Airworthiness Directive

ID: AD/PHZL/74 Amdt 2
Issue date: 2012-03-09
Source: CASA


 PHZL-074.pdf

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Two Blade 'Y" Shank Aluminium Hub

COMMONWEALTH OF AUSTRALIA (Civil Aviation Safety Regulations 1998), PART 39.001(1)
CIVIL AVIATION SAFETY AUTHORITY
SCHEDULE OF AIRWORTHINESS DIRECTIVES



AIRWORTHINESS DIRECTIVE
On the effective date specified below, and for the reasons set out in the background section, the CASA delegate whose signature appears below revokes
Airworthiness Directive (AD) AD/PHZL/74 Amdt 1 and issues the following AD under subregulation 39.001(1) of CASR 1998. The AD requires that the action set
out in the requirement section (being action that the delegate considers necessary to correct the unsafe condition) be taken in relation to the aircraft or aeronautical
product mentioned in the applicability section: (a) in the circumstances mentioned in the requirement section; and (b) in accordance with the instructions set out in the
requirement section; and (c) at the time mentioned in the compliance section.


Propellers - Variable Pitch - Hartzell

AD/PHZL/74 Two Blade ‘Y” Shank Aluminium Hub 6/2012
Amdt 2

Applicability:
1. () HC- () 2Y()- () propellers (also known as Y-shank propellers) that have a hub
serial number with “A”, “E”, or no suffix, and installed on or previously
installed on:

a. Piper PA-32 series aircraft with Textron Lycoming 540 series engines that
are rated at 300HP or higher; or

b. Pilatus Britten Norman or Britten Norman BN-2 series aircraft (also known
as Islander or Trislander) with Textron Lycoming 540 series engines; or

c. Any aircraft certified in the aerobatic category; or

d. Any aircraft routinely exposed to aerobatic manoeuvres; or

e. Any aircraft that has been used for agricultural operations whilst the
applicable propeller was installed.

Note 1: This AD does not apply to propellers with the suffix letter “B” at the end of
the hub serial number.

Note 2: Incorporation of a “B” suffix hub will provide terminating action for this
Directive.

2. () HC- () 2Y()- () propellers S/N’s listed in Table 1:

Table 1. () HC- () 2Y()- () propellers with the following S/N’s

DN3607A DN3609A DN3613A DN3615A

DN3628A DN3630A DN3641A DN3940A

DN3944A DN3949A DN3962A




Page 1 of 4
COMMONWEALTH OF AUSTRALIA (Civil Aviation Safety Regulations 1998), PART 39.001(1)
CIVIL AVIATION SAFETY AUTHORITY
SCHEDULE OF AIRWORTHINESS DIRECTIVES

Propellers - Variable Pitch - Hartzell

AD/PHZL/74 Amdt 2 (continued)

Requirement:
1. Eddy Current Inspection:

a. No Suffix: For propeller hubs without any serial number suffix carry out an
Eddy Current Inspection (ECI) of the propeller hub fillet radius for cracks in
accordance with Hartzell SB HC-SB-61-227 Revision 5 dated September 28,
2006 or later FAA approved revision.

b. If no cracks are found then permanently mark the end of the hub serial
number with the suffix “E” in accordance with Hartzell SB HC-SB-61-227
Revision 5 dated September 28, 2006 or later FAA approved revision.

c. E Suffix: For propeller hubs with serial number suffix “E” carry out
repetitive Eddy Current Inspections (ECI) of the propeller hub fillet radius
for cracks in accordance with Hartzell SB HC-SB-61-227 Revision 5 dated
September 28, 2006 or later FAA approved revision.

d. Table 1: For propeller hubs with a serial number hub listed in Table 1 carry
out initial and repetitive ECI as per Hartzell SB HC-SB-61-227 Revision 5
dated September 28, 2006 or later FAA approved revision.

e. Propeller hubs that are cracked are to be replaced prior to further flight.

2. Hub Replacement:

a. A Suffix: “A” suffix hubs not listed by serial number in Table 1 shall be
removed from service in accordance with Hartzell SB HC-SB-61-227
Revision 5 dated September 28, 2006 or later FAA approved revision.

b. Table 1: All hubs listed by serial number in Table 1 shall be removed from
service in accordance with Hartzell SB HC-SB-61-227 Revision 5 dated
September 28, 2006 or later FAA approved revision.

