AUTO GYRO CAVALON Manufacturer Maintenance Manual
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AUTO GYRO CAVALON Manufacturer Maintenance Manual

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See also: Pilot Operating Handbook
Manufacturer Maintenance Manual
(Heavy Maintenance)

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  • Page 1 Manufacturer Maintenance Manual (Heavy Maintenance)
  • Page 3 Manufacturer AutoGyro Maintenance Manual Cavalon Manufacturer Maintenance Manual for Gyroplane Cavalon Part A – Introduction and Declarations MMM-CV-A_16-02-08 Page 1 of 12...

  • Page 4: Dornierstraße

    Notifications to the Civil Aviation Authorities or other organisations based on legal regulations are unaffected. MTOsport, Calidus, Cavalon, the AutoGyro logo and word picture mark are trademarks or registered trademarks of AutoGyro AG, registered in Germany and other countries.
  • Page 5 Note that the manual is subdivided into 6 parts which will be revised individually. As an example, the revision index for the manufacturer maintenance manual (MMM), Cavalon (CV), Part B could be ‘MMM-CV-B_13-04-20’. Note that the date code is ‘yy-mm-dd’ so files will sort chronologically.
  • Page 6 Manufacturer AutoGyro Maintenance Manual Cavalon INTENTIONALLY LEFT BLANK Part A – Introduction and Declarations MMM-CV-A_16-02-08 Page 4 of 12...
  • Page 7 Manufacturer AutoGyro Maintenance Manual Cavalon Contents 0 – PREFACE ............................2 1 – INTRODUCTION ..........................3 Revision Service ........................... 3 Record of Revisions ..........................3 Maintenance Concept and Eligibility ....................7 Warnings, Caution and Notes ......................7 Organization and Handling of the Manual .................... 8 ATA100 Numbering System .........................
  • Page 8 Manufacturer AutoGyro Maintenance Manual Cavalon INTENTIONALLY LEFT BLANK Part A – Introduction and Declarations MMM-CV-A_16-02-08 Page 6 of 12...
  • Page 9 AutoGyro Maintenance Manual Cavalon Maintenance Concept and Eligibility The maintenance concept of the Cavalon gyroplane is structured into 4 qualification levels:  Basic operational (OPR) Maintenance / Pilot Checks and Servicing  Line (LNE) Maintenance (inspection of Critical Parts (CP) included) ...
  • Page 10 Manufacturer AutoGyro Maintenance Manual Cavalon Organization and Handling of the Manual This manual is structured according to ATA100 numbering system. The numbering system will be explained later in more detail. On document level, the manual is subdivided into 6 parts, named A to F. The designation and content...
  • Page 11 Manufacturer AutoGyro Maintenance Manual Cavalon Nomenclature and Structure of Maintenance Tasks (Job Cards) Part E of this manual describes maintenance tasks to be performed by a qualified person in order to check, inspect, replenish, adjust, replace, repair, clean, or to identify malfunctions. Each Task is outlined in detail in a [Maintenance] Job Card.
  • Page 12 Manufacturer AutoGyro Maintenance Manual Cavalon Effectivities A job card may contain information relating to different versions of the referred aircraft. This may be stipulated by optional equipment installed, by different design states (Serial Number driven), or modification (MI, AD). The keyword EFFECTIVITY, followed by a term describing its applicability, marks the start of instructions that apply exclusively to a specified version.
  • Page 13 Manufacturer AutoGyro Maintenance Manual Cavalon Abbreviations and Acronyms In this manual, a minimum number of abbreviations are used. Where possible the abbreviations and acronyms used correspond with regulations and common standards. Airworthiness Directive Air Transport Association Cylinder Head Temperature Critical Part...
  • Page 14 Manufacturer AutoGyro Maintenance Manual Cavalon Service Bulletin (SB) and Airworthiness Directives (AD) Service Bulletin (SB), old designation Manufacturer Information [Letters] (MI) (Herstellerinformationen) or Airworthiness Directives (AD) will be incorporated into the Maintenance Manual with the next revision. Part A – Introduction and Declarations...

  • Page 15: Table Of Contents

    Manufacturer AutoGyro Maintenance Manual Cavalon Contents CHAPTER 00 - INTRODUCTION / AIRCRAFT GENERAL ..............3 General ..............................3 CHAPTER 01 - GENERAL ........................4 01-11-00 Definitions, Terms and Standard Procedures ..............4 01-12-00 Standard Bolt Torques ...................... 6 01-21-00 Standard Commercial Tools ..................... 6 01-91-00 Conversion Tables ......................
  • Page 16 Manufacturer AutoGyro Maintenance Manual Cavalon CHAPTER 18 - VIBRATION & NOISE ANALYSIS ................23 CHAPTER 19–20 – UNASSIGNED / N/A ....................24 Part B – Master Servicing Manual (Ch. 00 – 20) MMM-CV-B_14-11-19 Page 2 of 24...

  • Page 17: Introduction

    CHAPTER 00 - INTRODUCTION / AIRCRAFT GENERAL General The Cavalon is a ‘new generation’ gyroplane with 3-bladed push propeller and a 2-blade aluminium main rotor system with swivelling rotor head and split mast with integrated rotor vibration damping. It features monocoque cabin with glazed canopy, stainless steel mast, engine support and keel tube.

  • Page 18: Chapter 01 - General

    Manufacturer AutoGyro Maintenance Manual Cavalon CHAPTER 01 - GENERAL 01-11-00 Definitions, Terms and Standard Procedures The following definitions, procedures and words with special meanings are used in this manual: adjust To put in specified position or condition, usually using tools or devices...

  • Page 19: Servicing

    Manufacturer AutoGyro Maintenance Manual Cavalon measure To find out dimensions, capacity or quantity of something. Except for counting of smaller numbers, calibrated measurement devices are needed. monitor To watch a parameter or item over a certain period of time in order to read an exact value, derive a trend or identify a change caused by an event.

  • Page 20: Standard Bolt Torques

    01-21-00 Standard Commercial Tools Most maintenance tasks on the Cavalon can be conducted using standard, commercially available metric tools. In addition, the following standard commercial tools are required:  Inclinometer (digital) / Digital spirit level with angle gauge ...

  • Page 21: Conversion Tables

    Manufacturer AutoGyro Maintenance Manual Cavalon 01-91-00 Conversion Tables LENGTH / DISTANCE Multiply to obtain / Multiply to obtain m (metre) 3.28 ft (feet) 0.305 mm (millimetre) 0.039 in (inch) 25.4 km (kilometre) 0.54 nm (nautical mile) 1.852 SPEED Multiply to obtain / Multiply...
  • Page 22 Manufacturer AutoGyro Maintenance Manual Cavalon -100 -150 -100 -75 100 125 150 175 200 225 250 Celsius - °C Celsius-Fahrenheit Conversion Chart Part B – Master Servicing Manual (Ch. 00 – 20) MMM-CV-B_14-11-19 Page 8 of 24...

  • Page 23: Chapter 02 - Tools, Spares And Consumable Materials

    Manufacturer AutoGyro Maintenance Manual Cavalon CHAPTER 02 - TOOLS, SPARES AND CONSUMABLE MATERIALS 02-51-00 Consumable Materials Consumable Material (CM) referenced throughout this Maintenance Manual is coded AG-XXX-NN where NN is a consecutive number and XXX represents the material code according to the...

  • Page 24: Chapter 03 - Minimum Equipment Requirement

    Manufacturer AutoGyro Maintenance Manual Cavalon CHAPTER 03 - MINIMUM EQUIPMENT REQUIREMENT In accordance with the Pilot’s Operating Handbook (POH) Section 2.11 the following equipment must be operative for flight Air speed indicator Altimeter Compass Side Slip Indicator Rotor RPM indicator...

  • Page 25: Chapter 04 – Manufacturer Life Limitations

    Manufacturer AutoGyro Maintenance Manual Cavalon CHAPTER 04 – MANUFACTURER LIFE LIMITATIONS For the safe operation over the specified lifecycle of the aircraft and liability reasons the following manufacturer limitations shall apply. In case the component has an operating hours and calendric time limit the first limit shall apply.

  • Page 26: Chapter 05 - Time Limits, Inspections & Checks

    Manufacturer AutoGyro Maintenance Manual Cavalon CHAPTER 05 - TIME LIMITS, INSPECTIONS & CHECKS For safe operation and continued airworthiness over the specified lifecycle of the aircraft the following inspection schedule shall apply. Note that specified tolerances must NOT be accumulated!

  • Page 27: Scheduled Inspections & Checks

    Daily / Pre-Flight Check All daily or pre-flight check list items consist of visual checks and do not replace professional mechanical inspection and maintenance. The Daily / Pre-Flight Checklist for the standard Cavalon gyroplane is provided in the current Pilot’s Operating Handbook.

  • Page 28: Unscheduled Inspections

    Manufacturer AutoGyro Maintenance Manual Cavalon 05-30-00 Unscheduled Inspections In case of the following events or occurrences, unscheduled inspections have to be performed. Event / Occurrence / Unusual Condition Action / Reference Rotor vibration CHAPTER 18 CHAPTER 18 Propeller vibration If in doubt contact AutoGyro customer support.

