MPC-28 Propeller Owner/Operator Information Manual
Contents
1. McCauley composite McCauley composite McCauley composite propeller overhaul facility propeller overhaul facility propeller overhaul facility 4 Scrapes initial owner assessment may need to be evaluated at an approved McCauley composite propeller overhaul facility NOTE Scrapes are generally considered damage that is the result of multiple impacts in an area that results in material being abraded and removed from the area of impact damage Refer to Table 102 Propeller Nick and Scrape Limits for additional limit information a Scrapes that affect areas less than 2 00 square inches and do not contact the underlying fiberglass fabric and are less than 0 005 inch deep Do the following 1 This type of damage repair may be deferred to propeller overhaul 2 Repair the propeller using the cosmetic surface repair technique by an approved McCauley composite propeller overhaul facility b Scrapes that affect areas greater than 2 00 square inches but less than 6 0 square inches do not contact the underlying fiberglass fabric and are greater than 0 005 inch deep Do the following This type of damage repair may be deferred to propeller overhaul Paint the affected area Repair the propeller using the cosmetic surface repair technique by an approved McCauley composite propeller overhaul facility no later than the next propeller overhaul c Scrapes that affect areas in excess of 6 0 square inches or has damage that extends in2. or by calling 316 831 4021 between 8 00 AM and 4 30 PM Central Time Thank you for letting McCauley fulfill your airplane propeller needs McCauley Propeller Systems Page 1 McCauley Propeller Systems Jun 30 2010 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL LIST OF REVISIONS 1 General A This manual MPC 28 includes the original issue and the revisions listed in Table 1 To ensure information in this manual is current and the latest maintenance and inspections procedures are available the revisions must be incorporated in the manual as they are issued Table 1 Original Issue June 30 2010 Revision Number Date Revision Number Date 1 March 7 2011 LIST OF REVISIONS Page 1 McCauley Propeller Systems Mar 7 2011 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL INTRODUCTION 1 General A This Owner Operator Manual provides familiarization and line maintenance instructions for McCauley fixed pitch composite propellers B All maintenance and service procedures described and authorized in this manual must be done only by qualified personnel C Overhaul or any repair procedure that involves the scarf repair stripping or resurfacing of the propeller must be done only by a McCauley authorized and qualified propeller overhaul facility in accordance with the appropriate McCauley propeller overhaul manual 2 Additional Reference Manuals A The following publications contain
3. 13 Leading Edge Guard Crack s Replace Guard or Scrap Prop Shop Level 14 Repair To New Condition Shop Level 61 30 01 Page 102 McCauley Propeller Systems Mar 7 2011 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL Table 101 Damage Assessment and Disposition continued Delamination in hub area Scrap Remove From Service Shop Level crankshaft mounting surface and propeller mounting bolt holes One or more carbon fiber Scrap Remove From Service Shop Level plies of the propeller spar is damaged Burn Damage or Discoloration Scrap Remove From Service Shop Level due to excessive heat Do not confuse the natural discoloration of composite materials exposed to UV radiation with heat damage NOTE The term Owner Level identifies a damage disposition the owner or operator can do The term Shop Level identifies a damage disposition that shall be dispositioned by an approved McCauley composite propeller overhaul facility All McCauley approved composite propeller overhaul facilities can do both Owner and Shop level dispositions B Expanded Propeller Damage Assessment and Disposition Definitions 1 Visual Inspection Owner assessment and initial inspection for cracks scratches nicks missing material exposed fibers or mesh unusual loft deviations dips waves paint damage raised or bubbled areas or other visually evident damage If a defect or damage is suspected the propeller must be taken to
4. Propeller Assembly Installation 61 30 01 Page 202 McCauley Propeller Systems Mar 7 2011 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL WARNING BE SURE THAT MAGNETO IS GROUNDED BEFORE TURNING PROPELLER OR CONNECTING EXTERNAL POWER NOTE McCauley recommends that propeller mounting nuts if applicable be replaced at each propeller installation whenever possible However nuts may be reused providing threads are in good condition and the locking material prevents turning of the nut on the stud by hand 1 Make sure the mating surfaces of the propeller crankshaft flange and spinner bulkheads are clean 2 Position the aft spinner bulkhead on the dowel pins between the propeller and spacer and press propeller and spacer together NOTE The bulkhead must be positioned so that the propeller blades emerge from the bulkhead and spinner with ample clearance 3 Rotate the engine crankshaft so the number 1 cylinder is Top Dead Center TDC on its compression stroke 4 Position the propeller on the engine crankshaft so the number 1 blade is clocked 60 degrees in the direction of engine rotation from TDC NOTE The number 1 blade will be located at approximately the 10 O clock position when viewed from in front of the engine looking aft 5 Install propeller on crankshaft flange WARNING Make sure there is no lubricant on the threads of the propeller attach nuts and bolts If the propeller attach bolts and n
5. additional information about this and other McCauley propellers These may be used as reference Each of the referenced publications has a specific application to the owners and operators of aircraft with McCauley propellers installed 1 McCauley Model 1L100 Series Maintenance and Overhaul manual This manual includes maintenance and overhaul information and an illustrated parts list NOTE The Model 1L100 Series Maintenance and Overhaul manual may be used only by McCauley approved propeller repair stations 2 McCauley Service Bulletins These are issued to advise of propeller design changes that must be incorporated to provide procedures for correcting problems that have been found in the field and to provide other important information 3 McCauley Service Letters These are issued to provide information such as warranty replacement policies parts availability information minor modifications and other supplemental information 4 FAA Advisory Circular 43 13 1 X This publication provides general acceptable inspection procedures for propellers 5 FAA Advisory Circular 20 37 X This publication provides general acceptable maintenance and inspection procedures for propellers NOTE FAA Advisory Circular 43 13 1 X and FAA Advisory Circular 20 37 X are written with propellers certified to Part 35 of Title 14 of the Code of Federal Regulations However the information contained within these Advisory Circulars contain information th
6. area less than 1 25 square inch and less than 1 75 inch maximum dimension in any direction and does not extend to the carbon fiber fabric Propeller may be repaired using a scarf repair by an approved McCauley composite propeller overhaul facility b A broken or shattered area of at least 1 25 square inch or more than 1 75 inch maximum dimension in any direction and extends to the carbon fiber fabric Propeller shall be removed from service and scrapped Exposed Blade Core Foam If the propeller blade core foam is visible the propeller must be removed from service and scrapped Notable Vibrations Owner assessment for unusual vibration if unusual vibration is suspected the propeller must be taken to an approved McCauley composite propeller overhaul facility for additional tests to confirm the condition of the propeller Dimensional Measurements vs Limits This is a test that requires specialized tools and training to accomplish by an approved McCauley composite propeller overhaul facility Propellers that are found to have dimensional measurements beyond the established limits must be repaired or removed from service and scrapped NOTE Forthe purposes of a propeller with a repair that is found to be beyond the dimensional limits of the propeller treat the repair area that is beyond the allowable limits as an area of debond and do a scarf repair If the area to be repaired is beyond the limits of a scarf repair the propeller must be remove
