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AutoGyro CALIDUS Maintenance Manual

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CALIDUS
Aircraft Maintenance Manual
Calidus | Rotax 915 iS | Rotax 916 iS

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Summary of Contents for AutoGyro CALIDUS

  • Page 1 CALIDUS Aircraft Maintenance Manual Calidus | Rotax 915 iS | Rotax 916 iS...
  • Page 2 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS Aircraft Maintenance Manual for Gyroplane Calidus 915 iS / 916 iS Part A – Introduction and AMM-CD-915iS/916iS-EN- Page 1 of 15 A-2025-04 Declarations...
  • Page 3 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS Content Preface 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 Nomenclature and Structure of Maintenance Tasks (Job Cards)
  • Page 4 E-Mail: info@auto-gyro.com All rights reserved. Under the copyright laws, this manual may not be copied, in whole or in part, without the written consent of AutoGyro GmbH. AutoGyro reserves the right to change or improve its products and to make changes in the content of this manual without obligation to notify any person or organisation of such changes or improvements.
  • Page 5 Introduction This manual provides accepted and recommended maintenance procedures applicable for the Calidus gyroplane fitted with the Rotax 915 iS / 916 iS engine, designed and manufactured by AutoGyro GmbH, Hildesheim, Germany. The generic term <maintenance= comprises checks, inspections, replacement, repair and other tasks, which are defined in <01-11-00 Definitions and Standard Procedures=.

  • Page 6: 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 the AutoGyro website and/or by E-Mail to each subscription customer. The document part9s revision index can be found in the footer on the left hand side of each page.
  • Page 7 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS INTENTIONALLY LEFT BLANK Part A – Introduction and AMM-CD-915iS/916iS-EN- Page 6 of 15 A-2025-04 Declarations...

  • Page 8: Maintenance Concept And Eligibility

    Maintenance Manual 915 iS / 916 iS Maintenance Concept and Eligibility The maintenance concept of the Calidus gyroplane is structured into two qualification levels: ▪ Basic Operator Maintenance / Pilot Checks and Servicing Professional Maintenance – Inspection and general maintenance tasks, inspection of Critical ▪...
  • Page 9 AutoGyro Aircraft Calidus Maintenance Manual 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

    AutoGyro Aircraft Calidus Maintenance Manual 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 five parts, named A to E. The designation and content of each part is listed below: •...

  • Page 11: Page Block Code

    AutoGyro Aircraft Calidus Maintenance Manual 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 Job Card.
  • Page 12 AutoGyro Aircraft Calidus Maintenance Manual 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 AutoGyro Aircraft Calidus Maintenance Manual 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 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS Light Emitting Diode 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 AutoGyro Aircraft Calidus Maintenance Manual 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: 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. Depending on the market, SB9s may be issued by AutoGyro or by AutoGyro Certification Ltd (formally RotorSport UK Ltd).
  • Page 17 AutoGyro Aircraft Calidus Maintenance Manual 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 General The Calidus 915 iS / 916 iS is a 8new generation9 gyroplane with either a 4-bladed push propeller or a 3-bladed 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

    AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS Chapter 01 - General 01-11-00 Definitions, Terms und 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 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS Maintenance Any one or combination of overhaul, repair, inspection, replacement, modification or defect rectification of an aircraft or component, with the exception of pre-flight inspection Measure To find out dimensions, capacity or quantity of something. Except for counting of smaller numbers, calibrated measurement devices are needed.

  • Page 21: Standard Bolt Torques

    01-21-00 Standard Commercial Tools Most maintenance tasks on the Calidus 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 AutoGyro Aircraft Calidus Maintenance Manual 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 AutoGyro Aircraft Calidus Maintenance Manual 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-CD-915iS/916iS-EN- Page 7 of 24 (Chapter 00 – 20)

  • Page 24: Chapter 02 - Tools, Spares And Consumable Materials

    PRIMER, PREPARATION FOR PAINTING GREASES (STORAGE) PRESERVATION HYDRAULIC FLUIDS The following consumable materials are referenced in the Maintenance Manual: CM-Item Material / Description AutoGyro Part Number AG-BAS-01 Loctite 221 red PN 30487 AG-BAS-02 Loctite 243 blue PN 30483 AG-BAS-03 Loctite 542 red...

  • Page 25: Chapter 03 - Minimum Equipment Requirement

    AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS CHAPTER 03 – MINIMUM EQUIPMENT REQUIREMENT In accordance with the Pilot9s Operating Handbook (POH) Section 2.11 the following equipment must be operative for flight • Air speed indicator • Altimeter •...
  • Page 26 Status and lifetimes of components, liquids and fluids is listed in the Event and Configuration Log form. The initial Event and Configuration Log is delivered with the gyroplane by AutoGyro. An empty form is provided for download on the AutoGyro website.
  • Page 27 AutoGyro Aircraft Calidus Maintenance Manual 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: Time Limits

    Status and lifetimes of components, liquids and fluids is listed in the Event and Configuration Log form. It is the obligation of the maintenance facility to keep this form current. An empty form is provided for download on the AutoGyro web site. Part B – Master Servicing Manual...
  • Page 29 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 Calidus 915 iS / 916 iS gyroplane is provided in the current Pilot9s Operating Handbook.

  • Page 30: Inspections - Special Operational Conditions

    Action / Reference Rotor vibration see CHAPTER 18 Propeller vibration see CHAPTER 18 If in doubt contact AutoGyro Technical support. 05-50-00 Conditional Inspections Depending on the conditions the gyroplane is operated in or special operational incident the following conditional inspection may apply: Inspections –...

  • Page 31: Inspections - Special Operational Incident

    In case the turning rotor hit the stabilizer/rudder, a detailed inspection of the affected components must be performed. In case CRITICAL damage is found, the rotor system must be replaced. Contact AutoGyro Technical Support. Propeller contact with obstacle or external impact Refer to engine manufacturer documentation.

  • Page 32: Ground Test Run

    Forms are available for download. A 8Life Limited Items Log9 (LLI) is delivered with the aircraft by AutoGyro and shall be kept current by the maintenance facility. An empty form is available for download. Part B – Master Servicing Manual...

  • Page 33: Chapter 06 - Dimensions And Areas

    AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS CHAPTER 06 – DIMENSIONS AND AREAS Length 4.78 m Width 1.73 m Height 2.77 m Rotor diameter 8.4 m (915iS) / 8.6m (916iS) Rotor disc area 55.4 sqm Propeller diameter 1.72 m...
  • Page 34 Maintain battery charged • Unload wheel gear • Cover aircraft with a light plastic tarpaulin or cloth Long-term Storage Contact AutoGyro Technical Support Return to Service Perform a 100 hrs Inspection. Part B – Master Servicing Manual AMM-CD-915iS/916iS-EN- Page 18 of 24 (Chapter 00 –...

  • Page 35: Chapter 11 - Placards And Markings

    AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS CHAPTER 11 – PLACARDS AND 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 AutoGyro Aircraft Calidus Maintenance Manual 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

    AutoGyro Aircraft Calidus Maintenance Manual 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 13-17 - Unassigned / N/A

    AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS CHAPTER 13-17 – UNASSIGNED / N/A Part B – Master Servicing Manual AMM-CD-915iS/916iS-EN- Page 22 of 24 (Chapter 00 – 20) B-2025-04...
  • Page 39 (increase) rotor control friction (see Job Card 62-32-00 5-1 in Part E of this manual) In case of unusual vibration, contact AutoGyro or an AutoGyro specialized service partner. If possible, try to describe the type of vibration as precise as possible as this will help to save time to reproduce and troubleshoot, or even allow a first remote assessment.
  • Page 40 AutoGyro Aircraft Calidus Maintenance Manual 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: Table Of Contents

    AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS Contents CHAPTER 21 VENTILATION / HEATING 21-00-00 Ventilation / Heating CHAPTER 22 UNASSIGNED / N/A CHAPTER 23 COMMUNICATIONS 23-10-00 Speech Communication / Radio 23-40-00 Interphone / Intercom CHAPTER 24 ELECTRICAL POWER...
  • Page 42 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS CHAPTER 61 PROPELLER 61-10-00 Propeller Assembly 61-20-00 Controlling CHAPTER 62 ROTOR 62-11-00 Rotor – Teetering Parts 62-31-00 Rotor Head Bridge, Bearing and Teeter Tower 62-32-00 Rotor Gimbal Head 62-41-00 Rotor RPM Monitoring...

  • Page 43: Ventilation / Heating

    AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS CHAPTER 21 - VENTILATION/ HEATING 21-00-00 Ventilation / Heating Two open/closable and adjustable fresh air vents on the right hand side of the canopy and one sliding window with pivoting vent are provided for ventilation.
  • Page 44 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS CHAPTER 22 - UNASSIGNED/ N/A AMM-CD-915iS/916iS-EN- Part C - System Description Page 4 of 56 Section (Chapter 21 – 90) C-2025-04...

