Aircraft Service Manual
Contents
1. A 11 3 2 PROPELLER TUNING JABIRU AIDERAMES essere nnne nter trennen rete nennen erret nnne 12 3 3 PROPELLER TUNING NON JABIRU AIDERAMES sssnsnssssensssseersssessesseseissesresssseerossersisrestessesesnosseseserresersrene 12 3 3 1 Propellor DESIN E 12 3 3 2 Airframe Drag and Power Settings sse 13 3 4 NORMAL e le EE 14 3 4 1 Ground Handling i oi icem a quiis eii Eee noe in d S 14 GAZ Hand MANOCUVING e 14 BAG PAKN 14 3 44 Daily ee 14 3 5 ABNORMAL e le 15 3 5 1 erte AD PAIN e NTA 15 4 PROPELLER MAINT ENANGE icssicccsssssssissescacescscassseveccacenvavessvesosvacsavocsesasesovsavevesvastcnacascoesoceaeoseascsetesoneastavestestess 16 4 1 INTRODUCTION 55 roii iieri OE CO Ea ERE E EET eae tetas ERA REO ass 16 4 1 1 Torque Specifications sese enne tette trennen ennt 16 41 2 Pitch Setting Specifications edet diete RR RU RET Pe XR TE iui sata datvee 16 41 3 Propeller Markings ERES EARE EAE NE ARAA x YER ELERE Ree ERR REN EERARES 16 4 2 MAINTAINER REQUIREMENTS 5 5 ae td ESA EEN EENEG 16 4 3 TOOLS GAUGE CONTROL creer tee ertt o PR RE rege neue EE Pe Eo eet eee nema 17 4 4 TOOLS eiie 17 4 5 CLEANING GROUND HANDLING amp STORAGE eee eene nenne nnne enn enne nrn inest tenete entrent 17 4 5 1 er2. 6 Head amp thread condition li 7 Tightness of screw in nut Replace anchor nuts if loose KR i i PROPELLER 8 Urethane condition li 9 Blade condition S i b 10 Hub condition E 7 7 11 Propeller Drive Bush Fit P j 12 Blade Pitch Check Un pinned Blades Only 13 Propeller Blade Stem Inspection 14 Hub Dye Penetrant Inspection PROPELLER BOLTS NUTS 15 Condition corrosion etc z j T This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled issue 1 Dated tst Feb 2013 Issued By DPS Page 19 of 32 LMilesManuals For Products WPropeller Manuals JPM0001 1 Prop Manual 1 doc Propeller Technical Manual Jabiru Aircraft pty ta gt oe JPMO0001 1 4A482U0D And 4A484E0D Propellers Each 500 Hours Annual Inspection Each 100 Hours 5 Hours After Hub Bolt Adjustment 16 Bolt Nut tension i s TRACKING 17 Propeller tracking i 18 Spinner tracking BALANCE 19 Check Propeller Balance S d PROPELLER FLANGE CRANKSHAFT SCREWS 20 Check Tension per Table 5 i 4 6 2 5 Hour 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
3. sess eene nennen tenete nennen 24 4 7 5 Procedure Propeller installation esses nne 25 4 7 6 Procedure Propeller Tracking eee esee esee eene teen ennt E totns nnt teen etn tone 27 4 77 Procedure Spinner Tracking esses eren eene nennen tenete enne 27 4 7 8 Procedure Propeller Balance Maintenance 27 4 8 TROUBLESHOOTING EE 28 4 8 1 IB eis 28 5 PROPELLER OVERHAUL eerte tertio tera ter ep tpe o Poit en ine PUP epa MESH ER SUR Tote ba PE eg Um SUE UE ee bo o vs ssbs s er EYES PEN teos 29 5 1 OVERHAULER REQUIREMENTS s ssssssessssssseeseseerirtsreresteteritsteestetorintstortstottt intse senteren ts sre ststotin estss sisretenes nese 29 5 2 TOOLS GAUGE CONTROL EE 29 53 TOOLS amp EQUIPMENT rin HERREN RICE RENTE e EO PRI OE EE UR R EERE PURA 29 5 3 1 Propeller Galancimg 29 5 4 OVERHAUL SEQUENCE sss seseceesescsenessssscscsssesvscscacscscscsesesesesececsenesenensasacesususavavaeacacececeeseseseneceseesenenenseteteteees 30 5 5 PROPELLER REMOVED INSPECTIONS sese eoe ib Ree tee rea i REED eR proce preste te nettle 30 5 6 REPAIR METHODS cie rs eec teri RENTE ara ce ete tede ie e EP EU DESEE YS 31 5 6 1 Propeller Balancing Procedure Overhaul sss 3l 5 6 2 Damage Limits amp Repairs eese seen ennt tn ennt teen enne E teens teen ennt teen ete tene 3l 56 3 G neral EE 31 GREP OR
4. Propeller Technical Manual Jabiru Aircraft pty ta gt oe WS JPMO0001 1 4A482U0D And 4A484E0D Propellers Propeller Technical Manual FOR 4A482U0D and 4A484E0D Propellers DOCUMENT No JPMO0001 1 DATED 1 Feb 2013 This Manual has been prepared as a guide to correctly operate amp maintain Jabiru 4A482UOD and 4A484E0D propellers 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 propeller 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 This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled issue 1 Dated 1st Feb 2013 Issued By DPS Page 1 of 32 L Miles Manuals_For_Products Propeller_Manuals JPM0001 1_Prop_Manual 1 doc Propeller Technical Manual Jabiru Aircraft pty ta gt oe JPMO0001 1 4A482U0D And 4A484E0D Propellers T3 CAPE RE
5. Dated 1st Feb 2013 Issued By DPS Page 13 of 32 LMilesManuals For Products WPropeller Manuals JPM0001 1 Prop Manual 1 doc Propeller Technical Manual Jabiru Aircraft pty ta gt oe Wen JPMO0001 1 4A482U0D And 4A484E0D Propellers 3 4 Normal Operations 3 4 1 Ground Handling e 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 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 3 4 2 Hand Manoeuvring e 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
6. OFF before walking near the propeller Do not go near the propeller if there is a person in or near the cockpit WARNING PROPELLER WILL BECOME HOT IN DIRECT SUNLIGHT 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 Do not park the propeller in a vertical orientation see notes below Section 3 4 3 3 4 3 Parking e 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 e For maximum life it is recommended that propeller blade covers be fitted if the aircraft is to be parked outside This is to protect the propeller from UV and other damage Propeller covers must be white or a light colour shade to minimise the temperature the blades are exposed to Covers must also be appropriately vented to prevent the accumulation of moisture inside the cover which can cause corrosion and blade discolouration 3 4 4 Daily Inspection e Inspect both blades for Urethane condition peeling tears pitting or abrasion Fibreglass condition stone chips trailing edge chips de laminations white
7. 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 e Check the tension of the propeller bolts nuts Tension if required e Re assemble 4 6 3 100 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 e Check the tension of the propeller bolts nuts Tension per Table 5 if required e Re assemble e Check spinner and Prop Tracking This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled issue 1 Dated 1st Feb
8. 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 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 2 2 Manufacturer Details Jabiru Aircraft P L PO Box 5792 Bundaberg West QLD 4670 Phone 07 4155 1778 Fax 07 4155 2669 Email info jabiru net au Street Address Jabiru Aircraft Airport Drive Hinkler Airport Bundaberg QLD 4670 This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled issue 1 Dated 1st Feb 2013 Issued By DPS Page 4 of 32 L Miles Manuals_For_Products Propeller_Manuals JPM0001 1_Prop_Manual 1 doc Propeller Technical Manual Jabiru Aircraft pty ta gt oe W JPMO0001 1 4A482U0D And 4A484E0D Propellers 2 3 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 THE PROPELLERS IN THIS MANUAL ARE DESIGNED AND TESTED FOR JABIRU ENGINES ONLY Jabiru Aircraft Pty Ltd has devoted significant resources and testing t
