STEMME S12 Maintenance Manual

MAINTENANCE MANUAL STEMME S12
This aircraft may only be maintained in accordance with the
instructions given in this manual.
CONTACT
STEMME AG
Flugplatzstrasse F2, Nr. 6-7
D-15344 Strausberg
Phone: +49.3341.3612-0
E-mail: [email protected]
Web: www.stemme.com
All rights reserved.
Reproduction or disclosure to third parties of this document any
part there of is not permitted, except with the prior and express
written permission of STEMME AG.
CHAPTER-PAGE 0-2
AMENDMENT: 00
DATE: --
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
MAINTENANCE MANUAL STEMME S12
THIS PAGE IS INTENTIONALLY LEFT BLANK
CHAPTER-PAGE 0-4
AMENDMENT: 00
DATE: --
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
MAINTENANCE MANUAL STEMME S12
0.2
LIST OF EFFECTIVE PAGES
This list is only valid for the serial no. specified on title page. The list contains all amendments
of the maintenance manual, effective until final approval of this serial no. amendments added
later must be recorded.
PAGE
APPROVED
AM. NO.
DATE
CHAPTER 0
PAGE
APPROVED
AM. NO.
DATE
2-6
00
JUL 20, 2016
2-7
00
JUL 20, 2016
2-8
00
JUL 20, 2016
0-1
00
JUL 20, 2016
0-2
00
JUL 20, 2016
0-3
00
JUL 20, 2016
0-4
00
JUL 20, 2016
3-1
00
JUL 20, 2016
0-5
00
JUL 20, 2016
3-2
00
JUL 20, 2016
0-6
00
JUL 20, 2016
3-3
00
JUL 20, 2016
0-7
00
JUL 20, 2016
3-4
00
JUL 20, 2016
0-8
00
JUL 20, 2016
3-5
00
JUL 20, 2016
0-10
00
JUL 20, 2016
3-6
00
JUL 20, 2016
0-11
00
JUL 20, 2016
3-7
00
JUL 20, 2016
0-12
00
JUL 20, 2016
3-8
00
JUL 20, 2016
0-13
00
JUL 20, 2016
3-9
00
JUL 20, 2016
0-14
00
JUL 20, 2016
3-10
00
JUL 20, 2016
0-15
00
JUL 20, 2016
3-11
00
JUL 20, 2016
0-16
00
JUL 20, 2016
3-12
00
JUL 20, 2016
0-17
00
JUL 20, 2016
3-13
00
JUL 20, 2016
0-18
00
JUL 20, 2016
3-14
00
JUL 20, 2016
0-19
00
JUL 20, 2016
3-15
00
JUL 20, 2016
0-20
00
JUL 20, 2016
3-16
00
JUL 20, 2016
3-17
00
JUL 20, 2016
CHAPTER 1
CHAPTER 3
1-1
00
JUL 20, 2016
3-18
00
JUL 20, 2016
1-2
00
JUL 20, 2016
3-19
00
JUL 20, 2016
1-3
00
JUL 20, 2016
3-20
00
JUL 20, 2016
1-4
00
JUL 20, 2016
3-21
00
JUL 20, 2016
1-5
00
JUL 20, 2016
3-22
00
JUL 20, 2016
1-6
00
JUL 20, 2016
3-23
00
JUL 20, 2016
3-24
00
JUL 20, 2016
3-25
00
JUL 20, 2016
CHAPTER 2
2-1
00
JUL 20, 2016
3-26
00
JUL 20, 2016
2-2
00
JUL 20, 2016
3-27
00
JUL 20, 2016
2-3
00
JUL 20, 2016
3-28
00
JUL 20, 2016
2-4
00
JUL 20, 2016
3-29
00
JUL 20, 2016
2-5
00
JUL 20, 2016
3-30
00
JUL 20, 2016
CHAPTER-PAGE 0-5
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
AMENDMENT: 00
DATE: --
MAINTENANCE MANUAL STEMME S12
PAGE
APPROVED
AM. NO.
DATE
PAGE
APPROVED
AM. NO.
DATE
3-31
00
JUL 20, 2016
4-6
X
00
JUL 20, 2016
3-32
00
JUL 20, 2016
3-33
00
JUL 20, 2016
3-34
00
JUL 20, 2016
5-1
00
JUL 20, 2016
3-35
00
JUL 20, 2016
5-2
00
JUL 20, 2016
3-36
00
JUL 20, 2016
5-3
00
JUL 20, 2016
3-37
00
JUL 20, 2016
5-4
00
JUL 20, 2016
3-38
00
JUL 20, 2016
5-5
00
JUL 20, 2016
3-39
00
JUL 20, 2016
5-6
00
JUL 20, 2016
3-40
00
JUL 20, 2016
5-7
00
JUL 20, 2016
3-41
00
JUL 20, 2016
5-8
00
JUL 20, 2016
3-42
00
JUL 20, 2016
5-9
00
JUL 20, 2016
3-43
00
JUL 20, 2016
5-10
00
JUL 20, 2016
3-44
00
JUL 20, 2016
5-11
00
JUL 20, 2016
3-45
00
JUL 20, 2016
5-12
00
JUL 20, 2016
3-46
00
JUL 20, 2016
5-13
00
JUL 20, 2016
3-47
00
JUL 20, 2016
5-14
00
JUL 20, 2016
3-48
00
JUL 20, 2016
5-15
00
JUL 20, 2016
3-49
00
JUL 20, 2016
5-16
00
JUL 20, 2016
3-50
00
JUL 20, 2016
5-17
00
JUL 20, 2016
3-51
00
JUL 20, 2016
5-18
00
JUL 20, 2016
3-52
00
JUL 20, 2016
5-19
00
JUL 20, 2016
3-53
00
JUL 20, 2016
5-20
00
JUL 20, 2016
3-54
00
JUL 20, 2016
5-21
00
JUL 20, 2016
3-55
00
JUL 20, 2016
5-22
00
JUL 20, 2016
3-56
00
JUL 20, 2016
5-23
00
JUL 20, 2016
3-57
00
JUL 20, 2016
5-24
00
JUL 20, 2016
3-58
00
JUL 20, 2016
5-25
00
JUL 20, 2016
3-59
00
JUL 20, 2016
5-26
00
JUL 20, 2016
3-60
00
JUL 20, 2016
5-27
00
JUL 20, 2016
3-61
00
JUL 20, 2016
5-28
00
JUL 20, 2016
3-62
00
JUL 20, 2016
5-29
00
JUL 20, 2016
5-30
00
JUL 20, 2016
5-31
00
JUL 20, 2016
CHAPTER 4
CHAPTER 5
4-1
X
00
JUL 20, 2016
5-32
00
JUL 20, 2016
4-2
X
00
JUL 20, 2016
5-33
00
JUL 20, 2016
4-3
X
00
JUL 20, 2016
5-34
00
JUL 20, 2016
4-4
X
00
JUL 20, 2016
5-35
00
JUL 20, 2016
4-5
X
00
JUL 20, 2016
5-36
00
JUL 20, 2016
CHAPTER-PAGE 0-6
AMENDMENT: 00
DATE: --
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
MAINTENANCE MANUAL STEMME S12
PAGE
APPROVED
AM. NO.
DATE
PAGE
5-37
00
JUL 20, 2016
5-38
00
5-39
5-40
AM. NO.
DATE
7-16
00
JUL 20, 2016
JUL 20, 2016
7-17
00
JUL 20, 2016
00
JUL 20, 2016
7-18
00
JUL 20, 2016
00
JUL 20, 2016
7-19
00
JUL 20, 2016
7-20
00
JUL 20, 2016
7-21
00
JUL 20, 2016
CHAPTER 6
APPROVED
6-1
00
JUL 20, 2016
7-22
00
JUL 20, 2016
6-2
00
JUL 20, 2016
7-23
00
JUL 20, 2016
6-3
00
JUL 20, 2016
7-24
00
JUL 20, 2016
6-4
00
JUL 20, 2016
7-25
00
JUL 20, 2016
6-5
00
JUL 20, 2016
7-26
00
JUL 20, 2016
6-6
00
JUL 20, 2016
7-27
00
JUL 20, 2016
6-7
00
JUL 20, 2016
7-28
00
JUL 20, 2016
6-8
00
JUL 20, 2016
7-29
00
JUL 20, 2016
6-9
00
JUL 20, 2016
7-30
00
JUL 20, 2016
6-10
00
JUL 20, 2016
7-31
00
JUL 20, 2016
6-11
00
JUL 20, 2016
7-32
00
JUL 20, 2016
6-12
00
JUL 20, 2016
7-33
00
JUL 20, 2016
6-13
00
JUL 20, 2016
7-34
00
JUL 20, 2016
6-14
00
JUL 20, 2016
7-35
00
JUL 20, 2016
6-15
00
JUL 20, 2016
7-36
00
JUL 20, 2016
6-16
00
JUL 20, 2016
7-37
00
JUL 20, 2016
7-38
00
JUL 20, 2016
7-39
00
JUL 20, 2016
CHAPTER 7
7-1
00
JUL 20, 2016
7-40
00
JUL 20, 2016
7-2
00
JUL 20, 2016
7-41
00
JUL 20, 2016
7-3
00
JUL 20, 2016
7-42
00
JUL 20, 2016
7-4
00
JUL 20, 2016
7-43
00
JUL 20, 2016
7-5
00
JUL 20, 2016
7-44
00
JUL 20, 2016
7-6
00
JUL 20, 2016
7-45
00
JUL 20, 2016
7-7
00
JUL 20, 2016
7-46
00
JUL 20, 2016
7-8
00
JUL 20, 2016
7-47
00
JUL 20, 2016
7-9
00
JUL 20, 2016
7-48
00
JUL 20, 2016
7-10
00
JUL 20, 2016
7-49
00
JUL 20, 2016
7-11
00
JUL 20, 2016
7-50
00
JUL 20, 2016
7-12
00
JUL 20, 2016
7-51
00
JUL 20, 2016
7-13
00
JUL 20, 2016
7-52
00
JUL 20, 2016
7-14
00
JUL 20, 2016
7-15
00
JUL 20, 2016
CHAPTER 8
CHAPTER-PAGE 0-7
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
AMENDMENT: 00
DATE: --
MAINTENANCE MANUAL STEMME S12
PAGE
APPROVED
AM. NO.
DATE
PAGE
8-1
00
JUL 20, 2016
8-2
00
8-3
AM. NO.
DATE
D-2
00
JUL 20, 2016
JUL 20, 2016
D-3
00
JUL 20, 2016
00
JUL 20, 2016
D-4
00
JUL 20, 2016
8-4
00
JUL 20, 2016
D-5
00
JUL 20, 2016
8-5
00
JUL 20, 2016
D-6
00
JUL 20, 2016
8-6
00
JUL 20, 2016
D-7
00
JUL 20, 2016
8-7
00
JUL 20, 2016
D-8
00
JUL 20, 2016
8-8
00
JUL 20, 2016
D-9
00
JUL 20, 2016
D-10
00
JUL 20, 2016
D-11
00
JUL 20, 2016
CHAPTER 9
APPROVED
9-1
00
JUL 20, 2016
D-12
00
JUL 20, 2016
9-2
00
JUL 20, 2016
D-13
00
JUL 20, 2016
9-3
00
JUL 20, 2016
D-14
00
JUL 20, 2016
9-4
00
JUL 20, 2016
D-15
00
JUL 20, 2016
9-5
00
JUL 20, 2016
D-16
00
JUL 20, 2016
9-6
00
JUL 20, 2016
ANNEX E
CHAPTER 10
10-1
00
JUL 20, 2016
10-2
00
JUL 20, 2016
E-1
00
JUL 20, 2016
E-2
00
JUL 20, 2016
ANNEX F
CHAPTER 11
F-1
00
JUL 20, 2016
11-1
00
JUL 20, 2016
F-2
00
JUL 20, 2016
11-2
00
JUL 20, 2016
F-3
00
JUL 20, 2016
F-4
00
JUL 20, 2016
F-5
00
JUL 20, 2016
ANNEX A
A-1
00
JUL 20, 2016
F-6
00
JUL 20, 2016
A-2
00
JUL 20, 2016
F-7
00
JUL 20, 2016
F-8
00
JUL 20, 2016
F-9
00
JUL 20, 2016
ANNEX B
B-1
00
JUL 20, 2016
F-10
00
JUL 20, 2016
B-2
00
JUL 20, 2016
F-11
00
JUL 20, 2016
F-12
00
JUL 20, 2016
F-13
00
JUL 20, 2016
ANNEX C
C-1
00
JUL 20, 2016
F-14
00
JUL 20, 2016
C-2
00
JUL 20, 2016
F-15
00
JUL 20, 2016
F-16
00
JUL 20, 2016
F-17
00
JUL 20, 2016
F-18
00
JUL 20, 2016
ANNEX D
D-1
00
JUL 20, 2016
CHAPTER-PAGE 0-8
AMENDMENT: 00
DATE: --
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
MAINTENANCE MANUAL STEMME S12
PAGE
APPROVED
AM. NO.
DATE
F-19
00
JUL 20, 2016
F-20
00
JUL 20, 2016
F-21
00
JUL 20, 2016
F-22
00
JUL 20, 2016
F-23
00
JUL 20, 2016
F-24
00
JUL 20, 2016
F-25
00
JUL 20, 2016
F-26
00
JUL 20, 2016
F-27
00
JUL 20, 2016
F-28
00
JUL 20, 2016
F-29
00
JUL 20, 2016
F-30
00
JUL 20, 2016
F-31
00
JUL 20, 2016
F-32
00
JUL 20, 2016
F-33
00
JUL 20, 2016
F-34
00
JUL 20, 2016
F-35
00
JUL 20, 2016
F-36
00
JUL 20, 2016
F-37
00
JUL 20, 2016
F-38
00
JUL 20, 2016
PAGE
APPROVED
AM. NO.
DATE
CHAPTER-PAGE 0-9
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
AMENDMENT: 00
DATE: --
MAINTENANCE MANUAL STEMME S12
THIS PAGE IS INTENTIONALLY LEFT BLANK
CHAPTER-PAGE 0-10
AMENDMENT: 00
DATE: --
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
MAINTENANCE MANUAL STEMME S12
0.3
CONTENTS
MANUAL CONTENTS
Cover Sheet.�������������������������������������������������������������������������������������������������������������� 0-1
0.1
Record of Amendments.������������������������������������������������������������������������������� 0-3
0.2
List of Effective Pages .��������������������������������������������������������������������������������� 0-5
0.3
Contents.���������������������������������������������������������������������������������������������������0-11
1.
General.������������������������������������������������������������������������������������������������������ 1-1
1.1
remarks on maintenance.������������������������������������������������������������������������������ 1-1
1.2
Conversion Table.������������������������������������������������������������������������������������������ 1-3
1.3
Abbreviations.���������������������������������������������������������������������������������������������� 1-4
1.4
Safety symbols.�������������������������������������������������������������������������������������������� 1-6
2.
Description.������������������������������������������������������������������������������������������������� 2-1
2.1
Technical Data.��������������������������������������������������������������������������������������������2-2
2.2
Three View Drawing.�������������������������������������������������������������������������������������2-7
3.
Description of Assemblies.������������������������������������������������������������������������������ 3-1
3.1
Airframe, Primary and Secondary Structure.����������������������������������������������������� 3-1
3.1.1
Wing.���������������������������������������������������������������������������������������������������������� 3-1
3.1.2
Fuselage.�����������������������������������������������������������������������������������������������������3-2
3.1.3
Tail Unit.������������������������������������������������������������������������������������������������������3-2
3.2
Cockpit.������������������������������������������������������������������������������������������������������3-2
3.2.1
General.������������������������������������������������������������������������������������������������������3-2
3.2.2
Control Elements and Instruments.�����������������������������������������������������������������3-3
3.2.3
Controls at the Instrument Panel.��������������������������������������������������������������������3-5
3.2.4
Instrument Panel.�����������������������������������������������������������������������������������������3-5
3.3
Flight Control System.������������������������������������������������������������������������������������3-9
3.3.1
Longitudinal Control.������������������������������������������������������������������������������������3-9
3.3.2
Longitudinal Trim (-).������������������������������������������������������������������������������������3-9
3.3.3
Wing Flap Control System.������������������������������������������������������������������������������3-9
3.3.4
Lateral Control.��������������������������������������������������������������������������������������������3-9
3.3.5
Control of Air Brakes.����������������������������������������������������������������������������������� 3-10
3.3.6
Directional Control.������������������������������������������������������������������������������������� 3-10
3.4
Power-Plant.�����������������������������������������������������������������������������������������������3-11
3.4.1
Engine.�������������������������������������������������������������������������������������������������������3-11
3.4.2
Lubrication System.��������������������������������������������������������������������������������������3-12
3.4.3
Cooling System.������������������������������������������������������������������������������������������ 3-13
3.4.4
Air Induction System.����������������������������������������������������������������������������������� 3-14
3.4.5Engine Exhaust incl. Turbocharger and Attachment.����������������������������������������� 3-14
3.4.6Fuel System.����������������������������������������������������������������������������������������������� 3-15
3.4.6.1
Fuel System Related Controls and Indication System.��������������������������������������� 3-15
3.4.6.2 Fuel System Design.������������������������������������������������������������������������������������� 3-16
3.4.6.3 Fuel System of the Fuselage.������������������������������������������������������������������������� 3-16
3.4.6.4 Electrical Layout and Operation of the Fuel Pumps.������������������������������������������3-17
CHAPTER-PAGE 0-11
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
AMENDMENT: 00
DATE: --
MAINTENANCE MANUAL STEMME S12
3.4.7
Engine Controls and Instrumentation.������������������������������������������������������������ 3-19
3.4.8Fire Protection.������������������������������������������������������������������������������������������� 3-19
3.4.9Engine Cowlings.���������������������������������������������������������������������������������������� 3-19
3.4.10
Propeller.��������������������������������������������������������������������������������������������������� 3-20
3.4.10.1 Design of Variable Pitch Propeller.������������������������������������������������������������������3-21
3.4.10.2 Propeller Blades.������������������������������������������������������������������������������������������3-21
3.4.10.3 Propeller Blade Angle Control Mechanism.�������������������������������������������������������3-21
3.4.10.4 Propeller Weight Balance.���������������������������������������������������������������������������� 3-24
3.4.10.5 Expansion Element and Control System.��������������������������������������������������������� 3-25
3.4.10.6 Identification of Propeller System and Assembly.��������������������������������������������� 3-26
3.4.11
Power Transmission.������������������������������������������������������������������������������������ 3-26
3.4.12
Forward Propeller Reduction Gearbox.����������������������������������������������������������� 3-26
3.4.13
Operation Mechanism of the Propeller Folding System.������������������������������������� 3-27
3.4.13.1 Nose-cone.������������������������������������������������������������������������������������������������ 3-27
3.4.13.2 Propeller Positioning.����������������������������������������������������������������������������������� 3-27
3.4.13.3 Propeller Brake.������������������������������������������������������������������������������������������ 3-28
3.4.14FLUIDS.����������������������������������������������������������������������������������������������������� 3-28
3.4.14.1 Fuel.��������������������������������������������������������������������������������������������������������� 3-28
3.4.14.2 Coolant Fluid.��������������������������������������������������������������������������������������������� 3-30
3.4.14.3 Lubricants.������������������������������������������������������������������������������������������������ 3-31
3.5
Landing Gear.�������������������������������������������������������������������������������������������� 3-33
3.5.1
Main Landing Gear.������������������������������������������������������������������������������������� 3-33
3.5.2
Tail Wheel.������������������������������������������������������������������������������������������������� 3-34
3.6
Flight Control Instruments, Pitot Static System.����������������������������������������������� 3-35
3.7
Electrical System.���������������������������������������������������������������������������������������� 3-37
3.7.1
General System Architecture.������������������������������������������������������������������������ 3-37
3.7.2
DC Generation (ATA 24-30-00).��������������������������������������������������������������������� 3-39
3.7.2.1
Main System DC Power Generation.��������������������������������������������������������������� 3-39
3.7.2.2
Engine System DC Power Generation.������������������������������������������������������������� 3-40
3.7.2.3
Over Voltage Protection.������������������������������������������������������������������������������ 3-41
3.7.3
DC Indication (ATA 24-37-00).���������������������������������������������������������������������� 3-41
3.7.3.1
Description.����������������������������������������������������������������������������������������������� 3-41
3.7.4
Parts Specification.������������������������������������������������������������������������������������� 3-41
3.7.5
Operation.������������������������������������������������������������������������������������������������� 3-41
3.7.6
DC Power Distribution System (ATA 24-60-00).������������������������������������������������ 3-42
3.7.6.1
Wire Specifications.������������������������������������������������������������������������������������� 3-42
3.7.6.2
Design of Electrical Connections.������������������������������������������������������������������ 3-42
3.7.6.3
Protection Devices.������������������������������������������������������������������������������������� 3-43
3.7.6.4
Fuse and CB Specifications: Main System.������������������������������������������������������� 3-44
3.7.6.5
Fuse Specifications: Engine System.��������������������������������������������������������������� 3-45
3.7.7
Switching Devices.�������������������������������������������������������������������������������������� 3-45
3.7.7.1
Manual Switches.���������������������������������������������������������������������������������������� 3-46
3.7.7.2
Electromechanical Relays.���������������������������������������������������������������������������� 3-46
CHAPTER-PAGE 0-12
AMENDMENT: 00
DATE: --
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
MAINTENANCE MANUAL STEMME S12
3.7.7.3
Semiconductor Switch Box.�������������������������������������������������������������������������� 3-47
3.7.8
Main System Distribution Box.���������������������������������������������������������������������� 3-47
3.7.9
Engine System Distribution Box .������������������������������������������������������������������� 3-47
3.7.10
TCU Board.������������������������������������������������������������������������������������������������ 3-47
3.7.11
Instrument Panel Bus System.����������������������������������������������������������������������� 3-49
3.7.12Engine Starting System (ATA 80-00-00).��������������������������������������������������������� 3-50
3.7.12.1 Description.����������������������������������������������������������������������������������������������� 3-50
3.7.12.2 Parts Specification.������������������������������������������������������������������������������������� 3-50
3.7.12.3 Operation.������������������������������������������������������������������������������������������������� 3-50
3.7.13Engine Ignition System (ATA 74-00-00).���������������������������������������������������������� 3-51
3.7.13.1 Description.����������������������������������������������������������������������������������������������� 3-51
3.7.13.2 Parts Specification.������������������������������������������������������������������������������������� 3-51
3.7.13.3 Operation.������������������������������������������������������������������������������������������������� 3-51
3.7.14Engine RPM Indicating System (ATA 77-14-00).������������������������������������������������ 3-52
3.7.14.1 Description.����������������������������������������������������������������������������������������������� 3-52
3.7.14.2 Parts Specification.������������������������������������������������������������������������������������� 3-52
3.7.14.3 Operation.������������������������������������������������������������������������������������������������� 3-52
3.7.15
Cylinder Head Temperature Indicating System (ATA 77-22-00).�������������������������� 3-52
3.7.15.1 Description.����������������������������������������������������������������������������������������������� 3-52
3.7.15.2 Parts Specification.������������������������������������������������������������������������������������� 3-52
3.7.15.3 Operation.������������������������������������������������������������������������������������������������� 3-52
3.7.16Oil Pressure Indicating System (ATA 79-31-00).������������������������������������������������ 3-53
3.7.16.1 Description.����������������������������������������������������������������������������������������������� 3-53
3.7.16.2 Parts Specification.������������������������������������������������������������������������������������� 3-53
3.7.16.3 Operation.������������������������������������������������������������������������������������������������� 3-53
3.7.17
Oil Temperature Indicating System (ATA 79-33-00).������������������������������������������ 3-53
3.7.17.1 Description.����������������������������������������������������������������������������������������������� 3-53
3.7.17.2 Parts Specification.������������������������������������������������������������������������������������� 3-53
3.7.17.3 Operation.������������������������������������������������������������������������������������������������� 3-54
3.7.18
Fuel Distribution System (ATA 28-20-00).�������������������������������������������������������� 3-54
3.7.18.1 Description.����������������������������������������������������������������������������������������������� 3-54
3.7.18.2 Parts Specification.������������������������������������������������������������������������������������� 3-54
3.7.18.3 Operation.������������������������������������������������������������������������������������������������� 3-54
3.7.18.4 Transfer Pump Control and Tank Selection.����������������������������������������������������� 3-55
3.7.19
Fuel Quantity Indication (ATA 28-40-00).������������������������������������������������������� 3-55
3.7.19.1 Description.����������������������������������������������������������������������������������������������� 3-55
3.7.19.2 Parts Specification.������������������������������������������������������������������������������������� 3-55
3.7.19.3 Operation.������������������������������������������������������������������������������������������������� 3-55
3.7.20
Fuel Pressure Indicating (ATA 73-32-00).��������������������������������������������������������� 3-56
3.7.20.1 Description.����������������������������������������������������������������������������������������������� 3-56
3.7.20.2 Parts Specification.������������������������������������������������������������������������������������� 3-56
3.7.20.3 Operation.������������������������������������������������������������������������������������������������� 3-56
3.7.21
Fire Detection System (ATA 26-12-00).������������������������������������������������������������ 3-56
CHAPTER-PAGE 0-13
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
AMENDMENT: 00
DATE: --
MAINTENANCE MANUAL STEMME S12
3.7.21.1
3.7.21.2
3.8
3.9
3.10
4.
4.1
4.2
4.2.1
4.3
4.4
5.
5.1
5.2
5.2.1
5.3
5.3.1
5.3.2
5.3.3
5.3.4
5.3.5
5.3.6
5.3.7
5.4
5.4.1
5.4.2
5.4.3
5.4.4
5.4.5
5.4.6
5.4.7
5.4.8
5.4.9
5.4.10
5.4.11
5.4.12
5.4.13
5.4.14
5.4.15
5.4.16
5.4.17
5.4.18
5.4.19
Description.����������������������������������������������������������������������������������������������� 3-56
Parts Specification.������������������������������������������������������������������������������������� 3-56
COM and NAV Equipment.���������������������������������������������������������������������������� 3-57
Oxygen System.������������������������������������������������������������������������������������������ 3-59
Wing Folding Device.����������������������������������������������������������������������������������� 3-61
Airworthiness Limitations Section.������������������������������������������������������������������ 4-1
General.������������������������������������������������������������������������������������������������������4-2
Maintenance Limitations.������������������������������������������������������������������������������4-2
Paint Finish.�������������������������������������������������������������������������������������������������4-2
Component Replacement and Overhaul Limitations.������������������������������������������4-3
Structural Limitations.���������������������������������������������������������������������������������� 4-5
Time Limits / Maintenance Checks.������������������������������������������������������������������ 5-1
Overhaul and Replacement Schedule.��������������������������������������������������������������5-2
Pre-Flight Inspections.�����������������������������������������������������������������������������������5-7
Rubber Hose and Clamp Integrity.�������������������������������������������������������������������5-7
Periodic Inspections.��������������������������������������������������������������������������������������5-7
Inspection Intervals.������������������������������������������������������������������������������������� 5-8
General Remarks on Periodic Inspections.������������������������������������������������������� 5-10
Unscheduled Maintenance.���������������������������������������������������������������������������5-11
Special Conditions and Cautionary Notice.����������������������������������������������������� 5-12
General Remarks on Maintenance.���������������������������������������������������������������� 5-12
Inspection Groups and Maintenance Criteria.�������������������������������������������������� 5-14
Other Particulars of Maintenance.����������������������������������������������������������������� 5-17
Check List for Periodic Inspections.���������������������������������������������������������������� 5-19
General.���������������������������������������������������������������������������������������������������� 5-19
Wings and Fuel System Components in the Wing Center Section.����������������������� 5-20
Forward Fuselage.��������������������������������������������������������������������������������������� 5-21
Cockpit.���������������������������������������������������������������������������������������������������� 5-22
Center Fuselage (except for fairings).������������������������������������������������������������ 5-23
Tail Boom.�������������������������������������������������������������������������������������������������� 5-24
Empennage.����������������������������������������������������������������������������������������������� 5-24
Fuel System Components in the Fuselage.������������������������������������������������������� 5-25
Engine and Engine Mountings.���������������������������������������������������������������������� 5-26
Lubrication System.������������������������������������������������������������������������������������� 5-28
Cooling System (Liquid Cooling, Ram Air Cooling).������������������������������������������� 5-29
Air Induction System.����������������������������������������������������������������������������������� 5-29
Engine Controls & Monitoring.����������������������������������������������������������������������� 5-29
Center Fuselage Fairing, Engine Cowlings and Firewall.�������������������������������������5-30
Propeller.��������������������������������������������������������������������������������������������������� 5-31
Drive Shaft with Propeller Reduction Gear.������������������������������������������������������ 5-32
Main Landing Gear.������������������������������������������������������������������������������������� 5-33
Tail Wheel.������������������������������������������������������������������������������������������������� 5-34
Flight Instrumentation and Pitot / Static Systems.�������������������������������������������� 5-34
CHAPTER-PAGE 0-14
AMENDMENT: 00
DATE: --
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
MAINTENANCE MANUAL STEMME S12
5.4.20
5.4.21
5.4.22
5.4.23
5.5
5.5.1
5.5.2
5.5.3
6.
6.1
6.2
6.3
Electric System (except for engine and TCU).�������������������������������������������������� 5-35
COM and NAV Equipment.���������������������������������������������������������������������������� 5-35
Completion Tasks.��������������������������������������������������������������������������������������� 5-36
Optional Equipment.����������������������������������������������������������������������������������� 5-37
Special Inspections.������������������������������������������������������������������������������������� 5-39
Inspection Following a Heavy Landing or a Wing Tip Landing.���������������������������� 5-39
Inspection Following an Impact to the Rotating Propeller.��������������������������������� 5-39
Inspection following Exceptional Events with Wing Folding Device.���������������������5-40
Maintenance Instructions, Tolerances, Adjustment Data for the Aircraft.�������������� 6-1
General Remarks.����������������������������������������������������������������������������������������� 6-1
Towing on ground, Jack Points and Lifting.������������������������������������������������������� 6-1
Determination of Empty Weight and Corresponding
.Center of Gravity; Weight Limits.���������������������������������������������������������������������6-3
6.4Flight Control System.����������������������������������������������������������������������������������� 6-8
6.4.1
Deflection of Control Surfaces, Control System Friction, and Control Forces.��������� 6-8
6.4.1.1
Control Surface Deflections.�������������������������������������������������������������������������� 6-8
6.4.1.2
Friction in Control System.����������������������������������������������������������������������������� 6-9
6.4.1.3
Pilot Forces.������������������������������������������������������������������������������������������������ 6-9
6.4.2
Weights and Moments of Control Surfaces.���������������������������������������������������� 6-10
6.4.3
Free Play in Flight Control System.����������������������������������������������������������������� 6-10
6.5
Lubrication.������������������������������������������������������������������������������������������������6-11
6.5.1
General Remarks.����������������������������������������������������������������������������������������6-11
6.5.2
Lubrication Plan.���������������������������������������������������������������������������������������� 6-12
6.6
Surface of Composite Structures.������������������������������������������������������������������ 6-13
6.7
Drainage and Ventilation Holes.�������������������������������������������������������������������� 6-15
6.8
Tightening Torques of Screwed Joints.������������������������������������������������������������ 6-15
7.Maintenance Instructions, Tolerances and Adjustment
.Data for Assemblies / Equipment.�������������������������������������������������������������������� 7-1
7.1Airframe.����������������������������������������������������������������������������������������������������� 7-1
7.1.1Wing.���������������������������������������������������������������������������������������������������������� 7-1
7.1.1.1Cracks and Structural Damage.���������������������������������������������������������������������� 7-1
7.1.1.2Drainage and Ventilation Holes.���������������������������������������������������������������������� 7-1
7.1.1.3
Wing Fittings.����������������������������������������������������������������������������������������������� 7-1
7.1.1.4
.Flaps and Ailerons.���������������������������������������������������������������������������������������7-2
7.1.2
Fuselage.�����������������������������������������������������������������������������������������������������7-3
7.1.2.1Cracks and Structural Damage.����������������������������������������������������������������������7-3
7.1.2.2
Drainage Holes.��������������������������������������������������������������������������������������������7-3
7.1.2.3
Nose-cone.��������������������������������������������������������������������������������������������������7-3
7.1.2.4
Center Fuselage.�������������������������������������������������������������������������������������������7-4
7.1.3
Empennage.�������������������������������������������������������������������������������������������������7-4
7.1.3.1General Condition.����������������������������������������������������������������������������������������7-4
7.1.3.2
Vertical Tail.�������������������������������������������������������������������������������������������������7-5
7.1.3.3
Horizontal Tail.���������������������������������������������������������������������������������������������7-6
7.1.3.4
Weights and Static Hinge Moments of Control Surfaces.�������������������������������������7-6
CHAPTER-PAGE 0-15
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
AMENDMENT: 00
DATE: --
MAINTENANCE MANUAL STEMME S12
7.2Cockpit.������������������������������������������������������������������������������������������������������7-7
7.2.1Canopy.�������������������������������������������������������������������������������������������������������7-7
7.2.1.1Condition and Function.��������������������������������������������������������������������������������7-7
7.2.1.2
Test of Canopy Emergency Jettison.�����������������������������������������������������������������7-7
7.2.1.3
Re-Installation of the Canopy.������������������������������������������������������������������������7-8
7.2.2Equipment and Systems.��������������������������������������������������������������������������������7-9
7.2.2.1
Seat Belts.���������������������������������������������������������������������������������������������������7-9
7.2.2.2
Instruments and Switches.�����������������������������������������������������������������������������7-9
7.2.2.3
Air Hoses.����������������������������������������������������������������������������������������������������7-9
7.2.2.4
Seats.���������������������������������������������������������������������������������������������������������7-9
7.3
Controls.��������������������������������������������������������������������������������������������������� 7-10
7.3.1
Controls in Fuselage.����������������������������������������������������������������������������������� 7-10
7.3.2
Controls in the Wing.������������������������������������������������������������������������������������ 7-11
7.3.3
Controls in Tail Cone /Vertical Tail.������������������������������������������������������������������ 7-11
7.3.4
Deflection of Control Surfaces, Control System Friction, Control Forces.���������������7-12
7.3.5
Free Play of Control System Bearings.�������������������������������������������������������������7-12
7.4
Power-Plant.�����������������������������������������������������������������������������������������������7-13
7.4.1
Engine.�������������������������������������������������������������������������������������������������������7-13
7.4.1.1General.�����������������������������������������������������������������������������������������������������7-13
7.4.1.2
Removal and Installation of The Engine.��������������������������������������������������������� 7-14
7.4.1.3
Cleaning of the Engine.�������������������������������������������������������������������������������� 7-15
7.4.1.4
Visual Check of Engine.�������������������������������������������������������������������������������� 7-15
7.4.1.5
Leakage Check.������������������������������������������������������������������������������������������ 7-15
7.4.1.6
Inspection of External Engine Components.���������������������������������������������������� 7-15
7.4.1.7
Check of Waste-Gate.��������������������������������������������������������������������������������� 7-15
7.4.1.8
Check of Gearbox.�������������������������������������������������������������������������������������� 7-16
7.4.1.9
Inspection of the Magnetic Plug.������������������������������������������������������������������� 7-16
7.4.1.10 Examination of Drive Gear Set.��������������������������������������������������������������������� 7-16
7.4.1.11 Check of the Carburetor.������������������������������������������������������������������������������ 7-16
7.4.1.12 Check of Engine Wiring.��������������������������������������������������������������������������������7-17
7.4.1.13 Check of V-Belt Tension.�������������������������������������������������������������������������������7-17
7.4.1.14 Replacement of Spark Plugs.�������������������������������������������������������������������������7-17
7.4.1.15 Checking of Spark Plug Connector.�����������������������������������������������������������������7-17
7.4.1.16 Check of Compression.���������������������������������������������������������������������������������7-17
7.4.1.17 Test Run of Engine.�������������������������������������������������������������������������������������� 7-18
7.4.1.18 Inspection of Engine Mountings.������������������������������������������������������������������� 7-18
7.4.2
Lubrication System.������������������������������������������������������������������������������������� 7-18
7.4.2.1
Visual and Leakage Check of Oil System.�������������������������������������������������������� 7-18
7.4.2.2
Oil Level Check.������������������������������������������������������������������������������������������ 7-19
7.4.2.3
Oil Change.������������������������������������������������������������������������������������������������ 7-19
7.4.2.4
Oil filter - Replacement and Inspection.��������������������������������������������������������� 7-19
7.4.3Cooling System.������������������������������������������������������������������������������������������ 7-19
7.4.3.1
Visual and Leakage Check of the System.������������������������������������������������������� 7-19
CHAPTER-PAGE 0-16
AMENDMENT: 00
DATE: --
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
MAINTENANCE MANUAL STEMME S12
7.4.3.2
7.4.3.3
7.4.3.4
7.4.4
7.4.4.1
7.4.4.2
7.4.5
7.4.5.1
7.4.5.2
7.4.5.3
7.4.6
7.4.6.1
7.4.6.2
7.4.7
7.4.8
7.4.8.1
7.4.8.2
7.4.8.3
7.4.9
7.4.10
7.4.10.1
7.4.10.2
7.4.10.3
7.4.10.4
7.4.10.5
7.4.10.6
7.4.10.7
7.4.10.8
7.4.10.9
Flushing of Cooling System.�������������������������������������������������������������������������� 7-20
Coolant Replacement.��������������������������������������������������������������������������������� 7-20
Ram Air Cooling.������������������������������������������������������������������������������������������7-21
Air Induction System.������������������������������������������������������������������������������������7-21
Intercooler and Air box.���������������������������������������������������������������������������������7-21
Air filter.�����������������������������������������������������������������������������������������������������7-21
Exhaust System.������������������������������������������������������������������������������������������7-21
Turbocharger / Muffler Mountings.������������������������������������������������������������������7-21
Exhaust Headers.���������������������������������������������������������������������������������������� 7-22
Heat Insulation.������������������������������������������������������������������������������������������ 7-22
Fuel System.����������������������������������������������������������������������������������������������� 7-23
Fuel System in the Wing.������������������������������������������������������������������������������ 7-24
Fuel System in the Fuselage.������������������������������������������������������������������������� 7-25
Engine Controls / Monitoring.������������������������������������������������������������������������ 7-26
Fire Protection.������������������������������������������������������������������������������������������� 7-28
Cowling-Fire Protective Painting.������������������������������������������������������������������ 7-28
Fire Protective Sleeves.��������������������������������������������������������������������������������� 7-29
Firewall.���������������������������������������������������������������������������������������������������� 7-29
Cowlings.�������������������������������������������������������������������������������������������������� 7-29
Propeller.��������������������������������������������������������������������������������������������������� 7-30
General.���������������������������������������������������������������������������������������������������� 7-30
Adjustment and Inspection Results, Tolerances.������������������������������������������������7-31
Visual Inspection of the Propeller Unit.������������������������������������������������������������7-31
Removal of the Propeller Unit.���������������������������������������������������������������������� 7-32
Installation of the Propeller Unit.������������������������������������������������������������������ 7-33
Spring Tension of the Propeller Folding Mechanism.������������������������������������������ 7-34
Checking of Pitch Control and Adjusting the Variable Pitch Propeller.����������������� 7-35
General Aspects of the Electrical Circuit.�������������������������������������������������������� 7-36
Adjustment of the Electrical Switch for the
.Take-Off Setting Indicator and Stop Switch.���������������������������������������������������� 7-36
7.4.10.10 Dynamic Balancing.������������������������������������������������������������������������������������ 7-37
7.4.11
Drive Shaft System.������������������������������������������������������������������������������������� 7-37
7.4.12
Propeller Gearbox, Mounting and Support.������������������������������������������������������ 7-38
7.4.13
Propeller Operation.������������������������������������������������������������������������������������ 7-40
7.5Landing Gear.�������������������������������������������������������������������������������������������� 7-41
7.5.1Main Landing Gear.������������������������������������������������������������������������������������� 7-41
7.5.1.1General.���������������������������������������������������������������������������������������������������� 7-41
7.5.1.2
Functional Test of the Retractable Landing Gear.��������������������������������������������� 7-42
7.5.1.3
Functional Check of Emergency Undercarriage Extension.�������������������������������� 7-44
7.5.1.4
Tires, Condition and Inflation Pressure.���������������������������������������������������������� 7-45
7.5.1.5
Adjustment and Bleeding of the Wheel Brake System.�������������������������������������� 7-45
7.5.1.6
Replacement of Brake Lining.����������������������������������������������������������������������� 7-46
7.5.1.7
Removal and Installation of Landing Gear Legs.���������������������������������������������� 7-46
CHAPTER-PAGE 0-17
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
AMENDMENT: 00
DATE: --
MAINTENANCE MANUAL STEMME S12
7.5.2
7.6
7.6.1
7.6.2
7.7
7.7.1
7.7.2
7.7.3
7.7.4
7.8
7.9
8.
8.1
8.2
8.3
9.
9.1
9.2
9.3
9.3.1
9.3.2
10.
11.
Tail Wheel.������������������������������������������������������������������������������������������������� 7-46
Flight Control Instruments and Pitot and Static Pressure System.����������������������� 7-47
Calibration of Stall Warning System (Optional).����������������������������������������������� 7-48
Maintenance on the Static Pressure System.��������������������������������������������������� 7-48
Electrical System.���������������������������������������������������������������������������������������� 7-49
General.���������������������������������������������������������������������������������������������������� 7-49
Batteries.�������������������������������������������������������������������������������������������������� 7-49
Grounding.������������������������������������������������������������������������������������������������ 7-50
E-Boxes.���������������������������������������������������������������������������������������������������� 7-50
Communication and Navigation Equipment.���������������������������������������������������7-51
Optional - Oxygen Equipment.����������������������������������������������������������������������7-51
List of Placards and their Positions.����������������������������������������������������������������� 8-1
Placards in the Cockpit, Front.������������������������������������������������������������������������ 8-1
Placards in the Cockpit, Rear.������������������������������������������������������������������������ 8-6
Placards on Fuselage.������������������������������������������������������������������������������������8-7
Equipment.�������������������������������������������������������������������������������������������������� 9-1
Minimum Equipment List.������������������������������������������������������������������������������ 9-1
Supplementary Equipment.����������������������������������������������������������������������������9-3
Additional Equipment and Systems.�����������������������������������������������������������������9-3
Additional Equipment.�����������������������������������������������������������������������������������9-3
Optional Systems.���������������������������������������������������������������������������������������� 9-5
List of Special Tools.�������������������������������������������������������������������������������������10-1
List of Maintenance Documents for Parts Being Approved
.Independently from the Aircraft.�������������������������������������������������������������������� 11-1
Annex A: Supplementary Instructions for Maintenance and Care,
.Maintenance Instructions.������������������������������������������������������������������������������A-1
Annex B: Service Bulletins, Airworthiness Directives.�������������������������������������������������������B-1
Annex C: Documents (Inspection and Operation Reports).�����������������������������������������������C-1
Annex D: Maintenance and Inspection Forms.����������������������������������������������������������������D-1
Annex E: Maintenance Manual (Line Maintenance) for ROTAX Engine Type 914 Series.���������� E-1
Annex F: Technical Drawings.�������������������������������������������������������������������������������������� F-1
a) Flight Controls: Pitch Control and Trim.����������������������������������������������������������������������F-3
b) Flight Controls: Lateral Control (Wing, Flap, Aileron).���������������������������������������������������F-5
c) Flight Controls: Airbrake Control.������������������������������������������������������������������������������F-7
d) Flight Controls: Rudder Control.��������������������������������������������������������������������������������F-9
e) Propulsion System.�������������������������������������������������������������������������������������������������F-13
f) S12 Main System - DC Generation.����������������������������������������������������������������������������F-15
g) S12 Main System - Landing Gear.������������������������������������������������������������������������������F-17
h) S12 Main System - Electrical Trim.���������������������������������������������������������������������������� F-19
i) S12 Main System - Autopilot.�������������������������������������������������������������������������������������F-21
j) S12 Main System - Fire Warning.������������������������������������������������������������������������������� F-23
k) S12 Main System - Lighting.������������������������������������������������������������������������������������ F-25
l) Transponder and Traffic Display.������������������������������������������������������������������������������� F-27
m) S12 Main System - Communication Radio.��������������������������������������������������������������� F-29
CHAPTER-PAGE 0-18
AMENDMENT: 00
DATE: --
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
MAINTENANCE MANUAL STEMME S12
n) S12 Engine System - DC Generation.�������������������������������������������������������������������������F-31
o) S12 Engine System - Engine Monitoring and Control.�������������������������������������������������� F-33
p) S12 Engine System - Fuel Pumps and Indication.�������������������������������������������������������� F-35
q) S12 Engine System - Propeller Control.���������������������������������������������������������������������� F-37
CHAPTER-PAGE 0-19
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
AMENDMENT: 00
DATE: --
MAINTENANCE MANUAL STEMME S12
THIS PAGE IS INTENTIONALLY LEFT BLANK
CHAPTER-PAGE 0-20
AMENDMENT: 00
DATE: --
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
MAINTENANCE MANUAL STEMME S12
1.
GENERAL
1.1
REMARKS ON MAINTENANCE
The legal owner or operator of the STEMME S12 is obliged to ensure that the maintenance of the
aircraft follows the instructions of this manual in accordance with applicable national laws and
regulations. Among others, these include:
• Scheduled maintenance,
• Adjustments,
• Replacement of fluids and lubricants,
• Replacement of parts after expiration of their service life,
• Minor repairs.
Any maintenance work must be documented (aircraft logbook).
The manufacturer must be informed immediately in case of any change of ownership. The message must be confirmed by the manufacturer, so that all information concerning airworthiness
(AD´s, SB´s) can be given to the legal owner.
For maintenance work the following documents are relevant:
1. This Maintenance Manual for the motorglider STEMME S12.
2. STEMME - Flight Manual for the motorglider STEMME S12.
3. ROTAX - Maintenance Manual (Line Maintenance) for ROTAX Engine Types ROTAX 912
and 914 Series.
4. ROTAX - Maintenance Manual (Heavy Maintenance) for ROTAX Engine Types ROTAX 912
and 914 Series.
5. ROTAX - Operating Manual ROTAX 914 F.
6. ROTAX - Installation Manual ROTAX 914 F.
7. ROTAX - Main Overhaul Manual ROTAX 914 F.
8. ROTAX - Spare Parts List ROTAX 914 F.
9. STEMME Document Number A26-11AM-M: Technical Specification of the ROTAX 914 F2/S1.
10. Maintenance instructions for the L’Hotellier quick-disconnects in flight control system.
11. Manufacturer’s documents referring to the equipment listed in the equipment list of the
corresponding S/N.
12. SB´s published by STEMME, ROTAX and manufacturer of other equipment installed.
13. Maintenance Instructions from STEMME.
14. Service Information from ROTAX.
15. Aircraft Logbook.
The amount and kind of maintenance work depend on the aircraft utilization, the climate, airfield
conditions, storage facilities and other factors, irrespective of the periodic checks. E. g., in sandy
environs it might be necessary to clean all filters before every commencement of operation; on
CHAPTER-PAGE 1-1
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
AMENDMENT: 00
DATE: --
MAINTENANCE MANUAL STEMME S12
the other hand in coastal or in rainy regions it is important to take more care of the preservation
of the aircraft.
The instructions in this manual are valid under normal conditions and use.
Use only spare parts from the manufacturer or according to the manufacturer’s requirements.
NOTICE
Materials required and recommended procedures for minor repairs on composite materials are
indicated in the repair guide »Small Repairs of Composite Materials« in Annex A of the S12 Aircraft
Maintenance Manual.
In case of any incident endangering airworthiness, the manufacturer must be informed immediately.
Maintenance work must be performed by qualified personnel.
NOTICE
This Maintenance Manual does not include instructions for assembly, daily inspection and Pre-flight
inspection, which are provided in section »4 Normal Operating Procedures« of the S12 Aircraft
Flight Manual. To perform these procedures, the S12 Aircraft Flight Manual must be available to
the maintenance personnel.
CHAPTER-PAGE 1-2
AMENDMENT: 00
DATE: --
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
MAINTENANCE MANUAL STEMME S12
1.2
CONVERSION TABLE
For the conversion of technical data the following factors have been used:
Data
1 cubic in
1 dr
100 fpm
1 ft
1 ft lb
1 hp
1 Imp.gal.
1 in
1 inHg
1 kgm
1 kgmm
1 kgmm
1 kt
1 lb
1 lbf
1 lbf ft
1 mph
1 sqft
1 oz.