  • Page 45: Chapter 23 - Communications

    AutoGyro Aircraft Calidus Maintenance Manual 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 manufacturer9s specifications and manuals for reference.

  • Page 46: Electrical Power

    AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS CHAPTER 24 - ELECTRICAL POWER The 12V DC electrical system consists of two engine driven electrical generators, a battery, master switch, indicators, switches, electrical consumers, and cabling. With the ROTAX 915 iS / 916 iS engine an electrical power supply is vital for continued engine operation as this engine variant solely relies on electrically driven fuel pumps and engine ECU.

  • Page 47: Dc Electrical Load Distribution

    AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS 24-60-00 DC Electrical Load Distribution The DC electrical load distribution system includes cockpit switches, control electronics (relays and logic components), fuses, electrical harnesses and cabling, and electrical consumers. Electrical schematics are provided in Part D - Diagrams and Charts of this manual.
  • Page 48 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS GEN 1 Primary Fuel Automotive Inst. Panel pump relay, where fitted GEN 2 Generator Automotive Inst. Panel operation, where fitted Cockpit All electrical Automotive Inst. panel gauges (rotor and engine...
  • Page 49 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS fuse and the cockpit supply Starter 100A ETFE Primary Midivale Engine bay cable supply from 80Amp 125A PVC battery to fuse, cable starter- published solenoid time at /starter and 80A,...

  • Page 50: Equipment / Furnishings

    AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS CHAPTER 25 - EQUIPMENT / FURNISHINGS 25-10-00 Flight Compartment The seats consist of seating surfaces and rear seat backrest which are an integral part of the monocoque structure. The front seat backrest is adjustable, see below. Seats and backrests are upholstered with removable cushions.

  • Page 51: Emergency

    AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS 25-60-00 Emergency An emergency hammer is located in the forward cabin station, reachable from both seats. The emergency hammer is placed in a separate bracket, screwed on the cabin floor and can be picked up in an emergency situation by simply grabbing and pulling.

  • Page 52: Chapter 26 - Fire Protection

    AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS CHAPTER 26 - FIRE PROTECTION Depending on customer9s 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 53: Flight Controls

    AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS CHAPTER 27 - FLIGHT CONTROLS 27-00-00 Flight Controls See CHAPTER 67 – ROTOR FLIGHT CONTROL. Note: Stabilizers are described in CHAPTER 55 - STABILIZERS. Flight Controls – Rudder 27-20-00 The Rudder (Fin) is connected to the foot pedals with steel cables which are routed horizontally along the main frame.

  • Page 54: Storage

    AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS CHAPTER 28 – FUEL 28-10-00 Storage The fuel system consists of two tanks permanently connected with a large bore crossover tube allowing them to be considered as one large tank, with a single filler port, fuel and ventilation lines, fuel level indicator, tank water drain point and gascolator.

  • Page 55: Distribution

    AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS 28-20-00 Distribution The fuel distribution system comprises fuel hoses, made of fabric-reinforced rubber, PTFE hose with stainless steel braid, a shut-off valve, a filter and two pumps. Fuel system ROTAX 915 iS / 916 iS: The safeguarded lever of the shut-off valve is located between the pilot and passenger seat below the intercom panel.
  • Page 56 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS CHAPTER 29-30 - UNASSIGNED / N/A AMM-CD-915iS/916iS-EN- Part C - System Description Page 16 of 56 Section (Chapter 21 – 90) C-2025-04...

  • Page 57: Indicating System

    AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS 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 58 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS Panel Layout - Standard 1 – Magnetic compass 18 – Manifold pressure gauge (if inst.) 2 – Warning lights 19 – Collision Avoidance System (if inst.) 3 – Engine RPM 20 –...
  • Page 59 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS Panel Layout – Moving Map Landscape 1 – Magnetic compass 18 – VSI 2 ¼= (47mm) (if installed) 2 – Warning lights 19 – Intercom/headphone sockets 3 – Rotor RPM 20 –...
  • Page 60 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS Panel Layout – Moving Map Portrait (Garmin 695) 1 – Magnetic compass 17 – Oil pressure 2 – Warning lights 18 – Oil temperature 3 – Overdrive push button 19 – Cylinder head temperature 4 –...

  • Page 61: Integrated Display Systems

    AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS 31-60-00 Integrated Display Systems The Glass Cockpit layout is tailored to the integrated flight and navigation suite DYNON AVIONICS SkyView. In addition to navigational and moving map functions, the system provides primary flight data and engine/vehicle monitoring.

  • Page 62: Landing Gear

    Calidus Maintenance Manual 915 iS / 916 iS CHAPTER 32 - LANDING GEAR The Calidus 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 63: Exterior

    33-40-00 Exterior All Calidus aircraft are approved for Day-VFR operation. Those equipped with the necessary additional equipment are approved for Day-VFR and Night-VFR. Electrical schematics / wiring diagrams are provided in Part D - Diagrams and Charts of this manual.
  • Page 64 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS Alternative navigation and strobes mounting either side of the tail fins. This improves conspicuity and reduces cabin flash. View of forward facing lamp with optional underbody landing light AMM-CD-915iS/916iS-EN- Part C - System Description Page 24 of 56 Section (Chapter 21 –...

  • Page 65: Flight Environment Data

    34-10-00 Flight Environment Data The Calidus 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 line.
  • Page 66 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS CHAPTER 35 - UNASSIGNED / N/A AMM-CD-915iS/916iS-EN- Part C - System Description Page 26 of 56 Section (Chapter 21 – 90) C-2025-04...

  • Page 67: Generation/ Compressor

    AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS CHAPTER 36 – PNEUMATIC Aircraft trim, rotor brake and activation of the pre-rotator is controlled by a pneumatic system, consisting of an electrically driven air compressor with filter/dryer, a pressure gauge in the cockpit, a pressure compensation vessel, solenoid valves, air lines, pneumatic actuators, and the respective cockpit controls.

  • Page 68: Distribution

    AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS 36-21-00 Distribution Air distribution comprises of hoses, valves (solenoids), (cockpit) controls and switches, (pressure) sensors, filter/dryer and a pressure compensation vessel. The main pneumatic switching logic is combined in the pneumatic master box which is installed below the rear seat and accessible through a service cover.
  • Page 69 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS CHAPTER 37-50 – UNASSIGNED / N/A AMM-CD-915iS/916iS-EN- Part C - System Description Page 29 of 56 Section (Chapter 21 – 90) C-2025-04...

  • Page 70: Standard Practices - Structures

    915 iS / 916 iS CHAPTER 51 - STANDARD PRACTICES – STRUCTURES Standard Practices – Structures 51-00-00 Structural repair of composite structures or the welded steel frame is limited to AutoGyro GmbH or its specialized service partners. AMM-CD-915iS/916iS-EN- Part C - System Description Page 30 of 56 Section (Chapter 21 –...

  • Page 71: Doors, Covers And Cowlings

    The gyroplane is embarked and disembarked from the right hand side while the canopy is held open by a restraint strap. The large, glazed canopy of the Calidus provides ingress, egress and emergency exit. The canopy is hinged at the left hand side using two hinges with bolts and self-locking nut. The canopy locking mechanism is located on the right hand side of the cockpit and can be opened from the outside as well as from the inside while the locking lever can be reached from both cockpit stations.
  • Page 72 (nose too high) during take-off, landing or wheel balance. The protection pad must be inspected regularly and replaced as necessary in order to protect the steel tubing. In case the steel tubing is abraded, contact AutoGyro Technical Support for assessment AMM-CD-915iS/916iS-EN-...
  • Page 73 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS CHAPTER 54 - UNASSIGNED / N/A AMM-CD-915iS/916iS-EN- Part C - System Description Page 33 of 56 Section (Chapter 21 – 90) C-2025-04...

  • Page 74: Rudder

    In order to assess the integrity of the stabilizer, carefully pull the fin tips in lateral direction (left/right) with a maximum of 150 N. A 8linear9 resistance must be felt. In case mechanical noises are heard/felt, contact AutoGyro Technical Support. 55-40-00 Rudder The rudder is made of GRP and is hinged to the central fin of stabilizer.

  • Page 75: Chapter 56 - Windows

    AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS CHAPTER 56 – WINDOWS 56-10-00 Flight Compartment / Canopy Outside visibility and environmental protection for pilot and occupant is provided by one large, undivided glazed canopy. The canopy consists of a GRP canopy frame with integrated seal and one large formed Plexiglas window.
  • Page 76 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS CHAPTER 57-60 - UNASSIGNED/ N/A AMM-CD-915iS/916iS-EN- Part C - System Description Page 36 of 56 Section (Chapter 21 – 90) C-2025-04...
  • Page 77 Adjustment of the fixed pitch propeller is described in a dedicated Job Card in Part E of this manual. The mechanical end stops of the variable pitch propeller are pre-adjusted by AutoGyro. In case, re- adjustment should be necessary on the variable pitch propeller, please refer to the manufacturer9s documentation.

