VAD-10005 Maintenance Manual

INTRODUCTION ............................................................................................................ 1-1 Purpose .................................................................................................................. 1-1 Summary ................................................................................................................ 1-1 Scope ..................................................................................................................... 1-2 Replacement Parts ................................................................................................. 1-3 Method ................................................................................................................... 1-3 A PPLICABLE THROUGHOUT ........................................................................................... 1-4 General Safety ....................................................................................................... 1-4 Safety of Flight Reporting Procedure ..................................................................... 1-5 Helpful Terminology ............................................................................................... 1-5 Abbreviations ......................................................................................................... 1-6 Units ....................................................................................................................... 1-7 TOOLS AND E XPENDABLES ........................................................................................... 1-8 E NGINE ..................................................................................................................... 1-12 LUBRICATIONS AND CAPACITIES .................................................................................. 1-13 Engine Oil............................................................................................................. 1-13 Brake Fluid ........................................................................................................... 1-13 Engine Coolant ..................................................................................................... 1-14 Fuel ...................................................................................................................... 1-14 Tire Pressures ...................................................................................................... 1-14 Torque Values ...................................................................................................... 1-15 G ENERAL P ROCEDURES ............................................................................................. 1-16 Lifting & Supporting the fuselage ......................................................................... 1-16 W EIGHT AND B ALANCE ............................................................................................... 1-18 E QUIPMENT L IST ....................................................................................................... 1-21 CHAPTER 2- SERVICE SCHEDULE .......................................................................... 2-1 CHAPTER 3- INSPECTION ......................................................................................... 3-1 O VERSTRESS .............................................................................................................. 3-1 O VERVIEW .................................................................................................................. 3-2 INSPECTION DESCRIPTION ............................................................................................ 3-3 Pre-inspection / Post-inspection ............................................................................. 3-3 Cockpit ................................................................................................................... 3-5 Radio ...................................................................................................................... 3-6 Optional Equipment ................................................................................................ 3-7 Emergency Locator Transmitter ............................................................................. 3-7 Propeller ................................................................................................................. 3-7 Engine .................................................................................................................... 3-8 Rev: 4 Van’s Aircraft Date: 08/30/24 Printed copies are uncontrolled. vii VAD-10005 Firewall Forward ..................................................................................................... 3-8 Fuselage .............................................................................................................. 