Aircraft 25hr Service Worksheet
Contents
1. Trim System Rotor Brake amp Pneumatics 183 Op C Full functional check pneumatic system refer as required to the maintenance manual for fault finding and rectification and a more comprehensive understanding of the test background REPEAT TEST FOR LEFT STICK IF FITTED TO AIRCRAFT In the Brake position engage brake confirm operation and that function is acceptable Pressurise to maximum Change to flight check for 8 sec max to release air from brake system In Flight position check that trim goes on and off in same direction as button In Flight position move stick fully forward Depress pre rotator button Ensure the rotor head cylinder engages and pump runs and when the stick is pulled back the pump stops Return the stick to the front release pre rotator and confirm that pressure is applied to trim and stick comes back slightly Press right roll and ensure stick then moves right and bar indicator does the same Repeat to left then centralise indicator and check for stick return to mid position In Brake position put 3 bar pressure on and ensure pre rotator does not function Press the Interlock release button and ensure that pre rotator functions movement of head cylinder with brake engaged Max pressure obtained Woodcomp KW 31 Propeller NOTE All propeller checks to be in accordance with manufacturers manual For propeller servicing refer2. all oil hoses and pipes for secure installation no leaks chafing hardening of pipes or abrupt direction changes Check condition of heat insulating tubes under engine 138 Inspect oil thermostat assembly for secure attachment no cracks or leaks from fittings 139 Inspect all coolant hoses for condition and secure installation no leaks chafing or porosity 140 Inspect condition of heat protection on coolant hose from Cylinder 2 141 Inspect coolant radiator for secure installation cleanliness leaks or damage 142 Inspect radiator fan for correct operation Fan runs in direction of ram airflow with no damage to cage or blades engine running 143 Inspect coolant overflow tank for correct Use dipstick for coolant level See coolant level secure installation no chafing Cavalon POH RSUK0334 144 Inspect exhaust system for general Use tap test to inspect for cracks condition secure installation no leaks cracks or loose rivets Check security of turbocharger installation 145 Inspect after muffler clamps for Note that rubber strips are not fitted to deterioration and secure fitment and that Cavalon Pro wire locking in place 2 plcs Fuel system 150 Inspect security of fuel tanks and fuel cross over tube clamps No evidence of leakage in fuel tank compartment 151 Inspect operation and sealing of fuel drain valve 154 Inspect fuel cap for condition tightness correct function
3. security of mounting and tyre clearance 22 Inspect main wheels general condition No fabric to show through the tread Tyres OK and pressures recorded correct pressure condition of tread correct area Recommended 0 5mm min tread seating of valve and cap secure No cracks in side walls installation free movement but no play in Tyre pressure 1 8 to 2 2 bar latter if Main LH wheel bearings presence and condition of heavily loaded Increase to 2 3bar if creep mark on tyre rim operating at 560kg MTOW gt Main RH Instrument S NoO 2 0 eeee eee es Calibrated until eee 23 Inspect wheel brakes for secure installation and correct operation no fluid leaks from caliper Condition of pads and brake disc 25 Inspect brake lines for secure installation no leaks or chafing Undercarriage nose wheel 40 Inspect wheel spat for general condition security of mounting and tyre clearance 41 Inspect nose wheel general condition No fabric to show through the tread Tyre OK and pressure recorded correct pressure condition of tread correct area Recommended 0 5mm min tread seating of valve and cap secure No cracks in side walls installation free movement but no play in Tyre pressure 2 0 to 2 4bar latter if Nose wheel bearings heavily loaded 42 Inspect nose wheel fork for general condition secure installation freedom of movement no excessive play distortion or damage 43 I
