Maintenance Manual: Poplar Farm Prolley Moor Wentnor Bishops Castle Sy9 5ej

Copyright of RotorSport UK Ltd
Document number RSUK0325
Maintenance Manual
for
IVO-prop variable pitch propeller
RotorSport UK Ltd
Poplar Farm
Prolley Moor
Wentnor
Bishops Castle
SY9 5EJ
Company Reg No 5486550
Phone: +44 (0) 1588 650769

Fax: +44 (0) 1588 650769
Email: [email protected]
CAA Approval No: DAI/9917/06
Page 1 of 43 Manual issue 2, dated 08.06.15

Applicability
Propeller type: IVO-prop DL3-68
Propeller serial no.
Engine type: Rotax 912ULS or 914UL
Aircraft: Calidus, Cavalon, MTOsport, MT-03
Calidus fitted with IVO-prop variable pitch propeller

CONTENTS AND CHECK LIST OF PAGES
Content Page No.
Cover page 1
Title page 1
Publishing details
Contents and checklist of pages 3
Section 1
Amendments to the schedule 4
Section 2
Foreword 6
Gyroplane Maintenance
Section 3
Owner/Operator responsibilities 7
Certifying persons responsibilities 7
General inspection standards 7
Airworthiness life limitations 7
Airworthiness Directives & Mandatory Permit Directives 7
Airworthiness Notices 7
Overhaul and test periods 7
Service information 7
Modifications 7
Duplicate inspections 8
Permit Maintenance Releases 8
Scheduled maintenance worksheets 8
Definitions 8
Section 4
Permit maintenance release 9
Section 5
The maintenance check cycle 10
Permitted variations 10
Notes 11
Section 6
Pilot's pre-flight check 12
Section 7
Scheduled maintenance worksheets 12
Section 8
Annual Inspection 12
Section 9
Propeller description and maintenance methods 13
Propeller identification & gen description 14
Performance 19
Design, structure and instructions for operation 19
Installation 26
Periodic inspections, overhauls 33
Gen maintenance, repairs, problems and elimination 39
Transport and storage 40
Section 10
Approved modifications to date 41
Service bulletins issued to date 41
Repair approval request form 42
SECTION 1
AMENDMENTS TO THE SCHEDULE
1. Where & when necessary RotorSport UK Ltd (hereafter referred to as RSUK) will issue
updates to this maintenance standard, and will notify known owners to review the changes
via the RSUK website with changes appropriately identified by a strike in the margin.
2. Aircraft operators are responsible for ensuring that amendments to their publication are
carried out immediately and in accordance with instructions contained in amendment
transmittal letters (where issued).
ISSUE DATE INSERTED ISSUE DATE INSERTED

NUMBER BY NUMBER BY
Initial 4
1 19.05.14 5
2 08.06.15 6
3 7
Issue Change summary

1 First issue
2 Additional applicability to Cavalon, MTOsport, MT-03

Re-formatted for clarity (all pages re-issued)
Signature: Signature: Signature:
Position: Position: Position:

Eng. Manager Head of Engineering Head of Airworthiness

List Of Effective Pages
Page Issue Date Page Issue Date

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SECTION 2
FOREWORD
1. Applicability
This Schedule is intended for use on the RSUK version of the IVO-prop DL3-68 only, as
released under addenda to AAN29345 (Cavalon), AAN29266 (Calidus), AAN29247
(MTOsport), AAN29134 (MT-03)
2. Guidance
This aircraft which this propeller is fitted to may be being flown & operated under a CAA
Permit to fly, and as such specific rules exist to cover maintenance actions, such as the
types of work allowed by owners on Permit aircraft or CAP520 ‘Light Aircraft
Maintenance’. It is the aircraft operators’ responsibility to ensure the aircraft is operated
within those rules and regulations.
3. Notes
RSUK provides this maintenance schedule so that, to the best of their knowledge, the
operator is able to maintain the aircraft in a manner that will preserve its airworthiness.
The manufacturer is unable to predict all operating conditions, and as such it is the
operator’s ongoing responsibility to assess the schedule for applicability to the
environment operated within.
Note; check your Permit to Fly – if compliance to this schedule is stated as
required, then non-compliance will invalidate the Permit to Fly.

