Avia Propeller AV-723-1-D-C-F-R Operation And Installation Manual

Reversible hydraulically controlled variable pitch propellers (constant speed)

Issue 4: October 06, 2017

Revision: March 4, 2019

Avia Propeller s.r.o., Beranových 65/666, 199 00 Praha 9 - Letňany, CZECH REPUBLIC

Tel.: +420/296336511, Fax.: +420/296336519, sales@aviapropeller.cz,

REVERSIBLE HYDRAULICALLY CONTROLLED

VARIABLE PITCH PROPELLERS

(CONSTANT SPEED)

AV-723-1-D-C-F-R(P)

AV-725-1-E-C-F-R(P), (W)

AV-803-1-E-C-F-R(W)

AV-804-1-E-C-F-R(W)

AV-844-1-E-C-F-R(G), (P), (W)

Document number:

ATA 61-10-20

The technical content of this document is approved

under authority of DOA No. EASA.21J.072.

www.aviapropeller.com

Table of Contents

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Summary of Contents for Avia Propeller AV-723-1-D-C-F-R

Page 1 Issue 4: October 06, 2017 The technical content of this document is approved Revision: March 4, 2019 under authority of DOA No. EASA.21J.072. Avia Propeller s.r.o., Beranových 65/666, 199 00 Praha 9 - Letňany, CZECH REPUBLIC Tel.: +420/296336511, Fax.: +420/296336519, sales@aviapropeller.cz, www.aviapropeller.com...
Page 2 ONLY BY QUALIFIED PERSONNEL. ANY ACTIVITIES BEYOND THE SCOPE OF THIS MANUAL TO BE PERFORMED ONLY BY A PERSON TRAINED AND AUTHORIZED BY AVIA PROPELLER. ALWAYS USE THE LATEST REVISION OF THIS MANUAL. THE LATEST REVISION OF THIS MANUAL IS AVAILABLE FREE OF CHARGE AT WWW.AVIAPROPELLER.COM.
Page 3: Table Of Contents
OPERATION AND INSTALLATION MANUAL EN-1320 TABLE OF CONTENTS Page LIST OF REVISIONS ....... II - 1 LIST OF EFFECTIVE PAGES .
Page 4: List Of Revisions
EN-1320 OPERATION AND INSTALLATION MANUAL LIST OF REVISIONS Rev.No. Page Revised Page Date R-106/17 2017-10-06 R-71/18 Cover, II-1, III-1, 5-14 2018-07-27 R-23/19 Cover, II-1, III-1, 5-2, 5-14, 12-6, 12-10, 12-11, 12-16, 12-37 2019-03-04 REVISION R-23/19 - SUMMARY  Aeroshell Grease 22 added as replacement of Aeroshell Grease 5 and 6 throughout the manual. ...
Page 5: List Of Effective Pages
OPERATION AND INSTALLATION MANUAL EN-1320 LIST OF EFFECTIVE PAGES Page Date Page Date Page Date Cover 2019-03-04 6-10 2017-10-06 12-8 2017-10-06 2017-10-06 6-11 2017-10-06 12-9 2017-10-06 II-1 2019-03-04 6-12 2017-10-06 12-10 2019-03-04 III-1 2019-03-04 6-13 2017-10-06 12-11 2019-03-04 6-14 2017-10-06 12-12 2017-10-06 2017-10-06...
Page 6: Airworthiness Limitations
EN-1320 OPERATION AND INSTALLATION MANUAL 1.0. AIRWORTHINESS LIMITATIONS This Airworthiness Limitations Section is EASA approved in accordance with Part 21A.31(a)(3) and CS-P40(b) and 14 CFR Part 35.4 (A35.4). Any change to mandatory replacement times, inspection intervals and related procedures contained in this section must also be approved. The Airworthiness Limitations Section is FAA approved and specifies maintenance required under §§...
Page 7: General
The overhaul should be accomplished if one of this limit is acquired, whichever occurs first. The overhaul shall be accomplished only by Avia Propeller or authorized service station in accordance with latest revision of the Overhaul manual mentioned in section „Related documents“...
Page 8 Some other parts may be replaced in the field only by person trained and authorized by Avia Propeller. Contact the Avia Propeller for information on part replacement. Parts that did not come through the manufacturer's quality control system will void the warranty and may render the propeller unairworthy.
Page 9: Model Designation
MODEL DESIGNATION 3.1. Hub designation A V - 72 5 - 1 - E - C - F - R (W) - ( ) Avia Propeller (manufacturer) V = Variable pitch propeller Type of blade shank Number of blades Consecutive number of series Code for propeller flange D = ARP 502, six mounting studs 1/2“-20UNF, two dowel pins,...
Page 10 EN-1320 OPERATION AND INSTALLATION MANUAL 3.2. Blade Designation CFR ( ) 230 - 433 ( ) Code for pitch change pin position CFR = pitch change pin for feathering and reverse ; pitch change forces to increase pitch Sense of rotation blank = right-hand, tractor Propeller diameter in cm Consecutive number of basic type...
Page 11 OPERATION AND INSTALLATION MANUAL EN-1320 4.0. DESIGN AND OPERATION INFORMATION The variable pitch propeller consists of the following main groups: - Hub with blade bearing - Pitch change mechanism - Propeller blades - Counterweights - Spinner - Propeller governor - Electrothermal de-icing system 4.1.
Page 12 EN-1320 OPERATION AND INSTALLATION MANUAL 4.2.1. For Pratt&Whitney Application Outside the hub there are check nuts and in the inner part of the hub there are 3 stop nuts. High pitch/feathering can be set by turning the check nuts. Low pitch can be set by turning the internal stop nuts The full reverse stop is not adjustable in the field.
