RotorSport UK Ltd Service Bulletin Title: Improved pre-rotator gearbox for Calidus. SB No.: 056 Iss 1

Related documents MC No: MC-212 CCAR No.: None

Applicability Aircraft type & model: Calidus

Aircraft serial nos. affected: Any prior to RSUK/CALS/021

Compliance Category:

OPTIONAL or RECOMMENDED or MANDATORY

This form is the response from RotorSport UK Ltd either against a problem found in the product in service requiring a containment or rectification action, or as service information for aircraft modification incorporation. For help, contact RotorSport on 44(0)1588 650769, or email [email protected].

Reason and overview of the Service Bulletin (cause of problem if known) Calidus aircraft making use of the original “Maedler” gearbox developed for MT-series have suffered a number of in-service failures. An uprated gearbox has been developed by AutoGyro which has:  a bigger gear-case of stronger internal construction  a 1.5:1 ratio (speed-reducing)  clutch engagement controlled by a pressure regulator in the pneumatic circuit. This allows the clutch to progressively transfer torque to the rotor and avoids any shock-loads from heavy-handed use of the pre-rotator controls To aid parts-management the new gearbox is supplied complete with friction clutch and is described as Pneumatic Coupling III BG3792 (C.PR10). This assembly replaces Pneumatic Coupling II BG3394 (C.PR08). To distinguish the installations two colours of over-ride control button are used – red for original (BT758), black for the improved version (BT7072) under MC-212 and this SB-056 Approval The technical content of this document is approved under the authority of the UK CAA Design Organisation Approval Ref: DAI/9917/06 Manpower estimates Accomplishment of this Service Bulletin requires the following personnel (i) A3-7 Authorised engineer (ii) Unskilled assistant to manipulate weight of fuel-tanks and visually check operation of bendix cylinder during pre-test (iii) Qualified gyroplane pilot to conduct functional test on completion of work and estimated manhours to complete the task as a standalone item are; (i) Total 6 hours Tooling required No special tooling required Weight and Balance Effects No significant change

Manuals affected Calidus POH RSUK0060 is changed to Iss4 Calidus AMM- RSUK0061 is changed to Iss5 Ref BP 2.18

Page 1 of 14

F041 rev 4

RotorSport UK Ltd Service Bulletin Title: Improved pre-rotator gearbox for Calidus. SB No.: 056 Iss 1

Related documents MC No: MC-212 CCAR No.: None

Applicability Aircraft type & model: Calidus

Aircraft serial nos. affected: Any prior to RSUK/CALS/021

Compliance Category:

OPTIONAL or RECOMMENDED or MANDATORY

Previous Modifications that affect the SB All Calidus aircraft up to RSUK/CALS/0021 will be found fitted with Pneumatic CouplingII under MC-168 (issued and incorporated pre-AAN release). The change is unaffected by this gearbox modification. Accomplishment instructions (Action required to implement this bulletin): Preamble Effective date of this SB is 01.10.12 There is no relevant MPD or other outside body documentation applicable. The attached SB worksheet provides the inspection record for the task The task may only be carried-out by, or under the certification of a CAA A3-7 approved person. Instructions 1. Preparatory work: Protect the suspension bow against dropped parts and the sharp edges of the fuel-tank straps when these are released 2. Remove all engine and mast cowlings 3. Remove the fuel tanks (photos 8-11): Drain all fuel, initially using a siphon or pump then through the drain located in the fuel transfer pipe. Remove the fuel breather pipes as a complete “T-construction” assembly At the RH side of the aircraft release the oil tank bracket retaining screws and temporarily support the weight of the tank. Release the two tank straps and recover the load-spreaders. With an assistant removing the fuel transfer pipe from the tank hose below, disengage the Velcro and remove the tank. At the LH side of the aircraft remove the two tank straps and recover the load spreaders. Disconnect the blue fuel-level gauge electrical connector. With an assistant removing the fuel-transfer pipe from the tank hose and disconnecting the fuel delivery pipe from the rear of the fuel cock, disengage the Velcro and partially remove the tank. Disconnect the lowfuel warning cable and remove the tank completely 4. Remove the battery (photo 7): Disconnect the negative lead first. Disconnect the positive lead (with in-line fuse-holder) and place to one side. Remove the two worm-drive straps (the aluminium corner protectors should stay attached to the battery casing). Slide the battery clear. 5. Optionally remove the coolant radiator (not essential but gives more access and visibility). Removal is straightforward but steps should be taken to prevent coolant from spilling over the engine (photo 12) Ref BP 2.18

