Van's Aircraft RV 12iS Скачать руководство пользователя страница 53

Страница: 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

Содержание RV 12iS

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

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ____...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

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

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 178: ...Rev 2 Date 11 15 18 17 4 THIS PAGE INTENTIONALLY LEFT BLANK...

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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 _______...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 204: ...Rev 2 Date 11 15 18 18 26 THIS PAGE INTENTIONALLY LEFT BLANK...

Страница 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...

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

Страница 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...

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

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

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

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 216: ...Rev 2 Date 11 15 18 19 4 THIS PAGE INTENTIONALLY LEFT BLANK...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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