CABRI® G2

Maintenance Manual
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This manual includes the material required to be furnished to the operator

by EASA CS 27 and Part 21.

Note : It is the user’s responsibility to maintain manual currency.

AIX-EN-PROVENCE, FRANCE

www.guimbal.com
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CABRI G2 TABLE OF CONTENT

Table of content

SECTION A GENERAL.................................................................................................. A-I

A-1 INTRODUCTION ............................................................................................................. A-1
Manual revisions ................................................................................................................ A-1
Abbreviations ..................................................................................................................... A-4
Maintenance authorization ................................................................................................. A-5
Overhaul authorization ....................................................................................................... A-5
A-2 CABRI G2 DESCRIPTION ................................................................................................ A-6
Night-VFR optional equipment ........................................................................................... A-6
External dimensions ........................................................................................................... A-7
A-3 HELICOPTER BASIC SERVICING....................................................................................... A-9

SECTION B MAINTENANCE INSPECTIONS ................................................................ B-I

B-1 INTRODUCTION ............................................................................................................. B-1
B-2 FIRST 25-HOUR INSPECTION .......................................................................................... B-2
B-3 50-HOUR INSPECTION .................................................................................................... B-3
B-4 100-HOUR / 12-MONTH INSPECTION ............................................................................... B-4
B-5 500-HOUR / 60-MONTH INSPECTION ............................................................................... B-5
B-6 SPECIAL INSPECTIONS ................................................................................................... B-6
B-61 Tail skid strike............................................................................................................ B-6
B-62 Tail rotor damage....................................................................................................... B-6
B-63 Main rotor strike ......................................................................................................... B-6
B-64 Rotor / engine overspeed........................................................................................... B-6
B-65 Hard landing .............................................................................................................. B-6

SECTION C AIRWORTHINESS LIMITATIONS ............................................................. C-I

C-1 GENERAL ..................................................................................................................... C-1
C-2 LIMITATIONS ................................................................................................................. C-1
Fatigue life-limited components.......................................................................................... C-1
Structural inspection intervals (On-condition limitation) ...................................................... C-1
Tail structure paint.............................................................................................................. C-2

SECTION D OTHER LIMITATIONS ............................................................................... D-I

D-1 TIME-IN-SERVICE RECORDS ........................................................................................... D-1
D-2 MANUFACTURER TIME LIMITS ......................................................................................... D-2
D-3 OVERHAUL REQUIREMENTS ........................................................................................... D-3
D-4 INCIDENTS AND ACCIDENT REPORTS ............................................................................... D-4

SECTION E MAINTENANCE INSTRUCTIONS........................................................... D-4-I

E-1 MAIN ROTOR ............................................................................................................... E-1-I
Introduction ..................................................................................................................... E-1-1
Description ...................................................................................................................... E-1-1
E-2 MAIN TRANSMISSION ................................................................................................... E-2-I
DESCRIPTION................................................................................................................ E-2-1
E-3 TAIL ROTOR AND TRANSMISSION .................................................................................. E-3-I
DESCRIPTION................................................................................................................ E-3-1
DESCRIPTION................................................................................................................ E-3-1
DESCRIPTION................................................................................................................ E-3-4
E-4 FLIGHT CONTROLS ...................................................................................................... E-4-I
DESCRIPTION................................................................................................................ E-4-1
E-5 ENGINE INSTALLATION ................................................................................................. E-5-I
INTRODUCTION............................................................................................................. E-5-1

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DESCRIPTION ................................................................................................................E-5-1
Description ......................................................................................................................E-5-6
E-6 AIRFRAME ................................................................................................................... E-6-I
DESCRIPTION ................................................................................................................E-6-1
Description ......................................................................................................................E-6-5
E-7 SYSTEMS ....................................................................................................................... E-I
INTRODUCTION .............................................................................................................E-7-1
Description ......................................................................................................................E-7-1
E-8 MISCELLANEOUS ......................................................................................................E-8-17

SECTION F TROUBLE SHOOTING .............................................................................. F-1

SECTION G APPENDIX ............................................................................................... G-1

G-1 APPROVED MATERIAL LIST............................................................................................. G-1
Greases............................................................................................................................. G-1
Oils .................................................................................................................................... G-1
Adhesives.......................................................................................................................... G-2
Sealants ............................................................................................................................ G-2
Torque seal........................................................................................................................ G-2
Paints, primers................................................................................................................... G-3
Varnishes .......................................................................................................................... G-4
Sealing compounds ........................................................................................................... G-4
G-2 SPECIAL TOOLS ............................................................................................................ G-5
G-3 TAIL ROTOR BLADE RIGGING CHECK TEMPLATE ............................................................... G-6
G-4 SAFETY PIN TABLE ........................................................................................................ G-7

SECTION H FLIGHT REPORT MODELS ......................................................................H-1

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Section A General

A-1 INTRODUCTION ............................................................................................................. A-1

Manual revisions ................................................................................................................ A-1
Abbreviations ..................................................................................................................... A-4
Maintenance authorization ................................................................................................. A-5
Overhaul authorization ....................................................................................................... A-5
A-2 CABRI G2 DESCRIPTION ................................................................................................ A-6
Night-VFR optional equipment ........................................................................................... A-6
External dimensions ........................................................................................................... A-7
A-3 HELICOPTER BASIC SERVICING....................................................................................... A-9
A-31 Ground handling..................................................................................................... A-9
A-32 Lubricants ............................................................................................................ A-11
A-33 Defueling.............................................................................................................. A-11
A-34 Doors removal & installation................................................................................. A-12
Door removal ..................................................................................... IPC x-xx ........... A-12
Door installation ................................................................................. IPC x-xx ........... A-12
A-35 Seats removal & installation ................................................................................. A-12
Seats removal .................................................................................... IPC x-xx ........... A-12
Seats installation ............................................................................... IPC x-xx ........... A-13
A-36 Cleaning............................................................................................................... A-13
A-37 Parking, tie-down and covers ............................................................................... A-13
A-38 Hoisting ................................................................................................................ A-14
A-37 Weighing .............................................................................................................. A-15

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A-1 Introduction

This manual contains reference material necessary for proper servicing, maintenance, and
handling of the Cabri G2 helicopter. This manual is to be used in conjunction with the Cabri
illustrated parts catalog, Cabri G2 Flight manual, Cabri G2 Service bulletins, Lycoming O-360
series operator’s manual and O-360-J2A Plasma Amendment to Lycoming operator’s manual,
engine maintenance publication, and any related technical data supplied by equipments
manufacturers.
As necessary, Service bulletins are issued by Helicopteres Guimbal (HG), Textron Lycoming, and
equipments manufacturers. Service bulletins compliance is mandatory, except for HG-
recommended and optional service bulletins.
Always read instructions completely before beginning a task.

Maintenance manual log of applicable pages, maintenance authorizations, helicopter and optional
equipments general description, and helicopter servicing instructions are given in this Section A.

Section B defines the maintenance schedule that is to be carried out on the helicopter to enable
its proper operation. It refers to maintenance actions that are detailed in Section E.

Section C gives authority-approved airworthiness limitations.

Section D gives additional manufacturer limitations together with issue report policy.

Sections E details all maintenance actions that can be carried out by maintenance organizations,
according to the authorities.

Section F describes troubleshooting recommendations.

General data and documentation are given in appendix at the end of this manual.

Manual revisions

Before using this manual, make sure it includes all current revisions.

The following table lists the EASA-approved pages :

Revision Revision
Page number Page number
number number

C-1 03 - -
Section C
Airworthiness limitations
C-2 03 - -

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The following table lists the pages approved under DOA EASA.21J.211 :
Revision Revision
Page number Page number
number number
Cover a 03 - -
Section A A-1 03 A-9 03
General
A-2 03 A-10 03
A-3 03 A-11 03
A-4 03 A-12 03
A-5 03 A-13 03
A-6 03 A-14 03
A-7 03 A-15 03
A-8 03 A-16 03
Section B B-1 03 B-4 03
Maintenance inspections
B-2 03 B-5 03
B-3 03 B-6 03
Section C C-1 03 - -
Airworthiness limitations
C-2 03 - -
Section D D-1 03 D-3 03
Other limitations
D-2 03 D-4 03
Section E E-1-1 03 E-1-9 03
E-1
E-1-2 03 E-1-10 03
Main rotor
E-1-3 03 E-1-11 03
E-1-4 03 E-1-12 03
E-1-5 03 E-1-13 03
E-1-6 03 E-1-14 03
E-1-7 03 E-1-15 03
E-1-8 03 E-1-16 03
E-2 E-2-1 03 - -
Main transmission
E-2-2 03 - -
E-3 E-3-1 03 E-3-7 03
Tail rotor and transmission
E-3-2 03 E-3-8 03
E-3-3 03 E-3-9 03
E-3-4 03 E-3-10 03
E-3-5 03 E-3-11 03
E-3-6 03 E-3-12 03
E-4 E-4-1 03 E-4-6 03
Flight controls
E-4-2 03 E-4-7 03
E-4-3 03 E-4-8 03
E-4-4 03 E-4-9 03
E-4-5 03 E-4-10 03

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Revision Revision
Page number Page number
number number
E-4 E-4-11 03 - -
Flight controls
E-4-12 03 - -
E-5 E-5-1 03 E-5-7 03
Engine installation
E-5-2 03 E-5-8 03
E-5-3 03 E-5-9 03
E-5-4 03 E-5-10 03
E-5-5 03 E-5-11 03
E-5-6 03 E-5-12 03
E-6 E-6-1 03 E-6-6 03
Airframe
E-6-2 03 E-6-7 03
E-6-3 03 E-6-8 03
E-6-4 03 - -
E-6-5 03 - -
E-7 E-7-1 03 E-7-9 03
Systems
E-7-2 03 E-7-10 03
E-7-3 03 E-7-11 03
E-7-4 03 E-7-12 03
E-7-5 03 E-7-13 03
E-7-6 03 E-7-14 03
E-7-7 03 E-7-15 03
E-7-8 03 E-7-16 03
E-8 E-8-1 03 - -
Miscellaneous
E-8-2 03 - -
Section F F-1 03 - -
Trouble shooting
F-2 03 - -
Section G G-1 03 G-5 03
Appendix
G-2 03 G-6 03
G-3 03 G-7 03
G-4 03 G-8 03
Section H H-1 03 H-5 03
Flight report models
H-2 03 H-6 03
H-3 03 H-7 03
H-4 03 H-8 03

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The following table gives the revision list :

Nb Page Revision object Issue Date Approval reference (*)

2-1, 2-2 EASA.R.145 dated 14/12/07

001 Creation 12 / 06 / 08
Approved under DOA EASA
All others
21J.211
EASA.R.C.0.0395 dated
2-1, 2-2
15/09/08
002 Update 04 / 09 / 08
Approved under DOA EASA
All others
21J.211
Update for 500 h Approved under DOA EASA
003 All pages 23 / 10 / 09
inspection 21J.211

(*) EASA letter number or “approved under the authority of DOA EASA 21J.211”

Note : Issue 03 of airworthiness limitations section was approved under DOA. Minor classification
of change was granted by EASA through letter DSAC/NO/NAV-090045.

Abbreviations

HG : Hélicoptères Guimbal company

OC : On-condition
OTL : Operating time limit
TBO : Time between overall

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Maintenance authorization

The only personnel authorized to perform the required inspections or to make repairs are :
• certified airframe & powerplant mechanics who have successfully completed an HG-
certified maintenance course,
• certified airframe & powerplant mechanics who are under direct supervision of an above-
stated mechanic.

Inspections must be performed by mechanics with inspection authorization, or repair stations

certified by the EASA, or by the national authority regulation.
The daily and preflight checks may be accomplished by the above-stated mechanics or by the
pilot, after careful study of the appropriate sections of the Flight Manual.

Overhaul authorization

Only appropriately certified mechanics who have completed an HG-certified course for
overhauling specific components, and possess the special tools and technical data supplied by
HG are authorized to disassemble and overhaul major components as required by Section C .

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A-2 Cabri G2 Description

The Cabri G2 is a two-seat helicopter in the category of CS 27 “Small Rotorcraft”, designed for a
large variety of missions.
It is powered by an aviation piston engine.
It features a conventional architecture, with a three-bladed main rotor, and a shrouded tail rotor.
With basic equipment, it is approved for day-VFR operation.

Its main characteristics are :

• Maximum gross weight .........................................................................................700 kg
• Typical empty weight ...........................................................................................425 kg
• Typical full power level speed ................................................................................100 kt
• Service ceiling .................................................................................................. 13.000 ft

• Engine ........................................................................................... Lycoming O-360-J2A

Atmospheric 180 hp derated to 145 hp
One Plasma electronic ignition system - One magneto

Night-VFR optional equipment

The night-VFR optional equipment is composed of :

• A wider instrument panel,
• Instrument panel lighting, with backup mode in direct battery,
• Two map lights, controlled through a switch on the overhead control module. This same
switch also activate the backup instrument panel lighting,
• Three gyroscopic instruments :
o Artificial horizon,
o Directional gyroscope,
o Turn coordinator.
• One approved primary navigation mean (VOR or approved GPS)
• A specific night vision filter for the EPM.

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External dimensions

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A-3 Helicopter basic servicing

A-31 Ground handling

Ground handling should only be done with approved wheels attached on dedicated attachment
points.

Caution : No one should be sitting in the helicopter during ground handling.

The two ground handling wheels are identical and can be used on the right or on the left without
distinction. They are composed of a tire, rims, a hub and a skid-interface part that can rotate
around the hub to raise the helicopter.
There is one lever for both wheels.
A locking pin is attached to each wheel.

Locking pin
Lever

Attaching tab

Installing the wheels

First, ensure that the rotating part is extended as shown :

Then install the wheel on the skid. Ensure that the supporting tab is fully engaged on the
shouldered bolts :

Shouldered bolts

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Engage the lever in the spindle,

Rotate 180 deg to raise the helicopter,
Lock with the push-pin.

Note : On very soft ground it might be necessary to fit both wheels on the skids
before raising the helicopter.

Caution :
• Make sure that the helicopter is clear from any obstacle since it may
move while it is raised.
• Do not let the lever go off to avoid a harmful back movement.

When both wheels are secured, maneuver the

helicopter as follows :

Use the vertical tail gearbox support tube as a handle

(right hand only) to raise the helicopter nose, and
maneuver.

Warning : Make sure that the blades won’t hurt your

fingers if they rotate. Do not use the shroud structure
as a handle.

Handing zone

Additional people can push the helicopter on the engine cowlings or main gear bow.

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A-32 Lubricants
Main and tail rotor gearboxes lubrication requirements are given by Cabri G2 Flight Manual.
Engine lubrication requirements are given by Cabri G2 Flight Manual and Lycoming Service
instruction 1014 (current revision).

All Cabri G2 bearings are sealed or self-lubricated and do not require frequent greasing. Refer to
Section B for specific periodic required greasing.

A-33 Defueling
When fueling or Defueling the helicopter, use only adequate hoses and tanks, with protection
against static electricity hazard.
Place a container under the gascolator valve.
Open and lock the gascolator drain valve :

Switch Master and Electrical fuel pump ON.

Switch OFF when fuel tank is empty.

Note : Use the opportunity if you can, when emptying the fuel tank, to check the
low-fuel warning light :
• watch the light below 20 liters or 5 US gal indicated,
• when it lights up, close the main fuel valve and wait for the indicated
quantity to stabilize. Note the quantity A,
• use appropriate container to measure the real quantity B remaining to
exhaustion.
B should be 12 +/- 2 liters (3.2 +/- 0.5 US gal)
If not, check the low fuel switch per operation 55-A-02

A - B (absolute) should be less than 2 liters (0.5 US gal)

If not, calibrate the fuel gage per operation 55-A-03

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A-34 Doors removal & installation

The right and left door can be removed for flight, per Flight Manual conditions.
Removal and installation require no tool.

Door removal IPC x-xx

a) Open the door,
b) Remove the small circular locking clip from either gas spring attachment. Snap the rod
end off, and secure the gas spring,
c) Remove the two hinges lock pins, and save the washers,
d) Slide the door off. Save the washers and pins on the door hinges.

Door installation IPC x-xx

a) Remove the lock pins from the door hinges,
b) Install the door, and check the plastic bushings,
c) Install one washer and one lock pin on each hinge.

Note : The lower hinge has its plastic bushing inverted, to take the upward
thrust from the gas spring. The washer is then important.

d) Snap the gas spring rod end on its sphere, and install the small locking pin in the rod
end.

Caution :
• Never install the gas spring without the hinge pins : the gas spring exerts
an upward force that would eject the door .
• The gas spring should be installed in the right direction : rod facing
inside/forward, body on the door side.

A-35 Seats removal & installation

The two seats are identical and can be exchanged.

The left seat may be removed and reinstalled as required, for particular missions or other
reasons. Flight is permitted without the left seat, with no particular restriction.

Removal/installation of a seat requires :

• One 13 mm wrench
• One 13 mm ¼” ratchet wrench

Caution : Always remove the copilot collective, cyclic sticks and pedals before
removing the passenger seat, and keep them secured when flying. They can
be stored in the nose baggage compartment.

Seats removal IPC x-xx

a) Reach below the seat pan. Remove the safety pin on the inner nut. DO NOT remove the
cotter pin on the other nut,
b) Release the nut. Pull the long stud outward as permitted,
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c) Rotate the absorber end backward slightly,
d) Slide the seat pan upward. Slamming may be necessary.
e) When the upper red slides escape the rails, rotate the seat forward, and release it from
the rails.
f) Remove the long go-through stud, to release the seat belt fitting if needed to remove the
seat from the cabin.

Seats installation IPC x-xx

a) Install the two aluminum spacers in the seat pan attachment holes,
a) Install the long go-through stud, with its nut and cotter pin, on the outer side of the seat,

Caution : Engage the inner seat belt fitting in the go-through stud before
installing the seat.

b) Holding the seat pan tilted forward approx. 20°, engage the two lower red slides in
corresponding slots in the rails,
c) Tilt the seat pan back, to engage the upper slides in the rails. When engaged, slam the
seat down until the upper (brown plastic) slides ends are flush with the rails ends.
d) Reach under the seat, and rotate the absorber forward to slide its clevis end between the
two aluminum spacers,
e) Push the long stud through the spacers. Engage the inner seat belt fitting, then washer,
castle nut.
f) Mark the stud for the safety pin hole orientation. Tighten the long stud to
contact plus one turn. Complete torque as needed to the next slot. Install the safety
pin.
g) Check the seat belt and shoulder harness.

A-36 Cleaning
Use only for cleaning the helicopter, products that are fully compatible with paint, acrylic
transparencies, natural rubber, plastics. Avoid detergents and solvents.
Do not use high pressure cleaner.

Do not spray magneto, electronic and electrical parts, main rotor hub, tail rotor gearbox
and swashplate area with high pressure water.

A-37 Parking, tie-down and covers

Refer to Flight Manual procedure, Section 8.

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A-38 Hoisting

Hoisting can be done with or without the tail, the cowlings or the engine installed. It cannot be
done with the engine and the tail removed together.
Hoisting is done with the special hook G81-01-100.
Install the hook above the rotor hub plastic plug, with the three studs in corresponding holes.
Take care to avoid scratching the paint.
Install the three nuts, each with a rubber and metal washer.
Screw the nuts to contact only. Check for a minimum of two threads protruding.
Use any appropriate sling or shackle to hoist.

Caution : When hoisting the helicopter with its tail installed, anticipate a
significant pitch-up motion, due to aft CG. Hold the tail to prevent shock and
damage.

When hoisting is necessary, and the hook not available, use an approximately 2 meter long, 12
mm diameter soft synthetic rope, of 4 kN (900 lbf) minimum strength around the main rotor hub.
The rope should be slipped between the blades root and the main rotor hub, just above the droop
stop ring. It should form three loops, one in each blade interval. The third loop is closed by
attaching both ends together.
The rope is then moved upward between the hub and the spherical bearings and through the
three hub holes. The helicopter can then be hoisted with a snap-hook as shown :

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A-37 Weighing

Refer to Flight Manual procedure, Section 6, for weight and balance.

