Van's Aircraft RV 12iS Maintenance Manual Download Page 53

Page: 53 / 222

Rev: 2

Date: 11/15/18

4-1

OVERVIEW

Visible deformation of or damage to any aircraft skin warrants a complete

inspection of the underlying parts or structures. If all damaged parts are replaced in

accordance with the Kit Assembly Instructions KAI no consultation of the manufacturer

is necessary.

Small patch repairs to skins as outlined in 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 than replacement of the

entire skin or patches to skins) of more than 60 square inches are not allowed without

consulting with the airplane manufacturer and receiving approval of the planned method

of repair. Note: Integral stringers formed on the edge of skins are considered interior

structure.

Chapter 4

- STRUCTURAL REPAIRS

Summary of Contents for RV 12iS

Page 1: ...Rev 2 Date 11 15 18 i MAINTENANCE MANUAL Aircraft Serial Number ___________________________...

Page 2: ...Rev 2 Date 11 15 18 ii THIS PAGE INTENTIONALLY LEFT BLANK...

Page 3: ...ntenance Manual MM compare the rev level found on the cover page with the latest revision posted on the RV 12 Service Information page of the Van s Aircraft web site Rev Page Change Date 0 None Initia...

Page 4: ...rcraft Inc of any safety of flight issue or significant service difficulty upon discovery using the Feedback Form provided in the Maintenance Manual The owner operator of an RV 12iS shall comply with...

Page 5: ...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 fuse...

Page 6: ...R 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 FLIGHT CONTROLS 6 1 OVERVIEW 6 2 SERVICE 6 3 C...

Page 7: ...chematics 13 4 SERVICE 13 6 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 CHAPTER 16 TROUBLESHOOTING 16 1 CHAPTER 17 FEEDBA...

Page 8: ...stallation 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...

Page 9: ...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 Fligh...

Page 10: ...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 serv...

Page 11: ...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 illustrat...

Page 12: ...ance 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...

Page 13: ...ultation 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 safe...

Page 14: ...r 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...

Page 15: ...05 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...

Page 16: ...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...

Page 17: ...1 9 Combination Wrenches Ratchet Screwdrivers Sockets Allen Wrenches Gap Gauge Oil Filter Cutter Heavy Stands Step Ladder Oil Filter Wrench Battery Charger Multi meter Magnifying Glass Square Air Pres...

Page 18: ...ev 2 Date 11 15 18 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: ...tax 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...

Page 20: ...he 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 Ser...

Page 21: ...ty 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 determin...

Page 22: ...ters 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...

Page 23: ...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...

Page 24: ...D CONTACTING ANTENNA FAIRINGS OR OTHER ACCESSORIES WHILE PLACING THE SUPPORT STANDS UNDER THE AIRCRAFT CAUTION REMOVE OR ATTACH THE WINGS PRIOR TO LIFTING AND SUPPORTING THE AIRCRAFT When the aircraft...

Page 25: ...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 v...

Page 26: ...easing 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...

Page 27: ...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 ____...

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

Page 29: ...ON SV D1100 T 57 90 DYNON DUAL SV D1100 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...

Page 30: ...Rev 2 Date 11 15 18 1 22 INSTALLED EQUIPMENT LIST ITEM WEIGHT lbs ARM in INSTALLED MOMENT in lbs GARMIN GTR225 PS ENGINEERING PM3000 RV TOTAL SKYVIEW...

Page 31: ...465 57 90 GARMIN GMC 305 307 57 57 GARMIN GEA 24 47 12 GARMIN GTX 23ES 50 93 GARMIN GMU 22 141 73 TCW IBBS 12V 3AH 50 73 GARMIN GSU 25 118 76 GARMIN GA 26C 43 13 GARMIN GA 26XM 43 13 GARMIN GTR 200 54...

Page 32: ...Rev 2 Date 11 15 18 1 22 INSTALLED EQUIPMENT LIST ITEM WEIGHT lbs ARM in INSTALLED MOMENT in lbs GARMIN GTR225 TOTAL G3X...

Page 33: ...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 L...

Page 34: ...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 colu...

Page 35: ...ection 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...

Page 36: ...3 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...

Page 37: ...l 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 R...

Page 38: ...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 Cov...

Page 39: ...e 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 interfe...

Page 40: ...e off position Test the full motion of the engine throttle control for smooth operation and proper operation of the friction control Test for proper operation of the fuel on off valve Confirm arm on v...

Page 41: ...nts Special Tools Torque wrench Blade pitch measuring tool WARNING THE MASTER POWER AND BOTH IGNITION SWITCHES MUST BE SHUT OFF DURING INSPECTION OF THE PROPELLER SERIOUS INJURY OR DEATH WILL RESULT I...

Page 42: ...xcessive temperature of components Check for wear to hoses cables wiring harnesses etc as a result of vibration while in contact with another object Check the forward side of the firewall especially a...