1 psi
1 US gal.
Factor
16.387 cm3
1.772 g
0.508 m/s
0.3048 m
1.356 Nm
0.7457 kW
4.546 l
25.4 mm
33.86 hPa
86.8 lb in
0.001 kgm
0.007 lb ft
1.852 kph
0.4536 kg
4.45 N
135.6 Ncm
1.609 kph
0.0929 m2
28.349 g
0.06895 bar
3.785 l
CHAPTER-PAGE 1-3
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
AMENDMENT: 00
DATE: --
MAINTENANCE MANUAL STEMME S12
1.3
ABBREVIATIONS
The following abbreviations are being used for clarity:
ACL
AD’s
AGL
AMM
ANSI
AOA
ASAP
ASI
AUW
CB
Anti-Collision Light
Airworthiness Directives
Above Ground Level
Aircraft Maintenance Manual
American National Standards Institute
Angle Of Attack
As Soon As Possible
Airspeed Indicator
All-Up-Weight
Circuit Breaker
CCT
CD
CFRP
CG
CHT
DCDI
EFIS
EMC
EQL
FBO
FOD
FRP
GEN
GFRP
GPS
IMC
IPC
KIAS
kt
LBA
Cylinder Coolant Temperature
Constant Depression
Carbon Fiber Reinforced Plastic
Center Of Gravity
Cylinder Head Temperature
Dual Capacitive Discharge Ignition
Electronic Flight Information System
Electromagnetic Compatibility
Equipment List
Fixed-Base Operator
Foreign Object Damage
Fiber Reinforced Plastic
Generator
Glass Fiber Reinforced Plastic
Global Positioning System
Instrument Meteorological Conditions
Illustrated Parts Catalog
Knots Indicated Airspeed
Knots (equivalent to KIAS)
Luftfahrtbundesamt German Civil Aviation Authority
Left Hand
Manifold Pressure
Maximum Continuous Power
Minimum Equipment list
Master Minimum Equipment list
Maximum Weight of Non Lifting Parts
Maximum Take-Off Weight
Non Lifting Part
LH
MAP
MCP
MEL
MMEL
MNLP
MTOW
NLP
CHAPTER-PAGE 1-4
AMENDMENT: 00
DATE: --
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
MAINTENANCE MANUAL STEMME S12
OAT
OVP
PIC
PPC
PTT
R/C
RH
RP
RPM
RTD
RWY
SB’s
SI
SL
STC
TBO
TBR
TC
TCDS
TCU
TE
T/O
TSO
TTL
Outside Air Temperature
Over Voltage Protection
Pilot In Command
Propeller Pitch Control
Push To Talk
Rate Of Climb
Right Hand
Reference Plane
Revolutions Per Minute
Resistance Temperature Detector
Runway
Service Bulletins
Service Information
Service Letter
Supplemental Type Certificate
Time Between Overhaul
Time Between Replacement
Type Certificate
Type Certificate Data Sheet
Turbocharger Control Unit
Total Energy
Take-Off
Technical Standard Order
Transistor-Transistor Logic
CHAPTER-PAGE 1-5
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
AMENDMENT: 00
DATE: --
MAINTENANCE MANUAL STEMME S12
1.4
SAFETY SYMBOLS
The following safety instructions are based loosely on the ANSI Z535.
Symbols
Z535.3 Criteria for Safety Symbols
Signs and Labels
Z535.4 Product Safety Signs and Labels
Product Safety
Z535.6 Product Safety Information in Product Manuals, Instructions,
and Other Collateral Materials.
WARNING
WARNING An operating procedure or technique that may result in
personal injury or loss of life if not followed.
CAUTION
CAUTION An operating procedure or technique that may result in
damage to equipment if not followed.
NOTICE
NOTICE An operating procedure or technique needing special emphasis.
CHAPTER-PAGE 1-6
AMENDMENT: 00
DATE: --
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
MAINTENANCE MANUAL STEMME S12
2.
DESCRIPTION
The STEMME S12 is a twin-seat, self-launching motorglider, constructed mostly from carbon fiber
and is aerodynamically optimized for high performance. The two seats are arranged side-by-side
(forward of the wing) and the S12 is equipped with dual controls.
The wing is shoulder mounted and consists of a center section with flaps and Schempp-Hirth air
brakes, two outer wing sections with continuous ailerons, two wing extensions with ailerons and
two winglets. The flaps and ailerons of inner and outer wing/wing extension are interconnected
(“flaperons”).
The motorglider is in “T”-tail design.
The retractable two-wheel main landing gear is electrically operated and is equipped with
hydraulic wheel brakes.
The engine of the STEMME S12 is based on the ROTAX 914 F2-01, which has been certificated by
BRP-ROTAX® GmbH & Co.KG, Austria. STEMME modified the arrangement of some accessories
(induction and exhaust system including turbo-charger, engine mounts etc.) to adapt the systems
to specific installation requirements of the S12. These modifications are certified in the STEMME
S12 as engine model ROTAX 914 F2-01/S1.
ENGINE DESCRIPTION
Four-cylinder, four-stroke opposed type Otto-engine, turbocharged with electronic manifold pressure control (TCU); a center cam shaft and tappets; OHV; liquid cooled cylinder heads, cylinder
barrels cooled by ram air; dry-sump lubrication; Dual Capacitive Discharge Ignition (DCDI); 2
CD-carburetors (variable-choke); integrated reduction gear with mechanical vibration absorber
and overload clutch.
The engine is mounted in the fuselage in a center steel frame near the aircraft´s CG. Engine power is transmitted via a propeller shaft made of composites and a spur gear to the variable pitch
propeller in the fuselage nose.
When the aircraft is in gliding configuration, the propeller blades are folded and covered by a
movable nose cone (nose-cone). Propeller pitch change from take-off into cruise position is
accomplished by electrically heated expansion elements, and from cruise back to take-off position
(elements unheated) by springs as well as aerodynamic and centrifugal forces.
A fuel tank is located at each outboard end of the wing center section. Each tank supplies the
feeder tank in the fuselage by use of electrically driven fuel pumps. From the feeder tank the fuel
is supplied by two fuel pumps (one main and one auxiliary) to the engine to provide required
redundancy.
CHAPTER-PAGE 2-1
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
AMENDMENT: 00
DATE: --
MAINTENANCE MANUAL STEMME S12
2.1
TECHNICAL DATA
FUSELAGE
Design
Length
Width
Cockpit width
Cockpit height
Height of tail unit
Front section CFRP-Kevlar-GFRP-structure, center
steel frame, GFRP-fairing, tail boom with integrated vertical tail fin (CFRP).
8.42 m
27.62 ft
1.18 m
3.87 ft
1.16 m
3.81 ft
0.93 m
3.05 ft
1.75 m
5.74 ft
WING
Design
5 sections CFRP-Spar with GFRP-shearweb,
CFRP-sandwich skin.
Wing span
25.07 m
82.25 ft
Center wing span
9.90 m
32.48 ft
Wing area
19.95 m²
214.75 sqft
Aspect ratio
31.5
Dihedral angle (V-form)
0.75° / 1.75° / 4°
Mean aerodynamic chord
0.741 m
2.43 ft
Wing Airfoil
HQ41/14.35
Sweep of wing center section leading edge
0°
Sweep of outboard wing leading edge up to the bend
0°
AIR BRAKES
Type
Length
Area
Maximum height above wing upper surface.
HORIZONTAL TAIL
Design
Span
Area
Aspect ratio
Airfoil
Two blade Schempp-Hirth type, position outer
part of wing center section.
1.50 m
4.92 ft / 59.01 in
0.22 m²
2.37 sqft
0.16 m
0.52 ft / 6.29 in
Web GFRP, skin CFRP-Sandwich, elevator
GFRP-Sandwich.
3.10 m
10.17 ft
1.46 m²
15.72 sqft
6.58
FX 71-L-150/25
CHAPTER-PAGE 2-2
AMENDMENT: 00
DATE: --
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
MAINTENANCE MANUAL STEMME S12
VERTICAL TAIL
Design
Span
Area
Airfoil
WEIGHTS
Max. T/O-weight
Empty weight
Maximum weight of
non-lifting parts
Total useful load
(Occupants, fuel, baggage)
Web GFRP, skin CFRP, rudder GFRP-sandwich.
1.60 m
5.25 ft
1.78 m²
19.16 sqft
FX71-L150/30 x*1.3
900 kg
1984 lb
690 kg
1556 lb
(approx., min. equipment.)
610 kg
1345 lb
210 kg
463 lb
WING FLAPS (CENTER WING)
Span
Area
Flap positions:
4.39 m
14.40 ft
0.75 m²
8.07 sqft
-10°, -5°, 0°, +5°, +10°, L (+16°)
AILERONS (OUTER WINGS AND EXTENSIONS)
Span
Area
5.70 m + 1.50 m
0.78 m² + 0.13 m2
18.70 ft + 4.92 ft
8.40 sqft. + 1.40 sqft
127x127-30
6.00-5
1.36 m
210 x 65
5.46 m
4.46 ft
LANDING GEAR
2 main wheels with brake discs, rim of wheel
Tire size
Wheel track
Tail wheel (steerable), tire size
Wheel base
17.91 ft
CHAPTER-PAGE 2-3
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
AMENDMENT: 00
DATE: --
MAINTENANCE MANUAL STEMME S12
ENGINE
Design
Type
Engine reduction gear ratio
Bore
Stroke
Displacement
Compression ratio.
Drive shafts turns.
Max. T/O power.
Max. cont. power.
Fuel flow at T/O power (115%).
Fuel flow at max cont. power (100%).
Fuel flow at 75% power.
Specific fuel consumption at max. cont.
power (100%).
4-cylinder 4-stroke-Otto-motor, opposed type,
turbocharged, electronic manifold pressure
control integrated reduction gear.
ROTAX 914 F2-01/S1
i = 2.4286
79.5 mm
3.13 in
61 mm
2.40 in
3
1211 cm
73.9 cubic in
9.0
Clockwise
84.5 kW at 5800 RPM
113.2 hp
73.4 kW at 5500 RPM
98.4 hp
33.0 l/h
8.72 US gal. / h
7.26 Imp.gal. / h
27.2 l/h
7.19 US gal. / h
5.98 Imp.gal. / h
20.4 l/h
5.34 US gal. / h
4.49 Imp.gal. / h
276 g/kWh
0.454 lb / hph
CHAPTER-PAGE 2-4
AMENDMENT: 00
DATE: --
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
MAINTENANCE MANUAL STEMME S12
PROPELLER
Design
Type
Propeller diameter
Mass of the propeller
(incl. outer-casing of needle bearing and
rubber buffers)
Overall mass of propeller blade
Max. propeller
Propeller blade angle (station 0.7)
Propeller blade pitch (station 0.7)
Max. current consumption of both resistor
elements
Propeller turns
2-blade folding propeller, CFRP blades, propeller
hub and blade suspension. Forks aluminum.
Pitch control via electrically heated thermo
elements.
STEMME 11 AP-V
1.63 m
5.35 ft
9350 g
20.61 lb
650 g ± 10 g
1.433 lbs ± 0.022 lb
2.650 RPM
17.65° in T/O 24.05° in cruise.
114 cm / 44.9 in (T/O position)
160 cm / 63.0 in (cruise position)
10 A
Counter-clockwise
IN-FLIGHT CENTER OF GRAVITY RANGE
In-flight center-of-gravity range aft of
265 - 420 mm
datum
(See section 6.3 for center wing leading edge)
PROPELLER GEARBOX
Design
Type
Drive shaft turns
Ratio of propeller gearbox
10.41 in - 16.5 in
Helical spur gear,
aluminum alloy-housing,
elastic mounting in rubber elements.
STEMME 11AG
Clockwise
i = 1.109
CHAPTER-PAGE 2-5
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
AMENDMENT: 00
DATE: --
MAINTENANCE MANUAL STEMME S12
FUEL SYSTEM
Design
Maximum fuel volume
Unusable fuel
2 FRP-tanks in wing center section + 1 feeder
tank, 1 electrical fuel transfer pump for each
wing-tank + 2 electrical pumps from feeder tank
to the engine.
126.0 l (± 2%)
33.28 US gal.
27.72 Imp.gal.
1.4 l
0.37 US gal.
0.31 Imp.gal.
NOTICE
For more technical data, please refer to the S12 Aircraft Flight Manual.
CHAPTER-PAGE 2-6
AMENDMENT: 00
DATE: --
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
MAINTENANCE MANUAL STEMME S12
2.2
THREE VIEW DRAWING
1.36 m / 4.46 ft
8.4 m / 27.56 ft
1.75 m / 5.74 ft
8.4 m / 27.56 ft
1.75 m / 5.74 ft
1.63 m / 5.35 ft
9.9 m / 32.48 ft
1.9 m / 6.23 ft
9.9 m / 32.48 ft
25.07 m / 82.25 ft
Figure 2.2.a
Three View Drawing of the S12
CHAPTER-PAGE 2-7
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
AMENDMENT: 00
DATE: --
MAINTENANCE MANUAL STEMME S12
THIS PAGE IS INTENTIONALLY LEFT BLANK
CHAPTER-PAGE 2-8
AMENDMENT: 00
DATE: --
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
MAINTENANCE MANUAL STEMME S12
3.
DESCRIPTION OF ASSEMBLIES
3.1
AIRFRAME, PRIMARY AND SECONDARY STRUCTURE
The Primary Structure includes:
• Wing spars, root ribs, and wing spar boxes
• Wing shells
• Center steel frame
• Tail boom and vertical stabilizer
• Front section of fuselage
• Horizontal stabilizer
• Fittings
The Secondary Structure includes:
• Control surfaces
• Cowlings, cooling air system ducts, cockpit components
3.1.1
WING
Structural design: 5 sections; CFRP-Spar with GFRP-shearweb, CFRP-sandwich skin.
The wing consists of four sections: A wing center section with a span of 9.9 m / 32.48 ft, two outer
wing sections and two wing extensions including winglets with a length of 1.9 m / 6.23 ft each.
Attachment of the wing center section to the fuselage is by means of four sliding bolts, attachment
of the outboard wings to the wing center section as well as the connection of wing extensions to
the outer wings is with one sliding bolt each.
A removable fairing covers the wing/fuselage junction. Beneath the fairings, free access to the
wing attachment, the control system joints and the combined aileron/flap controls is possible.
For disassembly, the wing center section can be lifted vertically.
The flaps extend over the total span of the wing center section and the ailerons over the total span
of the outboard wings. The controls of flaps and ailerons are interconnected (“flaperons”), the
ailerons acting as differential flaps and the flaps acting as differential ailerons. The flap deflection is reduced from the inner to the outer wing, the aileron deflection is reduced from the outer
wing to the wing center section and from up to down deflections (differential aileron deflection).
The ailerons of the wing extension are directly connected to those of the outer wing and have no
separate actuation.
Two-blade Schempp-Hirth air brakes are installed on the wing center section upper surface.
The flaps and aileron gaps are sealed with elastic adhesive tape and a sliding layer on the upper
surface of the wing and with a textile tape (optional: elastic adhesive tape and sliding layer) on
the lower surface.
A boundary layer turbulator (adhesive 60° zigzag tape, leading edge at 69% of chord,
12 x 0.5 mm / 0.47 x 0.02 in) on the wing lower surface ensures a defined flow transition.
CHAPTER-PAGE 3-1
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
AMENDMENT: 00
DATE: --
MAINTENANCE MANUAL STEMME S12
3.1.2
FUSELAGE
The fuselage is a modular construction of three assemblies with bolted joints: The forward fuselage section (CFRP) construction, the center fuselage framework (steel frame) and the tail boom
(CFRP construction).
Loads from the fuselage front section, the wing, the landing gear, the power-plant and the tail
unit are transmitted by center steel frame.
The center fuselage framework is covered by self-supporting fairings (upper fairing and engine
cowlings LH / RH as well as lower fairing) of GFRP sandwich. The attachment of the fairings is by
means of camlocks, which can be easily opened with a screw-driver. The upper fairing includes
an oil service access door, which can be opened without a tool.
3.1.3
TAIL UNIT
Horizontal Tail
• T-arrangement, easily removable (simple spring-bolt connection),
• Stabilizer as sandwich construction of CFRP, elevator made of CFRP.
• Elevator gaps sealed by elastic tape.
• Boundary layer turbulator (adhesive 60° zigzag tape, leading edge at 65% of chord,
12 x 0.5 mm / 0.47 x 0.02 in) on upper and lower side for defined flow transition.
Vertical Tail
• Stabilizer as a sandwich construction of CFRP, rudder as a sandwich construction of GFRP,
• Rudder gap sealed by elastic tape with integrated zigzag turbulator (combi-tape),
• COM antenna integrated in rudder.
3.2
3.2.1
COCKPIT
GENERAL
The two seats are arranged side by side (forward of the wing) and the S12 is equipped with dual
controls. The FRP seat backrests are multi-adjustable. Each seat is equipped with 4-point seat
belts with a center locking mechanism.
Between the seats a console covers both systems and the drive shaft tunnel. The instrument panel
is designed in mushroom-style panel arrangement.
The one-piece canopy is hinged at the front and held in its opened position by two gas springs.
Three canopy locks on each side of the canopy frame, left hand and right hand side, are operated by
one locking lever on each side. The locking levers are mechanically interconnected by two bowden
cables so that they act simultaneously. One additional lock to improve canopy emergency jettisoning (“Röger-hook”) is installed in the rear upper canopy frame, operated by adjacent handle.
CHAPTER-PAGE 3-2
AMENDMENT: 00
DATE: --
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
MAINTENANCE MANUAL STEMME S12
The emergency jettison will be activated by opening either lateral locking lever on canopy side
(operating one is sufficient) and the red T-shaped handle on the instrument panel.
Canopy hinge opens and is lifted approximately 0.1 m / 4 in by a gas spring.
The “Röger-hook” must remain closed, since it is the axis of rotation until the canopy is jettisoned.
The cockpit is ventilated via two nozzles (LH and RH side) in the instrument panel. The canopy
ventilation is via openings in the instrument panel cover.
3.2.2
CONTROL ELEMENTS AND INSTRUMENTS
COCKPIT CONTROLS AT THE AIRFRAME
Following overview includes the controls at the airframe.
No.
1.
2.
Name of Control
Control Stick
Rudder Pedals
3.
Airbrake Lever
4.
Flap Lever
5.
6.
Pedal Adjustment Handle
Canopy Locks
7.
Brake Lever
8.
9.
Trim Knob
Throttle Lever
10.
Choke Lever
Airframe Position
Centered in front of each seat.
For each seat and adjustable. The pedals also steer the tail
wheel, which is coupled to the rudder via spring device.
At the LH side of each seat. Blue lever at LH cockpit side
and on the center console between seats.
At the LH side of each seat. Black lever at LH cockpit side
and on the center console. Indication of settings (-10, -5,
0, +5, +10, L) in center console. Unlocking is by moving
lever to the right against a spring force which locks the
flap positions.
In front of each seat. Unlocking is by pulling the handle.
Two white handles with red stripe, one on left and one on
right side of the canopy frame, to open and lock the canopy. The handles are mechanically connected so that both
always move simultaneously. In addition a white handle at
rear top center of the canopy is provided to insure correct
movement of the canopy during jettison (“Röger-hook”).
Lever on each control stick. Separate lever for parking
brake valve on the floor panel console in front of the LH
control stick.
A green switch on the control stick.
One black lever on center console with two forward stops
(For max. continuous and max. T/O-power). It is coupled
with a spring acting forward in direction FULL POWER. Its
position is fixed by friction discs, which can be adjusted
with a knurled knob on LH side of the center console.
Black lever on center console, RH side of the throttle lever.
It is coupled with a spring acting rearward in direction
CHOKE OFF. Its position is fixed by friction discs, which
can be adjusted with a knurled knob on RH side of the
center console.
CHAPTER-PAGE 3-3
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
AMENDMENT: 00
DATE: --
MAINTENANCE MANUAL STEMME S12
No.
11.
Name of Control
Propeller Pitch
12.
Fuel Valve
Airframe Position
Switch on center console. The forward position is the TAKEOFF position. A green light located in the upper area of left
instrument panel indicates if propeller pitch (not switch)
is in T/O)-position.
Red handle on the rear console between the seat back
rests. Turning the handle into its horizontal position (fuel
valve CLOSED) cuts off the fuel supply for the engine.
NOTICE
Throttle positions for 115% and 100% can be selected by feel. The first stop is the 100% throttle
position. To select 115% the throttle lever must be moved through a throttle gate to the left and
then pushed to the next stop.
CHAPTER-PAGE 3-4
AMENDMENT: 00
DATE: --
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
MAINTENANCE MANUAL STEMME S12
3.2.3
CONTROLS AT THE INSTRUMENT PANEL
The following overview includes controls in the lower area of the instrument panel. These elements
are included in figure »3.2.3.a Arrangement of Elements on the Instrument Panel«, see section
»3.2.4«.
No.
1.
2.
3.
4.
5.
6.
7.
3.2.4
Name of Control
Airframe Position
Emergency Canopy Red pull-handle on LH side of the switch panel. It is pulled for emerRelease
gency canopy jettison after opening the canopy locks on LH or RH
side of the canopy frame.
Cowl Flap
Black T-handle on LH side of the lower middle section of the inAdjustment
strument panel to reduce engine cooling in cruise condition. The
foremost position means cowl flaps fully OPEN, 5 settings aft are
available to reduce the opening of the cowl flaps.
Nose-cone
Black handle in the bottom center of the instrument panel to open,
Operation
close and lock the nose-cone, linked to the engine electric master
switch. Unlock by lifting, lock by pushing down the handle. In the
forward position (Nose-cone OPEN) the engine master switch turns
ON when nose-cone is LOCKED.
Propeller Brake
Black T-handle to the RH side of the cowl flap adjustment to brake
the propeller to a full stop after engine has been switched off in
flight. Braking is by pulling the handle.
Propeller
Black T-handle to the RH side of the propeller brake to position the
Positioning
propeller to fit within the nose-cone contour. Operation is by a slow
and steady pull on the handle to its stop.
Air Vents
Two adjustable air vents for cockpit ventilation, one on LH and one
on RH side of the Instrument panel, are provided.
Canopy
Knob on RH side of the ignition/starter switch to ventilate the canVentilation
opy. The pulled position means canopy ventilation OPEN.
INSTRUMENT PANEL
The following description gives an overview of instruments, controls, monitor devices and CB’s
installed on the instrument panel. The minimum Equipment List of the S12 Aircraft Fligth Manual
is relevant.
The positions of the elements are shown in figure »3.2.3.a Arrangement of Elements on the Instrument Panel«, valid for the aircraft serial number as indicated on the title page of this Aircraft
Maintenance Manual.
The flight control instruments include at least
1. One ASI (airspeed range 50 – 300 km/h / 27 – 162 kt),
2. One Altimeter,
3. One magnetic compass,
4. Trim indicator display.
These instruments are located directly in the view area of the PIC (in front of LH seat). Dual instrumentation is possible to provide an optimum view on flight control instruments from the RH
CHAPTER-PAGE 3-5
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
AMENDMENT: 00
DATE: --
MAINTENANCE MANUAL STEMME S12
seat (e. g. instruction flights).
Additional avionics may be installed on customer demands and concurrent applicable approval.
Engine monitoring includes at least:
• Tachometer
• Oil pressure and oil temperature
• Cylinder head temperature (CCT) LH and RH
• Voltmeter and ammeter
• Fuel quantity in LH and RH wing tanks
• Engine hour-meter
These instruments are located as a rule, with the exception of the engine hour-meter, in the RH
area of the panel, if not installed (i. e. with dual flight instrumentation) in the center area. The
engine hour-meter is located on the center console between the seats.
The red fire-warning light (test by pushing light for optic and acoustic signal) is adjacent to the
engine instrumentation.
The following warning and monitoring lights are combined in a group, arranged independently
of its location on the instrument panel. They inform the pilot about the proper condition of the
aircraft at a glance. The group is always located at the upper instrument panel below the glare
shield to allow for glare-free reading.
The following lights are arranged:
A. Red fuel pressure warning,
B. Yellow low fuel warning,
C. Green status indication for fuel aux pump operation,
D. Red warning light for manifold pressure (boost pressure),
E. Yellow caution light for malfunction of TCU,
F. Red warning light for malfunction of external alternator (battery charge control),
G. Yellow caution light for malfunction of internal generator.
The landing gear position and warning indication is also located below the glareshield and consists
of two lights, indicating the situation with green or red steady or flashing light.
The following CB´s are combined in a group, arranged independently of its location at the panel:
• Master CB,
• CB for external alternator,
• Landing gear CB,
• CB´s for main, transfer and auxiliary fuel pumps.
CHAPTER-PAGE 3-6
AMENDMENT: 00
DATE: --
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
MAINTENANCE MANUAL STEMME S12
The lower center section of the instrument panel comprises a row of levers and switches. Any
switches, except a switch to select voltmeter indication at the upper RH panel, are systematically
arranged here. The red handle for canopy emergency jettison is installed LH of the row of switches.
Sequence of levers and switches, starting from the left, is:
1. Red handle for canopy emergency jettison,
2. Landing gear lever with three positions (down: extension, center: neutral (electrically
de-energized), up: retraction),
3. Switch for auxiliary fuel pump,
4. Fuel selector switch (positions “LEFT”, “BOTH”, “RIGHT”)
5. Electric master switch,
6. TCU emergency switch to isolate waste-gate actuator and TCU control in case of
malfunction (switch is guarded with a red protecting plate for unintended operation),
The control elements for propeller and nose-cone (propeller brake, propeller positioning and nosecone handle) are arranged below the row of switches in the center console. In the same area the
canopy ventilation knob and the ignition/starter switch (positions OFF, Right, Left, BOTH and
START) are installed.
The following figure »3.2.3.a Arrangement of Elements on the Instrument Panel« shows layout
and arrangement of the instrument panel of the aircraft serial number as indicated on the title
page, including control elements, monitoring devices and CB´s.
CHAPTER-PAGE 3-7
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
AMENDMENT: 00
DATE: --
EX
AM
PL
E
MAINTENANCE MANUAL STEMME S12
Figure 3.2.3.a
Arrangement of Elements on the Instrument Panel
(Related to S/N Indicated on Title Page)
CHAPTER-PAGE 3-8
AMENDMENT: 00
DATE: --
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
MAINTENANCE MANUAL STEMME S12
3.3
3.3.1
FLIGHT CONTROL SYSTEM
LONGITUDINAL CONTROL
Both control sticks are coupled by a connection tube. The control movements are transmitted
via push-pull rods to the end of the tail boom and then straight up to the elevator fitting. In the
tail boom, the push-pull rod is supported by linear motion ball bearings. Adjustable stops for the
longitudinal control are installed in the middle of the connection tube beneath the right control
system cover in the cockpit. A control tube connection in the tail boom is linked to the spring
trim system.
3.3.2
LONGITUDINAL TRIM (-)
Longitudinal trim is achieved by means of a spring system. The spring forces are adjusted by an
electrical actuator. This actuator is controlled by a switch on the control sticks. The actuator
together with the spring system and the linkage to the elevator control system are situated in
the front part of the tail-boom.
3.3.3
WING FLAP CONTROL SYSTEM
Both flap control levers are coupled by a connection tube beneath the control system cover in
the cockpit. Control inputs are transmitted from this connection tube via push-pull rods to a
“mixing shaft” in the center fuselage. From this “mixing shaft”, the control inputs are transmitted
via bell-crank levers, push-pull rods and quick release couplings to the control rods in the wing.
The control rods in the wing are supported by means of linear motion ball bearings. The control
movement is transmitted to the flap drive fittings via bell-crank levers.
At the mixing unit, the wing flap control is supported by a gas spring against the center steel
frame. This is to minimize loads on the flap lever at appropriate airspeeds related to the respective
flap setting. A viscous damper acting in both directions isolates shock loads from the flap lever
and the flap lock-in. The flap positions are locked at the output lever on the connection tube in
a gate beneath the control system cover.
3.3.4
LATERAL CONTROL
Lateral inputs with the control sticks are transferred via an adjustable push rod to a center
bell-crank lever beneath the connection tube of the longitudinal (elevator) control.
From this bell-crank lever, control inputs are transmitted via push rods to the “mixing shaft”
in center fuselage. Via this “mixing shaft”, bell-crank levers, push-pull rods and quick release
couplings, the control rods in the wing are moved.
Both sides of the wing center section contain a straight-through control rod, supported by several
linear motion ball bearings and equipped with a quick release coupling (L´Hotellier) at the division
of inner and outer wing. From the push-pull rods in the outboard wing, the control movements
are transmitted via two bell-crank levers to the drive fittings of the ailerons.
By means of the “mixing shaft”, the ailerons are moved together with flap position changes
and the flaps are moved together with aileron deflections (“flaperons”). The percentage of comovement depends on the position of the control surfaces. Stops for aileron control inputs (adjustment screws) are located LH and RH side of the elevator connection tube beneath the covers
of the control system well in the cockpit.
CHAPTER-PAGE 3-9
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
AMENDMENT: 00
DATE: --
MAINTENANCE MANUAL STEMME S12
3.3.5
CONTROL OF AIR BRAKES
The air brake-levers are coupled by means of a connection tube. Travel of the levers is transmitted
via push rods and bell-crank levers to a driving lever (over-center strut) in the center fuselage,
from which it is transmitted via push rods and quick release couplings to push-pull rods in the
wing, which then move the air brakes. The push rods in the wing are supported by linear motion
ball bearings.
The air brakes are locked in retracted position by over-center-locking of the over-center strut.
The locked position can be adjusted by a stop screw at the over-center strut. The fully extended
position is determined by a fixed rubber stop, which one end of the driving lever butts upon when
this position is reached.
3.3.6
DIRECTIONAL CONTROL
From the LH and RH rudder pedal supports, control cables are led through the center fuselage to
the tail boom behind the luggage compartment, where the control cables of the left pedals and
the right pedals meet to be directed further to the rudder driving lever. The rudder driving lever
is connected to the tail wheel by a spring assy. The stops for the directional control are mounted
on the lower rudder support, the pertinent adjustment screws are located at the rudder on the
drive fitting.
CHAPTER-PAGE 3-10
AMENDMENT: 00
DATE: --
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
MAINTENANCE MANUAL STEMME S12
3.4
POWER-PLANT
3.4.1
ENGINE
Engine description
Upper (rear) Engine Attachment
Lower (front) Engine Attachment
Type
See »Maintenance Manual (Heavy Maintenance)
for ROTAX Engine Types ROTAX 912 and 914
Series«, section 71.
A tubular steel frame at the upper engine flanges,
mounted in two vibration absorbing elements
in the upper lateral tube of the fuselage frame.
A separate tubular steel frame at the lower
engine flanges in two vibration absorbing
elements in the forward lateral framework
junctions.
ROTAX 914 F2/S1 (modified ROTAX 914 F Aircraft
engine, propeller shaft design with flange for
fixed pitch propellers).
The ROTAX 914 F2/S1 is modified by STEMME and based on the type ROTAX 914 F2. The modification
was completed as a co-operation with ROTAX and with approval by ROTAX.
The base engine ROTAX 914 F2/01 is certified according to JAR-E / FAR 33. It is turbocharged and
has an electronic dual ignition system.
The modified version ROTAX 914 F2/S1 was specially developed for the model S12, a derivative of
the motorglider STEMME S10.
The engine modifications are certified together with the S12 according to JAR 22. The modified
version ROTAX 914 F2/S1 has the STEMME (internal) production No. 11AM-M.
Due to special requirements for installation in the center fuselage, the following modifications
were made:
• Relocation of the turbocharger unit to the aft of the engine to stay within the outlines
of the S12 fuselage. The turbocharger unit is supported by five struts aft of the engine.
A supercharger inter-cooler is installed. Relocation of the turbocharger unit required
modifications of the exhaust system. The exhaust headers are attached to the turbocharger
by springs, positioning them in spite of the high thermal stress.
• The layout of the oil pipes for the turbocharger are modified.
• The exhaust headers and the muffler are shrouded by temperature-resistant material, thus
thermally isolating the system from the engine bay. The turbocharger unit and the air box
are isolated by radiation protective shields.
• The original ROTAX engine mounting is not used. STEMME specially developed an engine
mounting for a center installation, consisting of two upper and one lower supporting
element.
CHAPTER-PAGE 3-11
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
AMENDMENT: 00
DATE: --
MAINTENANCE MANUAL STEMME S12
• In the liquid cooling system, the combined function of the expansion reservoir and refill
container was split up in two separate containers, with the expansion reservoir located
above the engine and the refill container on the left side of the fire-wall.
• The ignition unit is installed above of the engine slightly behind the original ROTAX-position.
• The throttle levers on the carburetors have been slightly modified (modification does not
affect the throttle rigging of the original engine) and additional springs have been installed
(pulling towards full-power position) to compensate for friction due to the long control
cables between cockpit and engine bay.
Engine performance data of the ROTAX 914 F2/S1 are identical to those of the ROTAX 914 F.
ENGINE PERFORMANCE DATA
Max. T/O power.
Max. continuous power.
Engine reduction gear ratio
Max. propeller
3.4.2
84.5 kW at 5800 RPM
73.4 kW at 5500 RPM
i = 2.4286
2650 RPM
113.2 hp
98.4 hp
LUBRICATION SYSTEM
SYSTEM DESCRIPTION
Refer to »Maintenance Manual (Heavy Maintenance) for ROTAX Engine Types ROTAX 912 and 914
Series«, section 79.
The ROTAX 914 is equipped with a dry-sump pressure lubrication system. The pumps are part of
the engine. It was necessary to modify the routing of the oil pipes between oil pump and turbocharger. Oil is returned from the crankcase to the oil tank by compression blow-by pressure, and
from the turbocharger via the secondary oil pump (scavenge pump).
The oil tank is standard from ROTAX. It is installed behind the fire-wall on the LH side of the
fuselage frame. The oil filler cap is below a service access in the upper center fuselage fairing.
Oil is taken in flexible pipes from the oil tank through the fire wall to the engine bay. Any flexible
oil lines in the engine compartment are shrouded by fire protective sleeves.
The oil cooler is installed on the RH side of the fuselage frame and supplied with air from the RH
cowl flap.
CHAPTER-PAGE 3-12
AMENDMENT: 00
DATE: --
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
MAINTENANCE MANUAL STEMME S12
3.4.3
COOLING SYSTEM
SYSTEM DESCRIPTION
Refer to »Maintenance Manual (Heavy Maintenance) for ROTAX Engine Types ROTAX 912 and 914
Series«, section 75.
Engine is cooled by liquid cooled cylinder heads, ram air cooled cylinders and by cooling the oil.
LIQUID COOLING
The radiator for the coolant is installed on the LH side of the fuselage frame, supplied by ram air
from the LH cowl flap. The refill container is installed on the forward left side of the upper fire
wall. A thin tube links the relief valve in the refill container with the overflow container, which is
installed in the LH landing gear bay. The quantity of the coolant can be checked at the scale on
the overflow container and must be between min and max markings.
The coolant lines consist of flexible coolant hoses and aluminum tubes.
RAM AIR CYLINDER COOLING
Ram air for cylinder cooling is guided from the RH cowl flap through a duct to a distribution
plenum on the engine upper side. The distributor is made of special heat-resistant GFRP.
INLET COWL FLAPS
Oil cooler, radiator, inter-cooler, ram air cylinder cooling and the carburetors are supplied with
ram air from the LH and RH cowl flaps in the lateral engine cowlings. To avoid low engine temperatures during high cruising speeds or descents from high altitudes, the cowl flap aperture
can be reduced with a handle on the instrument panel. During T/O, climb and at high OAT´s, the
cowl flaps should be fully open. Five reduced apertures can be set for different conditions. It is
not possible to close the cowl flaps completely as long as the nose-cone is open. The cowl flap
control is linked to the nose-cone operation: closing of the nose-cone also closes the cowl flaps
and opening of the nose-cone opens the cowl flaps to the position set by the cowl flap handle.
OUTLET COWL FLAP
The warmed air streams exit the engine compartment via the lower outlet cowl flap. The aperture
of the outlet cowl flap, like the inlet cowl flaps, is controlled by the nose-cone operation as well as
by the cowl flap handle on the instrument panel. The shape of the small fuselage fairing behind
the outlet cowl flap maintains a slot when the cowl flap is closed with the nose-cone, to allow a
permanent ventilation of the engine compartment.
CHAPTER-PAGE 3-13
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
AMENDMENT: 00
DATE: --
MAINTENANCE MANUAL STEMME S12
3.4.4
AIR INDUCTION SYSTEM
SYSTEM DESCRIPTION
Refer to the »Maintenance Manual (heavy maintenance) for ROTAX Engine Types ROTAX 914
Series«, section 73.
The engine induction air is routed from the RH inlet cowl flap via a duct, an air filter, and a short
flexible tube to the turbocharger unit. Compressed air from the turbocharger is routed via two
tubes through the inter-cooler to the airbox. The inter-cooler, with a drain at its lowest point, is
installed on the RH side of the center fuselage frame.
Cooling air for the inter-cooler is taken from the RH inlet cowl flap, directed into the engine bay
and to the outside via the lower outlet cowl flap.
The airbox is supported by two rubber mounts on the diagonal strut of the turbocharger unit. The
airbox drainage lines are routed to the outlet cowl flap, in order to allow drained fuel to leave the
engine compartment.
3.4.5
ENGINE EXHAUST INCL. TURBOCHARGER AND ATTACHMENT
SYSTEM DESCRIPTION
Refer to the »Maintenance Manual (heavy maintenance) for ROTAX ENGINE TYPES 914 SERIES«,
section 78.
TURBOCHARGER ATTACHMENT
Five steel tube struts at aft engine mounts.
The turbocharger unit, consisting of turbocharger and muffler, is installed aft of the engine and
supported by five struts on the crankshaft housing. The turbocharger is supplied with oil by oil
suction and oil pressure pipes from the engine oil pump.
The exhaust headers are installed below the engine, constructed using original ROTAX connecting elements. The headers are isolated from heat sensitive components. The exhaust headers are
attached to the turbocharger by springs, positioning the headers in spite of the thermal effects.
The exhaust headers are shrouded by a temperature-resistant glass-fiber-tape (Frenzelit Isotherm
1000). The tape terminals are fixed by special spring-loaded brackets.
The muffler is covered by formed elements of an insulation material (Frenzelit „Isosafe“ 12 mm).
To avoid heat radiation, heat protective shields (stainless steel) are installed close to the turbocharger unit. The exhaust pipe of the muffler is routed through a hole in the LH engine cowling.
In order to protect overflowing fuel from contact with hot exhaust system parts, drain lines from
the drip trays below each carburetor are routed to the lower cowl flap.
CHAPTER-PAGE 3-14
AMENDMENT: 00
DATE: --
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
MAINTENANCE MANUAL STEMME S12
3.4.6
FUEL SYSTEM
3.4.6.1
FUEL SYSTEM RELATED CONTROLS AND INDICATION SYSTEM
The S12’s cockpit provides the following fuel system related controls and indication systems:
• The fuel shut-off valve (horizontal ”OFF”; vertical ”ON”) is located on the rear center console.
• The fuel selector switch (with positions ”LEFT”, ”BOTH”, and ”RIGHT”) is located on the
instrument panel.
• The switch for the auxiliary fuel pump (with positions ”ON” and ”OFF”) is located on the
instrument panel.
• The fuel pressure indication, the low-fuel light for the feeder tank as well as the green status light for the operation of the auxiliary fuel pump, are located on the instrument panel.
• The fuel quantity indicators for the two wing tanks are on the instrument panel.
• The four fuel pumps (one main and one auxiliary pump plus one transfer pump from each
wing fuel-tank) have separate fuses, which are located in the Electronic System Boxes on
top of the steel frame.
NOTICE
For the location of the listed switches, lights or indicators please refer to the S12 Aircraft Flight
Manual, section »7.3 Instrument Panel«.
CHAPTER-PAGE 3-15
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
AMENDMENT: 00
DATE: --
MAINTENANCE MANUAL STEMME S12
3.4.6.2
FUEL SYSTEM DESIGN
WING FUEL SYSTEM
Both wing tanks are located in the outer sections of the wing center section. The ends of the vent
lines are located at the lower, outer ends of the wing center section. The filler caps are located
on the upper surface of the wing center section. The fuel line from each tank includes a strainer,
a fine filter and quick drain as well as a piston pump including a fuel-check valve for each tank.
All these components are accessible through an opening in the lower wing skin near the root rib.
Depending on the position of the fuel selector switch and a float switch in the feeder tank, the
feeder receives fuel from either the right or the left tank separately, or from both tanks simultaneously. A single quick release connector is located between the fuel line from the wing and the
corresponding connection in the fuselage.
3.4.6.3
FUEL SYSTEM OF THE FUSELAGE
FUEL SYSTEM OF THE FUSELAGE
Beginning at the quick release connector, fuel flows directly to the feeder tank. A float switch in
the feeder tank prevents feeder tank overfilling. The feeder tank is vented through the right shell
of the forward fuselage above the landing gear door at the rear edge. The feeder tank has a sump
at its bottom that is connected to a quick drain. From the lower part of the feeder tank (approximately 1 cm above the bottom) the fuel is pumped by the main fuel pump (powered by the engine
electric system) or the auxiliary fuel pump (powered by the main electric system) to the engine.
The main pump runs continuously whenever the engine electrical system is powered (nose-cone
is pushed forward and locked). A fuel return line delivers surplus fuel back to the feeder tank.
Contaminated fuel (i.e. particles, water, etc.) from the sumps can be drained by use of the quick
drain in the landing gear bay or by the two quick drains in the wing tanks.
CHAPTER-PAGE 3-16
AMENDMENT: 00
DATE: --
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
MAINTENANCE MANUAL STEMME S12
3.4.6.4
ELECTRICAL LAYOUT AND OPERATION OF THE FUEL PUMPS
For normal operation, the auxiliary fuel pump is switched off, and only the main pump is operating. The main pump is electrically supplied by the internal generator of the engine, or the engine
battery respectively.
The auxiliary fuel pump can be added if necessary, for example during take-off and landing. It is
supplied by the external alternator, or the main battery respectively:
• The right wing tank pump operates with the fuel selector switch in position ”RIGHT” or
”BOTH” tanks and the float switch in the feeder tank switching the pumps “ON”.
• The left wing tank pump works with the fuel selector switch in position ”LEFT” or ”BOTH”
tanks, plus the float switch in the feeder tank switching the pumps “ON”.
• The main pump works when the engine electrical system is powered.
• The auxiliary fuel pump works when the main electrical system is powered and the auxiliary
fuel pump switch is selected “ON”.
CHAPTER-PAGE 3-17
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
AMENDMENT: 00
DATE: --
AMENDMENT: 00
DATE: --
Left Fuel Tank
Fine-Filter
Coarse-Filter
Engine-Compartment
PressureRegulators at
Carburetors
Air-Box
Check-Valve
Sump
Drainer
Fuel-Pressure
Air-Box-Pressure
Drainer
Pump off - Switch
Low fuel - switch
Fine-Filter
Check-Valve
Main-Fuel
Pump
Left
Transfer-Pump
Aux-Fuel
Pump
Quick-DisconnectFittings
Right
Transfer-Pump
Drainer
Sump
Check-Valves
Coarse-Filter
Fuel-Shut-Off-Valve
Fuel-Tank-Vents
Pressure-Difference-Sensor
Right Fuel Tank
Fuel-Tank Valves
MAINTENANCE MANUAL STEMME S12
Feeder Tank
Figure 3.4.6.a.
Diagram of the Fuel System
CHAPTER-PAGE 3-18
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
MAINTENANCE MANUAL STEMME S12
3.4.7
ENGINE CONTROLS AND INSTRUMENTATION
REFER ALSO SECTION »3.2.2«
The throttle and choke are operated by Bowden cables, linking the carburetors with the cockpit
levers, which have adjustable friction control. The throttle and choke lever are installed in the
center console between the pilots. The throttle lever has two stops, one for the 100% (max continuous) power position and one for the 115% (max takeoff) power position.
Engine cooling is controlled by the cowl flaps, opened and closed by a linkage to the nose-cone
handle. In addition, the cowl flap aperture can be reduced in five steps by the cowl flap operation
handle on the instrument panel (see section »3.4.3«).
Both engine ignition and engine starter are controlled by a key switch. A special feature is a
three-second ignition delay after switching the key to position “START”, to allow the propeller
blades to unfold before engine ignition (see section »3.7.11«).
The engine instruments are located on the RH instrument panel.
For positions and function of switches and instruments, refer to section »3.2.2« and »3.7«.
3.4.8
FIRE PROTECTION
The engine including exhaust and induction system is isolated from the front, top and rear areas
by firewalls. The firewalls consist of stainless steel sheets (thickness 0.38 mm / 0.015 in).
The insides of the engine cowlings on the LH and RH side of the engine and below the engine
are coated with a fire-protective painting (manufacturer: Courtaulds Aerospace). It consists of
three coats of a white fire resistant paint (type N 56582/T508) and one coat of clear varnish (type
4232-0303, hardener N39-1327 or N50/2509, thinner N39-3091).
The fuel and oil hoses in the engine compartment are covered by fire-protective sleeves.
The fire warning system is triggered by two bimetallic temperature sensors above the carburetors.
The fire warning is by means of a red warning light (push-to-test function) on the instrument
panel, combined with an acoustic warning tone via the loudspeaker.
3.4.9
ENGINE COWLINGS
COWL FLAPS: REFER TO SECTION »3.4.3«
The engine cowling consists of three, (LH, RH and lower) parts. The cowlings are self-supporting
and connected to the fuselage structure forward and aft by means of camlocks.
The LH and RH cowlings are each fastened to the structure by 5 camlocks. Each includes an inlet
cowl flap and air duct assy.
The cooling air duct of the LH cowling maintains a gap of approx. 5 mm / 0.19 in to the radiator
with the cowling installed, to allow for relative motion.
CHAPTER-PAGE 3-19
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
AMENDMENT: 00
DATE: --
MAINTENANCE MANUAL STEMME S12
The air inlet of the RH cowling distributes the air for cylinder ram air cooling, for the intercooler
and for the oil radiator.
When installing the RH cowling, the opening for the cylinder cooling is pressed against a rubber
sealing on the coupling sheet of the upper support of the cylinder cooling air hose, routed to the
distribution plenum for the cylinders. The induction air duct is prepared with a cut-out for the
induction air filter. The filter assy. on the turbocharger inlet, consisting of filter, sealing plate and
air hose, remain installed while cowling is removed.
The complete lower cowling forms the outlet cowl flap. It is fastened by its forward hinges and
positioned by a rear control cable assy., which counteracts two springs acting towards the open
position of the flap.
3.4.10
PROPELLER
The foldable propeller consists of a center hub and two propeller blades hinged to this central unit.
The folding axis allows the propeller blades to move in the plane of propeller rotation. When the
propeller is not rotating, the blades fold in by spring forces. The central part of the propeller is made
of high strength aluminum. The propeller blades consist of carbon, Kevlar and glass composite.
During engine starting, the blades unfold automatically by centrifugal force. Rubber stops protect
the blades in case of a possible over-swing. The fully folded position of the propeller blades also
has rubber stops. The propeller blades may be retracted at any possible pitch angle.
After engine shut-down in flight, the propeller must be stopped by the propeller brake to allow the
blades to fold in. The brake is operated by the propeller brake handle on the instrument panel. In
the folded position the propeller can be positioned with the propeller positioning handle on the
instrument panel to allow the nose-cone, which forms the fuselage nose, to retract to the closed
position. After closing the nose-cone with the nose-cone handle in the center part of the instrument panel, the propeller is completely enclosed within the contours of the fuselage to achieve
optimum soaring performance.
The propeller blade pitch can be changed from take-off (fine pitch) to cruise (coarse pitch) position. The pitch control is electrically actuated and operated by a switch on the center console
behind the throttle assy. The take-off position of the propeller blades (not merely the switch) is
indicated by the green light next to the switch.
CHAPTER-PAGE 3-20
AMENDMENT: 00
DATE: --
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
MAINTENANCE MANUAL STEMME S12
3.4.10.1
DESIGN OF VARIABLE PITCH PROPELLER
The numerical positions in the following text refer to the propeller diagram (see figure »3.4.10 a/b«).
The propeller blades (1) are hinged in a forked mounting plate (4). The complete assembly, consisting of the fork, blade and hub, is rotated in order to set the pitch angle of the blade. The hollow
axle (3) houses a spiral torsion spring (23) to fold the blade by means of a cam lever (22) that fits
into the aperture for the buffer-stop in the propeller blade.
Electrically heated expanding servo-elements (15) actuate the blade pitch mechanism. On
achieving their activating temperature, these expanding servo elements drive a piston connected
to the propeller blades. All components of blade angle mechanism are double-redundant and
mechanically interconnected by a coupling ring (12) so that both propeller blades always have
identical pitch.
3.4.10.2
PROPELLER BLADES
The propeller blades are manufactured from GFRP (Glass Fiber Reinforced Plastic) material in a
twin shell construction. The shells are of hybrid laminate type (glass, carbon, aramid). Polyurethane tape is affixed to the leading edges to improve protection against gravel.
To balance the pressure in the blades with the outside atmosphere there is a 1 mm bore hole in
the blade tip. These holes also drain condensed moisture by centrifugal force.
3.4.10.3
PROPELLER BLADE ANGLE CONTROL MECHANISM
When disconnected from the power supply (unheated), the dilation effect actuator (15) is pushed
inwards via the rocking lever (14) by the spring (20), thus moving the propeller blade into T/O
position via the push-rod (13), the synchronizing ring (12) and the connector (11).
Heating of the servo-element by the heating element (16) generates piston pressure that pushes
the swing-arm/push-rod system into the almost fully extended position, thus rotating the propeller blade against the spring towards high pitch. It is assured, that, in case of heating element
malfunction, propeller blade position is automatically in T/O under all operating conditions.
The transmission of the actuating forces to the fork is effected by the drive pin (10) which is
attached to the fork with an eccentric bolt to allow for accurate setting of propeller blades. The
available range of adjustment of the servo-elements is 12.1 mm / 0.476 in. The stop setting for the
T/O position is adjusted for the fully retracted piston. The range of the blade angle change is set
to 6° 24’, limited by a stop switch.
A mechanical stop is adjusted so that only minimum override of the end position switch setting
is possible (< 6’). The piston movement caused by the two-point control system, result in minor
changes in propeller blade pitch angle with neglectable influence on the propeller behavior.
CHAPTER-PAGE 3-21
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
AMENDMENT: 00
DATE: --
MAINTENANCE MANUAL STEMME S12
*
See
Figure 3.4.10.b.
Figure 3.4.10.a
Variable Pitch-Propeller
* The numbering of the position in accordance with the “Propeller Adjustment Report”.
CHAPTER-PAGE 3-22
AMENDMENT: 00
DATE: --
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
MAINTENANCE MANUAL STEMME S12
Position
Number
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
Part
Propeller blade
Needle bearing (articulated joint)
Hollow axle
Blade suspension fork
Thrust plate
Propeller hub
Grooved ball bearing
Axial needle bearing
Grooved ball bearing
Drive pin
Coupling Part
Synchronization ring
Push rod
Rocking lever
Dilation effect actuator
Heating element
Slip ring (+)
Slip ring (-)
Fly-weight
Compression spring
Rubber stop
Cam lever
Torsion Spring
Stop
Adjustment screw
Yield bolt
Base
Nut
Ball washer
NOTICE
In order to prevent incorrect assembly, all parts relevant for the variable pitch of one propeller
blade are marked with a red dot. All other parts remain unmarked.