Page 13: Design And Operation Information
OPERATION AND INSTALLATION MANUAL EN-1320 4.6. Propeller Governor 4.6.1. See Avia Manual No. E-1707 for Avia P-W( ) Series governors. 4.6.2. See Woodward Manual for: Garret TPE-331-( ): No. 33091-( ) Pratt and Whitney PT6A: No. 33163-( ) Primary No. 33048-( ) Overspeed 4.6.3.
Page 14: Installation And Operation Instruction
EN-1320 OPERATION AND INSTALLATION MANUAL INSTALLATION AND OPERATION INSTRUCTION CAUTION 1: DO NOT USE THE SPINNER BULKHEADS TO SUPPORT THE WEIGHT OF THE PROPELLER ASSEMBLY, OTHERWISE THEY COULD BE IRREPARABLY DAMAGED. CAUTION 2: DO NOT USE THE BLADES TO SUPPORT THE WEIGHT OF THE PROPELLER ASSEMBLY, OTHERWISE THEY COULD BE DAMAGED.
Page 15 OPERATION AND INSTALLATION MANUAL EN-1320 Installing the Blades into the Hub (except model AV-844) a) Observe the label located on the blade. When installing the blade into the hub, make sure that position number on the label corresponds with the number stamped on the hub, at the bushing where the blade will be installed.
Page 16 EN-1320 OPERATION AND INSTALLATION MANUAL FIGURE 5-2 FIGURE 5-3 FIGURE 5-4 h) Lubricate the screw and nut with graphite grease. Tighten and torque the clamp to 65-70 Nm (48-52 ftlb). CAUTION: TAKE CARE TO CORRECT SEATING OF THE BOLT HEAD WHEN TIGHTENING THE CLAMP - SEE FIGURE 5-5.
Page 17 OPERATION AND INSTALLATION MANUAL EN-1320 FIGURE 5-5 Check the clamp after tightening. The shoulders must not be in contact after tightening to a specified torque. See figure 5-6. CAUTION: THE CONTACT BETWEEN CLAMP SHOULDERS AFTER TORQUING INDICATES THAT THE CLAMP IS NOT PROPERLY TIGHTENED TO SPECIFIED TORQUE.
Page 18 EN-1320 OPERATION AND INSTALLATION MANUAL Electrothermal De-icing System (if installed) With the screws and toothed washers, connect the cables to matching contacts in the de-icers. See marking on the cable and on the de-icer. Before Installing the Propellers AV-725 and AV-844 Ending in -R(P) Before installing the propeller on the engine, the beta ring must be pushed forward to allow access to the propeller mounting flange.
Page 19 OPERATION AND INSTALLATION MANUAL EN-1320 FIGURE 5-9 Before Installing the Propeller Ending in -R(G) on the Engine Measure the distance “X“ (see Figure 5-10) for the dimension, how far the beta tube must be turned in (was recorded during previous propeller removal). This is important to set the low pitch stop.
Page 20 EN-1320 OPERATION AND INSTALLATION MANUAL Installing AV-( )-E-( ) Propeller on the Engine a) Hang the propeller on the crane hoist with a sling. Move the propeller to the engine mounting flange. WARNING: MARE SURE THE CRANE HOIST AND SLINGS HAVE A MINIMUM OF 450 KG (1000 LBS) LIFTING CAPACITY.
Page 21 OPERATION AND INSTALLATION MANUAL EN-1320 Installing AV-( )-D-( ) Propeller on the Engine a) Hang the propeller on the crane hoist with a sling. Move the propeller to the engine mounting flange. WARNING: MARE SURE THE CRANE HOIST AND SLINGS HAVE A MINIMUM OF 450 KG (1000 LBS) LIFTING CAPACITY.
Page 22 EN-1320 OPERATION AND INSTALLATION MANUAL FIGURE 5-11 FIGURE 5-12 Page 5-9 61-10-20 INSTALLATION AND OPERATION INSTRUCTION 2017-10-06...
Page 23 OPERATION AND INSTALLATION MANUAL EN-1320 5.10 After Installing the Propellers AV-725 and AV-844 Ending in -R(P) a) After installing the propeller on the engine, reinstall the beta feedback components into the hub. See Section 5.6. Apply engine oil to the thread of the cover caps, as necessary. b) Torque the cover caps to 10-12 Nm (7,5-9 ftlb).
Page 24 EN-1320 OPERATION AND INSTALLATION MANUAL 2) Fit the carbon block into the U-Type beta ring with side clearance 0,025 to 0,05 mm (0.001 to 0.002 inch) at new installation. Maximum clearance 0,25 mm (0.01 inch) is acceptable. Evenly sand the sides of carbon block with 600-grit sandpaper to achieve required clearance, as necessary.
Page 25 OPERATION AND INSTALLATION MANUAL EN-1320 5.13 Installing the Brush Block Assembly NOTE: Only models equipped with electrothermal de-icing system. a) Check free movement of all brushes in the assembly. Compress and release the brushes noticing any bind or hang up inside the block. b) Install the brush block assembly into its place on the engine gearbox.
Page 26 EN-1320 OPERATION AND INSTALLATION MANUAL FIGURE 5-17 5.14 Adjusting Mechanical low and high pitch stops, reverse and feathering, are adjusted during manufacture, according to the requirement of the aircraft/engine combination. Low pitch can only be adjusted via the beta-setup. Feathering can be adjusted by turning the check nuts. The reverse pitch stop cannot be changed in the field.
