RotorSport Calidus User manual

Copyright of RotorSport UK Ltd
Document number RSUK0061
Page 1 of 147 Page issue 7, dated 12.04.16
Maintenance Manual
Gyroplane Type Calidus (UK spec only)
RotorSport UK Ltd
Poplar Farm
Prolley Moor
Wentnor
Bishops Castle
SY9 5EJ
Company Reg No 5486550
Phone: [phone]
Fax: [phone]
Email: [email protected]
CAA Approval No: DAI/9917/06

Copyright of RotorSport UK Ltd
Document number RSUK0061
Page 2 of 147 Page issue 7, dated 12.04.16
Applicability
Aircraft Registration: G-
Aircraft serial no. RSUK/CALS/
Engine type: Rotax 912ULS & 914UL
Engine serial No:
Rotor blade type & diameter: Autogyro 8,4m rotor system (orange cap only)
or
Autogyro 8.4m RotorSystemII (red cap only)
when modified under SB-039
or
Autogyro 8.4m RotorSystemII TOPP (blue cap
only)
NB: all types have silver spacers (clamp
profiles)
Propeller type: HTC 1,73m with or without spinner.
or
IVO-prop DL3-68 in-flight variable
pitch propeller
Calidus gyroplane, fitted with semi enclosed canopy

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CONTENTS AND CHECK LIST OF PAGES
Content Page No.
Cover page 1
Applicability 2
Contents and checklist of pages 3
Section 1 Amendments to the schedule 5
Section 2 Foreword 9
Section 3 Owner/Operator responsibilities 9
Certifying persons responsibilities 9
General inspection standards 9
Airworthiness life limitations 9
Airworthiness Directives & Mandatory Permit Directives 10
Airworthiness Notices 10
Overhaul and test periods 10
Service information 10
Modifications 10
Duplicate inspections 10
Scheduled maintenance worksheets 10
Definitions 10
Section 4 Permit maintenance release 11
Pilot Maintenance 11
Annual check 12
Inspection after operational incident 12
Section 5 The maintenance check cycle 14
Permitted variations 14
Notes 14
Section 6 Pilot's pre-flight check (Check A) 15
Section 7 Scheduled maintenance worksheets & permit renewal 15
Section 8 Annual Inspection (Flight test) 17
Section 9 Aircraft systems description and maintenance methods 19
Airframe 25
Engine and controls 29
Electrical 549
Pneumatic 62
Rotor 68
Propeller (HTC) 79
Pre rotator 81

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Rotor brake and trim 85
Enclosure, seats, harnesses 87
Instruments 90
Suspension, wheels and brakes 102
Rudder and rudder control 108
Rotor head and rotor head control 116
Fuel system 123
Fire warning system 129
Canopy unlocked warning & interlock system 134
Canopy repairs 134
Section 10 IVO-prop in-flight variable pitch propeller 136
Section 11 Approved modifications to date 143
Service bulletins issued to date 143
Service Information Letters issued to date 144
Repair approval request form 145
Appendix A – Compass 146

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SECTION 1
AMENDMENTS TO THE SCHEDULE
1. Where & when necessary RotorSport UK Ltd (hereafter referred to as RSUK) will issue
updates to this maintenance standard, and will notify known owners to review the changes via
the RSUK website with changes appropriately identified by a strike in the margin.
2. Aircraft operators are responsible for ensuring that amendments to their publication are
carried out immediately and in accordance with instructions contained in amendment
transmittal letters (where issued).
ISSUE
NUMBER
DATE
INSERTED
BY
ISSUE
NUMBER
DATE
INSERTED
BY
Initial
4 13.03.12
1 14.01.11 5 01.07.13
2 08.06.11 6 10.06.14
3 12.9.11 7 12.04.16
Issue Change summary
5 Life limitations table (p10), Inspection after operational incident (p13-14),
Supplemental inspection (p15), Flight test requirement (p17, 18).
Inspection of rubber bushings (p28), oil hoses (p36), MC-255 ref added
(p37), further information 914UL (p61), warning on Binx nuts (p77),
thrust washers (p78), teeter bushings (p79), Improved pre-rotator
gearbox and clutch series II/III (p84), Trim cylinder seal kit (p86), Flymap
3 AHARS (p95-96), Baro fittings (p97), AI option (p97). different rpm
gauges (p102), ATR833 audio socket (p101), MC263 ref added, (p102),
nitrogen-filled tyres (p106), nosegear rubber replacement (p106), new
nosewheel (p106), push-pull cables (p120), base control unit (p121),
rotor head main bolt adjustment (p122), fuel sensor two years (p127),
Fuel filters life limited (p128).. Form F023 updated.
All pages republished at Iss5 01.07.13.
6 Life limited parts revised (p9), Section 10 now IVO-prop VP propeller
(p136-142). Modifications, service bulletins, etc.now Section 11 (p143)
7 TOPP rotor option added p2, p5,p6-7,p9, p68, p117
All pages republished at Iss7 12.04.16
Signature:
Position:
Eng. Manager
Signature:
Position:
Head of Engineering
Signature:
Position:
Head of Airworthiness

