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ATP GRID INDEX TO MANUFACTURER’S PUBLICATION:

HAMILTON STANDARD
ALUMINUM BLADES
MAINTENANCE MANUAL

SECTION TOPIC

GENERAL INFORMATION

TITLE PAGE
WARN I NG
LIST OF CHAPTERS (TABLE OF CONTENTS)
RECORD OF REVISIONS
RECORD OF TEMPORARY REVISIONS
LIST OF EFFECTIVE PAGES
SERVICE BULLETIN LIST

01 INTRODUCTION
02 MAINTENAMCE INSTRUCTIONS

END OF INDEX

03/06/96 Copyright (c)1996 Aircraft Technical Publishers PAGE: 1

(RCR2102) (HM 0100 MM)
IVIFGI

INTRO
 P5072

IHAIN’TEIVANCE INSTRUCrlOCIIS

ALU NIINU nn ALesu

PROPELLER BLADES

TECHNICALLY APPROVED BY

FAA DESIGNATED ENGINEERING REPRESENTATIVE

nunlnourrnruslo&
Divsand

UIICW
T6CWUOUKillS.

October 1~, 1978

 O"i"d
HIUIIIILTON STdWDARtb

WARNING

OTHER MANUFACTURER’S PRODUCTS USED fN COMPLY[NG WITH

THIS MANUAL SHOULD BE INVESTIGATED TO DETERMINE
WHETHER THEY WAVE ANY HAZARDOUS QUALITIES, RECIPIENTS

OF THIS MANUAL ARE WARNED TD OBSERVE ANY APPLICABLE

INSTRUCTIONS PERTAINING TO TWE USE OF ANOTHER MANU--
FACTURER’S’PRODUCT, WHOSE. INSTRUCTIONS MAY APPEAR ON
THE CONTAINER THEREOF, OR ANY ACCOMPANYING LITERATURE
PERTAINING THERETO. FAILURE. TO OBSERVE APPLICABLE
INSTRUCTIONS REGARDING OTHER MANUFACTURER’S PRODUCTS
HAVING HAZARDOUS QUALlflES COULD RESULT TN SOME CASES
1N INJURY rO TtlE USER ANI~ZOR IMPROPER OVERHAUL. THE RE-
FORE, TME APPLICABLE IN~TRUCTIONS PERTAINING TO THE CISE
OF ANOTHER MANUFACTURER’S PRODUCT SHOULD BE CONSULTED
tN EACH CASE TO DETERMINE THE CONSEQUENCES OF MISUSING.
SUCH PRODUCTS.
 RECORD OF REVISIONS

MFG RN
NO DESCRIPTION ISSUE DATE ATP REV DATEI INSERTED BY
 HAMILTON SCANDARD av-nd

RECORD OF REVISIONS

REV ISSVE DATE REV ISSVE DATE REV ISSUE DATE

BY BY Bv
NO.I DATE INSERTED NO. DATE INSERTED NO´• DATE INSERTED

P5072
Oct 15/78 1
Page
 RECORD OF TEMPORARY REVISIONS

ATP REV INSERT DATE REV REMOVE

RE/ NO DESCRIPTION ISSUE DATE DATE BY REMOVED INCOR BY
 HAMILTON STANDARD
~UEIITED
TECHWOUK;IES

RECORD OF TEMPORARY REVISIONS

T EM FOR AR Y I PAGE ISSUE DATE

BY BY
I DATE I I REMOVED
REV. NO. NUMBER

Oct 15/78 P5072

Page 1
 n~melron STANDARB

TABLE OF CONTENTS

S Page

I INTRODUCTION 1-1

1-1. General .........................i..............

1-1
1-4. Blade Description ..........,i´•´•´•´•´•´•´•´•´•´•´•´•´•´•´•´•´•´•´•´•´•
1-1
1-7´• Blade Designation 1-2

II lMAINTENANCE INSTRUCTIONS 2-1

2-1. General 2-1

2-8. Unusual Incident Overspeeds 2-2
2-9. Non-Surface-Treated Blades 2-2
2-10. Surface-Treated and Nickel-Plated Blades 2-2
2-11. Turbo-Propeller Surface-Treated Blades 2-4
2-12. Unusual Incident Impact 2-4
2-13. Surface Tr´•eated Blades 2-4
2-16. Non-Surface Treated Blades 2-7
2-17. Nickel Plated Blades 2-8
2-19, Blade Track 2-8
2-20. Cleaning 2-8
2-22. Inspection 2-9
2-25. Specific Inspection Procedures 2-9
2-27. Dye Penetrant Inspection 2-9
2-29. Blade Alignment Gages 2-10
2-31. Lightning Strikes 2-13
2-32. Blade Deicer Heater, Fairing, Feed Shoe and
Trough Inspection 2-13
2-33. Daily Maintenance 2-16
2-40. 75-120 Hours Maintenance 2-18
2-41. Repair Procedures 2-18
2-42. Blade Surface 2-18
2-43. Local Reworks in Shotpeened Airfoil Section 2-22
2-45. Local Peening of
Repaired Areas. 2-24
2-50. Operation of Peening Hammer 2-25
2-51. Care of Peening Hammer 2-26
2-52. Preparation 2-26
2-53´• Procedure 2-26
2-55. Inspection of Reworked Areas 2-27
2-57. Removal of Blade Heaters, Deicer Feed Shoes and
Troughs from Non-Fairing-Type Blades....,...... 2-28

Oct 15/78 P5072

 HAMILTOW STAWDARQ

TABLE OF CONTENTS (Cont)

Section Page

II 2-58A. Removal of Blade Heaters for Fairing-Type Blades.... 2-28

2-59. Repair of Blade Deicer Heaters, Deicer Feed Shoes,
and Troughs 2-29
2-61. Deicing Feed Shoe and Conductive Rubber Heaters..... 2-31
2-62. Repair of Blade Fairing, Boot, and Heater 2-31
2-62D. Blade Heater Element Repair 2-33
2-623. Alternate Blade Heater Repair ..............,c.,... 2-35
2-63. Blade Heater Installation, Non-Fairing Type Blades 2-36
2-64. Installation of Deicer Feed Shoes and Troughs 2-38
2-65´• Deleted 2-42
2-66. Abrasion Strip Installation 2-43
2-68. Turbo Propeller Blades A7109C-2 and A7111C-2. 2-44
2-72. Blade Repair -Turbo-Propeller Blades ......i....... 2-46
2-77. Blade Fairing Repair Turbo-Propeller Blades 2-49
2-78. Damaged Blade Slip Rings 2-51
2-80. Nickel Plated Aluminum Alloy Blades 2-51
2-82. Inspection 2-51
2-84. Daily Inspection. 2-51
2-85. 75-120 Hours Inspection .......,......t´•´•´•´•´•´•´•´•´•´•´•
2-52
2-87, Repair Procedures 2-52

P5072
Oct 15/78 ii
 HAmalroN STANDARQ
~kP ~p

LIST OF ILLUSTRATIONS

Number Title Page

1-1. Blade Nomenclature Diagram 1-6

2-1, Measuring Damage Depth 2-10

2-2. Use of Blade Alignment Gage 2-11
2-3. Typical Blade Alignment Gage Installation Non-Fairing
Typ, Blades 2-12
2-4. Typical BladeAlignment Gage Installation Fairing
Type Blades 2-12
2-4A. Rubber Parts Area ~Codes.; 2-15
2-5, Rework of Leading Edge 2-17
2-6, Damage Requiring No Rework Non-Surface Treated and
Surface Treated Blades, Piston Engine Type............... 2-18
2-7. Airfoil Local Repair Limits Non-Surface Treated and
Surface Treated Blades Piston Engine Type 2-20
2-8, Typical Nicks and Methods of Removal 2-21
2-9, Damage Rework.- Dimensions 2-21
2-10, Abrasion Before Rework 2-23
2-11, Filing Tool Application 2-23
2-12, Emery Cloth Application 2-23
2-13, Abrasion Area after Rework 2-23
2-14, Using HSP 3293 Power Driven Hammer 2-24
2-15, Manual Peening Repair Area 2-24
2-16. Dimensions of Manual Peening Hammer 2-24
2-17, Steps in Local Manual Peening 2-27
2-17A. Heater Wire Repair Limit 2-34
2-18, Repair of Conductive Rubber Type Heaters 2-36
2-19, Radial Location of Heater 2-37
2-20, Longitudinal Location of Heater and Cam Mount 2-37
2-21, Radial Location of Feed Shoe and
Trough 2-41
2-22, Longitudinal Location of Feed Shoe and Trough 2-41
2-23, ~amage Requiring No Rework Turbo-Prop Blades 2-48
2-24,’ Local Rework Limits on Leading and Trailing Edges
Turbo-Propeller Blades 2-48
2-25. Local Reworks on Face and Camber Sides Turbo Propeller
Blades 2-49

Oct 15/78 P5072

iii
 HAMILTON ST~NDARQ D"""

...._’";
?aRe ~EcnCroun;lEs.

LIST OF TABLES

Number

I Blade Terms 1-3

II Damage Definitions 1-5
III´• Maintenance Tools 1-7
IV Cement and Sealer Data 1-8
IVA Consumable Materials 1-10
V Report Covering Overspeeding Piston Engine Type Blades 2-3
VI Report Covering Overspeeds Turbo-Propellers 2-5
VII Report Covering Impact Damage Non-Surface Treated
and Surface-Treated Blades i..... 2-6
vm Blade Track 2-8
IX Blade Heater Location 2-38
X Feed Shoe and Trough Location 2-40
XI Nickel Plating %nd Seal Location 2-54
KII Blade Heater Resistance Data 2-55

Oct15/78 P5072
iv
 HAmlrrow srAwDn~D

LIST OF EFFECTIVE PAGES

Subj ect Page Date Subj ect Page Date

Title Oct 15/78 Section II- 2-5 Oct 15/78

(Continued) 2-6 Oct 15/78
Record of
2-7 Oct 15/78
Revisions 1 Oct 15/78
2-8 Oct 15/78
2 Blank
2-9 Oct 15/78
Record.of 1 Oct 15/78 2-10 Oct 15/78
Temporary Revisions 2 Blank 2-11 Oct 15/78
2-12 Oct 15/78
List of Effective 1 Oct 15/78
2-13 Oct 15/78
Pages 2 Oct 15/78
2-14 Oct 15/78
2-15 Oct 15/78
Service Bulletin 1 Oct 15/78
2-16 Oct 15/78
List 2 Blank
2-17 Oct 15/78
2-18 Oct 15/78
Table of Contents i Oct 15/78
2-19 Oct 15/78
ii Oct 15/78
2-20 Oct 15/78
List of Illustrations iii Oct 15/78 2-21 Oct 15/78
2-22 Oct 15/78
List of Tables iv Oct 15/78
2-23 Oct 15/78
Section I- 2-24 Oct 15/78
Introduction 1-1 Oct 15/78 2-2~ Oct 15/78
1-2 Oct 15/78 2-26 Oct 15/78
1-3 Oct 15/78 2-27 Oct 15/78
1-4 Oct 15/78 2-28 Oct 15/78
1-5 Oct 15/78 2-29 Oct 15/78
1-6 Oct 15/78 2-30 Oct 15/78
1-7 Oct 15/78 2-31 dct 15/78
1-8 Oct 15/78 2-32 Oct 15/78
1-9 Oct 15/78 2-32 Oct 15/78
1-10 Oct 15/78 2-33 Oct 15/78
1-11 Oct 15/78 2-34 Oct 15/78
1-12 Oct 15/78 2-35 Oct 15/78
2-36 Oct 15/78
Section II-
2-37 Oct15/78
Maintenance Instruc- 2-1 Oct 15/78
2-38 Oct 15/78
tions 2-2 Oct 15/78
2-39 Oct 15/78
2-3 Oct 15/78
2-40 Oct 15/78
2-4 Oct 15/78

Oct 15/78 P5072

 HAMILTOW
STAWDARBrrcnmworsa\nsion

_Subj_ect Page Date Subj ect Page Date

Section II- 2-41 Oct 15/78

(Continued) 2-42 Oct 15/78
2-43 Oct 15/78
2-44 Oct 15/78
2-45 Oct 15/78
2-46 Oct 15/78
2-47 Oct 15/78
2-48 Oct 15/78
2-49 Oct 15/78
2-50 Oct 15/78
2-51 Oct 15/78
2-52 Oct 15/78
2-53 Oct 15/78
2-54 Oct 15/78
2-55 Oct 15/78
2-56 Blank

Oct 15/78 P5072

 STAII~RD
UWITED
TsCHnnLnnlss.

SERVICE LIST

Revision No. Incorporation Date

Service BuZlet~nNo.

P5072
Oct 15/78 1
Page
 HAMILTON DIYIYOTld

~Rle ~ECnlYWOGIES.

SECTION I

INTRODUCTION

1-1. GENERAL

1-2. The purpose of this manual is to outline essential details pertaining to in-
spection and maincenance of Hamilton Standard aluminum alloy propeller blades to
assure the user of maximum service and dependability. These blades are manu-
factured by the Hamilton Standard Division, United Technologies, Windsor Locks,
CT. 06096, U. S.A.

1-3. The instruction cover in detail the precautions which shall be taken and the
maintenance procedures which are applicable between overhaul periods.

1-4. BLADE DESCRIKTION.

1_5. The complete blade assembly includes the basic blade assembly and all
attached parts particular to the blade, such as, fairing, blade cam, slip ring mount,
electric or fluid deicing parts, and abrasion strip. The basic blade consists of the
blade, beveled and flat thrust washers, (only a beveled washer on some blades),
balancing plug in the taper bore of the blade, blade bushing and its drive pins and
screws, thrust bearing assembly, teflon strip, and in some cases, a chafing ring.
Some blades have nickel plated airfoil surfaces which prolongs the surface life of
the blade because of the resistance of the nickel plating to erosion caused by water

spray, sand and grit, etc.

1-6. The following parts are used in various combinations of blades according to
installational´• needs and characteristics.

a. FAIRINGS. The molded

plastic fairings used on the particular blades
covered in this manual replaceable only at overhaul. However, line mainten-
are

ance may be accomplished. The fairing on reciprocating engine installations aids

in cooling the engine and on turbo-propeller installations, smooths the airflow into
the engine air inlet.

b. CAM MOUNT AND SLIP RING MOUNT. synthetic´•rubber cam mount is

A
cemented to the shanks of some provide a mounting surface for the blade
blades to
cams. These cams complete or terminate an electrical circuit in the propeller
system of operation. On other blades, a similar mount is provided for the instal-
lation of a blade heater electrical contact ring or slip ring.

