Maintenance Manual

5-1 00 JUL 20, 2016 5-2 00 JUL 20, 2016 5-3 00 JUL 20, 2016 5-4 00 JUL 20, 2016 5-5 00 JUL 20, 2016 5-6 00 JUL 20, 2016 5-7 00 JUL 20, 2016 5-8 00 JUL 20, 2016 5-9 00 JUL 20, 2016 5-10 00 JUL 20, 2016 5-11 00 JUL 20, 2016 5-12 00 JUL 20, 2016 5-13 00 JUL 20, 2016 5-14 00 JUL 20, 2016 5-15 00 JUL 20, 2016 5-16 00 JUL 20, 2016 5-17 00 JUL 20, 2016 5-18 00 JUL 20, 2016 5-19 00 JUL 20, 2016 5-20 00 JUL 20, 2016 5-21 00 JUL 20, 2016 5-22 00 JUL 20, 2016 5-23 00 JUL 20, 2016 5-24 00 JUL 20, 2016 5-25 00 JUL 20, 2016 5-26 00 JUL 20, 2016 5-27 00 JUL 20, 2016 5-28 00 JUL 20, 2016 5-29 00 JUL 20, 2016 5-30 00 JUL 20, 2016 5-31 00 JUL 20, 2016 5-32 00 JUL 20, 2016 5-33 00 JUL 20, 2016 5-34 00 JUL 20, 2016 5-35 00 JUL 20, 2016 5-36 00 JUL 20, 2016 DOCUMENT NUMBER: L500-912.820 ISSUE JUL 20, 2016 AMENDMENT: 00 DATE: -- CHAPTER-PAGE 0-7 MAINTENANCE MANUAL STEMME S12 PAGE APPROVED AM. NO. DATE 5-37 00 JUL 20, 2016 5-38 00 JUL 20, 2016 5-39 00 JUL 20, 2016 5-40 00 JUL 20, 2016 CHAPTER 6 6-1 00 JUL 20, 2016 6-2 00 JUL 20, 2016 6-3 00 JUL 20, 2016 6-4 00 JUL 20, 2016 6-5 00 JUL 20, 2016 6-6 00 JUL 20, 2016 6-7 00 JUL 20, 2016 6-8 00 JUL 20, 2016 6-9 00 JUL 20, 2016 6-10 00 JUL 20, 2016 6-11 00 JUL 20, 2016 6-12 00 JUL 20, 2016 6-13 00 JUL 20, 2016 6-14 00 JUL 20, 2016 6-15 00 JUL 20, 2016 6-16 00 JUL 20, 2016 CHAPTER 7 7-1 00 JUL 20, 2016 7-2 00 JUL 20, 2016 7-3 00 JUL 20, 2016 7-4 00 JUL 20, 2016 7-5 00 JUL 20, 2016 7-6 00 JUL 20, 2016 7-7 00 JUL 20, 2016 7-8 00 JUL 20, 2016 7-9 00 JUL 20, 2016 7-10 00 JUL 20, 2016 7-11 00 JUL 20, 2016 7-12 00 JUL 20, 2016 7-13 00 JUL 20, 2016 7-14 00 JUL 20, 2016 7-15 00 JUL 20, 2016 PAGE APPROVED AM. NO. DATE 7-16 00 JUL 20, 2016 7-17 00 JUL 20, 2016 7-18 00 JUL 20, 2016 7-19 00 JUL 20, 2016 7-20 00 JUL 20, 2016 7-21 00 JUL 20, 2016 7-22 00 JUL 20, 2016 7-23 00 JUL 20, 2016 7-24 00 JUL 20, 2016 7-25 00 JUL 20, 2016 7-26 00 JUL 20, 2016 7-27 00 JUL 20, 2016 7-28 00 JUL 20, 2016 7-29 00 JUL 20, 2016 7-30 00 JUL 20, 2016 7-31 00 JUL 20, 2016 7-32 00 JUL 20, 2016 7-33 00 JUL 20, 2016 7-34 00 JUL 20, 2016 7-35 00 JUL 20, 2016 7-36 00 JUL 20, 2016 7-37 00 JUL 20, 2016 7-38 00 JUL 20, 2016 7-39 00 JUL 20, 2016 7-40 00 JUL 20, 2016 7-41 00 JUL 20, 2016 7-42 00 JUL 20, 2016 7-43 00 JUL 20, 2016 7-44 00 JUL 20, 2016 7-45 00 JUL 20, 2016 7-46 00 JUL 20, 2016 7-47 00 JUL 20, 2016 7-48 00 JUL 20, 2016 7-49 00 JUL 20, 2016 7-50 00 JUL 20, 2016 7-51 00 JUL 20, 2016 7-52 00 JUL 20, 2016 CHAPTER 8 DOCUMENT NUMBER: L500-912.820 ISSUE JUL 20, 2016 AMENDMENT: 00 DATE: -- CHAPTER-PAGE 0-8 MAINTENANCE MANUAL STEMME S12 PAGE APPROVED AM. NO. DATE 8-1 00 JUL 20, 2016 8-2 00 JUL 20, 2016 8-3 00 JUL 20, 2016 8-4 00 JUL 20, 2016 8-5 00 JUL 20, 2016 8-6 00 JUL 20, 2016 8-7 00 JUL 20, 2016 8-8 00 JUL 20, 2016 CHAPTER 9 9-1 00 JUL 20, 2016 9-2 00 JUL 20, 2016 9-3 00 JUL 20, 2016 9-4 00 JUL 20, 2016 9-5 00 JUL 20, 2016 9-6 00 JUL 20, 2016 CHAPTER 10 10-1 00 JUL 20, 2016 10-2 00 JUL 20, 2016 CHAPTER 11 11-1 00 JUL 20, 2016 11-2 00 JUL 20, 2016 ANNEX A A-1 00 JUL 20, 2016 A-2 00 JUL 20, 2016 ANNEX B B-1 00 JUL 20, 2016 B-2 00 JUL 20, 2016 ANNEX C C-1 00 JUL 20, 2016 C-2 00 JUL 20, 2016 ANNEX D D-1 00 JUL 20, 2016 PAGE APPROVED AM. NO. DATE D-2 00 JUL 20, 2016 D-3 00 JUL 20, 2016 D-4 00 JUL 20, 2016 D-5 00 JUL 20, 2016 D-6 00 JUL 20, 2016 D-7 00 JUL 20, 2016 D-8 00 JUL 20, 2016 D-9 00 JUL 20, 2016 D-10 00 JUL 20, 2016 D-11 00 JUL 20, 2016 D-12 00 JUL 20, 2016 D-13 00 JUL 20, 2016 D-14 00 JUL 20, 2016 D-15 00 JUL 20, 2016 D-16 00 JUL 20, 2016 ANNEX E E-1 00 JUL 20, 2016 E-2 00 JUL 20, 2016 ANNEX F F-1 00 JUL 20, 2016 F-2 00 JUL 20, 2016 F-3 00 JUL 20, 2016 F-4 00 JUL 20, 2016 F-5 00 JUL 20, 2016 F-6 00 JUL 20, 2016 F-7 00 JUL 20, 2016 F-8 00 JUL 20, 2016 F-9 00 JUL 20, 2016 F-10 00 JUL 20, 2016 F-11 00 JUL 20, 2016 F-12 00 JUL 20, 2016 F-13 00 JUL 20, 2016 F-14 00 JUL 20, 2016 F-15 00 JUL 20, 2016 F-16 00 JUL 20, 2016 F-17 00 JUL 20, 2016 F-18 00 JUL 20, 2016 DOCUMENT NUMBER: L500-912.820 ISSUE JUL 20, 2016 AMENDMENT: 00 DATE: -- CHAPTER-PAGE 0-9 MAINTENANCE MANUAL STEMME S12 PAGE APPROVED AM. NO. DATE F-19 00 JUL 20, 2016 F-20 00 JUL 20, 2016 F-21 00 JUL 20, 2016 F-22 00 JUL 20, 2016 F-23 00 JUL 20, 2016 F-24 00 JUL 20, 2016 F-25 00 JUL 20, 2016 F-26 00 JUL 20, 2016 F-27 00 JUL 20, 2016 F-28 00 JUL 20, 2016 F-29 00 JUL 20, 2016 F-30 00 JUL 20, 2016 F-31 00 JUL 20, 2016 F-32 00 JUL 20, 2016 F-33 00 JUL 20, 2016 F-34 00 JUL 20, 2016 F-35 00 JUL 20, 2016 F-36 00 JUL 20, 2016 F-37 00 JUL 20, 2016 F-38 00 JUL 20, 2016 PAGE APPROVED AM. NO. DATE DOCUMENT NUMBER: L500-912.820 ISSUE JUL 20, 2016 AMENDMENT: 00 DATE: -- CHAPTER-PAGE 0-10 MAINTENANCE MANUAL STEMME S12 THIS PAGE IS INTENTIONALLY LEFT BLANK DOCUMENT NUMBER: L500-912.820 ISSUE JUL 20, 2016 AMENDMENT: 00 DATE: -- CHAPTER-PAGE 0-11 MAINTENANCE MANUAL STEMME S12 0.3 CONTENTS MANUAL CONTENTS Cover Sheet. .............................................................................................................. 0-1 0.1 Record of Amendments. ............................................................................... 0-3 0.2 List of Effective Pages . ................................................................................. 0-5 0.3 Contents. ...................................................................................................0-11 1. General. ...................................................................................................... 1-1 1.1 remarks on maintenance. .............................................................................. 1-1 1.2 Conversion Table. .......................................................................................... 1-3 1.3 Abbreviations. .............................................................................................. 1-4 1.4 Safety symbols. ............................................................................................ 1-6 2. Description. ................................................................................................. 2-1 2.1 Technical Data. ............................................................................................2-2 2.2 Three View Drawing. .....................................................................................2-7 3. Description of Assemblies............................................................................... 3-1 3.1 Airframe, Primary and Secondary Structure. ..................................................... 3-1 3.1.1 Wing. .......................................................................................................... 3-1 3.1.2 Fuselage. .....................................................................................................3-2 3.1.3 Tail Unit.......................................................................................................3-2 3.2 Cockpit. ......................................................................................................3-2 3.2.1 General. ......................................................................................................3-2 3.2.2 Control Elements and Instruments. .................................................................3-3 3.2.3 Controls at the Instrument Panel.....................................................................3-5 3.2.4 Instrument Panel. .........................................................................................3-5 3.3 Flight Control System.....................................................................................3-9 3.3.1 Longitudinal Control......................................................................................3-9 3.3.2 Longitudinal Trim (-). ....................................................................................3-9 3.3.3 Wing Flap Control System...............................................................................3-9 3.3.4 Lateral Control. ............................................................................................3-9 3.3.5 Control of Air Brakes.................................................................................... 3-10 3.3.6 Directional Control. ..................................................................................... 3-10 3.4 Power-Plant. ...............................................................................................3-11 3.4.1 Engine........................................................................................................3-11 3.4.2 Lubrication System.......................................................................................3-12 3.4.3 Cooling System. .......................................................................................... 3-13 3.4.4 Air Induction System.................................................................................... 3-14 3.4.5 Engine Exhaust incl. Turbocharger and Attachment.......................................... 3-14 3.4.6 Fuel System. ............................................................................................... 