CHAPTER-PAGE 3-23
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
AMENDMENT: 00
DATE: --
MAINTENANCE MANUAL STEMME S12
3.4.10.4
PROPELLER WEIGHT BALANCE
The variable pitch propeller is balanced by the manufacturer. Final balancing is accomplished
by means of balancing weight washers fastened on the base-plate of the pitch change unit. The
positions provided on the base-plate for fastening of the washers are shown in figure »3.4.10 c«.
Figure 3.4.10.b
Propeller for Mounting
Reference Point for
Propeller Adjustment
Red Side
*
Figure 3.4.10.c
Position of Balancing Weights
* The numbering of the position in accordance with the “Propeller Adjustment Report”.
CHAPTER-PAGE 3-24
AMENDMENT: 00
DATE: --
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
MAINTENANCE MANUAL STEMME S12
WARNING
Balancing the variable pitch propeller or its assemblies may only be performed by the manufacturer or by authorized and licensed maintenance facilities according to the specific instructions
and using appropriate equipment.
The positions, number and weights of the balancing weight washers of the individual propeller
must be entered in the maintenance form »Propeller Adjustment Report« (Annex D).
3.4.10.5
EXPANSION ELEMENT AND CONTROL SYSTEM
The thermo expansion actuators are heated electrically and cooled by convection and heat dissipation. Electric energy is transferred to the propeller blades by slip rings. The expansion elements
actuate only towards the high pitch angles. The propeller blades are rotated in the direction of
lower pitch position by the return spring at the lever mechanism assisted by mass and aerodynamic forces on the blades.
When the propeller switch in the cockpit is in „cruise“-position, the expansion elements are heated
with about 50 Watts (with the engine running). The elements are heated until a temperature of
55º C is achieved and the element expands. As soon as the stop is reached propeller blades are
in cruise position and are held in this position by the two-point control system. If the propeller
switch is set to T/O position, the heating elements are switched-off and the expansion elements
cool down. By duplicating any essential elements and realization of logic-OR the control system
is fully redundant.
Heat insulation of operating elements is optimized to insure that the time for full change of pitch
in either direction will not exceed 5 minutes under any operating conditions (from idle to full
power). Typical actuating time for full change of pitch is about 2 ½ min.
The electrical energy to the expansion elements is interrupted (blade pitch automatically to T/O)
as soon as the propeller switch is set to T/O or when the nose-cone handle is not locked in OPEN
position (engine master switch is OFF).
If the nose-cone is closed, electrical energy to engine and propeller is isolated to save energy
when soaring.
In order to check the pitch range mechanism, a push-button that can be operated from outside
is provided on the right hand side (in flight direction) of the front gearbox frame. With the master switch “ON” and the button pushed and held, the expansion elements are heated and the
propeller is brought into the cruise setting. When the cruise setting is achieved, the stop switch
disconnects the electrical current to the heating elements. For this check, the push-button must
be activated for about 3 to 4 minutes to heat the expansion elements. On releasing the push-button, the elements cool down and the propeller returns in the start position.
CHAPTER-PAGE 3-25
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
AMENDMENT: 00
DATE: --
MAINTENANCE MANUAL STEMME S12
3.4.10.6
IDENTIFICATION OF PROPELLER SYSTEM AND ASSEMBLY
Complete Propeller
Propeller Blade
11 AP V / XXXXX / YYYY
11 AP VB / XXXXX - ZZ
X
Number of ordering for production share (corresponds to the aircraft serial no. for
complete propeller); 5 digits, starting with 30001, in addition 20038;
Y
Month and Year of production, 4 digits;
Z
Consecutive number of production share, 2 digits.
3.4.11
POWER TRANSMISSION
The components of the power transmission system are:
• Centrifugal clutch (in between engine and drive shaft): A force transmitting clutch actuated
by direction of rotation and rotating speed. Since the centrifugal clutch transmits torque
by friction, it is also an overload protection.
• Drive shaft.
• Flexible coupling forward and aft, allowing for angular and torsional elasticity.
The rear terminal of the drive shaft is maintenance-free due to a hard film coating (30 µm), which
also is anti-corrosive. The sliding friction coefficient decreases with increasing torque by design.
Optimum behavior of the coating is only attained if not greased. The condition of the coating
should be checked regularly (refer to section »5.4.16«).
3.4.12
FORWARD PROPELLER REDUCTION GEARBOX
The propeller reduction gearbox utilizes helical gears in an cast aluminum housing with a gear
ratio of 1.109. It is almost maintenance-free. Propeller reduction gear oil level can be checked by
means of an inspection glass with MIN/MAX markings. The extension shaft is connected to the
lower gear drive shaft with a flexible coupling. The propeller is mounted on the upper propeller
shaft of the reduction gearbox.
The reduction gearbox is attached to a milled aluminum suspension, which is supported by 4 shock
mounts in the fuselage front frame to reduce vibrations. The cut-outs in the front frame for the
shock mounts are sealed by rubber adapter shapes.
CHAPTER-PAGE 3-26
AMENDMENT: 00
DATE: --
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
MAINTENANCE MANUAL STEMME S12
3.4.13
3.4.13.1
OPERATION MECHANISM OF THE PROPELLER FOLDING SYSTEM
NOSE-CONE
The nose-cone forms the fuselage nose in front of the cockpit section and covers the folded propeller during flight in glider configuration. To change from gliding to powered flight, the nosecone can be shifted forward to allow the propeller unfold and rotate after starting the engine. In
the forward position locking and unlocking of the nose-cone lever simultaneously operates the
engine master switch (see section »3.7.11«).
The nose-cone consists of a CFRP shell, a GFRP frame and an aluminum tube, which provides suspension of the nose-cone at the front fuselage. The aluminum tube is guided through the hollow
propeller drive shaft into an aluminum tubular guided pipe, including Teflon slip rings to allow
axial sliding of the nose-cone tube. The tubular guided pipe is firmly bonded to the GFRP guide
block in the forward cockpit.
Shifting the nose-cone is by means of the nose-cone handle, installed in the lower section of
the instrument panel (see figure »3.2.3.a«). The pull rod of the handle is connected to the nosecone sliding tube via a milled aluminum bracket, which is screwed to the rear tube terminal and
guided in a slot at the guide block. The bracket and the handle guide assy. prevent rotation of
the nose-cone. The handle assy. includes a spring which acts towards the locked (down) position
of the handle.
3.4.13.2
PROPELLER POSITIONING
The propeller positioning assy. allows rotation of the propeller drive shaft after engine shut down
and braking the propeller to a full stop, to the position so that the folded propeller fits into the
nose-cone contour. It is operated by a pull handle on the lower instrument panel next to the
propeller brake handle (see figure »3.2.3.a«).
The propeller positioning is driven by a Bowden cable. The bowden cable is routed from the handle
to and around an aluminum disc, which is pivoted on the guide block of the nose-cone sliding
tube in the forward cockpit. When the handle is pulled, the disc rotates against a circumferential
spring force until reaching a screw stop, which is adjustable and defines the final position of the
propeller. The spring is wound around the nose-cone guide block and rotates the disc back toward
its initial position when the handle is released.
A spring-loaded catch lever is installed on the disc and is connected to the bowden cable rotating
the disc. If not operated, the spring acts on the catch lever, so it is clear of the propeller brake
drum, mounted on the rear propeller drive shaft of the front gear. When the handle is pulled the
spring force unlocking the catch lever is over-balanced by the circumferential spring force acting
on the disc and the catch will engage in one of two notches of the brake drum, thus rotating
the drive shaft until reaching the screw stop of the disc. The two notches of the brake drum are
opposed; therefore the propeller rotates a maximum 180° as the handle is pulled to the stop.
CHAPTER-PAGE 3-27
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
AMENDMENT: 00
DATE: --
MAINTENANCE MANUAL STEMME S12
3.4.13.3
PROPELLER BRAKE
The propeller brake is used to decelerate the propeller rotation to a full stop after engine shut
down in flight, to allow folding of the propeller by spring forces. It is operated by a pull handle on
the lower instrument panel (see figure »3.2.3.a«).
The propeller brake is driven by a bowden cable, routed from the handle through the front fuselage frame to the propeller brake assy., which is mounted on the rear housing of the front gear.
The cable is connected to a spring-loaded shift lever, which is mounted on the lower front gear
housing and pulls down one terminal of a brake belt during operation of the brake. The brake
band consists of a steel sheet with a riveted brake lining. The brake band is installed around a
brake drum mounted on the propeller drive shaft of the propeller gearbox. The second brake band
terminal is fastened to the gear housing opposite the other, driven, terminal. Some adjustment
of the clearance between brake lining and drive shaft is possible by loosening and shifting the
bowden cable support.
3.4.14
FLUIDS
3.4.14.1
FUEL
It is recommended to use premium gasoline, unleaded, minimum RON 95.
Suitable fuels:
• Super DIN EN 228
• Super Plus DIN EN 228
ACCORDING DOT
Gasoline min. grade 1, AKI 90.0, acc. to Canadian General Standard Board CAN/CGBS 3.5
(Unleaded Automotive Gasoline)
ACCORDING FAA
Standard Specification for Automotive Spark-Ignition Engine Fuel, ASTM D 4814
AVGAS 100LL
When using AVGAS 100LL, valve seats are stressed by the high amount of lead and in addition
combustion chambers will accumulate residues. AVGAS should be used only in case of fuel vapor
problems or if other fuel is not available.
CAUTION
The engine manufacturer recommends not to use AVGAS for an extended period, because an
increased amount of residues may accumulate in the engine.
CHAPTER-PAGE 3-28
AMENDMENT: 00
DATE: --
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
MAINTENANCE MANUAL STEMME S12
CAUTION
Danger of fuel vapor lock when using “winter” fuel during summer time.
CAUTION
Use only the appropriate fuel, recommended for the climate zone.
NOTICE
In accordance with the EASA SIB 2011-01 R2 “Unleaded Aviation Gasoline (AVGAS) UL91” is also
approved for operation. (See STEMME »SB A31-10-104« latest approved revision).
CHAPTER-PAGE 3-29
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
AMENDMENT: 00
DATE: --
MAINTENANCE MANUAL STEMME S12
3.4.14.2
COOLANT FLUID
Mixture of 50% concentrated antifreeze agent with anti-corrosion additives and 50% water.
Freezing point of this mixture is about -38°C / -34°F. »BASF Glysantin Antikorrosion« has proved
to be good; this or equivalent coolant may be used.
WARNING
As the cooling system is pressurized, to avoid the risk of scalding by escaping hot coolant, do not
open the locking cap on the coolant expansion tank unless the engine is cold (or barely lukewarm).
NOTICE
Waterless coolant is not approved for operation.
CAUTION
Check of the coolant fluid: The quantity in the overflow container (lower left side in the landing
gear bay) must be between “min.” and “max.” markings. Missing coolant in the overflow container must be added.
CAUTION
If the level of coolant in the overflow container is below “min.” marking, proper supply to the
breather valve and coolant tank is not assured and air may have been introduced into the cooling
system. To check , confirm that the engine is cold, open the locking cap on the expansion tank
(left side on fire-wall in engine compartment), and add coolant if necessary.
NOTICE
If the engine is warm, the indicated quantity in the overflow container is noticeably higher. An
excessive coolant level in the overflow container will not result in engine damage, but will result
in overflow of coolant into the landing gear bay.
CHAPTER-PAGE 3-30
AMENDMENT: 00
DATE: --
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
MAINTENANCE MANUAL STEMME S12
3.4.14.3
LUBRICANTS
ENGINE WITH INTEGRATED REDUCTION GEAR
According to the ROTAX Operation Manual the following oil specification should be met:
• Use only oil with API classification SG or higher!
• Due to the high stresses in the reduction gears, oils with gear additives such as high
performance motor cycle oils are recommended.
• Heavy duty 4-stroke motor cycle oils meet all the requirements. These oils are usually not
mineral oils but semi- or full synthetic oils.
• Oils primarily for Diesel engines have insufficient high temperature properties and additives
which favor clutch slipping, and are generally unsuitable.
For more detailed information refer to appropriate ROTAX publications (SI-914-019 latest approved
revision).
Oil quantity
Oil consumption
0.8 US gal / 0.66 Imp. gal. / 3 l
(minimum 0.53 US gal / 0.44 Imp gal / 2 l)
max. 0.026 US gal/h / 0.022 Imp gal/h / 0.1 l/h
CAUTION
The reduction gear additives, specified “GL4” or “GL5”, are required for a safe lubrication of the
integrated reduction gear. Never use other oil additives!
CAUTION
A full synthetic oil in combination with AVGAS results in abnormally high abrasion and/or residues.
During utilization of AVGAS, only semi-synthetic oils should be used.
NOTICE
Full- or semi-synthetic oils are to be preferred because of the temperature stability and less
residue formation.
CHAPTER-PAGE 3-31
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
AMENDMENT: 00
DATE: --
MAINTENANCE MANUAL STEMME S12
a)
Viscosity:
Use of multi-grade oils is recommended. Viscosity of multi-grade oils is less depending on temperature compared to single-grade oils. Multi-grade oils can be used year-round; after an engine
start at low temperatures the engine components are lubricated faster and at higher temperatures
the oil is heavier. Temperatures of adjacent SAE-classes overlap, so for short-term temperature
variations there is no need to change oil. The suitable oil grade can be chosen from the table.
Figure: 3.4.14.3.a
Engine Oil Table
PROPELLER GEARBOX
Use reduction gear oils specified according to MIL-L-2105C (Grade 90) or automotive gear oils
HYP 80W (ARAL), HYP 85W-90, HYP 85W 140 according to API-GL5 or Shell Aviation Oil S 8350
according to DTD 900/4981.
NOTICE
Oil specification: Only use “GL5” oils according to the API-system.
CHAPTER-PAGE 3-32
AMENDMENT: 00
DATE: --
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
MAINTENANCE MANUAL STEMME S12
3.5
3.5.1
LANDING GEAR
MAIN LANDING GEAR
The landing gear (L/G) consists of a tail wheel and two retractable main landing gear legs, hinged
at the center fuselage frame with the hinge axis in flight direction and locked in the extended
position by means of an over-center locking strut (“elbow lever”) for each leg. The wheel is
mounted on a trailing arm that is supported against the leg’s frame by a pre-loaded elastomeric
spring for shock absorption purposes.
Retracting of the L/G legs and doors is managed by an electrically driven linear actuator for each
leg that is built up around a high precision ball screw. Each of the linear actuators is hinged with
the top end at the fuselage frame; the bottom end is coupled to the respective elbow strut by
means of a locking mechanism which can be released for emergency landing gear extension by
pulling a T-handle in the cockpit (one for each of the legs) and via a bowden cable. In case of
an emergency extension the two legs should be released in succession (right-side-first order is
suggested, but wrong order is not critical), they then extend out by gravitational force. Secure
locking in the extended position is achieved by a spring that forces the over-center strut into its
end position.
The actuators are controlled and sequenced by stop switches, the switches for EXTENDED being integrated in the elbow struts and detecting the over-center position, those for RETRACTED
mounted at the fuselage frame and detecting the top position of each L/G leg. All these switches
are in duplicate, the second one giving the signal for the indication and warning system, which is
displayed by focused green and red LED’s on the right face of the instrument panel (refer to the
S12 Aircraft Flight Manual).
Both L/G doors are actuated by the landing gear legs. The RH landing gear door is coupled directly
to the RH landing gear leg via a spring device. The LH door is controlled by a cable mechanism.
During retraction, the LH landing gear leg starts closing the LH door by means of a cable, but
it remains open enough to allow retraction of the RH landing gear leg. The RH landing gear leg
effects complete closing of the LH door via the cable during the last portion RH main gear retraction. Opening of the LH door is by a spring loaded roller strut, which rolls on the LH door. It
pushes the door to the outside against the cable to keep the door from moving due to air loads,
and is blocked with the landing gear retracted, thus locking the door. In closed position the doors
are additionally locked at the rear by means of magnets.
The disk brakes on the main L/G wheels are operated hydraulically. The master cylinders for both
the left and right wheel are located on the control sticks. The pressure line from the master brake
cylinders to the brake calipers of the wheel brakes in the center fuselage are designed as metal-shielded brake hoses. The brake fluid reservoir is located in the landing-gear bay, cabin rear
wall.
The parking brake valve to set and to release the parking brake is located on the floor panel console
in front of the LH control stick. The parking brake valve is operated by a lever respectively rotary
handle. Braking action is simultaneous on both main wheels. Maximum brake pressure for the
system layout is 115 bar / 1668 psi, maximum allowed system pressure is 200 bar / 2900 psi.
CHAPTER-PAGE 3-33
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
AMENDMENT: 00
DATE: --
MAINTENANCE MANUAL STEMME S12
MAIN LANDING GEAR EMERGENCY EXTENSION
By pulling two T-handles in the cockpit, one after the other, the landing gear actuators are disconnected from the locking elbow struts by means of Bowden cables and the landing gear legs
extend by gravity to the “gear down” position. The secure locking of each leg in the extended
position is achieved by a spring that forces the over-center strut into its over-center position.
In case of emergency extension the two legs should be released in the recommended sequence
(T-handles marked 1 & 2, wrong order is not critical). The RH gear strut is equipped with a mechanism to avoid jamming of the struts in case of an incorrect sequence.
3.5.2
TAIL WHEEL
139 mm / 5.47 in
779 mm / 30.67 in
372 mm / 14.64 in
The tail wheel is not sprung and fits in a trailing fork mounted in two bearings. The upper bearing
is a combined radial/axial sleeve bearing. The journal is constructed so that a certain friction
damping is produced at the axial sleeve surfaces when loaded in axial direction in order to avoid
tail wheel flutter whilst taxiing. For steering on the ground the tail wheel fork is coupled with the
rudder by means of two pre-loaded tension springs.
1360 mm / 53.54 in
Figure 3.5.1.a
Main Landing Gear
CHAPTER-PAGE 3-34
AMENDMENT: 00
DATE: --
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
MAINTENANCE MANUAL STEMME S12
3.6
FLIGHT CONTROL INSTRUMENTS, PITOT STATIC SYSTEM
Instruments: See Equipment List.
CAUTION
For modifications sections »3.8« and »9« must be respected.
Pitot pressure, static pressure and total energy compensation are measured by means of a
multi-purpose probe in the nose-cone. Its orifices are plumbed to the instrument panel through
the nose-cone sliding tube.
NOTICE
Some instruments, e. g. Bohli-diaphragm-type rate-of-climb indicator, need additional static ports
for proper operation at the widest area of the forward fuselage. These additional static ports are
installed only, if they were required for instrumentation at time of delivery.
All hose lines of the pitot-static system are equipped with a water separator/filter in the front
cockpit area below the instrument panel.
CHAPTER-PAGE 3-35
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
AMENDMENT: 00
DATE: --
MAINTENANCE MANUAL STEMME S12
Figure 3.6.a
Pitot and Static Pressure System
NOTICE
Any line must be as short as possible.
The water/separator filters must always be located upstream of the device and upstream of any
junction.
CHAPTER-PAGE 3-36
AMENDMENT: 00
DATE: --
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
MAINTENANCE MANUAL STEMME S12
3.7
3.7.1
ELECTRICAL SYSTEM
GENERAL SYSTEM ARCHITECTURE
The electrical system of the S12 consists of two independent, separate sub-systems: the main
system and the engine system. Each system incorporates a dedicated battery and generator
(actually an alternator and rectifier for the main system). Failures of one system will not interfere
the other system. There is no provision to cross-tie the two sub-systems.
The engine system powers exclusively those devices needed to operate the engine or which are
available only when the engine is running. Under normal conditions the engine system battery is
charged by the internal generator of the ROTAX engine. In gliding flight the engine system is shut
off completely. The operational mode of the engine battery is a stand-by mode, as it is normally
used only for engine starting. Under normal conditions it will not be discharged.
The main system powers all other devices of the aircraft. During powered flight its battery is
charged by the external belt driven alternator. During gliding flight the main system battery
powers all active devices. Once the main system battery is exhausted, the pilot is able to restart
the engine using the still fully charged engine system battery.
After successful restart of the engine, the external alternator will power the main system and will
recharge the main system battery. The operational mode of the main system battery is as a storage battery in cycle mode. Under normal conditions it will be regularly discharged and recharged.
CHAPTER-PAGE 3-37
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
AMENDMENT: 00
DATE: --
MAINTENANCE MANUAL STEMME S12
MAIN SYSTEM
ENGINE SYSTEM
COM / NAV
TRIM
LAND. GEAR
LIGHTS
AUTOPILOT
AUX.FUEL PUMP
ENGINE MAIN AND
TRANSFER FUEL PUMP
ENG MONITOR
TCU
PROP PITCH CTRL.
INT. GEN
MAIN
SYSTEM
BATTERY
START
EXT. ALT
ENGINE
SYSTEM
BATTERY
Figure 3.7.a
Electrical System S12
CHAPTER-PAGE 3-38
AMENDMENT: 00
DATE: --
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
MAINTENANCE MANUAL STEMME S12
3.7.2
DC GENERATION (ATA 24-30-00)
3.7.2.1
MAIN SYSTEM DC POWER GENERATION
The DC power for the main system is generated by the belt-driven alternator of the engine and
stored in a LiFePO4 battery.
MAIN SYSTEM BATTERY
TypeSuper B SB12V19E-EC
STEMME p/n831.489
Nominal Voltage
12.8 V
Nominal Capacity C1
19.2 Ah
Technology
Lithium Iron Phosphate LiFePO4
Protection device
Over-voltage protection device OVP-15.5
Qualification
Airworthiness and eligibility are proven in /A/
Location
Battery case at front ring frame of tail boom
MAIN SYSTEM ALTERNATOR
TypeNippon Denso 42A,
STEMME p/n830.600
DriveV-Belt
Excitation
External, controlled automatically depending on running engine
Field circuit protection
5 A fuse
Nominal Voltage:
14 V
Max Output Power
42 A
Voltage Regulator
built-in
Regulated Voltage
14.2 – 14.8V @ 25°C
Qualification
The alternator is part of the certified aircraft engine ROTAX 914 series
Location
Left side of propeller gear housing of engine
FUNCTION
When aircraft master switch is switched ON the main system master relay connects the battery
to the system. From that moment on all devices supplied by main system are powered, except
those with a dedicated ON/OFF switch. When the engine is running, a pulse train representing
the engine’s rpm is present at the input of a frequency-controlled relay. The relay switches on the
field circuit of the alternator and the alternator starts to generate voltage. The alternator output
is controlled by a voltage regulator built in the alternator. A red warning light indicates failures
at the alternator, e.g. a broken V-belt.
CHAPTER-PAGE 3-39
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
AMENDMENT: 00
DATE: --
MAINTENANCE MANUAL STEMME S12
3.7.2.2
ENGINE SYSTEM DC POWER GENERATION
The DC power for the engine system is generated by the crankshaft-mounted generator of the
engine and stored in a LiFePO4 battery. The battery is used to crank the engine to start.
ENGINE SYSTEM BATTERY
TypeSuper B SB12V7800P-CC
STEMME p/n831.488
Nominal Voltage
13.2 V
Nominal Capacity C1
7.8 Ah
Technology
Lithium Iron Phosphate LiFePO4
Protection device
Over-voltage protection device OVP-15.5
Qualification
Airworthiness and eligibility are proven in /A/
Location
Battery case at front ring frame of tail boom
ENGINE SYSTEM INTERNAL GENERATOR
Type
ROTAX (Part of engine)
STEMME p/nn/a
Drivecrankshaft, directly mounted
Excitationpermanent magnet
Nominal Voltage
14 V
Max Output Power
18 A
Voltage Regulator
external rectifier-regulator (ROTAX)
Regulated Voltage
13.7 – 14.3 V
Qualification
The generator is part of the certified air raft engine ROTAX 914 series
Locations
Coils and magnets mounted on aft end of crankshaft housing,
voltage regulator installed on TCU-Starter-Board.
FUNCTION
If aircraft master switch is switched ON and the aircraft nose cone is opened and locked, a micro
switch at the nose cone lever activates the engine system master relay. The relay connects the
battery to the engine system. The TCU and the main fuel pump operate immediately. Pushing the
ignition-starter key to START activates the starter relay and connects the battery to the starter.
When the engine is running the rotating magnets generate voltage in the generator coils. The
regulator limits the output voltage. A yellow warning light indicates failures of the generator system.
CHAPTER-PAGE 3-40
AMENDMENT: 00
DATE: --
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
MAINTENANCE MANUAL STEMME S12
3.7.2.3
OVER VOLTAGE PROTECTION
The outputs of the belt driven alternator and of the internal generator are monitored by a dedicated
over-voltage device OVP. The device senses the voltage of the related system and disconnects the
related alternator resp. generator in the case of system voltages of more than 15.2 V.
Each OVP is located in the related distribution box. A yellow light at the box indicates a triggered
over-voltage protection.
3.7.3
DC INDICATION (ATA 24-37-00)
3.7.3.1
DESCRIPTION
Each electrical system includes a voltmeter to indicate the system voltage and an ammeter to
indicate the current between system and battery. Both instruments can be toggled between
main and engine system by a common toggle switch. The ammeter is supplied by shunts in the
positive lines of the batteries. Positive reading indicates battery charging, negative reading
indicates battery discharging.
A red warning light indicates failure of the main system alternator.
A yellow warning light indicates failure of the engine system generator.
Voltmeter, ammeter, toggle switch and warning lights are located on the right hand part of the
instrument panels and easy to read and to operate by the crew. Switch and warning lights are
clearly labeled.
3.7.4
PARTS SPECIFICATION
Part
Voltmeter
Ammeter
Shunt
3.7.5
STEMME p/n
831.120
831.121
831.122
Manufacturer p/n
UMA N141100917V0A0
UMA N15110003CA000
UMA 1C1
OPERATION
Use toggle switch to choose indication of engine system voltage and current or main system
voltage and current.
CHAPTER-PAGE 3-41
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
AMENDMENT: 00
DATE: --
MAINTENANCE MANUAL STEMME S12
3.7.6
DC POWER DISTRIBUTION SYSTEM (ATA 24-60-00)
The system is designed to distribute electrical energy from the source to the electrical loads. Because the engine of the S12 is located in mid-fuselage, there are long distances between voltage
sources and the loads.
Therefore, special attention is paid to subdivide the system into functional assemblies which includes sub-distributions with related protective devices.
3.7.6.1
WIRE SPECIFICATIONS
Battery and Starter Cables
All other, unshielded and
shielded
Cross Section
16 mm²
AWG 24...8
Specification
EN 50525-2-81
MIL-22579/16 or
Raychem 44A
The cross section of each single wire is optimized individually.
The wires are bundled with spiral wrap to a wire harness. This harness is routed and fixed along
the aircraft’s steel tube frame from the electrical distribution rack to the instrument panel. Inside
the cockpit, the wire bundle is routed along the tunnel between the seats.
Sufficient distance to moving parts and heat sources is provided. Mechanical damage by tight
bending or chafing is prevented.
3.7.6.2
DESIGN OF ELECTRICAL CONNECTIONS
Electrical connections are made by screw terminals, push-on contacts or multiple position
connectors.
Terminals and contact pins are generally crimped to the wires. Use of soldering techniques is
minimized.
Terminals and connector systems meet industrial standards.
CHAPTER-PAGE 3-42
AMENDMENT: 00
DATE: --
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
MAINTENANCE MANUAL STEMME S12
3.7.6.3
PROTECTION DEVICES
Fuses and circuit breakers of different industrial standards are used to protect each electrical
circuit. The protective devices are rated according to the maximum allowed electrical load of the
protected wire. Protection devices are located as close as possible to the voltage source to minimize the length of unprotected wire.
Fuses are grouped in fuse holders at different locations at the aircraft. The fuse holders are not
reachable by the pilot in flight. Devices and circuits protected by fuse are considered as non-essential to safe flight. The loss of the related function caused by a blown fuse will not cause hazards to aircraft or crew. On the other hand, because of the fuse ratings there must be a severe
reason for a blown fuse. It is considered improbable, that this could be corrected by the pilot by
replacing a fuse in flight. A sufficient number of spare fuses is provided with the on-board tool
set for a repair on ground.
The circuits of landing gear and electronic equipment are protected by resettable circuit breakers,
located on the instrument panel and easy to reach by the crew in flight. This enables the pilot to
evaluate the state of power supply of such devices in the case of malfunction. In addition, it allows
the pilot to deactivate certain devices during gliding flight to save battery power (load shedding).
Each circuit breaker is clearly labeled with its function.
CHAPTER-PAGE 3-43
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
AMENDMENT: 00
DATE: --
MAINTENANCE MANUAL STEMME S12
3.7.6.4
FUSE AND CB SPECIFICATIONS: MAIN SYSTEM
Circuit
Main System Master
Fuse
External Alternator
Position Lights
Landing Headlight
ACL
(Anti-collision light)
Landing
Headlight
Auxiliary Fuel Pump
Ammeter Hi
Ammeter Lo
COM
XPDR
EFIS
GPS
Autopilot
Landing Gear
System
Trim System
Alternator Field
Fire Warning
Alternator
Warning Light
Soaring
Computer
Volt / Ammeter
Stall warning
Location of Fuse/CB
Fuse /CB
Rating (A)
STEMME p/n
Qualification
Main System Box
50
832.247
ISO 8820-5
Main System Box
50
5
5
832.247
ISO 8820-5
831.430
ISO 8820-3
832.241
IEC 60934
CB 7.5
832.235
LN 29886
5
5
2
831.430
831.430
5
Fuse holder Main System
Box
Instrument Panel Front
Fuse holder Instrument
Panel
5
5
5
5
CB 5
CB 5
CB 5
CB 5
CB 5
2
2
ISO 8820-3
831.429
2
2
CHAPTER-PAGE 3-44
AMENDMENT: 00
DATE: --
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
MAINTENANCE MANUAL STEMME S12
3.7.6.5
FUSE SPECIFICATIONS: ENGINE SYSTEM
Circuit
Starter
External Power Supply
System Master Fuse
Engine Bus Supply
Internal Generator
Prop Pitch Control Power
Main Fuel Pump
TCU Power
Fuel Transfer Pump RH
Fuel Transfer Pump LH
Ammeter Hi
Ammeter Lo
Internal Generator
warning
Starter Relay
Location of Fuse/CB
Engine System Box
Fuse holder Engine
System Box
Rating (A)
80
80
50
15
15
15
5
5
5
5
5
5
5
831.430
Low Fuel Warning Light
Tachometer
Ignition retarder
Fuel Pressure Indicator
Fuel Level Indicator Left
Fuel Level Indicator Right
Oil Press + CHT Left
Oil Temp + CHT Right
Fuel Flow Meter
Volt / Ammeter
Engine Hour Meter
Prop Pitch Sense
2
2
2
2
2
3.7.7
831.430
831.429
2
Fuse holder Instrument
Panel
831.432
2
Propeller Pitch Indication
Fuse holder Instrument
Panel
STEMME p/n Qualification
831.491
831.491
ISO 8820-5
831.247
2
2
2
2
2
2
ISO 8820-3
831.429
ISO 8820-3
831.429
ISO 8820-3
SWITCHING DEVICES
Power switching devices are located as close as possible to the voltage source. Due to the distances between voltage source and cockpit, the most electrical loads are remotely controlled. With
the manually operated toggle and rotary switches on the instrument panel the pilot controls the
negative (ground) lines of control circuits of electro-mechanical or semiconductor relays, which
are located on the electric distribution board. The wiring of the load circuits is routed directly from
distribution board to load device the voltage drop between power supply and load to minimize.
CHAPTER-PAGE 3-45
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
AMENDMENT: 00
DATE: --
MAINTENANCE MANUAL STEMME S12
3.7.7.1
MANUAL SWITCHES
Manual switches are located on the instrument panel and easy to reach by the crew. The position
of a toggle or rotary switch is indicated by the position of the operating lever or knob. The use of
momentary switches or push-buttons is limited to certain functions of electronic equipment, as
such electrical elevator trim, the PTT button of the communication radio, autopilot disengage
and the remote control unit of the soaring computer.
Each switching element is sufficiently rated to carry the electrical load of the related circuit. None
of the electrical circuits controlled by manual switches on the instrument panel has an electrical
consumption of more than 3 A. Each switch is clearly labeled with its function.
Function
Master Switch
Auxiliary Fuel Pump ON
Engine System Back-Up
TCU Emergency
Transfer Pump Selector
Landing Gear UP/DOWN
Ignition-Starter-Key-Switch
Position Light Switch
ACL Switch
Landing Light
Propeller Pitch
3.7.7.2
STEMME p/n
831.151
831.151
831.151
831.151
831.507
831.225
831.107
831.493
831.493
831.493
831.151
Electrical Load
Relay Coil, < 1 A
MOSFET Gate, < 0.1 A
Relay Coil, < 1 A
Relay Coil, < 1 A
Waste Gate Servo, < 2A
MOSFET Gate, < 0.1 A
Relay Coils, < 2 A
MOSFET Gate, < 0.1 A
MOSFET Gate, < 0.1 A
MOSFET Gate, < 0.1 A
MOSFET Gate, < 0.1 A
Rating
3A
3A
3A
3A
0.15 A
20 A
3A
3A
3A
3A
ELECTROMECHANICAL RELAYS
Power relays are used as master relays for the main system and the engine system, as starter relay
and as contactor for the optional ground power supply. The relays are typically ground-controlled,
the control switch is connected to the negative side of the relay coil. This improves the system
reliability.
Each relay is rated sufficiently for its electrical load.
Function
Main System Master
Engine System Master
Starter Relay
STEMME p/n
831.416
831.416
830.725
Ground Power Relay
831.111
Rating
70 A
70 A
75 A cont. / 300 A
short time
75 A
Fuse
50 A
50 A
80 A
Qualification
Part of certified
engine
80 A
CHAPTER-PAGE 3-46
AMENDMENT: 00
DATE: --
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
MAINTENANCE MANUAL STEMME S12
3.7.7.3
SEMICONDUCTOR SWITCH BOX
An 8-channel MOSFET-based switch box is installed to control the power for fuel pumps, lights
and variable pitch propeller. The use of semiconductors improves the system reliability, reduces
electromagnetic emissions and saves weight and space. The switch box is located close to the
batteries and to the distribution boxes.
The box includes 8 channels with a switching capacity of max. 36 A each.
Connector
System
Gray
Main
Black
Engine
3.7.8
Channel #
1
2
3
4
1
2
3
4
Function
Position lights
Anti-Collision Lights
Landing Light
Auxiliary Fuel Pump
-sparePropeller Pitch Control
Transfer Pump Left Wing
Transfer Pump Right Wing
Fuse
5A
5A
5A
5A
15 A
5A
5A
MAIN SYSTEM DISTRIBUTION BOX
4.7.8 Main System Distribution Box
This box includes a metallic bus bar to which the main system battery and the alternator are
connected via master fuses. The main system master relay and a number of fuses are located in
a combined fuse-relay-holder. The box is made of plastic with a sealed cover and is mounted on
a rack on the aft area of upper fire wall.
3.7.9
ENGINE SYSTEM DISTRIBUTION BOX
This box includes a metallic bus bar to which the engine system battery, the starter, the generator
and the external power supply are connected via master fuses. The engine system master relay
and a number of fuses are located in a combined fuse-relay-holder. The box is made of plastic
with a sealed cover and is mounted on a rack on the aft area of upper fire wall.
3.7.10
TCU BOARD
The following elements of engine control are located on this board:
• The turbocharger control unit TCU.
• The waste gate servo.
• The ambient pressure sensor.
• The starter relay.
• The voltage regulator of the internal generator.
• The power relay for the ground power supply.
CHAPTER-PAGE 3-47
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
AMENDMENT: 00
DATE: --
MAINTENANCE MANUAL STEMME S12
The elements are screwed to a mounting plate, which is fixed to the steel tube frame, aft of the
engine compartment.
1
2
3
4
1. Batteries
2. Shunts
3. Engine System Box
4. Main System Box
Figure 3.7.a
Electrical Components Center Fuselage
CHAPTER-PAGE 3-48
AMENDMENT: 00
DATE: --
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
MAINTENANCE MANUAL STEMME S12
2
5
3
4
2. Shunts
3. Engine System Box
4. Main System Box
5. TCU Box
Figure 3.7.b
Electrical Components Center Fuselage
3.7.11
INSTRUMENT PANEL BUS SYSTEM
Two fuse holders, one for each system, are located behind the instrument panel. Each fuse holder
forms a distribution bus. See chapter »7.3.1 «and »7.3.2« for a list of the connected devices on
each bus.
From the main system bus a wire leads to the group of circuit breakers on the instrument
panel front. These circuit breakers form the avionics bus. Radio communication and navigation
equipment is connected here.
All engine monitoring instruments are connected to the engine system bus.
CHAPTER-PAGE 3-49
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
AMENDMENT: 00
DATE: --
MAINTENANCE MANUAL STEMME S12
1
2 3
1. Circuit Breakers for Avionics
2. Engine Bus
3. Main Bus
Figure 3.7.c
Electrical Components Instrument Panel
3.7.12
ENGINE STARTING SYSTEM (ATA 80-00-00)
3.7.12.1
DESCRIPTION
The electrical starter is connected via starter relay to the engine system battery. The starter relay is controlled by the combined ignition-starter-key-switch located on the instrument panel.
The control circuit for the relay triggers an ignition retarding module which allows the foldable
propeller to unfold the blades completely before the engine fires. This protects the blade folding
mechanism from damages caused by engine starting torque.
3.7.12.2
PARTS SPECIFICATION
Starter and starter relay are part of the engine, their specifications can be found in the
ROTAX 914 Maintenance Manual.
3.7.12.3
OPERATION
The starter relay is triggered when the key switch is pushed to the “Start” position. The procedure
to start the engine is described in the S12 Aircraft Flight Manual.
CHAPTER-PAGE 3-50
AMENDMENT: 00
DATE: --
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
MAINTENANCE MANUAL STEMME S12
3.7.13
ENGINE IGNITION SYSTEM (ATA 74-00-00)
3.7.13.1
DESCRIPTION
The ROTAX 914 engine is equipped with a dual ignition. The ignition system works independently
from the aircraft’s electrical system and energy sources. The ignition system is part of the engine.
A detailed description can be found in the ROTAX 914 Maintenance Manual.
The ignition system is controlled by the combined ignition-starter-key-switch located on the
instrument panel. It includes the magneto check function. The ignition switch is connected with
two shielded AWG22 wires to the electronic ignition control boxes, one for each box.
When the switch is closed, the related control box is grounded and deactivated. An ignition
retarding module is connected in parallel to the ignition control boxes. It is actuated by the key
switch. When in “Start” position, the ignition retarder deactivates the ignition control boxes for
approximately 3 seconds. This allows the foldable propeller to unfold the blades completely before
the engine fires. After the delay time the ignition is activated automatically.
The ignition system is not fused. The fuse of the ignition retarding module is located at the
instrument panel fuse holder (engine bus).
3.7.13.2
PARTS SPECIFICATION
Part
Ignition-Starter-Key-Switch
Ignition Retarder Module
3.7.13.3
STEMME p/n
831.107
124.211
Manufacturer p/n
ACS 11-03170
n/a
OPERATION
• In “OFF” position the control inputs of both ignition boxes are connected to ground and
the ignition is deactivated.
• In “LEFT” position the control input of the right side ignition box is connected to ground
and the right ignition channel is deactivated.
• In “RIGHT” position the control input of the left side ignition box is connected to ground
and the left ignition channel is deactivated.
• In “BOTH” position the control inputs of both ignition boxes are open and both ignitions
are deactivated.
• In “START” position the control inputs of both ignition boxes are momentarily connected
to ground and the ignition is inhibited for approximately 3 seconds.
The engine starting procedure and operation of the ignition-starter-key-switch is described in
the S12 Aircraft Flight Manual.
CHAPTER-PAGE 3-51
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
AMENDMENT: 00
DATE: --
MAINTENANCE MANUAL STEMME S12
3.7.14
ENGINE RPM INDICATING SYSTEM (ATA 77-14-00)
3.7.14.1
DESCRIPTION
The RPM signal is delivered by a pick-up coil at the rotating magnets of the internal generator
to the tachometer input of the Turbocharger Control Unit (TCU). The TCU provides an output to
which the electrical tachometer on the instrument panel is connected. The tachometer is wired
with shielded AWG22 wire.
The RPM signal is secondarily used to trigger a frequency relay which activates the field circuit
for the belt-driven alternator.
The tachometer fuse is located at the instrument panel fuse holder (engine bus).
3.7.14.2
PARTS SPECIFICATION
Pick-up and tachometer are part of the engine, their specifications can be found in the
ROTAX 914 Maintenance Manual.
3.7.14.3
OPERATION
The engine RPM indicating system does not require operation actions by the pilot.
3.7.15
CYLINDER HEAD TEMPERATURE INDICATING SYSTEM (ATA 77-22-00)
3.7.15.1
DESCRIPTION
The CHT indicating system measures the cooling water temperature on two of the four cylinder
heads of the ROTAX 914 engine. The temperature signal is generated by resistive type probes (Pt-100
characteristics) and displayed to the pilot by one pointer-style gauge for each side of the engine.
The indicators share their fuses with the oil temperature resp. pressure indicator. The fuses are
located at the instrument panel fuse holder (engine bus).
3.7.15.2
PARTS SPECIFICATION
Part
Oil Temperature Indicator
Temperature probe RTD
(Resistance Temperature Detector RTD)
3.7.15.3
STEMME p/n
831.241
Manufacturer p/n
UMA T12113R150C050 TSO
831.243
UMA 1B4R
OPERATION
The CHT Indication system does not require operation actions by the pilot. Scale markings of
operational limits and instructions to the pilot about corrective actions in the case of exceeded
limits are defined in the S12 AFM.
CHAPTER-PAGE 3-52
AMENDMENT: 00
DATE: --
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
MAINTENANCE MANUAL STEMME S12
3.7.16
OIL PRESSURE INDICATING SYSTEM (ATA 79-31-00)
3.7.16.1
DESCRIPTION
The oil pressure indicating system measures the pressure at the output of the mechanical oil pump
of the ROTAX 914 engine. A transducer generates a voltage of 0…5 V proportional to the pressure.
This voltage is displayed to the pilot by a pointer-style gauge.
The indicator shares a fuse with the CHT-left indicator. The fuse is located at the instrument panel
fuse holder (engine bus).
3.7.16.2
PARTS SPECIFICATION
Part
Oil Pressure Indicator
Pressure Sender
3.7.16.3
STEMME p/n
831.115
831.116
Manufacturer p/n
UMA T04113U010B030 TSO
UMA T1EU150G
OPERATION
The Oil Pressure Indication system does not require operation actions by the pilot. Scale markings
of operational limits and instructions to the pilot about corrective actions in the case of exceeded
limits are defined in the AFM.
3.7.17
3.7.17.1
OIL TEMPERATURE INDICATING SYSTEM (ATA 79-33-00)
DESCRIPTION
The oil temperature indicating system measures the oil temperature in the crankcase of the
ROTAX 914 engine. The temperature signal is generated by a resistive type probe (Pt-100 characteristics) and displayed to the pilot by a pointer-style gauge.
The indicator shares a fuse with the CHT-right indicator. The fuse is located at the instrument
panel fuse holder (engine bus).
3.7.17.2
PARTS SPECIFICATION
Part
Oil Temperature Indicator
Temperature probe RTD
(Resistance Temperature Detector RTD)
STEMME p/n
831.241
Manufacturer p/n
UMA T12113R150C050 TSO
831.243
UMA 1B4R
CHAPTER-PAGE 3-53
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
AMENDMENT: 00
DATE: --
MAINTENANCE MANUAL STEMME S12
3.7.17.3
OPERATION
The oil temperature indication system does not require operation actions by the pilot. Scale
markings of operational limits and instructions to the pilot about corrective actions in the case
of exceeded limits are defined in the AFM.
3.7.18
FUEL DISTRIBUTION SYSTEM (ATA 28-20-00)
3.7.18.1
DESCRIPTION
The fuel is stored in two wing tanks of equal size, one in each side of the wing center section. Each
tank is vented to the atmosphere to prevent overpressure or vacuum situations. Each tank has
an over wing fuel filler. Each tank is connected via a coarse filter and quick drain to a dedicated
electric plunger pump with downstream check valves. These check valves close off the fuel line
when the pumps are not powered. The transfer pumps deliver the fuel into the feeder tank. The
fuel line between check valves and feeder tank includes a quick-disconnect to facilitate handling
during wing rigging and de-rigging.
The feeder tank incorporates two float switches to control the transfer pumps and to generate a
low fuel warning signal to the pilot. From the feeder tank the fuel is delivered by a turbine pump
(feeder pump) to the fuel pressure regulator, which provides the required fuel pressure to the
carburetors. The regulator’s return line ends in the feeder tank.
The feeder pump is backed up by another turbine pump of the same type.
3.7.18.2
PARTS SPECIFICATION
Part
Main and Auxiliary Feeder Pump
Fuel Transfer Pumps
3.7.18.3
STEMME p/n
11AB-M02
(830.209)
830.521
Manufacturer p/n
Pierburg E1F
HKT HEP-02
OPERATION
a) Main Feeder Pump Control
The main boost pump is supplied by the engine’s electrical system. It automatically starts to work
when the engine’s electrical system is activated by the pilot. Proper operation of the main boost
pump is indicated by the fuel pressure indicating system (refer 28-44-00). The electrical power
line of the main feeder pump is protected by a fuse located inside the engine system junction box
(refer 24-60-00).
b) Auxiliary Feeder Pump Control
The auxiliary boost pump is controlled by a switch to be manually activated by the pilot when
required. To achieve better redundancy of the fuel system, the auxiliary boost pump is powered by
the main electrical system, independently from the engine’s electrical system. The proper function of the auxiliary boost pump is indicated by a green light and by the fuel pressure indicating
system (ref 28-44-00). The electrical power line of the auxiliary boost pump is protected by a fuse
located inside the main system junction box (refer 24-60-00).
CHAPTER-PAGE 3-54
AMENDMENT: 00
DATE: --
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
MAINTENANCE MANUAL STEMME S12
3.7.18.4
TRANSFER PUMP CONTROL AND TANK SELECTION
The transfer pumps are powered by the engine electrical system. They transfer pumps are controlled by a float switch in the feeder tank and by a pump selector switch. At feeder tank fuel levels
below 90% the transfer pump control is active. The pilot selects the pump on a rotary switch with
the positions LEFT-BOTH-RIGHT. Due to the check valves downstream from the transfer pumps,
the related tank outlet will be closed off completely when the associated transfer pump is not
powered. Thus the pump selector switch functions as a tank selector.
The selected transfer pump/pumps stops automatically when the fuel level reaches 90% in the
feeder tank. On feeder tank-fuel level below 90% the selected transfer pump/pumps start automatically.
The transfer pumps can be activated manually by a test push-button in the cockpit center console
when the Master Switch is ON. This function is used for daily inspection or Maintenance Tasks.
The transfer pump/pumps to be tested can be selected by using the fuel selector switch (Left,
Right, Both).
3.7.19
3.7.19.1
FUEL QUANTITY INDICATION (ATA 28-40-00)
DESCRIPTION
A float type fuel level sender is installed in each fuel tank in the wing. The electrical resistance of
the sender changes depending on the float position. This resistance is measured and displayed
to the pilot on one pointer-type fuel level indicator for each tank. The indicator scale is marked
with lines, each representing one eighth of full.
A separate float type switch is installed in the feeder tank which activates a yellow low fuel warning light on the instrument panel at feeder tank fuel levels below ca. 2.5 ltr.
The fuses for the fuel level indicator system are located in the instrument panel fuse holder (engine bus).
3.7.19.2
PARTS SPECIFICATION
Part
Fuel Quantity Indicator
Fuel Level Sender
3.7.19.3
STEMME p/n
831.435
851.503
Manufacturer p/n
UMA T18112F1F4, TSO
VDO 226 801 015 001 G, modified
OPERATION
The fuel quantity indication system does not require any operation actions by the pilot.
Instructions to the pilot in case of low fuel level situation can be found in the AFM.
CHAPTER-PAGE 3-55
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
AMENDMENT: 00
DATE: --
MAINTENANCE MANUAL STEMME S12
3.7.20
FUEL PRESSURE INDICATING (ATA 73-32-00)
3.7.20.1
DESCRIPTION
The ROTAX 914 engine requires the measurement of fuel pressure in relation to the “upper deck”
air pressure of the turbocharger system. Therefore a differential pressure sender is installed which
generates a voltage output of 0 V … 5 V proportional to the difference between regulated fuel
pressure and air box pressure. This voltage is displayed to the pilot on a dedicated digital voltmeter
in the engine portion of instrument panel.
The operational range of 150 mbar … 350 mbar is marked on a placard close to the voltmeter.
The fuse for the fuel pressure indicator system is located in the instrument panel junction box
(engine bus).
3.7.20.2
PARTS SPECIFICATION
Part
Differential Pressure Indicator
Indicator
3.7.20.3
STEMME p/n
831.123
851.147
Manufacturer p/n
UMA N1EU07D
Conrad 134473
OPERATION
If the fuel pressure exceeds the limits, the pilot has to check the available amount of fuel and the
state of the tank selector and the auxiliary fuel pump. Instructions about appropriate corrective
actions are included in the S12 Aircraft Flight Manual.
3.7.21
FIRE DETECTION SYSTEM (ATA 26-12-00)
3.7.21.1
DESCRIPTION
Two bimetallic thermal switches are positioned on the upper firewall directly above the carburetors
to detect increasing temperatures. At temperatures above 160°C the switches (or at least one)
open the control circuit of a relay. This activates a red warning light and a piezo signal horn. The
system includes a test switch on the panel.
3.7.21.2
PARTS SPECIFICATION
Part
Thermoswitch Microtherm R20
Switch with indication light - housing
Switch with indication light - cap
Switch with indication light - bulb
STEMME p/n
10AM-F01
10AM-F02
10AM-F03
10AM-F04
Manufacturer p/n
on request
on request
on request
on request
CHAPTER-PAGE 3-56
AMENDMENT: 00
DATE: --
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
MAINTENANCE MANUAL STEMME S12
3.8
COM AND NAV EQUIPMENT
COM and NAV equipment is installed in the instrument panel.
