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Van's Aircraft RV-12, Maintenance Manual

The Van's Aircraft RV-12 is a popular two-seater light sport aircraft with a sleek design and excellent performance. To ensure a safe and enjoyable flying experience, make sure to download the user manual for free from manualshive.com for important information on operating and maintaining your RV-12.

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Rev. 2

 

7-1  

 

 

 

O

VERVIEW

 ....................................................................................................................... 7-2

 

Components ................................................................................................................ 7-2

 

S

ERVICE

 .......................................................................................................................... 7-2

 

Supplies ...................................................................................................................... 7-3

 

Tools ...................................................................................................................................................................... 7-3

 

Expendable ............................................................................................................................................................ 7-3

 

Replaceable ........................................................................................................................................................... 7-3

 

General ....................................................................................................................... 7-3

 

Master cylinder removal......................................................................................................................................... 7-3

 

Removal ............................................................................................................................................................. 7-3

 

Disconnection ..................................................................................................................................................... 7-4

 

Installation .......................................................................................................................................................... 7-4

 

Service Schedule Procedures ..................................................................................... 7-4

 

Brake pedal torque tube lubrication ....................................................................................................................... 7-4

 

Hydraulic fluid drain, flush, and replace ................................................................................................................. 7-5

 

Draining .............................................................................................................................................................. 7-5

 

Flushing .............................................................................................................................................................. 7-5

 

Replacing ........................................................................................................................................................... 7-5

 

Brake lining replacement ....................................................................................................................................... 7-6

 

 

 

CHAPTER 7 - BRAKE SYSTEM 

 

Summary of Contents for RV-12

Page 1: ...Revision 9 3 Date 12 18 18 RV 12 MAINTENANCE MANUAL Aircraft Serial Number ___________________________...

Page 2: ...6 07 16 16 iv viii 7 12 18 18 1 8 12 18 18 2 1 04 16 10 3 5 12 18 18 4 3 12 18 18 5 6 12 18 18 6 4 07 16 16 7 2 04 03 14 8 5 12 18 18 9 6 12 18 18 10 1 04 16 10 11 4 07 16 16 12 5 07 16 16 13 5 04 03...

Page 3: ...nt service difficulty upon discovery using the Feedback Form provided in the Maintenance Manual The owner operator of an RV 12 shall comply with all Van s Aircraft Inc issued notices of corrective act...

Page 4: ...ES 1 8 ENGINE 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 GENERAL PROCEDURES 1 16 Lifting Supporting the...

Page 5: ...RVIEW 4 1 MINIMUM CERTIFICATION 4 2 CHAPTER 5 STRUCTURES 5 1 OVERVIEW 5 2 FUSELAGE 5 2 WING AND FLAPERON 5 4 EMPENNAGE 5 6 LANDING GEAR 5 8 FAIRINGS WHEEL AND GEAR LEG 5 10 SERVICE 5 12 CHAPTER 6 FLIG...

Page 6: ...R 13 FUEL SYSTEM 13 1 OVERVIEW 13 2 Fuel System Schematic 13 3 SERVICE 13 3 CHAPTER 14 EXHAUST SYSTEM 14 1 OVERVIEW 14 2 SERVICE 14 4 CHAPTER 15 PAINTING AND COATINGS 15 1 OVERVIEW 15 2 SERVICE 15 3 C...

Page 7: ...ER 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...

Page 8: ...gure 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...

Page 9: ...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 wi...

Page 10: ...ion 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 t...

Page 11: ...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...

Page 12: ...ble 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 typica...

Page 13: ...hiness 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 availab...

Page 14: ...lliliters 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 Newt...

Page 15: ...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...

Page 16: ...nd 1 1 2 1 3 4 in dia Oil Filter wrench Oil Filter cutter and mallet Two 25 in padded stands each rated to support a minimum of 500 pounds Container various sizes suitable for petroleum 24 inch length...

Page 17: ...bination 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 Ga...

Page 18: ...Rev 8 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...

Page 19: ...ay 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 Loctit...

Page 20: ...e 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...

Page 21: ...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 to determine which oil type is compatible with the fuel being used See Figure 2 to determ...

Page 22: ...tions CAPACITY 0 6 gallon US 2 3 liters Fill expansion tank to between the min and max marks in the overflow bottle MINIMUM Expansion tank 2 3 full 2 liter 4 liq pt in overflow bottle FUEL SUITABLE FU...

Page 23: ...m 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...

Page 24: ...CTING 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 lif...

Page 25: ...and 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 verti...

Page 26: ...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 fl...

Page 27: ..._____ 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 _____ ______...

Page 28: ..._ in lb Revised Empty Arm __________________ in Signed ___________________________ As of this date ___ ___ ___ the following values represent current Weight and Balance calculations resulting from the...

Page 29: ...D 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...

Page 30: ...Rev 8 THIS PAGE INTENTIONALLY LEFT BLANK 1 22...

Page 31: ...NON DUAL SV D1000 T 57 90 DYNON SV EMS 220 47 12 DYNON SV XPNDR 261 47 66 DYNON SV BAT 320 54 58 DYNON SV ADAHRS 200 141 73 DYNON SV GPS 250 43 13 DYNON SV GPS 2020 43 13 GARMIN GTR 200 54 13 ACK 406...

Page 32: ...Rev 8 INSTALLED EQUIPMENT LIST ITEM WEIGHT Lbs ARM In INSTALLED MOMENT In lbs GARMIN GTR225 PS ENGINEERING PM3000 RV TOTAL SKYVIEW 1 22...

Page 33: ...RMIN 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 43 13 GARMIN GA 26XM 43 13 GARMIN GTR 200 54 13 ACK 406...

