RotorSport MT-03 User manual

Copyright of RotorSport UK Ltd
Document number RSUK0011
Page 1 of 64 Page issue 11, dated 01.04.15
Pilots Handbook
Gyroplane Type MT-03 (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]
Approval number DAI/9917/06

Copyright of RotorSport UK Ltd
Document number RSUK0011
Page 2 of 64 Page issue 12, dated 21.06.16
Applicability
Aircraft Registration: G-
Aircraft serial no. RSUK/MT-03/
Engine type: Rotax 912ULS or 914UL
Engine serial No:
Rotor blade type & diameter: Autogyro 8,4m (black end cap),, or
Autogyro hub/Aircopter blade (supplied
with aircraft serial 004 and 005), or
Aircopter rotor (AutoGyro modified,
supplied with aircraft serial 002 and 003), or
Autogyro 8.4m RotorSystem II (red cap only)
when modified under SB-040 Iss1, or
Autogyro 8.4m RotorSystem ll TOPP (blue cap
only) when modified under SB-040 Iss2
Note! Operation at 500KgMTOW on aircraft embodying service bulletin SB-013 is
only permissible when flown with AutoGyro rotor blade and AutoGyro rotor hub
assemblies.
Propeller type: HTC 1,73m
NOTE!
This autogyro may be operated only under adherence
to the operation limits and the information contained
in this manual. The manual should be carried on
board the aircraft.
The manual is not a replacement for theoretical and
practical training as to how to operate this machine.
Failure to adhere to its provisions or to take proper
instruction can have fatal consequences

Copyright of RotorSport UK Ltd
Document number RSUK0011
Page 3 of 64 Page issue 12, dated 21.06.16
Table of contents Page
1. GENERAL INFORMATION
1.1 Introduction 7
1.2 UK Authority for flight 7
1.3 Explanations and sensible safety measures 7
1.4 Aircraft description 8
1.5 Pictorial views 9
2. OPERATIONAL LIMITS
2.1 Introduction 13
2.2 Airspeed 13
2.3 Airspeed indicator marking 13
2.4 Engine 14
2.5 Engine instruments 14
2.6 Weight and balance 15
2.7 Fuel 16
2.8 General placards 17
3. EMERGENCY PROCEDURES
3.1 Introduction 23
3.2 Engine failure 23
3.3 Engine start in the flight 23
3.4 Abandoning the aircraft 24
3.5 Smoke and fire 24
3.6 Gliding flight & forced landings 24
3.7 Precautionary landings 25
3.8 Loss of control 25
3.9 Engine shutdown 25
4. NORMAL OPERATIONAL PROCEDURES
4.1 Introduction 25
4.2 Rotor rigging 26
4.3 Daily inspection 32
4.4 Flight Operation 34
4.5 Normal procedures and check list 34
5. PERFORMANCE
5.1 Performance data 40
5.2 Further data 41
5.3 Height speed diagram 42
6. DESCRIPTION
6.1 Structure 43
6.2 Controls 43
6.3 Instrument panel 48
6.4 Wheels and Tyres 52
6.5 Seats and belts 52
6.6 Engine 53
6.7 Fuel system 55
6.8 Electrical system 56
6.9 Pitot and static pressure 57

Copyright of RotorSport UK Ltd
Document number RSUK0011
Page 4 of 64 Page issue 10, dated 02.04.12
6.10 Avionics 57
6.11 Navigation lights 58
6.12 Options and Modifications 59
7. HANDLING, SERVICE AND MAINTENANCE
7.1 Introduction 60
7.2 Regular Maintenance Requirements 60
7.3 Repairs 61
7.4 Ground handling & road transport 61
7.5 Cleaning and care 61
7.6 Winter operation 61
8. EQUIPMENT
8.1 Minimum equipment 62
8.2 Additional equipment 62
APPENDIX
I Change of ownership form 63
II Incident reporting form 64

