The information in this presentation is not intended to supersede, replace, or be used in lieu of approved published documentation. 1 Technical Issues

The information in this presentation is not intended to supersede, replace, or be used in lieu of approved published documentation.

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Technical Issues Review

Presented By:

Michael Mayhill

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Composite BladesAluminum BladesHubsSealsSpinnerDe-iceMiscellaneousStatus Updates

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Your Input Appreciated

Some of our best fixes have been suggested by the field

You see these products in normal and extreme conditions every day –– What do you see that is working?– What do you see that is not working?– Do you have suggestions to make something

better?

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Composite BladesASC II

As of September 24th there were 4087 of the composite N7605( ) blades manufactured

These blades are becoming more and more popular with your customers

We are working to develop new applications

More are manufactured every day

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HC-SL-61-294:

Field Inspection and Minor Repair Criteria for N7605( ) blades [May 07/09]

Previously in Manual 135F only

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HC-SL-61-294:

Defines permitted field repairs for A&P mechanics

Damage beyond minor repair limitations must go to a certified propeller service facility

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Composite BladesInspection

HC-ASB-61-306 rev. 2:

N7605B blade ‘crack’ indication in boot area

– Evaluation found ‘soft spot’ at the ‘crack’ location

– Resin did not properly cure during early production process

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HC-ASB-61-306 rev. 2:

Inspections of N7605( )

– Effectivity is s/n specific to early production

– 387 blades affected

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HC-ASB-61-306 rev. 2:

Visual Inspection:– Recurring visual

inspection every 100 hrs/annual

• Reporting required• A&P can accomplish

– Warranty coverage for visual

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HC-ASB-61-306 rev. 2: Inspection of N7605( )

– Terminating Action UT Inspection at or before overhaul• Reporting required• Accomplished by Level II or III • 52 inspections completed, 6 blades replaced

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HC-ASB-61-306 rev. 2: Inspection of N7605( )

– UT equipment available for loan– Warranty coverage for UT at overhaul

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Composite BladesStaking Pins

Staking pins found sheared during standard engineering evaluation of high-time N7605( )blade

– No performance issues noted

– Design improvement with larger staking pins

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HC-SB-61-319: Staking Pins [pending]– Affects N7605( ) and

N7893( ) blades by s/n• 3658 blades

– Terminating Action at overhaul• Index to new location• Insert new, larger pins

– Does not affect life of product

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Was B-5996-628 Ø=0.125” Now B-5996-640 Ø=0.1875”(Production)

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Aluminum BladesProduction Rolling Issue

HC-SB-61-318 rev. 1: Blade Inspection [Jun 15/10]

Internal production process issue

– M, P, and R shank blades from Jul 09 – Jan 10

– Cost analysis led to engineering review• Reduced minimums approved• Manual update pending

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– M, P, and R shank blades by s/n• K85813 – K97065

– Optical Comparator Inspection

– Factory only rework

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– Reworked and non-reworked may be mixed in a propeller assembly if balance can be achieved

– No loss of clamping force due to clamp design

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Aluminum BladesNaCl Contamination

HC-ASB-61-322: Blade Replacement [pending]

– Fissure indication in the blade bore discovered at overhaul inspection

– Originated from Sodium Chloride contamination within the ingot

– Potentially all blades forged from that ingot could be contaminated

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– Affects Y-shank aluminum blades by serial number• 452 blades affected • 82 left Hartzell as blade only shipment

We are Considering:– Replacement within 250 hours/ 24 calendar months,

whichever occurs first• Any inventory/stock replacement within 24 calendar months

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– Affected blades MUST be retired and destroyed

– Airworthiness Directive is possible

– Warranty:• Replacement Blades free of charge until Nov 30, 2016• Some additional coverage for props maintained IAW SL61Y

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HubsLubrication Fittings

HC-SL-61-187 rev. 3: 45˚ Lubrication Fitting [Nov 13/09]

– Originally issued Oct 15/98

– Revision 3 removed torque • “Tighten until snug”

Any issues with the zerk fittings?

