Danny Ball

1
Danny Ball

• Design Engineering McCauley Propeller Systems

2
Product Improvements

• Single Piece Piston Rods
• C300 and C500 piston rods are currently a 2 piece
  brazed assembly
• SL2007-5 issued last year due to a faulty braze
  joint causing engine oil leakage into hub
• Single piece fully machined piston rod now in
  evaluation testing
• Production implementation in 2009

3
Product Improvements

• Constant Speed Cylinder Gasket Improvement
• New molded rubber gasket would eliminate the need
  for Permatex application
• Benefits
• Decreased assembly time/simplified installation
• More consistent cylinder screw torque holding
• Minimized chance of cylinder leakage
• Increased reliability
• Direct field replacement
• Limited release to the field is in work

4
Product Improvements

• Installation Examples
• Clean Surface Oil Residue Present

5
Product Improvements

• B-4746 Slot Blocks
• Ongoing issue with the bearing race loading slot
  block tabs being bent deformed
• Parts are being made from a stronger alloy, and
  will enter service when current stock is
  exhausted (1Q09)

6
Product Improvements

• Corrosion Resistance Improvements
• Currently evaluating the current Type I Cadmium
  plating of various hardware
• Engineering changes underway to change various
  fasteners to Type II for increased corrosion
  resistance
• Type II hardware will have a gold appearance vs.
  the silver finish of Type I plating

7
Product Improvements

• Deice Brush Material Change
• Current compound is being obsoleted for
  environmental reasons due to lead content
• Working with suppliers to develop/qualify a new
  material
• Current supply will last
• through 2009

8
Continued Airworthiness

• Jetstream 41 (C1101-C1104)
• Split retainer ends have made slight indentions
  on several of the cracked blade shanks
• Manufacturing will orient the split retainer ends
  approx. 90 from the counterweight hole
• SB255A has been sent to FAA for approval
• 3500 hour life limit, and wear limit
• Improved split retainers
• AD coming soon

9
Continued Airworthiness

• Jetstream 41 (C1101-C1104)
• Shelf wear limit

10
Product Improvements

• Threaded to Threadless
• Currently four TC packages approved by FAA that
  will provide a C200 series threaded propeller
  option for the following models
• Cessna 207 and T207
• Cessna A185EF
• Cessna 210D thru 210L and T210F thru T210L
• Cessna 206, P206, TU206, U206, and TP206
• Full TC approval and availability of Cessna
  service kits by the end 2008

11
Permatex Installation

• Permatex residue has been found in the blade
  o-ring groove, on the ID of the sockets, and on
  the o-ring.

12
Permatex Installation

• Old Gasket New Gasket
• Gasket changed to add cutouts for the bearing
  race loading slots.

13
Thank You!

• Questions/Comments