9. intended to be sufficient reference for a person with no other training to safely complete inspections amp maintenance Knowledge of standard aircraft practices such as are detailed in FAA AC43 is assumed The Spanner Scale Translation gt Simple basic straightforward A careful layman with guidance can achieve this y Straightforward but with some technical bits Basic knowledge care and guidance needed Y y oS Straightforward but requires special tools training and or judgement Sound basic knowledge guidance and a careful approach are required Y y A technical job Take your time double check everything Only for the experienced overhauler Y y SSS A difficult job Requires special tools solid skills good judgement Only for experts This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled EE ob E E Dated tst Feb 2013 Issued By DPS Page 7 of 32 LMilesWManuals For Products WPropeller Manuals JPM0001 1 Prop Manual 1 doc Propeller Technical Manual Jabiru Aircraft pty a D Wen JPMO0001 1 4A482U0D And 4A484E0D Propellers 2 8 Description amp Specifications 2 8 1 Description e The Jabiru Propellers detailed in this manual are 2 bladed Scimitar ground adjustable designs The blades are constructed of fibreglass composite while the hub is forged from Alu
10. 00 4662084 Family um E E00 4A482U0D ey Jabiru 2200 4662084 Family Aen M 4A482U0D Ce Jabiru 2200 4662084 Family EN Ben EE 4aag4EoD Yann En Jabiru 3300 4662084 Family s S s PM S 4A484E0D Pr Emi Jabiru 3300 4662084 Family ies 5x ii Geen eni 4a4g4EoD Yann Es Jabiru 3300 4662084 Family se 52 DM The UL family is known as the Calypso in some markets This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled issue 1 Dated tst Feb 2013 Issued By DPS Page 11 of 32 LMilesManuals For Products VPropeller Manuals JPM0001 1 Prop Manual 1 doc Propeller Technical Manual Jabiru Aircraft pty ta gt oe JPMO0001 1 4A482U0D And 4A484E0D Propellers 3 2 Propeller Tuning Jabiru Airframes Propeller pitch information is given in Table 3 and Table 4 for Jabiru Aircraft models The propeller must be installed as detailed in Section 4 7 3 Note the inspection requirements of Section 4 6 inspections are required after installation amp initial running 3 3 Propeller Tuning Non Jabiru Airframes e The following information has been included to assist operators in setting up their 4A482U0D propeller for their non Jabiru airframe The propeller must be installed as detailed in Section 4 7 3 Note the inspection requirements of Section 4 6 initial inspections are required after installat
11. 2013 Issued By DPS Page 20 of 32 L Miles Manuals_For_Products Propeller_Manuals JPM0001 1_Prop_Manual 1 doc Propeller Technical Manual Jabiru Aircraft pty ta gt oe m JPMO0001 1 4A482U0D And 4A484E0D Propellers 4 6 4 Annual Inspection Annual inspections include all the items listed for the 100 hourly inspection above plus the additional items below 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 Remove the propeller from the aircraft Thoroughly check the propeller for cracking wear or damage particularly in those areas not visible while the propeller is mounted to the engine Inspect the blade stems for cracking abrasion or deposits Test the fit of the propeller drive bushes as detailed in Section 5 5 Check the propeller balance as detailed in Section 4 7 6 Re fit the propeller to the aircraft Check spinner and Prop Tracking 4 6 5 500 Hour Inspection 500 hour inspections are based on time in service only They include the items listed for the annual inspection above plus the additional items below 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 Remove the propeller from the aircraft Disasse
12. FORGED HUB beat oT us Figure 7 Typical Propeller Installation fF t EH E Figure 8 Propeller Hub Assembly Spinner and blades not shown Jl EE Ee IMPORTANT For all Jabiru Aircraft 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 This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled issue 1 Dated 1st Feb 2013 Issued By DPS Page 26 of 32 LMilesManuals For Products Propeller Manuals JPM0001 1 Prop Manual 1 doc Propeller Technical Manual Jabiru Aircraft pty a gt oe JPMO0001 1 4A482U0D And 4A484E0D Propellers 4 7 6 Procedure Propeller Tracking Y 1 Locate a fixed object on a flat floor so that it clears the Propeller tips by a small margin 1 3mm 2 Rotate the Propeller by hand 3 Check that each blade clears the object by the same amount Measure the clearance for each blade 4 Maximum Tracking Error Tolerance is 2mm 5 If the Propeller is outside the approved tolerance refer to JABIRU Aircraft Pty Ltd or a JABIRU Approved Service Centre for rectification instructions 4 7 7 Procedure Spinner Tracking se e Locate a fixed object on a f
13. G eR riter erbe EON Sag Gees eden een ee 3 1 2 LIST OF TABLES ET 3 2 GENERAL INFORMATION sscsssssssscccsecsssssesscsssecsssssessssssecessssesscsssesecsssessssesecessssesscssesecssessssesesecssseseresses 4 2 1 FOREWORD mP M M M 4 2 2 MANUFACTURER DETAILS 4 2 3 WARNING KC E EUTS 5 2 4 LIST OF EFFECTIVE PAGES scie tr rere eret b Det pei er ede EE 6 29 APPLICABILITY d eerie ein eter eae aes lo laser eo Rue 6 2 5 1 Dec HE atten aeatents 6 2 6 READING THIS MANUALE 6 2 7 DEGREE OF DIFFICULTY tee rte REGES RIO eerie asda E EERUIER ER EPOR ee 7 2 8 DESCRIPTION amp SPECIFICATIONS s sssssseessstsstsesterestetetstttt testets tsere testets tettere ntsttn tatere nnstnts tsentre tennt entrete tes 8 2 8 1 ee e WE 8 2 8 2 4A482U0D Propeller Goechfications 9 2 8 8 4A484EO0D Propeller ZGpechtcatons 9 2 9 APPROVED PROPELLER amp ENGINE COMBINATIONS s ssssesestststsetsesteteststtstststereststsstntrttenrstentsrtenesrnrest ent 10 ZR MN co 10 3 PROPELLER OPERATION isssicscsecssssssnsastseceressvensosscooocessasnsesensassvecvosetecsqesnsassvasosesteseavossvssoscosesonsesesssssvedsesutocsae 11 3 1 OPERATING LIMITA IONS eese eren en nennen ne tetenenetntne teneret te tenete tete EASES entree 11 3 1 1 MAXIM APM RR 11 BAZ PION
14. T UN cec 32 6 1 1 Continued Operational Safety Reporting entente 32 6 1 2 Owner Change Of Address Notice ecscscssesesseseseeeseseseecesesesececseeceseaesececaeneeaescsececaeeeeateeeeeeeateees 32 1 1 Table of Figures Figure 1 Propeller Assembly Spinner Not Shown sssssesesssessssssssssssssississssstnsennsennnttnntnnnnnnnnnnnnnssnnnnnnnnn 8 Figure 2 Airframe Drag Curves nennen ennt sn ESSE entes nnns sn trn ss tete enne siens snnt senten 13 Figure 3 Hub Blade EE 23 Figure 4 Uer EE 23 Figure 5 Pitch Set 5M 25 Figure 6 Typical Propeller instalation ssenarinin aa aa aa EA RE a 26 Figure 7 Propeller Balancing rentre a AS etta E aA DAE Dee eene S da 30 1 2 List of Tables Table 1 4A482U0D Propeller Gpechflcatons nennen nennen nnns nennen 9 Table 2 4A484E0D Propeller Specifications essen enne nennen 9 Table 3 Factory Built Models esee cete eee he La ihnen he edere aA 11 Table 4 Kit Built Models eie reed iere Ere retta eta eels Exe etc ea cR e ae 11 ERR WEE Ee e TEE 16 Table ee Cha sussana 19 This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled issue 1 Dated tst Feb 2013 Issued By DPS Page 3 of 32 LMilesManuals For Products WPropeller Manuals JPM0001 1 Prop Manual 1 doc Propeller Te
