RV-12 MAINTENANCE MANUAL

O VERVIEW ....................................................................................................................... 2-1 CHAPTER 3- INSPECTION .............................................................................................. 3-1 O VERVIEW ....................................................................................................................... 3-1 I NSPECTION DESCRIPTION ................................................................................................. 3-3 Pre-inspection / Post-inspection .................................................................................. 3-3 Cockpit ........................................................................................................................ 3-5 Radio ........................................................................................................................... 3-7 Optional Equipment ..................................................................................................... 3-7 Emergency Locator Transmitter .................................................................................. 3-7 Propeller ...................................................................................................................... 3-7 Printed Copies Are Uncontrolled Rev: 9 vi Engine ......................................................................................................................... 3-8 Firewall Forward .......................................................................................................... 3-8 Fuselage ................................................................................................................... 3-10 Landing Gear ............................................................................................................ 3-11 Wing / Center Section/AOA ...................................................................................... 3-12 Rear Spar Doubler .................................................................................................... 3-13 Empennage ............................................................................................................... 3-14 Angle-Of-Attack System ............................................................................................ 3-17 Paperwork ................................................................................................................. 3-17 CHAPTER 4 - STRUCTURAL REPAIRS ......................................................................... 4-1 O VERVIEW ....................................................................................................................... 4-1 MINIMUM CERTIFICATION ................................................................................................... 4-2 CHAPTER 5 - STRUCTURES .......................................................................................... 5-1 O VERVIEW ....................................................................................................................... 5-2 FUSELAGE ........................................................................................................................ 5-2 W ING AND FLAPERON ....................................................................................................... 5-4 E MPENNAGE ..................................................................................................................... 5-6 L ANDING G EAR ................................................................................................................. 5-8 FAIRINGS - WHEEL AND GEAR LEG ..................................................................................... 5-10 S ERVICE ........................................................................................................................ 5-12 CHAPTER 6 - FLIGHT CONTROLS ................................................................................. 6-1 O VERVIEW ....................................................................................................................... 6-2 S ERVICE .......................................................................................................................... 6-3 CHAPTER 7 - BRAKE SYSTEM ...................................................................................... 7-1 O VERVIEW ....................................................................................................................... 7-2 S ERVICE .......................................................................................................................... 7-2 CHAPTER 8 - ELECTRICAL SYSTEM ............................................................................ 8-1 O VERVIEW ....................................................................................................................... 8-2 S ERVICE .......................................................................................................................... 8-4 CHAPTER 9 - INSTRUMENTS & AVIONICS ................................................................... 9-1 O VERVIEW ....................................................................................................................... 9-2 P ITOT & S TATIC ................................................................................................................ 