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RotorSport Calidus Maintenance Manual

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Copyright of RotorSport UK Ltd
Document number RSUK0061
Maintenance Manual
Gyroplane Type Calidus (UK spec only)
RotorSport UK Ltd
Poplar Farm
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
CAA Approval No: DAI/9917/06
Page 1 of 147
Page issue 7, dated 12.04.16

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  • Page 1 Copyright of RotorSport UK Ltd Document number RSUK0061 Maintenance Manual Gyroplane Type Calidus (UK spec only) RotorSport UK Ltd Poplar Farm 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...

  • Page 2: Applicability

    Autogyro 8.4m RotorSystemII TOPP (blue cap only) NB: all types have silver spacers (clamp profiles) Propeller type: HTC 1,73m with or without spinner. IVO-prop DL3-68 in-flight variable pitch propeller Calidus gyroplane, fitted with semi enclosed canopy Page 2 of 147 Page issue 7, dated 12.04.16...

  • Page 3: Table Of Contents

    Copyright of RotorSport UK Ltd Document number RSUK0061 CONTENTS AND CHECK LIST OF PAGES Content Page No. Cover page Applicability Contents and checklist of pages Section 1 Amendments to the schedule Section 2 Foreword Section 3 Owner/Operator responsibilities Certifying persons responsibilities...
  • Page 4 Copyright of RotorSport UK Ltd Document number RSUK0061 Rotor brake and trim Enclosure, seats, harnesses Instruments Suspension, wheels and brakes Rudder and rudder control Rotor head and rotor head control Fuel system Fire warning system Canopy unlocked warning & interlock system...

  • Page 5: Amendments To The Schedule

    SECTION 1 AMENDMENTS TO THE SCHEDULE 1. Where & when necessary RotorSport UK Ltd (hereafter referred to as RSUK) will issue updates to this maintenance standard, and will notify known owners to review the changes via the RSUK website with changes appropriately identified by a strike in the margin.
  • Page 6 Copyright of RotorSport UK Ltd Document number RSUK0061 List of Effective Pages Page Issue Date Page Issue Date Page 1 12.04.16 Page 49 12.04.16 Page 2 12.04.16 Page 50 12.04.16 Page 3 12.04.16 Page 51 12.04.16 Page 4 12.04.16 Page 52 12.04.16...
  • Page 7 Copyright of RotorSport UK Ltd Document number RSUK0061 Page Issue Date Page Issue Date Page 97 12.04.16 Page 123 12.04.16 Page 98 12.04.16 Page 124 12.04.16 Page 99 12.04.16 Page 125 12.04.16 Page 100 12.04.16 Page 126 12.04.16 Page 101 12.04.16...

  • Page 8: Foreword

    SECTION 2 FOREWORD 1. Applicability This Schedule is intended for use on the CALIDUS Gyroplane only, released on AAN29266. Guidance This aircraft may be being flown & operated under a CAA Permit to fly, and as such specific rules exist to cover maintenance actions, such as the types of work allowed by owners on Permit aircraft or CAP520 ‘Light Aircraft Maintenance’.

  • Page 9: Airworthiness Notices

    On reaching the manufacturer life limit (MLL) the component SHALL be replaced, regardless of its perceived condition. Equipment / System RotorSystem 1 Calidus blade BG1448 700 hours (orange end caps) Rotorsystem II 8.4m BG1793 (red end caps)

  • Page 10: Duplicate Inspections

    Copyright of RotorSport UK Ltd Document number RSUK0061 DUPLICATE INSPECTIONS Following initial assembly or any disturbance of a control system or vital point, the procedures outlined in British Civil Airworthiness Requirements (BCAR) Section A/8, Chapter A6-2/B6-2 and A5-3 shall be applied. Certifications must be recorded in the appropriate worksheet, log book or aircraft technical log.

  • Page 11: Permit Maintenance Release

    Copyright of RotorSport UK Ltd Document number RSUK0061 SECTION 4 PERMIT MAINTENANCE RELEASE This maintenance certification system is specific in accordance with BCAR A3-7. Owner operators must ensure their airframe and engine logbooks either contain a sticker with the wording ‘Any reference to a Certificate of Release to service in this logbook shall be construed as a PMR’...

  • Page 12: Annual Check

    12. Replacement of main rotor blades that are designed for removal where special tools are not required (as is the case on the Calidus). 13. Replacement of VHF communications equipment, only if is not combined with navigation equipment.
  • Page 13 Copyright of RotorSport UK Ltd Document number RSUK0061  CRITICAL: Inspect main gear spring spar (attachment ok, no cracks)  CRITICAL: Inspect fuselage, frame and attachment point for possible deformation or cracks  CRITICAL: Inspect engine rubber mounts and propeller to frame clearance approx. 5 ...

  • Page 14: The Maintenance Check Cycle

    Copyright of RotorSport UK Ltd Document number RSUK0061 SECTION 5 THE MAINTENANCE CHECK CYCLE Check title Content Period Check A Check A Prior to the first flight of the day First 25 hour check 25 hour check items (one Not exceeding 25 flying hours, or 1...

