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1. SEE 8 10 au er d I ERE GEL paie 8 11 Snap bushing replacement citer eie ud ed hie i ee suse al 8 12 Service Schedule 8 13 Battery terminal clearing s ici ti o de ud e EET e e trag o EHE E Seded deed 8 13 Battery recharge uet de ee eene eder Ai Ade v ie rtr dee Re der estote 8 13 Terminal tab cleanirg ERR ee Ad ERE LO qoot Pe Ee A et E oS Ee qp ae d MER e 8 13 e NOTE REFER TO THE SUPPLEMENT FOR A SCHEMATIC OF THE ELECTRICAL SYSTEM 8 1 Rev 1 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 NOTE This maintenance manual is inten
2. 3 15 Paper WO IC codice ai tme d ed eut ri a tuac DEL etal ME LEES 3 15 OVERVIEW The condition inspection is performed annually 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 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 1 inspection provided the airframe has been constructed and used within the terms defined by the manufacturer The Inspection Checklist provided in the Supplement wi
3. Im M E 6 3 6 3 C 107 107 ecce PL D ce pec o oC rt EP DER 6 3 2 oer e tete ice e gel Ho rp EU pe Deer ti Ve deben Ee Pee Eae a 6 3 Stabilator cable tension 6 4 Control cable replacement eu a Ban 6 6 Rod end replacement 5 necne dete iir eo Let in 6 7 Bellcrank bearing replacement niece crt ee et ae 6 8 Rudder pedal removal onset EISE Een E nime eres cest aes 6 8 M e I 6 9 Service Schedule Procedures eese 6 9 Control System rod end lubrication a s toit eee he tei ne e i e mdr ester s 6 9 Cable end hardware lubrication 6 9 6 1 Rev 2 OVERVIEW The control system enables the pilot to operate the control surfaces Forward or aft 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
4. 5 22 SERVICE ee ee eee ee ee ee ee 5 1 2 Service Schedule Procedures OS 5 23 SHUBPBIIBS 5 12 Wing attach location lubrication 5 23 TOOlS 4 ee ran 5 12 Fuselage 5 23 4442 444 2 2 5 12 Stub spar and Rear 5 23 5 12 Flaperon control connection lubrication 5 23 5 13 Flaperon bearings lubrication 9 24 Wing removal 5 13 AST attach hinge lubrication 5 24 Installation nenne 5 13 Nose wheel bearings replacement 5 24 Wing retention pin bushing replacement 5 13 Main wheel bearings lubrication os pee 5 25 In Center 5 13 Nose fork pivot tension and lubrication 5 25 In Wing 5 14 Canopy and frame removal 5 14 ee 5 14 Main wheel and tire assembly removal 5 15 5 1 Rev 1 OVERVIEW The RV 12 airframe uses blind pop style rivets as the primary fastener The wings are removable without the need of tools Screws bolts and solid rivets are used where necessary NOTE PRIOR TO PERF
5. ee ULL E A Mrd e 12 8 MIXIUIG SCE Wess 12 9 Throttle Handle Idle Position u 12 10 Vacuum Gauge f EET 12 11 vii Rev 2 viii Rev 1 4 16 10 CHAPTER 1 GENERAL INTRODUCTION PURPOSE The purpose of this manual is to provide guidance to RV 12 owners pilots mechanics regulatory officials and aircraft component 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 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
6. 16 1 CHAPTER 17 FEEDBACK amp REPLACEMENT PARTS 17 1 REPORTING METHODS 17 1 IBEP AGEMENT PARTS iie coe edo eoe ee a ace e d eed 17 2 CHAPTER 18 SUPPLEMENT 0007077 18 1 SERVIGE SCHEBU LE 4 c acd dL e OE 18 3 INSPECTION eee nri e Le Le nei 18 5 ELECTRICAL SYSTEM SCHEMATIC 01 1 18 21 18 23 FEEDBACK 10 0 1 18 25 CHAPTER 19 955 19 1 CHAPTER 20 20 1 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 2 TABLE OF ILLUSTRATIONS Oil
7. 13 7 13 6 13 7 Harness Shoulder 5 3 2800 3 5 5 22 Heat See Utilities Hinge 12 14 IAS ists ee het ad das td ede dad 5 24 4 5 17 5 18 5 19 1 Seti ise 12 12 Inner tube MA lI iiit acce a ect ertt 5 16 intenti o wc m a ne a rt ei 5 17 Inspektion 3 1 Checklist ttt metr rre eris 18 5 L Landing Gear 5 8 In SpectlOn i nn ea ea 3 11 Hs 8 1 EubriCarnt is ete e e 1 11 1 13 Main Landing Gear InSpections ei acne teens 3 11 InstallatiOD iiie rk 5 21 2 5 20 Main Wheel and Tire Inspection r nee 3 11 5 15 Removals reducta E 5 15 Main Wheel 5 9 Master cylinder 2 7 3 7 3 20 2 2 N Nose Gear Leg Fairing
8. 9 4 ao PETERE 9 5 RA ie ee ee ee eee age 9 5 Light replacement nter ei ed ise lane cet iren E 9 5 Service Schedule PIOGBOBEOS ana 9 6 Software updales dani tepida Heat a m ree cerei 9 6 9 1 Rev 1 OVERVIEW The Dynon D 180 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 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 NOTE This maintenance manual is intended to be used in conjunction with the RV 12 Kit Assembly Instructions KAI when completing maintenance or repair processe
9. DLE ee 5 6 NNN CRCI T Ne AINE 5 8 FAIRINGS WHEEL AND 1 4 4 rates ris 5 10 SERVICE ee ne 5 12 CHAPTER 6 FLIGHT 65 6 1 OVERVIEW 6 2 SERVICE nnn 6 3 CHAPTER 7 BRAKE SYSTEM 0 07 2712 7 1 oM 7 2 SERVICE D 7 2 CHAPTER 8 ELECTRICAL SYSTEM 8 1 oz cM 8 2 ein umgee EEEE m 8 4 CHAPTER 9 INSTRUMENTS amp 5 9 1 OVERVIEW hoon tate dete po uL D DELL 9 2 PIT OTe Ge TAT IC a oro diee done osea E bene semi DE ILE TM De sees Den pe Eee ep MILL OPE 9 3 SERVICE III SEE SUMA Mr EN E E nee casera 9 4 CHAPTER 10 UTILITY SYSTEMS 10 1 OVERVIEW a e M ARON NEL A LACE 10 2 ae te fe ns Me Ere ea od 10 2 VENT
10. LL 4 AVGAS Light Sport Aircraft LSA RM Light Sport Aircraft Repairman Maintenance rating Celsius CG Center of Gravity CHT Cylinder Head Temperature m Max EFIS Electronic Flight Information Statute mile System EGT Exhaust Gas Temperature Engine Monitoring System Millimeter F Fahrenheit Max ELT Emergency Locating Transmitter ml Milliliters Kph LL Itr m CST Category specific training Min ml mm Administration FARS foz fluid ounce U S oz Abs F P t Pint S r PWD Forward psi__ Pounds per Square Inch US GPS Global Positioning System RON Research Octane Test HP in in Research Octane Test m AT in Ib KAF kPa Klopascal pee 5 x 1 6 Rev 1 UNITS Speed 4144 1640 0469 Tm 284em rR m 0506 1 mi i 1 naut mi 12 5 280 ft 1 61 km 10 1 85 km 28 3 grams 16 2 0 454 kg 6 895 kPa o Volume 1 8 cubic in p imot 29 57 ml 32 fl oz 3 79 Itr 1 quart Torque 0 113 Nm 1 356 Nm EY EX Ea EN p RN 0 1 EN EN Fes 9 1 ft lb 12 in lb Temperature F 32 1 8 1 8x C 32 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
11. 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 Disconnect the fuel sending unit wire 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 mex NINE INSTALLATION 1 Installation procedure is reverse of the removal procedure Rev 1 FUEL SYSTEM COMPONENT REMOVAL A WARNING BEFORE PERFORMING ANY MAINTENANCE OR REPAIRS TURN THE MASTER SWITCH OFF AND DISCONNECT THE NEGATIVE BATTERY CABLE FROM THE BATTERY Tools 3 8 7 16 sockets 3 8 7 16 combination wrenches Noe Expendable None LSA RM or A amp P KAI 1 Isolate the component from fuel flow with either the fuel shutoff valve or by draining the fuel tank 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 SCHEDULE PROCEDURES 13 6 Rev 1 GASCOLATOR CLEANING 3 16 Standard screwdriver Ya drive socket extension 1 socket flat blade screw bit Safety wire pliers Expendable Gas 5 O ring gasket Service Rating Minimum Cert
12. Sight along each 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 Comet incorrect O Figure 8 Rudder Stop Rev 1 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 a
13. 1 Lifting amp Supporting the fuselage 4 1 CHAPTER 2 SERVICE SCHEDULE OVERVIEW CHAPTER 3 INSPECTION OMERN IEW eier an ee ee INSPECTION DESCRIPTION eter Pre inspection PoSEIDnSDOCHOf us eret eus Cockpit Optional EquIpITelil 25 26 en A catches Emergency Locator Transmitter Propeller ee Firewall Forward oie EA 3 10 kanding 3 11 Wing Center Section eccL 3 12 Ina elsi ceed epee PRU 3 13 PABELWOLK let cca lava eden RN E DM DUM DS 3 15 CHAPTER 4 STRUCTURAL REPAIRS 4 1 OVERVIEW soe ee eee ace ee hee te hein bain ttn ete fa lta Gan 4 1 CHAPTER 5 STRUCTURES 2 2 5 1 OVERVIEW zer a a TE et 5 2 iade c EE 5 2 WING AND FLAPERON 22 cecceeceeccecceeececceccaeececcueeeecuecaeecuecaeecuececaeeceecaeeseeseesaeeceeseeeaeeseeeaes 5 4 EMPENNAGE
14. 52 32 ons En eH ep m hit devait miii ires MI 13 7 13 1 Rev 1 OVERVIEW The fuel system consists of a fuel neck and cap 20 gallon fuel tank 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 gascolator Engine driven fuel pump and the fuel manifold The fuel valve provides the ability to permit or prevent fuel flow to the fuel 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 NOTE This maintenance manual is intended to be used in conjunction with the RV 12 Kit Assembly Instructions when completing maintenance or repair processes COMPONENTS Quantity Part or Assembly Name Part Number or Reference T 406A T 406A 1 Fuelnmeck 71411 1 Fueltank Cd See KA 1 Fuelstrainer A261 1 Electricfuelpump ES 40105 1 Fuelvalve 0B 1
15. 8 10 8 13 reet 3 12 Wing Retention Pin Bushing 5 4 5 5 Inspection ident 3 13 Replacement esee 5 13 Wire e hie Re tees 8 10 Replacement eese 8 11
16. 8 10 Wire terminal 1 16 Emergency Locator Transmitter InSpectiOn ai eR 3 7 5 6 Inspection o 3 13 ENGINE ee E Er 1 12 12 3 Firing 2 12 3 Inspection u See Rotax Manual Lubrication Goolant iti A aa 12 6 oj 1 13 12 5 Operating limits See Rotax Manual Specifications See Rotax Manual Exhaust 14 1 Installation 14 3 LUBFIGAUOM iive diens 14 4 REMOVA 14 3 Feedback esses See Safety Firewall Forward 3 8 Firewall 12 1 Flapper onera eh a 5 4 5 23 5 24 Fuel 13 1 Draining Ban 13 4 Fuel Tank Installation 2 2 2 13 5 Removal niet Ben 13 5 4 5 2 InSpectlori see 3 10 Lift and 1 16 Terminal Tab is uates 8 13 InSpectlon ne oct te dns 3 10 Fuselage Pins eese 5 3 Lu briCation o ndm ers 5 23 FUSES xod uten EAT ee n eM 8 6 G CC RERO 8 2 Gascolator Gleaning etie test eR 13 7
17. 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 cowl fasteners and hinges for missing eyelets security Check cowl shielding for signs of high temperature and proper attachment to cowl 3 9 Rev 1 FUSELAGE Tools Magnifying glass e Clean rag e Flashlight e Straight edge Inspection mirror CORRECT PATTERN MINI D fuselage skins and fasteners Check the fasteners by sighting along each rivet pattern for any inconsistent rivet profile among MISSING properly installed rivets as RIVET shown in Figure 6 D ix FAILING Figure 6 Rivet Inspection PAR e Inspect the exterior of the nz 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 e Test the condition and security of the left and right boarding steps e 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 torqu
18. GENERAL WING REMOVAL No tools or certification required CAUTION BE PREPARED WITH A HELPER OR SUPPORT STAND TO HANDLE THE WEIGHT AND AWKWARDNESS OF THE OBJECT TO BE REMOVED 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 torque 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 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