Page 43: ...ents in the engine compartment All hoses and other rubber components provided with the engine have a service life defined in the Rotax maintenance manual Service life of all other hoses and components...

Page 44: ...on VERTICAL STABILIZER Check the main skin and forward skin for deformation or cracks Check the main skin fasteners by sighting along each rivet pattern for any inconsistent rivet profile among simila...

Page 45: ...r any inconsistent rivet profile among similar properly installed rivets Inspect the Anti Servo Tab hinges fasteners and safety wire for wear and security Inspect the spar box for cracks deformation o...

Page 46: ...AST by actuating the stabilator through its full range of motion with the trim adjusted to the full nose up and full nose down settings AST movement must be smooth and relative to the stabilator move...

Page 47: ...ecurity of each of the landing gear legs The landing gear components may not have any free play in any direction Check that all attach hardware is at proper torque Remember to account for the prevaili...

Page 48: ...utboard portion of the rear spar Inspect the main spar rear spar and stub spar for corrosion deformation signs of wear or fatigue Inspect the rear spar and stub spar for lubrication at the inboard end...

Page 49: ...rning circuit by unlatching each pin individually to verify it causes the switch panel warning light to illuminate REAR SPAR DOUBLER If the W 1207B rear spar doubler has been trimmed too much the fini...

Page 50: ...ntil 130 kts indicates then stop Using a second syringe push plunger in to 7 5cc Use modeling clay to hook up the syringe and vacuum hose to the AOA port Pressurize the AOA port Watch the EFIS AOA ind...

Page 51: ...en in one minute If the AOA system does not hold test pressure for the required time inspect the modeling clay to wing seal before inspecting other AOA system components Inspect and repair or replace...

Page 52: ...Rev 2 Date 11 15 18 3 18 THIS PAGE INTENTIONALLY LEFT BLANK...

Page 53: ...lined in 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...

Page 54: ...s is an LSA Repairman Maintenance or an FAA certificated A P technician Refer to the KAI to identify individual parts and their corresponding part numbers NOTE Stop drill cracks per AC 43 13 Report an...

Page 55: ...allation 5 16 Main inner tube replacement 5 17 Nose inner tube replacement 5 17 Flaperon hinge replacement 5 18 Rudder hinge replacement 5 19 Stabilator hinge bearing replacement 5 20 Main gear remova...

Page 56: ...ON WITH THE RV 12IS 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 NEG...

Page 57: ...rence 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 01205 2 2 Occupant Harness System See shaded items below Ref...

Page 58: ...ub spar the main spar and the rear spar Two fuselage pins secure both main spars to the center section of the fuselage The left wing has a stall warning sender and AOA sensor port installed Electrical...

Page 59: ...W 1208C L 1 Rear Spar W 1207A L W 1207B 1 Stall Warning See 5 4 and KAI 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 Spa...

Page 60: ...he top of the vertical stabilizer rudder and are optional on the ends of the Stabilator The rudder is attached through hinges on the rear spar of the vertical stabilizer The stabilator attaches to hin...

Page 61: ...Lower 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 Re...

Page 62: ...rk attaches and pivots at the lower end An axle bolt and nut fastens the axle spacers and wheel and tire assembly to the nose fork The main gear legs are aluminum fastened to the center section channe...

Page 63: ...Inbd Wear Plate U 01203B 1 2 Doubler Plate U 01203C 1 2 Inbd Doubler Plate U 01203E 1 2 Main Wheel assembly See shaded items below 1 Main Wheel U MHMHE51B 2 Wheel Bearings BEARING LM 67000L A 1 Axle...

Page 64: ...held in place by a single screw The nose leg fairing is slotted to fit about the nose leg winching lug The wheel fairing aft attaches to the wheel fairing front which in turn attaches to the nose fork...

Page 65: ...fairings 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...

Page 66: ...ed at least 50 of its length 1 4 Flat Washer 2 and Hex Nut 30 drill bit Drill motor 1 8 clecos and pliers Blind rivet puller Rivet squeezer dies Cotter pins Safety wire Wheel bearing grease Spray lubr...

Page 67: ...ions as detailed on 5 26 2 Installation procedure is the reverse of the removal procedure Install the left wing first right wing second The wing root seal strip on the side of the fuselage can be used...

Page 68: ...able None Replaceable 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...

Page 69: ...itional References Matco User Manual Grove User Manual KAI 1 Lift and support the aircraft 1 16 2 Remove the stationary brake shoe bolts 2 washers 2 spacer and brake shoe 3 Remove the cotter pin axle...

Page 70: ...nimum 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 assembly 5 15 3 Remove the brake disc...

Page 71: ...te 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 pressure see page 1 14 8 Reassemble and i...

Page 72: ...THE WEIGHT AND AWKWARDNESS OF THE OBJECT TO BE REMOVED 1 Remove the wings 5 13 2 Make note of the flaperon hinge hardware configuration 3 Remove the flaperon hardware and flaperon assembly 4 Measure...