3-12 Landing Gear ....................................................................................................... 3-13 Wing / Center Section/AOA ................................................................................. 3-14 Empennage .......................................................................................................... 3-10 Angle-Of-Attack System ....................................................................................... 3-16 Paperwork ............................................................................................................ 3-17 CHAPTER 4 - STRUCTURAL REPAIRS .................................................................... 4-1 O VERVIEW .................................................................................................................. 4-1 M INIMUM 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 LANDING GEAR ............................................................................................................ 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 CHAPTER 10 - UTILITY SYSTEMS .......................................................................... 10-1 O VERVIEW ................................................................................................................ 10-2 HEAT ........................................................................................................................ 10-2 Rev: 4 Van’s Aircraft Date: 08/30/24 Printed copies are uncontrolled. viii VAD-10005 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 ................................................................................................................... 12-4 CHAPTER 13 - FUEL SYSTEM ................................................................................. 13-1 O VERVIEW ................................................................................................................ 13-2 Fuel System Schematics ..................................................................................... 13-4 S ERVICE ................................................................................................................... 13-6 CHAPTER 14 - EXHAUST SYSTEM ......................................................................... 14-1 O VERVIEW ................................................................................................................ 14-2 S ERVICE ................................................................................................................... 14-4 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 ................................................................................................... 17-2 CHAPTER 18 - SUPPLEMENT ................................................................................. 18-1 S ERVICE S CHEDULE ................................................................................................... 18-3 INSPECTION CHECKLIST ............................................................................................. 18-7 3-V IEW ................................................................................................................... 18-31 FEEDBACK F ORM ..................................................................................................... 18-33 CHAPTER 19 - GLOSSARY ...................................................................................... 19-1 CHAPTER 20 - INDEX ............................................................................................... 20-1 Rev: 4 Van’s Aircraft Date: 08/30/24 Printed copies are uncontrolled. ix VAD-10005 NOTE: Pages 1-21/22 and 1-23/24 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 Rev: 4 Van’s Aircraft Date: 08/30/24 Printed copies are uncontrolled. 1-1 VAD-10005 Chapter 1 - GENERAL INTRODUCTION PURPOSE The purpose of this manual is to provide guidance to RV-12iS 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-12iS light sport aircraft. The RV-12iS 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 RV-12iS is equipped with either a Rotax 912ULS (with dual carburetors) or a Rotax 912iS Sport (electronic fuel injection / FADEC) 100 hp four cylinder engine, enclosed in a fiberglass composite cowling at the front of the aircraft. Engine power is transferred via an integral gearbox to a 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 flaperons are operated from a switch near the throttle controlling an electric linear actuator. 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. Rev: 4 Van’s Aircraft Date: 08/30/24 Printed copies are uncontrolled. 