15. ading 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 4 5 4 then you can click on the 4 5 4 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 This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled issue 1 Dated 1st Feb 2013 Issued By DPS Page 6 of 32 L Miles Manuals_For_Products Propeller_Manuals JPM0001 1_Prop_Manual 1 doc Propeller Technical Manual Jabiru Aircraft pty uta gt oe m JPMO0001 1 4A482U0D And 4A484E0D Propellers 2 7 Degree Of Difficulty e In this manual we have used a spanner scale to help technicians 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 knowledge or the required tools e This manual is intended for use by experienced technicians While all processes will be explained as clearly as possible some knowledge is assumed This manual is not
16. are limited to 3300 RPM 3 1 2 adhered to for these models Pitch e The 4A482U0D and 4A484E0D propellers are ground adjustable in pitch e Pitch information for various airframe and engine combinations are given in the propeller type data sheet and are repeated here for information e Pitch limits are listed below for factory built models These are manufacturer specifications and must be e Pitch recommendations for various kit built airframe and engine combinations are listed below It is strongly recommended that operators use these recommendations for their aircraft Table 3 Factory Built Models Propeller Airframe Engine Propeller Flange pig X Pitch Limits Specification 4A482U0D Jabiru J120 C Jabiru 2200 4662084 Family 05065 eo 4A482U0D Jabiru J160 D Jabiru 2200 4662084 Family ERES Mo 4A482U0D Jabiru J170 C Jabiru 2200 4662084 Family SAN E 4A482UOD Jabiru J170 D Jabiru2200 4662084 Family A bp E 4A484E0D Jabiru J230 C Jabiru 3300 4662084 Family pe eG aa ee 4A484E0D Jabiru J230 D Jabiru3300 4662084 Family e y Bcc d Table 4 Kit Built Models Propeller Airframe Engine Propeller Flange orsi NM Limits 4A482U0D oe Jabiru 2200 4662084 Family eg SC d i 4A484E0D E Jabiru 3300 4662084 Family E x s PM 4A482U0D i d Jabiru 2200 4662084 Family ee Nep nOD 4A484E0D i Jabiru 3300 4662084 Family rs S s PM 4A482U0D ce Jabiru 22
17. ble for notifying the manufacturer of any safety of flight issue or significant service difficulty upon discovery The following proforma may be used Date Aircraft Model Aircraft Registration Aircraft S No Propeller Model Propeller S No Details of item Name of Reporter Preferred Contact Details of Reporter 6 1 2 Owner Change of Address Notice Each owner operator of a LSA is responsible for providing the manufacturer with current contact information where the manufacturer may send the owner operator supplemental notification bulletins The following proforma may be used amp sent to Jabiru Aircraft at info jabiru net au or the contact details given in Section 2 2 Aircraft Model Aircraft Registration Propeller Model Propeller S No Aircraft S No Previous Owner New Owner Contact Details of New Owner This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled 1 LL Dated tst Feb 2013 Issued By DPS Page 32 of 32 L Miles Manuals_For_Products Propeller_Manuals JPM0001 1_Prop_Manual 1 doc
18. chnical Manual Jabiru Aircraft pty ta gt oe JPMO0001 1 4A482U0D And 4A484E0D Propellers 2 General Information 2 1 Foreword It is the owner s 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 Airworthiness Publications such as Service Bulletins amp Service Letters released 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 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 contact details on file with JABIRU AIRCRAFT Pty Ltd remain 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 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
19. clude 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 2 years experience working on aircraft under supervision is recommended for commercial maintainers before working un supervised This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled 1 LL Dated tst Feb 2013 Issued By DPS Page 16 of 32 L Miles Manuals_For_Products Propeller_Manuals JPM0001 1_Prop_Manual 1 doc Propeller Technical Manual Jabiru Aircraft pty ta gt oe JPMO0001 1 4A482U0D And 4A484E0D Propellers 4 3 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 44 Tools amp Equipment e Access to the following tools wi
20. dges 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 1 LL Dated tst Feb 2013 Issued By DPS Page 29 of 32 L Miles Manuals_For_Products Propeller_Manuals JPM0001 1_Prop_Manual 1 doc Propeller Technical Manual Jabiru Aircraft pty ta Wf JPMO0001 1 4A482U0D And 4A484E0D Propellers Propeller balancing vertically Balance jig steel rulers mounted level Propeller balance shaft in this case an unserviceable but balanced crankshaft Propeller balancing horizontally d 5 4 Overhaul Sequence v a a wi Remove the propeller from the aircraft Figure 9 Propeller Balancing 2 Thoroughly clean amp inspect the propeller 3 Discard and replace all hardware nuts amp bolts with new parts Note that aircraft grade hardware must be used 4 Carry out the standard inspections propeller removed detailed in Section 5 5 5 Carry out any necessary repairs as detailed in Section 5 6 6 Carry out a final balance of the propeller as detailed in Section 5 6 1 7 Re fit the propeller to the aircraft as detailed in Section 4 7 3 8 Ensure the propeller blades and spinner are tracking correctly Section 4 7 6 amp 4 7 7 5 5 Propeller Removed Inspections LLLA Whenever the propeller is removed from the engine the following inspections are t
21. e propeller installation or adjustment of the hub mounting bolts the spinner must be removed and the propeller bolts checked for correct tension per Table 6 This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled E I TIET A Dated 1st Feb 2013 Issued By DPS Page 25 of 32 LMilesManuals For Products WPropeller Manuals JPM0001 1 Prop Manual 1 doc Propeller Technical Manual Jabiru Aircraft pty ta WM JPMO0001 1 4A482U0D And 4A484E0D Propellers ITEM PART NUMBER OESCRIPTION ary LS EA REAR PROP HJG MACHINED FORGING GROUND ADJUSTABLE 2 BLADE AE FRONT PROP HUB MACHINED FORGINO GROUND AOUUSTABLE 2 BADE Co FLANGE PROP MOUNT EXTENDED REVERSED PROPELLER BUSH INO BOLT SLATS 42482000 ASSY Sweat 4 MN a E 2200 PROVELLER SOMIT AR BLADE GROUND ADUS TABLE COMPOSITE 2 4 6e PROPELLER BUSH PER EEG WITH TOLERANCE DIFFERENCES T SANNER aSSy 546034334 PROP FAMILIES 1 Int PENNY WASHER T 4 ansia a pz o hol sf cf irl LABEL 42420900 FRONT HUS ROLL PN 1 5 x 1C LONG 2 C C 125 PROVECTION m DIE 5 orscus AVTECH PIL TIES CRAWING IS COPYRIGHT AND MUST NOT D x 1 ou en TUM Seon GE AEM en COPED WITHOUT THE CONSENT OF AVTEQ PTY LTD d z DATE P ET VETE SU LEE i gt SR ARDC HNXLERAINPORT 2200 PROPELLER ASSY COMPOSITE A48200D 2 PA DUNDASENG 4070 deg e BLADE
