Celier Aviation: Service Manual

CELIER AVIATION
SERVICE MANUAL
GYROCOPTER
Xenon 2
model: RST
FACTORY NUMBER:
DISTINGUISHING MARKS:
NUMBER ON FILE:
THE MANUAL WAS APPROVED WITH A DECISION OF PRESIDENT OF THE CIVIL AVIATION AUTHORITY
DATED …………………………………. NO. ………………………
“ULTRALIGHT”” CATEGORY
THIS GYROCOPTER CAN BE USED IN THE “ULTRALIGHT” CATEGORY FOR
LEISURE, SPORTS AND DISPLAY PURPOSES AS WELL AS OTHERS, EXCLUDING
AIR TRANSPORT.
USING THIS GYROCOPTER FOR TRAINING AND PRACTICE TO OBTAIN A
CERTIFICATE OF QUALIFICATIONS OF AN ULTRALIGHT GYROCOPTER PILOT AS
WELL AS HAVE QUALIFICATIONS ENTERED IN THIS CERTIFICATE CAN BE DONE
SOLELY IN A CERTIFIED TRAINING CENTRE.
THE GYROCOPTER MUST BE USED ACCORDING TO THE RESTRICTIONS AND
INFORMATION STATED IN THIS INSTRUCTION MANUAL.
THIS MANUAL MUST ALWAYS BE AVAILABLE WHEN PERFORMING SERVICE
ACTIVITIES, OVERHAULS AND PERIODIC WORK
ON THE GYROCOPTER.
Edition 1 24 Aug 2009

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Document no.: X2RST-001-PL
Downloaded from www.Manualslib.com manuals search engine

The manual has been developed as per the requirements of the regulations in Annexe No. 5
“Ultralight Aircraft” - of the Decree of the Minister of Infrastructure dated 25 April 2005 on
Excluding the Application of Some of the Laws of the Act on Air Law for Some Sorts of Aircraft
as well as Defining the Conditions and Requirements concerning the Use of this Aircraft (Official
Journal 107 section 904) with subsequent amendments.
It is not allowed to make any entries and supplements in this “Flight Manual” without the consent
of the Civil Aviation Authority.
In case this Manual is lost, you should notify the Civil Aviation Authority instantaneously, and
when outside the border of your country - an equivalent institution.
Any person to find this manual is requested to send it in instantaneously to Urząd Lotnictwa
Cywilnego (Civil Aviation Authority), 02-247 Warszawa, ul. Marcina Flisa 2, and when outside
the border of your country to an equivalent institution.

Document no.: X2RST-001-PL Change no.:

CELIER SERVICE MANUAL Xenon 2 RST
Aviation Organizational Information Chapter 0
Chapter 0 Organizational Information

0.1 Register of Changes
If necessary CELIER AVIATION will issue updates for this manual and will publish it in
the form of bulletins on its website.
Any changes of this manual must be instantaneously entered and written in the table below
as well as be approved by the Civil Aviation Authority (CAA).
A new or revised text in changed pages must be marked with a black vertical line on the
margin and a change number. The number of the last change in a given page and its date must be
placed in the page footer. Every time a change is entered, the pages listed in the table below must
be mentioned.
Change no. Description of change Refers to pages Entry date Signature

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Document no.: X2RST-001-PL Page 0-1

Change no. Description of change Refers to pages Entry date Signature

Page 0-2 Document no.: X2RST-001-PL Change no.:

Xenon 2
CELIER SERVICE MANUAL
RST
0.2 List of Up-to-date Pages

Chapter Page Date Chapter Page Date
Title 24.08.2009 4 4-1 24.08.2009
Reverse 24.08.2009 4-2 24.08.2009
0 0-1 24.08.2009 4-3 24.08.2009
0-2 24.08.2009 4-4 24.08.2009
0-3 24.08.2009 4-5 24.08.2009
0-4 24.08.2009 4-6 24.08.2009
1 1-1 24.08.2009 5 5-1 24.08.2009
1-2 24.08.2009 5-2 24.08.2009
1-3 24.08.2009 5-3 24.08.2009
1-4 24.08.2009 5-4 24.08.2009
2 2-1 24.08.2009 5-5 24.08.2009
2-2 24.08.2009 5-6 24.08.2009
2-3 24.08.2009 5-7 24.08.2009
2-4 24.08.2009 5-8 24.08.2009
2-5 24.08.2009 6 6-1 24.08.2009
2-6 24.08.2009 6-2 24.08.2009
2-7 24.08.2009 6-3 24.08.2009
2-8 24.08.2009 6-4 24.08.2009
2-9 24.08.2009 7 7-1 24.08.2009
2-10 24.08.2009 7-2 24.08.2009
2-11 24.08.2009 8 8-1 24.08.2009
2-12 24.08.2009 8-2 24.08.2009
3 3-1 24.08.2009 8-3 24.08.2009
3-2 24.08.2009 8-4 24.08.2009
3-3 24.08.2009 8-5 24.08.2009
3-4 24.08.2009 8-6 24.08.2009
3-5 24.08.2009 8-7 24.08.2009
3-6 24.08.2009 8-8 24.08.2009
3-7 24.08.2009 9 9-1 24.08.2009
3-8 24.08.2009 9-2 24.08.2009
3-9 24.08.2009 10 10-1 24.08.2009
3-10 24.08.2009 10-2 24.08.2009
3-11 24.08.2009 10-3 24.08.2009
3-12 24.08.2009 10-4 24.08.2009
3-13 24.08.2009 11 11-1 24.08.2009
3-14 24.08.2009 11-2 24.08.2009

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Xenon 2
RST
0.3 Table of Contents
Chapter Title
0 Organizational Information
1 General Information
2 Description of the Gyrocopter and its Systems
3 Assembly and Dismantling
4 Service Work, Operational Materials
5 Schedule of Overhauls and Service Work
6 Weighing and Specifying the Position of the Centre of Gravity
7 Durability of Structural Components
8 Adjustment Data and Deflections of Control Components
9 Other Service Information
10 List of Notices and Markings
11 Supplements

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Aviation General Information Chapter 1
Chapter 1 General Information

1. page
1.1 Introduction ................................................................................................. 1-2
1.2 Basis for Acknowledging Airworthiness..................................................... 1-2
1.3 Directives and Announcements of Airworthiness....................................... 1-2
1.4 Responsibility .............................................................................................. 1-3

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1.1 Introduction
This manual has been written to pass to pilots and engineers information that is essential to
correctly operate and properly handle gyrocopter Xenon 2 RST to ensure its airworthiness and
safe and effective operation.
The gyrocopter should be operated in accordance with this manual and the applicable
regulations. The owner/use of the gyrocopter is responsible for the compliance.
The gyrocopter can be used for flight only when it is technically operative and has a valid
authorization to perform flights. An authorization to perform flights is entered in the ultralight
aircraft book, which is a document identifying an ultralight aircraft and its subassemblies as well
as containing data on the record of usage.
Any modifications to the gyrocopter, made without the consent of the producer and the
aviation supervisory authority, will render this manual inappropriate for the modified specimen.
1.2 Basis for Acknowledging Airworthiness

The gyrocopter Xenon 2 RST can be used within the territory of the Republic of Poland on
the basis of the Decree of the Minister of Infrastructure dated 25 April 2005 on Excluding the
Application of Some of the Laws of the Act on Air Law for Some Sorts of Aircraft as well as
Defining the Conditions and Requirements concerning the Use of this Craft. The detailed
conditions and requirements concerning its use are set out in Annexe No. 5.
Under this Annexe, Xenon 2 RST has been classified as an Ultralight Aircraft, meeting the
following conditions (subsection 2.1.23.c): an ultralight gyrocopter - an aircraft being a rotorcraft
which gains lift in flight from the autorotation system of the rotor, is equipped with at least one
power unit ensuring independent take-off and climbing flight, having not more than 2 crew seats
and whose maximum takeoff weight (MTOW) does not exceed 495kg (for a two-seater).
For acknowledging the airworthiness of the gyrocopter, as technical requirements, the
Regulations for Constructing Ultralight Gyrocopters (Bauvorschriften für Ultraleichte
Tragschrauber - BUT) of 26 September 2001 have been adopted. For this reason, the maximum
takeoff weight (MTOM) of the gyrocopter Xenon 2 RST has been restricted in Poland to 450kg.
1.3 Directives and Announcements of Airworthiness

All applicable directives of airworthiness or other documents (notes, decrees) issued by civil
aviation authorities must be observed. Compliance with the directives should be recorded in the
Ultralight Aircraft Book (Gyrocopter Book) or approved in an equivalent manner.


