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MM - Van`s Aircraft, Inc.

1. DUAL EFIS p XPNDR OPTIONAL FUSE TO o Z5AWITH een ROTAX 912 ELT RADIO EFIS DUAL RADIO INTERCOM EFIS a TEE OPTION X ADSB FUSE 7 5A GTR200 S s RECTIFIER OPTIONAL 5 AMP SL 40 LATCHED REGULATOR 8 GPS SWITCH OPTIONAL USE 1 FUSE FOR EFIS INTERCOM GARMIN 495 6 OPTION MASTER gt GENERATOR CONTROL RELAY COCKPIT on _ USE AMP FUSE FOR 24115 225 STARTER Lichts V TRIM A GARMIN AERA OPTION CAPACITOR RELAY 2 lt COOLING MOTOR es x SPARPIN v gt FAN USE2AMP FOR DYNON MICRO DIMMER X u 3A ADS B OPTION SWITCHES e a KEYED COOLING P 4 105 FAN X NAV V AMP OFF MOM FUEL G STROBE GN D METER START 5 PUMP LIGHT LIGHT SWITCH Aa TRIM SPEED ODYSSEY lt Ip E BATTERY SPAR PIN CONTROLER sly IGNITION IGNITION DISENGAGED RELAY B H WARNING Q Fils LANDING vaster 07 2 E eem mn 10 ne ne oPrioNAL 1 0 BUZZER LIGHTS i 1 11 OPTIONAL 2 3 5 5 3 2A zsa 65A 30 A5 2 2 5A 2 sa E 5 POWER 1 1 Y Y OUTLET MAIN BUS 18 25 SKYVIEW
2. 8 9 AV Control board replacement een dii 8 9 Wire repalt re nr dee da ond deiecit oeil tec wie at eben de 8 11 Wire replacements cena EE 8 11 Snap bushing replacement isir Ans a dt eese ha Apt e ieee t e a ee ted 8 13 Service Schedule PFOCOOUEGS ee 8 14 Battery terminal cleaning Haase 8 14 Battery recharge aee pod HERR Eae hal Hal EE iin ee edu nen 8 14 E E 8 14 e NOTE REFER TO THE SUPPLEMENT FOR A SCHEMATIC OF THE ELECTRICAL SYSTEM 8 1 Rev 3 OVERVIEW A WARNING THE RV 12 CONTROL BOARD IS NOT SERVICEABLE SERIOUS RISK OF ELECTRIC SHOCK REMAINS AFTER THE POWER SUPPLY IS REMOVED The RV 12 electrical system is a 12 VDC negative ground system A 12 VDC sealed dry cell battery mounts on the forward side of the firewall The generator operates only while the engine is running The generator supplies power to the regulator which serves the primary aircraft power and charges the battery The primary aircraft power is a 30 amp fused circuit Lights servos fans avionics fuel pump and safety switches are all fused secondary circuits and part of the primary circuit e NOTE This maintenance manual is intended to be used in conjunction with the RV 12 Kit Assembly Instruc
3. 20 1 Rev 5 04 03 14 NOTE Pages 18 23 18 25 and 18 27 correspond to a particular EFIS installation Please remove all pages that do not correspond to your EFIS Specific EFIS type is noted next to the page number vii Figure 1 Figure 2 Figure 3 Figure 4 Figure 5 Figure 6 Figure 7 Figure 8 Figure 9 Figure 10 Figure 11 Figure 12 Figure 13 Figure 14 Figure 15 Figure 16 Figure 17 Figure 18 Figure 19 Figure 20 Figure 21 Figure 22 Figure 23 Figure 24 Figure 25 Figure 26 Figure 27 Figure 28 Figure 29 Figure 30 Rev 5 04 03 14 TABLE OF ILLUSTRATIONS VISEOSID rt ee 1 13 Terminal crimping me EP 1 17 Lifting and Supporting ss uei bae tasto 1 18 Remove for DES 3 4 COMICO SS TOS urn et out LM 3 6 qe totes oa tence cast cha ae a are er 3 10 Wing Retention Pin aceto operose eek 3 13 R dder EE PT RE 3 14 213 e o dat 5 3 Wing Verte er 5 4 SEMI ORIN AOS sa a Be ae ee 5 6 Landing PD 5 8 Nose Wheel and Gear Leg 5 5 10 Wheel F iringssa 2 use ee 5 11 a 5 18 Extracting the DW
4. See Safety Firewall 12 1 Inspection en 3 8 nase eisernen 5 4 Lubrication 5 23 5 24 Fuel System u 13 1 B rule 13 4 Fuel Tank Installation ee 13 5 Removal ceterae eet 13 5 5 2 Inspection nueces 3 10 Lift and 1 18 Terminal Tab cit teneis 8 14 Inspection 3 9 F selage Pins 5 1 een ee 5 3 EET 8 6 20 2 Rev 3 Lubrication nenne 5 23 G tar ee ver 9 2 9 4 Gascolator Gleaning 13 7 13 7 INSPOCUOM 3 9 Renmov ali is tti e 13 7 H Harness 5 3 Inspectior un 3 5 5 22 EH See Utilities Hinge 12 14 Anti Servo 5 24 Flaparor ne 5 17 R dd6rss 5 kennen 5 18 5 19 1 Idle Setting 12 13 Inner tube MAIN 5 16 5 17 Inspection vu ae 3 1 Sedi ut 18 8 L Landing 5 8 INSPECTION cscs 3 11 RE 8 1 L
5. 14 1 OVERVIEW ient eo en Urt n ft eed Sede gie Pao 14 2 SERVICE 14 2 CHAPTER 15 PAINTING AND COATINGS 15 1 OVERVIEW Eee eres ips 15 2 SERVICE Het b then ee Rin 15 3 CHAPTER 16 TROUBLESHOOTING 4 20 16 1 CHAPTER 17 FEEDBACK REPLACEMENT 17 1 REPORTING M EO DO niei ie eem cc REM 17 1 REPLAGEMENT PARTS e rto De ope d can Deut 17 2 SUBSTITUTETPARTS 3 Deed p ee a 17 2 CHAPTER 18 SUPPLEMENT 22 5 18 1 SERVICE SCHEDULES 3 dee Ee cea 18 3 INSPECTION CHECKLIST 18 7 ELECTRICAL SYSTEM SCHEMATIC 1 1 nnne nennen nenn 18 23 18 25 18 27 OQ VIEW EN 18 29 FEEDBACK FORM nen 18 31 CHAPTER 19 55 19 1 CHAPTER 20 1 2
6. eaae rte eter bee ett eltern 12 6 Air filter removal 12 7 E otal eet 12 7 Carburetor Syncr nizatio Msi 40 aate Sethe hs 12 7 Throttle G ble Hook p E EE 12 10 Vacuum Gauge nitidis das d ee ae HER Au leg lode p lees dta 12 10 Off Idle Settings 1 X 12 12 Idle Speed Adjustment ete cto cte het een leg tse ER HR nde be ts 12 12 Verify Functionality of Throttle Return mmm eere 12 14 Service Schedule Pr COedUF6S eoo e eue eate ctor oce Bened escis a 12 15 Cowl hinge pin lubrication 2e ror ete Regen ec exe eet adhd 12 15 Oil Replacement unn e EEE 12 15 Cooling Hose Replacernent iuit tertie LER Cere aed Lean intel edge 12 16 Manifold Pressure Hose 12 16 Rev 4 OVERVIEW Engine information is taken from Rotax documentation For complete engine information refer to the Rotax engine documentation Note Rotax is the primary authority for specifying the level of certification required by an individual performing maintenance or repair on a Rotax 912 engine Refer to the Rotax documentation to determine the qualifications or training required for any main
7. wees casera MEN RID UE 13 4 Euelitank removal edicti tete tete 13 5 Installation 13 6 Fuel system component 13 6 Installation 13 7 Service schedule Procedures nn 13 7 Gascolator cleanitg ciuem Bene Aene feu dete tta cede an das bette 13 7 Installations ee ED 13 7 Fuel strainer removal irte a dates IIR HIR air Hg a a 13 8 ES 13 8 Fuel Return Assembly nnns 13 8 Fuel Pr ssure Hose rte iecit rer a mn roe ende eran 13 9 Fuel Drain Hose Replacement asiria pariona aa teet in IE 13 10 13 1 Rev 1 OVERVIEW The fuel system consists of a fuel neck and cap 20 gallon fuel tank tank sending unit mechanical fuel gauge and electric fuel pump aft of the center section The ES 40105 Electric fuel pump is a 12V DC solid state pump This serves as an auxiliary fuel pump The VA 261 Fuel Strainer at the outlet of the fuel tank prevents any large foreign objects from proceeding into the rest of the fuel system Forward of the center section in order there is the fuel valve fuel flow transducer gascolator Engine driven fuel pump and the fuel manifold The fuel valve provides the ability to permit or prevent fuel flow to the fuel
8. se 9 2 9 3 9 4 CHAPTER 10 UTILITY SYSTEMS 22 2 10 1 OVERVIEW C 10 2 Mat 10 2 MENTIUATIGONLE s ceder ceo a ee tapes Le rr 10 3 Rev 5 04 03 14 SERVICE 2x E E a as EI Ml 10 4 CHAPTER T1 PROPEELER caet enemies 11 1 OVERVIEW eodera en etie cae vier tede bay dne pere ei ep ET E 11 2 SERVICE ce EEUU Um LU IUS D D COO UE OR NU df 11 2 Prop amp sted cr 11 3 CHAPTER 12 FIREWALL 12 1 OVERVIEW ee beatius tee rero we ne er ee ge 12 2 lis aes 12 3 SERVICE mmt eM n ML tUe ee RSEN Id 12 4 CHAPTER 13 FUEL 5 5 50004 13 1 OVERVIEW ouo T ipu al 13 2 Fuel System Schematic 13 3 SERVICE E roe E E FR NR E 13 3 CHAPTER 14 EXHAUST SYSTEM
9. 9 5 288 OROSII 9 5 Service Scheaule Pr geduress na ae nel 9 6 Software Updates eee ete rcr A esc ee E Fc EVE EE ERU rH ee 9 6 9 1 Rev 4 OVERVIEW The Dynon D 180 Dynon SkyView or Garmin G3X EFIS Electronic Flight Information System EMS Engine Monitoring System replaces the traditional mechanical flight information and engine monitoring instruments For removal installation inspection or servicing of the avionics components refer to the manufacturer user manuals The pitot and static systems provide static and dynamic pressure sources for flight data calculations The static system ports are located on each side of the tailcone A flexible plastic tube from the right static port crosses the tailcone to a plastic tee and joins the flexible plastic tube from the left port From the tee a flexible plastic tube routes to the floor then forward within the center tunnel to the air data computer located behind the instrument panel with the D 180 and in the aft fuselage with the Skyview and G3X The pitot port is an aluminum tube located at the tip of the spinner cone that extends aft to an adapter block mounted to the engine A flexible plastic tube continues aft from the adapter block to the air data computer e NOTE This maintenance manual is intended to be used in conjunction with the RV 12 Kit Assembly Instructions KAl when completing maintenance or repair processes COMPONENTS XP
10. denne 5 2 FUSELAGE he os ee tae hat 5 2 WING AND FLAPERON 02 eccceeeceeeeececeeceeececeaeecaecceeaecaeeceneauecaueceeaueeaeecueeseeeaeesaeesneeaeesaeees 5 4 nun nun anna rne 5 6 LANDING 1 4 4 44 ann 5 8 FAIRINGS WHEEL AND GEAR 1 12 1 5 10 SERVICE M et ine Ee e pest ea e cds eae ee O E 5 12 CHAPTER 6 FLIGHT 65 1 2 2 2 12 6 1 OVERVIEW an 6 2 SERVICE He Eh 6 3 CHAPTER 7 BRAKE SYSTEM 7 1 OVERVIEW A ne ee aaah apa en en Bleed 7 2 SERVICE 25 la na ET 7 2 CHAPTER 8 ELECTRICAL SYSTEM 8 1 OVERVIEW A een eignen nen E ee A Brenn abe age 8 2 SERVICE cv 8 4 CHAPTER 9 INSTRUMENTS 8 5 9 1 OVERVIEW
11. E ee 1 14 gii D UU UERSUM 1 14 Tre PSS SUS zn reed 1 14 Torgue Values rccte an 1 15 GENERAL PROCEDURES en ee 1 16 1 17 Lifting amp Supporting the Tuselagag dae al aue 1 17 CHAPTER 2 SERVICE SCHEDULE 2 1 OVERVIEW rc 2 1 CHAPTER 3 INSPEGTION 2 ee en 3 1 OVERVIEW T ee 3 1 INSPECTION DESORIPTION a nee obese doceo tee Ds desit ash 3 3 Pre inspection eigen ren eec ete pete aeta reb iesu pep bead eee gnus 3 3 BOCKBI prn ee 3 5 FRAC o ONE S 3 7 TERES 3 7 Emergency Locator Transmitter reset pep 3 7 Propeller use 3 7 Rev 5 04 03 14 ee DE See sn 3 8 Firewall OFWard Enns 3 8 FUSCA GS ma ee 3 10 tanding m c een ie 3 11 Wing Center Sections DE ie 3 12 Empennage ann een 3 13 Paperwork sus een 3 15 CHAPTER 4 STRUCTURAL REPAIRS 4 1 OVERVIEW dese ott iron Leere 4 1 CHAPTER 5 STRUCTURES Lene eoe eret coge vete eoe pe 5 1 OVERVIEW nahen
12. Lift and support the aircraft 1 16 Remove the main wheel and tire assembly Remove and clean the main wheel bearings 2 Apply wheel bearing grease to each of the bearings Install the wheel bearings Install the wheel and tire assembly 5 25 Rev 4 NOSE FORK PIVOT TENSION AND LUBRICATION Tools Needle nose pliers 1 1 2 socket Tensile weight scale Expendable Waterproof wheel bearing grease 1 Lift and support the aircraft 1 16 2 Remove the nose fork and attach hardware cotter pin nut washer spring washers 2 3 Clean the end of the nose gear leg and the nose fork bushings 4 Apply a liberal amount of marine trailer or waterproof equivalent wheel bearing grease to the nose fork bushings 5 Installation procedure is reverse of the removal procedure 6 Tighten the nut until a push or pull force of 18 20 Ibs applied at the axle is measured while the nose fork is rotated around the end of the nose gear leg TIRE ASSEM BALANCING PROCEDURE e NOTE IT IS NOT A MAINTENANCE REQUIREMENT THAT THE NOSE OR MAIN WHEEL TIRE ASSEMBLIES ON THE RV 12 BE BALANCED BECAUSE OF THE RELATIVELY LOW TAKEOFF AND LANDING SPEED SHOULD A VIBRATION BE DETECTED THAT IS SUSPECTED TO BE CAUSED BY A WHEEL TIRE IMBALANCE THIS PROCEDURE MAY BE USED 1 Remove the suspected out of balance wheel tire assembly s from the aircraft 2 Mount the Wheel Tire assy in a static balance test stand and allow the assy to rot
13. Capacities Carburetor Syncronization Center Section Inspection Cockpit Inspection Control cable Replacement Control Stops CHAPTER 20 INDEX 7 6 20 1 Rev 3 Control system 6 1 Rod End Lubrication sss 6 9 Coolaht 5 cds See Engine Cowl 12 2 12 14 Cowling Installation 2 12 5 tie exe es 12 4 D Decorative 15 5 einer 9 2 9 3 9 4 18 3 E Electrical 8 1 Schematic 18 21 18 23 Terminal 8 10 Wire terminal Crimping 1 17 Emergency Locator Transmitter Inspettion este lie 3 7 nsns eea 5 6 3 13 1 12 12 3 Firitig Order tt tenens 12 3 See Rotax Manual Lubrication Coola aire 12 7 Olli einen 1 13 12 6 Operating limits See Rotax Manual Specifications See Rotax Manual Exhaust 14 1 Installation oue Lee res 14 3 cd cie tede cts 14 4 Hiemioval itecto 14 3 F
14. FUEL PRESSURE HOSE FLUSH Left Side of Fuel Return Assembly LSA RM with Rotax Service certification or A amp P with Rotax Service certification Removal 1 Place rags beneath the Fuel Pressure Sender 2 Loosen VA 216 Fuel Return Assembly hose coupling while supporting elbow with second wrench Place container beneath hose and remove hose from fitting 4 With end of hose inside container flush hose by turning on fuel boost pump for two seconds Installation 1 Reinstall hose to elbow 13 9 Rev 1 FUEL DRAIN HOSE REPLACEMENT Additional References KAI Minimum Certification LSA RM with Rotax Service certification or A amp P with Rotax Service certification Removal 1 the tie wraps attaching the drain hose to the gascolator to fuel pump hose 2 Loosen two hose clamps on the interconnect hose and one clamp on the drain hose and slide the clamps onto the aluminum drain tube 3 Remove the hoses Installation 1 Install new hoses onto the fuel pump drain fitting and the drain tube 2 Slide hose clamps back into position over the hoses and tighten 3 Secure the drain hose to the gascolator to fuel pump hose using tie wraps 13 10 Rev 1 CHAPTER 14 EXHAUST SYSTEM EXHAUST TUBE SOCKET BRACKET JOINT SPRING MUFFLER Ed BALL JOINT 14 2 14 2 SERVIOE 14 2 DSUDDIIBS Naren a EN 14 2 TOONS 2
15. Fuel Pressure Hose Flush Fuel Drain Hose Replacement rrr nennen Pee en enin renda n Pee d a De e n ie doen e hende un 13 10 MM Page 13 10 Rev 5 Remove duplicate Fuel Drain Hose Replacement section MM Page 18 1 Rev 6 Updated all page references MM Page 18 3 Rev 6 After SERVICE SCHEDULE add CHECKLIST this now will match the table of contents MM Page 18 5 Rev 6 After SERVICE SCHEDULE add CHECKLIST this now will match the table of contents Add Wheel Balance Balance As Needed 5 26 MM Page 18 5 Rev 6 Add Throttle Return Springs Verify Function 50 hours or after carburetor maintenance 12 14 MM Page 18 9 Rev 6 Add Verify function of throttle return springs Springs pull throttle to wide open with friction control off see procedure on Page 12 14 Remove redundant Static RPM at full throttle MM Page 18 15 Rev 6 A C 43 13 should be 14 CFR 91 207 all places on page as A C 43 13 only cover the installation of ELT s and not the maintenance MM Page 18 21 Rev 6 Replace under paperwork F2295 06 Section 7 with Notice of Corrective Action MM Page 18 26 Rev 6 Add new page for Sky View SV AP Knob Panel electrical system MM Page 18 27 Rev 6 Add new page for G3X electrical system repaginate the remainder of the section MM Page 18 28 Rev 6 Add new page repaginate the remainder of the section MM Page 19 1 Rev 2 Add to Electronic Flight Information System and Engine Management System Dynon SkyView
16. Rev 6 ELECTRICAL SYSTEM SCHEMATIC SKYVIEW SV AP KNOB PANEL DUAL EFIS lt XPNDR OPTIONAL FUSE TO i ROTAX 912 4 ELT 4 RADIO Em 1 ACK RADIO INTERCOM EFIS OPTION ADSB FUSE 7 54 GTR200 gel RECTIFIER A 3 OPTIONAL DAMP 81 40 REGULATOR B CANOPY 3 GPS LATCHED SV KNOB PANEL OPTIONAL SWITCH STARTER TERS USE 1 AMP FUSE FOR lt INTERCOM GARMIN 495 6 OPTION MASTER GENERATOR 7 CONTROL RELAY Ho d COCKPIT 24115 22Kw STARTER Lights SERVO 4 GARMIN AERA OPTION RELAY o MOTORS COOLING H i 1 4j e H TRIM FAN f USE 2 AMP FOR DYNON i MICRO DIMMER MOTOR ADS B OPTION qo SWITCHES LLL KEYED COOLING Wo d OFF MOM rel LANDING FUEL FAN STROBE D NAV 1 START 27 LIGHT
17. m CAUTION INDICATES AN ACTION NECESSARY TO PREVENT DAMAGE TO PARTS OR PROPERTY e NOTE PROVIDES VALUABLE ADDITIONAL INFORMATION The Glossary provides definitions to many of the terms used throughout this manual 1 5 ABBREVIATIONS AKI Anti knock index octane rating API American Petroleum Institute Rev 5 Kilometers per hour AVGAS Light Sport Aircraft Celsius CHT Cylinder Head Temperature AST LL LSA RM A amp P Airframe and Power plant Kph Mechanic Light Sport Aircraft Repairman Maintenance rating CST Category specific training EFIS Electronic Flight Information System FAA ELT Emergency Locating Transmitter EMS F D FAR s Federal Aviation Regulations N fl oz ft ft Ibs FW j GPS HP n in in lb x kPa Kilopascal CG Center of Gravity Cylinder Head Temperature EGT Exhaust Gas Temperature 02 Foot Pounds P United States Federal Aviation naut mi Nautical miles Administration fluid ounce U S Statute mile Milliliters Engine Monitoring System Millimeter Fahrenheit Special Light Sport Aircraft kilogram Voltage Direct Current See glossary for definition 1 6 Rev 5 WEIGHT AND BALANCE It is the pilot s responsibility to insure that the aircraft is loaded properly and within the weight and balance limitations The weight and balance of the aircraft are factors that will affect all flight performance pro
18. Max and Min marks on the dipstick ENGINE COOLANT LEVEL CHECK WARNING DO NOT REMOVE THE RADIATOR CAP FROM A HOT COOLING SYSTEM SCALDING COOLANT WILL SPRAY ENGINE COMPONENTS TO COOL Tools Expendable Replaceable Service Rating Minimum Certification Additional References 1 Place arag over the expansion tank cap 2 Loosen cap to the first detent then step back for a few seconds 3 Remove the expansion tank cap 4 The expansion tank must be full of coolant 12 6 Rev 4 5 Replace the cap 6 The coolant level in the overflow bottle must be between the Max and Min marks FILTER REMOVAL 5 16 Socket Expendable None Replaceable Air filter Line Minimum Certification LSA RM or A amp P Additional References Rotax 912 Line Maintenance manual 1 Loosen the air filter clamp 2 Remove the air filter INSTALLATION 1 Installation procedure is reverse of the removal procedure CARBURETOR SYNCRONIZATION Tools 1 Vacuum gauge set 1 050 Allen wrench 2 3 8 in combination wrench 2 10 mm combination wrench 1 medium flat blade screwdriver 1 42 Phillips screwdriver None Minimum Certification LSA RM with Rotax Service certification or A amp P with Rotax Service certification Additional References Rotax Maintenance Manual e NOTE THIS PROCEDURE IS WRITTEN FOR A SINGLE CARBURETOR ADJUST BOTH CARBURETORS SIMULTANEOUSL Y THE CARBURETOR SYNCHRONIZATION PROCED
19. The aircraft utility systems are the systems that are not critical to flight The heat System enables the occupants to control the cockpit temperature with a push pull cable Hot air diverted from the heat exchangers provides cockpit heat Cabin ventilation air can be controlled with either of the two vents one on each side of the fuselage e NOTE This maintenance manual is intended to be used in conjunction with the RV 12 Kit Assembly Instructions KAl when completing maintenance or repair processes PUSH PULL CABLE COOLER BOX Air that passes through the engine coolant heat exchanger is heated The heated air continues into the cooler box A push pull cable controls a door in the cooler box that diverts the heated air into or away from the cockpit Rev 1 COMPONENTS Part or Assembly Name A hand operated vent on each side of the cockpit provides cockpit ventilation Each vent is a tip out door installed on each fuselage side skin Rev 1 COMPONENTS Part or Assembly Name Part Number or Reference Vent brackets F 1086 Vent doubler F 1096 Vent door sub assembly See shaded items below 2 Ventside F1087 2 Vent door doubler 2 F 10922 2 j Ventdor J F1098 L SERVICE The heating system does not require regular maintenance If the push pull cable operation is not smooth at the time of th
20. CLEAN AS REQUIRED 12 12 Rev 4 NOTE WHEN CHECKING THE IDLE SPEED DURING THE ADJUSTMENT PROCEDURE ONLY PULL LIGHTLY ON THE THROTTLE CONTROL UNTIL YOU JUST FEEL THE IDLE STOPS ON THE CARBURETORS A HEAVY PULL ON THE THROTTLE CONTROL WILL FLEX THE THROTTLE ARMS AND GIVE AN INACCURATE IDLE SPEED e NOTE IF THE THROTTLE HANDLE IS HELD FULLY AT IDLE FOR AN EXTENDED PERIOD THE IDLE MAY CREEP DOWN TO APPROXIMATELY 1550 RPM THIS IS PERMISSIBLE WHEN SETTING UP THE CARBURETORS BUT DURING NORMAL GROUND OPERATIONS THE IDLE SPEED SHOULD BE KEPT AT OR ABOVE 1650 RPM OR WHATEVER IDLE SPEED IS REQUIRED TO ALLOW THE ENGINE TO RUN SMOOTHLY OPERATING AT IDLE SPEEDS WHERE THE ENGINE IS MAKING A KNOCKING RATTLE TYPE NOISE WILL CAUSE GEARBOX DAMAGE e NOTE OFTEN TIMES WARMING THE ENGINE BY RUNNING IT ON THE GROUND DOES NOT QUITE BRING IT UP TO NORMAL OPERATING TEMPERATURES THIS WILL HAVE A SLIGHT EFFECT ON WHAT THE ACTUAL IDLE RPM WILL BE ONCE THE AIRPLANE HAS BEEN FLOWN FOR A FEW MINUTES FULLY WARMED UP THE DIFFERENCE TENDS TO BE A 50 75 RPM INCREASE FOR THIS REASON UNLESS YOU ARE DOING THE CARBURETOR SYNCHRONIZATION PROCEDURE IMMEDIATELY AFTER FLYING THE AIRPLANE ADJUSTING FOR AN IDLE SPEED NEAR THE BOTTOM OF THE RECOMMENDED RANGE WILL NET YOU A PROPER IDLE OF ABOUT 1650 RPM AFTER THE ENGINE IS FULLY WARMED e NOTE VERIFY THE IDLE SPEED AND ADJUST AS NECESSARY TO ACHIEVE 1600 1650 RPM AND SMOOTH ENGINE OPERATION REMEMBER TO ONLY PUL
21. Deformation Pas Fail Skins Deformation Cracks Signs of Wear Corrosion Footprint Area of Left amp Right Wing Signs of Wear Bulkheads amp Stringers Deformation Cracks Signs of Wear Corrosion Left amp Right Static Ports Clean Clear Secure i Left amp Right Boarding Step Security Seal Landing Gear Fasteners Corrosion Refer to Matco manual Pass Fail Main Gear Legs Brackets Security Wear Corrosion Landing Gear Attach Hardware Torque Brake Hydraulic Lines Leaks Security SE Wheel Bearings Lubrication Free Play Refer to Matco manual TE NN Brake Calipers Condition Refer to Matco manual REEL Brake Shoes Lining Limit Refer to Matco manual Brake Disks Cracks Deformation Refer to Matco manual Wheels Alignment Cracks Refer to Matco manual EEE Tires amp Valve Stem Wear Cracks Air Pressure Nose Gear and Fork Travel Security Break out Force FE ee Wings Center Section Fasteners Corrosion Deformation Pass Fail Skins Deformation Cracks Signs of Wear Corrosion Ribs amp Attach Angles Deformation Cracks Signs of Wear Corrosion Main Fwd amp Aft Spars Deformation Cracks Signs of Wear Corrosion Flaperon Smooth Operation Security 22452001 Hinges Smooth Operation Lubrication 353555 Stall Warning Secure Connection Condition Wing Retention Pins
22. PITOT AND STATIC SYSTEM COMPONENT REPLACEMENT Expendable Plastic tie wraps Replaceable Connector Tubing Minimum Certification LSA RM or A amp P Additional References REMOVAL 1 Make note of routing location and orientation of the component to replace 2 Remove the failing component INSTALLATION 1 Install anew component of equivalent properties and secure with plastic tie wraps 2 Complete the pitot static check as outlined in the RV 12 production acceptance test document 9 5 Rev 4 LIGHT REPLACEMENT WARNING BEFORE PERFORMING ANY MAINTENANCE OR REPAIRS TURN THE MASTER SWITCH OFF AND DISCONNECT THE NEGATIVE BATTERY CABLE FROM THE BATTERY Wire cutter Wire terminal crimper Needle nose pliers 2 Phillips screwdriver Expendable Replaceable Service Rating Minimum Certification Additional References REMOVAL 1 Remove the light and fastening hardware Cockpit light screws 3 Landing light screws 6 bolts 2 Navigation light allen screw 1 2 Label the wires that will be disconnected 3 Unplug the wire terminals nearest to the light INSTALLATION 1 Install mating wire terminals on the replacement light 2 Plug the light into the electrical system 3 Install the new light and hardware SERVICE SCHEDULE PROCEDURES NOTE THERE IS NO SCHEDULED MAINTENANCE OR SERVICE ON ANY OF THE AVIONICS OR OPTIONAL EQUIPMENT OTHER THAN THE PERIODIC REPLACEMENT OF THE ELT UNIT BA
