Aircraft Service Manual - Jabiru Aircraft & Engines Australia
Contents
1. e Using a sharp knife trim off the loose Urethane Take care not to damage the fibreglass below e Use superglue to seal the trimmed edge of the Urethane to the propeller e Do not leave a sudden step at the edge of the Urethane Mixing superglue with flour or similar makes a serviceable temporary filler which may be used to smooth out the edge of the Urethane and to fill small pits 6 7 5 Fibreglass fof of oS Type of Maintenance Overhaul Level of Certification LSA Repairman Inspection of Maintenance with Task Specific Training 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 6 7 2 This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled2. JPM3L1 3 C000242 C000262 4A401 Propeller Variants 5 10 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 e t is 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 This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled Dated 8th April 2014 Issued By DS Page 25 of 31 Propeller Technical Manual Jabiru Aircraft cu a me Ca JPM3L1 3 C000242 C000262 4A401 Propeller Variants 6 Propeller Overhaul As there are no removable parts for these propell
3. SJYLINNIN NI SNOISNAWIG GK Ald HOI 20 LNJSNOD LNOHLIMA DC 38 JON On ONY LHIIYAJOJ SI INIMYYO SIHL Figure 1 Typical Propeller Installation IMPORTANT For all Jabiru Aircraft Engines the spinner is an important and integral part of the propeller Assembly It is essential to ensure adequate engine cooling The aircraft must not be flown with the spinner removed 5 2 E o O G N o E oO Ri D a Se E D E Ei D fe 5 ER E Z n 2 Gi bi o lt D D E 2 o C 2 E s Q O O D D Z D o ei Te ba Bo o E s EC o wn ES o E D 2 2 5 2 E E oO Ei Ed E oO E bel re bei ke Ed Be Page 18 of 31 Issued By DS Dated 8th April 2014 Propeller Technical Manual Jabiru Aircraft cu a o OA JPM3L1 3 C000242 C000262 4A401 Propeller Variants 5 8 4 Procedure Propeller Tracking LLA Type of Maintenance Line Maintenance Level of Certification LSA Repairman Inspection of Maintenance Locate a fixed object on a flat floor so that it clears the Propeller tips by a small margin 1 3mm Rotate the Propeller by hand Check that each blade clears the object by the same amount Measure the clearance for each blade Maximum Tracking Error Tolerance is 2mm If the Propeller is outside the approved tolerance refer to JABIRU Aircraft Pty Ltd or a JABIRU Approved Service Centre for rectification
4. 16mm tube pressed through the central hole of the propeller The tube must be a firm fit This system is simple however any dents or bends in the tube can affect the accuracy of the balance In addition this requires that the knife edges be positioned one on either side of the propeller a configuration which means the overall jig must be bulky in order to check the propeller balance with the blades oriented vertically A propeller flange fitted to a crankshaft or similar heavy round shaft The propeller is fitted to the propeller flange with 2 drive bushes and bolts positioned in the propeller mounting holes aligned to the blades The heavy shaft is then mounted on the knife edges with the propeller cantilevered over 1 side of the jig This method allows the balance jig to be much less bulky and mounts the propeller as it would be on the engine to minimise balance differences e Ensure the balancing is being done in a closed room drafts or gusts of wind will rotate the propeller and give inconsistent balancing e Propeller balance jigs must be checked before each use to ensure that The knife edge balance blades are horizontal There are no bends dents nicks or damage to the knife edges or the balance shaft which may prevent the assembly from rotating This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled Dated 8th April 2
5. 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 When switched off Jabiru engines tend to come to rest with the flywheel magnets aligned with the ignition coils When fitting a propeller turn the crank of the engine by hand until the magnets are aligned and then fit the propeller with the blades horizontal This method makes it likely that when the engine is turned off the propeller will naturally tend to come to rest with the blades horizontal 4 Fit propeller to flange Ensure that the drive pins are snug fit in the propeller 5 Fit Propeller Bolts 6 off 6 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 7 Progressively tighten bolts ensuring equal distribution of load and in a normal criss cross torque sequence 8 Using Torque Wrench tighten Bolts to 6lb ft 72 inch Ibs 9 Check tracking of Propeller as detailed in Section 5 8 4 10 Locate Spinner on Spinner Flange and fix with Machine Screws through tinnerman Washers 11 Check Spinner tracking as detailed in Section 5 8 5 12 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 ingr
6. 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 e Only one person at a time may hold the propeller e Always hold the propeller as close as possible to the root in practice this normally means placing hands immediately beside the spinner 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 Section 3 2 3 3 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 3 2 4 Daily Inspection Inspect both blades for e Urethane condition peeling tears pitting or abrasion e Fibreglass condition stone chips trailing edge chips de laminations whitening e Resin condition cracks Pictures of typical damage are shown in Section 5 10 1 This document is controlled while it remains on the Jabiru server Once this no longer applie
7. 38 4A401A0D S Jabiru 4 Cylinder Propeller 3 lamination 60 pitch 42 4A401C0D Jabiru 4 Cylinder Propeller 3 lamination 60 pitch 44 C000242 propellers from S No 2900 onwards and 4A401 propellers from S No 002 onwards meet the applicability requirements for Australian Type Certificate Number VP503 issued by the Civil Aviation Safety Authority CASA of Australia 2 6 2 Other Models This manual also contains JABIRU recommended procedures and instructions for ground handling servicing and maintaining the following Jabiru propeller models C000262 D60P44 Jabiru 6 Cylinder Propeller 4 lamination 60 pitch 44 C000262 D60P48 Jabiru 6 Cylinder Propeller 4 lamination 60 pitch 48 C000262 D60P53 Jabiru 6 Cylinder Propeller 4 lamination 60 pitch 53 C000262 D60P55 Jabiru 6 Cylinder Propeller 4 lamination 60 pitch 55 These propellers are not type certified though certain serial numbers claim compliance with the requirements of CS 22 Subpart J or ASTM F2506 10 for operations in Light Sport Aircraft LSA category aircraft All propellers listed are certified for use on Jabiru 3300 Aircraft Engines 2 7 Approved Propeller amp Engine Combinations C000242 and 4A401 propellers are approved for use on all variants of the Jabiru 2200 Aircraft Engine only C000262 propellers are approved for use on all variants of the Jabiru 3300 Aircraft Engine only 2 8 Mass Moment of Iner
