ELA AVIACIÓN, S.L. · The gyroplane identification placard is placed on the left side of the mast,...

ELA 07-07S MAINTENANCE MANUAL

Version: M07-05

Issued: April 2012.

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/


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MAINTENANCE MANUAL FOR ELA 07-07S GYROPLANE

- Gyroplane model ELA 07_________

- 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.


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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 amendments to their publication are

effected immediately on receipt, in accordance with the amendment

instructions which will accompany the updates.

Amendment Record

Amend’t

No.

Description of Amendment Pages

affected

Date

1

New hub bar block

51 to 54

8th January

2016


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Contents

Section I – INTRODUCTION

1.1 General.

1.2 Applicability.

1.3 Terminology.

1.4 Conversion table.

1.5 Periodical maintenance.

1.6 Gyroplane degradation.

1.7 Cleaning.

1.8 Road transport.

1.9 Gyroplane identification.

1.10 Bolts torque.

1.11 Consumables.

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.

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 Prerotator.

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 VI – FUNCTIONAL TEST FLIGHT

5.1 Functional test flight


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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 07 series of gyroplanes. It explains the

maintenance processes to keep this aircraft airworthy and in good

conditions.

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 an operational incident like:

- 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.


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1.2 APPLICABILITY

This manual is applicable for all ELA 07 / 07S / 07 Agro gyroplanes.

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 PERIODICAL MAINTENANCE

Certain parts require scheduled maintenance regardless of flying hours. This

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

maintenance.

The relevant maintenance to the 100 hrs should be carried out (as an

annual inspection) in case that the gyroplane has not flown the 100 hrs

within a year.

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

hours, which comes first.

1.6 GYROPLANE DEGRADATION High humidity, especially in combination with salt-laden atmosphere will lead to degradation and corrosion of some parts of the gyroplane. Protect the metal parts of the gyroplane such the engine, rotor head, rotor

hub bar, control systems… 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.


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The manufacturer takes no responsibility for damage due to improper

usage.

1.7 CLEANING It is important to keep the gyroplane and its engine clean to maintain it in good conditions. When cleaning, some mistakes or damages can be found.

Rotor blades and propeller should be always clean as they are very important to keep the best performances.

In order to protect the gyroplane from dust, humidity, bird soil… is

advisable to cover it when parked in the hangar.

Use car soap with water to clean the external parts, windscreen should be cleaned only with polycarbonate soap or polish.

Protect the metal parts of the gyroplane and engine against corrosion,

especially in high humidity conditions with “WD-40” or ACF-50 oil.

1.8 ROAD TRANSPORT

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

damaged during transportation by road. Transport the gyro with minimum

fuel for safety.

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, oil

tank bracket. If you need to contact ELA Aviación, S.L. for any reason please, use your

gyroplane serial number for identification.

1.10 BOLTS TORQUE

All bolts of the gyroplane should be tightened with its appropriate torque. The maintenance technician should have a torque wrench from 5N/m to 60N/m to carry out every maintenance task.

Although some bolts have a special tightening torque, when it is not

specified in this manual, the general torque setting is the 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


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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 with water (see latest issue of engine

maintenance manual).

- “Meguiar´s Mirror Glaze” for the windscreens.


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Section II – DESCRIPTION OF THE AIRCRAFT

2.1 GENERAL

The ELA 07 gyroplane is designed as a 2-seater, tandem-configured three-

axis aircraft with dual controls and single engine, ideal for flight instruction

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 is one single part built from stainless steel TIG (tungsten-

inert-gas) welded to guarantee lifetime freedom from corrosion. The

gyroplane is a tricycle landing gear with front wheel.

The cockpit is made from composite materials, ensuring high strength with

low weight. The high sided open cockpits have clear polycarbonate

windshields to protect the occupants from wind effects but offer excellent

all-round visibility.

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 three bladed

composite propeller.

