Before You Begin / Leading Particulars Verify aircraft documentation is complete, see Inspection Protocol Cover Sheet (AG-F-PCS). Identify all relevant - Airworthiness Directives (AD) - Service Bulletins (SB) for airframe (AutoGyro) and power plant (ROTA). Examine Historical / Maintenance Records and Log Book. Identify - Time Change Items (TCI) - Due dates for replacements, overhauls and special activities - Reported problems Note / check all - Serial Numbers - Manufacturer Life Limits (MLL/SLL) - Airworthiness Limitations (AWL) - Inspection/Overhaul Time Limits (TBO) according to Event & Configuration Log (AG-F-ECL), respectively Inspection Protocol Cover Sheet (AG-F-PCS). Preparation Work Inspect teeter angle 14 +/- 1 Remove rotor - teetering parts (62-11-00 4-1). Perform a first visual inspection on all cowlings and mast covers, then remove (52-00-00 4-1). Perform a detailed inspection (no cracks, distortion, missing parts). Repair or replace, if necessary. Remove keel tube cover. Check fuel cap for condition, tightness, correct function. Perform a first visual inspection on all service covers and remove (52-40-00 0-1). Perform a detailed inspection (no cracks, distortion, missing parts). Repair or replace, if necessary. Remove centre console (67-10-00 4-1). Clean aircraft. Remove dirt, dust, leak fluids and loose items. Refer to 12-30-00. Rotor System Inspect rotor - teetering parts (62-11-00 6-1). Disassemble rotor - teetering parts (62-11-00 4-2) and inspect rotor blades (62-11-00 6-2). Re-assemble rotor - teetering parts (62-11-00 4-3). Inspect rotor hub bolts (62-11-00 6-3). 200h / 2y Page 1/8 - AG-F-PCA-CV-EN-V2.K
Nose gear Inspect nose wheel general condition, correct pressure, condition of tread, correct seating of the valve and cap, secure installation, no play in the wheel bearings. Inspect nose wheel fork general condition, secure installation, freedom of movement, no excessive play, distortion or damage. Inspect nose wheel rubber damper general condition and correct operation. Nose Gear, Rudder and Control Inspect all nose wheel/rudder forward control fittings general condition, security, freedom of movement, no damage (nose wheel control link). Lubricate pedal bearing and sliding block with AG-LUB-01 (Ballistol Oil). Check tension of nose wheel control cable (between central control link and nose wheel control link) and re-tension, if required. Check turnbuckles secured. Inspect cable lead-throughs, no chafing. Inspect inner and outer pedal control cables general condition, security, freedom of movement, cable lead-throughs, no chafing. Inspect all joints (clevis) at central control link secured, free to move, no chafing. Inspect central control link freedom of movement and main bolt secured (access behind dummy plug at bottom of the fuselage). Inspect rudder general condition, correct attachment, freedom of movement, no excessive play, cracks, chafing. Check/adjust rudder control angles (27-00-00 5-1). Inspect rudder control connections general condition, correct operation, secure installation, cleanliness. Lubricate control cables with AG-LUB-01 (Ballistol Oil). Main Gear and Brakes Inspect throttle/brake unit (removed) for correct operation, secure installation, condition of ratchet teeth, brake fluid level, no leaks. If level is low, check brake pad wear! Inspect main wheels general condition, correct pressure, condition of tread, correct seating of the valve and cap, secure installation, no play in the wheel bearings. Check presence and slip mark condition. Check sufficient clearance of wheel in wheel spat. Then remove wheel spats and inspect for general condition, no cracks. Inspect wheel brakes and brake lines for secure installation and correct operation, no leaks. Inspect brake pads. Inspect brake discs condition, torque check 4 x support bolts, check presence of serrated washers. Check main gear spring spar general condition, secure installation, no cracks (fuselage attachment and both axle attachments). Torque-check suspension bow attachment bolts. Up to Serial Nr. V00154: If possible torque tighten bolts M8 more than 25 Nm, replace with M10 (front/v.fa03). Starting with Serial Nr. V00154: If possible torque tighten bolts M10 more than 35 Nm, contact AutoGyro (airworthiness@auto-gyro.com). Page 2/8 - AG-F-PCA-CV-EN-V2.K
Remove bolts (4x) from main gear spring spar attachment individually and inspect for corrosion. Replace if required. Re-install and torque. Re-install wheel spats and inspect for secure installation. (initially at 400hrs) Pre-Rotator Check the pneumatic clutch for correct operation, secure installation, pneumatic connections, no wear or chafing. Inspect according to 63-11-10 6-1 and 63-11-10 5-1, adjust if necessary. Check front dog gear (clutch side) and rear dog gear (engine side) general condition, no cracks. Connect a manometer to the clutch pneumatics T-piece and check time to pressurize (0-5 bar within 10 sec). In case of discrepancies contact AutoGyro! Inspect the 90-degree-gearbox general condition, secure installation, smooth run, no leaks. Check pre-rotator drive shaft with sliding shaft coupling for general condition, secure