The loudspeaker is installed on the rear wall of the cockpit above the LH baggage compartment.
The gooseneck microphone is fastened between the backrests at the center console. When using
headsets it can be deselected.
Antennas are installed for:
• VHF-COM in rudder,
• VOR-NAV on cockpit floor. (Kevlar shell, optional equipment, retrofit is not possible.)
• Transponder antenna in the front part of the tail cone or on nose-cone.
Only equipment listed in section »9« of this Maintenance Manual and approved for installation
in the S12 may be installed without additional certification. Only this equipment has been proven
by the manufacturer in accordance with the relevant certification requirements regarding initial
airworthiness and proper function. For modifications, the installation instruction and the original
wiring harness of the aircraft manufacturer must be used.
This is also relevant for equipment approved for operation in motorglider or equipment without
certification requirements due to possible influence on power consumption, electromagnetic
influence and structural characteristics of the instrument panel. Outside Germany it must be
confirmed that the equipment is certified by the local authority in charge.
The weight limits for the equipment installed in the instrument panel and the influence on CG
must be respected. The Equipment List and the Weight and Balance Report must be updated.
When equipment is modified, conformity with the type must be checked and confirmed by an
inspector. If equipment is installed which is not certified for use in the relevant aircraft it must
be proven by the authority, when applicable requirements are fulfilled (modification of a single
aircraft).
CHAPTER-PAGE 3-57
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
AMENDMENT: 00
DATE: --
MAINTENANCE MANUAL STEMME S12
THIS PAGE IS INTENTIONALLY LEFT BLANK
CHAPTER-PAGE 3-58
AMENDMENT: 00
DATE: --
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
MAINTENANCE MANUAL STEMME S12
3.9
OXYGEN SYSTEM
One or maximum two oxygen system mountings (optional equipment) for one oxygen bottle each
are installed in the upper baggage compartment.
The mountings are suitable for oxygen bottles from various manufacturers, provided the diameter
is within a minimum of 0.132 m / 5.20 in, and the total length including regulator is approx.
0.45 m / 17.72 in up to a maximum of 0.52 m / 20.47 in.
The certification of the motorglider does not include a defined oxygen system and fulfillment of
the requirements must be demonstrated to the authority by the supplier or the facility, which
modified the aircraft (normally as a modification of a single aircraft).
CHAPTER-PAGE 3-59
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
AMENDMENT: 00
DATE: --
MAINTENANCE MANUAL STEMME S12
THIS PAGE IS INTENTIONALLY LEFT BLANK
CHAPTER-PAGE 3-60
AMENDMENT: 00
DATE: --
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
MAINTENANCE MANUAL STEMME S12
3.10 WING FOLDING DEVICE
The Stemme S12 optionally can be equipped with a wing folding device.
A description of the functioning and the handling is to be found in the associated supplement to
the S12 Aircraft Flight Manual.
The wing folding device is maintenance-free.
CHAPTER-PAGE 3-61
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
AMENDMENT: 00
DATE: --
MAINTENANCE MANUAL STEMME S12
THIS PAGE IS INTENTIONALLY LEFT BLANK
CHAPTER-PAGE 3-62
AMENDMENT: 00
DATE: --
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
MAINTENANCE MANUAL STEMME S12
4.1
GENERAL
This chapter defines the mandatory overhaul (TBO – Time Between Overhaul), replacement
(TBR – Time Between Replacement), and inspection intervals for components of the STEMME S12.
The chapter also defines the structural inspection requirements for the STEMME S12 composite
airframe. It contains information about the lifetime of all STEMME designed parts or components
that must be overhauled, rebuilt, inspected, or replaced at either specific flight time limits or
specified calendar time limits or that require monitoring through scheduled maintenance.
Compliance with the specified times and intervals is mandatory for maintaining continuing
airworthiness of the aircraft.
For airworthiness limitations of other parts installed in the aircraft not designed by STEMME or
with separate TC refer to chapter »5« and respective manufacturer documentation as amended
from time to time.
4.2
MAINTENANCE LIMITATIONS
Be sure to verify compliance with chapter »4 Airworthiness Limitations« when performing
scheduled maintenance per chapter »5«.
The following requirements must be adhered to consistent with applicable national regulations.
4.2.1
PAINT FINISH
To ensure that the temperature of the composite structure is kept below 54°C /130 °F, the airframe
must be painted white as approved. Only the nose cone may be a darker color. On the rest of the
airframe, you may only paint registration letters and numbers and placards in a color other than
white.
When re-painting is needed on a cowling, you must paint the engine side (interior side) of the
lower and side cowlings with aviation grade fire-resistant paint approved by STEMME.
Refer to P520-901.502 “Small Repairs of Composite Materials” (latest approved issue), Annex A
of this manual, for guidance on the paint approved for use by STEMME.
CAUTION
Aircraft control surface balance is critical to flight safety. Repair and removal or addition of any
paint or body filler to a control surface requires that the control surface is rebalanced according
Annex D of this manual.
APPROVED SECTION-PAGE 4-2
AMENDMENT: 00
DATE: --
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
MAINTENANCE MANUAL STEMME S12
4.3
COMPONENT REPLACEMENT AND OVERHAUL LIMITATIONS
This chapter defines replacement intervals and maintenance requirements for aircraft
components, systems, and structures determined to be life-limited or to be monitored by
scheduled maintenance.
Unless otherwise specified, the following components must be overhauled, rebuilt, or replaced
with components that have service life remaining, within the life-time limits specified. To
monitor remaining useful service life-time of components, maintenance work, e.g., overhauling,
rebuilding, repairing, or replacing each item, must be recorded in accordance with applicable
national regulations.
The IPC chapters mentioned below refer to the Illustrated Parts Catalog (IPC) for Type S10, Model
S12 Doc.-No- L530-912.830 or latest revision.
MAXIMUM ALLOWABLE OPERATING TIMES
No.
Part/Assembly/
Equipment
Manufacturer
1
Variable pitch
propeller
Propeller hub
STEMME AG
STEMME AG
STEMME AG
2
3
4
5
6
7
8
9
Propeller fork
and fasteners/
attachment
components
Propeller gear
box (gear
wheels)
Propeller gear
box mounting
Propeller Gear
Box mounting
elastomer parts
Centrifugal
clutch
(3 Flyweights)
Drive shaft
IPC
Chapter
Overhaul
Replacement
Notes
11AP-V
61-10
5 years
-
61-10
61-10
200 hr
2000 hr
400 hr
(1)
(2)
(1)
STEMME AG
10AP-V01
10AP-V88,
10AP-V76,
10AP-V77,
10AP-V78,
10AP-VU
11AG
72-10
1000 hr
-
(1)
STEMME AG
11AA
72-10
1000 hr
-
STEMME AG
11AA-S
11AA-36
72-10
-
12 years
(1)
(3)
(1)
(3)
STEMME AG
12AK
72-10
400 hr
-
(1)
STEMME AG
10AS-07
10AS-W
10AS-F
11AS-09
72-10
800 hr
-
(1)
72-10
-
12 years
(1)
Flexible disk of STEMME AG
the drive
shaft system
(Cardan Joints)
STEMME
p/n
APPROVED SECTION-PAGE 4-3
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
AMENDMENT: 00
DATE: --
MAINTENANCE MANUAL STEMME S12
NOTES
1. Overhauls of STEMME–manufactured components may only be performed in accordance
with manufacturer–approved data.
2. Under extreme environmental conditions (hot, dusty) greasing of the propeller blade
bearings as part of the overhaul can be required more frequently if indicated during
Annual Inspection.
3. Different Overhaul and Replacement intervals in the variable pitch propeller assy. are,
defined for specific individual mechanical components. Respective components are sorted
by their applicable TBO/TBR.
4. If the limitation is given in engine operating hours and in a calendar period, the first
occurring case applies for the affected components.
5. Even under ideal conditions, replacement or overhaul of parts or components may be
required before attaining the chapter »4 Life Limits«. Even life–limited parts are subject to
“on–condition” inspection before reaching TBO intervals.
APPROVED SECTION-PAGE 4-4
AMENDMENT: 00
DATE: --
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
MAINTENANCE MANUAL STEMME S12
4.4
STRUCTURAL LIMITATIONS
The airframe composite structure of the STEMME S12 (including various STEMME P/N’s) is currently
life limited to 6000 hours of flight time.
Extension of service life above 6000 hours can be achieved only by alteration from replacement (TBR) to TBO and introduction of an additional overhaul at 6000 hours and a subsequent
mandated overhaul interval (TBO) for continuing airworthiness. The TBO change will be notified
by a revision of this chapter.
The additional overhaul will include a comprehensive inspection of the airframe carried out in
accordance with approved data based on an agency approved TBO program.
APPROVED SECTION-PAGE 4-5
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
AMENDMENT: 00
DATE: --
MAINTENANCE MANUAL STEMME S12
THIS PAGE IS INTENTIONALLY LEFT BLANK
APPROVED SECTION-PAGE 4-6
AMENDMENT: 00
DATE: --
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
MAINTENANCE MANUAL STEMME S12
5.
TIME LIMITS / MAINTENANCE CHECKS
NOTICE
Violation of checks and recommended overhaul or replacement intervals as defined in chapter
»5« may impair proper function of the aircraft and/or aircraft systems.
This chapter defines intervals for overhauling, rebuilding, and replacing components; provides
guidance for scheduled and unscheduled maintenance; and specifies the minimum scope of
required periodic inspections required by the Federal Aviation Regulations. Chapter »5« consists
of the following sections:
• Section »5.1«: Overhaul and Replacement Schedule, lists manufacturer–recommended
times–in service for overhauling, rebuilding, and replacing components.
• Section »5.2»: Pre-Flight Inspections are defined in the S12 Aircraft Flight Manual.
• Section »5.3«: Periodic Inspections, discusses mandatory periodic inspections generally
with the caveat that less benign operating conditions reasonably entail more frequent
inspections than the required minimum intervals provide.
• Section »5.4«: Checklist for Periodic Inspections, lists the type and subject of mandatory
periodic inspections, organized by aircraft system or area and the recommended intervals
at which items must be inspected based on normal usage under average environmental
conditions.
• Section »5.5«: Special Inspections, covers unscheduled maintenance, such as after hard
landings, prop strikes or intense turbulence.
Maintenance, pre-flight Inspections and preventive maintenance must be carried out by qualified
and appropriately authorized personnel. In any case relevant national law must be respected.
Extreme environmental conditions, e.g. arid desert or humid lowlands, present added, albeit different maintenance and inspection challenges for the prudent owner and operator. In any event,
the owner and operator must consider the operating conditions in which the aircraft is operated
and stored when determining if the minimum specified inspections and intervals are adequate.
The owner and operator must share all relevant information with the responsible authorized
maintenance person (according to the requirements detailed in the Federal Aviation Regulations
or European Publications) who maintains or inspects the aircraft.
As with all certified aircraft, following each required annual or 100 hr Inspection, the aircraft must
be returned to service by the responsible authorized maintenance person (according to applicable
national regulations) before further flight.
CHAPTER-PAGE 5-1
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
AMENDMENT: 00
DATE: --
MAINTENANCE MANUAL STEMME S12
Owners and operators are responsible for complying with all applicable Federal Aviation Regulations or national regulations. STEMME strongly recommends you to choose your mechanic with
care and to demand diligence and documentation for all works.
5.1
OVERHAUL AND REPLACEMENT SCHEDULE
This section contains times recommended by the manufacturer for replacement or overhaul of
components not subject to the Maximum Allowable Operating Times of chapter »4«.
For life–limited parts with separate time certificate (TC) or technical standard order (TSO), refer to the
Airworthiness Limitations section of the manufacturer’s documentation (applicable
Maintenance Manual, Service Bulletin etc.) for permissible service–life limits prescribed by the respective
manufacturer.
The following components shall be overhauled or replaced at their respective specified TBO or
Replacement Interval (TBR) or sooner, if their condition so indicates, and reasonable care requires it.
STEMME strongly recommends adherence to the chapter »5« overhaul and replacement schedule,
including the overhaul and replacement times applicable to the components listed below.
Overhaul and replacement of these items is to be done on condition but as STEMME
recommendation not later than stated in the following table.
LOG BOOK ENTRIES
Inspections, maintenance, and preventive maintenance including correct observation of the
overhaul and replacement times and the date of removal, installation or overhaul of each
component shall be logged in strict compliance with applicable national requirements.
NOTICE
Aircraft storage or operation under less favorable or sub-normal conditions often requires more
frequent inspection, overhaul, or replacement of components than at the intervals recommended
below. More frequent inspection includes careful inspection before each flight. The owner and
operator are ultimately responsible for keeping the aircraft in airworthy condition based on the
defined requirements of the TC holder with the informed advice of an authorized maintenance
person.
CHAPTER-PAGE 5-2
AMENDMENT: 00
DATE: --
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
MAINTENANCE MANUAL STEMME S12
RECOMMENDED OPERATING TIMES BETWEEN OVERHAUL AND REPLACEMENT
No.
1
2
3
4
5
6
7
8
9
10
Part/Assembly/
Equipment
Manufacturer
Engine
STEMME AG,
ROTAX 914F2/S1
Rubber parts of ROTAX,Various
the engine
Rubber
Fuel hoses
Various,
STEMME AG
approved
Lubrication
Various,
hoses
STEMME AG approved
Coolant hoses
Various,
STEMME AG
approved
Neoprene hoses Various,
STEMME approved
Silicone hoses
Various,
STEMME approved
Elastomer parts Various,
Elastomer
of the landing
gear suspension
Seat belts
Various,
Four–Point
Control Rod
L’Hotellier,
Connectors
--
STEMME
p/n
--
IPC
Overhaul
Chapter
71-01
15 years
--
71-01
--
Replace- Notes
ment
-(1)(3)
(4)
5 years
(2)
--
28-10
--
5 years
(5)
--
79-20
--
5 years
(5)
--
75-20
--
5 years
(5)
--
75-20
--
5 years
(5)
--
75-20
--
5 years
(5)
--
32-00
--
10 years
(5)
--
24-10
See Note (7)
--
27-00
--
(6)(8)
3000h /
10 years
(7)(8)
CHAPTER-PAGE 5-3
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
AMENDMENT: 00
DATE: --
MAINTENANCE MANUAL STEMME S12
NOTES
1. The TBO for the STEMME engine type ROTAX 914 F2/S1 is established on the basis of the
engine type ROTAX 914 F2-01 in following ROTAX Service Bulletins »Extension of the Time
Between Overhauls« (TBO): SB 914-039, Initial Issue, dated March 25, 2010 or later approved.
The TBO stated in these Service Bulletins is according to respective engine S/N and is directly
applicable to the STEMME engine type ROTAX 914 F2/S1.
To further clarify, in accordance with the applicable Service Bulletin the stated TBO means:
TBO of 15 years
In all cases the limitation is given in operating hours and in a calendar period, the first
occurring case applies. Please note that only the above referenced Service Bulletins shall
apply to recommended TBO.
2. The recommended TBO for all rubber parts of STEMME’s engine ROTAX 914 F2/S1 is established on the basis of the engine type ROTAX 914 F2-01 as detailed in the ROTAX Maintenance Manual, Line Maintenance: ROTAX MML-914, Edition 2, Revision 2, dated February 1,
2015 or later version.
The recommended TBO for all rubber parts as stated in the latest revision of ROTAX MML914, Edition 2, applies to STEMME’s ROTAX 914 F2/S1 engine.
3. STEMME does NOT approve operating beyond the stated engine TBO (defined by ROTAX
and applied by STEMME) for its engine ROTAX 914 F2/S1. Any decision to operate beyond
the recommended TBO for the engine ROTAX 914 F2/S1 based on the informed recommendation of competent, ROTAX–qualified, authorized maintenance personnel is without the
recommendation of STEMME and as such STEMME does not assume the resultant risk.
4. STEMME builds the ROTAX 914 F2/S1 engine by modifying the certified ROTAX 914 F2-01 which
is its major component. STEMME certified the ROTAX 914 F2/S1 engine and its variable pitch
propeller as part of the S12 under EASA type certificate EASA.A.054. Only STEMME–approved
data is applicable for overhaul and inspection of STEMME’s ROTAX 914 F2/S1 engine.
5. STEMME strongly recommends that you not exceed the recommended TBOs as specified in
the table. In any case, components must be replaced “on condition” if inspection indicates
a need to do so or as required by mode of operation.
6. Seat belts must be inspected and, if needed, be repaired or replaced pursuant according
to applicable national regulations or product limitations.
7. The L’Hotellier connections wear by use, which may critically impair airworthiness. STEMME recommends to owners and operators to inspect these connectors per L’Hotellier Instructions for the Maintenance L’Hotellier Ball and Swivel Joints, Ref. IMA10.01, in the latest approved revision. This technical data can be
provided by L’Hotellier S.A., 93 Avenue Charles De Gaulle, 92270 Bois Colombes, France.
See Annex A, for L’Hotellier’s specified inspection procedure and tolerances.
CHAPTER-PAGE 5-4
AMENDMENT: 00
DATE: --
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
MAINTENANCE MANUAL STEMME S12
8. Refer to instructions prescribed by the component manufacturers—airworthiness limitations section of the manufacturer documentation, applicable maintenance manual, Service Bulletins, etc.—for those manufacturer’s permissible service life limits and overhaul
recommendations of components.
NOTICE
If the limitation is given in operating hours and in a calendar period, whichever limitation is
reached first is applicable. Even parts with recommended TBO/TBR are subject to “on-condition”
inspection before reaching the recommended interval.
CHAPTER-PAGE 5-5
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
AMENDMENT: 00
DATE: --
MAINTENANCE MANUAL STEMME S12
THIS PAGE IS INTENTIONALLY LEFT BLANK
CHAPTER-PAGE 5-6
AMENDMENT: 00
DATE: --
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
MAINTENANCE MANUAL STEMME S12
5.2
PRE-FLIGHT INSPECTIONS
Procedures for rigging, fueling, daily inspection and pre-flight inspection are defined in the S12
Aircraft Flight Manual.
5.2.1
RUBBER HOSE AND CLAMP INTEGRITY
To ensure that liquids remain safely contained during engine operation and during engine-off
flight, the outward appearance and surface condition of all rubber hoses must be visually and
manually inspected.
The scheduled maintenance, defined in chapter »5» is suitable to detect leaks, cracks, swelling,
inflexibility, loose ends and signs of excessive wear or aging.
Depending upon environmental and operating conditions, elastomeric parts like rubber hoses can
age more rapidly than expected.
Fuel system pressure tests are required with in Daily Inspection as defined in Chapter »4.« of the
S12 Aircraft Flight Manual. Pressure test the fuel system before first engine start each day and after
maintenance. Transfer pumps respond to draining of the feeder tank, refer to section »7.4.6.2«
In addition, the clamped connections of each rubber hose must be visually and manually inspected before first engine operation after maintenance to confirm that no hose can be pulled loose
from its respective fittings.
5.3
PERIODIC INSPECTIONS
The intervals for general maintenance and inspections depend upon operating conditions,
climate, storage conditions, and environmental factors. More frequent inspection and maintenance would be prudent under sub-normal conditions; however, the types and intervals of the
minimum required inspections and scheduled maintenance for the S12 are those mandated by
applicable national requirements and are defined below in section »5«.
Depending on applicable national regulations certified aircraft may also be required to be
inspected and maintained more frequently than specified in this chapter depending on the mode
of operation.
CHAPTER-PAGE 5-7
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
AMENDMENT: 00
DATE: --
MAINTENANCE MANUAL STEMME S12
5.3.1
INSPECTION INTERVALS
The reasonable intervals for general maintenance depend on operating conditions, climate, hangarage, etc. The types and intervals of the minimum scheduled maintenance established for the
S12 are indicated in the table below.
ANNUAL INSPECTIONS
The motorglider must undergo a complete inspection each 12 calendar months. The inspection has
to be carried out according to applicable national requirements by an authorized maintenance
person. A signed and dated record must be maintained as each inspection task is completed.
When all inspections have been completed, the Inspection Report shall be signed off in the Log
Book or Maintenance Record according to applicable national requirements in order to release
the aircraft into service.
This Chapter of the Maintenance Manual summarizes the inspection items that must cover in
each Annual Inspection. Annual Inspection items listed below in section »5.4« cover in scope to
the inspection items required in the 100 hours inspection.
100 HOURS INSPECTIONS (AIRFRAME)
In addition to the annual inspection specific inspection tasks are required also every 100 hours of
flight operating time.
The aircraft’s mandatory Annual Inspection also covers the scope of the 100 hours inspection
detailed in table »5.4«. The 100 hours interval between inspections must not be exceeded by
more than 10 hours. This tolerance is reserved to reach a location where the inspection can be
satisfactorily accomplished.
The time by which the inspection interval was exceeded must be included as flight hours in the
next 100 hr interval. For example, if a 100 hr inspection was due at 650 hours of flight and was
actually signed off at 658 flight hours, the next 100 hours inspection is due at 750 flight hours,
not at 758 hours of flight. Inspection tolerances may not be accumulated.
100, 200, 600 ENGINE OPERATING HOURS INSPECTIONS
Additional periodic inspections must be performed every 100, 200 and 600 engine operating
hours. They have to be carried out in accordance with the following Periodic Inspections Check
List, chapter »5.4«.
CHAPTER-PAGE 5-8
AMENDMENT: 00
DATE: --
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
MAINTENANCE MANUAL STEMME S12
This means that:
• A 100 engine hours inspection shall be done every 100 hours of engine operation;
• A 100 engine hours inspection shall be done every 200 hours of engine operation; plus
additional 200 engine hours checks:
-- Check spark plug connectors for tight fit;
-- Renew heat insulation of exhaust headers;
-- Flush coolant system and replace coolant;
-- Change air filter;
-- Change fine filters in fuel system.
• A 100 engine hours and a 200 engine hours inspection shall be done every 600 hours of
engine operating time, plus additional 600 engine hours check:
-- Check the reduction gear wheels of the engine.
Refer to the Periodic Inspections Check List, chapter »5.4« to see all relevant inspection tasks for
each inspection.
BREAK-IN INSPECTION OF ENGINE AND AIRFRAME
In order to demonstrate continuing airworthiness, a new, overhauled or rebuilt airframe and engine must be inspected initially once (Break-In Inspection) after
• the first 25 engine operating hours or
• first 100 hours of flight operating time,
whichever applies first.
Depending on applicable national regulations inspections every 100 flight hours may be mandated
depending on the mode of operation as if an Annual Inspection were being done.
CHAPTER-PAGE 5-9
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
AMENDMENT: 00
DATE: --
MAINTENANCE MANUAL STEMME S12
5.3.2
GENERAL REMARKS ON PERIODIC INSPECTIONS
If operations or conditions indicate that a scheduled maintenance action must be performed
before its current calendar or hour limit, a complete 100 hours inspection must be carried out.
Alternatively, the maintenance task that was done “early” must be repeated with the next scheduled 100 hours inspection.
A scheduled maintenance task can be performed before reaching the hour limit if operational
conditions reasonably require that. In this case all higher–level inspections also have to be advanced by the same time to avoid extended intervals.
Even though the operator can decide at each 100 flight hour airframe inspection, whether or not
the engine hour related inspections (100, 200, or 600 engine hours inspections) shall be performed
simultaneously, the manufacturer recommends simultaneous inspection provided the flight/engine hour ratio is less than 2:1.
The items to be checked are listed in section »5.4 Check List for Periodic Inspections«. A detailed
description of maintenance procedures, adjustment data, tolerances, torque values etc. can be
found in section »6« (for details of the aircraft generally) and in section »7 «(for specific assemblies of the aircraft). The relevant subsection is indicated for each inspection item shown on the
check list.
In addition, special inspections may be prescribed by the responsible authority or may be recommended by the manufacturer; those inspections must be performed as required in accordance
with the issued directives and the Federal Aviation Regulations that apply to N-registered STEMME
aircraft.
For instructions pertaining to maintenance of other equipment installed in the aircraft, refer to
Annex A »Supplementary Instructions for Maintenance and Care, Maintenance Instructions«.
NOTICE
The inspection lists in section »5.1 Overhaul and Replacement Schedule«, and in section
»5.4 Check List for Periodic Inspections«, cover the complete aircraft, including its propeller, its
drive-train, and its engine.
The periodic checks listed in section »5.1« and »5.4« substitute for section 05-20 (»Maintenance
Schedule«) of the »Maintenance Manual (Line Maintenance) for ROTAX Engine Type 914 F Series
found in Annex E.
Section 05-20 of the original ROTAX Maintenance Manual need not be observed during
maintenance of this aircraft.
CHAPTER-PAGE 5-10
AMENDMENT: 00
DATE: --
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
MAINTENANCE MANUAL STEMME S12
5.3.3
UNSCHEDULED MAINTENANCE
AIRWORTHINESS DIRECTIVES AND SERVICE BULLETINS
In addition to scheduled maintenance described above, the need for special inspections and additional maintenance may arise. Normally, these situations will be publicized with a manufacturer’s
Service Bulletin (SB) or an Airworthiness Directive (AD) published by the responsible authority
(e.g. EASA / FAA). Such notices typically include a deadline to complete the required actions.
Compliance with Airworthiness Directives is mandatory.
STEMME strongly recommends that owners and operators, as a matter of prudence and flight
safety, fully and promptly comply with all relevant Service Bulletins (except Service Bulletins
classified as “optional”).
ABNORMAL OPERATIONS
Abnormal airplane operations require special maintenance checks. Unscheduled checks following
overweight or hard landings, over-speed flight, severe air turbulence, lightning strike, foreign-object damage, and high drag or side loads due to ground handling should be performed by an
authorized maintenance person.
The inspector must conduct the relevant section »5.4«. Annual Inspection of the potentially
damaged components and systems, e.g. landing gear, control surfaces, tail boom, empennage,
etc. as appropriate and needed to assure airworthy condition of the aircraft.
In any case of doubt concerning the condition and possible unrevealed damage, the owner or
operator is advised to contact the manufacturer or another appropriately approved maintenance
organization specialized on diagnosing and repairing the affected type of components or systems.
Unscheduled Maintenance for Propeller Assembly, Engine Drive Section, and Front Gear Box Components
An unscheduled inspection, overhaul, repair, or replacement is mandatory following each case of:
• Sudden Stop or any Impact (possible ground contact) of the Propeller that reduces engine
RPM, or
• Failure to perform the periodic inspections specified in the S12 Maintenance Manual, or
• Foreign Object Damage (FOD)
If the inspection of the propeller indicates detectable damage beyond mere cosmetic distress to
the propeller, whether by ground contact, bird strike, stone strike or other impact, a qualified and
authorized maintenance person shall determine the extent of the damage.
For any damage which requires a Major Repair, the TC-holder or an approved agency must determine which parts of the complete drive system are affected and require repair (if practicable),
overhaul, rebuilding, or replacement. See detailed guidance for evaluating impact damage to the
Propeller in section »5.5.2« below.
CHAPTER-PAGE 5-11
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
AMENDMENT: 00
DATE: --
MAINTENANCE MANUAL STEMME S12
5.3.4
SPECIAL CONDITIONS AND CAUTIONARY NOTICE
Airplanes operated with high take-off/landing frequency or engaged in flight school use will likely
need more frequent inspections.
In addition, more frequent inspections and maintenance will be indicated for:
• Airplanes that are either stored or operated under other conditions than normal,
• Airplanes stored or operated in hot or humid tropical conditions,
• Airplanes stored or operated in cold or damp climates, and
• Airplanes stored or operated in extreme temperature or in arid conditions, etc.
The more frequent inspections should cover, at a minimum, wear, leaks, corrosion, delamination,
rubber deterioration, inflexibility, loose connections, and lack of lubricant, hydraulic fluid or coolant. Under the special conditions described above, the owner and operator and his authorized
maintenance person should perform periodic inspections at a more frequent rate, i.e. at shorter
intervals, until they can set their own more frequent inspection periods based upon experience.
5.3.5
GENERAL REMARKS ON MAINTENANCE
The recommended periods for maintenance and for inspection do not constitute a guarantee or
warranty that the item will reach the recommended TBO without malfunction, as the range of
in-service factors cannot be controlled by the manufacturer.
It is always and ultimately the responsibility of the owner, the operator and the authorized maintenance organization to make well informed decisions when and whether to shorten the components recommended TBO or TBR.
“On Condition” items are to be repaired, overhauled, rebuilt, or replaced using only manufacturer–specified parts or manufacturer–approved material and parts as appropriate, when inspection
or observed performance of these items reasonably reveals a potentially unserviceable or unsafe
condition.
The date on the applicable initial Certificate of Airworthiness issued with final production
inspection is to be used as the starting date for all inspected components listed in chapters »4«
and »5« of this aircraft’s Maintenance Manual. (Statement of Conformity, EASA Form 52).
CHAPTER-PAGE 5-12
AMENDMENT: 00
DATE: --
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
MAINTENANCE MANUAL STEMME S12
SCHEDULED MAINTENANCE CHECKS AND GOOD PRACTICE
The owner and operator are primarily responsible for maintaining the airplane in an airworthy
condition. This includes compliance with all applicable Airworthiness Directives. It is the responsibility of the owner and the operator to ensure that the airplane is inspected and maintained as
specified in sections 43 and 91 of Federal Aviation Regulations.
The inspection requirements set out in chapter »5« should be regarded as minimum requirements
that are not intended to be all-inclusive. More rigorous inspection will be appropriate when operating under harsh conditions. No maintenance checklist and table of requirements can replace
the good judgment of a certified airframe and power plant mechanic. STEMME urges owners and
operators, as these are primarily responsible for the airworthiness of the airplane, to select only
qualified and authorized maintenance persons who have or can obtain adequate qualification
and experience for STEMME and ROTAX products.
While the requirements stated in this chapter may be used as an outline, detailed information of
the many systems and components in the airplane will be found in the various chapters of the
maintenance manual and pertinent vendor publications.
The owner and operator are responsible to ensure that the airframe and power plant mechanic
who inspects the airplane has access to the previously noted documents, as well as to this Maintenance Manual and other relevant technical data provided by STEMME.
In performing maintenance and inspection of the aircraft, the authorized maintenance organization shall refer to the applicable Maintenance Handbooks, Service Instructions, Service Bulletins, applicable Regulations and Publications, Vendor’s Bulletins and Vendor Specifications for
clearances, torque values, settings, tolerances, best practices and other relevant requirements.
During the inspection, verify that all interior and exterior placards are legible and in place.
NOTICE
In addition to the inspections prescribed in chapter »5«, the altimeter and static system — and
for operation in airspace requiring transponder use, the altitude encoding transponder(s) — must
be tested and inspected in separate intervals in compliance with the requirements.
CHAPTER-PAGE 5-13
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
AMENDMENT: 00
DATE: --
MAINTENANCE MANUAL STEMME S12
5.3.6
INSPECTION GROUPS AND MAINTENANCE CRITERIA
VISUAL INSPECTION
When called for in conjunction with an inspection task, or at any time that an area is visible
during an inspection or maintenance action, the following visual inspection criteria shall be
accomplished without requiring disassembly or removal of adjacent equipment unless otherwise
specified or indicated.
The criteria will normally apply to those areas, surfaces, or items made visible by the removal or
opening of access panels, fairings, or cowlings. The visual inspection shall include an examination
by area, component, detail, assembly, or installation, as well as any associated equipment within
the immediate vicinity, using any inspection aids considered necessary.
When performing either an Annual or a 100 hr Inspection, each installed miscellaneous item not
specifically covered in Section »5.1« or in section »5.4 Checklist for Periodic Maintenance«, shall
also be inspected for proper installation and proper operation:
NOTICE
In addition to the inspections, you should carefully inspect the following categories of parts. All
Chapter 5 references to performance of maintenance inspections are to be understood as references to the following criteria for visual inspection of such parts.
Visual inspection criteria will normally consist of but are not limited to the following criteria:
• Moving Parts:
Proper operation,
correct alignment,
securely installed,
sealing,
cleanliness,
lubrication,
adjustment,
tension,
travel,
condition,
binding,
excessive wear,
cracking,
corrosion,
deformation, and
any other apparent damage.
• Composite Parts:
Securely installed,
condition,
cleanliness,
separation of bond,
indications of delamination,
CHAPTER-PAGE 5-14
AMENDMENT: 00
DATE: --
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
MAINTENANCE MANUAL STEMME S12
wear,
cracking,
obstruction of drainage or vent holes,
deformation,
signs of overheating, fluid saturation and
any other apparent damage.
• Metal Parts:
Securely installed,
condition of finish,
cleanliness,
distortion,
fatigue cracks,
welding cracks,
corrosion, and
any other apparent damage.
• Fuel, Air, Oil, Coolant and Hydraulic Fluid Lines and Hoses:
Leaks,
cracks,
dents,
kinks,
loss of flexibility,
sign of deterioration,
obstruction,
chafing,
improper bend radius,
cleanliness,
securely installed, and
any other apparent damage
• Electrical Wiring:
Cleanliness,
loose, corroded or broken terminals,
chafed, broken or worn insulation,
wires and wire bundles securely installed,
signs of heat deterioration, and
any other apparent damage.
• Bolts and Nuts:
Fretting,
wear,
damage,
stretch,
cross–threading,
proper torque,
corrosion, and
locking or safety wiring.
CHAPTER-PAGE 5-15
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
AMENDMENT: 00
DATE: --
MAINTENANCE MANUAL STEMME S12
• Filters and Screens:
Filters and screens shall be removed, cleaned, and inspected for contamination and
shall be replaced as appropriate or required.
Fuel filters encased in metal should be replaced at the recommended intervals.
• Wet Fuel Areas:
Cleanliness,
leaks,
bacterial growth,
corrosion,
delamination,
separation of bond,
deterioration of fuel tank lining,
and structural fatigue
• Fire Sleeves:
dents,
kinks, tears,
loss of flexibility,
deterioration,
obstruction,
chafing,
improper bend radius,
cleanliness,
securely installed,
open ends, and
any other apparent damage.
OPERATIONAL INSPECTION
When called for in conjunction with an inspection task, an “Operational Inspection” is a check to
determine that a component or system is fulfilling its intended purpose. The operational inspection
does not require quantitative tolerances.
FUNCTIONAL INSPECTION
When called for in conjunction with an inspection task, a “Functional Inspection” is a quantitative
check to determine if one or more functions of a component performs within specified limits.
The functional inspection is a comparative examination of a component or a system against a
specified standard.
CHAPTER-PAGE 5-16
AMENDMENT: 00
DATE: --
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
MAINTENANCE MANUAL STEMME S12
5.3.7
OTHER PARTICULARS OF MAINTENANCE
• Clean all screws and nuts before reinstalling the fasteners if not to be replaced. Inspect
seats and thread of fasteners and screw connections upon removal for good condition or
damage before re-use. Replace damaged, cross-threaded or corroded hardware.
• Self-locking nuts, once loosened or removed, must be replaced.
• Comply with torque values listed in relevant sections of this AMM, e.g. for the airframe,
section 6.8. For the STEMME-ROTAX 914 F2/S1 engine refer to torque values in the Maintenance Manual (Line Maintenance) for ROTAX Engine Type 914 Series (Annex E to this AMM)
and Maintenance Manual (Heavy Maintenance) for ROTAX Engine Types 912 and 914 Series.
• Clean or replace all filters, gaskets, lock washers, O-rings, and shaft seals before reassembly
or re-installation and as required by Maintenance Check List.
• Electrical wire condition is critical to flight safety. Check the condition of electrical wires
by inspecting for chafing, decay of the insulation, wearing or corrosion of terminals and
conductor connections to terminals. In case of a deficiency, replace or repair the deficient
wire and terminal. Any discrepancies must be found and corrected before further flight.
Also refer, e.g. to FAA AC 43.13-1B, Chapter 11, §6.
• Condition of flexible hoses is critical to flight safety. Always check the condition of flexible
hoses by examining for chafing, leakage, cracking, signs of decay from thermal or chemical effects, hardening and damage or defects at hose connections. Always look for cracks
at the clamps and confirm that all hose connections are securely installed. If defects or
deterioration are found, replace the hose, hoses of like kind and age, and the clamps. Then
identify and correct the cause of the defect before further flight. Also refer, e.g., to FAA AC
43.13-1B, Chapter 8, §2, Chapter 9, §2 and associated table.
WARNING
Prior to any maintenance work switch OFF Master Switch and Ignition!
STEMME recommends that you always disconnect the batteries and ground the aircraft to prevent
short circuits or arcing during maintenance work.
CHAPTER-PAGE 5-17
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
AMENDMENT: 00
DATE: --
MAINTENANCE MANUAL STEMME S12
THIS PAGE IS INTENTIONALLY LEFT BLANK
CHAPTER-PAGE 5-18
AMENDMENT: 00
DATE: --
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
MAINTENANCE MANUAL STEMME S12
5.4
CHECK LIST FOR PERIODIC INSPECTIONS
WARNING
Switch OFF Master-Switch and Ignition for any maintenance work!
NOTICE
Read maintenance instructions in sections »6« and »7« before carrying out adjustments!
Additionally to maintenance instructions, these sections indicate special maintenance intervals
(2 years) allowable for some items of the Annual inspection program in the following check list.
For explanation of type of inspection refer to section »5.3.1 and 5.3.4«.
1. Thoroughly clean aircraft and
engine, remove or open all
necessary inspection plates,
access doors, fairings and
cowlings.
2. Inspect aircraft surfaces and
markings (especially registration and national flag), renew
if necessary.
3. Check all drain and ventilation
holes (see position plan section 6.7).
4. Check all points of lubrication
and grease if required (ref. to
section 6.5)
5. Check function of flight controls.
6. Check slackness / free play of
aileron (outer wing and wing
extension), flap and elevator
controls.
7. Check friction and forces in
control system.
X
-
X
X
X
6.6, 7.1
Annual
X
Engine 600 hr
X
Engine 200 hr
Engine 100 hr
Type and Subject of Inspection
Aircraft 100 hr
GENERAL
Break-in
5.4.1
Refer to
Section
X
X
X
6.7
X
X
X
6.5
X
X
X
7.3
X
X
6.4.3
X
6.4.1
Sign-off
CHAPTER-PAGE 5-19
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
AMENDMENT: 00
DATE: --
MAINTENANCE MANUAL STEMME S12
1. Check fuel system components
at spar bridge of wing center
section.
2. Check vent line outlets at end
ribs of wing center section.
3. Check function of quick-release coupling (fuel supply
line).
4. Clean coarse filters.
5. Check quick drains and filters
in wing center section through
maintenance opening in lower
surface Clean fine filters,
check condition and change if
necessary.
6. Change fine filter.
7. Check condition, attachment
and function of electrical fuel
pumps through maintenance
opening in lower surface.
8. Check fuel filler cap for leakage and for signs of leakage of
wing tanks.
9. Check condition and backlash
of wing fittings, check securing device of wing attachment
bolts.
10. Check condition of wing flaps
and ailerons, check clearance
between components spanwise 3 ± 0.5 mm / 0.12 ± 0.02 in.
Check gap seals and fairings
on flap/aileron links.
11. Check all control rods and supports in wing center section
and wing attachment area,
check secure fastening of
spring bolt of each quick-connector.
7.4.6
X
X
X
7.4.6
X
X
X
7.4.6
X
7.4.6
X
X
Annual
X
Engine 600 hr
X
Engine 200 hr
X
Engine 100 hr
Type and Subject of Inspection
Aircraft 100 hr
WINGS AND FUEL SYSTEM COMPONENTS IN THE WING CENTER SECTION
Break-in
5.4.2
Refer to
Section
X
7.4.6.2
X
X
X
X
7.4.6.2
X
X
7.4.6
X
X
X
X
X
7.1.1
X
X
7.1.1
X
X
7.3.1
X
Sign-off
CHAPTER-PAGE 5-20
AMENDMENT: 00
DATE: --
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
12. Inspect L’Hotellier-connectors
of aileron control rod according to manufacturer instructions (Annex A). Check unloose-able fastening of safety
pin.
13. Check bell-crank levers and
adjacent components of wing
flaps and aileron system in
wing.
14. Check swaged terminals of all
control rods in wing.
15. Check condition of air brakes.
Annual
Engine 600 hr
Engine 200 hr
X
Engine 100 hr
X
Refer to
Section
X
7.3.2
X
7.3.2
X
X
7.3
X
X
7.3.2
Sign-off
1. Check safe locking of
nose-cone.
2. Check condition and backlash
(3 mm / 0.12 in at nose-cone
tip) of nose-cone.
Annual
Engine 600 hr
Engine 200 hr
Engine 100 hr
Type and Subject of Inspection
Aircraft 100 hr
FORWARD FUSELAGE
Break-in
5.4.3
Aircraft 100 hr
Type and Subject of Inspection
Break-in
MAINTENANCE MANUAL STEMME S12
Refer to
Section
X
X
7.1.2.3
X
x
7.1.2.3
Sign-off
CHAPTER-PAGE 5-21
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
AMENDMENT: 00
DATE: --
MAINTENANCE MANUAL STEMME S12
1. Inspect canopy for damage
and proper function of locking
mechanism, grease canopy
locks. Check tension of the
metal wire rope in locking
mechanism. Check and adjust the wire rope to ensure
uniform locking/unlocking at
each side.
2. Canopy emergency jettison:
Check function and gas spring
force (minimum 150 ± 30 N / 34
± 7 lbf compressed).
3. Check function of lateral gas
springs of canopy (canopy
must remain in open position).
4. Check seat belts and attachment points.
5. Check throttle and choke lever
assy. in cockpit. Check stops
of throttle lever. Check choke
lever adjustment. Check throttle valve positions by means
of the ROTAX communication
program.
6. Check controls in front fuselage for foreign objects, proper
condition and installation.
7. Check swagged terminals of
all control rods in fuselage.
8. Check condition and attachment of instruments, switches,
circuit breakers, fuses and wiring. Check fire warning light.
9. Check cockpit ventilation flexible hoses.
10. Check rudder pedals and cables, check pedal adjustment.
11. Check condition, attachment
and adjustment mechanism of
seats.
X
Annual
Engine 600 hr
X
Engine 200 hr
X
Engine 100 hr
Type and Subject of Inspection
Aircraft 100 hr
COCKPIT
Break-in
5.4.4
Refer to
Section
X
7.2.1
X
7.2.1
X
7.2.1
X
7.2.2
X
X
X
7.4.7
X
X
X
7.3.1
X
7.3
X
7.2.2
X
7.2.2
X
X
7.3.1
X
X
7.2.2
X
X
X
X
X
X
Sign-off
CHAPTER-PAGE 5-22
AMENDMENT: 00
DATE: --
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
12. Check nose-cone operation
(do not grease!).
13. Check condition, function and
smooth operation of propeller
positioning.
14. Check condition and smooth
operation of propeller brake
assy. Check propeller brake
band lining
(minimum 1.5 mm / 0.06 in).
X
X
X
7.4.13
X
X
X
7.4.13
Annual
7.4.13
Engine 600 hr
X
Engine 200 hr
X
Engine 100 hr
X
Refer to
Section
Sign-off
1. Check condition of center fuselage steel frame.
2. Check condition of framework
/ tail boom connection.
3. Check condition of upper and
lower connection framework /
front fuselage.
4. Check condition of control
assy. in center fuselage.
5. Check swagged terminals of
all control rods in center fuselage.
6. Check flap relief gas spring
assy. for proper condition and
tight fit.
X
X
Annual
Engine 600 hr
Engine 200 hr
Engine 100 hr
Type and Subject of Inspection
Aircraft 100 hr
CENTER FUSELAGE (EXCEPT FOR FAIRINGS)
Break-in
5.4.5
Aircraft 100 hr
Type and Subject of Inspection
Break-in
MAINTENANCE MANUAL STEMME S12
Refer to
Section
X
X
7.1.2.4
X
X
7.1.2.4
X
X
7.1.2.4
X
X
7.3.1
X
X
7.3
X
7.3.1
Sign-off
CHAPTER-PAGE 5-23
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
AMENDMENT: 00
DATE: --
MAINTENANCE MANUAL STEMME S12
1. Check elevator control lever in
lower vertical fin.
2. Check swaged terminals of all
control rods in tail boom.
3. Check rudder control cables in
forward tail boom.
4. Check trim system (actuator /
springs).
Annual
Engine 600 hr
Engine 200 hr
Refer to
Section
X
X
7.3.3
X
X
7.3
X
X
7.3.3
Sign-off
X
X
X
Annual
Engine 600 hr
X
Engine 200 hr
1. Check rudder fittings.
2. Check connection of COM
antenna cable (bottom of
rudder).
3. Check adjustment and condition of rudder control.
4. Check free movement of rudder, especially in case of tail
wheel blockage.
5. Check front fitting of horizontal stabilizer for spring tension, backlash of bolt, fatigue
cracks and corrosion.
6. Check rear fitting of horizontal stabilizer for wear of pins,
fatigue cracks, axial and radial
backlash and corrosion.
7. Check tight fit of screw connections of both horizontal
stabilizer fittings.
8. Check connection of elevator
control rod to rear fitting of
elevator.
Engine 100 hr
Type and Subject of Inspection
Aircraft 100 hr
EMPENNAGE
Break-in
5.4.7
X
Engine 100 hr
Type and Subject of Inspection
Aircraft 100 hr
TAIL BOOM
Break-in
5.4.6
Refer to
Section
X
X
7.1.3
X
X
7.1.3
X
X
7.3.3
X
7.3.1
X
X
X
X
7.3.1
X
X
X
7.3.1
X
X
X
7.3.1
X
X
X
7.3.1
Sign-off
CHAPTER-PAGE 5-24
AMENDMENT: 00
DATE: --
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
9. Check backlash in fittings
of horizontal stabilizer when
installed.
10. Check holes of water tank in
the right shell of vertical tail.
Verify correct markings of
quantity.
11. Check gap sealings and zigzag
tape on empennage.
X
Annual
Engine 600 hr
Engine 200 hr
Engine 100 hr
Refer to
Section
X
X
7.3.1
X
X
7.3.1
X
X
7.3.1
Sign-off
1. Check quick-release coupling
in fuel supply line.
2. Check condition of supply,
return and drain lines outside
the engine compartment, supply and return lines inside the
engine compartment.
3. Check condition, attachment
and function of electrical fuel
pumps.
4. Replace the main fuel pump –
every 1000 hours.
5. Check fuel valve, fuel check
valves and quick drains. Check
fire-wall penetration assy. of
supply and return lines for
tight connection and leakage.
6. Check drain lines of carburetor
drip trays and airbox.
7. Check fire protective sleeves
on fuel supply and return lines
in engine compartment.
7.4.6
X
X
X
7.4.6
X
7.4.6.2
X
7.4.6.2
X
X
Annual
X
Engine 600 hr
X
Engine 200 hr
X
Engine 100 hr
Type and Subject of Inspection
Aircraft 100 hr
FUEL SYSTEM COMPONENTS IN THE FUSELAGE
Break-in
5.4.8
Aircraft 100 hr
Type and Subject of Inspection
Break-in
MAINTENANCE MANUAL STEMME S12
Refer to
Section
X
X
X
7.4.6.2
X
X
X
7.4.6.2
X
X
X
7.4.8.2
Sign-off
CHAPTER-PAGE 5-25
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
AMENDMENT: 00
DATE: --
MAINTENANCE MANUAL STEMME S12
5.4.9
ENGINE AND ENGINE MOUNTINGS
Engine 600 hr
Engine 200 hr
Engine 100 hr
Refer to
Section
1. Engine cleaning.
2. Visual inspection of engine
and auxiliaries.
3. Engine check for leakage.
4. Check of engine auxiliaries.
5. Check of waste-gate.
6. Lubricate the waste-gate axle
(waste-gate flap).
7. Check of engine gearbox.
8. Check magnetic plug for metal
particles or foreign matter.
9. Check of reduction gear
wheels.
10. Removal/Assembly of the two
carburetors and carburetor
inspection.
11. Inspect the carburetor sockets
for damages and abnormalities, checking for cracks, wear
and good condition. Take note
of changes caused by temperature influence.
12. Check float weight.
13. Check carburetor synchronization – mechanical or pneumatic synchronization.
14. Check condition of fuel lines,
pressure connection lines and
compensating tube assy. at
carburetors and air box.
15. Check engine wiring and cables.
16. Visual inspection of the temperature sensor and the oil
pressure sensor, inspect for
tight fit and good condition.
17. Check of V-belt tension of
additional auxiliary generator.
X
X
X
7.4.1.3
X
X
X
7.4.1.4
X
X
X
X
X
X
X
X
X
7.4.1.5
7.4.1.6
7.4.1.7
X
X
X
7.4.1.7
X
X
X
7.4.1.8
X
X
X
7.4.1.9
X
7.4.1.10
X
X
7.4.1.11
X
X
7.4.1.11
X
X
7.4.1.11
X
X
X
Annual
Type and Subject of Inspection
Break-in
Aircraft 100 hr
(1) - use of leaded fuel more than 30% of operation
X
X
X
X
X
7.4.6.2
X
X
X
7.4.1.12
X
X
X
X
Sign-off
7.4.1.12
X
7.4.1.13
CHAPTER-PAGE 5-26
AMENDMENT: 00
DATE: --
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
X
X
X
1
2
3
Refer to
Section
X
7.4.1.14
X
7.4.1.14
Sign-off
7.4.1.15
X
Pressure drop (% or fraction)
Cyl #
Annual
Engine 200 hr
(1)
Engine 600 hr
Engine 100 hr
18. Replace spark plugs.
19. Check spark plugs, Radiator
can be removed (cam locks) if
required.
20. Check of spark plug
connectors for tight fit.
21. Check of compression pressure by differential pressure
method.
Test pressure: ...........hPa (psi)
Aircraft 100 hr
Type and Subject of Inspection
Break-in
MAINTENANCE MANUAL STEMME S12
X
7.4.1.16
4
bar/psi
22. Check mountings of turbocharger / muffler.
23. Check condition of exhaust
headers for crack formation
and uncharacteristic gunpowder burns (leaks);
(incl. attachment and
springs).