19. 5 6 7 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 aft 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 1 2 After reinstalling the stabilator readjust the stabilator control cable tensions in Rev 1 2 1 2 X 3 16 BOLT 7 16 SOCKET BEARING DWAK2X WASHER VA 146A d WASHER 3 4 SOCKET NUT Figure 16 Extracting the DWAK2X bearing Installation procedure is reverse of the removal procedure accordance 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 TO KAI MAIN GEAR REMOVAL Tools 7 16 1 2 9 16 socket 7 16 1 2 9 16 combo wrench Expendable Hydraul
20. 5 15 Rev 1 NOSE WHEEL AND TIRE ASSEMBLY REMOVAL Tools 9 16 socket 9 16 combo wrench Expendable Replaceable Service Rating Owner and SPC LSA RM or A amp P KAI 1 2 Remove the axle bolt washers 2 nut axle spacer and wheel and tire Lift and support the aircraft 1 16 assembly INSTALLATION 1 Installation procedure is reverse of the removal procedure MAIN INNER TUBE REPLACEMENT 3 16 1 4 Allen Safety wire Replaceable Main wheel assembly Tire Service Rating Minimum Certification Owner and SPC LSA RM or A amp P Additional Matco user manual References KAI 1 O 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 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 Reassemble and install the wheel and tire assembly 5 16 Rev 1 NOSE INNER TUBE REPLACEMENT 3 16 Allen Expendable Replaceable Nose wheel assembly Tire Service Rating Minimum Cer
21. Bulkheads amp Stringers Left amp Right Static Ports Left amp Right Boarding Step Landing Gear Main Gear Legs Brackets Brake Hydraulic Lines Wheel Bearings Brake Calipers Brake Shoes Brake Disks Wheels Tires amp Valve Stem Nose Gear and Fork Wings Center Section Skins Ribs amp Attach Angles Main Fwd amp Aft Spars Flaperon Hinges Stall Warning Wing Retention Pins amp Bushings Center Section Channel amp Bulkheads Fasteners Corrosion Deformation Deformation Cracks Signs of Wear Corrosion Signs of Wear Deformation Cracks Signs of Wear Corrosion Clean Clear Secure Security Seal Fasteners Corrosion Refer to Matco manual Security Wear Corrosion Leaks Security Lubrication Free Play Refer to Matco manual Condition Refer to Matco manual Lining Limit Refer to Matco manual Cracks Deformation Refer to Matco manual Alignment Cracks Refer to Matco manual Wear Cracks Air Pressure Travel Security Break out Force Fasteners Corrosion Deformation Deformation Cracks Signs of Wear Corrosion Deformation Cracks Signs of Wear Corrosion Deformation Cracks Signs of Wear Corrosion Smooth Operation Security Smooth Operation Lubrication Secure Connection Condition Signs of Fatigue Wear Maximum 1 0 1 505 inch Deformation Cracks Signs of Wear Corrosion Continued on next page 18 17 Rev 2 THIS PAG
22. Fwd Face of Firewall Studs amp Nuts Engine Mount Vibration Isolators Mount amp Isolator Hardware Wiring Harness Battery Cylinder Cooling Shroud Cabin Heat Door Left Carburetor Right Carburetor 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 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 15 Rev 2 THIS PAGE INTENTIONALLY LEFT BLANK 18 16 Fuselage Skins Footprint Area of Left amp Right Wing
23. Vibration at idle Propeller installed incorrectly Idle RPM too low 12 Carb sycronization out of balance Rotax line maint Engine suspension loose 9 Vibration at specific e Carburetor malfunction 12 Excessive rattling Loose fasteners 8 Corrosion Loose electrical connection Exposure to contamination Failing protective coating e Unlike metals exposed to moisture Flight control Insufficient lubrication resistance Control surface hinge axis not aligned Failing control system components Improper control system adjustments Erroneous engine Malfunctioning sensor status Loose connection e Malfunctioning EMS Abnormal engine noise Damaged or leaking exhaust system Open passage in firewall 3 16 2 Rev 1 4 16 10 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 limita
24. een tie Em 1 13 Terminalbermping 1 16 Lifting and SUpDOPHIDG a o sait eee De 1 17 Hempbve Torinspegtiofi uec in eon ioe renee UE Ee 3 4 Control LOD ene 3 6 Rivet ISIC CHO Mee dodo ia a AE AE ee 3 10 Wing Retention Pin 3 13 Aldder ee 3 14 icol acne ee 5 3 Wig arid siii cece ec RR DDR RU tA d SR OD Qu al 5 4 ea enter 5 6 GOAN ise rdum E eH 5 8 Nose Wheel and Gear Leg 02 40 444 5 10 Main Wheel FAIS cet aste did 5 11 axe ree c 5 18 Extracting the DW4K2 Xx Dean NG pectet ea etta e 5 20 eLocknhdg clip4GmoWValo oec rr Eee pe Doe oa IER ea eut 6 4 Tensioner barrel removal 2 2 2er 6 4 Torque tube lubrication ae Raa Ae ee deside eed m toos 7 5 Optional Wing Tip Lighting 8 3 USE DG UI M eines 8 6 Trim Servo assembly removal rss a 8 7 Pitch trim servo E 8 8 Stall warning o OUT lee 8 10 SNAD BUEHING ers td terete ee een ee 8 12 Rotax o T2 UES as 12 3 Garburetor
25. 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 wi RETURN SPRING 4 MIXTURE SCREW Figure 28 Mixture Screw 12 9 Rev 1 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 HANDLE 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 35 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 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 right side end by removing the securing
26. 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 None Expendable Wheel bearing grease None 20 Replaceable None Service Rating Minimum Certification Owner and SPC LSA RM or A amp P Additional References KAI 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 1 FLAPERON BEARINGS LUBRICATION None Expendable Spray lubricant Replaceable None Service Rating Preventative Minimum Certification Owner and SPC LSA RM or A amp P Additional References Flaperon hinge replacement 5 17 1 Wipe away any dirt accumulation from each of the flaperon 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 AST ATTACH HINGE LUBRICATION None Spray lubricant None Preventative Minimum Certification Owner and SPC LSA RM or A amp P KAI 1 Lower the AST by adjusting the trim Lower the trailing edge of the stabilator 2 Wipe
27. 2A0R5R70EN Blade Propeller hub Hub S 1201 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 than regular inspection and replacement of the bushing if excessive wear is detected SUPPLIES TOOLS EXPENDABLE Small hammer Screwdriver 2 Phillips REPLACEABLE e Spinner cone 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 inch X 4 inch paper strip from common note book paper typical thickness is about 003 inch Make a mark on the strip 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 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 KAI I
28. 3A T 5 7 ri COCKPIT LIGHTS LANDING SERVO LIGHT MOTORS fed re LUN pria AUTOPILOT Y LL J OPTIONAL Ed 4 t t ROTAX 912 o o RECTIFIER REGULATOR GGR BLC 2 STARTER jh GENERATOR RELAY 24115 22K UF STARTER CAPACITOR RELAY Y N SPAR PIN MIGRO SWITCHES E KEYED AMP OFF MOM METER START 127 SWITCH f ODYSSEY Hi BATTERY SPARPIN 3 E LEN DISENGAGED RELAY HT FATRY i WARNING rd AA IN uem sale qi LT OVERIDE 1 SWITCH i 30 A 5 2 5A MAIN BUS POWER OUTLET 18 21 Rev 2 THIS PAGE INTENTIONALLY LEFT BLANK 18 22 18 23 Rev 2 THIS PAGE INTENTIONALLY LEFT BLANK 18 24 Rev 2 Feedback Form Affected Paris ee Problem Description REM 18 25 Rev 2 THIS PAGE INTENTIONALLY LEFT BLANK 18 26 Rev 1 4 16 10 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
29. 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 an 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 Trim 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 The unit receives signals from Flight multiple sensors on the airframe and engine then pro
30. RM or A amp P Additional References 1 Use coarse grit sandpaper to remove 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 3 Clean and dry the entire prepared area 4 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 Tools Sandpaper Expendable Replaceable Service Rating 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 KAI 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 Rev 1 DECORATIVE PAINT REPAIR CAUTION ANY SCRATCH THAT HAS PENETRATED TO THE METAL MUST CLEANED AND PRIMED PRIOR TO APPLYING DECORATIVE PAINT NOTE WHEN PRIMING A REMOVABLE PART BETTER RESULTS BE ACHIEVED BY REMOVING THE PART Sandpaper Expendable Applicable touch up paint Minimum Certification Static structure Total area 64 in or less Owner and SPC Total area g
31. Rev 2 TABLE OF CONTENTS CHAPTER 1 GENERAL INTRODUCTION Purpose PT ee he es Replacement APPLICABLE THROUGHOUT oat aes er wowed ww dade wd wi a enn General Safety of Flight Reporting PIG ITO OG se 5 TOOESAND EXPENDABLES pisi ee gene een OR unl cs A 1 EUBRICATIONS AND CAPACITIES a FR PR a n PR rr I UR 1 Engine Ol LC 1 Brake leisten aded dada dada re 1 Engine 1 MR hnc 1 2 RES PE TEH 1 Torgu Vallese ht 1 GENERAL 84 1 Wire Terminal CM pN
32. Service Schedule 2 1 Table oie 18 3 Snap 8 12 Software nissen 9 6 Spark PIU end 12 3 12 5 StabilatO ees 5 7 Control cable pulley 6 3 3 15 Stub Spar LUbriCatloO nate epe RARE 5 23 supplementa cesan en a 18 1 T Throttle Cable Lead Hookup 12 10 Tire 1 14 TORQUG 22 edm pm 1 15 Troubleshooting 16 1 U Utilities m eee EE 10 1 M 10 2 Mentillatiori e omnii 10 3 i re o erra EE 10 5 20 3 Rev 2 V Vacuum Gauge Hookup 12 10 See Utilities Vertical Stabilizer 3 13 Vertical Stabilizer 5 7 Weight and 1 7 Wheel Bearings IEEE 5 25 22 2 HE eds 5 24 Wheel Fairings IET 5 11 d s 5 10 LI 5 4 3 12 Installation dae 5 13 5 23 Removal ens 5 13 Terminal Tab
33. a ea a Ht iE n pep re Pede des 7 6 Rev 1 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 NOTE This maintenance manual is intended to be used in conjunction with the RV 12 Kit Assembly Instructions KAI when completing maintenance or repair processes COMPONENTS 6 RefertoKAl 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 prior to further flight Refer to the service schedule checklist for component service frequency 7 2 Rev 1 SUPPLIES CAUTION USE ONLY MIL SPEC MIL H 5606A HYDRAULIC FLUID DO NOT USE AUTOMOTIVE BRAKE FLUID DAMAGE TO O RING SEALS MAY RE
34. aircraft are factors that will affect all flight performance procedures 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 1 7 Rev 1 TOOLS AND EXPENDABLES There are many aircraft tool suppliers available An Internet search can 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 Combination Allen wrenches Wooden dowels 1 2 1 inch dia wrenches 3 16 and 1 1 2 1 3 4 in dia 1 4 Oil Filter wrench 5 16 Oil Filter cutter and mallet 4mm Two 25 in padded stands 5mm each rated to support a 6mm minimum of 500 pounds 8mm Container various sizes Torque wrench suitable for petroleum in Ibs amp ft Ibs 24 inch length of 1 2 inch I D fuel 5 8 or 16 mm hose spark plug socket Scouring pad or equivalent Screwdrivers Sandpaper various grades 2 Phillips Spark plug gap tool wire type 3 Phillips Compression tester 3 16 Flat Blade Magnifying Glass Power drill Small square 30 drill bit Tire air pressure gauge Blind rivet tool Needle nose pliers Straight e