Xenon 2
RST
1.4 Responsibility
The user is responsible for conducting overhauls and servicing at the right time as described
in this manual.
The deadlines for overhauls and service work should follow those recommended by CELIER
Aviation. The Civil Aviation Authority can order to change the deadlines by issuing directives or
notes of airworthiness.
Persons that certify servicing should use their engineering knowledge and skills to specify
the extent of the necessary repairs and checks and other issues which can affect the airworthiness
of the gyrocopter.
The repairs and overhauls of the gyrocopter should be registered (with a listing of all defects,
shortages and additional servicing resulting from the execution of the work schedule) in the form
of reports and recorded in the Gyrocopter Book. Persons that certify servicing are responsible for
keeping these records. Every consecutive repair or overhaul should be conducted after previous
familiarization with the history of repairs and overhauls.
Servicing information (bulletins, lists etc) published by CELIER Aviation should be
assessed and taken into consideration by the user/owner, if the need arises, to ensure security and
infallibility during usage. Complying with the recommendations of servicing information should
be recorded in the Gyrocopter Book.

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Xenon 2
RST
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Aviation Description of the Gyrocopter and its Systems Chapter 2
Chapter 2 Description of the Gyrocopter and its Systems

2. page
2.1 General Description .................................................................................... 2-2
2.1.1 Technical Data ........................................................................................ 2-2
2.2 Figure in Three Projections ......................................................................... 2-3
2.3 Control Systems .......................................................................................... 2-4
2.3.1 Schema of the Control System with the Rotor........................................ 2-4
2.3.2 Schema of the Spring-Operated Relieving Device - “Trimmer” ........... 2-5
2.3.3 Schema of the Directional Control System............................................. 2-6
2.4 Fuel System ................................................................................................. 2-7
2.5 Oil System ................................................................................................... 2-8
2.6 Engine Cooling System ............................................................................... 2-9
2.7 Electrical System ......................................................................................... 2-10

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2.1 General Description

Xenon 2 RST is a two-seat ultralight gyrocopter. The main structural component is the
fuselage with composite structure. Two slender metal tail beams are guided from the fuselage, on
which vertical twin fin tail unit is constructed (stabilizers and rudders), on which in turn the
horizontal stabilizer with a symmetric profile is mounted, equipped with winglets. The control
surfaces are also of composite structure. A metal mast is affixed to the fuselage structure, on which
the control head with the lifting rotor is mounted.
The two-blade rotor with metal structure is manufactured and delivered in a set (blades + a
hub) by the AIRCOPTER Company. The blades, made from drawn aluminium, are entirely
anodized and perfectly balanced.
Xenon 2 RST is powered with a CA 912 ULT engine. It is a Rotax 912 UL engine,
modified by the CELIER AVIATION Company by adding an Iveco turbocompressor. It is
equipped with a three-blade composite propeller of the DUC brand, which has the capability to
manually change a stroke.
The undercarriage is a stationary three-wheel one in a set with the front wheel. The main legs
are elastic and made of aluminium. The front leg is dampened only with a wheel pneumatic unit. The
undercarriage can be made as “ordinary” with wheels with a diameter of 350mm or as a “Tundra”
with wheels with a diameter of 450mm.
The spacious cockpit with a width of 125cm is accessible through a large door on the left and
right sides. Rich glazing ensures optimum visibility. Two ergonomic bucket seats can be set up in 3
positions. Each chair is equipped with adjustable four-point belts.
2.1.1 Technical Data
Geometric data
Rotor diameter 8.40 m
Rotor surface 55.38 m2
Rotor blade chord 0.20 m
Overall length (w/o rotor) 4.90 m
Fuselage width 1.35 m
Cockpit width 1.25 m
Overall width 2.20 m 2.23
Overall height 2.80 m 2.85
Wheel diameter 0.35 m 0.45
undercarriage: “ordinary” “Tundra”
Weight data
Maximum take-off weight 450 kg
Bare weight 265 kg
Load capacity 185 kg


Xenon 2
RST
Data of the power unit

Engine type CA 912 ULT
Power 122 KM at 5800rpm
Reducer ratio 1 : 2.43
Propeller DUC FC Windspoon R
Propeller diameter 1.72m
Capacity of fuel tanks 2 × 42 litres
2.2 Figure in Three Projections

(variant equipped with “ordinary” undercarriage with 350mm diameter wheels)

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Xenon 2
RST
2.3 Control Systems

2.3.1 Schema of the Control System with the Rotor
Lifting Rotor Head
Wheel Brake Lever

(Optionally on the Left
or Right Stick) “Mixer”
Mechanism
Doubled
Control
Stick
Control
Column
Head
Control
Lever

Trimmer Lever
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Xenon 2
RST
2.3.2 Schema of the Spring-Operated Relieving Device - “Trimmer”
2448 Spring
2450 Trimmer Line
2453 Trimmer Grip
2454 Fair-Lead
2452 Stopper
2451 Roll
The length of the line (2450) from the fair-lead (2454) to the grip (2453), with the control stick
deflected backwards, should amount to 250mm.
The line should be replaced if any traces of wear are noticed (rubbed spots). Polyester sailing
line with a diameter of 2.8mm should be applied.

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Xenon 2
RST
2.3.3 Schema of the Directional Control System
Rudder Bar Lever

Bowden Strands
Rudder
Page 2-6 Edition 1 24 Aug 2009

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Xenon 2
RST
2.4 Fuel System (Schema)
Carburettors
Approaching System
T-pipe
Airbox
Fuel Regulator Turbo

Return to Tanks
T-pipe
Fuel Pumps
Fuel Filter
Fuel Fuel
Tank Tank

Fuel DrainDocument no.: X2RST-001-PL Page 2-7
Tank Connector
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Xenon 2
RST
2.5 Oil System (Schema)
Conduit 8mm
Oil Tank
Hose with Adaptor
Hose Dia 12
Gasket
Turbocompressor
Oil Cooler
Overflow Tank or
Deaeration Conduit
Turbine Oil Receptacle
Bolts with Locking Washers
Propeller

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Xenon 2
RST
2.6 Engine Cooling System (Schema)
Rear View
Aluminium Water Pipe
Aluminium Water Pipe
Conduit 25mm Aluminium Water Pipe
Right-Side View
Gate Peg
Water Pump
Overflow Tank
Cooler

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Xenon 2
RST
2.7 Electrical System (Schema)

The main source of electrical energy of the aeroplane is a direct current generator enclosed
on the engine (14V, 250W with 5800 rpm). The electrical system of the plane is a two-lead system
on account of the composite structure of the cockpit. The master switch is placed on the central
panel and is activated with a removable red key.
The electrical system serves to supply: the ignition system and engine start-up, the
electromagnetic prerotation clutch (bendix), the lighting of the cockpit and the navigation lighting,
the pumps and the fuel level sensor, the check instrument for engine work and its sensors, the
instrument and sensor for the rotational speed of the rotor. At the side of the instrument board,
there is a 12V socket (a typical automotive socket for a lighter) giving a possibility of connecting
additional devices.
Individual circuits are enabled with appropriate marked switches and secured with safety
fuses. When the generator is idle (e.g. the engine is off, it is at a low speed or there is a failure),
charging orange indicator light turns on on the instrument board, and the electric units are then
supplied from the battery YTX12-BS (12V, 10Ah).
Elucidation of denotations on the schema of the electrical system:
1 – Battery 16 – Slave Electric Pump

2 – Generator (integrated) 17 – Magneto Switch
3 – Electric Starter 18 – Magneto Switch
4 – External Controller 19 – Block of Fuses
5 – Starter Relay 20 – Block of Fuses
6 – Starter Switch 21 – Ignition Module “A”
7 – Capacitor 22 – Ignition Module “B”
8 – Cockpit Lighting CHT – Cooling Fluid Temperature
9 – Master Switch (red key) EGT – Exhaust Gas Temperature
10 – Master Fuse (30A) OT – Oil Temperature
11 – Prerotation Switch OP – Oil Pressure
12 – Prerotation Relay RC – Rotor Tachometer
13 – Bendix ABT – Approaching System Temperature
14 – 4-Switch Console MAP – Recharging Pressure
15 – Master Electric Pump FLS – Fuel Level Sensor

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Xenon 2
RST

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Xenon 2
RST
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Aviation Assembly and Dismantling Chapter 3
Chapter 3 Assembly and Dismantling

