ALERT SERVICE BULLETIN - McCauley Propeller Systems
Contents
1. ASB221E E Corrosion protect the propeller 1 Apply color chemical film treatment to all bare surfaces of the propeller that came in contact with the caustic etch solution Refer to the Standard Practices Manual Protective Treatments 60 00 04 Chemical Conversion Film Coating NOTE Make sure the chemical film treatment is swabbed inside the bolt holes where etching solution may have entered Or 2 Anodize the propeller Refer to the Standard Practices Manual Protective Treatments 60 00 04 Anodize F Repaint the propeller hub Refer to the Standard Practices Manual Paint Instructions 60 00 06 Do not paint the engine mounting surface of the hub within the dimensioned area as shown in Figure 12 NOTE Figure 12 is an illustration of the camber forward side of the propeller transfer the dimensioned area shown to the engine mounting surface face aft side of the propeller hub ASB221E Page 12 January 28 2010 ALERT SERVICE cL BULLETIN MCCAULEY ASB221E is All cracks shorter than 1 2 0 500 inch that do not contact a bolt hole and are more than 1 4 0 250 inch from hub edge and hub centerbore is acceptable Propeller may be reworked Crack less than 1 2 0 500 inch in length ACCEPTABLE Any crack longer than 1 2 0 500 inch that contacts a bolt hole is less than 1 4 0 250 inch from hub edge or is located in area of previous rework is unacceptable Remove unrepairable propeller from2. ASB221E is completed The completed form can be mailed or telefaxed to McCauley at the following address McCauley Propeller Systems Product Support Department P O Box 7704 Wichita Kansas 67277 7404 Fax 316 831 3858 Phone 316 831 4021 Make a logbook entry stating compliance with this service bulletin include details of inspection results and when the next inspection is due ASB221E January 28 2010 ALERT SERVICE BULLETIN MCCAULEY ASB221E C1590 Report Form for Compliance with McCauley Alert Service Bulletin ASB221E O O QO O O Please Sketch Exact Appearance of Crack Above This form must be completed following dye penetrant inspection of propeller in accordance with McCauley Alert Service Bulletin ASB221E This completed form may be either mailed or telefaxed to McCauley at the following McCauley Propeller Systems Product Support Department P O Box 7704 Wichita Kansas 67277 7404 Telefax 316 831 3858 Telephone 316 831 4021 Date of Compliance with ASB221E Propeller S N Propeller Total Time Propeller T S O Aircraft N number Aircraft S N Aircraft Total Time Owners Name Telephone Contact Person If different than owner Telephone Was the B 7287 Steel Reinforcement Plate and B 7306 Mylar Gasket installed on the propeller prior to this inspection Was a crack found Length of crack Depth of material removed Was propeller removed from
3. SERVICE cL BULLETIN MCCAULEY ASB221E 4 Steel Reinforcement Plate Inspection A Do avisual inspection of the B 7287 steel reinforcement plate 1 2 If the cadmium plating is worn replate the part in accordance with the Standard Practices Manual Section 60 00 04 Protective Treatments The following protective treatments are approved for this part a Cadmium plating b Zinc phosphate c Zinc nickel No defects are permitted B Doa magnetic particle inspection on the B 7287 steel reinforcement plate Refer to the Standard Practices Manual Section 60 00 03 Non Destructive Inspection for inspection procedures 1 No defects are permitted C Remove from service any part that has a visible defect or a defect made apparent by the magnetic particle inspection 5 Mylar Gasket Inspection A Do a visual inspection of the B 7306 mylar gasket 1 2 No defects are permitted Remove from service any gasket that has a visible defect 6 Reassembly A Install propeller refer to Figure 14 1 SB a A IO N O 8 ASB221E Clean mating surface of propeller crankshaft flange and spinner bulkheads WARNING BE SURE THAT MAGNETO IS GROUNDED BEFORE TURNING PROPELLER OR CONNECTING EXTERNAL POWER Put the aft spinner bulkhead between propeller and crankshaft flange Align propeller blade with t c mark on aft side of ring gear and rotate propeller clockwis
