SERVICE BULLETIN 234B

ALERT

November 19, 2001

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

SUBJECT: Inspection of Propeller Blade for Cracking

MODEL AFFECTED: 4HFR34C653/L106FA-0 All Serial Numbers

SERVICE MANUAL AFFECTED: 860201

AIRCRAFT AFFECTED: 1. Jetstream Series 3200

2. Ayres S2R-G5, -G10

If blades or propeller assembly has previously been
installed on a Jetstream Series 3200 or history is unknown.

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

Service Bulletin 234B replaces Service Bulletin 234A dated February 22, 2001 and Service
Bulletin 235A dated February 22, 2001. Service Bulletin 234B announces change letter and life
limit stamping to propeller blades and hub. When incorporated, the change letter and life limit
stamping eliminates the repetitive on wing inspection requirements as defined in Airworthiness
Directive (AD) 2000-15-10and provides an FAA approved alternate method of compliance
(AMOC) to AD2000-15-10.

NOTE: Operators must receive local FSDO concurrence for AMOC approval.

Lines in margins indicate changes.

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

© 2001 MCCAULEY PROPELLER SYSTEMS

McCauley Propeller Systems
3535 McCauley Drive
Vandalia, Ohio 45377 USA
Page 2 of 17 Service Bulletin 234B

CONDITION: During the initial inspection cycle, two additional blades were found with
cracks. Due to the discovery of additional cracked blades, McCauley is
requiring a repetitive inspection. The repetitive inspections must be per-
formed per Section I or Section II per Compliance Requirements.

McCauley is now requiring an initial and repetitive eddy current or dye

penetrant inspection of all L106FA-0 blades. Additionally, for Jetstream
Series 3200 aircraft, compliance with British Aerospace Jetstream Manda-
tory Service Bulletin 61-JK-12170 is required.

Blades without change letter "A" require inspection per Section I or Section II.
All blades without change letter "A" are now life limited. Blades must be retired
from service before December 1, 2001 or upon reaching 2400 flight hours
after August 1, 2000, or 16,000 hours time since new, whichever occurs first.

Blades stamped with change letter "A" and life limit stamping "L" do not
require inspection per Section I or Section II. Refer to Section III for change
letter and life limit stamping explanations. Blades stamped with this change
letter and life limit stamp are life limited to 16,000 flight hours.

When ALL FOUR blades in a propeller assembly are change letter "A". The
change letter "L" must be stamped following the model number stamping on
the hub. This stamping indicates that ALL FOUR blades installed are stamped
with change letter "A". Compliance with Section I or Section II is not required
for propeller assemblies with change letter stamping "L". Refer to Section III
for change letter stamping explanations.

CORRECTION: 1. Perform inspection as required per instructions in Section I or Section II.

2. Jetstream Series 3200 operators must comply with BAe Service Bulletin
61-JK-12170.
3. Make logbook entry of inspection.
4. Report findings after initial and repetitive inspections to McCauley using
report form on page 17.
5. In the event that a blade is rejected as a result of this inspection, all blades
in propeller assembly must be retired from service for further review by
McCauley.
Service Bulletin 234B Page 3 of 17

COMPLIANCE: 1. For U.S. Operators Only:

Perform initial inspection within 200 flight hours of receipt of this Service
Bulletin or May 31, 2000, whichever occurs first, unless previously
accomplished. Perform repetitive inspection every 600 flight hours after
initial inspection or after August 1, 2000, whichever occurs first. (Ref.
FAA AD 2000-15-10)

Blades without change letter "A" stamping must be retired from service
prior to December 1, 2001 or upon reaching 2,400 flight hours after
August 1, 2000 or 16,000 hours time since new, whichever occurs first.

2. For Non-U.S. Operators Only:

Perform initial inspection within 200 flight hours of receipt of this Service
Bulletin or May 31, 2000, whichever occurs first, unless previously
accomplished. Perform further inspections either 600 flight hours after
initial inspection or before April 30, 2001. Perform repetitive inspections
at intervals of 600 flight hours thereafter.

