AutoGyro MTOsport Maintenance Manual Download

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Manufacturer

Maintenance Manual

AutoGyro

MTOsport

MMM-CV-E_16-06-13

Part E - 61-10-00 4-2

Page 1 of 2

61-10-00 4-2 DISASSEMBLY-ASSEMBLY: PROPELLER - HTC

LNE

GENERAL, REFERENCES AND REQUIREMENTS

Task may only be performed by an organization or individual trained and entitled to do 'Line Maintenance'!

Propeller must be removed, see

61-10-00 4-1

SPECIAL TOOLS AND CONSUMABLE MATERIALS

PRECAUTIONS AND SAFETY MEASURES

PROCEDURES

Disassembly

Mark inner and outer propeller hub to indicate relative installation position.

Place propeller assembly on a horizontal and clean surface and support propeller hub so that assembly does
not lie on propeller blades.

Unscrew and remove bolts (4).

Remove outer propeller hub and remove individual blades.

Assembly

Place inner propeller hub on horizontal and clean surface and support propeller hub.

Insert individual blades in correct position.

Attach outer propeller hub, insert bolts (4) and hand-tighten.

Torque-tighten bolts (4) with 10 Nm in crosswise sequence.

PARTS LIST

Fig. Pos. Description

PC PIT

Remark

1 Spinner set, painted

L2 53-00-00-M-30587

2 Propeller attachment kit

L1 61-00-00-M-30064 incl. 3

6 HTC CCW-3B-172-CG Propeller 912

L1 61-00-00-S-31628 incl. 4, 5, 7

6 HTC CCW-3B-172-CG Propeller 914

L1 61-00-00-M-30398 incl. 4, 5, 7

8 atachment kit spinner HTC

L2 71-00-00-M-31116 incl. 9, 10

Summary of Contents for MTOsport

Page 1: ...Manufacturer Maintenance Manual Line Maintenance ...

Page 2: ......

Page 3: ...Manufacturer Maintenance Manual AutoGyro MTOsport MMM MT A_16 02 08 Part A Introduction and Declarations Page 1 of 12 Manufacturer Maintenance Manual for Gyroplane MTOsport ...

Page 4: ...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 Autho...

Page 5: ...cribed 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 Lett...

Page 6: ...Manufacturer Maintenance Manual AutoGyro MTOsport MMM MT A_16 02 08 Part A Introduction and Declarations Page 4 of 12 INTENTIONALLY LEFT BLANK ...

Page 7: ...rd 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 ...

Page 8: ...Manufacturer Maintenance Manual AutoGyro MTOsport MMM MT A_16 02 08 Part A Introduction and Declarations Page 6 of 12 INTENTIONALLY LEFT BLANK ...

Page 9: ...mentation 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 r...

Page 10: ...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...

Page 11: ...CAUTIONS 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 belo...

Page 12: ...FECTIVITY 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...

Page 13: ... LR Limited reusability Parts or components that can be used only once or a limited number of times such as self locking nuts split pins LTA Lufttüchtigkeitsanweisung AD issued by the Airworthiness Authority MAP Manifold Absolute Pressure MI Manufacturer Information Letter dt Herstellerinformation MLL Manufacturer Life Limit MMM Manufacturer Maintenance Manual N A not applicable NPI non procurable...

Page 14: ...ion and Declarations Page 12 of 12 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 ...

Page 15: ...ections 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 Tes...

Page 16: ...r Maintenance Manual AutoGyro MTOsport MMM MT B_14 11 19 Part B Master Servicing Manual Ch 00 20 Page 2 of 24 CHAPTER 13 17 UNASSIGNED N A 22 CHAPTER 18 VIBRATION NOISE ANALYSIS 23 CHAPTER 19 20 UNASSIGNED N A 24 ...

Page 17: ...with swivelling rotor head It features an open cockpit fuselage with two seats in tandem configuration The load carrying frame consists of inert gas welded stainless steel square tubing Fuselage 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 cons...

Page 18: ...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 ...

Page 19: ...ale 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 ...

Page 20: ...astic or unsupported tube joints 01 21 00 Standard Commercial Tools Most maintenance tasks on the MTOsport 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 To...

Page 21: ...iply 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...

Page 22: ...MTOsport MMM MT B_14 11 19 Part B Master Servicing Manual Ch 00 20 Page 8 of 24 Celsius Fahrenheit Conversion Chart 150 100 50 0 50 100 150 200 250 300 350 400 450 500 100 75 50 25 0 25 50 75 100 125 150 175 200 225 250 Fahrenheit F Celsius C ...

Page 23: ... 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 C...

Page 24: ...ion 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 require...

Page 25: ...fety independent of its condition ATA Equipment System MLL 24 30 00 Battery See manufacturer 25 10 00 Seat belts 10 yrs 25 60 00 ELT Battery See manufacturer 28 20 00 Fuel filter 200 hrs 2 yrs 28 20 00 Fuel pumps 5 yrs R912 28 20 00 Primary fuel pump 1000 hrs R914 62 00 00 Rotor System I 1500 hrs 62 00 00 Rotor System II 2500 hrs 62 31 00 Rotor main bearing 1500 hrs 62 32 00 Gimbal head bolts 1500...