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Section B Maintenance inspections

B-1 INTRODUCTION ............................................................................................................. B-1

B-2 FIRST 25-HOUR INSPECTION .......................................................................................... B-2
B-3 50-HOUR INSPECTION .................................................................................................... B-3
B-4 100-HOUR / 12-MONTH INSPECTION ............................................................................... B-4
B-5 500-HOUR / 60-MONTH INSPECTION ............................................................................... B-5
B-6 SPECIAL INSPECTIONS ................................................................................................... B-6
B-61 Tail skid strike............................................................................................................ B-6
B-62 Tail rotor damage....................................................................................................... B-6
B-63 Main rotor strike ......................................................................................................... B-6
B-64 Rotor / engine overspeed........................................................................................... B-6
B-65 Hard landing .............................................................................................................. B-6

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B-1 Introduction

This section describes the inspections that the maintenance organization has to carry-out in order
to maintain the helicopter in airworthy condition.

The inspections can be scheduled and periodic or linked to an event such as a disassembly or a
incident.

The required periodic maintenance inspections are :

• First 25 hours in service, or first 25 hours since installation of a new or rebuilt engine,
• 50 hours in service,
• 100 hours in service, or 12 months, whichever occurs first,
• 500 hours in service, or 60 months, whichever occurs first,
• Overhauls as prescribed page D-3.

The tolerance for these periodicity are as follows :

• + 10 % on 50-hour periods, with no report
• + 10 % on 100-hour periods, with no report
• + 10 hours on 500-hour period, with no report

The programs for these inspections are given in this section. They can refer to maintenance
instructions that are detailed in Section E of this manual.

Additional maintenance requirements

In addition to this manual’s requirements, the maintenance organization has to check for
applicable Airworthiness Directives and Service Bulletins issued by HG and equipments
manufacturers.

Limitations
In addition to these inspections, the operator should respect the airworthiness limitations (time
limits, inspection intervals) given page C-1 and C-2 and other manufacturer limitations given in
Section D of this manual.

Maintenance depending on events

In case of any event described at the end of this section, the prescribed special inspections have
to be carried out before resuming flight.

Issue reports
In case of any deviation, it should be reported as described in Section D of this manual.

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B-2 First 25-hour inspection

After the first 25 hours in service, the helicopter has to undergo the following operations :

Component Reference Operation Operation #

Main rotor hub G12-00-000 Torque check 12-A-02
Main rotor gearbox G21-00-000 Inspection 21-A-01
Tail rotor gearbox G31-00-000 Flush & Oil change 32-A-02
Inspection & Oil Textron Lycoming Operator’s
change manual Section 4-2.
Engine installation G50-00-000 HG Plasma Installation,
Inspection operator’s and maintenance
manual Section 4-2.

In addition, after installation of a new or overhauled engine, the helicopter has to undergo the
following operations :

Component Reference Operation Operation #

Inspection & Oil Textron Lycoming Operator’s
change manual Section 4-2.
Engine installation G50-00-000 HG Plasma Installation,
Inspection operator’s and maintenance
manual Section 4-2.

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B-3 50-hour inspection

Every 50 hours in service, the helicopter has to undergo the following operations :

Component Reference Operation Operation #

Main rotor blade G11-00-000 Inspection 11-A-02

Spherical bearings G13-00-000 Inspection 13-A-02
Lead-lag dampers G14-00-000 Inspection 14-A-02
Main gearbox G21-00-000 Inspection 21-A-01
Blades inspection & repair 31-B-01
Tail rotor G31-00-000
Tension packs inspection 31-B-02
Tail gearbox G32-00-000 Inspection 32-A-01
Tail rotor drive shaft G33-00-000 Inspection 33-A-01
Engine Textron Lycoming
Operator’s manual
G50-00-000 50-hour or 4-month inspection SECTION 4-3
Inspection 50-A-01
Engine installation
HG Plasma Installation,
Electronic ignition operator’s and
G50-01-000
50-hour or 4-month inspection maintenance manual
SECTION 4-3-(a)
Transmission belt G51-00-000 Inspection 51-A-01
Fuel system G55-00-000 Gascolator cleaning 55-A-01

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INSPECTIONS CABRI G2

B-4 100-hour / 12-month inspection

Every 100 hours in service, or every 12 months, whichever occurs first, the helicopter must
undergo the following operations, in addition to the 50-hour inspection :

Component Reference Operation Operation #

Main rotor G10-00-000 Dampers rod-ends free-play 14-A-04

Droop stop ring inspection
Droop stop ring G12-01-000 12-B-01
& regreasing
Rotor brake G34-00-000 Inspection 34-A-01
Pitch links backlash check 41-B-04
Flight controls G41-00-000 Swashplate inspection 41-A-01
Swashplate regreasing 41-A-02
Engine Textron Lycoming OM
G50-00-000 100-hour inspection SECTION 4-4

Engine installation Engine diagnostic 50-A-02

Electronic ignition Amendment to Textron

G50-01-000 Lycoming OM
100-hour inspection SECTION 4-4-(a)
Belt inspection 51-A-01
Primary transmission G51-00-000
Pulley inspection 51-A-02
Induction circuit inspection 53-A-01
Induction G53-00-000 Air filter replacement 53-A-04
Carburetor heater check 53-A-03
Fuel system G55-00-000 Fuel circuit inspection 55-A-01
Plexiglas inspection 61-A-02
Fuselage G61-00-000
Fuselage & cowlings inspection 61-A-01
Landing gear G62-00-000 Landing gear inspection 62-A-01
Engine mount G64-00-000 Engine mount inspection 64-A-01
Tail structure inspection 65-A-01
Tail structure G65-00-000
Tail skid inspection 65-A-05
Electrical system G71-00-000 Inspection 71-A-01
Pitot and static inspection 72-A-01
Instrument panel and
G72-00-000 Avionics & antennas 72-C-01
avionics
ELT inspection & test 72-C-02
Emergency floats G91-00-000 Inspection 91-A-01
Air conditioning G92-00-000 Inspection 92-A-01

When the program is completed, a ground run followed by a hover should be carried out. Oil and
grease leaks should then be looked for.

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CABRI G2 INSPECTIONS

B-5 500-hour / 60-month inspection

Every 500 hours in service, or every 60 months, whichever occurs first, the helicopter must
undergo the following operations, in addition to the 50-hour and 100-hour inspections :

Component Reference Operation Operation #

Main gearbox G21-00-000 Flush & Oil change 21-A-01

Detailed tension pack
31-B-03
Tail rotor hub G31-00-000 inspection
Plastic bearings check 31-B-05
Flush & Oil change 32-A-02
Tail rotor gearbox G32-00-000
Blades tip clearance check 32-A-03
Tail rotor drive shaft G33-00-000 Bearings regreasing 33-A-02
Thrust bearing inspection
Engine installation G50-00-000 51-A-03
& regrease
Main rotor controls inspection 41-B-01
Flight controls G40-00-000 Tail rotor controls inspection 41-C-01
Engine control inspection 44-A-01
Electronic ignition Electronic ignition inspection 50-B-02
G50-00-000
system Sparkplugs & wires inspection 50-B-03

After this program is completed, a flight check should be carried out per procedure defined in 0.

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B-6 Special inspections

B-61 Tail skid strike

Inspect and repair per operation 65-A-05

B-62 Tail rotor damage

Inspect and repair per operation 31-B-01

B-63 Main rotor strike

Inspect and repair per operations 11-A-05 & 11-A-06

B-64 Rotor / engine overspeed

TBC

B-65 Hard landing

In case of hard landing the following inspection shall be carried out. to detect yielding and/or
interference between parts :

a) Check the landing gear per operation 62-A-01,

b) Inspect the engine mount attachment to the structure per operation 64-A-01,

c) Inspect the tail boom attachment to the truss structure per operation 65-A-01,

d) Inspect the main gearbox attachment through the luggage compartment per operation
21-A-01,

e) Inspect the tail boom at the upper fin root, for clue of main blade strike,

f) Inspect the tail rotor shroud for marks of blades contact,

g) Check the tail skid per operation 65-A-05,

h) Check droop stops and mating plates for marks per operation 12-B-01,

i) Check Main rotor mast cap and mating blades forks edges for marks of interference,

j) Check the blades per operations 11-A-05 & 11-A-06.

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CABRI G2 AIRWORTHINESS LIMITATIONS

Section C Airworthiness limitations

C-1 GENERAL ..................................................................................................................... C-1

C-2 LIMITATIONS ................................................................................................................. C-1
Fatigue life-limited components.......................................................................................... C-1
Structural inspection intervals (On-condition limitation) ...................................................... C-1
Tail structure paint.............................................................................................................. C-2

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This airworthiness limitation section is approved by the EASA.

C-1 General

This chapter lists all parts or assemblies that are submitted to one or more airworthiness
limitations, and defines these limitations.

They can be in either of the following forms :

- Life limit : at the end of this life limit, the life limited component has to be scrapped.
- Inspection interval : these inspections have to be carried out periodically on a
limited number of times to ensure the component’s airworthiness condition.
- Specific rules

Note : Whenever an inspection requires a measurement or a description, the data have to be

noted on a specific card attached to the part.

Warning :
- Meeting these requirements is mandatory to ensure the helicopter’s airworthiness.
- Life limit and inspection intervals shall not be exceeded.
- Any deviation has to be the object of a request to EASA and HG. It requires formal
approval from both of them before implementing.

C-2 Limitations

Fatigue life-limited components

All parts are substantiated without life limitation.

Structural inspection intervals (On-condition limitation)

Following components have to be inspected before the prescribed time limit :

MAIN ROTOR BLADE P/N G11-00-000

Designation Part number Operation # Limit value

15 h /
11-A-01
last flight of the day
Main rotor blade G11-00-000
11-A-02 50 h

SPHERICAL BEARING P/N G13-00-000

Designation Part number Operation # Limit value

15 h /
13-A-01
Spherical last flight of the day
G13-00-100
bearing
13-A-02 50 h

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AIRWORTHINESS LIMITATIONS CABRI G2
LEAD-LAG DAMPER P/N G14-00-000

Designation Part number Operation # Limit value

15 h /
14-A-01
last flight of the day
Lead-lag damper G14-00-100
14-A-02 50 h

TAIL ROTOR P/N G31-00-000

Designation Part number Operation # Limit value

Tail rotor blade 31-B-02 50 h

G31-05-100
assembly inspection 31-B-03 500 h

TAIL ROTOR DRIVE SHAFT P/N G33-00-000

Designation Part number Operation # Limit value

15 h /
33-A-05
last flight of the day
Flexible coupling pack G33-00-000
33-A-06 50 h

Tail structure paint

The horizontal stabilizer surface (excluding the tips), and the tail boom upper surface must be
painted glossy white only. The restricted area is limited to 20° above the tail boom horizontal mid-
line :

WHITE GLOSSY

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CABRI G2 OTHER LIMITATIONS

Section D Other limitations

D-1 TIME-IN-SERVICE RECORDS ........................................................................................... D-1

D-2 MANUFACTURER TIME LIMITS ......................................................................................... D-2
D-3 OVERHAUL REQUIREMENTS ........................................................................................... D-3
D-4 INCIDENTS AND ACCIDENT REPORTS ............................................................................... D-4

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D-1 Time-in-service records

It is the operator’s responsibility to maintain accurate time-in-service records of the airframe and
of following components :

Designation Part number

Main rotor blade G11-00-0xx
Main rotor hub G12-00-1xx
Spherical bearing G13-00-1xx
Lead-lag damper G14-00-1xx
Main gearbox G21-00-0xx
Tail gearbox G32-00-0xx
Transmission shaft assembly G33-00-0xx
Swashplate assembly G41-00-0xx
Tail rotor flexible push-pull control G41-00-1xx
G55-00-1xx
Fuel bladder
or G55-04-1xx
Fuselage G61-23-1xx
Engine mount G64-00-8xx
Engine mount struts G64-00-8xx
Tail boom G65-00-1xx
Horizontal stabilizer G65-05-1xx
Electronic pilot monitor - EPM G72-15-2xx
Seat belts Refer to § D-2

The approved lives or intervals are based on operation time count given by the hourmeter.
Totally consistent with the EPM flight time counter, the hourmeter counts whenever the main rotor
tachometer exceeds 450 RPM (refer to Flight Manual BARC description).

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D-2 Manufacturer time limits

These limits are time limits given by the manufacturer in order to keep the aircraft in airworthy
conditions. In order to ease maintenance schedule, those limits can be exceeded by a maximum
of 10% of flight hours or 6 months in calendar time.

FUEL TANK P/N G55-00-000

Designation Part number Limit type Limit value

Fuel bladder G55-04-100 OTL 15 Y

SEAT BELT P/N G66-00-000

Designation Part number Limit type Limit value

HG64-0971
Schröth P/N 110Q70501
HG64-0972
Schröth P/N 110Q75501
Seat belt OTL 12 Y
HG64-1428
Schröth P/N 510192-01
HG64-1429
Schröth P/N 510191-01

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D-3 Overhaul requirements

The following assemblies must be overhauled before the prescribed limit value.

MAIN ROTOR GEARBOX P/N G21-00-000

Designation Part number Limit type Limit value

Main rotor gearbox G21-00-100 TBO 3000 H

TAIL ROTOR GEARBOX P/N G32-00-000

Designation Part number Limit type Limit value

Tail rotor gearbox G32-00-100 TBO 3000 H

ENGINE P/N G50-00-000

Designation Part number Limit type Limit value

12 Y
Engine O 360 J2A Plasma TBO
2000 H

As part of the TBO validation program, HG can carry out gearbox inspections on sample
helicopters before the above specified periods.

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D-4 Incidents and accident reports

Reporting every accident, failure, defect, malfunctioning or any incident that may have a
detrimental effect on airworthiness is a key factor to maintain airworthiness and ensure
continuous flight safety improvement.

Report to the authority : The operator must report any incident or accident to the airworthiness
authority he is subjected to, according to the local regulation.

Report to HG : the operator has to report to HG any accident or incident that was discovered
during operation or maintenance work.
These events include, but are not limited to :
- Incorrect assembly of helicopter parts or components found during an inspection or
test procedure not intended for that specific purpose,
- Any defect in a life-limited part causing its retirement before completion of its full
life,
- Any damage or deterioration (i.e. fractures, cracks, corrosion, delamination,
debonding, etc) resulting from any cause to any part of the helicopter.
- Any failure, malfunction or defect of any system or equipment, or damage or
deterioration found as a result of compliance with an Airworthiness Directive or
other mandatory instruction issued by a Regulatory Authority, when :
-

it is detected for the first time by the reporting organization implementing

compliance,

on any subsequent compliance where it exceeds the permissible limits
quoted in the instruction and/or published repair/rectification procedures are
not available.
- Failure of any emergency system or equipment, including all exit doors and
lighting, to perform satisfactorily, including when being used for maintenance or
test purposes.
- Non compliance or significant errors in compliance with required maintenance
procedures.
- Products, parts, appliances and materials of unknown or suspect origin,
- Misleading, incorrect or insufficient maintenance data or procedures that could lead
to maintenance errors,
- Failure, malfunction or defect of ground equipment used for test or checking of
aircraft systems, when the required routine inspection and test procedures did not
clearly identify the problem, if this results in a hazardous situation.

The report should include the following information :

event type : accident, incident, other,
event date, duration, and location,
the origin of the detection,
detailed identification of concerned aircraft and components (aircraft type, serial number, detailed
configuration, total flight time, flight time since last maintenance, components identification, flight
time)
A detailed description of the event.

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CABRI G2 MAIN ROTOR

Section E Maintenance instructions

E-1 Main rotor

Introduction ..................................................................................................................... E-1-1

Description ...................................................................................................................... E-1-1
10-A MAIN ROTOR ..................................................................................................... E-1-2
10-A-01 Main rotor removal (assembled) ........................................ IPC x-xx .......... E-1-2
10-A-02 Main rotor installation (assembled) ................................... IPC x-xx .......... E-1-2
10-A-03 Main rotor track & balance .................................................. IPC x-xx .......... E-1-3
11-A MAIN ROTOR BLADES ..................................................................................... E-1-4
11-A-01 Main rotor blades daily check .............................................. IPC x-xx .......... E-1-4
11-A-02 Main rotor blades complete inspection ............................... IPC x-xx .......... E-1-4
11-A-03 Main rotor blades removal ................................................... IPC x-xx .......... E-1-4
11-A-04 Main rotor blade installation ............................................... IPC x-xx .......... E-1-5
11-A-05 Main rotor blades erosion caps inspection & criteria ......... IPC x-xx .......... E-1-6
11-A-06 Main rotor blades damage criteria and repair ..................... IPC x-xx .......... E-1-6
12-A MAIN ROTOR HUB............................................................................................ E-1-8
12-A-01 Main rotor hub inspection ................................................... IPC x-xx .......... E-1-8
12-A-02 Main rotor Thrust bolts torque check ................................. IPC x-xx .......... E-1-8
12-A-03 Main rotor hub removal ...................................................... IPC x-xx .......... E-1-9
12-A-04 Main rotor hub installation ................................................... IPC x-xx .......... E-1-9
12-A-05 Main rotor hub repair ........................................................... IPC x-xx ........ E-1-10
12-B DROOP STOPS.............................................................................................. E-1-11
12-B-01 Droop stops inspection ........................................................ IPC x-xx ........ E-1-11
12-B-02 Droop stop plates replacement ........................................... IPC x-xx ........ E-1-11
12-B-02 Droop stop ring and guides removal & inspection .............. IPC x-xx ........ E-1-11
12-B-03 Droop stop ring and guides installation ............................... IPC x-xx ........ E-1-11
13-A SPHERICAL BEARINGS................................................................................. E-1-12
13-A-01 Spherical bearings daily check............................................ IPC x-xx ........ E-1-12
13-A-02 Spherical bearing inspection & criteria................................ IPC x-xx ........ E-1-12
13-A-03 Spherical bearing removal................................................... IPC x-xx ........ E-1-13
13-A-04 Spherical bearing installation .............................................. IPC x-xx ........ E-1-13
14-A LEAD-LAG DAMPERS ................................................................................... E-1-14
14-A-01 Lead-lag dampers daily check ............................................ IPC x-xx ........ E-1-14
14-A-02 Lead lag damper detailed inspection & criteria ................... IPC x-xx ........ E-1-14
14-A-02 Lead lag damper removal.................................................... IPC x-xx ........ E-1-14
14-A-03 Lead-lag damper installation ............................................... IPC x-xx ........ E-1-14
14-A-04 Lead-lag damper inspection : Rod-end radial play ............. IPC x-xx ........ E-1-15
14-A-05 Lead-lag damper rod-ends replacement ............................. IPC x-xx ........ E-1-16

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Introduction
This section contains the procedures and requirements for proper maintenance and servicing of
the main rotor. It includes the main rotor blades and hub, spherical bearings and lead-lag
dampers.

Description
The main rotor is three-bladed, fully articulated. Each blade is attached to the rotor hub by a
spherical laminated bearing, and partially retained dragwise by an elastomeric damper.

The rotor hub is machined from forged aluminum, and features a filament-wound outer ring to
give a high tolerance to damage. It is attached to the rotor mast by a pair of high resistance
plastic cones and a preloaded thrust nut.

Rotor Hub and blades

The rotor hub is removable from the mast, for its maintenance purposes, as well as for
swashplate removal.

Note : The complete rotor can be removed assembled with its blades, per operation 10-A-01.