Oct 15/78 P5072

1-1
 HAmllrow sia~DARe [h"Sx7nUf

rrcnwotocrs,,

c. DEICER FEED SHOE AND TROUGH. Some blade assemblies have a fluid
deicing system to prevent ice formation on the blades. A deicer trough is cemented
to the shank of the blade to receive the deicing fluid from the nozzle assembly on
the propeller barrel and directs it to the feed shoe or, in some cases, the bare
blade. The feed shoe is neoprene pad cemented to the leading edge of the
groved
blade and distributes the deicer fluid along the surface of the blade leading edge.

d. ELECTRIC DEICER BLADE HEATER AND CONNECTOR ASSEMBLY. The

electric heater type deicer consists of a neoprene rubber pad adhered to the exter-
nal surface of the blade leading edge. It covers about 60 percent of the bladelength.
The heater ccinsists of electrically conductive rubber strips or wire elements
Spaced to provide proper watt density. Electricial energy is converted to heat en-

ergy by the heater. The connector, part of some heaters, contains the leads to
the heater element, and it and the heater are molded into a single unit.

e. ABRASION STRIP. A synthetic rubber abrasion strip is installed over the

heater pad protect
to it from normal abrasive wear. The strip is cemented over

the leading edge of the heater along its outer portion.

f. plated blades are furnished with a nickel plate end seal (rubber
Nickel
sleeve which provides protectidn from contaminants and corrosion in the nickel
plate ending area.

1-7. BLAIjE DESIGNATION. Blades are identified by the blade assembly num-
ber and change letter stamped on the damber side of the blade parallel to the long-
itudinal axis. As an example, on a blade designated as "A7111C-2", the numbers
and letters incicate the following:

a. The first letter "A" indicates a~malded fairing has been a~ded over the

blade sharik.

b. The ni~mber "7111’’ indicates the basic blade design. A design number

"6801" and higher indicates that the blade has been subjected to some form of sur-

face treatment.

c. 7i11A indicates that the blade has a teflon strip adhered to the blade in the
area of the blade seal to prevent wear ~on the blade shank in this area.

d. The letter "C" indicates the bl~de has an electrical contact ring holder,

spinner seal, blade heater,and abrasion strip. This letter will change to indicate
the various combinations of parts attached to the blade.

Oct 15/78 P5072

1-2
 HAMILTON STd~NDAFaB D"IYalo(

IrlCr rrCn#OUK;IES.

e. The dash number indicates the number of inches the propeller diameter is
reduced from the basic propeller design. In this case the "-2" indicates the pro-
peller diameter has been reduced two inches tone inch from each blade).

1-8. Aluminum propeller blades shall beinspected at least once

every 18 months.
Service experience has shown that under certain conditions, low utilization of
blades results in extreme calendar time lengths between overhauls. Under this

circumstance, the blade taper bore and shank area may become corroded. There-
fore, damage to the blade will be minimized by inspection and overhaul if necessary
at least every 18 months or less.

1-9. See Tables I, II, and Figure 1-1 for~listing of blade terms used throughout
this manual. Table III lists maintenance tool required. Table IV lists cements
and sealing compounds used in blade maintenance.

TABLE I

BLADE TERMS

Tacky The condition of the final coats of cement before

mating parts are placed~in apposition. This stage is
is determined by placing the knuckles against the
partially dried cement surfaces. When the cement
adheres to the In~uckles but return to the cemented
surface on withdrawal of the la~uckles, the cement is
said to be tadky.

Airfoil Section That portion of the blade from the first blade station
to the blade tip.

Blade Alignment A measurement of the blade tip alignment relative to

the three fixed’reference support feet for positioning
the blade alignment gage.

Blade Reference Station A specific station for checking blade angles. Blades
having a basic diameter of less than 7. 5 feet use the
36 inches station. Blades haveing a basic diameter
of 14 feet or less use 42 inches station while blades
with a basic diameter greater than 14 feet use the 72
inches station. The station is indicated on the blade
face by a short yellow line.

Oct 15/78 P5072

1-3
 HAMILTON STANDARQ OM""

TABLE I(CONT)

BLADE TERP~S

Camber Side That side of the blade normally toward the direction
of flight. The camber side has a greater curve in
contour than the face side.

Face Alignment The dimension from a plane through the center line of
the blade paralled to the chord line to the highest
point onthe face side of the blade cross section at the
various’stations. On blades which have a concave

face, this measurement is taken from the intersection

of a plane through the center line parallel to the cord
line and a plane through the center line perpendicular

to the chorde line to the face side.

Face Side The thrust side of the blade normally apposite the
direction of flight. The face is less curved than the
camber side and on some blades may be concave or

flat.

Stations Locations perpendicular to the blade center line at

which dimensions are checked. They are usually
spaced at six-inch intervals.

Surface Treated Blades tvhich have the inboard

portion of the airfoil
section shotpeened and/or shank region cold rolled.

Thickness The maximum dimension of a blade cross section

measured perpendicularly to the chord at the respec-
tive blade stations.

Tip The portion of the blade outermost from the axis of

propeller rotation.

Oct 15/78 P5072

1-4
 HARIIILTON STAI~DARB """d

uwmD
~II* rrcnmnoclEs.

TABLE ii

DAMAGE

Blistering Separation and rising of a plated, painted, or adhered

surface from its base.

Burning Surface damage caused by excessive heat and evidenced

by discoloration, loss or flow of metal in severe cases.
May be caused by such action as lightning or shorting
ofthe blade heater.

Corrosion A result of chemical attack and breakdown of surface

areas.

Crack A material fracture either visually perceived or

revealed by caustic soda etch or similar inspection.

Erosion Metal removed by action of water or abrasives such as

sand, grit, etc.

Lightning Strikes Usually manifested by localized burning, discoloration,

puddled metal, and pits.

Fitting Small irregularly shaped cavities from which material

has been removed by erosion or corrosion. Corrosive

pitting is usually accompanied by a deposit formed by

the corrosive agent on the base metal.

Scoring~ Deep scratches or elongated gouges made by the sharp

edges of foreign material.

Scratches Narrow shallow marks lesser than a gouge, caused by

the contact of a sharp object across a surface.

Oct 15/78 P5072

1-5
 HAMILTON STANDARQ
~I

BLADE PLAN FORM

BL’ADE AIRFOIL SECTION

A. Leading Edge
B. Trailing Edge
C. Face Side
D. Camber Side
E. Tip
F. Butt
i;. Bu~t ~ace
Ii. Butt O. D.
I. Taper Bore
J. Center Line
K. Fillet
L. Shank Portion

Figure 1-1. Blade Nomenclature Diagram

Oct 15/78 P5072

1-6
 HAMILTON STAWDARD
~1* ~OCnm)LDGIE5,

TABLE III

MAINTENANCE TOOLS

TOOL NO. NOMENCLATURE APPLICATION

HSP 1297 Peening Hammer Used forlocal peening of

reworked areas in

shot-peened section of
blade.

HSP 1827 Blade Checking Indicator To check local damage

depths in blade surfaces.

Standard Ohmmeter. (Multi-range 0-5000/ Used to check heater

0-50,000/0-50,000,000) resistance.

Simpson Model 372

Ohmmeter or equivalent

Die Maker Riffler Files "0" cut, #10 and #17 For reworking airfoil
113"cut, #8, #10, #18 section of blade.

Die Sinker Riffler Files "3" cut, #11, and #16 For reworking airfoil
section of blade.

Electric Hand Grinder Used with abrasive wheel

in rework of blade

damage.

Abrasive Wheel A80D2RR Used with hand grinder

during rework of blade.

Magnifying Glass 5X-10X Used during inspection

of blades.

HS 8150 Blade Alignment Gage 6895E-8

6895E-12
6921G-8

Oct 15/78 P5072

1-7
 HAMILTON

TABLE III (CONT)

MAINTENANCE TOOLS

TOOL NO. NOMENCLATURE APPLICATION

HS’ 8250 Blade Alignment Gage 7019C-2

6901-0
6959D-0

HS 8350 Blade Alignment Gage 6993-4

HS 8550 Blade Alignment Gage 6903-24

A7109C-2
A7111C-2

TABLE IV

CEMENT AND SEALER DATA

MATERIAL DESCRIPTION TBMNER DRYING TIME"" REMARKS

Bostik 1007 Buna N rubber None 1 hour min. Used as received

cement

sostik 1096 Cement None 2 hours min. Consists by weight

of 7 parts Bostik
1096 adhesive and
1 part "Boscodur
#9 accelerator

EC 1300 Adhesive None 8 to 12 Use as received

minutes

EC 801 Sealer Methyl 1.5 hour min. Consists by weight

Ethyl 4 parts EC 801and
Ketone +1 part EC 807

EC 776, Resin Cement Methyl 45 minutes Thin to brushing

a

EC 807 Ethyl consistency

Ketone

P5072
Oct 15/78 1-8
 HAMILTON STANDARD
uNmD
TECnm)LDCIES

TABLE TV (CONT)

CEMENT AND SEALER DATA

MATERIAL DESCRIKTION THINNER DRYING TIME’F" REMARKS

EC 678 Synthetic Resin Methyl 1 hour min. Thin with toluol to

Coating Ethyl a brushing
Ketone consistency

Black Epon Epoxy Resin None 10 hours at Consists by weight

Cement room tem- 85 parts Epon 834
perature for 25 parts Epon 562
surface 10 parts of
treated blades "Allylglycidal ether
3-5 parts lamp
black
*6 parts diethy-
lenetriamene
+7 parts triethyl-
amine

F88 Filler None 1 hour min. 2 parts by weight

F-88CPP (powder)
1part by weight
F-88 CPL(licluid)

Cycleweld C-14 Resin None 1 hour min. by weight:

100 parts C-14A
"7 parts C-14B

Neoprene Patch Locally made from

Abrasion Strip
83643

These parts are skin sensitizers. Avoid contact with skin and eyes.

Drying times are based on 68degrees Fahrenheit at 70 percent humidity.

Variance of these conditions will alter cement drying time accordingly.

Oct 15/78 P5072

1-9
 ~UUHILTOW STANDARD
U1IITED
TECnlWKOGI~S

TABLE TVA
CONSUMABLE MATERIALS

COMMERCIAL REFERENCE
MATERIAL PRODUCT SOURCE SPE CIFICATION

Abrasive Cleaner Ajar, Old Dutch,or Gibson

Cleanser (Commercial available)

Adhesive EC 1300
Minnesota Mining Mig. Co.
St. Paul,~MN 55101

Adhesive Shell Chemical Co.

Div. of Shell Oil Co.,
P. O. Box 2463
Houston, TX 77001

Adhesiire Shell Chemical Co.

My. of Shell ´•Oil Co.,
P. O. Box 2463
Houston, TX 77001

Adhesive and Bostik 1096 and Boscodur #9

Curing Agent Bostik Di~ision of USM Corp.
Boston Street

Middleton, MA 01949

Adhesive and Bostik 1125 and Boscodur #29 MIL-A-5540

Curing Agent Bostik Division of USM Corp.

Boston Street
Middleton, MA 01949

Bonding Primer Bostik 1007 (formerly BB1007)

Bostik Division of USM Corp.
Boston Street

Middleton, MA 01949

Oct 15/78 P5072

1-10
 HAMILTON STAPSDABQ
L~mrrr,
TECn)lOUK;IES

TABLE rVA (CONT)

CONSUMABLE MATERIALS

COMMERCIAL REFERENCE
MATERIAL PRODUCT SOURCE SPE CIFICATION

Clear Polyureth~Lre LAMINAR X 500 7-C-1

Resin 10-C-32 Hardener
Midland Division
The Dexter Corporation
31500 Hayman Street
Hayward, C~A 94544

Electroplating Tape 3M Electroplating tape

(Scotch 470)
Minnesota Mining Mig. Co.
St. Paul, MN 55101

Emery Cloth Emery Grit 180, 240 320

Norton Company

Worcester, MA 01606

Filler CAB-O-SIL
Cabot Corporation
125 High Street
Boston, MA 02110

Filler F-88
American Consolidated Mfg. Co.
835 No. 19th Street
Philadelphia, PA 19130

Hardener Diethylenetriamine
Union Carbide Chemical Co.
1300 Lakeside Ave.

Cleveland, OH 44110

Laccluer MIL-C-11520
(Blackout)

Oct 1 5/7 8 P5072

1-11
 HA~ILTOW STBWDARQ
~le

TABLE rVA (CONT)

CONSUMABLE MATERIALS

COMMERCIAL REFERENCE
MATERIAL PRODUCT SOURCE SPECIFICATION

Lacquer TT-L-80

(Nonspecular black,
AN color No. 604)

Methyl Ethyl Ketone TTT-NI-261

Primer EC776
Minnesota Mining Mfg. Co.
St. Paul, MN 55101

Resin CYCLEWELD C-14

Cycleweld Products Plant

Division of Chrysler Corp.
Trenton, MI 48183

Resin C614R LOCKFOAM

Nopco Chemical Co., Inc.

North Arlington, NJ

Safety Solvent SOLVASOL 5 MIL-C-18718

Mobile Oil Corporation
North American Division
150 East 42nd Street
New York, NY 10017

Sandpaper 360 or 400 Grit Sandpaper

Sealer EC 801/EC 807

Minnesota Mining 1Mfg. Co.
St. Paul, MN 55101

Solder QQ-S-571
(Sn 95 WRPB!

Xylene TT -X-91 6

Oct 15/78 P5072

1-12
 HAMIILT~)N STANDARQ 0"1"""

~IF rrcnnoroclu.

SECTION II

MA~TENANCE INSTRUCTIONS

2-1. GENERAL.

2-2. These instructions cover in detail the

mandatory precautions which shall be
observed and the maintenance procedure which are applicable. The inspection
periods established are: the daily, periodic (75-120 hours) and those applicable to
unusual incidents involving known or possible and evident damage to the blade.
Daily inspection covers procedures which shall be accomplished after completion
of flight activities of the day to determine whether or not repairs if necessary, can
be accomplished without removal of the propeller from the airplane. If the damage
is within the limits noted in pertinent para~raphs and figures, no rework is re-

cluired.

2-3. Periodicinspections are carried out at the 75 to 120 hours periods. These
include daily inspection procedures. The inspection shall be performed with eyes
no further than two feet from that portion of the blade under inspection. Suspicious
indications shall be inspected using a~ 5X-10X power magnifying glass and the dye
penetrant method of inspection.

2-4. The inspection procedures for unusual incidents shall take place as soon’ as

possible aft~er any unusual occurrance which leads to suspicion of damage to the
blade or propeller assembly. This includes incidents such as impact with yielding
or non-yielding objects or possible damage due to overspeeding.

2-5. Any blade that is bent or damaged´•beyond the limits set up in this manual
shall be removed and sent to an approved overhaul facility for disposition.

2-6. The following instructions cover the maintenance of non-surface treated,

surface treated, and nickel plated blades usedon piston-engine propellers and sur-

face treated blades used on turbo-propeller engines.

2-7. The inspection and rework procedures of this manual are imperative in con-

sideration of safety and increased service life.

Oct 15/78 P5072

2-1
 STAP3DARQ ~vlym

UIIITED
TECn#OL~K;IES

2-8. UNUSUAL INCIDENT OVERSPEEDS.

NOTE

By "flyback" is meant that the airplane shall be returned

directly to its repair base for blade removal. Flyback is
contingent on the following: The return flight shall not
require more than 50 flight hours; in the case of over-
speed, the cause of the overspeed shall be corrected;
during fl3iback transit, propeller inspection shall be per-
formed before each take-off.

