ela aviaciÓn, s.l. · the airframe (mast, engine support and tail boom) is one single part built...

ELA 10-Eclipse MAINTENANCE MANUAL

Version: M10-04

Issued: July 2016.

Last modification: September 2017.

1

ELA AVIACIÓN, S.L.

POLIGONO INDUSTRIAL EL BLANQUILLO, M7 P26

14290 FUENTE OBEJUNA, CÓRDOBA, ESPAÑA

Phone: 0034 957 58 51 75 Fax: 0034 957 58 50 37

Email: [email protected] . Web: www.elaaviacion.com

mailto:[email protected]

http://www.elaaviacion.com/


Version: M10-04

Issued: July 2016.


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MAINTENANCE MANUAL FOR ELA 10-Eclipse GYROPLANE

- Gyroplane model ELA 10-Eclipse

- Gyroplane serial Nº _______________

- Engine model Rotax __________

- Engine serial Nº _______________

- Registration marks _______________

- Aircraft manufacturer and type certificate

holder: ELA Aviación, S.L.

- Owner ________________________

______________________ ______________________

______________________

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 permission from ELA Aviación, S.L.


Version: M10-04

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Amendments to this Manual

As necessary, ELA Aviación S.L. will issue updates to this manual and will

notify owners in the form of replacement pages with changes identified by

change bars in the margin.

Aircraft operators must ensure that this manual is amended and complied

without delay upon receipt, in accordance with the amendment instructions

that will accompany the updates.

Amendment Record

Amend’t

No.

Description of Amendment Pages

affected

Date


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Contents

Section I – INTRODUCTION

1.1 General.

1.2 Applicability.

1.3 Terminology.

1.4 Conversion table.

1.5 Periodic maintenance.

1.6 Gyroplane deterioration.

1.7 Cleaning.

1.8 Road transport.

1.9 Gyroplane identification.

1.10 Bolts torque and sealing.

1.11 Consumables.

1.12 Lifting points.

Section II – DESCRIPTION OF THE AIRCRAFT

2.1 General.

2.2 Constructional details.

2.3 Overall dimensions.

2.4 Technical data and performance.

2.5 Engine.

2.6 Main parts.

2.7 Controls.

Section III – MAINTENANCE DESCRIPTION

3.1 Maintenance schedule.

3.2 Periodical maintenance.


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Section IV – SYSTEMS

4.1 Airframe.

4.2 Rotor controls.

4.3 Steering controls.

4.4 Rotor head.

4.5 Rotor.

4.6 Pre-rotator.

4.7 Throttle and choke systems.

4.8 Landing gear.

4.9 Various.

4.10 Electrical/Pneumatic systems.

4.11 Propeller.

4.12 Engine.

4.13 Fuel system.

4.14 Cooling system.

4.15 Oil system.

Section V – FUNCTIONAL TEST FLIGHT

5.1 Functional test flight.

Section VI – SUPLEMENTS

6.1 Electrical system.

6.2 Pneumatic system.


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SECTION I – INTRODUCTION

1.1 GENERAL

This maintenance manual contains the necessary information for safe and

efficient operation of the ELA 10-Eclipse gyroplane. It explains the

maintenance processes to keep this aircraft airworthy and in good condition.

This guide describes the correct maintenance for the parts manufactured by ELA Aviación, S.L. The instructions for the engine maintenance and

servicing are not included in this manual. To carry out engine maintenance appropriately, please refer to the updated engine´s maintenance manual.

Some of the operations described in this manual should be carried out only by approved maintenance ELA staff. See “Maintenance Schedule”.

The owner/operator of this aircraft is the responsible to keep it properly

maintained according with the maintenance manuals, provided with this gyroplane.

Maintenance tasks must be performed by experienced mechanics.

Special inspections have to be performed after any operational incident, including:

- Hard landing. - Strikes in flight with birds, trees…

- Rotor contact with obstacles. - Lightning strike. - Rotor over-speed.

- Engine failure.

Contact ELA Aviación, S.L. for advice in case of any doubt.


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1.2 APPLICABILITY

This manual is applicable to the ELA 10-Eclipse gyroplane.

1.3 TERMINOLOGY

Aerodynamics

CAS Calibrated airspeed. The indicated airspeed corrected for position and instrument

error.

IAS Indicated airspeed. The speed indicated in the airspeed indicator.

TAS True airspeed. The calibrated airspeed corrected for altitude and temperature.

Vb Turbulence speed. Design speed for maximum gust intensity.

Vne Never exceed speed.

Vy Best rate of climb speed.

Vx Best angle of climb speed.

Meteorology

OAT Outside Air Temperature expressed in degrees Celsius (°C).

ISA International Standard Atmosphere.

Hp Standard altimeter setting. 1013 mb (or hectopascals).


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1.4 CONVERSION TABLE

Temperature from Symbol to Symbol Factor

Fahrenheit Fº Celsius Cº 5/9*(F-

32)

Celsius Cº Fahrenheit Fº 9/5*C+32

Weight from to

Kilograms Kg Pounds Lb *2,205

Pounds Lb Kilograms Kg * 0,4536

Speed from to

Metres per

second m/s Feet per minute ft/min * 196,86

Feet per minute ft/min Metres per second m/s * 0,00508

Kilometres per

hour km/h Knots Kts * 0,54

Knots kts Kilometres per

hour Km/h * 1,852

Knots Kts Miles per hour mph * 1,15

Miles per hour mph Knots Kts * 0,87

Pressure from to

Atmospheres Atm Pounds per square

inch psi * 14,8

Pounds per square

inch psi Atmospheres Atm * 0,06756

Distance from to

Kilometres Km Nautical Miles nm * 0,540

Nautical miles nm Kilometres Km. * 1.852

Statute miles sm Nautical Miles nm * 0,87


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Nautical Miles nm Statute miles sm * 1,15

Meters m Feet ft * 3.281

Centimetres cm Inches in * 0,3937

Inches in Centimetres cm. * 2.54

Volume from to

Litres lt US Gallons US gal * 0,2642

US Gallons US gal Litres lt * 3.785

Area from to

Square Meters m² Square Feet ft² * 10,76

Square Feet ft² Square Meters m² * 0,0929

1.5 PERIODIC MAINTENANCE

Certain parts require scheduled maintenance regardless of flight hours. This

maintenance must be carried out in addition to the flight hours related

maintenance.