22. e ventilation must be provided to prevent condensation forming condensation can cause corrosion and blade discolouration over time 4 5 5 Returning Propeller to Service When a propeller is returned to service after extended storage the following must be checked Propeller balance Ft of drive bushes into propeller hub must be a close fit with no free play Condition of the blades fibreglass blade leading edge protection amp leading edge tape where equipped Depending on the current service life of the propeller it may be prudent to carry out the 500 hour checks detailed in Table 6 before fitting the propeller to an aircraft 4 6 Maintenance Schedule This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled issue 1 Dated 1st Feb 2013 Issued By DPS Page 18 of 32 Note that while the spinner assembly is not considered a part of the propeller proper 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 5 Hours 100 hours Annually and at 500 hours The 5 hour inspection is carried out whenever the propeller mounting bolts have been adjusted during maintenance for example 5 hou
23. eck that the propeller drive bushes are a neat fit in the sockets of the propeller Section 5 5 gives details 4 7 2 we Procedure Removal of Existing Propeller Figure 7 shows a typical propeller installation PoONM gt 4 7 3 Remove Machine Screws and Tinnerman Washers from Spinner Remove Spinner Unbolt Propeller Bolts 4 off Remove Bolts Spinner Flanges Washers and Propeller Procedure Propeller Assembly e ww wi 5 OND Place the rear hub plate on a flat bench Fit the two blades to the hub By design there is a small space between the inner ends of the two blades Figure 4 Care must be taken to ensure that the blades are positioned with their retaining shoulders hard against the matching shoulders of the hub i e with the gap between blades as large as possible Failure to achieve this can result in one blade being positioned differently to the other resulting in an out of balance condition and increased vibration Place the front hub plate on the assembly taking care to align it with the pitch lock pins in the blades where equipped Loosely fit the 4 outer blade clamp bolts to the hub assembly Gradually tighten the 4 clamp bolts to the value given in Table 5 This is to settle the blades into the hub Ensure that the gap between the front and rear hubs is even on both sides Figure 5 Loosen the clamp screws For propellers without pitch lock pins use a static jig to set the blade angle
24. eller in the plane of rotation 750 mm gms approximately 1 gm at the tip 5 6 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 Only damage within the size tolerances described in Section 4 8 1 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 5 6 3 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 4 7 2 and checked for balance Section 5 6 1 prior to refitting Section 4 7 3 Always check blade amp spinner tracking after reassembly Section 4 7 3 This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled issue 1 Dated 1st Feb 2013 Issued By DPS Page 31 of 32 LMilesManuals For Products WPropeller Manuals JPM0001 1 Prop Manual 1 doc Propeller Technical Manual Jabiru Aircraft pty ta M JPMO0001 1 4A482U0D And 4A484E0D Propellers 6 Reporting 6 1 1 Continued Operational Safety Reporting The owner operator of a LSA is responsi
25. erglue to the fibres Capillary action will draw the glue into the glass and the colour will change from white to translucent Whitening extending up to 10mm along the blade trailing edge may be repaired in this way 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 After repair visually monitor the chip for growth 4 8 1 2 Stone Chips The propellers have been designed to be resistant to abrasion and stone chips however stone chips may still occur on the rear face of the blade Recommended Actions e Stone chips 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 Maximum chip size 8 x amm refer larger chips to Jabiru Aircraft for directions 4 8 1 3 Urethane Pitting The propellers have been designed to be resistant to abrasion to the urethane however over time especially in rain or when operating from gravel or grass runways wear will occur Recommended Actions e Minor damage can be sanded slightly to improve the smoothness of the leading edge e Major damage must be repaired by returning the propeller to the manufacturer to replace
26. he blades against the pitch set plates It may be necessary to loosen the bolts and adjust the blade position 11 Acceptable limits for blade pitch are given in Section 4 1 2 12 Set the 74 clamping bolts to the torque specified in Section 4 1 1 13 Remove the 5 16 bolts holding the propeller to the jig amp remove the propeller WARNING PROPELLER PITCH SETTING IS CRUCIAL FOR THE PERFORMANCE AND LONGEVITY OF THE AIRCRAFT AND ENGINE This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled issue 1 Dated tst Feb 2013 Issued By DPS Page 24 of 32 LMilesManuals For Products VPropeller Manuals JPM0001 1 Prop Manual 1 doc 4 7 5 DETAIL VIEW C SECTION AA Figure 6 Pitch Set Jig Procedure Propeller installation dii acti gt Figure 7 shows typical propeller installation details Ensure that Propeller drive bushes 6 off are in place in the Crankshaft Propeller Flange note that two are special short parts and face backwards compared to the others see Figure 8 Fit the rear spinner backing plate to the flange When fitting a propeller turn the crank of the engine by hand until the magnets are aligned vertically and then fit the propeller with the blades close to horizontal This method makes it likely that when the engine is turned off
27. ion and initial running WARNING CORRECT PROPELLER ADJUSTMENT IS VITAL FOR THE LIFE OF THE ENGINE OPERATION WITH INCORRECT PROPELLER ADJUSTMENT MAY RESULT IN ENGINE DAMAGE e Operators must ensure that the propeller is adjusted to a pitch setting which matches the power output of the engine This can be achieved by balancing the following considerations The propeller should be adjusted so that the engine will achieve 3200 3300 RPM in full power straight and level flight at sea level Propellers fitted to 2200 engines should achieve 2800 3000 RPM at the aircraft s best climb speed Propellers fitted to 3300 engines should achieve 2800 3000 RPM at the aircraft s best climb speed The 2200 engine should use 14 17 Litres of fuel per hour at cruise power The 3300 engine should use 23 26 Litres of fuel per hour at cruise power Cruise should be carried out at around 22 inhg manifold pressure at Sea Level EGT and CHT must remain within the limits given in the Engine Maintenance Manual of the Pilot s Operating Handbook or Flight Manual for the aircraft e Extensive testing has shown that these parameters will provide the best balance of performance e When compared with wooden propellers used on the Jabiru engine the 4A482U0D propeller must be set to a significantly lower pitch setting for equivalent performance For example when fitted to a Jabiru J120 airframe the 4A482U0D propeller set at 38 pitch will
