Hartzell Propeller Inc

HARTZELL PROPELLER INC.
One Propeller Place

Piqua, Ohio 45356-2634 U.S.A.
Telephone: 937.778.4200
Fax: 937.778.4215
MANUAL REVISION TRANSMITTAL
MANUAL 202A, VOLUME 3 (61-01-02)
Standard Practices Manual
REVISION 37 dated March 2016
Attached is a copy of Revision 37 to Hartzell Manual 202A, Volume 3

Page Control Chart for Revision 37
Remove Insert
Chapter/Page No. Chapter/Page No.
COVER COVER
cover and page 2 cover and page 2
REVISION HIGHLIGHTS REVISION HIGHLIGHTS
pages 1 thru 4 pages 1 thru 4
LIST OF EFFECTIVE PAGES LIST OF EFFECTIVE PAGES
pages 1 thru 4 pages 1 thru 4
ALUMINUM HUB OVERHAUL ALUMINUM HUB OVERHAUL
pages 1-3 thru 3-6 pages 1-3 thru 1-6
pages 1-112.1 thru 1-112.4, insert after page 1-112
pages 1-113 and 1-114 pages 1-113 and 1-114
pages 1-390.3 and 1-390.4, insert after page 1-390.2
pages 1-399 and 1-400 pages 1-399 thru 1-404
NOTE 1: When the manual revision has been inserted in the manual, record the information required
on the Record of Revisions page in this manual.
NOTE 2: Pages distributed in this revision may include pages from previous revisions if they are on
the opposite side of revised pages. This is done as a convenience to those users who
wish to print a two-sided copy of the new revision.
This page may be discarded after proper filing of the revision.

(This page is intentionally blank.)
Manual No. 202A, Volume 3
61-01-02
Revision 37
March 2016

Volume 3
Aluminum Hub Overhaul

Hartzell Propeller Inc.

One Propeller Place
Piqua, Ohio 45356-2634 U.S.A.
Phone: 937.778.4200
Fax: 937.778.4215
STANDARD PRACTICES MANUAL 202A
VOLUME 3
© 2004, 2005, 2007, 2008, 2010, 2014, 2015, 2016 - Hartzell Propeller Inc. - All rights reserved
COVER 61-01-02 Vol. 3, Page 2

Rev. 37 Mar/16
VOLUME 3
202A, VOLUME 3 - REVISION 37 HIGHLIGHTS

• Revised the Cover, Revision Highlights, and List of Effective Pages to match the
manual revision
• ALUMINUM HUB OVERHAUL
• 5. Check
• Table 1-1, "Inspection and Repair Requirements"
• Section 16.1, "5-Blade Lightweight Turbine Pitch Change Rod
Bore - Engine-side, That Has the Bushing Removed", added the section
• Added Figure 1-28.1, "Five Blade Lightweight Turbine with Engine-side
Pitch Change Rod Bushing Removed"
• Section 30, "B-5952-( ) Pitch Change Rod Bushing (Cylinder-Side
Hub Half)", revised the section
• Revised Figure 1-35, "B-5952 Pitch Change Rod Bushing Areas
of Inspection"
• Section 31, "B-6108-( ) Pitch Change Rod Bushing (Engine-Side
Hub Half)" revised the section
• Revised Figure 1-36, "B-6108 Pitch Change Rod Bushing Areas
of Inspection"
• 6. Repair
• E. "Repair of Stripped Cylinder Attachment Screw Holes", revised.the section
• F. "Repair of Anti-Rotation Rod Threaded Holes", revised the section
• 11. Masking for Painting, Shot Peening, and Anodizing
• Added Figures 1-100.1 thru 1-100.7, "105880 Lightweight Turbine
Aluminum Hub Shot Peen, Paint, and Anodize Masking"
• Added Table 1-11.1, "105880 Lightweight Turbine Aluminum Hub
Shot Peen, Paint, and Anodize Masking"
• 12. Assembly
• O. "Installation of the Pitch Change Rod Hub Bushing in Five-blade
Lightweight Turbine Series Hubs", added the section
• Added Figure 1-108.2, "Installing the Pitch Change Rod Hub
Bushing 104903"
• 14. Leak Inspection of Bushings in Four-blade Lightweight Turbine Series Hubs
and Five-blade Raptor Turbine Hubs
• C. "Leak Inspection for the Cylinder-side Hub Half", revised the section
• 15. Leak Inspection of the Bushing in the Engine-side Half of the Hub for
Five-blade Lightweight Turbine Series Hubs
• Added the section
• Added Figure 1-111, "Locally Manufactured Pin"
• Added Figure 1-112, "Checking the Plastic Bushing of a Five-Blade
Lightweight Turbine for Leaks"
• Made other minor language/format changes
REVISION HIGHLIGHTS 61-01-02 Vol. 3, Page 1

Rev. 37 Mar/16
VOLUME 3

Rev. 37 Mar/16
VOLUME 3
REVISION HIGHLIGHTS
1. Introduction
A. General
(1) This is a list of current revisions that have been issued against this manual.
Please compare to the RECORD OF REVISIONS page to make sure that all
revisions have been added to the manual.
B. Components
(1) Revision No. indicates the revisions incorporated in this manual.
(2) Issue Date is the date of revision.
(3) Comments indicates the level of the revision.
(a) New Issue is a new manual distribution. The manual is distributed in its
entirety. All the revision dates are the same and no change bars are used.
(b) Reissue is a revision to an existing manual that includes major content
and/or major format changes. The manual is distributed in its entirety. All
the revision dates are the same and no change bars are used.
(c) Major Revision is a revision to an existing manual that includes major
content or minor format changes over a large portion of the manual. The
manual is distributed in its entirety. All the revision dates are the same, but
change bars are used to indicate the changes incorporated in the latest
revision of the manual.
(d) Minor Revision is a revision to an existing manual that includes minor
content changes to the manual. Only the revised pages of the manual are
distributed. Each page retains the date and the change bars associated
with the last revision to that page.

Rev. 37 Mar/16
VOLUME 3
Revision No. Issue Date Comments
Original Mar/93 New

Revision 1 Jun/94 Minor Revision
Revision 2 Apr/95 Minor Revision
Revision 5 Nov/96 Minor Revision
Revision 6 Mar/97 Minor Revision
Revision 7 Oct/97 Minor Revision
Revision 8 Jan/98 Minor Revision
Revision 10 Dec/98 Minor Revision
Revision 11 Sep/99 Minor Revision
Revision 14 Feb/02 Minor Revision
Revision 15 May/02 Minor Revision
Revision 18 Aug/03 Minor Revision
Revision 23 Feb/04 Minor Revision
Revision 27 Oct/04 Major Revision - Volume 3
Revision 28 Jan/05 Minor Revision
Revision 35 Jul/15 Major Revision

Rev. 37 Mar/16
VOLUME 3
LIST OF EFFECTIVE PAGES
Chapter Volume Page Rev. Level Date
Cover/Cover back 3 Cover/Cover back Rev. 37 Mar/16

Revision Highlights 3 1 thru 4 Rev. 37 Mar/16
Record of Revisions 3 1 and 2 Rev. 35 Jul/15
Record of Temporary Revisions 3 1 and 2 Rev. 35 Jul/15
Service Document List 3 1 and 2 Rev. 36 Dec/15
List of Effective Pages 3 1 thru 4 Rev. 37 Mar/16
Table of Contents 3 1 and 2 Rev. 35 Jul/15
Introduction 3 1 and 2 Rev. 35 Jul/15
Introduction 3 3 Rev. 36 Dec/15
Introduction 3 4 Rev. 35 Jul/15
Introduction 3 5 and 6 Rev. 36 Dec/15
Introduction 3 7 thru 14 Rev. 35 Jul/15
Aluminum Hub Overhaul 3 1-1 and 1-2 Rev. 36 Dec/15
Aluminum Hub Overhaul 3 1-3 and 1-4 Rev. 37 Mar/16
Aluminum Hub Overhaul 3 1-5 Rev. 35 Jul/15
Aluminum Hub Overhaul 3 1-6 Rev. 37 Mar/16
Aluminum Hub Overhaul 3 1-9 thru 1-11 Rev. 37 Mar/16
Aluminum Hub Overhaul 3 1-13 thru 1-18 Rev. 36 Dec/15
Aluminum Hub Overhaul 3 1-20 Rev. 36 Dec/15
Aluminum Hub Overhaul 3 1-24 thru 1-28 Rev. 35 Jul/15
Aluminum Hub Overhaul 3 1-28.1 and 1-28.2 Rev. 36 Dec/15
Aluminum Hub Overhaul 3 1-112.1 thru 1-112.4 Rev. 37 Mar/16
LIST OF EFFECTIVE PAGES 61-01-02 Vol. 3, Page 1

