Page 1 Prolley Moor Wentnor Bishops Castle SY9 5EJ Company Reg No 5486550 Phone: +44 (0) 1588 650769 Fax: +44 (0) 1588 650769 Email: info@rotorsport.org Approval number DAI/9917/06 Pilot’s Operating Handbook for Gyroplane Cavalon RSUK0287_POH_Cavalon Revision 2, Issue Date 24.06.2015 Pre-pages 1...
Page 2 Flight and Operation Manual for Gyroplane Cavalon Model: Cavalon _________________________________________ Serial number: RSUK/CVLN/_____________________________________ Registration: G-???? _________________________________________ Engine: 914UL or 912ULS serial ____________________________ Propeller: HTC 1,73m ground adjustable propeller ________________ IVO-prop DL3-68 in-flight variable pitch propeller_________ Rotor: Autogyro 8.4m RotorSystem II RAO (red end caps, black...
Page 3 REVISION LOG Rev. Change summary Date Signature First formal release 12.04.13 560kg MTOW (MC-281) and 24.06.15 IVO-prop (MC-276) recognised. All pages republished at Rev 2. TOPP Rotor option added P1-4 06.04.16 para 1.9, P7-5 para 7.8, Caution para 8.15.1 Vertical CG limit increased to 940, page 2-7 para 2.7.2.
Page 4 Signature: Signature: Signature: Position: Position: Position: Head of Chief Test Pilot Engineering Manager Airworthiness RSUK0287_POH_Cavalon Revision 2, Issue Date 24.06.2015 Pre-pages 4...
Page 5: Table Of Contents
SECTION 1 - GENERAL....................1-1 Introduction....................1-1 Certification ....................1-1 Performance Data and Operating Procedures ..........1-1 Definition of Terms ..................1-3 Important Note....................1-3 Three-view of the Cavalon................1-4 Description ....................1-5 Technical Data ....................1-5 Rotor ......................1-5 1.10 Engine......................1-6 1.11 Propeller......................
Page 6 Flight Manual Table of Contents Cavalon List of Effective Pages 3.14 Rotor Bearing Temperature................. 3-10 3.15 Loss of Visibility................... 3-11 3.16 (not used)....................3-11 3.17 Rotor Icing....................3-11 3.18 Landing with a Deflated Tyre............... 3-11 3.19 Not used ..................... 3-12 3.20...
Page 7 Flight Manual Table of Contents Cavalon List of Effective Pages Weight and Balance Record ................6-1 Compliance with Weight and Balance............6-1 SECTION 7 - SYSTEM DESCRIPTION ................7-1 Introduction....................7-1 Airframe and Undercarriage................7-1 Doors, Windows and Exits ................7-1 Fuel System ....................
Page 8 Flight Manual Table of Contents Cavalon List of Effective Pages 9-2.1 General ......................1 9-2.2 Limitations......................1 9-2.3 Emergency Procedures..................1 9-2.4 Normal Procedures ..................1 9-2.5 Performance ....................1 9-2.6 Weight and Balance ..................1 9-2.7 System Description ..................1 9-2.8...
Page 9 Flight Manual Table of Contents Cavalon List of Effective Pages LIST OF EFFECTIVE PAGES Page(s) Rev. Date Page(s) Rev. Date 1-1 to 1-8 06.04.16 9-1 - 1 to 3 24.06.15 2-1 to 2-10 06.04.16 9-2 - 1 24.06.15 3-1 to 3-9 24.06.15...
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Page 11 GENERAL CONTENTS Introduction....................1-1 Certification ....................1-1 Performance Data and Operating Procedures ..........1-1 Definition of Terms ..................1-3 Important Note....................1-3 Three-view of the Cavalon................1-4 Description ....................1-5 Technical Data ....................1-5 Rotor ......................1-5 1.10 Engine......................1-6 1.11 Propeller......................1-6 1.12...
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Page 13: General
German national certifying authority. AUTHORITY FOR FLIGHT WITHIN THE UK The legal basis for the operation of this CAVALON autogyro is regulated in the Airworthiness Approval Notification (AAN29345), issued by the UK Civil Aviation Authority (CAA). It has been shown to comply with the requirements of BCAR Section T issue 4, and is considered as a factory built aircraft.
Page 14 Flight Manual SECTION 1 Cavalon GENERAL All documented performance data and operating procedures have been identified within the approval processes for this gyroplane by means of flight test and analysis. RSUK0287_POH_Cavalon Revision 3.0, Issue Date 06.04.16...
Page 15: Definition Of Terms
Flight Manual SECTION 1 Cavalon GENERAL Definition of Terms This manual uses WARNINGs, CAUTIONs and NOTEs in bold capital letters to indicate especially critical and important instructions. Additionally, the colour of the panel (red, yellow, and grey shading) highlights the significance of the instruction. Definitions for each term are given below.
Page 16: Three-View Of The Cavalon
Flight Manual SECTION 1 Cavalon GENERAL Three-view of the Cavalon RSUK0287_POH_Cavalon Revision 3.0, Issue Date 06.04.16...
Page 17: Description
Payload:................210.0 kg (nominal) Take-off weight/mass (max.): ............... 500.0 kg Fuel tank capacity: .................. 100 ltr If MC-281 “Cavalon upgrade to 560kg MTOW”embodied then the following apply: Empty weight: ............... 290.0 kg (nominal) Payload:................270.0 kg (nominal) Take-off weight/mass (max.): ............... 560.0 kg...