Copyright of RotorSport UK Ltd
Document number RSUK0011
Page 5 of 64 Page issue 12, dated 21.06.16
AMENDMENTS CONTROL PAGE
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
11 01.04.15
1 05/08/06 12
21.06.16
2 20/11/06 13
3 16.8.07 14
4 21/11/08 15
5 09/02/09 16
6 06.07.09 17
7 11.3.10 18
8 17.12.10 19
9 12.9.11 20
10 02.04.12 21
Issue Change summary
8 MC and SB changes incorporated to date, further Rotax information
added
9 Best glide speed/text amended. Conair SSM incorporated
RotorSystemII incorporated. Notes on retrofit of MTOS enclosure.
OEM stick grip option, ATR833 radio option added
10 Section 7 Comment on sunlight & damp conditions (p60).
11 Warning on Binx nuts (p31), different rpm gauges (p51), nitrogen-
filled tyres (p52) and pressures clarified in Checklist (p32), ATR833
audio socket (p57), cooler unblanking highlighted (p61), turbo
cooling note (p37), UL91 and Mogas E10 (p16), rotor brake
technique (p37).
12 TOPP rotor option added pages 2,5,6,15,16,26,27.
Clarification of CG limits p15, Binx photo added p31, format changes
p56, typo correction (hydrometer) p61

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Document number RSUK0011
Page 6 of 64 Page issue 12, dated 21.06.16
LIST OF EFFECTIVE PAGES
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Issue
Date
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RotorSport UK Ltd approval signatures for this Pilots Handbook
Signature:
Position:
Test Pilot & Eng. Manager
Signature:
Position:
Flight Test Observer
& Inspector
Signature:
Position:
Head of Airworthiness

Copyright of RotorSport UK Ltd
Document number RSUK0011
Page 7 of 64 Page issue 8, dated 17.12.10
GENERAL INFORMATION
1.1 INTRODUCTION
This manual is provided to give pilots and instructors information which contributes to the
safe and efficient operation of this autogyro.
It also contains basic information from the aircraft manufacturer, as well as the legal basis
for flight.
Pilots of this aircraft must hold an appropriate type licence, with type conversion training
by an authorised instructor.
Pilots must make themselves familiar before flight with the special characteristics of this
autogyro. You are obliged to read both this pilots manual and the maintenance manual to
ensure you are familiar with all equipment and aircraft structure/engine.
1.2 AUTHORITY FOR FLIGHT WITHIN THE UK
The legal basis for the operation of this MT-03 autogyro is regulated in the Airworthiness
Approval Notification (AAN29134), issued by the Civil Aviation Authority (CAA). It has
been shown to comply with the requirements of BCAR Section T issue 3, and is
considered as a factory built aircraft.
It is supplied by RotorSport UK Ltd.
The aircraft is equipped and permitted for daytime VFR flight only.
1.3 EXPLANATIONS AND SENSIBLE SAFETY MEASURES
The manual is not a replacement for theoretical and practical training on the operation of
this machine. Failure to take proper instruction can have fatal consequences.
The following definitions are used in this manual with warnings, precautionary measures
and remarks. Their sense and their meaning are described as follows.
WARNING: means that the neglect of the appropriate procedure will result in a direct or
critical reduction of flight safety.
NOTE: means that the neglect of the appropriate procedure will lead, on a longer time
base, to a reduction of flight safety.
REMARK: stresses the attention for a special circumstance, which does not affect safety
directly, but is still important.
PRECAUTIONARY & SENSIBLE SAFETY MEASURES
Before flight pilots should familiarise themselves with the appropriate navigational,
weather and safety information pertinent to their planned route.
Flight in severe turbulence is prohibited.
Flight near thunderstorms is prohibited
Aerobatics and manoeuvres resulting in reduced “g” are prohibited
Smoking in the aircraft is prohibited

