Whirlwind 400A Series, Owner'S Manual

Page 1: ...ers WHIRLWIND Owner s Manual 400A Series Rev 2018 1 WHIRL WIND AVIATION 1419 STATE ROUTE 45 SOUTH PO BOX 190 AUSTINBURG OH 44010 U S A PHONE 440 275 1540 FAX 440 275 3192 http www whirlwindaviation com Email support whirlwindaviation com A V I A T I O N ...

Page 2: ...Model 400A Serial Number 400A Manufacture Date Blade Color PPG No Tip Color PPG No ...

Page 3: ...tion 4 1 4 2 Spinner Dome Installation 4 4 4 3 Governor Installation 4 5 Section 5 Propeller System Operation 5 1 5 1 First Run Up 5 1 5 2 Inspection After First Run Up 5 2 5 3 Dynamic Balance of the Propeller 5 3 5 4 Inspection After First 2 Hours of Flight 5 3 5 5 Overspeed Warning 5 4 5 6 RPM Recommendation 5 4 Section 6 Propeller System Inspection 6 1 6 1 Preflight Check 6 1 6 2 50 Hours Inspe...

Page 4: ...ection 7 Propeller System Maintenance 7 1 7 1 Teardown Inspection Schedule 7 1 7 2 Use of Propeller Log Book 7 1 Section 8 Propeller Log Book 8 1 8 1 Maintenance History 8 1 8 2 Transfer of Ownership 8 7 ...

Page 5: ...constant at all flight airspeeds and power settings by the governor automatically The propeller control lever is used to set the desired engine RPM Once the engine RPM is set it is held constant by the governor which maintains this preset RPM by varying the propeller oil pressure automatically Mechanical stops for high and low pitch limit the pitch change travel of the propeller Whirl Wind propell...

Page 6: ...erized airfoil modeling Whirl Wind has made significant developments in the construction of the carbon composite propeller blades ensuring a strong light and durable propeller system The blade twist has been optimized for maximum performance and the wide chord allows for more low speed thrust and braking The 400A Series is a three blade hydraulically controlled constant speed propeller system desi...

Page 7: ...damage The 400A Series System includes propeller spinner and all hardware needed for installation The 400A Series hub is CNC machined from certified aerospace aluminum alloy which is then shot peened and anodized The hub blade sockets are equipped with ball bearings to ensure smooth pitch change of the blades throughout the life of the propeller system This propeller can be flown in rain and off u...

Page 8: ... number The propeller system blades will have individual serial numbers etched on the ferrule of each blade near the root end All Serial numbers can be found on the owner s data sheet Example 200G CS 108 Series and Hub Style 200G CS Propeller Serial Number 108 Blade Serial Numbers 112 113 3 1 Section 3 Section 3 Propeller Identification ...

Page 9: ...NSTALLED IT IS IMPARATIVE THAT THE FILL IN PIECES ALSO BE REMOVED The centrifugal force will damage or destroy the fill in pieces without the support of the spinner dome The engine and propeller can be operated with only the spinner rear bulkhead installed For safety reasons always turn the propeller opposite of the usual direction of rotation 4 1 Section 4 Section 4 Instructions For Installation ...

Page 10: ...ed in the propeller hub flange and make sure the O Ring is in good condition For Two Piece Rear Spinner Bulkhead Installation Step 2 Using the supplied AN3 bolts and nuts install the 2 temporary spinner installation plates as detailed below The installation plates are provided to maintain the proper spacing of the 2 spinner mounting plates when the propeller mounting studs are tightened 4 2 ...

Page 11: ...e hub when tightening the propeller bolts insure that the face of the prop hub is kept parallel with the face of the flywheel In most cases this will require tightening the propeller bolts a little at a time in an alternating pattern Step 4 Torque and safety wire the propeller hub bolts Refer to data sheet for torque dry non lubricated values 65 ft lbs for hardware or 47 ft lbs for 7 16 hardware S...

Page 12: ... bulkhead to the cylinder is to be snug BUT NOT SO TIGHT that excessive force is required to push it on If the fit is too tight sand the inside of the forward bulkhead flange If the fit is too loose apply the provided Teflon tape to the cylinder In some cases a combination of these processes will be required to obtain the proper fit Fasten the spinner dome and blade cutouts to the rear bulkhead us...

Page 13: ...e to engine drive and push governor up to seat against engine drive pad Install governor mounting hardware and torque to 150 in lbs Attach control cable to the governor control arm with the appropriate hardware Note The control arm is spring loaded to high RPM Make sure control arm moves freely through 45 degrees of travel 4 5 ...

Page 14: ...s on the ground because it can result in excessive engine temperatures and propeller blade foreign object damage 5 1 First Run Up To ensure proper first run up of your new Whirl Wind 400A Series propeller system refer to your engine s operation manual for the proper run up power setting At the proper run up power setting pull the propeller control lever back until the RPM drops by 300 400 RPM Push...