4. consistent with ambient conditions 260 Observing Rotax shut down requirements stop engine Inspect Power plant and coolant system for leaks Finalization work 270 Carry out a tool and loose article check 271 Inside the a c refit the stick gaitor s Verify full and free stick movement 272 Re install all inspection hatches internal and all service covers external 273 Re install all cowlings and mast cover 274 Ensure all log book entries completed appropriately List of documents for Task 1 Preparatory work Confirm Service bulletins incorporated from RSUK website full list available with applicability Confirm Airworthiness Directives incorporated from CAA website CAP747 and 661 CAP 747 Document date or issue checked plus notes CAP 661 Document date or issue checked plus notes EASA AD check EASA website note date checked and any actions required Copyright RotorSport UK Ltd Page 14 of 17 Form F192 Rev2 dated 17 03 15 RotorSport UK Ltd Confirm compliance to the Type Certificate Data Sheet TCDS for the Cavalon Pro Note any non compliances and actions taken Tasks completed by name Signature Initial Date to compare to check sheet Engine hours logged Airframe hours logged Aircraft hour meter reading The technical content of this document is approved under the authority of the UK CAA
5. and cleanliness of vent hole 156 Inspect in area protected by removable firewall and in engine compartment check all fuel lines for condition secure installation presence of fire protective sleeve no chafing or kinks Copyright RotorSport UK Ltd Page 8 of 17 Form F192 Rev2 dated 17 03 15 RotorSport UK Ltd 157 Inspect security and function of electric Function determined by sound on fuel pumps operation 158 Op C correct operation and security of fuel shut off valve correct operation of safety guard 159 Op C functionality of fuel gauge ie that the reading is consistent with that shown on the tank dip stick Pre rotator 170 Inspect security of gearbox and pneumatic pipe to pre rotator clutch 171 Inspect drive shafts for bend or damage No bearing play or cracks in flanges of u j couplings 174 Inspect bendix to ring gear engagement See Cavalon AMM RSUKO0335 Adjust if necessary 176 Service lube clean then apply a minimal NB Do not lubricate the bendix smear of light oil or WD40 to ring gear teeth mechanism 177 Service lube sliding shaft coupling with Castrol LM or equivalent grease and verify free movement 178 Service lube uppermost drive shaft Apply with brush do not spray protected with Waxoyl Copyright RotorSport UK Ltd Page 9 of 17 Form F192 Rev2 dated 17 03 15 RotorSport UK Ltd
6. Design Organisation Approval Ref DAI 9917 06 Certificate of Release to Service The work recorded above all pages has been completed to my satisfaction and in that respect the aircraft is considered fit for flight Name Signature Initial Date to compare to check sheet CAA Authorisation Ref No Comments Note to Engineer remember to reference this worksheet and RSUK0335 within the logbooks together with your CAA authorisation code Work undertaken may be noted on this worksheet or if required on another sheet such as F093 also referenced in the logbook Modifications undertaken must be noted with their MC approval no Check the back pages to complete these too for modifications service bulletins ADs etc Copyright RotorSport UK Ltd Page 15 of 17 Form F192 Rev2 dated 17 03 15 RotorSport UK Ltd Any cosmetic damage noted on first inspecting the aircraft should be marked on this graphic and brought to the owner s attention Copyright RotorSport UK Ltd Page 16 of 17 Form F192 Rev2 dated 17 03 15 RotorSport UK Ltd Appendix Requirements for certifying signatures initials on this worksheet With the exception of Permitted Pilot Maintenance see the relevant RSUK Aircraft Maintenance Manual and CAA publication CAP 733 all maintenance work on RSUK gyroplanes must be certified by a CAA Authorised Person a Licenced Engineer Case 1 for work not involving engine controls or flying contr