Page 18: Engine
Flight Manual SECTION 1 Cavalon GENERAL 1.10 Engine ROTAX 912 ULS  4-cylinder, four-stroke spark-ignition engine with opposed cylinders  Liquid cooled cylinder heads Air cooled cylinders   Dry sump forced lubrication with separate oil tank  Automatic valve adjustment by hydraulic tappet 2 carburettors ...
Page 19: Unit Conversion
Flight Manual SECTION 1 Cavalon GENERAL 1.12 Unit Conversion Multiply to obtain kts (knots) 1.852 km/h km/h (kilometres per hour) 0.54 mph (miles per hour) 1.61 km/h km/h (kilometres per hour) 0.62 ft (feet) 0.305 m (metres) 3.28 RSUK0287_POH_Cavalon Revision 3.0, Issue Date 06.04.16...
Page 20: Abbreviations And Terminology
Flight Manual SECTION 1 Cavalon GENERAL 1.13 Abbreviations and Terminology Anti-Collision Light Above Ground Level Air Traffic Control Calibrated AirSpeed – indicated speed corrected for installation errors Circuit Breaker Counter Clock Wise Centre of Gravity Cylinder Head Temperature Carbon Reinforced Plastic...
Page 21 Flight Manual SECTION 1 Cavalon GENERAL Square metres True AirSpeed – calibrated airspeed corrected for air density Turbo Control Unit (engine) Table Of Contents Take-Off Power Design maneuvering speed Design speed for maximum gust intensity Visual Flight Rules Maximum level-flight speed at maximum continuous power...
Page 23 Flight Manual SECTION 2 Cavalon LIMITATIONS CONTENTS General ......................2-1 Environmental Limitations................2-3 Colour Code for Instrument Markings ............2-3 Airspeed Limitations and Instrument Markings..........2-4 Rotor Speed Limitations and Instrument Markings.........2-4 Powerplant Limitations and Instrument Markings ........... 2-5 Weight and Balance ..................2-7 2.7.1...
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Page 25: Limitations
Flight Manual SECTION 2 Cavalon LIMITATIONS SECTION 2 - LIMITATIONS This section contains operating limitations, instrument markings and basic placards which are required for safe operation of the gyroplane, including its engine, and standard equipment or systems. General WARNING The operation of a gyroplane demands professional pilot instruction and dedicated training on gyroplanes.
Page 26 In common with other aircraft of this type the Cavalon utilises a non-certified engine. This means that there may be a higher risk of engine failure than in a certified aircraft, with the associated risks of damage or injury as the result of an unplanned landing.
Page 27: Environmental Limitations
Flight Manual SECTION 2 Cavalon LIMITATIONS Environmental Limitations Maximum wind speed or gust intensity............40 kts Maximum demonstrated crosswind component for take-off and landing..20 kts Maximum tailwind component for take-off and landing ........5 kts Maximum demonstrated operating altitude........... 10,000 ft Temperature ................- 20 to + 40 °C...
Page 28: Airspeed Limitations And Instrument Markings
Flight Manual SECTION 2 Cavalon LIMITATIONS Airspeed Limitations and Instrument Markings Air Speed Marking Red radial Never Exceed Speed 160 km/h (100mph) 130 – 160 km/h (80- Yellow arc 100mph Recommended manoeuvring speed range 30 - 130 km/h (20- Green arc...
Page 29: Powerplant Limitations And Instrument Markings
Flight Manual SECTION 2 Cavalon LIMITATIONS Powerplant Limitations and Instrument Markings Engine Speed Marking Red radial Maximum engine speed 5800 RPM 5 minute take-off power regime Yellow arc 5500 – 5800 RPM Green arc 1400 – 5500 RPM Maximum continuous power...
Page 30 Flight Manual SECTION 2 Cavalon LIMITATIONS Cylinder Head Temperature Marking Red radial Maximum cylinder head temperature 135 °C Green arc 50 – 135 °C Engine Oil Pressure Marking Red radial Maximum oil pressure 7 bar Yellow arc 5 – 7 bar Green arc 2 –...
Page 31: Weight And Balance
0 CG datum in x and z) when fitted with the RAO rotorsystem II, and 940 to 750 above the CG datum when fitted with the TOPP rotorsystem II. These limits are unchanged when MC-281 “Cavalon upgrade to 560kg MTOW” is embodied. RSUK0287_POH_Cavalon...
Page 32: Flight Crew
Demonstrated positive load factor (500 kg)..........+ 3.5 g Demonstrated negative load factor (500 kg) – structural limit...... - 1 g If MC-281 “Cavalon upgrade to 560kg MTOW” is embodied then Demonstrated positive load factor (560 kg)..........+ 3.0 g Demonstrated negative load factor (560 kg) –...
Page 33: Fuel
Flight Manual SECTION 2 Cavalon LIMITATIONS Excessive side-slip is prohibited! WARNING Side slip may be performed only with proper training and within safe boundaries. Use gentle pedal input for initiation and stabilization. Do not rely on airspeed indication in side slip. Never perform abrupt control stick input into the direction of motion.
Page 34: Placards
Flight Manual SECTION 2 Cavalon LIMITATIONS  Altimeter  Compass Side slip indicator   Rotor RPM indicator  Engine rpm gauge Engine instruments (oil pressure, RPM, CHT)   Pre-rotator 2.12 Placards In clear view of the pilot on centre panel...
