Technical Issues Review Presented By: Michael Mayhill

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

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?

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

Composite Blades ASC II HC-SL-61-294: Field Inspection and Minor Repair Criteria for N7605( ) blades [May 07/09] Previously in Manual 135F only

Composite Blades ASC II HC-SL-61-294: Defines permitted field repairs for A&P mechanics Damage beyond minor repair limitations must go to a certified propeller service facility

Composite Blades Inspection HC-ASB-61-306 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

Composite Blades Inspection HC-ASB-61-306 rev. 2: Inspections of N7605( ) Effectivity is s/n specific to early production 387 blades affected

Composite Blades Inspection HC-ASB-61-306 rev. 2: Visual Inspection: Recurring visual inspection every 100 hrs/annual Reporting required A&P can accomplish Warranty coverage for visual

Composite Blades Inspection HC-ASB-61-306 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

Composite Blades Inspection

Composite Blades Inspection

Composite Blades Inspection HC-ASB-61-306 rev. 2: Inspection of N7605( ) UT equipment available for loan Warranty coverage for UT at overhaul

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

Composite Blades Staking Pins HC-SB-61-319: 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

Composite Blades Staking Pins Was B-5996-628 Ø=0.125” Now B-5996-640 Ø=0.1875” (Production)

Aluminum Blades Production Rolling Issue HC-SB-61-318 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

Aluminum Blades Production Rolling Issue HC-SB-61-318 rev. 1: Blade Inspection [Jun 15/10] M, P, and R shank blades by s/n K85813 – K97065 Optical Comparator Inspection Factory only rework

Aluminum Blades Production Rolling Issue HC-SB-61-318 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

Aluminum Blades NaCl Contamination HC-ASB-61-322: 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

Aluminum Blades NaCl Contamination HC-ASB-61-322: 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

Aluminum Blades NaCl Contamination HC-ASB-61-322: 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

Hubs Lubrication Fittings HC-SL-61-187 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

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

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

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

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

Hubs Bonanza/Debonair Bushing HC-SB-61-315: 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

Hubs Bonanza/Debonair Bushing HC-SB-61-315: 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

Hubs Bonanza/Debonair Bushing HC-SB-61-315: 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

Hubs Bonanza/Debonair Bushing HC-SB-61-315: 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-10-21 issued to notify pilots

Hubs Bonanza/Debonair Bushing HC-SB-61-315: 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

Hubs Bonanza/Debonair Bushing HC-SB-61-315: Hub Bore Bushing [pending] Serial number prefix identifies affected hubs Perform applicable pitch change rod bore repair procedure IAW Manual 202A

Hubs Production Bushing (-1) HC-SL-61-305 [pending] Production change for all standard -1 hubs Does not match 202A repair Replace bushing at overhaul No machining required

Hubs Production Bushing (-1) HC-SL-61-305 [pending] Production change for all standard -1 hubs Already implemented in 113B for all Bonanza specific item # SL305 addresses all remaining standard -1 hubs

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]

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

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

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

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

Seals Grease Leaks HC-SL-61-293 rev. 1: Y Shank Aluminum Blades [Mar 12/10] Introduces C-3317-340-8 Approved alternate to quad seal Requires use of 0.010” Teflon® Cost analysis in process for production implementation

Seals Grease Leaks HC-SL-61-301: Supersedes all C-3317-340 [Mar 12/10] Introduces C-3317-340-8 Requires use of 0.010” Teflon® on alum blades Use existing C-3317-340 Composite blades use different wear strip No change required Production implemented

Seals Grease Leaks HC-SL-61-303: Supersedure in 1900D Installations [Apr 9/10] Introduces C-3317-340-8 May use existing energizer ring + blade seal in combination

Seals Grease Leaks HC-SL-61-303: Supersedure in 1900D Installations [Apr 9/10] Energizer ring + blade seal can not be mixed with C-3317-340-8 in same propeller assembly Production and overhaul kit implementation is complete