Blades without change letter "A" must be retired from service prior to
December 1, 2001 or upon reaching 2,400 flight hours after August 1,
2000 or 16,000 hours time since new, whichever occurs first.

3. Alternate Method of Compliance to AD 2000-15-10

When all four blades in a propeller assembly are stamped with change
letter "A" and life limit stamping "L", blades in assembly do not require
inspection per Section I or Section II.

Blades in propeller assemblies with hubs with change letter "L" do not
require inspection per Section I or Section II.

This alternate method of compliance has been coordinated with and

approved by the Manager of the Chicago Aircraft Certification Office,
2300 E Devon Avenue, Des Plaines, IL 60018. Wide disemmination of
this approved Alternate Method of Compliance to AD 2000-15-10 is
authorized.

Refer to Section III for change letter and life limit stamping explanations.
Page 4 of 17 Service Bulletin 234B

SECTION I

EDDY CURRENT INSPECTION

The following inspection may be performed on the aircraft. It is not necessary to remove deice
boots during inspection.

Surface Preparation:

1. On the camber side of the blade only,

a. Remove McCauley trademark decal with solvent.

b. Lightly smooth camber side of blade with Scotchbrite. This will extend probe life and
help eliminate false indications caused by excessive roughness.

c. Layout inspection areas per Figure 1. Use appropriate marker to indicate

inspection area. All shaded areas are to be inspected. There must be a 1 inch (25.4
mm) overlap in inspection areas.

d. Lay indexing tape from trailing edge to leading edge on camber side of blade
surface against outside boundary of the area to be inspected as shown in Figure 2.
Secure indexing tape to blade surface.

Personnel Requirements

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

Required Equipment:
WARNING: USE OF THE McCAULEY P/N B-7727 PROBE OR UNIWEST US-1334P PROBE
IS MANDATORY. NO SUBSTITUTIONS MAY BE MADE. PREVIOUSLY THE B-
7727 PROBE WAS THE ONLY ALLOWABLE PROBE. THE US-1334P PROBE
IS IDENTICAL TO THE B-7727.

NOTE: McCauley recommends the MP905-60 pencil probe but any equivalent probe is
acceptable. This is a field procurable probe.

a. Eddy Current Instrument:

Staveley Instruments Inc. NDT 24 or equivalent

b. Reference Standard:

0.008, 0.020, and 0.040 inch EDM notch aluminum calibration block
(0.20, 0.51, and 1.02 mm)
Service Bulletin 234B Page 5 of 17

c. Probe:

NDT Engineering Evaluation probe - MP905-60 or equivalent

(50-500 KHz absolute probe)

Large surface area probe - McCauley P/N B-7727 or Uniwest US-1334P

d Straight Edge

e. (2) Indexing Tapes

CAUTION: B-7727 AND THE US-1334P PROBES ARE EQUIPPED WITH AN 8 PIN BURNDY
CONNECTOR. SOME INSPECTION INSTRUMENTS MAY REQUIRE AN
ADAPTER.

McCauley will supply the McCauley probe B-7727, indexing tapes, and straight edge in kit form.
The kit P/N is B-7728. This kit is only available directly from McCauley. Contact McCauley Product
Support to procure kit.

McCauley Propeller Systems

Product Support Department
3535 McCauley Drive
Vandalia, Ohio 45377
USA

Telefax: (937) 890-6001

Telephone: 1-877-776-7435

Replacement probes US-1334P may only be procured directly from Uniwest. This is only a probe
not a kit.