1-2 VAD-10005 SCOPE •••• NOTE: This maintenance manual is intended to be used in conjunction with the RV-12iS Kit Assembly Instructions (KAI) when completing maintenance or repair processes. All of the service and maintenance requirements that are unique to the RV-12iS S-LSA are included in this manual. The general service and maintenance duties that are common to standard aircraft still apply to the RV-12iS regardless of the inclusion of those requirements in this manual, so FAA Advisory Circular - Aircraft Inspection, Repair, and Alterations, AC 43.13 is another valuable reference. All inspection and maintenance and all maintenance log entries must be made in accordance with 14 CFR / FAR’s and/or the aircraft’s Operating Limitations. The manufacturers of third party components provide manuals that include complete service and maintenance requirements that are specific to these components. The current service and maintenance manuals from any third party manufacturer, such as; engine, propeller, avionics, etc. always take precedence over the related content in this manual. There are references to third party documentation in this manual, as well as some supplementary information which is for convenience only. It is recommended to refer directly to the manufacturer’s service manuals for complete service information that is unique to applicable components. The manufacturers that provide operating and/or maintenance manuals to use in conjunction with this manual are as follows: ♦ Rotax – engine ♦ Sensenich – propeller ♦ Matco – wheels and brakes ♦ Grove – wheels and brakes ♦ Dynon – EFIS / EMS, GPS ♦ Garmin – EFIS / EMS, GPS and Nav/comm ♦ TCW – Backup Battery ♦ ACK – ELT ♦ Odyssey – battery ♦ EarthX – battery ♦ 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 an S-LSA RV- 12iS in the United States. 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 region in which the airplane is registered. The documents necessary to determine these requirements for S-LSA in the United States are as follows: ♦ RV-12 Maintenance Manual ♦ Federal Aviation Regulations for Light Sport Aircraft Maintenance Technicians Rev: 4 Van’s Aircraft Date: 08/30/24 Printed copies are uncontrolled. 1-3 VAD-10005 REPLACEMENT PARTS The RV-12iS 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 RV-12iS can be equipped with either a Rotax 912ULS or a Rotax 912iS engine. For the purpose of this manual, when entire sections, or specific maintenance or inspection tasks are specific to just one of the aircraft versions, a [ULS] or [iS] notation will be used. 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 Rev: 4 Van’s Aircraft Date: 08/30/24 Printed copies are uncontrolled. 1-4 VAD-10005 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 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 as dictated in ASTM F 2295 Section 5. 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-12iS 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 S-LSA RV-12iS. AN E-LSA RV-12iS has no level of certification requirement for maintenance or repairs, so none is given. The person completing an annual condition inspection on an E-LSA RV-12iS is required to possess a Repairman / Inspection certificate (airplane). 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, the underlying structure may also have 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 damaged parts must be replaced or 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. Safety wire, cotter pins, lock washers and similar hardware are only reliable for one term of service and should be replaced on removal with the exception of the Nordloc® washers used on the propeller bolts (refer to propeller documentation). It is permissible Rev: 4 Van’s Aircraft Date: 08/30/24 Printed copies are uncontrolled. 1-5 VAD-10005 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 but not limited to dust, salt, debris, bugs, will warrant more frequent inspections of air filters, coolant radiator, and oil cooler as defined in the Rotax maintenance manual. Frequent exposure to extreme conditions or altitudes may demand additional equipment or maintenance. Contact an authorized Rotax distributor for consultation. 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 compromise the airworthiness of the RV-12iS 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 Ÿ WARNING: INDICATES AN ACTION NECESSARY TO PREVENT INJURY OR DEATH . Ŷ CAUTION : INDICATES AN ACTION NECESSARY TO PREVENT DAMAGE TO PARTS OR PROPERTY. Ɣ NOTE: PROVIDES VALUABLE ADDITIONAL INFORMATION . The Glossary provides definitions to many of the terms used throughout this manual. Rev: 4 Van’s Aircraft Date: 08/30/24 Printed copies are uncontrolled. 1-6 VAD-10005 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 Rev: 4 Van’s Aircraft Date: 08/30/24 Printed copies are uncontrolled. 1-7 VAD-10005 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 Rev: 4 Van’s Aircraft Date: 08/30/24 Printed copies are uncontrolled. 