Cavalon Oil Thermostat Assembly Upgrade
AUTOGYRO CAVALON · Service Bulletins
Overview
This service bulletin outlines the mandatory upgrade of the oil thermostat assembly for the AutoGyro Cavalon aircraft fitted with the Rotax 915iS engine. It provides detailed instructions for replacing the oil thermostat and hose assembly to improve oil flow and system pressure, thereby enhancing engine life.
- Mandatory compliance for all Cavalon aircraft with Rotax 915iS engine up to serial V00473.
- Improves oil flow and pressure, extending engine life.
- Estimated completion time is 2 hours.
- Standard tools are required for the upgrade.
- No weight and balance effects from the upgrade.
- Documentation of compliance is required.
- Contact AutoGyro for support via email or phone.
- No previous modifications affect this service bulletin.
Document
Source
Originally published by auto-gyro.com. Sprinkle hosts a reference copy with an added summary, specifications and searchable full text.
Document details
- Type ·
- Service Bulletins
- Year ·
- 2020
- File size ·
- 1.1 MB
- Publisher ·
- auto-gyro.com
- Language ·
- en
Specifications & performance
Extracted from this document.
Specifications
- Oil pump adapter ·
- 45583
- Oil tank adapter ·
- 45534
- Oil hose set 280mm ·
- 47896
- Oil hose set 335mm ·
- 47817
- Thermostat part number ·
- 47748
Weight & balance
- Weight balance effects ·
- Nil
What is the Cavalon Oil Thermostat Assembly Upgrade?
The Cavalon Oil Thermostat Assembly Upgrade is a service bulletins for the AUTOGYRO CAVALON, dated 2020.
Where does the Cavalon Oil Thermostat Assembly Upgrade come from?
This copy of the Cavalon Oil Thermostat Assembly Upgrade was originally published by auto-gyro.com and is hosted on Sprinkle as a free, searchable reference copy.
What year was the Cavalon Oil Thermostat Assembly Upgrade published?
The Cavalon Oil Thermostat Assembly Upgrade — the AUTOGYRO CAVALON service bulletins on file — is dated 2020.
Most owners only have the POH. Here's the essential set for the AUTOGYRO CAVALON.
- Pilot's Operating Handbook / AFM
- Checklist
- Maintenance Manual
- Parts Catalog (IPC)
- Systems & Wiring
- Service Bulletins on file
- Type Certificate (TCDS)
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In this document
Applicability
Applies to all Cavalon aircraft fitted with the Rotax 915iS engine up to serial V00473, excluding V00398, V00443 & V00450.
Reason and Overview
Introduces an amendment to the accomplishment instructions and addresses oil pressure issues at altitude, providing instructions for replacing the oil thermostat and hose assembly.
Compliance
No minimum embodiment requirement, but the change is considered beneficial for engine life.
Accomplishment Instructions
Step-by-step instructions for replacing the oil thermostat and hose assembly, including necessary checks and tools.
Materials Required
List of components needed for the upgrade, including thermostats and hose sets.
Customer Support
Materials and labor hours are covered by this service bulletin, with a maximum of 2 hours labor claim.
Safety notes
- Failure to comply with mandatory actions may result in significant reduction of flight safety.
- Ensure correct adapter sizes are used to avoid oil pressure issues.
- All work must be performed by trained personnel.
Full document text
Service Bulletin Contact & Info: airworthiness@auto-gyro.com www.auto-gyro.com AutoGyro GmbH Dornierstr. 14 31137 Hildesheim AG-SB-2020-02-B-ENr2 Page 1 of 7 Title: Cavalon Oil Thermostat Assembly Upgrade AG-SB-2020-02-B-ENr2 Compliance Category: A - MANDATORY B – RECOMMENDED C - OPTIONAL Applicability Aircraft type & model: AutoGyro Cavalon Affected Serial number(s): All Cavalon fitted with the Rotax 915iS engine up to V00473 but excluding V00398, V00443 & V00450 The maintenance manual to be referenced is this stated or subsequent issue. As per AutoGyro website This form is the response from AutoGyro GmbH either against a problem found in the product in service requiring a containment or rectification action, or as service information for aircraft modification incorporation. For help, contact AutoGyro on +49(0)5121 88056-00, or email airworthiness@auto-gyro.com. Documentation (Service Bulletin Completion action) The accomplishment of this Service Bulletin, or the decision of its rejection, must be properly documented, if such procedure is required by the relevant authority Category Codes A – Mandatory – failure to comply result in a significant reduction of flight safety, injury or death B – Recommended – failure to comply may result in reduced safety margin, injury and/or equipment damage C - Optional – improves operating behavior, reliability and/or maintainability Chief Certification Officer Chief Technical Officer Service Bulletin Contact & Info: airworthiness@auto-gyro.com www.auto-gyro.com AutoGyro GmbH Dornierstr. 14 31137 Hildesheim AG-SB-2020-02-B-ENr2 Page 2 of 7 Reason and overview of the Service Bulletin (cause of problem if known) This revision (r1) introduces an amendment to paragraph 5 of the Accomplishment Instructions. “Confirm the size of the adapter at the oil cooler (Pic. 2).” Has been changed to read “Confirm the size of the connection at the oil tank (Pic. 2).” AutoGyro has received feedback from the market that in some circumstances in flight, particularly at altitude, the Rotax 915iS engine oil pressure can fall to its minimum operating pressure of 2 bar. AutoGyro have developed an improved thermostat and oil cooler circuit that replaces the original assembly, improving oil flow and system pressure. This service bulletin provides instructions on how to replace the oil thermostat and hose assembly. Manpower estimates The task may only be performed by an organization or individual entitled and trained to carry out maintenance on AutoGyro aircraft. Estimated man-hours to complete the task as a stand-alone item is: 2.0 hrs including functional and leak checks. Compliance There is no minimum embodiment requirement. However, the change improves oil flow and pressure, and therefore is considered to extend engine life. Customer Support Materials and labour hours are covered by this Service Bulletin. A maximum of 2 hrs labour may be claimed. Auto Gyro standard rate is 78.50€ per hour plus tax. The service bulletin reference AG-SB-2020-02-B-EN, gyro works number and engine serial number is to be quoted on all parts orders and labour claim submissions related to this SB. Tooling required Standard tools. Weight and Balance Effects Nil Service Bulletin Contact & Info: airworthiness@auto-gyro.com www.auto-gyro.com AutoGyro GmbH Dornierstr. 