Whirlwind GA-UL260-2B User manual

GA-UL260-2B (64”-66”)
Installation and Operation Instructions
(9”-11.3” Spinners)
For UL260 Engines

GA-UL260-2B For UL Engines
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Contents
Propeller Models ..................................... 1
Packing List ............................................. 1
Required Tools ......................................... 2
Installation .............................................. 3
General Propeller Installation Guidelines ................ 2
Installation Instructions............................................. 3
Set Blade Pitch Angle ................................................. 3
Verify Static RPM......................................................... 5
Inspections .............................................. 7
Tachometer Inspection .............................................. 7
Pre-Flight Inspection.................................................. 7
Initial 50-Hour Inspection and
Anual Inspections ....................................................... 7
Suspected Impact ....................................................... 8
Lighting Strike ............................................................ 8
Paint Wear On Blade................................................... 9
Continued Airworthiness
Requirements .......................................... 10
Limited Warranty..................................... 12
Propeller Models
These instructions apply to the following propellers:
Models Diameter(s)
GA-UL260-2B 64”-66”
Torque Values
5/16” Bolts 15 ft-lbs
(170 in-lbs)
Packing List GA-UL260-2B
Non-Threaded Flange
Part Qty.
Blades 2
Hub (forward & aft halves) 1
Mounting Bolts, Long (5/16”x 4”) 4
Mounting Bolts, Short AN5-15A (5/16”) 2
Mounting Flat Washers (5/16”) 12
Clamping Bolts (5/16” Grade 9) 4
Clamping Wedge-Lock Washers (5/16”) 4
Blade Pitch Paddle 1
(Table 1)

a. b.
c.
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Required Tools
Description
Congratulations! You have purchased one the
nest ground adjustable propellers on the
market today. Each WWPC propeller is manu-
factured to meet or exceed ASTM quality stand-
ards and is proudly made in USA. The blades are
manufactured of pre-pregnated carbon ber and
protected with a high quality automotive nish
then, each blade is equipped with an electrofor-
med nickle leading edge shield. The Hubs are
CNC milled out of 6061T6 Aluminium to exacting
tolerances.
Limitations
1. MAX RPM : 3300 (do not exceed by more than
10% for 2 minutes)
2. Min / Max Pitch : +15° / +22° at Pitch Paddle
Distance. Major Periodic Inspection: 2000
hours ( see p. 8 for inspection requirements).
3. Recommended Major Periodic Inspection
: 2000 hours ( see p. 8 for inspection
requirements).
 WARNING!:
Exceeding the noted RPM limitation for
an extended period of time may lead to
CATASTROPHIC FAILURE.
General Propeller Installation
Guidelines
Read and follow these guidelines to ensure a safe,
successful propeller installation.
CAUTION:Failure to follow these instructions
will void all warranties, expressed and implied.
Mounting diculties and increased vibration will
result with improper assembly of the propeller
blades and hub parts.
1. Verify the magneto (ignition) switch is “OFF”
and that both magnetos are grounded.
2. Chock the aircraft wheels to prevent
movement.
3. Clean all dirt and oil residue from the engine
ange.
4. Always use a calibrated torque wrench when
tightening mounting or clamping bolts, and
torque to the listed value for your propeller.
5. Take inventory of hardware and tools. Ensure
that you have the correct number of pieces
with the appropriate sizes and lengths.
6. Slide washers onto their corresponding bolts
so they are ready for installation
7. Never modify the propeller hub
 NOTE: WD-40 is recommended to clean the
prop ange before installation.
Description & Installation
You will need the following tools to assemble
your propeller:
a. Deep Socket and Ratchet
b. Torque Wrench
c. Digital Protractor
Hub Bolt Type Size Socket
UL260-2B Clamping 5/16” 1/2”
Mounting 5/16” 1/2”
(Table 2)

