Flight and Operation Manual for Gyroplane Cavalon

3.9 Warning and Caution Lights........................................................................... 3-5 3.10 Parameters out of Limits ................................................................................ 3-6 3.11 Rotor Bearing Temperature ........................................................................... 3-6 3.12 Loss of Visibility ............................................................................................. 3-7 3.13 Recovery System / Rotor System .................................................................. 3-7 Flight Manual Cavalon Table of Contents List of Effective Pages AutoGyro_FOM_Cavalon Revision 1.3 ñ Issue Date 01.04.2012 Index / LOEP 2 3.14 Rotor Icing..................................................................................................... 3-7 3.15 Landing with a Deflated Tyre ......................................................................... 3-7 3.16 Failure of CSP/VPP Propeller (if installed) ..................................................... 3-8 3.17 Alternative Method of Engine Shut-down ....................................................... 3-9 NORMAL PROCEDURES SECTION 4 - 4.1 Airspeeds for Safe Operation ........................................................................ 4-1 4.2 Preparation for Flight ..................................................................................... 4-1 4.3 Daily or Pre-flight Checks .............................................................................. 4-1 4.4 Before Boarding ............................................................................................ 4-4 4.5 Before Starting Engine .................................................................................. 4-4 4.6 Starting Engine.............................................................................................. 4-5 4.7 Taxi and Run-up............................................................................................ 4-6 4.8 Take-off Procedure ....................................................................................... 4-6 4.9 Take-off Run ................................................................................................. 4-8 4.10 Climb............................................................................................................. 4-8 4.11 Cruise ........................................................................................................... 4-8 4.12 Descent......................................................................................................... 4-9 4.13 Approach....................................................................................................... 4-9 4.14 Landing ......................................................................................................... 4-9 4.15 Go-around ................................................................................................... 4-10 4.16 After Landing............................................................................................... 4-10 4.17 Engine Shut-down ....................................................................................... 4-11 4.18 Parking........................................................................................................ 4-11 4.19 Special Procedure: Short Field Take-off ...................................................... 4-11 4.20 Special Procedure: Slow Speed Sink and Recovery .................................... 4-11 4.21 Flight with Doors Removed ......................................................................... 4-12 4.22 Training Engine In-flight Shut-down and Air Restart .................................... 4-12 4.23 Noise Abatement......................................................................................... 4-12 PERFORMANCE SECTION 5 - 5.1 Demonstrated Operating Temperature .......................................................... 5-1 5.2 Airspeed Calibration ...................................................................................... 5-1 5.3 Height-Velocity Diagram ................................................................................ 5-2 5.4 Speeds.......................................................................................................... 5-3 5.5 Rate of Climb ................................................................................................ 5-3 5.6 Take-off and Landing Data ............................................................................ 5-3 5.7 Influence on Take-off Distance and Climb Rate ............................................. 5-4 5.8 Sink Rate and Glide Ratio ............................................................................. 5-6 5.9 Additional Performance Data......................................................................... 5-6 5.10 Sound Exposure Level / Noise Characteristics .............................................. 5-6 WEIGHT AND BALANCE SECTION 6 - 6.1 General ......................................................................................................... 6-1 6.2 Weight and Balance Record .......................................................................... 6-1 6.3 Compliance with Weight and Balance ........................................................... 6-1 Flight Manual Cavalon Table of Contents List of Effective Pages AutoGyro_FOM_Cavalon Revision 1.3 ñ Issue Date 01.04.2012 Index / LOEP 3 SYSTEM DESCRIPTION SECTION 7 - 7.1 Introduction.................................................................................................... 7-1 7.2 Airframe and Undercarriage........................................................................... 7-1 7.3 Doors, Windows and Exits ............................................................................. 7-1 7.4 Fuel System .................................................................................................. 7-1 7.5 Pneumatic System......................................................................................... 7-3 7.6 Power Plant ................................................................................................... 7-4 7.7 Propeller ........................................................................................................ 7-4 7.8 Rotor System................................................................................................. 