Page 27 OPERATION AND INSTALLATION MANUAL EN-1320 AV-723 Propeller Ending in -R(P) Low pitch can be adjusted by turning the low pitch adjusting nuts in or out. See Figure 5-18. • Turning in: higher pitch • Turning out: lower pitch CAUTION 1: ALL STOPNUTS MUST HAVE THE SAME SETTING TO EACH OTHER, OTHERWISE THE PITCH CHANGE MECHANISM WILL BE DAMAGED BECAUSE OF WOBBLING OF THE BETA RING.
Page 28 EN-1320 OPERATION AND INSTALLATION MANUAL 5.18 Only models AV-( )-E( ) AFTER THE GROUND RUN OF THE ENGINE, INSPECT THE PROPELLER FLANGE SIDE FOR ANY TRACES OF ANTI-SEIZE COMPOUND ON THE BRUSH BLOCK, SLIP RING, BETA RING, ETC. THOROUGHLY WIPE BEFORE FLIGHT. CAUTION: ANI-SEIZE COMPOUND ON THE PARTS WILL CAUSE DAMAGE TO THE PARTS IN OPERATION.
Page 29: Inspections
Such leakage should cease within the first ten hours of operation. If the leakage persists or increases, contact Avia Propeller. d) Check the blades for excessive play in the retention bearing. Refer to the section “Loose blades”...
Page 30 43.13-1B, as well as using procedures for the blade repair in the Inspection Procedures section in this chapter. Other damage should be referred to Avia Propeller. 2) Inspect the propeller, blades and spinner for the traces of lightning strike. Refer to the Inspection Procedures section in this chapter if lightning strike is confirmed or suspected.
Page 31 CAUTION: IN CASE OF STRONG AND/OR DEEP CORROSION, IF IT IS NOT POSSIBLE TO REMOVE THE BLADE FROM THE BUSHING OR IN CASE OF ANY DOUBT REMOVE THE PROPELLER FROM SERVICE AND CONTACT AVIA PROPELLER. f) Install the blades into the hub. Refer to chapter Installation and Operation Instruction. Page 6-3...
Page 32 EN-1320 OPERATION AND INSTALLATION MANUAL 3) Functional test of overspeed governor NOTE: This test relates only to the propellers ending in -R(W). a) Remove the spinner dome. b) Remove the cover cap from overspeed governor. The spring support must protrude from the governor about 1,5 mm (0.06 inch).
Page 33 OPERATION AND INSTALLATION MANUAL EN-1320 Overspeed governor Propeller RPM at Functional model Test of Overspeed Governor 300-095 1900 - 1950 RPM 300-095-2 1720 - 1780 RPM TABLE 6-1 Page 6-5 61-10-20 INSPECTIONS 2017-10-06...
Page 34 Remove the spinner dome and visually inspect the entire blades and visible hub components for cracks, mechanical damage and other unusual condition. If crack is found or in case of any doubt contact Avia Propeller. c) Thread-type blade models only Check correct installation of the blades in the bushings.
Page 35 OPERATION AND INSTALLATION MANUAL EN-1320 3) Loose Blades a) Except model AV-844, any movement of the blade is not acceptable. b) Propeller AV-844 only 1 Except In and Out play, slight movement of the blade within ±0,5 mm (0.02 inch) is acceptable, provided that there is no hanging and the blade returns to its original position when released.
Page 36 CAUTION: THE DIFFERENCE GREATER THAN 3 MM (0.12 INCH) MAY BE AN INDICATION OF BENT BLADES OR DAMAGE OF PROPELLER SERVO INSIDE THE HUB. INDICATED BLADE TRACK PROBLEM SHOULD BE REFERRED TO AVIA PROPELLER. FIGURE 6-3 5) Electric De-icing System a) Inspect the slip ring for excessive wear on the copper rings.
Page 37 OPERATION AND INSTALLATION MANUAL EN-1320 6.5. REPAIR OF NICKS OR GOUGES ON BLADES Local repairs may be made using files, electrical or air powered equipment. Emery cloth, scotch brite, and crocus cloth are to be used for final finishing. Refer to figure 6-5. FIGURE 6-5 WARNING: Rework which involves cold working the metal, resulting in concealment of a damaged area, is not acceptable.
Page 38 For engine mounted accessories (for example, governors, pumps, and propeller control units) manufactured by Avia Propeller, any overspeed at a severity level and /or duration sufficient to require at minimum a search inspection for the propeller, will require the accessory to be disassembled and inspected in accordance with the applicable maintenance manual.
Page 39 OPERATION AND INSTALLATION MANUAL EN-1320 FIGURE 6-6 FIGURE 6-7 Corrective Actions When no action is necessary, no maintenance is necessary other than to verify that the overspeed was not caused by a mechanical problem. When overspeed inspection or overhaul is required the propeller must be removed from service and be sended to manufacturer or authorized repair station for inspection or overhaul.
Page 40 EN-1320 OPERATION AND INSTALLATION MANUAL RECORD ON PROPELLER SUBJECT TO OVERSPEED Owner: ........................... Aircraft manufacturer: ......Type:...... S/No.: ......Type of engine: ............... S/No.: ......Reduction gear: ......................Type of propeller governor: ............ S/No.: ......Type of propeller hub: ............S/No.: ......Type of propeller blade: ............