The blades are made of high-grade fiberglass filament winding, with carbon fiber skins, and PMA
foam core. They are protected against erosion by a thick CR steel leading edge cap, and against
lightning damage by copper mesh and a copper foil.
They include a plain steel tip mass, with four balancing cavities.
Tip mass,
Balancing cavities
and tip plate

Fork root and

damper attachment Leading edge caps Copper mesh
Copper foil (Both sides)
(lower side)

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10-A MAIN ROTOR

10-A-01 Main rotor removal (assembled) IPC x-xx

Removing the complete rotor with its blades enables to save significant time. It is indicated when
removing the rotor is very temporary, in such cases as swashplate replacement, or gearbox
replacement.
It requires a 3.5 m high gantry, or tackle. A 100 kg capacity is sufficient, but a 500 kg capacity is
better to save a pulling tool. It can be done by one person alone.

a) Remove the rotor hub plastic cap and thrust nut, per operation 12-A-03,
b) Mark with a permanent felt pen the relative angular positions of the mast and the hub.
This is to retain the best balancing
c) Disconnect the three pitch links at either end (pitch horns or swashplate), as preferred
for following work,
d) Protect the loose pitch links against knocking to the surrounding structure or mast,
e) Disconnect the rotating scissors, at either end of the “H” link. Beware to keep the two
bushings and the two washers with the long bolt,
f) Prepare to hoist the helicopter per operation A-38 of section A above,
g) Lift carefully a few centimeters, checking that the rotor actually pulls up from the mast,
h) Lift completely the rotor to clear the mast,
i) Remove the two plastic thrust cones, and the thrust washer, clean and keep with the
thrust nut,
j) Secure any two blades tips to prevent the rotor from swinging.

Caution : Keep the lead-lag dampers installed during this operation.

10-A-02 Main rotor installation (assembled) IPC x-xx

a) Clean and check the splines, the cones bearing surfaces, and the two plastic thrust
cones. Remove any mark of fretting (dark or brown marks) with scotch brite, or 600-grit
abrasive paper. Touch-up paint damage in the hub cone’s bearing surfaces with HG31-
0031 primer. Apply a very light and even coat, with an airbrush only, after sanding with
600-grit abrasive paper,
b) Slide the lower split plastic cone on the mast, to its mating surface,
c) Apply a thin and even coat of HG31-0017 chromate compound on the splines,
d) Move the helicopter to align the mast under the hub; rotate the mast to align the
disassembly marks,
e) Release the blades tip securing,
f) Descend very carefully the rotor, while guiding the lower plastic cone in the hub, and the
splines engagement on the mast,
g) Release the hook and the hoisting installation,
h) Install the upper plastic thrust cone, the thrust washer and nut, and complete the
installation per operation 12-A-04,
i) Install the “H” scissor link bolt. Torque to 7.5 - 9 N.m - install cotter pin,
j) Connect the three pitch links. Torque to 7.5 - 9 N.m - install cotter pin.

Caution : be careful for the two bearing washers, and bushing position inside
the scissor H-link. Check for a small free-play in the scissors after torquing.

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10-A-03 Main rotor track & balance IPC x-xx

Instrumentation - Preparation

a) Ground balance
b) Ground track
c) Hovering track
d) Hovering balance
e) Cruise track
f) Weights addition/subtraction
g) Finishing

When the track and balance is correct, safety-wire the tip bolts.

Note : The balance weights can make some noise inside when the blade’s tip is shaken. It also
may happen when the engine is idling on the ground, with the rotor stopped. This is normal.

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11-A MAIN ROTOR BLADES

11-A-01 Main rotor blades daily check IPC x-xx

The main rotor blade leading edge is protected by a two-part, bonded high resistance stainless
steel cap,

Inner cap Outer cap

This bonding should be checked during daily and inter-flight checks, per Flight Manual.

If a local debonding is reported following these checks, proceed to a detailed inspection per
operation 11-A-02.

11-A-02 Main rotor blades complete inspection IPC x-xx

The main rotor blades can be inspected as installed on the helicopter.

a) Inspect the leading edge cap for debonding per operation 11-A-05,
b) Inspect the paint for erosion or damage,
c) Inspect thrust bolts & nuts : no marks of fretting or corrosion at interface, locking tab
correctly engaged,
d) Inspect interface with the spherical bearing : no marks of fretting,
e) Inspect the fork attachment : no crack, nick, mark of erosion, no debonding around the
bushings,
f) Inspect the lead-lag dampers attachment tabs (blade side, hub side) : no corrosion, no
crack, no debonding,
g) Inspect the leading edge for erosion, impacts, cracks,
h) Inspect the tip plate for erosion or corrosion,
i) Inspect the two tip bolts and safety wire.

Damage criteria and repair are described per operation 11-A-06

11-A-03 Main rotor blades removal IPC x-xx

This operation requires two people, and two blades supporting masts.
The operation is possible standing on the baggage door, but a step ladder is desirable.
The lead-lag dampers can be removed with the blades, or left attached to, the hub indifferently.

One can remove one, two or three blades.

Steps a) to d) should be done for all the blades to remove before proceeding.

a) Bend back the tab on the nuts locking plate,

b) Remove the nuts with a long wrench and 24 mm socket, and remove the locking plate,
c) Remove the bolt linking the pitch link to the pitch horn. Protect the loose pitch link
against knocking the structure,
d) Remove the lead-lag damper attachment bolt at desired position blade or hub. Protect
loose dampers against knocking the blade or the hub,

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e) If the blade above the rotating scissors is to be removed, then remove the bolt attaching
the scissor’s H-link to the hub. Protect the loose scissor against knocking to the
swashplate.
f) Raise two blades to approximately zero coning, by supporting them with a mast with
cushion,
g) To remove the other blade, ask another operator to raise slowly its tip until the big bolts
slip freely by hand. Then ask the other operator at tip to freeze, and remove both bolts
together with the pitch horn,
h) Slip the blade fork out carefully, keeping it perfectly level,
i) Store the blade on an appropriate surface with cushion.

Caution : Never leave one or two blades installed and resting on their droop
stop for more than a few hours. In this case, support each blade on a mast to
prevent spherical bearing creeping.

Caution : Releasing the blade tip while the two bolts are partly removed can
badly damage the blade attachment. Remove the bolts at once, then
immediately slip the blade fork out.

Notes :
• It is preferable to slip the two bolts together with the pitch horn; hold it together in one hand.
• Using a mallet at beginning can be helpful, but should not be necessary; in case one bolts is
hard to remove, keep the other one installed, screw a long 6 mm bolt inside the seized bolt
tip thread (minimum six threads engaged), and use a mallet for pushing back.

11-A-04 Main rotor blade installation IPC x-xx

This operation requires two people, and two blades supporting masts.
The operation is possible standing on the baggage door, but a step ladder is desirable.

a) Prepare the blades, lead-lag dampers, rotor hub and swashplate for assembly.

Caution : Assort the correctly-colored (yellow, green, red) parts for each
position : blade, damper, pitch horn, and install each blade at proper position
for the pitch link color.

b) Before raising a blade, prepare a pitch horn fit with two thrust bolts and a droop stop
plate, within the reach of the operator at the hub,
c) Raise the blade with an assistant at blade tip, so as to align it with the spherical bearing,
d) When the alignment is perfect, slide the blade fork on the spherical bearing, while the
assistant freezes his position,
e) Align one set of bores together, and press one bolt in place. The assistant can now
move slightly,
f) Command fore-and-aft movement to the assistant, so as to align the other set of bores,
then press the second bolt in place,

Warning : Never use your finger to check the bores alignment, as it would be
cut in case the assistant drops the blade.

Slide the lead-lag damper’s rod end in its attachment, and press-in a bolt with a proper washer
(check side),
Rotate the blade to prepare for the next one, and support it in a higher-than-horizontal position,
Install the next blades in the same manner. When the three blades are installed, they can be
released on their droop stops,

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Following steps are for each blade :

a) Install all the locking plates with the tab facing outwards, then large nuts. Torque the two
nuts firmly, then to 120 – 170 N.m. Use the blade root as a lever to counter the torque,
b) On the damper attachment bolt, install the proper washer (check chamfer outside) and
nut. Torque nut to 19 - 23 N.m and install cotter pins,
c) Connect the pitch link to the pitch horn, and install the bolt,
d) Install the washer and the nut. Torque to 7.5 - 9 N.m and install cotter pin,

e) Connect the rotating scissor at its H-link per operation 41-A-07

11-A-05 Main rotor blades erosion caps inspection & criteria IPC x-xx

Use a stepladder to closely inspect both upper and lower faces. A debonding is more likely to
occur on the upper face.
Check all the steel cap surface for debonding, by tapping it gently with the edge of a coin. Use an
approximate 50 mm pace on the middle, and an approximate 20 mm pace along the caps edges.
Tighten the pace in case of doubt.

A debonding is easily detected by a change in sound, becoming more hollow.

If a debonded area is detected, mark its limits with a dotted line of thin permanent black marker.

A blade should be removed from service and sent for repair as soon as :

• A debonded area is longer than 200 mm (8 in) or,

• Cumulated debonded area span is longer than 300 mm (12 in), or
• A debonded area extends chordwise continuously from the upper cap edge to the lower
cap edge.

11-A-06 Main rotor blades damage criteria and repair IPC x-xx

Though they deserve extreme care, the Cabri G2 blades feature some tolerance, and were
qualified for flight with significant damage.

Following damage to the blades can be repaired on the helicopter, or on the bench :

a) Local paint damage

Paint can be touched-up on areas up to 60 cm² (10 sq.in) approximately. Prepare the
surface using 600-grit sandpaper; use a fine spray gun or a brush for small areas.
Use HG31-0177 primer then HG31-1303 (blue) top coat. Use HG31-1307 (bright
yellow) top coat for blade tip.
Repair can be blended using 100-grit sandpaper, then polished with coarse-cut
polish for better aspect.

b) Local shock or scratch on the carbon fiber skins

The damaged area should not exceed 2 cm² (0.5 sq.in) inside the carbon fiber skin, and
should not extend deeper than the skin.
Sand with 220-grit sandpaper through all the crushed area. Inspect closely to check that
the glass (white) structure is not damaged.
Touch-up paint per step a) above. Polyester filler can be used prior to paint touch-up to
improve the aspect.
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c) Dent in the trailing edge

A dent as deep as 3 mm (1/8 in) chordwise and as long as 12 mm (1/2 in) spanwise
can be repaired. If the carbon fiber is only delaminated and crushed, use HG32-0048
adhesive locally. Fair after curing using 220-grit sandpaper. Touch-up paint per a) above.

d) Corrosion at the tip plate

If corrosion is detected around the tip plate, remove it. Remove the corrosion using 600-
grit abrasive. Protect exposed areas with HG31-0031 primer.
If corrosion is detected in the blades cavities, apply a thin coat of HG31-0017 chromate
compound.
Apply a very thin bead of HG32-0087 on the internal face of the tip plate, and reinstall it.
Torque the two bolts to 7.5 N.m and lock with wire, unless the blade is stored, or
Installed with further rotor balancing.

e) Fretting-corrosion at the attachment bushings

Light fretting-corrosion can be tolerated and removed inside the blade attachment
bushings, or on their faces. Remove the brown marks using Scotch-Brite or 600-grit
sandpaper.
Surface sanding should not exceed 0.02 mm (0.001 in)

Caution : When repairing a shocked blade, always check the attachment

bushings for debonding.
Use a magnifying glass to detect cracks, and tap the bushings with a coin to
detect debonding.
Bushing debonding cannot be repaired.

Caution : Repairing a blade will usually degrade the rotor balancing. Proceed
to track & balance per operation 10-A-03 if needed.

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12-A MAIN ROTOR HUB

12-A-01 Main rotor hub inspection IPC x-xx

a) Inspect hub condition. Verify no nicks, scratches, gouges, or corrosion, particularly

around the edges and the filament belt as shown :

Sealant beads

b) Check bolts and cotter pins,

c) Inspect the lead-lag dampers attachments tabs : no cracks or corrosion,
d) Inspect the scissor attachment : no cracks nor corrosion.

12-A-02 Main rotor Thrust bolts torque check IPC x-xx

The torque check is needed to check that an appropriate preload still exists in the rotor hub-to-
mast assembly.
a) Remove the plastic cap per operation 12-A-03 (step a)
b) Cut the safety wire,
c) Mark the pressure head bolts for angular position,
d) Unscrew one bolt about half a turn, then torque it to 7.5 N.m. Proceed to the next bolt,
with a star pattern (1-4-2-5-3-6 order).
e) Torque the bolts to 15 N.m with the same order. and lock by pairs with safety wire,
f) Note the angular displacement of the bolts,
g) Check that the lock bar has some free-play. If not, check the proper installation of the
pressure plate and the two plastic cones.
h) Install the plastic cap. Use a soft wooden block to protect its surface, and slam it in place
with a strong hammer blow.

Caution : If the room temperature is lower than 20°C, warm-u p the cap before
installing it.

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12-A-03 Main rotor hub removal IPC x-xx

The hub can be removed with or without the spherical bearings installed. The blades are
supposed removed.
The G81-01-100 Hub puller tool is required.
Remove the rotor hub plastic cap : use a 20 – 30 mm chisel as a lever, and a 20 mm thick wood
block to protect the hub upper surface. Apply a high force with the chisel to disengage the cap. As
the cap is partly disengaged, use the chisel at the two other angular positions to prevent the cap
jamming.,
Cut the safety wire, and unscrew the six pressure bolts, until the thrust nut can unscrew. Remove
the thrust nut with its six pressure bolts and the lock bar.
Remove the pressure plate,
Disconnect the rotating scissors, at either end of the “H” link. Beware to keep the two bushings
and the two washers with the long bolt,
Install the puller tool with its central plug,
Gently pull a few centimeters, checking that the rotor actually pulls up from the mast, then remove
completely.
Remove the two plastic thrust cones, clean and keep with the thrust nut and pressure plate,

12-A-04 Main rotor hub installation IPC x-xx

The rotor mast splines and conical surfaces should be cleaned thoroughly and inspected for
crack, scratch, wear, fretting or corrosion.

a) Using a brush, apply a thin coat of HG31-0017 chromate compound on the mast splines
surface,
b) Install the lower cone on the lower mast conical bearing surface,
c) Carefully engage the rotor hub onto the splines, and the lower plastic cone,
d) Install the upper plastic cone, and the pressure plate,
e) Prepare the thrust nut by checking the six pressure bolts are flush to its lower face, and
the lock bar is properly installed,
f) Screw the thrust nut to contact on the pressure plate. Unscrew to the first engagement of
the lock bar,
g) Screw the six thrust bolts and torque to 7.5 N.m with a star pattern (1-4-2-5-3-6 order).
Then torque to 15 N.m with the same order, and lock by pairs with safety wire,
h) Check that the lock bar has some free-play. If not, check the proper installation of the
pressure plate and the two plastic cones.
i) Install the plastic cap. Use a soft wooden block to protect its surface, and slam it in place
with a strong hammer blow.

Caution : If the room temperature is lower than 20°C, warm u p the cap before
installing it.

j) Connect the rotating scissor at its H-link per operation 41-A-07.

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12-A-05 Main rotor hub repair IPC x-xx

The main rotor hub should be carefully repaired in any occurrence of nick, scratch, corrosion.
In case of such damage, repair as follows :

k) Sand through the damage using 220-grit abrasive, until damage has disappeared.
Respect a minimum radius of approx. 100 mm.
l) Smooth the sanded area using 600-grit abrasive,
m) Check the local depth of the repair is less than 0.5 mm (non-bearing surfaces only),
n) Touch-up the area with HG31-0031 chromate primer,
o) Touch-up with HG31-0033 paint.

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12-B DROOP STOPS

12-B-01 Droop stops inspection IPC x-xx

a) Inspect the reciprocal droop stop ring : no surface pitting, free motion with the blades,
b) Inspect the droop stop plate on each blade,
c) Apply a thin coat of HG30-1691 grease with a brush on bearing surfaces if needed,
d) Inspect the two ring’s guiding flanges : no mark nor damage.

12-B-02 Droop stop plates replacement IPC x-xx

A droop stop plate can be replaced by removal of the blade, or partial removal as follows :

a) Remove the blade’s bolts per operation 11-A-02 steps a), b), e), f), g). The pitch horn is
left in place.
b) Replace the droop stop plate,
c) Install the two bolts back per operation 11-A-03 steps e), f), j).

12-B-02 Droop stop ring and guides removal & inspection IPC x-xx

The droop stop ring can be replaced by removing the rotor hub.

a) Remove the blades per operation 11-A-02,

b) Remove the hub per operation 12-A-03. The spherical bearings can stay installed,
c) Installing the hub inverted on a bench, use a thin screwdriver to remove the spiral
locking ring. Apply a circular motion to release it in a spiral. Take care not to bend it, and
not to scratch the paint,
d) Remove the lower flange, the ring, the rubber sleeve, the upper flange,
e) Clean the parts, and inspect it. Replace damaged parts.

The ring can be touched-up using a fine file, and 600-grit abrasive. Maximum depth 0.2 mm.

12-B-03 Droop stop ring and guides installation IPC x-xx

a) Install the upper flange, takin care to the orientation pin and hole,
b) Install the rubber sleeve, the droop stop ring, the lower flange,
c) Apply a thin bead of HG31-0017 chromate compound in the circular groove,
d) Install the spiral lock ring, using a careful helicoidal motion, while compressing the
rubber sleeve with the lower flange,
e) Check the ring for free motion.

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13-A SPHERICAL BEARINGS

13-A-01 Spherical bearings daily check IPC x-xx

The spherical bearings’ elastomer is visually inspected during daily and/or pre-flight check per
Cabri G2 Flight Manual.
In case any visible damage is reported, proceed to a detailed inspection per operation 13-A-02.

13-A-02 Spherical bearing inspection & criteria IPC x-xx

This inspection can be done on the helicopter, without disassembly.

a) Closely inspect the elastomer surface : look for cracks, defects, debonding, rubber
extrusion.
A rubber extrusion of less than 20 mm (3/4 in) long is acceptable.

In case of an extrusion longer than 20 mm (3/4 in), measure depth with a thin feeler
gage or metal shim. Reject the bearing if deeper than 4 mm (5/32 in)

b) Inspect the metal fittings for shocks, cracks, corrosion.

Note : A small rubber pin may protrude on the large fixture side, between the
steel bushings. This injection residue is normal, and can be cut flush.

Typical damage

Inspection zone

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13-A-03 Spherical bearing removal IPC x-xx

One spherical bearing alone can be removed, installed, replaced.

Caution : never leave one or two blades installed and resting on their droop
stop for more than a few hours. In this case, support each blade on a mast to
prevent spherical bearing creeping.

a) Remove the corresponding blade per operation 11-A-02,

b) Remove the safety wire and the four Allen bolts attaching the spherical bearing, and
washers,
c) Slip the bearing out, and extract it out of the hub, with great care,
d) Save the anti-fretting shim.

Note : A small rubber pin may protrude on the large fixture side, between the
steel bushings. This injection residue is normal, and can be cut flush.

13-A-04 Spherical bearing installation IPC x-xx

a) Inspect the bearing area on the hub arm. Clean and smooth the surface.
b) Prepare the anti-fretting shim for position and side,
c) Slide the bearing in position while holding the shim. Use a piece of wood as a lever to
push the bearing in. Protect the hub paint with a cloth.
d) Install the four Allen bolts and washers. Tighten the four to contact firmly, then torque to
7 N.m with an X-pattern.
e) Apply safety wire.

Note : If a spherical bearing is difficult to slip in position due to interference, one

may use 600-grit sandpaper to delicately sand the green primer. Do NOT sand
to the metal.

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14-A LEAD-LAG DAMPERS

14-A-01 Lead-lag dampers daily check IPC x-xx

The lead-lag dampers’ elastomer is visually inspected during daily and/or pre-flight check per
Cabri G2 Flight Manual.
In case any visible damage is reported, proceed to a detailed inspection per operation 14-A-02.

14-A-02 Lead lag damper detailed inspection & criteria IPC x-xx

The lead-lag dampers elastomers inspected during daily and/or pre-flight check per Cabri G2
flight manual .
In case of any visible defect in the elastomer such as crack, an extrusion, a bulge or a debonding,
the pilot should refer to an approved mechanics that will inspect per following operation :

This inspection can be done one the helicopter, without disassembly.