1-8 VAD-10005 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 ♦ Combination wrenches: ƒ 1/4 ƒ 5/16 ƒ 11/32 ƒ 3/8 ƒ 7/16 (2) ƒ 1/2 ƒ 9/16 ƒ 11/16 ƒ 1 ½ ƒ 10mm ♦ Ratchet ♦ Sockets: ƒ 5/16 ƒ 11/32 ƒ 3/8 ƒ 7/16 ƒ 1/2 ƒ 9/16 ƒ 3/4 ƒ 1 1/2 ƒ 10 mm ƒ 11 mm ƒ 13 mm ♦ Allen wrenches: ƒ 3/16 ƒ 1/4 ƒ 5/16 ƒ 4mm ƒ 5mm ƒ 6mm ƒ 8mm ♦ Torque wrench (in/lbs & ft/lbs) ♦ 5/8 or 16 mm spark plug socket ♦ Screwdrivers: ƒ #2 Phillips ƒ #3 Phillips ƒ 3/16 Flat Blade ♦ Power-drill ♦ #30 drill bit ♦ Blind rivet tool ♦ Straight edge ♦ Razor knife ♦ Flashlight ♦ Step ladder ♦ Wire cutters ♦ Battery charger ♦ Multi-meter ♦ Syringes ♦ Wooden dowels 1/2 - 1 inch dia. and 1 1/2 - 1 3/4 in. dia. ♦ Oil Filter wrench ♦ Oil Filter cutter ♦ Two 25 in. padded stands each rated to support a minimum of 500 pounds ♦ Container (various sizes, suitable for petroleum) ♦ 24-inch length of 1/2-inch I.D. fuel hose ♦ Scouring pad or equivalent ♦ Sandpaper (various grades) ♦ Spark plug gap tool (wire type) ♦ Compression tester ♦ Magnifying Glass ♦ Small square ♦ Tire air pressure gauge ♦ Needle nose pliers ♦ 5-inch “C” clamp ♦ Terminal crimping tool ♦ Locking (vice grip style) pliers ♦ 2 1/2 x 3/16 bolt, washer, nut ♦ Vacuum gauge set ♦ Portable weight scale (tension type) ♦ Fire extinguisher ♦ Pump style oil can with hose ♦ Safety wire twisting pliers Ɣ NOTE: TOOLS DIFFER IN SIZE AND CONFIGURATION . THE FOLLOWING ILLUSTRATIONS ARE ONLY EXAMPLES OF WHAT A TOOL MAY LOOK LIKE . Ɣ NOTE: THIS TOOL LIST DOES NOT INCLUDE ALL OF THE TOOLS THAT MAY BE REQUIRED FOR THE INSPECTION AND M AINTENANCE PROCEDURES . ACCESS TO A TYPICAL GENERAL TOOL KIT IS ASSUMED . S PECIALTY TOOLS REQUIRED FOR A MAINT . OR INSPECTION PROCESS ARE LIST IN EACH SECTION WHEN RELEVENT . TOOLS Rev: 4 Van’s Aircraft Date: 08/30/24 Printed copies are uncontrolled. 1-9 VAD-10005 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 Rev: 4 Van’s Aircraft Date: 08/30/24 Printed copies are uncontrolled. 1-10 VAD-10005 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 Rev: 4 Van’s Aircraft Date: 08/30/24 Printed copies are uncontrolled. 1-11 VAD-10005 Ŷ C AUTION : R EPLACEMENT PARTS MUST BE OF THE EQUIVALENT SIZE, TYPE AND RATING AS THE ORIGINAL PARTS FROM THE MANUFACTURER . EXPENDABLE PARTS PART NUMBER Oil filter Rotax 825 701 (or equivalent) Fuel Filter [iS] Rotax 874 060 Copper crush ring (for oil tank drain plug) Rotax 250010 Gas-6 O-ring gasket [ULS] 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 ¼s 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, Tri-Flow, or similar Dry lubricant (candle wax, etc.) TOOL BOELUBE PASTE Wheel bearing grease Aeroshell 22 or equivalent Pipe Thread-Sealant Loctite 567 or equivalent Anti-seize compound, High temp Loctite Anti-Seize or equivalent (High Temp. Nickel based) Silicone Grease Down Corning #4 or equivalent Hydraulic fluid MIL-PRF-83282 (preferred) or MIL-H-5606A Air filter cleaner and 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 Primer Any protective primer suitable for use on aluminum and/or steel as appropriate Decorative touch-up paint From paint process Thread locking compound Loctite 243 or Equiv. Rev: 4 Van’s Aircraft Date: 08/30/24 Printed copies are uncontrolled. 1-12 VAD-10005 ENGINE DESCRIPTION The LSA covered by this manual may be equipped with either a Rotax 912ULS or a Rotax 912iS power plant. Both are an over-head valve four-stroke, horizontally opposed four-cylinder. The cylinder heads are liquid cooled. The cylinder barrels are air- cooled. The 912 ULS has dual constant depression carburetors to regulate the air/fuel mixture, and a dual breaker-less, capacitor discharge ignition system to provide the electrical energy to the spark plugs. The 912iS has a fully redundant electronic engine management system (EMS) controlling dual electronic ignition for the sparkplugs, dual electronic fuel injection, and dual power generation/distribution. For engine maintenance and inspection requirements and procedures, refer to the Rotax Engine Type 912ULS or 912iS Series Line Maintenance and Heavy Maintenance manuals. ENGINE SPECIFICATIONS SUMMARY Make Rotax 912 ULS Displacement 1352 cc Ignition Ducati Double CDI Carburetor Bing Rated Horsepower 100 Hp @ 5800 RPM Ɣ NOTE: THE ENGINE SPECIFICATION INFORMATION IS REFERENCED FROM THE R OTAX 912 SERIES , OPERATOR ’S MANUAL , OM EDITION 4, R EV.0. SUMMARY Make Rotax 912 iS Sport Displacement 1352 cc Ignition Computer controlled electronic Fuel Injection Computer controlled electronic Rated Horsepower 100 Hp @ 5800 RPM Ɣ NOTE: THE ENGINE SPECIFICATION INFORMATION IS REFERENCED FROM THE R OTAX 912 SERIES , OPERATOR ’S MANUAL , OM EDITION 1,R EV .3. Rev: 4 Van’s Aircraft Date: 08/30/24 Printed copies are uncontrolled. 