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Service and Repair Manual
applies to Sinus 503, Sinus 582 and Sinus 912
equipped with Rotax 503, Rotax 582
and Rotax 912 engines
(all TW and NW versions)
and
Virus 912 equipped with Rotax 912 engine
(all TW in NW versions)
Revision 1
updated 18th June, 2012
This is the original manual of Pipistrel d.o.o. Ajdovščina
Should third-party translations to other languages contain any inconsistencies,
Pipistrel d.o.o. Ajdovščina denies all responsibility.
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Summary of Contents for Pipistrel Sinus 503
- Page 1 Service and Repair Manual applies to Sinus 503, Sinus 582 and Sinus 912 equipped with Rotax 503, Rotax 582 and Rotax 912 engines (all TW and NW versions) Virus 912 equipped with Rotax 912 engine (all TW in NW versions)
- Page 2 Service manual Index of revisions Enter and sign the list of revised pages in the manual into the spaces provided below. All revised pages should be clearly designated in the upper right corner of the page, also, any changes in page content should be clearly visible (e.g.
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Page 3: Table Of Contents
Service manual List of valid pages This manual contains 74 original and revised pages listed below. Pages State Cover Original Index of revised pages Original List of valid pages Original Table of contents Original General 7 - 9 Original... - Page 4 Service manual This page is intentionally left blank.
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Page 5: Table Of Contents
Service manual Table of contents General Servicing the aircraft Schematics... - Page 6 Service manual This page is intentionally left blank.
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Page 7: General
Service manual General General Introduction Notes and remarks Materials used in manufacturing process... - Page 8 In case of aircraft damage or people injury resulting form disobeying instructions in the manual PIPISTREL d.o.o. denies any responsibility. All text, design, layout and graphics are owned by PIPISTREL d.o.o. Therefore this manual and any of its contents may not be copied or distributed in any manner (electronic, web or printed) without the prior consent of PIPISTREL d.o.o.
- Page 9 Service manual 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...
- Page 10 Service manual General This page is intentionally left blank.
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Page 11: Servicing The Aircraft
Service manual Servicing the aircraft Servicing the aircraft Introduction Repairs and spare part replacements Inspection periods Special check-ups Fibre reinforced plastic repairs Example of flaperon FRP repair Example of wing FRP repair Weight and Balance... - Page 12 Service manual Servicing the aircraft Introduction This chapter determines handling and (preventative) maintenance terms. Also, recommended ground handling is presented. Repairs, spare part replacements and preventative maintenance All major repairs and spare part replacements MUST be done by authorised service personnel.
- Page 13 Service manual Servicing the aircraft fist 5 1.000 10.000 daily hours hours hours hours hours hours hours FUSELAGE surface and structure condition elevator control tube bearing undercarriage struts attaching points doors, hinges rudder control wires and hinges CABIN control levers, instr. panel, seats control levers’...
- Page 14 Service manual Servicing the aircraft first 5 1.000 10.000 daily 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)
- Page 15 Service manual Servicing the aircraft first 5 1.000 10.000 daily hours hours hours hours hours hours hours O every 500 hrs or 5 years OIL AND WATER LINES oil and cooling fluids level oil and cooling fluids leakage four stroke engine oil (and engine...
- Page 16 Service manual Perform the adjustment as follows: Unscrew and remove the inner horizontal bolt of the airbrake’s plate. Do not lose any parts! Lift the airbrake in order to make room for further operation. Unscrew and remove the bolt attaching the rod-end bearing to the airbrake’s plate lever.
- Page 17 Service manual 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”...
- Page 18 Service manual Schematic of hydraulic brakes’ lining 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.
- Page 19 Service manual Connecting Auxiliary power supplies Should you be unable to start the engine due to a weak battery, auxiliary power supplies can be con- nected to help starting the engine. Battery’s & Relay’s location Battery & Relay (black)
- Page 20 Service manual Servicing the aircraft Fibre reinforced plastic repairs WARNING! Do not, under any circumstances attempt to repair damages greater than 50 mm in size (on wing) and/or 20 mm in size on any control circumstances. These require a treatment by...
- Page 21 Service manual Repair method for FRP Cut out damaged area, roughen the surrounding area for the overlap required. Repairs should be made such that bonding is wet over dry. Specific details concerning handling and using fibre rein- forced plastics can be obtained from various publications ie. “Petite Plane Patch Primer. ”...
- Page 22 Service manual 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.
- Page 23 Service manual Example of flaperon FRP repair WARNING! Do not, under any circumstances attempt to repair damages greater than 50 mm in size (on wing) and/or 20 mm in size on any control circumstances. These require a treatment by...
- Page 24 Service manual Phase II Remove the Peel Ply and adapt a new piece of foam (Herex 3 mm) as accurately as you possibly can and glue it with microballoons. WARNING! Do not apply too much pressure anywhere! Phase III Grind the foam if its level is too high.
- Page 25 Service manual Drawing of skin final repair...
- Page 26 Service manual Example of wing FRP repair WARNING! Do not, under any circumstances attempt to repair damages greater than 50 mm in size (on wing) and/or 20 mm in size on any control circumstances. These require a treatment by...
- Page 27 Service manual Phase II Laminating. Grind the outer fabric in a shape of a cone at least 25mm around the damaged area (see drawing below) and laminate only the ground surface with fabrics as follows: - Two (2) pieces of 92110 and - One (1) piece of 90070 When laminating be careful about the orientation of the fibres.
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Page 28: Weight And Balance
Service manual Weight and balance Weight and Balance This chapter provides information on aircraft’s weight and balance, which is essential for safe flying activity. Procedure How to weigh the aircraft and later determine the CG correctly: Make sure all listed aircraft parts and appliances are installed and in position. - Page 29 Service manual Weight and balance Determination of CG Weight’s lever Weight (kg) Torque (kg/cm) Remarks arm (cm) Basic cfg. empty weight CAUTION! Each newly installed part or appliance must be registered in the upper table. Also, new total weight and lever arm of CG values must be entered and position of CG re-determined.
- Page 30 Service manual Sample c.g. calculation Guidelines Gtotal is the total mass of empty aircraft. All calculations can be performed with aircraft empty weight and empty weight centre of gravity (c.g.), as the pilots sits directly below the centre of gravity and do not cause the c.g.
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Page 31: Schematics
Service manual Schematics Control levers Wings Tail surfaces Undercarriage Brakes Fuel system Engine cooling system Engine lubrication system Throttle and choke drive Electrical system... - Page 54 Service manual This page is intentionally left blank.
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Page 55: Repairs
Service manual Schematics Repairs Elevator vertical pushrod replacement VARIO Propeller Assembly VARIO Propeller Drive Replacement VARIO Propeller Bearing Replacement 3-Bladed Fixed Pitch Propeller Airbrake Control’s Drive Reinforcement (1) Airbrake Control’s Drive Reinforcement (2) Flaperon Hinge Replacement Flaperon Lateral Drive Assembly... - Page 62 Wing Control’s Drive Reinforcement (part 2)
- Page 67 Hydraulic Fluid Lines Assembly (wheel side)
- Page 72 Nose Wheel Strut Assembly...
- Page 74 Pipistrel d.o.o. Ajdovščina podjetje za alternativno letalstvo Goriška cesta 50a 5270 Ajdovščina Slovenija tel: +386 (0)5 3663 873 fax: +386 (0)5 3661 263 e-mail: info@pipistrel.si www.pipistrel.si...