3-15 3.4.6.1 Fuel System Related Controls and Indication System. ....................................... 3-15 3.4.6.2 Fuel System Design...................................................................................... 3-16 3.4.6.3 Fuel System of the Fuselage. ......................................................................... 3-16 3.4.6.4 Electrical Layout and Operation of the Fuel Pumps. ..........................................3-17 DOCUMENT NUMBER: L500-912.820 ISSUE JUL 20, 2016 AMENDMENT: 00 DATE: -- CHAPTER-PAGE 0-12 MAINTENANCE MANUAL STEMME S12 3.4.7 Engine Controls and Instrumentation............................................................. 3-19 3.4.8 Fire Protection. ........................................................................................... 3-19 3.4.9 Engine Cowlings. ........................................................................................ 3-19 3.4.10 Propeller. ................................................................................................... 3-20 3.4.10.1 Design of Variable Pitch Propeller. ..................................................................3-21 3.4.10.2 Propeller Blades. ..........................................................................................3-21 3.4.10.3 Propeller Blade Angle Control Mechanism. .......................................................3-21 3.4.10.4 Propeller Weight Balance. ............................................................................ 3-24 3.4.10.5 Expansion Element and Control System. ......................................................... 3-25 3.4.10.6 Identification of Propeller System and Assembly. ............................................. 3-26 3.4.11 Power Transmission. .................................................................................... 3-26 3.4.12 Forward Propeller Reduction Gearbox. ........................................................... 3-26 3.4.13 Operation Mechanism of the Propeller Folding System. ..................................... 3-27 3.4.13.1 Nose-cone. ................................................................................................ 3-27 3.4.13.2 Propeller Positioning. ................................................................................... 3-27 3.4.13.3 Propeller Brake. .......................................................................................... 3-28 3.4.14 FLUIDS. ..................................................................................................... 3-28 3.4.14.1 Fuel. ......................................................................................................... 3-28 3.4.14.2 Coolant Fluid.............................................................................................. 3-30 3.4.14.3 Lubricants. ................................................................................................ 3-31 3.5 Landing Gear.............................................................................................. 3-33 3.5.1 Main Landing Gear. ..................................................................................... 3-33 3.5.2 Tail Wheel. ................................................................................................. 3-34 3.6 Flight Control Instruments, Pitot Static System. ............................................... 3-35 3.7 Electrical System......................................................................................... 3-37 3.7.1 General System Architecture......................................................................... 3-37 3.7.2 DC Generation (ATA 24-30-00). ..................................................................... 3-39 3.7.2.1 Main System DC Power Generation. ............................................................... 3-39 3.7.2.2 Engine System DC Power Generation..............................................................3-40 3.7.2.3 Over Voltage Protection. .............................................................................. 3-41 3.7.3 DC Indication (ATA 24-37-00)........................................................................ 3-41 3.7.3.1 Description. ............................................................................................... 3-41 3.7.4 Parts Specification. ..................................................................................... 3-41 3.7.5 Operation. ................................................................................................. 3-41 3.7.6 DC Power Distribution System (ATA 24-60-00). ................................................ 3-42 3.7.6.1 Wire Specifications...................................................................................... 3-42 3.7.6.2 Design of Electrical Connections. .................................................................. 3-42 3.7.6.3 Protection Devices. ..................................................................................... 3-43 3.7.6.4 Fuse and CB Specifications: Main System. ....................................................... 3-44 3.7.6.5 Fuse Specifications: Engine System. ............................................................... 3-45 3.7.7 Switching Devices. ...................................................................................... 3-45 3.7.7.1 Manual Switches......................................................................................... 3-46 3.7.7.2 Electromechanical Relays............................................................................. 3-46 DOCUMENT NUMBER: L500-912.820 ISSUE JUL 20, 2016 AMENDMENT: 00 DATE: -- CHAPTER-PAGE 0-13 MAINTENANCE MANUAL STEMME S12 3.7.7.3 Semiconductor Switch Box. .......................................................................... 3-47 3.7.8 Main System Distribution Box........................................................................ 3-47 3.7.9 Engine System Distribution Box . ................................................................... 3-47 3.7.10 TCU Board. ................................................................................................ 3-47 3.7.11 Instrument Panel Bus System. ....................................................................... 3-49 3.7.12 Engine Starting System (ATA 80-00-00). ......................................................... 3-50 3.7.12.1 Description. ............................................................................................... 3-50 3.7.12.2 Parts Specification. ..................................................................................... 3-50 3.7.12.3 Operation. ................................................................................................. 3-50 3.7.13 Engine Ignition System (ATA 74-00-00). .......................................................... 3-51 3.7.13.1 Description. ............................................................................................... 3-51 3.7.13.2 Parts Specification. ..................................................................................... 3-51 3.7.13.3 Operation. ................................................................................................. 3-51 3.7.14 Engine RPM Indicating System (ATA 77-14-00). ................................................ 3-52 3.7.14.1 Description. ............................................................................................... 3-52 3.7.14.2 Parts Specification. ..................................................................................... 3-52 3.7.14.3 Operation. ................................................................................................. 3-52 3.7.15 Cylinder Head Temperature Indicating System (ATA 77-22-00). .......................... 3-52 3.7.15.1 Description. ............................................................................................... 3-52 3.7.15.2 Parts Specification. ..................................................................................... 3-52 3.7.15.3 Operation. ................................................................................................. 3-52 3.7.16 Oil Pressure Indicating System (ATA 79-31-00). ................................................ 3-53 3.7.16.1 Description. ............................................................................................... 3-53 3.7.16.2 Parts Specification. ..................................................................................... 3-53 3.7.16.3 Operation. ................................................................................................. 3-53 3.7.17 Oil Temperature Indicating System (ATA 79-33-00)........................................... 3-53 3.7.17.1 Description. ............................................................................................... 3-53 3.7.17.2 Parts Specification. ..................................................................................... 3-53 3.7.17.3 Operation. ................................................................................................. 