AUTOGYRO MT-03 GYROPLANE MAINTENANCE MANUAL

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AUTOGYRO MT-03 GYROPLANE

MAINTENANCE MANUAL

Aircraft Registration: _________________ Aircraft serial no.____________________ Engine type: ________________________ Engine serial No: ____________________ Rotor blade type & diameter: NACA 8H12 8,4m Propeller type: HTC 3B CW1,73m CONTENTS AND CHECK LIST OF PAGES Content Page Rev. Page No. Cover page Title page Publishing details Contents and checklist of pages Section 1

Amendments to the schedule Section 2

Foreword Gyroplane Maintenance

Section 3 Owner/Operator responsibilities Certifying persons responsibilities General inspection standards Airworthiness life limitations Airworthiness Directives & Mandatory Permit Directives Airworthiness Notices Overhaul and test periods Service information Modifications Duplicate inspections Permit Maintenance Releases Scheduled maintenance worksheets Definitions

Section 4 Permit maintenance release

Section 5 The maintenance check cycle Permitted variations Notes

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Section 6 Pilot's pre-flight check Check A

Section 7

Scheduled maintenance worksheets

Section 8 Annual Inspection (Flight test)

Section 9 Aircraft systems description and maintenance methods

a) Airframe b) Engine and controls c) Electrical d) Pneumatic e) Rotor f) Propeller g) Pre rotator h) Rotor brake and trim i) Enclosure, seats, harnesses j) Instruments k) Suspension, wheels and brakes l) Rudder and rudder control m) Rotor head and rotor head control

SECTION 1 AMENDMENTS TO THE SCHEDULE 1. Where & when necessary AutoGyro will issue updates to this maintenance standard, and will notify known owners in the form of replacement pages with changes appropriately identified. 2. Amendments must be incorporated without delay and recorded below 3. Issue 1, Oct 2005 Draft only, awaiting creation/clarification of service methods etc. Amend No.

Pages affected Comments Signature & date

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SECTION 2 FOREWORD 1. Applicability This Schedule is intended for use on the MT-03 Gyroplane only, released on AAN ????? 2. Guidance This aircraft may be being flown & operated under a PFA or CAA Permit to fly. In either case specific rules may exist, such as the types of work allowed by owners on PFA aircraft or CAP520 ‘Light Aircraft Maintenance’. It is the aircraft operators’ responsibility to ensure the aircraft is operated within those rules and regulations. 3. Notes AutoGyro provides this maintenance schedule so that, to the best of their knowledge, the operator is able to maintain the aircraft in a manner that will preserve its airworthiness. The manufacturer is unable to predict all operating conditions, and as such it is the operators ongoing responsibility to assess the schedule for applicability to the environment operated within. Note; check your Permit to Fly – if compliance to this schedule is stated as required, then non-compliance may invalidate the Permit to Fly. SECTION 3 OWNER/OPERATOR RESPONSIBILITIES Operators are responsible for the accomplishment of the maintenance prescribed in the schedule. CERTIFYING PERSONS RESPONSIBILITIES Certifying persons must use their engineering skill and judgement in determining the depth of inspection needed and other matters that could affect the airworthiness of the gyroplane. In order to claim any alleviation on subsequent inspections, the gyroplane maintenance records must record the extent of previous inspections upon which the alleviation is based. Certifying persons are responsible for recording in the appropriate log book or worksheet, any defects, deficiencies or additional maintenance required as a result of implementation of the schedule. GENERAL INSPECTION STANDARDS The general inspection standards applied to individual task inspections must meet the recommended standards and practices of AutoGyro. In the absence of general inspection standards, refer to CAA CAP 562 Civil Aircraft Airworthiness Information and Procedures (CAAIP) or other CAA recommended standards and practices, and/or the PFA Gyroplane Maintenance manual. Inspections may be carried out without component removal or dismantling unless considered necessary or where required by the schedule. AIRWORTHINESS LIFE LIMITATIONS (RETIREMENT/SCRAP LIVES) Airworthiness life limitations shall be those published by the CAA, state of design and AutoGyro . Airworthiness life limitations should be recorded in CAP 543 Time Limited Task Record, or an appropriate equivalent.

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AIRWORTHINESS DIRECTIVES All applicable Airworthiness Directives or Mandatory Permit Directives issued by the CAA or PFA and the state of design must be complied with. Compliance with AD’s or MPD’s should be recorded in Part C of CAP'S 398, 399 or 400, or an approved equivalent. AIRWORTHINESS NOTICES All applicable mandatory CAA Airworthiness Notices (CAP 455) must be complied with. Compliance with CAA Airworthiness Notices should be recorded in Part C of CAP'S 396, 399 or 400, or an approved equivalent. OVERHAUL AND TEST PERIODS Overhaul and test periods shall be those shown & recommended by AutoGyro . The CAA may vary or mandate overhaul and test periods by the issue of an Airworthiness Directive or Airworthiness Notice. Airworthiness Notice No. 35 relates to engines. The overhaul and test periods should be recorded in CAP 543 Time Limited Task Record, or an appropriate equivalent. SERVICE INFORMATION Service information (Service Bulletins, Service Letters, etc) published by AutoGyro should be formally technically assessed by the Owner/Operator and adopted if required to ensure operational safety and reliability, compliance with service information should be recorded in Part C of CAP 398, 399 or 400, or an approved equivalent. MODIFICATIONS Approved modifications which have been carried out to the gyroplane, engine, components and radio after original manufacture, must be recorded in the appropriate log book(s). Any recurring inspection or maintenance task resulting from approved modifications should be recorded in CAP 543 Time Limited Task Record, or an appropriate equivalent. DUPLICATE INSPECTIONS Following initial assembly or any disturbance of a control system or vital point, the procedures outlined in British Civil Airworthiness Requirements (BCAR) Section A/8, Chapter A6-2/B6-2 and A5-3 shall be applied. Certifications must be recorded in the appropriate worksheet, log book or aircraft technical log. In summary, this procedure requires that all and any such changes be cross checked by either a PFA approved Inspector or Certified Engineer prior to first flight, and this cross check shall be as thorough as practical – including physical tests if appropriate. In exceptional circumstances the PFA also allow another qualified gyroplane pilot to cross check modifications – this person must sign the logbooks to certify their actions. PERMIT MAINTENANCE RELEASE On completion of any check required (‘required’=stated in the Permit to Fly) by the schedule, except pilot maintenance (see section 5) and Check A (see section 6), an entry shall be made in Column 6 of CAP398 Aircraft Log Book, CAP399 Engine Log Book or an approved equivalent as Section 4. The certifying person's signature, authority and date must be made in Column 7 against the relevant category (Airframe, Engine, Radio). The following is an example of an entry acceptable to the PFA & CAA:

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Airframe

Engine

PERMIT MAINTENANCE RELEASE Cross refer to workpack ref; 50 hr/100 hr/Annual Check/Star Inspection (delete as appropriate) has been carried out to my satisfaction at total airframe hours……. and in that respect is considered fit for flight Signed…………………...Authorisation ref………….Date………. Maintenance Schedule Ref. SGL/MM/2003 Issue 1

Radio (Annual check only)

SCHEDULED MAINTENANCE WORKSHEETS Worksheets shown in Section 8 must be issued and the tasks certified for all scheduled maintenance checks. These worksheets become part of the maintenance records required to be kept by the operator. All maintenance carried out in connection with a particular check should be certified on suitably referenced worksheets and included in the gyroplane records. These worksheets must be cross-referenced in the appropriate log book(s) giving general details of the additional maintenance carried out. DEFINITIONS Throughout the schedule the following terms and abbreviations have the stated definitions; SERVICE/LUBRICATION (SERVICE/LUB): The term 'Service or Lubrication' requires that a component or system should be serviced and/or replenished as necessary with fuel, oil, grease, water, etc., to the condition specified. The term service may also be used to require filter cleaning or replacement. INSPECT (INSP): An ‘Inspection' is a visual check performed externally or internally in suitable lighting conditions from a distance considered necessary to detect unsatisfactory conditions/discrepancies using, where necessary, inspection aids such as mirrors, torches, magnifying glass etc. Surface cleaning and removal of detachable cowlings, panels, covers and fabric may be required to be able to satisfy the inspection requirements. OPERATIONAL CHECK (OP/C): An 'Operational Check' is a test used to determine that a system or component or any function thereof is operating normally. FUNCTIONAL CHECK (F/C): A 'Functional Check' is a detailed examination of a complete system, sub-system or component to determine if operating parameters are within limits of range of movement, rate of flow, temperature, pressure, revolutions per minute, degrees of travel, etc., as specified in the appropriate maintenance manual. Measured parameters should be recorded. CHECK (CHK): A 'Check' is the verification of compliance with the type design organisation's recommendations.

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SECTION 4 PERMIT MAINTENANCE RELEASE This maintenance certification system is specific for the PFA (Popular Flying Association), in accordance with BCAR A3-7. Owner operators must ensure their airframe and engine logbooks either contain a sticker with the wording ‘Any reference to a Certificate of Release to service in this logbook shall be construed as a PMR’ & ‘The certification at the top of each page in Part A of this logbook is superseded by the following statement; The work recorded below has been completed to my satisfaction and in that respect the aircraft is considered fit for flight’, or have new logbooks containing this information. In addition, for the older style logbooks, a sticker in Part A should be present saying ‘ The provisions of CAA exemption EX/02/2003/PMR for aircraft type…..registration….. are hereby revoked. The revised certification requirements of BCAR A3-7 in respect of the certification of maintenance are adopted in lieu of the previous requirements for a Flight Release Certificate’. The signatories for the PMR shall be one of the following:

• A person appropriately authorised by an organisation approved by the CAA or PFA for that purpose.

A PMR entry example is shown above in the previous section A signed PMR does not expire or is superseded by subsequent PMR’s, unless relating to a repeat of the same activity. A PMR remains active as long as the activity it relates to remains part of the aircraft. Pilot Maintenance A licensed pilot who is the owner or operator of the gyroplane may carry out certain maintenance tasks prescribed in Air Navigation (General) Regulation 16, but only if the gyroplane has a Permit to Fly in the private or special category. The issue of a PMR is not required. The pilot must include his pilot's licence number with his signature in the appropriate log book(s). The permitted pilot maintenance is as below; PERMITTED PILOT MAINTENANCE This section defines the type end extent of maintenance that may be carried out and certified by a pilot who is the owner of the aircraft and operates under a PFA Permit to Fly. 1. Replacement of landing gear tyres, or tailwheel.

(Including removal and replacement of wheels, cleaning and servicing of wheel bearings, application of creep marks, removal and refitting of brake units to the extent required for wheel removal and the removal and the renewal of brake pads/linings when special tools are not required. Replenishment of hydraulic brake system fluid level).

2. Replacement of defective safety wiring or split pins excluding those in engine, transmission, flight control and rotor systems.

3. Repairs to upholstery and decorative furnishing of the cabin or cockpit Interior when repair does not require dismantling of any structures or operating system or interfere with an operating system or affect the structure of the aircraft.

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4. Repairs, not requiring welding, to fairings, non-strutural cover plates and cowlings. 5. Replacement of safety belts or safety harness. 6. Replacement of seats or seat parts not involving dismantling of any structure of any operating

system. 7. Replacement of bulbs, reflectors, glasses, lenses or lights. 8. Replacement of any cowling not requiring removal of the propeller, rotors or disconnection of

engine or flight controls. 9. Replacement of unserviceable sparking plugs.

(Including removal, cleaning, gaping, testing and refitting of all spark plugs). 10. Replacement of batteries.

(Including maintenance of lead acid batteries) 11. Replacement of wings and tall surfaces and controls, the attachments of which are designed to

provide for assembly immediately before each flight and dismantling after each flight. 12. Replacement of main rotor blades that are designed for removal where special tools are not

required. 13. Replacement of VHF communications equipment, only if is not combined with navigation

equipment. 14. Manufacture and installation of required cockpit placards and notices. 15. Lubrication of aircraft.

(Including prior cleaning of hinges) 16. Inspection of engine Induction air filter.

(Including removal, cleaning and refitting). 17. Inspection of fuel filters.

(Including removal, cleaning and refitting). 18. Changing of engine oil.

(Including removal, cleaning/replacement, refitting of oil filter). Annual Check The annual check and all associated work must be accomplished under the supervision of an organisation appropriately approved by the CAA (eg Popular Flying Association approved Inspector). SECTION 5 THE MAINTENANCE CHECK CYCLE Check title Content Period Check A Check A Prior to the first flight of the day

50 hour check 50 hour check items Not exceeding 50 flying hours, or 6 months, whichever is the sooner

100 hour check 50 & 100 hour check items Not exceeding 100 flying hours

Annual check 50, 100 hour and annual check items

Not exceeding 12 months (see Note 5) & prior to renewal of Permit to Fly

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PERMITTED VARIATIONS (see Notes) Tasks controlled by flying hours Maximum Variation 50 hour and 100 hour 10% Tasks controlled by calendar time Maximum Variation 6 months 1 month Annual None Tasks controlled by more than one limit The more restrictive limit shall be applied Notes 1. Permitted variations may not be applied to applicable airworthiness life limitations, airworthiness directives or overhaul and test periods. 2. Permitted variations for tasks controlled by flying hours should not be understood to be a maintenance planning tool, but as an exceptional means to allow the operator to fly for a limited period of time until the required maintenance is performed. 3. Any application of a permitted variation to the maintenance cheek cycle period must be recorded in the appropriate log book(s) together with the reason for the variation by a person who is authorised to sign the log book entry for that particular check. Details of the permitted variation must be made visible to the pilot. 4. Permitted variations are not required to be deducted from the next scheduled check. 5. The annual check may be anticipated by a maximum period of 62 days without loss of the continuity of the maintenance check cycle. Thus, for example, where the full 62 days is invoked, the following annual check would become due 14 months after the completion of the annual check that was anticipated. The period by which the annual check was anticipated and the date of the next annual check shall be recorded in the appropriate log book(s). SECTION 6 PILOT'S PRE-FLIGHT CHECK Pre-flight checks are to be carried out in accordance with the Gyroplane Flight Manual, Pilot's Operations Handbook, Pilot's Notes or Operations Manual. CHECK A - PRIOR TO FIRST FLIGHT OF THE DAY

MT-03 GGYROPLANE PRE FLIGHT CHECKLIST This list is a guideline of items to be checked prior to the flight. No checklist is "All Inclusive", nor is it to be construed as a substitute for proper

training or pilot experience.

