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1. Page 8 IGA SUPPLEMENT UIST ooo ee eher are rear Page 1 00 CONTENTS Page 1 of 1 McCauley Propeller Systems Mar 13 2013 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL LIST OF REVISIONS 1 General A This manual MPC 26 includes the original issue and the revisions listed in Table 1 To ensure information in this manual is current and the latest maintenance and inspections procedures are available the revisions must be incorporated in the manual as they are issued Table 1 Original Issue April 7 2008 Revision Number Date Revision Number Date 1 Dec 7 2009 2 Mar 13 2013 B FAA Approved Airworthiness Limitations are incorporated in this maintenance manual as Chapter 4 Revisions to Chapter 4 are dated as approved by the FAA Regional Manager Aircraft Certification Office To ensure that the maintenance information required under Parts 43 16 and 91 403 of Part 14 of the Code of Federal Regulations is current the revisions listed in Table 2 must be incorporated in Chapter 4 as they are issued Table 2 Original Issue March 13 2013 Revision Number Date Revision Number Date 2 Export Compliance A This publication contains technical data and is subject to U S export regulations This information has been exported from the United States in accordance with export administration regulations Diversion contrary to U S law is prohibited ECCN 9E991 LIST OF
2. FEATHER J STOP PISTON VENT i 0102T1020 C300 Series Propeller Non Oil Filled Figure 2 Sheet 1 61 00 04 Page 4 McCauley Propeller Systems Mar 13 2013 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL C1190 BALL SEPARATOR RETAINING RING SPLIT RETAINER DETAIL HUB VENT FOR NON OIL FILLED PROPELLERS OIL FILL PLUG FOR OIL VIEW A A BLADE FILLED PROPELLERS BLADE ACTUATING PIN HUB ASSEMBLY A CYLINDER BALANCE MOUNT RING RING CONTROL ACTUATION SPRING CYLINDER S Q _____ TES SPACER SUPPORT LOW mer ne PITCH PISTON STOP LINK C400 Series Propeller Figure 3 Sheet 1 McCauley Propeller Systems 61 00 04 Page 5 Mar 13 2013 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL C1191 WIRE RING RETAINING RING O RING SHIM BALL LA SHIM CARRIER Z lt OUTER RACE INNER RACE HUB VENT FOR NON OIL FILLED PROPELLERS SPLIT OIL FILL RETAINER PLUG FOR DETAIL OIL FILLED PROPELLERS 5 VIEW BLADE A k A A ASSEMBLY LS SO Z x OK COUNTERWEIGHT T X AMK SPRINGS FEATHER STOP XLO S gt Wb 1 bor SIN x N ae SEEN x sa N zs
3. COLLAR SPRINGS hu SER ROD O 60 E CYLINDER SENT PISTON ss FEATHER BETA STOP ROD A WIRE RING BLADE O RING RETAINING RING LINK zen SOLID SHIM SPLIT SHIM OIL FILL SCREW ASSEMBLY SHIM CARRIER OUTER RACE AE NG SS BEING ESN CM NUMBER V 2 SS SEA 1 BLADE RY f INNER RACE SPLIT RETAINER DETAIL A VIEW A A 0101T1053 f C750 Series Propeller Figure 8 Sheet 1 61 00 04 Page 12 McCauley Propeller Systems Mar 13 2013 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL C1050 BLADE COUNTERWEIGHT PROPELLER HUB OIL FILL SCREW BLADE ACTUATING REVERSE PIN STOP BETA ROD BETA SPRING FEED BACK COLLAR PISTON ROD CYLINDER PISTON FEATHER STOP BETA ROD LINK SLIP RING ASSEMBLY WIRE RING RETAINING RING SOLID SHIM SPLIT SHIM O RING SHIM GARRIER OUTER RAGE BEARING INNER RACE SPLIT RETAINER DETAIL 0102T1075 C1000 Series Propeller Figure 9 Sheet 1 61 00 04 Page 13 McCauley Propeller Systems Mar 13 2013 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL C1196 Se Y BLADE PLUG COUNTERWEIGHT NN BLADE RETENTION BEARING N IE 7 SE PROPELLER HUB OIL 2 RETAINER FILL SCREW IES En SPLIT SUPPORT PLATE i SPLIT RETAINER IE PISTON LATCH PAWL cr Ra Ford SPRING HOU
4. Fixed Pitch Propeller Removal and Installation Constant Speed Reciprocating Engine Propeller Removal and Installation Piston C600 C650 C 1100 Series Propeller Removal and Installation C700 C750 C1000 Propeller Removall Installation PROPELLER ADJUSTMENT TEST e suqus Static a ta Propeller Pressure Leakage Check Requirements Ground Support Equipment Flight Idle Blade Angle Flight Idle Torque Checking and Adjustment Procedures Turbine Series Propellers Dynamic Balance klang 61 CONTENTS McCauley Propeller Systems 61 00 01 Page 1 61 00 01 Page 1 61 00 01 Page 2 61 00 04 Page 1 61 00 04 Page 1 61 00 04 Page 7 61 00 04 Page 15 61 00 04 Page 15 61 00 06 Page 101 61 00 06 Page 101 61 00 06 Page 101 61 00 06 Page 101 61 00 06 Page 102 61 00 06 Page 102 61 00 06 Page 103 61 00 06 Page 103 61 00 06 Page 105 61 00 06 Page 105 61 00 06 Page 105 61 00 06 Page 106 61 00 06 Page 107 61 00 06 Page 107 61 00 06 Page 109 61 00 06 Page 201 61 00 06 Page 201 61 00 06 Page 201 61 00 06 Page 202 61 00 06 Page 203 61 00 06 Page 204 61 00 06 Page 204 61 00 06 Page 401 61 00 06 Page 401 61 00 06 Page 401 61 00 06 Page 402 61 00 06 Page 410 61 0
5. CYLINDER BLADE ACTUATION PISTON an A LATCH NOTE LOW PITCH NOTE PROPELLER BLADE STOP PLATE LINK NOT SHOWN FOR CLARITY C500 Series Propeller Figure 4 Sheet 1 61 00 04 Page 6 McCauley Propeller Systems Mar 13 2013 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL deice harnesses slip ring assembly deice timer brush block assembly a The brush block deice harnesses and slip ring assembly conduct electrical power to the propeller blade deice boot elements which then heat b The heat melts a layer of the ice which allows the remaining ice to be removed from the propeller blades by centrifugal force F Propeller Anti Ice Refer to Figure 11 1 If propeller alcohol anti ice is installed the components include slinger ring assembly spray head assembly propeller blade feed shoe a The slinger ring distributes anti ice fluid from the fluid reservoir to the spray head assembly for each propeller blade Anti ice fluid is pumped into the rotating slinger ring and the centrifugal force of the rotating slinger ring forces the anti ice fluid to flow to the spray head assemblies b The spray head assembly transports the anti ice fluid from the slinger ring to the propeller blade feed shoe The spray head distributes the ant ice fluid across the grooves that are imbedded in the propeller blade feed shoes c The propeller blade feed shoe is attached to the leading edge of eac
6. McCauley Propeller Systems Mar 13 2013 2 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL IO Propeller damage depth greater than this limit is not field repairable NOTE An FAA approved Part 145 Propeller Repair Station or international equivalent may be able to do a repair Contact McCauley Product Support for disposition of any damage that is deeper than the specified limits Inspect Repaired Area 1 Do a fluorescent dye penetrant inspection to verify that the stress riser has been completely removed Refer toNon Destructive Inspection Procedures for fluorescent dye penetrant inspection procedures Blade Painting After Repair 1 Prepare the repaired area for touch up paint by wiping with a Methyl n Propyl Ketone MPK dampened cloth 2 Corrosion protect the propeller blade in the area of the repair Refer to Cleaning Painting Protective Treatments for instructions for the application of a chemical conversion film coating for example Alodine on the repaired area of the propeller 3 Touch up the propeller paint in accordance with the procedures in Cleaning Painting Protective Treatments to blend the paint with the original finish 4 Recheck the dynamic balance of the propeller if the propeller is installed on a turbine engine Blade Painting 1 General a Propeller blades are painted with polyurethane enamel paint This paint provides optimum durability and abrasion resistance If paint becom
7. Improper Propeller Static RPM Piston Improper Propeller Maximum RPM in Flight Constant Speed Piston Propeller Fails to Control Propeller Feathers at Shutdown 300 500 600 650 and 1100 Model Series Only Propeller Fails to Feather Properly Vibration Troubleshooting Unusual Aircraft Vibration Blade Shake nun BER Oil or Grease Leaks Propeller Overspeeding PROPELLER MAINTENANCE PRACTICES Ground Support Equipment Procedures For Maintenance Long Term Storage of Controllable Pitch Propellers Dynamic Balance aii sasa nn en eps E ea Spinner Repair and Chrome Plating Propeller Internal Lubrication PROPELLER REMOVAL INSTALLATION Ground Support Equipment Uncrating and Acceptance Checking a New Propeller
8. 1 2 If the part has scratches and minor dents the part can continue to be used If the part is cracked the part must be replaced McCauley strongly discourages the chrome plating of McCauley propeller spinners Field experience has shown that chrome plated spinners often peel after a short time in service Strong evidence also exists that chrome plating can lead to spinner fatigue cracking thus scrapping the spinner shell Chrome plating will void the McCauley warranty 6 Propeller Internal Lubrication A Servicing of Propeller Internal Lubrication 1 General a Unless significant oil leakage is observed periodic servicing of the oil in McCauley oil filled propellers is not necessary 61 00 06 Page 204 McCauley Propeller Systems Mar 13 2013 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL C670 SPINNER NAS1149F0332P AN970 3 FLAT WASHER WASHER MAXIMUM STACK 11 WASHERS MS21083 N3 NUT h AN502 10 X 0 125 INCH 6mm MAXIMUM SCREW PROJECTION SPINNER BULKHEAD DETAIL 0104T1004 AE 7735 Balance Weight Installation Figure 201 Sheet 1 61 00 06 Page 205 McCauley Propeller Systems Mar 13 2013 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL PROPELLER REMOVAL INSTALLATION Ground Support Equipment A following special equipment is required for field maintenance of McCauley propellers NAM
9. c Add or subtract shims to spinner support until spinner shell mounting holes are approximately half a hole from being in true alignment with bulkhead holes Push on the spinner shell and use an awl or a small punch in an adjacent hole to move the spinner shell screw hole into alignment with bulkhead hole and install washer and screw Repeat this procedure on opposing holes until eight evenly spaced screws and washers are installed Secure propeller spinner to the bulkhead and fillet assemblies with remaining screws and washers 5 600 650 1100 Series Propeller Removal and Installation A General 1 Propeller removal and installation shall be performed only by qualified maintenance personnel The following instructions are general in nature The aircraft maintenance manual or STC installation instructions should always be consulted for any specialized procedures applicable to a specific aircraft Various spinner and deice arrangements not manufactured by McCauley may be used which require additional procedures NOTE Qualified maintenance personnel means the person doing the maintenance activity is the holder of or is working under the direct supervision of the holder of the appropriate rating to approve the propeller for return to service after the maintenance activity has been accomplished 61 00 06 Page 413 McCauley Propeller Systems Mar 13 2013 2 McCAULEY PROPELLER SYSTEMS OWNERIOPERATOR INFORMATION MANUAL
10. 1 Governor Mode Cil is metered to and from the propeller by governor control valve as positioned by flyweights increasing and decreasing blade angle changing pitch as required when the propeller speed control setting is altered or increasing and decreasing pitch to control and stabilize engine speed with varying power conditions or flight attitudes with a fixed speed setting 2 Beta Mode The pilot may select beta mode for ground reversing or taxi operation by means of the aircraft engine mechanical linkage The linkage repositions the propeller reversing lever and beta valve to provide access for high pressure oil to reach the propeller piston and move the blades toward reverse pitch 61 00 04 Page 8 McCauley Propeller Systems Mar 13 2013 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL C1192 BLADE pa HUB ASSEMBLY A COUNTERWEIGHT ayer LATCH PAWL ACTUATING SPRINGS PIN b 8 8 CYLINDER TUBE LATCH START PISTON LOCK OC FEATHER BLADE STOP ACTUATING 3 LINK A WIRE RING RETAINING RING OIL FILL SOLID SHIM SPLIT SHIM O RING SHIM CARRIER OUTER RACE BEARING INNER RACE I SPLIT NUMBER 1 RETAINER BLADE DETAIL A VIEW A A 0101T1050 C600 Series Propeller Figure 5 Sheet 1 61 00 04 Page 9 McCauley Propeller Systems Mar 13 2013 McCAULEY PROPELLER SYS
11. B3D36C424 B3D36C429 B3D36C432 D3A36C435 D3A34C443 3FF32C501 3AF32C504 3AF32C507 3AF37C510 3AF36C514 3AF32C521 3AF32C524 B3DF36C527 3GFR34C601 4HFR34C653 4HFR34C663 3GFR34C701 3GFR34C704 4HFR34C762 4HFR34C766 4HFR34C771 D 83082044 D 183032017 D 183036044 D 183036049 D 183036042 E D3A36c435 E josasacaas E 2501 D AF320504 D AF320507 D 3AF370510 D SAFS6CS14 D 3AF320521 D 3AF320524 F B3DF36c527 F AHFR34C653 O AHFR34C663 b 3GFR34C701 G 3GFR34C704 G AHFRMCT62 G 4HFR34C766 G 775 b 4HFR34C775 61 00 06 Page 606 McCauley Propeller Systems Mar 13 2013 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL Table 601 Table 1 Propeller Models continued Model Designation Overhaul Model Designation Overhaul Model Designation Overhaul Frequency Frequency Frequency Note Note Note B5JFR36C1101 M CSJFR36C1102 M B5JFR36C1103 Fixed Pitch All Propeller All Propeller Propellers Governors Accumulators A 1200 hours or 60 calendar months whichever occurs first B 1000 hours or 60 calendar months whichever occurs first C 1500 hours or 60 calendar months whichever occurs first except Agricultural aircraft installations the overhaul frequency is 1200 hours or 60 calendar months whichever occurs first D 2000 hours or 72 calendar months wh
12. In the following instructions installation of propeller is based on the assumption that a McCauley spinner will be used If a spinner is not used or if the spinner is not manufactured by McCauley omit those steps which apply to the spinner Spinner Assembly Removal 1 Make alignment mark the spinner aft spinner bulkhead and an adjacent blade with felt tip pen This index mark insures accurate restoration of spinner position to lessen the distortion of any dynamic balance previously performed on the propeller assembly Remove screws and washers from spinner and fillet assemblies Remove spinner from the bulkhead and fillet assemblies Remove spinner support and shims from spinner Remove screws and washers attaching fillets to the bulkhead and remove the fillets Propeller Assembly Removal NOTE Propeller must be on start locks when beginning this procedure 1 2 Position power lever to full reverse position Activate the propeller unfeathering pump NOTE Do not operate the unfeathering pump more than one minute when oil is cold Restrict operation to 30 seconds maximum when oil is hot a The propeller blades will move toward reverse pitch and unload the start locks b Insert start lock release tools P N B 5021 in the four holes on the front forward end of the propeller cylinder Refer to Figure 404 c The tools will move the start lock weights outboard and disconnect the latch from the piston
13. OWNER OPERATOR INFORMATION MANUAL C871 ROD J 600 PROPELLER HUB Z INCHES 7 SAND BAG PA 2 INCHES MINIMUM 0101T1106 Remove Spacer From Propeller Figure 401 Sheet 1 61 00 06 Page 404 McCauley Propeller Systems Mar 13 2013 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL C1912 Use an arbor press or similar tool to simultaneously push both bolts down to remove the spacer from the propeller Propeller Mounting Bolt LIJ ets zl Reference Propeller f Reference a d b qb Propeller Spacer Reference 2 00 Inch 50 mm Minimum Ed E H ES Y x A Sand Bag 0 250 Inch 0 250 Inch 6 35 mm Reference 6 35 mm x 6 00 Inches 152 0 mm Bolt x 2 00 61 0 mm Inch Steel Bar Reference With 0 250 6 35 mm Inch Holes Drilled 2 875 Inches 73 03 mm Apart B 7925D Remove Spacer From Propeller 1A162 Only Figure 402 Sheet 1 61 00 06 Page 405 McCauley Propeller Systems Mar 13 2013 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL WARNING MAKE SURE THE MAGNETO IS GROUNDED BEFORE INSTALLING THE PROPELLER OR CONNECTING EXTERNAL POWER NOTE McCauley recommends that propeller mountin
14. All inspection intervals replacement time limits overhaul time limits the methods of inspection life limits cycle limits etc for non McCauley parts must come from the manufacturer and or seller of the non McCauley parts Inspection maintenance and parts requirements for Supplemental Type Certificate STC installations are not given in this manual When the propeller has an STC installation those parts of the propeller that the installation has an effect on must be examined in accordance with the inspection program published by the owner of the STC McCauley supplied inspection criteria may not be valid for propellers that have STC installations because they may change the systems interface operating characteristics and component loads or stresses on adjacent structures WARNING Any inspection and or repair requiring disassembly reassembly or overhaul of a McCauley propeller must be done in an FAA approved or international equivalent propeller repair station by qualified personnel Users of this manual are presumed to have sufficient training to follow these instructions carefully and correctly The inspection requirements are stated in a manner to establish what propeller component is to be inspected preferred inspection method and criteria for airworthiness to Get Customer Assistance REVISIONS REISSUES and TEMPORARY REVISIONS can be purchased directly from McCauley Attention Technical Publications e mail customercare mc
15. B 46227 ves 6 A25137 arcs A 16395 C 7726 1C235 LFA A 2973 6 B 4622 40 ves A 2513 92 A 1638 2 fna fm 846220 ves 5 A2513 0 A1000 10 NA _ c 1210 Note 2 B 46227 ves 6 A25137 A1638 13 A 16395 NA na 5 4622 36 ves 6 ars A463543 NA NA na 8 462230 ves 8 astro jatese ta na 11172 NA na p 4622 25 12 ves 6 251 6382 NA 1B175MFC NA A4001 B 46225 12 No 6 A2513 46 A16382 A 16392 1 na NA 8462214 Yes 6 A2513 9 1638 13 A oram NA A 2973 5 462220 ne ves 6 azot jateae t NA C 4513 raroaroom Hi 29706 o4622 2 ves A251377 atesora 1D200 0M NA A001 B 46225 12 No 6 A 2513 16 A 1638 2 A 1639 2 C 4513 1A101 PCM 451 29736 B 4622 12 jae ves A 2513 77 A 1638 14 Tezera NA annees 12 ves 6 ane 163630 NA Cars Na A 4001 B 46222 wa No 6 251 58 A 6382 A 16392 TC172 SBTM B 4425 Azores 8 462237 7m6 ves 6 azotes NA ves 6 azota Ad6382 NA NA A4001 846225 wa No 6 A2513 6 A 4638 2 A 16392 assec NA A4001 846225 wa No 6 azot A 638 2 A 16392 A 1638 13 and 1A162 TCD B 7925 A 7952 B 4622 49 3 8 No A 2513 105 A
16. Garrett part on beta tube and install using McCauley Beta Tube Adjustment Tool part number B 5378 1 Once the beta tube threads are engaged turn the beta tube the same amount of turns that were required to remove the beta tube Ifthe number of turns required to remove the beta tube is not known use 32 turns Make sure of proper rigging of engine controls Refer to the aircraft maintenance manual Do a propeller flight idle blade angle check NOTE Refer to the airplane maintenance manual airplane type certificate TC Supplemental Type Certificate STC and the propeller type certificate as required for the flight idle propeller blade angle a Place the base of the protractor on the top of the propeller cylinder and align it longitudinally to zero the propeller protractor b Position power lever at the flight idle position c Activate the unfeathering pump As oil pressure increases the propeller blades will rotate from feather towards the flight idle position NOTE Do not operate the unfeathering pump more than one minute when oil is cold Restrict operation to 30 seconds maximum when oil is hot d When the propeller blades have stopped in the flight idle position move the blade to be tested so the leading edge is up and blade is horizontal NOTE It is required to check the blade angle of only one blade e With the unfeathering pump still operating use a propeller protractor to measure the propeller blade angle at
17. McCauley Torque Wrench Adapter 61 00 06 Page 423 McCauley Propeller Systems Mar 13 2013 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL CAUTION Ifan adaptor or extension such as McCauley part number B 5588 is attached to torque wrench drive end and this adds to its length then the actual applied torque will be greater than the dial reading The following formula should be used to find what the dial should read in order to obtain the correct applied torque Torque Wrench Length x Desired Torque Dial Reading Torque Wrench Length Extension Length 13 Remove the D 5945 feedback collar retractor tool from the propeller 14 Make sure of proper rigging of engine controls Refer to aircraft maintenance manual or STC maintenance manual supplement a Feather reverse and low blade angles are set during assembly or overhaul These angles are NOT adjustable in the field CAUTION Do not operate the propeller below the minimum propeller idle speed operating restriction The minimum propeller idle speed operating restriction is the result of a specific vibratory resonant condition known as reactionless mode Ground operation at or near a reactionless mode vibratory resonance speed can cause very high stresses in the propeller blades and hubs These high stresses are more severe when operating in a tailing wind condition If the propeller is operated within a restricted RPM range or below a minimum RPM
18. NOTE Blade Shake is listed in the Propeller Troubleshooting section of this manual for informational purposes only as it has been misinterpreted in the past as a possible problem by some operators Despite it s appearance in this section it should never be considered a cause for concern or propeller replacement 1 Blade shake is the tendency for the blades to wobble slightly when the tip is physically moved by hand from the leading edge to the trailing edge Refer to Figure 101 a Total maximum allowable movement up to 0 125 inch 3 13 mm at the blade tip is considered normal Cause 1 This tendency is the natural result of a tolerance buildup A very small movement at the hub is magnified many times at the blade tip It is NOT the source of vibration or any other problems While the propeller is rotating centrifugal force on the blades seats them rigidly and positively against the retention bearings in the hub Corrective Action 1 No corrective action is required 13 Oil or Grease Leaks A The presence of oil or grease on propeller blades may or may not indicate a problem 1 Grease lubricated propellers may have grease deposits on the blade shank during the first 25 or 50 hours of operation after overhaul because the retaining bearings were packed with an excessive amount of grease 2 All propeller blades may show minor grease streaking when new or newly overhauled Such streaking is normal and is the result of lu
19. NOTE The start lock release tools should be inserted by hand with a light push Do not hammer on or forcibly insert the start lock release tools With the propeller blades off of the start locks and the propeller is in full reverse quickly loosen the beta tube locking screw at the end of the beta tube Tap the locking pin out of piston rod beta tube and remove the locking plug from the beta tube Release shut off the unfeathering pump a The blades will start moving toward the feather position NOTE You should hear a faint click as the start locks ride on the start lock release tools and pass over the latch position Remove start lock release tool The propeller is now free of the start locks and will be in the feather position Use the McCauley beta tube adjustment tool part number B 5378 to unscrew the beta tube Refer to Figure 404 CAUTION Never use a screwdriver or other unapproved tool to remove the beta tube Use of any tool other than McCauley B 5378 can severely damage beta tube and propeller piston rod threads rendering parts unusable and unrepairable a Count the number of turns that are required to remove the beta tube Record the number of turns required to free the beta tube for future reference when the propeller is to be installed Once the beta tube is free from all threads the o ring will create friction between the piston rod and the beta tube To overcome the o ring friction continue to turn the beta tube
20. Pay special attention to governor parts involved in a lightning strike Look closely for signs of burning or metal flow Any parts showing burns or metal flow must be scrapped and replaced d If parts pass inspection and are found to be acceptable governor may be reassembled tested and returned to service e If parts do not pass inspection replace damaged parts before governor is reassembled tested and returned to service Record a clear entry in the appropriate airframe and or engine logbook indicating inspection repair of the governor per this manual IWIN 8 Blade Track Check Check A 9 Turn propeller so that Number 1 blade is straight down Position a smooth board beneath the blade tip Block up the board firmly in place just clear of the blade tip Place a pencil mark approximately one inch 25 mm long on the board at the midpoint of the outer edge of Number 1 blade tip Turn the propeller so next blade is straight down Place a thin one inch 25 mm line on the board at the midpoint of the outer edge of the second blade tip Carefully turn propeller and repeat tracking measurement for each blade Each time a line is added measure the horizontal difference between the lines farthest apart a For propellers installed on piston engines all blades must measure within 0 0625 inch 1 6 mm of each other b For C1101 through C1104 models propellers installed on turbine engines all blades must measur
21. The sling and hoist should have a weight limit rating at least twice the weight of the propeller that is to be installed c The straps of the propeller sling should be placed on two of the propeller blades at least 6 inches 152 mm outboard of the propeller hub Make sure you protect the deice boots or anti ice shoes from potential propeller sling abrasion damage if installed CAUTION Propeller must be installed straight onto the engine flange Any rocking of the propeller with respect to the flange could result in damage to the engine propeller flange mating surfaces Mount the propeller on the engine propeller shaft Ensure threads of nuts and studs are free of burrs nicks and similar damage and clean of foreign material WARNING If the lubricant is not applied as required the nuts will be under torqued and the propeller could fail a For Garrett Honeywell engine installations CAUTION Do not use oil as a substitute for approved lubricant It is imperative that the correct specification of lubricant be used during installation Substitution of the approved grease with an unapproved lubricant or no lubricant could result in under torquing or severe over torquing of propeller attaching parts Lubricate the threads of studs and nuts and the faces of nuts spacers or washers with MIL PRF 83483 McCauley part number A 1637 16 grease 2 Install mounting nuts on mounting studs 3 Torque the mounting nuts in an alte
22. assignment Page numbering uses the three element number which matches the affected manuals 2 Referto the ICA Supplement List to determine the incorporation status for each manual affected 5 List of Obsoleted Documents following service information has been incorporated into this manual This service information is now obsolete and replaced by this manual for the propellers affected by this manual Service Bulletin Date Service Bulletin Number Manual Incorporation SB137AE 2 17 10 Revision 2 SB176E 3 3 03 Revision 2 SB177B 6 30 92 Revision 2 SB227B 8 28 01 Revision 2 Service Letter Number Service Letter Date Manual Incorporation SL1991 10A 10 29 96 Revision 2 1992 14C 6 28 96 Revision 2 1992 17 11 16 92 Revision 2 1994 24A 2 10 95 Revision 2 1995 5A 12 5 07 Revision 2 1996 7 10 29 96 Revision 2 1997 4 4 22 97 Revision 2 SL 1998 23 9 21 98 Revision 2 1999 8B 3 15 01 Revision 2 2000 7 8 1 00 Revision 2 2000 8A 11 20 00 Revision 2 2003 8 12 23 03 Revision 2 O McCauley Propeller Systems INTRODUCTION Page 4 Mar 13 2013 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL 6 List of Incorporated Documents A The following service information has been incorporated into this manual Due to the relationship of the service information to active Airworthiness Directives the service information also remains active Service Bulletin Service Bulletin Date Manual Incorporation Airworthiness Di
23. 000 hours Blades with change Applies only to 4HFR34C653 propeller letter A assembly blades that are installed on or blades that ever have been installed on Jetstream Series 3200 aircraft or the service history is unknown L106KA 0 Propeller Blade Replace 16 000 hours Applies to 4HFR34C663 propeller assemblies only L106FRA 0 Propeller Blade Replace 10 000 hours Applies to 4HFR34C665 propeller assemblies only 114GCA 0 Propeller Blade Replace 3500 hours Applies to B5JFR36C1101 114GCA 0 propeller assemblies only Refer to McCauley Alert Service Bulletin ASB255A and Federal Aviation Administration Airworthiness Directive AD 2009 19 04 4 11 00 Page 1 McCauley Propeller Systems Mar 13 2013 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL Table 1 Propeller Blade Life Limits continued Life Limited Component Part Number Description Life Limit L114GCA 0 Propeller Blade Replace 3500 hours Applies to C5JFR36C1102 L114GCA 0 propeller assemblies only Refer to McCauley Alert Service Bulletin ASB255A and Federal Aviation Administration Airworthiness Directive AD 2009 19 04 114HCA 0 Propeller Blade Replace 3500 hours Applies to B5JFR36C1103 114HCA 0 propeller assemblies only Refer to McCauley Alert Service Bulletin ASB255A and Federal Aviation Administration Airworthiness Directive AD 2009 19 04 L114HCA 0 Propeller Blade Replace 3500 hours Applies to C5JFR36C1104 L114HCA 0 propeller asse
24. 1 Possible Cause a Obstruction in the engine crankshaft 1 Correction action a Remove propeller and check for obstruction in the crankshaft oil gallery ie Rags shipping plugs etc b Internal governor problem 1 Corrective Action a Have the governor checked by an FAA approved Part 145 Propeller Repair Station or international equivalent NOTE Failure of an internal governor part may result in metal contamination in the engine oil lubrication system If internal governor failure is confirmed the engine and propeller should be checked for metal contamination in accordance with the specifications of the engine manufacturer c Internal Propeller problem 1 Corrective action a Have the propeller checked by an FAA approved Part 145 Propeller Repair Station or international equivalent 61 00 06 Page 104 McCauley Propeller Systems Mar 13 2013 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL d Engine transfer bearing collar oil leakage rate exceeds specification or rotated engine transfer bearing 1 Corrective Action a Check transfer bearing collar condition and oil leakage rate per the instructions of the engine manufacturer 8 Propeller Feathers at Shutdown 300 500 600 650 and 1100 Model Series Only WARNING Before starting an engine with a feathered propeller engine manufacturer should be consulted CAUTION Do not start the engine and do a run up with the cockpit propeller control lev