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A
If installing spinner place the aft bulkhead
on the engine ange or spacer (if installed)
making sure to line up the blade cut outs with
the ush drive lugs. Check to make sure the
protruding drive lugs stand out at least .200”
beyond the spinner bulkhead
B
Place aft hub half on the crankshaft sit over
the ush drive lugs and line up with the aft
bulkhead blade cut outs (if installed). Secure
aft hub half with the two short mounting bolts
andWedge-Lock washers. Hold the aft hub half
in place by inserting two long mounting bolts
and place a sturdy length of wood (roughly
the length of the torque wrench being used)
in between them to apply counter torque.
Torque Bolts to Appropriate Values (Table
1, Page 1).
 NOTE: we recommend using Loctite 242 or
262 on the internal mounting bolts as they
cannot be safety wired
C
Now the forward hub and blades can be
installed. This is easier with two people
however if you are installing the propeller by
yourself;
 Start by placing the blades hub hardware
and tools within arms reach of the mounted
aft hub.
 Next turn the aft hub until the blade
sockets are aligned vertically.
 Place the top blade in rst (with one hand)
and hold it in place using the forward hub
half (with the other hand).
 Now angle the hub half so that it holds the
top blade but provides a large enough gap
to insert the bottom blade and forward
hub half.
 Once both blade are in, lightly secure the
propeller assembly with the mounting and
clamping bolts.
Installation Instructions
 Make sure there is an even gap between
the two hub halves. The blades should be
secure but easily rotated.
D
Once the propeller is mounted on the prop
ange, you are ready to set the initial blade
pitch.
 NOTE: Certain aircraft manufacturers limit
the total pitch range to comply with aircraft
design regulations.
 NOTE: If the Clamping Bolts have already
been torqued, loosen the bolts so the blades
can rotate smoothly in the hub. The Wedge-
lock washers will click loudly when loosened.
1. Rotate the propeller so that the blades are
horizontal, or level with the ground.
2. Calibrate protractor by placing it on an
exposed at portion of the forward hub half
and zeroing read out.
3. Slide the pitch paddle and protractor on the
blade as shown. Make sure the pitch paddle
is parallel with the Blades cord line.
Install Propeller
17o
Vertical Axis
(Perpendicular
to Thrust Line)
Thrust Line
Pitch
Paddle
Digital
Protractor
Typical - UL260 - 107Hp

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1. Rotate the blade to a recommended starting
angleof17°.Thebladeandanglecombination
generate a static RPM of roughly 2500.
2. Rotate propeller 180° and repeat Steps 1-3
for the other blade.
A
After the blade pitch is set on both blades,
torque the Clamping Bolts to the
appropriate Value (Table 1, Page 1). Follow
the symmetrical pattern and tightening each
bolt 1/8 to 1/4 turn at a time. It is important to
maintain an even gap between the hub half
to prevent a change in pitch angle.
 NOTE: after all mounting and clamping bolts
have been properly tightened, Check the
blade angles again to make sure they have
not changed.
 IMPORTANT:After the rst 5 hours of
operation, or any blade angle (pitch) change,
re-check all hub mounting bolts and blade
clamping bolts torque values.
 NOTE: To lower RPM, increase the blade pitch.
To increase RPM, decrease the blade pitch.
NEVER MASK AN ENGINE PROBLEM WITH
A PITCH CHANGE. If you are unsure, please
contact the factory
 NOTE: both pitch angles should be within
0.20 degrees of each other.
 NOTE: After every 25 hours of use check bolt
torques
Installation Instructions

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B
Before operation, Verify Static RPM
 WARNING: Exceeding a Limitation for
an extended period of time may lead to
a CATASTROPHIC FAILURE and BODILY
INJURY OR DEATH.
 NOTE: Have your tachometer calibrated by
a professional before performing this next
operation.
1. With the brakes on, run the engine at full
throttle and note the static RPM on the
tachometer.
The static RPM at full throttle should
be 2400 to 2600 RPM. MAX RPM at full
throttle during straight and level ight
should be 3100 RPM.
 WARNING:NEVER EXCEED THE MAXIMUM
RPM RATING FOR YOUR ENGINE. If you
are not seeing your correct static RPM,
be certain the tachometer was properly
calibrated.
2. After the desired static RPM is achieved,
re-check all bolt torque values (The ideal
pitch setting will allow the propeller to
reach (with out exceeding) maximum RPM
at full throttle in level ight.)
 WARNING:Do not operate your propeller
above the recommended engine RPM. If
your propeller has been subjected to an over
speed condition of 10% over the maximum
rating (3300RPM MAX X 1.1 = 3630) for more
than 2 minutes, you must land and perform
a 100 hour inspection. After Suspected
Impact or an overspeed condition of
20% or higher, the propeller must be
removed from service and returned to
the manufacturer for inspection.
Installation Instructions

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Installation with 12” Spinner
Blade in Blade
Socket
AN5 5/16” Grade
9 Clamping Bolts
(Qty:4)
One Wedge-lock Washer
(2 Pieces with ramped
sides facing each other)
AN 365-524
locknuts
Engine
Flange
UL260 Drivelug
5/16”Wedge Lock
Washers (Qty:4)
AN5-15A Short
Mounting Bolts
(Qty:4)
AN 960-516 5/16”
Flat Washers
(Qty:12)
Torque Values
5/16” Bolts 15 ft-lbs
Hub Bolt Type Size Socket
GA-UL260-2B Clamping 5/16” 1/2”
Mounting 5/16” 1/2”
Aft Hub
5/16”, 4” Long Mounting
Bolts (Qty:4)
Forward Hub
Aft Spinner
Back Plate