  • Page 29: Inspections - Special Operational Incident

    Manufacturer AutoGyro Maintenance Manual Cavalon 05-55-00 Inspections - Special Operational Incident Event / Occurrence / Unusual Condition Action / Reference Suspected hard landing see below Rotor contact with obstacle see below Propeller contact with obstacle or external impact see below...

  • Page 30: Lightning Strike

    Manufacturer AutoGyro Maintenance Manual Cavalon Lightning strike A lightning is likely to have caused invisible damage to many components, especially the main rotor bearing. The aircraft must not be flown until satisfactory inspection has been undertaken and any rectification has been completed.

  • Page 31: Chapter 06 - Dimensions & Areas

    Manufacturer AutoGyro Maintenance Manual Cavalon CHAPTER 06 - DIMENSIONS & AREAS Length 4.60 m Width 1.75 m Height 2.82 m Rotor diameter 8.4 m Rotor disc area 55.4 sqm Propeller diameter 1.72 m Part B – Master Servicing Manual (Ch. 00 – 20)

  • Page 32: Chapter 07 - Lifting / Jacking / Shoring

    Manufacturer AutoGyro Maintenance Manual Cavalon CHAPTER 07 - LIFTING / JACKING / SHORING See Job Card 07-00-00 2-1 in Part E of this manual. CHAPTER 08 - LEVELING & WEIGHING Weighing shall be performed in a draft-free hangar on level ground, with the aircraft defueled to minimum useable fuel.

  • Page 33: Chapter 11 - Placards & Markings

    Manufacturer AutoGyro Maintenance Manual Cavalon CHAPTER 11 - PLACARDS & MARKINGS In clear view of the pilot: Only VFR day is approved Aerobatic flight prohibited! Low-G manoeuvres prohibited! Flight in icing conditions prohibited! For additional limitations see Flight Manual! Max. gross weight: ________...
  • Page 34 Manufacturer AutoGyro Maintenance Manual Cavalon At each storage compartment behind seats: Max. load: 10 kg W&B must be respected! At fuel filler neck: Min. ROZ 95 AVGAS 100LL Tank Capacity 100 litres At oil filler neck: Engine Oil: ___________________ Approved oil types see engine manual!

  • Page 35: Chapter 12 - Servicing

    Manufacturer AutoGyro Maintenance Manual Cavalon CHAPTER 12 - SERVICING 12-10-00 Cleaning Care and regular cleaning of engine, propeller, rotor system and fuselage is the basic foundation for airworthiness and reliability. Therefore, the gyroplane should be cleaned after every last flight of the day or more often, if environmental conditions dictate.