8. Dated 8th April 2014 Issued By DS Page 29 of 31 Propeller Technical Manual Jabiru Aircraft cu a o OA a JPM3L1 3 C000242 C000262 4A401 Propeller Variants 6 7 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 5 8 2 and checked for balance Section 6 7 1 prior to refitting Section 5 8 3 Always check blade amp spinner tracking after reassembly Section 5 8 3 7 Appendix A Worksheets The worksheet provided covers all inspection tasks required for 100 hour Annual Tasks listed Annual need only be done annually 100 hourly tasks are to be completed at both annual and 100 hour inspection intervals P indicates pass F indicates fail the Comments column should be used to note condition parts replaced etc INSPECTION TYPE oeircle 100 hourly eee Annual CARRIED OUT BY print name signature IOaiel 7 1 1 1 Spinner General condition check for cracks delamination etc P F Comments 100 hourly Screw holes check hole do not have excessive elongation P F Comments 100 hourly 7 1 1 2 Spinner Flange General condition Cracks around the perimeter of hub delamination etc P F Comments 100 hourly Anchor nuts amp rivets Check condition ensure they are secure
9. Remove the propeller from the aircraft e Carry out the inspections detailed in Section 6 4 e Thoroughly check the propeller for cracking wear or damage particularly in those areas not visible while the propeller is mounted to the engine Ensure the propeller does not exceed the wear amp damage limits detailed in Section 5 10 e Test the fit of the propeller drive bushes as detailed in Section 6 6 1 e Check the propeller balance as detailed in Section 5 8 4 5 7 4 Special Inspections AD PFP 1 e CASA Airworthiness Directive AD PFP 1 is applicable to the propellers detailed herein Operators amp Maintainers must ensure that the propeller is maintained in accordance with the latest revision of this AD e Amendment 3 was current at the time of writing This requires the following inspections Check propeller tracking Check hub bolts for tightness Inspect sheathing and tipping for looseness separation loose screws cracks or corrosion e These inspections must be carried out After the first flight following each installation At intervals not exceeding 100 hours time in service from installation or twelve months whichever occurs first e Jabiru Aircraft also require that these inspections be carried out When there has been a significant change in the ambient humidity due to a seasonal change or change in aircraft locality and Prior to the first flight after the aircraft has been idle for an extended period This doc
10. computer and want to be able to quickly zoom in and out Hold down the Ctrl key while rotating the wheel button on your mouse In most programs this will instantly zoom in or out e Todo the same thing on a modern laptop either plug in a wheel mouse as detailed above or use the built in track pad Put two fingers on the pad close together then move then apart diagonally To reverse put two fingers on the pad at opposite diagonal points on the pad and bring them together diagonally This works on most modern PC laptops e This document has been created with hyperlinks between referenced items So when reading the manual on a computer you can click on the page number of an item on the table of contents and the computer will skip to that page Also if a paragraph says refer to Section 5 1 then you can click on the 5 1 and automatically skip to that page Similarly if Figures or Tables are referenced e To open a search window press Ctrl f Depending on the program this will normally open a small search window where you can enter keywords For example searching for the word life will allow you to quickly find all reference to lifed maintenance items 2 5 Degree Of Difficulty e In this manual we have used a spanner scale to help overhaulers approach a job Anyone considering undertaking a task in this manual must realistically assess themselves against this scale and not attempt any task for which they lack knowledg
11. horizontal and then placing one hand on the propeller on either side of the spinner The aircraft can then be pulled forward WARNING Never move the aircraft in this manner whilst the engine is hot as it may fire when the propeller is moved and result in severe injury Always ensure that the Master and Ignitions are OFF Never approach the propeller when anyone is in the aircraft Always treat the propeller as LIVE IT KILLS 5 6 3 Parking e It is strongly recommended that aircraft are stored in hangars wherever possible to minimise degradation caused by the elements and pests e When parking the aircraft always orient the propeller with the blades horizontal to prevent gravity fed moisture migration to the lower blade e The propeller is susceptible to UV damage and should be covered if the aircraft is to be stored outside long term 5 6 4 Off Aircraft Storage e 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 Propellers may be stored horizontally on any flat dry shelf or surface Propellers should be positioned so that they are resting on the drive face Ensure no items are resting or leaning against the propeller Ensure the propeller is not subjected to direct sunlight Minimise the propeller s exposure to humidity while in storage As much as possible minimise the propeller
12. 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 6 7 2 gives details This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled Dated 8th April 2014 Issued By DS Page 27 of 31 Propeller Technical Manual Jabiru Aircraft cu a me Ca JPM3L1 3 C000242 C000262 4A401 Propeller Variants 6 6 Fits amp Clearances 6 6 1 Propeller Drive Bushes LLA Type of Maintenance Overhaul Level of Certification LSA Repairman Inspection of Maintenance with Task Specific Training e 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 6 7 6 7 Repair Methods 6 7 1 Propeller Balancing Procedure Overhaul fof of oS Type of Maintenance Overhaul Level of Certification LSA Repairman Inspection of Maintenance with Task Specific Training Propeller balance jigs must meet the requirements of Section 6 3 1 e Check the balance jig to ensure that the knife edges are straight and level e Ensure the propeller is clean and dry if necessary clean the
