Cavalon Periodic Service Worksheet

deformation or cracks at welds X X Inspect stabilizer security to airframe bolt torque X X 20Nm +/-5Nm Inspect stabilizer and rudder for signs of composite damage, particularly at joints and welds. Ensure drain holes are free X X Inspect presence & security of rudder trim tab X X Flight Control Inspect push pull cables for correct and secure installation, no play, no chafing, no cracks or splits visible at the end-fittings. Inspect security of PPC clamps X X Max play 5mm 67-00-00 6-1 67-00-00 8-1 Inspect left and right flight control stick general condition, freedom and full range of movement, secure installation, cable routing, no damage or chafing. X X Check adjustment of roll control travel limiters X X 2mm 27-10-00 5-1 Inspect flight control yoke general condition, freedom of movement, secure installation, damage or deformation, no chafing. Lubricate bearings and ball joints with AG-LUB-01 (Ballistol) X X Airframe/Fuselage Inspect left and right seats and hinges general condition, secure installation, no damage X X Inspect all left and right seatbelt mounting points for tightness and security X X Inspect left and right seatbelts for damage or frays and security of buckles X Manufacturers recommend’n 10yr Inspect backrest adjustment function, retaining mechanism and secure installation X X Inspect intercom panel for security, damage X X Inspect headset holder for security, damage X X Inspect left and right doors general condition, function, condition of seal, no damage or cracks X X Inspect left and right door hinges general condition, secure installation, freedom of movement, no cracks X X Inspect left and right door latches for correct operation, secure installation, wear marks or spurs. X X Inspect left and right door windows general condition, correct operation, no cracks or missing parts. Lubricate sliding window channels with silicone spray X X Ensure slip indicator is present and intact X X Inspect fuselage general condition, no cracks, damage or deformation X X 53-00-00 6-1 Inspect cabin ventilation sliding cover assembly for security, correct operation. Ensure port under body is free from obstruction X X Inspect all antenna and antenna mountings for security, no damage X X Inspect keel tube and keel tube to fuselage connection general condition, secure installation, no cracks or deformation/twisting X X Ac Works nr: Cavalon Periodic Service Worksheet Ac Registration: Service interval: Worksheet no. (If required/used): Date: Cavalon Series Periodic Service Worksheet Page 4 of 8 AG-F-PCA-CV-EN-V5 26.03.2019 Task Description 25h 100h Other MM Chapter/Job Card Reference Entry Nr in Work Report Initials Inspect keel tube protection pads condition and attachment. X X 55-00-00 8-1 Remove mast assembly, visually inspect mast mounting bushes, re-assemble mast assembly 200hr Inspect mast assembly for security, no deformation, no cracks (especially at welds). X Inspect mast rubber bushes for failure or free play, wear or damage. Inspect rubber mounting bush movement. Record movement on Work Report X 62-51-00 6-1 Check torque mast securing bolts. If movement is present, remove, re-apply Loctite and re-torque X 20Nm Inspect all placards/stickers readable and in line with operating limitations X Pilots Handbook or TADS Pitot-Static/Pneumatic System Inspect pitot/ram air tube general condition, secure installation, no obstructions X X Inspect static ports general condition, secure installation, no obstructions, no leaks. Clean and dry static lines as required X X 34-10-00 7-1 34-10-00 5-1 Inspect all pneumatic lines and connectors in the fuselage and engine compartment, no chafing, sharp bends or kinks X X Inspect pneumatic box and compressor for security, no chafing or damage X X Main Gear and Brakes Inspect suspension bow and attachments to airframe and axles for damage or fatigue (cracks & deformation). X X Inspect main wheels general condition, correct pressure, condition of tread, correct seating of valve and cap, secure installation and no play in wheel bearing. Inspect wheel bearing for smooth operation. Ensure slip mark is present and aligned X X 2.0 – 2.2 Bar Recommended 0.5mm min tread Inspect wheel spats for clearance to tyre, secure installation and general condition, no cracking X X Inspect brake lines for secure installation, no leaks, no chafing X X Inspect wheel callipers for secure installation and freedom of operation, no leaks X X 32-40-00 2-1 Inspect brake pads for wear (wear mark/groove must be visible) and condition X 32-40-00 8-2 Inspect brake disc condition. Check-torque 4 x attachment screws X Inspect the centre console throttle/brake unit for correct operation, secure installation, condition of ratchet teeth, brake fluid level, no leaks. X 76-10-00 8-1 Pre-rotator Check the pneumatic clutch for correct operation, secure