Uniwest
330 West Clark
Pasco, WA 99301
USA

Telefax: (509) 544-0868

Telephone: (509) 544-0720
Page 6 of 17 Service Bulletin 234B

Figure 1
Inspection Area Layout
Service Bulletin 234B Page 7 of 17

Figure 2
Layout of Inspection Area with
Straight Edge and Tape
Page 8 of 17 Service Bulletin 234B

SECTION I PART I
Surface Calibration and Inspection Procedure (B-7727 or US-1334P):

a. Attach the B-7727 or US-1334P probe to the instrument.

b. Instrument frequency 500KHz, low pass filter 100Hz, and high pass filter 5 Hz.

c. Place the probe on the reference standard. Null the instrument in an area of the
reference standard that does not have an EDM notch. Move the probe across the
0.020 EDM (.51mm EDM), adjust the angle to obtain maximum notch signal. Adjust
the gain to obtain a signal that is eight (8) major screen divisions, see Figure 3. The
sensitivity of the testing system is now standardized.

NOTE: The probe is directionally sensitive. Move in the direction of the arrows on
the probe.

d. Using the instrument's gating and alarm function, adjust the gate threshold to trigger
when the signal exceeds two (2) divisions peak to peak.

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

e. The scan area of the blade should be lightly smoothed with Scotchbrite to extend
probe life and help eliminate false indications caused by excessive roughness.

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

EACH BLADE INSPECTION AND ANY TIME THAT IT APPEARS THAT
THE TAPE IS WEARING OUT. FAILURE TO DO SO WILL RESULT IN
PREMATURE PROBE FAILURE.

f. Place the probe on the blade and balance the instruments.

g. All scanning is performed with the long axis of the probe body oriented and scanned
parallel to the leading and trailing edge of the blade. Blade shall be divided as shown
in Figure 1 for scanning purposes. Each area shall be scanned with a minimum of
one (1) inch (25.4 mm) overlap into the adjacent areas.

h. Scan speed shall not exceed 6 inches/second (152.4 mm/second). The scan
pattern shall overlap the previous pass by 0.2 inch (5.0 mm).

i. Hold straight edge perpendicular to each indexing tape, while scanning parallel to
the leading and trailing edge of the blade while in contact with the straight edge as
shown in Figure 2.

j. Move straight edge in 0.2 inch (5.0 mm) increments keeping straight edge
perpendicular to both tapes. See Figure 2. Continue to scan until complete area
has been covered prior to moving to another inspection area.
Service Bulletin 234B Page 9 of 17

k. Any relevant indication shall be indicated with approved markers. Areas with
suspect indications must be further evaluated per Section I Part II.

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

m. Report findings to McCauley using report form on page 17.

n. For Jetstream Series 3200 aircraft, comply with BAe Service Bulletin 61-JK-
12170.

SECTION I PART II
EVALUATION OF SUSPECT INDICATIONS

Standardization and Inspection (MP-905-60):

a. Attach the MP-905-60 probe.

b. Instrument frequency 200 KHz, low pass filter 10 Hz, high filter 0 Hz.

c. Adjust the angle to obtain lift-off in the horizontal direction. Using the 0.020 inch
(0.51 mm) notch in reference standard, adjust the instrument to obtain a minimum
separation of three (3) major divisions as shown in Figure 4.

d. Using the instrument's gating and alarm function, adjust the gate threshold to trigger
when the signal from the reference standard exceeds one (1) major division.

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

e. Place the probe on the painted surface of the propeller blade and balance the
instrument.

f. Scan all suspect areas marked during the initial scan. If an area can not be scanned
due to impact damage, scan around the damage and note any areas that have
indications extending out of the impact damaged areas.

NOTE: The painted surface may be lightly smoothed with Scotchbrite to aid in
evaluation. The paint should only be removed if the cause of indication can-
not be determined.

g. Any relevant indication that exceeds one major screen division shall be cause for
rejection. Remove propeller from aircraft and send to McCauley Authorized Service
Center.

h. Report findings to McCauley using report form on page 17.

Page 10 of 17 Service Bulletin 234B

i. For Jetstream Series 3200 aircraft, comply with BAe Service Bulletin 61-JK-
12170.