7-4 7.9 Vibration Damping ......................................................................................... 7-5 7.10 Flight Controls ............................................................................................... 7-5 7.11 Electrical System ........................................................................................... 7-7 7.12 Lighting System ............................................................................................. 7-8 7.13 Instrument Panel ........................................................................................... 7-8 7.14 Intercom ...................................................................................................... 7-12 7.15 Pitot Static ................................................................................................... 7-12 7.16 Indicators and Sensors ................................................................................ 7-12 7.17 Seats and Seatbelts .................................................................................... 7-12 7.18 Stowage Capacity........................................................................................ 7-12 HANDLING AND SERVICING SECTION 8 - 8.1 Maintenance Obligations ............................................................................... 8-1 8.2 General ......................................................................................................... 8-1 8.3 Ground Handling ........................................................................................... 8-2 8.4 Cleaning ........................................................................................................ 8-2 8.5 Refuelling ...................................................................................................... 8-2 8.6 Checking of Engine Oil Level ......................................................................... 8-3 8.7 Checking of Engine Coolant Level ................................................................. 8-3 8.8 Tire Pressure ................................................................................................. 8-3 8.9 Lubrication and Greasing............................................................................... 8-3 8.10 Replenishing of Fluids ................................................................................... 8-4 8.11 Engine Air Filter ............................................................................................. 8-4 8.12 Propeller ........................................................................................................ 8-4 8.13 Battery ........................................................................................................... 8-4 8.14 Winter Operation ........................................................................................... 8-4 8.15 Removal, Disassembly, Assembly and Installation of the Rotor ..................... 8-5 8.16 Road Transport ............................................................................................. 8-8 8.17 Repairs .......................................................................................................... 8-9 SUPPLEMENTS SECTION 9 - 9-1 Variable Pitch Propeller - IVO 9-2 Lights 9-3 GPS/Moving Map Systems 9-4 Fire Indication SAFETY TIPS SECTION 10 - Flight Manual Cavalon Table of Contents List of Effective Pages AutoGyro_FOM_Cavalon Revision 1.3 ñ Issue Date 01.04.2012 Index / LOEP 4 APPENDIX Operator Registration Form Customer Feedback Form Incident Reporting Form Flight Manual Cavalon Table of Contents List of Effective Pages AutoGyro_FOM_Cavalon Revision 1.3 ñ Issue Date 01.04.2012 Index / LOEP 5 LIST OF EFFECTIVE PAGES Page(s) Rev. Date Page(s) Rev. Date 1-1 to 1-8 1.3 01.04.2012 8-1 to 8-9 1.3 01.04.2012 2-1 to 2-10 1.3 01.04.2012 9-1 - 1 to 3 1.3 01.04.2012 3-1 to 3-9 1.3 01.04.2012 9-2 - 1 1.3 01.04.2012 4-1 to 4-13 1.3 01.04.2012 9-3 - 1 1.3 01.04.2012 5-1 to 5-6 1.3 01.04.2012 9-4 - 1 1.3 01.04.2012 6-1 1.3 01.04.2012 10-1 to 10-4 1.3 01.04.2012 7-1 to 7-12 1.3 01.04.2012 Flight Manual Cavalon Table of Contents List of Effective Pages AutoGyro_FOM_Cavalon Revision 1.3 ñ Issue Date 01.04.2012 Index / LOEP 6 INTENTIONALLY LEFT BLANK Flight Manual Cavalon SECTION 1 GENERAL AutoGyro_FOM_Cavalon Revision 1.3 ñ Issue Date 01.04.2012 1 - i CONTENTS 1.1 Introduction.................................................................................................... 1-1 1.2 Certification ................................................................................................... 1-1 1.3 Performance Data and Operating Procedures ............................................... 1-1 1.4 Definition of Terms ........................................................................................ 1-2 1.5 Important Note............................................................................................... 1-2 1.6 Three-view of the Cavalon ............................................................................. 1-3 1.7 Description .................................................................................................... 1-4 1.8 Technical Data .............................................................................................. 1-4 1.9 Rotor ............................................................................................................. 1-4 1.10 Engine ........................................................................................................... 1-5 1.11 Propeller ........................................................................................................ 1-5 1.12 Unit Conversion ............................................................................................. 1-6 1.13 Abbreviations and Terminology ..................................................................... 