The extent and state of revision of this manual may be obtained from the index and the revision index. Maintenance for the gyrocopter G 4-2 is to be performed ONLY by an authorized persons and/or aviation workshop in accordance with the instructions and intervals given in this manual as well as the manuals for engine and propeller.
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REVISIONS TO THIS MANUAL Description Page Date Name Previous manual Rev. 3.0 03.05.17 R. Farrag Maintenance manual G 4-2 Revision 05A – 03.05.2017 Doc. No.: TA-M-D-002-EN...
The fuel system Electrical system The hydraulic brake system PERIODIC PREVENTIVE MAINTENANCE Introduction Maintenance after the first 25 hours 50 hour interval maintenance 100 hour interval maintenance 500 hour interval maintenance Maintenance manual G 4-2 Revision 05A – 03.05.2017 Doc. No.: TA-M-D-002-EN...
Please use the forms at the end of this manual to report such defects. All warranties provided by the manufacturer of the gyrocopter are void, in the event that one or more of the instructions in this manual are ignored. Maintenance manual G 4-2 Revision 05A – 03.05.2017 Doc. No.: TA-M-D-002-EN...
All rules and regulations contained in these documents must be obeyed. The G 4-2 is constructed, manufactured and tested according to the construction regulations for ultra-light gyrocopters (BUT 2001) and Nfl II 13/09 dated 12.02.2009 and is registered under the identification number 61218 by the responsible German authority (DAeC).
• Rudder and stabilizers made from CFC The series G 4-2 includes 2 models: Liberty and Princess. Liberty is an entry-level model, which is designed to basically operate with an open cabin. However, this model can be converted with an optional kit to a closed version.
1.6 Side view, top view and front view (2 models) Note: The three views are not to scale! The model Liberty Maintenance manual G 4-2 Revision 05A – 03.05.2017 Doc. No.: TA-M-D-002-EN...
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Note: The three views are not to scale! The model Princess Maintenance manual G 4-2 Revision 05A – 03.05.2017 Doc. No.: TA-M-D-002-EN...
2 COMPONENTS 2.1 Introduction The components used in the gyrocopter series G 4-2 are illustrated and documented in this section of the maintenance manual. Bolts and nuts are to be tightened and inspected in accordance with the data provided in this manual and the tightening torque in the corresponding tables is to be used as a reference.
Cracks and damages to the frame are to be reported to the manufacturer of the gyrocopter with no delay. Note: All warranties are void in case that the instructions in this manual are not carefully followed. Maintenance manual G 4-2 Revision 05A – 03.05.2017 Doc. No.: TA-M-D-002-EN...
Note: All warranties are void in case that the instructions in this manual are not carefully followed. Rotor bridge for Rotor head type KK-1 Maintenance manual G 4-2 Revision 05A – 03.05.2017 Doc. No.: TA-M-D-002-EN...
2.4 Rotor head (2 types) 2 Rotor head types (KK-1 and TS-1) are certified for the series G 4-2: Type KK-1 is a tilt head design. It is designed and manufactured by Trixy Aviation. It is made of high quality materials and has passed all tests required under the German rules and specifications for type certification of ultra-light gyrocopters.
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Self-locking Hexagon nut M6 ISO 7042 8-26 Washer 8,4 DIN 125-B 8-27 Washer 6,4 DIN 125-B 8-28 STARTER ACTUATOR 8-29 Shaft 8-30 Spring pin 6x26 DIN 1481 8-31 Spring pin 3,5x26 DIN 1481 Maintenance manual G 4-2 Revision 05A – 03.05.2017 Doc. No.: TA-M-D-002-EN...
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Type TS-1 is a swash plate controlled head design. It is designed and manufactured by Trixy Aviation. It is made of high quality materials and has passed all tests required under the German rules and specifications for type certification of ultra-light gyrocopters. It is made of aircraft aluminium and stainless steel.