SECTION 3
OWNER/OPERATOR RESPONSIBILITIES
Operators are responsible for the accomplishment of the maintenance prescribed in the
schedule.
CERTIFYING PERSONS RESPONSIBILITIES
Certifying persons must use their engineering skill and judgement in determining the depth
of inspection needed and other matters that could affect the airworthiness of the gyroplane
or propeller. In order to claim any alleviation on subsequent inspections, the gyroplane
and propeller maintenance records must record the extent of previous inspections upon
which the alleviation is based.
Certifying persons are responsible for recording in the appropriate log book or worksheet,
any defects, deficiencies or additional maintenance required as a result of implementation
of the schedule.
GENERAL INSPECTION STANDARDS
The general inspection standards applied to individual task inspections must meet the
recommended standards and practices of RSUK.
In the absence of general inspection standards, refer to CAA CAP 562 Civil Aircraft
Airworthiness Information and Procedures (CAAIP) or other CAA recommended standards
and practices, and/or the LAA Gyroplane Maintenance manual.
Inspections may be carried out without component removal or dismantling unless
considered necessary or where required by the schedule.
AIRWORTHINESS LIFE LIMITATIONS (RETIREMENT/SCRAP LIVES)
Airworthiness life limitations shall be those published by the CAA, state of design and
RSUK.
Airworthiness life limitations should be recorded in the appropriate propeller worksheet
and/or the propeller logbook CAP388.
There are no life limited parts on this DL3-68 propeller
AIRWORTHINESS DIRECTIVES
All applicable Airworthiness Directives or Mandatory Permit Directives issued by the CAA
and the state of design must be complied with. Compliance with AD’s or MPD’s should be
recorded in Part C of CAP'S 398, 399 or 400 (logbooks), or an approved equivalent.
AIRWORTHINESS NOTICES
All applicable mandatory CAA Airworthiness Notices must be complied with. Compliance
with CAA Airworthiness Notices should be recorded in Part C of CAP'S 396, 399 or 400
(logbooks), or an approved equivalent.
OVERHAUL AND TEST PERIODS
Overhaul and test periods shall be those shown & recommended by RSUK.
The CAA may vary or mandate overhaul and test periods by the issue of an Airworthiness
Directive or Airworthiness Notice.
The overhaul and test periods should be recorded in the appropriate propeller worksheet.
SERVICE INFORMATION
Service information (Service Bulletins, Service Letters, etc) published by RSUK should be
formally technically assessed by the Owner/Operator and adopted if required to ensure
operational safety and reliability, compliance with service information should be recorded
in Part C of CAP 398, 399 or 400 (propeller) (logbooks), or an approved equivalent.
MODIFICATIONS
Approved modifications which have been carried out to the gyroplane, engine,
components and radio after original manufacture, must be recorded in the appropriate log
book(s).

Any recurring inspection or maintenance task resulting from approved modifications
should be recorded in CAP 543 Time Limited Task Record, or an appropriate equivalent.
DUPLICATE INSPECTIONS
Following initial assembly or any disturbance of a control system or vital point, the
procedures outlined in British Civil Airworthiness Requirements (BCAR) Section A/8,
Chapter A6-2/B6-2 and A5-3 shall be applied. Certifications must be recorded in the
appropriate worksheet, log book or aircraft technical log. In summary, this procedure
requires that all and any such changes be cross checked by either a CAA approved
Inspector or Certified or CAA Authorised Engineer prior to first flight, and this cross check
shall be as thorough as practical – including physical tests if appropriate. In exceptional
circumstances the CAA also allow another qualified gyroplane pilot to cross check
modifications – this person must sign the logbooks to certify their actions with their pilots
licence no.
SCHEDULED MAINTENANCE WORKSHEETS
Worksheets shown in Section 8 must be issued and the tasks certified for all scheduled
maintenance checks. These worksheets become part of the maintenance records required
to be kept by the operator.
All maintenance carried out in connection with a particular check should be certified on
suitably referenced worksheets (an example available from the RSUK website) and
included in the gyroplane records. These worksheets must be cross-referenced in the
appropriate log book(s) giving general details of the additional maintenance carried out.
DEFINITIONS
Throughout the schedule the following terms and abbreviations have the stated
definitions;
SERVICE/LUBRICATION (SERVICE/LUB):
The term 'Service or Lubrication' requires that a component or system should be serviced
and/or replenished as necessary with fuel, oil, grease, water, etc., to the condition
specified. The term service may also be used to require filter cleaning or replacement.
INSPECT (INSP):
An ‘Inspection' is a visual check performed externally or internally in suitable lighting
conditions from a distance considered necessary to detect unsatisfactory
conditions/discrepancies using, where necessary, inspection aids such as mirrors,
torches, magnifying glass etc. Surface cleaning and removal of detachable cowlings,
panels, covers and fabric may be required to be able to satisfy the inspection
requirements.
OPERATIONAL CHECK (OP/C):
An 'Operational Check' is a test used to determine that a system or component or any
function thereof is operating normally.
FUNCTIONAL CHECK (F/C):
A 'Functional Check' is a detailed examination of a complete system, sub-system or
component to determine if operating parameters are within limits of range of movement,
rate of flow, temperature, pressure, revolutions per minute, degrees of travel, etc., as
specified in the appropriate maintenance manual. Measured parameters should be
recorded.
CHECK (CHK):
A 'Check' is the verification of compliance with the type design organisation's
recommendations.

SECTION 4
PERMIT MAINTENANCE RELEASE
This maintenance certification system is specific in accordance with BCAR A3-7.

Owner operators must ensure their airframe and engine logbooks either contain a sticker
with the wording ‘Any reference to a Certificate of Release to service in this logbook shall
be construed as a PMR’ & ‘The certification at the top of each page in Part A of this
logbook is superseded by the following statement; The work recorded below has been
completed to my satisfaction and in that respect the aircraft is considered fit for flight’, or
have new logbooks containing this information.
For information on who can issue a PMR see CAP553; BCAR Section A, Chapter A3-7,
Paragraph 12.5.
A signed PMR does not expire or is superseded by subsequent PMR’s, unless relating to
a repeat of the same activity. A PMR remains active as long as the activity it relates to
remains part of the aircraft.
On completion of any check required (‘required’=stated in the Permit to Fly) by the

schedule, except pilot maintenance (see section 5) and Check A (see section 6), an entry
shall be made in Column 6 of CAP398 Aircraft Log Book, CAP399 Engine Log Book,
CAP400 Propeller logbook or an approved equivalent as Section 4. The certifying person's
signature, authority and date must be made in Column 7 against the relevant category
(Airframe, Engine, Radio).
The following is an example of an entry acceptable to the CAA, unless already pre-printed
on the page:
PERMIT MAINTENANCE RELEASE Airframe

