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Eiri KY PIK-20 E Service Manual

Self launching sailplane
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Download this manual See also: Flight Manual
PIK-20 E Service manual
SERVICE MANUAL
for
SELF LAUNCHING SAILPLANE
PIK-20 E
J
V EIRI KY
Kisällinkatu 8
SF 15170 Lahti 17

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Summary of Contents for Eiri KY PIK-20 E

  • Page 1 PIK-20 E Service manual SERVICE MANUAL SELF LAUNCHING SAILPLANE PIK-20 E V EIRI KY Kisällinkatu 8 SF 15170 Lahti 17...
  • Page 3 PIK-20 E Service manual SERVICE MANUAL SELF LAUNCHING SAILPLANE PIK-20 E SERIAL NO: REGISTRATION: This sailplane must be serviced in compliance with this Manual. Approved by National Board of Aviation, Finland -------------------------- eiri ky EDITION 2 Kisällinkatu 8 JANUARY 80...
  • Page 4 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 Dlack vertical line in the left hand margin and the Revision No. and date will be shown on the bottom of the page.

  • Page 5: Table Of Contents

    PIK-20 E Service manual >v II SERVICE MANUAL Page TABLE OF CONTENTS 1. ASSEMBLY AND DISASSEMBLY 11-1 1.1 Preparation II- 1 1.2 Wing assembly II- 3 1.3 Tailplane assembly II- 3 1.4 Disassembly II- 4 2. SYSTEM DESCRIPTION II- 5 2.1 Powerplant...
  • Page 6 PIK-20 E Service manual 11-39 7. EQUIPMENT eiri ky Kisällinkatu 8 page iv SM5170 Lahti 17...

  • Page 7: 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.
  • Page 8 PIK-20 E Service manual Fig 2 EIRI KY Kisällinkatu 8 page II-2 SF-15170 Lahti 17...

  • Page 9: Wing Assembly

    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.

  • Page 10: Disassembly

    PIK-20 E Service manual — Insert the horizontal stabilizer by moving the trim and flap lever to the 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.

  • Page 11: System Description

    PIK-20 E Service manual 2. SYSTEM DESCRIPTION 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...
  • Page 12 PIK-20 E Service manual Engine operational data: Takeoff power 31.7 kW/43 hp/6200 rpm/100 km/h Max continuous power 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/135km/h...

  • Page 13: Electrical System

    / -PIK-20 E Service manual FIG 2.1: ELECTRICAL SYSTEM EIRI KY------- Revision 2.21.8.-79 Kisällinkatu 8 page II-7 SF-15170 Lahti 17...
  • Page 14 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...

  • Page 15: Fuel System

    PIK-20 E Service manual FIG 2.2: FUEL SYSTEM Carburettors Fuel return line Engine fuel pump Fuel pump Fuel filter Fuel cock Filler opening with vent cap Fuel quantity gauge Fuel feed line Fuel tank Electric fuel pump f Finger strainer EIRI KY Revision 1.21.8-79...

  • Page 16: Water Ballast

    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 spar. The capacity of one bag is 40 litres gi­ ving a total capacity of 80 litres.

  • Page 17: Daily Check

    PIK-20 E Service manual 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, 5.51.

  • Page 18: Care And Maintenance

    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.