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HubsModification

HC-SI-61-206: Hub Modification – Bore Bushing

– Dimensional specifications for machining of bore and bushing on lightweight turbine propellers

– Available on request

– Revision needed for additional part numbers

Pending Changes related to Sample Program review

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Hubs1900D Inspection

HC-ASB-61-316 rev. 1: Hub Inspection [Jun 26/09]

– Two 1900D hubs found fractured near dowel holes and oversize inserts on mounting flange

– Found at overhaul inspection

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– ~800 hubs affected– Initial visual inspection

based on TSO– As required following visual:

• ECI• Stamp hub “K”• REPORTING

REQUIRED

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– 273 inspected • No indications

– Recurring ECI every 1000 hrs • REPORTING REQUIRED

– ECI required at each overhaul• REPORTING REQUIRED

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HubsBonanza/Debonair Bushing

HC-SB-61-315: Hub Bore Bushing [pending]– Compact -1 propeller on a

Beechcraft Bonanza stopped actuating in flight

– Investigation found failed bore bushing with oil behind the piston

– Hydraulic lock

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HC-SB-61-315: Hub Bore Bushing [pending]– Failure to seal due to:

• No bushing– Scored bore / damaged o-ring

• Bushing installed with adhesive – Failed adhesive– Bushing Slippage

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HC-SB-61-315: Hub Bore Bushing [pending]

– Propeller operates, doesn’t actuate

• Defaults to low pitch, high RPM

• Operates as fixed pitch propeller

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– Bonanza pilot set up for POH ‘Best Glide’

• Not compatible with low pitch, high RPM setting for Bonanza

– FAA SAIB-CE-10-21 issued to notify pilots

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– Compliance required for any Bonanza or Debonair w/ ( )HC-(C,G,L)(2,3,4)Y(F,K,R)-1( )

• Propellers NOT maintained IAW SL61Y: 200 hrs, 12 calendar months, or next major disassembly, whichever occurs first

• Propellers maintained IAW SL61Y:next major disassembly or SL61Y overhaul limit, whichever occurs first

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– Serial number prefix identifies affected hubs

– Perform applicable pitch change rod bore repair procedure IAW Manual 202A

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HubsProduction Bushing (-1)

HC-SL-61-305 [pending]

– Production change for all standard -1 hubs

• Does not match 202A repair

• Replace bushing at overhaul

• No machining required

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HubsProduction Bushing (-1)

HC-SL-61-305 [pending]

– Production change for all standard -1 hubs

• Already implemented in 113B for all Bonanza specific item #

• SL305 addresses all remaining standard -1 hubs

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HubsTB-10 Inspection

HC-SB-61-323: Hub Inspection [pending]– Affects propellers installed on Socata TB-10

– ECI of “A” suffix hubs, similar to SB269• Initial within 50 hours• Recurring every 100 hours or annual

– Terminating actions:• Hub Replacement with “B” suffix hub• Oil fill IAW SL273 [pending]

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Hubs Oil-Fill

HC-SL-61-273: Hub Modification [pending]

– ~4500 hrs in field– Only when directed

by Hartzell Service Bulletin

• Machine hub bore & breather holes

• Install bushing & retainer ring

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Hubs Oil-Fill

HC-SL-61-273: Hub Modification [pending]

– Only when directed by Hartzell Service Bulletin

• New sealant at parting line• Plugs instead of zerks• Red-dyed oil-filled for crack

detection

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SealsGrease Leaks

Silicone O-rings– Grease leaks have

been a concern in aluminum hub propellers

– Suggestion from the field for use of new material

– Engineering analysis for compatibility completed

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SealsGrease Leaks

Silicone O-rings– Field testing in alum

models ongoing– Over 30,000 SER

hours with NO leaks– Already implemented

in production for many models

Successful seal is also dependent upon a good installation of the appropriate wear strip

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SealsGrease Leaks

HC-SL-61-293 rev. 1: Y Shank Aluminum Blades [Mar 12/10]– Introduces C-3317-340-8– Approved alternate to

quad seal– Requires use of 0.010”

Teflon®

– Cost analysis in process for production implementation

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SealsGrease Leaks

HC-SL-61-301: Supersedes all C-3317-340

[Mar 12/10]– Introduces C-3317-340-8– Requires use of 0.010”

Teflon® on alum blades– Use existing C-3317-340– Composite blades use

different wear strip• No change required

– Production implemented

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SealsGrease Leaks

HC-SL-61-303: Supersedure in 1900D Installations [Apr 9/10]

– Introduces C-3317-340-8

– May use existing energizer ring + blade seal in combination

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SealsGrease Leaks

HC-SL-61-303: Supersedure in 1900D Installations [Apr 9/10]

– Energizer ring + blade seal can not be mixed with C-3317-340-8 in same propeller assembly

– Production and overhaul kit implementation is complete

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SealsGrease Leaks

HC-SB-61-321: Replacement in PC-21 Installations [Jun 15/10]

– Introduces C-3317-341-8 and 103379-1 wear strip

– Required at next o/h

– Optional at disassembly

– Requires use of thicker 103379-1 wear strip

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SealsGrease Leaks

HC-SB-61-321: Replacement in PC-21 Installations [Jun 15/10]

– Energizer ring + blade seal combination can not be mixed with C-3317-341-8 in same propeller assembly

