maintenance manual - trixy g 4-2 r · 2017. 5. 12. · maintenance manual g 4-2 revision 05a –...

Maintenance manual G 4-2 Revision 05A – 03.05.2017 Doc. No.: TA-M-D-002-EN 1

Maintenance manual

Trixy Aviation

Series

G 4-2


Maintenance Manual for Gyrocopter G 4-2

This manual contains information for basic maintenance and forms to document the performed maintenance, repairs and alterations done on the gyrocopter. The extent and state of revision of this manual may be obtained from the index and the revision index. Maintenance for the gyrocopter G 4-2 is to be performed ONLY by an authorized persons and/or aviation workshop in accordance with the instructions and intervals given in this manual as well as the manuals for engine and propeller.

This manual does not substitute the education of an aviation technician or the authorization of an aviation maintenance

workshop. IT is to be used in addition to the maintenance manuals of engine and propeller.

Revision: 05A Date issued: 03.05.2017

Sticker with individual gyrocopter date here!


REVISIONS TO THIS MANUAL

No. Description Page Date Name

01 Previous manual Rev. 3.0 All 03.05.17 R. Farrag


INDEX

1. GENERAL REMARKS 6

1.1 Introduction 6

1.2 Certification and Registration 7

1.3 Warnings and precautions 7

1.4 Description 8

1.5 Technical data 8

1.6 Side view, top view and front view 9

2 COMPONENTS 12

2.1 Introduction 12

2.2 Frame 13

2.3 Rotor 15

2.4 Rotor head 17

2.5 Rotor controls 31

2.6 Prerotator system 36

2.7 Propeller 41

2.8 Nose wheel and steering 45

2.9 Main gear 49

2.10 Main wheels and breaks 51

2.11 Empennage 52

2.12 Rudder controls 53

2.13 Dashboard 58

2.14 Engine 60

3 SYSTEMS 62

3.1 Introduction 62

3.2 Engine oil circuit 63

3.3 Engine coolant circuit 64

3.4 Engine ignition system 64

3.5 The fuel system 65

3.6 Electrical system 67

3.7 The hydraulic brake system 91

3 PERIODIC PREVENTIVE MAINTENANCE 94

4.1 Introduction 94

4.2 Maintenance after the first 25 hours 95

4.3 50 hour interval maintenance 96




4.6 Recommended overhalls 99

5 MAINTENANCE SERTIFICATES 100

6 DAMAGE OR ACCIDENT REPORTS 116

7 CERTIFICATES OF REPAIR AFTER DAMAGE 120

8 MODIFICATION CERTIFICATES 124


1 GENERAL REMARKS

1.1 Introduction

This manual contains information and instructions of the gyrocopter manufacturer, which must be made available to the operator of the gyrocopter to perform proper maintenance in accordance with the German regulations stated in (BUT). More details on engine and propeller maintenance are to be found in the manufacturer’s Maintenance manual for each item. Such details are very important and must be followed.

The operator is only permitted to exchange defective parts and/or components using original parts and/or components in an authorized aviation workshop after consulting the manufacturer of the gyrocopter. The operator must perform an annual inspection according to the German regulations. Such inspections must be approved and documented by an authorized inspector. DAeC as a German authority is currently overlooking these regulations and must be officially informed about annual inspections. Regulations in other countries must be taken in consideration, in case that the gyrocopter is registered in countries other than Germany.

The warranty provided by the manufacturer of the gyrocopter is only valid when maintenance is performed by an authorized person or authorized aviation workshop.

Technical defects, which may signal weak points in the design or the construction of the gyrocopter, must be reported without delay to the manufacturer of the gyrocopter.

Reporting incidents and accidents according to § 5 Luft VO in Germany or regulations in other countries are also to be reported to the responsible authority and the manufacturer of the gyrocopter.

Please use the forms at the end of this manual to report such defects.

All warranties provided by the manufacturer of the gyrocopter are void, in the event that one or more of the instructions in this manual are ignored.


Attention: means that the disregard of the corresponding procedure

leads to a reduction of flight safety over time.

Warning: means that the disregard of the corresponding procedure

leads to an immediate or major reduction of flight safety.

Note: attends to special issues which are not in direct relation to

flight safety, but are important or unusual.

1.2 Certification and Registration

The statutory basis for the operation of an ultra-light gyrocopter (ULG) is regulated in air traffic laws. Details are to be obtained from associated documents. All rules and regulations contained in these documents must be obeyed. The G 4-2 is constructed, manufactured and tested according to the construction regulations for ultra-light gyrocopters (BUT 2001) and Nfl II 13/09 dated 12.02.2009 and is registered under the identification number 61218 by the responsible German authority (DAeC).

1.3 Warnings and precautions

The following definitions are used for warnings, precautions and notes in this manual:


1.4 Description

• Gyrocopter with nose wheel steering

• Stainless steel frame welded in gas-shielded process

• Two seats in tandem configuration inside an open fuselage (model Liberty) or enclosed fuselage with removable hard top (model Princess). The fuselage and the canopy are made of carbon fiber composite.

• Main undercarriage strut, equipped with hydraulic brakes

• Rotor made of extruded aluminum profile

• Rotor head steering via push rods

• Rudder steering via steel wires

• Rudder and stabilizers made from CFC The series G 4-2 includes 2 models: Liberty and Princess.

Liberty is an entry-level model, which is designed to basically operate with an open cabin. However, this model can be converted with an optional kit to a closed version.

Princess is a top model, which is designed to basically operate with a closed cabin. This model can be converted with an optional kit to an open version. 1.5 Technical data

Length 4.90 m Width: 1.85 m Height: 2.80 m Empty weight: 265 - 310 kg (as equipped) Load capacity: 190 - 280 kg (as equipped) Max. Take-off weight: 500, 530 or 560 kg (as equipped) Tank capacity: 34 l / 68 l (as equipped)


Note: The three views are not to scale!

