Ela 07-07S Maintenance Manual

ELA 07-07S MAINTENANCE MANUAL
Version: M07-05-V2
Issued: April 2012.
Last modification: April 2020.
ELA AVIACIÓN, S.L.

POLIGONO INDUSTRIAL EL BLANQUILLO, M7 P26
14290 FUENTE OBEJUNA, CÓRDOBA, ESPAÑA
Phone: 0034 957 58 51 75 Fax: 0034 957 58 50 37
Email: ela@elaaviacion.com . Web: www.elaaviacion.com
1
Version: M07-05-V2
Issued: April 2012.
MAINTENANCE MANUAL FOR ELA 07-07S GYROPLANE
- Gyroplane model ELA 07_________
- Gyroplane serial Nº _______________
- Engine model Rotax __________
- Engine serial Nº _______________
- Registration marks _______________
- Aircraft manufacturer and type certificate

holder: ELA Aviación, S.L.
- Owner ________________________
______________________
______________________
______________________
No part of this manual may be reproduced or transmitted in any form or by any

means, electronic or mechanical, including photocopying, recording or by any
information storage or retrieval system, without permission from ELA Aviación, S.L.
2
Version: M07-05-V2
Issued: April 2012.
Amendments to this Manual
As necessary, ELA Aviación S.L. will issue updates to this manual and will
notify owners in the form of replacement pages with changes identified by
change bars in the margin.
Aircraft operators must ensure that amendments to their publication are
effected immediately on receipt, in accordance with the amendment
instructions which will accompany the updates.
Amendment Record
Amend’t Description of Amendment Pages Date
No. affected
1 New hub bar block 51 to 54 8th January

2016
14th April
2 Lifespan of prerotator belt. Point 6.3 25 and 57
2020
Lifespan of water cooler silent-blocks. Point 14th April

3 27 and 74
14.2 2020
3
Version: M07-05-V2
Issued: April 2012.
Contents
Section I – INTRODUCTION
1.1 General.
1.2 Applicability.
1.3 Terminology.
1.4 Conversion table.
1.5 Periodical maintenance.
1.6 Gyroplane degradation.
1.7 Cleaning.
1.8 Road transport.
1.9 Gyroplane identification.
1.10 Bolts torque.
1.11 Consumables.
Section II – DESCRIPTION OF THE AIRCRAFT
2.1 General.
2.2 Constructional details.
2.3 Overall dimensions.
2.4 Technical data and performance.
2.5 Engine.
2.6 Main parts.
Section III – MAINTENANCE DESCRIPTION
3.1 Maintenance schedule.

3.2 Periodical maintenance.
4
Version: M07-05-V2
Issued: April 2012.
Section IV – SYSTEMS
4.1 Airframe.
4.2 Rotor controls.
4.3 Steering controls.
4.4 Rotor head.
4.5 Rotor.
4.6 Prerotator.
4.7 Throttle and choke systems.
4.8 Landing gear.
4.9 Various.
4.10 Electrical/Pneumatic systems.
4.11 Propeller.
4.12 Engine.
4.13 Fuel system.
4.14 Cooling system.
4.15 Oil system.
Section VI – FUNCTIONAL TEST FLIGHT
5.1 Functional test flight
5
Version: M07-05-V2
Issued: April 2012.
SECTION I – INTRODUCTION
1.1 GENERAL
This maintenance manual contains the necessary information for safe and
efficient operation of the ELA 07 series of gyroplanes. It explains the
maintenance processes to keep this aircraft airworthy and in good
conditions.
This guide describes the correct maintenance for the parts manufactured by
ELA Aviación, S.L. The instructions for the engine maintenance and
servicing are not included in this manual. To carry out engine maintenance
appropriately, please refer to the updated engine´s maintenance manual.
Some of the operations described in this manual should be carried out only
by approved maintenance ELA staff. See “Maintenance Schedule”.
The owner/operator of this aircraft is the responsible to keep it properly

maintained according with the maintenance manuals, provided with this
gyroplane.
Maintenance tasks must be performed by experienced mechanics.
Special inspections have to be performed after an operational incident like:
- Hard landing.
- Strikes in flight with birds, trees…
- Rotor contact with obstacles.
- Lightning strike.
- Rotor over-speed.
- Engine failure.
Contact ELA Aviación, S.L. for advice.
6
Version: M07-05-V2
Issued: April 2012.
1.2 APPLICABILITY
This manual is applicable for all ELA 07 / 07S / 07 Agro gyroplanes.
1.3 TERMINOLOGY
Aerodynamics
CAS Calibrated airspeed. The indicated airspeed corrected for position and instrument
error.
IAS Indicated airspeed. The speed indicated in the airspeed indicator.
TAS True airspeed. The calibrated airspeed corrected for altitude and temperature.
Vb Turbulence speed. Design speed for maximum gust intensity.
Vne Never exceed speed.
Vy Best rate of climb speed.
Vx Best angle of climb speed.
Meteorology
OAT Outside Air Temperature expressed in degrees Celsius (°C).
ISA International Standard Atmosphere.
Hp Standard altimeter setting. 1013 mb (or hectopascals).
7
Version: M07-05-V2
Issued: April 2012.
1.4 CONVERSION TABLE
Temperature from Symbol to Symbol Factor
5/9*(F-
Fahrenheit Fº Celsius Cº
32)
Celsius Cº Fahrenheit Fº 9/5*C+32
Weight from to
Kilograms Kg Pounds Lb *2,205
Pounds Lb Kilograms Kg * 0,4536
Speed from to
Metres per
m/s Feet per minute ft/min * 196,86
second
Feet per minute ft/min Metres per second m/s * 0,00508
Kilometres per
km/h Knots Kts * 0,54
hour
Kilometres per
Knots kts Km/h * 1,852
hour
Knots Kts Miles per hour mph * 1,15
Miles per hour mph Knots Kts * 0,87
Pressure from to
Pounds per square

