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MPC-26 Propeller Owner/Operator Information Manual

1. CYLINDER BALANCE WEIGHT COUNTERWEIGHT ASSEMBLY COUNTERWEIGHT ASSEMBLY BLADE SHIM OUTER RACE BALL SEPARATOR SPLIT SHIM INNER RACE O RING SPLIT RETAINER LOW PITCH STOP PLATE J STOP PISTON VENT ea 010271020 C300 Series Propeller Non Oil Filled Figure 2 Sheet 1 61 30 01 Page 4 McCauley Propeller Systems Dec 7 2009 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL C1190 RETAINING RING SHIM CARRIER O RING OUTER RACE INNER RACE BALL SEPARATOR f gt SPLIT RETAINER DETAIL A HUB VENT FOR NON OIL FILLED PROPELLERS OIL FILL PLUG FOR OIL view A A BLADE FILLED PROPELLERS BLADE ACTUATING PIN HUB ASSEMBLY A CYLINDER BALANCE MOUNT RING RING CONTROL ACTUATION SPRING CYLINDER S Q _____ fe SPAGER SUPPORT LOW TU Jos PITCH PISTON STOP LINK C400 Series Propeller Figure 3 Sheet 1 61 30 01 Page 5 McCauley Propeller Systems Dec 7 2009 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL C1191 WIRE RING RETAINING RING O RING BALL D
2. 1 McCauley overhaul manuals These manuals provide maintenance and overhaul information and illustrated parts lists NOTE Overhaul manuals may be used only by approved propeller repair stations Blade Overhaul Manual and Standard Practices Manual These manuals include information to supplement the overhaul manual and provide information about procedures common to various propeller models The Blade Overhaul Manual includes minimum allowable thickness and width tables for blades NOTE Blade Overhaul Manual and Standard Practices Manual may be used only by approved propeller repair stations McCauley Application Guide MAG This Guide has a compilation of information published in the FAA CAA aircraft type data sheets regarding propeller spinner and governor installations on various aircraft NOTE This guide is not FAA approved and is for reference only Refer to the appropriate Type Certificate Data Sheet TCDS or Supplemental Type Certificate STC to verify information contained in this guide McCauley Service Bulletins These are issued to advise of design changes that must be incorporated to provide procedures for correcting problems that have been found and to provide other important service and overhaul information McCauley Service Letters These are issued to provide information such as warranty replacement policies parts availability information minor modifications and other supplemental information FAA Advisory
3. 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 Airworthiness Directives Service Bulletins and Service Letters have been complied with at the time of production McCauley Propeller Systems PROPELLER INSTALLATION PAGENUMBER T Owner Name Address Propeller Model NR WER GEN McCauley Propeller Systems INSTALLATION HISTORY PAGENUMBER T Aircraft Model Serial Number and Date Registration Number Engine Serial Number amp Position O McCauley Propeller Systems o 7 m Lu N lt Lu e PAGE NUMBER Aircraft Model Signature amp Certificate Number Maintenance Service History amp Registration Number Time Since Overhaul McCauley Propeller Systems o 2 Q lt mr Lu e PAGE NUMBER Blade Model Blade Serial No Installed
4. Each time a line is added measure the horizontal difference between the lines farthest apart a For propellers installed on piston engines all blades must measure within 0 0625 inch 1 6mm of each other b For 1101 through C1104 models propellers installed on turbine engines all blades must measure within 0 1875 inch 4 7mm of each other c For all propellers installed on turbine engines except C1101 through C1104 model propellers all blades must measure within 0 170 inch 4 3mm of each other If blade track difference exceeds the allowable limits recheck the blade face alignment Refer to Blade Overhaul Manual BOM100 6 Lightning Strike Inspection Requirements A If doubt exists as to the occurrence of a lightning strike the following criteria can be used to verify any suspicion 1 2 3 4 NOTE Check for burns or signs of arcing on blades and hub Using a magnetism detector check all exposed steel areas of propeller for magnetism Look for any signs of localized melting or metal flow particularly on blades If preliminary inspection suggests an actual strike a complete propeller overhaul is to be accomplished as per the applicable McCauley overhaul manual Dynamic Balance 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 61 30 01 Page 604 McCauley Pr
5. In Hub Model Serial Number Signature amp Certificate Number Maintenance amp Service History Aircraft Type amp Serial Number McCauley Propeller Systems FAA AIRWORTHINESS DIRECTIVE AND SERVICE BULLETIN SERVICE LETTER COMPLIANCE RECORD PAGE NUMBER Total Time Signature amp Propeller Since Airworthiness Directive Service Bulletin Service Letter Certificate Date Time Overhaul Number Number McCauley Propeller Systems
6. 11 Blade Shake A C Symptom NOTE Blade Shake is listed in the Propeller Troubleshooting section of this manual for informational purposes only as it has been misinterpreted in the past as a possible problem by some operators Despite it s appearance in this section it should never be considered a cause for concern or propeller replacement 1 Blade shake is the tendency for the blades to wobble slightly when the tip is physically moved by hand from the leading edge to the trailing edge Refer to Figure 101 a Total maximum allowable movement up to 0 125 inch 3 13 mm is considered normal Cause 1 This tendency is the natural result of a tolerance buildup A very small movement at the hub is magnified many times at the blade tip It is NOT the source of vibration or any other problems While the propeller is rotating centrifugal force on the blades seats them rigidly and positively against the retention bearings in the hub Corrective Action 1 corrective action is required 12 Oil or Grease Leaks A The presence of oil or grease on propeller blades may or may not indicate a problem 1 Grease lubricated propellers may have grease deposits on the blade shank during the first 25 or 50 hours of operation after overhaul because the retaining bearings were packed with an excessive amount of grease 2 All propeller blades may show minor grease streaking when new or newly overhauled Such streaking is norm
7. 4622 20 716 ves 5 1538 6381 NA _ 3927 42975 6 4622 16 ves 5 ass aime B4020 42756 8 462224 12 ves 5 A259 aise NA Deeg 07744 29757 6 462245 12 Yes 6 2515205 farcies A 1639 2 Dee oa ve ves _ 16382 A 1639 2 D se NA na B 462244 se ves 6 3 luess NA A40 fesses 12 No 5 amp 4_ 1 810 A 1639 2 Dreem 84516 A297368 6 462220 776 ves 6 1338 A T636 NA Dreem Case 4 2756 6 4622 20 716 ves 5 1538 6381 NA Deen NA fesses 12 ves 6 1315 fair NA NA Im fesses ve No 6 A251317 635 2 NA fesses w2 No 5 ass A 639 2 maso A2973 5 B 4622 17 ves 5 aassss aime __ 273_ 9 6 2 38 ves 6 NA NA D se ase A297356 B462219 ves 5 Aasiaat fan Deen NA fesse ves 8 fasse A ies9 n NA Dec 8430 9735 84622 se ves Ier aimes Gaam NA NA B 462244 ves 6 A251349 Ai63838 NA NA NA se ves 5 rs 8 35 42756 84622 715 Yes 6 assises fais B 4351 A297356 B 4622 12 ves 5 1377 aim
8. 6 B 4622 33 A 2513 41 1638 13 NA A A 2513 8 A 1638 13 NA A A A A 1A90 CF A A A A A 7 3 3 3 A 2513 9 A 1639 6 B 3515 2575 6 1622 35 3 1B90 CM 3 A 2513 9 A 1639 6 B 3718 A 2513 18 A 1639 2 B A 2513 18 A 1639 2 A 2513 38 N A 2513 8 NA 1A135 CRM ESCH Y Y Y Y Y Y N Y Y Y Y Y Y 0 5 5 O 0 5 5 5 0 5 5 es 0 5 es es es es es es 2 2 1 8 8 2 8 8 8 8 2 2 1 8 61 30 01 1002 McCauley Propeller Systems Dec 7 2009 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL Table 1003 Installation Parts for Fixed Pitch Propellers continued Basic Fixed Pitch Bolt Kit Propeller Model Spacer Dowel Bolt Kit Bolt Drilled No Washer Number P N P N P N Dia Head Bolts Bolt P N P N Nut P N Dap NA NA __ 4622 80 ss ves asso fais FiazoorDrA B 3434 429756 462228 12 ves 5 1318 16 810 _ Deem NA 4o fesses 12 No 6 A251346 farce 1635 D n 84180 4 29756 8462213 ves 5 fasses fais arom NA NA ves 8 assis fais NA NA 22 6 ves 1323 Iess Deem 07659 A25737 84622 12 ves 6 assis 1638 0 416892 Deem 07639 B46221 12 ves 5 assiste A 1639 0 A 1639 2 Deem 84516 A297358 8 4622 20 716 ves _6__ 61986 Deem case 29756 B
9. C750 Series Propeller Figure 8 Sheet 1 61 30 01 Page 12 McCauley Propeller Systems Dec 7 2009 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL C1050 BLADE COUNTERWEIGHT PROPELLER HUB OIL FILL SCREW BLADE ACTUATING REVERSE PIN STOP BETA ROD BETA SPRING FEED BACK COLLAR PISTON ROD CYLINDER PISTON FEATHER STOP BETA ROD LINK SLIP RING ASSEMBLY WIRE RING RETAINING RING SOLID SHIM SPLIT SHIM O RING SHIM CARRIER OUTER RACE BEARING e INNER RACE SPLIT RETAINER DETAIL A 0102T1075 C1000 Series Propeller Figure 9 Sheet 1 61 30 01 Page 13 McCauley Propeller Systems Dec 7 2009 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL C1196 P Y BLADE PLUG COUNTERWEIGHT oy BLADE RETENTION BEARING E lt 7 SE PROPELLER HUB OIL H RETAINER FILL SCREW Lh el EI SPLIT SUPPORT PLATE 2 SPLIT RETAINER Tae PISTON LATGH PAWL REVERSE STOP ART CG SPRING EE HOUSING SPRING CYLINDER LATCH START LOCK ACTUATING STUD FEATHER STOP PIN ACTUATING HUB LINK PROPELLER SECTIONAL DRAWING C1105 NOTE THE OIL FLOW BETA TUBE IS FURNISHED BY ENGINE MANUFACTURER C1100 Series Propeller Figure 10 Sheet 1 61 30 01 Page 14 McCauley Propeller Systems Dec 7 2009 McCAULEY PROPELLE
10. McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL Table 1003 Installation Parts for Fixed Pitch Propellers continued Basic Fixed Pitch Bolt Kit Propeller Model Spacer Dowel Bolt Kit Bolt Drilled Washer Number P N P N P N Dia Head Bolts Bolt P N P N SCH P N B 4622 43 1A103 TCM NOTE1 Yes A 2513 78 ew ne e aaa aim mA EREECHEN EES NOTE 1 Bolt Kit B 4622 43 contains 6 ea A 2513 78 bolts 6 B 73036 mylor gaskets 1 7287 Reinforcement Plate and 1 ea drawing 7387 NOTE 2 A 1170 bushings are included with the bolt kit 61 30 01 Page 1005 McCauley Propeller Systems Dec 7 2009 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 should be accomplished at your nearest McCauley Approved Service Station 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 Service Station may void your warranty 1 A FAA LOGBOOK REGULATIONS Maintenance Records Refer to 14 CFR 91 417 for a complete copy of this regu
11. OWNER OPERATOR INFORMATION MANUAL WARNING Use extreme care when you drill bulkheads near blades to avoid shank damage Blade shank damage could potentially require propeller disassembly and blade 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 possible sources of vibration 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 Exhaust stack touching engine cowling Component in engine compartment that is touching engine cowling OO WD 9 Overspeeding of Propellers A Following are inspection criteria for McCauley propellers involved in overspeed conditions WG ss Percentage Overspeed Action to be Taken All Propellers on Up to but not including 15 General external visual i
12. a way that the airfoil contour remains substantially the same File strokes must run from blade shank to blade tip Avoid abrupt changes in contour and blunt edges The length of the blended area shall be equal to 10 times the depth of the nick refer to Figure 202 Use a suitable fine cut file and course grain emery cloth crocus cloth or 600 grit sandpaper 5 Face and Camber Repair Procedures a CAUTION Care must be taken to control hand held grinder Remove metal at damaged area using hand held rotary grinder with 120 or less grit bob or by hand using course grain emery cloth Use of file in this area is not recommended 1 Grind with light pressure circular motion until the damage is totally removed The diameter of the repair shall be equal to 20 times the depth of the damage Refer to Figure 202 Smoothly finish surface with fine grain emery cloth crocus cloth or 600 grit sandpaper 6 Repair Completion a Following removal of damage the affected area should be prepared for touch up paint by wiping with a methyl propyl ketone MPK dampened cloth Apply polyurethane enamel paint to reworked area per Blade Painting 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 aluminum blade surface will be accelerated This is particularly true at blade t
13. aircraft operation 1 Possible Causes a 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 blade track or linkage problems within the propeller b 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 vibration occurs at only one RPM or within a limited RPM range the vibration is not normally due to a propeller problem 2 Corrective Action a Ifthe propeller is suspected as the cause of the vibration the following procedures should be performed 1 The ideal troubleshooting method is to temporarily replace the propeller with one which is known to be good and test fly the aircraft If the vibration is eliminated the propeller is highly suspect and should be sent to an authorized propeller repair station for evaluation If a replacement propeller is unavailable check the following a 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 f
14. are specifically designed for this operation Never install a propeller on an aircraft unless it is a model approved by 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 3 Fixed Pitch 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 In the following instructions installation of 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 have been grounded prior to approaching propeller Spinner Assembly Removal 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 Remove screws and wa