4. aft face of the propeller hub crankshaft mounting surface c Visually examine all bolt holes that have been reamed to 0 406 inch 10 31 mm diameter 1 Make sure the first 0 375 inches 9 53 mm as measured from the hub camber forward side of the reamed bolt hole is smooth and does not have any burrs or scratches ASB221E Page 4 January 28 2010 ALERT SERVICE cL BULLETIN MCCAULEY ASB221E ASB221E 2 If the reamed bolt hole has a drill tear line or scratch it is permissible to sand the hole in this area smooth with 400 grit sandpaper NOTE Drill tear lines or scratches that are observed 0 375 inch 9 53 mm or more from the propeller camber forward side surface are acceptable no action is required for this observation 3 Measure the diameter of all bolt holes that were sanded smooth 4 The maximum out of round hole diameter in the area of the sanded repair must not exceed 0 420 inch 10 67 mm 5 Remove from service any propeller with an out of round bolt hole diameter greater than 0 420 inch 10 67 mm 2 Measure the bolt hole wall thickness a Use acalipers or similar measuring device measure the wall thickness of all bolt holes to the outside of the propeller hub wall 0 375 inches 9 53 mm from the propeller hub camber forward side surface Remove from service any propeller that has a measured wall thickness less than 0 280 inches 7 11 mm at a depth of 0 375 inches 9 53 mm from the propeller hub cam
5. 221E January 28 2010 Page 9 ALERT SERVICE cL BULLETIN MCCAULEY ASB221E 2 Examine reworked area under 10X magnification after each cut g If crack appears to be totally removed repeat etch and fluorescent dye penetrant inspection of the reworked area to make sure the crack has been removed Refer to Figure 7 e If the crack extends beyond a depth of 0 040 inch the propeller must be removed from service C776 Figure 7 After Machining B Sand the camber forward side of the hub 1 Sand the camber forward side of the hub with sanding bob Cratex Rubberized Abrasives part number 11M to remove any sharp edges Refer to Figure 8 and Figure 9 C777 Figure 8 Sand Edges of Machining ASB221E Page 10 January 28 2010 ALERT SERVICE cL BULLETIN MCCAULEY ASB221E C778 Figure 9 After Sanding C Glass shot peen the hub 1 Glass shot peen the entire hub use AGB 18 glass shot AMS2431 6B or latest revision 80 100 PSI An approved alternate is MSH glass shot in accordance with MIL G 99544 or latest revision MIL Bead 8 Refer to Figure 10 C779 Figure 10 Shot Peened Surface D Stamp change letter S 1 Stamp change letter S using a 1 8 inch steel stamp in front of the propeller serial number NOTE If the change letter has been previously stamped a second stamp is not necessary ASB221E January 28 2010 Page 11 ALERT SERVICE cL BULLETIN MCCAULE Y
6. ALERT SERVICE cL BULLETIN McCAULEY January 28 2010 ASB221E TITLE INSPECTION OF MODEL 1A103 TCM PROPELLER HUB FOR CRACKING AND REWORK PROCEDURES TO FAA Approved Propeller Repair Stations Cessna Aircraft Company Aircraft Owners and Operators MODELS AFFECTED 1A103 TCM All Serial Numbers NOTE This bulletin does not contain an exhaustive list of aircraft which utilize this propeller because it is not possible to identify all aircraft using the affected propeller model e g installation approvals made by Supplemental Type Certificate or FAA Form 337 Major Repair and Alteration or Type Certificated models which have been inadvertently omitted Therefore it is the responsibility of the operator or person s performing aircraft inspections propeller overhauls to determine if an aircraft has an affected propeller AIRCRAFT AFFECTED Cessna 152 A152 Reims F152 FA152 PUBLICATIONS AFFECTED McCauley 730720 Fixed Pitch Overhaul Manual McCauley Standard Practices Manual SPM100 REASON McCauley has received reports of cracks in the 1A103 TCM model propeller hub Cracks have been found on the camber side of the propeller hub near the mounting bolt holes These crack s have been observed primarily in areas where fretting is present around propeller mounting bolt holes McCauley has recently received reports of model 1A103 TCM propellers with serial numbers that were not affected by Alert Service Bulletin 221C that ha
