1. Technical Issues Review
Presented By:
Michael Mayhill

2. Technical Issues Review
Composite Blades
Aluminum Blades
Hubs
Seals
Spinner
De-ice
Miscellaneous
Status Updates

3. Your Input Appreciated
Some of our best fixes have been suggested by the field
You see these products in normal and extreme conditions every day –
What do you see that is working?
What do you see that is not working?
Do you have suggestions to make something better?

4. Composite Blades ASC II
As of September 24th there were 4087 of the composite N7605( ) blades manufactured
These blades are becoming more and more popular with your customers
We are working to develop new applications
More are manufactured every day

5. Composite Blades ASC II
HC-SL :
Field Inspection and Minor Repair Criteria for N7605( ) blades [May 07/09]
Previously in Manual 135F only

6. Composite Blades ASC II
HC-SL :
Defines permitted field repairs for A&P mechanics
Damage beyond minor repair limitations must go to a certified propeller service facility

7. Composite Blades Inspection
HC-ASB rev. 2:
N7605B blade ‘crack’ indication in boot area
Evaluation found ‘soft spot’ at the ‘crack’ location
Resin did not properly cure during early production process

8. Composite Blades Inspection
HC-ASB rev. 2:
Inspections of N7605( )
Effectivity is s/n specific to early production
387 blades affected

9. Composite Blades Inspection
HC-ASB rev. 2:
Visual Inspection:
Recurring visual inspection every 100 hrs/annual
Reporting required
A&P can accomplish
Warranty coverage for visual

10. Composite Blades Inspection
HC-ASB rev. 2: Inspection of N7605( )
Terminating Action UT Inspection at or before overhaul
Reporting required
Accomplished by Level II or III
52 inspections completed, 6 blades replaced

11. Composite Blades Inspection

12. Composite Blades Inspection

13. Composite Blades Inspection
HC-ASB rev. 2: Inspection of N7605( )
UT equipment available for loan
Warranty coverage for UT at overhaul

14. Composite Blades Staking Pins
Staking pins found sheared during standard engineering evaluation of high-time N7605( )blade
No performance issues noted
Design improvement with larger staking pins
Not Safety of Flight

15. Composite Blades Staking Pins
HC-SB : Staking Pins [pending]
Affects N7605( ) and N7893( ) blades by s/n
3658 blades
Terminating Action at overhaul
Index to new location
Insert new, larger pins
Does not affect life of product
Not Safety of Flight

16. Composite Blades Staking Pins
Was B Ø=0.125”
Now B Ø=0.1875”
(Production)

17. Aluminum Blades Production Rolling Issue
HC-SB rev. 1: Blade Inspection [Jun 15/10]
Internal production process issue
M, P, and R shank blades from Jul 09 – Jan 10
Cost analysis led to engineering review
Reduced minimums approved
Manual update pending

18. Aluminum Blades Production Rolling Issue
HC-SB rev. 1: Blade Inspection [Jun 15/10]
M, P, and R shank blades by s/n
K85813 – K97065
Optical Comparator Inspection
Factory only rework

19. Aluminum Blades Production Rolling Issue
HC-SB rev. 1: Blade Inspection [Jun 15/10]
Reworked and non-reworked may be mixed in a propeller assembly if balance can be achieved
No loss of clamping force due to clamp design

20. Aluminum Blades NaCl Contamination
HC-ASB : Blade Replacement [pending]
Fissure indication in the blade bore discovered at overhaul inspection
Originated from Sodium Chloride contamination within the ingot
Potentially all blades forged from that ingot could be contaminated

21. Aluminum Blades NaCl Contamination
HC-ASB : Blade Replacement [pending]
Affects Y-shank aluminum blades by serial number
452 blades affected
82 left Hartzell as blade only shipment
We are Considering:
Replacement within 250 hours/ 24 calendar months, whichever occurs first
Any inventory/stock replacement within 24 calendar months

22. Aluminum Blades NaCl Contamination
HC-ASB : Blade Replacement [pending]
Affected blades MUST be retired and destroyed
Airworthiness Directive is possible
Warranty:
Replacement Blades free of charge until Nov 30, 2016
Some additional coverage for props maintained IAW SL61Y

23. Hubs Lubrication Fittings
HC-SL rev. 3: 45˚ Lubrication Fitting [Nov 13/09]
Originally issued Oct 15/98
Revision 3 removed torque
“Tighten until snug”
Any issues with the zerk fittings?
1900D operators are removing zerk fittings for service every 400 hrs – seeing several broken zerks

24. Hubs Modification HC-SI-61-206: Hub Modification – Bore Bushing
Dimensional specifications for machining of bore and bushing on lightweight turbine propellers
Available on request
Revision needed for additional part numbers
Pending Changes related to Sample Program review

25. Hubs 1900D Inspection HC-ASB-61-316 rev. 1: Hub Inspection [Jun 26/09]
Two 1900D hubs found fractured near dowel holes and oversize inserts on mounting flange
Found at overhaul inspection