15. due to fatigue Hub or blade failure has the potential of causing a catastrophic event due to blade separation The propeller RPM restriction is often placed below the minimum idle RPM however certain aircraft have a restriction that is above the propeller idle RPM setting Either restriction is important The propeller operating restrictions or limitations may be found in the Airplane Flight Manual AFM or Airplane Flight Manual Supplement AFMS The propeller installations may be controlled by the various airframe manufacturers Type Certificate TC or by Supplemental Type Certificate STC Spinner Installation CAUTION Undershimming or overshimming of the spinner aft bulkhead could result in spinner wobble vibration and or bulkhead and spinner cracking Please follow shimming procedures carefully 1 Install propeller spinner fillets on the bulkhead with screws and washers if required 2 Insert shims into the spinner support and lightly press spinner support onto the cylinder on the front end of the propeller 61 30 01 Page 211 McCauley Propeller Systems Dec 7 2009 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL 3 Mount the spinner onto the bulkhead and fillet assembly and check alignment of the mounting holes in the spinner and bulkhead a Make sure that alignment marks on the spinner and propeller blade are matched b Add or subtract shims to the spinner support until spinner mounting holes are al
16. facility in accordance with the applicable overhaul manual A hub must be declared unairworthy and scrapped if any blade in the propeller assembly is bent beyond repair limits 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 field repair limits is cause for propeller removal and repair Refer to Blade Maintenance in Propeller Field Maintenance Practices c Check blade track and make sure that all blades measure within 0 170 inch of each other This is a one time check after a blade strike Refer to Blade Track Check in Propeller Periodic Inspection Practices 61 30 01 Page 603 McCauley Propeller Systems Dec 7 2009 3 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL d Check blade twist All blades in a propeller should have the same amount of rotational play If the difference in rotational play between two blades is beyond 1 0 degree uneven internal wear or damage is the possible cause 1 For example rotational movement of No 1 blade measures 1 2 degrees and 2 blade measures 2 3 degrees This would be considered excessive since the difference is more than 1 0 degree 2 This check must be performed every 10 hours for the next 20 hours after bird strike If no change is seen after 20 hours inspections may be discontinue
17. installed The deice electrical harnesses connect the deice boots to the slip ring assembly to complete the deice electrical circuit d Deice Slip Ring Assembly if deice is installed The deice slip ring assembly is constructed of machined aluminum with bronze commutator rings bonded to one side Studs to attach the deice leads for each blade are located on the propeller side of the platter These are brazed to the commutator rings and pass through holes provided for that purpose Slip ring assemblies are secured to the hub or are sandwiched between the hub and the engine flange o o o 3 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 TBO for the propeller can be found in the latest revision of McCauley Service Bulletin 137 X NOTE specification is subject to change Any changes to TBO will be announced in revisions of McCauley Service Bulletin 137 X 4 Propeller Model Designation A B McCauley uses a model designation system to identify specific propellers This is done by utilizing a combination of hub and blade model designations Hub Model Designation 1 The hub model designation is steel stamped on the cylinder face of the propeller hub Examples of hub model designation 61 30 01 Page 15 McCauley Propeller Systems Dec 7 2009 McCAULEY PROPELLER SYSTEMS OWNER OPERATO
18. is installed The deice slip ring assembly is constructed of machined aluminum with bronze commutator rings bonded to one side Studs to attach the deice leads for each blade are located on the propeller side of the platter These are brazed to the commutator rings and pass through holes provided for that purpose Slip ring assemblies may be secured to the hub to the starter ring gear or the alternator belt drive pulley 2 Turbine Engine Propellers Turbine Engine Propeller Component Description 1 The McCauley C600 is a three blade propeller the C650 is a four blade propeller the C1100 is a five blade propeller Each consists of a hub assembly propeller blades piston and cylinder assembly blade start locks counterweights a spinner and spinner bulkhead assembly Refer to Figure 5 Figure 6 and Figure 10 a The McCauley C600 C650 and C1100 propellers are used on Honeywell Garrett turbine engines NOTE This manual does not include information for C1101 through C1104 propellers 61 30 01 Page 7 McCauley Propeller Systems Dec 7 2009 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL 2 The McCauley C700 is a three blade propeller the C750 is a four blade propeller the C1000 is a five blade propeller Each consists of a hub assembly propeller blades piston and cylinder assembly counterweights and beta shift mechanisms Refer to Figure 7 Figure 8 and Figure 9 a The McCauley C700 C7
19. major and reconditioning must be accomplished 4 Frequency of Overhaul Refer to the latest revision of McCauley Service Bulletin SB137 XX Revised Time Between Overhaul TBO Specifications for required propeller overhaul intervals Propellers shall also be overhauled or repaired as required for blade surface conditions The propeller mounting bolt torque should be checked at least once a year Propeller mounting bolts should be penetrant inspected whenever the propeller is removed from the engine 2 Blade Serial Number Stamping Information A Blade serial number information is stamped on the hub Refer to Figure 1 Table 1 Blade Year of Manufacture Code e SS u z far am 61 30 00 2 McCauley Propeller Systems Dec 7 2009 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL Table 2 Blade Month of Manufacture Code 1 Blade serial numbers assigned after 1980 and before June 15 2000 a The first letter represents the year of manufacture a b The second letter represents the month of manufacture c The following digits represent the number of the blade manufactured during the month of manufacture 2 Blade serial numbers assigned after June 15 2000 first or first and second letters represent the year of manufacture The second or third letters represent the month of manufacture first two digits repre
20. mounting surface to catch any spilled engine oil when the propeller is removed Break the torque on the propeller mounting nuts on Continental engine installations For Lycoming installations remove safety wire from bolts and break the torque Install propeller sling and attach to hoist If a hoist is not available the propeller may be supported and lifted by hand Take up slack on the propeller sling and hoist or support propeller and remove the nuts or bolts 61 30 01 Page 204 McCauley Propeller Systems Dec 7 2009 7 8 9 10 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL CAUTION Propeller must be removed from engine in a straight motion Any rocking on the engine could cause damage to the propeller mounting flange Carefully slide the propeller forward and remove from the engine Place propeller on a suitable support or propeller stand Install protective cover over propeller hub mounting flange Install protective cover over open end of engine propeller flange Propeller Assembly Installation 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 If required attach bulkhead mounting ring or bulkhead to hub Remove protective cover from end of engine propeller flange En
21. of the nut on the stud by hand 1 Refer to McCauley Fixed Pitch Service Manual P N 730720 latest revision for illustrated exploded views and the applicable parts list for the required parts used with the individual propeller installation 2 Dowel and spacer assembly a Refer to the applicable propeller assembly exploded view in the McCauley Fixed Pitch Service Manual and install dowels and spacers as illustrated NOTE Refer to the McCauley Fixed Pitch Service Manual for the location of the dowels in the spacer When dowels are in position the dowels will be engaged approximately half in the spacer or crankshaft flange and half in the propeller hub b The assembled propeller dowel and spacer should be a press fit and not separate easily Refer to the latest revision of McCauley Service Bulletin SB227 X Propeller Installation Mounting Torque for the correct installation torque values for propeller mounting hardware Assembly of the spinner installation is completed as the propeller is installed on the engine crankshaft flange Some installations have the spinner rear bulkhead held between the propeller hub and the spacer Other installations may have the front bulkhead clamped by the mounting bolts or nuts and the rear bulkhead clamped between the propeller and the crankshaft flange or starter ring gear Some installations use a spacer support pressed into the front propeller hub bore Assemble the propeller installation as foll
22. propeller installation whenever possible However nuts may be reused if the locking material prevents turning of the nut on the stud by hand Remove protective cover from the end of engine propeller flange Make sure the flange is clean and free of nicks and burrs Make sure that the engine propeller flange dowels and mounting stud holes are clean dry and free of nicks and burrs Remove the protective cover from the propeller hub mounting flange Make sure that the propeller hub mounting flange dowel pin holes and mounting studs are clean and undamaged Make sure that a new O ring is installed in the groove of propeller hub mounting flange Lubricate the O ring with engine oil prior to installation of propeller Hoist straps must be a minimum of 4 inches 100 mm wide Use a propeller sling and hoist or additional personnel to position the propeller close to the engine propeller flange and align engine flange dowel pins with the dowel pin holes on the propeller hub mounting flange Rotate engine propeller mounting flange as required to align the dowel pin holes CAUTION Propeller must be installed straight onto the engine flange Any cocking of the propeller with respect to the flange could result in damage to the engine propeller flange mating surfaces Mount the propeller on the engine propeller shaft Make sure threads of nuts and studs are free of burrs nicks and similar damage and clean of foreign material 11 McCaule
23. 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 blades for nicks scratches dents erosion corrosion cracks etc Apparent damage found should be referred to an appropriately rated mechanic A crack or bend is cause for removal of the propeller Check the propeller spinner attaching screws for security and check the spinner for damage Check the propeller for evidence of oil or grease leakage Clean propeller blades periodically using fresh water a non alkaline cleaner and a soft cloth or soft brush Dry with a soft cloth NOTE Always have the blade pointing down to prevent moisture from collecting in the hub Propellers operating in corrosive environments such as agricultural or costal operations a Clean the area of the propeller blade snap rings and the propeller hub blade sockets with water soft bristle brush do not use a hard bristle brush and clean towel 1 Remove as much foreign material from the propeller blade retaining ring area as possible b Make sure the propeller blade retaining ring area is dry c Apply LPS 3 Rust Inhibitor to the retaining ring area at the base of the propeller blades and hub sockets 4 Apply LPS 30 as frequently as necessary to prevent corrosion Ensure tha
24. 009 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL C320 ACTUATING PIN SPRING ASSEMBLY HUB 21 el Z pes 2 V YX VV CYLINDER ME SUPPORT PISTON SPACER HIGH PITCH BALANCE RING WIRE RING BLADE RETAINING RING SHIM O RING SPLIT SHIM SHIM CARRIER OUTER RACE BALLS SPACERS INNER RACE SPLIT I RETAINER VENT STATIC BALANCE WEIGHTS NON OIL FILLED mm C200 Series Propeller Figure 1 Sheet 1 61 30 01 Page 2 McCauley Propeller Systems Dec 7 2009 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL C336 OIL FILL ACTUATING ope SPRING ASSEMBLY HUB SPACER 2 20 LOW PITCH Em CYLINDER 521222244 SUPPORT PISTON SPACER HIGH PITCH BALANCE RING LINK WIRE RING BLADE RETAINING RING SHIM SPLIT SHIM SHIM CARRIER OUTER RACE BALLS SPACERS INNER RACE O RING SLOT BLOCK SPLIT RETAINER SERIAL NO BLADE PLUG STATIG BALANGE WEIGHTS OIL FILLED C200 Series Propeller Figure 1 Sheet 2 61 30 01 Page 3 McCauley Propeller Systems Dec 7 2009 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL C319 ACTUATING PIN ASSEMBLY HUB ASSEMBLY 17
25. 2 All blades showing evidence of unapproved repairs require removal of the entire propeller and proper assessment by a repair facility 3 Sighting along the leading edge of a propeller blade for any signs of bending can also provide evidence of unapproved blade straightening 4 Any deformation of the flat portion such as bows or kinks may indicate previous unauthorized straightening of the blade 5 Careful visual inspection of the leading edges and the flat faced portion of the blade may sometimes detect unapproved repairs 6 Blades should also be examined for any discoloration that would indicate unauthorized heating a Aluminum blades that have been heated for any repair must be removed from service since only cold room temperature straightening by an approved repair facility is authorized 7 Field service personnel should never straighten bent propellers to facilitate shipping when the propellers are being sent to a repair facility for inspection and repair This procedure can conceal important information related to the severity of the damage 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 unairw