25. 1638 14 A 1639 6 61 00 06 Page 1004 McCauley Propeller Systems Mar 13 2013 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL Table 1003 Installation Parts for Fixed Pitch Propellers continued Fixed Pitch Bolt Kit Basic Propeller Dri Model Spacer Dowel Bolt Kit Bolt led No Washer Number P N P N P N Dia Head Bolts Bolt P N P N Nut P N B 4622 43 ves azstszs ua na B 3821 2073 6 8 462222 ne No 6 fasses Ars NA 20 8 3637 A207386 B462244 172 ves 6 2513 102 Na NOTE 1 Bolt Kit B 4622 43 contains 6 ea A 2513 78 bolts 6 ea B 73036 mylor gaskets 1 ea B 7287 Reinforcement Plate and 1 ea drawing B 7387 NOTE 2 A 1170 bushings are included with the bolt kit NOTE 3 For propellers mounted on engines with a tapered splined crankshaft 61 00 06 Page 1005 McCauley Propeller Systems Mar 13 2013
26. 3 also occurs 3 McCauley should be contacted and given exact operating conditions for determination of corrective action for engine overtorque during one or more of the following conditions a 111 percent torque or higher b Overtorque during ground operations c In flight overtorque of between 102 percent and 110 percent for more than 30 seconds d Overtorque of between 102 percent and 110 percent for less than 30 seconds under the following 1 Banked turns of more than 45 degrees 2 Yaw of more than or equal to 2 3 ball as indicated by the airplane turn and bank indicator or similar instrument e Any overtorque condition outside the above criteria 61 00 06 Page 613 McCauley Propeller Systems Mar 13 2013 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL 12 Normal Criteria for Static Blade Shake and Twist of All Variable Pitch Propellers BLADE SHAKE Blade shake is defined as follows A B 1 2 The tendency for the propeller blades to wobble slightly when the tip is physically moved by hand lead edge to trail edge Refer to Figure 602 is known as blade shake a This tendency is a natural result of the fabrication of parts within the McCauley retention system While accumulation of tolerances is measured in thousandths of an inch it must be remembered that both the parts causing blade shake and the pivot point about which the blade rotates are near the blade root As a result very small
27. Cautions precede the text to which they apply and Notes follow the text to which they apply 1 WARNING Calls attention to use of materials processes methods procedures or limits which must be followed precisely to avoid injury or death to persons 2 CAUTION Calls attention to methods and procedures which must be followed to avoid damage to equipment 3 NOTE Calls attention to methods which will make the job easier 18 Log Book A The owner operator is required to maintain a permanent log book for each serial numbered propeller assembly containing the following information 1 The total time flight hours in service of each propeller assembly including flight hours on each serial numbered hub and blade 2 The airplane on which the propeller has been installed Recorded by the airplane manufacturer registration number tail number aircraft serial number and model types 3 The time in service flight hours and the calendar period months days years each propeller assembly recorded by hub and blade serial numbers was installed on an aircraft 4 Records of the maintenance inspections alterations and overhauls performed on each propeller assembly a The records must include A description of the work performed including the disposition of the affected parts The date that the work was accomplished The signature and certification number of the person approving the propeller assembly for return to s
28. McCauley Propeller Systems Mar 13 2013 1 C1390 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL FIXED PITCH PROPELLER DESCRIPTION Metal Fixed Pitch Propellers A The propellers of this model series are manufactured of one piece anodized aluminum alloy and have a fixed pitch NOTE Some fixed pitch propellers are certified with a defined spacer Refer to Propeller Installation Parts List Table 1003 Installation Parts for Fixed Pitch Propellers for the correct part number spacer for each applicable propeller model For identification the hub of each propeller is stamped with the complete model number serial number Federal Aviation Agency FAA type certificate number production certification number and the number of times the propeller has been reconditioned The complete model number is a combination of the basic model number and suffix numbers to indicate the propeller diameter and pitch 1 Propeller Model Designation a The hub model designation is steel stamped on the forward camber side face of the propeller hub 1 Example of hub model designation BASIC MODEL NUMBER 1F100 CM 69 54 INCHES PITCH AT 0 75 RADIUS PROPELLER DIAMETER INCHES ONE TO FOUR LETTERS INDICATING TYPE OF CRANKSHAFT ON WHICH PROPELLER IS INSTALLED BLADE TIP CONTOUR USE OF ADAPTER OR OTHER INFORMATION PERTAINING TO A SPECIFIC AIR CRAFT INSTALLATION BASIC DESIGN NUMBER PLANFO
29. OF PROPELLER SPEED MCCAULEY DESIGN REFERENCE INFORMATION REVERSING FULL FEATHERING HUB FLANGE CODE NUMBER OF BLADES INDEXING DOWEL HOLE LOCATION WITH RESPECT TO THE GENTER LINE OF THE NUMBER 1 BLADE SOCKET VIEWING THE HUB FROM THE FLANGE MOUNTING FACE NOTE SPECIFIC PROPELLER ASSEMBLY IS IDENTIFIED BY THE HUB SERIAL NUMBER WHICH IS STAMPED ON THE HUB ALL RECORDS OF PROPELLER COMPONENTS ARE KEPT WITH REFERENCE TO HUB SERIAL NUMBER THE FIRST TWO DIGITS OF THE HUB SERIAL ARE THE YEAR OF MANUFAGTURE THE REMAINING DIGITS ARE THE NUMBER OF THE HUB MANUFAGTURED IN THAT YEAR 61 00 04 Page 18 O McCauley Propeller Systems Mar 13 2013 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL C Blade Model Designation 1 All blades are impression stamped on the butt end with blade model designation propeller type certificate number and blade serial number This stamping is not visible from the outside of the propeller assembly The following is an example of blade model designation C1130 Pq L 80 HJ 0 Lo Reduction in diameter from basic inches Staking angle actuating pin placement Characteristics of blade design for example planform Basic design diameter in inches Designation for direction of rotation viewed from pilot s seat No letter blank Right L Left Change designation which may affect eligibility or interchangeability 61 00 04 Page
30. REVISIONS Page 1 McCauley Propeller Systems Mar 13 2013 1 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL INTRODUCTION General A The instructions for continued airworthiness ICA in this publication uses the data available at the time of publication This publication is updated supplemented and changed by service letters service bulletins publication revisions reissues ICA supplements and temporary revisions which are supplied by subscription services available from McCauley Product Support All of these changes become part of and are specifically included in this publication which is the principal manual for ICA The latest changes to this publication are given through the McCauley Product Support subscription services and or McCauley authorized service facilities WARNING The purchaser is warned not to use the data in McCauley s overhaul maintenance service information manuals when parts are designed manufactured remanufactured overhauled and or approved by entities other than McCauley or McCauley authorized entities are installed When non McCauley parts are used the data in McCauley s overhaul maintenance service information manuals is no longer applicable All of the inspection intervals replacement time limits overhaul time limits inspection methods life limits cycle limits etc McCauley recommends are given when new remanufactured or overhauled McCauley approved parts are installed
31. Systems Mar 13 2013 H McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL Nickel Plating 1 Parts that require Nickel plating shall be taken to an FAA approved Part 145 Propeller Repair Station or international equivalent for disposition and plating Thermal Black Oxide Plating 1 Parts that require Thermal Black Oxide plating shall be taken to an FAA approved Part 145 Propeller Repair Station or international equivalent for disposition and plating Chrome Plating 1 Parts that require Chrome plating shall be taken to an FAA approved Part 145 Propeller Repair Station or international equivalent for disposition and plating Anodize NOTE All repaired and overhauled hubs and all repaired blades must be anodized or have Chemical Conversion Film Coating applied for corrosion protection 1 Parts that require to be anodized shall be taken to an FAA approved Part 145 Propeller Repair Station or international equivalent for disposition and to be anodized Chemical Conversion Film Coating NOTE All repaired hubs and all repaired blades must be anodized or have Chemical Conversion Film Coating applied for corrosion protection 1 General a The process for aluminum components must be in accordance with MIL DTL 5541 and MIL DTL 81706 Class 1A b All repairs must be complete before the part is treated c All grease oil or other material must be removed using solvent and or a water based cleaner so the part or
32. air Engine vibration and stretch of the mount during operation can often aggravate the condition Therefore it is important the entire length of linkage be properly secured c Constant speed piston only If heat has distorted the plastic top cover replace it with an aluminum top cover B Once speed control and power settings are established for a flight attitude cruise and then the attitude is altered to climb without change of speed and power settings the engine speed may change slightly 1 Possible Causes a This effect is commonly known as creeping of the speed setting It is a natural result and comes about in the following manner When speed and power settings are established the governor control valve will be opened an amount to provide a pressure which balances the propeller counterweight forces and spring load and an oil flow which is determined by the leakage through the propeller pitch control bearing at that pressure This will maintain the blade angle such that set power may be absorbed at the desired speed b Ifthe attitude of the aircraft is altered and the airspeed changes the blade angle will change to absorb the power at this airspeed This change in blade angle will cause the forces to vary and consequently will change the control pressure and the propeller pitch control bearing leakage rate c Since the governor had been adjusted by the speed control for the first set of conditions the effect will be to
33. attention should be paid to engines exposed to fuel contamination which may have changed the fuel octane rating which could cause engine detonation 4 Engine Oil Contamination Refer to engine manufacturers service information for determination of oil contamination Any governor mounted to an engine which required servicing to remove oil contamination must comply with Governor Inspection Criteria 5 Sudden Engine Stoppage Refer to engine manufacturer s service information for determination of sudden engine stoppage Any governor mounted to an aircraft involved in a sudden engine stoppage must comply with Governor Inspection Criteria 61 00 06 Page 611 McCauley Propeller Systems Mar 13 2013 C McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL Governor Inspection Criteria 1 Any governor affected by Compliance above must perform the following steps a The governor must be tagged that it was involved in such an incident for the information of the overhauling agency b The governor must be overhauled by an authorized McCauley service facility in accordance with McCauley Service Manual 780401 c During the overhaul the service facility must pay particular attention to the following procedures 1 Perform magnetic particle inspection on flyweight assembly components idler gear and drive gear according to instructions in manual Carefully examine all rotating parts for signs of cracks or other damage
34. bent beyond repair limits Bird Strike a Bird Strike can be defined as the impact of any bird into the rotating propeller causing damage b Inspect all blades for damage such as scrapes gouges etc caused by the impact Any damage beyond normal field repair limits is cause for propeller removal and repair Refer to Blade Repair for field repair limits c Check the blade track and verify that all blades measure within the following limits 1 0 0625 inch 1 6mm of each other on piston engine propellers 2 0 170 inch 4 3mm of each other on turbine engine propellers except propeller models C1101 through C1104 3 0 1875 inch 4 7mm of each other on C1101 through C1104 models dj Check blade twist All blades in a propeller should have the same amount of rotational play If the difference in rotational play between two blades is beyond 1 0 degree uneven internal wear or damage is the possible cause 1 For example rotational movement of No 1 blade measures 1 2 degrees and No 2 blade measures 2 3 degrees This would be considered excessive since the difference is more than 1 0 degree 61 00 06 Page 610 McCauley Propeller Systems Mar 13 2013 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL IN This check must be performed every 10 hours for the next 20 hours after a bird strike If no change is seen after 20 hours inspections may be discontinued NOTE The results of a bird strike inspection
35. change the effective equilibrium speed of the propeller with no change in governor setting The amount of change varies with engine transfer bearing clearance d This speed change is generally a negligible amount and is not cause for concern since it is a normal reaction of the control system e Control friction lock in the aircraft is faulty 2 Corrective Action a Ifitis desired that the original speed setting be maintained in the new flight attitude it may be necessary to alter the propeller control lever as required after the aircraft is trimmed out 1 Refer to the aircraft maintenance manual Improper Propeller Static RPM Piston A Incorrect propeller speed at a given power and static RPM setting 1 Possible Cause a If maximum static RPM is incorrect the problem can normally be attributed to either incorrect low blade angle or insufficient engine horsepower However if the maximum in flight RPM is incorrect then an adjustment of the governor may be necessary NOTE On static runs the propeller should prevent the engine RPM from going to red line This is done to prevent overspeeding and is a design characteristic of the propeller However it should be within 100 RPM of red line 61 00 06 Page 102 McCauley Propeller Systems Mar 13 2013 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL 2 Corrective Action a One area that is often at fault for indicated RPM problems is the tachometer Avia
36. depth of the original damage plus 0 031 inch 0 8 mm Initial removal of material should be done using a small smooth cut mill file Alltraces of file marks in the repaired area should be removed with number 240 emery cloth or equivalent grit sandpaper ES 61 00 06 Page 804 McCauley Propeller Systems Mar 13 2013 d IN 100 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL Smooth the repaired area followed by polishing with number 320 emery cloth and 600 grit emery cloth or equivalent grit sandpaper NOTE Do not use sandpaper or emery cloth that contains iron oxide material on aluminum propellers Determine the depth of the repaired damaged area a The maximum depth of the damage repair area must be measured using a depth gage b The repair that is located on the leading or trailing edges must not exceed 0 125 inch 3 2 mm in depth Propeller damage depth greater than this limit is not field repairable NOTE FAA approved Part 145 Propeller Repair Station or international equivalent may be able to do a repair Contact McCauley Product Support for disposition of any damage that is deeper than the specified limits Face And Camber Repair Procedure 1 IN ln Determine the depth of the damaged area a The depth of damage must be measured using a depth gage b Damage that is located on the face or camber sides of the propeller must not exceed 0 061 inch 1 55
37. differences at the blade root will be magnified many times when measured at the tip 1 Total maximum allowable movement up to 0 125 inch 3 13 mm is considered normal 2 C1100 series propellers may have a maximum movement of 0 1875 inch 4 7 mm Normal blade shake less than maximum allowable movement is no cause for concern as it disappears during propeller rotation due to the high centrifugal forces acting on the blades 20 000 to 45 000 pounds 89 000 to 200 000 N a If blade shake exceeds maximum movement allowable it should be reduced when convenient by inserting shims in the blade assembly by an authorized McCauley overhaul facility BLADE TWIST Two Categories of Blade Twist exist They are defined as follows 1 Rotational play is defined as the sum total of rotational movement a propeller blade allows when moved by hand around its axis of rotation Refer to Figure 602 a This movement is to a limited degree considered normal and should not be cause for concern All blades in a propeller should have about the same amount of rotational play b Ifthe difference in rotational play between two blades is beyond 1 0 degree uneven internal wear and or damage is the possible cause EXAMPLE Rotational movement of No 1 blade measures 1 2 degrees and No 2 blade measures 2 3 degrees This would be considered excessive since their difference is beyond 1 0 degree c The cause of the excessive difference should be d
38. e Figure 201 Figure 202 etc All illustrations within a 300 page numbering section will begin with the number 3 Figure 301 Figure 302 etc 10 Dimensions and Units A Dimensions and Units 1 All dimensions and units are given in both English and metric International System of Units SI units in the text and the illustrations The English value is given and then the metric unit is given in parenthesis 2 Metric units are given in standard abbreviations 3 Station lines and locations are not given in metric units INTRODUCTION Page 6 McCauley Propeller Systems Mar 13 2013 11 12 13 14 15 16 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL Temporary Revisions A Additional information which becomes available may be provided by temporary revision This service is used to provide without delay new information which will assist in maintaining safety Temporary revisions are numbered consecutively within the ATA chapter assignment Temporary revisions are normally incorporated into the manual at the next regularly scheduled revision Material Presentation A This manual is available on paper and CD Service Bulletins A Service bulletins may require special inspections and authorize modifications to propellers As service bulletins are issued they will be incorporated in the next scheduled revision and noted in the Service Bulletin List included in this Introduction
39. euro A 2973 5 8 4622 13 ves 6 A2513 43 Na 61 00 06 Page 1002 McCauley Propeller Systems Mar 13 2013 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL Table 1003 Installation Parts for Fixed Pitch Propellers continued Basic Fixed Pitch Bolt Kit Propeller Dri Model Spacer Dowel Bolt Kit Bolt lled No Washer Number P N P N P N Dia Head Bolts Bolt P N P N Nut P N B 4622 30 Short Bolt N Kit Yes A 2513 10 A 1638 13 NA B 4622 36 Long Bolt N Kit A 2513 23 A 1638 14 B 4622 30 Short Bolt N Kit A 2513 10 A 1638 13 B 4622 36 Long Bolt N N Kit A 2513 23 A 1638 14 NA C 7639 KANES B 4622 1 Y A 2513 18 A 1638 10 A 1639 2 A 4001 7 16 A 2513 38 A 1638 11 1A170 DM z 1 170 2 gt 2 1A175 DM Co 1 175 gt 1A135 DRM 1C160 DTM B 4020 A 2973 6 B 4622 24 Y A 2513 103 A 1638 2 A 1639 2 1B90 ECM 1A170 EFA 1B235 EFC gt o o 20 C 7744 29137 8 4622 45 1C160 EGM N B 4622 14 1C172 EM A 4001 B 4622 3 20 26 3 1 Y A 2513 19 A 1638 13 N 1 A 2513 14 A 1638 10 A 1639 2 7116 Yes A 2513 38 A 1638 11 1 1 1 A 2513 15 A 1638 2 1 1A175 ETM B 4516 4592 A B 4516 A 2973 6 B 4622 2 C 4592 IAZOQEA NA 15 462226 2513 17 A 1638 2 A 1639 2 A A 2513 17 A 1
40. gear or the alternator belt drive pulley 2 Turbine Engine Propellers A Turbine Engine Propeller Component Description 1 McCauley C600 model series propellers have three propeller blades 650 model series propellers have four propeller blades C1100 model series propellers have five propeller blades Each propeller consists of a hub assembly propeller blades piston and cylinder assembly blade start locks counterweights a spinner and spinner bulkhead assembly Refer to Figure 5 Figure 6 and Figure 10 a The McCauley C600 C650 and C1100 model series propellers are used on Honeywell Garrett turbine engines McCauley C700 model series propellers have three propeller blades C750 model series propellers have four propeller blades C1000 model series propellers have five propeller blades Each propeller consists of a hub assembly propeller blades piston and cylinder assembly counterweights and beta shift mechanisms Refer to Figure 7 Figure 8 and Figure 9 a The McCauley C700 C750 and C1000 model series propellers are used on Pratt and Whitney turbine engines 61 00 04 Page 7 McCauley Propeller Systems Mar 13 2013 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL 3 Following is a breakdown of each of the propeller assemblies a Propeller Hub Assembly 1 The propeller hub is a single piece hollow forged aluminum assembly incorporating three four or five propeller blade sockets The
41. included in the propeller unattached parts kit which is included in the box with the propeller or hub assembly Install the O ring according to the assembly instructions in this Owner Operator Manual Install the propeller sling and attach to a hoist If a hoist is not available the propeller may be supported and lifted by hand NOTE Make sure an adequate number of people are available to support the propeller if a hoist is not used a The straps of the propeller sling should be placed on two of the propeller blades at least 6 inches 152 mm outboard of the propeller hub for three blade propellers and 12 inches 305 mm outboard of the propeller hub for two bladed propellers Make sure you protect the deice boots or anti ice shoes from potential propeller sling abrasion damage if installed 61 00 06 Page 411 McCauley Propeller Systems Mar 13 2013 2 9 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL b The sling and hoist should have a weight limit rating at least twice the weight of the propeller that is to be installed Position the propeller close to the engine propeller flange and align the dowel pins with the dowel pin holes if applicable CAUTION Propeller must be installed straight onto engine flange Any rocking of propeller relative to flange could result in damage to engine propeller flange mating surfaces Mount the propeller on the engine propeller shaft Trap the aft spinner bulkhead
42. indication Visible dye penetrants include AMS2644 Type 2 red dye penetrant or any vividly colored dye penetrant visible under ordinary white light AMS2644 Type 1 Fluorescent penetrants which are visible under ultraviolet light are considered different materials by standard practices and should not be considered a subset of visible dye penetrants Personnel a Individuals performing inspections for continued airworthiness defined in this manual shall hold an Airframe and Powerplant rating or international equivalent or the inspection is conducted at an FAA approved Part 145 Repair Station or international equivalent Acceptance Criteria a Any verified flaw indications are rejectable b Any indication which is believed to be non relevant shall be regarded as a defect and shall be reexamined by a McCauley authorized propeller service facility to verify whether or not actual defects are present 61 00 06 Page 616 McCauley Propeller Systems Mar 13 2013 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL 4 Post Cleaning a Residual penetrant and developer must be removed prior to recoating using a cleaning solvent or vapor degreasing refer to Cleaning Painting Protective Treatments Verify complete removal by inspecting under a ultraviolet light 61 00 06 Page 617 McCauley Propeller Systems Mar 13 2013 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL CLEANING PAINTING PROTECTIVE TREATME
43. is dyed red on some models to aid in the troubleshooting of suspected propeller leaks NOTE Periodic maintenance of the lubrication is NOT normally required f Propeller Start Lock C600 C650 and C1100 Series only 1 The propeller has a start lock mechanism installed within the cylinder The mechanism includes latching weights which will engage a fixed stop to block movement of the piston in the direction of increasing blade pitch beyond a predetermined start lock blade angle Latch engagement is possible only when the engine is shut off on the ground When the propeller is rotating the latch weights move out by centrifugal force so as to offer no interference to operation of the control system in flight During all normal operating conditions the weights are in a disengaged position and offer no resistance to feathering unfeathering or reversing of the propeller NOTE Special tools McCauley part number B 5021 2 are required to release start locks manually for maintenance purposes Description of Turbine Propeller Operating Principles 1 Propellers are a single acting unit in which hydraulic pressure opposes the forces of springs and counterweights to obtain the correct pitch for engine load Hydraulic pressure urges blades toward low pitch increasing RPM while springs and counterweights urge blades toward high pitch decreasing RPM The propeller is designed to operate in two modes of operation beta mode and governor mode
44. observed an appropriately rated mechanic should blend it out d The mechanic should remove all corrosion products and make sure that the section thickness has not been reduced below allowable limits 3 Erosion a Examine the blade for evidence of erosion 1 If blades appear to show erosion beyond limits the propeller should be removed from service and evaluated by an appropriately rated propeller repair facility 2 Measure the area of the blade with the most erosion damage a Damage that is located on the leading or trailing edges must not exceed 0 094 inch 2 39 mm in depth b Damage that is located on a repairable area of the face or camber side of the blade must not exceed 0 061 inch 1 55 mm in depth Erosion damage beyond these limits is not field repairable and the propeller should be removed from service and evaluated by an FAA approved Part 145 Propeller Repair Station or international equivalent repair facility b Check the condition of the paint on blades and spinners that have protective paint 1 Paint protects the surface of the blade from erosion The blade should be repaired before the paint wears through and the blade structure begins to erode 2 Do not apply excessive paint and do not paint propeller components unless it is in accordance with McCauley instructions since improper painting may affect propeller balance operation static electricity discharge or have other unintended consequences 4 Straightness a
45. overhaul frequency is 1500 hours or 72 calendar months whichever occurs first 10 000 hour life limit on blades and hub For 4HFR34C755 propellers comply with McCauley Service Bulletin 175 Converting Propeller Model 4HFR34C755 to a 4HFR34C754 then use the overhaul frequency for a 4HFR34C754 propeller 3000 hours or 72 calendar months whichever occurs first except Agricultural aircraft installations the overhaul frequency is 1200 hours or 60 calendar months whichever occurs first 6 Necessary Actions Following Object Strike of Stationary Propeller Blade Strike of Rotating Propeller Bird Strike or Sudden Engine Stoppage A Propellers with Blades Bent Beyond Repair 1 Ahub must be declared unairworthy and scrapped if any blade in the propeller assembly is bent beyond repair limits within the first 8596 of the blade radius refer to Figure 601 Object Strike of Stationary Propeller 1 Object Strike is defined as any impact of a non rotating propeller by a substantial moving object such as any personnel vehicle aircraft tug ground power unit or similar NOTE The definition is intended for use as an example only Determination as to whether or not an object strike actually occurred is ultimately the responsibility of the aircraft operator 61 00 06 Page 608 McCauley Propeller Systems Mar 13 2013 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL C90 IF BLADE IS BENT BEYOND REPAIR LIMITS OU
46. propeller blade sockets are O ring sealed to prevent leakage The rear hub face has threaded studs and dowel holes for alignment and proper mounting to the engine propeller shaft flange The cylinder is mounted to the hub face using screws and is O ring sealed to prevent leakage b Propeller Blades 1 The propeller blades are made of solid forged aluminum A set of steel split retainers inside the hub secures each blade in the hub at the propeller blade sockets Each blade rotates about its axis on a bearing assembly during pitch change and is match balanced to the other blades The propeller assembly is static balanced using balance weights mounted with screws to the blades c Piston and Cylinder Assembly 1 The piston and cylinder assembly through the feather springs counterweights and oil pressure transferred through the piston rod provide the forces necessary to accomplish propeller blade pitch changes d Counterweights 1 Counterweights are attached to the blades to assist the feathering spring located in front of the piston and cylinder assembly in feathering the propeller blades by means of centrifugal force whenever the propeller is rotating and oil pressure in the cylinder is removed e Internal Lubrication 1 The propeller hub cavity is partially filled with turbine oil which is sealed in the hub and isolated from engine oil This oil provides lubrication and corrosion protection to blade bearings and other internal parts The oil
47. propeller sling and attach to hoist If hoist is unavailable propeller may be supported and lifted by hand This will require additional personnel CAUTION The C700 propellers weigh approximately 120 pounds 54 kg the C750 propellers approximately 140 pounds 64 kg C1000 series propellers weigh 180 pounds 83 kg or more a Hoist straps must be a minimum of 4 inches 100 mm wide b The sling and hoist should have a weight limit rating at least twice the weight of the propeller that is to be removed c The straps of the propeller sling should be placed on two of the propeller blades at least 6 inches 152 mm outboard of the propeller hub Make sure you protect the deice boots or anti ice shoes from potential propeller sling abrasion damage if installed Take up the slack on the propeller sling and hoist or have additional personnel support the propeller and remove the nuts Carefully slide the propeller forward and remove from the engine Place the propeller on a suitable support or propeller stand a Do not let the propeller be supported by the tips of the propeller blades or stand the propeller on the propeller blade tips b The stand should be able to hold the propeller securely and have a weight limit rating at least twice that of the removed propeller c Make sure the propeller is protected from damaged while in the stand All areas of the stand that come in contact with the propeller should be padded sufficiently