14 31137 Hildesheim AG-SB-2020-02-B-ENr2 Page 3 of 7 Manuals affected POH & AMM AutoGyro is not affected. Previous Modifications that affect the SB None Accomplishment instructions (Action required to implement this bulletin): Effective date of this SB is 29 July 2020. All work is to be carried out in accordance with the latest model-relevant AutoGyro Aircraft Maintenance Manual Instructions 1. Ensure the wheel brakes are applied and the mag switches/ignition are switched in the “off” position. 2. Remove the upper and lower engine cowlings. 3. Measure the distance between the oil cooler corners as shown in Pic. 3 dimension ‘X’ to determine which hose set is required. If dimension ‘X’ is 280mm then oil hose set 47896 is required, if dimension ‘X’ is 335mm then oil hose set 47817 is required. 4. Confirm the size of the adaptor at the oil pump (Pic. 1 item A). If the thread size is anything other than 22mm then it must be replaced with adapter 45583. This should be assembled in the pump housing using Loctite 243 blue. If the thread is 22mm then no further action is required. 5. Confirm the size of the connection at the oil tank (Pic. 2). If the thread size is 18mm then adapter 45534 is required. This should be assembled in the oil tank using Loctite 638 green. If the thread is 22mm then no further action is required. 6. Return the oil in the system to the tank by turning the propeller until a gurgling sound is heard. 7. Place a container under the oil pump at the rear of the engine, and disconnect the oil hose (Pic. 1, item A). Allow any oil to drain and remove the P-clamp (Pic. 1, item B). 8. Disconnect the return hose from the right side oil cooler at the oil tank connection (Pic 2, item C) 9. Place a container under the oil cooler hose connections and disconnect the 4 hoses from the oil coolers (Pic 3. Items D, E, F & G). NOTE: Ensure to counter the adapters when dis-assembling and assembling the hoses on the coolers. Note: The thermostat and hoses are now supplied as separate items. 10. Assemble the new hoses (47896 or 47817) to the new thermostat (47748) loosely. Ensure that the items are assembled in the correct orientation as shown in Pic. 4. 11. Assemble the adaptors 45534 & 45583 in their respective components as required using Loctite as stated above in paragraphs 4 & 5. 12. Position the assembly between the oil coolers and connect the hoses to the 4 oil cooler connections, oil tank and oil pump. 13. Tighten all fittings using standard torques. Re-fit the P-clamp securing the oil pump hose. 14. Check the oil level in the tank and replenish if required.
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15. Carry out an oil system purge in accordance with the Rotax 915 Line Maintenance Manual Chapter 12-20-00. Service Bulletin Contact & Info: airworthiness@auto-gyro.com www.auto-gyro.com AutoGyro GmbH Dornierstr. 14 31137 Hildesheim AG-SB-2020-02-B-ENr2 Page 4 of 7 16. Re-check the oil level and replenish if required. 17. Carry out a loose tool and article check. 18. Carry out a ground run for a system leak check and thermostat functional check. 19. Check the oil level in the tank and replenish if required. 20. Refit the lower and upper engine cowlings. IMPORTANT: The Rotax 915iS is supplied with two possible sizes of oil tank and oil pump fittings depending on modification state. The earlier oil coolers on earlier versions of the Cavalon also have a varied position to the later versions. See 3, 4 and 5 above. Ensure that the correct items are ordered for the mod state of the gyro as stated. Service Bulletin Contact & Info: airworthiness@auto-gyro.com www.auto-gyro.com AutoGyro GmbH Dornierstr. 14 31137 Hildesheim AG-SB-2020-02-B-ENr2 Page 5 of 7 Illustrations (Pic. 1) (Pic. 2) (Pic. 3) A B C ‘X’ D E F G Service Bulletin Contact & Info: airworthiness@auto-gyro.com www.auto-gyro.com AutoGyro GmbH Dornierstr. 14 31137 Hildesheim AG-SB-2020-02-B-ENr2 Page 6 of 7 (Pic. 4) (Pic. 4) Completion of this Service Bulletin must be recorded within the aircraft documentation, in line with the requirements of the country of operation. Material information (Parts required to be made to implement this service bulletin): Nil List of components (with purchasable part numbers) 47748 Thermostat (all models) 47896 Hose set (280mm dimension between oil coolers) 47817 Hose set (335mm dimension between oil coolers) 45583 Adaptor Oil Pump 45534 Adaptor Oil Tank 30485 Loctite 638 Green 30483 Loctite 243 Blue Interchangeability Not affected To oil tank To oil pump Forward To left oil cooler rear connection To left oil cooler forward connection To right oil cooler rear connection To right oil cooler forward connection Service Bulletin Contact & Info: airworthiness@auto-gyro.com www.auto-gyro.com AutoGyro GmbH Dornierstr. 14 31137 Hildesheim AG-SB-2020-02-B-ENr2 Page 7 of 7 Parts disposition a) Disposal requirements – Nil b) Environmental hazards of parts containing hazardous materials – Nil c) Scrap requirements (e.g. mutilate scrapped items beyond use) – Nil