FP02-80 Propeller operator’s manual

Document No.: POM-160-00-60-001*

REVISION A00
Date of Issue: July 3rd, 2019

*This manual supersedes Pipistrel ALPHA Trainer wooden propeller operator’s

manual REV 6 (20th May, 2016)

Aircraft Registration Number:

Aircraft Serial Number:

This publication includes the material required to be supplied to the pilot by ASTM F2506.

WARNING! This document MUST be present inside the cockpit at all times. Should you be
selling the aircraft make sure this document is given to the new owner.

All rights reserved. Reproduction or disclosure to third parties of this document or any part thereof is not
permitted, except with the prior and express written permission of Pipistrel Group’s R&D division, Pipistrel
Vertical Solutions d.o.o., which is authorized to publish technical documentation for Pipistrel Group’s
subsidiaries.
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Index of document revisions

Enter and sign the list of revised pages in the manual into the spaces provided below. All revised pages
should be clearly designated in the bottom of the page, also, any changes in page content should be
clearly visible (e.g. marked with a bold vertical line).

Document
Reason for revision Date issued Issuer
revision

A00 Initial release July 3rd, 2019 SLO.DOA.002

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List of effective pages

This manual contains 20 original pages listed below.

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Cover Original -
2 Blank page -
3 Original 0
4 Blank page -
5 Original 0
6 Blank page -
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19 Blank page 0
20 Original -

CAUTION:
This manual is valid only if it contains all of the original and revised pages listed above.

Each page to be revised must be removed, shredded and later replaced with the new, revised page in
the exact same place in the manual.

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TABLE OF CONTENTS

CHAPTER SUBJECT PAGE NUMBER

01-00 GENERAL 8

02-00 HANDLING AND MAINTENANCE 12

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 FP02-80 Propeller operator’s manual

CHAPTER 01 – GENERAL

TABLE OF CONTENTS

SECTION SUBJECT PAGE NUMBER

01-00 INTRODUCTION 9

01-01 NOTES AND REMARKS 9

01-02 PROPELLER DESCRIPTION 9

01-03 MANUFACTURING METHODS 10

01-04 TECHNICAL DATA AND OPERATIONAL LIMITATIONS 10

01-05 PROPELLER CONSTRUCTION 11

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 FP02-80 Propeller operator’s manual GENERAL

01-00 INTRODUCTION
This manual contains all information needed for the appropriate and safe use of the Pipistrel
FP02-80 propeller.

In case of aircraft damage or personal injury resulting from disobeying the instructions in this
manual PIPISTREL denies any responsibility.

All text, design, layout and graphics are owned by PIPISTREL. Therefore this manual and any
of its contents may not be copied or distributed in any manner (electronic, web or printed)
without the prior written consent of PIPISTREL. with ecxeption of owners and maintainers of
Pipistrel aircraft making copies for their own use.

IT IS MANDATORY TO CAREFULLY STUDY THIS MANUAL PRIOR TO USE

OF PROPELLER

01-01 NOTES AND REMARKS

Safety definitions used in the manual:

WARNING! Disregarding the following instructions leads to severe deterioration of flight safety and
hazardous situations, including such resulting in injury and loss of life.

CAUTION! Disregarding the following instructions leads to serious deterioration of flight safety.

NOTE: Provides an information such as tip or hint that aid the mechanic when carrying out
a specific procedure.

01-02 PROPELLER DESCRPTION

The Pipistrel FP02-80 propeller is a fixed-pitch two-blade wooden propeller is primarily used
in tractor configuration on the Pipistrel ALPHA Trainer airplane. The propeller sizing and pitch
is designed to match the engine power curve of the Rotax 912 UL2 80 HP engine and maintain
compliance with the LSA performance requirements.

Starting May 2016 the supplier of the FP02-80 propeller is Woodcomp Propeller s.r.o.,
Vodolska 4, 250 70 Odolena Voda, Czech Republic.

This propeller is to be used primarily on the Rotax 912 80 HP series engines and is matched to
the ALPHA Trainer performance envelope.

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 FP02-80 Propeller operator’s manual

01-03 MANUFACTURING METHODS

The propeller core is made of laminated wood-composite, then milled, then protected with a
thin layer of fibreglass (70 g/sqm grade) and varnished for surface protection, the blade lead-
ing edge is protected by an insert. The propeller is fixed to the gearbox hub on the engine by
using 6 bolts that pass through the propeller and equalize the pressure via a metal retaining
plate.

