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M16 (C) TANDEM TRAINER

MAINTENANCE MANUAL

PAGE

ISSUE

98

A_November 2012

breakers

are

switched

OFF;

2.

Move

the

pulley

(1)

of

the

pre

‐

rotation

assembly

by

hand.

This

movement

of

the

pulley

(1)

should

correspond

to

the

movement

of

the

Bendix

gear

(2).

If

the

gear

(2)

does

not

move,

go

to

next

step.

Otherwise,

go

to

verification

b;

3.

Inspect

the

flexible

shaft

pn

118

as

explained

in

paragraph

3.1.2;

4.

Replace

it

the

flexible

shaft

pn

118

if

it

is

broken.

b.

Verification

of

the

Bendix

gear

1.

Before

starting

verify

that

the

engine's

ignition

key

and

push

‐

button

are

in

OFF

position

and

that

all

the

breakers

are

switched

OFF;

2.

Inspect

the

Bendix

gear,

as

explained

in

paragraph

3.6.2.

5.4.3

ANOMALY:

NO

FLEXIBLE

SHAFT

ENGAGING,

NO

SYSTEM

ENGAGING

During

pre

‐

rotation

the

system

does

not

get

engaged

when

pulling

the

control

lever

pn

415.

Anomalous

metallic

noises

can

be

heard

at

regular

intermittency.

The

flexible

shaft's

sheath

pn

119

does

not

get

overheated.

In

this

case,

it

is

very

likely

that

the

flexible

shaft

pn

118

is

rotating,

but

that

it

does

not

get

engaged

in

the

square

section

ending

of

the

splined

shaft

pn

040

of

the

Bendix

gear.

a.

Verification

of

the

splined

shaft

pn

040

1.

Before

starting

verify

that

the

engine's

ignition

key

and

push

‐

button

are

in

OFF

position

and

that

all

the

breakers

are

switched

OFF;

2.

Loosen

and

remove

the

two

bolts

M6x16

first,

then

remove

the

flexible

shaft's

sheath

pn

119

from

the

cup

pn

039;

3.

Extract

the

flexible

shaft

pn

118

from

the

seat

of

the

splined

shaft

pn

040;

4.

Inspect

the

shaft

pn

040

and

verify

the

entireness

of

the

square

section

seat

and

of

the

square

section

ending

of

the

flexible

shaft

pn

118;

5.

If

the

splined

shaft

pn

040

is

damaged,

replace

it

as

explained

in

paragraph

3.6.3.

b.

Verification

of

the

square

section

ending

of

the

splined

shaft

pn

118

1.

Before

starting

verify

that

the

engine's

ignition

key

and

push

‐

button

are

in

OFF

position

and

that

all

the

breakers

are

switched

OFF;

2.

Remove

the

flexible

shaft's

sheath

pn

119

from

the

cup

pn

039,

unscrewing

and

removing

the

two

bolts

M6x16;

3.

Extract

the

flexible

shaft

pn

118

from

the

square

seat

(3)

of

the

splined

shaft

pn

040;

4.

Inspect

the

square

section

ending

of

the

flexible

shaft

pn

118

and

verify

its

entireness.

If

some

damage

is

found,

it

is

possible

to

shim

the

flexible

shaft

pn

118

with

washers

on

the

lower

square

ending

(3)

so

as

to

guarantee

an

efficient

mesh.

Proceed

with

the

following

steps:

5.

Loosen

the

clamps

pn

4B

‐

25

‐

45

that

fix

the

sheath

of

the

flexible

shaft

pn

119

to

the

support

pn

193.

6.

Loosen

both

bolts

M6x16

and

remove

the

sheath

of

the

flexible

shaft

pn

119

from

the

pre

‐

rotation

assembly.

7.

Extract

the

flexible

shaft

pn

118

from

the

pre

‐

rotation

assembly

(1).

8.

Fit

two

washers12x24

to

the

square

section

ending

of

the

flexible

shaft

pn

118.

This

shimming

allows

the

flexible

shaft

pn

118

to

work

more

on

the

splined

shaft

pn

040,

thus

allowing

the

transmission

of

power.

9.

Insert

the

flexible

shaft

pn

118

in

the

square

seat

(3)

of

the

pre

‐

rotation

assembly

(1).

10.

Fix

the

sheath

pn

119

to

the

pre

‐

rotation

assembly

(1).

11.

Insert

the

flexible

shaft

pn

118

in

the

seat

of

the

shaft

pn

040

of

the

Bowden

gear

(2).

12.

Tighten

the

two

bolts

M6x16

to

fix

the

sheath

pn

119

of

the

flexible

shaft

pn

118

to

the

cup

pn

039.

13.

Tighten

the

clamps

pn

4B

‐

25

‐

45

that

fix

the

sheath

pn

119.

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Summary of Contents for M16C

Page 1: ...GE ISSUE 1 A_November 2012 ORDINARY MAINTENANCE MANUAL MAGNI M16 M16C GYROPLANE Issue A_NOVEMBER 2012 MAGNI GYRO Srl Via Volpina 23 I 21010 BESNATE VA ITALY WEB www magnigyro it ENQUIRIES info magnigyro it Tel 39 0331 274816 Fax 39 0331 274817 ...

Page 2: ...M16 C TANDEM TRAINER MAINTENANCE MANUAL PAGE ISSUE 2 A_November 2012 INTENTIONALLY LEFT WHITE ...

Page 3: ...ni Gyro Srl Maintenance Manual prepared and issued by Magni Gyro Srl This gyroplane shall at all times be maintained in accordance with this manual No part of this manual may be reproduced or transmitted in any form or by any means electronic or mechanical including photocopying recording or by any information storage or retrieval system without prior permission from Magni Gyro Copyright 2011 by M...

Page 4: ...M16 C TANDEM TRAINER MAINTENANCE MANUAL PAGE ISSUE 4 A_November 2012 INTENTIONALLY LEFT WHITE ...

