Manufacturer Maintenance Manual
Manufacturer Maintenance Manual
(Heavy Maintenance)
Manufacturer
Maintenance Manual
AutoGyro
Cavalon
Manufacturer Maintenance Manual
for Gyroplane Cavalon
MMM-CV-A_16-02-08
Part A – Introduction and Declarations
Page 1 of 12
Manufacturer
Maintenance Manual
AutoGyro
Cavalon
0 – PREFACE
This document contains proprietary information of AutoGyro GmbH, Germany which is provided in
confidence and solely for the purpose of supporting aircraft certification and providing applicable
information regarding the proper use, maintenance, inspection, repair, servicing and parts application
of AutoGyro GmbH products and services, as directed therein. Neither this manual nor any information
in it may be disclosed to others, or used for any other purpose, including but not limited to, design,
create, develop, reproduce, manufacture or derive any design, part, product, material, process,
modification, configuration change or repair, or to obtain airworthiness authorisation’s approval to do
so.
With the possession and use of this manual the user accepts and agrees to bound by the foregoing
terms.
If a Government agency or Department intends to disclose any information, written notice should be
given to:
AutoGyro GmbH
Dornierstraße 14
31137 Hildesheim
GERMANY
Phone: +49 (0) 51 21 / 8 80 56-00
Fax:
+49 (0) 51 21 / 8 80 56-19
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. Notifications to the Civil Aviation Authorities or other organisations based on legal regulations are unaffected.
MTOsport, Calidus, Cavalon, the AutoGyro logo and word picture mark are trademarks or registered trademarks of AutoGyro AG, registered in Germany and other
countries.
Other company and product names mentioned herein may be trademarks of their respective companies. Mention of third-party products is for informational purposes only
and constitutes neither an endorsement nor a recommendation. AutoGyro assumes no responsibility with regard to the performance or use of these products. All
understandings, agreements, or warranties, if any, take place directly between the vendors and the prospective users.
U.S. and foreign patents of AutoGyro AG are used in the Calidus and Cavalon gyroplanes - (US.Pat.No. 8,690,100; US.Pat.No. D699,153)
Every effort has been made to ensure that the information in this manual is accurate. AutoGyro GmbH is not responsible for printing or clerical errors.
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Part A – Introduction and Declarations
Page 2 of 12
Manufacturer
Maintenance Manual
AutoGyro
Cavalon
1 – INTRODUCTION
This manual provides accepted and recommended maintenance procedures applicable for the
Cavalon gyroplane, 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”. The manual also provides a full
description of the aircraft and its systems and troubleshooting (fault isolation) procedures. Where
applicable, the manual refers to related manuals, such as the engine manufacturer’s documentation or
Component Maintenance Manuals, for example battery, avionics, or optional equipment.
All task descriptions follow aerospace, industry and safety standards or special AutoGyro procedures.
The procedures, methods, instructions and parameters specified in this manual must be adhered to by
all means. It is not permitted to change procedures or to alter parameters provided herein. Proposed
deviations from the procedures, methods and instructions contained in this manual should be directed
to:
AutoGyro GmbH
Att.: Technical Publications
Dornierstraße 14
31137 Hildesheim
GERMANY
Fax:
+49 (0) 51 21 / 8 80 56-19
E-Mail: info@auto-gyro.com
The manual has been prepared in accordance with ATA Specification No. 100 being a common
standard in aviation and for your convenience. The ATA100 numbering system is described under
“Organization and Handling of the Manual”.
This manual will be revised as necessary to incorporate changes in design, parts, approved
procedures, or parameters. Note that the manual is only valid if available in current version. The use of
an out dated manual may render the aircraft in unsafe or even not airworthy condition. The revision
service is described below.
Manufacturer Information [Letters] (MI) or Airworthiness Directives (AD) will also be covered by the
revision service and incorporated in the maintenance manual.
Revision Service
This manual must always be maintained in current, up-to-date status. The latest version status is
available at www.auto-gyro.com. Note that the manual is subdivided into 6 parts which will be revised
individually. As an example, the revision index for the manufacturer maintenance manual (MMM),
Cavalon (CV), Part B could be ‘MMM-CV-B_13-04-20’. Note that the date code is ‘yy-mm-dd’ so files
will sort chronologically.
For the purpose of current status this manual will not be published in paper format. A current
personalized copy will be provided by AutoGyro GmbH for all certified and registered service partners
on the basis of a subscription service. Registered users will be informed about new revisions. We
recommend not to keep printouts or paper copies for reference.
Record of Revisions
The manufacturer will keep this manual current as an entire document. After each revision of a part
the latest revision index (i.e. list of revision indices for each part) will be published on AutoGyro’s web
portal and/or by E-Mail to each subscription customer. The document part’s revision index can be
found in the footer on the left hand side of each page.
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Cavalon
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Cavalon
Contents
0 – PREFACE ...........................................................................................................................................2
1 – INTRODUCTION ................................................................................................................................3
Revision Service ...................................................................................................................................3
Record of Revisions .............................................................................................................................3
Maintenance Concept and Eligibility ....................................................................................................7
Warnings, Caution and Notes ..............................................................................................................7
Organization and Handling of the Manual ............................................................................................8
ATA100 Numbering System .................................................................................................................8
ATA100 – Chapter Code ..................................................................................................................8
Nomenclature and Structure of Maintenance Tasks (Job Cards) ....................................................9
Page Block Code ..............................................................................................................................9
Effectivities......................................................................................................................................10
Parts List Codes – PC / PIT............................................................................................................10
Abbreviations and Acronyms ..............................................................................................................11
Service Bulletin (SB) and Airworthiness Directives (AD) ...................................................................12
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Cavalon
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Cavalon
Maintenance Concept and Eligibility
The maintenance concept of the Cavalon gyroplane is structured into 4 qualification levels:




Basic operational (OPR) Maintenance / Pilot Checks and Servicing
Line (LNE) Maintenance (inspection of Critical Parts (CP) included)
Heavy (HVY) Maintenance (Flight Safety Sensitive Maintenance Tasks, handling of CPs)
Specialized (SPC) Level Tasks (Major Modification, Repair & Overhaul, Special Topics)
The respective maintenance level for each maintenance task is printed in right hand position in the
header line on each Job Card as three-letter code for quick reference (see red circle in example
below) and repeated under ‘GENERAL, REFERENCES AND REQUIREMENTS’.
Maintenance tasks may be carried out solely by persons or organizations fulfilling the requirements for
personal qualification, infrastructure and required equipment, and only in strict compliance with the
documentation and manuals listed in below table. Examples are provided for better illustration:
Level
Qualification
Documentation
Example
OPR
Licensed Pilot or
trained/briefed person
Pilot’s Operating Handbook
and Job Cards marked ‘OPR’
Check and replenish
engine coolant.
LNE
AutoGyro maint. course (and
organization approval) ‘Line’
Manufacturer Maint. Manual
(MMM) Job Cards ‘LNE’
All tasks to perform a
100 hrs inspection
HVY
AutoGyro maint. course and
organization approval ‘Heavy’
Manufacturer Maint. Manual
(MMM) Job Cards ‘HVY’
Adj. / replace rotor
head, flight controls
SPC
AutoGyro special courses and
org. approval ‘Specialized’
MMM Job Cards ‘SPC’ and
manufacturer instructions
Main frame overhaul,
major mod., repair
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.
The meaning of each call-out is defined below:
WARNING: A warning means that the neglect of the appropriate procedure or
condition could result in personal injury or fatal accidents.
CAUTION: A caution means that the neglect of the appropriate procedure or
condition could result in damage to or destruction of equipment.
NOTE: A note stresses the attention for a special circumstance, which is essential
to emphasize.
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Part A – Introduction and Declarations
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Maintenance Manual
AutoGyro
Cavalon
Organization and Handling of the Manual
This manual is structured according to ATA100 numbering system. The numbering system will be
explained later in more detail.
On document level, the manual is subdivided into 6 parts, named A to F. The designation and content
of each part is listed below:
Part
Designation / Content
A
Introduction and Declarations
This section. Explains the basic concept, handling of this manual, its structure according to
the ATA100 numbering system, abbreviations and acronyms.
B
Master Servicing Manual (ATA Chapters 00 to 20)
General description of the aircraft, basic definitions and standard procedures, tools,
spares, airworthiness limitations, time limits, inspections and checks.
Briefly, part B describes ‘what is to be done, and when’.
C
System Description Section (ATA Chapters 21 to 90)
Part C describes all aircraft systems, following the ATA100 numbering system.
D
Diagrams and Charts
Part D contains diagrams and charts, if necessary in special sizes or as fold-outs.
E
Maintenance Job Cards
[Maintenance] Job Cards are collected in Part E. Note that the footer of Part E does not
spell out to the part’s designation, but just shows part and the job index of the referred
maintenance task according to the ATA100 numbering system.
Briefly, Part E describes ‘how something has to be done’.
(F)
Protocols and Forms
Protocols and forms, such as maintenance check lists, are available for download.
ATA100 Numbering System
ATA100 – Chapter Code
The Air Transport Association (ATA) Standard 100 numbering system is a widely accepted standard
that provides a 6 digit numbering system to identify aircraft systems, subsystems and individual
components in a structured, hierarchical approach.
The first or leftmost pair of digits defines the Chapter, respectively system. The next pair of digits
refers to the subsystem. The third pair of digits specifies a unit. Only complex systems use unit
numbers. In case of simple systems, all information is contained in the main chapter and there is no
subsystem or unit breakdown.
The ATA100 numbering system and the corresponding system designations were adopted where ever
possible and rational. In some cases the wording and nomenclature was adapted to match the design
specifics of a gyroplane in best possible way. Due to its high degree of system integration, some
systems cannot clearly be assigned to a single function. In this case the system or component was
categorized by its main function. Example: the pneumatic trim cylinder also acts as brake in its
secondary function.
Chapter 02 has been modified to contain “TOOLS, SPARES AND CONSUMABLE MATERIALS”.
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Cavalon
Nomenclature and Structure of Maintenance Tasks (Job Cards)
Part E of this manual describes maintenance tasks to be performed by a qualified person in order to
check, inspect, replenish, adjust, replace, repair, clean, or to identify malfunctions. Each Task is
outlined in detail in a [Maintenance] Job Card.
Each [Maintenance] Job Card (sometimes referred to as Task Card) consists of







Task Description (header, descriptive text) with task level in most right position
a section referring to GENERAL, REFERENCES AND REQUIREMENTS
a section listing SPECIAL TOOLS AND CONSUMABLE MATERIALS
a section pointing out PRECAUTIONS AND SAFETY MEASURES
a section called PROCEDURES, which lists all Work Steps to be performed subsequently
a PARTS LIST listing part numbers and associated information, and
explanatory GRAPHICS, such as explosion drawings or photographs
For ease of navigation each page in Part E shows a unique job index in the page footer consisting of 3
elements:



Chapter Code
(acc. to ATA100, see explanation below)
Page Block Code
(distinct index/number per type of maintenance action, see explanation below)
Sub-Index
Page Block Code
The pages within a chapter are structured and numbered according to the page block numbering
system as specified below:
Subject
Code
Introduction / Description and Operation
0
Fault Isolation / Trouble Shooting
1
Maintenance Procedures
2
Servicing
3
Removal / Installation / Disassembly / Assembly
4
Adjustment / Test
5
Inspection
6
Cleaning / Painting
7
Repair / Replacement / Retrofit / Modification
8
Storage
9
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Part A – Introduction and Declarations
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AutoGyro
Cavalon
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).
The keyword EFFECTIVITY, followed by a term describing its applicability, marks the start of
instructions that apply exclusively to a specified version. Examples:
EFFECTIVITY: Variable Pitch Propeller
The following instructions must be performed and are applicable only if a Variable Pitch Propeller is
installed
EFFECTIVITY: up to S/N 0123
The following instructions apply to serial numbers 0123 and before
EFFECTIVITY: S/N 0124 to S/N 0248
The following instructions refer only to serial numbers 0124 up to, and including, 0248
EFFECTIVITY: S/N 0124 and subsequent
The following instructions must be performed for serial numbers starting 0124 and subsequent
EFFECTIVITY: before MI 2011-99
Instructions refer to modification state before/without the referenced MI implemented
EFFECTIVITY: MI 2011-99 accomplished
Instructions apply only to those versions where the referenced MI has been accomplished
The end of the range of validity is marked by the term EFFECTIVITY – END
In case the effectivity solely comprises of the subsequent work step, or another effectivity statement is
introduced, the term EFFECTIVITY – END will be omitted.
Instructions outside of EFFECTIVITY statements apply to the standard model, respectively to all
versions.
Parts List Codes – PC / PIT
Parts Lists specify PC (Procurement Code) and PIT (procure item through) for each item (see
example). The procurement code may show L0, L1, L2 or L3 as explained below.
L0
Part/Assembly available for purchase for a registered pilot/operator (OPR)
L1
Part/Assembly orderable for individuals/organizations qualified to perform Line Maint.
L2
Part/Assembly orderable for organizations qualified to perform Heavy Maintenance
L3
Part/Assembly orderable for organizations qualified to perform Specialized Level tasks
‘PIT’ lists the order number of the part, bundle, set, or smallest assembly in which the referred part is
contained.
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AutoGyro
Cavalon
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.
AD
ATA
CHT
CP
CRP
DOM
ELT
FOD
GRP
hrs
i.f.d.
JNP
LED
LH
LR
LTA
MAP
MI
MLL
MMM
N/A
NPI
OAT
PC
PIT
POH
Qty.
RBT
rcv
rec.
RH
RPM
SB
SoC
sqm
STP
TADS
TBO
VPP
VSI
xmt
yr
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Airworthiness Directive
Air Transport Association
Cylinder Head Temperature
Critical Part
Carbon Reinforced Plastic
Date of Manufacture
Emergency Locator Transmitter
Foreign Object Damage (Debris)
Glass Reinforced Plastic
hours
in flight direction
Jahresnachprüfung (annual inspection, annual airworthiness review)
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, …)
Lufttüchtigkeitsanweisung (AD, issued by the Airworthiness Authority)
Manifold Absolute Pressure
Manufacturer Information [Letter] (dt. Herstellerinformation)
Manufacturer Life Limit
Manufacturer Maintenance Manual
not applicable
non procurable item
Outside Air Temperature
Procurement Code
procure item through
Pilot’s Operating Handbook
Quantity
Rotor Bearing Temperature
receive
recommended
right hand
Revolutions Per Minute
Service Bulletin
Statement of Compliance
square metre(s)
Stückprüfung (C of A, i.e. conformity of airworthiness)
Type Approval Data Sheet (dt.: Geräte-Kennblatt)
Time Between Overhaul
Variable Pitch Propeller
Vertical Speed Indicator
transmit
year(s)
Part A – Introduction and Declarations
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AutoGyro
Cavalon
Service Bulletin (SB) and Airworthiness Directives (AD)
Service Bulletin (SB), old designation Manufacturer Information [Letters] (MI) (Herstellerinformationen)
or Airworthiness Directives (AD) will be incorporated into the Maintenance Manual with the next
revision.
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Cavalon
Contents
CHAPTER 00 - INTRODUCTION / AIRCRAFT GENERAL .....................................................................3
General .................................................................................................................................................3
CHAPTER 01 - GENERAL .......................................................................................................................4
01-11-00
Definitions, Terms and Standard Procedures ..................................................................4
01-12-00
Standard Bolt Torques ......................................................................................................6
01-21-00
Standard Commercial Tools .............................................................................................6
01-91-00
Conversion Tables ............................................................................................................7
CHAPTER 02 - TOOLS, SPARES AND CONSUMABLE MATERIALS ...................................................9
02-51-00
Consumable Materials ......................................................................................................9
CHAPTER 03 - MINIMUM EQUIPMENT REQUIREMENT ....................................................................10
CHAPTER 04 – MANUFACTURER LIFE LIMITATIONS .......................................................................11
CHAPTER 05 - TIME LIMITS, INSPECTIONS & CHECKS ...................................................................12
05-10-00
Time Limits .....................................................................................................................12
05-20-00
Scheduled Inspections & Checks ...................................................................................13
Daily / Pre-Flight Check ..................................................................................................................13
Complementary / Servicing Tasks ..................................................................................................13
25 hrs Inspection (one-time / non-recurrent) ..................................................................................13
100 hrs / Annual Inspection ............................................................................................................13
05-21-00
Temporary Scheduled Inspections & Checks ................................................................13
05-30-00
Unscheduled Inspections ...............................................................................................14
05-50-00
Conditional Inspections ..................................................................................................14
05-51-00
Inspections - Special Operational Conditions .................................................................14
Operation in sand or dust ...............................................................................................................14
Winter operation .............................................................................................................................14
05-55-00
Inspections - Special Operational Incident .....................................................................15
Suspected hard landing ..................................................................................................................15
Rotor contact with obstacle ............................................................................................................15
Propeller contact with obstacle or external impact .........................................................................15
Birdstrike .........................................................................................................................................15
Lightning strike ...............................................................................................................................16
05-60-00
Ground Test Run ............................................................................................................16
05-70-00
Functional Test Flight .....................................................................................................16
05-90-00
Maintenance Records & Aircraft Logs ............................................................................16
CHAPTER 06 - DIMENSIONS & AREAS ...............................................................................................17
CHAPTER 07 - LIFTING / JACKING / SHORING ..................................................................................18
CHAPTER 08 - LEVELING & WEIGHING .............................................................................................18
CHAPTER 09 - TOWING & TAXIING ....................................................................................................18
CHAPTER 10 - PARKING, STORAGE & RETURN TO SERVICE ........................................................18
CHAPTER 11 - PLACARDS & MARKINGS ...........................................................................................19
CHAPTER 12 - SERVICING ..................................................................................................................21
12-10-00
Cleaning ..........................................................................................................................21
12-20-00
Lubrication ......................................................................................................................21
Lubrication: Teeter hinge ................................................................................................................21
Lubrication: Pre-rotator drive coupling sleeve ................................................................................21
12-30-10
Servicing: Engine Air Filter .............................................................................................21
12-30-20
Servicing: Tire Pressure .................................................................................................21
12-30-30
Servicing: Battery............................................................................................................22
12-30-40
Servicing: Engine Coolant ..............................................................................................22
12-40-00
Replenishing/Replacement of Fluids ..............................................................................22
CHAPTER 13-17 – UNASSIGNED / N/A ...............................................................................................22
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Cavalon
CHAPTER 18 - VIBRATION & NOISE ANALYSIS ................................................................................23
CHAPTER 19–20 – UNASSIGNED / N/A ..............................................................................................24
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Cavalon
CHAPTER 00 - INTRODUCTION / AIRCRAFT GENERAL
General
The Cavalon is a ‘new generation’ gyroplane with 3-bladed push propeller and a 2-blade aluminium
main rotor system with swivelling rotor head and split mast with integrated rotor vibration damping. It
features monocoque cabin with glazed canopy, stainless steel mast, engine support and keel tube.
Cabin, cowlings, covers and stabilizer with rudder are made from glass fibre reinforced (GRP) plastic.
The tricycle gear with GRP (glass fibre reinforced plastic) suspension bow features a steerable nose
gear.
Rotor flight control comprises conventional linkage and push-pull control cables.
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Cavalon
CHAPTER 01 - GENERAL
01-11-00
Definitions, Terms and Standard Procedures
The following definitions, procedures and words with special meanings are used in this manual:
adjust
To put in specified position or condition, usually using tools or devices
Example: Adjust the clearance to 1 mm
Check (noun)
A set of check items to be performed. Example: pre-flight check
check (verb)
To make sure that the item is present and/or a given requirement is fulfilled. No
tools are required.
Example: Warning Lights…Check NONE
Critical Part (CP)
“Critical Parts” are those parts whose failure during ground or flight operation could
have a disastrous effect on the gyroplane.
dent
Depression in a surface having area and depth with no sharp edges
(see also ‘nick’)
discard
Put away in order to exclude inadvertent or intentional re-use of the item. Comply
with FOD procedures.
dispose of
Discard item or substance while employing strict procedures, such as
environmental or legal requirements.
hand-tighten
Use the bare hand without any tools, gloves or extra efforts
inspect / examine To look carefully at an item and compare with its standard or specification. Tools or
devices may be needed. The condition may be explicitly specified (example: no
corrosion). Generally, or if not otherwise stated, inspect/examine means:
Make sure that the item
- is complete
- is correctly attached
- has no loose parts
- shows no signs of leaks
- is not cracked or damaged
- is not worn
Make sure that
- the surface protection is not damaged
- all locking devices are installed correctly
Make sure that items such as pipes, hoses and cables
- look serviceable
- do not rub against other items
For log books and other technical records:
- find pending faults
- make sure they are up-to-date and correctly maintained
Inspection
Maintenance procedure to be performed as described in this manual.
Example: 100 hrs / Annual Inspection
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
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Cavalon
measure
To find out dimensions, capacity or quantity of something. Except for counting of
smaller numbers, calibrated measurement devices are needed.
monitor
To watch a parameter or item over a certain period of time in order to read an exact
value, derive a trend or identify a change caused by an event.
Example: monitor rotor speed indication, monitor RPM drop, …
nick
A dent with sharp edges (see also ‘dent)
re-torque
Refer to procedure ‘torque-tighten’. In contrary to procedure ‘torque check’
attachment hardware may rotate during re-torquing.
Record (noun)
Technical name for a documentation that shows the accomplishment of
maintenance tasks or other activities, usually stating the responsible person’s
name and date of compliance.
record (verb)
To make an (official) entry in a maintenance record.
remove securing
hardware
Cut open and remove split pins, lock wire, and such. Wear eye protection. Hold
securing hardware with other hand to prevent particles from darting around. Collect
all splinters and particles of securing hardware and discard.
replace
To remove an unserviceable item and install a serviceable in the same location
servicing
Simple tasks such as lubrication and cleaning, checking and adjusting of air tire
pressure, replenishing of fluids
set
To change (or verify) status of equipment to a given parameter, condition or mode.
Example: set altimeter sub-scale to 1013 hPa
torque-check
Refer to procedure ‘torque-tighten’. Check with the (minimum) torque value
supplied. Attachment hardware must NOT turn! If rotation of attachment hardware
was noticeable the torque check FAILED. Refer to procedure described in Job
Card.
torque-tighten
Use a calibrated tool with the correct range and handle properly and carefully. Set
tool to minimum torque (if min. and max. torque values are provided). Use
stretched fingers at the long end of the tool and counterhold directly at the pivot
point.
Click-Type: Stop upon the first clicking. If multiple clicking is heard or further
rotation is suspected, open/unscrew and repeat. Replace attachment hardware if
appropriate. In order to align attachment hardware (for example in case of a split
pin) adjust tool to the maximum allowed torque and tighten carefully until hardware
aligns. NO clicking must be heard! If clicking was heard, redo the complete
procedure while trying different attachment hardware and/or in different installation
position.
verify
Check that a certain dimension or condition, or set of these, is in-line with given
specifications. In order to do so, a special (measurement) procedure will be
required and the reference to comply with will be specified.
If not otherwise stated the following standards are based on aeronautical regulations and
recommendations (AC43.13-1B), industry and safety standards, and general practices, and shall be
applicable throughout this manual. Examples are:







Torquing
Securing (handling of lockwire and other securing hardware)
Removal of securing hardware
FOD (foreign object damage) protection
Discard and disposal procedures
Handling of hazardous material
Workplace safety
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Maintenance Manual
01-12-00
AutoGyro
Cavalon
Standard Bolt Torques
Standard torques are M4 2-3 Nm, M5 5-6 Nm, M6 11 +/-1 Nm, M8 25 +/-3Nm, M10 35 +/-4Nm.
Always assess the joint to be tightened and use engineering judgement – do not overtighten plastic or
unsupported tube joints!
01-21-00
Standard Commercial Tools
Most maintenance tasks on the Cavalon can be conducted using standard, commercially available
metric tools. In addition, the following standard commercial tools are required:










Inclinometer (digital) / Digital spirit level with angle gauge
Spring balance / Dynamometer
Tensiometer (to measure cable tension)
1m aluminium ruler
Fuel hose clamp
Torque wrench (in required torque ranges)
Multimeter
3 m-tape measure
Torch light
Tyre pressure gauge / tyre filling device
MMM-CV-B_14-11-19
Part B – Master Servicing Manual (Ch. 00 – 20)
Page 6 of 24
Manufacturer
Maintenance Manual
01-91-00
AutoGyro
Cavalon
Conversion Tables
LENGTH / DISTANCE
Multiply
by
to obtain / Multiply
by
to obtain
m (metre)
3.28
ft (feet)
0.305
m
mm (millimetre)
0.039
in (inch)
25.4
mm
km (kilometre)
0.54
nm (nautical mile)
1.852
km
SPEED
Multiply
by
to obtain / Multiply
by
to obtain
m/s (metre per second)
196.85
ft/min (feet per minute)
0.0051
m/s
km/h (kilometre per hour)
0.54
kts (knots)
1.852
km/h
km/h (kilometre per hour)
0.62
mph (miles per hour)
1.61
km/h
PRESSURE
Multiply
by
to obtain / Multiply
by
to obtain
hPa (hectopascal)
1.0
mbar (millibar)
0.0001
bar
bar (Bar)
14.50
psi (lb per square inch)
0.0689
bar
bar (Bar)
0.0295
inHg (inch mercury)
33.864
bar
FORCE / WEIGHT
Multiply
by
to obtain / Multiply
by
to obtain
N (Newton)
2.205
lbf (pound force)
0.4536
N
N (Newton)
0.1019
(respective force of 1 kg)
9.81
N
MASS (WEIGHT)
Multiply
by
to obtain / Multiply
by
to obtain
kg (kilogram)
2.2046
lb (pound)
0.4536
kg
VOLUME
Multiply
by
to obtain / Multiply
by
to obtain
l [or ltr] (Litre)
0.2642
US gal (US gallons)
3.7854
l/ltr
l [or ltr] (Litre)
1.057
US qts (US quarts)
0.946
l/ltr
0.946
l/ltr
l [or ltr] (Litre)
0.0164
3
in (cubic inch)
TORQUE
Multiply
by
to obtain / Multiply
by
to obtain
Nm (Newton metre)
0.738
lbf.ft. (pound-foot)
1.3558
Nm
Nm (Newton metre)
0.113
lbf.in. (pound-inch)
8.851
Nm
kgmm
0.0098
Nm
101.94
kgmm
MMM-CV-B_14-11-19
Part B – Master Servicing Manual (Ch. 00 – 20)
Page 7 of 24
Manufacturer
Maintenance Manual
AutoGyro
Cavalon
500
450
400
350
Fahrenheit - °F
300
250
200
150
100
50
0
-50
-100
-150
-100 -75
-50
-25
0
25
50
75
100
125
150
175
200
225
250
Celsius - °C
Celsius-Fahrenheit Conversion Chart
MMM-CV-B_14-11-19
Part B – Master Servicing Manual (Ch. 00 – 20)
Page 8 of 24
Manufacturer
Maintenance Manual
AutoGyro
Cavalon
CHAPTER 02 - TOOLS, SPARES AND CONSUMABLE MATERIALS
02-51-00
Consumable Materials
Consumable Material (CM) referenced throughout this Maintenance Manual is coded AG-XXX-NN
where NN is a consecutive number and XXX represents the material code according to the
classification listed below:
Class
Description
Class
Description
BAS
BONDING, ADHESIVES AND
SEALANTS
LUB
LUBRICANTS
CCM
CHEMICAL CONVERSION MAT.
MSC
MISCELLANEOUS
CLA
CLEANING AGENTS
OIL
OILS
CPA
CORROSION PREVENTIVE AGENTS
PNT
PAINT AND LACQUERS
FUE
FUELS
PRM
PRIMER, PREPARATION FOR
PAINTING
GRS
GREASES
PRS
(STORAGE) PRESERVATION
HYF
HYDRAULIC FLUIDS
The following consumable materials are referenced in the Maintenance Manual:
CM-Item
Material / Description
AutoGyro Order Codes
AG-BAS-01
Loctite 221 red
88-00-00-S-30487
AG-BAS-02
Loctite 243 blue
88-00-00-S-30483
AG-BAS-03
Loctite 542 red
88-00-00-S-30488
AG-BAS-04
Loctite 638 green
88-00-00-S-30485
AG-CPS-01
‘Hohlraumspray’
88-00-00-S-34197
AG-GRS-01
Silicon grease Lagermeister
2002
88-00-00-S-30477
AG-LUB-01
Ballistol Öil Universal
88-00-00-S-31816 (5L can)
88-00-00-S-31846 (2ml injection syringe)
88-00-00-S-31847 (5ml Iinjection syringe)
AG-LUB-02
Anti-Seize Spray
88-00-00-S-31590
AG-LUB-03
HHS 2000
88-00-00-S-30476
AG-OIL-01
Oil Shell Advance AX7 10W40 API SG 1
88-00-00-S-31665
MMM-CV-B_14-11-19
Part B – Master Servicing Manual (Ch. 00 – 20)
Page 9 of 24
Manufacturer
Maintenance Manual
AutoGyro
Cavalon
CHAPTER 03 - MINIMUM EQUIPMENT REQUIREMENT
In accordance with the Pilot’s Operating Handbook (POH) Section 2.11 the following equipment must
be operative for flight
Air speed indicator
Altimeter
Compass
Side Slip Indicator
Rotor RPM indicator
Engine instruments (oil pressure, oil temperature, RPM, CHT)
HOBBS meter
Pre-rotator
Depending on the equipment state or relevant condition a limited or restricted operation may be
granted to facilitate maintenance efforts and operability.
Equipment / System
Condition
Limitation/Restriction
Compass
Defective
Local flights within the traffic pattern
and with ground reference.
Rotor RPM indicator
Defective
Flight to a maintenance facility.
Pre-rotator
Defective / No function
R-RPM indicator working
Flight to a maintenance facility under
the following conditions:
 Experienced pilot as sole
occupant
 Concrete/asphalt runway with a
minimum of 5 times the normal
required take-off roll distance
available
 Second briefed person
‘handpropping’ the rotor while
engine/propeller is off
 Steady, laminar headwind
Pre-rotator
Malfunction, R-RPM > 120
R-RPM indicator working
Flight to a maintenance facility under
the following conditions:
 Experienced pilot
 Concrete/asphalt runway with a
minimum of 3 times the normal
required take-off roll distance
available
 Steady, laminar headwind
MMM-CV-B_14-11-19
Part B – Master Servicing Manual (Ch. 00 – 20)
Page 10 of 24
Manufacturer
Maintenance Manual
AutoGyro
Cavalon
CHAPTER 04 – MANUFACTURER LIFE LIMITATIONS
For the safe operation over the specified lifecycle of the aircraft and liability reasons the following
manufacturer limitations shall apply. In case the component has an operating hours and calendric time
limit the first limit shall apply.
Note that at expiration of the specified manufacturer life limit (MLL) the component shall be replaced
for your own safety, independent of its condition.
ATA
Equipment / System
MLL
24-30-00
Battery
25-10-00
Seat belts
25-60-00
ELT Battery
28-20-00
Fuel filter
28-20-00
Fuel pumps
28-20-00
Primary fuel pump
32-20-00
Nose gear rubber damper
62-00-00
Rotor System II
2500 hrs
62-31-00
Rotor main bearing
1500 hrs
62-32-00
Gimbal head bolts
1500 hrs / 5 yrs
62-51-00
Mast bolts
1500 hrs / 5 yrs
62-51-00
Mast mounting bushings
1500 hrs / 5 yrs
67-00-00
Push-pull cables
71-20-00
Engine mounting bushings
See manufacturer
10 yrs
See manufacturer
200 hrs / 2 yrs
5 yrs (R912)
1000 hrs (R914)
5 yrs
1500 hrs
1500 hrs / 5 yrs
Status and lifetimes of components, liquids and fluids is listed in the Event and Configuration Log (AGF-ECL) form. The initial Event and Configuration Log is delivered with the gyroplane by AutoGyro. An
empty form is provided for download on the AutoGyro web site.
MMM-CV-B_14-11-19
Part B – Master Servicing Manual (Ch. 00 – 20)
Page 11 of 24
Manufacturer
Maintenance Manual
AutoGyro
Cavalon
CHAPTER 05 - TIME LIMITS, INSPECTIONS & CHECKS
For safe operation and continued airworthiness over the specified lifecycle of the aircraft the following
inspection schedule shall apply. Note that specified tolerances must NOT be accumulated!