Page 73: ...ESS OF THE OBJECT TO BE REMOVED 1 Remove the upper and lower tailcone fairing 3 4 2 Remove the rudder control cables and rudder assembly 3 Remove from the vertical stabilizer the rudder hinge hardware...

Page 74: ...CONE 2 Remove the two aft most belly inspection covers 3 Remove the Lock Clips from one of the cable tensioners Locking clips are one use only Clips must be discarded after removal 4 Rotate the tensio...

Page 75: ...surface of the bearing around the entire circumference next to the edge of the VA 146A Flange Housing 14 Pressing in the bearing Using the same process as removing use the small socket to press the be...

Page 76: ...he remaining inboard and outboard attach bracket hardware 7 Remove the main gear leg INSTALLATION 1 Installation procedure is reverse of the removal procedure 2 Add hydraulic fluid and bleed the brake...

Page 77: ...rvice Rating Line Minimum Certification Owner and SPC LSA RM or A P Additional References KAI WARNING HARNESS PARTS THAT SHOW ANY SIGN OF WEAR REQUIRE THAT THE ENTIRE HARNESS SET BE REPLACED IMMEDIATE...

Page 78: ...LSA RM or A P Additional References KAI 1 Based on the measurement from Section 3 Inspection choose one of the replacement W 1207B x rear spar doublers There are four different parts available rangin...

Page 79: ...r Pin insertion remove the wing un cleco the doubler and file the contour of the curve to reduce its profile by a few thousandths of an inch and test fit again Note When reducing the length the primar...

Page 80: ...he 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 each wing AOA ALUMINUM CONNECTOR TUBE 1 Wipe c...

Page 81: ...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 AST attach hinges 3 Apply lubricant along the top of the left...

Page 82: ...wheel bearings 6 Install the wheel and tire assembly and adjust as described in the appropriate wheel user manual NOSE FORK PIVOT TENSION AND LUBRICATION Special Tools Tensile weight scale Expendable...

Page 83: ...oard wheel 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 Thoroughl...

Page 84: ...Rev 2 Date 11 15 18 5 30 THIS PAGE INTENTIONALLY LEFT BLANK...

Page 85: ...al 6 3 Stabilator pulley replacement and cable tension adjustment 6 3 Control cable replacement 6 6 Rod end replacement 6 7 Bellcrank bearing replacement 6 7 Rudder pedal removal 6 8 Installation 6 8...

Page 86: ...sole Refer to the KAI to identify the individual parts and part s of the control system NOTE This maintenance manual is intended to be used in conjunction with the RV 12iS Kit Assembly Instructions KA...

Page 87: ...er pins Safety wire Spray lubricant MS21256 1 Lock Clips REPLACEABLE Stabilator pulley Stabilator cables Rudder cables Bearing DW4K2X Bellcrank Rod ends Control Stick M3414 CM 4MS Flaperon F3514M Trim...

Page 88: ...ys 5 Capture the stabilator cables between the bushing and the new pulleys 6 Install the pulley axle hardware 7 Place a small weight on the stabilator to hold it trailing edge down Remove the slack fr...

Page 89: ...l sticks are moved suddenly and repeatedly forward then aft 9 Remove the clamp and stick from the control stick and the weight from the stabilator Move the control stick between the forward and aft pi...

Page 90: ...ove the stabilator pulleys 6 4 NOTE TIE A STRING LONGER THAN THE CONTROL CABLE TO THE FWD END OF THE CONTROL CABLE AND WRAP THE SAME END OF THE CONTROL CABLE WITH A PIECE OF TAPE TO AVOID BULKHEAD DAM...

Page 91: ...body 4 Remove the rod end and jam nut 5 Add a jam nut to the new rod end shaft 6 Install the new rod end to the position from step 3 of the original rod end 7 Install the control rod and control rod a...

Page 92: ...HOUT DISCONNECTING THE BRAKE LINES 3 Label and then remove the master cylinders 4 from the rudder pedals 7 3 4 Remove the rudder cable hardware from each rudder cable cotter pin bolt washers 3 and nut...

Page 93: ...tion to penetrate then wipe away excess CABLE END HARDWARE LUBRICATION Expendable Spray lubricant Replaceable None Service Rating Line Minimum Certification LSA RM or A P Additional References KAI 1 R...

Page 94: ...Rev 2 Date 11 15 18 6 10 THIS PAGE INTENTIONALLY LEFT BLANK...

Page 95: ...Replaceable 7 3 General 7 3 Master cylinder removal 7 3 Removal 7 3 Disconnection 7 3 Installation 7 4 Service Schedule Procedures 7 4 Brake pedal torque tube lubrication 7 4 Hydraulic fluid drain flu...