The 100-hrs maintenance should be carried out every 100 flight hours or,

as an anual inspection, every 12 months, whichever comes first.

All rubber parts and hoses should be replaced every 5 years or 500 flight

hours, whichever comes first.

1.6 GYROPLANE DETERIORATION

High humidity, especially in combination with salt-containing atmosphere

will lead to deterioration and corrosion of some parts of the gyroplane. Protect the metal parts of the gyroplane such as the engine, rotor head,

rotor hub bar, control systems, etc., with WD-40 or ACF-50 oil.

Sunlight and heat impact can degrade the composite parts of the gyroplane. Whenever possible place the gyro in a protected area.

The manufacturer takes no responsibility for damage due to improper usage.


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1.7 CLEANING

It is important to keep the gyroplane and its engine clean to maintain it in

good condition. In addition, during cleaning, faults and damaged parts can be detected.

Rotor blades and propeller should be always clean as they are very

important to obtain the best performance. In order to protect the gyroplane from dust, humidity, bird soil, etc., is

advisable to cover it when parked in the hangar.

Use car soap diluted in water to clean the external parts, windscreen should

be cleaned only with polycarbonate soap or a suitable polish. Protect all metal parts of the gyroplane and engine against corrosion,

especially if the gyro is exposed to high humidity conditions, with “WD-40” or ACF-50 oil.

1.8 ROAD TRANSPORT

Take the rotor blades off and package them carefully since they can be

damaged during road transportation. For safety, transport the gyro with

minimum fuel content in its tank.

Caution

Do not use high pressure sprayers as they can damage electrical

connections, bearings or paint. Do not use solvents or gasoline as they can damage some parts of the

gyroplane.


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1.9 GYROPLANE IDENTIFICATION

The gyroplane identification placard is placed on the left side of the mast,

cockpit bracket.

Please provide your gyroplane serial number for identification if you need to contact ELA Aviación, S.L. for any reason.

1.10 BOLTS TORQUE

All bolts of the gyroplane should be tightened with their corresponding torque. The maintenance technician should have a torque wrench from 5N/m to 60N/m at hand to carry out all maintenance tasks.

Some bolts have a special tightening torque as given in this manual. If none

is specified, the general torque settings are as following:

KIND OF BOLT TORQUE TOLERANCE

Metric -5 6 N/m +/- 1

Metric – 6 10 N/m +/- 1

Metric – 8 25 N/m +/- 1

Metric – 10 53 N/m +/- 2

AN-4 10 N/m +/- 1

AN-5 18 N/m +/- 1

AN-6 23 N/m +/- 2

Critical threads have an inspection lacquer or torque seal, usually in red, which allows easy verification that components have not moved relative to

each other. This is called “sealing” in this manual.


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1.11 CONSUMABLES Consumables used to perform the maintenance or assembly parts in the

gyroplane:

- Lubricants: - Oil WD-40. - Spray grease Krafft.

- Grease Molykote BR2 Plus. - Grease “water repellent” Brugarolas JET-70.

- Oil ACF-50. - Valvoline sae-90.

- Threadlockers:

- Loctite 243. - Loctite 270. - Loctite 641.

- Loctite 638.

- Engine oil: (see latest issue of engine maintenance manual) - Coolant: 50/50 antifreeze and water (see latest issue of engine

maintenance manual).

- “Meguiar´s Mirror Glaze” for the canopy and “summer windscreen”.


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6.10 LIFTING POINTS

In case is necessary to lift the gyroplane for maintenance or loading

purposes, the most convenient attachment point is the pre-rotator gear-

box.

Point to lift the gyroplane to change one of the main wheels.


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How to place the gyroplane to change the front wheel.

In case is necessary to lift the gyroplane for maintenance or loading

purposes, the most convenient attachment point is the pre-rotator gear-

box.


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Section II – DESCRIPTION OF THE AIRCRAFT

2.1 GENERAL

The ELA 10-Eclipse gyroplane is designed as a 2-seater, tandem-configured

three-axis aircraft with single or dual controls and single engine, ideal for

leisure flight or training purposes. In addition to flight training and general

recreational flying, the flight characteristics of this gyroplane make such

aircraft ideally suited for tasks such as air transportation, forestry, border,

livestock and traffic surveillance, electrical pylon inspection, aerial still and

film photography, fumigation, crop spray etc. These are typically the kind of

activities which benefit from the very low speeds at which this gyroplane

can operate as well as its characteristic zero downwash. The manoeuvring

capability of the aircraft in all configurations is exceptionally high, and since

it is impossible for the machine to enter into a stall or a spin, it has an

unequalled flight safety record. Its characteristic short take-off and landing

runs make it particularly suitable for operation from fields of modest

dimension.

2.2 CONSTRUCTIONAL DETAILS

The airframe (mast, engine support and tail boom) is one single part built

from chromoly AISI 4130 steel, TIG (tungsten-inert-gas) welded. The

gyroplane is a tricycle landing gear with front wheel.