Page 34: ...Rev 8 INSTALLED EQUIPMENT LIST ITEM WEIGHT Lbs ARM In INSTALLED MOMENT In lbs GARMIN GTR225 PS ENGINEERING PM3000 RV TOTAL G3X 1 22...

Page 35: ...The owner or operator provided they are Sport Pilot certified or better A person certified as Repairman light sport aircraft Maintenance rating An FAA certificated A P mechanic At least one of the fo...

Page 36: ...ll 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 A...

Page 37: ...ut 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 REQUIREM...

Page 38: ...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 conditi...

Page 39: ...the systems check proceed with the following 1 Remove the left and right wing 2 Remove all access covers inspection plates fairing and cowling shown in Figure 4 Tools 3 8 socket 2 Phillips screwdrive...

Page 40: ...and security of all safe tied fasteners Figure 4 Remove for inspection Ref Name Ref Name 1 Left Wing 12 Access Hatch 2 Right Wing 13 Seat Floor Cover 3 Forward Skin 14 Cover Plates 5 4 Upper Forward F...

Page 41: ...and cockpit lights for operation Check the condition of in service fuses and the condition and presence of spare fuses Run a rag along the control cables to check for frays or broken strands that wil...

Page 42: ...ine control cables for smooth operation and proper operation of the friction throttle control or position lock choke control Test the operation of the fuel valve Check the security of the electric fue...

Page 43: ...e manufacturer at the time of purchase Refer to the related manual for special procedures for inspection See applicable manual provided with the component EMERGENCY LOCATOR TRANSMITTER The ELT must be...

Page 44: ...INSPECTION HOT ENGINE COMPONENTS WILL CAUSE SERIOUS BURNS Refer to the Rotax line maintenance manual for proper inspection procedure for engine and components supplied with engine The Rotax manual wi...

Page 45: ...firewall when Off Check each engine control cable for security and condition along the route to the firewall The throttle and choke cables must be securely connected to each of the carburetors and in...

Page 46: ...lage each wing spar mates with the fuselage the tailcone attaches to the forward fuse and the empennage components attach to the tailcone Visually inspect that both of the static ports are clear Test...

Page 47: ...h point Check for evidence of black dust at the attach points which is an indicator of movement Test the security of each of the landing gear legs The landing gear components may not have any free pla...

Page 48: ...n mirror to inspect spars ribs and attach angles on the interior of each wing Especially the inboard most ribs and ribs at the flaperon hinge attach points The aft outboard portion of the wings can be...

Page 49: ...pin latching mechanisms for security and proper operation Test the warning circuit by unlatching each pin individually to verify it causes the switch panel warning light to illuminate REAR SPAR DOUBLE...

Page 50: ...similar properly installed rivets Check the forward spar and fasteners for cracks deformation and signs of fatigue Inspect the rear spar spar fasteners and hinges for cracks deformation and signs of f...

Page 51: ...ounding the rudder horn for cracks or deformation Inspect the control cable swages link fasteners and attach area on the control horn for signs of wear or fatigue Check the rudder stops on the lower h...

Page 52: ...tailcone contact their corresponding hinge stop on the stabilator squarely and simultaneously ANTI SERVO TAB PITCH TRIM SERVO Check the anti servo tab skins for damage or deformation Check the anti se...

Page 53: ...on is in the red zone stop pushing in the syringe Move the left wing tip back and forth as per the REAR SPAR DOUBLER instructions in the WING CENTER SECTION while performing the AOA system leak test t...

Page 54: ...Rev 5 3 18 THIS PAGE INTENTIONALLY LEFT BLANK...

Page 55: ...n AC 43 13 are allowed without consulting the aircraft manufacturer if the total patch area does not exceed 60 square inches Repair to interior structural parts of the airframe or skin repairs other t...

Page 56: ...P technician Refer to the KAI to identify individual parts and their corresponding part numbers NOTE Stop drill cracks per AC 43 13 Report any cracks to Van s Aircraft using the feedback form found at...

Page 57: ...Installation 5 16 Main inner tube replacement 5 16 Nose inner tube replacement 5 17 Flaperon hinge replacement 5 17 Rudder hinge replacement 5 18 Stabilator hinge replacement 5 19 Main gear removal 5...

Page 58: ...THE RV 12 KIT ASSEMBLY INSTRUCTIONS KAI WHEN COMPLETING MAINTENANCE OR REPAIR PROCESSES WARNING BEFORE PERFORMING ANY MAINTENANCE OR REPAIRS TURN THE MASTER SWITCH OFF AND DISCONNECT THE NEGATIVE BAT...

Page 59: ...e 1 Canopy and Frame C 1201 WD 1219 1 Fuselage Refer to KAI 2 Fuselage Pin WD 1217 4 Wing Retention Pin Bushing W 1206U 1 Latch Block C 1205 2 Occupant Harness System See shaded items below Refer to K...

Page 60: ...nts the stub spar the main spar and the rear spar Two fuselage pins secure both main spars to the center section of the fuselage Electrical and control connections connect automatically during wing at...

Page 61: ...208C L 1 Rear Spar W 1207A L W 1207B 1 Stall Warning See 5 5 1 Right Wing See shaded items below Refer to KAI 2 Wing Retention Pin Bushing W 1206U 1 Stub Spar W 1208B R W 1208C R 1 Rear Spar W 1207A R...

Page 62: ...rings finish the top of the vertical stabilizer and rudder The rudder is attached through hinges on the rear spar of the vertical stabilizer The stabilator attaches to hinges on the aft bulkhead of th...

Page 63: ...wer Hinge VS 1210 VS 1211A COM 3 5 1 Upper Hinge VS 1210 VS 1211B COM 3 5 1 Fwd Skin VS 1204 1 Rudder See shaded items below Refer to KAI 1 Rudder Horn WD 1205 1 Stabilator See shaded items below Refe...