Page 96: ...ed to be used in conjunction with the RV 12iS Kit Assembly Instructions KAI when completing maintenance or repair processes COMPONENTS Quantity Part or Assembly Name Part Number or Reference 2 Disc an...

Page 97: ...ON THE LEFT AND RIGHT MASTER CYLINDERS ON EACH SIDE OF THE AIRCRAFT ARE NOT INTERCHANGABLE Expendable Hydraulic fluid Cotter pins Replaceable Left Right Brake master cylinder Service Rating Line Minim...

Page 98: ...laceable None Service Rating Line Minimum Certification LSA RM or A P Additional References KAI Section 28 NOTE SERVICE ONE PEDAL AT A TIME 1 Actuate the rudder pedals so that the brake pedal to be se...

Page 99: ...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 cali...

Page 100: ...g mounting plate 4 Check that the brake disc is within thickness wear limits Replace if necessary 5 Install new linings on the brake mounting plates per Matco or Grove instructions 6 Install the float...

Page 101: ...CE 8 4 Supplies 8 4 Special Tools 8 4 Expendable 8 4 Replaceable 8 4 General 8 5 Battery removal 8 5 Installation 8 5 Fuse replacement 8 6 Pitch trim servo replacement 8 7 Electrical component replace...

Page 102: ...rvos fans avionics and control switches are all fused secondary circuits and part of the primary circuit NOTE This maintenance manual is intended to be used in conjunction with the RV 12iS Kit Assembl...

Page 103: ...ached inside the wing skin The eyeball light mounts to the rollover structure Figure 20 Optional Wing Tip Lighting eyeball light not shown OPTIONAL COMPONENTS Quantity Part or Assembly Name Part Numbe...

Page 104: ...UST BE OF THE SAME TYPE AND RATING AS THE ORIGINAL PARTS There are no serviceable electrical components Replace malfunctioning or failed components Electrical components that are omitted from the comp...

Page 105: ...tion Owner and SPC LSA RM or A P Additional References EarthX or Odyssey owner s manual 1 Remove the top cowl 12 4 2 Remove the negative battery cable 3 Remove the positive battery cable 4 Remove the...

Page 106: ...SES FOR ANY 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 o...

Page 107: ...and then remove them from the servo INSTALLATION 1 Thread the jam nut onto the new pitch trim servo shaft until it contacts the pitch trim servo shaft housing Thread the pitch trim servo shaft onto th...

Page 108: ...st 8 2 Service Rating Line Minimum Certification LSA RM or A P Additional References KAI 1 Disconnect negative ground wire 2 Remove the applicable access covers to expose the failed component 3 4 3 La...

Page 109: ...iginal wire sharp 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 wi...

Page 110: ...that are 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...

Page 111: ...onal References 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 shou...

Page 112: ...y charger connected the automatic Start Power Button will no longer function see FTS Section VI START POWER SOLID STATE SWITCH 3 Charge the battery per the battery manufacturer instructions CAUTION TH...

Page 113: ...C 9 3 Components 9 4 SERVICE 9 4 Supplies 9 4 Special Tools 9 4 Expendable 9 4 Replaceable 9 4 General 9 5 Component replacement 9 5 Pitot Static and AOA component replacement 9 5 Light replacement 9...

Page 114: ...ock to the air data computer either under the baggage floor cover or in the upper tail cone A port similar to that used for the static system is located in the left wing for use as an Angle of Attack...

Page 115: ...ntroller See Garmin Manual 1 Landing light See Aero LED Manual 2 Navigation Strobe light See Aero LED Manual 1 Cockpit light LC ELC 01 1 SkyView HDX or G3X Dual EFIS EMS See Dynon or Garmin Manual 1 A...

Page 116: ...NENTS WIRE TERMINALS AND FUSES MUST BE OF THE SAME TYPE AND RATING AS THE ORIGINAL PARTS Software updates are often available online for the Skyview HDX and Garmin G3X The physical avionics components...

Page 117: ...er Expendable Plastic tie wraps Replaceable Connector Tubing Service Rating Line Minimum Certification LSA RM or A P Additional References KAI REMOVAL 1 Make note of routing location and orientation o...

Page 118: ...ht Module Service Rating Line Minimum Certification Owner and SPC LSA RM or A P Additional References KAI REMOVAL 1 Remove the light and fastening hardware Cockpit light screws 3 Landing light screws...

Page 119: ...245 Input Level Stall Warning AUX 1 AUX 1 EFIS Warning Set up Menu AUX 2 ALERT 1 Music Level Music Level no XM ENTERTAINMENT 1 XM Music NAV Audio 1 VOR ILS NAV AUDIO 1 GTN Main Audio Touch Clicks ALER...

Page 120: ...CEDURE PERIODIC CHECKS SHOULD BE MADE AT A MINIMUM OF EACH CONDITION INSPECTION TO DETERMINE IF ANY SOFTWARE UPDATES HAVE BEEN ISSUED FOR THE EFIS EMS OR GPS SOFTWARE UPDATES Special Tools Computer wi...