Page 35 Flight Manual SECTION 2 Cavalon LIMITATIONS Airspeed Limitations Maximum Indicated Airspeed (Vne): 100mph Other Limitations This aircraft shall be flown by day and under Visual Flight Rules only. Smoking in the aircraft is prohibited Occupant warning (beside both seat entry, and on centre panel):...
Page 36 Flight Manual SECTION 2 Cavalon LIMITATIONS At oil filler access panel: At fuel shut-off valve: At both static ports: Fitted to the doors inside RSUK0287_POH_Cavalon Revision 3.0, Issue Date 06.04.16 2-12...
Page 37 Flight Manual SECTION 2 Cavalon LIMITATIONS Fitted to the doors outside Fitted to the instrument panel Continuously lit Low Volt lamp indicates electrical demand exceeds supply, and the battery is being drained. If lit in flight, reduce demand until unlit. If not possible, expedite landing.
Page 38 Flight Manual SECTION 2 Cavalon LIMITATIONS On keel tube fin (where fitted, both sides) NO STEP CIRCUIT BREAKERS Circuit breakers Only attempt to reset (once) if essential for continued safe flight - Other If the compass deviation is more than 5° on all headings, then a deviation placard must be present.
Page 39 Flight Manual SECTION 3 Cavalon EMERGENCY PROCEDURES CONTENTS Engine Failure ....................3-1 Air Restart Procedure ..................3-2 Landing into Trees or High Vegetation............3-2 Degradation of Engine Power ................ 3-2 Evacuating the Aircraft................... 3-3 Smoke and Fire .....................3-3 Off-field Landing .................... 3-3 Flight Control Malfunction ................3-4...
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Page 41: Emergency Procedures
Flight Manual SECTION 3 Cavalon EMERGENCY PROCEDURES SECTION 3 - EMERGENCY PROCEDURES This chapter contains the check lists and procedures to be executed in emergency situations. Emergencies due to defects of the gyroplane or its engine are extremely unlikely if the aircraft is checked thoroughly before each flight, and maintained in accordance with the AMM.
Page 42: Air Restart Procedure
Flight Manual SECTION 3 Cavalon EMERGENCY PROCEDURES NOTE The best engine-off glide ratio is about 1:3 at 90 km/h (55-60mph). Depending on a possible headwind the glide may be extended by slightly increasing airspeed. It is heavily recommended to train your forced landing capabilities regularly, preferably with a qualified flight instructor.
Page 43: Evacuating The Aircraft
Flight Manual SECTION 3 Cavalon EMERGENCY PROCEDURES Evacuating the Aircraft In normal circumstances occupants should never leave the aircraft while the propeller or the rotors are turning. If abandoning the aircraft in an emergency the pilot should turn off the engine magneto switches and turn the master switch to “OFF”...
Page 44: Flight Control Malfunction
Flight Manual SECTION 3 Cavalon EMERGENCY PROCEDURES  Select a suitable landing site from safe altitude, considering slope, wind speed and direction  Fly a reconnaissance pattern to check for obstacles, especially power lines, wires, and cables in the approach and go-around path ...
Page 45: Pitch Oscillation Recovery
Flight Manual SECTION 3 Cavalon EMERGENCY PROCEDURES 3.8.4 Trim runaway Failure of a trim selector switch or pneumatic valve may result in trim runaway (where the trim system runs to one extreme and pushes the control stick accordingly). Although the...
Page 46 Flight Manual SECTION 3 Cavalon EMERGENCY PROCEDURES either through an impact (loose luggage, bird strike etc. passing through the propeller) or by some mechanical failure. In the event the pilot should make a precautionary landing for evaluation. Propeller damage may also be evident from a change in noise level.
Page 47: Door Open In Flight
Flight Manual SECTION 3 Cavalon EMERGENCY PROCEDURES Gauge suddenly goes to full scale deflection, other gauges reading normally – likely gauge fault Oil pressure falls to zero, possible loss of pressure. Stop engine, make precautionary landing Water temp gradually or suddenly rises above max temp. Possible loss of coolant.
Page 48: Warning And Caution Lights
Flight Manual SECTION 3 Cavalon EMERGENCY PROCEDURES 3.12 Warning and Caution Lights 3.12.1 GEN or Low Volt Indicator Light The GEN lamp, when lit, indicates that there is no voltage being supplied from the regulator circuit to the battery. It is normally lit when the engine is stationary or at very low rpm.
Page 49: Boost Warn Light 'Boost' (Red) - Only Rotax 914 Ul
Flight Manual SECTION 3 Cavalon EMERGENCY PROCEDURES Battery voltage of the system has dropped below a safe value. Refer to chapter above. Aircraft lights and the 12V power receptacle will be disabled automatically. 3.12.3 BOOST WARN Light ‘Boost’ (red) - only ROTAX 914 UL Continuously lit If continuously lit, the maximum admissible boost pressure was exceeded.
Page 50: Parameters Out Of Limits
Flight Manual SECTION 3 Cavalon EMERGENCY PROCEDURES 3.12.6 Low Fuel (if installed) The LOW FUEL warning light is triggered as soon as 5 litres or less of useable fuel remain in the tank. Perform a power-on landing at the nearest suitable location and be prepared for engine failure after approximately 10 minutes remaining flight time.
Page 51: Loss Of Visibility
Flight Manual SECTION 3 Cavalon EMERGENCY PROCEDURES 3.15 Loss of Visibility In case of windscreen misting, open air vents and windows to ensure proper ventilation. If the situation cannot be corrected or occurs suddenly, such as after a bird strike or windscreen icing, maintain safe attitude by visual reference to the sides, using the open sliding window, if necessary.
