SERVICE MANUAL for SELF LAUNCHING SAILPLANE
Contents
1. PIK 20 E Service manual 5 3 Calculations for actual empty weight and moment To calculate the actual empty weight and moment after a change in eguipment or ballast use the Sample Problem 5 5 as follows 1 Write down the empty weight and moment according to the last weighing document in approriate columns 2 Put the weight arm and moment of every single changed eguipment or fixed ballast weight down in proper columns Put sign for ad ded and sign for removed eguipment The moment you get by multiplying arm m x weight kg moment kgm 3 Addall weights and moments taking the signs into account and thus you get the actual empty weight and moment which can be recorded in the Flight Manual 6 4 5 4 Calculations for minimum and maximum pilot weight See sample Problem 5 5 Corresponding to the backmost allowed C of G limit the minimum pilot weight can be calculated as follows Mpmin 1 017 Mo 2 485 mo mp pilot weight including parachute kg mo sailplane actual empty weight kg Mo sailplane actual moment engine retracted kgm Empty weight and moment must not include fuel or water ballast be cause the C of G of the sailplane must be within the limits also with empty tanks both move the C of G backwards when emptying Note 1 If the sailplane s C of G is adjusted to be at the back limit with a pilot heavier than 70 kg the minimum pilot weight on the main placard must be changed accordingly Correspond2. E to ensure the right installation of the new belt Remove the belt Note 4 Lubricating the propeller drive gear bearings by pulling the belt and simultaneously turning the engine Ins Remove propeller and the toothed drive belt see Note 5 tall a new belt in reverse order Check the alignement of the Open the bearing nut by turning clockwise Use an extractor to ie gear position markings remove the gear and bearings Turn the gear while removing in If the belt feels very tight to instai check the right gear cen order not to defect the bearings ter to center distance Clean the bearings and check condition of bearings gear W K i and shaft Apply ball bearing grease and mount the gear 165 6 0 3 mm 6 520 0 012 in The gear can be warmed to 50 C 120 F to easy the E mounting Check that the back bearing is in right position The Note 6 Cylinder head bolts tightness back bearing protecting plate can be sealed by using e g sili Cylinder head should be tightened to 20 Nm 180 in pounds in cone glue KS the first 25 hour maintenance Dismount cooling baffles and When the gear is mounted check that the back bearing in the lower engine supporting plate ner ring is in the right position on the shaft ee Note 7 Decompression valves Mount the drive belt and run the engine for a while and re N The decompressien valves must be completely tight Crank the tighten the bearings when the gear has cooled down L 5 engine by hand and
3. choke decompression and throttle Remove the fuel feed line hoses from the carburettor and the return li ne hose from the connection tube at the carburettor hose Cover the free ends Disconnect the electric wires by opening the plug at the rectifier Dis connect the on line plug on the ignition switch cable at the root of the pylon Pull the cable through the pylon Disconnect the electric cable from the starter Disconnect the thermal lead by opening the two screws on the wire Remove the propeller Remove the bolt holding the lower engine shock mount Unscrew the nuts holding the upper engine shock mounts and remo ve the 45 kg engine 4 2 7 Trouble shooting 1 The engine does not start No fuel Check the fuel flow to the carburettors Check first the function of the fuel pumps With the electric fuel pump on the sound of the cirk ling fuel can be heard from the carburettors If there still is no smell of gasoline in the carburettors when starting the membrane needle valve situated in the membrane house should be cleaned When starting in cold weather the choke does not close fully No ignition spark Check the spark by removing the plugs and by con necting the plug to the cable Disconnect the ignition damping box cab EIRI KY Kis llinkatu 8 SF 15170 Lahti 17 page Il 23 PIK 20 E Service manual les Crank the engine by throwing from the propeller Try to move the propeller fast over the horizon
4. When properly installed and when clean the belt reguires little Note 1 Propeller bolts ja maintenance Propeller bolts tightness should be 15 to 17 Nm See Propeller If the edges are worn it can be due to misalignment Check Manual also the drive gear flange for straightness K When the belt is in right tension a 60 N force applied at the Note 2 Propeller blade condition and track midpoint of the span between the two pulleys should bend the For blade condition check see Propeller Manual Difference in N belt 2 5 mm 14 Ibs 3 32 in blade track should not be more than 3 mm measured 10 cm Excessive belt tension may cause excessive wear between from the blade tip at the trailing edge See Propeller Manual belt teeth A too loose belt may lead to jumping of teeth and N MSN cause vibrations Note 3 Play in propeller drive gear bearings Normally improper tension is a mark of some other defect There should be no play in the bearings when moving the pro improper gear center to center distance peller blade back and forward The bearings can be tightened KEN by adjusting the bearing nut located under the propeller The Changing the toothed drive belt nut is tightened when turning counter clockwise left Do not When the belt has worn too much it should be changed bend the same lock washer tab twice Do not overtighten the S Remove the propalan and Me Tange atthe sma Galt olive bearings gear Check that the position markings are aligned on the gears