7. as installed equipment on an airplane or by itself shall transfer to the purchaser at the time of sale the following records of that propeller 1 The records specified in CFR 91 417 a 1 2 The records specified in CFR 91 417 a 2 McCauley Propeller Systems 1 USE OF LOGBOOK Use of Logbook A B Proper maintenance of this logbook is the owner s responsibility it is an important record designed for the owner s information and protection If the propeller is sold or installed on another aircraft the logbook should be transferred with the propeller It is recommended that maintenance release tags and work orders be attached inside the logbook If a copy of the work order is not available the repair station and work order numbers should be referenced in the logbook entry All Service Bulletins and Service Letters have been complied with at the time of production McCauley Propeller Systems PROPELLER INSTALLATION CAGE NOMBRE S fownername eg Propeller Model Propeller Serial Number McCauley Propeller Systems INSTALLATION HISTORY ISCH Aircraft Model Serial Number and Registration Number Engine Serial Number amp Position McCautey Propeller Systems ture amp Certificate igna Number S rad o of S D GER 2 o E D og 0 Ka PROPELLER LOG Aircraft Model amp Regjistration Number McCauley Propeller Systems SERVIC
8. following should be checked corrected a Shimming of the spinner shell b Propeller installation properly torqued and installed flat against the mounting flange NOTE If the shimming of the spinner shell and propeller installation are found to be acceptable but the initial reading is still over 0 8 ips we recommend the propeller be taken to a McCauley approved repair facility for inspection If the initial reading is under 0 8 ips continue the dynamic balance in accordance with the balance equipment manufacturer s instructions CAUTION At no time are static balance weights to be moved to adjust dynamic balance If the test indicates the addition of weights temporarily place the indicated mass of balance washers in place of the spinner mounting screw at the location indicated by the testing equipment a An AN970 3 washer weight 0 144 ounces each 4 1 grams plus screw AN502 10 X Repeat the dynamic balance until the correct balance level approximately 0 07 ips or lower is achieved NOTE Most dynamic balance equipment manufacturers specify 0 15 0 2 ips as being an acceptable level McCauley Propeller Systems agrees that 0 15 0 2 is an acceptable level but our experience has shown that 0 07 ips or lower is noticeably smoother When dynamic balance is satisfactory a Remove balance washers and screw from the spinner attach screw hole b Permanently mount the balance washers and screws to the spinner bulkhead ass
9. inspection manual Inspection should include 1 Spinner Removal 2 Inspection of all attaching hardware including the hardware under the spinner for security Tighten if necessary 3 Repaint propeller as necessary in accordance with the Propeller Field Maintenance Practices Blade Painting 4 Examine all placards for legibility and security of installation Replace all placards that are illegible or not secure 5 The propeller mounting bolt torque should be checked at least once a year a Propeller mounting bolts must be magnetic particle inspected in accordance with ASTM E 1444 or liquid penetrant inspected in accordance with ASTM E 1417 or replaced at every propeller overhaul reconditioning or repair 4 Necessary Actions Following Object Strike of Stationary Propeller Blade Strike of Rotating Propeller Bird Strike or Sudden Engine Stoppage A Object Strike of Stationary Propeller 1 Object Strike is defined as any impact of a non rotating propeller by a substantial moving object such as any personnel vehicle aircraft tug ground power unit etc NOTE The definition is intended for use as an example only Determination as to whether or not an object strike actually occurred is ultimately the responsibility of the aircraft operator 2 Inspect the propeller blades for damage such as scrapes gouges cracks crushed areas etc caused by impact Any damage that is beyond normal operation limits is cause for propeller re
10. lightning strike the following criteria can be used to verify any suspicion 1 Check for burns or signs of arcing on blades and hub area NOTE The lightning mesh area of the propeller blade will have burn or scorching marks to help identify a propeller blade that has been struck by lightning 2 Look for any signs of localized melting or delamination particularly on the blades 61 30 01 Page 503 McCauley Propeller Systems Jun 30 2010 3 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL If preliminary inspection suggests an actual strike a complete propeller overhaul is to be accomplished as per the applicable McCauley overhaul manual 7 Dynamic Balance NOTE Some aircraft manufacturers do not approve dynamic balance of the propeller because of potential crack damage to spinner bulkhead from the installed weight A Recommended test equipment NAME NUMBER MANUFACTURER USE Balance Analyzer Model 2020 ACES Systems Pro Balancer 10737 Lexington Drive Analyzer Knoxville TN 37932 3294 Web www Acessystems com B Itis highly recommended that this procedure be performed following static balancing All of the procedures and guidelines listed below should be used in conjunction with the dynamic balance equipment manufacturer s instructions 1 2 Perform dynamic balance according to balance equipment manufacturer s instructions If the initial reading is over 0 8 ips McCauley recommends the
11. of the propeller hub and are greater than 0 250 inch 6 35 mm in diameter Propeller shall be inspected by an approved McCauley composite propeller overhaul facility to confirm the condition of the propeller and repair requirements This type of damage will result in a scarf type repair of the damaged area 61 30 01 Page 103 McCauley Propeller Systems Mar 7 2011 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL c Any nick in the propeller surface that contacts the underlying fiberglass fabric damage greater than 0 005 inch 0 13 mm deep andless than 5 inches 127 mm from center ofthe propeller hub Propeller shall be inspected by an approved McCauley composite propeller overhaul facility to confirm the condition of the propeller and consult with McCauley for repair requirements Table 102 Propeller Nick and Scrape Limits Area of Nick or Scrape Depth of Nick or Scrape Less than 2 0 Inches 2 0 to 6 0 Inches Greater than 6 0 Inches Less than 0 005 inch No Action Required Paint Damaged Area Propeller needs to be evaluated by an approved McCauley composite propeller overhaul facility Between 0 005 and 0 020 Paint Damaged Area Paint Damaged Area Propeller needs to be evaluated by an approved McCauley composite propeller overhaul facility More than 0 020 inch Propeller needs to be Propeller needs to be Propeller needs to be evaluated by an approved evaluated by an approved evaluated by an approved
12. time limits 7 For safety and glare reduction for conventional single engine tractor type aircraft keep the blade backs side of the propeller that faces the pilot painted flat black and the propeller tips painted with the appropriate colors to ensure good visibility Repaint blades equally so that the balance of the propeller is not disturbed The leading edge guard may be polished on the forward cambered surface of the propeller Pusher props may have unique paint color requirements for good visibility for ground personnel Refer to McCauley s maintenance documents 8 McCauley spinners can be polished use commercially available polishing compounds C Operators CANNOT do the following 1 Do not operate any aircraft after a propeller has been subjected to an impact without a thorough inspection by an appropriately rated person or repair facility 2 Never straighten a damaged propeller 3 Never chrome plate a spinner Plating will cause cracks and spinner failure 61 30 01 Page 201 McCauley Propeller Systems Mar 7 2011 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL 4 Do not attempt to repair or modify a propeller spinner or spinner components Welding riveting or bonding are not permitted on the spinner or spinner components 5 Do not fill any damaged areas of blades with bulk filler materials such as epoxy or auto body fillers This prevents areas of potential cracking from being inspected Addition