26. 40 1 B 4940 1 B 4940 1 Spinner Shim B 4940 2 B 4940 2 B 4940 2 B 4940 2 B 4940 2 B 4940 2 NOTE 1 C1100 Series does not include C1101 through C1104 Table 1003 Installation Parts for Fixed Pitch Propellers Basic Fixed Pitch Bolt Kit Propeller Model Spacer Dowel Bolt Kit Bolt Drilled No Washer Number P N P N P N Dia Head Bolts Bolt P N P N Nut P N 1A230 AFC A 2513 17 A1639 2 C190 ALM A 2513 30 A 1639 6 1 200 2513 17 1639 2 1A175 ATM B 4622 20 A 2513 38 NA 1A105 BCM B 4622 16 A 2513 20 NA 1B235 BFA A 2973 6 B 4622 27 A 2513 33 NA B T A 2513 99 NA 2513 18 1639 2 2513 18 1639 2 2513 79 I mw EN Le BCS B 4622 20 i 4622 16 EX B 4622 27 ES 1A170 BMS A 2973 6 B 4622 41 1 2 Yes 6 4622 1 B 4622 1 se E A 1638 13 and 2513 105 1638 14 1639 6 1600 IE ECH ka Ku KOM ER SC 1A135 BRM 4622 1 1A135 BRM 4622 1 10172 BTM B 4381 2973 6 4622 37 6 A 2513 8 1638 13 2513 9 A 1638 13 A 1639 6 A 1A170 CFA B 3637 2973 6 4622 23 B 4622 23 1A90 CH B 3515 Yes Yes B 4622 37 7 16 1A162 TCD 3 8 Yes Yes Yes A 2513 33 N No NA NA 36 age NA NA B a600 42 98 83557 425755 NA noez 1 1C90 CLM 3515 A 2973
27. 5 NA NA 846229 ve 6 fasses aieas Na NA NA E 462220 56 ves 1510 A 1650 13 NA NA NA 5 ve ves 6 A251343 NA D se NA Log fesses 12 No 6 A2513 6 A 6382 aise NA NA se ves 6 assis NA 8 4622 20 716 ves 6 Az51538 Aes9 NA Denn NA NA 229 ss ves A 6383 NA TAT02 OCM 0 461 429756 B 4622 42 58 ves 6 A251377 Ai638 4 NA Ta10200M 4593 22786 B462212 56 Yes 5 A251327 A 1635 4 NA gon NA 46225 ve No 6 seng fais 1635 C 4513 22786 ves 6 ass amsn mee C 4593 22786 B 4622 12 58 ves 6 A251377 Ai638 4 NA eeng NA A207S 6 B 4622 25 12 ves 5 assis luess Deem NA 646222 12 No 6 1558 fais 1635 1725 B4425 22786 8 4622 87 76 ves 6 Dee NA NA B46229 ss ve 4188819 gen NA NA fesses ve ves 6 aise NA moste NA Log 6225 12 No 6 A2513 t6 A 6382 16352 meer NA 25 12 No 6 A2513 t6 A 6382 163922 mee Ted Note2 846227 Yes 6 Az5197 A 1638 43 A 1639 6_ 61 30 01 Page 1004 McCauley Propeller Systems Dec 7 2009
28. 50 and C1000 propellers are used on Pratt and Whitney turbine engines 3 Following is a breakdown of each of the propeller assemblies a Propeller Hub Assembly 1 propeller hub is a single piece hollow assembly incorporating three four or five propeller blade sockets The propeller blade sockets are O ring sealed to prevent leakage The rear hub face has threaded studs and dowel holes for alignment and proper mounting to the engine propeller shaft flange The cylinder is mounted to the hub face using screws and is O ring sealed to prevent leakage b Propeller Blades 1 propeller blades are made of solid forged aluminum A set of split retainers inside the hub secures each blade in the hub at the propeller blade sockets Each blade rotates about its axis on a bearing assembly during pitch change and is match balanced to the other blades The propeller assembly is static balanced using balance weights mounted with screws to the blades c Piston and Cylinder Assembly 1 piston and cylinder assembly through the feather springs counterweights and oil pressure transferred through the piston rod provide the forces necessary to accomplish propeller blade pitch changes d Counterweights 1 Counterweights are attached to the blades to assist the feathering spring located front of the piston and cylinder assembly in feathering the propeller blades by means of centrifugal force whenever the propeller is rotating an
29. AULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL F Propeller Strike or Sudden Engine Stoppage 1 Refer to the latest revision of McCauley Service Bulletin SB176 X Necessary Actions Following Object Strike of Stationary Propeller Blade Strike of Rotating Propeller Bird Strike or Sudden Engine Stoppage for the current inspection requirements following a propeller strike type event G Lightening Strike 1 Refer to the latest revision of McCauley Service Bulletin SB177 X Lightening Strike Inspection Requirements for the current inspection requirements following a suspected propeller lightening strike type event H Definitions of Propeller servicing 1 Overhaul This term denotes a complete tear down and reassembly which is not necessarily applicable to a fixed pitch propeller The terms overhaul and reconditioning are synonymous for a fixed pitch propeller 2 Reconditioning The repair of minor or major blade damage caused by erosion or striking small objects during normal operation The propeller shall be penetrant inspected refinished and rebalanced Reconditioning is accomplished on an irregular basis as necessary and required 3 Repair The correction on an irregular basis as necessary of minor or major damage that has occurred to the propeller The amount degree and extent of damage determines whether or not the propeller can be repaired without refinishing If a propeller is bent or twisted the repair is
30. Circular 43 13 1 X This publication provides general acceptable maintenance procedures for propellers FAA Advisory Circular 20 37 X This publication provides general acceptable maintenance and inspection procedures for propellers 14 CFR Part 43 Appendix A This appendix defines the differences between minor and major propeller repairs Major repairs may only be performed by an approved propeller repair station INTRODUCTION i McCauley Propeller Systems Dec 7 2009 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL LIST OF REVISIONS 1 General A This manual MPC 26 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 April 7 2008 Revision Number Date Revision Number Date 1 Dec 7 2009 LIST OF REVISIONS Page McCauley Propeller Systems Dec 7 2009 1 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL FIXED PITCH PROPELLER DESCRIPTION Metal Fixed Pitch Propellers A The propellers of this model series are manufactured of one piece anodized aluminum alloy and a fixed pitch B For identification the hub of each propeller is stamped with the complete model number serial number Federal Aviation Agency FAA type certificate number producti
31. DETAIL A view A A 010171049 C650 Series Propeller Figure 6 Sheet 1 61 30 01 Page 10 McCauley Propeller Systems Dec 7 2009 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL C1194 BLADE A HUB ASSEMBLY BLADE COUNTERWEIGHT A ACTUATING PIN BETA SPRINGS L FEED BACK EX COLLAR PISTON J ROD CYLINDER H ri PISTON FEATHER BETA ROD STOP A A f LINK SLIP RING BETA ROD 4 ASSEMBLY WIRE RING RETAINING RING SOLID SHIM SPLIT SHIM O RING SHIM CARRIER NUMBER 1 BLADE OUTER RACE BEARING INNER RACE SPLIT PROPELLER RETAINER HUB OIL FILL SCREW DETAIL A view A A C700 Series Propeller Figure 7 Sheet 1 010171051 61 30 01 11 McCauley Propeller Systems Dec 7 2009 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL C1195 BLADE HUB ASSEMBLY A A BETA ROD COUNTERWEIGHT Gen FEED BACK COLLAR SPRINGS hu RN ROD EL 05 59 E CYLINDER PISTON el FEATHER BETA STOP e WIRE RING BLADE O RING RETAINING RING LINK Sen SOLID SHIM SPLIT SHIM OIL FILL SCREW ASSEMBLY SHIM CARRIER OUTER RACE AP rec SS BEARING ESN ZX NUMBER 2 SS SERA 1 BLADE RY 2 INNER RACE SPLIT RETAINER DETAIL A VIEW A A 0101T1053
32. ELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL 2 Painting Materials and Procedures NOTE Follow painting procedures specified by paint manufacturer when painting blades a It is recommended that final dry film paint thickness be 6 to 9 mils for best abrasion resistance 10 Propeller Internal Lubrication A Servicing of Propeller Internal Lubrication 1 General a Unless significant oil leakage is observed periodic servicing of the oil in McCauley propellers is not normally necessary 61 30 01 Page 216 McCauley Propeller Systems Dec 7 2009 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL PROPELLER PERIODIC INSPECTION PRACTICES 1 Limitations A B Operational and service personnel should be familiar with the following limitations during any inspection Corrosion Other than small areas of light surface corrosion with no evidence of pitting the presence of corrosion may require propeller removal and reconditioning by an appropriately rated repair facility Intergranular corrosion may be present when the corrosion protective coatings paint anodize etc have been lost Corrosion pitting should be removed as described in the overhaul manual and applicable ADs Unauthorized Straightening of Blades 1 A bent propeller cannot be straightened without special processing in an appropriately rated repair facility because bending may harden the aluminum and lead to catastrophic blade failure
33. PTIONAL LETTERING MAY BE ARCHED OR STRAIGHT BUT THE SERIAL NUMBER STAMPING IS FOUND AT THE NUMBER 1 BLADE 010171152 Fixed Pitch Blade Stamping Figure 1 Sheet 2 61 30 00 Page 5 McCauley Propeller Systems Dec 7 2009 1 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL CONSTANT SPEED PROPELLER SYSTEM DESCRIPTION and OPERATING PRINCIPLES Reciprocating Piston Engine Propellers A McCauley propellers for reciprocating engines are of two types constant speed or constant speed feathering Each type is provided in either a two blade or three blade configuration 1 The C200 Series is a two blade constant speed propeller Refer to Figure 1 2 The C300 Series is a two blade constant speed feathering propeller Refer to Figure 2 3 The C400 Series is a three blade constant speed propeller Refer to Figure 3 4 The C500 Series is a three blade constant speed feathering propeller Refer to Figure 4 Each propeller consists of a hub assembly propeller blades piston and cylinder assembly Description of the Propeller Assembly and Deice Components 1 Propeller Hub Assembly The propeller hub is a single piece hollow assembly with propeller blade sockets Each blade socket to blade shank is O ring sealed to prevent leakage The rear hub face has threaded studs or bolts for attachment to the engine flange Some engine flanges have dowels that mate with holes in the hub for alignment These ensure pr
34. R INFORMATION MANUAL cris rv PROPELLER BLADE SPINNER COWL DEICE BOOT H WIRE WIRE HARNESS HARNESS SLIP RING ASSEMBLY PROPELLER go ENG 4d p BRUSH BLOCK ASSEMBLY ELECTRIC DEICE PROPELLER CENTERLINE wo PROPELLER BLADE FEED SHOE I SPINNER SPRAY HEAD ASSEMBLY SLINGER RING ASSEMBLY FE PROPELLER N FUB TO ALCOHOL RESERVOIR PROPELLER CENTERLINE Propeller Deice Anti Ice Installation Figure 11 Sheet 1 61 30 01 Page 16 McCauley Propeller Systems Dec 7 2009 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL C1030 XI3AF32C517 X SAMPLE PISTON ENGINE HUB MODEL DESIGNATION IX 3 AF 32 C 517 X LETTER S DENOTING CHANGES TO THE CONFIGURATION THAT MAY AFFECT ELIGIBILITY OR INTERCHANGEABILITY NUMERALS THAT DEFINE A SPECIFIC HUB DESIGN 2XX C200 SERIES 3XX C300 SERIES ETC TYPE OF PROPELLER C CONSTANT SPEED MCCAULEY DESIGN REFERENCE INFORMATION FULL FEATHERING HUB FLANGE CODE NUMBER OF BLADES DOWEL LOCATION WITH RESPECT TO THE CENTER LINE OF THE NUMBER 1 BLADE SOCKET VIEWING THE HUB FROM THE FLANGE MOUNTING FACE NOTE ASPECIFIC PROPELLER ASSEMBLY IS IDENTIFIED BY THE HUB SERIAL NUMBER WHICH IS STAMPED ON THE HUB ALL RECORDS OF PROPELLER COMPONENTS ARE KEPT WITH REFERENCE TO HUB SERIAL NUMBER THE FIRST TWO DIGITS OF THE HUB SERIAL A
35. R SYSTEMS OWNER OPERATOR INFORMATION MANUAL The propeller is designed to operate in two modes of operation beta mode and governor mode 1 Governor Mode Oil is metered to and from the propeller by governor control valve as positioned by flyweights increasing and decreasing blade angle changing pitch as required when the propeller speed control setting is altered or increasing and decreasing pitch to control and stabilize engine speed with varying power conditions or flight attitudes with a fixed speed setting 2 Beta Mode The pilot may select beta mode for ground reversing or taxi operation by means of the aircraft engine mechanical linkage The linkage repositions the propeller reversing lever and beta valve to provide access for high pressure oil to reach the propeller piston and move the blades toward reverse pitch Propeller Deice refer to Figure 11 NOTE Only components sold by McCauley are described Some OEMs or STC owners may have different designs 1 d propeller deice is installed the components include electrically heated rubber boots deice harnesses slip ring assembly deice timer brush block assembly a The brush block deice harnesses and slip ring assembly conduct electrical power to the propeller blade deice boot elements which then heat b The heat melts a layer of the ice which allows the remaining ice to be removed from the propeller blades by centrifugal force c Deice Harness if deice is
36. RE THE YEAR OF MANUFACTURE THE REMAINING DIGITS ARE THE NUMBER OF THE HUB MANUFACTURED IN THAT YEAR 61 30 01 Page 17 McCauley Propeller Systems Dec 7 2009 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL C1031 X 3GFR32C61 8 X SAMPLE TURBOPROP HUB MODEL DESIGNATION X 3 G F R 32 C 618 X LETTER S DENOTING CHANGES TO THE CONFIGURATION THAT MAY AFFECT ELIGIBILITY OR INTERCHANGEABILITY NUMERALS THAT DEFINE A SPECIFIC HUB DESIGN 601 649 C600 SERIES 650 699 C650 SERIES 701 749 C700 SERIES ETC TYPE OF PROPELLER C CONSTANT SPEED MCCAULEY DESIGN REFERENCE INFORMATION REVERSING FULL FEATHERING HUB FLANGE CODE NUMBER OF BLADES INDEXING DOWEL HOLE LOCATION WITH RESPECT TO THE CENTER LINE OF THE NUMBER 1 BLADE SOCKET VIEWING THE HUB FROM THE FLANGE MOUNTING FACE NOTE ASPECIFIC PROPELLER ASSEMBLY IS IDENTIFIED BY THE HUB SERIAL NUMBER WHICH IS STAMPED ON THE HUB ALL RECORDS OF PROPELLER COMPONENTS ARE KEPT WITH REFERENCE TO HUB SERIAL NUMBER THE FIRST TWO DIGITS OF THE HUB SERIAL ARE THE YEAR OF MANUFACTURE THE REMAINING DIGITS ARE THE NUMBER OF THE HUB MANUFACTURED IN THAT YEAR 61 30 01 Page 18 McCauley Propeller Systems Dec 7 2009 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL C Blade Model Designation 1 All blades are impression stamped on the butt end with blade model designation propeller type certificate number and blade serial number
37. SHIM CARRIER SEPARATOR GK OUTER RAGE INNER RACE HUB VENT FOR NON OIL FILLED PROPELLERS SET GILET RETAINER PLUG FOR DETAIL OIL FILLED PROPELLERS 5 view 2 BLADE k A A ASSEMBLY S SO x COUNTERWEIGHT 2 4 SPRINGS FEATHER 4 STOP XLO 2 gt N NL X SS S S Re ETT SE 2 x J V CYLINDER BLADE ACTUATION PISTON Sr A LATCH NOTE LOW PITCH NOTE PROPELLER BLADE STOP PLATE LINK NOT SHOWN FOR CLARITY C500 Series Propeller Figure 4 Sheet 1 61 30 01 Page 6 McCauley Propeller Systems Dec 7 2009 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL deice harnesses slip ring assembly deice timer brush block assembly a The brush block deice harnesses and slip ring assembly conduct electrical power to the propeller blade deice boot elements which then heat b The heat melts a layer of the ice which allows the remaining ice to be removed from the propeller blades by centrifugal force e o o e F Propeller Anti Ice Refer to Figure 11 1 If propeller alcohol anti ice is installed the components include slinger ring assembly spray head assembly propeller blade feed shoe a slinger ring distributes anti ice fluid from the fluid reservoir to the spray head assembly for each propeller blade Anti ice fluid is pumped into the rotating slinger ring and the centrifugal force of the rota
