Alpi Aviation PIONEER 300, Maintenance Manual

Page 1: ...NEEDS TO BE COLOUR PRINTED DATE OF ISSUE OF LAST REVISION 23 07 2020 MAINTENANCE MANUAL AIRCRAFT MODEL PIONEER 300 THIS MANUAL ONLY APPLY FOR P300 AND P300FG FIXED AND VARIABLE PITCH PROPELLERS ENGINE ROTAX 912 ULS 912IS SPORT 915IS SHORT AND NORMAL WINGS ...

Page 2: ... of primary and secondary structures List of materials for quick repairs 2 25 06 2020 aircraft TBO definition at 2000h 3 23 07 2020 Definition of special tools placard and markings Table 1 history of document revisions CAUTION THIS MANUAL IS VALID ONLY IF IT CONTAINS ALL OF THE ORIGINAL AND REVISED PAGES LISTED ABOVE EACH PAGE TO BE REVISED MUST BE REMOVED SHREDDED AND LATER REPLACED WITH THE NEW ...

Page 3: ...2 Approved propeller types 12 1 4 Sources to purchase parts 13 1 5 List of disposable replacement parts 13 1 6 Weight and balance information 13 1 7 Handling 13 1 7 1 Ground handling 14 1 7 2 Parking and tie down 14 1 7 3 Jacking 14 1 7 4 Towing 15 1 7 5 Taxiing 15 1 8 Tire inflation pressures 15 1 9 Approved oil and capacities 15 1 10 Recommended fastener torque values 15 1 11 General safety info...

Page 4: ...3 Landing gear FIXED 21 3 1 4 Landing gear RETRACTABLE 21 3 1 5 Control system and aerodynamic surfaces 22 4 ENGINE 22 4 1 Engine Engine Mount 22 4 2 Engine cowling 23 4 3 Exhaust Muffler system 23 4 4 Air induction system 23 4 5 Oil system 23 4 6 Cooling system 23 5 FUEL SYSTEM 23 6 PROPELLER 24 7 UTILITY SYSTEMS 24 7 1 Cabin heat and cooling 24 8 INSTRUMENTS AND AVIONICS 24 8 1 Instruments that ...

Page 5: ... 27 10 3 Repair procedures 27 10 4 Materials necessary for small repairs 27 11 PAINTING AND COATINGS 28 12 FEEDBACK FORM 28 ANNEX A CHECKLIST OF MAINTENANCE OPERATIONAL SHEETS PD9001A0 29 ANNEX B REPORTING FLIGHT SAFETY CONCERNS 30 ANNEX C IMPROVEMENTS CORRECTIONS AND FEEDBACKS 31 ANNEX D CHANGE OF ADDRESS OWNERSHIP 32 ANNEX E NOTICES APPLICATION LOG 1 OF 33 ANNEX F MAINTENANCE LOG 1 OF 34 ANNEX G...

Page 6: ...ble 2 Standard configuration equipment 12 Table 3 Approved engine types 12 Table 4 Approved propeller types 13 Table 5 Disposable spare parts 13 Table 6 Final securing procedure 14 Table 7 Tire inflation pressure 15 Table 8 Approved oil grades and tank capacity 15 Table 9 Daily servicing 19 ...

Page 7: ...ixed Gear fpm Feet per minute ft Feet FTS Flight Training Supplement gal Gallons h hour IAS Indicated Air Speed IFR Instrument Flight Rules KCAS Calibrated Air Speed in Km h and in Kts Kg Kilograms KIAS Indicated Air Speed in Km h and in Kts kt Knots KTAS Calibrated True Air Speed L Left l Liters lb Pounds LE Leading Edge LMM Line Maintenance Manual MAC Mean Aerodynamic Chord MAUW Maximum All UP W...

Page 8: ...T ISSUE 1 07 2019 6 OS Operational Sheets POH Pilot Operating Handbook R Right RON Research Octane Number RPM Revolution per Minute sec Seconds SI International System of Units STD Standard VFR Visual Flight Rules ...