The tailplane is made from composite materials and consist of a fixed

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

center subdivided into a fixed vertical stabilizer and rudder.


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2.3 OVERALL DIMENSIONS

MEASUREMENT METRIC IMPERIAL

Total length 5.0 m. 16.40 ft.

Total height 2.8 m. 9.19 ft.

Cockpit width 0.75 m. 2.46 ft.

Landing gear width 1.75 m. 5.74 ft.

Rotor diameter 8.5 m. 27.89 ft.

1.73m

2.8m

1.3m

0.9m 1.76m

5 m


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2.4 TECHNICAL DATA AND PERFORMANCE

The following performance parameters were determined by flight testing with average piloting skills, aircraft with 450 kg MTOW, 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) 260 kg 575 lb 265 kg 585 lb

MTOW* 450 kg 1000 lb 500 kg 1100 lb

Useful load (minimum equipment) 190 kg 420 lb 235 kg 520 lb

Vne 160 kph 100 mph (85 kts)

160 kph 100 mph (85 kts)

Cruise speed 100 – 135 kph 60 – 85 mph

(55 – 73 kts) 100 – 145 kph

60 – 90 mph

(55 – 78 kts)

Min speed (level flight/full power)) 40 kph 25 mph

(22 kts) 35 kph

22 mph

(19 kts)

Rate of climb 3.3 m/s 650 ft/min 5 m/s 1000 ft/min

Take-off distance (roll) 100 m 330 ft 70 m 230 ft

Landing distance 0 – 30 m 0 – 65 ft 0 – 30 m 0 – 65 ft

Fuel Gasoline

Fuel capacity 75 l 20 gal

Unusable fuel 3 l 0.8 gal

Fuel consumption 13 – 20 l/h 3.5 – 5.5 gal/hr

* See the MTOW limitations for your country.


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2.5 ENGINE

1) Manufacturer ……………………………………………………………………………… Rotax

2) Take-off power: a. 912 ULS……………………………………………………………….………… 100 hp

b. 914 UL………………………………………………………………………….. 115 hp

3) Max. engine speed……………….……………………………….…………… 5800 rpm

4) Cooling system………………………………………………………………………. Air/liquid

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

6) Electric installation…………………………………………………………………………. 12v


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2.6 MAIN PARTS

1

2

3 4

12 11 13

9

5

6 10 7

8

Parts:

1 – Rotor blades.

2 – Hub bar.

3 – Rotor head.

4 – Mast.

5 – Rear keel.

6 – Landing gear.

7 – Main wheels.

8 – Front wheel.

9 – Cockpit.

10 – Landing light.

11 – Windscreens.

12 – Engine.

13 – Tailplane.


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8 1

4 5

2 3 6 7

Parts: 1 – Propeller. 2 – Oil cooler.

3 – Water cooler. 4 – Vertical stabilizer. 5 – Rudder.

6 – Winglet. 7 – Horizontal stabilizer.

8 – Control rods.


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2 3 1 4

5

6

7

Parts:

1 – Engine.

2 – Water tank. 3 – Horizontal pre-rotator drive shaft.

4 – Pre-rotator clutch. 5 – Carburettor. 6 – Oil tank.

7 – Air filter (914).


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5

1

2

3

4

Parts:

1 – Pre-rotator piston.

2 – Water cooler. 3 – Exhaust muffler. 4 – Fuel tank filler.

5 – Battery.


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Parts:

1 – Compass. 2 – Altimeter. 3 – Airspeed indicator.

4 – Vertical speed indicator. 5 – Rotor tachometer.

6 – Engine tachometer. 7 – Oil pressure. 8 – Trim pressure.

9 – Radio. 10 - EGT.

11 – Manifold pressure. 12 – Fuel pressure. 13 – Oil temperature.

14 – Cylinder head temperature. 15 – Flight/brake selector.

16 – Ignition switch.