48. repair 7 Ifthe rate of leakage increases do not operate the propeller Immediately send the propeller to a McCauley authorized propeller service facility 61 00 06 Page 107 McCauley Propeller Systems Mar 13 2013 C89 McCAULEY PROPELLER SYSTEMS OWNERIOPERATOR INFORMATION MANUAL MOVEMENT SHOWN IS GREATLY EXAGGERATED BLADE SHAKE MOVEMENT SHOWN IS GREATLY EXAGGERATED BLADE TWIST Blade Shake and Blade Twist Figure 101 Sheet 1 61 00 06 Page 108 McCauley Propeller Systems Mar 13 2013 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL C Oil leaks at locations other than blades Piston aircraft propellers 1 2 a b c Leakage from the cylinder area requires removal of the propeller and repair by an FAA approved Part 145 Propeller Repair Station or international equivalent If leaks are found on any other spot on the blade or the hub remove the propeller and repair by an FAA approved Part 145 Propeller Repair Station or international equivalent Leaks at the hub propeller shaft interface requires removal of the propeller and replacement of the rear hub O ring Turbine aircraft propellers a b c d Leakage from the cylinder or support plate area requires removal of the propeller and repair by an FAA approved Part 145 Propeller Repair Station or international equivalent Leaks at the hub propeller shaft interface requires removal of the propeller and replac
49. the part number A 2230 9 decal 3 Safety wire 0 041 corrosion resistant steel conforming to MS20995C41 the nuts in pairs to complete the installation c Ifrequired install the deice leads 10 Ifan adaptor or extension is attached to torque wrench drive end and this adds to its length then the actual applied torque will be greater than the dial reading The following formula should be used to find what the dial should read in order to obtain the correct applied torque actual torque required x torque wrench length Torque Wrench Reading TT my to Achieve the Required torque wrench length length of the adapter Actual Torque E Spinner Installation if applicable 9 CAUTION Under shimming or over shimming of the spinner front support could result in spinner wobble vibration and or bulkhead and spinner cracking Follow shimming procedures carefully If required install propeller spinner fillets on the bulkhead with screws and washers Insert the same number of shims into spinner support as were removed and lightly press the spinner support onto propeller cylinder Make sure the index marks made with a felt tip pen align between the spinner and the propeller blade Put the spinner shell onto the bulkhead and fillet assembly with the alignment marks matched a Press firmly aft on the spinner Make sure the spinner holes are approximately one half hole diameter forward of the matching holes in the bulkhead
50. the station indicated by a white or yellow mark on rear surface of the propeller blade usually will be the 30 inch or 42 inch station 61 00 06 Page 417 McCauley Propeller Systems Mar 13 2013 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL CAUTION Never use a screwdriver or other unapproved tool to adjust beta tube Use of any tool other than McCauley B 5378 can severely damage the beta tube and propeller piston rod threads rendering the parts unusable and unrepairable CAUTION Adjustment of the flight idle blade angle must be accomplished as quickly as possible as not to deplete the propeller oil supply f If adjustment is necessary use McCauley tool part number B 5378 to adjust the beta tube Turn the beta tube clockwise to decrease blade angle counterclockwise to increase blade angle 9 Move propeller control to full reverse and install the beta tube locking pin assembly and secure with locking screw 55 torque 25 to 30 inch pounds 2 82 to 3 39 N m 13 Feather start lock and reverse blade angles are set during assembly or overhaul These angles are NOT adjustable in the field CAUTION Spinner Installation Do not operate the propeller below the minimum propeller idle speed operating restriction The minimum propeller idle speed operating restriction is the result of a specific vibratory resonant condition known as reactionless mode Ground operation at or near a reactionless mo
51. to Turbo Oil 2380 6 Campus Drive MIL PRF 23699 Maple Plaza II IN Parsippany NJ 07054 NOTE Field technicians may not Phone 973 401 4350 combine different turbine Fax 973 401 4355 oils Web www airbp com Grease Convoy Oil Corp MIL T 83483 1412 Front street Philadelphia PA 19122 Phone 215 739 5281 Fax 215 739 6933 61 00 06 Page 702 McCauley Propeller Systems Mar 13 2013 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL Table 701 Lubricants continued Part w mper Description Manufacturer nos A 1637 18 Dyed Oil Turbine engines 1 gallon of BP Turbo Oil 2380 and 12 grams of A 4880 1 A 4880 1 Red B liquid dye NOTE A 4880 1 red B liquid dye does not have a shelf life LPS 3 Heavy LPS Laboratories In corrosive environments spray on duty Rust Inhibitor USA rings Fax 770 493 9206 6 7647 Hugh Howell Road blade retaining snap ring and area Tucker GA 30085 9206 to prevent corrosion of the retaining Adhesives and Sealants a Table 702 provides a listing of sealants approved for use in McCauley products Table 702 Adhesives and Sealants Part e A 1664 15 A 1664 16 A 1664 17 A 1664 17 Scotch Grip Brand Rubber Adhesive 1300L De icer Conductive Cement HA 56 B 82 076 De ice Boot Edge Sealer Kit De ice Boot Edge Sealer F63B12 3M Company Bldg 209 25 31 3M Center St Paul MN 55144 Phone 651 733 9288 Fax 651 736 8336 Sov
52. to 780 74 570 to 88 128 8 9 10 Ifan adaptor or extension is attached to torque wrench drive end and this adds to the length of the wrench then the actual applied torque will be greater than the torque indicated by the wrench reading The following formula should be used to determine what the torque wrench indicator should read in order to obtain the correct applied torque actual torque required x torque wrench length Torque Wrench Reading to Achieve the Required torque wrench length length of the adapter Actual Torque Torque the mounting bolts nuts in an alternating sequence to prevent the propeller from rocking on the engine flange For propeller mounting bolts with drilled heads install lockwire use a minimum diameter of 0 032 corrosion resistant steel conforming to MS20995C32 between pairs of bolt heads When shims are required for location of spinner support select quantity and thickness so that spinner shell screw holes are misaligned with the rear bulkhead holes or nuts by 1 2 hole diameter Use at least one mylar shim to contact bolt heads When the correct number of shims has been determined press or lightly tap support into hub bore apply force to spinner shell toward propeller to align screw holes with bulkhead holes or nuts and install washers and screws NOTE Make sure the felt tip marker line on the spinner aligns with the marker line on the aft spinner bulkhead and with the marker li
53. to prevent abrasion damage to the propeller Install a protective cover over the propeller hub mounting flange Install a protective cover over the open end of the engine propeller flange Remove the D 5945 feedback collar retractor tool from the propeller Propeller Installation NOTE McCauley recommends that the propeller mounting nuts McCauley part number A 1639 32 be replaced at each propeller installation whenever possible However nuts may be reused if the locking material prevents turning of the nut on the stud by hand Install the D 5945 feedback collar retractor tool on the propeller Remove protective cover from the end of engine propeller flange Make sure the flange is clean and free of nicks and burrs Make sure that the engine propeller flange dowels and mounting stud holes are clean dry and free of nicks and burrs Remove the protective cover from the propeller hub mounting flange Make sure that the propeller hub mounting flange dowel pin holes and mounting studs are clean and undamaged Make sure that a new O ring is installed in the groove of the propeller hub mounting flange Lubricate the O ring with engine oil prior to installation of the propeller NOTE Referto the Installation Parts For Turbine Engine Propellers Table 1002 for the O ring part number NOTE In the past new propeller assemblies shipped from McCauley the propeller hub engine O ring was installed in the O ring groove of new propelle
54. tractor type aircraft make sure the face back side of each propeller blade is painted flat black and the propeller tips on the camber forward side of each blade are painted with the appropriate colors to ensure good visibility Make sure that any propeller paint touch up is done equally to each blade so that the balance of the propeller is not disturbed Pusher props may have unique paint color requirements for good visibility for ground personnel Refer to McCauley s maintenance documents 11 McCauley spinners can be polished use commercially available polishing compounds Operators CANNOT do the following EN o TZ NOTE The following is a listing of actions that shall not be performed on or subject a McCauley propeller or component to 1 Do not operate any aircraft after the propeller has been subjected to impact damage without a thorough inspection and has been approved for return to service by an appropriately rated person or repair facility 2 Never straighten a damaged propeller Even partial straightening of blades to ease shipment to a repair facility may result in hidden damage not being detected and an unairworthy propeller being returned to service 3 Never repair any blade defect by welding heating or peening This can induce premature blade failure 4 Never chrome plate a spinner Plating will cause cracks and spinner failure 5 Do not attempt to repair or modify a propeller spinner or spinner com
55. 0 s 5HFR34C1105 This manual gives the necessary information required to help maintenance personnel service examine troubleshoot remove and install McCauley Propellers D Information in this manual is applicable to all U S and Foreign Certified propellers 4 Instructions for Continued Airworthiness ICA A Owner Operator Information Manual 1 Theinstructions provided in this manual are the principal instructions for continued airworthiness This manual may be revised to add changes to the ICAs or to add additional ICAs when changes to an affected propeller type design require changes to these instructions When a revision to this manual is not possible within the time constraints for these ICAs the instructions may be transmitted with a temporary revision or with an ICA supplement Temporary revisions will be incorporated in the next revision to this manual and ICA supplements will also be incorporated in the next revision unless these instructions require restricted distribution B Temporary Revisions 1 Temporary revisions may be produced to transmit supplemental instructions for continued airworthiness when a revision to the owner operator information manual is not possible within the time constraints for these ICAs They consist of complete page blocks which replace the existing paper and will temporally supersede the CD ROM data Temporary revisions will be INTRODUCTION Page 3 McCauley Propeller Systems Mar 1
56. 0 06 Page 413 61 00 06 Page 419 61 00 06 Page 501 61 00 06 Page 501 61 00 06 Page 501 61 00 06 Page 501 61 00 06 Page 501 61 00 06 Page 501 Page 1 of 2 Mar 13 2013 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL PROPELLER INSPECTION CHECK 2 vn l 61 00 06 Page 601 Limitatlons anne IE Si ish 61 00 06 Page 601 Definitions of Defects and Damage 61 00 06 Page 601 Daily or Preflight Inspection 61 00 06 Page 602 100 Hour and Annual Inspection 61 00 06 Page 603 Time Between Propeller Overhaul 61 00 06 Page 604 Necessary Actions Following Object Strike of Stationary Propeller Blade Strike of Rotating Propeller Bird Strike or Sudden Engine Stoppage 61 00 06 Page 608 Governors Exposed to Propeller Blade Strike Propeller Engine Lightning Strike Engine Detonation Oil Contamination or Sudden Engine Stoppage 61 00 06 Page 611 Blade Track Check 44442 61 00 06 Page 612 Lightning Strike Inspection Requirements 61 00 06 Page 612 Propeller Overspeed Inspection Requirements 61 00 06 Page 613 Propeller Overtorque Inspection Requirements 6
57. 1 00 06 Page 613 Normal Criteria for Static Blade Shake and Twist of All Variable Pitch Propellers 61 00 06 Page 614 Engine Oil Contamination Inspection Requirements 61 00 06 Page 614 Fire Inspection iiiv asa a yu a urt Dee ein adsense ER 61 00 06 Page 616 Non Destructive Inspection Procedures 61 00 06 Page 616 CLEANING PAINTING PROTECTIVE TREATMENTS 61 00 06 Page 701 Generale snart aes E RA 61 00 06 Page 701 Consumable Material 61 00 06 Page 701 Pre Cleaning Procedures 61 00 06 Page 707 Blade Cleaning FE hete babe bee pe IS 61 00 06 Page 707 Propeller Protective Treatments 61 00 06 Page 707 Blade Painting s s a sad eR re ee be kapa dia PRESTO ed 61 00 06 Page 709 Spinner Chrome Plating E eee 61 00 06 Page 710 PROPELLER APPROVED REPAIRS 61 00 06 Page 801 Blade Repair ut cute e ete bx E PEU px i 61 00 06 Page 801 Spinner az gakk ad das Ad ee beer ne RER 61 00 06 Page 806 PROPELLER INSTALLATION PARTS LIST 61 00 06 Page 1001 General ten ER BER An oa 61 00 06 Page 1001 61 CONTENTS Page 2 of 2
58. 1294 26 Turco Transpo Henkel Surface Technologies Paint remover Polane Paint DeBois Chemical Company Remover IDS 12D LT 8 Cleaners and Solvents a Table 704 provides a listing of approved cleaners and solvents for use on McCauley products Table 704 Cleaners and Solvents Part M Mam MPK methyl propyl ketone approved substitute for MPK mue Oil based Solvent Mixture One part lubrication oil MIL L 6082 Grade 10 30 and two parts MIL PRF 680 Type Stoddard Solvent 61 00 06 Page 705 McCauley Propeller Systems Mar 13 2013 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL Table 704 Cleaners and Solvents continued Part Mineral spirits MIL PRF 680 Type I or Ill Isopropyl Alcohol T T 735 Lee MIL R 81294 9 Miscellaneous Material a Table 705 provides a listing of recommended miscellaneous materials for use on McCauley products Table 705 Various Part m Description Manufacturer M tes Self Adhesive 3M Company Polyurethane Tape 3M Center 8671 St Paul MN 55144 Phone 800 362 3550 Fax 651 736 8336 Web www 3m com Non Etch Alkaline Enthone Crookston Electronics Cleaner NE 7 350 Frontage Rd Cleaner West Haven CT 06516 Phone 203 934 8611 Hypodermic syringe 15 cc with 20 and 24 gauge needles cotton swab Medical or Cosmetic Grade Non steril
59. 13 1 Blade Repair A McCAULEY PROPELLER SYSTEMS OWNERIOPERATOR INFORMATION MANUAL PROPELLER APPROVED REPAIRS Removal of Blade Damage General 1 3 b c The propeller blade is a highly stressed part The fact that propeller blades are subject to impact damage such as nicks gouges and scratches and corrosion primarily uniform etch and pitting corrosion but intergranular or exfoliation type corrosion can also occur demands frequent inspection and maintenance Repair of small nicks gouges and scratches that do not exceed the damage specifications identified in this section Blade Repair are considered Minor Repairs and may be performed by an appropriated rated mechanic or repair station After filing and polishing the damaged area should be inspected and when possible by fluorescent dye penetrant method to verify that all damage has been removed and the blade is not cracked The area should then be re protected by localized application of chemical film per MIL C 5541 for example Alodine and repainted as necessary NOTE Refer to the Non Destructive Inspection Procedures for fluorescent dye penetrant inspection procedures NOTE If it is not possible to inspect the repaired area using the fluorescent dye penetrant inspection method the repaired region should be inspected with a minimum 10x power lens to ensure any sharp notches or cracks have been removed All other damage that exceeds th
60. 19 O McCauley Propeller Systems Mar 13 2013 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL PROPELLER TROUBLESHOOTING General Information A Types of Problems Normally Encountered 1 This section outlines and explains a number of operating characteristics which have been observed in service There is some discussion of propeller design as it relates to these characteristics Procedures for locating and correcting causes of undesirable operation are given Operation in Restricted Power or RPM Conditions Turbine A There are several risks to the propeller blades and or hubs if the propeller is operated in restricted areas 1 Each propeller is subjected to rigorous vibration tests to determine that the conditions under which a particular propeller engine airframe combination will operate safely Certain power settings or RPM ranges are restricted by either the airframe manufacturer and or McCauley This is because vibrations produced in the restricted ranges can cause fatigue cracks in the hub or blades Such cracks could cause catastrophic failures of the propeller and a subsequent crash of the aircraft Always carefully obey the restrictions published in the aircraft AFM POH or the POH supplement provided with the STC under which the propeller is installed CAUTION Failure to follow the published limitations for any McCauley propeller could result in a reduced life or possibly even catastrophic loss of th
61. 2 inches 305 mm outboard of the propeller hub for two bladed propellers Make sure you protect the deice boots or anti ice shoes from potential propeller sling abrasion damage if installed b The sling and hoist should have a weight limit rating at least twice the weight of the propeller that is to be removed 61 00 06 Page 410 McCauley Propeller Systems Mar 13 2013 6 9 McCAULEY PROPELLER SYSTEMS OWNERIOPERATOR INFORMATION MANUAL Take up slack on the propeller sling and hoist or support the propeller by hand and remove the nuts or bolts CAUTION Propeller must be removed from engine in a straight motion Any rocking on the engine could cause damage to the propeller mounting flange For Lycoming propeller installations care must be taken to remove the propeller in a straight forward motion as the propeller stud and nut assembly are loosened from the engine crankshaft flange Carefully slide the propeller forward and remove from the engine Place the propeller on a suitable support or propeller stand a Do not let the propeller be supported by the tips of the propeller blades or stand the propeller on the propeller blade tips b The stand should be able to hold the propeller securely and have a weight limit rating at least twice that of the removed propeller c Make sure the propeller is protected from damaged while in the stand Allareas of the stand that come in contact with the propeller should be padd
62. 3 2013 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL included on the CD ROM on the next CD ROM release Temporary revisions are numbered consecutively in the ATA chapter assignment Page numbering uses the three element number which matches the owner operator information manual 2 Paper Version of the owner operator information a Paper temporary revisions will be distributed on yellow paper File the temporary revision cover sheet after the title page of the chapter to which it applies and substitute or add the remaining pages in the paper manual 3 Electronic Cesview Version of the Maintenance Manual a The cover sheet will be located in the maintenance manual Cesview library at the beginning of the chapter to which it applies and the changed or added pageblocks will be located in the appropriate location by ATA All revised or added information will be highlighted blue C ICA Supplements 1 ICA supplements may be produced to transmit supplemental instructions for continued airworthiness when a revision to the owner operator information manual is not possible within the time constraints for these ICAs ICA supplements will provide supplemental instructions for one or more ICA manual and is to be used in conjunction with the affected manuals maintenance manual wiring diagram manual etc until those instructions are incorporated into the manuals ICA supplements are numbered consecutively by model in the ATA chapter
63. 638 2 A 1639 2 A 2513 53 A 1638 14 NA NA B 1A175 FC N 1C200 FC N 1B90 FCM 1A170 FFA 1C160 FGM 1A200 FM 1A101 GCM 1A170 GM 1A175 GM 1A175 GMA 1A101 HCM 1A200 HFA 1B200 HM 1A135 JCM 1 1 B 4273 A 2973 6 B 4622 38 6462238 NA 5462231 7 29736 A2073 5 A 4001 B 4622 4 N B 4304 A 2973 6 A A A A B 4622 2 A4001 A A A 3 3 3 3 3 3 3 A 2513 43 A 1638 14 61 00 06 Page 1003 McCauley Propeller Systems Mar 13 2013 B 3927 A 2973 6 B 4622 18 3 2 2 2 2 2 8 2 8 16 8 8 8 8 8 2 16 8 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL Table 1003 Installation Parts for Fixed Pitch Propellers continued Fixed Pitch Bolt Kit Basic Propeller Dri Model Spacer Dowel Bolt Kit Bolt lled No Washer Number P N P N P N Dia Head Bolts Bolt P N P N Nut P N C 5464 1A170E JFA A 2973 6 B 4622 40 1 2 Yes A 2513 92 1638 2 amen 7726 Jason na C 5464 1A170E JHA C 7726 A 2973 6 B 4622 40 1 2 Yes A 2513 92 1638 2 NA masem B4446 A 2973 6 B 4622 19 se ves 6 azotar jatese ta na 1 B4273 2973 8 4622 38 12 Ves 6 Jazs zr na NA Mason 5462230 ves 8 A2513 0 ateses na LiBsoLCM 63000 A 2973 6 B 4622 10 ves 6 asin A163 13 NA _ c 1210 Note 2
64. A162 model propellers with a spacer installed Refer to Figure 401 NOTE The following procedure should be used to remove a rear spinner bulkhead when it a b c d e is clamped between a spacer and the propeller hub Support the propeller by nesting it between two shot or sand filled bags Put the supports as close to the hub as possible with the spacer down facing the bench or table top Make sure you allow sufficient clearance approximately 2 inches for the spacer to separate from the hub Select a punch with the proper diameter approximately 6 inches long and insert it into the dowel pin hole Alternately tap one dowel and then the other with light hammer blows to free the spacer from the propeller hub 2 For 1A162 model propellers with a spacer installed Refer to Figure 402 a Tool Fabrication NOTE The spacer removal tool can be fabricated locally or a tool part number A 8029 can be purchased from McCauley Use a steel bar that is at least 0 250 inch 6 35 mm thick and 2 00 inches 51 00 mm wide and 6 0 inches 152 0 mm long Drill two 0 250 inch 6 35 mm holes in the steel bar that are 2 875 inches apart 0 020 or 0 020 inches 73 03 mm 0 5 mm or 0 5 mm and 1 438 inches 0 020 or 0 020 inches 36 53 mm 0 5 mm or 0 5 mm from the center of the steel bar Remove the propeller and spacer assembly from the airplane Spacer Removal Procedure Refer to Figure 402 1 Att
65. Bolt DRY DRY Torque DRY or Nut Pound Pound Newton Meters Diameter Feet Inches N m 251030 30010360 33 895 to 40 675 10 Ifan adaptor or extension is attached to torque wrench drive end and this adds to its length then the actual applied torque will be greater than the dial reading The following formula should be used to find what the dial should read in order to obtain the correct applied torque actual torque required x torque wrench length Torque Wrench Reading Ts 77 to Achieve the Required torque wrench length length of the adapter Actual Torque 11 Torque the mounting bolts nuts in an alternating sequence to prevent the propeller from rocking on the engine flange 12 Safety wire propeller mounting bolts Install the safety wire around the bolt heads Do not install the safety wire over the top of the bolt head 13 Spinner Installation if applicable a Putthe spinner shell onto the bulkhead with the alignment marks matched b Press firmly aft on the spinner c Push on the spinner shell and use an awl or a small punch in an adjacent hole to move the spinner shell screw hole into alignment with bulkhead hole and install washer and screw Repeat this procedure on opposing holes until eight evenly spaced screws and washers are installed d Secure propeller spinner to the bulkhead with remaining screws and washers 61 00 06 Page 409 McCauley Propeller Systems Mar 13 2013 4 McCAULEY PROPE
66. CTION SUBJECT PAGE 04 Title 04 List of Effective Pages 04 Record of Temporary Revisions 04 Table of Contents 4 00 00 Page 1 4 10 00 Pages 1 3 4 11 00 Pages 1 2 APPROVED av Margaret Kline Manager Aircraft Certification om Federal Aviation Administration Wichita Kansas DATE OF APPROVAL 3 Z 2013 DATE Mar 13 2013 Mar 13 2013 Mar 13 2013 4 LIST OF EFFECTIVE PAGES Page 1 of 1 McCauley Propeller Systems Mar 13 2013 RECORD OF TEMPORARY REVISIONS Temporary Revision Number Page Number Issue Date By Date Removed McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL CONTENTS AIRWORTHINESS LIMITATIONS SCOPC A AAA SER eR asa qa Qa sq D finitions a cot ers u An u tete ee INSPECTION TIME LIMITS General uscar LM d he dd aga nels IAN reiht adie epider ia haa aad Inspection Schedule REPLACEMENT TIME 5 Generali os a ard Blade Life Eimits 2 2 rl a Ra ee Hub Life Limits 4 CONTENTS O McCauley Propeller Systems 00 Page 1 00 Page 1 00 Page 1 00 Page 1 00 Page 1 00 Page 1 00 Page 1 00 Page 1 00 Pa
67. D 2A34C216 B2D34C217 Be B2D34C218 D B2D34C219 D B2D34C220 E 6 2A34C221 2A37C223 less than C 2A37C223 C or E C higher B2D37C224 R B2A34C225 ma 2A34C227 less than EN C 2A34C227 C or B2A37C228 B2D37C229 ELE higher araco D jc ores D pzarsosos D2AF34C305 less A D2AF34C305 B or D2AF34C306 than B higher D2AF34C307 D D2AF34C308 D D2AF34C310 f gt D3A34C401 NE WU D3A34C402 mE E D3A34C403 NEC D3A34C404 B3D34C405 3A32C406 less than D 3A32C406 D or B3D32C407 LIN D3A32C408 higher 61 00 06 Page 605 McCauley Propeller Systems Mar 13 2013 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL Table 601 Table 1 Propeller Models continued Model Designation Overhaul Model Designation Overhaul Model Designation Overhaul Frequency Frequency Frequency Note Note Note S D3A32C409 D or T D3A36C410 higher B3D32C412 B3D34C413 C3D36C415 B3D36C416 3A32C418 B3D32C419 D3A34C420 D or E B3D34C421 higher 3A34C423 D or E higher 3A34C423 less than D x v F 3AF32C528 G 3GFR34C602 4HFR34C652 H 4HFR34C662 H 4HFR34C66 1 4HFR34C664 AHFR34C665 K 3GFR34C703 3GFR34C702 4HFR34C754 4JFR34C758 4HFR34C764 4HFR34C763 4HFR34C769 4HFR34C768 4HFR34C773 4HFR34C774 F 5HFR34C1008 H 5JFR36C1003 D3A32C409 less than D D3A32C411 B3D32C414 B3D32C417 D3A34C420 less than D 3A34C422
68. E PART NUMBER MANUFACTURER USE Spacer Removal A 8029 McCauley To separate and remove Tool the propeller spacer from the propeller hub for 14162 model propellers only Torque wrench B 5588 McCauley To torque turbine propeller adapter mounting nuts Feedback collar D 5945 McCauley To aid in removal and retractor installation of C700 C750 and C1000 series propellers Beta tube B 5378 McCauley To install and adjust beta installation and tube on C600 C650 and adjustment tool C1100 series propellers Start Lock Release B 5021 2 McCauley To release the start locks on 600 650 and 1100 series propellers 2 Uncrating and Acceptance Checking a New Propeller A Uncrating the propeller 1 2 3 4 S Place the crated propeller in an area that has good lighting and where there is sufficient room to remove the crating and packaging material with the propeller laying flat against the floor or table top of sufficient size to support the propeller with the propeller mounting flange facing down Inspect the exterior of the crated propeller for signs of damage If there are any signs of damage make sure the propeller is thoroughly inspected in the area of the observed crate damage after it has been removed from the packaging material Remove the crate and packaging material NOTE McCauley uses a variety of shipping containers and materials For two and three blade propellers the crating material is almost always co
69. Engine Propellers continued IN C600 Series C650 Series C700 Series C750 Series C1000 Series C1100 Series Spinner Washer A 1638 5 A 1638 5 A 1638 5 A 1638 5 A 1638 44 A 1638 5 fiber Spinner Shim B 4940 1 B 4940 1 B 4940 1 B 4940 1 B 4940 1 B 4940 1 Spinner Shim B 4940 2 B 4940 2 B 4940 2 B 4940 2 B 4940 2 B 4940 2 NOTE 1 C1100 Series does not include C1101 through C1104 Table 1003 Installation Parts for Fixed Pitch Propellers Basic Fixed Pitch Bolt Kit Propeller Dri Model Spacer Dowel Bolt Kit Bolt lled No Washer Number P N P N P N Dia Head Bolts Bolt P N P N Nut P N B3400 A 2973 6 B 4622 10 of ves asin aies NA 1 _ NA _ B 462225 12 ves 6 A2513 13 16382 CtramGM 63515 A 2973 B 4622 15 of ves 6 A 251325 A 1638 13 NA rAtToreMs 8 5627 A 2973 6 5 462241 12 ves 6 A2513 99 aicsez A 2973 7 1A135 BRM 3718 4622 1 1 2 A 2513 18 A 1638 10 A 1639 2 1A90 CF Note 3 NA NA B 4622 42 3 8 Yes A 2513 9 A 1638 13 A 1639 6 B 3515 A2973 G 4622 33 318 ves 6 A251341 A 1638 13 NA 1B90 CM Note 3 NA Note 2 B 4622 42 3 8 Yes A 2513 9 A 1638 13 A 1639 6 A 2973 7 1A135 CRM B 3748 My 18 4622 1 1 2 Yes A 2513 18 A 1638 10 A 1639 2 53896 A 2973 B 462220 716 ves 6 A251338 arcs NA JAIONDEM NA NA B 46229 aB ves 6 a25136 A163813 NA coom
70. If a dowel is loose the dowel will need to be replaced Install the spacer and if applicable the aft spinner bulkhead on the propeller a Locate propeller hub on a padded arbor press table spacer mating surface face up b Make sure the serial number on the spacer aligns with the number 1 propeller blade NOTE If the number 1 propeller blade cannot be identified align the spacer serial number to the propeller blade with the propeller serial number c Position the spinner bulkhead if applicable on the dowel pins between the propeller and spacer NOTE The spinner aft bulkhead must be positioned so that the propeller blades emerge from the bulkhead and spinner with ample clearance Make sure the felt tip marker line on the spinner aft bulkhead aligns with the mark on the propeller blade d Apply a film of oil on the dowel pins e Pressthe propeller and spacer together with the arbor press Make sure you do not scratch dent or deform the propeller or spacer during this assembly operation The assembled propeller dowel and spacer should be a press fit and not separate easily NOTE When the dowels are in position the dowels will be engaged approximately half in the spacer or crankshaft flange and half in the propeller hub Assembly of the spinner installation is completed as the propeller is installed on the engine crankshaft flange Some installations have the spinner aft bulkhead held between the propeller hub and the spac
71. LLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL Constant Speed Reciprocating Engine Propeller Removal and Installation Piston A General 1 Propeller removal and installation shall be performed only by qualified maintenance personnel The following instructions are general in nature The aircraft maintenance manual or STC installation instructions should always be consulted for any specialized procedures applicable to a specific aircraft Various spinner and deice arrangements not manufactured by McCauley may be used which require additional procedures NOTE Qualified maintenance personnel means the person doing the maintenance activity is the holder of or is working under the direct supervision of the holder of the appropriate rating to approve the propeller for return to service after the maintenance activity has been accomplished In the following instructions installation of propeller is based on the assumption that a McCauley spinner will be used If a spinner is not used or if the spinner is not manufactured by McCauley omit those steps which apply to the spinner WARNING Verify that engine magnetos have been grounded prior to approaching the propeller Spinner Assembly Removal CAUTION Make sure you do not damage or scratch the blades when removing the spinner shell Make an alignment mark on the spinner shell spinner aft bulkhead and adjacent blade with a felt tip pen This index mark ensures accurate restorati
