RotorSport Bishops Castle Maintenance Manual Download

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Document number RSUK0288

Page 1 of 55

Maintenance Manual

Gyroplane Type Cavalon (UK spec only)

RotorSport UK Ltd

Poplar Farm

Prolley Moor

Wentnor

Bishops Castle

SY9 5EJ

Company Reg No 5486550

Phone: +44 (0) 1588 650769

Fax: +44 (0) 1588 650769

Email:

[email protected]

CAA Approval No: DAI/9917/06

Page issue 4, dated 08.06.15

Summary of Contents for Bishops Castle

Page 1: ...tenance Manual Gyroplane Type Cavalon UK spec only RotorSport UK Ltd Poplar Farm Prolley Moor Wentnor Bishops Castle SY9 5EJ Company Reg No 5486550 Phone 44 0 1588 650769 Fax 44 0 1588 650769 Email in...

Page 2: ...craft serial no RSUK CVLN Engine type Rotax 912ULS 914UL Engine serial No Rotor blade type diameter Autogyro 8 4m RotorSystemII RAO red cap black clamp profile only Propeller type HTC 1 73m with or wi...

Page 3: ...ation 9 Modifications 9 Duplicate inspections 9 Scheduled maintenance worksheets 9 Definitions 9 Section 4 Permit maintenance release 10 Pilot Maintenance 11 Annual check 12 Section 5 The maintenance...

Page 4: ...s the AutoGyro Manufacturers Maintenance Manual by way of the pdf document copied into the RotorSport document as Appendix B Therefore 1 In the event of conflict between RotorSport and AutoGyro instru...

Page 5: ...ters where issued ISSUE NUMBER DATE INSERTED BY ISSUE NUMBER DATE INSERTED BY Initial 4 08 06 15 1 07 12 12 5 2 11 03 13 6 3 12 04 13 7 Issue Change summary 1 First issue for flight test 2 DRAFT for r...

Page 6: ...3 Page 11 2 11 03 13 Page 43 4 12 04 13 Page 12 2 11 03 13 Page 44 4 08 06 15 Page 13 2 11 03 13 Page 45 3 12 04 13 Page 14 2 11 03 13 Page 46 3 12 04 13 Page 15 4 08 06 15 Page 47 3 12 04 13 Page 16...

Page 7: ...owed by owners on Permit aircraft It is the aircraft operators responsibility to ensure the aircraft is operated within those rules and regulations 3 Notes RSUK provides this maintenance schedule so t...

Page 8: ...tenance manual Inspections may be carried out without component removal or dismantling unless considered necessary or where required by the schedule AIRWORTHINESS LIFE LIMITATIONS RETIREMENT SCRAP LIV...

Page 9: ...ts if appropriate In exceptional circumstances the CAA also allow another qualified gyroplane pilot to cross check modifications this person must sign the logbooks to certify their actions with their...

Page 10: ...been completed to my satisfaction and in that respect the aircraft is considered fit for flight or have new logbooks containing this information For information on who can issue a PMR see CAP553 BCAR...

Page 11: ...g of the cabin or cockpit interior when repair does not require dismantling of any structures or operating system or interfere with an operating system or affect the structure of the aircraft 4 Repair...

Page 12: ...of oil filter and wirelock of sump bolt Annual Check The annual check and all associated work must be accomplished under the supervision of a person or organisation appropriately approved by the CAA e...

Page 13: ...Copyright of RotorSport UK Ltd Document number RSUK0288 Page 13 of 55 Intentionally blank Page issue 2 dated 11 03 13...

Page 14: ...to be a maintenance planning tool but as an exceptional means to allow the operator to fly for a limited period of time until the required maintenance is performed 3 Any application of a permitted va...

Page 15: ...some specific requirements that must be met demonstrated during the permit renewal process These are 1 Demonstration of compliance with relevant AAN s 29345 downloadable from the CAA website at applic...

Page 16: ...serial No and Propeller serial number 11 Pilots Operating handbook Issue No You will need to show your copy 12 Logbooks modifications and service bulletins MPDs The aircraft and engine logbooks will b...

Page 17: ...corrosion prevention Keep the aircraft in a non humid ventilated area If humidity is present protect unplated components such as bolts etc with a proprietary spray such as WD40 or ACF50 10 Help prote...

Page 18: ...safe landing without it inevitably an aircraft rollover would result probably destroying the aircraft Critical parts The following parts and assemblies have been denoted critical during the design re...

Page 19: ...an alternative design of propeller will result in the requirement for a Permit Flight Release Certificate PFRC to be issued This is a simple document and is not included within the logbooks It must b...

Page 20: ...her side of the fuselage under the doors roughly 2 3rds of the length along and marked by white rings and black letters saying Static port do not block The static port connects to the ASI Altimeter an...

Page 21: ...the end of the pitot nozzle Check that the indicators have returned to zero Static port integrity With the above test in progress ie the system pressurised and showing 70mph block one static port with...

Page 22: ...with right trim left with left trim and the stick is pulled into the same direction Centre trim indicator which must return the stick to the middle ie the stick requires a small force to push for rol...

Page 23: ...ud dampened with Ambersil LO30 This step is important as any debris will weaken the finished repair 4 Seal one side of the slot with suitable scotch tape to prevent adhesive leakage during the bonding...

Page 24: ...nium CNC machined mounting plate and 9 M4 screws to hold the spinner to the plate with plastic washers under the heads Materials used 1 73m diameter 3 blade HTC composite propeller assembly Hub assemb...

Page 25: ...gine carries a datalogger available for interrogation of engine parameters by service engineers with appropriate equipment ALWAYS recheck all the hub bolt torques after first flight after adjustment a...