  • Page 36: Servicing: Battery

    Manufacturer AutoGyro Maintenance Manual Cavalon 12-30-30 Servicing: Battery The aircraft is fitted with a maintenance-free gel electrolyte battery. Maintenance is therefore limited to outside soundness, correct attachment, and cleaning. Check integrity of the battery as leaking fluid contains corrosive sulphuric acid which would lead to extensive damage when contacting the framework and attachments.
  • Page 37 Manufacturer AutoGyro Maintenance Manual Cavalon CHAPTER 18 - VIBRATION & NOISE ANALYSIS Vibration may be induced by the rotor system, the propeller or even the engine. Finding out the cause for vibration and its proper cure requires experience and special equipment. This is why vibration analysis and related maintenance can only be performed by specialized service partners (maintenance level ‘S’), or AutoGyro GmbH, Germany directly.
  • Page 38 Manufacturer AutoGyro Maintenance Manual Cavalon Noise is mainly created by the propeller. Engine and muffler play a secondary role in noise emission, as long as intact. Any deficiencies could be easily identified by a visual inspection or tap test. A defective muffler can be refilled with insulating material.
  • Page 39 Manufacturer AutoGyro Maintenance Manual Cavalon Contents CHAPTER 21 - VENTILATION / HEATING ..................... 3 21-00-00 Ventilation / Heating ......................3 CHAPTER 22 - UNASSIGNED / N/A ....................... 3 CHAPTER 23 - COMMUNICATIONS ...................... 3 23-10-00 Speech Communication / Radio ..................3 23-40-00 Interphone / Intercom .......................
  • Page 40 Manufacturer AutoGyro Maintenance Manual Cavalon 56-15-00 Canopy Windows ........................15 CHAPTER 57-60 - UNASSIGNED / N/A ....................15 CHAPTER 61 - PROPELLER ........................16 61-10-00 Propeller assembly ......................16 61-20-00 Controlling ........................16 CHAPTER 62 - ROTOR .........................16 Rotor – Teetering Parts ....................16 62-11-00 62-31-00 Rotor Head Bridge, Bearing and Teeter Tower ..............17...
  • Page 41 Manufacturer AutoGyro Maintenance Manual Cavalon CHAPTER 21 - VENTILATION / HEATING 21-00-00 Ventilation / Heating Each of the two cabin doors features an adjustable fresh air vent and one sliding window with pivoting vent for ventilation. The sliding window can be used as viewing hatch in case of emergencies and is wide enough to reach through with a hand.
  • Page 42 Manufacturer AutoGyro Maintenance Manual Cavalon 24-30-00 DC Generation and Battery Direct current is provided by an engine-integrated AC generator with external rectifier-regulator (12V 20 A DC). The battery is located at the rear wall on the LH side behind the removable fire wall. A dedicated charging receptacle is available at the lower LH side of the fuselage, just before the LH engine cowling.
  • Page 43 Manufacturer AutoGyro Maintenance Manual Cavalon refitting in a different position on the rails. In addition the backrest angle can be adjusted by modifying the lengths of the telescopic tubes. For each seat an adjustable four point harness is available. IMPORTANT NOTE: Seat belts are Manufacturer Life Limited (MLL)! A storage compartment is located behind each seat with a maximum capacity of 10 kg each.
  • Page 44 Manufacturer AutoGyro Maintenance Manual Cavalon CHAPTER 27 - FLIGHT CONTROLS 27-00-00 Flight Controls CHAPTER 67 – Rotors Flight Control. Note: Stabilizers are described in CHAPTER 27-20-00 Flight Controls - Rudder Rudder (Fin) and nose wheel are controlled simultaneously by adjustable foot pedals, control cables, central control link and nose wheel control link.
  • Page 45 Manufacturer AutoGyro Maintenance Manual Cavalon CHAPTER 28 - FUEL 28-10-00 Storage The fuel system consists of two tanks permanently connected with a big crossport, a single filler port, fuel and ventilation lines, fuel level indications, and drain. The filler port is located at the left hand side of the gyroplane.
  • Page 46 AutoGyro Maintenance Manual Cavalon The safeguarded lever of the shut-off valve is located between the pilot and passenger seat below the intercom panel. The actual valve is located in the vicinity of the fuel tanks and is articulated by a torsion bar.
  • Page 47 Manufacturer AutoGyro Maintenance Manual Cavalon Panel Layout – Standard / Moving Map Portrait 1 – Water temperature indication 20 – RBT indicator 2 – Engine RPM 21 – ATC transponder (if installed) 3 – Rotor RPM 22 – Collision Avoidance System (if inst.) 4 –...
  • Page 48 Manufacturer AutoGyro Maintenance Manual Cavalon 31-60-00 Integrated Display Systems The Glass Cockpit layout is tailored to the integrated flight and navigation suite DYNON AVIONICS SkyView. In addition to navigational and moving map functions, the system provides primary flight data and engine/vehicle monitoring. It is of utmost importance to read and understand the operators manual and to become familiar with the system before operation.
  • Page 49 Manufacturer AutoGyro Maintenance Manual Cavalon Panel Layout – Glass Cockpit - Dual Display 1 – Water temperature indication 13 – Pneumatic mode selector 2 – Magnetic compass 14 – 12V power receptacle (if installed) 3 – Warning lights 15 – Master/starter switch 4 –...
  • Page 50 AutoGyro Maintenance Manual Cavalon CHAPTER 32 - LANDING GEAR The Cavalon has a conventional tricycle gear with GRP (glass fibre reinforced plastic) suspension bow and a steerable nose gear. 32-10-00 Main Gear The main gear consists of a GRP suspension bow which is bolted to the underside of the fuselage.
  • Page 51 34-10-00 Flight Environment Data The Cavalon features a Pitot-Static System to measure accurate air data. Total pressure is picked up by a pitot type tube located in the nose section of the fuselage. The tube is connected to the integrated cockpit instruments by a plastic line.
  • Page 52 Manufacturer AutoGyro Maintenance Manual Cavalon CHAPTER 37-50 - UNASSIGNED / N/A CHAPTER 51 - STANDARD PRACTICES - STRUCTURES 51-00-00 Standard Practices - Structures Structural repair of composite structures or the welded steel frame is limited to AutoGyro GmbH or its specialized service partners (job cards labelled ‘SPC’).
  • Page 53 Manufacturer AutoGyro Maintenance Manual Cavalon CHAPTER 55 - STABILIZERS The stabilizer structure with rudder is made of GRP (or in certain cases CRP) and is bolted to the keel tube. Presence and function of the stabilizer plays a vital part in flight stability and safety. Inspect carefully all attachment points and the integrity of the composite component.
  • Page 54 Manufacturer AutoGyro Maintenance Manual Cavalon CHAPTER 61 - PROPELLER In standard configuration a 3-bladed, fixed pitch propeller with GRP propeller blades is installed. Depending on customer configuration a spinner may be installed! As an option, a variable pitch propeller may be available (country specific).
  • Page 55 NOTE: In order to simplify pre-rotation AutoGyro GmbH has developed a new 90- degree-gearbox with a transmission ratio specially geared to the Cavalon. The new gearbox is factory installed from serial numbers (Werk-Nr.) V00036 on, or may be retrofittet as a unit together with the pneumatic clutch.
  • Page 56 Manufacturer AutoGyro Maintenance Manual Cavalon The pre-rotator can be activated in BRAKE position to park the rotor blades fore-aft for taxi. To do so, the pre-rotator push-button and the overdrive/override switch in the cockpit panel have to be pressed simultaneously. Prolonged activation of the pre-rotator with rotor brake engaged should be avoided.
  • Page 57 Manufacturer AutoGyro Maintenance Manual Cavalon Trimming is effected by varying trim pressure in the pneumatic trim actuator which is installed in parallel with the rotor head tilt for pitch control. Aft or nose-up trimming activates the electrical compressor and increases trim pressure, causing the actuator to contract, and tilting the rotor disc aft.
  • Page 58 Manufacturer AutoGyro Maintenance Manual Cavalon CHAPTER 72 TO 74 - ENGINE RELATED For the (core) engine refer to the engine manufacturer’s documentation in its latest revision. Concerning fuel system (Filter, Pumps, Shut-off valve) see CHAPTER Engine cowlings are described in CHAPTER 52.
  • Page 59 Manufacturer AutoGyro Maintenance Manual Cavalon CHAPTER 76 - ENGINE CONTROLS Engine control consists of engine power lever / throttle with choke and related cockpit switches for engine shut-down and test. 76-10-00 Power Control / Choke Engine power / throttle is controlled by a control...
