STEMME S12 User manual

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: [phone]
E-mail: inf[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.
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0.2 LIST OF EFFECTIVE PAGES
This list is only valid for the serial no. specied on title page. The list contains all amendments
of the maintenance manual, eective until nal approval of this serial no. amendments added
later must be recorded.
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CHAPTER 8

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0.3 CONTENTS
MANUAL CONTENTS
Cover Sheet. .............................................................................................................. 0-1
0.1 Record of Amendments. ............................................................................... 0-3
0.2 List of Eective 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
3.4.5 Engine Exhaust incl. Turbocharger and Attachment.......................................... 3-14
3.4.6 Fuel 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

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3.4.7 Engine Controls and Instrumentation............................................................. 3-19
3.4.8 Fire Protection............................................................................................ 3-19
3.4.9 Engine 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 Identication 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
3.4.14 FLUIDS. ..................................................................................................... 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 Specication...................................................................................... 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 Specications...................................................................................... 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 Specications: Main System........................................................ 3-44
3.7.6.5 Fuse Specications: 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

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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
3.7.12 Engine Starting System (ATA 80-00-00).......................................................... 3-50
3.7.12.1 Description. ...............................................................................................3-50
3.7.12.2 Parts Specication...................................................................................... 3-50
3.7.12.3 Operation.................................................................................................. 3-50
3.7.13 Engine Ignition System (ATA 74-00-00)........................................................... 3-51
3.7.13.1 Description. ............................................................................................... 3-51
3.7.13.2 Parts Specication...................................................................................... 3-51
3.7.13.3 Operation.................................................................................................. 3-51
3.7.14 Engine RPM Indicating System (ATA 77-14-00)................................................. 3-52
3.7.14.1 Description. ............................................................................................... 3-52
3.7.14.2 Parts Specication...................................................................................... 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 Specication...................................................................................... 3-52
3.7.15.3 Operation.................................................................................................. 3-52
3.7.16 Oil Pressure Indicating System (ATA 79-31-00)................................................. 3-53
3.7.16.1 Description. ............................................................................................... 3-53
3.7.16.2 Parts Specication...................................................................................... 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 Specication...................................................................................... 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 Specication...................................................................................... 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 Specication...................................................................................... 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 Specication...................................................................................... 3-56
3.7.20.3 Operation.................................................................................................. 3-56
3.7.21 Fire Detection System (ATA 26-12-00)............................................................. 3-56

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3.7.21.1 Description. ............................................................................................... 3-56
3.7.21.2 Parts Specication...................................................................................... 3-56
3.8 COM and NAV Equipment............................................................................. 3-57
3.9 Oxygen System...........................................................................................3-59
3.10 Wing Folding Device. ................................................................................... 3-61
4. Airworthiness Limitations Section. .................................................................. 4-1
4.1 General. ......................................................................................................4-2
4.2 Maintenance Limitations. ..............................................................................4-2
4.2.1 Paint Finish. .................................................................................................4-2
4.3 Component Replacement and Overhaul Limitations...........................................4-3
4.4 Structural Limitations................................................................................... 4-5
5. Time Limits / Maintenance Checks. .................................................................. 5-1
5.1 Overhaul and Replacement Schedule. ..............................................................5-2
5.2 Pre-Flight Inspections....................................................................................5-7
5.2.1 Rubber Hose and Clamp Integrity....................................................................5-7
5.3 Periodic Inspections.......................................................................................5-7
5.3.1 Inspection Intervals...................................................................................... 5-8
5.3.2 General Remarks on Periodic Inspections........................................................ 5-10
5.3.3 Unscheduled Maintenance. ...........................................................................5-11
5.3.4 Special Conditions and Cautionary Notice. ..................................................... 5-12
5.3.5 General Remarks on Maintenance. ................................................................ 5-12
5.3.6 Inspection Groups and Maintenance Criteria................................................... 5-14
5.3.7 Other Particulars of Maintenance.................................................................. 5-17
5.4 Check List for Periodic Inspections................................................................. 5-19
5.4.1 General. .................................................................................................... 5-19
5.4.2 Wings and Fuel System Components in the Wing Center Section. .......................5-20
5.4.3 Forward Fuselage........................................................................................ 5-21
5.4.4 Cockpit. .................................................................................................... 5-22
5.4.5 Center Fuselage (except for fairings). ............................................................ 5-23
5.4.6 Tail Boom................................................................................................... 5-24
5.4.7 Empennage................................................................................................ 5-24
5.4.8 Fuel System Components in the Fuselage........................................................ 5-25
5.4.9 Engine and Engine Mountings.......................................................................5-26
5.4.10 Lubrication System......................................................................................5-28
5.4.11 Cooling System (Liquid Cooling, Ram Air Cooling)............................................5-29
5.4.12 Air Induction System....................................................................................5-29
5.4.13 Engine Controls & Monitoring........................................................................5-29
5.4.14 Center Fuselage Fairing, Engine Cowlings and Firewall......................................5-30
5.4.15 Propeller.................................................................................................... 5-31
5.4.16 Drive Shaft with Propeller Reduction Gear....................................................... 5-32
5.4.17 Main Landing Gear...................................................................................... 5-33
5.4.18 Tail Wheel. .................................................................................................5-34
5.4.19 Flight Instrumentation and Pitot/Static Systems. ............................................ 5-34