1.6 Side view, top view and front view (2 models)

The model Liberty


Note: The three views are not to scale!

The model Princess


Warning: This manual does not substitute the education of an aviation technician or the authorization of an aviation maintenance workshop. IT is to be used in addition to the maintenance manuals of engine and propeller. Attention: Only persons authorized by the gyrocopter manufacturer

are allowed to perform maintenance and repair works on the

gyrocopter. Persons to perform maintenance and repair works on

either engine or propeller must be authorized by the respective

manufacturer.

Note: All warranties are void in case that the instructions in this

manual are not carefully followed.

2 COMPONENTS

2.1 Introduction

The components used in the gyrocopter series G 4-2 are illustrated and documented in this section of the maintenance manual.

Bolts and nuts are to be tightened and inspected in accordance with the data provided in this manual and the tightening torque in the corresponding tables is to be used as a reference. In doubt, the maintenance technician or the aviation workshop performing the maintenance or repair works must contact the manufacturer of the gyrocopter, the engine manufacturer or the manufacturer of the propeller for further information.

Engine maintenance must be performed according to the instructions of the engine manufacturer. Maintenance, repairs or adjustments to the propeller must be conducted by authorized persons in accordance with the instructions provided by the propeller manufacturer.

Only original parts and/or components are to be used as spare parts.




Attention: Cracks or damage to the frame are dangerous and

reduce flight safety. Repairs on the frame may only be carried out by

persons who are authorized by the manufacturer of the gyrocopter.

Cracks and damages to the frame are to be reported to the

manufacturer of the gyrocopter with no delay.

Warning: The gyrocopter is not to be operated once cracks,

bends, dents or any other damages are detected in the frame and/or

the engine mounts.

2.2 Frame

The frame is the structure carrying the gyrocopter and connecting all its components together. It is made of a special stainless steel and welded under inert gas protection against corrosion. It is tested and passed the load requirements in BUT (the German specifications for type certification of ultra-light gyrocopters). Such high loads never occur in normal flight conditions. However, the gyrocopter may be exposed to higher loads and forces during taxiing, take-off and landing on rough terrain. This may cause damage to the frame and/or other components of the gyrocopter. It is, therefore, recommended to visually inspect the frame before every flight and to thoroughly inspect it by authorized persons in every scheduled maintenance. To be overhauled: 500 h To be exchanged: 2000 h


Attention: Cracks or damage in the rotor system are dangerous and

reduce flight safety. Repairs on the rotor may only be carried out by

persons who are authorized by the manufacturer of the gyrocopter.

Cracks and damages to the rotor are to be reported to the

manufacturer of the gyrocopter with no delay.

. Note: All warranties are void in case that the instructions in this



bends, dents or any other damages are detected in the rotor system.

2.3 Rotor (2 sizes)

Air foil: NACA 8H12 Manufacturer: Averso Aviation www.averso.info Rotor diameter: 8.40 or 8.60 m Rotor circle area: 55.4 or 58.1 m² Max. rotor load: 10.1 or 9.64 kg/m² To be overhauled: 500 h To be exchanged: 1500 h

Rotor bridge for Rotor head type KK-1


Pos. Description Qnt. Tightening torque

7-1 Hexagon bolt M10x90 8.8 4 40 Nm

7-2 Hexagon bolt M10x70 8.8 16 40 Nm

7-3 Self-locking Hexagon nut M10 ISO 7042 20

7-4 Washer 10,5 DIN 125-B 36

25-109 Hexagon bolts 4 40 Nm

Rotor bridge for Rotor head type TS-1


Attention: Cracks or damage in the rotor head are dangerous and

reduce flight safety. Repairs on the rotor head may only be carried

out by persons who are authorized by the manufacturer of the

gyrocopter. Cracks and damages to the head are to be reported to

the manufacturer of the gyrocopter with no delay.




bends, dents or any other damages are detected in the rotor head.

2.4 Rotor head (2 types)

2 Rotor head types (KK-1 and TS-1) are certified for the series G 4-2: Type KK-1 is a tilt head design. It is designed and manufactured by

Trixy Aviation. It is made of high quality materials and has passed all

tests required under the German rules and specifications for type

certification of ultra-light gyrocopters. It is made of aircraft aluminum

and stainless steel. The bolts, bushings and axes are of special design

and must not be replaced by standard parts.

To be overhauled: 500 h To be exchanged: 1500 h



8-1 Cylinder head bolt with internal hexagon M16x100 DIN 912 12.9

1 180 Nm

8-2 Fit bolt M12x130 10.9 1 60 Nm

8-3 Fit bolt M12x101,5 10.9 1 10÷30 Nm

8-4 Fit bolt M12x77,5 10.9 1 10÷30 Nm

8-5 Fit bolt M10x120 10.9 2 40 Nm

8-6 Tower nut M16 1

8-7 Tower nut M12 3


8-9 Washer 13 DIN 125-B 4

8-10 Washer 10,5 DIN 125-B 2

8-11 Fit bolt M8x50 10.9 2 25 Nm


2 10 Nm


4 10 Nm

8-14 Fit bolt M6x60 10.9 3 10 Nm



8-17 Washer 8,4 DIN 125-B 4

8-18 Washer 6,4 DIN 125-B 9

8-19 Conical bushing 1 4

8-20 Cylinder head bolt with internal hexagon DIN 7991 - M5 x10

4


7 25 Nm


4 25 Nm

8-23 Cylinder head bolt with internal hexagon DIN 7991 – M6 x 16

2 10 Nm



8-26 Washer 8,4 DIN 125-B 11

8-27 Washer 6,4 DIN 125-B 2

8-28 STARTER ACTUATOR 1

8-29 Shaft 1

8-30 Spring pin 6x26 DIN 1481 1

8-31 Spring pin 3,5x26 DIN 1481 1


Attention: Cracks or damage in the rotor head are dangerous and

reduce flight safety. Repairs on the rotor head may only be carried


gyrocopter. Cracks and damages to the head are to be reported to

the manufacturer of the gyrocopter with no delay.




bends, dents or any other damages are detected in the rotor head.