  • Page 60 Manufacturer AutoGyro Maintenance Manual Cavalon 77-40-00 Integrated Engine Instrument Systems Integrated display systems (glass cockpit) are described in 31-60-00 Integrated Display Systems. CHAPTER 78 - EXHAUST 78-00-00 Exhaust The basic exhaust system including manifold and turbo charger with waste gate (only ROTAX 914) is part of the core engine.
  • Page 61 Manufacturer AutoGyro Maintenance Manual Cavalon Contents Wiring Diagram – Aircraft Main Wiring Harness ..................3 Wiring Diagram – Cockpit RH........................5 Wiring Diagram – Optional Comfort Features Seats ................7 Wiring Diagram – Flight Control Sticks ..................... 9 Wiring Diagram – Landing Lights ......................11 Wiring Diagram –...
  • Page 62 Manufacturer AutoGyro Maintenance Manual Cavalon INTENTIONALLY LEFT BLANK Part D – Diagrams and Charts MMM-CV-D_15-01-09 Page 2 of 38...
  • Page 63 Manufacturer AutoGyro Maintenance Manual Cavalon Wiring Diagram – Aircraft Main Wiring Harness Part D – Diagrams and Charts MMM-CV-D_15-01-09 Page 3 of 38...
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  • Page 69 Manufacturer AutoGyro Maintenance Manual Cavalon Wiring Diagram – Flight Control Sticks Part D – Diagrams and Charts MMM-CV-D_15-01-09 Page 9 of 38...
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  • Page 71 Manufacturer AutoGyro Maintenance Manual Cavalon Wiring Diagram – Landing Lights Part D – Diagrams and Charts MMM-CV-D_15-01-09 Page 11 of 38...
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  • Page 73 Manufacturer AutoGyro Maintenance Manual Cavalon Wiring Diagram – NAV / Strobe Lights Part D – Diagrams and Charts MMM-CV-D_15-01-09 Page 13 of 38...
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  • Page 75 Manufacturer AutoGyro Maintenance Manual Cavalon Wiring Diagram – Cockpit LH (Standard) Part D – Diagrams and Charts MMM-CV-D_15-01-09 Page 15 of 38...
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  • Page 77 Manufacturer AutoGyro Maintenance Manual Cavalon Wiring Diagram – Main Fuse / Battery Part D – Diagrams and Charts MMM-CV-D_15-01-09 Page 17 of 38...
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  • Page 79 Manufacturer AutoGyro Maintenance Manual Cavalon Wiring Diagram – Cockpit Centre Part D – Diagrams and Charts MMM-CV-D_15-01-09 Page 19 of 38...
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  • Page 81 Manufacturer AutoGyro Maintenance Manual Cavalon Wiring Diagram – Cockpit (General) Part D – Diagrams and Charts MMM-CV-D_15-01-09 Page 21 of 38...
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  • Page 83 Manufacturer AutoGyro Maintenance Manual Cavalon Wiring Diagram – Pneumatic System (Standard / Comfort) Part D – Diagrams and Charts MMM-CV-D_15-01-09 Page 23 of 38...
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  • Page 85 Manufacturer AutoGyro Maintenance Manual Cavalon Wiring Diagram – Fuel Pumps Part D – Diagrams and Charts MMM-CV-D_15-01-09 Page 25 of 38...
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  • Page 87 Manufacturer AutoGyro Maintenance Manual Cavalon Wiring Diagram – Fuel Level and Low Level Sensors Part D – Diagrams and Charts MMM-CV-D_15-01-09 Page 27 of 38...
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  • Page 89 Manufacturer AutoGyro Maintenance Manual Cavalon Wiring Diagram – Engine Wiring Harness Part D – Diagrams and Charts MMM-CV-D_15-01-09 Page 29 of 38...
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  • Page 91 Manufacturer AutoGyro Maintenance Manual Cavalon Wiring Diagram – Engine Turbo Control Unit (TCU) Wiring Harness Part D – Diagrams and Charts MMM-CV-D_15-01-09 Page 31 of 38...
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  • Page 93 Manufacturer AutoGyro Maintenance Manual Cavalon Pneumatic Scheme - Standard Part D – Diagrams and Charts MMM-CV-D_15-01-09 Page 33 of 38...
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  • Page 95 Manufacturer AutoGyro Maintenance Manual Cavalon Pneumatic Scheme - Comfort Part D – Diagrams and Charts MMM-CV-D_15-01-09 Page 35 of 38...
  • Page 96 6LW] &R 3LORW 6LW] 3LORW 0RWRU 5RWRUNRSI 5RWRUNRSI 5RWRUNRSI PP EO PP NO &RFNSLW PP EO  %DU  %DU PP EO PP NO PP ZV 5ROOWULP PP ZV 6HQVRUER[ PP VZ PP VZ PP VZ PP VZ PP VZ PP VZ PP EO PP VZ...
  • Page 97 Manufacturer AutoGyro Maintenance Manual Cavalon Retrofit: End Position Detection IVO Propeller Part D – Diagrams and Charts MMM-CV-D_15-01-09 Page 37 of 38...
  • Page 98 2EHUIOlFKHQ]HLFKHQ ',1 ,62  5]  5=  5=  .XU]]HLFKHQ 3536 $ +((7^  KVWLQGO 7ROHULHUXQJ ,62  ,627ROHUDQ] ',1  %RKUXQJHQ + &06` )UHLPD‰ )RUP XQG /DJHWROHUDQ]HQ QDFK ,62 P+ ,QGH[ &06 bQGHUXQJ 'DWXP 1DPH 0DWHULDO  /HJLHUXQJ  1HQQPD‰...
  • Page 99 Manufacturer AutoGyro Maintenance Manual Cavalon Contents 07-00-00 2-1 LIFTING OF THE GYROPLANE 07-00-00 2-2 JACKING OF THE GYROPLANE 07-00-00 2-3 SHORING OF THE GYROPLANE 08-20-00 2-1 LEVELING OF THE GYROPLANE 24-30-00 4-1 REMOVAL-INSTALLATION: BATTERY 24-30-00 8-1 MODIFICATION: ELECTRICAL POWER SUPPLY TO THE FUEL PUMP I VIA...
  • Page 100 Manufacturer AutoGyro Maintenance Manual Cavalon 62-32-00 5-1 CHECK-ADJUSTMENT: ROTOR CONTROL FRICTION 62-32-00 6-1 INSPECTION: ROTOR GIMBAL HEAD 62-51-00 4-1 REMOVAL-INSTALLATION: TOP MAST 62-51-00 6-1 INSPECTION: MAST MOUNTING BUSHINGS 62-51-00 8-1 REPLACEMENT: MAST MOUNTING BUSHINGS 63-11-10 4-1 REMOVAL-INSTALLATION: PRE-ROTATOR CLUTCH 63-11-10 5-1...
  • Page 101 Manufacturer AutoGyro Maintenance Manual Cavalon 07-00-00 2-1 LIFTING OF THE GYROPLANE GENERAL, REFERENCES AND REQUIREMENTS Task may only be performed by an organization or individual trained and entitled to carry out 'Line Maintenance'! Secure gyroplane against unauthorized or unintended operation!
  • Page 103 Manufacturer AutoGyro Maintenance Manual Cavalon 07-00-00 2-2 JACKING OF THE GYROPLANE GENERAL, REFERENCES AND REQUIREMENTS Task may only be performed by an organization or individual trained and entitled to carry out 'Line Maintenance'! Secure gyroplane against unauthorized or unintended operation!
  • Page 105 Manufacturer AutoGyro Maintenance Manual Cavalon 07-00-00 2-3 SHORING OF THE GYROPLANE GENERAL, REFERENCES AND REQUIREMENTS Basic operational task, which can be performed by a licensed pilot or instructed personnel! Rotor system must be removed, see 62-11-00 4-1 SPECIAL TOOLS AND CONSUMABLE MATERIALS...
  • Page 106 Manufacturer AutoGyro Maintenance Manual Cavalon ILLUSTRATIONS Fig. 1 - Lash-down methods of gyroplane MMM-CV-E_16-06-13 Part E - 07-00-00 2-3 Page 2 of 2...
  • Page 107 Manufacturer AutoGyro Maintenance Manual Cavalon 08-20-00 2-1 LEVELING OF THE GYROPLANE GENERAL, REFERENCES AND REQUIREMENTS Task may only be performed by an organization or individual trained and entitled to carry out 'Line Maintenance'! Secure gyroplane against unauthorized or unintended operation!
  • Page 109 Manufacturer AutoGyro Maintenance Manual Cavalon 24-30-00 4-1 REMOVAL-INSTALLATION: BATTERY GENERAL, REFERENCES AND REQUIREMENTS Task may only be performed by an organization or individual trained and entitled to carry out 'Line Maintenance'! Secure gyroplane against unauthorized or unintended operation! Engine cowlings must be removed, see...
  • Page 111 Manufacturer AutoGyro Maintenance Manual Cavalon 24-30-00 8-1 MODIFICATION: ELECTRICAL POWER SUPPLY TO THE FUEL PUMP I VIA RECTIFIER-REGULATOR (ROTAX 914) GENERAL, REFERENCES AND REQUIREMENTS Task may only be performed by an organization trained and entitled to carry out 'Heavy Maintenance'!
  • Page 112 Manufacturer AutoGyro Maintenance Manual Cavalon 23 86:Fuel pumps wiring harness (black) 24 85 Fuel pumps wiring harness (blue) 25 30: Fuse carrier, middle upper right: (red / short) 4 mm 26 87 Fuse carrier, middle lower left (red / long) 4 mm 27 Route fuel pumps wiring harness above the fuse carrier and behind the engine mount down to the fuel pumps.
  • Page 113 Manufacturer AutoGyro Maintenance Manual Cavalon Fig. 3 – Attachment of the relay Fig. 4 – Secured capacitor Fig. 5 – Fuel pumps P1 / P2 and cable connector of fuel pump wiring harness MMM-CV-E_16-06-13 Part E - 24-30-00 8-1 Page 3 of 3...
  • Page 115 Manufacturer AutoGyro Maintenance Manual Cavalon 25-60-00 0-1 DESCRIPTION: EMERGENCY LOCATOR TRANSMITTER (ELT) GENERAL, REFERENCES AND REQUIREMENTS Task may only be performed by an organization trained and entitled to carry out 'Heavy Maintenance'! SPECIAL TOOLS AND CONSUMABLE MATERIALS Refer to the component/device manufacturer's documentation.
  • Page 117 Manufacturer AutoGyro Maintenance Manual Cavalon 26-00-00 0-1 DESCRIPTION: FIRE INDICATING SYSTEM GENERAL, REFERENCES AND REQUIREMENTS SPECIAL TOOLS AND CONSUMABLE MATERIALS PRECAUTIONS AND SAFETY MEASURES PROCEDURES MMM-CV-E_16-06-13 Part E - 26-00-00 0-1 Page 1 of 2...
  • Page 118 Manufacturer AutoGyro Maintenance Manual Cavalon ILLUSTRATIONS Tbl. 1 - Indication Logic Fig. 2 - Installation - seen from behind Fig. 3 - Installation - seen from LH side Fig. 4 - Installation - seen from RH side Fig. 5 - Installation (detail)
  • Page 119 Manufacturer AutoGyro Maintenance Manual Cavalon 27-10-00 5-1 CHECK-ADJUSTMENT: ROLL CONTROL TRAVEL LIMITATION GENERAL, REFERENCES AND REQUIREMENTS Task may only be performed by an organization or individual trained and entitled to carry out 'Line Maintenance'! Secure gyroplane against unauthorized or unintended operation!
  • Page 121 Manufacturer AutoGyro Maintenance Manual Cavalon 27-20-00 5-1 CHECK-ADJUSTMENT: RUDDER CONTROL ANGLES GENERAL, REFERENCES AND REQUIREMENTS Task may only be performed by an organization or individual trained and entitled to carry out 'Line Maintenance'! Secure gyroplane against unauthorized or unintended operation!
  • Page 122 Manufacturer AutoGyro Maintenance Manual Cavalon ILLUSTRATIONS Fig. 1 - Rudder control angle setting MMM-CV-E_16-06-13 Part E - 27-20-00 5-1 Page 2 of 3...
  • Page 123 Manufacturer AutoGyro Maintenance Manual Cavalon Fig. 2 - Measurement Procedure (example) MMM-CV-E_16-06-13 Part E - 27-20-00 5-1 Page 3 of 3...
  • Page 125 Manufacturer AutoGyro Maintenance Manual Cavalon 28-20-00 6-1 INSPECTION: FUEL FILTER GENERAL, REFERENCES AND REQUIREMENTS Task may only be performed by an organization or individual trained and entitled to carry out 'Line Maintenance'! Engine cowlings must be removed, see 52-00-00 4-1...
  • Page 126 Manufacturer AutoGyro Maintenance Manual Cavalon PARTS LIST Fig. Pos. Description PC PIT Remark Nylon fuel filter KL 23 L1 73-00-00-V-20575 Filter KL 145 L1 73-00-00-V-20581 Fuel Pump 912 L1 73-00-00-V-30199 fuel pump 914 serialised L1 73-00-00-S-31394 ILLUSTRATIONS Fig. 1 - Fuel pumps and filters (detail) Fig.
  • Page 127 Manufacturer AutoGyro Maintenance Manual Cavalon 28-20-00 8-1 REPLACEMENT: FUEL FILTER GENERAL, REFERENCES AND REQUIREMENTS Task may only be performed by an organization or individual trained and entitled to carry out 'Line Maintenance'! Engine cowlings must be removed, see 52-00-00 4-1...
  • Page 128 Manufacturer AutoGyro Maintenance Manual Cavalon ILLUSTRATIONS Fig. 1 - Fuel pumps and filters (detail) Fig. 2 - Fuel pumps and filters (detail) MMM-CV-E_16-06-13 Part E - 28-20-00 8-1 Page 2 of 2...
  • Page 129 Manufacturer AutoGyro Maintenance Manual Cavalon 28-20-00 8-2 REPLACEMENT: ELECTRICAL FUEL PUMPS GENERAL, REFERENCES AND REQUIREMENTS Task may only be performed by an organization or individual trained and entitled to carry out 'Line Maintenance'! Secure gyroplane against unauthorized or unintended operation!
  • Page 130 Manufacturer AutoGyro Maintenance Manual Cavalon ILLUSTRATIONS Fig. 1 - El. fuel pump terminal (detail) MMM-CV-E_16-06-13 Part E - 28-20-00 8-2 Page 2 of 2...
  • Page 131 Manufacturer AutoGyro Maintenance Manual Cavalon 32-10-00 8-1 REPLACEMENT: MAIN GEAR SUSPENSION BOW ATTACHMENT BOLTS GENERAL, REFERENCES AND REQUIREMENTS Task may only be performed by an organization trained and entitled to carry out 'Specialized Level Tasks'! Secure gyroplane against unauthorized or unintended operation!
  • Page 132 Manufacturer AutoGyro Maintenance Manual Cavalon ILLUSTRATIONS Fig. 1 - Main gear suspension bow cover and service cover Fig. 2 - Main gear suspension bow Fig. 3 - 10 mm drill bit equipped with washers Fig. 4 - Drilling to a diameter of 10 mm...
  • Page 133 Manufacturer AutoGyro Maintenance Manual Cavalon 32-20-00 8-1 REPLACEMENT: NOSE GEAR RUBBER DAMPER GENERAL, REFERENCES AND REQUIREMENTS Task may only be performed by an organization or individual trained and entitled to carry out 'Line Maintenance'! Gyroplane must be jacked, see 07-00-00 2-2...
  • Page 134 Manufacturer AutoGyro Maintenance Manual Cavalon ILLUSTRATIONS Fig. 1 - Nose gear assembly MMM-CV-E_16-06-13 Part E - 32-20-00 8-1 Page 2 of 2...
  • Page 135 Manufacturer AutoGyro Maintenance Manual Cavalon 32-40-00 4-1 REMOVAL-INSTALLATION: WHEELS GENERAL, REFERENCES AND REQUIREMENTS Task may only be performed by an organization or individual trained and entitled to carry out 'Line Maintenance'! Gyroplane must be jacked, see 07-00-00 2-2 SPECIAL TOOLS AND CONSUMABLE MATERIALS...
  • Page 136 Manufacturer AutoGyro Maintenance Manual Cavalon nose wheel steering O-Ring 30x5 steering bush L2 32-00-00-V-22169 nosewheel fork long welded steering bush L2 32-00-00-V-22169 shock absorber 2,5 Nose wheel spat nosewheel painted L1 53-00-00-V-32070 10 M6x12 round head 11 U6/18 12 M10, Si...
  • Page 137 Manufacturer AutoGyro Maintenance Manual Cavalon ILLUSTRATIONS Fig. 1 - Nose gear assembly Fig. 2 - Nose wheel MMM-CV-E_16-06-13 Part E - 32-40-00 4-1 Page 3 of 4...
  • Page 138 Manufacturer AutoGyro Maintenance Manual Cavalon Fig. 3 - Main gear assembly Fig. 4 - Main wheel MMM-CV-E_16-06-13 Part E - 32-40-00 4-1 Page 4 of 4...
  • Page 139 Manufacturer AutoGyro Maintenance Manual Cavalon 32-40-00 8-2 REPLACEMENT: MAIN WHEEL BRAKE PADS GENERAL, REFERENCES AND REQUIREMENTS Task may only be performed by an organization or individual trained and entitled to carry out 'Line Maintenance'! Gyroplane must be jacked, see 07-00-00 2-2...
  • Page 140 Manufacturer AutoGyro Maintenance Manual Cavalon 14 Cylinder bushing 22x10x6 15 Brake pad inner (big) L2 32-40-00-V-30511 16 Safety washer M6 17 M6x40 18 castle nut M18x1 L1 32-00-00-V-32136 19 Alu bush Prerotator brake L1 53-00-00-V-32781 20 U6/25 Big washer L1 53-00-00-V-32781...
  • Page 141 Manufacturer AutoGyro Maintenance Manual Cavalon 32-40-00 8-3 REPLACEMENT: WHEEL BEARING GENERAL, REFERENCES AND REQUIREMENTS Task may only be performed by an organization trained and entitled to carry out 'Heavy Maintenance'! Gyroplane must be jacked, see 07-00-00 2-2 Affected wheel must be removed, see...
  • Page 142 Manufacturer AutoGyro Maintenance Manual Cavalon ILLUSTRATIONS Fig. 1 - Nose wheel Fig. 2 - Main wheel and bearing MMM-CV-E_16-06-13 Part E - 32-40-00 8-3 Page 2 of 2...
  • Page 143 Manufacturer AutoGyro Maintenance Manual Cavalon 34-10-00 5-1 TEST: PITOT STATIC SYSTEM INTEGRITY GENERAL, REFERENCES AND REQUIREMENTS Task may only be performed by an organization or individual trained and entitled to carry out 'Line Maintenance'! SPECIAL TOOLS AND CONSUMABLE MATERIALS ContactAG...
  • Page 144 Manufacturer AutoGyro Maintenance Manual Cavalon ILLUSTRATIONS Fig. 1 - Pitot Static Integrity Test Equipment Fig. 2 - Pitot Static Instruments Connecting Diagram MMM-CV-E_16-06-13 Part E - 34-10-00 5-1 Page 2 of 2...
  • Page 145 Manufacturer AutoGyro Maintenance Manual Cavalon 34-10-00 7-1 CLEANING: PITOT STATIC SYSTEM GENERAL, REFERENCES AND REQUIREMENTS Task may only be performed by an organization or individual trained and entitled to carry out 'Line Maintenance'! Secure gyroplane against unauthorized or unintended operation!
  • Page 146 Manufacturer AutoGyro Maintenance Manual Cavalon Fig. 2 - Pitot Static Instruments Connecting Diagram MMM-CV-E_16-06-13 Part E - 34-10-00 7-1 Page 2 of 2...
  • Page 147 Manufacturer AutoGyro Maintenance Manual Cavalon 36-21-00 8-1 REPLACEMENT: FILTER/DRYER GENERAL, REFERENCES AND REQUIREMENTS Task may only be performed by an organization or individual trained and entitled to carry out 'Line Maintenance'! Secure gyroplane against unauthorized or unintended operation! Engine cowlings must be removed, see...
  • Page 149 Manufacturer AutoGyro Maintenance Manual Cavalon 52-00-00 4-1 REMOVAL-INSTALLATION: COWLINGS GENERAL, REFERENCES AND REQUIREMENTS Basic operational task, which can be performed by a licensed pilot or instructed personnel! Secure gyroplane against unauthorized or unintended operation! SPECIAL TOOLS AND CONSUMABLE MATERIALS PRECAUTIONS AND SAFETY MEASURES...
  • Page 150 Manufacturer AutoGyro Maintenance Manual Cavalon ILLUSTRATIONS Fig. 1 - Cowling and mast cover MMM-CV-E_16-06-13 Part E - 52-00-00 4-1 Page 2 of 2...
  • Page 151 Manufacturer AutoGyro Maintenance Manual Cavalon 52-40-00 0-1 DESCRIPTION: SERVICE COVERS IN COCKPIT SHELL GENERAL, REFERENCES AND REQUIREMENTS SPECIAL TOOLS AND CONSUMABLE MATERIALS PRECAUTIONS AND SAFETY MEASURES PROCEDURES MMM-CV-E_16-06-13 Part E - 52-40-00 0-1 Page 1 of 2...