35. any kind remove the propeller from service until it has been inspected and passed by qualified personnel Rev 2 e Whenever there is evidence of rough operation check for proper bolt torque For new installations it often helps to remove the propeller rotate it 180 and reinstall e lf the propeller shows any of the following signs 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 1 4 16 10 CHAPTER 12 FIREWALL FORWARD ENGINE COWLING ENGINE CONTROLS ENGINE OVERVIEW gt 12 2 COMPONENTS ai ANDERE T 12 2 RE AETA anh Nhe 12 3 Rotax 91 2UES oy u 12 3 Spark PIUJS c 12 3 tree ette tede Hte 12 3 oca oit Doi ora dea tu de mU D 12 4 cM LIES S M ML MeL MEM LI ds 12 4 ID im 12 4 12 4 Heplaceable E e ca e bei e eta tuti d teste cae repe ee 12 4 Et 12 4 Cowling removal u eek mn Hr RI ns ave iain 1
36. 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 1 INSTALL DAMPING VALVE BETWEEN GAUGE JA AND RUBBER HOSE IF NECESSARY PS 7 RUBBER HOSE RUBBER HOSE PUSH ON CONNECTION 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 1 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 engine and verify that the choke controls on both carburetors are in the full off posi
37. 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 1 GENERAL COMPONENT REPLACEMENT See 9 2 and 9 3 PITOT AND STATIC SYSTEM COMPONENT REPLACEMENT Expendable Plastic tie wraps Replaceable Connector Tubing Service Rating 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 new 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 LIGHT REPLACEMENT A WARNING BEFORE PERFORMING ANY MAINTENANCE OR REPAIRS TURN THE MASTER SWITCH 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 9 5 Rev 1 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
38. drilling out the rivets 4 Rivet the new vent brackets to the vent doorframe 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 10 5 Rev 1 10 6 Rev 2 4 16 10 CHAPTER 11 SENSENICH PROPELLER BLADE PITOT TUBE BEARING OVERVIEW minsen re rur cafe d PN MAREN AN ROA EM 11 2 T T 11 2 SEEN Ans e A DIR PDI M DU MD MM UM MD T SUPBIES Er 22 2 Eee TOOS sinpi Expendable Replaceable iii ea Ne et ea a eee 11 2 Spinner and Pitot Tube s c een 11 3 PIOD S BUD u E AE 11 3 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 NOTE This maintenance manual is intended to be used in conjunction with the RV 12 Kit Assembly Instructions KAI when completing maintenance or repair processes COMPONENTS Quantity Part or Assembly Name Part Number or Reference Propeller blade
39. tail tie down and test for horizontal and vertical stability Stabilize as necessary BOARDING STEP qu n RECEPTACLE ee Ii E PAR A REARS T a 2 4 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 1 Rev 1 4 16 10 OVERVIEW Adherence to the service or preventive maintenance schedule is essential for maintaining airworthiness and maximizing aircraft longevity There are specific requirements for who can perform preventive 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 person certified as Repairman light sport aircraft Maintenance rating FAA certificated A a
40. the Initial column to identify the person that performed the service 2 2 Rev 1 4 16 10 CHAPTER 3 INSPECTION OVERVIEW eek 3 2 INSPECTION DESCRIPTION ut ccc th hic ih tin obra re 3 3 TOONS aceite Geta kh Salih dedi eel A hele See ate Se Sel oe T 3 3 Pre nespectlon POStiINSpectiOM s issi uo e e ti ote eR Or a ERR 3 3 BOCK DIE re Se ET ee Ste 3 5 N NEE NE en eT 3 7 Communication een occu Iit At cer ur ot a an ee ertet ee onec ne ve ei 3 7 Inter COImm z besito Beteiligte A ine toa 3 7 RH DR ER Dd ambe REM ui OO RE 3 7 Optional Equipment iseer aeara eae inb uet ty ae ee eee 3 7 Emergency Locator 3 7 Prabelldt ME n E due 3 7 fr E 3 8 Firewall Forward PR 3 8 Fuselage re eee eee eee ene are ee eE ae 3 10 Landing Gear ar nae 3 11 WING Center Seci ec ar ro RR e ae ei a 3 12 ENGI MAGS Aer 3 13 Vettical StabiliZer s usted POEM BARRE RI Re ot DRE eet od 3 13 aeo E 3 13 STADION d cp 3 15 Anti Servo Tab amp Pitch trim nnne nnns
41. 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 5 EMS Garmin GPS Nav comm FlightCom intercom Artex ELT Odyssey battery Van s Aircraft RV 12 Kit Assembly Instructions KAI 9 9 9 9 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 t
42. 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 KAI to identify the individual parts and part s of the control system NOTE This maintenance manual is intended to be used in conjunction with the RV 12 Kit Assembly Instructions when completing maintenance or repair processes COMPONENTS Optional Components Autopilot Pitch Servo Autopilot Roll Servo 6 2 Rev 2 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 Needle nose pliers Cotter pins Socket e Safety wire 11 32 Spray lubricant 3 8 7 16 REPLACEABLE ay Stabilator pulley INNE Lock clips Wien Stabilator cables 7 16 Rudder cables Bearing DW4K2xX Bellcrank Rod ends Control Stick M3414 CM 4MS Flap Handle CM 4M Flaperon F3514M Trim Servo MM 3 Rudder pedal 11mm Screwdriver 2 Phillips 2 1 2x3 16 bolt washer and nut Cable tension meter Spring clamps 3 Stick 41 long GENERAL STABILATOR PULLEY REPLACEMENT Tools 3 8 7 16 socket 3 8 7 16 combo wrench Needle nose pliers Cable tension meter Spring clamps 3 Stick 41 long Lock cl
43. to be used in conjunction with the RV 12 Kit Assembly Instructions when completing maintenance or repair processes MINIMUM CERTIFICATION 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 Rev 1 4 16 10 CHAPTER 5 STRUCTURES EMPENNAGE LANDING GEAR OVERVIEW E 5 2 FUSELAGE 5 2 72 Components zen 5 3 Main inner tube replacement 5 16 WING AND FLAPERON 5 4 nn tube d _ aperon hinge replacement Components Rm SE E T TATUR ee 9 9 Rudder hinge replacement 5 18 EMPENNAGE eeee enne 5 6 Stabilator hinge replacement 5 19 5 7 Main gear 5 20 Installatiori eren 5 21 y i 1 Nose gear 5 21 5 Installatiori 2 ous 5 21 WHEEL amp GEAR LEG FAIRINGS 5 10 e e N 225 latch block replacement Components 5 10 Step replacement
44. 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 clarify some checkpoints of the aircraft Read Chapter 1 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 Service 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
45. 18 6 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 Static RPM at full throttle Electrical System Cool Down amp Shut Down Fluids Oil Hydraulic Fuel Coolant Static RPM at full throttle 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 Operational RPM Operational Volts Amps Effective Normal Leak Level Check Operational RPM Tone present in headphones when stall sense switch is lifted Continued on next page Rev 2 Rev 2 THIS PAGE INTENTIONALLY LEFT BLANK 18 8 Notes Cockpit Aft Face of Firewall Canopy Latch Fwd amp Aft Canopy Pre Inspection procedure Seats amp Seat Shoulder Harness Check Deformation Cracks Security Cracks Proper operation Cracks Deformation Deterioration Step 1 5 Page 18 9 Wear Fraying Continued on next page Rev 2 Rev 2 THIS PAGE INTENTIONALLY LEFT BLANK 18 10 Roll Bar and canopy frame Cockpit control markings Control Panel All Lights Fuses Flight Control Cables Engine Control Cables Cable Pulleys Control Stick Flap Lever Air amp Heat Vents Wiring Harness Syste
46. 2 1 Gascolator 7 GASH 1 Fuelquick drain 1 Fuel flow transducer 1 Flo Scan or 600 1 Fuelsendingunit IE F385B 1 Left carburetor See Rotax Documentation 1 Right carburetor See Rotax Documentation 1 Mechanical fuel pump See Rotax Documentation 1 1 Rev 1 FUEL SYSTEM SCHEMATIC MECHANICAL PUMP CAP AND FILLER NECK SENDING RIGHT CARBURETOR UNIT COARSE SCREEN GASCOLATOR ELECTRIC FLOW TRANSDUCER PUMP PRESSURE SENDER LEFT CARBURETOR SERVICE AVAILABLE A WARNING BEFORE PERFORMING ANY MAINTENANCE OR REPAIRS TURN THE MASTER SWITCH OFF AND DISCONNECT THE NEGATIVE BATTERY CABLE FROM THE BATTERY 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 AFT OF THE FUEL VALVE Rev 1 SUPPLIES TOOLS EXPENDABLE e Sockets e Safety wire 1 4 3 8 5 16 REPLACEABLE 716 Gas 5 Screen Combination wrench Gas 5 O ring gasket 3 8 7 16 1 2 11 16 3 4 Screwdriver 2 Phillips 3 16 Standard Hex flat blade screw bit Safety wire pliers Fuel Container 1 2 ID fuel hose GENERAL A WARNING ALWAYS HAV
47. 2 4 Installation rm ies ae ae aes a ed ee evs he eee 12 5 Spark plug replaGemMent Ae ee lan 12 5 Engine oll level check i ra iO DOMO HU OU Eo 12 5 Engirie coolant level Check oai recent dou Let eto tete n sin i shall 12 6 Air filter removal E 12 6 Installati n zs a oen Rite etie te Nee iore d cta ded ur d 12 6 5 2 5 sre OE 12 7 PEE ESAE IBI 12 10 MEICSTIVIMEEEUI Aa oro Nom 12 10 Off sre sic Sih 2 nde cde teed nar wand PE 12 12 Idle Speed Adjustment tiet een 12 12 Service Schedule 2424 00 01100 12 14 Cowl hinge pin I brication et o adel EP ve e ed 12 14 12 1 Rev 1 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 qualifica
48. 5 10 Nose Landing 5 8 specion xiii nen 3 11 Lubrication 5 24 5 26 Removal 5 21 Nose Wheel and Tire Installation inen een 5 16 Removal a ee 5 16 Nose Wheel 5 9 OI ee p ee See Engine P ict ette See Painting and coating Painting and Coating 15 1 Panel Circuit 8 9 Pitch Trim Servo Replacement 8 7 9 3 Powder coat 15 3 alu 15 4 Prope eer eritis 11 1 Inspeeti n u re 3 7 11 3 Push pull cable ttes 10 3 INSPECTION att gets 3 6 3 9 LUBPIGALION cie 10 5 R Radio INSPECTION is nen ee tote preme 3 7 Rear Spar 5 23 Rivet INSPECTION i ee Break 3 10 Rod end 6 9 44 6 7 R dder enini ice deed 5 7 Inspection eren ite e 3 13 Rudder Pedals Installation 2 2 6 9 Removal 6 8 RV 12 REESE 18 23 Ip 1 1 5 Safety Rh eid 1 4 Feedback uidentes 17 1 Feedback 18 25 Sensenich sess See Propeller
