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AUTO GYRO Cavalon Maintenance Manual

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Aircraft Maintenance Manual
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Summary of Contents for AUTO GYRO Cavalon

  • Page 1 Aircraft Maintenance Manual Cavalon | Rotax 915 iS | Rotax 916 iS...
  • Page 2 Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS Aircraft Maintenance Manual for Gyroplane Cavalon 915 iS / 916 iS Part A – Introduction and AMM-CV-915iS/916iS-EN- Page 1 of 15 A-2023-12 Declarations...

  • Page 3: Table Of Contents

    Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS Contents 0 – PREFACE 1 – INTRODUCTION Revision Service Record of Revisions Maintenance Concept and Eligibility Warnings, Cautions and Notes Organization and Handling of the Manual ATA100 Numbering System ATA100 Chapter Code...

  • Page 4: Preface

    Notifications to the Civil Aviation Authorities or other organisations based on legal regulations are unaffected. MTOsport, Calidus, Cavalon, the AutoGyro logo and word picture mark are trademarks or registered trademarks of AutoGyro AG, registered in Germany and other countries. Other company and product names mentioned herein may be trademarks of their respective companies. Mention of third-party products is for informational purposes only and constitutes neither an endorsement nor a recommendation.

  • Page 5: Introduction

    Note that the manual is subdivided into 6 parts which will be revised individually. As an example, the revision index for the aircraft maintenance manual (AMM), Cavalon 915 iS / 916 iS (CV_915iS / 916 iS), Part B could be ‘AMM-CV-915 iS/916 iS-B-2023-12’. Note that the date code is ‘yyyy-mm’...

  • Page 6: Record Of Revisions

    Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS Record of Revisions The manufacturer will keep this manual current as an entire document. After each revision of a part the latest revision index (i.e. list of revision indices for each part) will be published on AutoGyro’s web portal and/or by E-Mail to each subscription customer.
  • Page 7 Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS INTENTIONALLY LEFT BLANK Part A – Introduction and AMM-CV-915iS/916iS-EN- Page 6 of 15 A-2023-12 Declarations...

  • Page 8: Maintenance Concept And Eligibility

    Maintenance Manual Cavalon 915 iS / 916 iS Maintenance Concept and Eligibility The maintenance concept of the Cavalon gyroplane is structured into 3 qualification levels: ▪ Basic Operator (OPR) Maintenance / Pilot Checks and Servicing Line (LNE) Maintenance – Inspection and general maintenance tasks, inspection of Critical ▪...

  • Page 9: Warnings, Cautions And Notes

    Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS Warnings, Caution and Notes This manual uses WARNINGs, CAUTIONs and NOTEs in bold italic letters to indicate especially critical and important instructions. The call-outs appear at the top of the Maintenance Job Card if of general nature or applicable for the complete task, or will directly precede the individual Work Step.

  • Page 10: Organization And Handling Of The Manual

    Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS Organization and Handling of the Manual This manual is structured according to ATA100 numbering system. The numbering system will be explained later in more detail. On document level, the manual is subdivided into 6 parts, named A to F. The designation and content...

  • Page 11: Nomenclature And Structure Of Maintenance Tasks (Job Cards)

    Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS Nomenclature and Structure of Maintenance Tasks (Job Cards) Part E of this manual describes maintenance tasks to be performed by a qualified person in order to check, inspect, replenish, adjust, replace, repair, clean, or to identify malfunctions. Each Task is outlined in detail in a [Maintenance] Job Card.

  • Page 12: Effectivities

    Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS Effectivities A job card may contain information relating to different versions of the referred aircraft. This may be stipulated by optional equipment installed, by different design states (Serial Number driven), or modification (MI, AD).

  • Page 13: Abbreviations And Acronyms

    Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS Abbreviations and Acronyms In this manual, a minimum number of abbreviations are used. Where possible the abbreviations and acronyms used correspond with regulations and common standards. Anti-Collision Light Airworthiness Directive...
  • Page 14 Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS left hand Limited reusability (Parts or components that can be used only once or a limited number of times, such as self-locking nuts, split pins..) LOEP List of Affected Pages Lufttüchtigkeitsanweisung (AD, issued by the Airworthiness Authority)
  • Page 15 Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS Design manoeuvring speed Design speed for maximum gust intensity Visual Flight Rules Maximum level-flight speed at maximum continuous power Minimum level-flight speed Hmin Never Exceed Speed – maximum speed that must never be exceeded...
  • Page 16 Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS Service Bulletin (SB) and Airworthiness Directives (AD) Where appropriate, Service Bulletins (SB), Service Information Letters (SIL) or Airworthiness Directives (AD) will be incorporated into the Maintenance Manual with the next revision.
  • Page 17 Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS Contents CHAPTER 00 INTRODUCTION / AIRCRAFT GENERAL CHAPTER 01 GENERAL 01-11-00 Definitions, Terms and Standard Procedures 01-12-00 Standard Bolt Torques 01-21-00 Standard Commercial Tools 01-91-00 Conversion Tables CHAPTER 02 TOOLS, SPARES AND CONSUMABLE MATERIALS...

  • Page 18: Chapter 00 Introduction / Aircraft General

    CHAPTER 00 - INTRODUCTION / AIRCRAFT GENERAL General The Cavalon 915 iS / 916 iS is a ‘new generation’ gyroplane with either a 4-bladed push propeller or constant speed hydraulic propeller and a 2-blade aluminium main rotor system with swivelling rotor head and split mast with integrated rotor vibration damping.

  • Page 19: Chapter 01 General

    Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS CHAPTER 01 - GENERAL 01-11-00 Definitions, Terms and Standard Procedures The following definitions, procedures and words with special meanings are used in this manual: adjust To put in specified position or condition, usually using tools or devices...
  • Page 20 Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS measure To find out dimensions, capacity or quantity of something. Except for counting of smaller numbers, calibrated measurement devices are needed. monitor To watch a parameter or item over a certain period of time in order to read an exact value, derive a trend or identify a change caused by an event.

  • Page 21: Standard Bolt Torques

    01-21-00 Standard Commercial Tools Most maintenance tasks on the Cavalon can be conducted using standard, commercially available metric tools. In addition, the following standard commercial tools are required: ▪ Inclinometer (digital) / Digital spirit level with angle gauge ▪...

  • Page 22: Conversion Tables

    Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS 01-91-00 Conversion Tables LENGTH / DISTANCE Multiply to obtain / Multiply to obtain m (metre) 3.28 ft (feet) 0.305 mm (millimetre) 0.039 in (inch) 25.4 km (kilometre) 0.54 nm (nautical mile) 1.852...
  • Page 23 Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS -100 -150 -100 -75 100 125 150 175 200 225 250 Celsius - °C Celsius-Fahrenheit Conversion Chart Part B – Master Servicing Manual AMM-CV-915iS/916iS-EN- Page 7 of 24 (Chapter 00 – 20)

  • Page 24: Tools, Spares And Consumable Materials

    Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS CHAPTER 02 - TOOLS, SPARES AND CONSUMABLE MATERIALS 02-51-00 Consumable Materials Consumable Material (CM) referenced throughout this Maintenance Manual is coded AG-XXX-NN where NN is a consecutive number and XXX represents the material code according to the classification...

  • Page 25: Chapter 03 Minimum Equipment Requirement

    Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS CHAPTER 03 - MINIMUM EQUIPMENT REQUIREMENT In accordance with the Pilot’s Operating Handbook (POH) Section 2.11 the following equipment must be operative for flight • Air speed indicator • Altimeter •...

  • Page 26: Chapter 04 Manufacturer Life Limitations

    Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS CHAPTER 04 – MANUFACTURER LIFE LIMITATIONS (MLL) For the safe operation over the specified lifecycle of the aircraft and liability reasons the following manufacturer limitations shall apply. In case the component has an operating hours and calendric time limit the first limit shall apply.
  • Page 27 Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS Critical parts The following parts and assemblies have been denoted critical during the design review process, and special care must be taken with them during storage, handling and installation. Item & Part Number...

  • Page 28: Chapter 05 Time Limits, Inspections & Checks

    Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS CHAPTER 05 - TIME LIMITS, INSPECTIONS & CHECKS For safe operation and continued airworthiness over the specified lifecycle of the aircraft the following inspection schedule shall apply. Note that specified tolerances must NOT be accumulated!

  • Page 29: Scheduled Inspections & Checks

    All daily or pre-flight check list items consist of visual checks and do not replace professional mechanical inspection and maintenance. The Daily / Pre-Flight Checklist for the standard Cavalon 915 iS / 916 iS gyroplane is provided in the current Pilot’s Operating Handbook.

  • Page 30: Unscheduled Inspections

    Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS 05-30-00 Unscheduled Inspections In case of the following events or occurrences, unscheduled inspections have to be performed. Event / Occurrence / Unusual Condition Action / Reference Rotor vibration CHAPTER 18...

  • Page 31: Inspections - Special Operational Incident

    Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS 05-55-00 Inspections - Special Operational Incident Event / Occurrence / Unusual Condition Action / Reference Suspected hard landing see below Rotor contact with obstacle see below Propeller contact with obstacle or external impact...

  • Page 32: Lightning Strike

    Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS Lightning strike A lightning is likely to have caused invisible damage to many components, especially the main rotor bearing. The aircraft must not be flown until satisfactory inspection has been undertaken and any rectification has been completed.

  • Page 33: Chapter 06 Dimensions & Areas

    Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS CHAPTER 06 - DIMENSIONS & AREAS Length 4.60 m Width 1.75 m Height 2.82 m Rotor diameter 8.4 m Rotor disc area 55.4 sqm Propeller diameter 1.72 m Part B – Master Servicing Manual...

  • Page 34: Chapter 07 Lifting / Jacking / Shoring

    Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS CHAPTER 07 - LIFTING / JACKING / SHORING See Job Card 07-00-00 2-1 in Part E of this manual. CHAPTER 08 - LEVELING & WEIGHING Weighing shall be performed in a draft-free hangar on level ground, with the aircraft defueled to minimum useable fuel.

  • Page 35: Chapter 11 Placards & Markings

    Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS CHAPTER 11 - PLACARDS & MARKINGS To avoid duplication and error, placards are shown in the pilot operating handbook (POH or Rotorcraft Flight Manual). Placards may be market specific by language and or units of measure. Check in the respective handbook.

  • Page 36: Servicing

    Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS CHAPTER 12 - SERVICING 12-10-00 Cleaning Care and regular cleaning of engine, propeller, rotor system and fuselage is the basic foundation for airworthiness and reliability. Therefore, the gyroplane should be cleaned after every last flight of the day or more often, if environmental conditions dictate.

  • Page 37: Servicing: Battery

    Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS 12-30-30 Servicing: Battery The aircraft is fitted with a maintenance-free gel electrolyte battery. 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 38: Chapter 13 Unassigned / N/A

    Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS Engine Oil 3.4 ltr as documented CHAPTER 05 for respective time limits. CHAPTER 13-17 – UNASSIGNED / N/A Part B – Master Servicing Manual AMM-CV-915iS/916iS-EN- Page 22 of 24 (Chapter 00 – 20)
  • Page 39 Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS CHAPTER 18 - VIBRATION & NOISE ANALYSIS Vibration may be induced by the rotor system, the propeller or even the engine. Finding out the cause for vibration and its proper cure requires experience and special equipment. This is why vibration analysis and related maintenance can only be performed by specialized service partners , or AutoGyro GmbH, Germany directly.

