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Copyright of RotorSport UK Ltd
Document number RSUK0288
Maintenance Manual
Gyroplane Type Cavalon (UK spec only)
RotorSport UK Ltd
Poplar Farm
Prolley Moor
Wentnor
Bishops Castle
SY9 5EJ
Company Reg No 5486550
Phone: +44 (0) 1588 650769
Fax: +44 (0) 1588 650769
Email:
info@rotorsport.org
CAA Approval No: DAI/9917/06
Page 1 of 55
Page issue 4, dated 08.06.15
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Table of Contents
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Summary of Contents for RotorSport Poplar Farm
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Page 1: Maintenance Manual
Copyright of RotorSport UK Ltd Document number RSUK0288 Maintenance Manual Gyroplane Type Cavalon (UK spec only) RotorSport UK Ltd Poplar Farm Prolley Moor Wentnor Bishops Castle SY9 5EJ Company Reg No 5486550 Phone: +44 (0) 1588 650769 Fax: +44 (0) 1588 650769 Email: info@rotorsport.org... -
Page 2: Applicability
Copyright of RotorSport UK Ltd Document number RSUK0288 Applicability Aircraft Registration: Aircraft serial no. RSUK/CVLN/ Engine type: Rotax 912ULS & 914UL Engine serial No: Rotor blade type & diameter: Autogyro 8.4m RotorSystemII RAO (red cap, black clamp profile only) Propeller type:... -
Page 3: Table Of Contents
Copyright of RotorSport UK Ltd Document number RSUK0288 CONTENTS AND CHECK LIST OF PAGES Content Page No. Cover page Applicability Contents and checklist of pages Section 1 Amendments to the schedule Section 2 Foreword Section 3 Owner/Operator responsibilities Certifying persons responsibilities... -
Page 4: Cover
Appendix B – AutoGyro Manufacturers Maintenance Manual Note! This manual comprises a front section detailing UK specific requirements and information, and then incorporates the AutoGyro Manufacturers Maintenance Manual by way of the pdf document copied into the RotorSport document as Appendix B. Therefore: 1. -
Page 5: Section 1 Amendments To The Schedule
SECTION 1 AMENDMENTS TO THE SCHEDULE 1. Where & when necessary RotorSport UK Ltd (hereafter referred to as RSUK) will issue updates to this maintenance standard, and will notify known owners to review the changes via the RSUK website with changes appropriately identified by a strike in the margin. - Page 6 Copyright of RotorSport UK Ltd Document number RSUK0288 List of Effective Pages Page Issue Date Page Issue Date Page 1 08.06.15 Page 33 08.06.15 Page 2 08.06.15 Page 34 11.03.13 Page 3 08.06.15 Page 35 11.03.13 Page 4 08.06.15 Page 36 11.03.13...
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Page 7: Section 2 Foreword
Copyright of RotorSport UK Ltd Document number RSUK0288 SECTION 2 FOREWORD 1. Applicability This Schedule is intended for use on the CAVALON Gyroplane only, released on AAN29345 and by addenda released for flight at 560kg MTOW and fitted (optionally) with the IVO-prop DL3-68 in-flight variable pitch propeller 2. -
Page 8: Section 3 Owner/Operator Responsibilities
Copyright of RotorSport UK Ltd Document number RSUK0288 SECTION 3 OWNER/OPERATOR RESPONSIBILITIES Operators are responsible for the accomplishment of the maintenance prescribed in the schedule. CERTIFYING PERSONS RESPONSIBILITIES Certifying persons must use their engineering skill and judgement in determining the depth of inspection needed and other matters that could affect the airworthiness of the gyroplane. -
Page 9: Service Information
Copyright of RotorSport UK Ltd Document number RSUK0288 The overhaul and test periods should be recorded in the appropriate aircraft worksheet SERVICE INFORMATION Service information (Service Bulletins, Service Letters, etc.) published by RSUK should be Page issue 2, dated 11.03.13... -
Page 10: Section 4 Permit Maintenance Release
Copyright of RotorSport UK Ltd Document number RSUK0288 An 'Operational Check' is a test used to determine that a system or component or any function thereof is operating normally. FUNCTIONAL CHECK (F/C): A 'Functional Check' is a detailed examination of a complete system, sub-system or component to determine if operating parameters are within limits of range of movement, rate of flow, temperature, pressure, revolutions per minute, degrees of travel, etc., as... -
Page 11: Pilot Maintenance
Copyright of RotorSport UK Ltd Document number RSUK0288 Pilot Maintenance A licensed pilot who is the owner or operator of the gyroplane may carry out certain maintenance tasks prescribed in Air Navigation (General) Regulation 16. The issue of a PMR is not required. The pilot must include his pilot's licence number with his signature in the appropriate log book(s). -
Page 12: Annual Check
Copyright of RotorSport UK Ltd Document number RSUK0288 (Including removal, cleaning/replacement, refitting of oil filter, and wirelock of sump bolt). Annual Check The annual check and all associated work must be accomplished under the supervision of a person or organisation appropriately approved by the CAA (eg, CAA Authorised A3-7 engineer or approved organisation). - Page 13 Copyright of RotorSport UK Ltd Document number RSUK0288 Intentionally blank Page 13 of 55 Page issue 2, dated 11.03.13...