The cockpit is a monocoque made from carbon fibre and epoxy resin with a

built-in fuel tank, ensuring high strength with low weight. The canopy is

made from aeronautical Plexiglas to protect the occupants from cold and

wind.

The layout of the instrument panel house switches which fall easily to

hand around the desired set of instruments.

The rotor blades are made from aluminium and composite materials.

The power unit consists of a pusher piston engine and a three bladed

composite propeller.

The tailplane is made from carbon fibre and consist of a fixed horizontal

stabilizer with winglets at the ends and a vertical surface in the centre

subdivided into a fixed vertical stabilizer and a rudder.


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2.3 OVERALL DIMENSIONS

MEASUREMENT METRIC IMPERIAL

Total length 5.08 m. 16.67 ft.

Total height 2.85 m. 9.35 ft.

Landing gear width 1.75 m. 5.74 ft.

Rotor diameter 8.50 / 8.65 m. 27.89 / 28.38 ft.

2.85m

5.08m

0.3m 2.15m

1.55m

1.73m


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2.4 TECHNICAL DATA AND PERFORMANCE

The following performance parameters were determined by flight testing with average piloting skills, aircraft in good conditions and clean rotor

blades and propeller. The parameters apply to standard conditions ISA (15ºC temperature, sea level and standard pressure).

Gyroplane data With Rotax 912 ULS (100 HP)

With Rotax 914 TURBO (115 HP)

METRIC IMPERIAL METRIC IMPERIAL

Empty weight (minimum equipment) 283 kg 625 lb 293 kg 650 lb

MTOW* 500 kg 1100 lb 530 kg 1170 lb

Useful load (minimum equipment)* 217 kg 475 lb 237 kg 520 lb

Vne 190 kph 120 mph (103 kts)

190 kph 120 mph (103 kts)

Cruise speed 120 – 160 kph 75 – 100 mph

(65 – 85 kts) 120 – 160 kph

75 – 100 mph

(65 – 85 kts)

Min speed (level flight/full power)) 45 kph 30 mph (24 kts)

40 kph 25 mph (22 kts)

Rate of climb 3 m/s 600 ft/m 5 m/s 1000 ft/m

Take-off distance (roll) 120 m 400 ft 100 m 330 ft

Landing distance (roll) 0 – 30 m 0 – 65 ft 0 – 30 m 0 – 65 ft

Fuel Gasoline

Fuel capacity 87 l 23 gal

Unusable fuel 2 l 0.5 gal

Fuel consumption 12 – 20 l/h 3 – 5.5 gal/hr

* See the MTOW limitations for your country.


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2.5 ENGINE

i) Manufacturer ……………………………………………………………………………… BRP Rotax

ii) Take-off power:

a. 912 ULS…………………………………………………………… 100 hp b. 914 UL……………………………………………………………. 115 hp

iii) Max. engine speed……………….…………………………….…….……….……… 5800 rpm iv) Cooling system……………………………………………….….………..………..……. Air/liquid

v) Coolant………………………………………………………………………. 50% water/antifreeze

vi) Electric installation…………………………………………..…………………………………. 12v


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2.6 MAIN PARTS

Parts: 1 – Rotor blades. 2 – Hub bar.

3 – Rotor head.

4 – Mast and mast fairing. 5 – Rear keel. 6 – Landing gear. 7 – Main wheels. 8 – Front wheel. 9 – Cockpit. 10 – Landing lights.

11 – Canopy. 12 – Engine compartment. 13 – Tailplane.

1

2

3 4

5

6

7

8

9

10

11

12

13


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Parts:

1 – Propeller. 2 – Oil cooler. 3 – Water cooler.

4 – Vertical stabilizer. 5 – Rudder. 6 – Winglet.

7 – Horizontal stabilizer. 8 – Control rods. 9 – Fuel tank filler.

1

2

3

4 5

6 7

8

9


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Parts: 1 – Engine.

2 – Water tank. 3 – Horizontal pre-rotator drive shaft. 4 – Pre-rotator clutch. 5 – Carburettor. 6 – Oil tank. 7 – Air filter (912).

8 – Battery. 9 – Pre-rotator piston.

1

2 3

4

5

6

7

8

9


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Parts:

1 – Compass.

2 – Altimeter/VSI 3 – Airspeed indicator.

4 – KANARDIA EMSIS (to control engine parameters, rotor tachometer and fuel consumption)

5 – TRIM pressure 6 – Radio. 7 – Transponder.

8 – Flight/brake selector. 9 – Fuel level indicators.

10 – Ignition switch. 11 – 12V or USB power outlet.

1

2 3

4

5

6 7

8 9

10

11


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Parts:

1 – Caution and warning turbo lights (just in 914 engine).

2 – Headset jack. 3 – Battery charge. 4 – Landing and strobe lights switches.

5 – Circuit breakers. 6 – Master switch.

7 – Fuel pumps (only one for 912 ULS engine). 8 – Cabin heating switch.

5

2

1

4

3

6 7

8


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2.7 CONTROLS

Front Stick

Note: PTT radio in front stick is installed in the trigger in the new

gyroplanes

Rear Stick

Pre-rotator

Trim Ptt-radio

Trim

Pre-rotator

Ptt-radio


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Pedals

Throttle and wheel brakes

Front pedals

Rear pedals


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Choke

Old system New system

Shut-off valve: This valve interrupts the fuel supplied to the engine.

In case of fire, turn-over or crash, shut off the fuel as soon as

possible to prevent risk of fuel burning.


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Section III – MAINTENANCE DESCRIPTION

3.1 MAINTENANCE SCHEDULE

The 100-hrs maintenance should be carried out every 100 flight hours or,

as an anual inspection, every 12 months, whichever comes first.