Copyright of RotorSport UK Ltd
Document number RSUK0011
Page 8 of 64 Page issue 8, dated 17.12.10
The choice, selection and use of this particular aircraft for the purpose chosen is at the
sole discretion and responsibility of the owner/pilot. RotorSport UK Ltd takes no
responsibility for your decision to fly.
In common with other aircraft of this type the MT-03 utilises a non-certified engine. This
means that there may be a higher risk of engine failure than in a certified aircraft, with the
associated risks of damage or injury as the result of an unplanned landing. Therefore
strict compliance with the engine manufacturer’s maintenance schedules, operational
procedures and any additional instructions which may be given to you by RotorSport UK
Ltd, on behalf of the engine supplier, is essential. The aircraft must always be flown with
the risk of engine failure in mind, and must not be flown over any areas where a forced
landing cannot be safely executed.
1.4 AIRCRAFT DESCRIPTION
Characteristics:
Autogyro with nose gear wheel chassis
Airframe manufactured from inert gas welded stainless steel tube
Two-seat tandem configuration
GRP spring spar mainwheel undercarriage
Main wheels fitted with hydraulic disc brakes (operated from the front seat only).
Extruded aluminium rotor
Rotor head controlled with connecting rods
Rudder controlled via cable
GRP or optional carbon fibre fin, rudder and horizontal stabilizer
Engine four-stroke flat-four Rotax 912 ULS or optional Rotax 914 UL
Three-blade ground-adjustable 1.73m diameter HTC propeller
TECHNICAL DATA (see also fig. 1)
Rotor diameter: 8.40m
Rotor is either a modified version of the Aircopter product, with RSUK pre coned
hub system, or fully manufactured at AutoGyro.
Length: 5.08m
Height: 2.65m
Width: 1.82m
Rotor blade profile: NACA 8H12
Empty weight: 250 kg nominal (see individual aircraft load sheet for specific version
weight)
Payload: 250 kg nominal (if 500Kg MTOW, see individual aircraft load sheet for
specific version weight)
Take-off mass (max.): 450 or 500kg as shown on the permit to fly.
Fuel tank capacity: 35 ltrs or 70ltrs with optional second tank
Note: Aircraft may only be operated at 500kgMTOW if incorporating RotorSport
modification MC-070/AAN 29134 addendum 4. This is integrated in the aircraft
under RotorSport Service Bulletin SB-013.

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Document number RSUK0011
Page 9 of 64 Page issue 8, dated 17.12.10
1.5 PICTORIAL VIEWS OF THE MT-03
View from the left hand side

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Document number RSUK0011
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View from the rear

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Document number RSUK0011
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View from in front
View from left side, second generation front seat

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Intentionally blank

Copyright of RotorSport UK Ltd
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2. OPERATIONAL LIMITS
2.1 INTRODUCTION
This section defines the limit values for safe operation of the MT-03 autogyro. It contains
the operation limits established during flight testing, as well as limit values established by
test or computation. The existing instrument placards are described.
SPECIFIC LIMITATIONS AS PER THE CAA AIRWORTHINESS AUTHORISATION
NOTICE
These limitations are mandatory, and are printed out on the aircraft Permit to Fly.
Ensure you are aware of the limitations specific to your aircraft.
RSUK Aerobatic Limitations
Aerobatic manoeuvres are prohibited.
Manoeuvres involving a deliberate reduction in normal ‘g’ shall be avoided.
Maximum bank angle 60 degrees from vertical
Flight in icing conditions is prohibited.
Flight in strong gusty winds or wind velocities of more than 72 km/h = 20 m/s = 40 kts is
prohibited.
VMC (Visual Meteorological Conditions) only.
This aircraft shall be flown by day and under Visual Flight Rules only
Ensure you read your CAA Operational Limitations (part of the Permit to Fly) for exact
limitations of your aircraft.
2.2 AIRSPEED
The values below are indicated speeds (IAS) measured via the ASI metering hole,
centrically located in the fuselage nose, and based on an MTOW of 450Kg. or 500kg (if
SB-013 is incorporated)
VNE Maximum speed 100 mph
Vclimb Best climb speed 60-65mph
VAManoeuvre speed 50mph
VApproach Approach speed. 70mph (1st stage) 55mph (final)
VTMax speed in turbulence 70mph
Best glide speed (for maximum range) 60mph
Min rate of descent speed (min height loss) 40mph
2.3 AIRSPEED INDICATOR MARKS
Green range (normal range) from 0-50mph
Yellow range (caution, especially nearing Vne) from 50 to 100mph
Red line (VNE) at 100mph

