Guimbal Cabri G2 User manual

www.guimbal.com
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This manual includes the material required to be furnished to the operator
by EASA CS 27 and Part 21.
Note : It is the user’s responsibility to maintain manual currency.
A IX - EN -P ROVENCE , F RANCE

b Approved under DOA.EASA.21J.211 Issue 03
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Hélicoptères Guimbal Maintenance Manual
CABRI G2 TABLE OF CONTENT
Issue 03 Approved under DOA.EASA.21J.211 c
Table of content
SECTION A GENERAL..................................................................................................A-I
A-1 I NTRODUCTION ............................................................................................................. A-1
Manual revisions................................................................................................................ A-1
Abbreviations ..................................................................................................................... A-4
Maintenance authorization ................................................................................................. A-5
Overhaul authorization....................................................................................................... A-5
A-2 C ABRI G2 D ESCRIPTION ................................................................................................ A-6
Night-VFR optional equipment ........................................................................................... A-6
External dimensions........................................................................................................... A-7
A-3 H ELICOPTER BASIC SERVICING ....................................................................................... A-9
SECTION B MAINTENANCE INSPECTIONS................................................................B-I
B-1 I NTRODUCTION ............................................................................................................. B-1
B-2 F IRST 25- HOUR INSPECTION .......................................................................................... B-2
B-3 50- HOUR INSPECTION .................................................................................................... B-3
B-4 100- HOUR / 12- MONTH INSPECTION ............................................................................... B-4
B-5 500- HOUR / 60- MONTH INSPECTION ............................................................................... B-5
B-6 S PECIAL INSPECTIONS ................................................................................................... B-6
B-61 Tail skid strike............................................................................................................ B-6
B-62 Tail rotor damage....................................................................................................... B-6
B-63 Main rotor strike......................................................................................................... B-6
B-64 Rotor / engine overspeed........................................................................................... B-6
B-65 Hard landing.............................................................................................................. B-6
SECTION C AIRWORTHINESS LIMITATIONS .............................................................C-I
C-1 G ENERAL .....................................................................................................................C-1
C-2 L IMITATIONS .................................................................................................................C-1
Fatigue life-limited components..........................................................................................C-1
Structural inspection intervals (On-condition limitation) ......................................................C-1
Tail structure paint..............................................................................................................C-2
SECTION D OTHER LIMITATIONS...............................................................................D-I
D-1 T IME - IN - SERVICE RECORDS ...........................................................................................D-1
D-2 M ANUFACTURER TIME LIMITS .........................................................................................D-2
D-3 O VERHAUL REQUIREMENTS ...........................................................................................D-3
D-4 I NCIDENTS AND ACCIDENT REPORTS ...............................................................................D-4
SECTION E MAINTENANCE INSTRUCTIONS...........................................................D-4-I
E-1 M AIN ROTOR ............................................................................................................... E-1- I
Introduction.....................................................................................................................E-1-1
Description......................................................................................................................E-1-1
E-2 M AIN TRANSMISSION ................................................................................................... E-2- I
DESCRIPTION................................................................................................................E-2-1
E-3 T AIL ROTOR AND TRANSMISSION .................................................................................. E-3- I
DESCRIPTION................................................................................................................E-3-1
DESCRIPTION................................................................................................................E-3-1
DESCRIPTION................................................................................................................E-3-4
E-4 F LIGHT CONTROLS ...................................................................................................... E-4- I
DESCRIPTION................................................................................................................E-4-1
E-5 E NGINE INSTALLATION ................................................................................................. E-5- I
INTRODUCTION.............................................................................................................E-5-1

Maintenance Manual Hélicoptères Guimbal
TABLE OF CONTENT CABRI G2
d Approved under DOA.EASA.21J.211 Issue 03
DESCRIPTION................................................................................................................E-5-1
Description ......................................................................................................................E-5-6
E-6 A IRFRAME ...................................................................................................................E-6- I
DESCRIPTION................................................................................................................E-6-1
Description ......................................................................................................................E-6-5
E-7 S YSTEMS .......................................................................................................................E- I
INTRODUCTION.............................................................................................................E-7-1
Description ......................................................................................................................E-7-1
E-8 M ISCELLANEOUS ......................................................................................................E-8-17
SECTION F TROUBLE SHOOTING..............................................................................F-1
SECTION G APPENDIX............................................................................................... G-1
G-1 A PPROVED MATERIAL LIST ............................................................................................. G-1
Greases............................................................................................................................. G-1
Oils.................................................................................................................................... G-1
Adhesives.......................................................................................................................... G-2
Sealants ............................................................................................................................ G-2
Torque seal........................................................................................................................ G-2
Paints, primers................................................................................................................... G-3
Varnishes .......................................................................................................................... G-4
Sealing compounds........................................................................................................... G-4
G-2 S PECIAL TOOLS ............................................................................................................ G-5
G-3 T AIL ROTOR BLADE RIGGING CHECK TEMPLATE ............................................................... G-6
G-4 S AFETY PIN TABLE ........................................................................................................ G-7
SECTION H FLIGHT REPORT MODELS......................................................................H-1

