SERVICE BULLETIN 239C

ALERT

September 15, 2002

TO: FAA-Approved Propeller Repair Stations, Aircraft Owners and Operators

SUBJECT: Inspection of Propeller Hub and Blades

MODEL AFFECTED: 5JFR36C1003/L104DSZ-0

SERVICE MANUAL AFFECTED: 890119

AIRCRAFT AFFECTED: Raytheon Starship 2000

This service information is to be added to the appropriate McCauley Service Manual until the
next manual revision is issued.

Service Bulletin 239C replaces Service Bulletin 239B dated December 21, 2001 and Service
Bulletin 236 dated March 15, 2001. Service Bulletin 239C adds requirement for hub inspection.
Lines in margins indicate changes.

CONDITION: McCauley has received a report of a crack in the retention area of the blade
shank. This crack was discovered during a teardown inspection following
the inability to dynamic balance the propeller. Oil from the hub cavity had
leaked into the blade bore and the propeller could not be dynamic balanced.

Recent testing by McCauley and Raytheon has identified an aircraft oper-

ating condition that results in excessive propeller blade and hub operating
temperatures that may result in fatigue cracking.

McCauley is requiring an initial and a repetitive eddy current or liquid

penetrant inspection of all L104DSZ-0 blades and liquid penetrant inspec-
tion of hub D-6014/C1003.

APPROVAL: FAA approval has been obtained on technical data in this publication that
affects product type design.
TO OBTAIN SATISFACTORY RESULTS, PROCEDURES SPECIFIED IN THIS SERVICE INFORMATION MUST BE ACCOMPLISHED IN ACCORDANCE WITH ACCEPTED
METHODS AND PREVAILING GOVERNMENT REGULATIONS. MCCAULEY PROPELLER SYSTEMS CANNOT BE RESPONSIBLE FOR THE QUALITY OF WORK PERFORMED IN
ACCOMPLISHING THIS SERVICE INFORMATION.
© MCCAULEY PROPELLER SYSTEMS

McCauley Propeller Systems

3535 McCauley Drive
Vandalia, Ohio 45377 USA
Page 2 of 14 Service Bulletin 239C

CORRECTION: 1. Prior to first flight of the day, perform preflight inspection per Section I.
2. Aircraft must be operated in compliance with PROPELLER ROTA-
TIONAL SPEED LIMITS (Limitations Section) of the Raytheon Aircraft
Company Model 2000 FAA Approved Airplane Flight Manual, p/n 122-
590013-37.
3. Perform initial and repetitive inspection per instruction in Section II or
Section III.
4. Make logbook entry of inspection.
5. Report findings to McCauley using report form on page 13.
6. In the event that a blade or the hub is rejected as a result of inspection,
the other components in propeller assembly may not be returned to
service until written authorized is received from McCauley.

COMPLIANCE: 1. Inspection per Section I must be performed prior to first flight of the day.

2. Aircraft must be operated in compliance with Raytheon's soon to be

released placard prohibiting ground operations with propeller in feather.

3. Aircraft must be operated in compliance with PROPELLER ROTA-

TIONAL SPEED LIMITS (Limitations Section) of the Raytheon Aircraft
Company Model 2000 FAA Approved Airplane Flight Manual, p/n 122-
590013-37.

4. If blade total time is less than 1000 hours, blade must be inspected per
Section II or Section III prior to reaching 1100 hours or 200 hours from last
overhaul or inspection per Service Bulletin 239[X], whichever is greater.
Perform repetitive inspection every 200 hours thereafter.
5. If blade total time is greater than or equal to 1000 hours, blade must be
inspected per Section II or Section III within 100 flight hours of receipt of
this Service Bulletin or 200 hours from last overhaul or inspection per
Service Bulletin 239[X], whichever is greater. Perform repetitive inspec-
tion every 200 hours thereafter.
6. If propeller total time is less than 1000 hours, hub must be inspected per
Section III prior to reaching 1100 hours or 200 hours from last overhaul,
whichever is greater. Perform repetitive inspection every 200 hours
thereafter.

7. If propeller total time is greater than or equal to 1000 hours, hub must be
inspected per Section III within 100 flight hours of receipt of this Service
Bulletin or 200 hours from last overhaul, whichever is greater. Perform
repetitive inspection every 200 hours thereafter.
Service Bulletin 239C Page 3 of 14

NOTE: Compliance time for blades is based on "blade" time in service.

Compliance time for hubs is based on "propeller" time in service.

SECTION I
PREFLIGHT INSPECTION
Prior to first flight of the day, propeller assembly is to be inspected for blade shake. Blade
shake is defined as the tendency for blade tips to wobble slightly when the blade is physically

Figure 1
Inspection for Blade Shake
Page 4 of 14 Service Bulletin 239C

moved by hand (lead edge to trail edge See Figure 1). The inspection is for excessive move-
ment of blade in relation to other blades in an assembly. Aircraft vibration is to be inspected
per Raytheon Safety Communique No. 155, Rev. 1.