Page 26: ...r 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 en...

Page 27: ...tion Teeter hinge see Ch 12 Servicing 5 hrs rec N A Lubrication Pre rotator drive coupling sleeve as req N A Lubrication Pre rotator belt and pulleys as required N A Cleaning replacement Engine air filter as req N A 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...

Page 28: ... 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 antifreez...

Page 29: ...prox 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 ro...

Page 30: ...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 dow...

Page 31: ...l AutoGyro MTOsport MMM MT B_14 11 19 Part B Master Servicing Manual Ch 00 20 Page 17 of 24 CHAPTER 06 DIMENSIONS AREAS Length 5 08 m Width 1 88 m Height 2 71 m Rotor diameter 8 4 m Rotor disc area 55 4 sqm Propeller diameter 1 72 m ...

Page 32: ...rain 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...

Page 33: ...es prohibited Flight in icing conditions prohibited For additional limitations see Flight Manual In clear view of the pilot Max gross weight ________ Empty weight ________ Max useful load ________ At front seat Max weight in seat 125 kg Min weight in seat 60 kg At aft seat Max weight in seat 129 kg Solo from front seat only Occupant warning front and aft seat OCCUPANT WARNING This aircraft has not...

Page 34: ...ge compartment in nose section Max load 10 kg W B must be respected At fuel filler neck Min ROZ 95 AVGAS 100LL At each fuel tank Capacity 34 litres At fuel shut off valve if installed At oil filler neck Engine Oil ___________________ Approved oil types see engine manual At both static ports if installed Static Port Do not obstruct ...

Page 35: ...e below Lubrication Pre rotator belt and pulleys 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 th...

Page 36: ... 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 anti freeze and water which gives freezing protection down to 20 C Check protection temperature of the coolant and add anti freeze if necessary Verify coolant level in the expansion tank replenish as required up to the top Verify coolant level in the overfl...

Page 37: ... 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...

Page 38: ...bjective 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 Adjus...

Page 39: ...els 7 31 60 00 Integrated Display Systems 11 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 Dis...

Page 40: ... 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 20 00 Engine Mounts 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 Shutdo...

Page 41: ... 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 var...

Page 42: ... power demand for various consumers is provided in the following table ATA Reference Equipment System Power load 24 3 Generator 240 W 23 1 Radio ATR500 2 W rcv 35 W xmt 23 1 Radio ATR833 7 W rcv 35 W xmt 28 2 Electrical fuel pump ea 21 W 33 4 NAV Lights conventional 108 W 33 4 Strobe Lights conventional 83 W 33 4 Landing Light conventional 100 W 33 4 NAV Lights LED 9 W 33 4 Strobe Lights LED 28 W ...

Page 43: ...t station using steel cables which are routed horizontally along the main frame Both pairs of pedals are interconnected by a linkage The nose wheel steering is directly linked to pedal rudder control input by control rods The tension of the control cables that connect the aft pedals with the rudder can be adjusted by turnbuckles Tension value and procedure is described in Part E of this manual The...

Page 44: ...2 engine variant a secondary electrical pump P2 with filter can be configured as an option Fuel system ROTAX 912 Fuel system ROTAX 914 IMPORTANT NOTE Fuel filters are Manufacturer Life Limited MLL 28 40 00 Indicating Markings at the front side of the fuel tanks show fuel quantity in level attitude using a scale and numerical values for every 5 10 litres The marking shows fuel tank quantity per tan...

Page 45: ...it 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 The Glass Cockpit layout is tailored to the integrated flight and navigation suite FlyMap LD In addition to navigational a...

Page 46: ...installed 6 Cut out 3 1 8 for optional installations 20 MAG switches 7 Oil pressure 21 Master starter switch 8 End position detection IVO propeller 22 GEN and LOW VOLT warning lights if installed 23 Hour meter 9 Engine RPM 24 Low fuel warning light if installed 10 Pneumatic mode selector 25 BOOST Warn Caution light R914 11 Radio if installed 26 Trim brake pressure gauge 12 Manifold pressure gauge ...

Page 47: ...talled 6 Cylinder head temperature 20 Low fuel warning light if installed 7 End position detection IVO propeller 21 BOOST Warn Caution lights R914 if installed 22 Manifold pressure gauge if inst 8 12V power receptacle if installed 23 MAG switches 9 Overdrive push button 24 Master starter switch 10 Altimeter 25 Trim brake pressure gauge 11 Inst frame for moving map system 26 Rotor bearing temperatu...

Page 48: ... 18 ATC transponder if installed if installed 19 Oil pressure 6 Engine RPM 20 Oil temperature 7 Rotor RPM 21 Cylinder head temperature 8 Air speed indicator 22 GEN and LOW VOLT warning lights 9 Low fuel warning light if installed 23 BOOST Warn Caution light R914 10 Vertical compass if installed 24 Cut out 2 for optional installations 11 Fuel level indicator if installed 25 Switches 2 nd fuel pump ...