Page 64: ...es and pivots at the lower end An axle bolt and nut fastens the axle spacer and wheel and tire assembly to the nose fork The main gear legs are aluminum fastened to the center section channel with bra...

Page 65: ...Brkt U 1203 2 Inbd Wear Plate U 1203B 2 Doubler Plate U 1203C 2 Inbd Doubler Plate 2 Main wheel assembly See shaded items below 1 Main wheel U MHMHE51B 2 Wheel bearings BEARING LM 67000L A 1 Axle MHE5...

Page 66: ...in place by a single screw The nose leg fairing is slotted to fit about the nose leg winch lug The wheel fairing aft attaches to the wheel fairing front which in turn attaches to the nose fork Tow bar...

Page 67: ...airings are attached to the wheel fairing brackets which in turn attach to the bracket mount Figure 14 Main Wheel Fairings OPTIONAL COMPONENTS Quantity Part or Assembly Name Part Number or Reference 2...

Page 68: ...ooden dowel 1 1 2 1 3 4 inch dia Small wooden dowel 1 2 1 inch dia 2 1 2x3 16 bolt washer and nut Tensile weight scale Cotter pins Safety wire Wheel bearing grease Spray lubricant Inner tube Hydraulic...

Page 69: ...nstallation procedure is the reverse of the removal procedure install left wing first right wing second The wing root seal strip on the side of the fuselage can be used to help align the wing at the p...

Page 70: ...e Canopy and Frame Canopy struts Service Rating Line Minimum Certification LSA RM or A P Additional References KAI CAUTION BE PREPARED WITH A HELPER OR SUPPORT STAND TO HANDLE THE WEIGHT AND AWKWARDNE...

Page 71: ...reventative Minimum Certification Owner and SPC LSA RM or A P Additional References Matco user manual KAI 1 Lift and support the aircraft 1 16 2 Remove the stationary brake shoe bolts 2 washers 2 spac...

Page 72: ...e Service Rating Preventative Minimum Certification Owner and SPC LSA RM or A P Additional References Matco user manual KAI 1 Lift and support the aircraft 1 16 2 Remove the main wheel and tire assemb...

Page 73: ...he tire 5 SLOWLY inflate the tire Deflate it fully and re inflate it SLOWLY a couple more times to work out any wrinkles in the tube Inspect for a good seat around the wheel rim For final inflation pr...

Page 74: ...crewdriver Expendable None Replaceable Lower rudder hinge Upper rudder hinge Service Rating Line Minimum Certification LSA RM or A P Additional References KAI CAUTION BE PREPARED WITH ADDITIONAL PERSO...

Page 75: ...1 4 diameter 3 inches long must be threaded at least 50 of its length 1 4 Flat Washer 2 and Hex Nut Expendable Cotter pins Lock Clips 2 Loctite 648 Replaceable Bearing DW4K2X Service Rating Line Mini...

Page 76: ...ng the DW4K2X bearing 11 Carefully clean the new bearing and the inner bore of the VA 146A Flange Housing using denatured alcohol After cleaning handle the bearings with care as to not re contaminate...

Page 77: ...ain gear attach bracket 5 Remove the center bolt washer and nut from the inboard main gear attach bracket 6 Loosen the remaining inboard and outboard attach bracket hardware 7 Remove the main gear leg...

Page 78: ...he nose gear leg 2 Install the nose gear leg and attach hardware 3 Install the lower engine vibration isolator bolts BELT AND HARNESS REPLACEMENT Tools 7 16 socket 7 16 combo wrench Expendable None Re...

Page 79: ...dpaper Replaceable Left or Rt Rear Spar Doubler Service Rating Line Minimum Certification LSA RM or A P Additional References KAI 1 Based on the measurement from Section 3 Inspection chose one of the...

Page 80: ...lecoed in place the hinge assembly does not need to be in place for this step If the fit is too tight remove the wing un cleco the doubler and sand the contour of the curve 0 010 or less and test fit...

Page 81: ...age pin STUB SPAR AND REAR SPAR 1 Wipe clean the inboard end of the stub spar and rear spar of each wing 5 4 2 Apply anti seize compound sparingly to the inboard end of the stub spar and rear spar of...

Page 82: ...tification Owner and SPC LSA RM or A P Additional References KAI 1 Lower the Anti Servo Tab by adjusting the trim Lower the trailing edge of the stabilator 2 Wipe away any dirt accumulation from the A...

Page 83: ...eat around the wheel rim The final inflation pressure is 15 psi 9 Install the wheel and tire assembly MAIN WHEEL BEARINGS LUBRICATION Tools 1 1 2 socket Needle nose pliers Expendable Wheel bearing gre...

Page 84: ...rcraft 1 16 2 Remove the nose fork and attach hardware cotter pin nut washer spring washers 2 3 Clean the end of the nose gear leg and the nose fork bushings 4 Apply a liberal amount of marine trailer...

Page 85: ...flange opposite the heavy point of the wheel until the assy can be moved to any rotational position without it rotating Mark the position of the wheel weights and then remove them Thoroughly clean th...

Page 86: ...Rev 6 5 30 THIS PAGE INTENTIONALLY LEFT BLANK...

Page 87: ...ilator pulley replacement and cable tension adjustment 6 3 Control cable replacement 6 6 Rod end replacement 6 7 Bellcrank bearing replacement 6 8 Rudder pedal removal 6 8 Installation 6 9 Service Sch...

Page 88: ...with the RV 12 Kit Assembly Instructions KAI when completing maintenance or repair processes COMPONENTS Quantity Part or Assembly Name Part Number or Reference 1 Flap handle Pushrod Refer to KAI 1 Fl...