72. NTS 1 General A Cleaning Procedures CAUTION Do not clean any McCauley propeller part with a steel brush other metal brush hard bristle brush or tool of any type not specified CAUTION As applicable during cleaning procedures observe allowable dimension limits established for certain parts 1 Remove dirt paint when applicable grease and oil from all disassembled metal parts of propeller 2 Use McCauley approved cleaning mediums only Refer to Table 701 3 Clean all small highly finished parts separately a Be careful not to damage small metallic parts especially on working faces b Clean nonmetallic parts except gaskets packings and seals by wiping with a soft lint free cloth dampened with an approved cleaning medium c Remove thick or packed on grease or dirt with a soft brush d Allow cleaned parts to air dry NOTE Remove excess moisture with a gentle stream of clean dry compressed air keeping nozzle of air hose well away from parts 4 Protect cleaned parts from collecting dust and dirt during storage or during handling at overhaul NOTE Keep small parts in transparent plastic bags 2 Consumable Material A General 1 This section contains information on materials commonly used for cleaning repair rework painting etc 2 Contact McCauley Propeller Systems for approval to use materials not included on these lists WARNING Some of the chemicals used for cleaning painting or
73. OTE When the dowels are in position the dowels will be engaged approximately half in the spacer or crankshaft flange and half in the propeller hub Rotate the engine crankshaft so the number 1 cylinder is Top Dead Center TDC on its compression stroke 61 00 06 Page 408 McCauley Propeller Systems Mar 13 2013 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL 6 Position the propeller on the engine crankshaft so the number 1 blade is clocked 60 degrees in the direction of engine rotation from TDC NOTE The number 1 blade will be located at approximately the 10 O clock position when viewed from in front of the engine looking aft NOTE If you have not installed the propeller and spinner assembly on the engine before the use of a propeller sling and hoist is recommended to prevent accidental damage to the propeller If a hoist is not available the propeller may be supported and lifted by hand Make sure an adequate number of people are available to support the propeller if a hoist is not used 7 Install propeller on crankshaft flange WARNING Make sure there is no lubricant on the threads of the propeller attach nuts and bolts If the propeller attach bolts and nuts have lubricant on the threads the bolts will be over torqued and the propeller could fail 8 Install forward spinner bulkhead washers bolts and nuts 9 Tighten bolts and torque evenly in accordance with the following table Torque Torque
74. PACERS INNER RACE SPLIT E RETAINER VENT STATIC BALANCE WEIGHTS NON OIL FILLED 0511604 C200 Series Propeller Figure 1 Sheet 1 61 00 04 Page 2 McCauley Propeller Systems Mar 13 2013 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL C336 OIL FILL ACTUATING ope SPRING ASSEMBLY HUB SPACER NUNT LOW PITCH Em f O CYLINDER _ AA SUPPORT PISTON SPACER HIGH PITCH BALANCE RING LINK WIRE RING BLADE RETAINING RING SHIM SPLIT SHIM SHIM CARRIER OUTER RACE BALLS SPACERS INNER RACE O RING SLOT BLOCK SPLIT RETAINER SERIAL NO BLADE PLUG STATIG BALANCE WEIGHTS OIL FILLED C200 Series Propeller Figure 1 Sheet 2 61 00 04 Page 3 McCauley Propeller Systems Mar 13 2013 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL C319 ACTUATING PIN ASSEMBLY HUB ASSEMBLY I N 2 gt DF gt KES Val TO y CYLINDER BALANCE WEIGHT COUNTERWEIGHT ASSEMBLY COUNTERWEIGHT ASSEMBLY BLADE SHIM OUTER RACE BALL SEPARATOR SPLIT SHIM INNER RACE O RING SPLIT RETAINER LOW PITCH STOP PLATE J SERIAL NO
75. Propeller mounting bolts must be replaced whenever the propeller is involved in a blade strike as defined in Necessary Actions Following Object Strike of Stationary Propeller Blade Strike of Rotating Propeller Bird Strike or Sudden Engine Stoppage For 1A170E JHA XXXX propellers only installed on Aircraft Operating as Pilot Schools in accordance with 14 CFR Part 141 and all aircraft with 2000 or more cycles for every 1000 flight hours must be inspected in accordance with Service Bulletin 240 X every 1000 hours or 72 calendar months whichever occurs first For 1A103 TCM XXXX propellers only the overhaul frequency is every 1500 hours of operation or 72 calendar months whichever occurs first All propellers with 1500 or more hours total time in service must be inspected in accordance with Alert Service Bulletin 221 X every 750 hours of operation or 36 calendar months whichever occurs first All Propeller Governors 2000 hours or 60 calendar months whichever occurs first All Propeller Accumulators 1800 hours or 60 calendar months whichever occurs first 2000 hours or 72 calendar months 10 000 hour life limit on blades and hub except Aerobatic installations the overhaul frequency is 1000 hours or 72 calendar months whichever occurs first 10 000 hour life limit on blades and hub 2400 hours or 72 calendar months whichever occurs first 10 000 hour life limit on blades and hub except Aerobatic installations the
76. REVISION OWNER OPERATOR INFORMATION MANUAL REVISION 2 13 MARCH 2013 MPC26 02 The entire manual is provided with this revision OWNER OPERATOR INFORMATION MANUAL D Member of GAMA COPYRIGHT 2008 MCCAULEY PROPELLER SYSTEMS 7 AP RI L 2 WICHITA KANSAS USA REVISION 2 13 MARCH 2013 CHAPTER SECTION SUBJECT 00 Title 00 List of Effective Pages 00 Record of Revisions McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL LIST OF EFFECTIVE PAGES PAGE DATE 00 Record of Temporary Revisions 00 Table of Contents LIST OF REVISIONS INTRODUCTION ICA SUPPLEMENT LIST McCauley Propeller Systems Page 1 Mar 13 2013 Pages 1 8 Mar 13 2013 Page 1 Mar 13 2013 00 LIST OF EFFECTIVE PAGES Page 1 of 1 Mar 13 2013 RECORD OF REVISIONS Revsion Number Date Inserted Date Removed Page Number Revsion Number Date Inserted Date Removed Page Number RECORD OF TEMPORARY REVISIONS Temporary Revision Number Page Number Issue Date By Date Removed McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL CONTENTS LIST OF REVISIONS 22 dome are are pga B AEG Page 1 General u ne ee en Page 1 Export Compliance Lan e dete le eee be
77. RM ETC Consult the FAA TC Data Sheets for details relating to approved engine propeller airplane installations of fixed pitch propellers covered in this manual Propeller Mounting Torque 1 Refer to Propeller Removal Installation for the correct installation instructions and torque values for the propeller mounting hardware 61 00 01 Page 1 McCauley Propeller Systems Mar 13 2013 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL E Propeller Strike or Sudden Engine Stoppage 1 Refer to Necessary Actions Following Object Strike of Stationary Propeller Blade Strike of Rotating Propeller Bird Strike or Sudden Engine Stoppage for the inspection requirements following a propeller strike type event F Lightning Strike 1 Refer to Lightning Strike Inspection Requirements for the inspection requirements following a suspected propeller Lightning strike type event G Definitions of Propeller Maintenance 1 Overhaul This term denotes a complete tear down and reassembly which is not necessarily applicable to a fixed pitch propeller The terms overhaul and reconditioning are sometimes used synonymously for a fixed pitch propeller The overhaul of a propeller requires the propeller to be inspected for conformity to a fixed set of dimensions and is required on a predetermined interval while reconditioning can occur on an as needed basis 2 Reconditioning The repair of blade damage caused by erosion or striki
78. SING SPRING GYLINDER LATCH START LOCK AGTUATING FEATHERSTOP PIN AGTUATING LINK PROPELLER SEGTIONAL DRAWING C1105 NOTE THE OIL FLOW BETA TUBE IS FURNISHED BY ENGINE MANUFAGTURER C1100 Series Propeller Figure 10 Sheet 1 61 00 04 Page 14 O McCauley Propeller Systems Mar 13 2013 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL D Propeller Deice refer to Figure 11 NOTE Only components sold by McCauley are described Some OEMs or STC owners may have different designs 1 If propeller deice is installed the components include electrically heated rubber boots deice harnesses slip ring assembly deice timer brush block assembly a The brush block deice harnesses and slip ring assembly conduct electrical power to the propeller blade deice boot elements which then heat b The heat melts a layer of the ice which allows the remaining ice to be removed from the propeller blades by centrifugal force c Deice Harness if deice is installed The deice electrical harnesses connect the deice boots to the slip ring assembly to complete the deice electrical circuit d Deice Slip Ring Assembly if deice is installed The deice slip ring assembly is constructed of machined aluminum with bronze commutator rings bonded to one side Studs to attach the deice leads for each blade are located on the propeller side of the platter These are brazed to the commutator rings and pass throug
79. Sherwin Williams Chromate This primer has also Primer MIL P been identified as Pratt 8585 amp Lambert Product Number 723 400 Cessna RMPN K000440 Specification Certification TT P 1757 Rev B Type Class C Color Y F563TXB114 Flat Black Sherwin Williams Polane T Topcoat 92 4302 F63TXW114 Sherwin Williams Polane T Topcoat 45 4302 F63TXA1158 Gray Sherwin Williams Polane T Topcoat 2 4302 F63TXR1134 Sherwin Williams Polane T Topcoat 7 4302 F63TXS1443 Silver Sherwin Williams Polane T Topcoat 3 4302 F63TXW159 Matterhorn Sherwin Williams Polane T Topcoat 26 4302 Weight 61 00 06 Page 704 O McCauley Propeller Systems Mar 13 2013 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL Table 703 Paint and Protective Finish continued V66V27 Catalyst Sherwin Williams Polane B Base Component R7K84 Sherwin Williams Polane B Base Component F63B13 Static Black Hi Sherwin Williams Polane B Topcoat Gloss F63BXH120 Cirrus Linen Sherwin Williams Polane B Topcoat 27 White Beige Turcoat Liquid Accelagold Alodine 1200s Henkel Surface Technologies 32100 Stephenson Highway Madison Heights MI 19020 Phone 248 583 9300 Alodine 1201 Henkel Surface Technologies 207 High Plastic Kote Temperature 1000 Lake Rd Aluminum Medina OH 44256 Enamel Phone 330 725 4511 DE 1615 High Sherwin Williams Temperature Dupli Color Product Group Aluminum Chemical Stripper MIL R 81294 Type Il QPL 8
80. Sight down the edges to find any deformation 5 Looseness a Feel the blades and move them to find unusual changes in looseness and unusual play 1 Blade to blade differences indicate that an internal problem may exist C Spinner and Bulkhead 1 Externally check the spinner and bulkhead for security missing fasteners damage and cracks Cracks typically originate from the attachment screws a Repair of cracks is not permitted 2 Check for looseness of the bulkhead This could be an indication that the mounting bolts are loose 3 Wear depth on the inside of the spinner must not exceed 0 010 inch 0 25 mm NOTE Wear inside the spinner can be caused by improper shimming of the spinner or by deice leads rubbing General Condition E Control System 1 The control system governor should be checked to determine whether the system is operating properly and is not leaking F Maintenance Records 1 Note any indications in the logbook for future reference to determine whether a condition is getting worse 4 100 Hour and Annual Inspection A Ateach 100 hours Annual or other approved inspection interval examine the propeller in accordance with aircraft inspection manual Inspection should include 1 Spinner Removal 61 00 06 Page 603 McCauley Propeller Systems Mar 13 2013 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL 2 Inspection of all attaching hardware including the hardware unde
81. TBOARD OF 85 PERCENT BLADE STATION THE HUB MAY BE REUSED PENDING OVERHAUL INSPECTION ANY THREADLESS STYLE BLADE 85 PERCENT BLADE STATION IF THE BLADE IS BENT BEYOND REPAIR LIMITS IN THIS AREA HUB IS ALSO SCRAP 0 INCH REFERENCE STATION NOTE THE 85 PERCENT BLADE STATION VALUE IS WITH RESPECT TO THE BASIC DESIGN LENGTH OF A BLADE NOT THE CUT DOWN LENGTH Location of Blade Damage Figure 601 Sheet 1 61 00 06 Page 609 McCauley Propeller Systems Mar 13 2013 2 9 McCAULEY PROPELLER SYSTEMS OWNERIOPERATOR INFORMATION MANUAL Inspect all blades for damage such as scrapes gouges etc caused by the impact Any damage beyond normal field repair limits refer to Blade Repair for field repair limits is cause for propeller removal and repair as defined below Check the blade track and verify that all blades measure within the following limits a 0 0625 inch 1 6mm of each other on piston engine propellers 0 170 inch 4 3mm of each other on turbine engine propellers except propeller models C1101 through C1104 c 0 1875 inch 4 7mm of each other on C1101 through 61104 models Check blade twist All blades in a propeller should have the same amount of rotational play If the difference in rotational play between two blades is beyond 1 0 degree uneven internal wear or damage is the possible cause a For example rotational movement of No 1 blade measures 1 2 degrees and No 2
82. TE Mar 13 2013 Mar 13 2013 Mar 13 2013 Mar 13 2013 Mar 13 2013 Mar 13 2013 Mar 13 2013 Mar 13 2013 Mar 13 2013 Mar 13 2013 61 LIST OF EFFECTIVE PAGES Page 1 of 1 McCauley Propeller Systems Mar 13 2013 RECORD OF TEMPORARY REVISIONS Temporary Revision Number Page Number Issue Date By Date Removed McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL CONTENTS FIXED PITCH PROPELLER DESCRIPTION Metal Fixed Pitch Propellers Blade Serial Number Stamping Information CONSTANT SPEED PROPELLER SYSTEM DESCRIPTION AND OPERATING PRINCIPLES are ed A r Bode ee aga Reciprocating Piston Engine Propellers Turbine Engine Propellers nn Overhaul Period 2er ee de Propeller Model Designation PROPELLER TROUBLESHOOTING General Information sce A hete Leite eds Operation in Restricted Power or RPM Conditions Turbine Propeller RPM Fluctuations Constant Speed Piston Turbine Changing RPM or Creeping Constant Speed Piston Turbine
83. TEMS OWNER OPERATOR INFORMATION MANUAL C1193 HUB ASSEMBLY COUNTERWEIGHT LATCH PAWL A BLADE ACTUATING REVERSE SPRING PIN STOP PISTON ROD LATCH START CYLINDER BETA TUBE LOCK PISTON SUPPLIED BY FEATHER STOP THE ENGINE A MANUFACTURER WIRE RING LINK NUMBER1 RETAINING RING PROPELLER HUB BLADE OIL FILL SCREW RETAINER DETAIL A VIEW A A 010171049 0650 Series Propeller Figure 6 Sheet 1 61 00 04 Page 10 McCauley Propeller Systems Mar 13 2013 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL C1194 BLADE A HUB ASSEMBLY BLADE COUNTERWEIGHT A ACTUATING PIN BETA SPRINGS L FEED BACK E COLLAR PISTON J ROD CYLINDER H m PISTON 5 FEATHER BETA STOP TZ A LINK SLIP RING BETA ROD ASSEMBLY WIRE RING RETAINING RING SOLID SHIM SPLIT SHIM O RING SHIM GARRIER NUMBER 1 BLADE OUTER RAGE BEARING INNER RACE SPLIT 7 PROPELLER ER HUB OIL FILL SCREW DETAIL view A A C700 Series Propeller Figure 7 Sheet 1 010171051 61 00 04 11 McCauley Propeller Systems Mar 13 2013 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL C1195 BLADE HUB ASSEMBLY A A BETA ROD COUNTERWEIGHT
84. The list of service bulletins uses three columns to summarize information 1 Service Bulletin Number This column identifies the bulletin by number 2 Service Bulletin Date This column indicates the initial date the bulletin became active 3 Manual Incorporation This column indicates the date the service bulletin has been incorporated in the manual List of Effective Pages A A list of effective pages is provided at the beginning of each chapter All pages the specific chapter are listed in numerical sequence on the Effectivity Page s with the date of issue for each page Revision Filing Instructions A Regular Revision 1 Pages to be removed or inserted in the manual are determined by the effectivity page Pages are listed by the three element number chapter section subject and then by page number When two pages display the same three element number and page number the page with the most recent Date of Page Issue shall be inserted inthe manual The date column on the corresponding chapter effectivity page shall verify the active page B Temporary Revision 1 File temporary revisions in the applicable chapter s in accordance with filing instructions appearing on the first page of the temporary revision 2 The rescission of a temporary revision is accomplished by incorporation into the manual or by a superseding temporary revision A Record of Temporary Revisions is furnished in the Temporary Revision List located
85. Without the proper training and equipment the static balance of the propeller can be affected by the application of paint NOTE The propeller face side should be painted flat black unless otherwise noted A Paint and Primer Mixtures NOTE McCauley recommends Sherwin Williams products but any industry equivalent is acceptable The following list of paints are recommended but any equivalent paint that will achieve similar results is acceptable NOTE All drying times are based on 77 F 25 C and 45 relative humidity CAUTION No paint or primer is allowed in blade retention area orthe counterweight surface 1 Primer should be tack free in 10 to 20 minutes and can be recoated in 30 to 60 minutes 2 Allow for different drying times at different temperatures and humidity levels Table 707 Paint and Primer Mixtures PainuPrimer JO Misturenstrueioms Bei 1 Part Sherwin Williams P60G2 Industrial Wash Primer to 1 5 parts Sherwin Williams R7K44 Activator Thinner Semi Flat Black Mix as directed by the manufacturer with V66V27 catalyst and R7K84 reducer Note Paint F63TXB11492 1 Federal Standard 595 Color 37038 Semi Flat White Mix as directed by the manufacturer with V66V27 catalyst and R7K84 reducer Note Paint F63TXV11445 1 Federal Standard 595 Color 17875 Semi Flat Silver Mix as directed by the manufacturer with V66V27 catalyst and R7K84 reducer Note 1 Paint F63TX514433 4302 Semi Flat Gray Paint Mix as dire
86. Y PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL 0850 TYPE MODEL DESIGNATION CERTIFICATE DESIGNATES THE BLADE NUMBER LINE 2 INCLUDES PASSED EDDY CURRENT DIAMETER AND PITCH INSPECTION AFTER MANUFACTURE TC P 918 NUMBER 1 BLADE DESIGNATES THE BLADE PASSED EDDY CURRENT INSPECTION AFTER MANUFACTURE NOTE CERTIFICATE TC P 918 NUMBER 1 BLADE MODEL DESIGNATION LINE 2 INCLUDES DIAMETER AND PITCH TYPICAL 6 BOLT HOLE PROPELLER STAMPING PATTERN NOTE STAMPING ARRANGEMENT OR LOCATION OF THE SERIAL NUMBER IS OPTIONAL LETTERING MAY BE ARCHED OR STRAIGHT BUT THE SERIAL NUMBER STAMPING IS FOUND AT THE NUMBER 1 BLADE 0101T1151 Fixed Pitch Blade Stamping Figure 1 Sheet 1 61 00 01 Page 3 McCauley Propeller Systems Mar 13 2013 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL C851 DESIGNATES THE BLADE PASSED EDDY CURRENT INSPECTION AFTER MODEL DESIGNATION MANUFACTURE LINE 2 INCLUDES DIAMETER AND PITCH NOTE E NUMBER 1 BLADE O O TYPE CERTIFICATE NUMBER TYPICAL 8 BOLT HOLE PROPELLER STAMPING PATTERN NOTE STAMPING ARRANGEMENT OR LOCATION OF THE SERIAL NUMBER IS OPTIONAL LETTERING MAY BE ARCHED OR STRAIGHT BUT THE SERIAL NUMBER STAMPING IS FOUND AT THE NUMBER 1 BLADE 0101T1152 Fixed Pitch Blade Stamping Figure 1 Sheet 2 61 00 01 Page 4 McCauley Prop
87. ach the spacer removal tool to the propeller spacer using two 0 250 inch diameter bolts with UNC 3A threads IN NOTE Bolts to be used should be made of steel 0 250 inch in diameter have a UNC 3A thread and the grip length sized to match the thickness of the steel bar For steel bars that are 0 250 inch 6 35 mm thick a MS20074 04 06 bolt is an appropriate sized bolt for this application IN Position the propeller and spacer assembly under an arbor press or similar tool as shown in Figure 402 Place two propeller mounting bolts or equivalent sized steel dowels in the propeller and spacer assembly The bolts or dowels that are used to push the spacer from the propeller must be of equal length CAUTION Do use bolts that will be returned to service for this procedure This procedure can damage the threads of propeller mounting bolts ES Make sure there is at least 2 00 inches 50 mm clearance between the spacer removal tool attached to the propeller spacer and the work surface supporting the sandbags Using an arbor press or similar tool push the bolts or dowels down to remove the spacer from the propeller 6 Once the spacer is separated from the propeller remove the 0 250 inch bolts and the spacer removal tool from the spacer ln E Propeller Installation for all fixed pitch propellers except 1A162 model propellers 61 00 06 Page 403 McCauley Propeller Systems Mar 13 2013 McCAULEY PROPELLER SYSTEMS
88. ad mounting hole diameters while you push hard on the spinner shell Use an awl or a small punch in an adjacent hole to move the spinner screw hole into alignment with the bulkhead hole and install the screw Repeat the procedure on opposing holes until eight equally spaced screws and washers are installed 61 00 06 Page 424 McCauley Propeller Systems Mar 13 2013 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL 5 Secure the propeller spinner to the bulkhead and fillet assemblies with the remaining screws and washers 61 00 06 Page 425 McCauley Propeller Systems Mar 13 2013 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL PROPELLER ADJUSTMENT TEST 1 Static Balance A Checking and adjusting the propeller static balance shall be accomplished by an FAA approved Part 145 Propeller Repair Station or international equivalent 2 Propeller Pressure Leakage Check Requirements A Propeller pressure leakage tests of the cylinder and the hub shall be accomplished by an FAA approved Part 145 Propeller Repair Station or international equivalent 3 Ground Support Equipment A following special equipment is required for field maintenance of McCauley propellers NAME PART NUMBER MANUFACTURER USE Propeller protractor Commercially available To measure blade angles on 600 650 and 1100 Series propellers Start lock release B 5021 McCauley To release start locks on tools C600 C650 an
89. ally caused by inadequate shimming of the spinner bulkhead or a cracked or deformed spinner If a spinner is found to be wobbling it should be removed and reinstalled with the proper amount of shims as described in Fixed Pitch Propeller Removal and Installation Constant Speed Reciprocating Engine Propeller Removal and Installation Piston C600 C650 C1100 Series Propeller Removal and Installation or C700 C750 C1000 Propeller Removal Installation Any spinner found cracked must be replaced Check amount of blade twist of each propeller blade when rotated within its socket as shown in Figure 101 Look for variations in the amount of movement of each blade in relation to the other blade s If excessive blade twist is found in one or more blades in relation to the others the propeller could have an internal linkage problem It should be removed and sent to an FAA approved Part 145 Propeller Repair Station or international equivalent for evaluation NOTE The amount of total blade twist in each blade is in itself usually of no importance It is a difference in the amount of blade twist from blade to blade that should be considered Possible Cause Worn engine mounts Corrective Action Consult the OEM or engine mount manufacturer manual for replacement criteria a a 61 00 06 Page 106 McCauley Propeller Systems Mar 13 2013 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL 12 Blade Shake A Symptom
90. an be found the propeller may be at fault Although very rare hunting and surging may be due to excessive internal pressure in the propeller or overshimming of the propeller blades Corrective Action 1 Ifthe propeller is suspected as the cause it should be removed for examination by a McCauley authorized service facility 2 Surging has been encountered on ground operation after initial installation while purging air from the system a If encountered at other times the propeller should be cycled repeatedly to remove all air from the system 61 00 06 Page 101 McCauley Propeller Systems Mar 13 2013 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL b If the condition persists it may be attributable to the governor and the governor should be removed and tested The propeller should be purged of air again after the governor is reinstalled Changing RPM or Creeping Constant Speed Piston Turbine A Propeller RPM changing and holding new setting 1 Possible Cause a Excessive play in the linkage between the governor and the cockpit control often leads to erratic operation b Constant speed piston only Possible excessive engine compartment heat affecting the governor plastic top cover 2 Corrective Action a Trace linkage locate unsecured sections and tighten as needed b Please note that although linkage may appear to allow full governor control while the engine is off it may not in the
91. and order correct replacement parts for propeller field maintenance B These parts may be purchased through your local authorized McCauley propeller service facility Table 1001 Installation Parts for Constant Speed Piston Engine Propellers Series Series 0500 Seres Nom ees Spar Lem Mount O ring A 1633 3 A 1633 3 A 1633 3 A 1633 3 Mount O ring Lycoming A 1633 11 A 1633 11 A 1633 11 Spinner Screw bright nickel plated A 1635 133 A 1635 133 A 1635 133 Spinner Screw cadmium plated A 1635 39 A 1635 39 A 1635 39 Spinner Washer fiber A 1638 5 JA 1638 5 A 1638 5 Spinner Shim B 3410 16 B 3410 16 B 3410 16 Spinner Shim B 3410 32 B 3410 32 B 3410 32 NOTE 1 Mount nut A 1639 2 is 1 2 inch A 1639 32 is 9 16 inch NOTE 2 Not all parts listed for a propeller series are required for every model propeller Table 1002 Installation Parts for Turbine Engine Propellers seres 6550 series 0700 Seres 6760 Series 01000 Series 000 Seis Mamm O fe omo eese Spinner Screw A 1635 133 A 1635 133 A 1635 133 A 1635 133 A 1635 133 bright nickel plated Spinner Screw A 1635 39 A 1635 39 A 1635 39 A 1635 39 cadmium plated Spinner Screw A 1635 172 cadmium plated dyed black 61 00 06 Page 1001 McCauley Propeller Systems Mar 13 2013 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL Table 1002 Installation Parts for Turbine
92. aterial due to action of the elements Exposure is leaving a material open to action of the elements Fretting is the occurrence of shallow spherical surface depressions usually caused by vibratory chattering action or by a part which has a small radius in contact under high load with the material Galling or burnishing is the breakdown or buildup of a metal surface resulting from excessive friction between two moving parts NOTE Particles of the softer metal tear loose breakdown and weld to the surface of the harder metal buildup A Gouge is a small surface area where material has been removed by contact with a sharp object Impact damage occurs either in flight or on the ground when a propeller blade or hub assembly strikes or is struck by an object An Inclusion is the presence of an unspecified material that was introduced into a portion of stock metal during manufacturing processes such as rolling or forging A Nick is a localized break or edge notch usually with displacement of rather than loss of metal Pitting is seen as a number of extremely small possibly deep gouges usually with defined edges caused by wear and or deterioration on the surface of a material A Score is deeper than a gouge and may show discoloration from the temperature produced by friction from contact under pressure A Scratch is an elongated Gouge A Stain is a localized color change noticeably different from the surrounding surface a
93. ation or at any time the propeller is removed from service Storage time is determined from date of manufacture overhaul or removal from aircraft 1 Storage must be in a clean and dry environment preferably in the original shipping carton and above ground level to minimize exposure to dirt and moisture 61 00 06 Page 202 McCauley Propeller Systems Mar 13 2013 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL 2 Ifthe storage period exceeds 2 years before entering service or returning to service perform the following inspection a For all propeller models inspect externally for damage and corrosion Inspection may be accomplished by an A amp P mechanic or international equivalent Make a logbook entry stating compliance with this inspection requirement Make a reference to MPC26 and include the current revision level of this manual with the logbook entry stating compliance with this inspection requirement For non oil filled propeller models or propellers stored with one or more propeller blades removed remove propeller cylinder inspect for internal corrosion and signs of deterioration and repair as necessary This must be accomplished only by an FAA approved Part 145 Propeller Repair Station or international equivalent in accordance with the appropriate propeller overhaul manual Make a logbook entry stating compliance with this inspection requirement Make a reference to MPC26 and include the current revis
94. be performed only by qualified maintenance personnel The following instructions are general in nature The aircraft maintenance manual or STC installation instructions should always be consulted for any specialized procedures applicable to a specific aircraft Various spinner arrangements not manufactured by McCauley may be used which require additional procedures NOTE Qualified maintenance personnel means the person doing the maintenance activity is the holder of or is working under the direct supervision of the holder of the appropriate rating to approve the propeller for return to service after the maintenance activity has been accomplished In the following instructions installation of propeller is based on the assumption that a McCauley spinner will be used If a spinner is not used or if the spinner is not manufactured by McCauley omit those steps which apply to the spinner WARNING Verify that engine magnetos have been grounded prior to approaching the propeller B Spinner Assembly Removal 1 Make an alignment mark on the spinner shell aft bulkhead and adjacent blade with a felt tip pen This index mark ensures accurate restoration of spinner shell position to lessen the distortion of any dynamic balance previously performed on the propeller assembly Remove screws and washers from the spinner and fillet assemblies if fillet assemblies are installed Remove spinner from the bulkhead and fillet assemblies if fillet assemb