Page 49: ...d as backup instrumentation Panel Layout Glass Cockpit FlyMap LD 1 Magnetic compass 11 ELT remote control if installed 2 Back up altimeter 12 Pneumatic mode selector 3 Compass 2 cut out 13 GEN and LOW VOLT warning lights 4 Back up air speed indicator 14 Hour meter 5 End position detection IVO propeller 15 MAG switches if installed 16 Master starter switch 6a FlyMap Integrated Display 1 17 Low fuel...

Page 50: ... a little further to let the spring loaded locking pawl disengage and then release wheel brake 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...

Page 51: ...ystem consisting of an electrically driven air compressor with filter dryer a pressure gauge in the cockpit a pressure compensation vessel solenoid valves air lines pneumatic actuators and the respective cockpit controls The pneumatic system controls the following function rotor brake ON effects i e rotor disc flat flight control stick forward position brake mode adjustable longitudinal trim effec...

Page 52: ...ntre panel In order to access instruments radios and other avionics equipment the instrument panel must be removed Note that some of the instruments radios can be accessed through the cover of the storage compartment if installed in the nose section Access for maintenance and inspection is described in a dedicated job card 52 40 00 2 1 in Part D of this manual CHAPTER 53 FUSELAGE MAIN FRAME The lo...

Page 53: ...ght 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 for straight and level flight slip indic ball centred Corrective action seen from behind i e in flight direction Constant right pedal required Bend trim tab to the left Constant left pedal required Bend tri...

Page 54: ...ight 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...

Page 55: ...e 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...

Page 56: ... Trim CHAPTER 64 66 N A CHAPTER 67 ROTOR FLIGHT CONTROL Rotor flight control comprises of control stick a base control unit tube flight control base link and control rods push rods which are connected to the rotor head bridge 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 a base control unit tube runni...

Page 57: ...f torn or porous Defective rubber bushing can also cause undue engine propeller vibration IMPORTANT NOTE Engine mounting bushings are Manuf Life Limited MLL 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 switc...

Page 58: ...nt bore and hoses A single radiator is mounted on rubber isolators and brackets just in front of the propeller As an option two radiators may be fitted either side of the enclosure behind air scoops Hoses from to the radiator go to the engine water pump and return Hot water to the carburettor heat jackets is provided via T pieces MTOsport before Serial Number M01150 are not equipped with a thermos...

Page 59: ...gine 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 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 opt...

Page 60: ... 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 Cool...

Page 61: ...ess 3 Wiring Diagram Cockpit 5 Wiring Diagram Flight Control Stick 7 Wiring Diagram Main Fuse Battery 9 Wiring Diagram Engine Turbo Control Unit TCU Wiring Harness 11 Wiring Diagram Fuel Pumps 13 Wiring Diagram Landing Lights 15 Wiring Diagram NAV Strobe Lights 17 Wiring Diagram Helmet 19 Pneumatic Scheme 21 Retrofit End Position Detection IVO Propeller 23 ...

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Page 63: ...Manufacturer Maintenance Manual AutoGyro MTOsport MMM MT D_16 02 08 Part D Diagrams and Charts Page 3 of 24 Wiring Diagram Aircraft Main Wiring Harness ...

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Page 65: ...Manufacturer Maintenance Manual AutoGyro MTOsport MMM MT D_16 02 08 Part D Diagrams and Charts Page 5 of 24 Wiring Diagram Cockpit ...

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Page 67: ...Manufacturer Maintenance Manual AutoGyro MTOsport MMM MT D_16 02 08 Part D Diagrams and Charts Page 7 of 24 Wiring Diagram Flight Control Stick ...

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Page 69: ...Manufacturer Maintenance Manual AutoGyro MTOsport MMM MT D_16 02 08 Part D Diagrams and Charts Page 9 of 24 Wiring Diagram Main Fuse Battery ...

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Page 71: ...Manufacturer Maintenance Manual AutoGyro MTOsport MMM MT D_16 02 08 Part D Diagrams and Charts Page 11 of 24 Wiring Diagram Engine Turbo Control Unit TCU Wiring Harness ...

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Page 73: ...Manufacturer Maintenance Manual AutoGyro MTOsport MMM MT D_16 02 08 Part D Diagrams and Charts Page 13 of 24 Wiring Diagram Fuel Pumps ...

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Page 75: ...Manufacturer Maintenance Manual AutoGyro MTOsport MMM MT D_16 02 08 Part D Diagrams and Charts Page 15 of 24 Wiring Diagram Landing Lights ...

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Page 77: ...Manufacturer Maintenance Manual AutoGyro MTOsport MMM MT D_16 02 08 Part D Diagrams and Charts Page 17 of 24 Wiring Diagram NAV Strobe Lights ...

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Page 79: ...Manufacturer Maintenance Manual AutoGyro MTOsport MMM MT D_16 02 08 Part D Diagrams and Charts Page 19 of 24 Wiring Diagram Helmet ...

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Page 81: ...Manufacturer Maintenance Manual AutoGyro MTOsport MMM MT D_16 02 08 Part D Diagrams and Charts Page 21 of 24 Pneumatic Scheme ...

