VARIO Propeller

Operator’s manual

REV 2
07th July 2017
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pipistrel.si VARIO propeller manual 3
Rev. 2

Index of revisions
Enter and sign the list of revised pages in the manual into the spaces provided below. All revised pages
should be clearly designated in the upper corner of the page, also, any changes in page content should
be clearly visible (e.g. marked with a bold vertical line)

Name of Rev. No. Signature

Description
revision & date & date

1 17th July 2015 Tomazic Adjusted overhaul interval, page 19.

2 07th July, 2017 A. B. Horvat ALL

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pipistrel.si VARIO propeller manual 5
Rev. 2

List of valid pages

This manual contains 19 original and revised pages listed below.

Pages State:
Cover Revised
Page numbering Revised
Index of revised pages 3 Revised
List of valid pages 5 Revised
Table of contents 7 Revised
General 9 - 12 Revised
Handling and maintenance 13 - 18 Revised
Back Cover 19 Revised

Caution:
This manual is valid only if it contains all of the original and revised pages listed above.

Each page to be revised must be removed, shredded and later replaced with the new, revised page in
the exact same place in the manual.
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Rev. 2

Table of contents
General

Handling and maintenance

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General Rev. 2

General
Introduction

Notes and remarks

Propeller description

Manufacturing method

Technical data and

operational limitations

3D view of propeller
 10 VARIO propeller manual pipistrel.si
Rev. 2 General

Introduction
This manual contains all information needed for appropriate and safe use of Pipistrel VARIO pro-
peller.

In case of aircraft damage or people injury resulting form disobeying the instructions in the
manual PIPISTREL d.o.o. Ajdovščina denies any responsibility.

All text, design, layout and graphics are owned by PIPISTREL d.o.o. Ajdovščina .Therefore this
manual and any of its contents may not be copied or distributed in any manner (electronic,
web or printed) without the prior consent of PIPISTREL d.o.o. Ajdovščina.

IT IS MANDATORY TO CAREFULLY STUDY THIS MANUAL PRIOR TO USE

OF PROPELLER

Notes and remarks

Safety definitions used in the manual:

WARNING! Disregarding the following instructions leads to severe deterioration of flight

safety and hazardous situations, including such resulting in injury and loss of life.

CAUTION! Disregarding the following instructions leads to serious deterioration of flight

safety.

Propeller description
The Pipistrel VARIO propeller is a variable pitch propeller for Ultralight and Experimental aircrafts. The
VARIO propeller may be used as both, push or pull-type propeller and therefore suits all aircraft con-
struction types.

Propeller pitch may easily be adjusted in flight (see chapter “Handling and maintenance”) to achieve
maximum efficiency for every flight stage and type of operation.

WARNING! The Pipistrel VARIO propeller does not comply with ICAO rules and regulations and
is therefore used at one’s own responsibility.

CAUTION! Always fly in such a manner that you are able to reach at least one landing-out
site every moment of the flight. This especially applies to unpowered flight as ignition, en-
gine and/or propeller malfunction may prevent you from restarting the engine and resum-
ing normal powered flight.
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General Rev. 2

Manufacturing method
The VARIO propeller’s outer skin and inside parts are made of composite materials, namely
fibre reinforced plastic. The blade’s base is made of aluminium and stainless steel tube, which
lies within to ensure blade’s safe attachment to the propeller base (hub).

The propeller base (hub) is made of an aluminium alloy and features monolite construction.
Inside, all parts are made of metal alloys.

To achieve highest levels of propulsion and efficiency combined with low noise output the
manufacturer recommends a spinner to be mounted.

Technical data and operational limitations

Specifications VARIO for R503 VARIO for R912
Number of blades 2 2
Propeller diameter 1620 mm 1620 mm
Propeller pitch at 3/4 of prop. radius 19° - 88° 24° - 93°
Propeller pitch range w/o. feathering 19° - 33° 24° - 38°
Blade width 117 mm
Maximum safe propeller RPM 2550 RPM
Maximum safe engine power (permanent load) 75kW (100 HP)
Central hole diameter 1’’ (25,4 mm)
Propeller head (hub) bolts & nuts type M8
Mounting flange diameter 75 mm
Propeller bolt torque 25 NM

3D view of VARIO propeller

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Handling and maintenance Rev. 2

Handling and maintenance

Introduction

Delivery

Propeller pitch

Daily check-up

VARIO propeller operation

Overhauls & maintenance

Repairs

Ground handling
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Rev. 2 Handling and maintenance

Introduction
This chapter provides information on handling and maintenance of the Pipistrel VARIO propeller.

Delivery
The VARIO propeller comes pre-assembled and mounted onto the aircraft you own. Should you desire
to mount the VARIO propeller onto an aircraft, which does not ship with VARIO propeller, contact the
manufacturer for further details.

WARNING! Only the manufacturer and/or authorised service personnel are allowed to assem-
ble or disassemble the propeller unit due to the complexity of operation. Under no circumstances
attempt to mount, detach or inspect the internals of the unit yourself!

Propeller pitch
The propeller pitch is regarded as the angle of attack of the propellers profile and cannot be
measured anywhere along the propeller chord directly.

For aircraft that ship fitted with the VARIO propeller check the POH and maintenance manual
for reference and recommended propeller pitch settings.