Page 121: ...10 1 Chapter 10 UTILITY SYSTEMS OVERVIEW 10 2 HEAT 10 2 Components 10 3 VENTILATION 10 3 Components 10 4 SERVICE 10 4 Supplies 10 4 Expendable 10 4 General 10 4 Vent door adjustment 10 4 Service Sched...

Page 122: ...n ventilation 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 12iS Kit Assembly Instr...

Page 123: ...erence 1 Heat Muff Assy FF 00090 2 Heat Control Valve Vent 00001 Assy 3 Heat Muff Hose 2 SCAT FF 00091 2 Push Pull Cable CT A 740 BLACK VENTILATION A hand operated vent on each side of the cockpit pro...

Page 124: ...inspections are necessary to ensure all of the components remain in good condition SUPPLIES EXPENDABLE Spray lubricant GENERAL VENT DOOR ADJUSTMENT Expendable None Service Rating Line Minimum Certifi...

Page 125: ...Rev 2 Date 11 15 18 10 5 SERVICE SCHEDULE PROCEDURES NONE...

Page 126: ...Rev 2 Date 11 15 18 10 6 THIS PAGE INTENTIONALLY LEFT BLANK...

Page 127: ...Rev 2 Date 11 15 18 11 1 OVERVIEW 11 2 Components 11 2 SERVICE 11 2 Supplies 11 2 Special Tools 11 2 Expendable 11 2 Replaceable 11 2 Spinner and Pitot Tube 11 3 Prop Hub 11 3 Chapter 11 PROPELLER...

Page 128: ...njunction with the RV 12iS Kit Assembly Instructions KAI when completing maintenance or repair processes COMPONENTS Quantity Part or Assembly Name Part Number or Reference 1 Propeller 2A0R5R70EN V 1 S...

Page 129: ...the KAI 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 M...

Page 130: ...ate it 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...

Page 131: ...nt 12 6 Engine oil level check 12 6 Engine coolant level check 12 7 Air filter removal installation 12 7 Carburetor Syncronization 12 8 Verify Functionality of Throttle Return Spring 12 10 Throttle Ca...

Page 132: ...the 912iS there is only a throttle control NOTE This maintenance manual is intended to be used in conjunction with the RV 12iS Kit Assembly Instructions KAI when completing maintenance or repair proc...

Page 133: ...Rev 2 Date 11 15 18 12 3 ENGINE Figure 26iS Rotax 912iS Sport Figure 26ULS Rotax 912ULS Current engine product manuals and or specifications take precedence over any...

Page 134: ...umentation IGNITION Dual Breakerless Capacitor Discharge Firing Order 1 4 2 3 SERVICE Refer to the engine manual for full engine service details The cowling does not require regular maintenance The co...

Page 135: ...Remove the screws 4 that attach the air box filter plate to the engine air duct 3 Disconnect the SCAT hose from the inlet vent at the bottom left 4 Remove the aft hinge pins 4 and remove the lower co...

Page 136: ...T THE NEGATIVE GROUND WIRE TO THE BATTERY Expendable None Replaceable None Service Rating Line Minimum Certification Owner and SPC LSA RM or A P Additional References Rotax 912 Operator Manual 1 Remov...

Page 137: ...anual 1 Place a rag over the expansion tank cap 2 Loosen cap to the first detent then step back for a few seconds 3 Remove the expansion tank cap 4 The expansion tank must be full of coolant 5 Replace...

Page 138: ...1 Vacuum gauge set Expendable None Replaceable None Service Rating Line Minimum Certification LSA RM with Rotax Service certification or A P with Rotax Service certification Additional References Rot...

Page 139: ...GE NOTE OFTEN TIMES WARMING THE ENGINE BY RUNNING IT ON THE GROUND DOES NOT QUITE BRING IT UP TO NORMAL OPERATING TEMPERATURES THIS WILL HAVE A SLIGHT EFFECT ON WHAT THE ACTUAL IDLE RPM WILL BE ONCE T...

Page 140: ...P Additional References KAI If the throttle is not pulled to full during verification see Verify Functionality of Throttle Return Springs section remove and lubricate the cable REMOVAL 1 Remove F 0124...

Page 141: ...rse of the removal procedure 2 Perform the carburetor sync procedure found in this section Reference Service Bulletin 18 03 06 SERVICE SCHEDULE PROCEDURES COWL HINGE PIN LUBRICATION Expendable Dry lub...

Page 142: ...ailed in Rotax Service Instruction SI 912 018 COOLING HOSE REPLACEMENT WARNING BEFORE PERFORMING ANY INSPECTION OR SERVICE ALLOW THE ENGINE COMPONENTS TO COOL REMOVAL 1 With a catch pan located below...

