SERVICE BULLETIN 221C
Reims-Cessna F152 · Service Bulletins
Overview
Service Bulletin 221C, issued on September 7, 1999, addresses the inspection and rework procedures for the propeller hub of affected aircraft models, including the Cessna 152 and Reims F152. This bulletin is directed towards FAA-approved propeller repair stations, Cessna Aircraft Company, and aircraft owners and operators. It highlights the necessity for inspections due to reported cracking issues in the propeller hub, particularly near the mounting bolt holes. The bulletin outlines compliance timelines, inspection procedures, and corrective actions to be taken in case of detected cracks. It emphasizes that the procedures must be performed by certified personnel and that operators are responsible for determining if their aircraft is affected by the bulletin.
- Affected models include Cessna 152 and Reims F152.
- Inspection required for propellers with 3,000 hours or more total time in service within 50 hours of operation since last inspection.
- Repetitive dye check inspections every 12 months or 800 hours, whichever comes first.
- Cracks less than 1/2 inch may be reworked; larger cracks require scrapping the propeller.
- Compliance documentation must be maintained and reported to McCauley.
Document
Source
Originally published by www.cessna150152.com. Sprinkle hosts a reference copy with an added summary, specifications and searchable full text.
Document details
- Type
- Service Bulletins
- Year
- 1999
- Pages
- 21
- File size
- 1.4 MB
- Publisher
- www.cessna150152.com
Common. Rarer than 1% of the aircraft models we track.
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- Pilot's Operating Handbook / AFM
- Checklist
- Maintenance Manual
- Parts Catalog (IPC)
- Systems & Wiring
- Service Bulletins
- Type Certificate (TCDS)
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In this document
Compliance
Operators must inspect propellers with 3,000 hours or more total time in service within 50 hours of operation since the last inspection under Service Bulletin 219A. Repetitive dye check inspections are required every 12 calendar months or every 800 hours of operation, whichever occurs first.
Dye Penetrant Inspection Procedures
The bulletin provides detailed steps for conducting a dye penetrant inspection on the propeller hub. This includes removing the propeller, stripping paint, and applying a chemical etching solution to prepare the surface for inspection. Specific materials and equipment are required, including liquid penetrant and ultraviolet light for inspection.
Rework Procedures
If cracks are found, the bulletin specifies criteria for determining if the propeller can be reworked or must be scrapped. Cracks less than 1/2 inch and not touching bolt holes may be reworked, while larger cracks or those in critical areas require the propeller to be removed from service.
Reassembly
After inspections and any necessary rework, the bulletin outlines the reassembly process for the propeller, including torque specifications for mounting bolts and safety wire installation.
Reporting and Documentation
Operators are required to make logbook entries indicating compliance with the service bulletin and report findings to McCauley Propeller Systems.
Safety notes
- Cracks found on the camber side of the hub near mounting bolt holes may indicate a serious issue requiring immediate inspection and potential removal from service.
- All procedures must be performed in accordance with accepted methods and government regulations.
Full document text
SERVICE BULLETIN 221C ALERT September 7, 1999 TO: FAA-Approved Propeller Repair Stations, Cessna Aircraft Company, Aircraft Owners and Operators SUBJECT: Inspection of Propeller Hub for Cracking and Rework Procedures MODEL AFFECTED: 1A103/TCM[XXXX] Serial Numbers: 770001 through 777390 and BC001 up to, but not including, KC001 (see page 19 for explanation of serial number system). SERVICE MANUAL AFFECTED: 730720 AIRCRAFT MODELS AFFECTED: Cessna 152, A152; Reims F152, FA152 NOTE: This bulletin does not contain an exhaustive list of aircraft which utilize this propeller because it is not possible to identify all aircraft using the affected propeller model (e.g. installation approvals made by Supplemental Type Certificate or FAA Form 337 ìMajor Repair and Alterationî, or Type Certificated models which have been inadvertently omitted). Therefore, it is the responsibility of the operator or person(s) performing aircraft inspections/propeller overhauls to determine if an aircraft has an affected propeller. This service information