Page 5: ...ncluding any amendments Units of measure The following units are used in this manual and where appropriate on the instruments and placards Weight Kilograms kg Length aircraft geometry Millimetres mm Distance aircraft performance Feet ft or Metres m Altitude Feet ft Airspeed Knots Kn Moments Kilogram metres kgm Pressures Bars bar Temperatures Degrees Celsius C Liquid Quantities Litres l ...

Page 6: ...DMENTS This page 6 and subsequent amendment pages 6 1 etc will be reissued as necessary with each amendment list It is the responsibility of the owner to insure that the amendments are incorporated in the Maintenance Manual Amendment N and date Description of Amendment Pages Affected ...

Page 7: ...4 Lubrication and anticorrosion products specifications 19 1 7 5 Care and cleaning product specifications 19 1 8 SPECIFICATIONS 20 SECTION 2 DESCRIPTION OF GYROPLANE AND GENERAL MAINTENANCE REQUIREMENTS 2 1 MAIN STRUCTURE 23 2 2 ROTOR BLADES 23 2 3 FUSELAGE AND TAIL CONTROL SURFACES 24 2 4 MAIN STRUCTURE AND FLYING CONTROLS 24 2 4 1 Roll and pitch control system 25 2 4 2 Secondary controls 26 2 4 ...

Page 8: ...TIONING OF ROLL AND PITCH CONTROLS 51 3 7 1 Frictioning procedure 51 3 8 MAINTENANCE AND CHECKS OF CONTROL RODS 52 3 8 1 Replacement of control rods ball joint ends 52 3 9 SECONDARY CONTROLS 55 3 9 1 Choke control line 55 3 9 1 1 Replacement of choke cables 55 3 9 2 Replacement of rotor brake cable 56 3 9 3 Brake system cable line 58 3 9 3 1 Replacement of braking system cables 58 3 9 4 Replacemen...

Page 9: ...PLACEMENT OF ENGINE MOUNT VIBRATION DAMPERS 79 3 15 1 Replacement procedure 79 3 16 REPLACEMENT OF FUEL PIPES 80 3 16 1 Fuel pipe replacement procedure 80 3 17 AIR FILTER INSPECTION 82 3 17 1 Inspection and cleaning of filter 82 3 17 2 Air filter replacement 84 3 18 PROPELLER MAINTENANCE 84 3 18 1 Cleaning instructions 84 3 18 2 Leading edge impact damage 85 3 18 3 Cracks 85 3 18 4 Rod End 85 SECT...

Page 10: ...EVALUATION OF DAMAGE TO ROTOR BLADES 100 5 7 1 Damage to trailing edge 100 5 7 2 Damage to leading edge 101 5 7 3 Damage along blade s face or back 102 SECTION 6 TRANSPORTATION AND STORAGE 6 1 ROTOR RIGGING AND DE RIGGING 105 6 2 CORRECT TIGHTENING OF BOLT PAN 3009 136 107 6 3 ROTOR DE RIGGING 108 6 4 PROTECTION OF ROTOR BLADES 109 6 5 TRANSPORTATION 110 6 6 SHELTERING RULES 110 6 7 STORAGE RULES ...

Page 11: ...M16C GYROPLANE ISSUE 10 2012 No part of this manual may be reproduced or transmitted in any form or by any means electronic or mechanical including photocopying recording or by any information storage or retrieval system without prior permission from Magni Gyro Copyright 2011 by Magni Gyro All rights reserved ...

Page 12: ...M16 C TANDEM TRAINER MAINTENANCE MANUAL PAGE ISSUE 12 A_November 2012 INTENTIONALLY LEFT WHITE ...

Page 13: ...al is illustrated with drawings of all assemblies and systems and lists all codes and descriptions For each described maintenance procedure this manual lists all the required references page or drawing number so as to allow the best visualization of the parts and an easy understanding of the maintenance operation For a better explanation of the more complex operations pictures have been added to t...

Page 14: ...gyroplane and engine logbooks should be present at all inspections The number of flying hours flights and modifications carried out since the last inspection should be correct and up to date The engine logbook must show that the engine has been maintained in accordance with the manufacturer s instructions All periods in the schedule quoted in flying hours are to be calculated on the basis of the s...

Page 15: ...ted Production date month year The following notes explain how to read a serial number Serial numbers are composed of 8 digits the meaning of which is as follows XX XX XXX X XX the first two digits indicate the model of the gyroplane XX the second two digits indicate the year of production XXX the next three digits indicate the progressive production number X the last digit indicate the engine ori...

Page 16: ...or model identifiers which is due to the repeated use of the same part in different groups and models In this manual the parts are identified only through the first 3 digits of the pn the other 4 digits are complementary Example of part number reading pn 267 09 16 This identifies part number 267 appearing in page 09 of the spare parts catalogue of the M16 M16C gyroplane model 1 6 3 REQUEST FOR INT...

Page 17: ...l info magnigyro it Serial number When asking for technical assistance or for spare parts always quote the machine model SERIAL NUMBER and year of production Note the rating from the machine s identification plate which is fixed to the structure NOTE The machine s data plate is the only identification reference It is therefore important to keep it in a good state Do not modify it or remove any dat...

Page 18: ...TENING AND METHODS REQUIRED FOR ALL THREADED CONNECTIONS 1 Fiberlock nuts Never use them more than once Do not use them if the tightening is not locked After tightening there must be at least 1 1 5 thread clear of the nut 2 Lock washers spring lock washers Always place between nut and plain washer never directly on surfaces 3 Threadlocker Loctite Light locking purple Loctite 222 Medium locking blu...

Page 19: ... grease CASTROL GRAPHITE GREASE or equivalent Rear wheels pivot stem Water repellent grease CASTROL GRAPHITE GREASE or equivalent Inside of control cables sheaths Spray grease CASTROL CHAIN LUBE RACING or equivalent Floating bush of rotor hub bar Spray grease CASTROL CHAIN LUBE RACING or equivalent Rudder upper bush Lithium graphite grease CASTROL MOLY GREASE or equivalent Engine inner lubrication...