Rev. 37 Mar/16
VOLUME 3
Aluminum Hub Overhaul 3 1-114 and 1-115 Rev. 35 Jul/15

Aluminum Hub Overhaul 3 1-116.1 thru 1-116.4 Rev. 36 Dec/15
Aluminum Hub Overhaul 3 1-217 and 1-218 Rev. 37 Mar/16


Rev. 37 Mar/16
VOLUME 3

Aluminum Hub Overhaul 3 1-292.1 thru 1-292.4 Rev. 36 Dec/15
Aluminum Hub Overhaul 3 1-390.3 and 1-390.4 Rev. 37 Mar/16

Rev. 37 Mar/16
VOLUME 3

Rev. 37 Mar/16
VOLUME 3
ALUMINUM HUB OVERHAUL - CONTENTS

11. Masking for Painting, Shot Peening, and Anodizing, continued
F. Masking of the D-5108-5 Aluminum Hub........................................Vol. 3, 1-301
G. Masking of the E-6468 Aluminum Hub............................................Vol. 3, 1-301
H. Masking of the E-6826 and E-393-( )Aluminum Hubs.....................Vol. 3, 1-301
I. Masking of the E-6771 Aluminum Hubs..........................................Vol. 3, 1-301
J. Masking of the E-7369 Aluminum Hubs..........................................Vol. 3, 1-302
K. Hub Shot Peening Guidelines.........................................................Vol. 3, 1-302
12. Assembly..............................................................................................Vol. 3, 1-343
A. Hub Substitutions............................................................................Vol. 3, 1-343
B. Installation of Hub Extension Bolts..................................................Vol. 3, 1-345
C. Installation of Hub Mounting Flange Dowel Pins.............................Vol. 3, 1-347
D. Installation of Studs in D-Flange, F-Flange, N-Flange,
and W-Flange Hubs........................................................................Vol. 3, 1-349
E. Installation of Studs in K-flange, L-flange,
and R-flange Propellers..................................................................Vol. 3, 1-351
F. Mounting Bolt Ring Installation........................................................Vol. 3, 1-352
G. Installation of the Pitch Change Rod Hub Bushings
in Four-blade Lightweight Turbine Series Hubs and
Five-blade Raptor Turbine Hubs.....................................................Vol. 3, 1-355
H. Installation of the Pitch Change Rod Hub Bushings
for Compact and Lightweight Compact Hubs..................................Vol. 3, 1-360
I. Installation of an A-2249 Guide Bushing.........................................Vol. 3, 1-383
J. Installing a B-1243-( ) Threaded Staked Insert
in the Mounting Flange....................................................................Vol. 3, 1-385
K. Installing a Non-staked Insert in the W-flange Mounting Flange.....Vol. 3, 1-388
L. Installing the Beta Rod Bushing B-6045-6-6
for Propeller Models HC-E5N-3( )( ) and HC-A6A-3( ).......................Vol. 3, 1-389
M. Helicoil® Insert Installation............................................................Vol. 3, 1-390.1
N. Installation of Hub Sleeve 104488 in the F-flange Hub
Mounting Bore...............................................................................Vol. 3,1-390.3
O. Installation of the Pitch Change Rod Hub Bushing in
Five-blade Lightweight Turbine Series Hubs....................................Vol. 3,1-391
13. Leak Inspection of a Compact Hub That Uses a Bushing
in the Pitch Change Rod Bore..............................................................Vol. 3, 1-393
A. General...........................................................................................Vol. 3, 1-393
B. Leak Inspection of the Cylinder-side Hub Half................................Vol. 3, 1-393
C Leak Inspection of the Engine-side Hub Half..................................Vol. 3, 1-395
ALUMINUM HUB OVERHAUL 61-01-02 Vol. 3, Page 1-3

Rev. 37 Mar/16
VOLUME 3
ALUMINUM HUB OVERHAUL - CONTENTS

14. Leak Inspection of Bushings in Four-blade Lightweight
Turbine Series Hubs and Five-blade Raptor Turbine Hubs..................Vol. 3, 1-397
A. General...........................................................................................Vol. 3, 1-397
B. Leak Inspection for the Engine-side Hub Half.................................Vol. 3, 1-398
C. Leak Inspection for the Cylinder-side Hub Half...............................Vol. 3, 1-399
15. Leak Inspection of the Bushing in the Engine-side Half of the Hub
for Five-blade Lightweight Turbine Series Hubs...................................Vol. 3, 1-401
A. General...........................................................................................Vol. 3, 1-401
B. Leak Inspection for the Engine-side Hub Half ................................Vol. 3, 1-403

Rev. 37 Mar/16
VOLUME 3
LIST OF FIGURES
Sample Aluminum Hub Overhaul "Traveler".............................Figure 1-1..............Vol. 3, 1-12
Procedure for Removing a Threaded Staked Insert.................Figure 1-2..............Vol. 3, 1-26
HeliCoil® Extracting Tool...........................................................Figure 1-3..............Vol. 3, 1-28
Replication Material Placement on a Defect ...........................Figure 1-4..............Vol. 3, 1-31
Measuring the Depth of Damage from a Cross Section
of Replication Material .......................................................Figure 1-5..............Vol. 3, 1-31
Typical Propeller Flange Fretting..............................................Figure 1-6..............Vol. 3, 1-34
Location of Inspection Areas ...................................................Figure 1-7..............Vol. 3, 1-38
Detail A ....................................................................................Figure 1-8..............Vol. 3, 1-42
Sidewall of the Blade O-ring Groove........................................Figure 1-9..............Vol. 3, 1-54
Hub Lubrication Fitting Hole Locations,
Original Design "Y" Shank Hub ..........................................Figure 1-10............Vol. 3, 1-56
Hub Lubrication Fitting Hole Locations,
Improved Design "Y" Shank Hub .......................................Figure 1-11............Vol. 3, 1-56
Hydraulic Unit/Cylinder Mounting Area ....................................Figure 1-12............Vol. 3, 1-62
Hydraulic Unit/Cylinder Mounting Threads ..............................Figure 1-13............Vol. 3, 1-64
Compact and Lightweight Compact Hub with
Cylinder-side Pitch Change Rod Bushing Removed,
Configuration S, Configuration V, Configuration W,
and Configuration X Hub Bores..........................................Figure 1-14............Vol. 3, 1-66
Compact Hub Cylinder-side Pitch Change O-ring Groove,
Configuration Z Hub Bores ................................................Figure 1-15............Vol. 3, 1-70
Compact Hub Cylinder-side Pitch Change O-ring Groove,
Configuration Y, Configuration U,
and Configuration T Hub Bores ..........................................Figure 1-16............Vol. 3, 1-72
Configuration Z with Cylinder-side Pitch Change
Rod Repair Bushing Removed...........................................Figure 1-17............Vol. 3, 1-76
Configuration Y with Cylinder-side Pitch Change
Rod Repair Bushing Removed...........................................Figure 1-18............Vol. 3, 1-78
Configuration U and Configuration T with Cylinder-side
Pitch Change Rod Repair Bushing Removed.....................Figure 1-19............Vol. 3, 1-80
Compact and Lightweight Compact Hub with
Factory Installed Engine-side Pitch Change
Rod Bushing Removed, Configuration C,
Configuration E, Configuration F,
and Configuration I Hub Bores............................................Figure 1-20............Vol. 3, 1-84