23. Strobe Light Set NotShon shaded items below amp RefertoKAl Rect Reg Cooling Shroud 8 3 Rev 3 WARNING ALWAYS HAVE AN APPROPRIATE FIRE EXTINGUISHER READILY AVAILABLE WARNING BEFORE PERFORMING MAINTENANCE OR REPAIRS TURN THE MASTER SWITCH OFF AND DISCONNECT THE NEGATIVE BATTERY CABLE FROM THE BATTERY m CAUTION REPLACEMENT COMPONENTS WIRE TERMINALS AND FUSES MUST BE OF THE SAME TYPE AND RATING AS THE ORIGINAL PARTS There are no serviceable electrical components Replace malfunctioning or failed components Electrical components that are omitted from the component list on page 8 2 are not considered line maintenance SUPPLIES EXPENDABLE e Socket Baking soda water 3 8 e Wire terminals 7 16 Splice 10mm Spade male female Battery charger Ring Scouring pad or equivalent Wire terminal crimping tool Wire cutter REPLACEABLE Multi meter Razor knife Screwdriver 2 Phillips 8 Phillips Needle nose pliers Fire extinguisher 4mm Allen wrench See component list on page 8 2 Wire gauge original Snap bushing size original 8 4 Rev 3 GENERAL BATTERY REMOVAL A WARNING NEUTRALIZE BATTERY CORROSION WITH WATER BAKING SODA MIX Expendable Replaceable Service Rating Minimum Certification Owner and SPC LSA RM or A amp P Additional References Odyssey owner manual Tools 4 mm allen wrench 3 8 socket Remove the top cowl 1
24. cover plate only the aft two baggage cover baggage bulkhead corrugation upper tailcone fairing lower tailcone fairing fuel tank assembly 3 4 2 For rudder cable remove the rudder cable sleeve attach hardware bolts 3 washers 3 nuts 3 3 For the stabilator cable remove the tensioner barrels and stabilator pulleys 6 4 e NOTE TIE A STRING LONGER THAN THE CONTROL CABLE TO THE AFT END OF THE CONTROL CABLE AND WRAP THE SAME END OF THE CONTROL CABLE WITH A PIECE OF TAPE TO AVOID BULKHEAD DAMAGE 4 Disconnect the attach hardware see below at the forward and aft end of the cable to be removed Rudder cable end hardware Fwd bolt washer nut and cotter pin Aft bolt washers 3 nut and cotter pin Stabilator cable end hardware Fwd bolt washer 2 nut and cotter pin Aft bolt washers 3 nut and cotter pin 5 Pull the cable out from the opposite end of the string Remove the cable leaving the string in its place 6 Tie the new cable to the end of the string and cover the end with a piece of tape 6 6 Rev 3 NOTE THE SEAT RAMP COVER MUST BE INSTALLED PRIOR TO ADJUSTING THE CABLE TENSION 7 Installation procedure is reverse of the removal procedure 8 Adjust cable tension as described earlier in this chapter ROD END REPLACEMENT Tools 3 8 7 16 socket 3 8 7 16 combo wrench Expendable Cotter pins Coterpns 1 Remove applicable combination of the seat ramp cover sea
25. maintenance rating or an A amp P Part replacement must be consistent with the original from Van s Aircraft Priming factory alclad replacement parts remains at the repairmans discretion Non alclad parts must be primed per the KAl Any parts that require replacement due to corrosion warrant additional corrosion protection on the replacement part When in doubt prime the part Rev 1 SERVICE A WARNING PAINT OR SOLVENT MUST USED IN ACCORDANCE WITH THE A WARNING DO NOT DAMAGE ANY RIVET HEADS WHEN PREPARING A SURFACE FOR TOUCH UP PAINT m CAUTION EXPOSED STEEL MUST BE CLEANED AND COATED WITH PRIMER OR POWDER COAT TOUCH UP PAINT m CAUTION ANY SCRATCH THAT MAY HAVE PENETRATED THE ALCLAD COATING MUST BE CLEANED AND PRIMED PROPERLY SUPPLIES TOOLS EXPENDABLE e Scouring pad e Touch up paint Sandpaper various grades Primer Decorative touch up paint REPLACEABLE None SERVICE SCHEDULE PROCEDURES POWDER COAT REPAIR A WARNING IF CRACKS PENETRATING RUST OR CORROSION ARE FOUND IN THE COATING SURFACE OF POWDER COATED PRIMED OR PAINTED PARTS THE PART SHOULD BE CAREFULLY INSPECTED UNDER THE COATING FOR MATERIAL DAMAGE IF IN DOUBT THE PART SHOULD BE REPLACED 15 3 Rev 1 Sandpaper Expendable Touch up paint Replaceable None Line Minimum Certification Total area 4 ir or less Owner and SPC Total area greater than 4 in LSA RM or A amp P KAI 1 Use coarse grit sandpaper to remo
26. ARM FLAPERON MIXER BELLCRANK RUDDER PEDALS RUDDER CABLE OVERVIEW ea toos patre foci tend 6 2 a aa E E a E E E E E 6 2 SERVICE 6 3 SUDDIBS LAM M 6 3 6 3 Expendable 6 3 Replaceable I Cp 6 3 General ass noit E e MHz e agile 6 3 Stabilator pulley replacement and cable tension 6 3 Control cable replacement onc reellen a d dba ee o ee nie 6 6 Rod end replacemerit potete de e One Eier HERE ea 6 7 Bellcrank bearing eee enne nennen nnne nennen nennen ennemi nennen nennen 6 8 Rudder ped l removal 6 8 ER 6 9 Service Schedule 6 9 Control syst m rod end lubrication eR eee re EUER edere 6 9 Cable end hardware lubrication 6 9 6 1 Rev 3 OVERVIEW The control system enables the pilot to operate the control surfaces Forward or a
27. ERE ODYSSEY COOLING 5A BATTERY 1 STARTER 1 aba FAN n od GENERATOR LANDING MODE A OPTIONAL poss DIMMER 1S LIGHT CONTROLLER RELAY zw LJ OPTIONAL OPTIONAL COOLING 24115 1 I STARTER FUEL FAN CAPACITOR RELAY ROLL TRUM 4 ul gt PUMP m SPAR PIN SERVO MOTOR 2 RADIO o d SWITCHES PITCH 4 LJ Wh SERVO RADIO INTERCOM hoa KEYED A 4 INTERCOM ELT o du METER START 1 on SWITCH LEI STROBE NAV AUTOPILOT EFIS EMS lt LIGHT LIGHT OPTIONAL TRIM SPEED LEG 3A gt I SPAR PIN BE CONTROLER pz ADSB ADAHRS IGNITION IGNITION DISENGAGED RELAY LISTE 7 OPTIONAL Be Al 1 B LES 7 WARNING 1 ES E MASTER 27 V LIGHT AND NAV amp LN 1 4 417 swen 11 OVERIDE 24 STROBE LE LES BUZZER a CANOPY LATCHED SWITCH LIGHTS 11 SWITCH I 1 OPTIONAL PITCH d i i 754 55 AVIONICS soa 24 2 5A 5A 2 2 2 54 2 POWER i OUTLET MAIN BUS 18 27 G3X Rev 6 THIS PAGE INTENTIONALLY LEFT BLANK 18 28 18 29 Rev 6 THIS PAGE INTENTIONALLY LEFT BLANK 18 30 Rev 6 Feedback Form Owner Nance Phone Contact Nanc
28. Heat Hrn 10 2 Ventilation seen 10 3 Vent 2 10 5 V Vacuum Gauge Hookup 12 11 See Utilities Vertical Stabilizer nn 5 7 INSPECTION Giessen 3 13 WwW Weight and Balance 1 7 Wheel Bearings EI EE 5 25 056 nn ei A 5 24 20 5 Rev 3
29. PERSONEL OR TOOLS TO HANDLE THE WEIGHT AND AWKWARDNESS OF THE OBJECT TO BE REMOVED 1 Remove the upper and lower tailcone fairing 3 4 e NOTE BEFORE DISCONNECTING THE STABILATOR CONTROL CABLES BE PREPARED TO PREVENT THE ENDS OF THE CABLES FROM FALLING INTO THE TAILCONE 2 3 4 5 6 8 9 Remove the two aft most belly inspection covers Remove the Lock Clips from one of the cable tensioners Rotate the tensioning barrel to slacken the stabilator control cables Disconnect the stabilator control cables Disconnect the aft end of the Trim Servo Pushrod from the Anti servo Tabs Remove the two bolts attaching the counter balance arm to the stabilator Remove the two bolts attaching the stabilator to the aft end of the tail cone Remove the stabilator assembly Note while extracting the counterbalance arm from the fuselage rotate the counter balance arm 90 degrees to allow it to pass through the tailcone bulkhead 10 Use two sockets a bolt washers and a nut to extract the hinge bearing as shown in Figure 16 Turn the bolt while holding the nut stationary to extract the bearing from VA 146A 5 19 Rev 4 2 1 2 X 3 16 BOLT 7 16 SOCKET BEARING DW4K2X WASHER VA 146A d WASHER 3 4 SOCKET NUT Figure 16 Extracting the DWAK2X bearing 1 Installation procedure is reverse of the removal procedure 2 After reinstalling the stabilator readjust the stabilator control cable tensions in accordanc
30. PUMP LIGHT LIGHT Mi SWITCH SV AP TRIM SPEED ODYSSEY eo de req Wo d SPAR PIN E PANEL CONTROLER IE i IGNITION IGNITION DISENGAGED RELAY late 1 AL Hi B kal rh Hr WARNING req red EE 1 eH MASTER LIGHT AND L LA HANDING N AUTOPILOT STALL 22 ERST L OVERIDE 4 LLJ optiona 1 OPTIONAL 2 WARN BE STROBE SWITCH rp J BUZZER LIGHTS 1 N n bit 1 id OPTIONAL ry ry ry ry sa soa 2A 2 3ale 2 2 25 2 75A 5 2 POWER Y Y p OUTLET MAIN BUS 18 26 SKYVIEW SV AP KNOB PANEL ELECTRICAL SYSTEM SCHEMATIC G3X Rev 6 TCW BACKUP BATTERY RECTIFIERI REGULATOR ROTAX 912 av COCKPIT LIGHTS TO DIMMER pic KNOB n
31. REMOVAL 1 1 2 7 16 socket Safety wire Replaceable None Minimum Certification Owner and SPC LSA RM or A amp P 1 Lift and support the aircraft 1 16 2 Remove the stationary brake shoe bolts 2 washers 2 spacer and brake shoe 3 Remove the cotter pin axle nut washer and wheel and tire assembly INSTALLATION 1 Installation procedure is reverse of the removal procedure 5 15 Rev 4 NOSE WHEEL AND TIRE ASSEMBLY REMOVAL 9 16 combo wrench Minimum Certification Owner and SPC LSA RM or A amp P 1 Lift and support the aircraft 1 16 2 Remove the axle bolt washers 2 nut axle spacer and wheel and tire assembly INSTALLATION 1 Installation procedure is reverse of the removal procedure MAIN INNER TUBE REPLACEMENT 3 16 1 4 Allen Safety wire Tire Service Rating Service Rating or A amp P References KAI 1 Lift and support the aircraft 1 16 Remove the main wheel and tire assembly 5 15 Remove the brake disc socket head cap screws 3 and brake disc Deflate the inner tube Split the wheel assembly by removing the socket head cap screws 6 washers 9 and nuts 6 Replace the inner tube Orient the valve stem to the hole in the wheel and the colored dot on the tire 7 SLOWLY inflate the tire Deflate it fully and re inflate it SLOWLY a couple more times to work out any wrinkles in the tube Inspect for a good seat around the wheel rim For fin
32. Remove any loose or damaged paint 2 Use progressively finer grit sandpaper to achieve a smooth gradual taper to undamaged paint 3 Clean and dry the entire prepared area 4 Apply primer and touch up paint to the entire prepared area 15 5 Rev 1 THIS PAGE INTENTIONALLY LEFT BLANK 15 6 Rev 1 CHAPTER 16 TROUBLESHOOTING Related Chapter Recurring blown fuse Short in circuit Overloaded circuit Engine will turn over Insufficient ignition source 8 Insufficient fuel supply to engine Insufficient air supply to engine Engine fails to turn Insufficient battery power ibd Blown Start fuse Master or starter relay malfunction Starter malfunction Heater air is cool Low engine coolant Engine below operating temperature Blockage in coolant system Air leak around heater box Vent door stuck Damage to fuselage Damage to vent Over tightened vent hardware Wing attach pin very Insufficient lubrication difficult to insert or remove Structural damage Wing not fully inserted Force applied to wing Pulls to one side during Low tire pressure taxiing level surface N a aw al S wm Dragging brake Damage to landing gear Axle nut over tightened Shudder after touch Nose fork under tightened 5 down 16 1 Rev 1 Possible Causes Related Chapter Vibration at idle e Propeller installed incorrectly 11 RPM too low 12 Carb sycronization out of balance Ro
33. Rotate the nose fork about the gear leg Check for lubrication Check the break out force per KAI Use a straight edge to check that the unloaded gear leg is straight between the factory bends Rev 3 Inspect the condition of fasteners and cotter pins and the condition of attach locations at the nose fork pivot point and the three wheel Inspect the tires for cracks wear and tire pressure Valve and valve stem in good condition and capped Check the nose gear leg coating welds and brackets for cracks and signs of fatigue Check nose fork pivot point for lubrication Check the nose fork nut and cotter pin for condition and signs of fatigue WING CENTER SECTION Magnifying glass Clean Flashlight Straight edge Inspection mirror e Multi meter Wing retention pin bushing gauge Inspect the wing skins and fasteners for signs of damage or deformation Check the fasteners by sighting down each rivet pattern for any inconsistent rivet profile among properly installed rivets Any damage observed on the wing skins demands thorough inspection of the understructure of the damaged wing Use a flashlight and an inspection mirror to inspect spars ribs and attach angles on the interior of each wing Especially the inboard most ribs and ribs at the flaperon hinge attach points The aft outboard portion of the wings can be viewed through the lightening holes in the outboard portion of the rear spar I
34. SCHEDULE PROCEDURES WARNING ALWAYS HAVE AN APPROPRIATE FIRE EXTINGUISHER READILY AVAILABLE GASCOLATOR CLEANING 3 16 Standard screwdriver Ya drive socket extension 14 socket flat blade screw bit Safety wire pliers Fuel catch container Expendable Gas 5 O ring gasket Service Rating Minimum Certification Additional References Remove the engine cowling 12 4 Move the fuel valve to the OFF position Remove the fuel quick drain to drain the existing fuel from the gascolator bowl Remove the safety wire and screws 4 from around the gascolator bowl Note The inboard aft screw can be accessed through the hole provide in the bottom plate of the nose gear assembly by using drive socket extension 4 socket and a screw bit inserted in the socket 5 Remove the collar and the gascolator bowl Note Have a container available to catch any spillage of fuel that still remains in the gascolator and fuel lines 6 Usea small pointed tool to lift the edge of the filter screen and remove it for cleaning ann INSTALLATION 1 Installation procedure is reverse of the removal procedure 13 7 Rev 1 FUEL STRAINER REMOVAL Tools 3 4 combo wrench or deep socket Expendable Thread sealant paste Noe Replaceable None Service Rating Line 42 Minimum Certification LSA RM or A amp P Additional References NOTE IS NOT NECESSARY TO REMOVE THE FUEL TANK IN ORDER TO REMOVE T
35. Wheel bearing grease Additional References e NOTE SERVICE ONE PEDAL AT A TIME 1 Actuate the rudder pedals so that the brake pedal to be serviced is offset from the adjacent rudder and brake 4 pedal The WD 1211 L following steps Zr NUT relate to Figure 19 an X COTTER PIN Remove the SY master cylinder WASHER lower hardware 224 LUBRICATE HERE Remove the brake pedal hardware bolt washer and nut BRAKE MAST CYLLEFT 1 Figure 19 Torque tube lubrication 7 4 Rev 2 Remove the brake from the pivot tube Remove the pivot tube from the rudder pedal Clean the pivot tube then apply lubricant to the exterior of the tube Installation procedure is reverse of the removal procedure NOOA HYDRAULIC FLUID DRAIN FLUSH AND REPLACE Container Minimum Certification LSA RM or A amp P Additional References KAI Matco user manual DRAINING 1 Place suitable containers beneath each brake caliper to capture hydraulic fluid from each bleeder valve 2 Open the bleeder valve on each brake caliper and allow fluid to drain FLUSHING REPLACING 1 Install a clear hose on the top of the brake fluid reservoir and insert it in a container to catch fluid overflow 2 Attach a pump style oil can filled with hydraulic fluid to the bleeder valve on the bottom of one of the brake calipers Open the bleeder valve and pump the oil can until clean fluid flows in the
36. a vertical stabilizer rudder and stabilator with anti servo trim tab The airframe is a semi monocoque aluminum structure with some steel and fiberglass parts Fiberglass composite parts are used to finish some non structural portions of the aircraft The pilot and passenger board the aircraft from either side using the boarding step and a reinforced area near the leading edge of the wing The pilot is seated on the left side from within the cockpit of the aircraft A combination Electronic Flight Information System EFIS and Engine monitoring System EMS with graphical user interface is used to monitor and report flight and engine performance information to the pilot The Rotax 912ULS 100 hp four cylinder engine is enclosed in a fiberglass composite cowling at the front of the aircraft Engine power is transferred via an integral gearbox to the Sensenich composite propeller The pilot and the passenger both have full flight and ground controls Pitch and roll is controlled from either control stick The control sticks are linked by push pull rods and torque tubes to the flaperons and linked by cables to a stabilator The flap lever controls the flap function of the flaperons Yaw is controlled using rudder pedals linked by cables to a traditional rudder that is hinged to a fixed vertical stabilizer The rudder pedals have integrated left and right foot pedals that are used to independently control the wheel brake on the corresponding side
37. amp Bushings Signs of Fatigue Wear Maximum 1 0 1 505 Center Section Channel amp Bulkheads Deformation Cracks Signs of Wear Corrosion O Continued on next page 18 19 Rev 6 THIS PAGE INTENTIONALLY LEFT BLANK 18 20 Hinges amp Rod Ends Component Skins Control Cable Links amp Push Pull Rods Control Stops Paperwork Record Findings Record Inspection Record Maintenance Notes and explanation of discrepancies found Free play Smooth Operation Deformation Cracks Signs of Wear Corrosion Tension Wear Fatigue Security Deformation Alignment Aircraft Log Aircraft Log Aircraft Log End of inspection checklist 18 21 Rev 6 Rev 6 THIS PAGE INTENTIONALLY LEFT BLANK 18 22 ELECTRICAL SYSTEM SCHEMATIC D 180 Rev 6 ROTAX 912 DUAL EFIS i EFIS topTioNAL 1 RECTIFIER E REGULATOR y 3 FUSE 5A WITH GGRIB
38. clear tube at the top of the fluid reservoir Close the bleeder valve and remove the oil can and hose 3 Repeat the previous step on the other brake caliper 4 Confirm that the brake peddle at each seat position for the left and right brake systems feel firm with no sponginess when pressed Also confirm that there are no air bubbles visible in the translucent brake lines between the left and right seat rudder pedals If there is any sponginess or presence of air bubbles repeat the flushing replacing steps 5 Use a syringe to slightly reduce the fluid level in the reservoir and reinstall the reservoir cap 7 5 Rev 2 BRAKE LINING REPLACEMENT NOTE IT IS RECOMMENDED REPLACE ALL OF THE BRAKE LININGS ON BOTH SIDES EVEN IF ONLY ONE LINING REQUIRES REPLACEMENT Tools 7 16 socket Expendable Brake linings Safety wire Replaceable Brake disc Service Rating Line Minimum Certification LSA RM or A amp P Additional References Matco user manual Remove the 2 safety wired bolts and remove the stationary brake shoe Remove the brake housing from the brake plate use care to not damage the aluminum brake line Remove the floating brake shoe Check that the brake disc is within wear limits Replace if necessary Install new linings on the brake shoes per Matco instructions Install the floating brake shoe Install the brake housing on the brake plate Install the stationary brake shoe and safety wire the bolts Test
39. ee entis eer cie s Let etc 14 2 14 2 Replaceable si sac E N 14 2 General aeae ae 14 3 Exhaust system removal ete REDE exit RR 14 3 cibum E E A E einladen A 14 3 Serice schedule PIOGedbHleS ooa jean 14 4 Ball joint lubrieation E A T RE NE OE CHI EM 14 4 14 11 Rev 1 OVERVIEW The primary purpose of the exhaust system is to direct engine combustion gasses and heat away from the aircraft components and occupants The purpose of the muffler is to reduce engine noise e NOTE THIS MAINTENANCE MANUAL IS INTENDED TO BE USED IN CONJUNCTION WITH THE RV 12 ASSEMBLY INSTRUCTIONS KAI WHEN COMPLETING MAINTENANCE OR REPAIR PROCESSES COMPONENTS Quantity Part or Assembly Name Part Number or Reference Exhaust tube EXH 1201 1202 1203 1204 Muffler EXH 1205 8 JJoitsping 738 795 SERVICE SUPPLIES TOOLS EXPENDABLE 13 mm socket Anti seize compound high temp e Locking pliers REPLACEABLE See component list above 14 2 Rev 1 GENERAL EXHAUST SYSTEM REMOVAL A WARNING ALLOW THE EXHAUST COMPONENTS TO COOL BEFORE PERFORMING INSPECTION OR SERVICE Tools 13 mm socket Locking pliers Expendable Anti seize compound high temp Replaceable Joint spring Service Rating Line Minimum Certification L
40. engine and verify that the choke controls on both carburetors are in the full off position Also verify that both throttle cable leads see Figure 27 are resulting in full travel of the throttle arms to the full throttle position on both carburetors If both are satisfactory move to step 17 for making adjustments 17 Determine which carburetor has the higher vacuum reading Loosen the aft nut on the off idle adjustment hardware of the carburetor with the higher vacuum see Figure 27 and then tighten the fwd nut This will adjust the throttle for this carburetor open an additional amount 18 Restart the engine and run the engine through the middle of the throttle range Repeat the adjustment done in step 17 until the vacuum gauge readings for both carburetors are closely matched If you go too far and the carburetor that you have been adjusting ends up having a vacuum gauge reading lower than the other reverse the adjustment and bring it back to where the vacuum gauge readings match Once the off idle vacuum gauge readings are balanced confirm that the nuts on the throttle cable locking hardware are tight on both carburetors IDLE SPEED ADJUSTMENT A WARNING Do NOT ADJUST THE IDLE SPEED SCREWS MORE THAN 1 2 TURN EITHER WAY TO ACHIEVE THE PROPER IDLE SPEED F A SETTING OF MORE THAN 1 2 TURN IS REQUIRED REPEAT STEPS 1 8 IF NO SATISFACTORY RESULT CAN BE ACHIEVED INSPECT THE IDLE JET FOR TRANSLUCENT JELLY LIKE CONTAMINA TION AND FREE PASSAGE
41. etr 7 5 2 edd ceria nt anes 7 5 Brake lining replacements beine oar e E em tpe ipd eui y 7 6 7 1 Rev 2 OVERVIEW The brake system includes the necessary components to provide directional control and stopping ability while taxiing The left and right brakes are independently controlled hydraulic disc brakes The fluid reservoir supplies the master cylinders with hydraulic fluid Pressure applied to either brake pedal causes the master cylinder to force hydraulic fluid through the plastic and aluminum lines to the corresponding brake caliper Refer to the Matco instructions and the KAI to identify the individual parts of the brake system e NOTE This maintenance manual is intended to be used in conjunction with the RV 12 Kit Assembly Instructions KAl when completing maintenance or repair processes COMPONENTS Quantity Part or Assembly Part Number or Reference 6 SERVICE Use of the proper hydraulic fluid is necessary for proper operation of the brake system It is good practice to replace the hydraulic fluid every 5 years If any indication of contamination is present replace hydraulic fluid as soon as possible Since the brakes on the RV 12 are relied on for part of the airplanes steering control on the ground any detected leaks should be repaired p
42. inch length of 1 2 inch I D fuel hose Scouring pad or equivalent Sandpaper various grades Spark plug gap tool wire type Compression tester Magnifying Glass Small square Tire air pressure gauge Needle nose pliers 5 inch clamp Terminal crimping tool Locking vice grip style pliers 2 1 2 x 3 16 bolt washer nut Vacuum gauge set Portable weight scale tension type Fire extinguisher Pump style oil can with hose Safety wire twisting pliers 5 9 9 9 9 9 9 9 9 9 9 9 9 9 9 e NOTE TOOLS DIFFER IN SIZE AND CONFIGURATION THE FOLLOWING ILLUSTRATIONS ARE ONLY EXAMPLES OF WHAT A TOOL MAY LOOK LIKE 1 8 Combination Wrenches Sockets Oil Filter Cutter Oil Filter Wrench Rev 5 Ratchet Screwdrivers Allen Wrenches Heavy Stands Battery Charger Multi meter Air Pressure Gauge 1 9 Razor Knife Hardware Rev 5 Flashlight Needle nose Pliers Terminal Crimper Power drill Tensile Weight Scale Rev 5 m CAUTION REPLACEMENT PARTS MUST BE OF EQUIVALENT SIZE TYPE AND RATING AS THE ORIGINAL PARTS FROM THE MANUFACTURER EXPENDABLE PARTS PART NUMBER Oil filter Copper crush ring for drain plug U 5 00X5 Tire any aircraft grade 5 00X5 4 or 6 ply tire is acceptable U 5 00X5 6IT any aircraft grade 5 00X5 6 inner tube is acceptable Brake shoe linings 66 106 or equivalent Fuses 4 blade style 1 2 3 5 7 5 30 Amp rating All fus