13. 00242 C000262 4A401 Propeller Variants Figure 9 below shows cracking in the resin shell of the propeller near the hub Cracks of this type can occur in older propellers in areas 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 GT 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 mark near the top where moisture has entered through the crack amp stained the wood L Edge of hub markings visible Inner end of fibreglass sheathing Figure 9 Resin Crack This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled Dated 8th April 2014 Issued By DS Page 24 of 31 Propeller Technical Manual Jabiru Aircraft cu a AN
14. 014 Issued By DS Page 26 of 31 Propeller Technical Manual Jabiru Aircraft cu a GG srce JPM3L1 3 C000242 C000262 4A401 Propeller Variants Propeller balancing vertically Balance jig steel rulers mounted level Propeller balance shaft in this case an unserviceable but balanced crankshaft Propeller mounted to prop flange using 2 propeller drive bushes amp bolts Propeller balancing horizontally Figure 12 Propeller Balancing 6 4 Overhaul Sequence Remove the propeller from the aircraft Thoroughly clean amp inspect the propeller Carry out the standard inspections propeller removed detailed in Section 6 5 Carry out any necessary repairs as detailed in Section 6 7 Carry out a final balance of the propeller as detailed in Section 6 7 1 Re fit the propeller to the aircraft as detailed in Section 5 8 3 Ensure the propeller blades and spinner are tracking correctly Section 5 8 4 amp 5 8 5 NOaRwWN gt 6 5 Propeller Removed Inspections i ae Type of Maintenance Overhaul Level of Certification LSA Repairman Inspection of Maintenance with Task Specific Training 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
15. 20 of 31 Propeller Technical Manual Jabiru Aircraft cu a S JPM3L1 3 C000242 C000262 4A401 Propeller Variants 5 10 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 e 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 e Measure the length of the cracks amp compare 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 visible 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
16. 4 Issued By DS Page 19 of 31 Propeller Technical Manual Jabiru Aircraft cu a GG AN JPM3L1 3 C000242 C000262 4A401 Propeller Variants 5 10 Troubleshooting 5 10 1 Defect Recognition 5 10 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 In 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 If the fibreglass has been chipped or frayed apply a thin type of superglue to the fibres Capillary action will draw the glue into the glass and the colour will change from white to translucent 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 Maximum size to repair by the method above 13mm along the blade and extending up to 10mm towards the blade leading edge After repair visually monitor the chip for growth Figure 2 Trailing Edge Chip This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled Dated 8th April 2014 Issued By DS Page
17. CE retr restrrerorteerrsenreerr rer reeeer erorten 27 6 5 PROPELLER REMOVED INSPECTIONS cccccesesessesesescececestecsececsescacsesecacsesavaceesecacsenesaceesecaeeeavateeeecaeeeeataeeeees 27 6 6 FITS amp CLEARANCES EE 28 6 6 1 Propeller Drive BUSNGS c csecsssscsecessccecesesececesssceecusssccncussscncussscencuasscsncusssconcassscencaassescaasscseceasaeeeees 28 6 7 REPAIR METHODS EE 28 6 7 1 Propeller Balancing Procedure Overbaull 28 6 7 2 Damage Limits amp Repairs 0 ee sseseeccsseseeecseesesecsesseseccesseseceesceseceeeaesecaessesecaesaeseceesaeseceenaeseceeaeeeeeeeaeaeees 28 SC We ege 29 6 7 4 BE eebe eege 29 E SE Ee EE 29 676 Eeer eelere ee deefe 30 7T APPENDIX A WORKSHEETS eessen eegene 30 1 1 Table of Figures Figure 1 Typical Propeller Installation 2 0 0 eee cceecceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeaeeeeeeeaeeeeesaeeeeeseeeeeeeeeeaeeeseeeeeeeeeeaees 18 Figure 2 Trailing Edge Chip EE 20 Figure 3 HUB AGING DE 21 Figure 4 Hub Compression Cracking ccccsceceecceeeeeeeeeaeeeeeeeceeeeecaaeeeeaaeseeeesaeeesaaeseeaeeseeeeessaeeesaeeeeneessaees 21 Figure 5 Stone Chip amp Urethane Abrasion cccccececeeeeeeeceeeeeceeeeeceaeeeeaaeceeeecaeeesaaesseaeeseeeeseaeeesaeeneneeseaees 22 Figure 6 Urethane Abrasion AA 22 Figure Urethane Eng esnaera O SERGE EES dueeevseueestapedaeees 23 Figure 8 Moisture Ingress Leading Edge at Root eccceeseeeeeeeeeeeeeeeeeeeeeeeeenee
18. IFFICULTY eege Seceuen geen isaret avie Ee EE Ee EE EEEa EEEa ERESSE EE EE Ee EEE EEEn 6 26 APPLICABILITY cerere e r E E See E nee see 6 2 6 1 Type Certified Modelen 6 262 e TE 7 2 7 APPROVED PROPELLER amp ENGINE COMBINATIONS s s ssssesesssteststssststtrettstsstststttentstentststtnestattstntererenrstentn net 7 2 8 MASS MOMENT OF INERTIA seene 7 3 PROPELLER OPERATION sscississsccssscsssesscsicstsssesesesssedsessntsseavoscsieshoasuasocssondseosacsesetoareouseadseasonnasodsovessesssessesacesessoans 8 Sy HENN 8 3 1 1 MXIT APM estis inean AEEA A E AAE cla swdennensbatanis ee eer 8 B2 MICs re ies N cates tating te E E E A E EA A tee at eae een 8 3 2 NORMAL OPERATIONS i rretsi nanne ane o AE eSEE EEE EE E E E E EEEN S EO eet 8 3 2 1 GIOUNG Handling E 8 322 Hand RE E ni E E aai 8 B23 E le E 8 3 2 4 Daily INSPCCHON E 8 3 3 ABNORMAL OPERATIONS E 9 3 3 1 eidele AN AAI a E E A vaaked watlicewadtinvacdesbewaaaeewacieed 9 AIRWORTHINESS LIMITATIONS SECTION ccsssccssssssssssssecsssssssscsssecsssssessssesecessessssesssecessesessesesecessesers 10 PROPELLER MAINTENANCE cccsccsscssssssessssosecsssssesscessececsssessesssesecsssesssessesecssessssesesecessesscsssesecessessrseses 11 Bil INTRODUCTION eet Eeer Ee ie 11 5 2 DESCRIPTION zra E E E E 11 5 2 1 EE 11 5 22 Propeller Sp cificationS naisen imiiniissiniiiiiian pnia e eae o E aaar Ee eiaei Il 5 2 3 Type 1 Propeller MArKINGS iaciscscisccssosiecissosiecissnrinsisiest
19. P F Comments 100 hourly Visual Inspection Look for signs of fretting and looseness rubbing marks P F Comments 100 hourly 7 1 1 3 Spinner Screws General condition Check condition of the head and thread of each screw P F Comments 100 hourly Screw tightness check screw tightness adequately in anchor nuts replace if fittings are loose P F Comments 100 hourly 7 1 1 4 Propeller Urethane condition see section 6 7 P F Comments 100 hourly This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled Dated 8th April 2014 Issued By DS Page 30 of 31 Propeller Technical Manual Jabiru Aircraft cu a o OAN a JPM3L1 3 C000242 C000262 4A401 Propeller Variants Fiberglass condition see section 6 7 P F Comments 100 hourly Wood condition see section 6 7 P F Comments 100 hourly Hub condition see section 6 7 P F Comments 100 hourly Propeller Drive Bush Fit see section 6 6 1 P F Comments Annual 7 1 1 5 Propeller bolts amp nuts General condition Check for corrosion wear etc P F Comments 100 hourly Bolt tension Check correct tension P F Comments 100 hourly 7 1 1 6 Track