5. When storing the sailplane for longer periods it is good to use silica gel in the trailer and tape the trailer airtight to keep the air dry It should also be checked that there is no water in the wing The water bags should be drained carefully and the sealings should be removed from the wing rib to get the air to circulate All bare metal parts should be protected with grease 4 2 Powerplant maintenance 4 2 1 General The inspection and maintenance of the powerplant and powerplant sys tem depend on the engine hours Safe operation can be achieved only by following the maintenance instructions given in this Manual Mainte nance periods are 25 and 50 hours see 4 2 2 Powerplant Maintenance and Inspection Lists The spark plugs must be changed twice during the 25 hours mainte nance period The maximum allowed spark plug life is 15 hours If the engine use is little at least the 50 hours maintenance must be done yearly Major overhaul period is 300 hours This overhaul is made by the engi ne manufacturer or by a manufacturer authorized workshop In connection with an engine maintenance at least the monthly check is recommended to be done to the sailplane The maintenance must be done by a person who at least has sufficient experience of automobile or two stroke engine maintenance work EIRI KY Kis llinkatu 8 SF 15170 Lahti 17 page II 13 PIK 20 E Service manual 4 2 2 Inspection guide lines a MOVAB
6. check the tightness With closed valves Do not overtighten the bearings Check that the gear is tur neva K the gap between the rocker axle and valve head should be 3 ning lightly X N mm 0 1 in The spring on the cable must return the operating Gee Sermce keter H208 3 M lever fully If not lubricate the cable and check spring tension EIRI KY EIRI KY Kis llinkatu 8 E 4 Kis llinkatu 8 SF 15170 Lahti 17 page 11 18 Revision 5 1011 80 ae SF 15170 Lahti 17 page II 19 PIK 20 E Service manual Note 8 Note 9 Spark plugs The spark plugs must be changed twice during the 25 hours maintenance period Maximum spark plug replacing period is 15 hours i e change spark plugs every 10 to 15 hours Suitable spark plugs are NGK B8ES and Champion N3 can also be used The gap is 0 4 to 0 6 mm 0 016 to 0 024 in The tightening torgue moment is 28 Nm 250 in pounds Note The spark plug protector must be locked to the engine Ignition damping box check Remove the spark plug and stick it on spark plug protector Turn on the ignition and crank the engine There must be a spark Change the polarity of the cables of the ignition dam ping box only for test When the damping box is in order there should be no spark Change cables back to right polarity Note 10 lgnition Checking the ignition timing The timing mark is on the starter ring gear The corresponding mark is the crankcase assembly joint on the exhaust manifold
7. cylinder EIRI KY Kis llinkatu 8 SF 15170 Lahti 17 page Il 24 PIK 20 E Service manual 4 2 8 External power If the battery is dead an external power source can be used when star ting the engine If the glider has a battery mounted in the engine compartment the engine compartment doors must be open to reach the batterry ter minals Disconnect or loosen the engine brake in order to be able to crank the engine with the doors open Use a 12 volt auxiliary battery and connect the terminals with the bat tery cables Be careful to connect positive terminal to positive and nega tive to negative Start the engine normally and disconnect the auxiliary battery when the engine is running Stop the engine when it is warm enough to start with its own battery and connect the engine brake When the glider has the battery mounted below the instrument panel it is also equipped with wires for a jumper cable connection An auxiliary battery can then be connected to the wires and the engine started as described above NOTE The engine must not be run without a battery because the alternator may then produce high voltage peaks 4 2 3 Preserving the engine When the engine is stored for longer periods without use over 2 months the engine must be preserved as follows warm up the engine spray 20 ccm 0 8 oz special preserving oil Shell Ensis BP Protec tive Oil Mobilarma 524 or equal to carburettor
8. side Connect a timing device lamp or buzzer to the ignition switch wires The timing is shown by the change in the light or buzzing tone The timing is right when the marks do not differ more than 2mm 0 08 in This corresponds to 19 1 5 BTC 2 07 0 25 mm Timing the ignition The timing of the both ignition circuits is normally made by ad justing the contact breaker gaps within the given limits The contact breakers can be reached from the oval holes in the magneto housing The armature plate is adjusted by the manufacturer and should not be turned PIK 20 E Service manual Note 11 If the timing can not be made by adjusting the contact brea ker gaps within the given limits inspect armature plate and the contact breakers and replace if necessary Change of contact breaker assembly Remove the magneto wheel by removing the nut and using the puller Mount new contact breaker assemblies Adjust the gap 0 35 0 45 mm 0 014 0 018 in as described above Clean the shaft end and threads and corresponding surfaces onmag neto wheel carefully Apply Loctite 221 or equivalent on the ta per and threads Mount magneto wheel and nut Tighten nut to 100 Nm 800 in pounds Check ignition timing Note In case of disaseembling the armature plate it is recom mended to mark its position on crankcase Muffler shock mounts The attachment points of the muffler are dampened with silico ne rubber shock mounts W
9. Ball type slip indicator Model Tachometer Model Fuel quantity indic Model Cylinder head temp indicator Model Safety belts Model EIRI KY Kis llinkatu 8 SF 15170 Lahti 17 page 11 39 PIK 20 E Service manual Part Weight Arm Moment kg m kgm Seat cushion Model Mirror for checking the propeller position Hour meter Model It Optional Equipment Tow coupling Model Variometer Model Compensating bottle Turn and slip indicator Model Variometer Model Compensating bottle Variometer Model Compensating bottle EIRI KY SF 15170 Lahti 17 page 11 40 PIK 20 E Service manual m kgm Artifical horizon Model Aux unit for Art h Accelerometer Model Radio Model Battery Model Oxygen Equipment Model Oxygen bottle Model Water ballast tanks Model Water ballast system Model Clock Model EIRI KY Kis llinkatu 8 SF 15170 Lahti 17 page 11 41