  • Page 19: Powerplant Maintenance

    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.
  • Page 20 PIK-20 E Service manual 4.2.2 Inspection guide lines a) MOVABLE 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.
  • Page 21 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.
  • Page 22 PIK-20 E Service manual Engine hours No Item Reference Check tightness of cylinder head bolts (first 25 Note 6 hours service) Inspect decompression valves Note 7 Note 7 Inspect decompression mechanisms Inspect ignition harness condition Insoect ignition coils Note 8...
  • Page 23 PIK-20 E Service manual Engine hours Reference No Item Inspect safety wire and attachment and tauten if needed Inspect engine retracted position lock Note 14 Inspect engine brake Inspect engine compartment doors Note 15 Clean and lubricate the engine retracting and...
  • Page 24 PIK-20 E Service manual 4.2.4 Notes in powerplant maintenance list Note 1 Propeller bolts Propeller bolts tightness should be 15 to 17 Nm. See Propeller Manual. Note 2 Propeller blade condition and track For blade condition check, see Propeller Manual. Difference in blade track should not be more than 3 mm measured 10 cm from the blade tip at the trailing edge.
  • Page 25 PIK-20 E Service manual Note 5 The toothed drive belt When properly installed and when clean, the belt requires little maintenance. If the edges are worn it can be due to misalignment. Check also the drive gear flange for straightness.
  • Page 26 PIK-20 E Service manual Note 8 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 ever^ 10 to 15 hours. Suitable spark plugs are NGK B8ES and Champion N3 can also be used.
  • Page 27 PIK-20 E Service manual 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.
  • Page 28 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.
  • Page 29 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...
  • Page 30 PIK-20 E Service manual les. Crank the engine by throwing from the propeller. Try to move the propeller fast over the horizontal 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.
  • Page 31 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...

  • Page 32: Sailplane Maintenance

    PIK-20 E Service manual 4.3 Sailplane maintenance 4.3.1 Before assembly 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.
  • Page 33 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...
  • Page 34 PIK-20 E Service manual FIG 4.1: Water drain (v) and pressure relief holes Ip) EIRI KY - Kisällinkatu 8 page II-28 SF-15170 Lahti 17...
  • Page 35 PIK-20 E Service manual 1. Elevator hinges 2. Tailplane fittings 3. Wing fittings and main wing pin 4. Quick-release locks 5. Push rod guides 6. Canopy locking 7. Pedals 8. Canopy hinges 9. Airbrakes levers and locking system 10. Flap hinges 11.

  • Page 36: After Gear-Up Landing And After Rough Landing

    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.
  • Page 37 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.

  • Page 38: Weight And Balance

    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 7.1. The results of weighing by the manufacturer are given in the Weight and Balance Data Sheet (supplement of Flight Manual).
  • Page 39 PIK-20 E Service manual Levelling means: Slope 1000:28 C. of G. FIG 5.1: Weighing Scale Scale Position on Symbol Weight Tare Reading (kg) (kg) (kg) Main wheel (Wi) Tail wheel (W2) Moment Net weight Empty weight (kgm) (kg) and moment a = 2.116...
  • Page 40 PIK-20 E Service manual Empty C. of G . limits weight Fore 2,672 2,640 2.634 2,669 2.665 2.628 2.622 2.661 2.658 2.616 2,655 2.611 2.652 2.606 2.648 2,601 2,596 2.645 C. of G limits table. [kg] Figure 5.2. C. of G. range, with different empty weights, m0. Minimum pilot 70 kg, max.

  • Page 41: Calculations For Actual Empty Weight And Moment

    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 equipment 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 approbate columns.

  • Page 42: Sample Problem: Actual Empty Weight And Moment Of The Sailplane

    PIK-20 E Service manual In any case mpmax cannot be greater than 110 kg. The second Mote 2: 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 —...
  • Page 43 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 Foremost C. of G. limit gives rripmax = 1.271 x 793.2 - 2.881 x 296.3 - 32,1 = 122,4 kg...

  • Page 44: Transportation Of The Sailplane And Handling On The Ground

    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: —...
  • Page 45 7. EQUIPMENT The following list shows the equipment 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 equipment in the latest Weight and Balance Record in Flight Manual 6.4.
  • Page 46 PIK-20 E Service manual Moment Weight Part Item (kgm) (kg) Seat cushion Model: Mirror for checking the propeller position Hour meter Model: II Optional Equipment Tow coupling Model: Variometer Model: Compensating bottle Turn and slip indicator Model: Variometer Model: Compensating bottle...
  • Page 47 PIK-20 E Service manual Moment Weight Item Part (kgm) (kg) 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---------------------------------------------------------- ^ Kisällinkatu 8...
  • Page 48 PIK-20 E Service manual Moment Weight Item Part (kgm) (kg) EIRI KY - Kisällinkatu 8 page 11-42 SF-15170 Lahti 17...

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