1

2 3 4

5 6 7

8 9

15

10 11 12 13 14

16


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1 2 3 4 5 6 7

Parts:

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

2 – Headset jack. 3 – Battery charge.

4 – Landing light and strobe switch. 5 – Circuit breakers. 6 – Master switch.

7 – Fuel pumps (only one for 912 engine)


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Front/Rear Stick Front pedals

Trim

Pre-rotator

PTT Radio

Throttle, brake and roll trim

Throttle

Wheel brake

Roll trim


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Section III – MAINTENANCE DESCRIPTION

3.1 MAINTENANCE SCHEDULE

The relevant maintenance to the 100 hrs should be carried out (as an

annual inspection) in case that the gyroplane has not flown the 100 hrs

within a year.

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 mast X X X X X X X X X

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

1.3 Retighten bolts of seats and harnesses X X X X

1.4 Verify cockpit and instrument panel X X X X X X X X X

1.5 Retighten cockpit bolts X X X X

1.6 Verify mast straightness X X X X

1.7 Full airframe inspection (only approved staff)

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

2.6 Retighten bolts of control fork X X X X X

2.7 Replace bolts of control fork X X X X

2.8 Rotor controls overhaul

(only 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 Inspect control system X X X X X X X X X

3.5 Verify rudder cable tension X X X X X X X X X X

3.6 Check offset of rudder X X X X

3.7 Replace rudder control cable 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 the pre-rotator X X X X X X X X X

4.7 Grease top bearing of bendix (see version) X X X X X X X X X

4.8 Inspect rotor brake pad X X X X X X X X X

4.9 Clean/degrease rotor brake disc X X X X X X X X X

4.10 Replace rotor head bolts X

4.11 Inspect teeter towers


X

5 – ROTOR BLADES

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

5.2 Verify tightening of teeter bolt X X X X X X X X X

5.3 General inspection (only 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 cable (if fitted) X X X X X X X X X

6.5 Adjust the pre-rotator rubber pulley brake X X X X X X X X X

6.6 Inspect universal joints for play X X X X X X X X X

6.7 Inspect O-rings X X X X X X X X X

6.8 Grease bearing of tensioner X X X X X X X X X

6.9 Grease rod end bearing of piston X X X X X X X X X

6.10 Clean and regrease universal joints X X X

6.11 Inspect the pre-rotator gearbox X X X X X X X X X

6.12 Replace bearing of the tensioner X

6.13 Replace pre-rotator Bowden cable X

7 – THROTTLE AND CHOKE SYSTEMS

7.1 Inspect the 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 Verify sealing of landing gear bolts x x x x x x x x x x

8.3 Retighten landing gear bolts x x x x x

8.4 Inspect landing gear X X X X X X X X X X

8.5 Inspect brake pads X X X X X X X X X

8.6 Clean and regrease bearings 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

9.3 Replace tailplane bolts X

9.4 Verify condition of windscreens 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 harnesses X X X X X X X X X

10.2 Check battery level (old battery model) X X X X

10.3 Instrument panel X X X X

10.4 Oil the 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 X

11.3 Propeller pitch X X X X

11.3 Replace propeller bolts X

11.4 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 approved staff)

X

12.3 Replace engine attachment bolts


X

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

12.5 Inspect exhaust 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 filter X X X X X X X X X

13.3 Clean filters of 914 fuel pumps X X X

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

13.5 Inspect fuel 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 PERIODICAL MAINTENANCE Certain parts require scheduled maintenance regardless of flying hours. This

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

maintenance.

If the gyroplane does not fly for a total time of 100 hrs within a year, the

100hrs maintenance program should be carried out as an annual inspection.

All rubber parts and hoses should be replaced every 5 years independently

of the flight hours. 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 and install it with a new

stop nut. If corrosion or wear is found replace the bolt immediately.

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 silent-blocks X X X x

14.3 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 stainless steel, TIG welded. The airframe is one single unit which don´t have replaceable parts. Any repair or modification to the airframe by third persons are not allowed

or approved.