  • Page 40: Chapter 14 Unassigned / N/A

    AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS Noise is mainly created by the propeller. Engine and muffler play a secondary role in noise emission, as long as intact. Any deficiencies could be easily identified by a visual inspection or tap test. Repair or replace as necessary.
  • Page 41 Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS Contents CHAPTER 21 VENTILATION / HEATING 21-00-00 Ventilation / Heating CHAPTER 22 AUTOPILOT 22-00-10 System / Equipment Descriptions 22-00-11 GMC 507 Autopilot Mode Controller 22-00-12 GSA 28 Servo 22-00-13 Audio Output...
  • Page 42 Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS CHAPTER 22 22-08-40 Pre-Flight Test (PFT) 22-08-50 Normal Mode Tests 22-08-51 Servo Tests 22-08-52 Roll Servo Functional Check 22-08-53 Pitch Servo Functional Check 22-08-54 Yaw Damper Functional Check 22-08-60 GFC 500 Functional Checks...
  • Page 43 Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS 52-20-00 Emergency Exit 52-40-00 Service Covers and Cowlings 52-70-00 Door Warning CHAPTER 53 FUSELAGE CHAPTER 54 UNASSIGNED / N/A CHAPTER 55 STABILIZERS 55-40-00 Rudder CHAPTER 56 WINDOWS 56-10-00 Flight Compartment / Canopy...
  • Page 44 Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS CHAPTER 21 - VENTILATION / HEATING 21-00-00 Ventilation / Heating Each of the two cabin doors features an adjustable fresh air vent and one sliding window with pivoting vent for ventilation. The sliding window can be used as viewing hatch in case of emergencies and is wide enough to reach through with a hand.

  • Page 45: Autopilot

    Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS CHAPTER 22 – Autopilot 22-00-10 System / Equipment Descriptions 22-00-11 GMC 507 Autopilot Mode Controller The GMC 507 Autopilot mode controller is shown in Figure 22-1. The switches on the front panel of the GMC 507 provide inputs to the G5 and G3x instruments and GSA 28 servos for flight director computations.

  • Page 46: Gfc 500 Interface Summary

    Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS 22-00-20 GFC 500 Interface Summary The following figure provides a high-level summary of the GFC 500 autopilot system. Either the G5 or a G3X system is required to be installed. To avoid difficulties in the stability of the attitude indication the magnetometer GMU11 is always installed, the electric compass has shown a better functionality Figure 22-2 –...

  • Page 47: Autopilot Disconnect/Trim Interrupt Switch

    Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS 22-00-32 Autopilot Disconnect/Trim Interrupt Switch A Trim interrupt switch is not implemented in the Aircraft. An AP DISC switch is provided on both pilot’s stick grips to allow for manual disconnect of the autopilot system and to interrupt the pneumatic pitch trim.

  • Page 48: Consideration For Untreated Or Bare Dissimilar Metals

    Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS 22-00-41 Consideration for Untreated or Bare Dissimilar Metals – Advisory material The correct material finish is important when mating untreated or bare dissimilar metals. Materials should be galvanically compatible. When corrosion protection is removed to make an electrical bond any exposed area after the bond is completed should be protected again.

  • Page 49: Preparation Of Aluminium Surfaces

    Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS 22-00-42 Preparation of Aluminium Surfaces The following general procedure is recommended to prepare an aluminium surface for proper electrical bonding. Clean grounding location with solvent. Remove non-conductive films or coatings from the grounding location.

  • Page 50: Troubleshooting

    Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS 22-01-10 Troubleshooting This section provides information to assist with troubleshooting if problems occur. See the GFC 500 Autopilot Configuration Log retained in the aircraft permanent records for a list of the system configuration data.

  • Page 51: Gfc 500 Will Not Pass Pre-Flight Test (Pft)

    Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS depressed, the line should read “Open/High” for the GMC and “Open” for the servos. With the AP DISC switch depressed, the line should read “LOW”. If it does not, troubleshoot the wiring.

  • Page 52: Gfc 500 Can Bus Errors

    Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS Pitch/Roll Offset Calibration as described in 22-08-31 Yaw Offset and Pitch/Roll Offset Calibration. 22-01-24 GFC 500 CAN Bus Errors If there are CAN Bus errors, refer to the G5 Electronic Flight Instrument Part 23 AML STC Maintenance Manual, Garmin p/n 190-01112-11 or the G3X STC Maintenance Manual, Garmin p/n 190-02472-02 for troubleshooting.

  • Page 53: Servicing Information

    Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS 22-03-10 Servicing Information Servicing of the GFC 500 Autopilot equipment is ‘on condition’. In the event of system failure, troubleshoot the GFC 500 Autopilot in accordance with 22-01-10 Troubleshooting. 22-03-11 On Condition Servicing ‘On Condition’...

  • Page 54: Gmc

    Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS 22-04-11 GMC 507 Removal: De-energize the GFC 500 system by pushing the AUTOPILOT circuit breaker. Insert a 3/32” hex drive tool into the left and right access holes. Turn the hex drive tool counter clockwise until the tool stops.

  • Page 55: Autopilot Components Installation

    Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS Reinstall the servo and servo cables using the data provided in the appropriate model- specific installation manual addendum. Refer to the 22-08-A1 General Master Installation List and information later in this section.

  • Page 56: Yaw Components

    Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS 22-04-22 Yaw Components Part C – System Description Section AMM-CV-915iS/916iS-EN- Page 16 of 67 (Chapter 21 – 90) C-2023-12...
  • Page 57 Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS Adjust the turnbuckles and secure with safety wire. 2,5 times windings at the pulley of the Yaw servo are required Ensure that the windings in the neutral position is the same as shown in the picture.

  • Page 58: Roll Components

    Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS 22-04-23 Roll Components Part C – System Description Section AMM-CV-915iS/916iS-EN- Page 18 of 67 (Chapter 21 – 90) C-2023-12...

  • Page 59: Pitch Components

    Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS The arm of the Roll control lever and the arm of the Roll servo need to be parallel. If not, the push pull rod needs to be adjusted and secured again with locking paint.

  • Page 60: Cable Installation

    Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS The arm of the Pitch control base tube and the arm of the Pitch servo need to be parallel. If not, the push pull rod needs to be adjusted and secured again with locking paint.

  • Page 61: Additional Power Cable Installation

    Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS 22-04-28 additional power Cable installation Power supply Installation 1. Wire: highlighted in yellow Point 1 to point 3: Avionic switch to the fuse of the AP Circuit breaker 2. Wire: highlighted in green Point 2 to point 3: Pin 7 of the white (here in grey) 12 pin socket to the fuse of the AP Circuit breaker 3.

  • Page 62: Autopilot Disconnect Button And Pre-Rotator Button Change

    Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS 22-04-30 Autopilot disconnect button and Pre-rotator button change 22-04-31 Pre-rotator button The new pre-rotator button position is now integrated in the throttle lever. This button must be placarded. 22-04-32 Autopilot disconnect button On the stick (pilot and copilot) is now the Autopilot Disconnect button.

  • Page 63: Pneumatic System

    Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS 22-04-40 Pneumatic system New: 48377 Pneumatic System Comfort AP The AP is able to adjust the Pitch movement via the Pneumatic system, therefore a parallel system for the Pitch trim is added into the pneumatic system for the AP...

  • Page 64: Test Equipment

    Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS 22-05-12 Test Equipment A milliohm meter and Kelvin probes are recommended for this test. However, an alternate method may be used to provide equivalent results by using the following procedure and a standard voltmeter, power supply with adjustable current limit, and ammeter.

  • Page 65: Pitch And Roll Clamp Check

    Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS 22-05-30 Pitch and Roll clamp Check A clamp check needs to be made after: • The production of an Aircraft with Autopilot • Installing the Autopilot into an already existing Aircraft (aftermarket Solution) •...
  • Page 66 Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS This Bolds need to be loose or tighten if the clamp force needs to be adjusted. Pitch Roll Part C – System Description Section AMM-CV-915iS/916iS-EN- Page 26 of 67 (Chapter 21 – 90)

  • Page 67: Visual Inspection

    Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS 22-06-10 Visual Inspection Perform a visual inspection in accordance with requirements in Table 22-4. Check for corrosion, damage, or other defects of the GMC 507 and the GSA 28s. Replace any damaged parts as required.

  • Page 68: Gfc 500 Lru Replacement/Configuration & Testing

    Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS 22-08-10 GFC 500 LRU Replacement/Configuration & Testing This section provides procedures to be followed after any GFC 500 LRU is replaced. At the beginning of each LRU section, instructions are given to guide the technician for various removal/replacement scenarios.

  • Page 69: Gfc 500 System Configuration

    Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS 22-08-22 GFC 500 System Configuration For configuration items not related to the GFC 500 Automatic Flight Control System, refer to the Garmin G5 Electronic Flight Instrument Part 23 AML STC Maintenance Manual including ICA, p/n 190-01112- 11 or the Garmin G3X Touch Electronic Flight Instrument System Part 23 AML STC Maintenance Manual including ICA, p/n 190-02472-02.

  • Page 70: G3X Systems

    Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS Select Calibrate to start the calibration process. When the test is complete, select Done to return to the Flight Controls -> Mode Control Panel page. 22-08-33 G3X Systems Start the G3X PFD in configuration mode by pressing and holding the MENU button while applying power to the system.

  • Page 71: Servo Tests

    AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS If the aircraft is configured for miles per hour (mph) instead of knots (Kt), utilize mph as the unit in any step that references Kt. Conversion of value is not required.

  • Page 72: Autopilot Switch Checks

    Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS 22-08-61 Autopilot Switch Checks Power up the system in normal mode. Complete Pre-Flight Test (PFT) as shown in 22-08-40 Pre-Flight Test (PFT). Actuate the TRIM switch on the pilot’s flight controls in the nose down (forward) direction.

  • Page 73: Gps Mode Check

    Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS Verify that VOR is displayed in white with ROL, AP, YD, and PIT in green on the G5 or G3X PFD. Verify that the flight director command bars are displayed in level pitch and roll attitude.

  • Page 74: Vs Mode Check

    Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS Rotate the UP/DN thumbwheel on the GMC 507 DN until 140 KT is displayed to the right of IAS on the G5 or G3X PFD. Verify that the flight director command bars indicate a pitch down command and the flight controls respond in a nose down direction.

  • Page 75: Alts Mode Check

    Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS Press the AP button on the GMC 507 to engage the autopilot. Verify ROL and PIT are displayed on the G5 or G3X PFD. Press the ALT button on the GMC 507 to select ALT mode.

  • Page 76: 22-08- Appendix A: Installation Specific Information

    Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS Press the LVL button on the GMC 507. Verify that LVL and LVL are displayed in green and HDG and PIT are extinguished on the G5 or G3X PFD. Verify that the flight director command bars show level attitude and that the autopilot engages.