24. Check heat insulation (exhaust headers, muffler, heat
protection shields), renew if
required.
25. Check mounting points of
engine housing.
26. Check upper and lower
engine mountings.
X
X
X
7.4.5.1
X
X
X
7.4.5.2
X
X
X
7.4.5.3
X
X
X
7.4.1.18
X
X
X
7.4.1.18
CHAPTER-PAGE 5-27
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
AMENDMENT: 00
DATE: --
MAINTENANCE MANUAL STEMME S12
5.4.10
LUBRICATION SYSTEM
1. Check condition of oil radiator
and oil tank assemblies.
2. Check oil lines (engine and
turbocharger) and oil drain
line.
3. Check condition and routing of
fire protective sleeves.
4. Change oil. Unbolt oil cooler and rotate upward before
draining old oil. Check drains
plugs of oil tank and crankcase
for metal particles or foreign
matter.
5. Check and clean oil tank. Refill
oil tank with approx 3 ltr oil.
6. Remove old oil filter from the
engine. Install a new oil filter.
7. Cut old oil filter without producing any metal chips and
inspect the following components for wear and/or missing
materials:
Filter mat
Findings:
Filter Cover:
Findings:
Sealing lip (wear, cracks missing materials):
Findings:
Spring of bypass valve (small):
Findings:
Positioning spring (large):
Findings:
Annual
Engine 600 hr
Engine 200 hr
Engine 100 hr
Aircraft 100 hr
Type and Subject of Inspection
Break-in
(2) - every 50 hours - use of leaded fuel more than 30% of operation
Refer to
Section
X
X
X
7.4.2.1
X
X
X
7.4.2.1
X
X
X
7.4.8.2
X
X
(2)
7.4.2.3
X
X
(2)
7.4.2.3
X
X
(2)
X
X
(2)
X
Sign-off
7.4.2.4
7.4.2.4
CHAPTER-PAGE 5-28
AMENDMENT: 00
DATE: --
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
MAINTENANCE MANUAL STEMME S12
1. Check condition of the cooling
system assemblies: expansion
reservoir, refill container, overflow container and radiator.
2. Carry out visual of leakage
bore at the base of the water
pump for signs of leakage.
3. Check condition of coolant
hoses and pipes.
4. Flushing the cooling system –
When replacing the coolant.
5. Check ram air cooling assy.
(plenum) of cylinder barrels.
Annual
Engine 600 hr
Engine 200 hr
Refer to
Section
X
X
X
7.4.3
X
X
X
7.4.3
X
X
X
7.4.3
X
X
X
7.4.3
Engine 600 hr
Engine 200 hr
Engine 100 hr
Aircraft 100 hr
AIR INDUCTION SYSTEM
Refer to
Section
1. Check of intercooler assy.
2. Check condition of air filter
assy.: Clean or change air
filter.
3. Change of air filter
X
X
X
7.4.4
X
X
X
7.4.4
Annual
Type and Subject of Inspection
Sign-off
7.4.4
X
1. Throttle and choke: Check end
stops of carburetor,
springs and condition of
bowden cables.
X
X
Annual
Engine 600 hr
Engine 200 hr
Engine 100 hr
Type and Subject of Inspection
Aircraft 100 hr
ENGINE CONTROLS & MONITORING
Break-in
5.4.13
Sign-off
7.4.3
Break-in
5.4.12
Engine 100 hr
Type and Subject of Inspection
Aircraft 100 hr
COOLING SYSTEM (LIQUID COOLING, RAM AIR COOLING)
Break-in
5.4.11
X
Refer to
Section
Sign-off
7.4.7
CHAPTER-PAGE 5-29
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
AMENDMENT: 00
DATE: --
2. Check condition of TCU and
waste-gate-servo assy.
3. Check sensors for oil pressure,
oil temperature, cylinder coolant temperature, exhaust gas
temperature (if installed), fuel
pressure and fire warning.
4. Check ignition lock shorting
cables (aft firewall, lower LH
side)
5. Check function of ignition
retarder module.
6. Check function of engine instrumentation.
Annual
Engine 600 hr
Engine 200 hr
Engine 100 hr
Refer to
Section
X
X
X
7.4.7
X
X
X
7.4.7
X
X
7.4.7
X
X
7.4.7
X
7.4.7
X
X
Sign-off
1. Check condition of upper center fuselage fairing, including
oil service access.
2. Check condition of LH and RH
Cowling.
3. Check condition of cowling
fire protective paint. Repair if
required.
4. Check condition and function
of inlet and outlet cowl flaps.
5. Check fairing section aft of
outlet cowl flap.
6. Check openings of inlet cowl
flap (fully opened and fully
reduced aperture). Check if
flaps close properly when
nose-cone is closed.
7. Check condition of firewall
sheets.
7.4.9
X
X
X
7.4.9
X
X
X
7.4.8.1
X
X
X
7.4.9
Annual
X
Engine 600 hr
X
Engine 200 hr
X
Engine 100 hr
Type and Subject of Inspection
Aircraft 100 hr
CENTER FUSELAGE FAIRING, ENGINE COWLINGS AND FIREWALL
Break-in
5.4.14
Aircraft 100 hr
Type and Subject of Inspection
Break-in
MAINTENANCE MANUAL STEMME S12
Refer to
Section
X
X
X
7.4.9
X
X
X
7.4.9
X
X
X
7.4.8.3
Sign-off
CHAPTER-PAGE 5-30
AMENDMENT: 00
DATE: --
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
MAINTENANCE MANUAL STEMME S12
1. Visual inspection of load bearing elements.
2. Check complete propeller assembly.
3. Check rubber stops within
the blades and on the hub for
cracks.
4. Visual inspection of propeller
blades. Repair leading edge
protection tape if necessary
(use material supplied by
manufacturer only!).
5. Check propeller folding mechanism for ease of operation
and restoring force. Check
condition of the blade retraction coupling lever.
6. Check spring tension of propeller folding mechanism.
7. Check propeller blade ventilation and drain holes.
8. Check adjustment of propeller blade T/O and cruise pitch.
Check respective setting of
both blades and check for discrepancies.
9. Check function of pitch
change and time for pitch
change in each direction.
10. Check propeller blade T/O-position indication and pre-setting before reaching T/O
position.
11. Check carbon brushes, replace
if necessary. Check for excessive abrasion (copper dust),
clean slip rings with alcohol.
7.4.10
X
X
X
7.4.10
X
X
X
7.4.10.3
X
X
X
7.4.10.3
X
X
X
7.4.10.3
Annual
X
Engine 600 hr
X
Engine 200 hr
X
Engine 100 hr
Type and Subject of Inspection
Aircraft 100 hr
PROPELLER
Break-in
5.4.15
Refer to
Section
X
X
X
7.4.10.6
X
X
X
7.4.10.3
X
X
X
7.4.10.7
X
X
X
7.4.10.7
X
X
X
7.4.10.9
X
X
X
7.4.10.8
Sign-off
CHAPTER-PAGE 5-31
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
AMENDMENT: 00
DATE: --
MAINTENANCE MANUAL STEMME S12
1. Check noise and backlash of
propeller reduction gear (turn
propeller by hand).
2. Check condition of propeller
reduction gear suspension and
attachment on front fuselage
frame in shock mounts.
3. Check fastening and condition
of lower propeller reduction
gear fairing.
4. Check function of freewheel
clutch.
5. Check attachment of freewheel clutch on engine flange.
6. Check condition and tight fit
of cardanic rubber disc joint on
freewheel clutch.
7. Check condition and tight fit
of cardanic rubber disc joint on
propeller reduction gear.
8. Check condition of composite
shaft.
9. Check propeller reduction
gear visually for condition and
leakage
(for inspection Break- In and
aircraft 100h with the gear
installed).
10. Check oil quantity in propeller
reduction gear.
11. Check magnetic screw of propeller reduction gear.
12. Change oil of propeller
reduction gear.
X
X
X
X
Annual
Engine 600 hr
X
Engine 200 hr
X
Engine 100 hr
Type and Subject of Inspection
Aircraft 100 hr
DRIVE SHAFT WITH PROPELLER REDUCTION GEAR
Break-in
5.4.16
Refer to
Section
X
7.4.12
X
7.4.12
X
7.4.12
X
X
X
7.4.11
X
X
X
7.4.11
X
X
X
7.4.11
X
X
X
7.4.11
X
X
X
7.4.11
X
X
X
7.4.12
X
X
X
7.4.12
X
7.4.12
X
X
Sign-off
7.4.12
CHAPTER-PAGE 5-32
AMENDMENT: 00
DATE: --
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
MAINTENANCE MANUAL STEMME S12
1. Inspect the main landing gear
legs and trailing arms for deformation and possible cracks
as an result of overloads.
2. Check the linear actuators for
external damage.
3. Check main landing gear tires
for condition and creep markings.
Check tire pressure: (2.6 ± 0.1
bar / 37.7±1.5 p.s.i).
4. Check function of trailing link
spring suspension.
5. Check ease of operation and
backlash of wheel bearings.
6. Check brake master cylinder
and wheel cylinders, hoses and
tubes.
7. Check brake discs and brake
linings (at least 1.5 mm / 0.06
in.)
8. Check quantity of brake fluid.
9. Renew brake fluid (DOT 4) if
indicated.
10. Check brake effectiveness,
adjust brake if required.
11. Check condition of gear doors.
Clean and grease hinges of
gear doors.
12. Check free movement of doors
and actuating mechanism,
including Bowden cable assy.
of LH landing gear door.
13. Check function of landing
gear (support the aircraft on
trestles). Check stop switches, fit of gear doors, Bowden
cables for emergency release
and the release mechanism on
over-center strut.
7.5.1
X
X
X
7.5.1
X
X
X
7.5.1
X
X
X
7.5.1
X
7.5.1
X
7.5.1
X
X
7.5.1
X
X
7.5.1
(X)
7.5.1
X
7.5.1
X
7.5.1
X
7.5.1
X
7.5.1
X
X
X
X
X
X
X
X
X
X
X
X
X
Annual
X
Engine 600 hr
X
Engine 200 hr
X
Engine 100 hr
Type and Subject of Inspection
Aircraft 100 hr
MAIN LANDING GEAR
Break-in
5.4.17
Refer to
Section
Sign-off
CHAPTER-PAGE 5-33
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
AMENDMENT: 00
DATE: --
14. Check landing gear position
indication and warning (visual
and acoustic, during function
test).
15. Check function of emergency
gear extension.
Annual
Engine 600 hr
Engine 200 hr
Engine 100 hr
Refer to
Section
X
X
7.5.1
X
X
7.5.1
Sign-off
7.5.2
X
X
X
7.5.2
X
X
7.5.2
X
X
7.5.2
X
X
7.5.2
X
Annual
X
Engine 600h
X
Engine 200h
X
Engine 100h
Aircraft 100h
1. Tail wheel: Check ease of operation, clearance to fairing,
backlash.
2. Check tire condition, pressure
2.8 ± 0.2 bar / 40.6 ± 2.9 p.s.i
3. Check wheel fork for cracks
and deformation.
4. Check bearing of tail wheel
fork.
5. Check spring coupling assy.
between tail wheel and rudder.
Break-in
TAIL WHEEL
Type and Subject of Inspection
Refer to
Section
Sign-off
1. Check condition of Pitot / Static system and renew filters/
water separators if required.
2. Check condition and function
- service life limits if applicable- of flight instrumentation
(refer to equipment list).
X
Annual
Engine 600 hr
Engine 200 hr
Type and Subject of Inspection
Engine 100 hr
FLIGHT INSTRUMENTATION AND PITOT / STATIC SYSTEMS
Aircraft 100 hr
5.4.19
X
Break-in
5.4.18
Aircraft 100 hr
Type and Subject of Inspection
Break-in
MAINTENANCE MANUAL STEMME S12
Refer to
Section
X
X
7.6.2
X
X
7.6
Sign-off
CHAPTER-PAGE 5-34
AMENDMENT: 00
DATE: --
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
MAINTENANCE MANUAL STEMME S12
1. Check wiring of electric system.
2. Check condition of all installed
electric devices.
3. Check condition and function
of switches.
4. Check both batteries. Observe
maintenance instructions of
manufacturer
(Refer to Annex A).
5. Check condition of grounding.
6. Visually check electric distribution box (E-box).
X
Refer to
Section
X
7.7.1
X
7.7.1
X
7.7.1
X
X
7.7.2
X
X
7.7.3
X
X
7.7.4
X
X
X
Annual
Engine 600 hr
Engine 200 hr
X
Engine 100 hr
X
Sign-off
1. Check NAV and COM equipment for proper installation
and safe mounting and compare to equipment list.
2. Check function and, if applicable, service life limits of NAV
and COM equipment (Refer
to records of operating times,
Annex C).
3. Check each installed antenna.
Annual
Engine 600 hr
Engine 200 hr
Type and Subject of Inspection
Engine 100 hr
COM AND NAV EQUIPMENT
Aircraft 100 hr
5.4.21
Aircraft 100 hr
Type and Subject of Inspection
Break-in
ELECTRIC SYSTEM (EXCEPT FOR ENGINE AND TCU)
Break-in
5.4.20
Refer to
Section
X
7.8
X
7.8
X
7.8
Sign-off
CHAPTER-PAGE 5-35
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
AMENDMENT: 00
DATE: --
MAINTENANCE MANUAL STEMME S12
1. After end of maintenance
work on the drive system Engine test run.
2. Check IDLE speed.
3. Check of oil quantity.
4. Check for accomplishment of
all applicable Service Bulletins.
X
X
X
X
Annual
X
Engine 600 hr
X
Engine 200 hr
Engine 100 hr
Type and Subject of Inspection
Aircraft 100 hr
COMPLETION TASKS
Break-in
5.4.22
X
X
X
X
X
Refer to
Section
Sign-off
7.1.4.17
7.4.2.2
X
CHAPTER-PAGE 5-36
AMENDMENT: 00
DATE: --
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
MAINTENANCE MANUAL STEMME S12
5.4.23
OPTIONAL EQUIPMENT
WING FOLDING DEVICE
1. Check all screwed joints on
the wing roots on the cardan
flange for tightness.
2. Completely remove the folding device; for this purpose
separate in the cardan joint.
Unscrew the cardan flange from
the outboard wing and the slide
bearing from the inner wing.
First pull out the outboard wings
then the swivel arms completely.
3. Check the riveted joints on
the swivel arms for perfect
condition.
4. Check the slide bearing for
initial tearing or rupture,
especially in the area between
the lock-slit and the external
end.
5. Check the wing ribs in the area
of the attachment bolts for
initial tearing (crazing)
6. Check the adhesive joint
between the spar pocket and
the lower shell of the inner wing
for initial tearing.
Annual
Engine 600 hr
Engine 200 hr
Engine 100 hr
Aircraft 100 hr
Type and Subject of Inspection
Break-in
The wing folding device itself is maintenance-free. The sliding surfaces should not be lubricated
in order to avoid sticking of dirt, which could result in the formation of marks on the swivel arm
and thus to wear. From time to time, the swivel arm should be cleaned by means of a soft cloth.
Refer to
Section
Sign-off
X
X
X
X
X
X
CHAPTER-PAGE 5-37
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
AMENDMENT: 00
DATE: --
MAINTENANCE MANUAL STEMME S12
1. Check oxygen equipment if installed. Observe maintenance
instructions of manufacturer
(Refer to Annex A).
X
Annual
Engine 600 hr
Engine 200 hr
Engine 100 hr
Aircraft 100 hr
Type and Subject of Inspection
Break-in
OXYGEN EQUIPMENT
X
Refer to
Section
Sign-off
7.9
CHAPTER-PAGE 5-38
AMENDMENT: 00
DATE: --
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
MAINTENANCE MANUAL STEMME S12
5.5
SPECIAL INSPECTIONS
5.5.1
INSPECTION FOLLOWING A HEAVY LANDING OR A WING TIP LANDING
Following a heavy landing or a wing tip landing, the aircraft must be inspected extensively. The
inspection may be carried out by a skilled person, but, in case of obvious structural damage, by
an authorized inspector with the appropriate rating. The inspection program must be requested
from the manufacturer.
5.5.2
INSPECTION FOLLOWING AN IMPACT TO THE ROTATING PROPELLER
In the event of minor damage to the propeller blades (e.g. shortening of a propeller blade by less
than 0.03 m / 1.18 in – areas painted gray on both sides at the tips of the propeller blades are still
visible – ) the following procedure should be adopted:
1. Qualified staff must establish whether the propeller blades can be repaired or not. This is
not generally the case and the propeller blades have to be replaced.
2. The minimum requirement is that a 100 Engine Operating Hours Inspection is carried out
on the drive system in accordance with section »5.4.16« (as far as applicable).
3. After the propeller blades have been repaired or replaced, the drive system must be dynamically balanced, as laid down in A17-10AP-V/2-E »Dynamic Propeller Balancing STEMME
S10« (see Aircraft Maintenance Manual Annex A).
In the event of major damage to the propeller blades (e.g. shortening of a propeller blade by more
than 0.03 m / 1.18 in – areas painted gray on both sides at the tips of the propeller blades are no
longer visible – ) the following procedure should be adopted:
1. The propeller blades must be replaced.
2. The propeller must be inspected by the manufacturer or an authorized workshop.
3. The drive system must be inspected by the manufacturer or an authorized workshop.
4. After an inspection has been carried out and the propeller blades have been replaced,
the drive system must be dynamically balanced, as laid down in A17-10AP-V/2-E “Dynamic Propeller Balancing STEMME S10“ (Aircraft Maintenance Manual Annex A).
In contrast to other aircraft, a shock-loading inspection of the engine in either event is not required
because of an integrated over-load protection in the engine and the freewheel clutch as an additional safety device. Moreover the extension drive shaft system in between propeller and engine
prevents the engine drive flange from bending loads in case of propeller contact with obstacles.
CHAPTER-PAGE 5-39
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
AMENDMENT: 00
DATE: --
MAINTENANCE MANUAL STEMME S12
5.5.3
INSPECTION FOLLOWING EXCEPTIONAL EVENTS WITH WING
FOLDING DEVICE
Collision of the spar stub of the outboard wing with an obstacle during taxiing or maneuvering
in the hangar with the outboard wings folded:
• Inspection of the wing ribs for crazing in the area of the screw-on surfaces for the folding
device as well as inspection of the spar stubs and spar stub bolts for visual damage prior
to the next flight.
• Check the complete wing folding device for damage before using in the next time.
Shock loading of the folded wings by taxiing too fast over bump:
• Inspection of the wing ribs for crazing in the area of the screw-on surfaces for the folding
device prior to the next flight.
• Check the riveted joint on the swivel arms between the tube and the fittings before using
the folding device the next time.
If the outboard wing had been dropped while having been pulled out by more than
0.1 m / 3.94 in but not completely, high loads may have occurred on the inner wing between the
spar pocket and the shell, which in extreme cases might have resulted in initial tearing of the
adhesive joint.
• After the occurrence of such a load, the inner wing in the area of the joint between the spar
pocket and the lower shell has to be checked carefully for initial tearing prior the next flight.
CHAPTER-PAGE 5-40
AMENDMENT: 00
DATE: --
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
MAINTENANCE MANUAL STEMME S12
6.
MAINTENANCE INSTRUCTIONS, TOLERANCES, ADJUSTMENT DATA FOR THE
AIRCRAFT
6.1
GENERAL REMARKS
This section includes maintenance instructions, tolerances and adjustment data relevant to or
summarized for the entire motorglider. The instructions in section »7« for assemblies refer to this
section, if affected.
Forms related to inspections described in this section (weight and balance, controls adjustment,
control surface weights and hinge moments, propeller adjustment) are provided in Annex D of
this S12 Maintenance Manual and include further information about performing the inspections.
6.2
TOWING ON GROUND, JACK POINTS AND LIFTING
The S12 may only be towed in flight direction, since the tail wheel deflection is limited to 30° in
both directions.
For ground towing two ropes of textile material of at least 10 m / 32.80 ft each are needed. They
should be attached to the front struts of the main landing gear as low as possible (pay attention
to the hydraulic brake pipes). An instructed person should be seated in the cockpit. The towing
speed should be no faster then a walk.
For maneuvering on the ground, the manufacturer offers a tail wheel dolly. The aircraft may be
pushed backwards on level surface over a short distance without a tail wheel dolly, if the rudder
is controlled by hand.
Supporting points for lifting the aircraft are on the wing bottom surface in the spar area, about
1 m / 3.28 ft from the fuselage (position of the wing spar can be determined by light tapping).
The tail section is lifted approximately 0.5 m / 19.68 in supporting the tail wheel.
The wing supports for lifting must have an area of at least 0.2 m x 0.3 m / 9 in x 12 in (the longer
side in direction of wing span). A plywood sheet of 0.05 mm / 1.97 in thickness with a felt layer of
0.15 m to 0.2 m / 0.6 to 0.9 in thickness or a comparative device must be used. The support under
the plywood sheet center must be flexible so that it adapts to the wing contour and the wing is
evenly supported by the plywood plate.
The support must be capable of safely carrying the aircraft weight and be sufficiently stable. The
supporting surface may not be slippery.
WARNING
To avoid deformation and/or fatal damage of the wing shell and spar, ensure that the wings are
lifted simultaneously and that the supports are correctly positioned.
CHAPTER-PAGE 6-1
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
AMENDMENT: 00
DATE: --
MAINTENANCE MANUAL STEMME S12
During lifting and lowering of the aircraft, the wing chord should remain almost horizontal.
The fuselage with wing removed should be supported
• either in a felt-covered, adapted rigid tray, width 1 m / 3.28 ft and length 0.4 m / 15.75 in
directly in front of the landing gear doors, or
• by removing the front wing attachment bolts and by replacing the bolts by round steel
bars of St 37 or similar, Ø 19.8 ± 0.1 mm / 0.78 ±.004 in, 0.30 m / 11.81 in length. The steel
bars must be inserted by 0.15 m / 5.91 in and must be secured against displacement. The
fuselage can be suspended or supported at these bolts.
For rigging and derigging refer to the S12 Aircraft Flight Manual, chapter »4«.
For transport refer to the S12 Aircraft Flight Manual, chapter »8«.
CHAPTER-PAGE 6-2
AMENDMENT: 00
DATE: --
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
MAINTENANCE MANUAL STEMME S12
6.3
DETERMINATION OF EMPTY WEIGHT AND CORRESPONDING
CENTER OF GRAVITY; WEIGHT LIMITS
This section provides procedures to determine aircraft empty weight, component weights and CG
at empty weight and the certified weight and CG limits. To perform the inspection, the STEMME
form »Weight and Balance Report« (form according to Annex D) should be used.
The list of equipment on which weighing was based must be entered in the weight and balance
report and must correspond to the list in the inspection report. Any inspection documentation
can be found in Annex C of this S12 Aircraft Maintenance Manual.
CAUTION
Amended data of empty weight and CG position must be entered in the Report of »Empty Weight
and CG-Location« in section »6.3« of the S12 Aircraft Flight Manual and confirmed by authorized
personnel before operating the motorglider.
In addition, the placard on center console in the cockpit must be corrected accordingly.
DEFINITIONS
The reference plane (RP) is located at the leading edge of the inner wing at the wing root. It is
aligned vertically to the longitudinal-axis. This plane creates a reference line on the ground.
Longitudinal inclination: Place a wedge 1000:54 (3. 1° = 3°06‘) on the rear fuselage-section. Align
the top of the wedge horizontally. Keep in mind that the lateral axis must be almost horizontal
(figure »6.3.a«).
Figure 6.3.a
Definition of Reference Datum
Following items and fluids must be included when determining empty weight and CG:
Aircraft Logbook, S12 Aircraft Flight Manual, seat cushions and backrests with cushions or equivalent upholstery, standard tool-kit (baggage compartment behind backrest),
3.0 l / 0.8 US gal. / 0.66 Imp.gal. of engine oil, coolant level at max marking and unusable fuel in
wing tanks and feeder tank. For positions and other limiting conditions refer to the »Weight and
Balance Report« (see Annex D).
CHAPTER-PAGE 6-3
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
AMENDMENT: 00
DATE: --
MAINTENANCE MANUAL STEMME S12
Following an aircraft repair, painting or modification of equipment it always must be verified
that component weights, empty weight and CG at empty weight are still within certified limits.
If weight and arm of removed or installed equipment is known exactly, change of empty weight
and CG can be calculated. For calculation of empty weight CG, the arm of removed or installed
equipment or components is to be entered into the »Weight and Balance Report« (see Annex D).
FORMULA
xneu =
malt · xalt + mzus1 · xzus1 + mzus2 · xzus2 + ....
mneu
ABBREVIATIONS MEAN
-- malt
: Empty weight according to last weighing report
-- xalt
: CG at empty weight according to last weighing report
-- mzus
: Weight of added component
-- xzus
: Arms of added components with reference plane (RP)
-- mneu
: Resulting new total empty weight
-- xneu
: Resulting new total empty CG
Minimum load due to the modification can be taken from figure 6.3.b. and 6.3.c for two different loading conditions.
CAUTION
Basically the arms of weights in front of the reference plane (RP)must be counted negative, those
aft of the RP positive for any calculations.
If the effect of a modification or repair cannot be calculated (e. g. when having painted or following a repair of the composite structure) the aircraft must be weighed again.
To keep empty weight CG for unchanged minimum load within certified limits, it may be necessary
to install ballast at the front gear frame or at the aft part of the tail wheel bay (rear web of fin).
The required weight of the ballast can be calculated:
mBallast =
malt
xneu - xalt
xBallast - xneu
Where malt and xalt are empty weight and CG prior to the modification, xneu the target for CG at
empty weight and xBallast the arm of the ballast weight (in front or aft of RP). It must be observed,
that the maximum weight which can be installed at the rear web of the vertical fin is structurally
limited to 2.7 kg / 5.95 lb.
This procedure may be used also to position the CG for good soaring performance with high cockpit
payload. Following this a higher minimum cockpit load must be taken into account.
CHAPTER-PAGE 6-4
AMENDMENT: 00
DATE: --
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
MAINTENANCE MANUAL STEMME S12
If a revision proved the aircraft to be “tail-heavy“, the minimum load mP, min for an unchanged
empty weight mleer and CG position xleer can alternatively be determined by following formula:
mP, min =
With: Aftmost aft in-flight CG:
mleer
xleer - xFlug, h
xFlug, h - xP, h
xflug,h = 420 mm / 16.54 in
Aftmost aft seating (CG) position xP,h = - 650 mm / 25.54 in
of pilot:
(aft of RP)
(in front of RP)
The certified limits of the empty weight CG as a function of minimum load can be derived from
the following figure »6.3.b« and »6.3.c«. Two different minimum seat loads depending on the
loading conditions have to be determined and noted on the »Weight of Balance Report« (Annex
D), the weighing logsheet in the S12 Aircraft Flight Manual section »6.3« and the placards on the
center console:
• Full trim water ballast and luggage compartment - takes into account that the tail water
ballast tank and the luggage compartment in the tail-boom are fully loaded corresponding to their limitations. This “worst case” could lead values higher than the maximum load
and should draw the pilot’s attention to perform an operating weight and CG calculation
before flight.
• Empty trim water ballast and luggage compartment - expect no loading in the water
ballast tank and the luggage compartment in the tail-boom. This value could be used by
the pilot if this loading case is ensure before flight.
If maximum or minimum loads for the different compartments and seats are observed and the
empty weight CG is within limits, the in-flight aircraft CG is always within certified limits. This
means, that the load in the seats must equal or be higher than the minimum load, whereas total
cockpit load (pilot + co-pilot + parachutes + baggage) must be below the specified maximum load.
The difference of total cockpit load and the maximum load must at least allow for a fuel load
required for a 30 minutes flight at maximum continuous power (13.6 l / 3.6 US gal. / 3 Imp.gal.,
10 kg / 22.05 lb).
CHAPTER-PAGE 6-5
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
AMENDMENT: 00
DATE: --
MAINTENANCE MANUAL STEMME S12
Figure 6.3.b
Range of Empty Weight CG as a function of Empty Weight and Minimum Load
for worst tail-boom (full water ballast and luggage compartment)
CHAPTER-PAGE 6-6
AMENDMENT: 00
DATE: --
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
MAINTENANCE MANUAL STEMME S12
Figure 6.3.c
Range of Empty Weight CG as a function of Empty Weight and Minimum Load
for no tail-boom loading (empty water ballast and luggage compartment)
THE FOLLOWING WEIGHT LIMITS MAY NOT BE EXCEEDED UNDER NO CIRCUMSTANCES:
• Max. T/O weight 900 kg / 1984.16 lb,
• Max. weight of non-supporting parts (GNT) 610 kg / 1344.82 lb,
• Max. total load, which is cockpit-load plus fuel: 900 kg minus empty weight according to
valid »Weight and Balance Summary«,
• Max. cockpit-load, which is the sum of both cockpit occupants (incl. parachutes) plus
weight of baggage in baggage compartments: 202 kg / 445.33 lb, but not more than the
weight limit stated in the »Weight and Balance Report«,
• Max. 180 kg / 396.83 lb total for both occupants including parachutes,
• Max. weight per seat (pilot or copilot, incl. parachute) 110 kg / 243 242.51 lb,
• Max. baggage load in cockpit baggage compartments 22 kg / 48.5 lb, but maximum
is also the difference between max cockpit load and max weight of both occupants
(180 kg / 396.83 lb).
• Max. baggage load in tail-boom baggage compartments 20 kg / 44.09 lb, but maximum
is also the difference between max cockpit load and max weight of both occupants
(180 kg / 396.83 lb).
When loads are below minimum loads as stated in the flight manual (section »6.2«), the
difference between minimum load and actual load must be compensated by ballast.
CHAPTER-PAGE 6-7
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
AMENDMENT: 00
DATE: --
MAINTENANCE MANUAL STEMME S12
6.4
FLIGHT CONTROL SYSTEM
6.4.1
DEFLECTION OF CONTROL SURFACES, CONTROL SYSTEM FRICTION, AND
CONTROL FORCES
After any adjustment or assembly work on the control system, control deflections, friction and
forces in the control system must be measured.
For measurement procedures see form »Rigging Report» (Annex D). Rated values.
6.4.1.1
CONTROL SURFACE DEFLECTIONS
ELEVATOR
Measuring point is trailing edge of inner rib of elevator (140 mm / 5.51 in from hinge line).
Full Deflection
- 44 +2/-5 mm
(-1.73 +0.08/-0.2 in)
+ 44 +5/-2 mm
(+1.73 +0.2/-0.08 in)
RUDDER
Measuring point is lower rear corner of control surface (420 mm / 16.5 in. from hinge line).
Full Deflection
+220 ± 15 mm
(+8.7 ± 0.6 in)
-220 ± 15 mm
(-8.7 ± 0.6 in)
WING FLAPS AND AILERONS
Flap Lever
Control
Stick
Measurement points
1) Aileron: Inner rib of the control surface, 163 mm / 6.42 in. from hinge line.
2) Wing flap: Inner rib of the control surface, 175 mm / 6.89 in. from hinge line.
left aileron
left wing flap
right wing flap
right aileron
Position
Position
mm (in.)
- 10°
neutral
-31 ± 4 (-1.22 ± 0.16)
-31 ± 4 (-1.22 ± 0.16)
- 5°
neutral
-15 ± 4 (-0.6 ± 0.16)
-15 ± 4 (-0.6 ± 0.16)
left
-48 ± 4 (-1.89 ± 0.16)
0
neutral
0 ± 2 (0 ± 0.08)
0 ± 2 (0 ± 0.08)
0 ± 2 (0 ± 0.08)
right
+27 ± 3 (1.06 ±0.12)
+27 ± 3 (+1.06 ± 0.12)
0 ± 2 (0 ± 0.08)
-48 ± 4 (-1.89 ±0.16)
+ 5°
neutral
+15 ± 4 (+0.6 ± 0.16)
+15 ± 4 (+0.6 ± 0.16)
+ 10°
neutral
+31 ± 4 (+1.22 ± 0.16)
+31 ± 4 (+1.22 ± 0.16)
L (+16°)
neutral
+51 ± 4 (+2 ± 0.16)
+51 ± 4 (+2 ± 0.16)
Empty field: No measure to be checked.
CHAPTER-PAGE 6-8
AMENDMENT: 00
DATE: --
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
MAINTENANCE MANUAL STEMME S12
6.4.1.2
FRICTION IN CONTROL SYSTEM
MEASURING POINT
At the operating lever / control stick, mid of the grip.
If installed temporarily disconnect autopilot actuators.
6.4.1.3
Elevator
5 ± 2 N (1.1 ± 0.45 lbf)
Aileron
15 +5/-8 N (3.4 +1.1/-1.8 lbf)
Rudder (Tail wheel off the ground!)
25 +5/-8 N (5.6 +1.1/-1.8 lbf)
PILOT FORCES
Following rated forces apply for approx. 20°C, measured on ground. Measuring points for airbrake
and wing flap forces are the respective handles, for down-spring / trim spring forces the uppermost
finger notch of the control stick handle.
If installed temporarily disconnect autopilot actuators for elevator.
Air brake over-center lock and unlock
Wing Flap: Counter force in position L
Elevator: Down-Spring / Trim-Spring
Force at uppermost finger notch of
stick, stick full forward, trim setting
fully “nose down”.
Elevator: Down-Spring / Trim-Spring
Force at uppermost finger notch of
stick, stick full aft, trim setting fully
“nose down”.
150 + 50 N (34 + 11 lbf)
125 ± 25 N (28 ± 6 lbf)
40 ± 5 N (9 ± 1.1 lbf)
60 ± 5 N (13.5 ± 1.1 lbf)
CHAPTER-PAGE 6-9
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
AMENDMENT: 00
DATE: --
MAINTENANCE MANUAL STEMME S12
6.4.2
WEIGHTS AND MOMENTS OF CONTROL SURFACES
After repair and re-painting of control surfaces, weights and rear hinge moments must be checked
and confirmed to be within certified limits. If certified limits are exceeded, the manufacturer
must be contacted.
The Form »Control Surfaces Weights and Hinge Moments« (Annex D) includes procedures to
determine the weights and moments. Rated values are:
Control Surface
Weight of Control Surface
Hinge Moment of Control
Surface
Force at trailing edge
kg (lb)
Ncm (lbf ft)
N (lbf), Measuring point
Aileron
(outer wing)
4.1 (9.04) to 5.0 (11.02)
66.7 (0.49) to 106.7 (0.78)
9.2 (2.07) to 12.2 (2.74)
at inner operating rod.
r = 14.3 cm (5.63 in)
Aileron
(wing extension)
0.95 (2.1) bis 1.3 (2.86)
-1.9 (-0.01) bis 2.19 (0.02)
-0.19 (-0.04) to 0.219 (0.05)
at inner end rib
r = 10 cm (3.94 in)
Wing Flap
3.0 (6.61) bis 4.1 (9.03)
179 (1.32) bis 246 (1.81)
11.6 (2.61) to 15.8 (3.55)
at operating rod
r = 17.2 cm (6.77 in)
Elevator**
0.89 (1.96) bis 1.16 (2.55)
25.3 (0.19) bis 35.4 (0.26)
2.0 (0.45) to 2.7 (0.61)
at inner end rib
r = 14.0 cm (5.51 in)
Rudder
2.26 (4.98) bis 3.10 (6.83)
194 (1.43) bis 266 (1.96)
4.3 (0.967) to 5.3 (1.19)
at bottom rear corner
r = 42.5 cm (16.73 in)
** left and right measured separately
6.4.3
FREE PLAY IN FLIGHT CONTROL SYSTEM
For each control surface a maximum allowable slackness between cockpit control and control
surface is defined. Each control free play is measured at the point used for measurement of the
relevant control deflection (Refer to Form »Rigging Report«). For measuring, the controls are fixed
in the cockpit (control stick and flap operation handle).
Allowable free play
Aileron
2.5 mm / 0.1 in
Flaps
2.5 mm / 0.1 in
Elevator
2.5 mm / 0.1 in
The axial play of ailerons/flaps and elevator must be limited to a minimum without jamming,
using suitable washers if necessary.
CHAPTER-PAGE 6-10
AMENDMENT: 00
DATE: --
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
MAINTENANCE MANUAL STEMME S12
6.5
LUBRICATION
6.5.1
GENERAL REMARKS
LUBRICANTS
For friction bearings “steel-on-steel” and roller bearings lubricants and oils based on MoS2
are recommended. For bearings containing brass, bronze or copper components, only MoS2-free
lubricants and oils shall be used.
ENGINE
For lubrication of the engine, the instructions in the »Maintenance Manual (Line Maintenance)
for ROTAX Engine Type 914 Series«, section »12-20-00«, (Annex E) and the relevant Service
Information (SB), Service Information (SI) and Service Letter (SL) must be observed.
BEARINGS OF CONTROL SYSTEM AND CONTROL SURFACES
The control system bearings in the fuselage and in the wings are provided with permanent greasing
and do not require any service for a long period.
The control surface bearings (except rudder bearings) are coated and normally greasing is not
required. However, greasing may be necessary in aggressive environmental conditions when bolts
show first signs of corrosion. In this case use MoS2-free grease.
The rudder hinges must be greased depending on the degree of exposure to contamination
(especially the lower hinge).
CONNECTION OF THE PROPELLER EXTENSION SHAFT TO THE CLUTCH ON THE ENGINE SIDE
(SPLINED JOINT)
Shafts with hard film coating.
Commercially available Teflon spray or
non-acid grease can be used for lubrication
if there is only minor damage to the hard
film coating.
CANOPY LOCKING
Always keep well-greased. Use MoS2-free lubricant, since the rod bearing within the canopy
frame is made of brass.
CHAPTER-PAGE 6-11
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
AMENDMENT: 00
DATE: --
MAINTENANCE MANUAL STEMME S12
6.5.2
LUBRICATION PLAN
The lubrication points marked in the following figure should be checked and lubricated if required
and during scheduled maintenance or rigging as indicated on the table below. Additional lubrication may be required for additional equipment, observe maintenance instructions in Annex A.
Figure 6.5.2.a
Lubrication Plan
Position.
(1)
(2)
(3)
(4)
(5)
(6)
Description
Lubricant, Occasion and Remarks
(See also section 6.5.1)
Canopy locks
Grease (any scheduled maintenance)
Rear canopy lock (“Roeger Hook”) Oil (any scheduled maintenance)
T-Handles, locking clips (canopy
Grease (any scheduled maintenance)
emerg. handle, prop. brake, prop
positioning)
Center fuselage/wing fittings
Grease (any rigging and annually)
Connection bolt for:
Grease (any rigging and annually)
Inner/outer wing
outer wing / wing extension
wing extension / winglet
Shear fittings for:
Inner/outer wing
outer wing / wing extension
wing extension / winglet
Grease (any rigging and annually)
CHAPTER-PAGE 6-12
AMENDMENT: 00
DATE: --
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
MAINTENANCE MANUAL STEMME S12
Position.
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
6.6
Description
Forward and rear horizontal tail
fitting.
L´Hotellier connection aileron
control rod.
Spring parts of landing gear
doors.
Landing gear: Elbow strut, wheel
bearing, door hinges.
Hinge bolts of lower cowl flap.
Control rods in fuselage, swivel
joints.
Eye bolts of air brakes.
Flap control links.
Rudder hinges, control cable connection.
Tail wheel, lower axial guide.
Flap and elevator hinges
Lubricant, Occasion and Remarks
(See also section 6.5.1)
Grease (any rigging and annually)
Slightly grease only the ball (any rigging and
annually), see also manufacturer instruction
(Annex A)
Oil (any scheduled maintenance)
Grease (Inspection Type 2.c, door hinges annually)
Grease, (Inspection annually)
Grease, (every 2 years)
Grease, (every 2 years)
Grease, (every 2 years)
Grease, (every 2 years)
Grease, (every 2 years)
Grease, only if corrosion has occurred
SURFACE OF COMPOSITE STRUCTURES
During any 100 hours airframe or higher inspection (100 or more engine hours or annually) the
total surface of the motorglider shall be inspected for damage or cracks. Look carefully for signs
of hidden structural damage during inspection. Bottom sides of fuselage, wings and elevator shall
be checked for gravel strike damage.
• Check all labels and repair or renew if necessary.
Additional remarks about identification of structural damage, especially in force transfer areas
etc. can be found in section »7.1« in relevant subsections for components.
According to the type approval data sheet the surface may only be colored white except
for registration and areas for warning colors. Warning colors can be used from winglets to
0.30 m /11.81 in inboard, at the nose-cone and at the landing gear doors. For use of the white paint
observe the statements in the repair guide P520-901.502 »Small Repairs of Composite Materials«.
CHAPTER-PAGE 6-13
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
AMENDMENT: 00
DATE: --
MAINTENANCE MANUAL STEMME S12
THIS PAGE IS INTENTIONALLY LEFT BLANK
CHAPTER-PAGE 6-14
AMENDMENT: 00
DATE: --
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
MAINTENANCE MANUAL STEMME S12
6.7
DRAINAGE AND VENTILATION HOLES
The following position plan shows positions of the drains and ventilation holes (except for propeller).
Any drains and ventilation bores should be checked for blockage during any scheduled inspection.
Figure: 6.7.a.
Positions of Drainage and Ventilation Holes
6.8
TIGHTENING TORQUES OF SCREWED JOINTS
The tightening torques listed below applies to hexagon nuts, hexagon bolts and hexagon socket
screws of quality class 8.8 or higher:
Thread
Tightening Torque
Non-self-locking connection
Self-locking connection
[Nm]
[lbf ft]
[Nm]
[lbf ft]
M4
1.8+10%
1.33+10%
2.7-10%
2.0-10%
M5
3.6+10%
2.65+10%
5.2-10%
3.8-10%
M6
6.4+10%
4.72+10%
9.4-10%
6.9-10%
M8
16+10%
11.8+10%
22-10%
16-10%
M10
32+10%
23.6+10%
42-10%
31-10%
M12
57+10%
42.0+10%
72-10%
53-10%
M14
92+10%
67.8+10%
115-10%
85-10%
The above tightening torques are reduced by 25% if Loctite® or lubricated bolted joints are used.
CAUTION
Deviations from the standard tightening torque can be found also for some assemblies in
chapter »7«.
CHAPTER-PAGE 6-15
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
AMENDMENT: 00
DATE: --
MAINTENANCE MANUAL STEMME S12
NON-STANDARD TIGHTENING TORQUES INCLUDE THE FOLLOWING (FOR EXAMPLE)
Item
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Designation
Loctite
M8 connecting clutch and propeller
flange of the engine.
M10 connecting clutch and flexible disk
(drive shaft).
M10 connecting flexible disk and forked
sleeve of the drive shaft.
M10 connecting drive shaft and flexible
disk (front gear).
M10 connecting flexible disk and front
gear.
M8 connecting front gear in the gear suspension.
M8 fastening screws of the propeller hub
on the front gear flange.
M8 locking nut on the propeller fork.
WARNING
- not included in normal maintenance
Yield bolt fastening the fork on the propeller hub.
WARNING
- screw thread lubricated.
- not included in normal maintenance
Magnetic screw in the front gear.
Tightening Torque
[Nm]
[lbf ft]
without
22
16
243
35
25.8
243
35
25.8
243
35
25.8
221
35
25.8
without
16
11.8
without
1st step: 10
2nd step: 30
20
1st step: 7.4
2nd step: 22.1
14.7
without
1st step: 50
2nd step: 16
1st step: 36.9
2nd step: 11.8
without
15 - 20
11.1 – 14.7
without
CAUTION
Screws and bolts secured by Loctite 243!
ENGINE
For tightening torques of screw connections on the engine refer to »Maintenance Manual (Line
Maintenance) for ROTAX Engine Type 914 Series« (Annex E), »Maintenance Manual (Heavy
Maintenance) for ROTAX Engine Types ROTAX 912 and 914 Series« and applicable SI, SB and SL.
CHAPTER-PAGE 6-16
AMENDMENT: 00
DATE: --
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
MAINTENANCE MANUAL STEMME S12
7.
MAINTENANCE INSTRUCTIONS, TOLERANCES AND ADJUSTMENT
DATA FOR ASSEMBLIES / EQUIPMENT
7.1
AIRFRAME
7.1.1
WING
Description: See section »3.1.1«
Lubrication: See section »6.5«
7.1.1.1
CRACKS AND STRUCTURAL DAMAGE
• Check wings for cracks and abnormal surface (local buckles, roughness, holes and delamination), especially near to force transmission points (fittings, control links, flap hinges) and
at the division areas of inner and outer wing as well as of outer wing and wing extension.
See also section »6.6« and Annex A »Small Repairs of Composite Materials«.
7.1.1.2
DRAINAGE AND VENTILATION HOLES
• Check holes for cleanness and for fluid outflow; clean if necessary. Fuel trails found may
indicate fuel tank leakage. The holes are located next to the air brakes, fuel tanks and next
to the wing root of inner and outer wing and wing extension (see position plan in section
»6.7«).
7.1.1.3
WING FITTINGS
• Check backlash of the wing fittings by moving wing tips forward and aft and up and down.
If excessive backlash is found or in case of doubt the bolts and fittings must be measured
by means of a micro meter.
CLEARANCE OF WING/FUSELAGE ATTACHMENTS
Axial
Radial
Maximum 0.4 mm / 0.016 in
Maximum 0.15 mm / 0.006 in
CLEARANCE OF INNER-TO-OUTER WING ATTACHMENTS
Front and rear bolts, axial
Front and rear bolts, radial
Main bolt, radial
Spar stub bolts axial
Spar stub bolts radial
Maximum 0.3 mm / 0.012 in each
Maximum 0.2 mm / 0.008 in each
Maximum of 0.15 mm / 0.006 in
in the bearings of spar boxes.
Maximum 2 mm / 0.08 in
Maximum 0.2 mm / 0.008 in
CHAPTER-PAGE 7-1
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
AMENDMENT: 00
DATE: --
MAINTENANCE MANUAL STEMME S12
CLEARANCE OF OUTER WING TO WING EXTENSION ATTACHMENTS
Front and rear bolts, axial:
Front and rear bolts, radial
Main bolt, radial:
Spar stub bolts axial:
Spar stub bolts radial:
Maximum of 0.3 mm / 0.012 in each
Maximum 0.2 mm / 0.008 in each
Maximum of 0.15 mm / 0.006 in
in the bearings of spar boxes
Maximum 2 mm / 0.08 in
Maximum 0.2 mm / 0.008 in
These clearances are maximum allowable wears. If exceeded, the relevant bolt must be replaced
(the shear bolts at the inner-outer wing connection are provided with a thread).
• Check bushings for size, roundness and surface quality (striations). If necessary the bushings
must be reamed out and oversize bolts, available from the manufacturer, must be used.
CAUTION
Upon replacement of the bolts secure with Loctite type 638.
7.1.1.4
FLAPS AND AILERONS
• Check flaps for cracks, abnormal surface (local buckling, roughness, holes and
delamination) and corrosion, especially near force transmission points (fittings, control
links, flap hinges).
• Check wing flaps and aileron bearings for backlash (must be minimal).
• Check clearance between components and to wing spanwise.
• Check gap seals and tight fit of fairings on flap/aileron links.
Upon repair and re-painting the control surfaces weights and static hinge moments must be
measured. If the limits are exceeded, contact the manufacturer.
Weights and Hinge Moments:
See section »6.4.2«
Deflections:See section »6.4.1.1«
Clearance of Flaps:
In span direction and against each other
3 ± 0.5 mm / 0.12 ± 0.02 in
CHAPTER-PAGE 7-2
AMENDMENT: 00
DATE: --
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
MAINTENANCE MANUAL STEMME S12
7.1.2
FUSELAGE
Description: See section »3.1.2«
Lubrication: See section »6.5«
7.1.2.1
CRACKS AND STRUCTURAL DAMAGE
• Check forward fuselage and the tail boom for cracks and abnormal surface (local buckling,
roughness, holes and delamination), especially at the connection points to the center steel
frame, along the adhesive bindings of the tail boom and at the vertical tail root.
• Check the lower sides of forward fuselage and tail boom for gravel strike damage. Deep
damage to the coating, which may allow water to penetrate into the composite structure,
should be repaired.
See also section »6.6« and Annex A »Small Repairs of Composite Materials«.
7.1.2.2
DRAINAGE HOLES
• Check holes for cleanness, clean if necessary.
Positions:
See position plan in section »6.7«
7.1.2.3
NOSE-CONE
• Check proper fit of nose-cone on front fuselage.
• Check condition of composite structure, especially edge and bonding to nose-cone tube.
• Check operating lever for proper locking in both, forward and rear locked position. The force
to unlock must be sufficient to secure locking even under vibrations, ground and flight loads.
• Check condition and backlash of nose-cone sliding tube.
Allowable Backlash of Nose-cone: At the top, perpendicular to flight direction, 3 mm / 0.12 in.
NOSE-CONE HANDLE ADJUSTMENT
• Remove left and right coverings of instrument panel.
• Loosen forward connection of handle and nose-cone sliding tube.
• Loosen counter nut and adjust the eyebolt.
• Tighten nut to secure the eyebolt.
CHAPTER-PAGE 7-3
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
AMENDMENT: 00
DATE: --
MAINTENANCE MANUAL STEMME S12
RENEWAL OF LOCKING SPRING OF NOSE-CONE HANDLE
• Disassemble nose-cone operation.
• Change both locking springs and reassemble.
ADJUSTMENT OF ENGINE MASTER SWITCH
• Remove left and right coverings of instrument panel.
• Re-bend electrical contacts or change if necessary.
7.1.2.4
CENTER FUSELAGE
• Check the steel frame for damages. Repair damage of the paint and remove corrosion. If
damage from chafing has occurred, determine and eliminate the cause of chafing.
• Check parts of the frame near to the force transmitting fittings (forward fuselage, tail
boom, wings, landing gear), especially the welding seams, for cracks.
• Check the bolt connections of forward fuselage and tail boom to steel frame for tight
connection.
• Check condition of tail boom composite structure close to the force transmission points.
• Check condition of upper and lower attachment points “framework to forward fuselage”.