Page 20: ... 285kg Maximum take off weight 500kg PERFORMANCE Vne 87Kn Cruising speed 78Kn Absolute ceiling 10000ft Take off distance to 50ft 820ft Landing distance from 50ft 510ft Rate of climb 625ft min Tank capacity 69lt DIMENSIONS Rotor Diameter 8535mm Propeller Diameter 1700mm Width 1800mm Length 4700mm Height 2700mm ...

Page 21: ...M16 C TANDEM TRAINER MAINTENANCE MANUAL ISSUE PAGE A_November 2012 21 ...

Page 22: ...M16 C TANDEM TRAINER MAINTENANCE MANUAL PAGE ISSUE 22 A_November 2012 INTENTIONALLY LEFT WHITE ...

Page 23: ...2 2 ROTOR BLADES The rotor blades are manufactured by Magni Gyro to a very high standard and have proven to give excellent flying characteristics Prior to shipping the blades are matched and balanced thus they must always remain paired Should one blade be damaged and require replacing then it must be returned with the undamaged blade to Magni Gyro for repair if repair is possible Any non approved ...

Page 24: ... part of the rudder system must be replaced with Magni Gyro original parts 2 4 MAIN STRUCTURE AND FLYING CONTROLS The main structure of the gyroplane is also the anchoring point and reaction base for the flying controls Correct adjustment and functioning of the controls is essential for safe flight of the gyroplane All the pivots and joints of the control system use a combination of bearings and u...

Page 25: ...ings and aeronautical grade bolts and nuts A 4130 steel TIG welded fork articulated to the torsion rods on bearings conveys the movements of the torsion rods to the control rods The vertical line conveys the movements from the lower fork to the rotor head This vertical line is composed of two series of control rods made of 4130 steel with TIG welded threaded ends Rod ends with threaded stem are fi...

Page 26: ...cated in the maintenance manuals 2 4 3 RUDDER PEDALS SYSTEM The control on the vertical axis is gained by the rudder pedals system used by the pilot to yaw the gyroplane during flight and to direct it in ground manoeuvring such as taxiing and parking The rudder pedals control line starts with pedals pn 071 072 and pn 080 081 which are connected one to the other through rigid rods and ball joint en...

Page 27: ...a leaf spring in composite material The manufacturer does not authorize any repair of this unit Any crack or damage to the suspension has to be referred to Magni Gyro Minor surface abrasions and scratches can be repaired using standard composite repair techniques If any of the wheel or brake components are found to be damaged then replacement with new or repaired parts is the only option Magni Gyr...

Page 28: ...ion of the engine Fuel consumption data is available in ROTAX operator s manual according to the installed engine The fuel tank is manufactured in glass fibre composite materials Before installation it is subjected to a pressure test and to leak checks Minor repairs may be carried out using standard composite repair techniques but they must be tested to make sure it still satisfies the requirement...

Page 29: ...e follows the movement of the Bowden cable pn 403 controlled by the pilot from the cockpit For the gyroplanes serial number 16063694 onward the temperature is kept within the green range thanks to a three way thermostat fitted to the tubing between the expansion tank and the radiator The control of the entire system is done visually as described below The control of the cooling system must follow ...

Page 30: ...M16 C TANDEM TRAINER MAINTENANCE MANUAL PAGE ISSUE 30 A_November 2012 ...

Page 31: ...ed 8 f TRIM Green trim in end position 9 TEST Fuel reserve warning light test push button 10 0 1 x hour Hour meter 11 Engine r p m Engine tachometer 12 EGT Exhaust gas temperature indicator 13 CHT Cylinder head temperature 14 OIL TEMP Oil temperature 15 OIL PRESS Oil pressure 16 MAP Manifold pressure indicator 17 Rotor r p m Rotor tachometer 18 FUEL Press Fuel pressure indicator 19 Compass 20 ASI ...

Page 32: ...es composite blades of epoxy resin reinforced with carbon and glass The reinforcement extends the length of the blade and through aluminium collars at the blade foot The hub which takes three blades is an aluminium casting machined to accept the blades and fixing bolts The blades are protected from abrasion due to grass gravel or rain by use of an adhesive strip applied to the leading edges ...

Page 33: ...nded to use latex gloves to avoid skin grease direct contact The following are maintenance procedures for the flexible shaft system 3 1 1 REMOVAL OF FLEXIBLE SHAFT See Fig 3 1 1 3 1 5 1 Before starting verify that the ignition contact is in OFF position and that all the breakers are switched OFF 2 Put the control stick 2 in forward limit stop position 3 Loosen the clamps pn 4B 25 45 and release th...

Page 34: ... GR03 where the torsional stress is higher If the deformation is minimal less than 3 mm on the nominal diameter of 20 mm it is possible to re install the flexible shaft But a further inspection after the first 50 hours of use is strongly recommended In case of stronger deformation the shaft needs to be replaced 3 Longitudinal deformation the flexible shaft pn 118 should be immediately replaced if ...

Page 35: ...avoid direct contact with the grease during this operation 2 Block the flexible shaft pn 118 in a bench vice Tighten it very gently and take care not to damage the coils 3 Lay plenty of grease along the entire shaft The quality of the grease must comply with the mentioned specifications 4 Manually spread the grease evenly on the shaft s entire surface ...

Page 36: ...completely inserted in the sheath pn 119 carry this sheath to the pre rotator unit and insert the first part of the flexible shaft pn 118 into the square hole of the unit pn117 8 Climb a ladder so as to reach the upper part of the Bendix gear unit pn GR03 9 Using a key rotate the socket head screw M6x20 clockwise so as to facilitate the insertion of the square ends of the shaft pn 118 in their res...