7. Refer to the Standard Practices Manual Protective Treatments 60 00 04 Chemical Conversion Film Coating NOTE Make sure the chemical film treatment is swabbed inside the bolt holes where etching solution may have entered Or b Anodize the propeller Refer to the Standard Practices Manual Protective Treatments 60 00 04 Anodize 3 Repaint the propeller hub Refer to the Standard Practices Manual Paint Instructions 60 00 06 Do not paint the engine mounting surface face aft side of the hub within the dimensioned area as shown in Figure 12 NOTE Figure 12 is an illustration of the camber forward side of the propeller transfer the dimensioned area shown to the engine mounting surface face aft side of the propeller hub 4 Proceed to Step 4 Steel Reinforcement Plate Inspection JS Hub Camber Forward Side Crack Removal Procedure A Crack Removal 1 OPTION 1 Bridgeport Refer to Figure 2 a Lay the propeller on a Bridgeport Mill or similar machine b Align and center the crack with a 0 250 inch ball end mill in the direction of motion C771 Figure 2 Alignment of Bridgeport Mill c Clamp the propeller to the machine table d Lower the 0 250 inch ball end mill and touch hub surface This will be the zero 0 dimension Refer to Figure 3 ASB221E January 28 2010 Page 7 ALERT SERVICE cL BULLETIN MCCAULEY ASB221E C772 Figure 3 Zero Dimension e Set depth of first cut to 0 010 inch an
8. ber forward side surface Do a Fluorescent Dye Penetrant inspection of the hub area The fluorescent dye penetrant inspection must also include the first 0 375 inches 9 53 mm as measured from the hub camber forward side bolt holes Refer to Standard Practices Manual Nondestructive Inspection Procedures 60 00 03 Fluorescent Dye Penetrant Inspection NOTE This inspection deviates from the Standard Practices Manual Nondestructive Inspection Procedures 60 00 03 in the following areas The liquid penetrant must be a Type I with a Level 4 Ultra High Sensitivity The penetrant dwell time must be a minimum of 60 minutes The black light must produce a minimum light intensity of 2 000 uW cm at a distance of 15 inches 1 Ifa crack is found check the propeller serial number for change letter stamping If a letter S is located in front of the serial number indicating prior rework the area of the previous rework must be determined a Ifthe change letter S is not present or previous rework was at a different bolt hole mark the location of the crack path and length with a fine point felt tip pen prior to removing the ultraviolet light NOTE Marking the area of the crack indication prior to removing the ultraviolet light is important for aiding rework if the crack size and location are found to be within acceptable limits 2 f you find any of the of the following conditions the propeller must be removed from service Re
9. d begin removal of the crack Refer to Figure 4 NOTE Final depth of cut must not exceed 0 040 inch total when attempting to remove a crack NOTE The ball end mill may extend into the bolt hole when you remove the crack Do not allow the mill centerline to extend beyond the length of crack This will allow for end mill runout Refer to figure 4 C773 Figure 4 Initial Material Removal f Examine reworked area under 10x magnification after each cut Refer to Figure 5 ASB221E Page 8 January 28 2010 ALERT SERVICE cL BULLETIN MCCAULEY ASB221E C774 Figure 5 Final Machining g If the crack appears to be totally removed repeat etch and fluorescent dye penetrant inspection of the reworked area to make sure the crack has been removed h If the crack extends beyond a depth of 0 040 inch the propeller must be removed from service 2 OPTION 2 Rotary Grinder Refer to Figure 6 a Use a 3 16 inch grinding burr and begin to remove the crack C775 Figure 6 Crack Removal Using a Grinding Burr NOTE Do not remove more than 0 040 inch material total when attempting to remove a crack NOTE Do not grind beyond length of crack NOTE The grinding burr may extend into the bolt hole when you remove the crack Do not allow the grinding burr centerline to extend beyond the length of the crack This will allow for grinding burr runout Refer to figure 4 b Measure the depth of material removed with a depth gauge ASB