installation, pneumatic connections, no wear or chafing. X 63-11-10 6-1 ‘Procedures’ item 2: 0.5- 1.0mm for RHlll clutch (63-11-10 5-1 RHll clutch only) 63-11-10 6-1 Check front dog gear (clutch side) and rear dog gear (engine side) general condition, no cracks X 63-11-10 6-1 Ac Works nr: Cavalon Periodic Service Worksheet Ac Registration: Service interval: Worksheet no. (If required/used): Date: Cavalon Series Periodic Service Worksheet Page 5 of 8 AG-F-PCA-CV-EN-V5 26.03.2019 Task Description 25h 100h Other MM Chapter/Job Card Reference Entry Nr in Work Report Initials Connect a manometer to the clutch pneumatic pressure regulator using a T-connector and check time to pressurise. In the event of discrepancies contact AutoGyro Technical Support X X RHll 0-5 bar in 10 sec RHlll 0-8 bar in 10 sec 63-11-10 4-2 Inspect pre-rotator drive shafts with sliding shaft coupling for general condition, secure installation, no cracks (especially at the welded flanges) and free to slide. Lubricate sliding shaft coupling* X X *Liquid Moly LM 47 MoS2 (45506) Inspect angle gearbox general condition, secure installation, no cracks, smooth running, no leaks X X Inspect pre-rotator upper engagement. Inspect backlash X 63-11-30 6-1 Protect steel parts with chain wax, cavity spray or equivalent X Rotor Head Inspect brake/trim cylinder for correct attachment, security, no damage X Inspect roll trim cylinder for correct attachment, security, no damage X Inspect all pneumatic hoses at the rotor head general condition, security, no chafing, brittleness, sharp bends or kinks X X Renew teeter tower/bearing assembly 1500hr Inspect rotor head bridge. Carry out a torque check of the main bolt. Refit split pin X Minimum 120Nm 62-31-00 6-1 Inspect rotor head gimbal for correct operation and secure installation of all attached parts. Record controlled angles on Work Report. Lube AG-GRS-01 (WHS2002) X Fwd: -4° Rear: 20.5° Right: 7.5° Left: 8.75° 62-32-00 6-1 Only Gimbal ll (rotor head ll with conical washers) & Gimbal lll (rotor head lll): Measure breakout force at forward control stick grip. Adjust as required. Lube 200hr Absolute maximum 15Nm 62-32-00 5-1 Inspect three split pins present and secure X X Inspect rotor brake pad(s) for function & wear (also forward pad for rotor head lll) X Protect steel parts with chain wax, cavity spray or equivalent X Fuel System Inspect fuel tanks (from under drain cover) for security, no leaks or traces of leaks, swelling (hoses) or smell of fuel. X Inspect fuel level indication and compare with fuel gauge X Inspect tank interior for foreign debris. Remove if found X X Inspect functionality of low level warning light if fitted X 28-20-00 5-1 Inspect fuel venting lines condition and routing X X Inspect fuel water contamination drain, no leaks X Inspect fuel tank cap for seal deterioration, function & security of fit X Inspect all pipes & hoses of the fuel system for secure installation, no cracks, chafing, kinks or sharp direction changes, deterioration or hardening. X Ac Works nr: Cavalon Periodic Service Worksheet Ac Registration: Service interval: Worksheet no. (If required/used): Date: Cavalon Series Periodic Service Worksheet Page 6 of 8 AG-F-PCA-CV-EN-V5 26.03.2019 Task Description 25h 100h Other MM Chapter/Job Card Reference Entry Nr in Work Report Initials Replace nylon & KL45 fuel filter if contaminated. Replace as pair Recommended 500hr/3Yr or on condition 28-20-00 6-1 28-20-00 8-1 Inspect and clean electric fuel pump internal filter(s) if fitted X 28-20-00 6-1 Inspect the fuel shut-off valve correct operation, secure installation, presence and condition of safe- guard X Oil System Inspect oil cooler general condition, secure installation, cleanliness, no leaks, chafing, damage or deformed fins X Inspect all hoses and pipes of the oil system for secure installation, no leaks, chafing, tears/cracks, hardening, kinks or sharp direction changes. Inspect firm seating of hoses on the fittings. X Inspect thermostat assembly for secure attachment, no cracks, leaks or porous hoses X Coolant System Inspect all hoses and pipes of the coolant system for secure installation, no leaks, chafing, tears/cracks, hardening, kinks or sharp direction changes. Inspect firm seating of hoses on the fittings. X Inspect radiator general condition, secure installation, cleanliness, no leaks, chafing, damage or deformed fins X Inspect the radiator fan for correct operation, no damage of fan cage and blades X X Inspect presence/condition of heat protection on coolant hose from cylinder 2 X Inspect coolant overflow tank for correct coolant level (double rings on the Fuel and Engine Coolant Dipstick), secure installation, no chafing X X Inspect for secure attachment of thermostat, presence of earth cable, no leaks, damage or chafing X Propeller Inspect propeller blades for cracks, delamination or impact