AUTO GYRO Cavalon Maintenance Manual page 272

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.
5 Disconnect roll push-pull cable bulkhead. In order to do so, unscrew and remove top (outer) attachment nut
(Fig. 2).
6 Disconnect pitch push-pull cable bulkhead. In order to do so, unscrew and remove top (outer) attachment
nut.
7 Remove mast bushes (Fig. 3) and free mast bushes from grease residuals.
Pull top mast equipped with rotor head out of mast bottom. Lead push-pull control cables through attachment
8
consoles and pneumatic hose package through the inside of the pitch console.
Installation
9 If applicable remove transport securing devices.
10 Insert top mast equipped with rotor head into mast bottom. Lead push-pull control cables through attachment
consoles.
11 Lubricate pre-rotator drive with oil with AG-LUB-03 (spray in top pre-rotator drive shaft) and insert lower
sliding splined drive shaft into top pre-rotator drive shaft (Fig. 4).
12 Equip each threaded mast bush with a washer disc and a screw, grease mast bushes (AG-GRS-01) and
push into their designated openings as follows: Short mast bush in the upper opening, long mast bush in
lower opening. Equip each mast bush on opposite also with a washer disc and a screw. Apply Loctite 243
(AG-BAS-02) on each screw thread and torque-tighten with standard bolt torque.
IMPORTANT NOTE: When re-installing push-pull cable bulkhead make sure that the lower
(inner) attachment nut remains in original (marked) position.
13 Equip roll push-pull control cable bulkhead with a serrated washer and a counter nut. Torque-tighten counter
nut with 25 Nm and apply securing paint.
14 Equip pitch push-pull control cable bulkhead with a serrated washer and a counter nut. Torque-tighten
counter nut with 25 Nm and apply securing paint.
15 Re-install pitch control ball joint. In order to do so, insert bolt from left and install
1) spacer
2) ball joint
3) spacer
Secure with new locking nut and torque-tighten.
16 Re-install roll control ball joint and roll trim. In order to do so, insert bolt from front and install
1) plastic washer
2) ball joint roll control
3) small washer
4) spacer
5) ball joint trim actuator
6) spacer
7) large washer
Secure with new locking nut and torque-tighten.
17 Pull pneumatic hose package through the inside of the pitch console and fix with cable-ties (Fig. 1).
18 Apply Loctite 221 (AG-BAS-01) on pneumatic connection threads of roll trim actuator and pitch trim actuator.
Connect pneumatic hoses according to Fig. 1. Tighten union nuts of pneumatic hoses slightly with pliers and
fix hoses with cable ties. Prevent chafing of pneumatic hoses!
19 Connect rotor rpm sensor, lead cable on the right side of the mast. Fix cable according to Fig. 1 with cable
ties.
20 Move flight control stick carefully to all directions (full deflections) in order to ensure an installation without
strain or stresses.
21 Inspect rotor gimbal head according to
AMM-CV-915iS/916iS-EN-
E-2023-12
Aircraft
Maintenance Manual
62-32-00 6-1 and check/adjust rotor control angles.
Part E - 62-51-00 6-1
AutoGyro
Cavalon 915 iS / 916 iS
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