Field Service Engineer McCauley Propeller Systems Building On The Best Gary Peak Field Service Engineer McCauley Propeller Systems Gary 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.

Product Support for 2010 Technical Publications McCauley Training Foreign Certifications Threaded Propellers Service Bulletins & Letters Pending service Information Field Issues These are the topics that I would like to cover today At 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

Recent Manual Revisions MPC26 CD Owner’s Manual Rev. 1 Original issue April, 2008 Rev. 1 issued December, 2009 added the information for fixed pitch propellers Contains owner’s manual information for all C200 through C1100 series as well as fixed pitch aluminum propellers This CD is to be supplied with all constant speed and FP propellers Logbooks are still being supplied separately with each propeller

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 information Will include all De-Ice information (830415 De-ice manual will be obsolete) The majority of revisions just incorporated published service information

New Product Manuals MPC28 Owner’s Manual – Fixed Pitch Composite MPC110 Service/Overhaul Manual – Fixed Pitch Composite MPC3400 Service/Overhaul Manual- Constant Speed Composite MPC27 Propeller Operator’s Manual Composite Propellers BOM200 Blade Overhaul Manual (Constant Speed Composite Blades) Composite FP manuals will release 3rd quarter this year

McCauley Training McCauley Training Advantages: Flexible training schedule Class book provided can be used for future reference Competitive prices Knowledgeable trainers Cost effective way to train new employees without disrupting existing personnel Assistance in making lodging and rental car arrangements McCauley training facility is located in Wichita We offer a full line of overhaul, assembly/disassembly, and informational training Visit the website to obtain specific course descriptions and scheduling information

New Courses for 2010 C300/C500 Feathering Propeller Overhaul Intro. to McCauley Propeller and Field Maintenance Fixed Pitch Propeller Maintenance Boot R& I Optional With Constant Speed Overhaul The course listed here are new courses which were recently added

McCauley Training Available Classes Constant Speed Overhaul Turbine Overhaul Blade Overhaul Manual C703 Field Reassembly C1103 Field Reassembly Courses Can Be Combined Visit www.mccauley.textron.com for a full list of available courses McCauley training facility is located in Wichita We offer a full line of overhaul, assembly/disassembly, and informational training Visit the website to obtain specific course descriptions and scheduling information

Owner’s/Operators Class Propeller/Governor operation theory Participate in a build up/tear down of a C400 series propeller Discussion of active service letters and service bulletins Geared towards aircraft owner’s and A&P’s that desire a better understanding of propellers and propeller operation Enables the pilot to better recognize potential areas of concern thus enhancing safety Does not qualify the students to perform any propeller maintenance

Composite Training Development Composite Blade Overhaul 1L100 Overhaul C3400 Overhaul With the addition of composites to the McCauley product line, three new classes will be created for these new products Classes are still under development

Composite Blade Overhaul Class Damage assessment/Inspection Minor blade repair Leading edge guard replacement Resonance testing Damage assessment of the composite blade is if the black carbon has been damaged, the blade is scrap 3 layers of glass are over the carbon layer (approximately .030”) Blade repair will be similar to those used by other composite blade manufacturers Minor cracks in the LEG will be acceptable Removal and replacement of a LEG will be accomplished in class Additionally, the final determination of serviceability will be the resonance test X% of stiffness loss will be acceptable, anything over the limit will be scrap

C3400 Composite Overhaul Class Design overview Operational differences Damage assessment Assembly/Disassembly Adjustments Hub repairs With 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 weight This enables the replacement of a single blade in an assembly

1L100 Composite Overhaul Class Damage assessment/Inspection Minor Blade repair Leading edge guard replacement Resonance testing Damage assessment and repair will be very similar to the constant speed blades with the addition of inspection/repair in the hub area Resonance testing will also be similar, but will utilize a different mounting method

Composite Tooling Requirements Majority of tools utilized are common with other composite blade manufacturer’s McCauley specific tooling: Resonance Test Equipment Resonance Testing Fixture/Adapter Shank adapter for utilizing existing collets Majority of tools/equipment are common to other composite blades Vacuum pump required for installation of new LEG and surface repairs Can hopefully utilize existing table at facility for testing A shank adapter will be required to utilize current 90 collets with the smaller constant speed shank