is to be added to the appropriate McCauley Service Manual until the next manual revision is issued. Service Bulletin 221C replaces Service Bulletin 221B, dated January 23, 1997. Service Bulletin 221A was never released to the field. Service Bulletin 221C allows more than one crack per bolt hole and per propeller but these may be reworked one time only. Paint is now required on front face of hub. Lines in margin indicate changes. Following compliance with Service Bulletin 221, Service Bulletin 221B, or Service Bulletin 221C, periodic inspections required per Service Bulletin 219A dated October 15, 1995, are no longer necessary. Consequently, Service Bulletin 219A is obsolete for all propellers modified per these bulletins. 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 A Textron Company 3535 McCauley Drive Vandalia, Ohio 45377 USA Page 2 of 21 Service Bulletin 221C COMPLIANCE: See Section I on Page 3. CONDITION: There have been several reports of hub cracking on the affected propeller. Cracks have been found on the camber side of hub near the mounting bolt holes, usually in the area where fretting is present. Inspect and rework the propeller in accordance with the following instructions. Multiple small cracks found in bolt hole area may be reworked. Bolt hole area may be reworked one time only. Propeller must be removed from service if there is reappearance of crack at a bolt hole which was previously reworked. CORRECTION: Inspection and rework may be accomplished by an FAA certified A & P mechanic (or international equivalent). Service Bulletin 221C Page 3 of 21 SECTION I. COMPLIANCE 1. For propellers with 3,000 hours or more total time in service: Inspection, per Section II, and Rework procedures, per Section III, must be accomplished within 50 hours of operation since last inspection under Service Bulletin 219A. 2. Repetitive dye check inspection, per Section IV, is to be accomplished every 12 calendar months or every 800 hours of operation which ever occurs first. SECTION II. DYE PENETRANT INSPECTION PROCEDURES 1. Remove propeller from aircraft as follows (Ref: Figure 11): a. Remove spinner (1). b. Remove safety wire from mounting bolt heads (3). c. Remove bolts and washers and remove forward bulkhead (5). NOTE: The aft spinner bulkhead (7) is installed between propeller (6) and crankshaft flange (8), and is removed as the propeller is removed. 2. Using paint remover, plastic media blasting, or equivalent, strip paint, if present, inside the dimensioned area outlined in Figure 12 on the camber side of the hub. NOTE: Face side of hub should not be painted. Remove paint if present. CAUTION: OBSERVE MANUFACTURER'S PRECAUTIONS WHEN USING PAINT RE- MOVER TO PREVENT INJURY. ALSO, MASK AREA TO BE STRIPPED TO PREVENT PAINT REMOVER FROM BEING APPLIED EXCESSIVELY. 3. Remove anodize and etch camber side of hub using the following procedures: CAUTION: FOLLOW MANUFACTURER'S PRECAUTIONS AND WARNINGS WHEN USING CHEMICAL ETCHING SOLUTIONS. a. Remove anodize by chemical etching with a solution containing 4% to 15% sodium hydroxide (lye). Such solutions are available in many (not all) household oven cleaners. "Easy-Off" brand is recommended (Boyle- Page 4 of 21 Service Bulletin 221C Midway, Inc., New York) (use undiluted). Other optional products are: "Mr. Muscle" (Dracket Products Co., Cincinnati, OH) or "Dow Oven Cleaner" (Dow Chemical Co., Indianapolis, IN). Brush-on liquid is preferable to spray-on type (if spray-on type is used, additional masking may be re- quired). b. Apply even coat of solution to face of hub, making sure solution reaches to the edge of each bolt hole. Allow solution to remain "active" on hub for 10 minutes. Reapply solution continuously during this time to maintain a wet, chemically active coating. A black or grey "smut" will appear as anodize is being removed. (If "smut" does not appear, it is an indication that the solution is inadequate.) c. Remove solution and "smut" after 10 minutes with clean, nonmetallic scouring pad saturated with 50% solution of warm water and vinegar. Clean out any etching solution which may have entered bolt hole with water and vinegar solution and soft brush. d. Wipe area dry. e. Repeat steps b through d for additional and necessary etching. (The first application will remove the anodize finish, and the second application will provide surface etching for optimum results during dye penetrant inspec- tion.) f. Scrub camber side of hub and bolt holes with clean cloth soaked with MEK and allow to dry. This will ensure area is clean before visual or penetrant inspection.
