SECTION 49U: ULS ENGINE CONTROLS

BUSH-F-BS.189X.250X.263 3X NAS1149F0363P MS21042-3 MODIFIED GROMMET AN426AD3-3.5 49U-05 RV-12iS 0 05/01/18 PAGE: REVISION: DATE: VAN'S AIRCRAFT, INC. FIGURE 2: INSTALLING THE FUEL SHUTOFF CABLE Step 1: Route the CT-01204 through the hole in the Tunnel Cover Assembly, through the washer and nut called out in the detail view in Figure 2, through the center lightening hole in two of the F-01212 ribs, and through the rest of the fuselage into the tailcone as shown in Figure 2. Secure the CT-01204 to the Tunnel Cover Assembly by installing the nut and washer shown in the detail view of Figure 2. Step 2: Thread the CT-01204 through the hole in the F-12108B and secure the conduit using the nuts and lockwashers as shown in the detail view of Figure 2. Adjust the nuts so the F-12108B will be approximately centered on the threaded portion of the conduit, then tighten. Step 3: Secure the CT-01204 conduit to both ES-00301 using tie wraps as shown in the detail view in Figure 2. Ensure there are no abrupt bends or kinks along the full length of CT-01204. Step 4: Slide the CT-00100 Wire Swivel into the fuel shut-off valve arm as shown in the detail view in Figure 2. Loosen the set screws. Step 5: Install the washer, then insert the CT-01204 lead into the hole in the CT-00100 as shown in the detail view in Figure 2. Do not tighten the set screws in the CT-00100. Step 6: With the fuel shut-off valve fully open (aligned with the valve body) and the CT-01204 handle extended as shown in Figure 1, tighten the lower set screw in the CT-00100. Step 7: Tighten the upper set screw in the CT-00100. Actuate the fuel shut-off cable handle through the full range of motion. Ensure that the full range of motion of the fuel shut-off valve is achieved. Check for any interference throughout the full range of motion of the fuel shut-off valve lever, CT-00100, and fuel shut-off cable lead. FUEL SHUT-OFF VALVE 1/4 [6.4 mm] FIGURE 1: RIGGING THE FUEL SHUTOFF CABLE CT-01204 3/8-24 NUT (INCLUDED WITH CABLE) SPLIT WASHER (INCLUDED WITH CABLE) ROUTE CABLE THROUGH UPPER HOLE (TYP) TUNNEL COVER ASSEMBLY 2X M6 NUT 2X M6 WASHER (INCLUDED WITH CABLE) CT-00100 F-12108B NAS1149F0432P ES-00301 (SECTION 21iS/U AND 24iS/U) PLASTIC TIE WRAP 8" F-01212 TUNNEL COVER ASSEMBLY CT-01204 VAN'S AIRCRAFT, INC. PAGE: REVISION: DATE: 05/01/18 0 RV-12iS 49U-06 16X AN526C832R6 AN526C632R4 FIGURE 1: INSTALLING THE TUNNEL COVERS (F-01244-L SHOWN, REPEAT FOR F-01244-R) F-12101 FIGURE 2: INSTALLING THE FLAP COVER F-01245L F-01244-L Step 1: Install the F-01244-L, F-01245-L, and F-01244-R using the hardware called out in Figure 1. Step 2: Install the F-12101 using the hardware called out in Figure 2. FIGURE 3: THROTTLE FRICTION ASSEMBLY & TUNNEL COVER CT-01206 F-01245-R NAS1149F0432P BUSHING-AL.259X.375X.688 NAS1149F0432P SPRING-00007 NAS1149F0432P BOLT-00005 Step 3: Install the Throttle Friction Assembly hardware onto the BOLT-00005 as shown in the detail view in Figure 3. Step 4: Install the F-01245-R using the hardware called out in Figure 3. Step 5: Install the CT-01206 1/4-20 Knob as shown in Figure 3. 