9-3 S ERVICE .......................................................................................................................... 9-4 Printed Copies Are Uncontrolled Rev: 9 vii CHAPTER 10 - UTILITY SYSTEMS ............................................................................... 10-1 O VERVIEW ..................................................................................................................... 10-2 HEAT ............................................................................................................................. 10-2 V ENTILATION .................................................................................................................. 10-3 S ERVICE ........................................................................................................................ 10-4 CHAPTER 11 - PROPELLER ......................................................................................... 11-1 O VERVIEW ..................................................................................................................... 11-2 S ERVICE ........................................................................................................................ 11-2 Prop & Hub ............................................................................................................... 11-3 CHAPTER 12 - FIREWALL FORWARD......................................................................... 12-1 O VERVIEW ..................................................................................................................... 12-2 Engine ...................................................................................................................... 12-3 S ERVICE ........................................................................................................................ 12-3 CHAPTER 13 - FUEL SYSTEM ...................................................................................... 13-1 O VERVIEW ..................................................................................................................... 13-2 Fuel System Schematic ............................................................................................ 13-3 S ERVICE ........................................................................................................................ 13-3 CHAPTER 14 - EXHAUST SYSTEM .............................................................................. 14-1 O VERVIEW ..................................................................................................................... 14-2 S ERVICE ........................................................................................................................ 14-3 CHAPTER 15 - PAINTING AND COATINGS ................................................................. 15-1 O VERVIEW ..................................................................................................................... 15-2 S ERVICE ........................................................................................................................ 15-3 CHAPTER 16 - TROUBLESHOOTING .......................................................................... 16-1 CHAPTER 17 - FEEDBACK & REPLACEMENT PARTS .............................................. 17-1 REPORTING METHODS .................................................................................................... 17-1 REPLACEMENT P ARTS ..................................................................................................... 17-2 S UBSTITUTE P ARTS ........................................................................................................ 17-3 CHAPTER 18 - SUPPLEMENT ...................................................................................... 18-1 S ERVICE S CHEDULE ........................................................................................................ 18-3 I NSPECTION CHECKLIST .................................................................................................. 18-7 3-V IEW ........................................................................................................................ 18-25 FEEDBACK FORM .......................................................................................................... 18-27 Printed Copies Are Uncontrolled Rev: 9 viii CHAPTER 19 - GLOSSARY ........................................................................................... 19-1 CHAPTER 20 - INDEX .................................................................................................... 20-1 NOTE: Pages 1-21 and 1-22 correspond to a particular EFIS installation. Please remove all pages that do not correspond to your EFIS. Specific EFIS type is noted next to the page number. APPENDIX ‘A’ - KIT ASSEMBLY INSTRUCTIONS (KAI) (NOT PART OF, BUT AN APPENDIX TO THIS MANUAL) Addendum Documents list (Notification, Service Bulletin, etc.) DOCUMENT NAME DATE ADDED Printed Copies Are Uncontrolled Rev: 9 ix TABLE OF ILLUSTRATIONS Figure 1: Tools .................................................................................................................. 1-9 Figure 2: Oil Viscosity...................................................................................................... 