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4. Perform dye penetrant inspection using the following procedures: a. Required materials and Equipment 1. Liquid penetrant, Type 1, Level 4, Ultra-high sensitivity as listed in MIL-I-25135/QPL-25135 (Sherwin RC-88* or equivalent). 2. Penetrant Remover, Method C/Class 1 as listed in MIL-I-25135/ QPL-25135 (Sherwin DR-62* or equivalent). 3. Penetrant Developer, Form D, as listed in MIL-I-25135/QPL- 25135 (Sherwin D-100* or equivalent). Service Bulletin 221C Page 5 of 21 4. Ultraviolet light, 100 watt mercury vapor, providing 2000 uW/cm2 at 15" (Spectronics SB-100 or equivalent). 5. Ultraviolet light meter capable of measuring up to 6000 uW/cm2 (UVP J-221 or equivalent). 6. Paper towels, soft, lint free. *Products available from Sherwin, Inc., 5530 Borwick Ave., South Gate, CA 90280 b. Apply even coat of Type 1, Level 4 liquid penetrant on propeller camber side of hub, paying particular attention to area near bolt holes. NOTE: Ensure ambient temperature of propeller and liquid penetrant materials is in range of 60∞ to 120∞F before performing inspection. c. Allow liquid penetrant to remain on propeller camber side of hub for 1 hour minimum. d. Remove liquid penetrant from camber side of hub by wiping with paper towel until all penetrant residue appears to be removed. NOTE: Check 100 watt ultraviolet light output intensity before use. Output intensity should be minimum 2000uW/cm2 measured at 15 inches from the face of the ultraviolet light filter to the sensor on the ultraviolet light meter. e. Inspect propeller camber side of hub using a 100 watt ultraviolet light; there should be a green/yellow penetrant residue present. NOTE: Never spray liquid penetrant remover directly on area to be inspected. f. Using a soft paper towel dampened with class 1 penetrant remover, wipe camber side of propeller hub while viewing under a 100 watt ultraviolet light. Continue wiping with penetrant remover dampened towel until all evidence of penetrant residue is not visible when examined with an ultraviolet light. g. Spray light, even coat of Form D developer on camber side of propeller hub. Page 6 of 21 Service Bulletin 221C NOTE: Do not spray thick, heavy coats of developer onto component being inspected as this could mask over the defect and allow it to go undetected. h. Examine hub using a 100 watt ultraviolet light. i. If crack is found, check propeller serial number for change letter stamp- ing. If a letter 'S' is located in front of the serial number (indicating prior rework), area of previous rework must be determined. If current crack indication is at same bolt hole as previous rework, propeller is scrap. If previous rework was at another bolt hole, propeller may be reworked. If the change letter 'S' is not present or previous rework was at another bolt hole, mark the location of crack, path and length with fine point felt tip pen prior to removing ultraviolet light. This is important in aiding rework if crack size and location are found to be within acceptable limits. (Ref: Figure 1) Proceed to Section III for rework in- structions. Figure 1 j. If no crack is found, glass shot entire camber side of hub using MSH glass shot (MIL- G-9954A or latest revision, MIL Bead #8, 80-100 PSI). Apply alodine to unpainted camber side of hub in accordance with MIL-C-5541. Alodine all surfaces where etching may have removed anodize, make sure to swab alodine inside bolt holes where etching solution may have entered. Service Bulletin 221C Page 7 of 21 Paint camber side of hub only, do not paint face side of hub (engine mount- ing surface). Proceed to Reassembly instructions in Section V to return propeller to service. 5. Repetitive dye check inspection, per Section IV, is to be accomplished every 12 calendar months or every 800 hours of operation whichever occurs first. SECTION III. REWORK 1. Use the following criteria to determine if the cracks can be reworked or if the propeller is scrap (Ref: Figure 13): a. Propeller must be scrapped if: 1. Cracks are 1/2" or larger 2. Cracks touch a bolt hole 3. Crack are within 1/4" of hub outside edge 4. Crack are within 1/4" of centerbore 5. Change letter 'S' is located in front of propeller serial number stamping and location of previous rework can not be determined, or previously rework was in same bolt hole as current crack b. Propeller can be reworked if: 1. Cracks are less than 1/2" 2. Cracks do not touch a bolt hole 3. Cracks are more than 1/4" from hub outside edge 4. Cracks are more than 1/4" from centerbore 5. Cracks are located in different bolt hole than previous rework. NOTE: ALL of the above criteria must be met in order for the propeller to be eligible for rework. Page 8 of 21 Service Bulletin 221C 2. Follow these procedures to remove cracks from propeller hub. OPTION 