Type TS-1 is a swash plate controlled head design. It is designed and manufactured by Trixy Aviation. It is made of high quality materials and has passed all tests required under the German rules and specifications for type certification of ultra-light gyrocopters. It is made of aircraft aluminium and stainless steel. The bolts, bushings and axes are of special design and must not be replaced by standard parts.




25-06 Washer 8


25-10 Cylinder head bolt with internal hexagon 4 25Nm


25-13 Fit bolt 4 40Nm

25-14 Washer 4

25-18 Washer 1


25-20 Tube 1

25-32 Washer 8


25-34 Hexagonal bolt 8 10Nm


25-39 Short cylinder head bolt with internal hexagon 8 5Nm

25-40 Washer 8





25-57 Safety ring 1

25-58 Allen screw 2 5Nm

25-63 Safety ring 1

25-64 Safety ring 1



25-76 Short cylinder head bolt with internal hexagon 2 10Nm







Attention: Cracks or damage in the rotor controls are dangerous

and reduce flight safety. Repairs on the system may only be carried


gyrocopter. Cracks and damages to the rotor controls are to be

reported to the manufacturer of the gyrocopter with no delay.




bends, dents or any other damages are detected in the rotor control

system.

2.5 Rotor controls

The rotor control system is designed and manufactured of high quality materials by Trixy Aviation. It passed all tests required under the German rules and specifications for type certification of ultra-light gyrocopters. The bolts, bushings and axes are of special design and must not be replaced by standard parts. To be overhauled: 500 h



9-1 Fit bolt M6x40 10.9 11 10 Nm


9-3 Adjusting washer DIN 988 - 6 x 12 x 1 22

9-4 Adjusting washer M6x55 10.9 2 10 Nm



9-7 Washer 8,4 DIN 125-B 4

9-8 Conical bush 1 4

9-9 Fit bolt M8x50 10.9 2 25 Nm

9-10 Fit bolt M8x35 10.9 4 25 Nm


9-12 Washer 8,4 DIN 125-B 4


9-14 Conical bush 2 8

9-15 Washer 6,4 DIN 125-B 4

9-16 Adjusting washer M8x50 10.9 2 25 Nm


Attention: Cracks or damage in the pre-rotator system are dangerous and reduce flight safety. Repairs on the system may only be carried out by persons who are authorized by the manufacturer of the gyrocopter. Cracks and damages in the system are to be reported to the manufacturer of the gyrocopter with no delay. Only silicon spray is to be used for lubricating the clutch belt and the

pulleys. DO NOT USE OTHER SPRAY TYPES!




bends, dents or any other damages are detected in the pre-rotator

system. Removing and installing the propeller is to be performed by

authorized persons only.

2.6 Pre-rotator system

The pre-rotator system is designed and manufactured of high quality materials by Trixy Aviation. The belt must be periodically sprayed with silicon spray. Exchanging the clutch belt requires removing the propeller from the mounting flange (pulley). The main pre-rotator gear in the rotor head and the Bendix-gear in the pre-rotator system must be greased with neutral grease in all scheduled maintenance works.

System to be overhauled: 500 h Clutch belt to be exchanged: 250 h Gearbox to be exchanged: 500 h


Pos. Description Qnt. Tighten torque

10-1 Wuerth screw M6x16 7 10 Nm

10-2 Wuerth screw M6x16 4 10 Nm

10-3 Washer 8,4 DIN 125-B 3

10-4 Cylinder head bolt with internal hexagon 1 25 Nm


10-6 Internal hexagon bolt with flange 1 40 Nm

10-7 Lower cylinder head bolt with internal hexagon 1 10 Nm

10-8 Washer 6,4 DIN 125-B 1


10-10 Internal hexagon bolt with flange M6x20 1 10 Nm

10-11 Wuerth M6x30 1 10 Nm

10-12 Internal hexagon bolts with flange M8x30; ISO 7380 1 25 Nm

10-13 Big Washer 8,4 DIN 9021 1

10-14 Big Washer 6,4 DIN 9021 2

10-15 Wuerth M5x12 4 10 Nm

10-16 Wuerth M5x16 2 10 Nm



10-19 Cylinder head screw with internal hexagon 1 10 Nm

10-20 Big Washer 6,4 DIN 9021 1

10-21 Washer 6,4 DIN 125-B 1




10-34 Passschraube M6x60 1 10 Nm

10-35 Unterlegscheibe 1

10-37 Wuerth Linsenschraube mit Scheibe 4 10 Nm

10-40 Wuerth Linsenschraube mit Scheibe 1 10 Nm

10-41 Kurze Zylinderschraube mit Innensechskant 1 10 Nm

10-42 Sechskantmutter 1

10-43 Federscheibe 1

10-47 Zylinderschraube mit Innensechskant 1 10 Nm

10-34 Passschraube 1 10 Nm


2.7 Propellers (4 Types)

Type 1: 3B Inconel FC Windspoon left Manufacturer: DUC www.duc-helices.com No. of blades: 3 Diameter: 1727 mm Blade material: CFC Adjustment: Ground adjustable.

To be exchanged: 800 h

Type 2: CL3-V-70-(IP)-R2 Manufacturer: Neuform www.neuform-composites.de No. of blades: 3 Diameter: 1700 mm Blade material: CFC Adjustment: In flight adjustable


Type 3: TXL3-V-70-R2 Manufacturer: Neuform www.neuform-composites.de No. of blades: 3 Diameter: 1720 mm Blade material: CFC Adjustment: In flight adjustable


Type 4: EXCALIBUR Manufacturer: E-Props www. e-props.fr No. of blades: 6 Diameter: 1720 mm Blade material: CFC Adjustment: Ground adjustable.