Page 52: Not Used
Flight Manual SECTION 3 Cavalon EMERGENCY PROCEDURES 3.19 Not used 3.20 Alternative Method of Engine Shut-down If the engine continues running after the magnetos have been switched off use one of the following alternative methods: Engage full choke, wait a few seconds and open the throttle suddenly. This normally chokes the engine and causes it to stop Alternatively –...
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Page 55 Flight Manual SECTION 4 Cavalon NORMAL PROCEDURES CONTENTS Airspeeds for Safe Operation.................4-1 Preparation for Flight ..................4-1 Daily or Pre-flight Checks ................4-1 Before Boarding .................... 4-4 Before Starting Engine................... 4-5 Starting Engine....................4-6 Taxi and Run-up.................... 4-7 Take-off Procedure..................4-7 Take-off Run....................4-9 4.10...
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Page 57: Normal Procedures
All daily or pre-flight check list items consist of visual checks and do not replace professional mechanical inspection and maintenance. The following check list applies for the standard Cavalon gyroplane. Note that depending on optional equipment installed the necessary checks may include additional items according to the flight manual supplement provided with the optional equipment.
Page 58 Flight Manual SECTION 4 Cavalon NORMAL PROCEDURES The following checks must be carried out before each flight. However, if the gyroplane is operated by a single pilot or within an organization where the checks are performed by or under the supervision of qualified personnel, check list items marked with a preceding ‘ʘ’...
Page 59 Flight Manual SECTION 4 Cavalon NORMAL PROCEDURES Station 3 (main gear spring spar, RH) Main wheel running surface ..............Check Air pressure and slip mark ............. Visual check ʘ Brake, disc attachment (4 bolts) and wheel attachment......Check Wheel spat and attachment ..............Check ʘ...
Page 60: Before Boarding
Flight Manual SECTION 4 Cavalon NORMAL PROCEDURES Station 7 (engine, LH side) ʘ Engine frame rear side / welded joints ...... No cracks, no deformation Oil cooler and hoses ..........Clean, no leaks, fittings tight Exhaust system ..................No cracks Lower engine cowling ......Properly installed, all fasteners locked...
Page 61: Before Starting Engine
Flight Manual SECTION 4 Cavalon NORMAL PROCEDURES WARNING There is no vertical restraint provided for baggage stowed behind the occupant seats. Normally this baggage is restrained by the vertical tapering of the stowage area. It is the pilots responsibility to ensure any item stowed behind the seats, or anywhere else in the aircraft, is secure.
Page 62: Starting Engine
Flight Manual SECTION 4 Cavalon NORMAL PROCEDURES Starting Engine Fuel shut off valve ............... Open and guarded Parking brake ....................Set Cold engine: Throttle ......................Idle Choke..................Fully engaged Warm engine: Throttle .................Idle or slightly cracked Choke...................Disengaged Master switch ....................ON...
Page 63: Taxi And Run-Up
Flight Manual SECTION 4 Cavalon NORMAL PROCEDURES Taxi and Run-up During taxi do not exceed 15 km/h (10mph) which is approximately jogging speed and steer with careful pedal input. Use wheel brake carefully, if needed, but not before throttle lever has been completely pulled to idle.
Page 64 Flight Manual SECTION 4 Cavalon NORMAL PROCEDURES WARNING Before activating the pre-rotator, check area is clear. WARNING Prior to releasing the wheel brake, make sure that the control stick is fully aft, if headwind component allows. A take-off run with flat rotor system may have fatal consequences.
Page 65: Take-Off Run
Flight Manual SECTION 4 Cavalon NORMAL PROCEDURES WARNING In the event of pre-rotator failure, STOP and rectify the fault. Do NOT attempt to pre-spin by hand, as this involves considerable personal risk if the engine is running. Take-off Run  Check full power available for take-off. Otherwise, abort take-off ...
Page 66: Approach
Flight Manual SECTION 4 Cavalon NORMAL PROCEDURES 4.13 Approach  Switch ON second fuel pump (Pump 2)  Check all warning and caution indications OFF  Check all instruments in normal operating range  Check wheel brake unlocked  Maintain and trim approach speed ...
Page 67: Go-Around
Flight Manual SECTION 4 Cavalon NORMAL PROCEDURES 4.15 Go-around  Apply take-off power. Counteract yaw tendency and align gyroplane with rudder input  In horizontal flight, allow gyroplane to gain speed  Climb with safe or best rate of climb speed and adjust trim 4.16 After Landing...
Page 68: Engine Shut-Down
Flight Manual SECTION 4 Cavalon NORMAL PROCEDURES 4.17 Engine Shut-down Throttle ......................Idle Parking brake ....................Set Turbo charger cool-down (ROTAX 914 engine) ........ min. 2mins Second fuel pump (Pump 2) ..............OFF Avionics/Radio/Intercom/Lights (except ACL / Strobe) ........ OFF Both MAG switches ..................OFF ACL / Strobe (if installed)................
Page 69: Flight With Doors Removed
Flight Manual SECTION 4 Cavalon NORMAL PROCEDURES 4.21 Flight with Doors Removed Before flying with removed doors any loose objects must be removed from the cabin or safely stowed. A possible tail shake (fishtailing) tendency can be minimized by using a small side slip. In case where only one door is removed, perform a small side slip into the direction of the closed door (so that the removed door is on the lee-side).