Hélicoptères Guimbal Maintenance Manual
CABRI G2 GENERAL
Issue 03 Approved under DOA.EASA.21J.211 A-i
Section A General
A-1
I NTRODUCTION ............................................................................................................. A-1
Manual revisions................................................................................................................ A-1
Abbreviations ..................................................................................................................... A-4
Maintenance authorization ................................................................................................. A-5
Overhaul authorization....................................................................................................... A-5
A-2 C ABRI G2 D ESCRIPTION ................................................................................................ A-6
Night-VFR optional equipment ........................................................................................... A-6
External dimensions........................................................................................................... A-7
A-3 H ELICOPTER BASIC SERVICING ....................................................................................... A-9
A-31 Ground handling..................................................................................................... A-9
A-32 Lubricants ............................................................................................................ A-11
A-33 Defueling.............................................................................................................. A-11
A-34 Doors removal & installation................................................................................. A-12
Door removal ..................................................................................... IPC x-xx........... A-12
Door installation ................................................................................. IPC x-xx........... A-12
A-35 Seats removal & installation................................................................................. A-12
Seats removal .................................................................................... IPC x-xx........... A-12
Seats installation ............................................................................... IPC x-xx........... A-13
A-36 Cleaning............................................................................................................... A-13
A-37 Parking, tie-down and covers............................................................................... A-13
A-38 Hoisting................................................................................................................ A-14
A-37 Weighing.............................................................................................................. A-15

Maintenance Manual Hélicoptères Guimbal
GENERAL CABRI G2
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Hélicoptères Guimbal Maintenance Manual
CABRI G2 GENERAL
Issue 03 Approved under DOA.EASA.21J.211 A-1
A-1 Introduction
This manual contains reference material necessary for proper servicing, maintenance, and
handling of the Cabri G2 helicopter. This manual is to be used in conjunction with the Cabri
illustrated parts catalog, Cabri G2 Flight manual, Cabri G2 Service bulletins, Lycoming O-360
series operator’s manual and O-360-J2A Plasma Amendment to Lycoming operator’s manual,
engine maintenance publication, and any related technical data supplied by equipments
manufacturers.
As necessary, Service bulletins are issued by Helicopteres Guimbal (HG), Textron Lycoming, and
equipments manufacturers. Service bulletins compliance is mandatory, except for HG-
recommended and optional service bulletins.
Always read instructions completely before beginning a task.
Maintenance manual log of applicable pages, maintenance authorizations, helicopter and optional
equipments general description, and helicopter servicing instructions are given in this Section A.
Section B defines the maintenance schedule that is to be carried out on the helicopter to enable
its proper operation. It refers to maintenance actions that are detailed in Section E.
Section C gives authority-approved airworthiness limitations.
Section D gives additional manufacturer limitations together with issue report policy.
Sections E details all maintenance actions that can be carried out by maintenance organizations,
according to the authorities.
Section F describes troubleshooting recommendations.
General data and documentation are given in appendix at the end of this manual.
Manual revisions
Before using this manual, make sure it includes all current revisions.
The following table lists the EASA-approved pages :
Page number
Revision
number Page number
Revision
number
C-1 03 - -
Section C
Airworthiness limitations C-2 03 - -