43. manuals was Software updates are often available online for the Dynon D 180 and the Garmin GPS The avionics components are not serviceable by the consumer unless otherwise noted in the manufacturer user manuals MM Page 11 3 Rev 3 Under Prop amp Hub Check the hub clamping bolt torque after the first 5 hours and at each condition inspection was Check the hub clamping bolts every 25 hours of operation This now matches the specification in the Sensenich propeller manual MM Page 12 1 Rev 4 Engine Coolant Level Check 12 6 was 12 7 Carburetor Synchronization 12 7 was 12 8 Vacuum Gauge Hookup 12 10 was 12 11 Off Idle Setting 12 12 was 12 13 Idle Speed Adjustment 12 12 was 12 13 Add Verify Functionality of Throttle Return 12 14 Service Schedule procedures Cowl Hinge Lubrication Oil Hose Replacement 12 15 was 12 14 Add Oil Hose Replacement 12 15 Cooling Hose Replacement 12 16 Manifold Pressure Hose Replacement 12 16 If you have read this far in this NPR and not fallen asleep yet congratulations and why are you not out flying right now MM Page 12 14 Rev 4 Add Verify Functionality of Throttle Return Springs process MM Page 13 01 Rev 5 Add Fuel Return Assembly 13 8
44. of the strap material and stitching Check the installation fasteners and condition of each seat back Inspect the canopy windscreen and aft window for deterioration or breakage The canopy latch and latch block must be in good condition and installed correctly Test the security of the roll bar and check for any sign of fatigue Check the canopy frame for cracks security Check that the control panel items are marked permanently clearly and correctly Inspect all switch panel and instrument panel connections for security and condition Test all position lights landing lights and cockpit lights for operation Check the condition of in service fuses and the condition and presence of spare fuses Run a rag along the control cables to check for frays or broken strands that will snag the cloth The stabilator cables must be aligned with the corresponding pulley and free from physical interference The locking clips on the tensioner barrels must be installed and secure Actuate the control stick forward and aft to check the pulley operation The pulleys must turn smoothly without lateral play With the control stick pulled back the trailing edge of the stabilator must be up Hold either control stick stationary and gently wiggle each push pull rod there must not be free play or loose parts Check the rod end jam nuts for proper torque and check the security of the rod end connection fasteners Actuate the control stick left and right Operati
45. original part or substitute part is acceptable for installation in the aircraft Brake System 271 N 04X02 Male Nylon gt Van s FLF 00004 Male Nylon Tee gt MCMASTER CARR 5779 204 LEGIS 3103 56 11 Avionics System FN4MC 2 Nylon 1 4 Straight gt Van s FLF 00007 Elbow gt MCMASTER CARR 5779K151 gt LEGRIS 3109 56 11 Rev 6 CHAPTER 18 SUPPLEMENT bat Eat RT bod UE N ae 18 3 INSBECTIONGHECKLISTE A itor cle ne oed e ud ebbe aues e ite ede Sera 18 7 ELEGTRIGAE SYSTEM 82 3 d re eic Wc eon b oet o DR DE e gud 18 23 VIEW d d cU iS LL ME NC e m ace cR Uer 18 29 FEEBBACK FORM ists statutes tem iN Deni Se Ei Ud I MINUM endende 18 31 18 1 Rev 6 THIS PAGE INTENTIONALLY LEFT BLANK 18 2 Rev 6 SERVICE SCHEDULE CHECKLIST What Aircraft AST attach hinge Battery Battery terminals Brake fluid Brake pedal components Brake shoe linings Cable end hardware Control system rod ends Dynon Coolant Hoses Engine service procedures Exhaust ball joints Flaperon bearings Flaperon control connection Fuel Drain Hose Fuel Strainer Fuel Drain Interconnect Fuel Return Assembly Garmin Fuel Pressure Hose Gascolator Landing gear attach hardware Main wheel bearings Manifold Pressure Hose Service Action When How Date Initial Inspection 100 hours 3 1 Lubricate An
46. rivet pattern for any inconsistent rivet profile among similar properly installed rivets Check the spar and hinge brackets for cracks deformation and signs of fatigue especially the areas surrounding the hinge brackets Check the fiberglass fairing for condition and security Check the rudder control horn for coating damage Inspect for cracks missing fasteners and deformation Check the spar bottom rib surrounding the rudder horn for cracks or deformation Inspect the control cable swages link fasteners and attach area on the control horn for signs of wear or fatigue Check the rudder stops on the lower hinge for wear or deformation Make sure the rudder swings smoothly and the control horn contacts the rudder stops square and flush as shown in Figure 8 FLUSH CONTACT incorrect Figure 8 Rudder Stop 3 14 Rev 3 STABILATOR Check the main skin for damage or deformation Check the main skin fasteners by sighting along each rivet pattern for any inconsistent rivet profile among similar properly installed rivets Inspect the Anti Servo Tab hinges fasteners and safety wire for wear and security Inspect the spar box for cracks deformation or signs of fatigue especially the areas surrounding the control horns hinge brackets and counterbalance brackets Use an Inspection mirror to inspect the ribs for cracks or deformation Inspect the coating on the control horns counterbalance brackets and counterbalance
47. tailcone fairing 3 4 Label then disconnect the pitch trim servo wire terminal connections Remove the cushioned clamp and free the tailcone wire from the trim servo assembly Make note of the hardware configuration Disconnect the trim servo assembly from the AST assembly by removing the bolt washers 3 and nut as shown in Figure 22 Disconnect the trim servo assembly from the tailcone by removing the cotter pin bolt bushings 2 washer and nut Remove the trim servo assembly from the aircraft as shown in Figure 22 8 7 Rev 3 TAILCONE TRIM SERVO ASSEMBLY AST ASSEMBLY DOUBLER PITCH TRIM x SERVOMOTOR 7 Remove the pitch trim T servo attach screws 6 d PUSHROD washers 6 nuts 6 and ASSEMBLY doublers 2 as shown in an Figure 23 SERVOMOTOR Unscrew the pitch trim 3 servo from the pushrod assembly Remove the jam nut from the pitch trim servo shaft Clip the wire terminals off of the old servo and remove the snap bushing Slide the snap bushing onto the wires of the new servo Figure 23 Pitch trim servo removal 1 Install new terminals on the three colored wires of the servo 8 8 Rev 3 2 Thread the jam nut onto the new pitch trim servo shaft until it contacts the pitch trim servo shaft housing Thread the pitch trim servo shaft onto the clevis rod end on the pushrod assembly until it contacts the jam nut Back the pitch trim servo off two fu
48. the AST by actuating the stabilator through its full range of motion with the trim adjusted to the full nose up and full nose down settings AST movement must be smooth and relative to the stabilator movement There must not be any interference with the AST and the pitch trim servo components at any point of the stabilator travel PAPERWORK Make the appropriate log book entries Save the completed checklist in the aircraft file 3 15 3 16 Rev 3 Rev 1 CHAPTER 4 STRUCTURAL REPAIRS OVERVIEW Visible deformation of or damage to any aircraft skin warrants a complete inspection of the underlying parts or structures Repair of damage to skins is allowed without consultation of the manufacturer as long as a new skin is ordered from the manufacturer and installed in accordance with the RV 12 Kit Assembly Instructions KAI Small patch repairs to skins as outlined in AC43 13 are allowed without consulting the aircraft manufacturer if the total patch area does not exceed 60 square inches Repair to interior structural parts of the airframe or skin repairs other than replacement of the entire skin or patches to skins of more than 60 square inches are not allowed without consulting with the airplane manufacturer and receiving approval of the planned method of repair Note Integral stringers formed on the edge of skins are considered interior structure 4 1 Rev 1 e NOTE This maintenance manual is intended to be used in conjun
49. the two aft access covers from the fuselage bottom skin 3 4 3 Remove the screws 6 that attach the fuel neck to the fuselage Loosen the hose clamps and slide the rubber collar up to remove the fuel neck from the fuselage and fuel tank 4 Disconnect the fuel sending unit wire 5 Remove the ELT Antenna Bracket disconnect the coax cable and set aside m CAUTION DOUBLE WRENCH DURING THE REMOVAL OF THE SMALLER OF THE TWO FUEL LINES TO PREVENT ACCIDENTAL ROTATION OF THE FITTING IN THE FUEL TANK Disconnect the two fuel lines from the bottom of the tank Remove the two bolts from the forward fuel tank attach bracket Remove the bolt from the aft fuel tank attach bracket Remove the fuel tank an INSTALLATION 1 Installation procedure is reverse of the removal procedure FUEL SYSTEM COMPONENT REMOVAL WARNING BEFORE PERFORMING MAINTENANCE OR REPAIRS TURN THE MASTER SWITCH OFF AND DISCONNECT THE NEGATIVE BATTERY CABLE FROM THE BATTERY LEONE 3 8 7 16 combination wrenches 1 Isolate the component from fuel flow with either the fuel shutoff valve or by draining the fuel tank 13 6 Rev 1 2 Label then disconnect the electrical connections attached to the component if applicable 3 Disconnect the fuel line s attached to the component if applicable 4 Remove the attaching hardware and component INSTALLATION 1 Installation procedure is reverse of the removal procedure SERVICE
50. 1 3 Push pull cable 10 2 Inspeetion u nn ee ee 3 6 3 9 pe 10 5 R Radio een 3 7 Lubrieation ana 5 23 Rivet eei tuu 3 10 Rod end L brication ici 6 9 6 7 Rudder Pedals Installation re 6 9 6 8 R dder eee we 5 7 nei 3 13 6 8 20 4 Rev 3 RV 12 AT 18 25 anne 1 1 5 1 4 17 1 Feedback 18 27 Service 2 1 Table een an 18 3 Shap GUSNING Arara ea 8 13 E 9 6 Spark 12 3 12 5 5 7 Control cable 6 3 Inspecti n t ces ecce tee cete 3 15 Stub Spar E brication 1r rece 5 23 18 1 Substitute 17 2 T Throttle Cable Lead Hookup 12 10 Tire Pressure cie et n eere 1 14 TOGUE 1 15 16 1 U Utilities cn arten 10 1
51. 12NPR 04 03 14 1 Reason For Revision 1 RV 12 SkyView Touch Avionics Kit 2 RV 12 SkyView AP Knob Panels Kit 58 3 Add instructions for installation of 00062 4 Allow use of lighter springs on RV 12 throttle 5 Improve functionality of canopy latch Add switch to detect open canopy before takeoff Re Write ditching instructions in POH 6 Placarding changes to match and to the actual placarding on the aircraft 7 Make a new optional section for installation of a rudder trim tab MM Page i Rev 8 Added location for aircraft serial number to the front page of the manual MM Page iv Rev 5 Add Abbreviations 1 6 and Units 1 7 MM Page vi Rev 5 Inspection Checklist should be page 18 7 was 18 5 Electrical System Schematic 18 23 was 18 21 and 18 27 was 18 23 3 View page 18 29 was 18 25 Feedback Form page 18 31 was 18 27 MM Page vii Rev 5 Updated page references in Note MM Page viii Rev 5 Terminal Crimping page 1 17 was 1 16 Lifting and supporting page 1 18 was 1 17 Torques tube lubrication page 7 4 was 7 5 Trim Servo Assembly Removal page 8 8 was 8 7 MM Page 1 2 Rev 5 Add Garmin EFIS EMS GPS and Nav comm and TCW Backup Battery to the list of manufactures MM Page 3 7 Rev 3 Add under INTERCOM If Installed MM Page 5 1 Rev 4 Add Wheel Fairings 5 11 add Optional Components 5 11 Nose G
52. 2 4 Remove the negative battery cable Remove the positive battery cable Remove the battery channel Lift the battery to remove pue pM INSTALLATION 1 Installation procedure is reverse of the removal procedure 8 5 Rev 3 FUSE REPLACEMENT TYPE AND RATING AS SPECIFIED BY THE MANUFACTURER REPLACING ANY FUSE LARGER IS SPECIFIED MUST BE OF THE TYPE THAT ILLUMINATE WHEN BLOWN _ COMPLETE _ BROKEN ELEMENT ELEMENT A LES Fi Li um H d Remove the suspected blown fuse Perform visual inspection and or use multi meter to test fuse Insert new fuse with proper rating as shown in Figure 21 A recurring blown fuse indicates excessive current draw from the sump SkyView G3X corresponding circuit of the J electrical system See Chapter J 18 Uis JE e GPS eit D 180 Figure 21 Fuse panel 8 6 Rev 3 PITCH TRIM SERVO REPLACEMENT Tools 3 8 7 16 socket 3 16 combo wrench 2 Phillips screwdriver Wire cutter Terminal crimping tool Needle nose pliers Replaceable Pitch Trim servo Service Rating Expendable Replaceable Minimum Certification LSA RM or A amp P Additional References cR 1 2 Disconnect the negative battery cable Remove the upper and lower
53. 6 THIS PAGE INTENTIONALLY LEFT BLANK 18 6 Rev 6 INSPECTION CHECKLIST RV 12 Aircraft Inspection Reg Number Airframe S N Engine S N Airframe TT Engine TT Inspection Date Inspector Check all that apply to inspector and inspection Owner Operator Pilot A amp P LSA Repairman Inspection LSA Repairman Maintenance 100 hour Annual Extreme Conditions After Hard Landing Category Check Documents NENNEN NE Certificate of Airworthiness Onboard and Displayed Registration Onboard Onboard EEE Operating Limitations Onboard Switch and control placards Secure Legible Identification Plate Secure Legible Weight amp Balance Equipment List Onboard MEER Service Schedule Items due for service Systems amp Controls Test Operations Values Pre Inspection Post Inspection Engine Start Procedure Effective Complete TECH Starter Operational Strong Oil Pressure amp Temperature 1800 RPM Engine Run Up Refer to Rotax Line Maintenance Manual Continued on next page 18 7 Rev 6 THIS PAGE INTENTIONALLY LEFT BLANK 18 8 Oil Pressure amp Temperature Left and Right CHT idle amp operating temp Left and Right EGT idle amp operating temp Left and Right Wing Brake System Fuel Idle RPM at normal operating temp Verify function of throttle return springs Static RPM at full throttle Electrical
54. A RM or A amp P Additional References KAI 1 Remove the step attach bolts 2 washers 2 and the step 2 Install the new step and attach hardware 5 22 Rev 4 SERVICE SCHEDULE PROCEDURES WING ATTACH LOCATION LUBRICATION WINGS REMOVED Expendable Wheel bearing grease Anti seize compound Replaceable Fuselage Pin Minimum Certification Owner and SPC LSA RM or A amp P Additional References KAl FUSELAGE PINS 1 Wipe clean the fuselage pins 2 2 Wipe clean the wing retention pin bushings 8 3 Apply grease lubricant sparingly to the shaft of each fuselage pin STUB SPAR AND REAR SPAR 1 Wipe clean the inboard end of the stub spar and rear spar of each wing 5 4 2 Apply anti seize compound sparingly to the inboard end of the stub spar and rear spar of each wing FLAPERON CONTROL CONNECTION LUBRICATION WINGS REMOVED Tools Expendable Replaceable None None Service Rating Minimum Certification Owner and SPC LSA RM or A amp P Additional References Wing removal 5 13 1 Wipe clean the UHMW pivot guide and actuation bracket of each flaperon See page 5 4 Figure 10 2 Apply lubricant sparingly to the UHMW pivot guide and actuation bracket of each flaperon 5 23 Rev 4 FLAPERON BEARINGS LUBRICATION Expendable Spray lubricant Replaceable Additional References Flaperon hinge replacement 5 17 1 Wipe away any dirt accumulation from each of the flapero
55. A WARNING Do NOT REMOVE THE UPPER VIBRATION ISOLATOR BOLTS 3 Remove the lower engine vibration isolator bolts 2 4 Remove the nose gear leg hardware from the fuselage bolts 13 and washers 13 e NOTE THE ENGINE CAN BE LIFTED BY HAND AT THE GEARBOX 5 Lift the front of the engine only enough to remove the engine weight from the gear leg bracket 6 Remove the nose gear leg INSTALLATION 1 Lift the front of the engine only enough to provide room behind the engine mount for the nose gear leg 2 Install the nose gear leg and attach hardware 3 Install the lower engine vibration isolator bolts 5 21 Rev 4 BELT AND HARNESS REPLACEMENT Ei 7 16 combo wrench Minimum Certification Owner and SPC LSA RM or A amp P Additional References ENTIRE HARNESS SET BE REPLACED IMMEDIATELY Remove the seat ramp cover 3 4 Remove the crotch strap bolt bushing washer nut Remove each waist strap 2 bolt bushing washer nut Remove the shoulder straps bolt bushing washer nut Install the new harness set and attach hardware er OI CANOPY LATCH BLOCK REPLACEMENT 2 Phillips screwdriver None Latch Block Line LSA RM or A amp P Additional References KAI 1 Remove the latch block attach screws 2 and the latch block 2 Install the new latch block and attach hardware STEP REPLACEMENT 7 16 socket Expendable None Replaceable Left or Right Step Preventative Minimum Certification Owner LS
56. AK2X Dearing tesi dn Bere 5 20 en 6 4 Tensioner barrel removal sea 6 4 5 Torgue tube l brication ass 7 4 Optional Wing Tip Lighting zen E REIR 8 3 F se 8 6 Trim servo assembly removal asus 8 8 Pitch trim servo TemoVval a2 een 8 8 Stall Warning corte oret re 8 10 Snap BUSHING He Hrn 8 13 Hotax 9T2Ub5 ux na OU eee Ekel 12 3 Carburetor OVOLVIGW 12 8 Mixt re mele remis a ee 12 9 Throttle Handle Idle Position a msn dee rre Deut RE D ines 12 10 Vacuum T 12 11 viii Rev 5 CHAPTER 1 GENERAL INTRODUCTION PURPOSE The purpose of this manual is to provide guidance to RV 12 owners pilots mechanics regulatory officials and manufacturers that are certified to perform maintenance repairs and alterations on the light sport aircraft covered in this manual SUMMARY This manual contains maintenance instructions for the RV 12 light sport aircraft The RV 12 is a single engine fixed tricycle gear full cantilever monoplane The two seat cockpit is enclosed with a tip up windscreen canopy The occupants sit side by side aft of the engine and forward of the wing spar Both of the wings are quick removable The flaperons remain with the wings and self connect to the control linkage when the wings are installed The empennage consists of
57. Brakes Avionics amp Radio Each Main Unit Wiring amp Conduit Connections Antenna Mounts Optional Equipment Throughout Clear Correct Security Connections Security Condition Spares Tension Wear Fatigue Security Deformation Alignment Swages Kinks Interference Alignment Operation Kinks Interference Alignment Smooth Operation Alignment Security Smooth Operation Smooth Operation Operation Security Condition Connections Continuity Security Routing Condition Fittings Security Leaks Clean Secure Operation Security Inspect per Manufacturer Manual Condition Security Chafing Routing Security Corrosion Security Condition Security Inspect per Manufacturer Manual Continued on next page 18 13 Rev 6 THIS PAGE INTENTIONALLY LEFT BLANK 18 14 Emergency Locator Transmitter G Switch Calendar date Battery Propeller Spinner Back plate Blades Hardware Hub Gear Box Prop Track Comply with current FAR 91 207 Also refer to current 91 207 Also refer to current 91 207 Also refer to current 91 207 Refer to Sensenich Manual Cracks Deformation Delamination Cracks Damage Condition Torque Fasteners Security Leaks Fasteners Security Perpendicular to Axis Continued on next page 18 15 Rev 6 THIS PAGE INTENTIONALLY LEFT BLANK 18 16 Engine Engine and components Firewall Forward Fwd Face of Firewa
58. CEMENT AND CABLE TENSION ADJUSTMENT 3 8 7 16 socket 3 8 7 16 combo wrench Needle nose pliers Cable tension meter Spring clamps 3 Stick 41 long Cotter pins Lock clips Stabilator pulley Line LSA RM or A amp P 6 3 Rev 3 1 Remove the seat ramp cover and cover plate only the aft two 3 4 ALIGN V NOTCH IN BARREL WITH GROOVE IN CABLE END 2 Remove the LOCKING CLIP IF stabilator control cable barrel lock a7 227 clips from one barrel as shown in Figure 17 Figure 17 Locking clip removal BARREL TOWARD FRONT Loosen the tension of the TENSIONER i BARREL stabilator STABILATOR cables by CONTROL CABLE turning the tensioner WIRE TOOL MADE FROM barrel as WELDING WIRE shown in HANGER WIRE ETC Figure 18 Pd Figure 18 Tensioner barrel removal Remove the pulley axle hardware and pulleys Capture the stabilator cables between the bushing and the new pulleys Install the pulley axle hardware Place a small weight on the stabilator to hold it trailing edge down Remove the slack from the upper cable by tightening the upper outboard turnbuckle until the control stick and stabilator just start to lift off the stops at about the same time when the stick is moved aft STABILATOR CONTROL CABLE GROOVE AROUND 2 SEO Remove the slack from the other cable by adjusting the lower inboard turnbuckle Check the entire length of the cables to ensure the
59. G amp SUPPORTING THE FUSELAGE A WARNING USE STURDY SUPPORT STANDS THAT ARE EACH CAPABLE OF SUPPORTING AT LEAST 500 POUNDS m CAUTION AVOID CONTACTING ANTENNA FAIRINGS OR OTHER ACCESSORIES WHILE PLACING THE SUPPORT STANDS UNDER THE AIRCRAFT m CAUTION REMOVE OR ATTACH THE WINGS PRIOR TO LIFTING AND SUPPORTING THE AIRCRAFT When the aircraft is lifted whether or not a jack is used the method of support is the same Obtain two sturdy padded stands each capable of supporting at least 500 pounds The padded contacting surface must be at least 1 1 2 inches wide Two layers of 3 8 inch carpet are recommended Both stands need to be about 30 inches long and 25 inches high Rev 5 LIFTING WITH A JACK m CAUTION USE APPROPRIATE JACK LOCATING FIXTURES TO ENSURE A STABLE JACKING SURFACE m CAUTION INSTALL A JACKPOINT WHEN LIFTING AT THE WING TIE DOWN LOCATION 1 Place a jack as necessary to lift the lower end of the nose gear leg 2 Lift the front of the aircraft enough to position a stand along the lateral rivet pattern centered directly between the boarding steps 3 Remove the jack 4 Place the jack as necessary to lift on the tail tie down 5 Lift the tail of the aircraft enough to position a stand along the lateral rivet pattern centered directly beneath the rear wing spar receptacles 6 Remove the jack 7 Test stability of the aircraft Grab the tail tie down and test for horizontal and vertical stabilit
60. G SPINNER OVERVIEW Gott costo tomos co teu DI aes dta 1 Gave UE 1 wilde EE 1 SUPBIIBS CLE 1 Uo Expendable nde obe N ved ent ete tee dee ade breit epe Db ee have aha regen heey Spinner and PROLTUDG hb te n ecd etse edes tcd 1 Prop IAD een Pcr 1 Rev 2 OVERVIEW The RV 12 has a ground adjustable Sensenich propeller For instructions to adjust the propeller pitch refer to the user manual provided with the propeller The current propeller manuals and or specifications take precedence over referenced information in this manual Current revisions to products or specifications made by the propeller manufacturer will not be reflected in this manual e NOTE This maintenance manual is intended to be used in conjunction with the RV 12 Kit Assembly Instructions KAl when completing maintenance or repair processes COMPONENTS Part or Assembly Name SERVICE Brief instructions referenced from the propeller manual about caring for the prop and hub are included below For complete information refer directly to the propeller manual The spinner cone is constructed with a bushing for the pitot tube It has no scheduled maintenance requirement other t
61. HE FUEL STRAINER 1 Drain the Fuel System 13 4 2 Remove the two aft access covers from the fuselage bottom skin 3 4 3 Disconnect the fuel line forward most fitting from the bottom of the tank 4 Remove the fuel strainer 5 Clean the screen and inspect same for breakage or separation from fitting Installation 1 Installation procedure is reverse of the removal procedure Apply thread sealant paste to fuel strainer pipe threads before installation FUEL RETURN ASSEMBLY REPLACEMENT Tools 2X 9 16 11 16 7 8 14mm open end wrench 12mm socket torque wrench in lb wire cutters Expendable Plastic tie wrap 8in Replaceable Fuel Return Assembl Minimum Certification LSA RM with Rotax Service certification of A amp P with Rotax Service Certification Additional References NOTE WHEN LOOSENING OR TIGHTENING THE BANJO BOLT SUPPORT THE CLAMP BLOCK FUEL MANIFOLD APPROPRIATELY 1 Drain fuel system forward of fuel valve 13 4 2 Disconnect both ends of Fuel Return Assembly 3 Remove banjo bolt M8X1X17 from top of clamp block 4 Cut tie wraps and remove Fuel Return Assembly Installation 1 Installation of new hose assembly is reverse of removal procedure Rotax specifies that new copper crush washers be used 2 Torque banjo bolt M8X1X17 to 90 in Ibs Rev 1 FUEL PRESSURE SENDER ELBOW FUEL RETURN ASSEMBLY BLACK FITTING E Figure 31 Fuel Pressure Hose Flush