Composite Qualification Complete qualification process still under development Will require procurement of applicable tools and fixtures Approved personnel must complete McCauley composite training May require work to be completed on a “qualification blade” and then approved by McCauley prior to obtaining certification Likely several years before a sizeable population of 1L100 and C3400 series propellers become numerous in the field The 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

Recent Foreign Approvals COUNTRY AUTHORITY MODEL # Aircraft DATE RECD Argentina DNA C443 Cirrus SR22 3/12/2009 Brazil ANAC C447 - STC Cessna 400 8/11/2009 Indonesia DGCA 1A170/JHA Cessna 172 R/S 9/1/2009 1C235/LFA Cessna 172 R Korea CASA C98 Cessna A188B 8/14/2009 China CAAC Cessna 172R/S 9/15/2010 Cessna 172R C431 Cessna 182T C442 Cessna T182T C432 Cessna 206H/T206H I’ll make a quick mention of some recent foreign certifications These are some older approvals, but have been issued since our last WAPA meeting. 16

Recent Foreign Approvals COUNTRY AUTHORITY MODEL # Aircraft DATE RECD China CAAC C444/C447 Cessna 350/400 Submitted Germany EASA C447 Cessna 400 03/09/2010 Ukraine SAA C768 King Air C90A C703 Cessna 208/208B Most of these are Cessna applications and are done to support production deliveries Currently on an as requested basis from a specific customer or OEM Will be putting more emphasis on foreign approvals in the future Let us know if there is a high demand for a particular propeller that is not approved in your area, suggestions are always welcome 17

Threaded Propeller Part Production Ceased production of threaded blades in 2002 Last parts orders for threaded parts was 10/1/2010 Consumables and other purchase parts will continue to be available through McCauley Technical support of the product line will continue indefinitely 99% of threaded propeller applications have another propeller alternative whether it be a McCauley or another manufacturer Difficult to manufacture and inspect due to close tolerances and complex, truncated threads Introduce Chris Bell

Threaded Propeller Parts Stopped Sept 17, 2010

Service Information Overview Service information released since last WAPA meeting: Service Bulletins SB137AE ASB221E ASB250A ASB255A SB263 ASB264 Service Letters SL2008-3 SL2009-1 SL2010-1A SL2010-2 SL2010-3 Service Bulletins SB137AE, ASB221E, ASB250A, ASB255A, SB263, ASB264. Service Letters SL2008-3, SL2009-1, SL2010-1A, SL2010-2

Service Bulletins SB137AE - Time Between Overhaul (TBO) Adds long term storage requirements for TD propellers Increased governor TBO from 1800 hours/60 months to 2000 hours/60 months Adds a table with all of our component life limits Adds long term storage requirements for TD propellers Increased governor TBO from 1800 hours/60 months to 2000 hours/60 months Adds a table with all of our component life limits

Service Bulletins ASB221E – Inspection of 1A103/TCM Changes from ASB221D to ASB221E Adds inspection and reaming of the bolt holes Adds visual and mag particle inspection of steel reinforcement plate Adds mag particle inspection of mounting bolts Adds visual inspection of mylar gasket AD 2010-04-05, effective March 10, 2010 Adds inspection and reaming of the bolt holes Adds visual and mag particle inspection of steel reinforcement plate Adds mag particle inspection of mounting bolts Adds visual inspection of mylar gasket

Service Bulletins ASB221E (continued) ASB221E vs. AD 2010-04-05 The difference between the ASB and the AD is the repetitive inspection ASB221E has a repetitive inspection every 750 hours or 36 months, whichever occurs first AD 2010-04-05 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 inspection ASB221E has a repetitive inspection every 750 hours or 36 months, whichever occurs first AD 2010-04-05 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.