• Check condition of force transmission points in the front fuselage composite structure
(cracks) and bonding of upper shear sleeves for tight fit.
Tightening Torques: See section »6.8«
NOTICE
Original paint of steel frame has got a defined brittleness by design. It facilitates deflection of
cracks.
7.1.3
EMPENNAGE
Description: See section »3.1.3«
Lubrication: See section »6.5«
7.1.3.1
GENERAL CONDITION
• Check surface of vertical and horizontal tail (fins and stabilizer/rudder) for abnormal condition or cracks, especially near force transmission points (fittings, control links, hinges).
• Check condition and attachment of gap sealing / zigzag (turbulator) tape.
See also section »6.6« and Annex A »Small Repairs of Composite Materials«
CHAPTER-PAGE 7-4
AMENDMENT: 00
DATE: --
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
MAINTENANCE MANUAL STEMME S12
7.1.3.2
VERTICAL TAIL
RUDDER ATTACHMENT AND FREE MOVEMENT
• Check condition of rudder fittings (stainless steel), specially check lower fitting for cracks
and deformation.
• Check tight fit of screw connections and rivet connection of bearings, friction in bearings
(observe section »6.5 Lubrication«) and backlash. The axial backlash of the rudder should
be minimal (washer D125-08 must be installed between lower bearing and lower hinge bolt).
• Check condition of split pin. Move rudder to left and right stops to check for unobstructed
movement. Especially the tail wheel coupling must not obstruct rudder deflections if the
tail wheel steering is blocked.
ANTENNA
• Check condition of plug contact and heat-shrink tubing.
• Check fixing at lower rudder fitting (cable support).
• Check free movement of rudder without the coaxial cable obstructing rudder control cables
and coupling rods to tail wheel.
WATER BALLAST TANK (OPTIONAL)
• Check condition of drainage, ventilation and filling holes of the water ballast tank in the
right shell of the vertical tail for cleanliness, clean if necessary.
• Check the surrounding structure for abnormal surface (local buckling, roughness, holes
and delamination) and cracks/deformation.
• Check the empennage structure in the area of the tail wheel for residue of water. Findings
could indicate leaking of the water ballast tank. In this case check the interior space of the
vertical tail with camera or equivalent technique.
CHAPTER-PAGE 7-5
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
AMENDMENT: 00
DATE: --
MAINTENANCE MANUAL STEMME S12
7.1.3.3
HORIZONTAL TAIL
• Check forward fitting for cracks and corrosion, tight fit of screw connection, smooth operation of spring bolt (observe section »6.5 Lubrication«), backlash of bolt and sufficient
spring tension for safe locking.
• Check rearward fitting for cracks, especially in or close to welding seams and the cut-outs
of the fixing plates, tight fit of screw connection and wear of pins.
• Check nut of the assembly screw stop.
• Check backlash of the horizontal tail fitting (do not apply excessive force):
-- Move horizontal tail tip forward and aft and up and down.
-- Take hold of the mid section of the horizontal tail fin, push up and down.
If excessive backlash is found, the bolts and fittings must be measured.
MAXIMUM BACKLASH OF HORIZONTAL TAIL FITTINGS
Forward fitting
Rear fitting
7.1.3.4
Vertically 0.15 mm / 0.006 in
Vertically 0.15 mm / 0.006 in
Horizontally 0.1 mm / 0.004 in
Horizontally 0.15 mm / 0.006 in
WEIGHTS AND STATIC HINGE MOMENTS OF CONTROL SURFACES
Upon repair and re-painting the control surfaces weights and static hinge moments must be
measured. If the limits are exceeded, contact the manufacturer.
Weights and Hinge Moments:
See section »6.4.2«
Deflections:See section »6.4.1«
CHAPTER-PAGE 7-6
AMENDMENT: 00
DATE: --
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
MAINTENANCE MANUAL STEMME S12
7.2
COCKPIT
Description: See section »3.2«
Lubrication: See section »6.5«
7.2.1
CANOPY
7.2.1.1
CONDITION AND FUNCTION
• Check canopy for scratches and cracks, especially in the area of the clear vision / vent windows. Small cracks may be stop-drilled, long cracks must be repaired. (max. 200 mm length.)
• Check function and condition of the sliding window.
• Check canopy locks for smooth operation, clean bolts and bushings and observe section
»6.5 Lubrication«.
• Check equal and simultaneous opening of both lateral locking levers. If necessary adjust
cable tension so that both levers open completely and simultaneously.
• Check smooth function of lateral gas springs and whether they are able to balance the
canopy weight.
7.2.1.2
TEST OF CANOPY EMERGENCY JETTISON
Carry out jettisoning procedure as adopted from the instructions in the S12 Aircraft Flight Manual
• Detach lateral gas springs from the canopy frame and remove gas springs from cockpit.
• Support the canopy by two assistants standing to the right and to the left of the cockpit.
• Perform jettisoning procedure according to the S12 Aircraft Flight Manual.
NOTICE
The canopy must be supported by two assistants standing to the right and to the left at the front
of the aircraft.
• Check force of emergency release gas spring.
Force of Gas Spring
Compressed 150 ± 30 N / 34 ± 7 lbf
CHAPTER-PAGE 7-7
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
AMENDMENT: 00
DATE: --
MAINTENANCE MANUAL STEMME S12
7.2.1.3
RE-INSTALLATION OF THE CANOPY
• Unscrew the ball head bolted joint of the pneumatic springs which hold the canopy open.
• Loosen the M8 nuts on the fuselage side of the canopy hinge by two turns.
• Use a punch to brace the gas spring within the hinge (opening spring) and push the head
half way under the side-wall so that the spring is fixed in place. If required, use a wooden
block as support between the bonding seam of the hinge and the lower stationary part of
the fuselage (guide tube).
• Turn the locking lever parallel to the direction of flight (“Unlocked“ position).
• Two assistants are needed to hold the canopy in the open position and to ensure the precise
position of the hinges one to each other.
• Turn the locking lever through 90 degrees° (as far as the stop); check through inspection
window. Tighten M8 nut.
• Screw the pneumatic springs holding the canopy open back into the ball heads.
• Arm the opening mechanism by inserting a screw driver into the hole provided and press
the gas spring forward until a distinct click is audible.
WARNING
If the gas spring is not initialized as described before, the canopy will not open when releasing
jettisoned in flight.
CHAPTER-PAGE 7-8
AMENDMENT: 00
DATE: --
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
MAINTENANCE MANUAL STEMME S12
7.2.2
EQUIPMENT AND SYSTEMS
7.2.2.1
SEAT BELTS
• Check condition and function of seat belts.
• Check proper fastening of the belts to the attachment fittings.
• Check attachment fittings for corrosion and cracks.
• Check service life of seat belts according to manufacturer airworthiness limitation.
7.2.2.2
INSTRUMENTS AND SWITCHES
• Remove cover of instrument panel.
• Check instrument panel for loose screws.
• Check condition and attachment of instruments, switches, circuit breakers, fuses and
wiring. Press fire warning light to check it for acoustical and visual function.
7.2.2.3
AIR HOSES
• Check ventilation air hoses for condition (holes, crinkles) and proper attachment to the air
vents and the air inlet at the bottom front fuselage (NACA-Inlets).
7.2.2.4
SEATS
• Check surface of seat pans for local damage (e.g. local overloads due to parachute buckles).
• Check composite back rests for structural damages.
• Check condition and tight attachment of metallic components.
• Check lower and upper adjustment mechanism for proper function.
CHAPTER-PAGE 7-9
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
AMENDMENT: 00
DATE: --
MAINTENANCE MANUAL STEMME S12
7.3
CONTROLS
Description:See section »3.3«
Lubrication:See section »6.5«
Adjustment and Rated Data:
See section »6.4«
CONTROL RODS, GENERAL
The control rods must be checked with special attention on the condition of their terminals. The
swaged terminals of all control rods must be checked for longitudinal and radial cracks, all fork
terminals for cracks, especially at the transition area of fork root and side frame.
FUNCTION OF FLIGHT CONTROLS, GENERAL
• Check control sticks, pedals, flap levers and air brake levers for smooth and unobstructed
operation.
• Check for correct spring forces in controls and proper locking and unlocking of air brakes.
Check proper flap setting indication on center console.
• Check full deflections of stick and pedals to the relevant stops and symmetry of neutral
positions.
• Check electric trim for smooth and unobstructed operation over the whole operating range.
Compare trim indication in the instrument panel with position of the trim actuator (nose
down, neutral, nose up).
7.3.1
CONTROLS IN FUSELAGE
• Remove control system coverings in cockpit.
• Check condition, smooth operation, proper installation and tight screw and rivet
connections of components in cockpit (especially bearings, joints, rods and bell-cranks).
• Check for foreign objects.
• Check tight fit of control stops below stick cover.
• Check condition of pedals close to the cable guides and condition of cable guides.
• Check pedals for smooth adjustment, clean sliding guide with alcohol if required.
• Check all control rods and levers, including slides for rudder cables, in center fuselage for
tight fit of all joints, proper condition of bearings, damage, scratches and deformation.
NOTICE
Do not use grease or oil to improve smooth operation of pedal adjustment!
• Check condition and attachment of rubber stops on center steel frame.
• Check function and proper installation of trim assembly in luggage compartment of the
tail-boom. Check condition of springs, actuator and all screw connections.
• Check condition of flap gas spring assembly in flap controls for proper installation, tight
fit and signs of leakage of gas spring.
CHAPTER-PAGE 7-10
AMENDMENT: 00
DATE: --
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
MAINTENANCE MANUAL STEMME S12
• Check control rods and bearings in the area of wing-to-center fuselage attachments; check
condition of quick-release joints and securing of its spring bolts.
7.3.2
CONTROLS IN THE WING
For checks and maintenance of the L`Hotellier Connections (aileron control rods at the inner-to-outer wing division) refer to Annex A.
To check bell-crank levers and adjacent components of flap and aileron control system remove
fairings of the flap and aileron link rods and inspect the bell-crank levers and the other parts of
the flap and aileron drive systems in the wing by means of a borescope or mirror.
The air brakes should properly close flush with the wing surface when locked. To allow for wing
bending, there must be a clearance of minimum 1.5 mm / 0.06 in. between the inboard and outboard ends of the airbrake covers and the adjacent wing skins.
• Check tight fit and securing of upper screw joints, and condition and tight fit of bolts in
lower air brake.
7.3.3
CONTROLS IN TAIL CONE /VERTICAL TAIL
RUDDER CONTROL CONNECTIONS AND RUDDER STOPS
• Check condition of rudder control cables at the transition to PVC tube and connection of
rudder control cables at the tail boom entrance for proper condition.
• Check rudder control links for tight fit of screw connections and brass bushings for wear
(observe section »6.5 Lubrication«).
• Check proper installation of coupling rods to tail wheel.
• Check condition of rudder stops.
ADJUSTMENT OF RUDDER STOPS
• Adjust neutral position of rudder (use airfoil template), tail wheel free
• Mark reference on ground
• Adjust rudder stop screws on lower rudder fitting left/right for rated values according to
section »6.4.1.1«.
ELEVATOR CONTROL CONNECTION
• Check control link in rear horizontal tail fitting for condition, tight screw connection, low
friction of bearing (Observe section »6.5 Lubrication«).
To check bell-crank lever of the elevator control in the base of the vertical fin remove two stoppers
from inspection holes on LH side.
• Check bell-crank lever for condition, tight connections and proper installation by means
of an borescope.
CHAPTER-PAGE 7-11
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
AMENDMENT: 00
DATE: --
MAINTENANCE MANUAL STEMME S12
7.3.4
DEFLECTION OF CONTROL SURFACES, CONTROL SYSTEM FRICTION,
CONTROL FORCES
For rated values of deflection, friction and forces related to controls of aileron, flaps, elevator,
rudder and air brakes refer to section »6.4.1.1«, »6.4.1.2« and »6.4.1.3«.
For measurement procedures also refer to »Rigging Report«. (Annex D)
7.3.5
FREE PLAY OF CONTROL SYSTEM BEARINGS
Refer to section »6.4.3 Free Play in Flight Control System«.
CHAPTER-PAGE 7-12
AMENDMENT: 00
DATE: --
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
MAINTENANCE MANUAL STEMME S12
7.4
POWER-PLANT
7.4.1
ENGINE
Description: See section »3.4.1«
Lubrication: According to »Maintenance Manual (Heavy Maintenance) for ROTAX Engine
Types ROTAX 912 and 914 Series« and section »6.5«, as applicable.
NOTICE
Check regularly for ROTAX Service Bulletins (SB’s), Service Instructions (SI’s) and Service Letters
(SL’s)!
7.4.1.1
GENERAL
Except for the inspection list provided in section 5, the maintenance of the engine ROTAX 914
F2/S1 is basically performed according to the instructions in the »Maintenance Manual (Line
Maintenance) for ROTAX Engine Type 914 Series« (Annex E) and »Maintenance Manual (Heavy
Maintenance) for ROTAX Engine Types ROTAX 912 and 914 Series«.
Procedures affected by the modifications made for the S12 are included in this section. Otherwise
a reference to the relevant section in the original Maintenance Manuals given above is indicated.
Technical Service, especially maintenance of the engine ROTAX 914 F2/S1, may be performed by
STEMME as well as by authorized distributors and service centers approved by ROTAX.
(Refer to: www.flyrotax.com).
Service of modified components are carried out by STEMME only, as well as delivery of modified
spare parts.
For identification of components affected by the modifications and in any case of doubt it is
recommended to contact STEMME
STEMME AG
Flugplatzstrasse F2, Nr. 6-7
D-15344 Strausberg
Phone: +49.3341.3612-0
E-mail: [email protected]
Web: www.stemme.com
CHAPTER-PAGE 7-13
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
AMENDMENT: 00
DATE: --
MAINTENANCE MANUAL STEMME S12
7.4.1.2
a)
REMOVAL AND INSTALLATION OF THE ENGINE
Removal
• Disconnect battery.
• Remove fire wall sheets.
• Remove V-supports of the steel frame below the engine.
• Loosen clutch on engine side and push it forward on the sliding joint.
NOTICE
Do not lose bushings of screw joints!
• Disconnect electrical wiring, fuel hoses below the fire wall, Bowden cables, the oil and
lubricant hoses attached to the engine and the air induction hoses.
• Support the engine. Then loosen front (lower) engine mount at the attachment to the
frame, loosen upper (rear) engine mountings to the frame.
NOTICE
Mark distancing bushings LH/RH for re-installation!
• Lower the engine.
b)
Installation
In the opposite order as removal.
CHAPTER-PAGE 7-14
AMENDMENT: 00
DATE: --
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
MAINTENANCE MANUAL STEMME S12
7.4.1.3
CLEANING OF THE ENGINE
See »Maintenance Manual (Line Maintenance) for ROTAX Engine Type 914 Series«,
section 12-20-00, subsection, (Annex E).
7.4.1.4
VISUAL CHECK OF ENGINE
Special attention must be paid to the condition and the proper attachment of the two metal oil
lines between turbocharger and oil pump. In particular check the condition of the brazed joints
between the pipe and its fittings (check for cracks).
Further information see »Maintenance Manual (Line Maintenance) for ROTAX Engine Type 914
Series«, section 12-20-00, (Annex E).
7.4.1.5
LEAKAGE CHECK
Special attention during the leakage check must be paid to the brazed fittings of the two metal
oil lines between turbocharger and oil pump.
Further information see »Maintenance Manual (Line Maintenance) for ROTAX Engine Type 914
Series«, section 12-20-00, (Annex E).
7.4.1.6
INSPECTION OF EXTERNAL ENGINE COMPONENTS
See »Maintenance Manual (Line Maintenance) for ROTAX Engine Type 914 Series«,
section 12-20-00, (Annex E).
7.4.1.7
CHECK OF WASTE-GATE
Deviating from the figures in the ROTAX manual the waste-gate control of the ROTAX 914 F2/S1 has
been modified according to the following figure 7.4.1.7a. The servo cable and the spring are now
attached to an additional swiveling lever (1), which is mounted on the original lever of the waste-gate.
Information provided by the »Maintenance Manual (Line Maintenance) for ROTAX Engine Type
914 Series« will remain valid in an analogous sense.
Spare parts for the modified waste-gate-control can only be supplied by STEMME.
a) Check the components
In particular make sure that the whole waste-gate-control (cable, waste-gate including the
swiveling lever (1)) moves smoothly and easily.
Further information see »Maintenance Manual (Heavy Maintenance) for ROTAX Engine Types 912
and 914 Series«, section »78-00-00«, (Annex E).
b) Check the waste-gate position
See »Maintenance Manual (Line Maintenance) for ROTAX Engine Type 914 Series«,
section »12-20-00«, (Annex E).
CHAPTER-PAGE 7-15
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
AMENDMENT: 00
DATE: --
MAINTENANCE MANUAL STEMME S12
Figure 7.4.1.7a
Check of Waste Gate
7.4.1.8
CHECK OF GEARBOX
See »Maintenance Manual (Line Maintenance) for ROTAX Engine Type 914 Series«,
section »12-20-00«, (Annex E).
7.4.1.9
INSPECTION OF THE MAGNETIC PLUG
See »Maintenance Manual (Line Maintenance) for ROTAX Engine Type 914 Series«, section 12-2000, (Annex E).
7.4.1.10
EXAMINATION OF DRIVE GEAR SET
See »Maintenance Manual (Heavy Maintenance) for ROTAX Engine Types 912 and 914 Series«.
7.4.1.11
CHECK OF THE CARBURETOR
To access the right carburetor, it will be necessary to dismount and raise the oil cooler.
Visually check carburetor assy.: Check for proper installation, general condition and secure attachment of the carburetor assy. (carburetors, airbox, controls).
See »Maintenance Manual (Line Maintenance) for ROTAX Engine Type 914 Series«,
section »12-20-00«, (Annex E).
CHAPTER-PAGE 7-16
AMENDMENT: 00
DATE: --
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
MAINTENANCE MANUAL STEMME S12
7.4.1.12
CHECK OF ENGINE WIRING
• Check wiring in engine compartment for proper routing and support, tight connections
and condition of cables.
• Check wiring for mechanical damages (chafing, brittle parts, poor connections) and signs
of overheating (observe section »5.2.4«).
See also section »7.7 Electrical System« and »Maintenance Manual (Line Maintenance) for ROTAX
Engine Type 914 Series«, section 12-20-00, (Annex E).
7.4.1.13
CHECK OF V-BELT TENSION
See »Maintenance Manual (Line Maintenance) for ROTAX Engine Type 914 Series«,
section »12-20-00«, (Annex E).
7.4.1.14
REPLACEMENT OF SPARK PLUGS
The radiator on LH side can be removed prior to replacement the spark plugs.
See »Maintenance Manual (Line Maintenance) for ROTAX Engine Type 914 Series«,
section 12-20-00, (Annex E).
7.4.1.15
CHECKING OF SPARK PLUG CONNECTOR
See »Maintenance Manual (Line Maintenance) for ROTAX Engine Type 914 Series«,
section »12-20-00«, (Annex E).
7.4.1.16
CHECK OF COMPRESSION
According to the »Maintenance Manual (Line Maintenance) for ROTAX Engine Type 914 Series«,
the check of compression follows the pressure difference method.
To perform this method two pins can be screwed into the clutch to lock the freewheel, allowing
adjustment of the ignition T.D.C. by means of the propeller. Metric shank screws (M6) should be
used.
CAUTION
Remove locking pins in freewheel clutch after performing the compression test! Engine start with
screws installed may cause major damage to the propeller!
See »Maintenance Manual (Line Maintenance) for ROTAX Engine Type 914 Series«,
section 12-20-00, (Annex E).
CHAPTER-PAGE 7-17
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
AMENDMENT: 00
DATE: --
MAINTENANCE MANUAL STEMME S12
7.4.1.17
TEST RUN OF ENGINE
See »Maintenance Manual (Line Maintenance) for ROTAX Engine Type 914 Series«,
section 12-20-00, (Annex E).
7.4.1.18
INSPECTION OF ENGINE MOUNTINGS
• Check upper (rear) and front (lower) engine mounting frames for damages. Repair damage
to the paint and remove corrosion. If damages from chafing has occurred, determine and
eliminate the cause of chafing.
• Check parts of the frames near to the force transmitting fittings, especially the welding
seams, for cracks. Check screws for tight connection.
• Check condition of elastic elements (embrittlement).
See »Maintenance Manual (Line Maintenance) for ROTAX Engine Type 914 Series«,
section 12-20-00, (Annex E)
7.4.2
LUBRICATION SYSTEM
System Description : See section »3.4.2«
7.4.2.1
VISUAL AND LEAKAGE CHECK OF OIL SYSTEM
(Oil tank, oil cooler, oil lines.)
• Check oil tank, oil cooler and lines for leakage.
• Check suspension of oil tank and oil cooler for condition and tight fit.
• Check condition of flexible lubricant hoses especially close to clamps and tight attachment
of hoses to connections (observe section »5.2.1«).
• Check condition and tight fit of fire-wall penetration connections.
• Check routing of oil lines for clearance from hot parts, and for sufficient support of lines.
• Check condition, attachment and routing of drainage line from oil tank to rear lower fairing.
• Check condition of oil transfer lines to and from turbocharger, especially close to the collar
nut connections, and the line support to frame for tight attachment.
CAUTION
Check service life of lubricant hoses. Refer to section 4 »Airworthiness Limitations Section«.
See »Maintenance Manual (Line Maintenance) for ROTAX Engine Type 914 Series«,
section 12-20-00, (Annex E).
CHAPTER-PAGE 7-18
AMENDMENT: 00
DATE: --
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
MAINTENANCE MANUAL STEMME S12
7.4.2.2
OIL LEVEL CHECK
Oil specification
: See section 3.4.14.3
See »Maintenance Manual (Line Maintenance) for ROTAX Engine Type 914 Series«,
section 12-20-00, (Annex E).
CAUTION
If the engine is operated with AVGAS, do not use fully synthetic motor oil.
7.4.2.3
OIL CHANGE
Additionally to the procedure in the “Maintenance Manual (Line Maintenance) for ROTAX Engine
Type 914 Series”, fold up oil cooler (loosen lower camlocks) to drain old oil. In addition to the drain
screw of the oil tank remove one drain screw on the crankcase bottom side (rear plug screw) to
completely drain oil. Inspect both screws for metal particles or foreign matter. Clean screws, refit
and safety-wire screws before refilling with new oil.
Oil specification
: See section »3.4.14.3«
See also »Maintenance Manual (Line Maintenance) for ROTAX Engine Type 914 Series«,
section »12-20-00«, (Annex E) and »Operating Manual for ROTAX Engine Type 914 Series«.
CAUTION
If the engine is operated with AVGAS, do not use fully synthetic motor oil.
7.4.2.4
OIL FILTER - REPLACEMENT AND INSPECTION
See »Maintenance Manual (Line Maintenance) for ROTAX Engine Type 914 Series«,
section 12-20-00, (Annex E).
7.4.3
COOLING SYSTEM
System Description : See section »3.4.3«
7.4.3.1
VISUAL AND LEAKAGE CHECK OF THE SYSTEM
(Radiator, expansion reservoir, refill container, overflow container and coolant lines.)
• Check radiator, expansion reservoir, refill container and overflow container for condition,
attachment and leakage.
• Check condition and leakage of flexible coolant hoses, especially close to clamps and tight
attachment of hoses on connections (observe section »5.2.1«).
CHAPTER-PAGE 7-19
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
AMENDMENT: 00
DATE: --
MAINTENANCE MANUAL STEMME S12
• Check tight connections of flexible hoses and aluminum pipes.
• Check routing of lines for clearance from hot parts, and for sufficient support of tubes.
• Check condition, attachment and routing of drainage line from overflow container in
landing gear bay.
CAUTION
Check service life of coolant hoses. Refer to section 4 »Airworthiness Limitations Section«.
See also »Maintenance Manual (Line Maintenance) for ROTAX Engine Type 914 Series«,
section 12-20-00, (Annex E).
COOLANT LEVEL CHECK AND REPLENISHING
The coolant level in the overflow bottle must be between min. and max. marking. If the level is
below min. marking, refill completely the expansion tank on the upper LH firewall, then replenish
the overflow bottle to max. marking. After a short period of engine operation, check the level
again and repeat if necessary.
WARNING
Never open container cap when cooling system is hot. For safety’s sake, cover cap with a cloth
and open cap slowly. Sudden opening of the cap could provoke exit of boiling coolant and in
consequence, scalds.
Coolant specification
7.4.3.2
: See section »3.4.14.2«
FLUSHING OF COOLING SYSTEM
See »Maintenance Manual (Line Maintenance) for ROTAX Engine Type 914 Series«,
section 12-20-00, (Annex E).
7.4.3.3
COOLANT REPLACEMENT
Additionally to instructions of »Maintenance Manual (Line Maintenance) for ROTAX Engine Type
914 Series«: To drain the entire liquid cooling system, open the two valves installed in aluminum
tubes below the engine. To improve ventilation during refilling of new coolant, loosen bleed screw
on expansion reservoir on engine. Close screw after coolant replacement!
Coolant specification
: See section »3.4.14.2«
See »Maintenance Manual (Line Maintenance) for ROTAX Engine Type 914 Series«,
section 12-20-00, (Annex E) and »Operating Manual for ROTAX Engine Type 914 Series«.
CHAPTER-PAGE 7-20
AMENDMENT: 00
DATE: --
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
MAINTENANCE MANUAL STEMME S12
7.4.3.4
RAM AIR COOLING
• Check condition of composite distributor (plenum) on cylinder barrels
• Check tight fit, routing and condition of air hose from distributor to aluminum coupling
sheet.
• Check condition and attachment of the sheet to the fuselage steel frame and condition of
its rubber sealing to the RH cowling.
7.4.4
AIR INDUCTION SYSTEM
System Description : See section »3.4.4«
7.4.4.1
INTERCOOLER AND AIR BOX
• Check condition and tight fit of air hoses (observe section »5.2.1«) and routing between
turbocharger and air box.
• Check condition of inter cooler, tight fit of intercooler and condition of its suspension.
• Check tight fit of air box on the carburetors (clamps) and condition of connection tube.
• Check lower rubber support of air box on turbocharger suspension strut.
7.4.4.2
AIR FILTER
In addition to instructions in »Maintenance Manual (Line Maintenance) for ROTAX Engine Type
914 Series« check condition and tight fit of air hose assy. between turbocharger inlet and filter,
including composite sealing plate.
See »Maintenance Manual (Line Maintenance) for ROTAX Engine Type 914 Series«,
section 12-20-00, (Annex E).
7.4.5
EXHAUST SYSTEM
System description : See section »3.4.5«
7.4.5.1
TURBOCHARGER / MUFFLER MOUNTINGS
• Check tight fit of screw connections of the mounting struts, on engine housing and
turbocharger/muffler side, and tight fit of turbine-compressor and turbine-muffler screw
connections. Check tight fit of the clamp supporting the muffler.
• Check condition of struts (cracks, especially close to welding seams, corrosion, e.g. from
chafing).
• Check proper position of turbocharger unit (clearance of exhaust headers to fuselage steel
frame, especially cross-strut below engine).
CHAPTER-PAGE 7-21
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
AMENDMENT: 00
DATE: --
MAINTENANCE MANUAL STEMME S12
7.4.5.2
EXHAUST HEADERS
• Remove heat insulation tape. Visually check condition of headers (deformation and cracks,
especially connecting ends with spring supports and flanges).
• Check condition of screw connections on engine and manifold (Nuts M8, tightening torque
20 Nm / 14.7 lbf ft) with cold engine.
• Check condition of springs and proper overlapping of connecting ends of the exhaust bends
(min. 5 mm / 0.2 in).
• Check condition of support plate on lower engine mounting frame below engine, and tight
connection of header to the support plate.
• Re-assemble heat insulation tape.
7.4.5.3
HEAT INSULATION
CHECK OF HEAT INSULATION TAPE ON EXHAUST HEADERS
• Check condition of glass-fiber heat insulation tape on exhaust headers, especially close
to spring clamps. Renew if fiber tape is brittle (fibers fall off when touched), has holes or
is frayed.
• Check condition of spring clamps.
REPLACEMENT OF HEAT INSULATION TAPE
If required or at the latest after maximum 100 engine hours the heat insulation tape (type see
section »3.4.5«, available from STEMME) must be replaced:
• Remove spring clamps and insulation tape.
• Fix beginning of new tape by means of a suitable glue.
• Wind new tape round the exhaust header with an overlap of approx. 50% with some tension.
• Fasten tape ends by means of the spring clamps. The headers of Cyl. 1 and 2 have an
additional clamp midway along their length.
CHECK OF MUFFLER HEAT INSULATION
• Check condition of insulation cover and its fastening fittings.
• Check tight fit of springs and condition of securing wire to connect end wall insulation.
• Renew insulation if surface of cover is brittle or if fittings are loose (type see section »3.4.5«,
available from STEMME).
CHAPTER-PAGE 7-22
AMENDMENT: 00
DATE: --
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
MAINTENANCE MANUAL STEMME S12
REPLACEMENT OF MUFFLER HEAT INSULATION
• Remove upper heat protection steel sheet (M5 screw).
• Remove end wall insulation (cut off securing wire).
• Remove springs on muffler heat insulation.
• Remove muffler insulation to the rear.
• Re-assemble with new insulation in opposite order.
HEAT PROTECTION SHIELDS
• Check condition (cracks, deformation) of the heat protection shields (stainless steel).
• Check condition and tight fit of fastening elements (clamps, screws).
7.4.6
FUEL SYSTEM
System description : See section »3.4.6«
Fuels: See section »3.4.14.1«
FUEL LINES, GENERAL
The condition of the flexible fuel lines of the entire fuel system must be checked and the flexible
lines must be replaced if required according to section »4« and »5«.
WARNING
Fuel lines in the engine compartment must be inspected especially carefully, because leakage of
these lines under operating fuel pressure will probably result in fire.
CAUTION
Check service life of fuel hoses and check valves. Refer to section »4 Airworthiness Limitations
Section«.
QUICK RELEASE COUPLING
A quick release coupling is installed in the fuel supply line to allow for easy connection of wing and
fuselage fuel system during rigging. Keep the coupling clean, check for leakage, proper locking
and condition of rubber seal. Replace the coupling if condition is poor.
CHAPTER-PAGE 7-23
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
AMENDMENT: 00
DATE: --
MAINTENANCE MANUAL STEMME S12
7.4.6.1
FUEL SYSTEM IN THE WING
• Check condition of the steel supply lines at wing spar between the pump assemblies behind
the wing roots. Look for damage or chafing from rigging.
• Check the screw connections for tight fit without leakage.
• Check condition and function of quick release coupling.
• Check condition of vent line outlet assy. at each end rib of wing center section.
• Check condition of electrical connections of fuel pumps and quantity transmitters.
• Check connection of the fuel pumps in the wing through the opening in the lower wing
surface.
• To clean (or exchange) the filters the wing supply lines, loose clamps at flexible and then
loose the whole pump/drainer/filter package from it’s attachment (two M5 screws at the
lower edge of spar) and remove the package though the lower shell opening. Re-assemble
after the planned maintenance the package in reversed way.
CLEAN FINE FILTER OR RENEW IF REQUIRED
To clean (or exchange) the filters in the wing supply lines, loose clamps at flexible hose and then
loosen the whole pump/drain/filter package from its attachment (two M5 screws at the lower
edge of spar) and remove the package though the lower wing surface opening.
• Loosen clamps of fuel lines and remove filters in LH and RH wing.
• Install new filter using clamps of original. type (Spare parts available from STEMME.)
Re-assemble the package after the planned maintenance the package in reverse order.
REPLACEMENT OF FINE FILTERS (AT THE LATEST AFTER 200 ENGINE HOURS).
• Check fuel filler cap for leakage and proper locking. To check for leakage of wing tanks
look for signs of fuel leaking from drain holes of the wing center section or around the fuel
system maintenance opening.
CHAPTER-PAGE 7-24
AMENDMENT: 00
DATE: --
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
MAINTENANCE MANUAL STEMME S12
7.4.6.2
FUEL SYSTEM IN THE FUSELAGE
See also »Maintenance Manual (Line Maintenance) for ROTAX Engine Type 914 Series”,
section 12-20-00, subsection 2.3, (Annex E).
• Check condition and function of quick release coupling in the main supply line above the
feeder tank.
• Check condition, routing (sufficient support, clearance from moving components, kinks),
tight fit of clamp connections of the main supply line and supply/return line to/from engine.
• Check condition of the steel supply lines and the screw connection for tight fit without
leakage.
See also »Maintenance Manual (Line Maintenance) for ROTAX Engine Type 914 Series«,
section 12-20-00, (Annex E).
• Check fuel pump assy. in LH L/G bay for proper installation, condition and routing of lines
(kinks), for leakage of terminals and check valves and tight fit of clamps.
• Check condition of GFRP mounting, tight attachment of fuel pumps and condition of
electrical connections.
• Check that the drain is sealed properly.
FUNCTION CHECK OF FUEL PUMPS
Perform this function check with wings installed some fuel in both wing tanks, and feeder tank
partly drained (drain feeder tank until low fuel warning is ON):
• Switch master switch on, open and lock nose-cone, switch fuel selector switch to positions
“LEFT”, “BOTH” and “RIGHT”: Wing fuel pumps must operate corresponding to the switch
positions. Low Fuel Warning light must turn out finally.
• Main pump must operate.
• Switch auxiliary fuel pump switch on, auxiliary fuel pump must operate in addition to main
pump. Observe fuel pressure warning light.
• Check fuel shut-off valve and drain valve in LG bay for tight fit and function. After draining,
the drain must close without leakage. If the screw joint of the drain leaks, carefully tighten
the drain. If required, replace affected drain.
• Check for leakages at the feeder tank (Connections, switches, etc.).
• Check firewall penetration assembly of fuel lines for tight fit and for leakage. Check
clearance between air box and firewall penetration assy.
• Check condition and routing (clearance from moving components, kinks) of supply and
return lines inside the engine compartment. Check for tight fit of clamp connections at
firewall penetration and pressure regulator.
• Check condition, routing and tight fit of fuel lines from pressure regulator to both
carburetors, pressure connection hoses (air box, carburetors, pressure sensors) and compensating tube assy. at carburetors.
CHAPTER-PAGE 7-25
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
AMENDMENT: 00
DATE: --
MAINTENANCE MANUAL STEMME S12
See »Maintenance Manual (Line Maintenance) for ROTAX Engine Type 914 Series«,
section »12-20-00«, (Annex E).
• Check condition, attachment and routing (clearance from hot surfaces) of drain lines
from carburetor drip tray and airbox to outlets above lower cowl flap.
7.4.7
ENGINE CONTROLS / MONITORING
System description: See section »3.4.7«
ADJUSTMENT OF CARBURETORS
See »Maintenance Manual (Line Maintenance) for ROTAX Engine Type 914 Series«,
section 12-20-00, (Annex E).
CHECK OF THROTTLE ASSY.
• Check throttle lever in cockpit for condition, smooth operation and stops (115%, 100%, idle).
Adjust friction of throttle lever brake via knurled knob LH side of lever assy.
• Check condition of bowden-cable and spring on both carburetors. With throttle lever at
115%, spring on both carburetors must maintain slight tension.
• Check stop positions of 115% and idle via corresponding positions of both carburetor throttle
valve levers.
CHECK OF THROTTLE LEVER STOPS
• Adjust throttle lever to forward stop (end of gate): throttle valve lever on both carburetors
must reach 115% stop.
• Adjust throttle lever to aft idle stop: throttle valve lever on both carburetors must reach
screw stop for idle.
CHECK OF THROTTLE VALVE POSITIONS BY MEANS OF TCU COMMUNICATION PROGRAM
Perform this check by means of the TCU communication program. Usage is described »Maintenance Manual (Heavy Maintenance) for ROTAX Engine Types 912 and 914 Series«.
See »Maintenance Manual (Heavy Maintenance) for ROTAX Engine Types 912 and 914 Series«,
section 76-00.
CHECK OF CHOKE ASSY.
• Check condition and smooth operation of choke lever. Adjust friction of choke lever brake
via knurled knob RH side of lever assy.
• Check condition of bowden-cable and spring on both carburetors.
• Check reaching end stops of carburetor choke lever with forward and aft choke lever
positions in cockpit.
CHAPTER-PAGE 7-26
AMENDMENT: 00
DATE: --
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
MAINTENANCE MANUAL STEMME S12
CHECK OF TCU AND WASTEGATE SERVO
• Check condition, attachment and wiring of the TCU.
• Check pressure hoses (observe section »5.2.4«).
• Check condition of the wastegate servo assembly.
• Check condition of the bowden-cable driving the waste-gate.
CAUTION
It is most important to check condition and smooth operation of the bowden-cable actuating the
wastegate. Poor condition of the bowden-cable can result in uncontrolled wastegate positions
and engine malfunction in spite of intended function of the wastegate servo.
CHECK OF ENGINE INSTRUMENTS
Overview of Engine Monitoring Instruments: see equipment lists (section »9.1« and »9.3«).
Perform this check during engine test run, refer to section »7.4.1.17«.
• Check all engine instruments installed for intended function.
• Check tachometer indication by means of the TCU-Communication program.
Usage is described in »Maintenance Manual (Heavy Maintenance) for ROTAX Engine Types 912
and 914 Series«, section »76-00«.
CHECK OF ENGINE CONTROL AND INDICATION SENSORS
See »Maintenance Manual (Heavy Maintenance) for ROTAX Engine Types 912 and 914 Series«,
section »72-00-80«, in the first subsection each.
• Check condition, tight fit, leakage if applicable and wiring of sensor assemblies of TCU, oil
pressure, oil temperature, cylinder head coolant temperature, fuel pressure and fire warning.
CHECK OF IGNITION LOCK SHORTING CABLE ASSY.
• Check condition of shorting cables and connections on rear firewall lower LH side.
FUNCTIONAL CHECK OF IGNITION RETARDER MODULE
System Description: See section »3.7.13«
In addition to the periodic check (see section »5.4.13«) the Ignition Retarder Module must undergo
a functional check after a failure during engine start.
CHAPTER-PAGE 7-27
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
AMENDMENT: 00
DATE: --
MAINTENANCE MANUAL STEMME S12
To perform the following check, remove instrument panel cover. The module is mounted on the
electronics / CB plate on the RH side of the panel. Correct function can be examined by means
of two LED´s mounted on the circuit board, visible through an opening in the module housing.
• Disconnect the control line from the starter relay (located next to the main battery at the
foremost ring frame of the tail boom).
• Open and lock the nose-cone to switch the engine bus “ON”.
• Switch ignition/starter key switch to position “START” and hold in this position:
-- one red and one green LED must illuminate simultaneously,
-- after 3 seconds, the green LED must extinguish,
-- the red LED must remain illuminated as long as the key position “START” is hold.
• Unlock the nose-cone.
• If the check showed normal function, reconnect control line to starter relay.
• If the check revealed malfunction, check lines and connectors. If still defective, the module
must be exchanged.
WARNING
Never start the engine with a defective ignition retarder module.
7.4.8
FIRE PROTECTION
System Description: See section »3.4.8«
7.4.8.1
COWLING-FIRE PROTECTIVE PAINTING
• Check condition of the white fire protective painting. Repair if necessary. If signs of
excessive overheating are found or in case of doubt contact the manufacturer.
REPAIR OF THE FIRE PROTECTIVE PAINTING (OBSERVE MANUFACTURER INSTRUCTIONS)
• Completely polish off the damaged paint.
• Apply three coats of the fire protective paint.
Minimum coverage 300 g/m² / 0.06 lb/ft²
• Cover with one coat of clear varnish.
Specification of fire protective paint:
See section »3.4.8«
CHAPTER-PAGE 7-28
AMENDMENT: 00
DATE: --
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
MAINTENANCE MANUAL STEMME S12
7.4.8.2
FIRE PROTECTIVE SLEEVES
The fire protective sleeves must be checked for condition and complete cover of the fluid lines.
Check routing, especially for kinks in fire protective sleeves, which might obstruct fluid flow in
fluid lines covered.
7.4.8.3
FIREWALL
• Check condition (deformation, cracks) of firewall sheets, their connection to each other
and to the center steel frame.
• Check sheathing edges and renew if required. Look for chafing from firewall edges on
fuselage steel frame, cables, hoses etc.
• Check fastening of penetration fittings of oil lines.
7.4.9
COWLINGS
System Description: See section »3.4.9«
CAM LOCK FITTINGS, GENERAL
• Check condition, tight fit and function of camlock fasteners on upper center fuselage
fairing and engine cowlings.
• Check tight connection of camlock fittings in the composite structure of fairing/cowling
and counterparts in fuselage.
UPPER CENTRE FUSELAGE FAIRING
• Check condition and proper fit of the upper fuselage fairing.
• Check condition, function and tight attachment of oil service access door.
ENGINE COWLINGS
• Check condition and proper fit of the LH and RH and lower engine cowlings.
• Check condition of air ducts and proper fit to oil cooler, intercooler and radiator.
• Check fit and sealing to composite sealing plate of air induction and rubber seals on
coupling sheet of cylinder cooling air hose. Look for marks from chafing between ducts
and engine components or firewall.
CHAPTER-PAGE 7-29
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
AMENDMENT: 00
DATE: --
MAINTENANCE MANUAL STEMME S12
COWL FLAPS
• Check condition and fit of inlet and outlet cowl flaps. Grease hinge bolts of outlet cowl
flap (observe section »6.5«).
• Check cable lines and connections to flaps.
• Check function of inlet and outlet cowl flaps when operating nose-cone handle and cowl
flap reduction handle. Specially observe if flaps are fully opened by springs.
• Check fairing section aft of outlet cowl flap for condition, attachment and sealing to
fire-wall.
• Check if flaps close properly if nose-cone is closed.
• Check apertures of inlet cowl flaps corresponding to cowl flap handle positions “Open”
and “Closed” (5th notch) with nose-cone open and locked.
INLET COWL FLAP OPENINGS, MEASURED FROM LEADING EDGE OF FLAP TO COWLING:
Fully opened
Fully reduced opening (fifth notch)
7.4.10
120 ± 5 mm / 4.7 ± 0.2 in
30 ± 5 mm / 1.2 ± 0.2 in
PROPELLER
System description: See section »3.4.10«
The numerical positions in the following text refer to the propeller diagram (see figure »3.4.10.a«).
7.4.10.1
GENERAL
The complete propeller pitch control mechanism (including all mechanical and electrical components) is redundant and is able to operate each propeller blade separately. Both systems are coupled
to each other through a mechanical coupling ring and an electrical backup system. Hence, the
mechanism is fully redundant. In order to prevent incorrect assembly, all paired parts belonging
to the pitch change of the one propeller blade are marked with a red dot; those belonging to the
other blade remain unmarked.
Propeller pitch can be changed manually for inspection and maintenance purposes by swinging
the blades approx. 90 degrees outward, gripping the blades in the outer third of their length and
pushing them in the direction of flight (fine pitch) or against direction of flight (coarse pitch).
See also details in the S12 Aircraft Flight Manual, section »4 Daily Checks«.
Adjustment of the propeller or its electric system may only be performed by the manufacturer or
by qualified and authorized personnel. All results of an inspection of the adjustment or changes
in setting must be entered in a report according to Form »Propeller Adjustment Report« (Annex
D). The last valid report must be filed together with the Operational Documentation (Annex C).
Repair, overhaul and inspection of structural damage to the variable pitch propeller or to its
subsidiary assemblies after an operational interruption may only be performed by qualified and
authorized personnel.
CHAPTER-PAGE 7-30
AMENDMENT: 00
DATE: --
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
MAINTENANCE MANUAL STEMME S12
Balancing the variable pitch propeller or its assemblies may only be performed by the
manufacturer or by an authorized and licensed FBO according to the specific instructions and
using appropriate equipment.
Balancing weights have to be applied for static or dynamic balancing. Their arrangement must
be entered in the Rigging Report as laid down in the »Propeller Rigging Report« form (Annex D).
In the case of damage of one propeller blade only, a suitable exchange blade may possibly be
obtained from the manufacturer. The latest Report of Adjustment Settings must be transmitted
to the manufacturer and in this case, re-balancing may not be necessary.
7.4.10.2
ADJUSTMENT AND INSPECTION RESULTS, TOLERANCES
Changes in pitch angle
Settings, measurement taken at the propeller blade
mounting fork with reference to zero setting (this is
when the axis of the joint is parallel to the propeller
axis of rotation).
Initial tension of the contact spring for the take-off
position stop switch.
Duration of pitch change in each direction at an ambient
temperature of 15° - 25° C and battery voltage of
not less than 12 V under loaded conditions.
Unbalance: Permissible total static residual unbalance.
Permissible dynamic unbalance.
Permissible travel of the blade tips in the direction
of flight.
Track at propeller blade joint (difference between
both forks, measurement taken opposite the position ‘upper left gear mount’).
Track at propeller blade tips (difference between
both blades).
7.4.10.3
Δß = 6° 24’ ± 15’
Take-Off setting: -2° 30’± 5’
Cruise setting: +3° 54’± 10’
≈ 0.2 mm / 0.0079 in
(1/3 turn of the contact screw)
max. 3 Min.
200 g mm / 4.44 dr. in
see A17-10AP-V/2-E
4 mm / 0.16 in
0.3 mm / 0.12 in
3 mm / 0.12 in
VISUAL INSPECTION OF THE PROPELLER UNIT
• Check load bearing elements (hub and forks, blade suspension) for cracks, corrosion and
other damage.
• Check complete propeller assembly for loose components, loose bolt connections or other
apparent damage.
• Check condition of rubber stops within the blades and on hub for cracks.
• Check propeller blades for cracks or other damage, especially at blade tips, at bonding
seam and in the area of stop buffers. Repair leading edge protection tape if necessary (use
material supplied by the manufacturer only!).
CHAPTER-PAGE 7-31
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
AMENDMENT: 00
DATE: --
MAINTENANCE MANUAL STEMME S12
• Check propeller folding mechanism for ease of operation and restoring force.
• Check propeller blade ventilation and drain holes at the blade tips, clean if necessary.
If the ignition retarder module failed during engine start, the propeller must be checked for
damage. Special attention must be paid to the condition of the following items: blade side
rubber stops and surrounding blade structure, stop bolt in the blade suspension forks and the
blade retraction coupling levers.
7.4.10.4
REMOVAL OF THE PROPELLER UNIT
• Remove the nose-cone: remove left and right foot-well covers. Loosen clamp bolt at the
guide block of the nose-cone, pull out locking screw with nose-cone spring, pull off pitot/
static pressure lines, disconnect installed electrical wiring into the nose cone (XPDR antenna, sensor units,etc.), pull nose-cone off to the front.
• Unscrew the front cover of the variable pitch mechanism.
• Unscrew both sides of the electric covers (three M3 bolts).
• Disconnect the power supply to the electric element on both sides.
• Disconnect the drive pin (10) from the fork (4), (one M5 bolt, one M8 nut, one of the two
adjustment screws (25), the second adjustment screw remains secured to facilitate finding
the original position).
NOTICE
A counter-balancing weight washer may be attached to the inside of the fork by means of an M5
bolt. This washer must be re-installed at the same place on re-assembly.
• Loosen both bolts (M6 with secure washers) to separate the variable pitch mechanism from
the hub centerpiece (18). Remove the variable pitch mechanism to the front.
• Loosen the six M8 bolts (three bolts in each group secured with safety wire) connecting
propeller hub and propeller reduction gearbox. Remove the hub (with the propeller) to the
front.
CHAPTER-PAGE 7-32
AMENDMENT: 00
DATE: --
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
MAINTENANCE MANUAL STEMME S12
7.4.10.5
INSTALLATION OF THE PROPELLER UNIT
• Clean and degrease the propeller and the propeller gearbox flange with an appropriate
solvent. The torque is transmitted by friction fit, therefore, the surfaces must be even, clean
and free from grease.
• Inspect threaded bushings in the propeller gearbox flange for visible damage.
• Push carbon brushes fully into their supports and temporarily fix with adhesive tape
(or similar) to avoid damage to the brushes and their supports when the hub is fitted to
the gear flange.
• Tighten the M8 bolts securing the hub to the gear flange, using a torque wrench on
opposing pairs of bolts in two steps:
-- Step 1: Torque 10 Nm / 7.4 lbf ft
-- Step 2: Torque 30 Nm / 22.1 lbf ft
Secure groups of three bolts together using safety wire (diameter 0.8 mm / 0.03 in).
• Mount variable pitch mechanism to the hub centerpiece (18) and fasten with bolts
(two M6 bolts with locking washers). Pay attention to red marks.
• Release carbon brushes and check contact and appropriate pressure on the respective slip
rings.
• Bolt the drive pin (10) onto both sides of the fork (4). Attach M5 bolts first and then
screw on the M8 bolts loosely, then tighten the loose adjustment screw (25) and secure
with lock nut. Then tighten the M5 bolt and the M8 nut (using a torque wrench, torque
20 Nm / 14.7 lbf ft). Secure the adjustment screws with safety wire.
NOTICE
If necessary, bolt the counter- balancing weight washer back at the inside of the fork.
If both adjustment screws are loose at the beginning of this step, the propeller must be adjusted
again (see section »7.4.10.7 Checking of Pitch Control and Adjusting the Variable Pitch Propeller«).
• Connect the power supply to the electric element on both sides.
• Screw on both sides of the electric covers.
• Screw on the front cover of the variable pitch mechanism. Observe red marking (red point
must correspond to “red side” of the variable pitch propeller).
• Install nose-cone (reverse sequence of removal, do not forget locking).
• Check adjustment. If tolerances are not met, re-adjust propeller pitch (see section
»7.4.10.7 Checking of Pitch Control and Adjusting the Variable Pitch Propeller«).
CHAPTER-PAGE 7-33
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
AMENDMENT: 00
DATE: --
MAINTENANCE MANUAL STEMME S12
7.4.10.6
SPRING TENSION OF THE PROPELLER FOLDING MECHANISM
• Check the spring pre-load for each blade: after the propeller has been installed, turn it
until the leading edge of the (folded) lower propeller blade is in a horizontal position. The
static holding force (not the lift-off force) on the rubber catch in this position must be
1.7 N ± 0.1 N (approx. 30 mm / 1.18 in away from the tip of the propeller blade measured
with a spring balance or weight). Even after swinging out slightly it must return to the fully
folded position of its own accord. Move the propeller to the appropriate position before
repeating the measurement on the other propeller blade.