7. RotorSport UK Ltd Ste Gaa Aircraft 25hr Service Worksheet filet A Tsk Repetition or comments Actions taken amp comment Eng r Licenced Task Description No initial Eng r Purpose of this worksheet To be applied for the first 25hr 5hrs service of a Cavalon Pro Gyroplane with Woodcomp KW 31 variable pitch propeller If prior to renewal of the aircraft s Certificate of Validity the owner is also referred to the renewal requirement list on the RSUK website Refer to Maintenance Manual RSUK0335 Some of the checks and serviceability are on condition meaning the Engineer has the responsibility to decide if an item is acceptable for service Some of the work involved affects CRITICAL PARTS and or CRITICAL ASSEMBLIES as identified below when working on these items follow only the procedures described in the Maintenance Manual RSUK0335 NOTE Cowls and covers must be removed to undertake this service Refer to Cavalon Pro Pilots Handbook RSUK0334 for guidance The task numbers listed in the left most column are rationalised i e identical on all Cavalon Pro Service Worksheets The task numbers may not therefore be sequential Preparatory work 1 Review the aircraft documents and the list of publications towards the end of this Worksheet to determine any outstanding specific or additional requirements to be conducted 3 Clean the aircraft remove any dirt dust loose items During
8. cleaning inspect for any fluid leaks 4 Perform an external visual inspection of all Consult RSUK to organise any cowlings and mast covers Record any repairs or replacements required cosmetic damage on the graphic at the end of this document then remove the items Perform a detailed inspection no cracks distortion missing parts 5 Remove keel tube cover leaving loose on tube 6 Remove all service covers external Consult RSUK to organise any inspection hatches internal and the repairs or replacements required removable firewall panel Perform a detailed inspection no cracks distortion missing parts 7 Lift stick gaitor s away from the Velcro retention to cockpit floor Copyright RotorSport UK Ltd Page 1 of 17 Form F192 Rev2 dated 17 03 15 RotorSport UK Ltd Airframe Inspection 10 Check Bolt torques mast fittings Torque check the M8 countersunk 1 inspection screws to 22Nm 2 pairs If any visible Name movement remove screw re Loctite Engineer authorisation no 243 and replace tightening to 25Nm 3Nm SIG TEE Second signature required if any screw removed replaced oe inspection Name Engineer authorisation no Instrument S NO L ccc cee ee ee eee ee ees Or qualified pilot licence no Calibrated until 2 ceeeeeee SIG hetateretaetdeeldtebitedd aad tee 11 Inspect mast rubber bushings for failur
9. dent second person must enter his name CAA authorisation number or Pilots Licence number and full signature under oe inspection This second person must be suitably qualified and may be e another licenced or CAA authorised engineer e a qualified gyroplane pilot In this case the pilot must append his Pilot s Licence number to his signature It is the second signatory s responsibility to ensure he she understands the task and what it is they are inspecting and signing for Verification of Initials Signature and Authorisation The person performing the work must complete the Tasks completed by statement towards the end of the worksheet The licenced engineer must complete and sign the Maintenance Release on the last page of the Worksheet Copyright RotorSport UK Ltd Page 17 of 17 Form F192 Rev2 dated 17 03 15
10. der antenna Fitted to the rhs of the underbody check for damage and security 232 Inspect bearing temp indicator and OAT indicators for clear display 233 Check Fire warning LED flashes three times on power up then off 234 Overall check that all cockpit and panel fittings are secure Final ground run checks prior to release Follow safe practice aircraft tied down and with qualified operator or pilot only 250 Re install the removeable firewall panel 251 Re install keel tube cover 252 Check all service pipes and cables around engine are secured 253 Op C full functional check of engine start and run up to normal operating temperature 254 Op C with propeller set to fully fine Propeller may be damaged if in fully ensure engine achieves at least 5 400rpm coarse pitch during this test RPM achieved 06ceee on one fuel pump only and with both pumps running 255 OP C complete mag drop checks at See Cavalon POH RSUK0334 for limits 4 000rpm Copyright RotorSport UK Ltd Page 13 of 17 Form F192 Rev2 dated 17 03 15 RotorSport UK Ltd 256 Confirm Gen light is on when engine not running and off or flickering gently when running at above 2000rpm 257 Confirm Gen2 light is on when engine not If external generator fitted running and off or flickering gently when running at above 2000rpm 259 Inspect instruments for measurements