3. Page
3.1 Assembling and Dismantling the Rotor ...................................................... 3-2
3.1.1 Assembly Schema of the Rotor Hub ...................................................... 3-2
3.1.2 Dismantling the Rotor ............................................................................ 3-3
3.1.3 Assembling and Aligning the Rotor ....................................................... 3-4
3.1.4 Fitting the Rotor on the Gyrocopter ....................................................... 3-4
3.2 Assembly Schema of the Rotor Head ......................................................... 3-5
3.3 Assembly Schema of the Rotor Suspension Components on the Mast ...... 3-6
3.4 Prerotation Clutch ....................................................................................... 3-7
3.5 Control Systems .......................................................................................... 3-8
3.5.1 Assembly Schema of the Rotor Control System..................................... 3-8
3.5.2 Assembly Schema of the Directional Control System............................ 3-12
3.6 Replacing the Master Bearing ..................................................................... 3-14
3.7 Tightening Moments ................................................................................... 3-14

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3.1
3.1.1
M6x85 Bolt
6102 (x2) Steel Sleeve diam. 12
6153 (x2) Nylon Washer diam. 12
Page 3-2
6154 (x2) Washer diam. 12
CELIER
Aviation
M10 Nut (Nylonstop)
6104 M12 Bolt (+Cotter Pin)
6010 / 6145 (x2) Blade 6107 (x10) M8x65 Bolt

Assembly Schema of the Rotor Hub
Dismantling and Assembling the Rotor

SERVICE MANUAL
Assembly and Dismantling
6103 Complete Hub

Washer 6x14x1
Edition 1
M6 Nut (Nylonstop)
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(Tightening Moment 1kGm)
6105 (x2) Blade Pocket
6108 (x20) Washer 8x22x1.5 6109 (x10) M8 Nut (Nylonstop)

(Tightening Moment 2.4kGm)
Chapter 3
24 Aug 2009
Xenon 2 RST
Xenon 2
RST
3.1.2 Dismantling the Rotor
The rotor must be detached from the gyrocopter to be carried by road transport, and also to
be longer kept in a hangar.
CAUTION: When detaching the rotor, you must stand on the fuselage only in the spots
assigned for this purpose!
• Make sure the wheel brakes are activated (position 1).

• Set up and immobilize with tape the control stick in the extreme front position so that the
rotor head disc rests on the brake.
• Remove the safety cotter pin and unscrew the nut from the pin for rotor hub suspension in
the hub (teeter bolt).
• With the help of another person holding down the rotor, tuck out the pin (making sure the
sleeves remain in their places) and remove the rotor from the head.
• Unscrew the nuts, withdraw the M8x65 bolts (10 pieces) and tuck out the blades from the
sockets in the hub.
• Piece together and assemble back the hub, sockets, M8×65 bolts, washers and nuts.
• Place the pin (teeter bolt) in the hub with washers, screw on a nut and pass through the
cotter pin (safety pin).
The removed blades, for storage or transport, must be appropriately fastened and protected
against damage.

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Xenon 2
RST
3.1.3 Assembling and Aligning the Rotor
The blades and hub of the rotor are supplied with numbers to define their orientation in the
assembly kit. By matching numerical-literal marks, insert the rotor blades into the sockets in the
hub. Fit sets of five M8x65 bolts each (with washers at both sides) clipping the hub beams with
every blade. Next, screw down all the ten nuts to the first contact.
Even out the rotor blades by using stretched string, going through the centre of the hub and
along the grooves at the blade tips. The rotor must be placed on two supports with a soft surface
(to avoid damage) so that the strained string goes about 1cm above the central opening in the hub.
If the engine is not aligned properly, it will result in vibrations. The better the alignment of the
rotor is, the greater the comfort of flight is, the smaller the vibrations and the longer the life of the
machine and its subassemblies. When the string does not overlap the hub axle, two people are
needed for help: hold down the blade tips, then push the hub in the right direction. After
alignment, tighten the nuts with a torque spanner, first 18 Nm, next 24 Nm.
The correctness of alignment must be checked in the first flight.
3.1.4 Fitting the Rotor on the Gyrocopter
CAUTION: When placing the rotor, you must stand on the fuselage only in the spots
assigned for this purpose!
• Make sure the wheel brakes are activated (position 1).

• Set up and immobilize with tape the control stick in the extreme front position so that the
rotor head disc rests on the brake.
• Lubricate the master pin with a special lubricant through the central opening in the hub
(?).
• With the help of another person (and a ladder), raise the rotor and place it on the head.
• Insert the pin through the head and the hub (making sure the sleeves remain in their
places) and press it down to the end.
• Tighten the nut, next unscrew it by 1/4 of a rotation and pass the safety cotter pin through
the opening at the end of the pin.

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Xenon 2
RST
3.2 Assembly Schema of the Rotor Head
6144 Nut d 30KM (nylstop)

Bend after Tightening 6115 Crown Washer d 30MB
6130 (x2) M8x25 Bolt

6125 Nut d 30KM std
6116 (x4) Washer 8x16x1.5
6129 (x4) M8x45 Bolt
6135 (x2) Nylon Stop
6110 Main “U” Component
6128 (x2) M8 Nut 6118 Stop Base
6122 Bearing d 30 5206 ( □)
(!) Set up during Assembly
6117 Prerotator Disc
6139 (x2) M8 Nut (Nylonstop) 6139 (x8) M8 Nut (Nylstop)
6147 Toothed-Wheel Rim
6112 Cotter diam. 6 L=2 6

6152 (x4) M8x25 Bolt
6140 M8x45 Bolt
6134 Lining of Rotor Brake (▲▲
▲▲
▲▲)
6121 Steel Ring 30x11
6113 (x2) Bolt

M5x16
Fastening of Sensor
Rotational Speed of Rotor
(▲▲
▲▲
▲▲)
6131 M10 Nut (Nylstop)
6119 Outside Part 6141 Washer diam. 8
of Cardan Suspension
6120 Tilting Pin
6127 Washer outside diam. 22
6123 Central Axle diam. 30
6111 Spacer Sleeve (Nylon)
10x22x13 6127 (x2) Washer (nylon)
10x30x3
6124 Inside Part
WATCH FOR SETUP DURING ASSEMBLY of Cardan Suspension

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Xenon 2
RST
3.3 Assembly Schema of the Rotor Suspension Components on the Mast
6114 M10x120 Bolt + Cotter Pin

6151 (x2) Washer 10x22x2
6115 Spacer Sleeve (Nylon)

10x22x13
Washer (Nylon) 10x22x3
6131 Nut
(Nylonstop) d 10
6149 (x2) Spacer Sleeve

(Nylon) 10x30x9

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Xenon 2
RST
3.4 Prerotation Clutch
6207 Brake Foot
6267 Spacer Mandrel
6209 Straining Wheel
6220 Power Wheel
6204 Clutch Lever
6203 Clutch Bracket

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Xenon 2
RST
3.5 Control Systems

3.5.1 Assembly Schema of the Rotor Control System
Location of the Wheel Brake Lever Depends on the Pilot

(Right-Handed/Left-Handed)
3000a Doubled Control Stick (Pipes 25mm)
3016 M8x50 Bolt (+ counter component

+ lubricant + (▲▲▲
▲▲▲
▲▲▲))
3026 (x4) Steel Rivets 5x16

3017 (x4) M6 Nut (Nylonstop)
3020 (x4) Washer d 6

3034 (x4) Washer d 8
3021 (x4) M6x50 Bolt + (lubricant)
3037 (x4) Shaped Washer d 20
3003 Longitudinal Control Pusher

3002 Transverse Control Axle (25mm)
3038 (x4) Shaped Washer d 25
3023 Antivibration 3006 Front Transverse Tube
Block d8 3020 (x2) Washer 6x18x1.5
3024 Washer d8x30x2 3026 (x2) Steel Rivets 5x16
3015 (x2) M6x20 Bolt + ( ▲▲
▲▲)
M8x50 Bolt
(Opening in the Bolt + 2 Openings 3mm in diam. in the Cockpit
+ Safety Wire) + Lubricant
(!)
(all washers are nylon ones 8x17x2 unless stated otherwise )
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Xenon 2
RST
3102A (x2) Pusher
3117 Steel Rivet (x24)
3104 (x6) Pusher Tip
3105 (x8) M10 Nut
3117 Steel Rivet (x24)
3100 (x8) Ball-and-Socket Joint d10
3107 (x2) M10x1.5

Nut (Nylstop)
3108 (x4) Steel Spacer Sleeve

d10.3xD15x5
3101 (x2) M10x60 Bolt

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Xenon 2
RST
3108 (x4) Steel Spacer Sleeve d10.3x12x5