Task Nº

DESCRIPTION 25 hr

100 hr

200 hr

300 hr

400 hr

500 hr

600 hr

700 hr

800 hr

900 hr

1 - AIRFRAME

1.1 Inspect airframe X X X X X X X X X

1.2 Verify sealing of bolts X X X X X X X X X

1.3 Verify good condition of placards X X X X X X X X X

2 - ROTOR CONTROLS

2.1 Verify sealing of control system bolts X X X X X X X X X X

2.2 Verify absence of play X X X X X X X X X X

2.3 Inspect control rods X X X X X X X X X

2.4 Grease control rod ends X X X X X X X X X

2.5 Adjust friction in roll (if needed) X X X X X X X X X X

2.6 Retighten bolts of control fork X X X X X

2.7 Replace control fork bolts X X X

2.8 Rotor controls overhaul (only by approved staff)

X

3 – STEERING CONTROLS

3.1 Inspect front wheel fork X X X X X X X X X

3.2 Inspect control rods for straightness X X X X X X X X X

3.3 Inspect pedals X X X X X X X X X

3.4 Verify rudder cable tension X X X X X X X X X X

3.5 Check rudder setting X X X X

3.6 Replace rudder control cables X


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Task Nº

DESCRIPTION 25 hr

100 hr

200 hr

300 hr

400 hr

500 hr

600 hr

700 hr

800 hr

900 hr

4 – ROTOR HEAD

4.1 Verify sealing of bolts X X X X X X X X X X

4.2 Inspect rotor head X X X X X X X X X

4.3 Adjust tightness of roll and pitch pivot bolts X X X X X X X X X

4.4 Grease roll and pitch pivots X X X X X X X X X

4.5 Inspect pre-rotator ring gear and bendix pinion X X X X X X X X X

4.6 Grease pre-rotator X X X X X X X X X

4.7 Inspect rotor brake pad X X X X X X X X X

4.8 Clean/degrease rotor brake disc X X X X X X X X X

4.9 Replace rotor head bolts X

4.10 Inspect teeter towers (only by approved staff)

X

5 – ROTOR BLADES

5.1 Inspect rotor X X X X X X X X X

5.2 Verify tightness of teeter bolt X X X X X X X X X

5.3 General inspection (only by approved staff)

X

6 – PRE-ROTATOR

6.1 Verify sealing of bolts X X X X X X X X X X

6.2 Inspect pre-rotator X X X X X X X X X

6.3 Replace belt X X X

6.4 Adjust pre-rotator rubber pulley brake X X X X X X X X X

6.5 Inspect universal joints for play X X X X X X X X X

6.6 Inspect O-rings X X X X X X X X X

6.7 Grease bearing of the tensioner X X X X X X X X X

6.8 Grease rod end bearing of piston X X X X X X X X X

6.9 Clean and regrease universal joints X X X

6.10 Inspect pre-rotator gearbox X X X X X X X X X

6.11 Replace bearing of tensioner X

7 – THROTTLE AND CHOKE SYSTEMS

7.1 Inspect system for smooth operation X X X X X X X X X X

7.2 Inspect levers for damage X X X X X X X X X X

7.3 Adjust levers friction X X X X X X X X X X

7.4 Inspect choke system X X X X X X X X X X

7.5 Inspect locking wires X X X X X X X X X X

7.6 Adjust carburettor synchronization X X X X X X X X X

7.7 Replace carburettors Bowden cables X


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.Task Nº

DESCRIPTION 25 hr

100 hr

200 hr

300 hr

400 hr

500 hr

600 hr

700 hr

800 hr

900 hr

8 – LANDING GEAR

8.1 Tires and wheels X X X X X X X X X X

8.2 Retighten landing gear bolts X X X X X X X X X

8.3 Inspect brake pads X X X X X X X X X

9 - VARIOUS

9.1 Inspect tailplane X X X X X X X X X X

9.2 Retighten tailplane attachment bolts X X X X

9.4 Verify condition of canopy X X X X X X X X X

9.5 Verify placards X X X X X X X X X

10 – ELECTRICAL/PNEUMATIC SYSTEM

10.1 Inspect electrical harnesses X X X X X X X X X

10.3 Inspect instrument panel X X X X

10.4 Oil compressor X X X X X X X X X

11 - PROPELLER

11.1 Inspect propeller X X X X X X X X X X

11.2 Retighten propeller bolts X X X

11.3 Overhaul X X

12 – ENGINE (see engine´s maintenance manual)

12.1 Verify sealing of engine bolts X X X X X X X X X X

12.2 Replace engine silent-blocks (only by approved staff)

X

12.3 Replace engine attachment bolts (only by approved staff)

X

12.4 Inspect locking wire for the air filters X X X X X X X X X X

12.5 Inspect exhaust system X X X X X X X X X X

13 – FUEL SYSTEM

13.1 Clean gascolator X X X X X X X X X X

13.2 Replace fuel filter X X X X X X X X X

13.3 Clean filters of 914 fuel pumps X X X

13.4 Inspect hoses X X X X X X X X X

13.5 Inspect vent hoses X X X X X X X X X

13.6 Replace hoses X

13.7 Perform fuel tank test X X X X


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3.2 PERIODIC MAINTENANCE Certain parts require scheduled maintenance regardless of the number of

flying hours. This maintenance must be carried out in addition to the flight

hours related maintenance.

The 100-hrs maintenance program shoule be carried out as an annnual

inspection if the gyroplane has not reached 100 flying hours within the last

12-month period.

All rubber parts and hoses should be replaced every 5 years or 500 flight hours, whichever comes first.