Page 9: ...2 the Mandatory Service Bulletins are applied and recorded in the Table of ANNEX E and stored in the aircraft logbook A 1 Document references This manual has been prepared according to the standard ASTM F2483 12 while Pioneer 300 aircrafts have been shown to comply with standard ASTM F2245 This aircraft must be maintained following the standard ASTM F2295 Standard Practice for Continued Operationa...

Page 10: ...esponsibility All text design layout and graphics are owned by Alpi Aviation Srl Therefore this manual and any of its contents may not be copied or distributed in any manner electronic web or printed without the prior consent of Alpi Aviation Srl WARNING IT IS MANDATORY TO CAREFULLY STUDY THIS MANUAL PRIOR TO USE OF AIRCRAFT IT IS ASSUMED THAT THE OWNER THAT WILL NOT NOTIFY ANY REQUEST OF CLARIFIC...

Page 11: ...erns format ANNEX C improvements corrections and feedbacks format ANNEX D changing the address or ownership format ANNEX E notices application format ANNEX F maintenance log format B WARNING CAUTION AND NOTE WARNING MEANS THAT THE NON OBSERVATION OF THE CORRESPONDING PROCEDURE LEADS TO AN IMMEDIATE OR IMPORTANT DEGRADATION OF THE FLIGHT SAFETY CAUTION MEANS THAT THE NON OBSERVATION OF THE CORRESPO...

Page 12: ...ined by 14 CFR Part 35 authorized to perform the annual condition inspection on experimental light sport aircraft or an equivalent rating issued by other civil aviation authorities LSA repairman maintenance U S FAA certified repairman light sport aircraft with an inspection rating as defined by 14 CFR Part 35 authorized to perform line maintenance on aircraft certified as special LSA aircraft MRA ...

Page 13: ...TEMS MARKED WITH A FULL BLUE COLORED DOT WARNING SOME OPERATIONAL SHEETS ARE REFERRED TO P300 KITE MODEL THAT IS THE OLD DESIGNATION FOR THE ACTUAL P300FG CONFIGURATION 1 3 Standard equipment list Table 2 represents the standard format of components installed on a Pioneer 300 aircraft Usually this table is used to perform the weight balance operation before each flight For this reason in the prese...

Page 14: ...w Special tools are available on request and payment Please refer to PZ1012A0 attached Table 2 Standard configuration equipment 1 3 1 Approved engine types Table 3 lists the engine types that are allowed to be installed on the Pioneer 300 aircrafts and for those it is available the necessary documentation aimed to the maintenance MANUFACTURER ROTAX GmbH Co KG TYPE MAX RATED POWER 912 ULS 100 hp 91...

Page 15: ...isposable spare parts PART SUPPLY DATA Air Filter Alpi Aviation Fuel Filter Alpi Aviation Oil Filter Alpi Aviation or Rotax Nose Wheel tire Sava 4 00 4 tire tube or may be replaced with eq aircraft tire or tube Main wheel tire Sava 4 00 6 tire tube or may be replaced with eq aircraft tire or tube Oil See Notes in Para 1 4 refer to Rotax Manuals Coolant See Notes in Para 1 4 refer to Rotax Manuals ...

Page 16: ...be steered using the rudder or for sharp turns by lowering the tail to raise nose wheel off the ground In this case towing to the favourable CG location a gentle push on the tail cone just ahead of empennage surfaces is all that is needed Avoid dragging nose wheel sideways and do not attempt to counter any movement of the aircraft by handling it by its wing tips CAUTION AS A GENERAL RULE APPLY FOR...

Page 17: ...over loose gravel or cinders should be done at low engine speed to avoid abrasion and pebbles damage to the propeller NOTE DO NOT accelerate over loose gravel or cinders or propeller damage will result 1 8 Tire inflation pressures DESCRIPTION VALUE Standard Mains 2 2 bar 32 psi Nose 2 bar 29 psi Table 7 Tire inflation pressure 1 9 Approved oil and capacities DESCRIPTION VALUE Specification RON 424...