3105 (x2) M10 Nut
3106 (x2) M10x45 Bolt
+ (lubricant) 3107 (x2) Nut (Nylstop) d10x1.5
3120 Washer (Nylon) d10x30x3
3109 M8 Nut (Nylstop)
3111 M8x70 Bolt + (lubricant)
in the Direction of the Rotor
3112 (x2) Washer (Nylon) d8xD17xe2.1
3114 (x2) Spacer Sleeve (Nylon) 8x12x16

3113 Spacer Sleeve (Nylon) d8.2x12x20
3116 Mixer Grip

Mixer - Left Half
3115 Mixer Arm
in the Direction of the Cockpit

3100 Ball-and-Socket Joint d10
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Xenon 2
RST
3106 (x2) M10x60 Bolt
3106 (x4) M10 Nut (Nylstop)
6113 Control Lever V 3108 (x4) Steel Spacer Sleeve

d10.3x12.5
3105 (x4) M10 Nut
3104 (x2) Pusher Tip
3103 (x2) Pusher

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Xenon 2
RST
3.5.2 Assembly Schema of the Directional Control System
1104 Bowden Strand (3.75m)
3011 (x2) Pusher 12x120
3033 (x2) Nut (Nylstop)
3028 (x2) Washer (Nylon) 6x10x3
3009 (x2) Ball-and-Socket

Joint d6
3032 (x2) Ball-and
-Socket Joint d6
3012 (x2) M6x30 Bolt

3010 (x2) M6 Nut
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Xenon 2
RST
3014 (x2) M6x35 Bolt 3011 (x2) Pusher 12x120
3006 (x2) Pedal Unit
3018 (x6) Washer (Black

Nylon) d6.4x18x2
Antislip Band 3x
3010 (x2) M6 Nut
Ball-and-Socket Joint d8
3033 (x2) Nut (Nylstop) 1/4”-28

3009 (x2) Ball-and-Socket
Joint d6
3012 (x2) M6x30 Bolt Counter

Component
3008 (x6) Rivet 5x16
3007 (x2) Aluminium Angle Section (30x30x3)
Edition 1 24 Aug 2009 3027 (x4) M8x20 Bolt ( ▲▲

▲▲)
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3.6 Replacing the Master Bearing

See the figure in subsection 3.2 (page 3-5).
1. Unscrew and remove nut 6144, washer 6115 and nut 6125 from master axle 6123.
2. Screw out bolts 6129, remove stop base 6118 of rotor blade self-aligning movement (blade
stopper plate).
3. Remove head 6110 from prerotation disc 6117.
4. Heat up the head by means of an electric heater to attenuate the bond through Loctite
(green), and next remove bearing 6122 by means of the press.
5. Remove the residue of Loctite by means of sandpaper.
6. Apply a new layer of Loctite in the bearing socket.
7. By means of the press, place the new bearing in the head.
8. Assemble back the whole.
3.7 Tightening Moments

The table below shows the general recommended values of the tightening moments of bolts and
nuts.
thread Nm in×lb
M5 5-6 45-55
M6 7-10 60-90
M8 7-24 60-210
M10 10-38 90-335
M12 >12 >105

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Aviation Service Work, Operational Materials Chapter 4
Chapter 4 Service Work, Operational Materials

4. page
4.1 Introduction ................................................................................................. 4-2
4.2 Range of Service Work which can be Conducted by the Pilot ................... 4-2
4.3 Oil System.................................................................................................... 4-3
4.4 Engine Head Cooling System...................................................................... 4-3
4.5 Brake Fluid................................................................................................... 4-4
4.6 Air, Oil and Fuel Filters .............................................................................. 4-4
4.7 Lubrication Schedule .................................................................................. 4-5

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4.1 Introduction
The owner/user is responsible for conducting servicing at the right time as described in this
manual.
4.2 Range of Service Work which can be Performed by the Pilot

Being the owner and operator of the gyrocopter, the pilot can perform the following service
work. Then he should write the service work executed into the gyrocopter book and confirm it
with his signature and the licence number held (the qualification certificate).
1. Removing the undercarriage wheels; replacing the wheels; replacing the tyres; cleaning and
servicing the wheel bearings. Removing and fitting the brake components in the range
required in removing the wheels; removing the brake blocks unless specialist tools are
required. Replenishing the fluid in the braking system. Removing and fitting the tail wheels.
2. Replacing the damaged safety wires or cotter pins, except those belonging to the engine, the
drive transmission system, the flight control system and the rotor.
3. Repairing the upholstery and equipment of the cockpit interior.
Repairs inside the cockpit do not require dismantling any structural components or control
systems, and also they do not collide with these systems or interfere with the gyrocopter
structure.
4. Repairs that do not require welding, repairing the fairings and non-structural covers and
shields.
5. Replacing the safety belts.
6. Replacing the chairs and their parts.
7. Replacing the light bulbs, headlights, reflectors, lenses and lights.
8. Replacing all the shields not requiring to dismantle the propeller, disconnect the engine or
the control systems.
9. Replacing the ignition plugs, cleaning, checking the slot.
10. Replacing and servicing the battery.
11. Assembling and dismantling the blades and the rotor hub, which are designed so it is
possible to do it without using special tools.
12. Replacing the VHF equipment unless it is integrated with the navigation equipment.
13. Making and placing the required plaques and descriptions in the cockpit.
14. Lubricating the gyrocopter components (along with a prior cleaning of the hinges).
15. Checking air filters (removing, cleaning, fitting, replacing).
16. Checking fuel filters (removing, cleaning, fitting, replacing).
17. Replacing the engine oil; removing, cleaning, fitting, replacing the oil filter.


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4.3 Oil System

Engine oil of class 10W50 must be applied.
Recommended oil: Castrol 10W50 4T Racing.
Standard quantity of oil in the system: 3,5 dm3.
All work related to servicing the oil system, including: checking the oil level and its
replacement, deaerating the system, rinsing the system, replacing and checking the oil filter are
described in the Service Manual of Rotax engines.
Replacing the oil must be performed every 100 hours of engine work.
Setting up the Oil Cooler:

If the temperature of the oil is not correct, it is possible to change the position of the oil
cooler. If you want to change the position of the oil cooler, cut the band clips (red) and move the
cooler along the consoles to which it is fixed. Moving the cooler upwards gives a higher
temperature of oil in the circuit, whereas moving it downwards gives a lower temperature. After
setting up the cooler in the appropriate place, fix it by means of new band clips (6 pieces).
4.4 Engine Head Cooling System

Losses of the cooling fluid during usage must be replenished with distilled water.
The cooling fluid must be replaced completely every 2 years.
To fill in the cooling system it is necessary to apply a mixture of glycol and water with the 50:50
ratio.

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The system capacity amounts to 4.5dm3.

All work related to servicing the engine head cooling system, including: replacing the fluid,
and rinsing the system is described in the Service Manual of Rotax engines.

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4.5 Brake Fluid

The DOT 4 fluid is recommended for application with the wheel braking hydraulic system.
The fluid must be replaced not less than every 3 years. 0.5 dm 3 of the fluid must be prepared for
replacement.
To replace the brake fluid, it is necessary to unscrew completely the deaerator at the brake
pump mounted on the control stick and substitute it for a special deaerator with a transparent tube,
delivered with the factory kit, next mount the applicator (syringe) in the tube filled with a new
fluid. Unscrew the deaerator at the brake cylinder of one of the wheels. By moving the brake lever
and forcing in the fluid with the applicator, it must be forced through the system, and the old fluid,
flowing out through the deaerator at the wheel, must be gathered into a vessel. Make sure the
system is deaerated. Tighten the deaerator at the first wheel, unscrew one at the second and repeat
the actions. Screw out the special deaerator with the tube and change it to the original one. After
deaeration, tighten all the deaerators. Check that the system is leakproof.
CAUTION: due to the aggressive nature of the fluid, secure with paper or a cloth the places of
the deaerator at the brake pump mounted on the stick so it does not get onto other
gyrocopter components. Look after your own safety. Finally, cleanse all the
surfaces of the fluid.
4.6 Air, Oil and Fuel Filters

All the work related to replacing and cleaning air, oil and fuel filters is described in the
Service Manual of Rotax engines.