1.1 Inspect mast (every 100 flight hours)

Inspect the mast and its welds to confirm the absence of cracks in the

engine brackets.

Inspect the welds of the bracket for the pre-rotator gearbox.


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Inspect the battery bracket.

Inspect the oil tank bracket and the

mast reinforcement struts.


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Inspect the mast and welds at the bottom part.


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

Verify that the red marks are

aligned between nut and bolt in: - Rear four point harness (if fitted)

- 90º Prerotator box.

- Battery bracket.

- Engine brackets.

- Starter relay. - Regulator.


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1.4 Verify cockpit and instrument panel

(every 100 flight hours)

Verify that the cockpit and instrument panel are secured.

1.3 Retighten bolts of seats and harnesses


- Retighten the four M-6 attachment bolts for each seat. - Retighten the bolts for the harnesses.

1.5 Retighten cockpit bolts


Note

The M-10 bolts for the harness in the rear seat should be

tightened to 25 N/m.


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Retighten the cockpit bolts.

M-4 bolts gently tightened by hand.


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1.7 Full airframe inspection (only approved staff) (every 500 flight hours)

Inspection of all welds for possible cracks in the airframe.

1.6 Verify mast straightness


Remove the instrument panel and measure the distance between the mast

and the keel. The measurement should be between 2595 and 2615mm for the airframes manufactured until March 2014.

The measurement should be between 2633 and 2653mm for the airframes manufactured from March 2014.


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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 control system bolts in control columns,

control fork and vertical control rods.


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2.1 Verify sealing of control system bolts



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2.2 Verify 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. Some

millimetres of play at the top of the stick are allowed, 8 mm or more are not acceptable.

2.3 Inspect control rods (every 100 flight hours)

Visually inspect the vertical control rods for damage or cracks, especially at its ends.

2.4 Grease control rod ends


Clean the control rod ends (8) and grease with spray.


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

Some friction in the roll axis of the

rotor controls is more comfortable to avoid resonant vibration in flight. Slightly tight the bolts of the plastic

bracket. Test in ground the amount of

friction; it should be a compromise between handle and friction.

2.6 Retighten bolts of control fork

(100/300/500/700/900 flight hours)

Replace the nuts, retighten the bolts of the control fork and mark with

red paint the thread with the nut.


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2.7 Replace bolts of control fork


Replace the bolts and nuts of the control fork and mark with red paint the thread with the nut.

2.8 Rotor controls overhaul (only approved staff) (every 500 flight hours)

Disassembly the whole rotor control

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 of the control columns (8).


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Replace the bearings of the control

fork.

Replace the rod end bearings of the vertical rods (8).

Assembly the new rod end bearings with the following measurements

between centres: Upper rods:

- Right: 900mm.

- Left: 882mm. Lower rods:

Right and left: 770mm.

Grease the rod ends.

Replace all bolts and nuts of the

control system, 10 for the horizontal rods and 10 for the vertical rods.


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4.3 STEERING CONTROLS

3.2 Inspect control rods for straightness (every 100 flight hours)

Inspect the steering control rods for straightness through the front wheel

hole and from inside the cockpit.

3.1 Inspect front wheel fork


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.


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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.

3.4 Inspect control system


Inspect the entire rudder cable for wear or damage.

Inspect the rudder cable pulleys for free motion.

Inspect the condition of the cable retainers of the rudder.


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3.6 Check offset of rudder

(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

gyroplane is straight and measure the distance between the trailing edge at the top of the rudder and

the trailing edge of the top of the right winglet. It should be 90cm +/-

1.

3.5 Verify rudder cable tension (first 25 and every 100 flight hours)

Verify rudder cable tension. With the front wheel straight, the tension

should be between 45 and 55 pounds.

It is important that the tension of

this control cable is within limits to avoid a probably rudder flutter at

high speeds.