Remove the bolts of the rotor controls, rotor head and rotor blades/hub bar every two years and confirm the absence of corrosion or wear. Apply WD-40 or ACF-50 oil to the unthreaded part of the bolt. Elastic stop nuts should

be replaced after each single use and tighten with their corresponding torque. Any corrosion should be investigated to ensure that it does not

threaten the strength of the parts involved. If in doubt replace corroded parts!

Task Nº

DESCRIPTION 25 hr

100 hr

200 hr

300 hr

400 hr

500 hr

600 hr

700 hr

800 hr

900 hr

14 – COOLING SYSTEM

14.1 Inspect system X X X X X X X X X X

14.2 Replace hoses and coolant X

15 – OIL SYSTEM

15.1 Inspect system X X X X X X X X X X

15.2 Replace hoses and clamps X


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Section IV – SYSTEMS

4.1 AIRFRAME

The main airframe of the gyroplane is constructed from TIG-welded AISI

4130 steel. The airframe consists of a single unit which does not have replaceable parts. Any repair or modification to the airframe by third persons are not allowed

or approved.

1.1 Inspect airframe

(every 100 flight hours)

Inspect the airframe and it´s welds to

confirm the absence of cracks or

damage.


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1.2 Verify the sealing of bolts (every 100 flight hours)

Pre-rotator gearbox and top

bracket fuselage bolts.


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Engine top bracket bolts (2).

Main bracket fuselage bolts.


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Battery bracket bolts (4).

Engine low bracket bolts.


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Bottom bracket fuselage bolts.

Landing gear bolts.


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THROTTLE

MAX MIN

BRAKE

THROTTLE

MAX MIN

BRAK

E

1.3 Verify good condition of placards


Confirm all placards are in good condition and readable.

OPERATING LIMITATIONS

Aerobatic manoeuvres are prohibited.

Manoeuvres involving a deliberate reduction in normal ‘g’ shall be

avoided.

CG Range Limits (Gyroplane) – refer to Pilot Operator´s Handbook.

Maximum Indicated Airspeed (Vne): 190 km/hr.

This aircraft shall be flown by day and under Visual Flight Rules only.

Smoking in the aircraft is prohibited

AIRCRAFT PAYLOAD SPECIFICATION

Front seat pilot: 110Kg max, 60Kg min.

Rear seat passenger: 110Kg max.

Aircraft must only be flown solo from the front seat.

Empty weight: Kg

MTOW: 500/530Kg

Useful load: Kg

Pull up to OPEN Push down to CLOSE


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OCCUPANT WARNING

This aircraft has not been certificated to an

International Requirement

UNLEADED PETROL

(AVGAS PERMITTED)

MAX. CAPACITY

90 LITERS

MAX. 2 kg

MAX. 10 kg


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4.2 ROTOR CONTROLS

2.1 Verify sealing of control system bolts (first 25 and every 100 flight hours)

Verify the sealing of the front

control column bolts.

Check the sealing of the control

fork bolts.


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Control links in middle mast.

Controls in rotor head.


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2.2 Verify the absence of play (first 25 and every 100 flight hours)

With the rotor brake “ON”, hold the front stick and make some

pressure fore and aft to check if there is play in the whole control system. Few millimetres of play at the top end of the stick are

permissible; 8 mm or more are not acceptable.

2.3 Inspect the control rods


Visually inspect the vertical control rods for damage or cracks,

especially at its ends.

2.4 Grease the control rod ends


Clean the control rod ends (8x)

and grease with spray.


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2.5 Adjust friction in roll (if needed) (first 25 and every 100 flight hours)

FOTO

Some friction in the roll axis of

the rotor controls is helpful in dampening resonant vibrations

during flight. On the ground,

carefully adjust the amount of friction; it should be a

compromise between handle and friction.

2.6 Retighten the bolts of the control fork (100/300/500/700/900 flight hours)

Retighten the bolts of the control fork and mark the thread and nut

with red paint again.


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2.7 Replace the bolts of the control fork


Replace the bolts (2) and nuts of the control fork and mark the

thread and nut with red paint.


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2.8 Rotor controls overhaul (only approved staff)


Dismount the whole rotor system from the gyroplane.

Inspect every control rod (2

horizontal and 4 vertical) for

straightness, cracks or damage.

Inspect the control fork for cracks or damage.

Replace the bearings (x8) of the connection plates of the control

columns.

Replace the bearings (x4) of the

control fork.


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Replace the rod end bearings of

the vertical rods (x8).

Assembly the new rod end bearings so as to obtain the

following measurements between centres:

Upper rods:

- Right: 1168mm - Left: 1156mm

Lower rods:

Right and left: 983mm

Grease the rod ends.

Replace all bolts and nuts of the

control system, 10 for the horizontal rods and 12 for the

vertical rods.


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4.3 STEERING CONTROLS

3.2 Inspect control rods for straightness


Inspect the steering control rods for straightness.

3.3 Inspect pedals (every 100 flight hours)

Inspect the front and rear pedals for straightness, cracks or damage.

Verify the absence or play.

Install new ant-slip pads if necessary.

3.1 Inspect front wheel fork (every 100 flight hours)

Inspect the front wheel fork for straightness, cracks or damage.

Lift the nose of the gyroplane and verify that the fork is free to rotate by hand.

3.4 Verify rudder cable tension

(first 25 and every 100 flight hours)

Old system

Verify rudder cable tension. With

the front wheel fork blocked, hold the trailing edge of the rudder

and try to move it sideways. More than 2cm of play/flexibility

is not acceptable.

Remove the front seat and

retighten the right and left

turnbuckles to avoid play of the


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3.5 Check the rudder setting (every 200 flight hours and after adjusting the cable tension)

The rudder should be mounted offset with respect to the front wheel. Ensure the front wheel of the gyro is pointing forward and verify that

the distance between the lower part of the trailing edge of the rudder and the lower part of the trailing edge of the right winglet is 840mm.