  • Page 77: 22-08-A2 Configuration Log (For G5 Equipped Aircraft)

    Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS 22-08-A2 Configuration Log (for G5 Equipped Aircraft) Garmin G5 Config menu Value Main Level 1 Level 2 Flight Controls Garmin Autopilot Servos Pitch + Roll Yaw Damper Enabled Autopilot Roll…...
  • Page 78 Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS Pitch Trim… Trim Control DC Motor Trim Motor Voltage Trim Direction Reverse 85km/h Low Airspeed Threshold 45,9KIAS 52.5mph 160km/h High Airspeed Threshold 86,4KIAS 99.2mph Fastest Movement Speed 100% Slowest Movement Speed...

  • Page 79: 22-08-A3 Configuration Log (For G3X Equipped Aircraft)

    Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS 22-08-A3 Configuration Log (for G3X Equipped Aircraft) Garmin G3X Config menu Value Main Level 1 Level 2 Autopilot General Control Wheel Steering Disabled Engage AP Via CWS Input Disabled Autopilot Engage Limits...
  • Page 80 Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS Yaw Rate Filter Constant 0,08 Yaw Accel Filter Constant 0,16 Trim Roll Trim Roll Trim Motor Control Disabled Pitch Trim Pitch Trim Motor Control Enabled Pitch Trim Motor Direction Reverse...
  • Page 81 Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS selecting Nose Up should cause the trim to move in the nose up direction. Selecting this line and then selecting Nose Down should cause the trim to move in the nose down direction.

  • Page 82: Communications

    Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS CHAPTER 23 - COMMUNICATIONS 23-10-00 Speech Communication / Radio The communication system consists of an integrated VHF radio system installed in the instrument panel. Different versions may be possible. Please refer to the manufacturer’s specifications and manuals for reference.

  • Page 83: Dc Generation And Battery

    Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS 24-30-00 DC Generation and Battery Direct current is provided by two engine-integrated AC generators with 2 external rectifier-regulators (12V 20 A DC) attached to the engine fuse box. GEN1 is used by the engine only, GEN2 is used to supply the aircraft ancillary systems.

  • Page 84: Equipment / Furnishings

    Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS Fuses together with their values and application are listed below: Fuse / Name Value Application F2 Gen. 3 Generator 3 (if installed) F3 Compressor 15 A Electric Compressor F5 ECU Engine Turbo Control Unit (if inst.)

  • Page 85: Emergency

    Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS 25-60-00 Emergency The gyroplane is embarked and disembarked from each side through hinged, gull-wing type doors, both doors are held open by a gas spring. In case of emergency or a jammed door, the gyroplane can be evacuated through the opposite door, if necessary.

  • Page 86: Fire Protection / Fire Warning

    Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS CHAPTER 26 - FIRE PROTECTION / FIRE WARNING Depending on customer’s or market configuration the gyroplane may be equipped with a Fire indicator light to alert the pilot that a certain temperature in the engine compartment has been exceeded (the engine is on fire).

  • Page 87: Flight Controls

    Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS CHAPTER 27 - FLIGHT CONTROLS 27-00-00 Flight Controls CHAPTER 67 – Rotors Flight Control. Note: Stabilizers are described in CHAPTER 27-20-00 Flight Controls - Rudder Rudder (Fin) and nose wheel are controlled simultaneously by adjustable foot pedals, control cables, central control link and nose wheel control link.

  • Page 88: Chapter28 Fuel

    Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS CHAPTER 28 - FUEL 28-10-00 Storage The fuel system consists of two tanks permanently connected with a large cross port, a single filler port, fuel and ventilation lines, fuel level indications, and drain. The filler port is located at the left hand side of the gyroplane.

  • Page 89: Indicating

    Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS Location of gascolator drain point 28-40-00 Indicating An electronic fuel level gauge is provided in the cockpit. An independent low fuel sensor can be installed as an option in the right tank. The LOW FUEL warning light is triggered as soon as 7.5 litres or less of usable fuel remain in the tanks.

  • Page 90: Indicating System

    Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS CHAPTER 29-30 - N/A CHAPTER 31 – INDICATING SYSTEM Note: The hour meter / HOBBS meter is described in CHAPTER 77 - ENGINE INDICATING. 31-10-00 Instruments & Control Panels Different instrument panel layouts are available. The basic instrumentation arrangements include: ▪...
  • Page 91 Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS Panel Layout – Standard / Moving Map Portrait 1 – Water temperature indication 20 – RBT indicator 2 – Engine RPM 21 – ATC transponder (if installed) 3 – Rotor RPM 22 –...

  • Page 92: Right Panel Ii

    31-11-00 Right Panel II The new right panel II for Cavalon integrates the heater/ventilation controls from the new developed Heater system II (3) and the switchable circuit breaker for the lights (2) into the cockpit. 1 – Circuit Breaker Panel 2 –...
  • Page 93 Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS Panel Layout – Glass Cockpit - Single Display 1 – Water temperature indication 15 – MAG switches 2 – Magnetic compass 16 – Trim/brake pressure gauge 3 – Warning lights 17 –...
  • Page 94 Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS Panel Layout – Glass Cockpit - Dual Display 1 – Water temperature indication 13 – Pneumatic mode selector 2 – Magnetic compass 14 – 12V power receptacle (if installed) 3 – Warning lights 15 –...

  • Page 95: Landing Gear

    AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS CHAPTER 32 - LANDING GEAR The Cavalon has a conventional tricycle gear with GRP (glass fibre reinforced plastic) suspension bow and a steerable nose gear. 32-10-00 Main Gear The main gear consists of a GRP suspension bow which is bolted to the underside of the fuselage. The spar is designed to absorb even higher than normal landing loads in case of a hard landing or crash.

  • Page 96: Navigation

    34-10-00 Flight Environment Data The Cavalon features a Pitot-Static System to measure accurate air data. Total pressure is picked up by a pitot type tube located in the nose section of the fuselage. The tube is connected to the integrated cockpit instruments by a plastic pneumatic hose.

  • Page 97: Unassigned / N/A

    Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS CHAPTER 37-50 - UNASSIGNED / N/A CHAPTER 51 - STANDARD PRACTICES - STRUCTURES 51-00-00 Standard Practices - Structures Structural repair of composite structures or the welded steel frame is limited to AutoGyro GmbH or its specialized service partners (job cards labelled ‘SPC’).
  • Page 98 AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS The aft extension (keel tube) of the main frame is made of curved aluminium and carries the stabilizer. The keel tube is connected directly to mating counterparts of the monocoque structure by adhesive joint and secured by bolts.

  • Page 99: Stabilizers

    Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS CHAPTER 54 - N/A CHAPTER 55 - STABILIZERS The stabilizer structure with rudder is made of carbon reinforced plastic (CRP) and is bolted to the keel tube. Presence and function of the stabilizer plays a vital part in flight stability and safety. Inspect carefully all attachment points and the integrity of the composite component.

  • Page 100: Unassigned / N/A

    Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS CHAPTER 57-60 - UNASSIGNED / N/A CHAPTER 61 - PROPELLER In standard configuration a 4-bladed, fixed pitch ‘HTC’ propeller with GRP propeller blades is installed. Depending on customer configuration a spinner may be installed. As an option, the Woodcomp KW30 hydraulic constant speed variable pitch propeller may be fitted.

  • Page 101: Rotor

    Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS CHAPTER 62 - ROTOR The two-bladed, semi-rigid, teetering rotor system comprises high-strength aluminium extruded rotor blades, a hub bar, and a common teeter hinge assembly. Due to their working principle, every two-bladed teetering rotor system induces a certain amount of vibration, depending on flight condition (speed) and disc loading.

  • Page 102: Rotor Head Bridge, Bearing And Teeter Tower

    Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS 62-31-00 Rotor Head Bridge, Bearing and Teeter Tower The rotor head bridge is made of welded stainless steel. Rotor bearing (Manufacturer Life Limited!) and teeter tower represent one integrated component.

  • Page 103: Pre-Rotator Upper Engagement

    Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS 63-11-30 Pre-rotator Upper Engagement The pre-rotator upper engagement comprises a drive pinion with bearing, which is engaged by a small pneumatic actuator into the geared ring / sprocket wheel of the rotor head. The drive pinion is sliding on a helical gear to provide automatic lock-out in case of rotor RPM overrun.

  • Page 104: Unassigned / N/A

    Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS CHAPTER 68-70 - UNASSIGNED / N/A CHAPTER 71 - POWER PLANT Power plant comprises aircraft provisions, installations and systems related to the core engine. The CHAPTER 72 – engine itself is allocated to...

  • Page 105: Air / Engine Cooling

    Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS CHAPTER 72 TO 74 - ENGINE RELATED For the (core) engine refer to the engine manufacturer’s documentation in its latest revision. Concerning fuel system (Filter, Pumps, Shut-off valve) see CHAPTER...

  • Page 106: Engine Controls

    Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS CHAPTER 76 - ENGINE CONTROLS Engine control consists of engine power lever / throttle and related cockpit switches for engine shut- down and test. 76-10-00 Power Control Engine power / throttle is controlled by a control column installed in the centre console between the crew seats.

  • Page 107: Temperature

    Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS 77-20-00 Temperature For temperature indication, an engine coolant temperature (CT) gauge is provided. Due to the engine cooling principle (ram-air cooled cylinders with water cooled cylinder heads) the CT represents cylinder head coolant temperature.
  • Page 108 Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS Contents Wiring Diagram – Aircraft Main Wiring Harness ..................1 Wiring Diagram – Cockpit RH (Standard) ....................3 Wiring Diagram – Cockpit RH (EFIS) .......................5 Wiring Diagram – Cockpit RH (Upgrade Interior Heater II) ..............7 Wiring Diagram –...

  • Page 109: Wiring Diagram - Aircraft Main Wiring Harness

    Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS Wiring Diagram – Aircraft Main Wiring Harness AMM-CV-EN-915iS/916iS- Part D- Diagrams and Charts Page 1 of 80 D-2023-12...
  • Page 110 /25.5:H /15.1:A grün D-Sub /6.3:B 46830 Backup sup RD 2,5² 8.5:D Backup POW RD 2,5² 8.2:D BK 2,5² Backup GND 8.1:C Backup GND2 BK 2,5² 8.2:C BN 0,35² RD 0,5² Rotor RPM /2.2:C /8.9:C RD 2,5² WH/OG 0,35² BU 0,35² BK/WH 0,35²...

  • Page 111: Wiring Diagram - Cockpit Rh (Standard)

    Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS Wiring Diagram – Cockpit RH (Standard) AMM-CV-EN-915iS/916iS- Part D- Diagrams and Charts Page 3 of 80 D-2023-12...
  • Page 112 Option Option LED strip Compass /10.5:F /17a.4:H /17a.5:G 9 10 11 12 13 14 15 16 17 18 19 20 21 /2.10:A gooseneck lamp WH/RD 0,35² WH 0,35² BK 0,35² Option 220µF Strobe Taxi RD/YE 1,5² Land /1.11:B /1a.11:B RD/BK 1,0² RD/BU 1,0²...