95. between the hub and engine mounting flange if applicable Make sure the index marks made with a felt tip pen align between the aft spinner bulkhead and the propeller blade Ensure threads of nuts and studs are free of burrs nicks and similar damage and clean of foreign material a For Continental Franklin and Orenda engine installations WARNING If the lubricant is not applied as required the nuts will be under torqued and the propeller could fail CAUTION Do not use oil as a substitute for approved lubricant It is imperative that the correct specification of lubricant be used during installation Substitution of the approved grease with an unapproved lubricant or no lubricant could result in under torquing or severe over torquing of propeller attaching parts a Lubricate the threads of studs and nuts and the faces of nuts spacers or washers with MIL PRF 83483 McCauley part number A 1637 16 grease 2 Install mounting nuts on mounting studs 3 Torque the mounting nuts in an alternating sequence to prevent the hub rocking on the engine flange 4 When the hub is seated fully on the engine flange torque to the specification called out in the mounting decal located on propeller hub at the number 1 socket NOTE If the decal containing the propeller installation instructions is missing or illegible install a new decal For all applicable Continental engine installations use a part number A 2230 9 decal except installati
96. blade measures 2 3 degrees This would be considered excessive since the difference is more than 1 0 degree This check must be performed every 10 hours for the next 20 hours If no change is seen after 20 hours inspections may be discontinued NOTE The results of an object strike inspection should be noted in the propeller log book and if required note when the next inspection is due If any propeller blade is damaged beyond field repair limits the blade track or the propeller blade twist is beyond the limits contact McCauley for disposition of the propeller assembly C Blade Strike of Rotating Propeller 1 Blade Strike sometimes referred to as Ground Strike is defined as any impact or suspected impact of the rotating propeller upon such items as but not limited to the ground tow bars landing lights carts snow banks hedges etc Please note that this definition is intended for use as an example only Determination as to whether or not a blade strike actually occurred is ultimately the responsibility of the aircraft operator CAUTION Internal damage can occur without evidence of gross external damage a Any McCauley propeller experiencing a blade strike must be removed from the aircraft and overhauled by an FAA approved Part 145 Propeller Repair Station or international equivalent in accordance with the applicable overhaul manual A hub must be declared unairworthy and scrapped if any blade in the propeller assembly is
97. bration the aircraft typically vibrates throughout the entire RPM range although the intensity of the vibration may vary with the RPM If a vibration occurs at only one RPM or within a limited RPM range the vibration is not normally due to a propeller problem Corrective Action If the propeller is suspected as the cause of the vibration the following procedures should be performed a b a 1 The ideal troubleshooting method is to temporarily replace the propeller with one that is known to be good and is the same model and test fly the aircraft If the vibration is eliminated the propeller is highly suspect and should be sent to an FAA approved Part 145 Propeller Repair Station or international equivalent for evaluation 2 If a replacement propeller is unavailable check the following a 10 Im Propeller imbalance can be the cause of vibration Perform a dynamic balance on the suspect propeller to determine balance of the propeller If the propeller cannot be successfully dynamically balanced it should be removed and sent to an FAA approved Part 145 Propeller Repair Station or international equivalent for evaluation Check the spinner for cracks at the bulkhead attach points for a cracked bulkhead or for a cracked front support The propeller spinner can be a contributing factor to an out of balance condition An indication of this would be a noticeable spinner wobble while the engine is running This condition is norm
98. bricant applied to the blade O ring during assembly 3 Oil filled propellers may show signs of oil deposited on the blade shank during operation after an overhaul or after a prolonged period of inactivity Checking and correcting a leaking propeller at the blade C200 model series thru C1100 propeller model series only NOTE This procedure will only correct blade shank leaks at the blade shank O ring 1 Use a clean cloth dampened with mineral spirits to clean the blade of all traces of oil and dirt CAUTION Never exceed the published engine operational limits 2 Run the engine and cycle the propeller at least five times a Piston airplanes cycle from low to high pitch b Turbine airplanes cycle from reverse to high pitch 3 Check the blade for signs of continued leakage a If necessary clean the blade again with a cloth dampened with mineral spirits to clean the blade of all traces of oil and dirt 4 Run the engine and cycle the propeller at least five times a Piston airplanes cycle from low to high pitch b Turbine airplanes cycle from reverse to high pitch 5 If the leak has stopped completely no other action is required 6 Ifthe rate of leak has decreased it is permissible to continue operation of the propeller for up to 20 hours a If there is leakage after 20 hours the propeller must be removed from the aircraft and sent to an FAA approved Part 145 Propeller Repair Station or international equivalent for
99. by this publication require disassembly and checks required the overhaul manual 2 Inspection Schedule A Fixed Pitch Propellers 1 Refer to Table 1 Fixed Pitch Propeller Inspection Time Limits for a list of propellers that have an inspection time limit Table 1 Fixed Pitch Propeller Inspection Time Limits Designation Inspection Time Limit 1A103 TCM Propeller Initial inspection shall occur prior to Fluorescent Dye Penetrant Inspect 1500 hours of operation Repeat Applies to 1A103 TCM propellers the inspection every 750 hours of only Refer to McCauley Alert Service operation Bulletin ASB221E and Federal Aviation Administration Airworthiness Directive NOTE If time since new TSN AD 2010 04 05 for propeller inspection is unknown inspect the procedures propeller within 50 operating hours of the effective date of AD 2010 04 05 1A170 FFA Propeller Inspect every 200 hours of operation Fluorescent Dye Penetrant Inspect Applies to 1A170 FFA propellers only Refer to Federal Aviation Administration Airworthiness Directive AD 82 27 01 for propeller inspection procedures B Constant Speed Propellers 1 Propeller Blades a Refer to Table 2 Propeller Blade Inspection Time Limits for a list of propeller blades that have an inspection time limit 4 10 00 Page 1 O McCauley Propeller Systems Mar 13 2013 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL Table 2 Propeller Blade Inspection Time Lim
100. cauley textron com Telephone 316 517 5800 Telefax 316 517 7271 Product Support INTRODUCTION Page 1 McCauley Propeller Systems Mar 13 2013 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL McCauley Product Support McCauley Propeller Systems 5800 East Pawnee Mailing Address Wichita KS 67218 1 If you need assistance with a general support question publication information subscriptions or maintenance programs visit our website at www mccauley textron com or contact McCauley Product Support Wichita Kansas 1 800 621 7767 or 316 831 4021 Email Address productsupport mccauley textron com 3 Coverage Phone Numbers A McCauley MPC26 Owner Operator Information Manual is prepared with information given by the ATA Air Transport Association Specification Number 2200 for Manufacturer s Technical Data B The information in this Owner Operator Information Manual is applicable to the following model propellers Table 1 Table 1 Propeller Models Fixed Pitch Propeller Models GE Constant Speed Propeller Models INTRODUCTION Page 2 McCauley Propeller Systems Mar 13 2013 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL Table 1 Table 1 Propeller Models continued puce peace Daarsacaos porc I pascas oanaacaaa posacur pewoss armas TE ERES TEES Er B5JFR36C110 C5JFR36C11
101. clean the affected area ofthe propeller and chemical conversion film coat and if applicable touch up the paint in accordance with the Cleaning Painting Protective Treatments instructions For pitting intergranular or exfoliation type corrosion remove the corrosion and examine the affected area for stress riser damage If stress riser damage is found repair the damage Clean the affected area of the propeller and chemical conversion film coat and if applicable touch up the paint in accordance with the with the Cleaning Painting Protective Treatments instructions NOTE After the corrosion is removed measure the damaged area damage that is located on the leading or trailing edges must not exceed 0 094 inch 2 39 mm in depth and damage that is located on a repairable area of the face or camber side of the blade must not exceed 0 061 inch 1 55 mm in depth 6 If erosion is repaired corrosion protect the propeller blade in the area of the repair Chemical conversion film coat for example Alodine the repaired area and then touch up the propeller paint in accordance with the with the Cleaning Painting Protective Treatments instructions 4 Repair Criteria a b c Repair stress riser damage Stress riser damage is repaired by removing adjacent material from the damaged area so that there is no longer a notch of displaced material with a very small radius at the bottom of the damaged area Material is removed with sma
102. counterclockwise while gently pulling on the beta tube removal tool 61 00 06 Page 414 McCauley Propeller Systems Mar 13 2013 8 9 10 11 12 13 14 15 16 17 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL CAUTION Do not grab the beta tube with pliers or anything which could damage the threads of the beta tube Pull the beta tube out and handle very carefully Wipe the beta tube with a clean rag and store in a safe place Place a drip pan under the propeller mounting surface to catch any spilled engine oil when the propeller is removed Break the torque on the propeller mounting nuts McCauley Torque Wrench Adapter part number B 5588 may be used to gain easier access to mounting nuts Refer to Figure 403 Install a propeller sling and attach to hoist If hoist is unavailable propeller may be supported and lifted by hand This will require additional personnel CAUTION The C600 propellers weigh approximately 120 pounds 54 kg and the C650 propellers approximately 160 pounds 73 kg C1100 series propellers weigh 180 pounds 83 kg or more a Hoist straps must be a minimum of 4 inches 100 mm wide b The straps of the propeller sling should be placed on two of the propeller blades at least 6 inches 152 mm outboard of the propeller hub Make sure you protect the deice boots or anti ice shoes from potential propeller sling abrasion damage if installed The sling an
103. cted by the manufacturer with V66V27 catalyst and R7K84 reducer Note 1 F63YXA11582 Gloss Yellow Paint Mix as directed by the manufacturer with V66V27 catalyst and R7K84 reducer Note 1 F63BXY 11719 Semi Flat Red Paint Mix as directed by the manufacturer with V66V27 catalyst and R7K84 reducer Note F63TXR11347 1 Federal Standard 595 Color 31136 NOTE 1 The color numbers are assigned by the Atlanta Georgia Sherwin Williams facility B The painted surface must be recoated with the first coat of the finish enamel within four hours of application of the primer 61 00 06 Page 709 McCauley Propeller Systems Mar 13 2013 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL C Apply the paint in accordance with the manufacturer s instructions NOTE Overnight drying time is recommended after paint application D The recommended dry film paint thickness on constant speed and full feathering propeller blades should be 3 mils thick and on turbine propellers 6 mils thick NOTE Tip stripes should be painted on the camber side only so as not to interfere with the pilot s field of vision Some propellers installed in a pusher configuration and out of the pilot s field of view may have a different paint scheme for the propeller blade tips E turbine propellers only make sure there is a 2 inch 51 mm long by 0 070 inch 1 8 mm wide yellow or white line at the 30 inch 762 mm station except for the paint scheme t
104. d C1100 series propellers Beta tube B 5378 McCauley To install and adjust beta installation and tube on C600 C650 and adjustment tool C1100 series propellers 4 Flight Idle Blade Angle Flight Idle Torque Checking and Adjustment Procedures Turbine Series Propellers A Flight Idle Blade Angle Checking and Adjustment Procedure 1 Check the blade angles are within the limits specified in the FAA Aircraft Type Certificate Data Sheets or STC 2 The adjustment of the flight idle blade angle or flight idle torque is in accordance with the airplane maintenance instructions or STC instructions a Make sure the propeller blade angles or flight angle torque are within the limits specified in the FAA Aircraft Type Certificate Data Sheets or STC NOTE Transient operation below the minimum RPM limitation is permitted during feathering and unfeathering cycles 5 Dynamic Balance NOTE Some aircraft manufacturers do not approve dynamic balance of the propeller because of potential crack damage to spinner bulkhead from the installed weight A Referto Propeller Maintenance Practices Dynamic Balance for instructions to dynamically balance the installed propeller 61 00 06 Page 501 McCauley Propeller Systems Mar 13 2013 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL PROPELLER INSPECTION CHECK 1 Limitations A Operational and service personnel should be familiar with the following limitations during an
105. d from service since only cold room temperature straightening by an FAA approved Part 145 Propeller Repair Station or international equivalent repair facility is authorized 7 Field service personnel should never straighten bent propellers to facilitate shipping when the propellers are being sent to a repair facility for inspection and repair This procedure can conceal important information related to the severity of the damage Blade Shortening 1 Propeller tip damage will sometimes lead field maintenance personnel to consider removing damaged material from the blade tips However propellers are certified to the aircraft engine and airframe resonant frequency by being manufactured with a particular diameter to minimize vibration Shortening of the blades without reference to approved data could create an unairworthy condition Refer to the airplane type certificate data sheet aircraft specification sheet or supplemental type certificate data sheet as applicable for the allowable propeller diameter for each propeller installation 2 With certain limitations specific minor repairs may be accomplished a If the blade tip has been damaged and the removal of the damaged area would result in shortening of the propeller blade s the propeller shall be taken to an FAA approved Part 145 Propeller Repair Station or international equivalent for propeller blade repair b When conditions indicate inspect the blade tips for evidence of shorte
106. d hoist should have a weight limit rating at least twice the weight of the propeller that is to be removed Take up the slack on the propeller sling and hoist or have at least four persons support the propeller and remove the nuts Carefully slide the propeller forward and remove from the engine Place the propeller on a suitable support or propeller stand a Do not let the propeller be supported by the tips of the propeller blades or stand the propeller on the propeller blade tips b The stand should be able to hold the propeller securely and have a weight limit rating at least twice that of the removed propeller c Make sure the propeller is protected from damaged while in the stand All areas of the stand that come in contact with the propeller should be padded sufficiently to prevent abrasion damage to the propeller Install a protective cover over the propeller hub mounting flange Install a protective cover over the open end of the engine propeller flange Propeller Installation NOTE McCauley recommends that the propeller mounting nuts McCauley part number A 1639 1 2 3 4 5 32 be replaced at each propeller installation whenever possible However nuts may be reused if the locking material prevents turning of the nut on the stud by hand Remove protective cover from the end of engine propeller flange Make sure the flange is clean and free of nicks and burrs Make sure that the engine propeller fla
107. de vibratory resonance speed can cause very high stresses in the propeller blades and hubs These high stresses are more severe when operating in a tailing wind condition If the propeller is operated within a restricted RPM range or below a minimum RPM restriction for an extended period of time the propeller blades and hubs may become unairworthy due to fatigue Hub or blade failure has the potential of causing a catastrophic event due to blade separation The propeller RPM restriction is often placed below the minimum idle RPM however certain aircraft have a restriction that is above the propeller idle RPM setting Either restriction is important The propeller operating restrictions or limitations may be found in the Airplane Flight Manual AFM or Airplane Flight Manual Supplement AFMS The propeller installations may be controlled by the various airframe manufacturers Type Certificate TC or by Supplemental Type Certificate STC CAUTION Undershimming or overshimming of the spinner aft bulkhead could result in spinner wobble vibration and or bulkhead and spinner cracking Please follow shimming procedures carefully 1 Install propeller spinner fillets on the bulkhead with screws and washers if required 2 Insert shims into the spinner support and lightly press spinner support onto the cylinder on the front end of the propeller 3 Mount the spinner onto the bulkhead and fillet assembly and check alignment of the mounting holes i
108. e propeller and or aircraft If you are aware that a McCauley propeller has been operated outside the published limitations or in a restricted area immediately call McCauley Product Support for assistance Propeller RPM Fluctuations Constant Speed Piston Turbine A Symptoms 1 Hunting is a cyclic or constant variation of engine speed above and below that desired It will be shown by constant wavering of the tachometer reading 2 Surging is a wide or excessive increase or decrease in engine speed followed by return to the established speed after one or more oscillations 3 Surging will occur and should be considered normal if lever throttle is moved rapidly Possible Causes 1 Hunting is seldom if ever caused by the propeller itself Those conditions reported primarily have been caused by other parts of the system such as governor fuel control etc a For piston engine installations the propeller can be tested in flight by reducing the manifold pressure The propeller control should be in the full RPM position and the manifold pressure should be reduced until the RPM drops slightly This ensures that the propeller is against its low pitch stop and is eliminated from the equation 2 Surging may be caused by air in the propeller control hydraulic system governor not operating correctly or problems associated with the engine transfer bearing or collar 3 If the governor test is satisfactory and no other system faults c
109. e acting unit in which hydraulic pressure works against the forces of springs and the natural centrifugal moment of the rotating blade to provide the correct pitch for engine load Hydraulic pressure causes the blades to move toward high pitch decreasing rpm The springs and centrifugal moments urge blades toward low pitch increasing rpm 2 The C300 and C500 series propellers are constant speed and full feathering type They are a single acting unit in which hydraulic pressure works against the forces of springs and counterweights to provide the correct pitch for engine load Hydraulic pressure causes the blades to move toward low pitch increasing rpm The springs and counterweights urge blades toward high pitch decreasing rpm Propeller Deice Refer to Figure 11 NOTE Only components sold by McCauley are described Some OEMs or STC owners may have different designs 1 If propeller deice is installed the components include electrically heated rubber boots 61 00 04 Page 1 McCauley Propeller Systems Mar 13 2013 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL C320 ACTUATING PIN SPRING ASSEMBLY HUB 7 ll se _ Z DN Ds 90 N Annan Z CYLINDER NG SUPPORT PISTON SPACER HIGH PITCH BALANCE RING WIRE RING BLADE RETAINING RING SHIM O RING SPLIT SHIM SHIM CARRIER OUTER RACE BALLS S
110. e damage specifications identified in this section Blade Repair or other damage such as bent blades are considered Major Repairs and must be corrected by a McCauley authorized service facility and are not field repairable Damage Specifications a b c d The depth of damage must be measured using a depth gage Damage that is located on the leading or trailing edges must not exceed 0 094 inch 2 39 mm in depth Damage that is located on a repairable area of the face or camber side of the blade must not exceed 0 061 inch 1 55 mm in depth 1 For controllable pitch propellers a Impact and corrosion damage that is located at least 6 0 inches 152 mm from the hub socket is in an area that is field repairable 2 For fixed pitch propellers a Impact and corrosion damage that is located at least 12 0 inches 305 mm from the center of the propeller mounting flange is in an area that is field repairable Damage that is located outside the field repairable area or damage depth greater than these limits is not field repairable An FAA approved Part 145 Propeller Repair Station or international equivalent may be able to do a repair Contact McCauley Product Support for disposition of any damage that is deeper than the specified limits Repairable Damage a The primary type of blade damage that a mechanic need be concerned with is sharp stress riser type damage This type of damage is caused by stones or other small objects strikin
111. e environments such as agricultural or costal operations a Clean the area of the propeller blade snap rings and the propeller hub blade sockets with water soft bristle brush do not use a hard bristle brush and clean towel 1 Remove as much foreign material from the propeller blade retaining ring area as possible b Make sure the propeller blade retaining ring area is dry c Apply LPS 3 Rust Inhibitor to the retaining ring area at the base of the propeller blades and hub sockets d Apply LPS 3 as frequently as necessary to prevent corrosion 61 00 06 Page 201 McCauley Propeller Systems Mar 13 2013 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL 6 Ensure that the tachometer is appropriately marked for operational limitations of the propeller and that the tachometer accuracy is checked at periodic inspection intervals 7 Make sure that the applicable installation information and warning decals are on the propeller These decals may include warnings against pushing or pulling on the propeller the model number the correct bolt torque and dynamic balancing information 8 Make sure each propeller has its own maintenance record 9 The operator must arrange for the overhaul of the propeller when it reaches the McCauley recommended service time limits Refer to Time Between Propeller Overhaul for required propeller overhaul intervals For safety and glare reduction for conventional single engine
112. e within 0 1875 inch 4 7 mm of each other c For all propellers installed on turbine engines except C1101 through C1104 model propellers all blades must measure within 0 170 inch 4 3 mm of each other If blade track difference exceeds the allowable limits remove the propeller and have the propeller face alignment checked by an authorized McCauley service facility 9 Lightning Strike Inspection Requirements A If doubt exists as to the occurrence of a lightning strike the following criteria can be used to verify any suspicion 1 2 Check for burns or signs of arcing on blades and hub Using a magnetism detector check all exposed steel areas of propeller for magnetism A positive magnetic indication suggests the propeller was struck by lightening NOTE Any accepted industry standard magnetic detection device is permitted to be used to test for magnetism in the exposed steel parts of the propeller Look for any signs of localized melting or metal flow particularly on blades If preliminary inspection suggests an actual strike a complete propeller overhaul is to be accomplished in accordance with the applicable McCauley overhaul manual by an authorized McCauley overhaul facility 61 00 06 Page 612 McCauley Propeller Systems Mar 13 2013 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL 10 Propeller Overspeed Inspection Requirements A following are inspection criteria for McCauley propel
113. ed sufficiently to prevent abrasion damage to the propeller Install a protective cover over the propeller hub mounting flange 10 Installa protective cover over the open end of the engine propeller flange Propeller Assembly Installation NOTE McCauley recommends that propeller mounting nuts if applicable be replaced at each 6 propeller installation whenever possible However nuts may be reused providing threads are in good condition and the locking material prevents turning of the nut on the stud by hand If required attach bulkhead mounting ring or bulkhead to hub Make sure the felt tip pen alignment marks between the bulkhead and the propeller blade are in alignment Remove the protective cover from the end of the engine propeller flange Ensure that engine propeller flange hub mounting flange dowels and holes mounting studs and holes are clean dry and free of damage and foreign material Remove protective cover from the propeller hub mounting flange Ensure that a new McCauley O ring A 1633 3 or A 1633 49 Continental engines A 1633 11 Lycoming engines is installed in the groove of the propeller hub mounting flange Lubricate the O ring with engine oil prior to installation of propeller NOTE In the past new propeller assemblies shipped from McCauley the propeller hub engine O ring was installed in the O ring groove of new propellers and hub assemblies This practice has been discontinued The O ring is now
114. eet 1 61 00 04 Page 16 O McCauley Propeller Systems Mar 13 2013 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL C1030 X SAF32C517 X SAMPLE PISTON ENGINE HUB MODEL DESIGNATION IX 3 AF 32 C 517 X bo LETTER S DENOTING CHANGES TO THE CONFIGURATION THAT MAY AFFECT ELIGIBILITY OR INTERCHANGEABILITY NUMERALS THAT DEFINE A SPECIFIC HUB DESIGN 2XX C200 SERIES 3XX C300 SERIES ETC TYPE OF PROPELLER C CONSTANT SPEED MCCAULEY DESIGN REFERENCE INFORMATION FULL FEATHERING HUB FLANGE CODE NUMBER OF BLADES DOWEL LOCATION WITH RESPECT TO THE CENTER LINE OF THE NUMBER 1 BLADE SOCKET VIEWING THE HUB FROM THE FLANGE MOUNTING FACE NOTE A SPECIFIC PROPELLER ASSEMBLY IS IDENTIFIED BY THE HUB SERIAL NUMBER WHICH IS STAMPED ON THE HUB ALL RECORDS OF PROPELLER COMPONENTS ARE KEPT WITH REFERENCE TO HUB SERIAL NUMBER THE FIRST TWO DIGITS OF THE HUB SERIAL ARE THE YEAR OF MANUFACTURE THE REMAINING DIGITS ARE THE NUMBER OF THE HUB MANUFACTURED IN THAT YEAR 61 00 04 Page 17 O McCauley Propeller Systems Mar 13 2013 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL C1031 X 3GFR32C61 8 X SAMPLE TURBOPROP HUB MODEL DESIGNATION X 3 G F R 32 C 618 X LETTER S DENOTING CHANGES TO THE CONFIGURATION THAT MAY AFFECT ELIGIBILITY OR INTERCHANGEABILITY NUMERALS THAT DEFINE A SPECIFIC HUB DESIGN 601 649 C600 SERIES 650 699 C650 SERIES 701 749 C700 SERIES ETC TYPE
115. eller Systems Mar 13 2013 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL Table 2 Blade Month of Manufacture Code D April 1 2 3 Blade serial numbers assigned before 1980 a Prior to 1980 no calendar date information was encoded in the propeller serial number b Initially the serial number was a 4 digit number and the numbers were assigned in ascending order c Eventually the serial number became a 7 digit number Not all serial numbers are sequential there are large breaks between assigned propeller serial numbers Blade serial numbers assigned after 1980 and before June 15 2000 a The first letter represents the year of manufacture b The second letter represents the month of manufacture c The following digits represent the number of the blade manufactured during the month of manufacture Blade serial numbers assigned after June 15 2000 a The first or first and second letters represent the year of manufacture The second or third letters represent the month of manufacture c The first two digits represent a reference forging model The following digits represent the number of the blade manufactured during the month of manufacture 61 00 01 Page 5 McCauley Propeller Systems Mar 13 2013 1 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL CONSTANT SPEED PROPELLER SYSTEM DESCRIPTION AND OPERATING PRINCIPLES Reciprocating Piston Engine Propell
116. ement of the rear hub O ring A leak from the actuating spring area is engine oil and must be corrected immediately to prevent engine damage from lubrication oil depletion If leaks are found on any other spot on the hub remove the propeller and arrange to have the propeller repaired by an FAA approved Part 145 Propeller Repair Station or international equivalent 14 Propeller Overspeeding A During normal operation the propeller suddenly overspeeds past rated RPM Possible Causes 1 2 a A number of factors can cause propeller overspeeding but these are normally caused by the engine or governor Corrective Action a Refer to Propeller Overspeed Inspection Requirements for required action after an overspeed incident 61 00 06 Page 109 McCauley Propeller Systems Mar 13 2013 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL PROPELLER MAINTENANCE PRACTICES Ground Support Equipment A following special equipment is required for field maintenance of McCauley propellers NAME PART NUMBER MANUFACTURER USE Propeller protractor Commercially available To measure blade angles on 600 650 and 1100 Series propellers Torque wrench B 5588 McCauley To torque turbine propeller adapter mounting nuts Feedback collar D 5945 McCauley To aid in removal and retractor installation of C700 C750 and C1000 series propellers Start lock release B 5021 McCauley To release start locks on too
117. er Other installations may have the front bulkhead clamped by the mounting 61 00 06 Page 406 McCauley Propeller Systems Mar 13 2013 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL bolts or nuts and the rear bulkhead clamped between the propeller and the crankshaft flange or starter ring gear Some installations use a spacer support pressed into the front propeller hub bore NOTE The aircraft maintenance manual or STC installation instructions should always be consulted for any specialized procedures applicable to a specific aircraft Various spinner arrangements not manufactured by McCauley may be used which require additional procedures NOTE If you have not installed the propeller and spinner assembly on the engine before the use of a propeller sling and hoist is recommended to prevent accidental damage to the propeller If a hoist is not available the propeller may be supported and lifted by hand Make sure an adequate number of people are available to support the propeller if a hoist is not used Tighten the propeller mounting bolts with the correct torque The mounting bolt torque for McCauley fixed pitch propellers is determined by the bolt diameter Refer to the following table to determine the correct torque for the propeller mounting bolts Bolt or Nut TONE BI Diameter Inch Foot Pounds Inch Pounds 25 to 35 300 to 360 33 895 to 40 675 7116 40 to 45 480 to 540 54 233 to 61 012 55 to 65 660