Task
Daily / Pre-Flight Check
Complementary / Servicing Tasks
Interval
Recurrence
Tolerance
Before flight / daily
Each
N/A
5 hrs (rec.)
Each
N/A
25 hrs
Once
+/- 5 hrs
100 hrs / 1 yr
Each
+/- 10 hrs
1500 hrs / 5 yrs
Each
-
25 hrs Inspection
100 hrs / Annual Inspection
Supplemental Inspection
The 25 hrs inspection has to be performed once, within the specified tolerance.
The 100 hrs inspection has to be performed every 100 hours, within the specified tolerance, at latest
within 12 months, counted from issue of the aircraft’s Statement of Compliance (Stückprüfung) or
Annual Inspection (JNP).
Note that tolerances do not accumulate! However, a preponed (earlier) inspection outside the
tolerance will reduce the next inspection due cycle accordingly.
(Total aircraft hours, counted from engine start to engine shut-down, i.e. HOBBS meter)
05-10-00
Time Limits
In addition to time limits for inspection items and checks the following time limits for inspection or
overhaul of respective components or replacement of liquids and fluids apply. Please refer also to the
engine
manufacturer’s
manual
and
time
limits
specified
herein,
as
well
as
CHAPTER 04 - Airworthiness Limitations!
Components
ATA/Ref.
Equipment / System
Time Limit
53-00-00
Monocoque structure (incl. keel tube support), keel tube
on condition
Liquids and Fluids
ATA/Ref.
Equipment / System
Time Limit
75-00-00
Engine coolant (acc. to coolant manufacturer)
at latest 5 years
79-00-00
Engine oil (acc. to engine manufacturer)
at latest 100 hrs
Refer to CHAPTER 12 concerning replenishing/replacement procedures and types of liquids and
fluids.
Status and lifetimes of components, liquids and fluids is listed in the Event and Configuration Log (AGF-ECL) 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.
MMM-CV-B_14-11-19
Part B – Master Servicing Manual (Ch. 00 – 20)
Page 12 of 24
Manufacturer
Maintenance Manual
05-20-00
AutoGyro
Cavalon
Scheduled Inspections & Checks
Daily / Pre-Flight Check
All daily or pre-flight check list items consist of visual checks and do not replace professional
mechanical inspection and maintenance. The Daily / Pre-Flight Checklist for the standard Cavalon
gyroplane is provided in the current Pilot’s Operating Handbook.
Note that there is no ‘post-flight’ inspection mentioned. It is reasonable, however, to perform parts of
the pre-flight inspection after the last flight of the day in order to take maintenance action in advance, if
necessary.
Complementary / Servicing Tasks
The following tasks have to be performed in-between 100hrs inspections and may be performed on an
operational level by the pilot or a trained person.
Task
Interval
Tolerance
5 hrs (rec.)
N/A
Lubrication: Pre-rotator drive coupling sleeve
as req.
N/A
Cleaning/replacement: Engine air filter
as req.
N/A
Lubrication: Teeter hinge (see Ch. 12 – Servicing)
25 hrs Inspection (one-time / non-recurrent)
The inspection items of the 25 hrs inspection are covered within the 100 hrs inspection protocol, which
is available for download.
100 hrs / Annual Inspection
The maintenance protocol of the 100 hrs / Annual Inspection (AG-F-PCA-MT) is available for
download.
05-21-00
Temporary Scheduled Inspections & Checks
Temporary Scheduled Inspections and Checks may be introduced by MIs or AD’s (if any). Notice of,
and compliance with ADs is mandatory. If necessary, AutoGyro GmbH will point out the existence of
such information and will provide detailed procedures to registered service partners and owners.
Important Note: Temporary scheduled inspections introduced by the engine/powerplant manufacturer
will not be covered by process. As a contribution to fleet safety, AutoGyro may point out the existence
of such information, if possible.
MMM-CV-B_14-11-19
Part B – Master Servicing Manual (Ch. 00 – 20)
Page 13 of 24
Manufacturer
Maintenance Manual
05-30-00
AutoGyro
Cavalon
Unscheduled Inspections
In case of the following events or occurrences, unscheduled inspections have to be performed.
Event / Occurrence / Unusual Condition
Action / Reference
Rotor vibration
see CHAPTER 18
Propeller vibration
see CHAPTER 18
If in doubt contact AutoGyro customer 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:
05-51-00
Inspections - Special Operational Conditions
Condition
Action / Reference
Operation in sand or dust
see below
AVGAS
engine manufacturer documentation
Winter operation
see below
Operation in sand or dust





Refer to engine manufacturer documentation
Inspect/change air filter regularly
Reduce 100 hrs inspection interval to 50 hrs
Apply propeller leading edge protection strip
Operation with keel tube fin (recommended)
Winter operation
The cooling system for the cylinder heads of the engine is filled with a mixture of anti-freeze and
water, which gives freezing protection down to -20°C. Check protection temperature of the coolant and
add anti-freeze, if necessary.
If temperatures are expected to fall below protection temperature, drain the coolant, and if required for
service, refill with pure antifreeze. As anti-freeze ages, renew the coolant every five years. Read the
engine manual for the manufacturer’s recommendations.
During winter operations the necessary operating temperature for oil and cooling agent may not be
reached. This can be compensated by taping some portion of the coolers. Monitor all engine
temperatures closely after having the coolers taped and modify, if necessary.
When using heated clothing be aware of the electrical power demand in regard to the generator
performance. Do not exceed the generator output value in order not to drain the battery. A loss of
electric power affects avionics and radio communication and can lead to an engine failure in case of
ROTAX 914 engine (depending on configuration).
Before each flight inspect all control cables for free and easy movement and sufficient lubrication.
MMM-CV-B_14-11-19
Part B – Master Servicing Manual (Ch. 00 – 20)
Page 14 of 24
Manufacturer
Maintenance Manual
05-55-00
AutoGyro
Cavalon
Inspections - Special Operational Incident
Event / Occurrence / Unusual Condition
Action / Reference
Suspected hard landing
see below
Rotor contact with obstacle
see below
Propeller contact with obstacle or external impact
see below
Birdstrike
see below
Lightning strike
see below
Suspected hard landing
In case of a suspected hard landing perform the following checks:







Inspect nose gear, attachment, fork, linkage and wheel bearing
Inspect main gear axles and attachment
Examine possible rotor / propeller strike  see ‘Rotor / propeller contact with obstacle’
CRITICAL: Inspect main gear suspension bow (body attachment and both axle attachments
ok, no cracks)
CRITICAL: Inspect fuselage, frame and attachment point for possible deformation or cracks.
Perform levelling procedure (see JobCard 08-20-00 2-1)
CRITICAL: Inspect engine mounting and propeller to frame clearance approx. 5 cm
CRITICAL: Perform a rotor alignment check
Defective components must be replaced. In case one or more of the items marked ‘CRITICAL’ are
found defective or out of tolerance, contact AutoGyro customer support.
Rotor contact with obstacle
Rotor contact with obstacle include any rotor strike of the standing or turning rotor with an obstacle,
including propeller and fuselage structures. In case of rotor contact with obstacle:



Perform a rotor alignment check and adjust, if necessary
Examine damage of aluminium rotor profile:
 allowed damage: dent with max. depth of 1 mm
 CRITICAL damage: nick(s)
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 customer
support.
Propeller contact with obstacle or external impact
Refer to engine manufacturer documentation. Perform tap test on propeller blades.
Birdstrike



Perform detailed inspection of all affected component
If rotor blades are affected, proceed according to ‘Rotor contact with obstacle’
If propeller is affected, proceed according to ‘Propeller contact with obstacle or external
impact’
MMM-CV-B_14-11-19
Part B – Master Servicing Manual (Ch. 00 – 20)
Page 15 of 24
Manufacturer
Maintenance Manual
AutoGyro
Cavalon
Lightning strike
A lightning is likely to have caused invisible damage to many components, especially the main rotor
bearing. The aircraft must not be flown until satisfactory inspection has been undertaken and any
rectification has been completed.
05-60-00
Ground Test Run
The maintenance protocol of the Ground Test Run (AG-F-PGR-MT) is available for download.
05-70-00
Functional Test Flight
The maintenance protocol of the Functional Test Flight (AG-F-PTF-MT) is available for download.
05-90-00
Maintenance Records & Aircraft Logs
An illustrated ‘Parts List’ (AutoGyro Parts List) will be compiled individually and delivered with each
gyroplane.
Forms are available for download.
An ‘Event and Configuration Log’ (ECL) is delivered with the aircraft by AutoGyro and shall be kept
current by the maintenance facility. An empty form (AG-F-ECL) is provided for download.
MMM-CV-B_14-11-19
Part B – Master Servicing Manual (Ch. 00 – 20)
Page 16 of 24
Manufacturer
Maintenance Manual
AutoGyro
Cavalon
CHAPTER 06 - DIMENSIONS & AREAS
Length
4.60 m
Width
1.75 m
Height
2.82 m
Rotor diameter
8.4 m
Rotor disc area
55.4 sqm
Propeller diameter
MMM-CV-B_14-11-19
Part B – Master Servicing Manual (Ch. 00 – 20)
1.72 m
Page 17 of 24
Manufacturer
Maintenance Manual
AutoGyro
Cavalon
CHAPTER 07 - LIFTING / JACKING / SHORING
See Job Card 07-00-00 2-1 in Part E of this manual.
CHAPTER 08 - LEVELING & WEIGHING
Weighing shall be performed in a draft-free hangar on level ground, with the aircraft defueled to
minimum useable fuel.
Make sure each wheel of the gyroplane is located centred on the scales.
The weighing report AG-F-WRP-MT is available for download.
CHAPTER 09 - TOWING & TAXIING
Experience shows that aircraft may be exposed to much higher loads when operated on ground, than
when in flight. Such loads caused by rumbling on rough terrain, or bouncing the aircraft over the
hangar threshold may easily exceed the design load in peak.
Use caution when handling the gyroplane on ground. Care must be taken when pushing at the rudder
or at the outer stabilizers. Avoid excessive swing of the rotor blades as repeated bending ultimately
leads to fatigue or damage.
CHAPTER 10 - PARKING, STORAGE & RETURN TO SERVICE
Parking up to 6 months
No special measures need to be taken.
NOTE Don´t let E10 remain in the fuel system for unnecessary long time or for
long-term storage!
Parking more than 6 months


Refer to engine manufacturer documentation
Maintain battery charged
CAUTION No overwinter survival mode (snowflake) with Ctek charger MXS3.8 for
Super B batteries.


Unload wheel gear
Cover aircraft with a light plastic tarpaulin or cloth
Long-term Storage
Contact AutoGyro
Return to Service
Perform a 100 hrs Inspection.
MMM-CV-B_14-11-19
Part B – Master Servicing Manual (Ch. 00 – 20)
Page 18 of 24
Manufacturer
Maintenance Manual
AutoGyro
Cavalon
CHAPTER 11 - PLACARDS & MARKINGS
In clear view of the pilot:
Only VFR day is approved
Aerobatic flight prohibited!
Low-G manoeuvres prohibited!
Flight in icing conditions prohibited!
For additional limitations see Flight Manual!
Max. gross weight: ________
Empty weight:
________
Max. useful load:
________
At RH seat:
Max. weight in seat:
110 kg
Min. weight in seat:
60 kg
Max. weight in seat:
110 kg
At LH seat:
Solo from right hand seat only
Occupant warning (front and aft seat):
OCCUPANT WARNING
This aircraft has not been certified
to an international requirement
MMM-CV-B_14-11-19
Part B – Master Servicing Manual (Ch. 00 – 20)
Page 19 of 24
Manufacturer
Maintenance Manual
AutoGyro
Cavalon
At each storage compartment behind seats:
Max. load:
10 kg
W&B must be respected!
At fuel filler neck:
Min. ROZ 95
AVGAS 100LL
Tank Capacity 100 litres
At oil filler neck:
Engine Oil: ___________________
Approved oil types see engine manual!
At fuel shut-off valve:
At both static ports:
Static Port
Do not obstruct!
MMM-CV-B_14-11-19
Part B – Master Servicing Manual (Ch. 00 – 20)
Page 20 of 24
Manufacturer
Maintenance Manual
AutoGyro
Cavalon
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.
In order to protect the gyroplane against dirt, dust, bird soil, and sunlight, the aircraft should be
covered with a light plastic tarpaulin or cloth. Openings to the engine, service access ports and
airspeed indicator should be closed after the flight (insects, birds etc.).
Contamination can be cleaned with clean water, possibly with mild cleaning additives. To clean the
rotor it is best to soak contamination with a cloth or towel, wipe with soft or micro-fibre cloth, and rinse
thoroughly with water.
12-20-00
Lubrication
Component
Lubrication: Teeter hinge
Lubrication: Pre-rotator drive coupling sleeve
Application
Reference
5 hrs (recomm.)
see below
as required
see below
See CHAPTER 05 for respective time limits.
Lubrication: Teeter hinge
The teeter hinge consists of a steel bolt running in special Teflon coated bushings. In order to provide
proper bearing action and to avoid wear and bearing play, which will cause rotor vibration in
consequence, regular lubrication is essential. In order to do so, the best practise is to perform work
steps 5 to 7 from Job Card 62-11-00 6-1 INSPECTION: ROTOR – TEETERING PARTS. Make sure to
apply grease also on the outer (secondary) bearings inside the teeter tower.
Lubrication: Pre-rotator drive coupling sleeve
Apply a thin layer of lubricant AG-LUB-03 on coupling sleeve when in extended position in regular
intervals, at latest when the sliding surface feels dry or after flight through rain. Mast cover must be
removed!
12-30-10
Servicing: Engine Air Filter
The air intake filters need to be replaced or cleaned according to the manufacturer‘s recommendation.
Depending on environmental conditions, such as dust, sand, or pollution the recommended rate of
maintenance should be increased as required. Engine cowling must be removed!
12-30-20
Servicing: Tire Pressure
Main wheels
1.8 – 2.2 bar
Nose wheel
2.0 – 2.4 bar
NOTE: Green valve caps are used when the tire is filled with nitrogen.
MMM-CV-B_14-11-19
Part B – Master Servicing Manual (Ch. 00 – 20)
Page 21 of 24
Manufacturer
Maintenance Manual
12-30-30
AutoGyro
Cavalon
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.
Charge the battery only with a charging device which is suitable for gel electrolyte batteries.
CAUTION: The battery must never be deep discharged, as it will be damaged. If so,
it might need to be replaced.
CAUTION: No overwinter survival mode (snowflake) with Ctek charger MXS3.8 for
Super B batteries.
12-30-40
Servicing: Engine Coolant
The cooling system for the cylinder heads of
the engine is filled with a mixture of antifreeze and water, which gives freezing
protection down to -20°C. Check protection
temperature of the coolant and add antifreeze, if necessary.
Fuel and Engine Coolant
Dip Stick
If temperatures are expected to fall below
protection temperature, drain the coolant,
and if required for service, refill with pure
antifreeze. As anti-freeze ages, renew the
coolant every five years. Read the engine
manual
for
the
manufacturer’s
recommendations.
As a minimum, coolant must be visible in the
overflow bottle resp. on the dip stick. The
maximum coolant level is defined by the twin
rings marking on the Fuel and Engine
Coolant Dip Stick with the dip stick held at
the side with the triple rings. A larger
depiction of the dip stick is provided in the
POH.
12-40-00
Replenishing/Replacement of Fluids
Liquid / Fluid
Max. Filling Qty.
Type / Code
Engine coolant
3.8 ltr
as documented
Engine coolant with cabin heating (option) installed
4.2 ltr
as documented
Engine Oil
3.4 ltr
as documented
See CHAPTER 05 for respective time limits.
CHAPTER 13-17 – UNASSIGNED / N/A
MMM-CV-B_14-11-19
Part B – Master Servicing Manual (Ch. 00 – 20)
Page 22 of 24
Manufacturer
Maintenance Manual
AutoGyro
Cavalon
CHAPTER 18 - VIBRATION & NOISE ANALYSIS
Vibration may be induced by the rotor system, the propeller or even the engine. Finding out the cause
for vibration and its proper cure requires experience and special equipment. This is why vibration
analysis and related maintenance can only be performed by specialized service partners
(maintenance level ‘S’), or AutoGyro GmbH, Germany directly.
The following tests or fault isolation procedures should be performed in order to exclude systematic
errors in case of rotor vibration:






rotor system cleanliness
check/verify correct installation position of the shim washers relative to teeter block and teeter
tower (one or two dot markings on block, shim washer and teeter tower must align)
check for possible play in teeter bearing in axial or radial direction
check rotor system alignment (see Job Card 62-11-00 5-1)
check for possible play in rotor bearing
adjust (increase) rotor control friction (see Job Card 62-32-00 5-1)
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. The following table provides a basic
classification.
Vibration appearance / sensation / parameter
Lateral (left-right / back-forth) vibration with approximately 6 per second amplitude
Vertical (up-down) vibration with approximately 12 per second amplitude
Free-stick movement – carefully release control stick (if possible/safe) and describe path and
displacement of control stick head
Flight condition (weight, speed) with highest vibration level
Rotor RPM
Higher frequency vibration (around 50 Hz, like an electric razor), changing with RPM
Higher frequency vibration, frequency and amplitude significantly changing with power setting,
possibly irregular or erratic
RPM or power setting with highest vibration levels
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Cavalon
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. A
defective muffler can be refilled with insulating material. Repair as necessary.
Propeller noise is emitted by the fast turning blade tips and usually increases exponentially with RPM
and speed due to interaction of air disturbances with the blade tips.
As noise is a subjective perception, only measurement will provide reliable data. However, the
following table provides elements and countermeasure to troubleshoot and cure in case of unusual
noise emission.
Possible causes for noise / countermeasures
Check propeller condition (cleanliness, erosion, damaged or splintered blade tips). Clean or repair
propeller.
Check propeller RPM during take-off (full throttle) or cruise. Adjust/reduce if required.
Check/adjust propeller pitch. Check pitch setting of individual blades and adjust.
Check leading edge of propeller and leading edge protection strip (if installed). A damaged leading
edge protection strip (loose or sticking out end) may change noise signature significantly. Replace
as necessary.
Check airfilter condition and installation condition.
CHAPTER 19–20 – UNASSIGNED / N/A
MMM-CV-B_14-11-19
Part B – Master Servicing Manual (Ch. 00 – 20)
Page 24 of 24
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Cavalon
Contents
CHAPTER 21 - VENTILATION / HEATING .............................................................................................3
21-00-00
Ventilation / Heating .........................................................................................................3
CHAPTER 22 - UNASSIGNED / N/A .......................................................................................................3
CHAPTER 23 - COMMUNICATIONS ......................................................................................................3
23-10-00
Speech Communication / Radio .......................................................................................3
23-40-00
Interphone / Intercom .......................................................................................................3
CHAPTER 24 - ELECTRICAL POWER ...................................................................................................3
24-30-00
DC Generation and Battery ..............................................................................................4
24-60-00
DC Electrical Load Distribution .........................................................................................4
CHAPTER 25 - EQUIPMENT / FURNISHINGS .......................................................................................4
25-10-00
Flight Compartment ..........................................................................................................4
25-60-00
Emergency........................................................................................................................5
CHAPTER 26 - FIRE PROTECTION / FIRE WARNING .........................................................................5
CHAPTER 27 - FLIGHT CONTROLS ......................................................................................................6
27-00-00
Flight Controls...................................................................................................................6
27-20-00
Flight Controls - Rudder ...................................................................................................6
CHAPTER 28 - FUEL ...............................................................................................................................7
28-10-00
Storage .............................................................................................................................7
28-20-00
Distribution ........................................................................................................................7
28-40-00
Indicating ..........................................................................................................................8
CHAPTER 29-30 - N/A .............................................................................................................................8
CHAPTER 31 – INDICATING SYSTEM ...................................................................................................8
31-10-00
Instruments & Control Panels ...........................................................................................8
31-60-00
Integrated Display Systems ............................................................................................10
CHAPTER 32 - LANDING GEAR ...........................................................................................................12
32-10-00
Main Gear .......................................................................................................................12
32-10-00
Nose Gear ......................................................................................................................12
32-40-00
Wheels and Brakes ........................................................................................................12
CHAPTER 33 - LIGHTS .........................................................................................................................12
33-40-00
Exterior ...........................................................................................................................12
CHAPTER 34 - NAVIGATION ................................................................................................................13
34-10-00
Flight Environment Data .................................................................................................13
34-20-00
Attitude and Direction .....................................................................................................13
34-70-00
ATC Transponder ...........................................................................................................13
CHAPTER 35 - N/A ................................................................................................................................13
CHAPTER 36 - PNEUMATIC .................................................................................................................13
36-11-00
Generation / Compressor ...............................................................................................13
36-21-00
Distribution ......................................................................................................................13
CHAPTER 37-50 - UNASSIGNED / N/A ................................................................................................14
CHAPTER 51 - STANDARD PRACTICES - STRUCTURES .................................................................14
51-00-00
Standard Practices - Structures......................................................................................14
CHAPTER 52 - DOORS, COVERS AND COWLINGS ..........................................................................14
52-10-00
Passenger / Crew ...........................................................................................................14
52-20-00
Emergency Exit...............................................................................................................14
52-40-00
Service Covers and Cowlings .........................................................................................14
CHAPTER 53 - FUSELAGE ...................................................................................................................14
CHAPTER 54 - N/A ................................................................................................................................14
CHAPTER 55 - STABILIZERS ...............................................................................................................15
55-40-00
Rudder ............................................................................................................................15
CHAPTER 56 - WINDOWS ....................................................................................................................15
56-10-00 Flight Compartment / Canopy .............................................................................................15
MMM-CV-C_14-11-19
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Cavalon
56-15-00 Canopy Windows ................................................................................................................15
CHAPTER 57-60 - UNASSIGNED / N/A ................................................................................................15
CHAPTER 61 - PROPELLER ................................................................................................................16
61-10-00
Propeller assembly .........................................................................................................16
61-20-00
Controlling .......................................................................................................................16
CHAPTER 62 - ROTOR .........................................................................................................................16
62-11-00
Rotor – Teetering Parts ..................................................................................................16
62-31-00
Rotor Head Bridge, Bearing and Teeter Tower ..............................................................17
62-32-00
Rotor Gimbal Head .........................................................................................................17
62-41-00
Rotor RPM Monitoring ....................................................................................................17
62-51-00
Rotor Vibration Isolation .................................................................................................17
CHAPTER 63 - ROTOR DRIVE .............................................................................................................17
63-11-00
Pre-rotator.......................................................................................................................17
63-11-10
Pre-rotator Lower Engagement ......................................................................................18
63-11-20
Pre-rotator Drive .............................................................................................................18
63-11-30
Pre-rotator Upper Engagement ......................................................................................18
63-51-00
Rotor Brake System .......................................................................................................18
CHAPTER 64-66 - N/A ...........................................................................................................................18
CHAPTER 67 - ROTOR FLIGHT CONTROL.........................................................................................18
67-05-00
Pitch Trim System / Rotor Brake ....................................................................................18
67-06-00
Roll Trim System ............................................................................................................19
CHAPTER 68-70 - UNASSIGNED / N/A ................................................................................................19
CHAPTER 71 - POWER PLANT ............................................................................................................19
71-10-00
Engine Cowling ...............................................................................................................19
71-20-00
Engine Mounts ................................................................................................................19
71-30-00
Engine Firewalls .............................................................................................................19
71-50-00
Engine Electrical Harness ..............................................................................................19
71-60-00
Engine Air Intakes...........................................................................................................19
71-70-00
Engine Drains .................................................................................................................19
CHAPTER 72 TO 74 - ENGINE RELATED ............................................................................................20
CHAPTER 75 - AIR / ENGINE COOLING ..............................................................................................20
CHAPTER 76 - ENGINE CONTROLS ...................................................................................................21
76-10-00
Power Control / Choke ...................................................................................................21
76-20-00
Engine Shutdown / Emergency ......................................................................................21
CHAPTER 77 - ENGINE INDICATING ..................................................................................................21
77-10-00
Power ..............................................................................................................................21
77-20-00
Temperature ...................................................................................................................21
77-40-00
Integrated Engine Instrument Systems ..........................................................................22
CHAPTER 78 - EXHAUST .....................................................................................................................22
78-00-00
Exhaust ...........................................................................................................................22
CHAPTER 79 - OIL SYSTEM.................................................................................................................22
79-11-00
Storage / Oil tank ............................................................................................................22
79-20-00
Distribution and Cooling .................................................................................................22
79-21-00
Oil Hoses and Lines .......................................................................................................22
79-22-00
Oil Cooler ........................................................................................................................22
79-30-00
Indicating ........................................................................................................................22
MMM-CV-C_14-11-19
Part C – System Description Section (Ch. 21 – 90)
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Cavalon
CHAPTER 21 - VENTILATION / HEATING
21-00-00
Ventilation / Heating
Each of the two cabin doors features an adjustable fresh air vent and one sliding window with pivoting
vent for ventilation. The sliding window can be used as viewing hatch in case of emergencies and is
wide enough to reach through with a hand. For demisting and /or cabin ventilation. open and direct the
round air vents and pivoting vents as required. Used air can escape through an outlet at the bottom of
the cabin.
Cabin heating (if installed) is controlled by a labelled lever in the centre console. In order to switch
cabin heating on, the lever must be moved to the front which will activate the cabin heat blower fan by
means of of a micro switch. Heat output / temperature can be controlled corresponding to the position
of the lever. When activated, an electrical blower fan sucks air from the leg room and blows it through
a heat exchanger, which is connected to the engine cooling water circuit. Warm air escapes through
outlets at the dashboard below the front window, at two adjustable nozzles, and is redirected to the leg
room.
Concerning heating control, see 76-10-00 Power Control / Choke for reference.
CHAPTER 22 - UNASSIGNED / N/A
CHAPTER 23 - COMMUNICATIONS
23-10-00
Speech Communication / Radio
The communication system consists of an integrated airband radio system installed in the instrument
panel. Different versions may be possible. Please refer to the manufacturer’s specifications and
manuals for reference. Wiring diagrams are provided in Part D of this document. Different possible
cockpit layouts are described in 31-10-00 Instruments & Control Panels.
23-40-00
Interphone / Intercom
The standard intercom system features standard headset sockets (TRS / Tip Ring Sleeve) with
additional XLR-3 socket for active headset power supply. Sockets are provided at the aft console
between the crew seats. The intercom amplifier and VOX control is integrated in the respective radio.
See manufacturer’s manual for additional information.
As the intercom function is an integral part of the radio system, please refer to 23-10-00 Speech
Comm. / Radio.
CHAPTER 24 - ELECTRICAL POWER
The 12V DC electrical system consists of an engine driven electrical generator, a battery, master
switch, indicators, switches, electrical consumers, and cabling. With the ROTAX 914 UL engine an
electrical power supply is vital for continued engine operation as this engine variant solely relies on
electrically driven fuel pumps (depending on configuration).
Turning the master switch to the ON position closes the battery contact and energizes the gyroplane’s
electrical system. The red LOW VOLT warning light will illuminate briefly as a functional check. A
steady indication, however, warns the pilot that the voltage of the system has dropped below a safe
value. In this case a safety circuit (load shedding relay) will automatically disable the aircraft lights and
the 12V power receptacle.
A red GEN warning light is installed to indicate that the battery is not being charged.
MMM-CV-C_14-11-19
Part C – System Description Section (Ch. 21 – 90)
Page 3 of 22
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24-30-00
AutoGyro
Cavalon
DC Generation and Battery
Direct current is provided by an engine-integrated AC generator with external rectifier-regulator (12V
20 A DC). The battery is located at the rear wall on the LH side behind the removable fire wall. A
dedicated charging receptacle is available at the lower LH side of the fuselage, just before the LH
engine cowling.
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.
The power demand for various consumers is provided in the following table:
ATA Reference
Equipment / System
Power load
24-3
Generator
(-) 240 W
21-0
Cabin heat blower fan
23-1
Radio ATR500
2 W (rcv) / 35 W (xmt)
23-1
Radio ATR833
7 W (rcv) / 35 W (xmt)
25-1
Heated seats (ea)
96 W
28-2
Electrical fuel pump (ea)
21 W
33-4
NAV Lights LED
9W
33-4
Strobe Lights
28 W
33-4
Landing Light (LED)
10 W
34-7
ATC Transponder TRT800H
36-1
Pneumatic compressor
124 W (peak) / 103 W
75-0
Engine cooling fan
194 W (peak) / 97 W
85-21
Air conditioning system
85-34
Garmin 296
20 W
85-34
Garmin 496
20 W
85-34
Garmin 696
40 W
85-34
Flymap F7 / Sky-Map T7
5W
85-34
Flymap L
35 W
85-34
Flymap L (dual screen)
70 W
85-34
Flymap XL
45 W
85-34
AvMap
10 W
32 W
max.10W
(aux.generator)
CHAPTER 25 - EQUIPMENT / FURNISHINGS
25-10-00
Flight Compartment
The seats consist of seating surface as an integral part of the monocoque structure and adjustable
backrest, upholstered with removable cushions. The cushions consist of a foam core covered with an
easily cleanable, water-repellent fabric.
The backrest hinges are positioned by 2 countersunk Allen bolts on two seating rails. To suit to
different seating positions the backrest hinges can be adjusted by removing the Allen bolts and
MMM-CV-C_14-11-19
Part C – System Description Section (Ch. 21 – 90)
Page 4 of 22
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Cavalon
refitting in a different position on the rails. In addition the backrest angle can be adjusted by modifying
the lengths of the telescopic tubes.
For each seat an adjustable four point harness is available.
IMPORTANT NOTE: Seat belts are Manufacturer Life Limited (MLL)!
A storage compartment is located behind each seat with a maximum capacity of 10 kg each.
25-60-00
Emergency
The gyroplane is embarked and disembarked from each side through hinged, gull-wing type doors,
both doors are held open by a gas spring. In case of emergency or a jammed door, the gyroplane can
be evacuated through the opposite door, if necessary.
Depending on the customer’s configuration, an ELT may be installed below the LH seat. The ELT can
be accessed through the service cover below the seat cushion. ELT control panel with mode indicator
will be installed in the cockpit panel. If installed, please refer to the manufacturer’s documentation for
maintenance, time limits and testing. Be aware that the built-in battery has a limited lifetime and needs
to be replaced as specified. Replacement date should be placarded in the vicinity of the device or
control panel.
CHAPTER 26 - FIRE PROTECTION / FIRE WARNING
Depending on customer’s configuration the gyroplane can 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). The fire indication circuit consists of a cable routed inside the engine compartment. The cable
has two integrated wires separated by an insulation layer. At a defined temperature the insulation
layer will melt and the embedded wires close contact.
Engine fire (circuit short-closed, low resistance) will be indicated by a flashing/blinking Fire indicator
light in the Warning and Caution Panel. During normal operation (circuit closed, ‘normal’ resistance)
the Fire indicator light will be off. A malfunction of the system (circuit open) is indicated by a constantly
lit Fire indication. At power-on the system will perform a lamp test consisting of a series of three
flashes.
When installing or repairing the fire indication cable make sure not to overtorque the attachment
hardware as this might lead to uncontrolled contact of the embedded wires, which might lead to a false
Fire indication.
Indicator Light
System Status
OFF
Normal Operation (normal resistance / R ~ 1 kΩ)
FLASHING
Fire, abnormal temperature (circuit short-closed / R  0 Ω)
ON
System Malfunction (circuit open / R ∞ Ω)
MMM-CV-C_14-11-19
Part C – System Description Section (Ch. 21 – 90)
Page 5 of 22
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Cavalon
CHAPTER 27 - FLIGHT CONTROLS
27-00-00
Flight Controls
See CHAPTER 67 – Rotors Flight Control.
Note: Stabilizers are described in CHAPTER 55.
27-20-00
Flight Controls - Rudder
Rudder (Fin) and nose wheel are controlled simultaneously by adjustable foot pedals, control cables,
central control link and nose wheel control link. Both pairs of pedals are interconnected and can be
adjusted individually to suit different leg lengths. A shorter adjustment is achieved by pulling the
handle which moves the pedals closer. Pulling the handle while pushing with both feet gently against
the pedals allows longer adjustment.
In order to allow adjustment, the control cables are routed through teflon hoses which are fixated
inside the ‘S’-tube at the foot pedal. Outer and inner control cables are routed through/below the
bottom shell using plastic cable lead-throughs (not shown). The pedal control cables of both pedal
units are connected to the central control link. Ruder control is realized by push-pull control cables (not
shown) which are connected to the central control link and are routed through bottom shell and keel
tube. The schematic drawing shows pedals, control links, and the routing of the cables.