Page 143: ...MENT REMOVAL 1 Remove battery ground cable from negative battery terminal 2 Disconnect Heat valve SCAT hoses from heat muff 3 ULS only Disconnect fuel pump drain tube and hose where attached to the en...

Page 144: ...If not equipped remove fwd upper skin from fuselage 16 iS Only Disconnect both ECU harness cables from the ECU module refer to Rotax documentation 17 iS Only Remove harness cable cover plate from fir...

Page 145: ...Rev 2 Date 11 15 18 13 1 Chapter 13 FUEL SYSTEM ULS SYSTEM iS SYSTEM...

Page 146: ...gallon fuel tank tank fuel level sending unit mechanical fuel level gauge a finger screen fuel strainer at the bottom tank outlet preventing larger foreign objects from progressing through the fuel s...

Page 147: ...rse finger screen iS VA 265 1 Fuel shut off valve 250 Pipe Fuel Valve 4161089 1 Fuel Valve Cable Assy 100 CT 01204 1 Fuel quick drain CAV 110 1 Fuel sending unit IE F 385B 1 ADAPTOR 25X 25X 25X 125 NP...

Page 148: ...Rev 2 Date 11 15 18 13 4...

Page 149: ...Rev 2 Date 11 15 18 13 5...

Page 150: ...S THAT ARE FORWARD OF THE FUEL VALVE DRAIN THE FUEL SYSTEM TO SERVICE OR REMOVE COMPONENTS AFT OF THE FUEL VALVE SUPPLIES SPECIAL TOOLS EXPENDABLE Safety wire pliers Fuel Container 1 8 NPT x 3 8 hose...

Page 151: ...valve from the bottom of the gascolator ULS or fuel drain assembly iS 5 Install the hose barb with hose attached in the opening where the fuel drain was removed 6 Move the fuel selector control to th...

Page 152: ...onal References KAI 1 Drain the fuel system 13 17 2 Loosen the two clamps and remove the fuel filler hose from the fuel tank and filler neck assy 3 Remove the screws 4 and the center access cover plat...

Page 153: ...Safety wire pliers Fuel catch container Protective Gloves Expendable Safety wire Replaceable Gas 5 Screen Gas 5 O ring gasket Service Rating Line Minimum Certification Owner and SPC LSA RM or A P Addi...

Page 154: ...llation procedure is reverse of the removal procedure Apply thread sealant paste to fuel strainer pipe threads before installation FUEL PRESSURE RETURN ASSEMBLY REPLACEMENT ULS Special Tools torque wr...

Page 155: ...Hose Flush FUEL PRESSURE HOSE FLUSH ULS LEFT SIDE OF VA 216 HOSE ASSEMBLY Expendable NA Replaceable NA Service Rating Line Minimum Certification LSA RM with Rotax Service certification or A P with Rot...

Page 156: ...ditional References KAI 1 Place towels beside the Fuel Return hose connection at the firewall 2 Remove the VA 216 Fuel Return Assembly hose coupling from the firewall fitting and quickly move it to a...

Page 157: ...ain hose to the gascolator to fuel pump hose using tie wraps FUEL PRE FILTER CLEANING INSPECTION iS Special Tools Protective Gloves Safety Wire Expendable NA Replaceable NA Service Rating Line Minimum...

Page 158: ...ertification LSA RM or A P Additional References KAI 1 Move the fuel selector control to the OFF position 2 Place towels beneath the Main Fuel Filter CAUTION TURN OFF THE ELECTRIC FUEL PUMP IMMEDIATEL...

Page 159: ...r seal is undamaged New seal washers should be used on the banjo fittings Reinstall the main fuel filter assembly and related lines in the reverse order as removed Pay particular attention to proper p...

Page 160: ...ve the bowl and drain the fuel 4 Inspect gasket for integrity and position prior to installation 5 Bowl installation is reverse of removal WARNING EXPECT SOME FUEL DRAINAGE TO OCCUR AS THE BOWLS ARE R...

Page 161: ...UST SYSTEM OVERVIEW 14 2 Components 14 2 SERVICE 14 2 Supplies 14 2 Special Tools 14 2 Expendable 14 2 Replaceable 14 2 General 14 3 Exhaust system removal 14 3 Installation 14 3 Service Schedule Proc...

Page 162: ...BE USED IN CONJUNCTION WITH THE RV 12IS KIT ASSEMBLY INSTRUCTIONS KAI WHEN COMPLETING MAINTENANCE OR REPAIR PROCESSES COMPONENTS Quantity Part or Assembly Name Part Number or Reference 1 each ULS Cyl...

Page 163: ...om any pipe equipped ULS 2 iS 4 3 Remove the two upper SCAT hoses from the heat muff outlets NOTE TO AVOID NICKING THE EXHAUST ATTACH SPRINGS CLAMP A SHORT LOOP OF SAFETY WIRE IN LOCKING PLIERS HOOK T...