118. er in the feather position This results in latching mechanism failure After engine shut down the propeller may move slowly to the full feathered position 1 Possible Cause a Damaged latch mechanisms corrosion dirt or foreign matter in the mechanism causing latch weights to stick may be evidenced by intermittent condition b Propeller control not set to maximum RPM at shutdown 2 Corrective Action a Repair of latching mechanism must be performed by an FAA approved Part 145 Propeller Repair Station or international equivalent 9 Propeller Fails to Feather Properly A Failure of the propeller to feather normally after the propeller control is moved to the feathering position 1 Possible Causes a Lack of feather response may be due to one of the following causes Malfunction or incorrect rigging of control linkage Misadjusted governor High blade turning friction Improperly installed deice system 5 Inoperative start lock latches 2 Corrective Action a Check all propeller control rigging for incorrect adjustment Replace propeller governor with known working unit If neither of these actions eliminates the problem the propeller may be at fault Remove propeller for examination at an FAA approved Part 145 Propeller Repair Station or international equivalent QI IOO INI gt 10 Vibration Troubleshooting A Troubleshooting vibration problems can be very challenging and time consuming Most digital dyna
119. erede de Page 1 INTRODUCTION 282 E sa Ai aa sate cad Dunt dant Doe ue ceto etie ves ti dio asa Page 1 Cruce tasar le les ic AA Page 1 How to Get Customer Assistance Page 1 COVE GE be OT Page 2 Instructions for Continued Airworthiness ICA Page 3 List of Obsoleted Documents Page 4 List of Incorporated Documents Page 5 Applicable Service Bulletins and Service Letters Page 5 Cross Reference Listing of Popular Name Verses Model Numbers Page 5 Using the Owner Operator Information Manual Page 5 Dimensions and Units Page 6 Temporary Revisions I RR Ra ee dy ee a Page 7 Material Presentation Page 7 Service BUS viaria ma pa pa nee Ta kaa er Page 7 List of Effective Pages Page 7 Revision Filing Instructions Page 7 Identifying Revised Material _ Page 7 Warnings Cautions and Notes Page 8 Eog BOOK A ee L bau uh Page 8 Customer Comments on Manual
120. ereign Specialty Chemicals SIA Adhesives Inc 123 W Bartges Street Akron OH 44311 1081 Phone 330 374 2900 Fax 314 771 1858 BF Goodrich De Icing and Specialty Systems 1555 Corporate Woods Pkwy Uniontown OH 44685 Phone 800 334 2377 Sherwin Williams 101 Prospect Ave N W Cleveland OH 44115 Phone 216 566 2902 McCauley Propeller Systems Equivalent to Sterling Lacquer s system Mix eight parts sealer to one part accelerator 61 00 06 Page 703 Mar 13 2013 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL Table 702 Adhesives and Sealants continued Part Manufacturer A 1664 17 De ice Boot Sterling Lacquer Mfg Co Mix two parts A 1664 17 with one Edge Sealer 3160 Brannon Ave part A 1664 18 78 A 1003 St Louis MO 63139 Phone 314 776 4450 Fax 314 771 1858 Bostick 1096M Bostik Findley Inc Adhesive 211 Boston Street Middleton MA 01949 2128 Phone 978 777 0100 Web www bostik com Bostick 1008 Bostik Findley Inc Cement Paint and Protective Finish a Table 703 provides a listing of recommended paints primers and finish materials for use on McCauley products Table 703 Paint and Protective Finish P60G2 Wash primer Sherwin Williams P60G2 Wash primer to be mixed 591 Somerset Tr NE with R7K44 Reducer Atlanta GA 30306 Phone 404 885 5510 P60G2 Reducer Sherwin Williams P60G2 Wash primer to be mixed with R7K44 Reducer E90Y302 Zinc
121. ers A McCauley propellers for reciprocating engines are of two types constant speed or constant speed feathering Each type is provided in either a two blade or three blade configuration 1 The C200 Series is a two blade constant speed propeller Refer to Figure 1 2 The C300 Series is a two blade constant speed feathering propeller Refer to Figure 2 3 The C400 Series is a three blade constant speed propeller Refer to Figure 3 4 The C500 Series is a three blade constant speed feathering propeller Refer to Figure 4 Each propeller consists of a hub assembly propeller blades piston and cylinder assembly Description of the Propeller Assembly and Deice Components 1 Propeller Hub Assembly The propeller hub is a single piece hollow assembly with propeller blade sockets Each blade socket to blade shank is O ring sealed to prevent leakage The rear hub face has threaded studs or bolts for attachment to the engine flange Some engine flanges have dowels that mate with holes in the hub for alignment These ensure proper mounting to the engine propeller shaft flange 2 Propeller Blades The propeller blades are made of solid forged aluminum Each is match balanced to the other blades a The entire propeller assembly is static balanced as well using balance weights mounted with screws to the blades or the cylinder balance ring 3 Blade Retention A set of split retainers inside the hub secures each blade in t
122. ervice EIN 19 Customer Comments on Manual A McCauley Propeller Systems has endeavored to furnish you with an accurate useful and up to date manual This manual can be improved with your help Please return the registration card to receive revisions to this manual Please contact McCauley Product Support to report any errors discrepancies and omissions in this manual as well as any general comments you wish to make INTRODUCTION Page 8 McCauley Propeller Systems Mar 13 2013 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL ICA SUPPLEMENT LIST ICA Supplement Title ICA Number Supplement Date NOTE No ICA Supplements have been issued that affect this manual Manual Incorporation Date ICA SUPPLEMENT LIST Page 1 O McCauley Propeller Systems Mar 13 2013 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL CHAPTER AIRWORTHINE LIMITATIONS THE AIRWORTHINESS LIMITATIONS SECTION IS FAA APPROVED AND GIVES INSPECTIONS AND MAINTENANCE THAT ARE REQUIRED BY PARTS 43 16 AND 91 403 OF TITLE 14 OF THE CODE OF FEDERAL REGULATIONS UNLESS AN ALTERNATIVE PROGRAM HAS BEEN FAA APPROVED APPROVED BY Z x ui Margaret Kline Manager Aircraft Certification Qffice Federal Avialion Administration Wichita Kansas DATE OF APPROVAL _ 3 ech 2643 13 MARCH 2013 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL LIST OF EFFECTIVE PAGES CHAPTER SE
123. es eroded and is not repainted damage to aluminum blade surface will be accelerated This is particularly true at blade tips where operation in rain or reversing on sandy and or wet runways can cause accelerated wear It is therefore important to touch up the paint on the propeller blades frequently as part of a regular maintenance schedule 2 Painting Materials and Procedures WARNING Some of the chemicals used in painting the propeller can be harmful to the skin and eyes The manufacturer s safety precautions must be obeyed when handling paint and paint preparation materials NOTE Follow the painting procedures specified by the paint manufacturer when painting the a Spinner Repair propeller It is recommended that final dry film paint thickness be 6 to 9 mils for best abrasion resistance For more information concerning the propeller paint refer to the procedures in Cleaning Painting Protective Treatments NOTE Repainting the entire propeller blade or the propeller assembly should only be accomplished at a McCauley authorized propeller service facility Without the proper training and equipment the static balance of the propeller can be affected by the application of paint A repair is permitted on any McCauley spinner spinner front support or spinner bulkhead Follow these guidelines to determine if a part is airworthy 1 Ifthe 2 Ifthe part has scratches and minor dents the part can continue to be
124. ete a fluorescent dye penetrant examination of the affected area should be performed when possible to verify that the stress riser has been completely removed NOTE If it is not possible to inspect the repaired area using the fluorescent dye penetrant inspection method the repaired region should be inspected with a minimum 10x power lens to ensure any sharp notches or cracks have been removed A stress riser can cause the failure of a propeller blade if not repaired properly A stress riser is an increase in stress intensity surrounding an area of reduced cross sectional area A sharp stress riser is an increased stress intensity attributed to a notch like displacement of material resulting from a sharp object impact leaving a very small radius at the bottom of the displaced material refer to Figure 801 Sometimes a stress riser in the propeller may be referred to as a nick 3 Stress riser damage found during a routine inspection must be field repaired if it is not beyond the field repair limits If the damage appears to be beyond the field repair limits the blade must be evaluated and or replaced by an approved McCauley propeller service facility Stress risers may be caused by sharp hard objects striking the rotating blade or can develop from corrosion such as exfoliation or intergranular type corrosion Blade erosion is the abrading of surface material attributed to impact with small particles such as sand dir
125. etermined by an FAA approved Part 145 Propeller Repair Station or international equivalent at the next opportunity Blade angle split is a measurement of the angle differences between all the blades in the same propeller This value is much more critical than rotational play described above as a high blade angle split may indicate internal problems While such angle split is very rare the operator may want to measure it if a problem is suspected most notably by a marked increase in propeller vibration levels Blade angle split may be checked as follows a By hand twist all feathering blades toward high pitch By hand twist all non feathering blades toward low pitch This will eliminate any play in the propeller linkage and reduce the possibility of a false angle reading b Using a propeller protractor atthe appropriate reference station measure the angle ofeach blade 1 If measurements differ greatly more than 0 5 degrees between blades on the same propeller excessive wear or damage to internal parts may exist 2 If the blade angle split is in excess of 0 5 degrees the propeller must be overhauled at an FAA approved propeller service station or international equivalent at the next opportunity 13 Engine Oil Contamination Inspection Requirements A Any propeller exposed to engine oil contamination must be removed and sent to an FAA approved Part 145 Propeller Repair Station or international equivalent for inspection Refer to
126. evised maintenance information and or revised operational information which is intended to assist in improving propeller safety reliability durability and or performance SSP s typically contain similar information and or headings as service bulletins but are often tailored for special situations and or conditions or logistical requirements that may affect only a limited number of propellers One additional heading that can be found on a SSP is the heading titled Duration The Duration heading provides an expiration date for the SSP when used 8 Cross Reference Listing of Popular Name Verses Model Numbers A A All propellers are certified under model number designations However in this manual reference to specific propellers is almost always by the shortened propeller model number unless the full model number is necessary to differentiate between versions of the same basic model Example the D3A34C444 78ML X propeller assembly is shortened to the Hub model designation D3A34C444 which can also be shortened to C444 Using the Owner Operator Information Manual Division of Subject Matter 1 This manual is divided into two chapters which are divided by section and subject The manual divisions are as follows INTRODUCTION 5 McCauley Propeller Systems Mar 13 2013 B McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL Chapter Section Title Subject Introduction 4 00 00 Airworthiness Limitat
127. for applying a protective treatment can be harmful to the skin and eyes The manufacturer s safety precautions must be obeyed when handling cleaning painting or protective treatment materials Material Control Requirements 1 Materials purchased from McCauley Propeller Systems will be labeled with an expiration date control information required by McCauley in a different location from the manufacturer s label McCauley control information takes precedence should there be any conflicting information with the manufacturer s information 2 For materials purchased from other sources the purchaser is required to record the expiration date control information on the package Date Code Formats 1 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 2 Cure date for elastomeric products such as O rings gaskets and hoses is normally recorded on the packaging using the numbers 1 4 the letter Q and the last two numbers of the year This marking indicates that the material was cured during a particular quarter i e three month period of the stated year For example 1Q92 indicates a cure date of the first quarter of 1992 61 00 06 Page 701 McCauley Propeller Systems Mar 13 2013 3 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL Cure date marking will suffice for control pur
128. g the propeller blade as it rotates Erosion caused by sand water etc that does not create sharp stress riser type damage does not need to be repaired in the field 61 00 06 Page 801 McCauley Propeller Systems Mar 13 2013 b McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL CAUTION The use of a rasp file is not recommended for field repairs Rasp type files will remove more metal than necessary and may cause premature rejection of the blade at propeller overhaul NOTE If the propeller blade has erosion damage and there are no signs of corrosion no further action is required However it is recommended that erosion damage be protected from corrosion with a chemical conversion film coat for example Alodine and then touch up the propeller paint in accordance with the Blade Painting procedures Give close attention to deice boots during visual inspection Boot damage may have penetrated the boot heating element and damaged the blade Remove the boot and inspect the propeller blade if this type of damage is suspected NOTE Do not assume the deice boot if installed is not damaged if it is heating normally 1 Small object damage is normally found on the leading edge and face side of the propeller blade Damage will normally occur on reversing propellers on the camber side at the outboard stations It is very important that stress riser type damage be completely repaired When filing the damaged area is compl
129. g nuts if applicable be replaced at each propeller installation whenever possible However nuts may be reused providing the threads are in good condition and the locking material prevents turning of the nut on the stud by hand Propeller mounting bolts must be magnetic particle inspected in accordance with ASTM E 1444 or replaced whenever the propeller is removed from the engine NOTE The aircraft maintenance manual or STC installation instructions should always be 2 consulted for any specialized procedures applicable to a specific aircraft Various spinner arrangements not manufactured by McCauley may be used which require additional procedures Make sure the mating surfaces of the propeller crankshaft flange spinner bulkheads and spacer if installed are clean For propeller installations that use a spacer between the propeller and the crankshaft flange and the spacer has been removed from the propeller do the following a Make sure the serial number stamped on the spacer is the same as the serial number stamped on the propeller b Make sure the alignment dowels are secure in the spacer NOTE If a matched serial number pair of propeller and spacer is not available or if a dowel is loose the propeller assembly must be taken to an FAA approved Part 145 Propeller Repair Station or international equivalent If the serial numbers do not match then the static balance of the propeller is unknown and should not be installed
130. ge 1 00 Page 2 BHAA BAD d Mee FAR Page 1 of 1 13 2013 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL AIRWORTHINESS LIMITATIONS GENERAL 1 Scope A This chapter outlines the mandatory replacement times and inspection intervals for propeller components considered to be life limited or to require monitoring through scheduled inspections This chapter applies to items such as fatigue components and structures that are considered a part of the certification process NOTE The Airworthiness Limitations section is FAA Approved and specifies maintenance required by 14 CFR 43 16 and 91 403 unless an alternative program has been FAA approved 2 Definition A This chapter contains two sections as outlined below 1 Inspection Time Limits 4 10 00 describes and lists components that are required to be inspected at specified intervals The intervals specified represent the maximum time allowable between inspections 2 Replacement Time Limits 4 11 00 describes and lists life limited components that are to be replaced at a specific time 4 00 00 Page 1 McCauley Propeller Systems Mar 13 2013 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL INSPECTION TIME LIMITS 1 General A Theinspection time intervals for the following components represent the maximum inspection intervals which must be adhered to B inspections required
131. h holes provided for that purpose Slip ring assemblies are secured to the hub or are sandwiched between the hub and the engine flange 3 Overhaul Period A All propellers are to be overhauled at specific intervals Refer to Time Between Propeller Overhaul for required propeller overhaul intervals Propellers shall also be overhauled or repaired as required for blade surface conditions 4 Propeller Model Designation A McCauley uses a model designation system to identify specific propellers This is done by utilizing a combination of hub and blade model designations B Hub Model Designation 1 The hub model designation is steel stamped on the propeller hub Examples of hub model designation 61 00 04 Page 15 McCauley Propeller Systems Mar 13 2013 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL c1199 4rwo PROPELLER BLADE SPINNER COWL DEICE BOOT i WIRE WIRE HARNESS HARNESS SLIP RING ASSEMBLY PROPELLER i PUY sa DURUM El HUB ENG 0 ap 4 BRUSH BLOCK x ASSEMBLY ELECTRIC DEICE PROPELLER CENTERLINE wo PROPELLER BLADE FEED SHOE I x SPINNER SPRAY HEAD ASSEMBLY SLINGER RING ASSEMBLY proe d PROPELLER rm HUB m TO ALCOHOL 1 RESERVOIR DENN H jJ W Be PROPELLER CENTERLINE EE ME ALGOHOL ANTI IGE Propeller Deice Anti Ice Installation Figure 11 Sh
132. h propeller blade The feed shoes are made of rubber and have grooves to guide feed anti ice fluid alcohol along the leading edge of the rotating propeller by centrifugal force The alcohol that is distributed on the feed shoe and adjacent blade surface prevents the formation of ice on the propeller blades G Propeller Deice Boots Alcohol Anti Ice Feed Shoes if installed 1 The deice boots constructed of fabric reinforced abrasion resistant rubber Electrical deice boots have a wire mesh or foil element that heats as current is supplied to the boot A deice timer controls the current cycle that is applied to individual blades or boot segments Alcohol anti ice feed shoes are ridged for distribution of alcohol The outer surface that is exposed to the environment has a glossy finish while the side that is bonded to the propeller has a dull matte finish H Deice Harness if deice is installed The deice electrical harnesses connect the deice boots to the slip ring assembly to complete the deice electrical circuit l Deice Slip Ring Assembly if deice is installed The deice slip ring assembly is constructed of machined aluminum with bronze commutator rings bonded to one side Studs to attach the deice leads for each blade are located on the propeller side of the platter These are brazed to the commutator rings and pass through holes provided for that purpose Slip ring assemblies may be secured to the hub to the starter ring
133. hat is used on C1101 C1102 C1103 and C1104 model propellers which places the line at the 42 inch 107 mm station This line indicates the blade angle reference station Center the line between the trailing and leading edges When requested by the owner of a fleet this line may be left off or painted a specific color F Special Instructions for Fixed Pitch Propellers 1 Do not paint flat engine mating surface side of the propeller hub G Special Instructions for C1103 and C1104 model Propellers Figure 702 1 Make sure the thin dashed yellow lines at the 26 inch 660 mm station on both the face and camber sides of the blade are maintained and easily visible This marks the end of the shotpeen region of the blade refer to Figure 702 Spinner Chrome Plating A McCauley does not approve the chrome plating of McCauley propeller spinners Field experience has shown that chrome plated spinners often peel after a short time in service Strong evidence also exists that chrome plating can lead to spinner fatigue cracking thus scrapping the spinner shell Chrome plating will void the McCauley warranty 61 00 06 Page 710 McCauley Propeller Systems Mar 13 2013 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL c118 0 375 INCH 9 53 mm YELLOW 0 140 INCH 3 56 mm 26 000 660 40 mm Shotpeen Lines on C1103 and C1104 Figure 701 Sheet 1 61 00 06 Page 711 McCauley Propeller Systems Mar 13 20
134. he feedback bearing assembly from the feedback collar groove Refer to the aircraft or engine manual for procedure Remove the cowling as required for access to the mounting nuts Install the D 5945 feedback collar retractor tool to the beta rods NOTE Make sure the rods are inserted through the correct holes of the tool The beta rods must be pulled directly forward CAUTION Do not draw the feedback collar too far forward as the beta rods will be damaged Turn the large threaded rod of the retractor tool clockwise to draw the feedback collar forward to allow access to the propeller mounting nuts Break the torque on the propeller mounting nuts McCauley Torque Wrench Adapter part number B 5588 may be used to gain easier access to mounting nuts Refer to Figure 201 61 00 06 Page 419 McCauley Propeller Systems Mar 13 2013 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL C72 Propeller Torque Wrench Adapter Tool Figure 403 Sheet 1 61 00 06 Page 420 McCauley Propeller Systems Mar 13 2013 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL START LOCK RELEASE TOOLS PISTON ROD BETA TUBE BETA TUBE TOOL Propeller Beta Adjustment and Start Lock Release Tools Figure 404 Sheet 1 61 00 06 Page 421 O McCauley Propeller Systems Mar 13 2013 8 9 10 11 12 13 14 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL Install
135. he hub at the blade sockets During pitch change each blade rotates about its axis on a bearing assembly An actuating pin assembly is secured to the blade butt of each blade inside the hub by screws The actuating pin is driven by a link assembly attached to the piston yoke inside the hub cavity 4 Piston and Cylinder Assembly Oil pressure controlled by the propeller governor and an internal spring act on the piston to provide the forces necessary to accomplish propeller blade pitch changes The cylinder is mounted to the hub face with screws and is sealed to prevent leakage 5 Counterweight Feathering type propellers have counterweights attached to the blades to assist the rotation of the blade to the feathered position 6 Internal Lubrication On some models grease is applied to the bearings for lubrication when the propeller is assembled However on other models the lubrication medium is oil On oil filled propellers the hub cavity is partially filled with red dyed engine type oil which is sealed in the hub and isolated from engine oil This oil provides lubrication and corrosion protection to blade bearings and other internal parts The oil is dyed red to aid in the troubleshooting of suspected propeller leaks NOTE Periodic field maintenance of this lubrication is NOT normally required Description of Piston Engine Propeller Operating Principles 1 The C200 and C400 series propellers are constant speed type They are a singl
136. hemicals used in a fluorescent dye penetrant inspection can be harmful to the skin and eyes The manufacturer s safety precautions must be obeyed when handling fluorescent dye penetrant inspection materials Inspection is performed in accordance with standard ASTM E 1417 latest revision Standard Practice for Liquid Penetrant Examination McCauley requires all dye penetrant inspections to conform to the Type I Fluorescent Dye and with a sensitivity level 3 as described in the ASTM E 1417 latest revision standard NOTE The use of visible dye penetrants Type ll is not recommended for the inspection of the propeller and propeller hardware While Type II visible dye penetrants do have limited crack detection capability the constituents of visible dye penetrants are likely to deposit residue in crack voids The residue can be extremely difficult to remove from cracks regardless of the cleaning method employed Cracks can become fully or partially masked by the remaining residue Due to these characteristics visible dye penetrants can make follow on detection of existing cracks virtually impossible when using other NDI penetrant methods specifically Fluorescent Penetrant Inspection FPI Use of FPI for NDI type inspections on some propellers and propeller hardware is a requirement at propeller overhaul Furthermore visible dye residue contamination of fluorescent penetrant fluid is also known to significantly reduce the brightness of fluorescent
137. ichever occurs first except Agricultural aircraft installations the overhaul frequency is 1200 hours or 60 calendar months whichever occurs first Aerobatic installations the overhaul frequency is 1000 hours or 72 calendar months whichever occurs first 2400 hours or 72 calendar months whichever occurs first 3000 hours or 72 calendar months whichever occurs first 3500 hours or 72 calendar months whichever occurs first zonm 5000 hours or 72 calendar months whichever occurs first l 4000 hours or 72 calendar months whichever occurs first J 2000 hours or 72 calendar months whichever occurs first 5000 hours or 72 calendar months whichever occurs first 10 000 hour life limit on propeller blades and hub L 5000 hours or 72 calendar months whichever occurs first 16 000 hour life limit on propeller blades M 6000 hours or 60 calendar months whichever occurs first The hub assembly of any B5JFR36C1101or C5JFR36C1102 propeller that has never operated on a water methanol assist Jetstream 4100 aircraft Replace 6 000 hours The hub assembly of any B5JFR36C1101 or C5JFR36C1102 propeller that is operating on or has ever operated on a water methanol assist Jetstream 4100 aircraft Replace 6000 hours All 114GCA 0 and L114GCA 0 blades are life limited at 3 500 hours N 5000 hours or 60 calendar months whichever occurs first The hub assembly of any B5JFR36C1103 or C5JFR36C1104 propeller that has neve
138. in the spacer NOTE If a matched serial number pair of propeller and spacer is not available or if a dowel is loose the propeller assembly must be taken to an FAA approved Part 145 Propeller Repair Station or international equivalent If the serial numbers do not match then the static balance of the propeller is unknown and should not be installed If a dowel is loose the dowel will need to be replaced Install the spacer and if applicable the aft spinner bulkhead on the propeller a Locate propeller hub on a padded arbor press table spacer mating surface face up b Make sure the serial number on the spacer aligns with the number 1 propeller blade NOTE If the number 1 propeller blade cannot be identified align the spacer serial number to the propeller blade with the propeller serial number c Position the spinner bulkhead if applicable on the dowel pins between the propeller and spacer NOTE The spinner aft bulkhead must be positioned so that the propeller blades emerge from the bulkhead and spinner with ample clearance Make sure the felt tip marker line on the spinner aft bulkhead aligns with the mark on the propeller blade d Apply a film of oil on the dowel pins e Pressthe propeller and spacer together with the arbor press Make sure you do not scratch dent or deform the propeller or spacer during this assembly operation The assembled propeller dowel and spacer should be a press fit and not separate easily N
139. inistration Airworthiness Directive AD 2009 19 04 for propeller blade inspection procedures C1104 L114HCA 0 Propeller Blade Inspect at 2 500 hours Fluorescent Dye Penetrant and Eddy Total Time In Service Current Inspect TTIS Applies to C5JFR36C1104 L114HCA 0 propeller assemblies only Refer to McCauley Alert Service Bulletin ASB255A and Federal Aviation Administration Airworthiness Directive AD 2009 19 04 for propeller blade inspection procedures 4 10 00 Page 2 McCauley Propeller Systems Mar 13 2013 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL 2 Propeller Hubs a There are no inspection time limits for the propeller hubs 4 10 00 Page 3 McCauley Propeller Systems Mar 13 2013 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL REPLACEMENT TIME LIMITS 1 General A Components that have reached the replacement times listed must be permanently withdrawn from service 2 Blade Life Limits A Referto Table 1 Propeller Blade Life Limits for a list of propeller blades that are life limited Table 1 Propeller Blade Life Limits Life Limited Component Part Description Life Limit Propeller Blade Replace 10 000 hours Propeller Blade Replace 10 000 hours Propeller Blade Remove from service assembly blades that are installed on or blades that ever have been installed on Jetstream Series 3200 aircraft or the service history is unknown L106FA 0 Propeller Blade Replace 16