Page 37: ...lleys pn 124 thus reducing the efficiency of the power transmission to the rotor This is something that does not happen suddenly but appears after many hours of use and does not endanger the gyroplane s efficiency except at long term Depending on the conditions of the V belts and on available tools and equipment it is possible to correct this problem in various ways When the operator feels a reduc...

Page 38: ...ll the pre rotation control cable pn 1 5 x 3 900 and tighten the cable retainer pn 107 This will modify the position of the belt tightener 5 further stretching the belts A28 5 Verify that the brake shoe 2 of the belts A28 really touches the belts when the pre rotation activating lever pn 415 is in rest position If this is not the case release the bolt M5x40 then re position the shoe 3 as indicated...

Page 39: ...ation assembly to have access to the space washers 6x18 7 Add a washer to each locking bolt M6x30 NOTE Make sure the washers are all of the same thickness 8 Reposition the pre rotation assembly pn 117 on the support pn 120 and insert the locking bolts M6x30 9 Tighten the nuts M6 to the bolts so as to reduce the movement of the pre rotation assembly on the support pn 120 10 Reposition the pulley pn...

Page 40: ...there are no obstacles people or objects within the rotor range area as too much shimming may result in an immediate rotation of the rotor upon engine start up 2 Start the engine following the standard start procedure 3 Warm up the engine taking it to minimum operational temperature 4 Set engine to 1800 r p m rotation speed 5 Gently engage the pre rotation Keep in mind that the coupling will happe...

Page 41: ...all the operations except during pre rotation The pulley pn 124 and propeller are fixed with six bolts pn 284 to the engine flange thus its rotation is identical to the number of revolutions of the engine Furthermore the belts pn A28 are braked whenever they are not tightened through the pre rotation system So interference and a continuous slipping are created between the belts and pulleys which m...

Page 42: ...Lift the pre rotation assembly pn 117 and remove the spacer washers 6x18 in excess 8 Reposition the pre rotation assembly pn 117 on the support pn 120 and insert the locking bolts M6x30 9 Tighten the nuts M6 to the bolts so as to friction the movements of the pre rotation assembly on the support 10 Position the new pulley pn 124 on the flange of the propeller and verify that it rests on the entire...

Page 43: ...ion required and the conditions of operation The following factors must be taken into account when evaluating the state of the rotor head assembly a General condition of the paint of the notched gear pn 061 b Absence of abrasions and or parts where paint has been removed c Oxidation of bolts and nuts d Lubrication of the notched gear pn 061 e Presence of safety pins pn AN 416 1 f Correct locking 1...

Page 44: ...esent This should allow to check that there has been neither tampering nor unauthorized intervention g The freedom of movement of the lever pn 201 shows the correct functioning of the rotor brake system If the movement is too wide the wear of the brake linings is excessive h The visual inspection of the teeter bearings pn NKXR 15Z is recommended if the rotor is not installed In particular make sur...

Page 45: ...arings and NAS bolts AMBER COLOURED GREASE SHELL DARINA R2 Notched gear and forks BLUE WATER REPELLENT GREASE 3 5 ROTOR HEAD OVERHAUL See Fig 3 5 1 3 5 2 WARNING The overhaul of the rotor head can only be done by the Manufacturer or at Facilities authorized by the Manufacturer This overhaul includes specific checks of the wear of all the head components and the replacement of worn parts For any ov...

Page 46: ...re in OFF position and that all the breakers are switched OFF 2 Remove the safety pin pn AN 416 1 3 Unscrew and remove the nut pn 12 PCR 106 from the central bolt pn PAN 3009 136 of the flapping axle 4 Lift the rotor with a hoist 1 or crane so as to unload the central bolt 5 Extract the bolt pn PAN 3009 136 by hand or with the help of a rubber hammer 6 Remove the rotor lifting it from the rotor he...

Page 47: ...M16 C TANDEM TRAINER MAINTENANCE MANUAL ISSUE PAGE A_November 2012 47 ...

Page 48: ...se get disconnected from the rotor head 12 Remove the safety pin pn AN 416 1 from the longitudinal bolt pn NAS 628 52 13 Unscrew and remove the nut pn MS 21083 N8 of the longitudinal bolt pn NAS 628 52 of the head 14 Holding the rotor head by the fork pn 046 to which the trim spring pn 109 is fixed extract the bolt NAS 628 52 15 Remove the rotor head from the fork pn 051 3 5 4 ROTOR HEAD INSTALLAT...

Page 49: ...are the last link of the pre rotation chain The Bendix gear has its seat in the fork s tube pn 046 where it can slide and engage the notched gear pn 061 to transmit the movement of the flexible shaft A failure of the Bendix unit GR03 can cause a bad or no functioning at all of the pre rotation system In this case the operator can apply to the nearest maintenance centre or otherwise execute the fol...

Page 50: ...e care to correctly align the holes as to the tube of the fork pn 046 with the sheath pn 119 fastening holes which must be in line with the longitudinal axis of the gyroplane 3 Tighten the three bolts M5x12 that fix the cup pn 039 4 Insert the sheath pn 119 in the cup 5 Use an Allen wrench M6 1 to turn the Bendix unit GR03 clockwise thus facilitating the insertion of the flexible shaft pn 118 6 On...

Page 51: ...and pn 053 of the square pn 056 of the fork pn 052 of the safety pin pn AN 416 1 and of the nuts pn MS 21083 N8 The consequent play along the bolts NAS pn NAS 628 52 and pn NAS 628 30 results in vibrations of the controls 3 7 1 FRICTIONING PROCEDURE See Fig 3 6 1 3 6 3 1 Before starting verify that the engine s ignition key and push button are in OFF position and that all the breakers are switched...

Page 52: ...control line does not need short term maintenance just pre flight checks NOTE All the bolts of the control line 1 are marked after having been tightened at the factory so as to highlight incidental and unwished movements of the bolt nut coupling 3 8 1 REPLACEMENT OF CONTROL RODS BALL JOINT ENDS See fig 3 8 1 3 8 2 WARNING DANGER Replacing the ball joint ends is a very delicate operation which has ...