20. Propeller Technical Manual FOR C000242 Series Propellers 4A401A0D Series Propellers C000262 Series Propellers DOCUMENT No JPM3L1 3 DATED 8 April 2014 Issue 3 SID This Manual has been prepared as a guide to correctly operate amp maintain Jabiru Propeller Models It is the owner s responsibility to regularly check the Jabiru web site at www jabiru net au for applicable Service Bulletins and have them implemented as soon as possible Manuals are also updated periodically with the latest revisions available from the web site Failure to maintain the engine or aircraft with current service information may render the aircraft un airworthy and void Jabiru s Limited Express Warranty This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled Should you have any questions or doubts about the contents of this manual please contact Jabiru Aircraft Pty Ltd Propeller Technical Manual Jabiru Aircraft cu a me Cea JPM3L1 3 C000242 C000262 4A401 Propeller Variants 1 1 JEUNES HIE Eeer 3 1 2 Bug elek 3 d GENERAL INFORMATION coscscocecsceosscsacovessssssssscensessceetesssecveseavsesnsastsesseseessensavensavdeenssentecsssesesessesosesvesensssas 4 2 1 FOREWORD ee 4 2 2 WARNING S 9 522555 sosccot acs a a e E uacesaecvorsace e 5 2 3 LISTOF EFFECTIVE E EEGEN 6 2 4 READING THIS MANUAL eea a E E E E E dau NE E EE E 6 2 5 DEGREE OF D
21. SSC RH i a S E Not above 3300 RPM 4A401C0D KEE 85hp Dee Ger Kr S e Not above 3300 RPM C000262 D60P44 ee 120hp Sg ee 1l fee S e Not above 3300 RPM C000262 D60P48 ee 120hp Es eege 1 co i en Not above 3300 RPM C000262 D60P53 Pane 120hp Pas met a S Ge Not above 3300 RPM C000262 D60P55 Tenn 120hp SE BEE l a S SC Not above 3300 RPM This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled Dated 8th April 2014 Issued By DS Page 11 of 31 Propeller Technical Manual Jabiru Aircraft cu a me La JPM3L1 3 C000242 C000262 4A401 Propeller Variants 5 2 3 Type 1 Propeller Markings Each propeller is marked with the particulars indicated below nn DWG C000242 D60P42 Drawing No gt D1524 P 1067 Diameter gt JABIRU 2200 M gt Pich Engine Model J J 4 0001 L C ee et Composite Jabiru Sheath Prop Jabiru 4 4 Cylinder sSerialNo Leading Edge Engine 6 6 Cylinder Protection 5 2 4 Type 2 Propeller Markings Type 2 data tags are fitted to the rear face of the blade just outboard of the spinner E Drawing No DWG C000242 Pitch Diameter D 60 P D JABIRU 2200 Deeg ngine lt ven i Talk 7 LC Sheath Jah Prop wa 1 R Jabiru Leading Edge Engine 4 4 Cylinder Serial Protection 6 6 Cylinder 5 2 5 Type 1 Propeller Markings 4A401 Series Each propeller is marked with the particular
22. blades to ensure all deposits are removed then dry thoroughly e Fit the propeller to the balance shaft e Place the propeller on the rig with the balance shaft resting on the knife edges Initially test with the propeller blades horizontal the heavier blade will sink to the bottom e Repeat the test with the propeller blades vertical the heavier side of the propeller will sink towards the bottom e Ensure the balancing is being done in a closed room drafts or gusts of wind will rotate the propeller and give inconsistent balancing e The balance may only be corrected by the application of enamel paint Any other method of securing balance is PROHIBITED e 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 e Propellers outside these limits should be rejected as unserviceable or returned to JABIRU for assessment and possible repair Tolerances e Imbalance 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 6 7 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 Aircraft for repair Maximum size of damage approved for owner repair e Nicks in leading edge up to 4mm deep x 20m
23. document becomes uncontrolled Dated 8th April 2014 Issued By DS Page 10 of 31 Propeller Technical Manual Jabiru Aircraft pry ud Shaun Wi JPM3L1 3 C000242 C000262 4A401 Propeller Variants 5 Propeller Maintenance 5 1 Introduction The Jabiru Propellers detailed in this manual are 2 bladed fixed pitch designs constructed of wood fibreglass composite They are available in a range of different pitches WARNING ENSURE IGNITION SYSTEM IS OFF BEFORE COMMENCING ANY WORK ON PROPELLER DO NOT RUN ENGINE WITH PROPELLER DISCONNECTED OR ENGINE DAMAGE WILL RESULT 5 2 Description 5 2 1 General The Jabiru Propellers detailed in this manual are made from plantation Hoop Pine sheathed in fibreglass A Urethane protective coating is applied to the leading edge of both blades The propeller finish is normally clear enamel paint though other colours may be used for some applications 5 2 2 Propeller Specifications Note that approved propeller and engine combinations are detailed in Section 2 7 Guer ei EE Engine Geer Propeller Flange Dia x Pitch Remarks Limits C000242 D60P38 oe 85hp eee een e SECH Not above 3300 RPM 2 Ext 466218N C000242 D60P42 eee 85hp ae tee 1 or i rA Not above 3300 RPM 2 Ext 466218N C000242 D60P44 ee 85hp Bee ere l e x e Not above 3300 RPM 2 Ext 466218N 4A401B0D Ee 85hp a in ca a Not above 3300 RPM 4A401A0D T 85hp
24. e or the required tools Table 2 The Spanner Scale The Spanner Scale Translation y Simple basic straightforward A careful layman with guidance can achieve this yr Straightforward but with some technical bits Basic knowledge care and guidance needed y Straightforward but requires special tools training and or judgement Sound basic knowledge guidance and a careful approach are required Pyp A technical job Take your time double check everything Only for the experienced overhauler Go fi a x A difficult job Requires special tools solid skills good judgement Only for experts 2 6 Applicability 2 6 1 Type Certified Models This manual contains JABIRU recommended procedures and instructions for ground handling servicing and maintaining the following Jabiru propeller models This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled Dated 8th April 2014 Issued By DS Page 6 of 31 Propeller Technical Manual Jabiru Aircraft cu a me Cea geb JPM3L1 3 C000242 C000262 4A401 Propeller Variants C000242 D60P38 S Jabiru 4 Cylinder Propeller 3 lamination 60 pitch 38 C000242 D60P42 Jabiru 4 Cylinder Propeller 3 lamination 60 pitch 42 C000242 D60P44 S Jabiru 4 Cylinder Propeller 3 lamination 60 pitch 44 4A401B0D Jabiru 4 Cylinder Propeller 3 lamination 60 pitch
25. eeesaeeeeeseeeeeeseneaeeeseneaees 23 RICK Resin Crack EE 24 Figure 10 Fibreglass Delammaton eee aeeeeeeeeeeeeeeeaeeeeesaeeeeeseeeeeeseeaeeeseneeeeeeneeaees 25 Figure 11 Fibreglass Delammaton eee aeeeeeeaeeeeeseaeeeeeseeeeeeseeaeeeseeeeeeeeeneaees 25 Figure 12 Propeller Balancing EEN 27 1 2 List of Tables Table 1 List of Approved Revisions sssessssssssisssssrrsssirrsstinnnntinnnntinuant tuunattu uant An naat En nantan nannan nannan nannan nanena naaa 6 Table 2 The Spanner Scale ceccceecceeceeeeeeeeeeeneeceeeeeceaeeeeaaeeeeeeecaeeeeaaeeeeaaeseneeesaeeeeaaeseeaeeseueeescaeeseaeseneeesaas 6 Table 3 Inspection Chart 15 This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled Dated 8th April 2014 Issued By DS Page 3 of 31 Propeller Technical Manual Jabiru Aircraft cu a aech JPM3L1 3 C000242 C000262 4A401 Propeller Variants 2 General Information 2 1 Foreword It is the owners responsibility to become fully aware of the particular maintenance requirements 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 t