10. Clean and grease fittings marked with x in the Fig 4 2 4 3 2 Weekly inspection Clean the cabin and wheel box eg with a vacuum cleaner 4 3 3 Monthly inspection Make a careful daily check Inspect the cockpit and sailplane construction specially the belly wheel house doors skin and bulkhead bondings Check the play function and friction of all control systems Inspect the control mechanisms and attachments in the central fuse lage a i R ing washers can be inspected by removin i i Inspect the water tanks and assure that there is no water in the tie J Pa PIARC wings Inspect the tail wheel Clean and grease the tail wheel Clean the pitot static and compensation syst i Sign the monthly check in the log book j ap ET T air 0 3 bar 4 psi In the pitot line the use of an automobile in line fuel filter is recommended Inspect the instrumentation tubing for leaks Check the control surface deflections see Flight Manual 1 2 lt 1 4 Inspect the water tanks and ballast system for leaks When the sailplane is assembled check the locking of the airbrakes one at a time release the other airbrake operating rod The force on the handle has to be reasonable about 20 Ibs continued 4 3 4 Annual inspection and maintenance Inspect the composite constructions of the sailplane Inspect carefully the bondings for cracks and cracks in the paint The
11. EAND MAINTENANCE 11 12 relay 4 1 General care 11 12 S N s 20213 20214 4 2 Powerplant maintenance 11 13 20217 and up 4 3 Sailplane maintenance 11 26 Rev 3 11 10 Change in Jan 80 EIRI 4 4 After gear up landing and after rough landing 11 30 water tank 4 5 Balancing of control surfaces 11 30 volyme S N s 20247 5 WEIGHT AND BALANCE 11 32 and up 5 1 General 11 32 i 5 2 Weighing procedure 11 32 Rev 4 31 Revised control Mar 80 EN 5 3 Calculations for actual empty weight and moment 11 35 surfaces bataneing 5 4 Calculations for minimum and maximum pilot weight 11 35 instructions S N s 5 5 Sample Problem Actual empty weight 20257 and up and moment of the sailplane 11 36 Rev 5 11 19 Lubricating the Nov gO ae TEC drive 6 TRANSPORTATION OF THE SAILPLANE AND ings All s HANDLING ON THE GROUND 11 38 6 1 Transportation 11 38 6 2 Handling on the ground 11 38 EIRI KY EIRI KY Kis llinkatu 8 Kis llinkatu 8 SF 15170 Lahti 17 page ii SF 15170 Lahti 17 page iii PIK 20 E Service manual 7 EQUIPMENT EIRI KY Kis llinkatu 8 SF 15170 Lahti 17 page iv PIK 20 E Service manual 1 ASSEMBLY AND DISASSEMBLY 1 1 Preparation Three or even two persons can easily assemble and disassemble the PIK 20 E Before assembly prepare the wing assembly tool clean clot hes grease of mineral or synthetic basis Clean and grease all fitting sur faces bolts pins and control system connections EIRI KY Kis lli
12. LE PARTS for lubrication servicing security of attachment binding exessive wear safetying proper operation proper adjust ment correct travel cracked fittings security of hinges defective bearings cleanliness corrosion deformation sealing and tension FLUID LINES AND HOSES for leaks cracks dents kinks chafing proper radius security corrosion deterioration obstruction and fo reign matter METAL PARTS for security of attachment cracks metal distortion broken spotwelds corrosion condition of paint and any other appa rent damage d WIRING for security chafing burning defective insulation loose or broken terminals heat deterioration and corroded terminals e BOLTS IN CRITICAL AREAS for correct torque in accordance with torque values given in 4 2 5 when installed or when visual inspection indicates the need for a torque check b c EIRI KY Kis llinkatu 8 SF 15170 Lahti 17 page 11 14 PIK 20 E Service manual 4 2 3 MAINTENANCE AND INSPECTION LIST The maintenance and inspection list can be used to sign the completed items The crossed squares are not to be done Notes in the list refer to the Maintenance Instructions 4 2 4 Engine hours Reference No Item z PROPELLER Note 1 1 Check propeller bolts tightness and secure sa fety wires Note 2 2 Inspect blade and measure difference in track of blades Inspect propeller drive gear and teeth Chec
13. PIK 20 E Service manual SERVICE MANUAL for SELF LAUNCHING SAILPLANE PIK 20 E EIRI KY Kis llinkatu 8 SF 15170 Lahti 17 t z PIK 20 E Service manual SERVICE MANUAL for SELF LAUNCHING SAILPLANE PIK 20 E SERIAL NO REGISTRATION This sailplane must be serviced in compliance with this vu N K v Approved by National Board of Aviation Finland MA ja 4 lt EIRI KY JARS on N Kis llinkatu 8 O T SF 15170 Lahti 17 page i ANA e E si nl PIK 20 E Service manual PIK 20 E Service manual LOG OF REVISIONS Any revision of the present Manual must be recorded in the following table The new amended text in the revised page will be indicated by a II SERVICE MANUAL Page TABLE OF CONTENTS black vertical line in the left hand margin and the Revision No and date 1 ASSEMBLY AND DISASSEMBLY Il 1 will be shown on the bottom of the page 1 1 Preparation ll 1 1 2 Wing assembly Il 3 Rev Revised Description Date Signed 1 3 Tailplane assembly il 3 No Pages of Revision 1 4 Disassembly il 4 Edition 2 All pages New Edition Replaces previous 2 SYSTEM DESCRIPTION ll 5 edition dated 2 1 Powerplant Il 5 Nov 1978 2 2 Electrical system ll 6 Rev1 11 8 11 9 New fuel tank Jan 80 EIRI 2 3 Fuel system ll 8 S N s 20215 2 4 Water ballast 11 10 20221 and up 3 DAILY CHECK 11 11 Rev 2 1 7 Assembly of Jan 80 EIRI starter emergency 4 CAR
