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Hartzell Manual 170 - Hartzell Propeller Inc.

1. 1 3 Erosion Tape Removal MERE o o oS 1 4 Ipse NETT TE S 1 4 LIST OF FIGURES Determination or Repair Flow Chart uus tiun trasteros serene Figure 1 1 1 3 Repair Regions N shank Blades with Only Trailing Edge Foam Figure 1 2 1 5 Repair Regions N shank Blades with Both Trailing Edge and Leading Edge Figure 1 3 1 6 Repair Regions Bantam Blades Figure 1 4 1 7 Coin Tap sieisen read cakes Figure 1 5 1 8 INSPECTION PROCEDURES 61 1 3 70 gc n mE COMPOSITE PROPELLER BLADE FIELD HARTZ ELL MAINTENANCE AND MINOR REPAIR MANUAL 170 This page is intentionally left blank INSPECTION PROCEDURES 61 1 3 70 ip COMPOSITE PROPELLER BLADE FIELD HARTZ ELL MAINTENANCE AND MINOR REPAIR MANUAL 170 1 Inspection Procedures CAUTION INSTRUCTIONS AND PROCEDURES IN THIS SECTION INVOLVE PROPELLER CRITICAL PARTS REFER TO THE INTRODUCTION CHAPTER OF THIS MANUAL FOR INFORMATION ABOUT PROPELLER CRITICAL PARTS A Determination of Damage Limits 1 Upon inspection of a compostie propeller blade an operator should first determine whether the type of damage is airworthy or unairworthy Refer to Figure 1 1 to determine the type of repair a If the damage is determined to be airworth
2. Figure 3 1 3 5 Missing Portions of Nickel Erosion Shield Trail Side XO Figure 3 2 3 5 Measuring Lengthwise ESO Figure 3 32 3 7 Acceptable Erosion Shield Debond Non acceptable Crack Figure 3 4 3 7 Debonds in Excess of Allowable Limits Figure 3 5 3 9 LIST OF TABLES Repair Limits by Damage Type nde sa pip Baa Table 3 1 3 4 Page 3 2 REPAIR LIMITS 61 1 3 70 Oct 13 COMPOSITE PROPELLER BLADE FIELD HARTZ ELL MAINTENANCE AND MINOR REPAIR MANUAL 170 1 Definitions A Airworthy Unairworthy Damage 1 Airworthy damage is a specific condition to a blade installed on an aviation product that is within the airworthy damage limits as specified in Table 3 1 in this chapter a Airworthy damage does not affect the safety or flight characteristics of the propeller and conforms to its type design b Damage that is within the airworthy limits does not require repair before further flight but should be repaired as soon as posible to prevent degradation of the damage Unairworthy damage is a specific condition to a blade installed on an aviation product that exceeds the airworthy damage limits as specified in Table 3 1 in this chapter a Un
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4. SERVICE DOCUMENT AIRWORTHINESS LIMITATIONS eer ce ts create tees EPFEGTIVE TABLE OF CONTENTS Ace net Geeta INTRODUC TION INSPEC TION PROCEDURE S M DAMAGE EVAULATION mtv aix 95 pf MINOR REPAIR Lusisisecistiskbh pr ER TABLE OF CONTENTS 61 1 3 70 1 Oct 13 n mE COMPOSITE PROPELLER BLADE FIELD HARTZ ELL MAINTENANCE AND MINOR REPAIR MANUAL 170 This page is intentionally blank TABLE OF CONTENTS 61 1 3 70 d COMPOSITE PROPELLER BLADE FIELD HARTZ ELL MAINTENANCE AND MINOR REPAIR MANUAL 170 INTRODUCTION CONTENTS Te Statement ONF UPOS TR t E E E 3 Reguired TEE 4 Hartzell Propeller Inc 11 4 3 Personel gt 5 MINO REDAN 5 MEL 5 4 Safe Handling of Paints and Chemicals attaches 6 Die Component Lite and Se Rie NE 6 As Calendar EEE 6 B Componem DII __ 6 8 Manual Arrangement e nb bb EbpNI Qe qud qiu
5. 4 Nickel Erosion Shield Debond for all areas not covered by external de ice anti icing boot 5 Nickel Erosion Shield Chordwise Crack for all areas not covered by external de ice or anti icing boot 6 Nickel Erosion Shield Lengthwise Cracks for all areas not covered by an external de ice or anti icing boot 7 Nickel Erosion Shield Debonds Bounded by a Lengthwise Crack for all areas that are covered by external de ice or anti icing boot 8 Nickel Erosion Shield Debonds for all areas that are covered by external de ice or anti icing boot 9 Nickel Erosion Shield Debonds Bounded by Two Chordwise Cracks for all areas that are covered by external de ice or anti icing boot 10 thru 20 are not applicable to models included in this manual See the NOTE included in Table 2 1 21 Gouge or Loss of Composite Material Outboard region of Ihe e eei or retener ntes en pan 22 Gouge or Loss of Composite Material Trailing edge foam and leading edge foam regions of the blade 23 Gouge or Loss of Composite Material inboard Peg or the 2 du epe Sans ceste 24 Delamination Outboard region of the blade that is not covered by erosion screen 25 Delamination Outboard region of the blade that is covered by erosi
6. Figure 4 14 4 42 Sanding to Expose Erosi n Shield Figure 4 15 4 46 LIST OF TABLES Erosion Tape LengliLbOgOEE sena ilg iE ERREUR E RAM dU qud qaa Ere RUM eH dE AX Table 4 1 4 48 61 13 70 lius A COMPOSITE PROPELLER BLADE FIELD HARTZ ELL MAINTENANCE AND MINOR REPAIR MANUAL 170 1 General Instructions A General 1 The procedures in this section apply when specified for a minor repair of the blade models identified in this manual a Refer to the Personnel Requirements section in the Introduction chapter of this manual for descriptions and requirements of Minor and Major Repairs 294 0001 Surface of the Metal Erosion Shield Gouge Area Follow the applicable procedure for sanding and refinishing the blade surface Composite Material Field Repair of Minor Damage in Erosion Shield Figure 4 1 minorrerar 61 13 70 COMPOSITE PROPELLER BLADE FIELD HARTZ ELL MAINTENANCE AND MINOR REPAIR MANUAL 170 2 Nickel Erosion Shield CAUTION A Gouge Limits 1 Refer to Figure 4 1 1 INSTRUCTIONS AND PROCEDURES IN THIS SECTION INVOLVE PROPELLER CRITICAL PARTS REFER TO THE INTRODUCTION CHAPTER OF THIS MANUAL FOR INFORMATION ABOUT PROPELLER CRITICAL PARTS CAUTION DO NOT REMOVE SURFACE MATERIAL DEEPER THAN a 0 020 IN 0 50 mm INTO THE COMPOSIT
7. RF T Irregularly shaped separation within a material usually visible as a narrow opening at the surface 222 Separation of two materials that were originally bonded together in a separate operation Delamination Internal separation of the layers of composite material Depression Surface area where the material has been compressed but not removed Alteration of the original shape or size of a component Gradual wearing away or deterioration due to action of the elements EXPO SU Leaving material open to action of the elements PACS M RU The surface of the blade that is directed toward the rear of the aircraft The face side is the high pressure or thrusting side of the blade The blade airfoil sections are normally cambered or curved such that the face side of the blade may be flat or even concave in the midblade and tip region Face Alignment Distance from the blade centerline to the highest point on the face side perpendicular to the chord line ai Damage that develops when relative motion of small displacement takes place between contacting parts wearing away the surface Surface area where material has been removed Hazardous Propeller Effect The hazardous propeller effects are defined in Title 14 C
8. Damage Type by Blade Model Table 2 1 continued DAMAGE EVALUATION 6 1 1 3 70 EH mE EMEN COMPOSITE PROPELLER BLADE FIELD HARTZ ELL MAINTENANCE AND MINOR REPAIR MANUAL 170 Damage Type and Reference Section in this manual mmn Erosion shield only Limitst 35 emez ee Damage wear debond X X X X X X X X X X 138 Not Applicable see NOTE ______ _ _ OSO NOTE The numbered damage types in this table match the numbered damage types in Hartzell Propeller Inc Composite Propeller Blade Maintenance Manual 135F 61 13 35 for consistency only The damage types that do not apply to the affected blades in this manual have been omitted from this table Z LOYSZ a x x x Oxtover 1 x Damage by Blade Model Table 2 1 continued DAMAGE EVALUATION 61 1 3 70 COMPOSITE PROPELLER BLADE FIELD HARTZ ELL MAINTENANCE AND MINOR REPAIR MANUAL Ts 170 REPAIR LIMITS CONTENTS 3 3 A Airworthy Unairworthy 3 3 Operable Inoperable 3 3 Minor Major 3 4 REDAN LIMIS E 3 4 A Repair Limits by Damage 3 4 1 Nickel Erosion
9. __ ____ ___ p __ ____ __ _____ Oxeven 4 1 Damage by Blade Model Table 2 1 continued DAMAGE EVALUATION 6 1 1 3 70 e mE EMEN 8 COMPOSITE PROPELLER BLADE FIELD HARTZ ELL MAINTENANCE AND MINOR REPAIR MANUAL 170 Damage Type and Reference Section in this manual 22 Gouge or Loss of Composite Material Trailing Edge Foam and Leading Edge OSO9ZN 2 N 80269N lt 10 6 Foam Regions the Blade a Limits 1 b Limits 2 23 Gouge or Loss of Composite Material Inboard Region of the Blade a Limits 1 24 Delamination Outboard region of the blade that is not covered by erosion screen 25 Delamination Outboard region of the blade that is covered by erosion screen Limits 1 26 Delamination Trailing edge foam and leading edge foam regions of the blade x 27 Delamination Inboard region of the blade nel NOTE The numbered damage types in this table match the numbered damage types in Hartzell Propeller Inc Composite Propeller Blade Maintenance Manual 135F 61 13 35 for consistency only The damage types that do not apply to the affected blades in this manual have been omitted from this table x ox __ m xe __ p m PR Kul op 4 Oxe
10. 219 to dry In a container that is free from contamination mix the adhesive CM14 or CM15 in accordance with the manufacturer s instructions 1 Mix enough adhesive 14 or CM15 to perform the repair Laminate the repair material pattern piece layers 1 A Apply adhesive CM14 or CM15 to the area to be repaired CAUTION MAKE SURE THAT EACH LAYER BECOMES THOROUGHLY SATURATED WITH ADHESIVE CM14 OR CM15 AS THE LAYER LAMINATES TO THE REPAIR AREA Apply the repair material pattern piece layers over the repair area to achieve the original shape Refer to Figure 4 5 IN NOTE The repair material pattern pieces were cut so the weave overlap direction will alternate between 45 degrees 0 90 degrees I Beginning with the smallest repair material pattern piece laminate progressively larger material pattern pieces making sure that each repair material pattern piece is thoroughly saturated before applying the next layer Additional adhesive CM14 or CM15 may be applied if necessary 61 13 70 COMPOSITE PROPELLER BLADE FIELD HARTZ ELL MAINTENANCE AND MINOR REPAIR MANUAL x 170 Cure the repair in accordance with the section 3 G Curing Procedures in this chapter Sand the repair CAUTION DO NOT REMOVE ORIGINAL MATERIAL WHEN SANDING 1 Sand the repaired area to the original shape using caution not to remove original material 2 Using progressively finer grit sandpaper sand until t
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13. C Major Repair 1 2 3 4 Major repair work is that which exceeds the minor repair limits as specified in this manual To perform composite blade major repair the propeller repair station must employ at least one individual with valid Composite Blade Overhaul Major Repair and Recertification Individual Certification from Hartzell Propeller Inc All major repairs must be completed in a propeller repair station that is licensed by a government agency e g FAA EASA CAA Refer to the Hartzell Propeller Inc website at www hartzellprop com or contact the Hartzell Propeller Inc Product Support Department for a current list of authorized facilities INTRODUCTION 61 1 3 70 Eos COMPOSITE PROPELLER BLADE FIELD HARTZ ELL MAINTENANCE AND MINOR REPAIR MANUAL 170 4 Safe Handling of Paints and Chemicals A B C Always use caution when handling or being exposed to paints and or chemicals during propeller repair procedures Before using paint or chemicals always read the manufacturer s label on the container and follow specified instructions and procedures for storage preparation mixing and application Refer to the product s Material Safety Data Sheet MSDS for detailed information about physical properties health and physical hazards of any chemical 5 Component Life and Service A Calendar Limits 1 The effects of exposure to the environment over a period of time create a n
14. IQ Put the piece of polyester absorbent cloth CM59 over the Teflon bleeder cloth CM58 in the repaired area on one side of the blade and fold it over to cover the repaired area on the other side of the blade 1 If necessary to hold in place apply tape to the edges of the polyester absorbent cloth CM59 outside of the repaired area 2 Cuta piece of vacuum bag material CM45 large enough to cover the entire repaired area on one side of the blade and fold over to cover the repaired area on the other side of the blade 3 Put the piece of vacuum bag material CM45 on the repaired area on one side of the blade and fold it over to cover the repaired area on the other side of the blade If necessary to hold in place apply tape to the edges of the vacuum bag material CM45 outside of the repaired area c Curing the Repair 1 Option 1 Room Temperature Cure a Prepare two semi rigid plates to clamp over the repaired area 1 Make the plates from metal plastic Masonite or other semi rigid material 2 Make one plate long enough so that when the plates are clamped on the blade the plates will extend beyond the repaired area 3 When the repair is to a curved area of the blade a layer of compressive material such as foam rubber may be used between the repair area and the plate to help apply uniform pressure when curing the repaired area lo Put one plate over the repaired area on each side of the blade 1 If
15. LIST OF TABLES Damage Type by Blade Modal c dena baeo ba e bondades Table 2 1 2 3 DAMAGE EVALUATION 61 1 3 70 COMPOSITE PROPELLER BLADE FIELD HARTZ ELL MAINTENANCE AND MINOR REPAIR MANUAL 170 1 Damage Evaluation CAUTION INSTRUCTIONS AND PROCEDURES IN THIS SECTION INVOLVE PROPELLER CRITICAL PARTS REFER TO THE INTRODUCTION CHAPTER OF THIS MANUAL FOR INFORMATION ABOUT PROPELLER CRITICAL PARTS A Determining the Damage Type and Repair Limits 1 Inspection should identify the location and type of damage for each area of damage on the blade a Refer to Figures 1 2 thru 1 4 as applicable for definitions of blade regions by model 2 Locate the appropriate damage type in Table 2 1 based on the location and type of damage identified in the inspection 3 Using Table 2 1 determine the applicable repair limit for the specific blade model 4 Refer to the Repair Limits chapter in this manual for specific information regarding Airworthy Damage and Minor Repair Limits for each damage type Damage Type and Reference Section in this manual Nickel Erosion Shield Minor Deformation for the entire erosion shield a Limits 1 Nickel Erosion Shield Gouge for the entire erosion shield Limitst 00 Limits2 __ E ee ee Px OOF a so9zN __ 1 _ _ __ _ ___
16. 29 4 20 3 m 4 20 IN 22 Tu E 4 20 Crushed or Cracked Trailing Edge Ouiboard and Tip Regions or the Blade 4 21 ROR 4 21 2 Limits 2 not applicable doses 4 25 DD ENS uino cce 4 25 4 29 E Crushed or Cracked Trailing Edge Trailing Edge Foam Region of the Blade Limits 1 4 29 F Missing Erosion Screen Limits 4 33 5 Cung Procedures 4 36 Repair Area Limits Kevlar Carbon Hybrid Blade Only 4 43 minorrerar 61 13 70 COMPOSITE PROPELLER BLADE FIELD HARTZ ELL MAINTENANCE AND MINOR REPAIR MANUAL 170 4 Paint and or Filler 4 45 Loss of Paint and or Filler Material For the Erosion Shield Only Limits T sceicco 4 45 4 47 _ _____ __ PIRE 4 47 B 4 48 6 Documenting the aa a 4 50 Blade Damage Repair
17. A type of construction in which the outer skin carries all or a major part of the stresses A composite blade that is used in lightweight turbine compact and lightweight compact propellers Removal of paint and possibly a small amount of composite material not exceeding one layer typically 0 010 inch 0 25 mm Intended for non aircraft application such as Hovercraft or Wing In Ground effect WIG applications These products are certificated by an authority other than FAA The hub and blades will be stamped with an identification that is different from but comparable to TC and PC Intended for non aircraft application such as Hovercraft or Wing In Ground effect WIG applications These products are not certificated by any authority There is no identification stamp comparable to TC and PC on the hubs and blades Experimental parts are normally stamped with an X at or near the end of the part number INTRODUCTION 61 1 3 70 jo COMPOSITE PROPELLER BLADE FIELD HARTZ ELL MAINTENANCE AND MINOR REPAIR MANUAL 170 8 Abbreviations Abbreviation Term PAIS nit As Required Airline Transport Association Federal Aviation Administration Foot Pound Flight Hour ICA PNE Instructions for Continued Airworthiness E Inside Diameter aj Illustrated Parts List MA
18. CM158 ON ABLADE WITH AN ANTI ICE BOOT INSTALLATION OF EROSION CM158 WILL PREVENT PROPER FUNCTION OF THE ANTI ICE NOTE erosion tape 158 or anti icing boot whichever is applicable may be installed on the blade before propeller assembly after propeller assembly or on wing a Aminimum temperature of 60 F 10 is required for erosion tape CM158 application b Keep hands clean at all times Erosion Tape Edge Erosion Tape Length Inboard Location From per Blade the Outboard End of the Metal Shank LIIS N 7893 1 00 25 4 mm 1 00 25 4 mm Blade Model 5 176 01 15 60 inches 396 2 mm 1 00 25 4 mm 76 05 X 14 87 inches 377 6 mm 1 00 25 4 mm H79A06X 14 87 inches 377 6 mm 1 00 25 4 mm Erosion Tape Length Location Table 4 1 61 13 70 E COMPOSITE PROPELLER BLADE FIELD HARTZ ELL MAINTENANCE AND MINOR REPAIR MANUAL 170 CAUTION DO NOT INSTALL EROSION TAPE CM158 ON A BLADE THAT HAS PAINT THAT HAS CURED LESS THAN 8 HOURS If performed in conjunction with paint refinish or touch up paint must cure for a minimum of 8 hours before installing erosion tape CM158 Cut erosion tape CM158 to the correct length for each blade Refer to Table 4 1 Radius the corners of the erosion tape CM158 to 0 5 inch 13mm to remove any sharp corners Using a pencil or a ball point pen measure and make a mark on the non adhe
19. paint when material is 0 500 inch 12 70 mm The The maximum permitted depth of a measuring maximum permitted length of a gouge gouge or loss of composite material the depth of a or loss of material is 2 5 inches is 0 020 inch 0 50 mm Repair in gouge loss 63 mm The maximum permitted accordance with section 3 A 1 in the of composite depth of a gouge loss of material is Minor Repair chapter in this manual material 0 020 inch 0 50 mm b LIMITS 2 The maximum permitted diameter or For a gouge or loss of composite equivalent area 0 20 sq inch or material that does not expose the 129 sq mm of a gouge or loss of carbon layer repair in accordance with d material is 0 500 inch 12 70 section 3 A 2 in the Minor Repair measuring maximum permitted length of a gouge chapter in this manual the depth of a or loss of material is 2 5 inches 63 mm The maximum permitted For a gouge or loss of composite depth of a gouge or loss of material is material that does expose the carbon 0 020 inch 0 50 mm layer major repair is not authorized Send the blade to Hartzell Propeller Inc for evaluation FOR MAJOR REPAIRS REFER TO THE PERSONNEL REQUIREMENTS SECTION IN THE INTRODUCTION CHAPTER OF THIS SERVICE MANUAL gouge or loss of composite material Repair Limits by Damage Type Table 3 1 continued 61 13 70 n E COMPOSITE PROPELLER BLADE FIELD HART
20. 2 3 Revision No indicates the revisions incorporated in this manual Issue Date is the date of revision Comments indicates the level of the revision a b New Issue is a new manual distribution The manual is distributed in its entirety All the revision dates are the same and no change bars are used Reissue is a revision to an existing manual that includes major content and or major format changes The manual is distributed in its entirety All the revision dates are the same and no change bars are used Major Revision is a revision to an existing manual that includes major content or minor format changes over a large portion of the manual The manual is distributed in its entirety All the revision dates are the same but change bars are used to indicate the changes incorporated in the latest revision of the manual Minor Revision is a revision to an existing manual that includes minor content changes to the manual Only the revised pages of the manual are distributed Each page retains the date and the change bars associated with the last revision to that page Revision No Issue Date Comments New Issue Oct 13 New Issue REVISION HIGHLIGHTS 61 1 3 70 5 COMPOSITE PROPELLER BLADE FIELD HARTZ ELL MAINTENANCE AND MINOR REPAIR MANUAL 170 RECORD OF REVISIONS This is a permanent historical record of revisions inserted into this manual Revision Issue Date Inserted Revision Issue Date