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Short cylinder head bolt with internal hexagon 10Nm 25-77 Cylinder head bolt with internal hexagon 10Nm 25-78 Cylinder head bolt with internal hexagon 10Nm 25-82 Allen screw 25-91 Allen screw 10Nm 25-92 Allen screw 25Nm Maintenance manual G 4-2 Revision 05A – 03.05.2017 Doc. No.: TA-M-D-002-EN...
2.5 Rotor controls The rotor control system is designed and manufactured of high quality materials by Trixy Aviation. It passed all tests required under the German rules and specifications for type certification of ultra-light gyrocopters. The bolts, bushings and axes are of special design and must not be replaced by standard parts.
2.6 Pre-rotator system The pre-rotator system is designed and manufactured of high quality materials by Trixy Aviation. The belt must be periodically sprayed with silicon spray. Exchanging the clutch belt requires removing the propeller from the mounting flange (pulley). The main pre-rotator gear in the rotor head and the Bendix-gear in the pre-rotator system must be greased with neutral grease in all scheduled maintenance works.
500 h To be exchanged: 1000 h Type 4: EXCALIBUR Manufacturer: E-Props www. e-props.fr No. of blades: Diameter: 1720 mm Blade material: Adjustment: Ground adjustable. To be exchanged: 800 h Maintenance manual G 4-2 Revision 05A – 03.05.2017 Doc. No.: TA-M-D-002-EN...
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Cracks and damages in the propeller are to be reported to the manufacturer of the gyrocopter with no delay. Note: All warranties are void in case that the instructions in this manual are not carefully followed. Maintenance manual G 4-2 Revision 05A – 03.05.2017 Doc. No.: TA-M-D-002-EN...
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Type 1: Ground adjustable propeller. Contact DUC or Trixy Aviation for more details. Maintenance manual G 4-2 Revision 05A – 03.05.2017 Doc. No.: TA-M-D-002-EN...
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Type 2: In flight adjustable propeller. Contact Neuform or Trixy Aviation for more details. Pos. Description Qnt. Tightening Torque Cylinder head bolt with internal hexagon M8x125 11-1 25 Nm DIN 912 11-2 Self-locking Hexagon nut M8 ISO 7042 11-3 toothed washer 8,4...
2.8 Nose wheel and steering The nose wheel suspension and ist structure are designed and manufactured by Trixy Aviation of high quality materials. It passed all load tests required by the German rules and specifications for the certification of ultra-light gyrocopters. However, continuous stress during taxiing, take-offs and landings on rough terrain may cause damage to the nose wheel structure.
Note: All warranties are void in case that the instructions in this manual are not carefully followed. Maintenance manual G 4-2 Revision 05A – 03.05.2017 Doc. No.: TA-M-D-002-EN...
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Cylinder head screw with internal hexagon 13-3 10 Nm M6x40 DIN 912 13-4 Washer 8,4 DIN 125-B 13-5 Self-locking Hexagon nut M8 ISO 7042 13-6 Washer 6,4 DIN 125-B Maintenance manual G 4-2 Revision 05A – 03.05.2017 Doc. No.: TA-M-D-002-EN...
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The main wheels and the brakes are high quality products of Beringer Aero SA. The brake hydraulic system is designed and manufactured by Trixy Aviation. Use original parts only from the manufacturer to insure flight safety. See also main gear in the previous chapter and brake system in further in this manual.
2.12 Rudder controls The rudder and ist control system is designed and manufactured by Trixy Aviation. The rudder is made of CFC in sandwich construction under vacuum. It is controlled by bowden wires along with the nose wheel. The rudder control system is to be overhauled:...
50° C / max. 130° C Oil temperature: Fuel quality: EN228 Super (min ROZ 95) or EN228 Super plus (min ROZ 95) Alternative fuel (*): AVGAS 100 LL (ASTM D910) Maintenance manual G 4-2 Revision 05A – 03.05.2017 Doc. No.: TA-M-D-002-EN...