62. HEN IT NO LONGER MEETS THE CONTINUED AIRWORTHINESS REQUIREMENTS SPECIFIED BY THE MANUFACTURER The following will aid in the safe operation longevity and appearance of the propeller Do not spin your propeller above the Propeller RPM Limits specified by the manufacturer e Check the hub clamping bolt torque after the first 5 hours and at each condition inspection Always check in the tightening direction e Before each flight carefully Inspect the propeller blades and hub for looseness signs of damage excessive wear or any other condition that would make the propeller unsafe to operate e When the propeller is not in use position it horizontally If it is exposed to weather cover it with a weatherproof cover Do not use the propeller as a tow bar to move your aircraft Apply a good quality automotive paste wax to the blades at least once a year Avoid liquid waxes e Avoid running up in areas containing loose stones and gravel Loss of surface finish from the leading edge is considered normal wear and is dependent upon the amount of operation in rain and grit e Immediately following an impact of any kind remove the propeller from service until it has been inspected and passed by qualified personnel Rev 2 Whenever there is evidence of rough operation check for proper torque For new installations it often helps to remove the propeller rotate it 180 and reinstall If the propeller shows any of the following sign
63. Initial column to identify the person that performed the service 2 2 Rev 3 CHAPTER 3 INSPECTION OVERVIEW ee ee 3 2 INSPECTION DESCRIPTION Sa se gar 3 3 RE 3 3 ae 3 3 ee ee 3 5 3 7 EOMMUNICAHON A nennen eek aa ea caede var 3 7 niic me 3 7 Ic 3 7 Optional eben E 3 7 Emergency Locator Transmitter 2240er 3 7 Propeler ER T PT 3 7 mele c EET 3 8 uz rie P O 3 8 gio PE 3 10 landing Geal T 3 11 Wing Center Section s7 3 12 e 3 13 Vertical Stabilizer neie ian a e o iie nike INH nase 3 13 n ce tton ae der fee de fa 3 13 Stabilator 2 ES 3 15 Anti Servo Tab amp Pitchistrim Servo a oet em epe eet iot pete 3 15 PAPETWOTK quM DT 3 15 OVERVIEW The condition inspection is performed annua
64. L LIGHTLY AGAINST THE CARBURETORS IDLE STOPS 19 A final idle speed adjustment may be required by resetting the idle speed adjustment screws accordingly Turning the idle speed adjustment screw clockwise will increase the engine speed counter clockwise will decrease it Equal adjustments must be made to each carburetor Any major adjustments require verification of all parameters in this procedure Before moving on to the next step verify that the vacuum gauge readings for the two carburetors are balanced at idle and at off idle throttle settings 20 Use light pressure on the throttle control to hold it at the idle position then tighten 12 13 Rev 4 the friction lock to hold the throttle control in place Slide the CT 00101 Stop Nut back against the forward edge of the conduit in the orientation shown in Figure 27 then tighten the 00101 set screw Restart the engine and confirm that when the throttle is pulled hard to the idle stop the idle speed is correct and the vacuum gauge readings for the two carburetors are closely balanced If they not loosen the CT 00101 Stop Nuts on both carburetors and then repeat steps 19 and 20 until they are 22 Install the balance tube in the reverse sequence of removal Any minor differences in balance at idle will be compensated for by the balance tube at low engine RPM 2 VERIFY FUNCTIONALITY OF THROTTLE RETURN SPRINGS 1 This section must be done with the aircraft out
65. LC B INTERCOM DUAL EFIS OPTION RADIO STARTER MASTER i r GENERATOR i GPS RELAY 24115 1 STARTER em COCKPIT LIGHTS RELAY MOTOR Fi iH SPAR FIN B MICRO _ 2 1A SWITCHES KEYED T COOLING T A OFF MOM 1 FANS TRIM STROBE LANDING SERVO METER START 271 LIGHT LIGHT MOTORS ODYSSEY IH A EAR 5 eaten um 2 DISENGAGED RELAY Lt rare E WARMING EH TET TET MASTER L LIGHT AND STALL AVIONICS gen er AUTOPILOT 5A 2 SWITCH Voila LEI OVERIDE WARN td OPTIONAL 1 E BUSZER LIGHTS OPTIONAL SWITCH OP TIONAL EE c 4 4 4 4 4 4 4 39 5 53A 3A 75 MAIN BUS 1 t t 1 tod i t i POWER OUTLET 18 23 D 180 Rev 6 THIS PAGE INTENTIONALLY LEFT BLANK 18 24 ELECTRICAL SYSTEM SCHEMATIC SKYVIEW Rev 6
66. NDR 26X Dynon manual 9 2 Rev 4 OPTIONAL COMPONENTS 2 Module See Dynon Manual D 180 or D1000 or D1000T or G3X See Dynon or Garmin Dual EFIS EMS Manual PITOT amp STATIC PITOT BLOCK EST 9 3 Rev 4 COMPONENTS Quantity Part or Assembly Name Part Number or Reference Static Source Rivet SD 42 BSLF SERVICE AVAILABLE WARNING BEFORE PERFORMING ANY MAINTENANCE OR REPAIRS TURN THE MASTER SWITCH AND DISCONNECT THE NEGATIVE BATTERY CABLE FROM THE BATTERY THE SAME TYPE AND RATING AS THE ORIGINAL PARTS Software updates are often available online for the Dynon D 180 Skyview Garmin GPS and Garmin G3X The avionics components are not serviceable by the consumer unless otherwise noted in manufacturer user manuals A manufacturer authorized repair facility will perform diagnosis and service to the avionics components The Cockpit Nav Strobe and Landing lights have no user serviceable parts Check the supply voltage and circuit connections Replace the inoperable light if necessary SUPPLIES TooLs EXPENDABLE Wire cutter Wire terminals Wire terminal crimper e Plastic Tie Wraps 3 8 combination wrench 5 64 allen wrench REPLACEABLE Razor Knife See component list on page 9 2 Screwdrivers 2 Phillips Small flat blade Computer with internet Unit connection cable 9 4 Rev 4 GENERAL COMPONENT REPLACEMENT See 9 2 and 9 3
67. NE COMPONENTS WILL CAUSE SERIOUS BURNS e Refer to the Rotax line maintenance manual for proper inspection procedure for engine and components supplied with engine The Rotax manual will also provide fluid check and change procedure FIREWALL FORWARD A WARNING THE MASTER POWER AND BOTH IGNITION SWITCHES MUST BE SHUT OFF DURING INSPECTION OF THE FIREWALL FORWARD COMPONENTS SERIOUS INJURY OR DEATH WILL RESULT IF ENGINE IS UNINTENTIONALLY STARTED A WARNING ALLOW THE ENGINE AND APPLICABLE COMPONENTS TO COOL BEFORE PERFORMING SERVICE OR INSPECTION HOT ENGINE COMPONENTS WILL CAUSE SERIOUS BURNS Magnifying glass Clean rag Flashlight Compression Inspection mirror tester e Multi meter e Note any signs of leakage corrosion and high temperature Check for wear to hoses cables wiring harnesses etc as a result of vibration while in contact with another object 3 8 Rev 3 Check the forward side of the firewall especially around components and fasteners around the battery oil tank assembly heat exchangers cowl attach locations engine mount and nose gear The firewall must not have any open passages into the cockpit Inspect the engine mount for damaged coating corrosion and signs of fatigue Damaged engine mount coating demands closer examination and repair Inspect the engine vibration isolators for cracks deterioration and installation Check the engine compartment wiring including ground wires of the wiring harnes
68. OR VERTICALLY m CAUTION ALWAYS USE PADDED STANDS AND ALWAYS DISTRIBUTE THE LOAD ALONG A RIVET PATTERN WITH SEVERAL INTERSECTING RIVET PATTERNS e NOTE REFER TO GENERAL GENERAL PROCEDURES INDEX FOR INSTRUCTIONS ON LIFTING AND SUPPORTING THE AIRCRAFT Magnifying glass Clean rag Flashlight Straight edge Inspection mirror Saw horses Torque wrench Tensile weight scale e Check all landing gear components attach locations and fasteners for cracks and any other signs of fatigue Throughout the inspection of the landing gear be observant for signs of hydraulic fluid leakage e Inspect each landing gear leg and attach point Check for evidence of black dust at the attach points which is an indicator of movement e Test the security of each of the landing gear legs The landing gear components may not have any free play in any direction e Check that all attach hardware is at proper torque Remember to account for the prevailing torque of the nut If a torque wrench is used on the head of the bolt also account for the torque to overcome the friction to turn the bolt shank within the assembly Test the security of the brake lines and inspect for signs of wear Grab and shake the wheels and tires to check for bearing looseness Check for smooth low resistance rotation of each wheel Check for excessive play in both brake calipers Check the brake shoe linings brake disc and wheel assembly per Matco manufacturer specifications e
69. Rev 5 SCOPE NOTE This maintenance manual is intended to be used in conjunction with the RV 12 Kit Assembly Instructions when completing maintenance or repair processes All of the service and maintenance requirements that are unique to the RV 12 S LSA are included in this manual The general service and maintenance duties that are common to standard aircraft still apply to the RV 12 regardless of the inclusion of those requirements in this manual All inspection and maintenance and all maintenance log entries must be made in accordance with 14 CFR FAR s The manufacturers of third party components provide manuals that include complete service and maintenance requirements that are specific to these components The current service and maintenance manuals from any third party manufacturer such as engine propeller avionics etc always take precedence over the related content in this manual There are references to third party documentation in this manual as well as some supplementary information which is for convenience only It is recommended to refer directly to the manufacturer s service manuals for complete service information that is unique to applicable components The manufacturers that provide operating and or maintenance manuals to use in conjunction with this manual are as follows Rotax engine Sensenich propeller Matco wheels and brakes Dynon EFIS EMS Garmin EFIS EMS GPS and Nav comm TC
70. SA RM or A amp P Additional References KAI 1 Remove the engine cowling 12 4 2 Remove the muffler attachment springs 8 and muffler Note Use locking pliers for a tight grip on the springs during removal and installation 3 Remove the two nuts two washers and the exhaust tube from each cylinder exhaust port INSTALLATION 1 Lubricate the ball joints and all exhaust hardware 14 4 2 Installation procedure is reverse of the removal procedure 14 3 Rev 1 SERVICE SCHEDULE PROCEDURES BALL JOINT LUBRICATION A WARNING ALLOW THE EXHAUST COMPONENTS TO COOL BEFORE PERFORMING INSPECTION OR SERVICE Minimum Certification LSA RM or A amp P Additional Reference 1 Remove the muffler attachment springs 8 and muffler Note Use locking pliers for a tight grip on the springs during removal and installation 2 Apply a generous amount of lubricant to the exhaust tube where it meets the muffler flange 3 Reinstall the muffler 14 4 Rev 1 CHAPTER 15 PAINTING AND COATINGS Expendable Replaceable Service schedule PrOGGdUE6S s e ein rex va S M MU e RAP Erxl ex Aa M RUD 15 3 Powder coat repair Primer repair Decorative paint repair Rev 1 OVERVIEW e NOTE REFER TO KAI SECTION 4 AND 5 FOR ADDITIONAL INFORMATION The aluminum skins used on RV aircraft are all 2024 T3 alloy They are alclad meaning both sides of the sh
71. System Cool Down amp Shut Down Fluids Oil Hydraulic Fuel Coolant Stall warning Pre Values Pressure Temp Post Values Pressure Temp Pre Values Left Right Post Values Left Right Pre Values Left Right Post Values Left Right Secure Smooth operation of ailerons and flaps Operation Correct Indication RPM Springs pull throttle to wide open with friction control off see procedure page 12 14 Operational RPM Operational Volts Amps Effective Normal Leak Level Check Tone present in headphones when stall sense switch is lifted Continued on next page 18 9 Rev 6 Rev 6 THIS PAGE INTENTIONALLY LEFT BLANK 18 10 Notes Cockpit Aft Face of Firewall Canopy Latch Fwd amp Aft Canopy Pre Inspection procedure Seats amp Seat Shoulder Harness Cockpit Control Markings Roll Bar and canopy frame Check Cracks Deformation Security Cracks Proper operation Cracks Deformation Deterioration Step 1 5 Page 3 3 Wear Fraying Clear Correct Cracks Deformation Continued on next page 18 11 Rev 6 Rev 6 THIS PAGE INTENTIONALLY LEFT BLANK 18 12 Cockpit Control markings Control Panel Fuses Control Cable Links amp Push Pull Rods Control Stops Flight Control Cables Engine Control Cables Cable Pulleys Control Stick Flap Lever Air amp Heat Vents Wiring Harness System Lines Fuel Brake Static Fuel System Components Fuel Strainer Rudder Pedals amp
72. TTERY REFER TO THE ELT OWNERS MANUAL FOR THIS PROCEDURE PERIODIC CHECKS SHOULD BE MADE AT A MINIMUM OF EACH CONDITION INSPECTION TO DETERMINE IF ANY SOFTWARE UPDATES HAVE BEEN ISSUED FOR THE EFIS EMS GPS SOFTWARE UPDATES 9 6 Rev 4 Unitconnection cable Expendable Replaceable Service Rating Minimum Certification Owner and SPC LSA RM or A amp P Additional References AC 43 13B Refer to the applicable user manual for the instructions and website address 9 7 Rev 1 CHAPTER 10 UTILITY SYSTEMS VENTILATION HEAT SYSTEM ee RD Nr 10 2 HEAD ee sce dd Ed n LAE E Mcr 10 2 GOTO IES oa a d E 10 3 VENTILATION SS ee ehe re 10 3 er er es iE 10 4 SERVIOE ed en E 10 4 SUDDlIeS epee C Rte eres 10 4 I ete 10 4 Replaceable ee ete ee ERE 10 4 HR REESE T EIER 10 4 21262 oc rm 10 5 tee ERR RM RITE ERR RE ERRARE RR paces RARE 10 5 Service Schedule Procedures s e sees echa hae 10 5 Push pull cable lubrication issnin een me bee 10 5 Rev 1 OVERVIEW
73. UDIGAN a rannte 1 11 Lubrication rennen 1 13 Main Landing Gear Be rings u ee kn 5 25 Inspection 3 11 5 21 5 20 Main Wheel Tire Insp amp ction un c era 3 11 Installation sees 5 15 REMOVAl cred asc tete ig tes 5 15 Main Wheel 5 9 Master cylinder 20 3 Rev 3 Installation 7 4 Removal 7 3 Nose Gear Leg Fairing 5 10 Nose Landing 5 8 ItiSDeCtlOn enia teen age 3 11 bubrication 5 25 5 24 5 25 Nose Wheel and Tire Bearings ner ees 5 24 Installation an tette nere 5 16 5 16 Nose Wheel 5 9 op See Engine P See Painting and coating Painting and Coating 15 1 Panel Circuit 8 9 Pitch Trim Servo 8 7 Pitot amp Static ttes 9 3 Powder coat Repair DNE 15 3 Primera M EN 15 4 Propeller 11 1 Inspeetion esce een 3 7 1
74. UEL VALVE 13 3 Rev 1 SUPPLIES TOOLS EXPENDABLE Sockets e Safety wire 1 4 3 8 5 16 REPLACEABLE 7 16 Gas 5 Screen Combination wrench Gas 5 O ring gasket 3 8 7 16 1 2 11 16 3 4 9 16 Screwdriver 2 Phillips 3 16 Standard Hex flat blade screw bit Safety wire pliers Fuel Container 1 2 ID fuel hose GENERAL AVAILABLE SWITCH AND DISCONNECT THE NEGATIVE BATTERY FROM THE BATTERY DRAINING THE FUEL SYSTEM Fuel Container Expendable Replaceable Service Rating Minimum Certification Owner and SPC LSA RM or A amp P Additional References NOTE IF THERE IS A FAIR AMOUNT OF FUEL IN THE TANK REDUCE THE DRAIN TIME BY Rev 1 FIRST SIPHONING OUT AS MUCH AS POSSIBLE A SMALL WEIGHT SECURELY ATTACHED TO THE END OF A FLEXIBLE SIPHON HOSE WORKS WELL FOR REACHING THE TANK S BOTTOM FORWARD END 1 Put the fuel valve in the OFF position 2 Remove the engine cowling 12 4 3 Place a container beneath the gascolator with sufficient capacity for the fuel in the fuel tank e NOTE POSITION A RAG UNDER THE GASCOLATOR FITTING TO CATCH SPILLED FUEL IMMEDIATELY AFTER DISCONNECTING THE HOSE MOVE IT UPWARD AND POSITION THE END AS HIGH AS POSSIBLE TO MINIMIZE THE LOSS OF FUEL FROM THE HOSE 4 Disconnect the fuel hose from the 90 fitting on the output side of the gascolator 5 Temporarily connect a length of 1 2 ID hose to the 90 fitti
75. URE IN THE ROTAX MAINTENANCE MANUAL SHOULD BE CONSIDERED THE PRIMARY INFORMATION SOURCE FOR ANY AND ALL ENGINE MAINTENANCE THE FOLLOWING STEPS LIST THE SIMPLEST PROCESS VAN S AIRCRAFT HAS FOUND TO ACHIEVE THE SMOOTHEST RUNNING ENGINE POSSIBLE 12 7 Rev 4 MECHANICAL SYNCHRONIZATION THROTTLE CABLE LOCKING HARDWARE IDLE SPEED ADJUSTMENT SCREW IDLE STOP CONDUIT HOUSING 77 THROTTLE ARM FULL THROTTLE RETURN SPRING CT 00101 STOP NUT OFF IDLE ADJUSTMENT HARDWARE Figure 27 Carburetor Overview Right Carburetor Shown e NOTE FOR STEP 1 THROUGH STEP 8 REFER TO FIGURES 27 AND 28 1 Remove the throttle cable locking hardware from the throttle arm 2 3 Return the throttle arm to its idle position limit of travel by hand there should be Release the full throttle return spring from its attachment on the throttle arm no resistance during this procedure Turn the idle speed adjustment screw counterclockwise until it is no longer contacting the idle stop Hold the throttle arm lightly against its idle position limit of travel Insert a 1mm 004in feeler gauge between the idle speed adjustment screw and the idle stop Gently turn the idle speed adjustment screw clockwise until contact is made with the Imm feeler gauge Rev 4 6 From this point turn the idle speed adjustment screw clockwise 1 5 turns 7 Gently turn the mixture screw completely closed clockwise and then reopen by 1 5 turns coun
76. W Backup Battery FlightCom intercom ELT Artex ELT Odyssey battery Van s Aircraft RV 12 Kit Assembly Instructions KAI 999999 9 9 9 The service and inspection portions of this manual indicate the minimum certification requirements for a person doing maintenance or repairs on the RV 12 Certification requirements for service and maintenance may vary around the world It is essential to determine the correct and legal maintenance and certification requirements applicable to the area that the airplane is registered The documents necessary to determine these requirements for S LSA in the United States are as follows RV 12 Maintenance Manual RV 12 Kit Assembly Instructions Federal Aviation Regulations for Light Sport Aircraft Maintenance Technicians 1 2 Rev 5 Aircraft Inspection Repair and Alterations AC 43 13 1B REPLACEMENT PARTS The RV 12 KAI is the primary reference for replacement part information Section Four in the is a directory of all part numbers with reference information of where to find it within the main manual The documentation produced by third party parts manufacturers listed above should be used as the primary reference for part information for those components METHOD The pages throughout this maintenance manual are numbered at the bottom with the chapter number followed by a dash and the page number of the applicable chapter There are many cross references
77. acturer instructions TERMINAL TAB CLEANING Tools Expendable Replaceable Service Rating Minimum Certification Additional References 1 Remove the wings from the fuselage 5 13 2 Remove dirt carbon and corrosion from all of the terminal tabs on both sides of the fuse and both wings using a scouring pad 8 14 Rev 4 CHAPTER 9 INSTRUMENTS 8 AVIONICS GARMIN SL 40 GARMIN GXM30A AUTOPILOT MODULE OPTIONAL GARMIN GPS MAP 369 GARMIN GA26C STEREO INTERCOM GARMIN GTX327 DYNON D 180 WV on DYNON D 100 Bus D 100 N COCKPIT LIGHT PITOT TUBE P OPTIONAL EMERGENCY LOCATOR TRANSMITTER TRANSPONDER ANTENNA SKYVIEW XPNDR 26X SENSOR GARMIN SL 40 OR GARMIN GTR 200 AUTOPILOT AE A SERVOS AV 50000 7 AV 50001 AV 50002 STATIC SYSTEM EN VHF COMM ANTENNA OPTIONAL OVERVIEW een ge ee 9 2 Bomponenisc se 9 2 Optional Gomponenlsn are 9 3 Nee 9 3 n 9 3 BERNIE eis ICM IRI DNO MM M M MED DIL I ILE 9 4 so B 3 etie 9 4 MOONS 16 54 1c ts dettes reste e about exuded 9 4 Expendable fT Hair die vee nl eee 9 4 lazuErierm ela one 9 4 SERVER 9 5 Component replacement wise tete dee e amet decer enden ed
78. al inflation pressure see page 1 14 8 Reassemble and install the wheel and tire assembly O 5 16 Rev 4 NOSE INNER TUBE REPLACEMENT 3 16 Allen Expendable Replaceable Nose wheel assembly Tire Minimum Certification Owner and SPC LSA RM or A amp P Additional References KAI Lift and support the aircraft 1 16 1 Remove the nose wheel and tire assembly 5 16 2 Deflate the inner tube 3 Split the wheel assembly by removing the bolts 3 washers 6 and nuts 3 4 Replace the inner tube Orient the valve stem with the hole in the wheel and the colored dot on the tire SLOWLY inflate the tire Deflate it fully and re inflate it SLOWLY a couple more times to work out any wrinkles in the tube Inspect for a good seat around the wheel rim For final inflation pressure see page 1 14 6 Reassemble and install the wheel and tire assembly e FLAPERON HINGE REPLACEMENT Tools 3 8 socket 3 8 combo wrench Expendable None Replaceable Bearing MD3614M Service Rating Line Minimum Certification LSA RM or A amp P Additional References KAI m CAUTION BE PREPARED WITH ADDITIONAL PERSONEL OR TOOLS TO HANDLE THE WEIGHT AND AWKWARDNESS OF THE OBJECT TO BE REMOVED 1 Remove the wings 5 13 2 Make note of the flaperon hinge hardware configuration 3 Remove the flaperon hardware and flaperon assembly 5 17 Rev 4 FLAPERON 4 Measure and record the hinge bearing protrusion mea
79. and tire assembly removal 5 15 Installation recen 5 15 Nose wheel and tire assembly removal 5 16 a 5 16 Main inner tube replacement 5 16 Nose inner tube replacement 5 17 Flaperon hinge replacement 5 17 Rudder hinge replacement 5 18 Stabilator hinge replacement 5 19 Main gear 5 20 Installation eite pere 5 21 Nose gear removal 5 21 Installation orte 5 21 Belt and Harness replacement 5 22 Canopy latch block replacement 5 22 Step 5 22 Service Schedule Procedures 5 23 Wing attach location lubrication 5 23 Fuselage 5 23 Stub spar and Rear 5 23 Flaperon control connection lubrication 5 23 Flaperon bearings lubrication 5 24 AST attach hinge lubrication 5 24 Nose wheel bearings replacement 5 24 Main wheel bearings lubrication 5 25 Nose fork pivot tension and lubrication 5 25 Tire Assem Balancing Procedure 5 26 Rev 4 OVERVIEW The RV 12 airframe uses blind pop style rivets as the primary fastener The wi
80. arm Check the counterbalance arm for straightness Make sure the counterbalance weights are secure and the fasteners are in good condition Inspect the hinge brackets stops and fasteners for signs of wear and security Inspect the control horns and fasteners for wear and security Check the control cable fasteners for security or signs of wear The stabilator must swing smoothly and be limited only by the hinge stops Make sure that both hinge brackets on the tailcone contact their corresponding hinge stop on the stabilator squarely and simultaneously ANTI SERVO TAB amp PITCH TRIM SERVO Check the anti servo tab skins for damage or deformation Check the anti servo tab fasteners by sighting along each rivet pattern for any inconsistent rivet profile among similar properly installed rivets Check the spar and attach hinge for deformation and signs of fatigue Inspect the control horns and surrounding area for deformation cracks and signs of fatigue Check the control horn fasteners for wear and security Inspect the pitch trim servo push rod and link for damage or signs of fatigue Inspect the pitch trim servo and servo tray for deformation or cracks Check the fasteners and bushings that connect the pitch trim servo tray to the tailcone for security and wear There should be very little movement in the tab when the stabilator is held fixed Check the electrical connections and wire for condition and wear Test the operation of
81. ate to the heavy side down position 3 A Main Wheel assy Use tape to temporarily add stick on wheel weights obtain from a local automotive store commonly available wheel weights with self adhesive to the outboard wheel flange opposite the heavy point of the wheel until the assy can be moved to any rotational position without it rotating Mark the position of the wheel weights and then remove them Thoroughly clean the area of the wheel flange where the wheel weights will be located Remove the protective backing and press the wheel weights in place on the wheel flange B Nose Wheel assy Use tape to temporarily add stick on wheel weights to the interior area of the nose wheel working through the lightening holes in the wheel If the proper weight location coincides with one of the three wheel through bolts distribute the weight as close as possible to each side of the through bolt Thoroughly clean the interior area of the wheel where the wheel weights will be located Remove the protective backing and press the wheel weights in place on the interior area of the wheel 4 Re install the wheel assy on the aircraft 5 26 Rev 4 THIS PAGE INTENTIONALLY LEFT BLANK 5 27 Rev 3 CHAPTER 6 FLIGHT CONTROLS AUTOPILOT ROLL SERVO STABILATOR CABLE TENSION BARREL x FLAP HANDLE sr STAB CABLE PULLEY bc AUTOPILOT MODULE CONTROL STICK PUSHROD RL FLAPERON TORQUE
