Maintenence Manual
Contents
1. 6 kg Go kg js kg pipistrel si Weighing form NOSEWHEEL Service manual 37 Weight and balance Weighing point and symbol Scale reading Tare Nett right main wheel Gp left main wheel GL nose wheel G2 total G Gp GL G2 a 10 0 t Co Determination of CG Weight kg Weight s lever arm cm Torque kgcm Remarks Basic cfg emtpy 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 moment 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 leading edge Then sum up all momentums and divide the sum by the new total weight WARNING Regard to the POH for the specific aeroplane for allowable C G limitations 38 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 9 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 g2. connectors hoses radiator mount 16 ae bSC exhaust muffler aC aC bSC bSC exhaust pipe springs and fire protect aC bSC cR throttle choke propeller wire drive bSC cR ENGINE CONTROL do choke and throttle lever wire ropes __ 3C bSC levers aC bSC PROPELLER AND SPINNER bSC _ surface condition fastening bolts En propeller bushings bR propeller pitch bSC propeller balance bSC FUEL SYSTEM CO every 1000 hrs or 5 years general leakage aC bSC water inside gascolator dirt and gascolator filter aCL bR wing fuel tank caps aC fuel tank caps o ring level every 500 hrs or 5 years fuel valves and leakage aC ELECTRICAL WIRING cR battery aC aC bSC battery fluids aC 050 instr panel wires and connectors AC and LDG lights aC aC fuses aC aC pipistrel si Service manual 23 Servicing the aircraft dail first5 50 100 200 500 1 000 10 000 hours hours hours hours hours hours hours OIL AND WATER LINES CO every 500 hrs or 5 years oil and cooling fluids level and cooling fluids leakage four stroke engine and engine filter first 25 refer to engine manual cooling fluid level refer to engine manual hoses aC aC R radiators water radiator pressure cap refer to engine manual PITOT STATIC LINING bSC cO
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4. 159351414 pipistrel si Service manual Repairs 66 Wing Control s Drive Brace part 2 Assembling the additional brace Screw Mx 35 ang Zn For this screw use Shorter spanner 079 Screw M6x35 DIN 912 For this screw use longer spanner Additional brace gt Lock nut 6 Pay attention to the rotation of the brace DIN 985 Use LOCTITE 243 to lock the nut eu po 04 0 3111201 950 1 jadejasn aj Save 5 Uoi Ua V 17 3o q g Jaysem 7 86 94 11000 abuly dej Mau Duijquasse pue Duibueu jueuja240Juray 4 9 159351414 15 51414 inu 420 04 2 3111201 950 7 uey pue Jeg au 41 Jasur 0 uus papua xa Ue 951 15001 344 Jo sa bue jeuoijeurpap 1959 01 AJessaJau 1 Sueq au Bujquassead 3344Y 1 1909 429 01 211071404 446 ZL UNG SI GW SABIS anbuo NV Od N 54nu 344 490 04 esc 3111001 9s N 00 01 je 0021000 pue 92119 210135563 6 N 04 MB S au 10 Ady papua xa ue pue ay Jo Aa uiu papualxa Ue asp 340 3260 95 9 uo au au 192219 190249 au payJasul 57 94 344 101985 se sJeq de 344 OUI pj JNU PUL MAIS IY
5. pipistrel si Service manual 11 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 acrylic paint firewall glass aluminium sandwich Medal parts used are tubes materials Fe0146 Fe 0147 Fe0545 Fe1430 100 CR41 LN9369 sheet metal materials Fe0147 in Al 3571 rods materials 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 of a minimum 1 875 All parts and materials used in Pipistrel LSA aircraft are also being used in the glider and general aviation industry and all comply with aviation standards 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 EASA CS 22 certain sections EASA CS VLA certain sections for Slovenian market also Pravilnik o ultralahkih napravah Republike Slovenije WARNING wHEN SERVICING OR REPLACING PARTS ALWAYS USE THE SAME
6. 0 Z OISW 01 PA 109 9 ZNO 3 5 0 6 0590 XAYOIONS 7015 OL PA 103 009 rur 25 01 0 Od 0897 70157 01 02 09 507 3 5 21 0 16 Ad Clad B SO 2 wag B SIN 2 wuy 16 d Nd Tlel 4 SO uuo 1 WZA 610 p00 Mot 2 6 2 6 9 140009 35 21 5 199 pd bi 0097 901015 ZLOISY 8 XI PONS 07 0097 PRPS OSV 01 7020 une ed inafpoog 3 5 1 92 0690 ZLOISY B t UE 1ubua 1 01 wupori Wu 4 216 93545 jon4 ZG 53 Service manual pipistrel si Schematics Throttle and choke drive Rotax 912 howden cable za plet 1 2mm 1 2mm 1600mm 1670mm za plet 1 2mm 1 2mm za plet 1 2mm 1 2mm za plet 1 2mm 61 2mm za plet 1 2mm 61 2mm 1200mm 1400mm PLIN COK m EET 1600mm 1670mm 1 n LIE EIL 222 al ka ic E 5 gt 8 1200 1400 2 d JAd 8 5 2 Add Lied LEL LEZ 0
7. General Servicing the aircraft Schematics 8 Service manual pipistrel si PIPIETI zL This page is intentionally left blank pipistrel si Service manual 9 General General Introduction Notes and remarks Materials used in manufacturing process Assembling and disassembling the aircraft Keeping your aircraft in perfect shape 10 Service manual pipistrel si General Introduction This manual contains all information needed for appropriate and safe servicing of Sinus 912 LSA Virus 912 LSA Virus SW 80 100 LSA In case of aircraft damage or people injury resulting form disobeying instructions in the manual PIPISTREL LSA s r l denies any responsibility All text design layout and graphics are owned by PIPISTREL LSA s r l 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 LSA s r l 5 MANDATORY TO CAREFULLY STUDY THIS MANUAL PRIOR TO USING SERVICING OF THE AIRCRAFT Notes and remarks Safety definitions used in the manual WARNING 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 NOTE An operating procedure technique etc which is considered essential to emphasize