Page 70: Training Engine In-Flight Shut-Down And Air Restart
Flight Manual SECTION 4 Cavalon NORMAL PROCEDURES 4.22 Training Engine In-flight Shut-down and Air Restart The engine should not be stopped in flight deliberately except as part of forced landing training under the supervision of a qualified flight instructor. If possible, allow the engine to cool down at 3000 rpm for about 30 sec before turning it off.
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Page 73 Flight Manual SECTION 5 Cavalon PERFORMANCE CONTENTS Demonstrated Operating Temperature ............5-1 Airspeed Correction..................5-1 Height-Velocity Diagram ................5-2 Speeds ......................5-3 Rate of Climb....................5-3 Take-off and Landing Data ................5-3 Influence on Take-off Distance and Climb Rate ..........5-4 Sink Rate and Glide Ratio ................5-6 Additional Performance Data .................5-6...
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Page 75: Performance
Flight Manual SECTION 5 Cavalon PERFORMANCE SECTION 5 - PERFORMANCE The following data were determined by flight testing and demonstrated with average piloting skills, with engine and aircraft in good condition, as well as clean main rotor and propeller. The parameters apply to standard conditions (15 °C at sea level and standard pressure) and a gross mass of 500 kg.
Page 76: Height-Velocity Diagram
Flight Manual SECTION 5 Cavalon PERFORMANCE Height-Velocity Diagram The H/V diagram indicates combinations of height and speed (avoid area left side of the red graph) where a safe landing may not be possible in case of an engine failure. Therefore, operation on the left side of the red line must be avoided.
Page 77: Speeds
Flight Manual SECTION 5 Cavalon PERFORMANCE Speeds The following speeds are relevant for flight performance. For additional speed limitations refer to SECTION 2 LIMITATIONS of this manual. Mini horizontal speed (Vmin), TOP (Rotax 914)*, 500Kg...48 km/h (30mph) IAS Vmin, TOP (Rotax 914)* 560KgTOW ........61 km/h (38mph) IAS Vmin, TOP (Rotax 914)* 560Kg, IVO prop ......56 km/h (35mph) IAS...
Page 78: Influence On Take-Off Distance And Climb Rate
Flight Manual SECTION 5 Cavalon PERFORMANCE T/off distance, 914UL to clear a 15m obstacle at 560Kg MTOW ....780 m T/off distance, 914UL to clear a 15m obstacle at 560Kg MTOW, Ivoprop..590 m Take-off distance, 912ULS to clear a 15m obstacle ........550 m Landing roll...................0 –...
Page 79 Flight Manual SECTION 5 Cavalon PERFORMANCE Example: Given: Outside Air Temperature 28 °C and Pressure Altitude 3500 ft Result: 88 % increase in take-off distance and climb rate reduced by 53 % RSUK0287_POH_Cavalon Revision 2, Issue Date 24.06.2015...
Page 80: Sink Rate And Glide Ratio
Flight Manual SECTION 5 Cavalon PERFORMANCE Sink Rate and Glide Ratio The sink rate depending on airspeed with the engine in idle is plotted in the following diagram: At 560Kg MTOW expect a sink rate of 1050fpm at 35KIAS, 1200 at 43KIAS, 1120 at 52KIAS, 1320 at 61KIAS, 1550 at 70KIAS, and 1600 at 78KIAS.
Page 81 Flight Manual SECTION 5 Cavalon PERFORMANCE The noise certificate was granted according to the German requirements for noise protection microlight gyroplanes (“Lärmschutzverordnung für Ultraleichte Tragschrauber”) stating an overfly noise of 68 dB or less. RSUK0287_POH_Cavalon Revision 2, Issue Date 24.06.2015...
Page 83 Flight Manual SECTION 6 Cavalon WEIGHT AND BALANCE CONTENTS General ......................6-1 Weight and Balance Record ................6-1 Compliance with Weight and Balance............6-1 RSUK0287_POH_Cavalon Revision 2, Issue Date 24.06.2015 6 - i...
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Page 85: Weight And Balance
After modifications and at regular intervals a new weighing report and equipment list should be issued. Compliance with Weight and Balance The Cavalon gyroplane is designed in such way that compliance with weight and balance is provided, if ...
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Page 87 Flight Manual SECTION 7 Cavalon SYSTEM DESCRIPTION CONTENTS Introduction....................7-1 Airframe and Undercarriage................7-1 Doors, Windows and Exits ................7-1 Fuel System ....................7-1 Pneumatic System..................7-3 Power Plant ....................7-4 Propeller......................7-4 Rotor System....................7-4 Vibration Damping ..................7-5 7.10 Flight Controls ....................7-5 7.11...
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Page 89: System Description
Flight Manual SECTION 7 Cavalon SYSTEM DESCRIPTION SECTION 7 - SYSTEM DESCRIPTION Introduction This section contains the description of the gyroplane and its standard systems and equipment. Optional equipment is described in Chapter 9 of this manual. Airframe and Undercarriage The load carrying structure of the gyroplane consists of a composite monocoque occupant enclosure which is connected to the rotor tower and keel tube.
Page 90 Flight Manual SECTION 7 Cavalon SYSTEM DESCRIPTION visually using a dip stick (stored in the cabin) which has to be inserted diagonally from the fuel filler port (see 8.5). The tanks are ventilated by a ventilation line above the tanks leading through the midchannel directly to the outside.
Page 91: Pneumatic System
Flight Manual SECTION 7 Cavalon SYSTEM DESCRIPTION Pneumatic System Aircraft trim, rotor brake and activation of the pre-rotator is controlled by a pneumatic system, consisting of an electrically driven air compressor with dry cartridge, a pressure gauge in the cockpit, solenoid valves, air lines, pneumatic actuators, and the respective cockpit controls.