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Copyright of RotorSport UK Ltd
Document number RSUK0061
Page 8 of 147 Page issue 7, dated 12.04.16
SECTION 2
FOREWORD
1. Applicability
This Schedule is intended for use on the CALIDUS Gyroplane only, released on AAN29266.
Guidance
This aircraft may be being flown & operated under a CAA Permit to fly, and as such specific
rules exist to cover maintenance actions, such as the types of work allowed by owners on
Permit aircraft or CAP520 ‘Light Aircraft Maintenance’. It is the aircraft operators’ responsibility
to ensure the aircraft is operated within those rules and regulations.
3. Notes
RSUK provides this maintenance schedule so that, to the best of their knowledge, the
operator is able to maintain the aircraft in a manner that will preserve its airworthiness. The
manufacturer is unable to predict all operating conditions, and as such it is the operator’s
ongoing responsibility to assess the schedule for applicability to the environment operated
within.
Note; check your Permit to Fly – if compliance to this schedule is stated as required,
then non-compliance will invalidate the Permit to Fly.
SECTION 3
OWNER/OPERATOR RESPONSIBILITIES
Operators are responsible for the accomplishment of the maintenance prescribed in the
schedule.
CERTIFYING PERSONS RESPONSIBILITIES
Certifying persons must use their engineering skill and judgement in determining the depth of
inspection needed and other matters that could affect the airworthiness of the gyroplane. In
order to claim any alleviation on subsequent inspections, the gyroplane maintenance records
must record the extent of previous inspections upon which the alleviation is based.
Certifying persons are responsible for recording in the appropriate log book or worksheet, any
defects, deficiencies or additional maintenance required as a result of implementation of the
schedule.
GENERAL INSPECTION STANDARDS
The general inspection standards applied to individual task inspections must meet the
recommended standards and practices of RSUK.
In the absence of general inspection standards, refer to CAA CAP 562 Civil Aircraft
Airworthiness Information and Procedures (CAAIP) or other CAA recommended standards
and practices, and/or the LAA Gyroplane Maintenance manual.
Inspections may be carried out without component removal or dismantling unless considered
necessary or where required by the schedule.
AIRWORTHINESS LIFE LIMITATIONS (RETIREMENT/SCRAP LIVES)
Airworthiness life limitations shall be those published by the CAA, state of design and RSUK.
Airworthiness life limitations should be recorded in CAP 543 Time Limited Task Record, or an
appropriate equivalent.

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For safe operation over the specified lifecycle of the aircraft and for liability reasons, the
following manufacturer limitations shall apply. In the case where a component has operating
hours and calendar time limits the first-reached limit shall apply.
On reaching the manufacturer life limit (MLL) the component SHALL be replaced, regardless
of its perceived condition.
Equipment / System
MLL
RotorSystem 1 Calidus blade BG1448
(orange end caps) 700 hours
Rotorsystem II 8.4m BG1793 (red end caps) 2500 hours (fixed)
Rotorsystem II 8.4m BG8946 (blue end caps) 2500 hours – see below
This (fatigue) life limit of 2,500hrs assumes
2.8 (500Kg MTOW) ground-air-ground cycles
per flight hour on average over the 2,500hr
life. Operational use in excess of these values
will reduce the safe life of the rotor
accordingly. GAG cycles should be recorded
in the aircraft logbook.
Rotor main bearing 1500 hours
NB: as the publication of this table will have retrospective requirements on some
aircraft, the affected component(s) must be replaced no later than the next Annual
Check
AIRWORTHINESS DIRECTIVES
All applicable Airworthiness Directives or Mandatory Permit Directives issued by the CAA and
the state of design must be complied with. Compliance with AD’s or MPD’s should be
recorded in Part C of CAP'S 398, 399 or 400 (logbooks), or an approved equivalent.
AIRWORTHINESS NOTICES
All applicable mandatory CAA Airworthiness Notices must be complied with. Compliance with
CAA Airworthiness Notices should be recorded in Part C of CAP'S 396, 399 or 400
(logbooks), or an approved equivalent.
OVERHAUL AND TEST PERIODS
Overhaul and test periods shall be those shown & recommended by RSUK.
The CAA may vary or mandate overhaul and test periods by the issue of an Airworthiness
Directive or Airworthiness Notice.
The overhaul and test periods should be recorded in the appropriate aircraft worksheet
SERVICE INFORMATION
Service information (Service Bulletins, Service Letters, etc) published by RSUK should be
formally technically assessed by the Owner/Operator and adopted if required to ensure
operational safety and reliability, compliance with service information should be recorded in
Part C of CAP 398, 399 or 400 (logbooks), or an approved equivalent.
MODIFICATIONS
Approved modifications which have been carried out to the gyroplane, engine, components
and radio after original manufacture, must be recorded in the appropriate log book(s).
Any recurring inspection or maintenance task resulting from approved modifications should be
recorded in the aircraft worksheets.