Atmospheres Atm psi * 14,8
inch
Pounds per square

psi Atmospheres Atm * 0,06756
inch
Distance from to
Kilometres Km Nautical Miles nm * 0,540
Nautical miles nm Kilometres Km. * 1.852
Statute miles sm Nautical Miles nm * 0,87
8
Version: M07-05-V2
Issued: April 2012.
Nautical Miles nm Statute miles sm * 1,15
Meters m Feet ft * 3.281
Centimetres cm Inches in * 0,3937
Inches in Centimetres cm. * 2.54
Volume from to
Litres lt US Gallons US gal * 0,2642
US Gallons US gal Litres lt * 3.785
Area from to
Square Meters m² Square Feet ft² * 10,76
Square Feet ft² Square Meters m² * 0,0929
1.5 PERIODICAL MAINTENANCE
Certain parts require scheduled maintenance regardless of flying hours. This

maintenance must be carried out in addition to the flight hours related
maintenance.
The relevant maintenance to the 100 hrs should be carried out (as an
annual inspection) in case that the gyroplane has not flown the 100 hrs
within a year.
All rubber parts and hoses should be replaced every 5 years or 500 flight
hours, which comes first.
1.6 GYROPLANE DEGRADATION
High humidity, especially in combination with salt-laden atmosphere will

lead to degradation and corrosion of some parts of the gyroplane.
Protect the metal parts of the gyroplane such the engine, rotor head, rotor
hub bar, control systems… with WD-40 or ACF-50 oil.
Sunlight and heat impact can degrade the composite parts of the gyroplane.
Whenever possible place the gyro in a protected area.
9
Version: M07-05-V2
Issued: April 2012.
The manufacturer takes no responsibility for damage due to improper

usage.
1.7 CLEANING
It is important to keep the gyroplane and its engine clean to maintain it in

good conditions. When cleaning, some mistakes or damages can be found.
Rotor blades and propeller should be always clean as they are very
important to keep the best performances.
In order to protect the gyroplane from dust, humidity, bird soil… is

advisable to cover it when parked in the hangar.
CAUTION
Do not use high pressure sprayers as they can damage electrical
connections, bearings or paint.
Do not use solvents or gasoline as they can damage some parts of the
gyroplane.
Use car soap with water to clean the external parts, windscreen should be
cleaned only with polycarbonate soap or polish.
Protect the metal parts of the gyroplane and engine against corrosion,
especially in high humidity conditions with “WD-40” or ACF-50 oil.
1.8 ROAD TRANSPORT
Take the rotor blades off and package them carefully as they can be
damaged during transportation by road. Transport the gyro with minimum
fuel for safety.
10
Version: M07-05-V2
Issued: April 2012.
1.9 GYROPLANE IDENTIFICATION
The gyroplane identification placard is placed on the left side of the mast, oil
tank bracket.
If you need to contact ELA Aviación, S.L. for any reason please, use your
gyroplane serial number for identification.
1.10 BOLTS TORQUE
All bolts of the gyroplane should be tightened with its appropriate torque.
The maintenance technician should have a torque wrench from 5N/m to
60N/m to carry out every maintenance task.
Although some bolts have a special tightening torque, when it is not

specified in this manual, the general torque setting is the following:
KIND OF BOLT TORQUE TOLERANCE
Metric -5 6 N/m +/- 1

Metric – 6 10 N/m +/- 1
Metric – 8 25 N/m +/- 1
Metric – 10 53 N/m +/- 2
AN-4 10 N/m +/- 1
AN-5 18 N/m +/- 1
AN-6 23 N/m +/- 2
11
Version: M07-05-V2
Issued: April 2012.
1.11 CONSUMABLES
Consumables used to perform the maintenance or assembly parts in the

gyroplane:
- Lubricants:
- Oil WD-40.
- Spray grease Krafft.
- Grease Molykote BR2 Plus.
- Grease “water repellent” Brugarolas JET-70.
- Oil ACF-50.
- Valvoline sae-90.
- Threadlockers:
- Loctite 243.
- Loctite 270.
- Loctite 641.
- Loctite 638.
- Engine oil: (see latest issue of engine maintenance manual)
- Coolant: 50/50 antifreeze with water (see latest issue of engine

maintenance manual).
- “Meguiar´s Mirror Glaze” for the windscreens.
12
Version: M07-05-V2
Issued: April 2012.
Section II – DESCRIPTION OF THE AIRCRAFT
2.1 GENERAL
The ELA 07 gyroplane is designed as a 2-seater, tandem-configured three-

axis aircraft with dual controls and single engine, ideal for flight instruction
purposes. In addition to flight training and general recreational flying, the
flight characteristics of this gyroplane make such aircraft ideally suited for
tasks such as air transportation, forestry, border, livestock and traffic
surveillance, electrical pylon inspection, aerial still and film photography,
fumigation, crop spray, etc. These are typically the kind of activities which
benefit from the very low speeds at which this gyroplane can operate as
well as its characteristic zero downwash. The manoeuvring capability of the
aircraft in all configurations is exceptionally high, and since it is impossible
for the machine to enter into a stall or a spin, it has an unequalled flight
safety record. Its characteristic short take-off and landing runs make it
particularly suitable for operation from fields of modest dimension.
2.2 CONSTRUCTIONAL DETAILS

The airframe is one single part built from stainless steel TIG (tungsten-
inert-gas) welded to guarantee lifetime freedom from corrosion. The
gyroplane is a tricycle landing gear with front wheel.
The cockpit is made from composite materials, ensuring high strength with
low weight. The high sided open cockpits have clear polycarbonate
windshields to protect the occupants from wind effects but offer excellent
all-round visibility.
The layout of the instrument panel house switches which fall easily to
hand around the desired set of instruments.
The rotor blades are made from aluminium and composite materials.
The power unit consists of a pusher piston engine and three bladed
composite propeller.
The tailplane is made from composite materials and consist of a fixed
horizontal stabilizer with winglets at the ends and a vertical surface in the
center subdivided into a fixed vertical stabilizer and rudder.
13
Version: M07-05-V2
Issued: April 2012.
2.3 OVERALL DIMENSIONS
MEASUREMENT METRIC IMPERIAL
Total length 5.0 m. 16.40 ft.
Total height 2.8 m. 9.19 ft.
Cockpit width 0.75 m. 2.46 ft.
Landing gear width 1.75 m. 5.74 ft.
Rotor diameter 8.5 m. 27.89 ft.
1.73m
2.8m
1.3m
0.9m 1.76m
5m
14
Version: M07-05-V2
Issued: April 2012.
2.4 TECHNICAL DATA AND PERFORMANCE
The following performance parameters were determined by flight testing

with average piloting skills, aircraft with 450 kg MTOW, in good conditions
and clean rotor blades and propeller. The parameters apply to standard
conditions ISA (15ºC temperature, sea level and standard pressure).
With Rotax 914 TURBO (115