8. 8y9 839207 sui pueu Me RES 9 v 8 osndund njnui memes SNOILVIASYAdaV eseaJ 3 4 WOW 409 so2ejans SIO WAS NOILO3dSNI 5242419426 QY 15191351910 49 Service manual pipistrel si Schematics SYMBOLS glue INSPECTION PERIODS px lt gt B grease ABBEREVIATIONS oil multi purpuse grease hand insp Loctite 243 wi Loctite 648 48 Lose vertical tail surfaces 7 rea 89 339207 5 pue us K 9382071 9529 8 esnd nd nnuu m ow anys y 5 NOILO3dSNI 92IAJ9S 06 IS Joa1sidid 22272572 2 222227 WA WN lt lt 655 zs SS lt lt ar 555555 gt 8y9 apoq mes 899 91020 d lo 95298 i n 19 21 n p u 7 SNOLLVIA3388V oseoJ8 Name eni y 4 0 Ny gt SQORI3d 59 5242419426 S Jenueui 15191351910 15 51414 BL d Jd 6 0 9 SIAV 82 Not 5 7 792
9. MATERIAL AS USED ORIGINALLY SEE ABOVE 12 Service manual General pipistrel si Assembling and disassembling the aircraft CAUTION Prior to each assembling or disassembling action Virus SW must be placed inside a closed space Under no circumstances attempt to assemble or disassemble any parts of the aircraft in the sun or at temperatures higher or as high as 20 for you will not be able to assemble certain parts Assembling the wings Three people are needed to assemble the wings to the fuselage First block all three wheels for the fuselage to stay in position Clean and grease the main wing pins and in sertion openings Inside the cockpit set the flap handle to neutral position and leave the spoilers handle hanging down freely Make sure you have all bolts nuts washers and span ners needed at a reach of a hand Lift one wing half one person at each end and bring it closer to the fuselage While the two are holding the wing half high up the third person directs their movement to put the wing s main spar into the opening on the adjacent side of the fuselage As the wing is about 10 cm away from its final position fit the electrical cables fuel hose and pitostatic lines through the opening Now push the wing half into its final position slowly The person closest to the fuselage must make sure the spoiler and flap connectors have fitted into adequate fuselage fittings prop erly At the same time the person
10. 0 6 2 Original 0 1 4 Original 0 6 3 Original 0 1 5 Original 0 6 4 Original 0 1 6 Original 0 6 5 Original 0 2 1 Original 0 6 6 Original 0 2 2 Original 0 7 1 Original 0 2 3 Original 0 7 2 Original 0 2 4 Original 0 7 3 Original 0 2 5 Original 0 7 4 Original 0 2 6 Original 0 7 5 Original 0 2 7 Original 0 7 6 Original 0 2 8 Original 0 7 7 Original 0 2 9 Original 0 7 8 Original 0 2 10 Original 0 7 9 Original 0 2 11 Original 0 7 10 Original 0 2 12 Original 0 8 1 Original 0 2 13 Original 0 8 2 Original 0 2 14 Original 0 8 3 Original 0 3 1 Original 0 8 4 Original 0 3 2 Original 0 8 5 Original 0 3 3 Original 0 8 6 Original 0 3 4 Original 0 9 1 Original 0 3 5 Original 0 9 2 Original 0 3 6 Original 0 9 3 Original 0 3 7 Original 0 9 4 Original 0 3 8 Original 0 9 5 Original 0 4 1 Original 0 9 6 Original 0 4 2 Original 0 9 7 Original 0 pipistrel si Service manual 5 Log of Effective Pages continued Page number Page Status Rev number number Page Status Rev number 9 8 Original 0 9 9 Original 0 9 10 Original 0 9 11 Original 0 9 12 Original 0 9 13 Original 0 9 14 Original 0 9 15 Original 0 9 16 Original 0 9 17 Original 0 9 18 Original 0 9 19 Original 0 9 20 Original 0 10 1 Original 0 10 2 Original 0 10 3 Original 0 10 4 Original 0 10 5 Original 0 10 6 Original 0 Checklist Original 0 6 Service manual pipistrel si PIPIETI zL This page is intentionally left blank pipistrel si Service manua Table of contents
11. 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 25 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 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 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 equal number of screw rotations at both sides To check if the steering clutch is stiff enough lift the tail and rot
12. b 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 R E C2 CG 100 287mm 29mm 100 28 4 908 where CGmm is the position of CG in milimeters mm R is the difference between wing s leading edge and leading edge 29 mm MAC is the Mean Aerodynamic Chord 908 mm for Sinus it is 869 mm pipistrel si Service manual 39 Schematics Control levers Wings Tail surfaces Undercarriage Brakes Fuel system Engine cooling system Engine lubrication system Throttle and choke drive Electrical system ajpuey 4 10 5 0 7 SA9A9 043409 s neuleu s Op IS Joa1sidid 41 Service manual pipistrel si Schematics Flap handle 2 SYMBOLS INSPECTION PERIODS px lt gt glue grease ABBEREVIATIONS nd insp oil 4 hai 9 a 50 9 5 5 ag 55 2 0 UVM 648 7 42135102340 d 124 177 952948 esndand njnui 7mm WAN SNOILVIASYAdEV oseo48 0 ans y 4 iA SIOEWA IS oAsidid 5242419426 jenuew ZY puey 8 9 231020 879 gpg m