28. ircraft are stored in hangars wherever possible to minimise degradation caused by the elements and pests When parking the aircraft always orient the propeller with the blades horizontal to prevent gravity fed moisture migration to the lower blade The propeller is designed to be UV resistant however damage such as fading will gradually occur when the propeller is regularly exposed to sunlight The propeller should be covered if the aircraft is to be stored outside or in a location exposed to sunlight Propeller blade covers must be white or a similar light shade to minimise heat build up Covers must also be appropriately vented to prevent the accumulation of moisture inside the cover which can cause corrosion and blade discolouration 4 5 4 Off Aircraft Storage The propeller must always be stored horizontally to minimise uneven moisture accumulation in the blades causing imbalance 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 s exposure to changes in temperature amp humidity If the propeller is stored in packaging or under a cover adequat
29. itch 914mm 367 16 0 1092mm 43 18 9 940mm 37 16 4 1118mm 44 19 3 965mm 38 16 8 1143mm 45 19 7 991mm 39 17 2 1168mm 46 20 1 1016mm 40 17 7 1194mm 47 20 5 1041mm 41 18 1 1219mm 48 20 9 9 Remarks Limits Not above 3300 RPM Mass Moment of Inertia 0 20kgm nominal 2 8 3 4A484E0D Propeller Specifications e Note that approved propeller and engine combinations are detailed in Section 2 9 Table 2 4A484E0D Propeller Specifications Propeller Model 4A484E0D Engine Jabiru 3300 Variants Max Power 125hp Propeller Flange Std 4662084 2 Ext 466218N Pitch Tolerance Both blades to be within 0 25 of designated settin Blades to match within 0 1 Dia 1524 Dia 607 889 1118mm 35 48 All angle readings taken at a position 508mm from rotation axis Pitch Equiv Angle Pitch Equiv Angle 1143mm 45 19 7 1321mm 52 22 5 Pitch 1168mm 46 20 1 1346mm 53 22 9 1194mm 47 20 5 1372mm 54 23 3 1219mm 48 20 9 1397mm 55 23 6 1245mm 49 21 3 1422mm 56 24 0 1270mm 50 21 7 1448mm 57 24 4 1295mm 51 22 1 1473mm 58 24 8 9 Remarks Limits Not above 3300 RPM Mass Moment of Inertia 0 27kgm nominal 1 Pitch adjustable by operator Pitch adjustable by operator This document is controlled while it remains on the Jabiru ser
30. lat floor to just clear the lower edge of the tip of the Spinner 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 4 7 8 Procedure Propeller Balance Maintenance e e ww Propeller balancing in the course of maintenance follows the same procedure as during a propeller overhaul Therefore the procedure given in Section 5 6 1 must be used This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled Lal Dated istFeb 2013 Issued By DPS L Miles Manuals_For_Products Propeller_Manuals JPM0001 1_Prop_Manual 1 doc Propeller Technical Manual Jabiru Aircraft pty ta gt oe JPMO0001 1 4A482U0D And 4A484E0D Propellers 4 8 Troubleshooting 4 8 1 Defect Recognition 4 8 1 1 Chips The trailing edge of the propeller blades are relatively thin and may be damaged more easily than the remainder of the propeller This type of damage is normally caused in the hangar or while the propeller is in storage or being shipped Recommended Actions e 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 lf the fibreglass has been chipped or frayed apply a thin type of sup
31. lers not equipped with pitch lock pins The setting Jig is shown in Figure 6 1 Place the pitch setting jig on a flat level surface A special bench such as that shown in Figure 6 allows the assembly to sit level and the operator to adjust the 5 16 bolts without lifting it 2 Fit the pitch setting plates to either end of the jig 3 Using an accurate protractor measure the angles of the pitch setting plates relative to the central propeller mounting face Ensure that both pitch set plates are at the same angle to the mounting face a difference here may indicate damage to the jig 4 Assemble the hub halves and the blades fitting only the outer 74 bolts and tightening them evenly until the nuts just touch the hub halves 5 Place the propeller on the rig taking care not to damage the blades against the pitch set plates Pieces of thin cardboard or rubber may be placed on the pitch plates to protect the blades 6 Use the propeller drive pins to locate the propeller on the jig 7 Fit the four 5 16 bolts through the propeller pins and the propeller amp tighten until the nuts touch the hub 8 Remove any packing from between the blades and the pitch set plates Use a 0 75mm 0 030 steel feeler gauge to check the gap between the pitch plate and the blades this gap must be constant from one end of the pitch set plate to the other 9 Once the blade positions are set tighten both the 74 and 5 16 bolts to 5Ib ft 10 Re check t
32. ll be required All tools must be good quality items Ring open end spanner set Imperial 7 16 amp 72 sizes Ratchet 3 8 drive 2 extension bar socket set imperial 7 16 amp 72 sizes 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 at the values given in Table 5 e Access to the following equipment will be required Calipers Accurate level protractor Digital or Vernier type bubble level Propeller balance jig Propeller tracking rig Rags soft mallet hammers TorqueSeal brand security marking lacquer or similar such as coloured nail varnish 4 5 Cleaning Ground Handling amp Storage 4 5 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 e Water spots or oxidation may occur on the blade These spots can be removed using a mild polish or specialist water spot remover however operators must ensure that the polish is s
33. m M 17 4 5 2 Ground Handling essent nennen enne teen trt tenens 17 D nonc MEM le EE 18 4 5 4 Off Aircraft Storage E 18 4 5 5 Returning Propeller to Service sse eene enne 18 4 6 MAINTENANCE SCHEDULE isses te teens 18 4 6 1 Service Interval Tolerance sees entrent eterne 19 46 2 5 Hour Inspection esee ree E eee a AEAEE ART UEEY YET EXE RES EAE EUR XE ENTE Eee ees 20 4 6 3 100 Houtly Inspection seen eien aa r E ii 20 4 6 4 Annual Inspection 21 4 6 5 500 Hour Jnspechon 0 see ceceseeecsseseescseesesecseucesecseucesecsesaeseceescesecesucesecsesaesecsesaesecsenaesecsesaeseceeeaeseeaeaeaeees 21 4 7 MAINTENANCE PROCEDURES enorer areren En EEE EE EE EE EE R E 22 4 7 1 Acceptance Checking ssa e e ni e RR e i Hec He Hie e e i RR d Hi 22 4 7 2 Procedure Removal of Existing Propeiler AA 22 4 7 3 Procedure Propeller Assembly sees eene eene nnne 22 This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled issue 1 Dated tst Feb 2013 Issued By DPS Page 2 of 32 LMilesManuals For Products WPropeller Manuals JPM0001 1 Prop Manual 1 doc Propeller Technical Manual Jabiru Aircraft pty a D JPMO001 1 4A482U0D And 4A484E0D Propellers 4 74 Bench Mount Pitch Setting