21. 4 50 B Propeller rete 4 50 LIST FIGURES Field Repair of Minor Damage in Erosion Shield Figure 4 1 4 3 Repair of Debond at Edge of Nickel Erosion Shield Figure 4 2 4 6 Using C clamps to Apply Pressure to Erosion Shield Deboru Repani Arti RrEbKHEPLN UU MIR PP M nic Md PAPER EN EUM Figure 4 3 4 6 Unidirectional Material and Woven Material in a Sanded Area of a Carbon Blade onore tere reo Figure 4 4 4 9 Figure 4 5 4 11 Material Layers of the N shank Kevlar Carbon Hybrid Blade Figure 4 6 4 14 CAE EO Figure 4 7 4 22 Crushed Blade Trailing Edge Repair Cross Section View Figure 4 8 4 23 Bevel Length and Damaged Material Depth Figure 4 9 4 25 Repa Cayol TNR Figure 4 10 4 30 N shank Kevlar Carbon Hybrid Blade Repair Limits Figure 4 11 4 41 N shank Kevlar Carbon Hybrid Blade Repair Limits Figure 4 12 4 41 N shank Kevlar Carbon Hybrid Blade Repair Limits Figure 4 13 4 42 N shank Kevlar Carbon Hybrid Blade Repair Limits
22. Repair Limits by Damage Type Table 3 1 continued REPAIR LIMITS 61 1 3 70 b 6 E B COMPOSITE PROPELLER BLADE FIELD HARTZ E LL MAINTENANCE AND MINOR REPAIR MANUAL 170 Measurement of lengthwise crack Lengthwise crack refers only to the length of the crack To determine the length measure parallel to the pitch axis of the blade from the most inboard location to the most outboard location Measuring Lengthwise Crack Figure 3 3 Area of debond in the bounded area that is within maximum permitted limits Bounded area of crack CAMBER These two cracks are in violation of being within the same linear length Note that the cracks are on opposite sides of the blade NOTE The bounded area of a crack extends to both edges of the erosion shield Acceptable Erosion Shield Debond Non acceptable Crack Location Figure 3 4 REPAIR LIMITS 61 1 3 70 gri n E COMPOSITE PROPELLER BLADE FIELD HARTZ ELL MAINTENANCE AND MINOR REPAIR MANUAL 170 CAUTION REFER TO TABLE 2 1 IN THE DAMAGE EVALUATION CHAPTER OF THIS MANUAL FOR THE APPLICABLE DAMAGE TYPE AND REPAIR LIMITS BY BLADE MODEL REFER TO THIS TABLE FOR THE AIRWORTHY AND MINOR REPAIR LIMITS FOR EACH DAMAGE TYPE 4 NICKEL EROSION SHIELD DEBOND FOR ALL AREAS THAT NOT COVERED BY AN EXTERNAL OR ANTI ICING BOOT REFER TO FIGURE 3 1 LIMITS AIRWORTHY DAMAGE MINOR REPAIR DESIGNATION LIMITS INSTRUCTIONS LIMITS 1 A
23. a Using a clean tongue depressor utility knife or other similar tool gently pry apart the split edge and remove any contaminates WARNING ADHESIVES AND SOLVENTS ARE FLAMMABLE AND TOXIC b TO THE SKIN EYES AND RESPIRATORY TRACT SKIN AND EYE PROTECTION ARE REQUIRED AVOID PROLONGED CONTACT AND BREATHING OF VAPORS USE SOLVENT RESISTANT GLOVES TO MINIMIZE SKIN CONTACT AND WEAR SAFETY GLASSES FOR EYE PROTECTION USE INA WELL VENTILATED AREA AWAY FROM SPARKS AND FLAME READ AND OBSERVE ALL WARNING LABELS Using a clean cloth CM159 or equivalent dampened with solvent acetone CM173 MEK CM106 or MPK CM219 wipe the repair area CAUTION MAKE SURE THAT THE SOLVENT IS DRY BETWEEN THE COMPOSITE MATERIAL LAYERS IF APPLICABLE Permit the solvent acetone CM173 MEK 106 or 219 to dry 1 Additional drying time may be needed for solvent acetone CM173 CM106 219 that is between the composite layers In a container that is free from contamination mix adhesive 14 CM15 in accordance with the manufacturer s instructions Using adhesive CM14 or CM15 in a syringe CM3 inject as much adhesive as possible in the split making sure of coverage of the entire surface 1 Alternately push the adhesive 14 or 15 into the split using a clean flat tool Cure the repair in accordance with the section 3 G Curing Procedures in this chapter Sand the repair CAUTION DO NOT REMO
24. required to be tracked as defined above are not affected by the hub replacement and must be maintained separately INTRODUCTION 61 1 3 70 cu HA mE E COMPOSITE PROPELLER BLADE FIELD HARTZ ELL MAINTENANCE AND MINOR REPAIR MANUAL 170 C Propeller Critical Parts 1 Procedures in this manual involve Propeller Critical Parts PCP a These procedures have been substantiated based on Engineering analysis that expects this product will be operated and maintained using the procedures and inspections provided in the Instructions for Continued Airworthiness ICA for this product 2 Numerous propeller system parts can produce an aircraft Major or Hazardous effect even though those parts may not be considered as Propeller Critical Parts The operating and maintenance procedures and inspections provided in the ICA for this product are therefore expected to be accomplished for all propeller system parts 6 Manual Arrangement A Introduction 1 The Introduction chapter gives general instructions for using this manual including a Alist of required publications b Personnel and repair station requirements c Adescription of chapters in this manual d Definitions of terms used in this manual B Inspection Procedures 1 The Inspection Procedures chapter gives instructions for required procedures and indentifies the different inspection regions for blade models affected by this service manual C Damage Evaluation 1
25. 1 0 square inch Damage Limits repair in accordance 645 sq mm with section 3 A 2 in the Minor Repair chapter in this manual 25 DELAMINATION OUTBOARD REGION OF THE BLADE THAT IS COVERED BY EROSION SCREEN LIMITS AIRWORTHY DAMAGE MINOR REPAIR DESIGNATION LIMITS INSTRUCTIONS a LIMITS 1 The maximum permitted area of The maximum permitted area of delamination is 2 0 square inches delamination for a minor repair is 1290 sq mm On a Kevlar blade a 0 5 square inch 322 sq Repair dark brown stain or black stain is not in accordance with section 3 A 1 in the permitted Minor Repair chapter in this manual 26 DELAMINATION TRAILING EDGE FOAM AND LEADING EDGE FOAM REGIONS OF THE BLADE LIMITS AIRWORTHY DAMAGE MINOR REPAIR DESIGNATION LIMITS INSTRUCTIONS a LIMITS 1 The maximum permitted area of If the damage is within the Airworthy delamination is 2 0 square inch Damage Limits repair in accordance 1290 sq mm A dark brown stain with section 3 B 1 in the Minor Repair or a black stain is not permitted The chapter in this manual delamination must not be associated with a crack gouge or other damage to the composite material b LIMITS 2 The maximum permitted area of If the damage is within the Airworthy delamination is 2 0 square inch Damage Limits repair in accordance 1290 sq mm with section 3 B 2 in the Minor Repair chapter in this manual FOR MAJOR REPAIRS REFER TO THE PERSONNEL REQUIREMENT
26. 180 F NOTE Temperature indicating strips consist of four silver white dots Each dot is identified with the temperature at which it will turn black When examining the temperature indicating strips after removal of the blade repair blanket TE304 the 120 dot must be black while the 180 F through the 220 F dots must be white The colors of the 140 F and 160 F dots do not matter 2 Ifthe indicated temperature is below 120 F inadequate heating occurred Permit the repair to cure 12 hours at room temperature 3 Ifthe indicated temperature is above 180 F the composite material may be damaged Retire the blade or contact Hartzell Propeller Inc to arrange for evaluation d After cure return to applicable repair procedure for additional requirements MINOR REPAIR 61 1 3 70 cs mE EMEN COMPOSITE PROPELLER BLADE FIELD HARTZ ELL MAINTENANCE AND MINOR REPAIR MANUAL 170 2 Cure of Surface Repairs excludes trailing edge repairs a Procedure for Curing a Blade Surface Repair Clamping Method 1 Optionally Teflon bleeder cloth CM58 and polyester absorbent cloth CM59 may be used NOTE Using the Teflon bleeder cloth CM58 and polyester absorbent cloth CM59 will absorb excess resin minimize sanding and make clean up easier 00 Put the piece of Teflon bleeder cloth 58 over the repaired area NOTE Making the Teflon bleeder cloth CM58 approximately 1 inch 25 4 mm larger than t
27. 2 170 Information published in Service Bulletins Service Letters Service Advisories and Service Instructions may supersede information published in this manual The reader must consult active Service Bulletins Service Letters Service Advisories and Service Instructions for information that may have not yet been incorporated into the latest revision of this manual For Hartzell Propeller Inc service literature and revisions contact Hartzell Propeller Inc Telephone 937 778 4200 Attn Technical Publications Department Fax 937 778 4215 One Propeller Place E mail manuals hartzellprop com Piqua Ohio 45356 2634 U S A 3 Personnel Requirements A Personnel Requirements 1 2 Compliance to the applicable regulatory requirements established by the Federal Aviation Administration FAA or appropriate Aviation Authority is mandatory for anyone performing or accepting responsibility for any inspection and or repair of any Hartzell Propeller Inc product Any person signing for or performing inspections and or repairs to Hartzell Propeller Inc composite parts should be familiar with the objectives and procedures associated with the inspection and or repair of composite parts B Minor Repair 1 Damage that is within the minor repair limits as specified in this manual may be repaired by a certified airframe and powerplant mechanic or international equivalent in accordance with the Minor Repairs chapter in this manual
28. AND OBSERVE ALL WARNING LABELS Using a small plastic wedge or equivalent gently lift the erosion shield and clean the debonded area with solvent acetone CM173 MEK CM106 or MPK CM219 Refer to Figure 4 2 Permit the solvent acetone CM173 MEK 106 219 to dry In a container that is free from contamination mix adhesive 14 or CM 15 in accordance with the manufacturer s instructions While using one thin wedge to gently pry up the erosion shield use a small putty knife or other thin instrument to force adhesive CM14 or CM15 into the debond 1 debond occurred at a crack or where the erosion shield has been physically distorted and will not return to the original position fiberglass fabric 42 may be used to fill the debond a If needed cut fiberglass fabric CM42 so that when folded in half itis the size of the debond b Using adhesive CM14 or CM15 saturate the fiberglass fabric 42 61 13 70 COMPOSITE PROPELLER BLADE FIELD HARTZ ELL MAINTENANCE AND MINOR REPAIR MANUAL 170 the fiberglass fabric CM42 that is saturated with adhesive 14 or CM15 in the debond cavity Remove all tooling from the debond If the erosion shield returns to the original position permit the adhesive 14 or 15 to cure for 12 hours at room temperature 2 hours at 145 5 63 2 If there is a hump or deformation or if fiberglass fabric CM42 was u
29. Area Limits Kevlar Carbon Hybrid Blade Only in this chapter Using solvent acetone CM173 MEK CM106 or MPK CM219 wipe the repair area MINOR REPAIR 61 1 3 70 ico E E COMPOSITE PROPELLER BLADE FIELD HARTZ ELL MAINTENANCE AND MINOR REPAIR MANUAL 170 Repairs That ARE NOT Equal Depth Repairs That ARE Equal Depth Symetrical Repairs Figure 4 7 minorrerar 61 13 70 E B A EeUEEEREEERE COMPOSITE PROPELLER BLADE FIELD HARTZ ELL MAINTENANCE AND MINOR REPAIR MANUAL 170 APS0923 Original Shape Crushed Area Ground to Bevel Laminated Composite Material Plastic Wrapped Over Laminated Composite Materials Taped in Place to Eliminate Shifting Plates Cured Composite Material haa Ground to Original Shape Crushed Blade Trailing Edge Repair Cross Section View Figure 4 8 MINOR REPAIR 61 1 3 70 COMPOSITE PROPELLER BLADE FIELD HARTZ ELL MAINTENANCE AND MINOR REPAIR MANUAL o 170 Permit the solvent acetone 173 106 219 to Determine the number of layers of E glass 55 needed for each side of the repair based on the depth of the damage 1 areas where the depth of repairs on both sides are equal the repair materials may be folded to both sides of the blade Refer to Figure 4 7 In areas where the depth of repairs on both sides are not equal use additional layers s on the deeper side then
30. Bevel Length Damaged Material Removed Bevel Length and Damaged Material Depth Figure 4 9 MINOR REPAIR 61 1 3 70 ics COMPOSITE PROPELLER BLADE FIELD HARTZ ELL MAINTENANCE AND MINOR REPAIR MANUAL 170 2 Stop periodically and examine the progress NOTE Wiping the area with a clean cloth CM159 or equivalent dampened with solvent acetone CM173 106 or 219 can help to visually find the defect 3 Stop removing material when the damage has been sufficiently removed or the airworthy damage limit has been reached a Make a Coin Tap Inspection of the area surrounding the repair in accordance with the Inspection chapter of this manual 1 Ifthe results of the coin tap inspection are not satisfactory the blade requires a major repair Refer to the Personnel Requirements section in the Introduction chapter of this manual for the requirements to perform a major repair WARNING ADHESIVES AND SOLVENTS FLAMMABLE AND TOXIC TO THE SKIN EYES AND RESPIRATORY TRACT SKIN AND EYE PROTECTION ARE REQUIRED AVOID PROLONGED CONTACT AND BREATHING OF VAPORS USE SOLVENT RESISTANT GLOVES TO MINIMIZE SKIN CONTACT AND WEAR SAFETY GLASSES FOR EYE PROTECTION USE INA WELL VENTILATED AREA AWAY FROM SPARKS AND FLAME READ AND OBSERVE ALL WARNING LABELS c Using a clean cloth CM159 or equivalent dampened with solvent acetone CM173 MEK CM106 or MPK CM219 wipe the area to be repaired Permit the solvent acetone CM17
31. Inserted Number Date Inserted By Number Date Inserted By RECORD OF REVISIONS 61 1 3 70 Cc n mE EMEN COMPOSITE PROPELLER BLADE FIELD HARTZ ELL MAINTENANCE AND MINOR REPAIR MANUAL 170 RECORD REVISIONS This is a permanent historical record of revisions inserted into this manual Revision Issue Date Inserted Revision Issue Date Inserted Number Date Inserted By Number Date Inserted By RECORD OF REVISIONS 61 1 3 70 5 RB E COMPOSITE PROPELLER BLADE FIELD HARTZ ELL MAINTENANCE AND MINOR REPAIR MANUAL 170 RECORD OF TEMPORARY REVISIONS Update this page to show all Temporary Revisions inserted into this manual Temporary Section Issue Date Inserted Date Removed Revision No Page Date Inserted By Removed By RECORD OF TEMPORARY REVISIONS 61 1 3 70 o mE E COMPOSITE PROPELLER BLADE FIELD HARTZ ELL MAINTENANCE AND MINOR REPAIR MANUAL 170 RECORD OF TEMPORARY REVISIONS Update this page to show all Temporary Revisions inserted into this manual Temporary Section Issue Date Inserted Date Removed Revision No Page Date Inserted By Removed By RECORD OF TEMPORARY REVISIONS 61 1 3 70 jc ER A COMPOSITE PROPELLER BLADE FIELD HARTZ ELL MAINTENANCE AND MINOR REPAIR MANUAL 170 SERVICE DOCUMENT LIST CAUTION 1 DO NOT USE OBSOLETE OR OUTDATED INFORMATION PERFORM ALL INSPECTIONS OR WORK IN ACCORDANCE WITH THE MOST RECENT REVISION OF THE SERVICE DOCUMENT INFOR
32. Permit the acetone CM173 106 219 to Apply wash primer Mix Number 3 to the exposed erosion shield in accordance with section 2 B 1 in the Tooling and Materials chapter in this manual Permit the wash primer Mix Number 3 to dry Refinish the blade in accordance with section 5 Finish Procedures in this chapter Sand to Expose the Erosion Shield 0 5 inch 12 7 mm Erosion Shield Sanding to Expose Erosion Shield Figure 4 15 61 13 70 ict COMPOSITE PROPELLER BLADE FIELD HARTZ ELL MAINTENANCE AND MINOR REPAIR MANUAL 170 5 Finish Procedures CAUTION INSTRUCTIONS AND PROCEDURES IN THIS SECTION INVOLVE PROPELLER CRITICAL PARTS REFER TO THE INTRODUCTION CHAPTER OF THIS MANUAL FOR INFORMATION ABOUT PROPELLER CRITICAL PARTS A Paint 1 2 Propeller blades are painted with a durable specialized coating that is resistant to abrasion If this coating becomes eroded it is necessary to repaint the blades to provide proper corrosion and erosion protection Polane finish coating is a more durable coating than the aerosol finish coating However the aerosol finish coating is a quicker process and is an acceptable option for field repairs given time and location constraints a Regardless of the finish option wash primer Mix Number 3 is needed for good paint adhesion to the erosion shield 1 Wash primer Mix Number 3 is required for use with the Polane
33. REPAIR MANUAL 170 CAUTION MAKE SURE THAT EACH LAYER BECOMES THOROUGHLY SATURATED WITH ADHESIVE CM14 OR CM15 AS THE LAYER LAMINATES TO THE REPAIR AREA Apply the repair material pattern piece layers over the repair area to achieve the original shape Refer to Figure 4 8 jon NOTE repair material pattern pieces were cut so the weave overlap direction will alternate between 45 degrees 0 90 degrees 09 Beginning with the smallest repair material pattern piece laminate progressively larger material pattern pieces making sure that each repair material pattern piece is thoroughly saturated before applying the next layer Additional adhesive 14 or CM15 be applied if necessary lo Laminate a layer or two of the repair material that is large enough to cover the repair on one side of the blade and extend approximately 0 05 inch 12 mm beyond the edge of the blade Cure the repair in accordance with the section 3 G Curing Procedures in this chapter Sand the repair CAUTION DO NOT REMOVE ORIGINAL MATERIAL WHEN SANDING 1 Sand the repaired area to the original shape using caution not to remove original material 2 Using progressively finer grit sandpaper sand until the original shape is achieved Refer to Figure 4 8 3 Use 140 grit or finer sandpaper for final sanding Visually examine the repaired area 1 repaired area must be smooth and free from wrinkles voids or resin rich are
34. a Coin Tap Inspection of the repaired area in accordance with the Inspection chapter of this manual 61 13 70 COMPOSITE PROPELLER BLADE FIELD HARTZ ELL MAINTENANCE AND MINOR REPAIR MANUAL 170 1 Delaminations or voids are not permitted 2 Ifthe area of repair is not within the limits specified repair in accordance with the applicable repair instructions 3 Repeat the inspections and repair as necessary until the repair is satisfactory n Make an inspection of the finished repaired area in accordance with section 3 H Repair Area Limits Kevlar CarbonHybrid Blade Only in this chapter Refinish the blade in accordance with section 5 Finish Procedures in this Service Letter 2 Limits 2 not applicable to affected models 3 Limits 3 a Some of the blade material even though damaged may remain on the blade 1 If damaged material is fully intact it should remain on the blade NOTE If more than one layer remains on the blade but the layers are separated from each other adhesive CM14 or CM15 will be injected between these layers when the repair is made b Using a grinder or sander with no coarser than 60 grit sandpaper remove damaged composite material in the area to be repaired 1 While removing material make a bevel 0 25 to 0 75 inch 6 3 to 19 0 mm for each 0 010 inch 0 25 mm depth of damaged material removed Refer to Figure 4 8 and Figure 4 9 TI 135003 Depth of