1-7 Flight Manual Cavalon SECTION 1 GENERAL AutoGyro_FOM_Cavalon Revision 1.3 ñ Issue Date 01.04.2012 1 - ii INTENTIONALLY LEFT BLANK Flight Manual Cavalon SECTION 1 GENERAL AutoGyro_FOM_Cavalon Revision 1.3 ñ Issue Date 01.04.2012 1-1 GENERAL SECTION 1 - 1.1 Introduction This manual is designed as an operating guide for pilots, instructors, and owners/operators, providing information for the safe and efficient operation of this gyroplane. It includes material required to be furnished to the pilot by the competent certification authority. This handbook is not designed as a substitute for adequate and competent flight instruction, however. Pilots of this aircraft must hold a proper license including the class rating ëgyroplaneí, corresponding to the aircraftís registration. A special endorsement may be required to fly with passengers. It is the pilotís responsibility to be familiar with this handbook, the special characteristics of this gyroplane, and all other information and legal requirements relevant for the operation in his country. The pilot is responsible to determine the gyroplane is safe for flight, and to operate the aircraft with respect to the procedures and limitations provided in this manual. It is the ownerís/operatorís responsibility to have this gyroplane registered and insured, according to country-specific regulations. The aircraft owner/operator is also responsible for maintaining the gyroplane in airworthy condition. Maintenance instructions are provided in the Maintenance Manual and in SECTION 8 of this manual. Note that depending on the kind of operation, type of maintenance activity, or component involved, the competent authority may dictate qualified personnel and/or respective facilities. 1.2 Certification The Cavalon is designed, tested and certified according to the German design specifications for microlight gyroplanes (ìBauvorschriften f¸r Ultraleichte Tragschrauberî, BUT 2001) including its latest amendment published in ìNachrichten f¸r Luftfahrerî NfL II 13/09 issued 12.02.2009, as well as the British Civil Airworthiness Requirements (BCAR) Section T. The corresponding certification documents (Ger‰te-Kennblatt) have been issued by the responsible Germany department DULV (Deutscher Ultraleichtflugverband e.V.), respectively the German national certifying authority. The noise certificate was granted according to the German requirements for noise protection for microlight gyroplanes (ìL‰rmschutzverordnung f¸r Ultraleichte Tragschrauberî). 1.3 Performance Data and Operating Procedures The legal basis for operating a gyroplane is provided by national law and its respective regulations. The instructions and conditions contained have to be considered when operating the gyroplane. All documented performance data and operating procedures have been identified within the certification processes for this gyroplane by means of flight test and analysis. Flight Manual Cavalon SECTION 1 GENERAL AutoGyro_FOM_Cavalon Revision 1.3 ñ Issue Date 01.04.2012 1-2 1.4 Definition of Terms This manual uses WARNINGs, CAUTIONs and NOTEs in bold capital letters to indicate especially critical and important instructions. Additionally, the colour of the panel (red, yellow, and grey shading) highlights the significance of the instruction. Definitions for each term are given below. WARNING A warning means that the neglect of the appropriate procedure or condition could result in personal injury or loss of life. CAUTION A caution means that the neglect of the appropriate procedure or condition could result in damage to or destruction of equipment. NOTE A note stresses the attention for a special circumstance, which is essential to emphasize. 1.5 Important Note Before each flight pilots must make themselves familiar with the appropriate navigational, weather and safety information pertinent to their planned route. The limitations provided in SECTION 2 of this manual must be respected at all times. Check the manufacturerís web site www.auto-gyro.com regularly for flight manual updates, airworthiness directives, service bulletins, or safety information. Abrupt manoeuvres or flight in heavy turbulence must be avoided as this could lead to rotor speed variations associated with high stress, possible damage to the aircraft, or uncontrollable attitudes. Flight Manual Cavalon SECTION 1 GENERAL AutoGyro_FOM_Cavalon Revision 1.3 ñ Issue Date 01.04.2012 1-3 1.6 Three-view of the Cavalon Flight Manual Cavalon SECTION 1 GENERAL AutoGyro_FOM_Cavalon Revision 1.3 ñ Issue Date 01.04.2012 1-4 1.7 Description General Characteristics  Gyroplane with nose gear wheel chassis  Aircraft structure is a GRP/CRP monocoque  Two-seat side-by-side configuration (monocoque design)  Main landing gear with GRP (glass fibre reinforced plastic) spring spar and hydraulic disc brakes  Extruded aluminium rotor  Rotor head controlled with push-pull control cables  Rudder controlled with cables  Rudder and stabilizer surfaces made of GRP (or carbon fibre) 1.8 Technical Data Length: ...................................................................................................4.60 m Width: .....................................................................................................1.75 m Height: ....................................................................................................2.82 m Empty weight: ....................................................................... 250.0 kg (nominal) Payload: ............................................................................... 250.0 kg (nominal) Take-off weight/mass (max.): ................................................................ 500.0 kg Fuel tank capacity: ...................................................................................100 ltr 1.9 Rotor General Type: ..............................2-bladed, fixed pitch, free to teeter, with red end caps Material: ............................................... EN AW 6005A T6 aluminium extrusion Blade profile: ................................................................................. NACA 8H12 Rotor diameter.......................................................................................... 8.4 m Rotor disc area .................................................................................... 55.4 sqm Rotor disc load ................................................................................. 