Propeller Technical Manual
Contents
1. 13 Figure 3 Hub 14 Figure 4 Hub Compression Cracking 14 Figure 5 Stone Chip amp Urethane 15 Figure 6 Urethane Abraslonh ao abu e anao aca sakene 15 Figure 7 Urethane Plittirig uiii ptite tere iere bel ener eem saves ite co Etre goed esu er espe rettede 16 Figure 8 Moisture Ingress Leading Edge at 16 Figure 9 Resin Crack nus ciens eae rade eter nter dtt CE Rex FER DARE ce kaka RD RAS 17 Figure 10 Fibreglass 18 Figure 11 Fibreglass De lamination rrrnnvrrernnnvrnonnnnvnnenrnnvnnensnnnnnensnnnnnenrnnennenrnnennensnnnnnenrnnennenennennensnnnnnennn 18 1 2 List of Tables Table 1 Approved Propeller Engine Propeller Flange Combinations 7 Table 2 Inspection CHAM ERR TEE TET DEDE DT LL TS 11 2 Section 2 Service Manual 2 1 LIST OF EFFECTIVE PAGES Page Issue Date Page Issue Date Page Issue Date 1 1 16 4 082. 5 5 23 PARM E M 6 5 24 6 5 3 RUNNING IN me T E m 6 6 PROPELLER MAINTENANG E wisssssscsccsscessccssiesososisnsccersvssousovsasocensconenssasessncstossvesetseseasociosaestdcecaneedvarorensceoeeeadnranen 7 6 1 INTRODUCTION EMT 7 6 2 DESCRIPTION Ka 7 6 2 1 General sau TREE GU HS 7 6 22 X Approved Installations 7 6 2 8 Propeller Markings 000242 5 8 6 2 4 Propeller Markings 4A401 8 6 3 INSTRUGTIONS avse 8 6 3 1 Acceptance 8 6 3 2 Procedure Removal of Existing 8 6 3 8 Procedure Propeller installation eee eese enne 8 6 4 OPERATIONAL CHECKS D dei rr eda rd HEELS 11 6 5 MAINTENANCE SCHEDULE nennen tenete 11 6 6 TROVBLESHO OGTING anse he eee ae 13 6 6 1 BEET E I AETA EA
3. 031900 38 JON ISOM ONY IHOIHAdOO SI SNMYYO Figure 1 Typical Propeller Installation IMPORTANT For all Jabiru Aircraft Engines the spinner is an important and integral part of the propeller Assembly essential to ensure adequate engine cooling The aircraft must not be flown with the spinner removed It is N we T O av e ea OD 3 e 0 e e gt Q lt o o a E L Miles Propeller_Manuals 4_cyl 3_laminate Drafts JPM3L01 1_signed doc Jabiru Aircraft pia Mee Propeller Service Manual JPM3L01 1 6 4 Operational Checks Full power RPM with the aircraft stationary 2800rpm 50rpm 6 5 Maintenance Schedule Note that while the spinner assembly is not considered a part of the propeller some spinner inspections are included below for reference Table 2 Inspection Chart Annual Inspection Each 100 Hours SPINNER 1 General condition cracks etc 2 Screw holes are not excessively elongated x SPINNER FLANGE 3 General condition cracks around perimeter of hub etc 4 Anchor nuts amp rivets secure 5 Visual inspection for signs of fretting looseness ki SPINNER SCREWS 6 Head amp thread condition 7 Tightness of screw in nut Replace anchor nuts if loose y PROPELLER 8 Urethane condition Refer Section 7 3 2 for details 9 fiberglass c
4. Instructions The propeller must always be stored horizontally to minimse uneven moisture accumulation in the blades causing imbalance e Where possible the propeller should be stored at above 0 C freezing Minimise the propeller s exposure to humidity while in storage Dated Apr 2008 Issued By DPS Page 21 of 22 L Miles Propeller_Manuals 4_cyl 3_laminate Drafts JPM3L01 1_signed doc Jabiru Aircraft py pu Me Propeller Service Manual JPM3L01 1 Airworthiness Limitations Section CASA Approved 8 Airworthiness Limitations Section The Airworthiness Limitations Section is CASA Approved There are no Airworthiness Limitations applicable to the Jabiru C000242 and 4A401 series propellers Signed Date 2 3 4d OG sre Dinh Nguyen Delegate of the Authority Dated Apr 2008 Issued By DPS Page 22 of 22 LMilesPropeller Manuals V cyl 3 laminate WDraftsJPMS3LO01 1 signed doc
5. Jabiru Aircraft pty pa Mn Propeller Service Manual JPM3L01 1 Fit front spinner backing plate to front of propeller Fit Aluminium Propeller Flange Belleville Washers 42 off 8 per Bolt assembled in pairs as shown Progressively tighten bolts ensuring equal distribution of load and in a normal criss cross torque sequence Using Torque Wrench tighten Bolts to 6lb ft 72 inch lbs Check tracking of Propeller by locating a fixed object on a flat floor so that it just clears the Propeller tips when rotating the Propeller by hand Check that each blade clears the object by the same amount If the Propeller is outside the approved tolerance refer to JABIRU Aircraft Pty Ltd or a JABIRU Approved Service Centre Maximum Tracking Error Tolerance is 2mm Locate Spinner on Spinner Flange and fix with Machine Screws through tinnerman Washers Check Spinner tracking by locating a fixed object on a flat floor to just clear the lower edge of the front dome of the Spinner Rotate the propeller by hand and check that the Spinner runs true Correct any run out by loosening machine screws realigning spinner then retightening machine Screws Leading edge tape can be applied between the inner edge of the urethane leading edge and the spinner This optional tape protects the propeller and reduces the chances of moisture ingress After the first flight following the propeller installation the spinner must be removed and the propeller bolt
