AD 2009-19-04 Airworthiness Directives; McCauley Propeller Systems Propeller Models B5JFR36C1101/114GCA-0, C5JFR36C1102/L114GCA-0, B5JFR36C1103/114HCA-0, and C5JFR36C1104/L114HCA-0

Makes named: mccauley. Models named: 4100, 4101 series. Read the applicability below — it usually turns on serial or part numbers too.

This AD applies to McCauley Propeller Systems propeller models B5JFR36C1101/114GCA-0, C5JFR36C1102/L114GCA-0, B5JFR36C1103/114HCA-0, and C5JFR36C1104/L114HCA-0. These propellers are installed on, but not limited to, BAE Systems (Operations) Limited Jetstream Model 4100 and 4101 series airplanes (Jetstream 41).

You are responsible for having the actions required by this AD performed within the compliance times specified unless the actions have already been done. Life Limit (f) For propeller blades with more than 10,000 operating hours time-since-new (TSN) on the effective date of this AD, remove the propeller blades from service before further flight. These propeller blades are prohibited from installation in any configuration on any airframe. (g) For propeller blades with more than 3,000 operating hours TSN on the effective date of this AD, remove the propeller blades from service within the next 500 operating hours, not to exceed 10,000 operating hours TSN. These propeller blades are prohibited from installation in any configuration on any airframe. (h) For propeller blades with 3,000 or fewer operating hours TSN on the effective date of this AD, remove the propeller blades from service at or before reaching 3,500 operating hours TSN. These propeller blades are prohibited from installation in any configuration on any airframe. Removal From Service of Propeller Blades and Hubs From Propeller Assemblies That Have Had One or More Cracked Propeller Blades (i) Before further flight, remove the propeller blades and the hubs listed in Table 1 of this AD from service. The propeller blades and hubs listed in Table 1 are prohibited from installation in any configuration on any airframe. (j) Before further flight, remove from service any propeller blades and hubs found or documented to have been installed in any propeller assembly that has had one or more cracked propeller blades at any time. Propeller blades and the propeller hub of a propeller assembly that has had one or more cracked propeller blades are prohibited from installation in any configuration on any airframe. Table 1—Propeller Blade and Hub Serial Numbers Requiring Removal From Service Before Further Flight and Are Prohibited from Installation in Any Configuration on Any Airframe Hub Serial No. Blade Serial No. 023062 XH31043, XH31131, XE31002, XH31025, XI31014 040296 YA31058, YA31055, YB31084, YB31088, YB31090 041016 XB31009, XA31073, XA31071, XA31063, WK31013 051193 XH31018, XH31077, XH31081, XL31008, XL31043 040282 XG31015, XG31016, XH31113, XH31117, XI31017 051204 XI31049, XH31140, XH31129, XH31084, XH31074 051194 WF31010, WD31032, WF31002, WF31029, WF31078 Propeller Blade Inspection (k) Perform a fluorescent penetrant inspection and eddy current inspection of the propeller blades, and a visual inspection for a “step condition” of the blade shank. Use the Equipment Required and Accomplishment Instructions of McCauley Propellers Alert Service Bulletin (ASB) No. ASB255A, dated October 6, 2008, and the compliance schedule in Table 2 of this AD: Table 2—Inspection Compliance Schedule If on the effective date of this AD, the propeller blade: Then inspect the propeller blade: (1) Has more than 2,400 operating hours TSN, time-since-last inspection (TSLI), or time-since-overhaul (TSO) and has been inspected using AD 2008-08-01 or McCauley Propellers ASB No. ASB255, dated January 8, 2007 within the past 2,400 operating hours Upon reaching 2,500 operating hours TSLI. See TSLI definition paragraph (p) of this AD. (2) Has more than 2,400 operating hours TSN, TSLI, or TSO and has not been inspected using AD 2008-08-01 or McCauley Propellers ASB No. ASB255, dated January 8, 2007 within the past 2,400 operating hours Within the next 100 operating hours time-in-service. (3) Has 2,400 or fewer operating hours TSN, TSLI, or TSO Upon reaching 2,500 operating hours TSN, TSLI, or TSO. Propellers Failing Blade Inspection (l) Remove from service all of the propeller blades, and the propeller hub, if one or more propeller blades are found cracked on a propeller assembly. Propeller blades and the propeller hub of a propeller assembly that has had one or more cracked propeller blades are prohibited from installation in any configuration on any airframe. (m) Remove from service all propeller blades that exhibit a blade shank “step condition” of 0.005-inch or greater. Blades removed from service are prohibited from installation in any configuration on any airframe. Removal of C-5963 Split Retainers From Service (n) Remove from service all C-5963 split retainers at the time of blade inspection specified in paragraph (k) of this AD. C-5963 split retainers removed from service are prohibited from installation in any configuration on any airframe. (o) After the effective date of this AD, do not install propeller assemblies with C-5963 split retainers on any airframe. Definition (p) For the purpose of this AD, TSLI refers only to inspections performed using AD 2008-08-01 or McCauley ASB No. ASB255, dated January 8, 2007. Reporting Requirements (q) Within 10 calendar days of the inspection, use the Reporting Form in McCauley ASB No. ASB255A, to report all inspection findings to the FAA, Wichita Aircraft Certification Office, 1801 Airport Road, Room 100, Wichita, KS 67209, Attention: Jeff Janusz; telephone (316) 946-4148; fax (316) 946-4107; e-mail: jeff.janusz@faa.gov. (r) Include any photographs, and any other information related to the means of detection of the crack, and the history of the propeller and blades. (s) The Office of Management and Budget (OMB) has approved the reporting requirements and assigned OMB control number 2120-0056. Alternative Methods of

This AD results from eight reports of propeller blades found cracked since May of 2006. We are issuing this AD to detect cracks in the propeller blade that could cause failure and separation of the propeller blade and loss of control of the airplane.