EXEC 90 FLIGHT MANUAL

oil is spilled, it must be cleaned up before flight. 5 6 D. Tail rotor drive check: 1. Condition and tension of drive belts (1-3/8 ±1/8 inch at 10 lbs. pull) 2. Condition of the pulley and bearings 3. Idler pulley swing arm for travel (not bottoming out in bulkhead) IMPORTANT: New belts will tend to stretch and become loose. Belt tension must be monitored and adjusted fre quently until stretching has stopped. E. Tail rotor check: 1. Freedom of travel 2. Slider on key 3. Freedom and condition of the rod ends 4. For cracks in the skins around 3/16 retention bolts and pop rivets 5. End play on the blades and security of the snap rings and Pivot bolts F. Vertical trim fin check: 1. Structural security and angle G. Horizontal trim fin check: 1. Structural security and angle 2. Security of end caps H. Tail boom check: 1. For cracks, wrinkles, and structural security I. Engine area left side check: 1. Oil, fuel, and water leaks 2. Security and routing of pipes, lines, and wiring 3. Condition and tension of the fan drive and main drive belts 4. Clutch and idler pulley 5. Security of the rear landing gear brackets 6. For cracks and security of heat shielding 7 J. Collective control check: 1. Freedom of travel 2. All linkages for security 3. Throttle roll and butterfly travel in carburetor K. Cyclic control check: 1. Freedom of travel 2. Bias of the cables and security of rod ends L. Main drive chain check: 1. Security of the master link 2. Tension of the chain 3 Floor of the oil bath for broken rollers and link plates M. Rotor system check: 1. Security and wear of the scissors 2. For cracks around the ears of the swash plate and the hood bracket 3. For foreign matter in the bearing seal cavity area 4. To see if washer and snap rings on the drive pin are loose 5. End play between shaft and riser blocks 6. For loose bolts 7. Freedom and condition of both control rods N. Main rotor blades check: 1. All around bolts on retention straps for cracks 2. Bolts for signs of bending 3. Doublers for delamination 4. Blades for wrinkles or cracks near the root end 5. For separation of the skin to spar top and bottom 6. Security of the blade tip end plugs 7. Blade droop for any change 8 O. Fuel level: Use a dip hose to check the amount of fuel in the tanks and to verify the accuracy of the fuel gauge. To calibrate the dip hose, start with the fuel tanks empty and add a measured amount of fuel. Dip the hose all the way into the tank, up to the “T” handle. Take the hose out and permanently mark the fuel level with safety wire. (Insert the wire through the hose, then wrap and tie it securely around the hose.) Repeat the process for additional amounts of fuel. For future reference, record the marks and the corresponding fuel quantity on the dip hose drawing below. Before starting: Altimeter........................................... adjust Seat and shoulder harness.................. on and adjusted Doors................................................ secure Cyclic, collective, and pedals.............full travel and freedom of travel Starting (See switch panel diagram on page 27): Fuel valve.......................................... on Clutch handle.................................... out All switches (except alternator)..........on Cyclic and pedals............................... centered Collective.......................................... 3 degrees positive pitch Main rotor blades.............................. perpendicular to ship Area.................................................. clear Throttle............................................. closed until engine is turning Starter .............................................. keep engaged until engine is running smoothly 9 After Started: Throttle............................................. set at 2000 RPM Oil pressure....................................... 40-80 psi within 15 seconds Temperatures.................................... rising Pedals............................................... check smoothness and freedom Cyclic................................................ keep centered below 400 RPM Collective lever..................................check collective Ignition circuit checks: 1. Alternator switch on. Check voltage. 2. Switch No.1 ignition switch OFF then ON. Note that ignition indicator light #1 is operational when switch is on. 3. Switch No. 2 ignition switch OFF then ON. Note that ignition indicator light #2 is operational when switch is on. Run up: Oil temperature................................. rising Clutch handle.................................... in Pedals............................................... centered Cyclic................................................ centered Collective lever................................. set 3 to 3-1/2 degrees positive Throttle............................................. set at 100% rotor RPM Temperature and pressure................. green Battery voltage.................................. check for charge NOTE: During run up and run down, engine operations between 2500 and 3000 RPM should be limited due to main drive belt resonance frequency. 