1-13 Figure 3: Lifting and supporting ....................................................................................... 1-17 Figure 4: Remove for inspection ....................................................................................... 3-4 Figure 5: Control Stops ..................................................................................................... 3-6 Figure 6: Rivet Inspection................................................................................................ 3-10 Figure 7: Wing Retention Pin Bushing............................................................................. 3-13 Figure 7.1: Inspect Rear Spar Doubler ............................................................................ 3-14 Figure 8: Rudder Stop ..................................................................................................... 3-15 Figure 9: Fuselage ............................................................................................................ 5-3 Figure 10: Wing and Flaperon ........................................................................................... 5-4 Figure 11: Empennage ...................................................................................................... 5-6 Figure 12: Landing Gear ................................................................................................... 5-8 Figure 13: Nose Wheel and Gear Leg Fairings ............................................................... 5-10 Figure 14: Main Wheel Fairings ...................................................................................... 5-11 Figure 15: Flaperon hinge ............................................................................................... 5-18 Figure 16: Extracting the DW4K2X bearing..................................................................... 5-20 Figure 16.1: Rear Spar Doubler Replacement ................................................................ 5-24 Figure 17: Locking clip removal ......................................................................................... 6-4 Figure 18: Tensioner barrel removal ................................................................................. 6-4 Figure 19: Torque tube lubrication .................................................................................... 7-4 Figure 20: Optional Wing Tip Lighting ............................................................................... 8-3 Figure 21: Fuse panel ....................................................................................................... 8-6 Figure 22: Trim/Servo assembly removal .......................................................................... 8-8 Figure 23: Pitch-trim servo removal................................................................................... 8-8 Figure 24: Stall warning ground ...................................................................................... 8-10 Figure 25: Snap Bushing ................................................................................................. 8-13 Figure 26: Rotax 912ULS ................................................................................................ 12-3 Figure 27: Carburetor Overview ...................................................................................... 12-8 Figure 28: Mixture Screw ................................................................................................ 12-9 Figure 29: Throttle Handle Idle Position ........................................................................ 12-10 Figure 30: Vacuum Gauge ............................................................................................ 12-11 Figure 31: Fuel Pressure Hose Flush .............................................................................. 13-9 Printed Copies Are Uncontrolled Rev: 9 x THIS PAGE INTENTIONALLY LEFT BLANK Printed Copies Are Uncontrolled Rev. 10 1–1 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 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. Printed Copies Are Uncontrolled Rev. 10 1–2 SCOPE xx 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. All of the service and maintenance requirements that are unique to the RV-12 S- LSA are included in this manual. The general service and maintenance duties that are common to standard aircraft still apply to the RV-12 regardless of the inclusion of those requirements in this manual. All inspection and maintenance and all maintenance log entries must be made in accordance with 14 CFR / FAR’s. The manufacturers of third party components provide manuals that include complete service and maintenance requirements that are specific to these components. The current service and maintenance manuals from any third party manufacturer, such as; engine, propeller, avionics, etc. always take precedence over the related content in this manual. There are references to third party documentation in this manual, as well as some supplementary information which is for convenience only. It is recommended to refer directly to the manufacturer’s service manuals for complete service information that is unique to applicable components. The manufacturers that provide operating and/or maintenance manuals to use in conjunction with this manual are as follows: i Rotax – engine i Sensenich – propeller i Matco – wheels and brakes i Dynon – EFIS / EMS i Garmin – EFIS / EMS, GPS and Nav/comm i TCW – Backup Battery i FlightCom – intercom i ACK – ELT i Artex – ELT i Odyssey – battery i Van’s Aircraft  RV-12 Kit Assembly Instructions (KAI). The service and inspection portions of this manual indicate the minimum certification requirements for a person doing maintenance or repairs on the RV-12. Certification requirements for service and maintenance may vary around the world. It is essential to determine the correct and legal maintenance and certification requirements applicable to the area that the airplane is registered. The documents necessary to determine these requirements for S-LSA in the United States are as follows: i RV-12 Maintenance Manual i RV-12 Kit Assembly Instructions i Federal Aviation Regulations for Light Sport Aircraft Maintenance Technicians iAircraft Inspection, Repair, and Alterations, AC 43.13. Printed Copies Are Uncontrolled Rev. 10 1–3 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 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 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 one) in parenthesis. For example, an instruction step that requires the removal of one Printed Copies Are Uncontrolled Rev. 10 1–4 bolt, six washers and two nuts will appear as follows: 1. Remove the bolt, washers (6), and nuts (2). Chapter 16 offers direction for solving potential problems that may puzzle the owner of any aircraft. Chapter 17 provides instructions for reporting the discovery of anomalies that could compromise the 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 when applicable. Maintenance or repair classified in this manual as owner and SPC and in 14 CFR, FAR 43 Appendix 'A' can be done by an RV-12 owner or operator that possesses a Sport Pilot certificate or higher. An LSA repairman certificate with a maintenance rating or an FAA issued A&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 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. Printed Copies Are Uncontrolled Rev. 10 1–5 SAFETY OF FLIGHT REPORTING PROCEDURE To maintain the highest level of safety and as dictated in ASTM F 2295 Section 5, the FAA requires, and Van’s Aircraft Inc. requests notification of any safety of flight issue, or service or maintenance difficulties that could compromises the airworthiness of the RV-12 aircraft. A feedback form is provided in the Supplement section of this manual. Refer to Chapter 17 for a description of a valuable report and the different reporting methods available. HELPFUL TERMINOLOGY ▲ WARNING: INDICATES AN ACTION NECESSARY TO PREVENT INJURY OR DEATH . ■ CAUTION: INDICATES AN ACTION NECESSARY TO PREVENT DAMAGE TO PARTS OR PROPERTY . ● NOTE: PROVIDES VALUABLE ADDITIONAL INFORMATION . The Glossary provides definitions to many of the terms used throughout this manual. Printed Copies Are Uncontrolled Rev. 10 1–6 ABBREVIATIONS A&P* Airframe and Power-plant Mechanic Kph Kilometers per hour AKI Anti-knock index (octane rating) Kts Knots API American Petroleum Institute lb U.S. pound AST* Anti-servo/trim tab LL Low-Lead AVGAS Aviation Gasoline LSA Light Sport Aircraft C Celsius LSA-RM* Light Sport Aircraft – Repairman Maintenance rating CG Center of Gravity ltr Liter CHT Cylinder Head Temperature m meter cm Centimeter Max Maximum CST* Category specific training mb millibar EFIS* Electronic Flight Information System mi Statute mile EGT Exhaust Gas Temperature Min Minimum ELT* Emergency Locating Transmitter ml Milliliters EMS Engine Monitoring System mm Millimeter F Fahrenheit mph miles per hour FAA United States Federal Aviation Administration naut mi Nautical miles FAR’s Federal Aviation Regulations Nm Newton meters fl. oz. fluid ounce (U.S.) OAT Outside Air Temperature ft Feet oz Ounce ft/lbs Foot-Pounds POH* Pilot Operating Handbook FWD Forward psi Pounds per Square Inch gal Gallon pt Pint (U.S.) GPS* Global Positioning System RON Research Octane Test HP Horse Power RPM Revolutions Per Minute ID Inner Diameter S-LSA* Special Light Sport Aircraft in Inch (depending on context) S/N Serial Number in² Square inches SAE Society of Automotive Engineers in/lb Inch-Pound SPC* Sport Pilot Certified KAI* Kit Assembly Instructions TT Total Time kg kilogram VDC Voltage, Direct Current kPa Kilopascal * -- See glossary for definition Printed Copies Are Uncontrolled Rev. 10 1–7 UNITS : Speed: 1 mph = 1.64 kph = 0.869 kts Distances: 1 in = 2.54 cm 1 ft = 12 in = 0.305 m 1 mi = 5,280 ft = 1.61 km 1 naut mi = 1.15 mi = 1.85 km Mass: 1 oz = 28.3 grams 1 lb = 16 oz = 0.454 kg Pressure: 1 psi = 6.895 kPa 1 mb = 0.1 kPa Volume: 1.8 cubic in = 1 fl. oz = 29.57 ml 1 quart = 2 pints = 32 fl. oz 1 gal = 8 pints = 3.79 ltr Torque: = 1 in/lb = 0.113 Nm 1 ft/lb = 12 in/lb = 1.356 Nm Temperature: (F-32)/1.8 = (1.8 x C)+32 Printed Copies Are Uncontrolled Rev. 10 1–8 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 i Combination wrenches: ƒ 1/4 ƒ 5/16 ƒ 11/32 ƒ3/8 ƒ7/16 (2) ƒ1/2 ƒ9/16 ƒ11/16 ƒ1 1/2 i Ratchet iSockets: ƒ 5/16 ƒ 11/32 ƒ3/8 ƒ7/16 ƒ1/2 ƒ9/16 ƒ3/4 ƒ1 1/2 ƒ10 mm ƒ11 mm ƒ13 mm  i Allen wrenches: ƒ 3/16 ƒ 1/4 ƒ 5/16 ƒ 4mm ƒ 5mm ƒ 6mm ƒ 8mm  i Torque wrench (in/lbs & ft/lbs) i 5/8 or 16 mm spark plug socket i Screwdrivers: ƒ#2 Phillips ƒ#3 Phillips ƒ3/16 Flat Blade i Power-drill i #30 drill bit i Blind rivet tool i Straight edge i Razor knife i Flashlight i Step ladder i Wire cutters i Battery charger i Multi-meter i Syringes