1-13 VAD-10005 LUBRICATION AND CAPACITIES ENGINE OIL Ŷ CAUTION: ONLY USE API CLASS 'SG' OR HIGHER . Ŷ CAUTION: DO NOT USE O ILS WITH FRICTION MODIFIER ADDITIVES . Ŷ CAUTION: DO NOT USE O ILS FOR “CONVENTIONAL ” AIRCRAFT ENGINES . Ŷ CAUTION: DO NOT USE O ILS DESIGNED FOR DIESEL ENGINES . ♦ Capacity: 3 liter (3.2 US qts) ♦ The type of oil to use will be based on the type of fuel used. ♦ Refer to the Rotax operator’s manual and Service Instruction SI 912-016 for the appropriate engine model, to determine which oil type is appropriate for your operating temperatures and the fuel being used. BRAKE FLUID Ÿ WARNING: N EVER USE AUTOMOTIVE BRAKE FLUID . Use MIL-H- 5606A or MIL-PRF-83282 (preferred) Brake fluid draining, flushing, and replacing instructions Page 7-5. CAPACITY: 15.4 fl. oz. (US) (.455 liters) Rev: 4 Van’s Aircraft Date: 08/30/24 Printed copies are uncontrolled. 1-14 VAD-10005 ENGINE COOLANT S UITABLE COOLANTS COOLANT MIX: • 50% ethylene glycol concentrate with anticorrosion additives designed for aluminum without sulfates or phosphates. • 50% distilled or de-mineralized water. See the latest version of the Rotax Operators Manual and Service Instruction SI 912- 016 for further information on coolant types and limitations. CAPACITY: 0.7 gallon (US) (2.6 liters) Fully fill the expansion tank, and fill the over flow bottle midway between the ‘min’ and ‘max’ marks. MINIMUM: Fluid level at or above the minimum line on the overflow bottle when engine is cold. FUEL S UITABLE FUEL 91 AKI (premium unleaded automotive) 100 LL Aviation Fuel See the latest version of the Rotax Operators Manual and Service Instruction SI 912- 016 to determine other approved fuel types, limitations and maintenance considerations. CAPACITY: 20.2 US Gallons (76.5 liters) TIRE PRESSURES Tire psi psi max bar bar max kpa kpa max Nose 22 23 1.517 1.586 152 159 Main 25 28 1.724 1.931 172 193 Rev: 4 Van’s Aircraft Date: 08/30/24 Printed copies are uncontrolled. 1-15 VAD-10005 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 installed with self-locking nuts or nutplates, 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, known as friction-drag (or prevailing) torque, is required just to turn the nut on the bolt threads and does nothing to actually tighten the parts together and stretch the bolt (clamp load). Run the nut down to where it nearly contacts the washer or bearing surface (at least one thread should protrude from the nut) then measure the friction drag torque required just to turn the nut. Add this friction drag torque to the standard torque (examples of standard torque values appear in the table below) to get the final (or total) torque. The final torque is the amount of torque to be applied to the joint. A snap-over type torque wrench should be set to the final torque. For the two blade prop: refer to the latest version of the Sensenich INSTALLATION AND OPERATION MANUAL FOR JABIRU AND ROTAX ENGINES DOC#: 2A0. For the three blade prop: refer to the latest version of the Sensenich INSTALLATION AND OPERATION MANUAL FOR ROTAX ENGINES DOC#: 3Y0R5. Refer to the latest version of the Rotax Illustrated Parts Catalog for torque values and installation details regarding the 912ULS engine, and the line and Heavy Maintenance Manuals for the 912iS. 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) Rev: 4 Van’s Aircraft Date: 08/30/24 Printed copies are uncontrolled. 1-16 VAD-10005 GENERAL PROCEDURES TIRE REMOVAL REFER TO 5-1 WING REMOVAL CANOPY REMOVAL COWL REMOVAL REFER TO 12-1 O IL LEVEL CHECK FUEL SYSTEM DRAINING REFER TO 13-1 FUEL TANK REMOVAL LIFTING & SUPPORTING THE FUSELAGE Ÿ WARNING: U SE STURDY SUPPORT STANDS THAT ARE EACH CAPABLE OF SUPPORTING AT LEAST 500 POUNDS. Ŷ CAUTION : A VOID CONTACTING ANTENNA , FAIRINGS OR OTHER ACCESSORIES WHILE PLACING THE SUPPORT STANDS UNDER THE AIRCRAFT . Ŷ CAUTION : REMOVE OR ATTACH THE WINGS PRIOR TO LIFTING AND SUPPORTING THE AIRCRAFT . When the aircraft is lifted, whether or not a jack is used, the method of support is the same. Obtain two sturdy, padded stands each capable of supporting at least 500 pounds. The padded contacting surface must be at least 1 1/2 inches wide. Two layers of 3/8 inch carpet are recommended. Both stands need to be about 30 inches long and 25 inches high. Rev: 4 Van’s Aircraft Date: 08/30/24 Printed copies are uncontrolled. 1-17 VAD-10005 LIFTING WITH A JACK Ŷ CAUTION : U SE APPROPRIATE JACK LOCATING FIXTURES TO ENSURE A STABLE JACKING SURFACE . Ŷ 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. LIFTING WITHOUT A JACK Figure 3: Lifting and supporting Ɣ 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 tall 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. Rev: 4 Van’s Aircraft Date: 08/30/24 Printed copies are uncontrolled. 1-18 VAD-10005 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, and handling 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-12iS Weight & Balance Worksheet. 2. Drain all fuel from the tank. 3. Confirm that engine oil is at normal operating level. 4. Install both lower and upper cowl. 5. Check that all fairings, access covers/plates, etc. are fully installed. 