8.1 kg/sqm Flight Manual Cavalon SECTION 1 GENERAL AutoGyro_FOM_Cavalon Revision 1.3 ñ Issue Date 01.04.2012 1-5 1.10 Engine ROTAX 912 ULS  4-cylinder, four-stroke spark-ignition engine with opposed cylinders  Liquid cooled cylinder heads  Air cooled cylinders  Dry sump forced lubrication with separate oil tank  Automatic valve adjustment by hydraulic tappet  2 carburettors  Mechanical and electrical fuel pump  Electronic dual ignition  Propeller speed reduction unit, engine mount assembly  Electric starter (12V 0,6kW)  Air intake system, exhaust system with muffler ROTAX 914 UL  4-cylinder, four-stroke spark-ignition engine with opposed cylinders with turbo charger  Liquid cooled cylinder heads  Air cooled cylinders  Dry sump forced lubrication with separate oil tank  Automatic valve adjustment by hydraulic tappet  2 carburettors  2 electrical fuel pumps  Electronic dual ignition  Propeller speed reduction unit, engine mount assembly  Electric starter (12V 0,6kW)  Air intake system, exhaust system 1.11 Propeller HTC 3 Blade Airscrew with ground adjustable pitch made of CRP / GRP Model ......................................................................... HTC 3 Blade 172 ccw 3B Number of blades ............................................................................................ 3 Diameter ............................................................................................... 172 cm In-flight pitch adjustment ........................................................................... none Flight Manual Cavalon SECTION 1 GENERAL AutoGyro_FOM_Cavalon Revision 1.3 ñ Issue Date 01.04.2012 1-6 1.12 Unit Conversion Multiply by to obtain kts (knots) 1.852 km/h km/h (kilometres per hour) 0.54 kts mph (miles per hour) 1.61 km/h km/h (kilometres per hour) 0.62 mph ft (feet) 0.305 m m (metres) 3.28 ft Flight Manual Cavalon SECTION 1 GENERAL AutoGyro_FOM_Cavalon Revision 1.3 ñ Issue Date 01.04.2012 1-7 1.13 Abbreviations and Terminology ACL Anti -Collision Light AGL Above Ground Level ATC Air Traffic Control CAS Calibrated AirSpeed ñ indicated speed corrected for installation errors ccw Counter Clock Wise CG Centre of Gravity CHT Cylinder Head Temperature CRP Carbon Reinforced Plastic CSP Constant Speed Propeller DA Density Altitude DULV Deutscher UltraLeichtflugVerband e.V. Empty Wt Empty Weight of the gyroplane including oil, cooling liquid and unusable fuel FOM Flight and Operation Manual G / g G-loading as a factor of gravity GEN Generator GPS Global Positioning System GRP Glass Reinforced Plastic H/V Height-Velocity IAS Indicated AirSpeed ñ airspeed values in this manual refer to indicated air speed ICAO International Civil Aviation Organization In Hg (Manifold) Pressure, corresponding to inch mercury ISA International Standard Atmosphere JNP JahresNachPr¸fung ñ Annual Inspection LED Light Emitting Diode LH Left-Hand LOEP List Of Effective Pages ltr Litre MAP Manifold Absolute Pressure MCP Maximum Continuous Power MTOW Maximum Take-Off Weight (mass) OAT Outside Air Temperature PA Pressure Altitude RBT Rotor Bearing Temperature RH Right-Hand ROZ Research OktanZahlñ means: Octane Number RPM Revolutions Per Minute sqm Square metres TAS True AirSpeed ñ calibrated airspeed corrected for air density TCU Turbo Control Unit (engine) Flight Manual Cavalon SECTION 1 GENERAL AutoGyro_FOM_Cavalon Revision 1.3 ñ Issue Date 01.04.2012 1-8 TOC Table Of Contents TOP Take-Off Power VA Design maneuvering speed VB Design speed for maximum gust intensity VFR Visual Flight Rules VH Maximum level-flight speed at maximum continuous power VHmin Minimum level-flight speed VNE Never-Exceed Speed ñ maximum speed that must never be exceeded VOX Voice Operated eXchange, means: voice activation (level) VPP Variable Pitch Propeller VSI Vertical Speed Indicator VX Speed for best angle of climb VY Speed for best rate of climb and maximum endurance W&B Weight and Balance Flight Manual Cavalon SECTION 2 LIMITATIONS AutoGyro_FOM_Cavalon Revision 1.3 ñ Issue Date 01.04.2012 2 - i CONTENTS 2.1 General ......................................................................................................... 2-1 2.2 Environmental Limitations .............................................................................. 2-2 2.3 Colour Code for Instrument Markings ............................................................ 2-2 2.4 Airspeed Limitations and Instrument Markings............................................... 2-3 2.5 Rotor Speed Limitations and Instrument Markings ......................................... 2-3 2.6 Powerplant Limitations and Instrument Markings ........................................... 2-4 2.7 Weight and Balance ...................................................................................... 2-6 2.7.1 Weight Limits ............................................................................................ 2-6 2.7.2 Centre of Gravity (CG) Limits .................................................................... 2-6 2.7.3 Demonstrated Structural Load Factors...................................................... 2-6 2.8 Flight Crew .................................................................................................... 2-7 2.9 Kinds of Operation ......................................................................................... 2-7 2.10 Fuel ............................................................................................................... 2-8 2.10.1 Approved Fuel Grades ......................................................................... 2-8 2.10.2 Fuel Tank Capacities ........................................................................... 2-8 2.10.3 Unusable Fuel...................................................................................... 2-8 2.11 Minimum Equipment ...................................................................................... 2-8 2.12 Placards ........................................................................................................ 2-9 Flight Manual Cavalon SECTION 2 LIMITATIONS AutoGyro_FOM_Cavalon Revision 1.3 ñ Issue Date 01.04.2012 2 - ii INTENTIONALLY LEFT BLANK Flight Manual Cavalon SECTION 2 LIMITATIONS AutoGyro_FOM_Cavalon Revision 1.3 ñ Issue Date 01.04.2012 2-1 LIMITATIONS SECTION 2 - This section contains operating limitations, instrument markings and basic placards which are required for safe operation of the gyroplane, including its engine, and standard equipment or systems. 