13. E BULLETIN SERVICE LETTER COMPLIANCE RECORD PAGE NUMBER Total Time Signature amp Propeller Since Service Bulletin Service Letter Certificate Time Overhaul Number Number McCauley Propeller Systems
14. McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL 3 Secure propeller spinner to the bulkhead with remaining screws and washers 4 Spacer Removal A B Remove the propeller and spacer assembly from the airplane Refer to Propeller Removal and Installation for instructions to remove the propeller Tool Fabrication 1 Use a steel bar that is at least 0 250 inch 6 35 mm thick and 2 00 inches 51 00 mm wide and 6 0 inches 152 0 mm long 2 2 Drill two 0 250 inch 6 35 mm holes in the steel bar that are 2 875 inches apart 0 020 or 0 020 inches 73 03 mm 0 5 mm or 0 5 mm and 1 438 inches 0 020 or 0 020 inches 86 53 mm 0 5 mm or 0 5 mm from the center of the steel bar Spacer Removal Procedure Refer to Figure 201 1 Attach the steel bar to the propeller spacer using two 0 250 inch diameter bolts with UNC 3A threads NOTE Bolts to be used should be made of steel 0 250 inch in diameter have a UNC 3A thread and the grip length sized to match the thickness of the steel bar For steel bars that are 0 250 inch 6 35 mm thick a MS20074 04 06 bolt is an appropriate sized bolt for this application 2 Position the propeller and spacer assembly under an arbor press or similar tool as shown in Figure 201 3 Place two propeller mounting bolts or equivalent sized steel dowels in the propeller and spacer assembly The bolts or dowels are used to push the spacer from the propeller must be of equal le
15. Propeller Owner Operator Information Manual Click on a link below to select a section of the information manual Welcome Introduction List of Revisions Fixed Pitch 1L100 Series Composite Propellers Propeller Logbook Page 1 of 1 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL WELCOME Thank you for purchasing a McCauley propeller A This manual will provide you with information that is important for the continued airworthiness of your propeller 1 This manual is designed to provide you with quick access to the information you desire It provides you links that can be selected to carry you through the information pertaining to your model series of propeller Please take a few minutes to familiarize yourself with this manual Model Designations A The following can be used to determine your propeller model series e Two blade fixed pitch 1L100 Series Additional Resources A In addition to the information we included in this manual the FAA has issued the following Advisory Circulars AC that may aid you in continued airworthiness of your propeller AC35 4 1 Propeller Instructions for Continued Airworthiness e AC43 9 X Maintenance Records NOTE X signifies latest revision level B If you have any question about your propeller please contact your closest McCauley Service Center or McCauley Product Support 1 Current contact information can be found at www mccauley textron com 24 hours a day
16. ROPELLER REPAIRS General Information A McCauley allows specific repairs modifications to composite propellers Only the changes to the original propeller configuration as specified by McCauley are allowed CAUTION All disassembly overhaul testing repair and reassembly procedures on a McCauley composite propeller must be done in an approved propeller repair station or international equivalent by qualified personnel CAUTION Authorized propeller repairs are limited to procedures described in this manual and the propeller overhaul manual Replace the propeller if the propeller is damaged beyond the repair limits permitted B Refer to the aircraft manufacturer s manual as necessary for additional information C Inspect maintain repair and overhaul the propeller in accordance with the recommended procedures given in this section General Repair Instructions WARNING Do not apply any kind of autobody filler Bondo compound to fill and cover a surface defect NOTE McCauley Propeller Systems Product Support Department must be contacted if a part has unusual wear or damage to find out if it is airworthy or not A Follow each of the general repair instructions for all propeller repairs 1 Complete only those repairs that will not affect the operation or serviceability of the propeller 2 Complete a Daily or Preflight inspection and the 100 hour and annual inspection as shown in Propeller Periodic Inspection Practices E
17. STEMS OWNER OPERATOR INFORMATION MANUAL IN Do not apply excessive paint and do not paint propeller components unless it is in accordance with McCauley instructions The improper application of paint may affect propeller balance operation static electricity discharge lightning tolerance or have other unintended consequences NOTE Excessive paint thickness can cause damage to the propeller as a result of a lightning strike 4 Straightness a Sight down the edges to find any deformation 5 Looseness a Feel the propeller installation for security Push and pull on the propeller in the hub area to make sure the installation is not loose or has any unusual play Spinner and Bulkhead 1 Externally examine the spinner and bulkhead for security missing fasteners damage and cracks Cracks typically start from the screws that attach the spinner to the bulkhead a Repair of cracks in the spinner or spinner bulkhead is not permitted 2 Examine the bulkhead for security of installation This could be an indication that the mounting bolts are loose 3 Wear depth on the inside of the spinner must not be more than 0 010 inch 0 25 mm Maintenance Records 1 Note any indications in the logbook for future reference to determine whether a condition is getting worse 3 100 Hour and Annual Inspection A At each 100 hours Annual or other approved inspection interval examine the propeller in accordance with the aircraft
18. ally filling a damaged area will not correct the stress risers caused by the damaged area or those caused by the loading that introduced the damage 6 Do not run up engine in areas containing loose rocks gravel or debris Avoid quartering rear winds during ground run up whenever possible 7 Do not push or pull on propeller blades when moving the aircraft by hand Tow bars are specifically designed for this operation 8 Never install a propeller on an aircraft unless it is a model approved by the aircraft manufacturer or the aircraft type certificate data sheet TCDS or an appropriate supplemental type certificate STC The service history must be properly documented and a pre installation inspection must indicate that the propeller is airworthy 9 Do not attempt to file nicks depressions from the leading edge guard NOTE Itis permissible to remove burrs in the leading edge guard that are above the profile of the guard 3 Propeller Removal and Installation A General 1 Propeller removal and installation should be performed only by qualified maintenance personnel The following instructions are general in nature The aircraft maintenance manual or STC installation instructions should always be consulted for any specialized procedures applicable to a specific aircraft Various spinner arrangements not manufactured by McCauley may be used which require additional procedures 2 In the following instructions installation of