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4.7 Lubrication Schedule

Before lubrication, the parts must be cleansed of dirt and the residue of the old lubricant.
Lubrication after 50 and 100 hours must be performed during overhauls respectively: 50-hour/half-
year or 100-hour/yearly, depending on the mode of performing overhauls (see subsection 5.1).
Lubrication Lubricating
No. Lubricated Parts
Frequency Agent
1 Bendix sprocket and the wheel rim of the prerotation toothed wheel 10 hours WHS2002
2 Bowden tips in the rudder control system. 25 hours WD40
(+ after the first 10 hours) ←uwaga
3 Pusher tips for controlling the rotor head. 25 hours WD40
4 Door hinges. 50 hours WD40
5 Rudder hinges. 50 hours WHS2002
6 Rudder control pedals. 50 hours WHS2002
7 Head tilting pin and the head sloping pin. 50 hours WHS2002
8 Pin for rotor hub suspension on the head (teeter bolt) and slip sleeves. 50 hours *) WHS2002
9 Head joints (components nos. 6119 and 6124) and their nylon washers. 100 hours WD40
10 Lines from the suction, throttle and prerotation levers as well as their 100 hours WHS2002
passes.
11 Suction lever and prerotation axles. 100 hours WHS2002
*) The pin for rotor hub suspension on the head (teeter bolt) and the slip sleeves work in a
space filled with lubricant inside the rotor hub cube. Replacing the lubricant should take
place when replacing the pin and the sleeve every 250 hours of flight. Moreover, the pin and
the sleeves should be cleaned and covered with a layer of lubricant whenever the rotor is
fitted on the head.

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This page is left blank deliberately.

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Aviation Schedule of Overhauls and Service Work Chapter 5
Chapter 5 Schedule of Overhauls and Service Work

5. page
5.1 Introduction.................................................................................................. 5-2
5.2 Overhauls and Servicing as per Flight Time ............................................... 5-2
5.3 Overhauls and Servicing as per the Calendar.............................................. 5-2
5.4 Overhaul after the First 10 (25) Hours of Flight.......................................... 5-3
5.5 Service Work Every 10 Hours of Flight...................................................... 5-3
5.6 25-, 50- and 100-Hour Overhauls................................................................ 5-4
5.7 Other Service Work .................................................................................... 5-7

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5.1 Introduction
The owner/user is responsible for conducting overhauls and service at the right time as
described in this manual.
Overhauls and servicing must be performed basically depending on flying time. However, in
case of slightly intensive utilization (below 100 hours of flight during the year), it is necessary to
proceed to the calendar mode. If the intensity of utilization is diverse, the dates of overhauls and
servicing must be specified by applying a more restrictive criterion at a given moment - as per
flying time or the calendar.
Basically, three overhaul deadlines have been distinguished:
• 25 hours,
• 50 hours / half a year,
• 100 hours / 1 year.
Part of check activities must also be performed after the first 10 (25) flight hours. Some
service activities must be performed every 10 hours of flight, while others (replacing the parts or
operational fluids) after longer periods, eg every 250 or 500 hours of flight, or every 3 years. The
detailed schedule for overhauls and service work is in subsections, 5.4, 5.5, 5.6 and 5.7.
Overhauling and servicing the gyrocopter should be registered in the form of reports and
recorded in the Gyrocopter Book, in which the deadlines for successive overhauls should be
specified.
Overhauling and servicing the engine and the systems related to it
should be performed according to the instruction manual of the CA 912 ULT engine.
5.2 Overhauls and Servicing as per Flight Time

A 25-hour overhaul must be performed after 25 hours of flight (±2.5 hours) after the last
100-hour or 50-hour overhaul, or from the start of utilization.
A 50-hour overhaul must be performed after 50 hours of flight (±5 hours) after the last 100-
hour or from the start of utilization.
A 100-hour overhaul must be performed after 100 hours of flight (±10 hours) after the last
100-hour or from the start of utilization.
Admissible time tolerances for performing an overhaul do not add up. For example, (in case
of a constant specification of deadlines for overhauls as per flight time) the fourth 100-hour
overhaul should be performed after 400±10 hours of flight time rather than after 400±40 hours.
Performing an overhaul earlier than the admissible tolerance requires the commencement of
calculating successive overhauls anew, from the current flying status.
5.3 Overhauls and Servicing as per the Calendar

A 25-hour overhaul must be performed not later than after 25 hours of flight after the last
yearly or half-yearly overhaul, or from the start of utilization.
A half-yearly overhaul must be performed after 6 months (±1 month) after the last yearly
overhaul or from the start of utilization.


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A yearly overhaul must be performed after 12 months (±1 month) after the last yearly
overhaul or from the start of utilization.
Admissible time tolerances for performing an overhaul do not add up. For example, (in case
of a constant specification of deadlines for overhauls as per the calendar) the fourth yearly
overhaul should be performed after 48±1 months rather than after 48±4 months. Performing an
overhaul earlier than the admissible tolerance requires the commencement of calculating
successive overhauls anew, from the date of a performed overhaul.
5.4 Overhaul after the First 10 (25) Hours of Flight

No. Activity Deadline Notes
10.1 Checking the tightening moments of the bolts 10 M6 bolts: 10 Nm ± 1 Nm
fixing the rotor mast. M8 bolts: 24 Nm ± 1 Nm
10.2 Checking the tightening of the remaining bolts 10 If at least one bolt/nut loosens, tighten all the cooperating
of the fuselage structure (visually on the basis of bolts/nuts. The moment values according to subsection 3.7.
the paint marker).
10.3 Checking that all the pushers are straight and in 10
good condition.
10.4 Checking clearances (wear) in the control stick 10
system.
Checking the condition and security of the rear
flexible mounting of the torsional pipe.
10.5 Checking the condition of rudder bowdens for 10 Apply WD40; remove the excess.
rubbed spots, corrosion, excessive friction as
well as signs of the wear of the tips.
Checking the connection of the tips to the pedals
and to the control surfaces. Lubricating the tips.
10.6 Checking the clamping rings fixing the rudder 10 Replace even if they are only slightly damaged.
bowdens to the tail pipes.
10.7 Checking that the drive shafts are not bent or 10 Lubricate the belts with talc if drive transmission is not
damaged. fluent.
Checking that the gear belts are not cracked or If the belts are worn-out or damaged, replace them. Both
damaged otherwise. belts must always be replaced simultaneously.
10.8 Checking the fixing of the instruments to the 10
board and the connection of the electrical and
pneumatic leads to the instruments.
10.9 Checking that the tail wheels are not damaged or 10 Clean the axles and ensure the freedom of wheel rotation.
their clamping rings are not bent.
25.1 Checking that the rotor swing stops ensure 25 Nylon sleeves (6135) cannot be squeezed too firmly.
swing freedom ±10º.
5.5 Service Work Every 10 Hours of Flight

Activity Notes
Checking pressure in the tyres and that they Pressure in the tyres:
are not damaged or worn-out. standard: 2 bars; tundra: 1.5 bars.
Cleaning and lubricating the bendix Apply WHS2002.

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sprockets. Fixing the bendix on the head control lever, ensure

an apical clearance between the bendix toothed
wheels and the toothed-wheel rim is about 1 mm.


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5.6 25- , 50- and 100-Hour Overhauls

Explanation of the meanings of the columns:
25 - 25-hour overhaul
50 - 50-hour or half-yearly overhaul
100 - 100-hour or yearly overhaul
No. Activity 25 50 100 Notes

Airframe (Fuselage, Tail Beams, Control 25 50 100
Surfaces, Mast)
01 Checking the outside surface of the fuselage for ● ●
cracks or deformations.
02 Checking the airframe for damage, twists, ● If detected, the gyrocopter must be grounded and
buckling or other deformations. contact the manufacturer to specify the way to restore
airworthiness.
03 Checking the tightening moments of the bolts ● M6 bolts: 10 Nm ± 1 Nm
fixing the rotor mast. M8 bolts: 24 Nm ± 1 Nm
04 Checking the tightening of the remaining bolts ● If at least one bolt/nut loosens, tighten all the
of the fuselage structure (visually on the basis of cooperating bolts/nuts. The moment values according
the paint marker). to subsection 3.7.
05 Checking the fixing of the horizontal stabilizer ● ● ● The bolts are fixed by using blue Loctite. The contact
to the vertical stabilizers (4 bolts). surfaces of the stabilizers are sealed with silicone.
06 Checking the fixing of the vertical stabilizers to ● ● ● Remove loose or damaged rivets and replace them
the tail pipes (rivets). with new ones.
Flight Control Systems 25 50 100

10 Cleaning and lubricating the rotor head control ● ● ● Apply WHS2002; remove the excess.
pusher tips.
11 Checking the condition of the rotor head control ● Check the safety screws (blue Loctite).
pusher tips for cracks, movement freedom in the
full range.
12 Checking that the head reaches the stops in ● Check the displacement of the control stick (see
sloping and tilting it. figures, subsection 8.3).
13 Checking that all the pushers are straight and in ●
good condition.
14 Checking clearances (wear) in the control stick ● ● ●
system.
Checking the conditions and security of the rear
flexible mounting of the torsional pipe.
15 Checking the freedom of pedal movement. ● ●
Lubrication. WHS2002 lubricant.
16 Checking the condition of rudder bowdens for ● ● ●
rubbed spots, corrosion, excessive friction and
signs of the wear of the tips.
Checking the connection of the tips to the pedals
and the control surfaces.
Lubricating the tips. Apply WHS2002; remove the excess.