Procedure Prepared by: McCauley Propeller Systems

Procedure Approved by:

SECTION II

DYE PENETRANT INSPECTION

a. Blades may be fluorescent dye penetrant inspected per ASTM E 1417 (latest revision)
or international equivalent. The inspection must include stripping paint from blades and
etching per procedures called for in McCauley Standard Practices Manual SPM100-1.
Fluorescent dye penetrant inspection without stripping and etching is not adequate for
detection of cracks. This type of inspection must meet requirements of McCauley
Standard Practices Manual SPM100-1.

b. Mask deice boots and hub retention area as required. Removal of deice boots is not
required.

c. Personnel must be qualified per Section 1, page 3.

d. Materials used must meet requirements per QPL 25135 Qualified Products of Inspec-
tion Materials, Penetrant (latest revision) or international equivalent.

e. Since the anodize or alodine is removed from blades during the etching process,
blades must be alodined, MIL-5541 or international equivalent, prior to painting.

f. Repaint blades.

g. For Jetstream 3200 aircraft, comply with BAe Service Bulletin 61-JK-12170
Service Bulletin 234B Page 11 of 17

500 KHz
H gain 80
V gain 74
Angle 20°
P.Dr Hi
LPF 100
HPF 5

Figure 3
Calibration Display B-7727 Probe
Page 12 of 17 Service Bulletin 234B

F1
200 kHz
HdB 63.0
VdB 75.5
ROT 88°

F1
P. DR MID
LPF 10
HPF 0

Figure 4
Calibration Display MP905-60 Probe
Service Bulletin 234B Page 13 of 17
SECTION III
CHANGE LETTER AND LIFE LIMIT STAMPING
McCauley is introducing new change letters for the 4HFR34C653 hub and the L106FA-0
blades and a life limit for L106FA-0 blades with change letter. The new change letter identifies
blades which do not require inspection per Section I or Section II. The life limit stamping
indicate blades which are now life limited. The hub may be stamped with the new change
letter to indicate that ALL FOUR blades installed do not require inspection per Section I or
Section II.

NOTE: All four blades installed in propeller assemlby must be "A" change for alternate
method of compliance with AD 2000-15-10.

1. The change letter "A" will be stamped on the butt end of each blade preceding the
blade design number. The life limit stamping "L" will be stamped under the blade type
certificate stamping. See Figure 5 for blade stamping. Blades stamped with this
change letter and life limit stamp are life limited to 16,000 flight hours. Blades
stamped with this change letter do not require inspection per Section I or Section II.

2. Some blades were released from the factory or stamped in the field with change letter
"A" but without the life limit stamping. These blades must be stamped at overhaul with
the life limit stamping. Life limit indicator "L" must be stamped under blade type
certificate number (see Figure 5).

3. When ALL FOUR blades in a propeller assembly are change letter "A". The change
letter "L" must be stamped following the model number stamping on the hub (see
Figure 6). This stamping indicates that ALL FOUR blades installed are stamped with
change letter "A". Compliance with Section I or Section II is not required.

4. Hubs with change letter "K" and prior must be restamped in the field when ALL FOUR
blades with change letter "A" are installed. Add change letter "L" to hub stamping (See
Figure 7).

5. Blades with no change letter stamping may be used in a propeller assembly with
change letter "A" blades. This hub will require the change letter "K". Since blade
change letter stamping is not visible, compliance with Section I or Section II is
required for ALL blades in this assembly.

6. New hubs are manufactured with the change letter "L" (see Figure 6). Hubs with the
change letter "L" must be restamped in the field when ANY ONE OR MORE blades
with no change letter are installed. Strike out "L" stamping and restamp hub with "K"
(See Figure 8).

7. If any blade without change letter "A" stamping is installed into a hub with change letter
"L". hub stamping must be changed to "K" and inspection requirements per Section I or
Section II are reinstated.

8. Refer to McCauley Blade Overhaul Manual BOM100-1 and Standard Practices Manual
SPM100-1 for blade inspection requirements at overhaul.
Page 14 of 17 Service Bulletin 234B

NOTE: Change letters may be stamped out of sequence in the field. For example, a
propeller hub stamped "L" in the field does not necessarily indicate that the "K"
change has been completed.