Page 41 OPERATION AND INSTALLATION MANUAL EN-1320 RECORD ON PROPELLER SUBJECT TO OVERTORQUE Owner: ........................... Aircraft manufacturer: ......Type:...... S/No.: ......Type of engine: ............... S/No.: ......Reduction gear: ......................Type of propeller governor: ............ S/No.: ......Type of propeller hub: ............S/No.: ......Type of propeller blade: ............
Page 42 The hard landing within the load limit of the airplane does not require any action on the propeller. b) The hard landing above the load limit of the airplane requires inspection of the propeller in Avia Propeller or authorized repair center. Page 6-14 61-10-20...
Page 43: Maintenance
OPERATION AND INSTALLATION MANUAL EN-1320 7.0. MAINTENANCE 7.1. There are no frequent maintenance works required on the hub because all moving parts are inside the hub and not exposed to the environment. Blade bearings and pitch change mechanism are filled with special lubricants and there is no need to refill between overhauls. A corrosion protection of the hub with thinned engine oil or anticorrosion spray is recommended.
Page 44 EN-1320 OPERATION AND INSTALLATION MANUAL 7.4.2.5. Drilling holes for use with the AN3-( ) type bolts with self-locking nuts is acceptable. NOTE: Chadwick-Helmuth Manual AW-9511-2, „The Smooth Propeller„ specifies several generic bulkhead rework procedures. 7.4.2.6. All hole/balance weight locations must take into consideration, and must avoid, any possibility of interfering with the adjacent airframe, de-ice and engine components.
Page 45 OPERATION AND INSTALLATION MANUAL EN-1320 1 Rotate the propeller to place one of the blades parallel to the ground. Measure the angle of the blade. Make note this angle. 2 Rotate the propeller to place another blade to the same position as the previous blade was measured.
Page 46 EN-1320 OPERATION AND INSTALLATION MANUAL FIGURE 7-1 Page 7-4 61-10-20 MAINTENANCE 2017-10-06...
Page 47: Troubleshooting
OPERATION AND INSTALLATION MANUAL EN-1320 8.0. TROUBLESHOOTING 8.1. Blade shake 8.1.1. Fore and aft movement Cause: Blade bearing loose Remedy: If more than 3 mm, return propeller to the factory or any approved repair station to correct the pre-load of the blade retention bearing. 8.1.2.
Page 48 EN-1320 OPERATION AND INSTALLATION MANUAL 8.4. Rpm variations between ascend, cruise and descent although having identical propeller setting Up to ±50 rpm normal condition. If more : Cause: 1. Excessive friction in the propeller 2. Excessive friction in the governor 3.
Page 49 OPERATION AND INSTALLATION MANUAL EN-1320 8.8. Oil leakage (visible outside or hidden inside) Cause: Damaged seals Remedy: Replace gaskets or repair propeller 8.9. Rough running turbine, possibly in limited rpm range only Cause: 1. Bad static balance 2. Bad dynamic balance 3.
Page 50: Shipping And Storage
EN-1320 OPERATION AND INSTALLATION MANUAL 9.0. SHIPPING AND STORAGE 9.1. Use an original shipping boxes and fixing elements for any shipment of the propeller and blades. If it is not possible, properly fix the hub and blades to avoid damage during the shipment. Use an original hub flange protecting plug or protect the hub flange properly with soft material during the shipment or storage after removal of the propeller from engine.
Page 51: 10.0. Tooling
OPERATION AND INSTALLATION MANUAL EN-1320 10.0. TOOLING The following tools are required for propeller installation and removal:  Calibrated torque wrench  Compatible torque wrench inserts: 22 mm or 7/8 inch (all models) 19 mm or 3/4 inch (AV-725 series only) ...
Page 52 EN-1320 OPERATION AND INSTALLATION MANUAL 11.0. DRAWINGS AND PARTLISTS 11.1. AV-725-1-E-C-F-R(P) Figure 11-1: AV-725-1-E-C-F-R(P) Propeller Assembly Page 11-1 61-10-20 DRAWINGS AND PARTLISTS 2017-10-06...
Page 53 OPERATION AND INSTALLATION MANUAL EN-1320 Item Description Item Description Propeller blade 2.51 De-icer 2.52 Cotter pin O-ring 2.53 Screw 2.54 Washer Cylinder 2.55 Carbon block Front fork 2.57 Split ring Rear fork 2.58 Screw Piston 2.59 Washer Guide rod 2.60 Washer Washer Spinner dome...
Page 54 EN-1320 OPERATION AND INSTALLATION MANUAL 11.2. AV-725-1-E-C-F-R(W) Figure 11-2: AV-725-1-E-C-F-R(W) Propeller Assembly Page 11-3 61-10-20 DRAWINGS AND PARTLISTS 2017-10-06...
Page 55 OPERATION AND INSTALLATION MANUAL EN-1320 Item Description Item Description Propeller blade 2.52 De-icer 2.53 O-ring 2.54 Cotter pin 2.55 Screw Cylinder 2.56 Lock washer / Washer Piston 2.57 Overspeed governor Piston extension 2.58 O-ring Piston rod 2.59 Lock washer Distance bushing 2.60 Distance bushing 2.61...