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Page 14: Section 5 The Maintenance Check Cycle
Copyright of RotorSport UK Ltd Document number RSUK0288 SECTION 5 THE MAINTENANCE CHECK CYCLE Check title Content Period Check A Check A Prior to the first flight of the day First 25 hour check 25 hour check items (one Not exceeding 25 flying hours, or 1... - Page 15 For update control and one source of information, this check is not printed here. Refer to the Pilots Handbook. For all inspection checks reference must be made to RotorSport UK Ltd, either via the website or directly, for the latest schedule.
- Page 16 Note! There is no requirement to annually re weigh a gyroplane. If a re-assessment of the aircraft CG is required, please contact RotorSport UK Ltd. 10) Check of Aircraft hours, Engine serial No and Propeller serial number. 11) Pilots Operating handbook Issue No. You will need to show your copy.
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Page 17: Section 9 Aircraft Systems Description And Maintenance Methods
Copyright of RotorSport UK Ltd Document number RSUK0288 SECTION 9 – AIRCRAFT SYSTEMS DESCRIPTION AND MAINTENANCE METHODS General notes; 1. These instructions are not all encompassing, and should always be used in line with good aircraft engineering practices, and manuals such as AC43.13. - Page 18 Copyright of RotorSport UK Ltd Document number RSUK0288 Primary and Secondary structure determination: A primary structural part is one for which the failure would be catastrophic and would prevent continued safe flight and landing. All other structure can be considered as Secondary, thus failure of a Secondary structural part would not be immediately catastrophic and with due care continued safe flight and/or a safe precautionary landing could still be made.
- Page 19 Copyright of RotorSport UK Ltd Document number RSUK0288 General aircraft testing and requirements post maintenance. 1. Aircraft operation. Any engine service will require the operation of the engine, as will any maintenance action requiring adjustment of an engine control or subsystem, or affected system such as removal of the instrument panel.
- Page 20 Copyright of RotorSport UK Ltd Document number RSUK0288 b) Access to the top of the engine is achieved by undoing the camlock push and turn fasteners attaching the top cowl to the other cowls. Wriggle them free, and lift off the cowl.
- Page 21 Copyright of RotorSport UK Ltd Document number RSUK0288 Unit fitted to Calidus 1. The hypodermic scale is calibrated 0-100 units, this range being equivalent to 1ml of fluid. For both single and dual ASI installations withdraw the plunger to deliver 100 units.
- Page 22 Copyright of RotorSport UK Ltd Document number RSUK0288 Pneumatic system check: 1) Turn on aircraft keyswitch. 2) With changeover switch in the ‘Brake’ position, engage brake by depressing brake button on control stick, confirm pump and brake operation, and that function is acceptable.
- Page 23 Copyright of RotorSport UK Ltd Document number RSUK0288 Caution! Strobe light intensity is very high, do not stare at the strobes! 7. Backup (P2) fuel pump: turn on and off, and listen for function (both engine types) 8. P1 electric fuel pump: listen for function with keyswitch on (914UL engine...
- Page 24 Copyright of RotorSport UK Ltd Document number RSUK0288 HTC Propeller Basic description See RSDS7066 The HTC propeller is fitted as standard. This is a 3 bladed composite design with an aluminium 2 piece hub machined from solid. Each blade is a foam filled wet layup component in carbon and glass fibre.
- Page 25 Copyright of RotorSport UK Ltd Document number RSUK0288 After any blade adjustment, ensure all blades have the same angle to within 0.5deg – recheck after tightening the hub. Max ground rpm should be circa 5,400, but do not adjust the propeller blade angle to achieve this value - flight test to ensure the engine does not rev higher than the Rotax maximum, and, if then required, adjust to suit.
