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
INTENTIONALLY BLANK

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
A-ii Approved under DOA.EASA.21J.211 Issue 03
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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

Hélicoptères Guimbal Maintenance Manual
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