The tension of the control cables that connect central control link with nose wheel control link can be
adjusted by turnbuckles. Adjust in a way that there is no freeplay or slack, but do not overtense! In
case the tension of the control cables is suddenly low, check nose wheel control link.
The rudder fin is described in 55-40-00 Rudder.
Pedals, Control Links and Routing of Cables
1 – Adjustable pedals (assembly)
2 – Adjustment handle
3 – Outer pedal control cable
4 – Inner pedal control cable
MMM-CV-C_14-11-19
5 – Deflection roller
6 – Central control link
7 – Nose wheel control cable with turnbuckle
8 – Nose wheel control link
Part C – System Description Section (Ch. 21 – 90)
Page 6 of 22
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Cavalon
CHAPTER 28 - FUEL
28-10-00
Storage
The fuel system consists of two tanks permanently connected with a big crossport, a single filler port,
fuel and ventilation lines, fuel level indications, and drain. The filler port is located at the left hand side
of the gyroplane. In order to open the filler cap, lift, then turn the flap, and pull out. Reverse to close
cap.
The tanks are installed behind the seats and have a capacity of 100 litres. Fuel level can be checked
visually using a dip stick which has to be inserted diagonally from the fuel filler port.
Ventilation is provided by a vent line above the tanks leading through the mid channel directly to the
outside.
28-20-00
Distribution
The fuel distribution system comprises fuel hoses, made of fabric-reinforced rubber, a shut-off valve,
filters and pumps.
Possible fuel system versions differ with engine model, see schematics below. In case of ROTAX 914
engine variant, the fuel line with the second fuel pump P2 has a non-return valve to prevent flow-back
when the second pump is switched off.
Fuel system ROTAX 912:
Fuel system ROTAX 914:
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Part C – System Description Section (Ch. 21 – 90)
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The safeguarded lever of the shut-off valve is located between the pilot and passenger seat below the
intercom panel. The actual valve is located in the vicinity of the fuel tanks and is articulated by a
torsion bar.
IMPORTANT NOTE: Fuel filters are Manufacturer Life Limited (MLL)!
28-40-00
Indicating
Fuel level can be checked visually using a dip stick which has to be inserted diagonally from the fuel
filler port, and also by a fuel quantity indicator in the cockpit. Note that in both cases, fuel level is
measured from the left hand tank only. Due to the large crossport the filling level of the second tank
will be identical.
CHAPTER 29-30 - N/A
CHAPTER 31 – INDICATING SYSTEM
Note: The hour meter / HOBBS meter is described in CHAPTER 77 - ENGINE INDICATING.
31-10-00
Instruments & Control Panels
Different instrument panel layouts are available. The basic instrumentation arrangements include:
 Standard Layout / Moving Map Portrait
 Glass Cockpit – Single Display
 Glass Cockpit – Dual Display
The standard layout includes all instruments necessary for flight but also installation provisions for
additional conventional instrumentation.
The panel layouts Moving Map Landscape or Portrait include all relevant instruments arranged in a
way to accept most off-the-shelf moving map navigation devices in the respective format. For detailed
user information and instructions concerning the different moving map systems please refer to the
manufacturer’s documentation.
Depending on the chosen instrumentation and optional equipment, the depicted panels on the
following pages may vary. Note that the standard or backup compass is mounted to the glare shield.
MMM-CV-C_14-11-19
Part C – System Description Section (Ch. 21 – 90)
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Cavalon
Panel Layout – Standard / Moving Map Portrait
1 – Water temperature indication
2 – Engine RPM
3 – Rotor RPM
4 – Oil pressure
5 – Fuel level indicator
6 – Cylinder head temperature
7 – Oil temperature
8 – Magnetic compass
9 – Warning lights
10 – Lateral trim indicator
11 – Manifold pressure gauge (if installed)
12 – Air speed indicator
13 – Attitude Indicator (if installed)
14 – Altimeter
15 – Cut-out 57mm / 2 ¼” for optional inst.
16 – Basic Flight Instrument (if installed)
17 – Vertical Speed Indicator (if installed)
18 – VPP control and end position
detection IVO propeller (if installed)
19 – Cooling fan manual activation
MMM-CV-C_14-11-19
20 – RBT indicator
21 – ATC transponder (if installed)
22 – Collision Avoidance System (if inst.)
23 – Radio (if installed)
24 – MAG switches
25 – Pneumatic mode selector
26 – 12V power receptacle (if installed)
27 – Master/starter switch
28 – Trim/brake pressure gauge
29 – Audio in (if installed)
30 – OAT indicator
31 – Pre-rotator overdrive/override
32 – Hour meter
33 – Circuit Breaker Panel
34 – Switches
Part C – System Description Section (Ch. 21 – 90)
Page 9 of 22
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AutoGyro
Cavalon
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. It is of utmost importance to read and understand the operators
manual and to become familiar with the system before operation. In case of a system failure, a 2 ¼”
(47mm) altimeter, air speed indicator and rotor speed indicator are provided as backup
instrumentation.
Panel Layout – Glass Cockpit - Single Display
1 – Water temperature indication
2 – Magnetic compass
3 – Warning lights
4 – Lateral trim indicator
5 – Air speed indicator (back-up)
6 – Altimeter (back-up)
7 – Cut-out 57mm / 2 ¼” for optional inst.
8 – Vertical Speed Indicator (if installed)
9 – Cooling fan manual activation
10 – RBT indicator Switches (options)
11 – ATC transponder (if installed)
12 – Collision Avoidance System (if inst.)
13 – Radio (if installed)
14 – Pneumatic mode selector
MMM-CV-C_14-11-19
15 – MAG switches
16 – Trim/brake pressure gauge
17 – 12V power receptacle (if installed)
18 – Master/starter switch
19 – Audio in (if installed)
20 – Pre-rotator overdrive/override
21 – Glass Cockpit
22 – Hour meter
23 – Circuit Breaker Panel
24 – Switches
Part C – System Description Section (Ch. 21 – 90)
Page 10 of 22
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Cavalon
Panel Layout – Glass Cockpit - Dual Display
1 – Water temperature indication
2 – Magnetic compass
3 – Warning lights
4 – Lateral trim indicator
5 – Air speed indicator
6 – Altimeter
7a – Glass Cockpit Display I
7b – Glass Cockpit Display II
8 – Cooling fan manual activation
9 – ATC transponder (if installed)
10 – Collision Avoidance System (if inst.)
11 – Radio (if installed)
12 – MAG switches
MMM-CV-C_14-11-19
13 – Pneumatic mode selector
14 – 12V power receptacle (if installed)
15 – Master/starter switch
16 – Trim/brake pressure gauge
17 – Audio in (if installed) OAT indicator
18 – Pre-rotator overdrive/override
19 – Hour meter
20 – Circuit Breaker Panel
21 – Switches
Part C – System Description Section (Ch. 21 – 90)
Page 11 of 22
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Cavalon
CHAPTER 32 - LANDING GEAR
The Cavalon has a conventional tricycle gear with GRP (glass fibre reinforced plastic) suspension bow
and a steerable nose gear.
32-10-00
Main Gear
The main gear consists of a GRP suspension bow which is bolted to the underside of the fuselage.
The spar is designed to absorb even higher than normal landing loads in case of a hard landing or
crash.
32-10-00
Nose Gear
The nose gear consists of a steerable nose wheel in a fork made of stainless steel (CrMo4) tubing with
rubber damper (Manufacturer Life Limited!). Wheel and fork are covered by a wheel spat. Nose wheel
steering is realized by a linkage to pedal/rudder control input using control cables.
32-40-00
Wheels and Brakes
Both main wheels feature hydraulic disc
brakes. The hydraulic wheel brake is
actuated by pulling the brake lever (2). A
locking pawl mechanism allows setting for
use as parking brake. In order to release the
parking brake pull the brake lever a little
further to let the spring-loaded locking pawl
disengage, and then release wheel brake.
Throttle and brake panel
Do not try to disengage the locking pawl by
pressing the small release lever without
pulling the brake lever at the same time.
Releasing the pawl using the small release
lever only will lead to premature deterioration
of the teeth. If the teeth are worn the function
of the parking brake will be compromised!
The throttle and brake panel also supports
the brake fluid reservoir with screw cap and
fluid level min. and max. markings, as well as
the primary brake cylinder (panel must be
removed for access).
1 – Throttle lever
2 – Brake lever with locking pawl
3 – Choke control
4 – Cabin heating (if installed)
For correct tire pressure see 12-30-20 Servicing: Tire Pressure.
CHAPTER 33 - LIGHTS
33-40-00
Exterior
The aircraft is approved for day VFR operation only. As an option the following lights can be
configured on the Cavalon:
 Landing Light
 Position Lights with integrated Strobe Lights
Electrical schematics / wiring diagrams are provided in Part D - Diagrams and Charts of this manual.
Power consumption figures are listed in 24-60-00 DC Electrical Load Distribution.
MMM-CV-C_14-11-19
Part C – System Description Section (Ch. 21 – 90)
Page 12 of 22
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Cavalon
CHAPTER 34 - NAVIGATION
34-10-00
Flight Environment Data
The Cavalon features a Pitot-Static System to measure accurate air data. Total pressure is picked up
by a pitot type tube located in the nose section of the fuselage. The tube is connected to the integrated
cockpit instruments by a plastic line. The static pressure is measured across two ports, one on either
side of the fuselage. OAT data is measured by a probe located at the bottom of the fuselage behind
the nose gear and displayed in the cockpit as digital value.
34-20-00
Attitude and Direction
As part of minimum equipment, a magnetic compass is installed in the forward area below the
windshield in pilot’s sight. As an option, a vertical compass may be installed in the instrument panel.
34-70-00
ATC Transponder
An ATC Transponder may be installed as an option. Possible installation positions in the instrument
panel are described in CHAPTER 31. Please refer to the manufacturer’s documentation for reference.
CHAPTER 35 - N/A
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 and
a pressure compensation vessel, solenoid valves, air lines, pneumatic actuators, and the respective
cockpit controls.
The pneumatic system controls the following function:



rotor brake ON, i.e. rotor disc flat / flight control stick forward position (brake mode)
adjustable longitudinal trim, i.e. rotor disc/stick pulled aft (flight mode)
engagement of the pre-rotator, i.e. activation of the clutch and upper engagement
(only in flight mode or in brake mode with overdrive/override button)
The aforementioned functions are described in more detail in the dedicated chapters.
A schematic drawing of the pneumatic system is provided in Part D - Diagrams and Charts of this
manual.
36-11-00
Generation / Compressor
The electrically driven compressor and filter/dryer is located at the rear wall on the lower RH side
behind the removable fire wall. The wiring diagram is provided in Part D - Diagrams and Charts of this
manual.
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 at the rear wall on the lower RH side behind
the removable fire wall. See Part D - Diagrams and Charts for schematics.
Note that the pneumatics actuators (cylinders) are not described in this ATA Chapter, but assigned to
their mechanical main function.
Example: the brake/trim cylinder is described in 67-05-00 Pitch Trim System / Rotor Brake.
MMM-CV-C_14-11-19
Part C – System Description Section (Ch. 21 – 90)
Page 13 of 22
Manufacturer
Maintenance Manual
AutoGyro
Cavalon
CHAPTER 37-50 - UNASSIGNED / N/A
CHAPTER 51 - STANDARD PRACTICES - STRUCTURES
51-00-00
Standard Practices - Structures
Structural repair of composite structures or the welded steel frame is limited to AutoGyro GmbH or its
specialized service partners (job cards labelled ‘SPC’).
CHAPTER 52 - DOORS, COVERS AND COWLINGS
52-10-00
Passenger / Crew
The gyroplane is embarked and disembarked from each side while the doors are held open by a gas
spring. The gull-winged doors are hinged at the slanted door frame using two hinges with bolts and
self-locking nut or alternatively quick release pins. Due to the slant angle the doors can be opened and
closed in flight. The door locking mechanism is operated by moving an aluminium lever.
In order to close the door, pull the door close, move/lead the locking lever from ‘Open’ (aft position) to
‘Close’ (forward position) and let the lever snap sidewise into its locking detent. Do not pull by
reaching through the open sliding window as this will cause the plexiglass to crack. Only use the
dedicated grip/recess and operate locking lever with second hand while pulling door close.
Note that canopy windows are described in 56-15-00 Windows.
52-20-00
Emergency Exit
In case one of the doors is jammed or inaccessible, the opposite door is used as emergency exit.
52-40-00
Service Covers and Cowlings
In order to provide convenient access to engine, related components and other systems, service
covers, cowlings and fairings must be removed. Location and procedures for removal/installation of
service covers, cowlings and fairings are described in dedicated job cards in Part D of this manual.
CHAPTER 53 - FUSELAGE
The load carrying structure of the gyroplane consists of a composite monocoque occupant enclosure
which is connected to the rotor tower and keel tube. The composite structure, composite tower and aft
extension (keel tube) carries all loads induced by the crew stations, engine, rotor, undercarriage,
stabilizer, and serves as installation platform for additional equipment. Attachment points for the
engine installation are provided by a steel tube ring mount bolted to the rear of the monocoque
enclosure.
The aft extension (keel tube) of the main frame is made of curved aluminium and carries the stabilizer.
The keel tube is connected directly to mating counterparts of the monocoque structure by adhesive
joint and secured by bolts. Two plastic protection pads are bolted to the underside of the aluminium
tubing to protect the bow from abrasion in case of a tail slide (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
aluminium tubing. In case the tubing is abraded, contact AutoGyro for assessment.
CHAPTER 54 - N/A
MMM-CV-C_14-11-19
Part C – System Description Section (Ch. 21 – 90)
Page 14 of 22
Manufacturer
Maintenance Manual
AutoGyro
Cavalon
CHAPTER 55 - STABILIZERS
The stabilizer structure with rudder is made of GRP (or in certain cases CRP) and is bolted to the keel
tube. Presence and function of the stabilizer plays a vital part in flight stability and safety. Inspect
carefully all attachment points and the integrity of the composite component.
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 ‘linear’ resistance must be felt. In case mechanical noises are heard/felt,
contact AutoGyro.
55-40-00
Rudder
The rudder is made of GRP and is hinged to the central fin of stabilizer. An aluminium trim tab is
provided to eliminate constant pedal input during cruise flight and to provide a pre-defined rudder
setting in case of a control failure. The trim tab should be adjusted to allow pedal-off cruise flight.
Adjust according to the following table:
Pedal input
Corrective action
(for straight and level flight, slip indic./ball centred)
(seen from behind, i.e. in flight direction)
Constant right pedal required
Bend trim tab to the left
Constant left pedal required
Bend trim tab to the right
Avoid unnecessary bending as the tab may break at its perforation. A misadjusted or broken tab may
change flight characteristics significantly and in case of a rudder control failure, the gyroplane may
render difficult to control. Replace trim tab if it feels soft or if fissures at the perforated part are visible.
CHAPTER 56 - WINDOWS
56-10-00 Flight Compartment / Canopy
Outside visibility and environmental protection for pilot and occupant is provided by one large
undivided front window and a window in each door. The windows are made of formed Plexiglas which
is sealed into the door frame.
56-15-00 Canopy Windows
Each door window features an open/closable and adjustable fresh air vent and one sliding window
with pivoting vent for ventilation.
CHAPTER 57-60 - UNASSIGNED / N/A
MMM-CV-C_14-11-19
Part C – System Description Section (Ch. 21 – 90)
Page 15 of 22
Manufacturer
Maintenance Manual
AutoGyro
Cavalon
CHAPTER 61 - PROPELLER
In standard configuration a 3-bladed, fixed pitch propeller with GRP propeller blades is installed.
Depending on customer configuration a spinner may be installed! As an option, a variable pitch
propeller may be available (country specific).
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, readjustment should be necessary on the variable pitch propeller, please refer to the manufacturer’s
documentation or contact AutoGyro.
In certain cases, damaged propeller blades can be repaired (specialized / SPC maintenance task).
Concerning repair limits and allowable damage contact AutoGyro GmbH. Provide a precise
description of the damage, dimensions and preferably photos of the affected area.
61-10-00
Propeller assembly
The propeller assembly comprises propeller blades, hub and related attachment hardware.
61-20-00
Controlling
In case of a variable pitch propeller (VPP) refer to the manufacturer’s (IVO) documentation and
respective wiring diagrams in Part D of this manual.
CHAPTER 62 - ROTOR
The two-bladed, semi-rigid, teetering rotor system comprises high-strength aluminium extruded rotor
blades, a hub bar, and a common teeter hinge assembly.
Due to their working principle, every two-bladed teetering rotor system induces a certain amount of
vibration, depending on flight condition (speed) and disc loading. 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 or a specialized
service partners (maintenance level ‘S’).
IMPORTANT NOTE: Rotor Systems are Manufacturer Life Limited (MLL)!
Some guidelines to Vibration and Noise Analysis and classification schemes are provided in
CHAPTER 18 (Part B) of this manual.
62-11-00
Rotor – Teetering Parts
The teetering parts of the rotor system consist of teeter bolt, teeter block, rotor hub (bar), and rotor
blades. The rotor blades feature an aerodynamic profile especially suitable for rotorcraft which, in
combination with its relative centre of gravity, provides aerodynamic stability by eliminating negative
blade pitching moments and flutter tendency. The hollow blade profile is sealed at both ends by plastic
blade caps.
The aluminium rotor hub bar is pre-coned to the natural coning angle of the blades and connects the
blades firmly to each side using 6 fitting bolts and a clamping profile. In order to compensate for
asymmetric air flow in forward flight the blades are free to teeter. The hinge assembly consists of
teeter tower, teeter bolt and teeter block.
The teeter bolt runs in a long Teflon coated bushing in the teeter block (main bearing action), as well
as two shorter bushings in the teeter tower (emergency bearing action). The main bearing action is
supported by special grease which is applied through a grease nipple on top of the teeter block.
Servicing is described in CHAPTER 05 (Part B) of this manual.
MMM-CV-C_14-11-19
Part C – System Description Section (Ch. 21 – 90)
Page 16 of 22
Manufacturer
Maintenance Manual
62-31-00
AutoGyro
Cavalon
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. The rotor bearing temperature (RBT) sensor is
also allocated to the rotor head bridge, respectively the rotor bearing.
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 ‘hang point’ and represents a cardan hinge.
62-41-00
Rotor RPM Monitoring
Rotor RPM monitoring is realized by an inductive pick-up which is installed with a gap of 3-4 mm at the
sprocket wheel. The sensor counts the (10) holes in the sprocket disc. Rotor RPM is indicated in the
cockpit in an analogue -type instrument which also houses the control electronic. The system requires
power supply.
62-51-00
Rotor Vibration Isolation
A certain level of vibration is inherent to any 2-bladed rotor system. In order to reduce vibration levels
to a minimum, a vibration decoupling element in the rotor mast isolates rotor vibration from the
fuselage. Vibration isolation is realized by two mast mounting bushings which connect the split mast.
IMPORTANT NOTE: Mast mounting bushings are Manufacturer Life Limited (MLL)!
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. This prevents inadvertent activation of the pre-rotator during flight or in
BRAKE mode.
The pre-rotator is activated as long as the respective push-button on the control stick head is
depressed, provided the following pre-conditions are met:



pneumatic mode selector set to FLIGHT
control stick in full forward position
trim pressure less than 3 bar
In this case, the pneumatic clutch is activated and engine torque is transmitted through a 90° gearbox
and drive to the pinion which is engaged by another small pneumatic actuator into the geared ring /
sprocket wheel of the rotor head. The drive pinion is sliding on a helical gear to provide automatic
lock-out in case of rotor RPM overrun. In order to allow necessary changes in length the vertical prerotator drive shaft features a sliding sleeve coupling.
NOTE: In order to simplify pre-rotation AutoGyro GmbH has developed a new 90degree-gearbox with a transmission ratio specially geared to the Cavalon. The new
gearbox is factory installed from serial numbers (Werk-Nr.) V00036 on, or may be
retrofittet as a unit together with the pneumatic clutch.
The modified transmission ratio allows simpler handling during pre-rotation using
a slightly increased clutch speed. The configuration state pneumatic clutch III (new
90-degreegearbox) is easily discernible by having a black OVERDRIVE push button
instead of a red one.
Pneumatic clutches / gearboxes shall be retrofitted to configuration state III.
MMM-CV-C_14-11-19
Part C – System Description Section (Ch. 21 – 90)
Page 17 of 22
Manufacturer
Maintenance Manual
AutoGyro
Cavalon
The pre-rotator can be activated in BRAKE position to park the rotor blades fore-aft for taxi. To do so,
the pre-rotator push-button and the overdrive/override switch in the cockpit panel have to be pressed
simultaneously. Prolonged activation of the pre-rotator with rotor brake engaged should be avoided.
63-11-10
Pre-rotator Lower Engagement
Pre-rotator lower engagement consists of the pneumatically activated clutch.
For pneumatic control of the clutch refer to CHAPTER 36 - PNEUMATIC.
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 clutch. The pre-rotator drive shaft features a cardan joint right after the 90degree gearbox and a sliding shaft coupling in the upper area to allow changes in length due to the tilt
of the rotor head.
63-11-30
Pre-rotator Upper Engagement
The pre-rotator upper engagement comprises a drive pinion with bearing, which is engaged by a small
pneumatic actuator into the geared ring / sprocket wheel of the rotor head. The drive pinion is sliding
on a helical gear to provide automatic lock-out in case of rotor RPM overrun.
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. In order to increase brake pressure, move
the 4-way trim switch to aft. Note that this action will also push the control stick forward. At full brake
pressure the control stick will be maintained in its full forward position.
Due to its main function the pneumatic brake/trim actuator/cylinder itself is allocated to 67-05-00 Pitch
Trim.
CHAPTER 64-66 - N/A
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 (Manufacturer Life Limited!) which are routed vertically along
the mast and connected to the rotor head bridge.
Control stick head
Pitch and roll of the gyroplane is controlled by tilting the complete
rotor head by means of the control stick. Control input is transferred
via torsion tube and linkage running below the seats to the base link
and from there to the rotor head via push-pull control cables.
The control stick head is ergonomically shaped to fit the pilot’s right
hand and features control buttons for radio transmission (1), a fourway trim function (2), and activation of the pre-rotator (3).
67-05-00
Pitch Trim System / Rotor Brake
The Pitch Trim System comprises of a 4-way beep trim switch (2) /
“Chinese Hat” at the flight control stick and the pitch trim / brake
pneumatic actuator. Pneumatic control is allocated to and described
in CHAPTER 36. Components related to the rotor brake are allocated
to 63-51-00 Rotor Brake System.
MMM-CV-C_14-11-19
1 – Radio transmission
2 – Trim switch
3 – Pre-rotator
Part C – System Description Section (Ch. 21 – 90)
Page 18 of 22
Manufacturer
Maintenance Manual
AutoGyro
Cavalon
Trimming is effected by varying trim pressure in the pneumatic trim actuator which is installed in
parallel with the rotor head tilt for pitch control. Aft or nose-up trimming activates the electrical
compressor and increases trim pressure, causing the actuator to contract, and tilting the rotor disc aft.
Forward trimming opens the pressure relief valve to reduce trim pressure and allows the rotor disc to
flatten, due to the spindle head offset and the gyroplane’s weight. The actual trim condition is indicated
on the trim/brake pressure gauge in the centre panel of the cockpit.
67-06-00
Roll Trim System
Lateral/roll trim is available as an option and works accordingly, using a lateral pneumatic trim cylinder
installed in addition. With this option installed, lateral trim condition is indicated by a LED bar on the
instrument panel.
CHAPTER 68-70 - UNASSIGNED / N/A
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.
71-10-00
Engine Cowling
Concerning engine cowlings see CHAPTER 52 - DOORS, COVERS AND COWLINGS.
71-20-00
Engine Mounts
Attachment points for the engine installation are provided by a steel tube ring mount at the rear of the
mast. To provide vibration isolation, the engine is connected to the ring frame by 4 rubber mounting
bushings. The engine mounting bushings have to be inspected regularly and have to be replaced, if
torn or porous. Defective rubber bushing can also cause undue engine/propeller vibration.
IMPORTANT NOTE: Engine mounting bushings are Manuf. Life Limited (MLL)!
71-30-00
Engine Firewalls
An engine fire wall, installed at the rear end of the monocoque fuselage, isolates the engine
compartment from equipment installed at the rear wall, fuel tanks and passenger cabin. The engine
fire wall consists of a fixed part (inner part) and a removable part which is shaped like a ‘u’ around the
fixed part and overlap with the latter. The removable part actually consists of two parts joint by
connecting bolts which, in most cases, do not need to be separated at removal or installation.
71-50-00
Engine Electrical Harness
The engine electrical harness includes wiring, cables and cockpit switches for starting, energizing and
grounding of the dual breakerless capacitor discharge ignition circuits (including instructor killing
switches, if installed), and engine indication. A wiring diagram is provided in Part D of this manual.
Also refer to the engine manufacturer’s documentation.
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 air intake through
air filters mounted on each of the carburettors.
71-70-00
Engine Drains
Oil tank breathing is provided by a rubber hose that exits through lower engine cowling to the outside.
MMM-CV-C_14-11-19
Part C – System Description Section (Ch. 21 – 90)
Page 19 of 22
Manufacturer
Maintenance Manual
AutoGyro
Cavalon
CHAPTER 72 TO 74 - ENGINE RELATED
For the (core) engine refer to the engine manufacturer’s documentation in its latest revision.
Concerning fuel system (Filter, Pumps, Shut-off valve) see CHAPTER 28.
Engine cowlings are described in CHAPTER 52. For removal and installation see the dedicated Job
Card in Part E of this manual.
CHAPTER 75 - AIR / ENGINE COOLING
Engine cooling is provided by ram air cooled cylinders and liquid cooled cylinder heads. Therefore,
cylinder head temperature (CHT) indication in the cockpit corresponds to water temperature. 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 / overflow bottle with radiator cap, and hoses.
NOTE: The expansion tank / overflow bottle is located in the ram air duct in the
lower portion of the forward mast cover.
A single, large area radiator is mounted above the engine so that cooling air from the ram air duct
passes through the cooler, is directed around the engine’s cylinders, and finally escapes through gills
at the lower engine cowling. Force cooling is ensured by an electrically driven ducted fan controlled by
a thermo switch. A push-button in the cockpit allows manual activation temporarily which is typically
used to avoid possible heat build-up after shut-down.
For the relevant checking and replenishing procedures, refer to engine manufacturer’s manual.
Oil cooling is described in CHAPTER 79.
MMM-CV-C_14-11-19
Part C – System Description Section (Ch. 21 – 90)
Page 20 of 22
Manufacturer
Maintenance Manual
AutoGyro
Cavalon
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 / Choke
Engine power / throttle is controlled by a control
column installed in the centre console between
the crew seats. The unit combines a choke
control (3) as well as a lever for activation of the
wheel brake.
Throttle control (1) is conventional with IDLE in
aft (or pulled) and full throttle in most forward
position. With the ROTAX 914 UL engine the
boost range is entered by overcoming a small
resistance to the front. The throttle lever is linked
with cable controls to the carburettors. A
mechanical spring applies tension to the control
cables and brings the carburettors to full throttle
in case of a cable break. The throttle lever has a
pre-set friction brake which holds the throttle in
the selected position.
Throttle and brake panel
1 – Throttle lever
2 – Brake lever with locking pawl
3 – Choke control
4 – Cabin heating (if installed)
Choke (3) is used start a cold engine. In order to
do so, pull the choke lever fully to the rear or ON
position and be sure to have the throttle in idle
position. After starting the engine and a short warm-up, the choke can be slowly disengaged by
moving the lever into its forward or OFF position.
76-20-00
Engine Shutdown / Emergency
For normal and emergency shutdown, a pair of magneto switches (MAG 1 + MAG 2) is installed in the
cockpit centre panel. The magneto switches are also used for testing the individual ignition circuits.
The switches are protected against inadvertent operation by sheet metal safety plates.
CHAPTER 77 - ENGINE INDICATING
All relevant engine parameters are displayed in the cockpit, using analogue-type instruments in
standard version. In case of integrated cockpit systems (option), engine data may be displayed in the
integrated instrumentation system (glass cockpit). An hour meter (Hobbs Meter) is installed in the
cockpit to count engine operating time with an accuracy of two decimals (1/100 hrs). Although the
‘engine operating time’ is also used for total aircraft hours counting, the hour meter is allocated to this
chapter as the main function.
77-10-00
Power
With a piston engine with fixed pitch propeller, engine power indication solely consists of an engine
RPM indicator. In case a variable pitch propeller is installed, a manifold absolute pressure (MAP)
indicator is provided in addition. See CHAPTER 31 for different cockpit layouts.
77-20-00
Temperature
For temperature indication, a cylinder head temperature (CHT) gauge is provided. Due to the engine
cooling principle (ram-air cooled cylinders with water cooled cylinder heads) the CHT represents water
temperature at cylinder 2 head.
Oil temperature indication is described in CHAPTER 79 – OIL SYSTEM.
MMM-CV-C_14-11-19
Part C – System Description Section (Ch. 21 – 90)
Page 21 of 22
Manufacturer
Maintenance Manual
77-40-00
AutoGyro
Cavalon
Integrated Engine Instrument Systems
Integrated display systems (glass cockpit) are described in 31-60-00 Integrated Display Systems.
CHAPTER 78 - EXHAUST
78-00-00
Exhaust
The basic exhaust system including manifold and turbo charger with waste gate (only ROTAX 914) is
part of the core engine. Refer to the engine manufacturer’s documentation. The exhaust system is
supplemented by a silencer/muffler supplied by AutoGyro.
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.
79-11-00
Storage / Oil tank
The oil reservoir with dipstick is accessed through a cover on the right hand side of the fuselage. The
cover is held by 3 cam lock fasteners which can be locked or unlocked by a quarter turn. The oil tank
is made of stainless steel with oil filler cap. The cap can be unscrewed / tightened by a quarter rotation
in order to check the oil level using a dip stick or for replenishing of engine oil.
The type of lubrication system requires a special procedure for accurate oil level checking and to
prevent overfilling. Refer to the engine manufacturer documentation for detail and procedures.
79-20-00
Distribution and Cooling
Oil distribution and cooling is provided by a separate oil cooler, which is connected to the oil circuit by
oil hoses and a thermostat assembly.
79-21-00
Oil Hoses and Lines
Oil hoses are made of fabric reinforced rubber, or steel braided lines in later versions.
79-22-00
Oil Cooler
An oil cooler is fitted to the lower aft end of the fuselage. Oil flow through the cooler is regulated by a
thermostat assembly which opens the cooler circuit at approximately 80 – 90 °C
79-30-00
Indicating
Indicators of Oil Pressure (Oil-P) and Oil Temperature (Oil-T) are provided in the cockpit as analoguetype instruments in standard version. See CHAPTER 31 for different cockpit layouts.