19. an approved McCauley composite propeller overhaul facility for additional tests to confirm the condition of the propeller 2 Paint Wear a Paint wear less than 2 square inches repair at owner s discretion must be repaired at propeller overhaul Refer to Propeller Field Maintenance Practices Blade Maintenance for paint instructions b Paint wear greater than 2 square inches but less than 10 square inches repaint affected area cannot be deferred to propeller overhaul Refer to Propeller Field Maintenance Practices Blade Maintenance for paint instructions c Paint wear greater than 10 square inches take propeller to an approved McCauley composite propeller overhaul facility for inspection and paint repair 3 Nicks in Propeller Surface NOTE Nicks are generally considered damage that is the result of a single point of impact damage Refer to Table 102 Propeller Nick and Scrape Limits for additional limit information a Nicks in the propeller surface that do not damage the carbon fiber fabric damage less than 0 020 inch 0 5 mm deep and greater than 5 inches 127 mm from center of the propeller hub and are less than 0 250 inch 6 35 mm in diameter This type of damage may be deferred to propeller overhaul at which time it can be repaired using a scarf type repair b Nicks in the propeller surface that contacts the underlying fiberglass fabric damage greater than 0 005 inch 0 13 mm deep greater than 5 inches from center
20. apply solvent and clean again 3 Repeat this wiping process until there is no discoloration on the drying cloth Remove thick or packed on grease or dirt with a soft bristle brush Allow cleaned parts to air dry NOTE Remove excess moisture with a gentle stream of clean dry compressed air keeping nozzle of air hose well away from parts 6 Blade Maintenance A Removal of Blade Damage 1 General a b c The propeller blade is a highly stressed part The fact that propeller blades are subject to damage such as nicks gouges scratches pits etc demands frequent inspection and maintenance Refer to Figure 202 The disposition of small nicks and scratches may be performed by qualified mechanics in the field in accordance with procedures specified in Propeller Field Maintenance Practices Troubleshooting Large nicks or scratches or other damage involving such things as delaminated leading edge guard balance diameter reduction etc may be corrected only by an approved propeller repair facility 2 Repairable Damage a b Minor paint touch up is allowed All other damage repair except minor paint touch up must be accomplished at an approved McCauley composite propeller overhaul facility B Blade Painting 1 General a Propeller blades are painted with polyurethane enamel paint This paint provides optimum durability and abrasion resistance If paint becomes eroded and is not repainted damage to
21. at can be useful for propellers certified to ASTM F 2506 07 standards INTRODUCTION Page 1 McCauley Propeller Systems Jun 30 2010 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL PROPELLER SYSTEM DESCRIPTION AND OPERATING PRINCIPLES 1 Reciprocating Piston Engine Composite Propeller A McCauley fixed pitch composite propellers for reciprocating engines have a fixed pitch two blade configuration Refer to Figure 1 B Description of the Propeller Assembly Installation 1 Propeller The propeller is a single piece composite assembly 2 Propeller Blades The propeller blades are made of advanced composite materials C Overhaul or any repair procedure that involves the scarf repair stripping or resurfacing of the propeller must be done only by an authorized and qualified propeller overhaul facility in accordance with the appropriate McCauley propeller overhaul manual CAUTION McCauley composite propellers cannot be straightened or repitched Structural damage to the propeller will result if an attempt is made to straighten or repitch a composite McCauley propeller 2 Overhaul Period A All propellers are to be overhauled at specific intervals The time between overhaul TBO is specified in hours of operation as well as calendar limit NOTE TBO specification is subject to change Any changes to the propeller TBO will be announced in revisions to this Owner s Manual Table 1 Propeller Models Mode
22. aul facility 3 Sudden Engine Stoppage a Sudden Stoppage is defined as any propeller experiencing a sudden decrease in RPM This is commonly due to engine failure or seizure Please note determination as to whether or not sudden engine stoppage has occurred is ultimately the responsibility of the aircraft operator McCauley recommends consulting engine manufacturer s data to determine criteria for sudden engine stoppage b Any McCauley propeller experiencing a sudden stoppage must be removed from the aircraft and completely overhauled by a McCauley approved propeller repair facility 5 Blade Track Check A Check 1 Turn propeller so that Number 1 blade is straight down 2 Position a smooth board beneath the blade tip 3 Block up the board firmly in place just clear of the blade tip 4 Place a pencil mark approximately one inch 25 mm long on the board at the midpoint of the outer edge of Number 1 blade tip Turn the propeller so the other blade is straight down Place a thin one inch 25 mm line on the board at the midpoint of the outer edge of the second blade tip CAUTION Difference in blade track cannot exceed 0 170 inch 4 3 mm 7 Measure the horizontal difference between the lines If blade track difference exceeds 0 170 inch 4 3 mm determine if the propeller is warped or the engine crankshaft flange is bent 6 Lightning Strike Inspection Requirements A If doubt exists as to the occurrence of a
23. d be accomplished at your nearest McCauley Approved Composite Propeller Overhaul Facility For the location of the McCauley Approved Service Station nearest you refer to www mccauley textron com 24 hours a day or by calling 316 831 4021 between 8 00 AM and 4 30 PM Central Time NOTE Having work performed at a facility other than a McCauley Approved Composite Propeller Overhaul Facility may void your warranty McCauley Propeller Systems FAA LOGBOOK REGULATIONS 1 Maintenance Records A Refer to 14 CFR 91 417 for a complete copy of this regulation NOTE The following statements contain excerpts from CFR 91 417 concerning propeller maintenance records Except for work performed in accordance with CFR 91 411 Altimeter System and Altitude Reporting Equipment Tests and Inspections and CFR 91 413 ATC Transponder Tests and Inspections each owner or operator shall keep the following records as specified in paragraph C 1 Records of the maintenance preventive maintenance and alteration and records of the 100 hour annual progressive and other required or approved inspections as appropriate for each propeller The records must include a A description or reference to data acceptable to the Administrator of the work performed b The date of completion of the work performed c The signature and the certificate number of the person approving the aircraft for return to service 2 Records must contain the follo
24. d from service and scraped Frequency NDI Life Assessment This is a test that requires specialized tools and training to accomplish by an approved McCauley composite propeller overhaul facility If the frequency or resonance vibration pitch has changed from the original base line natural frequency to an out 61 30 01 Page 105 McCauley Propeller Systems Mar 7 2011 13 14 lt 15 Kg 16 17 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL of range frequency then this is an indication of propeller internal failure or an improper repair Propellers that are found to have an out of range frequency must be removed from service and scrapped NOTE Propellers that have a frequency or resonance vibration pitch that has changed from the original base line natural frequency but are within the acceptable frequency range no action required this can be an indication of the normal propeller aging process Leading Edge Guard Crack s Leading edge guards that have a total combined crack length of 3 inches or any two cracks that are within 1 inch of each other This is a condition that will require specialized training to determine the extent of leading edge guard cracking Propellers with leading edge guards that are cracked beyond these limits must have the leading edge guard replaced by an approved McCauley composite propeller overhaul facility or the propeller must be removed from service and