140. ion level of this manual with the logbook entry stating compliance with this inspection requirement 3 For all propeller models If storage period exceeds five 5 years before entering service or returning to service perform the following inspection and parts replacement a b Disassemble as necessary to replace all rubber seals and lubricants Total disassembly is not required unless evidence of corrosion warrants further disassembly This must be accomplished only by an FAA approved Part 145 Propeller Repair Station or international equivalent in accordance with the appropriate propeller overhaul manual Make a logbook entry stating compliance with this inspection requirement Make a reference to MPC26 and include the current revision level of this manual with the logbook entry stating compliance with this inspection requirement Inspect parts for damage and corrosion repair replace parts as necessary Work must be accomplished only by an FAA approved Part 145 Propeller Repair Station or international equivalent in accordance with the appropriate propeller service manual Make a logbook entry stating compliance with this inspection requirement Make a reference to MPC26 and include the current revision level of this manual with the logbook entry stating compliance with this inspection requirement 4 Dynamic Balance NOTE Some aircraft manufacturers do not approve dynamic balance of the propeller because of potential crack damage t
141. ions 4 10 00 Inspection Time Limits 4 11 00 Replacement Time Limits 61 00 01 Fixed Pitch Propeller 61 00 04 Constant Speed Propeller 61 00 06 Propeller Page Numbering System 1 All system subsystem unit chapter section subject maintenance data is separated into specific types of information description and operation troubleshooting maintenance practices Blocks of sequential page numbers are used to identify the type of information Page 1 through 99 Description and Operation Page 101 through 199 Troubleshooting Page 201 through 299 Maintenance Practices 2 Relatively simple units may not require description and operation troubleshooting information In such cases these pages are omitted When subtopics are brief they may be combined into a topic entitled Maintenance Practices Maintenance Practices is actually a combination of subtopics including Servicing Removal Installation Adjustment Test Cleaning Painting or Approved Repairs 3 Lengthy subtopics may be treated as an individual topic Page numbering for the individual topics is as follows Page 301 through 399 Servicing Page 401 through 499 Removal Installation Page 501 through 599 Adjustment Test Page 601 through 699 Inspection Check Page 701 through 799 Cleaning Painting Page 801 through 899 Approved Repairs 4 Illustrations are tied into the page numbering system For example all illustrations within a 200 page numbering section will begin with the number 2 i
142. its Propeller Inspection Time Model Limited Component Designation Part Number Description Inspection Time Limit C653 L106FA 0 Propeller Blade Inspect every 600 Fluorescent Dye Penetrant or Eddy hours of operation Current Inspect Applies to 4AHFR34C653 L106FA 0 propeller assemblies only Refer to McCauley Alert Service Bulletin ASB234 and Federal Aviation Administration Airworthiness Directive AD 2000 15 10 for propeller blade inspection procedures C1101 114GCA 0 Propeller Blade Inspect at 2 500 hours Fluorescent Dye Penetrant and Eddy Total Time In Service Current Inspect TTIS Applies to BBJFR36C1101 114GCA 0 propeller assemblies only Refer to McCauley Alert Service Bulletin ASB255A and Federal Aviation Administration Airworthiness Directive AD 2009 19 04 for propeller blade inspection procedures C1102 L114GCA 0 Propeller Blade Inspect at 2 500 hours Fluorescent Dye Penetrant and Eddy Total Time In Service Current Inspect TTIS Applies to C5JFR36C1102 L114GCA 0 propeller assemblies only Refer to McCauley Alert Service Bulletin ASB255A and Federal Aviation Administration Airworthiness Directive AD 2009 19 04 for propeller blade inspection procedures C1103 114HCA 0 Propeller Blade Inspect at 2 500 hours Fluorescent Dye Penetrant and Eddy Total Time In Service Current Inspect TTIS Applies to B5JFR36C1103 114HCA 0 propeller assemblies only Refer to McCauley Alert Service Bulletin ASB255A and Federal Aviation Adm
143. ized cotton ball Medical or Cosmetic Grade Non sterilized clean dry lint free cloths Abrasive paper 220 300 400 and 600 grit wet dry masking tape 0 25 inch 6 35 mm 0 5 inch 12 7 mm 1 0 inch 25 4 mm 2 0 inch 50 8 mm 61 00 06 Page 706 O McCauley Propeller Systems Mar 13 2013 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL Table 705 Various continued Part ScotchBrite alternative to sandpaper medium coarse fine Safety wire NASM20995C20 NASM20995C32 NASM20995C41 Syringe 1 5 cc hypodermic with 20 and 24 gauge needles 3 Pre Cleaning Procedures Table 706 Approved Solvent and Cleaning Medium Applications mem tano Methyl propyl ketone MPK or Acetone or 4 Blade Cleaning A Clean blade surfaces with a nonmetallic brush and or plastic rubber scraper B Thoroughly rinse cleaned blades with tap water and a soft brush 5 Propeller Protective Treatments A Cadmium Plating 1 Parts that require Cadmium plating shall be taken to an FAA approved Part 145 Propeller Repair Station or international equivalent for disposition and plating B Cadmium Alternatives Phosphate Treatment and Zinc Nickel Plating 1 Parts that require phosphate treatment or zinc nickel plating shall be taken to an FAA approved Part 145 Propeller Repair Station or international equivalent for disposition and plating 61 00 06 Page 707 McCauley Propeller
144. lers involved an overspeed condition he Percentage Overspeed Action to be Taken All Propellers on Up to but not including 15 General external visual inspection Reciprocating Engines No further action required 15 or Higher Contact McCauley Product Support for disposition All Propellers on Turbine Up to but not including 10 General external visual inspection Engines except C1101 No further action required SMS 10 or Higher Contact McCauley Product Support for disposition C1101 C1102 C1103 and Up to and including 6 percent Up to 5 minutes operation is permitted 61104 Operation beyond 5 minutes may require some inspection Contact McCauley Product Support for disposition Above 6 percent Teardown inspection is required This inspection can only be accomplished by an authorized McCauley service facility Record all details of the overspeed event and contact McCauley Product Support for disposition 11 Propeller Overtorque Inspection Requirements A following are inspection criteria for McCauley model C1101 C1102 C1103 and C1104 propellers involved in an overtorque condition NOTE This overtorque limitation inspection only applies to model C1101 thru C1104 propellers 1 Engine Overtorque up to and including 101 percent maximum continuous operation permitted 2 Engine overtorque of between 102 percent to 110 percent is permissible for up to 30 seconds duration provided no condition is section
145. lies are installed If required remove screws and washers attaching fillets to bulkhead and remove fillets Identify location of each fillet to the bulkhead NOTE On some spinner assemblies the fillets are riveted in place and cannot be removed from the bulkhead assembly C Propeller Removal 1 2 3 4 Remove cowling as required for access to mounting nuts NOTE Not all propellers use nuts to secure the propeller mounting bolts Remove the safety wire from the bolts if installed Break the torque on the propeller mounting bolts and nuts Support the propeller remove the mounting bolts and remove the propeller from the engine crankshaft flange NOTE Some propeller spinner front supports use the propeller mounting bolts to hold the front spinner support in position on the propeller NOTE If you have not removed or installed the propeller and spinner assembly from the engine before the use of a propeller sling and hoist is recommended to prevent accidental damage to the propeller If a hoist is not available the propeller may be supported and lifted by hand Make sure an adequate number of people are available to support the propeller if a hoist is not used 61 00 06 Page 402 McCauley Propeller Systems Mar 13 2013 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL 5 Place the propeller on a suitable work surface D Spacer Removal If Installed 1 Forall fixed pitch propellers except 1
146. ll smooth cut mill files emery cloth and or sandpaper When the stress riser removal is complete perform a fluorescent dye penetrant inspection to verify that the stress riser has been completely removed Refer to Non Destructive Inspection Procedures for fluorescent dye penetrant inspection procedures Do not remove more material than what is required to remove the stress riser from the propeller blade Unnecessary or excessive propeller blade material removal will cause premature replacement of the propeller blade at propeller overhaul Leading and Trailing Edge Repair Procedure 1 Determine the depth of the damaged area a The depth of damage must be measured using a depth gage b Damage that is located on the leading or trailing edges must not exceed 0 094 inch 2 4 mm in depth Damage depth greater than this limit is not field repairable IO NOTE An FAA approved Part 145 Propeller Repair Station or international equivalent may be able to do a repair Contact McCauley Product Support for disposition of any damage that is deeper than the specified limits IN Remove metal at the damaged area starting back from and working toward the edge in such a way that the contour remains substantially the same File strokes must run from blade shank to blade tip Avoid abrupt changes in contour and blunt edges The length of the blended area shall be equal to 10 times the depth of the damage Refer to Figure 802 The finished repair should be the
147. ls C600 C650 and C1100 series propellers Beta tube B 5378 McCauley To install and adjust beta 2 installation and adjustment tool tube on C600 C650 and C1100 series propellers Procedures For Maintenance A Maintenance begins with the operator and includes inspection together with regular care Many maintenance tasks that may be accomplished at a minimum cost can extend the life of the propeller and reduce or prevent costly repairs The following is a listing of what operators of aircraft CAN and CANNOT DO B Operators CAN do the following NOTE The following activities are not preventive maintenance activities as defined by Title 14 of 1 2 3 4 the Code of Federal Regulations Part 43 Appendix A Major Alterations Major Repairs and Preventive Maintenance Perform a visual preflight inspection of the blades for nicks scratches dents erosion corrosion cracks etc Apparent damage found should be referred to an appropriately rated mechanic A crack or bend is cause for the removal of the propeller Check the propeller spinner attaching screws for security and check the spinner for damage Check the propeller for evidence of oil or grease leakage Clean propeller blades periodically using fresh water a non alkaline cleaner and a soft cloth or soft brush Dry with a soft cloth NOTE Always have a blade pointing down to prevent moisture from collecting in the hub For propellers operating in corrosiv
148. luding the last day of the month For Example a propeller with a 60 calendar month inspection interval is inspected and approved upon any given day of the month This propeller will become due for inspection upon the last day of the same month 60 months later All deviations from published TBOs must be approved by your local Regulatory Authority with a recommendation from McCauley If the propeller is in storage in excess of two years additional inspections are required Once installed on an aircraft the propeller calendar limit is not interrupted by subsequent removal and or storage Propeller overhaul should as much as practical coincide with engine overhaul For example in a case where propeller TBO is 1500 hours and engine TBO is 1400 hours the propeller should be overhauled at the same time as the engine This is appropriate as long as neither TBO limit is exceeded CAUTION Review applicable FAA Airworthiness Directives or McCauley Service Bulletins These may require compliance prior to TBO TBO specifications are based on normal aircraft with normal and continuous usage Flight time and calendar limit must not be the only factors considered in determining when a propeller needs to be overhauled Factors such as operating conditions or environment often demand that a propeller governor or accumulator be overhauled prior to TBO Even though a propeller governor or accumulator may be operating normally and have a good external appea
149. may or may not be accompanied by noticeable external oil leakage 1 Possible Cause a Incorrectly adjusted governor 1 Corrective Action a Have the governor checked by an FAA approved Part 145 Propeller Repair Station or international equivalent b Incorrectly rigged governor 1 Corrective Action a Check governor control rigging in aircraft for proper operation c Engine transfer bearing collar oil leakage rate exceeds specification 1 Corrective Action a Check transfer bearing collar oil leakage rate per the instructions of the engine manufacturer d Loss of engine oil pressure 1 Corrective action a Verify the engine oil pressure in accordance with the instructions of the engine manufacturer e Obstruction in crankshaft 1 Correction action a Remove propeller and check for obstruction in the crankshaft oil gallery ie Rags shipping plugs etc f Internal governor problem 1 Corrective Action a Have the governor checked by an FAA approved Part 145 Propeller Repair Station or international equivalent NOTE Failure of an internal governor part may result in metal contamination in the engine oil lubrication system If internal governor failure is confirmed the engine and propeller should be checked for metal contamination in accordance with the specifications of the engine manufacturer Extreme sluggishness failure to respond to changes in RPM setting or failure to hold constant RPM with varying aircraft attitude
150. mblies only Refer to McCauley Alert Service Bulletin ASB255A and Federal Aviation Administration Airworthiness Directive AD 2009 19 04 3 Life Limits A Referto Table 2 Propeller Hub Life Limits for a list of propeller hubs that are life limited Table 2 Propeller Hub Life Limits Propeller Life Limited Model Component Part Designation Number Description Life Limit Caos Replace 10 000 hour Cog Replace 10 000 hour C665 D 6153 Hub Assembly Replace 10 000 hours C1101 D6713 1 Hub Assembly Replace 6000 hours Applies to B5JFR36C1101 114GCA 0 propeller assemblies onl C1102 D6713 2 Hub Assembly Replace 6000 hours Applies to C5JFR36C1102 L114GCA 0 propeller assemblies onl C1103 D6713 3 Hub Assembly Replace 6000 hours Applies to B5JFR36C1103 114HCA 0 propeller assemblies only C1104 D6713 4 Hub Assembly Replace 6000 hours Applies to C5JFR36C1104 L114HCA 0 propeller assemblies onl 4 11 00 Page 2 McCauley Propeller Systems Mar 13 2013 CHAPTER PROPELLERS McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL LIST OF EFFECTIVE PAGES CHAPTER SECTION SUBJECT PAGE 61 Title 61 List of Effective Pages 61 Record of Temporary Revisions 61 Table of Contents 61 00 01 Pages 1 5 61 00 04 Pages 1 19 61 00 06 Pages 101 109 61 00 06 Pages 201 205 61 00 06 Pages 401 425 61 00 06 Page 501 61 00 06 Pages 601 617 61 00 06 Pages 701 711 61 00 06 Pages 801 808 61 00 06 Pages 1001 1005 DA
151. ment mark on the spinner aft bulkhead and the propeller blade with are in alignment Ensure threads of nuts and studs are free of burrs nicks and similar damage and clean of foreign material WARNING If the lubricant is not applied as required the nuts will be under torqued and the propeller could fail a For Pratt amp Whitney engine installations CAUTION Do not use oil as a substitute for approved lubricant It is imperative that the correct specification of lubricant be used during installation Substitution of the approved grease with an unapproved lubricant or no lubricant could result in under torquing or severe over torquing of propeller attaching parts Lubricate the threads of studs and nuts and the faces of nuts spacers or washers with MIL PRF 83483 McCauley part number A 1637 16 grease 2 Install mounting nuts on mounting studs 3 Torque the mounting nuts in an alternating sequence to prevent the hub rocking on the engine flange 4 When the hub is seated fully on the engine flange torque to the specification called out in the mounting decal located on propeller hub at the number 1 socket NOTE If the decal containing the propeller installation instructions is missing or illegible install a new decal All Pratt amp Whitney engine installations use a part number A 2230 7 decal 5 After you apply the final torque apply torque seal to nut and stud threads b If required install the deice leads
152. mic equipment can also be used to track down vibration problems The digital dynamic balancing equipment can display the amplitude and frequency of the vibration which will help determine the vibration source While vibration problems are occasionally caused by the propeller they are usually caused by other things Below is a list of other possible sources of vibration 1 Engine 2 Worn old cracked or loose engine mounts 3 Cracked or loose engine mount structure 4 Cracked or broken spinner bulkheads 5 Loose or improperly mounted engine cowlings 6 Loose cowl flaps 7 Loose landing gear doors 8 Out of balance elevators Loose control yokes 10 Exhaust stack touching engine cowling 11 Component in engine compartment that is touching engine cowling 61 00 06 Page 105 McCauley Propeller Systems Mar 13 2013 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL 11 Unusual Aircraft Vibration A Apparently excessive vibration felt during normal aircraft operation CAUTION Ifa vibration starts suddenly and or is accompanied by the leaking of red dyed oil from the propeller determine the cause of the vibration and or oil leakage before continuing propeller operation 1 2 4 Possible Causes If the propeller is believed to be the cause of the vibration it is typically due to improper balance blade track or linkage problems within the propeller assembly When a propeller is the cause of vi
153. mm in depth Damage depth greater than this limit is not field repairable IO NOTE An FAA approved Part 145 Propeller Repair Station or international equivalent may be able to do a repair Contact McCauley Product Support for disposition of any damage that is deeper than the specified limits CAUTION Use extreme care to control the hand held grinder Remove metal at the damaged area by hand using a coarse grain emery cloth or by a hand held rotary grinder with 120 or finer grit bob Do not use a hand file in this area NOTE Do not use sandpaper or emery cloth that contains iron oxide material on aluminum propellers Grind blade with light pressure in a circular motion until damage is totally removed The diameter of the repair shall be equal to 20 times the depth of damage Refer to Figure 802 The finished repair should be the depth of the original damage plus 0 002 inch 0 05 mm Smooth the repaired area with number 240 and 320 emery cloth or equivalent grit sandpaper Polish the repaired area with number 600 grit emery cloth or equivalent grit sandpaper NOTE Do not use sandpaper or emery cloth that contains iron oxide material on aluminum propellers Determine the depth of the repaired damaged area a The maximum depth of the damage repair area must be measured using a depth gage b The repair that is located on the face or camber sides of the propeller must not exceed 0 063 inch 1 6 mm in depth 61 00 06 Page 805
154. n the spinner and bulkhead a Make sure that alignment marks on the spinner and propeller blade are matched b Add or subtract shims to the spinner support until spinner mounting holes are aligned within one half hole with the bulkhead mounting hole diameters while you push hard on the spinner shell 61 00 06 Page 418 McCauley Propeller Systems Mar 13 2013 4 S McCAULEY PROPELLER SYSTEMS OWNERIOPERATOR INFORMATION MANUAL Use an awl or a small punch in an adjacent hole to move the spinner screw hole into alignment with the bulkhead hole and install the screw Repeat the procedure on opposing holes until eight equally spaced screws and washers are installed Secure the propeller spinner to the bulkhead and fillet assemblies with the remaining screws and washers 6 700 750 1000 Propeller Removal Installation A General 1 2 Propeller removal and installation should be performed only by qualified maintenance personnel The following instructions are general in nature The aircraft maintenance manual or STC installation instructions should always be consulted for any specialized procedures applicable to a specific aircraft Various spinner and deice arrangements not manufactured by McCauley may be used which require additional procedures NOTE Qualified maintenance personnel means the person doing the maintenance activity is the holder of or is working under the direct supervision of the holder of the appr
155. namic balance If the test indicates the addition of weights temporarily place the indicated mass of balance washers in place of the spinner mounting screw at the location indicated by the testing equipment a An AN970 3 washer weight 0 144 ounces each 4 1 grams plus screw AN502 10 X Repeat the dynamic balance until the correct balance level approximately 0 07 ips or lower is achieved NOTE Most dynamic balance equipment manufacturers specify 0 15 0 2 ips as being an acceptable level McCauley Propeller Systems agrees that 0 15 0 2 is an acceptable level but our experience has shown that 0 07 ips or lower is noticeably smoother When dynamic balance is satisfactory a Remove balance washers and screw from the spinner attach screw hole b Permanently mount the balance washers and screws to the spinner bulkhead assembly at a point adjacent to the test location as shown on Figure 203 Always place at least one balance weight under screw head for stress relief see Figure 203 Return original spinner screw to hole WARNING Use extreme care when you drill bulkheads near blades to avoid shank damage Blade shank damage could potentially require propeller disassembly and blade replacement depending on the severity of the damage 5 Spinner Repair and Chrome Plating A No repair is permitted on any McCauley spinner spinner front support or spinner bulkhead Follow these guidelines to determine if a part is airworthy
156. ne on the propeller blade F Propeller Assembly Installation for model 1A162 propellers 61 00 06 Page 407 McCauley Propeller Systems Mar 13 2013 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL WARNING MAKE SURE THE MAGNETO IS GROUNDED BEFORE INSTALLING THE PROPELLER OR CONNECTING EXTERNAL POWER NOTE McCauley recommends that propeller mounting nuts if applicable be replaced at each propeller installation whenever possible However nuts may be reused providing threads are in good condition and the locking material prevents turning of the nut on the stud by hand Propeller mounting bolts must be magnetic particle inspected in accordance with ASTM E 1444 or replaced whenever the propeller is removed from the engine NOTE The aircraft maintenance manual or STC installation instructions should always be Q consulted for any specialized procedures applicable to a specific aircraft Various spinner arrangements not manufactured by McCauley may be used which require additional procedures Make sure the mating surfaces of the propeller crankshaft flange and spinner bulkheads are clean For propeller installations that use a spacer between the propeller and the crankshaft flange and the spacer has been removed from the propeller do the following a Make sure the serial number stamped on the spacer is the same as the serial number stamped on the propeller b Make sure the alignment dowels are secure
157. ng small objects during normal operation The propeller shall be fluorescent dye penetrant inspected refinished and rebalanced Reconditioning is accomplished on an irregular basis as necessary and required NOTE Refer to Non Destructive Inspection Procedures for fluorescent dye penetrant inspection procedures 3 Repair The correction on an irregular basis as necessary of damage that has occurred to the propeller The amount degree and extent of damage determines whether or not the propeller can be repaired without refinishing or removing the propeller from the engine If a propeller is bent or twisted the repair is major and reconditioning or overhaul of the propeller must be accomplished 4 Frequency of Overhaul Refer to Time Between Propeller Overhaul for required propeller overhaul intervals Propellers shall also be overhauled or repaired as required for blade surface conditions The propeller mounting bolt torque should be checked at least once a year Propeller mounting bolts must be magnetic particle inspected in accordance with ASTM E 1444 or replaced whenever the propeller is removed from the engine 2 Blade Serial Number Stamping Information A Blade serial number information is stamped on the hub Refer to Figure 1 Table 1 Blade Year of Manufacture Code tee from Bew uszm farm ver fas m as 61 00 01 Page 2 McCauley Propeller Systems Mar 13 2013 McCAULE
158. nge dowels and mounting stud holes are clean dry and free of nicks and burrs Remove the protective cover from the propeller hub mounting flange Make sure that the propeller hub mounting flange dowel pin holes and mounting studs are clean and undamaged 61 00 06 Page 415 McCauley Propeller Systems Mar 13 2013 6 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL Make sure that a new O ring is installed in the groove of propeller hub mounting flange Lubricate the O ring with engine oil prior to installation of propeller NOTE Referto the Installation Parts For Turbine Engine Propellers Table 1002 for the O ring part number NOTE In the past new propeller assemblies shipped from McCauley the propeller hub engine O ring was installed in the O ring groove of new propellers and hub assemblies This practice has been discontinued The O ring is now included in the propeller unattached parts kit which is included in the box with the propeller or hub assembly Install the O ring according to the assembly instructions in this Owner Operator Manual Use a propeller sling and hoist or additional personnel to position the propeller close to the engine propeller flange and align engine flange dowel pins with the dowel pin holes on the propeller hub mounting flange Rotate engine propeller mounting flange as required to align the dowel pin holes a Hoist straps must be a minimum of 4 inches 100 mm wide b
159. ning and if necessary measure the propeller diameter to determine if an unauthorized repair has altered it 2 Definitions of Defects and Damage A B Brinelling is the occurrence of shallow spherical depressions in a surface usually produced by a part having a small radius in contact with the surface under high load A Burr is a small thin section of metal which extends beyond the edge of a regular surface and usually is located on a corner of or on the edge of a bore or hole Corrosion is the loss of surface metal by a chemical or electrochemical action and the resulting product for example iron rust usually can be removed mechanically 61 00 06 Page 601 McCauley Propeller Systems Mar 13 2013 R S McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL A Crack is an irregularly shaped separation within a material at a location of excessive stress and usually is visible as a thin line across the surface of the material A Cut is a mechanical loss of metal e g by saw blade chisel or glancing blow of a sharp edge stone usually extending to a significant depth over a relatively long narrow area A Dent is a depression in a metal surface caused by an object striking the surface with force NOTE The surface around the dent usually will be sightly deformed Distortion or bending is the alteration of a component s original size or shape Erosion is the gradual wearing away or deterioration of a m
160. o spinner bulkhead from the installed weight A Recommended test equipment NAME Balance Analyzer NUMBER MANUFACTURER USE Model 2020 ACES Systems For propeller dynamic Pro Balancer 10737 Lexington Drive balance Analyzer Knoxville TN 37932 3294 Web www Acessystems com B It is highly recommended that this procedure be performed following static balancing All of the procedures and guidelines listed below should be used in conjunction with the dynamic balance equipment manufacturer s instructions 1 Perform dynamic balance according to balance equipment manufacturer s instructions 2 If the initial reading is over 0 8 ips McCauley recommends the following should be checked corrected a b Shimming of the spinner shell Propeller installation properly torqued and installed flat against the mounting flange NOTE If the shimming of the spinner shell and propeller installation are found to be acceptable but the initial reading is stillover 0 8 ips we recommend the propeller be taken to an FAA approved Part 145 Propeller Repair Station or international equivalent for inspection 61 00 06 Page 203 McCauley Propeller Systems Mar 13 2013 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL If the initial reading is under 0 8 ips continue the dynamic balance in accordance with the balance equipment manufacturer s instructions CAUTION Atnotime are static balance weights to be moved to adjust dy
161. ol A Constant speed non feathering only Propeller goes to low pitch high RPM of its own accord 1 Possible Cause a Governor linkage disconnected 1 Corrective Action a Check and repair governor linkage b Engine transfer bearing collar oil leakage rate exceeds specification 1 Corrective Action a Check transfer bearing collar oil leakage rate per the instructions of the engine manufacturer c Loss of engine oil pressure 1 Corrective action a Verify the engine oil pressure in accordance with the instructions of the engine manufacturer dj Obstruction in the crankshaft 1 Correction action a Remove propeller and check for obstruction in the crankshaft oil gallery ie rags shipping plugs etc e Internal governor problem 1 Corrective Action a Have the governor checked by an FAA approved Part 145 Propeller Repair Station or international equivalent NOTE Failure of an internal governor part may result in metal contamination in the engine oil lubrication system If internal governor failure is confirmed the engine and propeller should be checked for metal contamination in accordance with the specifications of the engine manufacturer 61 00 06 Page 103 McCauley Propeller Systems Mar 13 2013 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL Feathering propeller The propeller goes to high pitch or feathers of its own accord This may occur without warning from otherwise normal operation and
162. on of spinner shell position to lessen the distortion of any dynamic balance previously performed on the propeller assembly Remove screws and washers from the spinner and fillet assemblies Remove spinner from the bulkhead and fillet assemblies Remove the spinner support and shims from the front of the propeller cylinder If required remove screws and washers attaching fillets to bulkhead and remove fillets Identify location of each fillet to the bulkhead NOTE On some spinner assemblies the fillets are riveted in place and cannot be removed from the bulkhead assembly Propeller Assembly Removal 1 2 3 4 5 Remove cowling as required for access to mounting nuts If required remove the deice leads Place a drip pan under the propeller mounting surface to catch any spilled engine oil when the propeller is removed Break the torque on the propeller mounting nuts on Continental engine installations For Lycoming installations remove safety wire from the stud and nut assembly and break the torque Install the propeller sling and attach to a hoist If a hoist is not available the propeller may be supported and lifted by hand NOTE Make sure an adequate number of people are available to adequately support the propeller if a hoist is not used a The straps of the propeller sling should be placed on two of the propeller blades at least 6 inches 152 mm outboard of the propeller hub for three blade propellers and 1