Page 89: ...meter Spring clamps 3 Stick 41 long Cotter pins Safety wire Spray lubricant REPLACEABLE Stabilator pulley Lock clips Stabilator cables Rudder cables Bearing DW4K2X Bellcrank Rod ends Control Stick M34...

Page 90: ...axle hardware 7 Place a small weight on the stabilator to hold it trailing edge down Remove the slack from the upper cable by tightening the upper outboard turnbuckle until the control stick and stabi...

Page 91: ...shown in Figure 17 This tension will prevent the cables from slapping against the tailcone bulkheads when the control sticks are moved suddenly and repeatedly forward then aft 10 Remove the clamp and...

Page 92: ...sembly 3 4 2 For rudder cable remove the rudder cable sleeve attach hardware bolts 3 washers 3 nuts 3 3 For the stabilator cable remove the tensioner barrels and stabilator pulleys 6 4 NOTE TIE A STRI...

Page 93: ...gage cover and fuel tank assembly 3 4 2 Remove the control rod attach hardware from the rod end for replacement Control stick control stick pushrod bolt washers 3 and nut Control stick pushrod bellcra...

Page 94: ...ng on page 5 20 Figure 16 5 Installation procedure is reverse of the removal procedure RUDDER PEDAL REMOVAL Tools 11 32 3 8 socket 3 8 combo wrench Needle nose pliers 2 Phillips screwdriver Expendable...

Page 95: ...ver baggage cover and fuel tank assembly 3 4 2 Apply lubricant sparingly to the rod end bearings on each end of the following components Flap handle pushrod Control stick pushrod Flaperon pushrod Trim...

Page 96: ...Rev 4 6 10 THIS PAGE INTENTIONALLY LEFT BLANK...

Page 97: ...7 3 General 7 3 Master cylinder removal 7 3 Removal 7 3 Disconnection 7 4 Installation 7 4 Service Schedule Procedures 7 4 Brake pedal torque tube lubrication 7 4 Hydraulic fluid drain flush and repl...

Page 98: ...TS Quantity Part or Assembly Name Part Number or Reference 2 Disc and caliper Matco Refer to KAI 4 Brake shoes Refer to Matco manual 4 Brake shoe linings Refer to Matco manual 4 Brake pedal WD 1209 2...

Page 99: ...list on page 7 2 GENERAL MASTER CYLINDER REMOVAL CAUTION THE LEFT AND RIGHT MASTER CYLINDERS ON EACH SIDE OF THE AIRCRAFT ARE NOT INTERCHANGABLE Tools 3 8 socket 3 8 1 2 combo wrench Needle nose plie...

Page 100: ...16 socket 7 16 combo wrench Needle nose pliers Expendable Cotter pins Wheel bearing grease Replaceable None Service Rating Line Minimum Certification LSA RM or A P Additional References KAI NOTE SERVI...

Page 101: ...e top of the brake fluid reservoir and insert it in a container to catch fluid overflow 2 Attach a pump style oil can filled with hydraulic fluid to the bleeder valve on the bottom of one of the brake...

Page 102: ...the 2 safety wired bolts and remove the stationary brake shoe 2 Remove the brake housing from the brake plate use care to not damage the aluminum brake line 3 Remove the floating brake shoe 4 Check th...

Page 103: ...5 Fuse replacement 8 6 Pitch trim servo replacement 8 7 Electrical component replacement 8 9 AV Control board replacement 8 10 Wire repair 8 11 Wire replacement 8 11 Snap bushing replacement 8 13 Ser...

Page 104: ...ons KAI when completing maintenance or repair processes COMPONENTS Quantity Part or Assembly Name Part Number or Reference 1 Battery ES PC680 12 Blade Fuse ATO ATC blade style 1 2 3 5 7 5 30 Amp ratin...

Page 105: ...rollover structure Refer to the KAI for empennage component removal and installation Figure 20 Optional Wing Tip Lighting cooling shroud eyeball light not shown OPTIONAL COMPONENTS Quantity Part or As...

Page 106: ...ctrical components Replace malfunctioning or failed components Electrical components that are omitted from the component list on page 8 2 are not considered line maintenance SUPPLIES TOOLS EXPENDABLE...

Page 107: ...Battery Service Rating Preventative Minimum Certification Owner and SPC LSA RM or A P Additional References Odyssey owner manual 1 Remove the top cowl 12 4 2 Remove the negative battery cable 3 Remov...

Page 108: ...NY CIRCUIT IN WHICH A 5 AMP FUSE OR LARGER IS SPECIFIED MUST BE OF THE TYPE THAT ILLUMINATE WHEN BLOWN Good Fuse Blown Fuse 1 Remove the suspected blown fuse 2 Perform visual inspection and or use mul...

Page 109: ...the upper and lower tailcone fairing 3 4 3 Label then disconnect the pitch trim servo wire terminal connections Remove the cushioned clamp and free the tailcone wire from the trim servo assembly 4 Ma...

Page 110: ...re 23 8 Unscrew the pitch trim servo from the pushrod assembly Remove the jam nut from the pitch trim servo shaft 9 Clip the wire terminals off of the old servo and remove the snap bushing Slide the s...

Page 111: ...white wire positions and recheck 6 When the AST movement has been verified as correct install appropriate connectors on each wire for connecting to the pitch trim control cable ELECTRICAL COMPONENT R...

Page 112: ...oard With the master switch ON press the stall warning vane until the tone fades off If wings are removed ground the stall warning terminal tab at the fuselage side cover as shown in Figure 24 4 Verif...