49. 5 27 10 CHAPTER 18 SUPPLEMENT Nee ee 18 3 INSPECTION GHECKEIST attive ra exo ria eese d ind db dv cavete dtt einen een 18 5 EUECTRIGA SYSTEM an o vice ab e b Oo A o e er a dt or ale 18 21 3 ee ida c netto he deed cece AD aa n d sf A TAE Ad st M A S E M 18 23 PEEOBACK FORM RO TID ICT EET 18 25 Rev 2 THIS PAGE INTENTIONALLY LEFT BLANK 18 2 Rev 2 SERVICE SCHEDULE What Aircraft AST attach hinge Battery Battery terminals Brake fluid Brake pedal components Brake shoe linings Cable end hardware Control system rod ends Dynon Engine service procedures Exhaust ball joints Flaperon bearings Flaperon control connection Garmin Gascolator Main wheel bearings Nose fork pivot Nose wheel bearings Wing attach locations Wing interface terminal tabs Action When How Service Date Initial Inspection Annualor 100 hours 24 Lubricate 100 hours 5 24 Charge 872 Clean Asneeded 8 Flush amp repace 75 Lubricate 2yearsor200hous 74 Replace 6 Lubricate AnnudortOO0hous 68 Lubricate Annualor100hours 68 ee ee eee reer LI d updates Check amp perform 100 hours Rotax maintenance Lubricate Annual or 100 hour
50. ATH 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 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 e Clean rag Flashlight Compression Inspection mirror tester 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 1 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 examinat
51. E AN APPROPRIATE FIRE EXTINGUISHER READILY AVAILABLE A WARNING BEFORE PERFORMING ANY MAINTENANCE OR REPAIRS TURN THE MASTER SWITCH OFF AND DISCONNECT THE NEGATIVE BATTERY CABLE FROM THE BATTERY DRAINING THE FUEL SYSTEM Tools 1 2 3 4 combo wrench Fuel Container Expendable 1 2 ID fuel hose Replaceable Service Rating Minimum Certification Owner and SPC LSA RM or A amp P Additional References 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 Rev 1 the fuel tank 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 fitting Place the loose end in the fuel container 6 Put the fuel valve in the open position 7 Remove the fuel cap from the fuel neck CAUTION TURN OFF THE ELECTRIC FUEL PUMP IMMEDIATELY AFTER THE FUEL TANK IS DRAINED DO NOT ALLOW THE FUEL PUMP TO OPERATE WITH NO FUEL 8 Turn on the master switch and operate the ES 40105 Electric Fuel Pump until the fuel tank is empty FUEL TANK REMOVAL 5 16 3 8 7 16 socket 11 16 9 16 combo wrench 2 Phillips screwdriver 3 16 Standard screwdriver Expendable Replaceable Service Rating Minimum Certification Additional References Drain the fuel system 13 4 Remove the two aft access covers from the fuselage bottom skin 3 4
52. E INTENTIONALLY LEFT BLANK 18 18 Hinges amp Rod Ends Component Skins Control Cable Links amp Push Pull Rods Control Stops Paperwork F2295 06 Section 7 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 Safety Alert Service Bulletin Notification Aircraft Log Aircraft Log Aircraft Log End of inspection checklist 18 19 Rev 2 THIS PAGE INTENTIONALLY LEFT BLANK 18 20 ELECTRICAL SYSTEM SCHEMATIC Rev 2 DUAL EFIS EFIS INTERCOM RADIO san als 2 1A COOLING FANS TRIM qn TRIM SPEED CONTROLER Lt STALL WARN BUZZER 4 4 2 75A do STROBE LIGHT rad AVIONICS N a Tue 3A OPTIONAL FUSE WITH DUAL EFIS OPTION NAY amp STROBE H LIGHTS 1 OPTIONAL 4
53. EMOVED 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 2 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 Tools 2 Phillips S Ee 5 Service Rating Minimum Certification LSA RM or A amp P Additional References KAI 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 e 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 None Replaceable None Service Rating Minimum Certification LSA RM or A amp P KA 0 O Additional References KAI 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 6 10 Rev 2 Rev 1 4 16 10 CHAPTER 7 BRAKE SYSTEM CALIPER
54. Each vent is a tip out door installed on each fuselage side skin 10 3 Rev 1 COMPONENTS Vent door sub assembly shaded items below Vent slide F 1087 Vent door doubler F 1092 1093 SERVICE The heating system does not require regular maintenance If the push pull cable operation is not smooth at the time of the 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 e Spray lubricant Plastic tie wraps LP4 3 rivets 10 4 VENT DOOR REPAIR Expendable Replaceable Service Rating Minimum Certification Additional References Rev 1 GENERAL 30 drill bit Blind rivet tool 1 4 combo wrench 2 Phillips screwdriver LP4 3 rivets 4 Screw Plastic washers 2 Metal washer Nut Vent door sub assembly Vent brackets 2 Line LSA RM or A amp P KAI 1 Remove the existing vent brackets and vent door sub assembly by
55. GE 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 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 4 washer 8 Lower hinge bolt 4 washer 4 5 18 Rev 1 CAUTION UPPER AND LOWER RUDDER HINGES ARE 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 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 LSA RM or A amp P Additional KAI References CAUTION BE PREPARED WITH ADDITIONAL 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
56. IGHT OPTIONAL 12VDC SUPPLY GRIP SWITCH BATTERY COCKPIT LIGHT OPTIONAL WING NAV POSITION gt STOBE LIGHT COOLING FAN OPTIONAL x A PANEL CIRCUIT BOARD e FUSES STALL WARNING SWITCH WING TIP NAV POSITION STOBE LIGHT OPTIONAL V FUSELAGE PIN SWITCH INTERCOM JACKS V MIC amp HEADSET OAT SENDER OVERVIEW S sche ca E b D IDEALS estt AES ET 8 2 KG OND OIG ING boh hu LI UL A LM LA LM LA AL La n n prd 8 2 OPHONAalLIGHUnNg 8 3 Optional COITDOIefibs 8 3 jg een ee 8 4 joel Reema Erro 8 4 ID ET L X 8 4 eec et eti ele etes ed eite edo e eio dds Pret e ets 8 4 az c En 8 4 eis M E 8 5 Battery removal anie amis Qe etn ttem De ED HE oed cba Peer cede 8 5 Installation lee heine ren t diab dw ei 8 5 ee ee eres 8 6 Pitch trim servo replacement eiie re ERROREM HERR 8 7 Electrical component replacemoent 2 nn en neon ir kn ran 8 9 Control board replacements inosine ine 8 9
57. ILATION 10 3 ejus 10 4 CHAPTER 11 2 7 2 1 11 1 eod 11 2 SERVICE OIM a cL pa Ce tC LAU A alt ala 11 2 E 11 3 CHAPTER 12 FIREWALL 12 1 cet eee e ot oae a MA AMAA 12 2 d E 12 3 IAA 12 4 CHAPTER 13 FUEL 6 5 22 13 1 OVERVIEW STA ets tein alta ter tte ML ee GA he 13 2 Fuel System SoheimialiO 5o queue 13 3 Nisus 13 3 CHAPTER 14 EXHAUST 5 5 14 1 OVERVIEW 0 ccccccceccecceececceeececcuceceececueeseecuecececaeeceecaeeseeceeaeesuecaueseecuecaueseeeueeaeeceeeaeeseeeaes 14 2 Uum PEE n 14 2 CHAPTER 15 PAINTING AND COATINGS 15 1 OVERVIEW 15 2 SERVICE 5 15 3 CHAPTER 16 TROUBLESHOOTING
58. 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 2 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 KAI 1 Remove applicable combination of the seat ramp cover seat 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 flaper
59. ORMING STRUCTURAL REPAIRS READ CHAPTER 4 FOR LIMITATIONS NOTE THIS MAINTENANCE MANUAL IS INTENDED 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 1 CANOPY WING RETENTION A OE R PIN BUSHING we A 07 STABILATOR A HINGE FUSELAGE PIN OCCUPANT HARNESS Right Step IDEE 5 3 Rev 1 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 the wing detached from the fuselage the flaperon is removable RIGHT FLAPERON BRACKET PIVOT GUIDE RIGHT WING REAR SES FERN DE EES LEF
60. OT 12 3 12 6 12 6 Anti servo 5 7 3 15 5 24 AVIONIES 22 2 En 9 1 Optional 22 E Ec P ns 9 3 B irc arena 8 5 Charging vcr ree co Pee tees 8 13 Installation ae 8 5 Removal eere 8 5 Terminal E 8 13 Bellcrank 6 8 Brake pedal tts 7 4 Brake Shoe Lining Inspection See Matco Manual Replacement asenn i a 7 6 Brake Syste u 7 1 BITE 7 5 ga 7 5 Canopy c erede edes 5 3 22 2 5 14 Latch Block 5 3 5 22 5 14 CapacitleS ete Rp aas 1 13 Carburetor Syncronization 12 7 Center Section Inspection 3 12 Cockpit Inspection 3 5 Control cable 6 6 Control 6 1 See Engine Cowl 12 14 Cowling Installation nennen 12 5 Removal sse 12 4 20 1 D Decorative 15 5 un 9 2 Electrical 8 1 18 21 Terminal
61. OWING STEPS LIST THE SIMPLEST PROCESS VAN S AIRCRAFT HAS FOUND TO ACHIEVE THE SMOOTHEST RUNNING ENGINE POSSIBLE 12 7 Rev 1 MECHANICAL SYNCHRONIZATION THROTTLE CABLE LOCKING HARDWARE IDLE SPEED ADJUSTMENT SCREW IDLE STOP CONDUIT HOUSING 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 Release the full throttle return spring from its attachment on the throttle arm 3 Return the throttle arm to its idle position limit of travel by hand there should be no resistance during this procedure 4 Turn the idle speed adjustment screw counterclockwise until it is no longer contacting the idle stop 5 Hold the throttle arm lightly against its idle position limit of travel Insert a 4mm 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 1mm feeler gauge Rev 1 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 counter clockwise Note this step cannot be done without removing the carburetor from the manifold With a new engine initially assume it is
62. RV 12 MAINTENANCE MANUAL Rev 2 Date 2 18 11 REVISION SUMMARY Rev 2 Date 2 18 11 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 a 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 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 The owner operator of an RV 12 shall comply with all Van s Aircraft Inc issued notices of corrective action and comply with all applicable aviation authority regulations in regard to maintaining the airworthiness of the LSA An owner 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 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
63. S RECOMMENDATION OR EQUIVALENT 1 1 Water Ethylene Glycol refer to Rotax engine documentation WIRE SAFETY 032 Cardinal gray 3607 GR 230 Primer aluminum and or steel as appropriate Any protective primer suitable for use on Blind rivets LP4 3 unless otherwise specified Decorative touch up paint From paint process Rev 1 ENGINE e NOTE THE ENGINE SPECIFICATION INFORMATION IS REFERENCED FROM THE ROTAX 912 SERIES OPERATOR S MANUAL 4 SUMMARY Rotax 912 ULS Displacement 1352 cc Ducati Double CDI 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 maintenance requirements and procedures refer to the Rotax Engine Type 912 Series line maintenance and heavy maintenance manuals Rev 1 LUBRICATION AND CAPACITIES ENGINE OIL CAUTION ONLY USE API CLASS SG OR HIGHER m CAUTION USE OILS Multi Grade Oils WITH FRICTION MODIFIER ADDITIVES CAUTION DO NOT USE OILS t FOR CONVENTIONAL AIRCRAFT ENGINES m CAUTION DO NOT USE OILS DESIGNED FOR DIESEL ENGINES T
64. SHOES ALUMINUM LINE PLASTIC LINE MASTER CYLINDER 1 d x P AF gt FLUID RESERVOIR B RAKE PEDAL TORQUE TUBE e ET 7 1 COMM OIG tc 7 2 SERVICES euer rH Pb Metu o ruben i 7 2 5 Se awe eee ees ee eee 7 3 dors Achar eee EIER HS ies shaban eae a aa ieee ae 7 3 ETE 7 3 Replaceable cain eins Hl eis vide ee ee eee ne ee he ee eld See te 7 3 Gehelal he Ne ete eas 7 3 Master cylinder removal eite re ce Hed ee ine iene ie Mita 7 3 Removal iie mU ERI dii Pu E Pete eU M ERI ee AA 7 3 5 EE 7 4 Installaliori 5 2 nere ee D EO iiie neam dimit dtm reser qe tiere 7 4 service schedule PIOCedures a u pe QR Hn vec RUE 7 4 Brake pedal torque tube l briCatior ionic dette tdt edere ctae dre ries pie 7 4 Hydraulic fluid drain flush and 7 5 Pli ES 7 5 gl eeE W 7 5 Replacing LH ei 7 5 Brake lining replacement ee sa