i Wooden dowels 1/2 - 1 inch dia. and 1 1/2 - 1 3/4 in. dia. i Oil Filter wrench i Oil Filter cutter and mallet i Two 25 in. padded stands each rated to support a minimum of 500 pounds i Container (various sizes, suitable for petroleum) i 24-inch length of 1/2-inch I.D. fuel hose i Scouring pad or equivalent i Sandpaper (various grades) i Spark plug gap tool (wire type) i Compression tester i Magnifying Glass i Small square i Tire air pressure gauge i Needle nose pliers i 5-inch “C” clamp i Terminal crimping tool i Locking (vice grip style) pliers i 2 1/2 x 3/16 bolt, washer, nut i Vacuum gauge set i Portable weight scale (tension type) i Fire extinguisher i Pump style oil can with hose i Safety wire twisting pliers ● NOTE: T OOLS DIFFER IN SIZE AND CONFIGURATION . THE FOLLOWING ILLUSTRATIONS ARE ONLY EXAMPLES OF WHAT A TOOL MAY LOOK LIKE. ● NOTE: THIS TOOL LIST DOES NOT INCLUDE ALL OF THE TOOLS SUGGESTED FOR THE I NSPECTION PROCEDURES . TOOLS Printed Copies Are Uncontrolled Rev. 10 1–9 Combination Wrenches Ratchet Screwdrivers Sockets Allen Wrenches Gap Gauge Oil Filter Cutter Heavy Stands Step Ladder Oil Filter Wrench Battery Charger Multi-meter Magnifying Glass Square Air Pressure Gauge Figure 1 Printed Copies Are Uncontrolled Rev. 10 1–10 Razor Knife Flashlight Needle-nose Pliers C-clamp Terminal Crimper Wire Cutter Locking Pliers Blind Riveter Power-drill Hardware Dual Vacuum Gauge Tensile Weight Scale Figure 1 Printed Copies Are Uncontrolled Rev. 10 1–11 ■ CAUTION: R EPLACEMENT PARTS MUST BE OF EQUIVALENT SIZE, TYPE 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 Tire U-5:00X5 Tire (any aircraft grade 5:00X5, 4 or 6 ply tire is acceptable. Inner tube U 5:00X5-6IT (any aircraft grade 5:00X5-6 inner tube is acceptable) Brake shoe linings M66-106 (or equivalent) Fuses ATO/ATC ¼ “ 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. LUBRICANTS RECOMMENDATION OR EQUIVALENT Engine oil As specified in latest Rotax documentation Spray lubricant LPS2 or Tri-Flow Dry lubricant (candle wax, etc.) TOOL BOELUBE PASTE Wheel bearing grease Aeroshell 22 or equivalent Thread-lube Loctite 567 or equivalent Anti-seize compound, High temp Loctite Anti-Seize or equivalent Hydraulic fluid MIL-H-5606A or MIL- PRF-83282 Air filter oil EA K&N 99-5050 KIT MISCELLANEOUS RECOMMENDATION OR EQUIVALENT Engine coolant 1:1 Water/Ethylene Glycol (refer to Rotax engine documentation) Safety wire WIRE SAFETY .032 Fuel tank sealant MC-236-B1/2 or MC-236-B2 Plexus Cleaner/Polish CA CANOPY CLEANER Cotter pins MS24665-xyz Plastic tie wraps Non-specific Wire terminals Male & Female spade, splice, and ring Blind rivets LP4-3 (unless otherwise specified) Grey touch-up paint PAINT, TOUCHUP PGRAY Cardinal gray #3607-GR-230 Primer Any protective primer suitable for use on aluminum and/or steel as appropriate Decorative touch-up paint From paint process Printed Copies Are Uncontrolled Rev. 10 1–12 ENGINE ● NOTE: T HE ENGINE SPECIFICATION INFORMATION IS REFERENCED FROM THE R OTAX 912 SERIES , OPERATOR’S MANUAL , OM R EV .4. SUMMARY Make Rotax 912 ULS Displacement 1352 cc Ignition Ducati Double CDI Carburetor Bing 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. Printed Copies Are Uncontrolled Rev. 10 1–13 LUBRICATION AND CAPACITIES ENGINE OIL ■ CAUTION: ONLY USE API CLASS 'SG' OR HIGHER .  ■ CAUTION: DO NOT USE OILS WITH FRICTION MODIFIER ADDITIVES . ■ CAUTION: DO NOT USE OILS FOR “CONVENTIONAL” AIRCRAFT ENGINES . ■ CAUTION: DO NOT USE OILS DESIGNED FOR DIESEL ENGINES . i Capacity: 3 ltr (3.2 US qts) i The type of oil to use will be based on the type of fuel used. i Refer to the Rotax operator’s manual to determine which oil type is compatible with the fuel being used. i See Figure 2 to determine the viscosity best suited for the use of the aircraft. Figure 2: Oil Viscosity BRAKE FLUID ▲ WARNING: N EVER USE AUTOMOTIVE BRAKE FLUID . Use Mil Spec 5606A or MIL-PRF-83282 Brake fluid draining, flushing, and replacing instructions Page 7-5. C APACITY: 15.4 fl. oz. (US) (.455 liters) Printed Copies Are Uncontrolled Rev. 10 1–14 ENGINE COOLANT SUITABLE COOLANTS C OOLANT MIX: 50% ethylene glycol concentrate with anticorrosion additives designed for aluminum without sulfates and phosphates,. 50% distilled or de-mineralized water. See the latest version of the Rotax Operators Manual and SI 912-016 for further information on coolant types and limitations. C APACITY: 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 F UEL 91 AKI (premium unleaded automotive) 100 LL Aviation Fuel See the latest version of the Rotax Operators Manual and SI 912-016 to determine other approved fuel types, limitations and maintenance considerations. C APACITY: 19.8 US Gallons (75.0 liters) TIRE PRESSURES NOSE TIRE - 22 psi (23 psi maximum) MAIN TIRES - 25 psi (28 psi maximum) Printed Copies Are Uncontrolled Rev. 10 1–15 TORQUE VALUES Torque applied is for the size of the bolt shank not the wrench size. On smaller bolts use a torque wrench calibrated in inch pounds, not foot pounds. When tightening fasteners with self-locking nuts the chart values must be modified. The friction drag torque must be determined and then added to the standard torque from the table. Due to the friction of the locking device noticeable torque is required just to turn the nut onto the threads and does nothing to actually tighten the parts together and stretch the