Rev. 35 Jul/15
VOLUME 3
LIST OF FIGURES, CONTINUED

Engine-side Pitch Change O-ring Seal Groove,
Configuration A, Configuration B, Configuration G,
and Configuration H Hub Bores..........................................Figure 1-21............Vol. 3, 1-88
Engine-side Pitch Change O-ring Seal Groove,
Configuration J Hub Bores..................................................Figure 1-22............Vol. 3, 1-92
Configuration D Engine-side Bore
Dimensional Inspection Criteria..........................................Figure 1-23............Vol. 3, 1-94
Configuration A Hub with Engine-side Pitch Change Rod
Repair Bushing Removed...................................................Figure 1-24............Vol. 3, 1-98
Configuration B Hub with Engine-side Pitch Change Rod
Repair Bushing Removed...................................................Figure 1-25..........Vol. 3, 1-100
Configuration G and Configuration H Hubs with E
ngine-side Pitch Change Rod Repair Bushing Removed...Figure 1-26..........Vol. 3, 1-102
4-Blade Lightweight Turbine or 5-blade Raptor Turbine with
Cylinder-side Pitch Change Rod Bushing Removed..........Figure 1-27..........Vol. 3, 1-106
4-Blade Lightweight Turbine or 5-blade Raptor Turbine with
Engine-side Pitch Change Rod Bushing Removed............Figure 1-28.......... Vol. 3, 1-110
Five Blade Lightweight Turbine with Engine-side
Pitch Change Rod Bushing Removed................................Figure 1-28.1.... Vol. 3, 1-112.2
Location of Inspection Areas ...................................................Figure 1-29.......... Vol. 3, 1-114
Engine Side Hub Bore Inspection............................................Figure 1-29.1.... Vol. 3, 1-116.2
104488 Sleeve Inspection........................................................Figure 1-29.2.... Vol. 3, 1-116.4
F-flange Mounting Bore Inspection Area..................................Figure 1-30.......... Vol. 3, 1-118
"K" Flange.................................................................................Figure 1-31..........Vol. 3, 1-122
"R" Flange................................................................................Figure 1-32..........Vol. 3, 1-126
"L" Flange.................................................................................Figure 1-33..........Vol. 3, 1-130
Flange Dowel Pin Hole Inspection...........................................Figure 1-34..........Vol. 3, 1-138
B-5952 Pitch Change Rod Bushing Areas of Inspection .........Figure 1-35..........Vol. 3, 1-142
B-6108 Pitch Change Rod Bushing Areas of Inspection .........Figure 1-36.......Vol. 3, 1-142.4
102778 Pitch Change Rod Bushing Areas of Inspection .........Figure 1-37..........Vol. 3, 1-146
102779 Pitch Change Rod Bushing Areas of Inspection .........Figure 1-38..........Vol. 3, 1-148
102580-2 Pitch Change Rod Bushing Areas of Inspection .....Figure 1-39..........Vol. 3, 1-150
102580-1 Pitch Change Rod Bushing Areas of Inspection .....Figure 1-40..........Vol. 3, 1-152
Configuration D Hub Engine-side Bore Bushing 103433
Dimensional Inspection Criteria..........................................Figure 1-41..........Vol. 3, 1-154

Rev. 37 Mar/16
VOLUME 3
Shot Peening of D-1066 Six Blade Lightweight Turbine

Aluminum Hub....................................................................Figure 1-87..........Vol. 3, 1-318
Almen Strip Locations for a 6 Blade Lightweight Turbine
Aluminum Hub, D-1066 Only .............................................Figure 1-88..........Vol. 3, 1-319
D-5108-5 Lightweight Turbine Aluminum Hub Shot Peen,
Paint, and Anodize Masking ...............................................Figure 1-89..........Vol. 3, 1-320
E-6468 Lightweight Turbine Aluminum Hub Shot Peen,
E-6826 and E-393-( ) Lightweight Turbine Aluminum Hubs
Shot Peen, Paint, and Anodize Masking ............................Figure 1-94..........Vol. 3, 1-329
E-6771 and 103559 Lightweight Turbine Aluminum Hubs
Shot Peen, Paint, and Anodize Masking ............................Figure 1-97.1....Vol. 3, 1-334.1
Paint, and Anodize Masking................................................Figure 1-98..........Vol. 3, 1-337
Paint, and Anodize Masking................................................Figure 1-99..........Vol. 3, 1-338
Paint, and Anodize Masking ...............................................Figure 1-100........Vol. 3, 1-339
105880 Lightweight Turbine Aluminum Hub Shot Peen,
Paint, and Anodize Masking ...............................................Figure 1-100.1..Vol. 3, 1-340.2

Rev. 37 Mar/16
VOLUME 3

“K” and “R” Propeller Flange Identification...............................Figure 1-101........Vol. 3, 1-342
“N” and “P” Propeller Flange Identification...............................Figure 1-102 .......Vol. 3, 1-342
Pitch Change Rod Bushing Components ................................Figure 1-103........Vol. 3, 1-354
Configuration D Engine-Side Pitch Change Rod
Bore Procedure 3................................................................Figure 1-104........Vol. 3, 1-371
Configuration D Engine-Side Pitch Change Rod
Bore Components...............................................................Figure 1-105........Vol. 3, 1-372
Bushing Orientation in the Hub................................................Figure 1-106........Vol. 3, 1-373
Bushing Installation Tool...........................................................Figure 1-107........Vol. 3, 1-388
Helicoil® Insert Installation.........................................................Figure 1-108.....Vol. 3, 1-390.1
Sleeve 104488 Fit Placement..................................................Figure 1-108.1.. Vol. 3, 1-390.2
Installing the Pitch Change Rod Hub Bushing 104903.............. Figure 1-108.2.. Vol. 3, 1-390.4
Leak Inspection of the Compact Hub
Pitch Change Rod Bore......................................................Figure 1-109........Vol. 3, 1-392
Checking the Plastic Bushings for Leaks.................................Figure 1-110........Vol. 3, 1-396
Locally Manufactured Pin.........................................................Figure 1-111........Vol. 3, 1-400
Checking the Plastic Bushing of a
Five-Blade Lightweight Turbine for Leaks...........................Figure 1-112........Vol. 3, 1-402

Rev. 37 Mar/16
VOLUME 3
LIST OF TABLES
Inspection and Repair Requirements.......................................Table 1-1................Vol. 3, 1-39

Slimsert Specifications ............................................................Table 1-2..............Vol. 3, 1-208
Compact or Lightweight Compact Pitch Change Rod Bore
Repair, Overhaul, and Bushing Installation.........................Table 1-3..............Vol. 3, 1-237
Internal Spiral Retaining Ring Groove Dimensions..................Table 1-4..............Vol. 3, 1-239
Four-blade Lightweight Turbine Hubs That
May Require Modification ..................................................Table 1-5..............Vol. 3, 1-266
Pitch Change Bushing Components for Four-blade
Lightweight Turbine Hubs...................................................Table 1-6..............Vol. 3, 1-268
Paint, and Anodize Masking................................................Table 1-7..............Vol. 3, 1-323
Paint, and Anodize Masking................................................Table 1-8..............Vol. 3, 1-327
Shot Peen, Paint, and Anodize Masking.............................Table 1-9..............Vol. 3, 1-331
Shot Peen, Paint, and Anodize Masking ............................Table 1-10.........Vol. 3, 1-334.2
Paint, and Anodize Masking................................................Table 1-11............Vol. 3, 1-340
Paint, and Anodize Masking ...............................................Table 1-11.1......Vol. 3, 1-340.9
D-Flange, F-Flange, N-Flange, W-Flange Hub Stud
Usage and Installation Heights ..........................................Table 1-12............Vol. 3, 1-348
Pitch Change Rod Bushing Components
for Four-blade Lightweight Turbine Hubs
and Five-blade Raptor Turbine Hubs .................................Table 1-13............Vol. 3, 1-355
Hubs That are Not Approved for Installation of an Oversize
Threaded Staked Insert in the Mounting Flange...................Table 1-14............Vol. 3, 1-384

