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WOODCOMP KW-30 Technical Manual

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This organizational standard is intellectual property of Woodcomp Propellers s. r. o.
Any form of distribution without permission of company management is prohibited.
TECHNICAL MANUAL
KW-30 PROPELLER
OVERHAUL AND MEDIUM REPAIR
Position
Technologist
Quality Manager
Responsible Manager
21.01.2014
TN – 2 1
Name
Oldřich Ritter
Ing. Václav Matoušek
Aleš Křemen
Signature
Copy Number

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  • Page 1 Ing. Václav Matoušek Checked by Quality Manager Aleš Křemen Approved by Responsible Manager Valid from: 21.01.2014 Copy Number This organizational standard is intellectual property of Woodcomp Propellers s. r. o. Any form of distribution without permission of company management is prohibited.

  • Page 2: Table Of Contents

    OVERHAUL AND MEDIUM REPAIR OF KW-30 PROPELLER TN-21 A. GENERAL A1. Contents GENERAL ............................2 A1. Contents ................................2 A2. Revision history ..............................4 A3. List of valid pages .............................. 5 A4. Purpose of the document ..........................6 A5. Validity ................................6 A6.
  • Page 3 OVERHAUL AND MEDIUM REPAIR OF KW-30 PROPELLER TN-21 C14. Overview of tightening torques ......................50 C15. Overview of marked places......................... 50 CERTIFICATE OF RELEASE BY AUTHORIZED PERSON ..........51 STORAGE AND PACKAGING OF COMPLETE PROPELLERS ......... 51 E1. Storage ................................51 E2.

  • Page 4: A2. Revision History

    OVERHAUL AND MEDIUM REPAIR OF KW-30 PROPELLER TN-21 A2. Revision history Revision Date Description Changed pages Z-KW-3(x)-01 Technical change Change of minimum pitch blocking 2- 6, 9, 17, 20, 32, 41, 54, 11.08.2014 Addition of minimum pitch stop 57, 58, 60, 63...

  • Page 5: A3. List Of Valid Pages

    OVERHAUL AND MEDIUM REPAIR OF KW-30 PROPELLER TN-21 A3. List of valid pages Page Revision Date Page Revision Date Page Revision Date 21.01.2014 07.11.2024 07.11.2024 07.11.2024 07.11.2024 07.11.2024 07.11.2024 07.11.2024 07.11.2024 07.11.2024 07.11.2024 07.11.2024 07.11.2024 07.11.2024 07.11.2024 07.11.2024 07.11.2024 07.11.2024 07.11.2024...

  • Page 6: A4. Purpose Of The Document

    KW-30 propeller overhaul or other maintenance in Woodcomp Propellers s.r.o. or manufacturer’s authorized service centers. This document is based on current version of KW-30 propeller’s documentation, as well as the state of knowledge and practical experience from production and operation of the type. This document may be amended based on information newly obtained during manufacturing and operation of manufactured propellers.

  • Page 7: A7. Basic Rules

    TN-21 A7. Basic rules Overhaul must be performed according to current versions of KW-30 documentation. All assembly, adjustment and inspection procedures must be performed by personnel with required qualification. These activities may only be performed in enclosed facilities using clean, undamaged tools and equipment approved for the purpose.

  • Page 8: Basic Technical Parameters Of Kw-30

    The propeller is intended for aircraft's MTOM up to 2000kg (ELA 2), with piston engines equipped with reduction gear. KW-30 is three-blade, hydro mechanical, in-flight adjustable propeller, working as constant speed propeller with fitted hydraulic governor. The propeller is fitted onto engine flange using 6 studs. Oil supply from engine into piston chamber is through hollow shaft.

  • Page 9: B2. Basic Technical Data Of Propeller

    OVERHAUL AND MEDIUM REPAIR OF KW-30 PROPELLER TN-21 B2. Basic technical data of propeller Propeller model KW-30 Number of blades installed - 031 - 033 - 034 - 037 - 038 -041 Blade type („W“) („C“) („B“) (“WA”) (“WA”) (“G”) Right:1744 Diameter ±...