6. NE E N A E E E A O E E E 13 T PROPELLER OVERHAUL sssscssessesssscscscccsscsetensscussasccessaccsocsscasstessdcosecvesesecsdsocsdecvocesecevoucsasovacssdesseuatbestoccosesvessiesss 19 7 1 PROPELLER REMOVED INSPECTIONS ccccscccsscessesscesscesscessceseccsecssecsscesscesscesscsecssecsscesscesscesecesecsecsssenscesseegs 19 Te FTS 19 7 2 1 Propeller Drive Bushes sss entente tnter teens 19 13 REPAIR METHODS ss 19 7 3 1 Propeller Balancing Procedure eese esee esee a 19 7 3 2 Damage Limits amp Repairs sse nenne nnne trennen ener eene 19 7 9 31 NCK PRODU a e an RRE EE TE EERE EEE OE 20 7 3 4 20 735 FIDI6GIASS ER TODD 20 736 GONG ERES 20 7 Meri eiae fcm 21 8 AIRWORTHINESS LIMITATIONS SECTION isssesvsssssseeneseveuneneveunesenennensnesnenenensensnennenenensenssennenenenssnssensensnense 22 Dated Apr 2008 Issued By DPS Page 2 of 22 L Miles Propeller_Manuals 4_cyl 3_laminate Drafts JPM3L01 1_signed doc Jabiru Aircraft py pu Mn Propeller Service Manual JPM3L01 1 1 1 Table of Figures Figure 1 Typical Propeller Installation nmn rennen 10 Figure 2 Trailing Edge
7. be run in rain if required However the propeller is not intended for extended operation in heavy rain Running in heavy rain will erode the Urethane reducing the efficiency of the propeller blade and upsetting it s balance e After extended running in rain the Urethane may become so badly worn that the fibreglass leading edge underneath is exposed Once exposed the fibreglass will quickly be damaged by continued operation in rain It is possible that a propeller which has been damaged to this extent may suffer fibreglass de lamination from a blade massively reducing propeller efficiency and increasing vibration to the point where the engine must be shut down This makes continued operation with exposed fibreglass edges extremely hazardous Dated Apr 2008 Issued By DPS Page 6 of 22 L Miles Propeller_Manuals 4_cyl 3_laminate Drafts JPM3L01 1_signed doc Jabiru Aircraft JPM3L01 1 Propeller Service Manual 6 Propeller Maintenance 6 1 Introduction The Jabiru Propellers detailed in this manual are 2 bladed fixed pitch designs They are available in a range of different pitches and are certified to FAR Part 35 WARNING ENSURE IGNITION SYSTEM IS OFF BEFORE COMMENCING ANY WORK ON PROPELLER DO NOT RUN ENGINE WITH PROPELLER DISCONNECTED OR ENGINE DAMAGE WILL RESULT 6 2 Description 6 2 1 General The Jabiru Propellers detailed in this manual are made from plantation Hoop Pine sheat
8. 9 1 16 4 08 17 1 16 4 08 2 1 16 4 08 10 1 16 4 08 18 1 16 4 08 3 1 16 4 08 11 1 16 4 08 19 1 16 4 08 4 1 16 4 08 12 1 16 4 08 20 1 16 4 08 5 1 16 4 08 13 1 16 4 08 21 1 16 4 08 6 1 16 4 08 14 1 16 4 08 22 1 16 4 08 7 1 16 4 08 15 1 16 4 08 8 1 16 4 08 16 1 16 4 08 Issue Notes 1 Original Issue Dated Apr 2008 Issued By DPS Page 3 of 22 L Miles Propeller_Manuals 4_cyl 3_laminate Drafts JPM3L01 1_signed doc Jabiru Aircraft pty pa Propeller Service Manual JPM3L01 1 3 Introduction This manual contains JABIRU recommended procedures and instructions for ground handling servicing and maintaining the following Jabiru propeller models C000242 D60P38 Jabiru 4 Cylinder Propeller 3 lamination 60 pitch 38 C000242 D60P42 Jabiru 4 Cylinder Propeller lamination 60 pitch 42 C000242 D60P44 Jabiru 4 Cylinder Propeller lamination 60 pitch 44 4A401BOD Jabiru 4 Cylinder Propeller 3 lamination 60 pitch 38 4A401A0D Jabiru 4 Cylinder Propeller lamination 260 pitch 42 4A401CO0D Jabiru 4 Cylinder Propeller 3 lamination 60 pitch 44 These propellers hold an Australian Type Certificate Number VP503 issued by the Civil Aviation Safety Authority CASA of Australia All propellers listed are certified for use on Jabiru Aircraft Engines It is the owner s responsibility to become fully aware of the particular maintenance r