24X AN526C832R6 13X AN526C832R6 49U-07 RV-12iS PAGE: DATE:08/09/20 REVISION: 2 VAN'S AIRCRAFT, INC. NOTE: Instruction for synchronizing the carburetors is found in the RV-12iS Maintenance Manual. Complete all sections of the RV-12iS Assembly Instructions and the ground test portions of the RV-12iS Production Acceptance Procedures prior to synchronizing the carburetors. The remaining steps on this page and 49U-08 provide throttle cable installation for the right carburetor. Cable installation on the left carburetor is a mirror of the right and should be done at the same time. Step 1: Place marks on the Throttle Arm, Throttle Shaft, and Idle Stop to orient the parts relative to each other, remove and discard the Throttle Arm Spring supplied with the carburetor, then remove the Throttle Arm and Idle Stop from the Shaft. See Figure 1 below and Figure 2 on page 49U-08. FIGURE 1: THROTTLE CABLE TO CARBURETOR CONNECTION CT-01202 CONDUIT ROTAX STEP WASHER ROTAX FLAT WASHER MS21045-3 VA-219-2 THROTTLE ARM CABLE BRACKET CT-01202 LEAD THROTTLE CABLE LOCKING HARDWARE M6 NUT (SUPPLIED WITH CABLE) M6 LOCKWASHER (SUPPLIED WITH CABLE) CT-00101 (SUPPLIED WITH CABLE) ROTAX NUT ROTAX SPRING WASHER IDLE STOP THROTTLE SHAFT IDLE SPEED ADJUSTMENT SCREW NAS1149F0363P FIGURE 2: NEW THROTTLE SPRING INSTALLATION VAN'S AIRCRAFT, INC. PAGE: REVISION: DATE:09/24/20 2 RV-12iS 49U-08 FIGURE 3: SETTING THE IDLE POSITION 3/16 [4.8 mm] FIGURE 1: VA-00276 INSTALLATION VA-00276 THROTTLE SHAFT CABLE SUPPORT THROTTLE SHAFT IDLE STOP SPRING-00002-R-1 (LEFT SIDE SPRING-00002-L-1) VA-00276 CABLE SUPPORT NOTE: Refer to Rotax Illustrated Parts Catalog Section 73-00-00 for hardware and the Rotax Maintenance Manual (Heavy Maintenance) for torque specs. Step 1: Remove the two M4 screws in the Cable Support. Slide the VA-00276 Throttle Return Spring Retainer onto the Throttle Shaft as shown in Figure 1. NOTE: The manufacturing process causes VA-00276 to have a slight bend and creates the potential for the M4 screws to be cross threaded during installation. Do not apply excess force while installing the screws. If the screws cannot be installed easily, flatten VA-00276 and loosely install the screws to ensure proper threading. Step 2: Reinstall the two M4 screws removed in Step 1. See Figure 2. NOTE: Instructions below apply to installing SPRING-00002-R-1 and SPRING-00002-L-1. SPRING-00002-L-1 is marked with blue ink on one edge. Step 3: Slide the SPRING-00002-R-1 (SPRING-00002-L-1 on Left Carburetor) Throttle Spring onto the throttle shaft. Position the the inboard leg against the VA-00276 as shown Figure 2. Step 4: Reinstall the Idle Stop as shown in Figure 2 with the outboard arm of the SPRING-00002-R-1 against the bent lower arm of the stop plate. The SPRING-00002-R-1 should be coiled approximately 14 turn past the relaxed position when properly installed. Step 5: Reinstall the throttle arm with the nut and washer that was removed in Step 1 on page 49U-07 Figure 1. Step 6: Install the conduit of the CT-01202 (the longer of the two throttle cables) to the cable bracket using the hardware shown in Figure 1 on page 49U-07. Adjust the nuts so that the cable bracket will be approximately centered on the threaded portion of the conduit, then tighten. Step 7: Insert the CT-01202 lead through the CT-00101 Stop Nut and into the hole in the shank of the VA-219-2 Control Cable Bolt. Loosely attach the throttle cable locking hardware called out in Figure 1 on page 49U-07. Move the throttle lever forward from the aft end of the slot as shown in Figure 3. Fully tighten the throttle friction adjustment. Step 8: Actuate the throttle arm so that the Idle Stop is lightly contacting the idle speed adjustment screw. While holding tension on the CT-01202 lead, tighten the throttle cable locking hardware to 8-10 in-pounds. See Figure 1 on page 49U-07. Move the CT-00101 against the end of the cable housing and tighten the set screw. The final position will be adjusted during the carburetor balance procedure. Step 9: Loosen the throttle friction adjustment. 