  • Page 10: Overhaul

    OVERHAUL AND MEDIUM REPAIR OF KW-30 PROPELLER TN-21 C. OVERHAUL C1. Propeller admission On admission, exterior visual check of the propeller is performed, including completeness check as well as discovery of possible damage during transport. Complete propeller, with the spinner, bushings, and nuts used for mounting, must be delivered to the service facility.

  • Page 11: C3. Disassembly Of Propeller

    OVERHAUL AND MEDIUM REPAIR OF KW-30 PROPELLER TN-21 C3. Disassembly of propeller C 3.1 Propeller disassembly C 3.1.1 Propeller spinner removal 1) Use flat screwdriver to remove screws (42) around the perimeter of propeller spinner (39). Remove propeller spinner by pulling away from propeller.

  • Page 12: C 3.3 Propeller Blade Disassembly

    OVERHAUL AND MEDIUM REPAIR OF KW-30 PROPELLER TN-21 6) Use 7mm wrench to loosen piston rod 2 (9) and screw it out of the hub. 7) In center of piston (17) inside cylinder bore, unlock locking washer (21) around hex. head screw (22).
  • Page 13 OVERHAUL AND MEDIUM REPAIR OF KW-30 PROPELLER TN-21 Complete disassembly 1) Use retaining ring pliers to remove retaining ring (25) from propeller blade actuating pin. Remove slider (26) from pin. 2) Remove parts (29) and (30) of axial bearing from front face of ferrule.
  • Page 14 OVERHAUL AND MEDIUM REPAIR OF KW-30 PROPELLER TN-21 Partial disassembly 1) Use circlip pliers to remove the retaining ring (25) from the propeller blade pin. Remove the slider (26) from the pin. 2) Remove the thrust bearing parts (29) and (30) from the front of the blade ferrule.
  • Page 15 OVERHAUL AND MEDIUM REPAIR OF KW-30 PROPELLER TN-21 Page left intentionally blank Page 15 Date of issue: 07.11.2024 Revision 6...

  • Page 16: C4. Cleaning

    OVERHAUL AND MEDIUM REPAIR OF KW-30 PROPELLER TN-21 C4. Cleaning 1) Remove dirt, grease and oil from all disassembled parts of propeller. 2) Use benzine or equivalent (see chapter J. MATERIAL USED) for cleaning metal parts 3) Clean nonmetallic parts by wiping with a soft, lintfree cloth dampened with benzine equivalent (see chapter J.

  • Page 17: C5. Inspection

    OVERHAUL AND MEDIUM REPAIR OF KW-30 PROPELLER TN-21 C5. Inspection C 5.1 General 1) Visually check parts for cracks, scratches, dents, wear, corrosion, or signs starting corrosion. Repair minor damages according to chapter "Permitted repairs". 2) Check condition of fasteners. Elongation or stripping of threads, elongation/ bending of screw bodies, damage to screw heads, damaged surface treatment or occurrence of corrosion are not permitted C 5.2 Detailed Part Inspection...
  • Page 18 OVERHAUL AND MEDIUM REPAIR OF KW-30 PROPELLER TN-21 C 5.2.4 Spring housing (5) with bushing (2) 1) Check spring housing (5) with bushing (2). Check for damage, corrosion and dents caused by spring (6) on internal surface. Bushing (2) – check condition of hole Ø 12; it must not be step-bored (caused by piston rod 2 (9)) and its diameter must not be over 12.06mm.
  • Page 19 OVERHAUL AND MEDIUM REPAIR OF KW-30 PROPELLER TN-21 Diameter 81,35 B-1138-00 -0,05 81,40 B-1139-00 -0,05 81,45 B-1140-00 -0,05 81,50 B-1141-00 -0,05 Tab. C-3 Oversized pistons C 5.2.9 Back cover (24) 1) Check that cover is undamaged, focus on o-ring groove and chamfer on inner diameter (sealing surfaces).
  • Page 20 OVERHAUL AND MEDIUM REPAIR OF KW-30 PROPELLER TN-21 2) Perform thorough visual check of rolling elements. Rolling needles must not have peeled-out spots nor bigger local indentations – these could later develop into pitting and crater wear of needle material.
  • Page 21 OVERHAUL AND MEDIUM REPAIR OF KW-30 PROPELLER TN-21 Maximum repairable surface area of single damaged spot must not exceed 2cm . Repairs of damages are permitted in gelcoat or composite layers only if they did not penetrate to the wooden blade core; otherwise, the blade must be discarded.