Closely inspect the elastomer surface : Look for cracks, debonding, rubber extrusion or bulges.

Rejection criteria :
• Crack or debonding longer than 90° angular extension
• Rubber extrusion or bulge longer than 20 mm and higher than 2 mm

Dampers below these criteria are serviceable.

Maximum
damage length

Inspect the damper body for shock, crack, corrosion, loose rod-ends threads.

14-A-02 Lead lag damper removal IPC x-xx

Note : A blade can be left without its damper indefinitely. In this case, avoid in-
plane efforts on the blade tip.

a) Remove the dampers attachment cotter pins, nuts and washers,

b) Remove the bolts and the damper.

Note : The damper has a small metal rod loose inside for lightning path. Its
clinking is normal.

14-A-03 Lead-lag damper installation IPC x-xx

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a) Check the damper’s rod-ends : no free-play, locknuts and safety wires,

b) Check the two rod-ends parallelism,
c) Check the plastic rings on the blade and hub attachments,
d) Slide the damper’s rod-end (big end of the damper) in the hub attachment.
e) Install bolt and washer,

Caution : respect damper direction : rubber end facing outward.

f) Slide the other rod-end in the blade attachment. Use the blade as a lever to find the
correct position, and install the second bolt and washer,
g) Install washer and nut on each bolt. Torque nuts to 19 - 23 N.m. Install cotter pins.

14-A-04 Lead-lag damper inspection : Rod-end radial play IPC x-xx

This inspection can be done on the helicopter, without any disassembly.

The radial play to measure on every rod-end, inboard (attached to the hub) or outboard (attached
to the blade), is equivalent to an axial play in the damper.
Install a dial on the lead-lag damper per following figure :

One operator moves the blade back and forth by its tip, in the horizontal plane.
The other operator reads the radial play on the dial.

The total play should not exceed 0.1 mm.

Above this value, proceed to rod-end replacement per operation 14-A-05

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14-A-05 Lead-lag damper rod-ends replacement IPC x-xx

This operation requires the G81-02-100 setting tooling.

Note : It is recommended that the six rod-ends are changed altogether.

a) Remove the damper per operation 14-A-02,

b) Cut the safety wires, loose the locknuts,

Caution : the inner rod-end (big end side) has a left-hand thread.

c) Unscrew the rod-ends,

d) Apply HG31-0017 chromate compound on the new rod-ends shank. Screw new rod-
ends and locknuts in the damper. The inner rod-end thread is left-hand.
e) Install the damper on the G81-02-100 setting tooling,
nominal length = 244.6 mm
f) Adjust the damper length by twisting the body to make it loose on the centering pins.
Check the two rod-ends are held parallel in the tooling
g) Using two wrenches, torque the locknuts to 20 N.m
h) Check the damper is loose on the pins,
i) Apply safety wire to the lock nuts

Caution : Respect the left-hand direction for safety wire also.

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CABRI G2 MAIN TRANSMISSION

E-2 Main transmission

E-2 MAIN TRANSMISSION ................................................................................................... E-2-I

DESCRIPTION................................................................................................................ E-2-1
21-A MAIN GEARBOX ............................................................................................... E-2-1
21-A-01 Main gearbox inspection ..................................................... IPC x-xx .......... E-2-1
21-A-02 Main gearbox flush and oil change ..................................... IPC x-xx .......... E-2-1
21-A-03 Main gearbox removal ......................................................... IPC x-xx .......... E-2-2
21-A-04 Main gearbox installation..................................................... IPC x-xx .......... E-2-2
21-A-05 Freewheeling unit removal ................................................. IPC x-xx .......... E-2-2
21-A-06 Freewheeling unit installation .............................................. IPC x-xx .......... E-2-2
21-A-07 Main gearbox intake seal replacement ............................... IPC x-xx .......... E-2-2
21-A-08 Main gearbox intake pulley replacement ............................ IPC x-xx .......... E-2-2
21-A-09 Main gearbox overtemp inspection ..................................... IPC x-xx .......... E-2-2
21-A-10 Main gearbox chips light indicator ....................................... IPC x-xx .......... E-2-2

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MAIN TRANSMISSION CABRI G2

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CABRI G2 MAIN TRANSMISSION

DESCRIPTION

The main transmission is composed of a single stage, 92°-angle gearbox, driven by a multiple-V
pulley from the engine primary drive.
A freewheel unit is located inside the pulley, and allows the main rotor to rotate and to drive the
tail rotor, should the engine stop.

The main gearbox comprises the rotor mast, a set of spiral bevel gears, and two load-carrying
cases, rigidly bolted to the helicopter’s structure.
It is splash-lubricated, including the freewheel.

21-A MAIN GEARBOX

21-A-01 Main gearbox inspection IPC x-xx

a) Open the small access door in the main firewall,

b) Remove the magnetic chips detector finger,
c) Wipe the finger tip in a clean white soft cloth or tissue. Inspect the cloth for metal chips,
and keep the sample in case of doubt.
d) Reinstall the finger locked.
e) Check the oil level with a torchlight. Ensure that the helicopter is on a level ground,
without its wheels.

Caution : Make sure that the helicopter has no bank. Shim it between the rear
landing gear bow and the fuselage with a soft piece of wood to make it level if
needed.

Oil level should be between half and three quarter of gage sight. Close the access panel.

f) Step on the baggage compartment to inspect the gearbox upper casing. Check the two
inspection plugs, the attachment bolts, and surrounding composite structure.
g) In case of serious doubt, reach behind the furnishing inside the baggage compartment
upper face, and down on the side, to inspect the gearbox attachment bolts. Check the
bolts tightness and the surrounding composite, for visible cracks or delamination.

21-A-02 Main gearbox flush and oil change IPC x-xx

a) Ground-run the helicopter for a few minutes to warm main rotor gearbox oil,
b) Open the firewall access door. Remove the chip detector finger,
c) Disconnect the detector’s connector and using a clean white cloth, clean any
accumulation from detector’s magnetic probe,
d) Install G82-01-100 draining tool in chips detector housing with hose overboard. Allow to
drain. To stop the drain, unlock the finger.
e) Heat about 1,5 liter of HG30-1408 engine oil to approx 60 – 80°C (160-17 5°F). Fill the
gearbox.
f) Rotate the rotor about 10 turns by hand,
g) Drain the oil,
h) Connect and install the chips detector,
i) Fill the gearbox with oil reference HG30-0039. Level should be between half and top of
the sight gage with aircraft leveled (approx 1 liter needed).

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Caution : Make sure that the helicopter has no bank. Shim it between the rear
landing gear bow and the fuselage with a soft piece of wood to make it level if
needed.

21-A-03 Main gearbox removal IPC x-xx

TBC

21-A-04 Main gearbox installation IPC x-xx

TBC

21-A-05 Freewheeling unit removal IPC x-xx

TBC

21-A-06 Freewheeling unit installation IPC x-xx

TBC

21-A-07 Main gearbox intake seal replacement IPC x-xx

TBC

21-A-08 Main gearbox intake pulley replacement IPC x-xx

TBC

21-A-09 Main gearbox overtemp inspection IPC x-xx

TBC

21-A-10 Main gearbox chips light indicator IPC x-xx

TBC

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CABRI G2 TAIL ROTOR AND TRANSMISSION

E-3 Tail rotor and transmission

DESCRIPTION................................................................................................................ E-3-1
31-A TAIL ROTOR HUB ............................................................................................. E-3-1
DESCRIPTION................................................................................................................ E-3-1
31-A-01 Opening the tail rotor hub ................................................... IPC x-xx .......... E-3-1
31-A-02 Closing the tail rotor hub ..................................................... IPC x-xx .......... E-3-2
31-A-03 Tail rotor removal................................................................. IPC x-xx .......... E-3-3
31-A-04 Tail rotor installation ............................................................ IPC x-xx .......... E-3-3
31-A-05 Tail rotor balancing .............................................................. IPC x-xx .......... E-3-3
31-B TAIL ROTOR BLADES....................................................................................... E-3-4
DESCRIPTION................................................................................................................ E-3-4
31-B-01 Blades inspection & repair................................................... IPC x-xx .......... E-3-4
31-B-02 Tension packs inspection .................................................... IPC x-xx .......... E-3-4
31-B-03 Detailed tension packs inspection ....................................... IPC x-xx .......... E-3-5
31-B-04 Tail rotor blades removal ..................................................... IPC x-xx .......... E-3-6
31-B-05 Tail rotor blades installation ................................................ IPC x-xx .......... E-3-6
31-B-05 Plastic bearings check, criteria & replacement ................... IPC x-xx .......... E-3-6
31-B-06 Maximum pitch check ......................................................... IPC x-xx .......... E-3-7
32-A TAIL ROTOR GEARBOX ................................................................................... E-3-8
32-A-01 Tail rotor gearbox inspection ............................................... IPC x-xx .......... E-3-8
32-A-02 Tail gearbox flush & oil change ........................................... IPC x-xx .......... E-3-8
32-A-03 Blades tip clearance check ................................................. IPC x-xx .......... E-3-8
32-A-04 Tail gearbox removal ........................................................... IPC x-xx .......... E-3-8
32-A-04 Tail gearbox removal ........................................................... IPC x-xx .......... E-3-9
32-A-05 Tail gearbox installation....................................................... IPC x-xx .......... E-3-9
32-A-06 Chips detector ..................................................................... IPC x-xx .......... E-3-9
32-A-07 Rotor alignment ................................................................... IPC x-xx .......... E-3-9
33-A TAIL ROTOR DRIVE SHAFT ........................................................................... E-3-10
33-A-01 Drive shaft inspection .......................................................... IPC x-xx ........ E-3-10
33-A-02 Drive shaft bearings regreasing .......................................... IPC x-xx ........ E-3-10
33-A-03 Drive shaft removal.............................................................. IPC x-xx ........ E-3-10
33-A-04 Drive shaft installation ......................................................... IPC x-xx ........ E-3-10
33-A-05 Flexible coupling daily check ............................................... IPC x-xx ........ E-3-10
33-A-06 Flexible coupling detailed inspection .................................. IPC x-xx ........ E-3-10
34-00 ROTOR BRAKE ASSEMBLY .......................................................................... E-3-11
34-A-01 Rotor brake inspection ........................................................ IPC x-xx ........ E-3-11
34-A-02 Rotor brake rigging .............................................................. IPC x-xx ........ E-3-11
34-A-03 Rotor brake jaws replacement ............................................ IPC x-xx ........ E-3-11
34-A-04 Rotor brake mechanism removal ........................................ IPC x-xx ........ E-3-11
34-A-05 Rotor brake mechanism installation .................................... IPC x-xx ........ E-3-11
34-A-06 Rotor brake disc replacement ............................................. IPC x-xx ........ E-3-11
34-A-07 Overhead quadrant inspection ............................................ IPC x-xx ........ E-3-11
34-A-08 Rotor brake cable replacement ........................................... IPC x-xx ........ E-3-11

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CABRI G2 TAIL ROTOR AND TRANSMISSION

DESCRIPTION

The tail rotor mechanics consist of a single-stage gearbox, driving the tail rotor, its pitch control
mechanism, and the long driveshaft from the main gearbox.
They also include the rotor brake, which is installed on the tail driveshaft.

31-A TAIL ROTOR HUB

DESCRIPTION
The tail rotor is composed of :
• A hub, made of two halves bolted together. These halves are not matched,
• Seven blades,
• The pitch spider.

The hub is made of two forged and machined aluminum parts. They are bolted together around
two plastic rings per blade which constitute the blade pivot.

31-A-01 Opening the tail rotor hub IPC x-xx

a) Cut safety wires and remove the 7 assembly bolts and washers. Mark the balancing
washers and their position if any, if the hub is to be reassembled as it,
b) Using a felt pen or two pieces of tape, mark the two halves respective position to help
reinstallation,

Note : This marking is not necessary, as the two halves are not matched
together, and are polarized by an offset hole. Marking the parts is only to ease
reassembly, and to take care of existing balancing, when it is done.

c) Remove the outer hub by pulling gently. One may help by using two opposed blades as
levers for the first millimeters,
This operation is sufficient for visual inspection.

Tail rotor hub bolts

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31-A-02 Closing the tail rotor hub IPC x-xx

a) Check the seven spider’s nuts, and the central castle nut with cotter pin,
b) Check that every blade is correctly in place, with its rivet visible per fig 6-2,
c) Check that every plastic bearing is properly installed, and that the inner bearings cuts
are all visible per fig 6-2,
d) Check for no foreign object,
e) Install the outer hub, aligning the two angular marks. Press gently to close. Don’t force.

Note : If the two halves are not marked, find the appropriate angular position by
looking for the offset polarizing hole :

Offset hole

f) Install the seven screws with some HG31-0017 chromate compound, and the marked
balancing washers if applicable,
g) Torque to 5 N.m. Lock by safety wire (two, two and three bolts).

Rivet

Inner bearing cut

Opened tail rotor hub

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CABRI G2 TAIL ROTOR AND TRANSMISSION

31-A-03 Tail rotor removal IPC x-xx

a) Open the rotor hub per operation 31-A-01

b) Mark the central flange relatively to the spider and remove it by removing the central
castle nut and the seven peripheral nuts,
c) Mark the thrust plate angular position,
d) Cut the central safety wire and unscrew the seven pressure screws until the central
pressure plate is free to unscrew. Remove the central pressure plate with the seven
pressure screws,
e) Mark the hub relatively to the splined flange.
f) Use peripheral masking tape to secure the blades in place,
g) Remove the tail rotor hub. Mark flange position with respect to the pinion and remove it
together with the anti-fretting shim.

31-A-04 Tail rotor installation IPC x-xx

This installation follows a removal per operation 31-A-03.

h) Check all the blades are properly installed, with their pins, and the anti-fretting shim
between the hub and the torsion straps,
i) Install the splined flange on the inner hub according to the angular marks, with the
second anti-fretting shim,
j) Install the rotor on the gearbox according to the angular marks,
k) Prepare the central pressure plate by checking the seven pressure screw do not
protrude,
l) Install the pressure plate : screw to contact and unscrew the minimum angle to align the
pressure screws with the blade pins. Check the angular marks match.
m) Torque the seven pressure bolts to 2 N.m. Respect order 1-4-7-3-6-2-5. Torque again to
4 N.m. Respect the same order.
n) Check that the pitch control moves freely,
o) Apply the safety wire around the seven screws (only one peripheral wire),
p) Double-check that both anti-fretting shims are in place (each face of the rotor hub), and
that the pressure screws are aligned with the blades pins,
q) Install the central plate according to angular marking and torque the seven nuts to 5 Nm.
Apply torque-seal,
r) Install and torque the central castle nut to 6 to 7.5 N.m and install the cotter pin,
s) Close the rotor hub per operation 31-A-02.

31-A-05 Tail rotor balancing IPC x-xx

The tail rotor should be balanced in case of doubt, and after any of these operations :
• Blade replacement,
• Rotor removal and re-installation,
• Plastic pitch bearing replacement,
• Significant blade repair

TBC

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31-B TAIL ROTOR BLADES

DESCRIPTION
The blade is composed of:
• a tension-torsion pack,
• an injected plastic body,
• an aluminum blade root including a pitch control horn.

31-B-01 Blades inspection & repair IPC x-xx

Inspect the blades root and particularly the adhesive joint. Apply moderate bending force at blade
tip while inspecting.
Inspect the outer part of the blades for nicks, cracks or erosion.
Nicks and impacts can be faired using 220-, then 600-grit sandpaper. Best results are obtained
with water-sanding.

The blade must be discarded if :

• A faired nick exceeds 2 mm chordwise, or 1 mm chordwise x 20 mm spanwise
• Chord is eroded below 40 mm measured at the worst point,
• Any crack appears in the outer part of the blade,
• Any debonding appears at the blade root.

31-B-02 Tension packs inspection IPC x-xx

Tail rotor blades tension-torsion packs should be inspected through the hub holes. Inspect for
cracks, edge nicks or separated strips.

Inspection holes
Separated
external strip

Crack

Types of damage

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In case of doubt, proceed to detailed inspection per operation 31-B-03, or remove the blade per
operation 31-B-04
In case of crack, failure, or heavy marks of fretting on the tension pack, discard the blade.

31-B-03 Detailed tension packs inspection IPC x-xx

a) Open the rotor hub per 31-A-01.

b) Remove the central plate (seven self-locking nuts, one self-locking castle nut).
c) Check tension-torsion packs edge for cracks, especially at the root of the pack, in the
radius :

In case of crack, the corresponding blade should be discarded and replaced per
operation 31-B-04 and 31-B-05

d) Close the hub per operation 31-A-04 starting step i)

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31-B-04 Tail rotor blades removal IPC x-xx

a) Remove the hub per 31-A-03. If only one or two blades are to be replaced, one can
leave the rotor installed by omitting step g),
b) To remove a blade, pull its tension pack from the hub, keeping the pin installed,
c) To remove a pin from a tension pack, carefully hold the pack together while pulling the
pin out.

Caution :The tension pack should be maintained tight while the pin is
removed, in order to avoid straps bending damage.

d) Mark the spider relatively to the hub before removing it.

e) To remove inner plastic bearing from a blade, rotate it to place its cut opposed to the
pitch horn, then swing it over the pitch horn, running the tension pack in the cut.

31-B-05 Tail rotor blades installation IPC x-xx

Install the blades in their position, then install the rotor per operation 31-A-04.

31-B-05 Plastic bearings check, criteria & replacement IPC x-xx

a) Remove tail rotor blades per operation 31-B-04,

b) Remove the inner and outer pitch bearings,
c) Visually locate bearing zone inside the bearing and measure maximum wear :

Wear

Replace the bearings if wear exceeds 0.5 mm.

Caution : All the bearings of the same kind (inner, outer, pitch lever) must be
replaced together if one is worn.

Caution : When reinstalling bearings with significant wear, mark the bearing
zones with a felt pen, and align the marks with the hub joining plane.

d) In the same manner, check the small pitch levers bearings by measuring two
perpendicular diameters. Replace if maximum difference exceeds 0.5 mm
e) To remove or install a pitch lever bearing, press it with a piece of hard wood or plastic,
f) When the blades are inspected, and every defective bearing is replaced, proceed to
reinstallation per operation 31-B-05.

Note : The outer plastic bearings can be removed while keeping the blades
installed :

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a) Open the rotor hub per operation 31-A-01,
b) Carefully raise the blade to free the outer plastic bearing,
c) Slide it out of the blade.
d) When replacing the bearing, be careful to set the inner bearing in place.
e) Close the rotor hub per operation 31-A-02

31-B-06 Maximum pitch check IPC x-xx

a) Set tail rotor blades pitch to approximately zero,

b) Tape the rigging template (given in appendix 7) and adjust its angular position using one
blade trailing edge path,
c) Apply full right pedal;
d) Check that the tail gearbox lever contacts its stop bolt,
e) Check that tail rotor blade is aligned with the high pitch marks :

High pitch check

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32-A TAIL ROTOR GEARBOX

32-A-01 Tail rotor gearbox inspection IPC x-xx

a) Check oil level. Ensure that the helicopter is on a level ground, without its wheels.
b) Check for oil leakage,
c) Remove the magnetic chips detector finger,
d) Wipe the finger tip in a clean white soft cloth or tissue. Inspect the cloth for metal chips,
and keep the sample in case of doubt.
e) Reinstall the finger locked.

32-A-02 Tail gearbox flush & oil change IPC x-xx

a) Cut the safety wire, and remove the complete chips detector,
b) Let the oil drain completely, then reinstall the magnetic plug base,
c) Heat about 0.5 liter of HG30-1408 straight mineral oil to 60 –80°C (140 – 175°F),
d) Remove filler plug, and pour the hot oil.
e) Turn the main rotor by hand about 10 turns. Cycle the rudder about 10 times. Turn again
the main rotor about 10 turns.
f) Remove the chips detector socket, and let drain again completely,
g) Install the chips detector,
h) Check the gasket and lock with safety wire
i) Fill gearbox with HG30-0039 gearbox oil. Level should be between 1/2 and 3/4 of the
sight gage (with helicopter leveled).