  • Page 15: Pilot's Pre-Flight Check (Check A)

    For update control and one source of information, this check is not printed here. Refer to the Pilots Handbook. For all inspection checks reference must be made to RotorSport UK Ltd, either via the website www.rotorsport.org or directly, for the latest schedule.
  • Page 16 . Note! There is no requirement to annually re weigh a gyroplane. If a re-assessment of the aircraft CG is required, please contact RotorSport UK Ltd. 10) Check of Aircraft hours, Engine serial No and Propeller serial number. 11) Pilots Operating handbook Issue No. You will need to show your copy.
  • Page 17 Copyright of RotorSport UK Ltd Document number RSUK0061 SECTION 8 - ANNUAL FLIGHT TEST Annual Flight Test Schedule – refer to CAA check flight schedule CFS301 if it is decided that a flight test is needed. Intentionally blank Page 17 of 147...
  • Page 18 Copyright of RotorSport UK Ltd Document number RSUK0061 Intentionally blank Page 18 of 147 Page issue 7, dated 12.04.16...

  • Page 19: Aircraft Systems Description And Maintenance Methods

    Copyright of RotorSport UK Ltd Document number RSUK0061 SECTION 9 – AIRCRAFT SYSTEMS DESCRIPTION AND MAINTENANCE METHODS General notes; 1. These instructions are not all encompassing, and should always be used in line with good aircraft engineering practices, and manuals such as AC43.13. Repairs not shown must be approved by either the CAA or RSUK in writing.
  • Page 20 Copyright of RotorSport UK Ltd Document number RSUK0061 Primary and Secondary structure determination: A primary structural part is one for which the failure would be catastrophic and would prevent continued safe flight and landing. All other structure can be considered as Secondary, thus failure of a Secondary structural part would not be immediately catastrophic and with due care continued safe flight and/or a safe precautionary landing could still be made.
  • Page 21 Copyright of RotorSport UK Ltd Document number RSUK0061 Aircraft access for maintenance and inspection The aircraft is fully enclosed; which means access to the ‘workings’ is restricted unless access panels are removed. There are several areas of access. 1. Cabin area. The general cabin area is accessed via the lever on the RHS of the canopy.
  • Page 22 Copyright of RotorSport UK Ltd Document number RSUK0061 ensure the positive is attached to the MIDDLE terminal. The cowl attachment screws have a nylon washer between the screw head and the cowl, and must be securely tightened.. d) Access to the battery, fuel filters etc is achieved by loosening and moving the left (master) fuel tank out of the way.
  • Page 23 Copyright of RotorSport UK Ltd Document number RSUK0061 Unit fitted to Calidus 1. The hypodermic scale is calibrated 0-100 units, this range being equivalent to 1ml of fluid. For both single and dual ASI installations withdraw the plunger to deliver 100 units.
  • Page 24 Copyright of RotorSport UK Ltd Document number RSUK0061 Pneumatic system check: Turn on aircraft keyswitch. With changeover switch in the ‘Brake’ position, engage brake by depressing brake button on control stick, confirm pump and brake operation, and that function is acceptable.

  • Page 25: Airframe

    Copyright of RotorSport UK Ltd Document number RSUK0061 a) Airframe Basic description The airframe is made of 1.4301 stainless steel tube and laser cut brackets, jig welded together with 1.4571 wire. After assembly it is cleaned and electropolished. Side view of airframe Assembly methods None –...
  • Page 26 Copyright of RotorSport UK Ltd Document number RSUK0061 When fitting the bolts to retain the upper and lowers masts together Loctite 2701 must be applied to the threads. Always use new nyloc nuts! Special setup instructions None – factory assembled only Repair methods None.
  • Page 27 Copyright of RotorSport UK Ltd Document number RSUK0061 It is not permitted to weld the airframe unless via an RSUK approved repair scheme, using A8- 10 Approved welders. Inspection: Mast mounting bushings A similar measurement to the above permits assessment of the condition of the mast (rubber) mounting bushings.
  • Page 28 Copyright of RotorSport UK Ltd Document number RSUK0061 Page 28 of 147 Page issue 7, dated 12.04.16...