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5.4.20 Electric System (except for engine and TCU). .................................................. 5-35
5.4.21 COM and NAV Equipment............................................................................. 5-35
5.4.22 Completion Tasks........................................................................................ 5-36
5.4.23 Optional Equipment.................................................................................... 5-37
5.5 Special Inspections...................................................................................... 5-39
5.5.1 Inspection Following a Heavy Landing or a Wing Tip Landing. ............................5-39
5.5.2 Inspection Following an Impact to the Rotating Propeller..................................5-39
5.5.3 Inspection following Exceptional Events with Wing Folding Device......................5-40
6. Maintenance Instructions, Tolerances, Adjustment Data for the Aircraft................6-1
6.1 General Remarks. .........................................................................................6-1
6.2 Towing on ground, Jack Points and Lifting. .......................................................6-1
6.3 Determination of Empty Weight and Corresponding
Center of Gravity; Weight Limits......................................................................6-3
6.4 Flight Control System.................................................................................... 6-8
6.4.1 Deection of Control Surfaces, Control System Friction, and Control Forces.......... 6-8
6.4.1.1 Control Surface Deections........................................................................... 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
7.1 Airframe...................................................................................................... 7-1
7.1.1 Wing........................................................................................................... 7-1
7.1.1.1 Cracks and Structural Damage. ...................................................................... 7-1
7.1.1.2 Drainage 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
7.1.2.1 Cracks 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
7.1.3.1 General 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

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7.2 Cockpit. ......................................................................................................7-7
7.2.1 Canopy........................................................................................................7-7
7.2.1.1 Condition 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
7.2.2 Equipment 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 Deection 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
7.4.1.1 General. .....................................................................................................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 lter - Replacement and Inspection. ......................................................... 7-19
7.4.3 Cooling System........................................................................................... 7-19
7.4.3.1 Visual and Leakage Check of the System. ....................................................... 7-19

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7.4.3.2 Flushing of Cooling System........................................................................... 7-20
7.4.3.3 Coolant Replacement.................................................................................. 7-20
7.4.3.4 Ram Air Cooling...........................................................................................7-21
7.4.4 Air Induction System.....................................................................................7-21
7.4.4.1 Intercooler and Air box..................................................................................7-21
7.4.4.2 Air lter......................................................................................................7-21
7.4.5 Exhaust System. ..........................................................................................7-21
7.4.5.1 Turbocharger/ Muer Mountings. ..................................................................7-21
7.4.5.2 Exhaust Headers......................................................................................... 7-22
7.4.5.3 Heat Insulation........................................................................................... 7-22
7.4.6 Fuel System................................................................................................ 7-23
7.4.6.1 Fuel System in the Wing. .............................................................................. 7-24
7.4.6.2 Fuel System in the Fuselage. ......................................................................... 7-25
7.4.7 Engine Controls/Monitoring. ........................................................................ 7-26
7.4.8 Fire Protection............................................................................................ 7-28
7.4.8.1 Cowling-Fire Protective Painting. .................................................................. 7-28
7.4.8.2 Fire Protective Sleeves.................................................................................. 7-29
7.4.8.3 Firewall. .................................................................................................... 7-29
7.4.9 Cowlings.................................................................................................... 7-29
7.4.10 Propeller.................................................................................................... 7-30
7.4.10.1 General. .................................................................................................... 7-30
7.4.10.2 Adjustment and Inspection Results, Tolerances.................................................7-31
7.4.10.3 Visual Inspection of the Propeller Unit.............................................................7-31
7.4.10.4 Removal of the Propeller Unit. ...................................................................... 7-32
7.4.10.5 Installation of the Propeller Unit. .................................................................. 7-33
7.4.10.6 Spring Tension of the Propeller Folding Mechanism........................................... 7-34
7.4.10.7 Checking of Pitch Control and Adjusting the Variable Pitch Propeller. ................. 7-35
7.4.10.8 General Aspects of the Electrical Circuit. ........................................................ 7-36
7.4.10.9 Adjustment of the Electrical Switch for the
Take-O 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
7.5 Landing Gear.............................................................................................. 7-41
7.5.1 Main Landing Gear...................................................................................... 7-41
7.5.1.1 General. .................................................................................................... 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 Ination 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

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7.5.2 Tail Wheel. ................................................................................................. 7-46
7.6 Flight Control Instruments and Pitot and Static Pressure System. ....................... 7-47
7.6.1 Calibration of Stall Warning System (Optional)................................................7-48
7.6.2 Maintenance on the Static Pressure System. ................................................... 7-48
7.7 Electrical System......................................................................................... 7-49
7.7.1 General. .................................................................................................... 7-49
7.7.2 Batteries. .................................................................................................. 7-49
7.7.3 Grounding. ................................................................................................ 7-50
7.7.4 E-Boxes. .................................................................................................... 7-50
7.8 Communication and Navigation Equipment. ...................................................7-51
7.9 Optional - Oxygen Equipment.......................................................................7-51
8. List of Placards and their Positions. .................................................................8-1
8.1 Placards in the Cockpit, Front. ........................................................................ 8-1
8.2 Placards in the Cockpit, Rear......................................................................... 8-6
8.3 Placards on Fuselage.....................................................................................8-7
9. Equipment...................................................................................................9-1
9.1 Minimum Equipment List. .............................................................................. 9-1
9.2 Supplementary Equipment. ............................................................................9-3
9.3 Additional Equipment and Systems..................................................................9-3
9.3.1 Additional Equipment....................................................................................9-3
9.3.2 Optional Systems......................................................................................... 9-5
10. List of Special Tools. .....................................................................................10-1
11. 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 Trac Display................................................................................ F-27
m) S12 Main System - Communication Radio. ............................................................... F-29

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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

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