Copyright of RotorSport UK Ltd
Document number RSUK0011
Page 14 of 64 Page issue 12, dated 21.06.16
2.4 ENGINE
Manufacturer: Bombardier Rotax, Gunskirchen/A
Type: Rotax 912 ULS or Rotax 914UL
Take-off power: 100 HP/5800 rpm (5 minutes max operation) for 912ULS,
115HP/5800 rpm for 914UL (5 mins max operation)
Continuous duty: 90 HP/5500 rpm for 912ULS
(90HP/5000 rpm max continuous for 914UL unless a/c
upgraded to 500kgMTOW, then 100HP/5500rpm– see
Section 2.5 for further information)
Propeller: HTC 3 blade. Pitch angle: 19.5deg 912ULS, 20.5deg 914UL
(ground adjustable to suit engine and working environment).
Note that due to the concave face of the propeller measuring
this angle is difficult. Propeller is pitched for max ground rpm
of 5700.
For further data refer to the engine manual and parts catalogue.
WARNING! The engine must not be run without the propeller fitted – doing so may
result in severe engine damage.
2.5 ENGINE INSTRUMENTS
The following engine values are placarded on the instruments:
Note that, other than the engine rpm, the gauges are marked with these values internally.
Range
Maximum value
Unit of
measurement
Engine RPM
Green 1600
- 5500 912ULS-Amber 5500 - 5800/5min, red line 5800.
914UL – Amber 5000 to
5800rpm, red line 5800.
Amber 5500 to 5800 if 500Kg
MTOW under SB-013
rpm
Oil temperature
50 - 130 130 max °C
Cylinder head
temperature to 135 135 max °C
Oil pressure
0.8bar min
to 3,500
rpm, 2-5bar
above
7 (cold weather starting) bar

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Document number RSUK0011
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2.6 WEIGHT & BALANCE
The maximum take-off weight of the MT-03 is 450Kg (or 500kg if incorporating RotorSport
Service Bulletin SB-013/AAN 29134 addendum 4). This represents the empty weight (with
normal equipment), occupant weight(s), fuel and luggage.
If any accessories are fitted which increase the empty weight of the aircraft then the
aircraft’s maximum payload must be reduced accordingly.
The pilot is responsible for ensuring the aircraft is not flown overweight.
NOTE! Flying the aircraft overweight invalidates your Permit to Fly.
The maximum permissible positions of the centre of gravity may not be exceeded.
The centre of gravity of the aircraft type was determined during Section T Compliance
evaluation. The envelope operational extremes were tested and found satisfactory.
However operation outside of these evaluated points has not been tested!
Evaluation recorded that the approved envelope extremes (with maximum 10Kg baggage
in the rear passenger footwell) are as below (and affected by MTOW and rotor type):
Most Forward limit - 120pilot, 60Kg pass, min fuel – 596mm forward of mainwheel axle
Most Rearwards limit - 60Kg pilot, max fuel – 371mm (500kg) or 376mm (450kg) forward
of mainwheel axle
Most Highest limit - 60Kg pilot min fuel – 952mm (RS1, RSll rotors) or 972mm (RSll TOPP
rotor) above mainwheel axle
Most Lowest limit - 125Kg pilot, max fuel - 814mm (500kg) or 819mm (450kg) above
mainwheel axle
Vertical CG position (z) is relative to the wheel axle plane drawn between the main and
nose wheel. Longitudinal CG position (x) is fore or aft of the mainwheel axle plane
(positive forwards).
The weight and balance report (AWC) supplied with the aircraft shows the Empty Weight
and CG envelope calculated for that specific aircraft, with options supplied as new. Empty
weight means aircraft containing minimum flight accessories and minimum fuel.
The report also shows, for reference, the thrust line offset.
WARNING! Care must always be taken when flying at extremes of the operational
envelope.
Maximum occupant weight in the front seat = 125 kg
Maximum occupant weight in the rear seat (with a 60Kg front seat occupant) = 120Kg
Minimum occupant weight in the front seat = 60 kg
Front seat occupants under 60kg body weight must carry ballast.
Fuel loading permissible is 450Kg (or 500Kg if incorporating SB-013/AAN29134
addendum 4) minus occupant weight, minus aircraft empty weight, minus any baggage or
items added to the aircraft since weighed. Aircraft empty weight is placarded. Fuel mass is
0.72Kg/ltr.
Example: 500Kg – 256Kg (empty wt) – 90Kg (rear seat occupant) – 90Kg (pilot) – 5Kg
(luggage bag) = 59Kg. Useful fuel load is 59/0.72 = 82ltrs.
Maximum possible fuel load is 70ltrs, 50.4Kg