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17 Checking the rudders for operation freedom and ● ● ● If the control surface is excessively loose, contact the
clearances. manufacturer. Do not fly with damaged hinges.
Lubricating the hinges (every 50 hours). WHS2002 Lubricant.
18 Checking the clamping rings fixing the rudder ● ● ● Replace even if they are only slightly damaged.
bowdens to the tail pipes.
19 Checking the operation of the trimmer and the ● ● ● The line must be replaced to a new one even with the
condition of the line, stop, block and spring. smallest traces of wear (rubbed spots).
Undercarriage, Legs, Wheels, Brake System 25 50 100

20 Checking the wheel bearings for fluency work. ● Non-service bearings, sealed permanently.
21 Checking that the front wheel fork is not bent. ● Replace if bent.
If movement resistance is found, dismantle the fork,
lubricate with WHS2002.
22 Checking the undercarriage legs and their ● The spacing of the master undercarriage wheels in the
mounting to the fuselage for damage or signs of new gyrocopter amounts to 2.2m. The overall
material wear (cracks, deformations). maximum admissible opening amounts to 10 cm.
Replace in case of an overly large spacing.
23 Checking pressure in the tyres and that they are ● ● Pressure in the tyres:
not damaged or worn-out. standard: 2 bars; tundra: 1,5 bars.
24 Checking the wear of the wheel brake linings. ● ● Replace if need be.
If the brake blocks rub the disc or an uneven wear of
the linings occurred, unscrew the bolts fixing the brake
disc to the wheel hub and check the hammering of the
disc.
Rotor Head, Rotor, Blades, Hub 25 50 100

30 Checking the fixing of the toothed-wheel rim to ● M8 bolts: 24 Nm ± 1 Nm.
the head as well as fixing bolts.
31 Checking the pins for damage or wear. ● ●
Detaching, cleaning, lubricating and renewed
attaching. WHS2002 lubricant.
1. Pin for rotor hub suspension on the head
(teeter bolt);
2. Head tilting pin;
3. Head sloping pin.
32 Checking and lubricating the slip sleeves of the ● ● Replace if worn-out. WHS2002 lubricant.
pin for rotor hub suspension on the head (teeter
bolt).
33 Checking the head joints (components nos. ● Lubricating from the outside with the WD-40 agent is
6119 and 6124) and their nylon washers. recommended.
Detaching, cleaning, lubricating and renewed
attaching.
34 Checking the condition of the brake lining on ● The maximum wear of the cooperating frictional
the rotor head disc and the frictional component components amounts to 0.5 mm. If need be, replace
of stainless sheet metal. them with original parts.
35 Checking the operation of the rotor brake. ● ● ● If the contact of the frictional component with the
brake lining is not correct (full), adjust its position to
ensure the most effective braking.
36 Total cleaning of the hub and the rotor blades. ● Detach the blades from the hub.
Checking the condition of the connection of the After cleaning, the hub must be covered with a layer of
hub and the blades. WD-40. Attaching and aligning the rotor according to
Aligning the rotor blades. IUL subsection 4.2. Apply new nuts on the bolts fixing
the blades to the hub.

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37 Checking that the rotor swing stops ensure ● Nylon sleeves (6135) cannot be squeezed too firmly.
swing freedom ±10º.
38 Checking blade tracking and rotor balance. ● ● ● An admissible deviation of tracking amounts to 3 cm.
Visual evaluation on the rotating rotor. In case of a major deviation or sensible vibrations
generated by rotor imbalance, contact the
manufacturer.
39 Checking the rotation freedom of the pin for ● ● ● Tighten the nut to the first contact, and next unscrew it
rotor hub suspension on the head (teeter bolt) by 1/4 of a rotation. (Secure with the cotter pin).
and tightening the nut.
40 Checking the tightening moments of the bolts ● ● ● 22 Nm
and nuts clipping the blades and rotor hub.
41 Checking the condition of the rotor blades for ● ● ● Repairs to be done only by the manufacturer of the
damage. blades or an authorized representative.
Drive Transmission - Prerotator 25 50 100

44 Checking that the gear belts are not cracked, ● ● ● If the belts are worn-out or damaged, replace them.
overly stretched or damaged otherwise. Both belts must always be replaced simultaneously. If
drive transmission is not fluent, lubricate the belts with
talc.
45 Checking the angle section of the prerotation ● If the angle section is damaged, it must be replaced.
clutch brake.
46 Checking the movement freedom of the drive ● Rotate the shaft manually, observing the drive
shafts and clearances in the bearings. transmission system.
47 Checking the correct meshing of the bendix ● ● ● Lubrication every 10 hours (see subsection 5.5).
sprocket with the toothed-wheel rim of the head
disc.
Propeller 25 50 100
50 Checking blade tracking and propeller balance. ● ● ● In case of a noticeable deviation of blade tracking or
Visual evaluation on the rotating propeller. sensible vibrations generated by propeller imbalance,
contact the propeller manufacturer.
fixing the propeller (hub) to the engine shaft.
and nuts clipping the blades and the propeller
hub.
53 Checking the condition of the propeller blades ● ● ● Repairs to be made only after arrangement with the
for damage. propeller manufacturer.
Fuel System 25 50 100

60 Replacing or cleaning the fuel filter. ●
61 Checking the fuel inlet plug for gasket wear and ●
fixing reliability.
62 Checking the correct work of the fuel gauge. ● The indication of the fuel gauge must correspond with
the fuel level in the tank.
63 Checking that the ventilation fuel tanks are ●
unblocked.

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64 Checking that the fuel tank does not contain ● Rinse the tanks if need be.
pollutants.
65 Checking all fuel conduits for damage or wear. ● Replace if need be.
Electrical System, Board Instruments 25 50 100

70 Checking the fixing of the instruments to the ● ●
board and the connection of the electrical and
pneumatic leads to the instruments.
71 Checking the battery. ● ● Keep the battery charged and the appropriate level of
electrolite.
72 Calibrating the speedometer. ●
73 Calibrating the compass (if attached). ●
74 Calibrating the altimeter. ●
75 Checking the instruments. ●
Other 25 50 100
80 Checking that the tail wheels are not damaged ● ● ● Cleanse the axles and ensure the rotation freedom of
or their clamping rings are not bent. the wheels.
81 Checking the fixing of the central console. ● ● ● Check that the fixing screws are tight (screws mounted
on red Loctite).
82 Cleaning and lubricating the lines of the suction ● WHS2002 lubricant.
lever, throttle and prerotation and their passes.
83 Cleaning and lubricating the suction lever and ● WHS2002 lubricant. Do not lubricate the throttle liver
prerotation axles. axle or frictional washers.
84 Checking that the plaques and information tags ● ●
are legible and comply with the restrictions.
85 Checking the fixing of the crew belts, that the ● ●
bolts are tight and secure.
86 Checking that the crew belts are not damaged or ● ●
frayed as well as the condition and certainty of
the operation of the clipping clasp.
5.7 Other Service Work

No. Activity Period Notes
91 Replacing the pin for rotor hub suspension Every 250 hours The maximum admissible clearance between the rotor
on the head (teeter bolt) and the slip sleeves. hub and the sleeves amounts to 0.025 mm.
92 Checking that the drive shafts of the Every 250 hours
prerotation system are not bent or damaged.
93 Replacing the master bearing. Every 500 hours The tightening moment of the bearing bolt: 90 Nm ± 2
Nm (plus the crown washer).
The distance between the rotor rotation sensor and the
prerotation wheel disc = 1 mm.

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94 Replacing the brake fluid. Every 3 years See subsection 4.5.

95 Replacing the ventilation ducts of the fuel Every 3 years or if cracked or rubbed.
tanks.
96 Specifying the weight and position of the not less than After every change of the distribution of weights in the
centre of gravity of the empty gyrocopter. every 4 years gyrocopter (eg after repairs, changes in the fixed
equipment)
97 Draining the fuel and rinsing the fuel system If fuel is left in the system for a time longer than 3
with clean fuel. months.

