Pipistrel FP03-60E User manual

FP03-60E
Propeller
Operator’s manual
REV. A00
26th January 2018
WARNING!
This leaet MUST be present inside the cockpit at all times when required by law.
If the aircraft ownership changes, this manual must be handed over to the new owner.
This is an original document issued by Pipistrel.
Should third-party translations to other languages contain any inconsistencies,
Pipistrel denies all responsibility.

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Index of 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 upper right corner of the page, also, any changes in page content
should be clearly visible (e.g. marked with a bold vertical line)
Name of
revision
Rev.no.,
date: Signature, date: Description:
A00 26th January 2018 A. B. Horvat Initial

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Operator's manual
List of valid pages
This manual contains original and revised pages listed below.
Pages State:
Cover Original
Page numbering Original
Index of revised pages 2Original
List of valid pages 3Original
Table of contents 5Original
General 7 - 10 Original
Handling and maintenance 11 - 15 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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Operator's manual
Table of contents
General
Handling and maintenance

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Introduction
Notes and remarks
Propeller markings
Shipping list
Propeller description
Manufacturing method
Technical data and
operational limitations
General
General

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Introduction
This manual contains all information needed for appropriate and safe use of Pipistrel FP03-60E pro-
peller.
In case of aircraft damage or people injury resulting form disobeying instructions in the manual
PIPISTREL d.o.o. denies any responsibility.
All text, design, layout and graphics are owned by PIPISTREL d.o.o. Therefore this manual and any of
its contents may not be copied or distributed in any manner (electronic, web or printed) without the
prior consent of PIPISTREL d.o.o.
IT IS MANDATORY TO CAREFULLY STUDY THIS MANUAL PRIOR TO USE
OF PROPELLER
Notes and remarks
Safety denitions used in the manual:
WARNING! Disregarding the following instructions leads to severe deterioration of ight
safety and hazardous situations, including such resulting in injury and loss of life.
CAUTION! Disregarding the following instructions leads to serious deterioration of ight
safety.
Propeller markings
Every Pipistrel FP03-60E propeller is marked during manufacture for easier recognition. The marking
is engraved on the aluminium hub in the following form:
“ASD3K-XXX”
where the last three digits indicate the production serial number of the propeller, and the rst part
of the marking indicate the propeller model. The propeller’s part number is found on a sticker ap-
plied to the packaging, when the propeller is delivered as a spare part.
General

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General
Shipping list
Standard propeller (p/n 1253076) assembly, includes:
Propeller hub and bolts (6x M6)
Propeller blades (3)
Blade protection cloth (bag type)
Spinner, spinner backplate and screws
Installation material (p/n 1153194), includes:
Propeller plate adapter
Mounting bolts (6x M8) and washers
Propeller description
Pipistrel FP03-60E propeller is a xed pitch propeller for ultralight and experimental aircraft in pull
conguration.
Propeller and spinner assembly

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WARNING! Pipistrel FP03-60E propeller does not comply with ICAO rules and regulations
and is therefore used at one’s own responsibility.
Manufacturing method
The FP03-60E propeller’s outer skin and inside parts are made of composite materials, namely
bre reinforced plastic.The blade’s base is made of aluminium and stainless steel tube, which lies
within to ensure the blade’s safe attachment to the propeller base (hub).
Technical data and operational limitations
Propeller Designation FP03-60E
Number of blades 3
Propeller diameter 1640 mm
Spinner diameter 350 mm
Max. safe propeller RPM 2575 RPM
Max. safe engine power (permanent load) 60kW/80HP
Propeller weight (and spinner) ~4.5 kg
Rotation direction (seen from behind) Clockwise
Fastening bolts torque (6x M8) 24 Nm
General

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Introduction
Upon delivery
Propeller installation
Propeller removal
Scheduled maintenance
Daily check-up
Overhauls
Overspeed
Repairs
Paint jobs
Ground handling
Handling and maintenance
Handling and maintenance

