1. 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.

2. 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

3. 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

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

5. 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

6. 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

7. 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

8. McCauley Training Available Classes Constant Speed Overhaul
Turbine Overhaul
Blade Overhaul Manual
C703 Field Reassembly
C1103 Field Reassembly
Courses Can Be Combined
Visit 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

9. 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

10. 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

11. 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

12. 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

13. 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

14. 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

15. 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

16. 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

17. 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

18. 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

19. Threaded Propeller Parts Stopped
Sept 17, 2010

20. 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

21. 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

22. 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 , 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

23. 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 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 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 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

25. Service Bulletins
ASB255A – Jetstream J41 blade life limits and added blade inspections
All C blades are now life limited to 3,500 hours TTIS

26. 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

27. 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

28. Service Bulletins ASB255A (continued)
AD , 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

29. 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

30. 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 ( thru )
Drill point feature can vary in size
If it has a drill point feature of any size it is affected.

31. 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

32. Service Letters
SL2008-3
Added 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 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??

34. Service Letters

35. 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

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 only
Have been field testing it for 1 ½ years with no leakage problems
Neqw rubber gasket eliminates the need for all the retorquing

38. 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.

39. 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.

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 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

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.

45. Bonus
C400 series fixed pitch

46. Field Service Engineer McCauley Propeller Systems
Building On The Best
Gary Peak
Field Service Engineer
McCauley Propeller Systems
5800 East Pawnee
Wichita, Ks 67218
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.