AMM-100-00-60-001 - A00 LSA Maintenance Manual PDF

LSA AIRCRAFT
MAINTENANCE MANUAL
This manual is common to the following aircraft:
Sinus 912 LSA (glider and aeroplane)

Virus 912 LSA (glider and aeroplane)
Virus SW 80/100 LSA (aeroplane)
ALPHA Trainer (aeroplane)
Equipped with Rotax 912 (80 hp) and 912 series (100 hp) engines
Valid for tail-wheel and nose-wheel versions
Document No.: AMM-100-00-60-001*

*This document supersedes LSA maintenance manual REV 5 (19th November 2015)
REVISION A00
Date of Issue: March 22nd, 2019
Aircraft Registration Number:
Aircraft Serial Number:
All rights reserved. Reproduction or disclosure to third parties of this document or any part thereof is not permitted,
except with the prior and express written permission of Pipistrel Group’s R&D division, Pipistrel Vertical Solutions d.o.o.,
which is authorized to publish technical documentation for Pipistrel Group’s subsidiaries.
Sinus
Virus
ALPHA Trainer
LSA
WARNING!
As this manual applies to several models of Pipistrel aircraft, it is mandatory
to designate those specific parts of this manual that regard the aircraft you operate
The airplane must be operated in compliance with

information and limitations contained herein
PAGE PAGE REV. 0

ii
LSAALPHA
Sinus
Virus
Trainer
Table of contents
GROUP CHAPTER SUBJECT
INTRODUCTION
GENERAL
04-00 AIRWORTHINESS LIMITATIONS
05-00 TIME LIMITS AND MAINTENANCE CHECKS

06-00 DIMENSIONS AND AREAS
07-00 LIFTING AND SHORING
08-00 LEVELING AND WEIGHING
AIRCRAFT 09-00 TOWING AND TAXIING

10-00 PARKING, MOORING AND STORAGE
11-00 REQUIRED PLACARDS
12-00 SERVICING
20-00 STANDARD PRACTICES - AIRFRAME
21-00 ENVIRONMENTAL SYSTEMS
22-00 AUTOPILOT SYSTEM
24-00 ELECTRICAL POWER
25-00 EQUIPMENT AND FURNISHING
27-00 FLIGHT CONTROLS
SYSTEMS
28-00 FUEL
31-00 INDICATING/RECORDING SYSTEMS
32-00 LANDING GEAR
33-00 LIGHTS
34-00 NAVIGATION AND PITOT-STATIC SYSTEMS
51-00 STANDARD PRACTICES - STRUCTURES
52-00 DOORS
53-00 FUSELAGE
STRUCTURES
55-00 STABILIZERS
56-00 WINDOWS
57-00 WINGS
PROPELLER 61-00 PROPELLER
71-00 POWER PLANT

72-00 ENGINE
73-00 ENGINE FUEL
POWER
75-00 ENGINE COOLING
PLANT
76-00 ENGINE CONTROLS
77-00 ENGINE INDICATING
78-00 EXHAUST
91-00 WIRING DIAGRAMS
OTHER 95-00 SPECIAL PURPOSE EQUIPMENT

99-00 APPENDICES
PAGE REV. 0 PAGE

iii
Sinus
Virus
ALPHA Trainer
LSA
SCOPE
This LSA Aircraft Maintenance Manual (AMM) was prepared by Pipistrel Vertical Solutions d.o.o.
for trained aviation mechanics. It contains a wealth of information about how to successfully clean,
inspect, service, remove/install equipment on and operationally inspect the Pipistrel’s LSA aircaft.
It does not, however, contain everything needed to keep the aircraft in airworthy condition. This
manual must be used in conjunction with the installation/user/maintenance manuals pertaining
to the components/equipment found on the airplane. Moreover all airworthiness directives (AD)
issued by the NAA in the country where the aircraft is registered must be adhered to. For ordering
information and part numbers please refer to the applicable illustrated parts catalogue (IPC).
GENERAL NOTES
In case of aircraft damage or people injury resulting form disobeying instructions in the manual
PIPISTREL denies any responsibility. All text, design, layout and graphics are owned by PIPISTREL.
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, unless they are directly related
to the operation of our aircraft by an owner or his appointed maintenance authority.
IT IS MANDATORY TO CAREFULLY STUDY THIS MANUAL PRIOR TO

USING/SERVICING THE AIRCRAFT
The owner who is also a Sport Pilot Certificate holder or their appointed maintenance
provider are obliged to check for current documentation revisions before each maintenance
event.
SPARE PARTS
All OEM and non-OEM replacement and spare parts can be ordered directly from your local dis-
tributor/dealer.
WARNING: WHEN SERVICING OR REPLACING PARTS ALWAYS USE THE SAME PART
AS USED ORIGINALLY!
PAGE PAGE REV. 0

iv
LSAALPHA
Sinus
Virus
Trainer
USING THIS MANUAL
This manual’s structure is consistent with the standard chapter numbering system ATA 100. It’s
chapters also correlate to those listed in ASTM F2483-12, standard practice for maintenance and
the development of maintenance manuals for light sport aircraft (See APPENDIX 99-A). The header
on each page clearly displays the chapter number and chapter name. The page number and page
revision number are displayed in the footer of each page.
The following warnings, cautions and notes can be found throughout this manual. They provide ad-
ditional information about particular procedures and makes the owner/operator/mechanic aware
of any safety hazards.
WARNING: These provide crucial information about things that may cause bodily harm.
CAUTION: These provide information about things that may component damage.
NOTE: These provide information such as tips and hints that aid the mechanic when carrying out
a specific procedure.
Revision tracking, filing and identifying

Pages to be removed or replaced in the Aircraft Maintenance Manual are determined by the log
of effective pages located in this section. This log contains the page number and revision number
for each page within the AMM. As revisions to the AMM occur, the revision number on the effected
pages is updated and the page number in the log is highlighted with bold font type. When two
pages display the same page number, the page with the latest revision shall be used in the AMM.
The revision number on the log of effective pages shall also coincide with the revision number
of the page in question. As an 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 bar that extends the full length of deleted, new, or re-
vised text added to new or previously existing pages. This marker will be located adjacent to the
applicable text in the marking on the outer side of the page. The same system applies to revised
figures, tables and any other elements inside this AMM. A list of revisions is located at the begin-
ning of the log of effective pages. Pipistrel is not responsible for technical changes/updates to
OEM manuals supplied with the aircraft (e.g. radio, transponder, GPS, etc.).
PAGE REV. 0 PAGE

v
Sinus
Virus
ALPHA Trainer
LSA
TASK DESCRIPTION
Each inspection or maintenance task described in this manual is defined by an applicability and
qualification table. Applicability information defines to which aircraft type the task is applicable.
Qualification information defines the MINIMUM maintenance qualification owned by the technician
to be allowed to perform the task. American and Australian LSA ratings are described.
NOTE: This manual applies to multiple aircraft type. Some task descriptions are generalized in
order to be applicable to many types. Some tasks or descriptions might not apply to all the models
or equipments.
Applicability and qualification table
The example below refers to a task applicable to Sinus 912 LSA, Virus 912 LSA and ALPHA Trainer
types, but not to Virus SW model. Minimum required qualifications to perform the task are: Owner,
for USA LSA market and L1 maintenance authority or Pilot/Owner in the Australian market.
AUSTRALIAN LSA
Type applicability Qualification rating
Task designation information USA LSA
Qualification information
rating
information
PAGE PAGE REV. 0

vi
LSAALPHA
Sinus
Virus
Trainer
Aircraft types are defined by the following abbreviations and acronyms:
TYPE APPLICABILITY information:
Aircraft type Abbreviation or acronym
Sinus 912 LSA (glider and aeroplane) SIN
Virus 912 LSA (glider and aeroplane) VIR
Virus SW 80/100 LSA (aeroplane) VSW
ALPHA Trainer (aeroplane) AT
Technical qualification ratings are defined by the following abbreviations and acro-
nyms:
USA LSA - QUALIFICATION information:
(Minimum) qualification rating Abbreviation or acronym
Owner who holds a sport pilot certificate O
Light sport repairman with maintenance rating LSRM
Aircraft maintenance technician with appropriate

AMT
airframe (A) or powerplant (P) rating, or both
Certified repair station CRS
Manufacturer M
Task specific training TST
AUSTRALIAN LSA - QUALIFICATION information:

RA-Aus (minimum) qualification rating Abbreviation or acronym
Level 1 maintenance authority L1*
Level 2 maintenance authority L2
CASA (minimum) qualification rating Abbreviation or acronym

Pilot/Owner P/O
Light aircraft maintenance engineer LAME

*Any procedures found in this manual that require an L1 maintenance authority are to be performed
by an L2 maintenance authority IF the aircraft is used for hire or flight training.
PAGE REV. 0 PAGE

vii
Sinus
Virus
ALPHA Trainer
LSA
Index of document revisions
Document
Reason for revision Date issued Authority
revision
A00 Initial release March 22nd, 2019 SLO.DOA.002
PAGE PAGE REV. 0

viii
LSAALPHA
Sinus
Virus
Trainer
List of effective pages
PAGE PAGE PAGE PAGE PAGE PAGE PAGE PAGE

NUMBER REVISION NUMBER REVISION NUMBER REVISION NUMBER REVISION
7 11
Cover 0 05-01 0 07-01 0 11-01 0
ii 0 05-02 0 07-02 0 11-02 0
iii 0 05-03 0 07-03 0 11-03 0
iv 0 05-04 0 07-04 0 11-04 0
v 0 05-05 0 07-05 0 11-05 0
vi 0 05-06 0 07-06 0 11-06 0
vii 0 05-07 0 11-07 0

08-01 0
5 8
viii 0 05-08 0 11-08 0
08-02 0
ix 0 05-09 0 11-09 0
08-03 0
x 0 05-10 0 11-10 0
08-04 0
xi 0 05-11 0 11-11 0
08-05 0
xii 0 05-12 0
08-06 0 12-01 0
xiii 0 05-13 0
08-07 0 12-02 0
9 12
xiv 0 05-14 0
12-03 0
4
05-15 0 09-01 0
04-01 0 12-04 0
05-16 0 09-02 0
04-02 0 12-05 0
05-17 0 09-03 0
04-03 0 12-06 0
05-18 0 09-04 0
04-04 0 12-07 0
05-19 0 09-05 0
04-05 0 12-08 0
05-20 0
10-01 0 12-09 0
6 10
05-21 0
10-02 0 12-10 0
06-01 0 10-03 0 12-11 0
06-02 0 10-04 0 12-12 0
06-03 0 10-05 0 12-13 0
06-04 0 10-06 0
10-07 0
PAGE REV. 0 PAGE

ix
Sinus
Virus
ALPHA Trainer
LSA
List of effective pages (continued)

20-01 0 24-01 0 27-01 0 28-01 0
20 24
20-02 0 24-02 0 27-02 0 28-02 0
20-03 0 24-03 0 27-03 0 28-03 0
20-04 0 24-04 0 27-04 0 28-04 0
20-05 0 24-05 0 27-05 0 28-05 0
28
20-06 0 24-06 0 27-06 0 28-06 0
20-07 0 24-07 0 27-07 0 28-07 0
20-08 0 27-08 0 28-08 0

25-01 0
20-09 0 27-09 0 28-09 0
25-02 0
25 27
27-10 0 28-10 0
21-01 0 25-03 0
21
27-11 0 28-11 0
21-02 0 25-04 0
27-12 0 28-12 0
21-03 0 25-05 0
27-13 0 28-13 0
21-04 0 25-06 0
27-14 0 28-14 0
21-05 0 25-07 0
27-15 0 28-15 0
21-06 0 25-08 0
27-16 0 28-16 0
21-07 0 25-09 0
27-17 0 28-17 0
22-01 0 27-18 0
31-01 0
22
22-02 0 27-19 0
31-02 0
22-03 0 27-20 0
31-03 0
22-04 0 27-21 0
31-04 0
31
22-05 0 27-22 0
31-05 0
22-06 0 27-23 0
31-06 0
22-07 0 27-24 0
31-07 0
27-25 0
31-08 0
27-26 0
31-09 0
27-27 0
31-10 0
31-11 0
31-12 0
31-13 0
PAGE PAGE REV. 0

x
LSAALPHA
Sinus
Virus
Trainer

32-01 0 34-01 0 53-01 0 57-01 0
53
32-02 0 34-02 0 53-02 0 57-02 0
32-03 0 34-03 0 53-03 0 57-03 0
32-04 0 34-04 0 53-04 0 57-04 0
57
32-05 0 34-05 0 53-05 0 57-05 0
32 34
32-06 0 34-06 0 53-06 0 57-06 0
32-07 0 34-07 0 53-07 0 57-07 0
32-08 0 34-08 0 57-08 0
55-01 0
32-09 0 34-09 0 57-09 0
55-02 0
32-10 0
55
34-10 0 57-10 0
55-03 0
32-11 0 34-11 0 57-11 0
55-04 0
32-12 0 34-12 0 57-12 0
55-05 0
32-13 0 34-13 0 57-13 0
55-06 0
32-14 0 34-14 0 57-14 0
55-07 0
32-15 0 34-15 0
55-08 0 61-01 0
61
32-16 0
51-01 0 55-09 0 61-02 0
32-17 0
51
51-02 0 61-03 0
56-01 0
33-01 0 51-03 0 61-04 0
33
56-02 0
33-02 0
56
51-04 0 61-05 0
56-03 0
33-03 0 51-05 0 61-06 0
56-04 0
33-04 0 51-06 0 61-07 0
56-05 0
33-05 0 51-07 0
56-06 0
33-06 0 51-08 0
56-07 0
33-07 0
52
52-01 0 56-08 0
33-08 0
52-02 0 56-09 0
52-03 0
52-04 0
52-05 0
52-06 0
PAGE REV. 0 PAGE

xi
Sinus
Virus
ALPHA Trainer
LSA

75 95
71-01 0 75-01 0 91-01 0 95-01 0
71-02 0 75-02 0 91-02 0 95-02 0
71-03 0 75-03 0 91-03 0 95-03 0
71
71-04 0 75-04 0 91-04 0 95-04 0
71-05 0 75-05 0 91-05 0 95-05 0
71-06 0 75-06 0 91-06 0 95-06 0
76
71-07 0 91-07 0
76-01 0 99-01 0
71-08 0 91-08 0
76-02 0 99-02 0
71-09 0 91-09 0
76-03 0 99-03 0
71-10 0 91-10 0
91
76-04 0 99-04 0
71-11 0 91-11 0
76-05 0 99-05 0
71-12 0 91-12 0
99-06 0
71-13 0 77-01 0 91-13 0
72 77
99-07 0
77-02 0 91-14 0
72-01 0 99-08 0
77-03 0 91-15 0
99
72-02 0 99-09 0
77-04 0 91-16 0
72-03 0 99-10 0
77-05 0 91-17 0
72-04 0 99-11 0
77-06 0 91-18 0
99-12 0
73-01 0 77-07 0 91-19 0
99-13 0
73
73-02 0 91-20 0
78-01 0 99-14 0
73-03 0 91-21 0
78-02 0 99-15 0
78
73-04 0 91-22 0
78-03 0 99-16 0
73-05 0 91-23 0
78-04 0 99-17 0
73-06 0 91-24 0
78-05 0 99-18 0
73-07 0 91-25 0
78-06 0 99-19 0
91-26 0
78-07 0 99-20 0
91-91 0
78-08 0 99-21 0
91-28 0
78-09 0 99-22 0
91-29 0
99-23 0
99-24 0
PAGE PAGE REV. 0

xii
LSAALPHA
Sinus
Virus
Trainer
AIRCRAFT DESCRIPTION
Pipistrel’s Virus/Sinus/ALPHA-Trainer are all-composite, high wing monoplanes with cantilevered

wings, conventional empennage (T-tail) and tricycle or bicycle landing gear configuration (not avail-
able for ALPHA Trainer). The nose landing gear is integrated into the engine mount. It`s steerable,
connected to the pedals and incorporates an oil-spring shock-absorber element. The tail landing
gear is connected to the rudder and it is steerable actuating the rudder pedals. The load-bearing
structure of the airplane is made of carbon fiber composite material, the components of which, ep-
oxy resin as well as carbon fiber materials. The proven low-pressure wet lay-up method from sail
plain industry is used to build the airplane structure. The aircraft is powered by a Rotax - 80 or 100
hp, depending on aircraft type and configuration.
PAGE REV. 0 PAGE

xiii
Sinus
Virus
ALPHA Trainer
LSA
List of abbreviations
Abbreviation Description
AD Airworthiness directives
AMM Aircraft maintenance manual
COG or CG Centre of gravity
ELT Emergency locator transmitter
ICA Instructions for continued airworthiness
IPC Illustrated parts catalogue
MAC Mean aerodynamic chord
MLG Main landing gear
MM Maintenance manual
MRA Major repair and alteration
OEM Original equipment manufacturer
OM Operator’s manual
POH Pilot operating handbook
SB Service bulletin
SL Service letter
WBR Weight and balance report
PAGE PAGE REV. 0

xiv
LSAALPHA
Sinus
Virus
Trainer
List of applicable OEM documents
The following is a list of OEM documents that should be on hand whenever the aircraft is being ser-
viced or maintenance procedures are being performed. They’re referred to frequently throughout
this manual by a number in square brackets.
NOTE: Only the latest version/revision of the documents listed below should be used.
NOTE: Please refer to Pipistrel Website for the current status of all Pipistrel documents and bulle-
tins.
NOTE: Some of the maintenance procedures found in the OEM manuals below may or may not
be referenced to in this manual. It is the responsibility of the owner, operator and/or maintenance
personnel to acquaint themselves with their content before conducting any maintenance on the
aircraft.
Reference OEM Document

[1] Rotax 912 series MM
[2] Propeller manual - * see table below for type list and refer to the specific manual
[3] TOST GmbH operating manual for tow release
[4] Beringer wheel/brake system MM
[5] Kannad 406 AF compact / Artex 345 ELT MM **
* List of installed propellers and applicable manuals:

Propeller type Manual
FP02-80 ALPHA Trainer LSA - Wood propeller operators manual (by Pipistrel)
Vario D POM-VARIO-00-65-001 Pipistrel VARIO propeller operators manual
MTV (MT-Propeller)
Varia (Woodcomp) See propeller’s manufacturer original maintenance manual **
SR3000 (Woodcomp)
** Check the equipment list of the aircraft and refer to the applicable original technical documenta-
tion issued by the component manufacturer.
PAGE REV. 0 PAGE

xv
Sinus
Virus
ALPHA Trainer
LSA
ICAs and other applicable publications

The owner/operator or any maintenance personnel is required to acquaint themselves with all
applicable ICAs before performing any maintenance procedures. To access all publications that
pertain to your aircraft, including ICAs, please visit www.pipistrel-aircraft.com and login to our tech-
nical publication portal using the following:
Username: owner1
Password: ab2008
Repairs, alterations or maintenance not covered by AMM
According to the applicable ASTM standards, any repair, alteration or maintenance not covered
by the Aircraft Maintenance Manual (AMM) requires authorization from the Original Equipment
Manufacturer (OEM).
Please refer to Appendix 99-D for additional details what an LSA MRA is and how to request one.
PAGE PAGE REV. 0

xvi
04
Sinus
Virus
ALPHA Trainer
LSA
CHAPTER 04 – AIRWORTHINESS LIMITATIONS
TABLE OF CONTENTS
SECTION SUBJECT PAGE NUMBER

General
04-00 Maintenance limitations 04-03
Structural limitations
PAGE PAGE REV. 0

04-02
LSAALPHA
Sinus
Virus
Trainer
04-00
AIRWORTHINESS
LIMITATIONS
04-00 GENERAL
Chapter 04-00 of this airplane maintenance manual (Airworthiness Limitations) is approved under
the authority of SLO.DOA.002. It shows the mandatory limitations that apply to Virus/Sinus/ALPHA
Trainer series aircraft and outlines the maximum replacement intervals and/or maintenance re-
quirements for aircraft components, systems, and structures determined to be life limited and/or
require monitoring through scheduled maintenance.
Where an interval is given in both flight time and calendar years, the limit that is reached first must
be applied.
The time limits given in chapter 04 must be applied to ensure continued airworthiness of the air-
craft.
NOTE: Regular inspections of the airplane including replacement and overhaul of certain compo-
nents are required to ensure continued airworthiness of the aircraft.
The following airworthiness limitations and requirements are separated into groups as described
below.
Maintenance Limitations - Component and system checks required to be performed during air-
plane scheduled maintenance.
Structural Limitations – Listing of any limitations associated with the aircraft’s structure.
GENERAL
PAGE REV. 0 PAGE

04-03
Sinus
Virus
ALPHA Trainer
LSA
04-00
AIRWORTHINESS
LIMITATIONS
1. Maintenance limitations
The scheduled maintenance requirements listed below must be adhered to:
• Paint
Areas exposed to direct sunlight must remain in original white color. No other color is permitted.
Only certain areas which are defined in chapter 51-00 of this manual (for example, registration
markings, placards and warning markings) may have a different color. The color for registration
markings is (grey, red, blue).
• Paint Finish
Allowable paint on the wing will have an absorptivity not greater than 0.4, with an emissivity of at
least 0.9.
The maximum allowable paint on the fuselage will have an absorptivity not greater than 0.6, with
an emissivity of at least 0.7.
PAGE PAGE REV. 0

04-04
LSAALPHA
Sinus
Virus
Trainer
04-00
AIRWORTHINESS
LIMITATIONS
2. Structural limitations
The certification requirements require that the composite airframe structure, cabin, wing,
empennage, their carry-through and attaching structure, whose failure would be catastrophic,
must be designed to safe life cycle.
Pipistrel aircraft have been designed and tested for a selected airframe life of 10,000 hours with no
special structural limitations or inspections.
The structural inspections given in chapter 05-00 cover all required structure checks.
GENERAL
PAGE REV. 0 PAGE

04-05
This page is intentionally left blank.
05
Sinus
Virus
ALPHA Trainer
LSA
CHAPTER 05 – TIME LIMITS AND MAINTENANCE CHECKS
TABLE OF CONTENTS

05-00 GENERAL 05-03
05-10 TIME LIMITS 05-04
05-20 SCHEDULED MAINTENANCE 05-06

AIRPLANE OPERATIONAL AND FUNCTIONAL CHECK
05-30 Description 05-15
Maintenance practices
05-50 UNSCHEDULED MAINTENANCE 05-16
PAGE PAGE REV. 0

05-02
LSAALPHA
Sinus
Virus
Trainer
05-00
GENERAL
05-00 GENERAL
It is the aircraft owner’s responsibility to keep the Aircraft in good, airworthy condition at all times
and this chapter provides information on how to do it. It covers topics such as recommended
intervals for the overhaul/replacement of components, scheduled/unscheduled maintenance for
the Aircraft and general maintenance hints/tips. The time intervals mentioned in this chapter are
those recommended by the manufacturer, Pipistrel d.o.o., and should be considered the minimum
required to keep the airplane in good operating condition.
It should be noted, however, that the NAA in the country where the aircraft is registered may have
different requirements regarding time limits and maintenance checks. Its requirements must be
adhered to at all times, including any directives or bulletins it issues. The requirements found in this
manual DO NOT override those of the NAA.
All of the intervals and checks outlined in this manual were established based on test data taken
in moderate conditions on grass runways. If the aircraft is operated in extreme conditions, such
as those with drastically high/low temperatures, sandy environments and/or air with a higher than
normal salt content, shortening the recommended intervals is advisable.
CAUTION: The NAA of the country where the aircraft is registered may, if deemed necessary,
choose to shorten and/or lengthen the time limit/inspection intervals in this chapter. The aircraft
owner/operator is required to acquaint themselves with NAA alterations/changes before main-
taining/servicing the aircraft.
NOTE: Pipistrel reserves the right to change the contents of this manual, including maintenance
intervals, and all/any changes will be published in the form of a revision.
NOTE: Only qualified aircraft mechanics with the appropriate rating (see page vii) are permitted to
carry out the maintenance procedures outlined in this maintenance manual.
AIRCRAFT
PAGE REV. 0 PAGE

05-03
Sinus
Virus
ALPHA Trainer
LSA
05-10
TIME LIMITS
05-10 TIME LIMITS
Certain components installed on the Pipistrel’s aircrafts have time limits which dictate when they’re
supposed to be overhauled or replaced. This chapter provides information about these limits.
Pipistrel recommends the following items be overhauled or replaced at the following intervals or
“On Condition” (O/C). O/C items must be overhauled or replaced when, upon inspection, it’s deter-
mined that they’re faulty, have incurred damage, are unserviceable or in bad condition.
CAUTION: All of the time limits outlined in Table 05-001 must be considered when performing
the 100 hour/Annual inspection. Removal or overhaul of any these items must be entered into the
aircraft technical log book.
CAUTION: If a components time limit is to occur before the next planned inspection, it must be
included in the current inspection.
NOTE: The limits mentioned in Table 05-001 DO NOT indicate product lifetime and must not be
interpreted as such.
NOTE: The aircraft owner/operator and/or the person maintaining/servicing the aircraft is re-
quired to acquaint themselves with and implement the time limits listed in the various mainte-
nance manuals referred to in Table 05-001.
PAGE PAGE REV. 0

05-04
LSAALPHA
Sinus
Virus
Trainer
05-10
TIME LIMITS
Item Interval Maintenance

Description Notes/Reference
No. HRS YRS OH RPLC
Beringer wheel/brake Caliper pistons and piston seals. Wheel o-rings, bear-
1 10 X
assembly ings and bolts. See [4]
Beringer wheel/brake
2 5 X Brake disc. See [4]
assembly
5 Landing gear tires 5* X *On condition or every 5 years. See 32-00.
Standard wheel/brake
6 10000 X See 32-00
assembly - brake lines
See 32-40 and 12-10
7 Hydraulic brake fluid 1000* 5* X
*Whichever comes first
* After one hour of real transmission or before/on the
8 ELT battery 1* X
battery expiration date. [5]
9 ELT system 6* * Various tests, inspection and replacements. [5]
10 Propeller Assembly Depending on propeller installed See [2]
11 Engine Fuel Pump 5 X See [1] and Pipistrel video PV-111-001**
12 Auxiliary Fuel pump 2000 X
Akrapovič single and double
13 2000 X See 78-20
tail pipe muffler
14 Standard muffler 1000 X See 78-20
Exhaust system springs and
15 X On condition - all springs
fire protection
16 Throttle and choke cables 5 X See Pipistrel video PV-111-001**
See [1] – Extending or exceeding the TBO by %5 or 6
17 Engine 2000 15 X
months is allowed, whichever comes first
Or during overhaul at the latest or when the engine is
18 Coolant 5 X replaced, whichever comes first.
See Pipistrel video PV-111-001**
19 Nose gear shock absorber 2000 X See 32-20
20 All flexible fuel lines 5 X See Pipistrel video PV-111-001**
21 Flexible oil lines 5 X See Pipistrel video PV-111-001**
22 Flexible vent lines 5 X See Pipistrel video PV-111-001**
23 Rubber coolant hoses 5 X See Pipistrel video PV-111-001**
24 Gascolator filter 5 X See Pipistrel video PV-111-001**
Engine mount rubber *Replace earlier if required. See [1]
25 5* X
isolators See Pipistrel video PV-111-001**
26 Fuel filter (ALPHA Trainer) 500 5* X *Whichever comes first
GRS ballistic parachute *Rescue system needs to be removed, sent to OEM and
27 30 X
rescue system replaced. See 95-00
GRS ballistic parachute *Rescue system needs to be removed and sent to OEM
28 6*
rescue system for repacking. See 95-00
TOST tow release mecha- * (if present), 2000 takeoffs (equivalent to 10000 actua-
29 * * X
nism tions/releases). See [3]
Elevator trim cable
30 1000 X* * cable replacement
(mechanical trim)
AIRCRAFT
Control system springs

31 (rudder, el.trim, stabilizer X On condition
main bolt)
32 Electrical wiring 10000 X
**This video depicts the maintenance procedures required to be performed every 5 years. To gain access to the video send a request to
[email protected]
For Sinus and Virus aircraft the required kit part number is 1150267
For ALPHA Trainer the required kit part number is 1150270
Table 05-001
PAGE REV. 0 Time Limits PAGE
05-05
Sinus
Virus
ALPHA Trainer
LSA
05-20
SCHEDULED
MAINTENANCE
05-20 SCHEDULED MAINTENANCE

The inspection schedule outlined in this chapter is what the manufacturer, PIPISTREL, regards as
the minimum, in order to keep the aircraft in airworthy condition. The owner/operator is respon-
sible for keeping the aircraft in airworthy condition and shall use this chapter as a guide. It is not,
however, by any means the only guide that should be used. The airworthiness directives issued by
the aviation authority in the country the aircraft is registered in MUST be adhered to as well. The
The aircraft owner/operator is responsible to ensure maintenance/service personnel, chosen to
perform maintenance, meet the required qualifications, as outlined in this manual.
CAUTION: The owner/operator must give any personnel carrying out maintenance/servicing
procedures on the aircraft access to records of any past maintenance, as well as all of the air-
craft’s documentation.
VISUAL INSPECTION
The most common task found in the Aircraft’s inspection schedule is the visual inspection. This
is essentially an inspection to determine the general state of a component and typically does not
require disassembly/removal of any other assemblies/equipment nearby. It is to be performed ac-
cording to the following criteria and with any/all aids deemed necessary:
Metal Parts – discolouration due to heat exposure, distortion, wear/cracks due to fatigue, corro-
sion, weld damage, cleanliness and any other forms of damage.
Moving Components – Proper and unhindered operation, alignment, sufficient sealing, cleanli-
ness, sufficient lubrication, travel, general condition, fastening material secured, signs of excessive
wear, cracking, corrosion, deformation, and any other forms of damage.
Fuel, Air, and Oil Lines – Kinks, deterioration, chafing, poor flexibility, obstruction, bend radius,
cleanliness, sufficiently secured/fastened and any other forms of damage.
Fastening Material - corrosion, wear, damage, loosening (paint marker) and safety wiring intact.
Composite Components – general condition, cleanliness, deformation, dents, warpage, cracks,

scratches and any other forms of damage/wear. Composite surfaces that are bare, therefore, not
painted, can also be checked for signs of delamination, fluid saturation and wear.
NOTE: If any composite component damage is found, a tap test should be performed to determine
how extensive it is. Refer to 51-10 for additional guidelines on how to properly perform a visual in-
spection and/or tap test on composite components.
Electrical Installations - loose, corroded, or broken terminals/connectors; chafed, broken, or worn

insulation; fastening material intact, heat deterioration, deformation, hardening, and any other
forms of damage.
PAGE PAGE REV. 0

05-06
LSAALPHA
Sinus
Virus
Trainer
05-20
SCHEDULED
MAINTENANCE
Filters and Screens - contamination, obstructions, signs of wear/damage.
Areas with Liquids - Evidence of leaks, sealant condition, signs of bacteria growth, cleanliness,
corrosion, delamination, separation of bond, and structural fatigue.
OPERATIONAL INSPECTION
The second most common task found in the Aircraft’s inspection schedule is the operational in-
spection. This is essentially an inspection to determine whether the component/part/assembly
functions properly and does what it’s supposed to do. Operational inspections of control surfaces
must include a positive check, which is where one person holds the control surface steady, while
the other moves the flight controls in both directions. This check confirms that movement of the
flight controls results in movement of the control surface.
NOTE: It is expected that whenever a specific part or component is inspected, the inspection will
include observation and evaluation of the component’s surrounding area.
SCHEDULED MAINTENANCE PROGRAMS AND REQUIREMENTS
All airplanes of EU registry must undergo a complete “a 100 Hour Inspection Program” each 12
calendar months and additional requirements of the NAA of the country where the airplane is
registered.
The 100 Hour Inspection Program is required, in addition to a complete Annual Inspection, for all
airplanes of EU registry.
Inspection Program Intervals
Annual Inspection Time Intervals
The inspection interval to the next Annual Inspection may not exceed twelve calendar months.
For Example: If an inspection were signed off on 14 June 2005, the next Annual Inspection would
be due and must be accomplished no later than 29 June 2006. All subsequent Annual Inspec-
tions will be due in June unless the schedule is reset by performing an Annual Inspection early.
100 Hour Inspection Time Intervals

AIRCRAFT
The interval between 100 Hour Inspections should never be exceeded by more than 10 hours,
and then only if additional time is required to reach a place where the inspection can be satisfac-
torily accomplished. Additionally, the time the interval was exceeded must be included as hours
in the next interval. For example: If a 100 Hour Inspection was due at 650 hours and was actually
signed-off at 658 hours, the next 100 Hour Inspection is due at 750 hours, not 758 hours. Inspec-
tion tolerances cannot be accumulated.
PAGE REV. 0 PAGE

05-07
Sinus
Virus
ALPHA Trainer
LSA
05-20
SCHEDULED
MAINTENANCE
Airplane Operational and Functional Checks
Operational and Functional Checks must be performed before and after Scheduled Maintenance
Inspections to detect any airplane abnormalities or malfunctions. These inspections are listed in
chapter 05-30, Airplane Operational and Functional Checks. (See 05-30).
Unscheduled Maintenance Checks
Abnormal airplane operations require special maintenance checks. Definitions and inspection
procedures for hard/overweight landings, exceeded speed limit, severe air turbulence, lightning
strike, high drag/side loads due to ground handling, and ground gusts are listed in chapter 05-50,
Unscheduled Maintenance Checks.
SCHEDULED INSPECTION REPORT
All references to “05-20” under the “ATA Ref” reference column are to be understood as refer-
ence to Visual Inspection criteria defined above under Inspection Groups and Criteria.
Recommended Overhaul and Replacement Times
Recommended overhaul and replacement times are listed in chapter 05-10, Time Limits. These
maintenance items must be incorporated into the 100 Hour or Annual Inspections as applicable.
Special Inspections
Special/Major inspections are always highlighted in red. Those beginning with the word “and”
indicate that the special inspection is to be performed IN ADDITION TO the regularly scheduled
interval. For example, the following inspection states that in addition to checking the gascolator
every 100 Hours, the inspection should be performed after the first 5 and 50 hours of operation
as well.
Engine Group ATA Ref 50 Hr Annual/ 100 Hr
Gascolator - 05-20 [ ] [x]
Visual inspection and inspection/cleaning 28-20: 2.1.3.
Special Inspection: and after first 5 and 50 hours
If the special inspection includes the word “Only”, this means that the it’s to be performed ONLY
at the specified time interval. For example, the following inspection states that the horizontal sta-
bilizer should be checked every 100 hours following the tasks referenced in “ATA ref” column and
an additional major inspection should be performed ONLY every 2000 hours using the instruc-
tions given in section 51-10: 2.3.
Fuselage and Empennage Group ATA Ref 50 Hr Annual/ 100 Hr
Horizontal Stabilizer - 05-20 [ ] [x]
Visual Inspection 51-10: 2.1.
Major Inspection: Only every 2000 hours (see 51-10: 2.3.)
PAGE PAGE REV. 0

05-08
LSAALPHA
Sinus
Virus
Trainer
05-20
SCHEDULED
MAINTENANCE
Major Inspections
Major Inspections are also highlighted in red and accompanied by the word “and” or “only” (see
Special Inspections). They are thorough, in-depth inspections that determine whether or not the
load-bearing components have incurred any wear/damage that may affect the airworthiness of
the aircraft.
Scheduled Inspection Report

Make: Model: Serial Number: Registration Number:
Owner: Date: Place:

Type of Inspection: [ ] Annual Operating Time:
[ ] 50 Hour [ ] 200 Hour
[ ] 100 Hour [ ] 500 Hour Hours:
[ ] 1000 Hour
[ ] 10000 Hour Landings:
Item Annual/ 200 500 1000 10000

No.
Pre-Inspection ATA Ref 50 Hr
100 Hr Hr Hr Hr Hr
1
Wash and clean the aircraft fully (external and 12-20: 2.6. [ ] [x] [ ] [ ] [ ] [ ]
internal)
Operational/Functional Check 05-30 [ ] [x] [ ] [ ] [ ] [ ]
Perform an airplane run-up in accordance with
Operational Check in 05-30.
Record of all abnormalities during the inspec-
2 tion.
After completing the Operational Check, per-
form a walk around to detect fluid leaks or other
abnormalities.
Review compliance status with current NAA - [ ] [x] [ ] [ ] [ ] [ ]
Aviation Regulations. This includes inspection of
the following:
- Aircraft Log Book
- Registration Certificate
- Certificate of Airworthiness
3 - Weight and Balance Record
- NAA Airworthiness Directives
- POH
NOTE: Please refer to Pipistrel Website and

Tech Pub Portal for the current status of all Pipis-
trel documents that apply to the the airplane.
AIRCRAFT
PAGE REV. 0 PAGE

05-09
Sinus
Virus
ALPHA Trainer
LSA
05-20
SCHEDULED
MAINTENANCE
Annu-
Item 200 500 1000 10000
No.
Engine Group ATA Ref 50 Hr al/ 100
Hr Hr Hr Hr
Hr
25 Hour Inspection - [ ] [ ] [ ] [ ] [ ] [ ]
On new, rebuilt, or overhauled engine, perform
complete 100-Hour Engine Inspection in accor-
1 dance with the manufacturer’s approved Instruc-
tions for Continued Airworthiness, see [1]
Special Inspection: Only first 25 hours,
Perform 100-Hour Engine Inspection in accordance [ ] [x] [ ] [ ] [ ] [ ]
with the manufacturer’s approved Instructions for
2 Continued Airworthiness, see [1] chapter 05-20-00
Special inspection: and if more than 30% of AVGAS
is used.
Engine Cowling - 05-20 [ ] [x] [ ] [ ] [ ] [ ]
3 Perform visual Inspection
Perform operational inspection of oil filler door
4
Foam baffling/seals - 05-20 [ ] [x] [ ] [ ] [ ] [ ]
Visual Inspection, replace if necessary 71-00
Throttle, choke and propeller cable connections on 05-20 [ ] [x] [ ] [ ] [ ] [ ]
5 hot side of firewall - 76-00: 2.1.1.
Visual Inspection 53-30: 2.1.1.
Gascolator - 05-20 [ ] [x] [ ] [ ] [ ] [ ]
6 Visual inspection and inspection/cleaning 28-20: 2.1.3.
Special Inspection: and after first 5 and 50 hours
Exhaust System - 05-20 [ ] [x] [ ] [ ] [ ] [ ]
7 Visual Inspection for soot, distortion, general con-
dition
8
Engine cooling air inlet and diffuser - 05-20 [ ] [ ] [x] [ ] [ ] [ ]
Visual Inspection
Exhaust System - 78-20: 2.1.4. [ ] [*] [ ] [*] [ ] [ ]

Perform inspection/check
9 *100 hours for standard exhaust system, 500 hours
for either of the Akrapovič systems
10
Ventilation system - 05-20 [ ] [x] [ ] [ ] [ ] [ ]
Visual and operational Inspection
11
Engine mount and mounting fixture - 71-20: 2.1.1. [ ] [x] [ ] [ ] [ ] [ ]
Perform inspections/checks 71-20: 2.2.1.
12
Firewall - 53-30: 2.1.1. [ ] [ ] [ ] [ ] [x] [ ]
Visual Inspection
13
Battery cables - 05-20 [ ] [x] [ ] [ ] [ ] [ ]
Visual inspection
Lubrication - 12-20: 2.5. [ ] [*] [*] [ ] [ ] [ ]
14 *Time interval is 100 or 200 hours depending on
the component
Annu-
Item 200 500 1000 10000
No.
Propeller Group ATA Ref 50 Hr al/ 100
Hr Hr Hr Hr
Hr
1
Spinner - [ ] [x] [ ] [ ] [ ] [ ]
See applicable propeller manual [2]
2
Blades - [ ] [x] [ ] [ ] [ ] [ ]
3
Propeller Hub - [ ] [x] [ ] [ ] [ ] [ ]
PAGE PAGE REV. 0

05-10
LSAALPHA
Sinus
Virus
Trainer
05-20
SCHEDULED
MAINTENANCE
Annu-
Item 200 500 1000 10000
No.
Cabin Group ATA Ref 50 Hr al/ 100
Hr Hr Hr Hr
Hr
Cabin windows and windshield - 05-20 [ ] [x] [ ] [ ] [ ] [ ]
Visual Inspection for cracking, crazing, and general 56-00
1 condition.
Perform inspections/checks
2
Magnetic Compass - 05-20 [ ] [x] [ ] [ ] [ ] [ ]
Visual Inspection
Placards and Instrument Markings - 05-20 [ ] [x] [ ] [ ] [ ] [ ]
3 Visual Inspection for conformity, security, and con- 11-20
dition. Replace if necessary
4 Upholstery - Visual Inspection 05-20 [ ] [ ] [ ] [x] [ ] [ ]
5
Seats - 05-20 [ ] [x] [ ] [ ] [ ] [ ]
Visual and operational inspection
6
Safety harnesses - 05-20 [ ] [x] [ ] [ ] [ ] [ ]
7
Instrument Panel - 05-20 [ ] [x] [ ] [ ] [ ] [ ]
Visual Inspection
Avionics + Switch panel 05-20 [ ] [ ] [x] [ ] [ ] [ ]

8 Master switch ON - Avionics switch ON.
Perform visual and operational inspection
Control stick + control stick drive - 27-30: 2.4.1. [ ] [x] [ ] [ ] [ ] [ ]
9 Major Inspection: Only every 3000 Hr
(see 27-30: 2.4.2. and 27-30: 2.5.2. )
Ignition Switch - 05-20 [ ] [ ] [x] [ ] [ ] [ ]
10 Disconnect battery and carry out operational
inspection
Wiring behind the instrument and switch panel -

05-20 [ ] [ ] [ ] [x] [ ] [ ]
11 Perform inspection/check
31-10: 2.3.3.
31-10: 2.1.1.
Rudder Control System -

27-20: 2.1.3. [ ] [x] [ ] [ ] [ ] [ ]
12 Perform inspections/checks
27-20: 2.3.
27-20: 2.2.1.
13
Brake Master Cylinders ** - 05-20 [ ] [ ] [x] [ ] [ ] [ ]
Visual Inspection
14
Brake actuation hand lever ** - 05-20 [ ] [ ] [x] [ ] [ ] [ ]
Visual and operational Inspection
15
Flexible Brake Hoses - 05-20 [ ] [ ] [x] [ ] [ ] [ ]
Visual Inspection
16
Parking brake handle - 05-20 [ ] [x] [ ] [ ] [ ] [ ]
Fuel System Level Gauges ** -

28-40: 2.1.1. [ ] [x] [ ] [ ] [ ] [ ]
17 Perform inspection/check
18
Cabin Doors - 52-10: 2.1.3. [ ] [ ] [x] [ ] [ ] [ ]
Perform inspection/check 52-10: 2.1.4.
AIRCRAFT
Wing spar fastening material - 05-20 [ ] [ ] [x] [ ] [ ] [ ]

