Presentation on theme: "Field Service Engineer McCauley Propeller Systems"— Presentation transcript:
1 Field Service Engineer McCauley Propeller Systems Building On The BestGary PeakField Service EngineerMcCauley Propeller SystemsGary J. told me I had one hour to present McCauley items, and if you were here at my last presentation you know, you do not want to listen to me for an hour. So I’ll try to make this as short and painless as possible.I’ve got 10 pieces of service information to mention the revision of, and some training, along with the current status of McCauley We are not sending production to MEXICO” we are staying in the US.
2 Product Support for 2010 Technical Publications McCauley Training Foreign CertificationsThreaded PropellersService Bulletins & LettersPending service InformationField IssuesThese are the topics that I would like to cover todayAt the completion of these subjects, Chris Bell will be up to discuss new and upcoming service information in addition to some ongoing field issues that we have been receiving reports about
3 Recent Manual Revisions MPC26 CD Owner’s Manual Rev. 1Original issue April, 2008Rev. 1 issued December, 2009 added the information for fixed pitch propellersContains owner’s manual information for all C200 through C1100 series as well as fixed pitch aluminum propellersThis CD is to be supplied with all constant speed and FP propellersLogbooks are still being supplied separately with each propeller
4 Planned Manual Revisions MPC1100 (est. completion 4th qtr 2010)?CMM1100 (est. completion 4th qtr 2010)?BOM100 (est. completion 4th qtr 2010)?SPM100 (est. completion 4th qtr 2010)Should include C3400 hub informationWill include all De-Ice information( De-ice manual will be obsolete)The majority of revisions just incorporated published service information
6 McCauley Training McCauley Training Advantages: Flexible training scheduleClass book provided can be used for future referenceCompetitive pricesKnowledgeable trainersCost effective way to train new employees without disrupting existing personnelAssistance in making lodging and rental car arrangementsMcCauley training facility is located in WichitaWe offer a full line of overhaul, assembly/disassembly, and informational trainingVisit the website to obtain specific course descriptions and scheduling information
7 New Courses for 2010 C300/C500 Feathering Propeller Overhaul Intro. to McCauley Propeller and Field MaintenanceFixed Pitch Propeller MaintenanceBoot R& I Optional With Constant Speed OverhaulThe course listed here are new courses which were recently added
8 McCauley Training Available Classes Constant Speed Overhaul Turbine OverhaulBlade Overhaul ManualC703 Field ReassemblyC1103 Field ReassemblyCourses Can Be CombinedVisit for a full list of available coursesMcCauley training facility is located in WichitaWe offer a full line of overhaul, assembly/disassembly, and informational trainingVisit the website to obtain specific course descriptions and scheduling information
9 Owner’s/Operators Class Propeller/Governor operation theoryParticipate in a build up/tear down of a C400 series propellerDiscussion of active service letters and service bulletinsGeared towards aircraft owner’s and A&P’s that desire a better understanding of propellers and propeller operationEnables the pilot to better recognize potential areas of concern thus enhancing safetyDoes not qualify the students to perform any propeller maintenance
10 Composite Training Development Composite Blade Overhaul1L100 OverhaulC3400 OverhaulWith the addition of composites to the McCauley product line, three new classes will be created for these new productsClasses are still under development
11 Composite Blade Overhaul Class Damage assessment/InspectionMinor blade repairLeading edge guard replacementResonance testingDamage assessment of the composite blade is if the black carbon has been damaged, the blade is scrap3 layers of glass are over the carbon layer (approximately .030”)Blade repair will be similar to those used by other composite blade manufacturersMinor cracks in the LEG will be acceptableRemoval and replacement of a LEG will be accomplished in classAdditionally, the final determination of serviceability will be the resonance testX% of stiffness loss will be acceptable, anything over the limit will be scrap
12 C3400 Composite Overhaul Class Design overviewOperational differencesDamage assessmentAssembly/DisassemblyAdjustmentsHub repairsWith the new internal pitch change mechanisms comes an entirely new assembly procedure and typical composite operational characteristics.Will require rebalance of the propeller blade to a master weightThis enables the replacement of a single blade in an assembly
13 1L100 Composite Overhaul Class Damage assessment/InspectionMinor Blade repairLeading edge guard replacementResonance testingDamage assessment and repair will be very similar to the constant speed blades with the addition of inspection/repair in the hub areaResonance testing will also be similar, but will utilize a different mounting method