13. instrument to pitot tube lining instrument setting pitot tube condition clean firmly att aC aC aC aC whole pitot static lining 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 24 Service manual pipistrel si Perform the adjustment as follows 0 Unscrew and remove the inner horizontal bolt of the 5 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 3602 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 airbrakes for equal extension WARNING should the airbrakes not retract evenly
14. main axis nut especially after a wheel and or axis replacementnut 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 27 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 Top left nipple c positive wire here Exhaust connect negative wire here 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 rne 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 28 Service
15. rudder Deflect the rudder to one side fully and unscrew the nut of the bolt with which the rudder is at tached to the bottom hinge This is the bolt located in between the central bolt axis of rotation and the bolt holding the metal ropes DO NOT touch these two bolts unscrew the nut of the middle bolt ONLY Now deflect the rudder to the opposite direction and repeat the up stated procedure After both bolts have been unscrewed lift the rudder and detach it first from the bottom then from the top hinge Schematic of rudder dis assembly 16 Service manual pipistrel si General Keeping your aircraft in perfect shape Precautions 1 Eliminate the use of ALL aggressive cleaning solutions and organic solvents also the window cleaning spray benzene acetone aggressive shampoos etc 2 If you must use an organic solvent acetone on small areas remove certain glue leftovers or simi lar the surface in question MUST be polished thereafter The only section where polishing should be avoided is the edge on the wing where the sealing gasket is applied 3 When flying in regions with a lot of bugs in the air you should protect the leading edges of the airframe before flight propeller wings tail with Antistatic furniture spray cleaner Pronto transpar ent manufacturer Johnson Wax or anything equivalent Worldwide approximate price is only 3 USD 3 EUR for a 300 ml spray bottle Using such spray do not appl
16. service notice tracking To log into the Owner s section receive relevant updates and information relevant to Service Airworthyness go to www pipistrel eu and log in the top right corner of the page with Username 1 Password ab2008 pipistrel si Index of revisions Service manual 3 The table below indicated the Revisions which were made from the original release to this date Always check with your registration authority Pipistrel USA www pipistrel usa com or Pipistrel LSA s r l www pipistrel eu that you are fammiliar with the current release of the operation relevant documenta tion which includes this MM Reason for Affected Designation Mae Release date Issuer Revision pages Tomazic Original 25 October 2010 Pipistrel LSA s r l 4 Service manual pipistrel si Log of Effective Pages Use to determine the currency and applicability of your POH Pages are affected by the current revision are marked in bold text in the Page Number column Page number Page Status Rev number Page number Page Status Rev number Cover Original 0 4 3 Original 0 i 1 Original 0 4 4 Original 0 i 2 Original 0 4 5 Original 0 i 3 Original 0 4 6 Original 0 i 4 Original 0 5 1 Original 0 i 6 Original 0 5 2 Original 0 i 7 Original 0 5 3 Original 0 0 1 Original 0 5 4 Original 0 0 2 Original 0 5 5 Original 0 1 1 Original 0 5 6 Original 0 1 2 Original 0 6 1 Original 0 1 3 Original
17. 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 IN mE _ Microballoon vw HEREX 5mm fabric Inner fabric pipistrel si Service manual 35 Phase 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 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 2x92110 glass 1639 m2 X 1 90070 glass 10g m2 grind of Duther fabric 7 HEREX 5mm Inner fabric Phase III Grin
18. sunshine Machine polishing requires more skills and has its own particularities therefore it is recommended to leave it to a professional Cleaning the Lexan transparent surfaces It is most important to use really clean water no cleaning solutions are necessary and a really clean drying towel always use a separate towel ONLY for the glass surfaces Should the glass surfaces be dusty remove the dust first by pouring water not spraying and gliding your hand over the surface Using the drying towel simply glide it over the surface then squeeze it and soak it before touch ing the glass again If there are bugs on the windshield soak them with plenty of water first so less wiping is necessary Ultimately dry the whole surface and apply JT Plexus Spray 10 USD 10 EUR per spray or at least Pronto antistatic transparent spray and wipe clean with a separate soft cotton cloth 18 Service manual pipistrel si General PIPIETI zL This page is intentionally left blank pipistrel si Service manual 19 Servicing the aircraft Servicing the aircraft Introduction Priviliges Line maintenence Inspection periods Special check ups Fibre reinforced plastic repairs Example of flapperon FRP repair Example of wing FRP repair Weight and Balance 20 Service manual pipistrel si Servicing the aircraft Introduction This chapter determines periodic line maintenence and handling of various items T