3-54 3.7.18 Fuel Distribution System (ATA 28-20-00). ........................................................ 3-54 3.7.18.1 Description. ............................................................................................... 3-54 3.7.18.2 Parts Specification. ..................................................................................... 3-54 3.7.18.3 Operation. ................................................................................................. 3-54 3.7.18.4 Transfer Pump Control and Tank Selection. ..................................................... 3-55 3.7.19 Fuel Quantity Indication (ATA 28-40-00)......................................................... 3-55 3.7.19.1 Description. ............................................................................................... 3-55 3.7.19.2 Parts Specification. ..................................................................................... 3-55 3.7.19.3 Operation. ................................................................................................. 3-55 3.7.20 Fuel Pressure Indicating (ATA 73-32-00).......................................................... 3-56 3.7.20.1 Description. ............................................................................................... 3-56 3.7.20.2 Parts Specification. ..................................................................................... 3-56 3.7.20.3 Operation. ................................................................................................. 3-56 3.7.21 Fire Detection System (ATA 26-12-00). ............................................................ 3-56 DOCUMENT NUMBER: L500-912.820 ISSUE JUL 20, 2016 AMENDMENT: 00 DATE: -- CHAPTER-PAGE 0-14 MAINTENANCE MANUAL STEMME S12 3.7.21.1 Description. ............................................................................................... 3-56 3.7.21.2 Parts Specification. ..................................................................................... 3-56 3.8 COM and NAV Equipment............................................................................. 3-57 3.9 Oxygen System. .......................................................................................... 3-59 3.10 Wing Folding Device. ................................................................................... 3-61 4. Airworthiness Limitations Section. .................................................................. 4-1 4.1 General. ......................................................................................................4-2 4.2 Maintenance Limitations. ..............................................................................4-2 4.2.1 Paint Finish. .................................................................................................4-2 4.3 Component Replacement and Overhaul Limitations...........................................4-3 4.4 Structural Limitations................................................................................... 4-5 5. Time Limits / Maintenance Checks. .................................................................. 5-1 5.1 Overhaul and Replacement Schedule. ..............................................................5-2 5.2 Pre-Flight Inspections. ...................................................................................5-7 5.2.1 Rubber Hose and Clamp Integrity. ...................................................................5-7 5.3 Periodic Inspections.......................................................................................5-7 5.3.1 Inspection Intervals. ..................................................................................... 5-8 5.3.2 General Remarks on Periodic Inspections. ....................................................... 5-10 5.3.3 Unscheduled Maintenance. ...........................................................................5-11 5.3.4 Special Conditions and Cautionary Notice. ..................................................... 5-12 5.3.5 General Remarks on Maintenance. ................................................................ 5-12 5.3.6 Inspection Groups and Maintenance Criteria................................................... 5-14 5.3.7 Other Particulars of Maintenance.................................................................. 5-17 5.4 Check List for Periodic Inspections. ................................................................ 5-19 5.4.1 General. .................................................................................................... 5-19 5.4.2 Wings and Fuel System Components in the Wing Center Section. ....................... 5-20 5.4.3 Forward Fuselage. ....................................................................................... 5-21 5.4.4 Cockpit. .................................................................................................... 5-22 5.4.5 Center Fuselage (except for fairings). ............................................................ 5-23 5.4.6 Tail Boom................................................................................................... 5-24 5.4.7 Empennage................................................................................................ 5-24 5.4.8 Fuel System Components in the Fuselage........................................................ 5-25 5.4.9 Engine and Engine Mountings. ...................................................................... 5-26 5.4.10 Lubrication System...................................................................................... 5-28 5.4.11 Cooling System (Liquid Cooling, Ram Air Cooling)............................................ 5-29 5.4.12 Air Induction System.................................................................................... 5-29 5.4.13 Engine Controls & Monitoring. ....................................................................... 5-29 5.4.14 Center Fuselage Fairing, Engine Cowlings and Firewall......................................5-30 5.4.15 Propeller. ................................................................................................... 5-31 5.4.16 Drive Shaft with Propeller Reduction Gear....................................................... 5-32 5.4.17 Main Landing Gear. ..................................................................................... 5-33 5.4.18 Tail Wheel. ................................................................................................. 5-34 5.4.19 Flight Instrumentation and Pitot / Static Systems. ............................................ 5-34 DOCUMENT NUMBER: L500-912.820 ISSUE JUL 20, 2016 AMENDMENT: 00 DATE: -- CHAPTER-PAGE 0-15 MAINTENANCE MANUAL STEMME S12 5.4.20 Electric System (except for engine and TCU). .................................................. 5-35 5.4.21 COM and NAV Equipment............................................................................. 5-35 5.4.22 Completion Tasks. ....................................................................................... 5-36 5.4.23 Optional Equipment. ................................................................................... 5-37 5.5 Special Inspections...................................................................................... 5-39 5.5.1 Inspection Following a Heavy Landing or a Wing Tip Landing. ............................ 5-39 5.5.2 Inspection Following an Impact to the Rotating Propeller. ................................. 5-39 5.5.3 Inspection following Exceptional Events with Wing Folding Device. .....................5-40 6. Maintenance Instructions, Tolerances, Adjustment Data for the Aircraft................ 6-1 6.1 General Remarks. ......................................................................................... 6-1 6.2 Towing on ground, Jack Points and Lifting. ....................................................... 6-1 6.3 Determination of Empty Weight and Corresponding Center of Gravity; Weight Limits......................................................................6-3 6.4 Flight Control System.................................................................................... 6-8 6.4.1 Deflection of Control Surfaces, Control System Friction, and Control Forces. ......... 6-8 6.4.1.1 Control Surface Deflections. .......................................................................... 6-8 6.4.1.2 Friction in Control System.............................................................................. 6-9 6.4.1.3 Pilot Forces. ................................................................................................ 6-9 6.4.2 Weights and Moments of Control Surfaces...................................................... 6-10 6.4.3 Free Play in Flight Control System. ................................................................. 6-10 6.5 Lubrication. ................................................................................................6-11 6.5.1 General Remarks. ........................................................................................6-11 6.5.2 Lubrication Plan. ........................................................................................ 