New system

rudder. Verify the offset of the rudder (point 3.5)

Secure it again with safety wire.

In the new system, the turnbuckles are connected to the

rudder so it is not necessary to remove the front seat to adjust

the tension of the cables.


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3.6 Replace rudder control cables (every 500 flight hours)

Replace the rudder control cables and turnbuckles

4.4 ROTOR HEAD

4.1 Verify sealing of bolts (first 25 and every 100 flight hours)

Remove the mast fairing and

verify the sealing of the bolts of the rotor head.


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4.2 Inspect rotor head (every 100 flight hours)

Inspect the rotor head for cracks.

Inspect the rotor head for

deformities or twisting using a rule.

4.3 Adjust tightness of roll and pitch pivot bolts


Adjust the tightness of roll and

pitch bolts.

Torque to 20N/m and slacken about ¼ of turn, or sufficiently to

operate the controls easily. Secure with a new safety pin.


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4.4 Grease roll and pitch pivots (every 100 flight hours)

Grease the rotor head pivots with Molycote. Add grease until see it

coming out.

4.5 Inspect pre-rotator ring gear and bendix pinion


Inspect the pre-rotator ring gear and bendix pinion for wear or

damage. Replace if necessary.

4.6 Grease the pre-rotator


Grease the pre-rotator ring gear with “Brugarolas JET70” using a

small brush.

Engage the bendix with the ring

gear and grease the interior body of the bendix with WD-40 spray.


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4.7 Inspect rotor brake pad


Inspect the brake pad for excessive wear or damage.

4.8 Clean/degrease rotor brake disc


Clean/degrease the rotor brake disc.


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4.9 Replace rotor head bolts (every 500 flight hours)

Replace the rotor head bolts and nuts (10 bolts).


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4.11 Inspect teeter towers (only approved staff) (every 500 flight hours)

Disassemble the teeter towers, main shaft, pre-rotator ring gear

and main rotor bearing.

Clean the teeter towers and main shaft and perform a dye

penetrant test.

If no defect is found, clean the parts, fit the new main rotor

bearing with Loctite 641 and the correct tool. Mount the main

shaft with Loctite 641, with new

lock washers and nuts.

Handle these parts with extreme care. Damaging the main rotor

bearing during the assembly or other kind of mistake with these

parts could have fatal consequences.


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4.5 ROTOR

5.1 Inspect the rotor (every 100 flight hours)

Visually inspect the rotor blades for cracks, wear, deformities…

Visually inspect the hub bar for cracks, wear, deformities…

5.2 Verify tightening of teeter bolt (every 100 flight hours)

The teeter bolt should be tightened strong “BY HAND”.

Then tighten the Allen bolt and

secure with the safety pin.

A lower or higher torque will create rotor vibrations.


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5.3 General inspection


Disassemble the rotor from the gyroplane and put it over stands.

Mark each rotor blade with its side of the hub bar.

Mark the block with the hub bar.

Disassemble the parts of the

rotor, clean them and perform a dye penetrant test.


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If no defects found, clean the parts and mount them.

For the assembly, use new bolts,

washers and nuts and a new teeter bolt.


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4.6 PRE-ROTATOR

6.1 Verify sealing of bolts (first 25 and every 100 flight hours)

Verify the sealing of the pre-

rotator bolts.

Install a new threaded hub with “Brugarolas” grease in the thread

and before assembling the rotor, lubricate the bearings with

Molycote grease.


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6.2 Inspect pre-rotator (every 100 flight hours)

Inspect the pre-rotator tensioner and bracket for cracks or

damage.

Inspect the belt for damage or deformities.

Inspect the horizontal and

vertical drive shafts for cracks or deformities.

6.3 Replace belt

(max. every 300 flight hours or 5 years)

Remove the propeller and replace the belt. Install new bolts (6x) in

the propeller.


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6.4 Adjust pre-rotator rubber pulley brake (every 100 flight hours)

Adjust the pre-rotator rubber

pulley brake if needed.

The small pre-rotator pulley must rest on the rubber pulley, so the

pre-rotator shafts are braked.

Adjust the height of this part by

turning the eccentric pulley.

6.5 Inspect universal joints for play (every 100 flight hours)

Inspect the universal joints for excessive play.

Hold the vertical shaft and gently

try to turn it both ways to check the play of the joints.


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6.6 Inspect O-rings (every 100 flight hours)

Inspect the O-rings for damage.

Replace the O-rings when

needed. When installing, use Loctite 243

and tighten gently by hand.

6.7 Grease bearing of the tensioner (every 100 flight hours)

Lubricate the bearing of the

tensioner with spray grease.

6.8 Grease the rod end bearing of the piston


Lubricate the rod end bearing of the pre-rotator piston with spray

grease.


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6.9 Clean and regrease the universal joints


Remove the rubber covers of the universal joints for cleaning and

regrease with Molycote.

6.10 Inspect pre-rotator gearbox


Verify that the pre-rotator

gearbox has no oil leaks.

In case of leaks replace the oil seals.

6.11 Replace bearing of the tensioner (every 500 flight hours)

Replace the bearing of the tensioner.

Grease with Molycote before assembling.


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4.7 THROTTLE AND CHOKE SYSTEMS

7.1 Inspect system for smooth operation (first 25 and every 100 flight hours)

Operate the throttle from idle to full power position to confirm a

smooth operation.

7.2 Inspect levers for damage (first 25 and every 100 flight hours)

Inspect the front and rear levers for damage or malfunction.


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7.3 Adjust levers friction (first 25 and every 100 flight hours)

Adjust the friction of throttle

levers for smooth operation. If the friction is too strong, it is

difficult to operate with precision, if it is too slack it will move by

itself during flight.