19. to the MM occur the revision level on the effected pages is updated When two pages dis play the same page number the page with the latest revision shall be used in the MM The revision level on the Log Of Effective Pages shall also agree with the revision level of the page in question Alternative to removing and or replacing individual pages the owner can also print out a whole new manual in its current form which is always available from www pipistrel eu Revised material is marked with a vertical double bar that will extend the full length of deleted new or revised text added to new or previously existing pages This marker will be located adjecent to the applicable text in the marking on the outer side of the page The same system is in place when the header figure or any other element inside this MM was revised Next to the double bar there is also a number indicative to which revision the change occured in A list of revisions is located at the be ginning of the Log Of Effective Pages Warnings Cautions and Notes Safety definitions used in the manual WARNING 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 NOTE An operating procedure technique etc which is considered essential to emphasize Online updates
20. 0070 glass 709 2 WARNING if the damage 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 32 manual pipistrel si Phase 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 Ill 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 33 Drawing of skin final repair Inner fabric 1x90070 gass 709 3 HEREX Som ek 5m E 3mm Duther fabric 1x90070 glass 709 m2 190070 gloss 7Dg m F 1xCGI6D carbon 1604 2 X Pont 135 1 06160 carbon 160g m2 Grind off 34 manual pipistrel si Example of wing FRP repair WARNING po not under any circumstances attempt to repair damages greater than 50 mm in
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22. 9529 48 esndund njnui 7mm MA 7 SNOLLVIA39H388V oseoJ8 Name 0 eni y 05 0 bd STO WAS saorad NOLLO3dSNI SDIJEWBUIS 92195 pfo pejboud iuseup 18 G 099 0 0061 Du enc v 1eppny 15191351910 dsu puey BHD 931030 879 91120 OC 9529 48 esndund njnui SNOILVIASYAdaV 13 0 anys y lt gt 052 0 SIO WAS NOILLO3dSNI IS ja3sidid WAN 5 5 gt 5 jenuew py 5 dsui puey 8 9 911201 911207 v 9522 48 esndand n nui SNOLLIVIA33388V oseoJ8 Name 0 SSUIM STOaWAS SdOlMad NOLLO3dSNI 1592351414 5 gt 5 Schematics INSPECTION PERIODS A G p 4 Qu ABBEREVIATIONS wing s interior 89 9313907 Ep7 931207 952948 esndand njnui 7 SNOILLVIA39388V oseoJ8 Name eni y no 02 0 NY d STO WAS SGOMad NOLLO3dSNI 4 9 10 5 eJ qu IV IS o 3sidid LV daS S92eJJns jeguozuuou
23. 989 abuey 01 1169 92 uus e asn MAIS SIU ueque 01 19410 aac 364642 01 1169 MaN WAN e WAN 1590101 0 JLILJOT SN iWN9 SI andso 1309 64100355251 9 034 sed ujoq uo 001150094 WAN 9 INY Od 497 51910401 Duiua ubi NV LYOdHI Buljquassesip 3 10334 51201100 uo fyb ayy wey Ajquiassy Jajjadoig 19 1955 J Mads 41 Gc WN 9 xonbuo INY 1990 04 010 311001951 pue J 9440 36109 Big 00 51924812 J J UO BIAI ayy YAY t cc uy 9 onbJo NV 190401 340 1960 941 Ma DS ay 0 2609 sapejq JajadoJd 4400 uo g SJaysem aeda nok 7 9 6070 WU Jausen au gcc 0 uu si aouejsip au J 71 9 PIM 500 UU lt e 99 560 uu 01 SI v aul V aly aunseay 18400170844 9NDV 1934 sbulJeag yUaWade day buueueajoiny 15 2351 1 ZO JUBA 04 burjquasseaJ jue 0 SI SIY 0101 944 995 se s Jed ay yew J
24. 9H 9170109 WNL SI sje 20 anbJo bua ub NV OH IUO AJU IYJ UJIA ISIP 3 1 ay JejdaJ pue SM JIS ISI 3ADUSY 7 ayeig joeuM GZ IS jauysidid pipistrel si Repairs Nose Wheel Strut Assembly Remove the nut washer Engine holder Remove the screw A g Remove the filler plu 7 Noseleq When removing all described parts pull the out of the engine holder 76 Service manual PIPIETI zL This page is intentionally left blank PIPICGTRzL Letter of Authorisation Aircraft Mode Callsign es Serial number Airframe hrs engine hrs Service person Surname Requesting authorisation for Regular maintenence 100 hr inspection partially or entirely a 200 hr inspection partially or entirely 500 hr inspection partially or entirely 10 000 hr inspection partially or entirely Other Modification provide description Repair Replacement provide description return this form to email fax postal address send out the form to info pipistrel usa com or fax to 1 XXX YYY ZZZZ To be filled out by Pipistrel USA Pipistrel LSA s r l Applicant has received Authorisation granted by Signature Pipistrel USA Pipistrel LSA Factory Training YES NO Copyright 2010 Pipistrel LSA s r l Via Aquileia 75 34170 Gorizia It