SECTION II
BLADE
EDDY CURRENT INSPECTION

The following eddy current inspection is designed to detect circumferential cracks in the fillet area
near the retention groove radius (see Figure 2). An eddy current probe has been developed to
cover the complete zone in one pass.

This inspection is only approved for authorized facilities. Contact McCauley Product Support for
an authorized facility.

McCauley Propeller Systems

Attn: Product Support
3535 McCauley Drive
Vandalia, OH 45377
telephone: 877-776-7435
telefax: 937-890-6001

The following inspection must be performed with the propeller disassembled. Disassemble
propeller per McCauley manual 890119.

Surface Preparation:

In the inspection area of the blade only (see Figure 2).

1. Clean area with solvent and soft brush to remove dirt and oil. Wipe surface with non-
oil based solvent.

2. Ensure the peened inspection area is free of burrs, paying particular attention to the
blade retention area, as the groove radius transitions to the shank O.D. Lightly
smooth non-shotpeened area with Scotchbrite. This will assist in guiding the probe
resulting in better probe/blade contact that should extend probe life and help
eliminate false indications caused by excessive roughness.

Personnel Requirements
Service Bulletin 239C Page 5 of 14

Individuals performing inspections defined in this procedure must have a specialized rating
in the applicable inspection method. Personnel must be qualified and certified to the
minimum recommended requirements of "Level II" as described in Aerospace Industries
Standard -NAS 410 or equivalent national/international standard.

Required Equipment:

WARNING: USE OF THE US-1417 PROBE IS MANDATORY. NO SUBSTITUTIONS MAY BE

MADE.

1. Eddy Current Instrument:

Staveley Nortec 19, 24, 2000, Uniwest 450, or equivalent high

voltage drive impedance plane instrument

2. Reference Standard:

McCauley shank radius aluminum calibration block containing three

(3) EDM notches, part number C-7770

3. Probe:

Large surface area probe - US-1417 (4 pin Fischer)

CAUTION: THE US-1417 PROBE IS PROVIDED WITH A 8 PIN BURNDY CABLE CONNEC-
TOR. SOME INSPECTION EQUIPMENT MAY REQUIRE AN ADAPTER.

4. Teflon or Mylar wear tape

Maximum thickness 0.004 inch (0.102 mm)

Calibration block (C-7770), large surface probe (US-1417), and 8 pin burndy connector cable are
available from McCauley in a kit, PL-7771.

Surface Calibration and Inspection Procedure (US-1417):

1. Attach the US-1417 probe to the instrument.

2. Instrument frequency 250 kHz, low pass filter 35 Hz, and high pass filter 2 Hz. Filter
settings are to reduce noise effects of the shotpeened surface.

3. Place the form-fitting probe on the reference standard. Null the instrument in an area
of the reference standard that does not have an EDM notch. Move the probe across
the EDM notches (A, B, and C, Figure 3), adjust the phase angle to obtain maximum
notch signal in the vertical channel (Figure 4). Adjust the gain to obtain a signal for
the smallest defect response that is two and one-half (2.5) major screen divisions.
The sensitivity of the testing system is now calibrated.
Page 6 of 14 Service Bulletin 239C

NOTE: Ensure that pressure is applied downward and blade-wise radially inboard
to provide good contact of the wide area probe element.

4. Using the instrument's gating and alarm function, adjust the gate threshold to trigger
when the signal exceeds two and one-half (2.5) divisions peak to peak for vertical
in-phase indications.

NOTE: Use of the alarm and gate functions are at the inspector's discretion. The
CRT erase function is also recommended if available.

WARNING: THE TEFLON TAPE ON THE PROBE SHALL BE CHANGED AFTER

PERFORMING THREE (3) BLADE INSPECTIONS, AND ANY TIME THAT
IT APPEARS THAT THE TAPE IS WEARING OUT. FAILURE TO DO SO
WILL RESULT IN INCREASED BACKGROUND NOISE AND PREMA-
TURE PROBE FAILURE. WHEN APPLYING THE WEAR TAPE ON THE
CURVED SURFACE, ATTEMPT TO REMOVE OR SMOOTH OUT ANY
WRINKLES THAT MAY FORM. WEAR TAPE SHALL BE NO MORE THAN
0.004 INCH (0.102 mm) IN THICKNESS.

5. Place the probe on the blade shank retention radius and balance the instruments.

6. All scanning is performed with a smooth motion around the shank, ensuring a
coverage around the complete circumference. Typical noise signals caused by the
shotpeened surface is shown in Figure 6.