Page 113: ...edge chaffing heat etc 3 Route the new length of wire along the same path as the original wire 4 Use aircraft grade wire terminals to connect the new wire in place of the original wire 5 Test the cont...

Page 114: ...e the same type as those on the existing wire 3 Connect the new wire terminals to the terminals that are connected by the existing wire 4 Check the continuity of the replacement wire 5 Test the operat...

Page 115: ...nces KAI 1 Extract the failed snap bushing by compressing the two locking tabs and pushing it out of the mounting hole 2 Cut the new snap bushing as shown in Figure 25 The snap bushing should be of th...

Page 116: ...ndable None Replaceable None Service Rating Preventative Minimum Certification Owner and SPC LSA RM or A P Additional References Odyssey owner manual Battery charger owner manual 1 Remove the battery...

Page 117: ...nents 9 3 PITOT STATIC 9 3 Components 9 3 SERVICE 9 4 Supplies 9 4 Tools 9 4 Expendable 9 4 Replaceable 9 4 General 9 5 Component replacement 9 5 Light replacement 9 5 Service Schedule Procedures 9 6...

Page 118: ...pinner cone that extends aft to an adapter block mounted to the engine A flexible plastic tube continues aft from the adapter block to the air data computer NOTE This maintenance manual is intended to...

Page 119: ...PANEL See Dynon Manual 1 SV KNOB PANEL See Dynon Manual 1 Garmin GMC 305 Autopilot Controller See Garmin Manual 1 Landing light See Aero LED Manual 2 Navigation Strobe light See Aero LED Manual 1 Cock...

Page 120: ...e often available online for the Dynon D 180 Skyview Garmin GPS and Garmin G3X The avionics components are not serviceable by the consumer unless otherwise noted in the manufacturer user manuals A man...

Page 121: ...and orientation of the component to replace 2 Remove the failing component INSTALLATION 1 Install a new component of equivalent properties and secure with plastic tie wraps 2 Complete the pitot static...

Page 122: ...VIONICS OR OPTIONAL EQUIPMENT OTHER THAN THE PERIODIC REPLACEMENT OF THE ELT UNIT BATTERY REFER TO THE ELT OWNERS MANUAL FOR THIS PROCEDURE PERIODIC CHECKS SHOULD BE MADE AT A MINIMUM OF EACH CONDITIO...

Page 123: ...RVIEW 10 2 HEAT 10 2 Components 10 3 VENTILATION 10 3 Components 10 4 SERVICE 10 4 Supplies 10 4 Tools 10 4 Replaceable 10 4 Expendable 10 4 General 10 5 Vent door repair 10 5 Service Schedule Procedu...

Page 124: ...n air can be controlled with either of the two vents one on each side of the fuselage NOTE This maintenance manual is intended to be used in conjunction with the RV 12 Kit Assembly Instructions KAI wh...

Page 125: ...oler box FF 1204 1 Cooler box door FF 1205 1 Cooler box bracket FF 1205BC 1 Cooler box hinge FF 1206 1 Push Pull Cable CT A 740 VENTILATION A hand operated vent on each side of the cockpit provides co...

Page 126: ...e moving parts If the heated air temperature is noticeably cooler than previous uses see troubleshooting The pre flight and annual condition inspections are necessary to ensure all of the components r...

Page 127: ...rackets 2 Service Rating Line Minimum Certification LSA RM or A P Additional References KAI 1 Remove the existing vent brackets and vent door sub assembly by drilling out the rivets 4 2 Rivet the new...

Page 128: ...Rev 1 10 6 THIS PAGE INTENTIONALLY LEFT BLANK...

Page 129: ...Rev 4 11 1 OVERVIEW 11 2 Components 11 2 SERVICE 11 2 Supplies 11 2 Tools 11 2 Expendable 11 2 Replaceable 11 2 Spinner and Pitot Tube 11 3 Prop Hub 11 3 CHAPTER 11 PROPELLER...

Page 130: ...when completing maintenance or repair processes COMPONENTS Quantity Part or Assembly Name Part Number or Reference 2 Propeller blade 2A0R5R70EN Blade 1 Propeller hub Hub 1 Spinner cone S 1201 SERVICE...

Page 131: ...PROP HUB NOTE THERE IS NO SPECIFIED SERVICE LIFE FOR THE PROPELLER HOWEVER IT IS TO BE REMOVED FROM SERVICE WHEN IT NO LONGER MEETS THE CONTINUED AIRWORTHINESS REQUIREMENTS SPECIFIED BY THE MANUFACTUR...

Page 132: ...180 and reinstall If the propeller shows any of the following signs of damage it must either be repaired if possible or retired from service Cracks in the metal hub or bolts Loose metal leading edge A...

Page 133: ...ter removal 12 7 Installation 12 7 Carburetor Syncronization 12 7 Throttle Cable Hookup 12 10 Vacuum Gauge Hookup 12 10 Off Idle Setting 12 12 Idle Speed Adjustment 12 12 Verify Functionality of Throt...

Page 134: ...the only engine controls Air duct and engine cooling shrouds of similar construction provide cooling to the cylinders and heat exchangers NOTE This maintenance manual is intended to be used in conjun...

Page 135: ...ade by the engine manufacturer Refer to the engine manufacturer s operators manual for specifications SPARK PLUGS Type NGK DCPR8E Socket 16mm Electrode Gap See Rotax Documentation IGNITION Dual Breake...

Page 136: ...the F 1240B Cover Plate located at the top rear of the cowling to access the cowl attach hinge pins 2 Top Cowl Remove the top cowl fwd attach screws 6 side pin anchor screws 2 hinge pins 4 and the top...