Page 18: ... see paragraph A 2 2 Inspections Alpi Aviation considers the inspection schedule outlined below compulsory for safety operation on the airframe and systems over an extended period of time The described servicing requirements pertain to operation in non extreme climatic conditions For all the prescribed Rotax engines unless otherwise stated it is compulsory to adhere to maintenance requirements as ...

Page 19: ...company experience and mainly based on the engine early operation issue the company in addition to the 100 hr inspection requires the first scheduled maintenance at 25 hours Periodic inspections at every 100 hours Special inspections added to normal periodic inspections Singular inspection when aircraft has been exposed to conditions that may have damaged one or more of its components If aircraft ...

Page 20: ... Original or equivalent corrosion degradation prevention must be re applied after any alteration or repair If any trace of corrosion is detected it must be removed as soon as possible and immediately treated with the aim to prevent dangerous degradation of the affected component and related parts that could compromise the safety of overall flying operations The general guidelines to prevent corros...

Page 21: ...functional group 2 7 Lubrication Periodic lubrication of moving parts insures proper operation and considerably extends the life of the parts Lubrication type points and intervals are listed in the next paragraph and detailed in the ANNEX A Document Miscellaneous group Avoid excessive lubrication as this may cause external surfaces of hinges and bearing to collect dirt and dust If part is not lubr...

Page 22: ... or Retractable Steerable nose landing gear 2 place side by side arrangement with dual control sticks and a single central throttle Tractor propeller Hybrid structure made of wood and composite material glued together Horizontal stabilizer and vertical fin made of composite material Wood control surfaces fabric covered Detachable wing Good visibility Blue polycarbonate fully transparent canopy The...

Page 23: ...d is integrated in the fuselage skins while rudder is a wood fabric covered part too Trim control is achieved by an electrical actuated trim tab for both rudder and elevator Information about tail maintenance are given into ANNEX A Wings and Control Surfaces group 3 1 3 Landing gear FIXED The Pioneer 300 aircrafts can be equipped with a standard tricycle Landing Gear System which could be divided ...

Page 24: ... accurate switch The installed configuration includes a flap computer that permits to set the flaps in stages at pre configured values The Trim control system consists of two trims in the standard configuration while a third one the rudder that is optional All the trim tabs are actuated by an electrical push pull actuator controlled by the pilot through a suitable switch located in the center tunn...

Page 25: ...turer in the Engine Operators Manual 4 5 Oil system The oil system is an integral part of the engine except for the cooler that is mounted on the top right pilot view of the engine cooling plenum above the engine Moreover the air flow is forced by a dynamic duct that ensure a suitable air induction during the flight for best oil cooling The oil filler is on the right side of the engine too 4 6 Coo...

Page 26: ... on the lower left side of the engine cowling pilot s view This air intake also ducts the ram air through the system to the heat exchanger to provide heat to the cockpit if required Both the fresh air and the heated air can be opened closed and adjusted by the pilot by using the controls devices described in the POH See ANNEX A Cockpit and Interiors group for details about maintenance and repair a...

Page 27: ...by disconnecting the cap that closes the T fitting just outside the fuselage lower skin below the right wing root Servicing the system is very effortless and according to the checklist reported in ANNEX A Dashboard and Instruments group it can be carried out by simply removing the tubes from the instruments and blowing air in the direction of the ports and never vice versa clearing possible obstru...

Page 28: ...ical Avionics group consist of Navigation Lights Navigation lights are installed on the wing controlled by a single switch located on instrument panel and protected by a breaker A green light is located on right wing tip whilst a red light is on the left wing tip Landing lights The landing lights are located on the lower engine cowling Each light is protected by a breaker Switches and breakers are...

Page 29: ...ND ENSURE PROPELLER IS CLEAR ENSURE QUALIFIED PERSON IS IN THE PILOT S SEAT 10 Structural repair 10 1 Type of maintenance According to ASTM F2483 12 definition already recalled in para 1 1 the maintenance repair or alteration prescribed for this operations are defined Heavy 10 2 Minimum level of certification Repairman Light Sport Aircraft Maintenance RLSA M or higher For composite and wood compon...