10 Take off: Pedals............................................... even to half right pedal Cyclic................................................ within 3 inches of center The pilot should determine the correct control position during take off by noting and responding to the small movements of the aircraft when it becomes light on the skids. Slowly raise collective, adjusting throttle to maintain rotor RPM in the green. Economical cruise............................. manifold pressure 4 inches less than hover Rotor RPM (100% = 520 RPM)....... 96-104% maintain in flight Take off and operation should be conducted per height velocity diagram (see page 18). During flight, check all instruments for anomalies. After Landing: Throttle............................................. close to idle when light on the skids Collective lever................................. lower to 3 degrees pitch Shutdown: Throttle............................................. idle until temperature is stable Fuel valve.......................................... off Clutch handle.................................... out All switches....................................... off (as engine runs out of fuel) 11 Post flight check: Master link on chain.......................... in position Swash plate bearing.......................... check temperature Main thrust bearing........................... check temperature Top secondary bearing.......................check temperature Tail boom.......................................... check for wrinkles and temperature of bulkheads Tail rotor.......................................... inspect Vertical stabilizer.............................. secure Main Rotor blades............................. tie to tail boom Section 4. Emergency Procedures A. Engine failure General: 1. A change in noise level, a right yaw and low oil pressure may be the first indication of an engine failure. 2. Engine failure at high speed, high power, will result in a tendency for the helicopter to pitch nose up. B. Engine failure below approximately 8 feet AGL: 1. Maintain level attitude with cyclic. 2. Apply left pedal as required to prevent yawing. 3. Collective pitch should not be reduced by any significant extent. 4. Increase collective just before touchdown to cushion landing. C. Engine failure between 8 feet and 500 feet AGL: 1. Lower collective lever to maintain rotor RPM. The amount of and duration of collective reduction depends upon the height above the ground at which the engine failure occurs. 2. If height permits, adjust collective to achieve 100% rotor RPM (520 RPM). 3. Use cyclic and collective as required to carry out engine off landing. 4. Maintain heading with pedals. D. Engine failure above 500 feet AGL: 1. Lower collective to maintain rotor RPM and enter normal autorotation (see page 17). 2. Establish a steady autorotation descent at approximately 65 mph. 3. Adjust collective to keep rotor RPM 100% (520 RPM). 4. After a steady autorotation is established select a landing spot and maneuver as required so the landing will be upwind. 5. A restart may be attempted at pilot’s discretion, if sufficient time is available. 6. If unable to restart, turn off unnecessary switches and shut off the fuel valve if sufficient time is available. 12 13 7. At about 35 feet AGL, begin a cyclic flare to reduce forward and descent speed. Level at 3 to 5 feet of clearance between the tail rotor and the ground. Allow the aircraft to settle to 30 inches above the ground. At 30 inches, increase collective pitch as necessary to cushion the ground contact. 8. Maintain heading with the pedals. E. Glide distance configuration: 1. Airspeed approximately 65 mph. 2. Rotor RPM approximately 100% (520 RPM) 3. Increase rotor RPM to 104% when below 500 feet AGL. F. Engine fire in flight: 1. Enter autorotation. 2. Shut off fuel valve if time is available. 3. Execute an autorotation landing. After landing, if time per- mits, turn off ignition , instrument and alternator switches. 14 G. Electrical fire in flight: 1. Instrument and ignition switches on. 2. All other switches off. 3. Land immediately. 4. Extinguish fire and inspect for damage. (Note: Do not switch ignition off unless the engine has stopped). H. Air restart procedure: 1. Actuate the throttle as required. Press starter button on the cyclic. CAUTION: DO NOT ATTEMPT A RESTART IF ENGINE MALFUNCTION IS SUSPECTED UNTIL A SAFE AUTOROTATION IS ESTABLISHED. I. Tachometer failure: If the rotor or engine tach malfunctions in flight, use the operational tach to make a normal landing. J. Tail rotor failure during hover: 1. Failure is usually indicated by a left yaw which can not be stopped by applying right pedal. 2. Immediately close the throttle and perform a hovering power off landing. 