With Rotax 912 ULS (100 HP)
HP)
Gyroplane data
METRIC IMPERIAL METRIC IMPERIAL
Empty weight (minimum equipment) 260 kg 575 lb 265 kg 585 lb
MTOW* 450 kg 1000 lb 500 kg 1100 lb
Useful load (minimum equipment) 190 kg 420 lb 235 kg 520 lb

100 mph 100 mph
Vne 160 kph 160 kph
(85 kts) (85 kts)
60 – 85 mph 60 – 90 mph
Cruise speed 100 – 135 kph 100 – 145 kph
(55 – 73 kts) (55 – 78 kts)
25 mph 22 mph
Min speed (level flight/full power)) 40 kph 35 kph
(22 kts) (19 kts)
Rate of climb 3.3 m/s 650 ft/min 5 m/s 1000 ft/min
Take-off distance (roll) 100 m 330 ft 70 m 230 ft
Landing distance 0 – 30 m 0 – 65 ft 0 – 30 m 0 – 65 ft
Fuel Gasoline
Fuel capacity 75 l 20 gal

Unusable fuel 3l 0.8 gal
Fuel consumption 13 – 20 l/h 3.5 – 5.5 gal/hr
* See the MTOW limitations for your country.
15
Version: M07-05-V2
Issued: April 2012.
2.5 ENGINE
1) Manufacturer ……………………………………………………………………………… Rotax
2) Take-off power:
a. 912 ULS……………………………………………………………….………… 100 hp
b. 914 UL………………………………………………………………………….. 115 hp
3) Max. engine speed……………….……………………………….…………… 5800 rpm
4) Cooling system………………………………………………………………………. Air/liquid
5) Coolant………………………………………………………………. 50% water/antifreeze
6) Electric installation…………………………………………………………………………. 12v
16
Version: M07-05-V2
Issued: April 2012.
2.6 MAIN PARTS

1
3
4
12
11 13
9
5
6
10 7
8
Parts:
1 – Rotor blades.
2 – Hub bar.
3 – Rotor head.
4 – Mast.
5 – Rear keel.
6 – Landing gear.
7 – Main wheels.
8 – Front wheel.
9 – Cockpit.
10 – Landing light.
11 – Windscreens.
12 – Engine.
13 – Tailplane.
17
Version: M07-05-V2
Issued: April 2012.
8 1
4 5
2 3 6 7
Parts:
1 – Propeller.
2 – Oil cooler.
3 – Water cooler.
4 – Vertical stabilizer.
5 – Rudder.
6 – Winglet.
7 – Horizontal stabilizer.
8 – Control rods.
18
Version: M07-05-V2
Issued: April 2012.
2 3 1 4
Parts:
1 – Engine.
2 – Water tank.
3 – Horizontal pre-rotator drive shaft.
4 – Pre-rotator clutch.
5 – Carburettor.
6 – Oil tank.
7 – Air filter (914).
19
Version: M07-05-V2
Issued: April 2012.
Parts:
1 – Pre-rotator piston.
2 – Water cooler.
3 – Exhaust muffler.
4 – Fuel tank filler.
5 – Battery.
20
Version: M07-05-V2
Issued: April 2012.
2 3 4
5 6 7
8 9 10 11 12 13 14
15 16
Parts:
1 – Compass.
2 – Altimeter.
3 – Airspeed indicator.
4 – Vertical speed indicator.
5 – Rotor tachometer.
6 – Engine tachometer.
7 – Oil pressure.
8 – Trim pressure.
9 – Radio.
10 - EGT.
11 – Manifold pressure.
12 – Fuel pressure.
13 – Oil temperature.
14 – Cylinder head temperature.
15 – Flight/brake selector.
16 – Ignition switch.
21
Version: M07-05-V2
Issued: April 2012.
1 2 3 4 5 6 7
Parts:
1 – Caution and warning turbo lights (just in 914 engine).

2 – Headset jack.
3 – Battery charge.
4 – Landing light and strobe switch.
5 – Circuit breakers.
6 – Master switch.
7 – Fuel pumps (only one for 912 engine)
22
Version: M07-05-V2
Issued: April 2012.
Front/Rear Stick Front pedals
Trim
Pre-rotator
PTT Radio
Throttle, brake and roll trim
Throttle
Wheel brake
Roll trim
23
Version: M07-05-V2
Issued: April 2012.
Section III – MAINTENANCE DESCRIPTION
3.1 MAINTENANCE SCHEDULE
The relevant maintenance to the 100 hrs should be carried out (as an
annual inspection) in case that the gyroplane has not flown the 100 hrs
within a year.
Task DESCRIPTION 25 100 200 300 400 500 600 700 800 900
Nº hr hr hr hr hr hr hr hr hr hr
1 - AIRFRAME
1.1 Inspect mast X X X X X X X X X

1.2 Verify sealing of mast bolts X X X X X X X X X X
1.3 Retighten bolts of seats and harnesses X X X X
1.4 Verify cockpit and instrument panel X X X X X X X X X
1.5 Retighten cockpit bolts X X X X
1.6 Verify mast straightness X X X X
1.7 Full airframe inspection X
(only approved staff)
2 - ROTOR CONTROLS
2.1 Verify sealing of control system bolts X X X X X X X X X X

