Alpi Aviation PIONEER 300 User manual

DOCUMENT N° PD9B01M3
NOTE FOR PRINTING: ALL THESE PAGES NEEDS TO BE COLOUR PRINTED
DATE OF ISSUE OF LAST REVISION 23/07/2020
MAINTENANCE MANUAL
AIRCRAFT MODEL: PIONEER 300
THIS MANUAL ONLY APPLY FOR:
- P300 AND P300FG;
- FIXED AND VARIABLE PITCH PROPELLERS;
- ENGINE ROTAX 912 ULS, 912IS SPORT, 915IS;
- SHORT AND NORMAL WINGS.

A PD9B01M3 1ST ISSUE 23/07/2020
LIST OF VALID PAGES
This Manual is made by 34 pages (including the annexes), original and emended pages are herein
listed:
DOCUMENT REVISION SUMMARY
REVISION
DATE
CHANGES
0
1/07/2019
-Document issue
1
17/06/2020
-Definition of primary and secondary structures
-List of materials for quick repairs
2
25/06/2020
- aircraft TBO definition at 2000h
3
23/07/2020
Definition of special tools , placard and markings
Table 1: history of document revisions
CAUTION
THIS MANUAL IS VALID ONLY IF IT CONTAINS ALL OF THE ORIGINAL AND REVISED
PAGES LISTED ABOVE. EACH PAGE TO BE REVISED MUST BE REMOVED, SHREDDED
AND LATER REPLACED WITH THE NEW, REVISED PAGE IN THE EXACT SAME PLACE IN
THE MANUAL.

1 PD9B01M0 1ST ISSUE 1/07/2019
TABLE OF CONTENTS
LIST OF TABLES.......................................................................................................... 4
GLOSSARY................................................................................................................... 5
A. INTRODUCTION....................................................................................................... 7
A.1 Document references......................................................................................... 7
A.2 Original Equipment Manufacturer....................................................................... 7
A.3 Lifecycle Management........................................................................................ 8
A.4 Continuous Airworthiness................................................................................... 8
A.5 Document Organization...................................................................................... 8
B. WARNING, CAUTION AND NOTE........................................................................... 9
1GENERAL.................................................................................................... 10
1.1 ASTM F2483-12 Terminology ...................................................................... 10
1.2 How to read the operational sheets in the annexes...................................... 10
1.3 Standard equipment list................................................................................ 11
1.3.1 Approved engine types .....................................................................................12
1.3.2 Approved propeller types ..................................................................................12
1.4 Sources to purchase parts ........................................................................... 13
1.5 List of disposable replacement parts............................................................ 13
1.6 Weight and balance information................................................................... 13
1.7 Handling....................................................................................................... 13
1.7.1 Ground handling ...............................................................................................14
1.7.2 Parking and tie down.........................................................................................14
1.7.3 Jacking..............................................................................................................14
1.7.4 Towing..............................................................................................................15
1.7.5 Taxiing..............................................................................................................15
1.8 Tire inflation pressures................................................................................. 15
1.9 Approved oil and capacities ......................................................................... 15
1.10 Recommended fastener torque values......................................................... 15
1.11 General safety information ........................................................................... 15
1.12 Instruction for reporting information after maintenance................................ 16
1.12.1 Instruction for reporting possible safety/flight concerns.....................................16
1.12.2 Manual Improvements and feedbacks...............................................................16
1.12.3 Aircraft assembly ..............................................................................................16
1.12.4 Change in ownership ........................................................................................16

PD9B01M0 1ST ISSUE 1/07/2019 2
2INSPECTIONS .............................................................................................16
2.1 Inspection panels..........................................................................................16
2.2 Airframe and systems inspection schedule...................................................17
2.3 Inspections and checks ................................................................................17
2.4 100 hour/annual check list............................................................................18
2.5 Corrosion prevention ....................................................................................18
2.6 Servicing.......................................................................................................19
2.7 Lubrication....................................................................................................19
2.7.1 Lubrication points..............................................................................................19
3STRUCTURES .............................................................................................20
3.1 Airframe........................................................................................................20
3.1.1 Wing..................................................................................................................21
3.1.2 Tail....................................................................................................................21
3.1.3 Landing gear (FIXED) .......................................................................................21
3.1.4 Landing gear (RETRACTABLE)........................................................................21
3.1.5 Control system and aerodynamic surfaces........................................................22
4ENGINE........................................................................................................22
4.1 Engine & Engine Mount................................................................................22
4.2 Engine cowling..............................................................................................23
4.3 Exhaust/Muffler system.................................................................................23
4.4 Air induction system......................................................................................23
4.5 Oil system.....................................................................................................23
4.6 Cooling system.............................................................................................23
5FUEL SYSTEM.............................................................................................23
6PROPELLER................................................................................................24
7UTILITY SYSTEMS......................................................................................24
7.1 Cabin heat and cooling.................................................................................24
8INSTRUMENTS AND AVIONICS.................................................................24
8.1 Instruments that require sensors ..................................................................24
8.2 Pitot-static system.........................................................................................25
9ELECTRICAL SYSTEM ...............................................................................25
9.1 Battery check, removal and installation ........................................................26
9.2 Internal AC Generator...................................................................................26

