Whirlwind 400A Series User manual

Manufacturer of Composite Constant Speed Propellers
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: [phone]
FAX: [phone]
http://www.whirlwindaviation.com
Email: [email protected]
A V I A T I O N

Model:
400A
Serial Number:
400A-
Manufacture Date:
Blade Color:
PPG No:
Tip Color:
PPG No:

Section 1: Introduction................................................1-1
Section 2: Overview.....................................................2-1
2.1 Description .................................................................2-1
2.2 Construction...............................................................2-2
Section 3: Propeller Identification........................3-1
Section 4: Instructions for Installation................4-1
4.1 Propeller and Spinner Installation..............................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 Inspection...................................................6-2

Section 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

Congratulations on your propeller purchase from
Whirl WindAviation!
To ensure many hours of trouble free operation of your new Whirl
Wind propeller please read and follow the operation and
maintenance recommendations in this manual.
The Whirl Wind 400A Series propeller is a composite constant speed
hydraulically controlled propeller. This fully constant speed propeller
will automatically adjust blade pitch angle to maintain the selected
engine RPM setting. A single acting piston (inside the hub) powered
by engine oil changes the blade pitch. Oil pressure is adjusted and
regulated by the engine driven governor. Once an engine RPM is
selected, it will be held 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 propellers are experimental class and are not subject to any
Federal Aviation Administration regulations. The operator acknowledges that
these are experimental propellers and agrees to assume all risk in operating
them on an experimental aircraft or any other machine. Any and all
information in the owner’s manual, service letters and other documentation
are suggestions only and may not apply to an operator’s specific application.
1-1
Section
1
Section 1: Introduction

2.1 Description
The 400A Series propeller has been designed to maximize
the performance of your airplane! This propeller delivers
exceptional performance for the modern day utility aircraft.
The exceptional performance is derived from advanced
aerodynamic engineering techniques including computerized
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 designed for aircraft using
a Lycoming IO-540 or equivalent engine.
2-1
Section
2
Section 2: Overview

2.2 Construction
The 400A Series propeller blades are constructed from
advanced thermoset composite materials. Each blade is
equipped with a nickel leading edge erosion shield to protect
the blade leading edge from debris 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 unimproved airstrips.
2-2

Each Whirl Wind propeller system has a factory designated model
number and serial number, which will identify the hub and propeller
serial 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

4.1 Propeller and Spinner Installation
WARNING! DO NOT OPERATE THE ENGINE /
PROPELLER WITH ONLY THE SPINNER FILL-
IN PIECES INSTALLED!
IF THE ENGINE AND PROPELLER ARE TO BE RUN
WITHOUT THE SPINNER DOME INSTALLED 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

The Whirl Wind 400A Series propeller comes equipped with
a composite spinner and rear bulkhead.
Step 1: Before beginning installation of the 400A Series
propeller system inspect the O-Ring located 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

For One Piece Rear Spinner Bulkhead Installation:
Step 2: Note the factory position of the spinner rear bulkhead in the
spinner dome in relation to the blade cutouts to determine its
required position on the propeller hub. The spinner and spinner rear
bulkhead have been number coordinated to match the blade cutout
openings. Using the supplied AN3 bolts and nuts install the spinner
rear bulkhead to the spinner mounting plates. The supplied flat
washers are to be installed on the fiberglass side. The bulkhead is
to be installed on the aft side of the mounting plates. (The 14”
aerobatic spinner rear bulkheads are an exception; it is to be
installed on the forward side of the mounting plates. A slot is
provided in the bulkhead so it can be slipped over the mounting
plates into its forward position.) Tighten the bulkhead mounting
hardware.
Step 3: After lightly lubricating the O-Ring with clean oil or O-Ring
lube, carefully install the propeller on the engine crankshaft by
tightening the (6) propeller bolts.
Warning: To avoid severe damage to the 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 ½”
hardware or 47 ft-lbs for 7/16” hardware). Safety wire the prop bolts
in pairs with 0.32” stainless safety wire after installation.
** Installation with a one piece rear bulkhead is complete. Proceed to
Section 4.2 **
For Two Piece Rear Bulkhead Installation:
Step 5: Remove the (2) spinner installation plates. Save them for
future use.
Step 6: Note the factory position of the spinner rear bulkhead in the
spinner dome in relation to the blade cutouts to determine its
required position on the propeller hub. The spinner and spinner rear
bulkhead have been number coordinated to match the blade cutout
openings. Using the supplied AN3 bolts and nuts install the spinner
rear bulkhead to the spinner mounting plates. The supplied flat
washers are to be installed on the fiberglass side. The bulkhead is
to be installed on the aft side of the mounting plates. Tighten the
bulkhead mounting hardware.
4-3

4.2 Spinner Dome Installation
Install the spinner dome onto the propeller hub and rear
bulkhead. The spinner and spinner rear bulkhead have been
number coordinated to match the blade cutout openings.
The spinner dome has a forward bulkhead with a flanged hole
that must engage the cylinder (cap) on the front of the
propeller hub. The fit of the forward 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 using the supplied screws and nylon washers.
IMPORTANT: Periodically verify that the spinner screws
are tight during the first few hours of operation.
4-4