19 Remove wings and perform visual inspection of 57-10: 2.1.1.
wings spar pins/bolt
** if applicable
PAGE REV. 0 PAGE

05-11
Sinus
Virus
ALPHA Trainer
LSA
05-20
SCHEDULED
MAINTENANCE
Annu-
Item 200 500 1000 10000
No.
Cabin Group ATA Ref 50 Hr al/ 100
Hr Hr Hr Hr
Hr
20
Rudder Control System - 27-20: 2.1.2. [ ] [ ] [x] [ ] [ ] [ ]
21
Rudder Control System - 27-20: 2.1.3. [ ] [x] [ ] [ ] [ ] [ ]
22
Autopilot pitch and roll servo motors - 22-10:2.2. [ ] [ ] [x] [ ] [ ] [ ]
23
GRS ballistic parachute rescue system activation 95-00: 2.1.1. [ ] [ ] [ ] [x] [ ] [ ]
handle - Perform inspection/check
24 ELT - Visual inspection 05-20 [ ] [ ] [x] [ ] [ ] [ ]

25 ADAHRS - Visual inspection 05-20 [ ] [ ] [x] [ ] [ ] [ ]
Battery installation - 05-20 [ ] [x] [ ] [ ] [ ] [ ]
26 Visual inspection of mounting bracket, cables,
terminals
27
Battery installation - 24:30: 2.1.2. [ ] [ ] [x] [ ] [ ] [ ]
Flaperon control system - 27-50: 2.1.1. [ ] [ ] [x] [ ] [ ] [ ]
28 Major Inspection: Only every 3000 Hours (see 27-50: 2.3.
27-50: 2.4.2. ). 27-50: 2.4.1.
27-50: 2.5.1.
29
Brake system hydraulic fluid - 12-10: 2.5. [ ] [x] [ ] [ ] [ ] [ ]
Check and replenish if necessary
30
Cabin floor - 53-20: 2.1.1. [ ] [ ] [x] [ ] [ ] [ ]
Elevator control system - 27-30: 2.2.1. [ ] [ ] [x] [ ] [ ] [ ]
31 Major Inspection: Only every 3000 Hours (see 27-30: 2.1.
27-30: 2.2.2. ).
32
Air-brake control system - 27-60: 2.1.1. [ ] [ ] [x] [ ] [ ] [ ]
33
Brake actuation lever - 05-20 [ ] [x] [ ] [ ] [ ] [ ]
34
Fuel lines - 28-20: 2.4.1. [ ] [ ] [x] [ ] [ ] [ ]
Lubrication - 12-20: 2.5. [ ] [*] [*] [ ] [ ] [ ]
the system
PAGE PAGE REV. 0

05-12
LSAALPHA
Sinus
Virus
Trainer
05-20
SCHEDULED
MAINTENANCE
Annu-
Item 200 500 1000 10000
No.
Fuselage and Empennage Group ATA Ref 50 Hr al/ 100
Hr Hr Hr Hr
Hr
Exterior Placards - 05-20 [ ] [x] [ ] [ ] [ ] [ ]
1 Visual Inspection for conformity, security, and con- 11-10
dition. Replace if necessary
Fuselage skin/shell - 05-20 [ ] [x] [ ] [ ] [ ] [ ]
Visual inspection 51-10: 2.1.
2 Major Inspection: Only every 2000 Hours (see 53-
10: 2.1.1. and 51-10: 2.3.)
3
GRS ballistic parachute rescue system - 05-20 [ ] [x] [ ] [ ] [ ] [ ]
Visual Inspection of hatch and rocket exhaust hole
Vertical Stabilizer and Rudder Surfaces – 05-20 [ ] [x] [ ] [ ] [ ] [ ]
4 Visual Inspection + vertical stabilizer major bonding 51-10: 2.2.
line tap test
5
Rudder Control System - 27-20: 2.1.1.*** [ ] [x] [ ] [ ] [ ] [ ]
27-20: 2.1.1. [ ] [ ] [x] [ ] [ ] [ ]
27-20: 2.4.
Rudder Control System -
27-20: 2.5.1.
27-20: 2.6.1.
27-20: 2.7.1.
Horizontal Stabilizer - 05-20 [ ] [x] [ ] [ ] [ ] [ ]
7 Major Inspection: Only every 2000 Hours (see
51-10: 2.3.)
8
Elevator - 55-20: 2.1.3. [ ] [ ] [x] [ ] [ ] [ ]
9
Vertical/horizontal stabilizer - 55-30: 2.1.1. [ ] [x] [ ] [ ] [ ] [ ]
10
Vertical stabilizer - 55-30: 2.1.2. [ ] [ ] [x] [ ] [ ] [ ]
Elevator Control System [ ] [ ] [x] [ ] [ ] [ ]
11 Major Inspection: Only every 2000 Hours (see
27-30: 2.6.2.)
12
Fuselage Vent/Drain Holes - APPENDIX [ ] [x] [ ] [ ] [ ] [ ]
Visual Inspection for obstructions or blockage 99-C
13
Antennas - 05-20 [ ] [x] [ ] [ ] [ ] [ ]
Visual inspection
Baggage compartment bulkhead - 05-20 [ ] [ ] [ ] [x] [ ] [ ]
14 Visual Inspection of composite around safety har-
ness attachment points
15
Control Surface and Stabilizer Vent/Drain Holes - APPENDIX [ ] [ ] [x] [ ] [ ] [ ]
Visual Inspection for obstructions or blockage 99-C
Lubrication - 12-20: 2.5. [ ] [*] [*] [ ] [ ] [ ]
the system
Fuel filter and auxiliary fuel pump ** - 28-20: 2.3.3. [ ] [x] [ ] [ ] [ ] [ ]
AIRCRAFT
Special Inspection: and after first 5 hours
18
Fuel tank breather tube ** - 28-10: 2.1.4. [ ] [x] [ ] [ ] [ ] [ ]
** if applicable
***perform without removing the rudder (2.1.1.3) for the 100-hour check, just move rudder to one side and inspect/check.
Perform with rudder removed every 200 hours.
PAGE REV. 0 PAGE

05-13
Sinus
Virus
ALPHA Trainer
LSA
05-20
SCHEDULED
MAINTENANCE
Annu-
Item 200 500 1000 10000
No.
Wing Group ATA Ref 50 Hr al/ 100
Hr Hr Hr Hr
Hr
Wing surface - 05-20 [ ] [ ] [x] [ ] [ ] [ ]

10: 2.1.3. and 51-10: 2.3.)
2 Flaperon Surfaces - Visual Inspection 05-20 [ ] [x] [ ] [ ] [ ] [ ]

3
Flaperon system free play- 27-50: 2.1.3. [ ] [ ] [x] [ ] [ ] [ ]
4
Flaperon surfaces - 57-50: 2.1.2. [ ] [ ] [x] [ ] [ ] [ ]
5 Pitot tube - Perform inspection/check

05-20 [ ] [x] [ ] [ ] [ ] [ ]
34-10: 2.1.1.
6
Fuel Tank Cap / Vents - 28-10: 2.4.1. [ ] [x] [ ] [ ] [ ] [ ]
Wing Vent/Drain Holes - APPENDIX [ ] [x] [ ] [ ] [ ] [ ]
7 Visual Inspection for obstructions/blockage/ leak- 99-C
age (wing tanks)
8
Air brakes - 57-70: 2.1.1. [ ] [ ] [x] [ ] [ ] [ ]
Lubrication - 12-20: 2.5. [ ] [*] [*] [ ] [ ] [ ]
the system
Annu-
Item 200 500 1000 10000
No.
Landing Gear Group ATA Ref 50 Hr al/ 100
Hr Hr Hr Hr
Hr
1 Landing Gear Fairings - Visual inspection 05-20 [ ] [x] [ ] [ ] [ ] [ ]

2
Tires - 12-10: 2.4. [ ] [x] [ ] [ ] [ ] [ ]
Visual inspection and check/replenish tire pressure 05-20
Brake system - 32-42: 2.2. [ ] [x] [ ] [ ] [ ] [ ]
3 Perform visual Inspection according to [4] for
Beringer system and 05-20 for standard system.
Beringer Wheels - [ ] [x] [ ] [ ] [ ] [ ]

4 Visual inspection according to [4]
Standard Wheels - 05-20 [ ] [x] [ ] [ ] [ ] [ ]

5 Visual and operational Inspection. Replace bear- 32-41: 2.2.3.
ings on condition 32-41: 2.1.13.
6 Nose gear - Perform Inspection/Check

32-20: 2.2.1. [ ] [x] [ ] [ ] [ ] [ ]
32-50: 2.1.1.
7 Tail landing gear - Perform Inspection/Check 32-20: 2.3.3. [ ] [x] [ ] [ ] [ ] [ ]

MLG strut - Visual inspection 05-20 [ ] [x] [ ] [ ] [ ] [ ]
10: 2.1.1.) or after a hard landing (see 05-50: 2.2.)
9 Nose gear fork - Perform Inspection/Check 32-20: 2.2.2. [ ] [ ] [x] [ ] [ ] [ ]

10 Brake fluid - check and replenish if necessary 12-10: 2.5. [ ] [x] [ ] [ ] [ ] [ ]
PAGE PAGE REV. 0

05-14
LSAALPHA
Sinus
Virus
Trainer
05-30
AIRPLANE OPERATIONAL
AND FUNCTIONAL CHECK
05-30 AIRPLANE OPERATIONAL AND FUNCTIONAL CHECK
The following check must be performed before and after the Scheduled Maintenance Inspection
to detect any airplane abnormalities or malfunctions. A portion of the check is accomplished with
the engine running and warmed up. Please refer to the aircraft specific POH for additional details
about operating procedures and equipment.
WARNING: In order to perform the following check, the engine must be operating. Do not
stand or let anyone else stand close to the arc of the airplane’s propeller while conducting this
check.
CAUTION: During all engine operations outlined in this check, exercise caution to avoid harm or
damage to personnel and equipment due to propeller blast and rotating propeller blades.
CAUTION: Excessive engine temperatures must be avoided since run-up temperatures must
closely parallel in-flight temperatures.
Item
No.
Operational Inspection Report Check Notes
Flight Controls
1 Check for full range of travel and excessive friction. Visual Inspection for obstructions.
Engine Controls
2 Check full range of motion without any obstruction or excessive friction to travel.
MASTER switch + AVIONICS switch
When switches are toggled ON the following should occur (see aircraft specific POH for a
more detailed description of the equipment installed):
3 — MFD/PFD turn on and run with no indication of any errors (See POH).
— Other electrically powered flight instruments turn on (See POH).
— Radio and transponder turn on.
Engine
— Start engine (see POH).
— Check that starter spins propeller without slipping or dragging.
— Set engine speed to 2500 RPM and wait till oil temperature reaches green arc (50°C).
— Check that the oil pressure is in the green arc within 30 seconds.
— Check that the fuel pressure is in the green arc.
— Check voltage.
4
— Set engine to 4000 RPM and carry out magneto check as per latest version of Rotax 912
series MM.
— Throttle full forward for 5 seconds. Engine RPM should indicate between 5600 and 5800.
— Check that brakes hold aircraft stationary at full power with no slipping.
— Set engine to idle. Engine should cease when ignition key set to magneto OFF position.
— Shut down (see POH).
AIRCRAFT
PAGE REV. 0 PAGE

05-15
Sinus
Virus
ALPHA Trainer
LSA
05-50
UNSCHEDULED
MAINTENANCE
05-50 UNSCHEDULED MAINTENANCE

1. Description

The following describes those maintenance checks and inspections on the aircraft which are dic-
tated by special or unusual conditions which are not related to the time limits specified in 05-10,
Scheduled Maintenance Checks.
These includes inspections and checks for wing strike, hard/overweight landing, exceeded speed
limit, severe air turbulence, lightning strike, high drag/side loads, ground gusts, operation in harsh
environmental conditions, and operation on unimproved runway surfaces.
2. Maintenance practices
05-50: 2.1. Wing strike
05-50: 2.1.1. Fuselage

Required parts,
Step Action materials and tools
Reference
Aft Floor Structure – Area around and under the wing attach
1 points and overhead seat areas, inspect for delamination, crack-
ing, whitening, and any other evidence of structural damage.
05-50: 2.2. Hard landing
NOTE: A hard landing is any landing made at what is believed to be an excessive sink rate. An
overweight landing is defined as landing the airplane at any gross weight which exceeds the maxi-
mum take-off weight as specified in the Pilot’s Operating Handbook. If the hard/overweight landing
is combined with high drag/side loads, additional checks are required.
05-50: 2.2.1. Fuselage

Required parts,
Reference
Aft Floor Structure – Inspect for delamination, cracking, whiten-

1
ing, and any other evidence of structural damage.
Main landing gear strut - Inspect for security of attachment, per-
2 manent deformation, delamination, and cracking or splintering 32-10: 2.1.2.
of strut.
Main gear attachments and supporting structure - Inspect for se-
curity loose or failed fasteners, permanent deformation, damage
3
to fairings, tire damage, and any other evidence of structural
damage.
continued on the next page
PAGE PAGE REV. 0

05-16
LSAALPHA
Sinus
Virus
Trainer
05-50
UNSCHEDULED
MAINTENANCE
Required parts,
Reference
Nose gear and attaching structure - Inspect for security, loose

or failed fasteners, permanent deformation of strut or axle, strut
4 weld cracks, puck delamination and cracks, puck pan weld
cracks, engine mount weld cracks, damage to fairing, tire dam-
age, and any other evidence of structural damage.
Wings surface - Inspect for skin cracks, loose of failed fasteners,
5
and any evidence of structural damage.
Trailing edge - Inspect for any deformation effecting normal
6
flaperon operation.
05-50: 2.3. Exceeded speed limit
An exceeded speed limit inspection must be performed anytime the airplane has exceeded one or
more of the following:
- exceeding placard speed limits of flaps.
- exceeding design speeds.
- exceeding propeller and/or engine speed limits
05-50: 2.3.1. Airframe check (exceeded aircraft design speed or flaps speeds)
Required parts,
Reference
Landing gear - Main gear axle and fittings - Inspect for cracks,
security, and evidence of structural damage.
1
Tires - Inspect tires for flat spots, excessive wear, and tire slip-
page on the wheel rim.
Fuselage - Windshield and windows - Inspect for buckling,
2 dents, loose or failed fasteners, and any evidence of structural
damage.
Cowling - Inspect for buckling, cracks, loose or failed fasteners,
3
and indications of structural damage.
Stabilizers - Inspect skins, hinges and attachments, movable
surfaces, mass balance weights, and attaching structure for
4
cracks, dents, buckling, loose or failed fasteners, and evidence
AIRCRAFT
of structural damage.
Wings - Flaps - Inspect for skin buckling, cracks, loose or failed
5
fasteners, attachments and structural damage.
Flight control system - Perform visual and operational inspection
of flight surfaces control chain. Check pushrods integrity and
6 connection, ball-bearings, ball-joints, hinges, freeplay and move-
ments for smooth operation.
PAGE REV. 0 PAGE

05-17
Sinus
Virus
ALPHA Trainer
LSA
05-50
UNSCHEDULED
MAINTENANCE
05-50: 2.3.2. Propeller check (exceeded propeller rpm speed)
Please refer to [2].
05-50: 2.3.3. Engine check (exceeded engine rpm speed)
05-50: 2.4. Severe turbulence and/or maneuvers
Atmospheric conditions producing violent buffeting of airplane. Severe maneuvers can be defined
as any maneuvers exceeding the Pilot’s Operating Handbook and the airplane’s flight limits.
05-50: 2.4.1. Airframe check

Required parts,
Reference
Horizontal stabilizer, hinge fittings, and fittings - Inspect for

1 security, loose or failed fasteners, and any evidence of structural
damage.
Vertical stabilizer - Inspect for evidence of structural damage,
2
and damage to hinges and fittings.
Elevator and rudder balance weight supporting structure -
3 Inspect for security, loose or failed fasteners, and evidence of
structural damage.
Wing to body fittings and supporting structure - Inspect for secu-
4
rity, loose or failed fasteners, and evidence of structural damage.
Wing trailing Edge - Inspect for and deformation affecting nor-
5
mal operation of flap and aileron.
6
connection, ball-bearings, ball-joints, hinges, freeplay and move-
05-50: 2.5. Lightning strike
If flown through a region of the atmosphere where electrical discharge is occurring, the airplane
may become part of the discharge path. During a lightning strike, the current enters the airplane at
one point and exits another, usually at opposite extremities. It is in these entrance and exit points
where damage is most likely to occur. Burning and/or eroding of small surface areas of the skin
and structure may be detected during inspection. In most cases, the damage is obvious. In some
cases, however, hidden damage may result. In the case of lightning strike, this inspection must be
accomplished before returning it to service.
PAGE PAGE REV. 0

05-18
LSAALPHA
Sinus
Virus
Trainer
05-50
UNSCHEDULED
MAINTENANCE
05-50: 2.5.1. Communications
Required parts,
Reference
Antennas - Inspect all antennas for evidence of burning or

eroding. If damage is noted, call PIPISTREL for disposition. Any
1
component connected to the antenna may need to be returned
to manufacturer for servicing.
05-50: 2.5.2. Navigation

Required parts,
Reference
Compass should be considered serviceable if the corrected

heading is within plus or minus 10 degrees of heading indicated
1
by the remote compass system. If remote compass is not within
tolerance, remove, repair, or replace.
05-50: 2.5.3. Fuselage

Required parts,
Reference
1 Skin - Inspect surface of fuselage skin for evidence of damage.
05-50: 2.5.4. Stabilizers

Required parts,
Reference
1 Inspect surfaces of stabilizers for evidence of damage.
05-50: 2.5.5. Wings

Required parts,
Reference
1 Skin - Inspect for evidence of burning and eroding.

2 Wing tips - Inspect for evidence of burning and pitting.
Flight surfaces and hinging mechanisms - Inspect for burning
3
and pitting.
05-50: 2.5.6. Landing gear/wheels

Required parts,
Reference
Landing gear attach fittings and axles - Inspect for evidence of

1 pitting and damage.
2 Wheels - Inspect for evidence of pitting and damage.

Wheel pants and fairings - Inspect fasteners for pitting and
3
AIRCRAFT
damage.
Brake lines - Inspect for evidence of pitting, damage, or hydrau-
4
lic fluid leaks.
PAGE REV. 0 PAGE

05-19
Sinus
Virus
ALPHA Trainer
LSA
05-50
UNSCHEDULED
MAINTENANCE
05-50: 2.5.7. Propeller

Required parts,
Reference
Propeller - Inspect surfaces of stabilizers for evidence of dam-

1 age. If damage is noted, remove from service and have inspect- [2]
ed at an authorized repair station.
05-50: 2.5.8. Power plant

Required parts,
Reference
Engine - See the manufacturer’s approved Instructions For Con-

1
tinued Airworthiness.
05-50: 2.5.9. Flight control system

Required parts,
Reference

1
connection, ball-bearings, ball-joints, hinges, freeplay and move-
05-50: 2.6. High drag/side loads due to ground handling
A high drag/side load condition is defined as situations when the airplane skids or overruns from a
prepared surface onto an unprepared surface. This condition can also be met due to landings short
of prepared surfaces, landings which cause the blowing of tires, or skidding conditions where the
safety of the airplane was in question. This covers takeoffs, landings, or unusual taxi conditions.
05-50: 2.6.1. Landing gear

Required parts,
Reference
Main gear and fairings - Inspect for loose or failed fasteners,

1
buckling, security, cracks, and evidence of structural damage.
Nose gear and fairing - Inspect for loose or failed fasteners,
2
cracks, security, buckling, and evidence of structural damage.
05-50: 2.6.2. Wings

Required parts,
Reference
Wing to fuselage fittings and attaching structure - Inspect for

1 security, loose or failed fasteners, and evidence of structural
failure.
PAGE PAGE REV. 0

05-20
LSAALPHA
Sinus
Virus
Trainer
05-50
UNSCHEDULED
MAINTENANCE
05-50: 2.7. Ground gusts
Ground gusts are defined as conditions where a parked or taxiing airplane is exposed to side, aft
quartering, or aft wind gusts exceeding 40 knots. Such conditions can cause control system dam-
age due to rapid oscillation and/or slamming of the control surfaces against system stops.
05-50: 2.7.1. Rudder

Required parts,
Reference
Hinges - Inspect for loose or failed fasteners, deformation,

1 cracks, evidence of structural damage, and for any other evi-
dence of damage or premature wear.
Attaching structure - Inspect for loose or failed fasteners,
delaminating, cracks, evidence of structural damage, punctures,
2
scratches, and for any other evidence of damage or premature
wear.
Skin - Inspect for buckling, dents, misalignment, punctures,
3 scratches, and for any other evidence of damage or premature
wear.
Attaching hardware - Inspect for loose or failed fasteners,
deformation, cracks, security of mass balance weights, balance
4
weight supporting structure and for any other evidence of dam-
age or premature wear.
5 Bellcrank - Inspect for failed fasteners, cracks and deformation.
05-50: 2.7.2. Elevator

Required parts,
Reference

2
wear.
wear.
4 Bellcrank - Inspect for failed fasteners, cracks and deformation.
AIRCRAFT
PAGE REV. 0 PAGE

05-21
Sinus
Virus
ALPHA Trainer
LSA
05-50
UNSCHEDULED
MAINTENANCE
05-50: 2.7.3. Flaperons

Required parts,
Reference

2
wear.
wear.
05-50: 2.8. Operation on unimproved runway surfaces
Operation on unimproved runway surfaces will cause additional wear and may require additional
maintenance or inspection.
05-50: 2.9. Operation in humid areas
In humid areas, special care should be taken to keep engine, accessories, and airframe clean to
prevent oxidation. Fuel and oil should be checked frequently and drained of condensation to pre-
vent corrosion. Visually inspect flight control surfaces, nose landing gear and control systems for
corrosion in accordance with best aviation maintenance practice.
05-50: 2.10. Propeller strike
Please refer to [1] and [2].
PAGE PAGE REV. 0

05-22
LSAALPHA
Sinus
Virus
Trainer
05-50
UNSCHEDULED
MAINTENANCE
05-50: 2.11. Flutter
Flutter is a self-feeding and potentially destructive vibration where aerodynamic forces on an

object couple with a structure’s natural mode of vibration to produce rapid periodic motion.
The aircraft is designed and manufactured in a way that incurring into flutter is very unlikely if the
airplane is flown within the flight envelope.
Flutter can be potentially destructive or resulting in severe damage to the airframe structures. The
aircraft must be carefully inspected in case flutter has been experienced.
WARNING: Flutter occurrences must be reported to the manufacturer before the next flight!
05-50: 2.11.1. Airframe check

Required parts,
Reference
Fuselage - external surface - windshield and windows - Inspect

1 for buckling, dents, loose or failed fasteners, and any evidence
of structural damage. Inspect fuselage tailcone.
Cowling - Inspect for buckling, cracks, loose or failed fasteners,
2
and indications of structural damage.
Stabilizers - Inspect skins, hinges and attachments, movable
surfaces, mass balance weights, and attaching structure for
3
cracks, dents, buckling, loose or failed fasteners, and evidence
of structural damage.
Wings - Flaps - Inspect for skin buckling, cracks, loose or failed
4
fasteners, attachments and structural damage.
Flight control system - perform visual and operational inspection
5
connection, ball bearings, ball-joints, bellcranks, hinges, freeplay
and movements for smooth operation.
Engine mount - check for structural damage to the structure due
6
to vibrations or overstress.
Perform general visual and functional check to avionics systems
7
and components. Check for unfastened components and joints.
8 Check control surfaces balancing. 51-60
AIRCRAFT
PAGE REV. 0 PAGE

05-23
06
Sinus
Virus
ALPHA Trainer
LSA
CHAPTER 06- DIMENSIONS AND AREAS
TABLE OF CONTENTS

DIMENSIONS AND AREAS
06-00 Airplane dimensions and areas 06-03
3-VIEW DRAWINGS
PAGE PAGE REV. 0

06-02
LSAALPHA
Sinus
Virus
Trainer
06-00 DIMENSIONS AND AREAS
This chapter outlines the basic dimensions/areas of the airplanes treated in this manual.
1. Airplane dimensions and areas
VIRUS SW
SINUS 912 VIRUS 912 ALPHA Trainer
Basic 80/100
LSA LSA LSA
Dimensions LSA
Metric Imperial Metric Imperial Metric Imperial Metric Imperial
Length 6.50 m 21.32 ft 6.50 m 21.32 ft 6.45 m 21.16 ft 6.40 m 21.00 ft
Span 14.97 m 49.11 ft 12.46 m 40.83 ft 10.71 m 35.1 ft 10.50 m 34.45 ft
Height 1.85 m 6.07 ft 1.85 m 6.07 ft 2.06 m 6.75 ft 2.05 m 6.73 ft
WINGS
Area 12.26 m2 132 ft2 11.00 m² 118 ft² 9,51 m² 102.4 ft² 9.29 m² 99.99 ft²
MAC 0.869 m 2.85 ft 0.908 m 2.98 ft 0.90m 2.95 ft 0.90 m 2.95 ft
HORIZONTAL TAIL
Area 1.63 m2 17.5 ft² 1.63 m² 17.5 ft² 1.02 m² 10.9 ft² 1.02 m2 10.98 ft²
Span 2.97 m 9.74 ft 2.97 m 9.74 ft 2.18 m 7.15 ft 2.18 m 7.15 ft
VERTICAL TAIL
Area 1.1 m² 11,8 ft² 1.1 m² 11,8 ft² 1.24 m² 13.3 ft² 0.86 m² 9.26 ft²
Height 1.17 m 3.84 ft 1.14 m 3.74 ft 1.19 m 3.90 ft 1.11 m 3.64 ft
Drawing ref. Figure 06-001 Figure 06-002 Figure 06-003 Figure 06-004
AIRCRAFT
PAGE REV. 0 PAGE

06-03
Sinus
Virus
ALPHA Trainer
LSA
06-00
3-VIEW DRAWINGS
Figure 06-001
Sinus 912 LSA - 3-view drawing
PAGE PAGE REV. 0

06-04
LSAALPHA
Sinus
Virus
Trainer
06-00
3-VIEW DRAWINGS
Figure 06-002
Virus 912 LSA - 3-view drawing
PAGE REV. 0 PAGE

06-05
Sinus
Virus
ALPHA Trainer
LSA
06-00
3-VIEW DRAWINGS
Figure 06-003
Virus SW 80/100 LSA - 3-view drawing
PAGE PAGE REV. 0

06-06
LSAALPHA
Sinus
Virus
Trainer
06-00
3-VIEW DRAWINGS
Figure 06-004
ALPHA Trainer LSA - 3-view drawing
PAGE REV. 0 PAGE

06-07
Sinus
Virus
ALPHA Trainer
LSA
06-00
CONTROL SURFACES
DEFLECTION ANGLES
2. Control surfaces deflection angles
See the WBR supplied with the aircraft upon delivery.
PAGE PAGE REV. 0

06-08
07
Sinus
Virus
ALPHA Trainer
LSA
CHAPTER 07 – LIFTING AND SHORING
TABLE OF CONTENTS

LIFTING AND SHORING
07-00 07- 03
General
JACKING
07-10 Description 07- 04
Maintenance Practices
PAGE PAGE REV. 0

07-02
LSAALPHA
Sinus
Virus
Trainer
07-00
LIFTING AND SHORING
07-00 GENERAL
This chapter covers the materials and procedures that apply to lifting and shoring the aircraft.
The procedures outlined in this chapter mainly apply to situations where the aircrafts landing gear
needs to be attended to, serviced and/or removed.
AIRCRAFT
PAGE REV. 0 PAGE

07-03
Sinus
Virus
ALPHA Trainer
LSA
07-10
JACKING
07-10 JACKING
1. Description
Particular maintenance procedures require propping certain parts of the aircraft up. Removing the
main landing gear wheel, for example, requires propping up the landing gear strut. Removing the
nose landing gear wheel, on the other hand, requires propping up the front end of the aircraft. A
description of how to carry this out and the materials needed is outlined in this chapter.
2. Maintenance Practices
07-10: 2.1. Main landing gear strut
NOTE: Two people are required to carry out this procedure.
07-10: 2.1.1. Propping up one side

Applicability SIN VIR VSW AT Qualification O L1 P/O
Required parts,
Reference
1 Position the aircraft on a surface that is flat and hard. - Landing gear stand
(P/N 1190264)
2 Remove the main wheel fairing. - Torx screwdriver set 32-10
3 Lift the wing. - T-handle hex head Figure 07-001
screwdriver set
4 Place landing gear stand under landing gear strut. Figure 07-002
Slowly lower wing so that the landing gear strut rests on the
5
stand.
Figure 07-001
Lifting the wing
PAGE PAGE REV. 0

07-04
LSAALPHA
Sinus
Virus
Trainer
07-10
JACKING
Figure 07-002
Landing gear stand placement
NOTE: If necessary, the landing gear strut can be propped up on both sides using the same
stand and following the same procedure as outlined above.
07-10: 2.2. Nose landing gear
07-10: 2.2.1. Propping up

Required parts,
Reference
1 Position the aircraft on a surface that is flat and hard. - Tail cone Figure 07-003
counterweight
CAUTION: Position the aircraft so it’s front end is clear of all other (oblong bean bag)
objects. Make sure the propeller and/or engine cowlings won’t hit
anything when the front end is propped up.
2 Slowly place counterweight on tail cone.
AIRCRAFT
Figure 07-003
Tail cone counterweight
PAGE REV. 0 PAGE

07-05
Sinus
Virus
ALPHA Trainer
LSA
07-10
JACKING
07-10: 2.3. Tail landing gear
07-10: 2.3.1. Propping up the tail

Required parts,
Reference
1 Position the aircraft on a surface that is flat and hard. - Trestle
CAUTION: Position the aircraft so it’s front end is clear of all other
objects. Make sure the propeller and/or engine cowlings won’t hit
anything when the rear end is propped up.
Slowly lift the tail cone and support it placing a trestle below
2
the tail, just aft the tail landing gear strut.
PAGE PAGE REV. 0

07-06
08
Sinus
Virus
ALPHA Trainer
LSA
CHAPTER 08 – LEVELING AND WEIGHING
TABLE OF CONTENTS

LEVELING AND WEIGHING
08-00 08-03
General
LEVELING
WEIGHING
PAGE PAGE REV. 0

08-02
LSAALPHA
Sinus
Virus
Trainer
08-00
GENERAL
08-00 GENERAL
This chapter provides all the information needed to level and weigh the airplane properly. If the
aircraft is not operated in the right center of gravity envelope, flight performance and safety may
be compromised. The aircraft must be weighed and the center of gravity calculated/checked every
time a modification is carried out that could affect these characteristics.
AIRCRAFT
PAGE REV. 0 PAGE

08-03
Sinus
Virus
ALPHA Trainer
LSA
08-10
LEVELING
08-10 LEVELING
1. Description
This chapter describes how to level the airplane for any maintenance procedures which may be
necessary.
08-10: 2.1. Leveling
08-10: 2.1.1. Leveling the airplane using the leveling kit

Reference: POH
Required parts,
Reference
1 Inflate tires. - Aircraft leveling kit 12-10

(P/N 1190460)
Prop up starboard MLG wheel by pulling the port wing down - Spirit level
2 and place MLG balance block under wheel. Do the same for
the port MLG wheel by lifting the port wing.
Prop up nose wheel by weighing down the tail cone. Place
3
nose wheel wedge under wheel.*
4 Fit the tail cone with the leveling tool and place spirit level on it. Figure 08-001
5 Adjust nose wheel wedge until the spirit level reads 0°. *
*NOTE: in case of tail wheel configuration refer to 07-10: 2.3.1. for propping up the tail. Then adjust the fu-
selage leveling by inserting or removing some spacers between the tail cone and the trestle.
Figure 08-001
Leveling tool and spirit level setup
PAGE PAGE REV. 0

08-04
LSAALPHA
Sinus
Virus
Trainer
08-10
LEVELING
08-10: 2.1.2. Leveling the airplane without the leveling kit

This procedure can be use when the leveling kit is not available
Required parts,
Reference
1 Inflate tires. - Digital level 12-10

Prop up starboard MLG wheel by pulling the port wing down
2 and place MLG balance block under wheel. Do the same for
the port MLG wheel by lifting the port wing.
Prop up nose wheel by weighing down the tail cone. Place
3
nose wheel wedge under wheel.*
Calibrate the digital level so that it reads 0° when
4 positioned on the levelling surface. (i.e. the surface the aircraft
is on)
Adjust nose wheel wedge* until the digital level reads the same
value (in absolute value) when positioned above and under the
5 tail cone, just fore of the vertical stabilizer. The aircraft is level
once these two readings are the same in absolute value (tail
cone centerline is leveled).
*NOTE: in case of tail wheel configuration refer to 07-10: 2.3.1. for propping up the tail. Then adjust the fu-
selage leveling by inserting or removing some spacers between the tail cone and the trestle.
AIRCRAFT
PAGE REV. 0 PAGE

08-05
Sinus
Virus
ALPHA Trainer
LSA
08-20
WEIGHING
08-20 WEIGHING
1. Description
This chapter describes how to properly weigh the aircraft. Expected flight performance and
safety can only be achieved if the aircraft is operated in the approved center of gravity envelope.
If the aircraft is modified in any way, the center of gravity and weight must be recalculated and
verified as acceptable.
NOTE: For center of gravity calculation, weight & balance record and equipment list please see
chapter 6 in the pilot operating handbook (POH).
08-20: 2.1. Weighing
Reference: POH
08-20: 2.1.1. Preparation

Required parts,
Reference
1 Replenish the brake fluid reservoir. - Three scales (one

with minimum scale
12-10
2 Drain fuel system. capacity of 250 kg,
two with 500 kg)
3 Replenish the engine oil.
4 Close the doors, set the flaps to 0° and retract the air brakes.
5 Check/verify equipment list. POH
Level aircraft and place a scale under each of the MLG balance
6 08-10
blocks and over the nose/tail wheel wedge. Zero the scales.
NOTE: The two scales used under the MLG wheels must be equal in height and placed as outboard as
possible.
08-20: 2.1.2 Measuring - Nose landing gear configuration

Required parts,
Reference
Drop a plump bob from datum (each wing root leading edge at - Plump bob
- String
1 root) and stretch a line between the plump bobs and mark the Figure 08-002
- Measuring tape
position of the line at the airplane center line.
Stretch a line between the main wheel centers and mark the
2 Figure 08-003
PAGE PAGE REV. 0

08-06 continued on the next page
LSAALPHA
Sinus
Virus
Trainer
08-20
WEIGHING
Required parts,
Reference
Measure the distance between the position of the wing root

3 leading edge and the position of the MLG wheel centers hori- Figure 08-004
zontally along the airplane center line. Obtain value ‘b’.
NOTE: For center of gravity calculation, weight & balance record and equipment list please see
chapter 6 in the pilot operating handbook (POH).
Required parts,
Reference

4 leading edge and the position of the nose wheel center horizon-
tally along the airplane center line. Obtain value ‘a’. Figure 08-004
Remove the level/leveling fixture and record the weight values
5
show on the scales.
08-20: 2.1.3 Measuring - Tail landing gear configuration

Required parts,
Reference
Drop a plump bob from datum (each wing root leading edge at - Plump bob
- String
1 root) and stretch a line between the plump bobs and mark the Figure 08-002
- Measuring tape
Stretch a line between the main wheel centers and mark the
2 Figure 08-003
3 leading edge and the position of the MLG wheel centers hori-
zontally along the airplane center line. Obtain value ‘a’.
Drop a plump bob from the tailwheel axle and mark its position
4
on the airplane center line.
Measure the distance between the position of the MLG wheel Figure 08-005
centers along the airplane center line and the position of the tail
5
wheel center horizontally along the airplane center line. Obtain
value ‘a’.
Remove the level/leveling fixture and record the weight values
6
show on the scales.
AIRCRAFT
Figure 08-002
Plump bob from wing leading edge
PAGE REV. 0 PAGE
08-07
Sinus
Virus
ALPHA Trainer
LSA
08-20
WEIGHING
Figure 08-003
Plum bob from center of the MLG wheels
Figure 08-004
Weight and Balance measurements
Nose wheel configuration
Figure 08-005
Weight and Balance measurements
Tail wheel configuration
PAGE PAGE REV. 0

08-08
09
Sinus
Virus
ALPHA Trainer
LSA
CHAPTER 09 – TOWING AND TAXIING
TABLE OF CONTENTS

TOWING AND TAXIING
09-00 09-03
General
TOWING
TAXIING
PAGE PAGE REV. 0

09-02
LSAALPHA
Sinus
Virus
Trainer
09-00
GENERAL
09-00 GENERAL
This chapter describes how to properly tow and taxi the airplane along the ground.
AIRCRAFT
PAGE REV. 0 PAGE

09-03
Sinus
Virus
ALPHA Trainer
LSA
09-10
TOWING
09-10 TOWING
1. Description
One person can easily tow the Virus/Sinus/ALPHA-Trainer by him/herself along smooth, hard ter-
rain by pulling/pushing it. Turning is made easier by propping up the front end (or rear end in case
of tail wheel configuration) of the aircraft while simultaneously pushing/pulling it. The following
procedures describe how to properly tow the aircraft.
CAUTION: Never push or pull the aircraft using its control surfaces.
09-10: 2.1. Towing
09-10: 2.1.1. Backwards

Required parts,
Reference
1 Remove wheel chocks.

Check that there is nothing obstructing the way or any hazards
2 in the vicinity.
Push the aircraft backwards using the point halfway up the verti-
3
cal stabilizers as a push point.
4 Place wheel chocks under wheels.
09-10: 2.1.2. Forwards

Required parts,
Reference

2 in the vicinity.
Push the aircraft forwards using the point on the fuselage half-
3 way between the wing’s trailing edge and the vertical stabilizer
as a push point.
09-10: 2.1.3. Turning

Required parts,
Reference

1
in the vicinity.
Prop the front end of the aircraft up slightly by pushing down
(or pulling up in case of tailwheel configuration) on the tail cone
2
while simultaneously pushing the aircraft in the desired direc-
tion.

PAGE PAGE REV. 0
09-04
LSAALPHA
Sinus
Virus
Trainer
09-20
TAXIING
09-20 TAXIING
1. Description
This chapter provides instructions necessary to taxi the aircraft. The thrust needed to taxi it is
supplied by the propeller, while turning/steering is done by foot pressure on the rudder pedals.
The immediate area around the aircraft must be inspected for any obstructions/safety hazards and
cleared if necessary.
09-20: 2.1. Taxiing
CAUTION: Excessive braking can lead to worn brake pads/discs. The area must be cleared of all/
any personnel before taxiing ensues. All potholes and rough terrain should be avoided if possible.
Refer to the POH for all other procedures/checks pertaining to taxiing.
09-20: 2.1.1. Taxiing the airplane

Reference: POH
Required parts,
Reference

2 Start the engine.
Gradually throttle up until taxiing ensues and then immediately
3
check that the brakes work.
4 Taxi the aircraft to the desired location.
5 Shut the aircraft down.
AIRCRAFT
PAGE REV. 0 PAGE

09-05
10
Sinus
Virus
ALPHA Trainer
LSA
CHAPTER 10 – PARKING, MOORING AND STORAGE
TABLE OF CONTENTS

PARKING, MOORING AND STORAGE
10-00 10-03
General
PARKING
MOORING
STORAGE
PAGE PAGE REV. 0

10-02
LSAALPHA
Sinus
Virus
Trainer
10-00
GENERAL
10-00 GENERAL
This chapter describes how to park, moor and store the aircraft properly. Mooring is typically re-
quired when the aircraft is left outside for longer periods of time and may be exposed to windy
conditions. The recommended storage measures outlined in this chapter should be implemented
in order to prevent wear/deterioration of the aircraft structure/systems.
AIRCRAFT
PAGE REV. 0 PAGE

10-03
Sinus
Virus
ALPHA Trainer
LSA
10-10
PARKING
10-10 PARKING
1. Description
This chapter describes how to park the aircraft properly. It outlines measures that should be for
long term parking and parking in abnormal conditions.
2. Maintenance Practice
10-10: 2.1. Parking
10-10: 2.1.1. Temporary (< 10 days)

Reference: applicable POH
Required parts,
Reference
1 Engage the parking brake. - Wheel chocks
2 Set the fuel selector to OFF.