3 PD9B01M0 1ST ISSUE 1/07/2019
9.3 Exterior lights................................................................................................ 26
9.4 Stall warnings (if installed)............................................................................ 26
9.5 Flap computer (if installed)........................................................................... 27
9.6 External power source (for engine startup) .................................................. 27
10 STRUCTURAL REPAIR .............................................................................. 27
10.1 Type of maintenance.................................................................................... 27
10.2 Minimum level of certification ....................................................................... 27
10.3 Repair procedures........................................................................................ 27
10.4 Materials necessary for small repairs........................................................... 27
11 PAINTING AND COATINGS........................................................................ 28
12 FEEDBACK FORM...................................................................................... 28
ANNEX A: CHECKLIST OF MAINTENANCE OPERATIONAL SHEETS, PD9001A029
ANNEX B: REPORTING FLIGHT/SAFETY CONCERNS.......................................... 30
ANNEX C: IMPROVEMENTS, CORRECTIONS AND FEEDBACKS ........................ 31
ANNEX D: CHANGE OF ADDRESS/OWNERSHIP................................................. 32
ANNEX E: NOTICES APPLICATION LOG (1 OF … ) ................................................ 33
ANNEX F: MAINTENANCE LOG (1 OF … ) ............................................................. 34
ANNEX G: APPLICABLE PLACARD AND MARKINGS.......................................... 35
ANNEX H: SPECIAL TOOLS.................................................................................... 36

PD9B01M0 1ST ISSUE 1/07/2019 4
LIST OF TABLES
Table 1: history of document revisions.......................................................................................II
Table 2: Standard configuration equipment..............................................................................12
Table 3: Approved engine types ..............................................................................................12
Table 4: Approved propeller types...........................................................................................13
Table 5: Disposable spare parts. .............................................................................................13
Table 6: Final securing procedure............................................................................................14
Table 7: Tire inflation pressure.................................................................................................15
Table 8: Approved oil grades and tank capacity.......................................................................15
Table 9: Daily servicing............................................................................................................19

PD9B01M0 1ST ISSUE 1/07/2019 5
GLOSSARY
°C
Degrees Celsius (Centigrade)
°F
Degrees Fahrenheit
AOD
Aft of Datum
ASI
Air Speed Indicator
ASTM
American Standard for Testing & Materials
Aux
Auxiliary
BHP
Brake Horse Power
CG
Center of Gravity
CHT
Cylinder Head Temperature
EGT
Exhaust Gas Temperature
EGT-Split
Difference between the actual highest EGT value and the actual lowest
EGT value
EOM
Engine Operators Manual
FG
Fixed Gear
fpm
Feet per minute
ft
Feet
FTS
Flight Training Supplement
gal
Gallons
h
hour
IAS
Indicated Air Speed
IFR
Instrument Flight Rules
KCAS
Calibrated Air Speed in Km/h (and in Kts)
Kg
Kilograms
KIAS
Indicated Air Speed in Km/h (and in Kts)
kt
Knots
KTAS
Calibrated True Air Speed
L
Left
l
Liters
lb
Pounds
LE
Leading Edge
LMM
Line Maintenance Manual
MAC
Mean Aerodynamic Chord
MAUW
Maximum All UP Weight
max
Maximum
MRA
Major Repair and Alteration
MTOW
Maximum Takeoff Weight
nmi
Nautical Miles
OAT
Outside Air Temperature
ODDP
Owner Delivery Documentation Package
OEM
Original Equipment Manufacturer
OPT
Optional

PD9B01M0 1ST ISSUE 1/07/2019 6
OS
Operational Sheets
POH
Pilot Operating Handbook
R
Right
RON
Research Octane Number
RPM
Revolution per Minute
sec
Seconds
SI
International System of Units
STD
Standard
VFR
Visual Flight Rules