82. ated A amp P mechanic All Inspection and maintenance practices and all inspection and maintenance log entries must be made in accordance with pertinent FARs and the manufacturers specified requirements e NOTE FOR THE SERVICE SCHEDULE CHECKLIST SEE SUPPLEMENT PAGE 18 3 2 1 Rev 1 The service schedule checklist serves as an index of the service procedures section of each applicable chapter The service procedure section includes the recommended tools to complete each task Applicable hardware will be stated using the most general terms Refer to the original KAI for the specific hardware size location and configuration Manufacturers of third party components determine service procedures for those components The manual provided by the manufacturer for that component will provide service procedures All component manuals are included with the aircraft at the time of purchase The What column provides the name of the part or components to which the action applies The Action column will indicate what is necessary replace lubricate clean charge etc The When column specifies the amount of time or use that may elapse before action is necessary The How column will direct you to the chapter or manual that includes the instructions tools supplies and the level of certification required of the person performing the action for the given action Write the date of completion in the Service Date column Use the
83. be checked for signs of wear or fatigue Inspect the head shank and threads of bolts and the edges and threads of nuts Locking hardware may only be used for one term of service Safety wire cotter pins lock washers and similar hardware are only reliable after one term of service It is permissible to reuse nylock and all steel style self locking nuts if it is determined that the self locking feature has not been degraded Always replace questionable hardware Operation in Extreme Conditions Exposure to extreme climatic conditions including dust salt debris bugs will warrant frequent inspections of air filters coolant radiator and oil cooler as defined in the Rotax maintenance manual Frequent exposure to extreme conditions or altitudes demands adjustment of the carburetor and cooling system Contact an authorized Rotax distributor for consultation 1 4 Rev 5 SAFETY OF FLIGHT REPORTING PROCEDURE To maintain the highest level of safety and as dictated in ASTM F 2295 Section 5 the FAA requires and Van s Aircraft Inc requests notification of any safety of flight issue or service or maintenance difficulties that could compromises the airworthiness of the RV 12 aircraft A feedback form is provided in the Supplement section of this manual Refer to Chapter 17 for a description of a valuable report and the different reporting methods available HELPFUL TERMINOLOGY A WARNING INDICATES AN ACTION NECESSARY TO PREVENT INJURY OR DEATH
84. cation Owner and SPC LSA RM or A amp P Additional References REMOVAL 1 2 3 4 5 Remove Cowl 12 4 Drain oil system per Rotax Line Maint Manual including draining of the oil cooler Cut tie wraps and detach cushioned clamps from oil hoses Disconnect and remove oil hoses from the oil tank cover assembly engine and oil cooler Remove Oil Tank Vent Tube and Oil Vent Interconnect INSTALLATION 1 2 Installation of new hoses and tubes is reverse of removal procedure Perform oil purge procedure detailed in Rotax Service Instruction SI 912 018 12 15 Rev 4 COOLING HOSE REPLACEMENT A WARNING BEFORE PERFORMING ANY INSPECTION OR SERVICE ALLOW THE ENGINE COMPONENTS TO COOL 3 8 open end wrench screwdriver wire cutters Expendable Plastic tie wrap 8in Replaceable FF 1208A FF 1208B FF 1220 Minimum Certification Owner and SPC LSA RM or A amp P Additional References REMOVAL Drain cooling system per Rotax Line Maint Manual Disconnect cushioned clamps and cut tie wraps from coolant hoses Loosen hose clamps and slide them away from the component Disconnect hoses from reservoir engine and radiator Cut new hoses to same length as old ones Remove springs from old hoses and install in new hoses na N INSTALLATION 1 Installation procedure is reverse of removal procedure 2 Refer to Rotax Line Maint Manual to refill coolant MANIFOLD PRESSURE HOSE REPLACEMENT Wire cutt
85. cedures and characteristics of the aircraft Find the actual licensed empty weight and CG of the aircraft on the Weight and Balance Form This document is required to remain with the aircraft and must reflect any changes to the empty weight or CG From that information and the instructions from the POH the pilot can determine the useful load and proper load distribution for the aircraft Rev 5 TOOLS AND EXPENDABLES There are many aircraft tool suppliers available An Internet search be conducted to determine which supplier can provide the necessary tools e NOTE THIS TOOL LIST DOES NOT INCLUDE ALL OF THE TOOLS SUGGESTED FOR THE INSPECTION PROCEDURES TOOLS Combination wrenches 1 4 5 16 11 32 3 8 7 16 2 1 2 9 16 11 16 11 2 Ratchet Sockets 5 16 11 32 3 8 7 16 1 2 9 16 3 4 1 1 2 10 mm 11 mm 13 mm 5 9 9 9 9 9 Allen wrenches 3 16 1 4 5 16 4mm 5mm 6mm 8mm Torque wrench in Ibs amp 05 5 8 or 16 mm spark plug socket Screwdrivers 2 Phillips 3 Phillips 3 16 Flat Blade Power drill 30 drill bit Blind rivet tool Straight edge Razor knife Flashlight Step ladder Wire cutters Battery charger Multi meter Wooden dowels 1 2 1 inch dia and 1 1 2 1 3 4 in dia Oil Filter wrench Oil Filter cutter and mallet Two 25 in padded stands each rated to support a minimum of 500 pounds Container various sizes suitable for petroleum 24
86. ction with the RV 12 Kit Assembly Instructions KAl when completing maintenance or repair processes MINIMUM The minimum certification for completing a repair to aircraft skins is an LSA Repairman Maintenance or an FAA certificated A amp P technician Refer to the KAI to identify individual parts and their corresponding part numbers 4 2 FUSELAGE OVERVIEW ee area 5 2 FUSELAGE ee 5 2 Components ar are 5 3 WING AND FLAPERON 5 4 Components 5 5 EMPENNAGE vit 5 6 5 7 LANDING GEAR aka 5 8 Components as see 5 9 NOSE WHEEL amp GEAR LEG FAIRINGS 5 10 Components nee 5 10 Wheel Fairings 5 11 Optional Components 5 11 SERVICE 5 12 SUPPIIOS 5 12 Tools aan anna 5 12 3 2 5 12 5 12 General 5 13 Wing 2 5 13 Installation 5 13 Wing retention pin bushing replacement 5 13 In Center 5 13 In Wing 5 5 5 14 Canopy and frame removal 5 14 5 2 Rev 4 CHAPTER 5 STRUCTURES EMPENNAGE Installation 5 14 Main wheel
87. d then self align to allow for installing the attach screws SPARK PLUG REPLACEMENT OR RE INSTALLATION Tools 16mm socket Spark plug gap tool Expendable Heat conduction compound Replaceable Hinge pins Spark Plugs if serviceable Minimum Certification LSA RM with Rotax Service d certification or A amp P with Rotax Service Certification 1 Refer to the Rotax manual OIL FILTER REPLACEMENT OR RE INSTALLATION Oil filter wrench Expendable Oil Filter Replaceable Replaceable Minimum Certification Owner and SPC LSA RM or A amp P Additional References Rotax 912 Line Maintenance manual Rev 4 ENGINE LEVEL ENGINE COMPONENTS TO COOL WARNING TURN OFF MASTER POWER AND BOTH IGNITION SWITCHES DISCONNECT THE NEGATIVE GROUND WIRE TO THE BATTERY NOTE FOR ENGINE CAPACITY SEE ROTAX 912 OPERATORS MANUAL Tools Expendable Replaceable Service Rating Minimum Certification Additional References Rotax 912 Operator Manual 1 Remove the oil tank cap 2 Transfer oil from the crankcase to the oil tank by turning the propeller several times by hand in the direction of normal engine rotation Transfer is complete when gurgling sounds come from the oil tank m CAUTION FOR LONG FLIGHTS REPLENISH TO THE MARK ON THE DIPSTICK NOTE THE QUANTITY DIFFERENCE BETWEEN AND MIN MARKS OIL DIPSTICK IS 0 451 0 5 QUART 3 Oil level must be between the
88. e nspecto Name nspection io Location Oy Affected Parts Oooo OE Problem Description 18 31 Rev 6 THIS PAGE INTENTIONALLY LEFT BLANK 18 32 Rev 2 CHAPTER 19 GLOSSARY 100 hr Comparable to an annual condition inspection except that the Inspection interval of inspection is 100 hrs of operation instead of 12 calendar months This inspection applies to LSA used for commercial operations such as flight instruction or rental or both A amp P Airframe and power plant technician as defined in the U S by 14 technician CFR Part 65 or equivalent certification in other countries AC 43 13 Refers to the FAA Advisory Circular Acceptable Methods Techniques and Practices Aircraft Inspection and Repair Adverse Includes but not limited to conditions that could cause build up of conditions foreign matter or contamination or removal of lubrications such as extreme weather and dirty sandy or salty conditions thorough plane washing etc Annual Detailed inspection performed once a year on LSA in Condition accordance with instructions provided in the maintenance manual Inspection supplied with the aircraft and AC 43 13 Appendix D The purpose of the inspection is to identify any wear corrosion or damage before it compromises the safe operation and airworthiness of the aircraft Anti AST The anti servo trim tab has two functions It provides Servo Tri
89. e annual condition inspection lubricate the moving parts If the heated air temperature is noticeably cooler than previous uses see troubleshooting The pre flight and annual condition inspections are necessary to ensure all of the components remain in good condition No maintenance is required on either of the fresh air vents A damaged vent is replaceable provided the fuselage skin is undamaged SUPPLIES REPLACEABLE Razor Knife Connector to original 30 drill bit Tubing to original Blind rivet tool Vent door sub assembly Combination wrench Vent brackets 1 4 Screwdriver 2 Phillips EXPENDABLE Spray lubricant Plastic tie wraps LP4 3 rivets Rev 1 GENERAL VENT DOOR REPAIR 30 drill bit Blind rivet tool 1 4 combo wrench 2 Phillips screwdriver Expendable LP4 3 rivets 4 Screw Plastic washers 2 Metal washer Nut Replaceable Vent door sub assembly Line LSA RM or A amp P Additional References KAI 1 Remove the existing vent brackets and vent door sub assembly by drilling out the rivets 4 2 Rivet the new vent brackets to the vent doorframe 3 Install a new vent door sub assembly to the vent brackets using new hardware screw plastic washers 2 metal washer and nut SERVICE SCHEDULE PROCEDURES PUSH PULL CABLE LUBRICATION NONE Rev 1 THIS PAGE INTENTIONALLY LEFT BLANK 10 6 Rev 2 CHAPTER 11 SENSENICH PROPELLER BLADE PITOT TUBE _ BEARIN
90. e manual provided with the component EMERGENCY LOCATOR TRANSMITTER The ELT must be inspected in compliance with the FAR Part 91 207 d and accompanied by a logbook entry PROPELLER Refer to Sensenich Propeller manual A WARNING THE MASTER POWER AND BOTH IGNITION SWITCHES MUST BE SHUT OFF DURING INSPECTION OF THE PROPELLER SERIOUS INJURY OR DEATH WILL RESULT IF ENGINE IS UNINTENTIONALLY STARTED BY TURNING THE PROPELLER e Check the spinner cone and back plate fasteners for wear and security Inspect hub and fasteners for cracks and wear Check the pitot tube and bushing for wear and condition Check hub fastener torque Inspect the leading edge of the blades for loose metal Inspect each entire blade for cracks missing material and delamination 3 7 Rev 3 e NOTE PERFORM THE PROP TRACK TEST WITH THE SPARK PLUGS REMOVED e Test prop track by placing a stationary object in contact with the forward or aft face of one of the blade tips Then rotate the propeller to bring the opposite blade to the same point An off track propeller will not come to the same point ENGINE Refer to Rotax manual A WARNING THE MASTER POWER AND BOTH IGNITION SWITCHES MUST BE SHUT OFF DURING INSPECTION OF THE ENGINE UNLESS INSTRUCTED OTHERWISE SERIOUS INJURY OR DEATH WILL RESULT IF ENGINE IS UNINTENTIONALL Y STARTED A WARNING ALLOW THE ENGINE AND APPLICABLE COMPONENTS TO COOL BEFORE PERFORMING SERVICE OR INSPECTION HOT ENGI
91. e the clamp and stick from the control stick and the weight from the 11 stabilator Move the control stick between the forward and aft pitch stops The stabilator should reach its travel stops just before the corresponding control stick stops are reached If not adjust the turnbuckles an equal and opposite number of turns until this is achieved Example If the stabilator reaches its T E up stop too soon loosen the upper turnbuckle and tighten the lower turnbuckle This will lengthen the upper cable and shorten the lower cable After making adjustments repeat step 6 to reconfirm proper cable tension Once the proper tension is achieved and no more than three threads are exposed from the ends of the barrels align the V notch in the ends of the barrel with the groove in the cable ends and then insert the lock clips as shown in Figure 17 The hook end of the lock clips are inserted into the hole in the center of the barrel and must be completely pressed in until the hook springs open inside the barrel 6 5 Rev 3 CONTROL CABLE REPLACEMENT m CAUTION THE CONTROL SURFACE WILL SWING FREELY WHEN THE CONTROL CABLES ARE REMOVED e NOTE ALWAYS REPLACE CONTROL CABLES AS A SET Tools 3 8 7 16 socket 3 8 7 16 combo wrench Needle nose pliers String Cable tension meter Spring clamps 3 Stick 41 long Lock clips Rudder cables LSA RM or A amp P 1 Remove the tunnel cover step floor cover seat ramp cover seat floor cover
92. e tube for the wing to fully insert Note rotating the pin while pushing with the heal of your palm helps aid in pin insertion WING RETENTION PIN BUSHING REPLACEMENT Tools Mallet Large wooden dowel 1 1 2 1 3 4 inch dia Minimum Certification Owner LSA RM or A amp P Additional KAI References 1 Remove the wings IN CENTER SECTION Tap out the bushing from the non flanged end of the bushing 2 Tap the new bushing into place with the flanged end toward the wing spars 5 13 Rev 4 In WiNG SPARS 3 Tap out the bushing from the non flanged end of the bushing 4 the new bushing into place with the flanged end to be on the forward side of the wing spar CANOPY AND FRAME REMOVAL 7 16 socket Expendable Replaceable Canopy and Frame Canopy struts Minimum Certification LSA RM or A amp P Additional KAI References m CAUTION BE PREPARED WITH A HELPER OR SUPPORT STAND TO HANDLE THE WEIGHT AND AWKWARDNESS OF THE OBJECT TO BE REMOVED 1 Open and support the canopy Easiest with a partner 2 Remove the strut hardware bolts 2 3 Remove the pivot hardware bolts 2 and bushings 2 4 Remove canopy and frame INSTALLATION m CAUTION DO NOT OVERTIGHTEN THE CANOPY STRUT HARDWARE ALLOW THE CANOPY STRUT APPROXIMATELY 1 64 INCH OF TOTAL MOVEMENT ALONG THE BOLT SHANK 1 Installation procedure is reverse of the removal procedure 5 14 Rev 4 MAIN WHEEL AND TIRE ASSEMBLY
93. e values of 3 amp and higher are required to have LED blown fuse indicators LUBRICANTS RECOMMENDATION OR EQUIVALENT As specified in latest Rotax documentation Spray lubricant LPS2 or Tri Flow Dry lubricant candle wax etc TOOL BOELUBE PASTE Wheel bearing grease Aeroshell 22 or equivalent Thread lube Loctite 567 or equivalent Anti seize compound High temp Loctite Anti Seize or equivalent Hydraulic fluid MIL H 5606A or MIL PRF 83282 Air filter oil EA K amp N 99 5050 KIT MISCELLANEOUS RECOMMENDATION OR EQUIVALENT 1 1 Water Ethylene Glycol refer to Rotax engine documentation WIRE SAFETY 032 Cardinal gray 3607 GR 230 Primer Any protective primer suitable for use on aluminum and or steel as appropriate Decorative touch up paint From paint process Rev 5 ENGINE e NOTE THE ENGINE SPECIFICATION INFORMATION IS REFERENCED FROM THE 912 SERIES OPERATOR S MANUAL REV 4 SUMMARY Rotax 912 ULS Displacement 1352 cc Ducati Double Rated Horsepower 100 Hp 5800 RPM DESCRIPTION The LSA covered by this manual will have a Rotax 912ULS power plant The power plant is an over head valve four stroke horizontally opposed four cylinder The cylinder heads are liquid cooled The cylinder barrels are air cooled Dual constant depression carburetors regulate the air fuel mixture The dual breaker less capacitor discharge ignition system provides the electrical energy to the spark plugs For engine
94. e with the KAI and install new lock clips on the adjuster barrel m CAUTION BE SURE TO RE ORIENT THE COUNTERBALANCE ARM SO THAT THE COUNTERBALANCE WEIGHT IS POSITIONED CORRECTLY REFER MAIN GEAR REMOVAL Tools 7 16 1 2 9 16 socket 7 16 1 2 9 16 combo wrench Expendable Replaceable Left Main Gear Right Main Gear Outbd Main Gear Attach Brkt Outbd Wear Plate Inbd Main Gear Attach Brkt Inbd Wear Plate Service Rating Minimum Certification LSA RM or A amp P Additional References KAI Matco user manual 1 16 Lift and support the aircraft 1 16 Remove the two outboard center section Cover Plates on the belly 3 4 Drain the hydraulic fluid 7 5 Disconnect the brake line at the main gear attach bracket Remove the center bolt washer and nut from the inboard main gear attach bracket Loosen the remaining inboard and outboard attach bracket hardware Remove the main gear leg Ci CoS a 5 20 Rev 4 INSTALLATION 1 Installation procedure is reverse of the removal procedure 2 hydraulic fluid and bleed the brake system 3 Torque all landing gear attach hardware Remember to account for prevailing torque NOSE GEAR REMOVAL Tools 3 8 9 16 socket Service Rating Minimum Certification LSA RM or A amp P Additional References 1 Remove the top and bottom cowl 3 4 2 Lift and support the aircraft Place an additional support stand at the tail tie down 1 16
95. ear Removal 5 21 was 5 24 25 Nose Gear Installation 5 21 was 5 26 Add Tire Assem Balancing Procedure 5 26 MM Page 5 26 Rev 4 Add tire balance procedure MM Page 6 1 Rev 3 Add to Stabilator pulley replacement and cable tension adjustment Remove the line item for Stabilator cable tension adjustment 6 4 MM Page 6 2 Rev 3 Add to Components table Optional Components 1 Autopilot Module IF Dynon AP AP74V 12 or SV KNOB PANEL and SV AP PANEL or Garmin GMC 305 1 Autopilot Pitch Servo IF DYNON AP SV32 or Garmin GSA 28 1 Autopilot Roll Servo IF DYNON AP SV32 or Garmin GSA 28 MM Page 6 3 Rev 3 STABILATOR PULLEY REPLACEMENT AND CABLE TENSION ADJUSTMENT was STABILATOR PULLEY REPLACEMENT MM Page 7 1 Rev 2 Overview 7 2 was 7 1 Master Cylinder Removal Disconnection 7 4 was 7 3 MM Page 8 1 Rev 3 Snap Bushing replacement 8 13 was 8 12 Service Schedule Procedures 8 14 was 8 13 MM Page 8 6 Rev 3 In Figure 21 Fuse Panel SkyView G3X was SkyView Under recurring blown fuse See Chapter 18 was See page 18 21 MM Page 8 10 Rev 3 Update the Figure 24 to show the new style wing electrical connector MM Page 9 1 Rev 4 Add Optional Components 9 3 MM Page 9 2 Rev 4 Add in the opening paragraph Dynon SkyView or Garmin G3X EFIS Electronic Flight Information System EMS Engine Monitoring System then forward within the center tunnel t
96. ective action and comply with all applicable aviation authority regulations in regard to maintaining the airworthiness of the LSA a Anowner of an RV 12 shall ensure that any needed corrective action be completed as specified in a notice or by the next scheduled annual inspection a Should an owner operator not comply with any mandatory service requirement the RV 12 shall be considered not in compliance with applicable ASTM standards and may be subject to regulatory action by the presiding aviation authority Rev 5 04 03 14 TABLE OF CONTENTS CHAPTER 1 GENERAL INTRODUCTION ne er 1 1 PUD OSS aaa Dr 1 1 SUMMA eT E 1 1 M n 1 2 ReplacemenbRarls o aee ont omui atas Deb riet 1 3 em rc 1 3 APPLICABLE THROUGHOUT een le 1 4 PEDES 1 4 Safety of Flight Reporting Procedure 1 5 Helpful er ee ee 1 5 ADBBIBVISHOES a an error 1 6 TEICHE 1 7 WEIGHT AND BALAN OE aeter ee ee dE 1 7 TOOLSANDEXPENDABLES rn er nM CM ee 1 8 ENGINE MEI DL ar ee ee 1 12 LUBRICATIONS AND CAPACITIES sa a a Nee 1 13 ENGINE Oll ers a ee et 1 13 a a rennen 1 13 Engine Co9lan sac
97. eet are coated with pure aluminum during manufacture The thickness of the alclad layer on aluminum sheet 1 16 inch thick or less is 596 of the sheet thickness Alclad on aluminum sheet greater than 1 16 inch thick is 2 596 of the sheet thickness All non alclad aluminum parts such as 6061 T6 must be primed for corrosion protection Aluminum tubing other than fluid lines must be primed on both the interior and exterior surfaces Aluminum bar angle and tube used in the RV 12 are not alclad and must be primed to ensure corrosion resistance Zinc Chromate has been the traditional primer used on aircraft aluminum With proper surface cleaning this is still a good choice There are however many superior primers now available Most of these are two part catalytic curing primers Generally speaking it s preferable to replace a coated part with a coated part Following is a partial list of suitable primers DUPONT VERI PRIME PRIMER 615 and CONVERTER 6165 DITZLER DP 40 50 EPOXY PRIMER TEMPO brand Chromate a spray can PHATT 8 LAMBERT Vinyl Zinc Chromate EX ER 7 and T ER 4 Reducer SHERWIN WILLIAMS WASH PRIMER P60G2 and Catalyst Reducer R7K44 MARHYDE self etching primer available in a spray can as well as quarts Decorative paint on the structure of the aircraft can be touched up by the sport pilot certified owner or a certified repairman with maintenance rating Control surfaces can only be repainted by an LSA repairman with a
98. epair Only a qualified person may perform major repair alteration or Alteration or maintenance tasks that are not included in this maintenance Maintenance manual Manufacturer Any entity engaged in the production of an LSA or component used on an LSA Minor Repair Generally applies to repair alteration or maintenance covered by Alteration or instructions provided in the maintenance manual s supplied to the Maintenance consumer Overhaul Maintenance inspection repair or alterations that are only to be accomplished by the original manufacturer or a facility approved by the original manufacturer of the product 19 2 Rev 2 Overhaul Facility specifically authorized by the aircraft or component Facility manufacturer to overhaul the product originally produced by that manufacturer Pilot Operating POH The handbook provided with the aircraft that introduces the Handbook systems and features that are included in the RV 12 Includes air and ground operating procedures and defines performance and weight and balance information Preventative Simple or minor preservation operations and the replacement of maintenance small standard parts not involving complex assembly operations Special Light S LSA Applies to the aircraft covered in this manual provided it Sport Aircraft remains consistent with the manufacturers design specifications Manufacturer design specifications are in accordance with ASTM standards F2245 for airplane
99. erPumpDrainScrew 8 590 10 oaan Bolt size Standard nuts Threads per inch AN310 AN315 MS20365 Portions of this information has been adapted from AC 43 13 1B Section 7 40 GENERAL PROCEDURES TIRE REMOVAL REMOVAL CANOPY REMOVAL REFER TO 5 1 COWL REMOVAL OIL LEVEL CHECK REFER TO 12 1 FUEL SYSTEM DRAINING GASCOLATOR SAMPLE REFER TO 13 1 Rev 5 Rev 5 WIRE TERMINAL CRIMPING BARREL INSERTION DEPTH gt CRIMP 1 CRIMP WIRE TERMINAL Figure 2 Terminal crimping This figure shows the crimping method for wire smaller than the terminal rating Although a spade connector is shown the crimping method will be similar for ring terminals and splices 1 For wire smaller than terminal rating Strip 1 2 inch of insulation from the end of the wire lead Twist the copper strands together and fold the twisted strands in half For wire within the terminal rating Strip 1 4 inch of insulation from the end of wire Twist the copper strands together 2 Insert the end of the wire into the barrel of the connector to the insertion depth Measure the depth from the edge of the barrel as opposed to the edge of the plastic sheath 3 Crimp the wire twice First crimp the barrel onto the bare conductor and then crimp the barrel s skirt onto the wire insulation LIFTIN