2.2 Verify absence of play X X X X X X X X X X
2.3 Inspect control rods X X X X X X X X X
2.4 Grease control rod ends X X X X X X X X X
2.5 Adjust friction in roll (if needed) X X X X X X X X X
2.6 Retighten bolts of control fork X X X X X
2.7 Replace bolts of control fork X X X X
2.8 Rotor controls overhaul X
3 – STEERING CONTROLS
3.1 Inspect front wheel fork X X X X X X X X X

3.2 Inspect control rods for straightness X X X X X X X X X
3.3 Inspect pedals X X X X X X X X X
3.4 Inspect control system X X X X X X X X X
3.5 Verify rudder cable tension X X X X X X X X X X
3.6 Check offset of rudder X X X X
3.7 Replace rudder control cable X
24
Version: M07-05-V2
Issued: April 2012.
4 – ROTOR HEAD
4.1 Verify sealing of bolts X X X X X X X X X X

4.2 Inspect rotor head X X X X X X X X X
4.3 Adjust tightness of roll and pitch pivot bolts X X X X X X X X X
4.4 Grease roll and pitch pivots X X X X X X X X X
4.5 Inspect pre-rotator ring gear and bendix pinion X X X X X X X X X
4.6 Grease the pre-rotator X X X X X X X X X
4.7 Grease top bearing of bendix (see version) X X X X X X X X X
4.8 Inspect rotor brake pad X X X X X X X X X
4.9 Clean/degrease rotor brake disc X X X X X X X X X
4.10 Replace rotor head bolts X
4.11 Inspect teeter towers X
5 – ROTOR BLADES
5.1 Inspect rotor X X X X X X X X X

5.2 Verify tightening of teeter bolt X X X X X X X X X
5.3 General inspection X
6 – PRE-ROTATOR
6.1 Verify sealing of bolts X X X X X X X X X X

6.2 Inspect pre-rotator X X X X X X X X X
6.3 Replace belt X X X X
6.4 Adjust pre-rotator cable (if fitted) X X X X X X X X X
6.5 Adjust the pre-rotator rubber pulley brake X X X X X X X X X
6.6 Inspect universal joints for play X X X X X X X X X
6.7 Inspect O-rings X X X X X X X X X
6.8 Grease bearing of tensioner X X X X X X X X X
6.9 Grease rod end bearing of piston X X X X X X X X X
6.10 Clean and regrease universal joints X X X
6.11 Inspect the pre-rotator gearbox X X X X X X X X X
6.12 Replace bearing of the tensioner X
6.13 Replace pre-rotator Bowden cable X
7 – THROTTLE AND CHOKE SYSTEMS
7.1 Inspect the system for smooth operation X X X X X X X X X X

7.2 Inspect levers for damage X X X X X X X X X X
7.3 Adjust levers friction X X X X X X X X X X
7.4 Inspect choke system x x x x x x x x x x
7.5 Inspect locking wires x x x x x x x x x x
7.6 Adjust carburettor synchronization X X X X X X X X X
7.7 Replace carburettors Bowden cables X
25
Version: M07-05-V2
Issued: April 2012.
.Task DESCRIPTION 25 100 200 300 400 500 600 700 800 900
8 – LANDING GEAR
8.1 Tires and wheels X X X X X X X X X X

8.2 Verify sealing of landing gear bolts x x x x x x x x x x
8.3 Retighten landing gear bolts x x x x x
8.4 Inspect landing gear X X X X X X X X X X
8.5 Inspect brake pads X X X X X X X X X
8.6 Clean and regrease bearings X X X
9 - VARIOUS
9.1 Inspect tailplane X X X X X X X X X X

9.2 Retighten tailplane attachment bolts X X X X
9.3 Replace tailplane bolts X
9.4 Verify condition of windscreens X X X X X X X X X
9.5 Verify placards X X X X X X X X X
10 – ELECTRICAL/PNEUMATIC SYSTEM
10.1 Inspect harnesses X X X X X X X X X

10.2 Check battery level (old battery model) X X X X
10.3 Instrument panel X X X X
10.4 Oil the compressor x x X x x X x X X
11 - PROPELLER
11.1 Inspect propeller X X X X X X X X X X

11.2 Retighten propeller bolts X X X X
11.3 Propeller pitch X X X X
11.3 Replace propeller bolts X
11.4 Overhaul X X
12 – ENGINE
(see engine´s maintenance manual)
12.1 Verify sealing of engine bolts X X X X X X X X X X

12.2 Replace engine silent-blocks X
12.3 Replace engine attachment bolts X
12.4 Inspect locking wire for the air filters X X X X X X X X X X
12.5 Inspect exhaust X X X X X X X X X
13 – FUEL SYSTEM
13.1 Clean gascolator X X X X X X X X X X

13.2 Replace filter X X X X X X X X X
13.3 Clean filters of 914 fuel pumps X X X
13.4 Inspect vent hoses X X X X X X X X X
13.5 Inspect fuel hoses X X X X X X X X X
13.6 Replace hoses X
13.7 Perform fuel tank test X X X X
26
Version: M07-05-V2
Issued: April 2012.
14 – COOLING SYSTEM
14.1 Inspect system X X X X X X X X X X

14.2 Replace silent-blocks X X X
14.3 Replace hoses and coolant X
15 – OIL SYSTEM
15.1 Inspect system X X X X X X X X X X

15.2 Replace hoses and clamps X
3.2 PERIODICAL MAINTENANCE
Certain parts require scheduled maintenance regardless of flying hours. This

maintenance must be carried out in addition to the flight hours related
maintenance.
If the gyroplane does not fly for a total time of 100 hrs within a year, the
100hrs maintenance program should be carried out as an annual inspection.
All rubber parts and hoses should be replaced every 5 years independently
of the flight hours.
Remove the bolts of the rotor controls rotor head and rotor blades/hub bar
every two years and confirm the absence of corrosion or wear. Apply WD-
40 or ACF-50 oil to the unthreaded part of the bolt and install it with a new
stop nut. If corrosion or wear is found replace the bolt immediately.
27
Version: M07-05-V2
Issued: April 2012.
Section IV – SYSTEMS
4.1 AIRFRAME
The main airframe of the gyroplane is constructed from stainless steel, TIG
welded. The airframe is one single unit which don´t have replaceable parts.
Any repair or modification to the airframe by third persons are not allowed
or approved.
1.1 Inspect mast

