Airworthiness Directives; Hartzell Propeller Inc. HC-( )3Y( )-( ) Series Three-Bladed Propellers

DEPARTMENT OF TRANSPORTATION

14 CFR Part 39

[Docket No. 94-ANE-19; Amendment 39-9008; AD 94-17-13]

Airworthiness Directives; Hartzell Propeller Inc. HC-( )3Y( )-(

) Series Three-Bladed Propellers

AGENCY: Federal Aviation Administration, DOT.

ACTION: Final rule; request for comments.

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SUMMARY: This amendment supersedes an existing airworthiness directive

(AD), applicable to Hartzell Propeller Inc. HC-( )3Y( )-( ) series

three-bladed propellers, that currently requires initial and repetitive

visual and eddy current inspections for cracks in the area of the

grease fitting holes on the side of the propeller hub arm. This

amendment reduces the repetitive inspection interval from 25 hours time

in service (TIS) to 10 hours TIS. In addition, this amendment adds an

optional interim alternative method of compliance involving a

chamfering modification to extend the initial and repetitive inspection

compliance interval. This amendment also adds a terminating action to

require propeller hub replacement to a new hub configuration where

grease fittings are located in a reinforced area near the hub parting

line. This amendment is prompted by a report from the Aviation Accident

Investigation Board (AAIB) of the United Kingdom and a recent incident

that indicates a hub failure could have occurred in less time than the

25 hour TIS inspection interval. The actions specified by this AD are

intended to prevent possible propeller hub failure and subsequent

propeller blade separation and loss of the aircraft.

DATES: Effective September 15, 1994.

The incorporation by reference of certain publications listed in

the regulations is approved by the Director of the Federal Register as

of September 15, 1994.

Comments for inclusion in the Rules Docket must be received on or

before October 31, 1994.

ADDRESSES: Submit comments in triplicate to the Federal Aviation

Administration (FAA), New England Region, Office of the Assistant Chief

Counsel, Attention: Rules Docket No. 94-ANE-19, 12 New England

Executive Park, Burlington, MA 01803-5299.

The service information referenced in this AD may be obtained from

Hartzell Propeller Inc., One Propeller Place, Piqua, OH 45356-2834;

telephone (513) 778-4200, fax (513) 778-4391. This information may be

examined at the FAA, New England Region, Office of the Assistant Chief

Counsel, Burlington, MA; or at the Office of the Federal Register, 800

North Capitol Street, NW., suite 700, Washington, DC.

FOR FURTHER INFORMATION CONTACT: Tim Smyth, Aerospace Engineer, Chicago

Aircraft Certification Office, FAA, Small Airplane Directorate, 2300

East Devon Avenue, Room 232, Des Plaines, IL 60018; telephone (708)

294-7130, fax (708) 294-7834.

SUPPLEMENTARY INFORMATION: On October 20, 1989, the Federal Aviation

Administration (FAA) issued priority letter airworthiness directive

(AD) 89-22-05, to require visual inspection of the propeller hub

surface in the area of the grease fittings at intervals of 50 hours

time in service (TIS). That action was prompted by reports of propeller

hub failures caused by cracks initiating in the grease fitting holes on

the side of the hub arm. These cracks typically originate in the

threads of the hub grease fitting, then propagate around the blade arm

of the hub, resulting in failure of the hub. That condition, if not

corrected, could result in possible propeller hub failure and

subsequent propeller blade separation and loss of the aircraft.

Since the issuance of that AD, the FAA received a report from the

Civil Aviation Authority (CAA) of the United Kingdom of a propeller hub

failure on a propeller that had been visually inspected in accordance

with AD 89-22-05. The CAA's investigation revealed that the propeller

hub crack had corrosion on the fracture surface that was present for a

considerable time but the crack was undetectable by visual inspection.

The FAA, in conjunction with the CAA and the manufacturer, determined

that the visual inspection procedure alone is inadequate to reliably

find cracks in the propeller hub. On August 18, 1993, the FAA issued

priority letter AD 93-16-14, which requires initial and repetitive

visual inspections and eddy current inspections (ECI) for cracks in the

area of the grease fitting holes on the side of the propeller hub. The

FAA issued the final rule on this action on November 22, 1993, which

was published in the Federal Register on December 21, 1993 (58 FR

67307).