  • Page 22: C 5.3 Non-Destructive Tests

    OVERHAUL AND MEDIUM REPAIR OF KW-30 PROPELLER TN-21 are permitted; any sharp edges could be starting points of growing defects. No punctures or cracks are permitted, on entire length of leading edge. The leading edge must fully adhere to blade, and no gap between stainless strip edge and blade surface is permitted.
  • Page 23 OVERHAUL AND MEDIUM REPAIR OF KW-30 PROPELLER TN-21 Page left intentionally blank Page 23 Date of issue: 07.11.2024 Revision 6...

  • Page 24: C6. Replacement

    OVERHAUL AND MEDIUM REPAIR OF KW-30 PROPELLER TN-21 C6. Replacement 1) Replace parts with cracks 2) Replace heavily damaged parts (deep scratches or dents, with heavy or in–depth corrosion) . 3) Replace worn, damaged or corroding bearings and bushings. 4) Replace worn, damaged or corroding fasteners.

  • Page 25: C7. Permitted Repairs

    OVERHAUL AND MEDIUM REPAIR OF KW-30 PROPELLER TN-21 C7. Permitted repairs C 7.1 Surface protection 1) It is permitted to repair small area defects, < 2cm which only affect the surface (damaged edges, beveled edges, various scratches, scorching, etc.). Larger damage, corrosion at multiple locations – replacement with new parts.
  • Page 26 OVERHAUL AND MEDIUM REPAIR OF KW-30 PROPELLER TN-21 C 7.2.3 Spring housing (5) with bushing (2) 1) If spring housing (5) is undamaged but bushing (2) is enlarged and exceeds allowed wear parameters replace the bushing. Insert the assembly into the P-481 jig (Fig. C-5) and put it under the bench press.
  • Page 27 OVERHAUL AND MEDIUM REPAIR OF KW-30 PROPELLER TN-21 Use small round file to file-out deformed area of thread. Create smooth transition between repaired and undamaged area. Remove all file marks using fine sandpaper or scotch-brite. Clean all filing and sanding debris and check repaired thread using P-288 gauge. The gauge must be easy to screw into hub, using hand force only.
  • Page 28 OVERHAUL AND MEDIUM REPAIR OF KW-30 PROPELLER TN-21 Fig. C-6 Blade ferrule repair 2) Actuating pin replacement Carefully unscrew the pin using small adjustable pliers by grasping its Ø8 part. Clean the threaded hole using M10 tap; remove all traces of glue.
  • Page 29 OVERHAUL AND MEDIUM REPAIR OF KW-30 PROPELLER TN-21 Sand surface with 100 grit and then with 250 grit sandpaper. Protect unpainted areas using masking tape. Remove dust from painted area and degrease with acetone or MEK. Repaint area with 2K acrylic paint.
  • Page 30 OVERHAUL AND MEDIUM REPAIR OF KW-30 PROPELLER TN-21 Apply tape to prepared blade surface(Fig. C-10). Use plastic spatula to force out air bubbles, or puncture the tape by a pin, and press out air using a roller or finger pressure. Do not use a blade or razor to cut the tape!! Fig.

  • Page 31: C8. Reassembly Of Propeller

    OVERHAUL AND MEDIUM REPAIR OF KW-30 PROPELLER TN-21 C8. Reassembly of propeller C 8.1 Reassembly of propeller blades ! CAUTION ! If the parts were not replaced, assemble the same blade ferrule (32), (83) and other retention parts with the same blade (38), (84) from which they were removed.
  • Page 32 OVERHAUL AND MEDIUM REPAIR OF KW-30 PROPELLER TN-21 14) Protect propeller blade ferrule with assembled parts by winding protective tape upon it, or use plastic pouch to prevent damage until reassembly into propeller hub. Use protective sheath on blade. Fig. C-11 Position of blade actuating pin...