3. Keep ship level with the cyclic and increase the collective just before touchdown to cushion landing. K. Tail rotor failure during forward flight: 1. Failure is usually indicated by right or left yaw which can not be corrected by applying pedal. 2. Immediately enter a shallow descent into the wind. 3. Adjust the collective and the throttle to extend the glide if sideslip is not excessive and the aircraft does not tend to spiral. Cyclic and collective are used to limit sideslip angle. 4. Select landing site and perform a run-on landing using throttle to maintain heading. L. Engine fire during starting on the ground: 1. Continue cranking to get the engine started which would suck the flame and excess fuel into the engine. 2. If the engine starts, run at 2000 RPM for a short time. Shut down and inspect for damage. 3. If the engine fails to start, turn off the fuel, ignition, and battery switches. 4. Extinguish fire with fire extinguisher, wool blanket, or dirt. 5. Inspect for damage. 15 16 Section 5. Performance Hover in ground effect...................... 7000 feet Hover out of ground effect................ 5000 feet Service ceiling................................... 10,000 feet Range with maximum fuel at optimum cruise power....................... 180 miles/2hrs. Normal cruise.................................... 95 mph Maximum airspeed............................ 115 mph 17 Autorotation Procedure From Altitude: For asymmetrical Rotor blades 1. Hold approach airspeed of 65 mph. 2. Maintain rotor RPM of 100% (520 RPM) during steady state descent. Rotor RPM should build by 5-7% during flare, if the flare is performed properly. 3. Flare height is 35 feet AGL for full stop autorotation using 30 degree flare angle. Level aircraft at 3-5 feet of clearance between tail rotor and the ground. 4. During level off, add collective pitch if you are settling too rapidly. 5. Allow aircraft to settle to 30 inch AGL. At 30 inches, add collective pitch as necessary. Note: This envelope is designed for inexperienced, low time pilots. Out of ground (O.G.E.) hovers are prohibited for all Exec pilots under 150 hours. CAUTION! AVOID OPERATION IN SHADED AREA ALTITUDE IN FEET INDICATED AIRSPEED MPH 500' 400' 300' 200' 100' 0' 10 20 30 40 50 60 70 80 90 18 HEIGHT VELOCITY ENVELOPE 1. Cyclic handle position is affected by weight and balance. 2. The helicopter must be rigged in compliance with the rigging instructions provided. 3. The cyclic handle should remain in the center during normal operations. 4. The shaded circle is for limited time use only. 15” Cyclic (Total) 10° Swash Plate 6” Cyclic (Total) 4° Swash Plate 19 DIAGRAM FOR THE CYCLIC CONTROL AREA OF OPERATION 20 Section 6. Weight and Balance The center of gravity (C.G.) requirement for any helicopter is very important to its safe operation. In order to determine that your RotorWay “EXEC 90” has been built correctly and is weight and balanced properly, you will have to perform a static hang test. Prior to performing the hang tests, the following operating conditions and limitations should be reviewed: 1. The empty weight of the EXEC 90 is 925 lbs. 2. The maximum take off weight is 1500 lbs. 3. The maximum variable load, consisting of pilot, passenger, fuel, and any ballast is 525 lbs. 4. Maximum pilot weight is 210 lbs. 5. Maximum passenger weight is 210 lbs. 6. Maximum pilot and passenger weight is 400 lbs. 7. SOLO flight is performed ONLY FROM THE LEFT SEAT and must have the ballast weight placed on the front passenger skid. The cyclic handle should fall within the 6 inch diameter control area of operation in a hover (see diagram on page 19). 8. DUAL flight requires the ballast weight be placed on the rear mount tube under the tail boom. Again the cyclic handle should fall within the 6 inch diameter control area of operation in a hover (see diagram on page 19). 21 To perform this test it will require a facility that will allow the aircraft to be suspended approximately 6 inches from the ground, hanging from the knuckle of the main rotor shaft (see sketch below). For this test to be accurate the aircraft must be complete with the following: 1. Full coolant and oil in aircraft 2. No fuel in tanks 3. Enclosed area, no wind There will be three test configurations of the aircraft, each with a different cabin loading. If the helicopter falls within 1/2 degree (plus or minus) both laterally and fore/aft of the specified angles of the three tests, and if the helicopter has been properly rigged, the aircraft should be ready for the first run-ups and liftoffs. Using the Weight and Balance Diagram on page 23, the following results should be obtained within 1/2 degree (plus or minus) in all three tests. NOTE: During all tests the main rotor blades must remain in the fore and aft position (parallel to the tail boom). NOTE: Hook should be centered over shaft to distribute weight evenly. 