Recently, an inspector found an additional significant hub crack

evidenced by grease leaking from the propeller hub. The hub was eddy

current inspected and verified that a crack of significant length was

present. The hub had been previously inspected using the eddy current

inspection process with no crack indications present. A significant

crack indication occurred in less time than the current 25 hour TIS

inspection interval. Based on this latest service difficulty report,

the FAA has determined that it is necessary to reduce the current 25

hour TIS inspection interval to 10 hours TIS for hubs installed on

certain aircraft and to mandate replacement of existing designed hubs

to the new hub configuration as soon as practical on these aircraft. A

total of 24 hub cracks have been found to date. At the present time,

over 2,500 propeller hubs have been distributed with the new post-1983

configuration propeller hub.

The FAA has reviewed and approved the technical contents of

Hartzell Propeller Inc. Service Bulletin (SB) No. 165E, dated January

21, 1994, that describes procedures for visual inspections, and ECI or

fluorescent penetrant inspection (FPI), for cracks in the area of the

grease fitting holes on the side of the propeller hub. In addition,

this SB describes an interim alternative method of compliance that

involves chamfering the inside and outside surfaces of the propeller

hub arm by the grease fitting holes. This modification allows the

propeller to operate for 400 hours TIS, or 36 months after the

effective date of this AD, whichever occurs first, before requiring,

for propellers installed on certain aircraft, hub replacement with a

new post-1983 configuration propeller hub. This modification was

created to provide relief to certain aircraft that would have

difficulty in complying with the stringent repetitive inspection

intervals and could not obtain propeller hub replacement in the near

term. This modification was approved by the FAA as an alternative

method of compliance to AD 93-16-14, and has been added to this

proposed AD as a interim compliance option. Operators that have

accomplished this modification in accordance with Hartzell Propeller

Inc. SB No. 165E will be given 400 hours TIS, or 36 calendar months

after the effective date of this AD, whichever occurs first, prior to

mandating hub replacement for propellers installed on certain aircraft.

For propellers installed on other aircraft, this modification extends

the repetitive inspection interval to 400 hours TIS.

Since an unsafe condition has been identified that is likely to

exist or develop on other propellers of this same type design, this AD

supersedes AD 93-16-14 to reduce the repetitive inspection interval

from 25 hours TIS to 10 hours TIS for propellers installed on certain

aircraft. The proposed AD would also require for these propellers a

mandatory terminating action by June 1995, or for those propellers that

have been modified by chamfering, at 400 hours TIS, or 36 calendar

months after the effective date of this AD, whichever occurs first, by

requiring replacement of the existing pre-1983 configuration hubs with

a new post-1983 hub configuration. For affected propellers installed on

other aircraft, the chamfering modification extends the repetitive

inspection interval to 400 hours TIS, and the replacement of hubs as a

terminating action is optional. In addition, the FAA has restricted the

special flight permit paragraph to only allow ferry flights to a point

where the inspections can be performed, but to disallow ferry flights

when a crack is known or suspected. The actions are required to be

accomplished in accordance with the service bulletin described

previously.

Since a situation exists that requires the immediate adoption of

this regulation, it is found that notice and opportunity for prior

public comment hereon are impracticable, and that good cause exists for

making this amendment effective in less than 30 days.

Comments Invited

Although this action is in the form of a final rule that involves

requirements affecting flight safety and, thus, was not preceded by

notice and an opportunity for public comment, comments are invited on

this rule. Interested persons are invited to comment on this rule by

submitting such written data, views, or arguments as they may desire.

Communications should identify the Rules Docket number and be submitted

in triplicate to the address specified under the caption ADDRESSES. All

communications received on or before the closing date for comments will

be considered, and this rule may be amended in light of the comments

received. Factual information that supports the commenter's ideas and

suggestions is extremely helpful in evaluating the effectiveness of the

AD action and determining whether additional rulemaking action would be

needed.

Comments are specifically invited on the overall regulatory,

economic, environmental, and energy aspects of the rule that might

suggest a need to modify the rule. All comments submitted will be

available, both before and after the closing date for comments, in the

Rules Docket for examination by interested persons. A report that

summarizes each FAA-public contact concerned with the substance of this

AD will be filed in the Rules Docket.