Maintenance Manual Hélicoptères Guimbal
GENERAL CABRI G2
A-2 Approved under DOA.EASA.21J.211 Issue 03
The following table lists the pages approved under DOA EASA.21J.211 :
Page number
Revision
number Page number
Revision
number
Cover a 03 - -
A-1 03 A-9 03
A-2 03 A-10 03
A-3 03 A-11 03
A-4 03 A-12 03
A-5 03 A-13 03
A-6 03 A-14 03
A-7 03 A-15 03
Section A
General
A-8 03 A-16 03
B-1 03 B-4 03
B-2 03 B-5 03
Section B
Maintenance inspections
B-3 03 B-6 03
C-1 03 - -
Section C
Airworthiness limitations C-2 03 - -
D-1 03 D-3 03
Section D
Other limitations D-2 03 D-4 03
E-1-1 03 E-1-9 03
E-1-2 03 E-1-10 03
E-1-3 03 E-1-11 03
E-1-4 03 E-1-12 03
E-1-5 03 E-1-13 03
E-1-6 03 E-1-14 03
E-1-7 03 E-1-15 03
Section E
E-1
Main rotor
E-1-8 03 E-1-16 03
E-2-1 03 - -
E-2
Main transmission E-2-2 03 - -
E-3-1 03 E-3-7 03
E-3-2 03 E-3-8 03
E-3-3 03 E-3-9 03
E-3-4 03 E-3-10 03
E-3-5 03 E-3-11 03
E-3
Tail rotor and transmission
E-3-6 03 E-3-12 03
E-4-1 03 E-4-6 03
E-4-2 03 E-4-7 03
E-4-3 03 E-4-8 03
E-4-4 03 E-4-9 03
E-4
Flight controls
E-4-5 03 E-4-10 03

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CABRI G2 GENERAL
Issue 03 Approved under DOA.EASA.21J.211 A-3
Page number
Revision
number Page number
Revision
number
E-4-11 03 - -
E-4
Flight controls E-4-12 03 - -
E-5-1 03 E-5-7 03
E-5-2 03 E-5-8 03
E-5-3 03 E-5-9 03
E-5-4 03 E-5-10 03
E-5-5 03 E-5-11 03
E-5
Engine installation
E-5-6 03 E-5-12 03
E-6-1 03 E-6-6 03
E-6-2 03 E-6-7 03
E-6-3 03 E-6-8 03
E-6-4 03 - -
E-6
Airframe
E-6-5 03 - -
E-7-1 03 E-7-9 03
E-7-2 03 E-7-10 03
E-7-3 03 E-7-11 03
E-7-4 03 E-7-12 03
E-7-5 03 E-7-13 03
E-7-6 03 E-7-14 03
E-7-7 03 E-7-15 03
E-7
Systems
E-7-8 03 E-7-16 03
E-8-1 03 - -
E-8
Miscellaneous E-8-2 03 - -
F-1 03 - -
Section F
Trouble shooting F-2 03 - -
G-1 03 G-5 03
G-2 03 G-6 03
G-3 03 G-7 03
Section G
Appendix
G-4 03 G-8 03
H-1 03 H-5 03
H-2 03 H-6 03
H-3 03 H-7 03
Section H
Flight report models
H-4 03 H-8 03

Maintenance Manual Hélicoptères Guimbal
GENERAL CABRI G2
A-4 Approved under DOA.EASA.21J.211 Issue 03
The following table gives the revision list :
(*) EASA letter number or “approved under the authority of DOA EASA 21J.211”
Note : Issue 03 of airworthiness limitations section was approved under DOA. Minor classification
of change was granted by EASA through letter DSAC/NO/NAV-090045.
Abbreviations
HG : Hélicoptères Guimbal company
OC : On-condition
OTL : Operating time limit
TBO : Time between overall
Nb Page Revision object Issue Date Approval reference (*)
2-1, 2-2 EASA.R.145 dated 14/12/07
001 All others Creation 12 / 06 / 08
Approved under DOA EASA
21J.211
2-1, 2-2 EASA.R.C.0.0395 dated
15/09/08
002 All others Update 04 / 09 / 08
Approved under DOA EASA
21J.211
003 All pages Update for 500 h
inspection 23 / 10 / 09
Approved under DOA EASA
21J.211

Hélicoptères Guimbal Maintenance Manual
CABRI G2 GENERAL
Issue 03 Approved under DOA.EASA.21J.211 A-5
Maintenance authorization
The only personnel authorized to perform the required inspections or to make repairs are :
• certified airframe & powerplant mechanics who have successfully completed an HG-
certified maintenance course,
• certified airframe & powerplant mechanics who are under direct supervision of an above-
stated mechanic.
Inspections must be performed by mechanics with inspection authorization, or repair stations
certified by the EASA, or by the national authority regulation.
The daily and preflight checks may be accomplished by the above-stated mechanics or by the
pilot, after careful study of the appropriate sections of the Flight Manual.
Overhaul authorization
Only appropriately certified mechanics who have completed an HG-certified course for
overhauling specific components, and possess the special tools and technical data supplied by
HG are authorized to disassemble and overhaul major components as required by Section C .