Service Bulletins ASB250A – Hub life limits for C1101 – C1104 C1101, C1102, C1103, and C1104 hubs are now life limited to 6000 hours TTSN All hubs with more than 5750 hours TTSN Remove from service within next 250 hours TIS All hubs with less than 5750 hours TTSN Remove from service upon reaching 6000 hours TSN

Service Bulletins ASB255A – Jetstream J41 blade life limits and added blade inspections All C1101-1104 blades are now life limited to 3,500 hours TTIS

Service Bulletins ASB255A (continued) Changes the inspection compliance For blades with less than 2400 hours TTIS Inspect blades upon reaching 2500 hours TTIS For blades with more than 2400 hours TTIS If blades have been inspected in accordance with ASB255 within past 2400 hours TIS Inspect upon reaching 2500 hours time since last inspection If blades have not been inspected in accordance with ASB255 within the past 2400 hours TIS Inspect blades within next 100 hours TIS

Service Bulletins ASB255A (continued) Removes the repetitive inspection requirement Adds an inspection of the shelf on the blade shank where the split retainers ride C-5963 split retainers are replaced by C-7870 split retainers During reassembly the C-7870 split retainers must be installed with the ends clocked 90 degrees from the counterweight hole

Service Bulletins ASB255A (continued) AD 2009-19-04, effective October 27, 2009 AD has different compliance times than ASB Blades with more than 10,000 hours TSN must be removed from service before next flight Blades with more than 3000 hours TSN must be removed from service within next 500 hours TIS, not to exceed 10,000 hours TSN Blades with less than 3000 hours TSN must be removed from service upon reaching 3500 hours TSN

Service Bulletins SB263 – Measuring feather angle on C652 C652 has a high feather angle There have been issues with incorrect feather measurements and adjustments which resulted in the propellers rotating backwards when feathered Make sure the protractor is on the correct side of 90 degrees

Service Bulletins ASB264 – Hub dowel hole inspection Drill point feature in the bottom of the dowel holes on C1101, C1102, C1103, and C1104 hubs Specific S/N range (041002 thru 090133) Drill point feature can vary in size If it has a drill point feature of any size it is affected.

Service Bulletins ASB264 (continued) Both pictures feature different size drill points Use a magnifying glass, wooden stick or transfer putty to help identify drill the point There is a warranty program for this ASB

Service Letters SL2008-3 Added additional pitch range for the 1A100 and 1A135 fixed pitch

Service Letters SL2009-1 (New fixed pitch model) 1A162/TCD6754 Installed on Cessna 162 Skycatcher Designed for TCM O-200-D engine with lightweight “star” flange Requires proper indexing for smooth operation Segment of crankshaft flange with flat spot at 12 o’clock and the prop at 10 and 4 position Picture if flat spot??

Service Letters

Service Letters SL2010-1A (new governor models) C290D3/T53 C290D4/T5 Single rpm governor used on Cirrus SR22T C290D4/T5 Created for Atlantic Aero Inc for their IO-550 STC conversions on the Cessna 206 and 210 DCFUS290D10/T8 Counter-rotating mag head governor created for Colemill Enterprises on their Piper Navajo/Chieftain synch system STC conversions

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.

Service Letters SL2010-3 (new cylinder gasket) Rubber gasket that does not use permatex. Initially approved for use on C432 only Have been field testing it for 1 ½ years with no leakage problems Neqw rubber gasket eliminates the need for all the retorquing

Application Guide MAG (McCauley Application Guide) Latest revision is February 2010 Added Non-McCauley STC’s It is available on the McCauley website Let 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.

Pending Service Letters SL2010-X (single piece piston rod) Single piece piston rods for C300 and C500 series propellers Will eliminate pressure checking piston rods and leakage issues at the brazed connection between the two pieces.

Pending Service Letters SL2010-X 1L100 Spacer removal

Pending Service Letters SL2010-X Definitions of a Service Letter and Service Bulletin

Field Issues Deice lead restrainer strap installation Still having issues with tearing deice boots Purpose of the restrainer strap is to hold down the lead not the boot Looking at the feasibility of leaving the restrainer strap location the same but positioning the boot farther outboard

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.

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.

Bonus C400 series fixed pitch

Field Service Engineer McCauley Propeller Systems Building On The Best Gary Peak Field Service Engineer McCauley Propeller Systems 5800 East Pawnee Wichita, Ks 67218 800-621-7767 316-831-3844 gpeak@mccauley.textron.com Gary 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.