Commenters wishing the FAA to acknowledge receipt of their comments

submitted in response to this notice must submit a self-addressed,

stamped postcard on which the following statement is made: ``Comments

to Docket Number 94-ANE-19.'' The postcard will be date stamped and

returned to the commenter.

The regulations adopted herein will not have substantial direct

effects on the States, on the relationship between the national

government and the States, or on the distribution of power and

responsibilities among the various levels of government. Therefore, in

accordance with Executive Order 12612, it is determined that this final

rule does not have sufficient federalism implications to warrant the

preparation of a Federalism Assessment.

The FAA has determined that this regulation is an emergency

regulation that must be issued immediately to correct an unsafe

condition in aircraft, and is not a ``significant regulatory action''

under Executive Order 12866. It has been determined further that this

action involves an emergency regulation under DOT Regulatory Policies

and Procedures (44 FR 11034, February 26, 1979). If it is determined

that this emergency regulation otherwise would be significant under DOT

Regulatory Policies and Procedures, a final regulatory evaluation will

be prepared and placed in the Rules Docket. A copy of it, if filed, may

be obtained from the Rules Docket at the location provided under the

caption ADDRESSES.

List of Subjects in 14 CFR Part 39

Air transportation, Aircraft, Aviation safety, Incorporation by

reference, Safety.

Adoption of the Amendment

Accordingly, pursuant to the authority delegated to me by the

Administrator, the Federal Aviation Administration amends part 39 of

the Federal Aviation Regulations (14 CFR part 39) as follows:

PART 39--AIRWORTHINESS DIRECTIVES

1. The authority citation for part 39 continues to read as follows:

Authority: 49 U.S.C. App. 1354(a), 1421 and 1423; 49 U.S.C.

106(g); and 14 CFR 11.89.

Sec. 39.13 [Amended]

2. Section 39.13 is amended by removing Amendment 39-8704 (58 FR

67307, December 21, 1993), and by adding a new airworthiness directive,

Amendment 39-9008, to read as follows:

94-17-13 Hartzell Propeller Inc.: Docket No. 94-ANE-19. Supersedes

AD 93-16-14, Amendment 39-8704.

Applicability: Hartzell Propeller, Inc. HC-( )3Y( )-( )

series three-bladed propellers with model designations and serial

number ranges listed as follows:

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Propeller basic hub model Propeller serial No. range

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PHC-C3YF-1R()............................... EE1 through EE1461.

PHC-J3YF-1R()............................... FP1 through FP37.

PHC-L3YF-1R()............................... FD1 through FD7.

HC-C3YF-1R()................................ EC1 through EC1020.

HC-C3YK-1R() or HC-C3YR-1R()................ DY1 through DY1897.

HC-C3YK-1()................................. CT1 through CT101.

HC-C3YK-2() or HC-C3YR-2().................. CK1 through CK3510.

HC-C3YK-4() or HC-C3YR-4().................. EL1 through EL67.

HC-E3YK-1() or HC-E3YR-1().................. FM1 through FM487.

HC-E3YK-2() or HC-E3YR-2().................. DF1 through DF79.

HC-E3YK-2A() or HC-E3YR-2A()................ DJ1 through DJ7787.

HC-F3YK-2() or HC-F3YR-2().................. DA1 through DA1586.

HC-F3YK-1() or HC-F3YR-1().................. DB1 through DB137.

HC-I3YK-2() or HC-I3YR-2().................. FS1 through FS32.

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This airworthiness directive (AD) applies to the above affected

propellers when installed on any agricultural aircraft with any

engine, or installed on any aircraft utilizing Textron Lycoming TIO-

540 or LTIO-540 series reciprocating engines, or IO-540 series

reciprocating engines that have a turbocharger added by the airframe

manufacturer or have been modified by a Supplemental Type

Certificate (STC) to incorporate a turbocharger, or a turbocharger

retrofitted to an IO-540 engine by any other means. The known

affected propellers are generally installed on, but not limited to,

the following aircraft:

Agricultural Aircraft

Fletcher FU24-950

Cessna A188 Agwagon modified by STC SA895SO

Piper PA-36-285 and PA-36-300 (three-bladed propellers only)