6-12 6.6 Surface of Composite Structures. .................................................................. 6-13 6.7 Drainage and Ventilation Holes. .................................................................... 6-15 6.8 Tightening Torques of Screwed Joints. ............................................................ 6-15 7. Maintenance Instructions, Tolerances and Adjustment Data for Assemblies / Equipment. .................................................................... 7-1 7.1 Airframe...................................................................................................... 7-1 7.1.1 Wing. .......................................................................................................... 7-1 7.1.1.1 Cracks and Structural Damage. ...................................................................... 7-1 7.1.1.2 Drainage and Ventilation Holes. ...................................................................... 7-1 7.1.1.3 Wing Fittings................................................................................................ 7-1 7.1.1.4 Flaps and Ailerons. .......................................................................................7-2 7.1.2 Fuselage. .....................................................................................................7-3 7.1.2.1 Cracks and Structural Damage. ......................................................................7-3 7.1.2.2 Drainage Holes. ............................................................................................7-3 7.1.2.3 Nose-cone. ..................................................................................................7-3 7.1.2.4 Center Fuselage. ...........................................................................................7-4 7.1.3 Empennage..................................................................................................7-4 7.1.3.1 General Condition. ........................................................................................7-4 7.1.3.2 Vertical Tail. .................................................................................................7-5 7.1.3.3 Horizontal Tail. .............................................................................................7-6 7.1.3.4 Weights and Static Hinge Moments of Control Surfaces......................................7-6 DOCUMENT NUMBER: L500-912.820 ISSUE JUL 20, 2016 AMENDMENT: 00 DATE: -- CHAPTER-PAGE 0-16 MAINTENANCE MANUAL STEMME S12 7.2 Cockpit. ......................................................................................................7-7 7.2.1 Canopy........................................................................................................7-7 7.2.1.1 Condition and Function. ................................................................................7-7 7.2.1.2 Test of Canopy Emergency Jettison. .................................................................7-7 7.2.1.3 Re-Installation of the Canopy. ........................................................................7-8 7.2.2 Equipment and Systems. ................................................................................7-9 7.2.2.1 Seat Belts. ...................................................................................................7-9 7.2.2.2 Instruments and Switches. .............................................................................7-9 7.2.2.3 Air Hoses. ....................................................................................................7-9 7.2.2.4 Seats. .........................................................................................................7-9 7.3 Controls. ................................................................................................... 7-10 7.3.1 Controls in Fuselage. ................................................................................... 7-10 7.3.2 Controls in the Wing. ....................................................................................7-11 7.3.3 Controls in Tail Cone /Vertical Tail. ..................................................................7-11 7.3.4 Deflection of Control Surfaces, Control System Friction, Control Forces. ...............7-12 7.3.5 Free Play of Control System Bearings...............................................................7-12 7.4 Power-Plant. ...............................................................................................7-13 7.4.1 Engine........................................................................................................7-13 7.4.1.1 General. .....................................................................................................7-13 7.4.1.2 Removal and Installation of The Engine. ......................................................... 7-14 7.4.1.3 Cleaning of the Engine................................................................................. 7-15 7.4.1.4 Visual Check of Engine................................................................................. 7-15 7.4.1.5 Leakage Check. .......................................................................................... 7-15 7.4.1.6 Inspection of External Engine Components. .................................................... 7-15 7.4.1.7 Check of Waste-Gate. ................................................................................. 7-15 7.4.1.8 Check of Gearbox. ...................................................................................... 7-16 7.4.1.9 Inspection of the Magnetic Plug. ................................................................... 7-16 7.4.1.10 Examination of Drive Gear Set....................................................................... 7-16 7.4.1.11 Check of the Carburetor............................................................................... 7-16 7.4.1.12 Check of Engine Wiring. ................................................................................7-17 7.4.1.13 Check of V-Belt Tension. ...............................................................................7-17 7.4.1.14 Replacement of Spark Plugs. .........................................................................7-17 7.4.1.15 Checking of Spark Plug Connector. .................................................................7-17 7.4.1.16 Check of Compression. .................................................................................7-17 7.4.1.17 Test Run of Engine....................................................................................... 7-18 7.4.1.18 Inspection of Engine Mountings. ................................................................... 7-18 7.4.2 Lubrication System...................................................................................... 7-18 7.4.2.1 Visual and Leakage Check of Oil System. ........................................................ 7-18 7.4.2.2 Oil Level Check. .......................................................................................... 7-19 7.4.2.3 Oil Change................................................................................................. 7-19 7.4.2.4 Oil filter - Replacement and Inspection. ......................................................... 7-19 7.4.3 Cooling System. .......................................................................................... 7-19 7.4.3.1 Visual and Leakage Check of the System. ....................................................... 7-19 DOCUMENT NUMBER: L500-912.820 ISSUE JUL 20, 2016 AMENDMENT: 00 DATE: -- CHAPTER-PAGE 0-17 MAINTENANCE MANUAL STEMME S12 7.4.3.2 Flushing of Cooling System. .......................................................................... 7-20 7.4.3.3 Coolant Replacement. ................................................................................. 7-20 7.4.3.4 Ram Air Cooling...........................................................................................7-21 7.4.4 Air Induction System.....................................................................................7-21 7.4.4.1 Intercooler and Air box..................................................................................7-21 7.4.4.2 Air filter. .....................................................................................................7-21 7.4.5 Exhaust System. ..........................................................................................7-21 7.4.5.1 Turbocharger / Muffler Mountings. ..................................................................7-21 7.4.5.2 Exhaust Headers. ........................................................................................ 7-22 7.4.5.3 Heat Insulation........................................................................................... 7-22 7.4.6 Fuel System. ............................................................................................... 