  • Page 152 Manufacturer AutoGyro Maintenance Manual Cavalon ILLUSTRATIONS Fig. 1 - Service covers below seats ('Equipment Cover') Fig. 2 - Service cover for control linkage (LH) and below Fig. 3 - Rear Wall 'Installation Wall' (Fire Wall removed) seat (RH) MMM-CV-E_16-06-13 Part E - 52-40-00 0-1...
  • Page 153 Manufacturer AutoGyro Maintenance Manual Cavalon 55-00-00 8-1 REPLACEMENT: KEEL TUBE PROTECTION PAD GENERAL, REFERENCES AND REQUIREMENTS Task may only be performed by an organization or individual trained and entitled to carry out 'Line Maintenance'! Secure gyroplane against unauthorized or unintended operation!
  • Page 155 Manufacturer AutoGyro Maintenance Manual Cavalon 56-00-00 8-1 REPAIR: CRACKS IN ACRYLIC GLASS GENERAL, REFERENCES AND REQUIREMENTS Basic operational task, which can be performed by a licensed pilot or instructed personnel! Repair only by a competent person. Absolute cleanliness at any time during execution of the procedure must be ensured.
  • Page 156 Manufacturer AutoGyro Maintenance Manual Cavalon 15 Create dishwashing liquid solution (2-3 drops per 0.2 l lukewarm tap water). Sand with grit 320 wet sandpaper and dishwashing liquid solution to the surface of the tape. 16 When the adhesive tape is scratched, remove these and shade the area extensively with a felt pen (Edding blue or red).
  • Page 157 Manufacturer AutoGyro Maintenance Manual Cavalon 61-10-00 4-1 REMOVAL-INSTALLATION: PROPELLER - HTC GENERAL, REFERENCES AND REQUIREMENTS Task may only be performed by an organization or individual trained and entitled to carry out 'Line Maintenance'! Secure gyroplane against unauthorized or unintended operation!
  • Page 158 Manufacturer AutoGyro Maintenance Manual Cavalon PARTS LIST Fig. Pos. Description PC PIT Remark spinner HTC3B, painted L2 53-00-00-V-30587 M8x110 U8/24 M6x40 ROTAX 914 M6x40 ROTAX 912 Propeller hub rear L3 61-00-00-V-21191 ROTAX 912 Propeller hub front L3 61-00-00-V-21190 ROTAX 914...
  • Page 159 Manufacturer AutoGyro Maintenance Manual Cavalon 61-10-00 4-2 DISASSEMBLY-ASSEMBLY: PROPELLER - HTC GENERAL, REFERENCES AND REQUIREMENTS Task may only be performed by an organization or individual trained and entitled to carry out 'Line Maintenance'! Propeller must be removed, see 61-10-00 4-1...
  • Page 160 Manufacturer AutoGyro Maintenance Manual Cavalon ILLUSTRATIONS Fig. 1 - Propeller HTC MMM-CV-E_16-06-13 Part E - 61-10-00 4-2 Page 2 of 2...
  • Page 161 Manufacturer AutoGyro Maintenance Manual Cavalon 61-10-00 5-1 ADJUSTMENT: PROPELLER PITCH - HTC GENERAL, REFERENCES AND REQUIREMENTS Task may only be performed by an organization or individual trained and entitled to carry out 'Line Maintenance'! Spinner (if installed) must be removed, see...
  • Page 162 Manufacturer AutoGyro Maintenance Manual Cavalon ILLUSTRATIONS Fig. 1 - Propeller HTC Fig. 2 - Propeller pitch adjustment and tool MMM-CV-E_16-06-13 Part E - 61-10-00 5-1 Page 2 of 3...
  • Page 163 Manufacturer AutoGyro Maintenance Manual Cavalon Fig. 3 - Detail hub Fig. 4 - Detail blade MMM-CV-E_16-06-13 Part E - 61-10-00 5-1 Page 3 of 3...
  • Page 165 Manufacturer AutoGyro Maintenance Manual Cavalon 61-10-00 8-2 RETROFIT: END POSITION DETECTION IVO PROPELLER GENERAL, REFERENCES AND REQUIREMENTS Basic operational task, which can be performed by a licensed pilot or instructed personnel! Secure gyroplane against unauthorized or unintended operation! SPECIAL TOOLS AND CONSUMABLE MATERIALS...
  • Page 166 Manufacturer AutoGyro Maintenance Manual Cavalon PARTS LIST Fig. Pos. Description PC PIT Remark IVO installation kit L1 24-00-00-V-34771 IVO-end position indicator L1 24-00-00-V-34759 ILLUSTRATIONS Fig. 1 - Contents of the Kit Fig. 2 - Pin assignment of wiring harness Fig. 3 - Rocker Switch and LEDs Fig.
  • Page 167 Manufacturer AutoGyro Maintenance Manual Cavalon 61-20-00 1-1 TROUBLE-SHOOTING: IVO-VARIABLE PITCH PROPELLER GENERAL, REFERENCES AND REQUIREMENTS SPECIAL TOOLS AND CONSUMABLE MATERIALS PRECAUTIONS AND SAFETY MEASURES WARNING: Electrical shorting of the battery will produce high current with the risk of personal injury and...
  • Page 168 Manufacturer AutoGyro Maintenance Manual Cavalon ILLUSTRATIONS Fig. 1 – Fault Tree IVO Variable Pitch Propeller MMM-CV-E_16-06-13 Part E - 61-20-00 1-1 Page 2 of 2...
  • Page 169 Manufacturer AutoGyro Maintenance Manual Cavalon 62-11-00 4-1 REMOVAL: ROTOR - TEETERING PARTS GENERAL, REFERENCES AND REQUIREMENTS Basic operational task, which can be performed by a licensed pilot or instructed personnel! SPECIAL TOOLS AND CONSUMABLE MATERIALS AG-BAS-01 Loctite 221 red (88-00-00-S-30487) IMPORTANT NOTE: Procedure involves parts with limited reusability.
  • Page 170 Manufacturer AutoGyro Maintenance Manual Cavalon PARTS LIST Fig. Pos. Description PC PIT Remark Teeterbolt L0 27-30-00-S-30256 Chimm washer 3,5 L0 62-00-00-S-31706 L0 27-30-00-S-30256 M12 castle nut L0 27-30-00-S-30256 Split pin 3.2x40 L0 27-30-00-S-30256 Rotor head II compl. L2 27-30-00-V-33433 ILLUSTRATIONS Fig.
  • Page 171 Manufacturer AutoGyro Maintenance Manual Cavalon 62-11-00 4-2 DISASSEMBLY: ROTOR - TEETERING PARTS GENERAL, REFERENCES AND REQUIREMENTS Basic operational task, which can be performed by a licensed pilot or instructed personnel! Rotor system must be removed, see 62-11-00 4-1 SPECIAL TOOLS AND CONSUMABLE MATERIALS IMPORTANT NOTE: Procedure involves parts with limited reusability.
  • Page 172 Manufacturer AutoGyro Maintenance Manual Cavalon PARTS LIST Fig. Pos. Description PC PIT Remark shoulder bolt M8 37/12 L0 62-00-00-S-33324 1-5 M8x60 Rotor blade bolt 8.8 DIN 610 L0 62-00-00-V-20661 shoulder bolt M8 40/12 L0 62-00-00-S-33324 shoulder bolt M8 43/12 L0 62-00-00-S-33324...
  • Page 173 Manufacturer AutoGyro Maintenance Manual Cavalon 62-11-00 4-3 ASSEMBLY: ROTOR - TEETERING PARTS GENERAL, REFERENCES AND REQUIREMENTS Basic operational task, which can be performed by a licensed pilot or instructed personnel! SPECIAL TOOLS AND CONSUMABLE MATERIALS IMPORTANT NOTE: Procedure involves parts with limited reusability. Check parts list below...
  • Page 174 Manufacturer AutoGyro Maintenance Manual Cavalon ILLUSTRATIONS Fig. 1 - Assembly rotor - teetering parts (Effectivity: RS II) MMM-CV-E_16-06-13 Part E - 62-11-00 4-3 Page 2 of 2...
  • Page 175 Manufacturer AutoGyro Maintenance Manual Cavalon 62-11-00 4-4 INSTALLATION: ROTOR - TEETERING PARTS GENERAL, REFERENCES AND REQUIREMENTS Basic operational task, which can be performed by a licensed pilot or instructed personnel! Secure gyroplane against unauthorized or unintended operation! SPECIAL TOOLS AND CONSUMABLE MATERIALS...
  • Page 176 Manufacturer AutoGyro Maintenance Manual Cavalon PARTS LIST Fig. Pos. Description PC PIT Remark Teeterbolt L0 27-30-00-S-30256 Chimm washer 3,5 L0 62-00-00-S-31706 L0 27-30-00-S-30256 M12 castle nut L0 27-30-00-S-30256 Split pin 3.2x40 L0 27-30-00-S-30256 Rotor head II compl. L2 27-30-00-V-33433 ILLUSTRATIONS Fig.
  • Page 177 Manufacturer AutoGyro Maintenance Manual Cavalon 62-11-00 5-1 CHECK-ADJUSTMENT: ROTOR SYSTEM ALIGNMENT GENERAL, REFERENCES AND REQUIREMENTS Task may only be performed by an organization or individual trained and entitled to carry out 'Line Maintenance'! Rotor system must be removed, see 62-11-00 4-1...
  • Page 178 Manufacturer AutoGyro Maintenance Manual Cavalon ILLUSTRATIONS Fig. 1 - Rotor system placed on stands Fig. 2 - Positioning of measuring cord Fig. 3 - Reference point at grease nipple MMM-CV-E_16-06-13 Part E - 62-11-00 5-1 Page 2 of 2...
  • Page 179 Manufacturer AutoGyro Maintenance Manual Cavalon 62-11-00 6-1 INSPECTION: ROTOR - TEETERING PARTS GENERAL, REFERENCES AND REQUIREMENTS Task may only be performed by an organization or individual trained and entitled to carry out 'Line Maintenance'! Rotor system must be removed, see...
  • Page 180 Manufacturer AutoGyro Maintenance Manual Cavalon ILLUSTRATIONS Fig. 1 - Teeter bushings, block and tower - cross section view MMM-CV-E_16-06-13 Part E - 62-11-00 6-1 Page 2 of 2...
  • Page 181 Manufacturer AutoGyro Maintenance Manual Cavalon 62-11-00 6-2 INSPECTION: ROTOR BLADES GENERAL, REFERENCES AND REQUIREMENTS Basic operational task, which can be performed by a licensed pilot or instructed personnel! Rotor system must be disassembled, see 62-11-00 4-2 SPECIAL TOOLS AND CONSUMABLE MATERIALS...
  • Page 182 Manufacturer AutoGyro Maintenance Manual Cavalon ILLUSTRATIONS Fig. 1 - Critical blade area Fig. 2 - Measurement of blade root linearity MMM-CV-E_16-06-13 Part E - 62-11-00 6-2 Page 2 of 2...
