AUTO GYRO CAVALON User Manual (English)

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Manufacturer Maintenance Manual

(Heavy Maintenance)

Default Chapter4
- Dornierstraße4
- Record of Revisions5
- Revision Service5
- Table of Contents7
- Maintenance Concept and Eligibility9
- Warnings, Caution and Notes9
- ATA100 Numbering System10
- ATA100 – Chapter Code10
- Organization and Handling of the Manual10
- Abbreviations and Acronyms13
- Service Bulletin (SB) and Airworthiness Directives (AD)14
MMM-CV-A_16-02-08 Part a - Introduction and Declarations14
Chapter 00 - Introduction / Aircraft General17
Chapter 01 - General18
- Definitions, Terms and Standard Procedures18
- Standard Bolt Torques20
- Standard Commercial Tools20
- Conversion Tables21
  - Celsius-Fahrenheit Conversion Chart22
  - Servicing22
Chapter 02 - Tools, Spares and Consumable Materials23
Chapter 03 - Minimum Equipment Requirement24
Chapter 04 - Manufacturer Life Limitations25
- Liquids and Fluids26
Chapter 05 - Time Limits, Inspections & Checks26
- Time Limits26
- 100 Hrs / Annual Inspection27
- Complementary / Servicing Tasks27
- Daily / Pre-Flight Check27
- Hrs Inspection (One-Time / Non-Recurrent)27
- Temporary Scheduled Inspections & Checks27
- Conditional Inspections28
- Inspections - Special Operational Conditions28
- Operation in Sand or Dust28
- Unscheduled Inspections28
- Winter Operation28
- Birdstrike29
- Inspections - Special Operational Incident29
- Propeller Contact with Obstacle or External Impact29
- Rotor Contact with Obstacle29
- Suspected Hard Landing29
- Functional Test Flight30
- Ground Test Run30
- Lightning Strike30
- Maintenance Records & Aircraft Logs30
Chapter 06 - Dimensions & Areas31
Chapter 07 - Lifting / Jacking / Shoring32
Chapter 08 - Leveling & Weighing32
Chapter 09 - Towing & Taxiing32
Chapter 10 - Parking, Storage & Return to Service32
Chapter 11 - Placards & Markings33
Chapter 12 - Servicing35
- Cleaning35
- Lubrication: Pre-Rotator Drive Coupling Sleeve35
- Lubrication: Teeter Hinge35
- Servicing: Engine Air Filter35
- Servicing: Tire Pressure35
Chapter 13-17 - Unassigned / N/A36
- Replenishing/Replacement of Fluids36
- Servicing: Battery36
- Servicing: Engine Coolant36
- Vibration & Noise Analysis37
MMM-CV-B_14-11-1938
- Interphone / Intercom41
- Speech Communication / Radio41
- Ventilation / Heating41
- DC Electrical Load Distribution42
- DC Generation and Battery42
- Flight Compartment42
Chapter 21 - Ventilation / Heating41
Chapter 22 - Unassigned / N/A41
Chapter 23 - Communications41
Chapter 24 - Electrical Power41
Chapter 25 - Equipment / Furnishings42
Chapter 26 - Fire Protection / Fire Warning43
- Emergency43
- Flight Controls - Rudder44
- Pedals, Control Links and Routing of Cables44
Chapter 27 - Flight Controls44
- Fuel System ROTAX 91245
- Fuel System ROTAX 91445
Chapter 28 - Fuel45
- Distribution45
- Storage45
Chapter 29-30 - N/A46
Chapter 31 - Indicating System46
- Instruments & Control Panels46
Chapter 32 - Landing Gear50
Chapter 33 - Lights50
- Exterior50
Chapter 34 - Navigation51
Chapter 35 - N/A51
Chapter 36 - Pneumatic51
- Distribution51
Chapter 37-50 - Unassigned / N/A52
- ATC Transponder51
- Attitude and Direction51
Chapter 51 - Standard Practices - Structures52
Chapter 52 - Doors, Covers and Cowlings52
Chapter 53 - Fuselage52
Chapter 54 - N/A52
- Emergency Exit52
- Passenger / Crew52
- Service Covers and Cowlings52
- Standard Practices - Structures52
- 56-10-00 Flight Compartment / Canopy53
- 56-15-00 Canopy Windows53
Chapter 57-60 - Unassigned / N/A53
Chapter 55 - Stabilizers53
Chapter 56 - Windows53
Part C - System Description Section (Ch. 21 - 90)53
- Rudder53
- Controlling54
- Rotor – Teetering Parts54
Chapter 61 - Propeller54
Chapter 62 - Rotor54
- Propeller Assembly54
Chapter 63 - Rotor Drive55
- Pre-Rotator55
- Rotor Gimbal Head55
- Rotor Head Bridge, Bearing and Teeter Tower55
- Rotor RPM Monitoring55
- Rotor Vibration Isolation55
Chapter 64-66 - N/A56
Chapter 67 - Rotor Flight Control56
- Pitch Trim System / Rotor Brake56
- Pre-Rotator Drive56
- Pre-Rotator Lower Engagement56
Chapter 68-70 - Unassigned / N/A57
Chapter 71 - Power Plant57
- Engine Air Intakes57
- Engine Cowling57
- Engine Drains57
- Engine Electrical Harness57
- Engine Firewalls57
- Engine Mounts57
- Roll Trim System57
Chapter 72 To 74 - Engine Related58
Chapter 75 - Air / Engine Cooling58
Chapter 76 - Engine Controls59
Chapter 77 - Engine Indicating59
- Engine Shutdown / Emergency59
- Power Control / Choke59
- Temperature59
Chapter 78 - Exhaust60
Chapter 79 - Oil System60
- Distribution and Cooling60
- Indicating60
- Integrated Engine Instrument Systems60
- Oil Cooler60
- Oil Hoses and Lines60
- Storage / Oil Tank60