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Inspections
Initial 50-Hour Inspection,
Annual (100-Hour) Inspections
In addition to the recommendations for the
Pre-Flight Inspection, the propeller and spinner
should be visually examined in detail after the rst
50 hours (also annually and at 2000-Hour). This will
require the removal of the spinner for a detailed
examination.
Initial 50-Hour / 100-Hour or 12 calendar
month annual inspection:
1. Remove Spinner Dome and examine it for
damage, and cracks. If necessary, replace the
spinner dome.
2. Remove Clamping Bolts and dimensionally
check against one another. Any bolts that
exhibit stretching, corrosion or damage are
to be replaced.
3. Remove the Forward Hub-Half and set aside.
4. Remove each blade and inspect blade shanks
for any wear. A thorough visual inspection
is recommended together with a coin tap
inspection of each composite blade, including
the nickel erosion shield on the leading edge
(see AC 43-5).
 No dents in the metal erosion shield should
be deeper than 1/8”.
 No dents should puncture the metal
erosion shield.
 No excessive wear on the leading edge.
(If further inspection is required, return
the blades to the factory or an approved
propeller shop for further examination.)
5. Conditions requiring blade replacement:
 Any hole in hollow blade shell (doesn’t
apply if a replacement metal erosion shield
will cover hole)
 Any crack deeper than .025”
 Any solid tip damage that can’t be trimmed
o completely
Tachometer Inspection
An improperly operating tachometer can lead to
propeller failure, excessive vibration or cause an
engine to exceed maximum RPM limits established
by manufacturers.
Proper tachometer operation and accuracy should
always be checked (using the manufacturer’s pro-
cedure, if available) during normal maintenance
intervals.
Pre-Flight Inspection
Perform this inspection before every flight.
Before each ight, carefully examine the propeller
blades and hub for looseness, any signs of damage,
excessive wear or any other condition that would
make the propeller unsafe to operate.
The pre-ight walk-around is an important element
of the process of airworthiness maintenance. It
should not be merely a supercial look, but a
studied review of the condition of everything that
might give trouble during the forthcoming ight.
1. Carefully examine the propeller assembly for
looseness, any signs of damage, excessive
wear or any other condition that would make
the propeller unsafe to operate.
2. Check the leading edge of blades for cracks
and debonding.
3. Check the spinner and bulkhead for security,
missing screws, damage and cracks. Cracks
typically originate from the attachment
screws.
4. Check for looseness of the bulkhead. This
could be an indication that the mounting
bolts are loose and need to be retightened.
5. Note any indications in the logbook for
future reference to determine whether an
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Inspections
6. Remove Mounting Bolts and dimensionally
check against one another. Any bolts that
exhibit stretching, corrosion or damage such
as cracks or nicks are to be replaced.
7. Remove the Hub Mount Half . Inspect both
hub halves for corrosion.
8. Remove the rear spinner bulkhead and
examine for missing fasteners, damage,
and cracks. If damaged, replace the spinner
bulkhead.
9. REPLACE the special Wedge-lock washers.
10.Reinstall the assembly per the above
installation instructions.
2000-Hour Major Periodic Inspection
Must be accomplished by an A&P or IA.
1. Remove Spinner Dome and examine it for
damage, and cracks. If necessary, replace the
spinner dome.
2. Remove Clamping Bolts and washers and
retire both sets from service.
3. Remove the Hub Clamp Half and set aside.
4. Remove Mounting Bolts and washers and
retire both sets from service.
5. Remove the Hub Mount Half .
6. Remove the rear spinner bulkhead and
examine for missing fasteners, damage,
and cracks. If damaged, replace the spinner
bulkhead.
7. Send both hub half’s and both blades to an
Approved Propeller Repair Center for the
remaining 2000 hour inspection.
 NOTE: These blades do not have life
limitation. There is no specied over haul
time. The propeller parts are removed from
service when they can no longer meet the
Continued Airworthiness Requirements
Suspected Impact
Propellers that have been involved in a known or
suspected static or rotating impact with relatively
solid objects (e.g., ground, maintenance stands,
runway lights, birds, etc.) or relatively yielding
objects (e.g., snow banks, puddles of water, heavy
accumulation of slush, etc.) should be inspected for
damage before further ight.
If the inspection reveals one or more of the
following listed indications, the propeller should
be removed and sent to Whirl Wind Propellers for
evaluation.
 A blade that tracks out of limits or out of edge
alignment.
 Loose blades in the hub.
 Any diameter reduction (tip damage).
 Visible major damage to the hub that cannot
meet the Minor Hub Repairs criteria.
 Visible major damage to a blade that cannot
meet the Minor Blade Repairs criteria.
 Operating changes, such as vibration or
abnormal RPM.
 IMPORTANT:After any propeller strike the
bolts should be replaced.
Lighting Strike
Any Whirl Wind composite blade suspected of
lightning strike should be inspected and may
require repair or replacement.
Lightning strikes usually enter a composite blade
through the metal erosion shield. If a lightning
strike is present, a darkened area and possible
pitting, usually in the proximity of the tip, will be
noticeable.
If a lightning strike is suspected or detected,
consider the blade unairworthy. Return the blade
to the factory or an approved propeller repair
center for further examination.