  • Page 33: C 8.2 Reassembly Of Propeller Hub

    OVERHAUL AND MEDIUM REPAIR OF KW-30 PROPELLER TN-21 C 8.2 Reassembly of propeller hub C 8.2.1 Reassembly of yoke 1) Insert inserts(12) into grooves in yoke(11), align holes for screws, and thread-in screws (13). Use 4mm Allen key to tighten the screws.
  • Page 34 OVERHAUL AND MEDIUM REPAIR OF KW-30 PROPELLER TN-21 7) Apply few drops of Loctite 243 into internal M10 thread of piston rod 2 (9). Insert internal-threaded part of piston rod 2 ( 9) into Ø19mm hole in front side of hub, and use hand force to seat into piston rod 1. Tighten piston rod 2 using torque wrench set to 15Nm, with 7mm bit.
  • Page 35 OVERHAUL AND MEDIUM REPAIR OF KW-30 PROPELLER TN-21 12) Thread locking washer ( 21) onto screw ( 22) so that its locking tab faces head of screw. Thread O-ring (20) lubricated with engine oil onto screw. Apply Loctite 243 to last three threads of screw (22) and insert it into piston center bore.

  • Page 36: C 8.3 Installation And Adjustment Of Propeller Blades

    OVERHAUL AND MEDIUM REPAIR OF KW-30 PROPELLER TN-21 C 8.3 Installation and adjustment of propeller blades 1) Install reassembled propeller blades one after another into reassembled hub. Numerals 1, 2, and 3 stamped in front face of hub are blade number. First of all, install blade 1 into position 1.
  • Page 37 OVERHAUL AND MEDIUM REPAIR OF KW-30 PROPELLER TN-21 Fig. C-17 Slider measurement and marking 4) Try to insert sliders into groove in yoke. Slider without lubrication must easily move within groove, without noticeable free play. Use 0.05mm feeler gauge to check free play between all sliders and yoke. Feeler gauge must not fit between slider and yoke.
  • Page 38 OVERHAUL AND MEDIUM REPAIR OF KW-30 PROPELLER TN-21 10) Attach pitch angle laser indicator P-307 onto blade. Hold electronic protractor to bottom side of indicator, and read out pitch angle of propeller blade at reference diameter. Adjust Angle scale P-370 so that value indicated by laser corresponds to value measured with protractor.
  • Page 39 OVERHAUL AND MEDIUM REPAIR OF KW-30 PROPELLER TN-21 If measured angle deviation is negative, new slider must have thicker wall. To correct bigger deviations, install sliders manufactured with 0,1mm, 0,2mm or 0,3mm eccentricity. Mark selected new slider at both edges of selected (measured) side using black permanent marker, check its free play in yoke according to step 4 and grind it if needed.
  • Page 40 OVERHAUL AND MEDIUM REPAIR OF KW-30 PROPELLER TN-21 Engine Blade type Blade angle (degrees) Low pitch High pitch 15,0 35,0 Rotax 912 28,5 (80 HP) 10,0 30,0 10,0 37,0 17,0 37,0 Rotax 912 S 10,0 30,0 (100 HP) 12,0 32,0...
  • Page 41 OVERHAUL AND MEDIUM REPAIR OF KW-30 PROPELLER TN-21 Fig. C-19 Securing of retention nut by Loctite 243 (upper) and wire (lower) Fig. C-20 TORQUE SEAL application 30) If blades are equipped with counterweights (80) install them to the position measured before disassembly.

  • Page 42: C9. Leak Check

    OVERHAUL AND MEDIUM REPAIR OF KW-30 PROPELLER TN-21 C9. Leak check Leak checks are to be performed during assembly, after specific operations, as described in assembly instruction. Acceptance criteria are the same during all tests. Tests are performed to detect possible leak during assembly, so that detected leak can be repaired in time.

  • Page 43: C10. Accessorization Of Propeller

    OVERHAUL AND MEDIUM REPAIR OF KW-30 PROPELLER TN-21 C10. Accessorization of propeller C 10.1 Installation of spinner 1) Position the propeller, front face down, onto assembly support P-306. 2) Set backplate assembly (41) onto rear face of propeller hub. Position backplate so that red dot on external surface and numeral 1 on inside surface points towards blade 1.