4.3 Governor Installation
•Clean governor and engine governor mating surfaces.
•Place gasket on governor side.
•Align governor spline 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

WARNING: Operation of this propeller over maximum RPM
is strictly prohibited and may result in a catastrophic
structural failure of the propeller system. Any type of
structural failure may result in death or severe bodily
injury. Refer to your propeller data sheet for Maximum
RPM.
Be sure to limit engine power settings when performing ground run-
up. Engine and propeller manufacturers do NOT recommend high
engine power settings 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 the propeller
control lever forward and observe RPM increase. Cycle the
pitch three times to purge air out of the system. After first
run-up refer to “Section 5.2” for inspection.
5-1
Section 5: Propeller System Operation
Section
5

5.2 Inspection After First Run-Up
1. Inspect the propeller system blades and spinner for any nicks,
cracks, or chips.
2. Inspect each aluminum blade ferrule and blade intersection
(located at the root end of blade where the silicone sealant is
visible) for movement and/or signs of chafing. There should be
no movement between aluminum ferrule and blade. Notify Whirl
Wind Aviation immediately if movement is detected.
3. 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 degrees is
acceptable. If the check shows values above these tolerances
contact Whirl Wind Aviation immediately. Movement 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 of any kind or looseness.
6. No grease or oil leaks should be detected. NOTE: A small
amount of grease leakage may occur in new propellers (first 2 to
5 hours) or in hot climates with high RPM conditions.
7. 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 the engine and propeller
limitations. The RPM restrictions from the engine and propeller
manufacturers must be strictly observed.
5-2

5.3 Dynamic Balance of the Propeller
Your Whirl Wind Propeller System has been statically
balanced at the factory. However, it is recommended to have
the engine/propeller dynamically balanced before the first
flight.
Repeat the same inspection after balancing as for first run-up.
All engine RPM and power settings limitations 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 Whirl Wind 400A Series
propeller. Refer to your Whirl Wind propeller data sheet
for propeller operation limitations.
5-3

5.5 Overspeed Warning
It is possible to overspeed the propeller by rapid throttle
advancement. Therefore, always adjust the power and RPM
lever slowly and smoothly to avoid the possibility of
overspeed.
The 400A propeller is rated for an absolute
maximum 2,700 RPM.
The maximum rated RPM of the propeller is something to be
taken very seriously and often is not by many pilots. All Whirl
Wind propellers are designed with a conservative safety factor
based on the maximum RPM of 2,700. The centrifugal blade
forces are a squared function of RPM. For example, 2,700
RPM has double the blade centrifugal force 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 detailed below.
If an overspeed occurs:
Overspeed Occurrence
Required Action
up to 110 % of the max RPM A 50 hours inspection must be
performed immediately by a certified
A&P mechanic
111% to 120% of the max
RPM A mandatory teardown inspection at the factory is required
above 121% of the max RPM No further use of the propeller is
permitted! The propeller must be
returned to the factory for
inspection.
5-4

WARNING: Failure to adhere to these
guidelines may lead to a catastrophic
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

6.1 Preflight Check
1. Inspect the propeller system blades and spinner for any nicks,
cracks, or chips.
2. Inspect each aluminum blade ferrule and blade intersection
(located at the root end of blade where the silicone sealant is
visible) for movement and/or signs of chafing. There should be
no movement between aluminum ferrule and blade. Notify Whirl
Wind Aviation immediately if movement is detected.
3. 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 degrees is
acceptable. If the check shows values above these tolerances
contact Whirl Wind Aviation immediately. Movement 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 of any kind or looseness.
6. No grease or oil leaks should be detected. NOTE: A small
amount of grease leakage may occur in new propellers (first 2 to
5 hours) or in hot climates with high RPM conditions.
7. 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.
6-1
Section 6: Propeller System Inspection
Section
6

6.2 50 Hour Inspection
1. BLADES: Inspect the propeller system blades for any nicks,
cracks, or chips. Inspect blades for cracks in the composite
skins and nickel leading edges. No cracks are allowed in either.
If cracks are present return propeller for repair to a Whirl Wind
Aviation service center.
-Inspect the cambered side of each blade for chord-wise
cracks and the entire blade for any delamination of the
composite skin or obvious discoloration.
-Small cracks parallel along the nickel edge are allowed
as long as the leading edge is not loose. Scratches or
chips should be sealed up as soon as practicable.
-In case of any questionable conditions, please contact
the service department of Whirl Wind Aviation.
2. BLADE FERRULES: Inspect each aluminum blade ferrule and
blade intersection (located at the root end of blade where the
silicone sealant is visible) for movement and/or signs of chafing.
Gently flex the blade at the tip to check 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 degrees is acceptable. If the check shows values above
these tolerances, contact Whirl Wind Aviation immediately.
Movement is only allowed between the aluminum blade ferrule
and the propeller hub, not as described in item #2 above.
4. LEADING EDGE: 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. SPINNER: Remove spinner and check for nicks, cracks or
chips. Check spinner dome and the aft & forward bulkheads for
cracks of any kind or looseness. Also inspect for any signs of
chafing.
-Ensure secure attachment to the hub.
-Check AN3 bolt on aft bulkhead for tightness.
6-2