(every 100 flight hours)
Inspect the mast and its welds to

confirm the absence of cracks in the
engine brackets.
Inspect the welds of the bracket for

the pre-rotator gearbox.
28
Version: M07-05-V2
Issued: April 2012.
Inspect the battery bracket.
Inspect the oil tank bracket and the

mast reinforcement struts.
29
Version: M07-05-V2
Issued: April 2012.
Inspect the mast and welds at the

bottom part.
30
Version: M07-05-V2
Issued: April 2012.
1.2 Verify sealing of mast bolts

(first 25 and every 100 flight hours)
Verify that the red marks are

aligned between nut and bolt in:
- Rear four point harness (if fitted)
- 90º Prerotator box.
- Battery bracket.
- Engine brackets.
- Starter relay.
- Regulator.
31
Version: M07-05-V2
Issued: April 2012.
1.3 Retighten bolts of seats and harnesses

- Retighten the four M-6 attachment bolts for each seat.

- Retighten the bolts for the harnesses.
Note
The M-10 bolts for the harness in the rear seat should be
tightened to 25 N/m.
1.4 Verify cockpit and instrument panel

Verify that the cockpit and instrument panel are secured.
1.5 Retighten cockpit bolts

32
Version: M07-05-V2
Issued: April 2012.
Retighten the cockpit bolts.
M-4 bolts gently tightened by hand.
33
Version: M07-05-V2
Issued: April 2012.
1.6 Verify mast straightness

Remove the instrument panel and measure the distance between the mast
and the keel. The measurement should be between 2595 and 2615mm for
the airframes manufactured until March 2014.
The measurement should be between 2633 and 2653mm for the airframes
manufactured from March 2014.
1.7 Full airframe inspection (only approved staff)

Inspection of all welds for possible cracks in the airframe.
34
Version: M07-05-V2
Issued: April 2012.
4.2 ROTOR CONTROLS
2.1 Verify sealing of control system bolts

Verify the sealing of the control

system bolts in control columns,
control fork and vertical control
rods.
35
Version: M07-05-V2
Issued: April 2012.
2.1 Verify sealing of control system bolts

36
Version: M07-05-V2
Issued: April 2012.
2.2 Verify absence of play

With the rotor brake ON”, hold the front stick and make some pressure fore
and aft to check if there is play in the whole control system. Some
millimetres of play at the top of the stick are allowed, 8 mm or more are
not acceptable.
2.3 Inspect control rods

Visually inspect the vertical control rods for damage or cracks, especially at
its ends.
2.4 Grease control rod ends

Clean the control rod ends (8) and

grease with spray.
37
Version: M07-05-V2
Issued: April 2012.
2.5 Adjust friction in roll (if needed)

Some friction in the roll axis of the

rotor controls is more comfortable to
avoid resonant vibration in flight.
Slightly tight the bolts of the plastic
bracket.
Test in ground the amount of
friction; it should be a compromise
between handle and friction.
2.6 Retighten bolts of control fork

(100/300/500/700/900 flight hours)
Replace the nuts, retighten the bolts

of the control fork and mark with
red paint the thread with the nut.
38
Version: M07-05-V2
Issued: April 2012.
2.7 Replace bolts of control fork

Replace the bolts and nuts of the

control fork and mark with red paint
the thread with the nut.
2.8 Rotor controls overhaul (only approved staff)

Disassembly the whole rotor control

system from the gyroplane.
Inspect every control rod (2

horizontal and 4 vertical) for
straightness, cracks or damage.
Inspect the control fork for cracks or

damage.
Replace the bearings of the control

columns (8).
39
Version: M07-05-V2
Issued: April 2012.
Replace the bearings of the control

fork.
Replace the rod end bearings of the

vertical rods (8).
Assembly the new rod end bearings

with the following measurements
between centres:
Upper rods:
- Right: 900mm.
- Left: 882mm.
Lower rods:
Right and left: 770mm.
Grease the rod ends.
Replace all bolts and nuts of the

control system, 10 for the horizontal
rods and 10 for the vertical rods.
40
Version: M07-05-V2
Issued: April 2012.
4.3 STEERING CONTROLS
3.1 Inspect front wheel fork

Inspect the front wheel fork for

Lift the nose of the gyroplane and

verify that the fork is free to rotate
by hand.
3.2 Inspect control rods for straightness

Inspect the steering control rods for
straightness through the front wheel
hole and from inside the cockpit.
41
Version: M07-05-V2
Issued: April 2012.
3.3 Inspect pedals

Inspect the front and rear pedals for

Verify the absence or play.
Install new ant-slip pads if

necessary.
3.4 Inspect control system

Inspect the entire rudder cable for wear or damage.
Inspect the rudder cable pulleys for free motion.
Inspect the condition of the cable retainers of the rudder.
42
Version: M07-05-V2
Issued: April 2012.
3.5 Verify rudder cable tension

Verify rudder cable tension. With the

front wheel straight, the tension
should be between 45 and 55
pounds.
It is important that the tension of

this control cable is within limits to
avoid a probably rudder flutter at
high speeds.
Adjust the tension tightening the

turnbuckle near the rear/right pedal.
Secure it again with safety wire.
After adjusting the cable check the

offset of the rudder (see point 3.6)
3.6 Check offset of rudder

(every 200 flight hours and after adjusting the cable tension)
The rudder should be mounted

90 cm
offset with respect to the front
wheel.
Ensure the front wheel of the
gyroplane is straight and measure
the distance between the trailing
edge at the top of the rudder and
the trailing edge of the top of the
right winglet. It should be 90cm +/-
1.
43
Version: M07-05-V2
Issued: April 2012.
3.7 Replace rudder control cable

Replace the rudder control cable and turnbuckle.
4.4 ROTOR HEAD
4.1 Verify sealing of bolts