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Aviation Weighing and Specifying the Position of the Centre of Gravity Chapter 6
Chapter 6 Weighing and Specifying the Position

of the Centre of Gravity
6. page
6.1 Introduction ................................................................................................. 6-2
6.2 Position of the Centre of Gravity and a Datum Reference.......................... 6-2
6.3 Weighing and Specifying the CG Position by a Suspension Method.......... 6-3
6.4 Weighing and Specifying the CG Position by a Three-Scales Method....... 6-4

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Aviation Weighing and Specifying the Position of the Centre of Gravity Chapter 6
6.1 Introduction
Check weighing and specifying the position of the centre of gravity of the empty gyrocopter
must be performed not less than every 4 years, and also in every case in which a change of weight
or weight distribution can occur, e.g. after doing repairs, painting, introducing structural changes,
building in new or replacing fixed equipment with other.
6.2 Position of the Centre of Gravity and a Datum Reference

The position of the centre of gravity of the gyrocopter (a sideways view) is specified with the
value of the angle whose apex is located on the transverse axis of rotor head suspension on the mast,
one arm is parallel to the vertical axis of the coordinate system related to the fuselage, and the
second arm passes through the centre of gravity of the gyrocopter.
The Cartesian coordinate system, based on the fixed fuselage surfaces as on the figure below,
is helpful in specifying the position of the centre of gravity by a method of three-scales placed under
the undercarriage wheels.
In practice, to level the gyrocopter, use the upper flat surface of the tunnel inside the cockpit
between the chairs.


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Weighing and Specifying the Position of the

Aviation Centre of Gravity
Chapter 6
6.3 Weighing and Specifying the CG Position by a Suspension Method

A method of suspending the gyrocopter is a basic weighing method and specifying the
position of the centre of gravity applied by the manufacturer. It involves suspending the gyrocopter
(without the lift rotor) by the pin fixing the hub to the rotor head on dynamometric scales.
The gyrocopter weight is equal to a sum of the (net) weight read from the scales on which it
was suspended and the weight of the rotor which to be weighed separately.
The position of the centre of gravity is specified by means of an accurate level (accuracy
0.1º) held on the upper flat surface of the tunnel inside the cockpit between the chairs. Besides, it is
important that the control stick is not blocked (there is the freedom of sloping the rotor head).
The admissible range of the position of the centre of gravity of the empty gyrocopter is:
-0,5º ÷ +0,5º
The actual weight and the position of the centre of gravity of the empty gyrocopter for a
specific specimen is located in the up-to-date weighing report and is stated in subsection 6.4 of the
Flight Manual.

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Weighing and Specifying the Position of the

Aviation Centre of Gravity
Chapter 6
6.4 Weighing and Specifying the CG Position by a Three-Scales Method

A method of three-scales put under the wheels of the undercarriage is more intelligible for
the users. When put on scales, the gyrocopter must be levelled by means of an accurate level held
on the upper flat surface of the tunnel inside the cockpit between the chairs. The gyrocopter can be
weighed both with the rotor fitted and without it. It is central for the accurate specification of the
position of the centre of gravity that the rotor head axis be set up precisely vertically.
The gyrocopter weight is equal to a sum of (net) indications of all the three scales (plus the
rotor weight provided it was detached when weighing the gyrocopter).
M = WF + WRL + WRR (+ MR)
The position of the centre of gravity along axis X is calculated from the following formula:
WF × a + (WRL + WRR ) × b
xcg =
WF + WRL + WRR
where:
W – gyrocopter weight
WF – weight indication under the front wheel
WRL – weight indication under the rear left wheel
WRR – weight indication under the rear right wheel
WR – rotor weight
a = 1740 mm – axis coordinate of the front wheel
b = 90 mm – axis coordinate of the rear wheels
xcg [mm] – coordinate of the centre of gravity of the gyrocopter
Caution
The theoretical values of dimensions a and b are stated above.
The values must be measured when weighing and insert the actual values into the formula.
The admissible range of the position of the centre of gravity of the empty gyrocopter is:
188 ÷ 212 mm

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Aviation Durability of the Structural Components Chapter 7
Chapter 7 Durability of the Structural Components

7. page
7.1 Introduction ................................................................................................. 7-2
7.2 Operation Time of the Units ....................................................................... 7-2

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Aviation Durability of Structural Components Chapter 7
7.1 Introduction
Observing the admissible operational time of the individual units and parts as well as
replacing them or conducting a complete overhaul at the right time is a responsibility of the
owner/user. Complete overhauls are executed by or through the agency of the gyrocopter
manufacturer - Celier Aviation.
Replacing or overhauling completely the individual units and parts of the gyrocopter should
be recorded in the Gyrocopter Book.
Replacing the subunits and components of the engine and systems related to them should be
performed in accordance with the instruction manual of the CA 912 ULT engine.
7.2 Operation Time of the Units

The time is stated in flight hours or years from the date of being built in the gyrocopter, and
in case of the engine - working hours or in years from the date of being built in.
Structural Unit or Component Operation Time

Fuselage as a whole 6000 hours
Rotor mast 2000 hours replacement
Rotor (blade, hub) 2000 hours replacement
500 hours complete overhaul
Rotor head
2000 hours replacement
Pin for rotor hub suspension on the head (teeter 250 hours replacement
bolt) and the slip sleeves
Bolts clipping the rotor hub 500 hours replacement
Bolts and nuts fixing the rotor blades 1000 hours replacement
Master bearing 500 hours replacement
Propeller 600 hours complete overhaul
Propeller bolts 600 hours complete overhaul
Undercarriage legs 2000 hours replacement
Head control system pushers 2000 hours replacement
Bowdens in the rudder system 500 hours replacement
V-belts in the prerotation clutch 250 hours replacement
Tensioner wheel master bearing (6209) 500 hours replacement
in the prerotation clutch
Engine 1500 hours or 15 years complete overhaul
Rubber sleeves (dampers) of the engine frame 1500 hours replacement

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Aviation Durability of the Structural Components Chapter 7
Fuel pump 1000 hours or 5 years replacement

Fuel conduits 500 hours or 2 years replacement
Oil conduits 500 hours or 2 years replacement
Fuel tank ventilation ducts 3 years replacement

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Aviation Adjustment Data and Deflections of the Control Components Chapter 8
Chapter 8 Adjustment Data and Deflections

of the Control Components
8. page
8.1 Introduction.................................................................................................. 8-2
8.2 Angular Range of Rotor Head Movements.................................................. 8-2
8.3 Range of Control Stick Movement ............................................................. 8-4
8.4 Leg Flying Controls, Rudders and Relieving Flap...................................... 8-6
8.5 Prerotation Clutch ....................................................................................... 8-7

Change no.:

Aviation Adjustment Data and Deflections of the Control Components Chapter 8
8.1 Introduction
Chapter 8 states the design deflection values of the control components along with
admissible tolerances, and also some adjustment data which must be checked.
8.2 Angular Range of Rotor Head Movements
Head Deflection
Parking position and braking the rotor: -2° (+1°/-1°) extreme front
Position during horizontal flight: 7°
Rear position: 19° (+1°/-1°) extreme rear


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Adjustment Data and Deflections of the Control

Aviation Components
Chapter 8
Head Tilt
The maximum angles of head tilts to the left and right amount to 8° (+1°/-1°)
The extreme values of the deflection and tilting angles of the rotor head are determined by the
head structure and its suspension, and they are not adjustable.

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Aviation Components
Chapter 8
8.3 Range of the Control Stick Movement
Cowl Panel Edge
Vertical Position (Corresponds to 7o Head Deflection)
* dimensions (in millimetres) are measured in the horizontal from the cowl panel edge to the
centre of the control stick.
Position 1 corresponds to the extreme front deflection of the rotor head (-2°).
Position 2 (vertical) corresponds to the passing deflection of the rotor head (7°).

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Aviation Components
Chapter 8
Position 3 corresponds to the extreme rear deflection of the rotor head (-19°).

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Aviation Components
Chapter 8
Position 1 corresponds to a rotor head tilt to the left (8°).

Position 2 (vertical) corresponds to a neutral rotor head tilt (0°).
Position 3 corresponds to a rotor head tilt to the right (8°).
Adjusting the neutral position and control stick deflections is performed by changing the length of
the upper pushers controlling the rotor head.