25. ed or reconditioned The complete model number is a combination of the basic model number and suffix numbers to indicate the propeller diameter and pitch McCauley uses a model designation system to identify specific propellers Refer to Figure 2 Propeller Model Designation 1 The Propeller model designation is stamped on the propeller nameplate Examples of hub model designation 61 30 01 Page 3 McCauley Propeller Systems Mar 7 2011 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL C1675 Serial Number NOTE Blade Number Blade Number Blade Resonant Blade Resonant Frequency Frequency Model Number NOTE Put a center punch mark or a 0 063 inch drill point 0 020 inch deep in this area under the propeller serial number each time the propeller is overhauled or reconditioned 010271201 Composite Propeller Nameplate Figure 2 Sheet 1 61 30 01 Page 4 McCauley Propeller Systems Mar 7 2011 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL C1751 1L100LSA6754 X Sample Piston Engine Composite Fixed Pitch Propeller Model Designation Basic Model Number 11100 LSA 67 54 X Part Revision Inches Pitch Propeller Diameter Inches One to four letters indicating type of Crankshaft on which Propeller is installed Blade Tip Contour use of Adapter or other information pertaining to a specific Aircraft in
26. embly at a point adjacent to the test location as shown on Figure 501 Always place at least one balance weight under screw head for stress relief see Figure 1 Return original spinner screw to hole 61 30 01 Page 504 McCauley Propeller Systems Jun 30 2010 C1674 NAS1149F0332P Washer MS21083 N3 Nut 0 125 inch 6mm Maximum Projection McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL Spinner AN502 10 X Screw AN970 3 Flat Washer Maximum Stack 11 Washers Go 6 view A Balance Weight Installation Figure 501 Sheet 1 McCauley Propeller Systems 61 30 01 0102T1200 AA0102T1200 Page 505 Jun 30 2010 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL WARNING Use extreme care when you drill bulkheads near the propeller Drill damage could potentially require propeller replacement depending on the severity of the damage 8 Vibration Troubleshooting A Troubleshooting vibration problems can be very challenging and time consuming Most digital dynamic equipment can also be used to track down vibration problems The digital dynamic balancing equipment can display the amplitude and frequency of the vibration which will help determine the vibration source While vibration problems are occasionally caused by the propeller they are usually caused by other things Below is a list of other p
27. ey composite propeller overhaul facility 61 30 01 Page 802 McCauley Propeller Systems Jun 30 2010 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL INSTALLATION PARTS LIST 1 General A Use the Installation Parts List to identify and order correct replacement parts for propeller field maintenance refer to Figure 1001 B These parts may be purchased through your local authorized McCauley propeller service center 61 30 01 Page 1001 McCauley Propeller Systems Jun 30 2010 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL C1672 Crankshaft Reference 0955T1003 Installation Parts for Fixed Pitch Composite Propeller Figure 1001 Sheet 1 61 30 01 Page 1002 McCauley Propeller Systems Jun 30 2010 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL E saree GT 1 meer washer SE mer iN o ore sommes it Bolt Kit part number B 4622 49 consists of 6 each A 2513 105 bolts 6 each A 1638 13 washers 6 each A1638 14 washers and 6 each A 1639 6 nuts The A 1638 13 washers are not used for this installation 61 30 01 O McCauley Propeller Systems Page 1003 Jun 30 2010 PROPELLER LOGBOOK Dear Customer Congratulations on the purchase of your new McCauley propeller Engineered with the customer in mind it is designed to provide years of reliable and trouble free service Scheduled maintenance or servicing of your McCauley propeller shoul
28. h Remove only sharp edges of nicks and burrs If leading edge guard is cracked across the full width of the guard or in multiple places propeller must be taken to a propeller overhaul facility 010171164 A0101T1164 AA010171164 Field Blade Rework Criteria Figure 202 Sheet 1 61 30 01 Page 208 McCauley Propeller Systems Mar 7 2011 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL C1771 A Trailing Edge A W NOTE Leading Edge Guard 5h 18 00 Inches ki gt A OMEN Decal reading Edge Black Trailing Edge Front View Looking Rearward at the Camber Side of Blade Leading Edge Trailing Edge Rear View Looking Forward at the Face Side of Blade NOTE Do not prime or paint holes or counterbore 0 125 Inches Feather Edge F Leading Edge Guard Paint Top Coat Feather Edge Leet 3 0 Inches 0 045 Inches 0 045 Inches m 0 030 or 0 030 Inches Red Pai eee aint Top Coat gt 4 5 Inches Li _ l Le 1 5 Inches Surface Primer DETAIL VIEW A A Blade Painting Figure 203 Sheet 1 61 30 01 Page 209 McCauley Propeller Systems Mar 7 2011 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL PROPELLER PERIODIC INSPECTION PRACTICES 1 Limitations A Operational and service personnel should be familiar with the following limitations during any inspection B Unauthorized Repair of Blades All propellers sh
29. he aircraft If the vibration is eliminated the propeller is highly suspect and should be sent to an authorized propeller repair station for evaluation b If a replacement propeller is unavailable check the following 1 IN Le IR jo Propeller imbalance can be the cause of vibration Perform a dynamic balance on the suspect propeller to determine balance of the propeller If the propeller cannot be successfully dynamically balanced it should be removed and sent to an authorized propeller repair station for evaluation Check the spinner for cracks at the bulkhead attach points for a cracked bulkhead or for a cracked front support a The propeller spinner can be a contributing factor to an out of balance condition An indication of this would be a noticeable spinner wobble while the engine is running This condition can be caused by a cracked or deformed spinner and or spinner bulkheads If a spinner is found to be wobbling it should be removed and inspected to determine the cause of the wobbling Any spinner found cracked or deformed must be replaced Check the leading edge guard for delamination a If the leading edge guard is suspected of being delaminated do a coin tap test If the coin tap test indicates leading edge guard delamination the propeller will need to be evaluated at an approved McCauley facility Check the propeller for cracks delamination a If propeller delamination or cracks are suspected the propelle
30. l Number Overhaul Frequency 1L100LSA Every 2000 hours of operation or 72 calendar months 3 Propeller Operation A Operating the propeller over loose gravel or cinders should be done at low engine speed propeller RPM to avoid abrasion and stone damage to the propeller tips Do not operate the propeller in excess of the maximum RPM 4 Approved Installations A The following propeller and engine combinations have been approved by McCauley Table 2 Table 2 Approved Engine Propeller Combinations Propeller Model Engine Designation Horsepower BHP Airplane 1L100LSA6754 Teledyne 100 2750 Cessna Model 162 Continental O 200 D Mass Moment of Inertia A The mass moment of inertia for this propeller about its axis is 0 300 Slug ft 61 30 01 Page 1 McCauley Propeller Systems Mar 7 2011 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL C1750 Leading Edge STA STA STA STA 6 00 Ge 21 he 30 00 3350 Se VS Trailing Edge 11100 View Looking at Front of Propeller 010171165 1L100 Model Composite Propeller Figure 1 Sheet 1 61 30 01 Page 2 McCauley Propeller Systems Mar 7 2011 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL Propeller Identification A For identification a nameplate is attached to the hub of each propeller The nameplate is stamped with the propeller model number serial number and the number of times the propeller has been overhaul