Daily check-up
Perform as follows:

Grab the propeller blades. Gently rock the blades towards the engine and back again to verify
there is no free play.

Rotate one blade and make sure the adjacent blade rotates properly as well. The pitch move-
ments must be smooth and undisturbed.

Check for greasy spots on the blades and wipe them off using a soft piece of cloth.

Check the spring (located in the engine area) for firmness, proper setting and condition (not
deformed!).

Also check:

blades’ surface: clean, no cracks, no paint and/or edge separations

blade’s base - no damage, cracks, paint and/or edge separations
propeller base (visible part) - intact

WARNING! Should the propeller not pass the daily check-up as stated above, flying may
result in further damage and/or injury, including loss of life.
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Handling and maintenance Rev. 2

VARIO propeller operation

(setting propeller pitch)

Decreasing propeller pitch Increasing propeller pitch

The screw in the middle of the knob indicates propeller pitch status. The screw is deep
inside the knob when at minimum pitch and slides out as propeller pitch is increased.

When taking-off, make sure propeller is set to minimum pitch to ensure maximum engine
efficiency. To set the propeller to minimum pitch, rotate the propeller pitch knob located on
the instrument panel counter clockwise until it is loose. Prior to taking-off, engine and pro-
peller ground check must be performed. At full power and pitch at minimum, RPM must not
exceed designated limits. Verify also, that the RPM drop caused by setting the pitch to maxi-
mum (not feathered!) does not exceed 400 RPM.

CAUTION! Verify RPM and engine parameters multiple times.

If propeller pitch is increased (rotate knob clockwise), engine’s RPM will drop. Do not, under
any circumstances, allow engine underrotation. Should this occur, immediately decrease
prop. pitch to regain proper engine cruise parameters.

WARNING! Both engine under- and overrotation may cause significant damage to the
engine and propeller.
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Rev. 2 Handling and maintenance

VARIO propeller operation

(setting propeller to feather)

20 o

Propeller feathering Secure feathered position

WARNING! Feather the propeller only after the engine has completely stopped.

To feather the propeller, first reduce the airspeed to 90 km/h, then pull the propeller pitch
knobs base backwards fully (away from the instrument panel) and then rotate the knob 20°
clockwise. An average propeller pitch of approximately 90° is reached.

Propeller Unfeathering
To unfeather the propeller, first reduce the airspeed to 50 knots. Now pull the propeller pitch
knobs base slightly, then rotate the knob counter clockwise and gently push it all the way to
the instrument panel.

WARNING! Do not, under any circumstances, attempt to restart the engine while the pro-
peller is feathered. This could result in engine, propeller and/or aircraft’s structural damage.

Avoiding damage
On the ground, keep your propeller in the absolute best condition by fitting the propeller cov-
ers onto the blades. Also, try to keep your propeller out of the sun if possible to reduce even-
tual damage caused by UV radiation.

When starting-up the engine, always make sure the space around the propeller is clear. Don’t
try to start and rev the engine on gravel surfaces.

Do not ever attempt to land on a runway covered by deep water patches for that can result in
undercarriage and/or propeller damage.
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Handling and maintenance Rev. 2

Do not ever attempt to taxi through dense high grass for this causes propeller damage.

Be extremely careful when putting the aircraft into or out of the hangar not to damage the
blades.

Do not ever attempt to move around your aircraft by pushing or pulling it at the propeller.

Overhauls & maintenance

Follow the maintenence schedule prescribed within the aircraft MM. Overhauls must be done
by the manufacturer or appointed service center once every 1000 flight hours.

Maximum life span of the propeller

Other than checks every 1000 hours by the manufacturer or service center there is no known
life limit to the propeller.

Repairs
Small damage (cracks) in the paint layer of the blades may be repaired by the owner him/her-
self using dabbing lacquer.

Should the blades be damaged during transportation and/or hangaring the individual blades
can be replaced and the propeller dynamically balanced.

All damage which occurs during engine operation requires the entire power plant and propel-
ler to be verified for structural damage by authorised service personnel.

New replacement blades are available for a reasonable price. The manufacturer recommends
blade replacement in the event of extensive damage. However, should you desire to repair the
damage yourself from whatever reason, you should ONLY use “Schoiffler” epoxy hardener of
38% durability together with “Interglas” fiber rowing of 180 and 280 g/m2 density.

WARNING!
After every repair job, the propeller must be dynamically balanced to prevent potentially
lethal vibrations and further damage.

Paint jobs
Should you desire to repaint your propeller, please consult with the manufacturer prior to
painting.
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Rev. 2 Handling and maintenance

Ground handling
Only use pure water and a soft piece of cloth to clean the blades.

If you are unable to remove certain spots, consider using mild detergents.

Afterwards, rinse the entire surface thoroughly.

To protect the surfaces from the environmental contaminants use the best affordable car wax.

CAUTION!
Do not, under any circumstances, attempt to use rough cloth to remove durable stains. This
results in scratching the surface and by that degrades propeller performance
greatly.

When storing the aircraft inside closed areas make sure to use the propeller blade covers. This
will keep any dust or other contamination from accumulating on the blades.

Clean your propeller regularly, preferably before and after each flight to maintain best aircraft
performance.
 Pipistrel d.o.o. Ajdovščina
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e-mail: [email protected]
www.pipistrel.si