22 A. EMPTY AIRCRAFT (no cabin weight, ballast weight in solo front skid location) Fore and Aft...................................... 3 degrees aft Lateral.............................................. 2 degrees pass. side B. PILOT ONLY 150 lbs. (ballast weight in solo front skid location) Fore and Aft...................................... 1 degree fore Lateral.............................................. 0 degrees C. PILOT 210 lbs. and PASSENGER 210 lbs. (ballast weight in rear dual location) Fore and Aft...................................... 5 degrees fore Lateral.............................................. 1/2 degree pass. side The results of these tests should be recorded in the appropriate columns on the diagram provided on page 23. IMPORTANT: If you are unable to achieve within 1/2 degree the results specified above, contact RotorWay Customer Service Department for assistance before attempting to lift off the aircraft. The weight and balance of any helicopter is critical and this helicop- ter should not be flown until the pilot is aware of the weight and balance schedule and the hang test has been satisfactorily performed. 23 0 0 Fore and Aft Measurements: A.__________ B.__________ C.__________ Lateral Measurements: A.__________ B.__________ C.__________ WEIGHT AND BALANCE DIAGRAM 24 FORE / AFT LATERAL LATERAL FORE / AFT SAMPLE WEIGHT AND BALANCE AIRCRAFT ON SCALES Weight x Arm Inch = Moment Inch Total Moment Inch ÷ Total Weight = Balance Location WT. LBS. ARM INCH MOMENT INCH LBS. Front Scale 71 55.75 3958.25 Rear Scale 853 109.25 93190.25 924 97148.50 105.13 WT. LBS. ARM INCH MOMENT INCH LBS. Passenger Skid 474 31.5+ 14931.0 Pilot Skid 450 31.25- 14062.5- 924 868.5 .94+ WT. LBS. ARM INCH MOMENT INCH LBS. Basic Wt. 924 105.13 97148.50 Ballast Wt. Forward 27 37.25 1005.75 Pilot 210 71.0 14910.0 Fuel 60 100.0 6000.0 1221 119064.25 97.51 CG (See Chart on Page 26) WT. LBS. ARM INCH MOMENT INCH LBS. Basic Wt. 924 .94+ 868.5+ Ballast Wt. Pass. Skid 27 31.5 + 850.5+ Pilot 210 10.25- 2152.5- Fuel Pilot 30 18.25- 547.5- Fuel Pass. 30 18.5+ 555.0+ 1221 426. - .34 - CG (See Chart on Page 26) 6/93 25 2 3 1 FORE/AFT ARM INCH 1. DATUM 0 2. FORWARD WEIGHT POSITION 37.25 3. FORWARD WEIGHING POINT 55.75 4. SEATS 71.0 5. MAIN SHAFT AND GAS TANKS 100.0 6. REAR WEIGHING POINT 109.25 7. REAR WEIGHT POSITION 163.0 LATERAL ARM INCH PASSENGER SKID +31.5R PASSENGER SEAT +10.5R PASSENGER GAS TANK +18.5R PILOT SKID -31.25L PILOT SEAT -10.25L PILOT GAS TANK -18.25L DATUM SCALE IS GRADUATED IN INCHES. THESE CALCULATIONS ARE DETERMINED WITH THE MAIN ROTOR SHAFT 90 DEGREES TO THE GROUND WHEN THE AIRCRAFT IS WEIGHED. 4 5 6 7 6/93 26 ROTORWAY EXEC 90 CENTER OF GRAVITY LIMITS –1.0 .8 .6 .4 .2 .2 .4 .6 .8 +1.0 R 1100 25 50 75 1200 25 50 75 1300 25 50 75 1400 25 50 75 1500 25 1550 L CL 95 96 97 98 99 100 MAIN ROTOR CL MAIN ROTOR CL • • SAMPLE LATERAL C.G. LOCATION (.34 –) SAMPLE FORE / AFT C.G. LOCATION (97.50) MAXIMUM AIRSPEED 95 MPH WHEN C.G. FALLS WITHIN THE SHADED AREA (98 1/4 – 99) MAXIMUM TAILWIND WHILE HOVERING: 10 MPH, WHEN C.G. FALLS WITHIN THE SHADED AREA (96 1/8 – 96 1/2) GROSS WT. LBS. LATERAL C.G. INCH 8/97 SWITCH PANEL DIAGRAM (As viewed from below) 27 28 START UP, RUN UP & TAKE OFF 1. Preflight aircraft 2. Untie main and tail rotor blades 3. Oil chain and check master link 4. Check ballast weight location 5. Position blade perpendicular to ship 6. Fasten seat and shoulder harness and tuck in ends 7. Check controls 8. Clutch disengaged 9. Check fuel pumps and ignition lights 10. Key, instrument and ignition switches on 11. Turn gas valve on 12. Controls in start position 13. Clear area 14. Start engine - oil pressure within 5 seconds 15. Adjust idle with throttle until smooth (2000 RPM) 16. Engage clutch and turn on alternator 17. Check each ignition system 18. Idle until oil temp is on the gauge 19. Increase RPM to show a charge on voltmeter, then roll off throttle to check free wheel unit 20. Avionics and headset on 21. Stow checklist after reviewing #22-24 and #1-6 on landing list 22. Increase throttle to operating RPM 23. Establish ship light on the skids with instruments and controls within limits 24. Look outside, then slowly lift off LANDING, COOL DOWN & SHUT OFF 1. Position aircraft into the wind, RPM in the green 2. Maintain 12” to 18” hover over level ground 3. Relax, look outside off into the distance 4. Slowly begin lowering collective 5. Upon ground impact, continue lowering until ship is firmly positioned 6. Roll off throttle, keeping hands on controls 7. Listen and feel ship for any noise or vibration 8. Note oil temp reading for cool down 9. Check ignition system 10. After 10 degree oil temp drop, turn gas valve off 11. After engine shut down, ignition, instrument, alternator, avionics and key off 12. Disengage clutch 13. Remain in ship until rotor blades stop completely 14. Check keeper on the master link 15. Check bearing temps 16. Secure main rotor and tail rotor blades 17. Check under ship for leaks