  • Page 44: C11. Balance

    OVERHAUL AND MEDIUM REPAIR OF KW-30 PROPELLER TN-21 C11. Balance C 11.1 Static balance 1) Install propeller onto flange of balance machine ZZ–01. 2) Rotate propeller slowly and wait until it stops. Uppermost location is the lightest one. 3) Attach smaller piece of modeling clay under this location, onto rear wall of backplate, approximately 15–...

  • Page 45: C 11.2 Dynamic Balance

    OVERHAUL AND MEDIUM REPAIR OF KW-30 PROPELLER TN-21 it is possible to select different length of screw (59), or use washer(s) (58) under screw head. Screw threads must not protrude from brass weight including washer(s) more than 14mm, otherwise, thread in hub could be damaged.

  • Page 46: C12. Propeller Measurement

    OVERHAUL AND MEDIUM REPAIR OF KW-30 PROPELLER TN-21 C12. Propeller measurement Perform measurement during installation of propeller blades, recording results into assembly and measurement protocol. Propeller measurement is performed in inspection fixture P-07. Measurement of diameter of propeller and difference in radial blade tip position C 12.1...

  • Page 47: C 12.2 Measurement Of Angular Separation Of The Blades

    OVERHAUL AND MEDIUM REPAIR OF KW-30 PROPELLER TN-21 C 12.2 Measurement of angular separation of the blades. 1) Mark centre of the blade tip using template P-322, 323 or 324 (depending on blade type) . 2) Measure angular separation of blades (Fig. C-24). Permitted tolerance is 120º ± 30´...

  • Page 48: C 12.6 Weighing Of Propeller

    OVERHAUL AND MEDIUM REPAIR OF KW-30 PROPELLER TN-21 Fig. C-27 Blade angular play C 12.6 Weighing of propeller 1) Propeller weight in kilograms with double decimal precision is determined using scale with valid calibration. 2) Propeller is weighed as completely accessorized final product, including mounting hardware (bushings, nuts, spacer.

  • Page 49: C13. Application Of Identification Labels

    OVERHAUL AND MEDIUM REPAIR OF KW-30 PROPELLER TN-21 C13. Application of identification labels Propeller type label is applied onto root of blade No. 1. Fig. C-28 Propeller label Where: TCDS – Type certificate designation (EASA.P.177) Model – Propeller model KW-30 –...

  • Page 50: C14. Overview Of Tightening Torques

    OVERHAUL AND MEDIUM REPAIR OF KW-30 PROPELLER TN-21 C14. Overview of tightening torques Torques listed below are for clean, dry, and undamaged thread. Application of these torques to lubricated threads may lead to damage. Position Part name Part number Torque Screw B–1014–01...

  • Page 51: Certificate Of Release By Authorized Person

    OVERHAUL AND MEDIUM REPAIR OF KW-30 PROPELLER TN-21 D. CERTIFICATE OF RELEASE BY AUTHORIZED PERSON Propellers type-certified by European Aviation Safety Agency (EASA) or national Aviation Authority (ÚCL, LÚ SR) are released by authorized person, using product release procedure and issuing F1 EASA form to certify that the product was manufactured in line with approved or applicable documentation, and that it is suitable for safe operation.

  • Page 52: Work Safety, Ecology

    OVERHAUL AND MEDIUM REPAIR OF KW-30 PROPELLER TN-21 F. WORK SAFETY, ECOLOGY F1. Work safety 1) Each maintenance person bears responsibility for observing safety rules and working procedures at workplace. 2) Some operations performed during propeller repairs require use of PPE and safe working procedures.