38. This stamping is not visible from the outside of the propeller assembly The following is an example of blade model designation C1130 Pq L 80 HJ A 0 b Reduction in diameter from basic inches Staking angle actuating pin placement Characteristics of blade design for example planform Basic design diameter in inches Designation for direction of rotation viewed from pilot s seat No letter blank Right L Left Change designation which may affect eligibility or interchangeability 61 30 01 Page 19 McCauley Propeller Systems Dec 7 2009 EB McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL PROPELLER TROUBLESHOOTING 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 Operation in Restricted Power or RPM Conditions Turbine A There are several risks to the propeller blades and or hubs if the propeller is operated in restricted areas 1 Each propeller is subjected to rigorous vibration tests to determine that the conditions under which a particular propeller engine airframe combination will operate safely Certain power settings or RPM ranges are restricted by either the airf
39. Tighten if necessary 61 30 01 Page 602 McCauley Propeller Systems Dec 7 2009 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL Check entire propeller for corrosion cracks or other damage Contact a McCauley Service Center for disposition if any unusual damage is found Inspect entire propeller system for oil leakage If leakage is confirmed the propeller should be removed thoroughly inspected and resealed by an approved propeller repair facility or technician Repaint propeller blades as necessary per Propeller Field Maintenance Practices Blade Painting Examine all placards for legibility and security of installation Replace all placards that are illegible or not secure 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 or similar NOTE 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 Inspect all blades for damage such as scrapes gouges etc caused by the impact Any damage beyond normal field repair limits defined in other McCauley service information is cause f
40. aching parts Lubricate the threads of studs and nuts and the faces of nuts spacers or washers with MIL PRF 83483 McCauley part number A 1637 16 grease 2 Install mounting nuts on mounting studs 3 Torque the mounting nuts in an alternating sequence to prevent the hub cocking on the engine flange 4 When the hub is seated fully on the engine flange torque to the specification called out in the mounting decal located on propeller hub at the number 1 socket 5 After you apply the final torque apply torque seal to nut and stud threads 61 30 01 Page 205 McCauley Propeller Systems Dec 7 2009 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL WARNING Threads must be clean and dry If any lubricant is applied the attaching parts will be severely over torqued b For Lycoming engine installations 1 Start threads on all propeller mounting bolts and then tighten them in an alternating sequence to prevent the hub cocking on the engine flange 2 When the hub is seated fully on the engine flange torque to the specification called out on the mounting decal located on propeller hub at the number 1 socket 3 Safety wire the nuts in pairs to complete the installation c If required install the deice leads 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 fi
41. aining screws and washers 5 C600 C650 C1100 Series Propeller Removal and Installation A General 1 2 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 and deice arrangements not manufactured by McCauley may be used which require additional procedures In the following instructions installation of 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 Spinner Assembly Removal 1 Make an alignment mark on the spinner and an adjacent blade with a felt tip pen This index mark insures accurate restoration of spinner position to lessen the distortion of any dynamic balance previously performed on the propeller assembly Remove screws and washers from spinner and fillet assemblies Remove spinner from the bulkhead and fillet assemblies Remove spinner support and shims from spinner 61 30 01 Page 206 McCauley Propeller Systems Dec 7 2009 5 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL Remove screws and washers attaching fillets to the bulkhead and remove the fillets Propeller Assemb
42. al and is the result of lubricant applied to the blade O ring during assembly 3 Olil filled propellers may show signs of oil deposited on the blade shank during operation after an overhaul or after a prolonged period of inactivity 61 30 01 Page 106 McCauley Propeller Systems Dec 7 2009 C89 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL MOVEMENT SHOWN IS GREATLY EXAGGERATED BLADE SHAKE MOVEMENT SHOWN IS GREATLY EXAGGERATED BLADE TWIST Blade Shake and Blade Twist Figure 101 Sheet 1 61 30 01 107 McCauley Propeller Systems Dec 7 2009 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL B Checking and correcting a leaking propeller at the blade NOTE This procedure will only correct blade shank leaks at the blade shank O ring 1 Use a clean cloth dampened with mineral spirits to clean the blade of all traces of oil and dirt CAUTION Never exceed the published engine operational limits Run the engine and cycle the propeller at least five times a Piston airplanes cycle from low to high pitch b Turbine airplanes cycle from reverse to high pitch Check the blade for signs of continued leakage a If necessary clean the blade again with a cloth dampened with mineral spirits to clean the blade of all traces of oil and dirt Run the engine and cycle the propeller at least five times a Piston airplanes cycle from low to high pitch b Tu
43. amage Specifications a b d The depth of damage must be measured using a depth gage Damage that is located on the leading or trailing edges must not exceed 0 125 inch 3 2 mm in depth Damage that is located on a repairable area of the face or camber side of the blade must not exceed 0 063 inch 1 6 mm in depth Damage depth greater than these limits is not field repairable An approved propeller repair facility may be able to do a repair Contact McCauley Product Support for disposition of any damage that is deeper than the specified limits 3 Repairable Damage a b The primary type of blade damage that a mechanic need be concerned with is sharp stress riser type damage This type of damage is caused by stones or other small objects striking the propeller blade as it rotates Erosion caused by sand water etc that does not create sharp stress riser type damage does not need to be repaired in the field CAUTION The use of a rasp file is not recommended for field repairs Rasp type files will remove more metal than necessary and may cause premature rejection of blades at overhaul It is very important that stress riser type damage be completely repaired When filing damage is complete a dye penetrant examination of affected area should be performed when possible to verify the stress riser has been completely removed 4 Leading Edge Repair Procedure a b Remove metal at damaged area in such
44. at an approved propeller facility 13 Propeller Overspeeding A During normal operation the propeller suddenly overspeeds past rated RPM 1 2 Possible Causes a A number of factors can cause propeller overspeeding but these are normally caused by the engine or governor Corrective Action a Refer to Service Letter 1998 23 Overspeeding of Propellers for required action after an overspeed incident 61 30 01 Page 108 McCauley Propeller Systems Dec 7 2009 2 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL PROPELLER FIELD MAINTENANCE PRACTICES Ground Support Equipment A following special equipment is required for field maintenance of McCauley propellers NAME PART NUMBER MANUFACTURER USE Propeller protractor Commercially available To measure blade angles on 600 650 and 1100 Series propellers Torque wrench B 5588 McCauley To torque turbine propeller adapter mounting nuts Feedback collar D 5945 McCauley To aid in removal and retractor installation of C700 C750 and C1000 series propellers Start lock release B 5021 McCauley To release start locks on tools C600 C650 and C1100 series propellers Beta tube B 5378 McCauley To install and adjust beta installation and tube on C600 C650 and adjustment tool C1100 series propellers Procedures For Maintenance A Maintenance begins with the operator and includes inspection together with regular care Many maintenance
45. back until it reaches redline RPM Allow the RPM to stabilize Land the aircraft without touching the propeller control lever Adjust the propeller stop screw to the propeller control location Rig the aircraft power controls in accordance with the instructions of the manufacturer Do another flight test to verify the correct setting IN 7 Propeller Fails to Control A Constant speed non feathering only Propeller goes to low pitch high RPM of its own accord 1 Possible Cause a Governor linkage disconnected 1 Corrective Action a Check and repair governor linkage b Engine transfer bearing collar oil leakage rate exceeds specification 1 Corrective Action Check transfer bearing collar oil leakage rate per the instructions of the engine manufacturer c Loss of engine oil pressure 1 Corrective action Verify the engine oil pressure in accordance with the instructions of the engine manufacturer d Obstruction in the crankshaft 1 Correction action Remove propeller and check for obstruction in the crankshaft oil gallery ie Rags shipping plugs etc e Internal governor problem 1 Corrective Action a the governor checked by an approved repair station NOTE Failure of an internal governor part may result in metal contamination in the engine oil lubrication system If internal governor failure is confirmed the engine and propeller should be checked for metal contamination
46. ble Cause a Excessive play in the linkage between the governor and the cockpit control often leads to erratic operation b Possible excessive engine compartment heat affecting a plastic top cover 2 Corrective Action a Trace linkage locate unsecured sections and tighten as needed b Please note that although linkage may appear to allow full governor control while the engine is off it may not in the air Engine vibration and stretch of the mount during operation can often aggravate the condition Therefore it is important the entire length of linkage be properly secured c If heat has distorted the plastic top cover replace it with an aluminum top cover Once speed control and power settings are established for a flight attitude cruise and then the attitude is altered to climb without change of speed and power settings the engine speed may change slightly 1 Possible Causes a This effect is commonly known as creeping of the speed setting It is a natural result and comes about in the following manner When speed and power settings are established the governor control valve will be opened an amount to provide a pressure which balances the propeller counterweight forces and spring load and an oil flow which is determined by the leakage through the propeller pitch control bearing at that pressure This will maintain the blade angle such that set power may be absorbed at the desired speed b Ifthe attitude
47. d e If blades do not meet the above criteria the propeller must be removed from the aircraft and completely overhauled by an FAA approved propeller repairman per the applicable McCauley Service Manual 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 an FAA approved propeller repair facility in accordance with the applicable overhaul manual 5 Blade Track Check A Check 1 2 3 4 ra CO 9 Turn propeller so that Number 1 blade is straight down Position a smooth board beneath the blade tip Block up the board firmly in place just clear of the blade tip 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 next 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 Carefully turn propeller and repeat tracking measurement for each blade
48. d oil pressure in the cylinder is removed e Internal Lubrication 1 propeller hub cavity is partially filled with turbine oil which is sealed in the hub and isolated from engine oil This oil provides lubrication and corrosion protection to blade bearings and other internal parts The oil is dyed red on some models to aid in the troubleshooting of suspected propeller leaks NOTE Periodic maintenance of the lubrication is NOT normally required f Start Lock C600 C650 C1100 Series only The propeller has a start lock mechanism installed within the cylinder The mechanism includes latching weights which will engage a fixed stop to block movement of the piston in the direction of increasing blade pitch beyond a predetermined start lock blade angle Latch engagement is possible only when the engine is shut off on the ground When the propeller is rotating the latch weights move out by centrifugal force so as to offer no interference to operation of the control system in flight During all normal operating conditions the weights are in a disengaged position and offer no resistance to feathering unfeathering or reversing of the propeller NOTE Special tools McCauley part number B 5021 2 are required to release start locks manually for maintenance purposes B Description of Turbine Propeller Operating Principles 1 Propellers are a single acting unit in which hydraulic pressure opposes the forces of springs and c