01-04 TECHNICAL DATA AND OPERATIONAL LIMITATIONS

Propeller designation ALPHA FP02-80
Number of blades 2
1620-1660 mm
Propeller diameter
(63”-65’’)
Propeller pitch at 3/4 of prop. radius 14°
Blade width 110 mm (4.3’’)
Maximum safe propeller RPM
(corresponds to 5800 engine RPM)

WARNING! In the case the propeller is operated at over

speed by a value exceeding 5% the maximum (2.684 rpm) 2555 RPM
rotation speed and not beyond the maximum time of 20
seconds, it must be removed and sent back to the factory
for full inspection and corrective procedures.

Maximum safe engine power (permanent load) 80 HP

Central hole diameter 25.4 mm (1’’)
Propeller head (hub) bolts & nuts type M8
Mounting holes’ circle diameter 75 mm
16-18 Nm
Propeller bolt torque (11.8 -13.3 ft/lbs)
Maximum temperature limit 80 °C / 176 °F

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01-05 PROPELLER CONSTRUCTION

Basic material used for the construction of the propeller is Western Maple wood carefully se-
lected for this special application.

The material is preserved and conditioned according to the specifications of the manufacturer
and is continuously tested during curing and storage in order to maintain the quality require-
ments.

The propeller can be fully or partially covered with different materials (fibreglass, carbon fibre,
Kevlar). The propeller is constructed by the “propeller block” method by laminating 7 wood
planks together with ureic resin. This lamination is highly resistant to humidity and temperature
variations.

The high density laminated construction is ideal to make a propeller lacking any twist and/or
fissure defaults. The leading edge is inserted with a blade protection material.

The blade protection covers the leading edge up (about 2/3) to the tip of the propeller. It is
protected by an amniopolymer plastic material that is resilient in extreme conditions. It is elas-
tic and can easily withstand the stresses of normal use.

The blade protection strip is attached with polymer material pins fixed into holes made in the
wood, it can be replaced by the factory if damaged.

If required, the blade protection strip can be manufactured from structural brass extrusions,
fixed onto the leading edge by glue and rivets.

In order to further improve the hardness and rigidity of the propeller, the blade is covered in a
fibreglass coating, applied with polyester resin.

This process allows the propeller both superficial hardness and elastics in operation and the
blade will be more resistant to stone chips and cracks.

A further benefit of these manufacturing processes is excellent resistance to propeller twist and an
increase in dimensional stability.

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CHAPTER 02 – HANDLING AND MAINTENANCE

TABLE OF CONTENTS

SECTION SUBJECT PAGE NUMBER

02-00 INTRODUCTION 13

02-01 DELIVERY 13

02-02 PROPELLER REMOVAL 13

02-03 PROPELLER INSTALLATION 13

02-04 MAINTENANCE 14-15

02-05 DAILY CHECK-UP 15

02-06 TIME LIMITS 16

02-07 ANNUAL / 100 HOUR INSPECTION 16

02-08 REPAIRS 17

02-09 PAINT JOBS 17

02-10 GROUND HANDLING 18

02-11 AVOIDING DAMAGE 18

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 FP02-80 Propeller operator’s manual HANDLING AND
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02-00 INTRODUCTION
This chapter provides information on handling and maintenance of the Pipistrel FP02-80
propeller.

02-01 DELIVERY
On delivery check all parts inside the package for damage which may have occurred during
transportation. Included are: propeller (1 pcs), attachments bolts (6 pcs), washers (6 pcs),
retaining plate (1 pcs), nuts (6pcs).

02-02 PROPELLER REMOVAL

Required parts,
Step Action materials and tools
Reference

1 Loosen the nuts tightening the propeller to the engine gearbox. - ratchet set

2 Remove the 6 bolts and washers.

3 Remove the metal retaining plate on the front of the propeller.
4 Remove the propeller.

02-03 PROPELLER INSTALLATION

Required parts,
Step Action materials and tools
Reference

NOTE: The set-up procedure must be completed on an assembled aircraft. - ratchet set
- torque wrench
1 Place the propeller onto the engine gearbox hub.
2 Attach the metal retaining plate to the front of the propeller.
3 Insert the 6 bolts and washers.
4 Cross tighten the nuts gradually and apply 16-18 Nm (11.8 -13.3 ft/lbs).
CAUTION! When the propeller is new or you have fitted a replacement
propeller you must check the bolt torque at the following intervals. 10 hours,
25 hours, 50 hours and then verify the bolt torque every 50 engine hours.