  • Page 29: Engine And Controls

    Copyright of RotorSport UK Ltd Document number RSUK0061 b) Engine and controls Basic description Engine: The engine is either a Rotax 912 ULS or a 914UL. Both use the standard Rotax white frame engine mounting. Reference must be made to the Rotax service manual supplied with the aircraft and regular checks of the Rotax websites for information on any engineering changes or recommendations.
  • Page 30 Copyright of RotorSport UK Ltd Document number RSUK0061 1. Remove all engine cowls. 2. Disconnect battery, earth lead first. 3. Drain and remove fuel tanks. 4. Disconnect engine earth and live leads. 5. Disconnect fuel system from mechanical fuel pump and from electrical pump(s), or in the case of the 914, disconnect the feed and return hoses to the fuel regulator on top of the engine.
  • Page 31 Copyright of RotorSport UK Ltd Document number RSUK0061 Follow the instructions given in the Rotax handbook for the engine, unless specifically shown to be different in this manual If the magnetic drain plug or the adjacent M8 plug screw are removed ensure that both plugs are wire-locked after carrying-out the servicing required by the Rotax schedule.
  • Page 32 Copyright of RotorSport UK Ltd Document number RSUK0061 912ULS silencer & axial after muffler assy 912ULS exhaust system with Springs are secured by cables for safety. axial after-muffler Materials used See service parts list Special setup instructions Ensure swivel coupling are free to move, and correctly fastened.
  • Page 33 Copyright of RotorSport UK Ltd Document number RSUK0061 Silicone strip fitted under band-clamps (MC-193 / SB043) Basic Description - Oil cooling system: The oil system is a dry sump type. It comprises an oil tank mounted on the right of the aircraft, with hoses connecting it to the engine and cooling radiator via a thermostat.
  • Page 34 Copyright of RotorSport UK Ltd Document number RSUK0061 Return to tank by piston Flow Direction blow-by gas Filter Engine Oil tank RSD4178 (Part of Rotax engine kit, includes right angle tank Return to tank coupling) by pump Ps Thermostat Turbocharger...
  • Page 35 Copyright of RotorSport UK Ltd Document number RSUK0061 Return to tank Flow Direction by piston blow-by gas Filter Engine Oil tank RSD4178 (Part of Rotax engine kit, includes right angle tank coupling) Thermostat Oil cooler 912ULS engine Materials used: Refer spare parts list.
  • Page 36 Copyright of RotorSport UK Ltd Document number RSUK0061 Photo showing oil tank. Note top is flush with the bracket. Bracket is detachable to allow easy removal of the fuel tank. Drain plug is on the bottom. After draining the oil system, prime it in accordance with Rotax handbook procedures before starting the engine.
  • Page 37 Copyright of RotorSport UK Ltd Document number RSUK0061 If hoses are removed or replaced, take care to tie wrap securely as removed and as per photos. The oil pipes pass close to hot points and edges, and are exposed to vibration. Loose pipes will cause fretting and possible oil loss.
  • Page 38 Copyright of RotorSport UK Ltd Document number RSUK0061 Intentionally blank Page 38 of 147 Page issue 7, dated 12.04.16...
  • Page 39 Copyright of RotorSport UK Ltd Document number RSUK0061 Basic description - Water cooling system, 914UL and 912ULS standard This comprises a radiator mounted on top of the engine, with electric cooling fan bonded to the upper side. The system is as shown below in the system schematic. It includes a thermostat to enable the system to heat up faster and to regulate the engine temperature.
  • Page 40 Copyright of RotorSport UK Ltd Document number RSUK0061 Fill with a mix of 50/50 water and EthyleneGlycol antifreeze RSD4535 suitable for aluminium engines. It is highly recommended to use distilled water, as this will limit impurities and corrosion in the engine waterways.
  • Page 41 Copyright of RotorSport UK Ltd Document number RSUK0061 Page 41 of 147 Page issue 7, dated 12.04.16...
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  • Page 43 Copyright of RotorSport UK Ltd Document number RSUK0061 Intentionally blank Page 43 of 147 Page issue 7, dated 12.04.16...
  • Page 44 Copyright of RotorSport UK Ltd Document number RSUK0061 Basic description - Throttle, turbo (where fitted) and choke controls The system comprises a throttle body assembly that also carries the brake lever, on a single pivot bolt connected to the airframe. The choke lever is mounted on the same basic tube, just forward of the throttle body.
  • Page 45 Copyright of RotorSport UK Ltd Document number RSUK0061 Throttle connection to carb Choke connection to carb Photo 1 Carburettor. Ensure cables clamp nuts are securely tightened, approx 3Nm Eccentric idle stop bush. Adjust position by loosening fastening slightly, and turning.
  • Page 46 Copyright of RotorSport UK Ltd Document number RSUK0061 Choke lever Outer cable length adjusters sealed this end under hot melt tube Photo 3 Gap here 60mm nom. Brake reservoir Photo 4 Optional rear seat throttle, fitted with optional main wheel brake lever.
  • Page 47 Copyright of RotorSport UK Ltd Document number RSUK0061 Basic description - Engine electrical system There are three areas; Ignition system cut off, charging system, and starting system (i) The ignition system is cut off by earthing the leads from the coils. There are two wires (one for each coil) located in the connector block on top of the engine, as indicated in the Rotax handbook.
  • Page 48 Copyright of RotorSport UK Ltd Document number RSUK0061 Intentionally blank Page 48 of 147 Page issue 7, dated 12.04.16...