2.1 General WARNING The operation of a gyroplane demands professional pilot instruction and dedicated training on gyroplanes. Without a valid license the gyroplane must not be operated. WARNING During the entire flight adequate rotor loading must be maintained. Do not perform any manoeuvres resulting in the sensation of feeling light or near weightless. WARNING Smoking on board is prohibited! CAUTION This gyroplane has been designed and tested for a safe design load of 3g at maximum gross mass. Note that flying at higher speeds in turbulent air, especially in combination with aggressive manoeuvres or a steep turn, can easily create higher loads on the aircraft. NOTE This gyroplane does not comply with the terms of the international authority for civil aviation (ICAO). Therefore, it is not possible to operate it in international air traffic unless specific intergovernmental agreements allow doing so. The reason for this is that there is no international common basis for gyroplanes. Flight Manual Cavalon SECTION 2 LIMITATIONS AutoGyro_FOM_Cavalon Revision 1.3 ñ Issue Date 01.04.2012 2-2 NOTE During the certification process all required safe loads have been successfully demonstrated. However, the gyroplane may be exposed to much higher loads especially when operated on rough surfaces, such as an unprepared grass strip. In this case it is even more essential to perform a thorough pre-flight inspection and have components and parts replaced, where needed. 2.2 Environmental Limitations Maximum wind speed or gust intensity ..................................................... 40 kts Maximum demonstrated crosswind component for take-off and landing ... 20 kts Maximum tailwind component for take-off and landing ................................ 5 kts Maximum demonstrated operating altitude ........................................... 10,000 ft Temperature ................................................................................- 20 to + 40 ∞C WARNING Do not consider flying in the likelihood of severe weather. Thunderstorms may develop rapidly with the risk of heavy precipitation or hail, severe turbulence with strong vertical air movements, and lightning strike. If, despite proper flight planning, a thunderstorm should be encountered, consider a precautionary landing to avoid the squall line. A lightning strike may damage the main rotor bearing. Thorough inspection and maintenance after lightning strike must be performed. 2.3 Colour Code for Instrument Markings Red Operating limits. Pointer should not enter red during normal operation Yellow Precautionary or special operating procedure range Green Normal operating range Flight Manual Cavalon SECTION 2 LIMITATIONS AutoGyro_FOM_Cavalon Revision 1.3 ñ Issue Date 01.04.2012 2-3 2.4 Airspeed Limitations and Instrument Markings Air Speed Marking VNE Never Exceed Speed Red radial 160 km/h Yellow arc 130 ñ 160 km/h VA design maneuvering speed VB design speed for max. gust intensity and VNE for flight with doors removed Green arc 30 - 130 km/h Yellow arc 0 ñ 30 km/h WARNING The maximum speed VNE must never be exceeded! WARNING Sudden or large control input to the front must be avoided at all means, even at speeds below design maneuvering speed VA test. Do not exceed VB when flying through turbulence, gusts or rough winds! 2.5 Rotor Speed Limitations and Instrument Markings Rotor Speed Marking Rotor speed limit Red radial 610 RPM Rotor speed caution range Yellow arc 550 ñ 610 RPM Continuous rotor speed Green arc 200 ñ 550 RPM Maximum pre-rotation speed Yellow radial 240 RPM Flight Manual Cavalon SECTION 2 LIMITATIONS AutoGyro_FOM_Cavalon Revision 1.3 ñ Issue Date 01.04.2012 2-4 2.6 Powerplant Limitations and Instrument Markings Engine Speed Marking Maximum engine speed Red radial 5800 RPM 5 minute take-off power regime Yellow arc 5500 ñ 5800 RPM Maximum continuous power Green arc 1400 ñ 5500 RPM Recommended pre-rotation clutch speed Green radial 1800 RPM Yellow arc 0 ñ 1400 RPM Engine Oil Temperature Marking Maximum oil temperature Red radial 130 ∞C Yellow arc 110 ñ 130 ∞C Maximum continuous oil temperature Green arc 90 ñ 110 ∞C Yellow arc 50 ñ 90 ∞C Minimum oil temperature Red radial 50 ∞C Cylinder Head Temperature Marking Maximum cylinder head temperature Red radial 135 ∞C Green arc 50 ñ 135 ∞C Engine Oil Pressure Marking Maximum oil pressure Red radial 7 bar Yellow arc 5 ñ 7 bar Maximum continuous oil pressure Green arc 2 ñ 5 bar Yellow arc 0.8 ñ 2 bar Minimum oil pressure Red radial 0.8 bar Flight Manual Cavalon SECTION 2 LIMITATIONS AutoGyro_FOM_Cavalon Revision 1.3 ñ Issue Date 01.04.2012 2-5 Manifold Pressure* ROTAX 912 ULS Marking Maximum manifold pressure Red radial 31 In Hg Yellow arc 27 ñ 31 In Hg Maximum continuous MAP Green arc 0 - 27 In Hg Manifold Pressure* ROTAX 914 UL Marking Maximum manifold pressure Red radial 39 In Hg Yellow arc 31 ñ 39 In Hg Maximum continuous MAP Green arc 0 - 31 In Hg * Applicable only if installed, MAP gauge is optional equipment and recommended in conjunction with an adjustable pitch propeller. MAP limits do not apply at engine speeds above 5100 RPM, marked by a yellow triangle at the RPM gauge / engine speed indicator. Flight Manual Cavalon SECTION 2 LIMITATIONS AutoGyro_FOM_Cavalon Revision 1.3 ñ Issue Date 01.04.2012 2-6 2.7 Weight and Balance 2.7.1 Weight Limits Maximum take-off weight (MTOW): ......................................................... 500 kg CAUTION The take-off weight is the total weight of the gyroplane including empty weight, optional/additional equipment, occupants, fuel, and luggage at take-off. The maximum value specified above must never be exceeded. Maximum weight in RH seat (incl. compartment behind seat): ................ 110 kg Maximum weight in LH seat (incl. compartment behind seat): ................. 110 kg Maximum total weight in cockpit (both seats + compartments):................ 200 kg Minimum total weight in both seats: ........................................................... 60 kg NOTE Pilots in the right hand seat weighing less than 60 kg must carry corresponding ballast during solo operation. Storage compartments behind seats Maximum weight in each storage compartment (2 ea.) .............................. 10 kg NOTE When loaded, the weight in each storage compartment has to be deducted from the maximum weight in the respective seat. 2.7.2 Centre of Gravity (CG) Limits The centre of gravity is considered to be within limits if all weight limits above are respected. For details see SECTION 6 of this manual. 2.7.3 Demonstrated Structural Load Factors Demonstrated positive load factor (500 kg) ................................................ + 3 g Demonstrated negative load factor (500 kg) ñ structural limit ...................... - 1 g Important note: the indication of a demonstrated negative load factor represents a structural limit only. In flight, the limitations (see 2.9) have to be respected at all times. Flight Manual Cavalon SECTION 2 LIMITATIONS AutoGyro_FOM_Cavalon Revision 1.3 ñ Issue Date 01.04.2012 2-7 2.8 Flight Crew Minimum crew is one pilot in the RH seat. Harness in the LH seat must be fastened and tight, if not occupied. The LH flight controls must never be restricted by passenger or objects. Passengers must be briefed. 