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Paint Wear On Blade
Wear is inevitable on the metal erosion shield. The
wear rate depends on several factors, including
high operating RPM’s in rain or sandy areas, FOD
on taxiways and runways, etc.
Propeller Removal
1. Safe engine ignition system for maintenance
by disconnecting the aircraft battery.
2. Perform installation procedure as illustrated
on page 5 in reverse order of operation.
Inspections

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Continued Airworthiness Requirements
The following recommendations will help you
operate your propeller safely, keep it looking good
and help it to last.
 NOTE: There is no specied overhaul time.
The propeller parts are removed from service
when they can no longer meet the Continued
Airworthiness Requirements.
 Never install a propeller unless it is a model
approved for the aircraft/engine. The service
history must be properly documented, and the
propeller must pass a pre-installation inspection.
 A thorough visual inspection will could catch
a dangerous ight condition. Use touch and
hearing as well as visual clues. Changes in
surface roughness, unusual free play, and odd
sounds indicate conditions that may aect
airworthiness. Feel for roughness and look
for texture changes, waviness, and changes
in reection that may signal the removal of
protective coatings. Some areas may require
the use of a 10x magnifying glass to identify
small features or nd cracking.
 The pre-ight walk-around is very important,
and should be a studied review of any condition
that might give trouble during ight. Refer to
the Pre-Flight Inspection section for details.
 Do not paint over areas of corrosion on hub parts.
 Do not operate any aircraft after a propeller
has been subjected to an impact without a
thorough inspection. Refer to the Inspection
After Suspected Impact section for details.
 Do not use the propeller as a tow-bar to move
your aircraft.
 Apply a good quality automotive paste wax to
the blades at least once a year.
 Avoid running-up in areas containing loose
stones, sand, and gravel, to reduce erosion and/
or damage to the leading edges and blades.
 Finish loss o the leading edge is a normal
wear item and is dependent on the amount of
operation in rain and grit.
 Whenever there is evidence of engine
roughness, check bolt torque on both the
clamping and mounting bolts, and check the
propeller blades for track. The blades should
track within 1/8” of each other at the tip.
Rotating the propeller and reinstalling may
help.
 If the bolts are inadvertently over-torqued, they
should be replaced immediately.
 If your propeller blade(s) or hub assemblies
begin to show any of the following conditions,
it must be repaired by an approved propeller
shop or retired from service:
a. Cracks in the metal hub or bolts,
b. Loose metal leading edge,
c. Any crack across the blade,
d. Any crack along the blade length,
e. Blade impact damage with missing
composite material larger than 0.5 square
inches and/or deeper than 0.025”
f. Obvious damage or wear beyond
economical repair.