Page 2 of 14

F041 rev 4

RotorSport UK Ltd Service Bulletin Title: Improved pre-rotator gearbox for Calidus. SB No.: 056 Iss 1

Related documents MC No: MC-212 CCAR No.: None

Applicability Aircraft type & model: Calidus

Aircraft serial nos. affected: Any prior to RSUK/CALS/021

Compliance Category:

OPTIONAL or RECOMMENDED or MANDATORY

6. Remove the original gearbox assembly (photos 1-3): Disconnect the pneumatic pipe to the coupling Remove the fours screws/washers retaining the gearbox/back-plate to the pillars and pull the gearbox assembly clear of its mounting to the engine crankshaft (photo1) and disengage the splined shaft. (If there is insufficient clearance against the mast remove the uj from the top of the gearbox to enable the assembly to be rotated 90degrees). 7. Remove and visually inspect the rubber spider for cracks. Check the original mounting plate for cracks (photos 2 and 3). Replace with new if necessary. 8. For a field-upgrade certain parts of the new gearbox assembly BG3792 are not normally required. Cut the cable ties and separate into main assembly, engine coupling with rubber spider and mounting plate. Only the main assembly is required and this should be offeredup to the original engine drive coupling and attached to the original mounting plate pillars. Use Loctite 243 and tighten the screws progressively X-wise to 4Nm then 10Nm. See photographs 4-6 below for further information. 9. Reconnect the pneumatic coupling, using cable-ties as required to mount the new regulator with a simple 20mm stand-off manufactured from scrap 6 or 8mm fuel-hose. 10. Ensure mag switches are off then using the propeller carefully rotate the engine (normal direction of rotation only) and observe that the coupling does not drag and rotate the gearbox/drive shaft 11. If the coolant radiator was removed then replace, refill with coolant and check for leaks. 12. Refit the battery (photo 7) Push the battery into place (terminals facing aft) and connect the positive lead. Fit the battery retaining straps through the two trapezoidal holes in the lower engine mounts and over the corner protectors (which are attached to the battery casing with a small bead of Sikaflex EBT). Tighten the worm-drive screws until the battery is securely held in place. Attach the external charging point fuse holder using cable ties in the original location 13. Refit the fuel tanks. This task is easier if conducted by two people (photos 8-11): Fit the RH tank first, thus Offer into place and connect the fuel transfer pipe ensuring that the hose clip is correctly in place. Push the tank towards the centre of the aircraft (a recess in the tank should clear the battery) whilst engaging on the Velcro Fit the transverse tank strap over the black felt protection Fit the axial tank strap with two load spreaders Tighten the worm-drive screws to 4Nm Fit the breather “T-construction” into place and connect to the top of the RH tank Replace the oil tank mounting screws using new nyloc nuts/friction washer (as fitted) and tighten to 6Nm. Ref BP 2.18

Page 3 of 14

F041 rev 4

RotorSport UK Ltd Service Bulletin Title: Improved pre-rotator gearbox for Calidus. SB No.: 056 Iss 1

Related documents MC No: MC-212 CCAR No.: None

Applicability Aircraft type & model: Calidus

Aircraft serial nos. affected: Any prior to RSUK/CALS/021

Compliance Category:

OPTIONAL or RECOMMENDED or MANDATORY

Fit the LH tank, thus Offer into place and fit the low-fuel warning connector. Ensuring that the low-fuel warning connector is not trapped between the tank and the mast push the tank towards the centre of the aircraft. Connect the fuel transfer pipe and fuel delivery pipe ensuring that the hose clips are correctly fitted and engage the tank on the Velcro Fit the transverse tank strap over the black felt protection Fit the axial tank strap with two load spreaders Tighten the worm-drive screws to 4Nm Refit the breather pipe ensuring that it does not contact the pre-rotator vertical drive shaft. Reconnect the blue fuel-level-gauge connector and attach to the axial tank strap with cable-ties. 14. Refit the mast cowlings: Ensure that when replacing the LH cowling the fuel filler hose engages correctly with the tank inlet, that the clips are tightened and the earth wire connected to the filler cap (photo 8). Check that the foam infill in the rear mast cowl is clear of the pre-rotator vertical drive shaft. 15. Refit the engine cowlings: Refit the battery negative connection Ensure that the battery charging connectors are remade with the correct polarity Ensure that the oil and fuel breather pipes are correctly positioned through the cowling cutouts (fuel LH, oil RH) with NO kinks in the hoses. With a 914UL engine there is an additional clear breather which is positioned in the centre. 16. Test the fuel system: With the tanks empty of fuel turn on the master switch – the low fuel warning LED must be “on” and the fuel gauge should read empty. Turn off the master switch. Fill the tanks with 10 litres of fuel and repeat the test - the low fuel warning LED must be “off” and the fuel gauge should be just indicating. Under the aircraft check for any fuel leaks and ensure that the drain has been wire-locked. 17. Reach under the left-hand-side of the instrument panel to access the connectors on the red pushbutton at the left-hand side. Carefully pull the connectors from the switch, unscrew the retaining nut and remove the switch. Replace with the black push-button switch and remake the connections (there is no polarity requirement). 18. Pre-test the system: Whilst seated in the cockpit with the canopy closed turn on the master switch. Hold the stick fully forward and press the pre-rotation button. Assistant to confirm the function of the bendix drive cylinder. Switch off the master switch. 19. Functionally test the system: Move the aircraft to a safe area and with the aid of a qualified gyroplane pilot start and Ref BP 2.18