Cross refer to workpack ref;
25 hr/100 hr/Annual Check (delete as appropriate) Engine

has been carried out to my satisfaction at total propeller
hours*……. Propeller
and in that respect is considered fit for flight
Signed…………………...Authorisation
ref………….Date……….
Maintenance Schedule Ref. RSUK0325 Issue……
*Note: as a variable pitch propeller, the DL3-68 has its own log-book

Pilot Maintenance
A licensed pilot who is the owner or operator of the gyroplane may carry out certain
maintenance tasks prescribed in Air Navigation (General) Regulation 16. The issue of a
PMR is not required. The pilot must include his pilot's licence number with his signature in
the appropriate log book(s). The permitted pilot maintenance is as below;
PERMITTED PILOT MAINTENANCE

This section defines the type and extent of maintenance that may be carried out and
certified by a pilot who is the owner of the aircraft and operates under a CAA Permit to Fly.
Refer to CAA CAP 733 for more information.
1. Removal and replacement of the propeller spinner.

2. Replacement of slip ring brushes.
3. Blade repairs (see section 7.0 for limitations)
4. Replacement of propeller leading edge tape.
Annual Check
The annual check and all associated work must be accomplished under the supervision of
an organisation appropriately approved by the CAA (eg RSUK or other CAA Authorised
engineer).
Use form F189 from the RSUK website
SECTION 5
THE MAINTENANCE CHECK CYCLE
Check title Content Period
Check A Check A Prior to the first flight of the day
First 25 hour check 25 hour check items (one Not exceeding 25 flying hours, or 1
time check, after new build) year, whichever is the sooner
100 hour check 100 hour check items Not exceeding 100 flying hours
Annual check 25, 100 hour and annual Not exceeding 12 months (see Note
check items 5) & prior to renewal of Permit to Fly
Use form F189 inspection/service records for the propeller only
PERMITTED VARIATIONS (see Notes)

Tasks controlled by flying hours Maximum Variation
25 hour +/- 5hrs

100 hour +/- 10hrs
Tasks controlled by calendar time Maximum Variation
6 months 1 month
Annual Prior to Permit renewal
(see 5. below)
Tasks controlled by more than one limit
The more restrictive limit shall be applied

Notes
1. Permitted variations may not be applied to applicable airworthiness life limitations,
airworthiness directives or overhaul and test periods.
2. Permitted variations for tasks controlled by flying hours should not be understood to be
a maintenance planning tool, but as an exceptional means to allow the operator to fly for a
limited period of time until the required maintenance is performed.
3. Any application of a permitted variation to the maintenance check cycle period must be
recorded in the appropriate log book(s) together with the reason for the variation by a
person who is authorised to sign the log book entry for that particular check. Details of the
permitted variation must be made visible to the pilot.
4. Permitted variations are not required to be deducted from the next scheduled check.
5. The annual check may be anticipated by a maximum period of 62 days without loss of
the continuity of the maintenance check cycle. Thus, for example, where the full 62 days is
invoked, the following annual check would become due 14 months after the completion of
the annual check that was anticipated. The period by which the annual check was
anticipated and the date of the next annual check shall be recorded in the appropriate log
book(s).

SECTION 6
PILOT'S PRE-FLIGHT CHECK

Pre-flight checks are to be carried out in accordance with the relevant Gyroplane Pilots
Handbook for which this specific propeller is released.
CHECK A - PRIOR TO FIRST FLIGHT OF THE DAY

For update control and one source of information, this check is not printed here. Refer to
the Pilots Handbook.
For all inspection checks reference must be made to RotorSport UK Ltd, either via the
website www.rotorsport.org or directly, for the latest schedule.
SECTION 7 - SCHEDULED MAINTENANCE WORKSHEETS

To allow ongoing updates of these service sheets with field service information
received, they are located on the RotorSport UK Ltd website www.rotorsport.org.
F189 issue 1, 25hr/100hr or Annual service worksheet
SECTION 8 - ANNUAL INSPECTION

F189 issue issue 1, 25hr/100hr or Annual Service worksheet

SECTION 9 - Propeller systems description and maintenance methods
General notes;
1. These instructions are not all encompassing, and should always be used in
line with good aircraft engineering practices, and manuals such as AC43.13.
Repairs not shown must be approved by either the CAA or RSUK in writing.
2. Safety; working on an aircraft brings many hazards. Always wear suitable
personal protective equipment such as overalls, safety glasses, safety shoes,
gloves etc appropriate for the maintenance task. If possible render the engine
inoperable prior to starting work.
3. Wherever possible SI units are used
4. Always use good quality tools appropriate for the task
5. Use of non standard or unauthorised parts or repairs will invalidate the
warranty and the Permit to Fly. Parts specifically designed for this aircraft
and supplied by RSUK will carry an Approved Certificate, which must be kept
with the aircraft records.
6. Special tools (none at this time)
7. Lubricants. Use only as per instructions.
8. Loctites and sealants. As per instructions.
9. General corrosion prevention. Keep the aircraft in a non humid, ventilated
area. If humidity is present, protect unplated components such as bolts etc
with a proprietary spray such as WD40 or ACF50.
10. Help protect our environment by disposing of parts and fluids properly.
11. Standard bolt torques are M6 15Nm+/-2Nm, M8 25Nm+/-3Nm, M10 35Nm +/-
4Nm, M12 100Nm +/-10Nm. Always assess the joint to be tightened and use
engineering judgement – do not overtighten plastic or unsupported tube
joints!
12. Remember, maintenance, modification, and bulletin/MPD incorporations must
be recorded on suitable worksheets and within the aircraft/engine logbooks –
and signed appropriately.
13. Refer also to the Pilots Handbook as well as the drawings quoted and service
parts list, all available from the RSUK website.
WARNING! PROPELLERS KILL! WHEN WORKING ON THE AIRCRAFT, UNLESS