34. mble the blades from the hub Thoroughly check the propeller for cracking wear or damage particularly in those areas not visible while the propeller is mounted to the engine Inspect the blade stems for cracking abrasion or deposits Where equipped inspect the condition of the blade pitch locking pins Carry out a Dye Penetrant inspection of the front and rear hubs If cracking or defects are identified provide clear photographs to Jabiru Aircraft Pty Ltd for assessment Visually inspect and apply a test torque to the screws which hold the propeller flange to the front of the crankshaft Refer to the Engine Maintenance Manual and follow its procedures for this test Assemble propeller and set blade pitch Re fit the propeller to the aircraft Check spinner and Prop Tracking This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled issue 1 Dated 1st Feb 2013 Issued By DPS Page 21 of 32 L Miles Manuals_For_Products Propeller_Manuals JPM0001 1_Prop_Manual 1 doc Propeller Technical Manual Jabiru Aircraft pty ta gt oe JPMO0001 1 4A482U0D And 4A484E0D Propellers 4 7 4 7 1 Maintenance Procedures Acceptance Checking e Propellers supplied 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 Ch
35. minimum of 1 year experience working on propellers under supervision is recommended for commercial maintainers before working un supervised 5 2 Tool amp Gauge Control e As detailed in Section 4 3 5 3 Tools amp Equipment Access to the following tools will be required All tools must be good quality items e As detailed in Section 4 4 5 3 1 Propeller Balancing 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 is usually a propeller flange fitted to a crankshaft or similar heavy round shaft The propeller is fitted to the propeller flange with 4 off 5 16 drive bushes and bolts 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 e
36. minium e A Urethane protective coating is applied to the leading edge of both blades e The propeller finish is black Gel coat though other colours may be used for some applications e All propellers discussed within this manual are for TRACTOR applications only Figure 1 4A482U0D Propeller Assembly Spinner Not Shown Figure 2 4A484E0D Propeller Assembly Spinner Not Shown This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled issue 1 Dated tst Feb 2013 Issued By DPS Page 8 of 32 LMilesManuals For Products WPropeller Manuals JPM0001 1 Prop Manual 1 doc Propeller Technical Manual JPMO0001 1 Jabiru Aircraft pty Lia ef sech 4A482U0D And 4A484E0D Propellers 2 8 2 4A482U0D Propeller Specifications e Note that approved propeller and engine combinations are detailed in Section 2 9 Table 1 4A482U0D Propeller Specifications Propeller Model 4A482U0D Engine Jabiru 2200 Variants Max Power 85hp Propeller Flange Std 4662084 2 Ext 466218N Pitch Tolerance Both blades to be within 0 25 of designated settin Blades to match within 0 1 Dia 1524 Dia 60 889 1118mm 35 48 All angle readings taken at a position 508mm from rotation axis Pitch Equiv Angle Pitch Equiv Angle 889mm 35 15 6 1067mm 42 18 5 P
37. ning Resin condition cracks This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled issue 1 Dated tst Feb 2013 Issued By DPS Page 14 of 32 LMilesManuals For Products WPropeller Manuals JPM0001 1 Prop Manual 1 doc Propeller Technical Manual Jabiru Aircraft pty ta gt oe JPMO0001 1 4A482U0D And 4A484E0D Propellers 3 5 Abnormal Operations 3 5 1 Running In Rain e Jabiru Aircraft do not recommend or endorse operating in rain e 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 Maintain situational awareness do not fly into rising terrain or near high obstacles radio towers etc in low visibility conditions f forced to fly through rain reduce engine RPM 2600rpm or less is recommended though the pilot must maintain a safe airspeed 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 5 6 2 Do not fly on with damage beyond the limits set in Section 5 6 2 A Urethane leading edge is provided for impact protection and also allows the propeller to be run in rain if required However the propeller i
38. ns Table 5 Torque Specifications Part Hardware Torque nm Torque ft lbs Outer Blade Clamp Bolts 74 UNF thread AN4 11 8 Propeller Mounting Bolts 5 16 UNF thread AN5 16 12 Propeller Flange Screws 3 8 UNF thread Unbrako 1960 or Brighton Refer to Engine Maintenance Manual for Best 1960 Grade UNF 40 30 details Cap Screws 4 1 2 Pitch Setting Specifications The following apply when setting the propeller blade pitch in accordance with Section 4 7 4 Gap between blade and pitch plate 0 60 0 90mm 0 024 0 035 Maximum difference between gap at front and rear of each blade 0 05mm 0 002 IA 1 3 Propeller Markings Each propeller is marked with its model number and serial number via a label on the rear hub Each major component of the propeller blades front and rear hub are similarly identified by labels detailing the part number and serial number of the items IMPORTANT Labels are required for warranty and airworthiness monitoring If a label is damage or degraded contact Jabiru Aircraft for a replacement 4 2 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 in
39. o 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 Balance in accordance with Section 5 3 1 Alternatively operators seeking more accurate balance may return both propeller blades to the manufacturer for fine balancing 3 Hub condition inspection whenever the propeller is off the engine the general condition of the hub should be visually inspected Section 5 6 2 gives details 4 Dye Penetrant Inspection Carry out a Dye Penetrant inspection of the front and rear hubs If cracking or defects are identified provide clear photographs to Jabiru Aircraft Pty Ltd for assessment This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled 1 Dated 1st Feb 2013 Issued By DPS Page 30 of 32 L Mfiles Manuals_For_Products Propeller_Manuals JPM0001 1_Prop_Manual 1 doc Propeller Technical Manual Jabiru Aircraft pty ta gt oe JPMO0001 1 4A482U0D And 4A484E0D Propellers 5 6 Repair Methods 5 6 1 Propeller Balancing Procedure Overhaul d d d d Both propellers are balanced during manufacture using a method able to detect very small imbalances between blades e f an imbalance is detected in the propeller assembly during overhaul it is recommended that BOTH blades be returned to the manufacture
40. o develop 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 designed 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 you