2.9 Kinds of Operation Only day VFR operation is approved! Aerobatic flight is prohibited! NOTE Manoeuvres involving bank angles of more than 60∞ are considered to be aerobatic flight. Low-G manoeuvres are prohibited! WARNING Any maneuver resulting in a low-G (near weightless) condition can result in a catastrophic loss of lateral/roll control in conjunction with rapid main rotor RPM decrease. Always maintain adequate load on the rotor and avoid aggressive forward control input performed from level flight or following a pull- up. Excessive side-slip is prohibited! WARNING Side slip may be performed only with proper training and within safe boundaries. Use gentle pedal input for initiation and stabilization. Do not rely on airspeed indication in side slip. Never perform abrupt control stick input into the direction of motion. Be aware that excessive side slip may result in an uncontrollable and unrecoverable (low-G) attitude. Flight Manual Cavalon SECTION 2 LIMITATIONS AutoGyro_FOM_Cavalon Revision 1.3 ñ Issue Date 01.04.2012 2-8 Flight in icing conditions is prohibited! NOTE Icing may occur even at temperatures above freezing! Operation in strong gusts or wind speeds of more than 72 km/h (40 kts) is prohibited! 2.10 Fuel 2.10.1 Approved Fuel Grades Preferred fuel EN 228 Super or EN228 Super plus (min. ROZ 95) Alternative fuel AVGAS 100 LL (ASTM D910) For operational constraints and maintenance aspects when using preferred fuel and alternative fuel, refer to the engine manufacturerís manual. 2.10.2 Fuel Tank Capacities Maximum tank capacity ............................................................................100 ltr 2.10.3 Unusable Fuel Unusable fuel quantity ................................................................................. 2 ltr 2.11 Minimum Equipment The following equipment must be operative for flight:  Air speed indicator  Altimeter  Compass  Side slip indicator  Rotor RPM indicator  Outside Air Temperature (OAT) and Rotor Bearing Temperature (RBT) indicator  Engine instruments (oil pressure, RPM, CHT)  Pre-rotator Flight Manual Cavalon SECTION 2 LIMITATIONS AutoGyro_FOM_Cavalon Revision 1.3 ñ Issue Date 01.04.2012 2-9 2.12 Placards In clear view of the pilot: Only VFR day is approved Aerobatic flight prohibited! Low-G manoeuvres prohibited! Flight in icing conditions prohibited! For additional limitations see Flight Manual! Max. gross weight: ________ Empty weight: ________ Max. useful load: ________ At RH seat: Max. weight in seat: 110 kg Min. weight in seat: 60 kg Seats + baggage: max. 200 kg At LH seat: Max. weight in seat: 110 kg Solo from right hand seat only Occupant warning (front and aft seat): OCCUPANT WARNING This aircraft has not been certified to an international requirement Flight Manual Cavalon SECTION 2 LIMITATIONS AutoGyro_FOM_Cavalon Revision 1.3 ñ Issue Date 01.04.2012 2-10 At each storage compartment behind seats: Max. load: 10 kg W&B must be respected! At fuel filler neck: Min. ROZ 95 AVGAS 100LL Tank Capacity 100 litres At oil filler neck: Engine Oil: ______________ Approved oil types see engine manual! At fuel shut-off valve: Flight Manual Cavalon SECTION 3 EMERGENCY PROCEDURES AutoGyro_FOM_Cavalon Revision 1.3 ñ Issue Date 01.04.2012 3 - i CONTENTS 3.1 Engine Failure ............................................................................................... 3-1 3.2 Air Restart Procedure .................................................................................... 3-2 3.3 Landing into Trees or High Vegetation ........................................................... 3-2 3.4 Degradation of Engine Power ........................................................................ 3-2 3.5 Evacuating the Aircraft................................................................................... 3-3 3.6 Smoke and Fire ............................................................................................. 3-3 3.7 Off-field Landing ............................................................................................ 3-3 3.8 Flight Control Malfunction .............................................................................. 3-4 3.8.1 Engine Power Control / Throttle ................................................................ 3-4 3.8.2 Rudder Malfunction................................................................................... 3-4 3.8.3 Rotor Head Control ................................................................................... 3-4 3.9 Warning and Caution Lights........................................................................... 3-5 3.9.1 GEN or Low Volt Indicator Light ................................................................ 3-5 3.9.2 Low Volt.................................................................................................... 3-5 3.9.3 BOOST WARN Light ëBoostí (red) - only ROTAX 914 UL .......................... 3-5 3.9.4 BOOST CAUTION Light ëCautioní (orange) - only ROTAX 914 UL............ 3-5 3.9.5 Fire (if installed) ........................................................................................ 3-5 3.9.6 Low Fuel (if installed) ................................................................................ 3-6 3.9.7 Device (if installed) ................................................................................... 3-6 3.9.8 Fan ........................................................................................................... 3-6 3.10 Parameters out of Limits ................................................................................ 3-6 3.11 Rotor Bearing Temperature ........................................................................... 3-6 3.12 Loss of Visibility ............................................................................................. 3-7 3.13 Recovery System / Rotor System .................................................................. 3-7 3.14 Rotor Icing ..................................................................................................... 3-7 3.15 Landing with a Deflated Tyre ......................................................................... 3-7 3.16 Failure of CSP/VPP Propeller (if installed) ..................................................... 