Task Aircraft area Task & task type A1 General Note; wherever possible checks should be carried out with a qualified person in the pilot

seat in case of accidental starting, and to operate controls correctly. Op/C - Both ignition (magneto) switches in sound condition and switched OFF Remove frost, snow or ice, if present

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Check - that the gyroplane documents are available and in order. Ensure all loose equipment is correctly stowed and the gyroplane is free of extraneous items. If single seat operation, ensure rear seat cushion is stowed securely, and seat belt fastened. If the gyroplane has not been regularly used, ensure before resumption of flying that: (a) Either (i) the engine has been turned weekly or run fortnightly or (ii) the manufacturer's recommendations have been complied with (b) Previously reported defects have been addressed

A2 Windscreen Inspect - for damage and cleanliness (clean as required) A3 Fuselage Inspect - skin/covering, struts, and tubular structure for damage, corrosion, cracking and

security of all items Inspect - drain holes and vents for freedom from obstruction Remove pitot head cover if fitted, and inspect orifice for cleanliness Inspect - radio aerials for damage and security Inspect - condition and security of fiberglass enclosure

A4 Landing Gear Inspect - that extension appears normal Inspect - tyres for proper inflation (2,2bar main and 1,8bar nosewheel), damage and creep Inspect - brake installation for external evidence of leaks and correct fluid level, and for damage and security Inspect – brake disc securing screws (4 each) are tight Inspect – that nose wheel pivots easily and control rods are fastened correctly

A5 Flying Controls

Op/C - Rudder controls move rudder and nosewheel from lock to lock and operates in the correct sense. Inspect - Rudder pedals for security of hardware, for proper operation, and for absence of binding. Inspect - Rudder cables for security of hardware and nico clamps, cables for fraying and kinking. Op/C - Control stick moves freely to roll and pitch stops simultaneously with the rotor head and in the correct sense. Inspect – Pneumatic control set to ‘ROTOR LOCK’ not ‘FLIGHT’. Inspect – linkages between stick and rotor head for loose bearings, loose items, bent or damaged tubes or excess backlash.

A6 Powerplant/ Engine

Service/lube - Oil reservoirs (where fitted) are full & caps secure, & coolant system full with correct fluid. Inspect – coolant (water and oil) hoses free from splits Inspect - All springs secure and wired where appropriate, esp exhaust Inspect - Exhaust system securely mounted, and free from splits or cracks cracks, leaks etc. Inspect - Air filters clean and secure Inspect - Engine mountings in place and secure and rubbers free of cracks or any deterioration Inspect - Plugs and plug caps secure Inspect – coolant and oil radiator for condition, security and leakage, Note: inspect all soldered joints for evidence of cracking. Op/C - engine controls for full and free movement in the correct sense Inspect – all ‘loose’ cables around engine for correct attachment and connection

A7 Propeller Inspect - Propeller blades & hub clean and free of cracks, splits & damage Inspect - Propeller blades securely mounted to hub, and hub to engine (all bolts/nuts wirelocked & present) Op/C - Propeller and engine turns over smoothly (in normal direction of travel) with no undue noises etc (with ignition OFF and throttles closed!!) Remember, it may start!! If possible chock the aircraft and/or apply brakes!

A8 Fuel System Inspect - Both tanks for security and condition, ensure absence of leakage, check cap for seal and security, check sight gauge, check fuel level, check fuel shut off valve for proper

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operation. Inspect - check fuel line for security, cuts, dry rot, and kinks, check selector valve for proper operation. Inspect - Fuel filter – ensure filter is clear of debris

A9 Rotor Inspect - Rotor teeter bolt, nut and locking pin in place and rotates freely Inspect - Blade to hub bolts, nuts and locking pins (if used) in place Inspect - No sign of blade cracking or other failure (visual check) Op/C - Rotor teeters freely to stops (both planes) and rotates freely (check with/without control stick). Ensure centrifugal teeter stops swing freely Inspect - Blades clean and free from chips, dents or damage Inspect – that teeter bolt has been correctly lubricated

A10 Spin up mechanism

Op/C - Secure and free, and that the belt is free of splits/cracks Inspect – pre rotator gear wheel for cracks or damage Inspect - pre rotator universal joints for free operation or failure Inspect – engine mounting bracket for cracks/fractures

A11 Tail assembly Op/C - condition and security, check surface for delamination, check cables for fraying and firm connection to rudder, check nico clamps for security, check horizontal stabilisors and fins for security and any sign of damage from heavy tail down landings. Op/C – check rudder bearings for security and operation Op/C – check that cable pulleys work smoothly

A12 Cabin area & Instruments

Op/C - Safety harness mountings secure, webbing free of tears/frays, and connects/disconnects freely on demand Inspect that seats are securely attached to airframe (and rear seat refixed in place) Inspect - Radio secure, battery charged (if applicable) Inspect - Electrical wiring sound and secure - no sign of overheating or damage Inspect - instrument readings are consistent with ambient conditions Inspect - Test operation of electrical circuits Inspect - that markings and placards are legible

A13 Airframe Inspect – Welded joints for any sign of distress or accident damage. Inspect – all hardware for tightness/security

A14 Pneumatics Inspect airlines and cylinders for loose fittings

A15 Other Op/C - Ground run. Confirm full power obtainable (if practical), & that engine, propeller & rotor vibration is within normal limits. Confirm all gauges reading normally.