Rev. 37 Mar/16
VOLUME 3
Hartzell Aluminum Hub Overhaul Traveler
Customer Customer PO #
Date Work Order #
Description TSO
Manufacturer TSN
Prop Part #
Prop Serial # Revision TR's
All work will be performed in accordance with Hartzell 202A, Vol. 1
Manuals: 202A, Vol. 2
202A, Vol. 3
NOTE: (1) Stripping of anodize/chemical conversion coatings and all
202A, Vol. 6
rework procedures must be performed before the etch process. (2) The
etch process must be performed before penetrant inspection. (3) Strip 202A, Vol. 9
and etch must be performed as separate processes. 202A, Vol. 10
Crew
Description Reference
CU
Technician Date
Chief / QC
A V R
1 AIL REN
Remove and discard mounting hub components RE 202A, Volume 3
AB T F E
LE REV RE
2 Dimensionally inspect delrin bushing 202A, Volume 3
W E
SIT N T ISIO NCE202A, Volume 1
3 Mark bushing location and removeBbushings O or discard bushing 202A, Volume 3
4 Clean the hub
E A HE N O ON
5 Remove paint T W HA F T LY 1
202A, Volume
6 WW RTZ 202A, HISVolume --2
Eddy Current inspect the hub as specified
. H E L T R
7 Inspect threaded holes AR L P A
202A, Volume 3
V
8 Inspect the hub for damage T ZE
202A,
L
R OP3 ELER
Volume
Volume 10EL
202A, L
9 Strip chemical conversion coating PR
202A, VolumeO
LE IS
10 Repair - chamfer lubrication fitting holes 3P
.CO R INC
11 Repair - damaged areas 202A, Volume 3
M .
12 Inspect - Shot Peen coverage and location 202A, Volume 3
13 Drill, tap, and rework for slimserts / helicoils 202A, Volume 3
14 Inspect - Pitch change rod bores and repaired threaded holes 202A, Volume 3
Repair oversize pitch change rod bores, front/rear
15 202A, Volume 3
o-ring groove bore
16 Etch hub 202A, Volume 2
Dry Hub: Chose one option:
1) 150 degrees for 30 minutes.
17 Start time:____________ End time: ____________ 202A, Volume 2
2) Air dry for 24 hours.
Start time:____________ End time: ____________
18 Penetrant Inspect 202A, Volume 2
19 Shot peen the hub 202A, Volume 9
20 Inspect Shot Peen coverage and location. 202A, Volume 9
21 Restamp propeller identification 202A, Volume 6
22 Apply chemical conversion coating 202A, Volume 10
23 Inspect chemical conversion coating 202A, Volume 10
24 Install slimserts, helicoils and bushings 202A, Volume 3
25 Perform leak test 202A, Volume 3
26 Mask and Paint 202A, Volume 3
Notes:
NOTE: This document was created using all available resources. However, there is a possibility that the information may not be complete. The applicable
overhaul manuals and all service documents must be referenced to ensure compliance with all required tasks. Failure to perform the required inspections
and procedures may result in death, serious bodily injury, and/or substantial property damage.
Trav-1-R001
Original, Oct/07, Rev. 1 dated Jun 30/08
Sample Aluminum Hub Overhaul "Traveler"

Figure 1-1

Rev. 35 Jul/15
VOLUME 3
Inspect Serviceable Limits Corrective Action

16. 4-Blade Lightweight Turbine and 5-blade Raptor Turbine Pitch Change Rod Bore- Engine-side,
That Has the Bushing Removed, continued
Refer to Figure 1-28.
D. Visually examine the Minor scratches and abrasions Repair is permitted to a

areas identified as "All are permitted. Other damage maximum depth of
Other Surfaces" for that has sharp edges, causes 0.010 inch (0.25 mm). The
damage. material to be pushed up, maximum permitted area
interferes with the insertion of repair is 20% of each
of the bushing or O-ring, or surface. If the damage or the
of the fit of the bushing is not required repair is greater than
permitted. the serviceable limits or the
corrective action limits, replace
the hub in accordance with the
Part Retirement Procedures
chapter of Hartzell Propeller Inc.
202A (61-01-02), Volume 6.
Inspection and Repair Requirements

Table 1-1
ALUMINUM HUB OVERHAUL 61-01-02 Vol. 3, Page 1-112.1

Rev. 37 Mar/16
VOLUME 3
0.100 Inch (2.54 mm)

Shoulder Thickness "F"
Area "G"
0.220 Inch (5.59 mm)
ID "E"
All Other Surfaces
All Other Surfaces
Hub Configuration 1
TPI-202-3-031
Five Blade Lightweight Turbine

with Engine-side Pitch Change Rod Bushing Removed
Figure 1-28.1, Page 1 of 2

Rev. 37 Mar/16
VOLUME 3
Hub
0.100 Inch (2.54 mm)

Shoulder Thickness "F"
Area "G" 0.220 Inch (5.59 mm)
ID "E"
All Other Surfaces
All Other Surfaces
Hub Configuration 2
TPI-202-3-045
Five Blade Lightweight Turbine

with Engine-side Pitch Change Rod Bushing Removed
Figure 1-28.1, Page 2 of 2

Rev. 37 Mar/16
VOLUME 3

16.1 5-Blade Lightweight Turbine Pitch Change Rod Bore - Engine-side, That Has the Bushing Removed
Refer to Figure 1-28.1.
A. Visually examine the Damage is not permitted. Repair is permitted to a

engine-side hub maximum depth of 0.002 inch
half pitch change (0.05 mm). Polishing using
rod bore for damage. an abrasive pad CM47 or
equivalent is permitted. The
repair must be in an area no
greater than 25% of the pitch
change rod bore. If the damage
is greater than the serviceable
limits or the repair is greater
than the corrective action limits,
replace the hub in accordance
with the Part Retirement
Procedures chapter of
Hartzell Propeller Inc.
202A (61-01-02), Volume 6.
B. Visually examine Minor scratches are If the damage is greater than

ID "E" at Area "G" of permitted. Damage that the permitted serviceable limits,
the engine-side hub half affects the O-ring sealing replace the hub in accordance
pitch change rod bore. surface is not permitted. with the Part Retirement
Area "G" is an O-ring Procedures chapter of Hartzell
sealing surface. Propeller Inc. Standard
Practices Manual 202A
(61-01-02), Volume 6.
C. Measure ID "E" at The maximum permitted If the diameter of ID "E" at

Area "G" of the diameter of ID "E" at Area "G" is greater than the
engine-side hub Area "G" of the engine-side permitted serviceable limits,
half pitch change hub half pitch change replace the hub in accordance
rod bore. rod bore is 1.382 inches with the Part Retirement
(35.10 mm). Procedures chapter of Hartzell
Propeller Inc. Standard
Practices Manual 202A
(61-01-02), Volume 6.

Table 1-1

Rev. 37 Mar/16
VOLUME 3

16.1 5-Blade Lightweight Turbine Pitch Change Rod Bore - Engine-side, That Has the Bushing Removed
Refer to Figure 1-28.1.
D. Visually examine If there is wear, measure the If the thickness of

shoulder "F" for wear. thickness of shoulder "F". shoulder "F" is less than the
The minimum permitted permitted serviceable limits,
shoulder thickness is replace the hub in accordance
0.435 inch (11.05 mm). with the Part Retirement
Local spot repairs are not Procedures chapter of
permitted to be greater Hartzell Propeller Inc.
than 25% of the shoulder Standard Practices Manual
circumference for either 202A (61-01-02), Volume 6.
surface and are not to be
included in this measurement.
E. Visually examine the Minor scratches and abrasions Repair is permitted to a

areas identified as "All are permitted. Other damage maximum depth of
Other Surfaces" for that has sharp edges, causes 0.010 inch (0.25 mm). The
damage. material to be pushed up, maximum permitted area
interferes with the insertion of repair is 20% of each
of the bushing or O-ring or of surface. If the damage or the
the fit of the bushing is not required repair is greater than
permitted. the serviceable limits or the
corrective action limits, replace
the hub in accordance with the
Part Retirement Procedures
chapter of Hartzell Propeller Inc.
202A (61-01-02), Volume 6.

Table 1-1

Rev. 37 Mar/16
VOLUME 3
Area 9
Area 8 Bore 10A
O-ring Groove 10B
O-ring Groove
Corners
APS0932B
Location of Inspection Areas

Figure 1-29

Rev. 35 Jul/15
VOLUME 3

29. Hub Extension
(not shown)
A. Examine the hub The maximum permitted depth Repair is permitted to a depth
extension for a rough of a rough surface finish or an of 0.010 inch (0.25 mm). The
surface or pitting. imperfection is 0.005 inch repair must be in an area no
(0.12 mm). The maximum greater than 1.0 square inch
diameter of an individual pit is (645 sq. mm) and at least
0.0625 inch (1.587 mm). The 0.25 inch (6.4 mm) from any
maximum permitted depth of an other repaired area.
individual pit is 0.005 inch
(0.12 mm). Linear penetrant
indications are not permitted.