2_9. NON-SURFACE-TREATED BLADES. (See Table V)

a. blades, (those numbering below 6800 series) involved

Non-surface treated
in propeller overspeeds not exceeding 40 percent above take-off rpm may be con-
tinued in service with no inspection or rework required. If overspeeding above
40 percent has occurred, the blades shall be removed from service subject to fly-
back limitations. Blades removed from service shall be submitted to approved
an

overhaul facility for visual exIuninationfor material failure, inspection by the ano-
dize method, and magnetic inspection of.thrust washers.

2-10. SURFACE-TREATED AND NICKEL-PLATED BLADES.

a. Surface treated and nickel plated blades in the 6800 series and higher have
either the inboard area of the blade airfoil section shotpeened or the fillet area

cold rolled, or both. If these blades are involved in propeller overspeeds up to

20 percent above take-off rpm, they may be continued in service. If overspeeds
exceed 20 percent above take-off rpm, t~he blades shall be removed from service
subject to flyback limitations. Blades removed from service shall be treated as

follows

Overspeeds within the range of 20-40 percent above take-off rpm may
(1)
or may not require rework depending on normal design loading of the blades and

similar factors that will vary according to the installation. In cases of overspeeds
of this magnitude it is recommended that a report similar to Table V shall be com-

piled and submitted to the Hamilton Standard Division Service Department for spe-
cific evaluation. Pending disposition from Hamilton Standard, the blade shall be
removed from service,

Oct 15/78 P>5072

2-2
 DNISUn Of
#AmlUION STANDARD
UIIITED
TEC~INOUX;IES
g

TABLE V

REPORT COVERING OV%RSPEEDING PISTON-ENGINE-TYPE BLADES

Operator

Airplane Make Model Serial No.

Engine Model Serial No.

Propeller Gear Ratio

Nacelle

Control Serial No.

Propeller Model No. Serial No.

Blade Design No. Blade Serial No.

Maximum Overspeed Indicated or Estimated, (state which)

Blade Angle (blades against low pitch or reverse stop)

RPNI Setting BMEP MAP

Air Speed Altitude

Duration of Overspeed
Attitude ofAirplane During Overspeed
Gross Weight of Airplane During Overspeed
Cause of Overspeed (if Imown)

R emarks

Note: The above information is required on blades returned to Hamilton Standard

Division for overhaul in order that the effects of overspeeding can be

properly evaluated.

Oct 15/7 8 P5072

2-3
 ~QAMILTON avlyon d

UllmD
TEC)IWOUGIES

(2) Overspeeds of
than 40 percent above take-off require return of
more

the blade to Hamilton Standard for repair. Blades submitted shall be accompanied
by the detailed overspeed report for evaluation to determine the extent of repairs
required.

2-11. TURBO-PROPE LLER, BLADES. (See Table VI)

a. Blades involved in propeller overspeeds up to 20 percent above the 100 per-

cent aperating level may be continued in service. If the propeller overspeed ex-
ceeds 20 percent above the 100 percent operating level, the blades shall be removed
from the service subject to flyback limitations. Blades shall be treated as follows:

b. Blades which have experienced an overspeed within the range of 20-40 per-
cent above the 100 percent operating level may or may not require rework depending
on normal design loading of the blades and similar factors which could vary accord-
ing to the installation. In cases of overspeed of this magnitude, the report sub-
mitted to the overhaul activity and in turn to the Hamilton Standard Service Depart-
ment, will determine what individual disposition instruction shall be made.

c. Blades which have experienced an overspeed in excess of 40 percent above

the 100 percent operating level shall be removed from service and submitted to
an approved overhaul facility accompanied by an overspeed report compiled in ac-
cordance with Table VI. Overhaul activities shall hold the blades for disposition
instructions before forwarding the blades and accompanying overspeed report to
the Hamilton Standard Service Department for blade re-heat treatment and
re-surface treatment.

2-12; UNUSUAL INCIDENT-IMPACT.,. (See Table VII).

2-13. SURFACE-TREATED BLADES. Blades which have been involved in static

or rotating impact with
relatively solid and non’-continuous objects such as main-
tenance stands, runway lights, birds in~ flight,´•´• or an auxiliary vehicle, etc., shall
be inspected for gross damage and shall be treated as follows:

’NOT E

For the purpose of considering impact damage, surface

treated blades are classed as those blades having shotpeened
airfoil surfaces.

Oct 15/78 P5072

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 [Xnuond
HAMILTON STANDARD
~ITED
TEC)IWOLOCILS

TABLE VI

REPORT.COVERING OVERSPEEDINC TURBO-PROPELLERS

Operator
Aircraft Type Model Serial No.

Engine Model Serial No.

Propeller Gear Ratio Narcelle No.

Propeller Control Model No. Serial No.

Propeller Model No. Serial No.

Blade Drawing No. Blade Serial No. 1

No. 2

No. 3

No. 4

Percent Maximum Overspeed Indicated or Estimated (state which)

Did Propeller Lock Pitch

If so, What Blade Angle

Was Propeller Feathering Attempted

If so, Was Feathering Successful?

Configuration Prior to Overspeed (Power Lever Setting)

Tachometer Reading Torq(ue

Turbine Inlet Temperature Fuel Flow

Duration of Overspeed Altitude

Attitude of Aircraft: During Overspeed

Cause of Overspeed (if la~own)

R emarks

Oct 15/78 P5072

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 HAMBLTON STLaW~ARB avwnd

UIIITED
TECnWOUW;IES,

TABLE VII

REPORT COVERING IMPACT DAMAGE

NON-SURFACE TREATED AND SURFACE TREATED BLADES

Operator
Aircraft Type Model No. Serial No.

Nacelle No.

Engine Model Serial No.

Propeller Model No.

Propeller Gear Ratio

Blade Design No. Blade Serial N~o, 1

Blade SerialNo, 2

Blade Serial No. 3

Blade SerialNo. 4

Propeller Control Model No. Serial No.

RPM Setting at Time of Impact

Propeller Rotating or Static

Aircraft Speed at Time of Impact

Engine Speed at Time of Impact (rpm or percent)

Object; Struck

Object Moving or Static

Approximate Weight of Object Struck

Description of Visual Damage

Track or Blade Alignment Affected (State amount)

No. 1

No. 2

No. 3

No. 4

Remarks

Note: The above information is required on blades returned to the approved over-
haul facility or to the Service Department, Hamilton Standard Division, in
order that damage can be properly evaluated.

Oct 15/78 P5072

2-6
 STAldDARD
i~ uumo
TEC~IIOLDGIES

a. If the blade does not include an alignment gage reference value stenciled on

the camber side of the blade, if blade track is unaffected and there is no visual
evidence of bending, twisting or other gross damage and none is suspected, the
blade shall be removed from service as soon as possible but not later than 50 flight

hours. See Table VIII.

b. If the blade includes alignment gage reference value stenciled on the

an

camber side of the blade, measure the alignment as described in paragraph 2-29.

c. If blade track is affected or if bending

twisting or other
or gross damage is
evident or suspected, the blade shall be removed immediately.

2-14. Blades which have been involved in a known or suspected rotating impact
with relatively yielding or continuous objects such as snow banks, water slush,
sand piles, etc., shall be inspectedas follows:

a. If the blade does not include an alignment gage reference value stenciled on

the camber side of the blade, remove the blade from service immediately.

b. If the blade includes alignment gage reference value stenciled on the

an

camber side of the blade, measure the alignment as described in paragraph 2-29.
If the difference between the current reading and that measured exceeds 0. 040
inch the blade shall be removed immediately.

2-15. Removed blades shall be forwarded to approved overhaul facility accom-

an

panied by the impact report of Table VII and a complete discription of circumstances
surrounding the incident. The overhaul facility will in turn submit a report to
Hamilton Standard Division Service Department who will determine if the severity
of the impact will or will not warrant re-heat treatment in addition to re-surface
treatment at Hamilton Standard Division.

2-16. NON-SUR FACE-TREATED BLADES. Non-surface-treated blades involved

in la~own suspected impact incidents shall be inspected visually for evidence of
or

gross damage such as twisting, bending, and cracks. If gross damage is present,
the blade shall be removed immediately; If no evidence of gross damage is present,
the blade track shall be checked. See paragraph 2-19. If the track is within toler-
ance, the blade shall be removed as soon possible but no later than 50 hours. The
blade shall then be forwarded to an approved overhaul facility for face alignment
inspection. If the blade track is not within tolerance, the blade shall be removed
immediately and forwarded to the overhaul facility for disposition. See Table VIII.

Oct 15/78 P5072

2-7
 HA~ILTON STAWDARQ ~"yo""

TECnm)rOOES,

TABLE VIII

BLADE TRACK

BASIC DIAMETER TRACK TOLERANCE (INCHES)

13 feet or less o. 375 (3/8)

Over 13 feet to 15 feet inclusive o. 4062 (13/32)
Over 15 feet to 21 feet inclusive o. 5313 (17/32)

2-17. NICKEL-PLATED BLADES. Blades involved in impact incidents indicate a

bend by a crack or cracks in the nickel plating in addition to being out of track.
Remove these blades immediately.

2-18. Other types of unusual incidents which might affect the strength and contour
of the blade shall be referred to the Service Department of Hamilton Standard
Division.

2-19. BLADE TRACK. The following procedure,or similar steps, shall be used
in checking blade track:

a. Mark a chordwise line on the face side of each blade two inches from the
blade tip. Use a soft pencil or marking crayon.

b. Set each blade of the propeller (less the dome) so that the two-inch-marked
station is at angle of zero degrees with the plane of rotation.

c. Rotate the propeller and measure the perpendicular distance from a fixed
point to the mark on each blade. See’l’able VIII for blade track tolerances.

2-20. CLEANING.

2-21. Warm,clean,fresh safety solvent, Specifica-

water and soap, kerosene, or

tion MIL-S-18718 and suitable brushes and clean cloths shall be used for cleaning
aluminum blades, including nickel-plated blades. Do not permit any of these clean-
ing materials to contact the blade fairings or rubber parts attached to the blades.
Except as authorized, scrapers, power buffers, steel wool, wire brushes, any
tool or substance abrasive in nature, shall not be used on the blade. In special

Oct 15/78 P5072

2-8
 avwn of
HAMILfOW STIIISDJ~RD
TECnmWI~GIES

cases, where a high polish is desired,reference shall be made to Aluminum Blade

Overhaul Manual No. 130B. In the case of aircraft operating on or near salt water,
the blades shall be thoroughly washed with clean fresh water, thoroughly wiped dry,
and then coated with a film of clean,engine oil after completion of each day of activ-
ity.

2-22. INSPECTION.

2-23. All blades shall be inspected daily and at 75-150 hours intervals in accord-
ance with instructions covered for each type blade (non-surface-treated, surface-
treated and nickel-plated) in addition to the: general instructions following.

2-24. All blades shall be inspected for bends, nicks, and cracks. Use a 5-10

power magnifying glass on any questionable areas. When necessary, local dye-
penetrant inspect the suspected area. Do not dye penetrant inspect nickel-plated
blades.

2-25. SPECIFIC ´•INSPECTION PROCEDURES.

2-26. Measure the depth of each damaged area which shows appreciable depth

using dial indicator gage HSP 1827 or equivalent. First, remove any raised edges
adjacent to the damage which may interfere with the la~ife edge of the gage setting
flush on the true blade surface. The base of the gage shall be placed parallel to
the longitudinal blade axis. Gouge depth shall be determined as the difference be-
tween the deepest point in the damaged area and the adjacent blade surface. The
gouge depth in a previously reworked area shall be determined as the difference
between the deepest point in the damage and the adjacent unworked blade surface.
Check for misalignwent of the gage point with respect to the knife edge by rocking
the gage on a flat surface. See Figure 2-1.

2-27. DYE PENETRANT INSPECTION.

2-28. To iletect suspected cracks or other discontinuities, the dye penetrant

method of inspection shall be used according to the procedures covered in Specifi-
cation MIL-I-6866. The spray method shall be used for convenience in inspecting
local suspect areas.

CAUTION

Do not use the vapor degreasing method for cleaning parts.

See paragraph 2-20.

oct 15/78 P5072

2-9
 -’\"I´• D"IY~"d
)(AMILTOW STAWDARQ

Figure 2-1. Measuring Darrnage Depth

2-29. BLADE ALIGNMENT GAGES.

2-30. These gages are used to inspect the alignment of

specific blades during line
maintenance and to detect permanent deflection of the blade from normal alignment.
See Figure 2-2. Blade alignment gages are manufactured for non-fairing and
fairing type blades. See Figure 2-3 and 2-4 for typical blade alignment gage in-
stallations. See Table III.

a. A blade alignment reference value (B.A.R. which was established at blade

overhaul is stenciled on the camber side ~f the blade at the location of blade ident-
ification. This reference value is valid
during a given overhaul period only. The
gage may be used to check for blade bending not only on a routine basis, but also
to inspect following la~own or suspected impact incidents. These check readings
are taken in the same manner as the reference readings.

b. Set the blades at or near feather and in the horizontal position. Place the
blade alignment gage on the blade and install the index pins in the blade dimple and
in the slot in the shank patch. Make sure the three gage feet are resting on the
blade and that the index pins are not binding in the bushings. Record the dial in-
dicator reading and remove the gage. Repeat this procedure for a total of three
readings removing the gage from the blade each time. Add the three readings and
average by dividing by three. Compare this average~ value with the blade alignment
reference value stenciled on the blade.

Oct 15/78 P5072

2-10
 HAMILTON ST~LWDARB

18[3--77

Figure 2-2. Typical Blade:Alignznent GageInstallation

Oct 15/78 Fairing-?Srpe Blades P5072
2-11
 ~lsnof
IldMILTOW STANDARD
UNITED
rrCnm)L~K;IES

lllD-6U

Figure 2-3. Typical~Blade Alignment Gage Installation

Non- Fairing-Type Blades

LOCATING PIN
FIXED SUPPORT FOOT DIAL INDICATOR
AND CONTACT POINT
LOCATING PIN
FIXED SUPPORT FEET

ALIGNMENT CAGE

FACE SIDE

LOCATING DIMPLE

ENLARGED
VIEW

GAGE LOCATING
PATCH

_ _ _ _
i
I+-18T-Lll
I

Figure 2-4. Use of Blade Alignment Gage

P5072
Oct 15/78
2-12
 -´•\\I//-
HAMILTOW STAWDARQ~
TECnlK)LDWES.

NOTE

When recording indicator readings, remove hands fr~m

proximity of the gage and blade to avoid deflection except
that, if necessary, light lateral pressure is permissible
at the shank end only to stabilize the gage.

(1) On a periodic inspection, where impact is not suspected, if the

routine
differencebetween the current reading and the reference value is 0. 080 inch or
less, the blade is considered acceptable for further service. Blades exhibiting
differences from 0. 081 to 0. 250 inch should be removed from service subject to
flyback limitations. Blades showing more than 0. 250 inch should be removed from
service immediately.