  • Page 113: Wiring Diagram - Cockpit Rh (Efis)

    Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS Wiring Diagram – Cockpit RH (EFIS) AMM-CV-EN-915iS/916iS- Part D- Diagrams and Charts Page 5 of 80 D-2023-12...
  • Page 114 X2 - right panel to main wiring harness Color/Lbl Function Sensor Power Battery Backup Power 1 Option Option LED strip Compass RD/BK Pump 2 RD/BK Pump 2 Fan Power Battery Backup Power 2 Ground RD/WH Compressor Power Start Relay Power OG/BK Trim Power Battery Backup GND 2...

  • Page 115: Wiring Diagram - Cockpit Rh (Upgrade Interior Heater Ii)

    Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS Wiring Diagram – Cockpit RH (Upgrade Interior Heater II) AMM-CV-EN-915iS/916iS- Part D- Diagrams and Charts Page 7 of 80 D-2023-12...
  • Page 116 X2 - right panel to main wiring harness Option Option Color/Lbl Function LED strip Compass Sensor Power Battery Backup Power 1 RD/BK Pump 2 RD/BK Pump 2 Fan Power Battery Backup Power 2 Ground RD/WH Compressor Power Start Relay Power OG/BK Trim Power Panel...

  • Page 117: Wiring Diagram - Optional Comfort Features Seats

    Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS Wiring Diagram – Optional Comfort Features Seats AMM-CV-EN-915iS/916iS- Part D- Diagrams and Charts Page 9 of 80 D-2023-12...
  • Page 118 heater back seat heater Copilot Copilot Pilot Pilot BT6620 BT6619 VT 0,35² /11.6:A PK 0,35² YE 0,35² BK 1,5² /1.6:D BU 0,35² RD 2x0,35² seat heater Copilot BG3786 RD 1,5² Heat Switch heater back seat heater RD 1,5² /1.6:D Copilot BK 0,5²...

  • Page 119: Wiring Diagram - Flight Control Sticks

    Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS Wiring Diagram – Flight Control Sticks AMM-CV-EN-915iS/916iS- Part D- Diagrams and Charts Page 11 of 80 D-2023-12...
  • Page 120 Stick left Stick right /1.4:G /1.8:B /1.8:C Co-Sign 1: A002 14/002 Added pinouts 24.02.2014 H.STINDL A003 14/078 Changed plug 23 25.02.2014 H.STINDL A004 14/078 Changed plug to socket (23) 25.02.2014 H.STINDL Co-Sign 2: This drawing may not be used in any from without ourexplicit Modification Date Name...

  • Page 121: Wiring Diagram - Flight Control Sticks With Autopilot

    Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS Wiring Diagram – Flight Control Sticks with Autopilot AMM-CV-EN-915iS/916iS- Part D- Diagrams and Charts Page 13 of 80 D-2023-12...
  • Page 122 Stick left Stick right Prerotator_lever AP-Disc L AP-Disc R /4a.1:D /1.5:G /1.8:B /1.8:C /1a.5:G /1a.8:B /1a.8:C /4.1:A /4.3:A /4.5:A Co-Sign 1: Prerotator_lever A000 31.01.2022 H.STINDL Co-Sign 2: This drawing may not be used in any from without ourexplicit Modification Date Name permission.

  • Page 123: Wiring Diagram - Landing Lights

    Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS Wiring Diagram – Landing Lights AMM-CV-EN-915iS/916iS- Part D- Diagrams and Charts Page 15 of 80 D-2023-12...
  • Page 124 current source left left 1 left 2 350mA current source left/right BK 1,0² Landing lights GND 1.11:C RD/YE 1,0² Landing lights 12V right 3 left 3 1.11:C 350mA current source right right 1 right 2 350mA Co-Sign 1: A000 14.01.2014 H.STINDL A001 14/002...

  • Page 125: Wiring Diagram - Nav / Strobe Lights

    Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS Wiring Diagram – NAV / Strobe Lights AMM-CV-EN-915iS/916iS- Part D- Diagrams and Charts Page 17 of 80 D-2023-12...
  • Page 126 AVEO option Navigation Light Sync right green Strobe /1.3:A BU 0,5² BU 0,5² BK 1,0² RD/BK 1,0² RD/BK 1,0² BK 1,0² Navigation Light RD/BU 1,0² Sync left red RD/BU 1,0² Strobe Co-Sign 1: A001 14/002 23.01.2014 H.STINDL A002 14/002 Added pinouts 24.02.2014 H.STINDL A003...

  • Page 127: Wiring Diagram - Cockpit Lh (Standard)

    Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS Wiring Diagram – Cockpit LH (Standard) AMM-CV-EN-915iS/916iS- Part D- Diagrams and Charts Page 19 of 80 D-2023-12...
  • Page 128 Rotor Water Motor Fuel Water Temp Pressure Temp Flow /7.2:A /19.3:A /12.4:B /19.5:A /15.1:B /19.3:C grau Co-Sign 1: 21.06.2017 H.STINDL Harald Stindl A000 22.02.2019 H.STINDL 2019.04.17 11:48:28 +02'00' A001 Added dimmer function 17.04.2019 H.STINDL Co-Sign 2: This drawing may not be used in any from without ourexplicit Modification Date Name...

  • Page 129: Wiring Diagram - Starter / Battery

    Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS Wiring Diagram – Starter / Battery AMM-CV-EN-915iS/916iS- Part D- Diagrams and Charts Page 21 of 80 D-2023-12...
  • Page 130 Option Shunt 1.1:E 0,25A WH/OG 0.35² /1.1:B RD/YE 2,5² BK/WH 0,35² 1.1:E Main GY 2,5² charging plug 0,25A Lifter / 21.1:A GEN3 B+ 14.5:B RD 10,0² RD 1,5² BK 1,5² Regulator A RD 2,5² Backup POW / 1.2:A RD/YE 2,5² GY 2,5²...

  • Page 131: Wiring Diagram - Cockpit Center

    Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS Wiring Diagram – Cockpit Center AMM-CV-EN-915iS/916iS- Part D- Diagrams and Charts Page 23 of 80 D-2023-12...
  • Page 132 RD/YE 2,5² /2.3:F RD 1,0² BK 2,5² GY 2,5² RD 4,0² BK 2,5² RD 1,0² /1.11:G grün Co-Sign 1: 19.08.2016 H.STINDL Harald Stindl 21.06.2017 H.STINDL 2019.04.15 06:41:20 +02'00' A000 22.02.2019 H.STINDL Co-Sign 2: This drawing may not be used in any from without ourexplicit Modification Date Name...

  • Page 133: Wiring Diagram - Cockpit (General)

    Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS Wiring Diagram – Cockpit (General) AMM-CV-EN-915iS/916iS- Part D- Diagrams and Charts Page 25 of 80 D-2023-12...
  • Page 134 BK/BN 0,35² /1.8:G RD/BN 0,35² green WH/VT 0,35² Not NVFR Option Option NVFR YE/BK 0,35² NVFR Option without dimmer panel RD 0,5² RD 0,35² BK/GN 0,35² RD/GN 0,35² PWM Dimmer Option Option Altimeter OUT+ AutoGyro AutoGyro 1000 Fire Pitot GEN3 Low Fuel Oil P.

  • Page 135: Wiring Diagram - Pneumatic System (Standard / Comfort)

    Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS Wiring Diagram – Pneumatic System (Standard / Comfort) AMM-CV-EN-915iS/916iS- Part D- Diagrams and Charts Page 27 of 80 D-2023-12...
  • Page 136 Komfort RD/WH 1,0² /3.1:B RD 0,5² /1.4:H RD 0,5² RollTrim Sensor RD 0,5² BG2809 RD 0,5² BK 1,0² RD/WH 1,0² sensorline /1.4:H VT 0,35² RD 0,5² sensorline BK 0,5² BK 0,5² Firewall RD 0,5² sensorline RD 0,5² sensorline BK 1,0² RD 0,5²...

  • Page 137: Wiring Diagram - Pneumatic System (Autopilot)

    Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS Wiring Diagram – Pneumatic System (Autopilot) AMM-CV-EN-915iS/916iS- Part D- Diagrams and Charts Page 29 of 80 D-2023-12...
  • Page 138 OG/BK 0,35² /3.1:B GN/GY 0,35² /11.7:B YE/VT 0,35² VT/OG 0,35² /1.4:H /1a.4:H PK/GN 0,35² /11.9:B 10 11 12 13 14 15 green /11.4:C /11.4:C /11.5:C /11.5:C BK 0,35² /11.1:D / 11.1:D / 11.1:D / 11.2:D / 11.2:D YE 0,35² GN/VT 0,35² /1.5:H /1a.5:H /11.8:E...

  • Page 139: Wiring Diagram - Fan

    Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS Wiring Diagram – Fan AMM-CV-EN-915iS/916iS- Part D- Diagrams and Charts Page 31 of 80 D-2023-12...
  • Page 140 /1.1:E Water O. 90°C C. 95°C Co-Sign 1: 22.02.2019 H.STINDL Harald Stindl 15.04.2019 H.STINDL 2019.04.15 08:51:58 +02'00' A000 15.04.2019 H.STINDL Co-Sign 2: This drawing may not be used in any from without ourexplicit Modification Date Name permission. Nor may it be shown publically, by third party or for competitve purposes.

  • Page 141: Wiring Diagram - Fuel Level And Low Level Sensors

    Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS Wiring Diagram – Fuel Level and Low Level Sensors AMM-CV-EN-915iS/916iS- Part D- Diagrams and Charts Page 33 of 80 D-2023-12...
  • Page 142 /1.C:2 WH 0,35² A000 22.01.2014 H.STINDL co-sig 2: co-sig 1: Diese Zeichnung darf ohne unsere Genehmigung A001 14/002 23.01.2014 H.STINDL weder vervielfälltigt, noch veröffentlich, noch Index Datum Name Dritten oder dem Wettbewerb zugängig gemacht Änderung werden. Benennung / Interne ID Tank Sensor Satz Datum Name...

  • Page 143: Wiring Diagram - Engine Wiring Harness

    Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS Wiring Diagram – Engine Wiring Harness AMM-CV-EN-915iS/916iS- Part D- Diagrams and Charts Page 35 of 80 D-2023-12...
  • Page 144 RD 1,0² /1.1:C WH/VT 0,35² /16.5:A yellow YE/RD 0,35² BK 0,5² WH/OG 1,5² WH/VT 1,5² pressure switch BK 10,0² Option ex. GEN Co-Sign 1: 21.06.2017 H.STINDL Harald Stindl A000 22.02.2019 H.STINDL 2019.04.15 06:43:17 +02'00' A001 Removed fuel p. 15.04.2019 H.STINDL Co-Sign 2: This drawing may not be used in any from without ourexplicit Modification...

  • Page 145: Wiring Diagram - Can Convertor

    Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS Wiring Diagram – CAN Convertor AMM-CV-EN-915iS/916iS- Part D- Diagrams and Charts Page 37 of 80 D-2023-12...
  • Page 146 CAN_Converter /1.10:A 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 RD 0,5² /10.9:G BK 0,5² violet 46846 WH/BN 0,35² RD 0,5² /7.3:C VT/OG 0,35² /19.3:C BK 0,5² BU/GN 0,35² grau GN/WH 0,35² GN/RD 0,35²...