Propeller hubs removed from service as a result of this Directive shall have the hub
serial number and type certificate number permanently removed.

Previous credit is allowed for inspections, rework, and replacements that were done
using the preceding revisions of Hartzell Propeller Inc. SB No. HC-SB-61-227,
before the effective date of this AD.

Note 3: FAA AD 2001-23-08 Amdt 39-12505 refers.

Later revisions to Hartzell Propeller Inc. SB No. HC-SB-61-227, Revision 2, dated
May 8, 2000, approved by the United States Federal Aviation Administration (FAA)
as an Alternative Method of Compliance (AMOC) to FAA 2001-23-08 Amdt
39-12505, are considered acceptable for compliance with the equivalent
Requirements of this AD.



Page 2 of 4
COMMONWEALTH OF AUSTRALIA (Civil Aviation Safety Regulations 1998), PART 39.001(1)
CIVIL AVIATION SAFETY AUTHORITY
SCHEDULE OF AIRWORTHINESS DIRECTIVES

Propellers - Variable Pitch - Hartzell

AD/PHZL/74 Amdt 2 (continued)

Compliance:
1. Eddy Current Inspection:

a. No Suffix: Unless previously carried out; within 50 propeller hours Time In
Service (TIS) from the effective date of this Directive.

b. E Suffix: At intervals not to exceed 100 propeller hours TIS from the last
ECI.

c. Table 1: Unless previously carried out within 50 propeller hours TIS, and
thereafter at intervals not to exceed 100 hours from the last ECI.

2. Hub Replacement:

a. A Suffix: Propellers with the suffix “A” at the end of the hub serial number
excluding those S/N’s listed in Table 1 of applicability, are to be replaced as
follows:

i. PA-32 and BN-2 series aircraft; at next propeller overhaul but no later
than 2000 hours propeller TIS or 31 December 2005, whichever comes
first.

ii. Aircraft certified in the aerobatic category or aircraft routinely exposed
to aerobatic manoeuvres; at next propeller overhaul but not to exceed
1000 propeller hours TIS or 31 December 2005, whichever comes first.
For propeller hubs exceeding 1000 hours time in service as of the
original effective date of this Directive, remove from service within 15
propeller hours TIS.

iii. Agricultural aircraft; at next propeller overhaul, but not to exceed 2000
hours propeller TIS or 31 December 2005, whichever comes first.

b. Table 1: At next propeller overhaul but not to exceed 1000 hours propeller
TIS or 31 December 2005, whichever comes first. For propeller hubs
exceeding 1000 hours TIS as of the original effective date of this Directive,
remove from service within 15 hours propeller TIS.

Note 4: Installation of the “B” serial number suffix hub will require spinner
bulkhead modification per Hartzell Manual 113B or Hartzell Manual 117D
dependant on propeller type.

This Amendment becomes effective on 13 March 2012.




Page 3 of 4
COMMONWEALTH OF AUSTRALIA (Civil Aviation Safety Regulations 1998), PART 39.001(1)
CIVIL AVIATION SAFETY AUTHORITY
SCHEDULE OF AIRWORTHINESS DIRECTIVES

Propellers - Variable Pitch - Hartzell

AD/PHZL/74 Amdt 2 (continued)

Background:
There have been incidents of hub cracks in Hartzell two blade "compact" aluminum
hub propellers. Existing methods using visual inspection has proven to be
unsuccessful in detecting cracks. There have now been cases of blade separation.
ECI is now considered the only reliable method for detecting cracks. Cracks typically
initiate at the same point on the hub. The cracks originate in the hub at a point
adjacent to the blade called the "fillet radius". As the cracks propagate toward the
centre of the hub, their progression accelerates and results in failure of one hub half,
which can then potentially, progress to blade separation.

The original issue of this Airworthiness Directive became effective on 16 May 2002.

Amendment 1 introduced a change to include aircraft that can be routinely exposed to
aerobatic maneuvers.

Amendment 2 harmonizes the repetitive inspection interval with the latest revision of
the manufacturers service bulletin which is approved as an AMOC with FAA AD
2001-23-08.




Mike Higgins
Delegate of the Civil Aviation Safety Authority

9 March 2012




Page 4 of 4

This is a partial extract of the full document - please refer to the actual report for full information.
Sources as credited.