Adjust the brake lever friction for smooth operation and with no

play.

7.4 Inspect choke system (first 25 and every 100 flight hours)

Operate the choke system to confirm its smooth operation.


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7.5 Inspect locking wires (first 25 and every 100 flight hours)

Inspect the safety locking wires

of throttle and choke systems. Replace if necessary.


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7.6 Adjust carburettor synchronization (every 100 flight hours)

Adjust the carburettor synchronization according with the latest issue of the Rotax maintenance manual.

7.7 Replace Bowden cables


Replace carburettor and choke Bowden cables. Afterwards, it is necessary to re-adjust the carburettor synchronization.


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4.8 LANDING GEAR

8.1 Tires and wheels


Check the tires for wear, replace

when needed.

Verify tire pressure:

- Front wheel: 1,5 bar (22 psi) - Main wheels: 2 bar (30 psi)

Inspect the wheel rims for cracks

or damage.

Inspect the red marks between tires and rims. Lack of matching

indicates slipping and requires inspection.

8.2 Retighten landing gear bolts (every 100 flight hours)

Retighten the 2 x M-10 and the 2 x M-6 bolts that fix it to the frame.

8.3 Inspect brake pads


Inspect the wheel brake pads for wear. Replace when needed.


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4.9 VARIOUS

9.1 Inspect tailplane


Inspect tailplane and rudder for cracks or damage.

9.2 Retighten tailplane attachment bolts (every 200 flight hours)

Retighten tailplane attachment bolts (x3).

9.4 Verify condition of canopy


Verify the absence of scratches or cracks. Clean or polish it often

with “Meguiar´s Mirror Glaze” or similar.

9.5 Verify placards (every 100 flight hours)

Verify all placards are readable and in good condition. Replace if necessary.


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4.10 ELECTRICAL/PNEUMATIC SYSTEMS

10.1 Inspect harnesses


Inspect the routing and connections of the electrical and pneumatic harnesses for damage, wear, replacement of cable ties…

10.3 Inspect instrument panel (every 200 flight hours)

Remove the instrument panel for cleaning and inspect all wires and

connections for damage, wear…

10.4 Oil compressor (every 100 flight hours)

Lubricate the compressor with engine oil.

Remove the cover of the

compressor and lubricate it with 3 or 4 drops of engine oil and

connect it to run for a few

seconds.


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4.11 PROPELLER

4.12 ENGINE The instructions for the engine maintenance and servicing are not included in this manual. To carry out engine maintenance appropriately, please refer to the updated engine maintenance manual.

11.1 Inspect propeller (first 25 and every 100 flight hours)

Inspect the propeller blades and hub for cracks or damages.

11.2 Retighten the propeller bolts


Retighten all of the propeller bolts to 25N/m.

11.3 Overhaul (every 600 or 800 flight hours)

Send the propeller to the manufacturer for inspection:

- Helix Carbon GmbH propeller -- 600 flight hours. - DUC Flash-2 propeller ---------- 800 flight hours.

12.1 Verify sealing of engine bolts


Verify the red marks of the engine bolts.


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12.2 Replace engine silent-blocks (every 500 flight hours or 5 years)

Replace the engine silent-blocks.

12.3 Replace engine attachment bolts (every 500 flight hours)

Replace the engine attachment bolts.

12.4 Inspect safety locking wires of air filter(s)


Inspect the safety locking wires

of air filter(s).

Safety locking wires in 914 UL air filter.


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Safety locking wire in 912 ULS air

filters.


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12.5 Inspect exhaust system (first 25 and every 100 flight hours)

Inspect the exhaust system for cracks or damage.

Inspect the after muffler for cracks or damage. Replace the springs and safety wire of the exhaust system of the 912

engine.


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4.13 FUEL SYSTEM

13.1 Clean gascolator


Open and clean the gascolator.

13.2 Replace filter


Replace the fuel filter.

Use only paper filters having an

appropriate size.

The fuel filters with plastic mesh are NOT SUITABLE for this

installation.


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13.3 Clean filters of the 914 pumps


Carefully remove the fuel filters inside the electrical fuel pumps of

the 914 and clean them.

13.4 Inspect hoses


Inspect the routing of the fuel hoses for wear or damage.


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13.5 Inspect vent hoses (every 100 flight hours)

Inspect the routing of the vent hoses for wear or damage.


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13.6 Replace hoses

(every 500 flight hours or 5 years)

Replace the fuel and vent hoses and clamps.


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4.14 COOLING SYSTEM

13.7 Perform fuel tank test (every 200 flight hours)

Check the inside filter of the fuel tank, procedure:

- Fill the tank completely with fuel.

- Open the outlet of the tank (in the connection of the gascolator) and measure the time to get one litre.

- The max. time to get one litre to flow should be less than 35 seconds.

14.1 Inspect system


Verify the absence of leaks in the system.

Check coolant level. The black tank should be full. The white tank

should be filled to one half.

Inspect the rubber washer and spring of the cap of the black tank.

14.2 Replace hoses and coolant (every 500 flight hours or 5 years)

Replace the rubber hoses and clamps of the system.

Replace the coolant. (See engine´s maintenance manual for approved coolants, 50% water / 50% pure antifreeze.


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4.15 OIL SYSTEM

15.2 Replace hoses

(every 500 flight hours or 5 years)

Replace the hoses and clamps.

15.1 Inspect system


Verify the absence of leaks in the system.

Inspect the hoses for wear or damage.


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Section V – FUNCTIONAL TEST FLIGHT

5.1 FUNCTIONAL TEST FLIGHT

A functional test flight (FTF) should be done every year. This test

determines whether the gyroplane or its equipment is functioning according

to established specifications while the aircraft operates in its intended

environment. An FTF is to be performed when it is not possible to determine

proper operation by a ground test.

Test Nº Description Results/Comments Done

1 Weights

Aircraft weight:

Fuel weight:

Pilot weight:

Total:_________________

2 Ground test

Test manoeuvring stability, steering, throttle and

wheel brake systems.

3 Pre-rotator

Test the pre-rotator system for correct function.

4 Take off

Take off with full power using a standard

technique described in the POH.

Note any unusual characteristic.

5 Engine power/propeller pitch

Note the max engine rpm climbing at Vy (100

kph ~ 65 mph).

6 Instruments

Check every flight or engine instrument, check

radio/intercom for correct function.


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7 Climb

Note the time required to climb to 1000 feet at

Vy.

Airport elevation:

QNH:

Temp:

8 Controls

Test rotor and rudder controls in flight.

Note any unusual characteristic.

9 Speeds

Test general stability at speeds from 0-180 kph ~

0-112 mph.

10 Trim

Test trim function at speeds from 0-180 kph ~ 0-

112 mph.

11 Landing

Land with engine at idle speed and note any

unusual behaviour.

Comments/Remarks:

Date: Location:

Pilot Name: License Nº:


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Section VI – SUPLEMENTS

6.1 ELECTRICAL SYSTEM

- 12v DC electrical system diagram for Rotax 912 ULS.

Part 1º

Part 2º

Part 3º.


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Rotax 912 ULS, part 1º.


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- 12v DC electrical system diagram for Rotax 914 UL.

Part 1º

Part 2º

Part 3º


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Rotax 914 UL, part 1º.


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Power consumption of individual components.

Equipment / System Power load

Rotax engine generator (-) 240 W

Electrical fuel pump 912 ULS 18 W

x2 Electrical fuel pumps 914 UL 41 W

Pneumatic compressor 106 W (peak) / 54 W

Strobe light in mast 10 W

NAV and strobe lights

in tail winglets

Position / NAV 4 W

Strobe 29 W (in pulse)

Landing lights (LED) 5 W

Radio Funke ATR833 7 W (rcv) / 35 W

(xmt)

ATC Transponder Funke TRT800H max. 10 W

GPS Garmin 795 40 W

EMSIS (engine monitoring system) 5 W

Digital flight instruments 1 W

Cabin heating 6 W


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6.2 PNEUMATIC SYSTEM

12v DC electro-pneumatic diagram for pre-rotator, rotor brake and trim

systems.


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FROM POS 3 OF

SELECTOR VALVE

TO ROTOR BRAKE

(CYLINDER)

FROM POS 2

SELECTOR VALVE

TO POS 7 OF REAR CONNECTION

FROM POS 6 OF

REAR CONNECTION

TO POS 1 OF

SELECTOR VALVE

FROM POS 9 OF

REAR CONNECTION

TO TRIM PRESSURE

INDICATOR (9)

Instruments panel connection

OUTLET,

TO POS 6 OF

REAR

CONNECTION

INLET,

FROM AIR

PUMP

AIR TANK

INSTALLED IN

REAR PANEL


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FR

OM

OU

TL

ET

AIR

TA

NK

TO

SE

LE

CT

OR

VA

LV

(P

AN

EL

)

PO

SIT

ION

Nº

1

FR

OM

SE

LE

CT

OR

VA

LV

E

(PA

NE

L)

PO

SIT

ION

Nº

2

TO

PR

E-R

OT

AT

OR

CY

LIN

DE

R

TO

TR

IM C

YL

IND

ER

TO

TR

IM P

RE

SS

. IN

DIC

AT

OR

PRE-ROTATOR

SPEED

REGULATOR

TR

IM L

OA

D

SP

EE

D

RE

GU

LA

TO

R

TRIM DOWNLOAD

SPEED REGULATOR

TRIM

LOAD

VALVE

TRIM

DOWNLOAD

VALVE

PNEUMATIC

SYSTEM IN REAR

PANEL

PRE-ROTATOR

VALVE

40A RELAY

PRESSURE

REGULATOR

PRE-ROTATOR

TRIGGER

ACCUMULATOR


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Adjusting the system:

1) Pre-rotator speed: Adjust pre-rotator speed regulator to get 100 rotor rpm in

about 12 seconds.

Procedure: Start engine, clear of obstacles. Put selector valve in “FLIGHT” position

and wait for 5 to 10 seconds. Engine at 3000 rpm and push the pre-rotator button.

100 rotor rpm should be taken in about 12 seconds.

If it is faster, close (tighten) the knob a little and try again. If it is slower, the

opposite.

If pre-rotator doesn´t work, maybe the regulator is too close. When pressing the

pre-rotator button with the stick fully forward and master ON (engine stopped) you

have to hear a little noise. If you don´t hear the noise, maybe the sensor of the

trim-brake cylinder is not at the correct height. That sensor allows using the pre-

rotator ONLY when the stick is fully forward to prevent to connect it in flight.

2) Trim LOAD speed: Adjust to 1BAR/second.

3) Trim Download speed: Adjust to -1BAR/second.

Possible problems of the pneumatic system:

1) The pre-rotator has no energy (power).

Maybe there is an air leak in the system or in the pre-rotator piston. With Master ON, “FLIGHT” position and engine stopped, push the pre-rotator button to listen a possible leak. Sometimes the “rapid scape valve” is dirty and loses air when pre-rotating.


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2) The trim increase or decrease pressure by itself in flight. An electrical problem may be in the trim button but the also the trim valves could be dirty so they cannot close the air circuit. Remove the trim load and/or download valve for inspection/cleaning.

ela aviaciÓn, s.l. · the airframe (mast, engine support and tail boom) is one single part built...

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