100. ers straight slot screwdriver for prying hose Expendable Replaceable Manifold pressure hose Minimum Certification LSA RM with Rotax Service certification or A amp P with Rotax Service certification Additional References REMOVAL 1 the tie wrap attaching the manifold pressure hose to the manifold pressure sensor wires 2 Remove the hose from the manifold pressure sensor and the from the compensating tube assembly INSTALLATION 1 Cut the new hose to the length specified in the KAI 2 Installation is reverse of removal 12 16 Rev 1 CHAPTER 13 FUEL SYSTEM CAP amp FILLER MECHANICAL FUEL GAUGE X SENDING UNIT N PRESSURE SENDER N LEFT CARBURETOR RIGHT UN CARBURETOR te MECHANICAL amp ELECTRIC gt PUMP Soy aed SCREEN FUEL RETURN LINE FLOW TRANSDUCER OVERVIEW es E 13 2 Coniponentsz osos LU 13 2 Fuel System Schemat au 13 3 SERNICE PE Ener 13 3 13 4 TNI 13 4 edt OE UE RO ERES DUE REDE GC RTI AR Re 13 4 Replaceable i 13 4 oil MM m 13 4 Draining the fuelisystem
101. evice If the no go surface contacts the pe 6 bushing or mounting surface the wing retention pin bushing must be replaced See Figure 7 Figure 7 Wing Retention Pin Bushing Inspect the center section channel bulkheads fasteners and stiffeners for signs of amage or fatigue Check the center section left and right UHMW retainer block roller for security and wear Check the fuselage pin latching mechanisms for security and proper operation Test the warning circuit by unlatching each pin individually to verify it causes the switch panel warning light to illuminate EMPENNAGE e Magnifying glass Straight edge Flashlight Inspection mirror VERTICAL STABILIZER Check the main skin and forward skin for deformation or cracks Check the main skin fasteners by sighting along each rivet pattern for any inconsistent rivet profile among similar properly installed rivets Check the forward spar and fasteners for cracks deformation and signs of fatigue Inspect the rear spar spar fasteners and hinges for cracks deformation and signs of fatigue especially the areas surrounding the rudder hinge brackets Check the fiberglass fairing for condition and security Check for interference or signs of wear from the rudder Look through the forward spar lightening holes to inspect the rear spar ribs and rib flanges for cracks RUDDER Check the main skin for damage or deformation 3 13 Rev 3 Sight along each
102. following m CAUTION ALWAYS SUPPORT THE FLAPERON DURING WING REMOVAL AND STORAGE 1 Remove the left and right wing 2 Remove all access covers inspection plates fairing and cowling shown in Figure 4 Tools 3 8 socket 2 Phillips screwdriver Service rating Minimum Certification LSA RM or A amp P 3 3 1 2 3 Figure 4 Remove for inspection Left Wing Right Wing Forward Skin Rev 3 Bottom Cowl 7 27 i 4 ape Skin 16 1 Gere 8 TunnelCover 19 12 13 14 n _ 16 6 17 ED 18 8 19 a 20 Step Floor Cover Fuel Tank Assembly see chapter 13 for draining the fuel tank Fuselage Side Cover 2 Not numbered in order of removal 3 Perform visual inspection for and make note of any oil exhaust fuel hydraulic or reother leaks 4 Thoroughly clean engine fuselage cockpit undercarriage and other areas as needed to allow thorough inspection 5 Throughout the inspection check for cracks signs of fatigue corrosion wear deformation and or failure Always check condition and security of all safe tied fasteners 3 4 Rev 3 COCKPIT Magnifying glass Clean rag Flashlight Straight edge e Inspection mirror Inspect the aft face of the firewall for corrosion deformation or cracks especially around fasteners Inspect each occupant harness latching mechanism the condition
103. for proper brake system operation Check the hydraulic fluid level IE 7 6 CHAPTER 8 ELECTRICAL SYSTEM LANDING LIGHT __ OPTIONAL 12VDC SUPPLY GRIP SWITCH BATERY S COCKPIT LIGHT OPTIONAL WING TIP NAV POSITION a STOBE LIGHT COOLING FAN OPTIONAL N vd PANEL CIRCUIT BOARD X FUSES STALL WARNING SWITCH WING TIP NAV POSITION STOBE LIGHT OPTIONAL FUSELAGE PIN SWITCH INTERCOM JACKS u A KH MIC amp HEADSET OAT SENDER SERVOMOTOR Sap OVERVIEW en nannte 8 2 COMIDOMENIS ae 8 2 ONO S NERO es sean 8 3 Optional Comp ONEN S 8 3 SERV CE ne ee 8 4 SUE ol EA E ee 8 4 4 en EL eo n ERE Hie 8 4 Expendable ECCE 8 4 alteram Et 8 4 General 8 5 Battery remoV linan arena ae has Hahn 8 5 aj WIE 8 5 F seireplacemett reae ete te ob base gt Fe eae det qe tre ut det D Gated thas Ot rid nerd 8 6 Pitch trim servo etp Eada 8 7 Electrical component
104. ft movements of the control stick control the pitch The pitch control linkage is a pair of cables each routed around a pulley An electronic switch wired to the pitch trim servo controls the pitch trim Side to side movements of the control stick controls roll via push rods a bell crank and torque tubes Rudder pedals control yaw via cables to the rudder Refer to the KAl to identify the individual parts and part s of the control system e NOTE This maintenance manual is intended to be used in conjunction with the RV 12 Kit Assembly Instructions KAl when completing maintenance or repair processes COMPONENTS Quantity 1 Pitch Trim servo Optional Components and SV KNOB PANEL or Garmin GMC 305 1 Autopilot Roll Servo 6 2 Rev 3 SERVICE Annual lubrication will maximize the longevity of the control system Refer to the service schedule checklist for the specific service frequency of the components See Supplement for service schedule checklist SUPPLIES EXPENDABLE Needle nose pliers e Cotter pins Socket e Safety wire 11 32 Spray lubricant 38 1 19 REPLACEABLE 3 4 11 Stabilator pulley Lock clips Combination wrench iR Stabilator cables 3 8 7146 Rudder cables Bearing 4DWAK2X Bellcrank De P bolt washer and Flap Handle CM 4M Cable tension meter 22 Rudder Stick 41 long GENERAL STABILATOR PULLEY REPLA
105. g Minimum Certification LSA RM or A amp P Additional References 1 Remove the tunnel cover seat ramp cover upper tailcone fairing and lower tailcone fairing 3 4 2 Apply lubricant sparingly to the hardware at both ends of the rudder and stabilator control cables 6 9 Rev 3 THIS PAGE INTENTIONALLY LEFT BLANK 6 10 Rev 2 CHAPTER 7 BRAKE SYSTEM CALIPER SHOES ALUMINUM LINE LININGS PLASTIC LINE MASTER CYLINDER FLUID RESERVOIR BRAKE DISC 7 BRAKE PEDAL TORQUE TUBE OVERVIEW Erw D TES 7 2 5 85 aan 7 2 SERNICE ou erc Vx dtd edu ta NIE MER tuc PN ME 7 2 ES 7 3 MOOIS Sees sen ont Amat eh an aan Aina er erlebe 7 3 Expendable ne sa eee a ea eee avi tore ee eee eee 7 3 Replaceable de en e ebd e eee ect e ter ds 7 3 Cir ae Re 7 3 Master cylinder removal 2 ae ae BRD 7 3 REmMoVAlena sn tet ut et sem Ara a sf ntes al ous 7 3 Beeren m 7 4 Installation EET 7 4 SErVice Schedule Progedufes ange ee 7 4 Brake pedal torque tube 7 4 Hydraulic fluid drain flush and 7 5 ET 7 5 e tet rop ata
106. gure 24 Stall Warning Ground 8 10 Rev 3 WIRE REPAIR Tools Wire cutter Wire terminal crimper Multi meter Expendable Replaceable Minimum Certification LSA RM or A amp P Additional References AC 43 13B Page 18 21 m CAUTION THE REPLACEMENT WIRE SIZE AND TYPE MUST BE EQUAL TO THE ORIGINAL 1 Remove the entire damaged section of the wire 2 Fix the issue that caused damage to the original wire sharp edge chaffing heat etc 3 Route the new length of wire along the same path as the original wire 4 Use aircraft grade wire terminals to connect the new wire in place of the original wire 5 Test the continuity of the wire to ensure a complete connection 6 Test the operation of the electrical system WIRE REPLACEMENT Wire cutter Wire terminal crimper Needle nose pliers Multi meter Expendable Replaceable Service Rating Minimum Certification LSA RM or A amp P Additional References AC 43 13B Page 18 21 Rev 3 m CAUTION THE REPLACEMENT WIRE SIZE AND TYPE MUST BE EQUAL TO THE ORIGINAL 1 Bypass the existing wire with a new wire of equal length 2 Install new terminals on the new wire that are the same type as those on the existing wire 3 Connect the new wire terminals to the terminals that are connected by the existing wire 4 Check the continuity of the replacement wire 5 Testthe operation of the component that is connected by the replacement wire and test the operation of the en
107. han regular inspection and replacement of the bushing if excessive wear is detected SUPPLIES TOOLS EXPENDABLE 7 16 diam wood dowel Screwdriver 2 Phillips REPLACEABLE e Pitot tube bushing Rev 2 SPINNER AND PITOT TUBE Inspect the Pitot tube and bushing for excessive wear using a clearance gauge Make the clearance gauge by cutting a 34 inch X 4 inch paper strip from common note book paper typical thickness is about 003 inch Make a mark on the strip 34 inch from one end Lay the paper strip lengthwise on the portion of the pitot tube that protrudes out of the spinner with the marked end positioned nearest to the spinner Wrap the paper strip tightly around the radius of the pitot tube and attempt to insert it between the pitot tube and the bushing If the paper strip can be inserted to the marked 34 inch depth further inspection is needed Remove the spinner and inspect the portion of the pitot tube that turns within the bushing for wear damage If any is present the pitot tube and the bushing should be replaced To replace them see Section 47 of the If no wear damage is present on the pitot tube just the bushing should be replaced Remove the worn bushing by driving it out from the aft side of the spinner using a 7 16 in diameter dowel Install the new bushing per Section 47 of the KAl PROP amp HUB eNOTE THERE IS NO SPECIFIED SERVICE LIFE FOR THE PROPELLER HOWEVER IT IS TO BE REMOVED FROM SERVICE W
108. he bottom skin Check all fittings for leaks The system lines include from left to right while seated in the cockpit electrical wire bundle amp static line fuel return left brake line right brake line and fuel supply There must be snap bushings at each bulkhead and clamps or brackets to hold the lines secure Test the operation of the brake pedals Constant pressure must not cause any of the brake pedals to bottom out Without pressure each brake pedal must automatically return to the original position The rudder pedals must move opposite and relative to each other with no slack between them The rudder stops on the lower rudder hinge must limit the rudder and pedal travel 3 6 Rev 3 RADIO e Check the connections external condition and installation of each component the main unit the antenna and the jacks COMMUNICATION e the operation of the unit per manufacturer specs Refer to the Garmin manual INTERCOM e If Installed Test the operation of the unit per manufacturer specs Refer to the FlightCom manual TRANSPONDER e sure the transponder is in compliance with FAR 91 403 and log entries current OPTIONAL EQUIPMENT Confirm that optional equipment installed on the aircraft is correct and authorized Optional equipment is offered and installed on the aircraft by the manufacturer at the time of purchase Refer to the related manual for special procedures for inspection See applicabl
109. he wing detached from the fuselage the flaperon is removable RIGHT FLAPERON ACTUATION BRACKET PIVOT GUIDE RIGHT WING ED ipo 1 LEFT RE FLAPERON WING RETENTION gt _ BUSHING STALL WARNING MODULE LEFT WING FLAPERON HINGE Figure 10 Wing and Flaperon 5 4 Rev 4 COMPONENTS 5 5 Rev 4 EMPENNAGE The empennage components include the vertical stabilizer rudder anti servo trim tab and stabilator assemblies The vertical stabilizer front and rear spar attach to the tailcone Fiberglass fairings finish the top of the vertical stabilizer and rudder The rudder is attached through hinges on the rear spar of the vertical stabilizer The stabilator attaches to hinges on the aft bulkhead of the tailcone The AST attaches to the rear of and operates in sequence with the stabilator The AST also functions as a trim tab Refer to the KAl for empennage component removal and installation RUDDER HORN ANTI SERVO TAB Figure 11 Empennage 5 6 Rev 4 COMPONENTS Quantity Partor Assembly Name Part Number or Reference isa WT WD 1205 5 7 Rev 4 LANDING GEAR The landing gear includes the gear legs wheels and tires nose fork and mounting brackets The nose gear leg is steel with welded brackets The aluminum nose fork attaches and pivots at the lower end An axle bolt and nut fastens the axle spacer and wheel and t
110. hiness of the aircraft Chapter 18 includes the inspection checklist service schedule checklist and other helpful documents APPLICABLE THROUGHOUT GENERAL SAFETY Safety must be considered the first priority when performing maintenance or service on an aircraft or part The content in this manual is only for use in a safe work environment with all necessary safety equipment readily available and in use when applicable Maintenance or repair classified in this manual and in 14 CFR FAR 43 Appendix A can be done by an RV 12 owner or operator that possesses a Sport Pilot certificate An LSA repairman certificate with a maintenance rating or an FAA issued A amp P certificate are the minimum level of certification to perform line maintenance or repairs and the annual condition inspection on an RV 12 Prior to performing maintenance or repair always disconnect the negative battery cable from the battery The strength of an airframe designed using semi monocoque construction relies on both the skins and the skeleton for complete structural strength If a skin has been damaged typically the underlying structure has also been damaged Carefully inspect any damage to assess the extent of the damage If the damage is localized to just outer skins they can be removed and replaced If inspection indicates that the substructure is also damaged the aircraft manufacturer must be consulted for further assessment Every time hardware is removed it must
111. ight side end by removing the securing clamp from the push on connection Using the push on connection and the hose elbows on the intake manifolds install rubber hoses leading to a dual vacuum gauge See Figure 30 12 10 Rev 4 INSTALL DAMPING VALVE BETWEEN GAUGE AND RUBBER HOSE NR IF NECESSARY W RUBBER HOSE RUBBER HOSE 2 spell CBNNECTION Se 7 SECURING CLAMP HOSE ELBOW BALANCE TUBE SHOWN WITHOUT FUEL MANIFOLD Figure 30 Vacuum Gauge Hookup 13 Secure the aircraft to the ground using chocks ropes etc A WARNING SECURE AND OBSERVE THE PROPELLER ZONE DURING ENGINE OPERATION 14 Start the engine and warm it up until normal operating temperatures are achieved 12 11 Rev 4 OFF IDLE SETTING 15 After warming the oil temp to the minimum required for takeoff power application run the engine to full throttle and verify the engine is developing proper power with an indication of at least 4700 RPM 16 Verify that both vacuum gauge readings are the same when the throttle is slowly moved between near idle and full power Use of damping valves see Figure 30 may be required to smooth out the vacuum gauge readings Install valves if required and slowly close them until the vacuum gauge readings stop fluctuating rapidly If the vacuum gauge readings are not the same shut down the
112. in this manual Cross references within this manual are made using the page numbers unless otherwise specified Following is an example of a typical cross reference to additional information within this manual Example When there is additional information that is related to this sentence the cross reference to that page will be in parenthesis following the period 1 2 Chapter 1 will introduce general information that is helpful for using this manual General information includes manual introduction general safety information notification methods abbreviations collective tool list list of expendables lubrication and capacities and general procedures Chapter 2 introduces the service schedule checklist Chapter 3 provides an explanation of the annual 100 hour inspection checklist including illustrations that clarity some checkpoints of the aircraft Read Chapter 3 prior to performing the inspection and use it as a reference during the inspection Chapter 4 and following begin with an illustration of the subject discussed an Overview of the chapter content and a list of Components The Service section where applicable begins with a table of Supplies which includes Tools Expendable and Replaceable parts The service section provides instructions for General removal replacement and installation that are acceptable for the owner or operator to perform The service section also includes instructions for Ser
113. inspection item identifies specific things to check for with that item Generally the items on the Inspection Checklist will correspond to the bulleted items in this chapter It is always important to be generally observant to the condition of the aircraft regardless of what is specified for inspection During the inspection make note in the space provided or on a separate document of any discrepancies with parts components or fasteners that require service or replacement Complete the entire inspection prior to performing service or repairs This chapter recommends tools that are useful for each inspection category 3 2 Rev 3 INSPECTION DESCRIPTION Multi meter Compression tester Torque wrench in Ibs amp ft Ibs Tire pressure gauge Jack Padded stands Step ladder Flashlight Magnifying Glass Wing Retention Pin Bushing Inspection Mirror Clean rags Straight edge avoid scratches tape along one edge Small square Screwdrivers 2 Phillips Socket 3 8 9 9 9 9 9 PRE INSPECTION POST INSPECTION Perform the preliminary systems check and engine run up The Rotax line maintenance manual provides the run up procedure for the engine Test all of the engine systems and controls Test all of the airframe systems and controls Make note of any abnormalities or dysfunctional components Record the applicable values in the spaces given on the nspection Checklist After the systems check proceed with the
114. ire assembly to the nose fork The main gear legs are aluminum fastened to the center section channel with brackets and bolts Each main axle bolts to the lower end of each gear leg All three tires are 5 00 x 5 size either 4 ply or 6 ply tube type aircraft tires are acceptable OUTBOARD DOUBLER PLATE INBOARD MAIN GEAR PLATE HL RIGHT MAIN GEAR P ere j INBOARD DOUBLER PLATE WEAR PLATE Eu INBOARD WEAR PLATE OUTBOARD MAIN GEAR ATTACH BRACKET NOSE GEAR MAIN WHEEL P NOSE FORK NOSE WHEEL ASSEMBLY AND TIRE E ASSEMBLY AND TIRE Figure 12 Landing Gear 5 8 Rev 4 COMPONENTS 2 Inbd Doubler 1 Manwhel UMHMHEBSIB _ 2 Wheel bearings BEARINGLM 67000L A Oo 1 1 Nosegear 21 1 Nose wheel assembly See shaded items below 1 Noswhel U WHLNW51CC 625 e e 1 Whedbemng 3 Tire 50 5 3 Tbe 500 4 9 7 5 9 Rev 4 NOSE WHEEL AND GEAR LEG FAIRINGS The optional nose wheel and gear leg fairings include the glass fabric epoxy resin nose leg fairing wheel fairing front and the wheel fairing aft See Figure 13 The nose leg fairing is clamped about the nose leg using a piano hinge held in place by a single screw The nose leg fairing is slotted to fit about the nose leg winch lug The wheel fairi
115. ll Studs amp Nuts Engine Mount Vibration Isolators Mount amp Isolator Hardware Wiring Harness Battery Cylinder Cooling Shroud Cabin Heat Door Left Carburetor Right Carburetor Carburetor Drip Trays System Lines Fuel Pitot Gascolator Control Cables throttle choke etc Air Filters left amp right Heat Exchangers oil amp coolant Exhaust System Cowling Empennage Vertical Stabilizer Rudder Stabilator Refer to Rotax Manual Comply with Rotax manufacturer inspection recommendations Rotax Line Maintenance Manual Fasteners Deformation Corrosion Deformation Cracks Unsealed holes Torque Condition Cracks Signs of Fatigue Corrosion Cracks Deterioration Condition Torque Condition Connections Continuity Condition Corrosion Security Charge Security Condition Security Condition Operation Condition Secure Connections Condition Secure Connections Cracks Deformation Security Routing Condition Security Contamination Leaks Operation Condition Connection Clean Secure Leaks Condition Security Leaks Condition Security Condition Fasteners Fasteners Attachment Corrosion Deformation Cracks Signs of Wear Corrosion Deformation Cracks Signs of Wear Corrosion Deformation Cracks Signs of Wear Corrosion Continued on next page 18 17 Rev 6 THIS PAGE INTENTIONALLY LEFT BLANK 18 18 Fuselage Fasteners Corrosion
116. ll turns Tighten the jam nut against the pushrod assembly INSTALLATION 1 Install the servo on the servo tray by reversing the process done in step 7 2 Install the trim servo assembly by reversing the process used in step 6 3 Connect the three colored pitch trim servo wires with previously installed terminals to the matching colored wires on the pitch trim CONTROL CABLE 4 Temporarily connect the two white wires on the pitch trim servo to the remaining two wires on the pitch trim control cable 5 Switch on the master switch and verify that when the pitch trim is activated in the nose down direction the antiservo tab assembly moves up If the ast moves in the wrong direction swap the two white wire positions and recheck 6 When the AST movement has been verified as correct install appropriate connectors on each wire for connecting to the pitch trim control cable ELECTRICAL COMPONENT REPLACEMENT EXCLUDING THE PANEL CIRCUIT BOARD A WARNING BEFORE PERFORMING ANY MAINTENANCE OR REPAIRS TURN THE MASTER SWITCH OFF AND DISCONNECT THE NEGATIVE BATTERY CABLE FROM THE BATTERY m CAUTION REPLACEMENT COMPONENTS WIRE TERMINALS AND FUSES MUST BE OF THE SAME TYPE AND RATING AS THE ORIGINAL PARTS 3 8 7 16 socket 2 Phillips screwdriver Wire cutter Terminal crimping tool Needle nose pliers Expendable Replaceable Service Rating Minimum Certification Additional References Disconnect negative ground wire Rem
117. lly or every 100 hours of operation depending on the terms of use for the aircraft The condition inspection is essential for insuring safe operation throughout the aircraft s service life In order for anyone to perform a condition inspection on an S LSA category RV 12 aircraft they must possess at least one of the following SPECIFIC CERTIFICATION REQUIREMENTS A person certified as Repairman light sport aircraft Maintenance rating FAA certificated A amp P technician e NOTE FOR THE INSPECTION CHECKLIST SEE SUPPLEMENT PAGE 18 5 e NOTE This maintenance manual is intended to be used in conjunction with the RV 12 Kit Assembly Instructions KAl when completing maintenance or repair processes The inspector will identify any wear corrosion or damage that would compromise the safe operation of the aircraft All inspection practices must comply with the current Advisory Circular 43 13 1B regardless of the content of this manual During the inspection locations concealed from direct line of sight may be accessible by touch or with use of a mirror Inaccessible places do not require 3 1 Rev 3 inspection provided the airframe has been constructed and used within the terms defined by the manufacturer The Inspection Checklist provided in the Supplement will be a guide for the inspection procedure The bold print identifies each category of inspection and the general symptoms to check for throughout that category Each category