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DUPLICATE INSPECTIONS
Following initial assembly or any disturbance of a control system or vital point, the procedures
outlined in British Civil Airworthiness Requirements (BCAR) Section A/8, Chapter A6-2/B6-2
and A5-3 shall be applied. Certifications must be recorded in the appropriate worksheet, log
book or aircraft technical log. In summary, this procedure requires that all and any such
changes be cross checked by either a CAA approved Inspector or Certified or CAA Authorised
Engineer prior to first flight, and this cross check shall be as thorough as practical – including
physical tests if appropriate. In exceptional circumstances the CAA also allow another
qualified gyroplane pilot to cross check modifications – this person must sign the logbooks to
certify their actions with their pilots licence no.
SCHEDULED MAINTENANCE WORKSHEETS
Worksheets shown in Section 7 must be issued and the tasks certified for all scheduled
maintenance checks. These worksheets become part of the maintenance records required to
be kept by the operator.
All maintenance carried out in connection with a particular check should be certified on
suitably referenced worksheets (an example available from the RSUK website) and included
in the gyroplane records. These worksheets must be cross-referenced in the appropriate log
book(s) giving general details of the additional maintenance carried out.
DEFINITIONS
Throughout the schedule the following terms and abbreviations have the stated definitions;
SERVICE/LUBRICATION (SERVICE/LUB):
The term ‘Service or Lubrication’ requires that a component or system should be serviced
and/or replenished as necessary with fuel, oil, grease, water, etc., to the condition specified.
INSPECT (INSP):
An ‘Inspection’ is a visual check performed externally or internally in suitable lighting
conditions from a distance considered necessary to detect unsatisfactory
conditions/discrepancies using, where necessary, inspection aids such as mirrors, torches,
magnifying glass etc. Surface cleaning and removal of detachable cowlings, panels, covers
and fabric may be required to be able to satisfy the inspection requirements.
OPERATIONAL CHECK (OP/C):
An ‘Operational Check’ is a test used to determine that a system or component or any function
thereof is operating normally.
FUNCTIONAL CHECK (F/C):
A ‘Functional Check’ is a detailed examination of a complete system, sub-system or
component to determine if operating parameters are within limits of range of movement, rate
of flow, temperature, pressure, revolutions per minute, degrees of travel, etc., as specified in
the appropriate maintenance manual. Measured parameters should be recorded.
CHECK (CHK):
A ‘Check’ is the verification of compliance with the type design organisation’s
recommendations.