  • Page 78: Rotor - Teetering Parts

    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. AutoGyro optimizes each rotor system at a medium disc loading and speed before delivery. However, if the rotor system shall be tuned to a different flight condition or reveals undue vibration, contact AutoGyro Technical Support or a specialized service partner.

  • Page 79: Rotor Head Bridge, Bearing And Teeter Tower

    AutoGyro Aircraft Calidus Maintenance Manual 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 80: Rotor Gimbal Head

    AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS 62-32-00 Rotor Gimbal Head Tilting action or rotor flight control of the rotor is facilitated by the rotor gimbal head. The gimbal head is sometimes also referred to as 8hang point9 and represents a cardan hinge.

  • Page 81: Chapter 63 - Rotor Drive

    AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS CHAPTER 63 - ROTOR DRIVE 63-11-00 Pre-rotator The pre-rotator is used to quickly bring the rotor up to safe RPM for take-off run by the press of a button. Pre-rotation is activated by a push-button on the flight control stick. Because of a safety circuit, activation of the pre-rotator is only possible with the pneumatic mode selector in FLIGHT position and the control stick fully forward.

  • Page 82: Pre-Rotator Drive

    AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS 63-11-20 Pre-rotator Drive Power flow is realized through a 90-degree gearbox and drive shafts. The 90-degree gearbox is mounted directly to the disc coupling. The pre-rotator drive shaft features a cardan joint right after the 90-degree gearbox and a sliding shaft coupling in the upper area to allow changes in length due to the tilt of the rotor head.
  • Page 83 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS 63-51-00 Rotor Brake System The rotor brake system consists of a brake pad mounted to a bracket which is hinged to the rotor head bridge. With the pneumatic mode selector in BRAKE position the operation of the pneumatic trim actuator is reversed so that increased pressure causes the actuator to push the rotor head up (or level) and presses a brake pad against the rotor head disc.
  • Page 84 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS CHAPTER 64-66 - UNASSIGNED / N/A AMM-CD-915iS/916iS-EN- Part C - System Description Page 44 of 56 Section (Chapter 21 – 90) C-2025-04...

  • Page 85: Chapter 67 - Rotor Flight Control

    AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS CHAPTER 67 - ROTOR FLIGHT CONTROL Rotor flight control comprises of control stick, a control tube running horizontally along the bottom of the fuselage, and push-pull control cables which are routed vertically along the mast and connected to the rotor head bridge.
  • Page 86 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS CHAPTER 68-70 - UNASSIGNED / N/A AMM-CD-915iS/916iS-EN- Part C - System Description Page 46 of 56 Section (Chapter 21 – 90) C-2025-04...

  • Page 87: Chapter 71 - Power Plant

    AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS CHAPTER 71 - POWER PLANT Power plant comprises aircraft provisions, installations and systems related to the core engine. The engine itself is allocated to CHAPTER 72 – 74 ENGINE RELATED.

  • Page 88: Engine Air Intakes

    AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS 71-60-00 Engine Air Intakes A central engine air intake for cooling and aspiration is provided as ram air inlet in the lower area forward mast cover, just above the cabin. The engine aspirates air from the engine compartment through an air filter.
  • Page 89 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS CHAPTER 72 - 74 - ENGINE RELATED For the (core) engine refer to the engine manufacturer9s documentation in its latest revision. Concerning fuel system (Filter, Pumps, Shut-off valve) see CHAPTER 28 - FUEL.

  • Page 90: Chapter 75 - Air / Engine Cooling

    AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS CHAPTER 75 - AIR / ENGINE COOLING Engine cooling is provided by ram air cooled cylinders and liquid cooled cylinder heads. Sufficient cooling air flow is provided by a ram air duct in the lower portion of the forward mast cover. The water cooling system comprises of engine driven pump, radiator with thermo-activated electrical blower fan, expansion tank with radiator cap, overflow bottle, and hoses.

  • Page 91: Chapter 76 - Engine Controls

    AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS CHAPTER 76 – ENGINE CONTROLS Engine control consists of engine power lever / throttle with choke 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 left hand side of the pilot9s station.

  • Page 92: Chapter 77 - Engine Indicating

    Rotax CAN-Bus system to the gauges, via a digital to analogue Converter. On start up the gauges initially go to full scale deflection, the normal Road gauge manufacturer9s process. The AutoGyro Converter then self-checks by displaying the red line indication, dropping to the green line indication.

  • Page 93: Display Systems

    AutoGyro Aircraft Calidus Maintenance Manual 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 (air cooled cylinders with water cooled cylinder heads) the CT represents cylinder head coolant temperature.
  • Page 94 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS CHAPTER 78 – EXHAUST 78-00-00 Exhaust The basic exhaust system including manifold and turbo charger with waste gate is part of the core engine. Refer to the engine manufacturer9s documentation. The configuration meets the noise test requirements of Germany.

  • Page 95: Storage / Oil Tank

    AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS CHAPTER 79 - Oil SYSTEM The dry sump forced lubrication comprises oil pump, separate oil tank with dip stick, oil cooler, hoses, as well as oil temperature and oil pressure indication.

  • Page 96: Oil Cooler

    AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS 79-22-00 Oil Cooler An oil cooler is fitted to the lower aft end of the fuselage / enclosure, below the central section of the main gear suspension bow. Oil flow through the cooler is regulated by a thermostat assembly which opens the cooler circuit at approximately 90 °C.
  • Page 97 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS Contents Wiring Diagram – Aircraft Main Wiring Harness 915/916 Wiring Diagram – OAT / Roll Trim Wiring Diagram – Control Sticks Wiring Diagram – Wiring Harness Stick II Wiring Diagram – Landing / Taxi Lights Wiring Diagram –...
  • Page 98 Nor may it be shown publically, by third party or Modification Date Name for competitve purposes. Changes to the design, composition or processing require prior authorisation from AutoGyro. Name (engl.) / Name (ger.) / Part Number Main wiring 915 916 / => twisted Date /8.8:C...
  • Page 99 Name Modification permission. Nor may it be shown publically, by third party or for competitve purposes. Changes to the design, composition or processing require prior authorisation from AutoGyro. Name (engl.) / Name (ger.) / Part Number Sonstige komponeten Date Name...
  • Page 100 Date Name permission. Nor may it be shown publically, by third party or for competitve purposes. Changes to the design, composition or processing require prior authorisation from AutoGyro. Name (engl.) / Name (ger.) / Part Number Control sticks / Date Name Steuerknüppel...
  • Page 101 Name permission. Nor may it be shown publically, by third party or for competitve purposes. Changes to the design, composition or processing require prior authorisation from AutoGyro. Name (engl.) / Name (ger.) / Part Number Wiring harness stick II/ Date...
  • Page 102 Name permission. Nor may it be shown publically, by third party or for competitve purposes. Changes to the design, composition or processing require prior authorisation from AutoGyro. Name (engl.) / Name (ger.) / Part Number Landing / Taxi lights Date...
  • Page 103 Date Name permission. Nor may it be shown publically, by third party or for competitve purposes. Changes to the design, composition or processing require prior authorisation from AutoGyro. Name (engl.) / Name (ger.) / Part Number NAV / Strobe Date...
  • Page 104 Date Name permission. Nor may it be shown publically, by third party or for competitve purposes. Changes to the design, composition or processing require prior authorisation from AutoGyro. Name (engl.) / Name (ger.) / Part Number Wiring harness Nav/Strobe Date...
  • Page 105 Nor may it be shown publically, by third party or Modification for competitve purposes. Changes to the design, composition F_M3 Rotax Backup or processing require prior authorisation from AutoGyro. Name (engl.) / Name (ger.) / Part Number F_M4 Key switch T30 Main fuse attachment kit /...
  • Page 106 Date Name permission. Nor may it be shown publically, by third party or for competitve purposes. Changes to the design, composition or processing require prior authorisation from AutoGyro. Name (engl.) / Name (ger.) / Part Number Cockpit Standard 915/916 Date...
  • Page 107 Nor may it be shown publically, by third party or Modification for competitve purposes. Changes to the design, composition BK 1,5² BK 1,5² or processing require prior authorisation from AutoGyro. Name (engl.) / Name (ger.) / Part Number Compressor Pneumatic parts with relais Date...
  • Page 108 Name permission. Nor may it be shown publically, by third party or for competitve purposes. Changes to the design, composition or processing require prior authorisation from AutoGyro. Name (engl.) / Name (ger.) / Part Number Low fuel sensor / Benzin...
  • Page 109 Date Name permission. Nor may it be shown publically, by third party or for competitve purposes. Changes to the design, composition or processing require prior authorisation from AutoGyro. Name (engl.) / Name (ger.) / Part Number Engine bay wiring Date...
  • Page 110 Date Name permission. Nor may it be shown publically, by third party or for competitve purposes. Changes to the design, composition or processing require prior authorisation from AutoGyro. Name (engl.) / Name (ger.) / Part Number Copilot Lemo build-in Date...
  • Page 111 Name permission. Nor may it be shown publically, by third party or for competitve purposes. Changes to the design, composition or processing require prior authorisation from AutoGyro. Name (engl.) / Name (ger.) / Part Number Copilot control console / Date...
  • Page 112 Date Name permission. Nor may it be shown publically, by third party or for competitve purposes. Changes to the design, composition or processing require prior authorisation from AutoGyro. Name (engl.) / Name (ger.) / Part Number Cockpit light green Date Name Cockpitbeleuchtung grün...
  • Page 113 Date Name permission. Nor may it be shown publically, by third party or for competitve purposes. Changes to the design, composition or processing require prior authorisation from AutoGyro. Name (engl.) / Name (ger.) / Part Number Cockpit EFIS 915iS/916iS Date...
  • Page 114 Name permission. Nor may it be shown publically, by third party or for competitve purposes. Changes to the design, composition or processing require prior authorisation from AutoGyro. Name (engl.) / Name (ger.) / Part Number Cockpit EFIS with Com3 Date...
  • Page 115 Nor may it be shown publically, by third party or Modification Date Name for competitve purposes. Changes to the design, composition or processing require prior authorisation from AutoGyro. Name (engl.) / Name (ger.) / Part Number Garmin G3X cockpit Date Name...