32-A-03 Blades tip clearance check IPC x-xx

a) Set the rotor in a position and do not move it during the check,
b) Measure the gap between each blade and the shroud.

If the difference between the minimum and maximum gap exceeds 0.5 mm, proceed to rotor
realignment per operation 32-A-07.

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32-A-04 Tail gearbox removal IPC x-xx

TBC

32-A-05 Tail gearbox installation IPC x-xx

TBC

32-A-06 Chips detector IPC x-xx

TBC

32-A-07 Rotor alignment IPC x-xx

TBC

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33-A TAIL ROTOR DRIVE SHAFT

33-A-01 Drive shaft inspection IPC x-xx

a) Inspect the flexible coupling per operation 33-A-06 and check bolts tightness,
b) Inspect the first bearing, on the rear firewall : no free-play, no debris. Some grease leak
is normal after recent regreasing,
c) Check the paint mark for bearing non-rotation on its rubber sleeve,
d) Remove the rubber plugs and inspect the two middle bearing the same way,
e) Push on the tube with a finger to check attachment for rigidity,
f) Reinstall the plugs,
g) Check no free-play at the access hole in the tail gearbox input.

33-A-02 Drive shaft bearings regreasing IPC x-xx

a) Take-off the plug to open the two holes on top of the tail boom.
b) Open an engine cowling to access the third bearing located on top of the aft firewall.
c) For the three bearings, using a torchlight, carefully check the rubber sleeve under the
bearing, and check the paint mark to detect bearing rotation on its sleeve,
d) Use a syringe equipped with a needle to add 2 cc of HG30-0013 grease between
bearing’s seal lip and inner race.
e) Close the two holes with the plugs.

33-A-03 Drive shaft removal IPC x-xx

TBC

33-A-04 Drive shaft installation IPC x-xx

TBC

33-A-05 Flexible coupling daily check IPC x-xx

The flexible coupling is visually inspected during daily and/or pre-flight check per Cabri G2 Flight
Manual.
In case any visible damage is reported, proceed to a detailed inspection per operation 33-A-06.

33-A-06 Flexible coupling detailed inspection IPC x-xx

a) Visual and manual check :
• Check bolt assembly tightness and absence of fretting,
• Look for cracks by sliding your fingernail or finger on the shims perimeter.
• In case of any crack or fretting, the complete flexible pack should be replaced.

b) Move the driving flange slightly fore-and-aft on its splines, to check the coupling.

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34-00 ROTOR BRAKE ASSEMBLY

34-A-01 Rotor brake inspection IPC x-xx

TBC

34-A-02 Rotor brake rigging IPC x-xx

TBC

34-A-03 Rotor brake jaws replacement IPC x-xx

TBC

34-A-04 Rotor brake mechanism removal IPC x-xx

TBC

34-A-05 Rotor brake mechanism installation IPC x-xx

TBC

34-A-06 Rotor brake disc replacement IPC x-xx

TBC

34-A-07 Overhead quadrant inspection IPC x-xx

TBC

34-A-08 Rotor brake cable replacement IPC x-xx

TBC

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INTENTIONALLY BLANK

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CABRI G2 FLIGHT CONTROLS

E-4 Flight controls

DESCRIPTION................................................................................................................ E-4-1
41-A SWASHPLATE AND SCISSORS ....................................................................... E-4-1
41-A-01 Swashplate inspection ......................................................... IPC x-xx .......... E-4-1
41-A-02 Swashplate regreasing ........................................................ IPC x-xx .......... E-4-2
41-A-03 Swashplate removal ............................................................ IPC x-xx .......... E-4-2
41-A-04 Swashplate installation ........................................................ IPC x-xx .......... E-4-2
41-A-05 Swashplate guide liner replacement ................................... IPC x-xx .......... E-4-2
41-A-06 Rotating scissor removal ..................................................... IPC x-xx .......... E-4-3
41-A-07 Rotating scissor installation ................................................. IPC x-xx .......... E-4-3
41-A-08 Non-rotating scissor removal .............................................. IPC x-xx .......... E-4-3
41-A-09 Non-rotating scissor installation .......................................... IPC x-xx .......... E-4-3
41-A-10 Scissors bearings replacement ........................................... IPC x-xx .......... E-4-3
41-A-11 Scissors rod-end replacement ............................................ IPC x-xx .......... E-4-4
41-B MAIN ROTOR CONTROLS................................................................................. E-4-5
41-B-01 Main rotor controls inspection ............................................. IPC x-xx .......... E-4-5
41-B-02 Main rotor general rigging ................................................... IPC x-xx .......... E-4-5
41-B-03 Main rotor pitch links adjustment......................................... IPC x-xx .......... E-4-6
41-B-04 In-flight collective pitch fine adjustment .............................. IPC x-xx .......... E-4-7
41-B-04 Pitch rod-end backlash check ............................................. IPC x-xx .......... E-4-7
41-B-10 Collective controls removal ................................................. IPC x-xx .......... E-4-7
41-B-11 Collective controls installation ............................................. IPC x-xx .......... E-4-7
41-B-12 Twist grip removal ............................................................... IPC x-xx .......... E-4-7
41-B-13 Twist grip installation ........................................................... IPC x-xx .......... E-4-8
41-B-14 Connecting chain replacement & rigging ............................ IPC x-xx .......... E-4-8
41-B-20 Horizontal pitch rods removal.............................................. IPC x-xx .......... E-4-8
41-B-21 Horizontal pitch rods installation ......................................... IPC x-xx .......... E-4-8
41-B-30 Cyclic controls removal ....................................................... IPC x-xx .......... E-4-8
41-B-31 Cyclic controls installation ................................................... IPC x-xx .......... E-4-8
41-B-40 Vertical pitch rods removal .................................................. IPC x-xx .......... E-4-8
41-B-41 Vertical pitch rods installation .............................................. IPC x-xx .......... E-4-8
41-B-50 Swashplate bellcrank removal ............................................ IPC x-xx .......... E-4-8
41-B-51 Swashplate bellcrank installation ........................................ IPC x-xx .......... E-4-8
41-B-60 Copilot cyclic controls disassembly ..................................... IPC x-xx .......... E-4-8
41-B-61 Copilot cyclic controls assembly ......................................... IPC x-xx .......... E-4-8
41-B-62 Copilot cyclic rigging ............................................................ IPC x-xx .......... E-4-8
41-B-70 Copilot collective stick disassembly .................................... IPC x-xx .......... E-4-8
41-B-71 Copilot collective stick assembly ......................................... IPC x-xx .......... E-4-8
41-C TAIL ROTOR CONTROLS................................................................................ E-4-9
41-C-01 Tail rotor controls inspection ............................................... IPC x-xx .......... E-4-9
41-C-02 Tail rotor controls rigging..................................................... IPC x-xx .......... E-4-9
41-C-03 Tail rotor push-pull control disconnection ........................... IPC x-xx .......... E-4-9
41-C-04 Tail rotor push-pull control reconnection............................. IPC x-xx .......... E-4-9
41-C-05 Tail rotor push-pull control removal .................................... IPC x-xx .......... E-4-9
41-C-06 Tail rotor push-pull control installation ................................ IPC x-xx .......... E-4-9
41-D PEDALS ASSEMBLY....................................................................................... E-4-10
41-D-01 Pedals inspection ................................................................ IPC x-xx ........ E-4-10

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41-D-02 Pedals removal ................................................................... IPC x-xx ........E-4-10
41-D-03 Pedals installation ............................................................... IPC x-xx ........E-4-10
42-A CYCLIC TRIMS ................................................................................................E-4-10
42-A-01 Trims check ......................................................................... IPC x-xx ........E-4-10
42-A-02 Trims lubrication .................................................................. IPC x-xx ........E-4-10
42-A-03 Trims removal...................................................................... IPC x-xx ........E-4-10
42-A-04 Trims installation ................................................................. IPC x-xx ........E-4-10
42-A-05 Trims gas spring replacement............................................. IPC x-xx ........E-4-10
44-A THROTTLE CONTROLS ..................................................................................E-4-11
44-A-01 Throttle control inspection ................................................... IPC x-xx ........E-4-11
44-A-02 Throttle control rigging – idle adjustment............................ IPC x-xx ........E-4-11
44-A-03 Throttle cam mechanism replacement ............................... IPC x-xx ........E-4-11
44-A-04 Throttle push-pull cable replacement.................................. IPC x-xx ........E-4-11
44-B MIXTURE CONTROLS.....................................................................................E-4-12
44-B-01 Mixture controls inspection ................................................. IPC x-xx ........E-4-12
44-B-02 Mixture controls rigging ....................................................... IPC x-xx ........E-4-12
44-B-03 Mixture push-pull cable replacement .................................. IPC x-xx ........E-4-12

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CABRI G2 FLIGHT CONTROLS

DESCRIPTION

The Cabri G2 flight controls are conventional, with no power assistance.

Dual controls are standard equipment. The three copilot controls are quickly removable with no
tool.
All primary controls are actuated through push-pull rods except tail rotor, using a flexible push-
pull control.
The cyclic control is assisted by two electric trim actuators, one in pitch and one in roll. They are
controlled by a coolie-hat switch on pilot and copilot stick grip, through an electronic sequencer.
The collective lever is compensated by a gas spring, to compensate undesired motion in every
flight phases.
The throttle control is ensured by a twist-grip on both collective sticks, in parallel with the
governor-controlled electric motor. A friction clutch permits the pilot to overtake the governor at
any moment.
A cam mechanism provides adequate throttle correlation throughout the power range.

41-A SWASHPLATE AND SCISSORS

41-A-01 Swashplate inspection IPC x-xx

a) Inspect nuts tightening (Torque-Seal when applicable, cotter pins)

c) Check there is no angular free-play between the two swashplates
d) Measure upper swashplate rotational play as shown on figure below .
Maximum angular free-play = +/- 2 mm measured at pitch link

If the measured free-play is excessive, proceed to scissors bearings replacement per

operation 41-A-10, and rod-end replacement if necessary, per operation 41-A-11

e) Inspect the vertical guide’s liner, in both minimum collective, and maximum collective
positions. In case of any tearing, peeling or excessive wear (going through the fabric),
replace the liner per operation 41-A-05.

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41-A-02 Swashplate regreasing IPC x-xx

a) Use HG30-0013 grease with a hand-pump

b) Weight the complete pump with 2-gram accuracy
c) Inject grease and check by weighting the pump again.
d) Quantity to inject = approx 10 grams (0.4 oz.).
e) Check that injected grease exits between the swashplates
f) Wipe excess grease with cloth.

41-A-03 Swashplate removal IPC x-xx

The swashplate assembly can be removed after removing the main rotor.

a) Remove the main rotor assembly per operation 10-A-01, or the rotor hub per operation
12-A-03 if the blades are removed,
b) Disconnect the non-rotating scissors by removing the long bolt linking the H-link to the
guide,
c) Remove the band-clamp on the mast deflector,
d) Scratch the sealing compound using a sharp plexiglass chisel, and remove the deflector
by twisting it around the mast,

Caution : never scratch the mast surface.

e) Disconnect the three rod-ends at the lower (non-rotating) swashplate, by removing the
three pins, nuts, bolts & washers
f) Remove the swashplate assembly by sliding it out the guide.

Note : After removing the swashplate ass’y, always inspect the self-lubricating
liner on the guide. Change in case of any wear or tear, per operation 41-A-05

41-A-04 Swashplate installation IPC x-xx

a) Inspect the complete self-lubricating liner on the guide. Change in case of any wear or
tear, by operation 41-A-05
b) Slide the swashplate assembly on its guide carefully. Pay attention to the plastic sphere
engagement on the liner, to avoid initiating a peeling-off
c) Select the proper orientation (by aligning the non-rotating scissor with its attachment)
and engage the three rod-ends in the swashplate clevis arms.
d) Engage the three bolts, washers, nuts. Torque to 7.5 - 9 N.m and install cotter pin.
e) Install the long bolt which attaches the scissor H-link, with large washers, bushings, nut,
f) Torque to 7.5 - 9 N.m and install cotter pin,
g) Engage the deflector on the mast by twisting it. Slide the deflector down to contact on
the swashplate guide, then raise it 2 mm. Install the band-clamp and tighten it in position,
h) Apply a thin bead of HG31-0123 sealant at the deflector edge, and at its cut.

41-A-05 Swashplate guide liner replacement IPC x-xx

a) Disconnect the three pitch links from the rotating swashplate,

b) Disconnect the three control rods from the non-rotating swashplate,

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c) Disconnect the rotating and non-rotating scissors at either side of the H-link,
d) Remove the band clamp, and remove the sealing compound from the plastic deflector
and the mast, with a Plexiglass chisel,
e) Slide the plastic deflector as high as possible,
f) Slide the complete swashplate upward, to completely clear its guide. Attach it to the
main rotor hub, using strong scotch tape, or a fine rope,
g) Peel-off the old liner. Use petrol or Avgas to remove all the adhesive,
h) Take the new liner, and peel-off half its backing plastic,
i) Apply the new liner carefully on the guide, by aligning the protected part with the guide
edge, then pressing the unprotected part. To avoid formation of bubbles, press
progressively with a finger while tensioning the liner by hand,
j) Remove the other part of protective plastic, and apply all the liner.

Caution : check that the liner does not overlap, and forms no bubbles nor wrinkles.

k) Reinstall the swashplate and deflector per operation 41-A-04.

41-A-06 Rotating scissor removal IPC x-xx

a) Disconnect the pitch link from the swashplate arm where the scissor is attached,
b) Remove the cotter pin, nut and bolt attaching the driving rod-end,
c) Remove the cotter pin, nut and bolt linking the scissor to the hub. Be careful to recover
the washers and spacers,

Caution : While the rotating scissor is disconnected, do not turn the rotor.

41-A-07 Rotating scissor installation IPC x-xx

TBC

41-A-08 Non-rotating scissor removal IPC x-xx

a) Disconnect the right fore rod-end from the lower swashplate arm where the scissor is
attached,
b) Move the cyclic stick to right stop and raise the collective to disengage the rod-end from
the swashplate,
c) Remove the cotter pin, nut and bolt attaching the driving rod-end,
d) Remove the cotter pin, nut and bolt linking the scissor to the hub. Be careful to recover
the two washers and two spacers,

41-A-09 Non-rotating scissor installation IPC x-xx

TBC

41-A-10 Scissors bearings replacement IPC x-xx

This operation is similar on the two scissors, rotating and non-rotating.

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TBC

41-A-11 Scissors rod-end replacement IPC x-xx

This operation is similar on the two scissors, rotating and non-rotating.

TBC

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41-B MAIN ROTOR CONTROLS

41-B-01 Main rotor controls inspection IPC x-xx

TBC

41-B-02 Main rotor general rigging IPC x-xx

This operation is delicate and should be done very carefully. It is necessary after following
operations :
• Cyclic base welding assembly replacement,
• Collective pitch controls replacement,
• Rebuilding of the flight controls.

If the blades are removed for this operation, install G84-00-100 protractor support on one
spherical bearing, with the two spacers and the pitch horn. Tighten the nuts slightly.

If the blades are installed, three supporting masts should be installed to release the three blades
from their droop stop. The masts height should be adjusted approximately to a zero-flap angle for
the three blades. When turning the rotor, reinstall the masts.
Install G84-00-100 protractor support on one blade, without the spacers. Tighten the nuts slightly.

Use a 0.1-degree accuracy, calibrated protractor for this operation.

The rigging is done in three phases only :

1. Lateral cyclic travel adjustment. The longitudinal is not adjustable

2. Minimum collective pitch adjustment on one long rod
3. Neutral point (zero cyclic) adjustment

a) Set the helicopter attitude to perfectly vertical mast, using the end face of the rotor mast
as a reference. Shim the skids properly in pitch, use wooden sticks to shim in roll, at the
rear bow per figure :

Use a cloth to protect paint.

Take care to keep the perfect level throughout the rigging operation.

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b) Using the short G84-02-100 lock pin, lock the lateral cyclic pitch only,
c) Measure the travel space to the left cyclic stop.
Distance should be 10.5 +/- 0.2 mm
Check this distance using G84-02-200 caliper : red side should not enter, green side should.
Adjust if necessary by screwing or unscrewing the right connecting rod from the rod-end. This is
done by disconnecting the opposite rod-end from the stick base.
d) Remove the pin locking the lateral cyclic. Apply cyclic to the right stop, and check the
travel space to the right stop.
Distance should be 27.7 +/- 0.2 mm
Check this distance using G84-02-200 caliper : red side should not enter, green side should.
Adjust if necessary by screwing or unscrewing the rod-end at the pilot stick base. This is done by
disconnecting this rod-end from the stick base.

e) Set the proper rod-ends respective angles on the pilot connecting rod. For that, check
some angular free-play exist throughout the longitudinal travel.
f) Torque the two rod-ends locknuts to approx. 15 N.m. Bend the two lock washers.
g) Torque the castle nut on connecting bolt at pilot cyclic base to 7.5 - 9 N.m and install
cotter pin.

h) Using G84-02-100 lock pins, lock the lateral and longitudinal cyclic pitch at neutral,
i) Set the collective lever to full down, and set the friction,
j) Turn the rotor to align the protractor blade full forward in helicopter axis (the swashplates
arms should be perfectly aligned).
Check the pitch to minimum collective value : - 4.5° +/- 0.1° (nose down) at blade fork
Use the intermediate nut on corresponding long rod to adjust if needed,

k) Install a dial gauge between the upper swashplate and the mast per figure below.
Measure the swashplate oscillation while turning the rotor, and adjust the two lateral long
rods on the lower swashplate.
Adjust until the swashplate oscillation is lower than +/- 0.1 mm

Caution : Release the blades from their droop stops during measurements

l) When the rigging is satisfactory, remove the lock pins, and release the collective friction.
Check that every rod has a rotational free-play, in all controls position : four corners, low
and high collective. Realign rod-ends when necessary.
m) Torque all the locknuts to 15 N.m , and bend the lock tabs.

41-B-03 Main rotor pitch links adjustment IPC x-xx

The three pitch links should be initially set to the reference length. This length should be set prior
to fine track adjustment :
L = 246.5 mm with the two rod-ends parallel

To set a pitch link :

a) Check the lock tabs are released, loosen the two locknuts,
b) Install the link in the G81-02-100 tooling. Screw or unscrew the intermediate nut to adjust
the length loose on the pins. One turn = 0.5 mm.
c) Align the two rod-ends in the same plane using the tool, and torque the two locknuts to
15 N.m Check again the loose fit on the pins. Bend the lock tabs on the two locknuts.
d) If it’s the yellow pitch link (non-adjustable), apply the shrink sleeve, and shrink.

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CABRI G2 FLIGHT CONTROLS

41-B-04 In-flight collective pitch fine adjustment IPC x-xx

A fine adjustment of the minimum collective pitch should be done in flight, after following
operations :
• Replacement of any component in the control linkage : rods, rod-ends, bellcrank
• Replacement or overhaul of the main gearbox,
• Replacement of any of the main rotor hub, mounting cones,
• Replacement or overhaul of the swashplates,
• Replacement or repair of one or more blades.

Using the Flight test protocol detailed in appendix 6, check and fine adjust the minimum collective
pitch :
a) Carry flight test according to protocol, and note corresponding parameters. It is
recommended to make two different measurements,
b) For each case, determine precisely the reduced Gross Weight (RGW), using diagrams
given in Flight Manual pages 5-6 et 5-7. Use the accurate fuel quantity at the
measurement time, and an accurate weight for every on-board accessory.
c) Calculate the theoretical rotor speed using formula :

NR theoretic = 0.273 x RGW + 368 RPM RGW in kg

NR theoretical = 0.124 x RGW + 368 RPM RGW in lb

d) For every RPM in excess of NR theoretic, raise the swashplate by 7/1000 mm, and
opposite.
Tolerance is +/- 15 RPM (i.e. +/- 0.1 mm)

To lower or raise the swashplate, use the three rod-ends immediately below the lower
swashplate:
a) Bend back the locking tabs, and loosen the lock-nuts,
b) Use a wrench to screw or unscrew the intermediate nut. One turn = 0.5 mm
c) Align the rod-end with the swashplate fork,
d) Torque the lock-nuts to 15 N.m and lock by bending the tabs
e) Finally check every safety holes in the rod-ends : a piece of wire cannot go through.