  • Page 147: Wiring Diagram - 24V Option

    Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS Wiring Diagram – 24V Option AMM-CV-EN-915iS/916iS- Part D- Diagrams and Charts Page 39 of 80 D-2023-12...
  • Page 148 /1.1:D /14.4:A /18.7:B BK 0,5² RD 0,5² WH/VT 0,35² WH/VT 0,35² RD 0,5² RD 0,5² RD 4,0² RD 4,0² RD/BK 0,5² RD/BK 0,5² RD/BK 0,5² BK 4,0² BK 4,0² WH/VT 0,35² 20000µF RD 0,5² Generator 24V RD 4,0² Ladedose 24V BK 4,0²...

  • Page 149: Wiring Diagram - Cockpit Left Dimmer

    Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS Wiring Diagram – Cockpit left Dimmer AMM-CV-EN-915iS/916iS- Part D- Diagrams and Charts Page 41 of 80 D-2023-12...
  • Page 150 Water Water Fuel /7.2:A Pressure Temp Temp Flow /19.3:A /12.4:B /7.4:A PWM Dimmer OUT+ OUT- /7.3:C /15.1:B grau /10.10:C /20.3:A Co-Sign 1: 21.06.2017 H.STINDL Harald Stindl A000 22.02.2019 H.STINDL 2019.04.18 06:53:48 +02'00' changed resistor dimmer to PWM A001 17.04.2019 H.STINDL dimmer Co-Sign 2: This drawing may not be used in any from without ourexplicit...

  • Page 151: Wiring Diagram - Dimmer

    Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS Wiring Diagram – Dimmer AMM-CV-EN-915iS/916iS- Part D- Diagrams and Charts Page 43 of 80 D-2023-12...
  • Page 152 /10.10:C /10.11:E /19.5:C 6pol plug blue 3Pol plug Kabelfarbe (44) (101) BK/RD 0.5² OG/WH 0.5² 580 mm /7.5:A BK/RD 0.5² /7.5:A OG/WH 0.5² 400 mm positiv lock RD/OG timer stecker 3xMCP BK/RD - OG/WH - VT 350 mm 170 mm timer stecker Co-Sign 1: A000...

  • Page 153: Wiring Diagram - Camera Mount

    Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS Wiring Diagram – Camera Mount AMM-CV-EN-915iS/916iS- Part D- Diagrams and Charts Page 45 of 80 D-2023-12...
  • Page 154 /2.2:G /2.2:G RD 1,0² BK 1,0² Lifter down RD 1,0² BK 1,0² Lifter / 8.3:B green RD 6,0² BK 6,0² Lifter Pos down Gimbal PN Lifter BK 1,0² BK 1,0² /21.4:B PN Box Lifter Gimbal Compressor Lifter Pressure Lifter switch 8 Bar Co-Sign 1: A003...

  • Page 155: Wiring Diagram - Garmin G3X Cockpit 2 X 7

    Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS Wiring Diagram – Garmin G3X Cockpit 2 x 7” AMM-CV-EN-915iS/916iS- Part D- Diagrams and Charts Page 47 of 80 D-2023-12...
  • Page 156 GDU 450 GSU 25 GTP 59 GDU 450 RD3 0.35² /24b.2:A /24b.4:A /24b.5:A P251 OG 0.35² P252 /25.7:E Sub-D Sub-D BK 0.35² P4X02 Sub-D CAN_WH/BU 0.35² CAN_WH 0.35² BN 0.35² /24b.1:B WH 0.35² P4X01 Sub-D WH/BU 0.35² gelb BK 0.5² /24b.3:B /32.3:E blau...

  • Page 157: Wiring Diagram - Garmin G3X Cockpit 1 X 10

    Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS Wiring Diagram – Garmin G3X Cockpit 1 x 10” AMM-CV-EN-915iS/916iS- Part D- Diagrams and Charts Page 49 of 80 D-2023-12...
  • Page 158 GDU 460 GSU 25 GTP 59 RD3 0.35² /24a.3:A /24a.4:A /24a.5:A P251 OG 0.35² P252 /25.7:E Sub-D Sub-D BK 0.35² CAN_WH/BU 0.35² CAN_WH 0.35² BN 0.35² /24a.1:B WH 0.35² P4X01 WH/BU 0.35² Sub-D gelb /24a.3:B /32.3:E blau AUDIO - WH/BU 0.35² /24a.1:B /37.1:B P4X02...

  • Page 159: Wiring Diagram - G3X Installation Kit

    Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS Wiring Diagram – G3X Installation Kit AMM-CV-EN-915iS/916iS- Part D- Diagrams and Charts Page 51 of 80 D-2023-12...
  • Page 160 J244 Sub-D J242 GEA 24 GMU 11 J111 J241 Sub-D Sub-D /24a.3:D /24a.5:D /24b.3:D /24b.5:D grau purpur J243 S_GND 0,35² OG/BU 0,35² GN/YE 0,35² BK 0,35² 7,5V ZD GN/WH 0,35² GN/WH 0,35² 1A/200V /24a.5:A /24b.5:A BK/WH 0.35² WH/OG 0.35² Co-Sign 1: 22.02.2019 H.STINDL Harald Stindl...

  • Page 161: Wiring Diagram - G3X Installation

    Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS Wiring Diagram – G3X Installation AMM-CV-EN-915iS/916iS- Part D- Diagrams and Charts Page 53 of 80 D-2023-12...
  • Page 162 Sensoranalyser wiring harness (GEA 24 - J241) Magnetometer wiring harness (GMU 11) 9pol plug grey Garmin G3X - GEA 24 Anschlusssatz Garmin G3X - GMU 11 Einbausatz (21035) 9pol plug purpur (45851) (45853) Kabelfarbe Kabelfarbe (21035) 9 Pol. Kabelfarbe WH/BU 0.35² Kabelfarbe WH/BU 0.35²...

  • Page 163: Wiring Diagram - Gtx 35R Installation

    Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS Wiring Diagram – GTX 35R Installation AMM-CV-EN-915iS/916iS- Part D- Diagrams and Charts Page 55 of 80 D-2023-12...
  • Page 164 WH 0.35² /24b.11:A J2301 gelb Sub-D BK 0.35² RD 0.35² RD 0.35² WH/BU 0.35² OG 0.35² BK 0.35² BK 0.35² BK 0.35² RD 0.35² BN 0.35² BN 0.35² BK 0.35² OG 0.35² WH 0.35² OG 0.35² WH/BU 0.35² Co-Sign 1: 25.05.2018 H.STINDL Harald Stindl...
  • Page 165 Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS Wiring Diagram – GTX 35R Installation AMM-CV-EN-915iS/916iS- Part D- Diagrams and Charts Page 57 of 80 D-2023-12...
  • Page 166 Garmin G3X - GTX 35R installation kit (46171) 7 x timer contact Please preinstall the rack mount (male) Schirm unter Schirm auflegen Kontakt 50mm 1300 mm Co-Sign 1: 22.02.2019 H.STINDL Kabelfarbe M.Sc. Harald Stindl A000 22.02.2019 H.STINDL 2020.11.19 09:41:07 +01'00' WH 0.35²...

  • Page 167: Wiring Diagram - Gtr 20 Installation

    Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS Wiring Diagram – GTR 20 Installation AMM-CV-EN-915iS/916iS- Part D- Diagrams and Charts Page 59 of 80 D-2023-12...
  • Page 168 Shield RD 1.0² J2001 Binder Socket WH 0.35² CoPilot WH/BU 0.35² GMA - WH/BU 0.35² GMA - WH/BU 0.35² YE_C - WH/BU 0.35² YE_P - WH/BU 0.35² Binder Plug BN/YE 0,35² GMA 245 Connect GN_C - WH/BU 0.35² GN_P - WH/BU 0.35² GN_P - WH/BU 0.35²...
  • Page 169 Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS Wiring Diagram – GTR 20 Installation AMM-CV-EN-915iS/916iS- Part D- Diagrams and Charts Page 61 of 80 D-2023-12...
  • Page 170 Binder coupling (20951) pilot (22564) Binder plug pilot (21018) GMA 245 4 x N Binder coupling (22564) Schirm auflegen (20951) copilot copilot Garmin G3X - GTR 20 installation kit (46170) 1200 mm 150 mm 8 x timer contact (male) Jack Bush KLB4 (23731) Schirme unter Schirm auflegen...

  • Page 171: Wiring Diagram - Gma 245 Installation

    Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS Wiring Diagram – GMA 245 Installation AMM-CV-EN-915iS/916iS- Part D- Diagrams and Charts Page 63 of 80 D-2023-12...
  • Page 172 Passenger Shields connect /34.9:B with the plug case 7 pin /34.8:B /24a.8:C /29.7:B /24b.7:C J2401 /34.8:B brown Plug-PushPull Com 2 GMA2_YE - WH/BU 0.35² /34.2:C GMA2_YE- WH 0.35² green GMA2_GN - WH 0.35² GMA2_GN - WH/BU 0.35² /34.9:C Binder Plug 0,25A Pilot (blue) YE_P - WH/OG 0.35²...
  • Page 173 Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS Wiring Diagram – GMA 245 Installation AMM-CV-EN-915iS/916iS- Part D- Diagrams and Charts Page 65 of 80 D-2023-12...
  • Page 174 1500mm 500mm use cable tie min. 100mm A - 200mm Kabelbinder 2x B 20951 20951 wires to X68 5x20340 20951 Kabel für X68 BNYE 3x21473 G - 850mm KLB4 23731 Co-Sign 1: M.Sc. Harald Stindl 2020.11.19 09:45:02 +01'00' A000 06.10.2020 H.STINDL Co-Sign 2: This drawing may not be used in any from without ourexplicit...

  • Page 175: Wiring Diagram - Gma 245 To Atr833 Adaptor

    Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS Wiring Diagram – GMA 245 to ATR833 Adaptor AMM-CV-EN-915iS/916iS- Part D- Diagrams and Charts Page 67 of 80 D-2023-12...
  • Page 176 /28.7:B J2401 Shields connect with the plug case 9 10 11 12 33 34 35 36 37 Wiring harness /28.8:E J2402 Shields connect with the plug case Line In shield /24b.6:D /28.6:E Radio Co-Sign 1: A000 05.06.2018 H.STINDL Seite Harald Stindl 27.06.2018 H.STINDL 2018.08.10 10:01:08 +02'00'...
  • Page 177 Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS Wiring Diagram – GMA 245 to ATR833 Adaptor AMM-CV-EN-915iS/916iS- Part D- Diagrams and Charts Page 69 of 80 D-2023-12...
  • Page 178 SUB-D 25p. plug (male) 29376 450 mm Garmin G3X - GTR 245 (2 D-Sub plugs) SUB-D 25p. plug (famale) 29376 6 pol. plug (famale) 22183 500 mm Jack Bush KLB4 23731 700 mm Co-Sign 1: 22.02.2019 H.STINDL M.Sc. Harald Stindl A000 22.02.2019 H.STINDL...