Table 1-1

Rev. 35 Jul/15
VOLUME 3
"C"
Shoulder
"G"
"E"
"D"
"A"
"B"
"F"
Shoulder of the
Retaining Groove
Retaining Ring
Groove
Shoulder of the
Retaining Groove
APS5952, TPI-202-3-046
B-5952 Pitch Change Rod Bushing Areas of Inspection

Figure 1-35

Rev. 37 Mar/16
VOLUME 3

30. B-5952-( ) Pitch Change Rod Bushing (Cylinder-Side Hub Half)
A. Measure the pitch change Measure the pitch change rod Repair is not permitted. If not
rod bushing ID. Refer to bushing ID while the bushing is within the serviceable limits,
"A" in Figure 1-35. installed in the hub. A smooth replace the pitch change rod
surface finish is required. bushing.
The maximum permitted ID is
0.940 inch (23.87 mm).
B. Measure the pitch change Measure the pitch change rod Repair is not permitted. If not
rod bushing ID O‑ring bushing ID O-ring groove while within the serviceable limits,
groove. Refer to "B" in the bushing is installed in the replace the pitch change rod
Figure 1-35. hub. A smooth surface finish is bushing.
required. The maximum permitted
ID is 1.179 inch (29.94 mm).
C. Measure the pitch change The minimum permitted OD is Repair is not permitted. If the
rod bushing OD O-ring 1.958 inch (49.74 mm). OD is less than the permitted
groove. Refer to "C" in serviceable limits, replace the
Figure 1-35. pitch change rod bushing.
D. Measure the pitch change Light scoring is permitted. Repair is not permitted. If the
rod bushing OD between OD is less than the permitted
the retaining ring groove For B-5952 the minimum serviceable limits, replace the
and the end of the part permitted OD is 1.614 inch pitch change rod bushing.
away from the shoulder. (41.00 mm).
Refer to "D" in Figure 1-35.
For B-5952-1 the minimum
permitted OD is 1.618 inch
(41.10 mm).
E. Measure the pitch change Light scoring is permitted. Repair is not permitted. If the
rod bushing OD between OD is less than the permitted
the retaining ring groove For B-5952 the minimum serviceable limits, replace the
and the shoulder. Refer to permitted OD is 1.630 inch pitch change rod bushing.
"E" in Figure 1-35. (41.41 mm).

(41.51 mm).

Table 1-1

Rev. 37 Mar/16
VOLUME 3

30. B-5952-( ) Pitch Change Rod Bushing (Cylinder-Side Hub Half), continued
F. Measure the OD of the For B-5952 the minimum If the OD of the retaining ring
retaining ring groove. permitted OD of the retaining groove is less than the permitted
Refer to "F" in Figure 1-35. ring groove is 1.520 inch serviceable limits, replace the
(38.61 mm). pitch change rod bushing.

permitted OD of the retaining
ring groove is 1.524 inch
(38.71 mm).
G. Visually examine each The maximum permitted total If the damage for either shoulder
shoulder of the retaining accumulated damage for is greater than the permitted
ring groove for damage. each shoulder is 25% of the serviceable limits, replace the
circumference. rod hub bushing.
H. Measure the width of The maximum permitted width If the width of the retaining
the retaining ring groove. of the retaining ring groove is ring groove is greater than the
Refer to "G" in Figure 0.074 inch (1.87 mm). permitted serviceable limits,
1-35. replace the rod hub bushing.

Table 1-1

Rev. 37 Mar/16
VOLUME 3

Rev. 37 Mar/16
VOLUME 3
"C"
Shoulder
"E"
"G"
"E"
"D"
"A"
"B"
"F"
Shoulder of the
Retaining Ring Groove
Retaining Ring
Groove
Shoulder of the
APS6108A, TPI-202-3-047
Retaining Ring Groove
B-6108 Pitch Change Rod Bushing Areas of Inspection

Figure 1-36

Rev. 37 Mar/16
VOLUME 3

31. B-6108-( ) Pitch Change Rod Bushing (Engine-Side Hub Half)
A. Measure and visually Measure the pitch change rod If the ID of the pitch change
examine the pitch change bushing ID while the bushing is rod bushing is greater than the
rod bushing ID. Refer to installed in the hub. A smooth permitted serviceable limits or if
"A" in Figure 1-36. surface finish is required. the surface finish is not smooth,
The maximum permitted ID is replace the pitch change rod
0.815 inch (20.70 mm). bushing.
B. Measure and visually Measure the pitch change rod If the ID of the O-ring groove
examine the pitch change bushing ID O-ring groove while is greater than the permitted
rod bushing ID O‑ring the bushing is installed in the serviceable limits or if the surface
groove. Refer to "B" in hub. A smooth surface finish is finish is not smooth, replace the
Figure 1-36. required. The maximum permitted pitch change rod bushing.
ID is 1.055 inch (26.79 mm).
C. Measure the pitch change For B-6108 the minimum If the OD of the O-ring groove
rod bushing OD O-ring permitted OD is 1.270 inch is less than the permitted
groove. Refer to "C" in (32.26 mm). serviceable limits, replace the
Figure 1-36. pitch change rod bushing.
(32.36 mm).
D. Measure the pitch change Light scoring is permitted. If the OD of the pitch change rod
rod bushing OD between bushing is less than the permitted
the retaining ring groove For B-6108 the minimum serviceable limits or if there is
and the end of the part permitted OD is 1.363 inch more than light scoring, replace
away from the shoulder. (34.62 mm). the pitch change rod bushing.
Refer to "D" in Figure 1-36.
(34.73 mm).
E. Measure the pitch change Light scoring is permitted. If the OD of the pitch change rod
rod bushing OD between bushing is less than the permitted
the retaining ring groove For B-6108 the minimum serviceable limits or if there is
and the shoulder. Refer to permitted OD is 1.377 inch more than light scoring, replace
"E" in Figure 1-36. (34.98 mm). the pitch change rod bushing.

permitted OD is
1.381 inch (35.08 mm).

Table 1-1

Rev. 37 Mar/16
VOLUME 3

31. B-6108-( ) Pitch Change Rod Bushing (Engine-Side Hub Half), continued
F. Measure the OD of the For B-6108 the minimum If the OD of the retaining ring
retaining ring groove Refer permitted OD of the retaining groove is less than the permitted
to "F" in Figure 1-36. ring groove is 1.284 inch serviceable limits, replace the
(32.62 mm). pitch change rod bushing.

permitted OD of the retaining
ring groove is 1.288 inch
(32.71 mm).
G. Visually examine each The maximum permitted total If the damage for either shoulder
shoulder of the retaining accumulated damage for is greater than the permitted
ring groove for damage. each shoulder is 25% of the serviceable limits, replace the
circumference. rod hub bushing.
H. Measure the width of The maximum permitted width If the width of the retaining
the retaining ring groove. of the retaining ring groove is ring groove is greater than the
Refer to "G" in 0.062 inch (1.57 mm). permitted serviceable limits,
Figure 1-35. replace the rod hub bushing.

Table 1-1

Rev. 37 Mar/16
VOLUME 3

Rev. 37 Mar/16
VOLUME 3
"I"
"H" "G"
"F"
TPI-102778
102778 Pitch Change Rod Repair Bushing Areas of Inspection

Figure 1-37

Rev. 35 Jul/15
VOLUME 3
E. Repair of Stripped Cylinder Attachment Screw Holes

CAUTION: INSTRUCTIONS AND PROCEDURES IN THIS SECTION INVOLVE
PROPELLER CRITICAL PARTS. REFER TO THE INTRODUCTION
CHAPTER OF THIS MANUAL FOR INFORMATION ABOUT
PROPELLER CRITICAL PARTS. REFER TO THE ILLUSTRATED
PARTS LIST CHAPTER OF THE APPLICABLE OVERHAUL
MANUAL(S) FOR THE IDENTIFICATION OF SPECIFIC
PROPELLER CRITICAL PARTS.
(1) General
(a) This procedure is applicable to hubs used on propeller models
HC-A6A-3( ), HC-E5B-5( ), HC-E5(N,P)-3( ), HC-E5(N,P)-2( ), and
HC-E5A-3( ). This includes, but is not limited to, hubs D-1066( ),
D-3372-3( ), D-3398-3( ), E-2819( ),104904, and 105880.
(2) Procedure
(a) Drill to a minor diameter 0.331 to 0.336 x 0.743 inch
(8.41 to 8.53 x 18.87 mm) maximum depth.
(b) Tap the hole to 3/8-16 UNC-2B thread to a depth of 0.430 inch
(10.92 mm) minimum.
(c) Chamfer the tapped hole to 0.390 +/- 0.005 inch (9.91 +/- 0.12 mm)
x 90 degree included angle.
(d) Using clean compressed air, blow out any remaining unwanted material
from the hole.
(e) If the repair is not performed as part of a hub overhaul, apply chemical
conversion coating to the threaded hole.
1 For instructions about the application of chemical conversion coating,
refer to the Chromic Acid Anodizing chapter of Hartzell Propeller Inc.
Standard Practices Manual 202A (61-01-02), Volume 10.
(f) If the repair is performed as a part of hub overhaul, chromic acid anodize
the hub before installing the thread insert. Refer to the Chromic Acid
Anodizing chapter of Hartzell Propeller Inc. Standard Practices
Manual 202A (61-01-02), Volume 10.
(g) Install thread insert, Hartzell Propeller Inc. P/N B-6143-4, 0.010 to
0.030 inch (0.25 to 0.76 mm) below the surface, driving the locking keys
down.
(h) If there is surface scratching of the hub when the threaded insert is
installed, apply chemical conversion coating to the machined surfaces of
the hub near both ends of the installed threaded insert.