- Page 26 Engine rpm. This gauge is unique to RotorSport UK. Rotor rpm. This gauge is unique to RotorSport UK. Operation may be checked by spinning the rotor. Only works with the keyswitch on. Page issue 2, dated 11.03.13 Page 26 of 55...
- Page 27 Copyright of RotorSport UK Ltd Document number RSUK0288 Oil Temp gauge. This gauge is unique to RotorSport UK. May be checked by connection to a slave sensor immersed in water of known temperature (eg boiling =100degC). Oil Pressure gauge This gauge is unique to RotorSport UK, albeit a modified commercial gauge. Check by direct coupling to a pressure gauge and pump.
- Page 28 Copyright of RotorSport UK Ltd Document number RSUK0288 Compass (PAI-700 flat card type). This compass is used because the standard ball type compasses tend to pick up on rotor vibration and oscillate to an extent that is unreadable. The compass may be panel mounted or remote mounted as required to suit aircraft magnetic fields.
- Page 29 Copyright of RotorSport UK Ltd Document number RSUK0288 8. When the verification is complete, record on the aircraft worksheet the serial no and calibration date of the equipment used, the serial no of the transponder, and hexadecimal code confirmed correct.
- Page 30 Copyright of RotorSport UK Ltd Document number RSUK0288 View of front, prior to panel fitment. View of rear, showing battery slot for LR44 Unit is bonded to panel. Switch should be down – this changes the unit between deg C and deg F Compass.
- Page 31 Copyright of RotorSport UK Ltd Document number RSUK0288 3. At 2,000rpm confirm carbs are balanced. Adjust on LH carb ONLY if a 914 or either carb if a 912 by adjusting outer cable length at carburettor. Confirm balanced up to max power, and if needed make the best compromise for balance at 5,000 rpm.
- Page 32 Copyright of RotorSport UK Ltd Document number RSUK0288 Repair notes Replace worn components. The throttle lever and brake ratchet must be replaced (as a pair) if any of the teeth of the throttle lever are visibly deformed or protrude less than 1.5mm (may be assessed with a 1.5mm drill bit placed at the root of the tooth form)
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Page 33: Section 10 Ivo-Prop In-Flight Variable Pitch Propeller
This means that there are internal designs that make the product unique, and it must not be replaced by a propeller other than the part supplied by RotorSport UK Ltd. Construction: The blades comprise a resin core, with layers of carbon fibre on top for protection and structural strength. - Page 34 Copyright of RotorSport UK Ltd Document number RSUK0288 Propeller construction Propeller mounting flange with “torque-bushes” Page 34 of 55 Page issue 4, dated 08.06.15...
- Page 35 Copyright of RotorSport UK Ltd Document number RSUK0288 12VDC power is supplied to the propeller by means of two slip-rings in the hub assembly and a brush-box mounted on a fabricated bracket at the rear of the engine. Slip-rings immediately behind spinner.
- Page 36 Copyright of RotorSport UK Ltd Document number RSUK0288 Control: There is no constant-speed controller fitted to the RSUK IVO-prop installations and pitch adjustment is made manually by means of a rocker-switch mounted on the left of the instrument panel. There are no micro-switches to limit blade movement so the control system utilises a bespoke circuit-board (the end position controller) which detects the rapid rise in current and disconnects motor power when each pitch limit is reached.
- Page 37 Copyright of RotorSport UK Ltd Document number RSUK0288 ROTAX 914 UL Power setting Engine RPM Fuel flow [ltr/h] Max. TOP 5800 39.9 Max. MCP 5500 35.4 75% MCP 5000 65% MCP 4800 17.5 55% MCP 4300 12.5 MCP – Maximum Continuous Power TOP –...
- Page 38 Copyright of RotorSport UK Ltd Document number RSUK0288 Digital combined gauge Assembly methods The propeller-to-gearbox attachment bolts (M8 countersunk) are tightened to 25Nm, and are threadlocked with Loctite 243. The propeller main bolts (3/8” hex-head) with nyloc nuts are tightened (and periodically checked) to 40Nm.