CAUTION: ALWAYS USE A ROUND BOTTOM STAMP WHEN STAMPING A BLADE OR

HUB.

WARNING: JETSTREAM SERIES 3200 AIRCRAFT MUST HAVE OPERATING PLACARD

PER BRITISH AEROSPACE SERVICE BULLETIN 61-JK-12170 INSTALLED.

CAUTION: VERIFY CORRECT HUB STAMPING PRIOR TO INSTALLING BLADES IN

PROPELLER. ONCE BLADES ARE INSTALLED, CHANGE LETTER
STAMPING WILL NOT BE VISIBLE.

NOTE: Blades stamped with change letter "A" are life limited to 16,000 flight hours.

Prior to installing blades in a hub, attention must be paid to the blade and hub change letters.
Blades with different change letters may be installed in the same hub and may require the hub
stamping to be modified. Stamp hub with correct change letter per Table 1.

CAUTION: IF ANY BLADE IN A PROPELLER ASSEMBLY HAS NO CHANGE LETTER

STAMPING THEN CORRECT HUB STAMPING IS "K". A MODIFICATION TO
HUB STAMPING MAY BE REQUIRED. COMPLIANCE WITH SECTION I OR
SECTION II IS MANDATORY FOR ALL BLADES IN ASSEMBLY.

WHEN ALL FOUR BLADES IN ASSEMBLY ARE CHANGE LETTER "A",

COMPLIANCE WITH SECTION I OR SECTION II IS NOT REQUIRED.

Blade Hub Correct Hub Compliance

Change Letter Change Letter Stamping with Section I
or Section II
Required

blank K or prior K Yes

blank L K Yes

"A"
on ALL four blades K or prior L No

"A"
on ALL four blades L L No

Table 1
Correct Hub Stamping
Service Bulletin 234B Page 15 of 17

LIFE LIMIT STAMPING

STAMPING NOT
PERMITTED WHERE
ACTUATING
PIN BASE SEATS

REF. CHANGE LETTER OF BLADE

BLADE DESIGN NUMBER

Figure 5
Blade Stamping

TYP. HUB STAMPING REF.

McCAULEY
SERIAL NO. [X][X][X][X][X][X]
MODEL NO. 4HFR34C653-L
T.C.P.3NE P.C.3

Figure 6
New Hub Stamping
Page 16 of 17 Service Bulletin 234B

TYP. HUB STAMPING REF.

McCAULEY
SERIAL [X][X][X][X][X][X]
MODEL NO. 4HFR34C653-GHL
T.C.P. 3NE P.C.3

Figure 7
Modified Hub Stamping

TYP. HUB STAMPING REF.

McCAULEY
SERIAL NO. [X][X][X][X][X][X]
MODEL NO. 4HFR34C653-L X K
T.C.P.3NE P.C.3

Figure 8
Modified Hub Stamping
Service Bulletin 234B Page 17 of 17
This form must be completed following initial and repetitive eddy current or dye penetrant inspection of propeller blades
per McCauley Service Bulletin 234B.

Contact McCauley immediately of any suspect findings.

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
USA

Telefax: (937) 890-6001

Telephone: 1-877-776-7435

Date of Initial Inspection:_________________ Date of Repetitive Inspection:

Propeller S/N:________________________Propeller Total Time:___________________

Propeller T.S.O.:__________________

Owner's
Name:______________________________________________________________________________________________________

Telephone:( )________________________________

Contact Person (if different than

owner):__________________________________________________________________________________

Telephone: ( )________________________________

Inspection Report (Please write detailed description of findings. If a crack was found, please write details of its length,
width, and location. Please sketch exact appearance of crack on blade detail drawing below):
___________________________________________________________________________________________________________________

____________________________________________________________________________________________________________________

____________________________________________________________________________________________________________________

____________________________________________________________________________________________________________________

LOCATION

Sketch Location of Any Cracks Found