bolt (clamp load). This is called friction drag (or prevailing) torque. Run the nut down to where it nearly contacts the washer or bearing surface and check the friction drag torque required to turn the nut. (At least one thread should protrude from the nut). Add the friction drag torque to the standard torque. This sum is referred to as the final (or total) torque, which should register on the indicator or setting for a snap-over type torque wrench. The propeller manufacturer and the engine manufacturer have specific torque requirements for their equipment. Consult the appropriate manual for that information. ft-lb in-lb N-m Oil Tank Drain Screw 18 220 25 Oil Filter Contact + 3/4 Turn or as Specified Magnetic Plug 18 220 25 Water Pump Drain Screw 8 90 10 Carburetor Socket Screws 11 135 15 Spark Plugs 16mm 15 180 20 Exhaust Nuts 9 106 12 AN Bolt size Bolt size - Threads per inch Standard nuts AN310, AN315,MS20365 Inch pounds Foot Pounds AN3 #10-32 20-25 1.6-2.0 AN4 1/4-20 50-70 4.2-5.8 AN5 5/16-24 (with plain washers) 5/16-24 (with NORD LOCK washers) 100-140 220-240 8.3-11.6 18.3-20 AN6 3/8-24 160-190 13.3-15.8 AN7 7/16-20 450-500 37.5-41.7 AN8 1/2-20 480-690 40-57.5 AN9 9/16-18 800-1000 66.6-83.3 AN10 5/8-18 1100-1500 91.6-125 (Portions of this information has been adapted from AC 43. 13) Printed Copies Are Uncontrolled Rev. 10 1–16 GENERAL PROCEDURES T IRE REMOVAL REFER TO 5-1 W ING REMOVAL C ANOPY REMOVAL C OWL REMOVAL R EFER TO 12-1 OIL LEVEL CHECK F UEL SYSTEM DRAINING R EFER TO 13-1 GASCOLATOR SAMPLE LIFTING & SUPPORTING THE FUSELAGE ▲ WARNING: U SE STURDY SUPPORT STANDS THAT ARE EACH CAPABLE OF SUPPORTING AT LEAST 500 POUNDS . ■ CAUTION: A VOID 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. Printed Copies Are Uncontrolled Rev. 10 1–17 L IFTING WITH A JACK ■ CAUTION: U SE 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 tail tie-down and test for horizontal and vertical stability. Stabilize as necessary. L IFTING WITHOUT A JACK Figure 3: Lifting and supporting ● NOTE: STEPS 1 THROUGH 5 CORRESPOND TO THE NUMBERS IN F IGURE 3. 1. Raise the nose of the aircraft by lowering the tail. 2. Place a 25 inch stand along the lateral rivet pattern, centered directly between the boarding steps. 3. Lift the tail of the aircraft. 4. Place another 25 inch stand along the lateral rivet pattern centered directly beneath the rear wing-spar receptacles. 5. Check for horizontal and vertical stability. Stabilize as necessary. Printed Copies Are Uncontrolled Rev. 10 1–18 WEIGHT AND BALANCE It is the pilot’s responsibility to insure that the aircraft is loaded properly and within the weight and balance limitations. The weight and balance of the aircraft are factors that will affect all flight performance, 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. Weight and Balance Procedure 1. Make a copy of the RV-12 Weight & Balance Worksheet. 2. Install both lower and upper cowl. 3. Check that all fairings, access covers/plates etc are fully installed. 4. Place seat cushions in the aircraft, place the POH and fuel sample tube in the mapbox. 5. Check that there are no other items (tools, etc.) left in the cabin or map box. 6. Roll aircraft onto 2 inch (5cm) blocks under main wheels and chock wheels. 7. Level the canopy deck by inflating/deflating nose tire or main tires as appropriate or by increasing or decreasing block thickness. 8. Drop a plumb line off the leading edge of each wing just outboard of main wheel and mark a line on the floor between the two points. 9. Measure distance forward from left main wheel axle to the line on the floor and record on the RV-12 Weight & Balance Worksheet as D1. 10. Measure distance aft from nose wheel axle to line on floor and record on RV-12 Weight & Balance Worksheet as D2. 11. Measure distance forward from right main wheel axle to line on floor and record on RV-12 Weight & Balance Worksheet as D3. 12. Roll aircraft off blocks under main wheels. Place blocks on scale pads for main wheels. Zero scales. 13. Roll aircraft onto scales using ramps. Verify canopy deck is level (adjust tire inflation if/as necessary), close the canopy. 14. Record the left main wheel weight on RV-12 Weight & Balance Worksheet as W1. 15. Record the nose wheel weight on RV-12 Weight & Balance Worksheet as W2. 16. Record the right main wheel weight on RV-12 Weight & Balance Worksheet as W3. 17. On the RV-12 Weight & Balance Worksheet, calculate empty weight, empty moment, and empty arm. 18. Enter values for Empty Weight, Empty Moment, and Empty Arm into the table on “YOUR AIRPLANE” table within RV-12 Pilot Operating Handbook Section 6. 19. Place the RV-12 Weight & Balance Worksheet in the aircraft as it is part of the required documentation. 