Page 137: ...SPC LSA RM or A P Additional References Rotax 912 Line Maintenance manual ENGINE OIL LEVEL CHECK WARNING BEFORE PERFORMING ANY INSPECTION OR SERVICE ALLOW THE ENGINE COMPONENTS TO COOL WARNING TURN O...

Page 138: ...g Preventative Minimum Certification Owner and SPC LSA RM or A P Additional References Rotax 912 Operator Manual 1 Place a rag over the expansion tank cap 2 Loosen cap to the first detent then step ba...

Page 139: ...tification or A P with Rotax Service certification Additional References Rotax Maintenance Manual MECHANICAL SYNCHRONIZATION NOTE THIS PROCEDURE IS WRITTEN FOR A SINGLE CARBURETOR ADJUST BOTH CARBURET...

Page 140: ...no resistance during this procedure 4 Turn the idle speed adjustment screw counterclockwise until it is no longer contacting the idle stop 5 Hold the throttle arm lightly against its idle position lim...

Page 141: ...done without removing the carburetor from the manifold With a new engine initially assume it is properly set at the factory 8 Hook up the full throttle return spring previously disconnected back to it...

Page 142: ...10 in pounds See Figure 27 You must insure that the idle speed adjustment screw is resting on the idle stop and that there is no clearance between the two when the throttle handle is in the idle posi...

Page 143: ...Gauge Hookup 13 Secure the aircraft to the ground using chocks ropes etc WARNING SECURE AND OBSERVE THE PROPELLER ZONE DURING ENGINE OPERATION 14 Start the engine and warm it up until normal operatin...

Page 144: ...which carburetor has the higher vacuum reading Loosen the aft nut on the off idle adjustment hardware of the carburetor with the higher vacuum see Figure 27 and then tighten the fwd nut This will adj...

Page 145: ...HAS BEEN FLOWN FOR A FEW MINUTES FULLY WARMED UP THE DIFFERENCE TENDS TO BE A 50 75 RPM INCREASE FOR THIS REASON UNLESS YOU ARE DOING THE CARBURETOR SYNCHRONIZATION PROCEDURE IMMEDIATELY AFTER FLYING...

Page 146: ...nsated for by the balance tube at low engine RPM VERIFY FUNCTIONALITY OF THROTTLE RETURN SPRINGS 1 This section must be done with the aircraft outside 2 Chock main wheels tie down tail 3 BRAKES Apply...

Page 147: ...r A P Additional References KAI and ROTAX Line Maintenance Manual 1 Release the friction on the cockpit throttle control and move it to the full open position 2 Slip a small diameter screwdriver throu...

Page 148: ...se Oil Cooler Hose Oil Return Hose Oil Tank Vent Tube Oil Vent Interconnect Service Rating Preventative Minimum Certification Owner and SPC LSA RM or A P Additional References KAI REMOVAL 1 Remove Cow...

Page 149: ...REPLACEMENT Tools Wire cutters straight slot screwdriver for prying hose Expendable Tie wrap Replaceable Manifold pressure hose Service Rating Preventative Minimum Certification LSA RM with Rotax Serv...

Page 150: ...LLATION 1 Installation is reverse of removal 2 Refill coolant system to recommended level Tools 5 mm Allen wrench 12 13 mm socket wire cutters pliers 2 Phillips straight slot screwdrivers and others f...

Page 151: ...nk 9 Burp engine 10 Disconnect oil return hose from bottom of engine case 11 Disconnect oil return hose where tank is marked IN from top of oil tank 12 Drain cooling system per Rotax Line Maint Manual...

Page 152: ...Rev 5 12 20 THIS PAGE INTENTIONALLY LEFT BLANK...

Page 153: ...General 13 4 Draining the fuel system 13 4 Fuel tank removal 13 5 Installation 13 6 Fuel system component removal 13 6 Installation 13 7 Service Schedule Procedures 13 7 Gascolator cleaning 13 7 Inst...

Page 154: ...carburetors The gascolator serves as the primary fuel filter and water trap Sample the gascolator sump frequently to monitor the amount of water introduced into the fuel system The gascolator and fine...

Page 155: ...E OR REPAIRS TURN THE MASTER SWITCH OFF AND DISCONNECT THE NEGATIVE BATTERY CABLE FROM THE BATTERY CAUTION REPLACEMENT FUEL SYSTEM COMPONENTS MUST BE EQUIVALENT TO THE ORIGINAL PARTS NOTE CLOSE THE FU...

Page 156: ...ALWAYS HAVE AN APPROPRIATE FIRE EXTINGUISHER READILY AVAILABLE WARNING BEFORE PERFORMING ANY MAINTENANCE OR REPAIRS TURN THE MASTER SWITCH OFF AND DISCONNECT THE NEGATIVE BATTERY CABLE FROM THE BATTE...

Page 157: ...MMEDIATELY WHEN A CHANGE IN SOUND IS HEARD THE LOUDER CLACKING SOUND INDICATES THE FUEL PUMP IS NO LONGER PUMPING FUEL DO NOT ALLOW THE FUEL PUMP TO OPERATE WITHOUT FUEL OR PERMANENT DAMAGE MAY OCCUR...

Page 158: ...MALLER OF THE TWO FUEL LINES TO PREVENT ACCIDENTAL ROTATION OF THE FITTING IN THE FUEL TANK 6 Disconnect the two fuel lines from the bottom of the tank 7 Remove the two bolts from the forward fuel tan...

Page 159: ...ve Minimum Certification Owner and SPC LSA RM or A P Additional References KAI 1 Remove the engine cowling 12 4 2 Move the fuel valve to the OFF position 3 Remove the fuel quick drain to drain the exi...

Page 160: ...to fuel strainer pipe threads before installation FUEL RETURN ASSEMBLY REPLACEMENT Tools 2X 9 16 11 16 7 8 14mm open end wrench 12mm socket torque wrench in lb wire cutters Expendable Plastic tie wra...