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(last valid edition) by workshops and persons, who are authorized by Rotax. Note: All warranties are void in case that the instructions in this manual are not carefully followed. Maintenance manual G 4-2 Revision 05A – 03.05.2017 Doc. No.: TA-M-D-002-EN...
3 SYSTEMS 3.1 Introduction The systems of the gyrocopters G 4-2 are described and illustrated in this chapter of the maintenance manual. Construction drawings and material lists are not included in this manual. It is considered that authorized persons and/or authorized aircraft repair and maintenance workshops are to perform maintenance on the gyrocopter.
The pilot in command must insure correct oil pressure and oil temperature above 50 °C before applying full power. The maximum allowed oil temperature is 130 °C. Maintenance manual G 4-2 Revision 05A – 03.05.2017 Doc. No.: TA-M-D-002-EN...
The circuit must be check for leaks. All hoses must be in good conditions 3.4 Engine ignition circuits More information about the ignition circuits are found in Rotax manual. Maintenance manual G 4-2 Revision 05A – 03.05.2017 Doc. No.: TA-M-D-002-EN...
914 by an electrical pump fixed on the fire wall in a lower level than the tank. Both G 4-2 may be optionally equipped with an electric auxiliary fuel pump, which is then fixed on the lower part of the fire wall.
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It can, however, optionally be equipped with an auxiliary fuel pump and/or a back-up battery system. The Types G 4-2 RT, G 4-2 TI and G 4-2 TIS are equipped with 2 electrical fuel pumps, a back-up battery and a battery management system (BMS) in the standard configuration.
However, los of fluid may mean leaks in the system. This must be fixed to avoid brake failure. It is recommended to exchange the hydraulic fluid in the system every 500 h. Maintenance manual G 4-2 Revision 05A – 03.05.2017 Doc. No.: TA-M-D-002-EN...
3.1 Introduction This chapter explains the periodic preventive maintenance required and highly recommended to insure flight safety. Trixy Aviation Insists on professional and timely maintenance. The information in this chapter for maintenance intervals must be adhered to; otherwise all manufacturer warranties are void.
26. Inspect the rudder and its control system for function 27. Adjust the rudder control Bowden if needed 28. Inspect the attachment of the canopy to the cabin and the locks Maintenance manual G 4-2 Revision 05A – 03.05.2017 Doc. No.: TA-M-D-002-EN...
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27. Inspect landing light 28. Inspect defroster fan for function 29. Inspect navigation lights and strobe (if installed) 30. Inspect ELT for function (if installed) Maintenance manual G 4-2 Revision 05A – 03.05.2017 Doc. No.: TA-M-D-002-EN...
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13. Inspect electric auxiliary fuel pump function (if installed) 14. Inspect cabin heating system for function (if installed) 15. Inspect oil cooler and clean thoroughly 16. Inspect coolant heat exchanger assembly and clean thoroughly Maintenance manual G 4-2 Revision 05A – 03.05.2017 Doc. No.: TA-M-D-002-EN...
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26. Disassemble the main wheels and inspect the brake pads 27. Exchange the hydraulic fluid in the system and insure the system is properly vented. 28. Inspect fuel tanks (exchange after 2000 h), exchange fuel filters Maintenance manual G 4-2 Revision 05A – 03.05.2017 Doc. No.: TA-M-D-002-EN...
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Note: All warranties are void in case that the instructions in this manual are not carefully followed. Maintenance manual G 4-2 Revision 05A – 03.05.2017 Doc. No.: TA-M-D-002-EN...
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Gyrocopter in accordance with the instructions in this manual. Remarks: The gyrocopter is airworthy and is returned to service. Name of authorized person: ________________________ Signature: Date of certificate: ____________________ Stamp (if available): Maintenance manual G 4-2 Revision 05A – 03.05.2017 Doc. No.: TA-M-D-002-EN...