Page 30: ...UE 1 07 2019 28 o White finishing o Glass fiber fabric balanced 100 gr sqm o Metric Screws and bolts M3 to M6 o Self tapping screws 11 Painting and coatings See ANNEX A Fuselage Body group 12 Feedback form See ANNEX C ...

Page 31: ...uled within that document is associated with the proper illustrative operational sheet that explain by words and images the correct way to accomplish the maintaining tasks Instructions to the reading of these technical documents has been given in para 1 2 Please check only those functional groups regarding your actual aircraft configuration and follow the instructions WARNING SOME OPERATIONAL SHEE...

Page 32: ...CONCERNS REPORTING FORM NAME last first COMPANY ORGANIZATION ADDRESS NUMBER AND STREET CITY STATE PROVINCE POSTAL CODE COUNTRY TELEPHONE N EMAIL DESCRIPTION OF FLIGHT SAFETY CONCERNS FOUND DURING INSPECTIONS MAINTEN SIGNATURE DATE FOR THE COMPANY ONLY RECEIVED AND MANAGED BY DATE RECEIVED ...

Page 33: ...EMENTS OR CORRECTIONS FEEDBACK NAME last first COMPANY ORGANIZATION ADDRESS NUMBER AND STREET CITY STATE PROVINCE POSTAL CODE COUNTRY TELEPHONE N EMAIL DESCRIPTION OF SUGGESTED IMPROVEMENT CORRECTIONS OR FEEDBACKS SIGNATURE DATE FOR THE COMPANY ONLY RECEIVED AND MANAGED BY DATE RECEIVED ...

Page 34: ...R AIRCRAFT REGISTRATION NUMBER CURRENT OWNER Last First NEW OWNER Last First PREVIOUS ADDRESS STREET NUMBER NEW ADDRESS STREET NUMBER CITY CITY STATE PROVINCE POSTAL CODE STATE PROVINCE POSTAL CODE COUNTRY COUNTRY TELEPHONE N TELEPHONE N EMAIL EMAIL SIGNATURE DATE FOR THE COMPANY ONLY RECEIVED AND MANAGED BY DATE RECEIVED ...

Page 35: ... INTRODUC BY NAME SURNAME SIGN NOTE NOTICE N ISSUE DATE INTRODUC DATE INTRODUC BY NAME SURNAME SIGN NOTE NOTICE N ISSUE DATE INTRODUC DATE INTRODUC BY NAME SURNAME SIGN NOTE NOTICE N ISSUE DATE INTRODUC DATE INTRODUC BY NAME SURNAME SIGN NOTE NOTICE N ISSUE DATE INTRODUC DATE INTRODUC BY NAME SURNAME SIGN NOTE NOTICE N ISSUE DATE INTRODUC DATE INTRODUC BY NAME SURNAME SIGN NOTE ...

Page 36: ...EXECUTED BY NAME SURNAME SIGN NOTE DATE OF MAINTENANCE TYPE OF MAINTENANCE H METER RECORD EXECUTED BY NAME SURNAME SIGN NOTE DATE OF MAINTENANCE TYPE OF MAINTENANCE H METER RECORD EXECUTED BY NAME SURNAME SIGN NOTE DATE OF MAINTENANCE TYPE OF MAINTENANCE H METER RECORD EXECUTED BY NAME SURNAME SIGN NOTE DATE OF MAINTENANCE TYPE OF MAINTENANCE H METER RECORD EXECUTED BY NAME SURNAME SIGN NOTE DATE ...

Page 37: ...PD9B01M0 1ST ISSUE 1 07 2019 35 ANNEX G APPLICABLE PLACARD AND MARKINGS ...

Page 38: ...PD9B01M0 1ST ISSUE 1 07 2019 36 ANNEX H SPECIAL TOOLS ...

Page 39: ...PD9B01M0 1ST ISSUE 1 07 2019 XXXVIII END OF DOCUMENT ...