26. ent is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled Dated 8th April 2014 Issued By DS Page 15 of 31 Propeller Technical Manual Jabiru Aircraft cu a me Ca JPM3L1 3 C000242 C000262 4A401 Propeller Variants 5 7 2 100 Hourly Inspection e As all possible circumstances cannot be listed here the following is provided as guidance only A critical trained eye is required and inspections should include but not be limited to the following e Remove the spinner and carry out a thorough visual inspection checking for cracking fraying corrosion and other damage e Check for loose missing corroded or damaged fasteners and hardware e Check for deposits and radial markings which indicate fretting between moving parts e Visually check the condition of the propeller looking for damage to the leading edge protection glass de lamination and cracks splits or crushing of the propeller timber e Check the tension of the propeller bolts nuts Tension if required e Check spinner and Prop Tracking 5 7 3 Annual Inspection e Annual inspections include all the items listed for the 100 hourly inspection above plus the additional items below e As all possible circumstances cannot be listed here the following is provided as guidance only A critical trained eye is required and inspections should include but not be limited to the following e
27. ers overhaul effectively means major repair Major repairs may only be carried out by Jabiru Aircraft P L or authorised agents 6 1 Overhauler Requirements The following are recommended as the minimum requirements for someone carrying out overhauls on Jabiru Propellers 1 Facilities Enclosed workspace with sealed floor lighting compressed air amp mains electricity 2 Training Completion of an approved instruction course specific to Jabiru Propellers Approved courses include those offered by Jabiru Aircraft Australia or by local Jabiru Aircraft representatives 3 Rating Commercial maintainers must hold ratings required by their local Airworthiness Authority 4 Experience A minimum of 1 year experience working on propellers under supervision is recommended for commercial maintainers before working un supervised 6 2 Tool amp Gauge Control e As detailed in Section 5 4 6 3 Tools amp Equipment Access to the following tools will be required All tools must be good quality items e As detailed in Section 5 5 6 3 1 Propeller Balancing Jig e A basic propeller balance rig consists of 2 straight level knife edges Steel rulers are suitable when appropriately mounted e The rig must be constructed to allow checking of the blades in the horizontal and vertical positions e For balancing the propeller must be mounted on a shaft positioned at the propeller s axis of rotation This may be A piece of 5 8
28. erstand that proper skills and training are essential to minimize the unavoidable risks of property damage serious bodily injury and death that arise from the use of Jabiru products IMPORTANT Always think before acting Use common sense WORKING WITH PROPELLERS CAN BE EXTREMELY DANGEROUS This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled Dated 8th April 2014 Issued By DS Page 5 of 31 Propeller Technical Manual Jabiru Aircraft cu a me Cea geb JPM3L1 3 C000242 C000262 4A401 Propeller Variants 2 3 List of Effective Pages e This manual is revised as a whole All pages retain the revision status of the overall document e Altered technical content is shown in red Table 1 List of Approved Revisions 1 Original Issue 2008 2 2012 Updated to include other propeller models Layout amp content aligned with 2012 Jabiru Manual Format Maintainer requirements and formatting added as prescribed by ASTM F2483 12 3 More detailed and extensive worksheet added 2 4 Reading This Manual e This manual is intended for use by experienced technicians and while all processes will be explained as clearly as possible some knowledge is assumed This manual is not intended to be sufficient reference for a person with no other training to safely maintain or overhaul a propeller e f you are reading this manual on a
29. ess 13 After the first flight following the propeller installation the spinner must be removed and the propeller bolts checked for correct tension This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled Dated 8th April 2014 Issued By DS Page 17 of 31 ft Pty Ltd Jabiru Aircra C000242 C000262 4A401 Propeller Variants Manual ica JPM3L1 3 Propeller Techn fv 30 1a3HS Ol WALI 20 U dd ANOYOL 1034409 do ANN SIHL 38 LSW Ss SNOILOAYID 3LISOddO NI Ji SHYJHSYM ILON YANNidS NI G3IOH a3JNIYa J d Ag Q3LV901 SLNN YOH NY ZGeCop S108 MOTO ONINALHSIL H04 JONANOAS ASSY YSHSVM JNIA MY13 pss R G LdOduly YIINIH 26 982 O10 MO E NOUWTIVLSNI LAN YOHONY 9 IIA ALO NOWdIYISIO ON Lid Wall l YANNIdS 09r dogg l Yr L L Yid SNINSNY YINNIJS 09L d0d68 L Yt zZ Zl YIHSYM VPo ZLLO SE EV Zl AIDS JNIHOV ERIC t vin 201 9 V 43439 woTiadoud S 1108 VLE PNV 9 LAN MIOTAN 8ZP S9COZSN A ALNO AAH XIHSYM 2TIATTD9 N8 LOYtHd g 127 S S dOYd Hemg IANI KC LNNOW doad 2lvld eceler oi 31W1d ONIN7 YINNIJS O9 Lf g0968LYt LL JAM So EK AdVL Zl JNN YOHONY SOIG9OILZSW Cl YY NOILIAS JSNV14 ONUNTON dOu d LJYHSANYYO INABA 33S NOUNTIWLSNI LAN YOHINY H04 NOILIFrOYd J195 LON Gd gt e
30. he 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 Eligible JABIRU Type Certified Propellers described in this Technical Manual must be maintained by an Authorised Person LAME for CASA registered aircraft Owner or Level 2 Holder for RA Aus 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 Eligible JABIRU Propellers operating in the Light Sport Aircraft category must be maintained by an Authorised Person LAME for CASA registered aircraft Owner or Level 2 Holder for RA Aus registered aircraft In all cases NO MODIFICATIONS ARE PERMITTED without approval from the propeller manufacturer It is the owner s responsibility to ensure that their propeller is maintained by an appropriate person In the
31. he 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 5 10 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 its type At this stage it should be covered with prop tape and monitored e If the cracking progresses any open cracks should be sealed with a thin type of superglue Maintaining 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 This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled Dated 8th April 2014 Issued By DS Page 23 of 31 Propeller Technical Manual Jabiru Aircraft cu a GG AN JPM3L1 3 C0