Seals Grease Leaks HC-SB-61-321: Replacement in PC-21 Installations [Jun 15/10] Introduces C-3317-341-8 and 103379-1 wear strip Required at next o/h Optional at disassembly Requires use of thicker 103379-1 wear strip

Seals Grease Leaks HC-SB-61-321: Replacement in PC-21 Installations [Jun 15/10] Energizer ring + blade seal combination can not be mixed with C-3317-341-8 in same propeller assembly Reporting required Production and o/h kit implementation complete

Seals Grease Leaks HD-SL-61-042: Supersedure for Do-328 Installations [pending] Introduces C-3317-341-8 and 103379-1 wear strip Requires use of thicker 103379-1 wear strip

Seals Grease Leaks HD-SL-61-042: Supersedure for Do-328 Installations [pending] Energizer ring + blade seal combination can not be mixed with C-3317-341-8 in same propeller assembly

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

Spinner 835-54(P) Replacement HC-SB-61-311: Inspection of 835-54(P) Spinner Assembly & Introduction of New Spinner Assemblies Progression of document Original Issue: D-5769-1(P) dome, filler plate removal required

Spinner 835-54(P) Replacement HC-SB-61-311: Inspection of 835-54(P) Spinner Assembly & Introduction of New Spinner Assemblies Progression of document Original Issue: 2. 102965(P) dome released as supercedure to unsupported D-5769-1(P) 102965(P) includes bonded support

Spinner 835-54(P) Replacement HC-SB-61-311, Rev 1: Inspection of 835-54(P) Spinner Ass’y & Introduction of New Spinner Assemblies Revision 1 D-5769-1(P) dome uses field-installable forward bulkhead & spacers

Spinner 835-54(P) Replacement HC-SB-61-311, Rev 1: Inspection of 835-54(P) Spinner Ass’y & Introduction of New Spinner Assemblies No-Charge Warranty Components

Spinner 835-54(P) Replacement HC-SB-61-311, Rev 3: New Composite Spinner Ass’y Introduction Revision 2 (pending) Terminating Action within 13 calendar months/ 50 hours, whichever first

Spinner 835-54(P) Replacement HC-SB-61-311, Rev 3: New Spinner Ass’y Introduction 103585(F1) assembly with composite dome (Mooney) 2. 835-58(P) assembly with blunt, aluminum dome (Comanche) No Charge Warranty Coverage

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

De-Ice PC-12 Routing HC-SL-30-295 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

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

Miscellaneous Cam Follower Retention HC-SB-61-320 [June 2010]: Pitch Change Knob Bracket Affects HC-E5A-2 on Pilatus PC-21 Introduces new unit with improved cam follower retention design

Miscellaneous Preload Plate Wear HC-SL-61-282 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

Miscellaneous Preload Plate Wear HC-SL-61-282 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?

Miscellaneous Feathering Spring HC-SL-61-291 [obs] → HC-SB-61-324 [pending]: Feathering Compression Spring Reports of feathering issues in the field Unable to reach full feather at shutdown Disassembly found fractured feathering spring

Miscellaneous Feathering Spring HC-SL-61-291 [obs] → HC-SB-61-324 [pending]: Feathering Compression Spring Affects HC-B(4,5)(M,T)(A,N,P)-(1,2,3,5) Introduces 102877 spring as supercedure to A-3496 New 102877 has flat outer diameter and improved fatigue life

Miscellaneous Feathering Spring HC-SL-61-291 [obs] → HC-SB-61-324 [pending]: Feathering Compression Spring (new in SB324) At next overhaul, requires replacement of the A-3496 with new 102877

Status Updates SB269 Program HC-SB-61-269 rev. 4: Hub Inspection [Nov 13/09] FAA approved AMOC to AD 2009-22-08 AD 2009-22-08 superseded AD 2006-18-15 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

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