Page 161: ...on LSA RM with Rotax Service certification or A P with Rotax Service certification Additional References KAI Removal 1 Place rags beneath the Fuel Pressure Sender 2 Loosen VA 216 Fuel Return Assembly...

Page 162: ...onal References KAI Removal 1 Cut the tie wraps attaching the drain hose to the gascolator to fuel pump hose 2 Loosen two hose clamps on the interconnect hose and one clamp on the drain hose and slide...

Page 163: ...SYSTEM OVERVIEW 14 2 Components 14 2 SERVICE 14 2 Supplies 14 2 Tools 14 2 Expendable 14 2 Replaceable 14 2 General 14 3 Exhaust system removal 14 3 Installation 14 3 Service Schedule Procedures 14 4...

Page 164: ...NUAL IS INTENDED TO BE USED IN CONJUNCTION WITH THE RV 12 KIT ASSEMBLY INSTRUCTIONS KAI WHEN COMPLETING MAINTENANCE OR REPAIR PROCESSES COMPONENTS Quantity Part or Assembly Name Part Number or Referen...

Page 165: ...Additional References KAI 1 Remove the engine cowling 12 4 2 Remove the muffler attachment springs 8 and muffler Note To avoid nicking the springs clamp a short loop of safety wire in locking pliers H...

Page 166: ...xpendables Anti seize compound Replaceable None Service rating Line Minimum Certification LSA RM or A P Additional Reference KAI 1 Remove the muffler attachment springs 8 and muffler Note Use locking...

Page 167: ...R 15 PAINTING AND COATINGS OVERVIEW 15 2 SERVICE 15 3 Supplies 15 3 Tools 15 3 Expendable 15 3 Replaceable 15 3 Service Schedule Procedures 15 3 Powder coat repair 15 3 Primer repair 15 4 Decorative p...

Page 168: ...ow available Most of these are two part catalytic curing primers Generally speaking it s preferable to replace a coated part with a coated part Following is a partial list of suitable primers DUPONT V...

Page 169: ...H UP PAINT CAUTION ANY SCRATCH THAT MAY HAVE PENETRATED THE ALCLAD COATING MUST BE CLEANED AND PRIMED PROPERLY SUPPLIES TOOLS EXPENDABLE Scouring pad Sandpaper various grades Touch up paint Primer Dec...

Page 170: ...entire prepared area 4 Apply touch up paint to the entire prepared area PRIMER REPAIR NOTE WHEN PRIMING A REMOVABLE PART BETTER RESULTS CAN BE ACHIEVED BY REMOVING THE PART Tools Sandpaper Expendable...

Page 171: ...one Service Rating Line Minimum Certification Static structure Total area 64 in or less Owner and SPC Total area greater than 64 in LSA RM or A P Control surface Total area 16 in or less Owner and SPC...

Page 172: ...Rev 1 15 6 THIS PAGE INTENTIONALLY LEFT BLANK...

Page 173: ...ool Low engine coolant Engine below operating temperature Blockage in coolant system Air leak around heater box 12 Vent door stuck Damage to fuselage Damage to vent Over tightened vent hardware 3 5 KA...

Page 174: ...ose fasteners Loose baggage 3 Corrosion Loose electrical connection Exposure to contamination Failing protective coating Unlike metals exposed to moisture 8 3 15 15 Flight control resistance Insuffici...

Page 175: ...he parts identified as affected by the anomaly Description of the apparent condition of the parts prior to the anomaly de burred primed modified etc Statement as to whether the aircraft has remained w...

Page 176: ...craft Inc using the following information Van s Aircraft Inc 14401 Keil Road NE Aurora OR 97002 USA Phone 503 678 6545 Fax 503 678 6560 Website www vansaircraft com email orders vansaircraft com Part...

Page 177: ...07N 12mm 1 75 Quick Oil Drain Plug CCA 2450 Valve and CCA 2474 Extension SAF AIR M12175 Valve and RM12175 Extension Torx Drive Screw AN526C832 R8 Phillips Truss SS X 1 2 in Fastenal 0175181 Torx Pan H...

Page 178: ...Rev 4 17 4...

Page 179: ...Rev 4 17 5 THIS PAGE INTENTIONALLY LEFT BLANK...

Page 180: ...Rev 8 18 1 CHAPTER 18 SUPPLEMENT SERVICE SCHEDULE CHECKLIST 18 3 INSPECTION CHECKLIST 18 7 ELECTRICAL SYSTEM SCHEMATIC 18 23 3 VIEW 18 25 FEEDBACK FORM 18 27...

Page 181: ...Rev 8 18 2 THIS PAGE INTENTIONALLY LEFT BLANK...

Page 182: ...eplace 5 years 12 15 Engine service procedures Check perform 100 hours Rotax maintenance manual Exhaust ball joints Lubricate Annual or 100 hours 14 4 Flaperon bearings Lubricate 6 months or As needed...

Page 183: ...Rev 8 18 4 THIS PAGE INTENTIONALLY LEFT BLANK...

Page 184: ...24 Wheel Balance Balance As needed 5 26 Oil Supply Hoses Replace 10 years or engine overhaul 12 14 Propeller Hub Clamping Bolts Torque Annual or 100 hours 11 3 Wing attach locations Lubricate Each rem...

Page 185: ...Rev 8 18 6 THIS PAGE INTENTIONALLY LEFT BLANK...

Page 186: ...ments Pass Fail Certificate of Airworthiness Onboard and Displayed Registration Onboard POH Onboard Operating Limitations Onboard Switch and control placards Secure Legible Identification Plate Secure...