Verify the sealing of the bolts of the

rotor head.
44
Version: M07-05-V2
Issued: April 2012.
4.2 Inspect rotor head

Inspect the rotor head for cracks.
Inspect the rotor head for

deformities or twisting using a rule.
4.3 Adjust tightness of roll and pitch pivot bolts

Adjust the tightness of roll and pitch

bolts.
Torque to 20N/m and slacken about

¼ of turn, or the necessary to
operate the controls easily. Put a
new safety pin.
45
Version: M07-05-V2
Issued: April 2012.
4.4 Grease roll and pitch pivots

Grease with Molycote the rotor head

pivots. Add grease until you see the
grease coming out.
4.5 Inspect pre-rotator ring gear and bendix pinion

Inspect the pre-rotator ring gear

and bendix pinion for wear or
damage.
4.6 Grease pre-rotator

Grease the pre-rotator ring gear

with “Brugarolas JET70” using a
small brush.
Engage the bendix with the ring

gear and grease the interior body of
the bendix with WD-40 spray.
46
Version: M07-05-V2
Issued: April 2012.
4.7 Grease top bearing of the bendix (see version)

Grease the needle bearing at the top

of the bendix with spray grease.
See version. New version of bearing

is maintenance free.
4.8 Inspect rotor brake pad

Inspect the brake pad for excessive

wear or damage.
47
Version: M07-05-V2
Issued: April 2012.
4.9 Clean/de-grease rotor brake disc

Clean/degrease the rotor brake disc.
4.10 Replace rotor head bolts

Replace the rotor head bolts and

nuts (11 bolts).
48
Version: M07-05-V2
Issued: April 2012.
4.11 Inspect teeter towers (only approved staff)

Disassemble the teeter towers, main

shaft, pre-rotator ring gear and
main rotor bearing.
Clean the teeter towers and main

shaft and perform a dye penetrant
test.
If no defect is found, clean the

parts, fit the new main rotor bearing
with Loctite 641 and the correct
tool. Mount the main shaft with
Loctite 641, with new lock washers
and nuts.
Handle these parts with extreme

care. Damaging the main rotor
bearing during the assembly or
other kind of mistake with these
parts could have fatal consequences.
4.5 ROTOR
5.1 Inspect the rotor

49
Version: M07-05-V2
Issued: April 2012.
Visually inspect the rotor blades for cracks, wear, deformities…
Visually inspect the hub bar for cracks, wear, deformities…
5.2 Verify tightening of teeter bolt

Old system:
Tight the nut to 20N/m and slacken

about ¼ turn. Put safety pin.
New system:
That bolt should be tightened strong

“BY HAND”. Then tighten the Allen
bolt and put the safety pin.
A lower or higher torque will create

rotor vibrations.
5.3 General inspection

OLD SYSTEM (different hub block)
50
Version: M07-05-V2
Issued: April 2012.
Disassemble the rotor from the

gyroplane and put it over stands.
Disassemble the bearings from the

block.
Mark each rotor blade with its side

of the hub bar.
Mark the block with the hub bar.
51
Version: M07-05-V2
Issued: April 2012.
Disassemble the parts of the rotor,

clean them and perform a dye
penetrant test.
If no defects found, clean the parts

and mount them.
For the assembly, use new bolts,

washers and nuts and a new teeter
bolt.
Install new bearings in the block and

lubricate them with Molycote grease.
52
Version: M07-05-V2
Issued: April 2012.
53
Version: M07-05-V2
Issued: April 2012.
5.3 General inspection

NEW SYSTEM (different hub block)
Disassemble the rotor from the

gyroplane and put it over stands.
Mark each rotor blade with its side

of the hub bar.
Mark the block with the hub bar.
Disassemble the parts of the rotor,

clean them and perform a dye
penetrant test.
If no defects found, clean the parts

and mount them.
54
Version: M07-05-V2
Issued: April 2012.
For the assembly, use new bolts,

washers and nuts and a new teeter
bolt.
Install a new threaded hub with

“Brugarolas” grease in the thread
and before assembling the rotor,
lubricate the bearings with Molycote
grease.
55
Version: M07-05-V2
Issued: April 2012.
4.6 PRE-ROTATOR
6.1 Verify sealing of bolts

Verify the sealing of the prerotator

bolts.
56
Version: M07-05-V2
Issued: April 2012.
6.2 Inspect pre-rotator

Inspect the pre-rotator tensioner

and bracket for cracks or damage.
Inspect the belt for damage or

deformities.
Inspect the horizontal and vertical

drive shafts for cracks or
deformities.
6.3 Replace belt

(every 200 flight hours or 5 years)
Remove the propeller and replace the belt. Install new locking nuts (6) in
the propeller bolts.
57
Version: M07-05-V2
Issued: April 2012.
6.4 Adjust pre-rotator cable (if fitted)

Adjust the length of the prerotator

cable (if fitted).
With the parking brakes ON, throttle

in idle position pull the pre-rotator
lever and hold it with a force of
about 3-5 kg, the distance between
the throttle and pre-rotator lever
(centres) should be 12 cm.
6.5 Adjust pre-rotator rubber pulley brake

Adjust the pre-rotator rubber pulley

brake if needed.
The small pre-rotator pulley must

rest on the rubber pulley, so the
pre-rotator shafts are braked.
Adjust the height of this part by

turning the eccentric pulley.
58
Version: M07-05-V2
Issued: April 2012.
6.6 Inspect universal joints for play

Inspect the universal joints for

excessive play.
Hold the vertical shaft and gently try

to turn it both ways to check the
play of the joints.
6.7 Inspect O-rings

Inspect the O-rings (if fitted) for

damage.
Replace the O-rings when needed.

When installing, use Loctite 243 and
tight gently by hand.
59
Version: M07-05-V2
Issued: April 2012.
6.8 Grease bearing of the tensioner

Lubricate the bearing of the

tensioner with spray grease.
6.9 Grease rod end bearing of piston

Lubricate the rod end bearing of the

pre-rotator piston with spray grease
(if fitted).
6.10 Clean and regrease universal joint

Remove the rubber covers of the

universal joints for cleaning and
regrease with Molycote.
60
Version: M07-05-V2
Issued: April 2012.
6.11 Inspect pre-rotator gearbox

Verify that the pre-rotator gearbox

has no oil leaks.
In case of leaks replace the oil seals.
6.12 Replace bearing of the tensioner

Replace the bearing of the tensioner.