If present, leave air-brake handle unlocked, hanging down freely,
3
to unload the plate springs.
4 Check that the rescue system activation handle pin is inserted.
6 Close all the cabins windows/openings if wet weather is expected.
7 Moor the aircraft if windy weather is expected. 10-20
10-10: 2.1.2. Long term (> 10 days)
Follow the same procedure outlined above for temporary parking, however, consider the storage
measures outlined in 10-30.
PAGE PAGE REV. 0

10-04
LSAALPHA
Sinus
Virus
Trainer
10-20
MOORING
10-20 MOORING
1. Description
This chapter describes how to moor the aircraft properly. Each wing has a fixed mooring point
built into its bottom surface. In nose wheel configuration, the tail skid has a hole that can be used
as the third tie down point. These points can be used to fasten the aircraft to the ground.
10-20: 1.1. Mooring
10-20: 1.1.1. Mooring the airplane

Required parts,
Reference
1 Park the aircraft. - Wheel chocks 10-10

- Mooring rings
2 Retract the flaps fully. (P/N 1190014)
- Tie down straps
3 Block the control surfaces blocking the control stick movement. (synthetic)
4 Remove the mooring point caps.
5 Install the mooring rings.
Run tie down straps through the rings and secure them to the
6
ground.
For nose wheel configuration: run a tie down strap through the
tail skid hole and secure it to the ground.
7 For tail wheel configuration: pass a strap over the tail cone, just
in front of the vertical stabilizer, and secure the terminals to the
ground.
NOTE: Refer to chapter 10-30 for additional storage measures/procedures.
AIRCRAFT
PAGE REV. 0 PAGE

10-05
Sinus
Virus
ALPHA Trainer
LSA
10-30
STORAGE
10-30 STORAGE
1. Description
This chapter describes all of the measures necessary to store the airplane for temporary or long-
term storage.
10-30: 2.1. Storage
10-30: 2.1.1. Temporary storage (10-60 days)

Required parts,
Reference
Park the aircraft on a dry, level surface that is not exposed to

1 10-10
sunlight, but do not engage parking brake.
2 Moor if necessary. 10-20
3 Cover the pitot tube.
Check main and nose landing gear (for nose landing gear
4 configuration) tire pressure on a weekly basis and replenish if 12-10
necessary.
Turn each wheel by a quarter turn once a week to avoid warp-
5
ing/damage.
Disconnect the battery (pull the battery disconnect ring) and
6 consider all maintenance and shelf-life measures recommended
by the battery manufacturer.
7 Clean all aircraft surfaces and remove bugs/dirt.
8 Clean entire propeller and remove bugs/dirt.
9 Cover windshield and sunroof with a cotton sheet.
10 Replenish the fuel system so that the fuel tanks are full. 12-10
Implement the engine storage/preservation measures found in
11
the latest version of Rotax’s 912 OM and MM.
CAUTION: If the wings must be disassembled (see 57-10) due to hangar space limitations,
in airplanes equipped with wing tanks the fuel system must be drained (see 12-20) and wings
stored in a dry, cool space with no sunlight, and covered with a cotton sheet.
CAUTION: If fuel with any alcohol content is used, the fuel system must be drained (see 12-20).
10-30: 2.1.2. Long term storage (> 60 days)

PAGE PAGE REV. 0

10-06
LSAALPHA
Sinus
Virus
Trainer
10-30
STORAGE
Required parts,
Reference
Park the aircraft on a dry, level surface that is not exposed to

1 10-10
sunlight, but do not engage parking brake.
2 Moor if necessary. 10-20
3 Cover the pitot tube.
Check main and nose landing gear (if present) tire pressure on a
4 12-10
weekly basis and replenish if necessary.
Turn each wheel by a quarter turn once a week to avoid warp-
5
ing/damage.
Disconnect the battery (pull the battery disconnect ring) and
6 consider all maintenance and shelf-life measures recommended
by the battery manufacturer.
7 Clean all aircraft surfaces and remove bugs/dirt.
Clean entire propeller and remove bugs/dirt. Refer to the latest
8 revision of the propeller manufacturer’s OM and MM for addi-
tional long term storage/preservation measures.
9 Cover windshield and sunroof with a cotton sheet.
Implement the engine storage/preservation measures found in
10
the latest version of Rotax’s 912 OM and MM.
11 Drain fuel system. 12-20
CAUTION: If the wings must be disassembled (see 57-10) due to hangar space limitations,
in airplanes equipped with wing tanks the fuel system must be drained (see 12-20) and wings
stored in a dry, cool space with no sunlight, and covered with a cotton sheet.
AIRCRAFT
PAGE REV. 0 PAGE

10-07
11
Sinus
Virus
ALPHA Trainer
LSA
CHAPTER 11 – REQUIRED PLACARDS
TABLE OF CONTENTS

REQUIRED PLACARDS
11-00 11-03
General
EXTERIOR PLACARDS
INTERIOR PLACARDS
PAGE PAGE REV. 0

11-02
LSAALPHA
Sinus
Virus
Trainer
11-00
GENERAL
11-00 GENERAL
There are various placards located throughout the Virus/Sinus/ALPHA-Trainer aircraft that pro-
vide pilots, occupants and first responders with very important information. They identify safety
precautions, provide service instructions, indicated command direction/movements and provide
operating instructions. Those with a white background are made from polymeric stabilized PVC
film and have a permanent opaque acrylic adhesive on the back face. Those with a black back-
ground are made from translucent polymeric stabilized, cadmium-free vinyl film and have an acrylic
solvent-based adhesive. Those listed as Night VFR are made of a phosphorescent material that is
easily visible in the dark.
NOTE: Please refer to the POH of the specific aircraft for more details.
AIRCRAFT
PAGE REV. 0 PAGE

11-03
Sinus
Virus
ALPHA Trainer
LSA
11-10
EXTERIOR PLACARDS
11-10 EXTERIOR PLACARDS

1. Description
This chapter describes the maintenance practices which apply to those placards located on the
exterior of the aircraft, including: Door; Open & Close, Baggage Door Location, ELT Location, BPRS
Location, Oil-Door Location, Fuel Filler Location, Gnd Power Receptacle Location, No-Step, No
Push, and Rescue Instruction.
NOTE: Exterior placard illustrations are available in the specific aircraft IPC under chapter 11,
Placards and Markings. Please refer also to the applicable POH for more details.
11-10: 2.1. Exterior Placard
11-10: 2.1.1. Removal

Required parts,
Reference
Peel placard away from surface. If it doesn’t peel away easily, - Heat gun
1 apply heat with heat gun and try again.
CAUTION: Be careful when using the heat gun. Do not allow the surface temperature to exceed 54°C
(129°F), as this may cause structural damage.
Once removed, clean the surface with pure acetone to remove - Acetone (pure)
2
residual adhesive.
11-10: 2.1.2. Installation

Follow the same procedure outlined above for temporary parking, however, consider the storage
measures outlined in 10-30.
Required parts,
Reference
Wash/wipe the surface down with water and clean white cotton - Water
1 - Acetone (pure)
cloth.
- Clean white cotton cloth
2 Clean the surface with pure acetone. - Paper towel
3 Allow to air dry.

4 Remove placard from protective foil.
Apply placard to surface. Avoid creating wrinkles by applying one
5 edge of the placard first and then running your finger along it until
it’s completely adhered.
PAGE PAGE REV. 0

11-04
LSAALPHA
Sinus
Virus
Trainer
11-20
INTERIOR PLACARDS
11-20 INTERIOR PLACARDS

1. Description
This chapter describes the maintenance practices which apply to those placards located on the
interior of the Virus/Sinus/ALPHA-Trainer aircraft, including:
BPRS Handle Cover, Engine Control Panel, Circuit Breaker Panel, Bolster Switch Panel, Instrument
Panel, Audio Panel, Yoke Grip Switch Plate, Baggage Door, ELT Location, Alternate Induction Air, ,
and Parking Brake Release.
NOTE: Interior placard illustrations are available in the type specific IPC under chapter 11, Plac-
ards And Markings. Please refer also to the applicable POH for more details.
11-20: 2.1. Interior Placard
11-20: 2.1.1. Removal

Required parts,
Reference
Peel placard 11-05 away from surface. If it doesn’t peel away easi- - Heat gun
1 ly, apply heat with heat gun and try again.
CAUTION: Be careful when using the heat gun. Do not allow the surface temperature to exceed 54°C
(129°F), as this may cause structural damage.
Once removed, clean the surface with pure acetone to remove - Acetone (pure)
2
residual adhesive.
11-20: 2.1.2. Installation on non-composite and/or paint-coated composite surfaces

Required parts,
Reference
Wash/wipe the surface down with water and clean white cotton - Water
1 - Acetone (pure)
cloth.
- Clean white cot-
2 Clean the surface with pure acetone. ton cloth
AIRCRAFT
3 Allow to air dry. - Paper towel
4 Remove placard from protective foil.

Apply placard to surface. Avoid creating wrinkles by applying one
5 edge of the placard first and then running your finger along it until
it’s completely adhered.
PAGE REV. 0 PAGE

11-05
Sinus
Virus
ALPHA Trainer
LSA
11-20
INTERIOR PLACARDS
11-20: 2.1.3. Installation on bare composite surfaces

Required parts,
Reference
1 Clean the surface with pure acetone. - Acetone (pure)

- Paper towel
2 Allow to air dry. - Spray glue (Extra
3 Remove placard from protective foil. strong, Tesa)
Spray some glue on the back surface of the placard and apply
it to the surface. Avoid creating wrinkles by applying one edge
4
of the placard first and then running your finger along it until it’s
completely adhered.
PAGE PAGE REV. 0

11-06
12
Sinus
Virus
ALPHA Trainer
LSA
CHAPTER 12 – SERVICING
TABLE OF CONTENTS

SERVICING
12-00 12-03
General
REPLENISHING
SCHEDULED SERVICING
DISPOSABLE REPLACEMENT PARTS
12-40 12-14
Description
PAGE PAGE REV. 0

12-02
LSAALPHA
Sinus
Virus
Trainer
12-00
GENERAL
12-00 GENERAL
This chapter clearly outlines all of the procedures/practices involved in properly servicing the Vi-
rus/Sinus/ALPHA-Trainer aircraft. Procedures such as replenishing operating fuels, lubricating var-
ious components and keeping the aircraft clean, are key to ensuring the aircraft remains in good
condition, safe and airworthy.
The maintenance/servicing intervals specified in chapter 05-00 are those recommended by Pipis-
trel and shall be considered adequate in normal operating conditions. If the aircraft is operated
in abnormal conditions, such as salt water environments, extremely humid areas and dusty envi-
ronments, or if it’s operated any unusual conditions, it shall be considered prudent to shorten the
intervals in chapter 05-00.
CAUTION: Not adhering to the warning and cautions outlined in this chapter can cause damage
to the aircraft, harm to the aircrafts operator and possibly harm to others. Only those operating
fluids mentioned in this manual are permitted to be used. Mixing various fluids, using non-recom-
mended brands or using contaminated fluids is not permitted and can lead to aircraft damage or
harm to its operators/occupants.
AIRCRAFT
PAGE REV. 0 PAGE

12-03
Sinus
Virus
ALPHA Trainer
LSA
12-10
REPLENISHING
12-10 REPLENISHING
1. Description
This chapter outlines the maintenance procedures that pertain to replenishing the airplane
operating fluids. For servicing intervals refer to chapter 05-00. Table 12-001 contains information
about approved operating fluids and their capacity.
Description P/N or Spec. Capacity

Fuel AVGAS, MOGAS or car fuel. Please refer to latest Sinus/Virus - Total Tank Capacity:
revision of ROTAX Service Instruction No. SI-912- 100.0 L (26.4 US gal) total, or
016 Selection of Suitable Operating Fluids 60.0 L (15.8 US gal) total.
Total unusable fuel: 1.0 L
ALPHA-Trainer: 50.0 Lit (13.2 US
gal) in the fuselage tank.
Total unusable fuel: 2.0 L
Engine Oil Refer to ROTAX Service Instruction No. SI-912- 3.5 L (3.7 US Quarts) (min. oil
016 Selection of Suitable Operating Fluids for required marked on dipstick)
Rotax® Engine Type 912 I, 912 and 914 Series
Engine Coolant Referring to the latest revision of ROTAX Service 3 L (max and min coolant levels
Instruction No. SI-912-016 Selection of Suitable marked on overflow bottle)
Operating Fluids for Rotax® Engine Type 912 I,
912 and 914 Series
Brakes DOT 4 Hydraulic Fluid 0,20L
Nose Tire (Size Dry Compressed Air See applicable POH

4.00 X 4”)
Main Tires (Size Dry Compressed Air See applicable POH
4.00 X 6”)
Tail Wheel Tire Dry Compressed Air See applicable POH
(Size 2,50 X 4’’)
Table 12-001
Approved operating fluids and capacities
PAGE PAGE REV. 0

12-04
LSAALPHA
Sinus
Virus
Trainer
12-10
REPLENISHING
12-10: 2.1. Fuel system
WARNING: All electrical equipment, or any equipment that could produce a spark, must be
disabled before refueling and/or defueling.
WARNING: Smoking is not permitted within 30 meters of the aircraft while refueling/defuel-
ing. Nor is the presence of an open flame.
WARNING: The battery must be disabled before refueling/defueling.
WARNING: A fire extinguisher must be present at all times while refueling/defueling.
WARNING: The aircraft’s exhaust tailpipe and all fuel servicing equipment must be grounded
during all/any refueling/defueling procedures.
12-10: 2.1.1. Refueling

Required parts,
Reference
Locate the fuel filler on the wing (or in the fuselage for AT) and - Approved fuel Type spe-
1 (see 12-10), cific POH
place fire extinguisher near it.
- Fire extinguisher,
Use grounding cables to attach the nozzle to the aircraft’s exhaust - Grounding cables
2 tailpipe, the tailpipe to the fuel truck/cart and the fuel truck/cart to
an earth ground.
3 Remove the fuel filler cap.
4 Place nozzle in the fuel filler.

CAUTION: Do not touch the wing’s surface, the filler’s rim or the inner surface of the fuel tank
with the fuel nozzle as this could cause damage.
5 Refuel to desired level. - Approved fuel Type spe-
(see 12-10), cific POH
6 Install fuel filler cap. - Fire extinguisher,
7 Virus/Sinus: repeat steps 3 to 8 for the other wing’s fuel tank. - Grounding cables
8 Disconnect all of the grounding cables.

AIRCRAFT
PAGE REV. 0 PAGE

12-05
Sinus
Virus
ALPHA Trainer
LSA
12-10
REPLENISHING
12-10: 2.2. Oil system
CAUTION: Always ensure that the oil level is within the limits indicated on the dipstick before
flying.
CAUTION: The aircraft must be level before checking/replenishing oil levels.
12-10: 2.2.1. Replenishing the oil system

Required parts,
Reference
1 Master switch OFF, ignition OFF. - Flathead screwdriver,

- Approved oil
2 Remove engine cowlings. (see 12-10) 71-10: 2.1.1.
3 Remove oil tank cap.
Rotate propeller in normal direction until a gurgling noise is
4 heard. This is evidence that the oil has been pumped through
the system and has settled in the sump.
Replenish oil system until dipstick reading is within the marked
5
limits.
6 Reinstall dipstick and oil tank cap.
7 Install engine cowlings. 71-10: 2.1.2.
12-10: 2.3. Cooling system
12-10: 2.3.1. Replenishing the coolant

Required parts,
Reference
1 Remove engine cowlings (see 71-10). - Flathead screw- 71-10: 2.1.1.

driver,
2 Locate water cooler and remove cap. - Approved cool-
Replenish coolant level in water cooler until it’s completely ant, (see 12-10)
3
full.
4 Reinstall water cooler cap.
5 Locate cooling system’s overflow bottle.
6 Remove overflow bottle cap.
Replenish cooling system until level is within the limits marked
7
on the overflow bottle.
8 Install overflow bottle cap.
PAGE PAGE REV. 0

12-06
LSAALPHA
Sinus
Virus
Trainer
12-20
SCHEDULED SERVICING
12-10: 2.4. Tires
12-10: 2.4.1. Check/replenish tire air pressure (wheel fairings with inspection hatch)
Required parts,
Reference
1 Remove tire pressure inspection plug from wheel fairing. - Compressed air
- Pressure gauge
Roll aircraft a backwards or forwards a little until the tire’s (P/N 5610132)
2
valve stem lines up with the opening in the fairing.
3 Remove tire valve cap.
4 Measure tire air pressure.
Replenish if necessary with compressed air to the required
5 Table 12-001
pressure.
6 Release pressure from the tire if it is already overinflated.
7 Install tire valve cap.
8 Install tire pressure inspection plug.
12-10: 2.4.2. Check/replenish tire air pressure (wheel fairings w/out inspection hatch)
Required parts,
Reference
1 Remove the wheel fairing. - Compressed air 32-10

- Pressure gauge
2 Remove tire valve cap. (P/N 5610132)
3 Measure tire air pressure.
Replenish if necessary with compressed air to the required
4 Table 12-001
pressure.
5 Release pressure from the tire if it is already overinflated.
6 Install tire valve cap.
7 Re-install the wheel fairing.
AIRCRAFT
PAGE REV. 0 PAGE

12-07
Sinus
Virus
ALPHA Trainer
LSA
12-10
REPLENISHING
12-10: 2.5. Brake system hydraulic fluid
12-10: 2.5.1. Brake system replenishing procedure (Hand-brake system)

Required parts,
Reference
Open the brake fluid reservoir lid, by releasing the two screws - Phillips screw driv-
1 on the top. Pull the brake handle to reach the aft screw with the ers set
screw driver. - Meter or measuring
tape
Using a plastic cup, pour the brake fluid into the brake reservoir. - Plastic cups
2 Check the fluid level, and fill till the level is 10 mm measured 12-10
from the reservoir top edge.
3 Close the brake reservoir lid.
Bleed the brake system and perform a functional test. 32-42:
4 2.4.2.
12-10: 2.5.2. Brake system replenishing procedure (toe brakes system)

Required parts,
Reference
1
Open the brake fluid reservoir caps placed beside the main - Phillips screw driv-
cylinders on pilot’s pedals. ers set
- Meter or measuring
Using a plastic cup, pour the brake fluid into the brake reser-
tape
2 voir, till the level is between the max and min markings on the - Plastic cups
12-10
reservoir.
3 Close the reservoir caps.
Bleed the brake system if necessary and perform a functional
4 32-42: 2.4.1.
test.
3. Battery System
The battery or batteries can be found in the cabin, behind the instrument panel’s pedestal, or fas-
tened to first the bulkhead aft of the cabin. They are dry cell type and don’t require any replenish-
ing of operating fluids.
PAGE PAGE REV. 0

12-08
LSAALPHA
Sinus
Virus
Trainer
12-20
SCHEDULED SERVICING
12-20 SCHEDULED SERVICING
1. Description
This chapter describes the regular servicing requirements of the aircraft. Systems and components
such as fuel, oil, the brakes and the tires, need be serviced regularly in order to keep the aircraft
in good operating condition. How to clean the aircraft and its various components/assemblies is
also covered.
12-20: 2.1. Fuel system
WARNING: All electrical equipment, or any equipment that could produce a spark, must be
disabled before refueling and/or defueling.
WARNING: Smoking is not permitted within 30 meters of the aircraft while refueling/defuel-
ing. Nor is the presence of an open flame.
WARNING: The battery must be disabled before refueling/defueling
WARNING: A fire extinguisher must be present at all times while refueling/defueling.
WARNING: The aircraft’s exhaust tailpipe and all fuel servicing equipment must be grounded
during all/any refueling/defueling procedures.
12-20: 2.1.1. Defueling (gravity driven)

Required parts,
Reference
Place jerry can, canister or fuel tray under the valve located at the - Jerry can,
1 - Canister or fuel tray,
bottom of the firewall.
- Grounding cables
2 Make sure the fire extinguisher is within arm’s reach.
Ground the container to the aircraft’s exhaust tailpipe and the
3
aircraft to an earth ground.
Virus/Sinus: Turn the fuel selector to the tank to be drained.
4
ALPHA Trainer: Open the fuel valve.
5 Locate valve below gascolator, open it and drain.
Virus/Sinus: Turn the fuel selector to the opposite tank and repeat
6
steps 2 to 5.
AIRCRAFT
NOTE: A fuel hose (inner diameter 6 mm or 1/4 inch) can be attached to the gascolator’s valve
and led to the container to avoid splashing.
PAGE REV. 0 PAGE

12-09
Sinus
Virus
ALPHA Trainer
LSA
12-20
SCHEDULED SERVICING
12-20: 2.1.2. Defueling (electric fuel pump if available)

Required parts,
Reference
Place jerry can, canister or fuel tray under the valve located at - Jerry can,
1 - Canister or fuel tray,
the bottom of the firewall.
- Grounding cables
2 Make sure the fire extinguisher is within arm’s reach - Electric fuel pump
Ground the container to the aircraft’s exhaust tailpipe and the
3
aircraft to an earth ground
Virus/Sinus: Turn the fuel selector to the tank to be drained.
4
ALPHA Trainer: Open the fuel valve.
Run a fuel hose (inner diameter 6 mm or 1/4 inch) from the gas-
5 colator’s valve to the electric fuel pump and another from the
electric fuel pump to the container
Locate valve below the gascolator, open it and activate the elec-
6
tric fuel pump
Virus/Sinus: Turn the fuel selector to the opposite tank and
7
repeat steps 2 to 6.
12-20: 2.2. Oil system
12-20: 2.2.1. Oil level check

Required parts,
Reference
1 Master OFF, ignition OFF. - Paper towel
Remove the upper cowling or, if available, open the upper cowl-
2 71-10: 2.1.1.
ing’s oil check door.
3 Remove oil tank cap.
Slowly rotate the propeller in clockwise direction (when looking
4 in the direction of flight) until a gurgling sound is heard coming
from the oil tank.
5 Remove dipstick and wipe clean with paper towel.
6 Place the dipstick back in the oil tank .
7 Remove it again and take oil level reading.
CAUTION: The oil level must be kept between the dipstick’s min and max markings at all times.
8 Replenish if necessary. 12-10
9 Install oil tank cap.

10 Close the upper cowling’s oil check door.
For all other oil system servicing procedures, including how to change the oil filter, how to inspect
it and how to change the oil (i.e. drain the system), refer to chapter 11 of chapter 12-20 in the latest
revision of Rotax’s maintenance manual.
PAGE PAGE REV. 0

12-10
LSAALPHA
Sinus
Virus
Trainer
12-20
SCHEDULED SERVICING
12-20: 2.3. Cooling system
12-20: 2.3.1. Draining the system

Reference: the latest revision of Rotax’s maintenance manual.
Required parts,
Reference
1 Remove the engine cowlings. - Spring clamp pliers 71-10: 2.1.1.

- Jerry can
Locate cylinder #1’s coolant outlet fitting and the hose attached - Canister or fuel tray
2
to it.
3 Place jerry can, canister or fuel tray under cylinder #1 .
Roll the orange fire sleeve back to expose the spring clamp
4
securing the coolant hose to the outlet fitting.
5 Loosen the spring clamp and slide it off the outlet fitting.
Slowly slide the coolant hose off the outlet fitting and allow the
6
coolant to drain into the jerry can, canister or fuel tray.
12-20: 2.4. Tires and wheels
Tire and wheel servicing procedures are covered in 12-10: 2.4. “Tires”.
Refer to 32-40 for tire and wheel removal instructions.
12-20: 2.5. Lubrication
The aircraft has a number of components and assemblies that must be kept well lubricated in order
to avoid premature wear, deterioration and possible ceasing. The table below, Table 12-002, shall
be used as a lubrication guide. It clearly indicates what needs to be lubricated, how often and what
it should be lubricated with. All the joints in Table 12-002 must be cleaned first with some paper
towel before fresh lubricant is applied.
Interval
Group Component Recommended lubricant
(hrs)
Engine Joint between throttle control cable and carburetor lever 100 SKF LGMT 2/0.2 multipurpose grease
Engine Joint between choke control cable and carburetor lever 100 SKF LGMT 2/0.2 multipurpose grease
Cabin Battery terminals 200 SKF LGMT 2/0.2 multipurpose grease
All rod end bearings accessible from the cabin floor con-
Cabin 100 Wurth HHS Lube
trol stick openings
AIRCRAFT
Cabin Control stick drive end bearings 100 Wurth HHS Lube
All rod end bearings located between the cabin and
Cabin 200 Wurth HHS Lube
baggage compartment bulkheads
Cabin Joints between cables and rudder bellcrank 200 SKF LGMT 2/0.2 multipurpose grease
PAGE REV. 0 PAGE

12-11
Sinus
Virus
ALPHA Trainer
LSA
12-20
SCHEDULED SERVICING
Fuselage Door hinges 100 Wurth HHS Lube

Fuselage Elevator hinge pins 200* SKF LGMT 2/0.2 multipurpose grease
Fuselage Upper rudder hinge pin 200* Wurth white assembly paste
Fuselage Upper rudder bushing 200* Wurth white assembly paste
Fuselage Horizontal stabilizer T-fixation plate pins 100 Wurth white assembly paste
Fuselage Horizontal stabilizer att. bolt assembly 100 Wurth white assembly paste
Fuselage Vertical stabilizer bushings 100 Wurth white assembly paste
Fuselage Rudder cable bellcrank bearing 200 Wurth white assembly paste
Fuselage Wing shear pin bushings 200* Wurth white assembly paste
Fuselage Upper flaperon bellcrank clutch 200 Wurth white assembly paste
Fuselage Air brake lever clutch 200 Wurth white assembly paste
Vertical elevator push rod end bearings and aft horizontal
Fuselage 200 Wurth HHS Lube
elevator push rod end bearing
Wings Flaperon pins/bushings 200* SKF LGMT 2/0.2 multipurpose grease
Wings Wings spar pins 200 SKF LGMT 2/0.2 multipurpose grease
Wings Shear pins 200* Wurth white assembly paste
Wings Wing spar bushings 200 SKF LGMT 2/0.2 multipurpose grease
Wings Fuel tank cap thread 200 SKF LGMT 2/0.2 multipurpose grease
Wings Air brake relief pins/bushings 200 SKF LGMT 2/0.2 multipurpose grease
Wings Air brake rod end bearing 200 Wurth HHS Lube
*Shortening service interval is recommended for all aircraft that operate in unusual/abnormal environments (i.e. high
humidity, salt water, dusty conditions, extreme temperatures, etc.).
Table 12-002
Lubrication guide
12-20: 2.6. Cleaning
Inorder for the aircraft to perform the way it should, all of the airframe’s surfaces must be cleaned
on a regular basis. This is especially true for the wing’s leading edges, which can seriously affect
performance if left dirty. Cleaning must be carried out carefully, so that the aircraft’s composite
surfaces don’t incur any damage.
CAUTION: Rubbing any of the aircraft’s surfaces aggressively or polishing any of them is not
permitted and, if necessary, can only be carried out by an approve maintenance organization.
CAUTION: Avoid the use of ALL aggressive cleaning solutions and organic solvents whenever
possible, including window cleaning spray, benzene, aggressive shampoos etc.
CAUTION: When flying in regions with a lot of bugs in the air the leading edges of the airframe
(propeller, wings, tail) need to be protected before flight with antistatic furniture spray cleaner
such as Pronto (transparent, manufacturer: Johnson Wax), or something equivalent. When using
such spray, do not apply it directly onto the wing but onto a soft cloth instead (old T-shirts are
best).
CAUTION: 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 the leading edge was sprayed with an antistatic spray cleaner before
flight.
PAGE PAGE REV. 0

12-12
LSAALPHA
Sinus
Virus
Trainer
12-20
SCHEDULED SERVICING
After-flight wash down
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 (this can also be done using a drying towel, chamois or artificial leather
skin). Begin by soaking all the leading edges of the airframe first. Then wipe the aircraft’s entire
surface until it is completely dry. Clean the propeller and remove any grease spots separately using
a mild car shampoo with a wax.
CAUTION: 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, coast-
line, acid rains, etc.) make sure to clean the outer surface more thoroughly.
CAUTION! Do not, under any circumstances attempt to remove such bug-spots with abrasive
sponges and/or rough polishing pastes.
Periodical cleaning of all outer surfaces with car shampoo
It is recommended the aircraft be cleaned from top to bottom using a soft sponge. Be careful not
to use a sponge that is contaminated with any fine particles, such as those found in mud and sand,
as this could abrade/damage the surface. While cleaning, soak the surface and the sponge many,
many times. Use a separate sponge to clean the bottom of the fuselage, as is it usually greasier
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 chapter, parachute rescue system straps and cover,
pitot tube, tail static probe and/or engine cowlings.
Always rinse the shampooed surfaces again before they dry, then just wipe the whole aircraft dry
using a drying towel, chamois or artificial leather skin. Also, clean the control surface gap seals
on the wing and empennage. Lift the seals gently and insert ONE layer of cloth underneath, then
move along the whole span of the seal.
Cleaning the Lexan transparent surfaces
All the of the aircraft window surfaces are made of Lexan. Cleaning Lexan is not the same as clean-
ing Plexiglas. It is really important to only use clean water (no cleaning solutions are necessary)
when cleaning and a really clean drying towel.
CAUTION: Do not use the towel that was used to dry the airframe’s surfaces to dry the window
surfaces. Use another unused towel for the window surfaces.
Should the window surfaces be dusty, remove the dust first by pouring water (not spraying!) and
AIRCRAFT
gliding your hand over the surface. Glide the drying towel over the surface, squeeze it out and
soak it before touching the glass again. If there are bugs on the windshield, soak them with plenty
of water first, so less wiping is necessary. After drying the window surface, apply some antistatic
furniture spray cleaner such as Pronto (transparent, manufacturer: Johnson Wax), or something
similar and wipe the surface clean with a separate soft cotton cloth.
PAGE REV. 0 PAGE

12-13
Sinus
Virus
ALPHA Trainer
LSA
12-40
12-40 DISPOSABLE REPLACEMENT PARTS

1. Description
Table 12-003 contains a list of disposable parts found on the aircraft. Please refer to the type spe-
cific IPC for the part numbers.

Item
In-line fuel filter
Tires (see Table 12-004)
Air filter
Oil filter
Table 12-003
Disposable Replacement Parts
Table 12-004 contains a list of approved tires and tubes.
MAIN WHEELS TIRES

p/n Manufacturer Size Model Type # of plies
5050010 Mitas 4.00 x 6 B11 66L T tube 6
5050006 Sava 4.00 x 6 V-5501 TT tube 4
5050027 Aero Classic 4.00 x 6 DTR1285 tubeless 8
5050035 Aero Classic 4.00 x 6 DTR1280 tubeless 8
NOSE WHEEL TIRES
5050007 Duro 4.00 x 4 Duro tube 4
5050036 Chang shin 4.00 x 4 Chang Shin tube 4
5050034 Kenda 4.00 x 4 TL tubeless 4
N/A Aero Classic 4.00 x 4 DTR1270 tubeless 8
TAIL WHEEL TIRES
5050022 Tost 50 × 200 Tost Aero tube 6 PL
TUBES
p/n Manufacturer Size Model
5051028 CST 200 × 50 200-50/7×1*3/4
5051002 Mitas 4.00 x 6 JS 87 90/90
5051032 Aero Classic 850-6 TU850-6
Table 12-004
Approved tires and tubes
PAGE PAGE REV. 0

12-14
20
Sinus
Virus
ALPHA Trainer
LSA
CHAPTER 20 – STANDARD PRACTICES – AIRFRAME
TABLE OF CONTENTS

STANDARD PRACTICES – AIRFRAME
20-00 20-03
General
SEALANTS AND LUBRICANTS
20-10 20-04
Description
THREAD-LOCKING FLUIDS
20-20 20-05
Description
FASTENER INFORMATION AND TORQUE VALUES
20-30 20-06
Description
FASTENER/HARDWARE GENERAL REQUIREMENTS
ADHESIVES
20-50 20-09
Description
PAGE PAGE REV. 0

20-02
LSAALPHA
Sinus
Virus
Trainer
20-00
GENERAL
20-00 GENERAL
This chapter contains information about the standard practices that shall be followed when carry-
ing out any maintenance procedures on the aircraft. It covers topics such as fastening hardware,
torque values, approved thread locking fluids, sealants and adhesives.
AIRCRAFT
PAGE REV. 0 PAGE

20-03
Sinus
Virus
ALPHA Trainer
LSA
20-10
SEALANTS AND LUBRICANTS
20-10 SEALANTS AND LUBRICANTS
1. Description
Use of the sealants and lubricants outlined in table 20-001 is recommended when servicing Vi-
rus/Sinus/ALPHA-Trainer aircraft.
Approved Sealants and Lubricants

Item Supplier Specification Pipistrel P/N
SKF general purpose grease SKF group LGMT 2/0.2 5092004
Wurth white assembly paste Adolf Würth GmbH & Co. KG 0893 1041 5092021
Super Impact grease Xintex 502001 5092008
Krown Rust Inhibitor Krown rust control systems KL 73 5092020
Tekasil neutral profi white silicone TKK Srpenica d.d. - 5093024
Termosil 300°C neutral black silicone TKK Srpenica d.d. - 5093017
Termosil N6 TKK Srpenica d.d. - 5093018
Loctite 577 thread sealant Loctite Corp. - 5091033
Akrapovič ceramic anti-seize grease Akrapovič d.d. - 5092002
Akrapovič copper anti-seize grease Akrapovič d.d. - 5092001
Loctite silver grade anti-seize Henkel Corp. LB 8150 5091041
Table 20-001
Approved sealants and lubricants
NOTE: Please refer to the latest revision of the applicable IPC for additional information as to
where the sealants/lubricants listed in Table 20-001 are used.
CAUTION: When using the sealants and lubricants listed in Table 20-001 always refer to the
supplier’s instructions for information about how to store them properly, how to use them prop-
erly and any safety precautions.
WARNING: Don’t use any sealants or lubricants that have expired.
PAGE PAGE REV. 0

20-04
LSAALPHA
Sinus
Virus
Trainer
20-20
THREAD-LOCKING FLUIDS
20-20 THREAD-LOCKING FLUIDS
1. Description
Use of the thread locking fluids in table 20-002 is recommended when servicing Virus/Sinus/AL-
PHA-Trainer aircraft.
Approved Thread-Locking Fluids

Loctite 243 Loctite Corp. - 5091023
Table 20-002
Approved thread-locking fluids
NOTE: Please refer to the latest revision of the applicable IPC for additional information as to
where the thread-locking fluids listed in Table 20-002 are used.
CAUTION: When using the thread-locking fluids listed in Table 20-002 always refer to the sup-
plier’s instructions for information about how to store them properly, how to use them properly
and any safety precautions.
WARNING: Don’t use any thread-locking fluids that have expired.
WARNING: All of the aircraft bolted joints requiring thread-locking fluids are labeled in the lat-
est revision of its IPC. Failure to apply thread-locking fluids to the aforementioned bolted joints
can cause them to loosen and possibly a safety hazard.
AIRCRAFT
PAGE REV. 0 PAGE

20-05
Sinus
Virus
ALPHA Trainer
LSA
20-30
FASTENER INFORMATION AND
TORQUE VALUES
20-30 FASTENER INFORMATION AND TORQUE VALUES
1. Description
Information about the fastening material used on the aircraft can be found in the latest revision of
the applicable IPC. The large majority of bolts used adhere to the DIN (Deutsche Industrie Norm)
standard. Any bolted joints that require special torqueing are labeled in the IPC. All other bolted
joints that are otherwise not labeled with a specific torque, must be torqued to the values found
in Table 20-003.
Fastener Torque (Nm)

M4 2.8
M5 5.5
M6 9.5
M8 23.0
M10 46.0
M12 79.0
M14 125.0
Table 20-003
Standard torque values
WARNING: Bolts on the aircraft are only permitted to be replaced by equal or better grade
bolts.
CAUTION: When fastening bolted joints always torque the nuts whenever possible.
PAGE PAGE REV. 0

20-06
LSAALPHA
Sinus
Virus
Trainer
20-40
FASTENER /HARDWARE GENERAL
REQUIREMENTS
20-40 FASTENER/HARDWARE GENERAL REQUIREMENTS
1. Description
This chapter outlines the standard practices that apply to fastening material and hardware found
on the Virus/Sinus/ALPHA-Trainer aircraft. It covers the maintenance practices that apply to
torque marking, proper use of locknuts and fittings with tapered thread.
20-40: 2.1. Torque marking
Torque marking refers to act of marking a bolt joint after it’s been torqued (see Figure 20-001).
This allows for any loosening that may occur to be detected visually.
NOTE: All bolted joints on the aircraft must be torque marked after being torqued to ensure
easy detection of any loosening.
CAUTION: The fastening material of any bolted joint that has loosened must be removed and
replaced.
Figure 20-001
Example of torque marked bolted joints
20-40: 2.2. Locknuts

AIRCRAFT
Locknuts are used throughout the aircraft because they resist loosening. Their plastic lining cre-
ates additional friction between it and the bolt.
CAUTION: Reusing locknuts is not permitted on Virus/Sinus/ALPHA-Trainer aircraft.
PAGE REV. 0 PAGE

20-07
Sinus
Virus
ALPHA Trainer
LSA
20-40
FASTENER /HARDWARE GENERAL
REQUIREMENTS
20-40: 2.3. Fitting with tapered thread
Some of the components found on the Virus/Sinus/ALPHA-Trainer aircraft have tapered NPT
thread and thus require special attention when removing/installing them. All of the aforemen-
tioned components can be found in the latest revision of the IPC. The following points must be
adhered to when working with tapered thread on the aircraft:
• An approved thread sealant (Loctite 577) must be applied to the external thread before
fastening. This will ensure a leak-free seal.
• The component must be tightened by hand first and then tightened an additional two (2)
turns with a wrench, so that the thread deforms and creates the seal (unless stated otherwise in
any particular ICA).
CAUTION: Any components or fastening material with tapered thread, once removed, are not
permitted to be reused and must be replaced with new ones.
PAGE PAGE REV. 0

20-08
LSAALPHA
Sinus
Virus
Trainer
20-50
ADHESIVES
20-50 ADHESIVES
1. Description
Use of the adhesives in table 20-004 is recommended for when servicing Virus/Sinus/ALPHA-Train-
er aircraft.
Approved Sealants and Lubricants

Tesa professional spray glue Tesa SE 60022 5091063
Pattex universal classic contact adhesive Henkel - 5091011
Wurth window adhesive classic plus Adolf Würth GmbH & Co. KG 0890023701 5091018
Scotchmount primer 3M Deutschland GmbH 4297 5095009
Table 20-004
Approve adhesives
CAUTION: When using the adhesives listed in Table 20-004 always refer to the supplier’s in-
structions for information about how to store them properly, how to use them properly and any
safety precautions.
WARNING: Don’t use any adhesives that have expired.
AIRCRAFT
PAGE REV. 0 PAGE

20-09
21
Sinus
Virus
ALPHA Trainer
LSA
CHAPTER 21 – ENVIRONMENTAL SYSTEMS
TABLE OF CONTENTS

ENVIRONMENTAL SYSTEMS
21-00 General 21-03
VENTILATION SYSTEMS
Description
21-10 21-04
PAGE PAGE REV. 0

21-02
LSAALPHA
Sinus
Virus
Trainer
21-00
GENERAL
21-00 GENERAL
The chapter covers all of the systems that control/regulate air flow and temperature in the Virus/
Sinus/ALPHA-Trainer aircraft cabin.
SYSTEMS
PAGE REV. 0 PAGE

21-03
Sinus
Virus
ALPHA Trainer
LSA
21-10
VENTILATION SYSTEMS
21-10 VENTILATION SYSTEMS

1. Description
The Virus/Sinus/ALPHA-Trainer aircraft primary ventilation system consists of a set of sliding win-
dows and adjustable vents that direct fresh ram air into the cockpit. The starboard door has a slid-
ing window (1), while the port door has an adjustable circular vent (2). An additional circular vent is
built into the sun roof. (See Figure 21-001)
Figure 21-001
Primary ventilations system
PAGE PAGE REV. 0

21-04
LSAALPHA
Sinus
Virus
Trainer
21-10
VENTILATION SYSTEMS
21-10: 2.1. Primary ventilation system
21-10: 2.1.1. Inspection/check

Required parts,
Reference
Inspect the starboard door’s sliding window for free, unhindered

1
movement. Check for signs of damage and/or wear.
Ensure the sliding window’s springs are in good operating con-
2
dition.
Inspect the port door’s adjustable circular vent for free, unhin-
3
dered movement. Check for signs of damage and/or wear.
Inspect the sunroof’s adjustable circular vent for free, unhindered
4
movement. Check for signs of damage and/or wear.
SYSTEMS
PAGE REV. 0 PAGE

21-05
22
Sinus
Virus
ALPHA Trainer
LSA
CHAPTER 22 – AUTOPILOT SYSTEM
TABLE OF CONTENTS

AUTOPILOT SYSTEM
22-00 22-03
General
DYNON AUTOPILOT SYSTEM
PAGE PAGE REV. 0

22-02
LSAALPHA
Sinus
Virus
Trainer
22-10
22-00 GENERAL
Virus/Sinus LSA aircraft is equipped with two autopilot servo motors, that controls pitch and roll.
They are operated using the Dynon SkyView or Garmin G3X avionic system and offer a means of
automatically or manually controlling the flight path of the aircraft. The aircraft also has an elevator
trim assembly allows the pilot to control pitch without having to exert constant pressure on the
pitch control system.
ALPHA Trainer is not equipped with autopilot system.
SYSTEMS
PAGE REV. 0 PAGE

22-03
Sinus
Virus
ALPHA Trainer
LSA
22-10
22-10 AUTOPILOT SYSTEM

1. Description
The system is a dual axis autopilot system that provides roll stability, heading hold, NAV/GPS
tracking capabilities, and altitude hold capabilities controlled via a roll and pitch servo. (See Fig-
ures 22-001)
The system is available for Sinus/Virus models only.
The servo actuators are directly connected to the control chain, and are integrated into the Dynon
SkyView or Garmin G3X avionic system interface.
Figure 22-001
Autopilot Pitch and Roll Installation
(Dynon servos shown)
NOTE: For Dynon Skyview and Garmin G3X features description and functionalities please refer
to the device manual
PAGE PAGE REV. 0

22-04
LSAALPHA
Sinus
Virus
Trainer
22-10
22-10: 2.1. Removal/installation
For removal and installation, apply standard practices described in chapter 20-00 of this manual.
For all other maintenance procedures, including testing and troubleshooting, refer to the Dynon or
Garmin autopilot operation manual/service publications.
22-10: 2.2. Inspection/check
22-10: 2.2.1. Pitch autopilot controls system

Applicability SIN VIR VSW AT Qualification LSRM L1 LAME
Required parts,
Reference
1 Remove the control stick boots. 25-10: 2.3.1.
2 Carry out visual inspection. 05-20

3 Lubricate rod end bearings. 12-20
4 Install control stick boots. 25-10: 2.3.2.
22-10: 2.2.2. Roll autopilot control system

Required parts,
Reference
1 Remove the crew seats. 25-10: 2.1.1.
2 Remove the baggage compartment. 25-50: 2.1.1.