3-8 3.17 Alternative Method of Engine Shut-down ....................................................... 3-9 Flight Manual Cavalon SECTION 3 EMERGENCY PROCEDURES AutoGyro_FOM_Cavalon Revision 1.3 ñ Issue Date 01.04.2012 3 - ii INTENTIONALLY LEFT BLANK Flight Manual Cavalon SECTION 3 EMERGENCY PROCEDURES AutoGyro_FOM_Cavalon Revision 1.3 ñ Issue Date 01.04.2012 3-1 EMERGENCY PROCEDURES SECTION 3 - This chapter contains the check lists and procedures to be executed in emergency situations. Emergencies due to defects of the gyroplane or its engine are extremely seldom if the aircraft is checked thoroughly before each flight and continuously maintained. If there should occur a case of emergency anyhow, the guidelines of this chapter are to be followed in order to manage the emergency. However, these procedures do not replace the pilotís appreciation of the individual situation. This gyroplane, like most recreational air vehicles, is fitted with a non-certified engine. This means that there may be a higher risk of engine failure than with a certified aircraft engine, with the associated risks of damage or injury as the result of an unplanned landing. Therefore strict compliance with the engine manufacturerís maintenance schedules, operational procedures and any additional instructions is essential. The aircraft must always be flown with the risk of engine failure in mind, and must not be flown over any areas where a forced landing cannot be safely executed. 3.1 Engine Failure In case of an engine failure the following action is recommended: Engine failure during take-off run  Maintain directional control using sensitive but appropriate pedal input  With the rotor/stick remaining aft, let gyroplane decelerate. Wheel brakes may be used to assist  At walking speed level-off rotor disc, use wheel brakes and bring rotor to a stop Engine failure after lift-off and below 150 ft AGL  The climb-out should be performed according to the Height-Velocity-Diagram in CHAPTER 5  When engine failure occurs, immediately lower nose to enter glide attitude  Continue straight ahead ñ a 180 turn back to the airfield may be a bad option  Maintain airspeed until ground is approached, then perform flare  Depending on final approach speed be prepared to flare more distinctly than normal Engine failure at or above 150 ft AGL  Consider wind speed and direction  Select a suitable landing site  If time allows, a restart may be attempted, see ìAir restart procedureî below  Perform a landing into wind and/or upslope if possible  Prior to touch-down switch OFF Main Switch WARNING Always plan your route to remain within safe gliding distance to areas where a safe forced landing can be performed in case of an engine failure. A landing in high trees or open waters may end fatally. Flight Manual Cavalon SECTION 3 EMERGENCY PROCEDURES AutoGyro_FOM_Cavalon Revision 1.3 ñ Issue Date 01.04.2012 3-2 NOTE The best engine-off glide ratio is about 1:3 at 90 km/h. Depending on a possible headwind the glide may be extended by slightly increasing airspeed. It is heavily recommended to train your forced landing capabilities regularly, preferably with a qualified flight instructor. 3.2 Air Restart Procedure  Check fuel valve OPEN  Check fuel pump(s) ON  Check both magnetos ON  Throttle slightly open  With the left hand, turn the Main Switch/Starter key completely to OFF, then START  If possible, allow engine and oil to warm-up before full power is applied NOTE The starter interlock function prevents inadvertent starter engagement. Before attempting an engine start, the interlock must be reset by turning the Main Switch/Starter key to OFF. 3.3 Landing into Trees or High Vegetation  Assume the surface of the treetops or vegetation as level  Plan touch-down and flare with minimum ground speed and minimum rate of descent  As soon as the wheels contact the vegetation bring the rotor disc to level attitude to avoid partial blade tip contact with vegetation  Shut down engine by switching magnetos OFF and master switch OFF 3.4 Degradation of Engine Power A gradual decay in engine RPM, accompanied by a rough running engine or even vibration may be an indicator for carburettor icing. In this case, continue with a high power setting and change altitude into air which is less susceptible to carburettor icing. If the situation cannot be corrected be prepared for further loss of power and ultimately engine failure. NOTE The phenomenon of carburettor icing is extremely unlikely with this engine type as it is fitted with a hot water heated jacket around the carburettor inlets. Note that the system can work properly only when the engine is at operating temperature. Flight Manual Cavalon SECTION 3 EMERGENCY PROCEDURES AutoGyro_FOM_Cavalon Revision 1.3 ñ Issue Date 01.04.2012 3-3 3.5 Evacuating the Aircraft In normal circumstances occupants should never leave the aircraft while the propeller or the rotors are turning. If abandoning the aircraft in an emergency the pilot should turn off the engine magneto switches and turn the master switch to ìOFFî if this can be done without endangering the occupants. If abandoning the aircraft with either the propeller and/or the rotors turning the occupants should follow a path in line with the nose of the aircraft, to minimise the risk of being struck by either the rotor or the propeller. Occupants should be briefed before flight on emergency evacuation procedures, including:  Actions to be taken in the event of a forced landing  Operation of the seat harness  REMOVED: Disconnection of any intercom leads or other connections to the aircraft  How to open the doors, or to break the windshield if required (using the emergency hammer to break the Plexiglas)  How to safely exit and move away from the aircraft 3.6 Smoke and Fire Indications of smoke should be treated in the same way as a fire. In case of fire the following action is recommended: Smoke or fire on ground  Both magnetos OFF and master switch OFF to shut-down engine and fuel pumps  Evacuate aircraft  Close fuel shut-off valve  Extinguish fire and have damage inspected Fire in flight  Open ventilation for fresh air  Initiate an emergency landing  Initiate emergency call, if time and situation permits  As soon as a power-off landing can be assured, shut down engine by switching magnetos OFF and master switch OFF  Continue procedure as described in ìEngine Failureî and ìSmoke or fire on groundî 3.7 Off-field Landing A precautionary landing at a non-prepared site may be performed at pilotís discretion in order to avoid unexpected weather, in case of severe illness of the pilot or a passenger, or if technical defects are suspected, for example sudden and severe rotor vibrations.  