  • Page 49: Electrical

    ATR500 and ATR833) are unique items that connect to the main tree. The strobe sets connect to the main tree (two different options, AVEOflash or Skyflash). Wiring diagrams are below. Note that larger scale copies are available from the RotorSport website.
  • Page 50 Copyright of RotorSport UK Ltd Document number RSUK0061 Page 50 of 147 Page issue 7, dated 12.04.16...
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  • Page 56 Repair methods In line with normal aircraft practice (such as AC43 or relevant CAAIPs). Cable. The use of PVC cable is NOT permitted in this aircraft. The Calidus aircraft is fitted with Raychem type 44 cable and or type 55 cable.
  • Page 57 Copyright of RotorSport UK Ltd Document number RSUK0061 Fuses: Automotive type blade fuses are located on the left lower front of the instrument panel, and named on the right lower side. Note that in-line fuses are fitted to the battery charge circuit, and to the GPS units where fitted (within the equipment supply cable).
  • Page 58 Copyright of RotorSport UK Ltd Document number RSUK0061 Trim Supplies power to the stick Automotive Inst. panel controls operating pneumatic solenoid valves and the compressor relay Rotax regulator Charging circuit from regulator Automotive Engine bay fuse box, to battery/aircraft supply...
  • Page 59 Copyright of RotorSport UK Ltd Document number RSUK0061 The Skyflash system relies on a control to generate the strobe pulse. The navigation lights (if fitted) are powered independently. In the event of a strobe flash failure first check whether the control box or the head is faulty by swopping the head supply cables over at the control box.
  • Page 60 Copyright of RotorSport UK Ltd Document number RSUK0061 CTEK charging unit Charging point location with lead attached. FURTHER INFORMATION (914UL) Under MC-264/SB-073 a protection relay is introduced to provide continued electrical supply to the P1 fuel pump in certain failure conditions.
  • Page 61 Copyright of RotorSport UK Ltd Document number RSUK0061 Extract from Calidus wiring diagram BT5749 Stromlaufplan V now at Issue A002, showing new relay, capacitor and fuse at top-left. Note that for UK aircraft a 100A fuse replaces that shown as 125A.
  • Page 62 Copyright of RotorSport UK Ltd Document number RSUK0061 d) Pneumatic Basic description Refer to pneumatic diagram (choose with or without roll trim, shown at the end of the section). Principle of operation. Single electric pump feeds air into system via a water filter and electric...
  • Page 63 Copyright of RotorSport UK Ltd Document number RSUK0061 cylinder, and allows the other side to vent via a regulator. Releasing the button closes the valve. The same happens in the opposite direction when pressing the right roll trim button. Rotor brake operation Turn mechanical panel switch V1 to 'Brake'.
  • Page 64 Copyright of RotorSport UK Ltd Document number RSUK0061 Circuit diagram with roll trim Page 64 of 147 Page issue 7, dated 12.04.16...
  • Page 65 Copyright of RotorSport UK Ltd Document number RSUK0061 Pneumatic circuit without roll trim. Page 65 of 147 Page issue 7, dated 12.04.16...
  • Page 66 Copyright of RotorSport UK Ltd Document number RSUK0061 Materials used (as per parts list) Assembly methods Hoses are all push type fitting, push on with collet lock, or with thumbscrew lock Special setup instructions Ensure system and air dryer (‘filter’) are water free. Dryer (located under the rear seat) must be removed and either replaced or dried out every 100hrs.
  • Page 67 Copyright of RotorSport UK Ltd Document number RSUK0061 Loss of rotor brake pressure overnight. Normally an air leak, check at the cylinder connection, the changeover switch, & the pressure gauge – and the connections from the panel to the harness.
  • Page 68 The nut torque to clamp the blades to the hub bar is 25Nm. WARNING! The rotor blades used on the Calidus aircraft carry either orange end caps (approved for flight to 90mph) or red end caps (approved for flight to 120mph under...
  • Page 69 Copyright of RotorSport UK Ltd Document number RSUK0061 When assembling, or dis-assembling, do not remove or adjust any other nuts/bolts on the hub assembly – the tracking is factory set, and adjusting may change these settings and adversely affect rotor balance.
  • Page 70 Copyright of RotorSport UK Ltd Document number RSUK0061 The Orange end cap rotor system: View of rotor top Hub bar assy Blade 6 x Rotor blade attachment bolts with 9mm bore washer under head These bolts are all the same length...
  • Page 71 Copyright of RotorSport UK Ltd Document number RSUK0061 View of rotor installed Top view of rotor installed Page 71 of 147 Page issue 7, dated 12.04.16...
  • Page 72 Copyright of RotorSport UK Ltd Document number RSUK0061 Page 72 of 147 Page issue 7, dated 12.04.16...
  • Page 73 Copyright of RotorSport UK Ltd Document number RSUK0061 The red end cap rotor system (RotorSystem II) View of rotor installed in rotor head Note short teeter stops WARNING! It is important to fit the correct length bolt in the associated hole! Fitting the wrong length bolt may result in insufficient safety protrusion through the nylock nut, or that the nut jams on the shank of the bolt before the joint is properly tightened.
  • Page 74 Copyright of RotorSport UK Ltd Document number RSUK0061 Section view of Calidus rotor head with RotorSystem II parts shown. Page 74 of 147 Page issue 7, dated 12.04.16...