MMM-CV-C_14-11-19
Part C – System Description Section (Ch. 21 – 90)
Page 22 of 22
Manufacturer
Maintenance Manual
AutoGyro
Cavalon
Contents
Wiring Diagram – Aircraft Main Wiring Harness .......................................................................................3
Wiring Diagram – Cockpit RH...................................................................................................................5
Wiring Diagram – Optional Comfort Features Seats ................................................................................7
Wiring Diagram – Flight Control Sticks.....................................................................................................9
Wiring Diagram – Landing Lights ...........................................................................................................11
Wiring Diagram – NAV / Strobe Lights ...................................................................................................13
Wiring Diagram – Cockpit LH (Standard) ...............................................................................................15
Wiring Diagram – Main Fuse / Battery ...................................................................................................17
Wiring Diagram – Cockpit Centre ...........................................................................................................19
Wiring Diagram – Cockpit (General) ......................................................................................................21
Wiring Diagram – Pneumatic System (Standard / Comfort) ...................................................................23
Wiring Diagram – Fuel Pumps................................................................................................................25
Wiring Diagram – Fuel Level and Low Level Sensors ...........................................................................27
Wiring Diagram – Engine Wiring Harness ..............................................................................................29
Wiring Diagram – Engine Turbo Control Unit (TCU) Wiring Harness ....................................................31
Pneumatic Scheme - Standard...............................................................................................................33
Pneumatic Scheme - Comfort ................................................................................................................35
Retrofit: End Position Detection IVO Propeller .......................................................................................37
MMM-CV-D_15-01-09
Part D – Diagrams and Charts
Page 1 of 38
Manufacturer
Maintenance Manual
AutoGyro
Cavalon
INTENTIONALLY LEFT BLANK
MMM-CV-D_15-01-09
Part D – Diagrams and Charts
Page 2 of 38
Manufacturer
Maintenance Manual
AutoGyro
Cavalon
Wiring Diagram – Aircraft Main Wiring Harness
MMM-CV-D_15-01-09
Part D – Diagrams and Charts
Page 3 of 38
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Part D – Diagrams and Charts
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MMM-CV-D_15-01-09
Part D – Diagrams and Charts
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Manufacturer
Maintenance Manual
AutoGyro
Cavalon
Contents
07-00-00 2-1
LIFTING OF THE GYROPLANE
07-00-00 2-2
JACKING OF THE GYROPLANE
07-00-00 2-3
SHORING OF THE GYROPLANE
08-20-00 2-1
LEVELING OF THE GYROPLANE
24-30-00 4-1
REMOVAL-INSTALLATION: BATTERY
24-30-00 8-1
25-60-00 0-1
MODIFICATION: ELECTRICAL POWER SUPPLY TO THE FUEL PUMP I VIA
RECTIFIER-REGULATOR (ROTAX 914)
DESCRIPTION: EMERGENCY LOCATOR TRANSMITTER (ELT)
26-00-00 0-1
DESCRIPTION: FIRE INDICATING SYSTEM
27-10-00 5-1
CHECK-ADJUSTMENT: ROLL CONTROL TRAVEL LIMITATION
27-20-00 5-1
CHECK-ADJUSTMENT: RUDDER CONTROL ANGLES
28-20-00 6-1
INSPECTION: FUEL FILTER
28-20-00 8-1
REPLACEMENT: FUEL FILTER
28-20-00 8-2
REPLACEMENT: ELECTRICAL FUEL PUMPS
32-10-00 8-1
REPLACEMENT: MAIN GEAR SUSPENSION BOW ATTACHMENT BOLTS
32-20-00 8-1
REPLACEMENT: NOSE GEAR RUBBER DAMPER
32-40-00 4-1
REMOVAL-INSTALLATION: WHEELS
32-40-00 8-1
REPLACEMENT: BRAKE LOCKING MECHANISM (see 76-10-00 8-1)
32-40-00 8-2
REPLACEMENT: MAIN WHEEL BRAKE PADS
32-40-00 8-3
REPLACEMENT: WHEEL BEARING
34-10-00 5-1
TEST: PITOT STATIC SYSTEM INTEGRITY
34-10-00 7-1
CLEANING: PITOT STATIC SYSTEM
36-21-00 8-1
REPLACEMENT: FILTER/DRYER
52-00-00 4-1
REMOVAL-INSTALLATION: COWLINGS
52-40-00 0-1
DESCRIPTION: SERVICE COVERS IN COCKPIT SHELL
55-00-00 8-1
REPLACEMENT: KEEL TUBE PROTECTION PAD
56-00-00 8-1
REPAIR: CRACKS IN ACRYLIC GLASS
61-10-00 4-1
REMOVAL-INSTALLATION: PROPELLER - HTC
61-10-00 4-2
DISASSEMBLY-ASSEMBLY: PROPELLER - HTC
61-10-00 5-1
ADJUSTMENT: PROPELLER PITCH - HTC
61-10-00 8-2
RETROFIT: END POSITION DETECTION IVO PROPELLER
61-20-00 1-1
TROUBLE-SHOOTING: IVO-VARIABLE PITCH PROPELLER
62-11-00 4-1
REMOVAL: ROTOR - TEETERING PARTS
62-11-00 4-2
DISASSEMBLY: ROTOR - TEETERING PARTS
62-11-00 4-3
ASSEMBLY: ROTOR - TEETERING PARTS
62-11-00 4-4
INSTALLATION: ROTOR - TEETERING PARTS
62-11-00 5-1
CHECK-ADJUSTMENT: ROTOR SYSTEM ALIGNMENT
62-11-00 6-1
INSPECTION: ROTOR - TEETERING PARTS
62-11-00 6-2
INSPECTION: ROTOR BLADES
62-11-00 6-3
INSPECTION: ROTOR HUB BOLTS
62-11-00 8-1
REPLACEMENT: TEETER BUSHINGS
62-20-00 8-1
REPLACEMENT: DRIVE GEAR
62-31-00 5-1
CHECK-ADJUSTMENT: ROTOR HEAD MAIN BOLT AXIS
62-31-00 6-1
INSPECTION: ROTOR HEAD BRIDGE, BEARING AND TEETER TOWER
MMM-CV-E_16-06-13
Part E - Content
Page 1 of 2
Manufacturer
Maintenance Manual
AutoGyro
Cavalon
62-32-00 5-1
CHECK-ADJUSTMENT: ROTOR CONTROL FRICTION
62-32-00 6-1
INSPECTION: ROTOR GIMBAL HEAD
62-51-00 4-1
REMOVAL-INSTALLATION: TOP MAST
62-51-00 6-1
INSPECTION: MAST MOUNTING BUSHINGS
62-51-00 8-1
REPLACEMENT: MAST MOUNTING BUSHINGS
63-11-10 4-1
REMOVAL-INSTALLATION: PRE-ROTATOR CLUTCH
63-11-10 5-1
CHECK-ADJUSTMENT: PRE_ROTATOR CLUTCH
63-11-10 6-1
INSPECTION: PRE-ROTATOR CLUTCH
63-11-10 8-1
REPLACEMENT: PRE-ROTATOR CLUTCH LINING
63-11-10 8-2
REPLACEMENT: PRE-ROTATOR CLUTCH DOG GEAR
63-11-30 6-1
INSPECTION: PRE-ROTATOR UPPER ENGAGEMENT
63-11-30 8-1
REPLACEMENT: PRE-ROTATOR UPPER BEARINGS
63-11-30 8-2
REPAIR: PRE-ROTATOR UPPER ENGAGEMENT
63-51-00 8-1
REPLACEMENT: ROTOR BRAKE PAD
67-00-00 5-1
CHECK-ADJUSTMENT: ROTOR CONTROL ANGLES (see 62-32-00 6-1)
67-00-00 6-1
INSPECTION: FLIGHT CONTROL PUSH-PULL CABLES
67-00-00 8-1
RETROFIT: PPC CLAMPS
67-05-00 8-1
REPLACEMENT: PITCH TRIM/BRAKE PNEUMATIC SEAL
67-10-00 4-1
REMOVAL-INSTALLATION: CENTRE CONSOLE
71-20-00 6-1
INSPECTION: CLEARANCE ENGINE INSTALLATION (R914)
71-30-00 4-1
REMOVAL-INSTALLATION: FIRE WALL
75-00-00 4-1
REMOVAL-INSTALLATION:RADIATOR
75-00-00 8-2
MODIFICATION: RECONFIGURE FAN REVERSE
78-20-00 8-1
REPLACEMENT: WOOL OF MUFFLER TUBE
MMM-CV-E_16-06-13
Part E - Content
Page 2 of 2
Manufacturer
Maintenance Manual
07-00-00 2-1
AutoGyro
Cavalon
LIFTING OF THE GYROPLANE
LNE
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!
Rotor system must be removed, see 62-11-00 4-1
SPECIAL TOOLS AND CONSUMABLE MATERIALS
None
PRECAUTIONS AND SAFETY MEASURES
WARNING: Object is heavy! Inadequate handling could cause injury. Use proper lifting techniques or
assistance!
WARNING: When working with cranes or other lifting equipment the general safety regulations have to be
respected at all times!
CAUTION: Never attempt to lift gyroplane with rotor system attached!
PROCEDURES
1
Re-install teeter bolt, hand-tighten castellated nut and secure castellated nut adequately.
2
Loop a lifting belt around the teeter bolt and carefully lift the gyroplane.
CAUTION: Do not use a chain or any lifting gear that could damage the surface of the teeter
bolt
ILLUSTRATIONS
Lifting belt looped around teeter bolt
MMM-CV-E_16-06-13
Part E - 07-00-00 2-1
Page 1 of 1
Manufacturer
Maintenance Manual
07-00-00 2-2
JACKING OF THE GYROPLANE
AutoGyro
Cavalon
LNE
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!
Gyroplane must be placed on level ground and restrained (blocks, chocks)
SPECIAL TOOLS AND CONSUMABLE MATERIALS
None
PRECAUTIONS AND SAFETY MEASURES
PROCEDURES
Unload nose gear
1
In order to unload the nose gear lift at the jacking point at the fuselage belly right behind nose wheel, using a
soft non-slip lining.
Unload main gear
2
In order to unload one of the main wheels carefully lift at the main gear suspension spar. Use a soft non-slip
lining and chose lifting point close to the centre, but on the side of the affected wheel.
3
Continue to jack slowly and let the gyroplane rest stable on nose wheel, one main wheel and jack. Weights
may be used on the opposite side of the suspension spar.
NOTE: Sand bags or load may be used to add additional weight on the desired side.
4
Secure gyroplane adequately before commencing work and do not leave unattended in jacked position.
MMM-CV-E_16-06-13
Part E - 07-00-00 2-2
Page 1 of 1
Manufacturer
Maintenance Manual
07-00-00 2-3
AutoGyro
Cavalon
SHORING OF THE GYROPLANE
OPR
GENERAL, REFERENCES AND REQUIREMENTS
Basic operational task, which can be performed by a licensed pilot or instructed personnel!
Rotor system must be removed, see 62-11-00 4-1
SPECIAL TOOLS AND CONSUMABLE MATERIALS
None
PRECAUTIONS AND SAFETY MEASURES
CAUTION: Never use tie-down equipment or lashing straps in a way that would excert unsupported stress
or high momentum on the structure of the gyroplane!
CAUTION: The suspension bow is not designed to take up high longitudinal forces!
PROCEDURES
Shoring, road transport or container transport
WARNING: The rotor system must be removed, disassembled and carefully packed for road
transport.
CAUTION: When wrapping the gyroplane make sure that foil or stretch does not cover the
painted surface directly. Put a soft layer in between for damage protection and let plastic
components breathe. Do not expose wrapped gyroplane or parts to sun radiation or heat in
order to avoid paint damage.
1
Restrain main wheels (blocks/chocks). For container transport replace main wheels with wooden blocks to
provide safe stand.
2
Put a wooden block below the lowest point of the keel tube and lash keel tube against wooden block. The
block should be dimensioned so that the main wheels (if installed) are half way unloaded.
3
Lash-down both main wheels through the lashing lugs (use rims/axles alternatively) and/or the mast tie-down
kit (option).
4
Lash-down nose wheel through its axle.
5
For container transport or shipping, use the mast tie-down kit (option) and consider folding the mast.
PARTS LIST
Fig. Pos. Description
shipping attachment mast
MMM-CV-E_16-06-13
PC PIT
Remark
85-00-00-V-33480
Part E - 07-00-00 2-3
Page 1 of 2
Manufacturer
Maintenance Manual
AutoGyro
Cavalon
ILLUSTRATIONS
Fig. 1 - Lash-down methods of gyroplane
MMM-CV-E_16-06-13
Part E - 07-00-00 2-3
Page 2 of 2
Manufacturer
Maintenance Manual
08-20-00 2-1
AutoGyro
Cavalon
LEVELING OF THE GYROPLANE
LNE
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!
Gyroplane must be placed on level ground and restrained (blocks, chocks)
SPECIAL TOOLS AND CONSUMABLE MATERIALS
None
PRECAUTIONS AND SAFETY MEASURES
PROCEDURES
Measurement of Stabilizer Alignment
1
Measure distance from the edge of the stabilizer fin to the door handle recess (see Fig. 1). Note values for
RH and LH side.
2
RH dimension must be equal or less LH dimension. If in doubt contact AutoGyro customer support.
ILLUSTRATIONS
Fig. 1 - Measurement of Stabilizer Alignment (RH side shown)
MMM-CV-E_16-06-13
Part E - 08-20-00 2-1
Page 1 of 1
Manufacturer
Maintenance Manual
24-30-00 4-1
REMOVAL-INSTALLATION: BATTERY
AutoGyro
Cavalon
LNE
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!
Engine cowlings must be removed, see 52-00-00 4-1
Fire wall must be removed, see 71-30-00 4-1
SPECIAL TOOLS AND CONSUMABLE MATERIALS
LR
IMPORTANT NOTE: Procedure involves parts with limited reusability. Check parts list below
before starting job!
PRECAUTIONS AND SAFETY MEASURES
WARNING: Electrical shorting of the battery will produce high current with the risk of personal injury and
damage to equipment!
PROCEDURES
Removal
WARNING: Be careful to avoid electrical short cuts at all means.
1
Remove ground (L-) connection at the frame and isolate metallic cable shoe.
2
Remove hot (L+) cable at the battery.
3
Untighten battery retainer and remove battery.
Installation
4
Install battery in reverse order (work steps 3 to 1).
ILLUSTRATIONS
Fig. 1 - Installation Position Battery
MMM-CV-E_16-06-13
Part E - 24-30-00 4-1
Page 1 of 1
Manufacturer
Maintenance Manual
24-30-00 8-1
AutoGyro
Cavalon
MODIFICATION: ELECTRICAL POWER SUPPLY TO THE
FUEL PUMP I VIA RECTIFIER-REGULATOR (ROTAX 914)
HVY
GENERAL, REFERENCES AND REQUIREMENTS
Task may only be performed by an organization trained and entitled to carry out 'Heavy Maintenance'!
Secure gyroplane against unauthorized or unintended operation!
Self-locking nuts and split pins must only be used once and discarded! Check availability of new hardware before
commencing work!
Engine cowlings must be removed, see 52-00-00 4-1
Battery must be disconnected, see 24-30-00 4-1, steps 1-2
Fire wall must be removed, see 71-30-00 4-1
SPECIAL TOOLS AND CONSUMABLE MATERIALS
PRECAUTIONS AND SAFETY MEASURES
WARNING: Electrical shorting of the battery will produce high current with the risk of personal injury and
damage to equipment!
CAUTION: Failure to comply with this instruction will cause the loss of warranty referred and/or related
components.
PROCEDURES
1
Remove engine air filter.
2
Remove cable connector from rectifier-regulator (Fig. 1).
3
Remove all fuses and elect. contacts from the fuse carrier (Fig. 1).
4
Remove fuse carrier (Fig. 1) from fire wall.
5
Remove blade connector from cable connector position C and cut off, insulate and tie back wires with
insulating tape.
6
Remove blade connectors from cable connector positions R and B, discard cable.
7
Modify fuse carrier according to Fig.2 and reinstall fuse carrier in origin location to fire wall.
8
Connect rectifier-regulator bridge to cable connector, positions R, B and C.
9
Install fuses to safety carrier: - Upper right 30 A - Lower right 30 A - Upper left 10 A - Lower left 125 A
10 Connect ring-eye cable connectors to fuse box:
11 Outer upper right: Rectifier-regulator bridge
12 Middle lower right: Battery hot (L+) cable
13 Outer lower right: Cockpit
14 Outer lower left: Magneto switch
15 Outer upper left: Capacitor / fuel pump I
16 Middle lower left: Relay (red / long) 4 mm
2
17 Middle upper right: Relay (red / short) 4 mm
2
18 Middle upper left:
20 Screw relay on the upper left attachment bolt of the engine mount (just above the fuse carrier / use
attachment gear from 24-00-00-S-36780). Relay contacts must face downwards (Fig. 3)
21 Connect the black wire of the capacitor to the upper rectifier-regulator foot.
22 Connect wires to relay as follows:
MMM-CV-E_16-06-13
Part E - 24-30-00 8-1
Page 1 of 3
Manufacturer
Maintenance Manual
AutoGyro
Cavalon
23 86:Fuel pumps wiring harness (black)
24 85 Fuel pumps wiring harness (blue)
25 30: Fuse carrier, middle upper right: (red / short) 4 mm
26 87 Fuse carrier, middle lower left (red / long) 4 mm
2
2
27 Route fuel pumps wiring harness above the fuse carrier and behind the engine mount down to the fuel
pumps.
28 Secure capacitor with cable ties and spacers to fuel hose and engine mount. CAUTION: Capacitor must not
touch directly the fuel hose! (Fig. 4)
29 Reconnect cable connector to rectifier-regulator.
30 Disconnect the old fuel pumps wiring harness from fuel pumps P1, P2, disconnect the yellow connector,
remove pump wiring harness.
31 Connect the blue/white and respective black wire of the fuel pump wiring harness to fuel pump P2 (upper
pump) and connect the red and respective black wire of the fuel pump wiring harness to fuel pump P1 (lower
pump). Secure electrical contacts of both fuel pumps with securing paint.
32 Connect yellow cable connector of fuel pump wiring harness (Fig. 5 - 3)
33 Secure fuel pump wiring harness with cable ties and spacers.
34 Reinstall engine air filter.
PARTS LIST
Fig. Pos. Description
1
1
PC PIT
Conversion Kit 914 - P1 to charge controller
Remark
L2 24-00-00-S-36780
ILLUSTRATIONS
Fig. 2 – Modified fuse carrier
Fig. 1 - Cable connector on rectifier-regulator (1) and fuse
carrier (2)
MMM-CV-E_16-06-13
Part E - 24-30-00 8-1
Page 2 of 3
Manufacturer
Maintenance Manual
AutoGyro
Cavalon
Fig. 3 – Attachment of the relay
Fig. 4 – Secured capacitor
Fig. 5 – Fuel pumps P1 / P2 and cable connector of fuel pump
wiring harness
MMM-CV-E_16-06-13
Part E - 24-30-00 8-1
Page 3 of 3
Manufacturer
Maintenance Manual
25-60-00 0-1
AutoGyro
Cavalon
DESCRIPTION: EMERGENCY LOCATOR TRANSMITTER
(ELT)
HVY
GENERAL, REFERENCES AND REQUIREMENTS
Task may only be performed by an organization trained and entitled to carry out 'Heavy Maintenance'!
SPECIAL TOOLS AND CONSUMABLE MATERIALS
CMM
Refer to the component/device manufacturer's documentation.
PRECAUTIONS AND SAFETY MEASURES
Refer to the component/device manufacturer's documentation!
PROCEDURES
CAUTION: Device may only be tested with proper testing equipment. Intentional activation
for testing without proper testing equipment will lead to false alarms which may initiate an
expensive search and rescue alarm chain.
ILLUSTRATIONS
Fig. 1 - Installation Position ELT
MMM-CV-E_16-06-13
Part E - 25-60-00 0-1
Page 1 of 1
Manufacturer
Maintenance Manual
26-00-00 0-1
DESCRIPTION: FIRE INDICATING SYSTEM
AutoGyro
Cavalon
HVY
GENERAL, REFERENCES AND REQUIREMENTS
SPECIAL TOOLS AND CONSUMABLE MATERIALS
PRECAUTIONS AND SAFETY MEASURES
PROCEDURES
MMM-CV-E_16-06-13
Part E - 26-00-00 0-1
Page 1 of 2
Manufacturer
Maintenance Manual
AutoGyro
Cavalon
ILLUSTRATIONS
Tbl. 1 - Indication Logic
Fig. 2 - Installation - seen from behind
Fig. 3 - Installation - seen from LH side
Fig. 4 - Installation - seen from RH side
Fig. 5 - Installation (detail)
MMM-CV-E_16-06-13
Part E - 26-00-00 0-1
Page 2 of 2
Manufacturer
Maintenance Manual
27-10-00 5-1
AutoGyro
Cavalon
CHECK-ADJUSTMENT: ROLL CONTROL TRAVEL
LIMITATION
LNE
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!
Rotor system must be removed, see 62-11-00 4-1
Service cover for control linkage must be removed, see 52-40-00 0-1.
SPECIAL TOOLS AND CONSUMABLE MATERIALS
88-00-00-S-33588 Screw Securing and Thread-Sealing Varnish yellow
PRECAUTIONS AND SAFETY MEASURES
WARNING: Job includes work at critical flight controls. Duplicate inspection must be performed after
completion!
CAUTION: Failure to comply with this instruction will cause the loss of warranty referred and/or related
components.
PROCEDURES
1
Release brake pressure from rotor head by switching the pneumatic mode selector to ‘flight’. If necessary
switch between ‘brake’ and ‘flight’ several times to release brake pressure completely.
NOTE: Procedure will only be successful by checking and adjusting with flight control
sticks in neutral pitch position.
Check
2
Move and hold control sticks in fully left position so that left gimbal head stop is reached.
3
Measure gap at the base control unit between stop screw and ball joint on pilot side (RH), gap must be 2
mm.
4
Move and hold control sticks in fully right position so that right gimbal head stop is reached.
5
Measure gap at the base control unit between stop screw and ball joint on passenger side (LH), gap must be
2 mm.
Adjustment
6
Move and hold control sticks in fully left position so that left gimbal head stop is reached.
7
Untighten counter nut of the stop screw at the base control unit on pilot side (RH). Adjust stop screw until gap
between stop screw and ball joint is 2 mm.
8
Counter-tighten the counter nut to the stop screw to fix the adjustment.
9
Apply screw securing varnish to stop screw thread, counter nut and base control link to seal the fixed
adjustment.
10 Move and hold control sticks in fully right position so that right gimbal head stop is reached. Repeat steps 7 –
9 on the passenger side (LH).
MMM-CV-E_16-06-13
Part E - 27-10-00 5-1
Page 1 of 1
Manufacturer
Maintenance Manual
27-20-00 5-1
AutoGyro
Cavalon
CHECK-ADJUSTMENT: RUDDER CONTROL ANGLES
LNE
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!
SPECIAL TOOLS AND CONSUMABLE MATERIALS
PRECAUTIONS AND SAFETY MEASURES
PROCEDURES
NOTE: Measure points are aft rudder edge and left/right radius between stabilizer and
vertical outer fins.
1
Adjust pedals in neutral position
Note that the nose wheel should be pointed 3° to the left with pedals neutral.
2
Check/adjust N1 = 900 mm (+/- 10 mm) and N2 = 840 mm (+/- 10 mm). See Fig. 1 for reference.
3
Press full left pedal (with nose wheel slightly unloaded for ease of movement) and check/adjust L = 630 mm
(+/- 50 mm). See Fig. 1 for reference.
4
Press full right pedal (with nose wheel slightly unloaded for ease of movement) and check/adjust R = 530 mm
(+/- 50 mm). See Fig. 1 for reference.
5
Check push-pull control cables (threaded articulation rods) tight and secure.
MMM-CV-E_16-06-13
Part E - 27-20-00 5-1
Page 1 of 3
Manufacturer
Maintenance Manual
AutoGyro
Cavalon
ILLUSTRATIONS
Fig. 1 - Rudder control angle
setting
MMM-CV-E_16-06-13
Part E - 27-20-00 5-1
Page 2 of 3
Manufacturer
Maintenance Manual
AutoGyro
Cavalon
Fig. 2 - Measurement Procedure (example)
MMM-CV-E_16-06-13
Part E - 27-20-00 5-1
Page 3 of 3
Manufacturer
Maintenance Manual
28-20-00 6-1
AutoGyro
Cavalon
INSPECTION: FUEL FILTER
LNE
GENERAL, REFERENCES AND REQUIREMENTS
Task may only be performed by an organization or individual trained and entitled to carry out 'Line Maintenance'!
Engine cowlings must be removed, see 52-00-00 4-1
Fire wall must be removed, see 71-30-00 4-1
SPECIAL TOOLS AND CONSUMABLE MATERIALS
SP
IMPORTANT NOTE: Procedure involves spare parts. Check parts list below for ordering
details of affected components!
PRECAUTIONS AND SAFETY MEASURES
WARNING: Fuel and fuel vapors are HAZARDOUS MATERIAL, must be treated and handled accordingly,
and constitute a danger to health and hardware!
IMPORTANT NOTE: Depending on engine variant and optional equipment, number and type of installed
fuel filters may differ!
PROCEDURES
EFFECTIVITY: Engine variant ROTAX 912 (without second fuel pump P2)
1
Perform a visual inspect on nylon filter.
2
If contamination is found, nylon fuel filter must be replaced, see 28-20-00 8-1.
EFFECTIVITY - END
EFFECTIVITY: Engine variant ROTAX 912 with second fuel pump P2
NOTE: Fuel system consists of one nylon filter upstream of the mechanical fuel pump, a
(secondary) electrical fuel pump with built-in strainer and another filter (KL145) downstream
3
Perform a visual inspect on nylon filter.
4
If contamination is found or in case of scheduled replacement, nylon fuel filter AND KL145 must be replaced,
see 28-20-00 8-1 and strainer in electrical fuel pump must be inspected.
5
In order to do so, clamp both fuel lines to prevent fuel from spilling and disconnect incoming (lower) fuel line.
6
Carefully remove strainer from electrical fuel pump and inspect.
7
Clean strainer if necessary. Use brake cleaner and compressed air applied from the outside.
8
In case of residual contamination or damage, strainer has to be replaced, see 28-20-00 8-1.
EFFECTIVITY - END
EFFECTIVITY: Engine variant ROTAX 914
NOTE: Fuel system consists of two electrical fuel pumps with built-in strainer, each
preceded by a filter (KL145) downstream
9
Inspect strainer for both electrical fuel pumps. In order to do so, refer to 28-20-00 8-1.
10 In case of residual contamination or damage, strainer has to be replaced, see 28-20-00 8-1.
11 In any case, both KL145 filters must be replaced, see 28-20-00 8-1.
EFFECTIVITY - END
MMM-CV-E_16-06-13
Part E - 28-20-00 6-1
Page 1 of 2
Manufacturer
Maintenance Manual
AutoGyro
Cavalon
PARTS LIST
Fig. Pos. Description
PC PIT
Remark
1
1
Nylon fuel filter KL 23
L1 73-00-00-V-20575
1
2
Filter KL 145
L1 73-00-00-V-20581
1
3
Fuel Pump 912
L1 73-00-00-V-30199
1
4
fuel pump 914 serialised
L1 73-00-00-S-31394
ILLUSTRATIONS
Fig. 1 - Fuel pumps and filters (detail)
MMM-CV-E_16-06-13
Fig. 2 - Fuel pumps and filters (detail)
Part E - 28-20-00 6-1
Page 2 of 2
Manufacturer
Maintenance Manual
28-20-00 8-1
AutoGyro
Cavalon
REPLACEMENT: FUEL FILTER
LNE
GENERAL, REFERENCES AND REQUIREMENTS
Task may only be performed by an organization or individual trained and entitled to carry out 'Line Maintenance'!
Engine cowlings must be removed, see 52-00-00 4-1
Fire wall must be removed, see 71-30-00 4-1
SPECIAL TOOLS AND CONSUMABLE MATERIALS
SP
IMPORTANT NOTE: Procedure involves spare parts. Check parts list below for ordering
details of affected components!
PRECAUTIONS AND SAFETY MEASURES
WARNING: Fuel and fuel vapors are HAZARDOUS MATERIAL, must be treated and handled accordingly,
and constitute a danger to health and hardware!
PROCEDURES
NOTE: Depending on engine variant and optional equipment, number/type of installed fuel
filters may differ
1
CAUTION: Before disconnecting any fuel lines, clamp respective hoses to prevent fuel spillage.
Applicable to Nylon Filter and KL145
2
Disconnect filter and replace with new filter.
3
Re-connect hoses to filter and make sure tight fit (no leaks, dry).
4
Remove clamps from fuel hoses.
PARTS LIST
Fig. Pos. Description
PC PIT
1
1
Nylon fuel filter KL 23
L1 73-00-00-V-20575
1
2
Filter KL 145
L1 73-00-00-V-20581
1
3
Fuel Pump 912
L1 73-00-00-V-30199
1
4
fuel pump 914 serialised
L1 73-00-00-S-31394
MMM-CV-E_16-06-13
Part E - 28-20-00 8-1
Remark
Page 1 of 2
Manufacturer
Maintenance Manual
AutoGyro
Cavalon
ILLUSTRATIONS
Fig. 1 - Fuel pumps and filters (detail)
MMM-CV-E_16-06-13
Fig. 2 - Fuel pumps and filters (detail)
Part E - 28-20-00 8-1
Page 2 of 2
Manufacturer
Maintenance Manual
28-20-00 8-2
AutoGyro
Cavalon
REPLACEMENT: ELECTRICAL FUEL PUMPS
LNE
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!
Engine cowlings must be removed, see 52-00-00 4-1
Fire wall must be removed, see 71-30-00 4-1
SPECIAL TOOLS AND CONSUMABLE MATERIALS
SP
IMPORTANT NOTE: Procedure involves spare parts. Check parts list below for ordering
details of affected components!
PRECAUTIONS AND SAFETY MEASURES
WARNING: Fuel and fuel vapors are HAZARDOUS MATERIAL, must be treated and handled accordingly,
and constitute a danger to health and hardware!
PROCEDURES
WARNING: Make sure the electrical system is switched off and protected against
unintended activation
1
Clamp respective hoses to prevent fuel spillage.
2
Unscrew both terminal nuts and disconnect both ring eye cable connectors. Isolate blank connectors to
prevent electrical short-cut.
3
Disconnect fuel lines from pump.
4
Untighten attachment hardware and replace fuel pump.
5
Install new fuel pump and tighten attachment hardware.
IMPORTANT NOTE: The electrical terminals of the pump and the ring-eye cable connectors
have different diameters to ensure correct polarization
6
Re-connect electrical cable connectors and tighten terminal nuts. Secure terminal nuts with securing paint.
7
Re-connect hoses to pump and make sure tight fit.
8
Remove clamps from fuel hoses.
9
Activate respective fuel pump an check function and proper fuel line connection (no leaks, dry).
PARTS LIST
Fig. Pos. Description
PC PIT
Remark
1
1
Fuel Pump 912
L1 73-00-00-V-30199 ROTAX 912
1
2
fuel pump 914
L1 73-00-00-S-31395 ROTAX 914
MMM-CV-E_16-06-13
Part E - 28-20-00 8-2
Page 1 of 2
Manufacturer
Maintenance Manual
AutoGyro
Cavalon
ILLUSTRATIONS
Fig. 1 - El. fuel pump terminal (detail)
MMM-CV-E_16-06-13
Part E - 28-20-00 8-2
Page 2 of 2
Manufacturer
Maintenance Manual
32-10-00 8-1
AutoGyro
Cavalon
REPLACEMENT: MAIN GEAR SUSPENSION BOW
ATTACHMENT BOLTS
HVY
GENERAL, REFERENCES AND REQUIREMENTS
Task may only be performed by an organization trained and entitled to carry out 'Specialized Level Tasks'!
Secure gyroplane against unauthorized or unintended operation!
SPECIAL TOOLS AND CONSUMABLE MATERIALS
None
PRECAUTIONS AND SAFETY MEASURES
MANUFACTURER RECOMMENDATION: Fuel tanks should be defueled before starting task!
WARNING: Fuel and fuel vapors are HAZARDOUS MATERIAL, must be treated and handled accordingly,
and constitute a danger to health and hardware!
PROCEDURES
1
Remove main gear suspension bow cover (Fig. 1, 1).
2
Open service cover (Fig. 1, 2).
3
Untighten and remove bolt (Fig. 2, 1).
4
Clamp 10 mm drill bit into appropriate drill machine and equip drill bit with washers in order to avoid
damaging the fuel tank (Fig. 3).
WARNING: Do not damage or even puncture fuel tank!
5
Drill up the 8 mm drill hole with drill and with washers equipped 10 mm – drill bit (Fig. 4).
EFFECTIVITY: up to S/N (Werk-Nr.) V00089
6
Equip bolt M 10 x 100 with washer U10/30 and insert bolt M 10 x 100 into drill hole, place washer U10/30 and
M10 self-locking nut and hand tighten through the service opening.
EFFECTIVITY: S/N (Werk-Nr.) V00090 and subsequent
7
Equip bolt M 10 x 90 with washer U10/30 and insert bolt M 10 x 90 into the hole, place washer U10/30 and
M10 self-locking nut and hand tighten through the service opening.
8
Repeat work steps 3 - 6 with second bolt (Fig. 2, 2).
9
Torque-tighten bolts (Fig. 2, 1 and 2) with 35 Nm.