7. Scan speed shall be at least 1 inch/second (25.4 mm/second), but not to exceed 6
inches/second (152.4 mm/second), and consistent with the calibration scan speed.

8. Instrument standardization calibration shall be verified every 30 minutes.

9. Any suspect indication shall be evaluated using phase analysis and scanned in both
directions to verify. Any relevant indication shall be indicated with approved
markers. Blades with suspect indications must be returned to McCauley for further
evaluation. Any hub or blades in an assembly with a suspect blade may not be
returned to service until release authorization by McCauley Product Support.
Contact McCauley Product Support for a return authorization number.

10. Report findings to McCauley using report form on page 13.

Procedure Prepared by: McCauley Propeller Systems

Procedure Approved by:

Service Bulletin 239C Page 7 of 14

Figure 2
Blade Retention Inspection Area

C
B A

Figure 3
Calibration Standard C-7770
Page 8 of 14 Service Bulletin 239C

Frequency: 250 kHz

H-gain: 84

V-gain: 84

Angle: 0

HP Filter 2

LP Filter: 35

Probe Drive: High

Figure 4
Calibration Notch Phase Plane Display

Figure 5
Calibration Notch Response on EDM
Service Bulletin 239C Page 9 of 14

Figure 6
Typical Noise Response in Shotpeened Area
Page 10 of 14 Service Bulletin 239C

SECTION III

BLADE AND/OR HUB

FLUORESCENT PENETRANT INSPECTION

WARNING: DO NOT CLEAN WITH A STEEL BRUSH, OTHER METAL BRUSH, HARD
BRISTLE BRUSH, OR TOOL OF ANY TYPE NOT SPECIFIED.

WARNING: DO NOT CLEAN USING PLASTIC MEDIA BLAST.

1. Clean all hub surfaces and/or blade shank with non-oil based solvent to remove dirt,
grease and oil. Remove thick or packed-on grease or dirt with soft brush. Allow to air
dry or with gentle stream of clean, dry compressed air.

2. Inspection is performed in accordance with standard ASTM E 1417, Standard Practice

for Liquid Penetrant Examination, or international equivalent.

3. Personnel performing inspection must be Level II certified in accordance with ASNT-

SNT-TC-1A, Recommended Practice for Qualification and Certification, or international
equivalent.

4. Material and Equipment used to perform inspection are in accordance with QPL-AMS-
2644-1, Qualified Products of Inspection Material, Penetrant, or international equivalent.

5. Penetrants used must be Type I, Fluorescent dye, Level 3 sensitivity - high.

WARNING: DO NOT ETCH HUB OR BLADE SHANK PRIOR TO INSPECTION.

6. Fluorescent penetrant inspect blade shank area, paying careful attention to blade
retention area (Figure 2). Fluorescent penetrant inspect hub.

7. Hubs and/or blades with suspect indications must be returned to McCauley for further
evaluation. The other components in an assembly with a suspect hub or blade may not
be returned to service until release authorization by McCauley Product Support. Con-
tact McCauley Product Support for a return authorization number.

8. Report findings to McCauley using report form on page 13.

Service Bulletin 239C Page 11 of 14

SECTION IV

Returning Propeller to Service

1. Contact McCauley Product Support with any suspect findings.

2. Reassemble propeller per McCauley manual 890119.

3. Make logbook entry noting compliance with Service Bulletin 239[X].

Page 12 of 14 Service Bulletin 239C

This page intentionally left blank.

Service Bulletin 239C Page 13 of 14

Both sides of this form must be completed following eddy current or dye penetrant inspection of hub and/or
blades per McCauley Service Bulletin 239C.

Contact McCauley immediately of any suspect findings and prior to returning any hub or blade to McCauley.

This completed form may be either mailed or telefaxed to McCauley at the following:
Indicate inspection performed
McCauley Propeller Systems
Product Support Department
Hub Inspection Y N
3535 McCauley Drive
Vandalia, Ohio 45377 Blade Inspection Y N
USA

Telefax: (937) 890-6001

Telephone: 1-877-776-7435

Date of Inspection:_________________ Facility Performing Inspection:_________________________________

Propeller S/N:__________________Propeller Total Time:________________Blade S/N_____________________

Propeller T.S.O.:__________________

Owner's Name:________________________________________________________________________________

Telephone:( )________________________________

Contact Person (if different than owner): __________________________________________________________

Telephone: ( )________________________________

Inspection Report (Please write detailed description of findings. If an indication was found, please write details of
its length, width, and location. Please sketch exact appearance of indication on hub or blade drawing on Page
14.

Continued on Page 14
Page 14 of 14 Service Bulletin 239C

Sketch Location of Any Cracks Found