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Model Diameter(s) Weight Engines Limits
GA-UL260-2B 64”- 66” 8 lbs
UL260i, UL260iS,
UL260iSA,
UL260iF series
engines
3300 RPM MAX
(Propeller)
107 HP Max
Aproved Engine/Propeller Combinations and Limitations
Propeller Performance
PROPELLER PERFORMANCE
In selecting a propeller, keep in mind that both
aircraft and engines of the same model may vary
in performance, and that operators may want
dierent performance characteristics. For instance,
one person may require a high climb rate while
another seeks maximum cruising eciency.
RPM
Although the propeller can rotate at a maximum of
3300 RPM, Flight tests have show that full throttle
RPM of 3100 creates the best performance.
STANDARD PITCH / NORMAL FLYING
For normal or cross country ying, a propeller that
turns up to maximum continuous engine RPM at
full throttle level ight will give best all-around
performance.
CRUISE PITCH
A cruise propeller will turn 150 to 250 engine RPM
less than a standard pitch propeller. While cruise
pitches will provide 4-6 mph higher airspeeds at
cruise power rpm’s, maximum level ight speeds
are no better than climb or standard pitches, and
the take-o and climb performance will noticeably
suer.
CLIMB PITCH / HIGH ALTITUDE
OPERATION
For improved take-o and climb performance,
use a climb pitch propeller that will turn 100
to 200 engine rpm more than a standard pitch
propeller (Refer to your particular aircraft
operating manual for propeller limitations).
Climb pitches will typically reduce ight speeds
by 4-6 mph at cruise power RPM’s. A climb pitch
is also recommended for aircraft operating from
high density altitude runways.
PITCH NOTES AND LIMITATIONS
The faster the airplane the higher the pitch
setting that will be required to keep the engine
from overspeeding at Wide Open Throttle WOT
While the propeller may be structurally oper
ated at any pitch setting from +15° through +22°
the takeo RPM at WOT must meet the aircraft
manufacturer’s recommended limits to ensure
safe ight The propeller RPM should never ex
ceed the engine manufacturers recommended
maximum RPM
 NOTE: Certain aircraft manufacturers limit
the available propeller pitch range to comply
with aircraft design regulations

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Limited Warranty
We hope you enjoy your new composite propeller.We have worked hard to ensure that your propeller will meet or exceed
your expectations for years to come. We oer a one year limited warranty on any defect in materials and workmanship.
In the event a unit does not conform to this express warranty, Whirl Wind Propellers Corporation will repair or replace
the defective material at its place of business in El Cajon, CA, USA. Whirl Wind Propellers Corporation will decide which
remedy, repair, or replacement it will provide. Any replacement of a unit or a part of a unit during the warranty period
will not extend the warranty beyond the original duration. The remedy of repair or replacement is exclusive and does
not include the cost of shipping, removal, or installation, all of which are the customer’s responsibility.
Procedure For Obtaining Warranty Service
Units or parts that are defective must be shipped prepaid to Whirl Wind Propellers Corporation at the address listed
below:
Whirl Wind Propellers
1800-C Joe Crosson Dr
El Cajon, CA 92020
The unit must be accompanied by a copy of the original (Distributor or Dealer) invoice, a Return Authorization Number
(which can be obtained by phoning or emailing [email protected]), and a brief description of the defect.
Conditions, Exclusions, and Disclaimers
This limited warranty applies only to units that have been installed, used, and maintained properly in strict accordance
with our specications, instructions, and recommendations. It does not cover units that show abuse, alterations,
improper installation, improper maintenance or repair, or improper packaging for shipment; and it does not pertain
to damage due to object strike, or excessive blade wear due to operation. Overspeed of any kind or use on or with
engines or equipment not approved by Whirl Wind Propellers Corporation automatically voids this warranty. This
limited warranty is the only warranty provided with respect to covered units, and THERE ARE NO OTHER WARRANTIES,
REPRESENTATIONS, CONDITIONS OR GUARANTEES, EXPRESS OR IMPLIED, WITH RESPECT TO THE COVERED UNITS OR
THE MANUFACTURE THEREOF, INCLUDING, WITHOUT LIMITATION, ANY IMPLIED WARRANTIES OF MERCHANTABILITY OR
FITNESS FOR A PARTICULAR PURPOSE.
Repair or replacement of a nonconforming unit or part is the exclusive remedy for breach of this limited warranty, and
shall constitute fulllment of all liabilities of Whirl Wind Propellers to a customer or user, whether based on contract,
negligence or otherwise. IN NO EVENT SHALL WHIRL WIND PROPELLERS CORPORATION BE LIABLE FOR ANY OTHER
EXPENSES, CLAIMS OR DAMAMGES OF ANY KIND HOWSOEVER CAUSED, INCLUDING (WITHOUT LIMITATION) ANY OTHER
PRODUCT REPLACEMENT OR INSTALLATION COSTS AND/OR ANY DIRECT, INDIRECT, CONSEQUENTIAL, INCIDENTAL OR
SPECIAL DAMAGES.
The purchaser of the covered units has read, understood and, by purchasing the units, agrees to be bound by the above
terms and conditions. Some states do not allow the exclusion of incidental or consequential damages, so the above
limitations may not apply to you. This warranty gives you specic legal rights and you may also have other rights which
vary from state to state.
Whirl Wind Propellers Corporation
Whirl Wind Propellers
1800 Joe Crosson Drive, Ste C
El Cajon, CA 92020
[phone]
www.whirlwindpropellers.com
7FEB2018