4 Lubricate rod end bearings. 12-20
5 Install the baggage compartment. 25-50: 2.1.2.
6 Install the crew seats. 25-10: 2.1.2.
SYSTEMS
PAGE REV. 0 PAGE

22-05
24
Sinus
Virus
ALPHA Trainer
LSA
CHAPTER 24 – ELECTRICAL POWER
TABLE OF CONTENTS

ELECTRICAL POWER
24-00 24-03
General
DC GENERATION
EXTERNAL POWER
DC ELECTRICAL LOAD DISTRIBUTION
PAGE PAGE REV. 0

24-02
LSAALPHA
Sinus
Virus
Trainer
24-00
GENERAL
24-00 GENERAL
The aircraft is equipped with a single-generator, single-battery, 14-volt direct current (VDC) elec-
trical system designed to reduce the risk of electrical system faults. The system provides unin-
terrupted power for avionics, flight instrumentation, lighting, and other electrically operated and
controlled systems during normal operation.
SYSTEMS
PAGE REV. 0 PAGE

24-03
Sinus
Virus
ALPHA Trainer
LSA
24-30
DC GENERATION
24-30 DC GENERATION
1. Description
The electrical system is a 12-Volt DC system. Power is supplied by an integrated generator with
approximately 250W AC output at 5800 RPM and rectified with an electronic full-wave rectifier
regulator (RU 912). The generator system is capable of delivering max. 18A at 14V which feeds
the on-board battery (12V, 11Ah – see Figure 24-001). In case of emergency, the battery will supply
reduced number of necessary direct-current loads with power. The electrical system is controlled
by means of switches/fuses, which are arranged in one row on the upper half of the switch panel
under the instrument panel.
Figure 24-001
Example of battery installation
24-30: 2.1. Battery
24:30: 2.1.1. Removal

Required parts,
Reference
1 MASTER switch off, AVIONICS switch off. Metric ratchet/

socket set
2 Disconnect the battery.
3 Remove the straps securing it in place.
4 Remove terminal bolt caps.
5 Loosen/remove the terminal bolts.
6 Disconnect the cables.
7 Remove the battery.
PAGE PAGE REV. 0

24-04
LSAALPHA
Sinus
Virus
Trainer
24-30
DC GENERATION
24:30: 2.1.2. Inspection/check

Required parts,
Reference
Carry out visual inspection of the battery. 05-20

1 Inspect its terminals for any signs of oxidation. Figure 24-002
If necessary, remove the battery and remove oxidation. 24:30: 2.1.1.
Wipe away any residual lubricant on the terminals and re-
2 12-20
apply lubricant.
Figure 24-002
Example of battery terminal oxidation
24:30: 2.1.3. Installation

Required parts,
Reference
1 Position battery in mounting bracket and secure with straps. Metric ratchet/
socket set
2 Connect cables and secure them using bolts.
3 Install terminal bolt caps.
4 Connect battery.
SYSTEMS
PAGE REV. 0 PAGE

24-05
25
Sinus
Virus
ALPHA Trainer
LSA
CHAPTER 25 – EQUIPMENT AND FURNISHING
TABLE OF CONTENTS

EQUIPMENT AND FURNISHING
25-00 25-03
General
FLIGHT COMPARTMENT
BAGGAGE COMPARTMENT
EMERGENCY
PAGE PAGE REV. 0

25-02
LSAALPHA
Sinus
Virus
Trainer
25-00
GENERAL
25-00 GENERAL
This chapter describes all of the equipment and furnishings found in cabin and baggage compart-
ment. It covers everything from the seats and four-point seat safety harnesses to the upholstery
and control stick boots.
SYSTEMS
PAGE REV. 0 PAGE

25-03
Sinus
Virus
ALPHA Trainer
LSA
25-10
FLIGHT COMPARTMENT
25-10 FLIGHT COMPARTMENT

1. Description
This chapter describes all of the equipment and furnishings found in the cabin and outlines the
maintenance practices that apply to them.
Crew seats
The crew seats are comprised of a bottom cushion, hard padded back rest and a head rest. Two
options are available: standard seats and ergonomic leather seats.
The backrest and head rest are attached to the aft cabin bulkhead, while the bottom cushion is
attached to the seat shell. All of the seats’ components are secured in place by means of Velcro
patches. The seats’ position cannot be adjusted, nor can they be reclined, however, for ergonomic
version, the backrest features a manual pneumatic pump to adjust the size of the lumbar bladder
and consequently the amount of back support.
Safety harnesses
The harness is a 4-point restraint system with quick release buckle. The lap straps are attached
to the composite seat shell with M8 bolts in an area that is that is locally reinforced. The shoulder
straps are attached to the bottom of the rear baggage compartment bulkhead with M8 bolts. The
attachment point is also locally reinforced.
Control stick boots
Each control stick is equipped with a leather boot that protects the stick and prevents any dirt/
debris from entering the area beneath the cabin floor.
25-10: 2.1. Crew seats
25-10: 2.1.1. Removal

Required parts,
Reference
1 Tear head rest away from Velcro patches and remove it.
Tear backrest away from Velcro patches, slide shoulder straps
2
around it and remove it.
3 Tear bottom cushion away from Velcro patches and remove it.

PAGE PAGE REV. 0
25-04
LSAALPHA
Sinus
Virus
Trainer
25-10
FLIGHT COMPARTMENT
Required parts,
Reference
NOTE: in case of standard seats installed, after removing the back rest and head rest, it is necessary to
release the buckles of the supporting straps to access the aft cabin compartment.

Required parts,
Reference
NOTE: in case of standard seats, before installing the back rest and head rest, it is necessary to fasten the
buckles of the supporting straps.
Position bottom cushion in seat shell and press it up against the
1
Velcro patches on the seat shell.
Position the backrest behind the shoulder straps and press it up
2
against the Velcro patches on the aft cabin bulkhead.
Position the head rest so that it’s bottom flap rests behind the
3 backrest and then press it up against Velcro patches on the aft
cabin bulkhead.
25-10: 2.2. Safety harnesses
25-10: 2.2.1. Removal

Required parts,
Reference
1 Remove crew seats. T-handle socket 25-10: 2.1.1.

screwdriver set
2 Remove baggage compartment (if applicable). 25-50: 2.1.1.
Remove fastening material securing the harnesses to their at-
3
tachment points.
4 Remove safety harnesses.

Required parts,
Reference
1 Apply Loctite 243 to the fastening material thread. - T-handle socket

screwdriver set,
SYSTEMS
2 Fasten the safety harnesses to their attachment points. - Loctite 243

3 Install baggage compartment (if applicable). 25-50: 2.1.2.
4 Install crew seats. 25-10: 2.1.2.
5 Carry out operational inspection of seats. 05-20
PAGE REV. 0 PAGE

25-05
Sinus
Virus
ALPHA Trainer
LSA
25-10
FLIGHT COMPARTMENT
25-10: 2.3. Control stick boot
25-10: 2.3.1. Removal

Required parts,
Reference
Remove the self-tapping screws securing the base of the boot Phillips screwdriver
1
in place.
2 Release the strap at the top of the boot.
3 Remove the boot by sliding it off the control stick.

Required parts,
Reference
Slide the boot over the control stick and position it on the cab- Phillips screwdriver
1
in floor
2 Fasten it to the cabin floor using the self-tapping screws
3 Fasten the strap at the top of the boot
4 Carry out operational inspection of the control stick. 05-20
PAGE PAGE REV. 0

25-06
LSAALPHA
Sinus
Virus
Trainer
25-50
BAGGAGE COMPARTMENT
25-50 BAGGAGE COMPARTMENT

1. Description
The baggage compartment is positioned behind the seats. For ALPHA Trainer baggage compart-
ment is available as option only.
Depending on the aircraft equipment, it is accessible removing the crew seats, or via a dedicated
baggage door on the port side of the aircraft.
Two main configurations are possible: baggage net or CFRP floor and walls. In the latter case all of
its components are manufactured from CFRP and, aside from supporting baggage, they also act
as a barrier between it and the control rods nearby, so that luggage cannot interfere with them.
Components have different shape in case the airplane is equipped or not with ballistic rescue
parachute system.
25-50: 2.1. Baggage compartment - CFRP version
25-50: 2.1.1. Removal

Required parts,
Reference
-T-handle hex head 25-10: 2.1.1.

1 Remove crew seats.
screwdriver set,
Remove the bulkhead cover that is held in position by velcro patch- -Metric wrench set, Figure 25-
2 -Metric ratchet and 001
es.
socket set
Remove the two pieces floor board, held in position by velcro
3
patches.
4 Remove the vertical flaperon pushrod protective cover.
NOTE: if the aircraft is equipped with autopilot, it is necessary to dis-
connect the aileron servo rod to remove the flaperon protective cover.
5 Carry out visual inspection of baggage compartment components. 05-20
SYSTEMS
PAGE REV. 0 PAGE

25-07
Sinus
Virus
ALPHA Trainer
LSA
25-10
FLIGHT COMPARTMENT

Required parts,
Reference
1 Remove crew seats. 25-10: 2.1.1.
2 Install the vertical flaperon pushrod protective cover in place.

NOTE: if the aircraft is equipped with autopilot, reconnect the roll servo
rod.
3 Install the floor board, secured by velcro patches
4 Install the bulkhead cover in place, secured by velcro patches.
25-50: 2.2. Baggage compartment - Baggage net

25-50: 2.2.1. Removal
Required parts,
Reference
Unfasten the plastic buckles and release the straps that support the
2
baggage net.
3 Remove the baggage net Figure 25-002
4 Carry out visual inspection of baggage compartment components. 05-20

Required parts,
Reference
Install the baggage net running the support strap through the slots
2
on the cabin and baggage compartment bulkheads.
3 Fasten the plastic buckles on the support straps.
PAGE PAGE REV. 0

25-08
LSAALPHA
Sinus
Virus
Trainer
25-50
BAGGAGE COMPARTMENT
Figure 25-001
Example of CFRP Baggage compartment in Sinus/Virus
SYSTEMS
Figure 25-002
Baggage net
PAGE REV. 0 PAGE

25-09
Sinus
Virus
ALPHA Trainer
LSA
25-60
EMERGENCY
25-60 EMERGENCY
1. Description
Emergency locator transmitter (ELT)
The aircraft is equipped with a self-contained compact Kannad 406 AF ELT with remote control
panel (RCP). The ELT transmitter is installed immediately aft of the cabin bulkhead. The ELT is
mounted slightly to the right of the airplane centerline. The transmitter is accessible through the
baggage compartment, while the ELT antenna is located on the top of the cockpit.
ELT RCP
The Kannad 406 AF Compact ELT has a remote control panel (RCP) Kannad RC200, installed on
the instrument panel for easy access and checking of system’s proper functionality.
WARNING: ELT and RCP batteries must be inspected in accordance with the requirements
of the replacement schedule in chapter 5. The ELT and RCPI batteries must be replaced upon
reaching the date stamped on the batteries or whenever the batteries have been in use for one
cumulative hour.
NOTE: Electrical equipment and electrically powered instruments are individually protected by
means of circuit breakers, except the ELT which is separate from electrical system of the aircraft.
For additional information of the ELT, refer to the Kannad 406 AF Compact ELT Installation and
Operation Manual.
25-60: 2.1. Emergency locator transmitter (ELT)
25-60: 2.1.1. Removal

Required parts,
Reference

2 Locate ELT behind passenger seat.
3 Disconnect both cables.
4 Release strap.
5 Remove ELT.
PAGE PAGE REV. 0

25-10
LSAALPHA
Sinus
Virus
Trainer
25-60
EMERGENCY

Required parts,
Reference
1 Position ELT in composite mounting brace.

2 Secure using Velcro strap.
3 Connect it’s two cables.
SYSTEMS
PAGE REV. 0 PAGE

25-11
27
Sinus
Virus
ALPHA Trainer
LSA
CHAPTER 27 – FLIGHT CONTROLS
TABLE OF CONTENTS

FLIGHT CONTROLS
General
27-00 27-03
Description
RUDDER
ELEVATOR
FLAPERONS
AIR BRAKE LEVER
PAGE PAGE REV. 0

27-02
LSAALPHA
Sinus
Virus
Trainer
27-00
GENERAL
27-00 GENERAL
1. Description
This chapter describes the Virus/Sinus/ALPHA-Trainer control system and the maintenance proce-
dures that pertain to it.
The control system consists of various push/pull rods, bellcranks, cables and pulleys. An elevator
attached to the horizontal stabilizer gives longitudinal control, while a rudder, which is attached
to the vertical stabilizer, provides yaw control. The wings have flaperons attached to their trailing
edge which provide lateral control, as well as extra lift for landing and taking off.
The aircraft has a control stick for each pilot. The elevator can be trimmed using a trim knob found
in the center console, just between the two seats, or in the control panel.
Each pilot has a rudder pedal assembly that is attached to the cabin floor and allows for complete
yaw control as well as nose wheel steering. The rudder pedal assembly’s position is adjustable.
27-00: 2.1. Push/pull rods
27-00: 2.1.1. Adjusting length

Required parts,
Reference
1 Loosen jam nut. - Metric ratchet/socket set,

- Metric combination wrench set
Remove fastening material securing the rod end to
2
the stud/brace.
3 Slide rod end off stud/brace.
Rotate rod end bearing clockwise to shorten the
4
push/pull rod or counterclockwise to lengthen it.
5 Slide rod end back onto stud/brace.
Fasten rod to stud/brace. Torque and apply Loctite
6
if necessary (see pull/push rod assembly in IPC).
7 Carry out operational inspection. 05-20
SYSTEMS
PAGE REV. 0 PAGE

27-03
Sinus
Virus
ALPHA Trainer
LSA
27-20
RUDDER
27-20 RUDDER
1. Description
Rudder pedals are available for each pilot and are adjustable in flight in the fore-aft direction. Metal
cables in Teflon-coated protective sleeves run from the individual pedal to an intermediate junction
point inside the fuselage, and then directly to the rudder. Rudder cable tension can be adjusted
using turnbuckles.
The nose wheel is part of the yaw control system and moves whenever the pedal is pressed. The
cables that allow for nose wheel steering run from the aft rudder cables joints to the nose wheel
bellcrank, which has an anti-shimmy damper connected to it.
Figure 27-001
Rudder control system
PAGE PAGE REV. 0

27-04
LSAALPHA
Sinus
Virus
Trainer
27-20
RUDDER
27-20: 2.1. Rudder cables
27-20: 2.1.1. Inspection/check near the rudder

Required parts,
Reference
1 Remove rudder. - Metric ratchet/socket set 55-40: 2.1.1.

Carry out visual inspection of rudder cables in the
2 05-20
vicinity of the rudder cable bellcrank.
NOTE: Pay special attention to the cables’ individual strands, as if even one damaged strand requires
complete cable replacement. Also inspect their thimbles and sleeves for any signs of damage or wear.
Carry out operational inspection of the rudder ca-
3 05-20
bles in the vicinity of the rudder cable bellcrank.
4 Install the rudder. 55-40
27-20: 2.1.2. Inspection/check in the fuselage aft of the cabin

Required parts,
Reference
1 Remove the baggage compartment (if applicable). - Metric ratchet/socket set 25-50: 2.1.1.
- T-handle hex head screwdriver set
Carry out visual inspection of rudder cables behind
3 05-20
the cabin and in the fuselage tail cone.
complete cable replacement.
4 05-20
bles behind the cabin and in the fuselage tail cone.
5 Install the baggage compartment (if applicable) 25-50: 2.1.2.
6 Install crew seats 25-10: 2.1.2.
27-20: 2.1.3. Inspection/check in the cabin

Required parts,
Reference
Carry out visual inspection of rudder cables in the - Exhaust spring puller tool (hook)
SYSTEMS
1 05-20
cabin near the rudder pedals.
complete cable replacement.
PAGE REV. 0 PAGE

27-05
Sinus
Virus
ALPHA Trainer
LSA
27-20
RUDDER
Required parts,
Reference

2 05-20
bles in the cabin.
Detach the rudder pedal return springs to access to
3
the bottom end of the S-shaped tube.
NOTE: Pay special attention to the area where the cables enter and exit the pedals’ S-shaped tube (see
Figure 27-002).
4 Reattach the rudder pedal return springs.
Figure 27-002
Upper pedal-rudder cable joint
PAGE PAGE REV. 0

27-06
LSAALPHA
Sinus
Virus
Trainer
27-20
RUDDER
27-20: 2.2. Rudder pedals

Required parts,
Reference
1 Carry out visual inspection of rudder pedals. 05-20

2 Carry out operational inspection of rudder pedals. 05-20
27-20: 2.3. Rudder pedal return springs

Required parts,
Reference
Carry out visual inspection of the springs. Pay spe- - Rudder deflection verification
1 cial attention to the springs’ end hooks and check template (P/N 1190345) 05-20
for any signs of deformation.
Fit the aircraft with the rudder deflection verification
2
template.
3 Align the rudder with the template’s center mark.
Verify that the rudder pedals are parallel to each
4
other.
CAUTION: Damaged or deformed rudder pedal return springs can cause unexpected/odd yaw behavior.
Replace them if necessary (see 27-20).
5 Remove the rudder deflection verification template.
27-20: 2.3.2. Removal/installation

Required parts,
Reference
1 Unhook the springs from the pedals. - Vernier caliper

- Needle nose pliers
2 Install new springs - Rudder deflection verifica-
Check that the rudder pedals are parallel to each tion template (P/N 1190345)
3 27-20
other with the rudder centered.
Carry out operational inspection of the rudder ped-
SYSTEMS
4 05-20
al return springs.
PAGE REV. 0 PAGE

27-07
Sinus
Virus
ALPHA Trainer
LSA
27-20
RUDDER
27-20: 2.4. Rudder
27-20: 2.4.1. Inspect/check

Required parts,
Reference
1 Remove rudder. 55-40

Visual inspection of rudder seals. Replace if nec-
2 55-40: 2.2.
essary.
Inspect the paint marker on the threaded stopper
20-40: 2.1.
3 pins. If they have loosened/shifted, adjust the de-
27-20: 2.4.2.
flection angle.
4 Wipe clean and lubricate upper rudder bushing. 12-20
27-20: 2.4.2. Deflection angle adjustment

Required parts,
Reference
Position and fasten the rudder deflection template - Rudder deflection verifica-
1 tion template (P/N 1190345)
to the fuselage.
Verify that rudder’s deflections angles are within
2
tolerance using markings on template.
If necessary, adjust deflection angles by regulating
3 Chapter 6
threaded stopper pins on lower rudder hinge.
CAUTION: Rudder deflection angles that don’t adhere to those in the aircraft’s WBR can result in unex-
pected/odd yaw behavior.
27-20: 2.4.3. Radial free play check

Reference: Figure 27-004
Required parts,
Reference
1 Remove the horizontal stabilizer. - Vernier caliper 53-10

Place Vernier caliper between rudder and the ele-
vator retainer and, while moving the rudder back
2
and forth in the radial direction, measure the free
play.
CAUTION: The maximum permissible amount of radial rudder free play is 0.5 mm.
3 Install the horizontal stabilizer. see 53-10
PAGE PAGE REV. 0

27-08
LSAALPHA
Sinus
Virus
Trainer
27-20
RUDDER
Figure 27-004
Rudder radial free play check
27-20: 2.4.4. Axial free play check

Required parts,
Reference
1 Remove the horizontal stabilizer. - Vernier caliper 55-10

Place Vernier caliper as shown in Figure 27-005
2 and, while moving the rudder back and forth in the
axial direction, measure the free play.
3 Install the horizontal stabilizer. 55-10
SYSTEMS
Figure 27-005
Rudder axial free play check
PAGE REV. 0 PAGE

27-09
Sinus
Virus
ALPHA Trainer
LSA
27-20
RUDDER
27-20: 2.5. Upper rudder hinge

Required parts,
Reference
1 Remove rudder. - Metric ratchet/socket set 55-40

- Torque wrench
2 Carry out visual inspection of upper rudder hinge. - Paper towel 05-20
3 Inspect paint marker. 20-40: 2.1.
4 Clean hinge pin with paper towel and lubricate it. 12-20
5 Install rudder. 55-40
27-20: 2.6. Lower rudder hinge

Required parts,
Reference
1 Remove rudder. - Metric ratchet/socket set 55-40

- Torque wrench
2 Carry out visual inspection of lower rudder hinge. - Paper towel 05-20
Inspect paint marker.
3 20-40: 2.1.
4 Clean hinge pin with paper towel and lubricate it. 12-20
PAGE PAGE REV. 0

27-10
LSAALPHA
Sinus
Virus
Trainer
27-20
RUDDER
27-20: 2.7. Rudder cable bellcrank

Required parts,
Reference
1 Remove rudder. 55-40

2 Carry out visual inspection of rudder cable bellcrank. 05-20
3 Clean it with paper towel and lubricate it. 12-20
4 Inspect paint marker. 20-40: 2.1.
5 Carry out operational inspection of the rudder cable bellcrank. 05-20
SYSTEMS
PAGE REV. 0 PAGE

27-11
Sinus
Virus
ALPHA Trainer
LSA
27-30
ELEVATOR
27-30 ELEVATOR
1. Description
The elevator is fastened to the horizontal stabilizer and is operated using the pilot control sticks
(see Figure 27-006). The sticks are mounted on a common lateral drive assembly, which actuates
the horizontal elevator pushrod that runs along the entire length of the fuselage. A bellcrank is
located on the bottom side of the vertical stabilizer and can be inspected through a provision in
the vertical stabilizer end-rib. The hook-up to the elevator is via a composite U-shaped retainer
which conforms to the shape of the elevator. Upon removal of the horizontal stabilizer/elevator, the
U-member remains attached to the fuselage. The pitch control system does not include any cables.
The autopilot pitch servo (Optional - Virus/Sinus only) is connected to the main lateral push-rod via
a dedicated rod. Control stops are integrated into the lateral drive assembly for elevator deflection
control, or installed along the pushrod as hose-clamps in older airplanes.
Figure 27-006
Elevator control system
PAGE PAGE REV. 0

27-12
LSAALPHA
Sinus
Virus
Trainer
27-30
ELEVATOR
A spring-based elevator trim is activated mechanically by a linear cursor, or electrically by a servo

motor assembly located behind the baggage compartment (see Figure 27-007). The motion of the
linear servo is controlled through a cockpit switch and an integral position sensor. Trim position is
indicated with discrete steps on a dedicated LED display adjacent to the trim switch.
Figure 27-007
Elevator trim system and cockpit switch/display
27-30: 2.1. Elevator
27-30: 2.1.1. Inspection/check (stopper pins on stick drive assembly)

Required parts,
Reference
1 Remove the port control stick boot. 25-10: 2.3.1.

Inspect the paint marker on the threaded stopper pins
SYSTEMS
2 at port end of the control stick drive. If they have loos- 27-30: 2.1.2.
ened/shifted, adjust the deflection angle.
PAGE REV. 0 PAGE

27-13
Sinus
Virus
ALPHA Trainer
LSA
27-30
ELEVATOR
27-30: 2.1.2. Inspection/check (stopper hose clamps on elevator pushrod)

Required parts,
Reference

Inspect the hose clamps positioned along the elevator
3 pushrod in the baggage compartment. Check if they 27-30: 2.1.3.
have loosened/shifted, adjust the deflection angle.

(if required after performing inspection/check in 27-30: 2.1.1.)
Required parts,
Reference
Fit elevator deflection measurement tool on trailing - Elevator deflection

1 measurement kit ( P/N Figure 27-016
edge of elevator.
1190464)
Put elevator in neutral position by aligning it with
2
horizontal stabilizer. Set inclinometer to 0o.
3 Verify correct elevator deflection angles Aircraft WBR
Adjust the deflection angles by screwing/unscrew-
ing the control sticks’ longitudinal threaded stopper
05-20
4 pins, or, for hose clamp system, shifting the position Aircraft WBR
of the stopper hose clamps along the elevator push-
rod inside the baggage compartment.
CAUTION: Elevator deflection angles that don’t adhere to those in the aircraft’s WBR can result in unexpect-
ed/odd pitch behavior.
Figure 27-0016
Elevator deflection angle adjustment
PAGE PAGE REV. 0

27-14
LSAALPHA
Sinus
Virus
Trainer
27-30
ELEVATOR

Required parts,
Reference
1 Lower the tail chapter to the ground. - Vernier caliper

Place Vernier caliper between elevator and horizontal
2 stabilizer, while moving the rudder back and forth in the Figure 27-008
CAUTION: The maximum permissible amount of axial elevator free play is 0.5 mm
Figure 27-008
Elevator axial free play check

Required parts,
Reference
1 Lower the tail chapter to the ground. - Vernier caliper

Place Vernier caliper between elevator and horizontal
2 stabilizer, while moving the rudder back and forth in the Figure 27-009
radial direction, measure the free play.
3 Install the horizontal stabilizer. 55-10
SYSTEMS
Figure 27-009
Elevator radial free play check
PAGE REV. 0 PAGE
27-15
Sinus
Virus
ALPHA Trainer
LSA
27-30
ELEVATOR
2.2. Horizontal elevator pushrod

Required parts,
Reference

2 Remove the baggage compartment (if applicable). 25-50: 2.1.1.
Carry out visual inspection of horizontal elevator push-
rod. Inspect the push rod’s surface where it travels 05-20
3 through the bearings. Surface discoloration is accept- Figure 27-010
able, however, gouges and surface deformations are Figure 27-011
not.
CAUTION: Surface damage and/or gouges in the horizontal elevator pushrod deeper than 0.15 mm are a
safety hazard and require pushrod replacement.
Carry out operational inspection of horizontal elevator
4 05-20
pushrod.
Figure 27-010 Figure 27-011

Horizontal elevator pushrod surface discoloration Horizontal elevator pushrod surface gouges
27-30: 2.2.2. Major inspection

Applicability SIN VIR VSW AT Qualification AMT L1 LAME
Required parts,
Reference
1 Remove the control stick boots. Phillips screwdriver 25-10: 2.3.1.


Use borescope to carry out visual inspection of the hor-
4 05-20
izontal elevator push rod under the cabin floor.
5 Install the baggage compartment (if applicable). 25-50: 2.1.2.
7 Install control stick book. 25-10: 2.3.2.
PAGE PAGE REV. 0

27-16
LSAALPHA
Sinus
Virus
Trainer
27-30
ELEVATOR
27-30: 2.3. Elevator trim assembly

Required parts,
Reference
1 Remove the crew seats - Vernier caliper, 25-10: 2.1.1.

- Measuring tape
Carry out visual inspection of elevator trim assembly.
Inspect its springs for any signs of damage. Check that
05-20
3 the fastening material securing them to the assembly
Figure 27-012
hasn’t loosened. Make sure their end hooks aren’t
deformed. Replace if necessary.
Carry out operational inspection of elevator trim as-
4 05-20
sembly, including the elevator trim knob.
Verify that the hose clamps, securing the elevator trim
assembly’s springs to the horizontal elevator push-
rod, haven’t shifted in position. With the elevator and
control sticks fixed in the neutral position, they must
adhere to the following dimensions:
5
Fore hose clamp: 60 mm between hose clamp and
bearing housing.
Aft hose clamp: 3 mm between hose clamp and bear-
ing housing.

SYSTEMS
Figure 27-012
Elevator trim assembly spring fastening material
PAGE REV. 0 PAGE

27-17
Sinus
Virus
ALPHA Trainer
LSA
27-30
ELEVATOR
27-30: 2.4. Control sticks

Required parts,
Reference

2 Carry out visual inspection of the control sticks.
05-20
3 Carry out operational inspection of the control sticks.
Secure one control stick so that it can’t move and move the
4 other back and forth laterally. Measure the amount of free
play.
CAUTION: More than 8 mm of control stick free play is unacceptable and must be attended to immedi-
ately.
Carry out the same free play check for the other control
5
stick.
6 Install the control stick boots. 25-10: 2.3.2.

Required parts,
Reference

Use borescope to carry out visual inspection of the control
2 05-20
sticks.
27-30: 2.5. Control stick drive

Required parts,
Reference

2 Carry out visual inspection of the control stick drive.
05-20
3 Carry out operational inspection of the control stick drive.
Lubricate drive’s end bearings and all adjacent rod end
4 12-20: 2.5.
bearings.
PAGE PAGE REV. 0

27-18
LSAALPHA
Sinus
Virus
Trainer
27-30
ELEVATOR

Required parts,
Reference

Use borescope to carry out visual inspection of the control
2 05-20
stick drive assembly.
27-30: 2.6. Vertical elevator push rod

Required parts,
Reference
1 Remove the horizontal stabilizer. Phillips screwdriver 55-10: 2.1.

2 Remove rudder. 55-40: 2.1.
3 Carry out visual inspection of the vertical elevator push rod.
Carry out operational inspection of the vertical elevator 05-20
4
push rod.
Lubricate push rod end bearings and aft horizontal elevator
5 12-20: 2.5.
push rod end bearing.

Required parts,
Reference
1 Remove the horizontal stabilizer. Phillips screwdriver 55-10: 2.1.

2 Remove rudder. 55-40: 2.1.
Use borescope to carry out visual inspection of the verti-
3 cal elevator push rod from the opening in the lower rudder 05-20
hinge.
SYSTEMS
PAGE REV. 0 PAGE

27-19
Sinus
Virus
ALPHA Trainer
LSA
27-50
FLAPERONS
27-50 FLAPERONS
1. Description
Roll control is accomplished via symmetric deflection of the flaperons. The flaperon control system
consists of various bellcranks, push/pull rods and torque tubes (see Figure 27-013). The pilots can
change the flaperon deflection angle using a lever located between the seats. The lever’s handle
is spring-locked and has different positions corresponding to defined flap deflections (see Chapter
6 for details). The thumb-lock button prevents inadvertent lever movement. The aft end of the flap
lever connects to the main flaperon bellcrank.
Figure 27-013
Flaperon control system
PAGE PAGE REV. 0

27-20
LSAALPHA
Sinus
Virus
Trainer
27-50
FLAPERONS
27-50: 2.1. Flaperons

Required parts,
Reference
1 Remove the control stick boots. 25-10: 2.3.1.

Inspect the paint marker on both stopper bolts found
2 on the top of the control stick drive. If they have loos- 27-50: 2.1.2.
ened/shifted, adjust the flaperon deflection angle.

(if required after performing inspection/check 27-50: 2.1.1.)
Required parts,
Reference
Fit flaperon deflection measurement tool to trailing - Flaperon deflection

1 measurement kit ( Figure 27-017
edge of verification template.
P/N 1190463)
Put flaperon in neutral position by aligning it with wing.
2
Set inclinometer to 0o.
Verify correct deflection angles in all of the different
3 Aircraft WBR
flaperon handle positions.
Adjust the deflection angles by screwing/unscrewing
4
the control sticks’ lateral threaded stopper pins.
CAUTION: Flaperon deflection angles that don’t adhere to those in the aircraft’s WBR can result
in unexpected/odd roll behavior.
SYSTEMS
Figure 27-017
Flaperon deflection angle adjustment
PAGE REV. 0 PAGE

27-21
Sinus
Virus
ALPHA Trainer
LSA
27-50
FLAPERONS

Required parts,
Reference
1 Remove the wings. Vernier caliper 57-10: 2.1.1.

Place Vernier caliper between flaperon and the wingtip
2 and, while moving the flaperon back and forth in the Figure 27-014
CAUTION: The maximum permissible amount of axial flaperon free play is 0.5 mm.
Figure 27-014
Flaperon axial free play check

Required parts,
Reference
1 Remove the wings. Vernier caliper 57-10: 2.1.1.

Place Vernier caliper between flaperon and the wing-
2 tip and, while moving the flaperon back and forth in Figure 27-015
the radial direction, measure the free play.
PAGE PAGE REV. 0

27-22
LSAALPHA
Sinus
Virus
Trainer
27-50
FLAPERONS
Figure 27-015
Flaperon radial free play check
27-50: 2.2. Vertical flaperon pushrods

Required parts,
Reference

Carry out visual inspection of the vertical flaperon
3 05-20
pushrods.
Carry out operational inspection of the vertical flaperon
4 05-20
pushrods.
5 Lubricate pushrod bearings. 12-20
SYSTEMS
PAGE REV. 0 PAGE

27-23
Sinus
Virus
ALPHA Trainer
LSA
27-50
FLAPERONS
27-50: 2.3. Upper flaperon bellcranks

Applicability SIN VIR VSW AT Qualification LSRM L1 P/O
Required parts,
Reference
1 Carry out visual inspection of the upper flaperon bellcranks. 05-20

Carry out operational inspection of the upper flaperon bell-
2 05-20
cranks.

Required parts,
Reference
1 Remove wings. 57-10: 2.1.1.

2 Carry out visual inspection of the upper flaperon bellcrank clutch. 05-20
3 Clean and lubricate the upper flaperon bellcrank clutch. 12-20
4 Install wings. 57-10: 2.1.2.
5 Carry out operational inspection of the flaperons. 05-20
27-50: 2.4. Flaperon bellcrank assembly

Required parts,
Reference
3 Remove control stick boot. 25-10: 2.3.1.

4 Carry out visual inspection of the flaperon bellcrank assembly.
Carry out operational inspection of the flaperon bellcrank as- 05-20
5
sembly.
6 Lubricate bearings. 12-20
9 Install control stick boot. 25-10: 2.3.2.
PAGE PAGE REV. 0

27-24
LSAALPHA
Sinus
Virus
Trainer
27-50
FLAPERONS

Required parts,
Reference
1 Remove the control stick boots. Phillips screw- 25-10: 2.3.1.

driver 25-10: 2.1.1.
2 Remove the crew seats.
Use borescope to carry out visual inspection of the flaperon bell-
4 05-20
crank assembly sticks.
7 Install control stick boot. 25-10: 2.3.2.
27-50: 2.5. Flaperon handle assembly

Required parts,
Reference
1 Remove the crew seats. Phillips screw- 25-10: 2.1.1.

driver
3 Carry out visual inspection of the flaperon handle assembly.
05-20
4 Carry out operational inspection of the flaperon handle assembly.
5 Lubricate bearing. 12-20
SYSTEMS
PAGE REV. 0 PAGE

27-25
Sinus
Virus
ALPHA Trainer
LSA
27-60
AIR BRAKE LEVER
27-60 AIR BRAKE LEVER

1. Description
A Schempp-Hirth style air brake system is incorporated into the wings and is activated by a ceiling
mounted pull-lever in the cabin. The lever is connected to the air brake control system in the wings
via a self-fitting coupling mechanism. The pull-lever has a step-control mechanism that allows the
pilot to leave the lever in certain positions. The pull-lever can only be used once a thumb-trigger
lock is released.
PAGE PAGE REV. 0

27-26
LSAALPHA
Sinus
Virus
Trainer
27-60
AIR BRAKE LEVER
27-60: 2.1. Air brake lever

Required parts,
Reference
1 Remove the wings 57-10: 2.1.1.

2 Carry out visual inspection of the air brake lever. 05-20
3 Carry out operational inspection of the air brake lever. 05-20
4 Lubricate the air brake lever’s clutches. 12-20
27-60: 2.2. Air brake step control

Required parts,
Reference
Carry out visual inspection of the air brake step control

1
mechanism.
05-20
Carry out operational inspection of the air brake step con-
2 trol mechanism.
27-60: 2.2.2. Air brake step control installation

Required parts,
Reference
1 Insert ball bearing and spring into the regulation holder hole. - Allen key set
- Loctite 243
Install the regulation holder on the cabin strut and the regu- - Grease LGMT 2-0.2 05-20
2 lation plate on the airbrakes actuation torque tube. p/n 5092004
Apply Loctite 243 to the screws.
Adjust the positioning of the parts on the tubes until fit is
3 satisfactory. Tighten the holder’s two M6 x 20 screws.
4 Apply grease to the groove/holes on the regulation plate.
Insert and tighten the hexagon socket screw compressing
5
SYSTEMS
the spring in the holder.

Fully extend airbrakes, position the regulation plate so that
6 the ball bearing is in its last hole and tighten the two cylinder
head cap screws M6 x 25.
Check airbrake movement and assembly retaining effect.
7 If necessary change the retaining effect by adjusting the
hexagon socket screw acting on the ball bearing.
PAGE REV. 0 PAGE
27-27
Sinus
Virus
ALPHA Trainer
LSA
27-60
AIR BRAKE LEVER
27-60: 2.2.3. Air brake step control removal

Required parts,
Reference
Unfasten hexagon socket screw holding the spring in place. - Allen key set
1 Do not remove the screw, just reduce the pressure on the
bearing ball. 05-20
Remove the two cylinder head cap screws (M6 x 20) on the
2 regulation holder.
Remove the two cylinder head cap screws (M6 x 25) on the
3 regulation plate.
Disassemble the device and remove it from the airplane
4 strut.
5 Check the movement of the airbrake actuation lever.
PAGE PAGE REV. 0

27-28
28
Sinus
Virus
ALPHA Trainer
LSA
CHAPTER 28 – FUEL
TABLE OF CONTENTS

FUEL
28-00 28-03
General
STORAGE
DISTRIBUTION
INDICATING
PAGE PAGE REV. 0

28-02
LSAALPHA
Sinus
Virus
Trainer
28-00
GENERAL
28-00 GENERAL
Pipistrel’s aircraft use different fuel storage configurations, depending on the model.
1. ALPHA Trainer
Reference: ALPHA Trainer IPC
ALPHA Trainer aircraft is equipped with a single 50 lt (13.2 US gal) fuel tank positioned in the fu-
selage, aft the crew seats (See Figure 28-002). The feed fuel line runs through the fuel filter and
through the fuel pump (standard or facet type). Then the fuel enters the fuel shut-off valve, oper-
ated by a lever positioned on the cabin floor, and finally passes through the firewall, direct to the
engine compartment. Here the feed fuel line passes through the fuel drain valve, positioned at the
bottom of the hot side of the firewall and then through the gascolator before being directed to the
engine pump. The fuel return line enters the cabin through the firewall, passes below the crew
seats and then is connected to the upper part of the fuel tank.
Fuel level is monitored by a fuel sensor, positioned inside the fuel tank.
2. Sinus and Virus

Reference: SInus/Virus IPC
Sinus and Virus aircraft are equipped with two integral fuel tanks, one in each wing. The maximum
stored fuel quantity is 60 L (15.9 US gal) for the standard tanks or 100 L (26,4 US gal) for the long
range option (Avgas or Mogas, see chapter Limitations for applicable fuel grades). Two (left and
right) transparent vertical tubes, which are visible from the pilot position and connected to the
highest and lowers points of each respective tank, serve as a visual indicator of the fuel quantity
available. Venting of the fuel tanks is through the fuel caps.
After leaving the wing tank the fuel goes through a shut off valve (one per tank), located on the
wing root. Thereafter feed fuel lines join below the cabin floor and the fuel is directed through the
firewall to the engine compartment. There the fuel is fed through a gascolator, which has a drain
valve, before being directed to the engine pump. The gascolator removes water that may be in the
fuel and filters out any debris/foreign material.
Because of aircraft’s high wing configuration, the fuel system is completely gravity-fed, always en-
SYSTEMS
suring adequate fuel pressure. Fuel system venting is essential to system operation. Blockage of
the system will result in decreasing of fuel flow and eventual engine fuel starvation and stoppage.
PAGE REV. 0 PAGE

28-03
Sinus
Virus
ALPHA Trainer
LSA
28-10
STORAGE
28-10 STORAGE
1. Description
Refer to section 28-00 for system description.
28-10: 2.1. Fuel tank
28-10: 2.1.1. Leak inspection - wing tanks

Required parts,
Reference
Locate the two wing drainage holes located at the base of

1 Figure 28-001
the wing on its bottom surface.
Check for any signs of fuel. Any fuel or fuel residue, found
near the holes, must be reported to the local Pipistrel dis-
2 12-20
tributor. If the fuel tank is leaking profusely, purge the sys-
tem of fuel before contacting the local Pipistrel distributor .
Figure 28-001
Wing drainage holes
PAGE PAGE REV. 0

28-04
LSAALPHA
Sinus
Virus
Trainer
28-10: 2.1.2. Removal of fuselage main fuel tank

Applicability AT VIR VSW AT Qualification AMT L1 LAME
Required parts,
Reference
1 Drain the fuel system. - Flat head screwdriver 12-20

- Cutting nippers
2 Remove the seats. - Allen key set 25-10: 2.1.1.
Release the buckles disconnect the support straps behind - Combination wrench
3 set 25-10: 2.1.1.
the seats to access the aft cabin compartment.
Loosen hose clamps and disconnect fuel feed/return lines
4
from tank.
Loosen hose clamps and disconnect blue silicon fuel filler
5
hose.
Disconnect the fuel level sensor and remove the reservoir
6 cap on the back of the airplane.
Remove all the bolts and washers holding the fuel tank in
7
place on the bulkhead.
8 Slide the tank out from behind the cabin.
28-10: 2.1.3. Installation of fuselage main fuel tank

Applicability AT VIR VSW AT Qualification AMT L1 LAME
Required parts,
Reference
Apply Loctite 243 to the nuts bonded into the tank attach- - Flat head screwdriver
1 - Cutting nippers 12-20
ment bulkhead.
- Allen key set
2 Reposition the tank in place behind the cabin. - Combination wrench
Fix the tank to the bulkhead using the fixing bolts and wash- set
3 - Loctite 243
ers.
4 Connect the fuel sensor level plug.
Connect the feed and return hoses, and the blue silicon
5
filler hose on top of the tank.
6 Connect the seat support straps. 25-10: 2.1.2.
7 Install the seats. 25-10: 2.1.2.

SYSTEMS
PAGE REV. 0 PAGE

28-05
Sinus
Virus
ALPHA Trainer
LSA
28-10
STORAGE
Figure 28-002
ALPHA Trainer
Fuselage fuel tank system
Plastic and composite tank versions
28-10: 2.1.4. Fuselage fuel tank - breather tube blockage check

This task applies to ALPHA Trainers equipped with fuel tank vented through breather tube.
Applicability AT VIR VSW AT Qualification O L1 P/O
Required parts,
Reference
Locate the fuel tank breather tube, below the fuselage aft
1 Figure 28-003
the right MLG attachment point.
Inspect the breather tube. Check for any signs of wear and
2 12-20
make sure that it’s not blocked/clogged.
Figure 28-003
Fuel tank breather tube
PAGE PAGE REV. 0
28-06
LSAALPHA
Sinus
Virus
Trainer
28-10
STORAGE
28-10: 2.2. Collector tank
28-10: 2.2.1. Removal

Required parts,
Reference
1 Drain the fuel system. - Flathead screwdriver 12-20

- Allen key #4
Loosen the hose clamps and disconnect all of the fuel - Combination wrench #8
2
lines.
Locate the stainless steel mounting strap and remove
3
its fastening material.
4 Remove the collector tank.

Required parts,
Reference
Apply Loctite 243 to the bolts threads and fasten the - Flathead screwdriver
1 - Allen key #4
collector tank to the composite housing.
- Combination wrench #8
2 Torque mark. - Loctite 243 20-40
Connect all of the fuel lines and fasten them in place - Liquid paint marker
3
using hose clamps.
4 Torque mark. 20-40
Replenish the fuel system and carry out visual inspec- 12-10
5
tion. 05-20
28-10: 2.4. Vented fuel cap

Required parts,
Reference
1 Remove vented fuel cap.