Maintenance Manual Hélicoptères Guimbal
GENERAL CABRI G2
A-6 Approved under DOA.EASA.21J.211 Issue 03
A-2 Cabri G2 Description
The Cabri G2 is a two-seat helicopter in the category of CS 27 “Small Rotorcraft”, designed for a
large variety of missions.
It is powered by an aviation piston engine.
It features a conventional architecture, with a three-bladed main rotor, and a shrouded tail rotor.
With basic equipment, it is approved for day-VFR operation.
Its main characteristics are :
• Maximum gross weight.........................................................................................700 kg
• Typical empty weight ...........................................................................................425 kg
• Typical full power level speed................................................................................100 kt
• Service ceiling .................................................................................................. 13.000 ft
• Engine...........................................................................................Lycoming O-360-J2A
Atmospheric 180 hp derated to 145 hp
One Plasma electronic ignition system - One magneto
Night-VFR optional equipment
The night-VFR optional equipment is composed of :
• A wider instrument panel,
• Instrument panel lighting, with backup mode in direct battery,
• Two map lights, controlled through a switch on the overhead control module. This same
switch also activate the backup instrument panel lighting,
• Three gyroscopic instruments :
o Artificial horizon,
o Directional gyroscope,
o Turn coordinator.
• One approved primary navigation mean (VOR or approved GPS)
• A specific night vision filter for the EPM.

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CABRI G2 GENERAL
Issue 03 Approved under DOA.EASA.21J.211 A-7
External dimensions

Maintenance Manual Hélicoptères Guimbal
GENERAL CABRI G2
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CABRI G2 GENERAL
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A-3 Helicopter basic servicing
A-31 Ground handling
Ground handling should only be done with approved wheels attached on dedicated attachment
points.
Caution : No one should be sitting in the helicopter during ground handling.
The two ground handling wheels are identical and can be used on the right or on the left without
distinction. They are composed of a tire, rims, a hub and a skid-interface part that can rotate
around the hub to raise the helicopter.
There is one lever for both wheels.
A locking pin is attached to each wheel.
Installing the wheels
First, ensure that the rotating part is extended as shown :
Then install the wheel on the skid. Ensure that the supporting tab is fully engaged on the
shouldered bolts :
Locking pin
Lever
Attaching tab
Shouldered bolts

Maintenance Manual Hélicoptères Guimbal
GENERAL CABRI G2
A-10 Approved under DOA.EASA.21J.211 Issue 03
Engage the lever in the spindle,
Rotate 180 deg to raise the helicopter,
Lock with the push-pin.
Note : On very soft ground it might be necessary to fit both wheels on the skids
before raising the helicopter.
Caution :
• Make sure that the helicopter is clear from any obstacle since it may
move while it is raised.
• Do not let the lever go off to avoid a harmful back movement.
When both wheels are secured, maneuver the
helicopter as follows :
Use the vertical tail gearbox support tube as a handle
(right hand only) to raise the helicopter nose, and
maneuver.
Warning : Make sure that the blades won’t hurt your
fingers if they rotate. Do not use the shroud structure
as a handle.
Additional people can push the helicopter on the engine cowlings or main gear bow.
Handing zone

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CABRI G2 GENERAL
Issue 03 Approved under DOA.EASA.21J.211 A-11
A-32 Lubricants
Main and tail rotor gearboxes lubrication requirements are given by Cabri G2 Flight Manual.
Engine lubrication requirements are given by Cabri G2 Flight Manual and Lycoming Service
instruction 1014 (current revision).
All Cabri G2 bearings are sealed or self-lubricated and do not require frequent greasing. Refer to
Section B for specific periodic required greasing.
A-33 Defueling
When fueling or Defueling the helicopter, use only adequate hoses and tanks, with protection
against static electricity hazard.
Place a container under the gascolator valve.
Open and lock the gascolator drain valve :
Switch Master and Electrical fuel pump ON.
Switch OFF when fuel tank is empty.
Note : Use the opportunity if you can, when emptying the fuel tank, to check the
low-fuel warning light :
• watch the light below 20 liters or 5 US gal indicated,
• when it lights up, close the main fuel valve and wait for the indicated
quantity to stabilize. Note the quantity A,
• use appropriate container to measure the real quantity B remaining to
exhaustion.
B should be 12 +/- 2 liters (3.2 +/- 0.5 US gal)
If not, check the low fuel switch per operation 55-A-02
A - B (absolute) should be less than 2 liters (0.5 US gal)
If not, calibrate the fuel gage per operation 55-A-03