9. Capillary action will draw the glue into the glass and the colour will change from white to translucent e If the line of the trailing edge has been notched by a small amount up to 2mm the notch can be sanded away to leave a smooth trailing edge This must be done AFTER the glass weave has been stabilised with superglue e Maximum size to repair by the method above 13mm along the blade and extending up to 10mm towards the blade leading edge e After repair visually monitor the chip for growth Figure 2 Trailing Edge Chip Dated Apr 2008 Issued By DPS Page 13 of 22 L Miles Propeller_Manuals 4_cyl 3_laminate Drafts JPM3L01 1_signed doc Jabiru Aircraft pty Pt 9e i dm Propeller Service Manual JPM3L01 1 6 6 1 2 Propeller Hub Aging Figure 3 below shows an older propeller hub Several small cracks are visible extending along the blade from the hub bolts This type of damage is typically caused by over torquing the propeller bolts or not using Belleville washers on the installation as shown in Figure 1 Recommended Actions Ensure the propeller is installed as detailed in Figure 1 e Check the fit of the propeller drive bushes in the sockets is not loose Measure the length of the cracks amp compared to the limits shown below Maximum crack length outside central zone beyond lines 50mm 2 or up to the edge of the propeller If the crack touches the side of the prop it must be visi
10. JABIRU AIRCRAFT PTY LTD P O Box 5186 Phone 61 7 4155 1778 Bundaberg West Fax 61 7 4155 2669 Queensland Australia Email info jabiru net au Propeller Technical Manual l ss Propeller Model C000242 D60P38 Propeller Model C000242 D60P42 Propeller Model C000242 D60P44 Propeller Model 4A401A0D Propeller Model 4A401BOD Propeller Model 4A401C0D Issue 1 Date 16 April 2008 Jabiru Aircraft pty pa Mn Propeller Service Manual JPM3L01 1 1 1 8o duci 3 1 2 Ego NN ic cic TED 3 2 SECTION 2 SERVICE MANUAL esessesevessvensensveenensvensensvensensvensenssennenenensenenensenesensennsennensnensenenensensnensenssensenenense 3 2 1 EIS FOF EFFECTIVE PAGES tee Pis ie itte ett tee TI Pre dept Do ease 3 3 INTRODUCTION Pac 4 4 5 5 PROPELLER OPERATION 6ecccecssccecssscscecevsccorescasecsosastecssetocensacoresessossteesosetsacosessceoreseasocassessesseavssessaeoesesssorsteaserseses 5 5 1 LIMITATIONS MEER 5 5 1 1 Maximum e Re tp e RR Gees 2 EEE EEE sets Bist ilies moe dne tei mdi du erint du re n eH RIEN 5 5 2 NORMALOPERATIONS Tennene ere e reete eei ee onera eee eide 5 5 2 1 Ground Handling nennen nennt 5 5 22 Mano GUON
11. ark near the top where moisture has entered through the crack amp stained the wood lt Edge of hub markings visible Inner end of fibreglass sheathing Figure 9 Resin Crack Dated Apr 2008 Issued By DPS Page 17 of 22 L Miles Propeller_Manuals 4_cyl 3_laminate Drafts JPM3L01 1_signed doc Jabiru Aircraft pty pta SN T Propeller Service Manual JPM3L01 1 6 6 1 6 De lamination Figure 10 and Figure 11 below show an extreme example of the same type of damage shown in Figure 8 In this case the initial minor cracking was not sealed Over a period of several months more water entered and a small de lamination began the aircraft continued to be flown The result is that the fiberglass has delaminated from the wood over a large area Recommended Actions e IT IS NOT SAFE TO FLY WITH ANY AMOUNT OF DE LAMINATION Whenever de lamination is found the propeller must be removed from service and repaired 115 unusual for a de lamination to reach this size Normally air pressure acting on a smaller de lamination would rip the fibreglass off the entire blade Happening in flight this leads to an extremely out of balance propeller normally the engine must be shut down immediately and an emergency landing carried out Edge of delaminated area Wood exposed at leading edge Fibreglass no longer bonded to wood Figure 11 Fibreglass De lamination Dated Apr 2008 Issued By DPS Pa
12. ble down the side of the hob for no more than 10mm 0 39 Line through centres of outer bolt holes Maximum crack length within central zone between lines 25mm 1 Line through centres of outer bolt holes Maximum crack length outside central zone beyond lines 50mm 2 or up to the edge of the propeller If the crack touches the side of the prop it must be visible down the side of the hob for no more than 10mm 0 39 Figure 3 Hub Aging Figure 4 below shows the side of an older propeller hub A crack running along the grain is visible This type of damage is typically caused by over torquing the propeller bolts or not using Belleville washers on the installation as shown in Figure 1 Recommended Actions Check the propeller installation amp verify bolt tensions Where the crack has exposed the wood seal it using a thin type superglue to prevent moisture ingress Overall propeller hub thickness must be greater than 58mm Crack Figure 4 Hub Compression Cracking Dated Apr 2008 Issued By DPS Page 14 of 22 L Miles Propeller_Manuals 4_cyl 3_laminate Drafts JPM3L01 1_signed doc Jabiru Aircraft SE Propeller Service Manual JPM3L01 1 6 6 1 3 Urethane Abrasion Stone Chips Figure 5 below shows a stone chip and urethane abrasion near the tip of a propeller blade In this case some superglue has been applied to the stone chip This sort of damage is gen