41-B-04 Pitch rod-end backlash check IPC x-xx

TBC

41-B-10 Collective controls removal IPC x-xx

TBC

41-B-11 Collective controls installation IPC x-xx

TBC

41-B-12 Twist grip removal IPC x-xx

TBC

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41-B-13 Twist grip installation IPC x-xx

TBC

41-B-14 Connecting chain replacement & rigging IPC x-xx

TBC

41-B-20 Horizontal pitch rods removal IPC x-xx

TBC

41-B-21 Horizontal pitch rods installation IPC x-xx

TBC

41-B-30 Cyclic controls removal IPC x-xx

TBC

41-B-31 Cyclic controls installation IPC x-xx

TBC

41-B-40 Vertical pitch rods removal IPC x-xx

TBC

41-B-41 Vertical pitch rods installation IPC x-xx

TBC

41-B-50 Swashplate bellcrank removal IPC x-xx

TBC

41-B-51 Swashplate bellcrank installation IPC x-xx

TBC

41-B-60 Copilot cyclic controls disassembly IPC x-xx

TBC

41-B-61 Copilot cyclic controls assembly IPC x-xx

TBC

41-B-62 Copilot cyclic rigging IPC x-xx

TBC

41-B-70 Copilot collective stick disassembly IPC x-xx

TBC

41-B-71 Copilot collective stick assembly IPC x-xx

TBC

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41-C TAIL ROTOR CONTROLS

41-C-01 Tail rotor controls inspection IPC x-xx

TBC

41-C-02 Tail rotor controls rigging IPC x-xx

TBC

41-C-03 Tail rotor push-pull control disconnection IPC x-xx

TBC

41-C-04 Tail rotor push-pull control reconnection IPC x-xx

TBC

41-C-05 Tail rotor push-pull control removal IPC x-xx

TBC

41-C-06 Tail rotor push-pull control installation IPC x-xx

TBC

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41-D PEDALS ASSEMBLY

41-D-01 Pedals inspection IPC x-xx

TBC

41-D-02 Pedals removal IPC x-xx

TBC

41-D-03 Pedals installation IPC x-xx

TBC

42-A CYCLIC TRIMS

42-A-01 Trims check IPC x-xx

To check the trims simply, lift the three blades using three supporting masts, or one person at
each blade, to release the droop stops. Run the trims through the four corners. The complete
travel should take less than 20 seconds. The motors should stop at full travel, and start backward
after one or two seconds release.

42-A-02 Trims lubrication IPC x-xx

TBC

42-A-03 Trims removal IPC x-xx

TBC

42-A-04 Trims installation IPC x-xx

TBC

42-A-05 Trims gas spring replacement IPC x-xx

A gas spring should be replaced when a severe loss in its force is found, resulting in trim lack of
effectiveness. It cannot be repaired.
To replace a gas spring, use G84-03-100 installer.

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44-A THROTTLE CONTROLS

44-A-01 Throttle control inspection IPC x-xx

TBC

44-A-02 Throttle control rigging – idle adjustment IPC x-xx

TBC

44-A-03 Throttle cam mechanism replacement IPC x-xx

TBC

44-A-04 Throttle push-pull cable replacement IPC x-xx

TBC

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FLIGHT CONTROLS CABRI G2

44-B MIXTURE CONTROLS

44-B-01 Mixture controls inspection IPC x-xx

TBC

44-B-02 Mixture controls rigging IPC x-xx

TBC

44-B-03 Mixture push-pull cable replacement IPC x-xx

TBC

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CABRI G2 ENGINE INSTALLATION

E-5 Engine installation

INTRODUCTION............................................................................................................. E-5-1
DESCRIPTION................................................................................................................ E-5-1
50-A BASIC ENGINE.................................................................................................. E-5-2
50-A-01 Engine inspection ................................................................ IPC x-xx .......... E-5-2
50-A-02 Engine diagnostic ................................................................ IPC x-xx .......... E-5-2
50-A-10 Engine removal .................................................................... IPC x-xx .......... E-5-2
50-A-11 Engine installation ............................................................... IPC x-xx .......... E-5-2
50-A-12 Engine preparation for overhaul .......................................... IPC x-xx .......... E-5-2
50-A-13 Preparation of a new engine ............................................... IPC x-xx .......... E-5-2
50-B-01 Magneto timing .................................................................... IPC x-xx .......... E-5-3
50-B-02 Electronic ignition inspection & timing check ...................... IPC x-xx .......... E-5-3
50-A-03 Sparkplugs and wires inspection & criteria ......................... IPC x-xx .......... E-5-3
50-B-04 Ignition trigger check & replacement................................... IPC x-xx .......... E-5-3
50-A-05 Electronic ignition unit replacement .................................... IPC x-xx .......... E-5-3
50-A-10 Alternator belt tensioning..................................................... IPC x-xx .......... E-5-3
50-A-11 Alternator replacement ........................................................ IPC x-xx .......... E-5-3
50-A-12 Starter replacement ............................................................. IPC x-xx .......... E-5-3
50-A-20 Accessories support replacement ....................................... IPC x-xx .......... E-5-3
51-A PRIMARY TRANSMISSION & ENGINE SUPPORT ........................................... E-5-4
51-A-01 Belt inspection ..................................................................... IPC x-xx .......... E-5-4
51-A-02 Pulleys inspection ................................................................ IPC x-xx .......... E-5-4
51-A-03 Thrust bearing inspection & regrease ................................. IPC x-xx .......... E-5-4
51-A-04 Transmission belt replacement ........................................... IPC x-xx .......... E-5-5
51-A-05 Front engine supports replacement .................................... IPC x-xx .......... E-5-5
51-A-06 Rear engine supports replacement ..................................... IPC x-xx .......... E-5-5
51-A-07 Engine pulley replacement .................................................. IPC x-xx .......... E-5-5
51-A-08 Belt guides rigging ............................................................... IPC x-xx .......... E-5-5
51-B CLUTCH ACTUATOR & DISTRIBUTOR........................................................... E-5-6
Description ...................................................................................................................... E-5-6
51-B-01 Clutch general inspection .................................................... IPC x-xx .......... E-5-6
51-B-02 Clutch mechanism check .................................................... IPC x-xx .......... E-5-7
51-B-03 Clutch pressure switch adjustment ..................................... IPC x-xx .......... E-5-7
51-B-04 Clutch actuator assy removal .............................................. IPC x-xx .......... E-5-7
51-B-05 Clutch actuator assy installation.......................................... IPC x-xx .......... E-5-7
51-B-06 Clutch distributor removal.................................................... IPC x-xx .......... E-5-7
51-B-07 Clutch distributor installation ............................................... IPC x-xx .......... E-5-8
52-A COOLING INSTALLATION ............................................................................... E-5-8
52-A-01 Cooling inspection & cleaning ............................................. IPC x-xx .......... E-5-8
52-A-02 Foreign object removal ........................................................ IPC x-xx .......... E-5-8
52-A-03 Fanwheel balancing............................................................ IPC x-xx .......... E-5-8
52-A-04 Cooling scroll removal ......................................................... IPC x-xx .......... E-5-8
52-A-05 Cooling scroll installation & rigging ..................................... IPC x-xx .......... E-5-8
53-A INDUCTION CIRCUIT....................................................................................... E-5-8
53-A-01 Induction circuit inspection .................................................. IPC x-xx .......... E-5-8
53-A-02 Carburetor heating check .................................................... IPC x-xx .......... E-5-8
53-A-03 Air duct opening & closure .................................................. IPC x-xx .......... E-5-8
53-A-04 Air filter replacement............................................................ IPC x-xx .......... E-5-8

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53-A-05 Carburetor removal ............................................................. IPC x-xx ..........E-5-9
53-A-06 Carburetor inspection .......................................................... IPC x-xx ..........E-5-9
54-A OIL CIRCUIT .....................................................................................................E-5-9
54-A-01 Oil circuit inspection ............................................................ IPC x-xx ..........E-5-9
54-A-02 Oil filter replacement ........................................................... IPC x-xx ..........E-5-9
54-A-03 Oil cooler removal ............................................................... IPC x-xx ..........E-5-9
54-A-02 Oil cooler installation ........................................................... IPC x-xx ..........E-5-9
54-A-03 Oil filter adapter replacement .............................................. IPC x-xx ..........E-5-9
55-A FUEL CIRCUIT ...................................................................................................E-5-9
55-A-01 Fuel circuit inspection & drain ............................................. IPC x-xx ..........E-5-9
55-A-02 Cleaning gascolator ............................................................ IPC x-xx ........E-5-10
55-A-03 Low fuel switch check ......................................................... IPC x-xx ........E-5-10
55-A-04 Fuel gage check & calibration ............................................ IPC x-xx ........E-5-10
55-A-05 Fuel flow check & calibration ............................................. IPC x-xx ........E-5-10
55-A-10 Fuel manifold removal ......................................................... IPC x-xx ........E-5-10
55-A-11 Fuel manifold installation ................................................... IPC x-xx ........E-5-10
55-A-12 Fuel gage board replacement ............................................ IPC x-xx ........E-5-10
55-A-20 Fuel bladder removal .......................................................... IPC x-xx ........E-5-10
55-A-21 Fuel bladder installation ...................................................... IPC x-xx ........E-5-10
56-A EXHAUST & MUFFLER....................................................................................E-5-11
56-A-01 Exhaust removal.................................................................. IPC x-xx ........E-5-11
56-A-02 Exhaust installation ............................................................. IPC x-xx ........E-5-11

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CABRI G2 ENGINE INSTALLATION

INTRODUCTION

This section contains procedures for maintenance, removal and installation of the engine and its
systems. These systems include Electronic ignition, primary transmission, cooling and exhaust
systems. Refer to engine and engine equipments manufacturer’s maintenance publications for
products specific inspection, repair and maintenance procedures.

DESCRIPTION

The CABRI G2 is powered by a TEXTRON LYCOMING engine model O-360 J2A installed aft of
the main gearbox, with its crankshaft facing forward. It is hung below a truss-type engine mount,
which is also used to carry the tail boom.

The helicopter front structure is protected by a large firewall bulkhead, and the tail boom is
protected by a small, circular one. These two firewalls, together with a three-piece, non-structural
cowling, delimit the engine compartment.

The engine is fed by a single fuel tank, located between the firewall and the cabin bulkhead, on
the left side.

Through its propeller flange, the engine drives the primary transmission, made of a poly-V belt.

TEXTRON LYCOMING engine model O-360 J2A is a direct-drive, four cylinder, horizontally
opposed, air cooled engine, of a family widely used in airplanes and helicopters. It is adapted by
HG which replaced one magneto with an electronic ignition system. There is a specific oil filter
adapter and an air-conditioning compressor installation, for Cabri optional A/C.

Cooling is supplied by an engine-mounted fanwheel enclosed in a carbon fiber scroll. The scroll
ducts cooling air to the engine-mounted shroud which in turn directs the air to cylinders, oil
cooler, alternator and cabin heater.

Clutch actuator is a two-way cylinder, actuated by engine oil, and controlled by a four-way valve.

The fuel system is mainly composed of :

• A fuel tank located in the left side of fuselage,

• A fuel shutoff valve, located on the cabin bulkhead,
• An immersed, electric boost pump, of semi-centrifugal type,
• A gascolator, with water-separation screen, and drain valve,
• A fuel flow sender,
• An engine-installed diaphragm pump,
• Tank vent, filler cap, outlet screen, and connecting hoses.

All the hoses are made of PTFE, with steel-reinforcement and aluminum fittings. Inside the engine
compartment, the hoses are protected against fire, by a fireproof sleeve.

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50-A BASIC ENGINE

50-A-01 Engine inspection IPC x-xx

TBC

50-A-02 Engine diagnostic IPC x-xx

The engine diagnostic can be done with the engine cowlings just open, but is easier if it’s
removed.
Use the G85-01-100 Engine analyzer.
Before proceeding, run the engine 5 minutes if it’s cold, and proceed while its CHT is still higher
than approx. 50° C (120°F).

a) Remove the two upper engine air baffles,

b) Unplug the # 1 cylinder upper sparkplug, then replace it with the sensor fitting,
c) Connect the sensor fitting to the electronic sensor box with the fine hose,
d) Connect the sensor box to the engine analyzer,
e) Connect the engine analyzer ( two connectors) in serial in the electric regulator
male/female connector,
f) In the cabin, check the ignition switches are OFF (down), then apply starter 2 –3 engine
revolutions (4 – 6 strokes),
g) Note the parameters displayed by the analyzer,
h) Unplug the hose from the sparkplug-like fitting, then remove the fitting. Install the
sparkplug back, and torque to 20 – 27 N.m
i) Proceed from step b) above with following cylinders.

Acceptance criteria :
• Pressure > 8 bars
• Difference between two cylinders < 3 bars

Use HG30-0014 anti-seize compound for sparkplugs and inserts.

TBC

50-A-10 Engine removal IPC x-xx

TBC

50-A-11 Engine installation IPC x-xx

TBC

50-A-12 Engine preparation for overhaul IPC x-xx

TBC

50-A-13 Preparation of a new engine IPC x-xx

TBC

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50-B ENGINE EQUIPMENTS

50-B-01 Magneto timing IPC x-xx

TBC

50-B-02 Electronic ignition inspection & timing check IPC x-xx

TBC

50-A-03 Sparkplugs and wires inspection & criteria IPC x-xx

TBC
Plasma sparkplugs 20 – 27 N.m
Lower sparkplugs & Plasma inserts 47 N.m
Wires are to be replaced every 10 years or at each engine TBO.

50-B-04 Ignition trigger check & replacement IPC x-xx

TBC

50-A-05 Electronic ignition unit replacement IPC x-xx

TBC

50-A-10 Alternator belt tensioning IPC x-xx

TBC

50-A-11 Alternator replacement IPC x-xx

TBC

50-A-12 Starter replacement IPC x-xx

TBC

50-A-20 Accessories support replacement IPC x-xx

TBC

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51-A PRIMARY TRANSMISSION & ENGINE SUPPORT

51-A-01 Belt inspection IPC x-xx

The clutch is to be fully released for easier belt inspection.

a) Stick anywhere a piece of tape to mark the belt, to visualize a full revolution.
b) Rotate the belt by hand, sector after sector, until the tape reappears.
c) At each sector, inspect the outer face for marks of wear, nicks or cracks. Inspect the
inner face with the hand, by feeling for dents or cracks in the teeth.

Rejection criteria (any of them) :

• Crack at one edge more than 3 mm long
• Crack in the middle of outer face, going through,
• Marks of wear on the outer face showing belt tread cloth,
• Evidence of delamination on the belt edges,
• More than two dents, each being more than 20 mm long in the teeth.

51-A-02 Pulleys inspection IPC x-xx

The two pulleys should be inspected visually using a torch light.

The engine pulley is coated with a black-reflective coating. The gearbox pulley is coated with
clear reflecting coating. Check for peeling or wear of these hard coatings.
In case of significant damage of the coating, proceed to corresponding pulley’s replacement per
operation 51-A-07 (engine pulley) or 21-A-08 (gearbox pulley).

51-A-03 Thrust bearing inspection & regrease IPC x-xx

This bearing is located inside the engine pulley. It can be regreased through a grease nipple on
the front side of this pulley.
Check the bearing and its attachment by strongly shaking the engine. No significant free-play
should occur.
Check that no significant grease has leaked outside the bearing seal.

To regrease the bearing, use a grease pump. Carefully weight the pump before and after
pumping grease inside the nipple.
Ordinary quantity to be added is 10 – 20 grams

Caution :
During the first minutes of running after regreasing, excess grease will be
expelled out of the thrust bearing. Check it after post-maintenance check
flight, and wipe off.

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51-A-04 Transmission belt replacement IPC x-xx

TBC

51-A-05 Front engine supports replacement IPC x-xx

TBC

51-A-06 Rear engine supports replacement IPC x-xx

TBC

51-A-07 Engine pulley replacement IPC x-xx

TBC

51-A-08 Belt guides rigging IPC x-xx

TBC

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51-B CLUTCH ACTUATOR & DISTRIBUTOR

Description
The primary transmission is made of a belt which is tensioned by an hydraulic cylinder, making a
clutch.
This two-way cylinder is controlled by a four-way distributor and actuated by the engine oil
pressure. It thus cannot be moved when the engine is stopped.
The clutch is usually disengaged per engine shutdown procedure, but can be left engaged for
inspection purpose.

Notes :
• When left engaged, the clutch tension will slowly release (in hours,
depending on temperature) due to small internal leaks.
• When disengaged after the engine shutdown, the clutch will disengage
only under the gas spring force, taking minutes. It can be helped by hand
pushing the belt

For the clutch hydraulic and electric schematics, refer to section E-7 SYSTEMS

51-B-01 Clutch general inspection IPC x-xx

To check the four-way valve, check the rotating distributor’s Allen-head finger in its sector slot :
• When clutch is engaged, it should be next to the “E” engraved on the valve body
• When clutch is disengaged, it should be on the opposite side (90° rotation)

When the clutch switch is moved, the Allen finger should move from one position to opposite stop
in less than 5 seconds.

Notes :
• The distributor’s motor is controlled by a current-limitation device. If it
stops in intermediate position, try to cycle the switch 3 seconds to
reinitialize.
• The four-way valve can be moved by hand : use a 3 mm Allen wrench
and carefully use it as a lever to rotate the valve’s distributor. Never use
force, and always prefer to move it electrically.

The clutch should have no leak. Check its flexible hoses for marks of wear, chaffing, leaks.
The cylinder rod is coated with a black-reflective coating. Check this coating for marks of wear, or
scratches.
Check the two rod-ends for absence of free-play, and proper attachment.

Visually check the gas spring for absence of free-play.

A deficient gas spring is evidenced by the engine slowly moving downward in engaged position,
after shutdown.
This condition should be detected during pre-flight inspection, as the rotors cannot be turned
backwards.

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51-B-02 Clutch mechanism check IPC x-xx

a) Carry out a short ground run. Do not declutch at shutdown,

b) Measure the cylinder extension as shown on following sketch :
Max extension = 191 mm
If maximum is exceeded, the belt is worn. Confirm by visual inspection and replace the belt per
operation 51-A-04.

Cylinder extension

c) Check for oil leak,

d) Check for interference with the firewall,
e) Switch Master ON and Clutch DISENGAGE,
f) Manually ensure that declutching is carried out to its stop
g) Check for interference with the firewall,
h) Inspect the distributor and its wiring. Check for oil leak.

51-B-03 Clutch pressure switch adjustment IPC x-xx

TBC

51-B-04 Clutch actuator assy removal IPC x-xx

TBC

51-B-05 Clutch actuator assy installation IPC x-xx

TBC

51-B-06 Clutch distributor removal IPC x-xx

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TBC

51-B-07 Clutch distributor installation IPC x-xx

TBC

52-A COOLING INSTALLATION

52-A-01 Cooling inspection & cleaning IPC x-xx

TBC

52-A-02 Foreign object removal IPC x-xx

TBC

52-A-03 Fanwheel balancing IPC x-xx

TBC

52-A-04 Cooling scroll removal IPC x-xx

TBC

52-A-05 Cooling scroll installation & rigging IPC x-xx

TBC

53-A INDUCTION CIRCUIT

53-A-01 Induction circuit inspection IPC x-xx

TBC

53-A-02 Carburetor heating check IPC x-xx

TBC

53-A-03 Air duct opening & closure IPC x-xx

TBC

53-A-04 Air filter replacement IPC x-xx

a) Release the induction hose band clamp,

b) Remove the box screws,
c) Pull down the induction box,
d) Replace the air filter and check that the filter is correctly locked by the three bolts,
e) Check the carb heating mechanism, including the lip seal. Replace the seal if cracked,
worn, damaged. The seal lip should close hermetically,
f) Replace induction box with screws and hose clamp,
g) Check the carb heat mechanism : switch Master ON, then switch Carb heat on HOT, and
check that the actuator moves to alignment with the red mark.