Inspect the breather tube. Check for any signs of wear
2
and make sure that it’s not blocked/clogged.
3 Inspect the cap. Check for any signs of damage/wear.
Inspect the fuel cap’s o-ring. Check for any signs of
4
damage/wear. Replace if necessary.
SYSTEMS
5 Lubricate cap’s thread. 12-20

6 Install vented fuel cap.

PAGE REV. 0 PAGE

28-07
Sinus
Virus
ALPHA Trainer
LSA
28-20
DISTRIBUTION
28-20 DISTRIBUTION
1. Description
The fuel distribution system consists of thermoplastic polyurethane fuel hoses in the fuselage
and rubber hoses in the engine compartment. The latter are protected with either a certified
glass teflon coating or heat resistant sleeve.
The system features a fuel return circuit, fixed/quick-release fittings and a gascolator that’s located
on the bottom port side of the engine bay.
28-20: 2.1. Gascolator
28-20: 2.1.1. Removal (except Andair)

Required parts,
Reference
1 Put the fuel switch/es in the CLOSED position. - Flathead screwdriver,

- Wrench set
2 Drain the fuel system. 12-20
Loosen the hose clamp at the gascolator’s inlet and
3
outlet and disconnect the fuel hoses.
Loosen and remove the two M6 hex-head bolts secur-
4
ing the gascolator to its mounting support.
5 Remove the gascolator.
28-20: 2.1.2. Installation (except Andair)

Required parts,
Reference
Install the gascolator to its support using the two M6 - Flathead screwdriver,
1 - Wrench set
hex-head bolts.
- Liquid paint marker
2 Mark the two M6 bolts with paint marker.
Connect the feed fuel line and fasten it in place with
3
hose clamp.
Connect fuel line at gascolator outlet and secure with
5
hose clamp.
Replenish the fuel system and carry out visual inspec- 12-10
7
tion. 05-20
PAGE PAGE REV. 0

28-08
LSAALPHA
Sinus
Virus
Trainer
28-20
DISTRIBUTION

Gascolator Gascolator filter
28-20: 2.1.3. Inspection/Cleaning (except Andair)

Required parts,
Reference
Loosen the four screws that connect the bottom part - Allen key set
1 - Cleaning petrol Figure 28-004
of the gascolator to the upper part.
- Compressed air
2 Carefully remove the bottom part of the gascolator.
3 Remove the gasket and carry out visual inspection. 05-20
4 Replace the gasket if necessary.
Remove and carry out visual inspection of the filter
5 Figure 28-005
and internal spring.
6 Clean with benzene and compressed air.
Reassemble the gascolator repositioning the filter and
7
gasket.
8 Close the gascolator using the four screws.
SYSTEMS
PAGE REV. 0 PAGE

28-09
Sinus
Virus
ALPHA Trainer
LSA
28-20
DISTRIBUTION
28-20: 2.1.4. Removal (Andair type)

Required parts,
Reference
1 Put the fuel selector in the OFF position. - Flathead screwdriver,

- 11/16 in. combination
2 Drain the fuel system. wrench 12-20: 2.1.
Disconnect the AN nut coupling from the banjo bolt at the
3
gascolator’s outlet.
Loosen the hose clamp at the gascolator’s inlet and discon-
4
nect the fuel hose.
Loosen and remove the two M5 socket head bolts securing
5
the gascolator’s mounting brace to the two hose clamps.
6 Remove the gascolator.
28-20: 2.1.5. Installation (Andair type)

Required parts,
Reference
Apply Loctite 243 to the M5 bolts’ threads and fasten the - Flathead screwdriver,
1 gascolator tank to the two mounting hose clamps on the - 11/16 in. combination
engine mount. wrench
2 Mark the two M5 bolts with paint marker.
Connect the feed and outlet fuel lines and fasten them with
3
hose clamp.
4 Torque mark hose clamps. 20-40: 2.1.
Check that red plug, at the top of the gascolator, and the Figure 28-006
5
bowl mounting nut are still secured with safety wire. Figure 28-007
Replenish the fuel system and carry out visual inspection. 12-10: 2.1.1.
6 05-20

Bowl mounting nut safety wire (Andair) Red plug safety wire (Andair)
PAGE PAGE REV. 0

28-10
LSAALPHA
Sinus
Virus
Trainer
28-20
DISTRIBUTION
28-20: 2.1.6. Inspection/Cleaning (Andair type)

Required parts,
Reference
Remove the safety wire preventing the bowl mounting - Safety wire twist pliers
1 - Water
nut from loosening.
- Compressed air
2 Unscrew the bowl mounting nut and remove the bowl.
3 Remove the o-ring and carry out a visual inspection. 05-20
4 Replace the o-ring.

Unscrew, remove and carry out a visual inspection of
5 05-20
the filter screen.
CAUTION: When removing the filter screen be sure to grab it as close to it’s thread as possible, as you
could damage it by applying too much torque to the other end of it. 7
Clean with benzene cleaning agent and compressed
6
air.
Reassemble the gascolator so that the arrow on the
7 side of the bowl lines up with the line etched into the
Figure 27-008
gascolator’s housing.
Figure 28-006
8 Secure in place using safety wire.
Figure 28-007
SYSTEMS
Figure 28-008
Bowl arrow with etched line (Andair)
PAGE REV. 0 PAGE

28-11
Sinus
Virus
ALPHA Trainer
LSA
28-20
DISTRIBUTION
28-20: 2.2. Fuel selector
28-20: 2.2.1. Removal

Required parts,
Reference

- 2.5 mm T-handle hex-head
Access the area where the fuel selector is installed by screwdriver
2 temporarily detaching the control stick drive’s mount- - Cutting nippers
ing bracket. - 2 mm T-handle hex-head
3 Disconnect both fuel feed lines from the aft fuel drains. screwdriver
Disconnect both fuel return lines from the collector
4
tanks.
Loosen/Remove the hose clamp holding both of the
5 fuel lines fore of the selector to the surface of the fu-
selage.
Disconnect the fuel lines from the side of the fuel flow
6 sensors closest to the control stick opening in the cabin
floor.
Lift the fuel selector’s spring-loaded safety pin and un-
7
screw the bolt holding the lever in place.
8 Remove the lever.
Unscrew both M4 bolts holding the fuel selector in
9
place.
Take the fuel selector, along with the accompanying
10
fuel lines, out from under the cabin floor.
11 Disconnect all the fuel lines from the fuel selector.

Required parts,
Reference
Access the area where the fuel selector is installed by - Flathead screwdriver
1 temporarily detaching the control stick drive’s mount- - 2.5 mm T-handle hex-head
ing bracket. screwdriver
- Cutting nippers
Connect all of the fuel lines to the fuel selector using - 2 mm T-handle hex-head
2
plastic ties. screwdriver
Slide the fuel selector, along with the accompanying
3
fuel lines, through the control stick opening.
Run all of the aft fuel lines down the central conduit,
4
through their respective composite braces.
Fasten the fuel selector to the cabin floor using two
5
M4 bolts.
PAGE PAGE REV. 0

28-12
LSAALPHA
Sinus
Virus
Trainer
28-20
DISTRIBUTION
Required parts,
Reference
6 Apply liquid paint marker.

7 Fit the selector with its red lever.
8 Carry out operational check. 05-20
9 Connect the fuel feed lines to the aft fuel drains.
10 Apply liquid paint marker to the hose clamps.
11 Connect the fuel return lines to the collector tanks.
12 Apply liquid paint marker to the hose clamps.
Connect the two fore fuel lines to their respective fuel
13
flow sensors.
14 Apply liquid paint marker.
Refasten the two fore fuel lines to fuselage’s surface
15
using hose clamp.
Replenish the fuel system and carry out visual inspec-
16 12-10 and 05-20
tion.
Refasten the control stick drive’s mounting bracket
17
(P/N 1125027) to the cabin floor.
28-20: 2.3. Fuel filter and fuel pump
28-20: 2.3.1. Fuel filter removal

Required parts,
Reference

Disconnect the two fuel lines that are attached to the
2
fuel filter.
Cut the cable tie (if applicable) and remove the fuel fil-
3
ter.
28-20: 2.3.2. Fuel filter installation

Required parts,
Reference
Connect the inlet and outlet fuel lines to the filter. - Flathead screwdriver
1 - Liquid paint marker
SYSTEMS
CAUTION: When reinstalling the fuel filter be sure to position it properly. An arrow on the side of it’s
housing shows the flow direction.
2 Torque mark the hose clamps. 20-40
Replenish the fuel system and carry out visual, opera-
3 12-10 and 05-20
tional and leak inspection.
PAGE REV. 0 PAGE

28-13
Sinus
Virus
ALPHA Trainer
LSA
28-20
DISTRIBUTION
28-20: 2.3.3. Fuel filter and auxiliary pump inspection (if applicable)
Required parts,
Reference

Check the fuel filter/s for dirt and debris inside. Replace
2
if necessary.
CAUTION: Replace the fuel filter when more than one third of its volume is filled with debris or dirt.
Perform visual inspection of the fuel pump (if applica-
3
ble).

28-20: 2.3.4. Fuel pump removal

Required parts,
Reference

- Wrench set
4 Disconnect fuel pump electric connector.
Release hose clamps and disconnect inlet and outlet
5 Figure 28-009
hoses from the pump fittings.
Unscrew the two hex self locking nuts from the pump
6
housing and remove the fuel pump.
28-20: 2.3.5. Fuel pump installation

Required parts,
Reference
Connect the inlet and outlet fuel hoses to the fuel pump - Flathead screwdriver
1 - Wrench set 12-20
fittings using hose clamps.
2 Apply marker paint to the hose clamps screw heads.
Install the fuel pump using the two hex self locking nuts
3
and washers and apply marker paint to the nuts.
Connect the fuel pump electric plug and secure it with
4
a cable tie.
Perform visual, operational and leak inspection of the
7
fuel pump.
PAGE PAGE REV. 0

28-14
LSAALPHA
Sinus
Virus
Trainer
28-20
DISTRIBUTION
Figure 28-009
ALPHA Trainer
Fuel pump and fuel filter installation
28-20: 2.4. Fuel lines
28-20: 2.4.1. Leakage inspection/check

Required parts,
Reference
1 Remove crew seats. - Rag or cloth that stains 25-10: 2.1.1.

when comes in contact with
2 Remove baggage compartment (if applicable). liquids 25-50: 2.1.1.
3 Remove control stick boots. 25-10: 2.3.1.
Perform visual inspection of fuel lines, joints and collec-
4 05-20
tor tanks (Sinus/Virus only).
Check for fuel leakage signs along the lines and on the
line joints in the baggage compartment and below the
5
cabin floor. A stained rag indicates that a leak is pres-
ent.
SYSTEMS
6 Install baggage compartment. 25-50: 2.1.2.

8 Install control stick boots. 25-10: 2.3.2.
PAGE REV. 0 PAGE

28-15
Sinus
Virus
ALPHA Trainer
LSA
28-40
INDICATING
28-40 INDICATING
1. Description
In Sinus and Virus types, a fuel level sight gauge for each fuel tank is visible from the pilot posi-
tion and serves as a visual indicator of the fuel quantity available. It’s marked in Liters and color
coded with RED showing the unusable fuel quantity (see Figure 28-010). It also has a backlight
which illuminates the fuel quantity in the dark.
28-40: 2.1. Fuel level sight gauge - Wing tanks

Required parts,
Reference
Carry out visual inspection of the fuel level sight gauge. 05-20
1 Check for transparency. If the fuel level is difficult to
see, replace tube.
Figure 28-010
Fuel level sight gauge
PAGE PAGE REV. 0

28-16
LSAALPHA
Sinus
Virus
Trainer
28-40
INDICATING
28-40: 2.1.2. Fuel level sight gauge - Removal

Required parts,
Reference
1 Drain the fuel system completely. - Cutting nippers 12-20
2 Remove the wings. 57-10: 2.1.1.
Cut the cable ties securing the sight gauge to the fit-
3
tings.
4 Disconnect the fuel level sight gauge from the fittings.
5 Repeat the procedure on the other wing if necessary.
28-40: 2.1.3. Fuel level sight gauge - Installation

Required parts,
Reference
Connect the fuel level sight gauge to the two fittings

1
on the wing.
Secure the connection to the fittings using two cable Figure 28-011
2
ties each.
3 Repeat the procedure on the other wing if necessary.
4 Install the wings. 57-10: 2.1.2.
5 Refill the fuel system. 12-10: 2.1.1.
6 Perform leakage inspection. 05-20
SYSTEMS
Figure 28-011
Fuel level sight gauge connection detail
PAGE REV. 0 PAGE

28-17
31
Sinus
Virus
ALPHA Trainer
LSA
CHAPTER 31 – INDICATING/RECORDING SYSTEMS
TABLE OF CONTENTS

INDICATING/RECORDING SYSTEMS
31-00 31-03
General
INSTRUMENT AND CONTROL PANELS
PAGE PAGE REV. 0

31-02
LSAALPHA
Sinus
Virus
Trainer
31-00
GENERAL
31-00 GENERAL
This chapter describes the instrument panel, the main components and the basic maintenance
tasks needed to access the internal area behind the panel.
SYSTEMS
PAGE REV. 0 PAGE

31-03
Sinus
Virus
ALPHA Trainer
LSA
31-10
INSTRUMENT AND CONTROL
PANELS
31-10 INSTRUMENT AND CONTROL PANELS

1. Description
The instrument panel is designed for glare-free use in all flight conditions. It is designed so that it
can easily be used from both the left and right pilot seat. It’s central pedestal houses a switch panel
where all of the circuit breakers, fuses and switches, required for smooth operation, can be found.
Instrument panel configuration may vary upon aircraft type or equipment. In general the equipment
consists of flight, navigation and communication instruments, in the form of analog instruments or
Multi-Function displays. Please refer to the specific POH for more detailed information.
Figure 31-001
Example of instrument panel layout
PAGE PAGE REV. 0

31-04
LSAALPHA
Sinus
Virus
Trainer
31-10
PANELS
31-10: 2.1. Front panel
31-10: 2.1.1. Internal inspection/check

Required parts,
Reference
1 MASTER switch off, AVIONICS switch off.

2 Remove the instrument panel cover. 31-10: 2.2.1.
3 Perform visual inspection for any loose/damaged wires. 05-20
4 Install the instrument panel cover. 31-10: 2.2.2.
31-10: 2.2. Instrument panel cover
31-10: 2.2.1. Removal

Required parts,
Reference
1 MASTER switch off, AVIONICS switch off. - Torx screwdriver set

- Phillips screwdriver
2 Disconnect the battery. (standard + stubby)
Unscrew/remove all of the torx and self-tapping screws securing
3
the cover to the instrument panel/fuselage.
Lift cover and disconnect the Garmin G26C GPS antenna and the
4
compass’ lighting cable.
5 Remove the instrument panel cover.

Required parts,
Reference
1 Position the cover on the instrument panel. - Torx screwdriver set

- Phillips screwdriver
Lift cover and connect the Garmin G26C GPS antenna and the com- (standard + stubby)
2
pass’ lighting cable.
Fasten the cover to the instrument panel/fuselage using the torx
3
and self-tapping screws .
SYSTEMS

Carry out operational inspection of the Garmin G26C GPS antenna
5
and the compass light.
6 Connect the battery.
PAGE REV. 0 PAGE

31-05
Sinus
Virus
ALPHA Trainer
LSA
31-10
PANELS
31-10: 2.3. Switch panel
31-10: 2.3.1. Removal

Required parts,
Reference

Remove all of the torx screws securing the switch panel to
2
the instrument panel pedestal.
Carefully dislodge the panel and move it away from the
3
pedestal.

Required parts,
Reference
2 Carefully slide the panel into place on the pedestal.

3 Fasten it to the pedestal using torx screws.
31-10: 2.3.3. Internal inspection/Check

Required parts,
Reference
2 Remove the switch panel 31-10: 2.3.1.

3 Perform visual inspection for any loose/damaged wires
4 Install the switch panel 31-10: 2.3.2.
PAGE PAGE REV. 0

31-06
32
Sinus
Virus
ALPHA Trainer
LSA
CHAPTER 32 – LANDING GEAR
TABLE OF CONTENTS

LANDING GEAR
32-00 32-03
General
MAIN GEAR
NOSE GEAR
WHEELS AND BRAKES
32-40 32-09
General
WHEELS
BRAKES
STEERING
PAGE PAGE REV. 0

32-02
LSAALPHA
Sinus
Virus
Trainer
32-00
GENERAL
32-00 GENERAL
This chapter describes those units and components which furnish a means of supporting and
steering the airplane.
Two configurations are available: tricycle and tailwheel type. ALPHA Trainer ha tricycle configura-
tion only.
The tricycle-type landing gear consists of a composite, glass fiber strut that is bolted to the airframe
structure and provides adequate shock absorption, as well as a steerable nose gear strut, which is
of tubular aluminum and steel construction, has an oleo shock absorber and is integrated into the
engine mount.
Tail wheel type is equipped with a standard or composite steerable tail gear.
The main wheels have hydraulically operated brakes, actuated by pressing the toe brakes at each
crew position or by pulling a hand lever, depending on aircraft equipment. Standard or Beringer
brake system are available.
All wheels are optionally equipped with aerodynamic fairings made of CFRP.
SYSTEMS
PAGE REV. 0 PAGE

32-03
Sinus
Virus
ALPHA Trainer
LSA
32-10
MAIN GEAR
32-10 MAIN GEAR

1. Description
The main landing gear strut is made of basalt fiber and has two parallel elements that produce a
semi-redundant structure that allows for predictable stress point locations. The strut is composed
by two parallel elements producing a semi-redundant structure and allowing for predictable loca-
tions of stress points. During normal landing and taxi operations, the main gear legs act as primary
shock absorbing units and provide support for majority of aircraft weight. The strut is directly at-
tached to the bottom side of the cabin floor by four bolts and additionally supported by two com-
posite reinforcements (see Figure 32-001).
Figure 32-001
Tricycle Type
Landing Gear Installation
PAGE PAGE REV. 0

32-04
LSAALPHA
Sinus
Virus
Trainer
32-10
MAIN GEAR
32-10: 2.1. Main landing gear strut

Required parts,
Reference
1 Remove the main wheel fairings. 32-10

Carefully inspect the entire strut for any signs of damage.
Pay particular attention to where the strut is in contact with
2 Figure 32-002
the fuselage and where the wheels are fastened to it. Look
for any wear, chips, signs of delamination or cracks.
CAUTION: Any damage incurred by the main landing gear strut can be a safety hazard and must be
reported to Pipistrel. 6
3 Install main landing gear strut cover.
4 Install main wheel fairings. 32-10
Figure 32-002
Example of a damaged main landing gear strut
SYSTEMS
PAGE REV. 0 PAGE

32-05
Sinus
Virus
ALPHA Trainer
LSA
32-10
MAIN GEAR
32-10: 2.1.3. MLG strut removal - Nose wheel configuration

Required parts,
Reference
Detach the wings and support firmly the fuselage on a point - Allen key set
1 - Metric wrench set 57-10: 2.1.1.
aft the center of gravity of the fuselage itself.
2 Drain the brake lines fluid.
Disconnect the brake hydraulic lines from the pedals, hand
3 brake system or parking brake, depending on the actual air- 32-40
plane equipment.
Remove the seats from the cabin and locate the four M10
4
retainig hexagon socket screws of the MLG strut.
Remove the composite cover plate applied over the MLG
5 strut on the bottom of the fuselage. This is done by remov-
ing of the gap seal tape and of the six M4 fixing screws.
6 Slip from the bottom of the fuselage the brake lines.
Unscrew and remove from the cabin the four fixing M10
7
hexagon socket screws.
8 Separate the MLG Strut from the fuselage.
If necessary separate the wheel/axle assemblies from the 32-41: 2.1.5.
9
MLG strut. 32-41: 2.1.7.
32-10: 2.1.4. MLG strut removal - Tail wheel configuration

Required parts,
Reference
Detach the wings and support firmly the fuselage on a point - Allen key set
1 - Metric wrench set 57-10: 2.1.1.
aft the center of gravity of the fuselage itself.
2 Drain the brake lines fluid.
Disconnect the brake hydraulic lines from the pedals, hand 32-40
3 brake system or parking brake, depending on the actual air-
plane equipment.
Release the screws retaining the stick drive assembly in or-
der to access the area below the cabin floor. Locate the four
4
nuts and the two reinforcement metal plates of the MLG
strut attachment.
Remove the composite cover plate applied over the MLG
5 strut on the bottom of the fuselage. This is done by remov-
ing of the gap seal tape and of the six M4 fixing screws.
Unscrew and remove from the bottom of the fuselage the
6
four M10 bolts fixing the MLG strut to the fuselage.
Separate the MLG Strut and slip the brake lines form the
7
fuselage.
If necessary remove the wheel fairings and wheel/axle as- 32-10: 2.2.1.
8 semblies from the MLG strut. 32-41: 2.1.5.
32-41: 2.1.7.
PAGE PAGE REV. 0

32-06
LSAALPHA
Sinus
Virus
Trainer
32-10
MAIN GEAR
32-10: 2.1.5. MLG strut installation - Nose wheel configuration

Required parts,
Reference
Support firmly the fuselage on a point aft the center of grav- - Torque wrench
1 - Metric drill bit set
ity of the fuselage itself. Remove the seats.
- Allen key set
NOTE: in case the MLG strut that will be installed is a new spare- Loctite 243
part, it will come without mounting holes, that have to be drilled.
- Gap seal tape
Follow the instruction steps (3) to (5) for this case, otherwise skip
(5230023)
to step (6). - Red Marker paint
Prepare the MLG strut mounting the wheel/axle assemblies, - Hand driller and 32-41: 2.1.7
drill bit set
2 in case they are not already. 32-41: 2.1.6.
- Permanent mark-
er pen
Place the MLG strut below the fuselage into its groove.
Check the positioning and alignments. Cardboard spacers
can be used to center the positioning.
3 From the cabin floor, mark on the MLG strut the position Figure 32-003
where the fixing holes will be drilled. Use a permanent
marker pen to do this, passing it through the fixing holes on
the cabin floor.
Remove the MLG strut from the fuselage and drill on it the
4 fixing holes, first with 8 mm, then with a 10 mm drill bit.
NOTE: Please refer to Figure 32-004 for the drill bit geometry re-
Figure 32-004
quirements.
Run the brake lines through the strut out from the holes on
5
the bottom surface of the central part of the strut.
Place again the MLG strut below the fuselage into its groove,
6 Apply Loctite 243 to the four hexagon socket M10 screws,
insert them from the cabin and secure to 45 Nm torque.
7 Apply red marker paint on the M10 nuts.
Insert the hydraulic brake lines into the dedicated holes
through the fuselage and connect the line terminals to their
8 32-40
joints on the pedals, hand brake lever or parking brake, de-
pending on the installed equipment.
Cover the joint area of the MLG strut below the fuselage
9 with the composite cover plate. Secure it using six M4
screws and then apply sealing tape around the border.
10 Reinstall crew seats. 25-10: 2.1.2.
Refill the brake circuit. 12-10: 2.5.1.
11 12-10: 2.5.2.
Perform some taxi tests to check the correct functionality of
12
the MLG strut and brakes.
SYSTEMS
PAGE REV. 0 PAGE

32-07
Sinus
Virus
ALPHA Trainer
LSA
32-10
MAIN GEAR
Figure 32-003
MLG strut - correct orientation
32-10: 2.1.6. MLG strut installation - Tail wheel configuration

Required parts,
Reference
Support firmly the fuselage on a point fore the center of - Torque wrench
gravity of the fuselage itself.
- Allen key set
Prepare the MLG strut for the installation mounting the - Loctite 243
wheel/axle assemblies, in case they are not already. Run - Gap seal tape 32-41: 2.1.7
2
the brake lines through the strut out from the holes on the (5230023) 32-41: 2.1.6.
upper surface of the central part of the strut. - Marking paint
Release the screws retaining the stick drive assembly in or-
3 der to access the area below the cabin floor.
4 Place the MLG strut below the fuselage into its groove.
NOTE: in case the MLG strut that will be installed is a new spare
part, it will come without mounting holes, that have to be drilled.
Follow the instruction steps (5) to (7) for this case, otherwise skip
to step (8).
Check the positioning and alignments. Cardboard spacers
can be used to center the positioning.
From the drive stick access point, mark on the MLG strut
5
the position where the fixing holes will be drilled. Use a per-
manent marker pen to do this, passing it through the fixing
holes on the reinforcement plates.
Remove the MLG strut from the fuselage and drill on it the
6 Figure 32-004
fixing holes, first with 8 mm, then with a 10 mm drill bit.
Run the brake lines through the dedicated holes on the
7
MLG strut groove on the fuselage.
PAGE PAGE REV. 0

32-08
LSAALPHA
Sinus
Virus
Trainer
32-10
MAIN GEAR
Required parts,
Reference
Install the MLG strut on the fuselage, passing the brake lines - Torque wrench
through the holes on the fuselage.
- Allen key set
Apply Loctite 243 to the bolts, insert from below the four - Loctite 243
9 fixing M10 bolts and secure with he nuts through the stick - Gap seal tape
drive assembly opening. Torque to 45 Nm. (5230023)
- Marking paint
10 Apply red marker paint on the M10 nuts.
Connect the brake line terminals to their joints on the ped-
11 als, hand brake lever or parking brake, depending on the 32-40
installed equipment.
Cover the joint area of the MLG strut below the fuselage
12 with the composite cover plate. Secure it using six M4
screws and then apply sealing tape around the border.
13 Reinstall control stick drive assembly. 27-30: 2.5.
14 Reinstall crew seats. 25-10: 2.1.2.
Refill the brake circuit. 12-10: 2.5.1.
15 12-10: 2.5.2.
Perform some taxi tests to check the correct functionality of
16
the MLG strut and brakes.
Figure 32-004
Drill bit - Geometry requirements
SYSTEMS
PAGE REV. 0 PAGE

32-09
Sinus
Virus
ALPHA Trainer
LSA
32-10
MAIN GEAR
32-10: 2.2. MLG fairings
32-10: 2.2.1. Removal

Required parts,
Reference
Remove the hex head bolt securing the fairing to the fairing - T-handle hex head
1 screwdriver set,
spacer.
- Torx screwdriver set
Remove the six screws securing the fairing to the fairing
2 plate.
3 Remove fairing.

Required parts,
Reference
Position the spacer over the wheel and main landing gear - T-handle hex head
1 screwdriver set,
strut.
- Torx screwdriver set
2 Apply Loctite to the hex head bolt’s thread. - Loctite 243
3 Install fastening material to finger tight.
NOTE: Make sure there is adequate clearance between the fairing and other landing gear components.
4 Tighten fastening material.
32-10: 2.2.3. MLG wheel fairing modification - tire pressure measurement and inflation cap retrofit
Required parts,
Reference
1 Remove the MLG wheel fairings. - Drill bit set 32-10: 2.2.1.
- Hand drill
Drill an hole on the outer side of the fairing, positioned as - Deburring bit
2 indicated in figure 32-005. Use a small diameter bit first, - Decorative cap (p/n Figure 32-005
and reach the final diameter of 28 mm using a Deburring bit. 5019026)
3 Install the MLG fairings. 32-10: 2.2.2.
4 Apply the decorative cap (p/n 5019026) on the hole.
PAGE PAGE REV. 0

32-10
LSAALPHA
Sinus
Virus
Trainer
32-10
MAIN GEAR
32-10: 2.2.4. Nose wheel fairing modification - tire pressure measurement and inflation cap retrofit
Required parts,
Reference
1 Remove the nose wheel fairing. - Drill bit set 32-10: 2.2.1.
- Hand drill
Check in which side of the nose wheel the inflating fitting - Deburring bit
2 is located. - Decorative cap (p/n
5019026)
Drill an hole on the fairing, on the side where the fitting is
located. Position the hole as indicated in figure 32-005. Use
3 Figure 32-005
a small diameter bit first, and reach the final diameter of 28
mm using a deburring bit.
4 Install the nose wheel fairings. 32-10: 2.2.2.
5 Apply the decorative cap (p/n 5019026) on the hole.
Figure 32-005
SYSTEMS
Pressure check cap positioning

Beringer and Pipistrel/Standard wheels
PAGE REV. 0 PAGE

32-11
Sinus
Virus
ALPHA Trainer
LSA
32-20
NOSE GEAR
Figure 32-006
Pressure check cap
on nose gear fairing
PAGE PAGE REV. 0

32-12
LSAALPHA
Sinus
Virus
Trainer
32-20
NOSE GEAR
32-20 NOSE/TAIL GEAR

1. Description
The nose gear strut assembly consists of a tubular strut attached to the engine mount. The free
castering nose wheel’s maximum turning arc is 45 degrees either side of center. Shock absorption
is provided by a nitrogen and hydraulic fluid filled oleo-pneumatic strut in which compression of a
piston rod reacts against the engine mount.
32-20: 2.1. Nose wheel (Standard/Pipistrel wheel type)
32-20: 2.1.1. Nose wheel - Removal

Required parts,
Reference
Prop the nose landing gear up by weighing down the tail - Metric wrench set
1 - T-handle hex head screw- 07-10: 2.3.1.
cone.
driver set
Remove the fastening material nut and bolt (axle) securing - T-handle socket wrench
2
the wheel to nose gear fork. set
3 Remove nose wheel.
32-20: 2.1.2. Nose wheel - Installation

Required parts,
Reference
1 Position nose wheel in the fork. - Metric wrench set

- T-handle hex head screw-
2 Insert the bolt (axle). driver set
3 Apply Loctite 243 to nose wheel axle nut. - T-handle socket wrench
set
4 Fasten nose wheel bolt (axle) in place by tightening the nut. - Loctite 243 20-30
NOTE: After installing the wheel make sure there is adequate clearance between it and the other nose
gear components. Make sure that the wheel turns freely and isn’t hindered by anything.
Remove counterweight from tail cone and lower the nose
5
of aircraft.
SYSTEMS
PAGE REV. 0 PAGE

32-13
Sinus
Virus
ALPHA Trainer
LSA
32-20
NOSE GEAR
32-20: 2.1.3. Nose wheel fairing and fork - Removal (standard and Beringer wheel type)
Required parts,
Reference
NOTE: for aircraft not equipped with nose landing gear fairing - Metric wrench set
perform only steps 1 - 2 - 5. - T-handle hex head screw-
driver set
Prop the nose landing gear up by weighing down the tail - T-handle socket wrench
1 07-10: 2.3.1.
cone. set
2 Remove nose wheel. 32-20: 2.1.1.
3 Remove white tape securing fairing cover to fairing.
4 Remove fairing cover.
Remove fastening material securing the nose wheel fairing
5
and fork to the nose landing gear strut.
6 Separate nose wheel fairing from the fork.
32-20: 2.1.4. Nose wheel fairing and fork - Installation (standard and Beringer wheel type)
Required parts,
Reference
NOTE: for aircraft not equipped with nose landing gear fairing - Metric wrench set
perform only steps 1 - 4 - 5 - - T-handle hex head screw-
driver set
Prop the nose landing gear up by weighing down the tail - T-handle socket wrench
1 07-10: 2.3.1.
cone. set
2 Position the nose wheel fork inside the fairing. - Loctite 243
Position the nose wheel fairing and the fork on the nose
3
landing gear strut.
Fasten the nose wheel fork and fairing to the nose land-
4 ing gear strut flange. Apply Loctite 243 on the four cylinder
head cap screws.
5 Install nose wheel. 32-20: 2.1.2.
NOTE: After installing the wheel make sure there is adequate clearance between it and the other nose
gear components. Make sure that the wheel turns freely and isn’t hindered by anything.
6 Install nose landing gear fairing cover.
7 Apply tape to secure the nose landing gear fairing cover.
Remove counterweight from tail cone and lower front end
8
of aircraft.
PAGE PAGE REV. 0

32-14
LSAALPHA
Sinus
Virus
Trainer
32-20
NOSE GEAR
32-20: 2.2. Nose landing gear

Required parts,
Reference
Inspect nose landing gear strut for any signs of damage, - Metric wrench set,
1 - T-handle hex head screw- 32-20
such as deformation, cracks or corrosion.
driver set,
Grab the propeller with both hands, block the nose wheel - T-handle socket wrench
with your foot or a wedge and lean back. Inspect the move- set
2 ment of the nose landing gear’s shock absorber. Make sure - Loctite 243
it’s movement is smooth and unhindered.
Inspect the shock absorber for any signs of impact damage
3
or wear.
32-20: 2.2.2. Nose landing gear fork - Inspection/check

Required parts,
Reference
NOTE: for aircraft not equipped with nose landing gear fairing perform visual inspection
05-20
without carrying out the following steps.
1 Prop up the nose of the airplane. - Metric wrench set, 07-10: 2.3.1.
2 Remove the nose landing gear fairing and nose wheel. driver set, 32-20: 2.1.1.
Inspect the nose landing gear fork for any signs of damage, - T-handle socket wrench
3 set
such as deformation, cracks or corrosion.
- Loctite 243
4 Install nose wheel fairing and nose wheel. 32-20: 2.1.3.
5 Lower the aircraft nose down. 07-10: 2.3.1.
32-20: 2.2.3. Nose gear strut guard removal

Required parts,
Reference
Unscrew and remove the three M4 bolts on the rear part of - Metric wrench set
1 - Screw driver set
the strut guard.
Pull and separate the aft edges of the strut guard. The edg- driver set
2
es are connected by velcro stripes inside.
SYSTEMS
3 Remove the strut guard from the nose wheel strut.
PAGE REV. 0 PAGE

32-15
Sinus
Virus
ALPHA Trainer
LSA
32-20
NOSE GEAR
32-20: 2.2.4. Nose gear strut guard installation

Required parts,
Reference
Pull and open the aft edges of the strut guard. The edges - Metric wrench set
1 - Screw driver set
are connected by velcro stripes inside.
2 Install the strut guard on the nose wheel strut. driver set
Fix the strut guard to the supporting plate on the strut using
3
a M4 screw on the central hole of the guard.
4 Insert and secure the other two bolts.
Apply pressure on the back edges of the strut guard to con-
5
nect the parts with the velcro.
CAUTION: The strut guard must be aligned with the airplane longitudinal axis, when rudder and nose
wheel are centered. Strut guard acts as an aerodynamic surface and incorrect alignment can cause
unexpected yaw tendency.
32-20: 2.2.5. Nose gear shock absorber removal

Required parts,
Reference
1 Remove upper and lower engine cowlings. - Wrench/allen key set 71-10: 2.1.2.
- Spring hook tool
2 Remove the nose wheel strut guard (if installed). - Nose gear shock absorber 32-20: 2.1.3.
Unscrew the two cylinder head cap screws of the strut extractor (P/N 1190177)
3 guard fixation plate (if installed).
Release the two centering mechanism springs under the
4
dashboard in the cabin.
Unscrew and remove the two bolts connecting the two
5 steering rod forks to the bellcrank.
32-20
6 Unscrew the bellcrank hex nut and remove the bellcrank.

Remove the shock absorber securing bolt, placed along the
7 frontal part of nose gear tube on the engine mount. (Old
type shock absorber only)
Prop-up the airplane nose by pushing down the airplane tail
8 07-10: 2.2.1
and secure it by adding some weight on it.
Mount the shock absorber extractor tool on shock absorb-
er, push downward the shock absorber removal tool while Figure 32-
9 simultaneously rotating it slightly left and right to ease the 007
removal of the shock absorber from the engine mount.
Remove the plastic bushing from the engine mount by

10 pushing it out from the shock absorber housing tube using
a metal stud. (Old type shock absorber only)
PAGE PAGE REV. 0

32-16
LSAALPHA
Sinus
Virus
Trainer
32-20
NOSE GEAR
32-20: 2.2.6. Nose gear shock absorber installation (new type)

Required parts,
Reference
Apply some anti-seize lubricant on the shock absorber for - Wrench/allen key set
1 easy fit, before pushing it into the engine mount housing - Spring hook tool
tube. - Loctite 243
- Red marking paint
Insert the shock absorber into his housing tube on the en- - Loctite
2 32-20
gine mount. - Anti-seize
Install the nose landing gear fairing, if present, the nose
3 wheel and the fork.
4 Lower the aircraft nose.
5 Install the bellcrank and the retaining hex nut.
Mount and secure the two bolts connecting the two steer-
6 ing rod forks to the bellcrank.
7 Install the upper and lower engine cowling. 71-10: 2.1.2.
Connect the two centering mechanism springs under the
8
dashboard in the cabin.
9 Apply marker paint to nuts and bolts.
Check and if necessary adjust the alignment of the nose

10 landing gear. Check that the movement is free, with no fric- 32-50
tion and correct in range and direction.
SYSTEMS
Figure 32-007
nose gear shock absorber extractor (P/N
1190177)
PAGE REV. 0 PAGE

32-17
Sinus
Virus
ALPHA Trainer
LSA
32-20
TAIL GEAR
32-20: 2.3. Tail wheel assembly
32-20: 2.3.1. Removal of the composite tail landing gear strut

Required parts,
Reference
Disconnect the steering control cables by removing the two - Metric wrench set,
1 - T-handle hex head screw-
M5 x 30 mm bolts and spacers fastened to the rudder.
driver set,
Unscrew the M10 x 55 mm bolt connecting the tail strut to - T-handle socket wrench
2
the fuselage. set
In case the tail assembly is not reinstalled immediately, rest
3 the rear-end of the fuselage on a clean and soft surface to 07-10: 2.3.1.
prevent any damage to the structure and rudder.
32-20: 2.3.2. Installation of composite tail landing gear strut

Required parts,
Reference
Make sure the strut sits flush against the surface of the fu- - Metric wrench set,
1
selage, and there isn’t a gap or dirtiness between the two. - T-handle hex head screw-
driver set,
Remove from the strut the wheel assembly, by unscrewing - T-handle socket wrench
2
the M10 x 93 mm bolt. set
Install the strut to the fuselage by fastening the M10 x 55 - Loctite 243
mm bolt. - Torque wrench
3
Loctite 243 must be applied on the bolt. The fixing torque - Red marking paint
must be 35 Nm.
Install the wheel assembly using the M10 x 93 mm bolt. Loc-
4 tite 243 must be used on the bolt. The fixing torque must
be 35 Nm.
Connect the steering control cables fixing the two
M5 x 30mm hex head bolts and spacers which are
5
fastened to the rudder. Loctite 243 must be applied on the
bolt thread. Fixing torque is 6 Nm.
6 Apply paint marker to all of the nuts.
Make sure the tail wheel is completely in line with the rud-
der by adjusting the two bolts at the end of the steering
mechanism’s cables. This can be done by unclipping the
spring from the tail wheel fork, untightening the M5 locknut
7 and adjusting (screwing or unscrewing) the other end of the
spring. Then just reclip the spring onto the tail wheel fork
and check to see how well the tail wheel and the rudder
are in line. Repeat the process if you’re not satisfied. When
satisfied just tighten the locknut.
WARNING: Weight and balance must be redetermined in case of replacement of the standard tail wheel
strut with the composite version.
PAGE PAGE REV. 0

32-18
LSAALPHA
Sinus
Virus
Trainer
32-20
TAIL GEAR
32-20: 2.3.3. Standard tail landing gear - Inspection/check

Required parts,
Reference
1 Prop up the tail of the aircraft. 07-10: 2.3.1.

Visual inspection of the fuselage laminate where the tail
wheel attaches to it. Check for damage or signs of
2
overstress to the fuselage or to the wheel support
assembly.
Check the springs that connect the wheel to the rudder for
3 signs of damage or overstretching. Check movement of the
tail wheel by moving the rudder to the left/right.
Check the anti shimmy system operation, moving the wheel
4
to the right/left.
NOTE: for aircraft equipped with tail wheel with composite
spring, perform additional visual inspection to the composite 5-20
spring part.
SYSTEMS
PAGE REV. 0 PAGE

32-19
Sinus
Virus
ALPHA Trainer
LSA
32-40
WHEELS AND BRAKES
32-40 WHEELS AND BRAKES

General
This chapter describes the wheel and brakes system. This system is what allows the aircraft to
roll along the ground while taxiing and stop when needed.
32-41 WHEELS
1. Description
Wheel assembly and Tires
The aircraft can be equipped with two wheel types: Standard/Pipistrel made or Beringer made.
In general main wheels are 6 inches in diameter, tubeless (Beringer) or tube type tires fitted.
In particular Beringer’s type are made from high strength aluminum alloy, machined solid on CNC
and anodized for optimal corrosion resistance.
Nose Wheel and Tire
The nose wheel is of plastic construction and designed for tires with inner tubes. The 4.00 x 4
wheels use a 6-ply-rated tube tire and rotate on two bearings.
Beringer nose wheel is available as option, in this case the wheel hub is aluminium alloy made.
32-41: 2.1. MLG wheels
32-41: 2.1.1. MLG wheel removal (Beringer type)

Required parts,
Reference
1 Remove main landing gear fairings. - Metric wrench set 32-10: 2.2.1.
- Cutting nippers
2 Remove fairing spacer. - M25 slotted nut key
3 Prop MLG strut up with landing gear stand. (P/N 1190113) 07-10: 2.1.1.
- Landing gear stand
4 Cut/remove wheel locking wire around the brake disc. (P/N 1190264) Figure 32-009
5 Remove M25 slotted nut.

6 Slide wheel off axle.
If necessary remove the brake disk from the brake pad,
and then the brake pad from the axle unscrewing the three
7
M6 retaining bolts. Disconnect the brake lines from the
brake pad.
PAGE PAGE REV. 0
32-20
LSAALPHA
Sinus
Virus
Trainer
32-41
WHEELS
32-41: 2.1.2. MLG wheel installation (Beringer type)

Required parts,
Reference
Install the brake pad on the axle using three M6 bolts, - Metric wrench set,
1 and insert the brake disc in the brake pad slot. - 1 mm locking wire, Figure 32-009
Reconnect the brake line to the brake pad. - M25 slotted nut key
(P/N 1190113)
2 Position wheel on axle and brake disc. - Landing gear stand
Fasten wheel to axle using M25 slotted locknut. Tighten (P/N 1190264)
3 until the nut comes into contact with the wheel’s bear-
ing. Torquing is NOT required!
WARNING: Never reuse this, or any other locknut after removing it. Always replace it with a new one!
WARNING: After installing the wheel make sure there is no play between it and the axle. Make sure
that the wheel turns freely and isn’t hindered by anything.
4 Positive lock the brake disc with locking wire.
5 Remove landing gear stand.
6 Install main landing gear fairings. 32-10: 2.2.2.
32-41: 2.1.3. MLG wheel removal (Standard/Pipistrel wheel type)

Required parts,
Reference
1 Remove main landing gear fairings. - Metric wrench set 32-10: 2.2.1.
- Cutting nippers
2 Remove fairing spacer. - Landing gear stand
4 Unscrew the M14 hex nut on the outer center of the wheel.
5 Pull the wheel and slide it off the axle.
If necessary disconnect the brake pad from the brake line
6
and slide it off the axle.
SYSTEMS
PAGE REV. 0 PAGE

32-21
Sinus
Virus
ALPHA Trainer
LSA
32-41
WHEELS
32-41: 2.1.4. MLG wheel installation (Standard/Pipistrel wheel type)

Required parts,
Reference
Re-install the brake pad sliding it on the axle, and push it in - Metric wrench set
1 position gently hitting it with a hammer if necessary. - Hammer Figure 32-010
Reconnect the brake line to the brake pad. - Landing gear stand
(P/N 1190264)
Position the wheel on axle, and place on the hub the bear-
2
ing cover.
Insert and tighten on the axle the M14 nut right until the
3 wheel stops turning and then loose the nut for 1/4 turn so
that the wheel can rotate freely by hand turning.
Apply Loctite 243 on the wheel fairing spacers threads (if
4
installed) before fastening it on to the axle.
Remount the wheel fairing and fasten it in place (if installed
5 32-10: 2.2.2.
on the airplane).
32-41: 2.1.5. MLG wheel axle removal (Beringer type)

Required parts,
Reference
Remove main landing gear fairings and the fairing spacer - Metric wrench set
1 - Allen key set 32-10: 2.2.1.
(if installed).
- Cutting nippers
2 Prop MLG strut up with landing gear stand. - Landing gear stand 07-10: 2.1.1.
Drain/clamp and disconnect brake lines from the brake (P/N 1190264)
3
pad.
Unscrew from the MLG inner side the M14 lock-nut and the
four M6 cap-head screws connecting the wheel axle to
4
the MLG strut. Separate the wheel fairing support plate (if
installed) and collect the washers.
Pull from the wheel and slide the complete assemble off
5
from the MLG strut.
If required, separate the assembly component as de-
6 32-41: 2.1.1.
scribed in section 32-41: 2.1.1.
PAGE PAGE REV. 0

32-22
LSAALPHA
Sinus
Virus
Trainer
32-41
WHEELS
32-41: 2.1.6. MLG wheel axle installation (Beringer type)

Required parts,
Reference
1 Insert the wheel axle on the MLG strut. - Metric wrench set 32-10
- Allen key set
Mount the washers on the M6 screws and on the M14 nut, - landing gear stand
2 and secure them interposing the wheel fairing support (P/N 1190264)
plate if required. Torque the M14 nut to 55 Nm. - Torque wrench
WARNING: Torque the M14 nut to 55 Nm, using a torque
wrench!
3 Connect the brake line to the brake shoe.
4 Refill the brake circuit if necessary. 12-10: 2.5.2.
32-41: 2.1.7. MLG wheel axle removal (Standard/Pipistrel wheel type)

Required parts,
Reference
Remove main landing gear fairings and the fairing spacer - Metric wrench set
1 - Allen key set 32-10: 2.2.1.
(if installed).
- Landing gear stand
3 Drain/clamp and disconnect the brake lines.
Unscrew the four M5 cap-head screws and remove the
4
wheel fairing support plate (if present - Sinus/Virus only).
Pull from the wheel and slide the complete assemble off
5
from the MLG strut.
Remove the outer wheel axis fixation plate. (Sinus/Virus
6
only)
32-41: 2.1.8. MLG wheel axle installation (Standard/Pipistrel wheel type)

Required parts,
Reference
Insert the wheel axle on the MLG strut. (Sinus/Virus only: - Metric wrench set
1 install outer wheel axis support plate before inserting the - Allen key set 32-10
axle) - Landing gear stand
(P/N 1190264)
2 Fasten the axle to the strut using the M14 nut and washer. - Torque wrench
SYSTEMS
Virus/Sinus only: install the four M5 screws in the holes

3 located around the axle. Install the fairing fixation plate if
required.
WARNING: Torque the M14 nut to 55 Nm, using torque wrench
4 Connect the brake line to the brake shoe.
5 Refill the brake circuit if necessary. 12-10: 2.5.
PAGE REV. 0 PAGE
32-23
Sinus
Virus
ALPHA Trainer
LSA
32-41
WHEELS
32-41: 2.1.9. MLG tire removal (Pipistrel wheel type)

Required parts,
Reference
1 Remove MLG wheel. 32-41: 2.1.3.

