIPISTI L This page is intentionally left blank pipistrel si Service manual 31 Schematics Schematics Control levers Wings Tail surfaces Undercarriage Brakes Fuel system Engine cooling system Engine lubrication system Throttle and choke drive Electrical system pipistrel si Service manual 32 Schematics grease 7 oil Y hand insp INSPECTION PERIODS A Ed SD ABBEREVIATIONS Control levers Flap handle 1 gt deu puey x 33 1303 949 9120 E 097 se I8 sndund njnuu meme in SNOLIVIA24448V oseoJ8 en s y 00 d 07 o Ny 5109 5001832 NOILDAdSNI c olpuey de 6
31. y 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 aramidlayers can t be scarfed Only overlapping is possible Repair of the carbonfibre aramidfibre 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 Polyesterfiller 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 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 unt
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