31. ller spinner Standard 3 8 inch Commercially available To remove and install socket set propeller Standard Open Commercially available To remove and install end box end propeller wrench set Sand paper Commercially available Paint Commercially available 2 Procedures For Maintenance A Maintenance begins with the operator and includes inspection together with regular care Many maintenance tasks that may be accomplished at a minimum cost can extend the life of the propeller and reduce or prevent costly repairs The following is a listing of what operators of aircraft CAN and CANNOT DO B Operators CAN do the following 1 Perform a visual preflight inspection of the propeller for nicks scratches erosion cracks delamination etc Apparent damage found should be referred to an appropriately rated mechanic A crack or delamination is cause for removal of the propeller 2 Check the propeller spinner attaching screws for security and check the spinner for damage 3 Clean propeller blades periodically using clean water a non alkaline cleaner and a soft cloth or soft brush Dry with a soft cloth 4 Ensure that the tachometer is appropriately marked for operational limitations of the propeller and that the tachometer accuracy is checked at periodic inspection intervals 5 Each propeller should have its own maintenance record 6 The operator must have the propeller reconditioned or overhauled when it reaches the McCauley recommended service
32. moval and repair 61 30 01 Page 502 McCauley Propeller Systems Jun 30 2010 B McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL Blade Strike of Rotating Propeller 1 Blade Strike sometimes referred to as Ground Strike is defined as any impact or suspected impact of the rotating propeller upon such items as but not limited to the ground tow bars landing lights carts snow banks hedges etc Please note that the above definition is intended for use as an example only Determination as to whether or not a blade strike actually occurred is ultimately the responsibility of the aircraft operator CAUTION Internal damage can occur without evidence of gross external damage a Any McCauley propeller experiencing a blade strike must be removed from the aircraft and overhauled by an approved McCauley composite propeller overhaul facility in accordance with the applicable overhaul manual 2 Bird Strike a Bird Strike can be defined as the impact of any bird into the rotating propeller causing damage b Inspect all blades for damage such as scrapes gouges etc caused by the impact Any damage beyond normal limits is cause for propeller removal and repair Refer to Blade Maintenance in Propeller Field Maintenance Practices c Forapropeller that is found to be damaged beyond the normal limits the propeller must be removed from the aircraft and overhauled by an approved McCauley composite propeller overh
33. ngth CAUTION Do not use bolts that will be returned to service for this procedure This procedure can damage the threads of propeller mounting bolts 4 Make sure there is at least 2 00 inches 50 mm clearance between the steel bar attached to the propeller spacer and the work surface supporting the sandbags 5 Using an arbor press or similar tool push the bolts or dowels down to remove the spacer from the propeller 6 Once the spacer is separated from the propeller remove the 0 250 inch bolts and steel bar from the spacer 5 Propeller Cleaning A Cleaning Procedures CAUTION Do not clean any McCauley composite propeller part with a steel brush other metal brush hard bristle brush or tool of any type not specified in this manual or approved by McCauley CAUTION As applicable during cleaning procedures observe allowable dimension limits established for certain parts 1 Remove dirt paint when applicable grease and oil from all parts of the propeller 2 Use McCauley approved cleaning mediums only refer to Table 201 61 30 01 Page 204 McCauley Propeller Systems Mar 7 2011 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL Table 201 Solvents Cleaners NAME ScotchBrite Clean amp Finish material NUMBER Type A fine Wiping Cloth White Oil free Rymplecloth NOTE Wiping materials that meet the requirements of AMS 3819 Class 1 or 2 Grade A Form 1 or 2 may be subs
34. nted propeller blades it is permissible to dilute the soap with water and to rinse the propeller with water and dry with a soft cloth 1 Wipe the propeller surface with the wetted wiping material as required to dissolve or loosen soil or other foreign material Work on a small enough area so that the surface being cleaned remains wet McCauley Propeller Systems 61 30 01 Page 205 Mar 7 2011 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL c1912 Use an arbor press or similar tool to simultaneously push both bolts down to remove the spacer from the propeller Propeller Mounting Bolt bes Ers Reference Propeller i Reference pa qd b qb Propeller Spacer Reference 2 00 Inch 50 mm Minimum P H A Sand Bag 0 250 Inch 0 250 Inch 6 35 mm Reference 6 35 mm x 6 00 Inches 152 0 mm Bolt x 2 00 51 0 mm Inch Steel Bar Reference With 0 250 6 35 mm Inch Holes Drilled 2 875 Inches 73 03 mm Apart B 7925D Spacer Removal Figure 201 Sheet 1 61 30 01 Page 206 McCauley Propeller Systems Mar 7 2011 c d McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL 2 Immediately wipe the wet surface with a dry clean oil and lint free cloth NOTE If the surface dries before being wiped dry re
35. ossible sources of vibration 1 Engine Worn old cracked or loose engine mounts Cracked or loose engine mount structure Cracked or broken spinner bulkheads Loose or improperly mounted engine cowlings Loose cowl flaps Loose landing gear doors Out of balance elevators Loose control yokes 0 Exhaust stack touching engine cowling 1 Component in engine compartment that is touching engine cowling 9 Propeller Overspeeding A During operation if the propeller is subjected to an overspeed condition do the following 1 Follow the inspection requirements in accordance with the following categories for overspeeding of rated take off RPM Refer to the table that follows for an assessment of an overspeeding to the propeller Model Percentage Overspeed Action to be Taken 1L100 10 Fire A Up to but not including 15 General external visual inspection No further action is required 15 or Higher Contact McCauley Product Support for disposition Any propeller assembly propeller component or spinner component exposed to fire or excessive heat is considered unairworthy and must be scraped if it shows any of the following conditions Bubbled paint Discolored paint Discolored metal Discolored epoxy Melted areas Burnt areas amon ot E OO PO A TZ 61 30 01 Page 506 McCauley Propeller Systems Jun 30 2010 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL P
36. owing evidence of unapproved repairs require removal of the propeller and proper assessment by an approved McCauley composite propeller overhaul facility Sighting along the leading and trailing edges of a propeller blade for any signs of the blade being out of alignment can also provide evidence of unapproved blade repair Any deformation of the existing blade contour such as bows or kinks may indicate previous unauthorized repair of the blade Careful visual inspection of the leading and trailing edges of the blade may sometimes detect unapproved repairs Repair or filler material that is a different color than approved repair materials Blades should also be examined for any discoloration that would indicate heat damage a Composite blades that have been exposed to an elevated temperature that causes a discoloration of the composite material must be removed from service C Blade Shortening 1 Propeller tip damage will sometimes lead field maintenance personnel to consider removing damaged material from the blade tips However propellers are certified to the aircraft engine and airframe resonant frequency by being manufactured with a particular diameter to minimize vibration Shortening of the blades without reference to approved data could create an unairworthy condition Refer to the airplane manufacturer and the applicable McCauley Propeller Overhaul manual for the allowable propeller diameter for each propeller installation Wi