  • Page 183 Manufacturer AutoGyro Maintenance Manual Cavalon 62-11-00 6-3 INSPECTION: ROTOR HUB BOLTS GENERAL, REFERENCES AND REQUIREMENTS Task may only be performed by an organization or individual trained and entitled to carry out 'Line Maintenance'! Rotor system must be removed, see 62-11-00 4-1...
  • Page 184 Manufacturer AutoGyro Maintenance Manual Cavalon ILLUSTRATIONS Fig. 1 - Rotor hub MMM-CV-E_16-06-13 Part E - 62-11-00 6-3 Page 2 of 2...
  • Page 185 Manufacturer AutoGyro Maintenance Manual Cavalon 62-11-00 8-1 REPLACEMENT: TEETER BUSHINGS GENERAL, REFERENCES AND REQUIREMENTS Task may only be performed by an organization trained and entitled to carry out 'Heavy Maintenance'! Rotor system must be removed, see 62-11-00 4-1 SPECIAL TOOLS AND CONSUMABLE MATERIALS...
  • Page 186 Manufacturer AutoGyro Maintenance Manual Cavalon PARTS LIST Fig. Pos. Description PC PIT Remark Bushing TEF-MET 13/15/21x15 L0 27-30-00-V-20677 ILLUSTRATIONS Fig. 1 - Teeter bushings, block and tower - cross section view MMM-CV-E_16-06-13 Part E - 62-11-00 8-1 Page 2 of 3...
  • Page 187 Manufacturer AutoGyro Maintenance Manual Cavalon Fig. 2 - Teeter bushings, block and tower - exploded view MMM-CV-E_16-06-13 Part E - 62-11-00 8-1 Page 3 of 3...
  • Page 189 Manufacturer AutoGyro Maintenance Manual Cavalon 62-20-00 8-1 REPLACEMENT: DRIVE GEAR GENERAL, REFERENCES AND REQUIREMENTS Task may only be performed by an organization trained and entitled to carry out 'Heavy Maintenance'! Secure gyroplane against unauthorized or unintended operation! Gyroplane must be placed on level ground and restrained (blocks, chocks)
  • Page 190 Manufacturer AutoGyro Maintenance Manual Cavalon 20 Insert and secure new split pin (1). Make sure that ends do not contact rotating parts (Fig.2). 21 Inspect backlash of pre-rotator upper engagement again. Backlash should be as tight as possible, but also wide enough to allow easy engagement of the pinion into the sprocket wheel in any position.
  • Page 191 Manufacturer AutoGyro Maintenance Manual Cavalon ILLUSTRATIONS Fig.1 - Rotor head Fig.2 - Split pin and castle nut MMM-CV-E_16-06-13 Part E - 62-20-00 8-1 Page 3 of 4...
  • Page 192 Manufacturer AutoGyro Maintenance Manual Cavalon Fig.3 - Allen wrench between rotor head and main bolt Fig.4 - Hole or magnet in the 7 o´clock position in flight direction MMM-CV-E_16-06-13 Part E - 62-20-00 8-1 Page 4 of 4...
  • Page 193 Manufacturer AutoGyro Maintenance Manual Cavalon 62-31-00 5-1 CHECK-ADJUSTMENT: ROTOR HEAD MAIN BOLT AXIS GENERAL, REFERENCES AND REQUIREMENTS Task may only be performed by an organization trained and entitled to carry out 'Heavy Maintenance'! Secure gyroplane against unauthorized or unintended operation!
  • Page 194 Manufacturer AutoGyro Maintenance Manual Cavalon A: reduce pre-rotator backlash (tighter) 16 Tighten castle nut (2) with a torque value enough to fixate adjustment and re-check position. If position has changed start from step 15. 17 Torque-tighten castle nut (2) with final torque of 120 Nm and re-check position. If necessary return to step 15.
  • Page 195 Manufacturer AutoGyro Maintenance Manual Cavalon 62-31-00 6-1 INSPECTION: ROTOR HEAD BRIDGE, BEARING AND TEETER TOWER GENERAL, REFERENCES AND REQUIREMENTS Task may only be performed by an organization or individual trained and entitled to carry out 'Line Maintenance'! Mast cover must be removed, see...
  • Page 196 Manufacturer AutoGyro Maintenance Manual Cavalon ILLUSTRATIONS Fig. 1 - Rotor head bridge, bearing and teeter tower MMM-CV-E_16-06-13 Part E - 62-31-00 6-1 Page 2 of 2...
  • Page 197 Manufacturer AutoGyro Maintenance Manual Cavalon 62-32-00 5-1 CHECK-ADJUSTMENT: ROTOR CONTROL FRICTION GENERAL, REFERENCES AND REQUIREMENTS Task may only be performed by an organization trained and entitled to carry out 'Heavy Maintenance'! Rotor head bridge / gimbal head configuration state must conform to version II...
  • Page 198 Manufacturer AutoGyro Maintenance Manual Cavalon ILLUSTRATIONS Fig. 1 - Measurement of rotor control friction Fig. 2 - Gimbal head assembly, Rotor System II (with spring washers) MMM-CV-E_16-06-13 Part E - 62-32-00 5-1 Page 2 of 2...
  • Page 199 Manufacturer AutoGyro Maintenance Manual Cavalon 62-32-00 6-1 INSPECTION: ROTOR GIMBAL HEAD GENERAL, REFERENCES AND REQUIREMENTS Task may only be performed by an organization or individual trained and entitled to carry out 'Line Maintenance'! Rotor system must be removed, see 62-11-00 4-1...
  • Page 200 Manufacturer AutoGyro Maintenance Manual Cavalon ILLUSTRATIONS Fig. 1 - Rotor gimbal head - Version II Fig. 2 - Arrangement of spring washers on gimbal head - Version II MMM-CV-E_16-06-13 Part E - 62-32-00 6-1 Page 2 of 2...
  • Page 201 Manufacturer AutoGyro Maintenance Manual Cavalon 62-51-00 4-1 REMOVAL-INSTALLATION: TOP MAST GENERAL, REFERENCES AND REQUIREMENTS Task may only be performed by an organization trained and entitled to carry out 'Heavy Maintenance'! Secure gyroplane against unauthorized or unintended operation! A suitable stand should be used if possible!
  • Page 202 Manufacturer AutoGyro Maintenance Manual Cavalon (Fig. 6). Disconnect pitch push-pull cable bulkhead. In order to do so, unscrew and remove top (outer) attachment nut. Remove mast bushes (Fig. 7) and free mast bushes from grease residuals. Pull top mast equipped with rotor head out of mast bottom. Lead push-pull control cables through attachment consoles and pneumatic hose package through the inside of the pitch console.
  • Page 203 Manufacturer AutoGyro Maintenance Manual Cavalon ILLUSTRATIONS Fig. 1 - Temperature sensor Fig. 2 - Pneumatic connection Bendix Fig. 3 - Pneumatic hoses Fig. 4 - Roll control Fig. 5 - Pitch control MMM-CV-E_16-06-13 Part E - 62-51-00 4-1 Page 3 of 4...
  • Page 204 Manufacturer AutoGyro Maintenance Manual Cavalon Fig. 6 - Push-pull control cable bulkhead attachment Fig. 7 - Installation of mast bushes Fig. 8 - Top mast Fig. 9 - Pre-rotator drive MMM-CV-E_16-06-13 Part E - 62-51-00 4-1 Page 4 of 4...
  • Page 205 Manufacturer AutoGyro Maintenance Manual Cavalon 62-51-00 6-1 INSPECTION: MAST MOUNTING BUSHINGS GENERAL, REFERENCES AND REQUIREMENTS Task may only be performed by an organization or individual trained and entitled to carry out 'Line Maintenance'! Rotor system must be removed, see 62-11-00 4-1...
  • Page 206 Manufacturer AutoGyro Maintenance Manual Cavalon ILLUSTRATIONS Fig. 1 - Mast reference point Fig. 2 - Fuselage reference point Fig. 3 - Force applied against flight direction Fig. 3 - Force applied in flight direction MMM-CV-E_16-06-13 Part E - 62-51-00 6-1...
  • Page 207 Manufacturer AutoGyro Maintenance Manual Cavalon 62-51-00 8-1 REPLACEMENT: MAST MOUNTING BUSHINGS GENERAL, REFERENCES AND REQUIREMENTS Task may only be performed by an organization trained and entitled to carry out 'Heavy Maintenance'! Secure gyroplane against unauthorized or unintended operation! Gyroplane must be placed on level ground and restrained (blocks, chocks)
  • Page 208 Manufacturer AutoGyro Maintenance Manual Cavalon 16 Apply AG-GRS-01 on outer surface of bushing sleeves and install bushing sleeves. Use a rubber hammer, if required. 17 Install attachment hardware and torque-tighten with 20 Nm. Mark bolt heads with securing paint. 18 Re-install push-pull cable bulkhead and rod end for roll control. Mark attachment hardware with securing paint.
  • Page 209 Manufacturer AutoGyro Maintenance Manual Cavalon 63-11-10 4-1 REMOVAL-INSTALLATION: PRE-ROTATOR CLUTCH GENERAL, REFERENCES AND REQUIREMENTS Task may only be performed by an organization trained and entitled to carry out 'Heavy Maintenance'! Secure gyroplane against unauthorized or unintended operation! Engine cowlings must be removed, see...
  • Page 211 Manufacturer AutoGyro Maintenance Manual Cavalon 63-11-10 5-1 CHECK-ADJUSTMENT: PRE_ROTATOR CLUTCH GENERAL, REFERENCES AND REQUIREMENTS Task may only be performed by an organization or individual trained and entitled to carry out 'Line Maintenance'! Secure gyroplane against unauthorized or unintended operation! Rotor system must be removed, see 62-11-00 4-1...
  • Page 212 Manufacturer AutoGyro Maintenance Manual Cavalon ILLUSTRATIONS Fig. 1 - Upper pre-rotator drive connected to Bendix shaft Fig. 2 - Thread Pin M8x50 Fig. 3 - Connection of check valve to pressure reducer Fig. 4 - Connection between clutch and pressure reducer Fig.