Page 187: ...Rev 8 18 8 THIS PAGE INTENTIONALLY LEFT BLANK...

Page 188: ...g Secure Smooth operation of ailerons and flaps Brake System Operation Fuel Correct Indication Idle RPM at normal operating temp _________ RPM Verify function of throttle return springs Springs pull t...

Page 189: ...Rev 8 18 10 THIS PAGE INTENTIONALLY LEFT BLANK...

Page 190: ...anopy Latch Security Cracks Proper operation Fwd Aft Canopy Cracks Deformation Deterioration Pre Inspection procedure Step 1 5 Page 3 3 Seats Seat Shoulder Harness Wear Fraying Cockpit Control Marking...

Page 191: ...Rev 8 18 12 THIS PAGE INTENTIONALLY LEFT BLANK...

Page 192: ...Stick Smooth Operation Flap Lever Smooth Operation Air Heat Vents Operation Security Wiring Harness Condition Connections Continuity System Lines Fuel Brake Static Security Routing Condition Fittings...

Page 193: ...Rev 8 18 14 THIS PAGE INTENTIONALLY LEFT BLANK...

Page 194: ...ate Also refer to current CFR 91 207 Battery Also refer to current CFR 91 207 Propeller Refer to Sensenich Manual Pass Fail Spinner Back plate Cracks Deformation Blades Delamination Cracks Damage Hard...

Page 195: ...Rev 8 18 16 THIS PAGE INTENTIONALLY LEFT BLANK...

Page 196: ...Door Security Condition Operation Left Carburetor Condition Secure Connections Right Carburetor Condition Secure Connections Carburetor Drip Trays Cracks Deformation System Lines Fuel Pitot Security...

Page 197: ...Rev 8 18 18 THIS PAGE INTENTIONALLY LEFT BLANK...

Page 198: ...Shoes Lining Limit Refer to Matco manual Brake Disks Cracks Deformation Refer to Matco manual Wheels Alignment Cracks Refer to Matco manual Tires Valve Stem Wear Cracks Air Pressure Nose Gear and For...

Page 199: ...Rev 8 18 20 THIS PAGE INTENTIONALLY LEFT BLANK...

Page 200: ...ntrol Cable Links Push Pull Rods Tension Wear Fatigue Control Stops Security Deformation Alignment Rear Spar Doubler Check for Gap Paperwork Pass Fail Record Findings Aircraft Log Record Inspection Ai...

Page 201: ...Rev 8 18 22 THIS PAGE INTENTIONALLY LEFT BLANK...

Page 202: ...Rev 8 18 23 ELECTRICAL SYSTEM SCHEMATICS Refer to P O H or http www vansaircraft com public downloads htm...

Page 203: ...Rev 8 18 24 THIS PAGE INTENTIONALLY LEFT BLANK...

Page 204: ...Rev 8 18 25 3 VIEW...

Page 205: ...Rev 8 18 26 THIS PAGE INTENTIONALLY LEFT BLANK...

Page 206: ...umber Aircraft Model Contact Name Phone Number Total Time Serial Number Inspector Name Phone Number Engine Model Inspection Date Storage Inside outside etc Total Time Serial Number Location City State...

Page 207: ...Rev 8 18 28 THIS PAGE INTENTIONALLY LEFT BLANK...

Page 208: ...ear on an LSA in accordance with instructions provided in the maintenance manual supplied with the aircraft and F39 Appendix D The purpose of the inspection is to identify any wear corrosion or damage...

Page 209: ...acturer s maintenance manual LSA Repairman Inspection LSA RI U S FAA certified repairman light sport aircraft with an inspection rating as defined by 14 CFR Part 65 authorized to perform the annual co...

Page 210: ...tions and the replacement of small standard parts not involving complex assembly operations Special Light Sport Aircraft S LSA Applies to the aircraft covered in this manual provided it remains consis...

Page 211: ...Rev 3 19 4 THIS PAGE INTENTIONALLY LEFT BLANK...

Page 212: ...8 5 Charging 8 14 Installation 8 5 Removal 8 5 Terminals 8 14 Bellcrank Bearing 6 8 Stops 3 6 Brake pedal Lubrication 7 4 Brake Shoe Lining Inspection See Matco Manual Replacement 7 6 Brake System 7...

Page 213: ...ator Transmitter Inspection 3 7 Empennage 5 6 Inspection 3 13 Engine 1 12 12 3 Firing Order 12 3 Inspection See Rotax Manual Lubrication Coolant 12 6 Oil 1 13 12 6 Operating limits See Rotax Manual Re...

Page 214: ...ection 3 5 Replacement 5 22 Heat See Utilities Hinge Cowl 12 16 Hinge Anti Servo Tab 5 25 Flaperon 5 17 Rudder 5 18 Stabilator 5 19 I Idle Setting 12 12 Inner tube Main 5 16 Nose 5 17 Inspection 3 1 C...

Page 215: ...Assembly 5 9 O Oil See Engine P Paint See Painting and coating Painting and Coating 15 1 Panel Circuit Board 8 9 Piston Removal 12 18 Pitch Trim Servo Replacement 8 7 Pitot Static 9 3 Powder coat Repa...

Page 216: ...re 9 6 Spark Plug 12 3 Replacement 12 5 Stabilator 5 7 Control cable pulley 6 3 Inspection 3 15 Stub Spar Lubrication 5 23 Supplement 18 1 Substitute Parts 17 3 T Throttle Cable Lead Hookup 12 10 Thro...

Page 217: ...Rev 4 20 6 W Weight and Balance 1 18 Wheel Bearings Main 5 26 Nose 5 25 Wing Attach Location Lubrication 5 25 Fuselage Pins 5 25 Stub Spar and Rear Spar 5 25...

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