Pipistrel Sinus 503 Installation and operating manual

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)
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.
Revision 1
updated 18th June, 2012

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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. marked with a bold vertical line)
Name of
revision
Revision no.
date Signature, date Description
Revision 1 1, 18th June
2012
Tomazic, Coates
18th June 2012
Checked all spelling in document
US English

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List of valid pages
This manual contains 74 original and revised pages listed below.
Pages State
Cover 1Original
Index of revised pages 2Original
List of valid pages 3Original
Table of contents 5Original
General 7 - 9 Original
Servicing the aircraft 11 - 27 Original
Schematics 29 - 52 Original
Repairs 53 - 70 Original
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.

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Table of contents
General
Servicing the aircraft
Schematics

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Introduction
Notes and remarks
Materials used
in manufacturing process
General
General

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Introduction
This manual contains all information needed for appropriate and safe servicing of Sinus ultralight
motorglider models 503, 582, 912 and Virus 912.
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.
IT IS MANDATORY TO CAREFULLY STUDY THIS MANUAL PRIOR TO USE
OF AIRCRAFT
Notes and remarks
Safety denitions 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.
General

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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: gelcoat
heat resistant protection glass-aluminium sandwich
Metal parts used are:
tubes: materials: Fe0146, Fe 0147, Fe0545, Fe1430, AC 100, CR41 in LN9369
sheet metal: materials: Fe0147 in Al 3571
rods: materials: Fe 1221, Fe 4732, Č4130, 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 ber manufactured by Interglas GmbH.
All parts have been tested at safety factor 1.8, meaning stressed to 7,2 G
All parts are made in moulds, therefore no shape or structural dierences
can occur.
All designing, manufacturing and testing complies with following regulations:
• Bauvorschriften für Ultraleichtflugzeuge des Deutschen Aero Club e.V. Beauftragter des
Bundes-ministeriums für 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.
All parts and materials presented in all versions of Sinus ultralight motorglider and
Virus 912 are also being used in glider and general aviation industry and all comply
with aviation standards.
WARNING! WHEN SERVICING OR REPLACING PARTS ALWAYS USE THE SAME
MATERIAL AS USED ORIGINALLY SEE ABOVE.
General

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General
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Introduction
Repairs and
spare part replacements
Inspection periods
Special check-ups
Fibre reinforced plastic
repairs
Example of aperon FRP
repair
Example of wing FRP
repair
Weight and Balance
Servicing the aircraft
Servicing the aircraft

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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.
However, you 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 lter replacements.
The table below indicates recommended maintenance periods (see Service manual for detailed in-
formation).
Table legend:
CCheck-up - visual only, check for free play and whether everything is in position - DO IT YOURSELF
CL Cleaning - DO IT YOURSELF
LO Lubricating, oiling - lubricate all designated parts and spots using proper lubricant -
DO IT YOURSELF
RReplacement - replace designated parts regardless of state and condition.
You are encouraged to DO undemanding replacements YOURSELF, otherwise have replacements
done by AUTHORISED SERVICE PERSONNEL
SC Special check-up - measuring, verifying tolerances and functionality - DONE BY AUTHORISED
SERVICE PERSONNEL ONLY
OOverhaul
daily rst 5
hours
50
hours
100
hours
200
hours
500
hours
1.000
hours
10.000
hours
WING AND TAIL SURFACES SC O
surface and structure condition C SC
deections without free play C SC
bearings - moving parts’ bushings C SC
lights C
self-adhesive sealing tape C C SC
horizontal tail mount C C SC
drain holes CL

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Servicing the aircraft
daily st 5
hours
50
hours
100
hours
200
hours
500
hours
1.000
hours
10.000
hours
FUSELAGE SC O
surface and structure condition C SC
elevator control tube bearing C SC
undercarriage struts attaching points C C SC
doors, hinges C C SC LO
rudder control wires and hinges C C SC
CABIN SC O
control levers, instr. panel, seats C SC
control levers’ free play C C SC
instruments and pitot-static C check yearly
glass surfaces: clean, attached C C SC
rivet condition C SC
safety harnesses and attach. points C SC
parachute rescue sys. activation handle C SC
wing connectors: fuel, electrical C C SC
bolts and spar pins C C SC
wing main bushings, control connectors SC
UNDERCARRIAGE O
tires C replace on condition or every 5 years
main strut, tail /nose wh. strut condition C C SC
wheel axis and wheels C
hyd. brake lines C SC R
brake uid C SC R (500 hrs or 5 years)
brake discs SC (R on condition)
wheel bearings C SC R
tail wheel main bolt C R
wheel fairings CCC
tail wheel mounting bolt C SC
CONTROLS (LO every 200 hrs or yearly) R
general free play C C SC
control stick CLO SC
rudder pedals (damage, centered, paral.) C C C
rudder wire rope C SC
bolts, visible bearings (tail, fuselage) SC
dicult-to-reach bearings (wings, under cabin oor) LO+SC
aileron, elevator and rudder hinges SC
equal spoiler extension, undistributed m. C SC LO+SC
spoiler plate springs stiness CLO
ap handle C SC
elevator trim C R cable every 500 hrs
springs: aps, rudder, el. trim, stabilizer main fastening bolt LO C R
spoilers’(airbrakes’) drive ne adjustment see page 15 for detailed description