6. Place seat cushions in the aircraft. 7. Check that there are no other items (tools, etc.) left in the cabin. 8. Roll aircraft onto 2 inch (5cm) blocks under main wheels and chock wheels. 9. Level the aircraft with reference to the canopy side rail/deck by inflating/deflating nose tire or main tires as appropriate or by increasing or decreasing block thickness. 10. 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. 11. Measure distance forward from left main wheel axle to the line on the floor and record on the RV-12iS Weight & Balance Worksheet as D1. 12. Measure distance aft from nose wheel axle to line on floor and record on RV-12iS Weight & Balance Worksheet as D2. 13. Measure distance forward from right main wheel axle to line on floor and record on RV-12iS Weight & Balance Worksheet as D3. 14. Roll aircraft off blocks under main wheels. Place blocks on scale pads for main wheels. Zero scales. 15. Roll aircraft onto scales using ramps. Verify canopy deck is level (adjust tire inflation if/as necessary), close the canopy. 16. Record the left main wheel weight on RV-12iS Weight & Balance Worksheet as W1. 17. Record the nose wheel weight on RV-12iS Weight & Balance Worksheet as W2. 18. Record the right main wheel weight on RV-12iS Weight & Balance Worksheet as W3. 19. On the RV-12iS Weight & Balance Worksheet, calculate empty weight, empty moment, and empty arm. 20. Enter values for Empty Weight, Empty Moment, and Empty Arm into the table on “YOUR AIRPLANE” table within RV-12iS Pilot Operating Handbook Section 6. 21. Place the RV-12iS Weight & Balance Worksheet in the aircraft as it is part of the required documentation. 22. Enter values for Empty Weight, Empty Moment, and Empty Arm onto the Weight and Balance Record page in this section. Rev: 4 Van’s Aircraft Date: 08/30/24 Printed copies are uncontrolled. 1-19 VAD-10005 RV-12 IS W EIGHT & 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 Rev: 4 Van’s Aircraft Date: 08/30/24 Printed copies are uncontrolled. 1-20 VAD-10005 W EIGHT AND B ALANCE 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: ___________________________ Rev: 4 Van’s Aircraft Date: 08/30/24 Printed copies are uncontrolled. 1-21 VAD-10005 INSTALLED EQUIPMENT LIST ITEM WEIGHT lbs ARM in. INSTALLED MOMENT in-lbs. DYNON SV-HDX1100 3.35 58.43 DYNON (DUAL) SV-HDX1100 3.35 58.43 DYNON SV-EMS-220/221 0.63 47.12 DYNON SV-XPNDR-261 0.77 47.66 DYNON SV-BAT-320 0.8 54.58 DYNON SV-ADAHRS-200 0.5 142.22 DYNON SV-GPS-2020 0.44 43.13 GARMIN GTR 200 2.37 54.55 ACK 406 1.18 96.18 ODYSSEY PC680 BATTERY 14.38 43.56 EARTH X ETX900 BATTERY 4.9 43.56 DYNON SV-ADSB-472 0.3 123.26 DYNON SV AP / KNOB PANEL(s) 0.3 58.49 DYNON AUTOPILOT SERVO (PITCH) 2 78.6 DYNON AUTOPILOT SERVO (ROLL) 2 124.83 TOTAL -------- SKYVIEW Rev: 4 Van’s Aircraft Date: 08/30/24 Printed copies are uncontrolled. 1-22 VAD-10005 INSTALLED EQUIPMENT LIST ITEM WEIGHT lbs. ARM in. INSTALLED MOMENT in-lbs. TRIG TY96 2.09 55.00 TOTAL -------- SKYVIEW Rev: 4 Van’s Aircraft Date: 08/30/24 Printed copies are uncontrolled. 1-21 VAD-10005 INSTALLED EQUIPMENT LIST ITEM WEIGHT lbs. ARM in. INSTALLED MOMENT in-lbs. GARMIN GDU 460 4.6 58.00 GARMIN GMC 507 0.68 59.27 GARMIN GEA 24 0.71 47.63 GARMIN GTX 45R 2.9 51.51 TCW IBBS-12V-3AH 1.125 55.31 GARMIN GSU 25 0.48 119.00 GARMIN GA 26X 0.42 42.93 GARMIN GTR 200 2.37 54.42 ACK 406 ELT 1.18 133.25 EARTH X ETX900 BATTERY 4.9 43.56 GARMIN GA 36 0.5 42.93 GARMIN AUTOPILOT SERVO (PITCH) 1.4 78.72 GARMIN AUTOPILOT SERVO (ROLL) 1.4 125.75 TOTAL -------- G3X Rev: 4 Van’s Aircraft Date: 08/30/24 Printed copies are uncontrolled. 1-22 VAD-10005 INSTALLED EQUIPMENT LIST ITEM WEIGHT lbs. ARM in. INSTALLED MOMENT in-lbs. GARMIN GMU11 0.16 142.26 GARMIN GTN650Xi 5.5 54.02 GARMIN GAD29 0.38 52.85 GARMIN GMA245 1.78 55.57 RAMI AV-532L 0.88 219.98 TRIG TY96 2.09 55.00 TOTAL -------- G3X Rev: 4 Van’s Aircraft Date: 08/30/24 Printed copies are uncontrolled. 2-1 VAD-10005 Chapter 2 - SERVICE SCHEDULE OVERVIEW Adherence to the service schedule is essential for maintaining airworthiness and maximizing aircraft longevity. There are specific requirements for who can perform line maintenance, heavy maintenance, or annual condition inspections on an S-LSA. At least one of the following qualifications is necessary to perform line maintenance on an S-LSA RV-12iS: ♦ The owner or operator provided they are Sport Pilot certified or higher. ♦ A person certified as “Repairman (light-sport aircraft)-Maintenance rating” ♦ An FAA certificated A&P mechanic. At least one of the following qualifications is necessary to perform heavy maintenance on an S-LSA RV-12iS: ♦ A person certified as “Repairman (light-sport aircraft)-Maintenance rating” with task specific training. ♦ 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. Ɣ NOTE: O WNERS WHO POSSES A SPORT PILOT CERTIFICATE (OR HIGHER ) ARE AUTHORIZED BY THE FAA TO PERFORM SOME LINE MAINT . TASKS . REFER TO FAR 43, APPENDIX A FOR GUIDANCE Ɣ NOTE: FOR THE SERVICE SCHEDULE CHECKLIST SEE SUPPLEMENT PAGE 18-3. Rev: 4 Van’s Aircraft Date: 08/30/24 Printed copies are uncontrolled. 