THERE IS A SPECIFIC REQUIREMENT TO HAVE THE AIRCRAFT LIVE, ENSURE
THAT COILS ARE OFF AND KEYSWITCH OFF.
IF POSSIBLE DISCONNECT THE BATTERY, OR REMOVE THE SOLENOID

ACTUATOR WIRE FROM THE SOLENOID TO PREVENT POSSIBLE STARTING.
This statement is made here only, to avoid continued repetition. It is the engineer’s
responsibility to ensure a safe working environment.

1. Component identification
1.1 The hub

The hub consists of a number of circular parts that, when bolted together with the
propeller blades, mount the propeller assembly to the engine and provide integral slip-
rings for transfer of electrical power. These parts are not serial-numbered.
1.2 The blades

At the base of each blade root there an exposed resin area that is marked with indelible
felt-tip pen with the following data:
Blade set serial number (e.g. 519.1)

Blade weight
Date of manufacture
Each blade is embossed with a position number (1,2,3) to enable precise replacement if
removed.


1.3 Part numbers
C.xxnn = Calidus bill-of.materials

M.xxnn = MTOsport bill of materials (also MT-03 applicability)
V.xxnn = Cavalon bill of materials
Propeller, complete (and itemised) BG535 (C.KU37, V.KU503, M.KU38)
Propeller mounting kit BG967 (C.MO14, V.MO09)

BG 504 (M.MO23) or BG5312 (M.MO48 A2)
including brush bracket BG968
End position controller

(including LED indicators) BG7627 (C.EL301)
BG4759 (V.EL301)
BG4762 (M.EL302
Spinner BG1184 (C.KU43)

BG2743 (V.KU214)
BG1316 (M.KU53)
Spinner attach kit

(including backing plate) BG1483 (C.MO26, V.MO07, MO029)
BG5320 (M.MO50 A2)
Manifold pressure gauge kit .BG1420 (S.EL44) for 912ULS, or BG1419 (C.EL43) for
914UL or RSD4806 (combined digital pressure gauge/engine rpm gauge programmed for
either engine type)

Propeller internal part nos (for spares)


2 . Performance data
The following data are presented for information only and are in accordance with the
design and structural parameters of the propeller at its current stage of development.
Max. engine power output: 100HP (Rotax 912ULS) or 115 HP (Rotax 914UL)
Max. propeller RPM: 2650 rpm
Range of operating temperatures: -25degC - +50degC
Number of blades: 3
Diameter : 1727 mm (68inches)
The rate of pitch change from one end position to another (under aerodynamic load)
10sec nominal
Propeller mass: 8kg
One half of the hub assembly acts as a spacer for installation of the propeller and it is
placed between the propeller and the propeller flange of the engine, to which it is secured
by the countersunk fixing bolts.
3. Design, structure and instructions for operation
The propeller consists of the following main structural assemblies:

 Blades
 Hub (multiple pieces)
 Adjusting mechanism
 Spinner

3.1 Blades
The propeller blades are made of resin covered by carbon/graphite composite.
Set of three blades bolted together for transport
The root part of the blade is a robust flat section which is clamped between the two hub
halves by means of two 3/8” precision hex-head bolts and nyloc nuts which, aided by deep
knurling on the hub-halves, restrain the axial and radial forces.
For use in situations where greater blade wear is likely (sand airfield surfaces, float planes
etc.) the leading edges have bonded-on (replaceable) stainless steel foil protection for
maximum resistance against water and foreign objects.
The blade finish is black resin.
3.2. Hub
The material of hub is aluminium alloy. The hub consists of two primary parts and is
backed-up by a series of aluminium/nylon spacers to provide a slip-ring set. The hub fwd
half is mounted directly to the engine’s propeller flange by means of M8 countersunk
socket screws screwed into standard Rotax flange nuts (mounted in the same PCD as the
HTC propeller) and the remainder of the hub assembly attached to this by 3/8” precision
hexagon bolts and nyloc nuts.
Hub fwd half