Select a suitable landing site from safe altitude, considering slope, wind speed and direction  Fly a reconnaissance pattern to check for obstacles, especially power lines, wires, and cables in the approach and go-around path Flight Manual Cavalon SECTION 3 EMERGENCY PROCEDURES AutoGyro_FOM_Cavalon Revision 1.3 ñ Issue Date 01.04.2012 3-4  Overfly the landing site to check for obstructions such as fences, ditches, rocks, height of vegetation, and select most suitable touch-down zone  Perform a normal approach and touch-down into wind with minimal ground speed 3.8 Flight Control Malfunction In case of a flight control failure the gyroplane can be controlled with the remaining primary and secondary controls, including power and trim. An immediate reduction of power, respectively speed may be necessary to avoid pitch oscillations (phugoid) or other effects affecting dynamic or static stability. Navigate to a suitable landing site with wide and shallow turns and approach against the wind. 3.8.1 Engine Power Control / Throttle Throttle jammed open or max Navigate to a suitable landing site with the power set. If over safe terrain, magneto switches may be used to control power. When within gliding distance to the selected landing site, shut-down engine to perform a power-off landing as per Emergency Procedure ìEngine failureî. NOTE In case of a control cable breakage the carburettor will be automatically set to full throttle position. Throttle jammed closed Land as per Emergency Procedure ìEngine failureî. Residual power may be used to extend the glide. 3.8.2 Rudder Malfunction In case of a stuck or loose rudder, continue flight to a suitable, preferably wide landing site that allows a landing into the wind. If necessary reduce power to avoid excessive side slip. Align gyroplane prior to touch-down, using engine torque or lateral control input to the side where the nose is pointed. 3.8.3 Rotor Head Control In case of a rotor head control malfunction, control pitch attitude using careful trim input and power setting. Use rudder for directional control and for shallow turns. In some conditions it may be appropriate to reduce power/speed in order to avoid phugoid effects or a possible negative yaw-roll coupling. Approach landing site with wide and shallow turns. Flight Manual Cavalon SECTION 3 EMERGENCY PROCEDURES AutoGyro_FOM_Cavalon Revision 1.3 ñ Issue Date 01.04.2012 3-5 3.9 Warning and Caution Lights 3.9.1 GEN or Low Volt Indicator Light ROTAX 912 ULS: If any of the indicators are permanently lit, switch off all unnecessary electrical consumers and land at the nearest airfield where maintenance can be performed. ROTAX 914 UL: If any of the indicators are permanently lit, switch off all unnecessary electrical consumers and perform a precautionary landing within 15 minutes. Be prepared for an engine failure. NOTE A pulsed GEN indicator light is normal and indicates proper function of the generator. 3.9.2 Low Volt Battery voltage of the system has dropped below a safe value. Refer to chapter above. Aircraft lights and the 12V power receptacle will be disabled automatically. 3.9.3 BOOST WARN Light ëBoostí (red) - only ROTAX 914 UL Continuously lit If continuously lit, the maximum admissible boost pressure was exceeded. Reduce power into normal operating range and consider restricted engine performance or boost control malfunction. Record duration and have maintenance action performed. Blinking When blinking, the allowable 5 minutes take-off power time limit has been exceeded. Reduce power into continuous range. Record duration and have maintenance action performed. 3.9.4 BOOST CAUTION Light ëCautioní (orange) - only ROTAX 914 UL A blinking BOOST CAUTION light indicates a problem with the turbo/boost control, its sensors or the servo. Engine power is degraded and continuous operation may lead to engine damage. Perform a precautionary landing considering reduced engine performance and be prepared for engine failure. 3.9.5 Fire (if installed) Refer to emergency procedure ìSmoke and Fireî and Flight Manual Supplement. Flight Manual Cavalon SECTION 3 EMERGENCY PROCEDURES AutoGyro_FOM_Cavalon Revision 1.3 ñ Issue Date 01.04.2012 3-6 3.9.6 Low Fuel (if installed) The LOW FUEL warning light is triggered as soon as 5 litres or less of useable fuel remain in the tank. Perform a power-on landing at the nearest suitable location and be prepared for engine failure after approximately 10 minutes remaining flight time. 3.9.7 Device (if installed) This indication serves a ëmaster cautioní for glass cockpit solutions. Refer to the respective flight manual supplement and the glass cockpit manufacturerís documentation. 3.9.8 Fan The engine mounted electrical blower fan is active. Monitor engine instruments and mind higher electrical power consumption. If possible, reduce engine power and increase speed. 3.10 Parameters out of Limits PARAMETER EXCURSION CORRECTIVE ACTION Engine Oil Temperature Upper limit or yellow arc Reduce power and increase air speed. If condition cannot be corrected, land as soon as practicable. Lower limit Allow engine to warm-up on ground. Within lower yellow arc Increase power setting, if possible. If condition prevails in normal flight, have maintenance action performed. Cyl. Head Temperature Upper limit Reduce power and increase air speed. If condition cannot be corrected, land as soon as practicable. Engine Oil Pressure Upper limit or yellow arc Reduce power. If condition cannot be corrected, have maintenance action performed prior to next flight. Lower limit If combined with other indications, such as rising oil temperature or unusual engine behaviour, shut-down engine and perform a power-off landing as per Emergency Procedure ìEngine failureî. Otherwise, monitor engine instruments carefully and land as soon as practicable. Have maintenance action performed. 3.11 Rotor Bearing Temperature Outside Air Temperature (OAT) and Rotor Bearing Temperature (RBT) indicators are provided for condition monitoring of the rotor bearing. Both readings should be more or less equal. If, in stabilized conditions, RBT rises suddenly above OAT, have bearing inspected.