13. d during daily inspections Remove these isolated pieces of urethane Trim line for urethane edges p Figure 6 Urethane Abrasion Dated Apr 2008 Issued By DPS Page 15 of 22 L Miles Propeller_Manuals 4_cyl 3_laminate Drafts JPM3L01 1_signed doc Jabiru Aircraft py eta Me Propeller Service Manual JPM3L01 1 6 6 1 4 Urethane Pitting Figure 7 below shows urethane which has been pitted by flying through rain Recommended Actions Minor damage can be sanded slightly to improve the smoothness of the leading edge The pits shown would be treated this way e Major damage must be repaired by replacing the urethane leading edge protection Figure 7 Urethane Pitting 6 6 1 5 Resin Cracks Figure 8 below shows cracking in the resin shell of the propeller at the leading edge between the inboard end of the urethane and the start of the spinner The example shown is also fitted with leading edge prop tape This damage is usually caused by moisture ingress into the blade causing the wood to swell and crack the resin coating The moisture can enter whenever the blade is exposed to water flying through rain covered by dew overnight etc Recommended Actions e The damage shown below is a minor example of it s type At this stage it should be covered with prop tape and monitored e f the cracking progresses any open cracks should be sealed with a thin type of superglue Ma
14. e encourage owners to make suggestions related to design improvements However the final decision on their adoption or otherwise rests with JABIRU AIRCRAFT Pty Ltd Dated Apr 2008 Issued By DPS Page 4 of 22 L Miles Propeller_Manuals 4_cyl 3_laminate Drafts JPM3L01 1_signed doc Jabiru Aircraft pry pu Propeller Service Manual JPM3L01 1 Warnings IMPORTANT Always think before acting and use common sense Working with propellers can be extremely dangerous WARNING DO NOT GO NEAR THE PROPELLER IF THERE IS A PERSON IN OR NEAR THE COCKPIT ENSURE AIRCRAFT MASTER SWITCH IS OFF BEFORE COMMENCING ANY WORK ON PROPELLER DO NOT RUN ENGINE WITH PROPELLER DISCONNECTED OR ENGINE DAMAGE WILL RESULT 5 Propeller Operation 5 1 Limitations 5 1 1 Maximum RPM The propellers covered by this manual are limited to 3300 RPM 5 1 2 Life The propellers are assessed on condition There is no fixed life 5 2 Normal Operations 5 2 1 Ground Handling Impact from gravel grass insects and other objects can damage the propeller When operating from gravel runways the pilot should be aware of this at all times and plan their operations to suit Take care when carrying out ground tests of the engine either make sure the propeller is not over any loose gravel or perform run ups while rolling forwards at normal taxi speed note that this procedure requires some practice and is not recommended for
15. e temporary filler which may be used to smooth out the edge of the Urethane and to fill small pits 7 3 5 Fibreglass Damage to fibreglass generally appears as pits on the rear faces of the blades and damage to the tips Any damage to the glass which results in an unsealed edge or de lamination has the potential to cause the entire glass sheath to shed Therefore damage of this type must be treated as soon as possible using superglue Dab the superglue along the edge It will be drawn beneath the glass by capillary action and the white edge will become transparent as the air gap is filled by glue Repeat applications may be required in some cases The condition of the repair must be monitored and if it continues to deteriorate the propeller must be returned to Jabiru Aircraft for repair Maximum size of damage which may be repaired by the owner are listed in Section 7 3 2 7 3 6 General Repairs must always take account of the changes to balance of the Propeller Generally for repairs the propeller should be removed in accordance with the procedure described above Section 6 3 2 and checked for balance Section 7 3 1 prior to refitting Section 6 3 3 Always check blade amp spinner tracking after reassembly Section 6 3 3 Dated Apr 2008 Issued By DPS Page 20 of 22 L Miles Propeller_Manuals 4_cyl 3_laminate Drafts JPM3L01 1_signed doc Jabiru Aircraft py pu Propeller Service Manual JPM3L01 1 7 4 Storage
16. equirements and limitations applicable to the propellers when used in their application The information in this manual is based upon data available at the time of publication and is supplemented and kept current by Service Bulletins amp Service Letters published by JABIRU AIRCRAFT Pty Ltd These are distributed directly to owners in addition to being posted on the JABIRU website or provided to your local Dealer or Distributor so that they have the latest authorised recommendations for servicing the propellers New owners of pre owned certified propellers should ensure that the transfer of ownership has been advised to JABIRU AIRCRAFT Pty Ltd or your local dealer or distributor Existing owners should ensure that their postal address remains current IMPORTANT All maintenance should be undertaken with careful regard for the procedures outlined in this manual A detailed record of maintenance undertaken should be recorded in the Aircraft Log Books The JABIRU Propellers described in this Technical Manual are Type Certified As such they must be maintained by an Authorised Person LAME for CASA registered aircraft Owner or Level 2 Holder for RAAus registered aircraft In all cases NO MODIFICATIONS ARE PERMITTED without approval from a CAR 35 Authorised Person the aircraft manufacturer or equivalent It is the owner s responsibility to ensure that their propeller is maintained by an appropriate person In the interests of product development w
17. erally caused by operations from gravel runways and flying through rain Recommended Actions e Stone chips like the one shown below are not generally dangerous however they should be visually monitored during normal daily inspections as it is possible for glass de laminations to start from them Using a thin type of superglue to seal the chip is recommended to seal the damage amp stabilise the chip e The urethane damage shown below is minor The edge of the fibreglass is not exposed and there are no loose sections of urethane Note due to the abrasion of the urethane this propeller tip will be much more susceptible to damage when flying through rain than it would be if the urethane was in as new condition Stone chip Abraded amp damaged urethane Figure 5 Stone Chip amp Urethane Abrasion Figure 6 below shows more severe damage to the urethane This type of damage is generally caused by flying through rain or taxiing through long grass Recommended Actions e Urethane loss such as shown below is low medium level damage The leading edge of the fibreglass has been exposed and while the edges of the urethane appear stable they are irregularly shaped and may begin peeling A propeller tip in this condition is safe in normal use however it will be damaged much more rapidly by rain The irregular ends of the urethane can be carefully removed with a sharp knife and the exposed edge of the fibreglass should be specifically checke
18. fe edges e Place a length of 16mm 5 8 tube into the centre hole of the propeller The tube must be true and round and be a firm fit The balance rig consists of 2 straight level knife edges Steel rulers are suitable when appropriately mounted Where possible the rig should be constructed to allow checking of the blades in the horizontal and vertical positions The propeller is placed on the rig with the 16mm tube resting on the knife edges The heavier blade will sink to the bottom Ensure the balancing is being done in a closed room drafts or gusts of wind will rotate the propeller and give inconsistent balancing Tolerances e mbalance shall not exceed the following limit whatever the position of the Propeller in the plane of rotation 750 mm gms approximately 1 gm at the tip e The balance may only be corrected by the application of enamel paint Any other method of securing balance is PROHIBITED Do not apply paint over the Urethane leading edge it will rapidly flake off in service which is both unsightly and will affect the balance of the propeller Propellers outside these limits should be rejected as unserviceable or returned to JABIRU for assessment and possible repair 7 3 2 Damage Limits amp Repairs Any service or repair must take account of the risk of subsequent Propeller failure Therefore repairs by owners are limited to minor damage Larger damage must be referred to Jabiru Airc