14. careful of overheating the surface When gliding in rain the performance of the sailplane is better if wax is removed The wax can be removed with waxremover car motor de tergent or by sanding paper number 600 until the glossy finish of the wings is removed Surface tension lowering agents as dish washing detergent can be used on the wing surfaces Use thin layer and polish it with dry cloth The canopy surface may be cleaned according to the following inst ructions 1 Use plenty of water to rinse the canopy surface 2 Wash the acrylic sheet with dish washing detergent or mild soapwa ter Use a sponge in spreading the soapwater Do not rub because dirt scratches the acrylic sheet 3 Grease and oil spots can be removed with kerosene and a soft cloth 4 Never clean with a dry cloth Note Never use gasoline benzine alcohol acetone carbon tetrachiori de lacquer thinner of glass cleaner to clean the plexiglass EIRI KY Kis llinkatu 8 SF 15170 Lahti 17 page ll 12 PIK 20 E Service manual In hot sunshine it is recommended that the sailplane is protected with a light coloured covering Prior to hangaring water drain holes shown in Figure 6 should be inspected for free outlets and cleaned if necessary When storing the sailplane in a trailer it is important to see that there is no water laying in the trailer Felt on fuselage and wing holders should be dry There must be ventilation holes in the trailer
15. cracks in the paint may be marks of defects in the structure Clean and lubricate bearings and hinges marked with o or x in Figure 4 2 with grease and check the play max 0 1 mm in hinges bearings and rod ends Protect the flap and aileron hinge pins with lithium base grease Clean and lubricate the fittings marked with x in Figure 4 2 and check the play max 0 1 mm Most of the items which needs greasing have lubrication holes They can be lubricated with a greasing press without removing the item Grease containing molybdenium sulphite is recommended All the rod ends and the main part of the bearing bushings are lined with PTFE or acetal and need no lubrication Other lubricate than lithium base gre ase must not be used in PTFE or acetal lined bearings EIRI KY Kis llinkatu 8 SF 15170 Lahti 17 page 11 26 EIRI KY Kis llinkatu 8 SF 15170 Lahti 17 page 11 27 PIK 20 E Service manual PIK 20 E Service manual 1 Elevator hinges 2 Tailplane fittings 3 Wing fittings and main wing pin Quick release locks Push rod guides Canopy locking Pedais Canopy hinges Airbrakes levers and locking system 10 Flap hinges 11 Wing tip wheel 12 Wheel and wheel brake 0 13 Landing gear e 14 Tail wheel 15 Rudder hinges O 16 Elevator quick release lock Hl ONEN FIG 4 2 Lubrication scheme x Clean and
16. emost C of G limit gives Mpmax 1 271 x 793 2 2 881 x 296 3 32 1 122 4 kg 2 2 Maximum weight of nonlifting parts gives Mpmax 328 296 3 2 x 61X 25 128 7 kg 25 kg corresponds to the maximum weight of fuel 2 3 Maximum allowed pilot parachute weight Mpmax 110 kg see Flight Manual 3 4 2 4 Result Mpmax 110 kg Thus maximum weight of nonlifting parts allows still about 18 kg eg for extra eguipment x weight of wings 2 x 61 kg can be used For actual weight see Weight and Balance Data Sheet PIK 20 E Service manual 6 TRANSPORTATION OF THE SAILPLANE AND HANDLING ON THE GROUND 6 1 Transportation For transportation the use of the special PIK 20 trailer is recommended If the sailplane is being transported in another vehicle the following should be checked Depending on the transportation van the sailplane may be fixed and supported by the following elements wing spar root shanks bus hings of the fuselage for the wing attachment bevel pins for the ho rizontal stabilizer attachment undercarriage wheel take care of the gear doors and the tail wheel Besides this the wing fuselage and horizontal stabilizer may be placed in appropriate holding clamps It is advisable to use nylon sleeves when using wing fitting points or horizontal stabilizer fitting points for the support Fix all control surfaces using gust locks Lock the air brake and flap rods using cords or rubbe
17. er Bond the new lining with epoxy glue The new lining is best to be fitted on its own place by leaving it in press with the engine doors open Avoid too thick glue layer Do not turn the engine until the glue is hardened Normal automobile brake lining material can be used Note 15 Lubricating the retracting mechanism In many hinges there are holes for a grease press Grease con taining molybdenium sulphite is recommended Note 16 Adjusting the idling Synchronize the movement of the throttle valves by adjusting the idling position screws and cables The mixture screws should be opened about a 3 4 turn 5 8 to 7 8 Warm up the engine and adjust it to run about 2000 rpm by turning the throttle idle position screws equally Try to make the engine run smoother by turning the mixture screws within the limits one at a time To check that the both eylinders are running equally open one throttle at a time and listen if this af fects the run equally When the idling is adjusted check the synchronizing of the throttles EIRI KY Kis llinkatu 8 SF 15170 Lahti 17 page II 22 PIK 20 E Service manual 4 2 5 Torque moments on the engine Spark plug 28 Nm 250 inch pounds Cylinder head nuts 20 Nm 180 inch pounds Magneto nut 100 Nm 880 inch pounds Toothed belt driving gear bolt 50 Nm 440 inch pounds Bolts M 12 50 Nm 440 inch pounds M 8 24Nm 210 inch pounds M 6 10 Nm 90 inch pounds 4 2 6 Engine removal Remove the engine controls
18. er 29 4 kW 40 hp 6000 rpm 100 km h 75 max cont power 22 1 kW 30 hp 5500 rpm 100 km h 75 max cont power 22 1 kW 30 hp 6000 rpm 135 km h Max continuous rotational speed 6000 rpm Max rotational speed 6800 rpm Idling rotational speed appr 2000 rpm Cylinder head temperature Thermoring under spark plug max 250 C allowed Fuel consumption 100 power appr 22 4 I h 75 power appr 17 2 1 h Propeller Propeller model 1 HO 11 127B 87 2 EP P127 87 Propeller diameter 1270 mm Propeller type Two blade wooden fixed pitch 2 2 Electrical system The 12 volt electrical system includes a 12 volt battery for starting and use during soaring The engine has an alternator in connection with the magneto The current is rectified and regulated by a Tympanium type rectifier attached to the propeller axle The electric starter has 0 4 hp and is geared type The electric fuel pump is a solid state type Electrical switches are located on the left side of the instrument panel and the fuses are below the switches The main switch operates the main contactor which is located near the battery in the engine com partment or below the instrument panel The starter knob operates the starter contactor which is situated be side the main contactor The ground terminals of the electric fuel pump and the starter contac tor are connected to the ground over a microswitch The engine positi on operates the microswitch and the switch is connected only when t
