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The information in this presentation is not intended to supersede, replace, or be used in lieu of approved published documentation. 1 Technical Issues.

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Presentation on theme: "The information in this presentation is not intended to supersede, replace, or be used in lieu of approved published documentation. 1 Technical Issues."— Presentation transcript:

1 The information in this presentation is not intended to supersede, replace, or be used in lieu of approved published documentation. 1 Technical Issues Review Presented By: Michael Mayhill

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

3 3 Your Input Appreciated Some of our best fixes have been suggested by the field Some of our best fixes have been suggested by the field You see these products in normal and extreme conditions every day – 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 4 Composite Blades ASC II As of September 24 th there were 4087 of the composite N7605( ) blades manufactured As of September 24 th there were 4087 of the composite N7605( ) blades manufactured These blades are becoming more and more popular with your customers These blades are becoming more and more popular with your customers We are working to develop new applications We are working to develop new applications More are manufactured every day More are manufactured every day

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

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

7 7 Composite Blades Inspection HC-ASB rev. 2: HC-ASB rev. 2: N7605B blade ‘crack’ indication in boot area 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 8 Composite Blades Inspection HC-ASB rev. 2: HC-ASB rev. 2: Inspections of N7605( ) Inspections of N7605( ) –Effectivity is s/n specific to early production –387 blades affected

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

10 10 Composite Blades Inspection HC-ASB rev. 2: Inspection of N7605( ) HC-ASB rev. 2: Inspection of N7605( ) –Terminating Action UT Inspection at or before overhaul Reporting requiredReporting required Accomplished by Level II or IIIAccomplished by Level II or III 52 inspections completed, 6 blades replaced52 inspections completed, 6 blades replaced

11 11 Composite Blades Inspection

12 12 Composite Blades Inspection

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

14 14 Composite Blades Staking Pins Staking pins found sheared during standard engineering evaluation of high-time N7605( )blade Staking pins found sheared during standard engineering evaluation of high-time N7605( )blade –No performance issues noted –Design improvement with larger staking pins

15 15 Composite Blades Staking Pins HC-SB : Staking Pins [pending] HC-SB : Staking Pins [pending] –Affects N7605( ) and N7893( ) blades by s/n 3658 blades3658 blades –Terminating Action at overhaul Index to new locationIndex to new location Insert new, larger pinsInsert new, larger pins –Does not affect life of product

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

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

18 18 Aluminum Blades Production Rolling Issue HC-SB rev. 1: Blade Inspection [Jun 15/10] HC-SB rev. 1: Blade Inspection [Jun 15/10] –M, P, and R shank blades by s/n K85813 – K97065K85813 – K97065 –Optical Comparator Inspection –Factory only rework

19 19 Aluminum Blades Production Rolling Issue HC-SB rev. 1: Blade Inspection [Jun 15/10] 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 20 Aluminum Blades NaCl Contamination HC-ASB : Blade Replacement [pending] 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 21 Aluminum Blades NaCl Contamination HC-ASB : Blade Replacement [pending] HC-ASB : Blade Replacement [pending] –Affects Y-shank aluminum blades by serial number 452 blades affected452 blades affected 82 left Hartzell as blade only shipment82 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 monthsAny inventory/stock replacement within 24 calendar months

22 22 Aluminum Blades NaCl Contamination HC-ASB : Blade Replacement [pending] 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, 2016Replacement Blades free of charge until Nov 30, 2016 Some additional coverage for props maintained IAW SL61YSome additional coverage for props maintained IAW SL61Y

23 23 Hubs Lubrication Fittings HC-SL rev. 3: 45˚ Lubrication Fitting [Nov 13/09] HC-SL rev. 3: 45˚ Lubrication Fitting [Nov 13/09] –Originally issued Oct 15/98 –Revision 3 removed torque “Tighten until snug”“Tighten until snug” Any issues with the zerk fittings? Any issues with the zerk fittings?

24 24 Hubs Modification HC-SI : Hub Modification – Bore Bushing HC-SI : 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 Pending Changes related to Sample Program review

25 25 Hubs 1900D Inspection HC-ASB rev. 1: Hub Inspection [Jun 26/09] HC-ASB 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 26 Hubs 1900D Inspection HC-ASB rev. 1: Hub Inspection [Jun 26/09] HC-ASB rev. 1: Hub Inspection [Jun 26/09] –~800 hubs affected –Initial visual inspection based on TSO –As required following visual: ECIECI Stamp hub “K”Stamp hub “K” REPORTING REQUIREDREPORTING REQUIRED

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

28 28 Hubs Bonanza/Debonair Bushing HC-SB : Hub Bore Bushing [pending] 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

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

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

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

32 32 Hubs Bonanza/Debonair Bushing HC-SB : Hub Bore Bushing [pending] 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 firstPropellers 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 firstPropellers maintained IAW SL61Y: next major disassembly or SL61Y overhaul limit, whichever occurs first

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

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

35 35 Hubs Production Bushing (-1) HC-SL [pending] HC-SL [pending] –Production change for all standard -1 hubs Already implemented in 113B for all Bonanza specific item #Already implemented in 113B for all Bonanza specific item # SL305 addresses all remaining standard -1 hubsSL305 addresses all remaining standard -1 hubs

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

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

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

39 39 Seals Grease Leaks Silicone O-rings 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 40 Seals Grease Leaks Silicone O-rings 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 Successful seal is also dependent upon a good installation of the appropriate wear strip

41 41 Seals Grease Leaks HC-SL rev. 1: Y Shank Aluminum Blades [Mar 12/10] 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 42 Seals Grease Leaks HC-SL : HC-SL : Supersedes all C [Mar 12/10] Supersedes all C [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 requiredNo change required –Production implemented

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

44 44 Seals Grease Leaks HC-SL : Supersedure in 1900D Installations [Apr 9/10] 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 45 Seals Grease Leaks HC-SB : Replacement in PC-21 Installations [Jun 15/10] 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 46 Seals Grease Leaks HC-SB : Replacement in PC-21 Installations [Jun 15/10] 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 47 Seals Grease Leaks HD-SL : HD-SL : Supersedure for Do-328 Installations [pending] Supersedure for Do-328 Installations [pending] –Introduces C and wear strip –Requires use of thicker wear strip

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

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

50 50 Spinner (P) Replacement HC-SB : HC-SB : Inspection of (P) Spinner Assembly & Introduction of New Spinner Assemblies –Progression of document Original Issue:Original Issue: 1.D (P) dome, filler plate removal required

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

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

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

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

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

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

57 57 De-Ice PC-12 Routing HC-SL rev. 2: Wire Harness and Boot for PC-12 [Apr 9/10] 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 58 Miscellaneous TSN Questions on Time Since New of a propeller 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] 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 59 Miscellaneous Cam Follower Retention HC-SB [June 2010]: 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 60 Miscellaneous Preload Plate Wear HC-SL rev. 1, [Nov 09]: 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 sealLater reports identified wear on the preload plate caused by the new seal

61 61 Miscellaneous Preload Plate Wear HC-SL rev. 1, [Nov 09]: Preload Plate Wear Limits 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? What are you seeing in the field?

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

63 63 Miscellaneous Feathering Spring HC-SL [obs] → HC-SB [pending]: 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 lifeNew has flat outer diameter and improved fatigue life

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

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

66 66 Technical Issues Review Documents go through writing, review, editing, and approval – but still not perfect 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

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