To be exchanged: 800 h


Attention: Cracks or damage in the propeller are dangerous and reduce flight safety. Repairs on the propeller may only be carried out by persons who are authorized by the manufacturer of the propeller. Cracks and damages in the propeller are to be reported to the manufacturer of the gyrocopter with no delay.



Warning: The gyrocopter is not to be operated once cracks or

other damages are detected in the propeller. Removing and

installing the propeller is to be performed by authorized persons

only.


Type 1: Ground adjustable propeller.

Contact DUC or Trixy Aviation for more details.


Type 2: In flight adjustable propeller. Contact Neuform or Trixy Aviation for more details.

Pos. Description Qnt. Tightening Torque

11-1 Cylinder head bolt with internal hexagon M8x125 DIN 912

6 25 Nm


11-3 toothed washer 8,4 6

11-4 Washer 8,4 DIN 125-B 6

11-5 Indexing pin ø10x20 DIN 6325 LK75 3

11-6 Cylinder head bolt with internal hexagon M8x70 DIN 912

6

11-7 Washer 8,4 DIN 125-B 12



Warning: The gyrocopter is not to be operated once cracks or

other damages are detected in the nose wheel structure. Worn tires

are to be exchanged. Use original parts only from the manufacturer.

Attention: Cracks or damage in the nose wheel structure are dangerous and reduce flight safety. Repairs may only be carried out by persons who are authorized by the manufacturer. Cracks and damages are to be reported to the manufacturer of the gyrocopter with no delay.



2.8 Nose wheel and steering

The nose wheel suspension and ist structure are designed and manufactured by Trixy Aviation of high quality materials. It passed all load tests required by the German rules and specifications for the certification of ultra-light gyrocopters. However, continuous stress during taxiing, take-offs and landings on rough terrain may cause damage to the nose wheel structure. It is, therefore, recommended to check the structure of the nose wheel before every flight. Through inspection by authorized persons within every scheduled maintenance is also recommended by Trixy Aviation.

Nose wheel structure to be overhauled: 500 h

Nose wheel (Rim, axes and bearing): Manufacturer: BERINGER AERO SA www.beringer-aero.co Wheel type and size: 3.50-4" RA-003 Wheel axes: Fork AA-07 Tire: 4.00-4 PAG01



12-1 Cylinder head screw with internal hexagon M10x135 DIN 912

1 40 Nm


12-3 Washer 10,5 DIN 125-B 2

12-4 Split pin 3,2x32 DIN 94 1

12-5 Washer 17 DIN 125-B 1

12-6 Tower nut M16 DIN 979 1

12-7 Washer 8,4 DIN 125-B 1



Warning: The gyrocopter is not to be operated, once cracks or

other damages are detected in the main gear structure. Worn tires

are to be exchanged. Use original parts only from the manufacturer.

Attention: Cracks or damage in the main gear structure are dangerous and reduce flight safety. Repairs may only be carried out by persons who are authorized by the manufacturer. Cracks and damages are to be reported to the manufacturer of the gyrocopter with no delay.



2.9 Main gear

The main gear suspension is designed and manufactured by Trixy Aviation of GFC and CFC in sandwich construction under vacuum. It passed all load tests required by the German rules and specifications for the certification of ultra-light gyrocopters. However, continuous stress during taxi, take-off and landing on rough terrain may cause damage to the nose wheel structure. It is, therefore, recommended to check the structure of the main gear before every flight. Through inspection by authorized persons in every scheduled maintenance is also recommended.




4 25 Nm


6 10 Nm


10 10 Nm

13-4 Washer 8,4 DIN 125-B 8


13-6 Washer 6,4 DIN 125-B 16


Warning: The gyrocopter is not to be operated, once damages are

detected in the main wheels and brake system. Worn tires are to be

exchanged. Use original parts only from the manufacturer.

Attention: Damages in the main wheels or the brake system are dangerous and reduce flight safety. Repairs may only be carried out by persons who are authorized by the manufacturer.



2.10 Main wheels and brakes

The main wheels and the brakes are high quality products of Beringer Aero SA. The brake hydraulic system is designed and manufactured by Trixy Aviation. Use original parts only from the manufacturer to insure flight safety. See also main gear in the previous chapter and brake system in further in this manual. Main wheels and brakes: Manufacturer: BERINGER AERO SA www.beringer-aero.co Main wheel: 4.00-6" JAD01 Wheel axes: Alu AA-01 Main nut: Alu ZSA01 Tire: 400-6 6PLY PAD01 Hydraulic fluid: DOT 4 or Beringer

To be overhauled: 500 h


2.11 Empennage

The structure of the empennage is designed and manufactured of CFC in sandwich construction under vacuum. It passed the load tests required by the German rules and specifications for the certification of ultra-light gyrocopters. It is mounted on the tail of the frame by screws in 7 spots. It is also designed to carry the rudder (see the following chapter).


15-1 Internal hexagon bolts with flange M6x16 10 10 Nm

15-2 Big Washer 6,4 DIN 9021 10



Warning: The gyrocopter is not to be operated once damages are

detected in the rudder control system.

Attention: Damages in the rudder or its control system are dangerous and reduce flight safety. Repairs may only be carried out by persons who are authorized by the manufacturer.



2.12 Rudder controls

The rudder and ist control system is designed and manufactured by Trixy Aviation. The rudder is made of CFC in sandwich construction under vacuum. It is controlled by bowden wires along with the nose wheel.