1 - Bridgeport (Ref: Figure 2) a. Lay propeller on Bridgeport (or similar machine). b. Align and center crack with .250" ball end mill in the direction of motion. Figure 2 c. Clamp propeller to machine. d. Lower .250" ball end mill and touch hub surface. This will be the zero (0) dimension. Figure 3 Service Bulletin 221C Page 9 of 21 e. Set depth of cut to .010", and begin removing crack. (Ref: Figure 3) NOTE: Do not remove more than .040" material total when attempting to remove crack. NOTE: Ball end mill may extend into bolt hole when removing crack. Do not allow mill centerline to extend beyond length of crack. This will allow for end mill runout. (Ref: figure 4) Figure 4 f. Examine reworked area under 10x powerscope after each cut. (Ref: Figure 5) g. If crack appears to be totally removed, repeat etch and dye penetrant inspection using instructions in Section II to verify crack has been re- moved. h. If crack still exists after .040" material is removed, prop must be scrapped. Page 10 of 21 Service Bulletin 221C Figure 5 OPTION 2 - Rotary Grinder (Ref: Figure 6) a. Using 3/16" Grinding Burr, begin removing crack. Figure 6 NOTE: Do not remove more than .040" material total when attempting to remove crack. NOTE: Do not grind beyond length of crack. b. Verify amount of material removed with depth gauge. c. Examine reworked area under 10x powerscope after each cut. d. If crack appears to be totally removed (Ref: Figure 7), repeat etch and Service Bulletin 221C Page 11 of 21 dye penetrant inspection using instructions in Section IV to verify crack has been removed. e. If crack still exists after .040" material is removed, prop must be scrapped. Figure 7 3. Sand hub face with sanding bob (Cratex Rubberized Abrasives, p/n 11M) to remove any sharp edges. (Ref: Figure 8 and Figure 9) Figure 8 Page 12 of 21 Service Bulletin 221C Figure 9 4. Glass shot entire hub using MSH glass shot (MIL- G-9954A or latest revision, MIL Bead #8, 80-100 PSI). (Ref: Figure 10) Figure 10 5. Stamp change letter 'S', using a 1/8 inch steel stamp, in front of the propeller serial number. 6 Apply alodine to unpainted hub in accordance with MIL-C-5541. Alodine all Service Bulletin 221C Page 13 of 21 surfaces, including inside bolt holes, where etching may have removed anodize. Paint camber side of hub only. Do not paint hub mounting surface. NOTE: Repaint all areas of hub where paint was accidentally removed. Paint camber side of hub. DO NOT paint engine mounting surface of hub within dimensioned area as shown in figure 12. 7. Repetitive dye check inspection, per Section IV, is to accomplished every 12 calendar months or every 800 hours of operation which ever occurs first. NOTE: Propeller which has been reworked, indicated by change letter 'S', per instruc- tions in Section III may only be reworked again if area of previous rework can be determined. If current crack indication is at same bolt hole as previ- ous rework, propeller is scrap. If previous rework was at another bolt hole, propeller may be reworked. Bolt hole may be reworked one time. 8. Reassemble per Section V. SECTION IV. REPETITIVE DYE PENETRANT INSPECTION PROCEDURES 1. Remove propeller from aircraft as follows (Ref: Figure 14): a. Remove spinner (1). b. Remove safety wire from mounting bolt heads (3). c. Remove bolts, plate, forward bulkhead, and mylar gasket (Ref: Figure 14) NOTE: The aft spinner bulkhead (7) is installed between propeller (6) and crankshaft flange (8), and is removed as the propeller is removed. 2. Perform dye pentrant inspection per Section II. 3. If crack is found, check propeller serial number for change letter stamping. If a letter 'S' is located in front of the serial number (indicating prior rework), area of previous rework must be determined. If current crack indication is at same bolt hole as previous rework, propeller is scrap. If previous rework was at another bolt hole, propeller may be reworked. If the change letter 'S' is not present or previous rework was at another bolt hole, mark the location of crack, path and length with fine point felt tip pen prior to removing ultraviolet light. Page 14 of 21 Service Bulletin 221C This is important in aiding rework if crack size and location are found to be within acceptable limits. Proceed to Section III for rework instructions. NOTE : It is required that McCauley Product Support be notified if any propeller which passed the initial inspection and has been reworked is later found to have crack reappearance. Use the form on page 21 for notification. 