Page 53: ...en the bolts that fasten the rod 4 Remove the fastening screws pn AN4 14A and AN4 16A and the rod pn 032 taking care not to rotate the rod nor the ball joint ends pn 033 and pn 034 so as not to vary the rod length 5 Using the MG TO 001 tool measure the length of the rod pn 032 6 Tighten the measuring stop 6 of the MG TO 001 2 tool and remove the rod pn 032 from the rod 7 Remove the ball joint ends...

Page 54: ...tool 2 15 Fasten the rod to the control line keeping the right joint pn 034 in upper position with the bolts pn AN4 16A and pn AN4 14A 16 Replace the nuts MS 20365 428 for the bolts pn AN4 16A and AN4 14A and tighten them 17 Tighten the check nuts pn AN316 6 and pn AN316 6L of the control rod pn 032 18 After the check nuts pn AN316 6 and pn AN316 6L have been tightened make sure the rod can rotate...

Page 55: ...d that all the breakers are switched OFF 2 Put the choke lever pn 128 in OFF position 3 Cut the cable 1 2x1 000 and remove the cable terminal protection pn 103 located close to the lever of the carburettor 2 4 Loosen and free the cable 1 5x2500 from the cable retainer pn 107 that fastens it to the choke lever pn 128 5 Cut the cable 1 5x2 500 between the sheath pn 131 and the deformation 3 caused b...

Page 56: ...rs are switched OFF 2 Put the rotor brake lever pn 199 in OFF position 3 Cut the cable 1 5x3 900 and remove the cable terminal protection pn 103 located close to the rotor brake lever pn 201 on the rotor head 4 Using a 10 mm wrench loosen and free the cable from the retainer pn 202 that fastens it to the rotor brake lever pn 201 5 Cut the cable between the sheath and the deformation 3 caused by th...

Page 57: ...ber 2012 57 NOTE The movement of the rotor brake control lever must not be greater than 20 mm 19 Cut away the excess of cable 1 5x3 900 leaving at least 30 mm more than needed 20 Position the cable terminal protection pn 103 and tighten it with cutting nippers ...

Page 58: ... and push button are in OFF position and that all the breakers are switched OFF 2 Cut the cable 1 5x2 000 and remove the cable terminal cap located close to the brake lever pn 135 3 Use a 7 mm wrench to loosen the cable retainer pn 107 that fastens the cable 1 5x2 000 to the brake lever pn 135 4 Cut the cable below the deformation 2 caused by the tightening action of the retainer pn 107 This defor...

Page 59: ...fork pn 108 4 Cut the cable between the sheath and the deformation 1 caused by the tightening action of the retainer pn 107 This deformation could cause some problem when doing step 8 5 Put the pre rotation control lever pn 415 in ON position so as to make it easier to extract the cable1 5x3900 6 Completely extract the cable 3 7 Visually check the cable If there is no oxidation the gyroplane has b...

Page 60: ...EM TRAINER MAINTENANCE MANUAL PAGE ISSUE 60 A_November 2012 17 Cut the cable in excess leaving at least 30 mm more than needed 18 Position the cable terminal protection pn 103 and tighten it with cutting nippers ...

Page 61: ...pulley is absolutely normal and does not compromise the entireness of the cable But the wear can become important if the pulley does not turn freely because of excessive tightening or oxidation of the inner bearing pn 626 ZZ In such a case the friction between pulley and cable will not be rolling anymore instead there will be rubbing which will damage the cable Similar problems may arise if the po...

Page 62: ...OFF position and that all the breakers are switched OFF 2 Using the adequate tool To 006 check the tension of the cable at approximately the midpoint between the rudder pivot pn 086 and the rear pulley pn 084 of the rudder pedals line 3 If the measured tension is lower than the limit values indicated in the table remove the safety wiring on both screw couplings pn MS 21251 B3S 4 Screw in both scre...

Page 63: ...9 and shrink it with a heat gun 3 10 4 3 INSTALLATION OF CABLE See Fig 3 10 1 3 10 3 1 Before starting verify that the engine s ignition key and push button are in OFF position and that all the breakers are switched OFF 2 Insert the free end of the cable 3x49 from inside the cockpit through the front pulley pn 084 and then through the other pulleys thereby take care to follow the correct path 4 of...

Page 64: ...e 14 Grab the pedals pn 072 and pn 071 move it several times along the entire range of the movement so as to distribute the tension evenly on all the cable 15 Using the tool To 006 check the tension of the cable according to the indications of paragraph Check of cable tension 16 Lock the turnbuckles with the special safety wire 1 17 Shift the rudder at an angle of approx 10 to the right while keep...

Page 65: ...nding as well as the correct tightening of the locking bolts M5x42 M6x55 M6x25 M6x80 on the pedals Incorrect tightening may generate play and vibrations on the pedals pn 071 and pn 072 and consequently on the nose wheel 3 buffeting 3 10 6 INSPECTION OF PEDALS See Fig 3 10 5 1 Check the correct movement of the pedals pn 071 and 072 until they reach the stoppers 2 Verify that the pedals have no late...

Page 66: ... WHEEL AND FORK See Fig 3 11 3 The nose wheel 5 and fork 6 are assembled through the connection of the bolt pn M12x160 and the fork pn 093 for gyroplanes with serial number till 16053404 or pn 426 and the spacer pn 094 or pn 427 and the wheel 5 Tightening and blocking the wheel is done with a fibrelock nut M12 The tightening action of the bolt M12x160 must be adequate so as to avoid compression of...

Page 67: ... verify that the engine s ignition key and push button are in OFF position and that all the breakers are switched OFF 2 Put the pedals pn 071 and 072 in fig 3 10 5 in central position Visually check that the nose wheel 5 is aligned with the longitudinal axis of the gyroplane 8 fig 3 11 3 ...