25. General Make sure you tape the end attached to the wing not to spill any eventual leftover fuel over the fuselage or glass surfaces as substantial damage may occur Two people must now lift the wingtips one wingtip each and the person in the cock pit remove the main spar pins one by one smoothly Forcing pins out of their position may result in structural damage therefore the wingtip holders must hold the wing halfs precisely at certain height Using slight circular movement at the wingtip the wing halfs must now be pulled out of the fuselage slowly On pulling each wing half must be held by two one at the wingtip and one near the spar As the wing halfs have been pulled out place them onto a soft surface to prevent their damage 14 Service manual pipistrel si General Fitting the horizontal tail surfaces Horizontal stabilizer and elevator MUST be united during the following procedure To fit the horizon tal tail surfaces first set the trim handle inside the cockpit to full forward position Make sure the pins their holes and bushings have been cleaned and greased Lift the joint stabilizer and elevator and slide them into position by pushing them backwards while the elevator is deflected DOWN fully Now use the enclosed key to push the security screw down while spinning it clockwise until the screw is completely tightened Pull the T key out and make sure the safety pin holds the head of the screw so t
26. IS jauysidid 58 pipistrel si PIPIETI zL This page is intentionally left blank pipistrel si Service manual 59 Schematics Repairs Elevator vertical pushrod replacement Autofeathering Propeller Assembly Autofeathering Propeller Drive Replacement Autofeathering Prop Bearing Replacement 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 Bleeting the Hydraulic Brake Lines Wheel Brake Repair Nose Wheel Strut Assembly au pue 32 abuly au HDU 344 420 01 69 31101980 V Xx x ZZZZZ E x iDulJeaq Jaddn au 01 MaJIS 101100 4603 841 INSE 91 341 JSnu UOI JUI DU 300 3Y se aues 344 Jsnu Jeq Mou au JO juDua au 211 900 MAU 420 au 90080 12311001 9 SSS SS xx No Jeq au 4 1160 11 9A0U9J JOU Og HY 31001 9 403 3 15 2351 1 09 Durnquassesip 9 0190 1469 4400 uo 40111509 ayy buie Jp 19440
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28. LER AS Vu Maintenence Manual applies to Sinus 912 LSA glider Virus 912 LSA glider and aeroplane Virus SW 80 100 LSA aeroplane equipped with Rotax 912 80 HP and 912S 100 HP engines Valid for tail wheel and nose wheel versions ORIGINAL ISSUE 25 October 2010 This publication includes the material required to be furnished to the pilot by ASTM F2245 WARNING As this manual applies to several models of Pipistrel LSA aircraft it is mandatory to designate those specific parts of this manual that regard the aircraft you operate Copyright 2010 Pipistrel LSA s r l Via Aquileia 75 34170 Gorizia Italy EU 2 Service manual pipistrel si Coverage Maintenence manual MM is in the airplane at the time of delivery from Pipistrel LSA s r l con tains information applicable to the range of Pipistrel LSA aircraft mentioned on the cover All information is based on data available at the time of publication Supplements that cover non standard are individual documents and may be issued or revised with out regard to revision dates which apply to the MM itself The Log of Effective Pages should be used to determine the status of each supplement Revision tracking filing and identifying Pages to be removed or replaced in the MM are determined by the Log of Effective pages located in this section This log contains the page number and revision level for each page within the MM As revisions
29. SUN Of nU p0 19 910 Of E47 31120 95h 414 09 UNL S SW 5 912510 anbuoj INY Odi se oJnpa oJd 10 SLA Duis epad ayy pue Japui o ayy a quasseay 9 00 ui se 51014081002 9 a quasseay 0 Way M JISUN 04 YUIM WUY auo pue WUO 910 esf AUNG ay 440 54011221102 9501 0 GW 5 05 0A 344 jepad ayy 440 dund apuro ane spky ayy E DAMS JOU pue Si yeys ay dund au Jeus BY pue JES 440 di 5 ay 7 SUDIISOQ JY Je 5 01221102 dy 110 9504 34009 9Jnpa304d Durquiassesi ES K quuessy apis 314202 ayeig 7 Ive 3501 910 50500 A V4 Ayayes 15 2351 1 0 71 Service manual pipistrel si Repairs Hydraulic Fluid Lines Assembly wheel side Reassembling procedure 1 Put part A on the hose 1 Put parts B and on the hose J Put the larger O ring on part D and smaller D ring on part E Dart B Far easier assembling use some grease Set eee 4 Insert part E into part D 5 Screw parts E and D into the brake cylinder Use one 16mm and one 14mm wrench Pant C 6 Connect parts A and D WARNING The larger O ring and the groove on part D must face the bra