  • Page 116: For Competitve Purposes. Changes To The Design, Composition

    Modification permission. Nor may it be shown publically, by third party or for competitve purposes. Changes to the design, composition or processing require prior authorisation from AutoGyro. Name (engl.) / Name (ger.) / Part Number Garmin GTP 59 (OAT) Date...
  • Page 117 Date Name for competitve purposes. Changes to the design, composition or processing require prior authorisation from AutoGyro. Name (engl.) / Name (ger.) / Part Number Cockpit installation - 10 11 12 13 14 15 16 17 18 19 20 21 /1.10:B...
  • Page 118 PTT 2 (BN/YE) for competitve purposes. Changes to the design, composition Mic - Free or processing require prior authorisation from AutoGyro. Name (engl.) / Name (ger.) / Part Number PTT 1 (BN) PushPull 7pin. Plug Mic 1 positiv (MIC_WH/BU) Pilot...
  • Page 119 Nor may it be shown publically, by third party or Modification Date Name for competitve purposes. Changes to the design, composition or processing require prior authorisation from AutoGyro. Name (engl.) / Name (ger.) / Part Number GMA 345 installation kit Date Name...
  • Page 120 Date Name permission. Nor may it be shown publically, by third party or for competitve purposes. Changes to the design, composition or processing require prior authorisation from AutoGyro. Name (engl.) / Name (ger.) / Part Number SCU installation kit Date...
  • Page 121 Nor may it be shown publically, by third party or Modification for competitve purposes. Changes to the design, composition or processing require prior authorisation from AutoGyro. Name (engl.) / Name (ger.) / Part Number Garmin GTX 45R w/GPS Date...
  • Page 122 Modification Date Name permission. Nor may it be shown publically, by third party or for competitve purposes. Changes to the design, composition or processing require prior authorisation from AutoGyro. Name (engl.) / Name (ger.) / Part Number Date Name Lüfter Drawing 18.11.2024...

  • Page 123: Firewarning

    Date Name Modification permission. Nor may it be shown publically, by third party or for competitve purposes. Changes to the design, composition or processing require prior authorisation from AutoGyro. Name (engl.) / Name (ger.) / Part Number Firewarning Date Name...

  • Page 124: 2024 Harry

    Name permission. Nor may it be shown publically, by third party or for competitve purposes. Changes to the design, composition or processing require prior authorisation from AutoGyro. Name (engl.) / Name (ger.) / Part Number GMU22 installation kit / Date...
  • Page 125 Modification for competitve purposes. Changes to the design, composition RS232_3 Connext Format 1 Garmin GTX 45R or processing require prior authorisation from AutoGyro. Name (engl.) / Name (ger.) / Part Number Garmin GTX 45R / GPS 20A Date Name installation kit / Einbausatz Drawing 19.11.2024...
  • Page 126 Nor may it be shown publically, by third party or Modification /32.1:G for competitve purposes. Changes to the design, composition /32.3:C or processing require prior authorisation from AutoGyro. Name (engl.) / Name (ger.) / Part Number 7 pin Garmin GTR225 installation Date...
  • Page 127 Nor may it be shown publically, by third party or Modification /32.1:G for competitve purposes. Changes to the design, composition /32.3:C or processing require prior authorisation from AutoGyro. Name (engl.) / Name (ger.) / Part Number 7 pin Garmin GNC255 installation Date...
  • Page 128 Nor may it be shown publically, by third party or Modification /32.1:G for competitve purposes. Changes to the design, composition /32.3:C or processing require prior authorisation from AutoGyro. Name (engl.) / Name (ger.) / Part Number 7 pin Garmin GTR205 installation Date...
  • Page 129 Nor may it be shown publically, by third party or Modification /32.3:C for competitve purposes. Changes to the design, composition or processing require prior authorisation from AutoGyro. 7 pin Name (engl.) / Name (ger.) / Part Number Garmin GNC215 installation...
  • Page 130 Name permission. Nor may it be shown publically, by third party or for competitve purposes. Changes to the design, composition or processing require prior authorisation from AutoGyro. Name (engl.) / Name (ger.) / Part Number Garmin G5 installation kit Date...
  • Page 131 Name permission. Nor may it be shown publically, by third party or for competitve purposes. Changes to the design, composition or processing require prior authorisation from AutoGyro. Name (engl.) / Name (ger.) / Part Number Garmin G5 installation kit Date...
  • Page 132 Name permission. Nor may it be shown publically, by third party or for competitve purposes. Changes to the design, composition or processing require prior authorisation from AutoGyro. Name (engl.) / Name (ger.) / Part Number Garmin G5 installation kit Date...
  • Page 133 Name permission. Nor may it be shown publically, by third party or for competitve purposes. Changes to the design, composition or processing require prior authorisation from AutoGyro. Name (engl.) / Name (ger.) / Part Number Alinco DR-638 to GMA Plug-PushPull Com2...
  • Page 134 Name permission. Nor may it be shown publically, by third party or for competitve purposes. Changes to the design, composition or processing require prior authorisation from AutoGyro. Name (engl.) / Name (ger.) / Part Number Alinco DR-638 Einbausatz C Date...
  • Page 135 Name permission. Nor may it be shown publically, by third party or for competitve purposes. Changes to the design, composition or processing require prior authorisation from AutoGyro. Name (engl.) / Name (ger.) / Part Number Motorola MTM5400 Tetra Plug-PushPull Com3...