  • Page 75 Copyright of RotorSport UK Ltd Document number RSUK0061 Old rotor head assy Rotorsystem II head assy View of RotorSystem II fitted (rotor blades not installed). General notes for both rotors systems Special setup instructions Orange end cap teeter stop (the black plastic blocks) height is 18,8mm, red end cap is 7mm.
  • Page 76 Copyright of RotorSport UK Ltd Document number RSUK0061 WARNING! Never remove the blade balance bars that are bonded inside the blades, or add extra weights – it is an approved design standard and modification will invalidate the permit to fly – and may have fatal consequences.
  • Page 77 Copyright of RotorSport UK Ltd Document number RSUK0061 Repair methods Nicks and small edge damage can be flattened back with very fine wet ‘n’ dry paper and polished out. Dirt and insect debris should be removed prior to flight with soap and water– the smoother the rotor surface, the better the performance.
  • Page 78 Copyright of RotorSport UK Ltd Document number RSUK0061 Replacement of teeter bushings Caution: when disassembling mark all parts so that each and every part is reassembled in exactly the same location and orientation. Warning: aluminium parts must not become warmer than 160ºC or the material properties will be adversely affected.
  • Page 79 Copyright of RotorSport UK Ltd Document number RSUK0061 f) HTC Propeller Basic description See RSDS7066 The HTC propeller is fitted as standard. This is a 3 bladed composite design with an aluminium 2 piece hub machined from solid. Each blade is a foam filled wet layup component in carbon and glass fibre.
  • Page 80 Copyright of RotorSport UK Ltd Document number RSUK0061 After any blade adjustment, ensure all blades have the same angle to within 0.5deg – recheck after tightening the hub. Max ground rpm should be circa 5,400, but do not adjust the propeller blade angle to achieve this value - flight test to ensure the engine does not rev higher than the Rotax maximum, and, if then required, adjust to suit.
  • Page 81 Copyright of RotorSport UK Ltd Document number RSUK0061 or superglue and carbon. The area must be thoroughly cleaned of insect debris and dirt, and abraded to give a good fresh key to bond into. Mix and load the epoxy onto the blade as per the adhesive instructions.
  • Page 82 Copyright of RotorSport UK Ltd Document number RSUK0061 Parts available: engine pneumatic clutch assy, clutch disc and spring, gearbox, UJ assies, upper, middle and lower drive shafts, bendix gear, bearings and shaft. Views of the “Maedler” pre rotator gearbox Assembly methods Screws are loctited to the engine casing.
  • Page 83 Copyright of RotorSport UK Ltd Document number RSUK0061 Repair methods To change the bendix gear shaft or bearings. Ensure rotor head is braked forwards. This can be done without removing the rotors. Remove mast covers and upper engine cover. Remove vertical drive shaft UJ bolt, and slip off UJ from the bendix shaft.
  • Page 84 Copyright of RotorSport UK Ltd Document number RSUK0061 1-gearbox, 2-backing or mounting plate, 3-spacer. Clutch brake fitted here Removal 1. Disconnect the pneumatic hose at the quick-release coupling 2. Cut open and discard cable ties as required 3. Unscrew and remove 4 xM6 bolts and remove the pneumatic clutch with attach ring.
  • Page 85 Copyright of RotorSport UK Ltd Document number RSUK0061 h) Rotor brake and trim (mechanical system) Basic description A simple pneumatic system using a two way cylinder actuates either the rotor brake by applying upwards pressure to the rotor head, or the trim if in flight by pulling downwards.
  • Page 86 Copyright of RotorSport UK Ltd Document number RSUK0061 Intentionally blank Page 86 of 147 Page issue 7, dated 12.04.16...
  • Page 87 Copyright of RotorSport UK Ltd Document number RSUK0061 i) Enclosure, seats, harnesses Basic description Enclosure: The pilot enclosure is manufactured from GRP & CRP. Colour is spray applied and oven cured. Outside colour is to customer order, inside grey, call RSUK for original colour choice. It is fastened to the airframe behind the rear seat each side, left and right of the rear seat, to the main airframe.
  • Page 88 Copyright of RotorSport UK Ltd Document number RSUK0061 Adjustment positions for back of the front seat Left hand front seat locker Page 88 of 147 Page issue 7, dated 12.04.16...
  • Page 89 Copyright of RotorSport UK Ltd Document number RSUK0061 Right hand locker located under the passenger seat. The centre aluminium panel houses the pneumatic pump and circuitry. Assembly methods Enclosure fitment to body Canopy fitment to body – see RSUK0060 Seat fitment...
  • Page 90 Copyright of RotorSport UK Ltd Document number RSUK0061 j) Instruments The arrangement of the control elements and instrumentation in the cockpit is represented in the photos in fig. 2. Differences may occur depending on the equipment fitted – standard analogue, then with various GPS panel options. See table for warning lamp functions.
  • Page 91 Copyright of RotorSport UK Ltd Document number RSUK0061 Warning lamp description and function Item no Marking Function/description When lit, indicates the alternator is not charging the battery. (red) When off, indicates the alternator is charging the battery. May be seen to flicker gently in low light conditions. This is normal and acceptable.