Page 82: ...Datum Name A3 1 von 1 1 1 1 5 Benennung Interne ID Revision Datum Name Diese Zeichnung darf ohne unsere Genehmigung weder vervielfälltigt noch veröffentlicht noch Dritten oder dem Wettbewerb zugängig gemacht werden SolidWorks 2010 Maßstab Format Blatt Oberflächenzeichen Freimaß Form und Lagetoleranzen nach ISO 2768 mH 6 30 120 315 1000 2000 2000 Nennmaß Abmaß 0 1 0 2 0 3 0 5 0 8 1 2 2 Tolerierung ...

Page 83: ...Manufacturer Maintenance Manual AutoGyro MTOsport MMM MT D_16 02 08 Part D Diagrams and Charts Page 23 of 24 Retrofit End Position Detection IVO Propeller ...

Page 84: ...HU IIHQWOLFKW QRFK ULWWHQ RGHU GHP HWWEHZHUE XJlQJLJ JHPDFKW ZHUGHQ 6ROLG RUNV 0D VWDE RUPDW ODWW 2EHUIOlFKHQ HLFKHQ UHLPD RUP XQG DJHWROHUDQ HQ QDFK 62 P 1HQQPD EPD 7ROHULHUXQJ 62 1 62 XU HLFKHQ URK 5 5 5 Z 62 7ROHUDQ 1 RKUXQJHQ FKQJ 0RGHOO HSU HZLFKW J EPHVVXQJ EHUHFKQHW 2EHUIOlFKH 0DWHULDO HJLHUXQJ 92 6WHXHUXQJVSODWLQH 6FKHPDWLVFKH DUVWHOOXQJ K VWLQGO ...

Page 85: ...CESS 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 ...

Page 86: ...Osport MMM CV E_16 06 13 Part E Content Page 2 of 2 67 00 00 6 1 INSPECTION ROTOR FLIGHT CONTROL 67 00 00 6 2 INSPECTION FLIGHT CONTROL BASE LINK 76 10 00 8 1 REPLACEMENT THROTTLE CONTROL WITH BRAKE 78 20 00 8 1 REPLACEMENT WOOL OF MUFFLER TUBE ...

Page 87: ... 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 castella...

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Page 89: ...ERIALS None PRECAUTIONS AND SAFETY MEASURES PROCEDURES Unload nose gear 1 In order to unload the nose gear load or lash down keel tube in most aft position until gyroplane rests safely on both main wheels and keel tube Unload main gear 2 In order to unload one of the main wheels carefully jack the gyroplane at the keel tube 3 Let the gyroplane tip to the desired side and continue to jack slowly un...

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Page 91: ...sport 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 t...

Page 92: ...Manufacturer Maintenance Manual AutoGyro MTOsport MMM CV E_16 06 13 Part E 07 00 00 2 3 Page 2 of 2 ILLUSTRATIONS Fig 1 Lash down methods of gyroplane ...

Page 93: ...d 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 Measure Dimension D1 1 Use a tape measure and measure distance between mast reference point and fuselage reference point See Fig 1 for reference NOTE Mast reference point is defined as the inner edge of the upper mast...

Page 94: ...Manufacturer Maintenance Manual AutoGyro MTOsport MMM CV E_16 06 13 Part E 08 20 00 2 1 Page 2 of 2 ILLUSTRATIONS Fig 1 Dimension D1 Fig 2 Mast reference point Fig 3 Fuselage reference point ...

Page 95: ...IAL TOOLS AND CONSUMABLE MATERIALS None PRECAUTIONS AND SAFETY MEASURES WARNING Electrical shortcuts on 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 Untight...

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Page 97: ...CV E_16 06 13 Part E 27 20 00 0 1 Page 1 of 1 27 20 00 0 1 DESCRIPTION FLIGHT CONTROL RUDDER OPR GENERAL REFERENCES AND REQUIREMENTS SPECIAL TOOLS AND CONSUMABLE MATERIALS PRECAUTIONS AND SAFETY MEASURES PROCEDURES ILLUSTRATIONS Fig 1 Flight control Rudder ...

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Page 99: ...plane against unauthorized or unintended operation SPECIAL TOOLS AND CONSUMABLE MATERIALS None PRECAUTIONS AND SAFETY MEASURES PROCEDURES PROCEDURE Measure from the aft rudder edge horizontally to the trailing edge of the stabilizer vertical fins 1 Adjust nose wheel point straight 2 Check adjust pedals neutral 3 Check adjust N2 860 mm 10 mm See Fig 1 for reference 4 Check control rods and control ...

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Page 101: ...nce Secure gyroplane against unauthorized or unintended operation SPECIAL TOOLS AND CONSUMABLE MATERIALS 85 00 00 S 30472 Tensiometer PRECAUTIONS AND SAFETY MEASURES PROCEDURES 1 Adjust pedals neutral parallel with nose wheel unloaded 2 With a tensiometer measure rudder control cable tension Cable tension values 20 lbs 5 lbs DOM 11 2009 and later 35 lbs 5 lbs 3 In case cable tension is lower inspe...