Page 26: ...The Rotax recommended maximum out of balance force on the propeller shaft is 0 1ips Mass balance weights may either be washers fitted under the propeller fitment bolts or self adhesive aluminium wheel...

Page 27: ...s where the hex code etc is stored if the main transponder module goes faulty it may be replaced without having to reprogram the transponder system The antenna cable and base plate is mounted under ei...

Page 28: ...unction was verified in accordance with TGL13 The functional test undertaken is a transponder verification to confirm a System operation b ICAO 24bit address in transmission response and c Function of...

Page 29: ...Plug RSD7222 available from RSUK Refitting is a reverse of the above The panel must be fully checked for equipment function pneumatic electrical pressure after replacement Only repair instruments in...

Page 30: ...es are in place and basic setup only is needed Engine idle required 1600rpm 1 Remove the fastenings holding the centre console in place and lift up for access to the throttle idle stop 3 Set the throt...

Page 31: ...Recheck balance and if OK stop engine and remove equipment return to flight condition 6 After setting run the engine up and set idle and carb balance If using the Rotax service sheet record the setti...

Page 32: ...Replace worn components The throttle lever and brake ratchet must be replaced as a pair if any of the teeth of the throttle lever are visibly deformed or protrude less than 1 5mm may be assessed with...

Page 33: ...d on section of stainless steel foil Each blade has a substantial flat root area and two 3 8 high tensile precision bolts are used to attach this to the aluminium hub pieces the hub is split for assem...

Page 34: ...Copyright of RotorSport UK Ltd Document number RSUK0288 Page 34 of 55 Propeller construction Propeller mounting flange with torque bushes Page issue 4 dated 08 06 15...

Page 35: ...the engine The pressure connection is made to a spigot already fitted the carburettor balance pipe on the engine A 4mm industrial plastic tube is pre fitted to all aircraft to transfer this pressure...

Page 36: ...g the master switch temporarily to OFF and then back to ON In order to avoid pilot distraction indication of a possible defect is retriggered after another activation of the rocker switch Both the end...

Page 37: ...rked by a yellow triangle at the RPM gauge engine speed indicator Three types of manifold pressure gauge are available Analogue scale with limit placards for 912ULS normally aspirated engine Analogue...

Page 38: ...The screws fastening the brush box to the mounting bracket the bolts fastening the bracket to the gearbox and the screws retaining the cables to the brush box must be threadlocked with Loctite 243 Th...

Page 39: ...om the CAA website Service Bulletins issued to date For the listing of all approved service bulletins see the RotorSport website owners section where they are all are listed Service Information Letter...

Page 40: ...port UK and the CAA for the above purpose Return this form to RotorSport UK Ltd Poplar Farm Prolley Moor Wentnor Bishops Castle Shropshire SY9 5EJ Or email info rotorsport org or fax 01588 650769 Airc...

Page 41: ...info rotorsport org Repair No CCAR No Repair classification MAJOR or MINOR Aircraft type Aircraft serial No Repair problem description cause of problem if known Service repair authorised by RotorSpor...

Page 42: ...Copyright of RotorSport UK Ltd Document number RSUK0288 Page 42 of 55 Appendix A Compass calibration Page issue 4 dated 08 06 15...

Page 43: ...Copyright of RotorSport UK Ltd Document number RSUK0288 Page 43 of 55 Page issue 4 dated 08 06 15...

Page 44: ...l info rotorsport org Maintenance Concept and Eligibility p7 All maintenance work on UK registered Cavalon gyroplanes must conducted by or under the supervision of an A3 7 approved engineer See Sectio...

Page 45: ...45 of 55 Chapter 06 Dimensions Areas P17 The aircraft version supplied to the UK market conforms to the dimensions below Length 4 73 m Width 1 75 m Height 2 82 m Rotor diameter 8 4 m Rotor disc area 5...

Page 46: ...ribution Air conditioning is not available for UK registered aircraft At the time of first release under AAN29345 the only authorised electronic device that may be fitted to Cavalon is the Apple iPad...

Page 47: ...pilots handbook for cockpit instrument and equipment description CHAPTER 34 NAVIGATION 34 20 00 Attitude and Direction p13 Only the card compass shown immediately above is fitted to UK registered air...

Page 48: ...rt UK Ltd Refer to RSUK for further information 61 20 00 Controlling p16 An in flight variable pitch propeller is now available for UK registered aircraft CHAPTER 63 ROTOR DRIVE 63 11 00 p17 The lates...

Page 49: ...Copyright of RotorSport UK Ltd Document number RSUK0288 Page 49 of 55 Page issue 3 dated 12 04 13...

Page 50: ...correct but note the use of an extension cable RSD7223 to relocate the fuel gauge the engine rpm gauge and the rotor rpm gauge from the left hand panel to the main instrument panel of UK registered a...

Page 51: ...Copyright of RotorSport UK Ltd Document number RSUK0288 Page 51 of 55 Page issue 3 dated 12 04 13...

Page 52: ...Copyright of RotorSport UK Ltd Document number RSUK0288 Page 52 of 55 Page issue 3 dated 12 04 13...

Page 53: ...circuit diagram During aircraft flight test a modification to incorporate a 6bar pressure limit valve was made to the pitch trim system The circuit diagram below reflects the released version with th...

Page 54: ...Copyright of RotorSport UK Ltd Document number RSUK0288 Page 54 of 55 Page issue 3 dated 12 04 13...

Page 55: ...TOR TEETERING PARTS p1 and ASSEMBLY p1 UK registered aircraft utilise low profile Binx all metal locking nuts in place of nyloc nuts for retention of the teeter block to the hub bars assembly 4 plcs T...

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