20. Enter values for Empty Weight, Empty Moment, and Empty Arm onto the Weight and Balance Record page in this section. Printed Copies Are Uncontrolled Rev. 10 1–19 RV-12 WEIGHT & BALANCE WORKSHEET AIRCRAFT:_________(registration) _________(serial number) DATE:_________ TABLE 1 LEFT WHEEL NOSE WHEEL RIGHT WHEEL WEIGHT _______ lb (W1) _______ lb (W2) _______ lb (W3) DISTANCE FROM AXLE CENTER TO LEADING EDGE _______ inches (D1) _______ inches (D2) _______ inches (D3) TABLE 2 WEIGHT ARM MOMENT LEFT WHEEL _______ lb (W1) (70+_____ ) = ______inches (D1) (A1) ( _____ )*( _____ ) = _____ in-lb (W1) (A1) (M1) NOSE WHEEL _______ lb (W2) (70-_____ ) = ______inches (D2) (A2) ( _____ )*( _____ ) = _____ in-lb (W2) (A2) (M2) RIGHT WHEEL _______ lb (W3) (70+_____ ) = ______inches (D3) (A3) ( _____ )*( _____ ) = _____ in-lb (W3) (A3) (M3) EMPTY WEIGHT = ___________________ lb EMPTY ARM = __________________ inches (W1 + W2 + W3) (Empty Moment / Empty Weight) EMPTY MOMENT = __________________ in-lb (M1 + M2 + M3) Aircraft measured, weighed, and worksheet filled-out by: ___________________________ Printed Name/Title ___________________________ Signature Printed Copies Are Uncontrolled Rev. 10 1–20 WEIGHT AND BALANCE R ECORD As of this date: ___/___/___ the following values represent current Weight and Balance Calculations. Revised Empty Weight: __________________ lb Revised Empty Moment: __________________ in-lb Revised Empty Arm: __________________ in Signed: ___________________________ As of this date: ___/___/___ the following values represent current Weight and Balance calculations resulting from the installation of the _______________________________. Revised Empty Weight: __________________ lb Revised Empty Moment: __________________ in-lb Revised Empty Arm: __________________ in Signed: ___________________________ As of this date: ___/___/___ the following values represent current Weight and Balance calculations resulting from the installation of the _______________________________. Revised Empty Weight: __________________ lb Revised Empty Moment: __________________ in-lb Revised Empty Arm: __________________ in Signed: ___________________________ As of this date: ___/___/___ the following values represent current Weight and Balance calculations resulting from the installation of the _______________________________. Revised Empty Weight: __________________ lb Revised Empty Moment: __________________ in-lb Revised Empty Arm: __________________ in Signed: ___________________________ Printed Copies Are Uncontrolled Rev. 10 INSTALLED EQUIPMENT LIST ITEM WEIGHT Lbs. ARM In. INSTALLED MOMENT In-lbs. DYNON D-180 56.62 GARMIN GTX 327 55.30 GTX 327 TRAY 53.71 GARMIN GTX 328 53.86 GTX 328 TRAY 53.88 GARMIN SL-40 53.76 SL-40 TRAY 47.69 GARMIN X95/6 58.08 FLIGHTCOMFC 403 56.48 ARTEX ME-406 96.18 DYNON EDC-10A 147.73 BATTERY 43.56 TOTAL -------- D-180 1-21 Printed Copies Are Uncontrolled Rev. 10 THIS PAGE INTENTIONALLY LEFT BLANK 1-22 Printed Copies Are Uncontrolled Rev. 10 INSTALLED EQUIPMENT LIST ITEM WEIGHT Lbs. ARM In. INSTALLED MOMENT In-lbs. DYNON SV-HDX 1100 3.35 58.43 DYNON (DUAL) SV-HDX 1100 3.35 58.43 DYNON SV-EMS-220 .63 47.12 DYNON SV-XPNDR-261 .77 47.66 DYNON SV-BAT-320 .8 54.58 DYNON SV-ADAHRS-200 .5 141.73 DYNON SV-GPS-250 .44 43.13 DYNON SV-GPS-2020 .44 43.13 GARMIN GTR 200 2.37 54.13 ACK 406 1.18 96.18 BATTERY ODYSSEY PC-680 15.4 43.56 DYNON SV-ADSB-472 .3 52.38 DYNON SV AP PANEL .3 57.78 DYNON SV KNOB PANEL .4 57.78 TOTAL -------- SKYVIEW 1-21 Printed Copies Are Uncontrolled Rev. 10 INSTALLED EQUIPMENT LIST ITEM WEIGHT Lbs. ARM In. INSTALLED MOMENT In-lbs. DYNON AP SERVO PITCH 2 124.80 DYNON AP SERVO ROLL 2 78.64 TOTAL -------- SKYVIEW 1-22 Printed Copies Are Uncontrolled Rev. 10 INSTALLED EQUIPMENT LIST ITEM WEIGHT Lbs. ARM In. INSTALLED MOMENT In-lbs. GARMIN GDU 460 57.90 GARMIN GDU 465 57.90 GARMIN GMC 305/307 57.57 GARMIN GEA 24 47.12 GARMIN GTX 23ES 50.93 GARMIN GMU 22 141.73 TCW IBBS-12V-3AH 50.73 GARMIN GSU 25 118.76 GARMIN GA 26C OR GA26X 43.13 GARMIN GA 26XM 43.13 GARMIN GTR 200 54.13 ACK 406 96.18 BATTERY 43.56 GARMIN GA 36 OR GA 37 43.00 GARMIN GPS 20A 47.57 GARMIN GDL 39R GARMIN AUTOPILOT SERVOS TOTAL -------- G3X 1-21 Printed Copies Are Uncontrolled Rev. 10 INSTALLED EQUIPMENT LIST ITEM WEIGHT Lbs. ARM In. INSTALLED MOMENT In-lbs. GARMIN GTR225 PS ENGINEERING PM3000-RV TOTAL -------- G3X 1-22 Printed Copies Are Uncontrolled Rev. 1 2-1 CHAPTER 2 - SERVICE SCHEDULE OVERVIEW Adherence to the service (or preventative maintenance) schedule is essential for maintaining airworthiness and maximizing aircraft longevity. There are specific requirements for who can perform preventative maintenance, line maintenance, or annual condition inspections on a LSA. At least one of the following qualifications is necessary to perform preventative maintenance on an S-LSA RV-12: i The owner or operator provided they are Sport Pilot certified or better. i A person certified as “Repairman (light-sport aircraft)-Maintenance rating” i An FAA certificated A&P mechanic. At least one of the following qualifications is necessary to perform line maintenance on an S-LSA RV-12: i A person certified as “Repairman (light-sport aircraft)-Maintenance rating” i An FAA certificated A&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. ● NOTE: F OR THE SERVICE SCHEDULE C HECKLIST SEE SUPPLEMENT PAGE 18-3. Printed Copies Are Uncontrolled Rev. 1 2-2 The service schedule checklist serves as an index of the 'service procedures' section of each applicable chapter. The 'service procedure' section includes the recommended tools to complete each task. Applicable hardware will be stated using the most general terms. Refer to the original KAI for the specific hardware size, location, and configuration. Manufacturers of third party components determine service procedures for those components. The manual provided by the manufacturer for that component will provide service procedures. All component manuals are included with the aircraft at the time of