11. e If cracks or deformation found then or free play shown by any sign of wear or ground aircraft and call RSUK for damage between the upper mast stainless advice steel and lower mast part of body 13 Inspect upper mast for damage twisting If cracks or deformation found then CRITICAL PARTS amp ASSEMBLY buckling or other deformation or cracks ground aircraft and call RSUK for especially at welded joints advice 14 Inspect Condition of keel tube and If cracks or deformation found then CRITICAL PARTS amp ASSEMBLY security of attachment to composite body ground aircraft and call RSUK for Screws and band clamp advice Check tail plane horizontal i e keel tube not twisted 15 Inspect keel tube protection pads Replace if worn see Cavalon Pro condition and attachment AMM RSUK0335 16 Inspect External structure of body sound If cracks or deformation found then with no cracks distortion or damage Pay ground aircraft and call RSUK for particular attention to the lower mast area advice around the air intake duct Undercarriage main gear and brakes 20 Inspect landing gear spar and If cracks or deformation found then attachments to body for damage or fatigue ground aircraft and call RSUK for cracks amp deformation advice Copyright RotorSport UK Ltd Page 2 of 17 Form F192 Rev2 dated 17 03 15 RotorSport UK Ltd 21 Inspect wheel spats general condition
12. ecurity cracks or fractures 212 Inspect plexiglass surfaces 3 plcs for cleanliness and obscurity Determine if acceptable for flight 213 F C opening and closing operation and See Cavalon Pro AMM RSUK0335 for effectiveness of door locks load values 214 F C free and correct operation of sliding side windows DV windows 215 F C security and free movement of rotary window vents Pitot static system 220 Inspect pitot tube general condition secure installation no obstructions Check correct function of heater Caution risk of burn injury 221 Inspect static ports open placards installed no obstructions Other Copyright RotorSport UK Ltd Page 12 of 17 Form F192 Rev2 dated 17 03 15 RotorSport UK Ltd 225 Inspect Cabin ventilation ensure port under body is free from obstruction 226 F C Cabin heat if fitted ensure water valve opens and closes on cockpit demand and that electric fan starts on selection of hot 227 Inspect seat mountings secure and backrest adjustment correct operation 228 Inspect all seat belt attachment points for tightness and security 229 Inspect headset connector plate in good condition and headset hanger secure 230 Inspect external radio antenna check for Fitted centrally on the underbody damage and security 231 Inspect external transpon
13. eter bolt pitch bolt roll bolt replaced 1 inspection Name A3 7 authorisation no 2 inspection Name Engineer authorisation no Or qualified pilot licence no Copyright RotorSport UK Ltd Page 4 of 17 Form F192 Rev2 dated 17 03 15 RotorSport UK Ltd Rotor Head Controls 100 F C rod ends for cracks amp freedom of movement both free and at control extremes 101 F C rotor head reaches pitch and roll stops Inspect pitch and roll angles achieved 102 Inspect pitch and roll cable attachments to upper mast secure CRITICAL PARTS amp ASSEMBLY 104 Inspect inside a c all bearings free all bearing retaining rivets secure Pushrods attachments and pivot mountings secure with no damage or chafing Electrical cables and connectors undamaged 105 Service lube lubricate bearings and ball joints with Ballistol oil 106 Inspect push pull cable mountings secure with no chafing 107 Op C for free play in stick control eg bearings or cable wear Nose wheel and Rudder controls 110 Op C Check pedals for ease of movement Check from each seat 111 Inspect tension of cable between central control link mixer unit and nose wheel link and re tension if required Check turnbuckles secured and no chafing of cables See Cavalon AMM RSUK0335 112 Service lube lubricate pedal bearing and sliding b