3.3. Adjustment in flight
3.3.1. General description

The DL3-68 is an electrical in flight adjustable propeller. Blade adjustment is carried out by
means of an electrical servomotor, which is controlled manually from the cockpit by means
of a rocker switch (mounted on the left of the pilot). The propeller pitch angle relationship
to engine rpm is managed manually by the pilot with the aid of a manifold pressure gauge.
The characteristics of each engine type (912ULS normally aspirated or 914UL
turbocharged) are different so each Pilots Handbook is furnished with a look-up table for
use by the pilot.
ROTAX 912 ULS
Power Engine RPM MAP Fuel flow

setting [ltr/h]
Max. TOP 5800 27.5 27
Max. MCP 5500 27 26
75% MCP 5000 26 20
65% MCP 4800 26 18
55% MCP 4300 24 14
ROTAX 914 UL
Power Engine RPM MAP Fuel flow

setting [ltr/h]
Max. TOP 5800 39.9 33
Max. MCP 5500 35.4 26
75% MCP 5000 31 20
65% MCP 4800 29 17.5
55% MCP 4300 28 12.5
MCP – Maximum Continuous Power

TOP – Take-Off Power
MAP – Manifold Absolute Pressure

3.3.2 Propeller blade pitch stops

The propeller is manufactured with physical machined pitch stops (contacted by thrust-
washers selected on propeller assembly to suit engine type), in order to prevent the
propeller being run too fine or too coarse. There are no micro-switches to limit blade
movement so the control system utilises a bespoke circuit-board (the end position
controller) which detects the rapid rise in current and disconnects motor power when each
pitch limit is reached. Two amber LED indicators mounted adjacent to the rocker switch
provide status information:
Both LEDS off Propeller is not at an end position and no pitch change command active
Upper LED blinking Propeller changing pitch to FINE
Lower LED blinking Propeller changing pitch to COARSE
Upper LED steady ON End position FINE reached and electronic pitch inhibit FINE activated*
Lower LED steady ON End position COARSE reached and electronic pitch change inhibit COARSE
activated*
Both LEDS flashing fast Actuating motor does not work despite rocker switch activation.
Possible defects, e.g. brushes worn, cable break.**
*Electronic pitch change inhibit is deactivated after selecting pitch change in opposite direction for at least 1 second
**Indication can only be reset by switching the master switch temporarily to OFF and then back to ON. In order to avoid
pilot distraction, indication of a possible defect is retriggered after another activation of the rocker switch
WARNING! On no account may these thrust washers be changed, they are selected to
allow the aircraft to meet the performance and safety requirements of BCAR Section T.
The pitch limit stop setting results in the following nominal pitch angles (+/-1deg)
Fine pitch 13.0deg (912ULS) or 14.0deg (914UL) deg
Coarse pitch 20.0deg in (912ULS) or 21deg (914UL).
During first assembly on an aircraft the fine pitch limit stop shims are adjusted to achieve
5600rpm on the ground, with the aircraft tied to a suitable fixed object.
The pitch angle is relative to the propeller hub and is measured just inboard of each
propeller tip with the blade leading-edge set horizontal.
Checking the system of stops and LED indicators.

When carrying out pre-flight checks the system of propeller blade angle stops and the
respective LED indicators should always be checked (see status table above). With the
engine not running, the propeller should be adjusted from the one end position to other. If
the propeller adjustment stops in each end position in a normal manner and with correct
LED indication then the system is in order.

3.4. Spinner
The spinner diameter is 220mm.
Spinner material: Composite, painted to match the aircraft.
The whole spinner is fixed to the propeller backing plate by 9 steel screws, loctited with
Loctite 243.
The spinner backing plate is used for final balancing of the complete propeller, by means
of balancing weights glued inside the lower disk and held there by centrifugal force.
When a spinner is fitted the last aluminium spacer forming part of the propeller hub is
furnished with a locating spigot to locate (and trap) the spinner backing plate.

3.5 Brushgear
The attachment of the fabricated mounting bracket and carbon brush box on the Rotax
engine is shown in the picture below. The bracket is mounted by means of 2 bolts, which
screw into existing threaded bosses holes on the Rotax engine with Loctite 243.
The IVO-supplied plastic brush box assembly (housing, springs, brushes, 3/16”
connectors, retaining screws) is attached to the fabricated bracket by means of socket-
head screws that enable a limited amount of angular and linear adjustment. The brush-
box is set so that the each brush is central on its slip-ring and protruding about 0.5mm
from the plastic housing.

Carrier mounting/adjustment holes
Captive 3/16” “Faston” terminals
Brush length 10mm when new

4. Installation on Aircraft
4.1 Propeller installation and removal

The propeller’s fwd hub-half is mounted on the engine flange using 6 off M8 countersunk
socket head screws (torque 25Nm with Loctite 243) and the remainder of the propeller
assembly is attached to this by means of six 3/8” precision hex-head bolts and nyloc nuts
(torque 40Nm). When fully assembled with the fasteners tightened to the correct torque,
paint stripes must be applied between the M8 c/sunk screw threads/the propeller flange
and the 3/8” hex-nut/bolt ends (6-places each).
When removing or refitting the propeller it is necessary to be careful not to damage the
carbon brushes, which supply the electric power to the propeller. Therefore remove the
mounting bolts retaining the brush box bracket to the engine – this will improve access to
the propeller retaining nuts too. Remember to use Loctite 243 on the threads when
refitting! If a new engine first fit the Rotax flange nuts through the propeller flange, if the
IVO-prop is replacing an HTC propeller then these will already be in place.
Engine gearbox flange with Rotax flange nuts fitted
Propeller assembly
Place the steel thrust washers on the actuator motor’s lead-screw as shown in the
photograph, selecting for engine fitment:
• 912: 2 x out of C.KU37 rear (total 2.5mm)
• 3 x out of C.KU37 front (total 5.7mm)
or
• 914: 1 x out of C.MO14 rear (total 0.8mm)
• 4 x out of C.MO14 front (total 4.2mm)
NOTE!
 The front shim washers may be increased or decreased in order to achieve
5600rpm maximum whilst the aircraft is suitably restrained on the ground at full
power.
 The rear shim washers are set to achieve a minimum climb rate of 250fpm at
maximum take-off weight.
Ensure that the two rubber cushion washers are in place.
Rear Front
Clamp the actuator motor vertically in a vice (use soft-jaws) and using the 3/8” AN bolts
and washers fit the three blades. Ensure that the two cables are free.