10. d cracks in the propeller hub llO riginal Issue November 5 1996 Page 1 of 19 TO OBTAIN SATISFACTORY RESULTS PROCEDURES SPECIFIED IN THIS SERVICE INFORMATION MUST BE ACCOMPLISHED IN ACCORDANCE WITH ACCEPTED METHODS AND PREVAILING GOVERNMENT REGULATIONS MCCAULEY PROPELLER SYSTEMS CANNOT BE RESPONSIBLE FOR THE QUALITY OF WORK PERFORMED IN ACCOMPLISHING THIS SERVICE INFORMATION McCauley Propeller Systems PO Box 7704 Wichita Kansas 67277 7704 COPYRIGHT O 1996 McCauley Propeller Systems ALERT SERVICE cL BULLETIN McCAULEY ASB221E DESCRIPTION Alert Service Bulletin ASB221E does the following 1 Provides additional inspection procedures for the propeller bolt holes 2 Added inspections for the propeller steel reinforcement plate and the mylar gasket 3 Miscellaneous changes to increase bulletin clarity 4 Alert Service Bulletin ASB221E supersedes all previous versions of Alert Service Bulletin 221 COMPLIANCE MANDATORY All inspection and replacement requirements must be done at the compliance times and intervals shown below 1 For propellers with 1500 hours or more total time in service or if the propeller total time in service is unknown a Inspection and rework procedures must be done within the next 50 hours of service NOTE For propellers that have previously been inspected in accordance with Alert Service Bulletin 221C or of Alert Service Bulletin ASB221D compliance with the initial inspection requirements of Al
11. dles In order for Type I penetrant materials to fluoresce they must be exposed to ultraviolet light with a wavelength of 320 to 380 nanometers A The black light must produce a minimum light intensity of 2 000 uW cm at a distance of 15 inches from the face of the ultraviolet light filter to the sensor on the ultraviolet light meter Let the black light warm up for a minimum of 10 minutes before use WARNING PERSONNEL MUST NOT WEAR LIGHT SENSITIVE PHOTOCHROMIC LENSES DURING THE INTERPRETATION EVALUATION OF PARTS Both the ultraviolet light and ambient light intensities must be measured with a calibrated light meter before each inspection NOTE It is recommended that the inspector allow 3 minutes for the eyes to adapt to the dark before the interpretation evaluation of parts Do the inspection in accordance with standard ASTM E 1417 Standard Practice for Liquid Penetrant Examination or international equivalent except for dwell time 1 The penetrant dwell time must be a minimum of 60 minutes Materials used to do this inspection must be in accordance with the current version of QPL AMS 2644 Qualified Products of Inspection Material Penetrant or international equivalent CAUTION ALL MATERIALS USED IN A PROCESS MUST BE FROM THE SAME FAMILY GROUP Penetrants used must be Type I Fluorescent dye Level 4 sensitivity PERSONNEL REQUIREMENTS Individuals performing the inspections defined in this service bulletin must be a
12. e as viewed from the front to the first bolt hole Install B 7306 mylar gasket between the hub and the forward spinner bulkhead Install forward spinner bulkhead a Ifthe holes on the forward spinner bulkhead are cupped bulkhead deformation is the result of installation torques from propeller bolts and washers put the bulkhead on a flat surface and lightly work the cupped holes flat with a hammer b Remove any burrs or rough edges Diameter of holes should be 0 397 inches 0 10 or 0 10 inches Ream holes if necessary a a O I Remove from service any forward spinner bulkhead that has a bolt hole that is greater than 0 407 inches in diameter Install B 7287 steel reinforcement plate on the forward side of the forward spinner bulkhead Install new bolts A 2513 78 or bolts magnafluxed in accordance with ASTM E1444 91 without washers NOTE Bolts plate and gasket can be purchased in kit form the kit number is B 4622 43 Tighten bolts evenly then torque to 300 360 inch pounds or 25 30 foot pounds dry January 28 2010 Page 17 C i Page 18 ALERT SERVICE cL BULLETIN MCCAULEY ASB221E 9 Safety wire propeller mounting bolts make sure the safety wire is around the bolt heads not over the top Use 0 041 inch diameter safety wire 10 Install the spinner shell Report the inspection findings to McCauley 1 Make sure the Attachment Report Form for Compliance with McCauley Alert Service Bulletin