(2) Blades involved inIn~own or suspected static (non-rotating) impact, or

blades involved in rotating impact with relatively solid and non-continuous objects
such as runway lights, rubber tire treads, or birds in flight are considered accept-
able for further flight if the differe´•nce between the cufrent reading and the
reference reading does not exceed 0. 040 inch. Blades exhibiting difference be-
tween 0. 041 and 0. 250 inch should be removed from service subject to flyback lim-
itations. If the difference exceeds 0. 250 inch, the blade shall be removed from
service immediately.

(3) Blades involved In known or suspected rotating impact with relatively

yielding and/or continuous objects such as snow banks, water, slush, sand piles,
etc. and exhibiting a difference not exceeding 0. 040 inch between the current read-

ing and the reference reading should be removed from service subject to flyback
limitations. Blades showing more than 0. 040 inch deviation should be removed
from service immediately.

(4) Propellers removed from service should be treated as impact incidents

and shall be dispositioned as covered in paragraph 2-15.

2-31. LIGHTNING STRIKES. Lightning strikes on nickel plated and non-nickel

plated blades visually evident by localized burning, discoloration and puddled
are

metal or cracks. If any of these condictions are present, the blade shall be for-
warded to approved
an overhaul facility for return to Hamilton Standard Division
for disposition.

2-32. BLADE DEICER HEATER, FAIRING, FEED SHOE,AND TROUGH INSPEC-

TION. Inspect the blade deicer heater, cover stock of the fairing, fairing boot,
blade seal, electric contact ring holder and connector for poor adhesion and dam-

Oct 15/78 P5072

2-13
 HAMILTOU STANDARD DNluon of

U~ITED
TECI(WOU~CILS

age such as gouges, cuts, tears, abrasion, weather checking, and electrical burns
from lightning and deicer short circuits. Damage which has cut a heater element,
electrical burns from a heater element, and weather checking cracks deeper than
0. 070 inch acceptable.
are not In this case, the blade shall be removed from ser-

vice. Suspected damage to a blade deicer heater element and the possibility of
moisture entry in the element area shall be investigated by making an electrical
resistance check of the heater. (See Table XII.

a. Blisters, bubbles, delaminations, or separations which are iden-

Limits,
tified by swelling of the rubber material without rupture or charring from local
´•burnout of heater wires are acceptable as follows:

(1) Blade Fairing Coverstock.

(a) An affected area is not larger than four (4) square inches.

(b) There are not more than four such areas on either side (face or

camber) of the blade.

(c) There is not less than one and one-half (1-1/2) inches distance be-
tween affected areas.

(d) An affected area is not more than one-quarter (1/4) square inch

(for example, an area of 1/2 x 1/2 inch or 1/4 x 1 inch). There is no limit on the
number of areas one-quarter (1/4) square inch or less.

(e) There is not less than one-quarter (1/4) of an inch between affected
areas.

(2) Blade Fairing Boot and Heater.

(a) An affected area along the outboard edge of the boot on either side
(face or camber) of the blade is no longer than three (3) inches and no wider than
one-half (1/2) inch.

(b) An affected area under the heater or boot is not larger than one

(1) square inch.

(c) There is not less than two (2) inches distance between affected
areas.

(d) An affected area along the trailing edge of the heater on either side
(face or camber) of the blade is not longer than three (3) inches and is not wider
~than one-half (1/2) inch.

Oct 15/78 P5072

2-14
 -´•\\I//´•
HAMIILTON STAWDDARQ D"’"Mo’

~lllle rrCnm)uK;IES.

b. Acceptance Criteria for Rubber Parts. Acceptance criteria for blade heat-
ers, fairing coverstock, and fairing end boots are as follows (see Figure 2-4A).

(1) Soft spots in the EC801 fillet along the inboard edge of the heater

(area #1) are not indicative of blisters and are considered acceptable.

(2) Soft spots at the edges of the cable assemblyramp from the fairing to
theblade shank region (area #2) are indicative of boot bridging or local inadequate
EC 801 filleting under the boot, but are not of concern and therefore are acceptable.

(3) Looseness of the boot along its outboard edge (area #3) is not acceptable.
Repair per paragraph 2-61.

(4) Blistering of the coverstock along the edges of the gage locating plate
(area #4) and in area #5 is not acceptable. Repair per paragraph 2-61.

IIII 1\ :7

5\’ 3

Figure 2-4A. Rubber Parts Area Codes

Oct 15/78 P5072

 ~AMIILTi)N STA#DARQ
uwmD
’11111II’ TECn#OLDGIES.

(5) Blisters under the heater (area #6) are not acceptable. Repair per
paragraph 2-61.

(6) Blisters under theboot in the fairing butt face (area #7) are not accept-
able. Repair per paragraph 2-61.

2-33. DAILY MAINTENANCE.

2-34. thoroughly cleaned after each day of flying activity in ac-

Blades shall be
cordance with procedures of paragraph 2-20. After cleaning, the blades shall be

given a thorough inspection in accordance with applicable procedures of paragraph

2-22. Suspicious indications shall be inspected using a 5X-10X power magnifying
glass and the dye penetrant method of inspection.

a. Inspect the blade surface for damage such as scratches, gouges, nicks,
pitting, and bums caused by lightning strikes.

b. A crack or bend is cause for immediate removal of the blade.

c. Suspected impact damage or overspeed shall be cause for inspection pro-

cedures of paragraphs 2-8 and 2-12.

d. Inspect the blade in accordance with paragraph 2-32. If damage, burning,

or corrosion of the blade surface is la~own or suspected, refer to paragraph 2-59
blade heater to expose the
repair blade surface for inspection. If it is not possible
to expose the blade surface for inspection the blade shall be removed from service.

Repair of damaged blade surfaces is covered in paragraph 2-41.

2-35. Completely remove all corrosion and erosion pits on the leading edge of
hard alloy (HS 26) blades and remove an additional 0. 050 inch. Care shall be
taken to blend smoothly the reworked portion of the leading edge with adjacent areas
and to wake the repaired radius conform to the original as shown in Figure 2-5.
Allblades shall be inspected for possible splitting of leading edges and tip radius,
This condition is caused by abrasion or erosion occuring when operating in areas
of rough terrain such as sandy or rocky areas or in fog or rain. Corrosion de-

velops in the bottom of resultant pits eventually causing a splitting of the leading
edge and tip radius if not eliminated by rework. The repair of leading and trailing
edges, and tip radius is accomplished by the use of a file and emery cloth.

Oct 15/78
P5072
2-16
 )ILaMILTOW
STAWDARBDM,ILCmOLWESbJ

REWORK CONTOVR
TO POINT OF
MAXIL(UM

CORRECT MAINTAIN ORIGINAL RADIUS

DAMACEO PORTION

CONTOUR TOO BLUNT

INCORRECT RADIUS TOO LARGE

Figure 2-5. Rework of Leading Edge

2-36. Raised edges of cuts, scratches, and nicks shall be removed. If their re-

moval or treatment takes the blade below field repair limits, the blade shall be
sent to an approved overhaul facility for disposition.

2-37. Theonly acceptable method of removing damage is that which metal of and
adjacent to the damage is removed with die riffler files and emery cloth. All
traces of the damage shall be ~moothly faired into the blade surface. See Table nI
for listing of maintenance tools.

2-38. Reworks extending in a line across the- blade width are acceptable providing
the distance between reworks is i. 5 inches and the total width of the rework is
less than half the width of the blade. A blend of reworks shall not exceed six square
inches. Repairs on the leading and trailing edges may be opposite each other pro-
viding they are not at maximum depth.

2-39. If deicer feed shoes and troughs are damaged they shall be repaired in ac-

cordance with procedures described in paragraph 2-59.

Oct 15/78 P5072

2-17
 IQAMILTON STANDARQ
~L1 UIIITED

2-40. 75-120 HOURS MAINTENANCE.

a. inspection and maintenance procedures as covered in DAILY

Repeat the
INSPECTION. (See paragraph 2-33). Inspection shall be performed with the eyes
no further than two feet from that portion of the blade under inspection. Suspicious
indications shall be inspected using a 5X-10X power magnifying glass and the dye
penetrant method of inspection.

2-41. REPAIR PROCEDURES.

NOTE

The following procedures apply to turbo-propeller

blades and nickelplated blades with the exceptions
noted in paragraphs 2-72 and 2-80 respectively.

2-42. BLADE SURFACE.

a. Figure 2-6 defines the maximum depths of gouges and scratches on non-
surface treated blades which do not require rework with the following exceptions:

MAX. DEPTH OF DAMAGE REQUIRING-NO REWORK

0. 006 EXCEPT 0~ 004 IN A PREVIOUSLY 0. 016 EXCEPT 0 006 IN A PREVIOUSLY NO LIMIT

REWORKED AREA REWORKED AREA

BARREL LIP TO 3 FEET FROM TIP OR 1 3 FEET FROM TIP OR END OF SHOT--
END OF SHOT--PEENED AREA IF PEENED AREA IF LESS THAN 3.00
LESS THAN 3 FEET FROM TIP 3 FEET FROM TIP TO 3. 00 FROM TIP

FOR 6895/DC--6 TYPE AIRPLANES USING R-2800 ENGINES WITHOUT TUNGSTEN

STEEL DAMPERS THE LIMIT FOR THE AREA 3 FEET FROM TIP TO 3 INCHES
FROM TIP IS 0. 010 INCH EXCEPT 0. 004 INCH IN PREVIOUSLY REWORKED AREA.

FOR 690fO/L1049C E 7015--VD-377 AIRPLANES THE LIMIT FOR THE AREA

3 FEET FROM TIP TO 3 INCHES FROM TIP IS 0.012 INCH EXCEPT 0.004 INCH IN
PREVIOUSLY REWORKED AREA.

NOTES:
i. DIMENSIONS IN INCHES.
2. MATERIAL QO--A--367 OR AMS4130

HARDNESS 100 BHN MIN.

1 1 L182 29C

Figure 2-6. Damage Limits Requiring No Rework for Non-Surface Treated

and Surface Treated Piston Engine Type Blades

Oct 15/78 P5072

2-18
 )(A)((((LTON -\\\I’/~-D"YMd
~rme

(1) Douglas DC-6, -6A and 6B airplanes using R-2800 engines without
For

tungsten steel dampers, the Figure 2-6 limit for the area three feet to three inches
from the tip is 0. 010 inch except 0. 004 inch in a previously reworked area.

(2) For Lockheed 6903-0/L1049C and E, and also Boeing 7015-2/B-377

installations, the Figure 2-6 limit for the area three feet from the tip to three
inches from the tip is 0. 012 inch except 0. 004 inch in a previously reworked area.

NOTE

Rework in the area three inches from the blade tip

shown in Figures 2-6, and 2-7 is not limited by
depth, width, or length provided that the rework
does not extend in a line across the blade or will
cause deterioration in the blade structure at any
point. "No limit" does not permit shortening of
a blade or a set of blades by three inches.

NOTE

Either the leading or trailing edge may be reworked to

the maximum depth shown in Figure 2-7, provided
that the opposite edge (chordwise along the same station)
does not also require rework. For rework affecting

opposite edges, the combined rework depths shall not

exceed the value shown for one edge. For example, in
the edges where the maximum depth is 0. 150 inch, a
rework depth of 0. 100 inch in one edge will leave only
0. 050 inch rework depth (0. 100 0. 050 0. 150 inch
maximum) in the opposite edge.

b. Figure 2-7 defines the service limits for local repair. The number of re-
pairs in a given area on the blade is not limited provided their location with re-
spect to each other does not form a continuous line of repairs which would mater-
ially weaken the blade. Blades containing damage which cannot be repaired within
these limits shall be removed from service and forwarded to an approved overhaul

agency,

c. only acceptable methods of removing surface damage are those by

The
which metal and adjacent to the damage is removed from the blade. This
shall be done using any of the following tools:

Oct 15/7 8 P5072

2-19
 [h´•lsxld
~AMIMIISTAIIDARD
UI(ITiiD
TECnlKWGIES

rviAx DEPTH OF REWORK ALLOWED ON LEADING AND TRAILING EDGES

EITHER LEADING OR iRAILING EDGE (BUj NOT BOTH) MAY BE REWORKED
TO MAX DEPTH ALONG SAME STATION (CHORD LIN~E).

0.15 r0.25 r0.40

0.060

0.060 ~i(
li:15
0.25
fO.dO
FROM
BARREL LIP 12.00 FROM BP;RREL LIP 36.00 FROM TIP TO 18.~0 FROM TIP
TO 12.00 FROM id 36.d0 FROM TIP 18.00 FROM TIP TO 3.00 FROM TIP
BARREL LIP
LENGTH OF REiNORK IN~ LONGITUDINAL BLADE DIRECTION
SHALL BE NO L~SS i~AN iO TjMES DEPTH OF REWORK.
NOT LIMITED
MAX DEPTH OF REWORK ALLOWED ON FACE AND CAMBER SI’DES.

0.060~F BUT NO MORE THAN 2510F SECTION

THICKNESS AT POSITION OF REWORK.

BARREL LIP TO 3.00 FROM TIP

LENGTH OF REWORK iN LONGITUDINAL BLADE DIRECTION

SHALL ~iE NO LEjS THAN 30 TIMES DEPTH OF REWORK.

1 0.125 ALLOWED FOR NON SURFACE TREATED BLADES.

NOTES:
i. DIMENSIONS IN INCHES.
2. MATERIAL QQ--A --367 OR AMS4130
HARDNESS 100 BHN MIN.
11--L182--102

Figure 2-7. Airfoil Local Repair Limits for NoirSurfs~e Treated and Surface
Treated, Pistbn-Engine-Type ~lades

(1) Die maker riffler files "0" cut, #10 and #i7. Die maker riffler files
"3" cut, #8, #10 ~id #18. Die sinker rifeers "3" cut, #11 and #16.

(2) Emery cloth, Nos. 120, 180, 240, and 320.

(3) Small electric hand grinder with rubber abrasive wheel, Norton

A80D2RR, Norton Abrasive Co., Worcester, MA.

(4) Magnifying Glass, ~X-1OXpower.

Oct 15/78 P5072

2-20
 HAMILTON ~TANBARQ
~iu*mD
-Ilrm~ rrcNwotocrrs.

d. Reworks shall be made parallel to the longitudinal axis of the blade. Re-
move all traces of the damage and provide a smoothly-faired depression in the
blade surface. See Figures 2-8 and2-9.

b
SECTION A-A Acl
EXAGGERATED RECOMMENDEDMETHOD FOR RE- NICK IN FACE OF EXAGGERATED VIEW
VIEW OF NICKS MOVING NICKS BY RIFFLE FILE 8 BLADE REMOVED BY OF NICK IN FACE OF
IN LEADING CROCUS CLOTH. BLEND DEEPEST FILE AND CROCUS BLADE.
EDGE. PORTION OF NICK INTO LEADING CLOTH AS RECOM-
EDGE ALIGNMENT WITH MENDED.
SMOOTH CURVES.

Figure 2-8. Typical Nicks and Methods of Removal

"A"

FACE e CAMBER SIDES 30

LEADING e TRAILING EDGES 10

rlA" TIMES DEPTH OF REWORK

OF COUGE
OR BUR FAIR IN

TO TIP

DEPTH OF REWORK

0.00211 MIN. (GOUGE REWORK)

i~0.020" MIN. (ELECTRICAL BURN REWORIO

Ii-isz-nie

Figure 2-9. Damage Rework Dimensions.