32. igned to be maintained only in strict accordance with this Technical Manual Any variation of any kind including alteration to any component at all whether replacement relocation modification or otherwise which is not strictly in accordance with these manuals may lead to dramatic changes in the performance of the aircraft and may cause unexpected engine stoppage loss of control or have other detrimental effects on the aircraft which may lead to injury or death Jabiru Aircraft Pty Ltd does not support any modifications to the propeller its parts or components Any such actions may render the propeller amp aircraft un airworthy and will void any warranty issued by Jabiru Maintenance and modification cannot be supervised by the manufacturer Maintenance requires extreme cleanliness exact parts precise workmanship and proper consumables It is your responsibility to ensure absolute attention to detail no matter who may become involved in work on this propeller Your safety your life and your passenger s lives rely on precise and accurate following of instructions in this manual In exchange for the technical manual provided by Jabiru Aircraft Pty Ltd Jabiru hereby agree to waive release and hold Jabiru harmless from any injury loss damage or mishap that I my spouse heirs or next of kin may suffer as a result of my use of any Jabiru product except to the extent due to gross negligence or willful misconduct by Jabiru und
33. ing Propeller tracking See section 5 8 4 P F Comments 100 hourly Spinner tracking See section 5 8 5 P F Comments 100 hourly 7 1 1 7 Balance Check propeller balance See section 5 8 6 P F Comments Annual This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled Dated 8th April 2014 Issued By DS Page 31 of 31
34. instructions arwn gt 5 8 5 Procedure Spinner Tracking fof of Type of Maintenance Line Maintenance Level of Certification LSA Repairman Inspection of Maintenance 4 Locate a fixed object on a flat floor to just clear the lower edge of the tip of the Spinner 2 Rotate the propeller by hand and check that the Spinner runs true 3 Correct any run out by loosening machine screws realigning spinner then retightening machine screws 5 8 6 Procedure Propeller Balance Maintenance fof oS oS Type of Maintenance Line Maintenance Level of Certification LSA Repairman Task specific training 1 Propeller balancing in the course of maintenance follows the same procedure as during a propeller overhaul Therefore the procedure given in Section 6 7 1 must be used 5 9 Operational Checks LLA Type of Maintenance Line Maintenance Level of Certification LSA Repairman Inspection of Maintenance e For Type Certified C000242 D60P42 or 4A401A0D propellers full power RPM with the aircraft stationary is 2800rpm 50rpm e For other C000242 or 4A401 propellers Full power RPM with the aircraft stationary is 2700rpm 2950rpm e For C000262 propellers Full power RPM with the aircraft stationary is 2600rpm 2800rpm This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled Dated 8th April 201
35. interests of product development we encourage owners to make suggestions related to design improvements However the final decision on their adoption or otherwise rests with JABIRU AIRCRAFT Pty Ltd This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled Dated 8th April 2014 Issued By DS Page 4 of 31 Propeller Technical Manual Jabiru Aircraft cu a aech JPM3L1 3 C000242 C000262 4A401 Propeller Variants 2 2 Warnings 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 Jabiru Aircraft Pty Ltd has devoted significant resources and testing to develop the different Jabiru aircraft propellers for recreational flying and flight training Any other uses or applications not approved by Jabiru Aircraft P L may be extremely hazardous leading to property damage or injury or death of persons on or in the vicinity of the vehicle Jabiru Aircraft Pty Ltd does not support the use of this propeller in any applications which do not meet the requirements of the appropriate Pilot Operating Handbook or Flight Manual Any non compliant operation may render the propeller amp aircraft un airworthy and will void any warranty issued by Jabiru Jabiru Propellers are des
36. m long e 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 e Urethane de lamination up to 15mm long and no more than 5mm wide e Pits in fibreglass 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 This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled Dated 8th April 2014 Issued By DS Page 28 of 31 Propeller Technical Manual Jabiru Aircraft cu a AN JPM3L1 3 C000242 C000262 4A401 Propeller Variants 6 7 3 Nick Repair LLLA Type of Maintenance Overhaul Level of Certification LSA Repairman Inspection of Maintenance with Task Specific Training 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 5 8 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 Fibrefl
37. marking lacquer or similar such as coloured nail varnish 5 Minute epoxy resin Jabiru epoxy resin cotton fibre flock Q cells micro balloons containers scales mixers etc 5 6 Cleaning Ground Handling amp Storage 5 6 1 Cleaning e Keeping the propeller clean is important Besides maintaining the appearance of the aircraft cleaning makes inspection and maintenance easier e Generally the exterior surfaces can be kept bright by washing with water and a mild soap or detergent followed by a rinse with water and drying with a cloth or a chamois e Remove stubborn oil and grease with a cloth moistened with mineral turpentine then wash with water and a mild soap rinse and dry as stated before This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled Dated 8th April 2014 Issued By DS Page 13 of 31 Propeller Technical Manual Jabiru Aircraft cu a me Ca JPM3L1 3 C000242 C000262 4A401 Propeller Variants CAUTION DO NOT use Silicon based cleaning materials as Silicon is absorbed into the composite materials and may affect reparability CAUTION Do not use a wax based substance as this would make it almost impossible to refurbish the prop if needed at a later stage 5 6 2 Ground Handling e All Jabiru aircraft are relatively light and should always be moved by hand e The aircraft may also be moved by placing the propeller in the