10 Perform tool and loose-article check in service opening and close service cover.
11 Install gear suspension bow cover.
PARTS LIST
Fig. Pos. Description
attachmt. kit for undercarriage
MMM-CV-E_16-06-13
PC PIT
Remark
L2 32-00-00-S-34611
Part E - 32-10-00 8-1
Page 1 of 2
Manufacturer
Maintenance Manual
AutoGyro
Cavalon
ILLUSTRATIONS
Fig. 1 - Main gear suspension bow cover and service cover
Fig. 2 - Main gear suspension bow
Fig. 3 - 10 mm drill bit equipped with washers
Fig. 4 - Drilling to a diameter of 10 mm
MMM-CV-E_16-06-13
Part E - 32-10-00 8-1
Page 2 of 2
Manufacturer
Maintenance Manual
32-20-00 8-1
AutoGyro
Cavalon
REPLACEMENT: NOSE GEAR RUBBER DAMPER
LNE
GENERAL, REFERENCES AND REQUIREMENTS
Task may only be performed by an organization or individual trained and entitled to carry out 'Line Maintenance'!
Gyroplane must be jacked, see 07-00-00 2-2
SPECIAL TOOLS AND CONSUMABLE MATERIALS
AG-BAS-02
Loctite 243 blue (88-00-00-S-30483)
AG-GRS-01
Lagermeister WHS 2002 Grease (88-00-00-S-30477)
PRECAUTIONS AND SAFETY MEASURES
PROCEDURES
1
Remove bolt (1) and washer (2).
2
Pull control linkage (3) from square shaft. Caution: Hold wheel assembly and prevent from falling out. Discard
O-ring (4)!
3
Pull out front wheel assembly. Note that bushings (5) and (7) remain in the fuselage.
4
Remove rubber damper (8).
5
Install new rubber damper.
6
Apply AG-GRS-01 on the tube, but not on the threads. Install nose wheel assembly in reverse order. Make
sure wheel assembly is installed so that angled fork faces forward, i.e. extends to the front.
7
Install new O-ring (4).
8
Install control linkage (3) and washer (2).
9
Apply AG-BAS-02 to inner threads of nose gear assembly and install bolt (1).
10 Torque-tighten bolt (1) with 40 Nm.
PARTS LIST
Fig. Pos. Description
PC PIT
1
1
M10x20
NPI
1
2
U11x34x3
NPI
1
3
nose wheel steering
NPI
1
4
O-Ring 30x5
1
5
steering bush
1
6
nosewheel fork long welded
1
7
steering bush
1
8
shock absorber 2,5
1
9
Nose wheel spat nosewheel painted
1
10 M6x12 round head
NPI
1
11 U6/18
NPI
1
12 M10, Si
NPI
1
13 U10
NPI
1
14 Nosewheel axle M10x155 DIN 912
NPI
1
15
32-00-00-V-31914
MMM-CV-E_16-06-13
Remark
NPI
L2 32-00-00-V-22169
NPI
L2 32-00-00-V-22169
NPI
L1 53-00-00-V-32070
Part E - 32-20-00 8-1
Page 1 of 2
Manufacturer
Maintenance Manual
AutoGyro
Cavalon
ILLUSTRATIONS
Fig. 1 - Nose gear assembly
MMM-CV-E_16-06-13
Part E - 32-20-00 8-1
Page 2 of 2
Manufacturer
Maintenance Manual
32-40-00 4-1
AutoGyro
Cavalon
REMOVAL-INSTALLATION: WHEELS
LNE
GENERAL, REFERENCES AND REQUIREMENTS
Task may only be performed by an organization or individual trained and entitled to carry out 'Line Maintenance'!
Gyroplane must be jacked, see 07-00-00 2-2
SPECIAL TOOLS AND CONSUMABLE MATERIALS
AG-BAS-02
Loctite 243 blue (88-00-00-S-30483)
LR
IMPORTANT NOTE: Procedure involves parts with limited reusability. Check parts list below
before starting job!
PRECAUTIONS AND SAFETY MEASURES
PROCEDURES
Nose wheel - Removal
NOTE: If no assembly hole is present in wheel spat it is recommended to drill a hole through
which the bolt can be removed. Otherwise, the wheel spat must be removed.
1
Unscrew and remove nut (Fig.1, 12) and washer (Fig.1, 13). Discard nut.
2
Pull out and remove bolt (Fig.1, 14) with washer (Fig.1, 13) and remove wheel. Maintain spacers (Fig.1, 15)!
Nose wheel - Installation
3
Install wheel with spacers (Fig.1, 15) in place, bolt (Fig.1, 14) with washers (Fig.1, 13) in reverse order.
4
Install new self-locking nut (Fig.1, 12) and torque-tighten with 35 Nm.
5
Install plug in assembly hole, if required.
Main wheel - Removal
6
Remove wheel spat (if installed).
7
Remove and discard split pin (Fig. 3, 5) and unscrew the castellated nut (Fig.3, 18). Discard split pin (Fig. 3,
5).
8
Unscrew and remove 4 x bolt (Fig. 3, 3) with serrated washer (Fig. 3, 4). Mind limited reusability of serrated
washer!
9
Remove wheel from axle assembly (Fig. 3, 7/9).
Main wheel - Installation
10 Insert main wheel on axle assembly (Fig. 3, 7/9).
11 Insert 4 x bolt (Fig. 3, 3) with new serrated washer (Fig. 3, 4) and attach brake disc to main wheel.
12 Torque-tighten bolts (Fig. 3, 3) with 10 Nm in crosswise sequence.
13 Install castellated nut (Fig. 3, 18) and torque-tighten nut with 35 Nm.
14 Install split pin (Fig. 3, 5).
15 Check free rotation of wheel, radial run-out and braking action.
16 Install wheel spat, if required.
PARTS LIST
Fig. Pos. Description
PC PIT
1
1
M10x20
NPI
1
2
U11x34x3
NPI
MMM-CV-E_16-06-13
Part E - 32-40-00 4-1
Remark
Page 1 of 4
Manufacturer
Maintenance Manual
1
3
nose wheel steering
1
4
O-Ring 30x5
1
5
steering bush
1
6
nosewheel fork long welded
1
7
steering bush
1
8
shock absorber 2,5
1
9
Nose wheel spat nosewheel painted
1
10 M6x12 round head
NPI
1
11 U6/18
NPI
1
12 M10, Si
NPI
1
13 U10
NPI
1
14 Nosewheel axle M10x155 DIN 912
NPI
1
15
32-00-00-V-31914
3
1
53-00-00-V-32781
3
2
3
3
M6x12 round head
L1 32-40-00-V-30004
3
4
Safety washer M6
L1 32-40-00-V-30004
3
5
Split pin 3.2x40
L1 32-00-00-V-32136
3
6
spacer 26-5/20,2
L1 32-00-00-V-32136
3
7
wheel axis welded
L1 32-00-00-V-32136
3
8
Stop nut M6
L1 32-00-00-V-32136
3
9
brake caliper bracket installed
L1 32-00-00-V-32136
3
10 M6x25 counter sunk
3
11 Brake caliber
3
12 Brake pad outer (small)
L2 32-40-00-V-30512
3
13 Brake Disc
L1 32-40-00-V-30004
3
14 Cylinder bushing 22x10x6
3
15 Brake pad inner (big)
3
16 Safety washer M6
NPI
3
17 M6x40
NPI
3
18 castle nut M18x1
L1 32-00-00-V-32136
3
19 Alu bush Prerotator brake
L1 53-00-00-V-32781
3
20 U6/25 Big washer
L1 53-00-00-V-32781
3
21 M6x60 rounded head
L1 53-00-00-V-32781
4
1
Roller bearing 6204 ZRS
L2 32-00-00-V-20078
4
2
Tube standard
L0 32-00-00-V-26651
4
3
Tyre standard
L0 32-00-00-V-20080
4
4
Rimm installed
L1 32-00-00-V-30595
4
5
Spacer wheel
L1 32-00-00-V-30595
4
6
Roller bearing 6204 ZRS
L2 32-00-00-V-20078
AutoGyro
Cavalon
NPI
NPI
L2 32-00-00-V-22169
NPI
L2 32-00-00-V-22169
NPI
L1 53-00-00-V-32070
53-00-00-V-32781
MMM-CV-E_16-06-13
L1 32-00-00-V-32136
NPI
NPI
L2 32-40-00-V-30511
Part E - 32-40-00 4-1
Page 2 of 4
Manufacturer
Maintenance Manual
AutoGyro
Cavalon
ILLUSTRATIONS
Fig. 1 - Nose gear assembly
Fig. 2 - Nose wheel
MMM-CV-E_16-06-13
Part E - 32-40-00 4-1
Page 3 of 4
Manufacturer
Maintenance Manual
AutoGyro
Cavalon
Fig. 3 - Main gear assembly
Fig. 4 - Main wheel
MMM-CV-E_16-06-13
Part E - 32-40-00 4-1
Page 4 of 4
Manufacturer
Maintenance Manual
32-40-00 8-2
AutoGyro
Cavalon
REPLACEMENT: MAIN WHEEL BRAKE PADS
LNE
GENERAL, REFERENCES AND REQUIREMENTS
Task may only be performed by an organization or individual trained and entitled to carry out 'Line Maintenance'!
Gyroplane must be jacked, see 07-00-00 2-2
Affected wheel must be removed, see 32-40-00 4-1
SPECIAL TOOLS AND CONSUMABLE MATERIALS
AG-LUB-04
Silicone Spray (88-00-00-S-30490)
LR
IMPORTANT NOTE: Procedure involves parts with limited reusability. Check parts list below
before starting job!
SP
IMPORTANT NOTE: Procedure involves spare parts. Check parts list below for ordering
details of affected components!
PRECAUTIONS AND SAFETY MEASURES
IMPORTANT NOTE: Procedure involves handling and disposal of special materials. For your health and
environmental aspects respect all applicable regulations!
PROCEDURES
1
Pull out brake disc (13) between brake pads.
2
Remove 4 x shaft bolt (17) with serrated washer (16).
3
Remove brake pad (12) and (15). Dispose of properly!
4
Clean 4 x guide sleeves of axle assembly (14) and inspect for damage, scores or run-in grooves.
5
Apply a thin layer of silicone spray on guide sleeves of axle assembly.
6
Fit new brake pad (12) onto lower guide sleeves.
7
Fit new brake pad (15) onto upper guide sleeves.
8
Insert 4 x shaft bolt (17) with serrated washers (16) and torque-tighten with 10 Nm. Make sure that brake
caliper and pad moves easily about the running sleeve.
9
Insert brake disc between brake pads.
10 In order to re-install wheel continue with 32-40-00 4-1.
PARTS LIST
Fig. Pos. Description
PC PIT
1
1
1
2
1
3
M6x12 round head
L1 32-40-00-V-30004
1
4
Safety washer M6
L1 32-40-00-V-30004
1
5
Split pin 3.2x40
L1 32-00-00-V-32136
1
6
spacer 26-5/20,2
L1 32-00-00-V-32136
1
7
wheel axis welded
L1 32-00-00-V-32136
1
8
Stop nut M6
L1 32-00-00-V-32136
1
9
brake caliper bracket installed
L1 32-00-00-V-32136
1
10 M6x25 counter sunk
1
11 Brake caliber
1
12 Brake pad outer (small)
L2 32-40-00-V-30512
1
13 Brake Disc
L1 32-40-00-V-30004
Remark
53-00-00-V-32781
53-00-00-V-32781
MMM-CV-E_16-06-13
L1 32-00-00-V-32136
NPI
Part E - 32-40-00 8-2
Page 1 of 2
Manufacturer
Maintenance Manual
1
14 Cylinder bushing 22x10x6
1
15 Brake pad inner (big)
1
16 Safety washer M6
NPI
1
17 M6x40
NPI
1
18 castle nut M18x1
L1 32-00-00-V-32136
1
19 Alu bush Prerotator brake
L1 53-00-00-V-32781
1
20 U6/25 Big washer
L1 53-00-00-V-32781
1
21 M6x60 rounded head
L1 53-00-00-V-32781
AutoGyro
Cavalon
NPI
L2 32-40-00-V-30511
ILLUSTRATIONS
Fig. 1 - Main wheel with brake
MMM-CV-E_16-06-13
Part E - 32-40-00 8-2
Page 2 of 2
32-40-00 8-3
Manufacturer
Maintenance Manual
AutoGyro
Cavalon
REPLACEMENT: WHEEL BEARING
HVY
GENERAL, REFERENCES AND REQUIREMENTS
Task may only be performed by an organization trained and entitled to carry out 'Heavy Maintenance'!
Gyroplane must be jacked, see 07-00-00 2-2
Affected wheel must be removed, see 32-40-00 4-1
SPECIAL TOOLS AND CONSUMABLE MATERIALS
ContactAG
For special tools or assistance contact AutoGyro customer support
PRECAUTIONS AND SAFETY MEASURES
PROCEDURES
1
Perform work according to exploded views.
PARTS LIST
Fig. Pos. Description
PC PIT
2
1
Roller bearing 6204 ZRS
L2 32-00-00-V-20078
2
2
Tube standard
L0 32-00-00-V-26651
2
3
Tyre standard
L0 32-00-00-V-20008
2
4
Rimm installed
L1 32-00-00-V-30595
2
5
Spacer wheel
L1 32-00-00-V-30595
2
6
Roller bearing 6204 ZRS
L2 32-00-00-V-20078
MMM-CV-E_16-06-13
Part E - 32-40-00 8-3
Remark
Page 1 of 2
Manufacturer
Maintenance Manual
AutoGyro
Cavalon
ILLUSTRATIONS
Fig. 1 - Nose wheel
Fig. 2 - Main wheel and bearing
MMM-CV-E_16-06-13
Part E - 32-40-00 8-3
Page 2 of 2
Manufacturer
Maintenance Manual
34-10-00 5-1
AutoGyro
Cavalon
TEST: PITOT STATIC SYSTEM INTEGRITY
LNE
GENERAL, REFERENCES AND REQUIREMENTS
Task may only be performed by an organization or individual trained and entitled to carry out 'Line Maintenance'!
SPECIAL TOOLS AND CONSUMABLE MATERIALS
ContactAG
For special tools or assistance contact AutoGyro customer support
PRECAUTIONS AND SAFETY MEASURES
CAUTION: Instruments can easily be damaged if test is performed improperly. Manipulate test equipment
slowly and carefully. Monitor indicators and make sure that indication is always within normal indication
range!
PROCEDURES
Pitot System Test
1
Pull-out plunger of test equipment for the pitot nozzle (long silicone tube) to read 2 ml.
2
Attach test equipment to pitot nozzle.
3
Slowly depress plunger to read 1 ml. Airspeed indication must increase significantly.
NOTE: The actual value will depend on the length and cross-section of the pipework
installed.
4
Leave set-up unchanged and check decay over 10 seconds. Decay should be less than 10% per 10
seconds.
5
Gently ease tube off the pitot nozzle. Airspeed indicator(s) must return to zero.
6
If any of the preceding tests has failed, have system inspected and repaired.
Static System Test (if installed)
7
Block one static port with a strip of tape.
NOTE: Do not use transparent tape as this may be overlooked and forgotten. It is
recommended to use red insulating tape with a relatively large extending end.
8
Press in plunger of test equipment for the static port (short silicone adapter) completely.
9
Press and hold test equipment to the open static port tight to the hole.
10 Pull plunger slowly about 3 ml.
11 Indicated altitude and airspeed indication must increase.
12 If installed, VSI indication must increase momentarily and will slowly fade to zero.
13 Leave set-up unchanged and check decay over 10 seconds. There shall be no noticeable decay (except
VSI).
14 Remove silicone adapter from static port. Altitude must return to initial indication.
15 If any of the preceding tests has failed, have system inspected and repaired.
MMM-CV-E_16-06-13
Part E - 34-10-00 5-1
Page 1 of 2
Manufacturer
Maintenance Manual
AutoGyro
Cavalon
ILLUSTRATIONS
Fig. 1 - Pitot Static Integrity Test Equipment
Fig. 2 - Pitot Static Instruments Connecting Diagram
MMM-CV-E_16-06-13
Part E - 34-10-00 5-1
Page 2 of 2
34-10-00 7-1
Manufacturer
Maintenance Manual
AutoGyro
Cavalon
CLEANING: PITOT STATIC SYSTEM
LNE
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!
SPECIAL TOOLS AND CONSUMABLE MATERIALS
PRECAUTIONS AND SAFETY MEASURES
CAUTION: Make sure all pitot and static lines are disconnected from any instruments before blowing
through the lines!
CAUTION: Do not blow with the mouth directly into pitot or static ports. This will introduce moisture and
may damage instruments!
PROCEDURES
1
Disconnect all instruments from pitot and static lines. These are altimeter, airspeed, but also VSI and
integrated display systems, if installed.
NOTE: In most cases it is not necessary to remove the instrument panel.
2
With the help of compressed air clean all pitot and static lines by blowing from the inside (cockpit panel side)
to the outside.
3
Make sure to clean/check each branch of a line by closing the other open ends.
4
Re-connect all instruments and perform Pitot Static System Integrity Test, see 34-10-00 5-1.
ILLUSTRATIONS
Fig. 1 - Static ports (2 x ) and pitot port
MMM-CV-E_16-06-13
Part E - 34-10-00 7-1
Page 1 of 2
Manufacturer
Maintenance Manual
AutoGyro
Cavalon
Fig. 2 - Pitot Static Instruments Connecting Diagram
MMM-CV-E_16-06-13
Part E - 34-10-00 7-1
Page 2 of 2
Manufacturer
Maintenance Manual
36-21-00 8-1
AutoGyro
Cavalon
REPLACEMENT: FILTER/DRYER
LNE
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!
Engine cowlings must be removed, see 52-00-00 4-1
Fire wall must be removed, see 71-30-00 4-1
SPECIAL TOOLS AND CONSUMABLE MATERIALS
PRECAUTIONS AND SAFETY MEASURES
PROCEDURES
1
Unscrew inlet and outlet connection and discard old seal ring (compressor side only).
2
Replace filter/dryer with new one and make sure cartridge is tightened safely to rear wall. Install new seal
ring.
3
Re-connect and tighten inlet and outlet connection with moderate torque.
ILLUSTRATIONS
Fig. 1 - Rear wall (installation wall)
MMM-CV-E_16-06-13
Fig. 2 - Filter/dryer
Part E - 36-21-00 8-1
Page 1 of 1
Manufacturer
Maintenance Manual
52-00-00 4-1
AutoGyro
Cavalon
REMOVAL-INSTALLATION: COWLINGS
OPR
GENERAL, REFERENCES AND REQUIREMENTS
Basic operational task, which can be performed by a licensed pilot or instructed personnel!
Secure gyroplane against unauthorized or unintended operation!
SPECIAL TOOLS AND CONSUMABLE MATERIALS
PRECAUTIONS AND SAFETY MEASURES
PROCEDURES
Upper engine cowling (1) - Removal
1
Open all quick lock fasteners using a PH2 screw driver.
2
With help of a second person carefully remove upper engine cowling to the top.
Upper engine cowling (1) - Installation
3
With the help of a second person bring engine cowling into position.
4
Fasten all quick locks fasteners using a PH2 screw driver.
Lower engine cowling (2) - Removal
5
Upper engine cowling must be removed!
6
Remove all linse head bolts with poly washers and maintain. Make sure not to lose poly washers. The
cowling should be held by a second person.
7
With the help of a second person remove cowling. Make sure not to damage engine drain hoses.
Lower engine cowling (2) - Installation
8
Upper engine cowling must be removed!
9
With the help of a second person bring cowling into position. Make sure to insert drain hoses without
damage.
10 Insert linse head bolts with poly washers and screw in without tightening, preferably working from top to
bottom.
11 Fasten all bolts with 3 Nm.
Mast cover (3) - Removal
12 Remove and maintain linse head bolts with poly washers and remove mast cover.
13 Carefully bend open mast cover and slide over the mast to the front.
Mast cover (3) - Installation
25 Install mast cover in reverse order (work steps 13 - 12).
26 Fasten all bolts with 3 Nm.
MMM-CV-E_16-06-13
Part E - 52-00-00 4-1
Page 1 of 2
Manufacturer
Maintenance Manual
AutoGyro
Cavalon
ILLUSTRATIONS
Fig. 1 - Cowling and mast cover
MMM-CV-E_16-06-13
Part E - 52-00-00 4-1
Page 2 of 2
Manufacturer
Maintenance Manual
52-40-00 0-1
DESCRIPTION: SERVICE COVERS IN COCKPIT SHELL
AutoGyro
Cavalon
LNE
GENERAL, REFERENCES AND REQUIREMENTS
SPECIAL TOOLS AND CONSUMABLE MATERIALS
PRECAUTIONS AND SAFETY MEASURES
PROCEDURES
MMM-CV-E_16-06-13
Part E - 52-40-00 0-1
Page 1 of 2
Manufacturer
Maintenance Manual
AutoGyro
Cavalon
ILLUSTRATIONS
Fig. 1 - Service covers below seats ('Equipment Cover')
Fig. 2 - Service cover for control linkage (LH) and below
seat (RH)
MMM-CV-E_16-06-13
Fig. 3 - Rear Wall 'Installation Wall' (Fire Wall removed)
Part E - 52-40-00 0-1
Page 2 of 2
Manufacturer
Maintenance Manual
55-00-00 8-1
AutoGyro
Cavalon
REPLACEMENT: KEEL TUBE PROTECTION PAD
LNE
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!
SPECIAL TOOLS AND CONSUMABLE MATERIALS
AG-BAS-01
Loctite 221 red (88-00-00-S-30487)
SP
IMPORTANT NOTE: Procedure involves spare parts. Check parts list below for ordering
details of affected components!
PRECAUTIONS AND SAFETY MEASURES
PROCEDURES
1
Remove 2 x bolt and replace protection pad.
2
Apply AG-BAS-01 on threads of bolts an tighten.
ILLUSTRATIONS
Fig. 1 - Installation position of keel tube protection pad
MMM-CV-E_16-06-13
Part E - 55-00-00 8-1
Page 1 of 1
Manufacturer
Maintenance Manual
56-00-00 8-1
AutoGyro
Cavalon
REPAIR: CRACKS IN ACRYLIC GLASS
OPR
GENERAL, REFERENCES AND REQUIREMENTS
Basic operational task, which can be performed by a licensed pilot or instructed personnel!
Repair only by a competent person.
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.
SPECIAL TOOLS AND CONSUMABLE MATERIALS
PRECAUTIONS AND SAFETY MEASURES
WARNING Do not execute procedure in pilot´s line of sight!
CAUTION Acrylic glass may not get in contact with thinners, alcohol, fuels etc. Window cleaner contain
mostly alcohol. Vapours of thinners in workshops are also damaging.
NOTE The material strength in the area of repair is impaired.
®
NOTE Only AGOVIT 1900 is approved.
®
NOTE Adhesive (AGOVIT 1900 + KATALYSATOR 20) must be processed as quick as possible.
PROCEDURES
1
Clean acrylic glass with dishwashing liquid solution (2-3 drops per 0.2 l lukewarm tap water) and a clean
sponge; let air dry or dry with damp chamois leather; for the repair material and adhesive should have a
temperature of approx. 20°C.
2
Ensure a clean work environment with a temperature of approx. 20°C and good lighting conditions (day light
is recommended).
3
Recommendation: If possible temper the acrylic glass at 80°C before and after the repair for avoiding stress
cracks – material thickness divided by 3 to get the tempering duration in hours.
4
Stop drill the crack at the end using a 1.5 mm drill bit.
5
Fix crack with adhesive tape on the material bottom side, mill with low revolutions per minute (approx. 3000
-1
min ) and low pressure a channel into material top side using a small multifunction rotary tool (Fig. 1).
6
Remove shavings carefully.
7
Position material so the crack is horizontal and mask the surrounding, intact acrylic glass with adhesive tape.
Keep a distance to the edge of the channel of approx. 2 mm.
8
Stir AGOVIT 1900 with 3-6 % hardener KATALYSATOR 20 in a PE-cup or glass bubble-free using a glass
or metal stirring rod.
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 (Fig. 2). Any air
bubbles or dirt particles can be pushed into the bead of adhesive to the top, as this will later be sanded away
again. Next layers will be applied when the last layer is after approximately one hour hardened so far that it is
not possible to push a nail or wire in.
®
10 After application of the last layer let adhesive seam harden for two hours at approx. 20°C.
11 Turn material upside-down.
-1
12 Mill with low revolutions per minute (approx. 3000 min ) and low pressure a channel into material bottom
side using a small multifunction rotary tool (Fig. 3).
13 Proceed as in steps 7-10 (Fig. 4).
14 Sand adhesive area as follows, begin with the convex outside of the acrylic glass:
MMM-CD-E_16-02-08
Part E - 56-00-00 8-1
Page 1 of 2
Manufacturer
Maintenance Manual
AutoGyro
Cavalon
15 Create dishwashing liquid solution (2-3 drops per 0.2 l lukewarm tap water). Sand with grit 320 wet
sandpaper and dishwashing liquid solution to the surface of the tape.
16 When the adhesive tape is scratched, remove these and shade the area extensively with a felt pen (Edding
blue or red).
17 Create new dishwashing liquid solution (2-3 drops per 0.2 l lukewarm tap water). Rinse to be sanded area
and aids with dishwashing liquid solution. When carrying on wet sanding with grit 600 and dishwashing liquid
solution can now be seen exactly where material is removed.
18 Create new dishwashing liquid solution (2-3 drops per 0.2 l lukewarm tap water). Rinse to be sanded area
and aids with dishwashing liquid solution. Shade again (Edding blue or red) before reaching the surrounding
surface and continue sanding with grit 900 wet sandpaper and dishwashing liquid solution until the shaded
area and the adhesive bead are equally abraded.
19 Create new dishwashing liquid solution (2-3 drops per 0.2 l lukewarm tap water). Rinse to be sanded area
and aids with dishwashing liquid solution. With MicroMesh abrasive cloth grit 3200, a cellular rubber sanding
block and dishwashing liquid solution to carry on wet sanding until the surface is uniformly rough.
20 Create new dishwashing liquid solution (2-3 drops per 0.2 l lukewarm tap water). Rinse to be sanded area
and aids with dishwashing liquid solution. Finish-sand with Micro Mesh abrasive cloth grit 8000, a cellular
rubber sanding block and dishwashing liquid solution.
21 Create new dishwashing liquid solution (2-3 drops per 0.2 l lukewarm tap water). Clean acrylic glass with
dishwashing liquid solution and a clean sponge; let air dry or dry with damp chamois leather.
®
22 Polish with a polishing pad and polishing agent XERAPOL . Applicate a pea-sized mass of polishing agent
-1
on the polishing pad. The speed must be selected not higher than approx. 800 min . The polishing pad may
not be used for too long on one place. Remove at regular intervals used polishing agent with an unused
polishing cloth and repeat the process with new polishing agent. The XERAPOL® should result in a closed,
silky shimmering layer during polishing. If this is not the case, the amount of polishing agent is too small.
ILLUSTRATIONS
Fig. 1 – Milling of a channel on material top side
Fig. 2 – Filled channel on material top side
Fig 3. - Channel on material bottom side
Fig 4. - Filled channels on material top and bottom side
MMM-CD-E_16-02-08
Part E - 56-00-00 8-1
Page 2 of 2
Manufacturer
Maintenance Manual
61-10-00 4-1
AutoGyro
Cavalon
REMOVAL-INSTALLATION: PROPELLER - HTC
LNE
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!
SPECIAL TOOLS AND CONSUMABLE MATERIALS
AG-BAS-02
Loctite 243 blue (88-00-00-S-30483)
PRECAUTIONS AND SAFETY MEASURES
CAUTION: When removing or disassembling make sure to mark all parts so that each and every part of
the component is re-assembled and installed in exactly the same location and orientation!
PROCEDURES
Removal
1
Before removing the spinner (optional equipment) check marking (filed notch) is available on spinner (1) and
spinner base plate (8). If not, the installation position has to be marked accordingly.
2
Unscrew and remove bolts (9) with poly washers (10) and remove spinner.
3
Mark installation position of propeller hub, engine flange and spinner base plate (if installed) relative to each
other.
4
Release torque on each bolt (4) by turning bolt half a revolution in counter-clockwise direction. Do not
untighten or unscrew bolts (4)!
5
Unscrew and remove bolts (2) and washers (3).
Installation
6
Install propeller hub, bolts (2) with washers (3) in its original installation position.
7
Torque-tighten bolts (2) with 15 Nm in crosswise sequence.
8
Torque-tighten bolts (4) with 10 Nm in crosswise sequence.
9
Install spinner (1), spinner bolts (9) with poly washers (10). Make sure spinner is in correct installation
position relative to spinner base plate. Check marking.
10 Secure spinner bolts (9) with AG-BAS-02 and torque-tighten with 3 Nm in crosswise sequence.
MMM-CV-E_16-06-13
Part E - 61-10-00 4-1
Page 1 of 2
Manufacturer
Maintenance Manual
AutoGyro
Cavalon
PARTS LIST
Fig. Pos. Description
PC PIT
Remark
1
1
spinner HTC3B, painted
1
2
M8x110
L2 53-00-00-V-30587
NPI
1
3
U8/24
NPI
1
4
M6x40
NPI
ROTAX 914
1
4
M6x40
NPI
ROTAX 912
1
5
Propeller hub rear
L3 61-00-00-V-21191 ROTAX 912
1
5
Propeller hub front
L3 61-00-00-V-21190 ROTAX 914
1
6
61-00-00-V-32203 ROTAX 912
1
6
61-00-00-S-32464 ROTAX 914
1
7
Propeller hub rear
L3 61-00-00-V-21191 ROTAX 914
1
7
Propeller hub front
L3 61-00-00-V-21190 ROTAX 912
1
8
Spinner Plate
NPI
1
9
71-00-00-V-31051
1
10 U4, Poly
NPI
1
11 torque bush spacer
NPI
1
12 spacer propeller
NPI
ILLUSTRATIONS
Fig. 1 - Propeller HTC
MMM-CV-E_16-06-13
Part E - 61-10-00 4-1
Page 2 of 2
Manufacturer
Maintenance Manual
61-10-00 4-2
AutoGyro
Cavalon
DISASSEMBLY-ASSEMBLY: PROPELLER - HTC
LNE
GENERAL, REFERENCES AND REQUIREMENTS
Task may only be performed by an organization or individual trained and entitled to carry out 'Line Maintenance'!
Propeller must be removed, see 61-10-00 4-1
SPECIAL TOOLS AND CONSUMABLE MATERIALS
PRECAUTIONS AND SAFETY MEASURES
PROCEDURES
Disassembly
1
Mark inner and outer propeller hub to indicate relative installation position.
2
Place propeller assembly on a horizontal and clean surface and support propeller hub so that assembly does
not lie on propeller blades.
3
Unscrew and remove bolts (4).
4
Remove outer propeller hub and remove individual blades.
Assembly
5
Place inner propeller hub on horizontal and clean surface and support propeller hub.
6
Insert individual blades in correct position.
7
Attach outer propeller hub, insert bolts (4) and hand-tighten.
8
Torque-tighten bolts (4) with 10 Nm in crosswise sequence.
PARTS LIST
Fig. Pos. Description
PC PIT
Remark
1
1
spinner HTC3B, painted
L2 53-00-00-C-30587
1
2
M8x110
NPI
1
3
U8/24
NPI
1
4
M6x40
NPI
ROTAX 912
1
4
M6x40
NPI
ROTAX 914
1
5
Propeller hub front
L3 61-00-00-M-21190 ROTAX 914
1
5
Propeller hub rear
L3 61-00-00-M-21191 ROTAX 912
1
6
1
6
1
7
Propeller hub rear
L3 61-00-00-V-21191 ROTAX 914
1
7
Propeller hub front
L3 61-00-00-V-21190 ROTAX 912
1
8
Spinner Plate
1
9
71-00-00-V-31051
1
10 U4, Poly
NPI
1
11 torque bush spacer
NPI
1
12 spacer propeller
NPI
61-00-00-V-32203 ROTAX 912
61-00-00-S-32464 ROTAX 914
MMM-CV-E_16-06-13
NPI
Part E - 61-10-00 4-2
Page 1 of 2
Manufacturer
Maintenance Manual
AutoGyro
Cavalon
ILLUSTRATIONS
Fig. 1 - Propeller HTC
MMM-CV-E_16-06-13
Part E - 61-10-00 4-2
Page 2 of 2
Manufacturer
Maintenance Manual
61-10-00 5-1
AutoGyro
Cavalon
ADJUSTMENT: PROPELLER PITCH - HTC
LNE
GENERAL, REFERENCES AND REQUIREMENTS
Task may only be performed by an organization or individual trained and entitled to carry out 'Line Maintenance'!
Spinner (if installed) must be removed, see 61-10-00 4-1
SPECIAL TOOLS AND CONSUMABLE MATERIALS
PRECAUTIONS AND SAFETY MEASURES
PROCEDURES
1
Untighten bolts (Fig. 1, 4) so that bolt heads does not contact outer propeller hub.