35. enough adhesive 14 or CM15 to perform the repair If applicable inject adhesive CM14 or CM15 with a syringe CM3 between all the layers of the original material remaining in the damaged area Laminate the repair material pattern piece layers 1 Apply adhesive CM14 or CM15 to the area to be repaired CAUTION MAKE SURE THAT EACH LAYER BECOMES THOROUGHLY SATURATED WITH ADHESIVE CM14 OR CM15 AS THE LAYER LAMINATES TO THE REPAIR AREA 2 Apply the repair material pattern piece layers over the repair area to achieve the original shape Refer to Figure 4 8 NOTE Therepair material pattern pieces were cut so the weave overlap direction will alternate between 45 degrees 0 90 degrees a Beginning with the smallest repair material pattern piece laminate progressively larger material pattern pieces making sure that each repair material pattern piece is thoroughly saturated before applying the next layer Additional adhesive CM14 or CM15 may be applied if necessary b Laminate a layer or two of the repair material that is large enough to cover the repair 3 While holding all of the layers firmly in place carefully turn the blade over to the other side NOTE Holding or temporarily taping a flat plate over the layers will help keep the layers in place when turning the blade 4 Apply adhesive CM14 or CM15 to the area to be repaired MINOR REPAIR 61 1 3 70 COMPOSITE PROPELLER BLADE FIELD HARTZ ELL MAINTENANCE AND MINOR
36. euenjoL L Lb LpZo W on Lr Lv19 V Lv SOG SOW pZ on L OVOZL ydjopuey yenb ploy L 92 Lv49 V soa SOW pZ L OVOZL ydjopuey 92 7297 92 soa SOW pZ on 79 1 ydjopuey penb L S2 Lv49V soa SOW pZ on 79 1 S Uled ydjopuey 62 29 Gz vLS8 O TIN SOW pZ on Sjured ydjopuey 9SY yenb L Vc Lv49 V INOG vLS8 O TIN SOW pZ on ME Sjured ydjopuey 9SV 72 1 29 vc 092 2 62 20 62 3 44 3 44 2 06 sunoy UIN 105 944907 yy eAiseupy GL 2 90 324 00 pue ssew QOL sunoy Z jo 61INO C6LINO Jo e si sod 0 GZ 22 ejpueH 3 sow 2 on 09 S ep 6 055693 IosAH IexueH IdH yy 2 82 2 YL GO ww z 70 us00 0 0 N jqesods q 590 eju 20 20 9 100 x esoH eju c dwar uoneouyioedg 1eq Siseg uonduoseq Hed ON 11945 ng WNN
37. finished repaired area in accordance with section Repair Area Limits Kevlar Carbon Hybrid Blade Only in this chapter Refinish the blade in accordance with section 5 Finish Procedures in this chapter F Missing Erosion Screen 1 Limits 1 CAUTION 1 DO NOT REMOVE MATERIAL ANY DEEPER THAN NECESSARY TO FULLY REMOVE THE DAMAGE CAUTION 2 DO NOT SAND INTO THE UNIDIRECTIONAL UD MATERIAL OF THE BLADE Using a grinder or sander with no coarser than 60 grit sandpaper remove damaged screen and if applicable composite material in the area to be repaired When all damage has been removed there should be no loose or deformed screen wire NOTE Only remove damaged material Examine the repair area 1 If more than one composite layer had been removed and or if the total area is greater than the minor damage size limit retire the blade or send the blade to Hartzell Propeller Inc for evaluation IN From the surface of the blade with the paint removed the total depth of the screen and one layer of composite will be 0 022 inches 0 55 mm Make a Coin Tap Inspection in accordance with the Inspection chapter in this manual 1 _ If coin tap produces an indication greater in size than the limits defined in the Minor Repair Limits retire the blade or send the blade to Hartzell Propeller Inc for evaluation INO If the coin tap indication is within Minor Repair Limits remove delaminated material
38. the repair materials may be folded to both sides of the blade Refer to Figure 4 7 The maximum permitted number of layers of E glass CM55 that may be used on each side is three Each cured layer of E glass CM55 is 0 0085 inch 0 215 mm thick Cut each layer of E glass CM55 at a 45 degree angle relative to the blade pitch axis to match the shape of the beveled area to create a stair step pattern when laminating Refer to Figure 4 7 lo In container that is free from contamination mix adhesive 14 or CM15 in accordance with the manufacturer s directions If applicable inject adhesive CM14 or CM15 with a syringe CM3 or equivalent between all the layers of the original material remaining in the damaged area Put the previously cut E glass CM55 layers on the repair area a Using adhesive CM14 or CM15 saturate each layer of E glass CM55 after it is applied to the repair area Using adhesive CM14 or CM15 put layer s of fiberglass fabric CM42 over the entire repair area to achieve the original airfoil shape and to aid in the transition NOTE fiberglass fabric CM42 helps to blend the layers and most of it may be sanded away Cure the repair in accordance with the section 3 G Curing Procedures in this chapter Using no coarser than 60 grit sandpaper sand or grind to the original airfoil shape Refer to Figure 4 8 Make a visual inspection of the repaired area Repair any delaminations or voids Make
39. to the aircraft Type Certificate TC or Supplemental Type Certificates STC to determine installation eligibility of any propeller If installation eligibility is not identifiable an additional installation approval such as FAA form 337 field approval or Supplemental Type Certificate may be required If in doubt contact Hartzell Propeller Inc Product Support Contact the Product Support Department of Hartzell Propeller Inc about any maintenance problems or to request information not included in this publication NOTE When calling from outside the United States dial 001 before dialing the telephone numbers below a Hartzell Propeller Inc Product Support may be reached during business hours 8 00 a m through 5 00 p m United States Eastern Time at 937 778 4379 or at 800 942 7767 toll free from the United States and Canada b Hartzell Propeller Inc Product Support can also be reached by fax at 937 778 4391 and by e mail at techsupport hartzellprop com INTRODUCTION 61 1 3 70 Cu COMPOSITE PROPELLER BLADE FIELD HARTZ ELL MAINTENANCE AND MINOR REPAIR MANUAL 170 c After business hours you may leave a message on our 24 hour product support line at 937 778 4376 or at 800 942 7767 toll free from the United States and Canada A technical representative will contact you during normal business hours Urgent AOG support is also available 24 hours per day seven days per week via this message service d A
40. x gt NOTE The numbered damage types in this table match the numbered damage types Hartzell Propeller Inc Composite Propeller Blade Maintenance Manual 135F 61 13 35 for consistency only The damage types that do not apply to the affected blades in this manual have been omitted from this table Damage Type by Blade Model Table 2 1 DAMAGE EVALUATION 6 1 1 3 70 Es mE EMEN COMPOSITE PROPELLER BLADE FIELD HARTZ ELL MAINTENANCE AND MINOR REPAIR MANUAL 170 Damage Type and Reference Section in this manual 2509 8 8026 L0 85N vE88ON Z LOWSZ Nickel Erosion Shield Area Missing Along the Trailing Edge of the Erosion Shield for the entire erosion shield a Limits 1 Nickel Erosion Shield Debond for all areas not covered by external de ice or anti icing boot a Limits 1 5 Nickel Erosion Shield Chordwise Crack for all areas not covered by external de ice or anti icing boot a Limits 1 Nickel Erosion Shield Lengthwise Cracks for all areas not covered by external de ice or anti icing boot a Limits 1 Nickel Erosion Shield Debonds Bounded by a Lengthwise Crack for all areas that are covered by external de ice or anti icing boot s Limits 1 pepe Px Px Px Px Px Px Px x NOTE The numbered damage types in this table match the numbered damage types in Hartzell Propeller Inc Composite Propeller Blade
41. 25 31 7 gt 2 50 63 5 N shank Kevlar Carbon Hybrid Blade Repair Limits Figure 4 11 TI 00110L Trail Edge of the Original Expanded Foil TIP 1 25 inches 31 7 im 2 50 inches 63 5 N shank Kevlar Carbon Hybrid Blade Repair Limits Figure 4 12 MINOR REPAIR 61 1 3 70 n A mE EEE E COMPOSITE PROPELLER BLADE FIELD HARTZ ELL MAINTENANCE AND MINOR REPAIR MANUAL 170 TI 00110M Trail Edge of the Original Expanded Foil TIP p 2 Bw 1 eee 1 25 inches 31 7 gt 2 50 inches 63 5 mm N shank Kevlar Carbon Hybrid Blade Repair Limits Figure 4 13 00110 Trail Edge of the Original Expanded Foil wean 1 25 inches 31 7 mmy 2 50 inches 63 5 mm N shank Kevlar Carbon Hybrid Blade Repair Limits Figure 4 14 won 61 13 70 A COMPOSITE PROPELLER BLADE FIELD HARTZ ELL MAINTENANCE AND MINOR REPAIR MANUAL 170 5 Putone plate over the repaired area and the other plate on the other side of the blade a If necessary to hold in place apply tape to the plate CAUTION EXCESSIVE CLAMP FORCE WILL DAMAGE THE BLADE SECURE THE PLATE TO THE BLADE WITH MINIMAL FORCE b Install clamps as necessary to apply even pressure to the repaired area c Permit the adhesive to cure for 12 hours at room temperature or for 2 hour
42. 3 106 219 to dry Determine the number of layers of carbon cloth CM111 needed for the repair based on the depth of the damage 1 Each cured layer of carbon cloth CM111 is 0 0075 inch 0 190 thick 2 COutlayers of carbon cloth CM111 to match the shape of the beveled area to create a stair step pattern when laminating Refer to Figure 4 5 o Cut each layer at a 45 degree angle relative to the blade pitch axis 9 Cut an extra layer two of the repair material also at alternating angles to put on top of the repair NOTE The extra layers provide additional thickness that will be removed later resulting in a smooth repaired area 61 13 70 COMPOSITE PROPELLER BLADE FIELD HARTZ ELL MAINTENANCE AND MINOR REPAIR MANUAL f 170 Using a clean cloth CM159 or equivalent dampened with solvent acetone CM173 CM106 219 thoroughly clean the area to be repaired CAUTION MAKE SURE THAT THE SOLVENT IS DRY BETWEEN THE 9 h COMPOSITE MATERIAL LAYERS IF APPLICABLE Permit the solvent acetone CM173 MEK 106 219 to dry 1 Additional drying time may be needed for solvent acetone CM173 CM106 CM219 that is between the composite layers In a container that is free from contamination mix adhesive CM14 or CM 15 in accordance with the manufacturer s instructions 1 Mix
43. 61 13 70 HARTZELL Original October 2013 Composite Propeller Blade Field Maintenance and Minor Repair Manual N shank Composite Bantam Composite N7605 B K 75A01 2 N7605C L76A01X N76MO5C X H79A06X 7893 NG8301 NC8834 NC9208 Hartzell Propeller Inc One Propeller Place Piqua Ohio 45356 2634 U S A Phone 937 778 4200 Fax 937 778 4391 n mE COMPOSITE PROPELLER BLADE FIELD HARTZ ELL MAINTENANCE AND MINOR REPAIR MANUAL 170 This page is intentionally blank 2013 Hartzell Propeller Inc All rights reserved cover 61 13 70 A COMPOSITE PROPELLER BLADE FIELD HARTZ ELL MAINTENANCE AND MINOR REPAIR MANUAL 170 REVISION HIGHLIGHTS New manual issued in its entirety The information in this manual was previously provided in Hartzell Propeller Inc Service Letter HC SL 61 294 Blade Field Maintenance of Composite Blades This manual obsoletes Hartzell Propeller Inc Service Letter HC SL 61 294 Blade Field Maintenance of Composite Blades REVISION HIGHLIGHTS 61 1 3 70 Ga COMPOSITE PROPELLER BLADE FIELD HARTZ ELL MAINTENANCE AND MINOR REPAIR MANUAL 1 Introduction A General 170 REVISION HIGHLIGHTS This is a list of current revisions that have been issued against this manual Please compare to RECORD OF REVISIONS page to ensure that all revisions have been added to the manual B Components 1
44. ANCE AND MINOR REPAIR MANUAL 170 IO Visually examine the composite material in the area that contacts the exposed foam material for tight adhesion to the blade Loose material is not permitted 1 If there is loose material send the blade to Hartzell Propeller Inc for factory only repair Coin Inspection of the area around the exposed foam material in accordance with the Inspection chapter in this manual 1 Ifthe results of the coin tap inspection are not satisfactory send the blade to Hartzell Propeller Inc for factory only repair WARNING ADHESIVES AND SOLVENTS FLAMMABLE AND TOXIC f TO THE SKIN EYES AND RESPIRATORY TRACT SKIN AND EYE PROTECTION ARE REQUIRED AVOID PROLONGED CONTACT AND BREATHING OF VAPORS USE SOLVENT RESISTANT GLOVES TO MINIMIZE SKIN CONTACT AND WEAR SAFETY GLASSES FOR EYE PROTECTION USE INA WELL VENTILATED AREA AWAY FROM SPARKS AND FLAME READ AND OBSERVE ALL WARNING LABELS Using a clean cloth CM159 or equivalent dampened with solvent acetone CM173 MEK CM106 or MPK CM219 wipe the area to be repaired Permit the solvent acetone CM173 CM106 219 to dry Determine the number of layers of carbon cloth CM111 needed for the repair based on the depth of the damage 1 Each cured layer of carbon cloth CM111 is 0 0075 inch 0 190 thick 2 of carbon cloth CM111 to match the shape of the bev
45. E MATERIAL Using a vibratory sander and 60 to 80 grit sandpaper remove all paint from the metal surface in the area to be repaired if necessary making sure to minimize abrasion to the metal surface WARNING ADHESIVES AND SOLVENTS ARE FLAMMABLE AND TOXIC TO THE SKIN EYES AND RESPIRATORY TRACT SKIN AND EYE PROTECTION ARE REQUIRED AVOID PROLONGED CONTACT AND BREATHING OF VAPORS USE SOLVENT RESISTANT GLOVES TO MINIMIZE SKIN CONTACT AND WEAR SAFETY GLASSES FOR EYE PROTECTION USE INA WELL VENTILATED AREA AWAY FROM SPARKS AND FLAME READ AND OBSERVE ALL WARNING LABELS Using a clean cloth CM159 or equivalent dampened with solvent acetone 173 CM106 219 wipe the area Permit the solvent acetone CM173 MEK 106 219 to In a container that is free from contamination mix adhesive CM14 or CM15 in accordance with the manufacturer s directions CAUTION MAKE SURE THAT THE MILLED FIBERS CM56 ARE COMPLETELY SATURATED WITH ADHESIVE CM14 OR 15 Add to the adhesive CM14 or CM15 an amount of milled fibers CM56 that is equal to the amount of adhesive creating a paste 1 Add adhesive CM14 or CM15 to the mixture as necessary to make sure that the milled fibers CM56 are completely saturated Fill the area to be repaired with the mixture of adhesive CM14 or CM15 and milled fibers CM56 Permit the adhesive CM14 or CM15 to cure for 12 hours at room temperature or two hour
46. E PERSONNEL REQUIREMENTS SECTION IN THE INTRODUCTION CHAPTER OF THIS SERVICE MANUAL Repair Limits by Damage Type Table 3 1 continued REPAIR LIMITS 61 1 3 70 E B A COMPOSITE PROPELLER BLADE FIELD HARTZ ELL MAINTENANCE AND MINOR REPAIR MANUAL 170 CAUTION REFER TO TABLE 2 1 IN THE DAMAGE EVALUATION CHAPTER OF THIS MANUAL FOR THE APPLICABLE DAMAGE TYPE AND REPAIR LIMITS BY BLADE MODEL REFER TO THIS TABLE FOR THE AIRWORTHY AND MINOR REPAIR LIMITS FOR EACH DAMAGE TYPE 34 LOSS OF PAINT AND OR FILLER MATERIAL FOR THE EROSION SHIELD ONLY LIMITS AIRWORTHY DAMAGE MINOR DESIGNATION LIMITS REPAIR LIMITS a LIMITS 1 Paint and or filler material may be If the damage is within the Airworthy missing from the entire area of the Damage Limits repair in accordance erosion shield and the blade is with section 5 Finish Procedures in the airworthy Minor Repair chapter in this manual 35 MISSING EXPANDED FOIL MESH LIMITS AIRWORTHY DAMAGE MINOR DESIGNATION LIMITS REPAIR LIMITS 1 Not applicable to any affected blades b LIMITS 2 The expanded foil mesh may be Minor repair of the foil mesh is not missing because of other repairs authorized Send the blade to Hartzell completed in accordance with the Propeller Inc for factory only repair minor repair procedures in this manual 36 MISSING EROSION SCREEN LIMITS AIRWORTHY DAMAGE MINOR DESIGNATION LIMITS REPAIR LIMITS a LIMITS 1 There are no specific air
47. FIELD HARTZ ELL MAINTENANCE AND MINOR REPAIR MANUAL 170 This page is intentionally blank AIRWORTHINESS LIMITATIONS 61 1 3 70 2 COMPOSITE PROPELLER BLADE FIELD HARTZ ELL MAINTENANCE AND MINOR REPAIR MANUAL 170 LIST OF EFFECTIVE PAGES Chapter Page Rev Level Date Cover Cover Back Cover Cover Back Original Oct 13 Revision Highlights 1 2 Original Oct 13 Record of Revisions 1 and 2 Original Oct 13 Record of Temporary Revisions 1 and 2 Original Oct 13 Service Document List 1 and 2 Original Oct 13 Airworthiness Limitations 1 and 2 Original Oct 13 List of Effective Pages 1 and 2 Original Oct 13 Table of Contents 1 and 2 Original Oct 13 Introduction 1 thru 12 Original Oct 13 Inspection Procedures 1 1 thru 1 8 Original Oct 13 Damage Evaluation 2 1 thru 2 8 Original Oct 13 Repair Limits 3 1 thru 3 18 Original Oct 13 Minor Repair 4 1 thru 4 52 Original Oct 13 Tooling and Materials 5 1 thru 5 8 Original Oct 13 LIST OF EFFECTIVE PAGES 61 1 3 70 n mE COMPOSITE PROPELLER BLADE FIELD HARTZ ELL MAINTENANCE AND MINOR REPAIR MANUAL 170 This page is intentionally blank LIST OF EFFECTIVE PAGES 61 1 3 70 dh COMPOSITE PROPELLER BLADE FIELD HARTZ ELL MAINTENANCE AND MINOR REPAIR MANUAL 170 TABLE OF CONTENTS
48. FR section 35 15 g 1 Horizontal Balance Balance between the tip and the butt of the blade INTRODUCTION 6 1 1 3 7 0 COMPOSITE PROPELLER BLADE FIELD HARTZ ELL MAINTENANCE AND MINOR REPAIR MANUAL Term Impact Damage Inboard Inboard Region Inboard Trailing Edge Region Laminate Legacy Composite Blades Lengthwise Loose Material Major Propeller Effect Minor Deformation Non aviation Experimental 170 Description Occurs when the blade strikes or is struck by an object either in flight or on the ground Toward the butt of the blade The inboard portion of the blade encompassing both the face and camber sides of the blade The inboard portion of the blade encompassing the trailing edge To unite composite material by using a bonding material usually with pressure and heat Composite blades other than N shank and Bantam A direction that is generally parallel to the pitch axis Material that is no longer fixed or fully attached The major propeller effects are defined in Title 14 CFR section 35 15 g 2 Deformed material not associated with a crack or missing material less than 10 percent of the leading edge radius or no more than 0 080 inch 2 03 mm deep
49. HARTZ ELL MAINTENANCE AND MINOR REPAIR MANUAL 3 170 Both TSN and TSO are necessary for defining the life of the component Some parts are life limited which means that they must be replaced after a specified period of use TSN When a component or assembly undergoes an overhaul the TSO is returned to zero hours a Time Since New TSN can never be returned to zero b Repair without overhaul does not affect TSO or TSN Time Since New TSN and Time Since Overhaul TSO records must be maintained in the propeller logbook Blades and hubs are sometimes replaced while in service or at overhaul a Maintaining separate TSN and TSO histories for a replacement hub or blade is required b Other propeller components do not require time tracking unless specified in Hartzell Propeller Inc service publications c Hub replacement 1 Ifthe hub is replaced the replacement hub serial number must recorded the entry signed and dated in the propeller logbook 2 The propeller will assume the serial number of the replacement hub NOTE Propeller assembly serial numbers are impression stamped on the hub For stamping information refer to the Parts Identification and Marking chapter of Hartzell Propeller Inc Standard Practices Manual 202A 61 01 02 3 TSN and TSO of the replacement hub must be recorded and maintained in the propeller logbook 4 TSN and TSO of the remaining propeller components that are
50. HE SOLVENT IS DRY BETWEEN THE COMPOSITE MATERIAL LAYERS IF APPLICABLE c Permit the solvent acetone CM173 MEK CM106 or MPK CM219 to dry 1 Additional drying time may be needed for solvent acetone CM173 CM106 CM219 that is between the composite layers d a container that is free from contamination mix adhesive 14 or CM15 in accordance with the manufacturer s instructions e Using adhesive CM14 or CM15 in a syringe CM3 inject as much adhesive as possible in the split making sure of coverage of the entire surface 1 Alternately push the adhesive CM14 or CM15 into the split using a clean flat tool f Cure the repair in accordance with section Curing Procedures in this chapter g Sand the repair CAUTION DO NOT REMOVE ORIGINAL BLADE MATERIAL WHEN SANDING 1 Using no coarser than 60 grit sandpaper sand to remove excess adhesive CM14 or CM15 and fiberglass fabric 42 if applicable a After the final sanding the blade must have a smooth surface 61 13 70 COMPOSITE PROPELLER BLADE FIELD HARTZ ELL MAINTENANCE AND MINOR REPAIR MANUAL 170 Visually examine the repaired area to make sure that it is the original airfoil shape 1 Ifthe original airfoil shape is not achieved send the blade to Hartzell Propeller Inc for factory only repair Make a Coin Tap Inspection of the repaired area in accordance with the Inspection chapte