The rudder control system is to be overhauled: 1000 h



16-1 Fit bolt M6x40 10.9 2 10 Nm

16-2 Fit bolt M6x30 10.9 6 10 Nm


16-4 Washer 6,4 DIN 125-B 17

16-5 Special Aluminum nut M16x1,5 4 5÷15 Nm

16-6 Cotter pin 4x40 DIN 94 4


16-8 Pin 6x15 2

16-9 Cotter pin 1,6x12 DIN 94 2


16-11 Bush 1


2.13 Dashboard Type Liberty The standard Liberty panel is designed das shown in the illustration below. It includes all the necessary instruments and may optionally be equipped with a second Mini-Glascockpit (EMSIS) for GPS-navigation.

1. Mechanical air speed indicator (optional) 2. EMSIS II (A=Standard / B=GPS / optional)

3. Mechanical altimeter (Optional) 4. Transceiver (optional) 5. Transponder (optional) 6. Circuit breakers 7. Main switch 8. Mag 1 (ignition circuit switch 1) 9. Mag 2 (ignition circuit switch 2) 10. Auxiliary fuel pump (optional in type G 4-2 R with Rotax 912 ULS) 11. Avionics Switch 12. Landing light switch (optional) 13. Navigation light switch (optional) 14. Heating fan switch (optional with cabin heating) 15. Defroster Fan Switch (optional with cabin heating) 16. Engine start switch 17. GEN (alternator status Indicator) 18. Aircraft ID 19. Magnetic compass 20. ELT (optional) 21. Booster reset switch (with Rotax 914 UL engine only) 22. Booster warning lights (with Rotax 914 UL engine only) 23. Controller for constant speed propeller (optional) 24. Engine and Rotor RPM


Type PRINCESS The standard princess panel is designed as shown in the illustration below. It contains all instruments, GPS-navigation, circuit breakers and switches as well as optional electronic devices.

1. Mechanical air speed Indicator (optional) 2. NESIS glass cockpit (main instrument) 3. Mechanical altimeter (optional) 4. Transceiver (optional) 5. Transponder (optional) 6. Circuit breakers 7. Master switch 8. Mag 1 switch (ignition circuit switch 1) 9. Mag 2 switch (ignition circuit switch 2) 10. Auxiliary fuel Pump switch (optional with Rotax 912 ULS engine) 11. Avionic master switch (optional) 12. Landing Lt switch 13. Nav Lt switch (optional navigation and strobe light) 14. Heating fan switch (optional with cabin heating) 15. Ventilation fan switch 16. Engine start switch 17. Gen (alternator status indicator) 18. Aircraft ID 19. Compass (optional) 20. ELT remote control (optional) 21. Booster reset switch (Rotax 914 UL engine only) 22. Booster warning lights (Rotax 914 UL engine only) 23. Controller for constant speed propeller (optional)


2.14 Engines (4 Types) Rotax 912 ULS Max. Power: 100 HP / 5800 U/min Continuous power: 95 HP / 5500 U/min Max. Permitted RPM: 5800 Max. Continuous RPM: 5800 U/min Cylinder head temperature: max. 135° C Oil temperature: min. 50° C / max. 130° C Fuel quality: EN228 Super (min ROZ 95) or

EN228 Super plus (min ROZ 95) Alternative fuel (*): AVGAS 100 LL (ASTM D910) Oil type (*): SAE 10W-40, API SG or higher

(Example: Shell Advance VSX4)


Rotax 914 UL Max. Power: 115 HP / 5800 U/min Continuous power: 100 HP / 5500 U/min Max. Permitted RPM: 5800 Max. Continuous RPM: 5800 U/min Cylinder head temperature: max. 135° C Oil temperature: min. 50° C / max. 130° C Fuel quality: EN228 Super (min ROZ 95) or

EN228 Super plus (min ROZ 95) Alternative fuel (*): AVGAS 100 LL (ASTM D910) Oil type (*): SAE 10W-40, API SG or higher

(Example: Shell Advance VSX4)


Trixy 912 TI Max. Power: 130 HP / 5800 U/min Continuous power: 113 HP / 5500 U/min Max. Permitted RPM: 5800 Max. Continuous RPM: 5800 U/min Cylinder head temperature: max. 135° C Oil temperature: min. 50° C / max. 130° C Fuel quality: EN228 Super (min ROZ 95) or

EN228 Super plus (min ROZ 95) Alternative fuel (*): AVGAS 100 LL (ASTM D910)


Attention: Oil quantity coolant level and spark plug caps are to be

checked by the pilot in command before every flight.

The engine is to run on RPM lower than 3000 after start until oil

temperature of 50 °C before applying full power.

Scheduled maintenance and small repairs are to be performed

according to the engine maintenance manual (last valid edition) by

workshops and persons, who are authorized by Rotax.

Warning: The gyrocopter is not to be operated, once damages are

detected in the engine. DO not attempt to take-off with a rough

running engine. Always ensure that max. Power is available before

flight.



Oil type (*): SAE 10W-40, API SG or higher (Example: Shell Advance VSX4) To be overhauled: 1500 h Trixy 912 TIS Max. Power: 150 HP / 5800 U/min Continuous power: 140 HP / 5500 U/min Max. Permitted RPM: 5800 Max. Continuous RPM: 5800 U/min Cylinder head temperature: max. 135° C Oil temperature: min. 50° C / max. 130° C Fuel quality: EN228 Super (min ROZ 95) or

EN228 Super plus (min ROZ 95) Alternative fuel (*): AVGAS 100 LL (ASTM D910) Oil type (*): SAE 10W-40, API SG or higher (Example: Shell Advance VSX4) To be overhauled: 1500 h


Warning: This manual does not substitute the education of an aviation technician or the authorization of an aviation maintenance workshop. IT is to be used in addition to the maintenance manuals of engine and propeller. Attention: Only persons authorized by the gyrocopter manufacturer




manufacturer.