30. WARNING Both pilots weight 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 milimeters mm from the datum wing s leading edge at wing root For Tail wheel edition of Virus use the following formula CG a Cea UU c 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 s TONES A Tc 1020mm 287mm total total 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 a
31. a do d 91 Duijquassesip 3 10199 ipapajJe aq ue ayy au Bunquassesip Ag 1j Jed JA p1 X1 pue 4 ued YUM ayy 0i nas siy q paypasa ay ur aqoy e aq psnu aayy ajo aues 244 Y 6 burguassesip auajaq ji se 101 150 aues ayy ui g axe 9 561 234 mau Aq doud ay 31085529 Jajadoud ay Wes 3 pue q ysng 9 10 4 ued 040 0 Jed Jue nod lt Ma DSuf Y MAIS au e Aq 3y uo 01500 51 Jeu 04 3 05 ua ub 11471904417 g ped uo mass 401 500 aq 4JeW 4 15191351910 LEG 05 9 SMIDS 986 5110 31501 6 06 54 05 86 8 5105001 829 7 GU iWNG 519 25 0 0 buius ubi iUN 72 SI gW 5 912510 any buius ubi INV 140981 aps UOJ BY Je MOJIS 10 49456 7 95 SCL 5491524 quuessy 15 2351 1 79 sbumesp buimoyo aac abu dey uid INVI SDuimeup Duimoyo 995 gt JPUOIPPY LAYA MIN 1 med e eig s 043005 ex eaqui
32. aly EU pipistrel si Service manual 79 PIPIETI zL This page is intentionally left blank 2 PIPIS TRzL Pipistrel LSA s r l Via Aquileia 75 34170 Gorizia Italy EU info pipistrel usa com www pipistrel usa com www pipistrel eu
33. ate the fork left and right At the end reattach both springs to the tubes again see Service manual for photos Bleeding the hydraulic brakes 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 26 Service manual pipistrel si Schematic of hydraulic brakes lining TUR MM R 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
34. chopped cotton fibres 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 should be repaired pipistrel si Service manual 29 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 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
35. 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 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 Aramidf
36. ding 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 36 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 Weighing procedure Make sure all listed aircraft parts and appliances are installed and in position Remove all other objects e g tools mops tie downs and other items Empty fuel tanks except for the unusable fuel inflate tires to recommended operating pressures Fill up engine oil to the top marking Retract flaps and airbrakes optional leave control surfaces centred Level the aircraft inside a closed space 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 record all readings and fill out the bottom table CG lever arm formula for Tail wheel aircraft Sinus TW Virus TW any model Lever arm of 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 and symbol Scale reading Tare Nett right main wheel Gp left main wheel GL tail wheel G2 total G Gp GL 62
37. emplates for Letters of Authorisation are provided at the back of this MM Priviliges There are four levels of proficiencies indicating which jobs can be carried out with which priviliges They are marked as prefixes in the table of Line maintenence Level a Owner do it yourself automatic authorisation with this MM Level b LSA repairman or A amp P mechanic also owners themselves in presence of an A amp P mechanic Level c Licenced A amp P mechanic any level Level d Pipistrel LSA Pipistrel USA Factory Service Center Owners 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 Rotax training requirements for working on LSAs still apply With level and c at least one of the persons carrying out the tasks must have received Pipistrel LSA Pipistrel USA Factory training Line maintenence Inspection periods The table below indicates recommended maintenance periods see Service manual for detailed in formation Table legend Check up visual only check for free play and whether everything is in position CL Cleaning LO Lubricating oiling lubricate all designated parts and spots using proper lubricant Replace
38. hat eventual unscrewing will not occur At the end tape the gap between horizontal and vertical tail surfaces and cover the hole on top of the vertical stabilizer with a sticker Check control deflections for smooth unobstructed movement Detaching the horizontal tail surfaces Set the trim handle to full forward position and remove the safety sticker covering the hole on top of the horizontal stabilizer and the tape covering the gab between horizontal and vertical tail surfaces Now use the enclosed T key to push the safety pin screw down while spinning it counter clockwise until it is completely loose To detach the horizontal tail unit push it forward using firm palm strokes until the unit pops out When detached always place the horizontal tail unit onto a soft surface to prevent damage Schematic of horizontal tail surfaces dis assembly pipistrel si Service manual 15 General Attaching the rudder Bring the rudder close to fuselage and fit it first onto the top and then to the bottom hinge The rudder must then be fully deflected to one side to provide access to the rudder bolts Use a self securing pre glued M10 nut together with an aluminium washer and gently screw them onto the bolt using size 10 spanner To reach the other rudder bolt deflect the rudder to the opposite direc tion and repeat the up stated procedure With both nuts tightened check full rudder deflections for smooth unobstructed movement Detaching the