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53-A-05 Carburetor removal IPC x-xx

TBC

53-A-06 Carburetor inspection IPC x-xx

TBC

54-A OIL CIRCUIT

54-A-01 Oil circuit inspection IPC x-xx

TBC

54-A-02 Oil filter replacement IPC x-xx

TBC

54-A-03 Oil cooler removal IPC x-xx

TBC

54-A-02 Oil cooler installation IPC x-xx

TBC

54-A-03 Oil filter adapter replacement IPC x-xx

TBC

55-A FUEL CIRCUIT

55-A-01 Fuel circuit inspection & drain IPC x-xx

TBC

Rain water drain

Tank vent

FWD
Drain valve

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55-A-02 Cleaning gascolator IPC x-xx

a) Turn the fuel valve OFF,
b) Prepare a cup to retain spillage,
c) Remove the safety wire and unscrew the knurled ring to remove the gascolator cup,
d) Unscrew the fuel filter
e) Clean it with compressed air (from inside),

Caution : Use only compressed air or a soft brush, to avoid damaging the PTFE
coating on the screen

f) Reinstall filter and cup, hand-tight,

g) Lock with safety wire,
h) Turn fuel valve ON.

55-A-03 Low fuel switch check IPC x-xx

TBC

55-A-04 Fuel gage check & calibration IPC x-xx

TBC

55-A-05 Fuel flow check & calibration IPC x-xx

TBC

55-A-10 Fuel manifold removal IPC x-xx

TBC

55-A-11 Fuel manifold installation IPC x-xx

TBC

55-A-12 Fuel gage board replacement IPC x-xx

TBC

55-A-20 Fuel bladder removal IPC x-xx

TBC

55-A-21 Fuel bladder installation IPC x-xx

TBC

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CABRI G2 ENGINE INSTALLATION

56-A EXHAUST & MUFFLER

56-A-01 Exhaust removal IPC x-xx

a) The two lateral engine skirts must be removed.

b) Remove the muffler : remove the attachment bolt on the supporting brace, release the
two clamp bolts. Use twisting motion and anti-seize oil if necessary.
c) When preparing for engine removal, remove the brace from the engine case. Plug the
hole.
d) Remove the four-in-one manifold, preferably before releasing the clamping nuts on the
cylinders.
e) Remove the EGT probe clamp from #1 exhaust pipe.
f) Release the two heater hoses band clamps.
g) Remove the four exhaust pipes using a long reach socket with universal joint.

56-A-02 Exhaust installation IPC x-xx

a) Install the EGT probe on the #1 pipe,

b) Install the four exhaust pipes. Apply Carefully check the spiral exhaust gaskets. Do not
torque,
c) Slip the four-in-one manifold onto the four pipes ends, to their position. Install the four
locking bolts and leave loose,
d) Remove the plug and install the supporting brace on the engine drive pad. Torque to
10 N.m and apply torque seal,
e) Install the muffler, and slip the attaching band clamp to its position,
f) Torque the exhaust nuts to 20 N.m and apply torque seal,
g) Tighten the six clamping bolts slightly and apply torque seal,
h) Check the clearance between the muffler, the transmission shaft, the engine mount
tubes is at least 10 mm,
i) Slip the two cabin heater hoses on the heat muff tubes, and tighten the two band clamps
slightly,
j) Check the pipes fit and clearance, the EGT probe routing,
k) Re-install the lateral skirts.

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ENGINE INSTALLATION CABRI G2

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CABRI G2 AIRFRAME

E-6 Airframe

DESCRIPTION................................................................................................................ E-6-1
61-A MAIN AIRFRAME.............................................................................................. E-6-1
61-A-01 External cabin and cowlings inspection .............................. IPC x-xx .......... E-6-1
61-A-02 Plexiglas inspection ............................................................. IPC x-xx .......... E-6-1
61-A-03 Cabin inspection .................................................................. IPC x-xx .......... E-6-1
61-B COWLINGS...................................................................................................... E-6-1
61-B-01 Installation & removal .......................................................... IPC x-xx .......... E-6-1
61-B-02 Protection replacement ....................................................... IPC x-xx .......... E-6-1
61-C ENGINE COMPARTMENT ............................................................................... E-6-1
61-C-01 Central firewall removal....................................................... IPC x-xx .......... E-6-1
61-C-02 Central firewall installation .................................................. IPC x-xx .......... E-6-1
61-C-03 Battery shelter removal & installation ................................. IPC x-xx .......... E-6-1
62-A LANDING GEAR ............................................................................................... E-6-2
62-A-01 Landing gear inspection & check ........................................ IPC x-xx .......... E-6-2
62-A-02 Skid shoe replacement ........................................................ IPC x-xx .......... E-6-2
62-A-02 Landing gear removal .......................................................... IPC x-xx .......... E-6-2
62-01-03 Landing gear installation .................................................... IPC x-xx .......... E-6-2
62-A-04 Landing gear assembly ....................................................... IPC x-xx .......... E-6-3
62-A-05 Skid check, repair & criteria................................................. IPC x-xx .......... E-6-3
63-A DOORS............................................................................................................. E-6-3
63-A-01 Doors & mechanism inspection........................................... IPC x-xx .......... E-6-3
63-A-02 Door seals replacement ...................................................... IPC x-xx .......... E-6-3
63-A-03 Lock mechanism maintenance ........................................... IPC x-xx .......... E-6-3
63-A-04 Door hinges replacement .................................................... IPC x-xx .......... E-6-3
63-A-10 Baggage door check and rigging ........................................ IPC x-xx .......... E-6-3
63-A-11 Baggage door removal & installation .................................. IPC x-xx .......... E-6-3
64-A ENGINE MOUNT FRAME ASSY....................................................................... E-6-3
64-A-01 Engine mount & bars inspection ......................................... IPC x-xx .......... E-6-3
64-A-02 Engine mount criteria & repairs ........................................... IPC x-xx .......... E-6-3
64-A-03 Engine mount replacement ................................................. IPC x-xx .......... E-6-4
65-A TAIL STRUCTURE........................................................................................... E-6-4
65-A-01 Tail structure inspection ...................................................... IPC x-xx .......... E-6-4
65-A-02 Tail structure removal .......................................................... IPC x-xx .......... E-6-4
65-A-03 Tail structure installation...................................................... IPC x-xx .......... E-6-4
65-A-04 Horizontal stabilizer removal & installation ......................... IPC x-xx .......... E-6-4
65-A-05 Tail skid inspection & repair ................................................ IPC x-xx .......... E-6-4
66-A SEATS & HARNESSES .................................................................................... E-6-5
Description ...................................................................................................................... E-6-5
66-A-01 Crash absorbers check ....................................................... IPC x-xx .......... E-6-5
66-A-02 Crash absorber replacement ............................................... IPC x-xx .......... E-6-6
66-A-03 Seat upholstery replacement .............................................. IPC x-xx .......... E-6-6
66-A-04 Seat belt replacement ......................................................... IPC x-xx .......... E-6-6
67-A Cabin................................................................................................................ E-6-6
67-A-01 Arm rest removal ................................................................. IPC x-xx .......... E-6-6
67-A-01 Arm rest installation ............................................................. IPC x-xx .......... E-6-6
67-A-04 Cabin furnishing & carpet .................................................... IPC x-xx .......... E-6-7
67-A-05 Foot rest installation ............................................................ IPC x-xx .......... E-6-7

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CABRI G2 AIFRAME

DESCRIPTION

The Cabri airframe is constructed primarily of composite sandwich, with a welded-steel truss
engine support for fire resistance.
The landing gear is made of aluminum alloy.

Carbon fibers with polyimide honeycomb are used for the primary structure and the tail boom.
Fiberglass is used for the cowlings and the horizontal stabilizer.
The primary structure left box holds the fuel tank. The right box is the luggage compartment with
an outside access door.
The main fuselage and the tail boom are protected against engine fire by titanium firewalls.

61-A MAIN AIRFRAME

61-A-01 External cabin and cowlings inspection IPC x-xx

TBC

61-A-02 Plexiglas inspection IPC x-xx

TBC

61-A-03 Cabin inspection IPC x-xx

TBC

61-B COWLINGS

61-B-01 Installation & removal IPC x-xx

TBC

61-B-02 Protection replacement IPC x-xx

TBC

61-C ENGINE COMPARTMENT

61-C-01 Central firewall removal IPC x-xx

TBC

61-C-02 Central firewall installation IPC x-xx

TBC

61-C-03 Battery shelter removal & installation IPC x-xx

TBC

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AIRFRAME CABRI G2

62-A LANDING GEAR

62-A-01 Landing gear inspection & check IPC x-xx

a) Inspect the helicopter from the front and the sides in order to detect any unusual attitude
or height. Verify fuselage symmetry with landing gear.
b) Check parts for paint wear or scratch. If needed sand with 600 Grit abrasive. Then, apply
HG31-0031 chromate primer protection then paint.
c) Inspect for no cracks nor corrosion (pay particular attention to landing gear pants)
d) Inspect fuselage/landing gear attachment
• Check symmetry and condition
• Check no cracks on attachment straps and fuselage
• Inspect bolts and safety wires
• Check the fuselage troughs for damage
• Inspect rear bow worm clamps
e) Skid shoes : check the rivets, shoes, and the carbide pads for damage or tearing-off.
f) On a flat floor, check landing skid distance at bows, as shown on drawing below :

Maximum authorized outer width is :

 At rear bow : 1820 mm (71.6 in)
 At front bow : 1850 mm (72.8 in)

Maximum authorized height difference is 20 mm (3/4 in)

62-A-02 Skid shoe replacement IPC x-xx

TBC

62-A-02 Landing gear removal IPC x-xx

TBC

62-01-03 Landing gear installation IPC x-xx

TBC

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62-A-04 Landing gear assembly IPC x-xx

TBC

62-A-05 Skid check, repair & criteria IPC x-xx

TBC

63-A DOORS

63-A-01 Doors & mechanism inspection IPC x-xx

TBC

63-A-02 Door seals replacement IPC x-xx

TBC

63-A-03 Lock mechanism maintenance IPC x-xx

TBC

63-A-04 Door hinges replacement IPC x-xx

TBC

63-A-10 Baggage door check and rigging IPC x-xx

TBC

63-A-11 Baggage door removal & installation IPC x-xx

TBC

64-A ENGINE MOUNT FRAME ASSY

64-A-01 Engine mount & bars inspection IPC x-xx

a) Remove the three engine cowlings,
b) Thoroughly clean the truss and check for marks, cracks or corrosion,
c) Check the bolts for tightening and safety,
d) Check the tail rotor flexible control, the engine cooling skirts and cuffs for no chaffing and
proper condition,
e) Inspect the four engine mount attachment (on fuselage side)
• In case of any doubt (marks of corrosion, moisture,…), slide the fire sleeve on the
attachment for inspection.
• Inspect for no cracks or corrosion.

The right hand upper attachment cannot be inspected closely without opening the induction duct.
To open this duct, refer to operation 53-A-03.

64-A-02 Engine mount criteria & repairs IPC x-xx

TBC

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64-A-03 Engine mount replacement IPC x-xx
TBC

65-A TAIL STRUCTURE

65-A-01 Tail structure inspection IPC x-xx

TBC

65-A-02 Tail structure removal IPC x-xx

TBC

65-A-03 Tail structure installation IPC x-xx

TBC

65-A-04 Horizontal stabilizer removal & installation IPC x-xx

TBC

65-A-05 Tail skid inspection & repair IPC x-xx

Measure the distance between tail skid bottom and fin bottom :

Distance H = 190 mm nominal

If H > 180 mm, the skid could be let installed.

If H < 180 mm, remove the skid, and check its bent in the cylindrical part of it :

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CABRI G2 AIFRAME
If deflexion < 8 mm the skid can be bent back to approximately straight at its root. Use a stand
press and three blocks of soft wood or rubber. Make an entry in the helicopter maintenance log.
After one skid was bent for a cumulated deflexion of 20 mm, or if it cannot be bent back straight
to +/- 2 mm, discard the skid.

If D> 8 mm, discard and change the skid.

To install the skid, slide it in its fixture, using a twisting motion if necessary. Avoid scratching it.
Torque the attachment bolt to contact only, then add carefully to suppress free-play in the skid.
Do not overtorque.

After any significant tail skid strike, inspect :

• the bottom of the fin for marks or damage, composite delamination,
• the tail rotor shroud for marks of blades contact,
• the tail boom at the upper fin root, for clue of main blade strike,
• the tail boom root in the attachment bolts area for any clue of rivet debonding.

In case of any damage in these areas, the tail boom should be returned to the manufacturer.

66-A SEATS & HARNESSES

Description
The Cabri seats are installed on the main cabin bulkhead, and have a very high energy
absorption capability, thanks to their absorption device and stroking capacity.
The two seats are identical. The left seat can be removed as a routine operation.
For seats removal & installation, refer to operation A-35 of this manual.

66-A-01 Crash absorbers check IPC x-xx

Check the crash absorbers in case of very hard landing with landing gear damage, or in case of
doubt.

Simple check :

With an absorber in new condition, each upper seat (brown plastic) slide must be flush with each
slide rail at their upper end :
A maximum misalignment of 2 mm is permitted. Above this value, proceed to complete check as
below.

Complete check :

a) Remove the seat pan per operation A-35

b) Check the carbon fiber seat pan at its attachment
c) Check the long stud straightness. Maximum deflexion permitted : 2 mm
d) Check the two spacers, particularly where they bear on the absorber clevis.
e) Check the absorber attachment
f) Check the absorber for backlash. Maximum backlash permitted : 2 mm
g) Inspect the outer tube at its shoulder, for small blisters evenly spread. A maximum
indication of stroke of 2 mm is permitted.

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AIRFRAME CABRI G2
66-A-02 Crash absorber replacement IPC x-xx
Remove the upper attachment bolt, then reinstall the new absorber. Torque to contact plus a
slight preload allowing the absorber to rotate with friction. Apply torque seal.

66-A-03 Seat upholstery replacement IPC x-xx

TBC

66-A-04 Seat belt replacement IPC x-xx

TBC

67-A Cabin

67-A-01 Arm rest removal IPC x-xx

a) Remove the four lower instrument panel bolts,

b) Remove the instrument panel,
c) Remove the collective friction axle,
d) Remove avionics from their racks,
e) Remove intercom knobs and attaching screws,
f) Turn cabin heat control OFF and remove control knob,
g) Open the leather boot,
h) Remove the arm-rest, and unplug the MP3 input connector when installed,
i) Reinstall the collective friction axle to avoid collective over-travel.

67-A-01 Arm rest installation IPC x-xx

Warning : Before closing the armrest, always conduct a thorough inspection of the central box :

a) Check that no foreign object is left inside,

b) Check that every control rod is attached and secured with cotter pin or toque seal,
c) Check that a minimum clearance of 5 mm exist between every moving parts, by cycling
the cyclic at zero, and full collective setting, with no chaffing,
d) Check the pedals and tail rotor control by cycling the pedals stop-to-stop, inspecting for
no interference nor chafing,
e) Check the throttle control, and governor motor by cycling the twist grip at zero, and full
collective setting,
f) Check the trims mechanisms, for free motion and electrical wires clearance,
g) Check that every wire and electrical bundle is secured and free from chafing,
h) When available, ask a “new eye” to run again the above check-list.

To close the armrest :

a) TBC

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67-A-04 Cabin furnishing & carpet IPC x-xx

67-A-05 Foot rest installation IPC x-xx

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CABRI G2 SYSTEMS

E-7 Systems

INTRODUCTION............................................................................................................. E-7-1
71-A ELECTRICAL CIRCUIT.................................................................................... E-7-1
Description ...................................................................................................................... E-7-1
71-A-01 Electrical circuit inspection .................................................. IPC x-xx .......... E-7-2
72-A INSTRUMENTATION..................................................................................... E-7-15
72-A-01 Instrument panel removal and inspection ........................... IPC x-xx ........ E-7-15
72-B PITOT & STATIC CIRCUIT ............................................................................ E-7-16
72-B-01 Pitot and static inspection................................................... IPC x-xx ........ E-7-16
72-C AVIONICS...................................................................................................... E-7-16
72-C-01 Avionics & antennas inspection .......................................... IPC x-xx ........ E-7-16
72-C-02 ELT inspection & test .......................................................... IPC x-xx ........ E-7-16
75-A CABIN HEATING ............................................................................................ E-7-16

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CABRI G2 SYSTEMS

INTRODUCTION
This section covers the electrical circuit, instrumentation, Pitot-static circuit. avionics, and special
electronics.
It also covers optional air conditioning system and optional pop-out floats.

The Cabri G2 exists with two different instrument panels :

• The narrow, four-hole panel, limited to day-VFR operation,
• The wider, seven-hole panel, additionally capable of night-VFR equipment.

71-A ELECTRICAL CIRCUIT

Description
The electrical circuit is a conventional 12/14 V circuit, powered by the engine-driven alternator
through a lead-acid battery. It is described by the following general layout :

Voltage Regulator ALT.