  • Page 213 Manufacturer AutoGyro Maintenance Manual Cavalon 63-11-10 6-1 INSPECTION: PRE-ROTATOR CLUTCH GENERAL, REFERENCES AND REQUIREMENTS Task may only be performed by an organization or individual trained and entitled to carry out 'Line Maintenance'! Secure gyroplane against unauthorized or unintended operation! Engine cowlings must be removed, see...
  • Page 214 Manufacturer AutoGyro Maintenance Manual Cavalon ILLUSTRATIONS Fig. 1 - Pre-rotator clutch with attach ring MMM-CV-E_16-06-13 Part E - 63-11-10 6-1 Page 2 of 2...
  • Page 215 Manufacturer AutoGyro Maintenance Manual Cavalon 63-11-10 8-1 REPLACEMENT: PRE-ROTATOR CLUTCH LINING GENERAL, REFERENCES AND REQUIREMENTS Task may only be performed by an organization trained and entitled to carry out 'Heavy Maintenance'! Secure gyroplane against unauthorized or unintended operation! Engine cowlings must be removed, see...
  • Page 216 Manufacturer AutoGyro Maintenance Manual Cavalon PARTS LIST Fig. Pos. Description PC PIT Remark Replacement set friction plate PK II / III L1 61-00-00-S-33383 ILLUSTRATIONS Fig. 1 - Pneumatic Clutch III Fig. 2 - M8x20 screw plug Fig. 3 - Thread Pin M8x50 Fig.
  • Page 217 Manufacturer AutoGyro Maintenance Manual Cavalon 63-11-10 8-2 REPLACEMENT: PRE-ROTATOR CLUTCH DOG GEAR GENERAL, REFERENCES AND REQUIREMENTS Task may only be performed by an organization trained and entitled to carry out 'Heavy Maintenance'! Secure gyroplane against unauthorized or unintended operation! Engine cowlings must be removed, see...
  • Page 218 Manufacturer AutoGyro Maintenance Manual Cavalon ILLUSTRATIONS Fig. 1 - M8x20 screw plug Fig. 2 - Thread Pin M8x50 Fig. 3 - Loctite 648 on inner and outer thread Fig. 4 - Correct mounting position MMM-CV-E_16-06-13 Part E - 63-11-10 8-2...
  • Page 219 Manufacturer AutoGyro Maintenance Manual Cavalon 63-11-30 6-1 INSPECTION: PRE-ROTATOR UPPER ENGAGEMENT GENERAL, REFERENCES AND REQUIREMENTS Task may only be performed by an organization or individual trained and entitled to carry out 'Line Maintenance'! Secure gyroplane against unauthorized or unintended operation!
  • Page 221 Manufacturer AutoGyro Maintenance Manual Cavalon 63-11-30 8-1 REPLACEMENT: PRE-ROTATOR UPPER BEARINGS GENERAL, REFERENCES AND REQUIREMENTS Task may only be performed by an organization trained and entitled to carry out 'Heavy Maintenance'! Secure gyroplane against unauthorized or unintended operation! Gyroplane must be placed on level ground and restrained (blocks, chocks)
  • Page 222 Manufacturer AutoGyro Maintenance Manual Cavalon ILLUSTRATIONS Fig. 1 - Prerotator upper bearing MMM-CV-E_16-06-13 Part E - 63-11-30 8-1 Page 2 of 2...
  • Page 223 Manufacturer AutoGyro Maintenance Manual Cavalon 63-11-30 8-2 REPAIR: PRE-ROTATOR UPPER ENGAGEMENT GENERAL, REFERENCES AND REQUIREMENTS Task may only be performed by an organization trained and entitled to carry out 'Heavy Maintenance'! Secure gyroplane against unauthorized or unintended operation! Gyroplane must be placed on level ground and restrained (blocks, chocks)
  • Page 225 Manufacturer AutoGyro Maintenance Manual Cavalon 63-51-00 8-1 REPLACEMENT: ROTOR BRAKE PAD GENERAL, REFERENCES AND REQUIREMENTS Task may only be performed by an organization or individual trained and entitled to carry out 'Line Maintenance'! Secure gyroplane against unauthorized or unintended operation!
  • Page 226 Manufacturer AutoGyro Maintenance Manual Cavalon ILLUSTRATIONS Fig. 1 - Rotor bridge with brake pad MMM-CV-E_16-06-13 Part E - 63-51-00 8-1 Page 2 of 2...
  • Page 227 Manufacturer AutoGyro Maintenance Manual Cavalon 67-00-00 6-1 INSPECTION: FLIGHT CONTROL PUSH-PULL CABLES GENERAL, REFERENCES AND REQUIREMENTS Task may only be performed by an organization or individual trained and entitled to carry out 'Line Maintenance'! Secure gyroplane against unauthorized or unintended operation!
  • Page 228 Manufacturer AutoGyro Maintenance Manual Cavalon ILLUSTRATIONS Fig. 1 - Pitch and Roll - upper attachment Fig. 2 - Modification of rotor head stop Fig. 3 - Measurement of freeplay MMM-CV-E_16-06-13 Part E - 67-00-00 6-1 Page 2 of 2...
  • Page 229 Manufacturer AutoGyro Maintenance Manual Cavalon 67-00-00 8-1 RETROFIT: PPC CLAMPS GENERAL, REFERENCES AND REQUIREMENTS Task may only be performed by an organization trained and entitled to carry out 'Heavy Maintenance'! Secure gyroplane against unauthorized or unintended operation! Rotor system must be removed, see...
  • Page 230 Manufacturer AutoGyro Maintenance Manual Cavalon ILLUSTRATIONS PPC Clamps MMM-CV-E_16-06-13 Part E - 67-05-00 8-1 Page 2 of 2...
  • Page 231 Manufacturer AutoGyro Maintenance Manual Cavalon 67-05-00 8-1 REPLACEMENT: PITCH TRIM/BRAKE PNEUMATIC SEAL GENERAL, REFERENCES AND REQUIREMENTS Task may only be performed by an organization trained and entitled to carry out 'Heavy Maintenance'! Secure gyroplane against unauthorized or unintended operation! Mast cover must be removed, see...
  • Page 233 Manufacturer AutoGyro Maintenance Manual Cavalon 67-10-00 4-1 REMOVAL-INSTALLATION: CENTRE CONSOLE GENERAL, REFERENCES AND REQUIREMENTS Task may only be performed by an organization or individual trained and entitled to carry out 'Line Maintenance'! Secure gyroplane against unauthorized or unintended operation! SPECIAL TOOLS AND CONSUMABLE MATERIALS...
  • Page 234 Manufacturer AutoGyro Maintenance Manual Cavalon ILLUSTRATIONS Fig. 1 - Centre Console MMM-CV-E_16-06-13 Part E - 67-10-00 4-1 Page 2 of 2...
  • Page 235 Manufacturer AutoGyro Maintenance Manual Cavalon 71-20-00 6-1 INSPECTION: CLEARANCE ENGINE INSTALLATION (R914) GENERAL, REFERENCES AND REQUIREMENTS Task may only be performed by an organization or individual trained and entitled to carry out 'Line Maintenance'! Engine cowlings must be removed, see...
  • Page 237 Manufacturer AutoGyro Maintenance Manual Cavalon 71-30-00 4-1 REMOVAL-INSTALLATION: FIRE WALL GENERAL, REFERENCES AND REQUIREMENTS Task may only be performed by an organization or individual trained and entitled to carry out 'Line Maintenance'! Engine cowlings must be removed, see 52-00-00 4-1...
  • Page 239 Manufacturer AutoGyro Maintenance Manual Cavalon 75-00-00 4-1 REMOVAL-INSTALLATION:RADIATOR GENERAL, REFERENCES AND REQUIREMENTS Task may only be performed by an organization trained and entitled to carry out 'Heavy Maintenance'! Secure gyroplane against unauthorized or unintended operation! Engine cowlings must be removed, see...
  • Page 241 Manufacturer AutoGyro Maintenance Manual Cavalon 75-00-00 8-2 MODIFICATION: RECONFIGURE FAN REVERSE GENERAL, REFERENCES AND REQUIREMENTS Task may only be performed by an organization or individual trained and entitled to carry out 'Line Maintenance'! Secure gyroplane against unauthorized or unintended operation!
  • Page 242 Manufacturer AutoGyro Maintenance Manual Cavalon ILLUSTRATIONS Fig. 1 - Fan reverse control unit Fig. 2 - Fan reverse cable - detached Fig. 3 - Fan reverse cable - modified Fig. 4 - Fan reverse cable - secured MMM-CV-E_16-06-13 Part E - 75-00-00 8-2...
  • Page 243 Manufacturer AutoGyro Maintenance Manual Cavalon 78-20-00 8-1 REPLACEMENT: WOOL OF MUFFLER TUBE GENERAL, REFERENCES AND REQUIREMENTS Task may only be performed by an organization or individual trained and entitled to carry out 'Line Maintenance'! Secure gyroplane against unauthorized or unintended operation!
  • Page 244 Manufacturer AutoGyro Maintenance Manual Cavalon 15 Install the outer shell. Make sure that the rivets holes of muffler tube and the steel tube are perfectly lined up (Fig.6). 16 Insert the four rivets into the hole and install them with a rivet gun (Fig.6).
  • Page 245 Manufacturer AutoGyro Maintenance Manual Cavalon ILLUSTRATIONS Fig 1 - Rivets at the hot and hinge pin clamp Fig. 2 - Hose clamps Fig. 3 - Drill out the rivet pin MMM-CV-E_16-06-13 Part E - 78-20-00 8-1 Page 3 of 5...
  • Page 246 Manufacturer AutoGyro Maintenance Manual Cavalon Fig. 4 - Installation of absorption wool Fig. 5 - Rivets at the cold end of muffler tube Fig. 6 - Riveting of the outer shell MMM-CV-E_16-06-13 Part E - 78-20-00 8-1 Page 4 of 5...
  • Page 247 Manufacturer AutoGyro Maintenance Manual Cavalon Fig. 7 - Installation of hose clamps and hinge pin clamp Fig. 8 - Position of the muffler tube Fig. 9 - Installation of locking wire MMM-CV-E_16-06-13 Part E - 78-20-00 8-1 Page 5 of 5...
  • Page 249 Tragschrauber Flug- und Betriebshandbuch AutoGyro GmbH Dornierstrasse 14 Phone +49 (0) 5121 / 880 56– 00 31137 Hildesheim info@auto-gyro.com Germany www.auto-gyro.com...

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