7-23 7.4.6.1 Fuel System in the Wing. .............................................................................. 7-24 7.4.6.2 Fuel System in the Fuselage. ......................................................................... 7-25 7.4.7 Engine Controls / Monitoring. ........................................................................ 7-26 7.4.8 Fire Protection. ........................................................................................... 7-28 7.4.8.1 Cowling-Fire Protective Painting. .................................................................. 7-28 7.4.8.2 Fire Protective Sleeves.................................................................................. 7-29 7.4.8.3 Firewall. .................................................................................................... 7-29 7.4.9 Cowlings.................................................................................................... 7-29 7.4.10 Propeller. ................................................................................................... 7-30 7.4.10.1 General. .................................................................................................... 7-30 7.4.10.2 Adjustment and Inspection Results, Tolerances.................................................7-31 7.4.10.3 Visual Inspection of the Propeller Unit.............................................................7-31 7.4.10.4 Removal of the Propeller Unit. ...................................................................... 7-32 7.4.10.5 Installation of the Propeller Unit. .................................................................. 7-33 7.4.10.6 Spring Tension of the Propeller Folding Mechanism........................................... 7-34 7.4.10.7 Checking of Pitch Control and Adjusting the Variable Pitch Propeller. ................. 7-35 7.4.10.8 General Aspects of the Electrical Circuit. ........................................................ 7-36 7.4.10.9 Adjustment of the Electrical Switch for the Take-Off Setting Indicator and Stop Switch. .................................................... 7-36 7.4.10.10 Dynamic Balancing. .................................................................................... 7-37 7.4.11 Drive Shaft System. ..................................................................................... 7-37 7.4.12 Propeller Gearbox, Mounting and Support....................................................... 7-38 7.4.13 Propeller Operation. .................................................................................... 7-40 7.5 Landing Gear.............................................................................................. 7-41 7.5.1 Main Landing Gear. ..................................................................................... 7-41 7.5.1.1 General. .................................................................................................... 7-41 7.5.1.2 Functional Test of the Retractable Landing Gear. ............................................. 7-42 7.5.1.3 Functional Check of Emergency Undercarriage Extension. ................................ 7-44 7.5.1.4 Tires, Condition and Inflation Pressure. .......................................................... 7-45 7.5.1.5 Adjustment and Bleeding of the Wheel Brake System. ...................................... 7-45 7.5.1.6 Replacement of Brake Lining. ....................................................................... 7-46 7.5.1.7 Removal and Installation of Landing Gear Legs. .............................................. 7-46 DOCUMENT NUMBER: L500-912.820 ISSUE JUL 20, 2016 AMENDMENT: 00 DATE: -- CHAPTER-PAGE 0-18 MAINTENANCE MANUAL STEMME S12 7.5.2 Tail Wheel. ................................................................................................. 7-46 7.6 Flight Control Instruments and Pitot and Static Pressure System. ....................... 7-47 7.6.1 Calibration of Stall Warning System (Optional)................................................ 7-48 7.6.2 Maintenance on the Static Pressure System. ................................................... 7-48 7.7 Electrical System......................................................................................... 7-49 7.7.1 General. .................................................................................................... 7-49 7.7.2 Batteries. .................................................................................................. 7-49 7.7.3 Grounding. ................................................................................................ 7-50 7.7.4 E-Boxes. .................................................................................................... 7-50 7.8 Communication and Navigation Equipment. ...................................................7-51 7.9 Optional - Oxygen Equipment. ......................................................................7-51 8. List of Placards and their Positions. ................................................................. 8-1 8.1 Placards in the Cockpit, Front. ........................................................................ 8-1 8.2 Placards in the Cockpit, Rear. ........................................................................ 8-6 8.3 Placards on Fuselage. ....................................................................................8-7 9. Equipment. .................................................................................................. 9-1 9.1 Minimum Equipment List. .............................................................................. 9-1 9.2 Supplementary Equipment. ............................................................................9-3 9.3 Additional Equipment and Systems..................................................................9-3 9.3.1 Additional Equipment. ...................................................................................9-3 9.3.2 Optional Systems. ........................................................................................ 9-5 10. List of Special Tools. .....................................................................................10-1 11. List of Maintenance Documents for Parts Being Approved Independently from the Aircraft. .................................................................... 11-1 Annex A: Supplementary Instructions for Maintenance and Care, Maintenance Instructions...............................................................................A-1 Annex B: Service Bulletins, Airworthiness Directives.........................................................B-1 Annex C: Documents (Inspection and Operation Reports). ...............................................C-1 Annex D: Maintenance and Inspection Forms. ................................................................D-1 Annex E: Maintenance Manual (Line Maintenance) for ROTAX Engine Type 914 Series........... E-1 Annex F: Technical Drawings. ...................................................................................... F-1 a) Flight Controls: Pitch Control and Trim. ......................................................................F-3 b) Flight Controls: Lateral Control (Wing, Flap, Aileron). ...................................................F-5 c) Flight Controls: Airbrake Control................................................................................F-7 d) Flight Controls: Rudder Control. ................................................................................F-9 e) Propulsion System. .................................................................................................F-13 f) S12 Main System - DC Generation. ............................................................................F-15 g) S12 Main System - Landing Gear. ..............................................................................F-17 h) S12 Main System - Electrical Trim. ............................................................................ F-19 i) S12 Main System - Autopilot......................................................................................F-21 j) S12 Main System - Fire Warning. ............................................................................... F-23 k) S12 Main System - Lighting. .................................................................................... F-25 l) Transponder and Traffic Display................................................................................ F-27 m) S12 Main System - Communication Radio. ............................................................... F-29 DOCUMENT NUMBER: L500-912.820 ISSUE JUL 20, 2016 AMENDMENT: 00 DATE: -- CHAPTER-PAGE 0-19 MAINTENANCE MANUAL STEMME S12 n) S12 Engine System - DC Generation. .........................................................................F-31 o) S12 Engine System - Engine Monitoring and Control. .................................................. F-33 p) S12 Engine System - Fuel Pumps and Indication. ........................................................ F-35 q) S12 Engine System - Propeller Control....................................................................... F-37 DOCUMENT NUMBER: L500-912.820 ISSUE JUL 20, 2016 AMENDMENT: 00 DATE: -- CHAPTER-PAGE 0-20 MAINTENANCE MANUAL STEMME S12 THIS PAGE IS INTENTIONALLY LEFT BLANK DOCUMENT NUMBER: L500-912.820 ISSUE JUL 20, 2016 AMENDMENT: 00 DATE: -- CHAPTER-PAGE 1-1 MAINTENANCE MANUAL STEMME S12 1. GENERAL 1.1 REMARKS ON MAINTENANCE The legal owner or operator of the STEMME S12 is obliged to ensure that the maintenance of the aircraft follows the instructions of this manual in accordance with applicable national laws and regulations. Among others, these include: • Scheduled maintenance, • Adjustments, • Replacement of fluids and lubricants, • Replacement of parts after expiration of their service life, • Minor repairs. Any maintenance work must be documented (aircraft logbook). The manufacturer must be informed immediately in case of any change of ownership. The mes- sage must be confirmed by the manufacturer, so that all information concerning airworthiness (AD´s, SB´s) can be given to the legal owner. For maintenance work the following documents are relevant: 1. This Maintenance Manual for the motorglider STEMME S12. 2. STEMME - Flight Manual for the motorglider STEMME S12. 3. ROTAX - Maintenance Manual (Line Maintenance) for ROTAX Engine Types ROTAX 912 and 914 Series. 4. ROTAX - Maintenance Manual (Heavy Maintenance) for ROTAX Engine Types ROTAX 912 and 914 Series. 5. ROTAX - Operating Manual ROTAX 914 F. 6. ROTAX - Installation Manual ROTAX 914 F. 7. ROTAX - Main Overhaul Manual ROTAX 914 F. 8. ROTAX - Spare Parts List ROTAX 914 F. 9. STEMME Document Number A26-11AM-M: Technical Specification of the ROTAX 914 F2/S1. 10. Maintenance instructions for the L’Hotellier quick-disconnects in flight control system. 11. Manufacturer’s documents referring to the equipment listed in the equipment list of the corresponding S/N. 12. SB´s published by STEMME, ROTAX and manufacturer of other equipment installed. 13. Maintenance Instructions from STEMME. 14. Service Information from ROTAX. 15. Aircraft Logbook. The amount and kind of maintenance work depend on the aircraft utilization, the climate, airfield conditions, storage facilities and other factors, irrespective of the periodic checks. E. g., in sandy environs it might be necessary to clean all filters before every commencement of operation; on DOCUMENT NUMBER: L500-912.820 ISSUE JUL 20, 2016 AMENDMENT: 00 DATE: -- CHAPTER-PAGE 1-2 MAINTENANCE MANUAL STEMME S12 the other hand in coastal or in rainy regions it is important to take more care of the preservation of the aircraft. The instructions in this manual are valid under normal conditions and use. Use only spare parts from the manufacturer or according to the manufacturer’s requirements. NOTICE Materials required and recommended procedures for minor repairs on composite materials are indicated in the repair guide »Small Repairs of Composite Materials« in Annex A of the S12 Aircraft Maintenance Manual. In case of any incident endangering airworthiness, the manufacturer must be informed imme- diately. Maintenance work must be performed by qualified personnel. NOTICE This Maintenance Manual does not include instructions for assembly, daily inspection and Pre-flight inspection, which are provided in section »4 Normal Operating Procedures« of the S12 Aircraft Flight Manual. To perform these procedures, the S12 Aircraft Flight Manual must be available to the maintenance personnel. DOCUMENT NUMBER: L500-912.820 ISSUE JUL 20, 2016 AMENDMENT: 00 DATE: -- CHAPTER-PAGE 1-3 MAINTENANCE MANUAL STEMME S12 1.2 CONVERSION TABLE For the conversion of technical data the following factors have been used: Data Factor 1 cubic in 16.387 cm 3 1 dr 1.772 g 100 fpm 0.508 m/s 1 ft 0.3048 m 1 ft lb 1.356 Nm 1 hp 0.7457 kW 1 Imp.gal. 4.546 l 1 in 25.4 mm 1 inHg 33.86 hPa 1 kgm 86.8 lb in 1 kgmm 0.001 kgm 1 kgmm 0.007 lb ft 1 kt 1.852 kph 1 lb 0.4536 kg 1 lbf 4.45 N 1 lbf ft 135.6 Ncm 1 mph 1.609 kph 1 sqft 0.0929 m2 1 oz. 28.349 g 1 psi 0.06895 bar 1 US gal. 3.785 l DOCUMENT NUMBER: L500-912.820 ISSUE JUL 20, 2016 AMENDMENT: 00 DATE: -- CHAPTER-PAGE 1-4 MAINTENANCE MANUAL STEMME S12 1.3 ABBREVIATIONS The following abbreviations are being used for clarity: ACL Anti-Collision Light AD’s Airworthiness Directives AGL Above Ground Level AMM Aircraft Maintenance Manual ANSI American National Standards Institute AOA Angle Of Attack ASAP As Soon As Possible ASI Airspeed Indicator AUW All-Up-Weight CB Circuit Breaker CCT Cylinder Coolant Temperature CD Constant Depression CFRP Carbon Fiber Reinforced Plastic CG Center Of Gravity CHT Cylinder Head Temperature DCDI Dual Capacitive Discharge Ignition EFIS Electronic Flight Information System EMC Electromagnetic Compatibility EQL Equipment List FBO Fixed-Base Operator FOD Foreign Object Damage FRP Fiber Reinforced Plastic GEN Generator GFRP Glass Fiber Reinforced Plastic GPS Global Positioning System IMC Instrument Meteorological Conditions IPC Illustrated Parts Catalog KIAS Knots Indicated Airspeed kt Knots (equivalent to KIAS) LBA Luftfahrtbundesamt - German Civil Aviation Authority LH Left Hand MAP Manifold Pressure MCP Maximum Continuous Power MEL Minimum Equipment list MMEL Master Minimum Equipment list MNLP Maximum Weight of Non Lifting Parts MTOW Maximum Take-Off Weight NLP Non Lifting Part DOCUMENT NUMBER: L500-912.820 ISSUE JUL 20, 2016 AMENDMENT: 00 DATE: -- CHAPTER-PAGE 1-5 MAINTENANCE MANUAL STEMME S12 OAT Outside Air Temperature OVP Over Voltage Protection PIC Pilot In Command PPC Propeller Pitch Control PTT Push To Talk R/C Rate Of Climb RH Right Hand RP Reference Plane RPM Revolutions Per Minute RTD Resistance Temperature Detector RWY Runway SB’s Service Bulletins SI Service Information SL Service Letter STC Supplemental Type Certificate TBO Time Between Overhaul TBR Time Between Replacement TC Type Certificate TCDS Type Certificate Data Sheet TCU Turbocharger Control Unit TE Total Energy T/O Take-Off TSO Technical Standard Order TTL Transistor-Transistor Logic DOCUMENT NUMBER: L500-912.820 ISSUE JUL 20, 2016 AMENDMENT: 00 DATE: -- CHAPTER-PAGE 1-6 MAINTENANCE MANUAL STEMME S12 1.4 SAFETY SYMBOLS The following safety instructions are based loosely on the ANSI Z535. Symbols Z535.3 Criteria for Safety Symbols Signs and Labels Z535.4 Product Safety Signs and Labels Product Safety Z535.6 Product Safety Information in Product Manuals, Instructions, and Other Collateral Materials. WARNING WARNING An operating procedure or technique that may result in personal injury or loss of life if not followed. CAUTION CAUTION An operating procedure or technique that may result in damage to equipment if not followed. NOTICE NOTICE An operating procedure or technique needing special emphasis. DOCUMENT NUMBER: L500-912.820 ISSUE JUL 20, 2016 AMENDMENT: 00 DATE: -- CHAPTER-PAGE 2-1 MAINTENANCE MANUAL STEMME S12 2. DESCRIPTION The STEMME S12 is a twin-seat, self-launching motorglider, constructed mostly from carbon fiber and is aerodynamically optimized for high performance. The two seats are arranged side-by-side (forward of the wing) and the S12 is equipped with dual controls. The wing is shoulder mounted and consists of a center section with flaps and Schempp-Hirth air brakes, two outer wing sections with continuous ailerons, two wing extensions with ailerons and two winglets. The flaps and ailerons of inner and outer wing/wing extension are interconnected (“flaperons”). The motorglider is in “T”-tail design. The retractable two-wheel main landing gear is electrically operated and is equipped with hydraulic wheel brakes. The engine of the STEMME S12 is based on the ROTAX 914 F2-01, which has been certificated by BRP-ROTAX® GmbH & Co.KG, Austria. STEMME modified the arrangement of some accessories (induction and exhaust system including turbo-charger, engine mounts etc.) to adapt the systems to specific installation requirements of the S12. These modifications are certified in the STEMME S12 as engine model ROTAX 914 F2-01/S1. ENGINE DESCRIPTION Four-cylinder, four-stroke opposed type Otto-engine, turbocharged with electronic manifold pres- sure control (TCU); a center cam shaft and tappets; OHV; liquid cooled cylinder heads, cylinder barrels cooled by ram air; dry-sump lubrication; Dual Capacitive Discharge Ignition (DCDI); 2 CD-carburetors (variable-choke); integrated reduction gear with mechanical vibration absorber and overload clutch. The engine is mounted in the fuselage in a center steel frame near the aircraft´s CG. Engine pow- er is transmitted via a propeller shaft made of composites and a spur gear to the variable pitch propeller in the fuselage nose. When the aircraft is in gliding configuration, the propeller blades are folded and covered by a movable nose cone (nose-cone). Propeller pitch change from take-off into cruise position is accomplished by electrically heated expansion elements, and from cruise back to take-off position (elements unheated) by springs as well as aerodynamic and centrifugal forces. A fuel tank is located at each outboard end of the wing center section. Each tank supplies the feeder tank in the fuselage by use of electrically driven fuel pumps. From the feeder tank the fuel is supplied by two fuel pumps (one main and one auxiliary) to the engine to provide required redundancy. DOCUMENT NUMBER: L500-912.820 ISSUE JUL 20, 2016 AMENDMENT: 00 DATE: -- CHAPTER-PAGE 2-2 MAINTENANCE MANUAL STEMME S12 2.1 TECHNICAL DATA FUSELAGE Design Front section CFRP-Kevlar-GFRP-structure, center steel frame, GFRP-fairing, tail boom with inte- grated vertical tail fin (CFRP). Length 8.42 m 27.62 ft Width 1.18 m 3.87 ft Cockpit width 1.16 m 3.81 ft Cockpit height 0.93 m 3.05 ft Height of tail unit 1.75 m 5.74 ft WING Design 5 sections CFRP-Spar with GFRP-shearweb, CFRP-sandwich skin. Wing span 25.07 m 82.25 ft Center wing span 9.90 m 32.48 ft Wing area 19.95 m² 214.75 sqft Aspect ratio 31.5 Dihedral angle (V-form) 0.75° / 1.75° / 4° Mean aerodynamic chord 0.741 m 2.43 ft Wing Airfoil HQ41/14.35 Sweep of wing center section leading edge 0° Sweep of outboard wing leading edge up to the bend 0° AIR BRAKES Type Two blade Schempp-Hirth type, position outer part of wing center section. Length 1.50 m 4.92 ft / 59.01 in Area 0.22 m² 2.37 sqft Maximum height above wing upper surface. 