19. ge 18 of 22 L files Propeller_Manuals 4_cyl 3_laminate Drafts JPM3L01 1_signed doc Jabiru Aircraft pty pa Propeller Service Manual JPM3L01 1 7 Propeller Overhaul As there are no removable parts for these propellers overhaul effectively means major repair Major repairs may only be carried out by Jabiru Aircraft P L or authorised agents 7 1 Propeller Removed Inspections Whenever the propeller is removed from the engine the following inspections are to be carried out 1 Drive bush fit into hub should be a good fit The bush should not need to be forced into the hub and there must be no slop once the bush is fitted 2 Balancing checking the balance of the propeller is simple and Jabiru Aircraft recommend checking the balance whenever the propeller is removed from the aircraft 3 Hub condition inspection whenever the propeller is off the engine the general condition of the hub should be visually inspected Section 7 3 2 gives details 7 2 Fits amp Clearances 7 2 1 Propeller Drive Bushes Drive bushes must be a close fit in the propeller hub Push the bushes into the hub by hand If slack can be felt on two or more bushes the hole clearances must be adjusted Refer to Section 7 3 7 3 Repair Methods 7 3 1 Propeller Balancing Procedure Propeller balance should be checked by locating a 16mm tube to firmly fit the centre mounting hole of the Propeller and balancing on level kni
20. hed in fibreglass A Urethane protective coating is applied to the leading edge of both blades The propeller finish is normally a clear enamel paint though other colours may be used for some applications 6 2 2 Approved Installations The following combinations are approved for Type Certified Installations Table 1 Approved Propeller Engine Propeller Flange Combinations Propeller Engine Propeller Flange Dia x Pitch Remarks Limits C000242 D60P38 Jabiru 2200 ere d iu Mot ps ido C000242 D60P42 Jabiru2200 po 4223085 a P ip o M C000242 D60P44 Jabiru 2200 ene 1 X Hou ps aoe 4A401BOD Jabiru 2200 jer Rr 4A401A0D Jamo gone eu i m Ec 4A401COD Jabiru 2200 BET UN io a ME Dated Apr 2008 Issued By DPS Page 7 of 22 L Miles Propeller_Manuals 4_cyl 3_laminate Drafts JPM3L01 1_signed doc Jabiru Aircraft pty pa Propeller Service Manual JPM3L01 1 6 2 3 Propeller Markings C000242 Series Each propeller is marked with the particulars indicated below gt DWG C000242 D60P42 Drawing No D 1524 1067 n Diameter JABIRU 2200 Pitch Engine Model JJ40001L C NE Jabiru Jabiru 4 Cylinder Serial No Leading Edge Composite Prop Engine Protection Sheath 6 2 4 Propeller Markings 4A401 Series Each propeller is marked with the particulars indicated below Drawing No g
21. intaining a seal over the wood is the best way to prevent this type of damage from spreading Prop tape runs from the inboard end of the urethane through to the spinner Cracking visible in the resin at the leading edge Figure 8 Moisture Ingress Leading Edge at Root Dated Apr 2008 Issued By DPS Page 16 of 22 L Miles Propeller_Manuals 4_cyl 3_laminate Drafts JPM3L01 1_signed doc Jabiru Aircraft pty pa Men Propeller Service Manual JPM3L01 1 Figure 9 below shows cracking in the resin shell of the propeller near the hub Cracks of this type can occur in older propellers where there is only resin and no fibreglass covering the wood Recommended Actions e The inner end of the fibreglass can be seen as the colour of the composite covering the wood changes from a relatively opaque covering to a clearer coating Fibreglass resin composite is more opaque than resin alone The fibreglass coverings of the propellers covered by this manual run from the tip of the blade to a point approximately 100mm 4 from the centre of the propeller e Cracks such as this one are not a structural issue provided that they are no more than 110mm from the prop centre and are no longer than 50mm 2 e Where a crack has opened slightly it must be sealed with superglue to prevent moisture entering The black marking of the upper part of the crack shown below is due to moisture staining the wood Crack Note black m