41. provide cruise speeds slightly faster than a 42 pitch wooden propeller This is due to the increased blade stiffness of the composite propeller e The 4A484E0D propeller is set to the same pitch as the wooden propeller or slightly lower for equivalent performance For example when fitted to a Jabiru J430 airframe the 4A484E0D propeller set at 53 pitch will provide cruise speeds comparable to Jabiru 53 or 55 wooden propellers e n general both propellers perform best with pitch set slightly low or fine Testing with Jabiru J120 aircraft showed that the propeller produced similar cruise speeds for a range of pitches between 40 and 36 While the cruise speeds for the lower pitch settings were similar engine temperatures and fuel consumption were improved e Set at 38 the 4A482U0D propeller showed the following when compared to being set at 42 Cruise speed reduced by approximately 2 KIAS Engine temperatures reduced Oil consumption reduced Compression leakdown results improved Fuel consumption reduced Take off and climb performance improved EGT Temperature difference between hottest and coldest readings reduced Peak temperatures reduced 3 3 1 Propeller Design e The 4A482U0D propeller has been designed for an ideal condition where the aircraft moves forward at 100 Knots when the engine is operating at 2800 RPM e The 4A484E0D propeller has been designed for an ideal condition where the aircraft moves forward a
42. r for re balancing e The following procedure is given as a basic check of balance which may be done in the field however accuracy of this process is not as high as using the factory balancer e Propeller balance jigs must meet the requirements of Section 5 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 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 Prop
43. r 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 I 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 understand 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 issue 1 Dated tstFeb 2013 Issued By DPS Page 5 of 32 LMilesManuals For Products WPropeller Manuals JPM0001 1 Prop Manual 1 doc Propeller Technical Manual Jabiru Aircraft pty ta gt oe m JPMO0001 1 4A482U0D And 4A484E0D Propellers 2 4 List of Effective Pages This manual is revised as a whole All pages retain the revision status of the overall document Altered technical content is sho
44. rs after the propeller is installed or 5 hours after the hub bolts were loosened to allow blade pitch adjustment This is to ensure that the bolt tension is checked after the hub assembly has settled This inspection must be carried out between 4 and 6 hours after the mounting bolts have been adjusted When conducting an inspection at 100 hours all items marked under Each 100 Hours is inspected serviced or otherwise completed An inspection conducted annually includes the 100 hour items in addition to the items marked under Annual Inspection The 500 hour inspection is based on propeller time in service only L Miles Manuals_For_Products Propeller_Manuals JPM0001 1_Prop_Manual 1 doc Propeller Technical Manual Jabiru Aircraft pty ta gt oe m JPMO0001 1 4A482U0D And 4A484E0D Propellers 4 6 1 Service Interval Tolerance e A tolerance of plus or minus 3 hours is allowable on all service intervals set within this manual unless stated otherwise Table 6 Inspection Chart Each 500 Hours Annual Inspection Each 100 Hours 5 Hours After Hub Bolt Adjustment SPINNER 1 General condition cracks etc ii i 2 Screw holes are not excessively elongated R i P i SPINNER FLANGE 3 General condition cracks around perimeter of hub etc i i 4 Anchor nuts amp rivets secure ii i 5 Visual inspection for signs of fretting looseness KR S B SPINNER SCREWS
45. s This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled Lal Dated istFeb 2013 Issued By DPS L Miles Manuals_For_Products Propeller_Manuals JPM0001 1_Prop_Manual 1 doc Propeller Technical Manual Jabiru Aircraft pty ta D mE JPMO0001 1 4A482U0D And 4A484E0D Propellers Gap 2mm nominal Pitch Lock Pin af Ref ke E f Kin B d Propeller Flange Figure 4 Blade Assy Detail View from beside hub front hub not shown eh e z n Gap 1mm nominal Figure 5 Hub Gap View from beside hub This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled ISSUE tt Dated 1st Feb 2013 Issued By DPS Page 23 of 32 L Miles Manuals_For_Products Propeller_Manuals JPM0001 1_Prop_Manual 1 doc Propeller Technical Manual Jabiru Aircraft pty ta gt oe JPMO0001 1 4A482U0D And 4A484E0D Propellers 4 7 4 Bench Mount Pitch Setting Y Y Y SY The following procedure is the recommended method used to set the blade pitch of propel
46. s not intended for extended operation in heavy rain Running in heavy rain will erode the Urethane in time reducing the efficiency of the propeller blade and upsetting its balance After extended running in rain the Urethane may become so badly worn that the composite leading edge underneath is exposed Once exposed the fibreglass will quickly be damaged by continued operation in rain lt 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 issue 1 Dated tst Feb 2013 Issued By DPS Page 150f 32 LMilesWManuals For Products WPropeller Manuals JPM0001 1 Prop Manual 1 doc Propeller Technical Manual Jabiru Aircraft pty ta gt oe JPMO0001 1 4A482U0D And 4A484E0D Propellers 4 Propeller Maintenance 4 1 Introduction e The following chapter details the maintenance requirements of the Jabiru 4A482U0D and 4A484E0D propellers WARNING ENSURE IGNITION SYSTEM IS OFF BEFORE COMMENCING ANY WORK ON PROPELLER DO NOT RUN ENGINE WITH PROPELLER DISCONNECTED OR ENGINE DAMAGE WILL RESULT 4 1 1 Torque Specificatio
47. t 120 Knots when the engine is operating at 2800 RPM e While the propeller will still work effectively at other speed and RPM combinations efficiency will drop slightly and extra care must be taken to ensure the other installation factors are met This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled issue 1 Dated tst Feb 2013 Issued By DPS Page 12 of 32 LMilesManuals For Products WPropeller Manuals JPM0001 1 Prop Manual 1 doc Propeller Technical Manual Jabiru Aircraft pty ta D WP JPMO0001 1 4A482U0D And 4A484E0D Propellers 3 3 2 Airframe Drag and Power Settings e The following section is included to help operators understand the behaviour of their aircraft and propeller Speed Difference Max to Cruise High Drag Maximum Thrust 100 Power Speed Difference Max to Cruise Low Drag Low Drag Curve Airspeed Figure 3 Airframe Drag Curves e Figure 3 is a simple representation of a high drag aircraft compared with a low drag type showing how drag increases with airspeed e Two horizontal lines are shown on the chart a maximum thrust line and a cruise thrust line In this simple model it is assumed that the thrust is the same for both airframes and the thrust is directly related to engine power output e t can be seen that in terms of the difference in speeds reducing thr