39. holding the wingtip must start with slight circular move ments 1cm each direction in order to assure a tight fit of the wing and its adequate bushings As this is done the person at the wingtip must remain in positon holding the wing whereas the other two move over to the other wing half lift it and bring it closer to the fuselage Again all cables hoses and lines must be fitted through the openings prior the wing half be ing pushed into its final position Do not forget to make sure the spoiler and flap connectors have fitted into adequate fittings properly on this wing half as well Both wing halfs should now be in their final position but still being held at wingtips The person not holding the wings must now open the cabin door and insert both pre greased spar pins First insert the pin on the right hand side of the cockpit because of easier insersion thinner spar infront then the pin on the lefe hand side of the cockpit If necessary the two at the wingtips can assist by rocking the wings a couple of millimeters up and down Only when both spar pins have been inserted and secured wingtips may be released and door fully opened and fastened to the wing Now check all control deflections as well as flap and spoilers extensions for smooth unobstructed movement Insert all bolts and pins and secure them with self locking nuts Do not forget to put alumini um washers underneath the nuts Connect all electical c
40. ibre 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 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 30 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 sa
41. ircumstances attempt to remove such bug spots with abrasive sponges and or rough polishing pastes Periodical cleaning of all outer surfaces with car Shampoo Clean as you would clean your car starting at the top and working your way downwards using a soft sponge Be careful not to use a sponge that was contaminated with particles e g mud fine sand not to grind the surface While cleaning soak the surface and the sponge many many times Use a sepa rate sponge to clean the bottom fuselage as is it usually more greasy than the rest of the airframe When pouring water over the airframe be careful not to direct it over the fuel reservoir caps wing fuselage joining section parachute rescue system straps and cover pitot tube tail static probe and engine covers pipistrel si Service manual 17 General Always rinse the shampooed surfaces again before they become dry Thereafter wipe the whole of the aircraft dry using a drying towel chamois or artificial leather skin Also clean the Mylar seals on the wing and tail control surfaces Lift the seals gently and insert ONE layer of cloth underneath then move along the whole span of the seal Ultimately you may wish to apply Teflon grease in spray over the area where the seal touch the control surfaces Polishing by hand Use only the highest quality polishing compounds WITHOUT abrasive grain such as Sonax Extreme or similar Start polishing on a clean dry and cool surface never in the
42. ke cylinder Larger 0 ring Be Part 0 7 D Smaller O ring Part E 50 Note Pneumatic tire and wheel spat not drawn visibility purposes appe ag WU Cf DO 109528001 ayy 22614 6 ayy Oui buds pue Huds ayy 9 apuepind aj Joy ajo uu gg 11401 aseaj AaJes IY ub 922119 Buie p ay 25 aseaja 9125 24 pue JaJoq P JN axuepinb ayy Jo arejd aui we 6 aye ay JJASUI pue 3101 Gg 10 7 l oqe 341 995 pa quassy papavo ave uid quas pue aseajauAjajes 241 05 Z 10 aseaja Kjajes ay aumu c f Jes ayy uo Jnd C 5 ua pou fou bulyquassy 19501 pue ojo WBA e 100 NDS UN Gg qu aseajal pind Duy 5 0 i N 38 uid AyMas May QW PN a44 po 04 E97 31101980 0 ela Q Ajquiassy 15 2351 1 7 UNDA YIM auj pue S3104 NUQ EI 925 34 21420 ayy xij 0 jeuorippy ayy Buijquessy
43. lables fuel hoses fixed or click on connectors and pitostatic lines to their adequate fittings Check for adequate fuel flow through the fuel connectors before attempting the first flight 1 liter 1 quart per minute For fixed fuel connectors make sure you have tightened the metal clamp around the tube securely Screw on the pitot tube on bottom side of the right wing at aproximately 2 3 of the wing span Be extra careful not to switch the two tubes as this causes misinterpretation of indicated airspeed Finally tape the gap between the fuselage and the wing using self adhesive tape pipistrel si Disassembling the wings Three people again are needed to disassemble the wings First block all three wheels for the fuselage to stay in position Empty both fuel tanks by opening both fuel valves inside the cockpit and the drain valve beneath the bottom en gine cover Place a canister under the drain valve to intercept fuel While you wait for the tanks to empty disas semble the horizontal tail surfaces disconnect all electrical cables and pitot static lines Do not forget to unscrew the pitot tube on the bottom side of the right wing Then inside the cockpit unscrew the middle main spar screw first then unscrew and remove both pin bolts WARNING po not remove spar pins yet Once the fuel tanks are empty disconnect the fuel hoses inside the cockpit as well Schematic of wing dis assembly Service manual 13