2-2 VAD-10005 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 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 is the reference for service procedures. All component manuals are included with the aircraft at the time of purchase. The ‘What’ column in the Service Schedule Checklist 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 time or use interval that may elapse before the 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. Rev: 4 Van’s Aircraft Date: 08/30/24 Printed copies are uncontrolled. 3-1 VAD-10005 Chapter 3 - INSPECTION O VERSTRESS ........................................................................................................................................... 3-1 O VERVIEW ................................................................................................................................................ 3-2 INSPECTION DESCRIPTION ......................................................................................................................... 3-3 Special Tools .................................................................................................................................. 3-3 Pre-inspection / Post-inspection ......................................................................................................... 3-3 Cockpit ................................................................................................................................................ 3-5 Radio ................................................................................................................................................... 3-6 Communication ............................................................................................................................... 3-6 Intercom .......................................................................................................................................... 3-6 Transponder ................................................................................................................................... 3-6 Optional Equipment ............................................................................................................................ 3-7 Emergency Locator Transmitter ......................................................................................................... 3-7 Propeller .............................................................................................................................................. 3-7 Engine ................................................................................................................................................. 3-8 Firewall Forward ................................................................................................................................. 3-8 Empennage ....................................................................................................................................... 3-10 Vertical Stabilizer .......................................................................................................................... 3-10 Rudder .......................................................................................................................................... 3-11 Stabilator ....................................................................................................................................... 3-11 Anti-Servo Tab & Pitch-trim Servo ................................................................................................ 3-11 Fuselage ........................................................................................................................................... 3-12 Landing Gear .................................................................................................................................... 3-13 Wing / Center Section ....................................................................................................................... 3-14 Rear Spar Doubler ....................................................................................................................... 3-15 Angle-Of-Attack ................................................................................................................................. 3-16 Paperwork ......................................................................................................................................... 