installation, smooth run, no bearing play, distortion or cracks (especially at the flanges). Lubricate sliding shaft coupling with AG-GRS-01 (WHS 2002). Inspect pre-rotator upper engagement (63-11-30 6-1). Check backlash If the play has increased, contact Airworthiness (airworthiness@auto-gyro.com). Grease with AG-GRS-01 (WHS 2002). Rotor Head Remove top mast, visual inspection mast mounting bushings, install top mast Inspect rotor head bridge according to 62-31-00 6-1. Perform torquecheck on main bolt nut (120 Nm). Inspect rotor gimbal head for correct operation and secure installation of all attached parts. Proceed according to 62-32-00 6-1 and record control angles (see below). Grease with AG-GRS-01 (WHS 2002). Direction Required (see TADS/Kennblatt) Measured RH: LH: Fwd: Aft: Check the breakout force at the control stick grip and adjust, if necessary. For procedure and maximum values see 62-32-00 5-1. Check upper mast assembly for security, cracks, distortion. Inspect attachment hardware, cotter pins installed and secure. 200h Page 3/8 - AG-F-PCA-CV-EN-V2.K
Inspect rubber mounting bushings in and against FD (62-51-00 6-1). A (Dimension neutral): B (Dim. with force in FD): A B: in FD A (Dimension neutral): B (Dim. with force ag.fd): A B: (max. 5 mm @ 150 N) against FD (max. 5 mm @ 150 N) Inspect mast bottom. If cracks are evident, contact AutoGyro customer support. Flight Control Inspect flight control stick general condition, operation (freedom of movement for full travel), secure installation, electrical connectors, no damage or chafing. Inspect flight control base link and push links general condition, freedom of movement, securing hardware installed, no damage or chafing. Lubricate bearings and ball joints with AG-LUB-01 (Ballistol Oil). Check adjustment of roll control travel limitation. With reached rotor gimbal head stop (RH+LH) each side with 2 mm free play between stop screw and ball joint. If necessary adjust acc. to 27-10-00 5-1. Inspect push cables for secure installation, no play, no chafing. Proceed according to 67-00-00 6-1. With PPC clamps proceed according to 67-00-00 8-1. Pneumatic system Check secure connection of all pneumatic lines/harness. Ensure no chafing. Check the pneumatic box and compressor for correct operation, secure installation, no leaks or chafing of the pneumatic lines. Replace dryer cartridge (36-21-00 8-1). Fuselage Inspect seats and safety harnesses general condition, correct operation, secure installation, no damage. Inspect backrest adjustment function, detent mechanism and secure installation. Perform visual inspection of headset connector plate. Inspect headset holder condition and attachment, no cracks. Check all cockpit fittings general condition and secure installation. Voice radio ATR833: Check PTT-Button selection according to manufacturer documentation Operation and Installation. Recommended selection: Single mic Inspect cabin doors general condition, function, attachment, no damage. Inspect door hinges general condition, secure installation, freedom of movement no cracks. Check door latch function and detent mechanism of locking lever. Page 4/8 - AG-F-PCA-CV-EN-V2.K
Check front and door windows general condition, correct operation, no cracks or missing fittings. If necessary, apply PE strips to round windows if they are loose in their bezel. Check slip indicator present and intact. Pitot-Static Inspect pitot /ram-air tube general condition, secure installation, no obstructions. Inspect static ports open, placard installed, no blockages, no leaks. Clean and dry all pitot and static lines as required. Proceed according to 34-10-00 7-1. Propeller General: Inspect propeller blades for cracks, delamination or impact. Dents or score marks may indicate a propeller strike with possible damage to the propeller and other components. HTC: Perform a visual inspection of the hub and re-torque flange bolts with 15 Nm. Check that all propeller blades have same pitch. Inspect spinner and spinner mounting general condition, secure installation, no cracks. Unscrew one bolt and confirm spinner bolts are secured with AG-BAS-02 (Loctite 243). Secure and re-install bolt. If necessary, unscrew, secure and re-install all remaining spinner bolts according to 61-10-00 4-1. Structure / Stabilizer Inspect the frame/boom to body connection general condition, secure installation, no deformation, no cracks. Check against twisting! Check keel tube general condition, secure installation, no deformation, no cracks. Inspect stabilizer mounting lugs on keel tube, no deformation, no cracks in welding seam. Inspect keel tube protection pad condition and attachment. Replace if worn (55-00-00 8-1). Inspect stabilizer general condition, secure installation, no chafing, cracks, loose mountings. Check drain holes open. Fuel System Inspect fuel tank. To do so, remove drain cover and pay attention to possible leaks, visible leak traces, swellings (rubber hoses) and fuel smell. Check condition and fit of rubber hoses and connecting clamps. Check fuel drain valves not leaking. Re-install drain cover. Inspect fuel filters according to 28-20-00 6-1 and replace, if necessary (28-20-00 8-1 and AG-F-ECL). Inspect the electric fuel pump(s) for correct function (sound on operation), secure installation, no chafing. Page 5/8 - AG-F-PCA-CV-EN-V2.K
