Trixy Aviation G 4-2 User manual

Maintenance manual G 4-2 Revision 05A –03.05.2017 Doc. No.: TA-M-D-002-EN 1
Maintenance manual
Trixy Aviation
Series
G 4-2

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Maintenance Manual for
Gyrocopter G 4-2
This manual contains information for basic maintenance and forms to
document the performed maintenance, repairs and alterations done on
the gyrocopter. The extent and state of revision of this manual may be
obtained from the index and the revision index.
Maintenance for the gyrocopter G 4-2 is to be performed ONLY by an
authorized persons and/or aviation workshop in accordance with the
instructions and intervals given in this manual as well as the manuals
for engine and propeller.
This manual does not substitute the education of an aviation
technician or the authorization of an aviation maintenance
workshop. IT is to be used in addition to the maintenance manuals
of engine and propeller.
Revision: 05A Date issued: 03.05.2017
Sticker with individual gyrocopter date here!

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REVISIONS TO THIS MANUAL
No.
Description
Page
Date
Name
01
Previous manual Rev. 3.0
All
03.05.17
R. Farrag

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INDEX
1.
GENERAL REMARKS
6
1.1
Introduction
6
1.2
Certification and Registration
7
1.3
Warnings and precautions
7
1.4
Description
8
1.5
Technical data
8
1.6
Side view, top view and front view
9
2
COMPONENTS
12
2.1
Introduction
12
2.2
Frame
13
2.3
Rotor
15
2.4
Rotor head
17
2.5
Rotor controls
31
2.6
Prerotator system
36
2.7
Propeller
41
2.8
Nose wheel and steering
45
2.9
Main gear
49
2.10
Main wheels and breaks
51
2.11
Empennage
52
2.12
Rudder controls
53
2.13
Dashboard
58
2.14
Engine
60
3
SYSTEMS
62
3.1
Introduction
62
3.2
Engine oil circuit
63
3.3
Engine coolant circuit
64
3.4
Engine ignition system
64
3.5
The fuel system
65
3.6
Electrical system
67
3.7
The hydraulic brake system
91
3
PERIODIC PREVENTIVE MAINTENANCE
94
4.1
Introduction
94
4.2
Maintenance after the first 25 hours
95
4.3
50 hour interval maintenance
96
4.4
100 hour interval maintenance
97
4.5
500 hour interval maintenance
98

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4.6
Recommended overhalls
99
5
MAINTENANCE SERTIFICATES
100
6
DAMAGE OR ACCIDENT REPORTS
116
7
CERTIFICATES OF REPAIR AFTER DAMAGE
120
8
MODIFICATION CERTIFICATES
124

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1 GENERAL REMARKS
1.1 Introduction
This manual contains information and instructions of the gyrocopter
manufacturer, which must be made available to the operator of the
gyrocopter to perform proper maintenance in accordance with the
German regulations stated in (BUT).
More details on engine and propeller maintenance are to be found in
the manufacturer’s Maintenance manual for each item. Such details are
very important and must be followed.
The operator is only permitted to exchange defective parts and/or
components using original parts and/or components in an authorized
aviation workshop after consulting the manufacturer of the gyrocopter.
The operator must perform an annual inspection according to the
German regulations. Such inspections must be approved and
documented by an authorized inspector. DAeC as a German authority is
currently overlooking these regulations and must be officially informed
about annual inspections. Regulations in other countries must be taken
in consideration, in case that the gyrocopter is registered in countries
other than Germany.
The warranty provided by the manufacturer of the gyrocopter is only
valid when maintenance is performed by an authorized person or
authorized aviation workshop.
Technical defects, which may signal weak points in the design or the
construction of the gyrocopter, must be reported without delay to the
manufacturer of the gyrocopter.
Reporting incidents and accidents according to § 5 Luft VO in Germany
or regulations in other countries are also to be reported to the
responsible authority and the manufacturer of the gyrocopter.
Please use the forms at the end of this manual to report such defects.
All warranties provided by the manufacturer of the gyrocopter are void,
in the event that one or more of the instructions in this manual are
ignored.

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Attention: means that the disregard of the corresponding procedure
leads to a reduction of flight safety over time.
Warning: means that the disregard of the corresponding procedure
leads to an immediate or major reduction of flight safety.
Note: attends to special issues which are not in direct relation to
flight safety, but are important or unusual.
1.2 Certification and Registration
The statutory basis for the operation of an ultra-light gyrocopter (ULG) is
regulated in air traffic laws. Details are to be obtained from associated
documents. All rules and regulations contained in these documents
must be obeyed.
The G 4-2 is constructed, manufactured and tested according to the
construction regulations for ultra-light gyrocopters (BUT 2001) and Nfl II
13/09 dated 12.02.2009 and is registered under the identification
number 61218 by the responsible German authority (DAeC).
1.3 Warnings and precautions
The following definitions are used for warnings, precautions and notes
in this manual:

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1.4 Description
•Gyrocopter with nose wheel steering
•Stainless steel frame welded in gas-shielded process
•Two seats in tandem configuration inside an open fuselage
(model Liberty) or enclosed fuselage with removable hard top
(model Princess). The fuselage and the canopy are made of
carbon fiber composite.
•Main undercarriage strut, equipped with hydraulic brakes
•Rotor made of extruded aluminum profile
•Rotor head steering via push rods
•Rudder steering via steel wires
•Rudder and stabilizers made from CFC
The series G 4-2 includes 2 models: Liberty and Princess.
Liberty is an entry-level model, which is designed to basically operate
with an open cabin. However, this model can be converted with an
optional kit to a closed version.
Princess is a top model, which is designed to basically operate with a
closed cabin. This model can be converted with an optional kit to an
open version.
1.5 Technical data
Length 4.90 m
Width: 1.85 m
Height: 2.80 m
Empty weight: 265 - 310 kg (as equipped)
Load capacity: 190 - 280 kg (as equipped)
Max. Take-off weight: 500, 530 or 560 kg (as equipped)
Tank capacity: 34 l / 68 l (as equipped)

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Note: The three views are not to scale!
1.6 Side view, top view and front view (2 models)
The model Liberty

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Note: The three views are not to scale!
The model Princess

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Warning: This manual does not substitute the education of an
aviation technician or the authorization of an aviation maintenance
workshop. IT is to be used in addition to the maintenance manuals of
engine and propeller.
Attention: Only persons authorized by the gyrocopter manufacturer
are allowed to perform maintenance and repair works on the
gyrocopter. Persons to perform maintenance and repair works on
either engine or propeller must be authorized by the respective
manufacturer.
Note: All warranties are void in case that the instructions in this
manual are not carefully followed.
2 COMPONENTS
2.1 Introduction
The components used in the gyrocopter series G 4-2 are illustrated and
documented in this section of the maintenance manual.
Bolts and nuts are to be tightened and inspected in accordance with the
data provided in this manual and the tightening torque in the
corresponding tables is to be used as a reference. In doubt, the
maintenance technician or the aviation workshop performing the
maintenance or repair works must contact the manufacturer of the
gyrocopter, the engine manufacturer or the manufacturer of the
propeller for further information.
Engine maintenance must be performed according to the instructions of
the engine manufacturer. Maintenance, repairs or adjustments to the
propeller must be conducted by authorized persons in accordance with
the instructions provided by the propeller manufacturer.
Only original parts and/or components are to be used as spare parts.

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Note: All warranties are void in case that the instructions in this
manual are not carefully followed.
Attention: Cracks or damage to the frame are dangerous and
reduce flight safety. Repairs on the frame may only be carried out by
persons who are authorized by the manufacturer of the gyrocopter.
Cracks and damages to the frame are to be reported to the
manufacturer of the gyrocopter with no delay.
Warning: The gyrocopter is not to be operated once cracks,
bends, dents or any other damages are detected in the frame and/or
the engine mounts.
2.2 Frame
The frame is the structure carrying the gyrocopter and connecting all its
components together. It is made of a special stainless steel and welded
under inert gas protection against corrosion. It is tested and passed the
load requirements in BUT (the German specifications for type
certification of ultra-light gyrocopters). Such high loads never occur in
normal flight conditions. However, the gyrocopter may be exposed to
higher loads and forces during taxiing, take-off and landing on rough
terrain. This may cause damage to the frame and/or other components
of the gyrocopter. It is, therefore, recommended to visually inspect the
frame before every flight and to thoroughly inspect it by authorized
persons in every scheduled maintenance.
To be overhauled: 500 h
To be exchanged: 2000 h

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Attention: Cracks or damage in the rotor system are dangerous and
reduce flight safety. Repairs on the rotor may only be carried out by
persons who are authorized by the manufacturer of the gyrocopter.
Cracks and damages to the rotor are to be reported to the
manufacturer of the gyrocopter with no delay.
.
Note: All warranties are void in case that the instructions in this
manual are not carefully followed.
Warning: The gyrocopter is not to be operated once cracks,
bends, dents or any other damages are detected in the rotor system.
2.3 Rotor (2 sizes)
Air foil: NACA 8H12
Manufacturer: Averso Aviation
www.averso.info
Rotor diameter: 8.40 or 8.60 m
Rotor circle area: 55.4 or 58.1 m²
Max. rotor load: 10.1 or 9.64 kg/m²
To be overhauled: 500 h
To be exchanged: 1500 h
Rotor bridge for Rotor head type KK-1

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Pos.
Description
Qnt.
Tightening torque
7-1
Hexagon bolt M10x90 8.8
4
40 Nm
7-2
Hexagon bolt M10x70 8.8
16
40 Nm
7-3
Self-locking Hexagon nut M10 ISO 7042
20
7-4
Washer 10,5 DIN 125-B
36
25-109
Hexagon bolts
4
40 Nm
Rotor bridge for Rotor head type TS-1

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Attention: Cracks or damage in the rotor head are dangerous and
reduce flight safety. Repairs on the rotor head may only be carried
out by persons who are authorized by the manufacturer of the
gyrocopter. Cracks and damages to the head are to be reported to
the manufacturer of the gyrocopter with no delay.
.
Note: All warranties are void in case that the instructions in this
manual are not carefully followed.
Warning: The gyrocopter is not to be operated once cracks,
bends, dents or any other damages are detected in the rotor head.
2.4 Rotor head (2 types)
2 Rotor head types (KK-1 and TS-1) are certified for the series G 4-2:
Type KK-1 is a tilt head design. It is designed and manufactured by
Trixy Aviation. It is made of high quality materials and has passed all
tests required under the German rules and specifications for type
certification of ultra-light gyrocopters. It is made of aircraft aluminum
and stainless steel. The bolts, bushings and axes are of special design
and must not be replaced by standard parts.
To be overhauled: 500 h
To be exchanged: 1500 h

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