65. STEM SCALDING COOLANT WILL SPRAY ENGINE COMPONENTS TO COOL Tools Expendable Replaceable Service Rating Minimum Certification Additional References Place a rag over the expansion tank cap Loosen cap to the first detent then step back for a few seconds Remove the expansion tank cap The expansion tank must be full of coolant Replace the cap The coolant level in the overflow bottle must be between the Max and Min marks NEN AIR FILTER REMOVAL 5 16 Socket Expendable Replaceable Air filter Service Rating 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 Rev 1 CARBURETOR SYNCRONIZATION 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 2 Phillips screwdriver Expendable None Replaceable Service Rating Minimum Certification LSA RM with Rotax Service certification or A amp P with Rotax Service certification Additional References Rotax Maintenance Manual NOTE THIS PROCEDURE IS WRITTEN FOR A SINGLE CARBURETOR ADJUST BOTH CARBURETORS SIMULTANEOUSLY THE CARBURETOR SYNCHRONIZATION PROCEDURE IN THE ROTAX MAINTENANCE MANUAL SHOULD BE CONSIDERED THE PRIMARY INFORMATION SOURCE FOR ANY AND ALL ENGINE MAINTENANCE THE FOLL
66. SULT 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 e Container GENERAL MASTER CYLINDER REMOVAL CAUTION THE LEFT AND RIGHT MASTER CYLINDERS ON EACH SIDE OF THE AIRCRAFT ARE 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 Line 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 1 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 Expendable Cotter pins Wheel bearing grease Replaceable Service Rating Minimum Certification Additional References NOTE SERVICE ONE PEDAL TIME 1 Actuate the rudder pedals so that the RUDDER PEDAL bra
67. T STUB SPAR Oe FLAPERON WING RETENTION 1 9 PIN BUSHING STALL WARNING MODULE 6 LEFT WING FLAPERON HINGE Figure 10 Wing and Flaperon 5 4 Rev 1 COMPONENTS 5 5 Rev 1 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 KAI for empennage component removal and installation RUDDER HORN ANTI SERVO TAB FWD SKIN ES HINGE BRACKET Figure 11 Empennage 5 6 Rev 1 COMPONENTS Quantity Part or Assembly Name Part Number or Reference 5 7 Rev 1 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 tire 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 l
68. TENSION AND LUBRICATION Tools Needle nose pliers 1 1 2 socket Tensile weight scale Expendable Waterproof wheel bearing grease Expendable Replaceable Nose fork bushings S Line LSA RM or A amp P Additional References 1 Lift and support the aircraft 1 16 Remove the nose fork and attach hardware cotter pin nut washer spring washers 2 Clean the end of the nose gear leg and the nose fork bushings Apply a liberal amount of marine trailer or waterproof equivalent wheel bearing grease to the nose fork bushings Installation procedure is reverse of the removal procedure Tighten the nut until a push or pull force of 26 lbs applied at the axle begins to rotate the nose fork around the end of the nose gear leg 5 25 Rev 1 5 26 Rev 2 2 18 11 CHAPTER 6 FLIGHT CONTROLS AUTOPILOT ROLL SERVO STABILATOR CABLE TENSION BARREL PUSHROD FLAP HANDLE STAB CABLE PULLEY B AUTOPILOT MODULE FLAPERON TORQUE AUTOPILOT PITCH SERVO FLAPERON MIXER BELLCRANK RUDDER CABLE OVERVIEW e 6 2 SOMPOMCMIS od PDT A 6 2 SERVICE N 6 3 jog ko 2 eer err ere 6 3 1 5 Lustig Mea LS ed Ba eb NEL t o Pac EE SURE teen 6 3
69. 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 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 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 NOTE VERIFY THE IDLE SPEED AND ADJUST AS NECESSARY TO ACHIEVE 1600 1650 RPM AND SMOOTH ENGINE OPERATION REMEMBER TO ONLY PULL LIGHTLY AGAINST THE CARBURETORS IDLE STOPS 19 A final idle speed adjustment may b
70. The thickness of the alclad layer on aluminum sheet 1 16 inch thick or less is 5 of the sheet thickness Alclad on aluminum sheet greater than 1 16 inch thick is 2 5 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 PRATT amp 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 maintenance rating or an A amp P Part r
71. akerless Capacitor Discharge Firing Order 1 4 2 3 Rev 1 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 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 m 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 1 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 the Cowl 12 Guid
72. 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 1 e Inspect each fuselage pin and all wing retention pin bushings for wear or WING RETENTION cracks Inspect the center section area PIN BUSHING around the bushings for deformation or gt 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 NO GO en bushing then rotate the Gauge Pin SURFACE nn The Gauge Pin is a 90 no go devic
73. at the brake peddle at each seat position for the left and right brake systems feel firm with 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 Dg 7 5 Rev 1 BRAKE LINING REPLACEMENT e NOTE IS RECOMMENDED TO 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 Service Rating Minimum Certification LSA RM or A amp P Additional References KAI Matco user manual 1 Remove the 2 safety wired bolts and remove the stationary brake shoe 2 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 for proper brake system operation Check the hydraulic fluid level CO 7 6 Rev 1 4 16 10 CHAPTER 8 ELECTRICAL SYSTEM LANDING L
74. ation LSA RM or A amp P Additional References 1 Disconnect the negative battery cable 2 Label then disconnect the pitch trim servo wire terminal connections Remove Remove the upper and lower tailcone fairing 3 4 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 TAILCONE TRIM SERVO ASSEMBLY AST ASSEMBLY Figure 22 Trim Servo assembly removal 8 7 Remove the pitch trim Unscrew the pitch trim Clip the wire terminals off Rev 1 DOUBLER PITCH TRIM SERVOMOTOR servo attach screws 6 washers 6 nuts 6 ASSEMBLY doublers 2 as shown in Figure 23 servo from the pushrod assembly Remove the jam nut from the pitch trim servo shaft 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 Install new terminals on the three colored wires of the servo Thread the jam nut onto the new pitch trim servo shaft until it contacts the pitch trim servo shaft housing Thread the pitch t
75. 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 None Wheel bearings Preventative Owner LSA RM or A amp P Additional References Matco user manual 1 Lift and support the aircraft 1 16 2 Remove the nose wheel and tire assembly 5 16 3 Deflate the inner tube 4 Split the wheel and tire assembly by removing the bolts 3 washers 6 and 5 24 emm Rev 1 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 Tools 1 1 2 socket Needle nose pliers Expendable Wheel bearing grease Replaceable Replaceable QUU OT 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 NOSE FORK PIVOT
76. 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 1 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 CAUTION INDICATES AN ACTION NECESSARY TO PREVENT DAMAGE TO PARTS PROPERTY e NOTE PROVIDES VALUABLE ADDITIONAL INFORMATION The Glossary provides definitions to many of the terms used throughout this manual 1 5 Rev 1 ABBREVIATIONS A amp P Airframe and Power plant Kilometers per hour Mechanic AKI API American Petroleum Institute Ib U S pound AST Ant servo imtab
77. 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 the 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 1 RADIO e Check the connections external condition and installation of each component the main unit the antenna and the jacks COMMUNICATION e Test the operation of the unit per manufacturer specs Refer to the Garmin manual INTERCOM e Test the operation of the unit per manufacturer specs Refer to the FlightCom manual TRANSPONDER sure the transponder is in compliance with FAR 91 403 and log entries current OPTIONAL EQUIPMENT e Confirm that optional equipment installed on the aircraft is correct and authorized Optional equipment
78. ded to be used in conjunction with the RV 12 Kit Assembly Instructions when completing maintenance or repair processes COMPONENTS Quantity Part or Assembly Name Part Number or Reference 12 Blade Fuse ATO ATC 1 4 blade style 1 2 3 5 7 5 if 30 Amp rating All fuse values of 3 amp and higher are required to have LED blown fuse indicators 8 2 Rev 1 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 KAI for empennage component removal and installation WING TIP NAV POSITION STROBE LIGHT GREEN RIGHT WING LANDING LIGHT LENS ASSEMBLY c x N T LANDING LIGHT n T S DM T j x EXTENSION 2 7 LENS BACKING STRIP LANDING LIGHT RIB Figure 20 Optional Wing Tip Lighting cooling shroud amp eyeball light not shown OPTIONAL COMPONENTS E Part or Assembly Name Part Number or Reference 1 Lighting Seeshadeditems below amp Refe
79. dge 5 inch C clamp Razor knife Terminal crimping tool Flashlight Locking vice grip style pliers Step ladder 2 1 2 x 3 16 bolt washer nut Wire cutters Vacuum gauge set Battery charger Portable weight scale tension type Multi meter Fire extinguisher Pump style oil can with hose Safety wire twisting pliers 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 o o 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 Oil Filter Cutter Oil Filter Wrench Magnifying Glass Rev 1 Screwdrivers Allen Wrenches Heavy Stands Battery Charger Multi meter Air Pressure Gauge 1 9 Rev 1 Razor Knife Flashlight Needle nose Pliers Locking Pliers Blind Riveter Hardware Tensile Weight Scale Rev 1 CAUTION REPLACEMENT PARTS MUST BE OF EQUIVELENT SIZE AND RATING AS THE ORIGINAL PARTS FROM THE MANUFACTURER EXPENDABLE PARTS PART NUMBER Oil filter Rotax 825 701 Copper crush ring for drain plug Rotax 250010 Gas 5 O ring gasket GASKET GAS 345 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 ATO ATC 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 MISCELLANEOU
80. e If the no go surface contacts the MAIN SPAR BUSHING bushing or mounting surface the GAUGE PIN wing retention pin bushing must be replaced See Figure 7 Figure 7 Wing Retention Pin Bushing e 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 and roller for security and wear e 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 Magnifying glass Straight edge e Flashlight e Inspection mirror STABILIZER Check the main skin and forward skin for deformation or cracks e Check the main skin fasteners by sighting along each rivet pattern for any inconsistent rivet profile among similar properly installed rivets e Check the forward spar and fasteners for cracks deformation and signs of fatigue e 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 e Check for interference or signs of wear from the rudder e Look through the forward spar lightening holes to inspect the rear spar ribs and rib flanges for cracks RUDDER e Check the main skin for damage or deformation Rev 1