19. ertical plane 2 113 m 83 19 in forward of the first wing fitting tube foreward surface When the sailplane is leveled record the weight shown on each sca le Deduct the tare if any from each reading PIK 20 E Service manual Levelling means Slope 1000 28 FIG 5 1 Weighing W2 Scale Position on Symbol Scale Reading Tare kg kg Main wheel W41 pss Tail wheel W2 HA and moment kg m kgm W b 6 290 1810 13 Actual empty weight C ofG W 2 Cf is We is W1 W2 0 7 C of G position limits are minimum 2 267 m also with engine exten ded and maximum 2 443 m engine retracted If the Actual pilot weight range criteria is used by loading calcula te the minimum and maximum pilot parachute weights according to 5 4 _ 70 kg and 110 kg corresponding minimum and maximum pilot pa rachute can be used if the empty weight C of G corresponding actual empty weight is between the limits given in Figure 5 2 and in the C of G table EIRI KY EIR KY Kis llinkatu 8 Kis llinkatu 8 SF 15170 Lahti 17 page Il 32 SF 15170 Lahti 17 page 11 33 PIK 20 E Service manual C of G limits table m kg 340 330 320 310 300 290 2 600 2 650 ml Figure 5 2 C of G range with different empty weights m Minimum pilot 70 kg max pilot 110 kg incl parachute EIRI KY Kis llinkatu 8 SF 15170 Lahti 17 page Il 34
20. grease before assembly o Clean on annual inspection w Clean and grease on annual inspection FIG 4 1 Water drain v and pressure relief holes p EIRI KY Kis llinkatu 8 SF 15170 Lahti 17 page 11 29 EIRI KY Kis llinkatu 8 SF 15170 Lahti 17 page 11 28 PIK 20 E Service manual The locking position can be adjusted from the short control rod in the brake box by unscrewing the lock nuts and by screwing the rod 20 30 at a time both ends are right handed with different thread pitch The small inspection hole is for to have enough thread in the push rod To minimize the locking force the right airbrake should close some 3 mm before the left one Adjust from the quick release lock When clo sed there must be 3 5 mm space between the control lever and control stop in the cockpit Check the free play of the moving control surfaces to be less than the following 1 Elevator a stick locked 3 mm b the push rod in the fin locked 1 mm 2 Flaps stick and flap lever locked 5 0 mm from flap to flap 2 5 mm from aileron to flap 2 5 mm moving together both flaps up and down Repaint the damaged parts to protect the glassfibre construction Inspect the water drain and pressure relief holes see fig 4 1 Sign the annual inspection in the log book Note When the cockpit floor has been installed the free movement of all controls must be checked for all postitions 4 4 After gear up landing and after ro
21. he engine is fully extended EIRI KY Kis llinkatu 8 SF 15170 Lahti 17 page II 6 PIK 20 E Service manual FIG 2 1 ELECTRICAL SYSTEM EIRI KY Kis llinkatu 8 SF 15170 Lahti 17 Contact breaker Z n WL J 1 ED JJ Alternator Engine Cyl contactor Main contactor 26 Starter emergency g Fuel pump cs Revision 2 21 8 79 PIK 20 E Service manual The engine hourmeter and an optional barograph are operated directly by the alternator They cannot be switched off and are only operating when the engine is running The ignition switch is a dual switch and beside of the function as an ignition shut off it operates the tachometer and the fuel quantity gau ge The ignition line is also connected to the microswitch and the ignition is shut off when the engine is not fully extended The condition of the battery and the function of the alternator can be checked by the voltage meter The line between the red and black area corresponds to 12 volts 2 3 Fuel system The fuel capacity is 29 litres of which 28 litres are usable The fuel tank is situated behind the backrest Filler opening is on the fuselage between the canopy frame and the wing The fuel valve is situated on the tank The fuel guantity can be checked from the electrical guantity gauge The fuel tank vent in the cap should be inspected daily pr
22. hen mounting the muffler it should be checked that the attachment points are laying evenly on the supports when the muffler pipe is in the exhaust pipe Use silicone rubber sheets if needed Use proper distance sockets to have the bolt tight with pro per tension in the rubber Note 12 Engine shock mounts The condition of the shock mounts affects the vibrations of the engine The rubber bushings should be in proper condition change the bushings when needed The nut must always be tightened to the socket Note 13 Engine retracting mechanism The retracting crank in the cockpit is uppermost when the en gine is fully retracted and extended The locks on the chain prevent the crank going over these positions The force when retracting the engine fully and bringing the lever against the le ver lock in the chain must be less than 200 N 45 Ib If the for ce is greater examine the control system carefully before ad justing the chain EIRI KY EIRI KY Kis llinkatu 8 Kis llinkatu 8 SF 15170 Lahti 17 page Il 20 SF 15170 Lahti 17 page Il 21 PIK 20 E Service manual The extended position is adjusted with the lever against the chain lock and by tautening the safety wire Note 14 Engine brake When the engine doors are closed there should be about 1 mm 0 04 in gap between the brake lining and magneto wheel gear disc When changing linings remove the old lining and clean the surfaces carefully with grade 100 sanding pap