14. gyroplanes have a variant These rotor blades are lifed at of RotorSystemll in which the blades 2 500hrs have reduced angle of incidence The rotor must not be replaced with RotorSystem II 8 4m RAO a different type Identification is by red end caps and black clamping profile 201 Inspect blades to manufacturers Repair only as Cavalon AMM CRITICAL PARTS amp ASSEMBLY recommendations for any damage splits RSUK0335 etc 205 Confirm teeter bolt nut is hand tight 1 2Nm Dupilicate signature required if CRITICAL PARTS amp ASSEMBLY max and split pin fitted and correctly formed disturbed Engineer authorisation no Engineer authorisation no Or qualified pilot licence no Copyright RotorSport UK Ltd Page 11 of 17 Form F192 Rev2 dated 17 03 15 RotorSport UK Ltd 206 Check torques on blade to hub bar If any evidence of blade to hub CRITICAL PARTS amp ASSEMBLY bolts nuts in situ looseness it will be necessary to remove the rotor dis assemble blades from hub bar and check holes for wear or fretting On re assembly M8 Bolt torque is 25Nm Refer to Section 9 General Notes of the Maintenance Manual for re usage of nyloc nuts Instrument S NoO 0 0eeee ee eee Calibrated until 2 eeeeeee Body and doors 210 Inspect doors for cracks damage or distortion preventing easy opening and closing 211 Inspect door hinges for s
15. ite 243 and Engineer authorisation no replace tightening to 15Nm Second inspection required if any bolt SIGH spa Gis Bite oes car aa removed replaced 2 inspection Name Instrument S No 2 20eeee ee eee Engineer authorisation no Or qualified pilot licence no Calibrated until eeeeeee IG stats aint ates ane Syne 121 Inspect rudder to tail fastenings Torque check the single M6 or M8 bolt 1 inspection Inspect tail and rudder for signs of composite damage and cleanliness of drain holes at the top bearing If any visible movement remove bolt re Loctite 243 and replace M6 test at 8Nm fit to 10Nm M8 test at 10Nm fit to 12Nm Second inspection required if bolt removed replaced Name Engineer authorisation no 2 inspection Name Engineer authorisation no Or qualified pilot licence no Copyright RotorSport UK Ltd Page 6 of 17 Form F192 Rev2 dated 17 03 15 RotorSport UK Ltd 122 F C rudder control cable tension pedal load For limits and methods see Cavalon check AMM RSUK0335 Instrument S NO ceeeee tense ees Reading Calibrated until aaee eee 123 Inspect rudder control angles For limits and methods see Cavalon AMM RSUKO0335 Instrument S NO ceeeeeeeeee eres Readingin uia Calibrated until 0aanee 124 Overall check that all control system bolts are cor
16. lock of adjuster with Ballistol oil 113 Inspect visible rudder cables for frays corrosion wear or chafing and any crimped fittings for signs of movement Lubricate cables with Ballistol oil 114 Inspect all clevis joints at central control link mixer unit secured free to move and no chafing 115 Inspect central control link mixer unit freedom of movement and main bolt secured Access main bolt through rubber plug located centrally underneath body 116 Inspect security of wire locking retaining the rudder cables to the keel tube Copyright RotorSport UK Ltd Page 5 of 17 Form F192 Rev2 dated 17 03 15 RotorSport UK Ltd 117 Inspect tail rod end bearings for looseness and freedom of operation and fitted with snubbing washers Lubricate control cables with Ballistol oil 118 Inspect security and integrity of keel tube Use 10x magnifying glass and suitable CRITICAL PARTS amp ASSEMBLY in area of attachment to body illumination to check for cracks in the tube 119 Inspect integrity of tail attachment lugs Use 10x magnifying glass and suitable CRITICAL PARTS amp ASSEMBLY welded to keel tube 4 plcs illumination to check for cracks on outside of the joint 120 Inspect tail for security to airframe Torque check the M8 bolts to 12Nm 1 inspection 4 bolts 4 plcs If any visible movement Name remove each bolt re Loct
17. nspect nose wheel rubber damper general condition and correct operation External lights 50 Op C check red anti collision light function and security fitted to each mainwheel spat 51 Op C check strobe function 52 Op C check nav light function Red to left green to right white to rear Copyright RotorSport UK Ltd Page 3 of 17 Form F192 Rev2 dated 17 03 15 RotorSport UK Ltd 53 Op C check nose light function 54 Op C check landing light function and security fitted in binnacle under nose Electrical instruments 60 Inspect panel mounting screws secure 61 Inspect panel connections for security 62 F C slip indicator Confirm slip string undamaged and free moving 65 Inspect gel battery for security of If required connect ground power to mounting casing leakage and state of fully charge battery in anticipation of charge tests later in this Worksheet 66 Op C check function of instrument panel lights 67 Op C check function of cabin light if fitted Rotor head 83 Inspect brake pad for function Pad replaceable as a service item 84 Op C Check roll and pitch trim cylinders Seal service kit is available from RSUK for free function and slider damage or excess seal leakage 85 Check all attachment hardware secure and Second signature required if any pin CRITICAL PARTS amp ASSEMBLY verify 4 off split pins in place and correctly formed Main bearing bolt te