3 SYSTEMS

3.1 Introduction

The systems of the gyrocopters G 4-2 are described and illustrated in this chapter of the maintenance manual. Construction drawings and material lists are not included in this manual. It is considered that authorized persons and/or authorized aircraft repair and maintenance workshops are to perform maintenance on the gyrocopter. Such authorized persons and workshops must be trained by the manufacturers of the gyrocopter, the engine and the propeller. They may contact the manufacturer whenever more information is required.

All maintenance works and small repairs on both engine and propeller must be performed according to the instruction of the manufacturer.

Only original parts from the manufacturer are to be used, whenever replacing any part of the gyrocopter.


3.2 Engine oil circuit

1 Pressure regulator 2 Pressure transducer 3 Oil pump 4 Oil tank 5 Oil cooler (heat exchanger) 6 Oil filter 7 Vent line 8 Temperature sensor 9 Thermostat (not shown in the drawing)

The pilot in command must inspect the oil quantity prior to every flight: 1. Switch both ignition circuits off 2. Open the cover of the oil container (4)

3. Rotate the propeller counter clock wise 8 – 10 full rotations. 4. Check the oil level in the container between the middle and the

upper limit of the dip stick.

The pilot in command must insure correct oil pressure and oil temperature above 50 °C before applying full power. The maximum allowed oil temperature is 130 °C.


3.3 Engine coolant circuit

The pilot in command must insure correct coolant quantity before starting the engine. The coolant reservoir (1) must be completely full up to the cover (3). The expansion container (4) must show coolant level between the marks MIN and MAX. The heat exchanger (2) must be clean. The circuit must be check for leaks. All hoses must be in good conditions

3.4 Engine ignition circuits

More information about the ignition circuits are found in Rotax manual.


Attention: Water and contamination in the fuel system may lead to

losing power or engine failure. The pilot in command is to check the

fuel quality and the quantity before every flight.

Warning: A dirty fuel filter reduces the fuel flow to the engine and leads to losing power or engine failure. Leaks in the fuel system may lead to fire in the engine compartment.

3.5 The fuel system

The standard configuration includes one anti-explosion tank with a

capacity of 34 l. The tank is built in front of the fire wall beside the

passenger seat. It includes a fuel level sensor and is connected to the

filling neck on the right side of the gyrocopter. The fuel supply line is

connected to the tank in the lower back corner and leads to the fuel

pump(s) through a fuel filter. The supply line contains a drain valve at

the lowest point below the engine compartment. Excessive fuel is lead

back to the tank via return line, which connects to the tank on its upper

side. A vent line is also connected to the upper side of the tank.

An auxiliary tank is optionally built in the left side of the gyrocopter. It is

identical with the standard tank. In such a case, both tanks are

connected together through the fuel supply line. Fuel is supplied from

both tanks equally via a T-piece at the lowest point of the line between

the tanks. The vent line is also connected to the auxiliary tank.

Rotax 912 is equipped with a mechanical fuel pump while the fuel is

supplied to the type 914 by an electrical pump fixed on the fire wall in a

lower level than the tank. Both G 4-2 may be optionally equipped with

an electric auxiliary fuel pump, which is then fixed on the lower part of

the fire wall. The auxiliary pump may only be operated by the pilot in

emergency cases. The switch is in the instrument panel.

Fuel filters are to be inspected in every scheduled maintenance and

must be exchanged every 250 h. Only original filters are to be used.

It is strongly recommended to inspect and clean the tanks every 500 h.


3.6 The electric system

The Type G 4-2 R is equipped with a simple electric circuit which

includes one battery. It can, however, optionally be equipped with an

auxiliary fuel pump and/or a back-up battery system. The Types G 4-2

RT, G 4-2 TI and G 4-2 TIS are equipped with 2 electrical fuel pumps, a

back-up battery and a battery management system (BMS) in the

standard configuration.

Failure in the electric system in flight is dangerous and may lead to an

emergency landing. The pilot in command must always plan the flight

path and flight altitude, so that a safe landing in emergency is possible.

The normal circuit voltage is 13.2 V. The glass-Cockpit (NESIS) warns the pilot in the event that the voltage drops under 12 V. The screen of the glass cockpit switches off at 10 V, but the data in processed until the circuit voltage drops down to 6.5 V. The battery will not be recharged, once the voltage drops down to 8 V

or lower and it must be exchanged.

Authorized personnel must examine the battery and the battery

charging controller in every maintenance process. Faulty parts or

components of the system must be exchanged.

The wiring diagrams of G 4-2 R are to be found on pages 68 – 74.

The wiring diagrams of G 4-2 RT are to be found on pages 75 – 81.

The wiring diagrams of G 4-2 TI and G 4-2 TIS are to be found on

pages 81 – 88.

The wiring diagrams of the Battery Management System are to be

found on the pages 89 and 90 of this manual.

The battery must be exchanged every 250 operation hours or every

year, if 250 hours are not reached within a year time.


3.7 The hydraulic brake system

The hydraulic brake system works equally on the main wheels of the

gyrocopter. The system is operated by the pilot with a lever fixed on the

left wall of the cabin along with the fluid reservoir and the main brake

cylinder. The fluid (DOT 4 or Beringer brake fluid) is lead from the main

cylinder to the brake cylinders in the main wheels via hydraulic hoses

which is lead inside the main gear strut. An optional brake lever may be

installed on the left side of the co-pilot and in such a case it is

mechanically connect to the main brake lever in the front part of the

cabin.

The fluid reservoir is in sight of the pilot and must be inspected by the

pilot in command before flight. It must contain fluid up to 50% of its

volume. Use DOT 4 fluids or Beringer brake fluid to add fuel to the

system when needed. However, los of fluid may mean leaks in the

system. This must be fixed to avoid brake failure. It is recommended to

exchange the hydraulic fluid in the system every 500 h.