2 Deflate tire pressure to zero.
3 Remove M6 bolts securing wheel half.
4 Slide tire off the wheel.
32-41: 2.1.10. MLG tire installation (Standard/Pipistrel wheel type)

Required parts,
Reference
1 Slide new tire on wheel. - Metric wrench set

- Cutting nippers
2 Secure wheel halves using M6 bolts. - M25 slotted nut key
Replenish tube with compressed air to the required (P/N 1190113)
3 - Landing gear stand Table 12-001
pressure.
(P/N 1190264)
4 Install MLG wheel. 32-41: 2.1.4.
32-41: 2.1.11. MLG Tire removal (Beringer wheel type)

32-41: 2.1.12. MLG Tire installation (Beringer wheel type)

PAGE PAGE REV. 0

32-24
LSAALPHA
Sinus
Virus
Trainer
32-41
WHEELS
32-41: 2.1.13. MLG wheel bearing replacement (Standard/Pipistrel wheel type)

Required parts,
Reference
1 Remove the wheel and place it on the workbench. - Metric wrench set 32-41: 2.1.3.
-T-handle hex head
2 Remove the bearing cover. screwdriver set
Remove the tapered roller bearing by pulling it out of its - Hammer 200 gr.
3 - SKF multipurpose
housing.
grease
Use a piece of paper to clean the wheel and check for
4
any signs of damage or wear.
Use a hammer and a hex head screwdriver to push out
5 of place the ball bearing positioned on the other side of
the hub.
Flip the wheel over and use the hammer and hex screw-
6 driver to remove the tapered roll bearing bushing out of
its place.
Use a piece of paper to clean the wheel and check for
7
Install the replacement parts starting from the new roller
8 bearing bushing. Install it on the wheel knocking it in with
the hex head screwdriver handle and a hammer.
Install the tapered rolling bearing on its bushing applying
9
some grease on both the parts.
Apply some grease on the bearing cover and reinstall it
10
on the wheel.
11 Install the ball bearing on the other side of the wheel.
12 Install the wheel. 32-41: 2.1.4.
SYSTEMS
PAGE REV. 0 PAGE

32-25
Sinus
Virus
ALPHA Trainer
LSA
32-41
WHEELS
2.2. Nose landing gear wheel
32-41: 2.2.1. Removal/installation – see 32-20: 2.1.
Figure 32-008
Nose wheel
Standard type
without wheel fairing
PAGE PAGE REV. 0

32-26
LSAALPHA
Sinus
Virus
Trainer
32-41
WHEELS
32-41: 2.2.2. Tire/inner tube change (Standard/Pipistrel wheel type)

Required parts,
Reference
- Metric wrench + 32-20: 2.1.2.

1 Remove nose landing gear wheel.
socket set 32-41: 2.2.1.
- T-handle hex head
2 Deflate tire/tube.
screwdriver set
Remove the fastening material holding the wheel’s two - Loctite 243
3
halves together.
4 Remove both halves of the wheel.
5 Pull inner tube out of tire.
Inspect both the tire and tube for any signs of damage/
6
wear. Replace if necessary.
7 Insert the new inner tube in the tire.
Install the two halves of the wheel hub, applying Loctite
8
243 on the nuts’ thread before torquing.
9 Install the nose wheel.
10 Replenish tire air. 12-20: 2.4.
11 Install the nose wheel. 32-20: 2.1.2.
32-41: 2.2.3. Nose wheel bearings replacement (Standard/Pipistrel wheel type)

Required parts,
Reference
1 Remove nose wheel and place it on the workbench. - Metric wrench + 32-20: 2.1.
socket set
Use a hammer and a hex head screwdriver to push out of - T-handle hex head
2
place the ball bearings. screwdriver set
Use a piece of paper to clean the wheel and check for - Loctite 243
3 - Hammer 200 gr.
Install the replacement bearings on the wheel knocking
4
them in with the a hammer.
5 Install the nose wheel. 32-20: 2.1.

Required parts,
Reference
SYSTEMS
Prop the nose landing gear up by weighing down the tail - Metric wrench set
1 - T-handle hex head screw- 07-10: 2.3.1.
cone.
driver set
Remove the fastening material nut and bolt (axle) securing - T-handle socket wrench
2
the wheel to nose gear fork. set
3 Remove nose wheel.
PAGE REV. 0 PAGE

32-27
Sinus
Virus
ALPHA Trainer
LSA
32-42
BRAKES
32-42 BRAKES
1. Description
The brake system consists of a dual piston single disc brake assembly on each main landing gear
wheel, master cylinder for each rudder pedal, hydraulic fluid reservoir, parking brake, and associ-
ated hydraulic plumbing.
The hydraulically operated brakes are individually activated by floor mounted toe pedals located
at both pilot stations. The master cylinders are located forward of the pilot’s rudder pedals. The
reservoir is serviced with DOT 3 or DOT 4 hydraulic fluid.
The parking brake mechanism holds induced hydraulic pressure on the disc brakes for parking.
It’s control lever can be found on the cabin floor, on the port side of the instrument panel’s pedes-
tal.
32-42: 2.1. Hydraulic brake lines

Required parts,
Reference
1 Remove the main wheel fairings. (Virus/Sinus only) - T-handle hex head screw- 32-10: 2.2.1.
driver set
Inspect brake lines where they exit the main landing gear - Torx screwdriver set
2 strut and attach to the brake system. Check for signs of
chafing, wear and damage.
Do the same for all of the hydraulic brake lines that are
3
accessible in the cabin.
PAGE PAGE REV. 0

32-28
LSAALPHA
Sinus
Virus
Trainer
32-42
BRAKES
32-42: 2.2. Brake pads and brake discs
32-42: 2.2.1. Brake pads and brake discs inspection (Beringer type)
Required parts,
Reference
1 Remove main landing gear fairing. - Allen key set 32-10: 2.2.1.
- Vernier caliper
2 Prop up one side of the aircraft. - Landing gear stand 07-10: 2.1.1.
(P/N 1190264)
Cut and remove the locking wire securing the brake disk - Metric wrench set
3
to the wheel.
4 Remove MLG wheel. 32-41
Disconnect the brake lines and remove the caliper assem-
5
bly from the wheel axle.
Measure brake disc thickness and compare it to the maxi-
6 [4]
mum permissible wear found in [4]. Replace if necessary.
7 Remove assembly screws and open the caliper assembly.
Measure brake pad thickness and compare it to the maxi-
8 [4]
mum permissible wear found in [4]. Replace if necessary.
Check the two brake pistons and replace them if neces-
9 [4]
sary.
Install the brake caliper on the axle and place the brake
10 32-41: 2.1.2.
disc in the caliper slot.
Install the wheel and secure the brake disc to the wheel
11
using locking wire.
12 Install the MLG fairing. 32-10: 2.2.2.
13 Repeat the operation on the other side of the aircraft.
32-42: 2.2.2. Brake pads and brake discs inspection (Standard/Pipistrel wheel type)
Required parts,
Reference
1 Remove main landing gear fairing. - Allen key set 32-10: 2.2.1.
- Vernier caliper
2 Prop up one side of the aircraft. - Landing gear stand 07-10: 2.1.1.
3 Remove main landing gear wheel. (P/N 1190264) 32-41
- Metric wrench set
Remove the brake pad and measure the thickness on each - Loctite 243
4 of the eight protrusions using a Vernier caliper.
WARNING: If you get an average measurement of 2mm
SYSTEMS
or less, the brake pad must be replaced with a new one. A

measurement of 1.5 mm is the bare minimum and a safety
hazard!
PAGE REV. 0 PAGE

32-29
Sinus
Virus
ALPHA Trainer
LSA
32-42
BRAKES
Required parts,
Reference
Once the wheel has been removed, the brake disk is visi-
ble on the inner face of the wheel hub. Examine the heads
5 of the three bolts holding the disc in place. If the material
of the disc has been consumed till the bolt’s head, the disc
must be replaced.
Unfasten the M5 Hexagon socket head cap screws to
6 32-42: 2.3.3
remove the brake disc.
Replace the disc and fix it to the wheel applying Loctite
7
243 to the screws.
8 Install the brake pad.
9 Install the wheel. 32-41: 2.1.4.
10 Install the MLG fairing 32-10: 2.2.2.
11 Repeat the operation on the other side of the aircraft.
32-42: 2.3. Parking brake
32-42: 2.3.1. Beringer parking brake kit installation

Reference: [4]
Required parts,
Reference
Disconnect the brake lines from the pedals or from the - Wrench set
1 - torx set [4]
hand brake system, and drain the brake fluid.
- Alan key set
Prepare the parking brake assembly by removing the red - Triangular file
2
marking paint from the lever bolt head. - Hand drill
Remove the bolt and re-assemble the parking lever rotated - Dremel tool
3 by 180 degrees from the original position. Apply some - Ø4 mm drill bit
- Cut-off disk
Loctite 243 before fitting the bolt.
- Measuring tape
Remove both fittings labelled «flow» along with their - Loctite 243
4 - Loctite 577
springs. These fittings will be replaced by the new ones.
Prepare the new fittings included in the kit using a triangu-
lar file, adding a notch, similar to the one in the Beringer
5
fittings, except that you can extend it across the entire
surface.
Assemble on the new fittings the o-rings and the springs
6
removed from Beringer’s ones.
Apply some Loctite 577 on the fitting threads, spread it
7
around, and screw the fittings on the parking brake casing.
Connect the four quick-release fittings to the assembly.
The 90 degrees-curved one has to be installed on the side
8
opposite to the lever. Apply Loctite 577 before inserting
the fittings.
PAGE PAGE REV. 0

32-30
LSAALPHA
Sinus
Virus
Trainer
32-42
BRAKES
Required parts,
Reference
Use an hand drill and a Ø4 mm drill bit to drill out the holes
on the cabin floor. Use a dremel and a cut-off disk to cut
out the slot for the parking brake lever. The slot dimen- Figure 32-009 and
9
sions are 4mm wide and 45mm long. Figure 32-010
See figures for the correct positioning of slot and fixing
holes.
After drilling and cutting out the holes, use a file to smooth
10
over the edges.
Temporarily remove a control stick boot and unfasten one
side of the stick drive assembly from the cabin floor. This
25-10: 2.3.1. and
11 will provide an easy access point to the area below the
27-30: 2.5.
cabin where the parking brake assembly has to be in-
stalled.
Fasten the park-brake assembly in place using the M4
12
screws, M4 polystop nuts and M4 washers provided.
Connect the brake lines using the figure 32-010 as refer-
13 Figure 32-011
ence.
Fix again in position the control stick drive assembly and 25-10: 2.3.2.
14
the stick boot. 27-30: 2.5.
15 Install the plastic handle on the parking brake lever.
16 Refill the brake system with hydraulic fluid. [4]
17 Perform functional test of the brake system.

Beringer park brake Beringer park brake
SYSTEMS
Fixing holes location Lever slot location
PAGE REV. 0 PAGE

32-31
Sinus
Virus LSA
32-42 ALPHA Trainer
BRAKES
Figure 32-011
Beringer Parking brake hose connection diagram
32-42: 2.3.2. Beringer parking brake removal

Required parts,
Reference
Temporarily remove a control stick boot and unfasten one - Screwdriver set
side of the stick drive assembly from the cabin floor. This 25-10: 2.3.1. and
1
will provide an easy access point to the area below the 27-30: 2.5.
cabin where the parking brake assembly is installed.
2 Remove the plastic handle from the parking brake lever.
Unscrew the two M4 bolts holding the parking brake as-
3
sembly in position below the cabin floor.
Disconnect the brake lines from the parking brake assem-
4 bly, releasing the quick-release fittings.
5 Drain the brake fluid leaking from the hoses.
Extract the parking brake assembly through the control
6 stick drive opening on the cabin floor.
PAGE PAGE REV. 0

32-32
LSAALPHA
Sinus
Virus
Trainer
32-42
BRAKES
32-42: 2.4. Brake circuit bleeding procedure
32-42: 2.4.1. Brake circuit bleeding procedure - Toe brakes version (Standard/Beringer)
Reference: [4]
Required parts,
Reference
Disconnect the retaining springs on the right pedals, and - Wrench set
1 - Allen key set
tilt the pedals pulling them backwards.
- Pliers
Loosen the uniball’s nut at the base of every cylinder and - Extra brake fluid
2 rotate the cylinders inwards, so that their fittings are point-
ing upwards. Do this on both pilot and passenger side.
Using a wrench and Allen key, remove the right brake fluid
reservoir. Then remove it’s cover, it’s o-ring and the black
3
cap inside. During this operation hold the reservoir in verti-
cal position.
4 Pump the pilot’s right brake two/three times.
Take a small cup and place it near the passenger’s pedals.
Release the brake line from the right cylinder’s upper
5
fitting on the passenger side and place it over the cup.
Collect the fluid that drips out from the hose.
Repeat the steps (4) and (5) two or more times, until no air
bubbles are visible in the line. Refill the line from the reser-
6 voir from time to time, to make sure it doesn’t run out.
It is possible to refill using the fluid accumulated into the
cup.
Reconnect the brake line making sure that the fitting on
7
the cylinder is filled with fluid.
8 Pump the right brake a two or three of times .
Release the brake line from the brake fitting on the right
9 wheel and pump the brake a couple of times immediately
place it over a cup to catch the dripping brake fluid.
Check the right brake line to see if any air bubbles flow
10 out. Do not pump the brake during this operation and refill
the reservoir to make sure the fluid doesn’t run out.
Once the line has been purged of air bubbles just recon-
11
nect the brake line. Using some pliers to help this action.
Activate the right brake several time and check for residual
12
bubbles. Repeat the process from (8) to (11) if needed.
13 Repeat all of the steps above for the left brake line.
SYSTEMS
Reassemble the brake fluid reservoirs and refit the brake

14
pedal springs.
PAGE REV. 0 PAGE

32-33
Sinus
Virus
ALPHA Trainer
LSA
32-42
BRAKES
32-42: 2.4.2. Brake circuit bleeding procedure - hand brake version (Standard and Beringer
wheels)
Required parts,
Reference
Connect on the nipple fitting on the right brake a silicon - Wrench set
1 - Allen key set
hose of about 30 cm of lenght.
- Pliers
Pump the hand brake several times, in order to build up - Extra brake fluid
2
pressure on the system
3 Take a small cup and place it near the right wheel.
Release the nut at the base of the nipple, on the right

4 brake. Collect into the cup the fluid that drips out from the
hose.
Repeat the steps 2 to 4 two or more times, until no air bub-
5 bles remain in the line.
Screw and close the nipple nut and detach the auxiliary
6 silicon hose from the brake pad.
7 Refill the system from the cabin reservoir. 12-10: 2.5.1.
8 Repeat the steps from (1) to (7) for the left wheel brake line.
Refill the system again with hydraulic fluid from the cabin
9 12-10: 2.5.1.
reservoir.
10 Perform functional test of the brake system.
PAGE PAGE REV. 0

32-34
LSAALPHA
Sinus
Virus
Trainer
32-50
STEERING
32-50 STEERING
1. Description
In airplanes with nose gear configuration, the nose gear is steerable. It is connected to the rudder
pedal control system by a bellcrank and a set of cables/springs (see Figure 32-012).
In tail wheel configuration, the tail wheel is steerable and connected to the rudder.
Figure 32-012
Steering System
Nose landing gear configuration
SYSTEMS
PAGE REV. 0 PAGE

32-35
Sinus
Virus
ALPHA Trainer
LSA
32-50
STEERING
32-50: 2.1. Steering bellcrank

Required parts,
Reference
1 Remove the nose landing gear fairing. 32-20

Inspect the nose landing gear’s turning range. Confirm that
2
it’s movement is unhindered and smooth.
Confirm that the nose landing gear’s bellcrank is in good
3
working condition and moves freely.
4 Install nose landing gear fairing. 32-20
PAGE PAGE REV. 0

32-36
33
Sinus
Virus
ALPHA Trainer
LSA
CHAPTER 33 – LIGHTS
TABLE OF CONTENTS

LIGHTS
33-00 33-03
General
FLIGHT COMPARTMENT
EXTERIOR LIGHTING
PAGE PAGE REV. 0

33-02
LSAALPHA
Sinus
Virus
Trainer
33-00
GENERAL
33-00 GENERAL
This chapter contains information about the interior and exterior lighting systems used on the
aircraft. Exterior lighting consists of standard wing tip navigation lights with integral anti-collision
strobe lights. The separately controlled landing light, which also serves as the taxi light, is located
on the bottom engine cowling. All lights incorporate LED technology.
Interior lighting consists of a separately controlled, incandescent overhead light for general cabin
lighting, individual lights for the pilots and dimmable panel floodlights. The flight instruments and
avionics equipment are dimmable.
The instrument panel and fuel level indicators can be equipped with UV LED lights for night VFR
operation (Option - Sinus/Virus only).
SYSTEMS
PAGE REV. 0 PAGE

33-03
Sinus
Virus
ALPHA Trainer
LSA
33-10
FLIGHT
COMPARTMENT
33-10 FLIGHT COMPARTMENT

1. Description
A cabin flood-light is present and illuminates the master electrical panel and circuit breakers. The
fuel level indicator tubes are illuminated individually with dedicated LED elements. Illumination in-
tensity is synchronized and controlled by the SmartDim night light, either reacting to ambient light
conditions automatically or manually set by the pilot as well. Primary analogue instruments, such
as the airspeed indicator and the altimeter, are TSO’d and internally illuminated. Other instrumen-
tation has backlit dimmable LCD displays and illuminated buttons.
33-10: 2.1. Flight compartment

Required parts,
Reference
Carry out visual inspection of all the flight compartment

1 05-20
lights.
Carry out operational inspection of all the flight compart-
2 05-20
ment lights.
3 Replace if necessary.
PAGE PAGE REV. 0

33-04
LSAALPHA
Sinus
Virus
Trainer
33-40
EXTERIOR
LIGHTING
33-40 EXTERIOR LIGHTING

1. Description
The aircraft comes equipped with NAV/STROBE lights located on the wingtips and a LED landing
light fastened to the bottom engine cowling.
Navigation Lights
These lights are controlled by the NAV/STROBE light switch on the switch panel. 12 VDC for navi-
gation light operation is supplied through the NAV/STROBE light switch, which includes a resetta-
ble circuit breaker element (see Figure 33-001).
Strobe Light
Anti-collision strobe lights are integrated into the standard navigation light and controlled by the
same switch.
Figure 33-001
NAV/STROBE light installation
Landing Light
A High Intensity LED landing light is mounted in the lower engine cowl. The landing light is con-
trolled through the LDG light switch on the switch panel. 12 VDC for navigation light operation is
SYSTEMS
supplied through the LDG light switch, which includes a resettable circuit breaker element. The
landing light has thermal protection built in and its operation is not time limited (see Figure 33-002).
PAGE REV. 0 PAGE

33-05
Sinus
Virus
ALPHA Trainer
LSA
33-40
EXTERIOR
LIGHTING
Figure 33-002
Landing light installation
33-40: 2.1. NAV/STROBE lights

Required parts,
Reference
1 Carry out visual inspection of the NAV/STROBE lights.

05-20
2 Carry out operational inspection of the NAV/STROBE lights.
33-40: 2.2. LANDING light

Required parts,
Reference
1 Carry out visual inspection of the landing light.

05-20
2 Carry out operational inspection of the landing light.
PAGE PAGE REV. 0

33-06
LSAALPHA
Sinus
Virus
Trainer
33-40
EXTERIOR
LIGHTING
33-40: 2.3. LANDING light
33-40: 2.3.1. Removal

Required parts,
Reference
1 Locate landing light on lower cowling. - Torx screwdriver set
2 Disconnect landing light cable from connector.

Remove screws and washers connecting landing light to
3
lower cowling.
4 Disconnect and remove the old landing light.

Required parts,
Reference
1 Position new landing light into lower cowling. - Torx screwdriver set
- Loctite 243
Run the new landing light cable through the hole in the
2
fuselage.
3 Apply Loctite 243 to the bolts’ thread.
Tighten screws and washers connecting landing light to
4
lower cowling.
5 Fasten the new landing light to the fuselage.
6 Fit connector to cable.
NOTE: white wire is “+”, white with blue stripe is “-“.
7 Connect landing light to existent wire harness.
Adjust landing light position. The angle between the light
8 Figure 33-003
axes and the lower cowling is 20°.
20°
SYSTEMS
Figure 33-003
Landing light adjustment
PAGE REV. 0 PAGE

33-07
34
Sinus
Virus
ALPHA Trainer
LSA
CHAPTER 34 – NAVIGATION AND PITOT-STATIC SYSTEMS
TABLE OF CONTENTS

NAVIGATION AND PITOT-STATIC SYSTEMS
34-00 34-03
General
FLIGHT ENVIRONMENT DATA
ATTITUDE AND DIRECTION
PAGE PAGE REV. 0

34-02
LSAALPHA
Sinus
Virus
Trainer
34-00
GENERAL
34-00 GENERAL
The chapter describes the navigation systems used on the aircraft. It covers components such as
the pitot-static system, indicators and orientation systems.
SYSTEMS
PAGE REV. 0 PAGE

34-03
Sinus
Virus
ALPHA Trainer
LSA
34-10
FLIGHT ENVIRONMENTAL
SYSTEMS
34-10 FLIGHT ENVIRONMENTAL SYSTEMS

1. Description
This chapter discusses all of the equipment/instruments that collect data from the environment
and convert it into usable information for the pilot. This includes the pitot-static system, outside air
temperature sensor, vertical speed indicator, altimeter and airspeed indicator.
Pitot-Static system
The pitot tube is mounted on the starboard wing (see Figure 34-001). Three pitot tube types are
available: Standard, Dynon and heated Dynon. Static ports mounted in the fuselage are pres-
ent when Dynon Pitot tube is installed. The line from the static port drives the static pressure to
ADAHRS units as well as the mechanical airspeed indicator and altimeter. The Dynon pitot tube
also has a AOA sensing port.
Figure 34-001
Standard and Dynon Pitot tube installation
Outside Air Temperature
The outside air temperature sensor (OAT) is mounted to the fuselage just aft of the port side wing
(see Figure 34-002). It provides the PFD/MFD with data in degrees Celsius (°C).
PAGE PAGE REV. 0

34-04
LSAALPHA
Sinus
Virus
Trainer
34-10
SYSTEMS
Figure 34-002
OAT sensor installation
Airspeed indicator
The aircraft can be equipped with a mechanical airspeed indicator. When a PFD/MFD is installed,
the mechanical airspeed indicator can serve as backup instrument in case of failure of the electron-
ic devices. Indicated airspeed is shown on an airspeed indicator installed on the pilot’s instrument
panel. The instrument measures the difference between static and Pitot pressure, and displays the
result in knots on an airspeed scale.
Altimeter
The aircraft can be equipped with a mechanical barometric altimeter. When a PFD/MFD is installed,
the mechanical altimeter can serve as backup instrument in case of failure of the electronic devic-
es. The instrument senses the local barometric pressure adjusted for altimeter setting and displays
the result on the instrument in feet. The barometric altimeter settings are input through the baro-
metric adjustment knob at the lower left of the instrument.
SYSTEMS
PAGE REV. 0 PAGE

34-05
Sinus
Virus
ALPHA Trainer
LSA
34-10
SYSTEMS
34-10: 2.1. Pitot tube

Required parts,
Reference
Locate the pitot tube fastened to the bottom surface of the

1
starboard wing.
Carry out visual inspection. Make sure the wing’s composite
2 structure around the tube’s mounting flange hasn’t incurred 05-20
any damage and that the pitot inlet is clean.
34-10: 2.1.2. Removal

Required parts,
Reference
Locate the pitot tube fastened to the bottom surface of the - T-handle hex head
1 screwdriver set
starboard wing.
Unscrew/remove the screws securing the Pitot tube to the
2
wing.
Pull the Pitot tube away from the wing slightly to access the
3
hose ports.
4 Disconnect the Pitot (and AOA hoses from the tube.)
5 Remove the Pitot tube.
6 Carry out visual inspection of the Pitot tube and hoses. 05-20

Required parts,
Reference
1 Attach the Pitot (and AOA) hoses to the Pitot tube. - T-handle hex head
screwdriver set
2 Position the Pitot tube on the wing’s bottom surface.
3 Fasten the Pitot tube to the wing.
CAUTION: Install the Pitot tube so that it’s parallel to the aircrafts longitudinal axis, therefore,
pointing in the direction of flight. The readings given by navigation instruments will not be accu-
rate if it’s installed at an angle.
WARNING: Do not blow into the Pitot tubes entry ports as this could easily damage the instru-
ments.
PAGE PAGE REV. 0

34-06
LSAALPHA
Sinus
Virus
Trainer
34-20
ATTITUDE AND
DIRECTION
34-20 ATTITUDE AND DIRECTION

1. Description
This chapter contains information about all of the components that provide the pilot with navigation
data using magnetic, inertia or gyroscopic forces.
Some components are optional only, depending on aircraft type and configuration.
Magnetic Compass
A conventional liquid filled, magnetic compass is installed on top of the instrument panel so it can
be seen by the pilot at all times (see Figure 34-003). Its correction card is installed in the compass
itself.
Figure 34-003
Magnetic compass
Mechanical instruments for attitude and altitude are mounted in the upper segment of the instru-
ment panel and do not require electrical power to function.
SYSTEMS
Please refer to the components’ installation/user manuals for maintenance.
PAGE REV. 0 PAGE

34-07
51
Sinus
Virus
ALPHA Trainer
LSA
CHAPTER 51 – STANDARD PRACTICES - STRUCTURES
TABLE OF CONTENTS

STANDARD PRACTICES - STRUCTURES
51-00 51-03
General
DETECTING/ASSESSING COMPOSITE DAMAGE
51-60 CONTROL SURFACE BALANCING 51-07
51-70 REPAIRS 51-08
PAGE PAGE REV. 0

51-02
LSAALPHA
Sinus
Virus
Trainer
51-00
GENERAL
51-00 GENERAL
This chapter covers all the maintenance procedures that pertain to the aircraft structure. The air-
frame is a complex composite structure that needs to be checked periodically for signs of wear and
damage. Damage to composite components can be difficult to detect, but some simple techniques
can make it easier.
STRUCTURES
PAGE REV. 0 PAGE

51-03
Sinus
Virus
ALPHA Trainer
LSA
51-10
DETECTING/ASSESSING
COMPOSITE DAMAGE
51-10 DETECTING/ASSESSING COMPOSITE DAMAGE
1. Description
Composite damage comes in many forms and is sometimes difficult to detect. The most common
is impact damage, such as dents or punctures. These, as well as scratches and gouges, can usu-
ally be detected by visually inspecting the component. Other types of damage however, such as
delamination, which are sometimes just as critical as other forms of damage, can go easily go un-
detected. That is why thorough inspection of the airframe is advisable and needed in order to keep
the aircraft in good working condition and its occupants safe.
NOTE: The minimum qualifications required by maintenance personnel to perform the operations
described in this section are LSRM and LAME.
51-10: 2.1. Visual inspection of composite components
Light is an excellent visual inspection aid. Place the composite component, whether big or small,
in a well lit space and move it slowly so that the light reflects off it at different angles. Any bends,
warping and/or dents should be detectable by using this technique. Once detected, the extent of
the components damage needs to be assessed.
51-10: 2.2. Tap test
Composite components are known for mechanical strong and robust, yet very light. Their underly-
ing structure must remain intact in order to ensure good mechanical properties. Any damage that
it incurs, however, can easily go undetected, because it’s not visible.
One way of a detecting interior composite damage, or determining the extent of damage already
incurred, is a tap test. This is to be carried out with a hard, metallic object, such as a coin. To avoid
damaging the composite test specimen, be sure to use an object that isn’t sharp or pointed. Simply
tap the surface of the composite component with the blunt, metallic object and listen to the sound
this produces. Areas that are undamaged typically sound sharp and clear, whereas areas that have
suffered delamination or disband, sound hollow and/or flat.
51-10: 2.3. Major bonding lines tap test
Any damage to the major bonding lines of the structural components can also be detected by the
tap test described above. The following bonding lines, clearly depicted in Figures 51-001 to 51-004,
are to be considered major:
• Upper fuselage/vertical stabilizer bonding line
PAGE PAGE REV. 0

51-04
LSAALPHA
Sinus
Virus
Trainer
51-10
DETECTING/ASSESSING
COMPOSITE DAMAGE
• Lower fuselage bonding line
• Wing leading edge bonding line
• Horizontal stabilizer leading edge bonding line
Figure 51-001
Upper fuselage/vertical stabilizer bonding line
STRUCTURES
Figure 51-002
Lower fuselage bonding line
PAGE REV. 0 PAGE

51-05
Sinus
Virus
ALPHA Trainer
LSA
51-10
DETECTING/ASSESSING
COMPOSITE DAMAGE
Figure 51-003
Wing leading edge bonding line
Figure 51-004
Horizontal stabilizer leading edge bonding line

PAGE PAGE REV. 0

51-06
LSAALPHA
Sinus
Virus
Trainer
51-60
CONTROL SURFACE
BALANCING
51-60 CONTROL SURFACE BALANCING

All of the control surfaces on the aircraft must be balanced at all times to ensure the safety of its
occupants. They can, however, become unbalanced if altered or modified (i.e. damaged, repaint-
ed, repaired, etc.).
WARNING: If altered in any way, control surfaces must be rebalanced. Instructions on how
to properly balance them can be attained on request by contacting Pipistrel.
NOTE: After instructions have been provided, the minimum qualifications required by maintenance
personnel to perform control surface balancing are AMT, L1 and LAME.
STRUCTURES
PAGE REV. 0 PAGE

51-07
Sinus
Virus
ALPHA Trainer
LSA
51-70
REPAIRS
51-70 REPAIRS
Repairs on composite structural parts and surfaces require guidance and approval from Pipist-
rel. Please use MRA request form (see APPENDIX 99-D) to submit the damage information and
further instructions.
PAGE PAGE REV. 0

51-08
52
Sinus
Virus
ALPHA Trainer
LSA
CHAPTER 52 – DOORS
TABLE OF CONTENTS

DOORS
52-00 52-03
General
PASSENGER AND CREW DOORS
BAGGAGE DOOR
52-20 52-05
Description
PAGE PAGE REV. 0

52-02
LSAALPHA
Sinus
Virus
Trainer
52-00
GENERAL
52-00 GENERAL
This chapter describes the Aircraft doors. The windshield, upper window and door windows are
made from Lexan shatter-resistant polycarbonate. The fuselage has two cabin doors made out of
CFRP frames and one independent luggage compartment door on the left side. Doors are locked
in the closed position via 3 locking pins operated simultaneously by rotating a common central
handle.
The baggage compartment door (optional - Virus/Sinus only) provides access to the baggage com-
partment and can be locked to prevent it from opening during aircraft operation.
STRUCTURES
PAGE REV. 0 PAGE

52-03
Sinus
Virus
ALPHA Trainer
LSA
52-10
PASSENGER AND CREW
DOORS
52-10 PASSENGER AND CREW DOORS

1. Description
The two crew/passenger doors are fastened to the aircraft by hinges. They incorporate a
flush-mounted, outer door handle and a conventional inner door handle. The door latch handle
is centered at the bottom of the door window and actuates three latching pins that extend down-
wards/outwards into the fuselage.
52-10: 2.1.1. Removal
Required parts,
Reference
1 Put the door handle in the locked position. - 2.5 mm T-handle hex head
screwdriver,
Push the hinge pins out of the door’s hinges using the - Rubber hammer
2
T-handle hex head screwdriver and rubber hammer.
3 Unlock the door handle and remove the door.

Required parts,
Reference
Position door on the airframe and put door handle in locked - 2.5 mm T-handle hex head
1 screwdriver,
position.
- Rubber hammer
2 Lubricate hinge pin. 12-20
3 Slide hinge pin into hinge and center it.
4 Unlock door handle and carry out operational check. 05-20

Required parts,
Reference
1 Carry out visual inspection of doors. 05-20

2 Close the door and put door handle in locked position.
3 Lubricate hinge pin. 12-20
4 Unlock door handle and carry out operational check. 05-20
PAGE PAGE REV. 0

52-04
LSAALPHA
Sinus
Virus
Trainer
52-10
PASSENGER AND CREW
DOORS
52-10: 2.1.4. Door handle locking mechanism - Inspection/check

Required parts,
Reference
1 Check the locking force of the handle in both end positions. 05-20
WARNING: The latch handle cam can wear out with time. If locking force against the locking
pin is insufficient, the door can unlock and open in flight. Replace the latch handle cam and/
or the locking pin if necessary.
2 Repeat the check on the other door.
STRUCTURES
Figure 52-001
Handle locking mechanism
PAGE REV. 0 PAGE

52-05
Sinus
Virus
ALPHA Trainer
LSA
52-20
BAGGAGE DOOR
52-20 BAGGAGE DOOR (Optional - Virus/Sinus only)

1. Description
The baggage compartment door, located on the port side of the fuselage aft of the door, pro-
vides access to the baggage compartment. The baggage door is hinged on the forward edge and
latched on the rear edge. The door is locked from the outside with a key lock.
PAGE PAGE REV. 0

52-06
53
Sinus
Virus
ALPHA Trainer
LSA
CHAPTER 53 – FUSELAGE
TABLE OF CONTENTS

FUSELAGE
53-00 53-03
General
MAIN FRAME
CABIN FLOOR
FIREWALL
PAGE PAGE REV. 0

53-02
LSAALPHA
Sinus
Virus
Trainer
53-00
GENERAL
53-00 GENERAL
The aircraft fuselage incorporates a carbon fiber, honeycomb-sandwich main frame, reinforced
with various bulkheads and longerons. This chapter describes all of the main fuselage elements
and the maintenance practices that pertain to them.
STRUCTURES
PAGE REV. 0 PAGE

53-03
Sinus
Virus
ALPHA Trainer
LSA
53-00
GENERAL
Figure 53-001
Fuselage components description
1 Main frame 7 Sunroof frame 13 Port fore longeron

2 Firewall 8 Port roll cage beam 14 Port aft longeron
Cabin support
3 strut 9 Strbrd roll cage beam 15 Strbrd aft longeron
Cabin floor support
4 Cabin floor 10 Baggage comp. bulkhead 16 beam
5 Cabin bulkhead 11 Trim ass. bulkhead

Windshield
6 frame 12 Strbrd fore longeron
PAGE PAGE REV. 0

53-04
LSAALPHA
Sinus
Virus
Trainer
53-10
MAIN FRAME
53-10 MAIN FRAME

1. Description
The fuselage is designed as a carbon fiber honeycomb-sandwich construction that uses aramid
fibers as inner laminate in the cockpit area. The external structure is covered by a protective acrylic
paint coating, which has already been applied in the mold.
53-10: 2.1. Main frame
53-10: 2.1.1. Major inspection/check

Required parts,
Reference
1 Carry out visual inspection of the fuselage main frame. 51-10

Carry out visual inspection of the area where the main land-
ing gear strut is attached to the main frame. Check for any
2 Figure 53-002
signs of damage, such as cracks, delamination or deforma-
tion.
WARNING: Any damage incurred by the fuselage’s main frame is a safety hazard and must be
repaired immediately by an authorized maintenance/composite repair organization.
STRUCTURES
Figure 53-002
Example of fuselage main frame damage

PAGE REV. 0 PAGE

53-05
Sinus
Virus
ALPHA Trainer
LSA
53-20
CABIN FLOOR
53-20 CABIN FLOOR

1. Description
The cabin floor supports the crew seats and is made primarily out of CFRP. Some areas of the cabin
floor are reinforced with aramid fibers. It’s supported by two longerons and a central beam. The
passenger safety harness lap belts are fastened to the cabin floor.
53-20: 2.1.1. Inspection/check + tap test
Required parts,
Reference
1 Remove the crew seats. 25-10

Carry out visual inspection of the cabin floor. Pay special
attention to the area around the safety harnesses and un- 5-20 and
2
dercarriage strut attachment points. Check for any signs of Figure 53-002
damage, such as cracks, delamination or deformation.
3 Install the crew seats. 25-10
WARNING: Any damage incurred by the fuselage’s cabin floor requires immediate repair and
must be carried out by an authorized maintenance/composite repair organization.
Figure 53-003
Safety harnesses attachment point on the cabin floor

PAGE PAGE REV. 0

53-06
LSAALPHA
Sinus
Virus
Trainer
53-30
FIREWALL
53-30 FIREWALL
1. Description
The firewall is designed to separate the engine compartment from the rest of the fuselage and
support various airplane components on both the forward and aft side. The firewall, constructed of
a CFRP prepreg honeycomb sandwich, includes metal fittings that support the engine mount and
reinforced points that support various engine components. Fire protection is provided by a layer of
ceramic insulation covered by a sheet of stainless steel.
Required parts,
Reference
1 Remove engine cowlings. 71-10

Carry out visual inspection of the firewall. Check for any
signs of deformation due to high temperatures, such as de- 05-20
2
formation, charring or scorching. Check the area around the
engine mount attachment points for signs of damage.
3 Install the engine cowlings. 71-10
WARNING: Any damage incurred by the fuselage’s firewall requires immediate attention and
must be repaired out by an authorized maintenance/composite repair organization.
STRUCTURES
PAGE REV. 0 PAGE

53-07
55
Sinus
Virus
ALPHA Trainer
LSA
CHAPTER 55 – STABILIZERS
TABLE OF CONTENTS

STABILIZERS
55-00 55-03
General
HORIZONTAL STABILIZER
ELEVATOR
VERTICAL STABILIZER
RUDDER
PAGE PAGE REV. 0

55-02
LSAALPHA
Sinus
Virus
Trainer
55-00
GENERAL
55-00 GENERAL
The stabilizers consist of a detachable horizontal stabilizer, a single piece elevator, a fixed vertical
stabilizer and a detachable rudder. All of the empennage components are conventional spar (shear
web), rib, and skin construction. This chapter describes the maintenance practices that pertain to
the aforementioned components.
NOTE: The COG of the aircraft must be recalculated/verified following any stabilizer/control sur-
face repairs.
STRUCTURES
PAGE REV. 0 PAGE

55-03
Sinus
Virus
ALPHA Trainer
LSA
55-10
HORIZONTAL
STABILIZER
55-10 HORIZONTAL STABILIZER

1. Description
The horizontal stabilizer is attached to an aluminum bracket that is fastened to the vertical stabilizer
and can be removed. The design of the horizontal tail’s shell incorporates CFRP sandwich material.
55-10: 2.1. Horizontal stabilizer
55-10: 2.1.1. Removal

Required parts,
Reference
1 Weigh the tail cone down to access the horizontal stabilizer. - 14 mm spark plug socket 07-10: 2.2.1.
wrench (P/N 1190003),
2 Remove the attachment bolt’s black cap.
- Flathead screwdriver
Slide screwdriver perpendicularly through 14 mm socket wrench
3 and use it to unscrew/remove the horizontal stabilizers’ attach-
ment bolt assembly.
Lightly jolt the elevator’s trailing edge, so that the horizontal sta-
4 bilizer pops out of place.
5 Remove it and set it on a dry, padded surface.
6 Remove tail cone counterweight.

Required parts,
Reference
Weigh the tail cone down to access the horizontal sta- - 14 mm spark plug
1 socket wrench (P/N 07-10: 2.2.1.
bilizer.
1190003),
2 Lubricate horizontal stabilizer pins and bushings. - Flathead screw- 12-20
3 Lubricate horizontal stabilizer attachment bolt assembly. driver 12-20
Position the horizontal stabilizer so that it’s pins slide
4
into their respective bushings.
Use 14 mm socket wrench to fasten the horizontal stabi-
5 lizer to the aircraft while simultaneously pushing down Figure 55-001
on the bolt with the screwdriver.
Orient the bolt’s head so that slides into the spring-load-
6 Figure 55-002
ed locking mechanism.
Shake stabilizer a little to ensure it is secured to the air-
7
craft.
8 Install the attachment bolt assembly’s black cap.