  • Page 92 Copyright of RotorSport UK Ltd Document number RSUK0061 Fig 2, instrument panel, with Garmin GPS. WARNING! GPS options. (i) The GPS units supplied with the aircraft require regular updating of the map displays and potentially, the software included. It is the operators responsibility to ensure the equipment is correctly updated prior to flight, and to understand that the GPS system is NOT a primary navigational aid.
  • Page 93 Copyright of RotorSport UK Ltd Document number RSUK0061 12 (above panel) optional Blank 26,36 21, 9 Analogue panel – standard Page 93 of 147 Page issue 7, dated 12.04.16...
  • Page 94 Copyright of RotorSport UK Ltd Document number RSUK0061 Flymap L Instrument panel option. Note that the fitment of an AHRS module does not change the panel layout – with the exception that a placard stating ‘Day VMC only. Do not rely on this display’ must be affixed adjacent to the Flymap display.
  • Page 95 Copyright of RotorSport UK Ltd Document number RSUK0061 A similar installation is approved under MC-224 for fitment of the Airbox Foresight 3 GPS with AHRS module View of AVmap panel. Page 95 of 147 Page issue 7, dated 12.04.16...
  • Page 96 Copyright of RotorSport UK Ltd Document number RSUK0061 View of panel with GPS area in middle of panel for customer GPS mounting. Note that any aircraft modification – mounting holes, hard wiring to aircraft systems etc, requires CAA approval. It is the operators responsibility to ensure any equipment located in this area does not limit forward stick travel and is properly secure for flight.
  • Page 97 Copyright of RotorSport UK Ltd Document number RSUK0061 Two types of stick-grip are in use: The original “G205” grip has recessed pushbuttons in the top moulding and a soft-foam grip section: The alternative “OEM” stick grip is available (fitted as a complete interchangeable stick assembly) under MC-162 approval –...
  • Page 98 Engine rpm. This gauge is unique to RotorSport UK. Rotor rpm. This gauge is unique to RotorSport UK. Operation may be checked by spinning the rotor. Only works with the keyswitch on. Oil Temp gauge. This gauge is unique to RotorSport UK. May be checked by connection to a slave sensor immersed in water of known temperature (eg boiling =100degC).
  • Page 99 Copyright of RotorSport UK Ltd Document number RSUK0061 Standard commercial air pressure gauge. Used to indicate trim pressure in flight, or rotor brake pressure when on the ground. Roll trim indicator. LED scale used to display trim cylinder differential pressure.
  • Page 100 Copyright of RotorSport UK Ltd Document number RSUK0061 Special setup instructions ASI should be calibrated as an installed instrument with suitable equipment. Transponder. Follow the Funkwerk instructions for unit setup. Aircraft hex codes are available from the CAA G-INFO website. After initial setup the unit function must be confirmed using calibrated, proper equipment –...
  • Page 101 Copyright of RotorSport UK Ltd Document number RSUK0061 Take care with any pneumatic fittings if removed – some contain one way valves and must be replaced correctly orientated. WARNING! Once the panel is removed the engine kill switches are deactivated, and if started cannot be stopped easily.
  • Page 102 Copyright of RotorSport UK Ltd Document number RSUK0061 Compass. Calibrate compass according to the manufacturers instructions, lined with the aircraft keel. – see Appendix A. GPS units are permissible to be fitted in line with RSUK approved mounting (Garmin GPSmap, Flymap), or via RSUK service bulletins. Be careful when fitting device’s to the...
  • Page 103 Copyright of RotorSport UK Ltd Document number RSUK0061 Suspension rubber for nosefork. Note grease under (W2000 or equiv axle grease) Nosewheel in place. Lubricate fork axis with W2000 grease or equiv during assy. Top of fork tube has a square drive welded in which locates into the connecting plate.
  • Page 104 Copyright of RotorSport UK Ltd Document number RSUK0061 Connecting plate fitted. Loctite screw with 243. With the pedal bars aligned to each other by clamping a short bar between them, adjust the push rod lengths to give a 1 deg wheel offset to the left (Means the left rod is approx 6mm longer than the right rod.
  • Page 105 Copyright of RotorSport UK Ltd Document number RSUK0061 Rear seat pedal assy. Lubricate the ptfe liner during assembly with light oil such as ‘3 in 1’, RSD4531. Special setup instructions Tyre pressure 1,5 to 2,2bar main, 1,5 to 1,8bar nose Under modification MC-213 new aircraft are supplied with nitrogen-filled tyres.
  • Page 106 Copyright of RotorSport UK Ltd Document number RSUK0061 The mainwheels are cast aluminium, and care should be taken when handling to avoid damage. The standard tyres can be changed easily in situ, once the three bolts securing the wheel spat have been removed. Then raise the aircraft via a trolley jack under the lowest part of the keel, with a sandbag or similar on the opposite wheel to hold it on the ground.
  • Page 107 Copyright of RotorSport UK Ltd Document number RSUK0061 Remove these 4 bolts to remove brake pads Outer pad Bush Inner pad Calliper with piston Replace parts as required. When refitting there is put a thin smear of Vaseline or grease around the piston, and on the bushes.
  • Page 108 Copyright of RotorSport UK Ltd Document number RSUK0061 2. The brake lever is not returning properly to its stops. Ensure the lever returns – if not check that the rear seat brake cable (if fitted) is adjusted correctly, and that the...
  • Page 109 Copyright of RotorSport UK Ltd Document number RSUK0061 Pedal limit stop plate. Screws retained by loctite 243. Page 109 of 147 Page issue 7, dated 12.04.16...