51. MATION CONTAINED SERVICE DOCUMENT MAY BE SIGNIFICANTLY CHANGED FROM EARLIER REVISIONS FAILURE TO COMPLY WITH INFORMATION CONTAINED INA SERVICE DOCUMENT OR THE USE OF OBSOLETE INFORMATION MAY CREATE AN UNSAFE CONDITION THAT MAY RESULT IN DEATH SERIOUS BODILY INJURY AND OR SUBSTANTIAL PROPERTY DAMAGE CAUTION 2 THE INFORMATION FOR THE DOCUMENTS LISTED INDICATES THE REVISION LEVEL AND DATE AT THE TIME THAT THE DOCUMENT WAS INITIALLY INCORPORATED INTO THIS MANUAL INFORMATION CONTAINED SERVICE DOCUMENT MAY BE SIGNIFICANTLY CHANGED FROM EARLIER REVISIONS REFER TO THE APPLICABLE SERVICE DOCUMENT INDEX FOR THE MOST RECENT REVISION LEVEL OF THE SERVICE DOCUMENT Service Document Incorporation Service Document Incorporation Number Rev Date Number Rev Date SERVICE DOCUMENT LIST 61 1 3 70 on n mE E COMPOSITE PROPELLER BLADE FIELD HARTZ ELL MAINTENANCE AND MINOR REPAIR MANUAL 170 SERVICE DOCUMENT LIST Service Document Incorporation Service Document Incorporation Number Rev Date Number Rev Date SERVICE DOCUMENT LIST 61 1 3 70 5 A COMPOSITE PROPELLER BLADE FIELD HARTZ ELL MAINTENANCE AND MINOR REPAIR MANUAL 170 AIRWORTHINESS LIMITATIONS 1 Airworthiness Limitations Information A For airworthiness limitations information refer to the applicable Hartzell Propeller Inc owner s manual AIRWORTHINESS LIMITATIONS 6 1 1 3 70 pon n mE EMEN COMPOSITE PROPELLER BLADE
52. MINIMIZE SKIN CONTACT AND WEAR SAFETY GLASSES FOR EYE PROTECTION USE INA WELL VENTILATED AREA AWAY FROM SPARKS AND FLAME READ AND OBSERVE ALL WARNING LABELS b Using a clean cloth CM159 or equivalent dampened with solvent acetone CM173 MEK CM106 or MPK CM219 wipe the area to be repaired c Permit the solvent acetone CM173 MEK CM106 or MPK CM219 to dry Sanded Bevel for Repair i Undamaged Layers of Blade Material UD Material Laminating Pattern Figure 4 5 MINOR REPAIR 61 1 3 70 COMPOSITE PROPELLER BLADE FIELD HARTZ ELL MAINTENANCE AND MINOR REPAIR MANUAL d 170 Determine the number of layers of carbon cloth CM111 needed for the repair based on the depth of the damage 1 Each cured layer of carbon cloth CM111 is 0 0075 inch 0 190 mm thick 2 Cut layers of carbon cloth 111 to match the shape of the beveled area to create a stair step pattern when laminating Refer to Figure 4 5 Cut each layer at 45 degree angle relative to the blade pitch axis Ico Cut an extra layer or two of the repair material also at alternating angles to put on top of the repair NOTE extra layers provide additional thickness that will be removed later resulting in a smooth repaired area Using a clean cloth CM159 or equivalent dampened with solvent acetone CM173 MEK CM106 or MPK CM219 thoroughly clean the area to be repaired Permit the solvent acetone CM173 CM106
53. Maintenance Manual 135F 61 13 35 for consistency only The damage types that do not apply to the affected blades in this manual have been omitted from this table __ __ conan Damage by Blade Model Table 2 1 continued DAMAGE EVALUATION 61 1 3 70 COMPOSITE PROPELLER BLADE FIELD HARTZ ELL MAINTENANCE AND MINOR REPAIR MANUAL 170 Damage Type and Reference Section in this manual 0509 80Z6ON 8 F 89ON Z LOWSZ Nickel Erosion Shield Debonds for all areas that are covered by external de ice or anti icing boot a Limits 1 Nickel Erosion Shield Debonds Bounded by Two Chordwise Cracks for all areas that are covered by external de ice or anti icing boot a Limits 1 X X X Outboard Region of the Blade Limits A X X X X X X 6 J X X I I 1 1 1 1 4 NOTE numbered damage types in this table match the numbered damage types Hartzell Propeller Inc Composite Propeller Blade Maintenance Manual 135F 61 13 35 for consistency only The damage types that do not apply to the affected blades in this manual have been omitted from this table 10 11 12 13 14 15 16 T 18 19 20 Eeee A 10 LEN 14 15 16 2
54. ND WEAR SAFETY GLASSES FOR EYE PROTECTION USE INA WELL VENTILATED AREA AWAY FROM SPARKS AND FLAME READ AND OBSERVE ALL WARNING LABELS c Using cheesecloth CM159 or equivalent dampened with solvent acetone CM173 CM106 CM219 thoroughly wipe the area d Permit the solvent acetone CM173 106 or CM219 to dry e Apply wash primer Mix Number 3 to the exposed erosion shield in accordance with section 2 B 1 in the Tooling and Materials chapter in this manual f Permit the wash primer Mix Number 3 to dry g In a container that is free from contamination mix adhesive CM14 or CM15 in accordance with the manufacturer s instructions MINOR REPAIR 61 1 3 70 COMPOSITE PROPELLER BLADE FIELD HARTZ ELL MAINTENANCE AND MINOR REPAIR MANUAL h 00076 170 Using adhesive CM14 15 apply enough individual layers fiberglass fabric CM42 to the repair area to permit sanding the repair area down to the original airfoil shape Permit the adhesive 14 or 15 to dry Using 120 grit or finer sandpaper sand the blade until the original airfoil shape has been restored a If 0 50 inch 12 7 mm measured normal to the leading edge radius aft toward the trailing edge of the section has not been exposed sand to expose this area Refer to Figure 4 15 Using cheesecloth CM159 dampened with solvent acetone CM173 MEK CM106 CM219 thoroughly wipe the blade
55. ND SOLVENTS ARE FLAMMABLE AND TOXIC TO THE SKIN EYES AND RESPIRATORY TRACT SKIN AND EYE PROTECTION ARE REQUIRED AVOID PROLONGED CONTACT AND BREATHING OF VAPORS USE SOLVENT RESISTANT GLOVES TO MINIMIZE SKIN CONTACT AND WEAR SAFETY GLASSES FOR EYE PROTECTION USE INA WELL VENTILATED AREA AWAY FROM SPARKS AND FLAME READ AND OBSERVE ALL WARNING LABELS Using a cloth saturated with solvent acetone CM173 MEK 106 or MPK CM219 wipe the repair area Permit the solvent acetone CM173 MEK CM106 219 to Cut layers of E glass CM55 and fiberglass fabric CM42 Refer to Figure 4 10 1 Cut layers of E glass CM55 Cut each layer at a 45 degree angle relative to the blade pitch axis to match the shape of the beveled area to create a stair step pattern when laminating Refer to Figure 4 7 Cut each layer large enough to cover the repair area side of the blade and to wrap around the trail edge of the blade and cover the repair area on the opposite side of the blade 2 Cut layers of fiberglass fabric CM42 large enough to cover the repair area on one side of the blade and to wrap around the trail edge of the blade and cover the repair area on the opposite side of the blade In a container free from contamination mix adhesive CM14 or CM15 in accordance with the manufacturer s instructions On one side of the blade apply adhesive CM14 or CM15 to the repair area Put layers of the precut E glass CM55
56. ORS USE SOLVENT RESISTANT GLOVES TO MINIMIZE SKIN CONTACT AND WEAR SAFETY GLASSES FOR EYE PROTECTION USE INA WELL VENTILATED AREA AWAY FROM SPARKS AND FLAME READ AND OBSERVE ALL WARNING LABELS Using solvent acetone CM173 MEK CM106 or 219 clean the area Fiberglass Fabric CM42 E glass CM55 E glass CM55 Sanded Bevel E glass CM55 Layer for Repair the Blade Kevlar Layer of the Blade Carbon Layer of the Blade Material Layers of the N shank Kevlar Carbon Hybrid Blade Figure 4 6 minorrerar 61 13 70 k COMPOSITE PROPELLER BLADE FIELD HARTZ ELL MAINTENANCE AND MINOR REPAIR MANUAL a 170 Permit the solvent acetone CM173 106 219 to Determine the number of layers of E glass 55 needed for the repair based on the depth of the damage The maximum permitted number of layers of E glass CM55 that may be used is two Each cured layer of E glass CM55 is 0 0085 inch 0 215 mm thick Cut layers of E glass CM55 to match the shape of the beveled area to create a stair step pattern when laminating Refer to Figure 4 6 Cut each layer at a 45 degree angle relative to the blade pitch axis In a container that is free from contamination mix adhesive 14 CM 15 in accordance with the manufacturer s instructions Using adhesive CM14 or CM15 laminate one or two layers of E glass 55 Using adhesiv
57. R International Traffic in Arms Regulations RTT Pound s MEHREREN HT EO Maximum Us dau aqu UA Minimum ML C Military Specification j mere DE Major Periodic Inspection I Military Standard Material Safety Data Sheet Not Applicable National Aircraft Standards bg ee re rr re ce Nondestructive Testing INSITI Newton Meter Dr Outside Diameter OP T EEE Optional Production Certificate P issue peii denies dien ii dd utn Propeller Critical Part ac Pounds per Square Inch s GENERE RR Reference ISP DE une Revolutions per Minute PEPPER ERES Time Between Overhaul eT TON err Time Since New Time Since Inspection Time Since Overhaul eerie MS Wing In Ground effect INTRODUCTION 6 1 1 3 7 0 COMPOSITE PROPELLER BLADE FIELD HARTZ ELL MAINTENANCE AND MINOR REPAIR MANUAL 170 INSPECTION PROCEDURES CONTENTS 1 Inspection Procedures 1 3 Determination of Damage Limits eerte 1 3 B Determination of Type of
58. R LIMITS a LIMITS 1 Not applicable to any affected blades b LIMITS 2 crushed or cracked trailing edge Minor repair is not authorized Retire on the inboard region of the blade is the blade or send the blade to Hartzell unairworthy Propeller Inc for evaluation 31 CRUSHED OR CRACKED TRAILING EDGE OUTBOARD AND TIP REGIONS OF THE BLADE LIMITS AIRWORTHY DAMAGE MINOR DESIGNATION LIMITS REPAIR LIMITS a LIMITS 1 The maximum permitted depth of a If the damage is within the Airworthy crushed or cracked area is 0 25 inch Damage Limits repair in accordance 6 3 mm The maximum permitted with section 3 D 1 in the Minor Repair length of a crushed or cracked area is chapter in this manual 2 0 inches 50 mm b LIMITS 2 Not applicable to any affected blades c LIMITS 3 The maximum permitted depth of a If the damage is within the Airworthy crushed or cracked area is 0 25inch Damage Limits repair in accordance 6 3 mm The maximum permitted with section 3 D 3 in the Minor Repair length of a crushed or cracked area is chapter in this manual 2 0 inches 50 mm d LIMITS 4 The maximum permitted depth of a The maximum permitted area of a crushed or cracked area is 0 25 inch crushed or cracked area is 6 3 mm The maximum permitted 2 0 sq inches 1290 sq mm Repair length of a crushed or cracked area is within the Airworthy Damage Limits in 2 0 inches 50 mm accordance with section 3 D 4 in the Minor Repai
59. S SECTION IN THE INTRODUCTION CHAPTER OF THIS SERVICE MANUAL Repair Limits by Damage Type Table 3 1 continued 61 13 70 lr n mE EMEN COMPOSITE PROPELLER BLADE FIELD HARTZ ELL MAINTENANCE AND MINOR REPAIR MANUAL 170 CAUTION REFER TO TABLE 2 1 IN THE DAMAGE EVALUATION CHAPTER OF THIS MANUAL FOR THE APPLICABLE DAMAGE TYPE AND REPAIR LIMITS BY BLADE MODEL REFER TO THIS TABLE FOR THE AIRWORTHY AND MINOR REPAIR LIMITS FOR EACH DAMAGE TYPE 27 DELAMINATION INBOARD REGION OF THE BLADE LIMITS AIRWORTHY DAMAGE MINOR DESIGNATION LIMITS REPAIR LIMITS a LIMITS 1 A delamination on the inboard region Minor repair is not authorized Retire of the blade is unairworthy the blade or send the blade to Hartzell Propeller Inc for evaluation 28 SPLIT TRAILING EDGE TRAILING EDGE REGION OF THE BLADE LIMITS AIRWORTHY DAMAGE DESIGNATION LIMITS REPAIR LIMITS LIMITS 1 The maximum permitted depth of a If the damage is within the Airworthy split area is 0 5 inch 12 mm Damage Limits repair in accordance The maximum permitted length is with section 3 C 1 in the Minor Repair 6 0 inches 152 mm Damaged fibers chapter in this manual or exposed foam are not permitted LIMITS 2 Not applicable to any affected blades a b c LIMITS 3 The maximum permitted depth of a If the damage is within the Airworthy split area is 0 25 inch 6 3 mm Damage Limits repair in accordance The maximum permi
60. SN MEER NE E S ENT 5 4 B Consumable Materials Control 5 4 C Das Come c pape gt 5 5 D Consumable Material Management 5 5 Es S E PEN 5 6 1 uno 5 6 A Mixture Number 3 Wash lt lt 5 6 LIST OF FIGURES Example Figure 5 1 5 3 GOnSUMADIE 5 strate tte tor n de edo Table 5 1 5 7 TOOLING AND MATERIALS 61 1 3 70 n mE COMPOSITE PROPELLER BLADE FIELD HARTZ ELL MAINTENANCE AND MINOR REPAIR MANUAL 170 This page is intentionally blank TOOLING AND MATERIALS 61 1 3 70 A COMPOSITE PROPELLER BLADE FIELD HARTZ ELL MAINTENANCE AND MINOR REPAIR MANUAL 170 1 Tooling A Coin 1 A tool or coin is needed for the coin tap inspection a should be a washer shaped metal tapper approximately 2 5 inches 64 mm OD x 1 25 inches 32 mm ID x 0 25 inch 6 4 mm thick and weighing no less than 3 oz 85 05 g Refer to Figure 5 1 B Roller 1 Aroller such as TE330 p n 0500 TE331 p n MRO5020 be used for installation of the erosion CM158 where required C Composite Blade Repair Blanket 1 Acom
61. Shield Minor Deformation ecce 3 4 2 Nickel Erosi n Shield 3 6 3 Nickel Erosion Shield Area Missing Along the Trailing Edge of the Erosion Shield ek 3 6 4 Nickel Erosion Shield Debond for all areas not covered by external de ice or anti icing boot 3 8 5 Nickel Erosion Shield Chordwise Crack for all areas not covered by external de ice or anti icing boot 3 8 6 Nickel Erosion Shield Lengthwise Cracks for all areas not covered by an external de ice anti icing boot 3 8 7 Nickel Erosion Shield Debonds Bounded by a Lengthwise Crack for all areas that are covered by external de ice or anti icing boot 3 9 8 Nickel Erosion Shield Debonds for all areas that are covered by external de ice or anti icing boot 3 10 9 Nickel Erosion Shield Debonds Bounded by Two Chordwise Cracks for all areas that are covered by external de ice or anti icing boot 3 10 10 thru 20 are not applicable to models included in this manual 21 Gouge or Loss of Composite Material CUO region of the MENTRE o o T 3 11 22 Gouge or Loss of Composite Material Trailing edge foam and leading edge foam regions of the blade 3 12 23 Gouge or Loss of Composite Material inboard region clo metet D 3 12 24 De
62. The Damage Evaluation chapter lists each damage type and provides the applicable repair limits for blade models affected by this service manual D Repair Limits 1 The Repair Limits chapter gives dimensional limits for Airworthy Damage and Minor Repair E Minor Repair 1 The Minor Repair chapter specifies minor repair procedures F Tooling and Materials 1 The Tooling and Materials chapter gives information about tooling and materials referenced in this manual INTRODUCTION 61 1 3 70 pon HARTZELL 7 Definitions Term Aviation Certified Aviation Experimental Bantam Composite Blades Blade Pitch Axis Blade Station Camber Chord Line Chordwise Co bonded COMPOSITE PROPELLER BLADE FIELD MAINTENANCE AND MINOR REPAIR MANUAL 170 Description Intended for FAA or international equivalent type certificated aircraft applications A TC and PC number must be stamped on the hub and a PC number must be stamped on blades Intended for aircraft propeller applications not certified by the FAA or international equivalent Products marked with an X at or near the end of the model number part number or serial number are not certified by the FAA or international equivalent and are not intended to use on certificated aircraft A composite blade that is used in Bantam series propellers An imagin
63. VE ORIGINAL BLADE MATERIAL WHEN SANDING 1 Using no coarser than 60 grit sandpaper sand to remove excess adhesive 14 or 15 and fiberglass fabric CM42 if applicable After the final sanding the blade must have a smooth surface Visually examine the repaired area to make sure that it is the original airfoil shape 1 If the original airfoil shape is not achieved send the blade to Hartzell Propeller Inc for factory only repair MINOR REPAIR 61 1 3 70 i COMPOSITE PROPELLER BLADE FIELD HARTZ ELL MAINTENANCE AND MINOR REPAIR MANUAL 170 j a Coin Tap Inspection of the repaired area in accordance with the Inspection chapter of this manual Delaminations or voids are not permitted b Ifthe area of repair is not within the limits specified repair in accordance with the applicable repair instructions c Repeat the inspections and repair as necessary until the repair is satisfactory k Refinish the blade in accordance with section 5 Finish Procedures in this chapter Limits 2 not applicable to affected models Limits 3 a The repair procedure is the same as for Limits 1 Refer to section 3 C 1 Limits 4 a Using aclean tongue depressor utility knife or other similar tool gently pry apart the split edge and remove any contaminates b Using clean cloth CM159 or equivalent dampened with solvent acetone CM173 MEK CM106 or MPK CM219 wipe the repair area CAUTION MAKE SURE THAT T
64. Z ELL MAINTENANCE AND MINOR REPAIR MANUAL 170 CAUTION REFER TO TABLE 2 1 IN THE DAMAGE EVALUATION CHAPTER OF THIS MANUAL FOR THE APPLICABLE DAMAGE TYPE AND REPAIR LIMITS BY BLADE MODEL REFER TO THIS TABLE FOR THE AIRWORTHY AND MINOR REPAIR LIMITS FOR EACH DAMAGE TYPE 22 OR LOSS OF COMPOSITE MATERIAL TRAILING EDGE FOAM AND LEADING EDGE FOAM REGIONS LIMITS AIRWORTHY DAMAGE MINOR REPAIR DESIGNATION LIMITS INSTRUCTIONS a LIMITS 1 The maximum permitted diameter or If the damage is within the Airworthy equivalent area of a gouge or loss Damage Limits repair in accordance NOTE Do not include of composite material is 0 500 inch with section 3 B 1 in the Minor Repair 12 70 mm The maximum permitted chapter in this manual paint when length is 2 5 inch 63 mm measuring the depth of a The maximum permitted depth is 0 020 inch 0 50 mm Exposed foam ouge or loss M seins or a delamination is not permitted of composite material b LIMITS 2 The maximum permitted diameter or If the damage is within the Airworthy equivalent area of a gouge or loss Damage Limits repair in accordance of composite material is 0 500 inch with section 3 B 2 in the Minor Repair 2 12 70 mm The maximum permitted chapter this manual measuring length is 2 5 inch 63 mm the depth of a The maximum permitted depth is 0 020 inch 0 50 mm Exposed foam ouge or loss 2 che or a delamination is not permit
65. airworthy damage can affect the safety or flight characteristics of the propeller and does not conform to its type design b This condition makes the component unairworthy requiring appropriate corrective action to repair or remove it from service as applicable B Operable Inoperable Damage 1 Operable damage is specific condition to a blade installed on non aviation product that does not affect the safety or operational characteristics of the propeller blade a Fora blade that is used on non aviation application all references in this manual to airworthy damage apply to operable damage b Although a blade may continue in service with operable damage this type of damage should be repaired at the earliest practical time to prevent the damage from progressing to a condition that could require a more extensive repair to the blade Inoperable damage is a specific condition to a blade installed on non aviation product that exceeds the airworthy damage limits as specified in Table 3 1 a Inoperable damage can affect the safety or operational characteristics of the propeller and does not conform to its type design b This condition makes the component inoperable requiring appropriate corrective action to repair or remove it from service as applicable REPAIR LIMITS 61 1 3 70 mE EMEN 8 COMPOSITE PROPELLER BLADE FIELD HARTZ ELL MAINTENANCE AND MINOR REPAIR MANUAL 170 C Minor Major Repair 1 Min