48. the propeller will naturally tend to come to rest with the blades close to horizontal Note that this procedure does not apply to 3300 engines as they may stop in any position Fit propeller to flange Fit Propeller Bolts 4 off The bolts must be oriented with the nuts positioned furthest from the propeller flange nuts forward for a standard tractor installation Fit front spinner plate and penny washers to front of propeller Note the use of AN970 Penny Washers this is required to distribute the load applied by the bolts Ensure that both spinner plates are locating correctly on the spigots of the propeller hub The rear spinner plate is drilled to allow the rear hub bolt spigots to pass through and mate directly against the propeller flange There must be nothing between these mating faces Progressively tighten bolts ensuring equal distribution of load and in a normal criss cross torque sequence Ensure that the hub is tightened evenly check that the gap between the front and rear hub plates is the same on both sides of the propeller Using Torque Wrench tighten propeller mounting bolts to the value given in Table 5 Using Torque Wrench tighten the outer blade clamp bolts to the value given in Table 5 Check tracking of Propeller as detailed in Section 4 7 6 Locate Spinner on Spinner Flange and fix with Machine Screws through tinnerman Washers Check Spinner tracking as detailed in Section 4 7 7 After the first 5 hours following th
49. the urethane leading edge protection 4 8 1 4 Tip Cracks The tips of both propellers are relatively susceptible to damage due to their small size Recommended Actions e Minor damage to the tip may be addressed by grinding the damaged area off the blade a maximum of 3mm may be removed Note that to maintain propeller balance the same amount must be removed from both blades e Re balancing of the propeller afterwards is recommended This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled issue 1 Dated tst Feb 2013 Issued By DPS Page 28 of 32 LMilesManuals For Products WPropeller Manuals JPM0001 1 Prop Manual 1 doc Propeller Technical Manual Jabiru Aircraft pty ta gt oe JPMO0001 1 4A482U0D And 4A484E0D Propellers 5 Propeller Overhaul 5 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
50. uitable for use on epoxy resin composites and that it does not contain silicon Always follow the instructions of the manufacturer of the polish WARNING Silicon based cleaning compounds and certain wax polishes are absorbed into the composite materials Discolouration may occur and reparability will be affected Such compounds must not be used 4 5 2 Ground Handling e All Jabiru aircraft are relatively light and should always be moved by hand e The aircraft may be moved by placing the propeller in the 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 This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled issue 1 Dated tst Feb 2013 Issued By DPS Page 17 of 32 LMilesWManuals For Products VPropeller Manuals JPM0001 1 Prop Manual 1 doc Propeller Technical Manual Jabiru Aircraft pty a gt oe JPMO0001 1 4A482U0D And 4A484E0D Propellers Always treat the propeller as LIVE IT KILLS WARNING PROPELLER WILL BECOME HOT IN DIRECT SUNLIGHT 4 5 3 Parking It is strongly recommended that a
51. ust has much more effect on a low drag airframe A streamlined aircraft may have a cruse speed 20 30 knots or more below its maximum while a high drag aircraft might cruise only 5 or 10 knots below its maximum Both would be using the same cruise thrust setting e Assume that both aircraft are set up correctly with the propeller producing 3 250RPM in level flight at full power at sea level A low drag airframe might have to reduce engine RPM to 2 800 to reach cruise thrust while a high drag airframe could operate at 3 000 RPM and still be producing the same cruise thrust Again this is because the thrust and power required drops away so much more quickly for the high drag type as speed decreases e An important factor is that RPM is not always a direct indicator of the engine s current power output picture a car driving along a flat road or climbing a hill in both cases the RPM can be the same while the power output varies greatly So depending on what the aircraft is doing an engine turning at 2 800 RPM could be producing 1096 or 9596 power or any value between e Ultimately best practice is to fit a manifold pressure gauge calibrate it to the aircraft and use that to ensure that cruise power settings are within acceptable limits e Fuel flow and EGT can also be good indicators of power setting This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled E I TIET A
52. ver Once this no longer applies the document becomes uncontrolled EE BE Es LMilesManuals For Products WPropeller Manuals JPM0001 1 Prop Manual 1 doc Dated 1stFeb 2013 ted 1st Feb 2013 Issued By DPS Page 9 of 32 Propeller Technical Manual Jabiru Aircraft pty a gt oe Wm JPMO0001 1 4A482U0D And 4A484E0D Propellers 2 9 Approved Propeller amp Engine Combinations e 4A482U0D propellers are approved for use on all variants of the Jabiru 2200 Aircraft Engine only e 4A484E0D propellers are approved for use on all variants of the Jabiru 3300 Aircraft Engine only e All propellers discussed within this manual are for TRACTOR applications only 2 10 Life e The propeller has a designed time between overhaul of 1 000 hours Refer to Section 5 for overhaul details e Propeller components except hardware are assessed on condition There are no items with a fixed life This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled issue 1 Dated 1st Feb 2013 Issued By DPS Page 10 of 32 L Miles Manuals_For_Products Propeller_Manuals JPM0001 1_Prop_Manual 1 doc Propeller Technical Manual JPMO001 1 Jabiru Aircraft pty Lia ef sech 4A482U0D And 4A484E0D Propellers 3 Propeller Operation 3 1 3 1 1 Maximum RPM Operating Limitations e All propellers covered by this manual
53. wn in red Issue Notes 1 Original Issue 2 5 Applicability 2 5 1 Models This manual contains JABIRU recommended procedures and instructions for ground handling servicing and maintaining the following Jabiru propeller models 4A482U0D 2200 Scimitar Propeller Assy Ground Adjustable 2 Blade Composite 4A484E0D 3300 Scimitar Propeller Assy Ground Adjustable 2 Blade Composite These propellers are not type certified though certain serial numbers claim compliance with the requirements of ASTM F2506 10 for operations in Light Sport Aircraft LSA category aircraft The propellers listed are approved by JABIRU for use on Jabiru 2200 and Jabiru 3300 Aircraft Engines respectively The propellers are not approved for use on other engine types or models 2 6 Reading This Manual e f you are reading this manual on a 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 To do 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 re
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