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Gyrocopter in accordance with the instructions in this manual. Remarks: The gyrocopter is airworthy and is returned to service. Name of authorized person: ________________________ Signature: Date of certificate: ____________________ Stamp (if available): Maintenance manual G 4-2 Revision 05A – 03.05.2017 Doc. No.: TA-M-D-002-EN...
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Gyrocopter in accordance with the instructions in this manual. Remarks: The gyrocopter is airworthy and is returned to service. Name of authorized person: ________________________ Signature: Date of certificate: ____________________ Stamp (if available): Maintenance manual G 4-2 Revision 05A – 03.05.2017 Doc. No.: TA-M-D-002-EN...
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Gyrocopter in accordance with the instructions in this manual. Remarks: The gyrocopter is airworthy and is returned to service. Name of authorized person: ________________________ Signature: Date of certificate: ____________________ Stamp (if available): Maintenance manual G 4-2 Revision 05A – 03.05.2017 Doc. No.: TA-M-D-002-EN...
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Gyrocopter in accordance with the instructions in this manual. Remarks: The gyrocopter is airworthy and is returned to service. Name of authorized person: ________________________ Signature: Date of certificate: ____________________ Stamp (if available): Maintenance manual G 4-2 Revision 05A – 03.05.2017 Doc. No.: TA-M-D-002-EN...
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Gyrocopter in accordance with the instructions in this manual. Remarks: The gyrocopter is airworthy and is returned to service. Name of authorized person: ________________________ Signature: Date of certificate: ____________________ Stamp (if available): Maintenance manual G 4-2 Revision 05A – 03.05.2017 Doc. No.: TA-M-D-002-EN...
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Gyrocopter in accordance with the instructions in this manual. Remarks: The gyrocopter is airworthy and is returned to service. Name of authorized person: ________________________ Signature: Date of certificate: ____________________ Stamp (if available): Maintenance manual G 4-2 Revision 05A – 03.05.2017 Doc. No.: TA-M-D-002-EN...
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Gyrocopter in accordance with the instructions in this manual. Remarks: The gyrocopter is airworthy and is returned to service. Name of authorized person: ________________________ Signature: Date of certificate: ____________________ Stamp (if available): Maintenance manual G 4-2 Revision 05A – 03.05.2017 Doc. No.: TA-M-D-002-EN...
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Gyrocopter in accordance with the instructions in this manual. Remarks: The gyrocopter is airworthy and is returned to service. Name of authorized person: ________________________ Signature: Date of certificate: ____________________ Stamp (if available): Maintenance manual G 4-2 Revision 05A – 03.05.2017 Doc. No.: TA-M-D-002-EN...
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Gyrocopter in accordance with the instructions in this manual. Remarks: The gyrocopter is airworthy and is returned to service. Name of authorized person: ________________________ Signature: Date of certificate: ____________________ Stamp (if available): Maintenance manual G 4-2 Revision 05A – 03.05.2017 Doc. No.: TA-M-D-002-EN...
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Gyrocopter in accordance with the instructions in this manual. Remarks: The gyrocopter is airworthy and is returned to service. Name of authorized person: ________________________ Signature: Date of certificate: ____________________ Stamp (if available): Maintenance manual G 4-2 Revision 05A – 03.05.2017 Doc. No.: TA-M-D-002-EN...
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Gyrocopter in accordance with the instructions in this manual. Remarks: The gyrocopter is airworthy and is returned to service. Name of authorized person: ________________________ Signature: Date of certificate: ____________________ Stamp (if available): Maintenance manual G 4-2 Revision 05A – 03.05.2017 Doc. No.: TA-M-D-002-EN...
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Gyrocopter in accordance with the instructions in this manual. Remarks: The gyrocopter is airworthy and is returned to service. Name of authorized person: ________________________ Signature: Date of certificate: ____________________ Stamp (if available): Maintenance manual G 4-2 Revision 05A – 03.05.2017 Doc. No.: TA-M-D-002-EN...