Inspect all fuel lines condition, secure installation, presence/condition of heat protection, no hardening, tear, chafing or kinks. Inspect the fuel shut-off valve correct operation, secure installation, presence and condition of safe-guard. Open carburettor float chamber, remove and weigh floats. Floats must not weigh more than 3.0 g in drained condition. Removal and installation in accordance with documentation of the engine manufacturer. Engine and Accessories Inspect the oil cooler general condition, secure installation, cleanliness, no leaks, chafing or deformed fins. Inspect all hoses and pipes of the oil system for secure installation, no leaks, chafing, tears/cracks, hardening, kinks or sharp direction changes. Inspect the thermostat assembly for secure attachment, no cracks, leaks or porous hoses. Inspect all coolant hoses condition, secure installation, routing, no leaks, chafing, tear or hardening/porosity. Check presence/condition of heat protection on coolant hose from cylinder 2 and install/renew, if necessary. Inspect the radiator condition, secure installation, cleanliness, no leaks or damage. Inspect the radiator fan for correct operation, no damage of cage and fan blades. Inspect coolant overflow tank for correct coolant level, secure installation, no chafing. Inspect all hoses and pipes of the lubrication system for leaks, security, chafing, tears/cracks, hardening especially under the heat insulating tubing at the engine and replace if necessary. Check starter battery for security, deformation, cracks, chafing, leaks, oxidization, pole cover, charging state/condition. Inspect exhaust system general condition, secure installation, no leaks, cracks (tap test) or loose rivets. Check presence and condition of retaining springs and safety cable. Replace, if necessary. Check the silencer for secure installation of clamps, rivets and safety wire. Check safety wire of the screw clamps. If the securing worm screw is able to rotate, secure through the screw slot to prevent rotation and loss in case of failure. If removed, install propeller (61-10-00 4-1). Check propeller to frame clearance min.10 cm. In case of a lesser distance inspect engine mounting (see subsequent inspection points). If the situation cannot be corrected, contact AutoGyro customer support. Page 6/8 - AG-F-PCA-CV-EN-V2.K
Power Plant Inspect the engine mounting brackets general condition, no cracks or distortion. Check rectifier-regulator for general condition, secure installation, chafing of wiring, ground (L-) connectors not corroded or molten; connector tightness. Inspect the engine mounting bushes for secure installation and condition of rubber. Replace, if torn or porous. Inspect the engine mounting ring frame for secure installation, no chafing or distortion. R914: Check sufficient clearance between airbox and ringmount and re-adjust, if required (71-20-00 6-1). Perform power plant maintenance according to the engine manufacturer s documentation and include supplementary procedures below. Check the manufacturer's website and make sure to have the latest version available. Also check for applicable airworthiness directives, service bulletins and service instruction. Use the engine manufacturer's maintenance protocol/checklist and attach to this protocol. Supplementary Procedure: Oil Change When draining, let the oil run through a 190 micron screen and attach photo to this protocol. Supplementary Procedure: Inspection of Magnetic Plug Photo-document magnetic plug (before cleaning) and attach photo of magnetic plug to this protocol. Supplementary Procedure: Inspection of Old Oil Filter Attach photo of the filter mesh of the cut-open oil filter to this protocol. Supplementary Procedure: Check coolant level As a minimum, coolant must be visible in the overflow bottle resp. on the dip stick. The maximum coolant level is defined by the twin rings marking on the Fuel and Engine Coolant Dip Stick. Supplementary Procedure: Refilling of Oil Record type of oil in protocol cover sheet (AG-F-PCS). Perform Ground Test Run (05-60-00 / AG-F-PGR-CV). Finalization Work Carry out a tool and loose-article check. Re-install all service covers (52-40-00 0-1). Re-install centre console (67-10-00 4-1). Re-install keel tube cover. Re-install all cowlings and mast covers (52-00-00 0-1). Page 7/8 - AG-F-PCA-CV-EN-V2.K
Date Signature of inspector / responsible Interval Initial Remarks DOM : perform item each time???h: perform item each??? hours (example: 200h)?y: perform item every? years (example: 2y)???h/?y: perform item every??? hours or? years, whichever occurs first (example: 400h/4y) Put initials when performed or complied with. Put N/A for not applicable or N/P for not performed. Remember to enter initials and full name on cover sheet for identification Make a unique note (i.e. subsequent number), fill in remark on extra sheet and attach sheet(s) or any additional material (such as photos) to this protocol Date Of Manufacture Page 8/8 - AG-F-PCA-CV-EN-V2.K