Page 56 EN-1320 OPERATION AND INSTALLATION MANUAL 11.3. AV-803-1-E-C-F-R(W) Figure 11-3: AV-803-1-E-C-F-R(W) Propeller Assembly Page 11-5 61-10-20 DRAWINGS AND PARTLISTS 2017-10-06...
Page 57 OPERATION AND INSTALLATION MANUAL EN-1320 Item Description Item Description Propeller blade 2.51 Screw De-icer 2.52 O-ring 2.53 2.54 Cotter pin Cylinder 2.55 Screw Piston 2.56 Lock washer Piston extension 2.57 Overspeed governor Piston rod 2.58 O-ring Distance bushing 2.59 Guide ring Distance bushing Spinner dome Pitch change block...
Page 58 EN-1320 OPERATION AND INSTALLATION MANUAL 11.4. AV-844-1-E-C-F-R(G) Figure 11-4: AV-844-1-E-C-F-R(G) Propeller Assembly Page 11-7 61-10-20 DRAWINGS AND PARTLISTS 2017-10-06...
Page 59 OPERATION AND INSTALLATION MANUAL EN-1320 Item Description Item Description Propeller blade Spinner dome Spacer ring Front plate Spinner bulkhead Piston Spinner front plate Guide ring Cover plate Rear fork Rivet Spring guide Selflocking nutplate Guide rod Screw Front fork Washer Pitch change block 3.10 Screw...
Page 60 EN-1320 OPERATION AND INSTALLATION MANUAL 11.5. AV-844-1-E-C-F-R(P) Figure 11-5: AV-844-1-E-C-F-R(P) Propeller Assembly Page 11-9 61-10-20 DRAWINGS AND PARTLISTS 2017-10-06...
Page 61 OPERATION AND INSTALLATION MANUAL EN-1320 Item Description Item Description Propeller blade Spinner dome Spinner bulkhead Front plate Spinner front plate Piston Cover plate Rear fork Rivet Guide rod Selflocking nutplate Front fork Screw Spring guide Washer Washer Screw Pitch change block 3.10 Washer Guide block...
Page 62: Drawings And Partlists
EN-1320 OPERATION AND INSTALLATION MANUAL 11.6. AV-844-1-E-C-F-R(W) Figure 11-6: AV-844-1-E-C-F-R(W) Propeller Assembly Page 11-11 61-10-20 DRAWINGS AND PARTLISTS 2017-10-06...
Page 63 OPERATION AND INSTALLATION MANUAL EN-1320 Item Description Item Description Propeller blade Spinner dome Spinner bulkhead Front plate Spinner front plate Piston Cover plate Piston extension Rivet Guide rod Selflocking nutplate Distance bushing Screw Distance bushing Washer Pitch change block Screw Guide block 3.10 Washer...
Page 64 EN-1320 OPERATION AND INSTALLATION MANUAL 11.7. AV-804-1-E-C-F-R(W) Figure 11-7: AV-804-1-E-C-F-R(W) Propeller Assembly Page 11-13 61-10-20 DRAWINGS AND PARTLISTS 2017-10-06...
Page 65 OPERATION AND INSTALLATION MANUAL EN-1320 Item Description Item Description Propeller blade 2.51 Screw O-ring 2.52 2.53 Cylinder 2.54 Cotter pin Piston 2.55 Screw Piston extension 2.56 Lock washer Piston rod 2.57 Overspeed governor Distance bushing 2.58 O-ring Distance bushing 2.59 Guide ring Pitch change block 2.60...
Page 66 EN-1320 OPERATION AND INSTALLATION MANUAL 11.8. AV-723-1-D-C-F-R(P) Figure 11-8: AV-723-1-D-C-F-R(P) Propeller Assembly Page 11-15 61-10-20 DRAWINGS AND PARTLISTS 2017-10-06...
Page 67 2.42 Weight 2.43 Screw 2.44 Bushing 2.45 2.46 Beta rod 2.47 Spring 2.48 Beta ring 2.49 Piston rod 2.50 Bushing 2.51 2.52 Carbon block assembly Table 11-8: AV-723-1-D-C-F-R(P) Propeller Assembly - Part List Page 11-16 61-10-20 DRAWINGS AND PARTLISTS 2017-10-06...
Page 68 EN-1320 OPERATION AND INSTALLATION MANUAL 12.0. PROPELLER CONTROL SYSTEM 12.1 INTRODUCTION A. General The informations on function, installation, adjustment and testing of Jihostroj governors LUN7815 and/or LUN7816 are only included in this chapter. For information on other propeller governors refer to governor manufacturer’s manual.
Page 69: Propeller Control System (Installation With Jihostroj Lun-Series Governor)
OPERATION AND INSTALLATION MANUAL EN-1320 c) Underspeed Refer to figure 12-1C. The centrifugal force acting on the flyweights is lower than the speeder spring force. The flyweights tilt inward and lower the pilot valve. The pilot valve opens low pitch channel to high pressure channel, blades moves to lower pitch and RPM goes up to onspeed condition.
Page 70 EN-1320 OPERATION AND INSTALLATION MANUAL When the engine condition lever is moved, the outer valve is turned and oil channels are opened. Pressurized oil flows either through low pitch channel or through high pitch channel into the propeller (figure 12-2B). When the propeller reaches required position, the channels are again closed by moving of beta-ring feedback (figure 12-2C).
Page 71 OPERATION AND INSTALLATION MANUAL EN-1320 12.4 GOVERNOR INSTALLATION ON ENGINE A. Propeller Governor LUN7815.02 (1) Inspect the governor for damage. Shallow scratches in the governor housing and tool marks around the mounting bolt areas are only acceptable provided that the governor function is not affected. (2) Verify installation of spring on the lever "Rn"...