Page 92: Power Plant
Flight Manual SECTION 7 Cavalon SYSTEM DESCRIPTION Power Plant Engine There are two engine variants available, being the ROTAX 912 ULS normally aspirated reciprocating engine and the ROTAX 914 UL turbo charged version. Both engine types are 4 cylinder, horizontally opposed, 4 stroke engines.
Page 93: Vibration Damping
The rotor system fitted to Cavalon differs from the standard RotorSystem II in that the blade AOI is 0,4deg less. This is identified by the rotor blade assembly part no and black spacers fitted between the hub bar and rotor blade.
Page 94 Flight Manual SECTION 7 Cavalon SYSTEM DESCRIPTION interconnected. The nose wheel steering is directly linked to pedal/rudder control input by redirected cables. Both pairs of pedals can be adjusted to suit different leg lengths. A shorter adjustment is achieved by pulling the handle which moves the pedals closer. Pulling the handle while pushing with both feet gently against the pedals allows longer adjustment.
Page 95 Flight Manual SECTION 7 Cavalon SYSTEM DESCRIPTION Trim tab fitted to the rudder Throttle and brake panel The throttle and brake panel with choke and cabin heat / cabin temp control is located on the left side of the pilot station in the centre panel. Throttle control (1) is conventional with IDLE in aft (or pulled) and full throttle in most forward position.
Page 96: Electrical System
Flight Manual SECTION 7 Cavalon SYSTEM DESCRIPTION The quadrant also features the control for cabin heating / air conditioning system (4). All controls are labelled correspondingly by engraved text and symbols on the cover plate. Heater control (4) Throttle (1) Brake lever (2) Choke (3) 7.11 Electrical System...
Page 97: Lighting System
Flight Manual SECTION 7 Cavalon SYSTEM DESCRIPTION that the electrical system voltage has dropped below 12v, and, provided the charging circuit is working, that the electrical demand has exceeded supply. If lit, or intermittently lit, either reduce the electrical load or increase generator circuit output by increasing the engine rpm, as safe or appropriate to do, such that the lamp remains off.’...
Page 98 Flight Manual SECTION 7 Cavalon SYSTEM DESCRIPTION 914UL TCU Engine control unit Inst. Panel Cockpit All electrical gauges Inst. panel (rotor and engine rpm, oil pressure, water and oil temps, fuel gauge) and warning lamps Radio Radio (transceiver) Inst. panel...
Page 99: Avionics
Flight Manual SECTION 7 Cavalon SYSTEM DESCRIPTION aircraft console powered from “Heat” CB Note that the external charging point permits charging via a Ctek charger CAUTION Do not reset CB’s in flight unless essential for continued safe flight 7.14 Avionics Radio.
Page 100: Instrument Panel
Flight Manual SECTION 7 Cavalon SYSTEM DESCRIPTION 7.15 Instrument Panel Different instrument panel layouts are available. The basic instrumentation arrangements include: Standard Layout Standard layout with Ipad mounting The standard layout includes all instruments necessary for flight but also installation provisions for additional conventional instrumentation.
Page 101 Flight Manual SECTION 7 Cavalon SYSTEM DESCRIPTION Panel Layout – Standard with Ipad 1 – Hour meter 17 – Fuel level indicator 2 – Circuit Breaker Panel 18 – Cylinder head temperature 3 – Air outlet 19 – Oil pressure 4 –...
Page 102: Intercom
Flight Manual SECTION 7 Cavalon SYSTEM DESCRIPTION 7.16 Intercom The standard intercom system features standard headset sockets (TSR Tip Ring Sleeve) with additional XLR-3 socket for active headset power supply. Sockets are provided at the aft console between the crew seats. The intercom amplifier and VOX control is integrated in the respective radio.
Page 103 Flight Manual SECTION 8 RotorSport logo Cavalon HANDLING / MAINTENANCE CONTENTS Maintenance Obligations ................8-1 General ......................8-1 Ground Handling ................... 8-2 Cleaning ......................8-2 Refuelling ......................8-3 Checking of Engine Oil Level.................8-3 Checking of Engine Coolant Level ..............8-4 Tyre Pressure....................8-4 Lubrication and Greasing................
Page 104 Flight Manual SECTION 8 RotorSport logo Cavalon HANDLING / MAINTENANCE INTENTIONALLY LEFT BLANK RSUK0287_POH_Cavalon Revision 2, Issue Date 24.06.2015 8 - ii...
Page 105: Handling And Servicing
Flight Manual SECTION 8 RotorSport logo Cavalon HANDLING / MAINTENANCE SECTION 8 - HANDLING AND SERVICING This chapter contains guidelines for correct handling and servicing of the gyroplane, as well as manufacturer recommendations helping to keep its performance, reliability and value.
Page 106: Ground Handling
Flight Manual SECTION 8 RotorSport logo Cavalon HANDLING / MAINTENANCE Ground Handling Experience shows that aircraft may be exposed to much higher loads when operated on ground, than when in flight. Take care not to impose high loads caused by excessive and fast taxying on rough terrain, or hard bouncing of the aircraft over the hangar thresholds etc.
Page 107: Refuelling
Flight Manual SECTION 8 RotorSport logo Cavalon HANDLING / MAINTENANCE Refuelling Fuel and Engine Coolant Dip Stick Have aircraft grounded before refuelling. Be aware that most airfield refuelling equipment is laid out for larger diameter tank filler necks and high flow rates. To...