Fit the knurled clamping plate over the six protruding bolts, carefully pulling the two cables
through the plate.
If a spinner is to be fitted use the alternate knurled clamping plate and spinner backing
plate, ensuring that the blade cut outs align with the propeller blades..

Assemble the insulators and spacing plates in the order shown below

Fold over each of the cables so that one electrical cable connects to each plate:
NB: there is no solder or welding, electrical contact is made by the clamping pressure.
Make sure that the insulator bushes are in the correct position, if they have moved out
push them back into place with tool C.WZ3020

Install the adaptor plate on the engine using the M8 countersunk socket screws, Loctite
243 and torque (progressively) to 25Nm
Attach the whole prop unit to the adaptor plate using the 3/8 AN5 hex-head bolts and
nyloc nuts positioned in the recesses. Tighten the main prop bolts (progressively) to
40Nm. Note: Before fully tightening the bolts assess whether the nyloc nuts are “in safety”
(i.e. minimum two visible threads protruding). If not so, then replace the six bolts with
longer items RSD6401)
When everything is correctly located and the bolts tightened use a scalpel to trim any
protruding insulator flush with the outer diameter of the aluminium spacers
Paint stripe between M8 c/sunk screw and propeller flange, and between nut and bolt end,
6pls ea.
Check that there is clearance between the ends of the bolts and the propeller flange. If
there is no clearance, use the next size shorter bolt, or renew the plastic isolators, which
compress during use and tightening.
Install the brush holder as shown. Make sure that the brush housing has 0.5mm clearance
to the contact discs/spacers

Identify the two spare cables tied-back above the engine and using 3/16” crimp terminals
connect the two cables to the brush terminals.
Use cable ties and spacers (made from scrap fuel hose) to secure the cable as shown.
Ensure that the carbon brush housing is adjusted such that the brushes run in the centre
of the rings, and the brushes are free moving axially in the housing with about 0.5mm
static protrusion. Turn the propeller, to check that the carbon brushes seat properly in the
centres of the slip rings, and make contact with their entire surfaces.
When refitting the brush box, align such that the brushes are centred on the slip rings, and
running with the brush axis perpendicular to the ring. The brushes must have freedom of
movement in and out as the propeller turns – check this. The screws holding the brush
box to the bracket have some adjustment.

The brush box bracket-to-engine bolts must be threadlocked with Loctite 243.
When new the brush length is 10mm. if worn to less than 4mm, replace. Note that the
brushes must slide freely within the brush box, remove and clean them as required.
Removal of the propeller is the reversal of this process.

Loctite 243 should be used with the nyloc nuts but always renew nyloc nuts when the
residual torque of the nut’s locking element is less than 1Nm
4.3. Checking the installation

After installation and before starting the engine check the propeller functions:
1. Switch on the aircraft master switch.
2. Check the sense and function of the rocker switch on the instrument panel and the
function of the LED indicators signalling propeller movement and its end positions.
3. With the aid of an assistant visually check that all propeller blades move simultaneously
4. Return the propeller to the full-fine position in anticipation of engine start
5. Carry out an engine test on the ground. During the engine ground test there must not
occur any excessive vibration or unusual noise.
With engine speed 3000rpm adjust the propeller to full-coarse and verify that:
 there is a noticeable drop in engine rpm
 the manifold pressure gauge operates in accordance with table 3.3.1 above.
Return the propeller to full-fine and verify that the engine returns to the pre-set rpm
WARNING NOTICE
When making the engine ground test with the aircraft stationary, never adjust to the max.
coarse angle on the propeller when the engine runs at maximum power (full throttle). This
may produce stall flutter on the propeller with subsequent damage.
5 Periodic inspections and overhauls
5.1 Periodic inspections

Periodic inspections have to be carried out by the propeller producer or by an authorised
person at the following time intervals: Use form F189 (initial 25hr and 100hr) for details of
requirements
First 25 hours On the aircraft A3-7, LAA, or other Authorised Engineer

100 hours On the aircraft A3-7, LAA, or other Authorised Engineer
Annually (or coincident with 100hr interval) A3-7, LAA, or other Authorised Engineer
NOTE!
A record of these periodic inspections of the propeller must be kept in the propeller
logbook.
5.2 Special inspections

In case of significant (see section 7.0 for owner repair limits) blade damage, impact of a
significant foreign object on the propeller, or if propeller over-speeding by more than 200
rpm has occurred, it will be necessary to transport the propeller to RSUK for damage
assessment and frequency vibration of the blades to be carried out.
NOTE!
A record of any special inspection must be made in the propeller logbook.
5.3 Overhaul

The period to overhaul is “on condition” as determined by the 100hr/Annual inspections.
Only an authorised person or RSUK may carry out propeller overhaul.
To remove propeller:
1. Remove spinner by removing the 9 retaining screws.
2. Remove and fix out of the way the brush box assy.
3. Progressively release and remove the 6-off hex bolts
4. Carefully extract the propeller, remembering it weighs around 8Kg.
5. Place propeller on a suitable workbench to allow disassembly.
Dis-assembly and subsequent re-assembly is described in the IVO-prop document

MD12E that is embedded in this report RSUK0325 below.