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Servicing the aircraft
daily rst 5
hours
50
hours
100
hours
200
hours
500
hours
1.000
hours
10.000
hours
ENGINE
see enclosed Rotax engine manual for detailed engine maintenance information.
In addition to Rotax manual:
two-stroke engines (overhaul every 300 hours) C
four-stroke engines (overhaul every 1,500 hours) from engine serial number 4404718
engine cover screws C C C
engine mount C C SC
engine mount dumpers and other
rubber parts C SC R every 500 hrs or every 5 years
air lters C C CL SC
elect. terminals, joints and
connectors, hoses, radiator mount C C SC
exhaust muer C C SC SC
exhaust pipe springs and re protect. C C SC R
throttle, choke, propeller wire drive SC R
ENGINE CONTROL O
choke and throttle lever wire ropes C C SC R
levers C SC
PROPELLER AND SPINNER SC O
surface condition C
fastening bolts R
propeller bushings R
propeller pitch C SC
propeller balance C SC
FUEL SYSTEM O every 1000 hrs or 5 years
general leakage C C SC
water inside gascolator C
dirt and gascolator lter CL CL CL R
wing fuel tank caps C
fuel tank caps o-ring R every 500 hrs or 5 years
fuel valves and leakage C
ELECTRICAL WIRING SC R
battery C C SC
battery uids C C SC
instr.panel wires and connectors C C
NAV, AC and LDG lights C C
fuses C C

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Servicing the aircraft
1
2
34
5
4
daily rst 5
hours
50
hours
100
hours
200
hours
500
hours
1.000
hours
10.000
hours
OIL AND WATER LINES O every 500 hrs or 5 years
oil and cooling uids level C C
oil and cooling uids leakage C C
four stroke engine oil (and engine
lter) rst 25 hours + refer to engine manual
cooling uid (level) refer to engine manual
hoses C C R
radiators C C
water radiator pressure cap refer to engine manual
PITOT-STATIC LINING SC O
instrument to pitot tube lining C C
instrument setting C C
pitot tube condition (clean, rmly att.) C C
whole pitot-static lining C C
Spoilers’(airbrakes’) drive ne adjustment
CAUTION! Perform this operation only once after rst 50 ight hours! Check spoilers
thoroughly for unobstructed, smooth and even extension every 200 ight hours!
Schematic of spoilers’(airbrakes’) drive ne adjustment
(see next page for detailed description)

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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.
Do not lose any parts!
Rotate the rod-end bearing ne-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 360°!
Grease the drive around the rubber sleeve 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 verify airbrakes for equal extension.
WARNING! Should the airbrakes not retract evenly, apply step action 4 again for the air-
brake, which remains higher when retracting.
Vital stages of spoilers’ (airbrakes’) drive ne adjustment in pictures
1
2
3
4
5
Spoiler’s (Airbrake’s) plate
1 1
Horizontal bolt of the AB’s plate
3
Rod-end bearing
4

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Clicking noise overhead
The wings are factory tted to the fuselage to make a tight t at approximately 20° Celsius. When ex-
posed to low temperatures, materials shrink. Therefore, ying 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, typically 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 stiness
To adjust the stiness of tail wheel steering 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, tightening or loosing, you apply equal number of
screw rotations at both sides. To check if the steering clutch is sti enough, lift the tail and rotate the
fork left and right. At the end, reattach both springs to the tubes again.
(see Service manual for photos)
Venting the hydraulic brakes’lining
In case you notice poor braking action even when hydraulic brake levers are depressed fully, it is
most denitely necessary to vent the hydraulic lining. To do so, rst unscrew the caps of small uid
reservoirs (behind rudder pedals on one side of the cockpit) and remove the inner seal cap.
At the side where there are no uid reservoirs grab the whole rudder pedal and deect it back fully,
so that it becomes level with the cockpit’s oor beneath. Now, at the side where there are uid res-
ervoirs, jerk brake levers back and forth a couple of times - this will push air bubbles towards the
reservoir and out of the lining. When convinced air bubbles are no more, put seal caps back onto the
reservoirs and screw the caps on as well. Repeat the procedure for the other brake lever.
WARNING! Should you encounter any diculties during this procedure or the air bubbles
would not vent, please consult the manufacturer or authorised service personnel for further
instructions.

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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 main axis’nut (especially after a wheel and/or axis replacement nut) 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
Schematic of hydraulic brakes’lining

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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 (black) & Relay (top-right)
Top-left nipple (c. positive (+) wire here) Exhaust (connect negative (-) wire here)
To connect an auxiliary 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 rewall. This relay has 3 nipples; the positive (+) wire must be connected to the upper-left
nipple, 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!The 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.

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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
a FRP professional!
Denition of minor damage
Only the damage listed below can be considered as minor damage repairable by oneself.
Any damage limited to gelcoat or ller.
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)
Horizontal stabilizer: 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 ttings 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 lm or Styrofoam plates.
Filler
For gluing, the resin-hardener mix should be thickened with chopped cotton bres FL l f. (add
enough so that the resin no longer ows). The surfaces to be glued should be wetted with non-thick-
ened resin & hardener before.
To glue foam pieces into place when repairing sandwich sections and to ll 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 ocks.
WARNING! Only materials listed on page 9 should be used. Only damage dened above
should be repaired.