81. e 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 1 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 CT 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 are 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 SERVICE SCHEDULE PROCEDURES COWL HINGE PIN LUBRICATION 2 Phillips screwdriver Owner and SPC LSA RM or A amp P Additional References KAI 1 With the cowl hinge pins removed wipe each hi
82. e tubes 3 10 Rev 1 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 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 Flashlight Inspection mirror Torque wrench Clean rag Straight edge Saw horses 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 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 Rotate the nose fork about the
83. econnect the negative ground wire to the battery 11 Test for correct operation of all electrical circuits fomes p mm WIRE REPAIR Tools Wire cutter Wire terminal crimper Multi meter Expendable Replaceable 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 8 10 Rev 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 Route the new length of wire along the same path as the original wire 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 N 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 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 Check the continuity of the replacement wire Test the operation of the component
84. emperate SAE 5 40 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 Brake fluid draining flushing and replacing instructions Page 7 5 CAPACITY 15 4 fl oz US 455 liters Rev 1 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 Minimum Expansion tank 2 3 full 2 liter 4 liq pt in overflow bottle FUEL SUITABLE FUEL 91 AKI premium unleaded automotive 100 LL Aviation Fuel AVGAS min RON 95 CAPACITY 19 8 US Gallons 75 0 liters TIRE PRESSURES NOSE TIRE 20 psi 28 psi maximum MAIN TIRES 25 psi 28 psi maximum Rev 1 TORQUE VALUES OilFilter MagneticPlug Water Pump Drain Screw Carburetor Socket Screws Spark Plugs 16 ExhaustNuts Bolt size Standard nuts Threads per inch AN310 AN315 MS20365 Inch
85. en applicable Maintenance or repair classified in this manual and in 14 CFR FAR 43 Appendix 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 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
86. eplacement must be consistent with the original KAI from Van s Aircraft Priming factory alclad replacement parts remains at the repairmans discretion Non alclad parts must be primed per the KAI 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 MANUFACTURERS INSTRUCTIONS A WARNING DO NOT USE ANY TYPE OF BODY FILLER ON THE AIRCRAFT A WARNING DO NOT DAMAGE ANY RIVET HEADS WHEN PREPARING A SURFACE FOR TOUCH UP PAINT CAUTION EXPOSED STEEL MUST BE CLEANED AND COATED WITH PRIMER OR POWDER COAT TOUCH UP PAINT CAUTION ANY SCRATCH THAT MAY HAVE PENETRATED THE ALCLAD COATING MUST BE CLEANED AND PRIMED PROPERLY SUPPLIES TOOLS EXPENDABLE e Scouring pad 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 Tools Sandpaper Expendable Touch up paint Replaceable Service Rating Minimum Certification Total area 4 in or less Owner and SPC Total area greater than 4 in LSA
87. es The cooler should then self align to allow for installing the attach screws SPARK PLUG REPLACEMENT Tools 16mm socket Spark plug gap tool Expendable Replaceable Hinge pins Spark Plugs Service Rating Minimum Certification Owner and SPC LSA RM or A amp P Additional References Rotax 912 Line Maintenance manual 1 Refer to the Rotax manual ENGINE OIL LEVEL CHECK A WARNING BEFORE PERFORMING ANY INSPECTION OR SERVICE ALLOW THE ENGINE COMPONENTS TO COOL A WARNING TURN OFF MASTER POWER AND BOTH IGNITION SWITCHES DISCONNECT THE NEGATIVE GROUND WIRE TO THE BATTERY e NOTE FOR ENGINE OIL CAPACITY SEE ROTAX 912 OPERATORS MANUAL Tools Expendable Engine oil Replaceable Service Rating Minimum Certification Owner and SPC LSA RM or A amp P 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 OIL TO THE MAX MARK ON THE DIPSTICK 12 5 Rev 1 e NOTE THE QUANTITY DIFFERENCE BETWEEN AND MIN MARKS ON OIL DIPSTICK IS 0 45L 0 5 QUART 3 Oil level must be between the Max and Min marks on the dipstick ENGINE COOLANT LEVEL CHECK A WARNING DO NOT REMOVE THE RADIATOR CAP FROM A HOT COOLING SY
88. f 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 dowl Install the new bushing per Section 47 of the KAI PROP amp HUB e NOTE THERE IS NO SPECIFIED SERVICE LIFE FOR THE PROPELLER HOWEVER IT IS TO BE REMOVED FROM SERVICE WHEN 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 bolts every 25 hours of operation Always check in the tightening direction e Before each flight carefully Inspect the propeller blades and hub for looseness any 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 e Do not use the propeller as a tow bar to move your aircraft e 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 e 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
89. 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 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 1 3 Rev 1 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 airworthiness 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 wh
90. 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 e Inspect the condition of fasteners and cotter pins and the condition of attach locations at the nose fork pivot point and the three wheel axles Inspect the tires for cracks wear and tire pressure Valve and valve stem in good Rev 1 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 e Straight edge Inspection mirror 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 Inspect the main spar rear spar
91. glass e Clean rag e Flashlight e 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 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 stationar
92. he 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 Aircraft Inspection Repair and Alterations AC 43 13 1B 1 2 Rev 1 REPLACEMENT PARTS The RV 12 KAI is the primary reference for replacement part information Section Four in the KAI is a directory of all part numbers with reference information of where to find it within the main KAI 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 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
93. he 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 1 BELT AND HARNESS REPLACEMENT Tools 7 16 socket Expendable Replaceable Service Rating Minimum Certification Owner and SPC LSA RM or A amp P Additional References ENTIRE HARNESS SET BE REPLACED IMMEDIATELY 1 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 Qtr CANOPY LATCH BLOCK REPLACEMENT 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 Replaceable Left or Right Step Service Rating Minimum Certification Owner LSA RM or A amp P Additional References 1 Remove the step attach bolts 2 washers 2 and the step 2 Install the new step and attach hardware 5 22 Rev 1 SERVICE SCHEDULE PROCEDURES WING ATTACH LOCATION LUBRICATION WINGS REMOVED Tools None Expendable Wheel bearing grease Anti seize compound Replaceable Fuselage Pin Owner and SPC LSA RM or A amp P Additional References KAI FUSELAGE PINS 1 Wipe clean the fuselage pins 2 2 Wipe clean
94. ic fluid 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 a e SL Additional References KAI Matco user manual 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 5 20 Rev 1 INSTALLATION 1 Installation procedure is reverse of the removal procedure 2 Add hydraulic fluid and bleed the brake system NOSE GEAR REMOVAL Tools 3 8 9 16 socket Needle nose pliers 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 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 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 t
95. ification Additional References 1 Remove the engine cowling 12 4 2 Move the fuel valve to the OFF position 3 Use the fuel quick drain to drain the existing fuel from the gascolator bowl 4 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 Ya 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 Use a small pointed tool to lift the edge of the filter screen and remove it for cleaning INSTALLATION 1 Installation procedure is reverse of the removal procedure Rev 1 Rev 1 4 16 10 CHAPTER 14 EXHAUST SYSTEM EXHAUST TUBE SOCKET BRACKET JOINT SPRING BALL JOINT OVERVIEW eR a N Te COMPONENTS CPC SERVICE ke Replaceable nities ee EIE oe n Um LI Exhau
96. ion and repair Inspect the engine vibration isolators for cracks deterioration and installation Check the engine compartment wiring including ground wires of the wiring harness 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 Off 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
97. ips 6 3 1 2 AR Loosen the Rev 2 Remove the seat ramp cover and cover plate only the aft two 3 4 ALIGN V NOTCH IN BARREL WITH GROOVE IN CABLE END Remove the LOCKING CLIP 1 LL stabilator control cable 22 barrel lock S AN 220 clips from one barrel as shown in Figure 17 Figure 17 Locking clip removal BARREL TOWARD FRONT TENSIONER tension of the BARREL stabilator STABILATOR cables by CONTROL CABLE turning the tensioner WIRE TOOL MADE FROM f barrel as ae WELDING WIRE COAT shown in 5 HANGER WIRE ETC Figure 18 p d 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 d Remove the slack from the other cable by adjusting the lower inboard turnbuckle Check the entire length of the cables to ensure they 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 t
98. iring U 00007 5 10 Rev 1 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 WHEEL FAIRING S a FRONT P P 2 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 SERVICE 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 1 1 2 1 3 4 inch Small wooden dowel 1 2 1 inch Rev 1 SUPPLIES EXPENDABLE Cotter pins Safety wire Wheel bearing grease Spray lubricant Inner tube Hydraulic fluid REPLACEABLE 9 9 9 9 9 9 9 2 1 2x3 16 bolt washer and nut Tensile weight scale 5 12 See component lists on page 5 3 5 9 Canopy struts Bearing MD3614M Bearing DWAK2X Nose wheel bearings Main wheel bearings Nose fork bushings Pivot guide Upper rudder hinge Lower rudder hinge Rev 1