  • Page 53: List Of Propeller Parts

    OVERHAUL AND MEDIUM REPAIR OF KW-30 PROPELLER TN-21 G. LIST OF PROPELLER PARTS G1. Illustrated part list Fig. G-1 Propeller Assembly Part 1. Fig. G-2 Propeller Assembly Part 2 Page 53 Date of issue: 07.11.2024 Revision 6...
  • Page 54 OVERHAUL AND MEDIUM REPAIR OF KW-30 PROPELLER TN-21 Fig. G-3 Propeller Assembly Part 3 Fig. G-4 Propeller Assembly Part 4 - blade C, W before change Z-KW-3(x)-03. Fig. G-5 Propeller Assembly Part 5 - blade C, W after change Z-KW-3(x)-03 and G after change Z-KW-3(x)-07.
  • Page 55 OVERHAUL AND MEDIUM REPAIR OF KW-30 PROPELLER TN-21 Fig. G-6 Propeller Assembly Part 6 - blade B, WA. Fig. G-7 Propeller Assembly Part 7 Fig. G-8 Propeller Assembly Part 8 - spacer (optional) Page 55 Date of issue: 07.11.2024 Revision 6...
  • Page 56 OVERHAUL AND MEDIUM REPAIR OF KW-30 PROPELLER TN-21 Fig. G-9 Propeller Assembly Part 9 - spacer (optional) Fig. G-10 Blade type identification Page 56 Date of issue: 07.11.2024 Revision 6...

  • Page 57: G2. Part List

    OVERHAUL AND MEDIUM REPAIR OF KW-30 PROPELLER TN-21 G2. Part list The complete list of parts is contained in the illustrated catalog IPC KW-30 as amended. The numbering of the positions of the individual parts is the same as in this catalog. Page 57 Date of issue: 07.11.2024...

  • Page 58: Parts Due To Mandatory Replacement

    OVERHAUL AND MEDIUM REPAIR OF KW-30 PROPELLER TN-21 H. PARTS DUE TO MANDATORY REPLACEMENT Index Part number Part name A-1009-05 Self-locking nut A-1001-02 Screw A-1025-02 Spring washer A-1005-01 Screw A-1005-02 Screw A-1005-03 Screw A-1005-04 Screw A-1005-05 Screw A-1005-06 Screw A-1005-07...

  • Page 59: List Of Special Tools

    OVERHAUL AND MEDIUM REPAIR OF KW-30 PROPELLER TN-21 I. LIST OF SPECIAL TOOLS Number Name Note P-07 Inspection fixture P-47 Pressure test fixture P-54 Assembly fixture stand P-285 Blade gauge W (170 mm) P-286 Blade gauge C (210 mm) P-287...

  • Page 60: Material Used

    OVERHAUL AND MEDIUM REPAIR OF KW-30 PROPELLER TN-21 J. MATERIAL USED Materials not mentioned in part list, whose consumption is not precisely specified. Equivalents may be used if listed materials are not available. In such cases, equivalence must be demonstrated and approved.

  • Page 61: Medium Repair

    OVERHAUL AND MEDIUM REPAIR OF KW-30 PROPELLER TN-21 K. MEDIUM REPAIR K1. Time before medium repair Medium repair is periodical disassembly, inspection, refurbishment, and reassembly of complete propeller, which is carried out in the event that the maintenance of the propeller is carried out by a maintenance system with medium repair as allowed by SB 01 in the current wording.

  • Page 62: K 3.3 Blade Disassembly

    OVERHAUL AND MEDIUM REPAIR OF KW-30 PROPELLER TN-21 K 3.3 Blade disassembly Do not remove screws (37), blade ferrule and subsequent parts threaded onto blade ferrule. Full scope of disassembly is due only when excess free play of blades in propeller hub is discovered.

  • Page 63: Annex 1: Findings Sheet Example

    OVERHAUL AND MEDIUM REPAIR OF KW-30 PROPELLER TN-21 ANNEX 1: FINDINGS SHEET EXAMPLE Serial Propeller designation Work order number Type of maintenance PARTS IDENTIFICATION Type Blade No.1 Blade No.2 Blade No.3 Spacer Spinner MEASUREMENTS Nominal value Measured value Propeller diameter (± 4 mm) Max.

  • Page 64: Annex 2: Assembly And Measuremet Sheet Example

    OVERHAUL AND MEDIUM REPAIR OF KW-30 PROPELLER TN-21 ANNEX 2: ASSEMBLY AND MEASUREMET SHEET EXAMPLE Propeller Serial Work order designation number ASSEMBLY SHEET Type Blade No.1 Blade No.2 Blade No.3 Spacer Spinner MEASUREMENT SHEET Nominal value Measured value Propeller diameter (± 4 mm) Max.

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