Oct 15/78 P5072

2-21
 HdMILTON STIUID~LRD avls~n ot

i~i v#rrm
TEQ(~KOGIES

CAUTION

Methods: which, attempt to relocate metal by cold-working

to cover or conceal damage rather than remove the damage
are not acceptable.

e. Using a pencil or a marking device which will not penetrate

similar soft
the blade surface, mark light perpendicular lines on the blade surface so that they
intersect at the deepest point of the damaged area and extend them sufficiently to

permit location of the, deepest point of the daunage following rework.

f. Work out thedamage using the file with the cut most convenient. Blend in
the reworked area original Blade surface by filing to foam. a saucer shaped
with the.
depression being: careful to remove alltraces of the damage. The depressions
shall not exceed the dimensions´• indicated in Figure 2-9. Remove all traces of the
file marks with No. 240 emery cloth followed by No. 320 emery cloth leaving a
polished surface. See Figures 2-10, 2-11, 2-12, and 2-13. Inspect the reworked
area with the 5X-10X magnifying glass.. If no indication of damage remains, re-
move 0. 002 inch more stock by hand polishing.

g. After rework, using blade checking indicator HSP 1827, measure the
amounts of blade stock removal. If final depth´• exceeds permissable stock removal

depth, the blade shall be ~emoved´• from, service.

2-43. LOCAL REWORKS IN. SHOTPEENED AIRFOIL SECTION.

2-44. Nicks, dents, corrosion and erosion shall be removed locally from the
shotpeened area. To determine the effect the rework will have on the surface
treatment, an depth of the rework shall be maintained. The
accurate account of the

damage shall be removed by saucering out and blending the reworked portion into
the surrounding area working toward a circular pattern as much as possible. Check
the depth of the rework using blade checking indicator HSP 1827. If the depth of the
reworked has not exceeded 0. 008 inch and if a minimum of three shot impressions

per square inch remain, the surface treatment has not been adversely affected.
Local repeening is required if either of the above limitations are exceeded.

Oct 15/78 P5072

2-22
 HAMILTOW STAWDARB

Figure 2-10. Abrasion Before Rework Figure 2-12. Emery Cloth Application

Figure 2-11. Filing Tool Application Figure 2-13. Abrasion Area after Rework

ORIGINAL
As Received By
ATP
Oct 15/78 P5072
2-23
 I3AMILTON STAWDARQ DNlsond

UWtlED
IEQaYKOClfS

2-45. LOCAL PEENING OF’REPAIRED AREAS.

2-46.. Following rework and inspection of shotpeened areas it will be necessary

to cold work´•the repaired areato re-establish compressive stresses if less than
3 shot impressionslpea. square inch remain. As an aid in establishing a uniform

peening intensity and pattern, a power driven peening hammer, HSP 3293, (see
Figure 2-14) may be used. Manual´• peening using the hammer shown in Figure 2-15
and made to the dimensions shownin´•Figure 2-16 is permitted. However, a more
uniform pattern is obtainable´•with.the power driven hammer.

Figure 2-14. Using HSP 3293 Power Driven Figure 2-15. Manual Peening Repaired
Hammer Area

1.28

o.~sol*
t-"´•

C~ RADIUS

52100 STEEL
HEAT TREAT
S8- 68 Re

Figure 2-16. Dimensions of Manual Peening

Hammer

oct 15/78 ORIGINAL P5072

2-24
as Received By
ATP
 HANIILTON STAWDARQ ""’Y3"d

ul(mD

CAUTION

Local repeening extending across the entire width of

the blade is not acceptable.

2-47. Local peening is permitted in any part of the shotpeened airfoil portion of
the blade. Allpeening is prohibited in the blade seal area and the area of the
shank inboard from the seal area since hammer peening in these areas will spoil
the sealing surface or the seating surface for the beveled washer. Peening may
be accomplished in the rolled area outboard from the blade seal area.

CAUTION

Cold working is to be accomplished only in the pre-

scribed areas.

2-48. The local peening must cover the reworked area plus a band 0. 250 inch
surrounding the area. The minimum surface area which niay be peened shall be
equal to the area´• of a one inch diameter circle, or in an irregularly shaped repair
the minimum radius shall be 0. 500 inch at every point on its periphery. A rework
of 0. 250 inch or less will, not be reshotpeened. Stray impressions shall not appear
on the blade. If one occurs,, the area surrounding the stray impressions must be
worked into the original peened area or the minimum peened area established
around it.

2-49. The repeening of local areas in the field shall be limited as follows: There
shall be no more than ten locally reworked and these shall be separated
areas

from each other by inches; an individual area shall not exceed 10 square
at least 1. 5
inches nor extend across more than half the blade width. Blades that require com-
plete repeening or repeening of areas larger than the limits above will be tagged
for manufacturer’s repair (stating reason) and routed to the approved overhaul
facility.

2-50. OPERATION OF PEENING HAMMER. Peening Hammer HSP 3293 may be

used by inserting the drive shaft into the chuck of an electric hand drill or flexible
shaft which is attached to a motor. In no case shall the drive speed exceed a max-

imum of 1750 rpm. The peening hammer is operated by a cam on the drive shaft
which in turn operates the springloaded hammer. Spring tension is adjusted by re-
moving the cap from the end of the hammer and loosening the lock nut which will
allow turning the adjusting screw clockwise to increase tension and counterclock-
wise to decrease the tension. The nose piece of the peening hammer shall be ad-

justed so that a measurement taken from the end of the nose piece to the tip of the
protruding hammer will be 0. 0625 inch when the hammer shaft is free of the cain.

P5072
Oct 15/78
2-25
 ~eAmluoN srAN~aRe
~Ecnmnoclu,

Adjustments of the nose piece may be made by loosening the set screws and turning
the nose piece 0. 250 inch at at time in the direction desired until the correct mea-
surement is obtained. Make certain that the set screws locate in their grooves
when tightened.

2-51. CARE OF PEENING HAMMER. The peening hammer is to be used for the

specific purpose of repairing surface treated HS 26 aluminum alloy blades. Peening

any material harder than HS 26 is likely to damage the hammer tip. If the hammer
tip is accidently nicked or damaged, the radius may be reground to remove the
damage, being careful to obtain the same radius. A deviation in length due to
grinding can be taken up by the adjusting screw. To remove the hammer tip for
grinding or replacement, remove the nose piece by unscrewing the two set screws
and the nose piece. Hold the hammer shaft securely and unscrew the hammer tip
from the shaft. After grinding or when a new tip has been installed, check the dia-
meter of the impressions by peening on an HS 26 alloy test piece. The diameter of
the impressions shall be ~between 0. 038-0. 042 inch. A Brinell scope is suitable for
making these measurements. The diameter of the impressions are determined by
the spring tension. The peening hammer is packed with No. 130 AA Lubriplate

grease which may be purchased from Fiske Brothers Co., Lubriplate Division,
Lockwood and Neptune Streets, Newark, New Jersey.

2i52. PREPARATION. For both mechanical and manual peening, install a ntbber
mask approximately 0. 125 inch thick on the blade to prevent stray shot impressions.
The hole in the mask shall be sufficiently large to alloy peening of the reworked area
plus a band 0. 250 inch surrounding the area.

2-53. PR OC EDURE. When using the peening hammer, place the hammer tip on
the blade and press down until the shoulder of the nose piece is flat against the blade.
The hammer shall be perpendicular to the blade surface at all times. When peening
directly on the leading and trailing ´•edges, peening hammer shall be held per-
the

pendicularly to the surface being peened. Distinct peening impressions shall be

formed. Peening shall be continued until the area is completely covered with
overlapping impressions. A peening time of approximately one minute is required
to completely cover the minimum area. Mechanical peening shall be done in a
circular movement of the peening hammer. Too slow a rate of feed results in a
worm effect. When the repaired ´•area has been satisfactorily peened, remove the
mask from the blade. It is recommended that the area be left "as peened"; how-
ever, any high spots may be removed with No. 120 and then No. 240 emery cloth.
These repaired and peened areas are subject to the same general limitations as
shotpeened areas.

Oct 15/78 P5072

2-26
 IRm~a,
’bCnm)COC~

2-54. When using the manual hammer peening method, hold the hammer loosely
and allow it to rebound from the blade at an intensity which will produce 0. 075 inch
diameter impressions similar to those shown in Circle 1 of Figure 2-17. Impres-
sions from 0. 050-0. 090 inch diameter are acceptable but the majority of
impressions shall be 0. 075 inch, Continue peening until the repaired area is com-
pletely covered with overlapping impressions resulting in a pattern like that in
Circle 2. It is important that peening of damaged trailing edge repairs include the
area of the trailing edges radius. It is recommended that the face and camber sides
of the area be peened first. On thin trailing edge sections, the opposite side of the
blade at the area being peened shall be supported solidly with the trailing edge up-
permost. Maintain the proper radius on the trailing edge to minimize the tendency
of the trailing edge to roll during the peening operation. A peening time of approx-
imately two minutes has been found necessary to adequately treat the minimum
area, If stray impressions occur, the area surraunding the impressions shall be
reworked into the newly peened area or the minimum peened area established
around it.

2-55. INSPECTION OF REWORKED AREAS.

2-56, Reworked areas shall be inspected for possible

cracks that may become
exposed with the rework. The dye penetrant method of inspection shall be used.
(See paragraph 2-27.

Figure 2-17. Steps in Local Manual

Peening

Oct 15/78 ORIGINAL P5072

As Received By 2-27

ATP
 HAMILTON STL~NDARQ ´•-‘\’’I- D"IY)""
ull
~llllr rrcn~aoclEs.

2-57. REMOVAL OF BLADE HEATERS, DEICER FEED SHOES, AND TROUGHS

FROM NON-FAIRING-TYPE BLADES.

2-58. If it becomes necessary to replace a blade deicing heater the following steps
apply to non-fairing type blades only, Damaged blade heaters of fairing type blades
are removed in accordance with paragraph 2-58A.

a. If an strip is cemented to the blade heater and the blade, it shall

abrasion
be removed by loosening it from the heater using toluene, Specification TT-T-548,
and a brass or aluminum chisel or similar tool that will not damage the blade sur-
face. Abrasion strips removed in this manner shall be discarded and replaced
with a new like part,

b.Apply tol´•uene, Specification TT-T-548, to the outboard end of the heater,

feed shoe, or trough andsoak it until the cement securing the heater to the blade is
loosened. Pry the outboard end loose with a micarta scraper while applying more
solvent. Grasp the outboard end of the heater, feed shoe or trough and pull out-
ward firmly while applying more solvent. Continue until the element is free of the
blade, Discard the heater, feed shoe,and trough.

.CAUTION

Do not allow the solvent to contact other rubber parts

of the blade assembly.

2, 58A, REMOVAL OF BLADE HEATERS FROM FAIRING-TYPE BLADES.

a, Remove the blackout lacquer, sealer, and cements which cover the heater
tabs and the tabs of the special purpos~ cable assembly. Using a soldering iron,
free the soldered tab connections of the heater.

b, Loosen the heater lead straps from the butt face of the fairing rubber boot
by applying local heating to a maximum of 65, 60C (1500F) to soften the adhesive.
If the adhesive cannot be softened with heat, apply toluene to the areas. Also, use

a plastic wedge to pry the leads loose. Do not unbond the boot from the Lockfoam

fairing.

c, Starting at the outboard edge of the fairing rubber boot, cut the fairing cover-

stock along edge

the of the heater on each side of the blade. Continue the cuts out-
board in a straight line past the outboard end of the heater until the metal portion
of the blade is reached,

Oct 15/78
P5072
2-28
 D~yonof
STANDI\RD

CAUTION

Avoid cutting into the lockfoam of the fairing and do

not score or scratch the blade metal.

d. Loosen the outboard end of the coverstock from the blade metal between
the cuts as described in step b. preceding. Then, peel back the coverstock and
heater from the Lockfoam until the rubber boot is reached on each side of the
blade.

e. While pulling upward on one side of the heater and coverstock, loosen the
inboard end of the heater from the fairing boot as described in step b. preceding.
As the heater peels upward, fairing coverstock along the outboard edge of
cut the
the boot. Repeat this procedure for the other side of the blade and the leading
edge.

2-59. REPA~R OF BLADE DEICER HEATERS, DEICER FEED SHOES,AND

TROUGHS

NOTE

All exposed~rmbber surfaces of the finished blade

shall be painted with two coats of black colored
Blackout Lacquer, MIL-C-11520. Thinthe
Blackout Lacquer with toluene, Specification
TT-T-548 or Xylene, Specification TT-X-916
at the ratio of two parts by volu~ne of lacquer
to three parts by volume of thinner. Allow first
coat to dry tack free before applying second

coat. Unlessotherwise specified, the rubber

surfaces of the finished blade coated by Blackout
Lacquer shall have at least one black paint top
coat. This top coat shall be lacquer conforming
to Federal Specification TT-L-80 non-specular
black (AN Color No. 604).

2-60. Damage which does not penetrate through a rubber part shall be repaired
as follows providing there is no indication of damage to the blade beneath the rub-
ber part:

Oct 15/78 P5072

2-29
 ""M""
HA~ILTON STA#DARQ

CA~T;TTION

All cements, fillers, and sealants shall be allowed

to. set approximately eight hours before the engine is
run up. ~fter´• run-up, a close visual inspection of
the adhesion of parts shall be made. In cases where
the aircraft is operated in localities where elevated
temperatutres´• prevail consideration of drying time
shall be made´• accordingly. This also applies to
other localities where weat´•her´• condition are at a

variance from standard conditions.

a. Very small cuts, tears,~ gouges, or abrasions and cracks less than 0. 070
inch deep shall be sealed. Clean the area with methyl ethyl ketone Federal Speci-
fication TT-M-261 and wipe dry. Apply a coat of BB1007 Buna N rubber cement
and allow to dry for one hour minimum. Cover the BB1007 cement with a coat of

Bostik 1096 neoprene rubber cement and allow to dry for 2 hours minimum. Fill
the damage with EC 801’/807 until flush with the surrounding surface.

b. checking cracks less than 0. 070 inch deep in spinner seals, cam´•
Weather
mounts, slip ring mounts, and fairing boots shall be repaired by filling. Clean the
cracks with MEK and air blast the area to remove any cleaning fluid which may
have accumulated at the bottom of the cracks. Apply one coat each Bostik 1096
and Bostik 1007 as described in step a. preceding. Then, fill the cracks with
EC 801/807 until flush with the surrounding area.

c. Larger damaged area and checking cracks deeper than 0. 070 inch shall be
sealed as described in steps (a) and (b) respectively and then protected by patching.
Apply a coat of Bostik 1007 over the sealed area aid the surround area. Allow to
dry for 60 minutes. Select a neoprene patch slightly larger than the damaged area.
Apply a coat of Bostik 1096 over the Bostik 1007 and on the under surface of the
patch. Allow to dry for 2 hours minimum. Apply a second coat of Bostik 1096 to
the mating parts. and allow to dry for 30-60 minutes. Place the patch in position
and roll it down with a rubber roller. Seal the edges of the patch with EC 678 or
EC801/807. If a wire or wires of a wire element heater are exposed (but not dam-
aged) because of weather checking or other normalwear, cover with a neoprene
patch made from an abrasion strip using Bostik 1096 cement. Seal the edges of
the patch with EC 801/807 or EC 678 Sealer.