• Removal of the propeller blades (to renew the lubrication of the blade bearings, installation
in the reverse order):
NOTICE
Completely remove and reinstall the first blade before removing the second blade.
1. Unscrew the union nut of the hollow axle using a flat, size 30 nut wrench (approx. 4.5 mm
/ 0.18 in thick) while holding the hollow axle fast with a flat, size 22 nut wrench (approx.
4.5 mm / 0.18 in). Do NOT unscrew the castellated nut.
2. Twist the hollow axle (in an anti-clockwise direction) until the spring is no longer pre-loaded
(approx. 1½ turns) and press it out. Make sure the blade does not drop off when doing so
and then remove the blade from the fork (Warning: 2 thrust plates).
3. If necessary, dismantle the hollow axle (now undoing the castellated nut), clean, lubricate
and reassemble it.
4. Push out the inner ring of the blade bearing, remove and clean the needles, inspect them
for any damage, insert the 34 original needles with special grease in the outer ring, then
push the inner ring back in.
CAUTION
Under no circumstances must the needles and the inner rings of the two blade bearings be mixed
up. Should this nevertheless occur, send the entire (dismantled) propeller to the manufacturer
immediately. The needles and inner rings generally have different tolerances to cater for bearing
clearance.
• Setting the spring pre-load: the spring pre-load is generated by twisting the spiral torsion
spring (23), i.e. by twisting the pre-mounted hollow axle (3) against the fork (4).
• Renew the safety plate beforehand: remove the M4 locking screw for the safety plate
(beneath the union nut of the hollow axle), undo the union nut (see above: Dismantling
and …), renew the safety plate; screw the union nut tight again.
• Twist the hollow axle to achieve the required spring load. Drill a hole in the new safety
plate (diameter 4.3 mm / 0.17 in) so that the locking screw can be mounted in the required
position of the hollow axle (secure the locking screw by screwing it tight with a self-locking
nut and locking compound). Secure the union nut through the safety plate.
• Check the function (see above).
CHAPTER-PAGE 7-34
AMENDMENT: 00
DATE: --
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
MAINTENANCE MANUAL STEMME S12
7.4.10.7
CHECKING OF PITCH CONTROL AND ADJUSTING THE VARIABLE
PITCH PROPELLER
• The basic setting of the blade-angle is performed by the manufacturer or by a facility or
Field Base Operator (FBO) authorized by the manufacturer to perform major repairs on
the variable pitch propeller.
• The propeller unit must be positioned in the take-off setting. Check to confirm that the
pitch control mechanism is at the stop in the take-off setting by pressing the half opened
propeller blade to the rear (against the direction of flight), so that the expanding element
(15) is completely compressed. No significant further movement in the direction of fine
pitch should be possible.
• Check the propeller pitch angle for take-off with a precision protractor with a vernier or
digital scale. Turn the propeller to an approx. Vertical position, place the static arm of the
protractor to the lower left on the reduction gear base-plate, rotate the movable arm to an
approx. vertical position, then rotate the propeller clockwise until both fork cheeks are in
their operating position (see figure 3.4.10.c). Lock protractor and read off result. The setting
angle is -2° 30’ ± 5’. The acceptable difference in blade angle settings of both blades is 10’.
• Precision adjustment of the propeller pitch (e. g. to achieve correspondence between both
propeller blades) is accomplished by means of two adjustment screws (25). During adjustment, the drive lever is only set loosely (M5 screw and M8 nut are not fully tightened).
• Tighten the M5 bolt and the M8 nut. Tighten the adjustment screw and lock nut. Check
tightening torque of the M8 nut (20 Nm / 14.7 lbf) with a torque wrench. Re-check the
setting angle and secure adjustment screw with safety lock wire.
• Check the pitch control mechanism for ease of operation: swivel both blades out by 90
degrees° against the fork and then pull forward on the blades near the tip without using
too much force. The blades must be easily brought into cruise position and, after releasing
them, the spring tension must return the blades to the stop in the take-off position.
• Activate the pitch control mechanism (Master switch “ON”) by pressing the push button
at the front bulkhead for 3 to 4 minutes until the cruise position is reached (fly-weights
(19) are forced against the stop).
• Hold the push button (2nd person) and check the pitch angle of the propeller blades in the
cruise setting (the method corresponds to measuring the take-off setting). The rated value
is +3° 54’ ± 10’.
• Due to design, after successfully having adjusted the take-off setting, the cruise setting
must be within the permissible limits. If this cannot be achieved, damage or excessive
wear may be presumed. In this case, repair must be performed by the manufacturer or by
a facility or an FBO authorized by the manufacturer.
CHAPTER-PAGE 7-35
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
AMENDMENT: 00
DATE: --
MAINTENANCE MANUAL STEMME S12
7.4.10.8
GENERAL ASPECTS OF THE ELECTRICAL CIRCUIT
An expansion element is supplied with an electric power of 50 W through a heating resistor. The
supply period is determined mechanically by an adjustable end contact. Overheating is prevented
by an NTC resistor in connection with an electronic control circuit.
Components with a larger power consumption such as landing lights cannot be turned on in the
cruise setting.
Possible radio disruption caused by the slip ring contact is prevented by suppression capacitors.
The generator circuit is provided with radio disturbance suppression. In the case of excessive radio
disturbance, the carbon brushes and the slip rings should be cleaned with alcohol and checked
for damage.
Carbon brushes worn so that less than 10 mm / 0.39 in. of length remains within the brush holder
should be replaced (Use only parts supplied by the manufacturer). Remove abrasion dust from
slip rings with alcohol.
The function of the electrical variable pitch propeller can be checked while the engine is shut down
pushing the test button at the front bulkhead. The master switch must be on.
7.4.10.9
ADJUSTMENT OF THE ELECTRICAL SWITCH FOR THE
TAKE-OFF SETTING INDICATOR AND STOP SWITCH
Remove the lid of the adjusting unit and both lids of the electronic module.
Adjustment of the cruise setting stop switch: The contact screws at both rocker arms should be
adjusted in a way to ensure light pressure (0.2 mm / 0.008 in) against the stop switch in the closed
position. To achieve this, the propeller should be put in the cruise setting with the push button.
Maintaining this setting, the contact bolts should be adjusted so that the contact screw just is
in contact with the contact plate (use an ohmmeter and check several times). Finally, secure
contact screw.
Adjusting the take-off setting switch: allow the elements to cool down and check that the pitch
change mechanism is at the stop in the take-off setting by pressing the half opened propeller
blade to the rear, completely compressing the expansion element (15). The contact bolt protruding approx. 35 mm / 1.38 in out of the switch socket should be adjusted so that there is only light
contact between the flat lower surface of the bolt head and the contact spring (14), fitted at
the rocker arm (check with ohmmeter or with the take-off setting indicator in the cockpit). Then
rotate the bolt 1/3 of a revolution (0.2 mm / 0.008 in) further in (in the direction of the contact),
secure with lock nut and secure with sealing paint.
Check of the take-off setting indicator: the take-off setting indicator in the cockpit must illuminate
when the propeller is in the take-off setting. If the propeller is moved by hand in the direction of
the cruise setting (pressure should be applied near the tip of the half unfolded propeller blade,
pulling the blade forward), the take-off setting indicator must extinguish within a small change
in angle.
CHAPTER-PAGE 7-36
AMENDMENT: 00
DATE: --
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
MAINTENANCE MANUAL STEMME S12
7.4.10.10
DYNAMIC BALANCING
After repairing or replacing parts or carrying out maintenance on the propeller, which put the
dynamic balancing at risk (e.g. replacing or repairing the propeller blades, replacing the propeller
forks, replacing the blade coupling parts), the propeller must be dynamically balanced, as laid
down in Manufacturer’s Instruction A17-10AP-V/2-E (see Annex A).
The dynamic balancing must be recorded in Annex C of the S12 Maintenance Manual.
7.4.11
DRIVE SHAFT SYSTEM
System description: See section »3.4.11«
CHECK OF FREEWHEEL CLUTCH
Rotate propeller
• Check smooth rotation in normal running direction and heavy friction in opposite direction.
• Check tight fit of screw connections of freewheel clutch on engine flange.
CAUTION
Prior to function check, remove locking screw in freewheel clutch if installed for assembly or
disassembly of drive shaft unit.
CHECK OF DRIVE SHAFT
For inspection of the drive shaft remove propeller gear and drive shaft assy.
• Check condition of composite shaft (e. g. chafing, cracks) and steel ends (e. g. corrosion,
wear, abrasion of surface treatment).
• Check connection between composite shaft and steel ends.
CHECK OF CARDANIC RUBBER DISC JOINTS
• Check condition (cracks and embrittlement of rubber) and tight screw connections of
cardanic rubber disc joints on freewheel clutch and on forward drive shaft. To inspect
rubber discs for cracks and embrittlement, apply a torsional load on the discs and observe
rubber surface.
CHAPTER-PAGE 7-37
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
AMENDMENT: 00
DATE: --
MAINTENANCE MANUAL STEMME S12
REMOVAL OF DRIVE SHAFT
The propeller shaft can be removed together with propeller reduction gearbox and the propeller
in one step:
• Remove the nose-cone: Lift off left and right leg room coverings in the cockpit, loosen
clamping screw at the guide block of the nose-cone, pull out locking screw with nose-cone
spring, disconnect flexible hoses, disconnect the antenna connection to transponder/GPS,
withdraw the nose-cone to the front.
• Remove cover of gearbox, fastened by tape and spring.
• Disconnect the control cable of the propeller brake at the connector.
• Disconnect the electrical connection (carbon brush)
• Loosen fastening screws on the front gear supports (shock mounts); loosen balancing
spring on top of the propeller gearbox.
• Pull out propeller gearbox with propeller shaft.
• Disconnect the drive shaft on the gear (3x M10).
CAUTION
The free wheel clutch remains on the engine. Removal by loosening of the attachment screws on
the engine flange.
INSTALLATION OF DRIVE SHAFT
Removal sequence in reverse order. For tightening torques observe section »6.8«. Ensure bolts/
screw locked with Loctite 243.
CAUTION
Clean the splines and check the condition of the surface coating. No signs of corrosion should
be detectable in and around the splines, and the color of the tooth profiles should be the same
(see section »6.5.1«).
7.4.12
PROPELLER GEARBOX, MOUNTING AND SUPPORT
System Description: See section »3.4.12«
CHECK OF PROPELLER GEAR ASSY.
With front gear installed
• Check noise and internal backlash of propeller reduction gearbox by rotating propeller
unit clock- and counter clock- wise. Some (minor) backlash is allowable, in case of doubt
contact manufacturer.
• Check propeller gearbox visually for condition and leakage.
CHAPTER-PAGE 7-38
AMENDMENT: 00
DATE: --
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
MAINTENANCE MANUAL STEMME S12
• Check tight fit of propeller gearbox assy. in four rubber shock mounts on front fuselage
frame.
• Check weight balancing spring on propeller gearbox and its safety wire.
• Check connection of propeller brake control cable through hole in front fuselage frame.
• Check condition (composite structure, fastening spring assy.) and tight fit of lower
propeller gearbox fairing.
• Check quantity of oil to be between min. and max. markings of the inspection glass, with
the tail cone supported so that its axis is horizontal (approximate flight attitude). The
propeller gearbox should use only a minimum of oil, so normally refilling is not required
before scheduled oil change. Nevertheless some oil on the gear housing due to minor oil
vapor leakage through the shaft seals is normal.
With propeller gearbox removed
• Check condition of propeller gearbox housing.
• Check the propeller gearbox for leakage, especially the screwing of both halves of the gear
housing and the shaft sealings.
• Check condition of the milled aluminum suspension (cracks) and its connection to the
propeller gearbox.
• Check condition and tight fit of the shock mount assemblies on the front fuselage frame.
Especially check shock mount assemblies for tight bonding between rubber discs and milled
suspension rings. In case of poor condition (cracks in milled suspension, rubber discs brittle
or loose) renew shock mounts.
• Check composite structure of front fuselage frame close to the shock mounts for signs of
overload.
CHECK OF MAGNET SCREW
Remove magnetic screw from the lower right front wall of the gear housing and inspect screw for
possibly collected chips. In case of significant amount of chips on the screw and in case of doubt
contact the STEMME Service.
PROPELLER GEARBOX OIL CHANGE
To change oil completely suck out used oil by means of a flexible bottle or syringe with tube
via thread opening of magnetic screw. Refill new oil through same opening to max marking of
inspection glass, again with the tail cone supported in flight attitude. Secure magnetic screw
with safety-wire.
Oil specification:
See section »3.4.14«
CHAPTER-PAGE 7-39
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
AMENDMENT: 00
DATE: --
MAINTENANCE MANUAL STEMME S12
7.4.13
PROPELLER OPERATION
System Description: See section »3.4.13«
NOSE-CONE OPERATION
• Check condition and proper installation of components. Check smooth operation of
nose-cone handle. If required, clean nose-cone sliding guide with alcohol.
NOTICE
Never grease nose-cone PTFE sliding guide!
PROPELLER POSITIONING
• Check condition and proper installation of components. Operate propeller positioning
several times from different starting points.
• Check smooth operation and proper alignment of propeller in its end position.
• Check spring retraction of the T-handle and locking clip of the handle (observe section
»6.5 Lubrication«).
PROPELLER BRAKE
• Check condition and proper installation of components.
• Check smooth function of propeller brake handle and test brake function during
simultaneous rotation of propeller with propeller positioning.
• Check spring retraction of the T-handle and locking clip of the handle (observe section
»6.5 Lubrication«).
• Check thickness of brake lining.
Minimum Thickness of the Propeller Brake lining:
1.5 mm / 0.06 in
CHAPTER-PAGE 7-40
AMENDMENT: 00
DATE: --
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
MAINTENANCE MANUAL STEMME S12
7.5
LANDING GEAR
7.5.1
MAIN LANDING GEAR
Description: Adjustment data:
Lubrication:
7.5.1.1
See section »3.5.1«
See figure »3.5.1.a«
See section »6.5«
GENERAL
LANDING GEAR ASSY.
• Check condition of landing gear legs and trailing links (cracks in paint indicate overloads;
especially inspect areas of welding seams).
• Check condition and tight connections of over-center struts and jackscrew linear actuators
(especially upper swivel joint connection of actuators and fuselage frame).
• Check proper function of trailing link springs assy. by moving wing tips up and down. Move
and rotate wheel to check friction and backlash of wheel bearings (observe section »6.5«).
WHEEL DOOR ASSY.
• Check condition of composite structure of wheel doors, in particular for delaminations at
the hinges.
• Disconnect the joints of the actuation mechanism of the doors and check free movement
of doors.
• Clean and grease hinges of L/G doors if required (observe section »6.5«). Reconnect joints
(spring-securing at RH ball joint!).
• Check condition and function of spring linkage of the RH door.
• Check cable mechanism of the LH door for condition and proper installation of cables,
springs, pulleys and pulley guides and roller strut. With the gear extended, the closing
cable must have a minimum pre-load, barely free from slack. If required, adjust the
pre-load compression pressure spring of the closing cable.
• Check clearance between tires and doors to be at least 10 mm / 0.4 in. Adjust the RH door
at the ball joint and the LH door at the roller of the roller strut if required.
WHEEL BRAKES
• Check condition of brake assembly in forward fuselage and in landing gear bay (proper
routing, chafing and leakage of brake master cylinder, wheel cylinders, brake fluid lines
and thread fittings).
• Check condition of brake discs (wear, scratches, cracks) and brake pads.
Minimum brake lining thickness:
1.5 mm / 0.06 in
CHAPTER-PAGE 7-41
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
AMENDMENT: 00
DATE: --
MAINTENANCE MANUAL STEMME S12
BRAKE FLUID
To check brake fluid level, remove the top of the brake cylinder. If required refill through the bleed
valves on the brake calipers (refer to »7.5.1.5«).
WARNING
A rapid reduction of the brake fluid level indicates leakage of the system and must be investigated
and eliminated before the aircraft returns to service.
• Check brake efficiency prior of return to service.
• Change brake fluid every scheduled inspection 100h airframe (200 engine hours) at the
latest after 2 years (refer to »7.5.1.5«).
SPECIFICATION OF BRAKE FLUID: DOT 4
7.5.1.2
FUNCTIONAL TEST OF THE RETRACTABLE LANDING GEAR
Support the aircraft (clearance between the main wheels and the ground must be approximately
0.1 m / 3.9 in), remove upper cowling of the center fuselage.
CHECKING PROCEDURE:
• Inspect screw joints (torque paint).
• Check wheels for smooth turning.
• Joint heads of the over-center struts should not be jammed.
• The articulations of the spindles and the over-center strut must have play.
• Installation of the landing gear emergency release system without kinks/interference.
• Landing gear stop switches on the over-center struts: check for halfway position and proper
functioning, inspect wiring / connection.
• Retraction of left landing gear leg:
-- Check if the landing gear contacts surrounding components.
-- Brake hose must have regular bends, must not jam.
-- Check of stop switch adjustment: 2 – 5 mm / 0.08 to 0.2 in clearance between the landing
gear leg and the shaft housing.
-- The stop switch must be positioned in the middle of the landing gear strut.
-- Joint heads of the over-center strut must not be jammed.
-- Articulation between the spindle and the over-center strut must not jam.
• Extension of left landing gear leg: Check if over-center strut returns to its correct
over-center-locked position, if necessary adjust the switch.
CHAPTER-PAGE 7-42
AMENDMENT: 00
DATE: --
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
MAINTENANCE MANUAL STEMME S12
• Retraction of right landing gear leg:(independent from the left leg - for this purpose,first
actuate left stop switch »retracted«, then disconnect the arm linking the operating cable to
the left LG door - take care that the cable and arm do not jam as the right leg is retracted).
-- Check if the leg contacts surrounding components.
-- Brake hose must have regular bends, must not jam.
-- The stop switch must contact the center of the landing gear tube.
-- Joint heads of the operating over-center strut must not be jammed.
-- Articulation between the spindle and the operating over-center strut must not jam.
• Extension of right landing gear leg:
-- Check for correctly over-center-locked position of the operating elbow lever
• Retraction of both landing gear legs:
-- Interference check.
-- Align stop switch on the right landing gear leg for a clearance of 2 – 3 mm / 0.08 to 0.12 in
between both gear legs.
• Check of landing gear doors (first connect left LG door):
-- Smooth operation of gear doors.
-- Fit of gear doors.
-- Positive clearance between gear doors and wheels.
• Retract landing gear with the upper cowling of the center fuselage installed:
-- Check clearance between the drive spindles and the cowling.
-- The bowden cables of the emergency release system must not be buckled or get stuck
• Test of complete system: retract and extend the landing gear three times with intermediate
checks each time:
-- Inspect supports of switches.
-- Inspect switches (attachment), damage.
-- Listen to spindle motor noise.
-- If necessary, adjust brake bands.
-- Inspect for chafed spots on the brake hoses.
-- Check for stress-strain loads acting on the wiring.
-- Check position indication (LED’s on instrument panel: two greens when extended, red
flashing during operation, off when fully retracted) and acoustic warning (if L/G not fully
extended and air brake lever in rear, unlocked positions).
CHAPTER-PAGE 7-43
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
AMENDMENT: 00
DATE: --
MAINTENANCE MANUAL STEMME S12
7.5.1.3
FUNCTIONAL CHECK OF EMERGENCY UNDERCARRIAGE EXTENSION
• Support the aircraft and landing gear up.
• Landing gear switch “NEUTRAL”.
• Actuate the EMERGENCY-UNDERCARRIAGE handles (in sequence 1-2). Actuating force is
100 - 200 N / 22.5 to 45 lbf. The landing gear legs must remain in the extended position
(function of spring clips on the over-center struts).
• Re-connection of the over-center strut joints to the spindles: landing gear switch »DOWN«,
move the spindles by means of the stop switches on the over-center struts, until their
relative position to the articulations is correct.
• Install latch lever and shift it into the operating position, introduce release elbow lever,
lock with spring element. After that perform a functional check: retract and extend the
landing gear once.
Figure 7.5.1.a
Emergency Release Mechanism
CHAPTER-PAGE 7-44
AMENDMENT: 00
DATE: --
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
MAINTENANCE MANUAL STEMME S12
7.5.1.4
TIRES, CONDITION AND INFLATION PRESSURE
The tires must be replaced at the latest, if the treads are worn thin. Pay attention to the slip marks
rim/tire. Apply Loctite (metal glue) to the attachment screws on the wheel axles.
NOTICE
The left wheel attachment bolt has a left hand thread.
INFLATION PRESSURE
2.6 ± 0.1 bar / 37.7 ± 1.5 psi.
7.5.1.5
ADJUSTMENT AND BLEEDING OF THE WHEEL BRAKE SYSTEM
HYDRAULIC BRAKE SYSTEM (TOST BRAKE SYSTEM)
Replenishing and bleeding the hydraulic Brake System (bleed with brake fluid DOT 4)
• Install transparent flexible hose and drain bottle at the three bleed ports of the parking
brake valve and at the left and right brake caliper.
• Open the bleed valve of the parking brake valve.
• Replenish brake fluid by plastic injection nozzle to the brake fluid reservoir in landing gear
bay (use sealed adapter) until the brake fluid passing through the transparent flexible hose
at the parking brake valve is free of bubbles. If required dismount RH brake lever and tilt
gently back and forth while holding brake lever upside down.
• Close bleed valve at the parking brake valve.
• Open bleed valve at the LH brake caliper.
• While continually adding brake fluid to the brake fluid reservoir by using the refill-adapter
(Stemme P/N: 00FO-B17) as required; pump the brake fluid through the hydraulic brake
system by operation of the RH brake lever until the brake fluid passing through the transparent flexible hose at the bleed valve of the LH brake caliper is free of bubbles. If required
dismount LH brake lever and tilt gently back and forth while holding brake lever upside down.
• Close bleed valve at the LH brake caliper.
• Open bleed valve at the RH brake caliper.
• While continually adding brake fluid to the brake fluid reservoir as required, pump the
brake fluid through the hydraulic brake system by operation of the RH brake lever until
the brake fluid passing through the transparent flexible hose at the bleed valve of the RH
brake caliper is free of bubbles.
• Close bleed valve at the RH brake caliper.
• Operate LH and RH brake lever to check.
=>Firm back pressure must be felt. while operating.
Otherwise repeat entire bleeding procedure!
• Reinstall brake levers (if applicable).
CHAPTER-PAGE 7-45
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
AMENDMENT: 00
DATE: --
MAINTENANCE MANUAL STEMME S12
• Remove transparent flexible hose and check final brake fluid level at brake fluid reservoir.
• Perform functional check of brake system in accordance with pre-flight check, described
in the S12 Aircraft Flight Manual, chapter »4«.
7.5.1.6
REPLACEMENT OF BRAKE LINING
The linings must be replaced at the latest shortly before the attachment rivets are exposed.
The wheel brake calipers are provided with brake pads on both sides of the brake disc.
For replacement of the brake pads, the brake calipers can be removed by undoing both 1/4” bolts.
CAUTION
Do not actuate the brake at this time, as this could force the brake pistons out of the calipers. It is
recommended to temporarily insert suitable blocks (wood or similar) into the calipers to prevent
this in case of inadvertent brake actuation.
The pads with the riveted brake lining can now be replaced by new ones.
7.5.1.7
REMOVAL AND INSTALLATION OF LANDING GEAR LEGS
• Loosen all attachments to the frame.
• Remove locking screws in front of the main bearings.
• Push the bearing bolts out to the front and to the rear, respectively.
Installation is carried out in the reverse order.
7.5.2
TAIL WHEEL
Description: See section »3.5.2«
Lubrication: See section »6.5»
• Support tail cone to check tail wheel. Fully deflect rudder pedals left and right and check
clearance between wheel and fuselage structure (and additional fairing, if applicable) and
ease of operation.
• Check condition of fork (cracks, corrosion, deformation).
• Check condition of tire and observe the slip mark. The tire wears down within a relatively
short time, since during maneuvering on the ground, the high inertia moment of the wing
span of 25.07 m / 82.25 ft. counteracts the steering force.
INFLATION PRESSURE OF TAIL WHEEL TIRES
2.8 ± 0.2 bar / 41 ± 3 psi
CHAPTER-PAGE 7-46
AMENDMENT: 00
DATE: --
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
MAINTENANCE MANUAL STEMME S12
• Check friction damping of tail wheel: If pushed to its upper stops (under load) the fork
must show a heavy friction against turning.
• Check smooth steering of the fork if hanging free.
• Check axial and radial backlash of fork in its bearings (no diametrical backlash or tilting
due to worn out upper bearing, sufficient clearance for rudder control when tail is lifted).
Grease lower axial bearing if required (observe section »6.5«).
NOTICE
Never grease upper axial bearing of the tail wheel! The friction under load is required to prevent
tail wheel shimmy.
• Check condition of steering assembly coupled to rudder (springs, rods).
• Check rods and springs for safe connection, especially when spring tension is relieved, by
deflecting rudder to its stops.
7.6
FLIGHT CONTROL INSTRUMENTS AND PITOT AND STATIC PRESSURE SYSTEM
Description: See section »3.6«
Perform maintenance of the flight instruments according to instructions given by the
manufacturer concerned. (Manufacturer documents see Annex A).
NOTICE
If equipment is changed, the instructions in section »3.8« and »9« must be observed.
CHAPTER-PAGE 7-47
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
AMENDMENT: 00
DATE: --
MAINTENANCE MANUAL STEMME S12
7.6.1
CALIBRATION OF STALL WARNING SYSTEM (OPTIONAL)
IN-FLIGHT CALIBRATION
• Fly with a center of gravity position in the rear range with a total weight of 900 kg / 1985 lb.
• Configuration for the calibration: Wing flap position 0°, landing gear and air brakes
retracted, throttle 0%, propeller pitch T/O, wings level, not above 1000 m / 3300 ft MSL.
Maintain a speed of 87 km/h / 47 kt.
• Turn adjustment screw until the acoustic warning is actuated.
• Check several times.
SECOND CHECK CONFIGURATION
• Change wing flap position to L and throttle to IDLE°, the warning must operate at
80 km/h ± 3 km/h / 43 ± 1.5 kt
7.6.2
MAINTENANCE ON THE STATIC PRESSURE SYSTEM
See figure »3.6.a«
INSPECT AND CLEAN THE PRESSURE PORTS
Removable probe on the nose-cone (three ports: Static pressure, dynamic pressure, and TE-pressure)
and the opening in the nose-cone for the stall warning positioned below the removable probe.
• Check pressure system for proper condition of air hoses and hose connections to instruments, to pressure ports and to each other.
• The flexible hoses and the filters/water separators must be replaced in case of contamination, embrittlement or cracks.
• If moisture has accumulated in the hoses, they must be removed and can be reused after
they have been dried completely.
CHAPTER-PAGE 7-48
AMENDMENT: 00
DATE: --
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
MAINTENANCE MANUAL STEMME S12
7.7
ELECTRICAL SYSTEM
Description: See section »3.7« and »Maintenance Manual (Line Maintenance) for
ROTAX Engine Type 914 Series« (Annex E).
7.7.1
GENERAL
• Check wiring of entire electric system (observe section »5.2.4«). Specially check
cable routing for sufficient supports, for chafing in the area of penetrations of cable
(e. g. firewall) and for signs of overheating.
• Check condition of CB’s, replace if required.
• Check any electrical device and all switches for proper installation, tight fit and proper
cable connections.
• Check electrical switches in the cockpit for intended function. Perform this check during
an engine test run, refer to section »7.4.1.17«.
REGULATOR VOLTAGE
Average:
Maximum:
13.75 V
14.20 V
The values indicated are valid for the engine bus with internal generator and main bus with external, belt driven, alternator.
7.7.2
BATTERIES
• Check condition of avionic battery (housing, contacts, state of charge) and starter battery.
• Check mounting assy. of main battery in forward tail cone.
Voltage drop of a charged main battery
as new at approximately 15° C during starter operation:
2V
For maintenance on the batteries, please refer to the Manufacturer’s Instructions (Annex A).
WARNING
If battery energy is not required for test purposes during any maintenance on the electrical system,
the negative connection to the battery should be disconnected.
To remove the battery, disconnect the negative cable first. To install the battery, connect the
positive cable first, then connect the negative.
The engine must never be started from the auxiliary, external electrical power receptacle
(if installed) without the battery installed.
CHAPTER-PAGE 7-49
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
AMENDMENT: 00
DATE: --
MAINTENANCE MANUAL STEMME S12
7.7.3
GROUNDING
• Check condition of cables and connections and tight fit of main grounding cable: Battery
to engine suspension frame and grounding cable on LH engine suspension shock mount.
• Check condition of cables and connections and tight fit of grounding cables on fuel pumps.
7.7.4
E-BOXES
• Check condition of electric distribution box assy. on rear fuselage steel frame.
• Check tight fit of connections, tight fit of auxiliaries (capacitor, regulator) and fuses.
• Open E-boxes and check cables, connections and components for damage, fastening,
foreign objects and moisture.
CHAPTER-PAGE 7-50
AMENDMENT: 00
DATE: --
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
MAINTENANCE MANUAL STEMME S12
7.8
COMMUNICATION AND NAVIGATION EQUIPMENT
Description: See section »3.8«
During inspection and scheduled maintenance the following points must be observed:
• Check, if COM- and NAV-equipment installed correspond to the equipment lists.
• Check for correct installation and tight attachment.
• Check condition, function and - if applicable - records of operating times of the COM- and
NAV-equipment.
• Check any antenna installed for condition, intended function and tight attachment.
Maintenance, inspection and adjustment of equipment installed according to the equipment
list are performed according to instructions of the equipment manufacturers (see documents in
Annex A).
NOTICE
If equipment is changed, the instructions in section »3.8« and »9« must be observed.
Equipment listed in chapter »9« can be installed without prior additional certification.
Only these devices have been approved and faultless operation with respect to certification
requirements has been verified by the type certificate holder.
In countries outside of the European Union, the equipment can be installed and operated only if
it is certified also in the country in where the aircraft is registered.
If equipment will be installed which is not listed in the S12 Maintenance Manual, prior to the installation compliance with the relevant airworthiness requirements must be shown to the responsible
aviation authority (i.e. »Modification to the Individual Aircraft« or »Major Modification«).
Upon changing of equipment and prior to Release to Service, the equipment list and, if relevant,
the weight and balance report needs to be updated.
7.9
OPTIONAL - OXYGEN EQUIPMENT
Description: See section »3.9«
OXYGEN SYSTEM MOUNTING
• Check the oxygen system mounting, if installed as optional equipment, for condition and
tight fit of components.
OXYGEN SYSTEM
Perform maintenance on the oxygen system in accordance with the instructions of the
manufacturer (see Annex A).
CHAPTER-PAGE 7-51
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
AMENDMENT: 00
DATE: --
MAINTENANCE MANUAL STEMME S12
THIS PAGE IS INTENTIONALLY LEFT BLANK
CHAPTER-PAGE 7-52
AMENDMENT: 00
DATE: --
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
MAINTENANCE MANUAL STEMME S12
8.
LIST OF PLACARDS AND THEIR POSITIONS
This section shows placards and their location.
NOTICE
The size of the depicted placards may deviate from the original size. The detailed and complete
set of placards is available under part number »121990« and »121991«.
NOTICE
The units of limitations shown in the following placards must be adapted depending on the installed instrumentation and nationality. The values shown in chapter »2« of the S12 AFM apply.
Affected placards are marked with *.
8.1
PLACARDS IN THE COCKPIT, FRONT
PLACARD
LOCATION/REMARKS
a) Descriptions / Displays:
On the left side of the shaft tunnel*.
The placard is illustrated in reduced scale.
CHAPTER-PAGE 8-1
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
AMENDMENT: 00
DATE: --
MAINTENANCE MANUAL STEMME S12
PLACARD
LOCATION/REMARKS
On the instrument panel next to the trim
indication display.
On top of the shaft tunnel cover between
gas and chock lever.
(Nationality and registration)
On the instrument panel.
Next to the fuel diff. pressure indication
display.
On the flap of the front storage compartment in center tunnel cover*.
Near the fuel flow instrument (if option is
installed).
On the flap indication wheel at the
forward shaft tunnel cover.
The placard is illustrated in reduced scale.
CHAPTER-PAGE 8-2
AMENDMENT: 00
DATE: --
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
MAINTENANCE MANUAL STEMME S12
PLACARD
LOCATION/REMARKS
Next to the flap lever of the pilot and
copilot seat.
The placard is illustrated in reduced scale.
PLACARD
a) Handles:
LOCATION/REMARKS
Next to the canopy jettison knob in the
lower center part of the instrument panel.
Below the MLG-switch in the lower center
part of the instrument panel.
Canopy jettison symbol.
On the top of the canopy jettison knob.
On the head of the cowl flap operation
knob.
On the center instrument panel support
below the propeller brake and the position
handles.
On the top of the nose-cone lever.
On the top of the propeller brake handle.
On the top of the propeller position handle.
CHAPTER-PAGE 8-3
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
AMENDMENT: 00
DATE: --
MAINTENANCE MANUAL STEMME S12
PLACARD
LOCATION/REMARKS
On the right side of the shaft tunnel
cover near the copilot air brake lever and
on the left cockpit side wall near the pilot
air brake lever.
On the top of the pedal adjustment knob
for the pilot and the copilot seat.
On the center instrument panel support
next to the venting knob for the canopy.
Next to the parking brake knob on the
pilots seat between the pilots legs.
Right of the parking brake knob on the
pilots seat between the pilots legs (90°
position).
Above the parking brake knob on the pilots
seat between the pilots legs (0° position).
Next to the cold air supply nozzles left and
right on the instrument panel.
Canopy frame next to the locking levers;
location corresponding to function.
PLACARD
c) Switches:
LOCATION/REMARKS
Next to the auxiliary fuel pump switch in
the lower center part of the instrument
panel.
Next to the master switch in lower center
part of the instrument panel.
Next to the selector switch for the voltage
and the ampere indication in the instrument panel.
Next to the TCU emergency knob at the
instrument panel.
Above the fuel tank selector switch in the
lower center part of the instrument
panel*.
CHAPTER-PAGE 8-4
AMENDMENT: 00
DATE: --
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
MAINTENANCE MANUAL STEMME S12
PLACARD
LOCATION/REMARKS
Below the fuel tank selector switch in the
lower center part of the instrument panel.
Next to the selector switch for the
microphone / headset.
On the top of the pilots control sticks
around the trim operation switch.
Below the MLG-switch in the lower center
part of the instrument panel.
Label for every additional switch, naming so
that the function of the switch is clearly
comprehensible by the crew.
PLACARD
d) Fuses / Circuit breakers:
Label for every additional fuse, naming so
that the function of the fuse is clearly comprehensible by the crew.
PLACARD
e) Warn and Caution Lights:
Next to the corresponding switch.
LOCATION/REMARKS
Next to the landing gear circuit breaker
in the lower center part of the instrument
panel.
Next to the corresponding fuse.
LOCATION/REMARKS
Next to the landing gear indication lights.
Next to the indication light of the auxiliary
fuel pump.
The placard is illustrated in reduced scale.
Next to the corresponding indication light.
Next to the propeller pitch control
indication light.
Next to the fire warning indication light.
CHAPTER-PAGE 8-5
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
AMENDMENT: 00
DATE: --
MAINTENANCE MANUAL STEMME S12
8.2
PLACARDS IN THE COCKPIT, REAR
PLACARD
a) Descriptions / Displays:
LOCATION/REMARKS
On the flap of the rear storage compartment in the center tunnel cover*.
On the top edge of the luggage compartment behind the pilot and copilot seats*.
On the lower edge of the luggage compartments behind/between the pilot and
copilot headrests*.
50 mm / 1.97 in
On the lower edge of the luggage compartment behind/between the pilot and
copilot headrests (if option is installed)*.
Fireproof Type Placard, on the rear cockpit
wall.
102 mm / 4.01 in
The placard is illustrated in reduced scale.
PLACARD
b) Handles:
LOCATION/REMARKS
(red)
On the top of the landing gear emergency
extension handle for the right landing gear
strut (right knob in flight direction).
(red)
On the top of landing gear emergency
extension handle for the left landing gear
strut (left knob in flight direction).
Right to the fuel shut-off valve*.
Near the pilots headset connectors.
Near the copilots headset connectors.
CHAPTER-PAGE 8-6
AMENDMENT: 00
DATE: --
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
MAINTENANCE MANUAL STEMME S12
PLACARD
LOCATION/REMARKS
c) Switches:
Label for every additional switch, naming so
that the function of the switch is comprehensible clearly comprehensible to the crew.
PLACARD
d) Fuses / Circuit breakers:
Label for every additional fuse, naming so
that the function of the fuse is clearly comprehensible to the crew.
PLACARD
e) Warn and Caution Lights:
Label for every additional warning or caution
lights, naming so that the function oft the
light is clearly comprehensible to the crew.
8.3
Next to the corresponding switch.
LOCATION/REMARKS
Next to the corresponding fuse.
LOCATION/REMARKS
Next to the corresponding light.
PLACARDS ON FUSELAGE
PLACARD
LOCATION/REMARKS
Placard on the upper cover of the tailboom luggage compartment*.
On the coolant fluid reservoir on the left
side of the landing gear compartment.
On the brake fluid reservoir on the forward
side of the landing gear compartment.
On the right rear side of the steel frame
near the oil reservoir.
Markings of the water ballast holes in the
tail boom next to the holes.
CHAPTER-PAGE 8-7
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
AMENDMENT: 00
DATE: --
MAINTENANCE MANUAL STEMME S12
THIS PAGE IS INTENTIONALLY LEFT BLANK
CHAPTER-PAGE 8-8
AMENDMENT: 00
DATE: --
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
MAINTENANCE MANUAL STEMME S12
9.
EQUIPMENT
9.1
MINIMUM EQUIPMENT LIST
NOTICE
This Minimum Equipment List (MEL) does not comply with a Master Minimum Equipment List
(MMEL) as part of the operational suitability data.
Subject
Manufacturer
Type
TC No.,
Specification No.
Range,
Remarks
up to 300 km/h
up to 300 km/h and
vNE depending on the
altitude
Winter
6FMS4
TS10.210/15
up to 180 mph
up to 160 kt
up to 160 kt and vNE
depending on the
altitude
Airspeed Indicator
up to 300 km/h
up to 300 km/h and
vNE depending on the
altitude
Winter
7FMS4
TS10.210/19
up to 180 mph
up to 160 kt
up to 160 kt and vNE
depending on the altitude
Winter
4FGH10
TS10.220/46
up to 10.000 m
up to 30.000 ft
Winter
4FGH20
TS10.220/47
up to 10.000 m
up to 30.000 ft
Altimeter
Compass
Winter
4FGH40
TS10.220/48
up to 20.000 ft
Aerosonic
101735-0110...
FAA TSO C-10b
35.000 ft
United Instr.
S939 PM-3
20.000 ft
United Instr.
5934PAD-A132
35.000 ft
Kollsmann
A-37
80.000 ft
Smith
KAA 1803
50.000 ft
Airpath
C2300
-
Airpath
C2400
-
CHAPTER-PAGE 9-1
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
AMENDMENT: 00
DATE: --
MAINTENANCE MANUAL STEMME S12
Manufacturer
Type
TC No.,
Specification No.
Ludolph
FK16
10.410/3
-
Ludolph
FK5
10.410/1
-
Hamilton
HI400
TSO C7c Type 1
-
Precision Aviation
Inc.
PAI-700
TSO
-
Tachometer
ROTAX
966 403
-
up to 7000 min-1
Engine hour meter
Winter
FSZM
TS-GW 1510
-
VDO
331.811/010/2
-
-
Engine hour meter
Honeywell
85094
-
-
Oil pressure indicator
UMA Instruments
T04113U010B030
-
up to 10 bar
Oil temperature
indicator
UMA Instruments
T12116R150C010
-
up to 150°C / 302°F
Fuel contents
indicator LH, RH
UMA Instruments
T18112F1F4
-
-
CHT indicator LH, RH
UMA Instruments
T12116R150C010
-
up to 150°C / 302°F
Voltmeter
UMA Instruments
N141100917V0A0
-
9-17 V
Ammeter
UMA Instruments
N15110003CA000
-
±30 A
Gadringer
BaGu 5203
SchuGu 2700
40.070/32
40.071/05
-
Schroth
Automatic Shoulder
belt, left
Automatic Shoulder
belt, right
SL/1-08-C702
(with stop)
SR/1-08-C702
(with stop)
-
Subject
Compass
Four point seat belt
Back Cushion
Range,
Remarks
One per seat compressed 50 mm / 2 in thick.
(If no parachutes are used.)
CHAPTER-PAGE 9-2
AMENDMENT: 00
DATE: --
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
MAINTENANCE MANUAL STEMME S12
9.2
SUPPLEMENTARY EQUIPMENT
Depending on operational and environmental conditions, further equipment may be mandatory
or supplementary to the minimum compulsory equipment. The supplementary equipment allowed
to be installed is listed in the following selection list.
Certification in standard configuration is only approved for daytime VFR flights. According to
operational requirements additional lighting equipment may be required.
Subject
Manufacturer
Type
TC No.,
Specification No.
Range,
Remarks
Part No.
(STEMME)
Lighting Equipment
ACL / Position
Lights
Whelen / STEMME
OR6001G
Landing Light
Whelen / STEMME
Various
Contact manufacturer before
installation of
additional lighting equipment
Reserved
9.3
ADDITIONAL EQUIPMENT AND SYSTEMS
Different equipment and systems may be installed in the motorglider S12, which are not part of
the minimum or supplementary equipment and which normally are not series standard. Basically
the cases »Additional Equipment« and »Optional Systems« have to be distinguished and treated
differently.
9.3.1
ADDITIONAL EQUIPMENT
In addition to the minimum and supplementary equipment, installation of the following devices is
approved. A precondition is that the electrical energy requirements remain within certified limits
and the certified weight of equipment in the instrument panel is not exceeded.
Depending on the instrument panel type the following maximum equipment weights are certified.
Panel Type
Max. Equipment Weight
Standard
8 kg / 17.64 lb
Ultimate
12 kg / 26.46 lb
Premium
14 kg / 30.86 lb
Additionally a ground and flight test must be performed, showing electromagnetic compatibility (EMC). Changes of equipment may be performed by competent personnel only. An inspector
must confirm the correct installation by an entry in the aircraft-logbook, the EMC-test flight, the
continued compliance to the electrical energy requirement limit and the inclusion of the changes
into the equipment list and the weight and balance report. The above-mentioned inspection and
operation documents must be added to »Annex C« of the S12 Maintenance Manual.
CHAPTER-PAGE 9-3
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
AMENDMENT: 00
DATE: --
MAINTENANCE MANUAL STEMME S12
Subject
Manufacturer
Type
TC No.,
Specification No.
Mechanical
Variometer
various
various
-
-
VHF-COM
various
various
-
All approved TSO/
ETSO equipment.
PS Engineering
PM 1000 II
-
TELEX
Pro Com 4
-
Sigtronics
SPA-400
TSO
Flightcom
403-MC
-
Flightcom
ATC-2
-
Transponder
various
various
-
All approved TSO/
ETSO equipment.
Encoder
various
various
-
All approved TSO/
ETSO equipment.
Emergency
Transmitter (ELT)
various
various
-
All approved TSO/
ETSO equipment.
Intercom
Range,
Remarks
And mechanically
identical, all equipment, which is permanently mountable
to the instrument
panel due to its own
chassis or due to a
suitable installation
frame.
GPS & Moving Map
various
various
-
All equipment, which
is permanently
mountable to the instrument panel due
to its own chassis
or due to a suitable
installation frame.
EFIS
Dynon Avionics
EFIS D-10
System
-
-
Electronic Vario,
Soaring Computer
various
various
-
Collision warning
system
various
various
-
VHF NAV (VOR)
various
various
-
Horizon
various
various
-
Turn and Bank
Indicator
various
various
-
Directional Gyro
R.C.Allen
RCA15AK-2
-
Fire Warning System
STEMME AG
-
All equipment, which
is permanently
mountable to the instrument panel due
to its own chassis
or due to a suitable
installation frame.
All approved TSO/
ETSO equipment.
All approved TSO/
ETSO equipment,
which is permanently
mountable to the instrument panel due
to its own chassis
or due to a suitable
installation frame.
Standard equipment.
CHAPTER-PAGE 9-4
AMENDMENT: 00
DATE: --
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
MAINTENANCE MANUAL STEMME S12
9.3.2
OPTIONAL SYSTEMS
Optional systems are not normally included in the S12 Aircraft Maintenance Manual. A Service
Bulletin is assigned to each of these systems delivered by STEMME, providing the information
necessary for correct installation and inspection (e. g. Serial No.’s, Documents, supplementary
procedures).
If installation requires additional instructions, an installation instruction is provided. If flight
operation requires additional information, supplements to the Flight Manual are provided.
Information required for maintained airworthiness are published as maintenance instructions, to be
inserted in the Annex A of the S12 Aircraft Maintenance Manual and added to the list of maintenance
instructions on the cover sheet of Annex A.
CHAPTER-PAGE 9-5
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
AMENDMENT: 00
DATE: --
MAINTENANCE MANUAL STEMME S12
THIS PAGE IS INTENTIONALLY LEFT BLANK
CHAPTER-PAGE 9-6
AMENDMENT: 00
DATE: --
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
MAINTENANCE MANUAL STEMME S12
10.
LIST OF SPECIAL TOOLS
The following list includes tools, which may be required for maintenance of the S12 in addition to
standard tools normally available in facilities performing maintenance on light aircraft.
• Precision protractor for propeller blade adjustment.
• Torque wrench.
• Spark plug wrench.
• Borescope.
• Micrometer.
• Inclinometer.
• Spring scale (up to approx. 250 N / 56.20 lbf).
• TCU Communication Program (ROTAX Monitoring Kit, refer to »Maintenance Manual (Heavy
Maintenance) for ROTAX Engine Types 912 and 914 Series«, section 76-00, subsection 3.1.1.
• Further tools and devices for maintenance of the engine: See »Maintenance Manual (Heavy
Maintenance) for ROTAX Engine Types 912 and 914 Series«, section 00, subsection 10.6.
• Re-fill Adapter for hydraulic brake system (P/N: 00FO-B17.)
CHAPTER-PAGE 10-1
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
AMENDMENT: 00
DATE: --
MAINTENANCE MANUAL STEMME S12
THIS PAGE IS INTENTIONALLY LEFT BLANK
CHAPTER-PAGE 10-2
AMENDMENT: 00
DATE: --
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
MAINTENANCE MANUAL STEMME S12
11.
LIST OF MAINTENANCE DOCUMENTS FOR PARTS BEING APPROVED
INDEPENDENTLY FROM THE AIRCRAFT
ANNEX A COMPRISES
• Manufacturer’s maintenance documents for all instruments specified in the equipment list
for the aircraft serial number indicated on the title page.
• Procedural instruction »Dynamic balancing of the STEMME S 10 motorglider propeller in the
S10-V and S10-VT models« A17-10AP-V/2-E.
• »Small Repairs of Composite Materials« P520-901.502 a repair guide by the STEMME
Company for STEMME aircrafts.
• Instructions for the maintenance of “L’Hotellier” ball and swivel joints.
Maintenance instructions for equipment delivered by STEMME must be entered in the list on
the cover sheet of Annex A, if the relevant equipment is installed in the aircraft serial number
corresponding to the S12 Aircraft Maintenance Manual.
CHAPTER-PAGE 11-1
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
AMENDMENT: 00
DATE: --
MAINTENANCE MANUAL STEMME S12
THIS PAGE IS INTENTIONALLY LEFT BLANK
CHAPTER-PAGE 11-2
AMENDMENT: 00
DATE: --
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
MAINTENANCE MANUAL STEMME S12
ANNEX A: SUPPLEMENTARY INSTRUCTIONS FOR MAINTENANCE AND CARE,
MAINTENANCE INSTRUCTIONS
THIS ANNEX COMPRISES
• Manufacturer’s maintenance documents for all instruments specified in the equipment list
for the serial number indicated on the title page.
• Procedural instruction »Dynamic balancing of the STEMME S 10 motorglider propeller in the
S10-V and S10-VT models« A17-10AP-V/2-E.
• »Small Repairs of Composite Materials« P520-901.502 a repair guide by the STEMME
Company for the STEMME aircrafts.
• Instructions for the maintenance of “L’Hotellier” ball and swivel joints.
• Maintenance instructions by STEMME as entered in the list below. This list must comprise at
least those Maintenance Instructions relating to the additional equipment installed (refer
to the record of accomplished SB’s/AD’s under Annex B).
Maintenance Instr. No
Subject of the Maintenance Instruction
Date inserted
CHAPTER-PAGE A-1
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
AMENDMENT: 00
DATE: --
MAINTENANCE MANUAL STEMME S12
THIS PAGE IS INTENTIONALLY LEFT BLANK
CHAPTER-PAGE A-2
AMENDMENT: 00
DATE: --
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
MAINTENANCE MANUAL STEMME S12
ANNEX B: SERVICE BULLETINS, AIRWORTHINESS DIRECTIVES
THIS ANNEX COMPRISES
• The »List of Airworthiness Directives and Service Bulletins« issued by the manufacturer for
the aircraft type STEMME S10 (Document No. A31-10-000).
• The record of accomplished SB’s / AD’s for this serial number.
• All Service Bulletins already accomplished as well as those still to be accomplished.
CHAPTER-PAGE B-1
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
AMENDMENT: 00
DATE: --
MAINTENANCE MANUAL STEMME S12
THIS PAGE IS INTENTIONALLY LEFT BLANK
CHAPTER-PAGE B-2
AMENDMENT: 00
DATE: --
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
MAINTENANCE MANUAL STEMME S12
ANNEX C: DOCUMENTS (INSPECTION AND OPERATION REPORTS)
This Annex comprises any original documents for the serial number indicated on the title page
which may be of importance to maintenance and repair. Those documents are listed in the table
below.