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SECTION 4
PERMIT MAINTENANCE RELEASE
This maintenance certification system is specific in accordance with BCAR A3-7.
Owner operators must ensure their airframe and engine logbooks either contain a sticker with
the wording ‘Any reference to a Certificate of Release to service in this logbook shall be
construed as a PMR’ & ‘The certification at the top of each page in Part A of this logbook is
superseded by the following statement; The work recorded below has been completed to my
satisfaction and in that respect the aircraft is considered fit for flight’, or have new logbooks
containing this information.
For information on who can issue a PMR see CAP553; BCAR Section A, Chapter A3-7,
Paragraph 12.5.
On completion of any check required (‘required’=stated in the Permit to Fly) by the schedule,
except pilot maintenance (see section 5) and Check A (see section 6), an entry shall be made
in Column 6 of CAP398 Aircraft Log Book, CAP399 Engine Log Book or an approved
equivalent as Section 4. The certifying person’s signature, authority and date must be made in
Column 7 against the relevant category (Airframe, Engine, Radio).
The following is an example of an entry acceptable to the CAA, unless already pre printed on
the page:
PERMIT MAINTENANCE R
ELEASE
Cross refer to workpack ref;
25 hr/100 hr/Annual Check (delete as appropriate)
Has been carried out to my satisfaction at total airframe
hours…….
And in that respect is considered fit for flight
Signed……………………Authorisation ref………….Date……….
Maintenance Schedule Ref. RSUK0061 Issue …..
Airframe
Engine
Radio
(Annual check only)
A signed PMR does not expire or is superseded by subsequent PMR’s, unless relating to a
repeat of the same activity. A PMR remains active as long as the activity it relates to remains
part of the aircraft.
Pilot Maintenance
A licensed pilot who is the owner or operator of the gyroplane may carry out certain
maintenance tasks prescribed in Air Navigation (General) Regulation 16. The issue of a PMR
is not required. The pilot must include his pilot's licence number with his signature in the
appropriate log book(s). The permitted pilot maintenance is as below;
PERMITTED PILOT MAINTENANCE
This section defines the type and extent of maintenance that may be carried out and certified
by a pilot who is the owner of the aircraft and operates under a CAA Permit to Fly. Refer to
CAA CAP 733 for more information. Some of the wording is adjusted to suit gyroplane
terminology.
1. Replacement of landing gear tyres.
(Including removal and replacement of wheels, cleaning and servicing of wheel bearings,
application of creep marks, removal and refitting of brake units to the extent required for

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wheel removal and the removal and the renewal of brake pads/linings when special tools
are not required. Replenishment of hydraulic brake system fluid level).
2. Replacement of defective safety wiring or split pins excluding those in engine,
transmission, flight control and rotor systems (but including those designed to be pilot
maintainable and shown in the pilot’s handbook, e.g. teeter bolt split pin).
3. Repairs to upholstery and decorative furnishing of the cabin or cockpit interior when repair
does not require dismantling of any structures or operating system or interfere with an
operating system or affect the structure of the aircraft.
4. Repairs, not requiring welding, to fairings, non-structural cover plates and cowlings.
5. Replacement of safety belts or safety harness.
6. Replacement of seats or seat parts not involving dismantling of any structure of any
operating system.
7. Replacement of bulbs, reflectors, glasses, lenses or lights.
8. Replacement of any cowling not requiring removal of the propeller, rotors or disconnection
of engine or flight controls.
9. Replacement of unserviceable sparking plugs.
(Including removal, cleaning, gapping, testing and refitting of all spark plugs).
10.Replacement of batteries.
(Including maintenance of lead acid batteries)
11.Replacement of wings (rotors) and tail surfaces and controls, the attachments of which are
designed to provide for assembly immediately before each flight and dismantling after
each flight.
12.Replacement of main rotor blades that are designed for removal where special tools are
not required (as is the case on the Calidus).
13.Replacement of VHF communications equipment, only if is not combined with navigation
equipment.
14.Manufacture and installation of required cockpit placards and notices.
15.Lubrication of aircraft.
(Including prior cleaning of hinges)
16.Inspection of engine induction air filter.
(Including removal, cleaning and refitting (with wirelock)).
17.Inspection of fuel filters.
(Including removal, cleaning and refitting).
18.Changing of engine oil.
(Including removal, cleaning/replacement, refitting of oil filter, and wirelock of sump bolt).
Annual Check
The annual check and all associated work must be accomplished under the supervision of an
organisation appropriately approved by the CAA (e.g. RSUK or other CAA Authorised
engineer).
Use form F115 from the RSUK website
Inspections after operational incidents
It is essential that in the event of an operational incident a detailed inspection is carried-out as
defined below by an A3-7 authorised engineer. Defective components must be replaced. In
case one or more of the items marked ‘CRITICAL’ are found defective or out of tolerance,
ground the aircraft and contact RSUK.
1. Suspected hard landing
In case of a suspected hard landing perform the following checks:
Inspect nose gear, attachment, fork, linkage and wheel bearing
Inspect main gear axles
Examine possible rotor / propeller strike (see ‘Rotor / propeller contact with obstacle’)