23. ing to the foremost allowed C of G limit the maximum pilot weight can be calculated as follows Mpmax 1 271 Mo 2 881 mo 32 1 The effect of the maximum fuel amount and extending of the engine has been corrected in the formula The amount of the water baliast does not affect the foremost C of G location EIRI KY Kis llinkatu 8 SF 15170 Lahti 17 page 11 35 PIK 20 E Service manual Note 2 In any case Mpmax cannot be greater than 110 kg The second limit is the max weight for the nonlifting parts total weight weight of wings and water ballast Thus Mpmax 328 kg actual empty weight including equipment and fixed ballast weight of wings weight of fuel 5 5 Sample Problem Actual empty weight and moment of the sailplane Sample sailplane Your sailplane Weight Arm Moment EES Arm VEN kg m kgm SEI ma x See Weight and Balance Data Sheet 1 Empty Weight x last weighing 2 Eguipment At inst panel 3 Eguipment in luggage compartm 4 Nose ballast 5 Ballast at tail wheel Actual Empty Weight EIRI KY Kis llinkatu 8 SF 15170 Lahti 17 page 11 36 t EIRI KY Kis llinkatu 8 SF 15170 Lahti 17 page 11 37 PIK 20 E Service manual For allowed pilot parachute weight we get 1 Backmost C of G limit gives for minimum pilot Mpmin 1 017 x 793 2 2 485 x 296 3 70 4 kg 2 Maximum pilot 2 1 For
24. ior to first flight that it is free from obstruction To avoid accumulation of the wa ter and sediment the fuel in the tank should be examined daily prior to first flight and after refueling by using the sampler cup provided to drain fuel from the tank The drain valve is situated on the left fuselage side The fuel filter is an inline paper filter type with 16 um filtration 0 6 microin and nominal capacity 60 l h e g Purolator 00610 The filter is in the baggage compartment after the fuel cock The filter should be changed every 25 hours or yearly The auxiliary electric fuel pump is a solid state type and situated down in the engine compartment The primary pump is an engine driven impulse type The carburettors are provided with a return line to avoid airbubbles in the fuel feed Inspect and clean the tank carefully every year EIRI KY Kis llinkatu 8 Revision 1 21 8 79 SF 15170 Lahti 17 page II 8 PIK 20 E Service manual FIG 2 2 FUEL SYSTEM Carburettors Engine fuel pump Fuel pump Fuel filter drive line uel cock Filler opening with vent cap N elk Fuel quantity gauge Fuel feed line Fuel tank Electric fuel pump A 8 Finger strainer Drain EIRI KY Kis llinkatu 8 Revision 1 21 8 79 SF 15170 Lahti 17 page II 9 PIK 20 E Service manual 2 4 Water ballast The water ballast is a four meter long nylon reinforced plastic bag in both wings fore of the main s
25. k play in drive gear bearings Grease drive gear bearings every 100 hours Inspect toothed belt and check tension Inspect belt driving gear and teeth Inspect belt driving gear lock plate bolts and lock wires Note 3 Note 4 Note 5 TET MEN KK ON DO fF W ENGINE Check for marks of leaks exhaust and fuel Clean the engine compartment as needed be fore other service actions are performed 1 Inspect engine air ducts and cooling baffles 2 Inspect carburettor box cover and intake net Note 6 3 Inspect crankcase and cylinders EIRI KY Kis llinkatu 8 SF 15170 Lahti 17 page 11 15 PIK 20 E Service manual Reference No ltem Note 6 4 Note 7 5 Note 7 6 7 8 Note 8 9 Note9 10 11 12 13 Note 10 14 Note 10 15 16 Note 11 17 18 19 20 A Note 12 Note 13 EIRI KY Kis llinkatu 8 SF 15170 Lahti 17 XX a KS i Check tightness of cylinder head bolts first 25 hours service Inspect decompression valves Inspect decompression mechanisms Inspect ignition harness condition Inspect ignition coils Change spark plugs every 12 5 hours Check ignition damping box Inspect engine controls and linkage Inspect electrical wiring Clean magneto housing and contact breakers Inspect contact breakers Check ignition timing Inspect magneto wheel and gear Inspect muffler attachment shock mounts and springs Inspect exhaust pipe Inspect starter In
26. ng a Fokker pin Deflect the elevator upwards and connect the elevator control rod 6 and secure it using a Fokker pin 2 1 Powerplant Engine description Type Rotax 501 Two cylinders in line two cycles Otto engine Air cooled Oil mixed to fuel lubrication Single magneto ignition Propeller driven with a toothed belt reduction 2 1 Electric starter Alternator Fuel pump with impulse drive 1 4 Disassembly The wings and horizontal stabilizer are removed in the reverse sequence to assembly Engine technical data Bore 2x 72mm Stroke 61 mm Displacement 496 7 cm Compression ratio 10 8 10 3 11 3 Ignition system Bosch Magneto Generator SCP2 12 V 140 Watt alternator Contact breaker gap 0 35 0 45 mm Ignition timing 2 07 mm 0 25 19 BTC Spark plugs NGK B8ES Champion N3 Spark plug gap 0 4 0 6 mm Carburettors Tillotson Membrane carburettor HR Main nozzle Gr 0 046 Direction of rotation Counter clockwise facing the engine drive shaft Starter Geared starter Fuel Min 96 octane RON Super gasoline or Aviation gasoline 100LL twostroke mix Lubrication Oil mixed to fuel lubrication mixing ratio 1 40 with Super twostroke oil Weight With muffler and electric starter 33 5 kg EIRI KY EIRI KY Kis llinkatu 8 Kis llinkatu 8 SF 15170 Lahti 17 page Il 4 SF 15170 Lahti 17 page II 5 PIK 20 E Service manual Engine operational data Takeoff power 31 7 kW 43 hp 6200 rpm 100 km h Max continuous pow