CAUTION
Upon any Repair or Inspection the S12 Aircraft Maintenance Manual must be submitted including
a complete Annex of documents, to allow inspection reporting and continuing of operative documentation in accordance with the rules.
New documents which must be added (e.g. new weight and balance record, revised equipment list or inspection certificates for instruments newly installed) are to be filed in this Annex.
Documents which are no longer relevant should be kept in a separate file (service records).
Document
always
Certificate of Conformity Inspection.
X
Certificate of Avionic-Inspection.
X
if any
Last Certificate of Inspection for Continued Airworthiness.
X
Last Certificate of Inspection for Continued Airworthiness (Avionic).
X
Latest Records of Conformity Inspection or Inspection for Continued
Airworthiness.
Latest records of Avionic-Inspection or Inspection for Continued
Airworthiness (Avionic).
X
X
Release Certificate – Engine.
X
Release Certificate – Propeller.
X
Inspection Certificate for any instruments installed according to the
Equipment List (except for engine instruments and other instruments not
subject to certification).
X
Component Card for engine, propeller, front gear, clutch, drive shaft.
X
Review of Operating Times.
X
Current Equipment List.
X
Latest Rigging Report (controls).
X
Latest Rigging Report (variable pitch propeller).
X
Latest Report of Dynamic Balancing.
X
Latest Weight and Balance Record.
X
Report Control Surface Weights and Hinge Moments.
X
Latest Report on Compass Compensation.
X
CHAPTER-PAGE C-1
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
AMENDMENT: 00
DATE: --
MAINTENANCE MANUAL STEMME S12
Document
always
Flight Report related to the production inspection or to the last inspection
for Continuing Airworthiness.
X
if any
List of Constructional Deviations (“minor modifications”).
X
Latest Energy Balance Report following installation of Additional
Instrumentation according section »9.3.1«
X
CHAPTER-PAGE C-2
AMENDMENT: 00
DATE: --
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
MAINTENANCE MANUAL STEMME S12
ANNEX D: MAINTENANCE AND INSPECTION FORMS
This section provides patterns of maintenance and inspection forms, relevant to maintenance
according to sections »6« and »7«.
CHAPTER-PAGE D-1
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
AMENDMENT: 00
DATE: --
MAINTENANCE MANUAL STEMME S12
THIS PAGE IS INTENTIONALLY LEFT BLANK
CHAPTER-PAGE D-2
AMENDMENT: 00
DATE: --
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
MAINTENANCE MANUAL STEMME S12
Weight and balance report
STEMME S12
Serial Number:
Registration:
Document Number
1001-12-S12-2
Page 1 (of 2)
Relevant Equipment List:
Order No.:
This Weight and Balance Report was drawn up without weighing. Any weighing data have been taken from
the Weight and Balance Report dated ___________ and if need be corrected according to point 4.2.
Drawing Up Reason:
Conformity Inspection
Changes of Equipment:
Repair. Date of Findings Report:
Other:
1. Preparation and Conditions
1.1.
1.2.
1.3.
1.4.
1.5.
The fuselage weight must be determined including rudder, back rests with cushions or equivalent upholstery, seat
cushions, canopy, standard tool kit in baggage compartment behind backrest, Logbook and Flight Manual. Replenish
oil and coolant if necessary. Fixed ballast must be installed, loose ballast must be removed.
Wing weight must be determined with bolts and 1.4 l / 0.31 imp. gal (unusable volume).
Fixed supplementary equipment must be installed.
Points 1.2 through 1.4 must be observed if an overall weighing of the powered glider is performed. The canopy has
to be closed during weighing.
If weight and moment arm of additionally installed or removed items is known exactly, the new CG may be
determined numerically (see point 4.2)
2. Overview of Component Weights and Weight Limits
Component Weights from Separate
Weighing
[kg]
[lbs]***
Weight Limits
[kg]
[lbs]***
[kg]
[lbs]***
Maximum All Up Weight (incl. Fuel)
900kg
1984 lbs
Right Hand Outer Wing
Maximum Weight of Non-Lifting Parts
NLPmax (incl. Load in Cockpit)
610kg
1345lbs
Left Hand Outer Wing
Of that: Maximum weight of equipment on 7 kg / 15.4 lbs
Instrument Panel, without Minimum Equipment 11 kg/24.2 lbs
Fuselage
Maximum Load (MTOW - Empty Weight)
Horizontal Tail
Max. Load in Cockpit
(NLPmax - LNT**; maximum 202 kg / 445 lbs, of
that max. 180 kg / 397 lbs in seats, max.
110 kg / 243 lbs in each seat and max. 22 kg /
48.5 lbs in baggage compartments)
Cockpit load must be at least 10 kg / 22 lbs
less than maximum load!
Central Wing
Component Weight Sum
Empty
Weight*
LNT**
* Cross-check: compare with empty weight from 3.; Divergence of 2 kg / 4.4 lbs due to measure error is allowable.
** LNT: Empty weight of "Non Lifting Parts"
*** Units: cross out if not applicable
3. Determining of Empty Weight and Moment Arms
Weights and Moment Arms ***:
forward RH
mr
kg / lbs
forward LH
ml
kg / lbs
Tail Wheel
ms
kg / lbs
Σ=Empty Weight me
kg / lbs
Moment Arm
a
mm / in.
Moment Arm
b
mm / in.
Datum level: Leading Edge of
Central wing, vertical plane
Pitch: wedge 1000:54,2 (3,1°) on tail
cone, upper edge horizontal
CHAPTER-PAGE D-3
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
AMENDMENT: 00
DATE: --
MAINTENANCE MANUAL STEMME S12
Weight and balance report
Document Number
1001-12-S12-2
STEMME S12
Page 2 (of 2)
4. Determining of Empty Weight Center of Gravity
4.1.
xS =
After Weighing:
mS ⋅ b
+a
me
4.2.
x
[mm / in.]*** ⇒ x S =
=
+
mm / in.
***
After Changes, without Weighing:
Following changes have been made on the powered glider:
Install. /
Removal
+
Weight ( /-)
m = [kg / lbs]***
Item
Sum madd=
NOTE:
xS ,new =
+
Moment Arm ( /-)
x = [mm / in.]***
Sum Madd=
+
Moment ( /-)
M =[mm kg / in. lbs]***
-
Count weight installed positive, weights removed negative.
Count moment arms aft of datum positive, in front of datum negative.
mold ⋅ xold + M add
[mm / in.]*** ⇒ x
S , new =
madd
x
+
=
mm / in.
***
5. Definition of load
Empty Weight:
kg / lbs***
Empty weight CG aft of datum:
mm / in. ***
Minimum Load Required on seat (full water ballast and luggage)
(otherwise
Minimum Load Required on seat (empty water ballast and luggage) ballast)****
kg / lbs***
Maximum Load (MTOW - Empty Weight)
kg / lbs***
Max. Load in Cockpit (Cockpit load must be at least 10 kg / 22 lbs less than
maximum load!)
*** Units: cross out if not applicable
****According to Maintenance Manual, Section 6.3
kg / lbs***
kg / lbs***
Strausberg,
Site, Date
Inspector Statement:
Stamp
Sign Job Leader
All measured data are within the allowable ranges and correspond to the production
and
maintenance instructions of the type.
Strausberg,
Site, Date
Stamp
Sign Inspector
CHAPTER-PAGE D-5
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
AMENDMENT: 00
DATE: --
Document-No.:
Rigging Report
DE.21G.0068
Serial Number:
1001-08-S12-2
Page 1 (of 2)
STEMME S12
Registration:
12-
Order No.:
-
Drawing Up Reason:
Conformity Inspection
Inspection. Date of Finding Report:
Other:
1. Angle of Incidence
The following rated values and actual values of the angles of incidence apply to the upper edge of a wedge 1000:84 on the
straight part of the tail cone, with its vertex in flight direction.
Inspection of the angle of incidence is required for the Conformity Inspection and an Inspection following a heavy landing,
furthermore after Major Repair, if wing and/or tail mountings have been affected.
Rated
Reading
Angle of Incidence of the Wing Chord:
+2.0° ± 0.2°
°
Angle of Incidence of the Horizontal Tail Chord:
-2.0° ± 0.2°
°
Secondary Condition: The difference of actual angles of incidence wing/horizontal tail must be
between 3.7° and 4.4°
°
2. Control Surface Deflections
Positive values (+) indicate full control surface deflections downward or left, negative Values (-) indicate deflections upward
or right.
Elevator:
Full Deflection:
Rudder:
Full Deflection:
Measuring point is trailing edge of inner rib of elevator (140 mm / [5.51 in.] from hinge line).
Rated
Reading *
Rated
Reading *
- 44 +2/-5 mm
mm
+ 44 +5/-2 mm
mm
[-1.73 +0.08/-0.2 in.]
[in.] [+1.73 +0.2/-0.08 in.]
[in.]
Measuring point is lower rear corner of control surface (420 mm / [16.5 in.] from hinge line).
Rated
Reading *
Rated
Reading *
mm
mm
+220 ± 15 mm
-220 ± 15 mm
[+8.7 ± 0.6 in.]
[-8.7 ± 0.6 in.]
[in.]
[in.]
Wing Flaps and Ailerons:
Measurement points:
1) 1) aileron: inner rib of the control surface, 163 mm / 6.42 in. from hinge line.
Flap
Control
Lever
Stick 2) 2) wing flap: inner rib of the control surface, 175 mm / 6.89 in. from hinge line.
left aileron
left wing flap
right wing flap
Position Position
Rated
mm [in.]
Reading*
mm [in.]
Rated
mm [in.]
Reading*
mm [in.]
Rated
mm [in.]
- 10°
neutral
-31 ± 4
[-1.22 ± 0.16]
-31 ± 4
[-1.22 ± 0.16]
- 5°
neutral
-15 ± 4
[-0.6 ± 0.16]
-15 ± 4
[-0.6 ± 0.16]
neutral
-48 ± 4
[-1.89 ± 0.16]
0±2
[0 ± 0.08]
right
+27 ± 3
[1.06 ±0.12]
left
0
0±2
[0 ± 0.08]
0±2
[0 ± 0.08]
right aileron
Rated
mm [in.]
Reading*
mm [in.]
+27 ± 3
[+1.06 ± 0.12]
0±2
[0 ± 0.08]
-48 ± 4
[-1.89 ±0.16]
+ 5°
neutral
+15 ± 4
[+0.6 ± 0.16]
+15 ± 4
[+0.6 ± 0.16]
+ 10°
neutral
+31 ± 4
[+1.22 ± 0.16]
+31 ± 4
[+1.22 ± 0.16]
L (+16°)
neutral
+51 ± 4
[+2 ± 0.16]
+51 ± 4
[+2 ± 0.16]
erstellt / bearbeitet:
Reading*
mm [in.]
Freigabe:
Ausgabe vom:
Rutz
01.08.2011
1001-08-S12-2_Rigging_S12.doc-1/17.08.16 15:33/23.03.17 13:08
ersetzt Ausgabe vom:
Nicht belegt!
Control Surface Masses and Hing Moments Report
Document No.:
1001-12-S12-6
Page 1 (of 1)
STEMME S12
Serial No.:
Registration:
Order No.:
12Control
Surface
Mass of Control Surface
Reading *
Rated
kg [lb]
kg [lb]
left
Hinge Moment of Control Surface
Reading *
Rated
Ncm [lbf ft]
Ncm [lbf ft]
right
left
4,1 [9.02]
to
5,0 [11]
0,95 [2.1]
to
1,3 [2.86]
66,7 [0.5]
to
106,7 [0.79]
-1,9 [-0.01]
to
2,19 [0.02]
Wing Flap
3,0 [6.6]
to
4,1 [9.02]
179 [1.34]
to
246 [1.84]
Elevator**
0,89 [1.96]
to
1,16 [2.55]
25,3 [0.19]
to
35,4 [0.27]
Aileron
(outer wing)
Aileron
(wing
extension)
Force at trailing edge
Rated Value
Reading *
N [lbf]
N [lbf]
right
Measuring point
left
9.2 (2.07) to 12.2 (2.74)
at inner operating rod.
r = 14.3 cm (5.63 in.)
-0,19 (-0.04) to 0,219 (0.05)
at inner end rib
r = 10,7 cm (3.94 in.)
11.6 (2.61) to 15.8 (3.55)
at operating rod
r = 17.2 cm (6.77 in.)
2.0 (0.45) to 2.7 (0.61)
at inner end rib
r = 14.0 cm (5.51 in.)
194 [1.46]
2,26 [4.97]
to
to
3,10 [6.82]
266 [2])
* Units: cross out if not applicable, reading Error ≤ 2,5% acceptable
** left and right half of elevator separately
4.3 (0.967) to 5.3 (1.19)
at bottom rear corner
r = 42.0 cm (16.7 in.)
Rudder
Measuring of Static Hinge Moment
The relation between hinge moment and force is:
static hinge moment M = F • r,
wherein F is the force measured at the trailing edge of the control surface, and r is the horizontal distance between trailing edge
and hinge axis. F may be measured with a spring balance or another suitable scale with an error in measurement not exceeding
2.5%.
The friction of the hinge bearing should be less than 2.5 % of the maximum permissible hinge moment. If the detached control
surface is curved to the front or to the back at least three points should be used to ensure that the curvature is eliminated and
thus cannot falsify the measurement.
Measuring Procedure with Attached Control Surface (not applicable with rudder):
The surface is to be kept in horizontal position by means of the spring balance. Then move the balance slowly upwards (by
hand) and enter the force and direction of movement in the record at which the control surface overcomes the static friction and
starts going (e.g.: 11.2 N ↑ ).
After that, starting from the horizontal position again, the spring scale is to be slowly lowered until the control surface starts
moving. Note again force and direction (e.g. 10.8 N ↓ ).
Both results must be within the limits given in the above table.
Site, date
Stamp
Sign
Inspector Statement
The control surface masses and hinge moments are within the allowable ranges and correspond to the
production and maintenance instructions of the type.
Site, date
Stamp
Sign
right
Document number:
Propeller Adjustment Report
STEMME 11AP-V
DE.21G.0068
Serial No. of Propeller:
Drawing Up Reason:
0901-05-S10-7
Page: 1 (of 2)
Order No.:
Conformity Inspection
Repair or Inspection. Date of Finding Report:
Other:
No.
Item or inspection to be performed / inspection results
1.
Center of gravity [mm/ in.]*, mass [g ] and radial mass-moment [gm]
m [g/ dr.]
Propeller blade 1:
1
AP-VB/
AP-VB/
z [mm/ in.]
Jz [gm]
x [mm/ in.]
checked
y [mm/ in.]
blank
/
Propeller blade 2:
1
performed
finished
blank
/
finished
Blade No. 2 was marked red and installed on the corresponding side.
2.
Bearings (check appropriate block and complete items as indicated)
Blade No. 1
Variation 1  Needle bearings with
inner rings and needles
P/N
Inner ring
Needles
Blade No. 2
Inner ring
(„red“ side)
Needles
---
Variation 2  Needle bearings with needle cages
3.
Balance weight washers [number and type]
[g]
Pos
Fork No.1:
Number
P/N
Weight (sum)
A
Screw/Nut:
B
C
D
E
F
G
Hub No:
H
„Red“ Side
Fork No.2:
Screw/Nut:
J
K
Remarks:
erstellt / bearbeitet:
Freigabe:
Ausgabe vom:
ersetzt Ausgabe vom:
Affeld
Rutz
08.02.2013
21.06.2011
0901-05-7_S10-prop adj_report_10_11AP-V_08.02.2013.docx/ 23.03.17 13:19
Nicht belegt!
Document number:
Propeller Adjustment Report
No.
STEMME 11AP-V
DE.21G.0068
Page: 2 (of 2)
Item or inspection to be performed / inspection results
performed
4.
Propeller all up weight [g]
(incl. front cover)
5.
Clearance in blade bearings [mm / in.] (Measured in direction of rotation axle)
Blade 1
m=
g
a) at fork:
(No perceptible play)
b) at blade tips:
(max. 4 mm / 0.157 in.)
6.
Blade 2 („red“ side)
mm / in.
mm / in.
mm / in.
mm / in.
Track of propeller blades [mm / in.] (Difference between axial position of both blades)
a) at folding joint:
(max. 0.3 mm / 0.012 in.)
b) at blade tips:
(max. 3.0 mm / 0.12 in.)
7.
0901-05-S10-7
mm / in.
mm / in.
Propeller fork incidence angle [°] (check appropriate items)
Blade 1
Blade 2 („red“ side)
a) T/O- setting:
10AP-V: -3°18‘ ± 5‘
11AP-V: -2°30‘ ± 5‘
°
‘
°
‘
°
‘
°
‘
b) Cruise- setting:
10AP-V: +3°6‘ ± 10‘
11AP-V: +3°54‘ ± 10‘
8.
Static return force when blade rotated to cruise position [N / lbf]
(blade in 90°- position; measuring point on blade tip)
a) Blade 1:
N / lbf
b) Blade 2; „red“ side:
9.
N / lbf
Duration to change pitch [s] (15-20°C; Operation Voltage: 12 V, amperage: 6,5 A ± 0,5)
a) T/O-  Cruise- setting:
(≤180 s)
b) Cruise-  T/O- setting:
(≤180 s)
10.
s
s
Propeller blade force on rubber stop [N / lbf] (propeller folded, leading edge horizontal)
a) Blade 1:
10AP-V74
(1,7N ± 0,1N / 0.38 ± 0.02 lbf)
10AP-V79
(1,5N-0 /+0,1N / 0.34 - 0/ +0.02 lbf)
N / lbf
b) Blade 2; „red“ side:
10AP-V74
(1,7N ± 0,1N / 0.38 ± 0.02 lbf)
10AP-V79
(1,5N-0 /+0,1N / 0.34 - 0/ +0.02 lbf)
* Units; general: cross out if inapplicable
N / lbf
Remarks:
All measured data is correct. The data conforms to the type data sheet for this propeller.
site, date
0901-05-7_S10-prop adj_report_10_11AP-V_08.02.2013.docx/ 23.03.17 13:19
stamp
sign of Certifying Staff
checked
Document-No.:
Rigging Report
DE.21G.0068
1001-08-S12-2
Page 2 (of 2)
STEMME S12
3. Friction in Control System
Static friction is to be measured as follows: measuring point: 230mm [9.05 in.] above fulcrum of the operating lever / control
stick on the grip; measure the force being reached when the system sets going - three times in both directions. The average
of the higher values from each measurement is to be entered.
Prior to measuring trim should be positioned so as to center the stick approximately. To balance the "stick forward" force of
the downspring, the trim lever has to be locked at the rear, nearly fully "tail heavy" position.
Rated
Elevator
Reading *
5 ± 2 N [1.1 ± 0.45 lbf]
Aileron
Rudder (tail wheel off the ground!)
15
+5
25
+5
N [lbf]
/-8 N [3.4
+1.1
/-1.8 lbf]
N [lbf]
/-8 N [5.6
+1.1
/-1.8 lbf]
N [lbf]
4. Pilot Forces
Following forces must be measured on ground. Measuring points for airbrake and wing flap forces are the respective
handles, for down-spring / trim spring forces the uppermost finger notch of the control stick handle.
Rated
Reading *
Airbrake over-center lock and unlock
150 + 50 N
[34 + 11 lbf]
at 20°C
N [lbf]
at
[°C]
Wing Flap: Counter force in position L
125 ± 25 N
[28 ± 6 lbf]
at 20°C
N [lbf]
at
[°C]
YES
NO
Wing Flap: with jerky movement damping
perceptible in both directions?
Elevator-Force in direction "PULL", just to
release the stick from its forward stop (measured
at the uppermost finger notch of the stick handle,
with trim setting fully "nose down")
35 ± 5 N
[7.8 ± 1.1 lbf]
at 20°C
N [lbf]
at
[°C]
Elevator-Force in direction "PULL", directly
before reaching the rear elevator stop (measured
at the uppermost finger notch of the stick handle,
with trim setting fully "nose down")
65 ± 5 N
[14.6 ± 1.1 lbf]
at 20°C
N [lbf]
at
[°C]
* Units: delete as applicable
Strausberg,
Site, date
Certification of the Inspector:
Stamp
Sign Job Leader
All measured data are in the permissible range and comply with the Production and
Maintenance Instructions for the control system.
Strausberg,
Site, date
erstellt / bearbeitet:
Stamp
Freigabe:
Ausgabe vom:
Rutz
01.08.2011
1001-08-S12-2_Rigging_S12.doc-2/17.08.16 15:33/23.03.17 13:08
Sign Inspector
ersetzt Ausgabe vom:
Nicht belegt!
MAINTENANCE MANUAL STEMME S12
ANNEX E: MAINTENANCE MANUAL (LINE MAINTENANCE) FOR ROTAX ENGINE TYPE 914 SERIES
This Annex comprises the original »Maintenance Manual (Line Maintenance) for ROTAX Engine
Type 914 Series« (current issue).
The S12 Aircraft Maintenance Manual, is related to the motorglider including the modified
engine ROTAX 914 F2/S1.
This S12 Aircraft Maintenance Manual is subject to changes by the manufacturer of the original
engine, ROTAX.
CHAPTER-PAGE E-1
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
AMENDMENT: 00
DATE: --
MAINTENANCE MANUAL STEMME S12
THIS PAGE IS INTENTIONALLY LEFT BLANK
CHAPTER-PAGE E-2
AMENDMENT: 00
DATE: --
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
MAINTENANCE MANUAL STEMME S12
ANNEX F: TECHNICAL DRAWINGS
This section provides technical drawings and electric wiring diagrams relevant for maintenance.
CHAPTER-PAGE F-1
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
AMENDMENT: 00
DATE: --
MAINTENANCE MANUAL STEMME S12
THIS PAGE IS INTENTIONALLY LEFT BLANK
CHAPTER-PAGE F-2
AMENDMENT: 00
DATE: --
DOCUMENT NUMBER:
L500-912.820 ISSUE JUL 20, 2016
A) FLIGHT CONTROLS: PITCH CONTROL AND TRIM
B) FLIGHT CONTROLS: LATERAL CONTROL (WING, FLAP, AILERON)
C) FLIGHT CONTROLS: AIRBRAKE CONTROL
D) FLIGHT CONTROLS: RUDDER CONTROL
E) PROPULSION SYSTEM
F) S12 MAIN SYSTEM - DC GENERATION
Main System Box
Instrument Panel
Charge Socket
Ext Alt Lamp
Engine Cowl
Volt/Ampere
Ext Alt Field
PP1F
VV14P
#XX, 2A
#2, 5A
#7, 5A
#3, 2A
MAIN BUS - INSTRUMENT PANEL
VV10F
Solar Cells
AVIONICS BUS - INSTRUMENT PANEL
PC1P
PX5F
PX3P
PX1P
PX3Ps
50A
PX30Ps
2 x 56
2 x 831.697
refer to: P308-124.920
S12 Engine System DC Generation
50A
VV11F
External
Generator
Warning
PX10P
PC3P
PX30P
Shunt
Charge Controller
VV13P
1a 1b
2a 2b
3a 3b
1
2
3
PX4F
PL6F
+
-
5
1a 1b
2a 2b
1
2
4
PL5FN
PL5F
PP2P
PX2P
PX20P
PX6P
PC4P
PC4PN
UE3P
PX6Ps
#8, 10A
VV12F
MAIN BUS - SYSTEM BOX
#9, 2A
#10, 2A
red
Master
Split Switch
1
yellow
5
1
1b 1a
2b 2a
1
2
PC8F
PC7F
red
2
yellow
PC60F
OVP-1
PC5P
PC2P
blue
PC60FN
PL3FN
PL3P
PC6FN
22.000µF
refer to: P308-124.921
S12 Engine System Engine Monitoring and Control
PC6F
9
PC9F
9
PP2PN
PX20PN
ALT
ON
V
PX2PN
A
E216 E217
36 37
E1A
CPC
37pol
B+
36 37
L
G
Alternator
IG
optional
Charge Controller
USB Cable
Steel Frame GND
Steel Frame GND
USB Charge Socket
Center Console
Engine Compartment
Date
drawn
02
P061-2017-039
01
P061-2016-102
00
Rev.
Change
Name
27.03.2017
Gulbe
checked 27.03.2017
Baum
Title
S12 Main System
DC Generation
Doc Number
P308-124910
P069-E074-196
DE.21G.0068 EASA 21J.250
Page
01
G) S12 MAIN SYSTEM - LANDING GEAR
Control Linkage
Compartment
Instrument Panel
L/G Power
refer to: P308-124.910
S12 Main System DC Generation
L/G Ctrl
GA21F
GA23F
GX1F
GW30FN
GA1P
GW10FN
GW20FN
GX1F
GW1P
1 retract
3
Main
Right
Indicator
gn
gn
3
1
2
L/H L/G
RETRACTED
R/H L/G
RETRACTED
5
4
6
2
1
3
5
4
6
2
1
3
rd
rd
c
c
c
c
c
c
c
1
+
1k
-
GA21P
2
no
GX5P
GX4P
GX2P
GX3P
4 x 470R
GW2P
nc
no
nc
no
GA13F
nc
no
Air Brake
Switch
nc
no
L/H L/G
WARNING
no
nc
L/H L/G
EXTENDED
nc
R/H L/G
WARNING
no
nc
R/H L/G
EXTENDED
left spindle drive
M
M
GA6F
GA5F
GA6F
GA4F
GA5F
GA4F
GA3F
GA3F
GA22F
GW21F
GA24F
GW11F
GA14F
GA12F
GW31F
GX3F
GW2F
GX5F
right spindle drive
spindle drives:
+
-
GA3F
GA4F
+
-
Left Steel
Frame GND
Position shown: both Landing Gears extended and locked
Air Brakes retracted and locked
Date
Name
27.03.2017
Gulbe
checked 27.03.2017
Baum
drawn
+
GA3F
GA4F
actuation extend right
indication right extended
Landing Gear Controller
extend:
GA6F
GA5F
actuation extend left
Connector A: grey
Connector B: black
retract:
GA6F
GA5F
indication left extended
GA3F
indication and actuation
right retracted
GA6F
GA2FN
GA4F
indication and actuation
left retracted
A10 B3 A12 B1 A7 B7 A6 B12 A4 B9 A9 B10 B4 A3 A2 A11 A5 A8 B2 B11 B5 B8
GA5F
GA2FN
GA11P
GA2P
extend
Main
Left
Indicator
Horn
GA10PN
2
7,5A
GA2P
Landing Gear Compartment
Indication:
2 x 831.513
4 x 831.589
2 x 831.696
#1, 2A
MAIN BUS - INSTRUMENT PANEL
LA1F
refer to: P308-124.915
S12 Main System Lighting
+
Title
S12 Main System
Landing Gear
Doc Number
01
P061-2017-039
00
Rev.
Change
P308-124911
P061-2016-006
DE.21G.0068 EASA 21J.250
Page
01
H) S12 MAIN SYSTEM - ELECTRICAL TRIM
Trim System
Instrument Panel
MAIN BUS - INSTRUMENT PANEL
#6, 5A
refer to: P308-124.910
S12 Main System DC Generation
red
CT10P
CT1P
6
2
white
3
2
CT11Ps
orange
4
5
5
1
6
4
1
3
green
blue
Trim Servo
Connector
CPC 9pol
2
10
8
9
10
8
9
common
nose
tail
common
nose
black
1
tail
white
red
Trim
Servo
3
green
6
yellow
5
Copilot Stick
Connector
CPC 16pol
M
Stick left
Tail Boom Comp.
Date
drawn
Trim
Control
CT40F
CT20F
CT30F
Pilot Stick
Connector
CPC 16pol
4
CT1PN
CT2P
CT3P
CT4P
CT5P
CT6P
CT11Pr
CT11Pw
Trim
Indicator
CT11Pb
CT10PN
black
Name
27.03.2017
Gulbe
checked 27.03.2017
Baum
Stick right
Control Linkage Comp.
Title
S12 Main System
Electrical Trim
Doc Number
01
P061-2017-039
00
Rev.
Change
P308-124912
P069-E074-196
DE.21G.0068 EASA 21J.250
Page
01
I) S12 MAIN SYSTEM - AUTOPILOT
Instrument Panel
AVIONICS BUS - INSTRUMENT PANEL
AP1P
refer to: P308-124.910
S12 Main System DC Generation
5A
EFIS
2A
11 12
CPC
16pol
Right Stick:
Prepare wires for
AP Disengage
in copilot stick
connector
Autopilot
AP74
AP20P
Power 10-30V DC
AP2P
4
AP Disengage
white
DSAB A
3
black
Tail Boom Comp.
DSAB B 16
R/H Control Linkage Comp.
GND 17
AP20PN
CPC
9pol
red
1
black
11 12
1 x 831.332
Master Power +13,75V
11 12
white
DSAB
Coupler
1
Audio Out 18
2
CPC
16pol
AP3FN
AP4P
DSAB Master
EFIS D-10A
Power 10-30V DC
black
GND
3
green
4
Left Stick:
Connect PTT as
AP Disengage
Connect SC as PTT
5k
DSAB-A
blue
5
DSAB-B
yellow
6
Disengage
wht-grn
GND 16
7
(spare)
AP10Ps
wht-blu
black
DSAB B
5
DSAB A
4
8
(spare)
AP14Pb
EDC-D10A TX 11
AP14Pr
Switched Power Out 16.8V
9
AP10Pw
AP10Pb
white
Pitch
SERVO
SC
AP13PN
12
AP14Pw
AP3F
L/H Control Linkage Comp.
RS232 to PC
9
5
AP11Fw
Serial 1 GND
AP12F
AP14Ps
AP11Fb
EDC-D10A RX 23
EDC-D10A GND 24
CPC
9pol
red
black
Serial 1 TX 10
2
1
Serial 1 RX 22
Master GND
AP2FN
3
3
Power 10-30V DC
black
white
2
female
Sub-D-9
GND
3
green
AP14Ps
4
AP4PN
DSAB-A
blue
5
14 13 11 12 CPC
14 13 11 12 16pol
DSAB-B
yellow
6
AP13F
Disengage
wht-grn
7
(spare)
wht-blu
8
5
Data B
(spare)
EDC-D10A
9
6
blue
Roll
SERVO
PWR
Center Airframe
9
Data A
1
1
Data GND
2
2
3
7
yellow
red
(female D9)
Molex
3pol
Related manufacturer's doc:
EFIS D-10A Installation Guide
Dynon P/N 100341-000 Rev. J
Dynon Firmware Version 5.6.1.
OAT Probe
L/H Inner Wing
Date
CHECK FOR UPDATES BEFORE USING THIS DIAGRAM
All wires AWG22, except power supply and power ground: AWG20
DSAB lines: Twisted pair
RS232 lines: shielded, 2 conductor twisted
RS485 lines: shielded, 3 conductor twisted
drawn
Name
27.03.2017
Gulbe
checked 27.03.2017
Baum
Title
S12 Main System
Autopilot
Doc Number
01
P061-2017-039
00
Rev.
Change
P308-124913
P069-E074-196
DE.21G.0068 EASA 21J.250
Page
01
J) S12 MAIN SYSTEM - FIRE WARNING
Instrument Panel
Fire Warning
MAIN BUS - INSTRUMENT PANEL
WG1P
#4, 2A
refer to: P308-124.910
S12 Main System DC Generation
WG2P
WG11P
WG10P
WG12P
Molex
3pol
red
a
3
Warning
Light
"FIRE"
and
Test
Button
1
+
Horn
black
3
4
WG3P
WG12PN
WG11PN
b
Engine Compartment
160°C
160°C
WG4FN
WG4F
Date
Name
17.08.16
Gulbe
checked 17.08.16
Baum
drawn
Title
S12 Main System
Fire Warning
Doc Number
00
Rev.
P308-124914
P069-E074-196
DE.21G.0068 EASA 21J.250
Change
Page
01
K) S12 MAIN SYSTEM - LIGHTING
Outer Wing
RPC 6
Inner Wing
CPC 4
CPC 16
LC30FN
CPC 9
L/H Wing
Outer Wing Extension
Winglet
7
7
7
7
1
1
1
1
8
8
8
8
2
2
3
3
9
9
9
9
3
3
5
5
Lamp Housing
ACL
POS r
POS w
Engine Compartment
Instrument Panel
7 Channel MOSFET-Box
refer to: P308-124.911
S12 Main System Landing Gear
Landing
Light
Power
ACL
Power
S
S
S
G
G
G
D
D
D
Landing Gear
refer to: P308-124.910
S12 Main System DC Generation
#4, 5A
A2 A1 A12 A3 A4 A10 A6 A7 A8
#3, 5A
MAIN BUS - SYSTEM BOX
LB30F
LA4FN
Landing
Light
LA3F
LB2F
LC2F
Inner Wing
Outer Wing
RPC 6
LC3FN
CPC 4
LA4F
CPC 9
LC30F
LA1P
1
LA2P
2
LB1P
LC1P
2
POS
Light
Power
#2, 5A
1b 1a
CPC 16
2b 2a
LB3F
2b 2a
LC3F
Landing
Light
LB1PN
ACL
LC1PN
POS
Lights
Outer Wing Extension
Winglet
7
7
7
7
1
1
1
1
8
8
8
8
2
2
3
3
9
9
9
9
3
3
5
5
Lamp Housing
ACL
POS r
POS w
R/H Wing
Date
Name
24.01.17
Gulbe
checked 24.01.17
Baum
drawn
Title
S12 Main System
Lighting
Doc Number
01
P061-2017-007
00
Rev.
Change
P308-124915
P069-E074-196
DE.21G.0068 EASA 21J.250
Page
01
L) TRANSPONDER AND TRAFFIC DISPLAY
AVIONICS BUS
FLARM
VARIO
XPDR
GPS#1
GPS#2
2A
2A
2A
2A
2A
831.611
TN70 WAAS GPS
RG400
TNC RF
SX1P
6 9-32V DC
SX1PN
19 GND
7 RS232 Port 1 (OUT)
10 RS232 Port 1 SIGNAL GND
5
831.579
831.632
Port, Static
Alt to connected
Static
TC20 Controller
TT22 Transponder
SX9Fb
4 GPS RS232 GND
SX9Fw
5 GPS RS232 IN
SX9Fs
SX2P
15 11-33V DC
black
SX7Pb
10 GND
GND 1
red
SX7Pr
8 TMAP 2A
TMAP A 2
white
SX7Pw
9 TMAP 2B
TMAP B 3
SX7Ps
SX3P
13 TC20 PWR ON
Remote ON 7
SX4P
11 TC20 PWR OUT
PWR 8
SX5P
12 TC20 PWR GND
GND 9
SX6P
19 Squat Switch
to Stall Warning
IT-A100
TNC RF
2x 1N4001
E01-01-003
1 GND
SX2PN
SUB-D-9
3
Airspeed
Switch
IÜ-W011
SX2PN
14 GND
2
IT-A001
Antenna CI-105 on Tail Boom
7
Pitot Port
1
GPS
RED: PWR IN
GND 4VN
6
YELLOW: DATA IN
Close at 30...40 kts
RJ45
+12-28V DC
7
8
Garmin:
GPSMAP 695
Aera 796
Aera 660
2
6
BLUE: DATA OUT
3
4
1
1
ALL WIRES AWG22, EXCEPT POWER AND GROUND:AWG20
2
USE COMMON CRIMP TERMINAL
INSTALL DIODES CLOSE TO TERMINAL
PROTECT DIODES WITH SHRINKING TUBE
3
PREPARE AUDIO CABLE WITH CINCH PLUG
TO BE CONNECTED TO AUX AUDIO IN OF COM RADIO
TO DYNON EFIS D-10A
BLACK: GND
5
+12-28V DC
2
3,3V DC
3
GND
4
9
REV. 01
FLARM-B (opt)
TX RS232
5
RX RS232
6
GND
7
GND
8
GPS
POWERFLARM
CORE U.S.
V80 Indicator
SUB D15
SUB D9
AUDIO 1
+12-28V DC
4
8 +12V DC
15 +12V DC
7
black
RX RS232
3
TX RS232
2
Remote Control
3 TX RS232
white
FOR WIRING DETAILS OF LX SYSTEM
SEE MANUFACTURER'S MANUAL
AND
USE DELIVERED WIRE BUNDLE
11 RX RS232
RS485 Splitter
not conn. 4
1 GND
not conn. 6
2 GND
Compass Module
ADS-B (blue)
GND 5
9 GND
5V DC 8
10 GND
5
4
RS232 NEXNAV LEGACY PROTOCOL
SET TT22 GPS IN TO
"FREEFLIGHT NEXNAV ADS-B" @ 19,200 BPS
3,3V DC 9
Flap Sensor
FLARM-A (red)
LX 8xxx / 9xxx
6
7
Date
Name
27.03.17
Gulbe
checked 27.03.17
Baum
drawn
02
P061-2017-039
01
P061-2017-002
00
Rev.
Change
RS232 CONNECTOR
PIN 3 AND 5 TO EFIS D-10A
USE PINS 1,6,8,4,9 AS SOLDER JOINT TO
GARMIN GPSMAP695
VERIFY COLOUR TO SIGNAL ASSIGNMENT
WITH GARMIN MANUAL
Title
Transponder and Traffic Display
S12 Ultimate USA
Doc Number
Blatt
GND 4VN
P308-124918
P061-2016-079
DE.21G.0068 EASA 21J.250
1
M) S12 MAIN SYSTEM - COMMUNICATION RADIO
Standard Headset Jacks
J1
CFG 1:
STD MIC + HEADPHONE
red
1
MIC
black
Mic switch 23
7
10VV Instr. lighting
4VV-1
white
GND 24
1
8
CFG 2:
DYN MIC + SPEAKER
17
COPILOT
red
P1
4A
Backlight + 23
R
PH
black
2A
18
L
white
+13,75V 11
19
red
+13,75V 12
2
MIC
black
black
MIC STD 2 HI 9
13
white
white
MIC STD LO 8
14
PILOT
red
R
black
L
10
PH
black
Headphone 2 A 20
11
white
white
Headphone 2 B 22
12
3
1
+13,75V
25
5
Mic High
red
white
24
6
Mic Lo
white-blue
black
MIC STD 1 HI 18
white
black
Headphone 1 A 2
2
21
3
Phones L white
Headphone 1 B 3
22
4
Phones R black
Speaker Hi 1
20
2
A/C Ground black
white
PILOT
Speaker Lo 14
Lemo Headset Jacks
MIC DYN HI 5
COPILOT
MIC DYN LO 6
Aux Audio In 4
Pilot Stick
Connector
CPC 16pol
from Stallwarning
Cinch Jack
Aux Audio Lo 21
PTT 1 17
1
A/C GND 13
2
Pilot Stick
4
1
+13,75V
red
31
5
Mic High
white
30
6
Mic Lo
white-blue
27
3
Phones L white
28
4
Phones R black
26
2
A/C Ground black
1
2
Cockpit
Speaker
A/C GND 25
3
Copilot Stick
Connector
CPC 16 pol
Backlight - 10
Copilot Stick
1
32
2
33
Dyn Mic
AR 6201
23
1
ref. P308-124921
CONFIGURATION SETTINGS
29
+
HOBBS
-
34
4VN GND
IN/OUT CFG 1
IN/OUT CFG 2
MICROPHONE 1
STD 1 MIKE
STD 2 MIKE
STD 3 MIKE
DYN MIKE
NONE
37pol Plug
at Center Console
2
HEADPHONE OUTPUT #1 WIRED UNBALANCED BY GROUNDING OF PIN 3!
LEMO SOCKETS FOR BOSE HEADSETS MUST BE CONNECTED HERE!
MICROPHONE 2
X
X
STD 1 MIKE
STD 2 MIKE
STD 3 MIKE
DYN MIKE
NONE
MIC ACTIVATION
BOTH MIKES
OUTPUTS
HEADPHONE 1
HEADPHONE 2
SPEAKER
NONE
Date
Name
13.01.17
Gulbe
checked 13.01.17
Baum
drawn
Title
S12 Main System
Communication Radio
Doc Number
00
P061-2017-004
Rev.
Change
P308-124919
DE.21G.0068 EASA 21J.250
Page
01
N) S12 ENGINE SYSTEM - DC GENERATION
Engine System Box
Instrument Panel
Volt/Ampere
#12, 2A
ENGINE BUS - INSTRUMENT PANEL
KA1F
VV2F
PX5F
PX3P
3
KA2P
yellow
PX6Ps
VV1F
2
1
Internal
Generator
Warning
PX4F
#9, 2A
3b 3a
#10, 2A
2b 2a
ENGINE BUS - SYSTEM BOX
#8, 5A
1b 1a
Shunt
VV3F
#6, 25A
PX10P
PX3Ps
PX30Ps
refer to: P308-124.921
S12 Engine System Engine Monitoring and Control
PX1P
PX30P
refer to: P308-124.910
S12 Main System DC Generation
2
5
4
1
50A
PC43F
PX2P
PX6P
PX20P
PC42F
yellow
PC41F
red
5
1
yellow
PC40F
30A
PC40F
80A
PC40FN
PL2F
PL2FN
2 x AWG16
2 x AWG16
Starter Battery
C
B+
L
G
G
1A
R
Regulator
PL2F
PC33FN
9
blue
22.000µF
PC32FN
PC32F
9
PX2PN
V
PX20PN
PC30P
PC31P
OVP-1
A
- + +
Internal Generator
G
Ext.Power
Supply 12V
Steel Frame GND
Steel Frame GND
Steel Frame GND
Engine Compartment
Date
Name
27.10.16
Gulbe
checked 27.10.16
Baum
drawn
Title
S12 Engine System
DC Generation
Doc Number
01
Page
P061-2016-102
00
P069-E074-196
Rev.
Change
P308-124920
DE.21G.0068 EASA 21J.250
01
O) S12 ENGINE SYSTEM - ENGINE MONITORING AND CONTROL
REV 02
Instrument Panel
FuelPress
Tachometer
Center Console
Stall warning
Ignition Retarder
Ignition
#10, 2A
Oil T
CHT R
#9, 2A
Oil P
CHT L
Hobbs
PWR IN
JA2Ps
9
JB2Ps
2
#11, 2A
3
1b 1a
2b 2a
1
2
Ignition
Key
Switch
Bat
JC11P
S
TCU Status
R
TCU Emergency
KA1F
1b 1a
VV2F
D
UE3P
Transistor
IFR3205
or similiar
ENGINE BUS - SYSTEM BOX
VV3F
#2, 15A
KA2P
VV4F
JB1P
G
1
JC1PN
L
JA1P
2
JC2P
1
S
KD5P
2b 2a
KD4P
2
1b 1a
KD3P
3 Molex
6pol
3
KD2P
2
GRD
yellow
EM1PN
1
EN1PN
QW2Pb
QW2Pw
Manifold
S
red
1
QW2Pr
EK12P
EK11P
EK3P
EK2P
ED11P
ED12P
ED2Pw
ED2Pb
ED2Pr
-
refer to: P308-124.920
S12 Engine System DC Generation
Nose Cone
Lever
refer to: P308-124.910
S12 Main System DC Generation
80A
#7, 5A
+
2
EM1P
3
EW1PN
1
8
EW1P
5
EN2P
8
QW2Ps
ED2Ps
5
QW1PN
8
EK10PN
5
EK1PN
8
ED10PN
5
ED1PN
3
Engine System Box
UE1PN
9
1
KA3PN
9
JA2P
9
6
VV1F
refer to: P308S10 Stall warning
5
UE2P
4
CPC
37pol
UE1P
3
KA3P
2
Hobbs
29 29
Master
Split Switch
JC1P
UE4P
1
RPM
JB2P
FP
JC10P
#14, 2A
#8, 2A
EN1P
1 CHT R
Ignition Retarder
JC10PN
1 CHT L
QW1P
EK1P
EK10P
#7, 2A
#6, 2A
ED10P
ED1P
OT
1
UE4PN
23 23
-
OP
1
refer to: P308-124.917
S12 Main System Transp. and Traffic Disp.
+
#5, 2A
ENGINE BUS - INSTRUMENT PANEL
50A
Engine Compartment
1
1
2
2
3 10
3 10
4
4
5
5
6
6
7
7
8
8
9
9
1
1
2
2
3
3
4
C
7
C
8
C
4
C
3
C
6
C
5
C
10
C
11
C
9
C
12
C
1
C
2
4
C
7
C
8
C
4
C
3
C
6
C
5
C
10
C
11
C
9
C
12
C
1
C
2
1
25
JC2FN
KD1F
CPC
16pol
KD1FN
Starter Relais
CPC
4pol
1
2
3
1
2
3
4 CPC
4 4pol
CPC
16pol
14
2
13 26
28
10
35
11
2
ROTAX TCU
3
Crankcase GND
4
5 22 15 27 9
8
Starter
14
7; 19; 31
21 33 20 32
Starter Battery
M
M
Servo
L/H
R/H
Ignition
Ignition
Modul
Modul
A
B
Crankcase GND
Steel Frame GND
Crankcase GND
ROTAX TCU Sensor Set
Crankcase GND
Wires labeled with
ROTAX pin number
Date
Name
13.01.2017
Gulbe
checked 13.01.2017
Baum
drawn
02
2017-004
01
2016-119
00
2016-006
Rev.
Change
Title
S12 Engine System
Engine Monitoring and Control
Doc Number
P308-124921
DE.21G.0068 EASA 21J.250
Page
01
P) S12 ENGINE SYSTEM - FUEL PUMPS AND INDICATION
Instrument Panel
Fuel L
Fuel R
Fuel Flow
Low Fuel
28-40-05
1
#4, 2A
Auxiliary Pump
Indication
yellow
2b 2a
wt
bk
Engine Compartment
Fuel Selector
Switch
A
Fuel Flow FFDM-1
B
2
7 Channel MOSFET-Box
6
45
R/H
Transfer
Pump
Power
QB32P
QB22P
QB33P
QW11P
QF11Ps
QF11Pw
QF11Pb
QF11Pr
QF10Ps
QF10Pw
QF10Pb
QF10Pr
QX21Pb
QX21Pr
QX21Pw
QX11Pb
QX11Pw
QX11Pr
7 Channel MOSFET-Box
1
3
L/H
Transfer
Pump
Power
S
S
G
G
D
D
Auxiliary
Pump
Power
S
refer to: P308-124.920
S12 Engine System DC Generation
refer to: P308-124.910
S12 Main System DC Generation
G
D
#3, 5A
A5 A9 A11
QB41F
QB20F
#5, 5A
B11 B6 B12B10 B5 B1
MAIN BUS - SYSTEM BOX
QB10F
#4, 5A
prepared for prospective
fuel level sensor
prepared for prospective
fuel level sensor
ENGINE BUS - SYSTEM BOX
#1, 5A
rd
2
QB42P
QX21Ps
Low Fuel
Indication
QB43PN
8
QB43P
5
QF2PN
QX11Ps
3
QF2P
8
QF1PN
5
QX20PN
3
green
9
QX10PN
9
Auxiliary Pump
Switch
QB42PN
28-40-04
1
QF1P
QX20P
QX10P
28-40-03
28-40-10
28-40-05
28-40-02
QW10P
28-40-01
#1, 5A
#3, 2A
#2, 2A
ENGINE BUS - INSTRUMENT PANEL
QB40F
QB30F
QB21F
QB21FN
QB31FN
QB41FN
QB31F
QB10FN
QB42FN
QX12FN
QX22FN
QB33FN
QW11FN
1
2
3
4
1
2
3
4
QB50FN
5
4
5
combined equipotential bonding
for all metal parts in wing fuel system
1
2
3
1
2
3
1
2
3
1
2
3
1
2
3
1
2
3
FuelFlow
Forward
P
combined equipotential bonding
for all metal parts in wing fuel system
L/H
Transfer
Pump
28-20-02
QB31F
QB21FN
P
CPC
16pol
R/H
Transfer
Pump
28-20-04
FuelFlow
Return
4 CPC
4 4pol
Voltage Limiter
124.604
Full
Feeder
Low
Fuel
L/H Inner Wing
2
3
4
1
2
3
4
9 CPC
9 9pol
P
P
Main P.
28-20-02
Aux.P.
28-20-04
bottom
top
Feeder Tank
Date
Name
24.01.17
Gulbe
checked 24.01.17
Baum
drawn
L/H Fuel Tank
1
QB41FN
4
3
QB42FN
3
2
QB41F
2
1
9 CPC
9 9pol
QB10F
1
6
QB10FN
6
6
white
6
1
black
1
2
red
2
5
black
5
4
white
4
3
QB31FN
3
QB21F
CPC
16pol
CPC
4pol
red
CPC
4pol
Landing
Gear
Compartment
Title
S12 Engine System
Fuel Pumps and Indication
R/H Fuel Tank
R/H Inner Wing
02
P061-2017-007
01
P061-2016-079
P069-E074-198
00
Rev.
Doc Number
P308-124922
DE.21G.0068 EASA 21J.250
Change
Page
01
Q) S12 ENGINE SYSTEM - PROPELLER CONTROL
Engine Compartment
Instrument Panel
7 Channel MOSFET-Box
#13, 2A
ENGINE BUS - INSTRUMENT PANEL
Prop.
Pitch
Power
green
Propeller Pitch
Indication Module
S
5
4
3
2
1
refer to: P308-124.920
S12 Engine System DC Generation
KF10P
KF14P
KF11P
KF15P
D
ENGINE BUS - SYSTEM BOX
B3 B4 B2
#20, 2A
KF10PN
G
#1, 15A
6
KF12P
KF1F
KF2F
KF7F
KF5F
KF6FN
Collector ring
2
1
V.P.P. Test Switch
no
1b 1a
Cruise-Take Off
Switch
c
1
Center Console
KF8FN
KF3FN
Propeller Compartment
Steel Frame GND
drawn
Date
Name
24.01.17
Gulbe
checked 24.01.2017
Baum
Title
S12 Engine System
Propeller Control
Doc Number
01
P061-2017-007
00
Rev.
Change
P308-124923
P069-E074-196
DE.21G.0068 EASA 21J.250
Page
01
">