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Rev.5

12-18

YLINDER

PISTON AND VALVE ASSEMBLY REMOVAL

EMOVAL

1. Remove the exhaust system, see Exhaust System chapter.

2. Disconnect all wires and fuel pump drain tube from oil return tubes if/as required.

3. Disconnect oil pressure, EGT, and CHT wires from cylinder heads as required.

See Rotax Line and Heavy Maintenance Manuals for the remaining steps:

4. Drain coolant; remove intake manifolds, water hoses, valve covers, cylinders,

pistons, and valve assemblies.

NSTALLATION

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 for engine disassembly

Expendable

Tie wraps, engine coolant

Replaceable

Coolant Hoses - reuse if serviceable, coolant

Service Rating

Heavy

Minimum Certification

LSA-RM with Rotax Maintenance certification or

A&P with Rotax Maintenance certification

Additional References

KAI, Rotax Line and Heavy Maintenance

Manuals

▲

WARNING:

LLOW THE ENGINE AND APPLICABLE COMPONENTS TO COOL

BEFORE PERFORMING SERVICE OR INSPECTION

OT ENGINE COMPONENTS

WILL CAUSE SERIOUS BURNS

Содержание RV-12

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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 _____ ______...

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

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 178: ...Rev 4 17 4...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

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

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

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

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

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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