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CRITICAL: Inspect main gear spring spar (attachment ok, no cracks)
CRITICAL: Inspect fuselage, frame and attachment point for possible deformation or
cracks
CRITICAL: Inspect engine rubber mounts and propeller to frame clearance approx. 5
cm
CRITICAL: Perform a rotor alignment check
2. Rotor contact with an obstacle
Rotor contact with obstacle includes any rotor strike of the standing or turning rotor with any
obstacle, including propeller and fuselage structures.
In case of rotor contact with obstacle:
Perform a rotor alignment check and adjust, if necessary
Examine damage of aluminium rotor profile:
allowed damage: dent with max. depth of 1 mm
CRITICAL damage: dents(s) with depth >1mm and/or sharp-edged nick(s)
In the case where the turning rotor has hit the tail or rudder, a detailed inspection of the
affected components must be undertaken.
3. Propeller external impact or contact with an obstacle
Refer to engine manufacturer documentation.
4. Birdstrike
Perform detailed inspection of all affected components
If rotor blades are affected, proceed according to ‘Rotor contact with obstacle’
If propeller is affected, proceed according to ‘Propeller contact with obstacle or external
impact’
5 Lightning strike
A lightning strike may damage the main rotor bearing. Thorough inspection and maintenance
after a lightning strike is required. Ground aircraft and contact RSUK.

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SECTION 5
THE MAINTENANCE CHECK CYCLE
Check title Content Period
Check A Check A Prior to the first flight of the day
First 25 hour check 25 hour check items (one
time check, after new build) Not exceeding 25 flying hours, or 1 year, whichever is the sooner
100 hour check 100 hour check items Not exceeding 100 flying hours
Annual check As 100hr check items. Not exceeding 12 months from
previous 100hr or annual check (see
Note 5)
1500 hour check Supplemental inspection When 1500 flight hours reached.
Consult RSUK for further information
Use forms F114 25hr Service and F115 100hr Service/Annual Inspection Worksheets
PERMITTED VARIATIONS (see Notes)
Tasks controlled by flying hours Maximum Variation
25 hour +/- 5hrs
100 hour +/- 10hrs
Tasks controlled by calendar time Maximum Variation
6 months 1 month
Annual Prior to Permit renewal
(see 5. and 6. below)
Tasks controlled by more than one limit
The more restrictive limit shall be applied
Notes
1. Permitted variations may not be applied to applicable airworthiness life limitations,
airworthiness directives or overhaul and test periods.
2. Permitted variations for tasks controlled by flying hours should not be understood to be a
maintenance planning tool, but as an exceptional means to allow the operator to fly for a
limited period of time until the required maintenance is performed.
3. Any application of a permitted variation to the maintenance check cycle period must be
recorded in the appropriate log book(s) together with the reason for the variation by a
person who is authorised to sign the log book entry for that particular check. Details of the
permitted variation must be made visible to the pilot.
4. Permitted variations are not required to be deducted from the next scheduled check.
5. The annual check may be anticipated by a maximum period of 62 days without loss of the
continuity of the maintenance check cycle. Thus, for example, where the full 62 days is
invoked, the following annual check would become due 14 months after the completion of
the annual check that was anticipated. The period by which the annual check was
anticipated and the date of the next annual check shall be recorded in the appropriate log
book(s).
6. Where the aircraft requires an annual inspection, and was supplied new within that
preceding year, it is permissible for the 25hr airframe inspection to be accepted in lieu of
the annual inspection, provided the service has been undertaken within the 62 days
requirement in note 5.