Page 68: ...um is stable Support the gyroplane so it cannot drop back on the nose As the wheel has been removed for replacement in case the nose would fall it would crash on the ground thus damaging the lower part of the fuselage 8 Unscrew and extract the screw M12x160 that fix the front wheel to the fork then remove the wheel 9 Supporting the fork pn 093 or 426 loosen and remove the lock nut pn KM4 10 Extrac...

Page 69: ...ork 6 9 Tighten the pivot of the wheel as explained in the paragraph assembly of nose wheel and fork 3 11 2 10 Insert and tighten the cables through the turnbuckle see paragraph 3 10 4 3 Installation of the cable 11 Put safety wiring 2 on the turnbuckle See Fig 3 10 5 3 12 CHECK OF TIRES See Fig 3 12 WARNING The M16 M16C gyroplane tires are made of 6 ply tread with air tube The nominal dimensions ...

Page 70: ...n 167 by pulling them gently upward 5 Verify the wear of the tread 3 and check that there are no radial cracks on the rubber 4 6 Remove the inflating valve cap 5 7 Measure the tire pressure 2 and correct it according to the inflating pressure diagram given below 8 Close the valve with its cap 5 9 Only for gyroplanes prior to serial number 22063434 place the shim washers 10x20 on the head of the M5...

Page 71: ... to the radiator interspaces 3 Check the entireness of the hoses pn 1240 pn 870 pn 300 pn 240 and pn 540 Make sure there are no abrasions or contact points with damaging rubbing 4 Make sure the level of the coolant is correct as per parameters of paragraph 3 13 7 Coolant level 5 Verify the correct tightening of all the clamps pn 384 of the system 6 Only for gyroplanes with sn 16052934 to sn 220636...

Page 72: ...lve s cover Thereby pay attention to the discharge of the coolant still present in the system 8 Extract the thermal expansion valve 9 Visually inspect the valve remove any deposit and clean it accurately until its original conditions are restored 10 Place the thermal expansion valve in its container Take care to place the vent on top 11 Close the valve s radiator Make sure the seals are placed cor...

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Page 75: ...t 4 Gently remove the hose pn 1240 from the radiator connection and direct the liquid into the tray 5 To allow the complete discharge of the coolant from the cooling system remove the cap 2 of the engine s recovery reservoir 3 6 Loosen the clamp pn 384 1 connecting the elbow pn 385 to the upper connection of the radiator 7 Remove the elbow pn 385 from the radiator 8 Unscrew the 4 locking bolts M6x...

Page 76: ...er spacer anti rubbing sheath or removing the sharp contact edges 10 Replace the hose taking care to restore the original layout of the cooling system 11 Fasten the clamps pn 384 of the hoses to attach them to their connections 12 Fill the system from the engine s expansion tank as per level instruction of paragraph 3 13 7 Coolant level 13 Close the cap of the expansion tank 3 13 7 COOLANT LEVEL M...

Page 77: ...L FILTER See fig 3 14 1 CAUTION It is strongly recommended to respect the maintenance schedule and replace the fuel filter as per Magni Gyro diagram dates see Ordinary Maintenance Diagram Furthermore the replacement of the fuel filter is recommended whenever you think you have used fuel that is contaminated or has not been filtered correctly The fuel pressure indicator 1 gives hints about how clea...

Page 78: ...cated by arrows 7 Gently loosen the pipe wrench 4 located upstream the filter 8 Check that the new filter gets filled up with fuel and that the fuel flows out the downstream connection 9 Fit the filter in the hose downstream 3 the line 10 Remove the pipe clamps 4 and 5 11 Fit and tighten the clamps pn 176 12 Place the filter on the support pn 186 and block it with a new hose tightening cable tie t...

Page 79: ...ition and that all the breakers are switched OFF WARNING Replace the vibration dampers on the right side first and only then the dampers on the left side 2 Unscrew the 2 bolts M10x100 on the right side of the engine mount 3 Remove both right side bolts 4 Using a slotted screwdriver to lever remove the front vibration damper units spacer pn 242 vibration damper pn 243 5 Apply a constant force FC on...

Page 80: ...4 Remove the fuel pipe pn 175 from the connections of the various devices paying attention to possible spilling or loss of fuel especially if the pipe pn 175 is placed lower than the fuel level inside the tank 5 Replace the damaged fuel pipe pn 175 with a new pipe of the same length respect the original fuel line layout and its fixing systems 6 Insert the new pipe in the connections of the devices...

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Page 82: ... filter ensure there are no deformation cracks and damages the correct tightening of the filter fixing clamp the presence of the safety wiring 3 17 1 INSPECTION AND CLEANING OF FILTER 1 Before starting verify that the engine s ignition key and push button are in OFF position and that all the breakers are switched OFF 2 Completely remove the safety wiring 3 of the filter 3 Loosen the fixing clamp 2...

Page 83: ...irectly to the engine s turbine assembly which can reach very high temperatures when the engine is running Because of these high temperatures the collar made of rubber of the filter 1 gets altered this in turn can affect the tightening action of the filter clamp 2 It is strongly recommended to check the correct tightening of the clamp 2 within the first hour of use of the engine after the replacem...

Page 84: ...f the collar of the filters 3 18 PROPELLER MAINTENANCE Before each flight the blades must be carefully inspected The inspection should look for signs of impact particularly on the leading edges Evidence of cracks or defects in the blade coating should also be looked for There should be no signs of play between the blade and hub A clean finger should be run around the rod end and provide no trace o...

Page 85: ...than cracks are observed then the position and size should be monitored to check that the crack does not grow in size If elongation of the crack is noted then the blade should be returned immediately to the factory for repair 3 18 4 ROD END If any defect is observed on the rod end or any dust is evident upon wiping with a clean finger then the blade should be immediately returned to the factory fo...