163. ons that use the model 3FF32C501 propeller The model 3FF32C501 propeller requires the part number A 2230 7 decal All Franklin engine installations use a part number A 2230 9 decal All Orenda engine installations use a part number A 2230 7 decal NOTE McCauley C1 through C98 model propellers are not applicable to this manual refer to McCauley Service Bulletin SB227B or latest revision for propeller mounting torque information for McCauley C1 through C98 model propellers 5 After you apply the final torque apply torque seal to nut and stud threads b For Lycoming engine installations WARNING Threads must be clean and dry If any lubricant is applied the attaching parts will be severely over torqued 1 Start threads on all propeller mounting nut and stud assembly and then tighten them in an alternating sequence to prevent the hub rocking on the engine flange 61 00 06 Page 412 McCauley Propeller Systems Mar 13 2013 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL IN When the hub is seated fully on the engine flange torque to the specification called out on the mounting decal located on propeller hub at the number 1 socket NOTE If the decal containing the propeller installation instructions is missing or illegible install a new decal For all Lycoming engine installations use a part number A 2230 decal except installations that use the model 3AF32C524 propeller The model 3AF32C524 propeller requires
164. opriate rating to approve the propeller for return to service after the maintenance activity has been accomplished In the following instructions installation of propeller is based on the assumption that a McCauley spinner will be used If a spinner is not used or if the spinner is not manufactured by McCauley omit those steps which apply to the spinner B Spinner Assembly Removal 1 Make an alignment mark the spinner spinner aft bulkhead an adjacent blade with felt tip pen This index mark insures accurate restoration of spinner position to lessen the distortion of any dynamic balance previously performed on the propeller assembly Remove screws and washers from spinner and fillet assemblies Remove spinner from the bulkhead and fillet assemblies Remove spinner support and shims from spinner Remove screws and washers attaching fillets to the bulkhead and remove the fillets C Propeller Assembly Removal 1 6 7 Make sure the airplane propeller control lever has the FEATHER position selected and the propeller blades are in feather NOTE If the propeller control lever is not in the FEATHER position or the propeller blades are not in feather consult the Pilot s Operating Handbook for instructions to put the propeller control in the feather position and to feather the propeller Place a drip pan under the propeller mounting surface to catch any spilled engine oil when the propeller is removed Remove t
165. pection Criteria that follow Definitions 1 Propeller Blade Strike sometimes referred to as Ground Strike is defined as any impact or suspected impact of the rotating propeller upon such items as but not limited to the ground tow bars landing lights carts snow banks hedges etc Please note that the above definition is intended for use as an example only Determination as to whether or not a blade strike actually occurred is ultimately the responsibility of the aircraft operator CAUTION Internal damage can occur without evidence of gross external damage a Any governor mounted to an aircraft involved in a propeller ground strike must comply with Governor Inspection Criteria 2 Propeller Engine Lightning Strike Definition of propeller lightning strike can be found in Lightning Strike Inspection Requirements Refer to engine manufacturers service information for definition of engine lightning strike Any governor showing signs of arcing or pitting due to electrical discharge mounted on an aircraft exposed to engine or propeller lightning strike as defined in these documents must comply with Governor Inspection Criteria 3 Engine Detonation Refer to engine manufacturers service information for determination of engine detonation Exposure to detonation may impart severe stresses to the governor s rotating parts Any governor operated under the above conditions must comply with Governor Inspection Criteria NOTE Special
166. ponents Welding riveting or bonding are not permitted on the spinner or spinner components 6 Do not polish propeller blades unless specifically permitted by McCauley s instructions 7 Do not fill any damaged areas of metal blades with bulk filler materials such as epoxy or auto body fillers This prevents areas of potential cracking from being inspected Additionally filling a damaged area will not correct the stress risers caused by the dent or those caused by the loading that introduced the dent 8 Do not paint over areas of corrosion on blades Corroded areas must be removed in accordance with approved procedures prior to applying the approved protective finish 9 Do not run up engines in areas containing loose rocks gravel or debris Avoid quartering rear winds during ground run up because this activity can cause damaging stresses 10 Do not push or pull on propeller blades when moving the aircraft by hand Tow bars are specifically designed for this operation 11 Never install a propeller on an aircraft unless it is a model approved by the aircraft type certificate data sheet TCDS or an appropriate supplemental type certificate STC The service history must be properly documented and a pre installation inspection must indicate that the propeller is airworthy 3 Long Term Storage of Controllable Pitch Propellers A The following is applicable to new and overhauled propellers prior to entering service engine install
167. poses The actual date of expiration will occur after the last day of the quarter in the year projected from the cure date plus the allowable number of years for storage D Consumable Material Management Procedures 1 2 3 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 16 C may cause the epoxy to not cure at all The maximum storage time for O rings and gaskets a All O rings must adhere to the storage guidelines set forth in the SAE ARP 5316 b All gaskets the maximum storage life is 15 years from the date of cure Deice Boots a Deice boots do not have a shelf life if stored in accordance with the manufacturer s instructions Lubricants a Table 701 provides a listing of lubricants approved for use in McCauley products Table 701 Lubricants Part 5 Manufacturer A 1637 4 Orelube K 2 Orelube Corp Molybdenum disulfide non melt 201 E Bethpage Rd grease Plainview NY 11803 Phone 516 249 6500 A 1637 11 A 1637 13 A 1637 14 A 1637 16 Dyed Oil 1 gallon of Aeroshell Oil W65 and 12 Piston grams of A 4880 1 engines Aeroshell Oil Shell Oil Company Any SAE 10W or 10W multi grade W65 Recom P O Box 659501 piston engine oil is acceptable mended Houston TX 78265 9501 Turbine Oil BP Air Bp Lubricants Turbine oil conforming
168. previous to the Introduction A Manual Incorporation Date column on the Temporary Revision List page will indicate the date the Temporary Revision was incorporated thus authorizing the rescission of the temporary revision Identifying Revised Material A Additions or revisions to text in an existing section will be identified by a revision bar in the left margin of the page and adjacent to the change NOTE Due to the extensive changes and reformatting in revision 2 of this manual all change bars have been omitted for this revision B Revised text inside tables including Appendices will not display revision bars however the affected page will display the current revision date in the Date of Page Issue location C When extensive technical changes are made to text in an existing section that requires extensive revision revision bars will appear the full length of text D When art in an existing illustration is revised a revision bar along the entire vertical length of one side of the illustration will be used to indicate changes to the illustration INTRODUCTION Page 7 McCauley Propeller Systems Mar 13 2013 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL 17 Warnings Cautions and Notes A Throughout the text in this manual warnings cautions and notes pertaining to the procedures being accomplished are included These adjuncts to the text are used to highlight or emphasize important points Warnings and
169. r operated on a water methanol assist Jetstream 4100 aircraft Replace 6 000 hours The hub assembly of any B5JFR36C1103 or C5JFR36C 1104 propeller that is operating on or has ever operated on a water methanol assist Jetstream 4100 aircraft Replace 6000 hours All 114HCA 0 and L114HCA 0 propeller blades are life limited at 3 500 hours 61 00 06 Page 607 McCauley Propeller Systems Mar 13 2013 m McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL 5000 hours or 72 calendar months whichever occurs first Agricultural aircraft installations the overhaul frequency is 2000 hours or 60 calendar months whichever occurs first Only for L106FA 0 propeller blades used in the 4HFR34C653 propeller assemblies or blades that have been installed on Jetstream Series 3200 aircraft or history unknown Propeller blades without change letter A must be retired from service before December 1 2001 or upon reaching 2400 flight hours after August 1 2000 or 16 000 hours time since new whichever occurs first Blades with change letter A are life limited to 16 000 hours Fixed pitch propellers 2000 hours or 72 calendar months which ever occurs first Additionally the propeller mounting bolt torque should be checked at least once per year Propeller mounting bolts must be magnetic particle inspected in accordance with ASTM E 1444 or liquid penetrant inspected in accordance with ASTM E 1417 or replaced at every overhaul
170. r the spinner for security Tighten if necessary 3 Check entire propeller for corrosion cracks or other damage Contact a McCauley Service Center for disposition if any unusual damage is found 4 Inspect entire propeller system for oil leakage If leakage is confirmed the propeller should be removed thoroughly inspected and resealed by an FAA approved Part 145 Propeller Repair Station or international equivalent or technician 5 Repaint propeller blades as necessary in accordance with the instructions in Cleaning Painting Protective Treatments 6 Examine all placards for legibility and security of installation Replace all placards that are illegible or not secure 5 Time Between Propeller Overhaul A The following pages show McCauley s mandatory specified time between overhaul for propellers These specifications are based on hours of operation and calendar time whichever occurs first The starting point for the calendar limit is the date of first installation on an engine not from date of manufacture or overhaul Date of manufacture or overhaul is applicable when determining long term storage inspections If the propeller has been removed from service the TBO calendar limit still applies not long term storage NOTE Calendar month is the period of time from the first day of a month to the last day of the month When the term calendar month is used compliance can be achieved at any time during the month up to and inc
171. rance when the TBO flight time or calendar limit is reached operation beyond the specified TBO limits is not permitted Propeller Models 1 The propeller model designation is impression stamped on the propeller hub Change letters are frequently stamped at the end of the model designation e g 3A32C406 AD These letters indicate engineering changes and or previous overhaul modifications In Table 1 unless specific change letters are shown the overhaul frequency note applies to all propellers of that model regardless of change letters Use the highest letter stamped after hub model number to determine frequency of overhaul Refer to Tale 601 61 00 06 Page 604 McCauley Propeller Systems Mar 13 2013 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL Example Propeller model 3A32C406 AD D is the highest letter TBO note T applies Propeller model 3A32C406 B B is the highest letter TBO note S applies Table 601 Table 1 Propeller Models Model Designation Overhaul Model Designation Overhaul Model Designation Overhaul Frequency Frequency Frequency Note Note Note 2A34C201 less than C 2A34C201 C or E 2D34C202 C higher 2A34C203 less than 2A34C203 C or E C2A34C204 less C higher than C C2A34C204 C or E B2A34C205 A B2D34C206 higher B2D34C207 R B2D34C208 R 2A34C209 less than C 2A34C209 C or E 2A34C210 B2D34C211 higher B2D34C212 D B2D34C213 D B2D34C214 2D34C215
172. rea Daily or Preflight Inspection A Oil and Grease Leakage 1 Look for red oil or engine lubricant leaks in unusual places like the outside surfaces and seals 2 Oil or grease leakage may be due to a seal failure or a crack in the hub or blade a The source of the oil or grease leak should be determined before flight b During maintenance wipe the surfaces of the propeller after this inspection not before since oil leaking from a crack may assist in detecting it c Red oil gives a positive warning of a crack in the hub or a damaged seal Blade inspection 1 Wash the blades with a mild soap and water solution to remove all residue CAUTION Do not use solvents to clean the blades a Do not power wash as water may be forced past the O rings Water inside the hub will cause corrosion and may cause propeller failure b Make sure the blade that you are cleaning is pointing down c Do not spray into the blade retention area because water may be forced into the hub 61 00 06 Page 602 McCauley Propeller Systems Mar 13 2013 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL 2 Surface Damage a Look for surface damage on both sides of the blades such as dents nicks scratches and corrosion b Surface imperfections can also be felt by running your fingernail along the blade leading edge Damage should be repaired before flight c Whenever a noticeable dent nick corrosion pit or bump is
173. rective Number Number 7 Applicable Service Bulletins and Service Letters A Alert Service Bulletin 1 Alert Service Bulletins are technical documents that provide instructions and if applicable part information for the incorporation of an installation modification or repair to a specific propeller or propeller component Alert Service Bulletins are used to announce mandatory special product inspection criteria and modifications revised maintenance information and or revised operational information which has been determined to be critical for the continued safe and reliable performance of the propeller or propeller component Service Bulletin 1 Service Bulletins are technical documents that provide instructions and if applicable part information for the incorporation of an installation modification or repair to a specific propeller or propeller component Service Bulletins are used to announce special product inspection criteria and modifications revised maintenance information and or revised operational information which has been determined to be critical for the continued safe and reliable performance of the propeller or propeller component Service Letter 1 Service Letters are used to announce support and service information Special Service Project 1 Special Service Projects SSP s are similar to service bulletins and are used to announce special product inspection criteria and modifications r
174. restriction for an extended period of time the propeller blades and hubs may become unairworthy due to fatigue Hub or blade failure has the potential of causing a catastrophic event due to blade separation The propeller RPM restriction is often placed below the minimum idle RPM however certain aircraft have a restriction that is above the propeller idle RPM setting Either restriction is important The propeller operating restrictions or limitations may be found in the Airplane Flight Manual AFM or Airplane Flight Manual Supplement AFMS The propeller installations may be controlled by the various airframe manufacturers Type Certificate TC or by Supplemental Type Certificate STC Spinner Installation CAUTION Undershimming or overshimming of the spinner aft bulkhead could result in spinner wobble vibration and or bulkhead and spinner cracking Please follow shimming procedures carefully Install propeller spinner fillets on the bulkhead with screws and washers if required Insert shims into the spinner support and lightly press spinner support onto the cylinder on the front end of the propeller Mount the spinner onto the bulkhead and fillet assembly and check alignment of the mounting holes in the spinner and bulkhead a Make sure that alignment marks on the spinner and propeller blade are matched b Add or subtract shims to the spinner support until spinner mounting holes are aligned within one half hole with the bulkhe
175. rnating sequence to prevent the hub rocking on the engine flange 4 When the hub is seated fully on the engine flange torque to the specification called out in the mounting decal located on propeller hub at the number 1 socket NOTE If the decal containing the propeller installation instructions is missing or illegible install a new decal All Garrett Honeywell engine installations use a part number A 2230 7 decal a McCauley Torque Wrench Adapter 61 00 06 Page 416 McCauley Propeller Systems Mar 13 2013 10 11 12 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL CAUTION If an adaptor or extension such as McCauley part number B 5588 is attached to torque wrench drive end and this adds to its length then the actual applied torque will be greater than the dial reading The following formula should be used to find what the dial should read in order to obtain the correct applied torque Torque Wrench Length x Desired Torque Dial Reading Torque Wrench Length Extension Length 5 After you apply the final torque apply torque seal to nut and stud threads b Ifrequired install the deice leads Install the beta tube CAUTION Never use a screwdriver or similar tool to install the beta tube Use of any tool other than McCauley B 5378 can severely damage beta tube and propeller piston rod threads rending parts unusable and unrepairable a Lubricate with turbine oil and install a new O ring
176. rrugated cardboard with the box in the shape of a rectangle or a Y Four and five blade propellers are shipped in a square box usually made of wood After the propeller is free of the crate and packaging material place the propeller on a propeller stand of sufficient size to safely hold the propeller CAUTION Never store or stand a propeller on a propeller blade tip Damage to the propeller may occur if it is not properly handled after it has been removed from the shipping container Do a visual inspection of the propeller blades and hub for surface damage such as dents nicks scratches and corrosion Sight down the edges of each propeller blade to make sure there is no deformation NOTE It is possible for a propeller to sustain shipping damage while crated and for the shipping container to not sustain substantial damage as a result of the shipping damage 61 00 06 Page 401 McCauley Propeller Systems Mar 13 2013 6 NOTE McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL Retain the installation parts that are shipped with the propeller for use when the propeller is to be installed If the propeller has been shipped with one or more of the propeller blades removed from the hub the propeller must be reassembled by an FAA approved Part 145 Propeller Repair Station or international equivalent 3 Fixed Pitch Propeller Removal and Installation A General 1 Propeller removal and installation shall
177. rs and hub assemblies This practice has been discontinued The O ring is now included in the propeller unattached parts kit which is included in the box with the propeller or hub assembly Install the O ring according to the assembly instructions in this Owner Operator Manual 61 00 06 Page 422 McCauley Propeller Systems Mar 13 2013 8 9 10 11 12 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL Use a propeller sling and hoist or additional personnel to position the propeller close to the engine propeller flange and align engine flange dowel pins with the dowel pin holes on the propeller hub mounting flange Rotate engine propeller mounting flange as required to align the dowel pin holes a Hoist straps must be a minimum of 4 inches 100 mm wide b The sling and hoist should have a weight limit rating at least twice the weight of the propeller that is to be installed c The straps of the propeller sling should be placed on two of the propeller blades at least 6 inches 152 mm outboard of the propeller hub Make sure you protect the deice boots or anti ice shoes from potential propeller sling abrasion damage if installed CAUTION Propeller must be installed straight onto the engine flange Any rocking of the propeller with respect to the flange could result in damage to the engine propeller flange mating surfaces Mount the propeller on the engine propeller shaft Make sure the align
178. should be noted in the propeller log book and if required note when the next inspection is due If any propeller blade is damaged beyond field repair limits the blade track or the propeller blade twist is beyond the limits the propeller must be removed from the airplane and taken to and overhauled by an FAA approved Part 145 Propeller Repair Station or international equivalent 3 Sudden Engine Stoppage a Sudden Stoppage is defined as any propeller experiencing a sudden decrease in RPM This is commonly due to engine failure or seizure Please note determination as to whether or not sudden engine stoppage has occurred is ultimately the responsibility of the aircraft operator McCauley recommends consulting engine manufacturer s data to determine criteria for sudden engine stoppage b Any McCauley propeller experiencing a sudden stoppage must be removed from the aircraft and overhauled by an FAA approved Part 145 Propeller Repair Station or international equivalent in accordance with the applicable propeller overhaul manual Governors Exposed to Propeller Blade Strike Propeller Engine Lightning Strike Engine Detonation Oil Contamination or Sudden Engine Stoppage A Compliance Any governor exposed to propeller blade strike propeller and or engine lightning strike oil contamination engine detonation or sudden engine stoppage must not be returned to service as is It must be repaired or overhauled as defined in Governor Ins
179. t and water Small object impact typically does not cause sharp bottom radiuses and therefore do not result in sharp stress risers or significant material displacement that elevate the stress intensity to a level which cause crack initiation Erosion of the blade surface that does not result in stress risers does not require field repair of the damaged surface If significant material displacement has occurred measure the area of the blade with the most erosion damage a Damage that is located on the leading or trailing edges must not exceed 0 094 inch 2 39 mm in depth Damage greater than 0 094 inch 2 39 mm in depth is not field repairable ES 61 00 06 Page 802 McCauley Propeller Systems Mar 13 2013 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL C2010 SHARP STRESS RISER SHARP STRESS RISER A SHARP NOTCH LIKE DISPLACEMENT OF MATERIAL FOUND ON THE LEADING AND TRAILING EDGES CAUSED BY SHARP OBJECT IMPACT Sharp Stress Riser Figure 801 Sheet 1 61 00 06 Page 803 McCauley Propeller Systems Mar 13 2013 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL Damage that is located on repairable area of the face camber side of the blade must not exceed 0 061 inch 1 55 mm in depth Damage greater than 0 061 inch 1 55 mm in depth is not field repairable 5 If corrosion is observed on the propeller a For uniform etch type corrosion remove the corrosion and
180. the area of the part to be treated has a water break free surface as required by section 3 3 2 of MIL DTL 5541 2 All parts that are chemical conversion film coated must have paint applied except on the engine mounting flange cylinder mounting flange and the area of the hub socket where the shim carrier contacts the hub CAUTION Paint or primer is not allowed on the engine mounting flange cylinder mounting flange and the area of the hub socket where the shim carrier contacts the hub This is a 5 295 inch 134 5 mm diameter circle measured from the center of all blade sockets Paint and primer are not allowed inside of hub socket on threadless propellers Corrosion Protection 1 For propellers that operate in salt air or other corrosive environments a Apply LPS 3 around the blade retaining rings and shim carrier 61 00 06 Page 708 McCauley Propeller Systems Mar 13 2013 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL 6 Blade Painting NOTE McCauley strongly recommends that all blades be painted Paint and primer protect blades from corrosion McCauley recommends Sherwin Williams products but any industry equivalent is acceptable The following procedure is recommended but any procedure achieving similar results is acceptable NOTE Repainting the entire propeller blade or the propeller assembly should only be accomplished at an FAA approved Part 145 Propeller Repair Station or international equivalent
181. the service information of the engine manufacturer to determine if oil contamination has occurred or to determine the acceptable amount of metal particles allowed in engine oil 61 00 06 Page 614 McCauley Propeller Systems Mar 13 2013 C89 McCAULEY PROPELLER SYSTEMS OWNERIOPERATOR INFORMATION MANUAL MOVEMENT SHOWN IS GREATLY EXAGGERATED BLADE SHAKE MOVEMENT SHOWN IS GREATLY EXAGGERATED BLADE TWIST Blade Shake and Blade Twist Figure 602 Sheet 1 61 00 06 Page 615 McCauley Propeller Systems Mar 13 2013 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL 14 Fire Inspection A Any propeller or governor exposed to fire or excessive heat is considered unairworthy and must be removed from service and scraped propeller is considered exposed to fire or excessive heat if after the suspected exposure it shows any of the following conditions Bubbled paint Discolored paint Discolored metal Melted areas 1 2 3 4 15 Non Destructive Inspection Procedures A Fluorescent Dye Penetrant Inspection General 1 2 3 a Fluorescent dye penetrant inspection shall be performed as specified in this manual on products manufactured by McCauley Propeller Systems Penetrant inspection for continued airworthiness shall be used to detect cracks or discontinuities open to the surface which may not be evident by direct visual inspection WARNING Some of the c
182. tion tachometers can be inaccurate so begin troubleshooting by verifying the accuracy of the tachometer b Verify the propeller low blade angles are correct This is most effectively accomplished at a McCauley authorized propeller repair facility This is done by measuring the blade angle at the reference station generally the 30 inch 762 mm station and comparing the angles to those listed in either the type certificate of the airframe manufacturer or the STC under which the propeller was installed If the angles are correct then the engine is not producing the proper horsepower needed to make the rated static RPM c Begin troubleshooting the engine 6 Improper Propeller Maximum RPM in Flight Constant Speed Piston A Incorrect propeller speed with maximum RPM selected in flight 1 Possible Cause a Inaccurate tachometer reading b Linkage is out of rig c Governor stop screw requires adjustment 2 Corrective Action a Repair or replace the tachometer b Governor stop screw requires adjustment Do a test flight Pull the propeller control back until it reaches redline RPM Allow the RPM to stabilize Land the aircraft without touching the propeller control lever Adjust the propeller stop screw to the propeller control location Rig the aircraft power controls in accordance with the instructions of the manufacturer Do another flight test to verify the correct setting INITIO TA GIN 7 Propeller Fails to Contr
183. used part is cracked the part must be replaced 61 00 06 Page 806 McCauley Propeller Systems Mar 13 2013 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL 053 RECOMMENDED BLADE REPAIR 1 i REPAIR TYPICAL RADIUS 10d x zi TYPICAL CENTER AT DEEPEST POINT S SURFACE REPAIR d DEPTH OF REPAIR bd 2 5 x DEPTH OF REPAIR 10d 10 x DEPTH OF REPAIR FOR EDGE REPAIR ONLY d DEPTH OF NICK 0 031 INCH 0 8 mm FOR SURFACE REPAIR ONLY d DEPTH OF NICK 0 002 INCH 0 05 mm SURFACE REPAIR 2 D gt m Field Blade Rework Criteria Figure 802 Sheet 1 61 00 06 Page 807 McCauley Propeller Systems Mar 13 2013 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL 054 CORRECT LEAD EDGE REWORK METHOD d DEPTH OF NICK 0 031 INCH 0 8 mm ORIGINAL AIRFOIL ORIGINAL LEAD EDGE RADIUS SECTION INCORRECT LEAD EDGE REWORK METHOD N LEAD EDGE RADIUS TOO LARGE PROFILE CONTOUR TOO BLUNT GENERAL RULES DO NOT REDUCE THE MAXIMUM THICKNESS OF SECTION KEEP THE ORIGINAL LEAD EDGE RADIUS BLEND TO THE PROFILE OF THE AIRFOIL SECTION Field Blade Rework Criteria Figure 802 Sheet 2 61 00 06 Page 808 McCauley Propeller Systems Mar 13 2013 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL PROPELLER INSTALLATION PARTS LIST 1 General A Use the Installation Parts List to identify
184. y inspection Corrosion Other than small areas of light surface corrosion with no evidence of pitting the presence of corrosion may require propeller removal and reconditioning by an appropriately rated repair facility Intergranular corrosion may be present when the corrosion protective coatings paint anodize etc have been lost Corrosion pitting should be removed as described in the overhaul manual and applicable ADs Unauthorized Straightening of Blades 1 A bent propeller cannot be straightened without special processing in an FAA approved Part 145 Propeller Repair Station or international equivalent because bending may harden the aluminum and lead to catastrophic blade failure 2 All blades showing evidence of unapproved repairs require removal of the entire propeller and proper assessment by an FAA approved Part 145 Propeller Repair Station or international equivalent 3 Sighting along the leading edge of a propeller blade for any signs of bending can also provide evidence of unapproved blade straightening 4 Any deformation of the flat portion such as bows or kinks may indicate previous unauthorized straightening of the blade 5 Careful visual inspection of the leading edges and the flat faced portion of the blade may sometimes detect unapproved repairs 6 Blades should also be examined for any discoloration that would indicate unauthorized heating a Aluminum blades that have been heated for any repair must be remove

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