  • Page 110 Copyright of RotorSport UK Ltd Document number RSUK0061 View of complete pedal assy Page 110 of 147 Page issue 7, dated 12.04.16...
  • Page 111 Copyright of RotorSport UK Ltd Document number RSUK0061 Pedal limit stop is when the link plate touches this stop plate Cable to rudder attachments. Bushes are loctited to the retaining screws, and then split pinned in place for double security. The upper cable goes to the rudder, the lower to the rear seat pedals where fitted.
  • Page 112 Copyright of RotorSport UK Ltd Document number RSUK0061 4. When satisfactory, tighten locknuts on pushrods, and replace nylocks with new. Paint mark rod ends. 5. Attach cables to rudder. Adjust turnbuckle tension to achieve a load to move the pilot pedals of between 5 and 6Kg in mid position, and so that with pedals locked straight ahead the rudder offset is as below.
  • Page 113 Copyright of RotorSport UK Ltd Document number RSUK0061 Turnbuckle. Note wire locking fitted between turnbuckle pivot and the pinned end. Also shows view of rudder mounted to culisse. Note how the wire locking is located into the groove on the spacer between the rod end and the rudder culisse...
  • Page 114 M8 screw Pivot bush Plastic washer MTseries rudder top bearing, as fitted to Calidus 001 and as an authorised repair if the top rudder insert has been cross threaded. View of M6 top pivot, installed, production standard The rudder top bolt torque is 15Nm, secured with loctite 243, as are the four bottom M6 bolts.
  • Page 115 Copyright of RotorSport UK Ltd Document number RSUK0061 Trim tab fitted to the rudder The trim tab must be adjusted progressively, in no more than 5degree increments between flight evaluations. A bias greater than 35degrees should not be required. If in doubt refer to RSUK.
  • Page 116 Copyright of RotorSport UK Ltd Document number RSUK0061 Threaded insert Bushes Adhesive fillet m) Rotor head and rotor head control Basic description Roll angle: +/-8 deg nom (set 1 deg left) Pitch angle: -4 stick forward +20deg stick back The roll and pitch stops are set with pins and are not adjustable Grease nipples are fitted to the rotor, and pitch/roll block.
  • Page 117 Copyright of RotorSport UK Ltd Document number RSUK0061 Side views of the rotor head The damper shown above is always fitted with the orange end- cap rotor system but is optional with RotorSystemII (red end- caps) and Rotorsystem II TOPP variant (blue end caps) Page 117 of 147 Page issue 7, dated 12.04.16...
  • Page 118 Copyright of RotorSport UK Ltd Document number RSUK0061 Rotor head rear face Damper Special setup instructions Ensure that, after all setup, the rotor head is able to reach roll and pitch stops in both directions, and that at the extremes of operation the vertical control rods are still free to rotate.
  • Page 119 Copyright of RotorSport UK Ltd Document number RSUK0061 With the rear control stick in the mid roll, fully forwards position, and seat strap stops in place, there should be at least 5mm (-0, +10) clearance to front seat. The stick should not use the front seat as a ‘stop’...
  • Page 120 Copyright of RotorSport UK Ltd Document number RSUK0061 Check: Base control unit attachment 1. Check fasteners for corrosion and condition/presence of drain holes in the fabrication visible at the bottom aft end of the composite body. If no drain holes present contact RSUK.
  • Page 121 Copyright of RotorSport UK Ltd Document number RSUK0061 Check/adjustment: Rotor Head main axis bolt (A) The first adjustment is to adjust roll tendency. Roll tendency (to bank increasingly left or right) depends on the flight condition, such as mass and altitude, but mainly speed. Due to the turning direction of the rotor the gyroplane has a tendency to roll right at slow speed and roll left at high speed.
  • Page 122 Copyright of RotorSport UK Ltd Document number RSUK0061 Rotor head bridge, bearing and teeter tower Note: it should not be necessary to make either of these adjustments more than 0.5mm. If in doubt refer to RSUK Page 122 of 147...
  • Page 123 Copyright of RotorSport UK Ltd Document number RSUK0061 n) Fuel system Basic description Principles of the fuel system, Rotax 912 ULS: Page issue Vent 4, dated Filler Mech. Carb 2 Header KL145 filter Carb 1 cap, Pump tank E Pump...
  • Page 124 Copyright of RotorSport UK Ltd Document number RSUK0061 cover. ‘OFF’ is when the tap is at 90deg to the cover, and the cover does not close properly. From here the fuel travels as follows: 912ULS: the fuel line splits to provide a feed through a nylon filter into the mechanical fuel pump and to the carburettors, and also to the backup electric fuel pump into a metalclad filter and then to the carburettors.
  • Page 125 Copyright of RotorSport UK Ltd Document number RSUK0061 Right tank, installed Page 125 of 147 Page issue 7, dated 12.04.16...
  • Page 126 Copyright of RotorSport UK Ltd Document number RSUK0061 Left fuel tank, fitted. Note load spreaders The fuel hoses in the engine bay are additionally protected by a red fireproof sleeve. For both engine variants the backup electrical fuel pump is activated by the P2 switch, and is only normally used for take off and landing.
  • Page 127 Copyright of RotorSport UK Ltd Document number RSUK0061 Materials used All hoses within firewall area (rear of the battery) are Semperit FUHT , fire resistant hose. Further, this hose is covered with a red fireproof sheathing. This sheathing must be in place under the engine cowls.