MASTER Master BB Regulator
relay
BB Ammeter
+ Alternator
A+
Master
- + relay

BATTERY Starter
Direct relay Starter
ALT.
battery
Radios & starter
PLASMA
Plasma Interm. Starter
relay
Avionics Ancillaries
Gov.
Electronic Gov. Off
Starting
ignition logic START
B Brake
Doors Lock GOV. U
Oil P.
Magneto Auxiliar
Motor Governor S
inhibition
during starting
-ies MGB T.
Hour Counting
13.7 V. Aux
socket meter logic EPM Alt.
BARC Hr
backup BB meter

Backup NR EPM Warn light

Normal Alim 1 B
Mute Nav lights
A
BARC Nav. lights
Horn Alim 2
R
BARC
Alim 1 Landing light
main
Landing
NR lights light
Low Fuel Pump
Clutch Strobe, Trim

Strobe light
Clutch Trim
Control
Carb.
PUMP CLUTCH valve
heat

EPM Clutching BB Battery breaker

Carb. logic Hot wire
heat Fuel
pump

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71-A-01 Electrical circuit inspection IPC x-xx

TBC

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CABRI G2 SYSTEMS

B1 R adio s - S tarte r
15 A

B2 La ndin g ligh t
10 A

B3 Lig hting
10 A Alternator
G e nera tor

B4 S trob e – T rim regulator

re gu la tor

B 10 A
U B5 E P M – H o urm e te r – B A R C A 2
S 5 A

B6 A lterna to r ON
B 5 A
A B7
P u m p – C lutch – C a rb . h eatin g GALT.
EN.
R 5 A

B8 BARC A1
5 A EALT.
LEC. A lt.
B9 A n cilaries - R R M
5 A

+
BB2
B 10 W a rn ing lig hts
A m m e te r
5 A BARC
S p are P o w e r s u p p ly 2 (A 2 )
B 11 [N R c op y fo r M F D ]
15 A T o a n c illa ire s
M u te Backup D 1 (in lin e ) b o ard lo gic
E n gine +
-
P o w e r s u p p ly 1 (A 1 ) S ta rte r
[B A R C fu n ctio n s ]

B 12 P la sm a D 3 (in lin e )
NR
5 A N o m ina l TB R R
S ta rter M as te r
A nc illaries – A ux pow er so cke t re lay rela y

D 4 (in lin e )
NR BKP BB1 BB4 BB3
N o m in a l

Ancillaries – Aux. Power

PLASMA
BAR C panel

BARC Backup
A vio nics

A vion ic’s rela y

S ta rting c irc uit

logic
ON
G71-26-101 diagram
M A STER
Power generation and distribution

N O TA: A n c illa rie s b o a rd fu n c tio n s F or info rm atio n

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CABRI G2 SYSTEMS
MAGN.TSW Engine
Priseconnector
moteur Magneto
connector
Prise magnéto
P 4
R 3

CABRI G2
25-12 8

RRM
RRM g
2
BATTERY
PLASMA TSW -
B11 EPM 1
+
-
w

Switch
Plasma connector
Prise Plasma
Magneto
START
Tach
B9 7
2 15
B 8
U
S

B
16 Plasma sensor

GND
A
R 9
U Ch B
> 1 Bar
Shield

Ch A

Channel
13
< 1 Bar
1

A
P T B

Pression
R

Alim.
d’huile moteur
Ancillaries board
Carte servitude 4 V

Channel
2 J

B
p

B LSE PLASMA 2
CD IGNITION
A

G71-27-102 diagram
Cylindres Ignition circuit (compact sensor)
1 et 2
Cylindres
3 et 4

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CABRI G2 SYSTEMS
MAGN.TSW Engine
Prise connector
m oteur

P M agnéto

PLASMA TSW Sub-D

Prise Plasma
sub-d
BATTERY
B11
connector
Plasma
-
+ PLASM A
7
sensor
8
Bc
5 n

V
Channel B
START Shield

G
B9 10 p

1
2 15 N
B 2 m
U
N

2
S
1 T

Channel A
16

G
B
A Shield
R 9 U

V
R
4 V

> 1 Bar

13 LSE PLASMA 2
< 1 Bar

P
CD IGNITION
Pression
Engine oil
Ancillaries board
Carte servitude
d’huile moteur
pressure

CABRI G2
RRM
RRM

25-12
G71-27-101 diagram
Ignition circuit (large sensor)

EPM

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Starting en clucthing circuit

B1 Radios Alt.
Intercom
« Direct battery » circuit Ammeter
B9 B B1

START U
B2 +
S -
Starter

B
A
B11
R Master Starter
relay relay
First Starter B12 BB2
relay

MASTER
M

1"
MAGN
TSW Magneto

Antitheft

1'
& D15
> 1 Bar

Fly D16
< 1 Bar

Gnd P
Fly Pression
d’huile moteur
B5 0 0 0 0,0 Gnd
HOURS

Emb Hourmeter
B7
Deb
Fly
Emb Gnd
Serré
D17
Deb
D8
Brake switch
D34

CLUTCH B9
TBRR relay
BARC OIL P.
Fct°
TBRR
B10

BRAKE
M
< 4 Bar CLUTCH
Clutch.
Cyl
Vérin Emb. P
G71-27-101 diagram
G71-27-102 diagram
De-
Deb.
Clutch.
Starting and clutching circuit

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EPM

MFD-25-18

Polyswitch (in
line)
MFD-25-19

R
M
C-AIR

+ Chaud
f

- Carburator heating
relay (in line)

+
Froid M

Double
Double inverseur
alternation 3
switch
3positions
positions B
U
B7
S
G71-32-100 diagram
K Carburettor heating circuit
B
A
R
Nota :
L
: connecteur
Connector
C-PDB

FGP-2-F

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Vers faisceau radio

Faisceau manche cyclique

Pilote

AUDIO MODULE
Faisceau manche
cyclique Co-pilote

Chang. Freq. pilote

5

19 20 23 22
PTT co-pilote 18
9
2

A A’
5 (Piquer)

Trim pilote
B B’
A’ A
7 1 (Babord)
6

(Piquer)

B’ B BCT C C’
16 6 (Cabrer)
3

(Babord)

D D’
C’ C
17 4 (Tribord)
4

(Cabrer)

D’ D
15
1

(Tribord) 21
2
Trim co-pilote
24
Copilot
EntréeFreq
Chang. 25 3 10 11 12 13 PTT pilote
change
Freq. Co-pilote

B G71-31-100 diagram
M M
U Cyclic sticks circuit
En Reserve
réserve sur S Longitudinal Latéral
module de B4
Junction 10 A
jonction
module B
Strobe Nota : Copilot
connecteur copilote
connector
A
R

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SYSTEMS CABRI G2

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Hélicoptères Guimbal Maintenance Manual
CABRI G2 SYSTEMS

72-A INSTRUMENTATION

72-A-01 Instrument panel removal and inspection IPC x-xx

Before opening
• Inspect panel and attachment condition
• Check instruments fastening
• Clean panel and screen with soft cloth and soap or isopropylic alcohol

Narrow panel opening

• Opening and removal of the panel maybe done by one person

• Remove the glareshield (two bolts) and tilt instrument panel 30° backward,
• Disconnect the two EPM flat connectors, the static and pitot plastic tubes from the
instruments, the flat connector on the ancillaries board, and the main panel round
connector.
• The complete panel can then be removed (two bolts) or tilted flat backward. Protect the
EPM screen from interference with the collective lever.

Wide panel opening

TBC

Inspection
• Check electrical harness for neatness, security, no chafing, no loose or poor wire condition
• Verify static and Pitot circuit. Verify lines and fittings condition. Verify no condensation
TBC

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SYSTEMS CABRI G2

72-B PITOT & STATIC CIRCUIT

72-B-01 Pitot and static inspection IPC x-xx

a) Check condition
b) Check Pitot tube attachment
c) Check static port and plastic angle condition.

72-C AVIONICS

72-C-01 Avionics & antennas inspection IPC x-xx

TBC

72-C-02 ELT inspection & test IPC x-xx

TBC

75-A CABIN HEATING

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Hélicoptères Guimbal Maintenance Manual
CABRI G2 MISCELLANEOUS

E-8 Miscellaneous

81-A-01 Handling wheel disassembly IPC x-xx

To remove the wheel spindle from the attachment housing, remove the locking bolt, then slide the
spindle off, using twisting motion.

Locking bolt

To remove the wheel from the spindle, remove the snap-ring from the spindle, using a fine
screwdriver. Slide the screwdriver circularly around the tube, to avoid bending the snap-ring.
Use a plastic mallet to slip the wheel off.

81-A-02 Handling wheel tire replacement IPC x-xx

The tire must be changed when any blister, cut or delamination appears on its sides.
It is recommended to change the tube when changing the tire, unless very recent.

• Remove the wheel from the spindle per operation 81-A-01,

• Deflate completely the tire,
• Remove the three thrust bolts,
• Remove the tire from the rims. Use a plastic chisel if necessary as a lever
against the rim shoulder.

To reinstall the new tire, proceed the inverse way :

• Install the tube inside the tire,
• Inflate slightly the tube, to prevent it to be nipped in the wheel,
• Install one rim in the tire, with proper valve orientation,
• Install the other rim with the bolts, nuts and washers. The nuts must be on the
valve side.
• Torque the nuts to 9 N.m
• Inflate the tube to 4 .5 – 5 bars (65 -70 PSI)
• Reinstall the wheel on the spindle. Install the snap-ring with a circular motion.

81-A-03 Handling wheel bearings replacement IPC x-xx

• Remove the wheel from the spindle per operation 81-A-01,

• Deflate the tire,
• Heat the wheel to 80°C (180°F) to remove and reinst all the bearings
• Re-inflate the wheel,
• Reinstall the wheel on the spindle. Install the snap-ring with a circular motion.

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MISCELLANEOUS CABRI G2

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CABRI G2 TROUBLE SHOOTING

Section F Trouble shooting

 EPM doesn’t boot at Master switch-on

Check the EPM breaker
Cycle the Master switch. Wait 10 seconds after switching off.

 Engine doesn’t crank when pressing starter button

Check antitheft is disabled : Use the remote door lock transmitter. Press “Unlock” to double
check.

 Engine doesn’t start when cranked

Check the ignition switches are both “On”. The buzzer should be sounding.
Check the fuel shutoff valve is open
Check the fuel pressure

 Clutch doesn’t engage

Check the rotor brake is disengaged. The “Brake” light should be off.

 Clutch light doesn’t go off

Check the oil pressure.
Shutdown the engine without disengaging the clutch. Stop the rotor.
Open the right cowling, check by hand the belt tension; inspect the clutch cylinder position at the
gas spring rod.

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TROUBLE SHOOTING CABRI G2

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Hélicoptères Guimbal Maintenance Manual
CABRI G2 APPROVED MATERIAL LIST

Section G Appendix

G-1 Approved material list

The following items are available from the manufacturers or their distributors. Check with
appropriate regulatory authority for allowable use of primers, solvents, cleaners, fillers, putty,
strippers and paints.

Caution : Follow product manufacturer’s instructions for handling and storage.

Greases

HG N° Description Manufacturer Designation

Bearings grease Shell Aeroshell Grease 7
NATO G354 Castrol Aeroplex
HG30-0013
AIR 4210 Nyco Grease GN10
MIL G23827C Elf aviation Grease 10
Champion
HG30-0014 Anti-seize graphite compound # 2612
aerospace
Mineral graphite grease Shell Aeroshell Grease 8
HG30-1691 NATO G355 Nyco Grease GN06
AIR 4206 Elf aviation Grease 06

Oils

HG N° Description Manufacturer Designation

HG30-0016 Preservative oil Total Aeroprotective 219

HG30-0039 Gearbox oil Total TM 85W140

Engine straight mineral oil Total Aero 80
HG30-1408
AIR 3560/D Shell Aeroshell oil 80
Total Aero DM 15W50
HG30-1409 Multigrade engine oil
Shell Aeroshell W 15W50

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APPROVED MATERIAL LIST CABRI G2

Adhesives

HG N° Description Manufacturer Designation

HG32-0048 Structural epoxy high performance Axson Adekit 140

HG32-0084 Strong fit anaerobic Loctite # 638

HG32-0087 Black MS Polymer compound Henkel Terostat MS 937 black

HG32-0106 Soft threadlock anaerobic Loctite # 222

HG32-0107 Strong threadlock anaerobic Loctite # 2701

HG32-0108 Medium threadlock anaerobic Loctite # 243

HG32-1239 White MS Polymer compound Henkel Terostat MS 937 white

HG32-1240 High performance silicon Loctite # 5910

HG32-1388 Medium fit anaerobic Loctite # 643

Sealants

HG N° Description Manufacturer Designation

HG32-1346 Sealant – low viscosity anaerobic Loctite # 542

HG32-1461 Thread sealant anaerobic Loctite # 577

Torque seal

HG N° Description Manufacturer Designation

Organic White torque seal
HG39-1536 Torque seal products Schrauben-
Bäder sicherungslack

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CABRI G2 APPROVED MATERIAL LIST

Paints, primers
HG support can provide paint code numbers and references for specific helicopter serial numbers
if necessary for color matching.

HG N° Description Manufacturer Designation

Paints

HG31-0004 Glossy white exterior paint Mapaero A1500 M 9016

HG31-0012 Light grey interior paint Mapaero FR2-55 7040

HG31-0033 Bright metallic grey aluminum paint Mapaero A1500 M 7099

HG31-1189 Acrylic varnish Dupont 3550 S

HG31-1219 Dark grey interior paint Mapaero FR2-55 7376

HG31-1303 Semi gloss blue exterior paint Mapaero A1500 M 5159 60-80GU
CENTARI 5035 PGT
HG31-1307 Yellow exterior paint Dupont
EBH
HG31-1324 Light beige interior paint Mapaero FR2-55 1416

HG31-1562 White exterior paint Dupont CENTARI 6000 EWP

HG31-1585 Charcoal gray paint Monopol 903-910 grey model

HG31-1714 Acrylic paint base (generic) Dupont CENTARI 6000

Primers
Monopol P05 jaune 8194
HG31-0031 Strontium chromate epoxy primer
PRC DeSoto 7835ANV
Monopol L901
HG31-0177 Primer
PPG Aero Sanding surfacer
HG31-1669 Adhesion primer (stickers) 3M # 4298

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APPROVED MATERIAL LIST CABRI G2

Varnishes

HG N° Description Manufacturer Designation

HG31-0308 Anti-seize varnish (two-parts) Dow Corning Molykote 3400 A

HG31-1387 Anti-seize varnish (spray can) Dow Corning Molykote D-321R

Sealing compounds

HG N° Description Manufacturer Designation

Le Joint Français
HG31-0123 Anti-corrosion compound PR 1771B2
PRC DeSoto
Le Joint Français
HG31-0124 Fuel sealant PR 1776B
PRC DeSoto
Le Joint Français
HG31-1198 Fire sealant PR 812
PRC DeSoto

HG32-0197 High temperature silicon sealant GE Silicones RTV 110

Mastinox 6856 K
HG31-0017 Isolation chromate compound PRC DeSoto
Yellow

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Hélicoptères Guimbal Maintenance Manual
CABRI G2 APPENDIX

G-2 Special tools

Special tools are required to carry out some of the maintenance actions. They should be ordered
to HG as needed :

Reference Designation

G81-01-100 Hoist plate / Main rotor hub puller

G84-00-100 Pitch setting tool (protractor support)
G81-02-100 Lead-lag damper and pitch link setting tool
G82-01-100 Main and tail gearbox draining tool
G83-00-100 Tail rotor alignment tool
G84-02-100 Set of cyclic pitch lock pins
G84-00-200 Lateral pitch rigging caliper
G84-11-100 Governor friction setting tool
G84-03-100 Trim gas spring installer
G85-00-600 Engine stand
G85-01-100 Engine analyzer

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APPENDIX CABRI G2

G-3 Tail rotor blade rigging check template

Check alignment with one blade tip track

Axe cent r al

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CABRI G2 APPENDIX

G-4 Safety pin table

Torques should be applied as specified in each assembly procedure.

Torques specified “dry” should be applied to a clean nut on a clean bolt.
For wet assemblies, use specified grease.

Cotter pins dimensions :

Safety pin
Bolt diameter
diameter length
mm
mm in mm in
5 1 0,04 10 0,4
6 1,6 0,06 10 0,4
8 1,6 0,06 15 0,6
10 2 0.08 20 0.8

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APPENDIX CABRI G2

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Hélicoptères Guimbal Maintenance Manual
CABRI G2 FLIGHT REPORT

Section H Flight report models

Periodic inspections require to carry-out flight checks after all operations have been completed.

For each type of flight check, a flight report model is given in this appendix.

Appropriate acceptance criteria are given.

These flight reports should be printed, filled, dated, signed and kept in the helicopter maintenance
file with corresponding inspection reports.

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FLIGHT REPORT CABRI G2

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CABRI G2 FLIGHT REPORT

Post - 500 hrs inspection Flight Test Report Cabri G2 S/N : Registration :

Summary Gross weight C.G. Met Balancing installation

Airfield………………. Longitudinal Info Balancer :

Empty equipped…
Date………………….. Runway
Crew……………… Tracker :
Hobbs initial…...… Wind
Ballast……………
Flight time……………. OAT/Due point
Fuel……………… Lateral Accelero :
QNH
Nb startups…….…. (d = 0.72 kg/l)
QFE
Nb Landings…….… Take-off Gross : __________ Other :
(must be < 640 kg)

Optional equipments Operations carried-out prior to this flight Crew remarks following this flight

Main rotor track & balance summary :

Radio frequencies : Crew Name Signature

ATIS Pilot
GND Engineer
TWR

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FLIGHT REPORT CABRI G2

Proceeding Results & comments

Preliminary
Pre-flight check (per Flight Manual section 4) DONE
With master switch OFF
NR backup switch - Check light – Release PASS FAIL
Check map & backup panel light (when applicable) PASS FAIL
Switch Master ON
Set Units and time setting SET
Warning lights test (Low fuel retarded) PASS FAIL
Horn test - tone & level PASS FAIL
Sensors test PASS FAIL Note :

Electric trim (pilot & copilot) - check direction PASS FAIL

Navigation lights ON - Check & check EPM dim PASS FAIL
Carb. heat HOT – go out check actuator position
PASS FAIL
Carb. heat COLD – go out check actuator position
 AUTO Fuel Fuel
NM NR
Qty flow

Note EPM parameters

Carb. T CHT Oil T Oil P
Note warning lights and EPM warnings

Check full controls travel % mini % maxi

Low Collective
START START
Check collective friction
Check throttle indication : % mini % maxi
Full Collective
START START

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CABRI G2 FLIGHT REPORT

Fuel boost pump ON – note pressure Fuel P

Start engine
Apply standard procedure per Flight Manual
Start - Check starter light on PASS FAIL
Check Oil P warning light OFF - max 10 sec. PASS FAIL
Switch Alt. ON - Warn. light off @ NM>1500 RPM PASS FAIL
EPM gage green

Set throttle to 0 % - Engage clutch

Start the EPM stopwatch Rotor synchronization time :
Wait for idle to stabilize
Clutch light-off time :

When idle is stabilized

Fuel Fuel NR at
NM NR
Qty flow balancer

Carb. T CHT Oil T Oil P

Batt. OAT EGT Fuel P

Increase NR to 400 RPM

Test ignition systems Switch off Magneto 3 sec. : NM drop : (Max drop100 RPM) PASS FAIL

Switch off Plasma 3 sec. : NM drop : (Max drop 300 RPM) PASS FAIL

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FLIGHT REPORT CABRI G2

Switch governor ON - check “Gov off” light OFF PASS FAIL

Check governor engagement at 400 RPM
PASS FAIL
Stay in green arc – no overshoot
Test pilot override - underspeed & overspeed
Check low-NR light: Blink 455 RPM +/- 5 PASS FAIL
(decreasing) Cont. 471 RPM +/- 5 PASS FAIL
Test freewheel and low-RPM horn PASS FAIL
Check high-NM warning PASS FAIL

Test carb. heat : switch “HOT” Tcarb increase : Time to light : 1

2
3
Switch back “AUTO”
(red) 4
Indicated FE FE PASS FAIL
Check altimeter +/- 1 hPa
Check OAT +/- 2°C Indicated OAT OAT PASS FAIL

Rotor T&B - Ground / collective low stop :

Balance : Track
Measure track & balance
Change if : Balance > 0.2 IPS Phase : Blade 2:
Track > 5 mm Blade 3:

Correction history & Analysis :

Balance : Track

Final T&B Phase : Blade 2:

Blade 3:

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CABRI G2 FLIGHT REPORT

Stabilize IGE hover 2 minutes

Fuel Fuel NR at
MLI NR
Qty flow balancer

Time :………….. Carb. T CHT Oil T Oil P

Batt OAT EGT Fuel P

Check Track & balance Balance : Track

Change if : Balance > 0.2 IPS Phase : Blade 2:
Track > 5 mm
Blade 3:

Level flight @ 100 % MLI Balance : Track Prevailing frequencies :

Check Track & balance
Phase : Blade 2:
Change if : Balance > 0.2 IPS
Blade 3: Analysis :
Track > 10 mm

Cabin heater test PASS FAIL

Rate of NR at
If any operation was made on flight controls, IAS Zp OAT Fuel Qty NR
descent balancer
check low collective pitch setting :

Stabilize autorotation Governor OFF 1

Collective on stop 2
Vi = 50 kt
Refer to chapter 41-03-502 of Maintenance manual Swashplate adjustment :

Check in flight after adjustment :

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FLIGHT REPORT CABRI G2

Governor check
At 60 kt IAS Slowly lower collective
to desynchronization Desynchronized NM : PASS FAIL

Sharp acceleration – Quick stop

If always in green zone PASS FAIL

Final IGE hover Fuel Fuel

MLI NR
Qty flow

Time :…………..
Carb. T CHT Oil T Oil P

Batt OAT EGT Fuel P

Shutdown
Stabilize idle 30 sec. NM 200 - 300 RPM NM at idle PASS FAIL

Switch clutch to disengage. At desynch., shutdown

At NR 150 RPM apply rotor brake approx. 100 N
Time to stop : PASS FAIL
Start stopwatch (maximum 30 sec)

Fuel
Time Fl.time Hobbs
Qty

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