SECTION 7 - SCHEDULED MAINTENANCE WORKSHEETS

MT-03 Gyroplane General Maintenance Plan (to be read and actioned in conjunction with engine, propeller and rotor manufacturers service instructions)

Note – all annual checks are Star Inspections. Task No. Task Description First

10h Task interval

Repetition or comments Cert sig & date

Airframe Inspection All items – repeat inspections as shown

1 Check - Bolt torques – mast fittings X 100hr/ M6 bolts to 10Nm+/-1Nm 2 Check - Bolt torques – other X annual 3 Inspect - Wheel bearings smooth operation (3

places) 100hr/ Wheel bearings sealed for life

4 annual 5 Check nosewheel fork for straightness. Replace

if bent 100hr/

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6 Inspect landing gear spar and attachments to airframe for damage or fatigue (cracks & deformation). Replace if severe

annual

7 Check - tyre pressures & tyre creep (1,5 to 2,2bar if heavily loaded)

X 100hr/

8 Change brake fluid 3yrs This is a main dealer item! Refill from master cylinder with callipers immersed in fluid. If system is spongy after bleeding, check discs for flatness and wheel bolts for straightness.

9 Inspect - airframe for damage, twisting, buckling or other deformation, especially at welded joints at bottom of the mast. If found ground aircraft and return to supplier.

100hrs/annual

10 Inspect - External structure of enclosure sound and firmly fixed to airframe

50hr/ annual

Electrical/instruments

11 Inspect - panel connections for security X 50hr/ annual

Inspect – gel battery for leakage 50hr/ annual

Rotor head

12 Renew main bearing 1000hrs Bearing bolt torque 150Nm+/-10Nm (plus split pin) NOTE: when tightening hub onto backing plate ensure that the clearance between the main gear and bendix gear is minimised from 0.05 to 0.15mm Glue bearing temp sensor in with hot melt adhesive. Clearance of rotor speed sensor to gear is 1mm

13 Op/C - Ring gear security and bolt attachment 100hrs/annual

Bolts are 25Nm

14 Check, Service/lube - teeter bolt & bearings for damage & wear. Clean, regrease & refit

100hrs/ annual

Regrease via nipple on top of rotor. Grease TBA

15 Check, If worn, replace side bushes 100hr/ annual

16 Service/lube – Strip gimbal joints, check for wear, regrease and reassemble.

100hr/ annual

Torque up bolts to clamp side plates to gimbal block. Back off bolts by ½ turn.

Replace teeter bolt and bushes 100hrs Sideways float between hub bar and bushes 0.025mm

Lubricate Bendix gear & spiral gear with WD40 100hrs

Lubricate rotor brake pivot.

Check pad for function, change pad and backplate as one unit (service item)

100hrs

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Check Trim cylinder for free function and slider damage. Replace if required.

100hrs When replacing fit rod end fully onto shaft, and tighten. Loctite!

Protect bare metal with Motor Plus

Blades

Diss-assemble blades from hub bar 100hrs

Film of WD40 to allow blade movement

Blade to hub Bolt torque 7,5Nm. Teeter bolt torque 0-1Nm, bolt must be free to turn under 1Nm. Use new nuts!

Check Centrifugal teeter stops for free operation. Lubricate as required

First 25hr & 100hr

Rotor Head Controls

17 Service/lube - clean rod ends (if appropriate) 100hrs 18 F/C - control rod ends for cracks & freedom of

movement both free and at control extremes 100hrs

19 F/C- rotor head reaches pitch and roll stops 100hrs

20 Inspect - all tubes straight, all bearings free, all bearing retaining rivets secure

X 100hrs

Task No. Task Description First

10h Task interval


21 Op/C - for free play in stick control eg bearings or wear

X 25hr

22 Service/lube - Check pedals for ease of movement

50hr/ annual

23 Inspect for cable freedom of movement at tail and pedal attachment. Lubricate ends.

X 25hr

24 Inspect - rudder cables for frays, corrosion or chaffing, and nico sleeves for signs of movement.

X 25hr

25 Inspect - tail bearings for looseness and freedom of operation

25hr

26 Inspect - tail for security to airframe (4 bolts) 25hr 27 Op/C - all cable pulleys for security & wear 25hr 28 Inspect – rudder to tail fastenings 25hr 29 F/C rudder control cable tension 100hr/

annual ???? from Otmar

30 Engine Controls

NOTE! All engine checks to be in accordance with manufacturers manual!

For Rotax 912 or 914 refer to Bombardier Rotax document (unless specified otherwise in engine handbook)

Fuel system

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31 Service/lube - Completely drain system and flush with fresh

If fuel left standing for more than three months

32 Service/lube - Change or clean fuel filter (1 filter on S engine, three on the Turbo)

100hrs/annual

(Or as per engine manual)

33 Inspect - fuel tank caps for seal deterioration & security of fit

100hrs/annual

34 Op/C - functionality of fuel gauges 100hrs/annual

ie that full = full, and empty=empty if gauges fitted, or that sight level is still visible

Check breather pipe filter for blockage. Replace

100hr/ annual 3yrs

Check inside tanks for debris – flush as required 100hr/ annual

Check all hoses for cracks and deterioration 100hr/ annual

Pre rotator

35 Inspect- drive shafts for bend or damage and belt for splits or damage Lubricate belt with silicon spray if stick slip found. Replace belt when insufficient tension under pressure to operate pre rotator.