66. allest repair material pattern piece laminate progressively larger material pattern pieces making sure that each repair material pattern piece is thoroughly saturated before applying the next layer Additional adhesive CM14 or CM15 may be applied if necessary Cure the repair in accordance with the section 3 G Curing Procedures in this chapter Sand the repair 00 CAUTION DO NOT REMOVE ORIGINAL MATERIAL WHEN SANDING 1 Sand the repaired area to the original shape using caution not to remove original material 2 Using progressively finer grit sand paper sand until the original shape is achieved 3 Use 140 grit or finer sandpaper for final sanding Visually examine the repaired area 1 repaired area must be smooth and free from wrinkles voids or resin rich areas Make a Coin Tap Inspection of the repaired area in accordance with the Inspection chapter of this manual 1 Delaminations or voids are not permitted If the area of repair is not within the limits specified repair in accordance with the applicable repair instructions 3 Repeat the inspections and repair until the repair is satisfactory Refinish the blade in accordance with section 5 Finish Procedures in this chapter N 61 13 70 COMPOSITE PROPELLER BLADE FIELD HARTZ ELL MAINTENANCE AND MINOR REPAIR MANUAL 170 C Split Trailing Edge Tip and Trailing Edge Regions of the Blade Limits 1 1
67. and re inspect in accordance with 3 F 1 b and 3 F 1 c in this chapter MINOR REPAIR 61 1 3 70 icc COMPOSITE PROPELLER BLADE FIELD HARTZ ELL MAINTENANCE AND MINOR REPAIR MANUAL 170 WARNING ADHESIVES AND SOLVENTS ARE FLAMMABLE AND TOXIC TO THE SKIN EYES AND RESPIRATORY TRACT SKIN AND EYE PROTECTION ARE REQUIRED AVOID PROLONGED CONTACT AND BREATHING OF VAPORS USE SOLVENT RESISTANT GLOVES TO MINIMIZE SKIN CONTACT AND WEAR SAFETY GLASSES FOR EYE PROTECTION USE INA WELL VENTILATED AREA AWAY FROM SPARKS AND FLAME READ AND OBSERVE ALL WARNING LABELS Using a clean cloth CM159 or equivalent dampened with solvent acetone CM173 CM106 219 wipe the area to be repaired Permit the solvent acetone CM173 MEK 106 219 to dry Determine the number of layers of carbon cloth CM111 needed for the repair based on the depth of the damage 1 Each cured layer of carbon cloth CM111 is 0 0075 inch 0 190 thick 2 Cutlayers of carbon cloth CM111 to match the shape of the beveled area to create a stair step pattern when laminating Refer to Figure 4 5 Cut each layer at a 45 degree angle relative to the blade pitch axis 3 Cutan extra layer or two of the repair material also at alternating angles to put on top of the repair NOTE The extra layers provide additional thickness that will be removed later resulting in a smooth repaired area Using a clean cloth CM159 or eq
68. ary reference line through the length of a blade around which the blade rotates Refers to the station on a bare blade e g 30 inch station A specific station is found by measurement from the blade zero station to a point on the blade Blade stations are used for all blade specification data Reference the appropriate Overhaul Inspection Form for the location of the zero station Note Do not confuse blade station with reference blade radius they may not originate at the same point The surface of the blade that is directed toward the front of the aircraft It is the low pressure or suction side of the blade The camber side is convex in shape over the entire length of the blade A straight line drawn between the leading and trailing edge radii of the blade A direction that is generally from the leading edge to the trailing edge of an airfoil The act of bonding a composite laminate and simultaneously curing it to some other prepared surface INTRODUCTION 61 1 3 70 one COMPOSITE PROPELLER BLADE FIELD HARTZ ELL MAINTENANCE AND MINOR REPAIR MANUAL 170 Term Description Composite Blade Traveler A form that lists the applicable steps required for the overhaul of a specific blade model Composite Material Kevlar carbon or fiberglass fibers bound together with or encapsulated within an epoxy resin ro ioo NEMPE Gradual wearing away or deterioration due to chemical action
69. as Make a Coin Tap Inspection of the repaired area in accordance with the Inspection chapter in this manual 1 Delaminations or voids are not permitted 2 Ifthe area of repair is not within the limits specified repair in accordance with the applicable repair instructions 3 Repeat the inspections and repair until the repair is satisfactory Refinish the blade in accordance with section 5 Finish Procedures in this chapter 61 13 70 COMPOSITE PROPELLER BLADE FIELD HARTZ ELL MAINTENANCE AND MINOR REPAIR MANUAL 4 170 Limits 4 a The repair procedure is the same as for Limits 3 Refer to section 3 D 3 Limits 3 E Crushed or Cracked Trailing Edge Trailing Edge Foam Region of the Blade 1 Limits 1 CAUTION USE CARE WHEN GRINDING TO REMOVE MATERIAL GRINDING MAY CAUSE DAMAGE BEYOND THE SERVICEABLE LIMITS NOTE Itis recommended to use 180 grit sandpaper or equivalent when removing material in and around the damaged area a Using a customer supplied small angle grinder or equivalent remove damaged material including damaged foam on the camber side and face side of the blade approximately 0 5 inch 13 mm around the damaged area b Using grinder or sander remove damaged composite material to create a bevel in the area to be repaired 1 While removing material make a bevel that extends outward from the repair area 0 25 to 0 75 inch 6 3 to 19 0 mm for each 0 010 i
70. aterial that is large enough to prevent adhesive from getting on the blade repair blanket TE304 when it is applied Put the piece of vacuum bag material CM45 over the blade CAUTION DO NOT LET THE HINGE OF THE BLADE REPAIR BLANKET TE304 CRUSH THE LAMINATED COMPOSITE MATERIALS OF THE REPAIR Put the blade repair blanket TE304 on the trailing edge of the blade centered over the repair making sure that the hinge of the blade repair blanket does not crush the laminated composite materials minorrerar 61 13 70 E COMPOSITE PROPELLER BLADE FIELD HARTZ ELL MAINTENANCE AND MINOR REPAIR MANUAL 170 Put a minimum of two C clamps on the metal strip of the blade repair blanket TE304 in such a way that the clamping pressure is distributed over the entire repaired area WARNING DO NOT OPERATE THE BLADE REPAIR BLANKET Ih TE304 ENVIRONMENT OR BLADE DOING SO MAY CREATE AN ELECTRICAL HAZARD Connect the blade repair blanket TE304 to a 120 volt power source for a minimum of 130 minutes NOTE The minimum time includes 2 hours for curing plus 10 minutes to permit the blade repair blanket to warm to the correct temperature Unplug the blade repair blanket TE304 Remove the blade repair blanket TE304 and the repair hardware from the blade Examine the readings of the temperature indicating strips TE306 and TE307 1 The temperature readings must be greater than 120 F and less than
71. but in each or a crack there is no limit to the size area bounded by chordwise cracks of the repair attempted Repair in the maximum total area of debond is accordance with section 2 C 1 in the 40 percent Minor Repair chapter in this manual NOTE For crack limits refer to the applicable section in this table 10 NOT APPLICABLE 1 NOT APPLICABLE 2 NOT APPLICABLE 3 NOT APPLICABLE 4 NOT APPLICABLE 5 NOT APPLICABLE 6 NOT APPLICABLE 7 NOT APPLICABLE 8 NOT APPLICABLE 19 NOT APPLICABLE 20 NOT APPLICABLE FOR MAJOR REPAIRS REFER TO THE PERSONNEL REQUIREMENTS SECTION IN THE INTRODUCTION CHAPTER OF THIS SERVICE MANUAL Repair Limits by Damage Type Table 3 1 continued REPAIR LIMITS 61 1 3 70 COMPOSITE PROPELLER BLADE FIELD HARTZ ELL MAINTENANCE AND MINOR REPAIR MANUAL 170 CAUTION REFER TO TABLE 2 1 IN THE DAMAGE EVALUATION CHAPTER OF THIS MANUAL FOR THE APPLICABLE DAMAGE TYPE AND REPAIR LIMITS BY BLADE MODEL REFER TO THIS TABLE FOR THE AIRWORTHY AND MINOR REPAIR LIMITS FOR EACH DAMAGE TYPE 21 OR LOSS OF COMPOSITE MATERIAL OUTBOARD REGION OF THE BLADE LIMITS AIRWORTHY DAMAGE MINOR REPAIR DESIGNATION LIMITS INSTRUCTIONS a LIMITS 1 The maximum permitted diameter The maximum permitted area of a gouge equivalent area 0 20 sq inch or or loss of composite material is NOTE Do not include 129 sq mm of a gouge or loss of 2 0 sq inches 1290 sq mm
72. by the term ALTERNATE is CM Alternate consumable materials are considered acceptable for continued use and existing stock of consumable materials may be used for maintenance and or repair The consumable materials may be used interchangeably when ordering stocking new consumable materials 2 Supersedure Consumable material changes are identified by the terms SUPERSEDES CM or SUPERSEDED BY CM____ Superseded consumable materials are considered acceptable for continued use and existing stock of superseded consumable materials may be used for maintenance and or repair Superseded consumable materials may no longer be available and the new consumable material number must be used when ordering stocking new consumable materials 3 Replacement Consumable material changes identified by the terms REPLACES CM REPLACED considered airworthy for continued flight but must be replaced with the new consumable material at overhaul Existing stock of consumable materials may not be used for maintenance and or repair of affected assemblies Replaced consumable materials may no longer be available and the new consumable material number must be used when ordering stocking consumable materials 3 Mixtures A Mixture Number 3 Washer Primer 4 parts Wash Primer CM24 4 parts Reducer Wash Primer CM25 1 part Acid Diluent CM26 Let stand 1 2 hour before using NOTE The Hartzell Propeller Inc required mix rati
73. dditional information is available on the Hartzell Propeller Inc website at www hartzellprop com 4 Where possible this manual is written in the format specified by 5 2200 2 Required Publications A Hartzell Propeller Inc Publications 1 In addition to this manual one or more of the following publications are required for information regarding specific recommendations and procedures to maintain propeller assemblies Manual No n a 145 147 181 182 183 340 411 417 n a 61 00 45 61 00 47 30 60 81 61 12 82 61 12 83 61 00 11 61 00 17 Title Active Hartzell Propeller Inc Service Bulletins Service Letters Service Instructions and Service Advisories Hartzell Propeller Inc Propeller Owner s Manual Hartzell Propeller Inc Propeller Owner s Manual Hartzell Propeller Inc Protection System Component Maintenance Manual Hartzell Propeller Inc De ice Boot Removal and Installation Manual Hartzell Propeller Inc Anti icing Boot Removal and Installation Manual Hartzell Propeller Inc Propeller Owner s Manual Hartzell Propeller Inc Propeller Owner s Manual Hartzell Propeller Inc Propeller Owner s Manual All Hartzell Propeller Inc Owner s Manuals and Ice Protection System manuals are available at www hartzellprop com INTRODUCTION 61 1 3 70 4 Oct 13 COMPOSITE PROPELLER BLADE FIELD HARTZ ELL MAINTENANCE AND MINOR REPAIR MANUAL
74. dge of erosion shield on face side x leading edge of the blade Camber Side of Blade Trailing edge of erosion shield on camber side When calculating the area of damage and the proximity to other damage look at the erosion shield as a two dimensional shape as if it were unfolded and spread flat where the face and camber sides of the blade could be viewed at the same time Interpretation of Erosion Shield Damage Figure 3 1 TI 411 006A Typical chordwise crack Typical lengthwise crack win 0 25 in 6 3 mm Maximum Missing Portions of Nickel Erosion Shield Trail Side and Typical Cracks Figure 3 2 REPAIR LIMITS 61 1 3 70 mE EEE E COMPOSITE PROPELLER BLADE FIELD HARTZ ELL MAINTENANCE AND MINOR REPAIR MANUAL 170 CAUTION REFER TO TABLE 2 1 IN THE DAMAGE EVALUATION CHAPTER OF THIS MANUAL FOR THE APPLICABLE DAMAGE TYPE AND REPAIR LIMITS BY BLADE MODEL REFER TO THIS TABLE FOR THE AIRWORTHY AND MINOR REPAIR LIMITS FOR EACH DAMAGE TYPE 2 NICKEL EROSION SHIELD FOR THE ENTIRE EROSION SHIELD LIMITS AIRWORTHY DAMAGE MINOR REPAIR DESIGNATION LIMITS INSTRUCTIONS LIMITS 1 Exposed foam is not permitted The If the damage is within the Airworthy maximum permitted total accumulated Damage Limits repair in accordance area of gouges through the erosion with section 2 A 1 in the Minor Repair shield is 0 25 sq inch 161 2 sq mm chapter in this manual An erosion The maximum permitted dept
75. e A COMPOSITE PROPELLER BLADE FIELD HARTZ ELL MAINTENANCE AND MINOR REPAIR MANUAL 170 135001 Woven Fabric Unidirectional Material UD NOTE The figure shows the unidirectional material in a carbon blade Unidrectional Material and Woven Material in a Sanded Area of a Carbon Blade Figure 4 4 minorrerar 61 13 70 ron HA mE E COMPOSITE PROPELLER BLADE FIELD HARTZ ELL MAINTENANCE AND MINOR REPAIR MANUAL 170 3 Blade Material CAUTION INSTRUCTIONS AND PROCEDURES IN THIS SECTION INVOLVE PROPELLER CRITICAL PARTS REFER TO THE INTRODUCTION CHAPTER OF THIS MANUAL FOR INFORMATION ABOUT PROPELLER CRITICAL PARTS A Gouges Delaminations or Loss of Composite Material Outboard Region of the Blade 1 Limits 1 CAUTION 1 DO NOT REMOVE MATERIAL ANY DEEPER THAN NECESSARY TO FULLY REMOVE THE DAMAGE CAUTION 2 DO NOT SAND INTO THE UNIDIRECTIONAL UD MATERIAL OF THE BLADE a Using a grinder or sander with no coarser than 60 grit sandpaper remove damaged composite material in the area to be repaired 1 While removing material make a bevel 0 50 to 1 00 inch 12 7 to 25 4 mm for each 0 010 inch 0 25 mm depth of damaged material removed a Ifthe area requiring removal extends to an edge maintain the bevel to the edge b If the area requiring removal extends outside of the original region and into another region extend the bevel into the new region 1 The boundary of the region appli
76. e 14 15 laminate an additional layer s of fiberglass fabric CM42 over the entire repair area to achieve the original airfoil shape and to aid in the transition NOTE This layer s helps blend the layers and most of it may be sanded away Cure the repair in accordance with the section 3 G Curing Procedures in this chapter Using no coarser than 60 grit sandpaper sand the repaired area to the original airfoil shape Make a visual inspection of the repaired area 1 Repair any delaminations or voids Make a Coin Tap Inspection in accordance with the Inspection chapter of this manual Delaminations or voids are not permitted I If the area of repair is not within the limits specified repair in accordance with the applicable repair instructions 3 Repeat the inspections and repair until the repair is satisfactory Make an inspection of the finished repaired area in accordance with section 3 H Repair Limits Kevlar amp Carbon Hybrid Blade Only in this chapter Refinish the blade in accordance with section 5 Finish Procedures in this chapter MINOR REPAIR 61 1 3 70 iss COMPOSITE PROPELLER BLADE FIELD HARTZ ELL MAINTENANCE AND MINOR REPAIR MANUAL 170 B Gouges Delaminations or Loss of Composite Material Trailing Edge Foam and Leading Edge Foam Regions of the Blade 1 2 Limits 1 a Limits 2 The repair procedure is the same as for 3 A Gouges Delaminations or Loss of C
77. e been assigned 1 Y customer can get the consumable material either from Hartzell Propeller Inc or from a local source 2 N Hartzell Propeller Inc does not sell the consumable material the customer must purchase it locally 3 Hartzell Propeller Inc is the only supplier of the consumable material the customer must purchase the consumable material from Hartzell Propeller Inc The following codes are used to define shelf life DOM Date of Manufacture DOS Date of Shipment MD Manufacturer s Date on container e Iwo N I gt mos Months The following terms are used to define temperature control F Frozen store below 0 F 17 C R Refrigerate 40 60 F 4 15 C RT Controlled room temperature 60 80 F 15 26 C UC No special Hartzell Propeller Inc requirement follow manufacturer s requirements A W N I gt TOOLING AND MATERIALS 61 1 3 70 COMPOSITE PROPELLER BLADE FIELD HARTZ ELL MAINTENANCE AND MINOR REPAIR MANUAL 170 d After opening the container a consumable may remain at room temperature until it is used up or until it exceeds the pot life or shelf life limit e For materials purchased directly from Hartzell Propeller Inc the expiration date control information required by Hartzell Propeller Inc will be added to the package or container in a location different than where the manufacturer s label is located The Hartzell Propeller Inc control informatio
78. eed for propeller overhaul regardless of flight time aviation or operating time non aviation 2 Acalendar limit between overhauls is specified in Hartzell Propeller Inc Service Letters HC SL 61 61Y and HM SL 001 and in the applicable propeller owner s manual 3 Experience has shown that special care such as keeping an aircraft in a hangar is not sufficient to permit extension of the calendar limit 4 The start date for the calendar limit is when the propeller is first installed on an engine 5 calendar limit is not interrupted by subsequent removal and or storage 6 The start date for the calendar limit must not be confused with the warranty start date that is with certain exceptions the date of installation by the first retail customer Component Life 1 Certain components or in some cases an entire propeller may be life limited a Itis a regulatory requirement that a record of the time since new be maintained for all life limited parts b Refer to the Airworthiness Limitations chapter in the applicable Hartzell Propeller Inc Owner s Manual for a list of life limited components 2 Component life is expressed in terms of hours of service Time Since New TSN and in terms of hours of service since overhaul Time Since Overhaul TSO NOTE TSN TSO is considered as the time accumulated between rotation and landing i e flight time INTRODUCTION 61 1 3 70 pm COMPOSITE PROPELLER BLADE FIELD
79. eled area to create a stair step pattern when laminating Refer to Figure 4 5 a Cut each layer at a 45 degree angle relative to the blade pitch axis o Cut an extra layer or two of the repair material also at alternating angles to put on top of the repair NOTE The extra layers provide additional thickness that will be removed later resulting in a smooth repaired area Using a clean cloth CM159 or equivalent dampened with solvent acetone CM173 MEK CM106 or MPK CM219 thoroughly clean the area to be repaired Permit the solvent acetone CM173 CM106 219 to dry MINOR REPAIR 61 1 3 70 i COMPOSITE PROPELLER BLADE FIELD HARTZ ELL MAINTENANCE AND MINOR REPAIR MANUAL 9 170 In container that is free from contamination mix the adhesive 14 or CM 15 in accordance with the manufacturer s instructions 1 Mix enough adhesive CM14 or CM15 to perform the repair Laminate the repair material pattern piece layers 1 Apply adhesive CM14 or CM15 to the area to be repaired CAUTION MAKE SURE THAT EACH LAYER BECOMES THOROUGHLY SATURATED WITH ADHESIVE CM14 OR CM15 AS THE LAYER LAMINATES TO THE REPAIR AREA 2 Apply the repair material pattern piece layers over the repair area to achieve the original shape Refer to Figure 4 5 NOTE Therepair material pattern pieces were cut so the weave overlap direction will alternate between 45 degrees 0 90 degrees Beginning with the sm
80. es to the damage not to the boundary of the repair 2 Stop periodically and examine the progress NOTE Wiping the area with a clean cloth CM159 or equivalent dampened with solvent acetone CM173 106 or MPK CM219 can help to visually find the defect 3 Stop removing material when the maximum permitted depth of the repair has been reached or the unidirectional UD material has been exposed Refer to Figure 4 4 If the UD material has been exposed 4 the UD material for damage for example a gouge 1 Any damage to the UD material requires a major repair Refer to the Personnel Requirements section in the Introduction chapter of this manual for the requirements to perform a major repair minorrerar 61 13 70 COMPOSITE PROPELLER BLADE FIELD HARTZ ELL MAINTENANCE AND MINOR REPAIR MANUAL 170 b Make Inspection of the exposed UD material in accordance with the Inspection chapter of this manual 1 If the results of the coin tap inspection are not satisfactory the blade requires a major repair Refer to the Personnel Requirements section in the Introduction chapter of this manual for the requirements to perform a major repair WARNING ADHESIVES AND SOLVENTS FLAMMABLE AND TOXIC TO THE SKIN EYES AND RESPIRATORY TRACT SKIN AND EYE PROTECTION ARE REQUIRED AVOID PROLONGED CONTACT AND BREATHING OF VAPORS USE SOLVENT RESISTANT GLOVES TO