26. Hubs 1900D Inspection HC-ASB-61-316 rev. 1: Hub Inspection [Jun 26/09]
~800 hubs affected
Initial visual inspection based on TSO
As required following visual:
ECI
Stamp hub “K”
REPORTING REQUIRED

27. Hubs 1900D Inspection HC-ASB-61-316 rev. 1: Hub Inspection [Jun 26/09]
273 inspected
No indications
Recurring ECI every 1000 hrs
REPORTING REQUIRED
ECI required at each overhaul

28. Hubs Bonanza/Debonair Bushing
HC-SB : Hub Bore Bushing [pending]
Compact -1 propeller on a Beechcraft Bonanza stopped actuating in flight
Investigation found failed bore bushing with oil behind the piston
Hydraulic lock
Service Issue 5750 – Bonanza Bushing

29. Hubs Bonanza/Debonair Bushing
HC-SB : Hub Bore Bushing [pending]
Failure to seal due to:
No bushing
Scored bore / damaged o-ring
Bushing installed with adhesive
Failed adhesive
Bushing Slippage
Service Issue 5750 – Bonanza Bushing

30. Hubs Bonanza/Debonair Bushing
HC-SB : Hub Bore Bushing [pending]
Propeller operates, doesn’t actuate
Defaults to low pitch, high RPM
Operates as fixed pitch propeller
Service Issue 5750 – Bonanza Bushing

31. Hubs Bonanza/Debonair Bushing
HC-SB : Hub Bore Bushing [pending]
Bonanza pilot set up for POH ‘Best Glide’
Not compatible with low pitch, high RPM setting for Bonanza
FAA SAIB-CE issued to notify pilots

32. Hubs Bonanza/Debonair Bushing
HC-SB : Hub Bore Bushing [pending]
Compliance required for any Bonanza or Debonair w/ ( )HC-(C,G,L)(2,3,4)Y(F,K,R)-1( )
Propellers NOT maintained IAW SL61Y: 200 hrs, 12 calendar months, or next major disassembly, whichever occurs first
Propellers maintained IAW SL61Y: next major disassembly or SL61Y overhaul limit, whichever occurs first

33. Hubs Bonanza/Debonair Bushing
HC-SB : Hub Bore Bushing [pending]
Serial number prefix identifies affected hubs
Perform applicable pitch change rod bore repair procedure IAW Manual 202A

34. Hubs Production Bushing (-1)
HC-SL [pending]
Production change for all standard -1 hubs
Does not match 202A repair
Replace bushing at overhaul
No machining required

35. Hubs Production Bushing (-1)
HC-SL [pending]
Production change for all standard -1 hubs
Already implemented in 113B for all Bonanza specific item #
SL305 addresses all remaining standard -1 hubs

36. Hubs TB-10 Inspection HC-SB-61-323: Hub Inspection [pending]
Affects propellers installed on Socata TB-10
ECI of “A” suffix hubs, similar to SB269
Initial within 50 hours
Recurring every 100 hours or annual
Terminating actions:
Hub Replacement with “B” suffix hub
Oil fill IAW SL273 [pending]

37. Hubs Oil-Fill HC-SL-61-273: Hub Modification [pending]
~4500 hrs in field
Only when directed by Hartzell Service Bulletin
Machine hub bore & breather holes
Install bushing & retainer ring

38. Hubs Oil-Fill HC-SL-61-273: Hub Modification [pending]
Only when directed by Hartzell Service Bulletin
New sealant at parting line
Plugs instead of zerks
Red-dyed oil-filled for crack detection

39. Seals Grease Leaks Silicone O-rings
Grease leaks have been a concern in aluminum hub propellers
Suggestion from the field for use of new material
Engineering analysis for compatibility completed

40. Seals Grease Leaks Silicone O-rings
Field testing in alum models ongoing
Over 30,000 SER hours with NO leaks
Already implemented in production for many models
Successful seal is also dependent upon a good installation of the appropriate wear strip

41. Seals Grease Leaks
HC-SL rev. 1: Y Shank Aluminum Blades [Mar 12/10]
Introduces C
Approved alternate to quad seal
Requires use of 0.010” Teflon®
Cost analysis in process for production implementation

42. Seals Grease Leaks HC-SL-61-301: Supersedes all C-3317-340 [Mar 12/10]
Introduces C
Requires use of 0.010” Teflon® on alum blades
Use existing C
Composite blades use different wear strip
No change required
Production implemented

43. Seals Grease Leaks
HC-SL : Supersedure in 1900D Installations [Apr 9/10]
Introduces C
May use existing energizer ring + blade seal in combination

44. Seals Grease Leaks
HC-SL : Supersedure in 1900D Installations [Apr 9/10]
Energizer ring + blade seal can not be mixed with C in same propeller assembly
Production and overhaul kit implementation is complete

45. Seals Grease Leaks
HC-SB : Replacement in PC-21 Installations [Jun 15/10]
Introduces C and wear strip
Required at next o/h
Optional at disassembly
Requires use of thicker wear strip