Page 102: ...facturer Maintenance Manual AutoGyro MTOsport MMM CV E_16 06 13 Part E 27 20 00 5 2 Page 2 of 2 ILLUSTRATIONS Fig 1 Version Safety wire Fig 2 Version Shrining Hose Fig 3 Measurement of control cable tension ...

Page 103: ...em 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 Inspect nylon filter use a flashlight if appropriate 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 I...

Page 104: ...20 00 6 1 Page 2 of 2 PARTS LIST Fig Pos Description PC PIT Remark Nylon fuel filter KL 23 L1 71 00 00 M 20575 ILLUSTRATIONS Fig 1 Effectivity ROTAX 912 Fig 2 Effectivity ROTAX 914 Fig 3 Effectivity ROTAX 912 with optional second fuel pump P2 installed Fig 4 Effectivity ROTAX 914 ...

Page 105: ... 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 spil...

Page 106: ...toGyro MTOsport MMM CV E_16 06 13 Part E 28 20 00 8 1 Page 2 of 2 ILLUSTRATIONS Fig 1 Effectivity ROTAX 912 Fig 2 Effectivity ROTAX 914 Fig 3 Effectivity ROTAX 912 with optional second fuel pump P2 installed Fig 4 Effectivity ROTAX 914 ...

Page 107: ...ff 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 clamp and replace fuel pump 5 Install new fuel pump and tighten clamp IMPORTANT NOTE The electrical terminals of the pump and...

Page 108: ...toGyro MTOsport MMM CV E_16 06 13 Part E 28 20 00 8 2 Page 2 of 3 ILLUSTRATIONS Fig 1 Effectivity ROTAX 912 Fig 2 Effectivity ROTAX 914 Fig 3 Effectivity ROTAX 912 with optional second fuel pump P2 installed Fig 4 Effectivity ROTAX 914 ...

Page 109: ...Manufacturer Maintenance Manual AutoGyro MTOsport MMM CV E_16 06 13 Part E 28 20 00 8 2 Page 3 of 3 Fig 5 El fuel pump terminal ...

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Page 111: ... only be performed by an organization or individual trained and entitled to do 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 None PRECAUTIONS AND SAFETY MEASURES PROCEDURES 1 Press out piston max 10 mm 2 Clean and use silicon grease or spray on the running surface of the piston 3 Re install brake an...

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Page 113: ...ation 3 Install wheel with items Fig 1 12 and Fig 1 13 in place bolt Fig 1 11 with washer Fig 1 10 and washer Fig 1 9 in reverse order 4 Install new self locking nut Fig 1 12 and torque tighten with 40 Nm Main wheel Removal 5 Remove wheel spat if installed 6 Unscrew and remove nut Fig 2 13 and washer Fig 2 12 Discard nut 7 Unscrew and remove 4 x bolt Fig 2 1 with serrated washer Fig 2 2 Mind limit...

Page 114: ...00 M 30019 1 8 13 Front Axis L2 32 20 00 M 30018 2 3 Axis rear wheel with inner thread 12x160 L2 32 00 00 M 20001 2 5 Wheelspat bracket kit L1 32 00 00 M 30003 2 6 Rearaxis L1 32 00 00 M 30002 incl 3 4 12 13 2 7 Brake pad inner big L2 32 40 00 M 30511 2 8 Brake Disc Set L1 32 40 00 M 30004 incl 1 2 2 9 Brake pad outer small L2 32 40 00 M 30512 ILLUSTRATIONS Fig 1 Nose gear with wheel ...

Page 115: ...Manufacturer Maintenance Manual AutoGyro MTOsport MMM CV E_16 06 13 Part E 32 40 00 4 1 Page 3 of 3 Fig 2 Main gear wheel and brake ...

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Page 117: ...cted 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 8 between brake pads 2 Remove 4 x shaft bolt 11 with serrated washer 10 3 Remove brake pad 7 and 9 Dispose of properly 4 Clean 4 x guide sleeves of axle assembly 5 a...

Page 118: ...ark 1 3 Axis rear wheel with inner thread 12x160 L2 32 00 00 M 20001 1 5 Wheelspat bracket kit L1 32 00 00 M 30003 1 6 Rearaxis L1 32 00 00 M 30002 incl 3 4 12 13 1 7 Brake pad inner big L2 32 40 00 M 30511 1 8 Brake Disc Set L1 32 40 00 M 30004 incl 1 2 1 9 Brake pad outer small L2 32 40 00 M 30512 ILLUSTRATIONS Fig 1 Main wheel with brake ...

Page 119: ... 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 transp...

Page 120: ...ufacturer Maintenance Manual AutoGyro MTOsport MMM CV E_16 06 13 Part E 34 10 00 5 1 Page 2 of 2 ILLUSTRATIONS Fig 1 Pitot Static Integrity Test Equipment Fig 2 Pitot Static Instruments Connecting Diagram ...

Page 121: ...struments 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...

Page 122: ...Manufacturer Maintenance Manual AutoGyro MTOsport MMM CV E_16 06 13 Part E 34 10 00 7 1 Page 2 of 2 ILLUSTRATIONS Fig 1 Static ports 2 x and pitot port Fig 2 Pitot Static Instruments Connecting Diagram ...