Maintenance Manual Hélicoptères Guimbal
GENERAL CABRI G2
A-12 Approved under DOA.EASA.21J.211 Issue 03
A-34 Doors removal & installation
The right and left door can be removed for flight, per Flight Manual conditions.
Removal and installation require no tool.
Door removal IPC x-xx
a) Open the door,
b) Remove the small circular locking clip from either gas spring attachment. Snap the rod
end off, and secure the gas spring,
c) Remove the two hinges lock pins, and save the washers,
d) Slide the door off. Save the washers and pins on the door hinges.
Door installation IPC x-xx
a) Remove the lock pins from the door hinges,
b) Install the door, and check the plastic bushings,
c) Install one washer and one lock pin on each hinge.
Note : The lower hinge has its plastic bushing inverted, to take the upward
thrust from the gas spring. The washer is then important.
d) Snap the gas spring rod end on its sphere, and install the small locking pin in the rod
end. Caution :
• Never install the gas spring without the hinge pins : the gas spring exerts
an upward force that would eject the door .
• The gas spring should be installed in the right direction : rod facing
inside/forward, body on the door side.
A-35 Seats removal & installation
The two seats are identical and can be exchanged.
The left seat may be removed and reinstalled as required, for particular missions or other
reasons. Flight is permitted without the left seat, with no particular restriction.
Removal/installation of a seat requires :
• One 13 mm wrench
• One 13 mm ¼” ratchet wrench
Caution : Always remove the copilot collective, cyclic sticks and pedals before
removing the passenger seat, and keep them secured when flying. They can
be stored in the nose baggage compartment.
Seats removal IPC x-xx
a) Reach below the seat pan. Remove the safety pin on the inner nut. DO NOT remove the
cotter pin on the other nut,
b) Release the nut. Pull the long stud outward as permitted,

Hélicoptères Guimbal Maintenance Manual
CABRI G2 GENERAL
Issue 03 Approved under DOA.EASA.21J.211 A-13
c) Rotate the absorber end backward slightly,
d) Slide the seat pan upward. Slamming may be necessary.
e) When the upper red slides escape the rails, rotate the seat forward, and release it from
the rails.
f) Remove the long go-through stud, to release the seat belt fitting if needed to remove the
seat from the cabin.
Seats installation IPC x-xx
a) Install the two aluminum spacers in the seat pan attachment holes,
a) Install the long go-through stud, with its nut and cotter pin, on the outer side of the seat,
Caution : Engage the inner seat belt fitting in the go-through stud before
installing the seat.
b) Holding the seat pan tilted forward approx. 20°, engage the two lower red slides in
corresponding slots in the rails,
c) Tilt the seat pan back, to engage the upper slides in the rails. When engaged, slam the
seat down until the upper (brown plastic) slides ends are flush with the rails ends.
d) Reach under the seat, and rotate the absorber forward to slide its clevis end between the
two aluminum spacers,
e) Push the long stud through the spacers. Engage the inner seat belt fitting, then washer,
castle nut.
f) Mark the stud for the safety pin hole orientation. Tighten the long stud to
contact plus one turn. Complete torque as needed to the next slot. Install the safety
pin.
g) Check the seat belt and shoulder harness.
A-36 Cleaning
Use only for cleaning the helicopter, products that are fully compatible with paint, acrylic
transparencies, natural rubber, plastics. Avoid detergents and solvents.
Do not use high pressure cleaner.
Do not spray magneto, electronic and electrical parts, main rotor hub, tail rotor gearbox
and swashplate area with high pressure water.
A-37 Parking, tie-down and covers
Refer to Flight Manual procedure, Section 8.

Maintenance Manual Hélicoptères Guimbal
GENERAL CABRI G2
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A-38 Hoisting
Hoisting can be done with or without the tail, the cowlings or the engine installed. It cannot be
done with the engine and the tail removed together.
Hoisting is done with the special hook G81-01-100.
Install the hook above the rotor hub plastic plug, with the three studs in corresponding holes.
Take care to avoid scratching the paint.
Install the three nuts, each with a rubber and metal washer.
Screw the nuts to contact only. Check for a minimum of two threads protruding.
Use any appropriate sling or shackle to hoist.
Caution : When hoisting the helicopter with its tail installed, anticipate a
significant pitch-up motion, due to aft CG. Hold the tail to prevent shock and
damage.
When hoisting is necessary, and the hook not available, use an approximately 2 meter long, 12
mm diameter soft synthetic rope, of 4 kN (900 lbf) minimum strength around the main rotor hub.
The rope should be slipped between the blades root and the main rotor hub, just above the droop
stop ring. It should form three loops, one in each blade interval. The third loop is closed by
attaching both ends together.
The rope is then moved upward between the hub and the spherical bearings and through the
three hub holes. The helicopter can then be hoisted with a snap-hook as shown :