purchase. The ‘What’ column provides the name of the part or components to which the action applies. The ‘Action’ column will indicate what is necessary; replace, lubricate, clean, charge, etc. The ‘When’ column specifies the amount of time or use that may elapse before action is necessary. The ‘How’ column will direct you to the chapter or manual that includes the instructions, tools, supplies, and the level of certification required of the person performing the action, for the given action. Write the date of completion in the ‘Service Date’ column. Use the ‘Initial’ column to identify the person that performed the service. Printed Copies Are Uncontrolled Rev. 6 3-1 CHAPTER 3 - INSPECTION O VERVIEW ...................................................................................................................................................... 3-2 INSPECTION DESCRIPTION ............................................................................................................................... 3-3 Tools ..................................................................................................................................................... 3-3 Pre-inspection / Post-inspection ............................................................................................................... 3-3 Cockpit ...................................................................................................................................................... 3-5 Radio ......................................................................................................................................................... 3-7 Communication ..................................................................................................................................... 3-7 Intercom ................................................................................................................................................ 3-7 Transponder ......................................................................................................................................... 3-7 Optional Equipment .................................................................................................................................. 3-7 Emergency Locator Transmitter ............................................................................................................... 3-7 Propeller .................................................................................................................................................... 3-7 Engine ....................................................................................................................................................... 3-8 Firewall Forward ....................................................................................................................................... 3-8 Fuselage ................................................................................................................................................. 3-10 Landing Gear .......................................................................................................................................... 3-11 Wing / Center Section ............................................................................................................................. 3-12 Rear Spar Doubler ............................................................................................................................. 3-13 Empennage ............................................................................................................................................. 3-14 Vertical Stabilizer ................................................................................................................................ 3-14 Rudder ................................................................................................................................................ 3-14 Stabilator ............................................................................................................................................. 3-16 Anti-Servo Tab & Pitch-trim Servo ...................................................................................................... 3-16 Angle-Of-Attack ....................................................................................................................................... 3-17 Paperwork ............................................................................................................................................... 3-17 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: i A person certified as “Repairman (light-sport aircraft)-Maintenance” rating i FAA certificated A&P technician ● NOTE: F OR THE INSPECTION C HECKLIST SEE SUPPLEMENT PAGE 18-5. xx 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. 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 Printed Copies Are Uncontrolled Rev. 6 3-2 inspection provided the airframe has been constructed and used within the terms defined by the manufacturer. The Inspection Checklist provided in the Supplement will be a guide for the inspection procedure. The bold print identifies each category of inspection and the general symptoms to check for throughout that category. Each category 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.