Page 123: ... TOOLS AND CONSUMABLE MATERIALS PRECAUTIONS AND SAFETY MEASURES PROCEDURES 1 Perform PREP WORK SERVICE COVERS MAINTENANCE ACCESS see 52 40 00 2 1 2 Unscrew inlet and outlet connection and discard old seal ring compressor side only 3 Replace filter dryer with new one and make sure cartridge is tightened safely to airframe Install new seal ring 4 Re connect and tighten inlet and outlet connection wi...

Page 124: ...Manufacturer Maintenance Manual AutoGyro MTOsport MMM CV E_16 06 13 Part E 36 21 00 8 1 Page 2 of 2 ...

Page 125: ...er in position so that bores and threaded inserts align NOTE Bottom bolt s connect instrument panel plastic cover and support bracket 5 Tighten bolts Use engineering judgement and do not overtorque Instrument panel Removal Fig 3 6 Remove rotor system or secure 7 Release brake pressure and bring stick in most aft position 8 Unscrew and remove panel bolts 13 x IMPORTANT NOTE Protect panel and instru...

Page 126: ...toGyro MTOsport MMM CV E_16 06 13 Part E 52 40 00 2 1 Page 2 of 2 ILLUSTRATIONS Fig 1 Centre Panel and Components Fig 2 Access to compressor filter dryer fuses and cabling LH cover bent away Fig 3 Instrument Panel with attachment bolts ...

Page 127: ...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 installati...

Page 128: ...Manufacturer Maintenance Manual AutoGyro MTOsport MMM CV E_16 06 13 Part E 61 10 00 4 1 Page 2 of 2 ILLUSTRATIONS Fig 1 Propeller HTC ...

Page 129: ...face 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...

Page 130: ...Manufacturer Maintenance Manual AutoGyro MTOsport MMM CV E_16 06 13 Part E 61 10 00 4 2 Page 2 of 2 ILLUSTRATIONS Fig 1 Propeller HTC ...

Page 131: ...e 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 ...

Page 132: ...Manufacturer Maintenance Manual AutoGyro MTOsport MMM CV E_16 06 13 Part E 61 10 00 5 1 Page 2 of 3 ILLUSTRATIONS Fig 1 Propeller HTC Fig 2 Propeller pitch adjustment and tool ...

Page 133: ...Manufacturer Maintenance Manual AutoGyro MTOsport MMM CV E_16 06 13 Part E 61 10 00 5 1 Page 3 of 3 Fig 3 Detail hub Fig 4 Detail blade ...

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Page 135: ... connector see Fig 4 Isolate this second connector with the supplied shrinking hose Sqeeze extending hot hose with pliers CAUTION Do not push or pull at the LED cables Use proper tools at LED socket 5 Drill two 8mm holes right hand from the rocker switch see Fig 5 Deburr holesInsert LEDs without mounting ring and fastening nut 6 Fixate LED with mounting ring and nut from behind see Fig 6 Insert LE...

Page 136: ... E 61 10 00 8 2 Page 2 of 3 PARTS LIST Fig Pos Description PC PIT Remark ILLUSTRATIONS Fig 1 Contents of the Kit Fig 2 Pin assignment of wiring harness Fig 3 Rocker Switch seen from below Fig 4 Isolation of cable end Fig 5 LEDs mounting position Fig 6 LEDs seen from behind ...

Page 137: ...Manufacturer Maintenance Manual AutoGyro MTOsport MMM CV E_16 06 13 Part E 61 10 00 8 2 Page 3 of 3 Fig 7 Control Board Fig 8 Connected rocker switch from below Fig 9 Rocker switch ...

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Page 139: ...OTE 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 bla...

Page 140: ...Manufacturer Maintenance Manual AutoGyro MTOsport MMM CV E_16 06 13 Part E 61 20 00 1 1 Page 2 of 2 ILLUSTRATIONS Fig 1 Fault Tree IVO Variable Pitch Propeller ...

Page 141: ... 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 th...

Page 142: ... Remark 1 1 Teeterbolt L0 27 30 00 S 30256 RS II 1 2 Chimm washer 3 5 L0 62 00 00 S 31706 RS II 1 3 U13 L0 27 30 00 S 30256 RS II 1 4 M12 castle nut L0 27 30 00 S 30256 RS II 1 5 Split pin 3 2x40 L0 27 30 00 S 30256 RS II 1 6 Rotor head II compl L2 27 30 00 M 31879 RS II ILLUSTRATIONS Fig 1 Removal rotor teetering parts Effectivity RS II ...

Page 143: ...mble 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 Untighten 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 dow...

Page 144: ...der bolt M8 40 12 L0 62 00 00 S 33324 RS II 1 3 shoulder bolt M8 43 12 L0 62 00 00 S 33324 RS II 1 4 shoulder bolt M8 46 12 L0 62 00 00 S 33324 RS II 1 5 M8x60 Rotor blade bolt 8 8 DIN 610 L0 62 00 00 M 20661 RS II 1 6 U9 20 L0 62 00 00 S 33324 RS II 1 7 Rotorhub II L1 01 00 00 V 31793 1 8 U8 L0 62 00 00 S 33324 RS II 1 9 M8 Si L0 62 00 00 S 33324 RS II 1 10 Clamping profile blade L1 01 00 00 V 31...