Oct 15/78 P5072

2-30
 #ARIIILTON STAWDARQ
~lmnn,

2-61. DEICING FEED SHOE AND CONDUCTIVE RUBBER HEATERS. It is per-

missible to cut as must as six inches from the original length ofa conductive rub-
ber blade heater if it is damaged beyond practical local repair. A square cut-off
shall be made when reducing the length of the heater. If is permissible to cut 12
inches from the blade deicing feed shoe if it is damaged beyond practical local re-
pair. See Figure 2-18. However, should a blade heater or deicing feed shoe be
shortened to eliminate damaged section, a corresponding shortening of heaters
a

or feed shoes shall be made to the remaining heaters or feed shoes on three bladed

propeller assemblies. For four bladedpropeller assemblies, only the blade op-
posite to that being repaired shall have its heater or feed shoe shortened according-i
ly.

2-62. REPAIR OF BLADE FAIRING, BOOT, AND HEATER (see Figure 2-4A):

a. If the fairing end boot is loose along its outboard edge (area #3), use a heat
gun to soften the adhesive in the affected area. Do not exceed a surface tempera-
ture of 65. 60C (1500F). If the adhesive cannot be softened with heat, apply toluene
to the area. With the adhesive in a soft state, roll the area down with a rubber
roller making sure that no toluene is trapped in the affected area. Apply local

pressure until a bond is obtained.

b. If there is
blistering of the fairing coverstock along the edges of the gage
locating plate (area #4) or in area #5, repair as described in paragraph a. pre-
ceding. It may be necessary to slit the blister, apply toluene and roll down the
blister. In this case, take care to make certain no toluene is trapped in the blister.
Seal edges of slit with EC 801/807 mixture.

c. If there
blisters under the heater (area #6) or under the fairing end
are

boot on the fairing butt face (area #7), repair as described in paragraph a. pre-
ceding except, insert a sharp tool beneath the edge of the heater or boot and along
the underside to gain access to the blisters, apply toluene and roll down the blister.
Make certain no toluene is trapped in the blister.

2-62A. Affected areas beyond the limits of paragraph 2-32. a. shall be repaired as

follows

a. If´•it is not necessary to peel back the rubber part to gain access to the region,
puncture the affected area at its extremities with a needle. Use care to avoid
heater elements and position the punctures to allow outlet openings for re-cementing.
Using heat gun, soften the adhesi~e in the affected area. Do not exceed a surface
a

temperature of 65. 60C (1500F). If the adhesive cannot be softened with heat, slit

P5072

Oct 15/78 2-31

 nnmlLTOW STANDARD I)llron of

~rra,
TECNNOLDCIES

the area with a razor blade peel back the rubber and apply toluene to area. With
the adhesive in a soft state, roll the area with a rubber roller to expel any gas or

air and to press the rubber back in place. Make certain no toluene is trapped
within the affected area. Apply local pressure until a bond is obtained.

b. If necessary, peel back the rubber part in an affected area to gain access to
the region for repair. Then, re-cement as described in paragraph 2-61C step b.
following.

2-62B. If damage penetrated through a rubber part to the blade metal surface,
has

the surface shall be exposed and inspected for damage and corrosion. Cut away
the rubber for approximately 1/4 inch around the damage or peel back the rubber
and
part using MEK to loosen the cement. If a blade surface is damaged, inspect
repair as described previously under blade damage repair.

2-62C. Re-seal the metal surface which has been exposed beneath a rubber part
as follows. The use of EC 776 is not necessary if the peeled back portion is not
over the metal surface of the blade.

a. If the rubber has been cut away to expose the metal surface, the area shall
be filled with sealant. Clean the area with MEK to remove all traces of old cement
and foreign materials. Apply a coat of EC 776 to the exposed metal surface and
overlap it onto the rubber part. Allow to dry for 45 minutes. Apply a coat of
Bostik 1007 over the EC 776 and overlap it around the damaged area. Allow to dry
for 60 minutes. Apply a coat of Bostik 1096 over the Bostik 1007 and allow to dry
for 2 hours minimum. Fill any remaining cavity with EC 801/807 until flush with
the surrounding surface. Then, seal the area with a neoprene patch as described
in paragraph 2-60.c. preceding.

NOTE

EC -1300 adhesive may be used in place of Bostik 1096

for repair purposes only. If EC 1300 is used, use only
one coat of adhesive on each surface to be cemented
and air dry for 8 to 12 minutes before rolling parts in

place.

CAUTION

Do not allow Bostik 1007 to contact any metal surface.

Always apply it within the boundaries of EC 776 which

is applied to the metal surface first.

P5072

Oct 15/78 2-32

 #A~llron STAWDARB
~scnmKoclu,

b. If a rubber part is loose or has been pulled back to expose the metal sur-
face, it shall be recemented and the damaged area in the rubber part, if any, shall
be repaired. Trim any damaged area to make it smooth and even. Clean the area

and the peeled back rubber part with MEK. Mask off the metal surface 3/4 inch
from the peeled back portion of the rubber part. Apply a coat of EC 776 on the
metal surface within the masked area. Allow to dry for 45 minutes. Apply a coat
of Bostik 1007 over the EC 776, except for the area 1/4 inch from the masking

tape, and allow to dry for 2 hours minimum. Apply a second coat of Bostik 196
to the mating. parts and allow to dry for 30-60 minutes. Place the pelled back por-
tion of the rubber part in position and roll it down firmly with a rubber roller. Re-
move the masking tape and seal the edges of the recemented protion with EC 678 or

EC 801/807 mixture. The EC 678 or EC 801/807 mixture shall cover the previous
applications of EC 776, Bostik 1007, and Bostik 1096 and overlap onto the rubber
part. Next, if necessary, repair any damaged area in the rubber part as described
previously.

2-62D. BLADE HEATER ELEMENT REPAIR. damage´•involving cut or

Heater
broken heater wires due to small burns and stone strikes shall be repaired as
follows. If the damage is not visible, it can be located by isolating the brushes
from the blade slip rings, connecting an ohmmeter between the slip rings, and
manually pressing on the heater surface until the meter needle indicates the dam-
aged area. Repairs can be made by splicing a maximum of four wires in any one
heater. The wire used to make the splice repair shall be the same material and
size as that in the heater being repaired. This´• wire can be new or or it can be
obtained from a discarded heater of the same type. The "overlap" type of splice
shall be used. The ends of the wires making the repair shall be tinned with solder
conforming to Federal Specification QQ-S-571, Sn95WRP2. Use a low wattage
i~apid heating soldering gun for soldering.

NOTE

Repairs shall not extend outboard of a line 1. 5 inches

inljoard of the fairing
junction of the and the blade as

measured from the trailing edge as shown in Figure

2-17A.

a. Remove any contamination such as oil, grease, dirt, etc., from the dam-
aged area.

b. Cut away enough rubber to expose the damaged wire and those wires on
both side of the damage. Remove just enough rubber to permit working space ex-
that in the of bum blister, all loose, burned blistered
tpec.aera
material from the
case a or remove or

P5072
Oct 15/78 2-33
 HAMILTON STAPIBARb)
T~lllllr rrcnmroclu.

ir

ll--L18T--264B

Figure 2-17A, Heater Wire Repair Limit

c. If the repair area is located close to the blade metal surface, insulate the
area with a neoprene patch cut to fit the area. Apply the patch as described pre-

viously under rubber part repair.

d. Raise both ends of the broken wires and sand them lightly with fine sand-

paper. Tin them up to where the rubber is intact. Sand and tin the wires to be
used for splicing.

e. Place a piece of shim stock in the cavity and locate under the wires to be

spliced.

f. Bend both ends of the heater wires down and into place. Install the wires
to be spliced over the ends of the damaged’ wires and solder together in accordance
with Military Specification MIL-S‘-6872.

g. Remove the shim stock and check the heater resistance as described pre-

viously.

h. Fill the cavity with EC 801/807 mixture. Patch the repaired area as de-
scribed previously under rubber part repair. Air dry the patch for 24 hours or

bake at 65. 60C (1500F) for six hours.

i. After repair of the blade heater, make a resistancecheck by insulating the

blade brushes from the blade slip rings and measure the resistance through the

rings. The reading must be 5. 89 6. 82 ohms.

P5072
Oct 15/78 2-34
 HAMILTON STANDARD D~vlum d

U)IT~ED

CAUTION

Allow all cements, sealants, etc. to set for 6 days at

room temperature, or as much of these 6 days as cir-

cumstances permit, before running the engine. After

run-up, inspect visually for adhesion of repaired parts.

2-623. ALTERNATE BLADE HEATER REPAIR. An alternate procedure for re-

pairin~ damaged heater wires is described below:

a. Clean
damaged area and repair damaged wires in accordance with paragraph
2-62D. through step g.

b. Mix sealant, Laminar X500 Clear Polyurethane, one part by volume of

7-C-1 resin to one part of 10-C-32 hardener. Coat exposed wire and rubber sur-

faces with sealant.

c. Cure sealant with a heat gun at a temperature of 65. 6 79. 40C (150 -1750F)
for 15 minutes. Hold end of heat gun about 11-13 inches away from surface to be
cured.

d. potting compound, 100 parts by weight of Epon 828 or 834 to 10 parts of

Mix

Diethylenetria3nine and 5 parts of Cab-O-Sil. Fill rework depression with com-

pound. Remove excess.

e. Cure potting compound as described in step c.

f. Blend compound with surrounding heater surface by rubbing lightly with

fine sandpaper or file. Do not rub heater surface.

g. Coat potting compound and adjacent heater surface with sealant per step b.

h. Cure sealant for one hour and thirty minutes as described in step c.

NOTE

Curing must be performed in still air.

Oct 15/78 P5072

2-35
 -´•\’II- D"IY~ld

~u*mD´•
TEC~UYIUK;IES
ep

ABRASION LAYER

SEAL

PATCH

INSVkATION:LAYER LCEMENT1096

ABR~ASION LAYER

CEMENT IOOBi ~SEALING PATCH

1 I
ii

INSULATING LAYER LINSULATINC PATCH

3~T-sae

Figure 2’18. Repair of Conch~ctive-Rubber-Type Heaters

2~-63. BLADE HEATER INSTALLATION, NON-FAIRING-TYPE BLADES.

NOTE

If’the blade is ndt removed from the barrel assembly

thus making the angle markings on the blade butt in-
accessible, the center line of the heater shall coincide
with the center line of the leading edge. On blades
ha~ing cam mounts, the inboard end of the heater shall
butt against the outboard end of the mount. On blades
without cam mounts, the inboard end of the heater shall
be located at predetermined distance (former location)
a

from a fixed point on the barrel assembly, with the

center lines of heater and blade leading edge coinciding.

ORIGINAL
As Received By
Oct 15/78 P5072
ATP 2-36
 #A~ILTO# STLWDAI~B

NOTE

A more rapid rubber goods repair may be obtained

by the use of EC 1300 adhesive in place of Bostik 1096.
This is a one part system, no mixing required. Apply
EC 1300 to each bonding surface. Air dry for 8 to 12
minutes and then roll rubber part in place.

a. Mask off an area on the blade that is 0. 750 inch greater on all sides than the
actual heater size. (See Figures 2-19, 2-20 and Table M.

b. Clean the blade surface within the masked area with Dutch Cleanser, Ajar,
or equivalent. Rinse with clean water until a water-break free surface is obtained.

c. Apply a single coat of EC 776 resin cement to the masked off area and allow
to dry for 45 minutes minimum.

d. Apply a single coat of BE 1007 cement over the dried coat of EC 776 ce-

ment and allow it to air dry for one hour minimum.

e. Remove the protective cover from the new heater pad and using Grade
180-240 emery cloth, clean and roughen the protected side of the heater pad.

f. Apply a single coat Bostik 1096 cement to the cleaned surface of the heater

pad. Allow to dry 2 hours minimum.

OF HEATER

j
o~ cnM

CAM MOUNT I I

SHANK
DEGREES
LOCATIONi;
s~lir
Figure 2-19. Radial Location of Heater Figure 2-20. Longitudinal Location of Heater
and Cam Mount

Oct 15/78 P5072

2-37
 HAMILTON STANIDARQ DMYonol

uwntl3
TECnlKWGILS

TABLE M

BLADE HEATER LOCATION

B C
DE GRE E’S’
INCHES INCHES
BLADE (Figure 2-19)´•
(Figure 2-20) (Figure 2-20)

6521 62 4.94 4.88

6601 68 4.70

6851 68´• 3. 44

6873 68 3.44

6895 70 5.93 5.43

6921 70 5.43

7015 52 5.43

7019 70´• 5. 43

Butt edge of heater against cam mount.

g. Apply a second coat of Bostik 1096 cement to the heater pad. Allow to dry
30 to 60 minutes then roll the heater in place. Make sure the heater is laying
smooth without air bubbles and without oserlapping. When rolling on the heater
pad, align the center line of the pad with the leading edge of the blade. Roll the
camber side of the blade toward the trailing edge. Roll the face part of the pad in
the same manner.

h. Remove the masking tape and seal’ the edges of the heater with EC 678 or

EC 801/807 mixture.

i. Check heater and connector resistances. (See Table XII.

2-64. INSTALLATION OF DEICER FEED SHOES AND TROUGHS.

a. The metal portion of anodized blades:to be covered by the feed shoe and

trough plus one inch beyond this area shall´• be cleaned free of paint, oil, grease,
etc, using a solvent such as methyl ethyl ketone Specification TT-M-261. Do not
use abrasive cleaning on these blades. A water rinse of the cleaned area shall
produce a "water break-free surface", Allow surface to dry completely.

Oct 15/78 P5072

2-38
 HARIIILfON ST~\NDARQ ´•-\\’//´•-D"""
~LLu*mD
~1Rllr I1ECI(IKKDGIES.

b. Carefully clean the area of non-anodized satin finish blades with a mild
abrasive cleaner such as Ajar or Old Dutch Cleanser using a clean cloth. Rinse
with clean water. Repeat cleaning operation until no "water breaks" or greasy
spots are visible on the area to be cemented. Allow the surface to dry completely.

NOTE

Surfaces to be cemented shall not be touched by the

hands or otherwise become contaminated.

c.´• Mask off the cleaned blade area to allow a 0. 5 inch overlap of the cements
on the blade surface.

ci Cement application for the nibber parts shall be done at such time that
drying of the metal and rubber cemented surfaces will occur approximately atthe
same time. Use separate brush for each cement.

e. On aluminum and anodized surfaces apply one thin even coat of EC 776 ce-
ment. Allow to dry 45 minutes minimum. Apply one thin even coat of BE 1007
cement. Allow todry one hour minimum. Then apply one thin even coat of Bostik
1096 cement and allow to dry 2 hours minimum.