22. on 5 2 3 5 2 3 Parking To prevent the accumulation of moisture in the lower blade the propeller must always be left in the horizontal position when the engine is being parked for any length of time especially in conditions of high ambient humidity 5 2 4 Daily Inspection Inspect both blades for e Urethane condition peeling tears pitting or abrasion Fibreglass condition stone chips trailing edge chips de laminations whitening e Resin condition cracks Pictures of typical damage are shown in Section 6 6 1 5 3 Running In Rain Jabiru Aircraft do not recommend or endorse operating in rain The following is intended as a guide for owners who have for whatever reason been forced to fly through rain Do not operate in heavy rain or hail Know your limitations and the limitations of your aircraft If in doubt divert or land e Maintain situational awareness do not fly into rising terrain or near high obstacles radio towers etc in low visibility conditions e f forced to fly through rain reduce engine RPM 2600rpm or less is recommended though the pilot must maintain a safe airspeed e Monitor propeller condition on landing check the blades for damage Minor damage can be repaired in the field in accordance with the details given in Section 7 3 2 Do not fly on with damage beyond the limits set in Section 7 3 2 e AUrethane leading edge is provided for impact protection and also allows the propeller to
23. ondition Refer Section 7 3 2 for details i 10 Wood condition Refer Section 7 3 2 for details 7 11 Hub condition Refer Section 7 3 2 for details E PROPELLER BOLTS NUTS 12 13 TRACKING 14 Condition corrosion etc Bolt Nut tension Propeller tracking Dated Apr 2008 Issued By DPS Page 11 of 22 L Miles Propeller_Manuals 4_cyl 3_laminate Drafts JPM3L01 1_signed doc Jabiru Aircraft pry pu Propeller Service Manual JPM3L01 1 Annual Inspection Each 100 Hours 15 Spinner tracking BALANCE 16 i Dated Apr 2008 Issued By DPS Page 12 of 22 L Miles Propeller_Manuals 4_cyl 3_laminate Drafts JPM3L01 1_signed doc Jabiru Aircraft pty pa M Propeller Service Manual JPM3L01 1 6 6 Troubleshooting 6 6 1 Defect Recognition 6 6 1 1 Trailing Edge Chip Figure 2 below shows a minor trailing edge chip approximately 13mm 0 5 long This type of damage is normally caused in the hangar or while the propeller is in storage or being shipped Recommended Actions n general whitening is a sign that the resin matrix surrounding the fibreglass has been damaged This type of damage can allow moisture to enter and act as a starting point from which de laminations can grow e f the fibreglass has been chipped or frayed apply a thin type of superglue to the fibres
24. raft for repair Maximum size of damage approved for owner repair e Nicks in leading edge up to 4mm deep x 20mm long Nicks such as stone chips across the drive face of the blades flat sides up to 2mm deep x 6mm diameter or scratches not more than 0 5mm deep Dated Apr 2008 Issued By DPS Page 19 of 22 L Miles Propeller_Manuals 4_cyl 3_laminate Drafts JPM3L01 1_signed doc Jabiru Aircraft pty pa Propeller Service Manual JPM3L01 1 e Urethane de lamination up to 15mm long and no more than 5mm wide e Pits in fiberglass up to 7mm in diameter e Fibreglass edge de lamination up to 15mm long and no more than 2mm wide Only damage within the size tolerances described above may be repaired by owners All propellers with damage beyond these limits must be either rejected as unserviceable or returned to JABIRU Aircraft Pty Ltd or our local approved agent for assessment and possible repair 7 3 3 Nick Repair In composite leading edges nicks of a size described above may be repaired by filling with epoxy resin and Fibreflock using the procedure outlined below 1 Remove Propeller as per Paragraph 6 3 2 2 Sand nick with abrasive paper to remove any fractured particles 3 Mix resin carefully and thoroughly equal parts resin and hardener and thicken with Fibreflock to form a paste 4 Apply paste to sanded nick and allow to cure in low moisture environment for 24 hours 5 Lightly and ca
25. refully sand excess cured resin to a smooth surface matching exactly the previous aerofoil 6 Refurbish with clear paint 7 Rebalance Propeller see Section 7 3 1 8 Reassemble and replace Propeller and Spinner see Paragraph 6 3 3 9 Check Propeller tracking and Spinner balance see Paragraph 6 3 3 7 3 4 Urethane The Urethane leading edge applied to Jabiru Aircraft Propellers provides protection for the wood and fiberglass structure of the blade from rock amp insect impacts and abrasion from light rain Over time the Urethane will wear and may begin to delaminate Pitting and wear is not generally repairable in the field Excess roughness may be removed by lightly sanding the