118. m tab movement resistance control force feed back and also serves as a trim control surface The trim function is controlled with the pitch trim servo As needed At first sign of wear or abnormal operation and or following exposure to adverse conditions CFR 14 Code of Federal Regulations Title 14 Aeronautics and Space also known as the FAR s Check To verify the correctness of as by comparison to inspect or test the condition performance safety etc of Electronic EFIS Refers to the Dynon D 180 Dynon Skyview or Garmin G3X Flight The unit receives signals from multiple sensors on the airframe and Information engine then provides valuable engine and flight information based System on the signals from the sensors Emergency ELT The electronic device unit that sends a distress signal when G Locating loads exceed a critical value or when activated manually Transmitter Engine EMS Refers to the Dynon D 180 Dynon Skyview or Garmin G3X Management The portion of the EFIS unit that compiles and displays engine System information 19 1 Rev 2 Extreme Heavily contaminated air dust bugs smoke debris ash sand etc conditions or adverse climatic conditions Flaperon A control surface that combines the aileron and flap functions into one component with both functions Global GPS A navigational system involving satellites and computers that Positioning can determine the latitude and longitude of a receiver on Earth S
119. maintenance requirements and procedures refer to the Rotax Engine Type 912 Series line maintenance and heavy maintenance manuals Rev 5 LUBRICATION AND CAPACITIES ENGINE m CAUTION ONLY USE CLASS SG OR HIGHER m CAUTION DO NOT USE OILS Multi Grade Oils WITH FRICTION MODIFIER ADDITIVES m CAUTION DO NOT USE OILS FOR CONVENTIONAL AIRCRAFT ENGINES m CAUTION DO NOT USE OILS DESIGNED FOR DIESEL ENGINES Capacity 3 Itr 3 2 US qts The type of oil to use will be based on the type of fuel used Refer to the Rotax operators manual to determine which oil type is compatible with the fuel being used See Figure 1 to determine the viscosity best suited for the use of the aircraft Figure 1 Oil Viscosity BRAKE FLUID A WARNING NEVER USE AUTOMOTIVE BRAKE FLUID Use Mil Spec 5606A or MIL PRF 83282 Brake fluid draining flushing and replacing instructions Page 7 5 CAPACITY 15 4 fl oz US 455 liters Rev 5 ENGINE COOLANT SUITABLE COOLANTS COOLANT MIX 50 ethylene glycol concentrate with anticorrosion additives designed for aluminum without sulfates and phosphates 50 distilled or de mineralized water CAPACITY 0 6 gallon US 2 3 liters Fill expansion tank to between the min and max marks in the overflow bottle Expansion tank 2 3 full 2 liter 4 pt overflow bottle FUEL SUITABLE FUEL 91 AKI premium unleaded aut
120. n bearings 3 2 Apply lubricant sparingly to each of the flaperon bearings 3 Allow lubrication to penetrate for a minute or more Wipe away excess ANTI SERVO TAB ATTACH HINGE LUBRICATION Minimum Certification Owner and SPC LSA RM or A amp P 1 Lower the Anti Servo Tab by adjusting the trim Lower the trailing edge of the stabilator 2 Wipe away any dirt accumulation from the AST attach hinges 3 Apply lubricant along the top of the left and right AST attach hinges 4 Allow lubrication to penetrate for a minute or more Wipe away excess NOSE WHEEL BEARINGS REPLACEMENT Tools 3 16 Allen Small wooden dowel 1 2 1 inch dia Mallet Expendable Replaceable Wheel bearings Additional References 1 Lift and support the aircraft 1 16 2 Remove the nose wheel and tire assembly 5 16 3 Deflate the inner tube 5 24 gt 01 Rev 4 Split the wheel and tire assembly by removing the bolts 3 washers 6 and nuts 3 Press the wheel bearing out from the inside of each wheel half Press a new wheel bearing into each wheel half Reassemble the wheel and tire assembly SLOWLY inflate the tire Deflate it fully and re inflate it SLOWLY a couple more times to work out any wrinkles in the tube Inspect for a good seat around the wheel rim The final inflation pressure is 15 psi Install the wheel and tire assembly MAIN WHEEL BEARINGS LUBRICATION Needle nose pliers DAWNI
121. ncy of aircraft use may include runway conditions flying conditions storage methods etc REPORTING METHODS Mail to ATTN RV 12 Safety Alert Van s Aircraft Inc 14401 Keil Road NE Aurora OR 97002 USA Fax to RV 12 Safety Alert on cover page 503 678 6560 Hours 24 hours per day E mail to RV 12 Safety Alert in subject line engineering vansaircraft com Rev 2 REPLACEMENT PARTS Van s Aircraft Inc reserves the right to update modify or discontinue any part without notice Van s Aircraft Inc is not liable for the use of any part or material by the owner that does not appear on the kit s part list Use of any unauthorized part or material will be at the owner operators own risk For replacement parts contact Van s Aircraft Inc using the following information Van s Aircraft Inc Phone 503 678 6545 14401 Keil Road NE Fax 503 678 6560 Aurora OR 97002 USA Website www vansaircraft com email orders vansaircraft com Part number and description may be obtained from the Kit Assembly Instructions Whenever ordering replacement parts please provide the following information Name Builder Number Day Phone Fax if applicable Email Ship to Address Address City State Province Zip Postal Code Country part number description quantity payment method and corresponding account amp exp date if applicable SUBSTITUTE PARTS The following parts are approved for substitution Either the
122. ng Place the loose end in the fuel container 6 Putthe fuel valve in the open position 7 Remove the fuel cap from the fuel neck m CAUTION TURN OFF THE ELECTRIC FUEL PUMP IMMEDIATELY WHEN A CHANGE IN SOUND IS HEARD THE LOUDER CLACKING SOUND INDICATES THE FUEL PUMP IS NO LONGER PUMPING FUEL DO NOT ALLOW THE FUEL PUMP TO OPERATE WITHOUT FUEL OR PERMANENT DAMAGE MAY OCCUR 8 Turn on the master switch and operate the ES 40105 Electric Fuel Pump until the fuel pump stops pumping fuel 9 Put the fuel cap back in place in the fuel filler opening but do not latch it Just allow the cap to lay in the opening To aid in clearing the fuel lines use low pressure 5 10 PSI max air applied to the open end of the fuel hose that was disconnected from the gascolator s outlet fitting Repeat the previous two steps several times waiting for about 30 seconds between repitions to give the fuel time to flow past the tank s internal baffle Also the fuel valve may be partially closed reducing the flow rate to equal or slightly less than the tank drainage rate for fuel behind the internal baffle helping to reduce the number of run wait cycles 10 Reconnect the fuel line at the gascolator FUEL TANK REMOVAL Tools 5 16 3 8 7 16 socket 11 16 9 16 combo wrench 13 5 Rev 1 3 16 Standard screwdriver Minimum Certification LSA RM or A amp P Additional References 1 Drain the fuel system 13 4 2 Remove
123. ng aft attaches to the wheel fairing front which in turn attaches to the nose fork Tow bar access is provided by two 13 16 diameter holes in the wheel fairing front NOSE LEG FAIRING WHEEL FAIRING AFT WHEEL FAIRING FRONT Figure 13 Nose Wheel and Gear Leg Fairings OPTIONAL COMPONENTS Quantity Part or Assembly Name Part Number or Reference 1 Wheel Fairing Front U 00005A 1 Wheel Fairing Aft U 00005B 1 Nose Leg Fairing U 00007 5 10 Rev 4 WHEEL FAIRINGS The optional main wheel fairings include the glass fabric epoxy resin wheel fairing front and the wheel fairing aft See Figure 14 The fairings are attached to the wheel fairing brackets which in turn attach to the bracket mount BRACKETS Figure 14 Main Wheel Fairings OPTIONAL COMPONENTS Quantity Part or Assembly Name Part Number or Reference 2 Wheel Fairing Front U 00001A 2 Wheel Fairing Aft U 00001B 4 Wheel Fairing Bracket U 00002 2 Bracket Mount inner not shown U 00003 2 Bracket Mount outer U 00004 Needle nose pliers Sockets 3 8 5 16 7 16 1 2 9 16 3 4 11 2 11mm Combination wrenches 3 8 7 16 1 2 9 16 Allen wrenches 3 16 1 4 5 16 Screwdriver 2 Phillips Mallet Large wooden dowel 11 2 1 3 4 inch dia Small wooden dowel 1 2 1 inch dia Rev 4 SERVICE SUPPLIES EXPENDABLE Cotter pins Safet
124. ngs are removable without the need of tools Screws bolts and solid rivets are used where necessary e NOTE PRIOR TO PERFORMING STRUCTURAL REPAIRS READ CHAPTER 4 FOR LIMITATIONS e NOTE THIS MAINTENANCE MANUAL IS INTENDED TO BE USED IN CONJUNCTION WITH THE RV 12 ASSEMBLY INSTRUCTIONS KAI WHEN COMPLETING MAINTENANCE OR REPAIR PROCESSES A WARNING BEFORE PERFORMING ANY MAINTENANCE OR REPAIRS TURN THE MASTER SWITCH OFF AND DISCONNECT THE NEGATIVE BATTERY CABLE FROM THE BATTERY FUSELAGE The fuselage will be identified as the forward fuselage and the tailcone The forward fuselage is the baggage bulkhead and all airframe parts forward to and including the firewall The tailcone refers to all of the parts behind the baggage bulkhead excluding the empennage fairing and empennage components 5 2 Rev 4 CANOPY WING RETENTION Sr N R PIN BUSHING we et A STABILATOR 3 A 4 FUSELAGE HARNESS am LEFT STEP 1 04235 5 3 Rev 4 WING AND FLAPERON The wing and flaperon are removable as an assembly from each side of the fuselage Each wing mates to the fuselage at three points the stub spar the main spar and the rear spar Two fuselage pins secure both main spars to the center section of the fuselage Electrical and control connections connect automatically during wing attachment The left wing has a stall warning sender installed With t
125. nspect the main spar rear spar and stub spar for corrosion deformation signs of wear or fatigue Inspect the rear spar and stub spar for lubrication at the inboard end Inspect the flaperon condition and operation Inspect the flaperon skins and fasteners for damage or deformation The flaperon must swing smoothly without free play in any direction Inspect the flaperon control connection for signs of wear Check the fasteners in the flaperon hinge brackets on each wing for security Inspect inner surface of flaperon torque tubes for rust and corrosion Inspect the condition of the electrical connections that correspond to the fuselage The connections must be free of corrosion and damage Test the stall warning Vane for freedom of movement Check the micro switch for corrosion condition and security Check the wing skin for cracks around the stall warning vane penetration Check fuselage pin latching mechanisms for security and proper operation Test warning circuit by moving each latch independently and verifying warning light Rev 3 Inspect each fuselage pin and all wing retention pin bushings for wear or WING RETENTION cracks Inspect the center section area around the bushings for deformation or un cracks Use the Main Spar Bushing Gauge Pin to check the wear of both ends of all of the wing retention pin bushings Insert the Gauge Pin into the bushing then rotate the Gauge Pin The Gauge Pin is a go no go d
126. nualor 100 hours 554 Charge 2 Asneeded 1 8 1 Flush amp replace 75 Lubricate 2 2yearsor200hous 74 Replace Asneeded 76 o Lubricate Annudori00hous 688 S Lubricate Annudori00hous 68 S Check for updates needed Dynonusersmanual Replace years 1215 S S Check 8 perform 100 hours Rotax maintenance manual Lubricate 2 Annualor 100 hours 44 ame _ 23 5 years or with fuel 13 E I pump Clean amp inspect Annual or 100 hours Rus pene pump Replace 10 years or engine m m m elta e AnnudoriO0hous 157 o Torque l Amualor200hous 7 Lubricate 2yearsorAsneeded 55 1 Replace 10 years or eng ovhl 126 18 3 Rev 6 THIS PAGE INTENTIONALLY LEFT BLANK 18 4 Rev 6 SERVICE SCHEDULE CHECKLIST Service What Action When How Date Initial Nose fork pivot Lubricate 100 6 526 Nose wheel bearings Replace 7 Asneeedd 54 1 Wheel Balance Balance 7 556 7 1 overhaul overhaul Propeller Hub Clamping Bolts Torqile 25hows 11 3 Wing attach locations a Wing interface terminal tabs 100 hours Throttle Return Springs Verify Function 50 hours or after 12 14 carburetor maintenance End of service schedule 18 5 Rev
127. o the air data computer located behind the instrument panel with the D 180 and in the aft fuselage with the Skyview and G3X The pitot port is an aluminum tube located at the tip of the spinner cone that extends aft to an adapter block mounted to the engine A flexible plastic tube continues aft from the adapter block to the air data computer was then forward within the center tunnel to the instrument panel The pitot port is an aluminum tube located at the tip of the spinner cone that extends aft to an adapter block mounted to the engine A flexible plastic tube continues aft from the adapter block to the instrument panel Add under Components 1 Garmin G3X See Garmin Manual 1 Garmin GTX 327 or GTX 23 ES or SV XPNDR 26X See Garmin or Dynon Manual 1 Garmin GXM30A or GA26XM See Garmin Manual Page 9 3 Rev 4 To the top table remove the word Dynon from Autopilot Servo See Dynon or Garmin Manual was See Dynon Manual Add 1 SV AP PANEL See Dynon Manual Add 1 SV KNOB PANEL See Dynon Manual Add 1 Garmin GMC 305 Autopilot Controller See Garmin Manual D 180 01000 D1000T G3X Dual EFIS EMS See Dynon or Garmin Manual was 4 D 100 Dual EFIS EMS See Dynon Manual MM Page 9 4 Rev 4 Software updates are often available online for the Dynon D 180 Skyview Garmin GPS and Garmin G3X The avionics components are not serviceable by the consumer unless otherwise noted in the manufacturer user
128. omotive 100 LL Aviation Fuel AVGAS min RON 95 CAPACITY 19 8 05 Gallons 75 0 liters TIRE PRESSURES NOSE 22 psi 23 psi maximum MAIN TIRES 25 psi 28 psi maximum Rev 5 TORQUE VALUES Torque applied is for the size of the bolt shank not the wrench size On smaller bolts use a torque wrench calibrated in inch pounds not foot pounds When tightening fasteners with self locking nuts the chart values must be modified The friction drag torque must be determined and then added to the standard torque from the table Due to the friction of the locking device noticeable torque is required just to turn the nut onto the threads and does nothing to actually tighten the parts together and stretch the bolt clamp load This is called friction drag or prevailing torque Run the nut down to where it nearly contacts the washer or bearing surface and check the friction drag torque required to turn the nut At least one thread should protrude from the nut Add the friction drag torque to the standard torque This sum is referred to as the final or total torque which should register on the indicator or setting for a snap over type torque wrench The propeller manufacturer and the engine manufacturer have specific torque requirements for their equipment Consult the appropriate manual for that information ftib inib Nm OilFilter Contact 3 4 Turn or as Specified MagneticPlug 18 20 2 Wat
129. on must be smooth from stop to stop Operate the flap lever to each detent At each flap lever detent check the full motion of the control stick for smooth operation 3 5 Rev 3 CONTROL COLUMN CONTROL COLUMN STOP 3 SX sure the stabilator contacts its up and down stops before the WD 1210 Control NO 22 Column contacts its up MN lt 7 Ne mt down stops If not N loosen and tighten the lt NG EN stabilator cable N tensioner barrels an equal and opposite amount until the travel is full and correct The control column stops must limit excessive forward and aft pressure The bellcrank stops must limit the left and right control stick motion See Figure 5 SAN M MESA UNNA BELLCRANK ASSEMBLY Figure 5 Control Stops Actuate the vent door on each side of the cockpit and confirm a clear passage Actuate the cabin heat push pull cable confirm a clear passage to the cabin when and smooth operation Confirm that the heat door has a tight seal to the firewall when heat control is in the off position Test the full motion of each of the engine control cables for smooth operation and proper operation of the friction throttle control or position lock choke control Test the operation of the fuel valve Check the security of the electric fuel pump and the fuel flow transducer Inspect the system lines that run along the center of t
130. or Garmin G3X Manual Rev Level Changes MM Revision Levels Changed CHAPTER REVISION DATE COVER PAGE 8 04 03 14 BERN 04 03 14 iii viii 04 03 14 10 1 0416 10 13 5 040314 2 18 6 04 03 14 20 3 084243 m 6 RV 12 MAINTENANCE MANUAL Aircraft Serial Number Rev 8 04 03 14 REVISION SUMMARY CHAPTER DATE COVER PAGE 8 04 03 14 L3 e L a s a 5 S Z S Jo E Rev 5 04 03 14 OWNER OPERATOR RESPONSIBILITIES For continued airworthiness of an RV 12 aircraft the owner operator must comply with the following requirements as dictated in ASTM F 2295 Section 5 Each owner operator of an RV 12 shall read and comply with the maintenance manual and continued airworthiness information and instructions provided by Van s Aircraft Inc Each owner operator of an RV 12 shall provide Van s Aircraft Inc with up to date contact information so that Van s Aircraft may send the owner operator supplemental notification bulletins a The owner operator of an RV 12 shall notify Van s Aircraft Inc of any safety of flight issue or significant service difficulty upon discovery using the Feedback Form provided in the Maintenance Manual owner operator of an RV 12 shall comply with all Van s Aircraft Inc issued notices of corr
131. ove the applicable access covers to expose the failed component 3 4 Label the wires Disconnect the wire s from the failed component Make note of the hardware configuration Disconnect the mechanical connection if applicable Remove the hardware that secures the component and remove the component Install a new component new gaskets if applicable and hardware of the same NEIN 8 9 8 9 Rev 3 type Re attach applicable electrical and mechanical connections Reconnect the negative battery cable AV CONTROL BOARD REPLACEMENT small flat blade screwdriver Minimum Certification LSA RM or A amp P Additional References 9 10 Reconnect the 11 Test for correct Remove the control Install the new control Remove the panel cover 3 4 Disconnect negative battery cable Discharge the circuit board With the master switch press the stall warning vane until the tone fades off If wings are removed ground the stall warning terminal tab at the fuselage side cover as shown in Figure 24 Verify all plugs and connectors and their connected locations are properly labeled Disconnect the control board connections Remove the control board attachment hardware board board and hardware of the same type Re attach all plugs and connectors negative ground wire to the battery operation of all electrical circuits a C Fi
132. owl fasteners and hinges for missing eyelets security Check cowl shielding for signs of high temperature and proper attachment to cowl 3 9 Rev 3 FUSELAGE Magnifying glass Clean Flashlight Straight edge e Inspection mirror e Inspect the exterior of the fuselage skins and fasteners Check the fasteners by sighting along each rivet pattern for any inconsistent rivet profile among properly installed rivets as shown in Figure 6 FAILING OR UNSET I Figure 6 Rivet Inspection e Critical areas are where the firewall attaches to the fuselage each wing spar mates with the fuselage the tailcone attaches to the forward fuse and the empennage components attach to the tailcone e Visually inspect that both of the static ports are clear Test the condition and security of the left and right boarding steps Inspect the condition of the electrical connections that correspond to the wing The connections must be free of corrosion and any damage e Inspect the inside diameter of each aileron torque tube for rust corrosion and verify that the UHMW plastic spacers are in place in the actuating arms of the flaperon torque tubes 3 10 Rev 3 LANDING GEAR A WARNING A LIFTED AIRCRAFT MUST BE SECURELY SUPPORTED BY STATIC STANDS OTHER THAN THE JACKING DEVICE THE AIRCRAFT MAY NOT MOVE FROM ATTEMPT TO SHAKE HORIZONTALLY
133. r 1 4 2 3 Rev 4 SERVICE Refer to the engine manual for full engine service details The cowling does not require regular maintenance The cowl attach hinge pins may be lubricated with a dry lubricant to ease removal and installation SUPPLIES EXPENDABLE e Socket Spray lubricant 3 8 Engine coolant 5 16 Engine oil 9 16 Dry lubricant 16mm spark plug type Oil filter Combination wrench Safety wire 3 8 Cotter pins 9 16 Screwdriver 42 Phillips REPLACEABLE Spark plug gap tool wire type Hinge pins Needle nose pliers Spark Plugs Vibration isolator Air filter Push Pull cable GENERAL COWLING REMOVAL Additional References 1 Remove the screws 2 in the F 1240B Cover Plate located at the top rear of the cowling to access the cowl attach hinge pins 2 Top Cowl Remove the top cowl fwd attach screws 6 side pin anchor screws 2 hinge pins 4 and the top cowl 3 Bottom Cowl Remove the bottom cowl attach screws 12 located on the bottom of the cowl the oil cooler attach screws 2 located at the top of the oil Rev 4 cooler the hinge pins 4 and the bottom cowl Note The oil cooler will remain attached to the airplane hanging in place by its associated oil hoses INSTALLATION 1 Installation procedure is reverse of the removal procedure Note As the lower cowl is lifted into place maneuver the oil cooler so that its lower notches drop onto Cowl 12 Guides The cooler shoul
134. rior to further flight Refer to the service schedule checklist for component service frequency 7 2 Rev 2 SUPPLIES m CAUTION USE ONLY MIL SPEC MIL H 5606A HYDRAULIC FLUID DO NOT USE AUTOMOTIVE BRAKE FLUID DAMAGE TO O RING SEALS MAY RESULT TooLs EXPENDABLE Hydraulic fluid Socket 3 8 Wheel bearing grease 7 16 e Cotter pins Combination Wrench Brake shoe linings 1 4 3 8 REPLACEABLE 7 16 1 2 See component list on page 7 2 Needle nose pliers Container GENERAL MASTER CYLINDER REMOVAL m CAUTION THE LEFT AND RIGHT MASTER CYLINDERS ON EACH SIDE OF THE AIRCRAFT AHE NOT INTERCHANGABLE Tools 3 8 socket 3 8 1 2 combo wrench Needle nose pliers Expendable Hydraulic fluid Cotter pins Replaceable Left Right Brake master cylinder Service Rating Minimum Certification LSA RM or A amp P Additional References KAI Matco user manual REMOVAL 1 Remove the upper and lower master cylinder attach hardware Upper clevis pin washer and cotter pin Lower bolt washer nut and cotter pin 7 3 Rev 2 DISCONNECTION 1 Drain the hydraulic fluid 7 5 2 Make note of the hose connections 3 Disconnect brake lines from master cylinder INSTALLATION 1 Installation procedure is reverse of the removal procedure 2 Bleed the brake system 7 5 SERVICE SCHEDULE PROCEDURES BRAKE PEDAL TORQUE TUBE LUBRICATION Tools 7 16 socket 7 16 combo wrench Needle nose pliers
135. s Repair Facility Facility specifically authorized by the aircraft or component or Repair manufacturer to repair the product originally produced by that Station manufacturer Sport Pilot SPC A person who holds a current Sport Pilot Certificate A Certified certified sport pilot may perform preventative maintenance and approve for flight a private use S LSA aircraft that they own or operate Stabilator An aircraft control surface that combines the horizontal stabilizer and elevator into one fully movable component 19 3 Rev 2 THIS PAGE INTENTIONALLY LEFT BLANK 19 4 A Abbreviations Inspection Installation Remowval Anti servo trim tab Inspection Lubrication B Charging Installation Remowval Terminals Bellcrank Bearing SIOpS egens Brake pedal Lubrication Brake Shoe Lining Inspection Replacement Brake System zzz Cleaning Installation Inspection Latch Block Remowval