CAUTION

EC 776 cement shall be used on aluminum surfaces

whether anodized or not, before application of other
cements which shall not be permitted to extend beyond
the area covered with EC 776 cements.

f. On nickel plated surfaces, apply one thin even coat of BE 1007 cement.
Allow to dry one hour minimum and then apply one thin even coat of Bostik 1096
and air dry 2 hours minimum.

g. On the feed shoe and trough, apply a thin coat of Bostik 1096 cement. Allow
to dry 2 hours minimum and then apply a second coat of Bostik 1096 cement and
air dry 30 to 60 minutes.

Oct 15/78 P5072

2-39
 avlsm o(
IIAMILTOW ST~UIDIUU)
i~ uwmD
TECnm)rDCIES

NOTE

If the blade has not been removed from the propeller

assem~jly sindreplacement of the feed shoe or trough

isto-be mside,´• locate the position of the old feed shoe

o~ trough:by measurement of either from a fixed point
on the bar’rel assellibly. Use these dimensions for
installation of th~ new parts. The new feed shoe flap
shall 6e~ t~riinmed toextend 0.060 inch under the dis-

charge nbiile oftl;e t~ough. The center lines of the

fei~d s~oean’d blade l’eading edge shall coincide. The
center groove of the feed- shoe shall fall in line with
the ceriteli of the hole: in’ the trough within 0. 020 inch.

h. Installation Procedure.

(1) With c~ialk, mark´•a. centerline the length of the feed shoe for installa-
tion convenience. Penci’T mark´• a centerline on the blade shank in line with the "A"

degree marking as tabulated in X. Extend the line to the cemented area.

See´•Figure 2-21.

(2) Using a vernier? caliper or similar

measuring device, measure the "B"
and "C" distances as tabulated to locate axially the parts to be installed. Lightly
mark the location points on the blade beirig careful not to penetrate the outer layer
of cement. See Figure 2-22.

TABLE X
FEED SHOE AND TROUGH LOCATION

TYPE A B C SHOE LENGTH

BLADE DE-ICING DEGREES INCHES INCHES (INCHES t- 0. 13)

6869 Fluid 52 7. 15 5. 43 49. 10

6895 Fluid 70’ 7. 15 5. 43 49. 10

6901 Fluid 52 7. 15 5. 43 49. 10

6903 Fluid 52 7. 15 5. 43 49. 10

6959 Fluid 52 7. 32 5. 63 49. 10

6967 Fluid 52 7.32 5.63 49.10

6969 Fluid 70 7. 15 5.43 49. 10

6993 Fluid 52 7. 32 5. 63 49. 10

Oct 15/78 P5072

2-40
 HAMILTON STAWDARB ham"
~X ~unnu,
IEC~WOLOWES.

CENTER GROOVE

DISCHARGE HOLE

CENTER GROOVE OF SHOE

AND DISCHARGE HOLE IN
TROUGH MUST ALIGN
W\THIN 0.060 IFL. BOTH
POINTS

SHANK LOCATION
DEGREES

Figure 2-21. Radial Location of Feed Shoe and Trough

TO FEED SHOE~----------------- 8.
GROOVE
SHOULOER

TO FACE OFJ I I I I I‘\

TROUGH I/II 1 ‘~__

ill
~L1

Figure 2-22. Long´•itudial Location of Feed Shoe and Trough

Oct 15/78 P5072

2-41
 HAMILTOW STAWD~UIQ
~cnmrocrs.

(3) When the final coats of cement have air dried for 30 to 60 minutes, in-
stall the trough. Install the feed shoe using the markings for locating. Adhere the
pad to the blade along the leading edge and then carefully roll outward from the
centerline on the face andcamber side. Any method of application is permissible
provided the parts are well rolled to a smooth fit,free of overlaps, bulges, and air
bubbles

(4) Remove the masking tape and seal the edges of´•the parts with EC 678
or EC 801/807 sealer. The seal shall extend approximately 0. 250 ´•0. 500 inch
over each rubber part and 0. 250 inch beyond the band of exposed cement on the

blade.

.(5) permissible to relieve~ air bubbles under a feed shoe by puncturing

It is
the part with a #17 gage hypodermic needle. Do not scratch the:blade surface
when the hypodermic needle is pushed through the feed shoe.

NOTE

The cements used acquire their maximum strength

after five days degrees C (68 degrees Fl or
at 20

approximately one day at 60 degrees C (140 degrees

F.). Experience has shown that the curingtirYle for
cements is relatively short under normal conditions.
Under other conditions, such~as tropical;or arctic,
the operator shall make allowances accordingly.
However, it is recommended that the minimum time
lapse between feed shoe andtrough installation shall
not be’less than eight hours, normally.

2-65, Deleted.

Oct 15/78 P5072

2-42
 #nmlrToa STA~DARD
U#T~ED
TECnm)UKilES

2-66. ABRASION STRIP INSTALLATION.

2-67. Protection for aluminum blade heaters is provided by the use of replaceable
abrasion strips thus increasing the service life of the heater.

a. Clean the heater surface tobe covered with an approved solvent and mask
an additional 0. 500 inch area around the strip.

b. Roughen the surface of the strip to be cemented with No. 40-80 grit emery
orsand paper. Again, clean this surface.

c. coating of EC 776 onto the surface

Apply a to be covered by the abrasion
strip and follow with a coating of BE 1007. Allow one hour drying time between
each application of adhesive.

d. Apply one thin even coat of Bostik 1096 on the blade and strip surfaces to be
adhered.

e. Adhere the strip to the blade being certain that each side of the strip is
equidistant from the center line of propeller leading edge. Roll the surface to pro-
duce a surface free of air pockets and overlaps. The strip should extend 1. 00-1. 50
inches outboard of the heater outboard end.

f. Remove masking tape and seal edges of abrasion strip with EC 678 or

EC 801/807 sealer.

g. Allow at least five hours drying time before operation of blade in propeller.

2-68. TURBO-PROPELLER BLADES A7109C-2 AND A7111C-2.

2-69. Turbo propeller blades are surface treated and have Lockfoam fairings
located at the inboard end of the blade airfoil section. In addition, the blades have
deicing heaters, spinner seals and electric contact ring (slip ring) holders. Clean-
ing, Inspection, and Maintenance procedures for surface treated blades apply here
except for the procedures noted in the following paragraphs.

oct 15/78 P5072

2-43
 YIUII´•CCIU ~kvi5wnd
~ji ~wrrm
~F

2-70, Replace:blade .heater as.follows:

a, Trim any ragged edges of the coverstock along the end boot,

b, Remove-any ´•residual´•adhesive ,from the fairing boot and blade metal using
toluene,

c, residual.adhesive from the lockfoam by sanding, Also, sand

Remove any
an additional 1/2 -inch:minimum along;the length of the coverstock to the blade

metal on both sides of the blade.in Ipr.eparation for an overlapping patch,

d. Cut a single.piece of fairing.coverstock to replace the removed portion and

to oveil8p onto the ~sides of:the remaining coverstock for 1/2 inch minimum, Also,
the patch shall extend from.the ´•bootito the blade metal as far as the removed por-
tion, Mask off the remaining part ~of the blade metal.

e, Bond the coverstock´•patch to the ´•area as described in paragraph 2-62C,b,

f. Position’the.new heater fairing coverstock with its centerline aligned

on the
with the centerline of the fairing ´•leading edge within 1/16 inch, and with its inboard
end within 1/4 inch of the fairingbutt.face, Bend the heater lead straps into the
indented areas of the.fairing. The heater tabs shall overlap the cable tabs by at
least 1/4 inch in order to solder them together later and the tabs may be trimmed
as necessary. Both sides of the ´•lead and the ´•inboard end of the heater may be
trimmed a maximum of 1/8 ~inch ~if required to fit the fairing contours,

g, Mask off an area on the fairing co~erstock 1/2 to 3/4 inch wider than the
heater and 1/2 to 3/4 inch outboard of the heater. Remove the heater,

h, Prepare the mating Feater tabs and cable assembly tabs for tinning by
cleaning the metal surfaces to be soldered with fine sandpaper, Do not use emery
cloth, Tin the cleaned surfaces with solder conforming to Federal Specification
QQ-S-571 Sn95WRP2,

Oct 15/78 P5072

2-44
 ""YO""
HARIIILTON STAIIIBARQ
uwlm,
’i~Jll*

i. Using fine grit sandpaper (not emery cloth), roughen the fairing coverstock
surface to be covered by the heater including the indented areas in the fairing boot
butt face for the lead straps. Also, roughen the under surface of the heater in-
cluding the lead straps. Clean the roughened surfaces of the fairing coverstock
and heater with a clean cloth dampened with toluene, Federal Specification TT-T-
548. Allow to dry for 3 hours.

NOTE

After cleaning, do not touch the surfaces or allow them

to become contaminated with foreign materials.

j, Apply a coat of Bostik 1007 primer to the clean surface of the blade.heater.

Dry for 60 minutes minimum.

k. Apply a coat. of Bostik 1096 adhesive to the under surface of the heater in-

cluding the lead straps and the masked ares of the fairing coverstock and the in-
dented areas in the boot butt face which mate with the heater lead straps. Allow
to dry for two hours minimum.

second coat of Bostik 1096 mixture to the mating surfaces and dry
ylppAaggressively
a

for 30-60 minutes until .ykcat Place the heater in position as de-
scribed in step f. Using a hard rubber roller~about 1-7/8 inches wide by 1-7/8
inches in diameter, roll the heater down along the camber side of the fairing,
working from the leading edge toward the trailing edge. Use moderate pressure
only. Then, roll the heater down on the face side of the fairing in the same manner.
Also, roll or press the heater lead straps into position.

m. Shim beneath the heater tabs with a thinpiece of material not’ susceptible
to solder. The tabs shall have a minimum soldered connection of 1/4 inch in
length. Using a 300-400 watt soldering iron, heat sufficiently for
the tabs the

tinning to join them together in accordance with Specification n/IIL-S-6872. Re-

move the shims and clean up any flwr.

n. Coat the exposed metal braid of the tabs with Bostik 1007 and allow to dry
for 60 minutes. Fill the spaces around the tabs with EC 801 -so as to make a smooth
continuous appearance with the top of the tabs and the surrounding area.

Oct 15/78 P5072

2-45
 sTnwDaRB

CAUTION

Do not ´•allow ,the EC 801 covering each ´•tab area

to join together since electrical leakage between

the.tabs may result

o, ´•Bond a neoprene rubber.patch (0. 020 0. 080 inch thick) over the exposed
braid surfaces as described previously in paragraph 2-60. c.

~p. Seal ´•the eclges.of´•thepatch, the heater and its lead straps, and the cable
assembly lead straps (if necessary) with EC 678. Remove the masking tape.

q. After installation of a new´•blade deicer heater, apply two coats of blackout

lacquer per Specification MIL-’C-1´•1520 on the blade heater and leads. Allow to
dry after each coat. Then, finish up with a coat of black lacquer per Federal
Specification TT-L-20.

r. After all cements and sealants arecompletely dry, check the heater resis-
tance as described
previously under inspection, Then, perform an engine running
ground check of blade deicing and re-check the heater resistance. Also, inspect
all areas closely for burns or blisters and poor adherence.

CAUTION

Allow all adhesives, cements, sealants, etc., to set for

6 days at room temperature, or as much of these 6 days
as ~circumstances permit, before running the engine.
After run-up, inspect visually for adhesion of repaired
parts.

2-71. See paragraph 2-8 for disposal of blades that have

experienced an overspeed.
Paragraph 2-12 carries instructions for
disposal of blade involved in an impact in-
cident. See paragraph 2-29 for use of blade alignment indicator gage HS 8550 use
to detect changes in blade alignment after actual or suspected impact incidents.

2-72. BLADE REPAIR TURBO-PROPELLER BLADES.

2;73. Since the A7109C-2 and A7111C-2 blades are surface treated, inspection and

repair procedures as covered in paragraph 2-22 and paragraph 2-41 are followed

Oct 15/78 P5072

2-46
 HAMILTON ZbrAsJDARQ DI~YO""

~IIP’ ~Ecnwoun;lEs.

with the following differences: Figure 2-23 defines the maximum depth of gouges
on the blade metal surface which do not require rework until overhaul. Cuts, pits,
gouges, etc., exceeding the limits shown shall be reworked to remove all traces
of damage. After this rework, remove an additional 0. 002 inch from the bottom
of the area by polishing with No, 240.emery cloth followed up by No. 320 emery
cloth. Reworks exceeding the limits shpwn in Figures 2-24 and 2-25 are cause
for return of the blade to an approved overhaul facility.

NOTE

Rework in the area ten inches from the blade tip

shown in Figures 2-23, 2-24, and 2-25 is not limited
by depth, width, or length provided that the rework
does not extend in a line across the blade or will
cause deterioration in the blade structure at any
point. "No limit" does not permit shortening of a

blade or a set of blades by three inches.

NOTE

Either the leading or trailing edge may be reworked to

the maximum depth shown in Figure 2-24, provided that

opposite edge (chordwise along the same station) does

not also require rework. For rework affecting opposite
edges, the combined rework depths shall not exceed the
value shown for one edge. For example, in the edges where
the maximum depth is 0. 150 inch, a rework depth of 0. 100
inch in one edge will leave only 0. 050 inch rework depth

(0. 100 0. 050 0. 150 inch maximum) in the opposite edge.

2-74. Damage caused by lightning strikes’and other electrical burns shall be

treated in the
same manner as gouges with the exception that after all damage has

been removed, an additional 0. 020 inch shall be removed. The total stock removal
shall not exceed the limits shown in Figures 2-24 and 2-25.

2-75. The only acceptable method of removing damage is that which metal con-
taining and adjacent to the damage is removed from the blade by medhanical means

as stated in paragraph 2-41. All traces of damage shall be removed from the
blade and resultant depressions shall be smoothly faired into th blahe surface.
Methods by cold working to cover or conceal the damage are not acceptable.

Oct 15/78 P5072

2-47
 HAMIILTON STAWD~UIB
~JJ(llr 755555555155,

NO LIMIT
PERNOTE IN TEXT

0.020 (A710gC-2 BLADES)

0.012 (A7111C--2 BLADES)
0.006 EXCEPT 0.004 IN AIPREVIOUSLY EXCEPT 0.008 1N A PREVIOUSLY
REWORKED AREA.
REWORKED AREA.

3.00
LIP TO 32.00 FROM TIP -1-- 32.00 FROM TIP

NOTES:
1. DIMENSIONS IN INCHES.
2. MATERIAL Q(tA--367 OR AMS4130
HARDNESS 100 BHN MIN.

ll--L185--26A

Figure 2-23. Ilam~e Requiring No Rework Turb~Propeller Blades

MAX DEPTH OF REWORK ALLOWED ON LEADING AND TRAILING EDGES.