Grease with Molycote before assembling.
6.12 Replace the pre-rotator Bowden cable

Replace the pre-rotator Bowden cable (if fitted).
4.7 THROTTLE AND CHOKE SYSTEMS
7.1 Inspect system for smooth operation

Operate the system from idle to full power position to confirm a smooth
operation.
61
Version: M07-05-V2
Issued: April 2012.
7.2 Inspect levers for damage

Inspect the front and rear levers for damage or malfunction.
7.3 Adjust levers friction

Adjust the friction of throttle levers

for smooth operation. If the throttle
is too hard is difficult to operate with
precision, if it is too soft it will move
in flight by itself.
Adjust the brake lever friction for

smooth operation and with no play.
7.4 Inspect choke system

Operate the choke system to confirm its smooth operation.
62
Version: M07-05-V2
Issued: April 2012.
7.5 Inspect locking wires

Inspect the locking wires of throttle

and choke systems. Replace if
necessary.
63
Version: M07-05-V2
Issued: April 2012.
7.6 Adjust carburettor synchronization

Adjust the carburettor synchronization according with the latest issue of

the Rotax maintenance manual.
7.7 Replace Bowden cables

Replace carburettor and choke Bowden cables. Then it is necessary to

adjust the carburettor synchronization.
4.8 LANDING GEAR
8.1 Tires and wheels

Check the tires for wear, replace

when needed.
Verify tires pressure:
- Front wheel: 1,5 bar (22 psi)

- Main wheels: 2 bar (30 psi)
Inspect the wheel rims for cracks or

damage.
Inspect the red marks between tires

and rims.
64
Version: M07-05-V2
Issued: April 2012.
8.2 Verify sealing of landing gear bolts

Verify the sealing of the landing
gear bolts in the aluminium landing
gear (new).
8.3 Retighten landing gear bolts

In the old landing gear, made in
composite, retighten the 4 bolts that
fix it to the frame and retighten the
bolts that fix the wheels axles.
8.4 Inspect landing gear

Inspect the old landing gear (composite), for cracks or damage.
8.5 Inspect brake pads

Inspect the wheel brake pads for wear. Replace when needed.
65
Version: M07-05-V2
Issued: April 2012.
8.6 Clean and grease bearings

Clean and re-grease with Molycote

the wheels bearings in the old
system (open rollers bearings).
4.9 VARIOUS
9.1 Inspect tailplane

Inspect tailplane and rudder for cracks or damage.
9.2 Retighten tailplane attachment bolts

Retighten tailplane attachment bolts

(4).
9.3 Replace tailplane bolts

Replace tailplane bolts, use Loctite 243.
66
Version: M07-05-V2
Issued: April 2012.
9.4 Verify condition of windscreens

Verify the absence of scratches or cracks. Polish them often with

“Meguiar´s Mirror Glaze”.
9.5 Verify placards

Verify all placards, when fitted, are readable and in good conditions.
Replace if necessary.
4.10 ELECTRICAL/PNEUMATIC SYSTEMS
10.1 Inspect harnesses

Inspect the routing and connections of the electrical and pneumatic

harnesses for damage, wear, replacement of cable ties…
10.2 Check battery level

Check the battery level in the old battery (Varta), refill with distilled water
if necessary.
The new batteries DECA or Super-B don´t need maintenance.
10.3 Instrument panel

Remove the instrument panel for cleaning and inspect all wires and
connections for damage, wear…
10.4 Oil the compressor

67
Version: M07-05-V2
Issued: April 2012.
Oil the compressor (new system)

with engine oil.
Remove the cover of the compressor

and oil it with 3 or 4 drops of engine
oil.
4.11 PROPELLER
11.1 Inspect propeller

Inspect the propeller blades and hub for cracks or damages.
11.2 Retighten propeller bolts

Retighten all the propeller bolts.
68
Version: M07-05-V2
Issued: April 2012.
11.3 Propeller pitch

Verify that the pitch of the three propeller blades are equal.
11.4 Replace the propeller bolts

Replace the 6 propeller bolts of the centre of the hub.
11.5 Overhaul
(every 600 or 800 flight hours)
Send the propeller to the manufacturer for inspection:
- Helix Carbon GmbH propeller -- 600 flight hours.

- DUC Flash-2 propeller ---------- 800 flight hours.
4.12 ENGINE
The instructions for the engine maintenance and servicing are not included
in this manual. To carry out engine maintenance appropriately, please refer
to the updated engine maintenance manual.
12.1 Verify sealing of engine bolts

Verify the red marks of the engine bolts.
12.2 Replace engine silent-blocks

69
Version: M07-05-V2
Issued: April 2012.
Replace the engine silent-blocks.
12.3 Replace engine attachment bolts

Replace the engine attachment bolts.
12.4 Inspect locking wire of air filter(s)

Inspect the locking wire of air

filter(s).
Locking wire in 914 UL air filter.
70
Version: M07-05-V2
Issued: April 2012.
Locking wire in 912 ULS air filters.
12.5 Inspect exhaust system

Inspect the exhaust system for cracks or damage.

Inspect the after muffler for cracks or damage.
Replace the springs and safety wire of the exhaust system of the 912
engine.
4.13 FUEL SYSTEM
71
Version: M07-05-V2
Issued: April 2012.
13.1 Clean gascolator

Open and clean the gascolator.
13.2 Replace fuel filter

Replace the fuel filter.
Use only paper filters having an

appropriate size.
The fuel filters with plastic mesh are

NOT SUITABLE for this installation.
72
Version: M07-05-V2
Issued: April 2012.
13.3 Clean filters of the 914 pumps

Carefully remove the fuel filters

inside the electrical fuel pumps of
the 914 and clean them.
13.4 Inspect vent hoses

Inspect the routing of the vent hoses for wear or damage.
13.5 Inspect fuel hoses

Inspect the routing of the fuel hoses for wear or damage.
13.6 Replace hoses

Replace the fuel and vent hoses and clamps.
73
Version: M07-05-V2
Issued: April 2012.
13.7 Perform fuel tank test

Check the inside filter of the fuel tank, procedure:
- Fill completely the tank with fuel.