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SECTION 6
PILOT'S PRE-FLIGHT CHECK
Pre-flight checks are to be carried out in accordance with the Gyroplane Pilots Handbook
RSUK0060.
CHECK A - PRIOR TO FIRST FLIGHT OF THE DAY
For update control and one source of information, this check is not printed here. Refer to the
Pilots Handbook.
For all inspection checks reference must be made to RotorSport UK Ltd, either via the website
www.rotorsport.org or directly, for the latest schedule.
SECTION 7 - SCHEDULED MAINTENANCE WORKSHEETS
To allow ongoing updates of these service sheets with field service information
received, they are located on the RotorSport UK Ltd website www.rotorsport.org.
F114 issue 3, 25hr service worksheet
F115 issue 4, 100hr or Annual worksheet
F156 issue 2 Short term storage and return to service
F157 issue 2 Long term storage and return to service
F189 issue 1 IVO-prop 25hr or 100hr/Annual service worksheet
PERMIT RENEWAL
Over and above the annual inspection, the CAA have some specific requirements that must
be met/demonstrated during the permit renewal process. These are:
1) Demonstration of compliance with relevant AAN's (29266, downloadable from the CAA
website) at applicable issues and with any addendums. See the aircraft Certificate of
Conformity for details.
2) Demonstration of compliance with CAA Type Approval data sheet No. -BG-04 @ current
Issue (downloadable from CAA website)
3) Demonstration of Compliance with CAP 661 Mandatory Permit Directives - detailing the
Revision date/issue and stating relevant MPD's and method of compliance and
location/page of certification in log book. Achieved by checking the copy of the latest
document on the CAA website, and referencing it on the Annual Inspection worksheet.
4) Demonstration of Compliance with CAP 747 detailing the Revision date/issue and
applicable Generic Requirements. Achieved by checking the copy of the latest document
on the CAA website, and referencing it on the Annual Inspection worksheet.
5) Demonstration of Compliance with EASA AD's applicable to the Rotax 912/914 engine -
claim those for which are covered by mod state and detail those which are not relevant
to UL/ULS. Achieved by checking the copy of the latest document on the EASA website,
and referencing it on the Annual Inspection worksheet.
6) Demonstration of last completed Scheduled Maintenance check - reference Maintenance
Manual, requirements and significant maintenance tasks/repairs completed. Achieved by
showing the signed, completed service worksheets, which must be referenced in the
aircraft and engine logbooks together with reference back to the manual used.

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7) Flight test report – as of 2013 no longer required by the CAA, but at the discretion of the
aircraft owner and their A3-7 engineer. Note that if the aircraft is managed under the
LAA permit renewal scheme, a flight test may still be required.
8) Permit Flight Release Certificate, if previous Permit expired. Copy required.
9) Aircraft weighing report date and C of G schedule - copy required if changed since last
renewal.
Note! There is no requirement to annually re weigh a gyroplane. If a re-assessment of the
aircraft CG is required, please contact RotorSport UK Ltd.
10) Check of Aircraft hours, Engine serial No and Propeller serial number.
11) Pilots Operating handbook Issue No. You will need to show your copy.
12) Logbooks, modifications and service bulletins/MPDs. The aircraft and engine logbooks will
be inspected (as will the VP-propeller log book if such a prop is fitted), and MUST be
complete and up to date. In addition, they must show any modifications incorporated, both
in the white pages and in the back pages showing the mod summary. Service bulletins
and MPDs must be shown in either ‘one time requirements’ or ‘Repetitive requirements’ if
to be repeated at certain intervals. In the latter case, the repeat checks must have been
done.
They must be referenced with either CAA or RSUK mod numbers, and to their worksheets
if used to show embodiment – and to be available for review.
A well presented and completed document set as above will make the permit renewal
process relatively easy. See the RSUK website for further permit renewal guidance.
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SECTION 8 - ANNUAL FLIGHT TEST
Annual Flight Test Schedule – refer to CAA check flight schedule CFS301 if it is decided that a
flight test is needed.
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SECTION 9 – AIRCRAFT SYSTEMS DESCRIPTION AND MAINTENANCE METHODS
General notes;
1. These instructions are not all encompassing, and should always be used in line
with good aircraft engineering practices, and manuals such as AC43.13. Repairs
not shown must be approved by either the CAA or RSUK in writing.
2. Safety; working on an aircraft brings many hazards. Always wear suitable personal
protective equipment such as overalls, safety glasses, safety shoes, gloves etc
appropriate for the maintenance task. If possible render the engine inoperable prior
to starting work.
3. Wherever possible SI units are used
4. Always use good quality tools appropriate for the task
5. Use of non standard or unauthorised parts or repairs will invalidate the warranty
and the Permit to Fly. Parts specifically designed for this aircraft and supplied by
RSUK will carry a certificate of conformity, which must be kept with the aircraft
records.
6. Special tools
RSD7197.Coil earthing lead, used to earth the ignition coils should the instrument
panel be removed.
7. Propeller setting tool available, part no RSD4536 (914) and RSD4537 (912)
8. Lubricants. Use engine lubricants only as per Rotax instructions. Shell LM Bearing
grease RSD4530 or equivalent is suitable for aircraft grease lubrication points.
9. Loctites and sealants. See individual sections.
10. General corrosion prevention. Keep the aircraft in a non humid, ventilated area. If
humidity is present, protect unplated components such as bolts etc with a
proprietary spray such as WD40 or ACF50.
11. Help protect our environment by disposing of parts and fluids properly.
12. Standard bolt torques are M5 10Nm +/-2Nm, M6 15Nm+/-2Nm, M8 25Nm+/-3Nm, M10
35Nm +/-4Nm, M12 100Nm +/-10Nm. Always assess the joint to be tightened and
use engineering judgement – do not overtighten plastic or unsupported tube joints!
13. Specific aircraft parts list available separately from RSUK website.
14. Remember, maintenance, modification, and bulletin/MPD incorporations must be
recorded on suitable worksheets and within the aircraft/engine logbooks – and
signed appropriately.
15. Refer also to the pilots handbook as well as the drawings quoted and service parts
list, all available from the RSUK website.
16. Notes on “nyloc” nuts:
(i) Ideally a nyloc nut should be used once only. It may be re-used if the thread is
undamaged and when fitted to its mating fastener it must only turn with a torque
greater than the “Prevailing Torque” listed below (values factored from AC43.13-
1B): M6 0.8Nm, M8, 0.8Nm, M10 1.0Nm, M12 1.2Nm
(ii) Unless specified otherwise the minimum thread protrusion beyond the locking
element should be two thread-pitches.
WARNING! PROPELLERS KILL! WHEN WORKING ON THE AIRCRAFT, UNLESS THERE
IS A SPECIFIC REQUIREMENT TO HAVE THE AIRCRAFT LIVE, ENSURE THAT COILS
ARE OFF AND KEYSWITCH OFF.
IF POSSIBLE DISCONNECT THE BATTERY, OR REMOVE THE SOLENOID ACTUATOR
WIRE FROM THE SOLENOID TO PREVENT POSSIBLE STARTING.
This statement is made here only, to avoid continued repetition. It is the engineer’s
responsibility to ensure a safe working environment.