99. 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 applicable manual provided with the component EMERGENCY LOCATOR TRANSMITTER The ELT must be inspected in compliance with the FAR Part 91 207 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 1 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 DE
100. 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 1 1 Rev 1 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
101. ith an Repairman inspection rating as defined by 14 CFR 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 CFR 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 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 Repair 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 1 Overhaul Facilit
102. ke pedal to be serviced is offset from the adjacent WD 1209 w rudder and brake pedal The WASHER following steps relate to Figure 19 NUT Remove the gt master cylinder WASHER lower hardware 9 LUBRICATE HERE Remove the brake N pedal hardware QA BRAKE MAST CYL LEFT 1 bolt washer and nut Figure 19 Torque tube lubrication 7 4 Rev 1 Remove the brake pedal 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 EU HYDRAULIC FLUID DRAIN FLUSH AND REPLACE Container Line i Line 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 ina 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 clear tube at the top of the fluid reservoir Close the bleeder valve and remove the oil can and hose Repeat the previous step on the other brake caliper Confirm th
103. ll 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 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 1 INSPECTION DESCRIPTION Multi meter Compression tester Torque wrench in lbs amp ft Ibs Tire pressure gauge Jack Padded stands Step ladder Flashlight Magnifying Glass Wing Retention Pin Bushing Gauge 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 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 contro
104. ls 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 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 Rev 1 Figure 4 Remove for inspection Ref Name 2 RigtWig 13 Seat FloorCover 3 Forward Skin 14 CoverPlates 5 Lx Upper Forward Fuselage Baggage 255 Cover Skin 5 16 BagggeCover 6 Bottom Cowl 17 Baggage Bulkhead Corrugation _ 8 Tunnel Cover 19 Fairing 9 FloorCover 20 Fuel Tank Assembly see chapter 13 for draining the fuel tank Not numbered in order of removal 3 Perform visual a and make note of any oil exhaust fuel hydraulic or other 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 1 COCKPIT e Magnifying
105. m Lines Fuel Brake Static Fuel System Components Rudder Pedals amp Brakes Avionics amp Radio Each Main Unit Wiring amp Conduit Connections Antenna Mounts Optional Equipment Throughout Cracks Deformation Clear Correct Security Connections Operation Security Condition Spares 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 Operation Security Inspect per Manufacturer Manual Condition Security Chafing Routing Security Corrosion Security Condition Security Inspect per Manufacturer Manual Continued on next page 18 11 Rev 2 THIS PAGE INTENTIONALLY LEFT BLANK 18 12 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 A C 43 13 Also refer to current A C 43 13 Also refer to current A C 43 13 Refer to Sensenich Manual Cracks Deformation Delamination Cracks Damage Condition Torque Fasteners Security Leaks Fasteners Security Perpendicular to Axis Continued on next page 18 13 Rev 2 THIS PAGE INTENTIONALLY LEFT BLANK 18 14 Engine Engine and components Firewall Forward
106. mp 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
107. nd counterbalance 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 Te
108. nge pin clean 2 Immediately prior to re installation apply lubricant along the length of each hinge pin 12 14 Rev 1 4 16 10 PRESSURE SENDER LEFT CARBURETOR RIGHT CARBURETOR ELECTRIC PUMP COARSE SCREEN FUEL RETURN LINE VALVE FINE SCREEN FLOW TRANSDUCER QUICK DRAIN OVERVIEW oer rue diia 13 2 Le A AEEA EENE EAE EAEE E 13 2 Fuel System Scheltisllie n a et ll ea 13 3 A Se A A 13 3 E ne 13 4 016 E ae We ee aot eee 13 4 13 4 indienne tete de ee utet ha ia eis 13 4 C M Ps 13 4 Draining the f el System iui rs rn I la CUR euro eins 13 4 Fuel tank removal etn ee tete ee ee cce deat al Le Eve eese ere 13 5 oaths eek es ee aa area led Sd Ee al nee 13 5 Fuel systerm component removal detti iie i tenendi epe espe ee de ceo riae et 13 6 13 6 Service Schedule Procedures eese 13 6 Gascolator cleanirig 2 iioc ete mech HU eb i etas 13 7 Installatioris
109. o adjusting the cable tension 6 4 8 Rev 2 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 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 lbs 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 Remove the clamp and stick from the control stick and the weight from the 1 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
110. on 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 DR 6 7 Rev 2 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 B RUDDER PEDAL REMOVAL 11 32 3 8 socket 3 8 combo wrench Needle nose pliers 2 Phillips screwdriver Expendable Replaceable Rudder pedal Service Rating Minimum Certification LSA RM or A amp P Additional References KAI 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 R
111. onal References Odyssey owner manual Tools 4 mm allen wrench 3 8 socket Remove the top cowl 12 4 Remove the negative battery cable Remove the positive battery cable Remove the battery channel Lift the battery to remove C Gu pae INSTALLATION 1 Installation procedure is reverse of the removal procedure 8 5 Rev 1 FUSE REPLACEMENT TYPE AND RATING AS SPECIFIED BY THE MANUFACTURER REPLACING ANY FUSE e NOTE REPLACEMENT FUSES FOR ANY CIRCUIT IN WHICH A 5 AMP FUSE OR LARGER IS SPECIFIED MUST BE OF THE TYPE THAT ILLUMINATE WHEN BLOWN COMPLETE BROKEN ELEMENT lt ELEMENT Remove the suspected blown fuse m MAN START AWO Perform visual inspection and or 5 L use multi meter to test fuse g ff le Insert new fuse with proper rating as shown in Figure 21 TALL FE T LND STROBE STAC A recurring blown fuse indicates excessive current draw from the e corresponding circuit of the electrical system See page 18 21 Figure 21 Fuse panel 8 6 Rev 1 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 Expendable Replaceable Pitch Trim servo Service Rating Minimum Certific
112. ose pliers Expendable Replaceable Service Rating Minimum Certification Additional References Disconnect negative ground wire Remove 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 type Re attach applicable electrical and mechanical connections Reconnect the negative battery cable Son Ol gee BS Se AV CONTROL BOARD REPLACEMENT small flat blade screwdriver Service Rating Minimum Certification LSA RM or A amp P Additional References 1 Remove the panel cover 3 4 2 Disconnect negative battery cable 8 9 Rev 1 Discharge the circuit board With the master switch ON 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 4 Verify all plugs and connectors and their connected locations are properly labeled Disconnect the control board connections Remove the control board attachment hardware Remove the control board Install the new control board and hardware of the same type Re attach all plugs and connectors 10 R
113. ower 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 OUTBD WEAR PLATE INBD MAIN GEAR ON ATTACH BRKT INBD WEAR PLATE OUTBD MAIN GEAR ATTACH BRKT NOSE GEAR E E LEFT MAIN GEAR NOSE FORK if MAIN WHEEL 27 ASSEMBLY AND TIRE Figure 12 Landing Gear 5 8 Rev 1 COMPONENTS Quantity Part or Assembly Name Part Number or Reference Left Main Gear U 1220 L Right Main Gear U 1220 R 2 Outbd Main Gear Attach U 1202 Brkt Outbd Wear Plate U 1202B 2 Inbd Main Gear Attach U 1203 Brkt po Spacer 208 N 959 Rev 1 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 fairing 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 Fa
114. p the barrel s skirt onto the wire insulation LIFTING amp SUPPORTING THE FUSELAGE A WARNING USE STURDY SUPPORT STANDS THAT ARE EACH CAPABLE OF SUPPORTING AT LEAST 500 POUNDS CAUTION AVOID CONTACTING ANTENNA FAIRINGS OR OTHER ACCESSORIES WHILE PLACING THE SUPPORT STANDS UNDER THE AIRCRAFT 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 1 LIFTING WITH A JACK CAUTION USE APPROPRIATE JACK LOCATING FIXTURES TO ENSURE A STABLE JACKING SURFACE CAUTION INSTALL A JACKPOINT WHEN LIFTING AT THE WING TIE DOWN LOCATION 1 Place a jack as necessary to lift at 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
115. pounds X FootPounds ANS 4052 2025 1620 ANA 140 540 24258 ANS 585 624 100140 8516 ANG 384 160190 135458 AN 7460 45050 375417 ANS 1220 480690 2710575 ANS 91618 80000 6668353 588 110050 9165 GENERAL PROCEDURES TIRE REMOVAL WING REMOVAL REFER TO 5 1 CANOPY REMOVAL COWL REMOVAL OIL LEVEL CHECK FUEL SYSTEM DRAINING GASCOLATOR SAMPLE REFER TO 12 1 REFER 13 1 Rev 1 WIRE TERMINAL CRIMPING BARREL INSERTION DEPTH N 2 4 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 crim
116. r to KAI Wing Tip NAV Position LN 200 LN 200G shown Strobe Light Set W 1222 L and W 1222 R Lens Backing Strip W 1223E NotShown Seeshadeditems below 8 Refer to 8 3 Rev 1 SERVICE A WARNING ALWAYS HAVE AN APPROPRIATE FIRE EXTINGUISHER READILY AVAILABLE 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 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 Socket Baking soda water 3 8 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 1 GENERAL BATTERY REMOVAL A WARNING NEUTRALIZE BATTERY CORROSION WITH WATER BAKING SODA MIX Expendable Replaceable Battery Service Rating Minimum Certification Owner and SPC LSA RM or A amp P Additi
117. reater than 64 in LSA RM or A amp P Control surface Total area 16 in or less Owner and SPC Total area greater than 16 in LSA RM or A amp P 1 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 Rev 1 4 16 10 CHAPTER 16 TROUBLESHOOTING Symptom Related Chapter Recurring blown fuse Short in circuit e Overloaded circuit Engine will turn over Insufficient ignition source 8 fails to start Insufficient fuel supply to engine Insufficient air supply to engine Engine fails to turn Insufficient battery power ae 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 Structural damage remove Wing not fully inserted Force applied to wing Pulls to one side during Low tire pressure taxiing level surface N ao ax Oo _ a gt mM Dragging brake Damage to landing gear Axle nut over tightened Shudder after touch Nose fork under tightened 5 down Rev 1 Symptom Related Chapter 11