  • Page 179: Wiring Diagram - Gdl 50 Installation

    Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS Wiring Diagram – GDL 50 Installation AMM-CV-EN-915iS/916iS- Part D- Diagrams and Charts Page 71 of 80 D-2023-12...
  • Page 180 GDL 50 - ADS-B in RS 232 TX RS 232 RX Co-Sign 1: 22.02.2019 H.STINDL Harald Stindl A000 22.02.2019 H.STINDL 2019.06.27 08:43:03 +02'00' A001 Changed GDL 50 plug 27.06.2019 H.STINDL Co-Sign 2: This drawing may not be used in any from without ourexplicit Modification Date Name...

  • Page 181: Wiring Diagram - Gdl 50 Data / Power Cable

    Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS Wiring Diagram – GDL 50 Data / Power Cable AMM-CV-EN-915iS/916iS- Part D- Diagrams and Charts Page 73 of 80 D-2023-12...
  • Page 182 GDL50 data/power plug Round plug female insulated Round plug male insulated 50mm 650mm Co-Sign 1: A000 22.02.2019 H.STINDL M.Sc. Harald Stindl A001 Changed GDL 50 plug 27.06.2019 H.STINDL 2020.11.19 09:42:26 +01'00' A002 06.10.2020 H.STINDL Co-Sign 2: This drawing may not be used in any from without ourexplicit Date Name permission.

  • Page 183: Wiring Diagram - Gmc507 Installation

    Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS Wiring Diagram – GMC507 Installation AMM-CV-EN-915iS/916iS- Part D- Diagrams and Charts Page 75 of 80 D-2023-12...
  • Page 184 GSA 28 - Pitch GSA 28 - Roll GSA 28 - YAW AP-Disc L AP-Disc R /4a.2:A /4a.4:A /24a.3:C /24b.3:C /25.7:D /38.9:E grau /24a.3:C 10 11 12 13 14 15 /24b.3:C /25.7:D /2.11:E /38.9:C /38.3:E grau GMC 507 /2.11:E /38.2:E grau Co-Sign 1: A000...

  • Page 185: Pneumatic Scheme - Standard/Comfort

    Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS Pneumatic Scheme – Standard/Comfort NOTE! Item 20 6bar pressure limiter MUST be set fully open (unlimited) or replaced with a straight coupling for the 915 aircraft (Rotorhead III) configuration AMM-CV-EN-915iS/916iS-...
  • Page 186 NC / YE CoPilot Pilot BU / YE Cockpit WH/YE Pneumatic box comfort (R1) (R2) (EA) (EB) 26621 back cushion Rückenstütze Air 38774 pressure switch 3bar Druckschalter 3Bar 12473 4-ways valve 4-Wege Ventil 38135 pressure switch 8bar Druckschalter 8Bar 25162 Pressure control 0.5bar Druckregler 0.5bar 20856...

  • Page 187: Pneumatic Scheme - Autopilot

    Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS Pneumatic Scheme – Autopilot AMM-CV-EN-915iS/916iS- Part D- Diagrams and Charts Page 79 of 80 D-2023-12...
  • Page 188 NC/YE CoPilot Pilot BU/YE WH/YE AP – Trim 200hPa in 5sec, Down 31015 Dryer Trockner 31014 Compessor Kompressor A000 31.01.2021 H. Stindl 47245 Valve block Ventilblock 20856 Non-return valve Rückschlagventil A001 Move the non-return valve out of the valve block 12.05.2022 H.
  • Page 189 Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS Contents 07-00-00 2-1 LIFTING OF THE GYROPLANE 07-00-00 2-2 JACKING OF THE GYROPLANE 07-00-00 2-3 SHORING OF THE GYROPLANE 08-20-00 2-1 LEVELING OF THE GYROPLANE 24-30-00 4-1 REMOVAL-INSTALLATION: BATTERY 27-10-00 5-1...
  • Page 190 Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS 63-11-10 8-2 REPLACEMENT: PRE-ROTATOR COUPLING DOG GEAR 63-11-30 6-1 INSPECTION: PRE-ROTATOR UPPER ENGAGEMENT 63-51-00 8-1 REPLACEMENT: ROTOR BRAKE PAD 67-00-00 6-1 INSPECTION: FLIGHT CONTROL PUSH-PULL CABLES 67-05-00 8-1 REPLACEMENT: PITCH TRIM/BRAKE PNEUMATIC SEAL...
  • Page 191 Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS 07-00-00 2-1 LIFTING OF THE GYROPLANE GENERAL, REFERENCES AND REQUIREMENTS Task may only be performed by an organization or individual trained and entitled to carry out 'Professional Maintenance'! Secure gyroplane against unauthorized or unintended operation!

  • Page 192: General, References And Requirements

    Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS 07-00-00 2-2 JACKING OF THE GYROPLANE GENERAL, REFERENCES AND REQUIREMENTS Task may only be performed by an organization or individual trained and entitled to carry out 'Professional Maintenance'! Secure gyroplane against unauthorized or unintended operation!