2
Unscrew bolts (Fig. 1, 2) about 2 revolutions.
3
Position propeller pitch adjustment tool with the inner side on outer propeller hub and profiled section on the
propeller blade.
4
Carefully adjust blade pitch by tapping with a 200 g rubber hammer in the area of the blade's nose section so
that blade pitch increases or decreases. Never use hammer on trailing edge as the blade may be damaged
that way.
5
In order to read the correct setting it is advisable to let the blade's trailing edge rest in (touch) the tool while
allowing a small light gap between blade's back and the tool's profiled section.
6
Repeat work steps 3 to 5 for the remaining blades.
7
Hand-tighten bolts (Fig. 1, 2) and (Fig. 1, 4) and check blade pitch setting for all blades. If necessary,
untighten bolts and re-do from step 1.
8
Torque-tighten bolts (Fig. 1, 2) with 15 Nm in crosswise sequence.
9
Torque-tighten bolts (Fig. 1, 4) with 10 Nm in crosswise sequence.
10 Perform torque-check after first flight or ground run.
PARTS LIST
Fig. Pos. Description
PC PIT
Remark
1
1
spinner HTC3B, painted
1
2
M8x110
L2 53-00-00-C-30587
NPI
1
3
U8/24
NPI
1
4
M6x40
NPI
ROTAX 914
1
4
M6x40
NPI
ROTAX 912
1
5
Propeller hub front
L3 61-00-00-M-21190 ROTAX 914
1
5
Propeller hub rear
L3 61-00-00-M-21191 ROTAX 912
1
6
1
6
1
7
Propeller hub rear
L3 61-00-00-V-21191 ROTAX 914
1
7
Propeller hub front
L3 61-00-00-V-21190 ROTAX 912
1
8
Spinner Plate
61-00-00-V-32203 ROTAX 912
61-00-00-S-32464 ROTAX 914
NPI
1
9
71-00-00-V-31051
1
10 U4, Poly
NPI
1
11 torque bush spacer
NPI
1
12 spacer propeller
NPI
MMM-CV-E_16-06-13
Part E - 61-10-00 5-1
Page 1 of 3
Manufacturer
Maintenance Manual
AutoGyro
Cavalon
ILLUSTRATIONS
Fig. 1 - Propeller HTC
Fig. 2 - Propeller pitch adjustment and tool
MMM-CV-E_16-06-13
Part E - 61-10-00 5-1
Page 2 of 3
Manufacturer
Maintenance Manual
AutoGyro
Cavalon
Fig. 3 - Detail hub
Fig. 4 - Detail blade
MMM-CV-E_16-06-13
Part E - 61-10-00 5-1
Page 3 of 3
Manufacturer
Maintenance Manual
61-10-00 8-2
AutoGyro
Cavalon
RETROFIT: END POSITION DETECTION IVO PROPELLER
OPR
GENERAL, REFERENCES AND REQUIREMENTS
Basic operational task, which can be performed by a licensed pilot or instructed personnel!
Secure gyroplane against unauthorized or unintended operation!
SPECIAL TOOLS AND CONSUMABLE MATERIALS
PRECAUTIONS AND SAFETY MEASURES
CAUTION: Failure to comply with this instruction will cause the loss of warranty referred and/or related
components.
PROCEDURES
1
Contents of the kit (Fig. 1):
1) IVO-Control with pin assignment
2) 2 x Shrinking Hose to isolate unused connectors
3) 2 x LED-Mount for 5mm Status LEDs
4) 3 x Cable Ties to fixate cables and installation
5) Blind Plug to cover installation bore of removed thermo switch
6) Mask for rocker switch and LEDs
7) Rocker switch
8) 4 x screws and 4 x nuts for installation of the mask
2
Pin assignment of wiring harness - top to bottom (Fig. 2):
- red
- orange
- green
- black
- orange/white
- green/white
3
Equip mask as shown in Fig. 3 und install with screws and nuts in cockpit.
4
Fixate LED with mounting ring and nut from behind (see Fig. 4)
CAUTION: Do not push (or pull) at the LED cables. Use proper tools at LED socket.
5
Insert LEDs in mount (use pliers, if needed)
6
LED with cable color orange goes in upper position, green in bottom position.
7
Connect control board with rocker switch:
- Switch/position '1a' (top): green/white
- Switch/position '1' (middle): black
- Switch/position '1b' (bottom): orange/white
CAUTION: Do not mismatch electrical connectors as control board can be destroyed!
8
Connect cockpit controls to control board (see Fig. 5, note condensors facing up):
- white/orange (IVO)
- white/violett (IVO)
- black (GND)
- violett/orange (12V+)
9
Check switching and indication logic (Master switch ‘ON’!):
Press rocker switch ‘fine’ position
upper LED must blink, propeller must adjust to fine (take-off)
Press rocker switch ‘coarse’ pos.
lower LED must blink, propeller must adjust to coarse (cruise)
10 Fixate cables and control board with cable ties.
11 Perform functional check.
MMM-CV-E_16-06-13
Part E - 61-10-00 8-2
Page 1 of 2
Manufacturer
Maintenance Manual
AutoGyro
Cavalon
PARTS LIST
Fig. Pos. Description
PC PIT
Remark
IVO installation kit
L1 24-00-00-V-34771
IVO-end position indicator
L1 24-00-00-V-34759
ILLUSTRATIONS
Fig. 1 - Contents of the Kit
Fig. 2 - Pin assignment of wiring harness
Fig. 3 - Rocker Switch and LEDs
Fig. 4 - Rocker Switch and LEDs - seen from behind
Fig. 5 - Control Board
MMM-CV-E_16-06-13
Part E - 61-10-00 8-2
Page 2 of 2
Manufacturer
Maintenance Manual
61-20-00 1-1
AutoGyro
Cavalon
TROUBLE-SHOOTING: IVO-VARIABLE PITCH PROPELLER LNE
GENERAL, REFERENCES AND REQUIREMENTS
SPECIAL TOOLS AND CONSUMABLE MATERIALS
PRECAUTIONS AND SAFETY MEASURES
WARNING: Electrical shorting of the battery will produce high current with the risk of personal injury and
damage to equipment!
NOTE If it is necessary to connect the collector rings directly to electrical power within the fault tree
analysis pull off contacts from carbon brushes.
PROCEDURES
1
Inspect wear of carbon brushes, replace if necessary
2
Insulating disk may not protrude between collector rings, if necessary remove using a bevelled-edge chisel
3
Polish collector rings with non-woven web, so that collector rings are blank-surfaced
4
Perform ground test run immediately after the foregoing step
5
Do not clean collector rings from carbon abrasion debris (protection against oxidisation)
6
Execute fault tree analysis (Fig. 1)
MMM-CV-E_16-06-13
Part E - 61-20-00 1-1
Page 1 of 2
Manufacturer
Maintenance Manual
AutoGyro
Cavalon
ILLUSTRATIONS
Fig. 1 – Fault Tree IVO Variable Pitch Propeller
MMM-CV-E_16-06-13
Part E - 61-20-00 1-1
Page 2 of 2
Manufacturer
Maintenance Manual
62-11-00 4-1
AutoGyro
Cavalon
REMOVAL: ROTOR - TEETERING PARTS
OPR
GENERAL, REFERENCES AND REQUIREMENTS
Basic operational task, which can be performed by a licensed pilot or instructed personnel!
SPECIAL TOOLS AND CONSUMABLE MATERIALS
AG-BAS-01
Loctite 221 red (88-00-00-S-30487)
LR
IMPORTANT NOTE: Procedure involves parts with limited reusability. Check parts list below
before starting job!
PRECAUTIONS AND SAFETY MEASURES
WARNING: Wear eye protection and mind FOD when removing attachment hardware!
WARNING: Object is heavy! Inadequate handling could cause injury. Use proper lifting techniques or
assistance!
WARNING: Never place the rotor system on a dirty or grainy surface and avoid bending moments at the
blade attachments!
WARNING: When handled incorrectly the rotor system can be damaged irreparably. If undetected this
may have catastrophic consequences!
CAUTION: When removing or disassembling make sure to mark all parts so that each and every part of
the component is re-assembled and installed in exactly the same location and orientation!
IMPORTANT NOTE: Some rotor blades have loose washers in them which are required as balance
weights. Do not remove or restrain if present!
PROCEDURES
1
Secure the gyroplane on level ground by engaging the parking brake, adjust the rotor system lengthwise and
pump up the rotor brake to its maximum.
2
Remove and discard split pin and unscrew the castellated nut (4). The rotor system has to be tilted onto the
black rotor teeter stop.
3
The teeter bolt (1) has to be extracted by using only the hand, not a hammer. If needed tilt the rotor blades
carefully onto the teeter stop, in order to prevent the bolt from jamming. Make sure that the rotor stays level
in the teeter axis, if not the teeter bolt will damage the Teflon coated bushes, while being pushed out.
4
A supervised second person has to hold the rotor system in flying direction.
5
Lift the rotor system carefully out of the teeter tower and be aware of the position of the shim washers (2).
Their thicknesses may differ and it is essential that they are reinstalled on the correct side! They are marked
with dots to identify the correct side.
6
Remove the rotor system to one side by letting it rest on your shoulder and take care not to collide with
stabilizer or propeller.
7
The shim washers and the teeter block in the hub are marked on each side with one or two engraved dots.
Directly after the disassembly the shim washers need to be fixed on their respective side with cable ties.
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.
9
The rotor system must not be placed on a dirty or grainy surface, as the blades can scratch and damage
easily. The best way is to place the rotor blades centrally onto two stands, supporting the rotor at
approximately 2 m distance from the hub.
MMM-CV-E_16-06-13
Part E - 62-11-00 4-1
Page 1 of 2
Manufacturer
Maintenance Manual
AutoGyro
Cavalon
PARTS LIST
Fig. Pos. Description
PC PIT
1
1
Teeterbolt
L0 27-30-00-S-30256
1
2
Chimm washer 3,5
L0 62-00-00-S-31706
1
3
U13
L0 27-30-00-S-30256
1
4
M12 castle nut
L0 27-30-00-S-30256
1
5
Split pin 3.2x40
L0 27-30-00-S-30256
1
6
Rotor head II compl.
L2 27-30-00-V-33433
Remark
ILLUSTRATIONS
Fig. 1 - Removal rotor - teetering parts (Effectivity: RS II)
MMM-CV-E_16-06-13
Part E - 62-11-00 4-1
Page 2 of 2
Manufacturer
Maintenance Manual
62-11-00 4-2
AutoGyro
Cavalon
DISASSEMBLY: ROTOR - TEETERING PARTS
OPR
GENERAL, REFERENCES AND REQUIREMENTS
Basic operational task, which can be performed by a licensed pilot or instructed personnel!
Rotor system must be removed, see 62-11-00 4-1
SPECIAL TOOLS AND CONSUMABLE MATERIALS
LR
IMPORTANT NOTE: Procedure involves parts with limited reusability. Check parts list below
before starting job!
PRECAUTIONS AND SAFETY MEASURES
WARNING: When handled incorrectly the rotor system can be damaged irreparably. If undetected this
may have catastrophic consequences!
CAUTION: The rotor hub must never be disassembled!
CAUTION: When removing or disassembling make sure to mark all parts so that each and every part of
the component is re-assembled and installed in exactly the same location and orientation!
PROCEDURES
1
To disassemble the rotor system, place it upside down onto a clean surface or stands to support the rotor at
approximately 2 m from the hub.
2
Unscrew and discard self-locking nuts (9) on the first blade by counter-holding the corresponding bolt head to
prevent it from turning.
3
Push out all shoulder bolts (1 - 5) without any force, but use no more than a gentle tapping if necessary. Tilt
the rotor blade up and down to support easy removal of the bolt
4
Carefully pull the rotor blade out of the hub (7) in radial direction and take off the clamping profile (10).
5
Repeat step 2 to 4 on second rotor blade.
IMPORTANT NOTE: Do not disassemble the rotor hub!
6
Place rotor blades, clamping profile and rotor hub in a suitable way to prevent bending or surface damage.
IMPORTANT NOTE: Do not lift or support the rotor system at its blade tips as the bending
moment due to the weight of the hub assembly may overstress the blade roots. 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.
MMM-CV-E_16-06-13
Part E - 62-11-00 4-2
Page 1 of 2
Manufacturer
Maintenance Manual
AutoGyro
Cavalon
PARTS LIST
Fig. Pos. Description
1
1
1
PC PIT
shoulder bolt M8 37/12
1-5 M8x60 Rotor blade bolt 8.8 DIN 610
Remark
L0 62-00-00-S-33324
L0 62-00-00-V-20661
1
2
shoulder bolt M8 40/12
L0 62-00-00-S-33324
1
3
shoulder bolt M8 43/12
L0 62-00-00-S-33324
1
4
shoulder bolt M8 46/12
L0 62-00-00-S-33324
1
5
M8x60 Rotor blade bolt 8.8 DIN 610
L0 62-00-00-V-20661
1
6
U9/20
L0 62-00-00-S-33324
1
7
Rotorhub II
L1 01-00-00-V-31793
1
8
U8
L0 62-00-00-S-33324
1
9
M8 Si
L0 62-00-00-S-33324
1
10 Clamping profile blade
L1 01-00-00-V-31793
ILLUSTRATIONS
Fig. 1 - Disassembly rotor - teetering parts (Effectivity: RS II)
MMM-CV-E_16-06-13
Part E - 62-11-00 4-2
Page 2 of 2
Manufacturer
Maintenance Manual
62-11-00 4-3
AutoGyro
Cavalon
ASSEMBLY: ROTOR - TEETERING PARTS
OPR
GENERAL, REFERENCES AND REQUIREMENTS
Basic operational task, which can be performed by a licensed pilot or instructed personnel!
SPECIAL TOOLS AND CONSUMABLE MATERIALS
LR
IMPORTANT NOTE: Procedure involves parts with limited reusability. Check parts list below
before starting job!
PRECAUTIONS AND SAFETY MEASURES
WARNING: When handled incorrectly the rotor system can be damaged irreparably. If undetected this
may have catastrophic consequences!
CAUTION: When removing or disassembling make sure to mark all parts so that each and every part of
the component is re-assembled and installed in exactly the same location and orientation!
PROCEDURES
1
The rotor blades (11), clamping profile (10) and rotor hub (7) are each labelled with an engraved serial
number.
2
Insert the first rotor blade carefully into the clamping profile. Make sure that all serial numbers match.
IMPORTANT NOTE: Grease shaft with AG-LUB-03, but do not allow AG-LUB-03 to come into
contact with threads at any time!
3
Fit the rotor hub side with the according serial number to clamping profile (7) and blade (11). Insert 6 x
shoulder bolts (1-5) and corresponding washers (6) without using force so that the bolt end is on top when
the rotor system is installed. For re-identification and correct installation position the shaft length is provided
in the figure above. Example: 40/12 means shaft length 40mm.
4
Position the washers (8) and the self-locking nuts (9) and hand-tighten.
5
Torque-tighten nuts (9) with 15 Nm from the inside to the outside. When doing so, counter-hold bolts (5) to
prevent any damage to the hub and blade holes.
6
Repeat work steps 2 to 5 for the second rotor blade.
7
Check rotor system alignment according to 62-11-00 5-1 and adjust, if necessary.
PARTS LIST
Fig. Pos. Description
1
1
1
shoulder bolt M8 37/12
1-5 M8x60 Rotor blade bolt 8.8 DIN 610
PC PIT
L0 62-00-00-V-20661
1
2
shoulder bolt M8 40/12
L0 62-00-00-S-33324
1
3
shoulder bolt M8 43/12
L0 62-00-00-S-33324
1
4
shoulder bolt M8 46/12
L0 62-00-00-S-33324
1
5
M8x60 Rotor blade bolt 8.8 DIN 610
L0 62-00-00-V-20661
1
6
U9/20
L0 62-00-00-S-33324
1
7
Rotorhub II
L1 01-00-00-V-31793
1
8
U8
L0 62-00-00-S-33324
1
9
M8 Si
L0 62-00-00-S-33324
1
10 Clamping profile blade
MMM-CV-E_16-06-13
Remark
L0 62-00-00-S-33324
L1 01-00-00-V-31793
Part E - 62-11-00 4-3
Page 1 of 2
Manufacturer
Maintenance Manual
AutoGyro
Cavalon
ILLUSTRATIONS
Fig. 1 - Assembly rotor - teetering parts (Effectivity: RS II)
MMM-CV-E_16-06-13
Part E - 62-11-00 4-3
Page 2 of 2
Manufacturer
Maintenance Manual
62-11-00 4-4
AutoGyro
Cavalon
INSTALLATION: ROTOR - TEETERING PARTS
OPR
GENERAL, REFERENCES AND REQUIREMENTS
Basic operational task, which can be performed by a licensed pilot or instructed personnel!
Secure gyroplane against unauthorized or unintended operation!
SPECIAL TOOLS AND CONSUMABLE MATERIALS
AG-GRS-01
Lagermeister WHS 2002 Grease (88-00-00-S-30477)
LR
IMPORTANT NOTE: Procedure involves parts with limited reusability. Check parts list below
before starting job!
PRECAUTIONS AND SAFETY MEASURES
WARNING: Object is heavy! Inadequate handling could cause injury. Use proper lifting techniques or
assistance!
WARNING: When handled incorrectly the rotor system can be damaged irreparably. If undetected this
may have catastrophic consequences!
PROCEDURES
1
Secure the gyroplane on level ground by engaging parking brake, adjust the rotor head or teeter tower
corresponding to fore-aft and pressurize the rotor brake up to maximum.
2
Check correct matching of parts: The rotor hub and the teeter tower are marked with two dots according to
the orientation for installation.
3
Lift the rotor blade with a second briefed person (one person standing aft, one person standing directly in
front of the hub).
4
Approach with the rotor system from the side to the gyroplane and make sure not to collide with propeller or
stabilizer. Insert the rotor system into the hub from above while standing on a ladder or the rear seat.
5
The second person can let go, as soon as it is resting centrally in the teeter tower on the teeter stops.
6
Apply a thin layer of AG-GRS-01 on teeter bolt.
7
Insert teeter bolt by hand in the same orientation as it was before (bolt head should be at that side of the
teeter block which is marked with one dot) while matching the shim washers with the corresponding
installation positions. Insert teeter bolt by hand in the same orientation as it was before (bolt head should be
at that side of the teeter block which is marked with one dot) while matching the shim washers with the
corresponding installation positions.
8
Check direction of assembly and shim washers: rotor hub, teeter tower and shim washers are marked on
each side either with one or two engraved dots.
9
If the teeter bolt cannot be inserted, tilt the rotor blade along the teeter axis with the free hand.
10 Install washer and castellated nut. Hand-tighten only and secure with a new split pin. Use split pins only
once. Make sure that the teeter bolt can be turned easily by hand.
11 Grease nipple in teeter block.
MMM-CV-E_16-06-13
Part E - 62-11-00 4-4
Page 1 of 2
Manufacturer
Maintenance Manual
AutoGyro
Cavalon
PARTS LIST
Fig. Pos. Description
PC PIT
1
1
Teeterbolt
L0 27-30-00-S-30256
1
2
Chimm washer 3,5
L0 62-00-00-S-31706
1
3
U13
L0 27-30-00-S-30256
1
4
M12 castle nut
L0 27-30-00-S-30256
1
5
Split pin 3.2x40
L0 27-30-00-S-30256
1
6
Rotor head II compl.
L2 27-30-00-V-33433
Remark
ILLUSTRATIONS
Fig. 1 - Installation rotor - teetering parts (Effectivity: RS II)
MMM-CV-E_16-06-13
Part E - 62-11-00 4-4
Page 2 of 2
Manufacturer
Maintenance Manual
62-11-00 5-1
CHECK-ADJUSTMENT: ROTOR SYSTEM ALIGNMENT
AutoGyro
Cavalon
LNE
GENERAL, REFERENCES AND REQUIREMENTS
Task may only be performed by an organization or individual trained and entitled to carry out 'Line Maintenance'!
Rotor system must be removed, see 62-11-00 4-1
Rotor system must be placed on suitable supports to avoid scratching of the blades or bending moments at the
blade attachment
SPECIAL TOOLS AND CONSUMABLE MATERIALS
None
PRECAUTIONS AND SAFETY MEASURES
WARNING: Object is heavy! Inadequate handling could cause injury. Use proper lifting techniques or
assistance!
WARNING: Do not lift or support the rotor system at its blade tips as the bending moment due to the
weight of the hub assembly may overstress the blade roots!
WARNING: Never place the rotor system on a dirty or grainy surface and avoid bending moments at the
blade attachments!
WARNING: When handled incorrectly the rotor system can be damaged irreparably. If undetected this
may have catastrophic consequences!
PROCEDURES
1
Place rotor system on suitable stands on level ground. Make sure stand surface is level and stand is oriented
exactly 90 degrees to rotor blade (see Fig. 1).
2
String measuring cord between both outer blade tips. Position at rivet as depicted in Fig. 2 'Positioning of
measuring cord'.
3
Adjust distance of stand carefully so that measuring cord is strung slightly above the central grease nipple.
Verify centre position of grease nipple (Fig. 3).
4
In case the measuring cord deviates by more than 2 mm from centre position (i.e. grease nipple inner bore),
adjust rotor system linearity. To do so perform the following work steps:
5
Untighten the self-locking nuts of the blade attachment bolts, except for the most inner bolt(s). Counter-hold
bolt head to prevent it from turning.
6
Adjust linearity/alignment of rotor system and tighten nuts. Perform alignment check. If necessary, repeat
procedure from step 5 on.
7
Torque-tighten nuts with 15 Nm from the inside to the outside. When doing so, counter-hold bolts to prevent
any damage to the hub and blade holes.
8
Perform final linearity/alignment check. If necessary, repeat procedure from step 5 on.
9
Perform final linearity/alignment check. If necessary, repeat procedure from step 5 on.
MMM-CV-E_16-06-13
Part E - 62-11-00 5-1
Page 1 of 2
Manufacturer
Maintenance Manual
AutoGyro
Cavalon
ILLUSTRATIONS
Fig. 1 - Rotor system placed on stands
Fig. 2 - Positioning of measuring cord
MMM-CV-E_16-06-13
Fig. 3 - Reference point at grease nipple
Part E - 62-11-00 5-1
Page 2 of 2
Manufacturer
Maintenance Manual
62-11-00 6-1
AutoGyro
Cavalon
INSPECTION: ROTOR - TEETERING PARTS
LNE
GENERAL, REFERENCES AND REQUIREMENTS
Task may only be performed by an organization or individual trained and entitled to carry out 'Line Maintenance'!
Rotor system must be removed, see 62-11-00 4-1
SPECIAL TOOLS AND CONSUMABLE MATERIALS
AG-GRS-01
Lagermeister WHS 2002 Grease (88-00-00-S-30477)
PRECAUTIONS AND SAFETY MEASURES
WARNING: Never place the rotor system on a dirty or grainy surface and avoid bending moments at the
blade attachments!
WARNING: When handled incorrectly the rotor system can be damaged irreparably. If undetected this
may have catastrophic consequences!
PROCEDURES
1
Check inner and outer blade caps for tight fit and general condition. Visible insets or score marks may
indicate contact with obstacles with possible damage to the rotor system.
2
Perform visual inspection of clamping profile.
3
Perform visual inspection of rotor hub.
4
Perform visual inspection of grease nipple and check tight fit
5
Check rotor system alignment 62-11-00 5-1, i.e. work steps 1 to 3 for trend monitoring purposes.
6
Inspect teeter bolt. In order to do so, clean with lint-free cloth and inspect for wear marks and corrosion. If
corrosion or wear marks are evident (fingernail test), the teeter bolt must be discarded and replaced.
7
Apply a thin layer of AG-GRS-01 on teeter bolt using a lint-free cloth.
8
Inspect bushings in teeter block and teeter tower for correct seating (see Fig. 1 for positions of slits) and
secure installation (must not be possible to turn by hand). Otherwise, bushings must be replaced, see 62-1100 8-1.
9
Insert teeter bolt in teeter block and inspect for play. If any bearing play is evident, try with new teeter bolt. If
play is still evident, replace teeter block bushing, see 62-11-00 8-1.
10 Insert teeter bolt in teeter tower and inspect for play. If any bearing play is evident, try with new teeter bolt. If
play is still evident, replace teeter tower bushings, see 62-11-00 8-1.
PARTS LIST
Fig. Pos. Description
PC PIT
1
1
Bushing TEF-MET 13/15/21x15
L0 27-30-00-V-20677
1
2
Bushing TEF-MET 13/15/21x15
L2 27-30-00-V-20677
Teeterbolt kit
L0 27-30-00-S-30256
MMM-CV-E_16-06-13
Part E - 62-11-00 6-1
Remark
Page 1 of 2
Manufacturer
Maintenance Manual
AutoGyro
Cavalon
ILLUSTRATIONS
Fig. 1 - Teeter bushings, block and tower - cross section view
MMM-CV-E_16-06-13
Part E - 62-11-00 6-1
Page 2 of 2
Manufacturer
Maintenance Manual
62-11-00 6-2
AutoGyro
Cavalon
INSPECTION: ROTOR BLADES
OPR
GENERAL, REFERENCES AND REQUIREMENTS
Basic operational task, which can be performed by a licensed pilot or instructed personnel!
Rotor system must be disassembled, see 62-11-00 4-2
SPECIAL TOOLS AND CONSUMABLE MATERIALS
85-00-00-S-35077 Aluminium ruler 1000mm
PRECAUTIONS AND SAFETY MEASURES
WARNING: Do not use permanent marker on anodized (eloxated) parts!
CAUTION: Do not use sticky labels on aluminium or composite parts as they may be difficult to remove!
PROCEDURES
1
Inspect for cracks in the blade root area, especially in the area of the inner attachment bore (see Fig. 1
"Critical Area"). In case of any cracks the complete rotor system must be replaced.
2
Check each rotor blade in its root section for linearity. In order to do place each rotor blade with the nose
section facing down on the support stands and measure gap with an aluminium ruler in 1 m distance from the
inner end (see Fig. 2). Maximum allowed gap (dimension A) is 0.5 mm (LTA DULV-2010-004).
IMPORTANT NOTE: In order to avoid measuring errors draw a straight and parallel line 200
mm from the trailing edge. Use a lead pencil. Do not use permanent marker on anodized
(eloxated) parts!
MMM-CV-E_16-06-13
Part E - 62-11-00 6-2
Page 1 of 2
Manufacturer
Maintenance Manual
AutoGyro
Cavalon
ILLUSTRATIONS
Fig. 1 - Critical blade area
Fig. 2 - Measurement of blade root linearity
MMM-CV-E_16-06-13
Part E - 62-11-00 6-2
Page 2 of 2
Manufacturer
Maintenance Manual
62-11-00 6-3
AutoGyro
Cavalon
INSPECTION: ROTOR HUB BOLTS
LNE
GENERAL, REFERENCES AND REQUIREMENTS
Task may only be performed by an organization or individual trained and entitled to carry out 'Line Maintenance'!
Rotor system must be removed, see 62-11-00 4-1
Rotor system must be placed on suitable supports to avoid scratching of the blades or bending moments at the
blade attachment
SPECIAL TOOLS AND CONSUMABLE MATERIALS
AG-GRS-01
Lagermeister WHS 2002 Grease (88-00-00-S-30477)
LR
IMPORTANT NOTE: Procedure involves parts with limited reusability. Check parts list below
before starting job!
PRECAUTIONS AND SAFETY MEASURES
CAUTION: Remove and re-install only one bolt at a time. Never remove more than one bolt of the
installation!
PROCEDURES
1
Remove first Rotor Hub Bolt and discard self-locking nut. If necessary use a mandrel and a hammer and tap
carefully. Use caution not to damage the threads or the surface of the bore.
2
Inspect Rotor Hub Bolt for corrosion. In case of any signs of corrosion the bolt must be replaced.
3
Apply a thin layer of AG-GRS-01 on shaft, but NOT on the thread.
4
Re-install bolt with a slow turning motion and moderate pressure.
5
Install new self-locking nut and pre-torque to approximately 10 Nm.
6
Repeat work steps 1 to 5 for the remaining bolts.
7
Torque-tighten all Rotor Hub Bolts to the final torque of 25 Nm in opposing/crosswise sequence.
PARTS LIST
Fig. Pos. Description
PC PIT
1
1
M8x60 Rotor blade bolt 8.8 DIN 610
L0 62-00-00-V-20661
1
2
U9/20
L1 62-00-00-S-33355
1
3
U8
L1 62-00-00-S-33355
1
4
M8 Si
L1 62-00-00-S-33355
MMM-CV-E_16-06-13
Part E - 62-11-00 6-3
Remark
Page 1 of 2
Manufacturer
Maintenance Manual
AutoGyro
Cavalon
ILLUSTRATIONS
Fig. 1 - Rotor hub
MMM-CV-E_16-06-13
Part E - 62-11-00 6-3
Page 2 of 2
Manufacturer
Maintenance Manual
62-11-00 8-1
AutoGyro
Cavalon
REPLACEMENT: TEETER BUSHINGS
HVY
GENERAL, REFERENCES AND REQUIREMENTS
Task may only be performed by an organization trained and entitled to carry out 'Heavy Maintenance'!
Rotor system must be removed, see 62-11-00 4-1
SPECIAL TOOLS AND CONSUMABLE MATERIALS
AG-BAS-04
Loctite 638 green (88-00-00-S-30485)
85-00-00-S-36039 Puller bushing teeterblock
PRECAUTIONS AND SAFETY MEASURES
CAUTION: When removing or disassembling make sure to mark all parts so that each and every part of
the component is re-assembled and installed in exactly the same location and orientation!
PROCEDURES
Removal
CAUTION: It is advisable to heat up the teeter block in an oven. When removing the teeter
block marks all parts or use cable ties so that each and every part of the component is reassembled and installed in exactly the same location and orientation! This is especially
important for the shim plates between teeter block and hub bar.
WARNING: Affected aluminium parts must not become warmer than 160 °C.
1
Remove bushings from teeter block. In order to do so warm up teeter block to 120 °C, preferably in an oven.
2
Use appropriate tools to drive out bushings. Be careful not to damage the surface of bore.
3
Remove bushings from pre-heated teeter tower.
4
Use appropriate tools to drive out bushings. Be careful not to damage the surface of bore.
Installation
5
Clean bushing seatings / bores from bonding residues and de-grease.
6
Teeter block: Apply a thin layer of AG-BAS-04 to bore.
7
Press in first bushing with joint/slit facing up. Use a bench vise and press carefully until bushing flange is
flush.
8
Clean off excessive Loctite, if necessary.
9
Repeat step 6 to 8 for second bushing.
10 Teeter tower: Apply a thin layer of AG-BAS-04 to bore.
11 Press in first bushing with joint/slit facing down. Pull in bushing until flange is flush. Use thick washers on
both sides to protect teeter tower and bushing flange from damage.
12 Clean off excessive Loctite, if necessary.
13 Repeat step 10 to 12 for second bushing.
14 If necessary rework inner diameter of bushings in teeter tower with a reamer 13H7.
MMM-CV-E_16-06-13
Part E - 62-11-00 8-1
Page 1 of 3
Manufacturer
Maintenance Manual
AutoGyro
Cavalon
PARTS LIST
Fig. Pos. Description
1
1
PC PIT
Bushing TEF-MET 13/15/21x15
Remark
L0 27-30-00-V-20677
ILLUSTRATIONS
Fig. 1 - Teeter bushings, block and tower - cross section view
MMM-CV-E_16-06-13
Part E - 62-11-00 8-1
Page 2 of 3
Manufacturer
Maintenance Manual
AutoGyro
Cavalon
Fig. 2 - Teeter bushings, block and tower - exploded view
MMM-CV-E_16-06-13
Part E - 62-11-00 8-1
Page 3 of 3
Manufacturer
Maintenance Manual
62-20-00 8-1
AutoGyro
Cavalon
REPLACEMENT: DRIVE GEAR
HVY
GENERAL, REFERENCES AND REQUIREMENTS
Task may only be performed by an organization trained and entitled to carry out 'Heavy Maintenance'!
Secure gyroplane against unauthorized or unintended operation!
Gyroplane must be placed on level ground and restrained (blocks, chocks)
Rotor system must be removed, see 62-11-00 4-1!