46. Seals Grease Leaks
HC-SB : Replacement in PC-21 Installations [Jun 15/10]
Energizer ring + blade seal combination can not be mixed with C in same propeller assembly
Reporting required
Production and o/h kit implementation complete

47. Seals Grease Leaks HD-SL-61-042:
Supersedure for Do-328 Installations [pending]
Introduces C and wear strip
Requires use of thicker wear strip

48. Seals Grease Leaks HD-SL-61-042:
Supersedure for Do-328 Installations [pending]
Energizer ring + blade seal combination can not be mixed with C in same propeller assembly

49. Spinner Known cracking issues
Working to design a permanent fix by application

50. Spinner 835-54(P) Replacement
HC-SB :
Inspection of (P) Spinner Assembly & Introduction of New Spinner Assemblies
Progression of document
Original Issue:
D (P) dome, filler plate removal required

51. Spinner 835-54(P) Replacement
HC-SB :
Inspection of (P) Spinner Assembly & Introduction of New Spinner Assemblies
Progression of document
Original Issue:
(P) dome released as supercedure to unsupported D (P)
102965(P) includes bonded support

52. Spinner 835-54(P) Replacement
HC-SB , Rev 1:
Inspection of (P) Spinner Ass’y & Introduction of New Spinner Assemblies
Revision 1
D (P) dome uses field-installable forward bulkhead & spacers

53. Spinner 835-54(P) Replacement
HC-SB , Rev 1:
Inspection of (P) Spinner Ass’y & Introduction of New Spinner Assemblies
No-Charge Warranty Components

54. Spinner 835-54(P) Replacement
HC-SB , Rev 3:
New Composite Spinner Ass’y Introduction
Revision 2 (pending)
Terminating Action within 13 calendar months/ 50 hours, whichever first

55. Spinner 835-54(P) Replacement
HC-SB , Rev 3:
New Spinner Ass’y Introduction
103585(F1) assembly with composite dome (Mooney)
(P) assembly with blunt, aluminum dome (Comanche)
No Charge Warranty Coverage

56. De-Ice Hartzell de-ice components
Working to convert legacy components to Hartzell components
Making design improvements along the way
Your suggestions are welcome
If you have found a difficult installation and/or have design/installation suggestions please let us know

57. De-Ice PC-12 Routing
HC-SL rev. 2: Wire Harness and Boot for PC-12 [Apr 9/10]
Conversion to Hartzell components
Design improvements
New routing required
Expect similar updates for similar installations

58. Miscellaneous TSN Questions on Time Since New of a propeller
What parts to track time for
What happens when components are changed out
HC-SL-61-61Y rev. 3: Overhaul & Life Limits [Nov 13/09]
Definition of Time Since New (TSN)
Primary components = hub, blades, & life-limited parts
Propeller assembly TSN = highest TSN primary component installed

59. Miscellaneous Cam Follower Retention
HC-SB [June 2010]:
Pitch Change Knob Bracket
Affects HC-E5A-2 on Pilatus PC-21
Introduces new unit with improved cam follower retention design

60. Miscellaneous Preload Plate Wear
HC-SL rev. 1, [Nov 09]:
Preload Plate Wear Limits
E shank blade butt seal released in 2005 to prevent hub cavity grease migration
Later reports identified wear on the preload plate caused by the new seal

61. Miscellaneous Preload Plate Wear
HC-SL rev. 1, [Nov 09]: Preload Plate Wear Limits
Affects E shank lightweight turbines and Y shank compacts with composite blades (excludes N shank)
Preload plate inspection criteria at overhaul
What are you seeing in the field?

62. Miscellaneous Feathering Spring
HC-SL [obs] → HC-SB [pending]:
Feathering Compression Spring
Reports of feathering issues in the field
Unable to reach full feather at shutdown
Disassembly found fractured feathering spring

63. Miscellaneous Feathering Spring
HC-SL [obs] → HC-SB [pending]:
Feathering Compression Spring
Affects HC-B(4,5)(M,T)(A,N,P)-(1,2,3,5)
Introduces spring as supercedure to A-3496
New has flat outer diameter and improved fatigue life

64. Miscellaneous Feathering Spring
HC-SL [obs] → HC-SB [pending]:
Feathering Compression Spring
(new in SB324) At next overhaul, requires replacement of the A-3496 with new

65. Status Updates SB269 Program
HC-SB rev. 4: Hub Inspection [Nov 13/09]
FAA approved AMOC to AD
AD superseded AD
AD requires initial inspection within 50 flight hours
Contact local FSDO to discuss
Retained 100 flight hour recurring inspection
Removed ‘or annual inspection’
Pricing program (within TBO) expires April 30, 2011

66. Technical Issues Review
Documents go through writing, review, editing, and approval – but still not perfect
If you want clarification
If you find an error
If you have a suggestion
PLEASE CONTACT PRODUCT SUPPORT