X 100hrs/annual

36 Op/C – Cycle by hand thru full range – check drive shaft joints for free movement and bearings for play etc

100hrs/annual

37 Inspect – security of pneumatic cylinder and mountings

100hrs/annual

Inspect - drive unit engagement to rotor drive gear.

Do not grease this unit! – very light oil only or it will start to jam.

Check Wheel brake for function – if whel rotates freely, turn brake rubber thru 90 degrees to correct function. Replace when worn with service part.

Trim System, Rotor Brake & Pneumatics

38 Inspect – all hoses for leaks and slave cylinder for looseness

50hr/ annual

Change compressor water absorber annual Inspect – compressor. Listen for undue noises in

operation. 50hr/

annual Use manufacturers manual if needed

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Full functional check

100hr/ annual

In brake position, brake operates and function is acceptable. Change to flight. (2 to 3 sec change to release air from brake system – if otherwise adjust valve) In flight position check that trim goes on and off in same direction as button. Untrimmed position. Start pre rotator. Ensure cylinder engages, and when the stick is pulled back it disengages. Stick to front, release pre rotater and confirm that pressure is applied to trim and stick comes back slightly. In brake position, but 3 bar on and ensure pre rotator does not function.

Task No. Task Description First

10h Task interval


Propeller

41 F/C - tracking & balance to manufacturers recommendations

25hr Or as recommended by engine/propeller manufacturer

42 Check - prop bolt torques 25hr Check - torques on blade to hub bar bolts/nuts 25hr Inspect - blades to manufacturers

recommendations for any damage, splits etc. Repair only as manufactures recommendations

25hr Take care with water ingress into propeller blades. If necessary rotate slowly to drain water

Rotors

43 F/C - tracking & balance to manufacturers recommendations

25hr Or as recommended by engine/propeller manufacturer

44 Check - teeter bolt torque 25hr 45 Check - torques on blade to hub bar bolts/nuts 25hr 46 Inspect blades to manufacturers

recommendations for any damage, splits etc. Repair only as manufactures recommendations

25hr

Grease teeter bolt 25hr Other

47 Inspect - for brake pad wear. Replace as necessary. If clippers are sticking or uneven wear is found, remove wheel bolts and check for straightness.

50hr/ annual

Service part

48 Inspect - Confirm all placards readable and in line with Operating Limitations

50hr/ annual

49 Check aircraft weight and balance As required

Weight/balance check after any change in aircraft mass distribution

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50 Inspect all seat belt attachment points for tightness and security

50hr/ annual

51 Inspect each seat belt for damage or frays, and for security of main connection

50hr/ annual

52 F/C - ASI calibration annual

53 F/C – compass calibration annual

54 F/C – altimeter calibration annual

55 Op/C - Instrument checks annual

Final ground run checks prior to release

56 Inspect - Power plant and coolant system for leaks

57 Inspect – instruments for measurements consistent with ambient conditions

58 Inspect – all access covers secure

59 Ensure all log book entries completed appropriately

Tasks completed by: Date:

Engine hours logged: Airframe hours logged:

Tasks checked and certified by: Date: Inspector or licence no.:

Comments:

SECTION 8 - ANNUAL INSPECTION Annual Flight Test Schedule. All tests are classified as Op/C. Note, these are transposed with type modifications from the PFA Permit renewal application Test No.

Test Task Result Initial

1. Preparation Load aircraft to normal maximum operating weight – refer to Operating Limitations and hang check data as cross check. Record all up weight, including pilot.

Fr Pilot wt: Rr Pilot wt: Fuel load: Empty wt: (inc rotors) Rotor type:

2. Engine run & ground checks

Run engine to normal operating temperatures. Tie down and record max rpm and thrust achieved. Check operation of engine/fuel controls, ignition and carb heat (if fitted). Check flying & trimming controls for full & free movement, excess backlash and sense of operation.

Max rpm: Thrust: Comments (acceptable/unacceptable)

3. Taxying Check for maneuvering ability, ie, turning radii, directional stability under braking. Check braking efficiency and operation and for absence of nose-wheel shimmy at higher speeds.

Comments (acceptable/unacceptable)

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4. Pre spin operation

Check functioning of rotor pre-rotator mechanism, noting RPM achieved. Note rotor vibration level during the ground-handling phase.

Rpm achieved:

5. Take off The take off is to be made at full power, using standard gyroplane technique. Note any unusual characteristics.