PAGE PAGE REV. 0
55-04
LSAALPHA
Sinus
Virus
Trainer
55-10
HORIZONTAL
STABILIZER
Required parts,
Reference
9 Carry out operational inspection of the elevator. 05-20

10 Check elevator deflection angles. 27-30

Required parts,
Reference
1 Remove horizontal stabilizer. Retainer ring pliers 55-10: 2.1.

2 Remove attachment bolt retainer ring.
3 Remove attachment bolt assembly.
4 Carry out visual inspection of attachment bolt assembly. 05-20
5 Clean and lubricate attachment bolt assembly. 12-20
6 Install attachment bolt assembly.
Carry out operational inspection of attachment bolt assem-
7 05-20
bly.
Figure 55-001
Attachment bolt installation STRUCTURES
Figure 55-002
Attachment bolt assembly head orientation
PAGE REV. 0 PAGE

55-05
Sinus
Virus
ALPHA Trainer
LSA
55-20
ELEVATOR
55-20 ELEVATOR
1. Description
The elevator is designed as a bottom surface supported hinged flap. The elevator is actuated us-
ing a pushrod, which is connected to the elevator control bracket. The elevator shell is designed
as a 1-cell CFRP sandwich shell. The elevator is hinged in maintenance-free bushings mounted on
stainless steel brackets at the stabilizer rear spar and bottom shell.
55-20: 2.1. Elevator
55-20: 2.1.1. Removal

Required parts,
Reference
1 Remove horizontal stabilizer. Metric ratchet/ 55-10: 2.1.1

socket set
2 Flip it upside down on a dry, padded surface.
Remove the fastening material from the first port-side hinge
3
securing the elevator to the horizontal stabilizer.
Slightly wiggle the elevator up and down while simultane-
4
ously sliding it off its hinges.
5 Remove and place on a dry, padded surface.

Required parts,
Reference
Slide elevator into position on the horizontal stabilizer and Metric ratchet/
1 socket set
fasten it in place.
2 Carry out operational inspection of the elevator. 05-20
3 Install horizontal stabilizer. 55-10: 2.1.2.
4 Check elevator deflection angles. 27-30
PAGE PAGE REV. 0

55-06
LSAALPHA
Sinus
Virus
Trainer
55-20
ELEVATOR

Required parts,
Reference
1 Remove elevator. Metric ratchet/ 55-10: 2.1.1.

socket set
2 Visual inspection of elevator seals. Replace if necessary. 55-20: 2.2.
3 Carry out visual inspection of the elevator. 05-20
4 Lubricate elevator hinge pins. 12-20
5 Install elevator. 55-10: 2.1.2.
55-20: 2.2. Elevator control surface seals
The gap between the stabilizer and the elevator is sealed to improve performances, control sur-
face effectiveness and to prevent any foreign objects from entering the area between the two
parts. The sealing consists of a stripe of thin curved plastic material, applied externally along the
stabilizer upper surface and covering the gap with the elevator (see Figure 57-002). The stabilizer
has two sealing strips, one for each semi-elevator.
55-20: 2.2.1. Removal

Please refer to task “57-50: 2.2.1. Removal - Flaperon sealing” for removal procedure of elevator
sealings. The basic procedure is similar to the task described. It is easer to perform the task after
the horizontal stabilizer has been removed from the aircraft (see 55-10: 2.1.1.).

Please refer to task “57-50: 2.2.2. Installation - Flaperon sealing” for installation procedure of ele-
vator sealings. It is easer to perform the task after the horizontal stabilizer has been removed from
the aircraft (see 55-10: 2.1.1.). Refer to Figure 55-003 and Figure 55-004 for additional positioning
details of the seal and cover tape.
STRUCTURES

Elevator seal Elevator seal
Positioning details - tip area Positioning details - central area
PAGE REV. 0 PAGE

55-07
Sinus
Virus
ALPHA Trainer
LSA
55-30
VERTICAL
STABILIZER
55-30 VERTICAL STABILIZER

1. Description
The vertical stabilizer is designed to be one part with the tail fuselage, made of carbon honeycomb
sandwich with carbon spars. The bending moment is carried by one C-type spar which is rein-
forced by CFRP tapes at the flanges.
55-30: 2.1. Vertical stabilizer

Required parts,
Reference
1 Remove horizontal stabilizer. 55-10: 2.1.

Carry out visual inspection of vertical stabilizer bushings
2 05-20
for wear.
3 Clean and lubricate vertical stabilizer bushings.
Clean and lubricate horizontal stabilizer T-fixation plate 12-20
4
pins.
55-30: 2.1.2. Inspection/check + tap test

Required parts,
Reference
1 Remove horizontal stabilizer. 55-10: 2.1.

2 Carry out tap test around the vertical stabilizer bushings. 51-10
PAGE PAGE REV. 0

55-08
LSAALPHA
Sinus
Virus
Trainer
55-40
RUDDER
55-40 RUDDER
1. Description
The rudder is a single-cell GFRP sandwich shell that’s designed like centrally supported hinged
flap. It’s rotation is attributed to two maintenance-free spherical plain bearings. Balancing weights
are mounted on the front end of the rudder.
55-40: 2.1. Rudder

55-40: 2.1.1. Removal
Required parts,
Reference
Remove the fastening material securing the rudder’s two Metric ratchet/
1 socket set
bottom studs to the rudder cable bellcrank.
Support the rudder with both hands and give it a jolt up-
2
wards. It should slide of its hinges.
3 Place it on a dry, padded surface.
4 Carry out visual inspection of the rudder. 05-20 and 51-10

Required parts,
Reference
1 Lubricate the upper rudder hinge pin. Metric ratchet/ 12-20

socket set
Slide the rudder’s upper bushing over its upper hinge pin
2 while simultaneously sliding its two bottom studs into the
cable bellcrank.
3 Fasten it in place and torque nuts.
STRUCTURES
4 Carry out operational inspection. 05-20
5 Check the rudder deflection angles. 27-20: 2.4.2.
55-40: 2.2. Rudder control surface sealing
The gap between the vertical stabilizer and the rudder is sealed to improve performances, control
surface effectiveness and to prevent any foreign objects from entering the area between the two
parts. The sealing consists of a stripe of thin curved plastic material, applied externally along the
stabilizer upper surface and covering the gap with the rudder. The vertical stabilizer has two seal-
ing stripes, one on each side.
PAGE REV. 0 PAGE
55-09
Sinus
Virus
ALPHA Trainer
LSA
55-40
RUDDER
55-40: 2.2.1. Removal

Required parts,
Reference
Lift the top end of the control surface sealing using a plastic - Acetone
1 - Cloth
blade.
- Plastic blade
2 Remove the sealing tearing it off the vertical stabilizer.
Clean the vertical stabilizer surface using a cloth and ace-
3
tone.
4 Repeat the procedure on the other side.

Required parts,
Reference
Clean the vertical stabilizer surface along the hinge line - Acetone
1 - Cloth
using a cloth and acetone.
- Masking tape
Position temporarily the rudder seal on the vertical stabilizer
2 along the hinge line, without removing the protective tape
and keeping it in place using some masking tape.
Once the positioning is satisfactory, start removing the
3 protective tape from one end and stick the seal end to the Figure 55-005
vertical stabilizer.
Continue to remove the protective tape along the seal and
4
stick it to the vertical stabilizer
Run a smooth object along the seal to improve the adhe-
5
sion, and to squeeze out any air bubbles.
Repeat the procedure on the other side of the vertical stabi-
6
lizer.
Figure 55-005
Rudder control surface seal
PAGE PAGE REV. 0
55-10
56
Sinus
Virus
ALPHA Trainer
LSA
CHAPTER 56 – WINDOWS
TABLE OF CONTENTS

WINDOWS
General
56-00 56-03
Description
PAGE PAGE REV. 0

56-02
LSAALPHA
Sinus
Virus
Trainer
56-00
GENERAL
56-00 GENERAL
1. Description
The aircraft is equipped with a windshield, cabin door windows and a sunroof. All of the aforemen-
tioned windows are made from Lexan shatter-resistant polycarbonate and bonded/fastened to the
fuselage or door structure using adhesive and rivets. All the windows are fixed in place and cannot
be opened, the exception being the doors which have sliding windows for direct fresh ram air into
the cabin.
NOTE: The following maintenance practices apply to all of the window surfaces (i.e. windshield,
sunroof and door).
56-00: 2.1. Windows
56-00: 2.1.1. Surface inspection/check

Required parts,
Reference
Carry out visual inspection of the window. 51-10

Inspect the window for any signs of damage such as cracks,
Figure 56-001
1 scratches, chips or smudges.
Inspect the windows clarity: objects should appear clear and Figure 56-002 and
hazy or fuzzy. Figure 56-003
STRUCTURES
Figure 56-001
Cracked windshield
PAGE REV. 0 PAGE

56-03
Sinus
Virus
ALPHA Trainer
LSA
56-00
GENERAL
Figure 56-002
Example of adequate window clarity
Figure 56-003
Example of inadequate window clarity
WARNING: Damaged windows that impede pilot visibility are a safety hazard and must be
replaced.
PAGE PAGE REV. 0

56-04
LSAALPHA
Sinus
Virus
Trainer
56-00
GENERAL
56-00: 2.1.2. Rivet inspection/check

Required parts,
Reference
Carry out visual inspection of the window rivets. 05-20

1 Make sure that none of them have loosened and/or gone
Figure 56-004
missing. They should all be flush with the window’s surface.
Figure 56-004
Example of loosened window rivet
CAUTION: Any damaged and/or loosened window rivets must be replaced with new ones.
STRUCTURES
PAGE REV. 0 PAGE

56-05
Sinus
Virus
ALPHA Trainer
LSA
56-00
GENERAL
56-00: 3.1. Windshield
56-00: 3.1.1. Windshield removal

Required parts,
Reference
Peel off the cockpit interior material which is located under - Hand drill 51-10
1 the rivets so that it won’t be perforated by the rivet bodies - 4,2 mm drill Figure 56-002 and
while they are extracted. bit Figure 56-003
- Vacuum
Drill carefully the rivet heads using a 4,2 mm drill bit. Paycleaner
attention to drill off only the heads of the rivets, do not drill
- Punch pin of
2
completely through the rivets as you may damage the wind- 4 mm diameter
shield frame. - Flathead
screwdriver
3 Remove the existing windshield. - Permanent
The next step is to extract the rivet bodies from the wind- pen and Black
shield frame’s edge. This can be done by pushing the rivet acrylic paint
4
bodies out of the holes of the windshield frame’s edge using - Contact Ce-
ment
a punch pin of 4 mm diameter.
The rivet bodies on the upper horizontal frame might be
trapped inside the structure of the frame during the actions
5 described on step 4. To remove these residual parts might
be necessary to drill on the upper frame an hole and suck
out the rive bodies using a vacuum cleaner.
Remove from the windshield frame the residual silicone us-
6
ing a flathead screwdriver to grind off the material.
In case the operation on step 6 causes some damages on
7 the black paint of the frame, the coating can be restored us-
ing acrylic paint or a permanent pen for smaller scratches.
The cockpit interior material can be re-glued back in place
8
using some contact cement.
PAGE PAGE REV. 0

56-06
LSAALPHA
Sinus
Virus
Trainer
56-00
GENERAL
56-00: 3.1.2. Windshield installation

Required parts,
Reference
Place the new windshield in position and check the matching - Black silicone
1 between the holes on fuselage and the laser pre-cut holes (p/n 5093018) 51-10
on the windshield. Remove the windshield. - Rivets
- Rivet gun (or
Apply a 1 cm width line of black silicone along the windshield hand rivet tool)
2
frame’s edge.
Remove the protective plastic material from the windshield
3
inner surface.
4 Place the windshield in position on the fuselage.
5 Insert the rivets on the holes, starting from the upper frame.
Rivet the windshield to the fuselage using a rivet gun and
following the pattern indicated in picture 56-005 during this
action. Be sure to press down on the windshield when fixing
the rivet and hold the rivet gun at a 90° angle to the wind-
6 Figure 56-005
shield. The longer rivets have to be installed through both
windshield support beams holes on the lower horizontal
edge of the windshield frame (Virus SW) or through the sin-
gle windshield support beam hole (Sinus/Virus).
Remove and level the silicone excess that may have come
7 out from the windshield joint to the fuselage, using a curved
piece of paper or thin plastic.
8 Let the silicone dry for about 6/12 hours.
Clean and wipe the entire windshield using a cloth and
9
some alcohol-based cleaning solution.
STRUCTURES
Figure 56-005
Windshield riveting pattern
PAGE REV. 0 PAGE

56-07
Sinus
Virus
ALPHA Trainer
LSA
56-00
GENERAL
56-00: 3.1.3. Windshield support rod gasket replacement - Removal

Required parts,
Reference
Protect the windshield with tape around the rivet that - Masking tape
1 fastens the windshield support rod at its bottom end to the - Hand drill
fuselage. 3.5 or 4 mm drill bit.
- Screwdriver set
Drill and remove the blind rivet. Use a vacuum cleaner to
2
remove debris.
Enter the cabin and mark the position of the windshield
support rod housing on the cabin support strut assembly,
3
so that the original position can be restored in case of
movement during the process.
Unscrew the two cylinder head cap screws from the wind-
4
shield support rod housing.
To remove the windshield support rod, pull it towards the
aircraft’s nose while simultaneously pushing the windshield
5
outwards and forcing the top end of the rod out of its hous-
ing.
When the windshield support rod is out of its top housing,
6 pull it out of its bottom attachment point, by pulling the rod Figure 56-006
rearwards and remove it from the cabin.
Once the windshield support rod has been removed, peel
7 the gasket off from the rod and remove any leftover adhe-
sive.
56-00: 3.1.4. Windshield support rod gasket replacement - lnstallation

Required parts,
Reference
Prepare the new windshield support rod gasket by cutting it - Riveting tool
1 - Primer
to the same lenght of the rod.
Apply primer coating to the windshield support rod surface
2
and wait until it is dry.
Remove the protective layer from the gasket and apply it
3 to the windshield support rod. Position it on the rod slightly
offset towards the windshield centerline.
Enter the cabin with the windshield support rod and slide
4 its flat end in the bottom attachment hole. Push the support
rod as far as possible into the attachment hole.
Restore the position of the windshield support rod housing
5 on the cabin support strut assembly using the marked signs 56-00: 3.1.3.
as a reference.
Join the two windshield support rod housing halves togeth-
6
er using the two cylinder head cap screws.
PAGE PAGE REV. 0

56-08
LSAALPHA
Sinus
Virus
Trainer
56-00
GENERAL
Required parts,
Reference
Push the windshield outwards and insert the top end of the
7 Figure 56-006
windshield support rod into its housing.
Fasten the bottom end of the windshield support rod and
8 the windshield edge to the airframe using a blind rivet
A4x16.
Figure 56-006
Windshield support rod housing
STRUCTURES
PAGE REV. 0 PAGE

56-09
57
Sinus
Virus
ALPHA Trainer
LSA
CHAPTER 57 – WINGS
TABLE OF CONTENTS

WINGS
57-00 57-03
General
WING STRUCTURE
ATTACH FITTINGS
57-40 57-07
Description
FLIGHT SURFACES
AIR BRAKES
PAGE PAGE REV. 0

57-02
LSAALPHA
Sinus
Virus
Trainer
57-00
GENERAL
57-00 GENERAL
The detachable wing is a single spar cantilever wing. The left and right wing are connected by
two pins through the spar ends. The wing structure is made mostly from CFRP, while the main spar
shear web and the root ribs are made from GFRP. This is for visual inspection and easier damage
detection reasons. The spar caps are produced using carbon roving. The wing spar is designed
as double T-type spar. Lateral loads and twisting moments are conventionally transferred to the
fuselage through root ribs and lateral-force bolts.
STRUCTURES
PAGE REV. 0 PAGE

57-03
Sinus
Virus
ALPHA Trainer
LSA
57-10
WING STRUCTURE
57-10 WING STRUCTURE

1. Description
The wing shell is designed as a 2-cell CFRP sandwich shell which is closed by a rear shear web
which the flaperons are attached to. The wings are fastened together the same way classic glid-
ers are - two spar ends connected with two spar pins. There is also a middle bolt which mates the
wings to the fuselage and provides torsional stiffness. The wing roots have pins that slide into
bushings in the fuselage and thus allow the wings to be easily positioned/fitted. Virus and Sinus
models have, on each wing, glider type mechanically operated air brakes installed and one (1) 30
liters/ 13.92 US Gal each (60 L/ 15.85 US Gal total capacity) or 50 liters/ 13.2 US Gal each (100 L/
26.4 US Gal total capacity) semi-integrated fuel tank made of GFRP. The fuel tank is coated with
alcohol resistant coating. Alpha trainer can be optionally equipped with electric airbrakes and the
single fuel tank is positioned in the fuselage, behind the cabin. ALPHA Trainer’s fuel capacity is 50
liters/ 13.2 US Gal.
CAUTION: Installing and removing the wings must carried out in a space where the temperature
is equal to or lower than 20°C (68°F), as temperature higher than this could make certain parts
very difficult to assemble.
57-10: 2.1. Wing structure
57-10: 2.1.1. Wing removal

NOTE: A minimum of three people are required to carry out this task.
Required parts,
Reference
1 Engage the parking brake. - Metric ratchet

and socket set
2 Place wheel chocks under main landing gear wheels. - T-handle hex
3 Remove white wing-fuselage joint seal. head screwdriver
set
4 Remove pitot tube. 34-10
Enter the cabin and disconnect all fuel lines (if applicable),
5
static/pitot lines and electrical cables from the wing roots.
6 Support each wing at the wingtip. Figure 57-001
7 Remove central wing spar bolt.
With both wings supported at their ends, remove the two
8
spar pins.
NOTE: Moving the wingtips up and down slightly makes spar pin
removal easier.
With one person at each end of the wing, slowly remove
9
one of the wings from the fuselage.
10 Place it in wing cart or on any dry, padded surface.
PAGE PAGE REV. 0

57-04
LSAALPHA
Sinus
Virus
Trainer
57-10
WING STRUCTURE
Required parts,
Reference
With one person at each end of the wing, slowly remove the
11
other wing from the fuselage.
12 Place it in wing cart or on any dry, padded surface.
13 Disengage parking brake.
15 Carry out visual inspection of the wings. 05-20
Figure 57-001
Support the wings
57-10: 2.1.2. Wing installation

Required parts,
Reference
Clean spar pins, wing positioning pins/bushings and wing - Metric ratchet
1 spar bushings with a piece of paper towel and lubricate and socket set, 12-20
them. - T-handle hex
head screwdriver
2 Engage the parking brake. set,
3 Place wheel chocks under main landing gear wheels. - Paper towel,
white wing-fuse-
Support one wing at both ends and slide its spar into the lage joint seal
fuselage. When the wing root is about 10 cm away from the (P/N 5230014)
STRUCTURES
fuselage all/any electrical cables and fuel lines through their
4 respective openings in the fuselage. Slide the wing into its
final position using the wing positioning pins as a guide.
Continue to support the wingtip as the spar rests against
the fuselage.
PAGE REV. 0 PAGE

57-05
Sinus
Virus
ALPHA Trainer
LSA
57-10
WING STRUCTURE
Required parts,
Reference
Support the other wing at both ends and slide its spar into
the fuselage. When the wing root is about 10 cm away from
the fuselage all/any electrical cables and fuel lines through
5 their respective openings in the fuselage. Slide the wing
into its final position using the wing positioning pins as a
guide. Continue to support the wingtip as the spar rests
against the fuselage.
CAUTION: While pushing the wings into their final position
make sure that the flaperon and air brake control controls have
engaged properly.
With the wings supported at their wingtips, slide the spar
6 pins through the wing spar bushings and fasten them in
place.
CAUTION: If at this point the spar pins are properly inserted and
the wings are secured, it is no longer necessary to support the
wingtips.
7 Install central spar bolt and fasten it in place.
8 Carry out operational check of the flaperon control system. 05-20
9 Carry out operational check of the air brakes (if applicable). 05-20
Connect all fuel lines (if applicable), electrical cables and
10
pitot/static lines.
CAUTION: The pitot and static lines are marked in the cabin and
on the lines themselves with a P and S respectively.
11 Install pitot tube.
12 Carry out operational check of the pitot tube. 05-20
13 Apply white wing-fuselage joint seal.

Required parts,
Reference
1 Remove the wings. - Metric ratchet 57-10: 2.1.

and socket set
2 Remove flaperons. - T-handle hex 57-10: 2.1.
Remove vented fuel cap and use borescope to carry out head screwdriver
3 an internal visual inspection of the fuel tanks. (Sinus/Virus set 05-20
only)
4 Install vented fuel cap. (Sinus/Virus only)
5 Remove wing access panel.
PAGE PAGE REV. 0

57-06
LSAALPHA
Sinus
Virus
Trainer
57-10
WING STRUCTURE
Required parts,
Reference
Use borescope to carry out visual inspection of wing’s in-

6 ternal structure and air brake drive mechanism (Sinus/Virus Table 12-002
only). Lubricate rod end bearings.
7 Install flaperons. 57-50: 2.3.
STRUCTURES
PAGE REV. 0 PAGE

57-07
Sinus
Virus
ALPHA Trainer
LSA
57-50
FLIGHT
SURFACES
57-50 FLIGHT SURFACES

1. Description
Roll is controlled using flaperons that are activated using pushrod mechanisms. A flap handle can
be found in the cabin that allows the pilot to symmetrically displace the flaperons. This chapter
describes the maintenance practices that apply to the apply to the flaperons.
57-50: 2.1. Flaperons
57-50: 2.1.1. Removal

Required parts,
Reference
1 Remove the wings. - Metric combina- 57-10

tion wrench set
2 Place the wing upside down on a dry, padded surface.
Locate the flange hinge opening closest to the wing root,
3 remove cotter pin and castellated nut securing the flaper-
on to the wing.
Slide the flaperon off its hinges by pushing it towards the
4
wing root.
5 Carry out visual inspection of the flaperon. 05-20

Required parts,
Reference
1 Remove the flaperon. - Paper towel, 57-50

- Phillips screw-
2 Visual inspection of flaperon seals. Replace if necessary. driver 57-50: 2.2.
Check flaperon and its hinge pins for any signs of damage,
3
wear or corrosion.
4 Clean hinge bushings and hinge pins with a paper towel.
Check that the hinge pins have not come loose by sliding
5
a screwdriver through them and applying a bit of torque.
6 Lubricate the hinge bushings and pins. 12-20
PAGE PAGE REV. 0

57-08
LSAALPHA
Sinus
Virus
Trainer
57-50
FLIGHT
SURFACES
Required parts,
Reference
Fit the flaperon to the wing by sliding its hinge pins into the - Metric combina-
1 tion wrench set,
hinge bushings on the wing.
- Loctite 243
2 Install castellated nut and cotter pin.
3 Carry out operational check of the flaperon. 05-20
CAUTION: After being installed the flaperon must move completely unhindered. If this is not the
case the castellated nut may have been tightened too much. If this is the case, unscrew the cas-
tellated nut a little, reinstall the cotter pin and carry out the operational check again.
57-50: 2.2. Flaperon seals
The gap between the wing and the flaperon is sealed to improve performances, control surface
effectiveness and to prevent any foreign objects from entering the area between the flaperon and
the wing. The sealing consists of a stripe of thin curved plastic material, applied externally along
the wing upper surface and covering the gap with the flaperon (see Figure 57-002).
STRUCTURES
Figure 57-002
External type
control surface sealing
PAGE REV. 0 PAGE

57-09
Sinus
Virus
ALPHA Trainer
LSA
57-50
FLIGHT
SURFACES
57-50: 2.2.1. Removal - Flaperon sealing
Required parts,
Reference
1 Remove the wings. - Plastic blade 57-10

- Acetone
2 Place a wing on a dry, padded surface. - cloth
Use a plastic filling blade to lift a corner of the sealing
3
starting from the wing root.
Peel off and remove the sealing from the wing together
4
with the cover tape.
5 Remove the adhesive tape from the wing surface.
Use a cloth and acetone to clean the wing surface from
6 05-20
adhesive remains.
7 Repeat the procedure for the other wing
57-50: 2.2.2. Installation - Flaperon sealing

Required parts,
Reference
1 Remove the wings. - Masking tape 57-10

- Cloth
2 Place a wing on a dry, padded surface. Upper side up. - Acetone
3 Clean the wing along the hinge line.
Apply the double-sided adhesive tape on the wing upper
surface, along and against the hinge line. The tape must
4
be applied on the wing, not on the flaperon. Do not re-
move the protective strip from the tape at this point.
Run a smooth object along the tape to improve the adhe-
5
Position the wing seal over the double-sided tape. Align
Figure 57-002
6 one edge of the seal with the edge of the double-sided
Figure 57-003
tape.
Fix temporarily the ends of the seal strip to the wing using
7
pieces of masking tape.
Starting from one end, lift locally the seal, remove the pro-
8 tective strip from the double-sided tape and stick carefully
the seal to the tape.
Continue the step 8 along the hinge line. Remove progres-
9 sively the protective strip and stick the seal starting from
an end of the strip to the other.
Run a smooth object along the seal to improve the adhe-
10
Position the cover tape on the wing, in the same position Figure 57-002
11
of the double-sided tape. Figure 57-003

PAGE PAGE REV. 0
57-10
LSAALPHA
Sinus
Virus
Trainer
57-50
FLIGHT
SURFACES
Required parts,
Reference
Fix temporarily the ends of the cover tape to the wing

12
using pieces of masking tape.
Starting from one end, remove progressively the protective
13
strip from the cover tape and stick it carefully to the seal.
Run a smooth object along the cover tape to improve the
14
adhesion, and to squeeze out any air bubbles.
15 Repeat the procedure on the other wing.
STRUCTURES
Figure 57-003
control surface sealing
component layers
PAGE REV. 0 PAGE

57-11
Sinus
Virus
ALPHA Trainer
LSA
57-70
AIR BRAKES
57-70 AIR BRAKES

1. Description (Sinus/Virus only)
A Schempp-Hirth Style air brake system is incorporated into the wings of Virus and Sinus aircraft
and is activated by a ceiling mounted pull-lever in the cabin. It’s control system consists of a push-
rod and bellcrank fitted into the wing just aft of the main spar near the root-rib, which convert rotary
motion, introduced by the aforementioned pull-lever, into translational motion required to open
and close the air brakes.
Figure 57-004
Air brakes and control system
PAGE PAGE REV. 0

57-12
LSAALPHA
Sinus
Virus
Trainer
57-70
AIR BRAKES
57-70: 2.1. Air brakes

Required parts,
Reference
Carry out operational inspection. Check for even and un-

1 57-70: 2.2.1.
hindered extraction/retraction. Adjust if necessary.
2 Remove wings. 57-10: 2.1.1.
4 Inspect paint marker on the air brake’s fastening material. 20-40: 2.1.
12-20 and
5 Clean and lubricate the air brake’s relief pins/bushings.
Figure 57-005
12-20 and
6 Lubricate the air brake’s rod end bearing.
Figure 57-006
7 Retract air brakes and install wings. 57-10: 2.1.2.
Figure 57-005
Air brake relief pins/bushings
STRUCTURES
Figure 57-006
Air brake rod end bearing
PAGE REV. 0 PAGE

57-13
Sinus
Virus
ALPHA Trainer
LSA
57-70
AIR BRAKES
57-70: 2.2. Air brake control system
57-70: 2.2.1. Extension adjustment

Required parts,
Reference
Lift the airbrake, unscrew and remove the bolt that con- - Wrench set
1 nects the inner (close to the wing root) drive rod to the - Paint marker
airbrake plate. - Loctite 243
Unscrew and remove the bolt attaching the activation rod-

2
end to the airbrake lever.
Unscrew the nut that secures the rod-end bearing and
3
adjust the lenght of the rod by rotating the bearing.
Re-connect the bearing to the airbrake lever. Apply Loctite
4
243 to the bolt.
Re-connect the inner drive rod to the airbrake plate. Apply
5
Loctite 243 to the bolt.
Check the movement of the airbrake. If it is not satisfactory
6 or equal to the other, repeat steps 1 to 5 until the move-
ment is equal for both the airbrakes.
7 Apply red marker paint to the nuts and bolt heads.
8 Check airbrake closing moment on both the airbrakes. 57-70: 2.2.2.
57-70: 2.2.2. Closing moment check

Required parts,
Reference
1 Remove wings. - Airbrake moment 57-70: 2.1.

measurement kit
2 Position the wings on a flat surface. (P/N 1190459)
Extract the air brake with the torque wrench and the air
3 Figure 57-007
brake coupling key.
Measure the torque required to retract (i.e. close) the air
4 brake completely. Adjust the closing moment if not within 57-70: 2.2.3.
the 8-10 Nm range.
5 Install wings. 57-10: 2.1.2.
PAGE PAGE REV. 0

57-14
LSAALPHA
Sinus
Virus
Trainer
57-70
AIR BRAKES
57-70: 2.2.3. Closing moment check/adjustment

Applicability SIN VIR VSW AT Qualification LSMR L1 LAME
Required parts,
Reference
1 Remove wings. - Wrench set 57-70: 2.1.

- Paint marker
2 Extract air brake. - Airbrake moment
Locate the pushrod end bearing and remove fastening measurement kit
3 (P/N 1190459) Figure 57-006
material.
- Loctite 243
4 Loosen its jam nut.
Increase the air brake’s closing moment by shortening the
pushrod (i.e. screwing the rod end bearing inwards). De-
5
crease the air brake’s closing moment by lengthening the
pushrod (i.e. unscrewing the rod end bearing).
6 Tighten the jam nut and check closing moment. 57-70: 2.2.2.
When satisfactory closing moment is attained, mark nut/
7
bearing with paint marker.
Fasten pushrod to air brake using new locknut. Apply
8
Loctite 243.
9 Retract air brake.
10 Install wings. 55-10: 2.1.2.
STRUCTURES
Figure 57-007
Closing moment test
PAGE REV. 0 PAGE

57-15
61
Sinus
Virus
ALPHA Trainer
LSA
CHAPTER 61 – PROPELLER
TABLE OF CONTENTS

PROPELLER
61-00 61-03
General
PROPELLER ASSEMBLY
PAGE PAGE REV. 0

61-02
LSAALPHA
Sinus
Virus
Trainer
61-00
GENERAL
61-00 GENERAL
The propeller installed on the aircraft depends on the type, country of registration and local regu-
lations.
Possibilities range from fixed pitch propeller like the FP02-80, typically installed on the ALPHA
Trainer, Vario-D with feathering option, or other variable pitch or constant speed propellers like
MT-Propeller or Woodcomp.
PROPELLER
PAGE REV. 0 PAGE

61-03
Sinus
Virus
ALPHA Trainer
LSA
61-10
PROPELLER
ASSEMBLY
61-10 PROPELLER ASSEMBLY

1. Description
Please refer to [2] for propeller description and information.
Please refer to [2] for maintenance documentation and information.
PAGE PAGE REV. 0

61-04
71
Sinus
Virus
ALPHA Trainer
LSA
CHAPTER 71 – POWER PLANT
TABLE OF CONTENTS

POWER PLANT
COWLINGS
MOUNTS
INDUCTION AIR INTAKES
ENGINE DRAINS
PAGE PAGE REV. 0

71-02
LSAALPHA
Sinus
Virus
Trainer
71-00
POWER PLANT
71-00 POWER PLANT

1. Description
This chapter covers all the maintenance practices involved with the following components: engine,
baffling, cowling, mount, attach fittings, electrical harnesses, air intake, and engine drains.
71-00: 2.1. Engine
Virus/Sinus/ALPHA Trainer aircraft are powered by a Rotax 912 four cylinder, normally aspirated air
& water cooled, engine.
iS injected Rotax engine is also available, for Virus/Sinus only.
Power rating is depending on the engine version installed.
Two power options are normally available: 58,8 kW (80 hp) and 73,5 kW (100 hp) (Sinus/Virus only).
(See Figure 71-001)
POWER PLANT
PAGE REV. 0 PAGE

71-03
Sinus
Virus
ALPHA Trainer
LSA
71-00
POWER PLANT
Figure 71-001
Rotax 912 Series drawing (courtesy of Rotax)
71-00: 2.2. Baffling
The baffling consists of a carbon composite air intake, a carbon composite diffuser and various
foam seals. The former two ensure that all ram air, needed to cool the engine, is uniformly dis-
tributed over the engine’s cylinders. The latter rest between the engine’s cowlings and various
components in the engine compartment, and ensure optimum airflow needed for oil/water cooling.
PAGE PAGE REV. 0

71-04
LSAALPHA
Sinus
Virus
Trainer
71-00
POWER PLANT

Example of upper oil cooler seal Example of ram cooling air intake
Figure 71-004 Figure 71-005 POWER PLANT

Example of lower oil cooler seal Example of water cooler seal
PAGE REV. 0 PAGE

71-05
Sinus
Virus
ALPHA Trainer
LSA
71-00
POWER PLANT
71-00: 3.1. Engine baffle foam seals
71-00: 3.1.1. Removal

Required parts,
Reference
1 Remove engine cowlings. - Silicone remover 71-10: 2.1.1.

(Non-agressive and sol-
Tear seal away by hand. Use box cutter if necessary, being vent-based),
2
careful not to damage the component the seal bonded to. - Box cutter
Apply some silicone remover to any residual silicone that
3
is difficult to remove.

Required parts,
Reference
Clean the surface with pure acetone and wait for the sur- - Silicone (neutral, perma-
1 nently elastic, one-com-
face to dry.
ponent, permanent ex-
2 Apply primer. posure 250°C, temporary
3 Remove protective foil from back of foam. exposure 300°C),
- Primer (3m 4297),
4 Apply foam. - Aceton (pure)
5 Seal gap between foam and component using silicone.

PAGE PAGE REV. 0

71-06
LSAALPHA
Sinus
Virus
Trainer
71-10
COWLINGS
71-10 COWLINGS
1. Description
The aircraft comes equipped with two tight-fitting, all-composite engine cowlings that protect the
engine and ensure superb engine cooling. They’re attached to the fuselage and to each other by
quick-release cowling fasteners that allow the user to install and remove them easily.
71-10: 2.1. Cowlings
71-10: 2.1.1. Removal
NOTE: Installing and removing the engine cowlings, although it can be done by one person alone,
is much easier to carry out with the help of someone else. This will also decrease the chances of
any components getting scratched or damaged.
Required parts,
Reference
Open the oil check door and disconnect the cold air - Flathead screw-
1 ventilation line from the upper cowling’s NACA inlet (if driver,
equipped). - T-handle hex-
head screwdriver
2 Unscrew all of the upper cowling’s quick-release fasteners. set
Remove the upper cowling and, while doing so, make sure
it’s front end doesn’t rub up against the spinner. Discon-
3
nect the ventilation tubing from the upper cowling inlet, if
present.
4 Locate the landing light cable and disconnect it.
Remove all of the bottom cowling’s M4 screw EXCEPT for
5
the last one at the top on each side.
6 Remove all of the bottom M4 screws. POWER PLANT
Remove the last two quick-release fasteners while simulta-
7
neously supporting the bottom cowling.
Slowly slide the bottom cowling down and out from under
the engine, while making sure it doesn’t rub up against
8
the spinner, exhaust tailpipes and/or the nose wheel strut
guard.
PAGE REV. 0 PAGE

71-07
Sinus
Virus
ALPHA Trainer
LSA
71-10
COWLINGS

Required parts,
Reference
Slowly slide the bottom cowling over the exhaust tailpipes - Flathead screw-
1 and up against the fuselage, while making sure it doesn’t driver,
rub up against the spinner. - T-handle hex-
head screwdriver
2 Fasten it to the fuselage using M4 screws. set
3 Locate and connect the landing light cable.
Secure the upper cowling to the lower cowling and the fu-
4 selage using quick-release fasteners. Connect the ventila-
tion tubing to the cowling inlet, if present.
Open the oil check door and connect the cold air ventilation
5
line to the upper cowling’s NACA inlet.
PAGE PAGE REV. 0

71-08
LSAALPHA
Sinus
Virus
Trainer
71-20
MOUNTS
71-20 MOUNTS
1. Description
The aircraft’s engine is attached to the airframe by several tubular steel weldments, one of which
incorporates four conventional elastomeric isolators for vibration damping. The engine mount is
bolted to the composite firewall in five locations. The firewall attachment points are structurally
reinforced with gusset-type attachments that transfer thrust and bending loads into the fuselage
shell.
71-20: 2.1. Engine mount/Mounting fixture/Lower engine block mount

Required parts,
Reference
1 Remove engine cowlings. - Torque wrench 71-10: 2.1.1.

Inspect entire mount for any signs of wear, such as cracks
and/or deformation. Particular attention needs to be paid to
2
the mount’s joints, where two tubes meet and are welded
together.
Inspect fastening material paint marker. Check if any bolts
3 20-30
have loosened. Verify torque using torque wrench.
71-20: 2.2. Vibration damping isolators

Applicability SIN VIR VSW AT Qualification O L1 P/O POWER PLANT
Required parts,
Reference
1 Remove engine cowlings. 71-10: 2.1.1.

Inspect isolators for any signs of wear, such as cracks, de-
2
formation, tears, etc. Replace if necessary.
PAGE REV. 0 PAGE

71-09
Sinus
Virus
ALPHA Trainer
LSA
71-20
MOUNTS
71-20: 2.2.2. Replacement

Required parts,
Reference
- Wrench set
- Torque wrench
- Red marker paint
2 Drain the liquid cooling system. 12-20: 2.3.1.
Remove the liquid cooler to access the area where the up-
3 75-20: 2.1.1.
per damping isolators are located.
Use workshop hydraulic crane and heavy duty nylon strap/
4 belt to support the engine, passing it below the shaft behind
the propeller flange.
Unfasten the two upper bolts that connect the mounting fix-
5
ture to the engine mount.
In case the liquid cooler hoses hinder the operation, remove
6 the screws from the clamps that hold the hose attached to
the engine mount and move the hoses.
7 Tilt slightly downwards the engine lowering the crane.
Remove the vibration damping isolators end caps, the bolt
8
guides, the rubber isolators and the bolts.
9 Replace the upper vibration damping isolators.
Reinstall the two upper bolts together with bold guides and
10
the end caps.
11 Fasten the two upper bolts to 24 Nm.
Fasten the cooling hoses to the engine mount using the
12
clamps.
13 Unfasten the two lower bolts.
14 Tilt slightly upwards the engine lifting the crane.

Remove the isolators end caps, the bolt guides, the rubber
15
isolators and the bolts.
16 Replace the lower vibration damping isolators.
Reinstall the two lower bolts together with bold guides and
17
the end caps.
18 Fasten the two lower bolts to 24 Nm.
19 Remove the nylon strap/belt.
20 Reinstall the water cooler. 75-20: 2.1.2.
21 Apply red marker paint on all the bolts and nuts.
PAGE PAGE REV. 0

71-10
LSAALPHA
Sinus
Virus
Trainer
71-60
INDUCTION
AIR INTAKES
71-60 INDUCTION AIR INTAKES

1. Description
Each of the engines carburetors is equipped with an air intake filter that ensures the induction air is
free of any foreign particles/debris. The induction air is pulled directly from behind the water cooler,
eliminating the need for any carb heat.
71-60: 2.1. Induction air filter
71-60: 2.1.1. Removal

Required parts,
Reference
1 Remove engine cowlings. - Flathead screwdriver 71-10: 2.1.1.

2 Loosen the hose clamp holding the air filter in place.
3 Remove air filter.
4 Cover carburetor intake with plastic cap.

Required parts,
Reference
1 Remove plastic cap from carburetor intake. - Flathead screwdriver
2 Slide air filter onto the carburetor intake’s flange.

3 Fasten in place by tightening hose clamp.
POWER PLANT
71-60: 2.1.3. Inspection/Cleaning
Reference: Rotax 912 maintenance manual, chapter 2.1 in 12-20-00
Required parts,
Reference
1 Remove engine cowlings. - Flathead screwdriver, 71-10: 2.1.1.

- K&N air filter cleaner,
2 Follow steps in the referenced manual. - K&N air filter oil,
3 Install engine cowlings. - Water 71-10: 2.1.2.
PAGE REV. 0 PAGE

71-11
Sinus
Virus
ALPHA Trainer
LSA
71-70
ENGINE DRAINS
71-70 ENGINE DRAINS

1. Description
The engine comes with a drip collector for each carburetor and an oil reservoir breather. The fol-
lowing chapter describes the maintenance practices that pertain to the aforementioned compo-
nents.
71-70: 2.1. Carburetor drip collector line
71-70: 2.1.1. Removal

Required parts,
Reference
1 Remove engine cowlings. - Cutting nippers 71-10: 2.1.1.

2 Cut all of the plastic ties holding the tube in place.
3 Remove the tube.
If replacing, measure the length of the tube as a reference
4
for the new tube.

Required parts,
Reference
1 Fit the tube to the drip collector’s hose fitting. - Cable tie gun,
- Pliers,
2 Run it down to the firewall’s bottom edge. - Cutting nippers
3 Fasten in place using cable ties.
4 Cut away excess cable tie ends.
PAGE PAGE REV. 0

71-12
LSAALPHA
Sinus
Virus
Trainer
71-70
ENGINE DRAINS

Required parts,
Reference

2 Check tube for any signs of damage and/or wear.
3 Check tube for any kinks.
Check that the tube is still firmly fastened in place by plastic
4
ties.
5 Make sure the tube’s opening is not blocked by anything.
71-70: 2.2. Oil reservoir breather line
71-70: 2.2.1. Removal

Required parts,
Reference
1 Remove engine cowlings. - Cutting nippers 71-10: 2.1.1.

2 Cut all of the plastic ties holding the tube in place.
3 Remove the tube.
If replacing, measure the length of the tube as a reference for the
4
new tube.