37. quire specialized tools and training to accomplish The propeller leading edge guard repair or replacement must be accomplished by an approved McCauley composite propeller overhaul facility or the propeller must be removed from service and scrapped b Leading Edge Guard Delaminated 0 5 Square Inch or more Replace leading edge guard This repair will require specialized tools and training to accomplish Propeller leading edge guard replacement must be accomplished by an approved McCauley composite propeller overhaul facility or the propeller must be removed from service and scrapped Delamination excluding the leading edge guard a Delamination that affects less than 6 square inches in total area is under 4 inches along the longitudinal axis of the propeller and under 60 of local chord width and the delamination does not extend into the carbon fiber layers Repair the propeller by removing delaminated material and replace removed material with a scarf repair b Delamination that is found to be at least 6 square inches in total area is over 4 inches along the longitudinal axis of the propeller or is over 60 of local chord width or extends into a carbon fiber layer do the following must be removed from service and scrapped 1 Remove the propeller from service and scrap it Propeller Tip or Trailing Edge Area Damage NOTE Epoxy pieces may still be attached to the composite fiberglass or carbon fiber fabric a A broken or shattered
38. r will need to be evaluated at an approved McCauley facility Check the propeller mounting bolts for the correct torque a If the propeller mounting bolts have an incorrect torque retorque the mounting bolts to the correct torque 2 Worn engine mounts a Corrective Action 1 Consult the OEM or engine mount manufacturer service or maintenance manual for engine mount replacement criteria 3 Propeller Damage Assessment and Disposition A Refer to Table 101 for the assessment of damage to the propeller 61 30 01 Page 101 McCauley Propeller Systems Mar 7 2011 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL Table 101 Damage Assessment and Disposition 4 Scrapes Initial owner assessment may Owner Level need to be evaluated at an approved McCauley facility Initial owner assessment will Owner Level need to be evaluated at an approved McCauley facility 7 Delamination Initial owner assessment will Owner Level need to be evaluated at an approved McCauley facility Propeller tip and trailing edge Initial owner assessment will Owner Level damage need to be evaluated at an approved McCauley facility 9 Exposed Blade Core Foam Scrap Remove From Service 10 Notable Vibrations Take to shop for inspection and Owner Level assessment Dimensional Measurements vs Shop Assessment Shop Level Limits Frequency NDI Life Shop Assessment Shop Level Assessment Natural Frequency Out of Range
39. scrapped Erosion Damage Reconstruction This repair will require specialized tools and training to do successfully This type of repair can only be done by an approved McCauley composite propeller overhaul facility Delamination in Hub Area This is a condition that will require specialized tools and training to determine the extent of delamination Propellers that are suspected to have delaminated material in the hub area must be taken to an approved McCauley composite propeller overhaul facility The overhaul facility will determine if the propeller is repairable or must be removed from service and scrapped One or more Carbon fiber Plies are Damaged Propellers found with carbon fiber ply damage the propeller must be removed from service and scrapped Burn Damage or Discoloration Propellers that exhibit signs of burning or heat damage must be removed from service and scrapped 61 30 01 Page 106 McCauley Propeller Systems Mar 7 2011 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL PROPELLER FIELD MAINTENANCE PRACTICES 1 Ground Support Equipment A The following tools and material are required for field maintenance of McCauley composite fixed pitch propellers NAME PART NUMBER MANUFACTURER USE Torque Wrench Commercially available To torque propeller mounting nuts Safety Wire pliers Commercially available To remove and install safety wire 2 Phillips Commercially available To remove and install screwdriver prope
40. stallation Basic Design Number Planform etc 0102T1202 61 30 01 Page 5 McCauley Propeller Systems Mar 7 2011 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL PROPELLER TROUBLESHOOTING 1 General Information A Types of Problems Normally Encountered 1 This section outlines and explains a number of operating characteristics which have been observed in service There is some discussion of propeller design as it relates to these characteristics Procedures for locating and correcting causes of undesirable operation are given 2 Unusual Aircraft Vibration A Apparently excessive vibration felt during normal aircraft operation Although vibration can be caused by the propeller there are numerous other possible sources of vibration which can make troubleshooting difficult If the propeller is the cause of the vibration it is typically due to improper balance When a propeller is the cause of vibration the aircraft typically vibrates throughout the entire RPM range although the intensity of the vibration may vary with the RPM If a vibration occurs at only one RPM or within a limited RPM range the propeller is not normally the cause of the vibration problem 1 Ifthe propeller is suspected to be the cause of the vibration the following procedures should be performed a The ideal troubleshooting method is to temporarily replace the propeller with one which is known to be good and test fly t
41. th certain limitations specific minor repairs may be accomplished a When conditions indicate inspect the blade tips for evidence of shortening and if necessary measure the propeller diameter to determine if an unauthorized repair has altered it 2 Daily or Preflight Inspection A Blade inspection 1 2 Wash the blades with a mild soap and water solution to remove all foreign residue CAUTION Do not use solvents to clean the painted propeller blades a Make sure the blade that you are cleaning is pointing down Surface Damage a Look for surface damage on both sides of the blades such as gouges nicks scratches and delamination b Surface imperfections can also be felt by running your fingernail along the blade leading edge c The mechanic should remove all loose or raised material and make sure that the section thickness has not been reduced below allowable limits Erosion a Examine the blade for signs of erosion 1 If blades appear to show erosion beyond limits remove the propeller from service and have it examined by an appropriately rated propeller repair facility b Examine the condition of the paint on the propeller blades and the spinner if painted 1 Paint helps prevent erosion of the propeller blade surface Repair the paint before it is worn through and the propeller blade structure is damaged by erosion 61 30 01 Page 501 McCauley Propeller Systems Jun 30 2010 McCAULEY PROPELLER SY
42. the blade surface will be accelerated This is particularly true at blade tips where operation in rain or on sandy and or wet runways can cause wear It is therefore important to paint blades frequently as part of a regular maintenance schedule Refer to Figure 203 NOTE Atno time should the underlying composite material be visible through the paint The paint that is applied to the propeller must be opaque in color pigmentation for UV protection of the underlying composite material 2 Painting Materials and Procedures NOTE Follow painting procedures specified by paint manufacturer when painting the a propeller blades It is recommended that final dry film paint thickness be 6 to 9 mils for best abrasion resistance CAUTION Be careful to apply paint evenly on both propeller blades Uneven paint application can result in the propeller to become unbalanced and result in abnormal vibration during operation 61 30 01 Page 207 McCauley Propeller Systems Mar 7 2011 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL C1690 Leading Edge Guard Nick NOTE 1 Trailing Edge Leading Edge Guard NOTE 2 Leading Edge Guard NOTE 1 Nicks in composite surface less than 0 020 inch deep and greater than 5 00 inches from the center of the propeller and show no signs of delamination should not be repaired until propeller overhaul NOTE 2 Do not file nicks in leading edge guard smoot