14 Composite Tooling Requirements Majority of tools utilized are common with other composite blade manufacturer’sMcCauley specific tooling:Resonance Test EquipmentResonance Testing Fixture/AdapterShank adapter for utilizing existing colletsMajority of tools/equipment are common to other composite bladesVacuum pump required for installation of new LEG and surface repairsCan hopefully utilize existing table at facility for testingA shank adapter will be required to utilize current 90 collets with the smaller constant speed shank
15 Composite Qualification Complete qualification process still under developmentWill require procurement of applicable tools and fixturesApproved personnel must complete McCauley composite trainingMay require work to be completed on a “qualification blade” and then approved by McCauley prior to obtaining certificationLikely several years before a sizeable population of 1L100 and C3400 series propellers become numerous in the fieldThe propeller field maintenance plan is still under development, but please let me know if your shop would be interested in being considered for McCauley composite certification
16 Recent Foreign Approvals COUNTRYAUTHORITYMODEL #AircraftDATE RECDArgentinaDNAC443Cirrus SR223/12/2009BrazilANACC447 - STCCessna 4008/11/2009IndonesiaDGCA1A170/JHACessna 172 R/S9/1/20091C235/LFACessna 172 RKoreaCASAC98Cessna A188B8/14/2009ChinaCAACCessna 172R/S9/15/2010Cessna 172RC431Cessna 182TC442Cessna T182TC432Cessna 206H/T206HI’ll make a quick mention of some recent foreign certificationsThese are some older approvals, but have been issued since our last WAPA meeting.16
17 Recent Foreign Approvals COUNTRYAUTHORITYMODEL #AircraftDATE RECDChinaCAACC444/C447Cessna 350/400SubmittedGermanyEASAC447Cessna 40003/09/2010UkraineSAAC768King Air C90AC703Cessna 208/208BMost of these are Cessna applications and are done to support production deliveriesCurrently on an as requested basis from a specific customer or OEMWill be putting more emphasis on foreign approvals in the futureLet us know if there is a high demand for a particular propeller that is not approved in your area, suggestions are always welcome17
18 Threaded Propeller Part Production Ceased production of threaded blades in 2002Last parts orders for threaded parts was 10/1/2010Consumables and other purchase parts will continue to be available through McCauleyTechnical support of the product line will continue indefinitely99% of threaded propeller applications have another propeller alternative whether it be a McCauley or another manufacturerDifficult to manufacture and inspect due to close tolerances and complex, truncated threadsIntroduce Chris Bell
20 Service Information Overview Service information released since last WAPA meeting:Service BulletinsSB137AEASB221EASB250AASB255ASB263ASB264Service LettersSL2008-3SL2009-1SL2010-1ASL2010-2SL2010-3Service Bulletins SB137AE, ASB221E, ASB250A, ASB255A, SB263, ASB264. Service Letters SL2008-3, SL2009-1, SL2010-1A, SL2010-2
21 Service Bulletins SB137AE - Time Between Overhaul (TBO) Adds long term storage requirements for TD propellersIncreased governor TBO from 1800 hours/60 months to 2000 hours/60 monthsAdds a table with all of our component life limitsAdds long term storage requirements for TD propellersIncreased governor TBO from 1800 hours/60 months to 2000 hours/60 monthsAdds a table with all of our component life limits
22 Service Bulletins ASB221E – Inspection of 1A103/TCM Changes from ASB221D to ASB221EAdds inspection and reaming of the bolt holesAdds visual and mag particle inspection of steel reinforcement plateAdds mag particle inspection of mounting boltsAdds visual inspection of mylar gasketAD , effective March 10, 2010Adds inspection and reaming of the bolt holesAdds visual and mag particle inspection of steel reinforcement plateAdds mag particle inspection of mounting boltsAdds visual inspection of mylar gasket
23 Service Bulletins ASB221E (continued) ASB221E vs. AD 2010-04-05 The difference between the ASB and the AD is the repetitive inspectionASB221E has a repetitive inspection every 750 hours or 36 months, whichever occurs firstAD requires the repetitive inspection be performed every 750 hours. There is no calendar limit on the AD.If the propeller was previously inspected per ASB221C or D the initial inspection is not required. The repetitive inspection schedule should be followed.The difference between the ASB and the AD is the repetitive inspectionASB221E has a repetitive inspection every 750 hours or 36 months, whichever occurs firstAD requires the repetitive inspection be performed every 750 hours. There is no calendar limit on the AD.If the propeller was previously inspected per ASB221C or D the initial inspection is not required. The repetitive inspection schedule should be followed.