Required parts,
Reference
1 Fit the tube the oil reservoir’s breather fitting. - Cable tie gun,
- Pliers,
2 Run it down to the firewall’s bottom edge. - Cutting nippers
POWER PLANT
3 Fasten in place using cable ties.
4 Cut away excess cable tie ends.
PAGE REV. 0 PAGE

71-13
Sinus
Virus
ALPHA Trainer
LSA
71-70
ENGINE DRAINS

Required parts,
Reference

2 Check tube for any signs of damage and/or wear.
3 Check tube for any kinks.
4 Check that the tube is still firmly fastened in place by plastic ties.
5 Make sure the tube’s opening is not blocked by anything.
PAGE PAGE REV. 0

71-14
72
Sinus
Virus
ALPHA Trainer
LSA
CHAPTER 72 – ENGINE
TABLE OF CONTENTS
72-00 ENGINE 72-03
PAGE PAGE REV. 0

72-02
LSAALPHA
Sinus
Virus
Trainer
72-00
ENGINE
72-00 ENGINE
The Rotax 912 series engine is installed on the aircraft (see Figure 72-001 and Figure 72-002).
Please refer to the engine manufacturer’s documentation for detailed technical information about
all the engine types installed on Virus/Sinus/ALPHA trainer aircraft.
For information pertaining to this chapter such as maintenance practices, limits, and procedures
for teardown, cleaning, inspection, assembly, testing, etc., refer to the manufacturer’s approved
Instructions For Continued Airworthiness (Rotax 912 UL/ULS/iS Series Installation manual and Line
Maintenance Manual).
Please see Rotax documentation for engine specifications.
Figure 72-001
Rotax 912 UL/ULS
(Courtesy of Rotax GmbH)
POWER PLANT
PAGE REV. 0 PAGE

72-03
Sinus
Virus
ALPHA Trainer
LSA
72-00
ENGINE
Figure 72-002
Rotax 912 iS
(Courtesy of Rotax GmbH)
PAGE PAGE REV. 0

72-04
73
Sinus
Virus
ALPHA Trainer
LSA
CHAPTER 73 – ENGINE FUEL
TABLE OF CONTENTS

ENGINE FUEL
73-00 71-03
General
DISTRIBUTION
73-10 71-04
Description
INDICATING
PAGE PAGE REV. 0

73-02
LSAALPHA
Sinus
Virus
Trainer
73-00
GENERAL
73-00 GENERAL
This chapter describes the fuel system components integrated into the Rotax 912 series engine.
It also covers those components on the aircraft that measure fuel and air flow needed for proper
engine operation. Refer to chapter 28-00 for more data on the airplane fuel system.
POWER PLANT
PAGE REV. 0 PAGE

73-03
Sinus
Virus
ALPHA Trainer
LSA
73-10
DISTRIBUTION
73-10 DISTRIBUTION
1. Description
Figure 73-001 shows a diagram of the Rotax 912 UL/ULS fuel system. Gravity-fed fuel runs through
the mechanical fuel pump to the top of the engine where a distributor is located. This is where the
fuel is distributed to the carburetors. It’s also where the fuel pressure is measured. Any excess fuel
is returned to the collector tanks.
Figure 73-001
Rotax 912 fuel system
(courtesy of Rotax)
Induction air enters the engine compartment through the water cooler and is sucked through the
air filters into the carburetors, after which, the manifold pressure is measured.

PAGE PAGE REV. 0

73-04
LSAALPHA
Sinus
Virus
Trainer
73-10
DISTRIBUTION
Figure 73-002 shows a diagram of the Rotax 912 iS injected fuel system. Gravity-fed fuel runs
through the fuel pumps (main and aux) where pressure is increased for the injection of the fuel into
the engine.
POWER PLANT
Figure 73-002
Rotax 912 injected fuel system
(courtesy of Rotax)
PAGE REV. 0 PAGE

73-05
Sinus
Virus
ALPHA Trainer
LSA
73-30
INDICATING
73-30 INDICATING
1. Description
The feed fuel line can be equipped with a fuel flow sensor that provides the pilot with accurate fuel
consumption reading. The manifold pressure is measured using a sensor that is fastened to the
engine mount. The fuel pressure is also measured by a sensor screwed into the fuel distributor.
See chapter 28 for more information about the fuel system. Sensor presence may vary upon indi-
vidual aircraft equipment.
73-30: 2.1. Fuel flow sensor
73-30: 2.1.1. Removal

Required parts,
Reference
1 Drain the fuel system. - Flathead screwdriver, 12-20

- 3 mm T-handle hex-head
2 Remove the engine cowlings. screwdriver,
Locate the fuel flow sensor positioned on the port side of - 2.5 mm Allen key,
3 - Cutting nippers,
the engine.
- Side jaw ear clamp pin-
4 Disconnect the fuel flow sensors cable. cers
Loosen/remove the hose clamps holding both the inlet and
5
outlet fuel lines to the fuel flow sensor fittings.
6 Remove the fuel flow sensor.

Required parts,
Reference
Connect the fuel line coming from the fuel divider to the - Flathead screwdriver,
1 - 3 mm T-handle hex-head
inlet fitting of the fuel sensor.
screwdriver,
2 Secure the fuel line fastening the hose clamp. - 2.5 mm Allen key,
CAUTION: When reinstalling the fuel flow sensor be sure to po- - Liquid paint marker,
sition it properly. An arrow on the side of it’s housing shows the - Side jaw ear clamp
pincers
flow direction. 2
Connect to the outlet fitting of the flow sensor the fuel
3
lineing to the carburetor.
4 Secure the fuel line fastening the hose clamp.
5 Apply paint marker to the hose clamp screws.
6 Connect the fuel flow sensor’s cable.
12-10 and
7 Replenish the fuel system and carry out visual inspection.
05-20
PAGE PAGE REV. 0

73-06
LSAALPHA
Sinus
Virus
Trainer
73-30
INDICATING
73-30: 2.2. Fuel pressure sensor
73-30: 2.2.1. Removal

Required parts,
Reference
1 Remove engine cowlings. - Metric wrench set 71-10: 2.1.1.

2 Locate the fuel pressure sensor.
3 Remove the fuel pressure sensor by unscrewing it.
4 Disconnect it from its instrument/connector.
6 Carry out visual inspection of sensor. 05-20

Required parts,
Reference
1 Remove engine cowlings. - Metric wrench set, 71-10: 2.1.1.

- Loctite 577
2 Apply Loctite 577 to sensor thread.
3 Install sensor into fuel distributor and tighten.
4 Connect it to its instrument/connector.
6 Carry out functional inspection of fuel pressure sensor. 05-20
POWER PLANT
PAGE REV. 0 PAGE

73-07
75
Sinus
Virus
ALPHA Trainer
LSA
CHAPTER 75 – ENGINE COOLING
TABLE OF CONTENTS

ENGINE COOLING
75-00 75-03
General
AIR COOLING
LIQUID COOLING
PAGE PAGE REV. 0

75-02
LSAALPHA
Sinus
Virus
Trainer
75-00
GENERAL
75-00 GENERAL
This chapter describes the engine cooling system incorporated into the aircraft and the mainte-
nance practices that pertain to it.
POWER PLANT
PAGE REV. 0 PAGE

75-03
Sinus
Virus
ALPHA Trainer
LSA
75-10
AIR COOLING
75-10 AIR COOLING

1. Description
The Rotax engine is equipped with a carbon-composite diffuser and inlet that direct all cooling air
over the engine cylinders (see Figure 75-001). The diffuser’s inlet is coupled with a hole in the en-
gine cowlings on the starboard side.
Figure 75-001
Engine cooling air diffuser
The carbon-composite diffuser doesn’t require any maintenance and/or servicing. Refer to chapter
71-00 for more information about the maintenance practices that pertain to the foam seal that rests
between the diffuser and the engine cowlings.
PAGE PAGE REV. 0

75-04
LSAALPHA
Sinus
Virus
Trainer
75-20
LIQUID COOLING
75-20 LIQUID COOLING

1. Description
The Rotax engine is both air and liquid cooled. The liquid cooling system consists of a cooler that
receives ram air, an engine-driven mechanical pump and an overflow bottle (see Figure 75-002).
For more information about approved operating fluids, including the engine coolant, please refer
to the latest revision of ROTAX Service Instruction No. SI-912-016 Selection of Suitable Operating
Fluids for Rotax® Engine Type 912 I, 912 and 914 Series.
POWER PLANT
Figure 75-002
Engine liquid cooling system
PAGE REV. 0 PAGE

75-05
Sinus
Virus
ALPHA Trainer
LSA
75-20
LIQUID COOLING
For information about how to replenish the liquid cooling system please refer to chapter 12-00.
For additional maintenance practices information about the engines liquid cooling system please
refer to the latest revision of ROTAX’s maintenance manual.
75-20: 2.1.1. Water cooler removal

Required parts,
Reference
Drain the cooling system. - Metric wrench set

1 12-20: 2.3.1.
Cut the cable tie securing the silicon breather tube to the fitting
2
near the water cooler cap.
3 Disconnect the silicon breather tube from the fitting.
Loosen the hose clamp securing the feed and return hoses to the
4
water cooler.
5 Disconnect the hoses from the cooler.
6 Remove the bolts securing the water cooler to its mount.
7 Remove the water cooler.
75-20: 2.1.2. Water cooler installation

Required parts,
Reference
1 Fasten the water cooler to its mount. Apply Loctite 243 to the bolts. - Metric wrench set
- Red marker paint
Secure the feed and return hoses to the water cooler using hose - Loctite 243
2
clamps.
3 Apply paint marker to the bolts.
4 Secure the hoses to the engine mount using plastic ties.
Reconnect the silicone breather tube to the fitting near the water
5
cooler cap.
6 Secure the silicone breather tube using a plastic tie.
Replenish the system with coolant.
7 12-10: 2.3.1.
PAGE PAGE REV. 0

75-06
LSAALPHA
Sinus
Virus
Trainer
75-20
LIQUID COOLING
75-20: 2.1.3. Water expansion tank removal

Required parts,
Reference
- Allen key set

1 Drain the cooling system.
- Nippers
12-20: 2.3.1.
Cut the cable tie securing the breather tube to the fitting near the
2
water cooler cap.
3 Disconnect the silicon breather tube from the fitting.
Remove the retainer securing the expansion tank to the hose
4
clamps on the engine mount .
5 Remove the expansion tank.
75-20: 2.1.4. Water expansion tank installation

Required parts,
Reference
Fasten the water expansion tank to the clamps on the engine - Allen key set
1 - Red marker paint
mount. Apply Loctite 243 to the bolts.
- Loctite 243
Connect the breather tube to the fitting positioned near water cool-
2
er cap.
3 Secure the breather tube using a cable tie.
4 Apply paint marker to the bolts.
Replenish the system with coolant.
5 12-10: 2.3.1.
POWER PLANT
PAGE REV. 0 PAGE

75-07
76
Sinus
Virus
ALPHA Trainer
LSA
CHAPTER 76 – ENGINE CONTROLS
TABLE OF CONTENTS

ENGINE CONTROLS
General
76-00 76-03
Description
PAGE PAGE REV. 0

76-02
LSAALPHA
Sinus
Virus
Trainer
76-00
GENERAL
76-00 GENERAL
1. Description
This chapter describes the engine control assembly, the system that the pilot uses to operate the
engine. Incorporating a standard control quadrant design, the engine control system consists of a
single-lever power (throttle) control and a choke lever. The throttle lever controls the throttle valve
in the carburetor, by two separate Bowden type cables working synchronously. The choke lever
actuates the choke shaft of both carburetors synchronously, which provides assistance with cold
starts. The levers are easily accessible to both pilots, as their housing is fastened to the cabin floor
between the two crew seats (see Figure 76-001). All Bowden cables run from the control quadrant
under the cabin floor, up through the instrument panel, through firewall grommets and to the car-
buretor control levers.
POWER PLANT
Figure 76-001
Example of engine control quadrant (throttle and choke)
PAGE REV. 0 PAGE

76-03
Sinus
Virus
ALPHA Trainer
LSA
76-00
GENERAL
76-00: 2.1. Engine control cables
CAUTION: The joints where the engine control cables are attached to their respective control
levers in the engine compartment must be lubricated on a regular basis (see 12-20).

Required parts,
Reference
1 Remove the engine cowlings. - Phillips screw- 71-10: 2.1.1.

driver,
2 Carry out visual inspection of the engine control cables. - T-handle hex head 05-20
3 Clean joints between control cables and levers. screwdriver set
4 Lubricate joints between control cables and levers. 12-20

5 Carry out operational inspection of the engine control cables. 05-20
6 Remove control stick boots. 25-10: 2.3.1.
Carry out visual inspection of the engine control cables under the
7 05-20
cabin floor.
8 Remove instrument panel cover. 31-10
Carry out visual inspection of the engine control cables behind
9 05-20
the instrument panel.
CAUTION: The engine control cables must be kept in good working condition. Any wear or
damaged incurred could lead to loss of engine control and consequently a safety hazard. Attend
to and amend any issues immediately after noticing them.
76-00: 2.2. Engine control levers

Required parts,
Reference
1 Carry out visual inspection of the engine control cables.

05-20
2 Carry out operational inspection of the engine control cables.
PAGE PAGE REV. 0

76-04
LSAALPHA
Sinus
Virus
Trainer
76-00
GENERAL
76-00: 2.2.2. Movement friction adjustment

Required parts,
Reference
1 Remove the decorative nut cap. - Flathead screwdriver

- Metric wrench set
Tighten or loosen friction adjustment nut depending on wheth-
2
er the levers movement is too slack or too stiff.
CAUTION: The engine control cables are attached to spring-loaded levers at the carburetors. If
any of the control quadrant levers shift towards the full-forward position by themselves this means
the friction adjustment nut needs to be adjusted for stiffer movement.
POWER PLANT
PAGE REV. 0 PAGE

76-05
77
Sinus
Virus
ALPHA Trainer
LSA
CHAPTER 77 – ENGINE INDICATING
TABLE OF CONTENTS

ENGINE INDICATING
77-00 77-03
General
POWER
TEMPERATURE
PAGE PAGE REV. 0

77-02
LSAALPHA
Sinus
Virus
Trainer
77-00
GENERAL
77-00 GENERAL
This chapter describes the various sensors installed on the aircraft that provide the pilot with en-
gine power and temperature information. All of the data supplied by these sensors is displayed on
the PFD/MFD.
POWER PLANT
PAGE REV. 0 PAGE

77-03
Sinus
Virus
ALPHA Trainer
LSA
77-10
POWER
77-10 POWER
1. Description
RPM on the aircraft’s engine is measured via ignition system pulses. There is no remote tachom-
eter. The PFD presents manifold pressure and RPM the upper left area of the display in horizontal
tape format and beside it as text.
The manifold pressure reading is taken from the compensating tube assembly between the two
intake manifolds and measured by a sensor installed on the engine mount (see Figure 77-001).
Figure 77-001
Manifold pressure sensor installation
PAGE PAGE REV. 0

77-04
LSAALPHA
Sinus
Virus
Trainer
77-10
POWER
CAUTION: When removing any sensors in the engine compartment be sure insulate/plug any
and all openings in order prevent the ingression of dirt or debris.
77-10: 2.1. Manifold pressure sensor
77-10: 2.1.1. Removal

Required parts,
Reference
1 Remove the engine cowlings. - T-handle ball head 71-10: 2.1.1.

screwdriver set,
2 Locate the starboard firewall connector. - Cutting nippers
3 Extract the manifold pressure sensor pins. - metric wrench set, Figure 77-001
- Pin extraction tools
Cut/remove all the zip ties securing the sensor’s cable in (M81969/17-03 and
4
place. M81969/17-04)
5 Locate the barbed fitting the sensor is fastened to.
6 Remove the hose clamp securing it.
7 Unscrew/remove the sensor.
8 Carry out visual inspection of the sensor. 05-20

Required parts,
Reference
1 Apply Loctite 577 to the sensors thread. - T-handle ball head

screwdriver set,
2 Install the sensor in the barbed fitting. - Metric wrench set, 20-40
3 Fasten the barbed fitting in place. - Loctite 577,
- Pin insertion tools
4 Torque mark the hose clamps bolt. (M81969/19-01 and
5 Run the sensors cable to the starboard firewall connector. M81969/19-01) POWER PLANT
6 Fasten it in place using zip ties.
7 Insert the sensors pins.
8 Carry out operational inspection of the sensor. 05-20
PAGE REV. 0 PAGE

77-05
Sinus
Virus
ALPHA Trainer
LSA
77-20
TEMPERATURE
77-20 TEMPERATURE
1. Description
Four exhaust gas temperature (EGT) sensors are installed on the aircraft, one for each cylinder.
They are fastened to a port in the exhaust headers, just downstream from where the gases exit the
cylinders (see Figure 77-002).
Two coolant temperature (CT) sensors are installed, one for cylinder #2 and one for cylinder #3
(see Figure 77-003). The former is designated as CT1 in the PFD/MFD and the latter as CT2. These
sensors provide the pilot with temperature data of the coolant running through the cylinder heads
during operation.
Figure 77-002
EGT sensor installation
PAGE PAGE REV. 0

77-06
LSAALPHA
Sinus
Virus
Trainer
77-20
TEMPERATURE
Figure 77-003
CT sensor installation
CAUTION: When removing any sensors in the engine compartment be sure insulate/plug any
and all openings in order prevent the ingression of dirt or debris
77-20: 2.1. EGT sensor
77-20: 2.1.1. Removal

Required parts,
Reference
1 Remove the engine cowlings. - Cutting nippers, 71-10: 2.1.1.

POWER PLANT
- Metric wrench set,
2 Locate the starboard firewall connector. - Pin extraction
3 Extract the EGT sensor pins. tools (M81969/17-
03 and M81969/17-
4 Cut/remove all the zip ties securing the sensor’s cable in place. 04)
5 Locate the EGT sensor.
6 Unscrew/remove the sensor.
7 Carry out visual inspection of the EGT sensor. 05-20
PAGE REV. 0 PAGE

77-07
78
Sinus
Virus
ALPHA Trainer
LSA
CHAPTER 78 – EXHAUST
TABLE OF CONTENTS

EXHAUST
78-00 78-03
General
COLLECTOR
NOISE SUPPRESSOR
PAGE PAGE REV. 0

78-02
LSAALPHA
Sinus
Virus
Trainer
78-00
GENERAL
78-00 GENERAL
PIpistrel Virus/Sinus/ALPHA Trainer LSA aircraft are equipped with an exhaust system that expels
exhaust gases from the aircraft via a single or double tail pipe that protrudes out of the bottom
surface of the lower engine cowling.
The engine exhaust system consists of exhaust headers, Y-pipe collectors, an exhaust muffler with
integrated tailpipe and associated joints/fasteners.
Each engine cylinder, on port and starboard side of the engine, is equipped with an exhaust header
that leads down to a Y collector that joins the two. The exhaust gases then leave the Y-collector
and enter the exhaust muffler, finally exiting the exhaust system via the tailpipes.
Joints are employed to allow movement due to heat expansion and normal operating loads at the
pipes connections.
Three different systems can be found in LSA aircraft: standard Pipistrel exhaust system (Figure 78-
001), Akrapovič single tail pipe (Figure 78-002) and Akrapovič double tailpipe (Figure 78-003). The
latter two are titanium made.
POWER PLANT
PAGE REV. 0 PAGE

78-03
Sinus
Virus
ALPHA Trainer
LSA
77-00
GENERAL
Figure 78-001
Standard Pipistrel
steel exhaust system
Figure 78-002
Akrapovič single tail pipe
titanium exhaust system
Figure 78-003
Akrapovič double tail pipe
titanium exhaust system
PAGE PAGE REV. 0

78-04
LSAALPHA
Sinus
Virus
Trainer
78-00
COLLECTOR
78-10 COLLECTOR
1. Description
This chapter describes the portion of the exhaust system which collects the exhaust gases from
the cylinder and dumps them overboard. Exhaust headers and collector weldments combine to
form the exhaust header assemblies.
Each of the four headers are connected to the engine by nuts screwed onto threaded studs. The
two headers on each side of the engine are connected to a Y-pipe collector weldment through a
slip joint and a spring to allow for contraction and expansion as well as engine movement. This
Y-pipe collector combines the 2 header pipes on each side of the engine into one pipe (per side).
A slip joint connects the Y-pipe collectors which takes the exhaust gas across to the LH
and RH side of the engine and then aft to the exhaust muffler with or without built-in heat
exchanger. Slip joints are employed to allow movement due to heat expansion and normal oper-
ating loads. See Figure 78-001, Figure 78-002 and Figure 78-003.
78-00: 2.1. Tailpipes
Tailpipes are removable from the muffler only in Akrapovič double tail pipe exhaust system (Figure
78-003).
78-00: 2.1.1. Removal (Akrapovič double tail pipe system only)

Required parts,
Reference
1 Remove engine cowlings. -T-handle ball-end- 71-10: 2.1.1.

ed hex screwdriver
2 Cut/remove safety wire. set,
3 Loosen the tailpipe clamp. - Cutting nippers POWER PLANT
4 Slide tailpipe out of muffler.
Carry out visual inspection. Replace any components if deemed
5 05-20
necessary.
PAGE REV. 0 PAGE

78-05
Sinus
Virus
ALPHA Trainer
LSA
78-00
COLLECTOR
78-00: 2.1.2. Installation (Akrapovič double tail pipe system only)

Required parts,
Reference
Clean tailpipe mating surface with paper towel so that it’s free - T-handle ball-ended
1 hex screwdriver set,
of all grease/anti-seize residue and burrs.
- Ceramic anti-seize
Apply a thin layer of ceramic anti-size grease to the tailpipe’s grease (Akrapovič),
2
mating surface. - Copper anti-seize
3 Slide tailpipe into muffler’s mating joint. grease (Akrapovič),
- Exhaust spring
Position tailpipe so that it makes a 45° (approx.) angle with the puller,
4
aircrafts horizontal axis. - Paper towel
5 Apply copper anti-seize grease to the clamps bolt and tighten it.
6 Positive lock the tailpipe using safety wire and swage sleeves.
NOTE: Reset the angle of the tailpipe if installing the engine cowlings proves to be difficult.
78-00: 2.2. Headers and Y-collector
78-00: 2.2.1. Removal

Required parts,
Reference
1 Remove engine cowlings. - T-handle ball-ended 71-10: 2.1.1.

hex screwdriver set,
2 Remove upper two Y-collector springs. - Metric wrench set,
3 Remove the EGT sensor from the fore exhaust header. - Phillips screwdriver, 77-20
- Exhaust spring puller
4 Remove the fore exhaust header nuts.
5 Remove the fore exhaust header.
6 Loosen carburetor clamp.
Remove both hex head bolts holding the carburetor drip col-
7
lector in place.
Shift the carburetor assembly backwards so that the aft ex-
8
haust header can be accessed.
9 Remove the EGT sensor from the aft exhaust header. 77-20
10 Remove the aft exhaust header nuts.
11 Remove the aft exhaust header.
12 Remove lower two Y-collector springs.
13 Remove Y-collector.
Carry out visual inspection of all components. Replace any if
14 05-20
deemed necessary.
PAGE PAGE REV. 0

78-06
LSAALPHA
Sinus
Virus
Trainer
78-00
COLLECTOR

Required parts,
Reference
Clean all mating surfaces with paper towel so that they’re free - T-handle ball-ended
1 hex screwdriver set,
of all grease/anti-seize residue and burrs.
Apply a thin layer of ceramic anti-size grease to all mating grease (Akrapovič)
2
surfaces. - Copper anti-seize
NOTE: use Loctite LB8150 anti-seize only on standard steel exhaust grease (Akrapovič)
system (Figure 78-001). - Loctite LB8150 an-
ti-seize
Slide Y-collector into muffler’s mating joint and fasten in place - Paper towel
3
using exhaust springs.
4 Install EGT sensor. 77-20
5 Slide aft header onto engine studs and Y-collector.
Apply copper anti-seize grease to header nuts and install
6
finger tight.
NOTE: use Loctite LB8150 anti-seize only on standard steel exhaust
system (Figure 78-001).
7 Fasten aft header to Y-collector using exhaust spring.
8 Reattach carburetor assembly to engine.
9 Install EGT sensor. 77-20
10 Slide fore header onto engine studs and Y-collector.
Apply copper anti-seize grease to header nuts and install
11
finger tight.
12 Fasten fore header to Y-collector using exhaust spring.
13 Torque header nuts. 20-30
14 Reinstall the carburetors and fasten the carburetor clamps
POWER PLANT
PAGE REV. 0 PAGE

78-07
Sinus
Virus
ALPHA Trainer
LSA
78-20
NOISE SUPPRESSOR
78-20 NOISE SUPPRESSOR

1. Description
The exhaust system incorporates a muffler that suppresses all/any noise the system generates
and dumps all exhaust gases overboard. It’s attached to the engine block by one or two brackets
and attached to the exhaust collector/headers by a slip joint. The muffler also comes optionally
with a heat exchanger or “heat muff” that provides hot air for cabin heat purposes.
78-20: 2.1. Muffler
78-20: 2.1.1. Removal

Required parts,
Reference
1 Remove engine cowlings. - T-handle ball-end- 71-10: 2.1.1.

ed hex screwdriver
2 Disconnect scat ducting from heat muff. set,
3 Remove collectors/headers. - Flathead screw- 78-10
driver
Unscrew the two bolts securing the muffler to its support brack-
4
ets.
5 Remove muffler.
78-20: 2.1.2. Heat muff disassembly (if applicable)

Required parts,
Reference
1 Loosen clamps and remove heat muff. - Phillips screw-

driver
78-20: 2.1.3. Heat muff assembly (if applicable)

Required parts,
Reference
1 Position heat muff on muffler and fasten it in place using clamps. - Phillips screw-
driver
Carry out visual inspection to make sure the muff is firmly fas-
2 05-20
tened to the muffler.
PAGE PAGE REV. 0

78-08
LSAALPHA
Sinus
Virus
Trainer
78-20
NOISE SUPPRESSOR

Required parts,
Reference
1 Remove the muffler.

78-20
2 Disassemble the heat muff.
Conduct visual inspection. Check all seams and welds for signs of
3 05-20
wear or damage.
Shake the muffler and listen for a clinking noise. Any loose debris
4 in the muffler indicates that the muffler has incurred internal dam-
age.
WARNING: Any serious exhaust system damage is a safety hazard and must be repaired im-
mediately.

Required parts,
Reference
Clean all of the muffler’s mating surfaces with paper towel so that - T-handle ball-end-
1 it’s free of all grease/anti-seize residue and burrs. Do the same for ed hex screwdriver 71-10
the two hex head bolts. set,
Apply copper anti-seize grease to the muffler’s fastening bolts grease (Akrapovič)
2
and install to finger tight. - Copper anti-seize
NOTE: use Loctite LB8150 anti-seize only on standard steel exhaust sys- grease (Akrapovič)
- Loctite LB8150
tem (Figure 78-001).
anti-seize
Apply a thin layer of ceramic anti-seize grease to the muffler’s - Exhaust spring
3
mating surfaces. puller,
- Paper towel
NOTE: use Loctite LB8150 anti-seize only on standard steel exhaust sys-
tem (Figure 78-001).
4 Install collectors/headers. 78-10
5 Connect scat ducting to heat muff.
POWER PLANT
PAGE REV. 0 PAGE

78-09
95
Sinus
Virus
ALPHA Trainer
LSA
CHAPTER 95 – SPECIAL PURPOSE EQUIPMENT
TABLE OF CONTENTS

SPECIAL PURPOSE EQUIPMENT
General
95-00 95-03
Description
PAGE PAGE REV. 0

95-02
LSAALPHA
Sinus
Virus
Trainer
95-00
GENERAL
95-00 GENERAL
1. Description
This chapter describes the special purpose equipment on the aircraft. It covers the Galaxy Rescue
System GRS 6/600 SD SPEEDY, installed as serial equipment. The system is not accounted for in
the sense of “alternative level of safety”. It is considered a true “second chance” beyond what is
required by the certification standard.
The system is placed inside a durable cylinder mounted on the right hand side of the baggage
compartment. The parachute, which is stored inside a deployment bag with a rocket engine un-
derneath, is installed in the aforementioned cylinder. Its brand new design presents a canopy that
safely opens after 0,4 to 0,7 seconds in distance of 15-18 meters above the aircraft. It is launched
in a special deployment bag, which decreases the risk of aircraft debris breaching the canopy. The
parachute rescue system is activated manually, by pulling the activation handle mounted on the
cabin bulkhead. After being activated, the main canopy opens and fully inflates within 3,2 seconds.
WARNING! The activation handle safety pin should be inserted when the aircraft is parked or
hangared to prevent accidental deployment. The safety pin MUST be removed before operating
the aircraft.
OTHER
PAGE REV. 0 PAGE

95-03
Sinus
Virus
ALPHA Trainer
LSA
95-00
GENERAL
Figure 95-001
GRS rocket charged parachute
rescue system
1 Carbiner 5 Container cover mask

2 Kevlar belt 6 Adhesive label
3 GRS Rescue system GRS 6-600 7 Parachute container assembly
4 Rocket blast tube 8 Parachute release handle fastening material
PAGE PAGE REV. 0

95-04
LSAALPHA
Sinus
Virus
Trainer
95-00
GENERAL
WARNING: The rescue system incorporates a ballistic rocket that can cause serious injuries
and bodily harm if not dealt with carefully.
WARNING: DO NOT, IN ANY CIRCUMSTANCES, ACTIVATE THE RESCUE SYSTEM ON THE

GROUND. People in the vicinity of the aircraft may be injured and the aircraft will be rendered
out of service until repaired.
WARNING: Operating the aircraft is NOT PERMITTED if the rescue system is not in good work-
ing condition (i.e. functional). The aircraft is NOT AIRWORTHY if the rescue system is inopera-
tive.
95-00: 2.1. Activation handle

Required parts,
Reference
1 Locate the activation handle in the cabin.

2 Carry out visual inspection of the handle. 05-20
Remove the safety pin. Rotate the handle to determine
whether it moves unhindered and hasn’t incurred any dam-
3
age. DO NOT PULL THE HANDLE! JUST LEAVE IT IN ITS
HOUSING AND ROTATE IT.
4 Install the safety pin.
95-00: 2.2. Rescue system hatch

Required parts,
Reference
Locate the rescue system hatch on the top of the fuselage,

1
just behind the sunroof.
Carry out visual inspection of the rescue system hatch.
2 05-20
Make sure it’s not obstructed by anything.
OTHER
PAGE REV. 0 PAGE

95-05
Sinus
Virus
ALPHA Trainer
LSA
95-00
GENERAL
95-00: 2.3. Rocket exhaust hatch

Required parts,
Reference
Locate the rocket exhaust hatch on the bottom of the fuse-

1
lage, marked by a dedicated placard and a red circle.
WARNING: The rescue system must be repacked every 6 years and replaced every 30. The
repacking date is indicated on the parachute canister. REMOVAL AND INSTALLATION MUST
BE CARRIED OUT FOLLOWING PIPISTREL’S INSTRUCTIONS AND ONLY BY A CERTIFIED AVI-
ATION MECHANIC. ONLY GALAXY HOLDING s.r.o. IS PERMITTED TO REPACK THE RESCUE
SYSTEM. ONCE THE SYSTEM IS REMOVED FROM THE AIRCRAFT, IT IS THE OWNER/OPERA-
TOR’S RESPONSIBILITY TO CONTACT GALAXY HOLDING s.r.o. AND ARRANGE FOR IT TO BE
REPACKED OR REPLACED.
To get the rescue system repacked, please contact:
GALAXY HOLDING s.r.o.

Třída 1. máje 24a
460 01 Liberec 3
Czech Republic
tel./fax: ++420 48 510 44 92
mobile: ++420 777 55 00 91
NOTE: Refer to PI-121-25-61-002_A00 Parachute Repacking Instructions
To get the rescue system replaced, please contact:
PIPISTREL d.o.o.
GORIŠKA CESTA 50a
SI-5270 AJDOVŠČINA
SLOVENIA
tel.: +386 5 36 63 873
fax.: +386 5 36 61 263
NOTE: Refer to PI-121-25-61-001_A02 Parachute Installation Manual
PAGE PAGE REV. 0

95-06
99
Sinus
Virus
ALPHA Trainer
LSA
CHAPTER 99 – APPENDICES
TABLE OF CONTENTS
APPENDIX SUBJECT PAGE NUMBER

APPENDIX 99-A ASTM F2483 CROSS-REFERENCE CHART 99-03
APPENDIX 99-B FAULT-MALFUNCTION REPORT (FDO-0010-342) 99-05
APPENDIX 99-C VENT/DRAIN HOLE LOCATIONS 99-09
APPENDIX 99-D LSA MRA (Major Repair and Alterations) 99-11
PAGE PAGE REV. 0

99-02
APPENDIX 99-A
Sinus
Virus
ALPHA Trainer
LSA
APPENDIX 99-A
ASTM F2483-12 CROSS-REFERENCE CHART
CORRESPONDING CHAPTER
ASTM F2483-12
IN THIS MANUAL
5.1.1.1 TBD - POH
5.1.1.2 TBD
5.1.1.3 12-40
5.1.1.4 72-00
5.1.1.5 08-10, 08-20
5.1.1.6 12-10
5.1.1.7 12-10
5.1.1.8 20-30
5.1.1.9 INTRO, 04-00, 05-00, 20-00
5.1.1.10 Appendix 99-B
5.1.2 05-00
5.1.3.1 51-00, 57-00
5.1.3.2 51-00, 55-00
5.1.3.3 32-00
5.1.3.4 51-00, 55-00
5.1.4 72-00
5.1.5 28-00
5.1.6 61-00
5.1.7 21-00
5.1.8 31-00, 34-00
5.1.10 51-00
5.1.11 04-00
5.1.12 INTRO
5.1.13 Appendix 99-B
PAGE PAGE REV. 0

99-04
APPENDIX 99-B
Sinus
Virus
ALPHA Trainer
LSA
APPENDIX 99-B
Pipistrel
Mail: [email protected]
Fax-No.: +386-5-366 1263
In case of many malfunction or severe occurrences:

Pipistrel phone-No. +386-5-365 8160, at sun- and holidays: 00386-5-366 1263
Owner/user/holder:
Address: Present position of aircraft:
Phone:
Fax:
e-mail:
A/C Registration: A/C Serial-No.:

When / where did the malfunction happened?
Date: Location:
Description of the malfunction:
Date: Time: Location:
Failure description (photos, sketches):
PAGE PAGE REV. 0

99-06
LSAALPHA
Sinus
Virus
Trainer APPENDIX 99-B
The Occurrence after malfunction induced to:
Accident with Personal injury Damage to property
Was the occurrence reported to local aviation authority/ accident investigation branch?
YES NO
Is the aircraft still in operation?
YES NO Restricted
Unsafe condition:
Did warning / safety-systems function properly?
YES NO
Immediate action (if required):
Internal distribution: HOA HDO
Date: Head of Airworthiness:
PAGE REV. 0 PAGE

99-07
APPENDIX 99-C
Sinus
Virus
ALPHA Trainer
LSA
APPENDIX 99-C
VENT/DRAIN HOLE LOCATIONS
1. Two on the bottom surface of the wing at the wing root

2. One at each end of the air brake bay
3. One at each end of the flaperons
4. One at the bottom of the rudder
5. One near the horizontal stabilizer’s hinges
6. One on the elevator
7. One on the bottom surface of the fuselage just aft of the undercarriage strut
8. One on the bottom surface of the fuselage near the control sticks
PAGE PAGE REV. 0

99-10
APPENDIX 99-D
Sinus
Virus
ALPHA Trainer
LSA
APPENDIX 99-D
LSA MRA (Major Repair and Alteration)
According to the applicable ASTM standards, any repair, alteration or maintenance not covered
by the Aircraft Maintenance Manual (AMM) requires authorization from the Original Equipment
Manufacturer (OEM). Until now Pipistrel has authorized such repairs/alterations/maintenance with
a Letter of Authorization (LOA), however, due to recent changes to the aforementioned standards,
we have replaced it with a new document called LSA Major Repair and Alteration (LSA MRA).
What is an LSA MRA?
LSA MRA is a document issued by Pipistrel that approves a certain repair, alteration or
maintenance. It includes:
1. Detailed information about what’s needed to perform the requested

repair/alteration/maintenance, who’s permitted to carry it out and how to perform it.
2. Advice on how to verify that the repair/alteration/maintenance has been performed

correctly and test it if necessary.
3. A statement from Pipistrel confirming that the aircraft will maintain compliance with the
requirements of the applicable ASTM design and performance standards after the
repair/alteration/maintenance has been performed.
When is an LSA MRA needed?
Owners/Operators of Pipistrel LSA aircraft MUST request and attain an LSA MRA BEFORE
performing any major repairs, alterations or maintenance. LSA MRA’s requested subsequent
to the repair/alteration/maintenance being performed will NOT be issued.
What is a major repair/alteration/maintenance?
According to the applicable ASTM standards, an LSA MRA is required for any repair, alteration
or maintenance that is not covered by the maintenance manual (AMM) or any other
instruction for continued airworthiness (ICA) (i.e. service bulletin, service information, etc.).
Therefore, if instructions on how to perform the repair, alteration or maintenance are not
included in the AMM or any ICA’s, OR if the repair isn’t specifically classified as minor in the
AMM, then it’s be considered major and an LSA MRA is required.
How can I get an LSA MRA?
The process of attaining an LSA MRA goes as follows:
1. Fill out the online LSA MRA request form in the SUPPORT area of Pipistrel’s website and
send it to Pipistrel (i.e. press the submit button at the end of the form). To access the form, enter
the password lsa2019mra.
2. Look for immediate confirmation that the LSA MRA request was successfully submitted.
Report any issues to [email protected]
PAGE PAGE REV. 0

99-12
LSAALPHA
Sinus
Virus
Trainer APPENDIX 99-D
3. The LSA MRA request is evaluated by Pipistrel and either denied or approved within two
working days. If the request is denied, Pipistrel will send an email explaining why. If the
request is approved, Pipistrel will determine a cost estimate for the LSA MRA.
4. Notification of denial or approval sent to customer. If approved, the notification is

accompanied by a proforma invoice for the LSA MRA*.
5. Payment made to Pipistrel.
6. LSA MRA request is put in queue and issued upon completion along with a receipt*.
NOTE: All LSA MRA’s issued by Pipistrel include or refer to a list of materials/parts
required to carry out the repair/alteration. To avoid excessive shipping costs and any
confusion as to what’s required for the repair/alteration/maintenance, we highly
recommend ordering materials/parts through your local Pipistrel dealer AFTER the
LSA MRA is issued.
A minimum fee of €50 will be charged for each repair/alteration/maintenance to cover overhead
costs. The minimum fee will be charged in instances where the repair/alteration/maintenance is
very basic/simple or where the MRA has already been performed and can basically just be cop-
ied. If, however, the repair/alteration/maintenance is complicated/extensive or has never been
requested before, additional engineering work may be required to determine whether such a
repair/alteration/maintenance is feasible, how it should be carried out, how it should be
tested/verified, etc. In this case an additional engineering work fee applies, which will be indica-
tedin the proforma invoice and must be covered by the initial requester.
Pipistrel is obliged to evaluate any major repairs, alterations or maintenance it’s LSA customers
wish to carry out. It is our responsibility as OEM to ensure that the aircraft being
repaired/altered/maintained will still meet the requirements of the applicable ASTM specifications
subsequent to being modified. We kindly ask you, our customer, to understand that we are not
looking to profit from LSA MRA’s, but merely cover the costs involved. We plan on streamlining
the LSA MRA evaluation/approval process as much as possible to reduce the time needed to
process a LSA MRA request. Furthermore, we plan on including more basic maintenance
procedures in the next revision of our AMM with the hopes of reducing the need for MRA’s.
Any questions regarding LSA MRA’s or the process of attaining one can be forwarded to Pipist-
rel’s MRA office at [email protected]
*LSA MRA requestees can expect any invoices and/or receipts to be issued by PIPISTREL
VERTICAL SOLUTIONS d.o.o., as per agreement 2018-1, signed by both manufacturers of Pipistrel
LSA aircraft, Pipistrel Italia s.r.l and Pipistrel d.o.o..
PAGE REV. 0 PAGE

99-13
Pipistrel d.o.o.,
podjetje za alternativno letalstvo
Goriška cesta 50a
SI-5270 Ajdovščina
Slovenija - EU
t +386 (0)5 3663 873

f +386 (0)5 3661 263
[email protected]
www.pipistrel.si
Pipistrel Italia
Via Fratelli Rusjan, 26
34070 Savogna d’Isonzo (GO)
Italia - EU
t +39 0481 522000

f +39 0481 522110
[email protected]
www.pipistrel.eu
Pipistrel Vertical Solutions d.o.o.

Vipavska cesta 2
SI-5270 Ajdovščina
Slovenija - EU
t +386 5 366 38 73
f +386 5 366 12 63
[email protected]
www.pipistrel.si

AMM-100-00-60-001 - A00 LSA Maintenance Manual PDF

Uploaded by

Copyright:

Available Formats

AMM-100-00-60-001 - A00 LSA Maintenance Manual PDF

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

AMM-100-00-60-001 - A00 LSA Maintenance Manual PDF

Uploaded by

Copyright:

Available Formats

What is the purpose and scope of this manual?

What is the purpose and scope of this manual?

What are the main sections and chapters covered in the manual?

What are the main sections and chapters covered in the manual?

LSA AIRCRAFT

Sinus 912 LSA (glider and aeroplane)

Document No.: AMM-100-00-60-001*

Aircraft Registration Number:

Aircraft Serial Number:

The airplane must be operated in compliance with

PAGE PAGE REV. 0

05-00 TIME LIMITS AND MAINTENANCE CHECKS

AIRCRAFT 09-00 TOWING AND TAXIING

PROPELLER 61-00 PROPELLER

71-00 POWER PLANT

OTHER 95-00 SPECIAL PURPOSE EQUIPMENT

PAGE REV. 0 PAGE

IT IS MANDATORY TO CAREFULLY STUDY THIS MANUAL PRIOR TO

PAGE PAGE REV. 0

USING THIS MANUAL

Revision tracking, filing and identifying

PAGE REV. 0 PAGE

Applicability and qualification table

PAGE PAGE REV. 0

Aircraft types are defined by the following abbreviations and acronyms:

TYPE APPLICABILITY information:

Aircraft type Abbreviation or acronym

Sinus 912 LSA (glider and aeroplane) SIN

Virus 912 LSA (glider and aeroplane) VIR

Virus SW 80/100 LSA (aeroplane) VSW

ALPHA Trainer (aeroplane) AT

USA LSA - QUALIFICATION information:

(Minimum) qualification rating Abbreviation or acronym

Owner who holds a sport pilot certificate O

Light sport repairman with maintenance rating LSRM

Aircraft maintenance technician with appropriate

Task specific training TST

AUSTRALIAN LSA - QUALIFICATION information:

Level 2 maintenance authority L2

Level 3 maintenance authority L3

Level 4 maintenance authority L4

CASA (minimum) qualification rating Abbreviation or acronym

Light aircraft maintenance engineer LAME

PAGE REV. 0 PAGE

Index of document revisions

A00 Initial release March 22nd, 2019 SLO.DOA.002

PAGE PAGE REV. 0

List of effective pages

PAGE PAGE PAGE PAGE PAGE PAGE PAGE PAGE

ii 0 05-02 0 07-02 0 11-02 0

iii 0 05-03 0 07-03 0 11-03 0

iv 0 05-04 0 07-04 0 11-04 0

v 0 05-05 0 07-05 0 11-05 0

vi 0 05-06 0 07-06 0 11-06 0

vii 0 05-07 0 11-07 0

06-01 0 10-03 0 12-11 0

06-02 0 10-04 0 12-12 0

06-03 0 10-05 0 12-13 0

PAGE REV. 0 PAGE

Exhaust System - 78-20: 2.1.4. [ ] [] [ ] [] [ ] [ ]