43. the propeller is based on the assumption that a McCauley spinner will be used If a spinner is not used or if the spinner is not manufactured by McCauley omit those steps which apply to the spinner WARNING Verify that engine magnetos ignition system has been grounded prior to approaching the propeller Spinner Assembly Removal 1 Make an alignment mark on the spinner shell and adjacent blade with a felt tip pen This index mark ensures accurate restoration of spinner shell position to lessen the distortion of any dynamic balance previously performed on the propeller assembly 2 Remove screws and washers from the spinner 3 Remove spinner from the propeller installation Propeller Assembly Removal 1 Remove cowling as required for access to propeller mounting nuts 2 Break the torque on the propeller mounting nuts on Continental engine installations 3 Support the propeller the propeller may be supported and lifted by hand 4 Carefully remove the propeller from the engine 5 Aft spinner bulkhead and spacer removal CAUTION Do not use heavy strikes with a mallet to separate the spacer from the propeller Delamination of propeller composite material may result in the area of the spacer if excessive force is used to separate the spacer from the propeller a Lightly tap propeller spacer with a soft rubber mallet around the circumference of the spacer to work the spacer and aft spinner bulkhead loose from the propeller
44. tituted for Rymplecloth Mild soap or detergent hand dishwashing type without abrasives Methyl n Propyl CAS 107 87 9 Ketone MPK Isopropyl Alcohol TT I 735 Lacquer Thinner Acetone Reference Specification ASTM D329 cleaning medium NOTE MANUFACTURER 3M Co 3M Center St Paul MN 55101 Commercially available American Fiber amp Finishing Inc PO Box 2488 Albemarle NC 28001 Commercially available Eastman Chemical Products Inc Wilcox Dr and Lincoln St PO Box 431 Kingsport TN 37662 Commercially available Commercially available Commercially available a Be careful not to damage parts especially on working faces b Clean nonmetallic parts by wiping with a soft lint free cloth dampened with an approved USE To clean To clean To clean composite and metal surfaces that are to be repaired painted or bonded To clean painted propeller surface To clean composite and metal surfaces that are to be repaired painted or bonded To clean composite painted and metal surfaces To loosen grease loosen remove general adhesives and sealants to loosen and remove decals To loosen grease loosen remove general adhesives and sealants to loosen and remove decals The solvent must be applied to the clean wiping material and not to the surface being cleaned The wiping cloth shall not be wet to the point of dripping NOTE When using mild soap to clean the pai
45. to the underlying fiberglass fabric and the damage is greater than 0 005 inch deep Do the following 1 A scarf repair shall be accomplished by an approved McCauley composite propeller overhaul facility before next flight Cracks excluding the leading edge guard Owner assessment during visual inspection A Propeller that is suspected to have a crack must be taken to an approved McCauley composite propeller overhaul facility to confirm the condition of the propeller a Epoxy matrix crack s that do not extend into the underlying fiberglass may be repaired using a cosmetic surface repair b Crack s that extend past the epoxy matrix and into the fiberglass layers of the propeller may be repaired using a scarf repair IWIN 61 30 01 Page 104 McCauley Propeller Systems Mar 7 2011 10 a 11 12 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL c Crack s that extend past the fiberglass layers of the propeller and into the carbon fiber layers of the propeller the propeller must be removed from service and scrapped Leading Edge Guard and Laminate Coin Tap Tests Owner assessment for initial test If a delamination is suspected the propeller must be taken to an approved McCauley composite propeller overhaul facility to confirm the delamination condition a Leading Edge Guard Delaminated Less than 0 5 Square Inch Repair leading edge guard or replace leading edge guard This repair will re
46. uts have lubricant on the threads the bolts will be over torqued and the propeller could fail 6 Install forward spinner bulkhead washers bolts and nuts 7 Tighten bolts and torque evenly in accordance with the following table Torque Bolt DRY Torque DRY or Nut Pound Newton Meters Diameter Inches N m 30 to 25 36010300 40 675 to 33 895 8 If an adaptor or extension is attached to torque wrench drive end and this adds to its length then the actual applied torque will be greater than the dial reading The following formula should be used to find what the dial should read in order to obtain the correct applied torque actual torque required x torque wrench length Torque Wrench Reading tO Achieve the Required torque wrench length length of the adapter Actual Torque 9 Safety wire propeller mounting bolts Install the safety wire around the bolt heads Do not install the safety wire over the top of the bolt head E Spinner Installation if applicable 1 Put the spinner shell onto the bulkhead with the alignment marks matched a Press firmly aft on the spinner 2 Push on the spinner shell and use an awl or a small punch in an adjacent hole to move the spinner shell screw hole into alignment with bulkhead hole and install washer and screw Repeat this procedure on opposing holes until eight evenly spaced screws and washers are installed 61 30 01 Page 203 McCauley Propeller Systems Mar 7 2011
47. wing information a The total time in service of the propeller b The current status of life limited parts of each propeller c The time since last propeller overhaul d The current inspection status of the propeller including the time since the last inspection required by the inspection program under which the propeller is maintained The owner or operator shall retain the following records for the periods prescribed 1 The records specified in paragraph B 1 shall be retained until the work is repeated or superseded by other work or for 1 year after the work is performed 2 The records specified in paragraph B 2 shall be retained and transferred with the propeller at the time the aircraft is sold 3 A list of defects furnished to a registered owner or operator under CFR 43 11 shall be retained until the defects are repaired and the propeller is approved for return to service The owner or operator shall make all maintenance records required to be kept by this section available for inspection by the Administrator or any authorized representative of the National Transportation Safety Board NTSB 2 Transfer of Maintenance Records A Refer to 14 CFR 91 419 for a complete copy of the regulation concerning the transfer of propeller maintenance records NOTE The following statements contain excerpts from CFR 91 419 concerning the transfer of propeller maintenance records Any owner or operator who sells a propeller
48. xposed Blade Core Foam A If the propeller blade core foam is visible the propeller must be removed from service and scraped No repairs are permitted on propellers with exposed blade core foam Delamination A Large Area Delamination 1 A Large area Delamination is defined as being at least 6 square inches of area over 4 inches along the longitudinal axis of the propeller or over 60 of local chord width Propellers found with large areas of delamination must be removed from service and scrapped No repairs are permitted on propellers that are found to have a large area of delamination Carbon Fiber Ply Repair A Ifa carbon fiber ply of the propeller spar is damaged the propeller must be removed from service and scrapped No repairs are permitted on propellers that are found to have a damaged carbon fiber ply Leading Edge Guard Repair A Delamination 1 Leading edge guard that is delaminated less than 0 5 square inch is repairable The repair must be accomplished by an approved McCauley composite propeller overhaul facility or the propeller must be removed from service and scraped 61 30 01 Page 801 McCauley Propeller Systems Jun 30 2010 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL 2 Leading edge guard that is delaminated 0 5 square inch or more the leading edge must be removed and replaced or the propeller must be removed from service and scraped The repair must be accomplished by an approved McCaul
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