13. ert Service Bulletin ASB221E is not required 2 For propellers with less than 1500 hours total time in service a Inspection and rework procedures must be done at 1500 hours total time in service or within the next 50 hours of service whichever occurs later 3 Repetitive Inspections a After completing the initial inspection of the propeller steel reinforcement plate and mylar gasket repetitive inspections must be accomplished every 36 calendar months or every 750 hours of service whichever occurs first APPROVAL FAA approval has been obtained on technical data in this publication that affects product type design ASB221E Page 2 January 28 2010 ALERT SERVICE cL BULLETIN MCCAULEY ASB221E EQUIPMENT REQUIRED NOTE Equivalent substitutes can be used for the following materials or equipment All penetrant materials must be listed in the current version of QPL AMS 2644 NAME NUMBER MANUFACTURER USE Liquid Penetrant Type I Method Magnaflux Penetrant inspection C Level 4 3624 West Lake Avenue Ultra High Glenview IL 60026 Sensitivity www magnaflux com Radiometer DSE 2000A Spectronics Corp Measure light intensity 956 Brush Hollow Rd Westbury NY 11590 www spectroline com Ultraviolet Light ZB 100F Magnaflux To do penetrant inspection LIGHTING EQUIPMENT ENVIRONMENT 1 The penetrant inspection must be done in a darkened environment where the ambient white light intensity is not more than 2 fc foot can
14. fer to Figure 11 a Crack s in the camber forward side of the hub are 0 50 inch 13 mm or longer b Crack s in the camber forward side of the hub touch a bolt hole c Any crack on the camber forward side of the hub that is within 0 25 inch 6 4 mm of the outside edge of the hub d Any crack on the camber forward side of the hub that is within 0 25 inch 6 4 mm of the outside edge of the center bore e Acrack in any part of a propeller bolt hole including the chamfered surfaces and any depth January 28 2010 Page 5 ALERT SERVICE cL BULLETIN MCCAULEY ASB221E f The change letter S is stamped in front of the propeller serial number and the location of the previous rework cannot be determined g The change letter S is stamped in front of the propeller serial number and the crack is adjacent to a bolt hole that was previously reworked by Alert Service Bulletin 221 221B or 221C h Any part of a crack that cannot be removed by the procedures in this Service Bulletin NOTE The McCauley 1A103 TCM model propeller is no longer available from McCauley Replacement Sensenich propellers and STC information are available for the Cessna Model 152 A152 and Reims Model F152 and FA152 airplanes The replacement Sensenich propeller installation STC and necessary parts are available from McCauley Service Centers and Cessna Single Engine Service Stations 3 If you find a small crack s on the camber
15. forward side of the hub near the bolt holes that meet the following criteria the propeller can be reworked and the crack s must be removed Refer to Figure 1 and Figure 11 C770 Figure 1 Crack Identification a Allof the following criteria must be met in order for the propeller to be eligible for rework 1 Crack s in the camber forward side of the hub are less than 0 50 inch 13 mm long 2 Crack s in the camber forward side of the hub do not touch a bolt hole 3 No part of the camber forward side of the hub crack is within 0 25 inch 6 4 mm of the outside edge of the hub 4 No part of the camber forward side of the hub crack is within 0 25 inch 6 4 mm of the outside edge of the center bore 5 Ifthe propeller has previously been reworked the crack is located adjacent to a different bolt hole than one that has previously been reworked I 4 Proceed to Step 3 Hub Camber Forward Side Crack Removal Procedure C If no crack is found 1 Glass shot peen the entire camber side of the hub use AGB 18 glass shot AMS2431 6B or latest revision 80 100 PSI An approved alternate is MSH glass shot in accordance with MIL G 9954A or latest revision MIL Bead 8 i Page 6 ASB221E January 28 2010 ALERT SERVICE cL BULLETIN MCCAULEY ASB221E 2 Corrosion protect the propeller a Apply color chemical film treatment to all bare surfaces of the propeller that came in contact with the caustic etch solution