4. Reassemble per Section V. 5. Repetitive dye check inspection, per Section IV, is to accomplished every 12 calendar months or every 800 hours of operation which ever occurs first. SECTION V. REASSEMBLY 1. Referencing Figure 14, reinstall propeller as follows: a. Clean mating surface of propeller, crankshaft flange, and spinner bulkheads. WARNING: BE SURE THAT MAGNETO IS GROUNDED BEFORE TURNING PROPEL- LER, OR CONNECTING EXTERNAL POWER. b. Position aft spinner bulkhead between propeller and crankshaft flange. c. Align propeller blade with t.c. mark on aft side of ring gear, and rotate propel- ler clockwise, as viewed from the front, to first bolt hole. d. Install mylar gasket (p/n B-7306). e. Install forward spinner bulkhead. If holes on front bulkhead are cupped due to previous torques from bolts and washers, place bulkhead on flat surface and lightly pound cupped holes flat with hammer. Remove any burrs or rough edges. Diameter of holes should be 0.375". Ream holes if necessary. f. Install steel reinforcement plate (p/n B-7287). g. Install new bolts, A-2513-78, or bolts magnafluxed per ASTM E1444-91, without washers. Bolts, plate and gasket may be purchased in kit form, B-4622-43. h. Tighten bolts evenly, then torque to 300-360 in.-lb. or 25-30 ft.-lb (dry). Service Bulletin 221C Page 15 of 21 i. Safety wire propeller mounting bolts, ensuring that safety wire is around bolt heads, not over top. Use .041" diameter safety wire. j. Install spinner shell. 2. Make logbook entry indicating compliance with this service bulletin. 3. Using form on page 21, report findings to McCauley. Page 16 of 21 Service Bulletin 221C 1. Spinner 2. Screw 3. Bolt 4. Washer 5. Forward Spinner Bulkhead 6. Propeller 7. Rear Spinner Bulkhead 8. Crankshaft (With Ring Gear) 1 2 3 4 5 6 7 8 Figure 11. Original Configuration of 1A103/TCMXXXX Propeller and Spinner Installation Service Bulletin 221C Page 17 of 21 Figure 12. Typical Crack Appearance and Location Page 18 of 21 Service Bulletin 221C Within 1/4 (0.250) inch Within 1/4 (0.250) inch Crack less than 1/2 (0.500) inch in length. Figure 13. Reworkable & Non-Reworkable Cracks All cracks shorter than 1/2 (0.500) inch, do not contact bolt hole, and are more than 1/4 (0.250) inch from hub edge and hub centerbore is acceptable. Propeller may be reworked. Any crack longer than 1/2 (0.500) inch, contacts a bolt hole, is less than 1/4 (0.250) inch from hub centerbore is unacceptable, or is located in area of previous rework. Remove unrepairable propeller from service. Any crack longer than 1/2 (0.500) inch, contacts a bolt hole, is less than 1/4 (0.250) inch from hub edge is unacceptable or is located in area of previous rework. Remove unrepairable propeller from service. Service Bulletin 221C Page 19 of 21 D J 241 241st propeller manufactured in that month Month: October Year: 1983 In 1980 McCauley began a new serial number system as shown below: A A XXX Number of propeller manufactured that month Month: (A) January, (B) February, (C) March, etc... Year: (A) 1980, (B) 1981, (C) 1982, etc... Example of serializing system is shown below: NOTE - Some propellers may have an "R", "P", "PR", or "RP" stamped in front of the serial number, indicating compliance with earlier service information. These identifiers are not a part of the serial number designation and are to be disregarded when considering applicability of this service bulletin. APPROVAL: FAA approval has been obtained on technical data in this publication that affects product type design. Page 20 of 21 Service Bulletin 221C 1. Spinner 2. Screw 3. Bolt 4. Steel Reinforced Plate 5. Forward Spinner Bulkhead 6. Mylar Gasket 7. Propeller 8. Rear Spinner Bulkhead 9. Crankshaft (With Ring Gear) 1 2 3 4 5 6 7 8 9 Figure 14: Reworked Configuration for 1A103/TCMXXXX Propeller and Spinner Installation Service Bulletin 221C Page 21 of 21 This form must be completed following dye penetrant inspection of propeller per McCauley Service Bulletin 221C. See Section II or Section III of Service Bulletin 221C for further details. This completed form may be either mailed or telefaxed to McCauley at the following: McCauley Propeller Systems Product Support Department 3535 McCauley Drive Vandalia, Ohio 45377 Telefax: (937) 890-6001 Telephone: (937) 890-5246 Date of Compliance with S.B. 221C:_________________ Propeller S/N:________________________ Propeller Total Time:___________________ Propeller T.S.O.:__________________ Aircraft N-number:_____________________ Aircraft S/N:__________________________Aircraft Total Time:_________________ Owners Name:______________________________________________________________________________________________________ Telephone:( )________________________________ Contact Person (if different than owner):__________________________________________________________________________________ Telephone: ( )________________________________ Please Sketch Exact Appearance of Crack Above Report Form for Compliance with McCauley Service Bulletin 221C Was crack found Length of crack Depth of material removed Was propeller removed from service due to crack