0.16 m 0.52 ft / 6.29 in HORIZONTAL TAIL Design Web GFRP, skin CFRP-Sandwich, elevator GFRP-Sandwich. Span 3.10 m 10.17 ft Area 1.46 m² 15.72 sqft Aspect ratio 6.58 Airfoil FX 71-L-150/25 DOCUMENT NUMBER: L500-912.820 ISSUE JUL 20, 2016 AMENDMENT: 00 DATE: -- CHAPTER-PAGE 2-3 MAINTENANCE MANUAL STEMME S12 VERTICAL TAIL Design Web GFRP, skin CFRP, rudder GFRP-sandwich. Span 1.60 m 5.25 ft Area 1.78 m² 19.16 sqft Airfoil FX71-L150/30 x*1.3 WEIGHTS Max. T/O-weight 900 kg 1984 lb Empty weight 690 kg (approx., min. equipment.) 1556 lb Maximum weight of non-lifting parts 610 kg 1345 lb Total useful load (Occupants, fuel, baggage) 210 kg 463 lb WING FLAPS (CENTER WING) Span 4.39 m 14.40 ft Area 0.75 m² 8.07 sqft Flap positions: -10°, -5°, 0°, +5°, +10°, L (+16°) AILERONS (OUTER WINGS AND EXTENSIONS) Span 5.70 m + 1.50 m 18.70 ft + 4.92 ft Area 0.78 m² + 0.13 m 2 8.40 sqft. + 1.40 sqft LANDING GEAR 2 main wheels with brake discs, rim of wheel 127x127-30 Tire size 6.00-5 Wheel track 1.36 m 4.46 ft Tail wheel (steerable), tire size 210 x 65 Wheel base 5.46 m 17.91 ft DOCUMENT NUMBER: L500-912.820 ISSUE JUL 20, 2016 AMENDMENT: 00 DATE: -- CHAPTER-PAGE 2-4 MAINTENANCE MANUAL STEMME S12 ENGINE Design 4-cylinder 4-stroke-Otto-motor, opposed type, turbocharged, electronic manifold pressure control integrated reduction gear. Type ROTAX 914 F2-01/S1 Engine reduction gear ratio i = 2.4286 Bore 79.5 mm 3.13 in Stroke 61 mm 2.40 in Displacement 1211 cm3 73.9 cubic in Compression ratio. 9.0 Drive shafts turns. Clockwise Max. T/O power. 84.5 kW at 5800 RPM 113.2 hp Max. cont. power. 73.4 kW at 5500 RPM 98.4 hp Fuel flow at T/O power (115%). 33.0 l/h 8.72 US gal. / h 7.26 Imp.gal. / h Fuel flow at max cont. power (100%). 27.2 l/h 7.19 US gal. / h 5.98 Imp.gal. / h Fuel flow at 75% power. 20.4 l/h 5.34 US gal. / h 4.49 Imp.gal. / h Specific fuel consumption at max. cont. power (100%). 276 g/kWh 0.454 lb / hph DOCUMENT NUMBER: L500-912.820 ISSUE JUL 20, 2016 AMENDMENT: 00 DATE: -- CHAPTER-PAGE 2-5 MAINTENANCE MANUAL STEMME S12 PROPELLER Design 2-blade folding propeller, CFRP blades, propeller hub and blade suspension. Forks aluminum. Pitch control via electrically heated thermo elements. Type STEMME 11 AP-V Propeller diameter 1.63 m 5.35 ft Mass of the propeller (incl. outer-casing of needle bearing and rubber buffers) 9350 g 20.61 lb Overall mass of propeller blade 650 g ± 10 g 1.433 lbs ± 0.022 lb Max. propeller 2.650 RPM Propeller blade angle (station 0.7) 17.65° in T/O 24.05° in cruise. Propeller blade pitch (station 0.7) 114 cm / 44.9 in (T/O position) 160 cm / 63.0 in (cruise position) Max. current consumption of both resistor elements 10 A Propeller turns Counter-clockwise IN-FLIGHT CENTER OF GRAVITY RANGE In-flight center-of-gravity range aft of datum (See section 6.3 for center wing leading edge) 265 - 420 mm 10.41 in - 16.5 in PROPELLER GEARBOX Design Helical spur gear, aluminum alloy-housing, elastic mounting in rubber elements. Type STEMME 11AG Drive shaft turns Clockwise Ratio of propeller gearbox i = 1.109 DOCUMENT NUMBER: L500-912.820 ISSUE JUL 20, 2016 AMENDMENT: 00 DATE: -- CHAPTER-PAGE 2-6 MAINTENANCE MANUAL STEMME S12 FUEL SYSTEM Design 2 FRP-tanks in wing center section + 1 feeder tank, 1 electrical fuel transfer pump for each wing-tank + 2 electrical pumps from feeder tank to the engine. Maximum fuel volume 126.0 l (± 2%) 33.28 US gal. 27.72 Imp.gal. Unusable fuel 1.4 l 0.37 US gal. 0.31 Imp.gal. NOTICE For more technical data, please refer to the S12 Aircraft Flight Manual. DOCUMENT NUMBER: L500-912.820 ISSUE JUL 20, 2016 AMENDMENT: 00 DATE: -- CHAPTER-PAGE 2-7 MAINTENANCE MANUAL STEMME S12 2.2 THREE VIEW DRAWING Figure 2.2.a Three View Drawing of the S12 1.36 m / 4.46 ft 9.9 m / 32.48 ft 9.9 m / 32.48 ft 25.07 m / 82.25 ft 8.4 m / 27.56 ft 8.4 m / 27.56 ft 1.63 m / 5.35 ft 1.75 m / 5.74 ft 1.75 m / 5.74 ft 1.9 m / 6.23 ft DOCUMENT NUMBER: L500-912.820 ISSUE JUL 20, 2016 AMENDMENT: 00 DATE: -- CHAPTER-PAGE 2-8 MAINTENANCE MANUAL STEMME S12 THIS PAGE IS INTENTIONALLY LEFT BLANK DOCUMENT NUMBER: L500-912.820 ISSUE JUL 20, 2016 AMENDMENT: 00 DATE: -- CHAPTER-PAGE 3-1 MAINTENANCE MANUAL STEMME S12 3. DESCRIPTION OF ASSEMBLIES 3.1 AIRFRAME, PRIMARY AND SECONDARY STRUCTURE The Primary Structure includes: • Wing spars, root ribs, and wing spar boxes • Wing shells • Center steel frame • Tail boom and vertical stabilizer • Front section of fuselage • Horizontal stabilizer • Fittings The Secondary Structure includes: • Control surfaces • Cowlings, cooling air system ducts, cockpit components 3.1.1 WING Structural design: 5 sections; CFRP-Spar with GFRP-shearweb, CFRP-sandwich skin. The wing consists of four sections: A wing center section with a span of 9.9 m / 32.48 ft, two outer wing sections and two wing extensions including winglets with a length of 1.9 m / 6.23 ft each. Attachment of the wing center section to the fuselage is by means of four sliding bolts, attachment of the outboard wings to the wing center section as well as the connection of wing extensions to the outer wings is with one sliding bolt each. A removable fairing covers the wing/fuselage junction. Beneath the fairings, free access to the wing attachment, the control system joints and the combined aileron/flap controls is possible. For disassembly, the wing center section can be lifted vertically. The flaps extend over the total span of the wing center section and the ailerons over the total span of the outboard wings. The controls of flaps and ailerons are interconnected (“flaperons”), the ailerons acting as differential flaps and the flaps acting as differential ailerons. The flap deflec- tion is reduced from the inner to the outer wing, the aileron deflection is reduced from the outer wing to the wing center section and from up to down deflections (differential aileron deflection). The ailerons of the wing extension are directly connected to those of the outer wing and have no separate actuation. Two-blade Schempp-Hirth air brakes are installed on the wing center section upper surface. The flaps and aileron gaps are sealed with elastic adhesive tape and a sliding layer on the upper surface of the wing and with a textile tape (optional: elastic adhesive tape and sliding layer) on the lower surface. A boundary layer turbulator (adhesive 60° zigzag tape, leading edge at 69% of chord, 12 x 0.5 mm / 0.47 x 0.02 in) on the wing lower surface ensures a defined flow transition. DOCUMENT NUMBER: L500-912.820 ISSUE JUL 20, 2016 AMENDMENT: 00 DATE: -- CHAPTER-PAGE 3-2 MAINTENANCE MANUAL STEMME S12 3.1.2 FUSELAGE The fuselage is a modular construction of three assemblies with bolted joints: The forward fuse- lage section (CFRP) construction, the center fuselage framework (steel frame) and the tail boom (CFRP construction). Loads from the fuselage front section, the wing, the landing gear, the power-plant and the tail unit are transmitted by center steel frame. The center fuselage framework is covered by self-supporting fairings (upper fairing and engine cowlings LH / RH as well as lower fairing) of GFRP sandwich. The attachment of the fairings is by means of camlocks, which can be easily opened with a screw-driver. The upper fairing includes an oil service access door, which can be opened without a tool. 3.1.3 TAIL UNIT Horizontal Tail • T-arrangement, easily removable (simple spring-bolt connection), • Stabilizer as sandwich construction of CFRP, elevator made of CFRP. • Elevator gaps sealed by elastic tape. • Boundary layer turbulator (adhesive 60° zigzag tape, leading edge at 65% of chord, 12 x 0.5 mm / 0.47 x 0.02 in) on upper and lower side for defined flow transition. Vertical Tail • Stabilizer as a sandwich construction of CFRP, rudder as a sandwich construction of GFRP, • Rudder gap sealed by elastic tape with integrated zigzag turbulator (combi-tape), • COM antenna integrated in rudder. 