SPECIAL TOOLS AND CONSUMABLE MATERIALS
AG-BAS-02
Loctite 243 blue
LR
IMPORTANT NOTE: Procedure involves parts with limited reusability. Check parts list below
before starting job!
PRECAUTIONS AND SAFETY MEASURES
CAUTION: When removing or disassembling make sure to mark all parts so that each and every part of
the component is re-assembled and installed in exactly the same location and orientation!
PROCEDURES
1
Switch pneumatic mode selector to BRAKE.
2
Remove and dispose the split pin (1) (Fig.1 and 2).
WARNING: Wear eye protection when removing attachment hardware!
3
Insert a 10mm allen wrench between the rotor head bridge and main bolt head on one side (left or right)
(Fig.3).
Note: Use an allen wrench without ball head!
4
Determine the exact installation position of the main bolt by moving the allen wrench.
Important: The position of the main bolt is important for the roll tendency of the gyroplane!
5
Undo the castle nut (2) (Fig.1 and 2).
6
Switch pneumatic mode selector to FLIGHT.
7
Remove the castle nut (2) (Fig.1 and 2).
8
Remove the teeter tower with the drive gear. Fix the teeter tower in a bench vise carefully.
9
Remove and dispose the 6 screws and 6 washers of the drive gear. Remove the drive gear.
10 Put new drive gear on teeter tower.
11 Apply Loctite 243 to the six screws and six washers of the drive gear. Tighten the screws with a torque of 25
Nm.
12 Rotate rotor head so that rotor blades (removed!) would point exactly in flight direction.
13 Put teeter tower with new drive gear on the rotor head.
14 Align the hole or magnet to the 7 o´clock position in flight direction (Fig.4).
15 Make sure that the main bolt is in correct position by moving the 10mm allen wrench (see work step 5).
16 Tighten castle nut (2) with a torque value enough to fix the adjustment and of the main bolt.
17 Inspect backlash of pre-rotator upper engagement. 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.
18 Torque-tighten castle nut (2) with final torque of 120 Nm and re-check position. Apply further torque until the
split pin can be inserted.
19 Remove the 10 mm allen wrench.
MMM-CV-E_16-06-13
Part E - 62-20-00 8-1
Page 1 of 4
Manufacturer
Maintenance Manual
AutoGyro
Cavalon
20 Insert and secure new split pin (1). Make sure that ends do not contact rotating parts (Fig.2).
21 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.
22 Install the rotor system, according to 62-11-00 4-4.
23 Perform jobcard 63-11-30 6-1 "INSPECTION: PRE-ROTATOR UPPER ENGAGEMENT".
PARTS LIST
Fig. Pos. Description
PC PIT
Splitpins, 10 pieces
L0 27-30-00-S-30261
Rotor sprocket mounted
L2 27-30-00-M-36385
Kit – Rotor sprocket
L2 27-30-00-S-42957
MMM-CV-E_16-06-13
Part E - 62-20-00 8-1
Remark
Page 2 of 4
Manufacturer
Maintenance Manual
AutoGyro
Cavalon
ILLUSTRATIONS
Fig.1 - Rotor head
Fig.2 - Split pin and castle nut
MMM-CV-E_16-06-13
Part E - 62-20-00 8-1
Page 3 of 4
Manufacturer
Maintenance Manual
AutoGyro
Cavalon
Fig.3 - Allen wrench between rotor head and main bolt
Fig.4 - Hole or magnet in the 7 o´clock position in flight
direction
MMM-CV-E_16-06-13
Part E - 62-20-00 8-1
Page 4 of 4
Manufacturer
Maintenance Manual
62-31-00 5-1
AutoGyro
Cavalon
CHECK-ADJUSTMENT: ROTOR HEAD MAIN BOLT AXIS
HVY
GENERAL, REFERENCES AND REQUIREMENTS
Task may only be performed by an organization trained and entitled to carry out 'Heavy Maintenance'!
Secure gyroplane against unauthorized or unintended operation!
Gyroplane must be placed on level ground and restrained (blocks, chocks)
SPECIAL TOOLS AND CONSUMABLE MATERIALS
AG-GRS-01
Lagermeister WHS 2002 Grease (88-00-00-S-30477)
PRECAUTIONS AND SAFETY MEASURES
PROCEDURES
Adjust roll tendency
NOTE:
Roll tendency (tendency to bank increasingly left or right) depends on the flight condition,
such as gross mass and altitude, but mainly speed.
Due to the turning direction of the rotor, the gyroplane has a tendency to roll right at slow
speeds and roll left at high speeds. In a certain speed range, the gyroplane shows no roll
tendency, i.e. flies straight with no lateral control force required.
1
Fly with medium gross mass and 120 km/h, or the desired flight condition for which roll tendency shall be
adjusted, and find 'no-roll' speed range.
2
After landing, measure lateral position of rotor head main bolt axis. Use a feeler gauge or any other method
providing an accuracy of at least 0.5 mm.
3
Calculate new lateral position assuming 0.5 mm lateral shift (R/L) per 10 km/h intended shift in speed range.
NOTE:
R: to correct roll tendency to the right or to adjust the rotor axis for a slower 'no-roll' speed
L: to correct roll tendency to the left or to adjust the rotor axis for a faster 'no-roll' speed
4
Remove and discard split pin (1).
5
Untighten castle nut (2) and adjust main bolt to new lateral position. Make sure to maintain longitudinal
position (backlash) constant.
6
Tighten castle nut (2) with a torque value enough to fixate adjustment and re-check position. If necessary
return to step 5.
7
Torque-tighten castle nut (2) with final torque of 120 Nm and re-check position. If necessary return to step 5.
8
If necessary apply further torque until split pin can be inserted.
9
Insert new split pin (1) and secure. Make sure that ends do not contact rotating parts.
10 Perform duplicate inspection and test-fly result. If necessary, repeat procedure starting from step 1.
11 Perform 63-11-30 6-1 "INSPECTION: PRE-ROTATOR UPPER ENGAGEMENT"
Adjust backlash
12 Inspect backlash of pre-rotator upper engagement. 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.
13 If necessary adjust backlash by performing work steps 14 to 19.
14 Remove and discard split pin (1).
15 Untighten castle nut (2) and adjust main bolt longitudinal position. Make sure to maintain lateral position (roll
tendency) constant.
NOTE:
F: increase pre-rotator backlash (less tight)
MMM-CV-E_16-06-13
Part E - 62-31-00 5-1
Page 1 of 2
Manufacturer
Maintenance Manual
AutoGyro
Cavalon
A: reduce pre-rotator backlash (tighter)
16 Tighten castle nut (2) with a torque value enough to fixate adjustment and re-check position. If position has
changed start from step 15.
17 Torque-tighten castle nut (2) with final torque of 120 Nm and re-check position. If necessary return to step 15.
18 If necessary apply further torque until split pin can be inserted.
19 Insert new split pin (1) and secure. Make sure that ends do not contact rotating parts.
20 Perform duplicate inspection.
ILLUSTRATIONS
Fig. 1 - Adjustment of rotor head main bolt axis
MMM-CV-E_16-06-13
Part E - 62-31-00 5-1
Page 2 of 2
Manufacturer
Maintenance Manual
62-31-00 6-1
AutoGyro
Cavalon
INSPECTION: ROTOR HEAD BRIDGE, BEARING AND
TEETER TOWER
LNE
GENERAL, REFERENCES AND REQUIREMENTS
Task may only be performed by an organization or individual trained and entitled to carry out 'Line Maintenance'!
Mast cover must be removed, see 52-00-00 4-1
SPECIAL TOOLS AND CONSUMABLE MATERIALS
LR
IMPORTANT NOTE: Procedure involves parts with limited reusability. Check parts list below
before starting job!
PRECAUTIONS AND SAFETY MEASURES
WARNING: Wear eye protection and mind FOD when removing attachment hardware!
PROCEDURES
1
Inspect rotor head bridge (5) function and condition, i.e. no misalignment, dents, nicks, corrosion, or cracks.
In case of any of the aforementioned is evident or suspected contact AutoGyro customer support.
2
Inspect teeter stops (4) for correct attachment and condition.
3
Inspect teeter tower (3) for correct attachment and condition, i.e. no cracks. In case of cracks or unusual
condition or appearance contact AutoGyro customer support.
4
Perform torque-check on main bolt nut (2). In order to do so, remove and discard split pin (1) and torquecheck castle nut with 120 Nm.
6
If torque-check fails mark component / gyroplane unserviceable and contact AutoGyro customer support.
7
Insert new split pin (1) and secure. Make sure that ends do not contact rotating parts.
WARNING: Do not fly gyroplane in case torque-check failed. Clearly mark as unserviceable
and prevent from use until resolved.
PARTS LIST
Fig. Pos. Description
PC PIT
1
1
Splitpins, 10 pieces
1
2
M20 castle nut flat
1
3
27-30-00-V-33433
1
4
27-30-00-V-33433
1
5
Rotorhub bottom mounted
NPI
1
6
M20x1_5x73,8
NPI
MMM-CV-E_16-06-13
Remark
L0 27-30-00-S-30261
NPI
Part E - 62-31-00 6-1
Page 1 of 2
Manufacturer
Maintenance Manual
AutoGyro
Cavalon
ILLUSTRATIONS
Fig. 1 - Rotor head bridge, bearing and teeter tower
MMM-CV-E_16-06-13
Part E - 62-31-00 6-1
Page 2 of 2
Manufacturer
Maintenance Manual
62-32-00 5-1
AutoGyro
Cavalon
CHECK-ADJUSTMENT: ROTOR CONTROL FRICTION
HVY
GENERAL, REFERENCES AND REQUIREMENTS
Task may only be performed by an organization trained and entitled to carry out 'Heavy Maintenance'!
Rotor head bridge / gimbal head configuration state must conform to version II
Rotor system must be removed, see 62-11-00 4-1
SPECIAL TOOLS AND CONSUMABLE MATERIALS
85-00-00-S-34115 Spring balance / Dynamometer
PRECAUTIONS AND SAFETY MEASURES
PROCEDURES
1
Switch pneumatic mode selector to flight and release trim pressure completely. If necessary, switch
repeatedly!
2
Attach spring balance / dynamometer as shown in Fig. 1 and pull carefully until control stick starts to move.
Note maximum value (breakout force).
3
Breakout force can be adjusted by tightening the gimbal head pitch bolt. If the split pin drill of the gimbal head
pitch bolt is covered by the castle nut, place shim washers between the washers (Fig. 2, Pos. 10). Note: 0.1
mm shim washer equates approximately 20° nut rotating angle.
4
Rotor vibration levels will decrease with higher control friction, but handling qualities will suffer, if control
friction is too high. Friction should not exceed 10 N, with an absolute maximum of 15 N!
5
After completion, switch pneumatic mode selector to BRAKE, apply brake pressure and secure rotor system.
PARTS LIST
Fig. Pos. Description
PC PIT
2
1
ROLL/PITCH BOLT
2
2
axial bushing 14
2
3
disc spring 12,2X25,0X0,9 drilled 14,5
2
4
Gimbal head II
2
5
U13
NPI
2
6
M12 castle nut
NPI
2
7
Split pin 3.2x50
2
8
ROLL/PITCH BOLT
2
9
U13
2
10 M12 castle nut
NPI
2
11 Split pin 3.2x50
NPI
MMM-CV-E_16-06-13
Remark
L2 27-30-00-V-20675
NPI
NPI
L2 57-00-00-S-33615
NPI
L2 27-30-00-V-20675
NPI
Part E - 62-32-00 5-1
Page 1 of 2
Manufacturer
Maintenance Manual
AutoGyro
Cavalon
ILLUSTRATIONS
Fig. 1 - Measurement of rotor control friction
Fig. 2 - Gimbal head assembly, Rotor System II (with spring washers)
MMM-CV-E_16-06-13
Part E - 62-32-00 5-1
Page 2 of 2
Manufacturer
Maintenance Manual
62-32-00 6-1
AutoGyro
Cavalon
INSPECTION: ROTOR GIMBAL HEAD
LNE
GENERAL, REFERENCES AND REQUIREMENTS
Task may only be performed by an organization or individual trained and entitled to carry out 'Line Maintenance'!
Rotor system must be removed, see 62-11-00 4-1
SPECIAL TOOLS AND CONSUMABLE MATERIALS
AG-GRS-01
Lagermeister WHS 2002 Grease (88-00-00-S-30477)
85-00-00-S-31438 Inklinometer / Digital Spirit Level
PRECAUTIONS AND SAFETY MEASURES
PROCEDURES
1
Inspect gimbal head (4) for correct function and condition, i.e. check split pin (7) and (11) is installed and no
play at the hinge points is evident.
2
Verify angles of gimbal head mechanical end stops. In order to do so perform the following work steps:
3
Place gyroplane on level ground with zero roll attitude and centre console horizontal.
4
Rotate rotor head so that rotor blades (removed!) would point exactly fore-aft. Place inclinometer on top of
teeter tower and measure RH and LH end stop angle. Make sure that mechanical stops are reached. Record
values.
5
Rotate rotor head so that rotor blades (removed!) would point exactly left-right. Place inclinometer on top of
teeter tower and measure FORE and AFT end stop angle. Make sure that mechanical stops are reached.
Record values.
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 customer support.
PARTS LIST
Fig. Pos. Description
PC PIT
1
1
ROLL/PITCH BOLT
1
2
axial bushing 14
1
3
disc spring 12,2X25,0X0,9 drilled 14,5
1
4
Gimbal head II
1
5
U13
NPI
1
6
M12 castle nut
NPI
1
7
Split pin 3.2x50
1
8
ROLL/PITCH BOLT
1
9
U13
1
10 M12 castle nut
NPI
1
11 Split pin 3.2x50
NPI
MMM-CV-E_16-06-13
Remark
L2 27-30-00-V-20675
NPI
NPI
L2 57-00-00-S-33615
NPI
L2 27-30-00-V-20675
NPI
Part E - 62-32-00 6-1
Page 1 of 2
Manufacturer
Maintenance Manual
AutoGyro
Cavalon
ILLUSTRATIONS
Fig. 1 - Rotor gimbal head - Version II
Fig. 2 - Arrangement of spring washers on gimbal head - Version II
MMM-CV-E_16-06-13
Part E - 62-32-00 6-1
Page 2 of 2
Manufacturer
Maintenance Manual
62-51-00 4-1
AutoGyro
Cavalon
REMOVAL-INSTALLATION: TOP MAST
HVY
GENERAL, REFERENCES AND REQUIREMENTS
Task may only be performed by an organization trained and entitled to carry out 'Heavy Maintenance'!
Secure gyroplane against unauthorized or unintended operation!
A suitable stand should be used if possible!
Self-locking nuts and split pins must only be used once and discarded! Check availability of new hardware before
commencing work!
Rotor system must be removed, see 62-11-00 4-1
Mast cover must be removed, see 52-00-00 4-1
SPECIAL TOOLS AND CONSUMABLE MATERIALS
AG-BAS-01
Loctite 221 red (88-00-00-S-30487)
AG-BAS-02
Loctite 243 blue (88-00-00-S-30483)
AG-GRS-01
Lagermeister WHS 2002 Grease (88-00-00-S-30477)
AG-LUB-03
Würth HHS2000 Oil Spray (88-00-00-S-30476)
PRECAUTIONS AND SAFETY MEASURES
WARNING: Safety Critical Part - May have catastrophic consequences when component or part is
missing, damaged, or handled incorrectly!
WARNING: Job includes work at critical flight controls. Duplicate inspection must be performed after
completion!
WARNING: Object is heavy! Inadequate handling could cause injury. Use proper lifting techniques or
assistance!
WARNING: When working with cranes or other lifting equipment the general safety regulations have to be
respected at all times!
CAUTION: When removing or disassembling make sure to mark all parts so that each and every part of
the component is re-assembled and installed in exactly the same location and orientation!
PROCEDURES
Removal
1
Disconnect temperature sensor and rotor rpm sensor, remove cable ties on top mast (Fig. 1).
2
Disconnect pneumatic hoses from Bendix pneumatic actuator, roll trim actuator and pitch trim actuator (Fig.
2, Fig. 3).
CAUTION: When removing or disassembling make sure to mark all parts so that each and
every part of the component is re-assembled and installed in exactly the same location and
orientation!
3
Remove bolt (Fig. 4) from roll control and roll trim. Maintain attachment hardware, discard self-locking nut!
CAUTION: When removing or disassembling make sure to mark all parts so that each and
every part of the component is re-assembled and installed in exactly the same location and
orientation!
4
Remove bolt (Fig. 5) from pitch control. Maintain attachment hardware, discard self-locking nut!
IMPORTANT NOTE: When disconnecting the push-pull cable bulkhead at the top mast,
unscrew only top (outer) attachment nut and leave lower (inner) attachment nut unchanged
and mark position.
5
Disconnect roll push-pull cable bulkhead. In order to do so, unscrew and remove top (outer) attachment nut
MMM-CV-E_16-06-13
Part E - 62-51-00 4-1
Page 1 of 4
Manufacturer
Maintenance Manual
AutoGyro
Cavalon
(Fig. 6).
6
Disconnect pitch push-pull cable bulkhead. In order to do so, unscrew and remove top (outer) attachment
nut.
7
Remove mast bushes (Fig. 7) and free mast bushes from grease residuals.
8
Pull top mast equipped with rotor head out of mast bottom. Lead push-pull control cables through attachment
consoles and pneumatic hose package through the inside of the pitch console.
Installation
9
If applicable remove transport securing devices.
10 Insert top mast equipped with rotor head into mast bottom. Lead push-pull control cables through attachment
consoles (Fig. 8)
11 Lubricate pre-rotator drive with oil with AG-LUB-03 (spray in top pre rotator drive shaft) and insert lower
sliding splined drive shaft into top pre-rotator drive shaft (Fig. 9)
12 Equip each threaded mast bush with a washer disc and a screw, grease mast bushes (AG-GRS-01) and
push into their designated openings as follows: Short mast bush in the upper opening, long mast bush in
lower opening. Equip each mast bush on opposite also with a washer disc and a screw. Apply Loctite 243
(AG-BAS-02) on each screw thread and torque-tighten with standard bolt torque (Fig. 7).
IMPORTANT NOTE: When re-installing push-pull cable bulkhead make sure that the lower
(inner) attachment nut remains in original (marked) position.
13 Equip roll push-pull control cable bulkhead with a serrated washer and a counter nut. Torque-tighten counter
nut with 25 Nm and apply securing paint (Fig. 6).
14 Equip pitch push-pull control cable bulkhead with a serrated washer and a counter nut. Torque-tighten
counter nut with 25 Nm and apply securing paint.
15 Re-install pitch control ball joint (Fig. 5). In order to do so, insert bolt from left and install
1) spacer
2) ball joint
3) spacer
Secure with new locking nut and torque-tighten.
16 Re-install roll control ball joint and roll trim (Fig. 4). In oder to do so, insert bolt from front and install
1) plastic washer
2) ball joint roll control
3) small washer
4) spacer
5) ball joint trim actuator
6) spacer
7) large washer
Secure with new locking nut and torque-tighten.
17 Pull pneumatic hose package through the inside of the pitch console and fix with cable-ties (Fig. 3).
18 Apply Loctite 221 (AG-BAS-01) on pneumatic connection threads of roll trim actuator actuator and pitch trim
actuator. Connect pneumatic hoses according to Fig. 3. Tighten union nuts of pneumatic hoses slightly with
pliers and fix hoses with cable ties. Prevent chafing of pneumatic hoses!
19 Connect temperature sensor and rotor rpm sensor, lead cable on the right side of the mast. Fix cable
according to Fig. 1 with cable ties.
20 Move flight control stick carefully to all directions (full deflections) in order to ensure an installation without
strain or stresses.
21 Inspect rotor gimbal head according to 62-32-00 6-1 and check/adjust rotor control angles.
MMM-CV-E_16-06-13
Part E - 62-51-00 4-1
Page 2 of 4
Manufacturer
Maintenance Manual
AutoGyro
Cavalon
ILLUSTRATIONS
Fig. 1 - Temperature sensor
Fig. 2 - Pneumatic connection Bendix
Fig. 3 - Pneumatic hoses
Fig. 4 - Roll control
MMM-CV-E_16-06-13
Fig. 5 - Pitch control
Part E - 62-51-00 4-1
Page 3 of 4
Manufacturer
Maintenance Manual
AutoGyro
Cavalon
Fig. 6 - Push-pull control cable bulkhead attachment
Fig. 7 - Installation of mast bushes
Fig. 8 - Top mast
Fig. 9 - Pre-rotator drive
MMM-CV-E_16-06-13
Part E - 62-51-00 4-1
Page 4 of 4
Manufacturer
Maintenance Manual
62-51-00 6-1
AutoGyro
Cavalon
INSPECTION: MAST MOUNTING BUSHINGS
LNE
GENERAL, REFERENCES AND REQUIREMENTS
Task may only be performed by an organization or individual trained and entitled to carry out 'Line Maintenance'!
Rotor system must be removed, see 62-11-00 4-1
Secure gyroplane against unauthorized or unintended operation!
Gyroplane must be placed on level ground and restrained (blocks, chocks)
A suitable stand should be used if possible!
Work should be performed with the aid of a second briefed person!
SPECIAL TOOLS AND CONSUMABLE MATERIALS
85-00-00-S-34115 Spring balance / Dynamometer
PRECAUTIONS AND SAFETY MEASURES
PROCEDURES
1
Neutral mast position, no force applied: Measure diagonal distance from mast reference point to fuselage
reference point (see illustrations in Fig. 1) and record value 'A' in protocol.
2
Repeat measurement with 150 N, applied horizontally in flight direction (see Fig. 1). Record value 'B' in
protocol.
3
Calculate deflection value 'A-B' and record in protocol. If deflection 'A-B' exceeds 5 mm, contact AutoGyro
customer support.
4
If advised by AutoGyro, repeat measurement with 150 N, applied against flight direction (see Fig. 1).
MMM-CV-E_16-06-13
Part E - 62-51-00 6-1
Page 1 of 2
Manufacturer
Maintenance Manual
AutoGyro
Cavalon
ILLUSTRATIONS
Fig. 1 - Mast reference point
Fig. 2 - Fuselage reference point
Fig. 3 - Force applied against flight direction
Fig. 3 - Force applied in flight direction
MMM-CV-E_16-06-13
Part E - 62-51-00 6-1
Page 2 of 2
Manufacturer
Maintenance Manual
62-51-00 8-1
AutoGyro
Cavalon
REPLACEMENT: MAST MOUNTING BUSHINGS
HVY
GENERAL, REFERENCES AND REQUIREMENTS
Task may only be performed by an organization trained and entitled to carry out 'Heavy Maintenance'!
Secure gyroplane against unauthorized or unintended operation!
Gyroplane must be placed on level ground and restrained (blocks, chocks)
Rotor system must be removed, see 62-11-00 4-1
A suitable stand should be used if possible!
SPECIAL TOOLS AND CONSUMABLE MATERIALS
AG-BAS-04
Loctite 638 green (88-00-00-S-30485)
AG-GRS-01
Lagermeister WHS 2002 Grease (88-00-00-S-30477)
AG-LUB-03
Würth HHS2000 Oil Spray (88-00-00-S-30476)
PRECAUTIONS AND SAFETY MEASURES
WARNING: Job includes work at critical flight controls. Duplicate inspection must be performed after
completion!
CAUTION: When removing or disassembling make sure to mark all parts so that each and every part of
the component is re-assembled and installed in exactly the same location and orientation!
IMPORTANT NOTE: Before disconnecting and removing push-pull cables, mark position of (inner)
counter nut and ball end in order to avoid re-adjustment (rigging) of flight controls!
PROCEDURES
1
Disconnect rod end of roll control push-pull cable at upper attachment point.
2
Disconnect rod end of pitch control push-pull cable at upper attachment point.
NOTE: When disconnecting the push-pull cable bulkhead at the top mast, unscrew only top
(outer) attachment nut and leave lower (inner) attachment nut unchanged.
3
Disconnect roll push-pull cable bulkhead. In order to do so, unscrew and remove top (outer) attachment nut.
4
Disconnect pitch push-pull cable bulkhead. In order to do so, unscrew and remove top (outer) attachment
nut.
5
Disconnect sonsor cable from rotor speed sensor, pneumatic hoses from pneumatic cylinders and remove
respective cable ties.
6
Support the upper mast (using a crane or suitable lifting device) and remove mast attachment hardware.
7
Screw-in an 8 x 120 mm bolt and drive out rubber bushing sleeves using a rubber hammer.
8
Make sure all support lines, cables and controls are safely disconnected and out of the way. Carefully pull out
upper mast
9
Heat up seatings of rubber bushings with a heat gun and push out rubber bushings using appropriate tools.
10 Clean inner bores from residual Loctite and degrease with brake cleaner.
11 Clean outer surface of new bushings. Use abrasive cloth to ensure clean, metallic surface.
12 Check that bushings can be inserted tightly into bores. If necessary, rework outer surface of bushing.
13 Apply AG-BAS-04 (Loctite 638) on outer surface of bushings and install bushings in upper mast. Bushings
shall be centred so that they extend equally to both sides.
14 Remove excessive Loctite. Use brake cleaner, if needed.
15 Apply AG-LUB-03 to pre-rotator drive coupling sleeve and position upper mast. Make sure that coupling
sleeve joins easily.
MMM-CV-E_16-06-13
Part E - 62-51-00 8-1
Page 1 of 2
Manufacturer
Maintenance Manual
AutoGyro
Cavalon
16 Apply AG-GRS-01 on outer surface of bushing sleeves and install bushing sleeves. Use a rubber hammer, if
required.
17 Install attachment hardware and torque-tighten with 20 Nm. Mark bolt heads with securing paint.
18 Re-install push-pull cable bulkhead and rod end for roll control. Mark attachment hardware with securing
paint.
19 Re-install push-pull cable bulkhead and rod end for pitch control. Mark attachment hardware with securing
paint.
20 Re-connect support lines and cables. Secure support lines and cables with cable ties.
21 Have duplicate inspection performed on correct attachment of flight controls, i.e. push-pull cables and
attachments.
WARNING: The ball joint must be installed with at least 8 threads on the rod end of the
push-pull control cable .
22 Check rotor head control angles 62-32-00 6-1 and re-adjust, if necessary.
PARTS LIST
Fig. Pos. Description
PC PIT
Remark
ILLUSTRATIONS
Fig. 1 - Bottom mast with mast mounting bushings
MMM-CV-E_16-06-13
Part E - 62-51-00 8-1
Page 2 of 2
Manufacturer
Maintenance Manual
63-11-10 4-1
AutoGyro
Cavalon
REMOVAL-INSTALLATION: PRE-ROTATOR CLUTCH
HVY
GENERAL, REFERENCES AND REQUIREMENTS
Task may only be performed by an organization trained and entitled to carry out 'Heavy Maintenance'!
Secure gyroplane against unauthorized or unintended operation!
Engine cowlings must be removed, see 52-00-00 4-1
SPECIAL TOOLS AND CONSUMABLE MATERIALS
AG-BAS-02
Loctite 243 blue (88-00-00-S-30483)
LR
IMPORTANT NOTE: Procedure involves parts with limited reusability. Check parts list below
before starting job!
PRECAUTIONS AND SAFETY MEASURES
PROCEDURES
Removal
1
Remove hoses from oil reservoir and seal open ends against contamination.
2
Remove oil reservoir.
3
Loop a lifting belt around the propeller/gearbox shaft and take the load off the engine mounts using
appropriate lifting equipment.
NOTE: Both engine mounts in the LH side remain in place.
4
Unscrew and remove 2 x attachment hardware of engine mounts on RH side. Discard self-locking nuts.
5
With the engine weight unloaded, tilt engine around remaining LH engine mounts as far as necessary (do not
overstretch rubber bushings) in order to get access to the pneumatic clutch.
6
Disconnect pneumatic hose at quick connect coupling.
7
Cut open and discard affected cable ties.
8
Unscrew and remove 4 x M6 bolts and remove pneumatic clutch with attach ring.
NOTE: Do not separate attach ring from clutch and let adapter frame remain on engine.
9
Remove pneumatic clutch by pulling apart sliding shaft coupling.
Installation
10 Insert sliding shaft coupling and position pneumatic clutch with attach ring on adapter frame.
11 Apply AG-BAS-02 on threads and torque-tighten 4 x M6 bolts with 10 Nm.
12 Check that vertical pre-rotator drive can be easily turned by hand.
13 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 clutch, white line to pneumatic box).
14 Perform functional check (engine off) and monitor clutch actuation.
EFFECTIVITY: Pneumatic Clutch III
15 Check clutch activation pressure 5 bar +/- 0.1
16 Re-install engine mounts. Use new self-locking nuts and torque-tighten.
17 Remove lifting belt.
18 Install oil reservoir.
19 Remove seals and re-connect oil hoses to reservoir.
MMM-CV-E_16-06-13
Part E - 63-11-10 4-1
Page 1 of 1
Manufacturer
Maintenance Manual
63-11-10 5-1
AutoGyro
Cavalon
CHECK-ADJUSTMENT: PRE_ROTATOR CLUTCH
LNE
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!
Rotor system must be removed, see 62-11-00 4-1
Engine cowlings must be removed, see 52-00-00 4-1
Mast cover must be removed, see 52-00-00 4-1
SPECIAL TOOLS AND CONSUMABLE MATERIALS
AG-LUB-03
Würth HHS2000 Oil Spray (88-00-00-S-30476)
85-00-00-S-35145 Adjusting Tool Pre-Rotator (CV)
85-00-00-S-36114 Adjusting Scale Pre-Rotator Clutch (CV)
PRECAUTIONS AND SAFETY MEASURES
PROCEDURES
1
Remove shear bolt between Bendix shaft and upper pre-rotator drive (Fig. 1), remove upper pre-rotator drive.
2
Remove M8x20 screw plug with seal ring from the crankcase. Turn the crankshaft by propeller into top dead
centre (TDC) position of cylinder 1 and 2. TDC can be checked with the aid of a lamp through the opening of
the removed screw. When the crankshaft is in correct position screw thread pin (Fig. 2) so that the crankshaft
is blocked.
3
Connect check valve to pressure reducer (see Fig. 3), free flow through check valve in direction to pressure
reducer.
4
Install pressure gauge with T-piece between pre-rotator clutch and pressure reducer (Fig. 4).
5
Switch pneumatic mode selector to FLIGHT, activate and hold pre-rotator until compressor stops working.
The pressure gauge connected between the pre-rotator clutch and the pressure reducer must display about 5
bar.
IMPORTANT NOTE: For the following measurement, ensure that pre-rotator spline shaft is in
a vertical position and that scale and adjusting lever form a right angle.
6
Slide adjusting lever on the pre-rotator spline shaft, hook scale in adjusting lever and pull scale until the
clutch slips noticeably (Fig. 5). Scale must display a breakout force of 80 N ±5 N (or a breakout torque on the
spline shaft of 40 Nm ±2.5 Nm)
7
If necessary adjust pre-rotator clutch via knurled nut on the pressure reducer (Fig. 6) until a breakaway force
of 80 N ±5 N is achieved on the adjusting lever. Secure adjustment with knurled nut.
Upon finalisation a pressure between 5 and 7 bar should be readable on the pressure gauge. If the given
values are not achieved execute 63-11-10 6-1.
8
Remove all adjustment tools and auxiliary devices from the gyroplane, reconnect pneumatic hoses to the
pressure reducer (Fig. 6).
9
Switch pneumatic mode selector to BRAKE.
10 Remove thread pin. Install screw plug with new copper seal ring and tighten with a torque of 15 Nm. For
checking, carefully turn propeller by hand.
11 Lubricate pre-rotator spline shaft with AG-LUB-03, insert upper pre-rotator drive, install shear bolt between
Bendix shaft and upper pre-rotator drive (Fig. 1).
MMM-CV-E_16-06-13
Part E - 63-11-10 5-1
Page 1 of 2
Manufacturer
Maintenance Manual
AutoGyro
Cavalon
ILLUSTRATIONS
Fig. 1 - Upper pre-rotator drive connected to Bendix shaft
Fig. 2 - Thread Pin M8x50
Fig. 3 - Connection of check valve to pressure reducer
Fig. 4 - Connection between clutch and pressure reducer
Fig. 5 - Measurement of breakout torque
Fig. 6 - Pressure reducer
MMM-CV-E_16-06-13
Part E - 63-11-10 5-1
Page 2 of 2
Manufacturer
Maintenance Manual
63-11-10 6-1
AutoGyro
Cavalon
INSPECTION: PRE-ROTATOR CLUTCH
LNE
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!