Page 108: Checking Of Engine Coolant Level
Flight Manual SECTION 8 RotorSport logo Cavalon HANDLING / MAINTENANCE Checking of Engine Coolant Level Between flights, the engine coolant level is checked by verifying the level in the header tank. Insert Fuel and Engine Coolant Dip Stick. Coolant level must be visible. Replenish as necessary.
Page 109: Lubrication And Greasing
Flight Manual SECTION 8 RotorSport logo Cavalon HANDLING / MAINTENANCE Lubrication and Greasing Between maintenance intervals the owner/operator is entitled to do the following lubrication and greasing: Component Interval Application Type Teeter hinge 5 hrs (recomm.) as required AutoGyro S.VB6007...
Page 110: Battery
Flight Manual SECTION 8 RotorSport logo Cavalon HANDLING / MAINTENANCE 8.13 Battery The aircraft is fitted with a maintenance-free gel electrolyte. Maintenance is therefore limited to outside soundness, correct attachment, and cleaning. Check integrity of the battery as leaking fluid contains corrosive sulphuric acid which would lead to extensive damage when contacting the framework and attachments.
Page 111: Removal Of The Rotor System
Flight Manual SECTION 8 RotorSport logo Cavalon HANDLING / MAINTENANCE 8.15.1 Removal of the Rotor System 1. Secure the gyroplane on level ground by engaging parking brake, adjust the rotor head or teeter tower corresponding to 30deg from fore-aft and pressurize the rotor brake up to maximum.
Page 112: Disassembly Of The Rotor System
HANDLING / MAINTENANCE CAUTION Cavalon is approved only with RotorSystem II ROA or TOPP. The RAO rotor has a reduced blade angle of attack, as is easily notable by using black blade to hub clamping profiles, and red end caps. The TOPP rotor has clear anodised (silver) spacers and blue end caps.
Page 113: Installation Of The Rotor System
Flight Manual SECTION 8 RotorSport logo Cavalon HANDLING / MAINTENANCE 1. The rotor blades, clamping profile and rotor hub are labelled with an engraved serial number. 2. Insert the first rotor blade carefully into the clamping profile. Make sure that all serial numbers match.
Page 114: Road Transport
Flight Manual SECTION 8 RotorSport logo Cavalon HANDLING / MAINTENANCE 8.16 Road Transport If road transport cannot be avoided, transport with minimum fuel, which reduces airframe loads and prevents fuel spilling through vent pipes. Tie-down the fuselage using the following procedure: ...
Page 115: Pilot Maintenance
Flight Manual SECTION 8 RotorSport logo Cavalon HANDLING / MAINTENANCE Pilot maintenance Permitted pilot maintenance is shown in the AMM. Note! Most fasteners larger than M4 – for example, wheel spat bolts, are retained by Loctite 243. Always apply Loctite 243 to these threads before refitment.
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Page 117: Supplements
Flight Manual SECTION 9 Cavalon SUPPLEMENTS SECTION 9 - SUPPLEMENTS LIST OF SUPPLEMENTS 9-1 IVO-prop in-flight adjustable variable pitch propeller. 9-2 Lights 9-3 GPS/Moving Map Systems 9-4 Fire Indication 9-5 Not used 9-6 not used RSUK0287_POH_Cavalon Revision 3.0, Issue Date 06.04.16...
Page 118 Flight Manual SECTION 9 Cavalon SUPPLEMENTS INTENTIONALLY LEFT BLANK RSUK0287_POH_Cavalon Revision 3.0, Issue Date 06.04.16 9-ii...
Page 119: Ivo-Prop In-Flight Adjustable Variable Pitch Propeller
Flight Manual SECTION 9-1 Cavalon Variable Pitch Propeller - IVO 9-1 IVO-prop in-flight adjustable variable pitch propeller. 9.1. INTRODUCTION A variable pitch propeller (VPP) manufactured by IVO Prop Corp of Long Beach California, is available as optional equipment to optimise propeller efficiency, fuel consumption and noise in all flight regimes and power settings.
Page 120 Flight Manual SECTION 9-1 Cavalon Variable Pitch Propeller - IVO The logic table for operation of the propeller controller is: Both LEDS off Propeller is not at an end position and no pitch change command active Upper LED blinking Propeller changing pitch to FINE...
Page 121 Flight Manual SECTION 9-1 Cavalon Variable Pitch Propeller - IVO 9.5. CIRCUIT PROTECTION The propeller controller is supplied from the propeller power supply (Circuit breaker F5 16A). 9.6. PILOT TRAINING & EXPERIENCE These notes assume that the pilot already has some experience of operating a variable pitch propeller.
Page 122 Flight Manual SECTION 9-1 Cavalon Variable Pitch Propeller - IVO Where: MCP – Maximum Continuous Power TOP – Take-Off Power MAP – Manifold Absolute Pressure 9.8. PRE-FLIGHT INSPECTION Visual: Check each of the propeller blades for damage, small nicks or delamination of the stainless- steel edge protector, and security of attachment to hub.
Page 123 Flight Manual SECTION 9-1 Cavalon Variable Pitch Propeller - IVO 4. Before levelling-out or initiating descent consider the manifold pressure/engine RPM and re-select COARSE when required Caution: flying at low airspeeds with the propeller set fully coarse means that there may be little ram-airflow through the propeller, increasing the chance of engine stall at low or idle rpm.