Adjust the tension tightening the turnbuckle near the rear/right pedal.

Secure it again with safety wire.

After adjusting the cable check the offset of the rudder (see point 3.6)


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3.7 Replace rudder control cable


Replace the rudder control cable and turnbuckle.

4.4 ROTOR HEAD

4.1 Verify sealing of bolts


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 the necessary to operate the controls easily. Put a

new safety pin.


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

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

4.6 Grease 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 Grease top bearing of the bendix (see version)


Grease the needle bearing at the top of the bendix with spray grease.

See version. New version of bearing is maintenance free.

4.8 Inspect rotor brake pad


Inspect the brake pad for excessive wear or damage.


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4.10 Replace rotor head bolts


Replace the rotor head bolts and nuts (11 bolts).

4.9 Clean/de-grease rotor brake disc


Clean/degrease the rotor brake disc.


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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


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


Old system:

Tight the nut to 20N/m and slacken about ¼ turn. Put safety pin.

New system:

That bolt should be tightened strong “BY HAND”. Then tighten the Allen

bolt and put the safety pin.

A lower or higher torque will create

rotor vibrations.


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5.3 General inspection

OLD SYSTEM (different hub block) (every 500 flight hours)

Disassemble the rotor from the

gyroplane and put it over stands.

Disassemble the bearings from

the block.

Mark each rotor blade with its

side of the hub bar.

Mark the block with the hub bar.


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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.

Install new bearings in the block and lubricate them with Molycote

grease.


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5.3 General inspection

NEW SYSTEM (different hub block)


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


Verify the sealing of the prerotator

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 (6) in the propeller.


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6.4 Adjust pre-rotator cable (if fitted) (every 100 flight hours)

Adjust the length of the prerotator

cable (if fitted). With the parking brakes ON, throttle

in idle position pull the pre-rotator lever and hold it with a force of

about 3-5 kg, the distance between the throttle and pre-rotator lever (centres) should be 12 cm.

6.5 Adjust pre-rotator rubber pulley brake


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.


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6.6 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.

6.7 Inspect O-rings


Inspect the O-rings (if fitted) for damage.

Replace the O-rings when needed.

When installing, use Loctite 243 and tight gently by hand.


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

Lubricate the bearing of the tensioner with spray grease.

6.9 Grease rod end bearing of piston


Lubricate the rod end bearing of the

pre-rotator piston with spray grease (if fitted).

6.10 Clean and regrease universal joint


Remove the rubber covers of the universal joints for cleaning and

regrease with Molycote.


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6.11 Inspect pre-rotator gearbox (every 100 flight hours)

Verify that the pre-rotator gearbox

has no oil leaks. In case of leaks replace the oil seals.

6.12 Replace bearing of the tensioner


Replace the bearing of the tensioner. Grease with Molycote before assembling.

6.12 Replace the pre-rotator Bowden cable


Replace the pre-rotator Bowden cable (if fitted).

4.7 THROTTLE AND CHOKE SYSTEMS

7.1 Inspect system for smooth operation


Operate the system from idle to full power position to confirm a smooth operation.


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

Inspect the front and rear levers for damage or malfunction.

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

Adjust the friction of throttle levers

for smooth operation. If the throttle is too hard is difficult to operate with precision, if it is too soft it will move

in flight by itself.

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 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. Then it is necessary to adjust the carburettor synchronization.

4.8 LANDING GEAR

8.1 Tires and wheels (first 25 and every 100 flight hours)

Check the tires for wear, replace

when needed. Verify tires 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.


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8.2 Verify sealing of landing gear bolts (first 25 and every 100 flight hours)

Verify the sealing of the landing

gear bolts in the aluminium landing gear (new).

8.3 Retighten landing gear bolts


In the old landing gear, made in

composite, retighten the 4 bolts that fix it to the frame and retighten the bolts that fix the wheels axles.