Page 164: ...ove the two SCAT hoses from the upper outlets on the heat muff NOTE TO AVOID NICKING THE EXHAUST ATTACH SPRINGS CLAMP A SHORT LOOP OF SAFETY WIRE IN LOCKING PLIERS HOOK THE LOOP ONTO THE SPRING AND TH...

Page 165: ...Chapter 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 Decor...

Page 166: ...or primers now 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 prim...

Page 167: ...UP PAINT CAUTION ANY SCRATCH THAT MAY HAVE PENETRATED THE ALCLAD COATING MUST BE CLEANED AND PRIMED PROPERLY SUPPLIES SPECIAL TOOLS EXPENDABLE Scotchbrite type pad Sandpaper various grades Touch up p...

Page 168: ...ry the entire prepared area 4 Apply primer and 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 Special T...

Page 169: ...aint Primer Replaceable None 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...

Page 170: ...Rev 2 Date 11 15 18 15 6 THIS PAGE INTENTIONALLY LEFT BLANK...

Page 171: ...ool 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 KAI Wing attach pin v...

Page 172: ...oose 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 Insuffic...

Page 173: ...commodate the BUDS ECU 9 pin d sub See Figure BUDS is a ROTAX product designed to read and extract data from the 912iS ECU Engine Control Unit The BUDS system utilizes BRP windows based software and a...

Page 174: ...Rev 2 Date 11 15 18 16 4 THIS PAGE INTENTIONALLY LEFT BLANK...

Page 175: ...of the 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 remai...

Page 176: ...t 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 numb...

Page 177: ...n Torx Drive Screw AN526C832 R8 Phillips Truss SS X 1 2 in Fastenal 0175181 Torx Pan Head SS X 1 2 in 0175180 3 8 in NOTE May be used in place of screws that hold all interior panels Rivets AN470AD ri...

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Page 179: ...Rev 2 Date 11 15 18 18 1 Chapter 18 SUPPLEMENT SERVICE SCHEDULE CHECKLIST 18 3 INSPECTION CHECKLIST 18 7 ELECTRICAL SYSTEM SCHEMATIC 18 29 3 VIEW 18 31 FEEDBACK FORM 18 33...

Page 180: ...Rev 2 Date 11 15 18 18 2 THIS PAGE INTENTIONALLY LEFT BLANK...

Page 181: ...ours 6 8 EFIS software Check for updates Annual or As needed Dynon or Garmin user s manual Coolant Hoses Replace 5 years 12 11 Engine coolant Replace 5 years Rotax maintenance manual Engine service pr...

Page 182: ...Rev 2 Date 11 15 18 18 4 THIS PAGE INTENTIONALLY LEFT BLANK...

Page 183: ...Pressure Hose Replace 10 years or eng ovhl 12 11 Nose fork pivot Lubricate Annual or 100 hours 5 28 Nose wheel bearings Replace As needed 5 27 Wheel Balance Balance As needed 5 29 Oil Supply Hoses Rep...

Page 184: ...Rev 2 Date 11 15 18 18 6 THIS PAGE INTENTIONALLY LEFT BLANK...

Page 185: ...ng Category Check Documents Pass Fail Certificate of Airworthiness Onboard and Displayed Registration Onboard POH Onboard Operating Limitations Onboard Switch and control placards Secure Legible Ident...

Page 186: ...Rev 2 Date 11 15 18 18 8 THIS PAGE INTENTIONALLY LEFT BLANK...

Page 187: ...gs pull throttle to wide open with friction control off see procedure page 12 10 Static RPM at full throttle Operational RPM ________________ Electrical System Operational Volts _________ Amps _______...

Page 188: ...Rev 2 Date 11 15 18 18 10 THIS PAGE INTENTIONALLY LEFT BLANK...

Page 189: ...tion Rudder Pedal Assemblies Cracks Proper operation Brake Pedal Assemblies Proper Operation Leaks Control Sticks Proper Operation Control system cables Wear Fraying Control system Excess play Frictio...

Page 190: ...Rev 2 Date 11 15 18 18 12 THIS PAGE INTENTIONALLY LEFT BLANK...

Page 191: ...and OFF position Wiring Harness Condition Connections Security System Lines Fuel Brake Static Security Routing Condition Fittings Fuel System Components Security Leaks Fuel Strainer Gascolator ULS onl...

Page 192: ...Rev 2 Date 11 15 18 18 14 THIS PAGE INTENTIONALLY LEFT BLANK...

Page 193: ...efer to current CFR 91 207 Audio Alert Indicator Battery See Manufacturer s Manual Remote Control Panel Ind Battery See Manufacturer s Manual Propeller Refer to Sensenich Manual Pass Fail Spinner Back...

Page 194: ...Rev 2 Date 11 15 18 18 16 THIS PAGE INTENTIONALLY LEFT BLANK...