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Page 39: Service Bulletins Issued To Date
Document number RSUK0288 Section 11 Modifications approved to date For the listing of all approved modifications see the RotorSport website owners section where they are all listed, or the Type Approval Data sheet (TADS) from the CAA website. Service Bulletins issued to date For the listing of all approved service bulletins see the RotorSport website owners section where they are all are listed. - Page 40 Depending on the problem identified, a corrective action is investigated and, if needed, CAA involvement and approval obtained prior to repair authorisation. The information given is stored on a computer, and is only used within RotorSport UK and the CAA for the above purpose.
- Page 41 Copyright of RotorSport UK Ltd Document number RSUK0288 This form (Part 2 of 2) is the response from RotorSport UK Ltd to a Service Repair and Evaluation/Approval request, which specifies the company authorised repair method. Deviation from this method renders the authorisation ineffective.
- Page 42 Copyright of RotorSport UK Ltd Document number RSUK0288 Appendix A Compass calibration Page issue 4, dated 08.06.15 Page 42 of 55...
- Page 43 Copyright of RotorSport UK Ltd Document number RSUK0288 Page issue 4, dated 08.06.15 Page 43 of 55...
- Page 44 Chapter 03 – Minimum Equipment Requirement (p10) UK-registered aircraft may not be operated without Required Equipment other than a ferry flight authorised by CAA – refer to RotorSport UK for guidance Chapter 04 Manufacturer Life Limitations (p11) UK-registered aircraft are not fitted with an ELT device.
- Page 45 Copyright of RotorSport UK Ltd Document number RSUK0288 Chapter 06 – Dimensions & Areas (P17) The aircraft version supplied to the UK market conforms to the dimensions below. Length 4.73 m Width 1.75 m Height 2.82 m Rotor diameter 8.4 m Rotor disc area 55.4 sqm...
- Page 46 Copyright of RotorSport UK Ltd Document number RSUK0288 CHAPTER 10 – PARKING, STORAGE & RETURN TO SERVICE (p18) RSUK have published specific worksheets for short and long-term storage. These are detailed in Section 7 (p15) above and are available for download from the RSUK website (www.rotorsport.org).
- Page 47 Only the card-compass shown immediately above is fitted to UK-registered aircraft CHAPTER51 – STANDARD PRACTICES – STRUCTURES 51-00-00 (p14) Only RotorSport UK Ltd may implement structural repairs to UK-registered aircraft. In the event of structural damage being found consult RSUK at the earliest opportunity and before the next flight.
- Page 48 CHAPTER 61 – PROPELLER (p16) Simple repairs to the propeller are permitted as described on p25 above (HTC) and p28 (IVO). More complex repairs may be implemented only by RotorSport UK Ltd. Refer to RSUK for further information. 61-20-00 Controlling (p16) An in-flight variable pitch propeller is now available for UK-registered aircraft.
- Page 49 Copyright of RotorSport UK Ltd Document number RSUK0288 Page 49 of 55 Page issue 3, dated 12.04.13...
- Page 50 Copyright of RotorSport UK Ltd Document number RSUK0288 The other diagrams shown are correct, but note the use of an extension cable RSD7223 to relocate the fuel gauge, the engine rpm gauge and the rotor rpm gauge from the left-hand panel to the main instrument panel of UK-registered aircraft.
- Page 51 Copyright of RotorSport UK Ltd Document number RSUK0288 Page issue 3, dated 12.04.13 Page 51 of 55...
- Page 52 Copyright of RotorSport UK Ltd Document number RSUK0288 Page issue 3, dated 12.04.13 Page 52 of 55...
- Page 53 Copyright of RotorSport UK Ltd Document number RSUK0288 Pneumatic circuit diagram. During aircraft flight test a modification to incorporate a 6bar pressure limit valve was made to the pitch trim system. The circuit diagram below reflects the released version with this valve, as fitted to Cavalon RSUK/CVLN/001 onwards.
- Page 54 Copyright of RotorSport UK Ltd Document number RSUK0288 Page 54 of 55 Page issue 3, dated 12.04.13...
- Page 55 Copyright of RotorSport UK Ltd Document number RSUK0288 25-60-00 0-1 DESCRIPTION: EMERGENCY LOCATOR TRANSMITTER (p1) UK-registered aircraft are not fitted with an ELT 26-00-00 0-1 DESCRIPTION: FIRE INDICATING SYSTEM (p1) Although functionally the same as the system described in the AutoGyro MMM, the system fitted to UK-registered aircraft has the detector wire extended into the protected compartment between the cockpit bulkhead and the removable fire-resistant panel.
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