8.4 Inspect landing gear


Inspect the old landing gear (composite), for cracks or damage.

8.5 Inspect brake pads (every 100 flight hours)

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


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4.9 VARIOUS

8.6 Clean and grease bearings (every 300 flight hours)

Clean and re-grease with Molycote the wheels bearings in the old

system (open rollers bearings).

9.1 Inspect tailplane (first 25 and every 100 flight hours)

Inspect tailplane and rudder for cracks or damage.

9.2 Retighten tailplane attachment bolts


Retighten tailplane attachment bolts (4).

9.3 Replace tailplane bolts (every 500 flight hours)

Replace tailplane bolts, use Loctite 243.


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4.10 ELECTRICAL/PNEUMATIC SYSTEMS

9.4 Verify condition of windscreens


Verify the absence of scratches or cracks. Polish them often with “Meguiar´s Mirror Glaze”.

9.5 Verify placards


Verify all placards, when fitted, are readable and in good conditions. Replace if necessary.

10.1 Inspect harnesses (every 100 flight hours)

Inspect the routing and connections of the electrical and pneumatic

harnesses for damage, wear, replacement of cable ties…

10.2 Check battery level (every 200 flight hours)

Check the battery level in the old battery (Varta), refill with distilled water

if necessary. The new batteries DECA or Super-B don´t need maintenance.

10.3 Instrument panel (every 200 flight hours)

Remove the instrument panel for cleaning and inspect all wires and

connections for damage, wear…


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4.11 PROPELLER

10.4 Oil the compressor (every 100 flight hours)

Oil the compressor (new system)

with engine oil.

Remove the cover of the compressor and oil it with 3 or 4 drops of engine oil.

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

Inspect the propeller blades and hub for cracks or damages.

11.2 Retighten propeller bolts (every 200 flight hours)

Retighten all the propeller bolts.


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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.

11.3 Propeller pitch (every 200 flight hours)

Verify that the pitch of the three propeller blades are equal.

11.4 Replace the propeller bolts (every 400 flight hours)

Replace the 6 propeller bolts of the centre of the hub.

11.5 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 locking wire of air filter(s)


Inspect the locking wire of air filter(s).

Locking wire in 914 UL air filter.


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Locking wire in 912 ULS air filters.

12.5 Inspect exhaust system (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 fuel 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 (every 300 flight hours)

Carefully remove the fuel filters inside the electrical fuel pumps of

the 914 and clean them.

13.4 Inspect vent hoses (every 100 flight hours)

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

13.5 Inspect fuel hoses (every 100 flight hours)

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

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 completely the tank with fuel. - Open the outlet of the tank and measure the time to get one litre.

- The max. time to get one litre should be less than 40 seconds.

14.1 Inspect system


Verify the absence of leaks in the system. Inspect the condition of the silent-blocks of the cooler.

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 silent-blocks

(every 200 flight hours or 5 years)

Replace the silent-blocks of the cooler.


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4.15 OIL SYSTEM

15.2 Replace hoses (every 500 flight hours or 5 years)

Replace the hoses and clamps.

14.3 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.

15.1 Inspect system (first 25 and every 100 flight hours)

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 should be done every year. This test determines

whether the gyroplane or its equipment is functioning according to

established standards while the aircraft operates in its intended

environment. An FTF is 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 (96 kph

~ 60 mph).

6 Instruments

Check every flight or engine instrument, check

radio/intercom for correct function.


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7 Climb

Note the time for climbing 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 0-160 kph ~

0-100 mph.

10 Trim

Test trim function at speeds from 0-160 kph ~ 0-

100 mph.

11 Landing

Land with engine at idle speed and note any

unusual behaviour.

Comments/Remarks:

Date: Location:

Pilot Name: License Nº:

Date post:	16-Oct-2019
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ELA AVIACIÓN, S.L. · The gyroplane identification placard is placed on the left side of the mast,...

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