- Open the outlet of the tank and measure the time to get one litre.
- The max. time to get one litre should be less than 40 seconds.
4.14 COOLING SYSTEM
14.1 Inspect system

Verify the absence of leaks in the system.
Inspect the condition of the silent-blocks of the cooler.
Check coolant level. The black tank should be full. The white tank should
be filled to one half.
Inspect the rubber washer and spring of the cap of the black tank.
14.2 Replace silent-blocks

Replace the silent-blocks of the cooler.
74
Version: M07-05-V2
Issued: April 2012.
14.3 Replace hoses and coolant

Replace the rubber hoses and clamps of the system.
Replace the coolant. (See engine´s maintenance manual for approved

coolants, 50% water / 50% pure antifreeze.
4.15 OIL SYSTEM
15.1 Inspect system

Verify the absence of leaks in the system.
Inspect the hoses for wear or damage.
15.2 Replace hoses

Replace the hoses and clamps.
75
Version: M07-05-V2
Issued: April 2012.
Section V – FUNCTIONAL TEST FLIGHT
5.1 FUNCTIONAL TEST FLIGHT

A functional test flight should be done every year. This test determines
whether the gyroplane or its equipment is functioning according to
established standards while the aircraft operates in its intended
environment. An FTF is performed when it is not possible to determine
proper operation by a ground test.
Test Nº Description Results/Comments Done

1 Weights
Aircraft weight:
Fuel weight:
Pilot weight:
Total:_________________
2 Ground test
Test manoeuvring stability, steering, throttle and
wheel brake systems.
3 Pre-rotator
Test the pre-rotator system for correct function.
4 Take off
Take off with full power using a standard
technique described in the POH.
Note any unusual characteristic.
5 Engine power/propeller pitch
Note the max engine rpm climbing at Vy (96 kph
~ 60 mph).
6 Instruments
Check every flight or engine instrument, check
radio/intercom for correct function.
76
Version: M07-05-V2
Issued: April 2012.
7 Climb
Note the time for climbing to 1000 feet at Vy.
Airport elevation:
QNH:
Temp:
8 Controls
Test rotor and rudder controls in flight.
Note any unusual characteristic.
9 Speeds
Test general stability at speeds from 0-160 kph ~
0-100 mph.
10 Trim
Test trim function at speeds from 0-160 kph ~ 0-
100 mph.
11 Landing
Land with engine at idle speed and note any
unusual behaviour.
Comments/Remarks:
Date: Location:
Pilot Name: License Nº:
77

Ela 07-07S Maintenance Manual

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Ela 07-07S Maintenance Manual

Uploaded by

Copyright:

Available Formats

ELA 07-07S MAINTENANCE MANUAL

ELA AVIACIÓN, S.L.

MAINTENANCE MANUAL FOR ELA 07-07S GYROPLANE

- Gyroplane model ELA 07_________

- Gyroplane serial Nº _______________

- Engine model Rotax __________

- Engine serial Nº _______________

- Registration marks _______________

- Aircraft manufacturer and type certificate

No part of this manual may be reproduced or transmitted in any form or by any

Amendments to this Manual

1 New hub bar block 51 to 54 8th January

Lifespan of water cooler silent-blocks. Point 14th April

Section II – DESCRIPTION OF THE AIRCRAFT

Section III – MAINTENANCE DESCRIPTION

3.1 Maintenance schedule.

Section VI – FUNCTIONAL TEST FLIGHT

5.1 Functional test flight

The owner/operator of this aircraft is the responsible to keep it properly

Maintenance tasks must be performed by experienced mechanics.

Special inspections have to be performed after an operational incident like:

Contact ELA Aviación, S.L. for advice.

This manual is applicable for all ELA 07 / 07S / 07 Agro gyroplanes.

IAS Indicated airspeed. The speed indicated in the airspeed indicator.

Vb Turbulence speed. Design speed for maximum gust intensity.

Vne Never exceed speed.

Vy Best rate of climb speed.

Vx Best angle of climb speed.

OAT Outside Air Temperature expressed in degrees Celsius (°C).

ISA International Standard Atmosphere.

Hp Standard altimeter setting. 1013 mb (or hectopascals).

1.4 CONVERSION TABLE

Temperature from Symbol to Symbol Factor

Celsius Cº Fahrenheit Fº 9/5*C+32

Kilograms Kg Pounds Lb *2,205

Pounds Lb Kilograms Kg * 0,4536

Feet per minute ft/min Metres per second m/s * 0,00508

Knots Kts Miles per hour mph * 1,15

Miles per hour mph Knots Kts * 0,87

Pounds per square

Pounds per square

Kilometres Km Nautical Miles nm * 0,540

Nautical miles nm Kilometres Km. * 1.852

Statute miles sm Nautical Miles nm * 0,87

Nautical Miles nm Statute miles sm * 1,15

Meters m Feet ft * 3.281

Centimetres cm Inches in * 0,3937

Inches in Centimetres cm. * 2.54

Litres lt US Gallons US gal * 0,2642

US Gallons US gal Litres lt * 3.785

Square Meters m² Square Feet ft² * 10,76

Square Feet ft² Square Meters m² * 0,0929

1.5 PERIODICAL MAINTENANCE

Certain parts require scheduled maintenance regardless of flying hours. This

1.6 GYROPLANE DEGRADATION

High humidity, especially in combination with salt-laden atmosphere will

The manufacturer takes no responsibility for damage due to improper

It is important to keep the gyroplane and its engine clean to maintain it in

In order to protect the gyroplane from dust, humidity, bird soil… is

1.8 ROAD TRANSPORT

1.9 GYROPLANE IDENTIFICATION

1.10 BOLTS TORQUE