  • Page 136: Date Name

    Changes to the design, composition or 26621 back cushion Rückenstütze Air processing require prior authorisation from Co-Sign 1: Pneumatic box comfort 34523 Roll trim sensor box Rolltrimsensorbox AutoGyro 20855 T-connector T-Stück 22200 Trim cyl. C85N16-100 Trimmzyl. C85N16-100 33792 Pneumatic coupling Pneumatik Kupplung...
  • Page 137 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS Contents 07-00-00 2-1 LIFTING OF GYROPLANE 07-00-00 2-2 JACKING OF GYROPLANE 07-00-00 2-3 SHORING OF GYROPLANE 08-10-00 2-1 WEIGHING OF GYROPLANE 24-30-00 4-1 REMOVAL - INSTALLATION: BATTERY 27-20-00 5-1 CHECK - ADJUSTMENT: RUDDER CONTROL ANGLES...
  • Page 138 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS 62-31-00 5-1 ADJUSTMENT: BACKLASH 62-31-00 6-1 INSPECTION: ROTOR HEAD BRIDGE, BEARING AND TEETER TOWER 62-32-00 5-1 CHECK - ADJUSTMENT: ROTOR CONTROL FRICTION 62-32-00 6-1 INSPECTION: ROTOR GIMBAL HEAD REMOVAL – INSTALLATION: TOP MAST...
  • Page 139 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS 07-00-00 2-1 LIFTING OF 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! Rotor system must be removed, see Job Card 62-11-00 4-1.
  • Page 140 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS ILLUSTRATIONS Figure 1 - Lifting belt looped around teeter bolt Part E – 07-00-00 2-1 AMM-CD-915iS/916iS-EN- Page 2 of 2 E-2025-04...
  • Page 141 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS 07-00-00 2-2 JACKING OF 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! Gyroplane must be placed on level ground and restrained (blocks, chocks).
  • Page 142 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS 07-00-00 2-3 SHORING OF 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 Job Card 62-11-00 4-1...
  • Page 143 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS ILLUSTRATIONS: Figure 1 – Lash-down methods of gyroplane Figure 2 – lashing lugs on the main wheels Figure 3 – lashing down through the keel tube AMM-CD-915iS/916iS-EN- Part E - 07-00-00 2-3...
  • Page 144 None PROCEDURES/ DESCRIPTION NOTE: Weighing is performed by measuring the weight below each wheel on a level surface. The actual AutoGyro weighing form should be used and is available for download on the AutoGyro website. AMM-CD-915iS/916iS-EN- Part E - 08-10-00 2-1...
  • Page 145 AutoGyro Aircraft Calidus Maintenance Manual 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 146 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS ILLUSTRATIONS Figure 1 – Position of the Earth X battery seen from behind in direction of flight on 916iS aircraft Part E – 24-30-00 4-1 AMM-CD-915iS/916iS-EN- Page 2 of 2...
  • Page 147 AutoGyro Aircraft Calidus Maintenance Manual 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'!
  • Page 148 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS ILLUSTRATIONS Figure 1 – Rudder control angle setting Figure 2 – Measurement procedure (Example) AMM-CD-915iS/916iS-EN- Part E - 27-20-00 5-1 Page 2 of 2 E-2025-04...
  • Page 149 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS 28-20-00 6-1 INSPECTION: FUEL FILTER (GASCOLATOR) 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 IMPORTANT NOTE: Procedure involves spare parts.
  • Page 150 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS ILLUSTRATIONS Figure 1 – Location of gascolator drain point. Figure 2 – Housing unscrewed AMM-CD-915iS/916iS-EN- Part E - 28-20-00 6-1 Page 2 of 3 E-2025-04...
  • Page 151 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS Figure 3 – Filter removed from Gascolator cap for inspection and cleaning AMM-CD-915iS/916iS-EN- Part E - 28-20-00 6-1 Page 3 of 3 E-2025-04...
  • Page 152 AutoGyro Aircraft Calidus Maintenance Manual 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'! Secure gyroplane against unauthorized or unintended operation!
  • Page 153 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS ILLUSTRATIONS Figure 1 – Location of fuel filter Position may be different depending on configuration Part E – 28-20-00 8-1 AMM-CD-915iS/916iS-EN- Page 2 of 2 E-2025-04...
  • Page 154 AutoGyro Aircraft Calidus Maintenance Manual 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! One fuel the tank must be removed.

  • Page 155: Parts List

    AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS PARTS LIST Figure Position Description Remarks Fuel Pump Rotax Part Rotax Fuel Pump 915 engine Fuel Pump Rotax Part Rotax Fuel Pump 916 engine ILLUSTRATIONS Figure 1 – Electrical fuel pumps seen from RH and LH – Position may vary depending on the engine type Figure 1 –...
  • Page 156 AutoGyro Aircraft Calidus Maintenance Manual 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 Job Card 07-00-00 2-2...
  • Page 157 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS PARTS LIST Figure Position Description Remarks Membrane grommet DG M50 Steering bush 22169 Control Nose wheel 46115 Shock Absorber with metal 27553 Nose wheel axle M10x155 M10_Si U11x34x3 M10x20 Front fork spat attachment welded...
  • Page 158 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS ILLUSTRATIONS Figure 1 - Nose wheel assembly AMM-CD-915iS/916iS-EN- Part E - 32-40-00 4-1 Page 3 of 5 E-2025-04...
  • Page 159 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS Figure 2 – Rear Wheel assembly Figure 3 – M6 x 12 Screw and serrated wash holding the brake disc on the rim AMM-CD-915iS/916iS-EN- Part E - 32-40-00 4-1 Page 4 of 5...
  • Page 160 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS Figure 4 – detailed view of attachment AMM-CD-915iS/916iS-EN- Part E - 32-40-00 4-1 Page 5 of 5 E-2025-04...
  • Page 161 AutoGyro Aircraft Calidus Maintenance Manual 915iS / 916 iS 32-40-00 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 Job Card 07-00-00 2-2...
  • Page 162 AutoGyro Aircraft Calidus Maintenance Manual 915iS / 916 iS PARTS LIST Figure Position Description Remarks Membrane grommet DG M50 Steering bush 22169 Control Nose wheel 46115 Shock Absorber with metal 27553 Nose wheel axle M10x155 M10_Si U11x34x3 M10x20 Front fork spat attachment...
  • Page 163 AutoGyro Aircraft Calidus Maintenance Manual 915iS / 916 iS ILLUSTRATIONS Figure 1 – Nose gear assembly AMM-CD-915iS/916iS-EN- Part E - 32-40-00 8-1 Page 3 of 3 E-2025-04...
  • Page 164 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS 32-40-00 8-2 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 Job Card 07-00-00 2-2...
  • Page 165 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS PARTS LIST Figure Position Description Remarks 9, 10 Brake pad Set 30044 Serrated Washer 20009 ILLUSTRATIONS Figure 1 – Brake calliper AMM-CD-915iS/916iS-EN- Part E - 32-40-00 8-2 Page 2 of 2...
  • Page 166 AutoGyro Aircraft Calidus Maintenance Manual 915iS / 916 iS 32-40-00 8-3 REPLACEMENT: MAIN WHEEL BEARING 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 Job Card 07-00-00 2-2...
  • Page 167 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS 32-40-00 8-4 REPLACEMENT: O-RING BRAKE PISTON 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 Job Card 07-00-00 2-2...
  • Page 168 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS PARTS LIST Figure Position Description Remarks Cylinder bushing 22x10x6 Brake Calliper Brake Piston Copper Washer 6mm 21399 M4x6 Washer 6mm 21403 Hollow Screw O-Ring 48751 Inner Brake Pad 30044 9+10 as set...
  • Page 169 Task may only be performed by an organization or individual trained and entitled to carry out 'Professional Maintenance'! SPECIAL TOOLS AND CONSUMABLE MATERIALS For special tools or assistance contact AutoGyro Technical Support PRECAUTIPONS AND SAFETY MEASURES CAUTION: Instruments can easily be damaged if test is performed improperly. Manipulate test equipment slowly and carefully.
  • Page 170 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS Figure 1 – Pitot static integrity test equipment Figure 2 – Pitot static instruments connecting diagram AMM-CD-915iS/916iS-EN- Part E - 34-10-00 5-1 Page 2 of 2 E-2025-04...
  • Page 171 AutoGyro Aircraft Calidus Maintenance Manual 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 172 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS ILLUSTRATIONS Figure1 – Static ports (2x) and pitot port Figure 2 – Example for static lines, disconnect clear hose from instruments and use compressed air AMM-CD-915iS/916iS-EN- Part E - 34-10-00 7-1...
  • Page 173 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS Figure 3 - Pitot static instruments connecting diagram AMM-CD-915iS/916iS-EN- Part E - 34-10-00 7-1 Page 3 of 3 E-2025-04...
  • Page 174 AutoGyro Aircraft Calidus Maintenance Manual 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 175 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS ILLUSTRATIONS Figure 1 – Location of filter/ dryer Part E – 36-21-00 8-1 AMM-CD-915iS/916iS-EN- Page 2 of 2 E-2025-04...
  • Page 176 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS REMOVAL – INSTALLATION: FUEL TANKS 51-00-00 4-1 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 Job Card 52-00-00 4-1, tanks must be empty!
  • Page 177 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS ILLUSTRATIONS Figure 1 – Oil tank bracket removed Figure 2 – Tank vent line needs to be disconnected AMM-CD-915iS/916iS-EN- Part E - 51-00-00 2-1 Page 2 of 6 E-2025-04...
  • Page 178 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS Figure 3 – Clamp removed from tank connection Figure 4 – Retaining straps AMM-CD-915iS/916iS-EN- Part E - 51-00-00 2-1 Page 3 of 6 E-2025-04...
  • Page 179 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS Figure 5 – Tank can be removed carefully Figure 6 – Tank outlet to tank connection hose AMM-CD-915iS/916iS-EN- Part E - 51-00-00 2-1 Page 4 of 6 E-2025-04...
  • Page 180 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS Figure 7: Intercooler removed Figure 8 - LH tank ground connection and fuel hose clamp AMM-CD-915iS/916iS-EN- Part E - 51-00-00 2-1 Page 5 of 6 E-2025-04...
  • Page 181 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS Figure 9 – Fuel vent hose LH fuel tank Figure 10 – Fuel shut-off valve needs to be disconnected AMM-CD-915iS/916iS-EN- Part E - 51-00-00 2-1 Page 6 of 6 E-2025-04...
  • Page 182 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS 52-00-00 4-1 REMOVAL - INSTALLATION: COWLINGS AND FAIRINGS 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 183 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS RH cowling: 2. With the help of a second person bring cowling into position. Make sure to insert drain hoses without damage. 3. Insert round head bolts with poly washers and screw in without tightening, preferably working from top to bottom.
  • Page 184 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS ILLUSTRATIONS Figure 1 – Cowling and mast cover AMM-CD-915iS/916iS-EN- Part E - 52-00-00 4-1 Page 3 of 5 E-2025-04...
  • Page 185 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS Figure 2 – Air filter Figure 3 – Screws for the cylinder head cooling tube AMM-CD-915iS/916iS-EN- Part E - 52-00-00 4-1 Page 4 of 5 E-2025-04...
  • Page 186 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS Figure 4 – Screw installed in the front of the forward mast cover AMM-CD-915iS/916iS-EN- Part E - 52-00-00 4-1 Page 5 of 5 E-2025-04...
  • Page 187 See Figure 1 for reference. In case the breakout force is less than 40 N or more than 60 N adjust locking mechanism. If impossible or in doubt, contact AutoGyro Technical Support. ILLUSTRATIONS Figure 1 –...
  • Page 188 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS 52-10-00 6-1 INSPECTION: CANOPY FRAME GAP 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 189 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS ILLUSTRATIONS Figure 1 – Plasticine ball (modelling dough) on fixed canopy frame Figure 2 – Positions for attachment bores Part E – 52-10-00 6-1 AMM-CD-915iS/916iS-EN- Page 2 of 3 E-2025-04...
  • Page 190 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS Figure 3 – Attachment bores drilled Figure 4 – Canopy spacers installed Part E – 52-10-00 6-1 AMM-CD-915iS/916iS-EN- Page 3 of 3 E-2025-04...
  • Page 191 SPECIAL TOOLS AND CONSUMABLE MATERIALS None PROCEDURES/DESCRIPTION There are several covers in the Calidus cockpit which needs to be removed to get access to parts of the aircraft which needs to be inspected for maintenance purposes or needs access for mechanical repairs and/or replacements.
  • Page 192 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS Figure 2 Figure 3 The cover on the right side in the direction of flight (1) has to be removed to get to the pneumatic system. And to the static port and the connected static hose. The cover on the left side (3) needs to be removed for checking the static port L/H.
  • Page 193 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS Service cover in the front of the aircraft Figure 4 1 – cover underneath the front seat to the rear stick – access to parts of the steering 2 – cover on the pedals and the teflon bearings 3 –...
  • Page 194 SPECIAL TOOLS AND CONSUMABLE MATERIALS None PRECAUTIONS AND SAFETY MEASURES None PROCEDURES 1. Inspect all main frame weld seams. 2. If a crack is detected, contact AutoGyro Technical Support. Part E – 53-00-00 6-1 AMM-CD-915iS/916iS-EN- Page 1 of 6 E-2025-04...
  • Page 195 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS ILLUSTRATIONS See figure 2 See figure 3 See figure 4 See figure 5 See figure 6 Figure 1 – Main frame See figure 8 See figure 7 Part E – 53-00-00 6-1...
  • Page 196 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS Figure 2 – Welding seams Part E – 53-00-00 6-1 AMM-CD-915iS/916iS-EN- Page 3 of 6 E-2025-04...
  • Page 197 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS Figure 3 Figure 4 – Welding seams Part E – 53-00-00 6-1 AMM-CD-915iS/916iS-EN- Page 4 of 6 E-2025-04...
  • Page 198 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS Figure 5 – Welding seams Figure 6 – Welding seams Part E – 53-00-00 6-1 AMM-CD-915iS/916iS-EN- Page 5 of 6 E-2025-04...
  • Page 199 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS Figure 7 – Welding seams Figure 8 – Welding seams Part E – 53-00-00 6-1 AMM-CD-915iS/916iS-EN- Page 6 of 6 E-2025-04...
  • Page 200 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS 53-20-00 4-1 REMOVAL - INSTALLATION: ENGINE SUPPORT ARM GENERAL, REFERENCES AND REQUIREMENTS Task may only be performed by an organization or individual trained and entitled to carry out 'Professional Maintenance'!