27. nkatu 8 SF 15170 Lahti 17 page II 1 PIK 20 E Service manual PIK 20 E Service manual 1 2 Wing assembly Figure 2 Insert the right hand wing ensuring that the wing bevel pins 1 and 2 are in the seats 4 and 5 in the fuselage Insert the left hand wing in the same way and watch that the bevel pins 6 and 7 go correctly into their seats Draw the wings together with the wing assembly tool and install the main wing pin and secure it using a Fokker pin It is necessary to lift the wing tips when using the assembly tool Connect the flap and airbrake control rods with quick release locks and secure them with Fokker pins Connect the water ballast hoses to the fuselage Install the venturi tube 1 3 Tailplane assembly Fig 3 Fig 3 EIRI KY EIRI KY Kis llinkatu 8 Kis llinkatu 8 SF 15170 Lahti 17 page II 2 SF 15170 Lahti 17 pagell 3 PIK 20 E Service manual PIK 20 E Service manual Insert the horizontal stabilizer by moving the trim and flap lever to the 2 SYSTEM DESCRIPTION foremost position and by lifting the leading edge up a little and by pushing the ball bearings 1 and 2 on to the pins 3 and 4 on the vertical stabilizer Pull out the locking pin 5 with a tool Fokker pin of the wing bolt and push the leading edge into place Remove the tool and push the locking pin in Ensure that the front fitting is engaged and secure the pin usi
28. par The capacity of one bag is 40 litres gi ving a total capacity of 80 litres The tanks are filled through the drai ning hole on the underside of fuselage The water bailast valve is opera ted by a cable The operating knob is on the left side auxiliary panel in the cockpit Filling instructions 1 Install the 2 4 m long filling tube with threaded filling connector into the outlet hole 2 Keep the wing in level Open the ballast valve and fill the system through a funnel Note 1 1 m is the maximum filling height distance from the funnel to the wing Higher pressure than this 0 1 BAR 0 1 kp cm can cause serious damages to the wing No pressurized filling system is allowed 3 When filled check the equal amounts wings stay level 4 If the amounts are not equal then keep the valve open and lift the heavier wing and wait for the water to flow Check if the wings are not yet in balance then shake the wing having the lightest tip down 5 If the balance is not achieved then you have to put the lightest tip down and let the water flow out through the filling hose 6 When the amounts are equal shut the valve and remove the filling hose Note 2 When maximum amount of water is needed it is recommen ded before filling to suck all the air from the system through the fil ling hose e g with a vacuum cleaner EIRI KY Kis llinkatu 8 Revision 3 21 1 80 SF 15170 Lahti 17 page Il 10 PIK 20 E Service man
29. r bands Take care of that no shifting jamming or deformation can arise and avoid entry of dirt and water into the sailplane Onan open trailer protect the canopy the area of the horizontal sta bilizer attachment and the wing roots and cover the pitot tube static pressure vents and the venturi tube hole Ensure that any component cannot move during the transportation For more information see 4 1 General care 6 2 Handling on the ground The easiest way to move the sailplane on the ground is to use the engi ne When moving it by hand the forward direction is recommended When moving the sailplane backwards the sailplane s steerable tail wheel must be locked by a pin to avoid damages Therefore it is recommended to lock the tail wheel by the pin also when having it in hangar remove it before taxying The use of the tail dolly makes the handling easier The sailplane shall not be pushed from the control surfaces EIRI KY Kis llinkatu 8 SF 15170 Lahti 17 page 11 38 PIK 20 E Service manual 7 EOUIPMENT The following list shows the eguipment items which may be installed in the PIK 20 E Items marked x are included in the empty weight recor ded in the latest weighing document and after changes in eguipment in the latest Weight and Balance Record in Flight Manual 6 4 kg m kgm Standard Equipment Airspeed indicator Model Altimeter Model Magnetic compass Model
30. s and stop the engine turn the engine by hand until the compression feels higher cover carburettors and exhaust pipe drain the fuel system Especially when the engine is stored during the winter period the condi tions can be rather corrosive without preserving When the engine use per year is little good care lengthens the life of the engine EIRI KY Kis llinkatu 8 SF 15170 Lahti 17 page Il 25 PIK 20 E Service manual PIK 20 E Service manual Inspect the ends of the rudder cables and especially the section going through the S tube Inspect the guide hose for wear Change cables after 1000 flight hours Inspect the Bowden control cables of the tow release wheel brake and the pedal adjustment and the push pull cables of the cabin venti lation and the water ballast valve Inspect the tow release coupling see Tost Tow Hook Manual Inspect the landing gear wheel brake bearings and wheel doors Check the play in the landing gear control mechanism It must not be over 10 mm when the gear is unlocked Check that the knuckle is slightly tightened when the gear is locked in the extended position Check that there is at least 10 mm space between the wheel and wheel doors when the gear is locked in the retracted position If the glider is provided with a spring loaded landing gear the spr 4 3 Sailplane maintenance 4 3 1 Before assembly
31. spect starter attachments and electrical cab le Inspect starter gear ENGINE ATTACHMENT AND PROPELLER AXLE Inspect propeller axle and attachments Check tightness of bolts Inspect engine pylon and attachment Inspect engine shock mounts Inspect retracting mechanisms page 11 16 PIK 20 E Service manual hours es aa Ee e Reference No Item 5 Inspect safety wire and attachment and tauten if needed 6 Inspect engine retracted position lock Note 14 7 Inspect engine brake 8 Inspect engine compartment doors Note 15 9 Clean and lubricate the engine retracting and door mechanisms every 100 hours FUEL SYSTEM 1 Inspect hoses attachments hose clips and in lets 2 Inspect fuel pump attachments and electric wires Change fuel filter Inspect fuel cock and drain valve Inspect fuel tank filler opening and ventilation O ah W Inspect electric wiring of the fuel tank ELECTRIC SYSTEM Inspect battery and check acid level Inspect battery ventilation Clean battery compartment Inspect battery terminals and battery attach ment 5 Inspect wires switches fuses and terminals After a maintenance check the function of the engine by running up s O N Note 16 EIRI KY Kis llinkatu 8 SF 15170 Lahti 17 page 11 17 PIK 20 E Service manual a PIK 20 E Service manual 4 2 4 Notes in powerplant maintenance list K Note 5 The toothed drive belt