Page 72 EN-1320 OPERATION AND INSTALLATION MANUAL Figure 12-4 Governor LUN7815.02 View from engine Figure 12-5 Governor LUN7815.02 View from propeller (6) Remove cotter pin, nut and remove pin from rod "Sv" 65. Then place the rod out from slotted piece "Sv" - see figure 12-4. (7) Secure with suitable manner the rod "Sv"...
Page 73 OPERATION AND INSTALLATION MANUAL EN-1320 NOTE: Install the rod after governor basic adjustment, see section 12.6. (8) With lever "Rn" at maximum RPM stop 15 , verify lever "Bc" travel from basic position up to reverse, when the guideline on the lever with cam is against reverse range on the governor scale. Then move the lever "Bc"...
Page 74 EN-1320 OPERATION AND INSTALLATION MANUAL (17) Use correct and clean packing. Place the governor onto engine gear box. Drive rod gearing must be correctly inserted into the gear box drive. (18) Fix the governor using four bolts (figure 12-7) using suitable wrench. A spring washer is at bolt head and the second washer is inserted into governor flange recess with chamfer facing governor.
Page 75 OPERATION AND INSTALLATION MANUAL EN-1320 Figure 12-8 Connection of LUN7880 and LUN7840 (22) Connect rod from RPM control system to the lever "Rn" (figure 12-3) and secure. (23) Connect the control rod from engine to the lever "Bc" in its basic position (guideline on the lever with cam is aligns with minimum flight pitch guideline on the governor scale and the control lever pin touching the stop 58) - figure12-3 - and secure.
Page 76 EN-1320 OPERATION AND INSTALLATION MANUAL Figure 12-9 Governor LUN7815.03 View to engine Figure 12-10 Governor LUN7815.03 View from engine PROPELLER CONTROL SYSTEM Page 12-9 61-10-20 2017-10-06 (Installation With Jihostroj LUN-Series Governor)
Page 77 OPERATION AND INSTALLATION MANUAL EN-1320 Figure 12-11 Governor LUN7815.03 View from propeller (8) Lubricate the carbon block assembly pins with Aeroshell Grease 5, 6 or 22. WARNING: REMOVE DAMAGED ASSEMBLY FROM OPERATION! (9) Verify function of the microswitch "V" (figure 12-9) by moving lever "Zv" in the direction of arrow (figure 12-10).
Page 78 EN-1320 OPERATION AND INSTALLATION MANUAL CAUTION: CATCH THE BLADES AT ITS SHANK, NEVER AT BLADE TIP. NOTE: It is recommended to move the lever "Rn" to feather stop 16, to facilitate servomechanism movement. (17) Install the carbon block assembly (figure 12-6) onto the lever "Zv" and the beta-ring. Install the washer and safety with cotter pin 1,6x10.
Page 79 OPERATION AND INSTALLATION MANUAL EN-1320 Figure 12-12 Governor LUN7816 View to engine Figure 12-13 Governor LUN7816 View from engine PROPELLER CONTROL SYSTEM Page 12-12 61-10-20 (Installation With Jihostroj LUN-Series Governor) 2017-10-06...
Page 80 EN-1320 OPERATION AND INSTALLATION MANUAL Figure 12-14 Governor LUN7816 View from propeller (12) Try to turn with drive rod. The rod should rotate freely. (13) If the propeller is installed, remove carbon block assembly form lever "Zv" (figure 12-6). CAUTION: DO NOT INSTALL THE GOVERNOR WITH THE CARBON BLOCK ASSEMBLY INSTALLED WHEN THE PROPELLER IS INSTALLED.
Page 81 OPERATION AND INSTALLATION MANUAL EN-1320 b) Make sure that the pipes are loose at the connection to the auxiliary pump LUN7840 and to the valve LUN7880. Otherwise remove the safety wire and loosen the nuts. c) Connect the pipe from the valve LUN7880 to the inlet marked with arrow and lightly tighten the nut. d) Connect the pipe from the auxiliary pump LUN7840 to opposite inlet of the fitting and lightly tighten the nut.
Page 82 EN-1320 OPERATION AND INSTALLATION MANUAL 12.6 BASIC ADJUSTMENT AFTER INSTALLATION ON ENGINE CAUTION: ALL REMOVAL, INSTALLATION AND REPAIR WORKS PUBLISHED IN THIS MANUAL MUST BE PERFORMED BY PERSONNEL WITH APPROPRIATE QUALIFICATION. A. Propeller Governor LUN 7815.(-) (1) Governor adjustment with element 32. (for governors LUN7815.02, LUN7815.03) NOTE: Perform this adjustment with propeller installed.
Page 83 OPERATION AND INSTALLATION MANUAL EN-1320 g) Measure total clearance as follows: Without gage 1531-042 press lightly the carbon block assembly to one side of the beta-ring (figure 12-16) and measure the total clearance using feeler gauge. h) After adjustment and clearance measurement, tighten both nuts of the rod 32 and secure with lock wire. (2) Axial clearance of blocking valve adjustment with element 37 and coupled connection 65.
Page 84 EN-1320 OPERATION AND INSTALLATION MANUAL Figure 12-18 Adjustment of axial clearance of blocking valve Adjust the blades by hand so that the beta-ring protruded from the propeller hub and fix it by appropriate means at distance of 4,5 mm (0.177 inch) from the hub flange. Place the rod "Sv" 65 with yoke onto the gate "Sv"...