WARNINGS:
MARK THE PROP POSITION IN RELATION TO THE REDUCTION FLANGE.

THERE ARE MULTIPLE POSITIONS TO MOUNT THE 3 BLADE PROP. THIS MAKES A
GREAT DIFFERENCE IN HOW THE PROP AND ENGINE VIBRATE TOGETHER AND
EACH POSITION CREATES A TOTALLY NEW SITUATION.
THE KNURLED PLATES ARE INSTALLED SO THAT THE KNURLING FINISH ON EACH
PLATE IS IN CONTACT WITH THE BLADES.
THE KNURLED PATTERN IS 60 DEGREES SYMMETRICAL, SO IF YOU REINSTALL THE

BLADES BETWEEN CRUSH PLATES LATER IN A DIFFERENT POSITION, THE IMPRINT
ON THE BLADES SHOULD MATCH THE KNURLED PATTERN. HOWEVER (BECAUSE
OF MANUFACTURING TOLERANCES) TO GET THE BEST MATCH YOU NEED TO
NUMBER THE BLADES AND PLATES AND ALWAYS PUT THE BLADES BACK IN THE
SAME PLACE.
IF YOU GET A NEW BLADE OR BLADES START A PROGRESSIVE TORQUE SCHEDULE

OVER AGAIN

6. Maintenance
In normal operation the propeller does not require any special maintenance.
In case of propeller contamination wash its surface with a cloth dipped in warm water with
addition of household detergent.
WARNING!
No other cleaning means or solvents are allowed.
7. Repairs (by owners)

Surface damage not tearing through the glass or carbon fibre, and not exceeding 10mm in
length or width, may be repaired using suitable epoxy resin, or superglue and carbon. The
area must be thoroughly cleaned of insect debris and dirt, and abraded to give a good
fresh key to bond into. Mix and load the epoxy onto the blade as per the adhesive
instructions. Superglue repairs are built up in stages, a small drop of glue followed by a
sprinkle of carbon or charcoal (which instantly sets the adhesive). Build up in layers to the
height required. Once the adhesive is fully cured, flat back to the original blade profile and
polished in for best performance. If the stainless-steel prop tape is damaged, replace it
with a new service strip of tape. Ensure the original tape and any adhesive debris is
removed first, and that the surface is clean and dry before adhering the new tape in place.
Try to get it in exactly the same position as the original, to maintain propeller balance. All
other work, unless specifically allowed under CAP733, must be completed by a CAA
authorised person
Sealing the edge of the tape with cyanoacrylate adhesive helps ensure the tape stays
attached to the blade longer.
WARNING! The edge of the stainless steel strips are VERY sharp. Handle with care
to avoid damage to skin.
8. Problems and their elimination.

The following problems may occur during the propeller operation:
Possible problem cause and rectification
Vibration in flight or on the ground: Static imbalance of the propeller
Check on the ground that the balance weights inside the spinner back plate are not
missing and that there are no missing broken parts of the blades, which could cause the
imbalance.
A well balanced propeller will significantly improve the engine and ancillary component
service life. The Rotax recommended maximum is 0.1ips.
Mass balance weights used should be self adhesive aluminium wheel balance weights as
used on car wheels, fitted inside the propeller spinner backing disc hub to a well cleaned,
dry, surface.
Aerodynamic imbalance of the propeller

Check on the ground, with engine out of operation, if all three blades are adjusting
simultaneously and smoothly. These defects can be rectified by a service agent.
The propeller does not adjust the blades and the panel lamp stays off.
Broken, worn or wrong contact of carbon brushes. Replace or adjust the brushes.
Check according to the diagram if there is proper electrical connection of propeller and of
electrical joints.

9. Transport and storage
9.1 Storage
9.1.1 Manner of storage

If removed from the aircraft, the propeller can be stored horizontally or vertically, but only
in such a way that it is supported by the six M8 fixing bolts attaching it to the pad. In either
case the ends of the blades must not support the propeller.
WARNING!
It is forbidden to store the propeller in such a manner, that it is put on the ends of two
blades and supported by the wall. During such long term storage distortion of the blades
will occur.
9.1.2. Climatic conditions

Normal room temperature and relative humidity up to 80%.

Section 10
Modifications approved to date
Mod Description Use and comments
No.
Service Bulletins issued to date
If in doubt about any service instruction, or service

method, then refer to RSUK on the form below.