81. finish option when refinishing any portion of the erosion shield 2 Wash primer Mix Number is not required for use with the aerosol finish option 3 When applying wash primer Mix Number do so in accordance with section 2 B 1 in the Tooling and Materials chapter in this manual b If the Polane finish coat is preferred contact one of the following 1 An authorized propeller repair facility to complete the finish procedure 2 Hartzell Propeller Inc Product Support for the applicable procedure information from Hartzell Propeller Inc Standard Practices Manual 202A 61 01 02 c If the aerosol finish coat is preferred refinish the repaired area s in accordance with the Painting of Composite Blades section of the Maintenace Practices chapter in the applicable Hartzell Propeller Inc Propeller owner s manual MINOR REPAIR 61 1 3 70 icc EH mE EMEN COMPOSITE PROPELLER BLADE FIELD HARTZ ELL MAINTENANCE AND MINOR REPAIR MANUAL 170 B Erosion Tape 1 Installation of Erosion Tape CM158 is required for N7605C N 7893 NG8301 75A01 2 L76A01X N76MO5C X and H79A06X non booted blades CAUTION 1 EROSION CM158 MUST BE INSTALLED ON ALL N7605C N 7893 NG8301 75A01 2 L76A01X N76MO5C X and H79A06X NON BOOTED BLADES FAILURE TO INSTALL THE EROSION TAPE ON THESE PROPELLER MODELS CAN RESULT IN SERIOUS DAMAGE TO THE BLADE CAUTION 2 DO NOT INSTALL EROSION
82. ge or a crack Bounded area of crack Camber Debonds in bounded area exceed the permitted limits Debond that does extend to an edge or a crack Debonds in Excess of Allowable Limits Figure 3 5 REPAIR LIMITS 61 1 3 70 a COMPOSITE PROPELLER BLADE FIELD HARTZ ELL MAINTENANCE AND MINOR REPAIR MANUAL 170 CAUTION REFER TO TABLE 2 1 IN THE DAMAGE EVALUATION CHAPTER OF THIS MANUAL FOR THE APPLICABLE DAMAGE TYPE AND REPAIR LIMITS BY BLADE MODEL REFER TO THIS TABLE FOR THE AIRWORTHY AND MINOR REPAIR LIMITS FOR EACH DAMAGE TYPE 8 NICKEL EROSION SHIELD DEBONDS FOR ALL AREAS THAT ARE COVERED BY AN EXTERNAL DE ICE OR ANTI ICING BOOT REFER TO FIGURE 3 1 LIMITS AIRWORTHY DAMAGE MINOR REPAIR DESIGNATION LIMITS INSTRUCTIONS a LIMITS 1 maximum of 40 percent of the For a debond that extends to the edge erosion shield may be debonded in or a crack there is no limit to the size any 6 inch length 153 mm section of of the repair attempted Repair in the erosion shield accordance with section 2 C 1 in the Minor Repair chapter in this manual 9 NICKEL EROSION SHIELD DEBONDS BOUNDED BY TWO CHORDWISE CRACKS FOR ALL AREAS THAT ARE COVERED BY AN EXTERNAL DE ICE OR ANTI ICING BOOT REFER TO FIGURE 3 1 LIMITS AIRWORTHY DAMAGE MINOR REPAIR DESIGNATION LIMITS INSTRUCTIONS a LIMITS 1 Any number of chordwise cracks For a debond that extends to the edge permitted even full width
83. h of shield repaired within this limit must be damage to the blade surface below replaced at overhaul the erosion shield is 0 020 inch 0 50 mm NOTE This is two layers of fibrous material Damage cannot be permanently repaired without replacement of the erosion shield but within these limits does not make the blade unairworthy LIMITS 2 A gouge through the erosion shield to Minor repair is not authorized the blade surface below the erosion shield is not permitted NICKEL EROSION SHIELD AREA MISSING ALONG THE TRAILING EDGE OF THE EROSION SHIELD FOR THE ENTIRE EROSION SHIELD REFER TO FIGURE 3 1 AND FIGURE 3 2 LIMITS AIRWORTHY DAMAGE MINOR REPAIR DESIGNATION LIMITS INSTRUCTIONS a LIMITS 1 Pieces of material from the trailing If the damage is within the Airworthy edge of the erosion shield may Damage Limits repair in accordance be missing because of erosion or with section 2 B 1 in the Minor Repair sanding performed during the erosion chapter in this manual shield installation procedure The missing area must be no farther than 0 25 inch 6 3 mm from the trailing edge of the erosion shield Refer to Figure 3 2 for an example of permitted missing material Damage cannot be permanently repaired without replacement of the erosion shield but within these limits does not make the blade unairworthy FOR MAJOR REPAIRS REFER TO THE PERSONNEL REQUIREMENTS SECTION IN THE INTRODUCTION CHAPTER OF THIS SERVICE MANUAL
84. he original shape is achieved 3 Use 140 grit or finer sandpaper for final sanding Visually examine the repaired area 1 The repaired area must be smooth and free from wrinkles voids resin rich areas Make a Coin Tap Inspection in accordance with the Inspection chapter of this manual Delaminations or voids are not permitted I gt If the area of repair is not within the limits specified repair in accordance with the applicable repair instructions 3 Repeat the inspections and repair until the repair is satisfactory Refinish the blade in accordance with section 5 Finish Procedures in this chapter MINOR REPAIR 61 1 3 70 ilc COMPOSITE PROPELLER BLADE FIELD HARTZ ELL MAINTENANCE AND MINOR REPAIR MANUAL 2 170 Limits 2 a Using a grinder or sander remove material to create a bevel that extends outward from the repair area 0 50 inch 12 7 mm for each 0 010 inch 0 254 mm in depth Refer to Figure 4 6 1 If the bevel extends into the leading edge the erosion shield must be removed to complete the repair Replacement of the erosion shield is a major repair performed at overhaul INO For repaired area limits refer to section 3 H Repair Area Limits Kevlar Carbon Hybrid Blade Only in this chapter WARNING ADHESIVES AND SOLVENTS ARE FLAMMABLE AND TOXIC TO THE SKIN EYES AND RESPIRATORY TRACT SKIN AND EYE PROTECTION ARE REQUIRED AVOID PROLONGED CONTACT AND BREATHING OF VAP
85. he repaired area will prevent sticking of the vacuum bagging material to the repaired area 1 If necessary to hold place apply tape to the edges of the Teflon bleeder cloth CM58 outside of the repaired area Put a piece of polyester absorbent cloth CM59 over the Teflon bleeder cloth CM58 in the repaired area NOTE Making the polyester absorbent cloth CM59 slightly smaller than the Teflon bleeder cloth CM58 will reduce the sanding needed 1 If necessary to hold in place apply tape to the edges of the polyester absorbent cloth CM59 outside of the repaired area 2 Cuta piece of vacuum bag material CM45 large enough to cover the entire repaired area 3 Put the piece of vacuum bag material CM45 on the repaired area 4 Prepare two semi rigid plates to clamp over the repaired area a Make the plates from metal plastic Masonite or other semi rigid material b one plate long enough so that when the plates are clamped on the blade the plates will extend beyond the repaired area IO When the repair is to a curved area of the blade a layer of compressive material such as foam rubber may be used between the repair area and the plate to help apply uniform pressure when curing the repaired area 61 13 70 E E B E COMPOSITE PROPELLER BLADE FIELD HARTZ ELL MAINTENANCE AND MINOR REPAIR MANUAL 170 TI 00110H Trail Edge of the Original TIP 2 0 1
86. in the repair area and align the layers to fit within the repair area adjacent to the foam surface and the Kevlar surface Refer to Figure 4 10 1 Using adhesive CM14 or CM15 saturate each layer of E glass CM55 after it is applied to the repair area 2 Use the layers of precut E glass CM55 that were cut to wrap around the trail edge of the blade and cover the opposite side of the repair area but do not wrap the layers around the blade at this time MINOR REPAIR 61 1 3 70 n COMPOSITE PROPELLER BLADE FIELD HARTZ ELL MAINTENANCE AND MINOR REPAIR MANUAL 170 Apply layer s of precut fiberglass fabric CM42 over the entire repair area to achieve the original airfoil shape but do not wrap the layer s around to the other side of the blade at this time Refer to Figure 4 10 NOTE The fiberglass fabric 42 helps to blend the layers and most of it may be sanded away 1 Using adhesive CM14 or CM15 saturate the fiberglass fabric 42 Holding all of the layers firmly in place carefully turn the blade over to the other side NOTE Holding or temporarily taping a flat plate over the layers will help keep the layers in place when turning the blade Using very small pieces of E glass 55 fill in the area where the foam is missing Refer to Figure 4 10 1 Using adhesive CM14 or CM15 saturate the E glass CM55 that was used to fill in the area where the foam is missing and the entire repair area Wrap E glass CM55 from
87. ion Inboard Limit of the Tip and Trailing Edge Region Trailing Edge Foam X is measured from the tip Region Repair From the of the blade Blade Tip N7605 B K 2 17 93 inches 455 42 mm XE EISE 7893 4 50 inches 114 3 mm 25 00 635 0 10 52 267 20 26 25 666 75 9 02 inches 229 10 24 75 inches 628 65 mm NC9208 3 63 inches 92 2 mm 28 31 inches 719 0 mm 21 74 inches 552 1 mm Repair Regions N shank Blades with Only Trailing Edge Foam Figure 1 2 INSPECTION PROCEDURES 61 1 3 70 COMPOSITE PROPELLER BLADE FIELD HARTZ ELL MAINTENANCE AND MINOR REPAIR MANUAL 170 135014 For each blade model listed this table refer to Table 2 1 for limits of damage permitted in the regions shown Inboard Outboard Trailing Edge Foam and Tip and Trailing Edge Inboard Limit of the Leading Edge Foam Region Repair From the Blade Tip nz Leading Edge Foam Region Distance From the Blade Tip M to the Inboard Region of the Blade Outboard Ww Region X gt ny Inboard Limit of the Tip and Trailing Edge Region Trailing Edge Foam Region X is measured from the tip Repair From the Blade Tip of the blade NC8834 27 00 inches 3 85 inches 1 03 inches 27 00 inches 20 74 inches 685 8 mm 97 8 mm 26 1 mm 685 8 mm 526 7 mm Repa
88. ir Regions N shank Blades With Both Trailing Edge and Leading Edge Foam Figure 1 3 INSPECTION PROCEDURES 61 1 3 70 ips A COMPOSITE PROPELLER BLADE FIELD HARTZ E LL MAINTENANCE AND MINOR REPAIR MANUAL 170 TI 135013a For each blade model listed in this table refer to Table 2 1 for limits of damage permitted in the regions shown Inboard Outboard Trailing Edge Foam and Tip and Trailing Edge TZ Distance From the Blade Tip to the Inboard Region of the Blade Bh Trailing Edge Foam Region Tip and Trailing Edge Region X is measured from the tip of the blade myn Inboard Limit of the Trailing Edge Foam Region Repair From the Blade Tip Repair Regions Bantam Blades Figure 1 4 INSPECTION PROCEDURES 61 1 3 70 edits COMPOSITE PROPELLER BLADE FIELD HARTZ ELL MAINTENANCE AND MINOR REPAIR MANUAL 170 b Composite blades incorporate a separate foam trailing edge and some models also have a foam leading edge The foam regions have a different tone when coin tapped 1 To avoid confusing sounds coin tap the foam region s and the transition area between the foam region s and the blade separately from the blade area Refer to Figures 1 2 thru 1 4 2 Mapping of the area to be coin tapped is desirable to make sure that the entire surface is sufficiently inspected Refer to Figure 1 5 a Make a coin tap inspection within an imaginary grid or matrix consis
89. kles and that no air is trapped under the erosion tape CM158 CAUTION DO NOT DAMAGE THE BLADE WHEN REMOVING AIR BUBBLES 3 Remove air bubbles under the erosion tape by carefully puncturing the erosion tape CM158 with a sharp pin and pressing out the trapped air 4 Repeat step 5 B 1 m 1 thru 3 on the other side of the blade 61 13 70 k A COMPOSITE PROPELLER BLADE FIELD HARTZ ELL MAINTENANCE AND MINOR REPAIR MANUAL 170 6 Documenting the Repair A Blade Damage Repair Sheet 1 Complete the Blade Damage Repair Sheet from the applicable Hartzell Propeller Inc Propeller owner s manual to log in the propeller logbook identifying all repairs B Propeller Logbook 1 Make an entry in the propeller logbook that a repair has been made in accordance with this service manual and reference the applicable Blade Damage Repair Sheet MINOR REPAIR 61 1 3 70 n mE COMPOSITE PROPELLER BLADE FIELD HARTZ ELL MAINTENANCE AND MINOR REPAIR MANUAL 170 This page is intentionally blank minorrerar 61 13 70 ER A COMPOSITE PROPELLER BLADE FIELD HARTZ ELL MAINTENANCE AND MINOR REPAIR MANUAL 170 TOOLING AND MATERIALS CONTENTS Te Mc err emen MR 5 3 5 3 5 3 Composite Blade Repair Blanket 5 3 VE C CI NERO 5 4 Ar G
90. l material 2 Starting with 80 grit or finer sandpaper and using progressively finer grit sandpaper sand until the original shape is achieved 3 Use 140 grit or finer sandpaper for final sanding Visually examine the repaired area 1 The repaired area must be smooth and free from wrinkles voids or resin rich areas Make a Coin Tap Inspection of the repaired area in accordance with the Inspection chapter in this manual Delaminations or voids are not permitted I If the area of repair is not within the limits specified repair in accordance with the applicable repair instructions 3 Repeat the inspections and repair until the repair is satisfactory Refinish the blade in accordance with section 5 Finish Procedures in this chapter MINOR REPAIR 61 1 3 70 COMPOSITE PROPELLER BLADE FIELD HARTZ ELL MAINTENANCE AND MINOR REPAIR MANUAL G Curing Procedures 1 Cure of Trailing a General CAUTION 170 Edge Repairs DO NOT USE CURE OPTION 2 FOR CURINGA TRAILING EDGE FOAM REPAIR 1 There are two options for curing the repair a lo b Preparing Cure Option 1 uses a room temperature or oven cure cycle for curing the repair 1 Plates and clamps are used to apply even pressure to the repaired area Cure Option 2 uses a blade repair blanket TE304 that supplies heat for accelerated curing of the repair 2 The blade repair blanket TE304 and clamps are used to apply even pressure to
91. l to 2 75 inches 69 8 Select the largest R of the two finished repaired areas Determine D between the two individual finished repair areas lo I D must be equal to or greater than the largest R 61 13 70 icon COMPOSITE PROPELLER BLADE FIELD HARTZ ELL MAINTENANCE AND MINOR REPAIR MANUAL 170 4 Paint and or Filler Material CAUTION INSTRUCTIONS AND PROCEDURES IN THIS SECTION INVOLVE PROPELLER CRITICAL PARTS REFER TO THE INTRODUCTION CHAPTER OF THIS MANUAL FOR INFORMATION ABOUT PROPELLER CRITICAL PARTS A Loss of Paint and or Filler Material For the Erosion Shield Only 1 Limits 1 a Using 120 grit or finer sandpaper remove the paint and expose the entire area to be repaired 1 Feather the area into the non repair area of the blade CAUTION DO NOT SAND THROUGH THE MESH MATERIAL USE EXTREME CARE WHEN SANDING DOWN TO THE BLADE SURFACE AN N SHANK COMPOSITE BLADE HAS ALUMINUM MESH ON THE BLADE SURFACE THAT FORMS PART OF THE LIGHTNING PROTECTION SYSTEM b If the damaged area still contains filler material continue to sand the area using 120 grit or finer sandpaper until all filler material and damaged material is removed WARNING ADHESIVES AND SOLVENTS ARE FLAMMABLE AND TOXIC TO THE SKIN EYES AND RESPIRATORY TRACT SKIN AND EYE PROTECTION ARE REQUIRED AVOID PROLONGED CONTACT AND BREATHING OF VAPORS USE SOLVENT RESISTANT GLOVES TO MINIMIZE SKIN CONTACT A
92. lable on the Hartzell Propeller Inc website at www hartzellprop com 38 NOT APPLICABLE FOR MAJOR REPAIRS REFER TO THE PERSONNEL REQUIREMENTS SECTION IN THE INTRODUCTION CHAPTER OF THIS SERVICE MANUAL REPAIR LIMITS 61 1 3 70 ER A COMPOSITE PROPELLER BLADE FIELD HARTZ ELL MAINTENANCE AND MINOR REPAIR MANUAL 170 MINOR REPAIR CONTENTS elei ett EIE 4 3 ELT rc T 4 3 2 Nickel Erosion 4 4 f 4 4 nm M 4 4 jte 4 5 B Missing Area Along Trailing Edge of Erosion Shield Limits 1 4 5 Debond Extending to the Trailing Edge and or a Crack Limits 1 4 7 2 Blade eec 4 10 Gouges Delaminations or Loss of Composite Material Outboard Region of the 2 4 10 4 10 2 DMS 4 14 Gouges Delaminations Loss of Composite Material Trailing Edge Foam and Leading Edge Foam Regions of the Blade 4 16 4 16 vog 4 16 C Split Trailing Edge and Trailing Edge Regions of the 4 19 4 19
93. lamination Outboard region of the blade that is not covered by erosion screen 3 13 25 Delamination Outboard region of the blade that is covered by erosion screen 3 13 26 Delamination Trailing edge foam and leading edge foam regions of the blades 3 13 27 Delamination MM M NNNM 3 14 28 Split Trailing Edge and trailing edge regions of the blade 3 14 REPAIR LIMITS 61 1 3 70 COMPOSITE PROPELLER BLADE FIELD HARTZ ELL MAINTENANCE AND MINOR REPAIR MANUAL 170 29 Split Trailing Edge inboard redion of the IAD enter 3 14 30 Crushed or Cracked Trailing Edge inboard region of the 6 3 15 31 Crushed or Cracked Trailing Edge Ouiboard and tip regions Of the Blade oit a tret inn 3 15 32 Crushed or Cracked Trailing Edge Trailing edge foam region of the blade eene 3 15 32 Paint Erosion Tor the entre blade dao oe ab bte 3 16 34 Loss of Paint and or Filler Material for the erosion shield only 3 17 35 Missing Expanded Foil MBSIL D tp Iu pt tr poe 3 17 36 Missing Erosion SCOM a a 3 17 37 De ice or Anti icing Boot Damage wear 3 17 38 Not applicable to models included in this manual LIST OF FIGURES Interpretation of Erosion Shield
94. m eeo Bp b aM RO PIDE 8 SN ee o RET TOR D TRO RIEN TIVE TUN 8 Inspection Procedures sisne ee gt 8 C Damage 8 8 E Minot 8 8 9 O ADD 12 INTRODUCTION 61 1 3 70 Cu n mE COMPOSITE PROPELLER BLADE FIELD HARTZ ELL MAINTENANCE AND MINOR REPAIR MANUAL 170 This page is intentionally blank INTRODUCTION 61 1 3 70 pom COMPOSITE PROPELLER BLADE FIELD HARTZ ELL MAINTENANCE AND MINOR REPAIR MANUAL 170 1 Statement of Purpose A General 1 2 This manual has been reviewed and accepted by the FAA Additionally this manual contains data that has been approved in a manner acceptable to the FAA Administrator This manual provides field maintenance and minor repair procedures for the Hartzell Propeller Inc composite blade models listed below Blade Model Material Construction N7605 B K Kevlar Carbon Hybrid N7605C All Carbon N76MO5C X All Carbon N 7893 Kevlar Carbon Hybrid NG8301 All Carbon 75A01 2 All Carbon L76A01X Carbon H79A06X All Carbon NC8834 All Carbon NC9208 All Carbon a The propeller blade models addressed in this manual may be Type Certificated by the FAA or may be experimental Experimental parts must not be installed on a type certified propeller Always refer
95. maximum of 20 percent of the A debond that is within the airworthy erosion shield may be debonded in damage limits and is no farther than any 6 inch 153 mm length of the 0 25 inch 6 3 mm from the trailing erosion shield edge may be repaired in accordance with section 2 C 1 in the Minor Repair chapter in this manual NICKEL EROSION SHIELD CHORDWISE CRACK FOR ALL AREAS THAT ARE NOT COVERED BY AN EXTERNAL DE ICE OR ANTI ICING BOOT REFER TO FIGURE 3 1 LIMITS AIRWORTHY DAMAGE MINOR REPAIR DESIGNATION LIMITS INSTRUCTIONS LIMITS 1 Two full width chordwise cracks may Minor repair is not authorized not be within 6 0 inches 153 mm of each other A chordwise crack may not be within 6 0 inches 153 mm of the blade tip A chordwise crack may not be within 6 0 inches 153 mm of the outboard end of the de ice or anti icing boot A chordwise crack may not be within 6 0 inches 153 mm of the inboard end of the erosion shield when not covered by a de ice or anti icing boot 6 NICKEL EROSION SHIELD LENGTHWISE CRACKS FOR ALL AREAS THAT ARE NOT COVERED BY AN EXTERNAL DE ICE OR ANTI ICING BOOT REFER TO FIGURE 3 1 FIGURE 3 3 AND FIGURE 3 4 LIMITS AIRWORTHY DAMAGE MINOR REPAIR DESIGNATION LIMITS INSTRUCTIONS LIMITS 1 The maximum permitted length of Minor repair is not authorized a crack is 2 0 inches 50 mm Two lengthwise cracks may not be within the same linear length on the erosion shield This includes cracks on o