Page 15: ...ent is only allowed between the aluminum blade ferrule and the propeller hub not as described in item 2 above 4 Inspect the nickel leading edge erosion shield The nickel erosion shield should not be loose or have any cracks Small paint cracks parallel to and along the edge of the shield where the nickel and paint meet are acceptable 5 Check spinner dome and the aft and forward bulkheads for cracks...

Page 16: ...itations must be followed when operating the Whirl Wind 400A Series propeller Refer to your Whirl Wind propeller data sheet for propeller operation limitations 5 4 Inspection after First 2 Hours of Flight Repeat entire inspection done in section 5 2 Inspection after first run up after the first two hours of flight All engine RPM and power settings limitations must be followed when operating the Wh...

Page 17: ...orce than that of 2 000 RPM Considering this relationship what could be perceived as a small 10 over speed will result in a 21 increase in blade centrifugal force loads Therefore even a small increase in RPM over the maximum limit will quickly diminish the propeller s structural safety factor It is critical to always follow the propeller s RPM limitations and over speed inspection procedures as de...

Page 18: ...phic propeller structural failure Any type of structural failure may result in death or severe bodily injury 5 6 RPM Recommendation Maximum RPM Restriction The only limitation or restriction on Whirl Wind propellers is the maximum operating engine speed of 2 700 RPM 5 5 ...

Page 19: ...he aluminum blade ferrule and the propeller hub not as described in item 2 above 4 Inspect the nickel leading edge erosion shield The nickel erosion shield should not be loose or have any cracks Small paint cracks parallel to and along the edge of the shield where the nickel and paint meet are acceptable 5 Check spinner dome and the aft and forward bulkheads for cracks of any kind or looseness 6 N...

Page 20: ...eck for any movement between the aluminum ferrule and blade root no movement is allowed There should be no movement between aluminum ferrule and blade Notify Whirl Wind Aviation immediately if movement is detected 3 BLADE MOVEMENT Gently shake each propeller blade to feel for blade movement in the hub Blade shake movement is allowed up to 1 8 inch measured from the tip Radial play of up to 2 degre...

Page 21: ... conditions 7 FLANGE BOLTS Check propeller flange bolts for tightness 65 ft lbs 8 Before every flight the prop control should be cycled at least twice to circulate the engine oil In cruise flight any number of RPM settings are possible within engine and propeller limitations The RPM restrictions from the engine and propeller manufacturers must be strictly observed 6 3 ...

Page 22: ... schedule If the original data sheet cannot be found please contact Whirl Wind Aviation directly to confirm the recommended schedule for your propeller 7 2 Use of Propeller Log Book 1 Proper maintenance of this logbook is the owner s responsibility It is an important record designed for the owner s information and protection 2 If the propeller is sold or installed on another aircraft the logbook s...

Page 23: ...Time Total Time Since Overhaul Description of Work Repairman Repair Station Certificate Numbers Date Total Propeller Time Total Time Since Overhaul Description of Work Repairman Repair Station Certificate Numbers 8 1 Section 8 Section 8 Propeller Log Book ...

Page 24: ...irman Repair Station Certificate Numbers Date Total Propeller Time Total Time Since Overhaul Description of Work Repairman Repair Station Certificate Numbers Date Total Propeller Time Total Time Since Overhaul Description of Work Repairman Repair Station Certificate Numbers 8 2 ...

Page 25: ...irman Repair Station Certificate Numbers Date Total Propeller Time Total Time Since Overhaul Description of Work Repairman Repair Station Certificate Numbers Date Total Propeller Time Total Time Since Overhaul Description of Work Repairman Repair Station Certificate Numbers 8 3 ...

Page 26: ...irman Repair Station Certificate Numbers Date Total Propeller Time Total Time Since Overhaul Description of Work Repairman Repair Station Certificate Numbers Date Total Propeller Time Total Time Since Overhaul Description of Work Repairman Repair Station Certificate Numbers 8 4 ...

Page 27: ...irman Repair Station Certificate Numbers Date Total Propeller Time Total Time Since Overhaul Description of Work Repairman Repair Station Certificate Numbers Date Total Propeller Time Total Time Since Overhaul Description of Work Repairman Repair Station Certificate Numbers 8 5 ...

Page 28: ...irman Repair Station Certificate Numbers Date Total Propeller Time Total Time Since Overhaul Description of Work Repairman Repair Station Certificate Numbers Date Total Propeller Time Total Time Since Overhaul Description of Work Repairman Repair Station Certificate Numbers 8 6 ...

Page 29: ...otes _______________________________________________________ _______________________________________________________ _______________________________________________________ _______________________________________________________ New Owner Name _________________________________________ Address _______________________________________ City State Zip __________________________________ Phone No _______...