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If ballast is required to meet the minimum front seat loading condition of 60Kg, then it
should be in the form of thin lead sheet placed behind and under the pilot seat cushion.
Carrying of bags or other items inside the aircraft is not recommended due to the
presence of control cables and linkages. If used, ensure there is no control obstruction!
Bags fitted into the rear seat must be securely attached to the seat harness, and included
in the weight/balance calculation.
WARNING! The rear seat harness must be fastened correctly around the seat in single
seat operation. DO NOT leave loose behind the seat, it may entangle with the rotor
controls and prevent correct function!
A small detachable bag is fitted inside the aircraft. Its purpose is to carry the rotor tie down
strap and basic aircraft documents only.
Note: MC-184 enables replacement of a damaged MT-03 enclosure with the MTOsport
enclosure. The latter has a fwd luggage locker accessible through a hatch in the nose of
the aircraft. Inside this locker there is a bulkhead to contain the contents, which must be
no more than 10kg (in accordance with the local placard). If the luggage locker is fully
loaded the front seat loading limit is reduced to 110kg (from 125kg) thus having no effect
on aircraft CG.
If MC-184 is incorporated there is an alternative “Aircraft Payload Specification” placard
(see para 2.8)
2.7 FUEL
The engine manufacturer recommends unleaded gas station premium fuel (MOGAS).
AVGAS 100LL can be used, although not recommended for long term operation, as the
lead in the fuel causes excess plug fouling and problems with the slipper clutch – refer to
the engine manual for further information. Alternatively, unleaded aviation gasoline Avgas
UL91 is now available at some airfields and is approved for use with Rotax engines.
MOGAS should not be used if the fuel temperature exceeds 20°C or at altitudes above
6000ft due to the increased risk of vapour bubble formation in fuel lines. In these
conditions AVGAS 100LL should be used. Note: MOGAS E10 (unleaded gasoline blended
with 10% ethanol) is not recommended.
Whilst refuelling:
1. Ensure that the fuel is clean and water-free.
2. Always use a filter when refuelling, preferably with a water trap
3. Ensure the aircraft keyswitch is OFF before commencing refuelling
4. If refuelling on the port (LH) aircraft side, adjacent to the electrical passenger
switches, take care not to spill fuel on the switches. If a spillage occurs, mop up
quickly and leave to evaporate totally before turning electrical system back on.
5. Ensure filler caps are tight after refuelling, and any spillage in the base of the
aircraft drained/mopped up pre flight.
The balance pipe between the two fuel tanks (where two are fitted) is not capable of
transferring fuel from tank to tank at the same rate that fuel can be input to a tank; it may
take several minutes for a full tank to equalise levels with an empty one. If it is required to
refill both tanks at a fast rate, fill one tank first, then the other, and top up either as
required.
Before flight, use the water drain points under each tank to ensure the fuel is water free.