96. n takes precedence over any conflicting information from the manufacturer or in Table 5 1 in this chapter f Materials purchased directly from Hartzell Propeller Inc will not have storage temperature control information added to the package or container The temperature control information contained in Table 5 1 in this chapter takes precedence over any conflicting information from the manufacturer g For materials purchased from other sources the purchaser is required to record the expiration date control information required by Hartzell Propeller Inc on the package or container in accordance with Table 5 1 in this chapter Storage temperature control information in Table 5 1 must be observed C Date Code Formats 1 The expiration date may be recorded using the letters Exp followed by a month and year In this case the shelf life of that material extends through the last day of the month and year recorded D Consumable Material Management Procedures 1 2 Rotate stock on a first in first out basis Epoxy and other materials normally require at minimum a room temperature cure Lower temperatures may greatly increase the cure time Temperatures below 60 F 15 C my cause the epoxy not to cure at all TOOLING AND MATERIALS 61 1 3 70 ina HA mE E COMPOSITE PROPELLER BLADE FIELD HARTZ ELL MAINTENANCE AND MINOR REPAIR MANUAL 170 E Revisions 1 Alternate Alternate consumable materials are identified
97. nch 0 254 mm in depth on each side of the blade Refer to Figure 4 6 IN Stop periodically and examine the progress NOTE Wiping the area with a clean cloth CM159 or equivalent dampened with solvent acetone CM173 MEK CM106 or MPK CM219 can help to visually find the defect For repaired area limits refer to section 3 H Repair Area Limits Kevlar Carbon Hybrid Blade Only in this chapter Ico A Stop removing material when the damage has been sufficiently removed or the minor repair limit has been reached c After removing material examine the repair area 1 The remaining layers must be fully bonded 2 l fdamaged material remains after reaching the minor repair limit send the blade to Hartzell Propeller Inc for factory only repair 3 Make a Inspection of the repaired area in accordance with the Inspection chapter in this manual a Ifthe results of the coin tap inspection are not satisfactory send the blade to Hartzell Propeller Inc for factory only repair MINOR REPAIR 61 1 3 70 icc n mE EMEN COMPOSITE PROPELLER BLADE FIELD HARTZ ELL MAINTENANCE AND MINOR REPAIR MANUAL 170 Area to be Filled with Adhesive CM14 or CM15 Small Pieces of E glass CM55 Layers of E glass CM55 Layers of Fiberglass Fabric CM42 Repair Layers Figure 4 10 MINOR REPAIR 61 1 3 70 M COMPOSITE PROPELLER BLADE FIELD HARTZ ELL MAINTENANCE AND MINOR REPAIR MANUAL 170 WARNING ADHESIVES A
98. necessary to hold in place apply tape to the plate outside of the repaired area MINOR REPAIR 61 1 3 70 ati COMPOSITE PROPELLER BLADE FIELD HARTZ ELL MAINTENANCE AND MINOR REPAIR MANUAL 170 CAUTION EXCESSIVE CLAMP FORCE WILL DAMAGE THE IO d e BLADE SECURE THE PLATE TO THE BLADE WITH MINIMAL FORCE Install clamps as necessary to apply even pressure to the repaired area Permit the adhesive to cure for 12 hours at room temperature or for 2 hours at 145 5 F 63 2 Remove the plates and the cure materials from the blade CAUTION DO NOT USE CURE OPTION 2 FOR CURING A TRAILING EDGE FOAM REPAIR 2 Cure Option 2 Blade Repair Blanket Cure CAUTION DO NOT PUT THE TEMPERATURE INDICATING 00 STRIPS DIRECTLY OF THE REPAIR Put two temperature indicating strips one each of TE306 and TE307 on each side of the blade adjacent to the repair area to monitor the temperature during the cure cycle 1 One strip TE306 has a temperature range of 120 to 180 F 2 The second strip TE307 has a temperature range of 190 to 220 F 3 Monitoring of the temperature of both sides of the blade is necessary because the blade repair blanket TE304 is constructed with two heating elements one for each side of the blade a Each element is independently controlled by a nonadjustable controller contained within the blade repair blanket TE304 Cut a piece of vacuum bag m
99. o dry Cut two pieces of E glass CM55 to the shape of the missing area 1 Alternately four layers of fiberglass fabric CM42 may be used Put one layer of E glass CM55 or fiberglass fabric CM42 on the area to be repaired Using adhesive CM14 or CM15 completely saturate the layer of E glass CM55 or fiberglass fabric CM42 Put the second layer of E glass CM55 or fiberglass fabric CM42 on the area to be repaired making sure that the layer is completely saturated 1 Apply additional adhesive CM14 or CM15 and layers of fiberglass fabric 42 if necessary Permit the adhesive CM14 or CM154 to cure for 12 hours at room temperature or for 2 hours at 145 5 F 63 2 C Using no coarser than 60 grit sandpaper sand to the original shape 61 13 70 irs n E COMPOSITE PROPELLER BLADE FIELD HARTZ ELL MAINTENANCE AND MINOR REPAIR MANUAL 170 50323 0322 Using a plastic wedge gently lift edge of erosion shield far enough to permit brushing on the cleaning solvent and positioning the optional fiberglass fabric Erosion shield with debond extending to crack 0 O optional fabric shown Cut optional fiberglass fabric and saturate MN with adhesive mixture Place piece of fabric on putty knife position it in front of lifted edges of erosion shield and slide it into debond area If fabric is not used force adhesive into debond cavity with putty knife or small flat ins
100. o is as shown here The mix ratio differs from the manufacturer s label Make sure to use the mix ratio that is specified by Hartzell Propeller Inc TOOLING AND MATERIALS 61 1 3 70 COMPOSITE PROPELLER BLADE FIELD AND MINOR REPAIR MANUAL HARTZELL 170 VS 91991 9 qeuinsuo s u w nb SJainjoesnueW MOJJOJ eroeds ou 9N 29 92 6 4208 09 0 91 4009 0 Y 2241 4 0 uezoJ 4 uo qW Sujuoul Jeijddng jueuudius jo Sod eJnjoejnue w IWOG Jejjedoug jeuejeu y eseuound eui ejqeuunsuoo jo Jal ddns Ajuo y 1 1ejjedoJug IdH jJe20 eseuound Jeuiojsno eu ejqeuunsuoo eu S jou SBOP Jejedoug N BDO JO JejedoJg 2 Jeuyie ejqeuinsuoo y ueo 2 A SdSSV 19 dial ADVYOLS S3009 3417 413HS S3309 SISV8 AlddNS JOO X 996 U BE on gouno 2 4 7297 42 on enb
101. omposite Material Outboard Region of the Blade Limits 2 Refer to section 3 A 2 in this chapter CAUTION 1 DO NOT REMOVE MATERIAL ANY DEEPER THAN NECESSARY TO FULLY REMOVE THE DAMAGE CAUTION 2 DO NOT SAND INTO THE FOAM MATERIAL OF THE BLADE Using a grinder or sander with no coarser than 60 grit sandpaper remove damaged composite material in the area to be repaired 1 9 A While removing material make a bevel 0 50 to 1 00 inch 12 7 to 25 4 mm for each 0 010 inch 0 25 mm depth of damaged material removed Ifthe area requiring removal extends to an edge maintain the bevel to the edge Stop periodically and examine the progress NOTE Wiping the area with a clean cloth CM159 or equivalent dampened with solvent acetone CM173 MEK CM106 or MPK CM219 can help to visually find the defect Stop removing material when the damage has been removed or the foam material has been exposed the foam material has been exposed Visually examine the foam for damage for example a crack crushed foam or a gouge 1 Ifthe foam is damaged send the blade to Hartzell Propeller Inc for factory only repair lo The maximum permitted length of exposed foam is 1 0 inch 25 mm 1 Ifthe amount of exposed foam is greater than the permitted limit send the blade to Hartzell Propeller Inc for factory only repair 61 13 70 E COMPOSITE PROPELLER BLADE FIELD HARTZ ELL MAINTEN
102. on screen 26 Delamination Trailing edge foam and leading edge foam regions of the blade 27 Delamination inboard regionot the blade ote irent 28 Split Trailing Edge Tip and trailing edge regions of the blade 29 Split Trailing Edge inboard quein ORE DAMAGE EVALUATION 6 1 1 3 70 E COMPOSITE PROPELLER BLADE FIELD HARTZ ELL MAINTENANCE AND MINOR REPAIR MANUAL 170 30 Crushed or Cracked Trailing Edge inboard region of the 2 7 31 Crushed Cracked Trailing Edge Outboard and tip regions of the 2 7 32 Crushed or Cracked Trailing Edge Trailing edge foam region of the 2 7 33 Paint Erosion for the entire 2 7 34 Loss of Paint and or Filler Material for the erosion shield 2 8 35 Missing Expanded Foil 2 8 36 Missing Erosion 2 8 37 De ice or Anti icing Boot Damage wear 2 8 38 Not applicable to models included in this manual See the NOTE included in Table 2 1
103. or repair is that which may be done safely in the field by a certified aircraft mechanic 2 Major repair work is that which exceeds the minor repair limits as specified in Table 3 1 in this chapter 2 Repair Limits CAUTION INSTRUCTIONS AND PROCEDURES IN THIS SECTION INVOLVE PROPELLER CRITICAL PARTS REFER TO THE INTRODUCTION CHAPTER OF THIS MANUAL FOR INFORMATION ABOUT PROPELLER CRITICAL PARTS A Repair Limits by Damage Type Refer to Table 3 1 CAUTION REFER TO TABLE 2 1 IN THE DAMAGE EVALUATION CHAPTER OF THIS MANUAL FOR THE APPLICABLE DAMAGE TYPE AND REPAIR LIMITS BY BLADE MODEL REFER TO THIS TABLE FOR THE AIRWORTHY AND MINOR REPAIR LIMITS FOR EACH DAMAGE TYPE 1 NICKEL EROSION SHIELD MINOR DEFORMATION FOR THE ENTIRE EROSION SHIELD LIMITS AIRWORTHY DAMAGE MINOR REPAIR DESIGNATION LIMITS INSTRUCTIONS a LIMITS 1 Deformed material not associated Minor repair is not authorized with a crack or missing material less than 10 percent of the leading edge radius or no more than 0 080 inch 2 03 mm deep because of impact damage or erosion FOR MAJOR REPAIRS REFER TO THE PERSONNEL REQUIREMENTS SECTION IN THE INTRODUCTION CHAPTER OF THIS SERVICE MANUAL Repair Limits by Damage Type Table 3 1 REPAIR LIMITS 61 1 3 70 E B COMPOSITE PROPELLER BLADE FIELD HARTZ ELL MAINTENANCE AND MINOR REPAIR MANUAL 170 APS6041 Chordwise Full width crack gt Lengthwise Face Side of Blade Trailing e
104. posite blade repair blanket TE304 p n HZP161001 may be used for cure of repairs in accordance with section 3 G Curing Procedures in the Minor Repair chapter in this manual a Ifthe composite blade repair blanket is used Temp Plate Recorder indicating strips TE306 p n 240 120F and TE307 p n 240 190F must also be used Example of a Coin Figure 5 1 TOOLING AND MATERIALS 61 1 3 70 Eu COMPOSITE PROPELLER BLADE FIELD HARTZ ELL MAINTENANCE AND MINOR REPAIR MANUAL 2 Materials A General 170 1 Safe Handling of Paints and Chemicals a b Always use caution when handling or being exposed to paints and or chemicals during propeller overhaul and maintenance procedures Before using paint or chemicals always read the manufacturer s label on the container and follow specified instructions and procedures for storage preparation mixing and application Refer to the product s Material Safety Data Sheet MSDS for detailed information about physical properties health and physical hazards of any chemical B Consumable Materials Control Requirements 1 Table 5 1 lists the supply basis cure time pot life storage temperature and shelf life for the consumable materials referenced in this manual a Supply basis codes have been assigned to each consumable material to indicate if the item can be purchased from Hartzell Propeller Inc The following supply basis codes hav
105. pposite sides of the blade FOR MAJOR REPAIRS REFER TO THE PERSONNEL REQUIREMENTS SECTION IN THE INTRODUCTION CHAPTER OF THIS SERVICE MANUAL Repair Limits by Damage Type Table 3 1 continued REPAIR LIMITS 61 1 3 70 E B COMPOSITE PROPELLER BLADE FIELD HARTZ ELL MAINTENANCE AND MINOR REPAIR MANUAL 170 CAUTION REFER TO TABLE 2 1 IN THE DAMAGE EVALUATION CHAPTER OF THIS MANUAL FOR THE APPLICABLE DAMAGE TYPE AND REPAIR LIMITS BY BLADE MODEL REFER TO THIS TABLE FOR THE AIRWORTHY AND MINOR REPAIR LIMITS FOR EACH DAMAGE TYPE 7 NICKEL EROSION SHIELD DEBONDS BOUNDED BY ALENGTHWISE CRACK FOR ALL AREAS THAT ARE COVERED BY AN EXTERNAL DE ICE OR ANTI ICING BOOT REFER TO FIGURE 3 1 FIGURE 3 4 AND FIGURE 3 5 LIMITS AIRWORTHY DAMAGE MINOR REPAIR DESIGNATION LIMITS INSTRUCTIONS a LIMITS 1 In the area bounded alengthwise For a debond that extends to the edge crack and the trailing edge of or crack there is no limit to the size the erosion shield the maximum of the repair attempted Repair in permitted area that may be debonded accordance with section 2 C 1 in the is 40 percent Minor Repair chapter in this manual NOTE For crack limits refer to the applicable section in this table FOR MAJOR REPAIRS REFER TO THE PERSONNEL REQUIREMENTS SECTION IN THE INTRODUCTION CHAPTER OF THIS SERVICE MANUAL Airworthy and Minor Repair Limits Table 3 1 continued Debond that does not extend to an ed
106. r chapter in this manual 32 CRUSHED OR CRACKED TRAILING EDGE TRAILING EDGE FOAM REGION OF THE BLADE LIMITS AIRWORTHY DAMAGE DESIGNATION LIMITS REPAIR LIMITS a LIMITS 1 The maximum permitted depth of a The maximum permitted depth of a crushed or cracked area is 0 25 inch crushed or cracked area is 6 3 mm The maximum permitted 0 375 inch 9 52 mm The maximum length of a crushed or cracked area is permitted length of a crushed or 2 0 inches 50 mm cracked area is 2 0 inches 50 mm Repair in accordance with section 3 E 1 in the Minor Repair chapter in this manual FOR MAJOR REPAIRS REFER TO THE PERSONNEL REQUIREMENTS SECTION IN THE INTRODUCTION CHAPTER OF THIS SERVICE MANUAL Repair Limits by Damage Type Table 3 1 continued 61 13 70 lr mE EEE OE COMPOSITE PROPELLER BLADE FIELD HARTZ ELL MAINTENANCE AND MINOR REPAIR MANUAL 170 CAUTION REFER TO TABLE 2 1 IN THE DAMAGE EVALUATION CHAPTER OF THIS MANUAL FOR THE APPLICABLE DAMAGE TYPE AND REPAIR LIMITS BY BLADE MODEL REFER TO THIS TABLE FOR THE AIRWORTHY AND MINOR REPAIR LIMITS FOR EACH DAMAGE TYPE 33 PAINT EROSION FOR THE ENTIRE BLADE LIMITS AIRWORTHY DAMAGE MINOR DESIGNATION LIMITS REPAIR LIMITS a LIMITS 1 For the areas of the blade where If the damage is within the Airworthy there is composite material the Damage Limits repair in accordance maximum permitted exposure of the with section 5 Finish Procedures in
107. r of this manual Delaminations or voids are not permitted b Ifthe area of repair is not within the limits specified repair in accordance with the applicable repair instructions c Repeat the inspections and repair as necessary until the repair is satisfactory Make an inspection of the finished repaired area in accordance with section 3 H Repair Limits Kevlar amp Carbon Hybrid Blade Only in this chapter Refinish the blade in accordance with section 5 Finish Procedures in this chapter D Crushed or Cracked Trailing Edge Outboard and Tip Regions of the Blade 1 Limits 1 Using a grinder or sander remove loose surface material 1 Some of the blade material even though damaged may remain on the blade a l fdamaged material is fully intact it should remain on the blade NOTE If more than one layer remains on the blade but the layers are separated from each other adhesive CM14 or CM15 will be injected between these layers when the repair is made Using a grinder or sander remove material to create a bevel that extends outward from the repair area 0 500 inch 12 7 mm for each 0 010 inch 0 254 mm in depth on each side of the blade Refer to Figure 4 6 1 If the bevel extends into the leading edge the erosion shield must be removed to complete the repair a Replacement of the erosion shield is a major repair performed at overhaul 2 For repaired area limits refer to the section Repair
108. re the erosion tape CM158 will be installed 2 Apply a thin uniform layer of adhesive promoter CM124 to the area of the blade where the erosion tape CM158 will be installed d Remove the masking material CAUTION THE ADHESIVE PROMOTER CM124 WILL BEGIN TO LOSE ADHESION AFTER 60 MINUTES AT ROOM TEMPERATURE 4 Permit the adhesive promoter CM124 to dry at room temperature for minimum of 15 minutes and a maximum of 60 minutes Peel the backing material from the erosion tape CM158 Holding the erosion tape CM158 with the adhesive side toward the blade align the end of the erosion tape with the alignment mark on the blade outboard of the metal blade shank and near the leading edge while aligning the centerline that was marked on the erosion tape with the leading edge of the blade Press the erosion tape 158 into position on the leading edge of the blade while maintaining light tension on the erosion tape to minimize air bubbles and keep the tape straight 1 Using a roller such as TE330 or TE331 or fingers press the erosion tape CM158 down onto the leading edge of the blade Using a roller such as TE330 or TE331 or fingers work the erosion tape CM158 into position on one side of the blade 1 Starting at the outboard end of the blade and working toward the shank use a hard rubber or nylon roller such as TE330 or TE331 or fingers to firmly seat the erosion tape 158 to the blade 2 Make sure that there are no wrin
109. s at 145 5 F 63 2 C Using no coarser than 60 grit sandpaper sand the repaired area smooth Visually examine the repaired area for adhesion and correct shape 61 13 70 ir COMPOSITE PROPELLER BLADE FIELD HARTZ ELL MAINTENANCE AND MINOR REPAIR MANUAL 170 Refinish the blade in accordance with section 5 Finish Procedures in this chapter 2 Limits 2 Minor repair is not authorized B Missing Area Along Trailing Edge of Erosion Shield 1 Limits 1 b Using no coarser than 60 grit sandpaper sand by hand the area under the missing area of the erosion shield just enough to remove the smooth surface NOTE Sanding to remove the smooth surface will permit the new composite material to adhere better Using no coarser than 60 grit sandpaper sand smooth any burrs rough or sharp areas around the missing area WARNING ADHESIVES AND SOLVENTS ARE FLAMMABLE AND TOXIC TO THE SKIN EYES AND RESPIRATORY TRACT SKIN AND EYE PROTECTION ARE REQUIRED AVOID PROLONGED CONTACT AND BREATHING OF VAPORS USE SOLVENT RESISTANT GLOVES TO MINIMIZE SKIN CONTACT AND WEAR SAFETY GLASSES FOR EYE PROTECTION USE INA WELL VENTILATED AREA AWAY FROM SPARKS AND FLAME READ AND OBSERVE ALL WARNING LABELS Using a clean cloth CM159 or equivalent dampened with solvent acetone CM173 CM106 219 wipe the area Permit the solvent acetone CM173 MEK 106 219 t
110. s at 145 5 F 63 2 C d Remove the plates and the cure materials from the blade c After cure return to applicable repair procedure for additional requirements Repair Area Limits Kevlar Carbon Hybrid Blade Only 1 General a The limits in this section apply when specified for a repair given in this manual b Ifthe amount of expanded foil remaining is less than the permitted limits given in this section factory only repair of the expanded foil may be possible Contact Hartzell Propeller Inc for determination 2 Tip Area Refer to Figure 4 11 thru Figure 4 14 a The repair procedures defined in this chapter may be performed in this area b If any damage or repair area extends beyond the tip area of the blade 1 damage in the tip area must be repaired in accordance with the repair procedures for the tip area as given in this manual 2 damage that extends beyond the tip area must be repaired in accordance with the repair procedures specific to that area as given in this manual Even though removal of the entire expanded foil in the Tip Area is permitted it is recommended to keep each repair as small as possible MINOR REPAIR 61 1 3 70 COMPOSITE PROPELLER BLADE FIELD HARTZ ELL MAINTENANCE AND MINOR REPAIR MANUAL 170 3 All Other Areas Refer to Figure 4 11 thru Figure 4 14 a b The location and size of each finished repair area is determined by the amo