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Page 87: ...emoving all residues This will also enhance the aerodynamic properties of the surfaces Magni Gyro s choice of cleaning products is supplied as a sample with the STARTER KIT The STARTER KIT includes products and instructions on how to use them best so as to clean your gyroplane in a safe and appropriate manner A vacuum cleaner should be used to remove any dirt inside the aircraft It is possible to ...

Page 88: ...en stored in a hanger or outside it is recommended to cover the gyroplane with a snug fitting non marking cover The use of an adequate cover supplied by Magni Gyro is strongly recommended This cover is produced with ventile materials to allow the evaporation of humidity that can occur when the cover touches the gyroplane s surface Before covering the gyroplane ensure that all the surfaces are drie...

Page 89: ... consists of an electric linear actuator pn 102 placed behind the mast 1 that acts through a sheathed cable 2x1 500 pn 104 on the spring pn 109 fixed to the rotor head fork pn 046 When the actuator is operated there is a constant stress applied to the rotor head This allows to obtain the angle of incidence and by consequence the gyroplane attitude required by the pilot The pilot controls the actua...

Page 90: ...Inspection of the welding on the trim switch pn 112 contacts WARNING When assembling the switch pn 112 take care to place the blue or gray wire towards the front 1 Loosen the grub screw pn M4x6 of the trim switch 2 Extract the trim control switch pn 112 and check the welding 3 on the switch 3 Reposition the switch pn 112 in its seat while keeping the blue wire in front 4 Tighten the grub screw pn ...

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Page 92: ...wer supply connector 7 to the new unit board supplied by Magni Gyro 4 Re insert the six numbered wires in the terminal board in progressive order as per drawing Complete the operation as follows 1 Place the unit board 5 in its original position 2 Put the actuator s pn 102 cover 3 back in its original position taking care not to damage the numbered wires 3 Tighten the cover fixing screws 4 4 Reposi...

Page 93: ...hat all the breakers are switched OFF 2 Clean the sensor pn 238 using some paper and passing it between the sensor and the notched gear so as to remove residual grease and dirtiness 3 Verify the distance between the sensor pn 238 and the notched gear pn 061 which must be within the following range 1 0 mm 0 4 0 4 If the distance is out of range remove or insert washers 5mm diameter so as to take th...

Page 94: ...e pilot must evaluate the vibrations on the controls Hereby he may find that the vibrations are getting worse with time But prior to any adjustment the vibrations must be checked during a periodical or special inspection by a pilot approved by the producer The first step towards the solution of the problem is to identify the type of vibration so as to define the type of intervention needed and eli...

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Page 96: ...e required Check the correct tightening of the lock nut pn 283 on the threaded bushing pn 247 Check the tightening of the control joint bolts see paragraph 3 7 Stiffening of controls 5 3 5 CHECK OF CORRECT TIGHTENING OF LOCK NUT pn 283 ON THREADED BUSHING pn 247 A slight loosening of the lock nut pn 283 might cause high amplitude vibrations on the control stick possibly with vertical vibrations of...

Page 97: ...ot get engaged No strange noises are heard nor anomalous vibrations are felt It is quite likely that there is no power transmission between the propeller pn 125 and the belts pn A28 The belts pn A28 are not driven or their movement is not sufficient to engage the system a Verification of the pre rotation control line 1 Before starting verify that the engine s ignition key and push button are in OF...

Page 98: ...ess of the square section seat and of the square section ending of the flexible shaft pn 118 5 If the splined shaft pn 040 is damaged replace it as explained in paragraph 3 6 3 b Verification of the square section ending of the splined shaft pn 118 1 Before starting verify that the engine s ignition key and push button are in OFF position and that all the breakers are switched OFF 2 Remove the fle...

Page 99: ...ot just show at the point of impact but may be referred to another point of the gyroplane All the controls and components of the gyroplane must be examined for distortion or damage Any distortion of the airframe cracked welds jammed controls bent rods bent rod ends etc make the gyroplane unfit to fly and must be referred to Magni Gyro for advice and classification of damage Any damaged part remove...

Page 100: ...The trailing edge is the most delicate part of the Magni Gyro rotor because of the reduced thickness which is extremely efficient from an aerodynamic point of view but at the same time most exposed to damage during garaging transport and installation The following diagram shows the relation existing between the deepness on the chord and the length on the diameter of the damage on the blade s trail...

Page 101: ... very well The efficacy of the gyroplane can only be limited by de bonding of the superficial covering along the leading edge or by more than 5 mm deep deformations In this case the rotor with its two blades and its hub pn 285 for 28 ft must be completely removed from the gyroplane according to the procedure indicated in paragraph 6 3 and sent to Magni Gyro for control repair or replacement ...

Page 102: ... from the gyroplane according to the procedure indicated in paragraph 6 3 and sent to Magni Gyro for control repair or replacement WARNING DANGER Flight is forbidden in case of debonding of the covering of the blade s face or back of deformation and anomalous swelling Any repainting or repair of the blades must be communicated to Magni Gyro and will only be allowed under the supervision of Magni G...

Page 103: ...rticular attention to their blades during these checks WARNING DANGER Any cracks should remain within the zone defined in and be of a vertical nature just outboard of the aluminium root fitting The cracks must only be evident on the fwd or aft faces of the blade they must not extend onto the upper or lower faces of the blade Any cracks that do not conform to the appearance of those shown in the ph...

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Page 105: ... edge of the rotor blades being this the more delicate and fragile part of the rotor b Rotor installation procedure The rotor blades are produced by Magni Gyro according to a very high production standard They have demonstrated excellent characteristics during flight Previously to flight tests the blades 1 are coupled and balanced thus the couple must always remain the same The couple of blades is...

Page 106: ... and needs to be checked prior to carrying on 4 With the help of another operator fit the second blade to the hub bar always checking the exact matching of the markings 4 5 Lift the tip of the blade to help lining up the fixing holes of the blade with those of the hub bar 6 Insert the bolts AN 8 41A with the washer pn 12x24 under the head of the bolt that have to be on the leading edge side of the...