This form is Part 1 of 2. This is the customer request form, Part 2 is the reply
This form is supplied to enable the owner/operator/maintainer to request factory support for a repair
not documented in the maintenance manual supplied with the aircraft from RotorSport UK Ltd.
Depending on the problem identified, a corrective action is investigated and, if needed, CAA
involvement and approval obtained prior to repair authorisation.
The information given is stored on a computer, and is only used within RotorSport UK and the CAA for
the above purpose.
Return this form to:
RotorSport UK Ltd, Poplar Farm, Prolley Moor, Wentnor, Bishops Castle, Shropshire,
SY9 5EJ. Or email [email protected], or fax 01588 650769
Aircraft type Aircraft serial No.
Aircraft Registration No. Aircraft Engine No.
Logbook Aircraft hours Logbook Engine hours
Owner/operator name & contact Maintenance organisation identified to carry

detail out repair & contact detail
Repair problem description & cause of problem if known
Name and address of contact person for this request Sheet

of
Signature & date
Telephone:
Email:
Date entered onto CCAR Acknowledgement sent Job opened by (name & sig)
or REPAIR database: (date)
CCAR No.: Job closed by: (name, sig & date)

REPAIR No.: Final reply sent
Form F023 Part 1 of 2

This form (Part 2 of 2) is the response from RotorSport UK Ltd to a Service Repair and
Evaluation/Approval request, which specifies the company authorised repair method. Deviation from
this method renders the authorisation ineffective.
Upon completion of the repair the repairer must enter details into the logbook/worksheet with the
repair number and sign as normal.
If any problems with carrying out the work authorised, contact RSUK immediately on +44(0)1588
650769, or email [email protected].
Repair No. and Issue: CCAR No.: Repair

classification:
Mod approval No: MAJOR or
Aircraft type Aircraft serial No.
MINOR
First application:
Repair problem description & cause of problem if known
Limitations on implementation
Approval statement.
The technical content of this document is approved under the authority of the UK CAA Design
Organisation Approval Ref: DAI/9917/06.
Tooling required.
Weight and balance.
Manuals affected.
Previous modifications affecting this SRA.

List of materials required to complete this SRA:
List of components required to complete this SRA:
Interchangeability:
Parts disposition:
Accomplishment instructions/details of the repair:
Reference to other documentation:
Test and inspection records:
Special Tools & Health and Safety requirements, and/or components required for repair:
Quality Inspection requirements after repair:
Flight test requirements after repair:
Documentation completion:
Service repair authorised by: (name, signature, and date of signature)
Quality Control Engineering Chief Test Pilot CVE Head of

Manager Manager (where an effect Airworthiness
on flight
performance or
safety)
Document effectivity date:
Form F023 Issue 4 Part 2 of 2

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Document number RSUK0325

Phone: +44 (0) 1588 650769

CAA Approval No: DAI/9917/06

Page 1 of 43 Manual issue 2, dated 08.06.15

Propeller type: IVO-prop DL3-68

Propeller serial no.

Engine type: Rotax 912ULS or 914UL

Aircraft: Calidus, Cavalon, MTOsport, MT-03

Calidus fitted with IVO-prop variable pitch propeller

Page 2 of 43 Manual issue 2, dated 08.06.15

ISSUE DATE INSERTED ISSUE DATE INSERTED

Issue Change summary

2 Additional applicability to Cavalon, MTOsport, MT-03

Signature: Signature: Signature:

Position: Position: Position:

Page 4 of 43 Manual issue 2, dated 08.06.15

Page Issue Date Page Issue Date

Page 5 of 43 Manual issue 2, dated 08.06.15

Page 6 of 43 Manual issue 2, dated 08.06.15

Page 7 of 43 Manual issue 2, dated 08.06.15

Page 8 of 43 Manual issue 2, dated 08.06.15

PERMIT MAINTENANCE RELEASE

This maintenance certification system is specific in accordance with BCAR A3-7.

On completion of any check required (‘required’=stated in the Permit to Fly) by the

PERMIT MAINTENANCE RELEASE Airframe

25 hr/100 hr/Annual Check (delete as appropriate) Engine

Page 9 of 43 Manual issue 2, dated 08.06.15

PERMITTED PILOT MAINTENANCE

1. Removal and replacement of the propeller spinner.

PERMITTED VARIATIONS (see Notes)

25 hour +/- 5hrs

Page 10 of 43 Manual issue 2, dated 08.06.15

Page 11 of 43 Manual issue 2, dated 08.06.15

PILOT'S PRE-FLIGHT CHECK

CHECK A - PRIOR TO FIRST FLIGHT OF THE DAY

SECTION 7 - SCHEDULED MAINTENANCE WORKSHEETS

SECTION 8 - ANNUAL INSPECTION

Page 12 of 43 Manual issue 2, dated 08.06.15

WARNING! PROPELLERS KILL! WHEN WORKING ON THE AIRCRAFT, UNLESS

IF POSSIBLE DISCONNECT THE BATTERY, OR REMOVE THE SOLENOID

Page 13 of 43 Manual issue 2, dated 08.06.15

1.1 The hub

1.2 The blades

Blade set serial number (e.g. 519.1)

Page 14 of 43 Manual issue 2, dated 08.06.15

Page 15 of 43 Manual issue 2, dated 08.06.15

C.xxnn = Calidus bill-of.materials

Propeller, complete (and itemised) BG535 (C.KU37, V.KU503, M.KU38)

Propeller mounting kit BG967 (C.MO14, V.MO09)

End position controller

Spinner BG1184 (C.KU43)

Spinner attach kit

Page 16 of 43 Manual issue 2, dated 08.06.15

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Page 18 of 43 Manual issue 2, dated 08.06.15

3. Design, structure and instructions for operation

The propeller consists of the following main structural assemblies:

Page 19 of 43 Manual issue 2, dated 08.06.15