Page 4 of 14

F041 rev 4

RotorSport UK Ltd Service Bulletin Title: Improved pre-rotator gearbox for Calidus. SB No.: 056 Iss 1

Related documents MC No: MC-212 CCAR No.: None

Applicability Aircraft type & model: Calidus

Aircraft serial nos. affected: Any prior to RSUK/CALS/021

Compliance Category:

OPTIONAL or RECOMMENDED or MANDATORY

warm the engine then conduct a pre-rotation to rotor speed 200 rpm. Verify smooth engagement and no untoward noises.

Photographs - components

(1) Original gearbox ready for removal

(2) Rubber spider removed from drive dog for visual inspection

Ref BP 2.18

(3) Drive dog on engine crankshaft and mounting plate on crankcase

Page 5 of 14

F041 rev 4

RotorSport UK Ltd Service Bulletin Title: Improved pre-rotator gearbox for Calidus. SB No.: 056 Iss 1

Related documents MC No: MC-212 CCAR No.: None

Applicability Aircraft type & model: Calidus

Aircraft serial nos. affected: Any prior to RSUK/CALS/021

Compliance Category:

OPTIONAL or RECOMMENDED or MANDATORY

(4) The complete assembly BG3792 (C.PR10) as supplied Certain parts are not required for a field-upgrade, as shown below

(5) Parts to be retained/fitted

Ref BP 2.18

(6) Parts not normally required. If not used, these to be returned to RSUK (together with gearbox assembly removed from a/c)

Page 6 of 14

F041 rev 4

RotorSport UK Ltd Service Bulletin Title: Improved pre-rotator gearbox for Calidus. SB No.: 056 Iss 1

Related documents MC No: MC-212 CCAR No.: None

Applicability Aircraft type & model: Calidus

Aircraft serial nos. affected: Any prior to RSUK/CALS/021

Compliance Category:

OPTIONAL or RECOMMENDED or MANDATORY

Photographs – installations

Band-clamps (2)

Corner protectors (4)

Fuse to external charging socket

(7) Battery installation on airframe beneath gearbox

(8) Fuel connection between tank and filler neck (shown without fire-proof sleeving for clarity). Ref BP 2.18

Page 7 of 14

F041 rev 4

RotorSport UK Ltd Service Bulletin Title: Improved pre-rotator gearbox for Calidus. SB No.: 056 Iss 1

Related documents MC No: MC-212 CCAR No.: None

Applicability Aircraft type & model: Calidus

Aircraft serial nos. affected: Any prior to RSUK/CALS/021

Compliance Category:

OPTIONAL or RECOMMENDED or MANDATORY

Note earth lead to filler neck.

Load-spreaders used to protect the fire-proof matting Ref BP 2.18

Page 8 of 14

F041 rev 4

RotorSport UK Ltd Service Bulletin Title: Improved pre-rotator gearbox for Calidus. SB No.: 056 Iss 1

Related documents MC No: MC-212 CCAR No.: None

Applicability Aircraft type & model: Calidus

Aircraft serial nos. affected: Any prior to RSUK/CALS/021

Compliance Category:

OPTIONAL or RECOMMENDED or MANDATORY

(9) Left-hand fuel tank installed

Ref BP 2.18

Page 9 of 14

F041 rev 4

RotorSport UK Ltd Service Bulletin Title: Improved pre-rotator gearbox for Calidus. SB No.: 056 Iss 1

Related documents MC No: MC-212 CCAR No.: None

Applicability Aircraft type & model: Calidus

Aircraft serial nos. affected: Any prior to RSUK/CALS/021

Compliance Category:

OPTIONAL or RECOMMENDED or MANDATORY

(10) Right-hand fuel tank installed

(11) Fuel-tank crossover tube with drain fitted - wire-lock on refitment

Ref BP 2.18

Page 10 of 14

F041 rev 4

RotorSport UK Ltd Service Bulletin Title: Improved pre-rotator gearbox for Calidus. SB No.: 056 Iss 1

Related documents MC No: MC-212 CCAR No.: None

Applicability Aircraft type & model: Calidus

Aircraft serial nos. affected: Any prior to RSUK/CALS/021

Compliance Category:

OPTIONAL or RECOMMENDED or MANDATORY

(12) Coolant radiator above engine

Ref BP 2.18

Page 11 of 14

F041 rev 4

RotorSport UK Ltd Service Bulletin Title: Improved pre-rotator gearbox for Calidus. SB No.: 056 Iss 1

Related documents MC No: MC-212 CCAR No.: None

Applicability Aircraft type & model: Calidus

Aircraft serial nos. affected: Any prior to RSUK/CALS/021

Compliance Category:

OPTIONAL or RECOMMENDED or MANDATORY

(13) “Interlock” Pushbutton on instrument panel Replace with black pushbutton supplied in kit

Ref BP 2.18

Page 12 of 14

F041 rev 4

RotorSport UK Ltd Service Bulletin Title: Improved pre-rotator gearbox for Calidus. SB No.: 056 Iss 1

Related documents

Compliance Category:

MC No: MC-212 CCAR No.: None

Applicability Aircraft type & model: Calidus

Aircraft serial nos. affected: Any prior to RSUK/CALS/021

OPTIONAL or RECOMMENDED or MANDATORY

Material information (Parts required to be made to implement this service bulletin): Installation of the uprated gearbox requires that a simple rubber stand-off is manufactured locally in order to attach the new pressure regulator by cable ties (see instructions above). List of components (with purchasable part nos) Pre-rotator improvement kit RSD7220 which contains: 1-off BG3792 Pneumatic coupling III (incudes miniature pressure regulator pre-set to 6.5-7bar) 1-off BT7072 Black pushbutton switch Interchangeability No restrictions Parts disposal a) Disposal requirements – return all removed and unused items to RSUK b) Environmental hazards of parts containing hazardous materials – Do not clean old coupling or engine locality with compressed-air as dust particles may be ejected. c) Scrap requirements – no scrap items Documentation (Service Bulletin Completion action) a) Entries within the aircraft logbooks, eg CAA BCAR A3-7 Authorised Person to certify that the work is completed by writing ‘SB-056 Improved pre-rotator gearbox incorporated’ in the aircraft logbook white pages, and record the action in the pink pages entitled ‘Aircraft Modifications’. Both entries must be signed by the CAA Authorised Person together with their CAA Authorisation number. b) Completion of the SB worksheet (attached). This contains a PMR statement, and a final check item that no tools or equipment have been left within the aircraft.

Document approval signatures Engineering Manager

Gerry Speich Oct 5 2012 11:02 AM

Ref BP 2.18

CVE (as required)

Chief Test Pilot (if flight performance or safety effect)

david starkey Oct 12 2012 12:26 PM

Page 13 of 14

Gerry Speich Oct 5 2012 4:08 PM

Head of Airworthiness

Andrew Lyons Apr 30 2013 4:37 PM

F041 rev 4

RotorSport UK Ltd Service Bulletin Aircraft type Aircraft serial no.

Service Bulletin implementation Worksheet

Date raised: Raised by:

Registration GPurpose – record service bulletin implementation actions taken to Document reference: SB-056 inspect aircraft and return to service. Calidus - RSUK0061 Iss5 of 10/10/12 Maintenance manual referred-to and issue level/date: Note; attach SB sheets to this document Task

Notes

Eng’r check/date

Inspector check/date

Fuel tank installation leak-proof, fuellevel and low-fuel sensor connected and proven. Fuel-drain wire-locked Mast cowlings, fuel inlet and grounding cable re-fitted Lower engine cowlings re-fitted with breather pipes correctly located and external charging cable in place Upper engine cowling securely re-fitted Pre-test showing bendix movement satisfactory Confirm all tools and loose items removed from aircraft Functional test of pre-rotator satisfactory

Customer acceptance: Name:

Aircraft hobbs meter reading Confirm logbooks annotated:

Signature/date:

Permit Maintenance Release: The work recorded above has been completed to my satisfaction and in that respect the aircraft is considered fit for flight. Engineer/Inspector signature

Date of work

Name: CAA Authorisation code :

Location where work completed

Ref BP 2.18

Page 14 of 14

F041 rev 4