- Wiring Diagram - Aircraft Main Wiring Harness63
MMM-CV-D_15-01-09 Part D - Diagrams and Charts97
- Retrofit: End Position Detection IVO Propeller98
- Lifting Belt Looped Around Teeter Bolt101
- Lifting of the Gyroplane101
- Precautions and Safety Measures101
- Jacking of the Gyroplane103
- Precautions and Safety Measures103
- Special Tools and Consumable Materials103
WARNING: Object Is Heavy! Inadequate Handling Could Cause Injury. Use Proper Lifting Techniques or Assistance169
- Removal Rotor - Teetering Parts (Effectivity: RS II)170
- Disassembly: Rotor - Teetering Parts171
- Disassembly Rotor - Teetering Parts (Effectivity: RS II)172
- Assembly: Rotor - Teetering Parts173
- Installation: Rotor - Teetering Parts175
- Installation Rotor - Teetering Parts (Effectivity: RS II)176
- Check-Adjustment: Rotor System Alignment177
- Positioning of Measuring Cord178
- Reference Point at Grease Nipple178
- Rotor System Placed on Stands178
- Inspection: Rotor - Teetering Parts179
- Teeter Bushings, Block and Tower - Cross Section View180
- Inspection: Rotor Blades181
- Critical Blade Area182
- Measurement of Blade Root Linearity182
- Inspection: Rotor Hub Bolts183
- Rotor Hub184
- Replacement: Teeter Bushings185
- Teeter Bushings, Block and Tower - Exploded View187
- Replacement: Drive Gear189
- Rotor System Must be Removed, See 62-11-00189
  - Rotor Head191
  - Split Pin and Castle Nut191
  - Allen Wrench between Rotor Head and Main Bolt192
  - Check-Adjustment: Rotor Head Main Bolt Axis193
  - Adjustment of Rotor Head Main Bolt Axis194
  - Inspection: Rotor Head Bridge, Bearing and Teeter Tower195
  - Check-Adjustment: Rotor Control Friction197
  - Gimbal Head Assembly, Rotor System II (with Spring Washers)198
  - Measurement of Rotor Control Friction198
  - Inspection: Rotor Gimbal Head199
  - Arrangement of Spring Washers on Gimbal Head - Version II200
  - Rotor Gimbal Head - Version II200
  - Removal-Installation: Top Mast201
WARNING: When Working with Cranes or Other Lifting Equipment the General Safety Regulations Have to be Respected at All Times201
- Pneumatic Connection Bendix203
- Pneumatic Hoses203
- Roll Control203
- Temperature Sensor203
- Installation of Mast Bushes204
- Push-Pull Control Cable Bulkhead Attachment204
- Top Mast204
- Inspection: Mast Mounting Bushings205
- Force Applied against Flight Direction206
- Force Applied in Flight Direction206
- Fuselage Reference Point206
- Mast Reference Point206
- Replacement: Mast Mounting Bushings207
- Bottom Mast with Mast Mounting Bushings208
- Removal-Installation: Pre-Rotator Clutch209
- Check-Adjustment: Pre_Rotator Clutch211
- Connection between Clutch and Pressure Reducer212
- Connection of Check Valve to Pressure Reducer212
- Thread Pin M8X50212
- Upper Pre-Rotator Drive Connected to Bendix Shaft212
- Inspection: Pre-Rotator Clutch213
- Replacement: Pre-Rotator Clutch Lining215
- Loctite 648 on Inner and Outer Thread216
- M8X20 Screw Plug216
- Pneumatic Clutch III216
- Replacement: Pre-Rotator Clutch Dog Gear217
- Inspection: Pre-Rotator Upper Engagement219
- Replacement: Pre-Rotator Upper Bearings221
- Prerotator Upper Bearing222
- Repair: Pre-Rotator Upper Engagement223
- Replacement: Rotor Brake Pad225
- Rotor Bridge with Brake Pad226
- Inspection: Flight Control Push-Pull Cables227
- Measurement of Freeplay228
- Modification of Rotor Head Stop228
- Pitch and Roll - Upper Attachment228
- Retrofit: Ppc Clamps229
- PPC Clamps230
- Replacement: Pitch Trim/Brake Pneumatic Seal231
- Removal-Installation: Centre Console233
- Centre Console234
- Inspection: Clearance Engine Installation (R914)235
- Fire Wall - Removable Part(S)237
- Removal-Installation: Fire Wall237
- Removal-Installation:radiator239
- Modification: Reconfigure Fan Reverse241
- Fan Reverse Cable - Detached242
- Fan Reverse Cable - Modified242
- Fan Reverse Cable - Secured242
- Fan Reverse Control Unit242
- Replacement: Wool of Muffler Tube243
- Drill out the Rivet Pin245
- Hose Clamps245
- Rivets at the Hot and Hinge Pin Clamp245
- Installation of Absorption Wool246
- Riveting of the Outer Shell246
- Rivets at the Cold End of Muffler Tube246
- Installation of Hose Clamps and Hinge Pin Clamp247
- Installation of Locking Wire247
- Position of the Muffler Tube247

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AUTO GYRO CAVALON Specifications

General

Manufacturer	AutoGyro GmbH
Model	Cavalon
Type	Gyroplane
Seats	2
Engine Type	Rotax 912 series
Maximum Speed	185 km/h (115 mph)
Cruise Speed	160 km/h
Range	800 km
Fuel Capacity	100 liters
Rotor Diameter	8.4 m
Height	2.7 m

AUTO GYRO CAVALON Manufacturer Maintenance Manual

Table of Contents

Other manuals for AUTO GYRO CAVALON

AUTO GYRO CAVALON Specifications