area with 180 grit sandpaper taking care to maintain the shape of the leading edge De laminations can not be repaired in the field generally a complete replacement of the Urethane is required As an emergency measure de laminations up to 15mm long along the blade and 5mm wide my be treated as follows Note that these measures are to be used in an emergency and are not considered permanent the propeller should be returned to Jabiru Aircraft for repair as soon as practical Using a sharp knife trim off the loose Urethane Take care not to damage the fibreglass below Use superglue to seal the trimmed edge of the Urethane to the propeller Do not leave a sudden step at the edge of the Urethane Mixing superglue with flour or similar makes a serviceabl
26. s checked for correct tension Dated Apr 2008 Issued By DPS Page 9 of 22 L Miles Propeller_Manuals 4_cyl 3_laminate Drafts JPM3L01 1_signed doc ft pty Pia Aircra iru Jab Propeller Service Manual JPM3L01 1 sv I 40 1 19395 E Q0V68 ON 9 d EN 3105 OL N3LI 39315 dOHd 3noHOl 19384800 404 AVM SIHL 38 ISNN SNOLLO3MId 3llSOddO NI 3Ov4 SH3HSV 310N ASSY YSHSVM 3TIA3TI38 11130 Ad n Odal YITINIH 982 010 169 o quw sv ean ub ON lavd we S HYANNIS 0917 GoBeelvr I L SNNONV 0917 aodesivr 21 U3HSVM VPZ ZLO SETEV NOLLYTIVLSNI LAN YOHONY 8 7130 oh 3495 ISO 69TOSW v VIVO O V 83338 s 9 nog VLE PNY 9 9 IAN 4OO1AN 87 89058 Z S3HSVM 3TIATTISB NelovrHd 8 9 OTZ S S dod Hsna YS0SSOY 6 INNOW dONd 3lvid fzzleor OI I 091 0006819 LI yt LAM 2 E E zi INN YOHONY 80169012SW ci VV N UILO3S YANNIdS NI SJIOH G9T1MO 3Yd 9 0319001 SINN YOHONY Z G e g p 51109 YITIIdOUd SNIN3IHSIL 304 JONINDIS JONY SNLINNON dOMd lJVHSMNYHO Wiad 335 NOLIYTINLSNI LAN MOHONY 303 NOLO3POsd 3135 LON OG fer NI SNOISN3HIQ
27. student pilots Unless required due to short runway length do not hold the aircraft on the brakes while increasing power at the start of the takeoff roll Take care when taxiing through ditches or over rough or uneven ground Reduce speed pass over the ditch diagonally and do not abruptly increase power to climb out the far side If unsure stop the engine and push the aircraft across the ditch by hand 5 2 2 Hand Manoeuvring The aircraft may be moved by hand using the propeller as a handle However the following procedures must be used IMPORTANT Always think before acting and use common sense Working with propellers can be extremely dangerous Ensure that the aircraft s master switch is OFF before walking near the propeller Do not go near the propeller if there is a person in or near the cockpit Only one person at a time may hold the propeller Always hold the propeller as close as possible to the root in practice this normally means placing hands immediately beside the spinner Dated Apr 2008 Issued By DPS Page 5 of 22 L Miles Propeller_Manuals 4_cyl 3_laminate Drafts JPM3L01 1_signed doc Jabiru Aircraft pty pa Propeller Service Manual JPM3L01 1 e Orient the propeller horizontally unless manoeuvring the aircraft past an obstruction which would hit the propeller if it were left horizontal However do not park the propeller in a vertical orientation see notes below Secti
28. t DWG 4A401A0D D 1524 P 1067 Diameter Pitch Engine Model JABIRU 2200 J4A401 0001 LC NV Leading Edge Composite Prop Model Descriptor Protection Sheath Serial No 6 3 Instructions 6 3 1 Acceptance Checking Propellers supplied by Jabiru Aircraft are balanced before shipping Balancing before fitting to an aircraft is not necessary Visually inspect propeller to ensure that it has not been damaged in transit Before fitting check that the propeller drive bushes are a neat fit in the sockets of the propeller Section 7 2 1 gives details 6 3 2 Procedure Removal of Existing Propeller Figure 1 shows a typical propeller installation 1 Remove Machine Screws and Tinnerman Washers from Spinner 2 Remove Spinner 3 Unbolt Propeller Bolts 6 off 4 Remove Bolts Spinner Flange Aluminium Propeller Flange Belleville Washers and Propeller 6 3 3 Procedure Propeller installation 1 Figure 1 shows typical propeller installation details 2 Ensure that Propeller drive bushes 6 off are in place in the Crankshaft Propeller Flange Where equipped fit the rear spinner backing plate to the flange 3 Fit propeller to flange Ensure that the drive pins are snug fit in the propeller 4 Fit Propeller Bolts 6 off Dated Apr 2008 Issued By DPS Page 8 of 22 L Miles Propeller_Manuals 4_cyl 3_laminate Drafts JPM3L01 1_signed doc
Download Pdf Manuals
Related Search