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Introduction
This chapter provides information on handling and maintenance of Pipistrel FP03-60E propeller.
CAUTION!Prior to servicing the propeller the area around the aircraft must be cleared and barricade
tape put up, to warn passers by of the possible hazard.
WARNING! Make sure that engine/motor can not be started during servicing operations.
Upon delivery
Upon delivery please verify all parts inside the package for eventual damage which could occur dur-
ing transportation.
WARNING!The self-locking nuts that come with the propeller may only be used once. Any
self-locking nuts that are removed MUST be replaced with new ones.
Propeller installation
• Place the propeller plate adapter and the spinner backplate on the center of motor front side.
• Fit the M8 hex-head bolts with a washer and apply some Loctite 243 to their thread.
• Place the propeller on the spinner backplate.
• Fasten the propeller to the motor using the six M8 hex-head bolt. Cross-tighten them rst to 10
Nm and then torque them to 24 Nm.
• Install the spinner. Make sure that the notch on the spinner matches the one on the backplate.
• Fasten the spinner to the backplate using the nine M4 hexagon socket button head screws.
WARNING! Do not attempt, under no circumstances, to torque the bolts more than 24 Nm.
Should you ever desire to replace the bolts and nuts, make sure you use bolts and nuts that comply
with the durability class of at least 8.8.
Propeller removal
- Unscrew the nine M4 Hexagon socket button head screws connecting the spinner to the backplate.
- Remove the spinner by bending it slightly, sliding it o the back plate and around the propeller.
- Unscrew the six M8 hex-head bolts and washers.
- Mark the respective angular positioning of propeller and spinner backplate using tape or a pen
marker. These markings must be respected during the re-installation of the propeller on the air-
craft.
- Remove the propeller, the backplate and the plate adapter from the motor.
- Separate the backplate and the propeller and collect the fastening material.
Handling and maintenance

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Handling and maintenance
Scheduled maintenance
Every 100 ight hours perform a check to the following components:
• Spinner and spinner backplate
• Blades
• Hub
The check has to be performed as follows:
• Visual inspection to the spinner: no cracks, no paint and/or edge separations
• Remove the spinner
• Visual inspection of the blades and blade’s base: clean, no cracks, no paint and/or edge separa-
tions
• Hub: No cracks or deformation
• Inspect paint marker on bolt heads for signs of loosening.
The following pictures show an example of possible blade damage
Daily check-up
Verify the following:
blades - rmly attached to the propeller hub, no free play
blades’ surface: clean, no cracks, no paint and/or edge separations
spinner - clean, no cracks, no paint and/or edge separations
WARNING! Should the propeller’s status determined during daily check-up not comply with
the stated above, ying may result in further damage and/or injury, including loss of life.

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Handling and maintenance
Overhauls
Overhauls must be done by the manufacturer once every 1000 ight hours.
Maximum life span of the propeller
Until present time, no boundaries of FP03-60E propeller’s life span are known. Several Pipistrel FP03-
60E propellers have been in operations without showing any structural abnormalities.
Overspeed
In case of propeller overspeed (propeller rpm exceeds the value given in“Technical data and opera-
tional limitation”, contact the manufacturer for further instructions.
Repairs
Small damage (cracks) in the paint layer of the blades may be repaired by the owner him/herself
using dabbing lacquer. Should the blades be damaged during transportation and/or hangaring, the
individual blades can be replaced, however, this requires a special tool/template. Contact the manu-
facturer for further guidance.
All damage which occurs during engine operation requires for the entire power plant and propeller
to be veried for structural damage by authorised service personnel. Consult with the manufacturer.
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, manufacturer denies any
responsibility.
Paint jobs
Should you desire to repaint your propeller, please consult with the manufacturer prior to painting.

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Handling and maintenance
Ground handling
Use pure 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 best aordable car wax.
CAUTION! Do not, under any circumstances, attempt to use rough cloth to remove durable
stains. This results in scratching the surface and by that degrades propulsion performance
greatly.
Storing the aircraft inside closed space, make sure there is not any dust accumulating on the blades.
Clean your propeller regularly, preferably before and after each ight to maintain best propulsion
performance.
Avoiding damage
On ground, keep your propeller intact by putting the protection cloth onto the blades. Also, try to
keep your propeller o the sun if possible, for eventual damage caused by UV radiation.
When starting-up the motor/engine, always make sure the space around the propeller is clear.
Do not ever attempt to land on a runway covered by deep water patches for that can result in under-
carriage and propeller damage.
Do not ever attempt to taxi through dense high grass for this causes propeller damage.
Be extremely careful when putting the aircraft into or out of the hangar not to damage the blades.
Do not ever attempt to move around your ultralight aircraft by pushing or pulling it by the propeller.

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