38. me 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 This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled Dated 8th April 2014 Issued By DS Page 9 of 31 Propeller Technical Manual Jabiru Aircraft py ru Wach W i JPM3L1 3 C000242 and 4A401 Propeller Variants Airworthiness Limitations Section CASA Approved 4 Airworthiness Limitations Section THIS AIRWORTHINESS LIMITATIONS SECTION IS APPROVED BY THE CIVIL AVIATION SAFETY AUTHORITY OF AUSTRALIA IT SPECIFIES THE AIRWORTHINESS LIMITATIONS REQUIRED TO MAINTAIN COMPLIANCE WITH THE CERTIFICATION BASIS AS SPECIFIED IN THE TYPE CERTIFICATE NO VP503 CASR Part 35 per FAA FAR 35 STANDARD and CAO 101 55 REGULATIONS There are no Airworthiness Limitations applicable to the Jabiru C000242 and 4A401 series propellers Signature For Civil Aviation Safety Authority Date This document is controlled while it remains on the Jabiru server Once this no longer applies the
39. nce A minimum of 2 years experience working on aircraft under supervision is recommended for commercial maintainers before working un supervised 5 4 Tool amp Gauge Control e Tool amp gauge control is an important part of aviation maintenance systems Tools amp gauges must be accurate enough for the intended use i e a 12 steel ruler is not the appropriate tool to use to measure the thickness of the middle of the propeller blade amp be accurately calibrated by an approved laboratory e Calibrations must be kept up to date This means a check calibration every year or more frequently for regularly used critical tooling e Even quality equipment will wear over time so items like reams and go no go gauges must periodically be checked to ensure they remain within limits 5 5 Tools amp Equipment Access to the following tools will be required All tools must be good quality items Ring open end spanner 7 16 Ratchet 3 8 drive 2 extension bar 7 16 socket Screwdrivers flat blade and Phillips head in various sizes Torque wrench 3 8 drive name brand Snap On Warren amp Brown etc recently calibrated The wrench must have a suitable scale for use on the fasteners typically found on Jabiru Access to the following equipment will be required Bench vice with padded jaws Calipers Saw horses Accurate level protractor Propeller balance jig Rags soft mallet hammers TorqueSeal brand security
40. o 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 checked during daily inspections Remove these isolated pieces of urethane Trim line for urethane edges Figure 6 Urethane Abrasion This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled Dated 8th April 2014 Issued By DS Page 22 of 31 Propeller Technical Manual Jabiru Aircraft cu a GG AN JPM3L1 3 C000242 C000262 4A401 Propeller Variants 5 10 1 4 Urethane Pitting Figure 7 below shows urethane which has been pitted by flying through rain Recommended Actions e Minor damage can be sanded slightly to improve t
41. ocesioatesisiestncasiendotasiestecastendacdstesincasbeteacasdentncutdandate 12 5 2 4 Type 2 Propeller Marking incissssiccisiesincisinatecassescotssiestocssinatesistestacasieteatasiestocasvencatdsiesiacdsbetioddsdentecatdandats 12 5 2 5 Type 1 Propeller Markings 4A401 Gees 12 5 2 6 Type 2 Propeller Markings 4A401 Gees 12 5 3 MAINTAINER REQUIREMENTS seicseeisstonnese ne ae ores rris oE urse E raes PEEP EEPE TES AENA SARANEN EIEEE DRE TAE EEEE SE aaa e 13 5 4 Keele ug BEE 13 5 5 Deel EU EE 13 5 6 CLEANING GROUND HANDLING amp STORAGE cccccccccssessscescscscesesvsceececssssvavsceecscsessvavsceesecsessvavsceevecnenavaveceeses 13 5 6 1 CAIN EEN 13 5 6 2 Ground Handling ssie eree Er A E A rE NEE EE EE ETE EENE EE EE iE 14 IOS PO GET 14 5 6 44 Off Aircraft Giorage eceececcccsseseseseesesesesseseseseecenesssseseseseaesssaesesesseaesssaeaeseseaesssaeseseeeeaeseeaeaeeeeseeeeeeatarees 14 5 6 5 Returning Propeller to ZGervice 14 5 7 MAINTENANCE DCHEDULE tetett stet tett EESE EEEE ASEE EENES EE EENE ESKESEN E EESE REENEN E rEnt Entet rnent 14 5 7 1 Service Interval Tolerance ecccsccsccceseseseesesesesceseseseseesescscesescseeecnesseseseseeeesesceaeseecaeseeetaeseeseaeeetatarees 15 5 7 2 1OO HOUPTY Jnspechon ccceseeccsseseescseeseseeseesesecseusesecsessesecaensesecsesseseceesaesecaenaeseceesaeseceeeaeaeeeesaeaeeeeeaeatens 16 573 ANU AT Inspetor riiintean Enn en iR E A ER TEE EA EENE EE EERE E SOE EEES 16 5 7 4 Special Inspecti
42. ock to form a paste 4 Apply paste to sanded nick and allow to cure in low moisture environment for 24 hours 5 Lightly and carefully sand excess cured resin to a smooth surface matching exactly the previous aerofoil 6 Refurbish with clear paint 7 Rebalance Propeller see Section 6 7 1 8 Reassemble and replace Propeller and Spinner see Paragraph 5 8 3 9 Check Propeller tracking and Spinner balance see Paragraph 5 8 3 6 7 4 Urethane LLLA Type of Maintenance Overhaul Level of Certification LSA Repairman Inspection of Maintenance with Task Specific Training The Urethane leading edge applied to Jabiru Aircraft Propellers provides protection for the wood and fibreglass 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 cannot 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 may 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
43. ons AD PFP 1 ccccssecsssssesesceeseseseseeseseucecesesececaesssaseseecaesesseaeseeeeaeaeeaeseeeeetaeeeeataters 16 5 8 MAINTENANCE DROCEDURES tatter ttrt StSt e tSt EE EESE SE SESE EEEE SESE SESE EE EEn EStnn estere nesen enen ent 17 5 8 1 Acceptance CHECKING u esecccceseceseesesesesesseseseseecesencssesesescesenssasesesecaesessesesesesenenaeseseecaeaeeaeseeeeeesenenataeees 17 5 8 2 Procedure Removal of Existing Propeller AA 17 5 8 3 Procedure Propeller mstallaton 17 5 8 4 Procedure Propeller Tracking eseeccsseseesesseseescseeseeeeseeseseeseeaesecseeaeeecaeaeeecasedeeecaeeaeeeeaeeaeeeaseaeerenees 19 5 8 5 Procedure Spinner Trackimg 19 5 8 6 Procedure Propeller Balance Maumtenancel 19 5 9 OPERATIONAL CHECKS ccccsscoccsscsscstcesecesesecoecsscssestenseccensecatesecsecstcnsesusnsecaeesscatestensesuensecetesscatcatenseeuensecneease 19 Dated 8th April 2014 Issued By DS Page 2 of 31 Propeller Technical Manual Jabiru Aircraft cu a me Cea geb JPM3L1 3 C000242 C000262 4A401 Propeller Variants CL fern te Ee Re 20 5 10 1 Defect RECOQIILION scese E EEEE E 20 6 PROPELLER OVERHAUL cvisc c c ccescecocessosesscsacevsseessesscosesececscvensncceacsesdevedarosssvesenssencedeasendevssesoteavescusscecestevoseseades 26 6 1 OVERHAULER BREOUIDEMENTS 26 6 2 TOOL amp GAUGE CONTROL area r E SE e Rinse eda 26 6 3 TOOLS A EQUIPMENT ee Ee 26 6 3 1 Propeller Balancing e TE 26 6 4 OVERHAUL DGEOUEN