3-17 OVERSTRESS In the event that the airframe’s allowable flight load factor is exceeded, as indicated by the G Meter reading outside the parameters listed below, the airframe must be inspected for possible damage due to an overstress condition. This inspection must be performed by an individual with the minimum qualifications listed and an appropriate log book entry made. Damage caused by the overstress which affects airworthiness must be repaired before the next flight. Category Limit Load Factor Light Sport Category 4.0g/-2.0g Minimum Certification LSA-RM or A&P Additional References KAI, POH (load factor) Rev: 4 Van’s Aircraft Date: 08/30/24 Printed copies are uncontrolled. 3-2 VAD-10005 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-12iS aircraft they must possess at least one of the following SPECIFIC CERTIFICATION REQUIREMENTS: ♦ A person certified as “Repairman (light-sport aircraft)-Maintenance” rating ♦ FAA certificated A&P technician Ɣ NOTE: FOR THE INSPECTION C HECKLIST SEE SUPPLEMENT PAGE 18-7. •••• NOTE: This maintenance manual is intended to be used in conjunction with the RV-12iS 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 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. Rev: 4 Van’s Aircraft Date: 08/30/24 Printed copies are uncontrolled. 3-3 VAD-10005 INSPECTION DESCRIPTION PRE-INSPECTION / POST-INSPECTION Perform the preliminary systems check and engine run-up as detailed in the Inspection Checklist. The Rotax line maintenance manual provides the run-up procedure for the engine. Test all of the engine systems and controls. Test all of the airframe systems and controls. Make note of any abnormalities or dysfunctional components. Record the applicable values in the spaces given on the Inspection Checklist. After the systems check, proceed with the following: Service rating Line Minimum Certification LSA-RM, or A&P 1. Remove the left and right wing. (5-12) 2. Remove all access covers, inspection plates, fairing and cowling shown in Figure 4. SPECIAL T OOLS ♦ Wing Retention Pin Bushing Gauge ♦ Jack ♦ Padded stands ♦ Step ladder ♦ Tensile weight scale ♦ Multi-meter ♦ Compression tester ♦ Carburetor vacuum gauges ♦ Torque wrench (in/lbs & ft/lbs) ♦ Tire pressure gauge Ŷ CAUTION: A LWAYS SUPPORT THE FLAPERON DURING WING REMOVAL AND STORAGE. Rev: 4 Van’s Aircraft Date: 08/30/24 Printed copies are uncontrolled. 3-4 VAD-10005 3. Perform visual inspection for and make note of any oil, exhaust, fuel, hydraulic fluid leaks. 4. Thoroughly clean engine, fuselage, cockpit, undercarriage and other areas as needed to allow thorough inspection. 5. Throughout the inspection check for cracks, signs of fatigue, corrosion, wear, deformation, and/or failure. Always check condition and security of all safe- tied fasteners. Figure 4: Remove for inspection *Ref. # Name *Ref. # Name 1 Right Wing 12 Left Wing 2 Upper Fwd Fuse Skin 13 Cover Plates (6) 3 Fuselage Side Cover (2) 14 Baggage Floor Cover 4 Top Cowl 15 Baggage Cover 5 Spinner 16 Baggage Bulkhead Corrugation 6 Bottom Cowl 17 Lower Tailcone Fairing 7 Tunnel Fwd Side Cover 18 Upper Tailcone Fairing 8 Tunnel Aft Side Cover 19 Forward Skin 9 Seat Floor Cover 20 Fuel Tank Assembly (see chapter 13 for draining the fuel tank) 10 Flap Motor Cover 11 Access Hatch * - Not numbered in order of removal Rev: 4 Van’s Aircraft Date: 08/30/24 Printed copies are uncontrolled. 3-5 VAD-10005 COCKPIT • Inspect the aft face of the firewall for corrosion, deformation or cracks, especially around fasteners. • Inspect the welded rudder pedal assemblies for cracks / damage, smooth movement with no heavy resistance, etc. • Test the operation of the brake pedals. With constant pressure they should feel firm and not spongy. Without pressure, each brake pedal must automatically return to the original position. Check for hydraulic fluid leaks. • Actuate the control stick forward and aft and left and right. Operation must be smooth from stop to stop. Verify freedom of movement of the pulleys and confirm that they turn smoothly and without lateral play. With the control stick pulled back the trailing edge of the stabilator must be up. • Run a rag along the control cables to check for frays or broken strands that will snag the cloth. The stabilator cables must be aligned with the corresponding pulley and free from physical interference. Confirm that the locking clips on the tensioner barrels are installed and secure. • Hold either control stick stationary and gently wiggle each push/pull rod; there must not be free play or loose parts. Check the rod-end jam nuts for proper torque and check the security of the rod-end connection fasteners. • Make sure the stabilator contacts its up and down stops before the WD-1210 Control Column contacts it’s up and down stops. If not, loosen and tighten the stabilator cable tensioner barrels an equal and opposite amount until the travel is full and correct. The control column stops must limit excessive forward and aft pressure. The bellcrank stops must limit the left and right control stick motion. See Figure 5. Figure 5: Control Stops