Page 124 Flight Manual SECTION 9-1 Cavalon Variable Pitch Propeller - IVO Before take-off Do not take-off Try to keep climbing to a safe altitude, return to the airfield and land. If the aircraft does not During take-off and climb climb, maintain altitude and plan to return in a flat curve.
Page 125 Flight Manual SECTION 9-1 Cavalon Variable Pitch Propeller - IVO INTENTIONALLY LEFT BLANK RSUK0287_POH_Cavalon Revision 2, Issue Date 24.06.2015 9-1 - 7...
Page 127: Lights
Flight Manual SECTION 9-2 Cavalon Lights 9-2 Lights 9-2.1 General Depending on customer’s configuration the gyroplane can be equipped with optional  Landing lights Navigation /position lights   Strobe lights 9-2.2 Limitations No change to standard aircraft 9-2.3 Emergency Procedures No change to standard aircraft 9-2.4 Normal Procedures...
Page 128 Flight Manual SECTION 9-2 Cavalon Lights INTENTIONALLY LEFT BLANK RSUK0287_POH_Cavalon Revision 2, Issue Date 24.06.2015 9-2 - 2...
Page 129: Gps/Moving Map Systems
Flight Manual SECTION 9-3 Cavalon GPS/Moving Map Systems 9-3 GPS/Moving Map Systems 9-3.1 General Depending on customer’s configuration the gyroplane can be equipped with different GPS/Moving Map Systems as optional equipment. At the point of compiling this manual only the Ipad, mounted on the left panel, and powered from the aircraft electrical system is permitted to be fitted for flight.
Page 130 Flight Manual SECTION 9-3 Cavalon GPS/Moving Map Systems INTENTIONALLY LEFT BLANK RSUK0287_POH_Cavalon Revision 2, Issue Date 24.06.2015 9-3 - 2...
Page 131: Fire Indication
Flight Manual SECTION 9-4 Cavalon Engine Fire Indication 9-4 Fire Indication 9-4.1 General The UK aircraft configuration includes a Fire indicator light to alert the pilot that a certain temperature in the engine compartment has been exceeded (the engine is on fire). The fire indication circuit consists of a cable routed inside the engine compartment, and also within the electrical fuel system compartment forward of the engine firewall.
Page 132 Flight Manual SECTION 9-4 Cavalon Engine Fire Indication INTENTIONALLY LEFT BLANK RSUK0287_POH_Cavalon Revision 2, Issue Date 24.06.2015 9-4 - 2...
Page 133: Not Used
Flight Manual SECTION 9-6 Cavalon 9-5 Not used 9-6 Not used RSUK0287_POH_Cavalon Revision 2, Issue Date 24.06.2015 9-6 - 1...
Page 135 Flight Manual SECTION 10 Cavalon SAFETY TIPS CONTENTS Low-G Avoidance....................... 10-1 Side Slip in Gyroplanes....................10-1 Flying Low on Fuel Is Dangerous ................10-2 Do Not Push the Envelope and Remain Easy On the Controls........10-2 Strobe Lights On – For Your Own and Other’s Safety ..........10-2 Propellers and Rotors Can Be Extremely Dangerous ..........
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Page 137: Safety Tips
Flight Manual SECTION 10 Cavalon SAFETY TIPS SECTION 10 - SAFETY TIPS General This section provides miscellaneous suggestions and guidance to help the pilot operate the gyroplane more safely. Low-G Avoidance Never push the control stick forward to descend or to terminate a pull-up (as you would in an aeroplane).
Page 138: Flying Low On Fuel Is Dangerous
Flight Manual SECTION 10 Cavalon SAFETY TIPS Flying Low on Fuel Is Dangerous Never intentionally allow the fuel level to become critically low. Although a gyroplane leaves much more options than a fixed wing aircraft and is easier to control during power-off than a helicopter, a forced landing into unknown terrain always poses unnecessary and unpredictable risk with danger to material, health, or life.
Page 139: Overconfidence Prevails In Accidents
Flight Manual SECTION 10 Cavalon SAFETY TIPS disorientation, wrong control inputs, and an uncontrolled crash. This type of situation is likely to occur when a pilot attempts to fly through a partially obscured area and realizes too late that he is losing visibility. He loses control of the gyroplane when he attempts a turn to regain visibility but is unable to complete the turn without visual references.
Page 140: Beware Of Demonstration Or Initial Training Flights
Flight Manual SECTION 10 Cavalon SAFETY TIPS with his built-in senses and programmed reflexes represents a vital part in the active control feedback loop. Helicopter pilots, on the other hand, may underestimate the characteristics of gyroplanes and the necessity for proper training. The simplicity of design may lead them to the assumption that gyroplanes are easy to fly throughout the envelope.
Page 141: Appendix
APPENDIX APPENDIX LIST OF APPENDICES Operator Registration Form Incident Reporting Form Appendix...
Page 142 APPENDIX INTENTIONALLY LEFT BLANK Appendix...
Page 143 APPENDIX 1 Operator Registration Form This form is supplied to enable the new owner to register the change of ownership, so that he/she may receive any service or other information relating to the aircraft. The information is stored on a computer, and is only used within RotorSport UK for the above purpose.
Page 145 APPENDIX 2 Customer Feedback Form Appendix...
Page 147 APPENDIX 3 Incident Reporting Form This form is supplied to enable the owner/operator to inform (anonymously if needed) RotorSport UK Ltd of any incident, accident or other field or service failure that they feel appropriate. The owner must also, of course, inform the relevant authorities if that is appropriate –...

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