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Bulletin Service Cat. Mandatory

Aircraft Type: Xenon R/RT/RST Page 1 of 2

BS018 Rev. No.:1 Original Issue Date: 17/05/2011 Revision Date: 17/05/2011

MAST fixation preflight check

Pic.1

Pic.2

Celier Aviation reminds that it is mandatory to do a preflight check.

Before every flight and after every hard landing check top fixation mast area. It is convenient to use a torch to see better the mast fixation points. (see Pic.1)

Search for excessive wear, fatigue or cracks. (see Pic.2) Remember that service manual says that every 100 hours during overhaul service it is

mandatory to check the tightening moment of every fixation bolts.

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Bulletin Service Cat. Mandatory

Aircraft Type: Xenon R/RT/RST Page 2 of 2

BS018 Rev. No.:1 Original Issue Date: 17/05/2011 Revision Date: 17/05/2011

TBC for top mast fixation aluminum angle (CAXen-K-M-6003A) is 100 hours.

Pic.3. Aluminum angle of mast fixation to replace

It is obligatory to replace every 100 hours the 2 aluminum angles (6003A) (see Pic.3.) fixing mast to fuselage.

During replacement of aluminum angles it is obligatory to carefully inspect fixation points on the cabin and the mast searching for excessive wear, fatigue or cracks.

We remind, as per the XENON maintenance manual, to inspect deeply after any hard

landing, suspected shock, these parts.

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Mast Buffeti n ServiceIntroduction

Modification of mast fixation to the fuselage.

Due to have found masts showing an initial crack on external edges, we have decided topropose an upgrade and a reinforcement for the mast in the zone subjected to wear.

The original mounting is absolutely correct, and matches classic safety standards. The core ofthe mast being the most important part, it is not directly bolted, but only its flanges. Thesecond inferior bolting zone is capable of holding full loads and stresses. This is calledredundant safety. This is why masts do not brake in normal use despite a beginning crack onthe edges. Still the last top fixation point was specifically designed to create a breaking pointwhen a top shock is made, like in a severe blade flapping, rotor severe gtound strike, crashsituation. This is a very important feature on the Xenon to save occupants from flappingblades around the cabin, instead the rotor flies away. The mass inertia of a full motion rotor isaround 2 tons, this energy has to dissipate somewhere, best not on hitting a cabin...The upgrade, retains the possibility of this safety point, while offering more solidity in severeUSES.

We have found, that most Xenon users, DO NOT inspect deeply their machine after a hardlanding. Thus it is mandatory as per the Maintenance Manual. Machines with bent rear wheelaxles, bent aluminium landing gears, abused / forced pre-rotation sequences, very bumpyrunways, should definitely inspect more often the structure. We also observe very hardhandlings, and acrobatic manoeuwes. Let's remember gyroplanes are not acrobatic airplanes.The Xenon is known for its extreme solidity I strength, very forgiving machine, handlingschooling perfectly. Still it is not a reason to forget about the discipline of controlling /inspecting, as it should be done on any aircraft. Let's be more respectful to the technology.

The upgrade kit is available immediately, please contact orr spare part service to order it.

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Pic. 2. Mast modiJication

Date: l'7t05t20tf --l

| | | Revision Datez 17/0512011

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Bulletin Service Aircraft Type: Xenon R/RT/RSTPage 3 of9

Hex socket button head cap scre\id i Steel ISO 7380 - M5 x 15

l"last sooiler fixätion olate Stainless Sieel CAXen-K-tq-6032

ltrasher I Sbel, Mild Dtl'r 125 -A 5,324 Hex nut Nylon-stop Steel, tqild DIN 985 - M5

Alu reiriforcernert bar long 2 m7 (AriJ2024) CAXen-K-Nl-6031

Alu reinforcement bar sho* ) pA7 (Ar,iJ2024) CAXen-K-M-6030

21 Headphones holders 7 Pq6 (Art2017A) CAXen-K-A-1012

?0 \tasher 44 Sbel, l4 i ld DIN125.A6,4

19 Hex nut Nylon-stop 72 $eel, Mi ld DIN 985 . Iq6

18 Hex socket head cap scre| z 5bel, t l i ld ANSI 818.3.1F1 - M6x1

x90

t7 Cap special screrii M5x40,/30 .1 Shel, Mi ld CAXen-K-M-6036

lo Cap special s(reru M6x40125 ö Sbel, Mi ld CAXe n-K-lr1^6035

15 Cap spBcial scre\u F15x35j20 SEel, t' ' l i ld C.4Xen-K-M-6034

14 Cap special scre| M6x35r'16 SEel, Mild CAXen-K-M-6033

CäD sDecial screri,, MBx40,r30 Steel. f'l i ld CAXen-K-M-60371f, Cap special xreru 1,18x45/35 a Steel, Mild CAXen-K-14-6038