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02-04 MAINTENANCE
Maintaining proper bolt torque is the most important maintenance item for a wooden propeller.
Loss of proper bolt torque will result in the decrease or loss of hub compression and thus the
loss of drive friction between the propeller mounting hub face and the engine drive flange. At
this point the torque is transferred only by the engine flange and attaching bolts, which will
begin to elongate the bolt holes and counterbores in the rear face of the wooden propeller.
This can eventually cause cracking in the hub and/or failure of the attaching bolts and possible
separation of the propeller from the aircraft.

The main factor that leads to the loss of propeller bolt torque is the variation of the wood hub
thickness. The hub thickness will vary with (a) wood moisture content changes and (b) temper-
ature changes. Even though your propeller has been sealed and/ or painted, changes in wood
moisture content will occur which can significantly change the thickness of the hub. A one
percent (1%) change in the moisture content of a propeller (increase / decrease) will cause a
0.010” change in hub thickness. As the required compression for a typical 80 HP wood propel-
ler is 0.025”, almost half of the required hub compression has now been lost. Moisture content
changes are not immediate and can span several weeks or months, depending on many
factors such as temperature, humidity, and operating schedules.

Operating temperature changes have similar effects but are not as severe. For the above rea-
sons, it is important to follow the maintenance schedule below:

1. Before First Flight (after aircraft assembly) – After the first flight, recheck the bolt torque.
Refer to Bolt Torque Check.

2. After First 10 Hours – After the first 10 hours, recheck the propeller bolt torque. Refer to Bolt
Torque Check Procedure.

3. After First 25 Hours – After the first 25 hours, recheck the propeller bolt torque. Refer to
Bolt Torque Check Procedure.

4. Every 50 Hours – After the first 25 hour recheck, it is Mandatory that the propeller bolt torque be
rechecked every 50 hours. Refer to Bolt Torque Check Procedure.

5. Environment Changes - Should the operating environment change significantly in temperature

and/or humidity for a long period of time, the propeller bolt torque must be rechecked.

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 FP02-80 Propeller operator’s manual HANDLING AND
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BOLT TORQUE CHECK PROCEDURE

1. Be certain that magneto switch is off, MASTER OFF. Remove the spinner cone.

2. With a calibrated torque wrench, check bolt torque by applying the torque in a tightening direction
until the bolt begins to turn. Torque check values and required actions are given below.

IMPORTANT! Improper torque values will be obtained by measuring the breaking torque in a
loosening direction. The torque should be checked in a tightening direction and adjusted as
needed.

Respect the following when applying torque values:

Torque below 10 Nm (below 7 ft-lbs) - Remove propeller, inspect hub for damage.

Torque between 10 Nm and 16 Nm (7-10.5 ft-lbs) - Adjust torque to 15-18 Nm (11-13 ft-lbs).

Torque between 16 Nm and18 Nm (11-13 ft-lbs) - No action required.

Torque above 18 Nm (13 ft-lbs) - Loosen bolts, then retorque to 15-18 Nm (11-13 ft-lbs).

02-05 DAILY CHECKUP

Verify the following:

- blades surface: clean, no cracks, no varnish and/or edge separations

- blades base - no damage, cracks, varnish and/or edge separations
- retaining metal plate - no damage, no bends, cracks
- bolts, washers and nuts - no visible damage
- metal leading edge - no visible damage

WARNING! Should the propeller’s status determined during daily check-up not comply with
the conditions stated above, flying may result in further damage and/or injury, including loss of
life.

Small superficial cracks of external lacquer are due to work vibrations and are not to be considered
serious. However they should not be numerous and/or exceeding the layer of external lacquer.
If the depth is deeper and there is a possibility that some dirt or moisture could have penetrated
inside then please contact the factory.

Deep cracks to the extremity of the blade in the longitudinal direction indicate a flexing vibration
action and are to be considered dangerous because they can cause breakages or damages in flight.
Send the propeller to the factory in case of such cracks.

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MAINTENANCE

Transversal cracks are due to torque vibrations and are normally caused by external lacquer layer
drying. This phenomena is not caused by structural causes but it’s advisable to contact the factory,
especially in case of deep cracks.