3.2 COCKPIT 3.2.1 GENERAL The two seats are arranged side by side (forward of the wing) and the S12 is equipped with dual controls. The FRP seat backrests are multi-adjustable. Each seat is equipped with 4-point seat belts with a center locking mechanism. Between the seats a console covers both systems and the drive shaft tunnel. The instrument panel is designed in mushroom-style panel arrangement. The one-piece canopy is hinged at the front and held in its opened position by two gas springs. Three canopy locks on each side of the canopy frame, left hand and right hand side, are operated by one locking lever on each side. The locking levers are mechanically interconnected by two bowden cables so that they act simultaneously. One additional lock to improve canopy emergency jetti- soning (“Röger-hook”) is installed in the rear upper canopy frame, operated by adjacent handle. DOCUMENT NUMBER: L500-912.820 ISSUE JUL 20, 2016 AMENDMENT: 00 DATE: -- CHAPTER-PAGE 3-3 MAINTENANCE MANUAL STEMME S12 The emergency jettison will be activated by opening either lateral locking lever on canopy side (operating one is sufficient) and the red T-shaped handle on the instrument panel. Canopy hinge opens and is lifted approximately 0.1 m / 4 in by a gas spring. The “Röger-hook” must remain closed, since it is the axis of rotation until the canopy is jettisoned. The cockpit is ventilated via two nozzles (LH and RH side) in the instrument panel. The canopy ventilation is via openings in the instrument panel cover. 3.2.2 CONTROL ELEMENTS AND INSTRUMENTS COCKPIT CONTROLS AT THE AIRFRAME Following overview includes the controls at the airframe. No. Name of Control Airframe Position 1. Control Stick Centered in front of each seat. 2. Rudder Pedals For each seat and adjustable. The pedals also steer the tail wheel, which is coupled to the rudder via spring device. 3. Airbrake Lever At the LH side of each seat. Blue lever at LH cockpit side and on the center console between seats. 4. Flap Lever At the LH side of each seat. Black lever at LH cockpit side and on the center console. Indication of settings (-10, -5, 0, +5, +10, L) in center console. Unlocking is by moving lever to the right against a spring force which locks the flap positions. 5. Pedal Adjustment Handle In front of each seat. Unlocking is by pulling the handle. 6. Canopy Locks Two white handles with red stripe, one on left and one on right side of the canopy frame, to open and lock the can- opy. The handles are mechanically connected so that both always move simultaneously. In addition a white handle at rear top center of the canopy is provided to insure correct movement of the canopy during jettison (“Röger-hook”). 7. Brake Lever Lever on each control stick. Separate lever for parking brake valve on the floor panel console in front of the LH control stick. 8. Trim Knob A green switch on the control stick. 9. Throttle Lever One black lever on center console with two forward stops (For max. continuous and max. T/O-power). It is coupled with a spring acting forward in direction FULL POWER. Its position is fixed by friction discs, which can be adjusted with a knurled knob on LH side of the center console. 10. Choke Lever Black lever on center console, RH side of the throttle lever. It is coupled with a spring acting rearward in direction CHOKE OFF. Its position is fixed by friction discs, which can be adjusted with a knurled knob on RH side of the center console. DOCUMENT NUMBER: L500-912.820 ISSUE JUL 20, 2016 AMENDMENT: 00 DATE: -- CHAPTER-PAGE 3-4 MAINTENANCE MANUAL STEMME S12 No. Name of Control Airframe Position 11. Propeller Pitch Switch on center console. The forward position is the TAKE- OFF position. A green light located in the upper area of left instrument panel indicates if propeller pitch (not switch) is in T/O)-position. 12. Fuel Valve Red handle on the rear console between the seat back rests. Turning the handle into its horizontal position (fuel valve CLOSED) cuts off the fuel supply for the engine. NOTICE Throttle positions for 115% and 100% can be selected by feel. The first stop is the 100% throttle position. To select 115% the throttle lever must be moved through a throttle gate to the left and then pushed to the next stop. DOCUMENT NUMBER: L500-912.820 ISSUE JUL 20, 2016 AMENDMENT: 00 DATE: -- CHAPTER-PAGE 3-5 MAINTENANCE MANUAL STEMME S12 3.2.3 CONTROLS AT THE INSTRUMENT PANEL The following overview includes controls in the lower area of the instrument panel. These elements are included in figure »3.2.3.a Arrangement of Elements on the Instrument Panel«, see section »3.2.4«. No. Name of Control Airframe Position 1. Emergency Canopy Release Red pull-handle on LH side of the switch panel. It is pulled for emer- gency canopy jettison after opening the canopy locks on LH or RH side of the canopy frame. 2. Cowl Flap Adjustment Black T-handle on LH side of the lower middle section of the in- strument panel to reduce engine cooling in cruise condition. The foremost position means cowl flaps fully OPEN, 5 settings aft are available to reduce the opening of the cowl flaps. 3. Nose-cone Operation Black handle in the bottom center of the instrument panel to open, close and lock the nose-cone, linked to the engine electric master switch. Unlock by lifting, lock by pushing down the handle. In the forward position (Nose-cone OPEN) the engine master switch turns ON when nose-cone is LOCKED. 4. Propeller Brake Black T-handle to the RH side of the cowl flap adjustment to brake the propeller to a full stop after engine has been switched off in flight. Braking is by pulling the handle. 5. Propeller Positioning Black T-handle to the RH side of the propeller brake to position the propeller to fit within the nose-cone contour. Operation is by a slow and steady pull on the handle to its stop. 6. Air Vents Two adjustable air vents for cockpit ventilation, one on LH and one on RH side of the Instrument panel, are provided. 7. Canopy Ventilation Knob on RH side of the ignition/starter switch to ventilate the can- opy. The pulled position means canopy ventilation OPEN. 3.2.4 INSTRUMENT PANEL The following description gives an overview of instruments, controls, monitor devices and CB’s installed on the instrument panel. The minimum Equipment List of the S12 Aircraft Fligth Manual is relevant. The positions of the elements are shown in figure »3.2.3.a Arrangement of Elements on the In- strument Panel«, valid for the aircraft serial number as indicated on the title page of this Aircraft Maintenance Manual. The flight control instruments include at least 1. One ASI (airspeed range 50 – 300 km/h / 27 – 162 kt), 2. One Altimeter, 3. One magnetic compass, 4. Trim indicator display. These instruments are located directly in the view area of the PIC (in front of LH seat). Dual in- strumentation is possible to provide an optimum view on flight control instruments from the RH DOCUMENT NUMBER: L500-912.820 ISSUE JUL 20, 2016 AMENDMENT: 00 DATE: -- CHAPTER-PAGE 3-6 MAINTENANCE MANUAL STEMME S12 seat (e. g. instruction flights). Additional avionics may be installed on customer demands and concurrent applicable approval. Engine monitoring includes at least: • Tachometer • Oil pressure and oil temperature • Cylinder head temperature (CCT) LH and RH • Voltmeter and ammeter • Fuel quantity in LH and RH wing tanks • Engine hour-meter These instruments are located as a rule, with the exception of the engine hour-meter, in the RH area of the panel, if not installed (i. e. with dual flight instrumentation) in the center area. The engine hour-meter is located on the center console between the seats. The red fire-warning light (test by pushing light for optic and acoustic signal) is adjacent to the engine instrumentation. The following warning and monitoring lights are combined in a group, arranged independently of its location on the instrument panel. They inform the pilot about the proper condition of the aircraft at a glance. The group is always located at the upper instrument panel below the glare shield to allow for glare-free reading. The following lights are arranged: A. Red fuel pressure warning, B. Yellow low fuel warning, C. Green status indication for fuel aux pump operation, D. Red warning light for manifold pressure (boost pressure), E. Yellow caution light for malfunction of TCU, F. Red warning light for malfunction of external alternator (battery charge control), G. Yellow caution light for malfunction of internal generator. The landing gear position and warning indication is also located below the glareshield and consists of two lights, indicating the situation with green or red steady or flashing light. The following CB´s are combined in a group, arranged independently of its location at the panel: • Master CB, • CB for external alternator, • Landing gear CB, • CB´s for main, transfer and auxiliary fuel pumps.