Rev. 37 Mar/16
VOLUME 3
F. Repair of Anti-Rotation Rod Threaded Holes

(1) General
(a) The following procedure is applicable to propeller hubs used on
propeller models HC-E5B-5( ), HC-E5(N,P)-3( ), and HC-E5(N,P)-2. This
includes, but is not limited to, propeller hubs D-3372(-), D-3398(-),
E-2819(-), 104904, and 105880.
(2) Procedure
(a) Using a 7/16-20UNF-3NB true position indicator or a thread tap to locate
off of the thread pitch diameter, determine the center of the threaded hole.
1 Optionally, the largest drill blank that will fit into the minor diameter of
the threaded hole may also be used to determine the center of the hole.
(b) Bore the hole to a diameter 0.4483 to 0.4561 (11.386 to 11.584 mm).
(c) Deburr the edges of the hole on both sides of the hub.
(d) Using clean compressed air, blow out any remaining unwanted material
from the hole.
(e) Using Heli-Coil® STI Tap part number 7FBB, 7FSB, 7FPB, or equivalent,
tap the newly bored hole.
(f) Using clean compressed air, blow out any remaining unwanted material
from the hole.
(g) Using a Heli-Coil® thread gauge part number 3694, or equivalent, make an
inspection of the tapped hole.
1 The "GO" thread end must install freely.
2 Retap the hole until the inspection of the tapped hole is satisfactory.
CAUTION: DO NOT PAINT THE THREADED HOLE BECAUSE PAINT
WILL AFFECT THE FIT OF THE HELI-COIL®.
(h) If the repair is not performed as part of a hub overhaul, apply chemical
conversion coating to the threaded hole.

Rev. 37 Mar/16
VOLUME 3
SHOT
ITEM FIGURE REQUIREMENT PAINT ANNODIZE
PEEN
K Figure 1-100 Mask the bore to 1.25 ± 0.050 inch diameter X X --
(31.8 ± 1.27 mm) on the engine-side hub half
for all shot peen and paint operations.
L Figure 1-100 Mask the through holes to 0.850 ± 0.050 inch X X --

diameter (21.59 ± 1.27 mm) for all shot peen
and paint operations. There are twelve holes on the
engine-side hub half inside surface.
M Figure 1-100 Mask the bore to 4.50 ± 0.050 inch diameter X X --

(114.3 ± 1.27 mm) on the cylinder-side hub half
for all shot peen and paint operations.
N Figure 1-100 Mask the bore to 5.55 ± 0.05 inch (141.0 ± 1.3 mm) X X --
diameter on the cylinder-side hub half for all
shot peen and paint operations.
O Figure 1-98 Mask the surface of the hub preload plate shelf for -- X X
all paint and anodize operations.
NOTE: Areas that are masked for anodize must
have chemical conversion coating applied
after the masking material is removed.
P Figure 1-99 Mask the blind holes to 0.45 ± 0.05 inch X X --

(11.4 ± 1.3 mm) for all shot peen and
paint operations.
E-7369 Lightweight Turbine Aluminum Hub Shot Peen, Paint, and Anodize Masking
Table 1-11, Page 2 of 2

Rev. 37 Mar/16
VOLUME 3
B B
A A
TPI-202-3-100-1
105880 Lightweight Turbine Aluminum Hub Shot Peen, Paint, and Anodize Masking
Figure 1-100.1

Rev. 37 Mar/16
VOLUME 3
F
D
TPI-202-3-100-2
Engine-Side Half of the Hub
Figure 1-100.2

Rev. 37 Mar/16
VOLUME 3
E I
K S
K
E
H
TPI-202-3-100-3
Cylnder-Side Half of the Hub
Figure 1-100.3

Rev. 37 Mar/16
VOLUME 3
Surfaces
Internal
M
S
Diameter
1.60 ± 0.05 inch N
O
40.6 ± 1.2 mm
Diameter
5.550 ± 0.050 inch
140.97 ± 1.27 mm
Diameter
5.100 ± 0.050 inch
129.54 ± 1.27 mm
M
Internal
Surfaces
P P
TPI-202-3-100-4
Figure 1-100.4

Rev. 37 Mar/16
VOLUME 3
Q
R T
TPI-202-3-100-5
Figure 1-100.5

Rev. 37 Mar/16
VOLUME 3
D E
TPI-202-3-100-6
Figure 1-100.6

Rev. 37 Mar/16
VOLUME 3
L
TPI-202-3-100-7
Figure 1-100.7

Rev. 37 Mar/16
VOLUME 3
CHROMATE
SHOT
ITEM FIGURE REQUIREMENT PAINT ANODIZE CONVERSION
PEEN
COAT
A Figure 1-100.1 Mask the threaded holes to 0.305 ± 0.055 inch X -- -- --
(7.75 ± 1.40 mm) diameter for all shot peen
operations. There are ten holes on each
hub half.
A Figure 1-100.1 Mask the threads only for paint operations -- X -- --
B Figure 1-100.1 Mask the threaded lubrication fitting holes to X -- -- --

0.405 ± 0.105 inch diameter (10.29 ± 2.67 mm)
for all shot peen operations.
B Figure 1-100.1 Mask the threads of the lubrication fitting hole -- X -- --

only for paint operations.
C Figure 1-100.1 Mask the hub half mating surfaces for paint -- X -- --
and operations.
Figure 1-100.3
C Figure 1-100.1 Shot peen the hub half mating surfaces on the X -- -- --
and cylinder-side and the engine-side hub halves.
Figure 1-100.3
D Figure 1-100.2 Do not shot peen and do not paint the inside X X -- --
and diameter surfaces of the hole from the inside
Figure 1-100.6 or from the outside of the hub.
E Figure 1-100.3 Do not shot peen and do not paint the the X X -- --
and inside diameter surface of the hole from the
Figure 1-100.6 inside or from the outside of the hub.
F Figure 1-100.2 Do not shot peen and do not paint the ten X X -- --
threaded holes in the engine-side hub half
from the outside.
G Figure 1-100.4 Shot peen and paint all external surfaces as X X -- --

indicated. Refer to Figure 1-82 for information
about the two step shot peening process for
outside surfaces.
H Figure 1-100.3 Do not shot peen the two counterbored X -- -- --

clamping bolt holes that are adjacent to the
mating surfaces on the engine-side and the
cylinder-side of the hub halves.
Table 1-11.1, Page 1 of 3

Rev. 37 Mar/16
VOLUME 3
CHROMATE
SHOT
PEEN
COAT
I Figure 1-100.3 Do not shot peen the 13 hub clamping bolt X -- -- --
holes in the cylinder-side hub half and the
13 hub clamping bolt holes in the
engine-side hub half.
J Figure 1-100.3 Do not shot peen and do not paint the ten X X -- --
threaded holes for cylinder mounting that are
in the cylinder-side hub half from the inside or
from the outside of the hub.
K Figure 1-100.3 Do not shot peen and do not paint from the X X -- --
and inside or from the outside, the two threaded
Figure 1-100.7 holes in the cylinder-side hub half that receive
the threaded portion of the anti-rotation rods.
L Figure 1-100.7 Do not shot peen the two flat bottom holes X -- -- --
in the engine-side hub half that receive the
anti-rotation rods.
M Figure 1-100.4 Except for those features that are masked X X -- --

in accordance with this table, shot peen and
paint internal surfaces as indicated. Includes
blade arm inside diameters, O-ring grooves,
and bearing retention pockets at five locations.
Refer to Figure 1-82 for information about
the inside surfaces one step shot peening
process.
N Figure 1-100.4 Do not shot peen or paint the mounting flange X X -- --

surface, the eight mounting bolt through holes,
the two dowel pin holes, or the pitch change
rod bore and associated bushing as indicated.
O Figure 1-100.4 Do not shot peen the cylinder pilot bore or X -- -- --

the adjacent surfaces during the inside or
outside shot peen operations as dimensionally
indicated.
P Figure 1-100.4 Shot peen overspray is permitted at the -- X -- --

entrance of 30 holes opposite from the hub
half parting surface to a depth of 0.50 inch
(12.7 mm) when shot peening the outside
surfaces in Area G.