  • Page 201: Parts List

    AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS PARTS LIST Figure Position Description Remarks Motor support tube welded engine support welded half clamp engine mount distance 12651 spacer engine mount silent block engine mount 13813 washer engine mount...
  • Page 202 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS Figure 2 – Lower attachment of the engine support arm Figure 3 and 4 – Upper attachment points at the gear box Figure 5 – Screws on the clamp on the keel tube Part E –...
  • Page 203 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS Figure 6 – thrust angle Part E – 53-20-00 4-1 AMM-CD-915iS/916iS-EN- Page 4 of 4 E-2025-04...
  • Page 204 AutoGyro Aircraft Calidus Maintenance Manual 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 'Line Maintenance'! Secure gyroplane against unauthorized or unintended operation!
  • Page 205 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS ILLUSTRATIONS Figure 1 – Installation position of keel tube protection pad Part E – 55-00-00 8-1 AMM-CD-915iS/916iS-EN- Page 2 of 2 E-2025-04...
  • Page 206 Absolute cleanliness at any time during execution of the procedure must be ensured. The following procedure is only approved for ductile (not brittle) canopies and windows without IR-/UV- protection of AutoGyro aircrafts. Part must be in removed condition for executing the procedure.
  • Page 207 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS 9. The adhesive must be applied in layers of approx. 2 mm thickness into the channel. The first layer must cover all areas of the channel and must protrude approx. 2 mm over the channel edge (Figure 2).
  • Page 208 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS ILLUSTRATIONS Figure 1 – Milling of a channel on material top side Figure 2 – Filled channel on material top side Figure 3 – Channel on material bottom side Figure 4 – Filled channels on material top and bottom side Part E –...
  • Page 209 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS 61-10-00 4-2 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 210 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS PARTS LIST Figure Position Description Remarks spinner HTC4B, painted 46905 M8x130 U8/24 M6x40 Hub 4B-LK101, 6-47 front Propeller Blade CCW-172, cut 35393 Hub 4B-LK101, 6-47 rear M4 x 12 U4, Poly...
  • Page 211 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS 61-10-00 4-3 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'!
  • Page 212 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS ILLUSTRATIONS Figure 1 – Propeller and Hub AMM-CD-915iS/916iS-EN- Part E - 61-10-00 4-3 Page 2 of 2 E-2025-04...
  • Page 213 AutoGyro Aircraft Calidus Maintenance Manual 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 Job Card 61-10-00 4-1...
  • Page 214 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS ILLUSTRATIONS Figure 1 – Propeller and Hub Figure 2 - Propeller pitch adjustment and tool AMM-CD-915iS/916iS-EN- Part E - 61-10-00 5-1 Page 2 of 3 E-2025-04...
  • Page 215 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS Figure 3 – Hub detail Figure 4 – Blade detail AMM-CD-915iS/916iS-EN- Part E - 61-10-00 5-1 Page 3 of 3 E-2025-04...
  • Page 216 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS 61-10-10 4-1 REMOVAL - INSTALLATION: PROPELLER - WOODCOMP GENERAL, REFERENCES AND REQUIREMENTS Task may only be performed by an organization or individual trained and entitled to carry out 'Professional Maintenance'!
  • Page 217 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS PARTS LIST Figure Position Qty. Description Remarks Propeller KW30 hydraulic 915 white 48705 Rotax 915 engine Propeller KW30 hydraulic 915 carbon 48231 Rotax 915 engine Propeller KW30 hydraulic 916 white...
  • Page 218 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS Figure 2 – Woodcomp spinner Figure 3 – Propeller hub bolts AMM-CD-915iS/916iS-EN- Part E - 61-10-10 4-1 Page 3 of 3 E-2025-04...
  • Page 219 AutoGyro Aircraft Calidus Maintenance Manual 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 Loctite 221 red (PN 30487) IMPORTANT NOTE: Procedure involves parts with limited reusability.
  • Page 220 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS 8. If possible, handle with two persons while holding approximately in the middle of each blade. When supporting the system use two stands each positioned in about 2 metres distance from the hub.
  • Page 221 AutoGyro Aircraft Calidus Maintenance Manual 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 Job Card 62-11-00 4-1!
  • Page 222 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS PARTS LIST Figure Position Description Remarks Shoulder Bolt M8 37/12 Shoulder Bolt M8 40/12 Shoulder Bolt M8 43/12 Shoulder Bolt M8 46/12 Shoulder Bolt M8 49/12 20393 Rotor Hub II...
  • Page 223 AutoGyro Aircraft Calidus Maintenance Manual 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 Adhesive Lubricant HHS 2000 (PN 30476) IMPORTANT NOTE: Procedure involves parts with limited reusability.
  • Page 224 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS PARTS LIST Figure Position Description Remarks Shoulder Bolt M8 37/12 Shoulder Bolt M8 40/12 Shoulder Bolt M8 43/12 Shoulder Bolt M8 46/12 Shoulder Bolt M8 49/12 20393 Rotor Hub II...
  • Page 225 10. Install washer and castellated nut (Figure 1; 3, 4). Check lateral play of the teeter block in the teeter tower (Figure 2, 2). If it is greater than 0.2mm contact AutoGyro for further support. Tighten the castellated nut of the teeter bolt by hand until there is no lateral play discernible between teeter block and teeter tower, but at least one shim is able to be rotated (Figure 3).
  • Page 226 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS on the teeter bolt and not the teeter bolt in the teeter tower (Figure 4). Fit a new split-pin. Use split-pins only once. 11. Grease nipple in teeter block. PARTS LIST...
  • Page 227 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS Figure 2 Figure 3 Figure 4 – bolt is not allowed to turn if rotor system teeters AMM-CD-915iS/916iS-EN- Part E - 62-11-00 4-4 Page 3 of 3 E-2025-04...
  • Page 228 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS CHECK – ADJUSTMENT: ROTOR SYSTEM ALIGNMENT 62-11-00 5-1 GENERAL, REFERENCES AND REQUIREMENTS Task may only be performed by an organization or individual trained and entitled to carry out 'Line Maintenance'!
  • Page 229 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS ILLUSTRATIONS Figure 1 – Rotor system placed on stands Figure 2 – Positioning of measuring cord Figure 3 – Reference point at grease nipple Part E – 62-11-00 5-1 AMM-CD-915iS/916iS-EN-...
  • Page 230 AutoGyro Aircraft Calidus Maintenance Manual 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 Job Card 62-11-00 4-1...
  • Page 231 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS ILLUSTRATIONS Figure 1 – Teeter block and rotor hub Figure 2 – Teeter tower AMM-CD-915iS/916iS-EN- Part E - 62-11-00 6-1 Page 2 of 3 E-2025-04...
  • Page 232 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS Figure 3 – Teeter block Figure 4 – Teeter tower AMM-CD-915iS/916iS-EN- Part E - 62-11-00 6-1 Page 3 of 3 E-2025-04...
  • Page 233 More damage must be discussed with AutoGyro technicians. Remember, damage that changes the aerodynamic profile will affect the flight characteristic of the blade in that area. The further outboard the damage is, the faster the blade is turning, and thus the aerodynamic effect is greater.
  • Page 234 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS Important Note: More substantial damage. In all instances where the suffered damage such that the blade is bent in any plane, then the rotorsystem as a whole must be replaced. Rotor blades are carefully weighed and measured, and paired through the process for optimum performance.
  • Page 235 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS ILLUSTRATTIONS Figure 1 – Critical blade area Figure 2 – Crack in root area, inner cap removed AMM-CD-915iS/916iS-EN- Part E - 62-11-00 6-2 Page 3 of 5 E-2025-04...
  • Page 236 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS Figure 3 – View of the tope side of the rotor root (RSII, 6-hole attachment) Figure 4 – Damage on trailing edge AMM-CD-915iS/916iS-EN- Part E - 62-11-00 6-2 Page 4 of 5...
  • Page 237 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS Figure 5 – dent in surface Figure 6 – Rotor Blade Inspection AMM-CD-915iS/916iS-EN- Part E - 62-11-00 6-2 Page 5 of 5 E-2025-04...
  • Page 238 AutoGyro Aircraft Calidus Maintenance Manual 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 Job Card 62-11-00 4-1...