Page 85 OPERATION AND INSTALLATION MANUAL EN-1320 (3) BETA-range microswitch adjustment (for governors LUN7815.02, LUN7815.03) a) Energize BETA-range circuit in the aircraft cockpit. NOTE: During adjustment ask another person for assistance in the aircraft cockpit. b) Adjust the setting screw 38 on the lever contacting the microswitch such way, that the microswitch switches on when the pin is 0,8 mm (0.0315 inch) above the cam base 27 (figure 12-20).
Page 86 EN-1320 OPERATION AND INSTALLATION MANUAL HOLD THE BLADES NEAR BLADE SHANK AT TURNING, NEVER AT TIP. 3 Safety the cam 27 after adjustment with the securing screw. NOTE: It is possible to check when the circuit is energized, using power supply (max. 12V) and a suitable lamp connected to connector pins 3 and 4 (figure 12-20).
Page 87 OPERATION AND INSTALLATION MANUAL EN-1320 WARNING: IGNORE OF THE REQUIREMENTS STATED IN TABLE 12-1 CAN RESULT IN PROPELLER OVERSPEEDING ! B. Propeller Governor LUN7816.(-) (1) Governor adjustment with element 32. Perform when: - the propeller is installed - the propeller governor is installed - the engine is installed Adjustment of minimum flight pitch using the governor element 32 after installation on the engine and at propeller reinstallation.
Page 88 EN-1320 OPERATION AND INSTALLATION MANUAL CAUTION: After replacement of lever "Sv" the BETA-range microswitch must be adjusted. e) Adjust the element 32 (rod length) that the clearance between control lever pin and the lever "Sv" corresponds to the dimension "Y". Check the clearance with feeler gauge. CAUTION: SHORTEN THE ROD ONLY INSTALLED ON THE GOVERNOR! DO NOT REMOVE THE ROD AT ANY END!
Page 89 OPERATION AND INSTALLATION MANUAL EN-1320 (2) BETA-range microswitch adjustment Perform when: - the propeller governor is installed - the engine installation a) Energize BETA-range circuit in the aircraft cockpit. NOTE: During adjustment ask another person for assistance in the aircraft cockpit. b) Adjust the setting screw 38 on the lever contacting the microswitch such way, that the microswitch switches on when the pin is 0,8 mm (0.0315 inch) above the cam base 27 (figure 12-20).
Page 90 EN-1320 OPERATION AND INSTALLATION MANUAL HOLD THE BLADES NEAR BLADE SHANK AT TURNING, NEVER AT TIP. 3 Safety the cam 27 after adjustment with the securing screw. NOTE: It is possible to check when the circuit is energized, using power supply (max. 12V) and a suitable lamp connected to connector pins 3 and 4 (figure 12-20).
Page 91 OPERATION AND INSTALLATION MANUAL EN-1320 If the guidelines of the lever and on the scale are not aligned, adjust according to the engine operational manual. NOTE: Verify final adjustment with multiple setting from idle to maximum reverse position and recheck stops. Figure 12-26 Maximum reverse output adjustment –...
Page 92 EN-1320 OPERATION AND INSTALLATION MANUAL 12.7 TESTING A. Propeller Governor LUN7815.(-) (1) Basic adjustment check (only for governor LUN7815.02) a) Disconnect the rod "Sv" 65 from the gate "Sv" - loose and remove nut and remove the pin from the rod fork.
Page 93 OPERATION AND INSTALLATION MANUAL EN-1320 (2) Basic adjustment check (only for governor LUN7815.03) a) Propeller condition lever must be placed in maximum RPM position and then the lever "Rn" must be at maximum RPM stop 15. b) Place the propeller condition lever into the feather position and fix, the lever "Rn" must be at its feather stop 16.
Page 94 EN-1320 OPERATION AND INSTALLATION MANUAL e) Maximum RPM check 1 Propeller control lever in maximum RPM position. 2 Move engine control lever to maximum take-off power position. 3 Maximum ground RPM should be 2080 -120 rpm. NOTE: Specified value for RPM is only for information. It depends on engine performance and atmospheric conditions.
Page 95 OPERATION AND INSTALLATION MANUAL EN-1320 4 „CONTROL FEATHERING“ function check. a Place engine control lever to maximum continuous power position. b Set with propeller control lever propeller speed to 1900 rpm. c Switch on the „FEATHERING“ breaker. d Press „TEST - FEATHERING“ button. e Observe „FEATHERING PUMP“...
Page 96 EN-1320 OPERATION AND INSTALLATION MANUAL c) Purge the propeller control system: 1 Place the engine condition lever into idle position. 2 Move the propeller condition lever into feather position, propeller RPM reduces to ≈350 rpm. 3 Move back the propeller condition lever after about ≈15 s delay to maximum RPM position and wait to previous RPM.