Piper PA-36-375

Piper PA-36 Pawnee modified by STC SA3952WE

Transavia Airtruk Models and PL-12/T-300 Skyfarmer

Aircraft With Textron Lycoming TIO-540, LTIO-540, and Turbocharged IO-

540 Series Engines

Cessna 310 and 320 modified by Riley STC SA2082WE

Gulfstream 700 (formerly Rockwell 700, Fuji FA-300-12)

Helio H-700

Piper PA-23-250 and PA-E23-250 (with TIO-540 only)

Piper PA-31 Navajo (with TIO-540 only)

Piper PA-31-325 Navajo C/R

Piper PA-31-350 Navajo ``Chieftain''

Piper PA-31P-350 Mohave

Piper T-1020 (same as PA-31-350)

Piper PA-32(R)-301T Turbo Saratoga

Aerostar PA-60-600, PA-60-601, PA-60-601P, PA-60-602P, and PA-60-

700P.

Propellers with model designations and serial number ranges

listed above and installed on non-agricultural aircraft, which do

not utilize Textron Lycoming TIO-540, LTIO-540, or turbocharged IO-

540 series engines are exempt from this AD.

Propellers with new post-1983 hub configurations, i.e., which

have the relocated grease fitting holes near the hub parting line as

shown in Figure 1, page 9, of Hartzell Propeller, Inc., Service

Bulletin (SB) No. 165E, dated January 21, 1994, even though the

propeller model and serial number are listed above, are exempt from

this AD.

Compliance: Required as indicated, unless accomplished

previously.

To prevent possible propeller hub failure due to cracks that

originate in the grease fitting holes on the side of the hub, which

could result in propeller blade separation and loss of the aircraft,

accomplish the following:

(a) For propellers installed on Textron Lycoming TIO-540 or

LTIO-540 series reciprocating engines or turbocharged IO-540 series

reciprocating engines which are installed on Piper PA-31-325 Navajo

C/R, PA-31-350 Navajo ``Chieftain,'' T-1020 (same as PA-31-350), PA-

60-700P, Aerostar 700P aircraft, or propellers installed on any

agricultural aircraft with any engine, accomplish the following:

(1) Within 10 hours time in service (TIS) after the effective

date of this AD, but not to exceed 25 hours TIS since the last

inspection, whichever occurs first, and thereafter at intervals of

10 hours TIS, perform a visual inspection for presence of grease on

the propeller and determine the source of this grease leakage prior

to further flight. Following the visual inspection, perform an eddy

current inspection (ECI) or fluorescent penetrant inspection (FPI)

for cracks in accordance with Hartzell Propeller, Inc. SB No. 165E,

dated January 21, 1994.

Note: Use of a black light to inspect the suspect area can aid

in determining the source of grease leakage because authorized

grease contains fluorescent properties.

(i) If grease is leaking from the hub arm or wall, replace the

propeller with a serviceable propeller prior to further flight.

(ii) If grease is determined to be leaking from other causes,

take the appropriate corrective maintenance action and record in

appropriate maintenance records.

(2) If a crack is found in a propeller hub during the

inspections required in paragraph (a)(1) of this AD, replace the

propeller hub prior to further flight with a new post-1983

configuration propeller hub, or with a serviceable 1983 or earlier

hub that has been inspected in accordance with Hartzell Propeller

Inc. SB No. 165E, dated January 21, 1994. Thereafter, perform a

visual inspection, and ECI or FPI, for cracks in accordance with

Hartzell Propeller Inc. SB No. 165E, dated January 21, 1994, at

intervals not to exceed 10 hours TIS since the last inspection,

unless a new post-1983 later style propeller hub is installed, per

paragraph (d) of this AD.

(b) For propellers installed on all other aircraft models,

except for the four non-agricultural models listed in paragraph (a)

of this AD, and that utilize Textron Lycoming TIO-540, LTIO-540, or

turbocharged IO-540 series reciprocating engines accomplish the

following:

(1) Within 50 hours TIS after the effective date of this AD, but

not to exceed 50 hours TIS since the last inspection, and thereafter

at intervals of 50 hours TIS, perform a visual inspection for

presence of grease on the propeller and determine the source of this

grease leakage prior to further flight. Following the visual

inspection, perform an ECI or FPI for cracks in accordance with

Hartzell Propeller Inc. SB No. 165E, dated January 21, 1994.

Note: Use of a black light to inspect the suspect area can aid

in determining the source of grease leakage because authorized

grease contains fluorescent properties.