PD9B01M0 1ST ISSUE 1/07/2019 7
A. INTRODUCTION
The Maintenance Manual here presented provides the guidelines for the qualifications to
accomplish the various levels of maintenance on Pioneer 300 aircrafts. It also represents a
continuous part of the Pilot’s Operating Handbook delivered together with this manual. For this
reason, some arguments will be just recalled instead of being fully re-written. A careful reading of
the engine and propeller manuals is strongly recommended in any case because it will give you
more information about safe maintaining and hence it will ensure a safer flight.
This manual contains very detailed indications about maintenance, repairs and alterations
providing illustrative sketches on how to do that. Furthermore, indications about periodic
inspections and advice about the right care of the overall Pioneer 300 aircrafts are also provided
into this manual in order to give you all the satisfactory indications towards the correct operations.
Pioneer 300 aircrafts are built with some parts not manufactured by Alpi Aviation, for those it is
necessary to refer to the original manufacturer’s manual in order to get complete information.
Pioneer 300 aircrafts legal WARRANTY is guaranteed only if:
1) the herein prescribed maintenance is carried out by the appropriate personnel, recorded in the
Table of ANNEX F and stored in the aircraft logbook;
2) the Mandatory Service Bulletins are applied and recorded in the Table of ANNEX E and stored
in the aircraft logbook.
A.1 Document references
This manual has been prepared according to the standard ASTM F2483-12, while Pioneer 300
aircrafts have been shown to comply with standard ASTM F2245. This aircraft must be maintained
following the standard ASTM F2295, Standard Practice for Continued Operational Safety
Monitoring of a Light Sport Aircraft. Please note that this standard describes the responsibilities of
the Owner/Operator.
Pioneer 300 aircrafts are included into a wider family of P300 aircraft types, mainly divided into
Fixed and Retractable landing gear, and for this the airplane only one P300 Maintenance Manual
exists.
In details the following ASTM standards have been used to demonstrate compliance and
therefore to prepare this document:
1) F2483-12 Standard Practice for Maintenance and the Development of Maintenance
Manuals for Light Sport Aircraft;
2) F2245-12d Standard Specification for Design and Performance of Light Sport Aircraft;
3) F2279-06 Standard Practice for Quality Assurance in the Manufacture of Fixed Wing Light
Sport Aircraft;
4) F2295-06 Standard Practice for Continued Operational Safety Monitoring of a Light Sport
Aircraft;
5) F2746-12 Standard Specification for Pilot’s Operating Handbook (POH) for Light Sport
Aircraft;
6) F2930-12 Standard Guide for Compliance with Light Sport Aircraft Standards.
A.2 Original Equipment Manufacturer
The Pioneer 300 aircrafts have been manufactured by Alpi Aviation Srl whose contact information
are herein listed:

PD9B01M0 1ST ISSUE 1/07/2019 8
Name: Alpi Aviation Srl;
Location: Via dei Templari 24, 33080, San Quirino (PN), Italy
Phone N°: [phone]
Fax N°: [phone]
Email: [e-mail]
Website: www.alpiaviation.com
A.3 Lifecycle Management
The aircraft owner shall comply with all requirements, procedures and limitations with respect to the
Maintenance Manual instructions prescribed in this manual. It is responsibility of the aircraft owner
to maintain this manual up to date and to report the date of incorporation and his signature on the
Amendment Record Sheet. Whenever the revision status of his manual could be in question, each
owner should contact the local Alpi Aviation Dealer, or directly Alpi Aviation Srl in Italy. No entries
or endorsements may be made to this Manual except in the manner and by persons authorized for
the purpose. In case of aircraft damage or personal injury resulting from noncompliance to
instructions in the manual, Alpi Aviation Srl denies all responsibility. All text, design, layout and
graphics are owned by Alpi Aviation Srl. 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 Alpi
Aviation Srl.
WARNING
IT IS MANDATORY TO CAREFULLY STUDY THIS MANUAL PRIOR TO USE OF AIRCRAFT. IT
IS ASSUMED THAT THE OWNER THAT WILL NOT NOTIFY ANY “REQUEST OF
CLARIFICATION/MODIFICATION” USING THE ATTACHED FORM IN ANNEX CWITHIN 30
DAYS FROM THE AIRCRAFT PURCHASE, WILL FULLY AGREE ON THE CONTENT.
WARNING
IT IS MANDATORY TO FILL THE MAINTENANCE LOG SHEETS IN ANNEX FWITH ALL THE
USEFUL RECORDS THAT PERMIT TRACKING OF THE AIRCRAFT MAINTENANCE HISTORY.
THIS LOG MUST BE SIGNED BY THE PERSON IN CHARGE FOR THE SINGLE TASK
ACCOMPLISHED.
A.4 Continuous Airworthiness
It is a Pilot/Owner responsibility to get access to continuous airworthiness NOTICES by registering
himself into the Company website (Customer page), in order to get a Customer account. NOTICES
include:
- Safety Alert;
- Service Bulletin;
- Notification.
A.5 Document Organization
The document has been organized in sections as herein summarized:
CHAPTER 1 general information,
CHAPTER 2 inspections,