Chips in the fibre glass protection are not important as long as they don’t expose the wooden
part of the blade. Even the presence of exposed wood of a diameter smaller than 2 mm doesn’t
compromise the propeller from functioning but it’s advisable to keep them under control with
regular inspection and immediate repair. Longitudinal cracks in the hub area are to be considered
dangerous; they need to be valuated by the factory.

02-06 TIME LIMITS

The FP02-80 is a fiber glass reinforced propeller that has been in operation on many aircraft
for well over 1,000 flight hours without showing any abnormalities. It has a limited lifetime of
2000 hours, after which replacement is mandatory. Replace any bolts that have been over-
torqued or damaged.

02-07 ANNUAL / 100 HR INSPECTION

Do the following procedures in addition to the daily check:

Remove the propeller from the hub, and check for any damage, especially on the two sides of
the hub normally hidden by the front pressure plate and engine flange.

WARNING! Cracks beyond the lacquer layer are not permissible. Cracks on the surface can
be repaired with another lacquer layer.

NOTE: Every material or product used for propeller repairing has to be original and suggested by the
factory.

WARNING! If there is any doubt or more serious damage contact the factory for corrective mea-
sures or return the propeller for inspection/repair.

Clean the propeller using only neutral and not abrasive detergents and protect them with sili-
con free furniture spray wax like lemon pledge.

Install the propeller again on the engine.

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02-08 REPAIRS
Only small repairs which are allowed to be done by the owner are presented here. The owner
is obligated to make a record into the Propeller logbook about each repair and used technol-
ogy. Other damages shall be repaired either by manufacturer or an authorized maintenance
organization only.

Repairs of small scratches and cuttings which appear at the location above the blade radius
R = 250mm may be done by owner. Maximum 3 repairs may be done on one blade. All major
repairs, especially damage which appears at the root section of the blade, shall be repaired
either by manufacturer or an authorized maintenance organization only. Maximum permissible
depth of damage that may be repaired by the owner at the leading or trailing edge is 2 mm.
The minimum distance between two damaged locations is 80 mm and the length must be
equal to 60 mm or less. Maximum permissible depth of damage that may be repaired by the
owner at the top or bottom side of blade is 0.7 mm. The minimum distance between two dam-
aged locations is 100 mm and the area of each of them must be less than 1 cm2.

Repair sprocedure:

1. Clean and dry the damage location.

2. Use fine sand paper or a file to make the damaged location smooth.
3. Apply epoxy-based filler to the location.
4. Shape the solid filler to the form of blade surface by a file or sand paper.
5. Coat the location with a layer of polyurethane or nitrocellulose-based lacquer.

WARNING! After every repair job, the propeller must be re-balanced to prevent potentially
lethal vibrations.

WARNING! For all repair jobs conducted by owners themselves. The manufacturer denies
any respons

02-09 PAINT JOBS

Should you desire to repaint your propeller, please consult with the manufacturer prior to paint-
ing.

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02-10 GROUND HANDLING

Use water and a soft piece of cloth to clean the blades. If you are unable to remove certain
spots, consider using mild detergents. Afterwards, rinse the entire surface thoroughly.
To protect the surfaces from the environmental contaminants, use a good quality silicon free
furniture spray wax like lemon pledge.

CAUTION! Do not, under any circumstances, attempt to use a rough cloth to remove durable
stains. This results in scratching the surface and that degrades propulsion performance greatly.

When storing the aircraft inside a closed area, make sure there is no dust accumulating on the
blades. Clean your propeller regularly, preferably before and after each flight to maintain best
performance.

02-11 AVOIDING DAMAGE

On the ground, keep your propeller in perfect condition by using the protection sleeves for the
blades. Also, try to keep your propeller out of the sun if possible to avoid damage caused by UV
radiation.

When starting-up the engine always make sure the space around the propeller is clear.

Be extremely careful when moving the aircraft in or out of the hangar not to damage the blades.

Don’t attempt to move around your Pipistrel ALPHA Trainer aircraft by pushing or pulling it by
the propeller tips, if you must use the propeller to help move the aircraft only do so by grabbing
the propeller at the base right next to the spinner.

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Italia - EU
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[email protected]
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Pipistrel Vertical Solutions d.o.o.

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