Engine cowlings must be removed, see 52-00-00 4-1
SPECIAL TOOLS AND CONSUMABLE MATERIALS
None
PRECAUTIONS AND SAFETY MEASURES
PROCEDURES
1
Check wear state of clutch lining. Wear mark (groove in the lining) must be recognizable. See Fig. 1,
dimension A. Replace clutch if necessary.
2
Measure clearance between clutch lining and clutch plate. See Fig. 1, dimension B. Clearance must be
between 1.0 - 1.5 mm. In case clearance is less than 1 mm or more than 1.5 mm contact AutoGyro customer
support.
3
Measure clearance between inner (engine side) drive star disc and outer (clutch side) drive star claws. See
Fig. 1, dimension C. Clearance must be between 1.0 - 1.5 mm. In case clearance is less than 1 mm or more
than 1.5 mm contact AutoGyro customer support.
MMM-CV-E_16-06-13
Part E - 63-11-10 6-1
Page 1 of 2
Manufacturer
Maintenance Manual
AutoGyro
Cavalon
ILLUSTRATIONS
Fig. 1 - Pre-rotator clutch with attach ring
MMM-CV-E_16-06-13
Part E - 63-11-10 6-1
Page 2 of 2
Manufacturer
Maintenance Manual
63-11-10 8-1
AutoGyro
Cavalon
REPLACEMENT: PRE-ROTATOR CLUTCH LINING
HVY
GENERAL, REFERENCES AND REQUIREMENTS
Task may only be performed by an organization trained and entitled to carry out 'Heavy Maintenance'!
Secure gyroplane against unauthorized or unintended operation!
Engine cowlings must be removed, see 52-00-00 4-1
SPECIAL TOOLS AND CONSUMABLE MATERIALS
88-00-00-S-35915 Loctite 7063 Super Clean
88-00-00-S-31023 Loctite 648
88-00-00-S-35790 Installation Aid Dog Gear
PRECAUTIONS AND SAFETY MEASURES
PROCEDURES
1
Disconnect battery according to 24-30-00 4-1, work steps 1 - 2.
2
Remove M8x20 screw plug (Fig. 2) with seal ring from the crankcase. Turn the crankshaft by propeller into
top dead centre (TDC) position of cylinder 1 and 2. TDC can be checked with the aid of a lamp through the
opening of the removed screw. When the crankshaft is in correct position screw thread pin M8x50 (Fig. 3) so
that the crankshaft is blocked.
3
Remove pre-rotator clutch according to 63-11-10 4-1, work steps 1 - 9
IMPORTANT NOTE: New clutch liners feature an with improved design additional brake pad.
Stock items having old design shall be returned to AutoGyro or discarded.
4
Replace clutch liner
In order to do so, untighten central screw. Should it not be possible untighten central screw bore out bolt
head and remove remaining screw thread with pliers. Pull friction plate off the drive shaft axially. Place spare
part and fix it with new central screw.
5
Remove clutch dog gear with ‘Installation Aid Dog Gear’
6
Thoroughly clean the crankshaft and the driver stud with Loctite 7063
CAUTION: For the following work step, use Loctite 648 only! The use of other brands or
alternative products will prevent correct functioning.
7
Apply Loctite 648 on inner and outer thread in sufficient quantity (Fig.4)
CAUTION: For the following work step, the clutch dog gear must be easily screwable
(floating) up to the stop!
8
Screw dog clutch gear onto the thread and remove excess Loctite
9
Tighten dog clutch gear using ‘Installation Aid Dog Gear’ with a torque of 140 Nm (Fig. 5). Clean driver free
of Loctite residues.
10 Check with feeler gauge 0.05 mm whether dog clutch gear is contacted with the flywheel. Feeler gauge 0.05
mm must not be able to stick in between dog clutch gear and flywheel (Fig. 6).
11 Remove thread pin M8x50. Mount M8x20 screw plug with new copper seal ring and tighten with a torque of
15 Nm. For checking, turn carefully the propeller by hand.
12 Re-connect battery according to 24-30-00 4-1, work steps 2 - 1.
13 Re-install pre-rotator clutch according to 63-11-10 4-1, work steps 10 - 19
MMM-CV-E_16-06-13
Part E - 63-11-10 8-1
Page 1 of 2
Manufacturer
Maintenance Manual
AutoGyro
Cavalon
PARTS LIST
Fig. Pos. Description
PC PIT
Replacement set friction plate PK II / III
Remark
L1 61-00-00-S-33383
ILLUSTRATIONS
Fig. 1 - Pneumatic Clutch III
Fig. 2 - M8x20 screw plug
Fig. 3 - Thread Pin M8x50
Fig. 4 - Loctite 648 on inner and outer thread
Fig. 5 - Torque dog gear with 140 Nm
Fig. 6 - Correct mounting position
MMM-CV-E_16-06-13
Part E - 63-11-10 8-1
Page 2 of 2
Manufacturer
Maintenance Manual
63-11-10 8-2
AutoGyro
Cavalon
REPLACEMENT: PRE-ROTATOR CLUTCH DOG GEAR
HVY
GENERAL, REFERENCES AND REQUIREMENTS
Task may only be performed by an organization trained and entitled to carry out 'Heavy Maintenance'!
Secure gyroplane against unauthorized or unintended operation!
Engine cowlings must be removed, see 52-00-00 4-1
SPECIAL TOOLS AND CONSUMABLE MATERIALS
88-00-00-S-35915 Loctite 7063 Super Clean
88-00-00-S-31023 Loctite 648
85-00-00-S-35790 Installation Aid Dog Gear
PRECAUTIONS AND SAFETY MEASURES
PROCEDURES
1
Disconnect battery according to 24-30-00 4-1, work steps 1 - 2.
2
Remove M8x20 screw plug (Fig. 1) with seal ring from the crankcase. Turn the crankshaft by propeller into
top dead centre (TDC) position of cylinder 1 and 2. TDC can be checked with the aid of a lamp through the
opening of the removed screw. When the crankshaft is in correct position screw in thread pin M8x50 (Fig. 2)
so that the crankshaft is blocked (for further information see Rotax Maintenance Manual 12-20-00).
3
Remove pre-rotator clutch according to 63-11-10 4-1, work steps 1 - 9
4
Remove clutch dog gear with ‘Installation Aid Dog Gear’
5
Thoroughly clean the crankshaft and the driver stud with Loctite 7063.
CAUTION: For the following work step, use Loctite 648 only! The use of other brands or
alternative products will prevent correct functioning.
6
Apply Loctite 648 on inner and outer thread in sufficient quantity (Fig.4)
CAUTION: For the following work step, the clutch dog gear must be easily screwable
(floating) up to the stop!
7
Screw dog clutch gear onto the thread and remove excess Loctite
8
Tighten dog clutch gear using ‘Installation Aid Dog Gear’ with a torque of 140 Nm (Fig. 5). Clean driver free
of Loctite residues.
9
Check with feeler gauge 0.05 mm whether dog clutch gear is contacted with the flywheel. Feeler gauge 0.05
mm must not be able to stick in between dog clutch gear and flywheel (Fig. 6).
10 Remove thread pin M8x50. Install M8x20 screw plug with new copper seal ring and tighten with a torque of
15 Nm. For checking, carefully turn propeller by hand.
11 Re-connect battery according to 24-30-00 4-1, work steps 2 - 1
12 Re-install pre-rotator clutch according to 63-11-10 4-1, work steps 10 - 19.
PARTS LIST
Fig. Pos. Description
pressure plate rear
MMM-CV-E_16-06-13
PC PIT
Remark
L1 61-00-00-V-33792
Part E - 63-11-10 8-2
Page 1 of 2
Manufacturer
Maintenance Manual
AutoGyro
Cavalon
ILLUSTRATIONS
Fig. 1 - M8x20 screw plug
Fig. 2 - Thread Pin M8x50
Fig. 3 - Loctite 648 on inner and outer thread
Fig. 4 - Correct mounting position
MMM-CV-E_16-06-13
Part E - 63-11-10 8-2
Page 2 of 2
Manufacturer
Maintenance Manual
63-11-30 6-1
AutoGyro
Cavalon
INSPECTION: PRE-ROTATOR UPPER ENGAGEMENT
LNE
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!
Gyroplane must be placed on level ground and restrained (blocks, chocks)
Mast cover must be removed, see 52-00-00 4-1
SPECIAL TOOLS AND CONSUMABLE MATERIALS
AG-GRS-01
Lagermeister WHS 2002 Grease (88-00-00-S-30477)
PRECAUTIONS AND SAFETY MEASURES
PROCEDURES
1
Inspect wear pattern and gear mesh of pre-rotator upper engagement. If in doubt, contact AutoGyro
customer support.
2
If the wear pattern is uneven (see Fig. 1), e.g. due to dynamic skew, the pre-rotoator upper engagement /
Bendix shaft must be repaired acc. to 63-11-30 8-2.
IMPORTANT NOTE: adjustment job is classified as heavy maintenance (HVY)!
3
Inspect backlash of pre-rotator upper engagement. Backlash should be as tight as possible, but also wide
enough to allow easy engagement of the pinion into the sprocket in any position.
4
If necessary, have backlash adjusted 62-31-00 5-1.
IMPORTANT NOTE: adjustment job is classified as heavy maintenance (HVY)!
5
Grease with AG-GRS-01.
ILLUSTRATIONS
Fig. 1 - Wear Pattern (uneven)
MMM-CV-E_16-06-13
Part E - 63-11-30 6-1
Page 1 of 1
Manufacturer
Maintenance Manual
63-11-30 8-1
AutoGyro
Cavalon
REPLACEMENT: PRE-ROTATOR UPPER BEARINGS
HVY
GENERAL, REFERENCES AND REQUIREMENTS
Task may only be performed by an organization trained and entitled to carry out 'Heavy Maintenance'!
Secure gyroplane against unauthorized or unintended operation!
Gyroplane must be placed on level ground and restrained (blocks, chocks)
Mast cover must be removed, see 52-00-00 4-1
SPECIAL TOOLS AND CONSUMABLE MATERIALS
AG-BAS-02
Loctite 243 blue (88-00-00-S-30483)
AG-BAS-05
Loctite 2701 green (88-00-00-S-30482)
PRECAUTIONS AND SAFETY MEASURES
PROCEDURES
1
Remove bolts (1/9) and washers (2/8).
2
Remove bracket (3/7) and replace bearing as required.
3
Apply a thin layer of AG-BAS-02 on threads of bolts (1/9), install bolts with serrated washers (2/8) and
torque-tighten bolts.
4
Perform 63-11-30 6-1 "INSPECTION: PRE-ROTATOR UPPER ENGAGEMENT"
PARTS LIST
Fig. Pos. Description
PC PIT
1
1
Rivet 4x12 A2
1
2
Bearing 6200 ZZNR
1
3
Bracket pre rot top
1
4
bendix
1
5
M8x71 DIN 912 8x90
NPI
1
6
U8
NPI
1
7
M8 Si
NPI
1
8
Bendix shaft helix
NPI
1
9
Bendix shaft
1
10 Bearing 6202 ZZNR
1
11 Bracket pre rot bottom
NPI
1
12 Safety washer M4
NPI
1
13 M4x8
NPI
MMM-CV-E_16-06-13
Remark
NPI
L2 27-30-00-V-20719
NPI
L2 27-30-00-V-20700
NPI
L2 27-30-00-V-20719
Part E - 63-11-30 8-1
Page 1 of 2
Manufacturer
Maintenance Manual
AutoGyro
Cavalon
ILLUSTRATIONS
Fig. 1 - Prerotator upper bearing
MMM-CV-E_16-06-13
Part E - 63-11-30 8-1
Page 2 of 2
Manufacturer
Maintenance Manual
63-11-30 8-2
AutoGyro
Cavalon
REPAIR: PRE-ROTATOR UPPER ENGAGEMENT
HVY
GENERAL, REFERENCES AND REQUIREMENTS
Task may only be performed by an organization trained and entitled to carry out 'Heavy Maintenance'!
Secure gyroplane against unauthorized or unintended operation!
Gyroplane must be placed on level ground and restrained (blocks, chocks)
SPECIAL TOOLS AND CONSUMABLE MATERIALS
AG-BAS-04
Loctite 638 green (88-00-00-S-30485)
PRECAUTIONS AND SAFETY MEASURES
PROCEDURES
NOTE: For removal, replacement or re-installation of bearings, refer to 63-11-30 8-1
"REPLACEMENT: PRE-ROTATOR UPPER BEARINGS"
1
Remove lower bearing and ensure that the shaft is, in free load condition, centrally positioned in the bearing
seating. If free play in the upper bearing is present, the following must be carried out:
2
Free play due to bearing abrasion: Replace upper bearing and glue Bendix shaft with Loctite 638 (high
strength / AG-BAS-04) into the upper bearing. Re-assemble lower bearing.
3
Free play due to abrasion of the Bendix shaft from ball bearing inner ring: Glue Bendix shaft with
Loctite 638 (high strength / AG-BAS-04) into upper bearing. Re-assemble lower bearing. If free play is
greater than 1/10 mm, then replace Bendix shaft with new part and glue new part with Loctite 638 (high
strength / AG-BAS-04) into upper bearing. Re-assemble lower bearing.
4
If in doubt or different cause of error suspected, contact AutoGyro customer support.
5
Grease with AG-GRS-01.
PARTS LIST
Fig. Pos. Description
PC PIT
Bearing 6200 ZZNR
L2 27-30-00-V-20719
Bendix shaft long
L2 27-30-00-V-31801
MMM-CV-E_16-06-13
Part E - 63-11-30 8-2
Remark
Page 1 of 1
Manufacturer
Maintenance Manual
63-51-00 8-1
AutoGyro
Cavalon
REPLACEMENT: ROTOR BRAKE PAD
LNE
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!
Gyroplane must be placed on level ground and restrained (blocks, chocks)
Mast cover must be removed, see 52-00-00 4-1
SPECIAL TOOLS AND CONSUMABLE MATERIALS
AG-BAS-02
Loctite 243 blue (88-00-00-S-30483)
SP
IMPORTANT NOTE: Procedure involves spare parts. Check parts list below for ordering
details of affected components!
PRECAUTIONS AND SAFETY MEASURES
IMPORTANT NOTE: Procedure involves handling and disposal of special materials. For your health and
environmental aspects respect all applicable regulations!
PROCEDURES
NOTE: Brake pad can be replaced without disassembly of the rotor head.
1
Turn rotor so that bolts (1) can be accessed through the holes in the pre-rotator sprocket disc.
2
Unscrew bolts (1) and replace brake pad (2). Dispose of properly!
3
Install new brake pad.
4
Apply AG-BAS-02 on threads, install bolts (1) and tighten.
PARTS LIST
Fig. Pos. Description
PC PIT
1
1
M6x8 Countersunk
1
2
Brake pad assembly
1
3
brake pad ground plate
NPI
1
4
M6 35/8
NPI
1
6
Spacer 13-5,5/10-6/6
NPI
MMM-CV-E_16-06-13
Remark
NPI
L1 27-30-00-V-31054
Part E - 63-51-00 8-1
Page 1 of 2
Manufacturer
Maintenance Manual
AutoGyro
Cavalon
ILLUSTRATIONS
Fig. 1 - Rotor bridge with brake pad
MMM-CV-E_16-06-13
Part E - 63-51-00 8-1
Page 2 of 2
Manufacturer
Maintenance Manual
67-00-00 6-1
AutoGyro
Cavalon
INSPECTION: FLIGHT CONTROL PUSH-PULL CABLES
LNE
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!
Mast cover must be removed, see 52-00-00 4-1
SPECIAL TOOLS AND CONSUMABLE MATERIALS
None
PRECAUTIONS AND SAFETY MEASURES
PROCEDURES
1
Inspect upper attachment points of pitch and roll control push-pull cables. Check firm installation, colour seal
intact. Check condition of rubber seal.
2
Inspect lower attachment point of pitch control push-pull cable. Check firm installation, colour seal intact.
3
Inspect lower attachment point of roll control push-pull cable. Check firm installation, colour seal intact.
4
Check free play of the pitch control push-pull cable. In order to do so, modify the rotor head stop using the
shaft of a drill or similar (see Fig. 1) and apply a minimum of 8 bar of brake pressure. Measure free play /
dead travel of flight control stick as depicted in Fig. 1.
5
Check free play of the roll control push-pull cable. Measure lateral free play / dead travel of flight control stick
against the natural friction of the gimbal head.
6
If free play in any control axis exceeds 8 mm at control stick head contact AutoGyro customer support.
MMM-CV-E_16-06-13
Part E - 67-00-00 6-1
Page 1 of 2
Manufacturer
Maintenance Manual
AutoGyro
Cavalon
ILLUSTRATIONS
Fig. 1 - Pitch and Roll - upper attachment
Fig. 2 - Modification of rotor head stop
Fig. 3 - Measurement of freeplay
MMM-CV-E_16-06-13
Part E - 67-00-00 6-1
Page 2 of 2
Manufacturer
Maintenance Manual
67-00-00 8-1
AutoGyro
Cavalon
RETROFIT: PPC CLAMPS
HVY
GENERAL, REFERENCES AND REQUIREMENTS
Task may only be performed by an organization trained and entitled to carry out 'Heavy Maintenance'!
Secure gyroplane against unauthorized or unintended operation!
Rotor system must be removed, see 62-11-00 4-1
SPECIAL TOOLS AND CONSUMABLE MATERIALS
88-00-00-S-33587 Screw Securing and Thread-Sealing Varnish yellow
PRECAUTIONS AND SAFETY MEASURES
WARNING: Job includes work at critical flight controls. Duplicate inspection must be performed after
completion!
CAUTION: Braided steel lines are highly abrasive!
CAUTION: Failure to comply with this instruction will cause the loss of warranty referred and/or related
components.
PROCEDURES
1
Open service access cover to reach middle radius of the push-pull control cables.
2
If necessary push aside disturbing lines and remove relevant cable ties.
3
Attach the PPC clamps to the PPC Pitch and PPC Roll in the middle radius of push-pull control cables. Insert
two M5 bolts and two serrated washers and torque-tighten bolts with 1.5 Nm (Fig.1).
4
Check the roll and nick control with the stick and make sure a constant is resistance is noticeable.
5
If you notice resistance peaks (chattering) in flight control, untighten the respective PPC clamp(s) and torquetighten with 1.0 Nm again. Increase the torque value of PPC clamps in 0.1 Nm steps until there are
resistance peaks in flight control noticeable. Finally, decrease the torque value of PPC clamps in 0.1Nm
steps until there is constant resistance in the stick noticeable
6
Check the push-pull control cables according to 67-00-00 6-2.
7
Secure bolts of PPC clamps with securing paint.
8
Reposition pushed-aside lines from step 2 into original position and fix with cable ties.
9
Close the access service cover.
PARTS LIST
Fig. Pos. Description
PPC clamp
MMM-CV-E_16-06-13
PC PIT
Remark
27-30-00-V-37944
Part E - 67-05-00 8-1
Page 1 of 2
Manufacturer
Maintenance Manual
AutoGyro
Cavalon
ILLUSTRATIONS
PPC Clamps
MMM-CV-E_16-06-13
Part E - 67-05-00 8-1
Page 2 of 2
Manufacturer
Maintenance Manual
67-05-00 8-1
AutoGyro
Cavalon
REPLACEMENT: PITCH TRIM/BRAKE PNEUMATIC SEAL
HVY
GENERAL, REFERENCES AND REQUIREMENTS
Task may only be performed by an organization trained and entitled to carry out 'Heavy Maintenance'!
Secure gyroplane against unauthorized or unintended operation!
Mast cover must be removed, see 52-00-00 4-1
SPECIAL TOOLS AND CONSUMABLE MATERIALS
AG-BAS-02
Loctite 243 blue (88-00-00-S-30483)
SP
IMPORTANT NOTE: Procedure involves spare parts. Check parts list below for ordering
details of affected components!
PRECAUTIONS AND SAFETY MEASURES
PROCEDURES
1
Install rotor lash bag to support rotor system.
2
Switch pneumatic mode selector to FLIGHT and release trim pressure completely. If necessary, switch
repeatedly!
3
Disconnect ball joint (rod end) from rotor brake bracket (ground plate).
4
Retract cylinder (pneumatic mode selector to FLIGHT and trim aft) and remove ball head from rod end.
5
Remove circlip / snap ring with appropriate tool.
6
Tilt pneumatic cylinder aft and pull out piston completely. In order to do so, switch pneumatic mode selector
to BRAKE and apply brake pressure.
NOTE: The servo-valve requires a certain system pressure to switch-over to BRAKE mode.
If brake pressure is not built-up during compressor activation, switch to FLIGHT, run the
compressor (trim AFT) for some seconds and switch-over to BRAKE mode with the
compressor engaged.
7
Remove old seal ring and discard. Install new seal ring using the special grease provided in the package.
8
Re-install piston and re-assemble pneumatic cylinder. Re-install circlip / snap ring.
9
Apply AG-BAS-02 on threads, install ball head and tighten.
10 Re-connect ball joint with rotor brake bracket (ground plate).
PARTS LIST
Fig. Pos. Description
PC PIT
Pneumatic cylinder brake/trim repair kit
MMM-CV-E_16-06-13
Remark
L1 27-30-00-S-32926
Part E - 67-05-00 8-1
Page 1 of 1
Manufacturer
Maintenance Manual
67-10-00 4-1
REMOVAL-INSTALLATION: CENTRE CONSOLE
AutoGyro
Cavalon
LNE
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!
SPECIAL TOOLS AND CONSUMABLE MATERIALS
None
PRECAUTIONS AND SAFETY MEASURES
PROCEDURES
Removal
1
Untighten the 3 central bolts by about 5 revolutions.
2
Unscrew and remove the 10 circumference bolts.
EFFECTIVITY: Cabin heating installed
3
Remove dummy plug and unscrew bolt in order to detach heating control lever from heating control valve
(use a 2.5 mm round head Allen key).
4
Apply tape at the surrounding areas as surface protection.
5
Pull console aft and slip-out brake fluid reservoir (front).
Installation
6
Re-install in reverse order (work steps 5 to 1)
NOTE: The heating control lever is connected to the valve by a force-type connection.
Ensure correct installation and operation!
MMM-CV-E_16-06-13
Part E - 67-10-00 4-1
Page 1 of 2
Manufacturer
Maintenance Manual
AutoGyro
Cavalon
ILLUSTRATIONS
Fig. 1 - Centre Console
MMM-CV-E_16-06-13
Part E - 67-10-00 4-1
Page 2 of 2
Manufacturer
Maintenance Manual
71-20-00 6-1
AutoGyro
Cavalon
INSPECTION: CLEARANCE ENGINE INSTALLATION (R914) LNE
GENERAL, REFERENCES AND REQUIREMENTS
Task may only be performed by an organization or individual trained and entitled to carry out 'Line Maintenance'!
Engine cowlings must be removed, see 52-00-00 4-1
SPECIAL TOOLS AND CONSUMABLE MATERIALS
None
PRECAUTIONS AND SAFETY MEASURES
PROCEDURES
NOTE: A clearance of less than 3 mm between airbox and engine support and/or wear marks
may indicate worn-out engine mounting bushings. If the following work steps do not
corrects the situation the engine mounting bushings must be replaced 71-20-00 8-1.
1
Untighten the connection couplings (see markings in Fig. 1).
2
Adjust clearance of at least 5 mm.
3
Tighten the connection couplings.
ILLUSTRATIONS
Fig. 1 - Clearance airbox to engine mounting frame
(R914)
MMM-CV-E_16-06-13
Part E - 71-20-00 6-1
Page 1 of 1
Manufacturer
Maintenance Manual
71-30-00 4-1
AutoGyro
Cavalon
REMOVAL-INSTALLATION: FIRE WALL
LNE
GENERAL, REFERENCES AND REQUIREMENTS
Task may only be performed by an organization or individual trained and entitled to carry out 'Line Maintenance'!
Engine cowlings must be removed, see 52-00-00 4-1
SPECIAL TOOLS AND CONSUMABLE MATERIALS
None
PRECAUTIONS AND SAFETY MEASURES
PROCEDURES
Removal
NOTE: The removable part actually consists of two parts joint by connecting bolts which, in
most cases, do not need to be separated at removal or installation.
1
Remove air intake box.
2
Remove 24 x attachment bolt with plastic washer.
3
Carefully pull out fire wall - removable part(s).
Installation
5
Install fire wall in reverse order (work steps 3 to 1) using moderate torque.
ILLUSTRATIONS
Fig. 1 - Fire Wall - removable part(s)
MMM-CV-E_16-06-13
Part E - 71-30-00 4-1
Page 1 of 1
Manufacturer
Maintenance Manual
75-00-00 4-1
AutoGyro
Cavalon
REMOVAL-INSTALLATION:RADIATOR
HVY
GENERAL, REFERENCES AND REQUIREMENTS
Task may only be performed by an organization trained and entitled to carry out 'Heavy Maintenance'!
Secure gyroplane against unauthorized or unintended operation!
Engine cowlings must be removed, see 52-00-00 4-1
Execute procedure only in cold engine condition!
SPECIAL TOOLS AND CONSUMABLE MATERIALS
AG-CPA-02
Radiator coolant BASF G48 Protect Plus (71-70-00-V-30163)
CMM
Refer to the component/device manufacturer's documentation.
PRECAUTIONS AND SAFETY MEASURES
PROCEDURES
Removal
1
Disconnect coolant outlet on cylinder 1, open expansion tank and drain coolant
2
Unscrew radiator brackets (left and right hand side) from propeller gearbox
3
Disconnect electronic connectors for radiator fan
4
Disconnect coolant hose between expansion tank and radiator from the radiator
5
Unscrew the two forward radiator attachment points
6
Disconnect radiator inlet and outlet hoses from radiator
7
Remove radiator from the engine
8
Remove radiator brackets (left and right hand side / see step 2) from radiator
Installation
9
For installation execute removal in reverse order
10 For coolant mixture and filling quantity refer to 12-40-00 and engine manufacturers manual.
MMM-CV-E_16-06-13
Part E - 75-00-00 4-1
Page 1 of 1
Manufacturer
Maintenance Manual
75-00-00 8-2
AutoGyro
Cavalon
MODIFICATION: RECONFIGURE FAN REVERSE
LNE
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!
Engine cowlings must be removed, see 52-00-00 4-1
Fire wall must be removed, see 71-30-00 4-1
SPECIAL TOOLS AND CONSUMABLE MATERIALS
None
PRECAUTIONS AND SAFETY MEASURES
WARNING: Electrical shorting of the battery will produce high current with the risk of personal injury and
damage to equipment!
PROCEDURES
1
Disconnect battery according to 24-30-00 4-1, work steps 1 - 2.
2
Detach fan reverse control unit (Fig. 1) from rear wall, cut fan reverse cable (Fig. 2) and remove fan reverse
control unit.
3
Isolate red wire 0,5 mm and black wire 0,5 mm with shrinking hoses and remove insulation of all 1,5 mm
wires (Fig. 2).
4
Crimp isolated butt connectors to wires and connect red/red and black/black (Fig. 3). Make sure connectors
are properly isolated to avoid shortcut.
5
Secure cable and connectors with cable ties according to Fig. 4.
6
Re-connect battery according to 24-30-00 4-1, work steps 2 - 1.
7
Perform functional check.
2
2
2
PARTS LIST
Fig. Pos. Description
Replacement set Mast Attachment
MMM-CV-E_16-06-13
PC PIT
Remark
L2 27-30-00-S-35972
Part E - 75-00-00 8-2
Page 1 of 2
Manufacturer
Maintenance Manual
AutoGyro
Cavalon
ILLUSTRATIONS
Fig. 1 - Fan reverse control unit
Fig. 2 - Fan reverse cable - detached
Fig. 3 - Fan reverse cable - modified
Fig. 4 - Fan reverse cable - secured
MMM-CV-E_16-06-13
Part E - 75-00-00 8-2
Page 2 of 2
Manufacturer
Maintenance Manual
78-20-00 8-1
AutoGyro
Cavalon
REPLACEMENT: WOOL OF MUFFLER TUBE
LNE
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!
Execute procedure only in cold engine condition!
Engine cowlings must be removed, see 52-00-00 4-1!
SPECIAL TOOLS AND CONSUMABLE MATERIALS
LR
IMPORTANT NOTE: Procedure involves parts with limited reusability. Check parts list below
before starting job!
SP
IMPORTANT NOTE: Procedure involves spare parts. Check parts list below for ordering
details of affected components!
PRECAUTIONS AND SAFETY MEASURES
WARNING: Risk of severe burns and scalds! Hot engine parts! Always allow engine to cool down to
ambient temperature before start any work!
WARNING: Wear eye protection and mind FOD when removing attachment hardware!
CAUTION: When removing or disassembling make sure to mark all parts so that each and every part of
the component is re-assembled and installed in exactly the same location and orientation!
PROCEDURES
Removal
1
Remove and dispose the locking wire of the hose clamps.
2
Loosen the hinge pin clamp (Fig.1).
3
Before replacing the muffler tube, mark the position so that the muffler tube can be exactly installed in the
same location and orientation.
4
Remove the hose clamps and keep them for the installation procedure (Fig.2). Inspect the hose clamps for
possible damage.
5
Remove and clamp muffler tube in bench vise carefully.
6
Use appropriate tools to drive out the riveting mandrels.
7
Drill out the rivet pin (Fig.3). Then, use appropriate tool to tap out the pin of the rivet
9
Remove the rivet mandrel and rivet heads from the wool if it is left in place. Make sure any metal swarf is
removed.
10 Check the wool. If it is visibly burnt, remove it completely.
11 Install the whole new wool with tension tightly around the pipe (Fig.4).
Installation
Important: Rivet the outer shell to the hot end of the muffler tube.
Effectivity: When the outer shell is riveted to the cold end (Fig.5).
12 When the outer shell is riveted to the cold end, reposition the outer shell so that the outer shell can be riveted
to the hot end (Abb.1).
13 Install the outer shell and mark the position of the four rivet holes.
14 Remove the outer shell and drill four holes. Make sure any metal swarf is removed.
Effectivity: END
MMM-CV-E_16-06-13
Part E - 78-20-00 8-1
Page 1 of 5
Manufacturer
Maintenance Manual
AutoGyro
Cavalon
15 Install the outer shell. Make sure that the rivets holes of muffler tube and the steel tube are perfectly lined up
(Fig.6).
16 Insert the four rivets into the hole and install them with a rivet gun (Fig.6).
17 Set and fix the muffler tube into the correct position with hose clamps and hinge pin clamp, so that the muffler
tube remains adjustable (Fig.7).
18 Fix the bottom cowling according to chapter 52-00-00 4-1. Make sure that the pipe of muffler tube is placed in
the middle opening (surrounding 15 mm). If necessary, adjust the position of the muffler tube (Fig.8).
19 Remove the bottom cowling and tighten the two hose clamps and hinge pin clamp.
20 Secure the screws of hose clamps with locking wire (Fig.9).
21 Install the cowling according to chapter 52-00-00 4-1 .
PARTS LIST
Fig. Pos. Description
PC PIT
Replacement kit wool aftersilencer
L1 78-20-00-S-33478
Conversion Kit overflow muffler shell
L1 78-20-00-S-42441
MMM-CV-E_16-06-13
Part E - 78-20-00 8-1
Remark
Page 2 of 5
Manufacturer
Maintenance Manual
AutoGyro
Cavalon
ILLUSTRATIONS
Fig 1 - Rivets at the hot and hinge pin clamp
Fig. 2 - Hose clamps
Fig. 3 - Drill out the rivet pin
MMM-CV-E_16-06-13
Part E - 78-20-00 8-1
Page 3 of 5
Manufacturer
Maintenance Manual
AutoGyro
Cavalon
Fig. 4 - Installation of absorption wool
Fig. 5 - Rivets at the cold end of muffler tube
Fig. 6 - Riveting of the outer shell
MMM-CV-E_16-06-13
Part E - 78-20-00 8-1
Page 4 of 5
Manufacturer
Maintenance Manual
AutoGyro
Cavalon
Fig. 7 - Installation of hose clamps and hinge pin clamp
Fig. 8 - Position of the muffler tube
Fig. 9 - Installation of locking wire
MMM-CV-E_16-06-13
Part E - 78-20-00 8-1
Page 5 of 5
Tragschrauber Flug- und Betriebshandbuch
AutoGyro GmbH
Dornierstrasse 14
31137 Hildesheim
Germany
Phone +49 (0) 5121 / 880 56– 00
info@auto-gyro.com
www.auto-gyro.com
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