24 Service Bulletins ASB250A – Hub life limits for C1101 – C1104 C1101, C1102, C1103, and C1104 hubs are now life limited to 6000 hours TTSNAll hubs with more than 5750 hours TTSNRemove from service within next 250 hours TISAll hubs with less than 5750 hours TTSNRemove from service upon reaching 6000 hours TSN
25 Service BulletinsASB255A – Jetstream J41 blade life limits and added blade inspectionsAll C blades are now life limited to 3,500 hours TTIS
26 Service Bulletins ASB255A (continued) Changes the inspection complianceFor blades with less than 2400 hours TTISInspect blades upon reaching 2500 hours TTISFor blades with more than 2400 hours TTISIf blades have been inspected in accordance with ASB255 within past 2400 hours TISInspect upon reaching 2500 hours time since last inspectionIf blades have not been inspected in accordance with ASB255 within the past 2400 hours TISInspect blades within next 100 hours TIS
27 Service Bulletins ASB255A (continued) Removes the repetitive inspection requirementAdds an inspection of the shelf on the blade shank where the split retainers rideC-5963 split retainers are replaced by C-7870 split retainersDuring reassembly the C-7870 split retainers must be installed with the ends clocked 90 degrees from the counterweight hole
28 Service Bulletins ASB255A (continued) AD , effective October 27, 2009AD has different compliance times than ASBBlades with more than 10,000 hours TSN must be removed from service before next flightBlades with more than 3000 hours TSN must be removed from service within next 500 hours TIS, not to exceed 10,000 hours TSNBlades with less than 3000 hours TSN must be removed from service upon reaching 3500 hours TSN
29 Service Bulletins SB263 – Measuring feather angle on C652 C652 has a high feather angleThere have been issues with incorrect feather measurements and adjustments which resulted in the propellers rotating backwards when featheredMake sure the protractor is on the correct side of 90 degrees
30 Service Bulletins ASB264 – Hub dowel hole inspection Drill point feature in the bottom of the dowel holes on C1101, C1102, C1103, and C1104 hubsSpecific S/N range ( thru )Drill point feature can vary in sizeIf it has a drill point feature of any size it is affected.
31 Service Bulletins ASB264 (continued) Both pictures feature different size drill pointsUse a magnifying glass, wooden stick or transfer putty to help identify drill the pointThere is a warranty program for this ASB
32 Service LettersSL2008-3Added additional pitch range for the 1A100 and 1A135 fixed pitch
33 Service Letters SL2009-1 (New fixed pitch model) 1A162/TCD6754 Installed on Cessna 162 SkycatcherDesigned for TCM O-200-D engine with lightweight “star” flangeRequires proper indexing for smooth operationSegment of crankshaft flange with flat spot at 12 o’clock and the prop at 10 and 4 positionPicture if flat spot??
35 Service Letters SL2010-1A (new governor models) C290D3/T53 C290D4/T5 Single rpm governor used on Cirrus SR22TC290D4/T5Created for Atlantic Aero Inc for their IO-550 STC conversions on the Cessna 206 and 210DCFUS290D10/T8Counter-rotating mag head governor created for Colemill Enterprises on their Piper Navajo/Chieftain synch system STC conversions
36 Service Letters SL2010-2 (C447 oil level) Increased the oil fill level from 1300cc up to 2000cc.As the Cessna Team thought their were experiencing some vibration on the Corvallis 400.
37 Service Letters SL2010-3 (new cylinder gasket) Rubber gasket that does not use permatex.Initially approved for use on C432 onlyHave been field testing it for 1 ½ years with no leakage problemsNeqw rubber gasket eliminates the need for all the retorquing
38 Application Guide MAG (McCauley Application Guide) Latest revision is February 2010Added Non-McCauley STC’sIt is available on the McCauley websiteLet me know if you find any errors or have additional information you want added, or changed.The very helpful application guide of which Chris has done a fantansic job of gathering all the data for this guide, and please Let us know if you find any errors or have additional information you want added, or changed.
39 Pending Service Letters SL2010-X (single piece piston rod)Single piece piston rods for C300 and C500 series propellersWill eliminate pressure checking piston rods and leakage issues at the brazed connection between the two pieces.
40 Pending Service Letters SL2010-X 1L100 Spacer removal
41 Pending Service Letters SL2010-X Definitions of a Service Letter and Service Bulletin
42 Field Issues Deice lead restrainer strap installation Still having issues with tearing deice bootsPurpose of the restrainer strap is to hold down the lead not the bootLooking at the feasibility of leaving the restrainer strap location the same but positioning the boot farther outboard
43 Field Issues Cad plated hardware You may notice a change in the appearance of the Cad plating on some of our hardware. We are changing from type I to type II.
44 Enlist your Help We also want your help. Let us know if you have any ideas for new STC’s or other products to add to our line up.
46 Field Service Engineer McCauley Propeller Systems Building On The BestGary PeakField Service EngineerMcCauley Propeller Systems5800 East PawneeWichita, Ks 67218Gary J. told me I had one hour to present McCauley items, and if you were here at my last presentation you know, you do not want to listen to me for an hour. So I’ll try to make this as short and painless as possible.I’ve got 10 pieces of service information to mention the revision of, and some training, along with the current status of McCauley We are not sending production to MEXICO” we are staying in the US.