Rev. 37 Mar/16
VOLUME 3
CHROMATE
SHOT
PEEN
COAT
P Figure 1-100.4 Paint overspray is permitted at the entrance -- X -- --
of 30 holes opposite from the hub half parting
surface to a depth of 0.75 inch (19.0 mm)
when painting the outside surfaces specified
in Area G.
Q Figure 1-100.5 Do not paint the cylinder pilot bore inside -- X -- --
diameter during the inside or outside paint
operations.
R Figure 1-100.5 Mask the mounting bolt through holes on X -- -- --

the inside surface to 0.850 +/- 0.050 inch
diameter (21.59 +/- 1.27 mm) for all shot
peen operations. There are eight holes on the
engine-side hub half inside surface.
S Figure 1-100.3 Inside surfaces for supporting the preload -- X X X

and plate at five locations on the cylinder-side and
Figure 1-100.4 on engine-side hub half. Mask to not anodize.
Mask to not paint. Chromate conversion coat.
T Figure 1-100.5 Do not paint the mounting bolt through hole -- X -- --

inside diameters during the inside surface
paint operations. (Additional paint may cause
through bolts to not install correctly.) There are
eight bolt through holes on the engine-side
hub half.

Rev. 37 Mar/16
VOLUME 3
“K” Flange - Four counter-sunk holes “R” Flange - Five counter-sunk holes
APS6168, APS6172
“K” and “R” Propeller Flange Identification
Figure 1-101
“N” Flange - Two dowel pin holes “P” Flange - Four dowel pin holes
W10045, W10046
“N” and “P” Propeller Flange Identification

Figure 1-102

Rev. 35 Jul/15
VOLUME 3
N. Installation of Hub Sleeve 104488 in the F-flange Hub Mounting Bore

(1) General
(a) This repair is applicable to F-flange compact hubs only.
(b) For the hub repair to use hub sleeve 104488, refer to the section "Repair
of an F-flange Hub Mounting Bore to Use Hub Sleeve 104488" in this
chapter.
(2) Materials Needed:
(a) Hub sleeve, Hartzell Propeller Inc. part number 104488
(b) O-ring, Hartzell Propeller Inc. part number C-3317-145
(c) Grease, CM12
(3) Procedure
(a) Apply a small amount of grease CM12 on O-ring C-3317-145 for ease
of installation.
(b) Install the O-ring C-3317-145 in the OD O-ring groove of the hub
sleeve 104488.
(c) Install the hub sleeve 104488 with the O-ring into the bore of the
engine side half of the hub.
1 The hub sleeve 104488 must be below the surface of the flange face
of the hub. Refer to Figure 1-108.1
NOTE: The OD O-ring on the hub sleeve 104488 is compressed
against the hub ID. The O-ring interference between the
hub and hub sleeve 104488 is what holds the hub sleeve
104488 in the hub.

Rev. 37 Mar/16
VOLUME 3
Shoulder of the Shoulder of the

Pitch Change Rod Pitch Change Rod
Hub Bushing Hub Bushing
O-ring
Pitch Change Rod

Hub Bushing
External Spiral
Retaining Ring
Hub Configuration 1 Hub Configuration 2
NOTE: Two hub configurations are possible for the five-blade

TPI-202-3-048,049
lightweight turbine series hubs.
Installing the Pitch Change Rod Hub Bushing 104903

Figure 1-108.2

Rev. 37 Mar/16
VOLUME 3
O. Installation of the Pitch Change Rod Hub Bushing in Five-blade Lightweight Turbine
Series Hubs
(1) General
(a) This procedure gives instructions for installing the pitch change rod hub
bushing 104903 in the engine-side half of a hub of five-blade lightweight
turbine series hub.
(b) The pitch change rod hub bushing 104903 uses an O-ring C-3317-026-2
installed on the OD of the pitch change rod hub bushing and an external
spiral retaining ring A-6153-137 to retain the pitch change rod hub bushing.
(2) Installing the pitch change rod hub bushing 104903. Refer to Figure 1-108.2.
(a) Before installing the pitch change rod hob bushing, re-anodize the hub
in accordance with the aluminum hub overhaul requirements. Refer to
the Chromic Acid Anodizing chapter of Hartzell Propeller Inc. Standard
Practices Manual 202A (61-01-02), Volume 10.
WARNING: ADHESIVES AND SOLVENTS ARE FLAMMABLE AND TOXIC

TO THE SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND
EYE PROTECTION ARE REQUIRED. AVOID PROLONGED
CONTACT AND BREATHING OF VAPORS. USE SOLVENT
RESISTANT GLOVES TO MINIMIZE SKIN CONTACT AND
WEAR SAFETY GLASSES FOR EYE PROTECTION. USE
IN A WELL VENTILATED AREA AWAY FROM SPARKS AND
FLAME. READ AND OBSERVE ALL WARNING LABELS.
(b) Using a clean cloth dampened with solvent CM11, thoroughly clean the
OD of the pitch change rod hub bushing and the bore of the hub.
(c) Permit the solvent CM11 to dry.
(d) Install the O-ring C-3317-026-2 on the OD in the O-ring groove of the pitch
change rod hub bushing.
(e) Apply a light layer of grease CM12 to the bore of the engine-side
half of the hub.
(f) From the outside of the engine-side half of the hub, push the pitch change
rod hub bushing 104903 into the bore of the hub until the shoulder of the
bushing touches the counterbore of the hub.
(g) From the inside of the engine-side half of the hub, install an external spiral
retaining ring A-5839-87 in the groove provided for it in the pitch change
rod hub bushing.
(h) Do a test on the hub for a leak between the installed pitch
change rod hub bushing and the hub in accordance with the section,
"Leak Inspection of the Bushing in the Engine-side Half of the Hub for
Five-blade Lightweight Turbine Series Hubs" in this chapter.

Rev. 37 Mar/16
VOLUME 3
Cylinder-side hub half Modified pitch

O-ring change rod
Modified cylinder
Fork
Air valve
Apply leak detector

CM122 here
NOTE: Repair bushing is not shown.

Engine-side hub half
Cylinder-side Hub Half Leak Inspection
Engine-side hub half
TE441
Fork Modified pitch change rod

Air valve O-ring
O-ring
Apply leak detector
CM122 here
Cylinder-side hub half

TPI-202-3-027, TPI-202-3-028
NOTE: Repair bushing is not shown.
Engine-side Hub Half Leak Inspection
Leak Inspection of the Compact Hub Pitch Change Rod Bore

Figure 1-109

Rev. 35 Jul/15
VOLUME 3
C. Leak Inspection for the Cylinder-side Hub Half

(1) With the bushing ID O-ring installed, insert fixture TE393 or TE429, as
applicable, through the bushing.
NOTE: TE393 and TE429 are threaded and attach to the hub in the same fashion
as the cylinder during reassembly.
(2) Attach an air hose to the quick disconnect of the TE393 or TE429 fixture.
(3) Apply 100 psi (6.89 bars) of line pressure to the fixture.
(4) Examine for leaks.
(a) Apply leak detector CM122 to the following areas:
1 Inside the hub around the area where the pitch change rod meets the
bushing. Refer to Figure 1-110.
2 Inside the hub around the area where the bushing meets the hub.
(b) A leak is not permitted.
(c) If a leak is detected:
1 Inspect the O-ring seals for unwanted material.
a Remove any unwanted material.
2 Replace the O-ring(s).
3 Repeat the leak inspection procedure.
4 If the leak(s) cannot be stopped, inspect the hub and bushing in
accordance with the serviceable limits in this chapter. If required,
replace the bushing or replace the hub in accordance with the Part
Retirement Procedures chapter of Hartzell Propeller Inc. Standard
(5) After the test is complete, discard the bushing ID O-ring.