49. e NA use 84585 A 2973 5 842229 ve ves 6 A251370 Teens Deem c12as na 224 716 ves 8 assise Iess mea 83827 429756 86228 ves 6 assises aise C 5464 A2973 5 B462240 12 ves 5 152 Atessa NA 07726 42756 6 4622 40 12 ves 5 1552 Atessa NA 61 30 01 Page 1003 McCauley Propeller Systems Dec 7 2009 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL Table 1003 Installation Parts for Fixed Pitch Propellers continued Fixed Pitch Bolt Kit Propeller Model Spacer Dowel Bolt Kit Bolt Drilled No Washer Number P N P N P N Dia Head Bolts Bolt P N P N Nut P N Dem C 5464 29756 2240 ve ves 5 fasses 16382 NA 7 0776 20736 2240 12 ves 5 rase 1682 NA TATSSKOM 84446 42975 B 4622 19 58 ves 5 A251341 atesa Daun 84273 22756 12 ves 6 NA NA Garon eez ve asso A1639 3 NA euro 5400 429756 84622 10 58 ves 6 Azsi Dat 1200 Note2 46227 58 ves 5 A25137 _ A 1698 13 416895 Deeg Tea 29756 B462240 12 ves 5 A251532 aise NA IGSSLFA Tee 29756 62240 12 ves 6 lees fais NA NA NA B4ezeso ss ves 10 luess Noez B46227 58 ves 5 A25137 A 163838 1689
50. es a Do not power wash as water may be forced past the O rings Water inside the hub will cause corrosion and may cause propeller failure b Make sure the blade that you are cleaning is pointing down c Do not spray into the blade retention area because water may be forced into the hub urface Damage a Look for surface damage on both sides of the blades such as dents nicks scratches and corrosion b Surface imperfections can also be felt by running your fingernail along the blade leading edge Damage should be repaired before flight c Whenever a noticeable dent nick corrosion pit or bump is observed an appropriately rated mechanic should blend it out d The mechanic should remove all corrosion products and make sure that the section thickness has not been reduced below allowable limits 3 Erosion a Examine the blade for evidence of erosion 1 If blades appear to show erosion beyond limits the propeller should be removed from service and evaluated by an appropriately rated propeller repair facility b Check the condition of the paint on blades and spinners that have protective paint 1 Paint protects the surface of the blade from erosion The blade should be repaired before the paint wears through and the blade structure begins to erode 2 not apply excessive paint and do not paint propeller components unless it is in accordance with McCauley instructions since improper painting may affect propeller bala
51. foreign material 12 McCauley Torque Wrench Adapter CAUTION If an adaptor or extension such as McCauley part number 5588 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 Torque Wrench Length x Desired Torque Dial Reading Torque Wrench Length Extension Length 13 Remove the D 5945 feedback collar retractor tool from the propeller 14 Make sure of proper rigging of engine controls Refer to aircraft maintenance manual or STC maintenance manual supplement a Do a propeller blade angle check For details refer to Blade Angle Checking and Adjustment in Propeller Field Maintenance Practices CAUTION Do not operate the propeller below the minimum propeller idle speed operating restriction The minimum propeller idle speed operating restriction is the result of a specific vibratory resonant condition known as reactionless mode Ground operation at or near a reactionless mode vibratory resonance speed can cause very high stresses in the propeller blades and hubs These high stresses are more severe when operating in a tailing wind condition If the propeller is operated within a restricted RPM range or below a minimum RPM restriction for an extended period of time the propeller blades and hubs may become unairworthy
52. he engine and propeller should be checked for metal contamination in accordance with the specifications of the engine manufacturer Extreme sluggishness failure to respond to changes in RPM setting or failure to hold constant RPM with varying aircraft attitude 1 Possible Cause a Obstruction in the engine crankshaft 1 Correction action Remove propeller and check for obstruction in the crankshaft oil gallery ie Rags shipping plugs etc b Internal governor problem 1 Action a Have the governor checked by an approved repair station NOTE Failure of an internal governor part may result in metal contamination in the engine oil lubrication system If internal governor failure is confirmed the engine and propeller should be checked for metal contamination in accordance with the specifications of the engine manufacturer c Internal Propeller problem 1 Corrective action a the propeller checked by an approved repair station d Engine transfer bearing collar oil leakage rate exceeds specification or rotated engine transfer bearing 1 Corrective Action Check transfer bearing collar condition and oil leakage rate per the instructions of the engine manufacturer 61 30 01 Page 104 McCauley Propeller Systems Dec 7 2009 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL 8 Propeller Feathers at Shutdown 300 500 600 650 and 1100 Model Series Only WARNING Before starti
53. hed b Add or subtract shims to the spinner support until spinner mounting holes are aligned within one half hole with the bulkhead mounting hole diameters while you push hard on the spinner shell 4 Use an awl or a small punch in an adjacent hole to move the spinner screw hole into alignment with the bulkhead hole and install the screw Repeat the procedure on opposing holes until eight equally spaced screws and washers are installed 5 Secure the propeller spinner to the bulkhead and fillet assemblies with the remaining screws and washers 6 C700 C750 C1000 Propeller Removal 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 and deice arrangements not manufactured by McCauley may be used which require additional procedures 2 Inthe following instructions installation of 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 B Spinner Assembly Removal 1 Make an alignment mark on the spinner and an adjacent blade with a felt tip pen This index mark insures accurate restoration of spinner position to
54. igned within one half hole with the bulkhead mounting hole diameters while you push hard on the spinner shell 4 Use an awl or a small punch an adjacent hole to move the spinner screw hole into alignment with the bulkhead hole and install the screw Repeat the procedure on opposing holes until eight equally spaced screws and washers are installed 5 Secure the propeller spinner to the bulkhead and fillet assemblies with the remaining screws and washers Blade Angle Checking and Adjustment A General Information on Propeller Blade Angle Measurement 1 Blade angles on McCauley propellers are normally measured with a propeller protractor at the 30 inch reference station NOTE Certain models are measured at the 40 5 or 45 inch station 2 The reference station is indicated by a white or yellow painted line on the face of the propeller blade 3 protractor can be placed directly onto the surface of the blade for measuring No leveling pins are necessary NOTE Feather and start lock blade angles set during assembly or overhaul These angles are NOT adjustable in the field Flight Idle Blade Angle Checking and Adjustment Procedures C600 C650 and C1100 Series Propellers A Flight Idle Blade Angle Checking and Adjustment Procedure 1 Open engine cowling 2 Remove the propeller spinner 3 Make sure that the engine controls are properly rigged 4 Place the base of the protractor on the top of the propeller cy
55. in accordance with the specifications of the engine manufacturer 61 30 01 Page 103 McCauley Propeller Systems Dec 7 2009 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL Feathering propeller The propeller goes to high pitch or feathers of its own accord This may occur without warning from otherwise normal operation and may or may not be accompanied by noticeable external oil leakage 1 Possible Cause a Incorrectly adjusted governor 1 Corrective Action a the governor checked by an approved repair station b Incorrectly rigged governor 1 Corrective Action Check governor control rigging in aircraft for proper operation c Engine transfer bearing collar oil leakage rate exceeds specification 1 Corrective Action Check transfer bearing collar oil leakage rate per the instructions of the engine manufacturer d Loss of engine oil pressure 1 Corrective action Verify the engine oil pressure in accordance with the instructions of the engine manufacturer e Obstruction in crankshaft 1 Correction action Remove propeller and check for obstruction in the crankshaft oil gallery ie Rags shipping plugs etc f Internal governor problem 1 Corrective Action the governor checked by an approved repair station NOTE Failure of an internal governor part may result in metal contamination in the engine oil lubrication system If internal governor failure is confirmed t
56. ips where operation in rain or reversing on sandy and or wet runways can cause accelerated wear It is therefore important to paint blades frequently as part of a regular maintenance schedule 61 30 01 Page 213 McCauley Propeller Systems Dec 7 2009 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL C53 RECOMMENDED BLADE REPAIR 1 i REPAIR TYPICAL RADIUS 10d TYPICAL CENTER AT DEEPEST POINT S SURFACE REPAIR d DEPTH OF REPAIR 5d 5 x DEPTH OF REPAIR 10d 10 x DEPTH OF REPAIR FOR EDGE REPAIR ONLY d DEPTH OF NICK 0 031 INCH 0 8 mm FOR SURFACE REPAIR ONLY d DEPTH OF NICK 0 002 INCH 0 05 mm SURFACE REPAIR d gt Field Blade Rework Criteria Figure 202 Sheet 1 61 30 01 Page 214 McCauley Propeller Systems Dec 7 2009 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL C54 CORRECT LEAD EDGE REWORK METHOD DEPTH OF NICK 0 031 INCH 0 8 mm ORIGINAL AIRFOIL ORIGINAL LEAD EDGE RADIUS SECTION INCORRECT LEAD EDGE REWORK METHOD i3 LEAD EDGE RADIUS TOO LARGE PROFILE CONTOUR TOO BLUNT GENERAL RULES DO NOT REDUCE THE MAXIMUM THICKNESS OF SECTION KEEP THE ORIGINAL LEAD EDGE RADIUS BLEND TO THE PROFILE OF THE AIRFOIL SECTION Field Blade Rework Criteria Figure 202 Sheet 2 61 30 01 Page 215 McCauley Propeller Systems Dec 7 2009 McCAULEY PROP
57. ired f Copies of the forms prescribed by CFR 43 9 for each major alteration to the propellers The owner or operator shall retain the following records for the periods prescribed 1 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 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 following statements contain excerpts from CFR 91 419 concerning the transfer of propeller maintenance records Any owner or operator who sells a propeller 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 1 2 The records specified in CFR 91 417
58. lation 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 Adescription 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 certificate number of the person approving the propeller for return to service 2 Records must contain the following information a The total time in service of each 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 e The current status of applicable airworthiness directives AD including the method of compliance the AD number and revision date If the AD involves recurring action the time and date when the next action is requ
59. lessen the distortion of any dynamic balance previously performed on the propeller assembly Remove screws and washers from spinner and fillet assemblies Remove spinner from the bulkhead and fillet assemblies Remove spinner support and shims from spinner 2 3 4 5 Remove screws and washers attaching fillets to the bulkhead and remove the fillets DIO I wae C Propeller Assembly Removal 1 Feather the propeller 61 30 01 Page 208 McCauley Propeller Systems Dec 7 2009 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL C72 Propeller Torque Wrench Adapter Tool Figure 201 Sheet 1 61 30 01 Page 209 McCauley Propeller Systems Dec 7 2009 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL 2 Place a drip pan under the propeller mounting surface to catch any spilled engine oil when the propeller is removed 3 Remove the feedback bearing assembly from the feedback collar groove Refer to the aircraft or engine manual for procedure 4 Remove the cowling as required for access to the mounting nuts 5 Install the D 5945 feedback collar retractor tool to the beta rods NOTE Make sure the rods are inserted through the correct holes of the tool The beta rods must be pulled directly forward CAUTION Do not draw the feedback collar too far forward as the beta rods will be damaged 6 Turn the large threaded rod of the retractor tool clockwise to draw the feedback colla
60. linder and align it longitudinally to zero the propeller protractor Position power levers at the flight idle position When the propeller blades have stopped in the flight idle position move the blade to be tested so the leading edge is up and 90 degrees from vertical 5 6 dese TZ NOTE Itis required to check the blade angle of only one blade Blade Maintenance A Removal of Blade Damage 1 General a The propeller blade is a highly stressed part The fact that propeller blades are subject to damage such as nicks gouges scratches corrosion pits etc demands frequent inspection and maintenance b Repair of small nicks and scratches may be performed by qualified mechanics in the field in accordance with procedures specified in FAA Advisory Circular 43 13 1 X and the following sections After filing and polishing the damaged area should be inspected when possible by dye penetrant method to verify that all damage has been removed and the blade is not cracked The area should then be re protected by localized application of chemical film per MIL C 5541 for example Alodine and repainted as necessary c Large nicks or scratches or other damage involving such things as bent blades balance diameter reduction etc may be corrected only by an approved propeller repair facility 61 30 01 Page 212 McCauley Propeller Systems Dec 7 2009 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL 2 D