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2.8 GENERAL PLACARDS AND MARKINGS:
In conformity with BCAR Section T the following placards and markings are installed:
- All emergency controls are coloured red.
- All cockpit controls are clearly marked as to their function and method of operation.
- Fuel and oil filler openings are clearly marked, together with the grade or type required.
- Fuel tank capacity is clearly marked.
- Loading conditions are clearly marked as follows:
- Standard placards
Loading conditions (Placard will show 450 or 500Kg MTOW as permitted)
For aircraft incorporating MC-184 only this placard is changed to:
Where xxxKg is either 450Kg or 500Kg (if SB-013 has been embodied)
Aircraft Payload Specification
Front seat; max occupant weight 125Kg max, 60Kg min
Front seat occupant must carry ballast to meet 60Kg
min.
Rear seat occupant 120Kg max
Empty weight (as measured) Kg
Fuel load 0.72Kg/ltr
MTOW 500Kg
Aircraft Payload Specification
Front seat pilot: 125Kg max, 60Kg
min
Reduced pro rata to 110Kg max
with up to 10Kg (max) of luggage
in the nose locker.
Pilot must carry ballast to meet
60Kg min.
Rear seat passenger 120Kg max
Empty weight (as measured) Kg
Fuel load 0.72Kg/ltr
MTOW xxxKg
Aircraft must only be flown solo
from the front seat.

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Occupant warning
Primary control marking
Limitations
Fuel gauge (for those gauges with pushbutton)
Auxiliary socket (where fitted). May alternatively be engraved on the panel.
OPERATING LIMITATIONS
Aerobatic Limitations
Intentional spinning is prohibited.
Aerobatic manoeuvres are prohibited.
Manoeuvres involving a deliberate reduction in normal ‘g’ shall be avoided.
CG Range Limits (Gyroplane) – refer to Pilots Handbook data.
Airspeed Limitations
Maximum Indicated Airspeed (Vne): 100mph
Other Limitations
This aircraft shall be flown by day and under Visual Flight Rules only.
Smoking in the aircraft is prohibited
The aircraft shall not fly closer than 110 metres to any assembly of persons
OCCUPANT WARNING
This aircraft has not been certificated to an
International Requirement
12v DC
auxiliary
socket
MAX
↑
THROTTLE
CHOKE
↓
ON
BRAKE
↓
ENGAGE
Press before reading!

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Rotor RPM gauge (only where the gauge is marked internally as ‘x100’, but actually reads
x10)
Coolant overflow bottle Engine oil tank
Fuel tank (both, where two fitted) (on tank or side of enclosure by filler neck)
On keel tube below instrument panel
Placard for Placard for glove
side pockets box (where fitted)
(where fitted to rear
of the front seat)
For nose luggage locker (where fitted)
Side tank fuel
capacity:
35 ltrs
UNLEADED
PETROL
(AVGAS
permissible)
Coolant
Header Tank
.
Filled with Evans NPG+,
equivalent, or 50/50
water/antifreeze
X 10
Oil tank
Capacity 3 ltrs.
Use Shell VSX or
equivalent Motorcycle
oil SF or SG
Pilot rudder pedal
position in this aircraft is
Long/middle/short
Contents weight
2Kg max
Contents weight
1Kg max
Baggage Load:
10Kg MAX

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Fuel cut-off valve Interlock placard (until engraved on panel)
Instructor pack (where fitted). On early versions the switch toggles may go forwards ‘off’
rather than backwards). Brake placard only where brake is fitted.
Note! Where a deviation exists between the front master and rear seat slave ASI’s, it is
permissible at initial build for RotorSport UK Ltd only to placard the rear seat ASI
accordingly to show the error (front is assumed as the correct ‘master’). E.g.
Low voltage placard mounted on instrument panel (where fitted).
Warning lamp placards (where fitted)
Ignition cut off
switches.
To switch off,
lift safety flaps
and pull
toggles
backwards.
Off
On
Fuel cut-off
valve
Pre-rotator &
rotor brake
interlock release
MAX
↑
THROTTLE
Nose
down
Trim
control
BRAKE
↓
ENGAGE
Continuously lit Low Voltage lamp
indicates electrical demand exceeds
supply, and the battery is being drained.
If lit in flight, reduce demand until unlit.
If flashing intensely, land asap.
Low
Fuel
Low
Voltage
ASI under-reads
4mph at 100mph