  • Page 193: Rotor System Must Be Removed, See

    Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS 07-00-00 2-3 SHORING OF THE GYROPLANE GENERAL, REFERENCES AND REQUIREMENTS Basic operational task, which can be performed by a licensed pilot or instructed personnel! Rotor system must be removed, see...
  • Page 194 Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS ILLUSTRATIONS AMM-CV-915iS/916iS-EN- Part E - 07-00-00 2-3 Page 2 of 2 E-2023-12...
  • Page 195 Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS 08-20-00 2-1 LEVELING OF THE GYROPLANE GENERAL, REFERENCES AND REQUIREMENTS Task may only be performed by an organization or individual trained and entitled to carry out 'Professional Maintenance'! Secure gyroplane against unauthorized or unintended operation!
  • Page 196 Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS 24-30-00 4-1 REMOVAL-INSTALLATION: BATTERY GENERAL, REFERENCES AND REQUIREMENTS Task may only be performed by an organization or individual trained and entitled to carry out 'Professional Maintenance'! Secure gyroplane against unauthorized or unintended operation!
  • Page 197 Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS 27-10-00 5-1 CHECK-ADJUSTMENT: ROLL CONTROL TRAVEL LIMITATION GENERAL, REFERENCES AND REQUIREMENTS Task may only be performed by an organization or individual trained and entitled to carry out 'Professional Maintenance'! Secure gyroplane against unauthorized or unintended operation!
  • Page 198 Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS 27-20-00 5-1 CHECK-ADJUSTMENT: RUDDER CONTROL ANGLES GENERAL, REFERENCES AND REQUIREMENTS Task may only be performed by an organization or individual trained and entitled to carry out 'Professional Maintenance'! Secure gyroplane against unauthorized or unintended operation!
  • Page 199 Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS ILLUSTRATIONS AMM-CV-915iS/916iS-EN- Part E - 27-20-00 5-1 Page 2 of 3 E-2023-12...
  • Page 200 Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS Fig. 2 - Measurement Procedure (example) AMM-CV-915iS/916iS-EN- Part E - 27-20-00 5-1 Page 3 of 3 E-2023-12...
  • Page 201 Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS 28-20-00 6-1 INSPECTION: FUEL FILTER GENERAL, REFERENCES AND REQUIREMENTS Task may only be performed by an organization or individual trained and entitled to carry out 'Professional Maintenance'! Engine cowlings must be removed, see...
  • Page 202 Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS 28-20-00 8-1 REPLACEMENT: FUEL FILTER GENERAL, REFERENCES AND REQUIREMENTS Task may only be performed by an organization or individual trained and entitled to carry out 'Professional Maintenance'! Engine cowlings must be removed, see...
  • Page 203 Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS ILLUSTRATIONS Fuel Pumps Fig 1 Gascolator Fuel Filter AMM-CV-915iS/916iS-EN- Part E - 28-20-00 8-1 Page 2 of 2 E-2023-12...
  • Page 204 Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS 28-20-00 8-2 REPLACEMENT: ELECTRICAL FUEL PUMPS GENERAL, REFERENCES AND REQUIREMENTS Task may only be performed by an organization or individual trained and entitled to carry out 'Professional Maintenance'! Secure gyroplane against unauthorized or unintended operation!
  • Page 205 Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS ILLUSTRATIONS Fuel Pumps Gascolator Fuel Filter Fig. 1 - Electrical fuel pump terminal (detail) AMM-CV-915iS/916iS-EN- Part E - 28-20-00 8-2 Page 2 of 2 E-2023-12...
  • Page 206 Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS 32-20-00 8-1 REPLACEMENT: NOSE GEAR RUBBER DAMPER GENERAL, REFERENCES AND REQUIREMENTS Task may only be performed by an organization or individual trained and entitled to carry out 'Professional Maintenance'! Gyroplane must be jacked, see...
  • Page 207 Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS 32-00-00-V-31914 AMM-CV-915iS/916iS-EN- Part E - 32-20-00 8-1 Page 2 of 3 E-2023-12...
  • Page 208 Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS ILLUSTRATIONS Fig. 1 - Nose gear assembly AMM-CV-915iS/916iS-EN- Part E - 32-20-00 8-1 Page 3 of 3 E-2023-12...
  • Page 209 Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS 32-40-00 4-1 REMOVAL-INSTALLATION: WHEELS GENERAL, REFERENCES AND REQUIREMENTS Task may only be performed by an organization or individual trained and entitled to carry out 'Professional Maintenance'! Gyroplane must be jacked, see...
  • Page 210 Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS 14 Install split pin (Fig. 3, 5). 15 Check free rotation of wheel, radial run-out and braking action. 16 Install wheel spat, if required. AMM-CV-915iS/916iS-EN- Part E - 32-40-00 4-1...
  • Page 211 Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS PARTS LIST Fig. Pos. Description PC PIT Remark M10x20 U11x34x3 nose wheel steering O-Ring 30x5 steering bush L2 32-00-00-V-22169 Nose wheel fork long welded steering bush L2 32-00-00-V-22169 Shock Absorber 2,5...
  • Page 212 Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS ILLUSTRATIONS Fig. 1 - Nose gear assembly Fig. 2 - Nose wheel AMM-CV-915iS/916iS-EN- Part E - 32-40-00 4-1 Page 4 of 5 E-2023-12...
  • Page 213 Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS Fig. 3 - Main gear assembly Fig. 4 - Main wheel AMM-CV-915iS/916iS-EN- Part E - 32-40-00 4-1 Page 5 of 5 E-2023-12...
  • Page 214 Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS 32-40-00 8-1 REPLACEMENT: MAIN WHEEL BRAKE PADS GENERAL, REFERENCES AND REQUIREMENTS Task may only be performed by an organization or individual trained and entitled to carry out 'Professional Maintenance'! Gyroplane must be jacked, see...
  • Page 215 Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS 11 Brake caliber 12 Brake pad outer (small) L2 32-40-00-V-30512 13 Brake Disc L1 32-40-00-V-30004 14 Cylinder bushing 22x10x6 15 Brake pad inner (big) L2 32-40-00-V-30511 16 Safety washer M6...
  • Page 216 Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS 32-40-00 8-2 REPLACEMENT: WHEEL BEARING GENERAL, REFERENCES AND REQUIREMENTS Task may only be performed by an organization trained and entitled to carry out 'Professional Maintenance'! Gyroplane must be jacked, see...
  • Page 217 Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS ILLUSTRATIONS Fig. 1 - Nose wheel Fig. 2 - Main wheel and bearing AMM-CV-915iS/916iS-EN- Part E - 32-40-00 8-2 Page 2 of 2 E-2023-12...
  • Page 218 Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS 34-10-00 5-1 TEST: PITOT STATIC SYSTEM INTEGRITY GENERAL, REFERENCES AND REQUIREMENTS Task may only be performed by an organization or individual trained and entitled to carry out 'Professional Maintenance'! SPECIAL TOOLS AND CONSUMABLE MATERIALS...
  • Page 219 Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS ILLUSTRATIONS Fig. 1 - Pitot Static Integrity Test Equipment Fig. 2 - Pitot Static Instruments Connecting Diagram AMM-CV-915iS/916iS-EN- Part E - 34-10-00 5-1 Page 2 of 2 E-2023-12...
  • Page 220 Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS 34-10-00 7-1 CLEANING: PITOT STATIC SYSTEM GENERAL, REFERENCES AND REQUIREMENTS Task may only be performed by an organization or individual trained and entitled to carry out 'Professional Maintenance'! Secure gyroplane against unauthorized or unintended operation!
  • Page 221 Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS Fig. 2 - Pitot Static Instruments Connecting Diagram AMM-CV-915iS/916iS-EN- Part E - 36-21-00 8-1 Page 2 of 3 E-2023-12...
  • Page 222 Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS 36-21-00 8-1 REPLACEMENT: FILTER/DRYER GENERAL, REFERENCES AND REQUIREMENTS Task may only be performed by an organization or individual trained and entitled to carry out 'Professional Maintenance'! Secure gyroplane against unauthorized or unintended operation!
  • Page 223 Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS 52-00-00 4-1 REMOVAL-INSTALLATION: COWLINGS GENERAL, REFERENCES AND REQUIREMENTS Basic operational task, which can be performed by a licensed pilot or instructed personnel! Secure gyroplane against unauthorized or unintended operation! SPECIAL TOOLS AND CONSUMABLE MATERIALS...
  • Page 224 Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS Install mast cover in reverse order (work steps 13 - 12). Fasten all bolts with 3 Nm. AMM-CV-915iS/916iS-EN- Part E - 52-00-00 4-1 Page 2 of 3 E-2023-12...
  • Page 225 Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS ILLUSTRATIONS AMM-CV-915iS/916iS-EN- Part E - 52-00-00 4-1 Page 3 of 3 E-2023-12...
  • Page 226 Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS 55-00-00 8-1 REPLACEMENT: KEEL TUBE PROTECTION PAD GENERAL, REFERENCES AND REQUIREMENTS Task may only be performed by an organization or individual trained and entitled to carry out 'Professional Maintenance'! Secure gyroplane against unauthorized or unintended operation!
  • Page 227 Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS 56-00-00 8-1 REPAIR: CRACKS IN ACRYLIC GLASS GENERAL, REFERENCES AND REQUIREMENTS Basic operational task, which can be performed by a licensed pilot or instructed personnel! Repair only by a competent person.
  • Page 228 Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS 13 Proceed as in steps 7-10 (Fig. 4). 14 Sand adhesive area as follows, begin with the convex outside of the acrylic glass: 15 Create dishwashing liquid solution (2-3 drops per 0.2 l lukewarm tap water). Sand with grit 320 wet sandpaper and dishwashing liquid solution to the surface of the tape.
  • Page 229 Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS 61-10-00 4-1 REMOVAL-INSTALLATION: PROPELLER - HTC GENERAL, REFERENCES AND REQUIREMENTS Task may only be performed by an organization or individual trained and entitled to carry out 'Professional Maintenance'! Secure gyroplane against unauthorized or unintended operation!
  • Page 230 Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS PARTS LIST Fig. Pos. Description PC PIT Remark Spinner HTC4B, painted L2 53-00-00-V-46905 M8x110 U8/24 M6x40 ROTAX 915 Propeller L3 61-00-00-V-45479 ROTAX 915 Propeller L3 61-00-00-V-45479 ROTAX 915 Propeller 61-00-00-V-45479 ROTAX 915...
  • Page 231 Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS 61-10-00 4-2 DISASSEMBLY-ASSEMBLY: PROPELLER - HTC GENERAL, REFERENCES AND REQUIREMENTS Task may only be performed by an organization or individual trained and entitled to carry out 'Professional Maintenance'! Propeller must be removed, see...
  • Page 232 Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS PARTS LIST Fig. Pos. Description PC PIT Remark Spinner HTC4B, painted L2 53-00-00-V-46905 M8x110 U8/24 M6x40 ROTAX 915 Propeller L3 61-00-00-V-45479 ROTAX 915 Propeller L3 61-00-00-V-45479 ROTAX 915 Propeller 61-00-00-V-45479 ROTAX 915...
  • Page 233 Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS ILLUSTRATIONS Fig. 1 - Propeller HTC (Note: a 3 bladed propeller is shown, the current HTC propeller for 915iS engines is 4 bladed) AMM-CV-915iS/916iS-EN- Part E - 61-10-00 4-2 Page 3 of 3...
  • Page 234 Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS 61-10-00 5-1 ADJUSTMENT: PROPELLER PITCH - HTC GENERAL, REFERENCES AND REQUIREMENTS Task may only be performed by an organization or individual trained and entitled to carry out 'Professional Maintenance'! Spinner (if installed) must be removed, see...
  • Page 235 Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS ILLUSTRATIONS (Note: Propellers shown are 3 blade. 915 engines are fitted with a 4 blade HTC propeller, but the same principles apply) Fig. 1 - Propeller HTC Fig. 2 - Propeller pitch adjustment and tool...
  • Page 236 Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS Fig. 3 - Detail hub Fig. 4 - Detail blade AMM-CV-915iS/916iS-EN- Part E - 61-10-00 8-2 Page 3 of 3 E-2023-12...
  • Page 237 Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS 61-20-00 1-1 TROUBLE-SHOOTING: HTC Propeller GENERAL, REFERENCES AND REQUIREMENTS Propeller repair. Surface damage not tearing through the glass or carbon fibre, or splitting through the mould line (middle of the leading edge along the blade), may be repaired using suitable epoxy resin, or superglue and carbon.
  • Page 238 Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS Propeller Balancing Mass balance weights may either be suitably weighted washers fitted under the propeller fitment bolts, or self- adhesive aluminium wheel balance weights as used on car wheels, fitted inside the propeller hub to a well cleaned, dry surface.
  • Page 239 Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS 62-11-00 4-1 REMOVAL: ROTOR - TEETERING PARTS GENERAL, REFERENCES AND REQUIREMENTS Basic operational task, which can be performed by a licensed pilot or instructed personnel! SPECIAL TOOLS AND CONSUMABLE MATERIALS...
  • Page 240 Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS PARTS LIST Fig. Pos. Description PC PIT Remark Teeter bolt L0 27-30-00-S-30256 Chimm washer 3,5 L0 62-00-00-S-31706 L0 27-30-00-S-30256 M12 Castle nut L0 27-30-00-S-30256 Split pin 3.2x40 L0 27-30-00-S-30256 Rotor head II compl.
  • Page 241 Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS 62-11-00 4-2 DISASSEMBLY: ROTOR - TEETERING PARTS GENERAL, REFERENCES AND REQUIREMENTS Basic operational task, which can be performed by a licensed pilot or instructed personnel! Rotor system must be removed, see...
  • Page 242 Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS PARTS LIST Fig. Pos. Description PC PIT Remark Shoulder bolt M8 37/12 L0 62-00-00-S-33324 1-5 M8x60 Rotor blade bolt 8.8 DIN 610 L0 62-00-00-V-20661 Shoulder bolt M8 40/12 L0 62-00-00-S-33324...
  • Page 243 Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS 62-11-00 4-3 ASSEMBLY: ROTOR - TEETERING PARTS GENERAL, REFERENCES AND REQUIREMENTS Basic operational task, which can be performed by a licensed pilot or instructed personnel! SPECIAL TOOLS AND CONSUMABLE MATERIALS IMPORTANT NOTE: Procedure involves parts with limited reusability.
  • Page 244 Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS ILLUSTRATIONS Fig. 1 - Assembly rotor - teetering parts AMM-CV-915iS/916iS-EN- Part E - 62-11-00 4-3 Page 2 of 2 E-2023-12...
  • Page 245 Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS 62-11-00 4-4 INSTALLATION: ROTOR - TEETERING PARTS GENERAL, REFERENCES AND REQUIREMENTS Basic operational task, which can be performed by a licensed pilot or instructed personnel! Secure gyroplane against unauthorized or unintended operation!
  • Page 246 Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS PARTS LIST Fig. Pos. Description PC PIT Remark Teeter bolt L0 27-30-00-S-30256 Chimm washer 3,5 L0 62-00-00-S-31706 L0 27-30-00-S-30256 M12 Castle nut L0 27-30-00-S-30256 Split pin 3.2x40 L0 27-30-00-S-30256 Rotor head II compl.
  • Page 247 Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS 62-11-00 5-1 CHECK-ADJUSTMENT: ROTOR SYSTEM ALIGNMENT GENERAL, REFERENCES AND REQUIREMENTS Task may only be performed by an organization or individual trained and entitled to carry out 'Professional Maintenance'! Rotor system must be removed, see...
  • Page 248 Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS ILLUSTRATIONS Fig. 1 - Rotor system placed on stands Fig. 2 - Positioning of measuring cord Fig. 3 - Reference point at grease nipple AMM-CV-915iS/916iS-EN- Part E - 62-11-00 5-1...
  • Page 249 Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS 62-11-00 6-1 INSPECTION: ROTOR - TEETERING PARTS GENERAL, REFERENCES AND REQUIREMENTS Task may only be performed by an organization or individual trained and entitled to carry out 'Professional Maintenance'! Rotor system must be removed, see...
  • Page 250 Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS ILLUSTRATIONS Fig. 1 - Teeter bushings, block and tower - cross section view AMM-CV-915iS/916iS-EN- Part E - 62-11-00 6-1 Page 2 of 2 E-2023-12...
  • Page 251 Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS 62-11-00 6-2 INSPECTION: ROTOR BLADES GENERAL, REFERENCES AND REQUIREMENTS Basic operational task, which can be performed by a licensed pilot or instructed personnel! Rotor system must be disassembled, see 62-11-00 4-2...
  • Page 252 Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS ILLUSTRATIONS Fig. 1 - Critical blade area Fig. 2 - Measurement of blade root linearity AMM-CV-915iS/916iS-EN- Part E - 62-11-00 6-2 Page 2 of 2 E-2023-12...
  • Page 253 Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS 62-11-00 6-3 INSPECTION: ROTOR HUB BOLTS GENERAL, REFERENCES AND REQUIREMENTS Task may only be performed by an organization or individual trained and entitled to carry out 'Professional Maintenance'! Rotor system must be removed, see...
  • Page 254 Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS ILLUSTRATIONS Fig. 1 - Rotor hub AMM-CV-915iS/916iS-EN- Part E - 62-11-00 6-4 Page 2 of 2 E-2023-12...
  • Page 255 Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS 62-11-00 6-4 CHECK TEETER ANGLE GENERAL, REFERENCES AND REQUIREMENTS Task may only be performed by an organization or individual trained and entitled to carry out 'Professional Maintenance' SPECIAL TOOLS AND CONSUMABLE MATERIALS...
  • Page 256 AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS You can see that the hub is in contact with the forward teeter strop on the left picture. Zero the level and you can check the angle by putting the rotor to the rear teeter stop...
  • Page 257 Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS 62-11-00 8-1 REPLACEMENT: TEETER BUSHINGS GENERAL, REFERENCES AND REQUIREMENTS Task may only be performed by an organization trained and entitled to carry out 'Professional Maintenance'! Rotor system must be removed, see...
  • Page 258 Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS PARTS LIST Fig. Pos. Description PC PIT Remark Bushing TEF-MET 13/15/21x15 L0 27-30-00-V-20677 ILLUSTRATIONS Fig. 1 - Teeter bushings, block and tower - cross section view AMM-CV-915iS/916iS-EN- Part E - 62-11-00 6-4...
  • Page 259 Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS Fig. 2 - Teeter bushings, block and tower - exploded view AMM-CV-915iS/916iS-EN- Part E - 62-11-00 6-4 Page 3 of 3 E-2023-12...
  • Page 260 Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS 62-20-00 8-1 REPLACEMENT: DRIVE GEAR GENERAL, REFERENCES AND REQUIREMENTS Task may only be performed by an organization trained and entitled to carry out 'Professional Maintenance'! Secure gyroplane against unauthorized or unintended operation!
  • Page 261 Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS PARTS LIST Fig. Pos. Description PC PIT Remark Split Pins, 10 pieces L0 27-30-00-S-30261 Rotor sprocket mounted L2 27-30-00-M-36385 Kit – Rotor sprocket L2 27-30-00-S-42957 AMM-CV-915iS/916iS-EN- Part E - 62-31-00 6-1...
  • Page 262 Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS ILLUSTRATIONS Fig.1 - Split pin and castle nut AMM-CV-915iS/916iS-EN- Part E - 62-31-00 6-1 Page 3 of 4 E-2023-12...
  • Page 263 Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS Fig.2 - Rotor head III AMM-CV-915iS/916iS-EN- Part E - 62-31-00 6-1 Page 4 of 4 E-2023-12...
  • Page 264 Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS 62-31-00 6-1 INSPECTION: ROTOR HEAD BRIDGE, BEARING AND TEETER TOWER GENERAL, REFERENCES AND REQUIREMENTS Task may only be performed by an organization or individual trained and entitled to carry out 'Professional...
  • Page 265 Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS ILLUSTRATIONS Fig. 1 - Rotor head bridge, bearing and teeter tower AMM-CV-915iS/916iS-EN- Part E - 62-31-00 6-1 Page 2 of 2 E-2023-12...
  • Page 266 Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS 62-32-00 5-1 CHECK-ADJUSTMENT: ROTOR CONTROL FRICTION GENERAL, REFERENCES AND REQUIREMENTS Task may only be performed by an organization trained and entitled to carry out 'Professional Maintenance'! Rotor head bridge / gimbal head configuration state must conform to version II...
  • Page 267 Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS ILLUSTRATIONS Fig. 1 - Measurement of rotor control friction Fig. 2 - Gimbal head assembly, Rotor System II (with spring washers) AMM-CV-915iS/916iS-EN- Part E - 62-32-00 5-1 Page 2 of 3...
  • Page 268 Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS Fig.3 - Arrangement of spring and shim washers on gimbal head - Version III AMM-CV-915iS/916iS-EN- Part E - 62-32-00 5-1 Page 3 of 3 E-2023-12...
  • Page 269 Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS 62-32-00 6-1 INSPECTION: ROTOR GIMBAL HEAD GENERAL, REFERENCES AND REQUIREMENTS Task may only be performed by an organization or individual trained and entitled to carry out 'Professional Maintenance'! Rotor system must be removed, see...
  • Page 270 Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS ILLUSTRATIONS Fig. 1 - Rotor gimbal head - Version III AMM-CV-915iS/916iS-EN- Part E - 62-51-00 6-1 Page 2 of 5 E-2023-12...