136. s Wire insulation must be secure intact and flexible free from cracks burns or separation All wire terminations must be tight Check the battery for proper voltage condition of the case and that the connections are secure Engine cooling shroud must be secure and free of cracks Cabin heat cable and connection must be secure and operate smoothly All ducting must be secure and in good condition Heat door must close tightly against firewall when Check each engine control cable for security and condition along the route to the firewall The throttle and choke cables must be securely connected to each of the carburetors and in good condition Throttle and choke cables must operate the carb levers from stop to stop Inspect the air filters for cleanliness attachment and condition Inspect the heat exchangers for proper attachment cleanliness and condition The flexible lines provided with the engine have a service life defined in the Rotax maintenance manual Static and other flexible lines must be in good condition connected and fastened securely Check the fuel lines for good condition secure mounting routing and connections Inspect the the screen and bowl of the gascolator for contaminant build up Check the O ring for condition and deterioration Check the exhaust system for security Check for signs of exhaust leaks Inspect the cowling for overall condition loose paint material separation signs of wear Check the c
137. s of damage it must either be repaired if possible or retired from service Cracks in the metal hub or bolts Loose metal leading edge A crack across the blade A long or deep crack along the blade length Any portion of composite material missing Obvious damage or wear beyond economical repair Rev 4 CHAPTER 12 FIREWALL FORWARD ENGINE COWLING ENGINE CONTROLS ENGINE OVERVIEW PM Lc E 12 2 12 2 eT M 12 3 Rotax 912 S 2 6 oem d t 12 3 Nri Succ o 12 3 IQMItON PD DUAE 12 3 SERV CE cT 12 4 Supplies E 12 4 Tools Au ii atit tatu e be eite 12 4 Expendable 452 225 ttt ete tno e de c a a ae cde ef aA eee 12 4 6 dio Rete D P Ee RE HE Eee ee 12 4 12 4 Hr BRI o 12 4 Installation eden ee T 12 5 Spark pl g replacererit sa reis Actes ha tara deve 12 5 Oilfilter replacement a ncc De es C e ae Eo ee 12 5 Engine oillevelicheck eret nto nate tita Ei eap etr dar d ee aee dte chet 12 6 Engine coolant level Check
138. se pliers 2 Phillips screwdriver Expendable Replaceable Rudder pedal Service Rating Minimum Certification LSA RM or A amp P Additional References KAl Matco user manual 1 Remove the tunnel cover 3 4 2 Remove the rudder pedal access covers directly aft of the horizontal tubes of the rudder pedals and hardware screws 3 washers 2 and nuts 2 NOTE THE MASTER CYLINDERS BE REMOVED WITHOUT DISCONNECTING THE BRAKE LINES 3 Label and then remove the master cylinders 4 from the rudder pedals 7 3 4 Remove the rudder cable hardware from each rudder cable cotter pin bolt washers 3 and nut Rev 3 5 Remove the rudder pedal block hardware bolts 2 and washers 2 from each of the rudder pedal blocks 3 6 Remove rudder pedal assembly INSTALLATION 1 Installation procedure is reverse of the removal procedure SERVICE SCHEDULE PROCEDURES CONTROL SYSTEM ROD END LUBRICATION 3 8 7 16 sockets Minimum Certification LSA RM or A amp P Additional References 1 Remove the seat ramp cover seat floor cover baggage cover and fuel tank assembly 3 4 2 Apply lubricant sparingly to the rod end bearings on each end of the following components Flap handle pushrod Control stick pushrod Flaperon pushrod Trim Servo pushrod 3 Allow lubrication to penetrate then wipe away excess CABLE END HARDWARE LUBRICATION Tools Expendable Spray lubricant Replaceable Service Ratin
139. side 2 Chock main wheels tie down tail 3 BRAKES FULL 4 Master switch ON avionics switch ON then power down transponder com radio and GPS 5 Check EFIS for fuel pressure indication 6 Start engine check for oil pressure functioning and showing pressure 7 Warm the engine to 1229 8 THROTTLE Completely loosen throttle friction knob and observe throttle advance rate If the throttle advances rapidly to a partial position then slowly advances the throttle to full the springs are functioning correctly This may take up to 15 seconds If the throttle is not pulled to full the return springs and or throttle cable need to be replaced before further flight Consult the RV 12 KAI Section 50 12 14 Rev 4 SERVICE SCHEDULE PROCEDURES COWL HINGE PIN LUBRICATION 2 Phillips screwdriver Minimum Certification Owner and SPC LSA RM or A amp P Additional References 1 With the cowl hinge pins removed wipe each hinge pin clean 2 Immediately prior to re installation apply lubricant along the length of each hinge pin OiL HOSE REPLACEMENT A WARNING BEFORE PERFORMING ANY INSPECTION OR SERVICE ALLOW THE ENGINE COMPONENTS TO COOL Tools 1 4 3 8 7 8 combo end wrenches Phillips screwdriver wire cutters Expendable Plastic tie wrap 8in Replaceable Oil Supply Hose Oil Cooler Hose Oil Return Hose Oil Tank Vent Tube Oil Vent Interconnect Preventative Preventative Minimum Certifi
140. surement aa as shown in nn Figure 15 d HINGE BEARING PROTRUSION Figure 15 Flaperon hinge 5 Remove the flaperon hinge bearing from the wing 6 Install the new flaperon hinge bearing to the same protrusion measurement 7 Install the flaperon assembly RUDDER HINGE REPLACEMENT Tools 3 8 socket 3 8 combo wrench 2 Phillips screwdriver Expendable None Replaceable Lower rudder hinge Upper rudder hinge Service Rating Line Minimum Certification LSA RM or A amp P Additional References KAI m CAUTION BE PREPARED WITH ADDITIONAL PERSONEL OR TOOLS TO HANDLE THE WEIGHT AND AWKWARDNESS OF THE OBJECT TO BE REMOVED Remove the upper and lower tailcone fairing 3 4 Remove the rudder control cables and rudder assembly Remove from the vertical stabilizer the rudder hinge hardware see below and the rudder hinge to be replaced Upper hinge bolt 4 washer 8 Lower hinge bolt 4 washer 4 DM 5 18 Rev 4 m CAUTION UPPER AND LOWER RUDDER HINGES ARE NOT INTERCHANGABLE 4 Install the new rudder hinge and hardware 5 Install the rudder assembly 6 Install the upper and lower tailcone fairing STABILATOR HINGE REPLACEMENT Tools 3 8 3 4 11 mm socket 3 8 combo wrench Needle nose pliers 2 1 2x3 16 bolt washer and nut Expendable Cotter pins Lock Clips 2 Replaceable Bearing DWAK2X Minimum Certification LSA RM or A amp P Additional KAI References m CAUTION BE PREPARED WITH ADDITIONAL
141. system downstream of the fuel valve The manifold feeds the fuel pressure sender fuel return line and the left and right carburetors The gascolator serves as the primary fuel filter and water trap Sample the gascolator sump frequently to monitor the amount of water introduced into the fuel system The gascolator and fine fuel screen requires inspection and cleaning at regular intervals at least annually e NOTE This maintenance manual is intended to be used in conjunction with the RV 12 Kit Assembly Instructions KAl when completing maintenance or repair processes COMPONENTS Quantity Assembly Name PartNumberorReference 13 2 Rev 1 FUEL SYSTEM SCHEMATIC FUEL VENT CAP AND FILLER NECK MECHANICAL PUMP X MECHANICAL FUEL GAUGE SENDING RIGHT CARBURETOR UNIT COARSE SCREEN ch 11 oan GASCOLATOR r 1 m FINE SCREEN 7 57 4 rt VALVE TANK ELECTRIC FLOW TRANSDUCER PUMP PRESSURE SENDER LEFT CARBURETOR SERVICE AVAILABLE WARNING BEFORE PERFORMING ANY MAINTENANCE OR REPAIRS TURN THE MASTER SWITCH AND DISCONNECT THE NEGATIVE BATTERY CABLE FROM THE BATTERY m CAUTION REPLACEMENT FUEL SYSTEM COMPONENTS MUST BE EQUIVALENT TO THE ORIGINAL PARTS NOTE CLOSE THE FUEL VALVE TO SERVICE OR REMOVE COMPONENTS THAT ARE FORWARD OF THE FUEL VALVE DRAIN THE FUEL SYSTEM TO SERVICE OR REMOVE COMPONENTS OF THE F
142. t floor cover baggage cover and fuel tank assembly 3 4 2 Remove the control rod attach hardware from the rod end for replacement Control stick control stick pushrod bolt washers 3 and nut Control stick pushrod bellcrank washer and nut Bellcrank flap handle pushrod bolt and washers 2 Bellcrank flaperon pushrod bolt washer and nut Flaperon pushrod flaperon torque arm bolt washers 2 and nut Make note of the number of threads exposed on the rod end shaft and the clocking of the bearing body Remove the rod end and jam nut Add a jam nut to the new rod end shaft Install the new rod end to the position from step 3 of the original rod end Install the control rod and control rod attach hardware NOOA 6 7 Rev 3 BELLCRANK BEARING REPLACEMENT Tools 3 8 7 16 3 4 11 mm socket 3 8 7 16 combo wrench 2 1 2x3 16 bolt washer and nut Expendable Replaceable Replaceable References 1 Remove the seat ramp cover and seat floor cover 3 4 2 Remove the pushrod to bellcrank hardware Control stick pushrod washer and nut Flap handle pushrod bolt and washers 2 Flaperon pushrod bolt washer and nut Remove the bellcrank Use the same method instructed for extracting the DWAK2X hinge bearing on page 5 20 Figure 16 5 Installation procedure is reverse of the removal procedure RUDDER PEDAL REMOVAL 11 32 3 8 socket 3 8 combo wrench Needle no
143. tax line maint Engine suspension loose Vibration at specific Carburetor malfunction 12 RPM Ignition malfunction Rotax line maint Excessive rattling Loose fasteners Loose baggage Corrosion Loose electrical connection Exposure to contamination Failing protective coating Unlike metals exposed to moisture Flight control Insufficient lubrication Fossa o Control surface hinge axis not aligned Failing control system components Improper control system adjustments Erroneous engine e Malfunctioning sensor status Loose connection Malfunctioning EMS Abnormal engine noise Damaged or leaking exhaust system Open passage in firewall 3 16 2 Rev 2 CHAPTER 17 FEEDBACK amp REPLACEMENT PARTS FEEDBACK To maintain the highest level of safety the FAA requires and Van s Aircraft Inc requests notification of any safety of flight issue service or maintenance difficulty that could compromise airworthiness of the RV 12 aircraft A feedback form is provided in the Supplement section of this manual A valuable description will include e Specific flight condition if applicable e List of the parts identified as affected by the anomaly e Description of the apparent condition of the parts prior to the anomaly de burred primed modified etc e Statement as to whether the aircraft has remained within the operating limitations defined in the POH e Brief description of the type and freque
144. tenance or repair action The top and bottom engine cowling are a formed composite of fiberglass cloth and epoxy resin The cowl is attached using screws and segments of piano hinge Hinge also attaches the top and bottom cowl halves together Adhesive heat shielding protects the inner surface of the cowl The throttle and choke are the only engine controls Air duct and engine cooling shrouds of similar construction provide cooling to the cylinders and heat exchangers e NOTE This maintenance manual is intended to be used in conjunction with the RV 12 Kit Assembly Instructions KAl when completing maintenance or ir processes COMPONENTS Quantity Part or Assembly Name Part Number or Reference 1 Rotax 912ULS Refer to Rotax documentation amp See Figure 26 Engine controls See shaded items below Cowling Seeshadeditemsbelow 12 2 Rev 4 ENGINE THROTTLE ARM 2 PLACES CYLINDER 4 CYLINDER 2 Figure 26 Rotax 912ULS Current engine product manuals and or specifications take precedence over any associated information referenced in this manual for convenience This manual will not reflect current revisions to products or specifications made by the engine manufacturer Refer to the engine manufacturer s operators manual for specifications SPARK PLUGS NGK Socket 16mm Electrode Gap See Rotax Documentation IGNITION Dual Breakerless Capacitor Discharge Firing Orde
145. ter clockwise Note this step cannot be done without removing the carburetor from the manifold With a new engine initially assume it is properly set at the factory 8 Hook up the full throttle return spring previously disconnected back to its original position on the throttle arm IDLE SPEED ADJUSTMENT SCREW THROTTLE ARM IDLE STOP FULL THROTTLE RETURN SPRING MIXTURE SCREW Figure 28 Mixture Screw 12 9 Rev 4 HOOKING THE THROTTLE CABLE LEAD TO THE THROTTLE ARM 9 Pull the throttle handle away from the instrument panel the distance prescribed in Figure 29 then tighten the friction adjustment This is the idle position THROTTLE CABLE THROTTLE a HANDLE FRICTION ADJUSTMENT Figure 29 Throttle Handle Idle Position 10 Actuate the throttle arm so that the idle stop is lightly contacting the idle speed adjustment screw While holding tension on the throttle cable lead tighten the throttle cable locking hardware to 15 20 in pounds See Figure 27 You must insure that the idle speed adjustment screw is resting on the idle stop and that there is no clearance between the two when the throttle handle is in the idle position 11 Loosen the friction adjustment See Figure 29 VACUUM GAUGE HOOKUP e NOTE THERE ARE THREE WAYS TO CONNECT A VACUUM GAUGE AS DESCRIBED IN THE ROTAX MAINTENANCE MANUAL THE FOLLOWING STEP ASSUMES THE USE OF OPTION 3 12 Unhook the balance tube at the r
146. tions KAl when completing maintenance or ir processes COMPONENTS Quantity Part or Assembly Name Part Number or Reference Batter ES PC680 Battery Blade Fuse 1 4 blade style 1 2 3 5 7 5 30 Amp rating All fuse values of 3 amp and higher are required to have LED blown fuse indicators 1 2 Fuselage pin switch ES MSTS T3 7A 2 1 2 2 1 1 1 8 2 Rev 3 OPTIONAL LIGHTING The lighting components include the wing tip strobe light extension landing light rib landing light lens backing strip landing light lens cooling shroud and red eyeball cockpit light See Figure 20 The wing tip light mounts in the extension which attaches to the wing tip The landing light is mounted to the landing light rib which is attached inside the wing skin The cooling shroud mounts to the top of the rectifier regulator The eyeball light mounts to the rollover structure Refer to the KAl for empennage component removal and installation WING TIP NAV POSITION STROBE LIGHT GREEN RIGHT WING LANDING LIGHT LENS ASSEMBLY t LANDING LIGHT ve j tO Inf EXTENSION 2 7 LENS BACKING STRIP 22 27 LANDING j LIGHT RIB Figure 20 Optional Wing Tip Lighting cooling shroud amp eyeball light not shown OPTIONAL COMPONENTS Quantity Part or Assembly Name Part Number or Reference See shaded items below amp Refer to
147. tire electrical system Rev 3 SNAP BUSHING REPLACEMENT Tools Expendable Replaceable Snap bushing Service Rating Line Line Minimum Certification LSA RM or A amp P Additional References 1 Extract the failed snap bushing by compressing the two locking tabs and pushing it out of the mounting hole CUT HERE 2 Cutthe PS new snap bushing as shown in Figure 25 The snap bushing should be of the same size and type as the original CUT HERE Figure 25 Snap Bushing 3 Flex open the bushing enough to insert the routed elements 4 Snap the bushing into the corresponding hole 8 13 Rev 3 SERVICE SCHEDULE PROCEDURES BATTERY TERMINAL CLEANING A WARNING NEUTRALIZE BATTERY CORROSION WITH WATER BAKING SODA Tools Expendable Baking soda water Replaceable Service Rating Minimum Certification Owner and SPC LSA RM or A amp P Additional References 1 Remove the battery from the aircraft 8 5 2 Clean and score both battery and wire terminals with a scouring pad or equivalent 3 Re install the battery BATTERY RECHARGE Tools Expendable Replaceable Service Rating Minimum Certification Additional References Battery charger owner manual 1 Remove the battery from the aircraft 8 5 2 Connect the battery charger per the battery charger manufacturer instructions 3 Charge the battery per the battery manuf
148. ve the entire area of loose stained or cracked coating Discolored powder coat could conceal underlying rust damage and requires removal 2 Gradually progress to finer grit sandpaper to achieve a smooth gradual taper to undamaged coating Clean and dry the entire prepared area Apply touch up paint to the entire prepared area PRIMER REPAIR NOTE WHEN PRIMING A REMOVABLE PART BETTER RESULTS BE ACHIEVED BY REMOVING THE PART Sandpaper Primer None Line Minimum Certification Static structure Total area 56 in or less Owner and SPC Total area greater than 144 in LSA RM or A amp P Control surface Total area 10 in or less Owner and SPC Total area greater than 10 in LSA RM or A amp P 1 Remove any loose or damaged primer 2 Use progressively finer grit sandpaper to achieve a smooth gradual taper to undamaged primer 3 Clean and dry the entire prepared area 4 Apply primer to the entire prepared area 15 4 Rev 1 DECORATIVE PAINT REPAIR m CAUTION ANY SCRATCH THAT HAS PENETRATED TO THE METAL MUST BE CLEANED AND PRIMED PRIOR TO APPLYING DECORATIVE PAINT e NOTE WHEN PRIMING A REMOVABLE PART BETTER RESULTS CAN BE ACHIEVED BY REMOVING THE PART Minimum Certification Static structure Total area 64 ir or less Owner and SPC Total area greater than 64 in LSA RM or A amp P Control surface Total area 16 ir or less Owner and SPC Total area greater than 16 in LSA RM or A amp P 1
149. vice Schedule Procedures which correspond to the items on the Service Schedule Checklist Each service section task includes a table that summarizes the properties of the task The task summary table lists the Tools Expendable and replaceable items that are task specific Only tools specific to the immediate task will be listed In cases that another task must be done to complete the immediate task the tools needed for the other task will be given in the instructions that correspond to that task Some recommended tools will require other tools to be effective for example sockets will require a ratchet drill bits will require a drill Unless otherwise specified the driving tool is implied rather than listed The table also includes the Service Rating applicable to the task the Minimum Certification required to perform the task legally and Additional References that may be helpful or necessary to complete the task Each hardware item to be removed in the service instructions will be followed by the quantity if greater than 1 3 Rev 5 one in parenthesis For example an instruction step that requires the removal of one bolt six washers and two nuts will appear as follows 1 Remove the bolt washers 6 and nuts 2 Chapter 16 offers direction for solving potential problems that may puzzle the owner of any aircraft Chapter 17 provides instructions for reporting the discovery of anomalies that could compromise the airwort
150. y Stabilize as necessary LIFTING WITHOUT A JACK BOARDING STEP 5 TAIL TIE DOWN REAR SPAR 1 RECEPTACLE 74 22 500 LB CAPACITY STAND Raise the nose of the aircraft by lowering the tail Place a 25 inch stand along the lateral rivet pattern centered directly between the boarding steps Lift the tail of the aircraft Place another 25 inch stand along the lateral rivet pattern centered directly beneath the rear wing spar receptacles Check for horizontal and vertical stability Stabilize as necessary Rev 5 Rev 1 CHAPTER 2 SERVICE SCHEDULE A OVERVIEW Adherence to the service or preventative maintenance schedule is essential for maintaining airworthiness and maximizing aircraft longevity There are specific requirements for who can perform preventative maintenance line maintenance or annual condition inspections on a LSA At least one of the following qualifications is necessary to perform preventative maintenance on an S LSA RV 12 The owner or operator provided they are Sport Pilot certified or better A person certified as Repairman light sport aircraft Maintenance rating FAA certificated A amp P mechanic At least one of the following qualifications is necessary to perform line maintenance on an S LSA RV 12 A person certified as Repairman light sport aircraft Maintenance rating certific
151. y are free from interference are properly aligned in the pulleys and do not touch each other Pull the stick aft to make sure that the stabilator trailing edge moves up NOTE The F 1227 Seat Ramp Cover must be installed prior to adjusting the cable tension 6 4 8 Rev 3 Install the F 1227 Seat Ramp Cover refer to KAI If the four screw holes for the F 1233 Control Column Mount Brackets refer to KAI do not align with the cover a light upward pull on the stick will correct the misalignment until the screws are inserted and tightened NOTE Cable tension will change significantly with changing temperature The cable tensions given below are for an aircraft inside a 70 F hanger Position one of the WD 1212 Control Sticks so that the top end is 10 inches from the instrument panel Secure the control stick in place using a spring clamp to attach it to a 41 long stick bridged between and clamped to the upper longerons Check the cable tension just aft of the F 1207B Baggage Bulkhead using a calibrated cable tension meter making sure the control stick is correctly positioned Adjust turnbuckles an equal number of turns each to achieve 35 45 Ibs of tension with the groove in the cable ends aligned with a V notch in each turnbuckle barrel as shown in Figure 17 This tension will prevent the cables from slapping against the tailcone bulkheads when the control sticks are moved suddenly and repeatedly forward then aft 10 Remov
152. y wire Wheel bearing grease Spray lubricant Inner tube Hydraulic fluid REPLACEABLE 5 9 9 9 9 2 1 2x3 16 washer and nut Tensile weight scale See component lists on page 5 3 5 9 Canopy struts Bearing MD3614M Bearing DW4AK2X Nose wheel bearings Main wheel bearings Nose fork bushings Pivot guide Upper rudder hinge Lower rudder hinge Rev 4 GENERAL WING REMOVAL No tools or certification required m CAUTION BE PREPARED WITH A HELPER OR SUPPORT STAND TO HANDLE THE WEIGHT AND AWKWARDNESS OF THE OBJECT TO BE REMOVED m CAUTION ALWAYS SUPPORT THE FLAPERON DURING WING REMOVAL AND STORAGE 1 Retract the fuselage pin stopper on each fuselage pin and withdraw each of them only enough to release the right wing spar Note rotating the pin back and forth while pulling makes removal easier 2 Grasp the wing at the wing tip end lift very slightly and pull to remove it from the fuselage and set it aside 3 Fully remove both of the fuselage pins 4 Remove the left wing using the same procedure and set aside INSTALLATION 1 Installation procedure is the reverse of the removal procedure install left wing first right wing second The wing root seal strip on the side of the fuselage can be used to help align the wing at the proper angle of attack while inserting it into the fuselage The root end of the flaperon must be properly aligned with the clevis portion of the flaperon torqu
153. ystem Heavy Maintenance inspection repairs or alteration that a manufacturer Maintenance has designated to require special training equipment or facilities Only a qualified person may perform heavy maintenance Kit Assembly Refers to the original kit assembly instructions that are Instructions provided by the manufacturer to complete the assembly of a kit plane Line Any repair maintenance scheduled checks servicing inspections Maintenance or alterations not considered heavy maintenance by the manufacturer with instructions provided in the manufacturer s maintenance manual LSA LSA RI U S FAA certified repairman light sport aircraft with an Repairman inspection rating as defined by 14 Part 65 authorized to Inspection perform the annual condition inspection on experimental light sport aircraft or an equivalent rating issued by other civil aviation authorities This requires a 16 hour course LSA LSA RM U S FAA certified light sport aircraft technician with a Repairman maintenance rating as defined by 14 Part 65 This certificate is Maintenance authorization to perform line maintenance inspections and repairs on any LSA certified aircraft The maintenance rating is category specific I E Fixed wing weight shift lighter than air etc Maintenance Manual provided by an LSA manufacturer or supplier that specifies Manual s all maintenance repairs and alterations authorized by the manufacturer Major R

MM - Van`s Aircraft, Inc.

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