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Aviation Components
Chapter 8
8.4 Leg Flying Controls, Rudders and Relieving Flap

With the neutral positions of the pedals of the leg flying controls, both rudders should be
deflected by 2º to the right (against the planes of the vertical stabilizer chords). Adjusting the
neutral position of the control surfaces is possible by fixing appropriately the bowdens to the
consoles on tail beams.
The maximum deflection angles of the control surfaces amount to 20º ÷ 25º to the right and
left against the neutral position. The values are much higher from the maximum deflection angles
which can occur in flight. They are not adjustable.
The relieving flap is preset after the phase of test flights. The aim of applying it is to
facilitate flight straight ahead without the necessity to use pedals by the pilot. If the need arises,
you can correct the flap position by delicately bending it in or out. It is not allowed to strain the
control surfaces too firmly as they can become damaged. The flap is stuck with polyurethane glue.
Bending the flap to the left deflects the flight direction of the gyrocopter to the right, and inversely.

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Aviation Components
Chapter 8
8.5 Prerotation Clutch
Figure 1
Active Brake Disconnected clutch
Optimal Contact Point - Brake foot clamps V-belts to

the driven wheel.
- Checking (adjusting) the
dimensions as per the figure;
1-2 mm clearance on the
activating line.
Figure 2
Inactive Brake
Activated clutch
- Inactive brake.
- The tightening wheel strains
Active Tightening Wheel
the V-belts, as a result, the
driving wheel can transmit
Spacer Mandrel the torque to the prerotation
system.
- With a full strain, the V-
belts do not touch the spacer
mandrel.

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Aviation Components
Chapter 8
CAUTION!
When the belts are new, before every use of prerotation remember to sprinkle them with
children’s powder or graphite powder. This action will allow the fluent work of the clutch
and avoiding violent drive transmission.

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Aviation Components
Chapter 8

Change no.:

Aviation Other Service Information Chapter 9
Chapter 9 Other Service Information

9. page
9.1 Manoeuvring on the Ground, Road Transport ............................................ 9-2
9.2 Cleaning and Maintenance .......................................................................... 9-2
9.3 Repairs and Modifications .......................................................................... 9-2

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Aviation Other Service Information Chapter 9
9.1 Manoeuvring on the Ground, Road Transport

When transporting or moving the gyrocopter, the control stick should always be immobilized
with a turnbuckle.
For road transport (on a trailer, in a container), detach the rotor (see subsection 3.1.2) and fix
the gyrocopter to the base by the undercarriage legs.
Moving the gyrocopter on the ground should be performed with great caution by using a
forked drawbar, grappled by the front wheel axle or a rope grappled by the front leg.
When parking with the rotor fitted, tie the rotor to the fuselage by means of turnbuckles with
pockets fitted on the blade tips or by using two tapes.
9.2 Cleaning and Maintenance

The outside surfaces of the fuselage, rotor and propeller must be washed with water with an
addition of mild soap. Hard-to-wash stains of lubricant or oil can be removed by means of a piece
of cloth wetted with heavy aliphatic petrol.
For seasoned painted surfaces, you can use any high-grade waxes or an abrasive compound
of the automotive type. Soft fabrics or suede must be used for polishing.
The glazing is to be rinsed with clean water or a water solution with an addition of mild soap
and next wiped up with clean soft fabric, sponge or suede. Exercise great caution with it to avoid
scratches.
CAUTION:
To clean the glazing do not apply agents containing alcohol!
The cockpit interior, chairs, rugs and upholstery should be cleaned with a vacuum cleaner. It
is recommended to apply commercially available cleaning agents for car upholstery, however, the
guidelines located on the wrapping must by strictly observed.
Clean the engine in accordance with the Engine Manual.
9.3 Repairs and Modifications

All repairs and modifications in the structure can be conducted only by authorized personnel
and in an agreement with the gyrocopter manufacturer.
CAUTION:
Before performing any modification of the gyrocopter,
contact the aviation authority to make sure the planned modification
will not undermine gyrocopter airworthiness.
On performing a repair or modification, weigh the empty gyrocopter and specify the position
of its centre of gravity as well as record the data in the table in subsection 6.4 of the Flight Manual.


Aviation List of Notices and Markings Chapter 10
Chapter 10 List of Notices and Markings

10. Page
10.1 Introduction ................................................................................................. 10-2
10.2 Notices and Markings ................................................................................. 10-2

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10.1 Introduction
Chapter 10 presents all the operational and warning notices and markings as well as their
placement on the gyrocopter.
10.2 Notices and Markings
notice or marking description, placement
On both sides of the fuselage, at every
ULTRALIGHT entrance to the fuselage, made with

letters at least 4 cm in height.
This aircraft has received an authorization to perform Inside the cockpit in a visible place.
flights in the “ULTRALIGHT” category
and does not meet the requirements regarding
the broad and detailed regulations on airworthiness,
which are based on Annexe 8
to the Convention on International Civil Aviation
AEROBATIC MANOEUVRES ARE BANNED

Straight ahead of the pilot.
I
A
SVNE = 210 km/hVY = 105 km/hVA = 80 km/h
1 os.V = 95 km/hVmin = 30 km/hVA = 90 km/h
X
I
2 os.
A
SVNE = 113 ktVY = 57 ktVA = 43 kt
1 os.V = 51 ktVmin = 16 ktVA = 49 kt
X
2 os.
Speed plaque
On the cowl panel, straight ahead of the pilot, one of the
presented plaques depending on the scaling of the
speedometer
SOLO FLIGHT (kg)PILOT50 - 6060 - 8080 - 100BALAST12108
SOLO FLIGHT (lb)PILOT110 - 132132 - 176176 - 220BALAST26,52217,5
Ballast equalization plaque for solo flights


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On the cowl panel, straight ahead of the passenger, one

of the presented plaques with values expressed in
kilograms or pounds
Level scale of fuel in the tanks

shows the total capacity of both tanks
On either tank container, from the
cockpit side (2 pieces)
Description of the control lever:

CHOKE - suction
BENDIX - toothed clutch
PREROTATOR - prerotation clutch
THROTTLE
On the central console
Do not grip!
On the outside of both winglets of the
horizontal stabilizer (2 pieces)
Fuel sort and the capacity of the tanks

Above the fuel inlet
Pressure in the tyres

On every undercarriage leg in a visible
place (3 pieces)
Battery
Before the undercarriage front leg,
between the bolts - the tips for
charging the battery

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Watch for the propeller!

On the engine casing, on the right and
left sides, respectively the top and
bottom arrows directed with the head
backwards
Master switch
Starter
On the instrument board under the
start-up button
Fuel pump
Magnetos
On the instrument board under the
switches
Microphone and earphone sockets

On the instrument board under every
pair of the sockets
The proper name of the type

On both sides of the fuselage
Maximum weight of the crew

On the instrument board


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Trimmer Electric sockets
On the left side of the instrument board over the socket

On the central console, before the trimmer strand

Change no.:

Aviation Supplements Chapter 11
Chapter 11 Supplements
11. page
11.1 Introduction ................................................................................................. 11-2
11.2 List of Introduced Supplements .................................................................. 11-2

Change no.:

Aviation Supplements Chapter 11
11.1 Introduction
Chapter 10 embraces appropriate supplements central to the safe and efficient operation of
the gyrocopter when it is equipped with various additional systems and equipment not applied in
the standard variant.
11.2 List of Introduced Supplements
Document no. Title of an attached supplement Notes
In the “Notes” column, confirm manually the existence of additional equipment or systems
in the gyrocopter specimen for which the following manual is intended.


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CELIER AVIATION

DATED …………………………………. NO. ………………………

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Chapter 0 Organizational Information

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Aviation Organizational Information Chapter 0

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Aviation Organizational Information Chapter 0

0.3 Table of Contents

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Chapter 1 General Information

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1.2 Basis for Acknowledging Airworthiness

1.3 Directives and Announcements of Airworthiness

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Chapter 2 Description of the Gyrocopter and its Systems

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2.1 General Description

2.1.1 Technical Data

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Aviation Description of the Gyrocopter and its Systems Chapter 2

Data of the power unit

2.2 Figure in Three Projections

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Aviation Description of the Gyrocopter and its Systems Chapter 2

2.3 Control Systems

Lifting Rotor Head

Wheel Brake Lever

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Aviation Description of the Gyrocopter and its Systems Chapter 2

2.3.2 Schema of the Spring-Operated Relieving Device - “Trimmer”

2450 Trimmer Line

2453 Trimmer Grip

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Aviation Description of the Gyrocopter and its Systems Chapter 2

2.3.3 Schema of the Directional Control System

Rudder Bar Lever

Page 2-6 Edition 1 24 Aug 2009