44. pection conducted annually includes the 100 hour items in addition to the items marked under Annual Inspection e Acomplete propeller inspection includes all 100 hour and Annual items together 5 7 1 Service Interval Tolerance e A tolerance of plus or minus 3 hours is allowable on all service intervals set within this manual Table 3 Inspection Chart Annual Inspection Each 100 Hours SPINNER 1 General condition cracks etc x S 2 Screw holes are not excessively elongated SPINNER FLANGE 3 General condition cracks around perimeter of hub etc KR 4 Anchor nuts amp rivets secure 5 Visual inspection for signs of fretting looseness i SPINNER SCREWS 6 Head amp thread condition 7 Tightness of screw in nut Replace anchor nuts if loose S PROPELLER 8 Urethane condition Refer Section 6 7 2 for details KR i 9 fiberglass condition Refer Section 6 7 2 for details amp 10 Wood condition Refer Section 6 7 2 for details S KR 11 Hub condition Refer Section 6 7 2 for details 12 Propeller Drive Bush Fit Refer Section 6 6 16 7 2 for details 7 PROPELLER BOLTS NUTS 13 Condition corrosion etc 7 14 Bolt Nut tension i KR TRACKING 15 Propeller tracking r S 16 Spinner tracking R BALANCE 17 Check Propeller Balance 18 SPECIAL INSPECTIONS Refer to Section 5 7 4 This docum
45. s exposure to changes in temperature amp humidity 5 6 5 Returning Propeller to Service When a propeller which has been stored is returned to service the following must be checked e Propeller balance e E of drive bushes into propeller hub must be a close fit with no free play e Condition of the propeller timer composite leading edge protection amp leading edge tape where equipped e f the propeller has been stored for more than a year it is recommended that it be returned to Jabiru Aircraft or an authorised service centre to check the blade pitches 5 7 Maintenance Schedule e Note that while the spinner assembly is not considered a part of the propeller some spinner inspections are included below for reference The chart below shows the recommended intervals at which items are to be inspected Additional detail of the maintenance required in each section is given below the inspection chart As shown in the chart there are items to be inspected each 100 hours and Annually When conducting an inspection at 100 hours all items marked under Each 100 Hours is inspected serviced or otherwise completed This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled Dated 8th April 2014 Issued By DS Page 14 of 31 Propeller Technical Manual Jabiru Aircraft pry a AN Wi JPM3L1 3 C000242 C000262 4A401 Propeller Variants e An ins
46. s indicated below Drawing No gt DWG 4A401A0D Diameter __ D 1524 P 1067 Engine Model ___ JABIRU 2200 J4A401 0001 LC Composite Prop Model Descriptor Sheath Serial No Leading Edge Protection 5 2 6 Type 2 Propeller Markings 4A401 Series Type 2 data tags are fitted to the rear face of the blade just outboard of the spinner Drawing No _ gt DWG 4A401A0D Pitch a Diameter D 60 P 42 JABIRU 2200 Engine Composite J4A401 La Jabini Prop s K Sheath Prop Model Descriptor Sma SE ae This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled Dated 8th April 2014 Issued By DS Page 12 of 31 Propeller Technical Manual Jabiru Aircraft cu a AN JPM3L1 3 C000242 C000262 4A401 Propeller Variants 5 3 Maintainer Requirements The following are recommended as the minimum requirements for someone carrying out maintenance amp inspection on Jabiru Propellers 1 Facilities Enclosed workspace with sealed floor lighting compressed air amp mains electricity 2 Training Completion of an approved instruction course specific to Jabiru Aircraft Approved courses include those offered by Jabiru Aircraft Australia or by local Jabiru Aircraft representatives 3 Rating Commercial maintainers must hold ratings required by their local Airworthiness Authority 4 Experie
47. s the document becomes uncontrolled Dated 8th April 2014 Issued By DS Page 8 of 31 Propeller Technical Manual Jabiru Aircraft cu a me Cea geb JPM3L1 3 C000242 C000262 4A401 Propeller Variants 3 3 Abnormal Operations 3 3 1 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 e Do not operate in heavy rain or hail e 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 6 7 2 Do not fly on with damage beyond the limits set in Section 6 7 2 e A Urethane leading edge is provided for impact protection and also allows the propeller to 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 its balance e After extended running in rain the Urethane may beco
48. tia 0 2 0 3kgm This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled Dated 8th April 2014 Issued By DS Page 7 of 31 Propeller Technical Manual Jabiru Aircraft cu a me Cea geb JPM3L1 3 C000242 C000262 4A401 Propeller Variants 3 Propeller Operation 3 1 Limitations 3 1 1 Maximum RPM e All propellers covered by this manual are limited to 3300 RPM 3 1 2 Life e The propellers are assessed on condition There is no fixed life 3 2 Normal Operations 3 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 e 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 student pilots e 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 e 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 3
49. torquing the propeller bolts or not using Belleville washers on the installation as shown in Figure 1 Recommended Actions e Check the propeller installation amp verify bolt tensions e Where the crack has exposed the wood seal it using a thin type superglue to prevent moisture ingress e Overall propeller hub thickness must be greater than 58mm for 3 laminate propellers shown or 78mm for 4 laminate propellers Crack Dated 8th April 2014 Issued By DS Page 21 of 31 Propeller Technical Manual Jabiru Aircraft py ua S JPM3L1 3 C000242 C000262 4A401 Propeller Variants 5 10 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 generally 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 t
50. ument is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled Dated 8th April 2014 Issued By DS Page 16 of 31 Propeller Technical Manual Jabiru Aircraft cu a me Ca JPM3L1 3 C000242 C000262 4A401 Propeller Variants 5 8 Maintenance Procedures 5 8 1 Acceptance Checking LLA Type of Maintenance Line Maintenance Level of Certification LSA Repairman Inspection of Maintenance e Propellers supplied by Jabiru Aircraft are balanced before shipping Balancing before fitting to an aircraft is not necessary e Visually inspect propeller to ensure that it has not been damaged in transit e Before fitting check that the propeller drive bushes are a neat fit in the sockets of the propeller Section 6 6 1 gives details 5 8 2 Procedure Removal of Existing Propeller aa Type of Maintenance Line Maintenance Level of Certification LSA Repairman Inspection of Maintenance Figure 1 shows a typical propeller installation Remove Machine Screws and Tinnerman Washers from Spinner Remove Spinner Unbolt Propeller Bolts 6 off Remove Bolts Spinner Flange Aluminium Propeller Flange Belleville Washers and Propeller Fons 5 8 3 Procedure Propeller installation LLA Type of Maintenance Line Maintenance Level of Certification LSA Repairman Inspection of Maintenance i Figure
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