111. sed to fill the debond apply pressure when curing the adhesive CM14 or CM15 as follows 1 Puta piece of vacuum bag material CM45 over the repaired area to prevent the plates from bonding to the blade Refer to Figure 4 3 2 Put plates made of metal plastic Masonite or other semi rigid material over the repaired area one on the face side and one on the camber side of the blade 3 Put C clamps on the plates and tighten the C clamps enough to apply moderate pressure to the repair CAUTION MAKE SURE THAT THE RAISED PORTIONS OF THE EROSION SHIELD ARE HELD FLAT BEFORE THE ADHESIVE CURES Permit the adhesive CM14 or CM15 to cure for 12 hours at room temperature or 2 hours at 145 5 F 63 2 C 5 Remove the C clamps plates and vacuum bag material CM45 14 Using no coarser than 60 grit sandpaper sand the repaired area smooth Make a Coin Tap Inspection in accordance with the Inspection chapter of this manual Delaminations or voids are not permitted I gt If the area of repair is not within the limits specified repair in accordance with the applicable repair instructions 3 Repeat the inspections and repair until the repair is satisfactory The repair must be within the airworthy damage limits specified in the Repair Limits chapter of this manual before being released to service Refinish the blade in accordance with section 5 Finish Procedures in this chapter 61 13 70 ro
112. sive side of the erosion tape CM158 to indicate the centerline of the erosion tape Using a non graphite pencil CM162 or equivalent measure and make a mark on the blade outboard of the metal blade shank near the leading edge Refer to Table 4 1 for the correct measurement 1 This alignment mark on the blade will be used to align the inboard edge of the erosion tape at installation WARNING ADHESIVES AND SOLVENTS ARE FLAMMABLE AND TOXIC TO THE SKIN EYES AND RESPIRATORY TRACT SKIN AND EYE PROTECTION ARE REQUIRED AVOID PROLONGED CONTACT AND BREATHING OF VAPORS USE SOLVENT RESISTANT GLOVES TO MINIMIZE SKIN CONTACT AND WEAR SAFETY GLASSES FOR EYE PROTECTION USE INA WELL VENTILATED AREA AWAY FROM SPARKS AND FLAME READ AND OBSERVE ALL WARNING LABELS Using a clean cloth dampened with solvent CM106 MEK CM219 or CM41 toluene thoroughly clean the area of the blade where the erosion tape CM158 will be installed 1 Using a clean lint free cloth immediately wipe the area dry 2 Permit the area to air dry 3 Repeat the cleaning and drying of the area MINOR REPAIR 61 1 3 70 isst COMPOSITE PROPELLER BLADE FIELD HARTZ ELL MAINTENANCE AND MINOR REPAIR MANUAL i 170 Application of Optional Adhesive Promoter CM124 NOTE Adhesive promoter CM124 will increase the adhesion between the erosion tape CM158 and the blade 1 Apply masking tape or equivalent as masking material to the perimeter of the area whe
113. tape CM158 b Work around the perimeter of the erosion tape CM158 lifting the edge of the tape from the blade c After the edge of the erosion tape CM158 is pulled up from the blade pull the erosion tape off one side of the blade toward the leading edge d With the erosion tape 158 stuck to only one side of the blade grasp one end of the erosion tape and pull toward the other end e Discard the removed erosion tape CM158 f Using a clean cloth dampened with solvent CM106 CM219 or CM41 Toluene remove all visible adhesive from the blade D Coin Tap Inspection 1 Composite blades are inspected for delaminations and debonds by tapping the entire surface of the blade with a washer shaped metal tapper or coin If an audible change is apparent sounding hollow or dead a debond or delamination is likely a Refer to the Tooling and Materials chapter of this manual for the description of a coin INSPECTION PROCEDURES 61 1 3 70 A en COMPOSITE PROPELLER BLADE FIELD HARTZ ELL MAINTENANCE AND MINOR REPAIR MANUAL 170 00055 For each blade model listed in this table refer to Table 2 1 for limits of damage permitted in the regions shown Inboard Outboard Trailing Edge Foam and Tip and Trailing Edge nnt Distance From the Blade Tip to the Inboard Region of the Blade Outboard 4 Inboard Region Region Trailing Edge Foam Reg
114. ted of composite material 23 GOUGE OR LOSS OF COMPOSITE MATERIAL INBOARD REGION OF THE BLADE LIMITS AIRWORTHY DAMAGE MINOR REPAIR DESIGNATION LIMITS INSTRUCTIONS a LIMITS 1 A gouge or loss of composite material Minor repair is not authorized on the inboard region of the blade is unairworthy Refer to Figures 1 2 thru 1 4 for specific region FOR MAJOR REPAIRS REFER TO THE PERSONNEL REQUIREMENTS SECTION IN THE INTRODUCTION CHAPTER OF THIS SERVICE MANUAL Repair Limits by Damage Type Table 3 1 continued REPAIR LIMITS 61 1 3 70 COMPOSITE PROPELLER BLADE FIELD HARTZ ELL MAINTENANCE AND MINOR REPAIR MANUAL 170 CAUTION REFER TO TABLE 2 1 IN THE DAMAGE EVALUATION CHAPTER OF THIS MANUAL FOR THE APPLICABLE DAMAGE TYPE AND REPAIR LIMITS BY BLADE MODEL REFER TO THIS TABLE FOR THE AIRWORTHY AND MINOR REPAIR LIMITS FOR EACH DAMAGE TYPE 24 DELAMINATION OUTBOARD REGION OF THE BLADE THAT IS NOT COVERED BY EROSION SCREEN LIMITS AIRWORTHY DAMAGE MINOR REPAIR DESIGNATION LIMITS INSTRUCTIONS a LIMITS 1 The maximum permitted area of If the damage is within the Airworthy delamination is 2 0 square inches Damage Limits repair in accordance 1290 sq mm On a Kevlar blade with section 3 A 1 in the Minor Repair dark brown stain or black stain is not chapter in this manual permitted b LIMITS 2 The maximum permitted area of If the damage is within the Airworthy delamination is
115. the composite material and or of the Minor Repair chapter in this manual primer filler is 5 0 square inches 3225 sq mm NOTE This limit does not refer to the primer sealer gray layer For the areas of the blade where there is an erosion shield paint may be missing from the entire area of the erosion shield and the blade is airworthy For maintenance scheduling purposes propellers with blades that show more than 5 0 square inches 3225 sq mm of paint erosion may continue operation for an additional 250 hours or 1 one month whichever occurs first b LIMITS 2 For the areas of the blade where H79A06X blades are finish coated with there is composite material the a paint that is restricted by U S law maximum permitted exposure of the and is subject to ITAR controls Contact composite material and or of the the airframe manufacturer for blade primer filler is 5 0 square inches repair information or return the blade to 3225 sq mm Hartzell Propeller Inc NOTE This limit does not refer to the primer sealer gray layer For the areas of the blade where there is an erosion shield paint may be missing from the entire area of the erosion shield and the blade is airworthy For maintenance scheduling purposes propellers with blades that show more than 5 0 square inches 3225 sq mm of paint erosion may continue operation for an additional 250 hours or 1 one month whichever occurs first FOR MAJOR REPAIRS REFER TO TH
116. the other side of the blade around the blade and apply to the repair area on this side of the blade 1 Align each layer of E glass CM55 to fit within the repair area adjacent to the foam surface and the Kevlar surface INO Using adhesive CM14 or 15 saturate each layer of E glass CM55 after it is applied to the repair area Wrap the fiberglass fabric CM42 from the other side of the blade around the blade and over the entire repair area to achieve the original airfoil shape 1 Using adhesive 14 or 15 saturate the fiberglass fabric CM42 CAUTION DO NOT USE OPTION NO 2 BLADE REPAIR BLANKET CURE WHEN CURING A TRAILING EDGE FOAM REPAIR Cure the repair in accordance with the section 3 G Curing Procedures in this chapter Using no coarser than 60 grit sandpaper sand or grind to the original airfoil shape Refer to Figure 4 8 G Make a visual inspection of the repaired area Repair any delaminations or voids minorrerar 61 13 70 COMPOSITE PROPELLER BLADE FIELD HARTZ ELL MAINTENANCE AND MINOR REPAIR MANUAL r t 170 Make a Coin Tap Inspection of the repaired area in accordance with the Inspection chapter in this manual Delaminations or voids are not permitted N I If the area of repair is not within the limits specified repair in accordance with the applicable repair instructions 3 Repeat the inspections and repair until the repair is satisfactory Make an inspection of the
117. the repaired area the Repaired Area for Curing 1 Optionally use Teflon bleeder cloth CM58 and polyester absorbent cloth 59 NOTE Using the Teflon bleeder cloth 58 and polyester 09 absorbent cloth CM59 will absorb excess resin minimize sanding and make clean up easier Cut a piece of Teflon bleeder cloth CM58 large enough to cover and extend beyond the repaired area on one side of the blade and fold over to cover and extend beyond the repaired area on the other side of the blade NOTE Making the Teflon bleeder cloth CM58 approximately 1 inch 25 4 mm larger than the repaired area will prevent sticking of the vacuum bagging material to the repaired area Put the piece of Teflon bleeder cloth CM58 over the repaired area on one side of the blade and fold it over to cover the repaired area on the other side of the blade 1 If necessary to hold in place apply tape to the edges of the Teflon bleeder cloth CM58 outside of the repaired area 61 13 70 en COMPOSITE PROPELLER BLADE FIELD HARTZ ELL MAINTENANCE AND MINOR REPAIR MANUAL 170 Cut a piece of polyester absorbent cloth CM59 large enough to cover the repaired area on one side of the blade and fold over to cover the repaired area on the other side of the blade IO NOTE Making the polyester absorbent cloth CM59 slightly smaller than the Teflon bleeder cloth CM58 will reduce the sanding needed
118. ting of 2 inch 51 mm squares on the composite blade surface b Acareful coin tapping of the erosion shield is necessary because of its size and shape 1 2 3 Tap in a smaller grid pattern up and down the length of the erosion shield Look and feel for any slight deformation of the erosion shield that may indicate a debonded area a deformation is found use more in that area when doing the coin tap inspection Ifa suspected delamination or debond is discovered a localized careful coin tap inspection is required to define the precise area of delamination or debond d Using a pencil outline the suspected area to determine the approximate size of the damage 3 Make a record of the damage and the repair in the propeller logbook em Coin tap on composite blade Coin tap along entire surface surface to check for delamination of erosion shield to check for debond Coin Tap Inspection Figure 1 5 INSPECTION PROCEDURES 61 1 3 70 p Damage Evaluation A Determining Damage Type and Repair Limits 1 Nickel Erosion Shield Minor 2 Nickel Erosion Shield Gouge 2 COMPOSITE PROPELLER BLADE FIELD HARTZ ELL MAINTENANCE AND MINOR REPAIR MANUAL 170 DAMAGE EVALUATION CONTENTS 3 Nickel Erosion Shield Area Missing Along the Trailing Edge of the Erosion Shield
119. trument Repair of Debond at Edge of Nickel Erosion Shield Figure 4 2 APS0320 One plate on each side of the blade Vacuum bag material CM45 under the top plate to prevent it from bonding to the blade Using C Clamps to Apply Pressure to Erosion Shield Debond Repair Figure 4 3 61 13 70 ires COMPOSITE PROPELLER BLADE FIELD HARTZ ELL MAINTENANCE AND MINOR REPAIR MANUAL k 1 170 Make a Coin Tap Inspection in accordance with the Inspection chapter of this manual Delaminations or voids are not permitted I gt If the area of repair is not within the limits specified repair in accordance with the applicable repair instructions 3 Repeat the inspections and repair until the repair is satisfactory Refinish the blade in accordance with section 5 Finish Procedures in this chapter C Debond Extending to the Trailing Edge and or a Crack 1 Limits 1 Make Coin Tap Inspection in accordance with the Inspection chapter of this manual 1 Usinga pencil or felt tip marker outline the area of the debond of the erosion shield WARNING ADHESIVES AND SOLVENTS ARE FLAMMABLE AND TOXIC TO THE SKIN EYES AND RESPIRATORY TRACT SKIN AND EYE PROTECTION ARE REQUIRED AVOID PROLONGED CONTACT AND BREATHING OF VAPORS USE SOLVENT RESISTANT GLOVES TO MINIMIZE SKIN CONTACT AND WEAR SAFETY GLASSES FOR EYE PROTECTION USE INA WELL VENTILATED AREA AWAY FROM SPARKS AND FLAME READ
120. tted length of a with section 3 C 3 in the Minor Repair split trailing edge is 2 0 inches chapter in this manual 50 mm Damaged fibers or exposed foam is not permitted d LIMITS 4 The maximum permitted depth of a If the damage is within the Airworthy split area is 0 5 inch 12 mm Damage Limits repair in accordance The maximum permitted length is with section 3 C 4 in the Minor Repair 6 0 inches 152 mm Damaged fibers chapter in this manual or exposed foam are not permitted 29 SPLIT TRAILING EDGE INBOARD REGION OF THE BLADE LIMITS AIRWORTHY DAMAGE DESIGNATION LIMITS REPAIR LIMITS a LIMITS 1 A split trailing edge on the inboard Minor repair is not authorized Retire region of the blade is unairworthy the blade or send the blade to Hartzell Propeller Inc for evaluation FOR MAJOR REPAIRS REFER TO THE PERSONNEL REQUIREMENTS SECTION IN THE INTRODUCTION CHAPTER OF THIS SERVICE MANUAL Repair Limits by Damage Type Table 3 1 continued REPAIR LIMITS 61 1 3 70 E B A lt COMPOSITE PROPELLER BLADE FIELD HARTZ ELL MAINTENANCE AND MINOR REPAIR MANUAL 170 CAUTION REFER TO TABLE 2 1 IN THE DAMAGE EVALUATION CHAPTER OF THIS MANUAL FOR THE APPLICABLE DAMAGE TYPE AND REPAIR LIMITS BY BLADE MODEL REFER TO THIS TABLE FOR THE AIRWORTHY AND MINOR REPAIR LIMITS FOR EACH DAMAGE TYPE 30 CRUSHED OR CRACKED TRAILING EDGE INBOARD REGION OF THE BLADE LIMITS AIRWORTHY DAMAGE MINOR DESIGNATION LIMITS REPAI
121. uivalent dampened with solvent acetone CM173 MEK CM106 or MPK CM219 thoroughly clean the area to be repaired Permit the solvent acetone CM173 MEK 106 219 to dry In a container that is free from contamination mix the adhesive 14 or CM 15 in accordance with the manufacturer s instructions 1 Mix enough adhesive CM14 or CM15 to perform the repair 61 13 70 COMPOSITE PROPELLER BLADE FIELD HARTZ ELL MAINTENANCE AND MINOR REPAIR MANUAL 170 Laminate the repair material pattern piece layers 1 Apply adhesive CM14 or CM15 to the area to be repaired CAUTION MAKE SURE THAT EACH LAYER BECOMES THOROUGHLY SATURATED WITH ADHESIVE CM14 OR CM15 AS THE LAYER LAMINATES TO THE REPAIR AREA Apply the repair material pattern piece layers over the repair area to achieve the original shape NOTE repair material pattern pieces were cut so the weave overlap direction will alternate between 45 degrees 0 90 degrees 00 Laminate each repair pattern piece making sure that each repair material pattern piece is thoroughly saturated before applying the next layer Additional adhesive CM14 or CM15 may be applied if necessary Cure the repair in accordance with section 3 G Curing Procedures in this chapter Sand the repair CAUTION DO NOT REMOVE ORIGINAL MATERIAL WHEN SANDING 1 Sand the repaired area to the original shape using caution not to remove origina
122. unt of expanded foil removed to maintain lightning protection Before starting any repair remove the paint around the repair area and inspect the expanded foil to make sure the finished repair and any previous repairs will meet the finished repair area limits stated below 1 Using 120 grit or finer sandpaper remove the paint around the area to be repaired to expose the expanded foil and or previous repair areas for inspection The following finished repaired area limits apply R is the largest permitted dimension of any individual finished repair area R must be less than or equal to 2 75 inches 69 8 mm D is the distance between two individual finished repair areas D must be equal to or greater than R After the repair is completed there must be a minimum total of 1 60 inches 40 6 mm measured in a straight line of original expanded foil remaining between the trail edge of the erosion shield and the trail edge of the original expanded foil at any blade section I gt Examples 1 In Figure 4 11 and Figure 4 14 the sum of A and B must be equal to or greater than 1 60 inches 40 6 mm 2 In Figure 4 12 the sum of A B and C must be equal to or greater than 1 60 inches 40 6 mm 3 In Figure 4 13 the sum of A B C and E must be equal to or greater than 1 60 inches 40 6 mm Example Choose two finished repaired areas IN Determine R for each finished repaired area must be less than or equa
123. ven 1069 6 1 Damage by Blade Model Table 2 1 continued DAMAGE EVALUATION 61 1 3 70 b COMPOSITE PROPELLER BLADE FIELD HARTZ ELL MAINTENANCE AND MINOR REPAIR MANUAL 170 Damage Type and Reference Section in this manual 28 Split Trailing Edge and Ge edge regions of the blade 5 2 XD9S0N9 N 1 a to any affected blades Limits3 ___ a Limits4 29 Split Trailing Edge 30 Crushed or Cracked Trailing Edge Inboard region of the blade b Limts2 XT XT XL XI a am mss d ______ de Crushed or Cracked Trailing Edge aie edge foam region of the blade 33 o Erosion a the entire blade 31 Crushed or Cracked Trailing Edge amp tip regions of the blade a Z4 J X XIX XIX XIX X X pumsz NOTE The numbered damage types in this table match the numbered damage types Hartzell Propeller Inc Composite Propeller Blade Maintenance Manual 135F 61 13 35 for consistency only The damage types that do not apply to the affected blades in this manual have been omitted from this table
124. worthy Individual areas damaged within a damage limits for missing erosion 0 50 inch 1 2 mm diameter that do screen The gouge limits for the not exceed more than one layer of specific blade model apply in the composite material in depth may be erosion screen area repaired in accordance with section 3 F 1 in the Minor Repair chapter in this manual FOR MAJOR REPAIRS REFER TO THE PERSONNEL REQUIREMENTS SECTION IN THE INTRODUCTION CHAPTER OF THIS SERVICE MANUAL Repair Limits by Damage Type Table 3 1 continued 61 13 70 Br EH mE EMEN COMPOSITE PROPELLER BLADE FIELD HARTZ ELL MAINTENANCE AND MINOR REPAIR MANUAL 170 CAUTION REFER TO TABLE 2 1 IN THE DAMAGE EVALUATION CHAPTER OF THIS MANUAL FOR THE APPLICABLE DAMAGE TYPE AND REPAIR LIMITS BY BLADE MODEL REFER TO THIS TABLE FOR THE AIRWORTHY AND MINOR REPAIR LIMITS FOR EACH DAMAGE TYPE 37 DE ICE OR ANTI ICING BOOT DAMAGE WEAR DEBOND LIMITS AIRWORTHY DAMAGE MINOR DESIGNATION LIMITS REPAIR LIMITS a LIMITS 1 Refer to Hartzell Propeller Ice Refer to Hartzell Propeller Inc Propeller Protection System Component Electrical De ice Boot Removal and Maintenance Manual 181 Installation Manual 182 61 12 82 or 30 60 81 Manual 181 is available Hartzell Propeller Inc Propeller on the Hartzell Propeller Inc website Anti icing Boot Removal and Installation at www hartzellprop com Manual 183 61 12 83 as applicable Manuals 182 and 183 are avai
125. y the craft may continue in service however the operator should make arrangements to have repairs performed as soon as practical b Any damage that exceeds the airworthiness limitations stated in this manual must be repaired before further flight operation B Determination of Type of Repair 1 Because of the infinite types of damage possible not all types of damage that can be considered airworthy are covered in this manual If there is any doubt about the airworthiness of the blade contact Hartzell Propeller Inc Damaged Blade Inspection Airworthy Unairworthy defined in chapter 3 defined in chapter 3 Repair Limits Repair Limits Minor Repair limits and instructions defined in chapter 3 Repair Limits Major Repair Factory Repair exceeds minor exceeds minor and major repair limits repair limits Determination of Repair Flow Chart Figure 1 1 INSPECTION PROCEDURES 61 1 3 70 kc COMPOSITE PROPELLER BLADE FIELD HARTZ ELL MAINTENANCE AND MINOR REPAIR MANUAL 170 C Erosion Tape Removal NOTE Depending on the location of the damage it may be necessary to remove 1 the erosion tape CM158 before inspection and or repair Blades with ice protection boots do not have erosion tape installed If erosion tape 158 is installed in the damage inspection area remove as follows CAUTION USE EXTREME CARE NOT TO DAMAGE THE BLADE WHILE REMOVING THE EROSION TAPE a Carefully lift one edge of the erosion

Hartzell Manual 170 - Hartzell Propeller Inc.

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