6. Climb The time taken to climb from 1,000 feet to 2,000 feet (QNH) should be recorded. Prior to reaching 1,000 feet, the aircraft must be established in the climb at the normal best climb airspeed, with full throttle set and zero sideslip. Care must be taken to ensure the aircraft has settled in the climb and the airspeed is kept within plus or minus 2Kts/3mph of the selected speed throughout. The climb should not be carried out near cloud or turbulent air and a steady heading must be maintained into wind to limit sideslip.

QNH: Air temperature: Climb airspeed kts/mph: Climb engine RPM: Time to climb Comments (acceptable/unacceptable)

7. In Flight maneuvering

The aircraft should possess an adequate range of control function to enable full control about its three axes at all flight speeds. It must be operable without a requirement for high piloting skills during any maneuver. It should not exhibit any serious tendency to enter pilot induced oscillation at any power settings. Should this occur, It should remain fully controllable using standard gyroplane-piloting techniques. Control forces during all manoeuvres should be normal for a gyroplane. Monitor control responses and rotor/airframe vibration levels throughout all the following maneuvers. Accomplish: High speed flight up to published VNE speed (162km/hr). Minimum slow-speed flight using maximum engine-power to sustain altitude. Steep turns in each direction using sufficient power to maintain altitude, flying at a constant bank-angle of 45° (30° at Vmax, 10° at Vne) and at a constant turn-rate. Spiral descent at flight idle engine-RPM, using minimum rate of descent airspeed with turns in each direction; check directional stability. Vertical descent at 25mph indicated airspeed using standard entry and recovery techniques; (entry at minimum of 1,500 feet AGL, power on). Recovery to stable powered climb following a baulked glide approach (Vmin, power off).


8. Functional checks

Control: during flight Op/C that all controls including trimmer systems operate without excessive friction and their operation does not provide a distraction to the pilot. Check rudder trim-tab/centering springs for adjustment. Instruments: Inspect all instruments for correct indications with particular emphasis on the flight instruments, including ASI, Altimeter, Compass


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and Rotor Tachometer. Engine: Op/C all engine controls function in a satisfactory manner and all indications are normal. Fuel should be selected from all fitted fuel tanks for a period of not less than three minutes each.

9. Radio, where fitted.

Op/C radio transmit/receive at 2,000 feet (maximum) and 30 nautical miles distance from ground station (including hand held where using aircraft mounted wiring)

Radio strength:

10. Landing Using standard gyroplane-handling technique for landing, monitor any unusual handling or functioning characteristics of the machine including the rotor and rotor brake.


Notes:

Test pilot full name ________________ PPL(G) No______________ Date of flight______________________ Place of flight____________

SECTION 9 - Aircraft systems description and maintenance methods General notes;

1. These instructions are not all encompassing, and should always be used in line with good aircraft engineering practices, and manuals such as AC43.13 or similar.

2. Safety; working on an aircraft brings many hazards. Always wear suitable personal protective equipment such as overalls, safety glasses, safety shoes, gloves etc appropriate for the maintenance task. If possible render the engine inoperable prior to starting work.

3. Wherever possible SI units are used 4. Always use good quality tools appropriate for the task 5. Use of non standard or unauthorised parts or repairs will invalidate the warranty 6. Special tools (list) 7. Lubricants (list oils and greases) 8. Loctites and sealants (list)

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9. General corrosion prevention 10. Help protect our environment by disposing of parts and fluids properly. 11. Standard bolt torques are M4 no spec, M6 15Nm+/-2Nm, M8 25Nm+/-3Nm, M10

35Nm +/-4Nm, M12 100Nm +/-10Nm a) Airframe Basic description The airframe is made of 1.4301 stainless steel tube and laser cut brackets, jig welded together with 1.4571 wire. After assembly it is cleaned and electropolished to improve the surface finish. Assembly methods Insert top and side view of airframe None – factory assembled only Special setup instructions None – factory assembled only Repair methods None. In the event of an accident damaging the airframe, then the only sensible action is to replace the airframe. Do not take risks with the primary structure! Contact the manufacturer for more information, such as key dimensions for checking straightness etc. b) Engine and controls Basic description The engine is either a Rotax 912 ULS or a 914. Both use an identical engine mounting. Materials used Engine mounting frame Engine Radiator Oil cooling radiator Standard Rotax hoses Fasteners Assembly methods Bolt torques to mounting frame Bolt torques other Brackets Control cables Fuel system (picture of fuel system etc) Special setup instructions Repair methods For engine repairs see the Rotax service instructions

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c) Electrical Basic description This is a ..volt DC system, supplied via the engine alternator Circuit diagram needed Materials used Alternator Battery Rectifier Assembly methods Special setup instructions Repair methods d) Pneumatic Basic description A small pneumatic pump supplies a reservoir. From this air is used to pressurise a cylinder to engage the pre rotator, and to operate a two way cylinder that either engages the rotor brake or the trim system. Circuit diagram Materials used Pump & reservoir Trim/brake cylinder Pre rotator cylinder Assembly methods Special setup instructions Repair methods e) Rotor Basic description The rotor is a two blade teetering design. Each blade is an extruded section, containing tip weights and an end closure plate. The blades are stamped to match the hub assembly to prevent incorrect assembly. The torque to clamp the blades to the hub is functionally important, as the blades are allowed to move to find their own balance point