\iJasher 4 kel , Iq i ld Dit\ 9021 - 8,4

10 itash€r il Steel, Flild DrN U5 -A 8,{

Fiex nut NYlon-stop + Steel, Mild DTN 985 . M8

d Boltom fronl alu angle 1 PA7 (AW202,+) CAXen-K-lq-6001

7 Bottom tlack alu angle 1 m7 (A!.J2024) CAXen-K-F1-600 lA

Bottom steel angle 1 SEeI CAXen-K-M-6003C

5 Top steel angle 7 Steel CAXen-K-M-6003ts

I l-{oriz, alu angle- möst to fuselage tr15x30x3 BC7 (AWr2024) CAXen-K-F1-6003

Vert. älu angle- masl to fuselage 120xil0x3 Bq7 (A'uq/2024) CAXen-K-M-6003A

fvläst 1 Al AtiJ-5106 CAXen-K-M-6000

I Part of the cabin 1

I$o. Part title a$ l'laterial ftft f'lo i Ständard Comments

U kit consist of:Part Quantitv Part No / StandardAlu reinforcement bar long 2 603 1Alu reinforcement bar short 2 6030Mast spoiler fixation plate 2 6032Hex socket button head caD screw 4 ISO 7380 - M5x16Cap special screw M6x40/30 4 6036Cap special screw M6x40/25 8 6035Cao special screw M6x35/20 4 6034Cap special screw M6x35/16 4 6033Cap special screw M8x40/30 2 6037Cap special screw M8x40/35 2 6038Washer M6 22 DrN 125-A 6.4Washer M5 8 DrN 125-A 5,3Hex nut Nvlon-stop M5 4 DIN 985 - M5Extra alu rivets 6 6016

BSO19 Rev. No.:l Original Issue Date: l'/1051201Revision Date: 17 105 l20ll

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Bulletin Service Aircraft Type: Xenon R/RT/RSTPage 4 of9

Modification of mast spoiler fixation to the mast.

FIIl i t lpt It i t lPt Il : l lH]iqlHI T, T

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Pic.4.Mast spoiler cut

To fix front mast spoiler to the mast, cut it in accordance to Pic.4.Then attach it to the mast and rivet it in accordance to Pic.5

BSOl9 Rev. No.:l Original Issue Date: I'710512011Revision Datez 17 105 l20ll

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Bulletin Service Aircraft Type: Xenon R/RT/RSTPase 5 of9

A-A(1:2)

Csmments:1. Benü part (bracket) 6032accoroingly tE the mast sFoiler shape

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1

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DIl"l 7337 - 84,8 x 1Z

1 I Al Ar"'.j-6106

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Pic. 5. Mast spoi ler fixat ion

BS0l9 lRev. No.:L lOriginallssueDate: rTtlstz}rrRevision Datez 17 105 l20ll

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Bulletin ServiceCat.

Aircraft Type: Xenon R/RT/RSTPase 6 of9

Pic.6. Example of crack - it makes mast change mandatory

The core ofthe mast is the main holding sutfaces, and is attached through 2 extra points, to the back and downthe cabin. The safety margin is very high, as per the stress analysis shows, at 525 kg x 3.5 G x 2.1 safetyfactor.Total usable strength is 3858 kg.

BSOl9 Rev. No.:1 Original Issue Date: I'710512011Revision Datez 17 105 l20ll

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Bulletin Service Aircraft Type: Xenon R/RT/RSTPase 7 of9

Stress Analysis Repoft

Autodesk.

i Analiza wytrzymaloiciowa wzmocnionegoli i masztu wiatrakowca Xenon 2 dla

i |MTOW= 450k9 and MTOlflf = 560k9 I

Two stress analysis were performed for new mast fixation and reinforcement,

First one considered Xenon gyroplane with MTOW= 450k9 and the second onewith MTOW= 560kg (Typical results presented below). In both cases simulationshowed better results than without mast upgrade:

. Each simulation was peformed for the load factor of 3,5 and safety factorof 1,5;Simulations were peformed without the participation of additional partsthat helps in load/vibrations distribution and stress concentration (such ascabin structure);The Ultimate Tensile Strength of the weakest material used is 250MPa andthe stress do not exceed this value (in a rqion that is to be taken into account- notin very close drrtance to the ho/es- influence of phenomena that are NOTperfectly describedwith the stress analysis ). Obtained values of stress give the margin of 30-10%above limit required by airworthiness rules and legislation.The original mast without reinforcement is still reliable structure.The proposed modification makes the mast structure stronger for:repetitive impacts, out of scale vibrations, overloaded gyroplane, usage ofprerotator beyond its limitations. Reinforced version still retains thecapacity for the mast to break upon strong blade flapping and/or groundstrike protecting the occupants.

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No.:1 Original Issue Date: I'710512011Revision Date: 17 I 05 l20tl

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Bulletin Service Aircraft Type: Xenon R/RT/RSTPage 8 of9

Von Mises Stress;

BS0l9 | Rev. No.:l I Original Issue Date: rTt}stz}rlRevision Datez 17 105 l20ll

Pic.7. Typical diagram of Von Mises Stress obtained in simulation.

CELIER Bulletin ServiceAVTATTON I

Aircraft Type: Xenon R/RT/RSTPase 9 of9

Original tested mounting of the Mast was done with a limit load of 525kg and load factor 3,5multiplied by safety factor 2,1. Results have shown adequate strength in normal conditions of

use (Pic.7).

- l1ffiI , ' I i :'

, I . I I I i' I I l

Pic.7. Original stress analysis of mastfixation

Rev. No.:l Original Issue Date: 1710512011Revision Date: l7 105 l20ll