61. ly Removal NOTE Propeller must be on start locks when beginning this procedure Feather the propeller For details refer to Start Lock Release Procedures in Constant Speed Propeller System Description and Operating Principles Place a drip pan under the propeller mounting surface to catch any spilled engine oil when the propeller is removed Break the torque on the propeller mounting nuts McCauley Torque Wrench Adapter part number B 5588 may be used to gain easier access to mounting nuts Refer to Figure 201 Install propeller sling and attach to hoist If hoist is unavailable propeller may be supported and lifted by hand This will require additional personnel CAUTION The C600 propellers weigh approximately 120 pounds 54 kg and the C650 propellers approximately 160 pounds 73 kg C1100 series propellers weigh 180 pounds 83 kg or more a Hoist straps must be a minimum of 4 inches 100 mm wide Take up the slack on the propeller sling and hoist or have at least four persons support the propeller and remove the nuts Carefully slide the propeller forward and remove from the engine Place the propeller on a suitable support or propeller stand Install a protective cover over the propeller hub mounting flange Install a protective cover over the open end of the engine propeller flange Propeller Installation NOTE McCauley recommends that the propeller mounting nuts McCauley part number A 1639 32 be replaced at each
62. nce operation static electricity discharge or have other unintended consequences 4 Straightness a Sight down the edges to find any deformation 5 Looseness a Feelthe blades and move them to find unusual changes in looseness and unusual play 1 Blade to blade differences indicate that an internal problem may exist Spinner and Bulkhead 1 Externally check the spinner and bulkhead for security missing fasteners damage and cracks Cracks typically originate from the attachment screws a Repair of cracks is not permitted 2 Check for looseness of the bulkhead This could be an indication that the mounting bolts are loose 3 Wear depth on the inside of the spinner must not exceed 0 010 inch 0 25 mm NOTE Wear inside the spinner can be caused by improper shimming of the spinner or by deice leads rubbing General Condition Control System 1 The control system governor should be checked to determine whether the system is operating properly and is not leaking 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 aircraft inspection manual Inspection should include 1 Spinner Removal 2 Inspection of all attaching hardware including the hardware under the spinner for security
63. nd what the dial should read in order to obtain the correct applied torque actual torque required x torque wrench length Torque Wrench Reading ooo to Achieve the Required torque wrench length length of the adapter Actual Torque Spinner Installation if applicable S CAUTION Under shimming or over shimming of the spinner front support could result in spinner wobble vibration and or bulkhead and spinner cracking Follow shimming procedures carefully If required install propeller spinner fillets on the bulkhead with screws and washers Insert the same number of shims into spinner support as were removed and lightly press the spinner support onto propeller cylinder Put the spinner shell onto the bulkhead and fillet assembly with the alignment marks matched a Press firmly aft on the spinner b Make sure the spinner holes are approximately one half hole diameter forward of the matching holes in the bulkhead c Add or subtract shims to spinner support until spinner shell mounting holes are approximately half a hole from being in true alignment with bulkhead holes 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 Secure propeller spinner to the bulkhead and fillet assemblies with rem
64. ng an engine with a feathered propeller engine manufacturer should be consulted CAUTION Do not start the engine and do run up with the cockpit propeller control lever in the feather position This results in latching mechanism failure A After engine shut down the propeller may move slowly to the full feathered position 1 Possible Cause a Damaged latch mechanisms corrosion dirt or foreign matter in the mechanism causing latch weights to stick may be evidenced by intermittent condition b Propeller control not set to maximum RPM at shutdown 2 Corrective Action a Repair of latching mechanism must be performed by an approved propeller repair station 9 Propeller Fails to Feather Properly A Failure of the propeller to feather normally after the propeller control is moved to the feathering position 1 Possible Causes a Lack of feather response may be due to one of the following causes Malfunction or incorrect rigging of control linkage Misadjusted governor High blade turning friction 4 Improperly installed deice system 2 Corrective Action a Check all propeller control rigging for incorrect adjustment Replace propeller governor with known working unit If neither of these actions eliminates the problem the propeller may be at fault Remove propeller for examination at an authorized propeller repair station 10101 10 Unusual Aircraft Vibration A Apparently excessive vibration felt during normal
65. ngine oil This oil provides lubrication and corrosion protection to blade bearings and other internal parts The oil is dyed red to aid in the troubleshooting of suspected propeller leaks NOTE Periodic field maintenance of this lubrication is NOT normally required Description of Piston Engine Propeller Operating Principles 1 C200 and C400 series propellers are constant speed type They a single acting unit in which hydraulic pressure works against the forces of springs and the natural centrifugal moment of the rotating blade to provide the correct pitch for engine load Hydraulic pressure causes the blades to move toward high pitch decreasing rpm The springs and centrifugal moments urge blades toward low pitch increasing rpm 2 The C300 and C500 series propellers are constant speed and full feathering type They are a single acting unit in which hydraulic pressure works against the forces of springs and counterweights to provide the correct pitch for engine load Hydraulic pressure causes the blades to move toward low pitch increasing rom The springs and counterweights urge blades toward high pitch decreasing rpm Propeller Deice Refer to Figure 11 NOTE Only components sold by McCauley are described Some OEMs or STC owners different designs 1 If propeller deice is installed the components include electrically heated rubber boots 61 30 01 Page 1 McCauley Propeller Systems Dec 7 2
66. nspection No Reciprocating Engines further action required 15 or Higher Contact McCauley Product Support for disposition All Propellers on Turbine Up to but not including 10 General external visual inspection No Engines except C1101 further action required Mga ANa 10 or Higher Contact McCauley Product Support for disposition 10 Engine oil contamination A Any propeller exposed to engine oil contamination must be removed and sent to an approved propeller repair station for inspection Refer to the service information of the engine manufacturer to determine if oil contamination has occurred or to determine the acceptable amount of metal particles allowed in engine oil 11 Fire A Any propeller propeller component spinner component or governor exposed to fire or excessive heat is considered unairworthy and must be scraped if it shows any of the following conditions 1 Bubbled paint 2 Discolored paint 3 Discolored metal 4 Melted areas 61 30 01 Page 607 McCauley Propeller Systems Dec 7 2009 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 B These parts may be purchased through your local authorized McCauley propeller service center I Table 1001 Installation Parts for Constant Speed Piston Engine Propellers fn
67. nstallation instructions should always be consulted for any specialized procedures applicable to a specific aircraft Various spinner and deice arrangements not manufactured by McCauley may be used which require additional procedures In the following instructions installation of 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 have been grounded prior to approaching propeller B Spinner Assembly Removal 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 Remove screws and washers from the spinner and fillet assemblies Remove spinner from the bulkhead and fillet assemblies Remove the spinner support and shims from the front of the propeller cylinder If required remove screws and washers attaching fillets to bulkhead and remove fillets Identify location of each fillet to the bulkhead NOTE some spinner assemblies the fillets are riveted in place and cannot be removed from the bulkhead assembly C Propeller Assembly Removal Remove cowling as required for access to mounting nuts If required remove deice leads Place a drip pan under the propeller
68. nting screw at the location indicated by the testing equipment a 970 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 assembly at a point adjacent to the test location as shown on Figure 601 Always place at least one balance weight under screw head for stress relief see Figure Return original spinner screw to hole 61 30 01 Page 605 McCauley Propeller Systems Dec 7 2009 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL C670 SPINNER NAS1149F0332P WASHER MS21083 N3 NUT 0 125 INCH 6mm MAXIMUM PROJECTION SPINNER BULKHEAD AN970 3 FLAT WASHER MAXIMUM STACK 11 WASHERS H 502 10 SCREW DETAIL A 0104T1004 AE 7735 Balance Weight Installation Figure 601 Sheet 1 61 30 01 Page 606 Dec 7 2009 O McCauley Propeller Systems McCAULEY PROPELLER SYSTEMS
69. of the aircraft is altered and the airspeed changes the blade angle will change to absorb the power at this airspeed This change in blade angle will cause the forces to vary and consequently will change the control pressure and the propeller pitch control bearing leakage rate Since the governor had been adjusted by the speed control for the first set of conditions the effect will be to change the effective equilibrium speed of the propeller with no change in governor setting The amount of change varies with engine transfer bearing clearance d This speed change is generally a negligible amount and is not cause for concern since it is a normal reaction of the control system e Control friction lock in the aircraft is faulty 2 Corrective Action a If itis desired that the original speed setting be maintained in the new flight attitude it may be necessary to alter the propeller control lever as required after the aircraft is trimmed out 1 Refer to the aircraft maintenance manual Improper Propeller Static RPM Piston A Incorrect propeller speed at a given power and static RPM setting 1 Possible Cause a maximum static RPM is incorrect the problem can normally be attributed to either incorrect low blade angle or insufficient engine horsepower However if the maximum in flight RPM is incorrect then an adjustment of the governor may be necessary NOTE On static runs the propeller should prevent the engine RPM from g
70. oing to red line This is done to prevent overspeeding and is a design characteristic of the propeller However it should be within 100 RPM of red line 2 Corrective Action a One area that is often at fault for indicated RPM problems is the tachometer Aviation tachometers can be inaccurate so begin troubleshooting by verifying the accuracy of the tachometer 61 30 01 Page 102 McCauley Propeller Systems Dec 7 2009 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL b Verify the propeller low blade angles are correct This is most effectively done at an approved propeller shop This is done by measuring the blade angle at the reference station generally the 30 inch 762 mm station and comparing the angles to those listed in either the type certificate of the airframe manufacturer or the STC under which the propeller was installed If the angles are correct then the engine is not producing the proper horsepower needed to make the rated static RPM c Begin troubleshooting the engine 6 Improper Propeller Maximum RPM in Flight Constant Speed Piston A Incorrect propeller speed with maximum RPM selected in flight 1 2 Possible Cause a Inaccurate tachometer reading b Linkage is out of rig c Governor stop screw requires adjustment Corrective Action a Repair or replace the tachometer b Governor stop screw requires adjustment Do a test flight Pull the propeller control
71. on certification number and the number of times the propeller has been reconditioned The complete model number is a combination of the basic model number and suffix numbers to indicate the propeller diameter and pitch 1 Propeller Model Designation a The hub model designation is steel stamped on the cylinder face of the propeller hub 1 Example of hub model designation C1390 BASIC MODEL NUMBER 1F100 CM 69 54 INCHES PITCH AT 0 75 RADIUS 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 AIR CRAFT INSTALLATION BASIC DESIGN NUMBER PLANFORM ETC C Consult the FAA TC Data Sheets for details relating to approved engine propeller airplane installations of fixed pitch propellers covered in this manual D Propeller Time Between Overhaul TBO and Life Limited Parts 1 Refer to the latest revision of McCauley Service Bulletin SB137 XX Revised Time Between Overhaul TBO Specifications for required propeller overhaul intervals and life limited parts E Propeller Mounting Torque 1 Refer to the latest revision of McCauley Service Bulletin SB227 X Propeller Installation Mounting Torque for the correct installation instructions and torque values for propeller mounting hardware 61 30 00 Page 1 McCauley Propeller Systems Dec 7 2009 McC