Rev. 37 Mar/16
VOLUME 3
0.872 ± 0.001 inch Diameter

(22.14 ± 0.025 mm)
TPI-202-3-102
Locally Manufactured Pin

Figure 1-111

Rev. 37 Mar/16
VOLUME 3
15. Leak Inspection of the Bushing in the Engine-side Half of the Hub for Five-blade
Lightweight Turbine Series Hubs

PROPELLER CRITICAL PARTS. REFER TO THE ILLUSTRATED PARTS
LIST CHAPTER OF THE APPLICABLE OVERHAUL MANUAL(S) FOR
THE IDENTIFICATION OF SPECIFIC PROPELLER CRITICAL PARTS.
A. General
(1) This procedure is used to examine for leaks around the plastic bushing in
five-blade lightweight turbine hubs.
(a) This procedure does not apply to five-blade Raptor hubs.
1 For leak inspection of five-blade Raptor hubs, refer to the section
"Leak Inspection of Bushings in Four-blade Lightweight Turbine
Series Hubs and Five-blade Raptor Turbine Hubs" in this chapter.
(2) Equipment
(a) Use the following equipment. This equipment may be manufactured
locally. Refer to Figure 1-111 and Figure 1-112. If there are questions,
contact Hartzell Propeller Inc. Product Support.
1 TE390 or TE441-1 or similar plate that is locally manufactured
a Some modification of TE390 could be required to clear the
bushing.
2 Pin, locally manufactured - Refer to Figure 1-111
a The pin OD interfaces with the bushing ID O-ring and must be
the diameter specified in Figure 1-111 to correctly take the place
of the pitch change rod.
(1) All other dimensions are at the discretion of the local
manufacturer.
(2) The recommended surface finish for the pin is
16 Ra micro-inches (0.40 Ra micro-meters).
b Optionally, part of a scrapped pitch change rod that has been
plugged so that it will not let air escape, can be used as the pin.

Rev. 37 Mar/16
VOLUME 3
Air Hose
Quick
Disconnect Area A 2
1
Area B
1. O-ring C-3317-212-2, used in the bushing ID O-ring groove

2. Pin, locally manufactured
3. O-ring C-3317-230, used on TE390, TE441-1, or locally manufactured plate
4. TE390, TE441-1, or similar plate that is locally manufactured
5. External spiral retaining ring A-6153-137
TPI-202-3-101A
6. O-ring C-3317-026-2, used when bushing is installed
Checking the Plastic Bushing of a Five-Blade Lightweight Turbine for Leaks

Figure 1-112

Rev. 37 Mar/16
VOLUME 3
B. Leak Inspection for the Engine-side Hub Half - Refer to Figure 1-112.
(1) Install the bushing ID O-ring C-3317-212-2 in the bushing ID O-ring groove.
(2) Insert the pin through the bushing.
(3) Install the O-ring C-3317-230 on the TE390, TE441-1, or locally manufactured
plate that attaches to the hub.
(4) Bolt the TE390, TE441-1, or locally manufactured plate to the hub.
(a) For this test, the use of two opposing bolts that are finger tight is sufficient.
(5) Attach an air hose to the quick disconnect of the fixture TE390, TE441-1,
or locally manufactured plate.
(6) Apply 100 psi (6.89 bars) of line pressure to the fixture.
(7) Examine for leaks.
(a) Apply leak detector CM122 to the following areas:
1 Inside the hub around the area of the bushing where the pin
meets the bushing around the circumference of the pin. Refer to
Figure 1-112, Area A.
2 Inside the hub around the area where the bushing meets the hub.
Refer to Figure 1-112, Area B.
a Apply leak detector CM122 to completely cover the area over
the external spiral retaining ring A-6153-137 and around the
circumference of the bushing.
(b) A leak is not permitted.
(c) If a leak is detected:
1 Inspect the O-ring seals for unwanted material.
a Remove any unwanted material.
2 Replace the O-ring(s).
3 Repeat the leak inspection procedure.
4 If the leak(s) cannot be stopped, inspect the hub and bushing in
accordance with the serviceable limits in this chapter. If required,
replace the bushing or replace the hub in accordance with the Part
Retirement Procedures chapter of Hartzell Propeller Inc. Standard
(8) After the test is complete, remove and discard the bushing ID O-ring and the
O-ring on the TE390, TE441-1, or locally manufactured plate.

Rev. 37 Mar/16
VOLUME 3
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Rev. 37 Mar/16

Hartzell Propeller Inc

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HARTZELL PROPELLER INC.

One Propeller Place

Attached is a copy of Revision 37 to Hartzell Manual 202A, Volume 3

This page may be discarded after proper filing of the revision.

Standard Practices Manual

Hartzell Propeller Inc.

COVER 61-01-02 Vol. 3, Page 2

202A, VOLUME 3 - REVISION 37 HIGHLIGHTS

REVISION HIGHLIGHTS 61-01-02 Vol. 3, Page 1

(This page is intentionally blank.)

REVISION HIGHLIGHTS 61-01-02 Vol. 3, Page 2

REVISION HIGHLIGHTS 61-01-02 Vol. 3, Page 3

Revision No. Issue Date Comments

Original Mar/93 New

REVISION HIGHLIGHTS 61-01-02 Vol. 3, Page 4

LIST OF EFFECTIVE PAGES

Chapter Volume Page Rev. Level Date

Cover/Cover back 3 Cover/Cover back Rev. 37 Mar/16

LIST OF EFFECTIVE PAGES 61-01-02 Vol. 3, Page 1

LIST OF EFFECTIVE PAGES

Chapter Volume Page Rev. Level Date

Aluminum Hub Overhaul 3 1-114 and 1-115 Rev. 35 Jul/15

LIST OF EFFECTIVE PAGES 61-01-02 Vol. 3, Page 2

LIST OF EFFECTIVE PAGES

Chapter Volume Page Rev. Level Date

Aluminum Hub Overhaul 3 1-246 thru 1-270 Rev. 35 Jul/15

LIST OF EFFECTIVE PAGES 61-01-02 Vol. 3, Page 3

(This page is intentionally blank.)

LIST OF EFFECTIVE PAGES 61-01-02 Vol. 3, Page 4

ALUMINUM HUB OVERHAUL - CONTENTS

ALUMINUM HUB OVERHAUL 61-01-02 Vol. 3, Page 1-3

ALUMINUM HUB OVERHAUL - CONTENTS

ALUMINUM HUB OVERHAUL 61-01-02 Vol. 3, Page 1-4

ALUMINUM HUB OVERHAUL 61-01-02 Vol. 3, Page 1-5

LIST OF FIGURES, CONTINUED

ALUMINUM HUB OVERHAUL 61-01-02 Vol. 3, Page 1-6

LIST OF FIGURES, CONTINUED

Shot Peening of D-1066 Six Blade Lightweight Turbine

ALUMINUM HUB OVERHAUL 61-01-02 Vol. 3, Page 1-9

LIST OF FIGURES, CONTINUED

ALUMINUM HUB OVERHAUL 61-01-02 Vol. 3, Page 1-10

Inspection and Repair Requirements.......................................Table 1-1................Vol. 3, 1-39

ALUMINUM HUB OVERHAUL 61-01-02 Vol. 3, Page 1-11

Hartzell Aluminum Hub Overhaul Traveler

Sample Aluminum Hub Overhaul "Traveler"

ALUMINUM HUB OVERHAUL 61-01-02 Vol. 3, Page 1-12

Inspect Serviceable Limits Corrective Action

D. Visually examine the Minor scratches and abrasions Repair is permitted to a

Inspection and Repair Requirements

ALUMINUM HUB OVERHAUL 61-01-02 Vol. 3, Page 1-112.1

0.100 Inch (2.54 mm)

0.220 Inch (5.59 mm)

All Other Surfaces

All Other Surfaces

Five Blade Lightweight Turbine

ALUMINUM HUB OVERHAUL 61-01-02 Vol. 3, Page 1-112.2

0.100 Inch (2.54 mm)

All Other Surfaces

All Other Surfaces

Five Blade Lightweight Turbine

ALUMINUM HUB OVERHAUL 61-01-02 Vol. 3, Page 1-112.3

Inspect Serviceable Limits Corrective Action

A. Visually examine the Damage is not permitted. Repair is permitted to a