Page 145: ...me 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 wa...

Page 146: ...Manufacturer Maintenance Manual AutoGyro MTOsport MMM CV E_16 06 13 Part E 62 11 00 4 3 Page 2 of 2 ILLUSTRATIONS Fig 1 Assembly rotor teetering parts Effectivity RS II ...

Page 147: ... 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...

Page 148: ...mark 1 1 Teeterbolt L0 27 30 00 S 30256 RS II 1 2 Chimm washer 3 5 L0 62 00 00 S 31706 RS II 1 3 U13 L0 27 30 00 S 30256 RS II 1 4 M12 castle nut L0 27 30 00 S 30256 RS II 1 5 Split pin 3 2x40 L0 27 30 00 S 30256 RS II 1 6 Rotor head II compl L2 27 30 00 M 31879 RS II ILLUSTRATIONS Fig 1 Installation rotor teetering parts Effectivity RS II ...

Page 149: ...rophic 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 ce...

Page 150: ...r Maintenance Manual AutoGyro MTOsport MMM CV E_16 06 13 Part E 62 11 00 5 1 Page 2 of 2 ILLUSTRATIONS Fig 1 Rotor system placed on stands Fig 2 Positioning of measuring cord Fig 3 Reference point at grease nipple ...

Page 151: ...al 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...

Page 152: ...Manufacturer Maintenance Manual AutoGyro MTOsport MMM CV E_16 06 13 Part E 62 11 00 6 1 Page 2 of 2 ILLUSTRATIONS Fig 1 Teeter bushings block and tower cross section view ...

Page 153: ...um 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 s...

Page 154: ...Manufacturer Maintenance Manual AutoGyro MTOsport MMM CV E_16 06 13 Part E 62 11 00 6 2 Page 2 of 2 ILLUSTRATIONS Fig 1 Critical blade area Fig 2 Measurement of blade root linearity ...

Page 155: ...emove 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 t...

Page 156: ...Manufacturer Maintenance Manual AutoGyro MTOsport MMM CV E_16 06 13 Part E 62 11 00 6 3 Page 2 of 2 ILLUSTRATIONS Fig 1 Rotor hub ...

Page 157: ...for correct attachment and condition 4 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 5 Perform torque check on main bolt nut 2 In order to do so remove and discard split pin 1 and torque check castle nut with 120 Nm 6 If torque check fails mark component gyroplane unserviceable and co...

Page 158: ...Manufacturer Maintenance Manual AutoGyro MTOsport MMM CV E_16 06 13 Part E 62 31 00 6 1 Page 2 of 2 ILLUSTRATIONS Fig 1 Rotor head bridge bearing and teeter tower ...

Page 159: ... Maintenance SPECIAL TOOLS AND CONSUMABLE MATERIALS None PRECAUTIONS AND SAFETY MEASURES PROCEDURES 1 If Gimbal Head I version a or Gimbal Head II is installed no further action is required 2 In case Gimbal Head I version b or c is installed modify to Gimbal Head II 62 32 00 8 1 IMPORTANT NOTE The conversion to Gimbal Head II is classified as heavy maintenance HVY ILLUSTRATIONS Fig 1 Gimbal head I...

Page 160: ...Manufacturer Maintenance Manual AutoGyro MTOsport MMM CV E_16 06 13 Part E 62 32 00 0 1 Page 2 of 2 Fig 5 Arrangement of spring washers on gimbal head II ...

Page 161: ...ore 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 wit...

Page 162: ...Manufacturer Maintenance Manual AutoGyro MTOsport MMM CV E_16 06 13 Part E 62 32 00 6 1 Page 2 of 2 ILLUSTRATIONS Fig 1 Gimbal head assembly ...

Page 163: ...ION MAST BOLTS LNE GENERAL REFERENCES AND REQUIREMENTS Task may only be performed by an organization or individual trained and entitled to do Line Maintenance SPECIAL TOOLS AND CONSUMABLE MATERIALS None PRECAUTIONS AND SAFETY MEASURES PROCEDURES PARTS LIST Fig Pos Description PC PIT Remark ILLUSTRATIONS Fig 1 Mast bolts ...

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Page 165: ...ng seating NOTE If correctly installed the axle stump of the upper pulley is inserted in the inner bearing seating with Loctite 638 If the upper pulley can not be disassembled with normal effort the seating might me intact In this case re consider the need for disassembly 3 Inspect shaft for abnormal wear in the area of the bearing seating In case the diameter of the affected area is less than 14 ...

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Page 167: ...causes excessive wear heat and further shrinking 4 Check that pneumatic piston is not at its mechanical stop during clutch activation belt is short enough In order to do so activate pre rotation engine off until clutch is fully engaged Check that pneumatic cylinder is not in its mechanical end stop by manually compressing the cylinder further Fig 3 5 Check that upper pulley actuation arm can easil...