  • Page 271: Warning: Object Is Heavy! Inadequate Handling Could Cause Injury. Use Proper Lifting Techniques Or Assistance

    Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS 62-51-00 4-1 REMOVAL-INSTALLATION: TOP MAST GENERAL, REFERENCES AND REQUIREMENTS Task may only be performed by an organization trained and entitled to carry out 'Professional Maintenance'! Secure gyroplane against unauthorized or unintended operation!
  • Page 272 Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS IMPORTANT NOTE: When disconnecting the push-pull cable bulkhead at the top mast, unscrew only top (outer) attachment nut and leave lower (inner) attachment nut unchanged and mark position. Disconnect roll push-pull cable bulkhead. In order to do so, unscrew and remove top (outer) attachment nut (Fig.
  • Page 273 Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS ILLUSTRATIONS Fig. 1 - Pneumatic hoses Fig. 2 - Push-pull control cable bulkhead attachment Fig. 3 - Installation of mast pins Fig. 4 - Prerotator drive AMM-CV-915iS/916iS-EN- Part E - 62-51-00 6-1...
  • Page 274 Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS 62-51-00 6-1 INSPECTION: MAST MOUNTING BUSHINGS GENERAL, REFERENCES AND REQUIREMENTS Task may only be performed by an organization or individual trained and entitled to carry out 'Professional Maintenance'! Rotor system must be removed, see...
  • Page 275 Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS ILLUSTRATIONS (Note: Rotor head II is shown, the principle is the same for rotor head III) Fig. 2 - Fuselage reference point Fig. 1 - Mast reference point AMM-CV-915iS/916iS-EN- Part E - 62-51-00 6-1...
  • Page 276 Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS 62-51-00 8-1 REPLACEMENT: MAST MOUNTING BUSHINGS GENERAL, REFERENCES AND REQUIREMENTS Task may only be performed by an organization trained and entitled to carry out 'Professional Maintenance'! Secure gyroplane against unauthorized or unintended operation!
  • Page 277 Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS 15 Apply AG-LUB-03 to pre-rotator drive coupling sleeve and position upper mast. Make sure that coupling sleeve joins easily. 16 Apply AG-GRS-01 on outer surface of bushing sleeves and install bushing sleeves. Use a rubber hammer, if required.
  • Page 278 Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS 63-11-10 4-1 REMOVAL-INSTALLATION: PRE-ROTATOR COUPLING GENERAL, REFERENCES AND REQUIREMENTS Task may only be performed by an organization trained and entitled to carry out 'Professional Maintenance'! Secure gyroplane against unauthorized or unintended operation!
  • Page 279 Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS EFFECTIVITY: Pneumatic Coupling III 15 Check coupling activation pressure 5 bar +/- 0.1 16 Re-install engine mounts. Use new self-locking nuts and torque-tighten. 17 Remove lifting belt. 18 Install oil reservoir.
  • Page 280 Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS 63-11-10 6-1 INSPECTION: PRE-ROTATOR COUPLING GENERAL, REFERENCES AND REQUIREMENTS Task may only be performed by an organization or individual trained and entitled to carry out 'Professional Maintenance'! Secure gyroplane against unauthorized or unintended operation!
  • Page 281 Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS ILLUSTRATIONS Fig. 1 - Pre-rotator coupling with attach ring AMM-CV-915iS/916iS-EN- Part E - 63-11-10 8-1 Page 2 of 2 E-2023-12...
  • Page 282 Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS 63-11-10 8-1 REPLACEMENT: PRE-ROTATOR COUPLING LINING GENERAL, REFERENCES AND REQUIREMENTS Task may only be performed by an organization trained and entitled to carry out 'Professional Maintenance'! Secure gyroplane against unauthorized or unintended operation!
  • Page 283 Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS PARTS LIST Fig. Pos. Description PC PIT Remark Replacement set friction plate PK III / IV L1 61-00-00-S-46137 ILLUSTRATIONS Fig. 1 - Pneumatic Coupling III/IV Fig. 2 - M8x20 screw plug Fig.
  • Page 284 Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS 63-11-10 8-2 REPLACEMENT: PRE-ROTATOR COUPLING DOG GEAR GENERAL, REFERENCES AND REQUIREMENTS Task may only be performed by an organization trained and entitled to carry out 'Professional Maintenance'! Secure gyroplane against unauthorized or unintended operation!
  • Page 285 Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS ILLUSTRATIONS Fig. 1 - M8x20 screw plug Fig. 2 - Thread Pin M8x50 Fig. 4 - Tighten dog gear to 150Nm Fig. 3 - Loctite 648 on inner and outer thread...
  • Page 286 Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS 63-11-30 6-1 INSPECTION: PRE-ROTATOR UPPER ENGAGEMENT GENERAL, REFERENCES AND REQUIREMENTS Task may only be performed by an organization or individual trained and entitled to carry out 'Professional Maintenance'! Secure gyroplane against unauthorized or unintended operation!
  • Page 287 Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS 63-51-00 8-1 REPLACEMENT: ROTOR BRAKE PAD GENERAL, REFERENCES AND REQUIREMENTS Task may only be performed by an organization or individual trained and entitled to carry out 'Professional Maintenance'! Secure gyroplane against unauthorized or unintended operation!
  • Page 288 Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS ILLUSTRATIONS Fig. 1 - Rotor bridge with brake pads AMM-CV-915iS/916iS-EN- Part E - 63-51-00 8-1 Page 2 of 2 E-2023-12...
  • Page 289 Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS 67-00-00 6-1 INSPECTION: FLIGHT CONTROL PUSH-PULL CABLES GENERAL, REFERENCES AND REQUIREMENTS Task may only be performed by an organization or individual trained and entitled to carry out 'Professional Maintenance'! Secure gyroplane against unauthorized or unintended operation!
  • Page 290 Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS 67-05-00 8-1 REPLACEMENT: PITCH TRIM/BRAKE PNEUMATIC SEAL GENERAL, REFERENCES AND REQUIREMENTS Task may only be performed by an organization trained and entitled to carry out 'Professional Maintenance'! Secure gyroplane against unauthorized or unintended operation!
  • Page 291 Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS 67-10-00 4-1 REMOVAL-INSTALLATION: CENTER CONSOLE GENERAL, REFERENCES AND REQUIREMENTS Task may only be performed by an organization or individual trained and entitled to carry out 'Professional Maintenance'! Secure gyroplane against unauthorized or unintended operation!
  • Page 292 Aircraft AutoGyro Maintenance Manual Cavalon 915 iS / 916 iS ILLUSTRATIONS Fig. 1 - Center Console AMM-CV-915iS/916iS-EN- Part E - 67-10-00 4-1 Page 2 of 2 E-2023-12...
  • Page 293 Tragschrauber Flug- und Betriebshandbuch AutoGyro GmbH Phone +49 (0) 5121 / 880 56– 00 Dornierstrasse 14 31137 Hildesheim info@auto-gyro.com Germany www.auto-gyro.com...

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