72. opeller 2 Remove protective cover from the end of engine propeller flange 3 Make sure the flange is clean and free of nicks and burrs 4 Make sure that the engine propeller flange dowels and mounting stud holes are clean dry and free of nicks and burrs Remove the protective cover from the propeller hub mounting flange Make sure that the propeller hub mounting flange dowel pin holes and mounting studs are clean and undamaged 7 Make sure that a new O ring is installed in the groove of propeller hub mounting flange Lubricate the O ring with engine oil prior to installation of propeller 8 Hoist straps must be a minimum of 4 inches 100 mm wide 9 Use a propeller sling and hoist or additional personnel to position the propeller close to the engine propeller flange and align engine flange dowel pins with the dowel pin holes on the propeller hub mounting flange Rotate engine propeller mounting flange as required to align the dowel pin holes 61 30 01 Page 210 McCauley Propeller Systems Dec 7 2009 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL CAUTION Propeller must be installed straight onto the engine flange Any cocking of the propeller with respect to the flange could result in damage to the engine propeller flange mating surfaces 10 Mount the propeller on the engine propeller shaft 11 Make sure threads of nuts and studs are free of burrs nicks and similar damage and clean of
73. opeller Systems Dec 7 2009 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL 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 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 an FAA approved Certified Propeller Repair Facility or international equivalent 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 Atnotime 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 mou
74. oper mounting to the engine propeller shaft flange 2 Propeller Blades The propeller blades are made of solid forged aluminum Each is match balanced to the other blades a The entire propeller assembly is static balanced as well using balance weights mounted with screws to the blades or the cylinder balance ring 3 Blade Retention A set of split retainers inside the hub secures each blade in the hub at the blade sockets During pitch change each blade rotates about its axis on a bearing assembly An actuating pin assembly is secured to the blade butt of each blade inside the hub by screws The actuating pin is driven by a link assembly attached to the piston yoke inside the hub cavity 4 Piston and Cylinder Assembly Oil pressure controlled by the propeller governor and an internal spring act on the piston to provide the forces necessary to accomplish propeller blade pitch changes The cylinder is mounted to the hub face with screws and is sealed to prevent leakage 5 Counterweight Feathering type propellers have counterweights attached to the blades to assist the rotation of the blade to the feathered position 6 Internal Lubrication On some models grease is applied to the bearings for lubrication when the propeller is assembled However on other models the lubrication medium is oil On oil filled propellers the hub cavity is partially filled with red dyed engine type oil which is sealed in the hub and isolated from e
75. or propeller removal and repair as defined below Check blade track and verify that all blades measure within 0 170 inch 4 3mm of each other on turbine propellers This is a one time check Check blade twist All blades in a propeller should have the same amount of rotational play If the difference in rotational play between two blades is beyond 1 0 degree uneven internal wear or damage is the possible cause a For example rotational movement of No 1 blade measures 1 2 degrees and No 2 blade measures 2 3 degrees This would be considered excessive since the difference is more than 1 0 degree This check must be performed every 10 hours for the next 20 hours If no change is seen after 20 hours inspections may be discontinued B 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 completely overhauled by an FAA approved propeller repair
76. or a cracked bulkhead or for a cracked front support IN 61 30 01 105 McCauley Propeller Systems Dec 7 2009 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL The propeller spinner can be 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 is normally caused by inadequate shimming of the spinner bulkhead or a cracked or deformed spinner If a spinner is found to be wobbling it should be removed and reinstalled with the proper amount of shims as described in Spinner Installation Any spinner found cracked must be replaced Check amount of blade twist of each propeller blade when rotated within its socket as shown in Figure 101 Look for variations in the amount of movement of each blade in relation to the other blade s If excessive blade twist is found in one or more blades in relation to the others the propeller could have an internal linkage problem It should be removed and sent to an authorized propeller repair station for evaluation o NOTE The amount of total blade twist in each blade is in itself usually of no importance It is a difference in the amount of blade twist from blade to blade that should be considered 3 Possible Cause a Worn engine mounts 4 Corrective Action a Consult the OEM or engine mount manufacturer manual for replacement criteria
77. orthy condition Refer to the airplane type certificate data sheet aircraft specification sheet or supplemental type certificate data sheet as applicable for the allowable propeller diameter for each propeller installation 2 With certain limitations specific minor repairs may be accomplished a The McCauley Blade Overhaul Manual shows the criteria for determining whether or not a minor repair of a blade tip represents blade shortening b 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 Oil and Grease Leakage 1 Look for red oil or engine lubricant leaks in unusual places like the outside surfaces and seals 2 Oil or grease leakage may be due to a seal failure or a crack in the hub or blade a The source of the oil or grease leak should be determined before flight b During maintenance wipe the surfaces of the propeller after this inspection not before since oil leaking from a crack may assist in detecting it c Red oil gives a positive warning of a crack in the hub or a damaged seal Blade inspection 1 Wash the blades with a mild soap and water solution to remove all residue 61 30 01 Page 601 McCauley Propeller Systems Dec 7 2009 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL CAUTION Do not use solvents to clean the blad
78. ounterweights to obtain the correct pitch for engine load Hydraulic pressure urges blades toward low pitch increasing RPM while springs and counterweights urge blades toward high pitch decreasing RPM 61 30 01 Page 8 McCauley Propeller Systems Dec 7 2009 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL C1192 BLADE HUB ASSEMBLY A COUNTERWEIGHT LATCH PAWL ACTUATING SPRINGS L PIN Wo m V CYLINDER TUBE LATCH START PISTON LOCK FEATHER BLADE STOP ACTUATING LINK A WIRE RING RETAINING RING SOLID SHIM SPLIT SHIM O RING SHIM CARRIER RACE Y 4 o p SS us amm OUTER N Yp eS OIL FILL PLUG Wu S Ah o BEARING INNER RACE I SPLIT NUMBER 1 RETAINER er BLADE DETAIL A VIEW A A 010171050 C600 Series Propeller Figure 5 Sheet 1 McCauley Propeller Systems 61 30 01 Page 9 Dec 7 2009 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL C1193 HUB ASSEMBLY COUNTERWEIGHT LATCH PAWL A BLADE ACTUATING REVERSE SPRING PIN STOP PISTON ROD LATCH START CYLINDER BETA TUBE LOCK PISTON SUPPLIED BY FEATHER STOP THE ENGINE A MANUFACTURER WIRE RING LINK NUMBER1 RETAINING RING PROPELLER HUB BLADE OIL FILL SCREW RETAINER
79. ows 1 Tighten the propeller mounting bolts with the correct torque The mounting bolt torque for McCauley fixed pitch propellers is determined by the bolt diameter Refer to the following table to determine the correct torque for the propeller mounting bolts 61 30 01 Page 203 McCauley Propeller Systems Dec 7 2009 Bolt or Nut McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL Torque Dry Diameter Inch Foot Pounds Inch Pounds 25 to 35 300 to 360 33 895 to 40 675 7 16 40 to 45 480 to 540 54 233 to 61 012 55 to 65 660 to 780 74 570 to 88 128 4 2 3 4 For propeller mounting bolts with drilled heads install lockwire between pairs of bolt heads When shims are required for location of spinner support select quantity and thickness so that spinner shell screw holes are misaligned with the rear bulkhead holes or nuts by 1 2 hole diameter Use at least one mylar shim to contact bolt heads When the correct number of shims has been determined press or lightly tap support into hub bore apply force to spinner shell toward propeller to align screw holes with bulkhead holes or nuts and install washers and screws Constant Speed Reciprocating Engine Propeller Removal and Installation Piston 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 STO i
80. prd 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 Series Propellers C200 C300 C400 and C500 Model Series Propellers C600 C650 and C1100 Model Series Propellers C700 C750 and C1000 Model Series Propellers Propeller Logbook McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL WELCOME Thank you for purchasing a McCauley propeller A manual on this CD provides you with information that is important for the continued airworthiness of your propeller 1 This CD 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 CD Use the CD Contents Most Effectively A Display the bookmark pane on the manual PDF 1 You will see several model series bookmarks each of which can be expanded or minimized If you expand the bookmark that applies to your propeller you will see many named bookmarks that will link you directly to the applicable text as it refers to your propeller series 2 Click with your mouse on the topic named in the bookmark pane to display the desired text or illustration Model Designations A following can be used to determine your constant speed propelle
81. r forward to allow access to the propeller mounting nuts 7 Break the torque on the propeller mounting nuts McCauley Torque Wrench Adapter part number B 5588 may be used to gain easier access to mounting nuts Refer to Figure 201 8 Install propeller sling and attach to hoist If hoist is unavailable propeller may be supported and lifted by hand This will require additional personnel CAUTION The C700 propellers weigh approximately 120 pounds 54 kg the C750 propellers approximately 140 pounds 64 kg C1000 series propellers weigh 180 pounds 83 kg or more a Hoist straps must be a minimum of 4 inches 100 mm wide 9 Take up the slack on the propeller sling and hoist or have additional personnel support the propeller and remove the nuts Carefully slide the propeller forward and remove from the engine Place the propeller on a suitable support or propeller stand Install a protective cover over the propeller hub mounting flange Install a protective cover over the open end of the engine propeller flange 14 Remove the D 5945 feedback collar retractor tool from the propeller Propeller Installation NOTE McCauley recommends that the propeller mounting nuts McCauley part number A 1639 32 be replaced at each propeller installation whenever possible However nuts may be reused if the locking material prevents turning of the nut on the stud by hand 1 Install the D 5945 feedback collar retractor tool on the pr
82. r model series Two blade constant speed 200 series Models 201 299 Two blade constant speed and feathering 300 series Models 301 399 Three blade constant speed 400 series Models 401 499 Three blade constant speed and feathering 500 series Models 501 599 Three blade constant speed feathering and reversing for Allied Signal Garrett Honeywell engines 600 series Models 601 649 Four blade constant speed feathering and reversing for Allied Signal Garrett Honeywell engines 650 series Models 651 699 Three blade constant speed feathering and reversing for Pratt amp Whitney engines 700 series Models 701 749 Four blade constant speed feathering and reversing for Pratt amp Whitney engines 750 series Models 751 799 Five blade constant speed feathering and reversing for Pratt amp Whitney engines 1000 series Models 1001 1049 Five blade constant speed feathering and reversing for Allied Signal Garrett Honeywell engines 1100 series Models 1101 1149 excluding Models 1101 through 1104 Fixed pitch propellers For the purposes of this manual McCauley fixed pitch metal propellers are the same model series Additional Resources A 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 NOTE X signifies latest revi
83. rame manufacturer and or McCauley This is because vibrations produced in the restricted ranges can cause fatigue cracks in the hub or blades Such cracks could cause catastrophic failures of the propeller and a subsequent crash of the aircraft Always carefully obey the restrictions published in the aircraft AFM POH or the POH supplement provided with the STC under which the propeller is installed CAUTION Failure to follow the published limitations for any McCauley propeller could result in a reduced life or possibly even catastrophic loss of the propeller and or aircraft If you are aware that a McCauley propeller has been operated outside the published limitations or in a restricted area immediately call McCauley Product Support for assistance Propeller RPM Fluctuations Constant Speed Piston Turbine A Symptoms 1 Hunting is a cyclic or constant variation of engine speed above and below that desired It will be shown by constant wavering of the tachometer reading 2 Surging is a wide or excessive increase or decrease in engine speed followed by return to the established speed after one or more oscillations 3 Surging will occur and should be considered normal if lever throttle is moved rapidly Possible Causes 1 Hunting is seldom if ever caused by the propeller itself Those conditions reported primarily have been caused by other parts of the system such as governor fuel control etc a The propeller can be tes