49U-09 RV-12iS PAGE: DATE:08/09/20 REVISION: 1 VAN'S AIRCRAFT, INC. NOTE: See Section 5.28 for detailed information on cable trimming. Step 1: Trim the CT-01201 and CT-01202 leads to the dimension given in Figure 1. Step 2: Install the F-12135U using the hardware as called out in Figure 2. Do not over tighten the screws. Step 3: Actuate the Throttle Lever through its full range of travel. Ensure that the full range of motion of both throttle arms is achieved (idle stop screw-to-full open stop). Check for any interference throughout the full tange of motion of the throttle arm, throttle arm hardware, and throttle cable leads. Ensure that the idle speed adjustment screw on both carburetors are resting on the idle stop and that there is no clearance between the two when the throttle lever is in the idle position. NOTE: Optional alternate throttle grip is available to install. Order KIT 12iS THROTTLE GRIP from Van's Aircraft. Step 4: Install the CT-01205 using the hardware shown in Figure 2. AN3-21A MS21083-N3 F-12135U FIGURE 2: THROTTLE GUIDE & T-HANDLE 4X MS24693-26B 2X CT-01205 WASHER 5702-75-60 CT-01202 LEAD 1.0 [25.4 mm] (CHECK FOR INTERFERENCE BETWEEN THE END OF THE WIRE AND OTHER COMPONENTS) OPTIONAL: SOLDER OR HEAT SHRINK THROTTLE ARM FIGURE 1: TRIMMING THE THROTTLE CABLES THROTTLE CABLE LOCKING HARDWARE VAN'S AIRCRAFT, INC. PAGE: REVISION: DATE:08/09/20 1 RV-12iS 49U-10 Step 1: Move the CT-01203 handle all the way forward to the off position as shown in Figure 1. FIGURE 1: CHOKE HANDLE POSITION FIGURE 2: CHOKE CABLE LEAD-TO-CARB CONNECTION Step 2: Slide the CT-00100 Wire Swivel into the choke lever as shown in Figure 2. Loosen the outer set screw. Step 3: Insert the CT-01203 lead into the cable mount tube, then through the hole in the CT-00100 as shown in Figure 2, Detail A-A. Guide the conduit of the choke cable into the cable mount tube as shown in Figure 2. Step 4: With the choke lever resting against the lower stop, secure the CT-01203 lead by tightening the CT-00100 set screws. Step 5: Trim the CT-01203 lead to the dimension given in Figure 2, Detail A-A. Step 6: Curl the end of the CT-01203 lead outboard as shown in Figure 2 and reclock the carburetor fuel supply fitting as necessary to avoid interference. Actuate the CT-01203 handle through the full range of motion. Ensure that the full range of motion (lower stop-to-upper stop) of the choke lever is achieved. Check for any interference throughout the full range of motion of the choke lever, CT-00100, and CT-01203 lead. END OF SECTION A A DETAIL A-A CT-01203 CABLE MOUNT TUBE CHOKE LEVER CT-01203 LEAD CT-00100 HOLE 1.0 [25.4 mm] (CHECK FOR INTERFERENCE BETWEEN THE END OF THE WIRE AND OTHER COMPONENTS) UPPER STOP OPTIONAL: SOLDER OR HEAT SHRINK CABLE MOUNT TUBE CT-00100 CHOKE SPRING ATTACH POINT (SPRING MUST BE INSTALLED) NOTE: See Section 5.28 for detailed information on cable trimming. The steps on this page provide choke cable installation for the right carburetor. Cable installation on the left carburetor is a mirror of the right and should be done at the same time. LOWER STOP OUTER SET SCREW CARBURETOR FUEL SUPPLY FITTING CT-01203 VAN'S AIRCRAFT, INC. PAGE: REVISION: DATE: 05/01/18 0 RV-12iS 49U-10 THIS PAGE INTENTIONALLY LEFT BLANK