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Primary and Secondary structure determination:
A primary structural part is one for which the failure would be catastrophic and would prevent
continued safe flight and landing.
All other structure can be considered as Secondary, thus failure of a Secondary structural part
would not be immediately catastrophic and with due care continued safe flight and/or a safe
precautionary landing could still be made.
Because of the simplicity of the aircraft structure some parts have a dual role – such as the
airframe. As an example, the composite body of the aircraft is primary structure, but the
attachment points to the airframe are not (they are multiple redundant due to the number of
attachments).
The primary structural elements are considered to be:
Airframe box section joining the rotor head to the rear of the body, engine, tail, and
undercarriage.
Connection assemblies joining the rotor head to the airframe mast.
The rotor assembly and rotor head
The tail and rudder assy
The rudder and rotor control system
The main undercarriage and nosegear
Whilst other items may have an effect on flight safety, they are considered secondary to the
above. The undercarriage is included, as whilst it does not contribute to safe flight, it is difficult
to make a safe landing without it - inevitably an aircraft rollover would result, probably
destroying the aircraft.
General aircraft testing and requirements post maintenance.
1. Aircraft operation. Any engine service will require the operation of the engine, as will any
maintenance action requiring adjustment of an engine control or subsystem, or affected
system such as removal of the instrument panel. Safely operating an aircraft, even for a
ground run, requires training, and should only be undertaken with a pilot or suitably
experienced person in the pilot seat. Operation must never be undertaken in a confined
space, and always in the open with the propeller wash pointing away from any buildings
or anything of value.
Ensure there are no loose materials in the vicinity that could be sucked into the propeller,
leading to expensive damage.
Ensure the aircraft is chocked to prevent a runaway.
Ensure there are no persons (especially children) or animals in the vicinity of the aircraft.
Any persons required to be present (eg support staff) MUST be suitably trained or briefed
of the danger they are in.
2. This aircraft is equipped with a pitot and static port system. For safe aircraft operation it is
very important that these systems are correctly fitted and checked if disturbed. Any
maintenance operation which removes the instrument panel or instrument connected to
this system must be properly verified for function prior to flight, as per Pitot System
Integrity Test under Standard system checks.
3. Any maintenance action which requires a flight test (eg fitment of an alternative design of
propeller) will result in the requirement for a Permit Flight Release Certificate (PFRC) to
be issued. This is a simple document, and is not included within the logbooks. It must be
retained with the aircraft records.