16. n employee of an FAA approved facility or international equivalent with a specialized service rating in the applicable inspection method Employees must be qualified and certified to the minimum recommended requirements of Level II as described in Aerospace Industrial Standard NAS 410 ASNT s SNT TC 1A or equivalent national international standard ASB221E January 28 2010 Page 3 ALERT SERVICE cL BULLETIN MCCAULEY ASB221E ACCOMPLISHMENT INSTRUCTIONS NOTE Make sure you read and understand all of the instructions in this service bulletin before the work to comply with this service bulletin is started 1 Preparation A Remove the propeller from the airplane 1 For propellers that are not in compliance with previous revisions of this service bulletin refer to the Cessna 152 Series Service Manual and Figure 13 2 For propellers that are in compliance with previous revisions of this service bulletin refer to the Cessna 152 Series Service Manual and Figure 14 B Strip paint from the propeller hub area 1 There should be no paint on the face aft side of the propeller hub If there is make sure all paint in that area is removed Remove the paint from the camber forward side of the propeller hub Make sure all paint is removed from the hub area of the propeller Refer to Figure 12 for an illustration of the inspection area on the camber forward side of the propeller a Remove paint Refer to the Standard Practices Man
17. service Y C Within 1 4 0 250 inch REMOVE FROM SERVICE Any crack longer than 1 2 0 500 inch that contacts a bolt hole is less than 1 4 0 250 inch from hub centerbore or is located in area of previous rework is unacceptable Remove unrepairable propeller from service Within 1 4 0 250 inch REMOVE FROM SERVICE Figure 11 Reworkable and Non Reworkable Cracks Sheet 1 ASB221E January 28 2010 Page 13 ALERT SERVICE cL BULLETIN MCCAULEY ASB221E C1112 NOTE All dimensions shown are in inches l l l a Typical l l Crack Figure 12 Typical Crack Appearance and Location Sheet 1 ASB221E Page 14 January 28 2010 ALERT SERVICE cL BULLETIN MCCAULEY ASB221E C1113 Crankshaft With Ring Gear Forward Propeller Spinner Bulkhead Screw Rear Spinner Bulkhead Washer Bolt Spinner 0102T1076 Figure 13 Original Configuration of 1A103 TCMXXXX Propeller and Spinner Installation Sheet 1 ASB221E January 28 2010 Page 15 ALERT SERVICE cL BULLETIN MCCAULEY ASB221E C1110 Crankshaft With Ring Gear Propeller Forward Spinner Bulkhead Screw Rear Spinner Bulkhead Mylar Gasket Steel Bolt Reinforced Plate Spinner 0102T1076 Figure 14 Reworked Configuration for 1A103 TCMXXXX Propeller and Spinner Installation Sheet 1 ASB221E Page 16 January 28 2010 ALERT
18. service due to crack ASB221E January 28 2010 Page 19
19. ual Cleaning Procedures 60 00 01 Paint Removal C Caustic etch the inspection area of the propeller hub Refer to Standard Practices Manual Nondestructive Inspection Procedures 60 00 03 Caustic Soda Etch 1 Make sure the anodize coating has been removed from the inspection area 2 Make sure there are no burrs or other metal obstructions on the area to be inspected on the propeller hub 2 Inspection NOTE For the purposes of this inspection the chamfered area around each bolt hole is considered a part of the bolt hole A Determine condition of all propeller bolt holes 1 Visually examine the propeller bolt holes with a 10X power magnifying glass a Make sure there is sufficient light available to illuminate each propeller bolt hole If required use a flashlight or similar light source to illuminate each propeller bolt hole b Make sure there are no burrs or other metal obstructions in the propeller bolt holes If burrs and scratches are detected remove the burrs and scratches in accordance with the following instructions 1 Ream bolt hole to a diameter of 0 406 inch 0 002 or 0 002 inches 10 31 mm 0 05 or 0 05 mm NOTE The entire length of the bolt hole must be reamed NOTE Reaming may not result in a smooth bolt hole surface throughout the entire length of the bolt hole NOTE This procedure does not affect the 0 636 inch 0 003 or 0 002 inch 16 15 mm 0 08 or 0 05 mm bolt hole counterbore on the
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