18. ols or vital structural points The person s performing the work should complete the worksheet columns as below e Ifthe person completing Eng r does not have Licenced Engineer authorisation there must be a second initial by a CAA authorised person in each adjacent Licenced Engineer cell denoting acceptance of the task specified e Ifthe person has Engineer authorisation the Eng r cell should be struck out and a single entry of initials made in the Licenced Eng r certifier cell Case 2 for work where engine controls or flying controls or vital structural points are disturbed where a duplicate inspection is required and shown in the worksheet The person s performing the work should complete the worksheet columns as shown above and repeated below e Ifthe person completing Eng r does not have Licenced Engineer authorisation there must be a second initial by an CAA authorised person in each adjacent Licenced Engr cell denoting acceptance of the task specified e Ifthe person has Licenced Engineer authorisation the Eng r cell should be struck out and a single entry of initials made in the Licenced Eng r cell In addition to the above there is a requirement for inspection then duplicate inspection by an independent person of the finished task e The licenced engineer certifying the task must enter his name CAA authorisation number and full signature under 1 inspection e The indepen
19. rect items properly fitted and tight Engine For engine servicing refer to the engine manual issued with the aircraft Rotax 914F The NOTE All engine checks to be in full annual engine service is required only when no engine servicing has been carried out accordance with manufacturers manual in the last 12 months Otherwise apply on condition Servicing must be carried out in line with and recorded on the Rotax service schedule contained within the Line Maintenance manual for the engine fitted A record of any work carried out must be made in the Engine Log Book 130 Engine service fasteners If the magnetic inspection plug or the crankshaft locking screw plug are disturbed then any wire locking present must be properly reinstated Engine other 133 Service lube Ensure choke and throttles move freely from stop to stop and that turbo detent can be felt correctly Ensure cables are synchronised 135 Inspect engine bearer bolts for paint stripe and if moved re loctite and tighten to Instrument S NO cceeeee cece eee 35Nm Otherwise check bolt torque Re Calibrated until cccceeeeeeeee apply paint stripe as required 136 Inspect oil cooler general condition security of mountings no leaks or cracks in fittings Copyright RotorSport UK Ltd Page 7 of 17 Form F192 Rev2 dated 17 03 15 RotorSport UK Ltd 137 Inspect
20. to the Woodcomp User Manual UM 05 EN issued with the aircraft Servicing must be carried out in line with the Woodcomp service schedule contained within the propeller manual A record of any work carried out must be made in the Propeller Log Book 190 Check propeller blades for cracks delamination or impact damage Minor damage may be repaired as defined in Woodcomp User Manual Section 19 191 Check security of propeller protection tape May be replaced as defined in Woodcomp User Manual Section 19 192 Check satisfactory condition function of the tab washers between mounting bolts and gearbox flange 6 plcs If replacement is required first tighten the bolts progressively to 22Nm before setting the tab locking Copyright RotorSport UK Ltd Page 10 of 17 Form F192 Rev2 dated 17 03 15 RotorSport UK Ltd 193 Check security of brush box fasteners Minimum engagement of brush in and condition of brushes housing 4mm Original length 14mm Instrument S NO ceeeeeeeeee ees Calibrated until eee es 197 Adjust the propeller to the fully coarse pitch position visually verifying that all blades move correctly and simultaneously and that the controller LED2 Max warning light functions correctly Return the propeller to the fully fine position verifying correct function of the LED1 Min warning light Rotor Cavalon Pro
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