Page 107: ...e tightening of this bolt due to the low strength required The operator must rely on the rotation applied to the nut pn 12PCR106 after this nut has put the bushes pn 248 and pn 247 against the bearings pn NKXR 15Z of the aluminium head pn 066 Follow the procedure described below 1 Tighten the bolt PAN 3009 136 until the bush pn 248 touches the bearings of the head pn NKXR 15Z stop tightening when ...

Page 108: ...en and remove the nut 12PCR106 and its washers 4 Lift the rotor with the help of other operators or with a hoist see fig 3 5 1 so as to lighten the load on the bolt PAN 3009 136 and make its extraction easier 5 Extract the bolt PAN 3009 136 by hand or if necessary use a soft rubber hammer 6 Remove the rotor from the head and place it on the already prepared stable platforms 7 Before starting the d...

Page 109: ...acle with the blades e g walls doors gates etc especially along the very fragile trailing edge 3 Be sure there are enough operators helping you at least three or use a hoist see fig 3 5 1 to lift the rotor to assemble it on the gyroplane rotor head 4 When moving the gyroplane to the hangar move it carefully and pay attention not to damage the blades as said in point 3 NOTE When garaging the gyropl...

Page 110: ...tor blades 2 fitted The gyroplane is best secured by using ratchet straps or strong ropes 3 around the landing gear leaf spring 4 and anchoring them to the supports 5 on the trailer platform This will prevent forward and rearward movements on the trailer An elevating platform 6 placed below the keel tube as shown in the figure or a support strut will prevent any vertical movement of the gyroplane ...

Page 111: ...from dust and humidity with the special ventile cover supplied by Magni Gyro WARNING Do not put the cover on the gyroplane when the engine is still hot as this could damage the engine cover and cause burning and scorching WARNING Any rest outside should only be occasional Proceed as follows 1 Avoid letting the gyroplane under the sun for lengthy periods 2 If the gyroplane is exposed to the sun cov...

Page 112: ...ge 2 Empty the fuel tank completely 3 Carry out engine storage procedures as per ROTAX manual 4 Clean and polish all the surfaces well 5 Coat all the metal parts with a water repellent product anticorrosive ACF 50 6 If necessary remove the engine and protect the blades as per the indications given in paragraphs 6 3 ROTOR DE RIGGING and 6 4 PRESERVATION OF ROTOR BLADES 7 Protect the cockpit engine ...

Page 113: ...ried out systematically and thoroughly prior to flight as per hereunder copied checklist 1 INSTRUMENT PANEL 2 CHECK OF PEDALS 3 CHECK OF CONTROL STICK 4 CHECK INSIDE OF COCKPIT 5 COCKPIT AND FUSELAGE RIGHT HAND SIDE 6 COOLANT LEVEL 7 ENGINE OIL LEVEL 8 FREEDOM AND ENTIRENESS OF CONTROL RODS 9 ROTOR HEAD RIGHT HAND SIDE 10 UNDERCARRIAGE RIGHT HAND SIDE 11 WHEELS AND WHEEL PANTS 12 ENGINE MOUNT RIGH...

Page 114: ...legible EXTERNAL CHECKS 5 COCKPIT AND FUSELAGE RIGHT HAND SIDE Check the condition of the external surface of the fuselage and remove any foreign object or dirt Ensure it is clean Check that the windscreens are fixed well and not damaged Ensure correct visibility Examine pilot and passenger restraint systems and make sure they are not damaged Pay particular attention to any cut chafing contaminati...

Page 115: ...ts 11 WHEELS AND WHEEL PANTS Check the state and safety of the anchoring of the wheel hub axle and wheel pants Check all the tires and make sure their inflation pressure is correct Check their state possible damage and unbalance of rubbing marks Either roll the gyroplane forward or remove the wheel pants to check all the tires Ensure any dirt and debris have been removed from inside the wheel pant...

Page 116: ...d make sure they are free of cracks or damage Check the anchoring of the tail planes Check the safety of the rudder and make sure it is completely free to move Push down so that the nose wheel is lifted thus reducing the strain on the controls Check the state and freedom of movement of the tail wheel 19 ENGINE LEFT HAND SIDE Proceed as for the right side Furthermore check the state of the battery ...

Page 117: ...ding or restriction As regards the ROTAX 914 ensure that the front throttle lever can be extended past the 100 stop and reach the 115 stop Check the state of the brake levers Make sure that the maximum braking power is available and that the lever turns back when released 26 NOSE WHEEL Check the state of the nose wheel and ensure its correct inflation pressure Check that the full range of movement...

Page 118: ...NIZED INTO A LOGICAL PATTERN THAT MAKES ONE COMPLETE ROUND OF THE GYROPLANE AND BECOMES SECOND NATURE WITH PRACTICE THIS PATTERN STARTS WITH THE INSPECTION OF THE INSTRUMENT PANEL AND CONTINUES CLOCKWISE AROUND THE GYROPLANE AS DESCRIBED IN THE FOLLOWING FIGURE WARNING The importance of this check and the level of diligence needed during it cannot be overemphasized A well executed daily pre flight...

Page 119: ...WARNING DANGER This manual must be read and fully understood before starting the engine Failure to do so will lead to an extremely hazardous situation with great risk of injury or death Refer to the Magni Gyro Gyroplane Pilot Handbook before attempting an engine start sequence Once the engine is started and warmed up carry out a full functional check of all the engine indicating and warning system...

Page 120: ...12 7 4 CL 4 ORDINARY MAINTENANCE SCHEDULE The correct maintenance of the gyroplane avoids troubles and inconvenience that can compromise the safety of flight operations Magni Gyro strongly recommends complying with the published M16 M16C Maintenance Schedule 045 00 16 C ...

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