Page 168: ...Manufacturer Maintenance Manual AutoGyro MTOsport MMM CV E_16 06 13 Part E 63 11 10 6 1 Page 2 of 3 ILLUSTRATIONS Fig 1 Area for accurate crack inspection Fig 2 Alignment check with ruler ...

Page 169: ...Manufacturer Maintenance Manual AutoGyro MTOsport MMM CV E_16 06 13 Part E 63 11 10 6 1 Page 3 of 3 Fig 3 Sufficient travel piston not in mechanical endstop when clutch is engaged ...

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Page 171: ...ane against unauthorized or unintended operation Propeller must be removed see 61 10 00 4 1 SPECIAL TOOLS AND CONSUMABLE MATERIALS None PRECAUTIONS AND SAFETY MEASURES PROCEDURES 1 Replace clutch belt Note length of belt may vary slightly 2 Perform 63 11 10 6 1 INSPECTION PRE ROTATOR CLUTCH work steps 3 and 4 Adjust if necessary PARTS LIST Fig Pos Description PC PIT Remark 1 2 V ribbed Belt PJ762 ...

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Page 173: ...ividual trained and entitled to do Line Maintenance SPECIAL TOOLS AND CONSUMABLE MATERIALS None PRECAUTIONS AND SAFETY MEASURES PROCEDURES PARTS LIST Fig Pos Description PC PIT Remark 1 1 Drive Shaft Prerotator long L1 61 00 00 M 30172 1 2 driveshaft engine L2 63 11 00 M 30166 1 3 Gearbox prerotator B112DG L1 61 00 00 M 30173 1 4 5 Attachment kit gearbox L1 61 00 00 M 30179 1 6 7 replacement set P...

Page 174: ...Manufacturer Maintenance Manual AutoGyro MTOsport MMM CV E_16 06 13 Part E 63 11 20 0 1 Page 2 of 2 ILLUSTRATIONS Fig 1 Pre rotator drive ...

Page 175: ...S 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...

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Page 177: ... CV E_16 06 13 Part E 67 00 00 0 1 Page 1 of 1 67 00 00 0 1 DESCRIPTION ROTOR FLIGHT CONTROL OPR GENERAL REFERENCES AND REQUIREMENTS SPECIAL TOOLS AND CONSUMABLE MATERIALS PRECAUTIONS AND SAFETY MEASURES PROCEDURES ILLUSTRATIONS Fig 1 Rotor flight control ...

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Page 179: ...nt elements using tactile sense if necessary with help of a second person 3 A 5 mm free play measured at the top end of the control stick is considered within limits as long as the free play is only a result of equal play in the ball joints CAUTION Control base link and ball bearing must be free of play 4 If a ball joint exhibits above average play the respective ball joint must be replaced 5 If c...

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Page 181: ...in full aft position 1 Switch pneumatic mode selector to FLIGHT and allow control stick to move to most aft position 2 Make sure that gimbal head rests in its aft mechanical stops 3 Disconnect upper ball joint of lower RH flight control rod from bell crank see picture Let gimbal head rest in aft mechanical stops while flight control stick is in full aft position laterally centred NOTE The bar of t...

Page 182: ...Gyro MTOsport MMM CV E_16 06 13 Part E 67 00 00 6 2 Page 2 of 2 ILLUSTRATIONS Fig 1 Clearance in flight control base link Fig 2 Connection of upper ball joint of lower RH flight control rod with bell crank step3 5 Fig 3 Offset measurement ...

Page 183: ...NCES AND REQUIREMENTS Task may only be performed by an organization or individual trained and entitled to do Line Maintenance Secure gyroplane against unauthorized or unintended operation SPECIAL TOOLS AND CONSUMABLE MATERIALS None PRECAUTIONS AND SAFETY MEASURES PROCEDURES PARTS LIST Fig Pos Description PC PIT Remark ILLUSTRATIONS Fig 1 Throttle control and brake lever ...

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Page 185: ...ng 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 too...

Page 186: ...et 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 Secure the screws of hose clamps with locking wire Fig 8 PARTS LIST Fig Pos Description PC PIT Remark Replacement kit wool aftersilencer L1 78 20 00 S 33478 Conversion Kit overflow muffler shell L1 78 20 00 S 42441 ...

Page 187: ...nufacturer Maintenance Manual AutoGyro MTOsport MMM CV E_16 06 13 Part E 78 20 00 8 1 Page 3 of 5 ILLUSTRATIONS Fig 1 Rivets at the hot and hinge pin clamp Fig 2 Hose clamps Fig 3 Drill out the rivet pin ...

Page 188: ...turer Maintenance Manual AutoGyro MTOsport MMM CV E_16 06 13 Part E 78 20 00 8 1 Page 4 of 5 Fig 4 Installation of absorption wool Fig 5 Rivets at the cold end of muffler tube Fig 6 Riveting of the outer shell ...

Page 189: ...Manufacturer Maintenance Manual AutoGyro MTOsport MMM CV E_16 06 13 Part E 78 20 00 8 1 Page 5 of 5 Fig 7 Installation of hose clamps and hinge pin clamp Fig 8 Installation of locking wire ...

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Page 191: ...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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