Warning: This manual does not substitute the education of an aviation technician or the authorization of an aviation maintenance workshop. IT is to be used in addition to the maintenance manuals of engine and propeller.

Attention: Only persons authorized by the gyrocopter manufacturer




manufacturer.



4 PERIODIC PREVENTIVE MAINTENANCE

3.1 Introduction

This chapter explains the periodic preventive maintenance required and highly recommended to insure flight safety. Trixy Aviation Insists on professional and timely maintenance. The information in this chapter for maintenance intervals must be adhered to; otherwise all manufacturer warranties are void. Contact Trixy Aviation with any questions, which might arise or for more information whenever needed.

The maintenance works described in this manual are compulsory works for gyrocopters, which are privately owned and operated less than 200 hours a year. The manual describes 50 hours maintenance intervals. Gyrocopters, which are commercially operated over 300 hours a year (flight schools), may include maintenance works to be performed in 50 hours in the works to be performed in 100 hours. It is assumed that flight schools frequently perform a professional pre-flight check and may recognize fatigue and defects early in time. The maintenance prescribed by the engine manufacturer in the engine maintenance manual remains unaffected by this rule.


3.2 Maintenance after the first 25 hours

It is important to thoroughly inspect the gyrocopter after the first 25

hours of operation:

1. Engine inspection and maintenance in accordance with the

requirements in engine maintenance manual

2. Inspect attachment of the exhaust system and tighten bolts

3. Inspect the fuel system for leaks and the fuel filter for dirt

4. Inspect the propeller blades for cracks and tightness on the nob

5. Tighten the propeller bolts in the nob

6. Inspect the rotor for cracks, dents and other defects

7. Inspect the torque and tighten the rotor bolts


9. Inspect the nick and roll axes of the rotor head for function

10. Inspect and tighten the bolts connecting rotor heat and mast

11. Inspect the rotor control system for cracks bends and defects

12. Inspect the torque of the bolts in the rotor control system

13. Inspect the pre-rotation system for function and defects

14. Apply silicon spray on pre-rotator clutch belt and pulleys

15. Inspect the hydraulic brake system on function and leaks

16. Add hydraulic fluid (Dot 4), if needed

17. Inspect the nose wheel construction for bends, cracks and

damages

18. Inspect torque and tighten the nut of the nose wheel if needed

19. Inspect the air pressure in the nose wheel (2.5 bar / 38 psi)

20. Inspect the main wheels for defects

21. Inspect torque and tighten the nuts of the main wheels if needed

22. Inspect torque and tighten the main wheel bolts (x6) if needed

23. Inspect the air pressure in the main tires (3.0 bar / 45 psi)

24. Inspect the frame for cracks, dents and deformation

25. Inspect the attachment of the empennage on the frame

26. Inspect the rudder and its control system for function

27. Adjust the rudder control Bowden if needed

28. Inspect the attachment of the canopy to the cabin and the locks


3.2 Maintenance in 50 hours intervals

1. Engine inspection and maintenance in accordance with the

requirements in engine maintenance manual

2. Inspect attachment of the exhaust system and tighten bolts

3. Inspect the fuel system for leaks and the fuel filter for dirt

4. Inspect the propeller blades for cracks and tightness on the nob


6. Inspect the rotor head for cracks, dents and other defects

7. Inspect the nick and roll axes of the rotor head for function

8. Inspect the rotor control system for cracks bends and defects

9. Inspect nick trim system for function

10. Inspect roll trim system for function (if installed)

11. Inspect the pre-rotation system for function and defects

12. Lubricate pre-rotator pedal

13. Inspect and lubricate re-rotation gear and bendix-gear

14. Apply silicon spray on pre-rotator clutch belt and pulleys

15. Inspect the hydraulic brake system on function and leaks

16. Add hydraulic fluid (Dot 4), if needed

17. Inspect the nose wheel construction for cracks and damages

18. Inspect the air pressure in the nose wheel (2.5 bar / 38 psi)

19. Inspect the main wheels for defects

20. Inspect the air pressure in the main tires (3.0 bar / 45 psi)

21. Inspect attachment of the main gear strut to the frame

22. Inspect the frame for cracks, dents and deformation

23. Inspect the attachment of the empennage on the frame

24. Inspect the rudder and its control system for function

25. Inspect the attachment of the canopy to the cabin and the locks

26. Inspect attachment of pilot seat and insure it is not touching the

upper rotor control rod underneath with load on the seat

27. Inspect landing light

28. Inspect defroster fan for function

29. Inspect navigation lights and strobe (if installed)

30. Inspect ELT for function (if installed)



Perform all maintenance works required in 50 hours intervals and add

the following works:

1. Tighten the propeller bolts in the nob

2. Inspect the torque and tighten the rotor bolts

3. Inspect and tighten the bolts connecting rotor heat and mast

4. Inspect torque and tighten the nut of the nose wheel if needed

5. Inspect the steering system of the nose wheel

6. Inspect torque and tighten the nuts of the main wheels if needed

7. Inspect torque and tighten the main wheel bolts (x6) if needed

8. Inspect tires for thread and damage (exchange if needed)

9. Inspect the attachment of the cabin on the frame

10. Inspect the attachment of the fire wall on the frame

11. Inspect fuel system for leaks

12. Inspect battery and charging

13. Inspect electric auxiliary fuel pump function (if installed)

14. Inspect cabin heating system for function (if installed)

15. Inspect oil cooler and clean thoroughly

16. Inspect coolant heat exchanger assembly and clean thoroughly



Perform all maintenance works required in 100 hours intervals and add the following works:

1. Detach the rotor from the rotor head (exchange after 1500 h)

2. Thoroughly inspect the rotor for cracks, dents and other defects

3. Exchange the main bearings in the rotor

4. Exchange the titer bolt (use original spare part / fit bolt)

5. Detach the rotor head from the mast and upper control rods and

pre-rotator and inspect the mast for cracks and deformation

6. Disassemble the rotor head (exchange after 1500 h)

7. Inspect all parts of the rotor head for wear, cracks and damage

8. Exchange the main rotor bearing

9. Exchange nick and roll axis (use original spare parts / fit bolts)

10. Exchange all bushings (use original spare parts)

11. Inspect main pre-rotator gear and exchange bendix-gear

12. Inspect rotor brake pad and exchange if needed

13. Assemble the rotor head and attach it to the mast

14. Attach the rotor to the rotor head and secure it

15. Detach, disassemble the thoroughly inspect the propeller

16. Exchange worn blades or any defective parts (use origin parts)

17. Assemble all parts, balance and adjust the propeller

18. Disassemble the pre-rotation system and inspect all parts

19. Exchange the angular gear of the pre-rotator and the clutch belt

20. Inspect and grease all cross joints

21. Assemble the pre-rotation system and install it in position

22. Bolt the propeller on the pre-rotation disc and mind the torque

23. Inspect the frame and the engine mounts for cracks dents and

deformation (exchange after 2000 h), NO WELDING ALLOWED

24. Disassemble the nose wheel, inspect the structure, exchange

the bushings and grease the main axes

25. Exchange the nose wheel bearings and assemble structure

26. Disassemble the main wheels and inspect the brake pads

27. Exchange the hydraulic fluid in the system and insure the

system is properly vented.

28. Inspect fuel tanks (exchange after 2000 h), exchange fuel filters


3.5 Recommended overhauls

Fuel filter Exchange 250 hours Fuel tank Overhaul 500 hours Fuel tank Exchange 2000 hours Pre-rotator clutch belt Exchange 250 hours Pre-rotator angular gear Exchange 500 hours Pre-rotator Bendex-gear Exchange 500 hours Rotor Overhaul 500 hours Rotor Exchange 1500 hours Rotor head Overhaul 500 hours Rotor head Exchange 1500 hours Frame Inspection 500 hours Frame Exchange 2000 hours DUC-Propeller Overhaul 500 hours DUC-Propeller Exchange 800 hours Neuform-Propeller Overhaul 500 hours Neuform-Propeller Exchange 1000 hours Hydraulic fluid Exchange 500 hours Engine Exchange 2000 hours




4 MAINTENANCE CERTIFICATES

All maintenance works on the gyrocopter are to be timely performed by

authorized aviation workshops and authorized persons according to the

instructions in this manual. Engine and propeller are to be maintained

by authorized workshops and authorized persons by the respective

manufacturer.

All maintenance works are to be documented in the following

certificates in this chapter of the manual. The certificates must be

signed by the authorized person, who performed the maintenance

works with date and stamp (if available).

Records of engine maintenance must be recorded in the engine

logbook and must be signed and dated by the authorized person, who

performed the maintenance works on the engine.


Maintenance certificate after the first 25 hours Gyrocopter type: ________________________________

Call sign: ________________________________

Hour meter: ______________

Date of maintenance: Start ______________ End _______________

I certify herewith, that the maintenance works are successfully

performed on this Gyrocopter in accordance with the instructions

in this manual.

Remarks:

The gyrocopter is airworthy and is returned to service.

Name of authorized person: ________________________

Signature:

Date of certificate: ____________________

Stamp (if available):



Call sign: ________________________________

Hour meter: ______________




in this manual.

Remarks:



Signature:




Maintenance certificate after the first hours Gyrocopter type: ________________________________

Call sign: ________________________________

Hour meter: ______________




in this manual.

Remarks:



Signature:





Call sign: ________________________________

Hour meter: ______________




in this manual.

Remarks:



Signature:




5 DAMAGE OR ACCIDENT REPORTS

Gyrocopter type: ______________ Serial No.:______________

Year built: ____________ Call sign: D-M__________

Engine No.:________________ Manufacturer:________________

Operator:_________________________________________________

Total hours: Gyrocopter: ____________ Engine: _____________

Pilot logged hours: Total: ___________ Gyrocopter: ____________

Description of the damage:

Description of the damage course of events:

Person established this record: Name: _____________________________________ Address: _____________________________________ _____________________________________ _____________________________________ Tel./Fax: _________________ / __________________ Location: ______________ Datum: __________________

Signature: Please send this report to: and to: DAeC Trixy Aviation GmbH Hermann-Blenk-Strasse 28 Eschbuehel 10 F D-38108 Braunschweig A-6850 Dornbirn Germany Austria Telefax: +49 531 23540-66 [email protected]





Operator:_________________________________________________








CERTIFICATE OF REPAIR AFTER DAMAGE




Operator:_________________________________________________ Damage reported on: __________________


Date of repair works: Start ______________ End _______________

Description of repairs:

I herewith certify that this gyrocopter was repaired using original

spare parts under the instructions and with the permission of the

manufacturer.



Signature:














manufacturer.



Signature:




MODIFICATION CERTIFICATE




Operator:_________________________________________________


Date of modification: Start ______________ End _______________

I certify herewith, that the modification made to this gyrocopter

was made after consulting the manufacturer and obtaining the

needed permissions.

Modification:

I have weighed the gyrocopter after the modification according to

the method described in the flight and operation manual and I have

issued a weight and balance report, which is documented in the

flight and operation manual on page no. ________ of the manual.

The gyrocopter is airworthy and was returned to cervice.


Signature:








Operator:_________________________________________________





needed permissions.

Modification:







Signature:




The content of this manual, (including text, pictures and drawings) is not to copy without the written permission of Trixy Aviation GmbH.

maintenance manual - trixy g 4-2 r · 2017. 5. 12. · maintenance manual g 4-2 revision 05a –...

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