  • Page 239: Parts List

    AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS PARTS LIST Figure Position Description Remarks Rotor Hub II Top Pin Rotor Hub II Rotor Hub II Bottom 20393 M8, Si 20121 20663 Shoulder bolt M8 49/12 U9/20 Teeter Tower III, mounted...
  • Page 240 AutoGyro Aircraft Calidus Maintenance Manual 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'! Secure gyroplane against unauthorized or unintended operation!
  • Page 241 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS 6. Do it again for the blade which points to the end of the aircraft. This blade is above the horizontal line and the angle is the difference between both measurements.
  • Page 242 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS 62-11-00 8-1 REPLACEMENT: TEETER 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 Job Card 62-11-00 4-1...
  • Page 243 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS 10. If necessary rework inner diameter of bushings in teeter tower with a reamer 13H7. PARTS LIST Figure Position Description Remarks Bushing TEF-MET 13/16/21x30 20662 Bushing TEF-MET 13/15/21x15 20677 ILLUSTRATIONS Figure 1 –...
  • Page 244 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS Figure 2 – Teeter block Figure 3 – Teeter tower AMM-CD-915iS/916iS-EN- Part E - 62-11-00 8-1 Page 3 of 4 E-2025-04...
  • Page 245 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS Figure 4 – Bushing removal tool teeter block Figure 5 – Bushing removal tool for teeter tower AMM-CD-915iS/916iS-EN- Part E - 62-11-00 8-1 Page 4 of 4 E-2025-04...
  • Page 246 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS 62-20-00 8-2 REPLACEMENT: ROTOR SPROCKET 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 247 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS 16. Insert and secure new split pin (Figure 1; 1). Make sure that ends of the split pin do not contact rotating parts (Figure 5). 17. Inspect backlash of pre-rotator upper engagement again. Backlash should be as tight as possible, but also wide enough to allow easy engagement of the pinion into the sprocket wheel in any position.
  • Page 248 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS Figure 2 – Rotor sprocket Figure 3 – Rotor sprocket AMM-CD-915iS/916iS-EN- Part E - 62-20-00 8-1 Page 3 of 4 E-2025-04...
  • Page 249 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS Figure 4 – Rotor sprocket with split pin installed AMM-CD-915iS/916iS-EN- Part E - 62-20-00 8-1 Page 4 of 4 E-2025-04...
  • Page 250 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS 62-31-00 5-1 ADJUSTMENT: BACKLASH 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 251 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS ILLUSTRATIONS Figure 1 – rotor head III with Bendix assembly Part E – 62-31-00 5-1 AMM-CD-915iS/916iS-EN- Page 2 of 2 E-2025-04...
  • Page 252 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS Part E – 62-31-00 5-1 AMM-CD-915iS/916iS-EN- Page 3 of 1 E-2024-05...
  • Page 253 2. Inspect teeter stops for correct attachment and condition. 3. Inspect teeter tower (Figure 1) for correct attachment and condition, i.e. no cracks, no looseness, no corrosion. In case of cracks or unusual condition or appearance contact AutoGyro Technical Support.
  • Page 254 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS ILLUSTRATIONS Figure 1 – Rotor head III, teeter tower Figure 2 – Rotor head III, rotor head bridge Figure 3 – Rotor head III, gimbal head Part E – 62-31-00 6-1...
  • Page 255 AutoGyro Aircraft Calidus Maintenance Manual 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 or individual trained and entitled to carry out 'Professional Maintenance'!
  • Page 256 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS Figure 2 – Gimbal Assembly Rotor System III (with spring washers) Figure 3 – Arrangement of spring and shim washers on gimbal head – Version II Part E – 62-32-00 5-1...
  • Page 257 6. Verify measured angles comply with the values specified in the corresponding type certificate data sheet. If any of the values differs by more than 1° from the specified value mark component unserviceable and contact AutoGyro Technical Support. ILLUSTRATIONS Figure 1 – gimbal head...
  • Page 258 AutoGyro Aircraft Calidus Maintenance Manual 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 or individual trained and entitled to carry out 'Professional Maintenance'! Secure gyroplane against unauthorized or unintended operation!
  • Page 259 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS 6. Remove both bearing retaining plates of the long pre-rotator drive shaft and remove snap ring so that drive shaft can be pulled out. 7. Bring rotor head in horizontal position and remove pre-rotator shaft.
  • Page 260 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS Part E – 62-51-00 4-1 AMM-CD-915iS/916iS-EN- Page 3 of 3 E-2025-04...
  • Page 261 Repeat measurement with 150 N, applied horizontally in flight direction (see Figure 1). Record value in protocol. Tolerances can be found on the Calidus Periodic Service work sheet. Check if side plates move to contact the mast. Mast contact indicates worn bushes or failed bush retention.
  • Page 262 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS Illustrations Figure 1 – Mast reference point Figure 2 – Fuselage reference point Figure 3 – Force applied in flight direction AMM-CD-915iS/916iS-EN- Part E - 62-51-00 6-1 Page 2 of 2...
  • Page 263 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS 62-51-00 8-1 REPLACEMENT: MAST MOUNTING BUSHES 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 264: Parts List

    AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS PARTS LIST Figure Position Description Remarks M12 62-19 Bushing TEF-Met 16/18/24x22 45861 Clamp bush mast 45826 Bush mast top bottom 45827 Rubber Bushing 90 shore 11082 M12_SI 20005 Shim washer 0,2mm...
  • Page 265 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS Picture 5 – Preparation mast Figure 6 – Pay attention to the gap in the lower bushing AMM-CD-915iS/916iS-EN- Part E - 62-51-00 8-1 Page 3 of 3 E-2025-04...
  • Page 266 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS 63-11-00 4-1 REMOVAL-INSTALLATION: 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! Engine cowlings must be removed, see Job Card 52-00-00 4-1.
  • Page 267 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS 5. Re-connect pneumatic hose at quick connect coupling. Make sure flow control valve is in place and installed in correct flow direction (blue line to coupling, white line to pneumatic box).
  • Page 268 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS Figure 3 – M6 screw and M6 Si nut Figure 3 – Location of M6x20 screws (PN 45753) AMM-CD-915iS/916iS-EN- Part E - 63-11-00 4-1 Page 3 of 3 E-2025-04...
  • Page 269 3. Measure clearance between inner (engine side) drive star disc and outer (coupling side) drive star claws. See Figure 1, dimension C. Clearance must be between 0,5 – 1,0 mm. In case clearance is less than 0, 5 mm or more than 1,0 mm contact AutoGyro Technical Support. AMM-CD-915iS/916iS-EN-...
  • Page 270 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS ILLUSTRATIONS Figure 1 – Pre-rotator coupling Figure 2 – Wear limit without wear marking AMM-CD-915iS/916iS-EN- Part E - 63-11-00 6-1 Page 2 of 2 E-2024-09...
  • Page 271 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS 63-11-00 8-1 REPLACEMENT: PRE-ROTATOR FRICTION PLATE 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! Engine cowlings must be removed, see Job Card 52-00-00 4-1.
  • Page 272 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS PARTS LIST Figure Position Description Remarks Shim washer 0,1 47396 Shim washer 0,2 47397 Shim washer 0,3 47398 M5x25, allen countersunk 23612 Replacement Kit Friction Plate 46137 ILLUSTRATIONS Figure 1 – Central screw and pressure plate removed with previous installed shim washers Figure 2 –...
  • Page 273 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS 63-11-00 8-2 REPLACEMENT: PRE-ROTATOR CRANKSHAFT DOG GEAR 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! Engine cowlings must be removed, see Job Card 52-00-00 4-1.
  • Page 274 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS PARTS LIST Figure Position Description Remarks Sealing ring A 8x13 950141 Rotax part O-ring dog gear 45591 Carrier crankshaft 43879 ILLUSTRATIONS Figure 1 – M8 x 20 screw plug Part E – 63-11-00 8-2...
  • Page 275 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS Figure 2 – Thread pin M8 x 50 Figure 3 – Old part removed Figure 4 – New part with O-ring Figure 5 – Loctite onto thread Part E – 63-11-00 8-2...
  • Page 276 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS Figure 6 – New part installed Figure 7 – Tool to torque-tighten the part in the engine Part E – 63-11-00 8-2 AMM-CD-915iS/916iS-EN- Page 4 of 4 E-2025-04...
  • Page 277 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS 63-11-00 8-3 REPLACEMENT: PRE-ROTATOR COUPLING PRESSURE PLATE 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! Engine cowlings must be removed, see Job Card 52-00-00 4-1.
  • Page 278 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS PARTS LIST Figure Position Description Remarks Pressure plate mounted 31713 Shim washer 0,1 47396 Shim washer 0,2 47397 Shim washer 0,3 47398 ILLUSTRATIONS Figure 1 – Removed coupling with central screw Figure 2 –...
  • Page 279 PROCEDURES/ DESCRIPTION 1. Inspect wear pattern and gear mesh of Pre-Rotator upper engagement. If in doubt, contact AutoGyro Technical Support. 2. If the wear pattern is uneven (Figure 1), e.g. due to dynamic skew, the Pre-Rotator upper engagement / Bendix shaft must be repaired according to Job Card 63-11-30 8-2.
  • Page 280 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS 63-11-30 8-1 REPLACEMENT: PRE-ROTATOR UPPER AND LOWER BEARING GENERAL, REFERENCES AND REQUIREMENTS Task may only be performed by an organization or individual trained and entitled to carry out 'Professional Maintenance'!
  • Page 281 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS 6. Degrease the new bearing and install it in the lower bearing mount. 7. Press the Bendix shaft into the new bearing. 8. Apply Loctite 648 on the Bendix shaft and put the lower bearing mount together with the re- assembled Bendix shaft into the upper bearing and let it cure.
  • Page 282 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS ILLUSTRATIONS Figure 1 – Rotor head bridge III Figure 2 – Mounting direction of ball bearing (part number not visible) AMM-CD-915iS/916iS-EN- Part E - 63-11-30 8-1 Page 3 of 5...
  • Page 283 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS Figure 3 – Lower bendix assembly Figure 4 – Drive shaft top disconnected from bendix shaft AMM-CD-915iS/916iS-EN- Part E - 63-11-30 8-1 Page 4 of 5 E-2024-09...
  • Page 284 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS Figure 5 – Lower bearing mount removed from rotor head Figure 6 – Lower bearing mount AMM-CD-915iS/916iS-EN- Part E - 63-11-30 8-1 Page 5 of 5 E-2024-09...
  • Page 285 1/10 mm, then replace Bendix shaft with new part and glue new part with Loctite 648 green into upper bearing. Re-assemble lower bearing, see Job Card 63-11-30 8-1. 4. If in doubt or different cause of error suspected, contact AutoGyro Technical Support. AMM-CD-915iS/916iS-EN-...
  • Page 286 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS 63-51-00 8-1 REPLACEMENT: ROTOR BRAKE PADS 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! Gyroplane must be placed on level ground and restrained (blocks, chocks).
  • Page 287 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS ILLUSTRATIONS Figure 1 – Rotor Bridge III with Brake Pad Part E – 63-51-00 8-1 AMM-CD-915iS/916iS-EN- Page 2 of 2 E-2025-04...
  • Page 288 8bar of brake pressure. Measure free play/ dead travel at flight control stick as depicted in figure 5. To do so, carefully move control stick forward and aft. 5. If free play exceeds 5mm contact AutoGyro Technical Support. If free play is ok remove block. Part E – 67-00-00 6-1...
  • Page 289 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS ILLUSTRATIONS Figure 1 – pitch and roll upper attachment Figure 2 – pitch ppc lower attachment Part E – 67-00-00 6-1 AMM-CD-915iS/916iS-EN- Page 2 of 4 E-2025-04...
  • Page 290 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS Figure 3 – roll ppc lower attachment seen from below block Figure 4 – blocked rotor head Part E – 67-00-00 6-1 AMM-CD-915iS/916iS-EN- Page 3 of 4 E-2025-04...
  • Page 291 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS Figure 5 – measurement of free play Part E – 67-00-00 6-1 AMM-CD-915iS/916iS-EN- Page 4 of 4 E-2025-04...
  • Page 292 AutoGyro Aircraft Calidus Maintenance Manual 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 or individual trained and entitled to carry out 'Professional Maintenance'! Secure gyroplane against unauthorized or unintended operation!
  • Page 293 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS PARTS LIST Figure Position Description Remarks Pneumatic cylinder brake/trim repair kit 32926 M6 Si A2 Shim washer Spacer rotor brake M6 56/10 A4-80 U6 A2 ILLUSTRATIONS Figure 1 – Repair kit Figure 2 –...
  • Page 294 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS Figure 3 – Cylinder disconnected Figure 4 – Circlip which has to be removed AMM-CD-915iS/916iS-EN- Part E - 67-05-00 8-1 Page 3 of 4 E-2025-04...
  • Page 295 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS Figure 5 – Correct order of the parts to re-install pneumatic cylinder AMM-CD-915iS/916iS-EN- Part E - 67-05-00 8-1 Page 4 of 4 E-2025-04...
  • Page 296 NOTE: For the 915iS/916iS. There are different engine mounts build by Rotax. Rotax has factory fitted a nut to the turbocharger plate. AutoGyro now use Nord-Lock washer in combination with this nut. This washer is only required for Rotax 915 iS / 916 iS engines with a fixed nut. Otherwise, the all-metal nut is used as before.
  • Page 297 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS ILLUSTRATIONS Figure 1 – Lifting points Rotax 915 / 916 engines Figure 2 – Engine mounting set 48114 AMM-CD-915iS/916iS-EN- Part E - 71-20-00 8-1 Page 2 of 3 E-2024-09...
  • Page 298 AutoGyro Aircraft Calidus Maintenance Manual 915 iS / 916 iS Figure 3 – 915 / 916 version with fixed nut Figure 4 – Nord lock washer AMM-CD-915iS/916iS-EN- Part E - 71-20-00 8-1 Page 3 of 3 E-2024-09...
  • Page 299 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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