– Reporting required

– Production and o/h kit implementation complete

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SealsGrease Leaks

HD-SL-61-042: Supersedure for Do-328

Installations [pending]

– Introduces C-3317-341-8 and 103379-1 wear strip

– Requires use of thicker 103379-1 wear strip

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SealsGrease Leaks

HD-SL-61-042: Supersedure for Do-328

Installations [pending]

– Energizer ring + blade seal combination can not be mixed with C-3317-341-8 in same propeller assembly

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Spinner

Known cracking issues

Working to design a permanent fix by application

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Spinner835-54(P) Replacement

HC-SB-61-311:

Inspection of 835-54(P) Spinner Assembly & Introduction of New Spinner Assemblies– Progression of document

• Original Issue:

1.D-5769-1(P) dome, filler plate removal required

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HC-SB-61-311:

Inspection of 835-54(P) Spinner Assembly & Introduction of New Spinner Assemblies– Progression of document

• Original Issue:

2. 102965(P) dome released as supercedure to unsupported D-5769-1(P)

– 102965(P) includes bonded support

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HC-SB-61-311, Rev 1:

Inspection of 835-54(P) Spinner Ass’y & Introduction of New Spinner Assemblies

• Revision 1

1.D-5769-1(P) dome uses field-installable forward bulkhead & spacers

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HC-SB-61-311, Rev 1:

Inspection of 835-54(P) Spinner Ass’y & Introduction of New Spinner Assemblies

No-Charge Warranty Components

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HC-SB-61-311, Rev 3:

New Composite Spinner Ass’y Introduction

– Revision 2 (pending)

– Terminating Action within 13 calendar months/ 50 hours, whichever first

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HC-SB-61-311, Rev 3:

New Spinner Ass’y Introduction

1.103585(F1) assembly with composite dome (Mooney)

2. 835-58(P) assembly with blunt, aluminum dome (Comanche)

No Charge Warranty Coverage

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De-Ice

Hartzell de-ice components

– Working to convert legacy components to Hartzell components

– Making design improvements along the way• Your suggestions are welcome• If you have found a difficult installation and/or have

design/installation suggestions please let us know

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De-IcePC-12 Routing

HC-SL-30-295 rev. 2: Wire Harness and Boot for PC-12 [Apr 9/10]– Conversion to Hartzell

components– Design improvements– New routing required– Expect similar

updates for similar installations

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MiscellaneousTSN

Questions on Time Since New of a propeller – What parts to track time for– What happens when components are changed out

HC-SL-61-61Y rev. 3: Overhaul & Life Limits [Nov 13/09]– Definition of Time Since New (TSN)– Primary components = hub, blades, & life-limited parts – Propeller assembly TSN = highest TSN primary

component installed

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MiscellaneousCam Follower Retention

HC-SB-61-320 [June 2010]:

Pitch Change Knob Bracket

– Affects HC-E5A-2 on Pilatus PC-21

– Introduces new unit with improved cam follower retention design

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MiscellaneousPreload Plate Wear

HC-SL-61-282 rev. 1, [Nov 09]:Preload Plate Wear Limits

– E shank blade butt seal released in 2005 to prevent hub cavity grease migration

• Later reports identified wear on the preload plate caused by the new seal

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MiscellaneousPreload Plate Wear

HC-SL-61-282 rev. 1, [Nov 09]: Preload Plate Wear Limits

– Affects E shank lightweight turbines and Y shank compacts with composite blades (excludes N shank)

– Preload plate inspection criteria at overhaul

What are you seeing in the field?

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MiscellaneousFeathering Spring

HC-SL-61-291 [obs] → HC-SB-61-324 [pending]:

Feathering Compression Spring

Reports of feathering issues in the field

– Unable to reach full feather at shutdown

– Disassembly found fractured feathering spring

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– Affects HC-B(4,5)(M,T)(A,N,P)-(1,2,3,5)

– Introduces 102877 spring as supercedure to A-3496

• New 102877 has flat outer diameter and improved fatigue life

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– (new in SB324) At next overhaul, requires replacement of the A-3496 with new 102877

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Status UpdatesSB269 Program

HC-SB-61-269 rev. 4: Hub Inspection [Nov 13/09]– FAA approved AMOC to AD 2009-22-08

• AD 2009-22-08 superseded AD 2006-18-15

– AD requires initial inspection within 50 flight hours • Contact local FSDO to discuss

– Retained 100 flight hour recurring inspection• Removed ‘or annual inspection’

– Pricing program (within TBO) expires April 30, 2011

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Documents go through writing, review, editing, and approval – but still not perfect– If you want clarification– If you find an error– If you have a suggestion

PLEASE CONTACT PRODUCT SUPPORT