84. rbine airplanes cycle from reverse to high pitch If the leak has stopped completely no other action is required If the rate of leak has decreased it is permissible to continue operation of the propeller for up to 20 hours a If there is leakage after 20 hours the propeller must be removed from the aircraft and sent to an approved propeller shop for repair If the rate of leakage increases do not operate the propeller Immediately send the propeller to an authorized propeller facility Oil leaks at locations other than blades 1 Piston aircraft propellers a Leakage from the cylinder area requires removal of the propeller and repair by an approved propeller facility b If leaks are found on any other spot on the blade or the hub remove the propeller and repair at an approved propeller facility c Leaks atthe hub propeller shaft interface requires removal of the propeller and replacement of the rear hub O ring Turbine aircraft propellers a Leakage from the cylinder or support plate area requires removal of the propeller and repair by an approved propeller facility b Leaks atthe hub propeller shaft interface requires removal of the propeller and replacement of the rear hub O ring c Aleak from the actuating spring area is engine oil and must be corrected immediately to prevent engine damage from lubrication oil depletion d If leaks are found on any other spot on the hub remove the propeller and repair
85. sent a reference forging model d The following digits represent the number of the blade manufactured during the month of manufacture 61 30 00 Page 3 McCauley Propeller Systems Dec 7 2009 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL C850 TYPE MODEL DESIGNATION CERTIFICATE DESIGNATES THE BLADE NUMBER LINE 2 INGLUDES PASSED EDDY CURRENT DIAMETER AND PITCH INSPECTION AFTER MANUFACTURE TC P4918 NUMBER 1 BLADE DESIGNATES THE BLADE PASSED EDDY CURRENT INSPECTION AFTER MANUFACTURE NOTE CERTIFICATE TC 918 NUMBER 1 BLADE MODEL DESIGNATION LINE 2 INCLUDES DIAMETER AND PITCH TYPICAL 6 BOLT HOLE PROPELLER STAMPING PATTERN NOTE STAMPING ARRANGEMENT OR LOCATION OF THE SERIAL NUMBER IS OPTIONAL LETTERING MAY BE ARCHED OR STRAIGHT BUT THE SERIAL NUMBER STAMPING IS FOUND AT THE NUMBER 1 BLADE 0101T1151 Fixed Pitch Blade Stamping Figure 1 Sheet 1 61 30 00 Page 4 McCauley Propeller Systems Dec 7 2009 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL C851 DESIGNATES THE BLADE PASSED EDDY CURRENT INSPECTION AFTER MODEL DESIGNATION MANUFACTURE LINE 2 INCLUDES DIAMETER AND PITCH NOTE E NUMBER 1 BLADE Q CERTIFICATE NUMBER TYPICAL 8 BOLT HOLE PROPELLER STAMPING PATTERN NOTE STAMPING ARRANGEMENT OR LOCATION OF THE SERIAL NUMBER IS O
86. series C300 Series Cano Series C500 Series o faser __ Spar fa Mount Oring Lycoming Jar Spinner Screw bright nickel plated A 1635 133 A 1635 133 A 1635 133 Spinner Screw cadmium plated A 1635 39 A 1635 39 A 1635 39 Spinner Washer fiber A 1638 5 446385 A 1638 5 Spinner Shim B 3410 16 B 3410 16 B 3410 16 Spinner Shim B 3410 32 3410 32 3410 32 NOTE 1 Mount nut 1639 2 is 1 2 inch 1639 32 is 9 16 inch NOTE 2 Not all parts listed for a propeller series are required for every model propeller Table 1002 Installation Parts for Turbine Engine Propellers es Series Seres 6700 Seres 750 Series 61000 Series C1100 Seis Maa lees Spinner Screw A 1635 133 A 1635 133 A 1635 133 A 1635 133 A 1635 133 bright nickel plated Spinner Screw A 1635 39 1635 39 1635 39 1635 39 cadmium plated Spinner Screw A 1635 172 cadmium plated dyed black 61 30 01 Page 1001 McCauley Propeller Systems Dec 7 2009 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL Table 1002 Installation Parts for Turbine Engine Propellers continued 5 i C600 Series C650 Series C700 Series C750 Series 1000 Series 1100 Series Spinner Washer A 1638 5 A 1638 5 A 1638 5 A 1638 5 1638 44 1638 5 fiber Spinner Shim B 4940 1 B 4940 1 B 4940 1 B 49
87. shers from the spinner and fillet assemblies if fillet assemblies are installed Remove spinner from the bulkhead and fillet assemblies if fillet assemblies are installed 61 30 01 Page 202 McCauley Propeller Systems Dec 7 2009 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL 4 Remove the spinner support and shims from the front of the propeller cylinder if installed 5 If required remove screws and washers attaching fillets to bulkhead and remove fillets Identify location of each fillet to the bulkhead NOTE On some spinner assemblies the fillets are riveted in place and cannot be removed from the bulkhead assembly Propeller Removal 1 Remove cowling as required for access to mounting nuts NOTE Not all propellers use nuts to secure the propeller mounting nuts 2 Remove the safety wire from the bolts if installed on Continental engine installations For Lycoming installations remove safety wire from bolts 3 Break the torque on the propeller mounting bolts and nuts 4 Support the propeller remove the mounting bolts and remove the propeller from the engine crankshaft flange 5 Place the propeller on a suitable work surface Propeller Installation 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
88. sion level AC20 37 X Aircraft Metal Propeller Maintenance AC35 4 1 Propeller Instructions for Continued Airworthiness AC43 9 X Maintenance Records B If you have any questions 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 day 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 01 McCauley Propeller Systems Dec 7 2009 1 General A B C McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL INTRODUCTION This Owner Operator Manual provides familiarization and line maintenance instructions for McCauley propellers All maintenance and service procedures described and authorized in this manual must be done only by qualified personnel Overhaul or any repair procedure that involves the internal components of the propeller must be done only by an authorized and qualified propeller overhaul facility in accordance with the appropriate McCauley propeller overhaul manual 2 Additional Reference Manuals A The following publications contain additional maintenance and service information about McCauley propellers Each of the referenced publications has a specific application to the owners and operators of aircraft with McCauley propellers installed
89. sure that engine propeller flange hub mounting flange dowels and holes mounting studs and holes are clean dry and free of damage and foreign material Remove protective cover from propeller hub mounting flange Ensure that a new McCauley O ring A 1633 3 or A 1633 49 Continental engines A 1633 11 Lycoming engines is installed in the groove of propeller hub mounting flange Lubricate O ring with engine oil prior to installation of propeller Position propeller close to engine propeller flange and align dowel pins with the dowel pin holes if applicable CAUTION Propeller must be installed straight onto engine flange Any cocking of propeller relative to flange could result in damage to engine propeller flange mating surfaces Mount the propeller on engine propeller shaft Trap the bulkhead between hub and engine mounting flange if applicable Ensure threads of nuts and studs are free of burrs nicks and similar damage and clean of foreign material WARNING If the lubricant is not applied as required the nuts will be under torqued and the propeller could fail a For Continental Franklin and Orenda engine installations CAUTION Do not use oil as a substitute for approved lubricant It is imperative that the correct specification of lubricant be used during installation Substitution of the approved grease with an unapproved lubricant or no lubricant could result in under torquing or severe over torquing of propeller att
90. t a thorough inspection by an appropriately rated person or repair facility Never straighten a damaged propeller Even partial straightening of blades to ease shipment to a repair facility may result in hidden damage not being detected and an unairworthy propeller being returned to service Never repair any blade defect by welding heating or peening This can induce premature blade failure Never chrome plate a spinner Plating will cause cracks and spinner failure 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 Do not polish propeller blades unless specifically permitted by McCauley s instructions Do not fill any damaged areas of metal blades with bulk filler materials such as epoxy or auto body fillers This prevents areas of potential cracking from being inspected Additionally filling a damaged area will not correct the stress risers caused by the dent or those caused by the loading that introduced the dent Do not paint over areas of corrosion on blades Corroded areas must be removed in accordance with approved procedures prior to applying the approved protective finish Do not run up engines in areas containing loose rocks gravel or debris Avoid quartering rear winds during ground run up because this activity can cause damaging stresses Do not push or pull on propeller blades when moving the aircraft by hand Tow bars
91. t the tachometer is appropriately marked for operational limitations of the propeller and that the tachometer accuracy is checked at periodic inspection intervals Make sure that the applicable installation information and warning decals are on the propeller These decals may include warnings against pushing or pulling on the propeller the model number the correct bolt torque dynamic balancing information Each propeller should have its own maintenance record 61 30 01 Page 201 McCauley Propeller Systems Dec 7 2009 10 11 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL The operator must recondition or overhaul the propeller when it reaches the McCauley recommended service time limits Refer to McCauley Service Bulletin SB137 X for the latest propeller overhaul intervals For safety and glare reduction for conventional single engine tractor type aircraft keep the blade backs 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 Pusher props may have unique paint color requirements for good visibility for ground personnel Refer to McCauley s maintenance documents McCauley spinners can be polished use commercially available polishing compounds Operators CANNOT do the following 1 2 Do not operate any aircraft after a propeller has been subjected to an impact withou
92. ted in flight by reducing the manifold pressure The propeller control should be in the full RPM position and the manifold pressure should be reduced until the RPM drops slightly This ensures that the propeller is against its low pitch stop and is eliminated from the equation 2 Surging may be caused by air in the system defective governor or problems associated with the engine transfer bearing or collar 3 Ifthe governor test is satisfactory and no other system faults can be found the propeller may be at fault Although very rare hunting and surging may be due to excessive internal pressure in the propeller or overshimming of propeller blades Corrective Action 1 Ifthe propeller is suspected as the cause it should be removed for examination by an approved propeller repair station 2 Surging has been encountered on ground operation after initial installation while purging air from system a encountered at other times the propeller should be cycled repeatedly to remove all air from the system 61 30 01 Page 101 McCauley Propeller Systems Dec 7 2009 I 4 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL b If the condition persists it may be attributable to the governor and the governor should be removed and tested Propeller should be purged again after governor is reinstalled Changing RPM or Creeping Constant Speed Piston Turbine A Propeller RPM changing and holding new setting 1 Possi
93. ting slinger ring forces the anti ice fluid to flow to the spray head assemblies b The spray head assembly transports the anti ice fluid from the slinger ring to the propeller blade feed shoe The spray head distributes the ant ice fluid across the grooves that are imbedded in the propeller blade feed shoes c The propeller blade feed shoe is attached to the leading edge of each propeller blade The feed shoes are made of rubber and have groves to guide feed anti ice fluid alcohol along the leading edge of the rotating propeller by centrifugal force The alcohol that is distributed on the feed shoe and adjacent blade surface prevents the formation of ice on the propeller blades G Propeller Deice Boots Alcohol Anti Ice Feed Shoes if installed 1 The deice boots are constructed of fabric reinforced abrasion resistant rubber Electrical deice boots have a wire mesh or foil element that heats as current is supplied to the boot A deice timer controls the current cycle that is applied to individual blades or boot segments Alcohol anti ice feed shoes are ridged for distribution of alcohol The outer surface that is exposed to the environment has a glossy finish while the side that is bonded to the propeller has a dull matte finish H Deice Harness if deice is installed deice electrical harnesses connect the deice boots to the slip ring assembly to complete the deice electrical circuit Deice Slip Ring Assembly if deice
94. y Torque Wrench Adapter 61 30 01 207 McCauley Propeller Systems Dec 7 2009 McCAULEY PROPELLER SYSTEMS OWNER OPERATOR INFORMATION MANUAL CAUTION If an adaptor or extension such as McCauley part number B 5588 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 Torque Wrench Length x Desired Torque Dial Reading Torque Wrench Length Extension Length 12 Make sure of proper rigging of engine controls Refer to aircraft maintenance manual 13 Do a propeller blade angle check For details refer to Blade Angle Checking and Adjustment in Propeller Field Maintenance Practices E Spinner Installation CAUTION Undershimming or overshimming of the spinner aft bulkhead could result in spinner wobble vibration and or bulkhead and spinner cracking Please follow shimming procedures carefully 1 Install propeller spinner fillets on the bulkhead with screws and washers if required 2 Insert shims into the spinner support and lightly press spinner support onto the cylinder on the front end of the propeller 3 Mount the spinner onto the bulkhead and fillet assembly and check alignment of the mounting holes in the spinner and bulkhead a Make sure that alignment marks on the spinner and propeller blade are matc

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