118. rim servo shaft onto the clevis rod end on the pushrod assembly until it contacts the jam nut Back the pitch trim servo off two full turns Tighten the jam nut against the pushrod assembly INSTALLATION 1 2 3 4 Install the servo on the servo tray by reversing the process done in step 7 Install the trim servo assembly by reversing the process used in step 6 Connect the three colored pitch trim servo wires with previously installed terminals to the matching colored wires on the pitch trim CONTROL CABLE Temporarily connect the two white wires on the pitch trim servo to the remaining two wires on the pitch trim control cable 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 When the AST movement has been verified as correct install appropriate connectors on each wire for connecting to the pitch trim control cable 8 8 Rev 1 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 n
119. s COMPONENTS as MENS 1 FF 1202 AT6 058X5 16 1 Piotinetbing 42660 O 177 Static line tubing Ur ERE POLYPROPYLENE 9 2 Rev 1 OPTIONAL COMPONENTS Dynon AP 74 Autopilot Interface IF DYNON AP AP74V 12 Module See Dynon Manual Navigation Strobe light See Aero LED Manual Cockpit light LC ELC 01 D 100 Dual EFIS EMS See Dynon Manual Landing light See Aero LED Manual PITOT amp STATIC STATIC SOURCE PLASTIC TEE PITOT TUBE PITOT BLOCK A COMPONENTS 1 Doe Pitot Block FF 1201 UHMW 1 PitotTube 1202 6 058 5 16 9 3 Rev 1 SERVICE AVAILABLE A WARNING BEFORE PERFORMING ANY MAINTENANCE OR REPAIRS TURN THE MASTER SWITCH OFF 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 and the Garmin GPS The avionics components are not serviceable by the consumer unless otherwise noted in the 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 Plastic Tie Wraps 3 8
120. s 6 months or As needed ER S eR for Annual or 100 hours users manual updates Clean JAnnudor OOhous 157 Lubricate 2 years or As needed 5 25 1 Lubricate 1 100 8 6 Replace 54 Lubricate Each removal 592 Annudor OOhous 84 End of service schedule Rev 2 THIS PAGE INTENTIONALLY LEFT BLANK 18 4 INSPECTION CHECKLIST RV 12 Aircraft Inspection Airframe S N Airframe TT Inspection Date Reg Number Engine S N Engine TT Inspector Check all that apply to inspector and inspection Owner Operator Pilot A amp P LSA Repairman Inspection 100 hour Annual Extreme Conditions After Hard Landing Category Check Documents Certificate of Airworthiness Registration POH Operating Limitations Switch and control placards Identification Plate Light Sport Placard Experimental for E LSA Weight amp Balance Equipment List Service Schedule Systems amp Controls Test Engine Start Procedure Starter Oil Pressure amp Temperature 1800 RPM Engine Run Up Onboard and Displayed Onboard Onboard Onboard Secure Legible Secure Legible Displayed Onboard Items due for service Operations Values Effective Complete Operational Strong Refer to Rotax Line Maintenance Manual Continued on next page Rev 2 LSA Repairman Maintenance Rev 2 THIS PAGE INTENTIONALLY LEFT BLANK
121. st system removal Installation ara anne an ei sco Service Schedule aan nee 14 4 Ball joint l bricatior eto Dee te m Dette ee eee abet hiatal ies 14 4 14 1 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 NOTE THIS MAINTENANCE MANUAL IS INTENDED USED IN CONJUNCTION WITH THE RV 12 KiT ASSEMBLY INSTRUCTIONS KAI WHEN COMPLETING MAINTENANCE OR REPAIR PROCESSES COMPONENTS Part or Assembly Name 8 Jointsping 73875 SERVICE SUPPLIES TOOLS EXPENDABLE 13mm socket Anti seize compound high temp 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 LSA 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 c
122. st the operation of 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 Rev 1 Rev 1 4 16 10 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 NOTE This maintenance manual is intended
123. 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 2 CONTROL CABLE REPLACEMENT 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 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
124. t etta RE oct VORNE EP ORI ORE FUORI HEREDI A i ERE 10 4 Expendable niini eH RRWEI ee eaedem oda tne 10 4 PITE 10 5 ee eet ee 10 5 Service Schedule ProGedileS su nasce ansehen 10 5 Push pull cable IubriCatiOni 5 eee erem eie ER eR ERE 10 5 10 1 Rev 1 OVERVIEW 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 NOTE This maintenance manual is intended to be used in conjunction with the RV 12 Kit Assembly Instructions KAI when completing maintenance or repair processes PUSH PULL CABLE 77 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 10 2 Rev 1 COMPONENTS Quantity Part or Assembly Name 1 VENTILATION VENT DOOR SUB ASSEMBLY DOUBLER hand operated vent on each side of the cockpit provides cockpit ventilation
125. that is connected by the replacement wire and test the operation of the entire electrical system y 8 11 Rev 1 SNAP BUSHING REPLACEMENT Tools Expendable Replaceable Snap bushing Line 0 O Service Rating Line Minimum Certification Additional References 1 Extract the failed snap bushing by compressing the two locking tabs and pushing it out of the mounting hole CUTHERE 2 Cutthe 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 12 Rev 1 SERVICE SCHEDULE PROCEDURES BATTERY TERMINAL CLEANING WARNING NEUTRALIZE BATTERY CORROSION WITH WATER BAKING SODA MIX Tools Scouring pad 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 man
126. the flanged end toward the wing spars 5 13 Rev 1 IN WING SPARS Tap out the bushing from the non flanged end of the bushing Tap the new bushing into place with the flanged end to be on the forward side of the wing spar CANOPY AND FRAME REMOVAL Tools 7 16 socket Expendable None Replaceable Canopy and Frame Canopy struts Service Rating Line Minimum Certification LSA RM or A amp P Additional KAI References CAUTION BE PREPARED WITH A HELPER OR SUPPORT STAND HANDLE THE WEIGHT AND AWKWARDNESS OF THE OBJECT TO BE REMOVED Open and support the canopy Easiest with a partner Remove the strut hardware bolts 2 Remove the pivot hardware bolts 2 and bushings 2 Remove canopy and frame INSTALLATION 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 1 MAIN WHEEL AND TIRE ASSEMBLY REMOVAL 1 1 2 7 16 socket Safety wire Replaceable Service Rating Minimum Certification Owner and SPC LSA RM or A amp P KAI 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
127. 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 BATTERY 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 or GPS SOFTWARE UPDATES Unit connection cable 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 6 Rev 1 4 16 10 CHAPTER 10 UTILITY SYSTEMS VENTILATION HEAT SYSTEM COVERVIEW S tact vot pot atv Go t ded 10 2 rper 10 2 COMBOMGING sect c ETE 10 3 AEN EHEACT 10 3 COMPONEINS 10 4 C 10 4 2186 10 4 I e a 10 4 Replaceable ise ub
128. tification Owner and SPC LSA RM or A amp P 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 5 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 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 1 FLAPERON 4 Measure and record the hinge bearing protrusion measurement as shown in Figure 15 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 HIN
129. tion 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 IF 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 CONTAMINATION AND FREE PASSAGE CLEAN AS REQUIRED 12 12 Rev 1 NOTE WHEN CHECKING THE IDLE SPEED DURING
130. tions defined in the POH e Brief description of the type and frequency 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 1 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 Rev 2
131. tions or training required for any maintenance 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 NOTE This maintenance manual is intended to be used in conjunction with the RV 12 Kit Assembly Instructions KAI when completing maintenance or repair processes COMPONENTS Quantity Part or Assembly Name Part Number or Reference 1 Rotax 912ULS Refer to Rotax documentation amp See Figure 26 Engine controls 7 Seeshadeditemsbelow Cowling f Seeshadeditemsbelow Rev 1 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 Type NGK DCPR8E Socket 16mm Electrode Gap 7 8 mm 028 032 in IGNITION Dual Bre
132. ufacturer instructions 3 Charge the battery per the battery manufacturer instructions TERMINAL TAB CLEANING Tools Scouring pad 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 13 8 14 Rev 1 Rev 1 4 16 10 CHAPTER 9 INSTRUMENTS amp AVIONICS GARMIN SL 40 AUTOPILOT MODULE OPTIONAL GARMIN GXM30A GARMIN GPS MAP 369 5 7 DYNON D 100 OPTIONAL ELT REMOTE C COCKPIT LIGHT PITOT TUBE EES Rura s OPTIONAL EMERGENCY GARMIN GA26C f LOCATOR h TRANSMITTER STEREO INTERCOM DYNON D 180 MAPS GARMIN GTX327 AUTOPILOT SERVOS OPTIONAL TRANSPONDER ANTENNA STATIC SYSTEM VHF COMM ANTENNA NM M MOLINA IOS 9 2 COMP OMENS T 9 2 PITOT amp STATIC 9 3 oa oIan os oe i Pm 9 3 SERVIDE enne ne E ee E EE A A 9 4 AAA AAAA o 9 4 pu Cpu LI 9 4 6 9 4
133. vides Information valuable engine and flight information based on the signals from System 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 The portion of the EFIS unit that Management compiles and displays engine information System 19 1 Rev 1 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 System 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 KAI 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 w
134. y 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 Operation 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 1 CONTROL COLUMN CONTROL COLUMN STOP ON Y e sure the stabilator contacts its up and down stops before the WD 1210 Control Column contacts its up and down stops If not loosen and tighten the stabilator cable 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 ya SR N SI N INDIEN motion See Figure 5 BSS L 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
135. y 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 Preventive 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 airplanes 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 preventive 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 1 THIS PAGE INTENTIONALLY LEFT BLANK 19 4 Rev 2 2 18 11 CHAPTER 20 INDEX A Abbreviations 1 6 AI T
136. ylinder 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 4 16 10 CHAPTER 15 PAINTING AND COATINGS OVERVIEW 15 2 oA c E P 15 3 SUDDIIGS DL LL LI LE 15 3 Beer EM AE 15 3 Expendable 5 onere itae ena TD DIO 15 3 EE 15 3 Service Schedule Procedures eese 15 3 Powder coat repalr este dc HO eee aisle itte ER Dre i indie RR 15 3 Primer Ier EL E 15 4 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 sheet are coated with pure aluminum during manufacture

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