  • Page 128 Copyright of RotorSport UK Ltd Document number RSUK0061 Intentionally blank Page 128 of 147 Page issue 7, dated 12.04.16...
  • Page 129 Copyright of RotorSport UK Ltd Document number RSUK0061 o) Fire warning system Basic description & principle of operation The system comprises the following elements: a. Single colour red led warning lamp b. Diagnostic box c. Harness connection to engine bay d.
  • Page 130 Copyright of RotorSport UK Ltd Document number RSUK0061 Protectowire terminator Left engine installation, 914UL Protectowire 914UL engine rear wire installation Page 130 of 147 Page issue 7, dated 12.04.16...
  • Page 131 Copyright of RotorSport UK Ltd Document number RSUK0061 914UL engine right side installation 912ULS installation under engine rear Page 131 of 147 Page issue 7, dated 12.04.16...
  • Page 132 Copyright of RotorSport UK Ltd Document number RSUK0061 912ULS installation right side 912ULS installation, left side. Page 132 of 147 Page issue 7, dated 12.04.16...
  • Page 133 Copyright of RotorSport UK Ltd Document number RSUK0061 Materials: see parts list. Special set up and test. There are no special setup requirements. After installation, the system must be tested. Turn the keyswitch on. The led must pulse red, then go off.
  • Page 134 Copyright of RotorSport UK Ltd Document number RSUK0061 p) Canopy unlocked warning This device is designed to prevent take off with the canopy unlocked. It consists of a magnetically activated two pole reed switch mounted behind the inner canopy handle (when locked).
  • Page 135 Copyright of RotorSport UK Ltd Document number RSUK0061 3. Thoroughly clean the slot of all swarf, dust and other residues using a scraper, vacuum cleaner, soft bristle brush then a lint-free cloth (or cotton-bud) dampened with Ambersil LO30. This step is important, as any debris will weaken the finished repair.
  • Page 136 This means that there are internal designs that make the product unique, and it must not be replaced by a propeller other than the part supplied by RotorSport UK Ltd. Construction: The blades comprise a resin core, with layers of carbon fibre on top for protection and structural strength.
  • Page 137 Copyright of RotorSport UK Ltd Document number RSUK0061 Propeller construction Propeller mounting flange with “torque-bushes” Page 137 of 147 Page issue 7, dated 12.04.16...
  • Page 138 Copyright of RotorSport UK Ltd Document number RSUK0061 12VDC power is supplied to the propeller by means of two slip-rings in the hub assembly and a brush-box mounted on a fabricated bracket at the rear of the engine. Slip-rings immediately behind spinner.
  • Page 139 Copyright of RotorSport UK Ltd Document number RSUK0061 Control: There is no constant-speed controller fitted to the RSUK IVO-prop installations and pitch adjustment is made manually by means of a rocker-switch mounted on the left of the instrument panel. There are no micro-switches to limit blade movement so the control system utilises a bespoke circuit-board (the end position controller) which detects the rapid rise in current and disconnects motor power when each pitch limit is reached.
  • Page 140 Copyright of RotorSport UK Ltd Document number RSUK0061 Principle of operation: The propeller assembly is an in-flight variable pitch design. Pitch of the three blades is adjusted simultaneously via a cam system inside the propeller. The cams are driven by a 12v motor.
  • Page 141 Copyright of RotorSport UK Ltd Document number RSUK0061 Three types of manifold pressure gauge are available:  Analogue scale with limit placards for 912ULS normally aspirated engine  Analogue scale with limit placards for 914UL turbocharged engine These may be fitted in a the main instrument panel or in a small sub-panel to the lower left of the main instrument panel ...
  • Page 142 Copyright of RotorSport UK Ltd Document number RSUK0061 Assembly methods The propeller-to-gearbox flange attachment bolts (M8 countersunk) are tightened to 25Nm, and are thread-locked with Loctite 243. The propeller main bolts (3/8” hex-head, AN5-36A) with MS21044-N5 nyloc nuts are tightened (and periodically checked) to 40Nm.
  • Page 143 Document number RSUK0061 Section 11 Modifications approved to date For the listing of all approved modifications see the RotorSport website owners section where they are all listed, or the Type Approval Data sheet (TADS) from the CAA website. Service Bulletins issued to date For the listing of all approved service bulletins see the RotorSport website owners section where they are all are listed.
  • Page 144 Depending on the problem identified, a corrective action is investigated and, if needed, CAA involvement and approval obtained prior to repair authorisation. The information given is stored on a computer, and is only used within RotorSport UK and the CAA for the above purpose.
  • Page 145 Copyright of RotorSport UK Ltd Document number RSUK0061 This form (Part 2 of 2) is the response from RotorSport UK Ltd to a Service Repair and Evaluation/Approval request, which specifies the company authorised repair method. Deviation from this method renders the authorisation ineffective.
  • Page 146 Copyright of RotorSport UK Ltd Document number RSUK0061 Appendix A Compass calibration Page 146 of 147 Page issue 7, dated 12.04.16...
  • Page 147 Copyright of RotorSport UK Ltd Document number RSUK0061 Page 147 of 147 Page issue 7, dated 12.04.16...

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