Page 195: ...or Hardware Condition Torque Wiring Harness Condition Connections Continuity Battery Condition Corrosion Security Charge Cabin Heat valves and controls Security Condition Operation Throttle Control Ca...

Page 196: ...Rev 2 Date 11 15 18 18 18 THIS PAGE INTENTIONALLY LEFT BLANK...

Page 197: ...nge Brackets Deformation Cracks Signs of Wear Rudder Fiberglass Fairing Condition Security Rudder Control Horn Coating Damage Cracks Deformation Missing Fasteners Rudder Control Cables Swages Fastener...

Page 198: ...Rev 2 Date 11 15 18 18 20 THIS PAGE INTENTIONALLY LEFT BLANK...

Page 199: ...Alignment Cracks Refer to Matco manual Tires Valve Stem Wear Cracks Air Pressure Nose Gear and Fork Travel Security Break out Force Internal Cor Continued on next page Empennage Continued Check Pass...

Page 200: ...Rev 2 Date 11 15 18 18 22 THIS PAGE INTENTIONALLY LEFT BLANK...

Page 201: ...a of Left Right Wing Signs of Wear Cracks Damaged Fasteners Bulkheads Stringers Deformation Cracks Signs of Wear Corrosion Left Right Static Ports Clean Clear Secure Wing Electrical Connectors Corrosi...

Page 202: ...Rev 2 Date 11 15 18 18 24 THIS PAGE INTENTIONALLY LEFT BLANK...

Page 203: ...ar Corrosion Hinges Smooth Operation Play Lubrication Electrical Connections Corrosion Damage Stall Warning Secure Connection Condition Fuselage Pin Latching Mechanism Test Operation and Warning Indic...

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Page 205: ...Date 11 15 18 18 27 Paperwork Completed Record Findings Aircraft Log Record Inspection Aircraft Log Record Maintenance Aircraft Log Notes and explanation of discrepancies found End of inspection chec...

Page 206: ...Rev 2 Date 11 15 18 18 28 THIS PAGE INTENTIONALLY LEFT BLANK...

Page 207: ...Rev 2 Date 11 15 18 18 29 Electrical System Diagrams Refer to P O H or the Downloads Section under the Support tab of Van s Aircrafts web site www vansaircraft com...

Page 208: ...Rev 2 Date 11 15 18 18 30 THIS PAGE INTENTIONALLY LEFT BLANK...

Page 209: ...Rev 2 Date 11 15 18 18 31 3 VIEW...

Page 210: ...Rev 2 Date 11 15 18 18 32 THIS PAGE INTENTIONALLY LEFT BLANK...

Page 211: ...Phone Number 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 Cit...

Page 212: ...Rev 2 Date 11 15 18 18 34 THIS PAGE INTENTIONALLY LEFT BLANK...

Page 213: ...r 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 b...

Page 214: ...e manufacturer 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 an...

Page 215: ...ial Light Sport Aircraft S LSA Applies to the aircraft covered in this manual provided it remains consistent with the manufacturers design specifications Manufacturer design specifications are in acco...

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Page 217: ...Battery 8 5 Charging 8 12 Installation 8 5 Removal 8 5 Bellcrank Bearing 6 7 Stops 3 5 Brake pedal Lubrication 7 4 Brake Shoe Lining Inspection See Matco Manual Replacement 7 6 Brake System 7 1 Drain...

Page 218: ...age 5 6 Inspection 3 10 Engine 1 12 12 3 Firing Order 12 4 Inspection See Rotax Manual Lubrication Coolant 12 7 Oil 1 13 12 6 Operating limits See Rotax Manual Replacement 12 13 Specifications See Rot...

Page 219: ...spection 3 6 Removal 13 9 H Harness Shoulder 5 3 Inspection 3 6 Replacement 5 22 Heat See Utilities Hinge Cowl See Cowl Hinge Hinge Anti Servo Tab 5 27 Flaperon 5 18 Rudder 5 19 Stabilator 5 20 I Idle...

Page 220: ...d Tire Bearings 5 27 Installation 5 16 Removal 5 16 Nose Wheel Assembly 5 9 O Oil See Engine Overstress 3 1 P Paint See Painting and coating Painting and Coating 15 1 Pitch Trim Servo Replacement 8 7...

Page 221: ...nap bushing 8 11 Software 9 6 Spark Plug 12 4 Replacement 12 5 Stabilator 5 6 Control cable pulley 6 3 Inspection 3 11 Storage Long Term 13 15 Stub Spar Lubrication 5 26 Supplement 18 1 Substitute Par...

Page 222: ...Rev 2 Date 11 15 18 20 6 Wheel Bearings Main 5 28 Nose 5 27 Wing Attach Location Lubrication 5 26 Fuselage Pins 5 26 Stub Spar and Rear Spar 5 26...

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Van's Aircraft RV 12iS, Maintenance Manual

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