32. tal and vertical positions If there is no spark with the old spark plugs try with new ones If there still is no spark it is possible that the grounding cables do not disconnect or there is a short circuit from the cable to the engine The cable connections can be defective on the coil Check the spark plugs cables and ignition system and see that con tact breakers are in proper condition The engine is flooding Use the decompression and crank the engine with the starter until there is a spark Or Use full throttle and crank the engine until it starts If the engine is flooding continuously turn the electric fuel pump on and look into the carburettor venturi If the gasoline is flooding clean the membrane needle valve 2 The engine is too hot The fuel nozzles are dirty The fuel flow is insufficient The fuel filter is dirty The cooling air ducts are damaged The spark plugs are defective The ignition timing is incorrect 3 The engine is not running with full rom The fuel flow is insufficient The carburettors are dirty The throttles do not open fully The choke does not open fully The spark plugs are defective The contact breakers are in inproper condition The decompression valves are not sealed The fuel pump drive line impulse line is dirty or leaking check with electric fuel pump The engine is running on one cylinder Try if both cylinders are hot If not check the ignition and fuel flow of the cold
33. ter having replaced the cockpit floor and flap and trim position plate it must be checkd that the stick moves freely with all flap positi ons EIRI KY Kis llinkatu 8 Revision 4 15 3 80 SF 15170 Lahti 17 page Il 31 PIK 20 E Service manual 5 WEIGHT AND BALANCE 5 1 General The sailplane has been weighed with the equipment marked with x in the Equipment list see Service Manual 7 The results of weighing by the manufacturer are given in the Weight and Balance Data Sheet supplement of Flight Manual After changing the equipment or fixed nose or tail ballast the sailplane must be weighed again to get the new actual weight and moment These changes can also be taken into ac count by calculations The result must be recorded in the flight Manual 6 4 The equipment list markings must also be updated 5 2 Weighing procedure 5 2 1 Preparation Ensure that all items marked in the sailplane equipment list are instal led in their proper location in the sailplane Drain the water ballast system and fuel tank Retract the engine Remove dirt moisture foreign objects such as rags and tools from the sailplane before weighing Weigh the sailplane inside a closed building to prevent errors in scale readings due to wind 5 2 2 Weighing Level the sailplane see figure 5 1 Levelling means Slope of top surface of rear fuselage between stations 4 5 m and 5 5 m 1000 to 28 tail down Datum V
34. ual 3 DAILY CHECK After the sailplane has been rigged and before the first flight of the day the daily check must be done The check list and checking procedures are given in the Flight Manual Normal procedures 5 1 5 5 It is important that the daily check is properly done It is possible that some defect has not been noticed during the monthly check or some thing has appered during the previous flights Especially after rigging it is important to check that all guick release locks are properly connected and secured It is best to sign the assemb ly in the log book Cracks in paint may be marks of defects in the structure and all at tachments should be checked carefully The powerplant with retracting mechanisms should also be checked for cracks and loose bolts and wear EIRI KY Kis llinkatu 8 SF 15170 Lahti 17 page Il 11 PIK 20 E Service manual 4 CARE AND MAINTENANCE 4 1 General care The outside of the sailplane can be kept bright and smooth simply by washing with water and mild soap Avoid abrasive or harsh detergents Rinse with clean water and dry with terry cloth towels or a chamois It is always best to keep a good wax layer on the paint to protect the surface from humidity and dirt and also to minimize the bug building on the leading edges during flight A whole plane polish once a year is recommended with car polishing agent or solid polishing wax for acrylic or plastic with polishing machine be
35. ugh landing If you make a gear up landing inspect the skin and ribs of the front fu selage and clean and inspect the tow coupling After a rough landing inspect the main landing gear and tail wheel ca refully If the tail wheel is damaged inspect also the rudder hinges Note If the sailplane is damaged the structural repair schemes are gi ven in the PIK 20 E Repair Manual 4 5 Balancing of control surfaces Always when the control surfaces have been repaired or repainted the balancing of the control surfaces must be done EIRI KY Kis llinkatu 8 SF 15170 Lahti 17 page 11 30 PIK 20 E Service manual Remove the control surfaces while balancing The balancing is made by suspending the control surface at the hinges and then measuring the weight at the surface trailing edge with a sensitive scale The control surface must be horizontal in order to get a correct result The moment product F a and the total mass m must be within the given limits Moment Total mass kgmm kg Aileron 46 61 Flap 119 154 Rudder 52 68 Elevator 41 51 FIG 4 3 Balancing of the control surface m total mass of the control surface kg F the scale reading kg a the distance between the scale supporting point and the hinge line mm F a moment kgmm Note The given moment of the rudder balances also the tail wheel That is why a tail wheel of the same weight as the original wheel must be used Note Af
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