(i) If grease is leaking from the hub arm or wall, replace the

propeller with a serviceable propeller prior to further flight.

(ii) If grease is determined to be leaking from other causes,

take the appropriate corrective maintenance action and record in

appropriate maintenance records.

(2) If a crack is found in a propeller hub during the

inspections required in paragraph (b)(1) of this AD, replace the hub

prior to further flight with a new post-1983 configuration propeller

hub, or with a serviceable 1983 or earlier hub that has been

inspected in accordance with Hartzell Propeller Inc. SB No. 165E,

dated January 21, 1994. Thereafter, perform a visual inspection, and

ECI or FPI, at intervals not to exceed 50 hours TIS since the last

inspection, in accordance with paragraph (b)(1) of this AD, unless a

new post-1983 configuration propeller hub is installed, per

paragraph (d) of this AD.

(c) An alternative method of compliance in Hartzell Propeller

Inc. SB No. 165E, dated January 21, 1994, describes a propeller hub

modification to chamfer the inside and outside hub arm surfaces of

the grease hole fitting. Performing this interim modification allows

an operator to extend the initial and repetitive inspection period

as required by paragraphs (a)(1) or (b)(1) of this AD, as

applicable, to 400 hours TIS.

(1) For propellers installed on aircraft listed in paragraph (a)

of this AD, once 400 hours TIS is reached, or 36 calendar months

after the effective date of this AD, whichever occurs first, the

propeller hub must be replaced in accordance with paragraph (d) of

this AD.

(2) For propellers installed on aircraft listed in paragraph (b)

of this AD, once 400 hours TIS is reached, or 36 calendar months

after the effective date of this AD, whichever occurs first, an

internal inspection is required at intervals not to exceed 400 hours

TIS since last inspection in accordance with Hartzell Propeller Inc.

SB No. 165E, dated January 21, 1994, or replacement of the hubs must

be determined in accordance with paragraph (d) of this AD.

(d) For propellers installed on aircraft listed in paragraph (a)

of this AD, install new post-1983 configuration propeller hubs that

have fitting holes near the hub parting line prior to June 30, 1995,

or in accordance with the time extension provided in paragraph (c)

of this AD. For propellers installed in aircraft listed in paragraph

(b) of this AD, this replacement is optional. For all affected

propellers, this replacement constitutes terminating action to the

inspection requirements of this AD.

(e) Propeller hubs that are configured 1983 or earlier, with the

grease fitting holes located on the side of the hub, that have been

removed from service cannot ever be approved for return to service.

(f) An alternative method of compliance or adjustment of the

compliance time that provides an acceptable level of safety may be

used if approved by the Manager, Chicago Aircraft Certification

Office. The request should be forwarded through an appropriate FAA

Maintenance Inspector, who may add comments and then send it to the

Manager, Chicago Aircraft Certification Office.

Note: Information concerning the existence of approved

alternative methods of compliance with this airworthiness directive,

if any, may be obtained from the Chicago Aircraft Certification

Office.

(g) Special flight permits may be issued in accordance with

sections 21.197 and 21.199 of the Federal Aviation Regulations (14

CFR 21.197 and 21.199) to operate the aircraft to a location where

the inspections may be performed.

(h) The inspections and modification shall be done in accordance

with the following service document:

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Document No. Pages Date

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Hartzell Propeller Inc., SB No. 165E..... 1-10 Jan. 21, 1994.

Total pages: 10

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This incorporation by reference was approved by the Director of the

Federal Register in accordance with 5 U.S.C. 552(a) and 1 CFR part

51. Copies may be obtained from Hartzell Propeller Inc., One

Propeller Place, Piqua, OH 45356-2834; telephone (513) 778-4200, fax

(513) 778-4391. Copies may be inspected at the FAA, New England

Region, Office of the Assistant Chief Counsel, 12 New England

Executive Park, Burlington, MA; or at the Office of the Federal

Register, 800 North Capitol Street, NW., suite 700, Washington, DC.

(i) This amendment becomes effective on September 15, 1994.

Issued in Burlington, Massachusetts, on August 15, 1994.

Jay J. Pardee,

Manager, Engine and Propeller Directorate, Aircraft Certification

Service.

[FR Doc. 94-20595 Filed 8-30-94; 8:45 am]

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