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Materials used Blade material Assembly methods Blade to hub torque Teeter bolt torque Do not remove the balance bars or their retaining screws. Special setup instructions Repair methods Nicks and small edge damage can be flattened back with very fine wet ‘n’ dry paper and polished out. Dirt and insect debris should be removed prior to flight – the smoother the rotor surface, the better the performance. Damage resulting from impacting a fixed object hard, even if not visible to the naked eye, should result in grounding the aircraft for a thorough inspection for mast torque twisting and blade root stress. If in doubt, replace the rotors. f) Propeller Basic description The HTC propeller is fitted as standard. This is a 3 bladed composite design with an aluminium hub. Materials used 1,73m diameter HTC propeller assembly M6x.. bolt with nylock nuts Assembly methods Bolt torque…Nm Approx blade angle Special setup instructions Use gauge to match angle blade to blade Blade runout max Repair methods None – replace damaged blades g) Pre rotator Basic description A belt drive takes the power from the propeller disc to a simple drive shaft arrangement to the rotorhead via small universal joints. Engagement to the toothed wheel attached to the rotor head is through an ordinary centrifugal gear as used on car starter motors.

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Materials used Assembly methods Bolt torques Special setup instructions Repair methods The belt is a service item h) Rotor brake and trim Basic description A simple pneumatic system using a two way cylinder actuates either the rotor brake or the trim if in flight. Picture Materials used Assembly methods Special setup instructions Repair methods The brake pad is a service item i) Enclosure, seats, harnesses Basic description The pilot enclosure is manufactured from GRP (or if ordered specially, carbon fibre). The seats are the same, with cushions for comfort. The seat belts are four point harnesses. Note that the front seat shoulder harness is attached to the rear of the seat only, and is not approved as a full restraint! Materials used Assembly methods Enclosure and seat retaining screw torques Seat belt harness retaining bolt torques Special setup instructions Ensure seat belt links to the airframe are able to swivel freely

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Repair methods Seat belts – none. Replace if damaged, worn or frayed GRP parts. Small accident damage can be repaired using normal GRP techniques. Recommended resin is; j) Instruments Basic description ASI Altitude Engine rpm Rotor rpm Exhaust gas Cylinder head temp Fuel level Pneumatic pressure Materials used List manufacturer Assembly methods Special setup instructions Ensure any replaced instruments have suitable placards fitted Repair methods Only repair instruments in accordance with manufacturer recommendations k) Suspension, wheels and brakes Basic description The main suspension spar is a GRP moulding (as are the wheel spats) The brake system and wheels are manufactured by Autogyro Europe Tires are (nose) (main). There is no tail wheel. Brake pads are service items Materials used Tyres Tubes? Assembly methods Wheel bolt torque Spar to airframe bolt torque Special setup instructions Tire pressure 2,2bar main, 1,8bar nose Nosegear centralisation setup

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Nosegear to pedal linkage setup Repair methods Brake pads are service items. Brake seals Brake tube Brake fluid is….. Brake bleeding is achieved by… l) Rudder and rudder control Basic description The rear tail assembly and rudder are GRP mouldings. The rudder pivots on a ball bearing on the bottom, with a simple top pivot. The tail is mounted on the airframe via 4 x M bolts The rudder is controlled via steel foot pedals, for pilot and passenger (linked via rods), linked to the rudder via two steel cables. Adjustment is via a turnbuckle in each cable. Cable is supported on pulleys along the airframe. Diagram of cable layout Materials used Cable spec Assembly methods Required cable tension is Individual foot pedal mid position is Rudder offset left/right at pedals central position is 85cm +/-1cm from rudder tip to top of radius of RH side fin Show cable path Repair methods Cable may be replaced by new identical material. Ensure that nicopress sleeves are correctly crimped and cable load tested. m) Rotor head and rotor head control Basic description All rotor head parts (excepting bolts) are stainless steel or aircraft aluminium as per the airframe. (pictures) The roll and pitch stops are set with bolts and are not adjustable Lubrication points are fitted. Control tubes Rod ends Bearings

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Materials used Head bearing spec Assembly methods Pitch/roll M x .. bolt torque Nm Rotor head to mast M x .. bolt torque Nm Other bolt torques Special setup instructions Ensure that, after all setup, the rotor head is able to reach roll and pitch stops in both directions, and that at the extremes of operation the vertical control rods are still free to rotate. Teeter stops must be set to give a +/- 15° rotor blade movement. Check that at this angle the blade does not impact the rudder. Ensure that the head rotates freely without any binding or bearing noise. Replace the bearing if needed. Ensure there is no freeplay in the control system by moving the stick(s) with the rotor head held still. If found, locate the cause and rectify. Repair methods This is a primary control system – do not take chances! Bent tubes must be replaced Teeter bolt or pitch/roll bolts and bushes should be replaced if noticeable wear is found.

Documents

AUTOGYRO MT-03 GYROPLANE MAINTENANCE MANUAL