44. 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 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
45. ment replace designated parts regardless of state and condition SC Special check up measuring verifying tolerances and functionality O Overhaul dail first 5 50 100 200 500 1 000 10 000 Y hours hours hours hours hours hours hours WING AND TAIL SURFAaCES dO aC bSC surface and structure condition lights a self adhesive sealing tape bSC horizontal tail mount MESS bSC drain holes pipistrel si Service manual 21 Servicing the aircraft dail fist 5 50 100 200 500 1 000 10 000 Y hours hours hours hours hours hours hours FUSELAGE bSC dO surface and structure condition bSC elevator control tube bearing bSC undercarriage struts attaching points aC bSC doors hinges aC bSC rudder control wires and hinges aC bSC CABIN bSC dO control levers instr panel seats bSC control levers free play aC bSC glass surfaces clean attached 46 7 b5C rivet condition bSC safety harnesses and attach points bSC parachute rescue sys activation handle aC bSC wing connectors fuel electrical aC aC bSC bolts and spar pins aC aC bSC wing main bushings control connectors bSC UNDERCARRIAGE dO tires aC level a replace on condition or every 5 years main strut tail nose wh strut condition 46 bSC wheel axis and wheels hyd brake line
46. nd 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 31 Example of flapperon 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 flapperon Colton 4 resin Microballoon resin Quther fabric 1x90070 gloss 70g m2 100160 carbon 1609 m2 HEREX 3mm Inner fabric 1x90070 glass 70g m2 X 182125 glass 280g m2 gt 1x9
47. s aC bSC cR brake fluid aC bSC bR 500 hrs 5 years brake discs 652 bR on condition bSC bR wheel bearings wheel fairings tail wheel attachment bolt aC aC aC leveel a fasten every 50 landings CONTROLS every 200 hrs or yearly dR general free play aC bSC control stick aC aLO bSC rudder pedals damage centered 3C aC bSC rudder wire rope aileron elevator and rudder hinges b5C equal spoiler extension undisrupted m C bSC 05 spoiler plate springs stiffness aC 20 flap handle b5C elevator trim aC cR cable every 500 hrs springs flaps rudder el trim stablizer main fastening bolt bR spoilers airbrakes drive fine adjustment level b see page 23 for detailed description 22 Service manual pipistrel si Servicing the aircraft dail first5 50 100 200 500 1 000 10 000 hours hours hours hours hours hours hours ENGINE see enclosed Rotax engine manual for detailed engine maintenance information In addition to Rotax manual two stroke engines overhaul every 300 hours aC four stroke engines overhaul every 1 500 hours from engine serial number 4404718 engine cover screws aC aC aC engine mount aC aC bSC engine mount dumpers and other aC bSC level c R every 500 rubber parts hrs or every 5 years air filters aC aC bCL bSC elect terminals joints and
48. y it directly onto the wing but into a soft cloth instead old T shirts are best 4 After having finished with flight activity for the day clean the leading edges of the airframe as soon as possible with a lot of water and a drying towel chamois artificial leather skin This will be very easy to do if you applied a coat of Pronto before flight Detailed handling Airframe cleaning instructions Every day care after flight Bugs which represent the most of the dirt to be found on the airframe are to be removed with clean water and a soft cloth can be also drying towel chamois artificial leather skin To save time soak all the leading edges of the aircrame fist Make sure to wipe ALL of the aircraft s surface until it is com pletely dry at the end Clean the propeller and the areas with eventual greasy spots separately using a mild car shampoo with wax CATUION Do not under any circumstances attempt to use aggressive cleaning solutions as you will severely damage the lacquer which is the only protective layer before the structural laminate When using the aircraft in difficult atmospheric conditions intense sunshine dusty winds coastline acid rains etc make sure to clean the outer surface more thoroughly If you notice you cannot remove the bug spots from the leading edges of the aircraft this means the lacquer is not protected any more therefore it is necessary to polish these surfaces CAUTION Do not under any c
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