EITHER LEADING OR TRAILING EDGE (BUT NOT BOTH) MAY BE REWORKED
TO MAX DEPTH ALONG SAME STATION (CHORD LINE).

o.15 r" 0.40-7 NO LIMIT

PER NOTE IN TEXT

0.06

0.06

ROM

Ui
LIP
TO 12.00
FROMBAEL 0.15
0.25
BARREL LIP 3´•00
1~.00 FROM BARREL LIP TO 32. -32.00 FROM TIP TO 18.00--t~18.00 FROM--CI
FROM TIP FROM TIP TIP TO 3.00 FROM TIP
NOTES:
i. DIMENSIONS IN INCHES. LENGTH OF REWORK IN LONGITUDINAL BLADE DIRECTION SHALL BE
2. MATERIAL GO-A-367 OR AMS4130 NO LESS THAN TEN TIMES DEPTH OF REWORK.
HARDNESS 100 BHN MIN.

ll--L185--8D

Figure 2-24. Local Rework Limits on Leading and Trailing Edges

Turbo-Propeller Blades

Oct 15/78 P5072

2-48
 STANDARQ DIYLShXIO1

m
T~llllr

NO LIMIT
PER NOTE IN TEXT

0.060 BUT NO MORE THAN 251 OF SECTION

THICKNESS AT POSITION OF REWORK.

BARREL LIP TO 3.00 FROM TIP I---r 3.00

LENGTH OF REWORK IN LONGITUDINAL BLADE DIRECTION SHALL

NOTES:
BE NO LESS THAN THIRTY TIMES DEPTH OF REWORK.
i. DIMENSIONS IN INCHES.
2. MATERIAL QQ--A--367 OR AMS4130
HARDNESS--100BHN MIN. ll--L18S--9D

Figure 2-25. Local Reworks on Face and Camber Sides Turbo-Propeller Blades

2-76. The number of repairs in a given area on the blade is not limited
providing
their locations with respect to one another do not form a continuous line of repairs
that would material weaken the blade structure. Local rework forming a continu-
ous line across the blade width are NOT acceptable. Bending or twisting of the
blade is cause for immediate removal of the blade.

2-77. BLADE FA~RING REPAIR TURBO-PROPELLER BLADES.

a. If damage penetrated through the rubber fairing boot or the neoprene

has
coverstock to the Lockfoam formed fairing, the Lockfoam shall be exposed by
cutting away the damaged covering plus an additional 1/2 inch around the damage.
Inspect and repair as follows:

(1) If the Lockfoam is just slightly damaged, sand it until smooth. Clean
the Lockfoam with a cloth dampened slightly with MEK or toluene. Then, apply a

neoprene patch as described in step (5).

(2) If the Lockfoam is damaged, cut out the damaged portion. If the re-

sulting cavity is larger than 4 square inches by 1/2 inch deep or 2 square inches
by 1/2 inch deep or 2 square inches by 1 inch deep, or if the total area of more
than one rework on one side of a fairing will exceed 5 square inches, or if the
blade surface is exposed, the propeller shall be removed from service. Cavities
smaller than these dimensions shall be refilled as described next in step (3) ex-

Oct 15/78 P5072

i-49
 DNlun or
HdMILTOIISTANDARD
UllmD
TECnl(OLDGIES

cept that a cavity in the trailing edge of the fairing that is not larger than 2 inches

long by 1/2 (chordwise)

inch wide need not be refilled. In the latter case, clean

the exposed Lockfoam with a cloth dampened slightly with MEK or toluene. Apply
a coat of Bostik 1007 to the exposed Lockfoam overlapping it onto the surrounding

covering. Allow to dry for one hour minimum. Apply a coat of EC 801/807 over
the Bostik 1007 and allow to dry. It is not necessary to apply a neoprene patch.

(3) Cavities not larger than 4 square inches by 1/8 inch deep, or 2 square
inches by 1/4 inch deep, or 1 square inch by 1/2 inch deep shall be refilled with
Epon 834 or Cycleweld C-14. First, clean the Lockfoam area with a cloth damp-
ened slightly with MEK or toluene. Then, if necessary, mask off the cavity to
farm a mold for retention of the filler whein it is poured into the cavity. Allow
to dry for 30 minutes minimum at 32. 2 79. 4"C (90 175 OF). After the filler has
hardened, blend the surface in with the surrounding area using a file and sandpaper.
Then, apply a neoprene patch as described in step (5) following.

(4) larger than the limits in step (3) but not larger than the limits
Cavities
in step (2) refilled with a piece of cured Lockfoam held in place with resin.
shall be
First, scrape the cavity and Sit the Lockfoam. Clean the area with a cloth damp-
ened slightly with MEK or toluene. Coat the cavity with Epon 834 or Cycleweld
C_14 -and insert the filler. Allow to dry for 30 minutes at 65.6 79.40C (150
1750F). After the resin has cured, blend the surface in with the surrounding area

using a file and sandpaper. Then apply a neoprene patch as described next in
step (5).

NOTE

EC 1300 adhesive may be used in place of Bostik 1096

for repair purposes only. If EC 1300 is used, use
only one coat of adhesive on each surface to be cemented
and air dry for 8 to 12 minutes before rolling parts
in place,

(5) After a rubber fairing boat or the neoprene coverstock has been cut
away for inspection land repair, iS´•necessary) of the Lockfoam fairing, the covering
shall be patched except for the trailing edge area as described in step (2) above.
$elect patch of neoprene coverstock about 1/2 inch larger all around than the
a

exposed Lockfoam except that the ´•patch shall not pass around the trailing edge of
the blade,. Apply a coat of Bostik 1007 to the exposed Lockfoam overlapping it on-
to the covering for about 3/4 inch around the exposed Lockfoam. Allow to dry for
60 minutes. Apply a coat of Bostik 1096 over the Bostik 1007 and on the under

Oct 15/78 P5072

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 HAMILTON STANDARQ ""’S"n"

~uwmD

surface of the patch. Allow to dry for 2 hours minimum. Apply another coat
Bostik 1096 to the mating parts and allow to dry for 30 to 60 minutes. Place the
patch in position and roll it down gently with a roller. Seal the edges of the patch
including the exposed cement with EC 678 or EC 801/807 mixture.

(6) If the fairing coverstock is lifting at the edges, the affected area is not
contaminated with oil or grease, and there is no moisture entry, apply one coat of

Bostik 1096 to the area and air dry for 30 to 60 minutes, then roll the coverstock
back in place. Coat the edge with EC 678 or EC 801/807 mixture. If the area is

contaminated, remove the cover stock from the affected area. Apply patch of
a

coverstock as described in above paragraphs and coat with EC 678 or EC 801/807

mixture. In cases of more than slight damage, repairs would be made with either
Epon 834 or Cycleweld’C-14 in the same manner as above-mentioned repairs.

CAUTION

Allow all adhesives, cements, sealants, etc., to set for

6 days attemperature, or as much of these 6 day as
room

circumstances permit, before running the engine. After

Run-up, inspect visually for adhesion of repaired parts.

2-78. DAMAGED BLADE SLIP RINGS.

2-79. Grooving, gouging or pitting on blade slip rings shall be removed using a
flat stone, file, or emery cloth. Reworks shall be well blended and polished with
No, 320 emery cloth. Reworks on (slip) rings exceeding
contact 0. 005 inch are

not acceptable in which case, the slip ring shall be replaced.

2-80. NICKE GPLATED BLADES.

2-81. plated blades

Nickel involved in impact and overspeeds shall be handled in
accordance with procedures of paragraphs 2-8 and 2-12 with the follo~´•ing additions.

2-82, INSPECTION.

2-83. Blades shall be inspected daily and at 75-150 hour periods.

2-84. DAILY INSPECTION. Blades shall be given a careful visual inspection once

each day of operation.

a. Blades with gauges, abrasions, nicks, scratches, pits, etc., shall be

treated as follows:

Oct 15/78 P5072

2-51
 )(AM(LTON STL~SDARQ "wurx~ot

U#TtED
TECnmWCIES,

b. Gouges and isolated pitting less than Oi 004 inch need not be removed. Gou-
ges and pits greater than 0. 004 inch shall be cause for tagging the blade for man-
ufacturer’s repair and routed to supply.

c. A blade with one or more gouges which penetrate the nickel plating shall
be removed subject to flyback limita~ioris.

d. Blades with evidence of lightning strike damage, such as blisters, bums,

discoloration, puddled metal shall be removed subject to flyback limitations.

e. Any corrosion, pitt;ing, or burns in the area of the nickel plating end seal
shall be reri~oved subject to flyback limitations.

2-85. 75-120 HOURS INSPECTION.

2-86. Blades shall be thoroughly cleaned per paragraph 2-20 to remove all signs
of dirt, oil, grease or other conta3ninants and then given a careful visual examin-
ation with eyes no further than two feet from that portion of the blade to be inspected.
Repeat DAILY INSPECTION PROCEDURES.

2-87. REPAIR PROCEDURES.

2-88. See Table IV for cement and sealer data. Local rework in the unplated area
covered by the nickel plated end seal because of mechanical damage, is permissible
provided repairs are made in accordance with Figure 2-9 and the rework blend is
closer than 0. 50 inch to the nickel plate ending.

2-89. If the nickel plate end seal is to be removed because of damage to it and the
blade surface underneath, it shall be removed by using a thin micarta or brass
chisel and methyl ethyl ketone (MEK) Specification TT-M-261. With chisel and
MEK, loosen the outboard edge of the seal and work toward the inboard edge. DO
NOT WORK INBOARD Tb OUTBOARD. After removal, discard the seal. A clean
cloth dampened with MEK and well wrung out may be used to clean the seal area.
The deicing trough can be loosened and peeled back far enough to allow access to
the nickel plating end seal, the loosened portion of the trough shall be replaced in
accordance with instructions of paragraph 2-64.

CAUTIOhT

When approaching the nickel plate ending use care apply-

ing MEK. Apply it sparingly since the solvent may damage
the nickel-to-aluminum bond. Never allow any type of

P5072
Oct 15/78
2-52
 #ANIILTON STAND~RQ
~L ~mD

fluid to contact the adhesive layer beneath the nickel at

the plate ending. Therefore, seal the plating ending with
31M Electroplating Tape (Scotch 470) as a preventive.

2-90. Repair damaged nickel plate end seals by removing the damaged portion of
rubber using a knife made of copper, brass, or aluminum. Clean the blade area
over which the repair is to be made, using methyl ethyl ketone Specification TT-M-

261. Apply EC 776 cement to the exposed metal area and overlap onto the rubber
slightly to assure complete metal coverage. Air dry one hour. Apply one thin
coat’of BE 1007 over the EC 776. Air dry one hour. Fill in the cavity with EC 801/
807 and air dry for a minimum of time of two hours before the blade’is placed in
service.

2-91. If a trough, electric deicer shows evidence of damage which has

feed shoe,

penetrated to the blade surface, the rubber shall be peeled back or cut away locally
to permit examination and evaluation of the damage. If no visual damage to the
blade is present, the rubber shall be repaired in accordance with instructions of

i~aragraph 2-59.

2-92. Installation of Nickel Plate End Seal.

a. Inspect the areaby the nickel plating end seal. If no abnormalities

covered
are present, tape the nickel ending to prevent entry of fluids, using 3M Electro-

plate Tape (Scotch #470). The tape shall extend 0. 250 inch onto the nickel and
0. 250 inch onto the anodized blade. Clean the seal area using pumice and water
to obtain a water break-free surface. Remove the masking tape and clean the
area with a clean cloth dampened with methyl ethyl ketone Specification TT-M-261,

well wrung out.

b. Apply 0. 250 inch masking tape to enclose the seal area allowing 0.500 inch
additional on either side of this area. (See Table XI.

c. Apply EC 776 cement to the bare aluminum and zinc plated surfaces. Over-

lap onto the nickel plate 0. 500 inch. Air dry 45 minutes.

d. Apply a thin coat of BE 1007 cement to the bare aluminum and zinc plated
surfaces between the tapes. Allow to dry one hour minimum.

CAUTION

Never apply BE 1007 directly to the bare aluminum.

EC 776 is the non-corrosive cement to be used as a

primary coat.

Oct 15/78 P5072

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 ~ULMILTOW SeANDARD
UIIITIED
TbCnm~LLnilES

TABLE XI

NICKEL PLATING END SEAL LOCATION

BLADE BUTT TO SEAL

BLADE PLATING SEAL INBOARD EDGE (INCHES)

515863 6.62-6.72
6967A

515862 6. 62-6. 72
6969A

515862 5.15-5.25
7007A

549480 5.15-5.25
7113A

e. Apply a thin coat of Bostik 1096 cement over the BE 1007 cement.

Roughen both sides of the plating end seal with No. 180 emery cloth to re-
f,
move gloss, talc, wax, etc. Clean the surface with a clean cloth dampened with
toluene Federal Speci~fication TT-T-548.

Slip the s~eal over the blade butt and place it in the position it is finally to
g.
assume. Expose the surface that is to adhere to the blade by turning seal inside
out. Coat this surface with 8ostik 1096 and allow to dry for 2 hours minimum and
then apply a second coat and allow to dry 30 to 60 minutes. When the cement is
tack free turn the seal right side out making certain it falls into the proper location,
Roll the seal for proper adhesion. Trapped air shall be removed by "tunneling"
with a preheated wire or hypodermic needle. DO NOT DAMAGE THE ALUMINUM
BLADE SURFACE.

h. Seal the edges of plating seal with BE 1096 cement except in an area where
a heater or feed shoe will overlap. Air dry for 2 hours minimum. Apply one coat
of EC 678 or EC 801/807 sealer over the Bostik 1096 cement, Air dry.

Oct 15/78 P5072

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 ~kvluond
HAMILTOW STANDbRD
i~ uwrrm
TECn~OUnaES

TABLE XII

BLADE HEATER RESISTANCE DATA

RESISTANCE RESISTANCE
HEATER HEATER BEFORE AFTER SERVICE
PART NUMBER TYPE INSTALLATION INSTALLATION HIGH

75776 Conductive Rubber 0. 38-0. 48 0. 45-0. 60 0. 60

78932 Conductive Rubber 0. 30-0. 38 0. 34-0. 48 0. 52

78934 Conductive Rubber 0. 41-0. 51 0. 48-0. 62 0. 62

84763 Conductive Rubber 0. 30-0. 38 0. 34-0. 48 0. 52

90100 Conductive Rubber 0. 3~-0. 38 0. 34-0. 44 0. 52

95096 Conductive Rubber 0. 30-0. 38 0. 34-0. 48 0. 52

501239 Wire Element 0. 37-0. 41 0. 37-0. 41 0. 52

503718 Wire Element 0. 37-0. 41 0. 37-0. 41 0. 52

505050 Wire Element 0. 43-0. 47 0. 43-0. 47 0. 52

513531 Conductive Rubber 0. 28-0. 36 0. 36-0. 44 0, 52

514392 Wire Element 0. 37-0. 41 0. 37-0. 41 0. 52

548588 Conductive Rubber 0. 30-0. 38 0. 34-0. 48 0. 52

"537232 Wire Element 5. 89-6. 51 5. 89-6. 51 6. 82

~538876 Wire Element 6. 93-7. 66 6. 93-7. 66 8. 03

*After heater installation apply 70-75V AC or DC for 20-30 seconds. Reapply

70-75V AC or DC for 20-30 seconds. There shall be no evidence of surface
imperfections or local overheating.

Oct 15/78 P5072

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