damage X X Remove and inspect spinner (if fitted), inspect spinner mounting plate general condition, secure installation, no cracks. X X 61-10-00 4-1 Inspect propeller to frame clearance X X 10cm minimum HTC: Perform a visual inspection of the hub. Ensure safety paint on head of bolt to hub is not broken (if applied). Check torque flange bolts and re-apply paint if required X X 15Nm HTC: Inspect leading edge protective tape (if fitted) for air bubbles, lifted edges or deterioration X X HTC: Ensure all blades have the same pitch X AG propeller pitch gauge 61-10-00 5-1 IVO: Inspect blades for loose pitch lever (tap test), condition of contact plate brushes and tension strips between blades if fitted. Check torque flange bolts X X 40Nm IVO: Inspect leading edge protection for lifted edges or deterioration X X Ac Works nr: Cavalon Periodic Service Worksheet Ac Registration: Service interval: Worksheet no. (If required/used): Date: Cavalon Series Periodic Service Worksheet Page 7 of 8 AG-F-PCA-CV-EN-V5 26.03.2019 Task Description 25h 100h Other MM Chapter/Job Card Reference Entry Nr in Work Report Initials IVO: Inspect leading edge protection for lifted edges or deterioration X X IVO: Inspect cable routing, ensure secure X Refit spinner (if applicable) using AG-BAS-02 Loctite 243 X X Engine and Accessories NOTE: All engine checks to be carried out in accordance with manufacturer’s instructions. Include supplementary procedures below. Inspect starter battery for security, deformation, cracks, chafing leaks, oxidization, pole cover, Charge state/condition. X Inspect the engine mounting frame general condition, no cracks or distortion X Inspect the engine mounting bushes for secure installation and condition of rubber X Inspect the engine mounting ring frame for secure installation, no chafing, distortion, cracks or missing paint. Check torque 4 ring mount to engine securing bolts X 40Nm Inspect rectifier-regulator general condition, secure installation, no chafing of wiring, , ground (L-) connectors not corroded or molten, connector tightness X Inspect exhaust system general condition, secure installation, no leaks, cracks (tap test) or loose rivets. Inspect presence and condition of retaining springs and safety cable. Ensure the sliding joint is free to move at exhaust manifold from cylinder 1. Lube with anti-seize or copper paste X Inspect the silencer for secure installation of clamps, rivets and lock wire. Ensure lock wire passes through clamp screw housing and slot in screw head X Ensure wire locking is present on: Oil tank drain plug Oil sump drain plug Oil pump Magnetic plug (after the first 100hr service) X X Ensure choke and throttle lever moves freely from stop to stop, and that turbo detent can be positively felt. Ensure cables are mechanically synchronised. Lube lever joints AG-LUB-01 (Ballistol) X X Inspect clearance between airbox (if fitted) and engine mounting frame X X 71-20-00 6-1 Supplementary procedure: Oil change: On draining all oil, ensure it is run through a 190 micron filter paper, attach photo of findings to this protocol X Supplementary procedure: Inspection of magnetic plug: Attach a photo of the magnetic plug before cleaning to this protocol X Supplementary procedure: Inspection of oil filter: Attach a photo of the paper mesh from the cut open filter to this protocol X Ac Works nr: Cavalon Periodic Service Worksheet Ac Registration: Service interval: Worksheet no. (If required/used): Date: Cavalon Series Periodic Service Worksheet Page 8 of 8 AG-F-PCA-CV-EN-V5 26.03.2019 Task Description 25h 100h Other MM Chapter/Job Card Reference Entry Nr in Work Report Initials Supplementary procedure: Refilling of oil: Record type of oil used to refill in the Work Report X Finalization Work Assemble the rotor system on the aircraft. Lube teeter assembly through grease nipple with AG- GRS-01 (WHS 2002) X X 62-11-00 4-4 Carry out a tool and loose article check X X Ensure all service covers, cowlings and keel tube cover are re-installed X X 52-00-00 0-1 52-00-00 4-1 52-40-00 0-1 Securely tie down the aircraft and carry out a ground run X X MM 05-60-00 AG-F-PGR-CD Re-install centre console X X 67-10-00 4-1 Carry out a test flight if required X X Ensure all log book entries are completed appropriately, and service record updated X X Carry out any other documentation requirements by the countries Airworthiness Administration X X Tasks completed by (Name): Signature: Initials: Date: Engine hours logged: Airframe hours logged: The technical content of this document should be approved with the national Airworthiness Authority as required. Maintenance Release: The work recorded above (all pages) has been completed to my satisfaction and in that respect the aircraft is considered fit for flight. Signature: Initials: Date: Inspector or licence number (if required): Dated: Comments: