Manual No.

491
61-10-91
Original
November 2018

Three Blade Raptor Series Reciprocating

Propeller Overhaul Manual

For Constant Speed and Feathering Propeller Models:

3C2-( )( )( )

Hartzell Propeller Inc.

One Propeller Place
Piqua, Ohio 45356-2634 U.S.A.
Phone: 937.778.4200
Fax: 937.778.4215
PROPELLER MAINTENANCE MANUAL
491

© 2018 - Hartzell Propeller Inc. - All rights reserved

INSIDE COVER 61-10-91 Inside Cover

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

REVISION HIGHLIGHTS
• Original Issue manual issued in its entirety

REVISION HIGHLIGHTS 61-10-91 Page 1

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

REVISIONS HIGHLIGHTS

1. Introduction

A. General
(1) This is a list of current revisions that have been issued against this manual.
Please compare to the RECORD OF REVISIONS page to make sure that all
revisions have been added to the manual.

B. Components
(1) Revision No. indicates the revisions incorporated in this manual.
(2) Issue Date is the date of revision.
(3) Comments indicates the level of the revision.
(a) New Issue is a new manual distribution. The manual is distributed in its
entirety. All the revision dates are the same and no change bars are used.
(b) Reissue is a revision to an existing manual that includes major content
and/or major format changes. The manual is distributed in its entirety. All
the revision dates are the same and no change bars are used.
(c) Major Revision is a revision to an existing manual that includes major
content or minor format changes over a large portion of the manual. The
manual is distributed in its entirety. All the revision dates are the same, but
change bars are used to indicate the changes incorporated in the latest
revision of the manual.
(d)  Minor Revision is a revision to an existing manual that includes minor
content changes to the manual. Only the revised pages of the manual are
distributed. Each page retains the date and the change bars associated
with the last revision to that page.

Revision No. Issue Date Comments

Original Nov/18 New Issue

REVISION HIGHLIGHTS 61-10-91 Page 2

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

RECORD OF REVISIONS
This is a permanent historical record of revisions inserted into this manual.

Revision Issue Date Inserted Revision Issue Date Inserted

Number Date Inserted By Number Date Inserted By

Orig. Nov/18 Nov/18 HPI

RECORD OF REVISIONS 61-10-91 Page 1

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

RECORD OF REVISIONS
This is a permanent historical record of revisions inserted into this manual.

Revision Issue Date Inserted Revision Issue Date Inserted

Number Date Inserted By Number Date Inserted By

RECORD OF REVISIONS 61-10-91 Page 2

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

RECORD OF TEMPORARY REVISIONS

Update this page to show all temporary revisions inserted into this manual.

Temporary Section/ Issue Date Inserted Date Removed

Revision No. Page Date Inserted By Removed By

RECORD OF TEMPORARY REVISIONS 61-10-91 Page 1

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

RECORD OF TEMPORARY REVISIONS

Update this page to show all temporary revisions inserted into this manual.

Temporary Section/ Issue Date Inserted Date Removed

Revision No. Page Date Inserted By Removed By

RECORD OF TEMPORARY REVISIONS 61-10-91 Page 2

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

SERVICE DOCUMENT LIST

CAUTION 1: DO NOT USE OBSOLETE OR OUTDATED INFORMATION. PERFORM

ALL INSPECTIONS OR WORK IN ACCORDANCE WITH THE MOST
RECENT REVISION OF THE SERVICE DOCUMENT. INFORMATION
CONTAINED IN A SERVICE DOCUMENT MAY BE SIGNIFICANTLY
CHANGED FROM EARLIER REVISIONS. FAILURE TO COMPLY WITH
INFORMATION CONTAINED IN A SERVICE DOCUMENT OR THE USE
OF OBSOLETE INFORMATION MAY CREATE AN UNSAFE CONDITION
THAT MAY RESULT IN DEATH, SERIOUS BODILY INJURY, AND/OR
SUBSTANTIAL PROPERTY DAMAGE.

CAUTION 2: THE INFORMATION FOR THE DOCUMENTS LISTED INDICATES THE

REVISION LEVEL AND DATE AT THE TIME THAT THE DOCUMENT
WAS INITIALLY INCORPORATED INTO THIS MANUAL. INFORMATION
CONTAINED IN A SERVICE DOCUMENT MAY BE SIGNIFICANTLY
CHANGED FROM EARLIER REVISIONS. REFER TO THE APPLICABLE
SERVICE DOCUMENT INDEX FOR THE MOST RECENT REVISION
LEVEL OF THE SERVICE DOCUMENT.

Service Document Incorporation Service Document Incorporation

Number Rev./Date Number Rev./Date

61-10-91
Page 1
SERVICE DOCUMENT LIST Nov/18
 PROPELLER MAINTENANCE MANUAL
491

SERVICE DOCUMENT LIST

Service Document Incorporation Service Document Incorporation

Number Rev./Date Number Rev./Date

SERVICE DOCUMENT LIST 61-10-91 Page 2

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

AIRWORTHINESS LIMITATIONS

1. Certain component parts, as well as the entire propeller, may have specific life limits
established by the FAA. Such limits require replacement of items after a specific number
of hours of use.

2. Airworthiness limitations information:

A. For airworthiness limitations information, refer to Hartzell Propeller Inc. Owner's

Manual 480 (61-00-80).

AIRWORTHINESS LIMITATIONS 61-10-91 Page 1

Nov/18
PROPELLER MAINTENANCE MANUAL
491

(This page is intentionally blank.)

AIRWORTHINESS LIMITATIONS 61-10-91 Page 2

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

LIST OF EFFECTIVE PAGES

Chapter Page Rev. Level Date

Cover Cover and Inside Cover Original Nov/18

Revision Highlights 1 and 2 Original Nov/18
Record of Revisions 1 and 2 Original Nov/18
Record of Temporary Revisions 1 and 2 Original Nov/18
Service Document List 1 and 2 Original Nov/18
Airworthiness Limitations 1 and 2 Original Nov/18
List of Effective Pages 1 and 2 Original Nov/18
Table of Contents 1 and 2 Original Nov/18
Introduction 1 thru 22 Original Nov/18
Description and Operation 1 thru 4 Original Nov/18
Testing and Fault Isolation 1-1 thru 1-10 Original Nov/18
Automatic Test Requirements 2-1 and 2-2 Original Nov/18
Disassembly 3-1 thru 3-16 Original Nov/18
Cleaning 4-1 thru 4-4 Original Nov/18
Check 5-1 thru 5-42 Original Nov/18
Repair 6-1 thru 6-10 Original Nov/18
Assembly 7-1 thru 7-50 Original Nov/18
Fits and Clearances 8-1 thru 8-8 Original Nov/18
Special Tools, Fixtures and Equipment 9-1 thru 9-4 Original Nov/18
Illustrated Parts List 10-1 thru 10-18 Original Nov/18

LIST OF EFFECTIVE PAGES 61-10-91 Page 1

Nov/18
PROPELLER MAINTENANCE MANUAL
491

(This page is intentionally blank.)

LIST OF EFFECTIVE PAGES 61-10-91 Page 2

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

TABLE OF CONTENTS

REVISION HIGHLIGHTS....................................................................................................... 1
RECORD OF REVISIONS..................................................................................................... 1
RECORD OF TEMPORARY REVISIONS.............................................................................. 1
SERVICE DOCUMENT LIST................................................................................................. 1
AIRWORTHINESS LIMITATIONS.......................................................................................... 1
LIST OF EFFECTIVE PAGES................................................................................................ 1
TABLE OF CONTENTS.......................................................................................................... 1
INTRODUCTION.................................................................................................................... 1
DESCRIPTION AND OPERATION......................................................................................... 1
TESTING AND FAULT ISOLATION..................................................................................... 1-1
AUTOMATIC TEST REQUIREMENTS................................................................................ 2-1
DISASSEMBLY................................................................................................................... 3-1
CLEANING.......................................................................................................................... 4-1
CHECK................................................................................................................................ 5-1
REPAIR............................................................................................................................... 6-1
ASSEMBLY......................................................................................................................... 7-1
FITS AND CLEARANCES................................................................................................... 8-1
SPECIAL TOOLS, FIXTURES, AND EQUIPMENT............................................................. 9-1
ILLUSTRATED PARTS LIST............................................................................................. 10-1

TABLE OF CONTENTS 61-10-91 Page 1

Nov/18
PROPELLER MAINTENANCE MANUAL
491

(This page is intentionally blank.)

TABLE OF CONTENTS 61-10-91 Page 2

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

INTRODUCTION - CONTENTS

1. Statement of Purpose.................................................................................................. 3
A. General.................................................................................................................. 3
2. Required Publications.................................................................................................. 4
A. Hartzell Propeller Inc. Publications........................................................................ 4
B. References to Hartzell Propeller Inc. Publications................................................. 5
C. Vendor Publications............................................................................................... 5
3. Personnel Requirements............................................................................................. 6
A. Inspection, Repair, and Overhaul........................................................................... 6
4. Safe Handling of Paints and Chemicals...................................................................... 7
5. Calendar Limits and Long Term Storage..................................................................... 7
A. Calendar Limits...................................................................................................... 7
B. Long Term Storage................................................................................................. 7
6. Component Life and Service....................................................................................... 7
A. Overhaul................................................................................................................. 7
B. Damage.................................................................................................................. 8
C. Repair..................................................................................................................... 9
D. Component Life...................................................................................................... 9
E. Propeller Critical Parts......................................................................................... 10
7. Definitions...................................................................................................................11
8. Abbreviations............................................................................................................. 20
9. Contact Information................................................................................................... 22

INTRODUCTION 61-10-91 Page 1

Nov/18
PROPELLER MAINTENANCE MANUAL
491

(This page is intentionally blank.)

INTRODUCTION 61-10-91 Page 2

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

1. Statement of Purpose

A. General
(1) This manual has been reviewed and accepted by the FAA. Additionally, this
manual contains data that has been approved in a manner acceptable to the
FAA Administrator.
(2) This manual provides maintenance and overhaul procedures for
constant speed, feathering Raptor-series propellers manufactured by
Hartzell Propeller Inc.
(3) This manual is to be used by propeller repair stations with personnel who are
trained and experienced with Hartzell Propeller Inc. products.
(a) This manual does not provide complete information for an inexperienced
technician to attempt propeller overhaul without supervision.
(4) This manual is intended to be the primary source of maintenance and
overhaul information for constant speed, feathering Raptor-series propellers.
(a) The propeller models addressed in this manual may be Type Certificated
by the FAA, or may be experimental. Experimental parts must not be
installed on a type certified propeller. Always use the current illustrated
parts list for the assembly of any propeller. Always refer to the aircraft
Type Certificate (TC) or Supplemental Type Certificates (STC) to
determine installation eligibility of any propeller. If installation eligibility
is not identifiable, an additional installation approval, such as FAA form
337 field approval or Supplemental Type Certificate may be required. If
in doubt, contact Hartzell Propeller Inc. Product Support.
(5) This manual makes reference to other Hartzell Propeller Inc. manuals
that provide important details for procedures such as anodizing, penetrant
inspection, and overhaul procedures for hubs.
(6) Where possible, this manual is written in the format specified by
ATA iSpec 2200.

INTRODUCTION 61-10-91 Page 3

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

2. Required Publications

A. Hartzell Propeller Inc. Publications

(1) In addition to this manual, one or more of the following publications are
required for information regarding specific recommendations and procedures
to maintain propeller assemblies that are included in this manual.
(2) Information published in Service Bulletins, Service Letters, Service
Advisories, and Service Instructions may supersede information published
in this manual. The reader must consult active Service Bulletins or Service
Letters for information that may have not yet been incorporated into the latest
revision of this manual.

Manual No. Hartzell Propeller Inc.

Title
(ATA No.) Website
n/a Yes Active Hartzell Propeller Inc. Service Bulletins,
Service Letters, Service Instructions, and
Service Advisories
Manual 127 Yes Hartzell Propeller Inc. Metal Spinner
(61-16-27) Maintenance Manual
Manual 135F Hartzell Propeller Inc. Composite Propeller
(61-13-35) Blade Maintenance Manual
Manual 159 Yes Hartzell Propeller Inc. Application Guide
(61-02-59)
Manual 165A Yes Hartzell Propeller Inc. Illustrated Tool and
(61-00-65) Equipment Manual
Manual 180 Yes Hartzell Propeller Inc. Propeller Ice Protection
(30-61-80) System Manual
Manual 202A Vol. 7, Yes Hartzell Propeller Inc. Standard Practices
(61-01-02) Manual, Volumes 1 through 11
Manual 480 Yes Hartzell Propeller Inc. Propeller Owner’s
(61-00-80) Manual and Logbook for Raptor Reciprocating
Propeller Series with Composite Blades
Constant Speed, Non-counterweighted

INTRODUCTION 61-10-91 Page 4

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

B. References to Hartzell Propeller Inc. Publications

(1) Item references throughout the text in this manual refer to item numbers in
the Illustrated Parts List chapter of this manual. The item numbers appear in
parentheses directly following the part name. Only the item base number will
appear in the text of the manual. Item base numbers and the alpha variants
of the base numbers will appear in the illustrated parts list. There are two
reasons for the use of alpha variants:
(a) A part may be superseded, replaced, or obsoleted by another part. For
example, the pitch change block unit (105733) that is item 320 was
superseded by the pitch change block unit (105733-1) that is item 320A.
(b) An Illustrated Parts List may contain multiple configurations. Effectivity
codes are used to distinguish different part numbers within the same list.
For example, one configuration may use a piston (B-2419) that is
item 80, yet another configuration uses a piston (104256) that is
item 80A. Effectivity codes are very important in the determination of
parts in a given configuration.
(2) Special tooling may be required for procedures in this manual. For further
tooling information, refer to Hartzell Propeller Inc. Illustrated Tool and
Equipment Manual 165A (61-00-65).
(a) The reference numbers for tooling appear with the prefix “TE” directly
following the tool name to which they apply. For example, a protractor that
is reference number 96 will appear as: template TE96.
(3) Consumable materials are referenced in certain sections throughout this
manual. Specific approved materials are listed in the Consumable Materials
chapter of Hartzell Propeller Inc. Standard Practices Manual 202A (61‑01‑02)
(Available on the Hartzell Propeller Inc. website at www.hartzellprop.com).
(a) The reference number for a consumable material appears with the prefix
“CM” directly following the material to which it applies. For example, an
adhesive that is reference number 16 will appear as: adhesive CM16. Only
those items specified may be used.

C. Vendor Publications
None.

INTRODUCTION 61-10-91 Page 5

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

3. Personnel Requirements
A. Inspection, Repair, and Overhaul
(1) Compliance to the applicable regulatory requirements established by
the Federal Aviation Administration (FAA) or international equivalent,
is mandatory for anyone performing or accepting responsibility for any
inspection and/or repair and/or overhaul of any Hartzell Propeller Inc.
product.
(2) Personnel inspecting, repairing, and overhauling Hartzell Propeller Inc.
aluminum hub propellers must have adequate training and experience.
(3) Inspection and repair of propeller parts require a high degree of skill;
therefore, personnel with inspection and supervisory responsibility are
expected to have all of the following:
(a) An FAA Propeller Repairman's Certificate or international equivalent
(b) A minimum of 18 months practical experience with Hartzell
Propeller Inc. aluminum hub propeller overhaul
(4) Participation in Hartzell Propeller Inc. training classes is strongly
recommended.
4. Safe Handling of Paints and Chemicals
A. Always use caution when handling or being exposed to paints and/or chemicals
during propeller overhaul and maintenance procedures.
B. Before using paint or chemicals, always read the manufacturer’s label on the
container and follow specified instructions and procedures for storage, preparation,
mixing, and application.
C. Refer to the product’s Material Safety Data Sheet (MSDS) for detailed information
about physical properties, health, and physical hazards of any chemical.

INTRODUCTION 61-10-91 Page 6

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

5. Calendar Limits and Long Term Storage

A. Calendar Limits
(1) The effects of exposure to the environment over a period of time create a
need for propeller overhaul regardless of flight time.
(2) A calendar limit between overhauls is specified in Hartzell Propeller Inc.
Service Letter HC-SL-61-61Y and in the propeller owner's manual.
(3) Experience has shown that special care, such as keeping an aircraft in a
hangar, is not sufficient to permit extension of the calendar limit.
(4) The start date for the calendar limit is when the propeller is first installed on
an engine.
(5) The calendar limit is not interrupted by subsequent removal and/or storage.
(6) The start date for the calendar limit must not be confused with the warranty
start date, that is with certain exceptions, the date of installation by the first
retail customer.
B. Long Term Storage
(1) Propellers that have been in storage have additional inspection requirements
before installation. Refer to the Packaging and Storage chapter of Hartzell
Propeller Inc. Standard Practices Manual 202A (61‑01‑02).
6. Component Life and Service
WARNING: CERTAIN PROPELLER COMPONENTS USED IN NON-AVIATION
APPLICATIONS ARE MARKED WITH DIFFERENT PART NUMBERS
TO DISTINGUISH THEM FROM COMPONENTS USED IN AVIATION
APPLICATIONS. DO NOT ALTER THE PART NUMBERS SHOWN
ON PARTS DESIGNATED FOR NON-AVIATION APPLICATIONS
OR OTHERWISE APPLY THOSE PARTS FOR USE ON AVIATION
APPLICATIONS.
A. Overhaul
(1) Overhaul is the periodic disassembly, cleaning, inspecting, repairing as
necessary, reassembling, and testing in accordance with approved
standards and technical data approved by Hartzell Propeller Inc.
(2) The overhaul interval is based on hours of service, i.e., flight time, or on
calendar time.
(a) At such specified periods, the propeller hub assembly and the blade
assemblies must be completely disassembled and inspected for cracks,
wear, corrosion, and other unusual or abnormal conditions.
(b) Parts that are not replaced at overhaul must be inspected in accordance
with the Check chapter of this manual.
1 Parts that must be replaced at overhaul are identified by a "Y" in
the O/H column of the Illustrated Parts List chapter of this manual.

INTRODUCTION 61-10-91 Page 7

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

WARNING: DO NOT USE OBSOLETE OR OUTDATED INFORMATION.

PERFORM ALL INSPECTIONS OR WORK IN ACCORDANCE WITH
THE MOST RECENT REVISION OF THIS MANUAL. INFORMATION
CONTAINED IN THIS MANUAL MAY BE SIGNIFICANTLY
CHANGED FROM EARLIER REVISIONS. FAILURE TO
COMPLY WITH THIS MANUAL OR THE USE OF OBSOLETE
INFORMATION MAY CREATE AN UNSAFE CONDITION THAT
MAY RESULT IN DEATH, SERIOUS BODILY INJURY, AND/OR
SUBSTANTIAL PROPERTY DAMAGE. FOR THE MOST RECENT
REVISION LEVEL OF THIS MANUAL, REFER TO THE HARTZELL
PROPELLER INC. WEBSITE AT WWW.HARTZELLPROP.COM.
(3) Overhaul must be completed in accordance with the latest revision of
the applicable component maintenance manual and other publications
applicable to, or referenced in, the component maintenance manual.
(4) The information in this manual supersedes data in all previously published
revisions of this manual.

B. Damage
(1) Airworthy Damage
(a) Airworthy damage is a specific condition to a propeller component
identified in the Check chapter 5 of this manual that does not affect the
safety or flight characteristics of the propeller and conforms to its type
design by meeting the condition inspection criteria limitations found in this
manual.
1 The maximum limits of airworthy damage are specified in the
Check chapter 5 of this manual.
a The Check chapter 5 in this manual specifies inspection
criteria and instructions for evaluating damage to determine
continued airworthiness.
(2) Unairworthy Damage
(a) Unairworthy damage is damage that exceeds the airworthy damage
limits as specified in the Check chapter 5 of this manual.
1 Unairworthy damage can affect the safety or flight characteristics of
the propeller and does not conform to its type design.
2 This condition deems the component unairworthy, requiring
appropriate corrective action to repair or remove it from service, as
applicable.

INTRODUCTION 61-10-91 Page 8

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

C. Repair
(1) Minor Repair
(a) Minor repair is that which may be done safely in the field by a certified
aircraft mechanic.
(b) For information about repair criteria for composite blades, refer to
Hartzell Propeller Inc. Composite Propeller Blade Maintenance
Manual 135F (61-13-35).
(2) Major Repair
(a) Major repair is correction of damage that cannot be done by elementary
operations.
(b) Major repair work must be accepted by an individual that is certified by
the Federal Aviation Administration (FAA) or international equivalent.
1 Preferably the individual who accepts the work also holds a Factory
Training Certificate from Hartzell Propeller Inc.
2 The repair station must meet facility, tooling, and personnel
requirements and is required to participate in Hartzell Propeller Inc.
Sample Programs as defined in the Approved Facilities chapter of
Hartzell Propeller Inc. Standard Practices Manual 202A (61-01-02).

D. Component Life
(1) Certain components, or in some cases an entire propeller, may be life limited.
(a) It is a regulatory requirement that a record of the time since new be
maintained for all life limited parts.
(b) Refer to the Airworthiness Limitations chapter in the applicable Hartzell
Propeller Inc. Owner's Manual for a list of life limited components.
(2) Component life is expressed in terms of hours of service (Time Since
New, TSN) and in terms of hours of service since overhaul (Time Since
Overhaul, TSO).

NOTE: TSN/TSO is considered as the time accumulated between rotation

and landing, i.e., flight time.
(3) Both TSN and TSO are necessary for defining the life of the component.
Some parts are "life limited," which means that they must be replaced after a
specified period of use (TSN).
(4) When a component or assembly undergoes an overhaul, the TSO is returned
to zero hours.
(a) Time Since New (TSN) can never be returned to zero.
(b) Repair without overhaul does not affect TSO or TSN.

INTRODUCTION 61-10-91 Page 9

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

(5) Time Since New (TSN) and Time Since Overhaul (TSO) records must be
maintained in the propeller logbook.
(6) Blades and hubs are sometimes replaced while in service or at overhaul.
(a) Maintaining separate TSN and TSO histories for a replacement hub or
blade is required.
(b) Other propeller components do not require time tracking unless
specified in Hartzell Propeller Inc. service publications.
1 The TSN and TSO of other propeller components are not affected
by hub replacement and must be maintained separately.
(c) Hub replacement
1 If the hub is replaced, the replacement hub serial number must be
recorded (the entry signed and dated) in the propeller logbook.
2 The propeller will be identified with the serial number of the
replacement hub.

NOTE: Propeller assembly serial numbers are impression stamped

on the hub. For stamping information, refer to the Parts
Identification and Marking chapter of Hartzell Propeller Inc.
Standard Practices Manual 202A (61-01-02).
3 The TSN and TSO of the replacement hub must be recorded and
maintained in the propeller logbook.

E. Propeller Critical Parts

(1) Procedures in this manual may involve Propeller Critical Parts (PCP).
(a) These procedures have been substantiated based on Engineering
analysis that expects this product will be operated and maintained
using the procedures and inspections provided in the Instructions for
Continued Airworthiness (ICA) for this product.
(b) Refer to the Illustrated Parts List chapter for the applicable propeller
model for the identification of Propeller Critical Parts.
(2) Numerous propeller system parts can produce an aircraft Major or Hazardous
effect, even though those parts may not be considered as Propeller Critical
Parts. The operating and maintenance procedures and inspections provided
in the ICA for this product are, therefore, expected to be accomplished for all
propeller system parts.

INTRODUCTION 61-10-91 Page 10

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

7. Definitions
A basic understanding of the following terms will assist in maintaining and operating
Hartzell Propeller Inc. propeller systems.

Term Definition

Abrupt Transition ��������������� A physical difference in diameter in the pressure transition

zone of a blade shank caused by a sudden decrease in
rolling pressure during the rolling process

Alignment Bushing ������������ An alignment bushing is either a drill bushing or

manufactured steel bushing with a through bore of
0.753 ±0.001 inches (19.12 ±0.025 mm). This bushing is used
to control the concentricity of the face plate weldment shaft
to the right angle gear motor shaft during the assembly
process described in this manual.

Annealed ��������������������������� Softening of material due to overexposure to heat

Aviation Certified ��������������� Intended for FAA or international equivalent type certificated
aircraft applications. A TC and PC number must be stamped
on the hub, and a PC number must be stamped on blades.

Aviation Experimental ������� Intended for aircraft/propeller applications not certified by

the FAA or international equivalent. Products marked with
an “X” at or near the end of the model number, part number,
or serial number are not certified by the FAA or international
equivalent and are not intended to use on certificated
aircraft.

Bantam
Composite Blades ������������� A composite blade that is used in Bantam series propellers

Beta Operation ������������������ Manual blade angle control in the beta range to select
positive blade angles for positive thrust, negative blade
angles for negative thrust, and zero blade angle for no thrust

Beta Range ����������������������� Blade angles between low pitch and maximum reverse blade
angle

Beta System ���������������������� Parts and/or equipment related to operation (manual control)
of propeller blade angle between low pitch blade angle and
full reverse blade angle

Blade Angle ����������������������� Measurement of blade airfoil location described as the angle
between the blade airfoil and the surface described by
propeller rotation

INTRODUCTION 61-10-91 Page 11

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

Term Definition
Blade Pitch Axis ���������������� An imaginary reference line through the length of a blade
around which the blade rotates

Blade Station ��������������������� Refers to a location on an individual blade for blade

inspection purposes. It is a measurement from the blade
“zero” station to a location on a blade, used to apply blade
specification data in blade overhaul manuals
NOTE: Do not confuse blade station with reference blade
radius; they may not originate at the same location.

Blemish ����������������������������� An imperfection with visible attributes, but having no impact

on safety or utility

Brinelling ��������������������������� A depression caused by failure of the material in

compression

Bulge ��������������������������������� An outward curve or bend

Camber ����������������������������� The surface of the blade that is directed toward the front
of the aircraft. It is the low pressure, or suction, side of the
blade. The camber side is convex in shape over the entire
length of the blade.

Chord �������������������������������� A straight line distance between the leading and trailing
edges of an airfoil

Chord Line ������������������������ A straight line drawn between the leading and trailing edge
radii of the blade

Chordwise ������������������������� A direction that is generally from the leading edge to the
trailing edge of an airfoil

Co-bonded ������������������������ The act of bonding a composite laminate and simultaneously

curing it to some other prepared surface.

Cold Rolling ����������������������� Compressive rolling process for the retention area of single
shoulder blades that provides improved strength and
resistance to fatigue

Composite
Blade Traveler ������������������� A form that lists the applicable steps required for the
overhaul of a specific blade model

Composite Material ����������� Kevlar®, carbon, or fiberglass fibers bound together with, or
encapsulated within an epoxy resin

INTRODUCTION 61-10-91 Page 12

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

Term Definition
Constant Force ����������������� A force that is always present in some degree when the
propeller is operating

Constant Speed ���������������� A propeller system that employs a governing device to

maintain a selected engine RPM

Corrosion (Aluminum) ������� The chemical or electrochemical attack by an acid or alkaline

that reacts with the protective oxide layer and results in
damage of the base aluminum. Part failure can occur from
corrosion due to loss of structural aluminum converted to
corrosion product, pitting, a rough etched surface finish, and
other strength reduction damage caused by corrosion.

Corrosion (Steel) ��������������� Typically, an electrochemical process that requires the

simultaneous presence of iron (component of steel),
moisture and oxygen. The iron is the reducing agent (gives
up electrons) while the oxygen is the oxidizing agent (gains
electrons). Iron or an iron alloy such as steel is oxidized
in the presence of moisture and oxygen to produce rust.
Corrosion is accelerated in the presence of salty water or
acid rain. Part failure can occur from corrosion due to loss
of structural steel converted to corrosion product, pitting,
a rough etched surface finish and other strength reduction
damage caused by corrosion.

Corrosion Product
(Aluminum) ������������������������ A white or dull gray powdery material that has an increased
volume appearance (compared to non-corroded aluminum).
Corrosion product is not to be confused with damage left in
the base aluminum such as pits, worm holes, and etched
surface finish.

Corrosion Product
(Steel) ������������������������������� When iron or an iron alloy such as steel corrode, a corrosion
product known as rust is formed. Rust is an iron oxide which
is reddish in appearance and occupies approximately six
times the volume of the original material. Rust is flakey and
crumbly and has no structural integrity. Rust is permeable
to air and water, therefore the interior metallic iron (steel)
beneath a rust layer continues to corrode. Corrosion product
is not to be confused with damage left in the base steel such
as pits and etched surface finish.

Crack ��������������������������������� Irregularly shaped separation within a material, sometimes

visible as a narrow opening at the surface

INTRODUCTION 61-10-91 Page 13

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

Term Definition
Debond ����������������������������� Separation of two materials that were originally bonded
together in a separate operation

Defect �������������������������������� An imperfection that affects safety or utility

Delamination ��������������������� Internal separation of the layers of composite material

Dent ���������������������������������� The permanent deflection of the cross section that is visible
on both sides with no visible change in cross sectional
thickness

Depression ������������������������ Surface area where the material has been compressed but
not removed

Distortion ��������������������������� Alteration of the original shape or size of a component

Dragging ��������������������������� A resistance to the roller rotation when moving on a spinning

blade. Dragging can cause blade surface damage.

Edge Alignment ����������������� Distance from the blade centerline to the leading edge of the
blade

Erosion ������������������������������ Gradual wearing away or deterioration due to action of the

elements

Exposure ��������������������������� Leaving material open to action of the elements

Face ���������������������������������� The surface of the blade that is directed toward the rear of
the aircraft. The face side is the high pressure, or thrusting,
side of the blade. The blade airfoil sections are normally
cambered or curved such that the face side of the blade may
be flat or even concave in the midblade and tip region.

Face Alignment ����������������� Distance from the blade centerline to the highest point on the
face side perpendicular to the chord line.

Feathering ������������������������� The capability of blades to be rotated parallel to the relative

wind, thus reducing aerodynamic drag

Fraying ������������������������������ A raveling or shredding of material

Fretting ������������������������������ Damage that develops when relative motion of small

displacement takes place between contacting parts, wearing
away the surface.

Galling ������������������������������� To fret or wear away by friction

INTRODUCTION 61-10-91 Page 14

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

Term Definition
Gauge (Bearing Ball) �������� A term to describe an amount by which the mean diameter
may differ from the nominal diameter

Gouge ������������������������������� Surface area where material has been removed

Hazardous Propeller
Effect ��������������������������������� The hazardous propeller effects are defined in
Title 14 CFR section 35.15(g)(1)

Horizontal Balance ������������ Balance between the blade tip and the center of the hub

Impact Damage ���������������� Damage that occurs when the propeller blade or hub
assembly strikes, or is struck by, an object while in flight or
on the ground

Inboard ������������������������������ Toward the butt of the blade

Inboard Region ����������������� The inboard portion of the blade encompassing both the face
and camber sides of the blade

Inboard Trailing
Edge Region ��������������������� The inboard portion of the blade encompassing the trailing
edge

Intergranular Corrosion ����� Corrosion that attacks along the grain boundaries of metal
alloys

Jog ������������������������������������ A term used to describe movement up/down, left/right, or

on/off in short incremental motions

Laminate ��������������������������� To unite composite material by using a bonding material,

usually with pressure and heat

Legacy
Composite Blades ������������� Composite blades other than N-shank, Bantam, or Raptor

Lengthwise ����������������������� A direction that is generally parallel to the pitch axis

Loose Material ������������������ Material that is no longer fixed or fully attached

Low Pitch �������������������������� The lowest blade angle attainable by the governor for
constant speed operation

Major Propeller Effect �������� The major propeller effects are defined in Title 14 CFR
section 35.15(g)(2)

INTRODUCTION 61-10-91 Page 15

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

Term Definition
Minor Deformation ������������ Deformed material not associated with a crack or missing
material less than 10 percent of the leading edge radius or
no more than 0.080 inch (2.03 mm) deep

Monocoque ����������������������� A type of construction in which the outer skin carries all or a
major part of the stresses

N-shank
Composite Blades ������������� A composite blade that is used in lightweight turbine,
compact, and lightweight compact propellers

Nick ����������������������������������� Removal of paint and possibly a small amount of material

Non-Aviation Certified ������� Intended for non-aircraft application, such as Hovercraft or

Wing in Ground Effect (WIG) applications. These products
are certificated by an authority other than FAA. The hub and
blades will be stamped with an identification that is different
from, but comparable to TC and PC.

Non-Aviation
Experimental ��������������������� Intended for non-aircraft application, such as Hovercraft or
Wing-In-Ground effect (WIG) applications. Products marked
with an “X” at or near the end of the model number, part
number, or serial number are not certified by any authority
and are not intended for use on certificated craft.

Onspeed ��������������������������� Condition in which the RPM selected by the pilot through
the propeller control/condition lever and the actual engine
(propeller) RPM are equal

Open Circuit ���������������������� Connection of high or infinite resistance between points in a

circuit which are normally lower

Outboard ��������������������������� Toward the tip of the blade

Outboard Region ��������������� The outboard portion of the blade encompassing both the
face and camber sides of the blade

Outboard Trailing
Edge Region ��������������������� The outboard portion of the blade encompassing the trailing
edge

Overhaul ��������������������������� The periodic disassembly, inspection, repair, refinish,

and reassembly of a propeller assembly to maintain
airworthiness

INTRODUCTION 61-10-91 Page 16

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

Term Definition
Overspeed ������������������������ Condition in which the RPM of the propeller or engine
exceeds predetermined maximum limits; the condition in
which the engine (propeller) RPM is higher than the RPM
selected by the pilot through the propeller control/condition
lever

Overspeed Damage ���������� Damage that occurs when the propeller hub assembly
rotates at a speed greater than the maximum limit for which
it is designed

Parting Line ����������������������� The Parting line is formed where the face and camber
composite materials meet at the leading and trailing edges
of the blade. They are most visible in the shank area of the
blade.

Pitch ���������������������������������� Same as “Blade Angle”

Pitting �������������������������������� Formation of a number of small, irregularly shaped cavities

in surface material caused by corrosion or wear

Pitting (Linear) ������������������� The configuration of the majority of pits forming a pattern in
the shape of a line

Porosity ����������������������������� An aggregation of microvoids. See “voids”

Propeller Critical Parts ������ A part on the propeller whose primary failure can result in
a hazardous propeller effect, as determined by the safety
analysis required by Title 14 CFR section 35.15

Raptor
Composite Blades ������������� A composite blade that is used in Raptor series propellers

Reference Blade Radius ��� Refers to the propeller reference blade radius in an
assembled propeller, e.g., 30-inch radius. A measurement
from the propeller hub centerline to a point on a blade, used
for blade angle measurement in an assembled propeller. A
yellow adhesive stripe (blade angle reference tape CM160)
is usually located at the reference blade radius location.
NOTE: Do not confuse reference blade radius with blade
station; they may not originate at the same point.

Reversing �������������������������� The capability of rotating blades to a position to generate

reverse thrust to slow the aircraft or back up

INTRODUCTION 61-10-91 Page 17

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

Term Definition
Rolling ������������������������������� Compressive rolling process for the retention area of single
shoulder blades, that provides improved strength and
resistance to fatigue

Scratch ������������������������������ Same as “Nick”

Short ��������������������������������� Connection of low resistance between points on a circuit

between which the resistance is normally much greater

Shot Peening �������������������� Process where steel shot is impinged on a surface to create
compressive surface stress, that provides improved strength
and resistance to fatigue

Single Acting ��������������������� Hydraulically actuated propeller that utilizes a single oil
supply for pitch control

Split ����������������������������������� Delamination of blade extending to the blade surface,

normally found near the trailing edge or tip

Station Line ����������������������� See Blade Station

Superseded ����������������������� Parts that are considered airworthy for continued flight but
may no longer be available

Synchronizing ������������������� Adjusting the RPM of all the propellers of a multi-engine

aircraft to the same RPM

Synchrophasing ���������������� A form of propeller sychronization in which not only the RPM
of the engines (propellers) are held constant, but also the
position of the propellers in relation to each other

Test Bar ����������������������������� A machined round bar used to check runout and parallelism
of the chuck to the carriage. The diameter runout should not
be greater than 0.001 inch (0.025 mm).

Ticking ������������������������������� A series of parallel marks or scratches running

circumferentially around the diameter of the blade

Track ��������������������������������� In an assembled propeller, a measurement of the location

of the blade tip with respect to the plane of rotation, used to
verify face alignment and to compare blade tip location with
respect to the locations of the other blades in the assembly

Trailing Edge ��������������������� The aft edge of an airfoil over which the air passes last

INTRODUCTION 61-10-91 Page 18

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

Term Definition
Trimline ����������������������������� Factory terminology referring to where the part was trimmed
to length

Underspeed ���������������������� The condition in which the actual engine (propeller) RPM
is lower than the RPM selected by the pilot through the
propeller control/condition lever

Unidirectional Material ������ A composite material in which the fiber are substantially
oriented in the same direction

Variable Force ������������������� A force that may be applied or removed during propeller
operation

Vertical Balance ���������������� Balance between the leading and trailing edges of a two-
blade propeller with the blades positioned vertically

Voids ��������������������������������� Air or gas that has been trapped and cured into a laminate

Windmilling ������������������������ The rotation of an aircraft propeller caused by air flowing

through it while the engine is not producing power

Woven Fabric �������������������� A material constructed by interlacing fiber to form a fabric

pattern

Wrinkle ������������������������������ Overlap or fold within the material

Wrinkling ��������������������������� A degradation of the surface finish of a compressively

rolled blade shank where the surface has been physically
deformed by the rolling process. This results in a wavy
appearance caused by high and low material displacement.

INTRODUCTION 61-10-91 Page 19

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

8. Abbreviations
Abbreviation Term
AD ������������������������������������� Airworthiness Directives
AMM ���������������������������������� Aircraft Maintenance Manual
AN ������������������������������������� Air Force-Navy (or Army-Navy)
AOG ���������������������������������� Aircraft on Ground
AR ������������������������������������� As Required
ATA ������������������������������������ Air Transport Association
CSU ����������������������������������� Constant Speed Unit
FAA ����������������������������������� Federal Aviation Administration
FH ������������������������������������� Flight Hour
FM ������������������������������������� Flight Manual
FMS ����������������������������������� Flight Manual Supplement
FT-Lb ��������������������������������� Foot-Pound
HMI ������������������������������������ Human Machine Interface
ICA ������������������������������������ Instructions for Continued Airworthiness
ID ��������������������������������������� Inside Diameter
In-Lb ���������������������������������� Inch-Pound
IPL ������������������������������������� Illustrated Parts List
IPS ������������������������������������ Inches Per Second
ITAR ���������������������������������� International Traffic in Arms Regulations
kPa ������������������������������������ Kilopascals
Lb(s). ��������������������������������� Pound(s)
Max. ���������������������������������� Maximum
Min. ����������������������������������� Minimum
MIL-X-XXX ������������������������ Military Specification
MPI ������������������������������������ Major Periodic Inspection (Overhaul)
MS ������������������������������������� Military Standard
MSDS �������������������������������� Material Safety Data Sheet
N ���������������������������������������� Newtons
N/A ������������������������������������ Not Applicable
NAS ����������������������������������� National Aerospace Standards
NASM �������������������������������� National Aerospace Standards, Military
NDT ����������������������������������� Nondestructive Testing
NIST ���������������������������������� National Institute of Standards and Technology
N•m ����������������������������������� Newton-Meters
OD ������������������������������������� Outside Diameter
OPT ����������������������������������� Optional
PC ������������������������������������� Production Certificate
PCP ����������������������������������� Propeller Critical Part
PLC ����������������������������������� Programmable Logic Controller
PMB ���������������������������������� Plastic Media Blasting (Cleaning)
POH ���������������������������������� Pilot’s Operating Handbook

INTRODUCTION 61-10-91 Page 20

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

Abbreviation Term
PSI ������������������������������������ Pounds per Square Inch
RF ������������������������������������� Reference
RPM ���������������������������������� Revolutions per Minute
SAE ����������������������������������� Society of Automotive Engineers
STC ����������������������������������� Supplemental Type Certificate
TBO ����������������������������������� Time Between Overhaul
TC ������������������������������������� Type Certificate
TSI ������������������������������������� Time Since Inspection
TSN ����������������������������������� Time Since New
TSO ����������������������������������� Time Since Overhaul
UID ������������������������������������ Unique Identification
WIG ����������������������������������� Wing-In-Ground-Effect

NOTE: TSN/TSO is considered as the time accumulated between rotation and

landing, i.e., flight time.

INTRODUCTION 61-10-91 Page 21

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

9. Contact Information

A. Hartzell Propeller Inc. Product Support Department

(1) Contact the Product Support Department of Hartzell Propeller Inc. about
any maintenance problems or to request information not included in this
publication.

NOTE: When calling from outside the United States, dial (001) before dialing
the telephone numbers below.
(a) Hartzell Propeller Inc. Product Support may be reached during business
hours (8:00 a.m. through 5:00 p.m., United States Eastern Time) at
(937) 778-4379 or at (800) 942-7767, toll free from the United States
and Canada.
(b) Hartzell Propeller Inc. Product Support can also be reached by fax at
(937) 778-4215, and by e-mail at techsupport@hartzellprop.com.
(c) After business hours, you may leave a message on our 24 hour product
support line at (937) 778-4376 or at (800) 942-7767, toll free from the
United States and Canada.
1 A technical representative will contact you during normal business
hours.
2 Urgent AOG support is also available 24 hours per day, seven days
per week via this message service.
(d) Additional information is available on the Hartzell Propeller Inc. website
at www.hartzellprop.com.

B. Hartzell Propeller Inc. Technical Publications Department

(1) For Hartzell Propeller Inc. service literature and revisions, contact:
Hartzell Propeller Inc. Telephone: 937.778.4200
Attn: Technical Publications Department Fax: 937.778.4215
One Propeller Place E-mail: manuals@hartzellprop.com
Piqua, Ohio 45356-2634 U.S.A.

INTRODUCTION 61-10-91 Page 22

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

DESCRIPTION AND OPERATION - CONTENTS

1. Description................................................................................................................... 3
A. General.................................................................................................................. 3
B. Components........................................................................................................... 3
2. Operation..................................................................................................................... 3
A. Raptor Series Constant Speed and Feathering Propellers.................................... 3
3. Model Designation System.......................................................................................... 4
A. Propeller Model Designation.................................................................................. 4
B. Blade Shank Designation....................................................................................... 4

LIST OF FIGURES
Raptor Series Constant Speed and Feathering Propellers ....................Figure 1.................. 2

DESCRIPTION AND OPERATION 61-10-91 Page 1

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

Blade Retention Bearing

Spinner Bulkhead
Blade Shim
and Blade Seal
Mounting
Nut
Piston
Mounting Spring
Stud Hub Cylinder
Low Pitch
Stop

Air Valve

Fork
Engine Flange

Counterweight
Pitch Change Rod TPI-MB-0245

Raptor Series Constant Speed and Feathering Propeller

Figure 1

DESCRIPTION AND OPERATION 61-10-91 Page 2

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

1. Description

A. General
CAUTION: INSTRUCTIONS AND PROCEDURES IN THIS CHAPTER MAY
INVOLVE PROPELLER CRITICAL PARTS. REFER TO THE
INTRODUCTION CHAPTER OF THIS MANUAL FOR INFORMATION
ABOUT PROPELLER CRITICAL PARTS. REFER TO THE
ILLUSTRATED PARTS LIST CHAPTER OF THIS MANUAL FOR THE
IDENTIFICATION OF SPECIFIC PROPELLER CRITICAL PARTS.
(1) Hartzell Propeller Inc. Raptor 3C2-( )( )( ) series propellers use composite
blades mounted in an aluminum hub. The hub is held together with bolts and
contains the pitch change mechanism. The pitch change components include
the pitch change rod, fork, and pitch change blocks.

B. Components
(1) The model designation system for propellers included in this manual is
given in the Hartzell Propeller Inc. Application Guide Manual 159 (61-02-59)
and the applicable owner's manual, available on the Hartzell Propeller Inc.
website at www.hartzellprop.com.

2. Operation

A. Raptor Series Constant Speed and Feathering Propellers

(1) The 3C2 models are constant speed propellers that use an air charge,
spring, and counterweights (if installed) to move the blades to high pitch/
feather position. Blade centrifugal twisting moment acts to move the blades
to low pitch, but the air charge, spring, and counterweights overcome this
force. Oil pressure against a propeller mounted hydraulic piston opposes the
counterweight, spring, and air charge forces to move the blades to low blade
angle (low pitch).
(2) The action of the air charge, spring, and counterweights tends to move the
blades to a higher blade angle (high pitch), reducing engine RPM. Oil pressure
toward low pitch increases engine RPM.
(3) If oil pressure is lost during operation, the propeller will feather. Feathering
occurs because the air charge, spring, and blade counterweights are no
longer opposed by hydraulic oil pressure. The air charge, spring, and blade
counterweights are then free to increase blade pitch to the feathering (high
pitch) stop.
(4) Normal in-flight feathering of these propellers is accomplished when the pilot
retards the propeller pitch control past the feather detent. This allows control oil
to drain from the cylinder and return to the engine sump. The engine can then
be shut down.

DESCRIPTION AND OPERATION 61-10-91 Page 3

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

(5) Normal in-flight unfeathering is accomplished when the pilot positions the
propeller pitch control into the normal flight (governing) range and an engine
restart is attempted.
(6) Some aircraft are equipped with a hydraulic accumulator that stores a supply of
oil under pressure. This oil supply is released to unfeather the propeller during
an in-flight engine restart. Pressurized oil is directed to the propeller, resulting
in blade angle decrease. The propeller begins to windmill, and engine restart is
possible.
(7) When the engine is stopped on the ground, it is undesirable to feather the
propeller, as the high blade angle prevents the engine from starting. To prevent
feathering during normal engine shutdown on the ground, the propeller
incorporates spring energized latches. If propeller rotation is approximately 800
RPM or above, the latches are disengaged by centrifugal force acting on the
latches to compress the springs. When RPM drops below 800 RPM (and blade
angle is typically within 7 degrees of the low pitch stop), the springs overcome
the latch weight centrifugal force and move the latches to engage the high
pitch stops, preventing blade angle movement to feather during normal engine
shutdown.

3. Model Designation System

A. Propeller Model Designation

(1) Hartzell Propeller Inc. uses a model number designation system to identify
specific propeller and blade assemblies. An example model number would
be 3C2-FP650A1/C79C03-2, with the slash mark separating the propeller
designation from the blade designation.
(2) The propeller model number is impression stamped on the propeller hub. The
blade model number is impression stamped on the butt end of the blade, as
well as ink stamped or identified by a label on the cylinder.
(3) For additional information about the model number designation system, refer
to the Hartzell Propeller Inc. Application Guide Manual 159 (61-02-59) or the
applicable owner's manual, available on the Hartzell Propeller Inc. website at
www.hartzellprop.com.

B. Blade Shank Designation

(1) For more information about blade shank designs, refer to Hartzell Propeller Inc.
Composite Propeller Blade Maintenance Manual 135F (61-13-35).

DESCRIPTION AND OPERATION 61-10-91 Page 4

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

TESTING AND FAULT ISOLATION - CONTENTS

1. Troubleshooting Guide........................................................................................1-3
A. Pitch Control Difficulty....................................................................................1-3
B. Friction............................................................................................................1-3
C. Abnormal Propeller Vibration.........................................................................1-4
D. Slight Vibration...............................................................................................1-4
E. Surging RPM or Torque..................................................................................1-5
F. Oil Leakage....................................................................................................1-7
G. Grease Leakage.............................................................................................1-7
H. End-Play Movement of the Blade...................................................................1-8
I. Fore-and-Aft Movement of the Blade.............................................................1-8
J. In-and-Out Movement of the Blade................................................................1-8
K. Excessive Radial Play of the Blade (backlash)..............................................1-8
L. Blades Not Tracking.......................................................................................1-8
2. Lightning Strike on Hub or Blade.........................................................................1-9

LIST OF FIGURES
Areas of Leaking Oil or Grease............................................................. Figure 1-1.............. 1-6

61-10-91
Page 1-1
TESTING AND FAULT ISOLATION Nov/18
PROPELLER MAINTENANCE MANUAL
491

(This page is intentionally blank.)

61-10-91
Page 1-2
TESTING AND FAULT ISOLATION Nov/18
 PROPELLER MAINTENANCE MANUAL
491

1. Troubleshooting Guide

CAUTION: INSTRUCTIONS AND PROCEDURES IN THIS CHAPTER MAY

INVOLVE PROPELLER CRITICAL PARTS. REFER TO THE
INTRODUCTION CHAPTER OF THIS MANUAL FOR INFORMATION
ABOUT PROPELLER CRITICAL PARTS. REFER TO THE
ILLUSTRATED PARTS LIST IN THIS MANUAL FOR IDENTIFICATION
OF PROPELLER CRITICAL PARTS.
The purpose of this guide is to help isolate probable causes and suggest possible
remedies for some of the more common propeller service problems. In all cases, the
remedy for a problem should follow the procedures detailed in the applicable section of
this manual.

Problem Probable Cause Remedy

A. Pitch Control Difficulty Too much friction in moving Refer to problem, "Friction" in this
parts. chapter.

or Oil leaking around the piston Disassemble the propeller

causing underspeed. and examine the O-ring and
piston-to-cylinder sealing surfaces.
Replace the defective O-ring.

B. Friction Lack of lubrication. Add approved lubricant.

or Blade is shimmed too tight. Disassemble the propeller and

readjust the blade shim.

or Balls in the blade retention Replace the blade retention split

split bearing are unusually bearing assembly.
rough, corroded, or chipped.

or Not enough clearance between Examine the moving parts

the various moving parts in individually. Increase the
the pitch change mechanism. clearances between the individual
parts as necessary to decrease
friction in the mechanism.
Refer to the section, "Pitch Change
Block Button Modification" in the
Repair chapter of this manual.

or Wear strip is damaged causing too Replace the damaged wear strip
much friction on the blade butt seal and the seal O-ring.
O-ring.

61-10-91
Page 1-3
TESTING AND FAULT ISOLATION Nov/18
 PROPELLER MAINTENANCE MANUAL
491

Problem Probable Cause Remedy

C. Abnormal Propeller Bent, cracked, or damaged Refer to Hartzell Propeller Inc.

Vibration blade or pitch change knob. Composite Propeller Blade
Maintenance Manual 135F
(61-13-35).

or Cracked or damaged hub. Refer to the Aluminum Hub

Overhaul chapter of Hartzell
Propeller Inc. Standard Practices
Manual 202A (61-01-02).

or Broken blade retention split Replace the bearings and inspect

bearings. the other blade retention
components.

or Grease leakage. Refer to the problem, "Grease

Leakage" in this chapter.

D. Slight Vibration Blades not tracking. Refer to the problem, "Blades Not
Tracking" in this chapter.

or Static balance incorrect. Refer to the Static and Dynamic

Balance chapter of Hartzell
Propeller Inc. Standard Practices
Manual 202A (61-01-02).

or Dynamic balance incorrect. Refer to the Static and Dynamic

Balance chapter of Hartzell
Propeller Inc. Standard Practices
Manual 202A (61-01-02.

or Blade wear. Refer to Hartzell Propeller Inc.

Composite Propeller Blade
Maintenance Manual 135F
(61-13-35).

or Grease leakage. Refer to the problem, "Grease

Leakage" in this chapter.

or Blade-to-blade pitch variance is Disassemble the propeller and

too great. correct the blade-to-blade pitch
variance.

61-10-91
Page 1-4
TESTING AND FAULT ISOLATION Nov/18
 PROPELLER MAINTENANCE MANUAL
491

Problem Probable Cause Remedy

E. Surging RPM or Torque Too much friction in the pitch Refer to the problem, "Friction" in
change mechanism. this chapter.

or Air is trapped in the propeller After propeller installation and

actuating piston or in the engine before each flight, exercise the
shaft. propeller by changing pitch or
feathering.

The engine should have a

provision for trapped air to escape
from the system during one-half of
the pitch cycle.

or Governor problem. Refer to the airframe or the engine

manufacturer's maintenance
manual for installation instructions.

61-10-91
Page 1-5
TESTING AND FAULT ISOLATION Nov/18
PROPELLER MAINTENANCE MANUAL
491

Oil leakage between the low

pitch stop and the cylinder

Grease leakage at the seal

between the cylinder and the
cylinder-side half of the hub

Grease leakage at the

interface between the
halves of the hub

Grease leakage from

any lubrication fitting

Grease leakage at the

blade socket of the hub
TPI-MB-0322

Areas of Leaking Oil or Grease

Figure 1-1

61-10-91
Page 1-6
TESTING AND FAULT ISOLATION Nov/18
 PROPELLER MAINTENANCE MANUAL
491

Problem Probable Cause Remedy

F. Oil Leakage Defective O-ring seal between Remove the propeller from the
(Refer to Figure 1-1) the engine flange and the engine and visually examine the
propeller mounting flange. O-ring and the sealing surface.
Replace the defective O-ring.

or Defective O-ring seal between Remove the cylinder and visually

the cylinder and the hub. examine the O-ring and the sealing
surface. Replace the defective
O-ring.

or Defective O-ring seal between Remove the cylinder and visually

the piston and the cylinder, examine the piston O-ring and
resulting in leakage between the cylinder sealing surface. Replace
pitch change rod plug and the the defective O-ring.
cylinder.

or Defective O-ring seal between Remove the lubrication fitting at

the pitch change rod and either the bottom of the hub and insert
hub half, resulting in leakage a wire. If oil runs out, then one or
from the hub and from around both O-rings are defective.
the blade shanks.
Remove the propeller from the
engine and disassemble. Visually
examine both O-rings and sealing
surfaces. Replace the defective
O-ring(s).

G. Grease Leakage Defective lubrication fitting. Replace defective lubrication

(Refer to Figure 1-1) fittings.
A new or newly overhauled
propeller can leak slightly or Defective seal at blade socket Disassemble the propeller
during the first several in the hub. and visually examine the seal
hours of operation. The and the sealing surface. Replace
leakage can be caused by defective seal.
the seating of seals and
O-rings, and the slinging
of lubricants used during
assembly. This leakage
should stop within the first
ten hours of operation.

61-10-91
Page 1-7
TESTING AND FAULT ISOLATION Nov/18
 PROPELLER MAINTENANCE MANUAL
491

Problem Probable Cause Remedy

H. End-Play Movement of the Blade retention bearing is worn. Follow the Blade Retention
Blade Split Bearing Inspection and
NOTE: Refer to Table 8-2, Replacement Procedures.
"Blade Tolerances"
in the Fits and or Internal blade shim is worn. Disassemble the propeller, remove
Clearances chapter the blade shim, and inspect the
in this manual. blade shim. Replace the worn
blade shim.

I. Fore-and-Aft Movement of Blade retention bearing is worn. Follow the Blade Retention
the Blade Split Bearing Inspection and
NOTE: Refer to Table 8-2, Replacement Procedures.
"Blade Tolerances"
in the Fits and or Internal blade shim is worn. Disassemble the propeller, remove
Clearances chapter the blade, and inspect the blade
in this manual. shim. Replace the worn blade
shim.

J. In-and-Out Movement of Blade retention bearing is worn. Follow the Blade Retention
the Blade Split Bearing Inspection and
NOTE: Refer to Table 8-2, Replacement Procedures.
"Blade Tolerances"
in the Fits and
Clearances chapter
in this manual.

K. Excessive Radial Play of Pitch change fork is worn. Disassemble the propeller. Inspect
the Blade (backlash) and replace the fork, as required.
NOTE: Refer to Table 8-2,
"Blade Tolerances"
in the Fits and
Clearances
chapter in this
manual.

L. Blades Not Tracking Ground strike damage. For a composite blade, refer to
Hartzell Propeller Inc. Composite
Propeller Blade Maintenance
Manual 135F (61-13-35).

61-10-91
Page 1-8
TESTING AND FAULT ISOLATION Nov/18
 PROPELLER MAINTENANCE MANUAL
491

2. Lightning Strike on Hub or Blade

A. In the event of a propeller lightning strike, an inspection is required before further

flight.
(1) A lightning strike on the propeller usually leaves arcing damage on the blade,
as evidence of where it entered or left the tip of the blade.
(2) Refer to the Special Inspections chapter of Hartzell Propeller Inc. Standard
Practices Manual 202A (61-01-02) for lightning strike inspection criteria.

61-10-91
Page 1-9
TESTING AND FAULT ISOLATION Nov/18
PROPELLER MAINTENANCE MANUAL
491

(This page is intentionally blank.)

61-10-91
Page 1-10
TESTING AND FAULT ISOLATION Nov/18
 PROPELLER MAINTENANCE MANUAL
491

AUTOMATIC TEST REQUIREMENTS (NOT APPLICABLE)

NOTE: In accordance with ATA iSpec 2200 specification this space is reserved for
automatic test requirements. Such requirements are not applicable to the
Hartzell Propeller Inc. propellers included in this manual.

61-10-91
Page 2-1
AUTOMATIC TEST REQUIREMENTS Nov/18
PROPELLER MAINTENANCE MANUAL
491

(This page is intentionally blank.)

Page 2-2
AUTOMATIC TEST REQUIREMENTS 61-10-91 Nov/18
 PROPELLER MAINTENANCE MANUAL
491

DISASSEMBLY - CONTENTS
1. Removal of the Propeller Assembly from the Engine............................................... 3-3
2. Marking Before Disassembly.................................................................................... 3-3
3. Removal of the Propeller Ice Protection System...................................................... 3-4
4. Disassembly of 3C2-( )( )( ) Propeller Models.......................................................... 3-4
A. Cylinder Removal................................................................................................ 3-5
B. Disassembly of the Internal Pitch Change Parts................................................. 3-8
C. Hub Plug Removal............................................................................................ 3-10
D. Hub Disassembly.............................................................................................. 3-10
E. Disassembly of the Blade Retention Parts........................................................ 3-12
F. Disassembly of the Blade ................................................................................. 3-12
G. Feathering Spring Disassembly........................................................................ 3-13

LIST OF FIGURES
Air Valve/Low Pitch Stop Removal ..........................................Figure 3-1.................... 3-5
Using the Spring Assembling Tool TE9....................................Figure 3-2.................... 3-6
Fork Removal...........................................................................Figure 3-3.................... 3-8
Hub Plug/Hub Mounting Components.....................................Figure 3-4.................. 3-10
Blade Retention Components..................................................Figure 3-5.................. 3-11
Assembling Tool TE9 in a Vise.................................................Figure 3-6.................. 3-13
Positioning the Cylinder on the Assembling Tool TE9.............. Figure 3-7.................. 3-14
Removing the Feathering Spring Assembly Screws................ Figure 3-8.................. 3-15
Feathering Spring Assembly Components...............................Figure 3-9.................. 3-16

DISASSEMBLY 61-10-91 Page 3-1

Nov/18
PROPELLER MAINTENANCE MANUAL
491

(This page is intentionally blank.)

DISASSEMBLY 61-10-91 Page 3-2

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

1. Removal of the Propeller Assembly from the Engine

A. Remove the propeller from the aircraft engine in accordance with the instructions
in Hartzell Propeller Inc. Owner's Manual 480 (61-00-80). Refer to the Introduction
chapter of this manual for a list of the applicable publications.

2. Marking Before Disassembly

NOTE: Specific Hartzell Propeller Inc. manuals and service documents are available
on the Hartzell Propeller Inc. website at www.hartzellprop.com. Refer to the
Required Publications section in the Introduction chapter of this manual for
the identification of these publications.
A. Make a record of the serial number and model number of the hub and the blades
and compare with the data in the propeller logbook.

CAUTION: DO NOT ETCH, SCRIBE, PUNCH MARK OR SIMILARLY IDENTIFY

PARTS IN ANY MANNER THAT MAY BE HARMFUL TO THE
STRENGTH OR FUNCTION OF THE PROPELLER.
B. To minimize reassembly problems with the propeller balance and blade angle settings,
keep all blades and pitch change components with their respective assemblies. Make a
record of the location and orientation of these parts when disassembling the propeller.

CAUTION: GRAPHITE ("LEAD") PENCIL MARKS WILL CAUSE CORROSION.

ALL MARKS MADE ON PARTS MUST BE MADE WITH A CRAYON OR
SOFT, NON-GRAPHITE PENCIL SUCH AS CM162.
C. Where possible, each blade should be reinstalled in the hub socket from which
it is removed.
(1) Using a crayon or soft, non-graphite pencil such as CM162, number the blades
counterclockwise from the propeller serial number impression stamped on the
propeller hub unit.
(2) For the propeller serial number location, refer to the Parts Identification
and Marking chapter of Hartzell Propeller Inc. Standard Practices
Manual 202A (61-01-02).

DISASSEMBLY 61-10-91 Page 3-3

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

3. Removal of the Propeller Ice Protection System

A. If the propeller is equipped with an ice protection system that uses components
supplied by Hartzell Propeller Inc., applicable instructions and technical information
can be found in Hartzell Propeller Inc. Ice Protection System Manual 180 (30-61-80)
available on the Hartzell Propeller Inc. website at www.hartzellprop.com.
B. Propeller ice protection system components not supplied by Hartzell Propeller Inc.
are controlled by the applicable TC or STC holder’s Instructions for Continued
Airworthiness (ICA).
C. Remove the bulkhead dynamic balance weights and attaching screws.

4. Disassembly of 3C2-( )( )( ) Propeller Models

WARNING: THE USE OF BLADE PADDLES TO MOVE BLADES CAN RESULT

IN THE OVERLOAD AND DAMAGE OF BLADE PITCH CHANGE
KNOBS. THIS DAMAGE IS NOT REPAIRABLE AND CAN RESULT
IN SEPARATION BETWEEN THE BLADE AND THE PITCH
CHANGE KNOB, CAUSING LOSS OF PITCH CONTROL DURING
FLIGHT.

CAUTION 1: INSTRUCTIONS AND PROCEDURES IN THIS CHAPTER MAY

INVOLVE PROPELLER CRITICAL PARTS. REFER TO THE
INTRODUCTION CHAPTER OF THIS MANUAL FOR INFORMATION
ABOUT PROPELLER CRITICAL PARTS. REFER TO THE
ILLUSTRATED PARTS LIST IN THIS MANUAL FOR IDENTIFICATION
OF PROPELLER CRITICAL PARTS.

CAUTION 2: USE COMPRESSED AIR THAT HAS BEEN FILTERED FOR

MOISTURE, OR NITROGEN TO ACTUATE THE PROPELLERS.
CAUTION 3: DO NOT USE MORE THAN 175 PSI (12.06 BARS) OF PRESSURE
WHEN ACTUATING PROPELLERS INCLUDED IN THIS MANUAL.
CAUTION 4: USE ENOUGH PRESSURE TO MAKE SURE THAT THE PROPELLER
ACTUATES AGAINST EACH POSITIVE STOP.

DISASSEMBLY 61-10-91 Page 3-4

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

A. Cylinder Removal
(1) To simplify the assembly process and make it easier to set the necessary blade
angles, make a record of the location and orientation (where applicable) of each
part in the propeller hub assembly.
(2) Attach the propeller assembly to the rotatable fixture TE125 or equivalent on
the assembly table TE129 or equivalent.
(3) Remove the air valve cap if present.
(4) Using an air gauge or other appropriate instrument, depress the needle in the
air valve (10) to release the air charge in the cylinder (50).

WARNING: INTERNAL CYLINDER AIR PRESSURE MUST BE REDUCED TO

ZERO BEFORE REMOVING THE AIR VALVE (10).
(5) Remove and discard the air valve (10). Refer to Figure 3-1.
(6) Remove the blade counterweights if applicable. Refer to Hartzell Propeller Inc.
Composite Propeller Blade Maintenance Manual 135F (61-13-35).
(7) Remove the set screw (35) from the cylinder wrench attachment hole.
(8) Remove and discard the self-locking nut (20).
(9) Remove the low pitch stop (30) from the cylinder (50). Refer to Figure 3-1.
(a) Remove and discard the O-ring (40) from the low pitch stop (30).

10

120
20
130
35 140
30
150
40 145
50

50
TPI-MB-0254

Air Valve/Low Pitch Stop Removal

Figure 3-1

DISASSEMBLY 61-10-91 Page 3-5

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

(10) Using air pressure in the rotatable fixture TE125 or equivalent, move the
propeller to low pitch position.

WARNING: HOLD THE PROPELLER BLADES AT LOW PITCH WITH AIR

PRESSURE IN THE ROTATABLE FIXTURE TE125. REMOVAL
OF THE STOP SCREW (120) WITHOUT AIR PRESSURE COULD
CAUSE SUDDEN AND EXPLOSIVE ROTATION OF THE BLADES
TO FEATHER PITCH, RESULTING IN PERSONAL INJURY
AND DAMAGE TO THE INTERNAL COMPONENTS OF THE
PROPELLER.
(11) Using the T-handle wrench TE381 or equivalent, remove the stop screw (120),
washer (130), feather adjust washer(s) (140), high pitch stop sleeve (150), and
high pitch adjust washer(s) (145). Refer to Figure 3-1.
(a) Make a record of the number of washers both under the feathering stop
and on top of the feathering stop to reference during reassembly.
(b) Discard the stop screw (120), washer (130), feather adjust
washer(s) (140), and high pitch adjust washer(s) (145).
(c) Retain the high pitch stop sleeve (150).
(12) Release the air pressure in the rotatable fixture to permit the propeller to move
to feather position.

TE290
TE289
TE291

50
TPI-MB-0255

Using the Spring Assembling Tool TE9

Figure 3-2

DISASSEMBLY 61-10-91 Page 3-6

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

WARNING: USE EXTREME CAUTION WHEN REMOVING THE CYLINDER

(50) AND FEATHERING SPRING ASSEMBLY (110). WHEN
COMPRESSED, THE FEATHERING SPRING ASSEMBLY IS
LOADED TO APPROXIMATELY 750 POUNDS (341 KG) FORCE.
ENSURE THE SAFETY OF PERSONNEL IN THE VICINITY
DURING THE DISASSEMBLY PROCEDURES.
CAUTION: CYCLE THE PROPELLER BEFORE BEGINNING THE
CYLINDER (50) REMOVAL PROCESS. FAILURE TO CYCLE THE
PROPELLER MAY CAUSE THE PITCH CHANGE ROD (200) TO
PREMATURELY DISENGAGE FROM THE FORK (300).
(13) Cycle the propeller through the entire range of movement and cycle back to
no pressure or low pitch before beginning disassembly.
(14) Attach a cylinder wrench TE153 to the top of the cylinder (50).
(15) Insert the small threaded end of the feather assist spring assembling tool TE9
into the cylinder and turn the tool into the end of the pitch change rod (200)
until tight.
NOTE: Using the spring assembling tool TE9 prevents the spring from
forcefully releasing if the spring retainer is broken or the screws are
damaged.
(16) Tighten the hex nut TE290 on the spring assembling tool TE9 until the guide
washer TE291 and the thrust bearing TE289 are snug against the cylinder (50).
Refer to Figure 3-2.
(17) Loosen the spring assembling tool TE9 hex nut TE290 approximately two full
turns. Refer to Figure 3-1.

CAUTION: DO NOT DAMAGE THE CYLINDER THREADS WHEN REMOVING

THE CYLINDER (50) FROM THE HUB (240).
(18) Turn the cylinder wrench TE153 counterclockwise until the cylinder (50) threads
are free from the hub (240).
NOTE: The feathering spring assembly (110) attached to the cylinder (50) is
removed with the cylinder.
(19) Unthread the hex nut TE290 on the spring assembly tool TE9, allowing the
feather assist spring to gradually extend.
NOTE: The feather assist spring is completely extended when the hex nut
TE290, washer TE291, and thrust bearing TE289 become loose.
(20) Remove the feather assist spring assembly tool TE9 and the cylinder wrench
TE153 from the cylinder (50).
(21) Remove the cylinder (50), with the feather assist spring assembly (110), from
the propeller.
(a) Remove and discard the cylinder O-ring (210) from the hub (240).
(22) Set aside the cylinder (50) with the feather assist spring assembly (110) for
further disassembly.

DISASSEMBLY 61-10-91 Page 3-7

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

B. Disassembly of the Internal Pitch Change Parts

(1) Remove and discard the piston nut (170).
(2) Remove the piston (180).
(3) Remove and discard the piston O-ring (160).
(4) Using the wrench adapter TE6, remove the pitch change rod (200).
(5) Remove and discard the hub nuts (350) and washers (340).
(6) Remove the hub clamping bolts (230).
(a) If the spinner bulkhead is mounted to the propeller with the hub bolts,
remove the spinner bulkhead.
(7) Remove the cylinder-side half of the hub unit (240).
(a) A plastic wedge and rubber mallet may be used to separate the hub
halves.
(8) Remove and discard the hub guide bushing (260).
(9) Remove and discard the pitch change rod O-ring (220) from the cylinder-side
hub half.
(10) Using blade retention clamp TE24 if desired, remove blade number one from
the hub (220).

Fork (300)

Pitch Change
Block (320)
TPI-490-014

Fork Removal
Figure 3-3

DISASSEMBLY 61-10-91 Page 3-8

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

(11) Remove the fork (300). Refer to Figure 3-3.

(a) Remove and discard the fork bumpers (310).
(12) Using blade retention clamp TE24 if desired, remove the remaining blades
from the hub (240).
(13) Remove the pitch change block (320) from each pitch change knob.
(a) Make a mark to indicate the direction of the thin wall of each pitch
change block (320) to the fork (300).
(14) Remove and discard the pitch change block button (330) from each pitch
change block (320).

DISASSEMBLY 61-10-91 Page 3-9

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

C. Hub Plug Removal - Refer to Figure 3-4

(1) Turn the engine-side half of the hub unit (240) over to get access to the
propeller mounting flange.
(2) Remove the hub plug (370).
(3) Remove and discard the O-ring (390) from the OD of the hub plug (370).
(4) Remove and discard the O-ring (380) from the ID of the hub plug (370).
(5) Remove and discard the internal spiral retaining ring (360).
D. Hub Disassembly
(1) For hub unit disassembly instructions, refer to the Aluminum Hub Overhaul
chapter of Hartzell Propeller Inc. Standard Practices Manual 202A (61-01-02).
(2) Disassembly of the Hub Mounting Hardware - Refer to Figure 3-4
(a) Use a wrench to hold the mounting nut (510), then use a standard stud
removal tool to remove the mounting stud (500) from the mounting
nut (510).
(b) Discard the mounting stud (500), mounting nut (510), and washer (520).
(c) Repeat the removal steps for the remaining mounting studs (500).
(d) Remove and discard the dowel pins (530).

390
380
370
360
530

240

510
520
500
TPI-MB-0256

Hub Plug/Hub Mounting Components

Figure 3-4

DISASSEMBLY 61-10-91 Page 3-10

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

Blade

720
730
600
610
670
620
680
660
690
640
700
650
710
630
TPI-MB-0218

Blade Retention Components

Figure 3-5

DISASSEMBLY 61-10-91 Page 3-11

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

E. Disassembly of the Blade Retention Parts - Refer to Figure 3-5

(1) Remove and discard the blade O-ring (720).
(2) Remove the hub-side blade bearing race (660).
(3) Remove and discard the bearing balls (640).
(4) Remove and discard the ball spacer (650).
(5) Remove and discard the pitch change knob bushing (730).
(6) Remove the blade seal (700) and the blade shim (680) from the blade.
(a) To make reassembly of the propeller easier, measure the thickness of the
blade shim (680) and make a record of the measurement.
(7) Remove and discard the O-ring (690) from the ID of the blade seal (700).
(8) Remove and discard the O-ring (710) from the OD of the blade seal (700).
(9) Remove and discard the internal spiral retaining ring (620) from the bore of
the blade.
(10) Remove the blade plug (610).
(a) Turn a screw with 8-32 UNC-3B threads into the threaded hole in the
blade plug (610).
(b) Pull the blade plug (610) from the bore of the blade.
(11) Remove and discard the O-ring (600) from the OD of the blade plug (610).
(12) Using a suitable gear puller or brass drift, remove the bearing retaining
ring (670).
(13) Remove the blade-side blade bearing race (630) of the blade retention bearing.
F. Disassembly of the Blade
(1) For composite blade overhaul procedures, refer to Hartzell Propeller Inc.
Composite Propeller Blade Maintenance Manual 135F (61-13-35).

DISASSEMBLY 61-10-91 Page 3-12

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

G. Feathering Spring Disassembly

WARNING: WHEN COMPRESSED, THE FEATHERING SPRING

ASSEMBLY (110) IS LOADED TO APPROXIMATELY 750 POUNDS
(341 KG) FORCE. ENSURE THE SAFETY OF PERSONNEL IN THE
VICINITY DURING DISASSEMBLY PROCEDURES.

CAUTION: DO NOT ATTEMPT TO DISASSEMBLE THE FEATHERING SPRING

ASSEMBLY (110) WITH THE CYLINDER TORQUE WRENCH
ADAPTER TE153 ATTACHED TO THE CYLINDER.
(1) Put the assembling tool TE9 in a vise with the flattened portion of the
threaded rod TE287 between the jaws of the vise, and tighten the vise.
Refer to Figure 3-6.

Assembling Tool
TE9

TPI-APS6181

Assembling Tool TE9 in a Vise

Figure 3-6

DISASSEMBLY 61-10-91 Page 3-13

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

Cylinder Cap
TE380

TE388

TE387

Cylinder
TE288
(70)

TE287

Hex Nut
TE290

TPI-BST2853
TPI-W10033

Positioning the Cylinder on the Assembly Tool TE9

Figure 3-7

DISASSEMBLY 61-10-91 Page 3-14

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

CAUTION: DO NOT DAMAGE THE CYLINDER THREADS WHEN INSTALLING

THE CYLINDER CAP TE380.
(2) Install the cylinder cap TE380 on the cylinder (50). Refer to Figure 3-7.
(3) Slide the cylinder (50) onto the assembling tool TE9 with the small opening of
the cylinder toward the vise. Refer to Figure 3-7.
(4) Put the drilled washer TE288 over the end of the set screw TE388 in the end of
the assembling tool TE9. Refer to Figure 3-7.
(5) Install two nuts TE387 on the set screw TE388. Refer to Figure 3-7.
(6) Turn the hex nut TE290 until the drilled washer TE288 is snug against the
weight (920) with two screws (910) visible through the large holes in the drilled
washer TE288. Refer to Figure 3-8.
(7) Remove and discard the two screws (910).
(8) Loosen the hex nut TE290 until the drilled washer TE288 can be rotated over
the weight (920) and two screws (910) inside the spring guide (950).
(9) Turn the drilled washer TE288 until the heads of the remaining two
screws (910) can be seen through the large holes in the drilled washer TE288.
Refer to Figure 3-8.
(10) Tighten the hex nut TE290 until the drilled washer TE288 is tight against the
weight (920).
(11) Remove the remaining two screws (910).

TE288

Screws (910)

Spring Guide
(950)
TPI-APS6191

NOTE: For clarity, the cylinder

cap TE380 is not shown.

Removing the Feathering Spring Assembly Screws

Figure 3-8

DISASSEMBLY 61-10-91 Page 3-15

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

(12) Remove the cylinder cap TE380. Refer to Figure 3-7.

(13) Loosen the hex nut TE290 until the feather assist spring (960) is fully released.
(14) Remove the two nuts TE387 and the drilled washer TE288.
(15) Remove the weight (920) and the flyweight plate (940). Refer to Figure 3-9.
(16) Remove and discard the spring guide (950).
(17) Remove the feathering spring (960).
(18) Remove and discard the screws (100) holding the start lock housing (970) in
place.
(19) Remove the start lock housing (970).
(20) Remove and discard the cylinder ID O-ring (160).

950

960

970

900

910
920

930
TPI-W10043

940

Feathering Spring Assembly Components

Figure 3-9

DISASSEMBLY 61-10-91 Page 3-16

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

CLEANING - CONTENTS

1. General Procedures for Cleaning Parts................................................................... 4-3

2. Specific Cleaning Procedures................................................................................. 4-3
A. Cleaning Steel Parts for Magnetic Particle Inspection....................................... 4-3
B. Cleaning Steel Parts for Cadmium Replating Procedures................................. 4-3
C. Cleaning Aluminum Parts for Penetrant Inspection............................................ 4-3
D. Cleaning Aluminum Parts for Chromic Acid Anodizing Procedures................... 4-3

CLEANING 61-10-91 Page 4-1

Nov/18
PROPELLER MAINTENANCE MANUAL
491

(This page is intentionally blank.)

CLEANING 61-10-91 Page 4-2

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

1. General Procedures for Cleaning Parts

A. Refer to the Cleaning chapter of Hartzell Propeller Inc. Standard Practices

Manual 202A (61-01-02).

2. Specific Cleaning Procedures

A. Cleaning Steel Parts for Magnetic Particle Inspection

(1) Refer to the Magnetic Particle Inspection chapter of Hartzell Propeller Inc.
Standard Practices Manual 202A (61-01-02).

B. Cleaning Steel Parts for Cadmium Replating Procedures

(1) Refer to the Cadmium Replating chapter of Hartzell Propeller Inc. Standard
Practices Manual 202A (61-01-02).

C. Cleaning Aluminum Parts for Penetrant Inspection

(1) Refer to the Penetrant Inspection chapter of Hartzell Propeller Inc. Standard
Practices Manual 202A (61-01-02).

D. Cleaning Aluminum Parts for Chromic Acid Anodizing Procedures

(1) Refer to the Chromic Acid Anodizing chapter of Hartzell Propeller Inc. Standard
Practices Manual 202A (61-01-02).

CLEANING 61-10-91 Page 4-3

Nov/18
PROPELLER MAINTENANCE MANUAL
491

(This page is intentionally blank.)

CLEANING 61-10-91 Page 4-4

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

CHECK - CONTENTS

1. Inspection Interval Requirements............................................................................. 5-3

2. Inspection Requirements.......................................................................................... 5-3
3. Replacement Requirements..................................................................................... 5-5
4. Repair....................................................................................................................... 5-5
5. Specific Inspection Procedures................................................................................ 5-5
6. Specific Checks........................................................................................................ 5-6
A. NUT, 15/16-20, HEX (Item 20)............................................................................ 5-7
B. PITCH STOP (Item 30)....................................................................................... 5-9
C. CYLINDER, 3-BLADE PROPELLER (Item 50)................................................. 5-11
D. STOP SLEEVE (Item 150)................................................................................ 5-13
E. PISTON (Item 180)............................................................................................ 5-15
F. PITCH CHANGE ROD (Item 200)..................................................................... 5-17
G. BOLT, 3/8-24, HEX HEAD................................................................................. 5-19
H. FORK, THREE BLADE ASSEMBLY (Item 300)................................................ 5-23
I. PITCH CHANGE BLOCK (Item 320)................................................................. 5-25
J. HUB PLUG (Item 370)...................................................................................... 5-27
K. BLADE PLUG (Item 610).................................................................................. 5-29
L. RACE (Item 630 and Item 660) ........................................................................ 5-31
M. BEARING RETAINING RING (Item 670).......................................................... 5-35
N. BLADE SHIM (Item 680)................................................................................... 5-37
O. BLADE SEAL (Item 700)................................................................................... 5-39
P. BALANCE WEIGHT (Item 810) ........................................................................ 5-41

CHECK 61-10-91 Page 5-1

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

LIST OF FIGURES
Pitch Stop Dimensions...................................................................... Figure 5-1................. 5-8
Cylinder Dimensional Inspection Criteria.......................................... Figure 5-2............... 5-10
Stop Sleeve....................................................................................... Figure 5-3............... 5-12
Piston Dimensional Inspection Criteria.............................................. Figure 5-4............... 5-14
Pitch Change Rod ............................................................................ Figure 5-5............... 5-16
Hex Head Bolt................................................................................... Figure 5-6............... 5-18
A-2043-1 Nut Modification................................................................. Figure 5-7............... 5-20
Fork................................................................................................... Figure 5-8............... 5-22
Pitch Change Block........................................................................... Figure 5-9............... 5-24
Hub Plug ........................................................................................... Figure 5-10............. 5-26
Blade Plug Inspection Area............................................................... Figure 5-11.............. 5-28
Race.................................................................................................. Figure 5-12............. 5-30
Bearing Retaining Ring..................................................................... Figure 5-13............. 5-34
Blade Shim........................................................................................ Figure 5-14............. 5-36
Blade Seal......................................................................................... Figure 5-15............. 5-38
Balance Weight................................................................................. Figure 5-16............. 5-40

LIST OF TABLES
Component Inspection Criteria.......................................................... Table 5-1................... 5-7

CHECK 61-10-91 Page 5-2

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

1. Inspection Interval Requirements

NOTE: Specific Hartzell Propeller Inc. manuals and service documents are available
on the Hartzell Propeller Inc. website at www.hartzellprop.com. Refer to the
Required Publications section in the Introduction chapter of this manual for
the identification of these publications.

A. For information about life limited components and mandatory inspections, refer to
the Airworthiness Limitations chapter of Hartzell Propeller Inc. Raptor Owner's
Manual 480 (61-00-80).
(1) Hartzell Propeller Inc. Owner's Manual 480 (61-00-80) is available on the
Hartzell Propeller Inc. website at www.hartzellprop.com.

B. For overhaul periods of Hartzell Propeller Inc. propellers, refer to Hartzell

Propeller Inc. Service Letter HC-SL-61-61Y.
(1) Hartzell Propeller Inc. Service Letter HC-SL-61-61Y is available on the
Hartzell Propeller Inc. website at www.hartzellprop.com.
2. Inspection Requirements

CAUTION: INSTRUCTIONS AND PROCEDURES IN THIS CHAPTER MAY

INVOLVE PROPELLER CRITICAL PARTS. REFER TO THE
INTRODUCTION CHAPTER OF THIS MANUAL FOR INFORMATION
ABOUT PROPELLER CRITICAL PARTS. REFER TO THE
ILLUSTRATED PARTS LIST IN THIS MANUAL FOR IDENTIFICATION
OF PROPELLER CRITICAL PARTS.

A. Inspect the specified parts to determine if they meet the specifications in this chapter.
(1) Retire any serial-numbered part found unairworthy in accordance with the
Mandatory Parts Retirement Procedure chapter of Hartzell Propeller Inc.
Standard Practices Manual 202A (61-01-02).

B. Visual Inspection
(1) Visually examine all parts.
(a) A part that has obvious defects or damage that would affect form, fit, or
function must be removed from service.
(2) Definitions
(a) Corrosion is active electrochemical deterioration, such as rust, that can
result in pitting.
(b) Linear pitting is the configuration of the majority of pits forming a pattern
in the shape of a line.

CHECK 61-10-91 Page 5-3

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

C. Penetrant Inspection
(1) Penetrant inspect aluminum parts, as required. Refer to Table 5-1,
"Component Inspection Criteria", in this chapter.
(a) For inspection of aluminum parts, use the procedures in the Penetrant
Inspection chapter of Hartzell Propeller Inc. Standard Practices
Manual 202A (61-01-02).

D. Magnetic Particle Inspection

(1) Magnetic particle inspect steel parts, as required. Refer to Table 5-1,
"Component Inspection Criteria", in this chapter.
(a) For inspection of steel parts, use the procedures in the Magnetic Particle
Inspection chapter of Hartzell Propeller Inc. Standard Practices
Manual 202A (61-01-02).

E. Dimensional Inspection
(1) When measuring the diameter of a part with a two point measuring
instrument, take at least two measurements unless specified differently.
(a) Obtaining a measurement outside the specified tolerance at any point of
measurement is cause for retirement of the part when a minimum of two
measurements are taken.
(b) Alternately, take eight evenly spaced measurements, unless specified
differently.
1 Obtaining a measurement outside the specified tolerance on three
or more measurements is cause for retirement of the part when
eight measurements are taken (two of eight measurements may be
out of specified tolerance).
2 This alternate method may not be used to accept a diameter that
has obvious damage beyond repairable (serviceable) limits.
(2) When measuring the diameter of a part with a three point measuring
instrument, take one measurement. A measurement outside the specified
tolerance is cause for retirement of the part.
(3) Inspect the part features to the number of decimal places specified. If three
decimal places are specified, inspect the part to three decimal places only.

CHECK 61-10-91 Page 5-4

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

3. Replacement Requirements

A. If the component has cracks, corrosion, wear, obvious defects, or damage that is
greater than the permitted serviceable limits, the component must be repaired or
replaced in accordance with Corrective Action in this chapter.

B. If the component has corrosion, wear, obvious defects, or damage that is less than
the permitted serviceable limits, no further action is required.

4. Repair

A. Parts that can be repaired are specified in the Corrective Action section of Table 5-1,
"Component Inspection Criteria", in this chapter.

B. Repair procedures are found in the Repair chapter of this manual, unless specified
differently.

5. Specific Inspection Procedures

A. For daily inspection procedures of a propeller with composite blades, refer to Hartzell
Propeller Inc. Propeller Owner's Manual and Logbook 480 (61-00-80).

B. For requirements and procedures for inspecting aluminum hub units, refer to
the Aluminum Hub Overhaul chapter of Hartzell Propeller Inc. Standard Practices
Manual 202A (61-01-02).

C. For requirements and procedures for inspecting composite blades, refer to Hartzell
Propeller Inc. Composite Propeller Blade Maintenance Manual 135F (61-13-35).

D. For foreign object strike inspection procedures, refer to the Special Inspections
chapter of Hartzell Propeller Inc. Standard Practices Manual 202A (61-01-02).

E. If the propeller is equipped with an ice protection system that uses components
supplied by Hartzell Propeller Inc., applicable instructions and technical information
can be found in Hartzell Propeller Inc. Ice Protection System Manual 180 (30-61-80)
available on the Hartzell Propeller Inc. website at www.hartzellprop.com.

F. Propeller ice protection system components not supplied by Hartzell Propeller Inc.
are controlled by the applicable TC or STC holder’s Instructions for Continued
Airworthiness (ICA).

G. For spinner assembly inspection procedures, refer to Hartzell Propeller Inc.

Metal Spinner Assembly Maintenance Manual 127 (61-16-27) or Hartzell Propeller Inc.
Composite Spinner Maintenance Manual 148 (61-16-48).

CHECK 61-10-91 Page 5-5

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

6. Specific Checks

CAUTION: INSTRUCTIONS AND PROCEDURES IN THIS CHAPTER MAY

INVOLVE PROPELLER CRITICAL PARTS. REFER TO THE
INTRODUCTION CHAPTER OF THIS MANUAL FOR INFORMATION
ABOUT PROPELLER CRITICAL PARTS. REFER TO THE
ILLUSTRATED PARTS LIST IN THIS MANUAL FOR IDENTIFICATION
OF PROPELLER CRITICAL PARTS.
For specific component checks, refer to Table 5-1, "Component Inspection Criteria" in
this chapter.

CHECK 61-10-91 Page 5-6

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

Component Inspection Criteria

Table 5-1
Inspect Serviceable Limits Corrective Action

A. NUT, 15/16-20, HEX

(Item 20)

(1) Visually examine each nut The corners between the File away unwanted material
for wrenching damage. wrenching flats may be displacement.
rounded. Two (2) wrenching
flats must be sufficiently Replace the nut if a minimum of
undamaged to withstand two (2) flats will not withstand
installation torque. Material installation torque.
may not be displaced above or
below the nut that could result
in interference with the mating
parts.

(2) Visually examine each nut The maximum permitted depth If there is material loss deeper
for corrosion on all surfaces of material loss is 0.005 inch than the permitted serviceable
and wear on surfaces other (0.12 mm). limits, replace the nut.
than wrenching flats.

(3) Visually examine the nut for Cadmium plating must be Cadmium replate the nut in
cadmium plating coverage. present on all surfaces. accordance with the Cadmium
Replating chapter of Hartzell
Propeller Inc.Standard Practices
Manual 202A (61-01-02).

CHECK 61-10-91 Page 5-7

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

"Y"

"X"

Part No. "X" Dimension "Y" Dimension

A-2404-4 2.00 ± 0.03 inch 0.500 ± 0.010 inch
(50.8 ± 0.8 mm) (12.70 ± 0.05 mm)
A-2404-3 2.35 ± 0.03 inch 0.700 ± 0.010 inch
(59.7 ± 0.8 mm) (17.78 ± 0.05 mm)
A-2404-2 2.00 ± 0.03 inch 0.600 ± 0.010 inch
(50.8 ± 0.8 mm) (15.24 ± 0.05 mm)
A-2404-1 2.10 ± 0.03 inch 0.700 ± 0.010 inch
(53.3 ± 0.8 mm) (17.78 ± 0.05 mm)
A-2404 2.25 ± 0.03 inch 0.800 ± 0.010 inch
(57.2 ± 0.8 mm) (20.32 ± 0.05 mm)
LOWSTOP.XLS
APS6256

Pitch Stop Dimensions

Figure 5-1

CHECK 61-10-91 Page 5-8

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

Component Inspection Criteria

Table 5-1
Inspect Serviceable Limits Corrective Action

B. PITCH STOP
(Item 30)
Refer to Figure 5-1

(1) Visually examine the pitch Slight damage is permitted. If the damage is more than the
change rod/pitch stop Damage must not affect the permitted serviceable limits,
contact surface for damage. performance of the pitch stop. replace the pitch stop.

(2) Visually examine the One damaged thread is If more than one thread is
external threads of the pitch permitted. damaged, replace the pitch stop.
stop for damage.

(3) Visually examine the One damaged thread is If more than one thread is
internal threads of the pitch permitted. damaged, replace the pitch stop.
stop for damage.

(4) Visually examine the air The air passage must be clean If the air passage cannot be
hole in the center of the and unobstructed. cleared, replace the pitch stop.
pitch stop.

(5) Visually examine the Loss of Hard Anodize on the If there is loss of Hard Anodize
Hard Anodize on the "Y" "Y" dimension is not permitted. on the "Y" dimension, replace
dimension surface of the The OD threads may be bare the pitch stop.
pitch stop. aluminum or be coated with
anodize.

CHECK 61-10-91 Page 5-9

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

High pitch stop Low pitch stop threads

Cylinder "B"
"D"

"A"
"C" "D" Wall
thickness
"E"

Cylinder wrench attachment hole

"A" "B" "C"

Part Number Bushing O-ring Groove Low Pitch Stop O-ring Groove
Maximum Diameter Maximum Diameter Maximum Diameter
B-2423-1 4.759 inch 5.235 inch 0.989 inch
(120.88 mm) (132.97 mm) (25.12 mm)
APS6230
CYL.XLS

Cylinder Dimensional Inspection Criteria

Figure 5-2

CHECK 61-10-91 Page 5-10

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

Component Inspection Criteria

Table 5-1
Inspect Serviceable Limits Corrective Action

C. CYLINDER - 3 BLADE PROPELLER

(Item 50)
Refer to Figure 5-2.

(1) Visually examine the All external surfaces: maintain Using an abrasive pad CM47
external surfaces of the a wall thickness of 0.079 inch or equivalent, polish to blend
cylinder for wear, nicks, (2.00 mm), repaired area must out damage. High spots are not
scratches or other damage. be less than 0.5 inch (12.7 mm) permitted. If base aluminum is
in diameter, repairs must be exposed, chromate conversion
separated by a minimum of coat. If damage is greater than
0.5 inch (12.7 mm). the permitted serviceable limits,
replace cylinder.

Damage in circular area "D" If damage is greater than the

limited to 0.020 inch (0.50 mm) permitted serviceable limits,
depth. Sufficient flat surface replace the cylinder.
must remain to support the nut.

(2) Visually examine the A maximum of 1/4 of one Refer to the Repair chapter in
cylinder wrench attachment thread accumulated damage this manual for repair of cylinder
threads for damage. per wrench attachment hole is wrench attachment threads.
permitted.

(3) If cylinder wrench The minimum permitted wall If the wall thickness under the
attachment holes are thickness under the center center point of the hole is less
repaired with a slimsert, point of the hole is 0.080 inch than the seviceable limits,
measure the wall thickness, (2.03 mm). replace the cylinder.
"E".
(4) Visually examine the low Damage is not permitted If there is damage, replace the
pitch stop threads for cylinder.
damage.

(5) Visually examine the ID of If the cylinder bushing or If the ID is greater than the
the cylinder bushing and surrounding area shows signs permitted serviceable limits,
the immediate surrounding of wear, dimensionally inspect replace the cylinder bushing. For
cylinder wall area for signs the cylinder ID in accordance cylinder bushing replacement
of bushing wear. with Figure 5-2. procedures, refer to the
Special Adhesive and Bonding
Procedures chapter of Hartzell
Propeller Inc. Standard Practices
Manual 202A (61-01-02).
(6) Visually examine the An unbonded area is not If there is an unbonded area,
adhesive bond of the permitted. replace the bushing. For
cylinder bushing. cylinder bushing replacement
procedures, refer to the
Special Adhesive and Bonding
Procedures chapter of Hartzell
Propeller Inc. Standard Practices
Manual 202A (61-01-02).

CHECK 61-10-91 Page 5-11

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

Corner "A"

OD

103339, A-2499

Stop Sleeve
Figure 5-3

CHECK 61-10-91 Page 5-12

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

Component Inspection Criteria

Table 5-1
Inspect Serviceable Limits Corrective Action

D. STOP SLEEVE
(Item 150)
Refer to Figure 5-3

(1) Visually examine the OD The maximum permitted Smooth out the damaged area.
of the stop sleeve for wear, depth of damage is 0.005 inch If the depth of damage is greater
nicks, scratches, or other (0.12 mm). than the permitted serviceable
damage that would affect fit limits, replace the stop sleeve.
or performance.

(2) Visually examine the Except for a few scratches and If the damage is greater than
cadmium plating on the corners with cadmium plating the serviceable limits, cadmium
surface of the stop sleeve. missing, complete coverage is replate and bake the stop sleeve
required. in accordance with the Cadmium
Replating chapter of Hartzell
Propeller Inc. Standard Practices
Manual 202A (61-01-02).

(3) Visually examine corner "A" Minor rounding of the corner If the rounding or damage of the
for rounding and damage. that does not affect the corner affects the engagement of
engagement by the high pitch the high pitch stop pins, replace
stop pins is permitted. the stop sleeve.

CHECK 61-10-91 Page 5-13

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

"E"

"D"

"B" "C" "A"

Nut contact
surface.

"A" "B" "C" "D" "E"

Part
Minimum Maximum Maximum Minimum Max. Surface
Number
Piston OD Bore ID O-ring ID O-ring Width Micro Finish

4.746 inch 0.739 inch 0.982 inch 0.146 inch

B-3683 16
(120.55 mm) (18.77 mm) (24.94 mm) (3.71 mm)
PISTON.XLS
APS6231

Piston Dimensional Inspection Criteria

Figure 5-4

CHECK 61-10-91 Page 5-14

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

Component Inspection Criteria

Table 5-1
Inspect Serviceable Limits Corrective Action

E. PISTON
(Item 180)
Refer to Figure 5-4.

(1) Visually examine the The maximum permitted If the depth of damage is
anodized surfaces of depth of damage is 0.005 inch greater than the serviceable
the piston (that are not (0.12 mm). limits, replace the piston.
referenced below or in
Figure 5-4), for wear, nicks,
scratches, or other damage.

(2) Visually examine the piston Anodize must be present on If corrosion, wear, damage, or
OD for corrosion, wear, all OD surfaces. The maximum loss of anodize coverage is
damage, and anodize permitted diameter of damage greater than the serviceable
coverage. is 0.030 inch (0.76 mm).The limits, replace the piston.
maximum permitted depth of
damage is 0.002 (0.50 mm).
Damage must not penetrate the
anodize. Pushed-up material is
not permitted.

(3) Visually examine the piston If the piston shows wear, If the wear is greater than the
areas "A", "B", "C", and "E". dimensionally inspect in serviceable limits, replace the
accordance with Figure 5-4. piston.

(4) Visually examine the If there is damage, If the damage is greater than the
nut contact surface for dimensionally inspect Area "D" serviceable limits, replace the
corrosion, wear, or damage. in accordance with Figure 5-4. piston.
The maximum permitted
depth of damage is 0.007 inch
(0.17 mm).

CHECK 61-10-91 Page 5-15

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

No chrome in this area

Oil Hole wall (thin wall)
Oil Hole
0.09 inch
(2.28 mm)

"C" "B" "A"

"D"

No chrome No chrome
0.090 inch 0.090 inch
(2.28 mm) (2.28 mm)
maximum maximum

Smallest diameter of the taper

"D"
APS6282A
APS6282B
APS6282

Pitch Change Rod

Figure 5-5

CHECK 61-10-91 Page 5-16

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

Component Inspection Criteria

Table 5-1
Inspect Serviceable Limits Corrective Action

F. PITCH CHANGE ROD

(Item 200)
Refer to Figure 5-5.

(1) Visually examine the chrome Any area worn below the If the wear is greater than the
plating of the pitch change rod chrome plating is cause for serviceable limits, replace the
for damage, in the areas of replacement. pitch change rod.
diameters "A and "B".

(2) Visually examine the One damaged thread is If the damage is greater than the
external threads for permitted. serviceable limits, replace the
damage. pitch change rod.

(3) Measure area "B" of the pitch The minimum permitted If the diameter is less than the
change rod. diameter is 0.732 inch serviceable limits, replace the
(18.60 mm). pitch change rod.

(4) Measure area "A" of the pitch The minimum permitted If the diameter is less than the
change rod. diameter is 0.662 inch serviceable limits, replace the
(16.82 mm). pitch change rod.

(5) Visually examine the taper Corrosion, wear, or damage is If damage causes high spots
area "D" for corrosion, wear, not permitted at the smallest above the existing surface,
and damage. diameter of the taper. remove only the high spots. If
Remaining taper surface may corrosion, wear, or damage is
have a maximum damage depth more than the serviceable limits,
of 0.004 inch (0.10 mm) over replace the pitch change rod.
25% of the surface area.

(6) Visually examine the pitch The rod must be straight. If the rod is not straight, replace
change rod for straightness. Bending is not permitted. the pitch change rod.

(7) Measure area "C" of the pitch The minimum permitted If the diameter is less than the
change rod. diameter is 0.732 inch permitted serviceable limits,
(18.60 mm). replace the pitch change rod.

(8) Magnetic particle inspect A relevant indication is not If there is a relevant indication,
the pitch change rod. permitted. replace the pitch change rod.

NOTE: Do not strip

the chrome
plating.

(9) Examine the oil supply Unwanted material is not Remove all unwanted material.
bore using a borescope or permitted.
fiberoptic flashlight.

CHECK 61-10-91 Page 5-17

Nov/18
PROPELLER MAINTENANCE MANUAL
491

AREA "A"
Threads

Fillet
AREA "A"

Fillet

Hex Head
TPI-143012-2

Hex Head Bolt

Figure 5-6

CHECK 61-10-91 Page 5-18

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

Component Inspection Criteria

Table 5-1
Inspect Serviceable Limits Corrective Action

G. BOLT, 3/8-24, HEX HEAD

(Item 230)
Refer to Figure 5-6

(1) Visually examine the hex Corrosion is not permitted. The Corrosion may be removed using
head bolt for corrosion and maximum permitted depth of glass bead cleaning. Refer to
pitting. pitting is 0.002 inch (0.05 mm). the Cleaning chapter of Hartzell
No more that 5% of the total Propeller Inc. Standard Practices
unthreaded surface may be Manual 202A (61-01-02). If
pitted. The maximum permitted the pitting is greater than the
diameter of an individual pit is permitted serviceable limits,
0.032 inch (0.81 mm). Pitting replace the hex head bolt.
is not permitted in the fillet
between the hex head and the
grip, Area "A". Pitting must not
affect the fit or function of the
hex head bolt.

(2) Except for the threads, The maximum permitted depth Pushed up material may be
visually examine the hex of damage or a scratch is removed with a thread file. Use
head bolt for damage or 0.002 inch (0.05 mm). of the thread file must not affect
scratches. Scratches or damage must not the fit or function of the hex head
affect the fit or function bolt. If the depth of a scratch
of the hex head bolt. Pushed-up or damage is greater than the
material is not permitted. permitted serviceable limits or if
the scratch, damage, or repair
affects the fit or function of the
hex head bolt, replace the hex
head bolt.

(3) Visually examine the hex Circumferential scoring that If the scoring is greater than the
head bolt for circumferential reduces the diameter of the hex permitted serviceable limits or if
scoring caused by head bolt is not permitted. The the OD in Area "A" is less than
installation and removal. minimum permitted OD in the permitted serviceable limits,
Area "A" is 0.370 inch replace the hex head bolt.
(9.40 mm).

(4) Visually examine the Limited damage from wrenching Remove metal movement with a
wrenching surfaces of the is permitted, but it must be file or equivalent. Only corners
head of the hex head bolt possible to torque the hex head may be repaired. Refacing
for metal movement caused bolt and metal movement must a complete surface is not
by wrenching. not interfere with the installation permitted. If metal movement
of the hex head bolt or cause is greater than the permitted
damage to the hub. serviceable limits, replace the
hex head bolt.

CHECK 61-10-91 Page 5-19

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

CAUTION: DO NOT USE MODIFIED A-2043-1 NUTS ON THE PROPELLER

ASSEMBLY. A-2043-1 NUTS THAT HAVE BEEN MODIFIED ARE
TO BE USED ONLY FOR THE HEX HEAD BOLT THREAD CHECK.

Plastic Locking Element

Nut May Be Machined To Remove The
Plastic Locking Element And Metal
Housing Or Only The Plastic Locking
Element May Be Removed
TPI-143011-1

A-2043-1 Nut Modification

Figure 5-7

CHECK 61-10-91 Page 5-20

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

Component Inspection Criteria

Table 5-1
Inspect Serviceable Limits Corrective Action

G. BOLT, 3/8-24, HEX HEAD,

CONTINUED
(Item 230)
Refer to Figure 5-6

(5) Visually examine the A maximum total accumulation Limited thread file repair is
threads of the hex head bolt of 3/4 thread of damage and permitted, but must be considered
for damage and pitting. pitting is permitted. Thread as thread damage. If the damage
damage must not cause and pitting is greater than the
damage to the mating part. permitted serviceable limits,
An A-2043-1 nut with the plastic replace the hex head bolt.
locking element removed should
be able to be freely rotated by
hand on the bolt threads. For
the modification of the nut, refer
to Figure 5-7.

(6) Magnetic particle inspect A relevant indication is not If there is a relevant indication,
each bolt in accordance permitted. replace the hex head bolt.
with the Magnetic Par-
ticle Inspection chapter
of Hartzell Propeller Inc.
Standard Practices
Manual 202A (61-01-02).
NOTE: It is not necessary
to strip the
cadmium plating
from the hex
head bolt before
magnetic particle
inspection.

(7) Visually examine the hex Cadmium plating must If cadmium plating coverage
head bolt for cadmium completely cover the bolt with is less than the permitted
plating coverage. the following exceptions: A few serviceable limits, cadmium
scratches and corners with replate and bake for a minimum
cadmium plating missing, minor of 23 hours within four hours
abrading of cadmium plating on after plating the hex head bolt
the threads, or minor abrading in accordance the Cadmium
of the cadmium plating on the Replating chapter of Hartzell
hex head because of wrenching Propeller Inc. Standard Practices
are permitted. Manual 202A (61-01-02).

CHECK 61-10-91 Page 5-21

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

Fork Slot

Pitch Change Rod

Engagement Threads
of the Fork Bore

Tapered Portion
of the Fork Bore

TPI-105732

Fork
Figure 5-8

CHECK 61-10-91 Page 5-22

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

Component Inspection Criteria

Table 5-1
Inspect Serviceable Limits Corrective Action

H. FORK, THREE BLADE ASSEMBLY

(Item 300)
Refer to Figure 5-8

(1) Visually examine the Corrosion is not permitted. Remove corrosion using glass
cadmium plating of the If there is corrosion, remove it bead cleaning. Refer to the
fork (excluding the slots, in accordance with the Cleaning chapter of Hartzell
threaded bore, and tapered corrective action repair limits. Propeller Inc. Standard Practices
section of the bore) for The maximum permitted Manual 202A (61-01-02). If the
corrosion, pitting, wear, depth of pitting, wear, scratches, corrosion cannot be removed
scratches, or other damage. or damage is 0.003 inch or if the pitting, wear, scratches,
(0.07 mm). or damage is greater than the
permitted serviceable limits,
replace the fork.

(2) Visually examine the pitch One thread of total accumulated If the damage is greater than
change rod engagement damage in each hole is the permitted serviceable limits,
threads of the fork bore for permitted. replace the fork.
damage.

(3) Visually examine the If there is wear, nicks, fretting, or If wear, nicks, fretting, or
tapered portion of the damage, measure the depth of damage is greater than the
fork bore for wear, nicks, wear or damage. The maximum permitted serviceable limits,
fretting, or other damage. permitted depth of wear, nicks, replace the fork.
fretting, or damage is 0.003 inch
(0.07 mm).

(4) Visually examine the fork If there is damage, measure the If the damage is greater than the
slots for damage. depth of damage. The maximum permitted serviceable limits,
permitted depth of damage is replace the fork.
0.006 inch (0.15 mm).

(5) Perform a magnetic A relevant indication is not If a relevant indication can be

particle inspection of the permitted repaired and is within the
fork in accordance with permitted serviceable limits in
the Hartzell Propeller Inc. this section, cadmium replate
Standard Practices and bake the fork in accordance
Manual 202A (61-01-02). with the Cadmium Replating
NOTE: Remove the chapter of Hartzell Propeller Inc.
cadmium Standard Practices Manual 202A
plating (61-01-02). If the relevant
from the fork indication cannot be repaired
before within the permitted serviceable
magnetic limits, replace the fork.
particle
inspection.

CHECK 61-10-91 Page 5-23

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

C
B

Part
"A" Minimum "B" Maximum "C" Minimum
Number
0.869 inch 0.6890 inch 0.575 inch
105733
(22.08 mm) (17.500 mm) (14.61 mm)
TPI-490-002

Pitch Change Block

Figure 5-9

CHECK 61-10-91 Page 5-24

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

Component Inspection Criteria

Table 5-1
Inspect Serviceable Limits Corrective Action

I. PITCH CHANGE BLOCK

(Item 320)
Refer to Figure 5-9

(1) Visually examine the pitch If there is damage, measure the If the depth of damage is greater
change block for damage. depth of damage. The maximum than the permitted serviceable
permitted depth of damage is limits, replace the pitch change
0.005 inch (0.12 mm). block.

(2) Visually examine the pitch If there is wear, measure the If the wear is greater than the
change block for wear. pitch change block. Refer to permitted serviceable limits,
Figure 5-9 for the maximum replace the pitch change block.
permitted wear dimensions.

(3) Magnetic particle inspect A relevant indication is not If there is a relevant indication,
the pitch change block in permitted. replace the pitch change block.
accordance with Hartzell
Propeller Inc. Standard
Practices Manual 202A
(61-01-02).

CHECK 61-10-91 Page 5-25

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

"C"

"A"

"B" "D"

Hub Plug Removal Feature

"A" "B" "C" "D"

Part
Minimum O-ring Maximum O-ring Minimum Plug Maximum Bore
Number
Groove OD Groove ID OD ID

2.015 inch 0.846 inch 2.246 inch 0.670 inch

A-2481
(51.18 mm) (21.48 mm) (57.05 mm) (17.01 mm)
TPI-A2481

Hub Plug
Figure 5-10

CHECK 61-10-91 Page 5-26

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

Component Inspection Criteria

Table 5-1
Inspect Serviceable Limits Corrective Action

J. HUB PLUG
(Item 370)
Refer to Figure 5-10

(1) Visually examine the hub Corrosion is not permitted. If there is corrosion, replace the
plug for corrosion. hub plug.

(2) Visually examine the If the hub plug O-ring groove If the hub plug O-ring groove
O-ring groove OD "A". OD "A" is worn or damaged, OD "A" is less than the permitted
measure in accordance with serviceable limits, replace the
Figure 5-10. hub plug.

(3) Visually examine the If the hub plug O-ring groove If the hub plug O-ring groove
O-ring groove ID "B". ID "B" is worn or damaged, ID "B" is greater than the
measure in accordance with permitted serviceable limits,
Figure 5-10. replace the hub plug.

(4) Visually examine the hub If the hub plug OD "C" is If the hub plug OD "C" is less
plug OD "C". worn or damaged, measure than the permitted serviceable
in accordance with Figure 5-10. limits, replace the hub plug.

(5) Visually examine the hub If the hub plug ID bore "D" is If the hub plug ID bore "D"
plug ID bore "D". worn or damaged, measure in is greater than the permitted
accordance with Figure 5-10. serviceable limits, replace the
hub plug.

(6) Visually examine the hub Slight damage is permitted. If the damage is greater than
plug removal feature for Damage must not interfere the permitted serviceable limits,
damage. with the ability to remove the replace the hub plug.
hub plug from the hub.

CHECK 61-10-91 Page 5-27

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

Threads

TPI-106048

Blade Plug Inspection Area

Figure 5-11

CHECK 61-10-91 Page 5-28

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

Component Inspection Criteria

Table 5-1
Inspect Serviceable Limits Corrective Action

K. BLADE PLUG
(Item 610)
Refer to Figure 5-11

(1) Visually examine the Corrosion is not permitted. If Remove corrosion to a maximum
blade plug for corrosion there is corrosion, remove it in depth of 0.010 inch (0.25 mm)
and pitting. accordance with the corrective using glass bead cleaning. If the
action repair limits. corrosion cannot be removed,
replace the blade plug. Refer to
The maximum permitted the Cleaning chapter of Hartzell
depth of pitting is 0.010 inch Propeller Inc. Standard Practices
(0.25 mm). The maximum Manual 202A (61-01-02). If
permitted total area of pitting is the depth or amount of pitting
20% of the blade plug surface. is greater than the permitted
serviceable limits, replace the
blade plug.

(2) Visually examine the A maximum of one thread of If the damage is greater than
threads of the blade plug total accumulated damage is the permitted serviceable limits,
for damage. permitted. replace the blade plug.

(3) Visually examine the blade The maximum permitted Using an abrasive pad CM47
plug for scratches, gouges, depth of a scratch, gouge, or or equivalent, polish pushed
or other damage. other damage is 0.010 inch up material to blend with the
(0.25 mm). Damage must not surrounding surfaces. If a
interfere with the fit of the blade scratch, gouge, or other damage
plug in the blade bore. is greater than the permitted
serviceable limits, replace the
blade plug.

CHECK 61-10-91 Page 5-29

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

Hub Contact
Surface

Hub-side Race

Radial
Depth

Ball Bearing Groove

(dashed lines)

Blade-side Race
Outer
Diameter

Blade Contact Surface

Chips Cracks

Race Mating Surface

Chips
TPI-MB-0202

Race
Figure 5-12

CHECK 61-10-91 Page 5-30

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

Component Inspection Criteria

Table 5-1
Inspect Serviceable Limits Corrective Action
L. RACE
(Item 630 and Item 660)
(Refer to Figure 5-12)

(1) Visually examine the ball Corrosion is not permitted. If Remove corrosion using glass
bearing groove in each there is corrosion, remove it in bead cleaning. For glass bead
race for corrosion. accordance with the corrective cleaning refer to the Cleaning
action repair limits. chapter of Hartzell Propeller
Inc. Standard Practices
Manual 202A (61-01-02). If the
corrosion cannot be removed,
replace the race.

(2) Visually examine the ball The maximum permitted depth of If the pitting is greater than the
bearing groove in each pitting is 0.003 inch (0.076 mm) serviceable limits, replace the
race for pitting, wear, in the ball bearing groove. race.
fretting, and damage.
The maximum permitted
diameter of a pit is 0.032 inch
(0.81 mm).

The maximum permitted total

area of pitting in the ball bearing
groove on a complete race is
0.12 square inch
(77.4 square mm) (two races for
each bearing set). Pitting must
not interfere with bearing ball
movement or support.

If the ball bearing groove has If the wear is greater than the
wear, measure the wear. The permitted serviceable limits,
maximum permitted depth of replace the race.
wear is 0.005 inch (0.12 mm).

Fretting damage is not permitted. If there is fretting damage,

replace the race.

For damage other than pitting or If damage is greater than the

fretting, the maximum permitted permitted serviceable limits,
depth of damage is 0.003 inch replace the race.
(0.076 mm) and must not
interfere with bearing ball
movement or support.

CHECK 61-10-91 Page 5-31

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

Component Inspection Criteria

Table 5-1
Inspect Serviceable Limits Corrective Action
L. RACE, CONTINUED
(Item 630 and Item 660)
(Refer to Figure 5-12)

(3) Except for the ball Corrosion is not permitted. If Remove corrosion using glass
bearing groove, visually there is corrosion, remove it in bead cleaning. For glass bead
examine all other accordance with the corrective cleaning refer to the Cleaning
surfaces of each race for action repair limits. chapter of Hartzell Propeller
corrosion. Inc. Standard Practices
Manual 202A (61-01-02). If the
corrosion cannot be removed,
replace the race.

(4) Except for the ball The maximum permitted If the pitting is greater than the
bearing groove, visually depth of pitting is 0.005 inch permitted serviceable limits,
examine all other (0.12 mm). replace the race.
surfaces of each race for
pitting, wear, fretting, and The maximum permitted
damage. diameter of a pit is 0.062 inch
(1.57 mm).

The maximum permitted total

area of pitting on all surfaces
except the ball bearing groove
of a complete race is
0.25 square inch
(161.2 square mm) (two races for
each bearing set).

Fretting damage is permitted on Clean the fretted area

the outer diameter of the races thoroughly using an abrasive
that interface with the bearing pad CM47 or equivalent to
retaining ring (670). Fretting must decrease fretting damage to
not loosen the tight fit with the a minimum. If the fit of the
bearing retaining ring (670). bearing retaining ring (670)
to the race is not tight, replace
the race.

Wear is not permitted. If there is wear, replace the

race.

For damage other than pitting, If the damage is greater than

the maximum permitted depth the permitted serviceable limits,
of damage is 0.005 inch replace the race.
(0.12 mm) and must not interfere
with the mating surfaces.

CHECK 61-10-91 Page 5-32

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

Component Inspection Criteria

Table 5-1
Inspect Serviceable Limits Corrective Action
L. RACE, CONTINUED
(Item 630 and Item 660)
(Refer to Figure 5-12)

(5) Visually examine the Chips or cracks that are adjacent If there are chips or cracks
race for chips or cracks to the mating surfaces of the adjacent to the mating
that are adjacent to the race are not permitted. surfaces of the race, replace
mating surfaces of the the race.
race.

(6) Magnetic particle inspect A relevant indication is not If there is a relevant indication,
each race in accordance permitted. replace the race.
with the Magnetic Particle
Inspection chapter of
Hartzell Propeller Inc.
Standard Practices
Manual 202A (61-01-02).

CHECK 61-10-91 Page 5-33

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

Area "A"

BEARING RETAINING RING B-7071

B-7071

Bearing Retaining Ring

Figure 5-13

CHECK 61-10-91 Page 5-34

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

Component Inspection Criteria

Table 5-1
Inspect Serviceable Limits Corrective Action

M. BEARING RETAINING RING

(Item 670)
Refer to Figure 5-13

(1) Except for Area “A”, Corrosion is not permitted. If Remove corrosion using glass
visually examine the there is corrosion, remove it in bead cleaning. Refer to the
bearing retaining ring for accordance with the corrective Cleaning chapter of Hartzell
corrosion and pitting. action repair limits. Propeller Inc. Standard Practices
Manual 202A (61-01-02). If the
The maximum permitted corrosion cannot be removed,
depth of pitting is 0.005 inch replace the bearing retaining
(0.12 mm). Pitting must not ring. If the corrosion or pitting
interfere with the ability of the is greater than the permitted
bearing retaining ring to fit serviceable limits, replace the
tightly to the blade and the bearing retaining ring.
bearing race.

(2) Visually examine the Corrosion, pitting, or wear If there is corrosion, pitting,
bearing retaining ring for through the cadmium plating in or wear through the cadmium
corrosion, pitting, or wear Area "A" is not permitted. plating, replace the bearing
in Area "A”. retaining ring.

(3) Except for Area "A", The bearing retaining ring must If wear, damage, or fretting
visually examine the fit tightly to the blade and the is greater than the permitted
bearing retaining ring for bearing race when installed serviceable limits, replace the
wear, damage, or fretting. over the blade and bearing bearing retaining ring.
race.

(4) Visually examine the entire A few random scratches If cadmium plating is not on all
bearing retaining ring for and corners with cadmium surfaces, replate the bearing
cadmium plating coverage. plating missing are permitted; retaining ring in accordance
otherwise, complete coverage with the Cadmium Replating
is required. chapter of Hartzell Propeller Inc.
Standard Practices Manual 202A
(61-01-02).

CHECK 61-10-91 Page 5-35

Nov/18
PROPELLER MAINTENANCE MANUAL
491

Thickness

TPI-105758

Blade Shim
Figure 5-14

CHECK 61-10-91 Page 5-36

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

Component Inspection Criteria

Table 5-1
Inspect Serviceable Limits Corrective Action

N. BLADE SHIM
(Item 680)
Refer to Figure 5-14

(1) Visually examine the blade Damage, missing material, If there is damage, missing
shim for damage, missing separation, or form irregularities material, separation, or form
material, separation, or are not permitted. irregularities, replace the
form irregularities as a blade shim.
continuous ring.

(2) Measure the thickness of The minimum permitted If the thickness is less than the
the blade shim. thickness of the blade shim permitted serviceable limits,
is 0.040 inch (1.02 mm). replace the blade shim.

(3) Measure the thickness The maximum permitted If the thickness variation is
variation of the blade shim thickness variation is greater than the permitted
at five equally spaced 0.005 inch (0.12 mm). serviceable limits, replace the
places on the blade shim. blade shim.

CHECK 61-10-91 Page 5-37

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

Diameter Diameter
"A" "A"

Diameter
"B"

Diameter
"E"

Width "C2"
Width "C1"

Width "F"
O-ring
Groove

Thickness "D"

"A" "B" "C1" "C2" "D" "E"

MAXIMUM MAXIMUM MINIMUM MINIMUM MINIMUM MINIMUM
DIAMETER DIAMETER WIDTH WIDTH THICKNESS DIAMETER

4.550 inches 4.750 inches 0.060 inch 0.050 inch 0.065 inch 5.075 inches
(115.57 mm) (120.65 mm) (1.53 mm) (1.27 mm) (1.66 mm) (128.91 mm)
106064

Blade Seal
Figure 5-15

CHECK 61-10-91 Page 5-38

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

Component Inspection Criteria

Table 5-1
Inspect Serviceable Limits Corrective Action

O. BLADE SEAL
(Item 700)
Refer to Figure 5-15

(1) Visually examine the blade Corrosion is not permitted. If Using an abrasive pad CM47
seal for corrosion, pitting, there is corrosion, remove it in or equivalent, polish to remove
wear, or damage. accordance with the corrective corrosion, pitting, wear, or
action repair limits. If there damage to a maximum depth
is pitting, wear, or damage, of 0.010 inch (0.25 mm). If
measure the depth. The the corrosion, pitting, wear, or
maximum permitted depth of damage is greater than the
pitting, wear or damage is permitted serviceable limits
0.007 inch (0.17 mm). or the corrective action limits,
replace the blade seal.

(2) Measure the O-ring groove The maximum permitted If the O-ring groove width "F"
width "F". width of O-ring groove "F" is greater than the permitted
is 0.175 inch (4.44 mm). serviceable limits, replace the
blade seal.

(3) Measure the O-ring groove The maximum permitted width If the width variation of O-ring
width "F" for uniform width variation of O-ring groove "F" groove "F" is greater than the
variation. is 0.015 inch (0.38 mm). permitted serviceable limits,
replace the blade seal.

(4) Measure the pre-load plate The permitted limits are given If any measurement is not within
seal housing features "A", in the table in Figure 5-15. the permitted serviceable limits,
"B", "C1", "C2", "D", and replace the blade seal.
"E".

CHECK 61-10-91 Page 5-39

Nov/18
PROPELLER MAINTENANCE MANUAL
491

A-2424

A-2424A

A-2424-1
TPI-152-027-1,-2,-3

Balance Weight
Figure 5-16

CHECK 61-10-91 Page 5-40

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

Component Inspection Criteria

Table 5-1
Inspect Serviceable Limits Corrective Action

P. BALANCE WEIGHT
(Item 810)
Refer to Figure 5-16.

(1) Visually examine the The maximum permitted depth Using an abrasive pad CM47
balance weight for pitting, of pitting, wear, or damage is or equivalent, polish to a
wear, or damage. 0.003 inch (0.07 mm). maximum depth of
0.005 inch (0.12 mm). If the
depth of pitting, wear, or damage
is greater than the serviceable
limits or the corrective action
limits, replace the balance
weight.

(2) For an aluminum

(gray color) balance
weight:

(a) Visually examine Corrosion is not permitted. If Remove corrosion using glass
the balance weight there is corrosion, remove it in bead cleaning. Refer to the
for corrosion. accordance with the corrective Cleaning chapter of Hartzell
action repair limits. Standard Practices Manual 202A
(61-01-02).

(b) Visually examine Except for a few scratches and Re-anodize the balance weight
the balance weight corners with anodize coating in accordance with the Chromic
for anodize coverage. missing, complete coverage is Acid Anodizing chapter of
required. Hartzell Standard Practices
Manual 202A (61-01-02).

(3) For a steel (silver color)

weight:

(a) Visually examine Corrosion is not permitted. If Remove corrosion using glass
the balance weight there is corrosion, remove it in bead cleaning. Refer to the
for corrosion. accordance with the corrective Cleaning chapter of Hartzell
action repair limits. Standard Practices Manual 202A
(61-01-02).

(b) Visually examine Except for a few scratches and If the coverage is less than
the balance weight corners with cadmium plating the permitted serviceable limits,
for cadmium plating missing, complete coverage is replate the balance weight in
coverage. required. accordance with the Cadmium
Replating chapter of Hartzell
Standard Practices Manual 202A
(61-01-02).

CHECK 61-10-91 Page 5-41

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

Component Inspection Criteria

Table 5-1
Inspect Serviceable Limits Corrective Action

P. BALANCE WEIGHT, CONTINUED

(Item 810)
Refer to Figure 5-16.

(4) For a brass (gold color) Brass must be bare of any Remove applied coating using
balance weight, visually applied coating. Bare brass glass bead cleaning. Refer to
examine the balance will have a muted yellow color the Cleaning chapter of Hartzell
weight for a bare surface similar to gold. Oxidized or Standard Practices Manual 202A
(does not include oxidized tarnished brass is permitted and (61-01-02).
or tarnished surface). will appear brown to black or
blue-green.

CHECK 61-10-91 Page 5-42

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

REPAIR - CONTENTS
1. General Repair Requirements.................................................................................. 6-3
A. Shot Peening....................................................................................................... 6-3
B. Aluminum and Steel Parts................................................................................... 6-4
2. Blade Repair............................................................................................................. 6-5
3. Hub Repair............................................................................................................... 6-5
4. Spinner Assembly Repair/Modification..................................................................... 6-5
5. Specific Repair Requirements.................................................................................. 6-6
A. Brass Counterweight Slug Mounting Hole Repair............................................... 6-6
B. Repair of the B-1593 Start Lock Housing............................................................ 6-8
6. Pitch Change Block Button Modification................................................................... 6-9

LIST OF FIGURES
Brass Counterweight Slug Mounting Hole Repair................. Figure 6-1........................ 6-5
Repair of the B-1593 Start Lock Housing............................. Figure 6-2........................ 6-7
Pitch Change Block Button Modification............................... Figure 6-3........................ 6-9

REPAIR 61-10-91 Page 6-1

Nov/18
PROPELLER MAINTENANCE MANUAL
491

(This page is intentionally blank.)

REPAIR 61-10-91 Page 6-2

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

WARNING: DO NOT ATTEMPT IN THE FIELD ANY REPAIR, REPLACEMENT,

REPLATING, RE-ANODIZING, OR RE-SHOT PEENING PROCEDURE NOT
SPECIFICALLY AUTHORIZED BY HARTZELL PROPELLER INC.
OR NOT SPECIFICALLY REFERRED TO IN HARTZELL PROPELLER INC.
MANUALS. CONTACT HARTZELL PROPELLER INC. FOR GUIDANCE
ABOUT THE AIRWORTHINESS OF ANY PART WITH UNUSUAL WEAR
OR DAMAGE.

CAUTION: INSTRUCTIONS AND PROCEDURES IN THIS CHAPTER MAY INVOLVE

PROPELLER CRITICAL PARTS. REFER TO THE INTRODUCTION
CHAPTER OF THIS MANUAL FOR INFORMATION ABOUT PROPELLER
CRITICAL PARTS. REFER TO THE ILLUSTRATED PARTS LIST IN THIS
MANUAL FOR IDENTIFICATION OF PROPELLER CRITICAL PARTS.

1. General Repair Requirements

A. Shot Peening

CAUTION: THE PEENING MARKS ON CERTAIN PROPELLER PARTS ARE

NOT TOOL MARKS AND SHOULD NOT BE REMOVED.
(1) Certain surfaces of propeller assembly parts have been shot peened at Hartzell
Propeller Inc. to improve fatigue strength.
(2) Shot peened surfaces may require re-shot peening because of rust, corrosion,
fretting, or nicks. For shot peening procedures, refer to the Shot Peening
chapter of Hartzell Propeller Inc. Standard Practices Manual 202A (61-01-02).

REPAIR 61-10-91 Page 6-3

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

WARNING: FAILURE TO CORRECTLY SHOT PEEN APPLICABLE

PROPELLER PARTS MAY CREATE AN UNSAFE CONDITION
THAT MAY RESULT IN DEATH, SERIOUS BODILY INJURY,
AND/OR SUBSTANTIAL PROPERTY DAMAGE. A QUALITY
SHOT PEENING PROCESS IS CRITICAL FOR FLIGHT
SAFETY. SHOT PEENING OF PROPELLER PARTS
REQUIRES SPECIAL TECHNIQUES, TRAINING, MATERIALS,
AND EQUIPMENT.
(a) Hartzell Propeller Inc. has a certification procedure for shot peening
and highly recommends that only repair stations that are certified by
Hartzell Propeller Inc. perform shot peening on Hartzell Propeller Inc.
parts. For the requirements for certification, refer to the Approved
Facilities chapter of Hartzell Propeller Inc. Standard Practices
Manual 202A (61-01-02).
1 A list of the repair stations that are certified by Hartzell Propeller Inc.
to perform shot peening and the expiration dates of the sample
approvals may be found by:
a Referring to Sample Program Approvals on the Hartzell
Propeller Inc. website at www.hartzellprop.com
b Contacting Hartzell Propeller Inc. Product Support by telephone
at (937) 778-4379, or at (800) 942-7767 toll free from the
United States and Canada.
c E-mail request to techsupport@hartzellprop.com.
B. Aluminum and Steel Parts
(1) Eliminate all evidence of scratches, nicks, burrs, and other minor damage
using a fine emery cloth or abrasive pad CM47.
(a) Make sure to blend the polished area with the surrounding area.
(b) Use extreme care to completely remove the damage while removing as
little material as possible.
(2) Make sure that the part is still within tolerance after any type of repair. Refer to
the Check chapter and the Fits and Clearances chapter of this manual.

REPAIR 61-10-91 Page 6-4

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

2. Blade Repair
A. For composite blade repair, replacement, and modification instructions, refer to
Hartzell Propeller Inc. Composite Propeller Blade Maintenance Manual 135F
(61-13-35).

3. Hub Repair
A. For requirements and procedures for repairing aluminum hubs, refer to the
Aluminum Hub Overhaul chapter of Hartzell Propeller Inc. Standard Practices
Manual 202A (61-01-02).

4. Spinner Assembly Repair/Modification

NOTE: Specific Hartzell Propeller Inc. manuals and service documents are available
on the Hartzell Propeller Inc. website at www.hartzellprop.com. Refer to the
Required Publications section in the Introduction chapter of this manual for
the identification of these publications.
A. For requirements and procedures for repairing or modifying spinner assemblies, refer
to Hartzell Propeller Inc. Metal Spinner Assembly Maintenance Manual 127 (61-16-27)
or Hartzell Propeller Inc. Composite Spinner Maintenance Manual 148 (61-16-48).

Repair diameter
0.750 ± 0.010 inch
(19.05 ± 0.25 mm)

Corner Radius
Through Hole
TPI-TI-113001

Brass Counterweight Slug Mounting Hole Repair

Figure 6-1

REPAIR 61-10-91 Page 6-5

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

5. Specific Repair Requirements

A. Brass Counterweight Slug Mounting Hole Repair

CAUTION: INSTRUCTIONS AND PROCEDURES IN THIS SECTION

MAY INVOLVE PROPELLER CRITICAL PARTS. REFER TO
THE INTRODUCTION CHAPTER OF THIS MANUAL FOR
INFORMATION ABOUT PROPELLER CRITICAL PARTS. REFER
TO THE ILLUSTRATED PARTS LIST IN THIS MANUAL FOR
IDENTIFICATION OF PROPELLER CRITICAL PARTS.
(1) General
(a) This procedure provides the instructions to remove wear around the
counterweight slug mounting through hole.
(2) Procedure
(a) Use a locally procured end mill cutter that is 0.750 ± 0.010 inch
(19.05 ± 0.25 mm) outside diameter.
1 The corner radius blending between the outside diameter and the
cutting end must be 0.005 to 0.033 inch (0.13 to 0.83 mm).
(b) Put the brass weight slug in the end mill.

CAUTION: MAKE SURE THAT THE BRASS WEIGHT SLUG IS HELD

TIGHTLY IN PLACE WITH THE THROUGH HOLE CENTERED
UNDER THE END MILL CUTTER.
(c) Center the through hole that will be repaired under the end mill cutter and
make sure that the brass weight slug is held tightly in place.

CAUTION: DO NOT SPOTFACE DEEPER THAN THE MAXIMUM

PERMITTED DEPTH.
(d) Spotface the brass weight slug to remove wear damage.
1 The maximum permitted depth of repair is 0.020 inch (0.50 mm).
2 Spotface to a greater depth is not permitted.
3 If the repair is greater than the maximum permitted depth of repair,
replace the brass weight slug.
(e) Remove all burrs.
(f) Break any sharp corners.
(g) Visually examine the repair to make sure that the repair is centered on the
through hole.
(h) Cadmium plate of any bare brass surface is required. Refer to the Check
chapter of this manual.

REPAIR 61-10-91 Page 6-6

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

45 ± 0.5
degrees
1.19 ± 0.03 inch
(30.2 ± 0.7 mm)

Air/Gas Passage Hole ID

0.1495 +0.008/-0.002 inch
(3.797 +0.20/-0.05 mm)

TPI-TI-00168

Repair of the B-1593 Start Lock Housing

Figure 6-2

REPAIR 61-10-91 Page 6-7

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

B. Repair of the B-1593 Start Lock Housing

(1) General
(a) This repair procedure provides the instructions for adding an air/gas
passage hole to the B-1593 start lock housing.
(2) Procedure
(a) Drill a hole in the B-1593 start lock housing in accordance with the
dimensions specified in Figure 6-2.
(b) The surface finish of the newly drilled hole must not exceed 89RA.
(c) Apply a layer of chemical conversion coating to the ID of the newly drilled
hole in accordance with Chromic Acid and Anodizing chapter of Hartzell
Propeller Inc. Standard Practices Manual 202A (61-01-02).

REPAIR 61-10-91 Page 6-8

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

6. Pitch Change Block Button Modification

A. Purpose
(1) To improve the response rate of the propeller when going from low pitch to
high pitch, modify the pitch change block buttons (330) in accordance with the
procedure below.

B. Procedure
(1) Using an abrasive pad CM47, sandpaper, or equivalent, polish the top surface
of the pitch change block button (330) to reduce the height "A" of the button.
Refer to Figure 6-1.
(a) The minimum permitted height "A" of the pitch change block button (310)
is 0.090 inch (2.29 mm).

Pitch Change Block Button (330)

(top)

Height "A"
Minimum Height:
0.090 inch (2.29 mm)

TPI-MB-0275

Pitch Change Block Button Modification

Figure 6-1

REPAIR 61-10-91 Page 6-9

Nov/18
PROPELLER MAINTENANCE MANUAL
491

(This page is intentionally blank.)

REPAIR 61-10-91 Page 6-10

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

ASSEMBLY - CONTENTS
1. General..................................................................................................................... 7-5
2. Assembly of 3C2-FP( )( ) Propeller Models.............................................................. 7-7
A. Hub Assembly Procedures................................................................................. 7-9
B. Blade Assembly Procedures............................................................................ 7-11
C. Blade Installation.............................................................................................. 7-16
D. Cylinder-side Hub Half Installation................................................................... 7-21
E. Pitch Change Unit Assembly and Blade Tolerance Checks............................. 7-22
F. Cylinder Spring Assembly Installation.............................................................. 7-27
G. Piston and Cylinder Installation ....................................................................... 7-36
H. Setting the Blade Angles.................................................................................. 7-39
I. Charging the Propeller with Air........................................................................ 7-44
3. Leak Check............................................................................................................. 7-45
A. Lubrication Fitting/Lubrication Hole Plug Installation....................................... 7-45
B. Leak Check Procedure.................................................................................... 7-45
4. Counterweight Installation...................................................................................... 7-46
5. Propeller Lubrication............................................................................................... 7-46
6. Static Balance......................................................................................................... 7-46
7. Labels..................................................................................................................... 7-46
8. Propeller Disassembled for Shipping..................................................................... 7-47
A. General............................................................................................................ 7-47
B. Preparing the Propeller for Shipping................................................................ 7-47
9. Reassembly of a Propeller Disassembled for Shipping.......................................... 7-48
A. Unpacking the Propeller and Blades................................................................ 7-48
B. Preparing Propeller for Reassembly................................................................ 7-49
C. Propeller Reassembly...................................................................................... 7-49

ASSEMBLY 61-10-91 Page 7-1

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

LIST OF FIGURES
Hub Assembly................................................................................... Figure 7-1................7-8
Blade Assembly................................................................................. Figure 7-2..............7-10
Blade Seal and Blade Shim Installation............................................ Figure 7-3..............7-12
Bearing Ball Installation..................................................................... Figure 7-4..............7-13
Bearing Race Installation.................................................................. Figure 7-5..............7-14
Installing a Blade in the Hub Socket.................................................. Figure 7-6..............7-15
Fork Installation................................................................................. Figure 7-7..............7-17
Cylinder-side Hub Half Installation.................................................... Figure 7-8..............7-18
Sealing the Hub Halves..................................................................... Figure 7-9..............7-20
Torquing the Pitch Change Rod........................................................ Figure 7-10............7-22
Using a Spacer/Stop to Check Blade Angles.................................... Figure 7-11.............7-23
Checking Blade Angles..................................................................... Figure 7-12............7-24
Using the Assembling Tool TE9......................................................... Figure 7-13............7-26
Start Lock Housing Installation.......................................................... Figure 7-14............7-27
Cylinder on the Assembling Tool TE9................................................ Figure 7-15............7-28
Installing the Assembly Guides TE319.............................................. Figure 7-16............7-28
Extension Spring Installation............................................................. Figure 7-17............7-29
Flyweight Plate Installation................................................................ Figure 7-18............7-30
Flyweight Installation......................................................................... Figure 7-19............7-30
Using the Drilled Washer TE288....................................................... Figure 7-20............7-31
Compressing the Extension Spring................................................... Figure 7-21............7-32
Installing the Cylinder Cap TE380..................................................... Figure 7-22............7-33
Installing the Flyweight Screws ........................................................ Figure 7-23............7-34
Sealing the Cylinder.......................................................................... Figure 7-24............7-36
Cylinder Installation........................................................................... Figure 7-25............7-37
Parts for Adjusting the Pitch Angle.................................................... Figure 7-26............7-38
Checking the Feather Angle.............................................................. Figure 7-27............7-39
Air Pressure Check Warning Tag...................................................... Figure 7-28............7-44
Hub Leak Check................................................................................ Figure 7-29............7-45

ASSEMBLY 61-10-91 Page 7-2

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

LIST OF TABLES
Blade Shim Thickness....................................................................... Table 7-1................7-12

ASSEMBLY 61-10-91 Page 7-3

Nov/18
PROPELLER MAINTENANCE MANUAL
491

(This page is intentionally blank.)

ASSEMBLY 61-10-91 Page 7-4

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

1. General
CAUTION 1: INSTRUCTIONS AND PROCEDURES IN THIS CHAPTER MAY
INVOLVE PROPELLER CRITICAL PARTS. REFER TO THE
INTRODUCTION CHAPTER OF THIS MANUAL FOR INFORMATION
ABOUT PROPELLER CRITICAL PARTS. REFER TO THE
ILLUSTRATED PARTS LIST IN THIS MANUAL FOR IDENTIFICATION
OF PROPELLER CRITICAL PARTS.
CAUTION 2: THE USE OF BLADE PADDLES TO MOVE THE BLADES CAN
RESULT IN OVERLOAD AND DAMAGE OF BLADE PITCH CHANGE
KNOBS. THIS DAMAGE IS NOT REPAIRABLE AND CAN RESULT
IN SEPARATION BETWEEN THE BLADE AND THE PITCH CHANGE
KNOB, CAUSING LOSS OF PITCH CONTROL DURING FLIGHT.

NOTE: Specific Hartzell Propeller Inc. manuals and service documents are available
on the Hartzell Propeller Inc. website at www.hartzellprop.com. Refer to the
Required Publications section in the Introduction chapter of this manual for
the identification of these publications.
A. Read all assembly instructions before beginning the assembly procedures.
B. For blade bore bearing and hub-side split bearing race installation procedures
for a composite blade, refer to Hartzell Propeller Inc. Composite Propeller Blade
Maintenance Manual 135F (61-13-35).
C. For specific blade angle information, refer to the Hartzell Propeller Inc. Application
Guide Manual 159 (61-02-59).
D. For information about additional weight slugs that may be required to be
attached to the counterweight, refer to the Hartzell Propeller Inc. Application Guide
Manual 159 (61-02-59).
E. For information about installation of a spinner assembly, refer to the applicable
aircraft type certificate data sheet, Hartzell Propeller Inc. Application Guide
Manual 159 (61-02-59), or the propeller owner's manual.
F. Protect all unassembled components from damage.
G. Unless specified differently, safety wire in accordance with NASM33540 using
0.032 inch (0.81 mm) safety wire.
H. Use applicable torque values. Refer to Table 8-1, Torque Values, in the Fits and
Clearances chapter of this manual.
I. Unless specified differently, lubricate all O-rings with lubricant CM12 before installing
them in the propeller assembly.
J. Hartzell Propeller Inc. recommends that the lot number and cure date for each
O-ring be recorded with all work orders when an O-ring is installed in any propeller
assembly.

ASSEMBLY 61-10-91 Page 7-5

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

K. Before beginning the assembly of the propeller, determine if an ice protection system
is required.
(1) If the propeller is equipped with an ice protection system that uses components
supplied by Hartzell Propeller Inc., applicable instructions and technical
information can be found in Hartzell Propeller Inc. Ice Protection System
Manual 180 (30-61-80) available on the Hartzell Propeller Inc. website at
www.hartzellprop.com.
(2) Propeller ice protection system components not supplied by Hartzell
Propeller Inc. are controlled by the applicable TC or STC holder’s Instructions
for Continued Airworthiness (ICA).

ASSEMBLY 61-10-91 Page 7-6

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

2. Assembly of 3C2-( )( )( ) Propeller Models

CAUTION 1: INSTRUCTIONS AND PROCEDURES IN THIS CHAPTER MAY

INVOLVE PROPELLER CRITICAL PARTS. REFER TO THE
INTRODUCTION CHAPTER OF THIS MANUAL FOR INFORMATION
ABOUT PROPELLER CRITICAL PARTS. REFER TO THE
ILLUSTRATED PARTS LIST IN THIS MANUAL FOR IDENTIFICATION
OF PROPELLER CRITICAL PARTS.

CAUTION 2: ACTUATION OF PROPELLERS MUST BE ACCOMPLISHED USING

EITHER COMPRESSED AIR THAT HAS BEEN FILTERED FOR
MOISTURE, OR NITROGEN.

CAUTION 3: DO NOT USE A PRESSURE THAT IS GREATER THAN

175 PSI (12.06 BARS) WHEN ACTUATING PROPELLERS THAT
ARE INCLUDED IN THIS MANUAL.

CAUTION 4: USE ENOUGH PRESSURE TO MAKE SURE THAT THE PROPELLER

ACTUATES AGAINST EACH POSITIVE STOP.

ASSEMBLY 61-10-91 Page 7-7

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

540
390
370
360

240
380

240

220
TPI-MB-0257

Hub Assembly
Figure 7-1

ASSEMBLY 61-10-91 Page 7-8

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

A. Hub Assembly Procedures

(1) Hub Assembly - Refer to Figure 7-1

WARNING: ADHESIVES AND SOLVENTS ARE FLAMMABLE AND TOXIC

TO THE SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND
EYE PROTECTION ARE REQUIRED. AVOID PROLONGED
CONTACT AND BREATHING OF VAPORS. USE SOLVENT
RESISTANT GLOVES TO MINIMIZE SKIN CONTACT AND
WEAR SAFETY GLASSES FOR EYE PROTECTION. USE
IN A WELL VENTILATED AREA AWAY FROM SPARKS AND
FLAME. READ AND OBSERVE ALL WARNING LABELS.
(a) Refer to the Aluminum Hub Overhaul chapter of Hartzell Propeller Inc.
Standard Practices Manual 202A (61-01-02) for assembly procedures
of the hub unit before following the propeller assembly procedures in
this manual.
(b) Apply a light layer of lubricant CM12 to the pitch change rod O-ring (220).
(c) Install the pitch change rod O-ring (220) in the cylinder-side of the
hub (240).
(d) Install the hub plug (370). Refer to Figure 7-1.
1 Install the internal spiral retaining ring (360) in the groove provided
for it in the bore of the engine-side of the hub (240).
2 Apply a light layer of lubricant CM12 to the hub plug OD O-ring (390).
3 Install the O-ring (390) in the groove on the OD of the hub plug (370).
4 Apply a light layer of lubricant CM12 to the O-ring (380).
5 Install the O-ring (380) in the groove on the ID of the hub plug (370).
(e) Apply a layer of lubricant CM12 to the flange mounting O-ring (540).
(f) Install the flange mounting O-ring (540) on the engine-side half of the
hub (240).
(g) Install the engine-side half of the hub (240) on the propeller assembly
table TE129.
(h) Apply a layer of lubricant CM12 to the bearing seats of the blade retention
sockets and the blade O-ring grooves.

ASSEMBLY 61-10-91 Page 7-9

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

Blade

720
730
600
610
670
620
680
660
690
640
700
650
710
630
TPI-MB-0218

Blade Assembly
Figure 7-2

ASSEMBLY 61-10-91 Page 7-10

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

B. Blade Assembly Procedures

(1) General
(a) The following procedure assumes that the blade has been inspected
and repaired and that the blade wear strip, blade side bearing race,
and bearing retaining ring are installed on each blade in accordance
with Hartzell Propeller Inc. Composite Propeller Blade Maintenance
Manual 135F (61-13-35).
(2) Pitch Change Knob Bushing (730) Installation
(a) For installation of the pitch change knob bushing (730), refer to the Special
Adhesive and Bonding Procedures chapter of Hartzell Propeller Inc.
Standard Practices Manual 202A (61-01-02).
(3) Install the blade plug (610) in the bore of each blade in accordance with
Figure 7-2 and the following steps:
(a) Apply a light layer of lubricant CM12 to the blade plug O-ring (600).
(b) Install the blade plug O-ring (600) on the OD of the blade plug (610).
(c) Install the blade plug (610) in the bore of the blade.
(d) Install the internal spiral retaining ring (620) in the groove provided for it
in the bore of the blade.
(4) Installation of the blade seal (700), O-rings (690, 710), and the blade
O-ring (720).
(a) Using lubricant CM12, lubricate the blade O-ring (720).
(b) Install the blade O-ring (720) on the outboard blade wear strip on
the blade. Refer to Figure 7-2.
(c) Using lubricant CM12, lightly lubricate O-rings (690 and 710).

ASSEMBLY 61-10-91 Page 7-11

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

Thickness Thickness
Part Number
(inch) (mm)
105758-050 0.050 1.27
105758-055 0.055 1.39
105758-060 0.060 1.52
105758-063 0.063 1.60
105758-065 0.065 1.65
105758-067 0.067 1.70
105758-070 0.070 1.78
105758-073 0.073 1.85
105758-075 0.075 1.90
105758-077 0.077 1.95
Blade Shim Thickness
Table 7-1

Bearing Retaining
Ring (670)
Blade Shim (680)

Blade Seal (700) Blade Butt

O-Ring (690)

O-Ring (710) Blade Shank

Wear Strip
TPI-496-17

Blade Seal and Blade Shim Installation

Figure 7-3

ASSEMBLY 61-10-91 Page 7-12

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

(d) Install the O-ring (690) in the groove provided for it on the ID of the
blade seal (700). Refer to Figure 7-3.
(e) Install the O-ring (710) in the groove provided for it on the OD of the
blade seal (700). Refer to Figure 7-3.
1 Make sure that the O-rings (690, 710) are seated in the grooves of
the blade seal (700) as shown in Figure 7-3.
(f) Install the blade seal (700) with the blade shim (680) and the
O-rings (690, 710) on the blade.
1 The measurement of the thickness of the blade shim (680) that was
noted at disassembly will help determine the thickness of the blade
shim (680) that should be used. Refer to Table 7-1.
2 Using lubricant CM12, lightly lubricate the O-rings (690, 710)
before installing the blade seal (700) with the blade shim (680)
and the O-rings (690, 710) on the blade.
3 Using lubricant CM12, lubricate the inboard blade shank wear strip.
4 With the blade shim (680) pointing toward the bearing retaining
ring (670), install the blade seal (700) with the blade shim (680)
and the O-rings (690, 710) on the blade. Refer to Figure 7-3.

Blade O-Ring (720)

Ball Spacer (650)

Blade-side Bearing Race (630)

Bearing Retaining Ring (670)

APS2002

Bearing Balls (640)

Bearing Ball Installation

Figure 7-4

ASSEMBLY 61-10-91 Page 7-13

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

5 Firmly seat the blade seal (700) with the blade shim (680) and the
O-rings (690, 710) against the bearing retaining ring (670).

CAUTION: MAKE SURE THAT THE O-RINGS (690, 710)

ARE SEATED IN THE GROOVES OF THE BLADE
SEAL (700) WHEN THE BLADE SEAL (700) IS
INSTALLED ON THE BLADE.
6 Make sure that the O-rings (690, 710) are seated in the grooves of
the blade seal (700).
(5) Installation of the Bearing Balls and Hub-side Bearing Race - Refer to Figure 7-4
(a) Using lubricant CM12, lubricate the blade-side bearing race (630).
(b) Put the ball spacer (650) on the blade-side bearing race (630).

CAUTION: ALL THE BEARING BALLS IN A SINGLE BEARING MUST BE

OF THE SAME SIZE AND GAUGE. BEARING BALLS SUPPLIED
BY HARTZELL PROPELLER INC. ARE THE SAME GAUGE.
(c) Put the bearing balls (640) in the openings of the ball spacer (650) on the
blade-side bearing race (630).

O-ring (720)

Hub-side Bearing Race (660)

Bearing Balls (640)

TPI-490-027

Bearing Race Installation

Figure 7-5

ASSEMBLY 61-10-91 Page 7-14

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

CAUTION: THE BEARING RACE HALVES MUST HAVE MATCHING

SERIAL NUMBERS.
(d) Put the hub side bearing race (660) on the bearing balls (640).
Refer to Figure 7-5.
1 Install the hub-side bearing race with the parting line perpendicular
to the hub parting line when installed in the hub (240). Refer to
Figure 7-6.
(e) Repeat steps 3.B.(4) through 3.B.(5)(d)1 for the remaining blades.

90 degrees Hub parting line

Split in outer races of the

blade retention bearing

Trailing edge of the blade

APS0820

Installing a Blade in the Hub Socket

Figure 7-6

ASSEMBLY 61-10-91 Page 7-15

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

C. Blade Installation

CAUTION: TO AVOID BLADE OR HUB DAMAGE, DO NOT USE FORCE TO

INSTALL THE BLADE INTO THE SOCKET.
(1) Apply a thin film of lubricant CM12 to the blade retention radii and the O-ring
grooves of the hub (220).

CAUTION: EACH BLADE MUST BE SHIMMED IN THE HUB SOCKET THAT

IT WILL OCCUPY WHEN ASSEMBLED. DO NOT SHIM ALL THE
BLADES IN THE SAME SOCKET.
(2) Install each previously constructed blade assembly using the following steps:
(a) Install a blade assembly into the socket of the engine-side half of the
hub (240).
(b) Using a feeler gage, measure the gap between the hub and the hub-side
bearing race while pushing the blade bearing down into the hub socket.
A gap of 0.002-0.004 inch (0.05-0.10 mm) is recommended.
1 If the gap is less than 0.002-0.004 inch (0.05-0.10 mm), remove
the blade and replace the blade shim (680) with a thinner blade
shim. Refer to Table 7-1.
2 If the gap is greater than 0.002-0.004 inch (0.05-0.10 mm), remove
the blade and replace the blade shim (680) with a thicker blade shim.
Refer to Table 7-1.
(3) Make sure that the parting line of the hub-side bearing race (660) is
perpendicular to the hub parting line when the blade is installed in the
hub (240). Refer to Figure 7-6.
(4) When all the blades have been successfully installed in the sockets of the
hub (240), temporarily install the cylinder-side half of the hub (240).
(a) Install the three hub clamping bolts (230) in the hub clamping bolt holes
that are next to the leading edge of each blade.
(b) Install a washer (340) and a nut (350) on each hub clamping bolt (230).
(c) Tighten the nuts (350) until snug. Do not torque the nuts (350) at this time.
(5) Examine each blade for free rotation.
(a) If the blade does not rotate freely in the hub socket, make sure that the
blade O-ring (720) is seated correctly in the hub socket.
(6) Examine the blade play of each blade.
(a) If any blade is loose in the hub socket, remove the blade and replace the
blade shim (680) with a thicker blade shim (680). Refer to Table 7-1.
(7) When the blade play and rotation are satisfactory, remove the nuts (350), the
washers (340), and the hub clamping bolts (230) from the hub (240).
(8) Remove the cylinder-side half of the hub (240).

ASSEMBLY 61-10-91 Page 7-16

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

(9) Remove blade number one.

(10) Install the pitch change fork bumpers (310) on the pitch change fork (300).
(11) Install the pitch change block buttons (330) into the pitch change block (320).
(12) Apply anti-seize compound CM118 to the outside of each pitch change knob
bushing (730).
(13) Apply anti-seize compound CM118 to the threads of the fork (300) and to each
pitch change block groove of the pitch change fork (300).
(14) With the round extension of the pitch change block (320) pointing away from the
blade, install a pitch change block (320) on each pitch change knob.
(a) When installing a new pitch change block (320), make sure that the
pitch change block (320) is installed with the thin wall pointing in the
correct direction.
1 At initial assembly, install the pitch change blocks (320) in the
fork (300) with the thin wall pointing toward the engine-side half
of the hub (240).
2 For a pitch change block (320) that has been marked during
disassembly to indicate the direction that the thin wall is pointing,
install the pitch change block (320) in accordance with the marking.

Fork (290)

Pitch Change
Block (320)
TPI-490-014

Fork Installation
Figure 7-7

ASSEMBLY 61-10-91 Page 7-17

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

CAUTION: MAKE SURE THAT THE TAPER IN THE FORK (300) MATCHES
THE TAPER IN THE PITCH CHANGE ROD (200). IF THE PITCH
CHANGE ROD IS INCORRECTLY ATTACHED TO THE
FORK, THE SEATING AREA OF THE PITCH CHANGE
ROD WILL BE DAMAGED.
(15) Install the fork (300) on the pitch change blocks (320) of blades number two
and three. Refer to Figure 7-7.
(16) Reinstall blade number one in the engine-side hub half socket.
(a) Put the pitch change block (320) into the fork (300).
(17) Install the cylinder-side half of the hub (240).
(18) Install three bolts (230), three washers (340), and three nuts (350) at the center
of the hub (240). Refer to Figure 7-8.
(a) When the propeller is assembled without the bulkhead, additional washers
may be used to help with clamping the halves of the hub (240) during the
cure of the sealant CM92.
(19) Torque the nuts (350) in accordance with Table 8-1, "Torque Values" in the Fits
and Clearances chapter of this manual.

Bolt (230)

Washer (340)

Nut (350)
TI-490-020

Cylinder-side Hub Half Installation

Figure 7-8

ASSEMBLY 61-10-91 Page 7-18

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

CAUTION: INCORRECT SHIMMING CAN CAUSE THE BLADES TO BE TOO

LOOSE OR TOO TIGHT IN THE HUB.
(20) Examine each blade for free rotation, blade end play, and fore-and-aft movement.
(a) Free rotation
1 If the blade does not rotate freely in the hub socket, make sure that the
blade O-ring (720) is seated correctly in the hub socket.
(b) Blade End play and Fore-and-Aft Movement (Refer to Figure 8-2)
1 Using one finger and thumb, apply a light load of approximately 5 lbs.
(0.45 kg) to the blade in the direction of the check being performed.
a Apply the load at the mid-span of the blade approximately
in line with the blade decal.
2 Measure the blade movement at the tip of the blade
a Make sure that the blade end play and fore-and-aft movement
is within the limits specified in Table 8-2, Blade Tolerances, in
the Fits and Clearances chapter of this manual.
(21) If any blade does not rotate freely in the hub socket, or if blade movement
for any blade is greater than the limits specified in Table 8-2 in the Fits and
Clearances chapter of this manual:
(a) Remove the cylinder-side half of the hub (240).
(b) Remove the blade.
(c) Remove the blade seal (700) and O-rings (690, 710).
(d) Remove the blade shim (680).
(e) Replace the blade shim (680) with the next thinner or next thicker blade
shim (680), as necessary. Refer to Table 7-1.
(f) Install the blade shim (680) in the recess of the blade seal (700).
(g) Using lubricant CM12, lightly lubricate O-rings (690, 710) before
installation of the blade shim (680) and blade seal (700) with
O-rings (690, 710) on the blade.
(h) With the blade shim (680) pointing toward the bearing retaining ring (670),
install the blade shim (680) and blade seal (700) with O-rings (690, 710)
on the blade.
(i) Firmly seat the blade seal (700) against the blade shim (680).

ASSEMBLY 61-10-91 Page 7-19

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

CAUTION: MAKE SURE THAT THE O-RINGS (690, 710) ARE SEATED
IN THE GROOVES OF THE BLADE SEAL (700) WHEN THE
BLADE SEAL (700) IS INSTALLED ON THE BLADE.
(j) Make sure that the O-rings (690, 710) are seated in the grooves of the
blade seal (700).
(k) Install the cylinder-side half of the hub (240).
(l) Install the hub clamping bolts (230) in the hub clamping bolt holes that are
next to the leading edge of each blade.
1 Install a washer (340) and a nut (350) on each hub clamping bolt (230).
2 Tighten the nuts (350) until snug. Do not torque the nuts at this time.
(m) Examine each blade for free rotation.
(22) Repeat steps 3.C.(20) through 3.C.(21)(m) until all blades rotate freely in
the hub (240) and the maximum permitted blade end play and fore-and-aft
movement is within the limits specified in the section, "Blade Tolerances" in the
Fits and Clearances chapter of this manual.

Apply Sealant CM92 in accordance

with the dashed line

APS2040A

Sealing the Hub Halves

Figure 7-9

ASSEMBLY 61-10-91 Page 7-20

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

D. Cylinder-side Hub Half Installation

WARNING: ADHESIVES AND SOLVENTS ARE FLAMMABLE AND TOXIC TO

THE SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE
PROTECTION ARE REQUIRED. AVOID PROLONGED CONTACT
AND BREATHING OF VAPORS. USE SOLVENT RESISTANT
GLOVES TO MINIMIZE SKIN CONTACT AND WEAR SAFETY
GLASSES FOR EYE PROTECTION. USE IN A WELL VENTILATED
AREA AWAY FROM SPARKS AND FLAME. READ AND OBSERVE
ALL WARNING LABELS.

CAUTION: HUB MATING SURFACES MUST BE CLEAN AND FREE OF ALL

CONTAMINANTS TO PERMIT SEALING OF THE HUB PARTING
LINE.
(1) Using solvent MEK CM106 or MPK CM219, clean the cylinder-side and engine-
side hub mating surfaces to make sure that all oil, grease, and unwanted
material have been removed.
(2) Permit the solvent MEK CM106 or MPK CM219 to dry.
(3) Install the hub guide bushing (260) in the hole provided for it in the engine-side
half of the hub (240).
(4) Apply a bead of sealant CM92 on the cylinder-side and engine-side hub mating
surfaces in accordance with Figure 7-9.
(a) The quantity of sealant applied to the mating surfaces must be sufficient to
permit a small amount to be squeezed out along the entire parting surface
when the hub bolts are correctly torqued.
(b) Do not permit the sealant CM92 to enter any of the hub clamping
bolt holes.
(c) Do not permit the sealant CM92 to enter the blade O-ring groove.
(5) Install the cylinder-side half of the hub (240).
(6) Install all bolts (230), washers (340), and nuts (350). Refer to Figure 7-8.
(a) When the propeller is assembled without the bulkhead, additional washers
may be used to help with clamping the halves of the hub (240) during the
cure of the sealant CM92.
(7) Torque the nuts (350) in accordance with Table 8-1 "Torque Values", in the Fits
and Clearances chapter of this manual.

ASSEMBLY 61-10-91 Page 7-21

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

E. Pitch Change Unit Assembly and Blade Tolerance Checks

(1) Insert the pitch change rod (200) through the cylinder-side of the hub (240)
and start the pitch change rod in the threads of the fork (200).
(2) Put the modified socket TE385 of the torque wrench adaptor TE6 in place on
the pitch change rod (200) as shown in Figure 7-10.
(3) Insert the anti-rotation pin TE386 of the torque wrench adaptor TE6 into the
hole in the modified socket TE385. Make sure the flat side of the anti-rotation
pin is toward the pitch change rod (200).

NOTE: The anti-rotation pin TE386 keeps the socket from turning on the
pitch change rod.
(4) Torque the pitch change rod (200) in accordance with Table 8-1 "Torque
Values", in the Fits and Clearances chapter of this manual.
(5) Move the blades by hand to make sure the blades have a full range of
movement from low pitch to feather pitch.

Torque Wrench

Modified Socket TE385

Anti-rotation Pin TE386

TPI-APS6276

Torquing the Pitch Change Rod

Figure 7-10

ASSEMBLY 61-10-91 Page 7-22

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

(6) Blade Angle Check

(a) Insert a pin with appropriate diameter into the hole in the pitch change
rod (200) as shown in Figure 7-11.
(b) Place a spacer/stop between the pin and the hub.

NOTE: The spacer/stop should be long enough, approximately

2.25 inches (5.7 cm), to allow measurement of the blade
angles near low pitch.
(c) Rotate the blades by hand until the pin contacts the stop, checking that
the pitch change parts are firmly engaging the pitch change knob of the
blades.

NOTE: Rotate the blades by hand toward high pitch to remove any
slight blade angular looseness.

Pitch Change Rod (200)

Pin
(customer supplied)

Spacer/Stop
(customer supplied)
TPI-APS6277

Using a Spacer/Stop to Check Blade Angles

Figure 7-11

ASSEMBLY 61-10-91 Page 7-23

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

CAUTION 1: DO NOT ETCH, SCRIBE, PUNCH MARK OR SIMILARLY

IDENTIFY PARTS IN ANY MANNER THAT MAY BE HARMFUL
TO THE STRENGTH OR FUNCTION OF THE PROPELLER.

CAUTION 2: GRAPHITE ("LEAD") PENCIL MARKS WILL CAUSE

CORROSION.
(d) Mark a line on each blade at the 30-inch reference blade radius.

NOTE: The line at the 30-inch reference blade radius is for

measurement reference purposes and will also be used when
checking the feather angle of the blade.
(e) Check all the blade angles at the 30-inch reference blade radius for 0.2
degree maximum tolerance between blades. Refer to Figure 7-12.

TPI-APS6274

Checking Blade Angles

Figure 7-12

ASSEMBLY 61-10-91 Page 7-24

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

(f) If the blade angle differs more than 0.2 degree between blades, turn one
or more of the pitch change blocks (320).
1 To turn the blocks, remove the pitch change rod (200), and the
cylinder-side of the hub (240).
2 Make the appropriate adjustments to the pitch change blocks (320).

NOTE: Pitch change blocks (320) should be installed in the

fork (300) with the thin wall toward the engine-side half
of the hub (240) during initial assembly. Rotating the
pitch change block 180 degrees will decrease the pitch of
the corresponding blade approximately 0.3 to 0.4 degree
on a tractor propeller. Rotating the pitch change block
180 degrees will increase the pitch of the corresponding
blade approximately 0.3 to 0.4 degree on a pusher
propeller. It is possible to bring pitch angles differing as
much as 0.5 degree into 0.2 tolerance by rotating the pitch
change blocks.
(g) Reassemble the propeller, then recheck the blade angle tolerance
between blades following steps 3.E.6.(a) through 3.E.6.(f)2.

ASSEMBLY 61-10-91 Page 7-25

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

TE388
TE387

TE288

TE287

Assembling Tool TE9

TE291

TE289
TE290

Assembling Tool TE9

positioned in vise
TPI-APS6181
TPI-BST2853

Using the Assembling Tool TE9

Figure 7-13

ASSEMBLY 61-10-91 Page 7-26

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

F. Cylinder Spring Assembly Installation

CAUTION: ASSEMBLING TOOL TE9 MUST BE USED TO COMPRESS THE

CYLINDER MOUNTED SPRING.
(1) Place the assembling tool TE9 in a vise with the flattened portion of the
threaded rod TE287 between the jaws of the vise as shown in Figure 7-13.

CAUTION: DO NOT ATTEMPT TO INSTALL THE SPRING ASSEMBLY WITH

THE CYLINDER TORQUE WRENCH ADAPTER TE153 ATTACHED
TO THE CYLINDER.
(2) Put the start lock housing (970) in the cylinder (50) and align the holes in the
start lock housing with the holes in the cylinder.
(3) Apply thread locking compound CM21 to the screws (100).
(4) Attach the start lock housing (970) to the cylinder (50) with screws (100).
Refer to Figure 7-14.
(5) Torque the screws (100) in accordance with Table 8-1 "Torque Values", in the
Fits and Clearances chapter of this manual.
(6) Install the cylinder ID O-ring (160) in the groove inside the cylinder (50).

Cylinder (50)

Screws (100)
Start Lock Housing
(970)
TPI-APS6180

Start Lock Housing Installation

Figure 7-14

ASSEMBLY 61-10-91 Page 7-27

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

Assembling Tool TE9

Cylinder (50)

TPI-APS6182
Cylinder on the Assembling Tool TE9
Figure 7-15

Assembly Guides TE319

Assembling Tool
TE9

Cylinder (50)

Start Lock
Housing (970)
TPI-APS6183

Installing the Assembly Guides TE319

Figure 7-16

ASSEMBLY 61-10-91 Page 7-28

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

(7) Put the cylinder (50) on the assembling tool TE9 with the small opening of the
cylinder toward the vise as shown in Figure 7-15.

NOTE: The small diameter shoulder of the guide washer TE291 will fit in the
small opening of the cylinder.
(8) Install the assembly guides TE319 into the screw holes in the start lock
housing (970) as shown in Figure 7-16.

NOTE: Make sure the assembly guides are installed 180 degrees apart.
(9) Put the extension spring (960) and spring guide (950) over the assembly
guides TE319 in the cylinder (50) as shown in Figure 7-17.

Assembly Guides TE319

Spring Guide (950)

Extension Spring (960)

Cylinder (50)
TPI-APS6184

Extension Spring Installation

Figure 7-17

ASSEMBLY 61-10-91 Page 7-29

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

Flyweight Plate (940)

Assembly Guides (raised side facing up)
TE319

Assembling Tool TE9

Cylinder (50)

TPI-APS6185
Flyweight Plate Installation
Figure 7-18

Extension Spring (930)

Assembly Guides
TE319

Threaded Rod TE287

Flyweight (920)
TPI-APS6186

Flyweight Installation
Figure 7-19

ASSEMBLY 61-10-91 Page 7-30

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

(10) With the raised side of the flyweight plate (940) facing up, line up the holes
in the flyweight plate with the assembly guides TE319 as shown in Figure 7-18.
(11) Push the flyweight plate (940) onto the assembly guides TE319 until the
flyweight plate is snug against the bottom of the spring guide (950) as shown
in Figure 7-18.

NOTE: The raised side of the flyweight plate (940) should be visible.
(12) Put the extension spring (930) in the groove around both halves of the
flyweight (920). Refer to Figure 7-19.

NOTE: Position the connection point of the extension spring (930)

90 degrees from the meeting point of the flyweight halves (920).
(13) Line up two of the small holes in the flyweight (920) with the assembly
guides TE319 as shown in Figure 7-19.

CAUTION: THE FLYWEIGHT (920) MUST REST AROUND THE LARGE

DIAMETER OF THE THREADED ROD TE287.
(14) Push the flyweight (920) onto the assembly guides TE319 until the flyweight
rests around the large diameter of the threaded rod TE287 and against the
flyweight plate (940) at the bottom of the spring guide (950) as shown in
Figure 7-19.
(15) Line up the two small holes in the drilled washer TE288 with the assembly
guides TE319 as shown in Figure 7-20.

Nuts TE387

Drilled Washer TE288

Assembly Guides
TE319
TPI-APS6187

Using the Drilled Washer TE288

Figure 7-20

ASSEMBLY 61-10-91 Page 7-31

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

(16) Push the drilled washer TE288 onto the assembly guides TE319 and over the
end of the set screw TE388 in the end of the assembling tool TE9.
(17) Install the two nuts TE387 on the set screw TE388 and tighten.
Refer to Figure 7-20.

WARNING: WHEN COMPRESSED, THE FEATHERING SPRING ASSEMBLY

IS LOADED TO APPROXIMATELY 750 POUNDS (341 KG) FORCE.
ENSURE THE SAFETY OF PERSONNEL IN THE VICINITY
DURING ASSEMBLY PROCEDURES.

CAUTION: DO NOT EXCEED 10 FT-LB (34 N•M) OF TORQUE WHEN

COMPRESSING THE SPRING.
(18) Turn the hex nut TE290 with the appropriate wrench to fully compress the
spring (960). Refer to Figure 7-21.

Spring (960)

Hex Nut TE290

TPI-APS6188

Compressing the Extension Spring

Figure 7-21

ASSEMBLY 61-10-91 Page 7-32

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

CAUTION: DO NOT DAMAGE THE THREADS OF THE CYLINDER (50)

WHEN INSTALLING THE CYLINDER CAP TE380.
(19) Apply lubricant CM12 to the threads of the cylinder cap TE380.
(20) Install the cylinder cap TE380 until snug. Refer to Figure 7-22.

NOTE: The cylinder cap is designed to accommodate two different size

cylinders. Make sure the cylinder cap threads are aligned with the
cylinder threads.

CAUTION: DO NOT APPLY SEALANT TO THE SHOULDER OF SCREW (910).

(21) Apply one drop of sealant CM21 to the threads of two screws (910).

NOTE: Excessive sealant may inhibit movement of the flyweight (920).

Assembly Guides TE319

Cylinder Cap TE380

Cylinder (50)

TPI-APS6196

Installing the Cylinder Cap TE380

Figure 7-22

ASSEMBLY 61-10-91 Page 7-33

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

NOTE: For clarity, the cylinder cap has been removed.

Assembly Guides TE319

Screws (910)
(first two screws)

Hex Nut TE290

Drilled Washer TE288

TPI-APS6189
Drilled Washer TE288
Screws (910)
(last two screws)

TPI-APS6191

Installing the Flyweight Screws

Figure 7-23

ASSEMBLY 61-10-91 Page 7-34

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

(22) Install a screw (910) in each of the threaded holes that can be seen through the
large holes in the drilled washer TE288. Refer to Figure 7-23.
(23) Torque the screws (910) in accordance with Table 8-1 "Torque Values", in the
Fits and Clearances chapter of this manual.
(24) Remove the assembly guides TE319.
(25) Loosen the hex nut TE290 until the drilled washer TE288 can be rotated past
the heads of the installed screws (910).
(26) Turn the drilled washer TE288 until the threaded holes for the remaining two
screws (910) can be seen through the large holes in the drilled washer TE288.
Refer to Figure 7-23.
(27) Tighten the hex nut TE290 to draw the drilled washer TE288 tight against the
heads of the two screws (910) already installed.

CAUTION: DO NOT APPLY SEALANT TO THE SHOULDER OF SCREW (910).

(28) Apply one drop of sealant CM21 to the threads of the other two screws (910).

NOTE: Excessive sealant may inhibit weight movement.

(29) Install a screw (910) in each of the threaded holes that can be seen through the
large holes in the drilled washer TE288. Refer to Figure 7-23.
(30) Torque the screws (910) in accordance with Table 8-1 "Torque Values", in the
Fits and Clearances chapter of this manual.
(31) Loosen the hex nut TE290 until the drilled washer is clear of the cylinder (50)
and the cylinder cap TE380.
(32) Remove the two nuts TE387 and the drilled washer TE288.

WARNING: USE CARE WHEN HANDLING THE CYLINDERS (50) WITH THE
SPRING ASSEMBLY (110) INSTALLED.
(33) Remove the cylinder (50) from the assembly tool TE9.
(34) Operate the flyweight (920) with a screwdriver to check for proper operation.

CAUTION: DO NOT DAMAGE THE THREADS OF THE CYLINDER (50)

WHEN REMOVING THE CYLINDER CAP TE380.
(35) Remove the cylinder cap TE380.

NOTE: If possible, leave the cylinder cap in place on the cylinder (50) until
just before installation as an additional safety precaution.

ASSEMBLY 61-10-91 Page 7-35

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

G. Piston and Cylinder Installation

(1) Install a new cylinder O-ring (210) at the base of the cylinder attachment
threads on the cylinder-side of the hub (240).
(2) Install a new O-ring (190) in the groove in the small opening of the piston (180).
(3) Install the piston (180) on the pitch change rod (200) with the small opening
toward the hub (240).
(4) Install the piston nut (170) on the pitch change rod (200).
(5) Torque the piston nut (170) in accordance with Table 8-1 "Torque Values", in the
Fits and Clearances chapter of this manual.
(6) Stack washers (145) (same number as were removed during disassembly) on
top of the pitch change rod (200).

NOTE: The number of washers (145) determines the high pitch (start lock)
blade angle.
(7) Install the high pitch stop sleeve (150) over the pitch change rod (200) and
washers (145).
(8) Lubricate the outside of the piston (180) using lubricant CM12.
(9) Pour 2.25 fluid ounces (63.93 ml) of hydraulic oil CM157 into the piston (180).

NOTE: When assembling a propeller that will be disassembled for shipping, it is

not necessary to apply sealant CM92 around the shoulder of the cylinder
half of the hub (240) next to the O-ring (210).

O-ring (210)

Sealant CM92

Hub (240)
TPI-APS6198

Sealing the Cylinder

Figure 7-24

ASSEMBLY 61-10-91 Page 7-36

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

(10) Apply a bead of sealant CM92 on the cylinder O-ring (210) where the
cylinder (50) and the hub (240) will meet at installation. Refer to Figure 7-24.
(12) Apply lubricant CM12 to the threads of the cylinder (50).
(13) Attach the cylinder torque wrench adapter TE153 to the cylinder (50).
Refer to Figure 7-25.
(14) Put the spring guide (900) in the piston (50) with the raised portion of the
spring guide away from the hub (240).
(14) Put the cylinder (50) over the piston (180).
(15) Insert the cylinder installation rod TE384 into the cylinder (50) and press down
to push the high pitch stops apart, allowing the cylinder to drop into the position
to be started on the threads of the hub (240).

CAUTION: DO NOT DAMAGE THE THREADS WHEN INSTALLING THE

CYLINDER (50).
(16) By hand, start the cylinder (50) onto the threads of the hub (240).

NOTE: Make sure the cylinder threads are aligned with the hub threads.
(17) Torque the cylinder (50) in accordance with Table 8-1, "Torque Values".
(18) Remove the cylinder installation rod TE384, as applicable.
(19) Remove the cylinder torque wrench adapter TE153 from the cylinder (50).

Cylinder Torque Wrench

Adapter TE153

Cylinder (50) TPI-APS2023A

Cylinder Installation
Figure 7-25

ASSEMBLY 61-10-91 Page 7-37

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

Pitch Change Rod (200)

High Pitch Stop

Washers (145)

High Pitch Stop

Sleeve (150)

Feather Adjust
Washers (140)

The total number of washers, both

inside and outside of the high pitch
stop sleeve (150), sets the feather angle.

Feather Stop Washer (130)

Washer (135)*

Stop Screw (120)

*NOTE: In some propellers, the proper low pitch blade angle cannot be set
even though the high pitch stop sleeve and low pitch stop are correctly
positioned. This is due to the threaded low pitch stop bottoming in the
cylinder. In this situation, add washer(s) (135) as required to reposition
the low pitch stop between bottoming in the cylinder and a thread
minimum engagement when correct low pitch blade angle is obtained.
TPI-APS6237

Parts for Adjusting the Pitch Angle

Figure 7-26

ASSEMBLY 61-10-91 Page 7-38

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

H. Setting the Blade Angles - Refer to Figure 7-26

NOTE 1: Grease may be used between the washers (140) and the feathering
stop washer (130) for ease of removal if blade angle adjustment is
required. Washers that fall into the propeller may be retrieved with a
magnet.

NOTE 2: When setting feather or high pitch angles, the approximate degree of
movement achieved per washer is:
B-3851-0532 or A-2435-1 washer equals 1.5 degree
B-3851-0563 or A-2435 washer equals 3 degrees
(1) Install washers (140) and the feathering stop washer (130) on top of the high
pitch stop sleeve (150) using feathering tool TE383.

NOTE: The total number of washers, both inside and outside the sleeve, sets
the feather angle.
(2) Tighten the feathering tool TE383 into the pitch change rod (200) until snug.
(3) Check the feather blade angle at the reference blade radius previously marked.
Refer to Figure 7-27.
(a) If feather angle adjustment is required, loosen the feathering tool TE383
and remove the feather stop washer (130) and washer(s) (140) by
skewing the tool sideways.
(b) Remove or add washer(s) (140) as needed.

NOTE: Add washers under the feather stop washer (130) to increase
the feather angle. Remove washers (130) from under the
feather stop washer (130) to decrease the feather angle.

TPI-APS0336

Checking the Feather Angle

Figure 7-27

ASSEMBLY 61-10-91 Page 7-39

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

(c) Install the washer(s) (140) and feather stop washer (130) with the
feathering tool TE383.
(d) Check the feather blade angle at the reference blade radius previously
marked.
(e) Repeat steps 2.H.(3) through 2.H.(4)(d) until feather angle is correct.
(4) When the feather angle is correct, apply air pressure to move the propeller into
high pitch position, with the feathering tool TE 383 still installed.

NOTE: The flyweight (920) will click into place when the propeller is moved
to high pitch.
(5) Release the air pressure to allow the flyweight (920) to hold the propeller at
high pitch.
(6) Check the high pitch blade angles.

NOTE: Refer to the Type Certificate Data Sheet or the Hartzell Propeller Inc.
Application Guide Manual 159 (61-02-59) for the propeller high
pitch angle.

CAUTION: IF HIGH PITCH REQUIRES ADJUSTMENT, CONTROL

THE BLADE ANGLE BY ADDING AIR PRESSURE TO THE
PROPELLER TO MOVE AND HOLD THE PROPELLER OFF
THE HIGH PITCH STOP LATCHES.
(a) If high pitch angle adjustment is required, loosen the feathering tool TE383
and remove the feather stop washer (130), washer(s) (140), high pitch
stop sleeve (150), and washers (145) from the pitch change rod (200) by
skewing the tool sideways.

CAUTION: AFTER THE FEATHER ANGLE HAS BEEN SET, THE TOTAL
NUMBER OF WASHERS (140, 145) MUST BE MAINTAINED.
CHANGING THE POSITIONS OF THE WASHERS TO
ACHIEVE HIGH PITCH WILL NOT EFFECT THE FEATHER
ANGLE. ADDING OR REMOVING ANY WASHERS (140, 145)
THAT HAVE ALREADY BEEN INSTALLED WILL CHANGE THE
FEATHER AND HIGH PITCH ANGLES.
(b) To decrease high pitch angle, move high pitch adjust washer(s) (145)
from between the high pitch stop sleeve (150) and the pitch change
rod (200) to between the high pitch stop sleeve (150) and the feather
stop washer (130).
(c) To increase high pitch angle, move feather adjust washer(s) (140)
from between the high pitch stop sleeve (150) and the feather stop
washer (130) to between the high pitch stop sleeve (150) and the pitch
change rod (200).

ASSEMBLY 61-10-91 Page 7-40

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

(d) Using the feathering tool TE383, reinstall the parts stack.

NOTE: The parts stack includes: washers (145), high pitch stop
sleeve (150), washers (140), feather stop washer (130), and
stop screw (120).
(e) Release the air pressure to allow the flyweight (920) to hold the propeller
at high pitch.
(f) Check the high pitch blade angles.
(g) Repeat step 2.H.(6) through 2.H.(6)(f) until angles are correct.

CAUTION: TO AVOID DAMAGE TO THE PROPELLER COMPONENTS, BE

SURE THE AIR PRESSURE IS APPLIED BEFORE REMOVING THE
FEATHERING TOOL TE383.
(7) When angles are correct, remove the feathering tool TE383.

NOTE: When removing the feathering tool TE383, make sure the washers
(140) and the feathering stop washer (130) stay in place on top of the
high pitch sleeve (150).
(8) Using a magnet, remove only the feathering stop washer (130) from the washer
stack on top of the high pitch sleeve (150).
(9) Install the feathering stop washer (130) on the stop screw (120).

NOTE: The self-locking patch on the threads of the stop screw (120) makes
it difficult to put the feathering stop washer (130) on the stop screw.
(10) Apply one drop of thread locking compound CM74 to the threaded end of the
stop screw (120).
(11) Using the T-handle wrench TE381, install the feathering stop washer (130) and
the stop screw (120) through the top of the cylinder (50) into the pitch change
rod (200), making sure that the washers (140) are still in position on top of the
pitch change rod (200).

NOTE: A small amount of lubricant CM12 on the head of the stop

screw (120) will hold the screw to the T-handle wrench long enough
to guide the screw and the feathering stop washer (130) into the
threaded hole in the pitch change rod (200).
(12) Tighten the stop screw (120) with the T-handle wrench TE381. Maintain a
minimum screw engagement of seven threads.
(13) Release the air pressure to allow the flyweight (920) to hold the propeller at
high pitch.

ASSEMBLY 61-10-91 Page 7-41

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

(14) Re-check the high pitch blade angles.

CAUTION: IF HIGH PITCH REQUIRES ADJUSTMENT, CONTROL

THE BLADE ANGLE BY ADDING AIR PRESSURE TO THE
PROPELLER TO MOVE AND HOLD THE PROPELLER OFF
THE HIGH PITCH STOP LATCHES.
(a) If high pitch angle adjustment is required, remove the stop screw (120),
feather stop washer (130), feather adjust washer(s) (140), high pitch stop
sleeve (150), and high pitch adjust washers (145) from the pitch change
rod (200).

CAUTION: AFTER THE FEATHER ANGLE HAS BEEN SET, THE TOTAL
NUMBER OF WASHERS (140, 145) MUST BE MAINTAINED.
CHANGING THE POSITIONS OF THE WASHERS TO
ACHIEVE HIGH PITCH WILL NOT EFFECT THE FEATHER
ANGLE. ADDING OR REMOVING ANY WASHERS (140, 145)
THAT HAVE ALREADY BEEN INSTALLED WILL CHANGE THE
FEATHER AND HIGH PITCH ANGLES.
(b) To decrease high pitch angle, move high pitch adjust washer(s) (145)
from between the high pitch stop sleeve (150) and the pitch change
rod (200) to between the high pitch stop sleeve (150) and the feather
stop washer (130).
(c) To increase high pitch angle, move feather adjust washer(s) (140)
from between the high pitch stop sleeve (150) and the feather stop
washer (130) to between the high pitch stop sleeve (150) and the
pitch change rod (200).
(d) Using the T-handle wrench TE381, reinstall the parts stack.

NOTE: The parts stack includes: high pitch adjust washer(s) (145), high
pitch stop sleeve (150), feather adjust washers (140), feather
stop washer (130), and stop screw (120).
(15) Tighten the stop screw (120) with the T-handle wrench TE381. Maintain a
minimum screw engagement of seven threads.
(16) When the high pitch angle is correct, install a new low stop O-ring (40) in the
top of the cylinder (50).

CAUTION: THE LOW PITCH STOP (30) MUST BE TURNED A MINIMUM OF

FIVE THREADS INTO THE CYLINDER.
(17) Install the low pitch stop (30) in the top of the cylinder (50).

NOTE: If necessary, refer to Figure 5-1, "Pitch Stop Dimensions" in the

Check chapter of this manual to determine the appropriate low stop
stop (30) for the blade angle required.

ASSEMBLY 61-10-91 Page 7-42

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

(18) Check the low pitch stop angle.

(a) Rotate the blades to the low pitch position and set the propeller pitch
in accordance with the aircraft Type Certificate Data Sheet and/or the
Hartzell Propeller Inc. Application Guide Manual 159 (61-02-59).
(b) Adjust the low pitch angle with the low pitch stop (30).
1 To increase pitch, turn the low pitch stop (30) clockwise.
2 To decrease pitch, turn the low pitch stop (30) counterclockwise.

CAUTION 1: BE SURE AIR PRESSURE IS APPLIED BEFORE

REMOVING THE STOP SCREW (120).

CAUTION 2: ADD WASHERS BETWEEN THE STOP SCREW (120)

AND THE FEATHER STOP WASHER (130) ONLY.
3 If low pitch cannot be obtained because the low pitch stop (30)
bottoms out or exceeds the five thread engagement minimum,
washers (135) may be added or removed between the stop screw
(120) and the feather stop washer (130) only.

NOTE: This will not change the feather (high pitch) blade angle.

ASSEMBLY 61-10-91 Page 7-43

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

I. Charging the Propeller with Air

(1) To determine the proper pressure, refer to the Maintenance Practices chapter
of Hartzell Propeller Inc. Owner's Manual 480 (61-00-80).
(2) Using proper control, charge the cylinder with dry air or nitrogen.

NOTE: Nitrogen is the preferred charging medium.

(3) Apply solution CM122 to the air valve (10) pin to check for air leaks.
(4) Apply solution CM122 where the air valve (10) and the low pitch stop (30) meet
to check for air leaks.
(5) Apply solution CM122 where the low pitch stop (30) and the nut (20) meet to
check for air leaks.
(6) Recheck the air charge pressure in the cylinder to make sure that there are no
air leaks.
(a) If primer CM127 was not used on the air valve (10), permit twelve hours
between pressure checks.
(b) If primer CM127 was used on the air valve (10), permit two hours between
pressure checks.
(7) Install tag B-7588 or equivalent on the air valve assembly. Refer to
Figure 7-28.

WARNING

TPI-B7588

Air Pressure Check Warning Tag

Figure 7-28

ASSEMBLY 61-10-91 Page 7-44

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

3. Leak Check
A. Lubrication Fitting/Lubrication Hole Plug Installation
(1) For information about the location of lubrication fittings (280) and
lubrication hole plugs (270), refer to the Propeller Lubrication chapter of
Hartzell Propeller Inc. Standard Practices Manual 202A (61-01-02).
(2) Install the lubrication fittings (280) and lubrication hole plugs (270) in
the lubrication holes in the hub (240).
(a) Leave one lubrication hole in the cylinder-side half of the hub (240) open
for the leak check.
(3) Tighten each lubrication fitting (280) and lubrication hole plug (270) until
finger-tight, then tighten one additional 360 degree turn.
B. Leak Check Procedure
(1) While the hub (240) is installed on the propeller test stand, actuate the propeller
to high pitch to purge air trapped in the hub.
(2) Apply soap solution CM122 to the hole where the lubrication fitting (280) or the
lubrication hole plug (270) was removed. Refer to Figure 7-29.
(3) If there is any indication of air exiting the hub (240), perform troubleshooting of
the propeller assembly to identify and correct the cause.
(4) After a satisfactory leak check, install the remaining lubrication fitting (280) or
lubrication plug (270) in the hub (240).
(a) Tighten the lubrication fitting (280) or lubrication plug (270) until
finger-tight, then tighten one additional 360 degree turn.

Soap Solution CM122

TPI-490-011

Hub Leak Check

Figure 7-29

ASSEMBLY 61-10-91 Page 7-45

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

4. Counterweight Installation

NOTE: Specific Hartzell Propeller Inc. manuals and service documents are available
on the Hartzell website at www.hartzellprop.com. Refer to the section,
"Required Publications" in the Introduction chapter of this manual for
identification of these publications.
A. For the correct counterweight (2000) for the propeller, refer to the Hartzell
Propeller Inc. Application Guide Manual (61-02-59).
B. For installation of a counterweight (2000) on a composite blade, refer to
Hartzell Propeller Inc. Composite Propeller Blade Maintenance Manual 135F
(61-13-35).

5. Propeller Lubrication
A. Lubricate the propeller in accordance with the Propeller Lubrication chapter
of Hartzell Propeller Inc. Standard Practices Manual 202A (61-01-02).

6. Static Balance
A. Perform static balance of the propeller in accordance with the Static and Dynamic
Balance chapter of Hartzell Propeller Inc. Standard Practices
Manual 202A (61-01-02).

7. Labels
A. For installation of labels, refer to the Parts Identification and Marking chapter of
Hartzell Propeller Inc. Standard Practices Manual 202A (61-01-02) or to Hartzell
Propeller Inc. Composite Blade Manual 135F (61-13-35).

ASSEMBLY 61-10-91 Page 7-46

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

8. Propeller Disassembled for Shipping

CAUTION: INSTRUCTIONS AND PROCEDURES IN THIS SECTION MAY

INVOLVE PROPELLER CRITICAL PARTS. REFER TO THE
INTRODUCTION CHAPTER OF THIS MANUAL FOR INFORMATION
ABOUT PROPELLER CRITICAL PARTS. REFER TO THE
ILLUSTRATED PARTS LIST IN THIS MANUAL FOR IDENTIFICATION
OF PROPELLER CRITICAL PARTS.
A. General
(1) A propeller disassembled for shipping has had one or more blades removed
from the propeller after assembly. The propeller was fully assembled, tested,
inspected, lubricated, and statically balanced before blade removal and
shipping.
(2) A propeller disassembled for shipping must be assembled by trained personnel
in accordance with Hartzell Propeller Inc. manuals.
(3) For additional general assembly information, refer to the section, "General" at
the beginning of this chapter.
B. Preparing the Propeller for Shipping
(1) New hardware was installed during propeller assembly for shipping. When
disassembling a propeller for shipping, it is not necessary to discard hardware
that would require replacement at overhaul.
(2) New O-rings have been installed during propeller assembly for shipping. During
propeller disassembly for shipping, it is not necessary to replace O-rings unless
damaged during component installation or removal.
(3) Before removal, make a mark to indicate alignment of each blade assembly,
fork unit, spinner bulkhead, and balance weight location with the hub unit.
Refer to the section, "Marking Before Disassembly" in the Disassembly chapter
of this manual.
(a) Before removal of the pitch change block (320), make a mark to indicate
position and orientation to the pitch change fork unit.
1 The pitch change blocks may be taped in place in the pitch
change fork.
(4) Remove all balance weight screws (800) and balance weights (810).
(5) Disconnect the electric de-ice lead wires from the hub and bulkhead, if
applicable.
(6) Disassemble the propeller to the point of blade removal. Refer to the section,
"Propeller Disassembly" in the Disassembly chapter of this manual.

ASSEMBLY 61-10-91 Page 7-47

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

(7) Propeller Reassembly with Blades Removed for Shipping

(a) Reassemble the propeller without the blade assemblies in accordance
with the applicable assembly instructions in this chapter.
1 The pitch change blocks (320) can be taped in position in the
fork (300).
(8) Packing the Propeller and Blades for Shipping
(a) Refer to the Packaging and Storage chapter of Hartzell Propeller Inc.
Standard Practices Manual 202A (61-01-02), for packing the propeller
and blades for shipping.
(b) Pack the propeller without blades for shipping.
(c) Pack the blades for shipping with the blade seal, blade bearings, and
lubricant on each blade shank.

9. Reassembly of a Propeller Disassembled for Shipping

CAUTION: INSTRUCTIONS AND PROCEDURES IN THIS SECTION MAY

INVOLVE PROPELLER CRITICAL PARTS. REFER TO THE
INTRODUCTION CHAPTER OF THIS MANUAL FOR INFORMATION
ABOUT PROPELLER CRITICAL PARTS. REFER TO THE
ILLUSTRATED PARTS LIST IN THIS MANUAL FOR IDENTIFICATION
OF PROPELLER CRITICAL PARTS.
A. Unpacking the Propeller and Blades
(1) Carefully unpack the propeller and blades from shipping.
(2) Visually examine each propeller component for shipping damage.
(a) If damage is found, refer to the Check chapter of this manual for the
inspection, serviceable limits, and corrective action criteria for the specific
component.

ASSEMBLY 61-10-91 Page 7-48

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

B. Preparing Propeller for Reassembly

NOTE 1: New hardware was installed during propeller assembly for shipping. When
disassembling a propeller from shipping, it is not necessary to discard
hardware that would require replacement at overhaul.

NOTE 2: New O-rings have been installed during propeller assembly for shipping.
During propeller disassembly for shipping, it is not necessary to replace
O-rings, unless they were damaged during component installation or
removal.
(1) Make sure that each blade assembly, the fork unit, and each balance
weight (810) has been marked for alignment with the hub unit.
(2) Remove all balance weight screws (800) and balance weights (810), if
necessary.
C. Propeller Reassembly
(1) Reassemble the propeller in accordance with the Assembly instructions in this
chapter.
(2) Reconnect the electric de-ice lead wires to the bulkhead, if applicable.

ASSEMBLY 61-10-91 Page 7-49

Nov/18
PROPELLER MAINTENANCE MANUAL
491

(This page is intentionally blank.)

ASSEMBLY 61-10-91 Page 7-50

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

FITS AND CLEARANCES - CONTENTS

1. Torque Values......................................................................................................8-4
2. Blade Tolerances.................................................................................................8-7

LIST OF FIGURES
Determining Torque Value of a Standard Torque Wrench
with Adapter..........................................................................Figure 8-1.................... 8-3
Blade Play..................................................................................Figure 8-2.................... 8-6

LIST OF TABLES
Torque Values ............................................................................Table 8-1...................... 8-5

61-10-91
Page 8-1
FITS AND CLEARANCES Nov/18
PROPELLER MAINTENANCE MANUAL
491

(This page is intentionally blank.)

61-10-91
Page 8-2
FITS AND CLEARANCES Nov/18
 PROPELLER MAINTENANCE MANUAL
491

Torquing Adapter
Standard Torque Wrench

1.00 foot 0.50 foot

(304.8 mm) (152.4 mm)

(actual torque required) x (torque wrench length) torque wrench reading

= to achieve required
(torque wrench length) + (length of adapter)
actual torque

EXAMPLE:
reading on torque
100 Ft-Lb (136 N•m) x 1 ft (304.8 mm) 66.7 Ft-Lb wrench with 6-inch
= (152.4 mm) adapter
1 ft (304.8 mm) + 0.50 ft (152.4 mm) (90.1 N•m)
for actual torque of
100 Ft-Lb (136 N•m)

The correction shown is for an adapter that is aligned with the centerline of the
torque wrench. If the adapter is angled 90 degrees relative to the torque wrench
centerline, the torque wrench reading and actual torque applied will be equal.
APS212

Determining Torque Value of a Standard Torque Wrench with Adapter

Figure 8-1

61-10-91
Page 8-3
FITS AND CLEARANCES Nov/18
 PROPELLER MAINTENANCE MANUAL
491

1. Torque Values

CAUTION: INSTRUCTIONS AND PROCEDURES IN THIS CHAPTER MAY

INVOLVE PROPELLER CRITICAL PARTS. REFER TO THE
INTRODUCTION CHAPTER OF THIS MANUAL FOR INFORMATION
ABOUT PROPELLER CRITICAL PARTS. REFER TO THE
ILLUSTRATED PARTS LIST IN THIS MANUAL FOR IDENTIFICATION
OF PROPELLER CRITICAL PARTS.
A. The structural integrity of joints in the propeller that are held together with threaded
fasteners is dependent upon proper torque application.
(1) Vibration can cause an incorrectly tightened fastener to fail in a matter of
minutes.
(2) Correct tension in a fastener depends on a variety of known load factors and
can influence fastener service life.
(3) Correct tension is achieved by application of measured torque.
B. Use accurate wrenches and professional procedures to make sure of correct
tensioning.
C. For the torque values to use when assembling a Hartzell Propeller Inc. propeller,
refer to Table 8-1, "Torque Values" in this chapter.
D. When an adapter is used with a torque wrench, use the equation in Figure 8-1 to
determine the correct torque value.

61-10-91
Page 8-4
FITS AND CLEARANCES Nov/18
 PROPELLER MAINTENANCE MANUAL
491

CAUTION 1: TORQUE VALUES ARE BASED ON NON-LUBRICATED THREADS,

UNLESS SPECIFIED IN TABLE 8-1.

CAUTION 2: FOR TORQUE READING WHEN USING A TORQUE WRENCH ADAPTER,

REFER TO FIGURE 8-1.

Item Part Description Torque

No. Number
Ft-Lb In-Lb N•m

10 B-1938 Valve Assembly Torque until tight and no air leaks from around valve.

20 A-2405-4 Nut, 15/16-20, Hex 25-30 300-360 34-40

50 B-2423-1 Cylinder 120-150 wet 1440-1800 wet 163-203 wet

100 B-3841-8 Screw, 1/4-28, Fillister Head - 50 5.7

120 A-3205 Screw, 5/16-24, Cap 10-15 120-180 14-20

170 B-3807 Nut, 5/8-18, Hex, Self-Locking 15-25 180-300 20-34

200 B-2491-5 Pitch Change Rod 40 wet 480 wet 54 wet

350 A-2043-1 Nut, 3/8-24, Hex, Self-Locking 24-26 288-312 33-35

910 A-1595 Screw, Shoulder, 1/4" - 48 5.5

NOTE 1: Torque tolerance is + 10 percent unless otherwise noted. Refer to the

Assembly chapter of this manual when wet torque is designated.

NOTE 2: Refer to the text in the Assembly chapter of this manual for the
maximum value.

Torque Values
Table 8-1

61-10-91
Page 8-5
FITS AND CLEARANCES Nov/18
 PROPELLER MAINTENANCE MANUAL
491

Fore-and-Aft Movement

In-and-Out Play

Radial Play

End Play

TI-411-026

Blade Play
Figure 8-2

61-10-91
Page 8-6
FITS AND CLEARANCES Nov/18
 PROPELLER MAINTENANCE MANUAL
491

2. Blade Tolerances

Tolerances Affecting the Blades - Refer to Figure 8-2

In-and-Out Blade Play 0.020 inch (0.50 mm)

End Play (leading edge to trailing edge) ± 0.05 inch (1.27 mm)
0.100 inch (2.54 mm) total

Fore-and-Aft (Face to camber)

± 0.05 inch (1.27 mm)
0.100 inch (2.54 mm) total

Radial Play (pitch change) ± 0.5 degree (1 degree total)
measured at reference station

Blade Track ± 0.125 inch (3.17 mm)

or 0.25 inch (6.3 mm) total

Blade Pitch Setting Tolerance 0.2 degree
Between Blades at Low Pitch

NOTE: Hartzell Propeller Inc. Raptor-series propellers use specially

designed spacers within the propeller to achieve the required
blade fit. The blades may feel loose in the hub when compared
to Hartzell Compact-series propellers. During propeller
rotation, the blade fit within the propeller is the same as other
Hartzell propeller models.

Blade Tolerances
Table 8-2

61-10-91
Page 8-7
FITS AND CLEARANCES Nov/18
PROPELLER MAINTENANCE MANUAL
491

(This page is intentionally blank.)

61-10-91
Page 8-8
FITS AND CLEARANCES Nov/18
 PROPELLER MAINTENANCE MANUAL
491

SPECIAL TOOLS, FIXTURES, AND EQUIPMENT - CONTENTS

1. Minimum Facility and Tooling Requirements.......................................................9-3

A. Tooling............................................................................................................9-3
B. Facilities.........................................................................................................9-3
2. Special Tools........................................................................................................9-3
A. General..........................................................................................................9-3
B. Special Tools..................................................................................................9-4

61-10-91
Page 9-1
SPECIAL TOOLS, FIXTURES, AND EQUIPMENT Nov/18
 PROPELLER MAINTENANCE MANUAL
491

(This page is intentionally blank.)

SPECIAL TOOLS, FIXTURES, AND EQUIPMENT 61-10-91 Page 9-2

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

1. Minimum Facility and Tooling Requirements

A. Tooling
(1) Propeller repair stations certified by the FAA or international equivalent to
overhaul Hartzell Propeller Inc. propellers are expected to possess precision
fixtures, tools, and blade tables for blade inspection and repair.
(a) Except as specifically required in this manual, locally fabricated tooling is
acceptable for most repair and inspection operations.
B. Facilities
(1) Grinding, plating, and painting of propeller components have the potential for
health and safety hazards beyond that of other areas of a typical workshop.
(a) It is expected that such areas be in compliance with industry standards
and governmental regulations concerning occupational safety and health,
as well as environmental protection.
(2) Workshop areas need to be segregated to prevent contamination.
(a) Separate areas should be designated for cleaning, inspection, painting,
plating, and assembly.
(b) Propeller balancing must be performed in a draft free area.

2. Special Tools
A. General

NOTE: Specific Hartzell Propeller Inc. manuals and service documents are
available on the Hartzell Propeller Inc. website at www.hartzellprop.com.
Refer to the Required Publications section in the Introduction chapter
of this manual for the identification of these publications.
(1) While Hartzell Propeller Inc. does not maintain an exact list of standard tools
used in repair or servicing of our propellers, Hartzell Propeller Inc. frequently
also requires the use of special tools during servicing, repair, or overhaul.
(a) The applicable overhaul manual and Hartzell Propeller Inc. Illustrated Tool
and Equipment Manual 165A (61-00-65) provide this necessary tooling
information.
(b) It is the responsibility of the repair station or the technician performing the
repair or servicing to use these special tools as required.

61-10-91
Page 9-3
SPECIAL TOOLS, FIXTURES, AND EQUIPMENT Nov/18
 PROPELLER MAINTENANCE MANUAL
491

B. Special Tools

NOTE: Specific Hartzell Propeller Inc. manuals and service documents are
available on the Hartzell Propeller Inc. website at www.hartzellprop.com.
Refer to the Required Publications section in the Introduction chapter
of this manual for the identification of these publications.
(1) Hartzell Propeller Inc. Illustrated Tool and Equipment Manual 165A (61-00-65)
contains a listing of required tools.

SPECIAL TOOLS, FIXTURES, AND EQUIPMENT 61-10-91 Page 9-4

Nov/18
 PROPELLER MAINTENANCE MANUAL
491

ILLUSTRATED PARTS LIST - CONTENTS

1. Introduction...........................................................................................................10-3
2. The Illustrated Parts List.......................................................................................10-5
A. Detailed Parts List........................................................................................... 10-5
B. Revisions......................................................................................................... 10-7
C. Vendors........................................................................................................... 10-8
PROPELLER ASSEMBLIES
Propeller Model 3C2-FP650A1 ............................................................................... 10-11
B-1589-2 Spring Assembly Components................................................................. 10-17

LIST OF FIGURES
Propeller Model 3C2-FP650A1 .............................................Figure 10-1................ 10-10
Propeller Model 3C2-FP650A1 Blade Retention System...... Figure 10-2................ 10-14
B-1589-2 Spring Assembly....................................................Figure 10-3................ 10-16

61-10-91
Page 10-1
ILLUSTRATED PARTS LIST Nov/18
PROPELLER MAINTENANCE MANUAL
491

(This page is intentionally blank.)

61-10-91
Page 10-2
ILLUSTRATED PARTS LIST Nov/18
 PROPELLER MAINTENANCE MANUAL
491

1. Introduction

CAUTION: INSTRUCTIONS AND PROCEDURES IN THIS CHAPTER MAY

INVOLVE PROPELLER CRITICAL PARTS. REFER TO THE
INTRODUCTION CHAPTER OF THIS MANUAL FOR INFORMATION
ABOUT PROPELLER CRITICAL PARTS. REFER TO THE
ILLUSTRATED PARTS LIST IN THIS MANUAL FOR IDENTIFICATION
OF PROPELLER CRITICAL PARTS.

NOTE: Specific Hartzell Propeller Inc. manuals and service documents are available
on the Hartzell Propeller Inc. website at www.hartzellprop.com. Refer to the
Required Publications section in the Introduction chapter of this manual for
the identification of these publications.
A. General
(1) This Illustrated Parts List contains all of the current configurations for the
specified propellers manufactured by Hartzell Propeller Inc. included in this
manual and supersedes any prints that may have previously been supplied for
part and assembly information. The parts lists contained within the Illustrated
Parts List are to be used to make sure of the configuration of propeller models
and for ordering parts.

CAUTION: ILLUSTRATIONS IN THE ILLUSTRATED PARTS LIST ARE TO BE

USED FOR IDENTIFYING PARTS AND SHOULD NOT BE USED AS
A MAINTENANCE REFERENCE FOR ASSEMBLY.
(2) Figures are for reference only. The figures provide general views of parts.
For ease of illustration, typical views of some parts were created and shown
in multiple figures. For this reason, illustrated parts may not exactly reflect
parts contained in some propeller assemblies.

61-10-91
Page 10-3
ILLUSTRATED PARTS LIST Nov/18
 PROPELLER MAINTENANCE MANUAL
491

B. Using the Illustrated Parts List

(1) Every effort has been made to include all applicable propellers and
configurations manufactured by Hartzell Propeller Inc. If a repair station has
questions about a propeller configuration as stated in the Illustrated Parts List,
contact the Hartzell Propeller Inc. Product Support Department.
(2) Basic Propeller Parts: Refers to all of the propeller components that may be
unique to a particular propeller model.

NOTE 1: Counterweight slugs and counterweight slug mounting hardware are

application specific. Refer to Hartzell Propeller Inc. Application Guide
Manual 159 (61-02-59).

NOTE 2: Spinner parts and mounting hardware are application specific. Refer
to Hartzell Propeller Inc. Application Guide Manual 159 (61-02-59).
(3) Balance Parts: These components are common to all Raptor series propellers.
C. Propeller Assemblies Configured with an Ice Protection System
(1) If the propeller is equipped with an ice protection system that uses components
supplied by Hartzell Propeller Inc., applicable instructions and technical
information can be found in Hartzell Propeller Inc. Ice Protection System
Manual 180 (30-61-80) available on the Hartzell Propeller Inc. website at www.
hartzellprop.com.
(2) Propeller ice protection system components not supplied by Hartzell
Propeller Inc. are controlled by the applicable TC or STC holder’s
Instructions for Continued Airworthiness (ICA).

61-10-91
Page 10-4
ILLUSTRATED PARTS LIST Nov/18
 PROPELLER MAINTENANCE MANUAL
491

2. The Illustrated Parts List

A. Detailed Parts List
(1) The Detailed Parts List consists of the Figure/Item Number (Fig./Item Number),
Part Number, Description, Effectivity Code (EFF Code), Units Per Assembly
(UPA), Overhaul (O/H), and Propeller Critical Parts (PCP). Space is reserved
for the Airline Stock Number (Airline Stock No.). The following is an explanation
of each column.
(a) Fig/Item Number
1 Figure Number refers to the illustration where items appear. Item
Numbers are assigned in broken sequence to allow the insertion
of subsequent additional parts. Items listed but not illustrated are
identified by a dash to the left of the item number.
2 Alpha variants will be used to add additional items. There are two
reasons for the use of alpha variants:
a A part may have an alternate, or may be superseded, replaced,
or obsoleted by another part. For example, the self locking nut
(A-2043) that is item 10 was superseded by the self locking nut
(A-2043-1) that is item 10A.
b An Illustrated Parts List may contain multiple configurations.
Effectivity codes are used to distinguish different part numbers
within the same list. For example, one configuration may use
a rod, pitch change (A-2418-14) that is item 150, yet another
configuration uses a rod, pitch change (A-2418-14) that is
item 150A. Effectivity codes are very important in the
determination of parts in a given configuration.
(b) Part Number
1 Use the Hartzell Propeller Inc. part number when ordering the part
from Hartzell Propeller Inc. or a Hartzell Propeller Inc. approved
distributor. Digits of Hartzell Propeller Inc. Part Numbers have no
significance other than to identify a part.
(c) Airline Stock Number
1 Space is reserved for the Airline Stock Number.

61-10-91
Page 10-5
ILLUSTRATED PARTS LIST Nov/18
 PROPELLER MAINTENANCE MANUAL
491

(d) Description
1 This column identifies the item. The relationship of parts to the
assembly is indicated by the use of indentations. The description in
this column may also contain a Propeller Critical Parts prefix “PCP:”
or a vendor CAGE code, as applicable. Information regarding part
alternative, supersedure, replacement, or obsolecence may also be
found in this column. Refer to Revisions, in this section, for further
information regarding alternate, superseded, replaced, or obsoleted
parts.
(e) Effectivity Code (EFF CODE)
1 The effectivity column shows the prefix and/or suffix of the propeller
model to which the parts apply. In some cases, the specific engine or
aircraft manufacturer may be called out. Effectivity codes assigned
apply only to the figure/listing in which they appear. Parts common to
all end items show no code.
(f) Units Per Assembly (UPA)
1 Designates the total quantity of an item required for the next higher
assembly or subassembly.
(g) Overhaul (O/H)
1 Designates the parts to be replaced at overhaul. A “Y” identifies the
parts that must be replaced at overhaul.

NOTE: An overhaul kit may not contain all the parts identified with
a "Y" for a particular model propeller. An example of parts
that may not be included in the overhaul kit is spinner
mounting parts.
(h) Propeller Critical Part (PCP)
1 This column identifies the Propeller Critical Parts that are contained
in each propeller model. A critical part on the propeller is one
whose primary failure can result in a hazardous propeller effect,
as determined by the safety analysis required by Title 14 CFR
Section 35.15. Maintenance and Repair procedures that apply to the
propeller models in this manual have been substantiated based on
Engineering analysis that expects this product will be operated and
maintained using the procedures and inspections provided in the ICA
for this product.

61-10-91
Page 10-6
ILLUSTRATED PARTS LIST Nov/18
 PROPELLER MAINTENANCE MANUAL
491

B. Revisions
(1) Alternate
(a) Alternate parts are identified by the term "ALTERNATE" in the Description
column. Alternate items are considered airworthy for continued flight
and existing stock of parts may be used for maintenance and/or repair.
The new or alternate part numbers may be used interchangeably when
ordering/stocking new parts.
(2) Supersedure
(a) Part changes are identified by the terms “SUPERSEDES ITEM _____” or
­“SUPERSEDED BY ITEM _____” in the Description column. Superseded
items are considered airworthy for continued flight and existing stock of
superseded parts may be used for maintenance and/or repair. Once the
superseding part has been incorporated/installed into an assembly, the
original superseded part may no longer be used. Superseded parts may
no longer be available, and the new part number must be used when
ordering/stocking new parts.
(3) Replacement
(a) Part changes identified by the terms "REPLACES ITEM _____” or
“REPLACED BY ITEM _____” in the Description column are considered
airworthy for continued flight, but must be replaced with a part with the
new part number at overhaul. Existing stock of replaced parts may not
be used for maintenance and/or repair of effected assemblies. Replaced
parts may no longer be available, and the new part number must be used
when ordering/stocking new parts.
(4) Obsolescence
(a) Obsolete parts are identified by "OBS” in the Units Per Assembly (UPA)
column. Obsolete items are considered unairworthy for continued flight.
(5) Service Documents and Airworthiness Directives
(a) In the event of modification or repair of an existing part, the supersedure,
replacement, or obsolescence of a part, or the addition of parts installed
by a Service Bulletin (SB) or Service Letter (SL), the SB or SL number will
appear in the Description column as “SB_____”, or "SL_____” after the
description.

61-10-91
Page 10-7
ILLUSTRATED PARTS LIST Nov/18
 PROPELLER MAINTENANCE MANUAL
491

C. Vendors
(1) Many O-rings, fasteners, and other vendor supplied hardware listed in Hartzell
Propeller Inc. manuals have previously been specified with AN, MS, NAS or
vendor part number. To provide internal controls and procurement flexibility,
Hartzell Propeller Inc. has made engineering changes to provide all O-rings,
fasteners, and hardware with a Hartzell Propeller Inc. part number. Part
shipments from Hartzell Propeller Inc. will specify only the Hartzell Propeller Inc.
part numbers.
(2) Some O-rings, fasteners, and hardware manufactured in accordance with
established industry specifications (certain AN, MS, NAS items) are acceptable
for use in Hartzell Propeller Inc. products without additional standards imposed
by Hartzell Propeller Inc.
(a) For a listing of part number interchangeability, refer to the Vendor
Cross Reference chapter of Hartzell Propeller Inc. Standard Practices
Manual 202A (61-01-02).
(b) Where permitted, both the Hartzell Propeller Inc. part number item and
AN, MS, NAS, and other specified vendor number items can be used
interchangeably.
(c) The Hartzell Propeller Inc. part number must be used when ordering these
parts from Hartzell Propeller Inc.

61-10-91
Page 10-8
ILLUSTRATED PARTS LIST Nov/18
PROPELLER MAINTENANCE MANUAL
491

(This page is intentionally blank.)

61-10-91
Page 10-9
ILLUSTRATED PARTS LIST Nov/18
 PROPELLER MAINTENANCE MANUAL
491

180
170
160
140
130
190
135
120
110 145
35 150
100
30
20
50 200
40
540
380
370
10
350 530 360
340
390
330
320
510
310
520
300 500

230
290
280
220
260 240

270
240
210
TPI-MB-0247

Propeller Model 3C2-FP650A1

Figure 10-1

61-10-91
Page 10-10
ILLUSTRATED PARTS LIST Nov/18
 PROPELLER MAINTENANCE MANUAL
491

FIG./ITEM PART AIRLINE DESCRIPTION EFF UPA O/H PCP

NUMBER NUMBER STOCK NO. 1 2 3 4 5 6 7 CODE

10-1 3C2-FP650A1 PROPELLER ASSEMBLY PARTS

10 B-1938 • VALVE ASSEMBLY 1 Y

20 A-2405-4 • NUT, 15/16-20, HEX 1
30 A-2404-( ) • STOP, PITCH 1
35 B-7589 • SCREW, SET, 1/4-28, DRILLED 1 Y
40 C-3317-117 • O-RING 1 Y
50 B-2423-1 • CYLINDER UNIT 1
100 B-3841-8 • SCREW, 1/4-28, FILLISTER HEAD 4 Y
110 B-1589-2 • SPRING ASSEMBLY (FEATHER ASSIST) 1
REFER TO FIGURE 10-3
120 A-3205 • SCREW, 5/16-24, CAP 1 Y
130 A-2411-1 • WASHER 1 Y
135 B-3837-0563 • WASHER, CORROSION RESISTANT A/R Y
135A B-3837-0532 • WASHER, CORROSION RESISTANT A/R Y
140 B-3837-0563 • WASHER, CORROSION RESISTANT A/R Y
140A B-3837-0532 • WASHER, CORROSION RESISTANT A/R Y
145 A-2435 • WASHER, 5/16" A/R Y
145A A-2435-1 • WASHER, 5/16"
150 A-2499-( ) • SLEEVE, STOP 1
160 C-3317-427-1 • O-RING 1 Y
170 B-3807 • NUT, 5/8-18, HEX, SELF-LOCKING 1 Y
180 B-3683 • PISTON 1
190 C-3317-210-1 • O-RING 1 Y
200 B-2491-5 • ROD, PITCH CHANGE 1
210 C-3317-247 • O-RING 1 Y
220 C-3317-210-1 • O-RING 1 Y
230 A-2432 • BOLT, 3/8-24, HEX HEAD 9
240 107007 • PCP: HUB UNIT, 3C2-FP( )A1 1 PCP
-250 A-2245-8 • • HUB BUSHING, ROD (ENGINE SIDE) 1 Y
260 A-2249 • • HUB BUSHING, GUIDE 1 Y
270 106545 • PLUG, LUBRICATION (CYLINDER-SIDE OF HUB) C 3 Y
280 A-279 • FITTING, LUBRICATION (ENGINE-SIDE OF HUB) C 3 Y
290 B-6544 • CAP, FITTING, LUBRICATION 3 Y
300 105732 • FORK, THREE BLADE ASSEMBLY 1
310 A-3256 • BUMPER, FORK 3 Y
320 105733 • BLOCK, PITCH CHANGE 3

EFFECTIVITY MODEL EFFECTIVITY MODEL

C REFER TO THE PROPELLER LUBRICATION

CHAPTER OF HARTZELL PROPELLER INC.
STANDARD PRACTICES MANUAL 202A (61-01-02).

- ITEM NOT ILLUSTRATED

Propeller Model 3C2-FP650A1

61-10-91
Page 10-11
ILLUSTRATED PARTS LIST Nov/18
 PROPELLER MAINTENANCE MANUAL
491

FIG./ITEM PART AIRLINE DESCRIPTION EFF UPA O/H PCP

NUMBER NUMBER STOCK NO. 1 2 3 4 5 6 7 CODE

10-1 3C2-FP650A1 PROPELLER ASSEMBLY PARTS,

CONTINUED
330 106136 • BUTTON, BLOCK, PITCH CHANGE 3 Y
340 B-3834-0632 • WASHER 9 Y
350 A-2043-1 • NUT, 3/8-24, HEX, SELF-LOCKING 9 Y
360 A-5839-225 • RING, RETAINING, INTERNAL SPIRAL 1 Y
370 A-2481 • PLUG, HUB 1
380 C-3317-115-1 • O-RING 1 Y
390 C-3317-226 • O-RING 1 Y

F-FLANGE MOUNTING PARTS

500 A-2429-( ) • STUD, MOUNTING, 1/2-20 A 6
510 A-2044 • NUT, 1/2-20, HEX, SELF-LOCKING 6 Y
520 A-1381 • WASHER, 1/2" CRES 6 Y
530 B-6138-8-9 • DOWEL PIN 2 Y
540 C-3317-228 • O-RING 1 Y

EFFECTIVITY MODEL EFFECTIVITY MODEL

A MOUNTING STUDS ARE APPLICATION
SPECIFIC. REFER TO THE HARTZELL
PROPELLER INC. APPLICATION GUIDE
MANUAL 159 (61-02-59)
- ITEM NOT ILLUSTRATED
Propeller Model 3C2-FP650A1

61-10-91
Page 10-12
ILLUSTRATED PARTS LIST Nov/18
 PROPELLER MAINTENANCE MANUAL
491

FIG./ITEM PART AIRLINE DESCRIPTION EFF UPA O/H PCP

NUMBER NUMBER STOCK NO. 1 2 3 4 5 6 7 CODE

10-1 3C2-FP650A1 PROPELLER ASSEMBLY PARTS,

CONTINUED
BALANCE PARTS
-800 B-3840-( ) • SCREW A/R Y
-810 A-2424-( ) • BALANCE WEIGHT A/R

COUNTERWEIGHTS AND COUNTERWEIGHT SLUGS

-9000 • COUNTERWEIGHT PCP
APPLICATION SPECIFIC
REFER TO HARTZELL PROPELLER INC.
APPLICATION GUIDE MANUAL 159 (61-02-59)
FOR PART NUMBER AND PROPELLER CRITICAL
PART (PCP) IDENTIFICATION
-9010 • COUNTERWEIGHT SLUG PCP
APPLICATION SPECIFIC
REFER TO HARTZELL PROPELLER INC.
APPLICATION GUIDE MANUAL 159 (61-02-59)
FOR PART NUMBER AND PROPELLER CRITICAL
PART (PCP) IDENTIFICATION

SPINNER PARTS
-9020 • SPINNER ASSEMBLIES AND SPINNER MOUNTING
HARDWARE ARE APPLICATION SPECIFIC.
REFER TO HARTZELL PROPELLER INC.
APPLICATION GUIDE MANUAL 159 (61-02-59)
AND HARTZELL PROPELLER INC. METAL SPINNER
ASSEMBLY MAINTENANCE MANUAL 127 (61-16-27)
OR COMPOSITE SPINNER MAINTENANCE
MANUAL 148 (61-16-48).

EFFECTIVITY MODEL EFFECTIVITY MODEL

- ITEM NOT ILLUSTRATED

Propeller Model 3C2-FP650A1

61-10-91
Page 10-13
ILLUSTRATED PARTS LIST Nov/18
 PROPELLER MAINTENANCE MANUAL
491

Blade

720
730
600
610
670
620
680
660
690
640
700
650
710
630
TPI-MB-0218

Propeller Model 3C2-FP650A1 Blade Retention System

Figure 10-2

61-10-91
Page 10-14
ILLUSTRATED PARTS LIST Nov/18
 PROPELLER MAINTENANCE MANUAL
491

FIG./ITEM PART AIRLINE DESCRIPTION EFF UPA O/H PCP

NUMBER NUMBER STOCK NO. 1 2 3 4 5 6 7 CODE

3C2-FP650A1 PROPELLER ASSEMBLY PARTS,

CONTINUED
10-2 BLADE RETENTION PARTS
600 C-3317-028 • O-RING (BLADE PLUG) 3 Y
610 106048 • PLUG, BLADE 3
620 A-5839-156 RING, RETAINING, INTERNAL SPIRAL (BLADE
• 3 Y
PLUG)
630 C-792-B • RACE, BLADE SIDE 3
640 B-6144-1 • BALL, BEARING, 3/8" DIA 99 Y
650 B-793 • BALL SPACER 3 Y
660 C-792-A • RACE, HUB SIDE 3
670 101512 • RING, RETAINING, BEARING 3
680 105758-( ) • SHIM, BLADE 3
690 C-3317-246 • O-RING (BLADE SEAL ID) 3 Y
700 107223 • SEAL, BLADE 3
710 C-3317-158 • O-RING (BLADE SEAL OD) 3 Y
720 C-3317-341-8 • O-RING 3 Y
730 105731 • BUSHING, KNOB, PITCH CHANGE 3 Y

EFFECTIVITY MODEL EFFECTIVITY MODEL

- ITEM NOT ILLUSTRATED

Propeller Model 3C2-FP650A1

61-10-91
Page 10-15
ILLUSTRATED PARTS LIST Nov/18
 PROPELLER MAINTENANCE MANUAL
491

950

960

970

900

910
920

930
940
TPI-W10043

B-1589-2 Spring Assembly

Figure 10-3

61-10-91
Page 10-16
ILLUSTRATED PARTS LIST Nov/18
 PROPELLER MAINTENANCE MANUAL
491

FIG./ITEM PART AIRLINE DESCRIPTION EFF UPA O/H PCP

NUMBER NUMBER STOCK NO. 1 2 3 4 5 6 7 CODE

10-3 B-1589-2 SPRING ASSEMBLY PARTS 1

900 A-1591 • SPRING GUIDE 1

910 A-1595 • SCREW, SHOULDER, 1/4" 4 Y
920 B-318 • FLYWEIGHT, START LOCK 1
930 A-1596 • SPPRING, EXTENSION 1 Y
940 A-3744 • PLATE, FLYWEIGHT 1
950 B-1592-1 • GUIDE, SPRING, PLASTIC 1 Y
960 B-1594-1 • SPRING, COMPRESSION 1
970 B-1593 • HOUSING, START LOCK 1

EFFECTIVITY MODEL EFFECTIVITY MODEL

- ITEM NOT ILLUSTRATED

B-1589-2 Spring Assembly Components

61-10-91
Page 10-17
ILLUSTRATED PARTS LIST Nov/18
PROPELLER MAINTENANCE MANUAL
491

(This page is intentionally blank.)

61-10-91
Page 10-18
ILLUSTRATED PARTS LIST Nov/18