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Gyrocopter in accordance with the instructions in this manual. Remarks: The gyrocopter is airworthy and is returned to service. Name of authorized person: ________________________ Signature: Date of certificate: ____________________ Stamp (if available): Maintenance manual G 4-2 Revision 05A – 03.05.2017 Doc. No.: TA-M-D-002-EN...
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Gyrocopter in accordance with the instructions in this manual. Remarks: The gyrocopter is airworthy and is returned to service. Name of authorized person: ________________________ Signature: Date of certificate: ____________________ Stamp (if available): Maintenance manual G 4-2 Revision 05A – 03.05.2017 Doc. No.: TA-M-D-002-EN...
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Location: ______________ Datum: __________________ Signature: Please send this report to: and to: DAeC Trixy Aviation GmbH Hermann-Blenk-Strasse 28 Eschbuehel 10 F D-38108 Braunschweig A-6850 Dornbirn Germany Austria Telefax: +49 531 23540-66 info@trixyaviation.com Maintenance manual G 4-2 Revision 05A – 03.05.2017 Doc. No.: TA-M-D-002-EN...
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Location: ______________ Datum: __________________ Signature: Please send this report to: and to: DAeC Trixy Aviation GmbH Hermann-Blenk-Strasse 28 Eschbuehel 10 F D-38108 Braunschweig A-6850 Dornbirn Germany Austria Telefax: +49 531 23540-66 info@trixyaviation.com Maintenance manual G 4-2 Revision 05A – 03.05.2017 Doc. No.: TA-M-D-002-EN...
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Location: ______________ Datum: __________________ Signature: Please send this report to: and to: DAeC Trixy Aviation GmbH Hermann-Blenk-Strasse 28 Eschbuehel 10 F D-38108 Braunschweig A-6850 Dornbirn Germany Austria Telefax: +49 531 23540-66 info@trixyaviation.com Maintenance manual G 4-2 Revision 05A – 03.05.2017 Doc. No.: TA-M-D-002-EN...
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The gyrocopter is airworthy and is returned to service. Name of authorized person: ________________________ Signature: Date of certificate: ____________________ Stamp (if available): Maintenance manual G 4-2 Revision 05A – 03.05.2017 Doc. No.: TA-M-D-002-EN...
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The gyrocopter is airworthy and is returned to service. Name of authorized person: ________________________ Signature: Date of certificate: ____________________ Stamp (if available): Maintenance manual G 4-2 Revision 05A – 03.05.2017 Doc. No.: TA-M-D-002-EN...
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The gyrocopter is airworthy and is returned to service. Name of authorized person: ________________________ Signature: Date of certificate: ____________________ Stamp (if available): Maintenance manual G 4-2 Revision 05A – 03.05.2017 Doc. No.: TA-M-D-002-EN...
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________ of the manual. The gyrocopter is airworthy and was returned to cervice. Name of authorized person: ________________________ Signature: Date of certificate: ____________________ Stamp (if available): Maintenance manual G 4-2 Revision 05A – 03.05.2017 Doc. No.: TA-M-D-002-EN...
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________ of the manual. The gyrocopter is airworthy and was returned to cervice. Name of authorized person: ________________________ Signature: Date of certificate: ____________________ Stamp (if available): Maintenance manual G 4-2 Revision 05A – 03.05.2017 Doc. No.: TA-M-D-002-EN...
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________ of the manual. The gyrocopter is airworthy and was returned to cervice. Name of authorized person: ________________________ Signature: Date of certificate: ____________________ Stamp (if available): Maintenance manual G 4-2 Revision 05A – 03.05.2017 Doc. No.: TA-M-D-002-EN...
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The content of this manual, (including text, pictures and drawings) is not to copy without the written permission of Trixy Aviation GmbH. Maintenance manual G 4-2 Revision 05A – 03.05.2017 Doc. No.: TA-M-D-002-EN...
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