Page 97 OPERATION AND INSTALLATION MANUAL EN-1320 7 Idle RPM must be the same like before. Check of feathering (installation with feathering pump) 1 "AUTOMATIC FEATHERING" check . (only when this function is involved) a Verify "AUTOMATIC FEATHERING" function according to aircraft flight manual. 2 "MANUAL FEATHERING"...
Page 98 EN-1320 OPERATION AND INSTALLATION MANUAL a) Move propeller control lever in cockpit such way, that governor lever “Rn” is not touching maximum RPM stop. b) Loose stop 15 - figure 12-29. c) Loose the nut and adjust the maximum RPM by turning of max. RPM stop screw 15 . Screw-in = decreasing of RPM Screw-out = increasing of RPM One turn (360°) of the stop screw change the RPM approx.
Page 99 OPERATION AND INSTALLATION MANUAL EN-1320 e) Loosen the stop nut on the feathering stop screw 16 (fig. 12-30]. Rotate the screw clockwise 2 to 2.5 turns. The travel of lever “Rn” (fig. 12-30) to feather position will increase. Move propeller control lever easy up to the stop, which is not the stop 16 but blocking valve, to which the pilot valve inside the governor, moved by the lever "Rn", will hit.
Page 100 EN-1320 OPERATION AND INSTALLATION MANUAL (3) Feather position adjustment (for governor LUN7815.03) a) Perform when feathering time is higher than 15s, adjusting is possible by using the stop 16 . b) Remove seal and lock wire from the stop 16 - figure 12-30. c) Move propeller control lever in cockpit to maximum RPM position, the lever "Rn"...
Page 101 OPERATION AND INSTALLATION MANUAL EN-1320 Figure 12-32 Dimension "B" check counterclockwise turning clockwise turning Stop 58 1 turn 0,5 turn 0,5 turn 1 turn RPM change (approximately) Table 12-5 Stop 58 influence onto idle RPM NOTE: Adjusting the stop 58 based on propeller idle speed difference half, reduce the speed at idle of propeller with higher RPM, and increase the speed at idle of propeller with lower RPM.
Page 102 EN-1320 OPERATION AND INSTALLATION MANUAL Figure 12-33 Adjustment using rod 29 n) Use the same procedure for the second governor. o) Secure the stops 58 for both governors. p) Record works in governor documentations. B. Propeller Governor LUN7816.(-) (1) Maximum RPM adjustment To be performed: after control flight Perform maximum RPM adjustment according to procedure in section 12.8.
Page 103 OPERATION AND INSTALLATION MANUAL EN-1320 12.9 TROUBLESHOOTING Trouble: Relief valve leakage (after pressure adjustment). Probably cause: a) Defective sealing. b) Loose valve. Remedy: a) See section Maintenance practices. b) See section Maintenance practices. Trouble: Non-return valve with fitting leakage Probably cause: a) Defective sealing.
Page 104 EN-1320 OPERATION AND INSTALLATION MANUAL 12.10 MAINTENANCE PRACTICES There are described maintenance practices in this section together for all governor models LUN7815 and LUN7816, if no other note applied. (1) Cleaning DO NOT USE PRESSURE WASHING EQUIPMENT. PRESSURE WASHING CAN FORCE WATER AND/OR CLEANING SOLVENTS INTO THE GOVERNOR, WHICH CAN LEAD TO CORROSION OF INTERNAL COMPONENTS AND/OR INCORRECT FUNCTION.
Page 105 OPERATION AND INSTALLATION MANUAL EN-1320 Propeller rpm Pressure 2,30 - 2,45 MPa (333,6 - 355,3 psi) 2080 2060 2,28 - 2,43 MPa (330,7 - 352,4 psi) 2040 2,27 - 2,42 MPa (329,2 - 351,0 psi) 2020 2,25 - 2,40 MPa (326,3 - 348,1 psi) 2000 2,23 - 2,38 MPa (323,4 - 345,2 psi) Table 12-6 Pressure for LUN7815.02...
Page 106 EN-1320 OPERATION AND INSTALLATION MANUAL In the case, that the pressure will be adjusted using sealing washers - element 76 - under the cover, then adding/removing of a washer will reduce/increase the pressure. Washer thickness of 1 mm (0.04 inch) means pressure change as for the element 73, see above.
Page 107 OPERATION AND INSTALLATION MANUAL EN-1320 Install new sealing rings 89 onto the turning screw 78 and the feedback body 45 with ring 88 in position shown, it is arrow up – figure 12-36 – and screw the turning screw into the governor body without final tightening.
Page 108 EN-1320 OPERATION AND INSTALLATION MANUAL CAUTION: BE CAREFUL NOT TO LOSE THE 5/16 BALL [92, FIG. 12-37]. IT FITS INSIDE FITTING [44, FIG.12-37] AND MUST BE IN PLACE PRIOR TO REASSEMBLY. Reinstall both fittings 44 and 46 and tighten (be careful with ball 92). Connect tube 86 from the feathering pump LUN7840-8 (if installed) to the fitting 44 and tighten cap nuts on both ends.
Page 109 OPERATION AND INSTALLATION MANUAL EN-1320 WARNING: TAKE CARE WHEN THE SURFACE IS CLEANED TO DON’T ENTER CLEANER INTO THE GOVERNOR THROUGH GOVERNOR FLANGE, AROUND COAXIAL VALVES 18, 19, LOCKING VALVE 35 AND INTO THE MICROSWITCH HOUSING 23. DON’T DEGREASE ROD BEARINGS 29, 32 AND 65, LEVER "Sv"...
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