[Federal Register Volume 61, Number 177 (Wednesday, September 11, 1996)]
[Rules and Regulations]
[Pages 47809-47813]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 96-22770]


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DEPARTMENT OF TRANSPORTATION
14 CFR Part 39

[Docket No. 95-ANE-30; Amendment 39-9738; AD 96-18-14]
RIN 2120-AA64


Airworthiness Directives; Hartzell Propeller Inc. HC-A3V, HC-B3M, 
HC-B3T, HC-B4M, HC-B4T, and HC-B5M Series Propellers

AGENCY: Federal Aviation Administration, DOT.

ACTION: Final rule.

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SUMMARY: This amendment adopts a new airworthiness directive (AD), 
applicable to Hartzell Propeller Inc. (Hartzell) HC-A3V, HC-B3M, HC-
B3T, HC-B4M, HC-B4T, and HC-B5M series propellers, that requires hub 
replacement over a 10-year time period with a concurrent blade and 
blade clamp inspection. This amendment is prompted by reports of two 
propeller hub failures and one crack indication that occurred on 
Mitsubishi MU-2B-60 aircraft, the similarity of construction and load 
transfer paths between the Hartzell propeller models installed on the 
Mitsubishi MU-2 aircraft and Hartzell's 3, 4, and 5-bladed steel hub 
propeller models, several blade shank failures, and reports of cracks 
in blade clamps. The actions specified by this AD are intended to 
prevent propeller hub, blade, or blade clamp failure, which can result 
in loss of aircraft control.

DATES: Effective October 16, 1996.
    The incorporation by reference of certain publications listed in 
the regulations is approved by the Director of the Federal Register as 
of October 16, 1996.

ADDRESSES: The service information referenced in this AD may be 
obtained from Hartzell Propeller Inc., One Propeller Place, Piqua, OH 
45356-2634, ATTN: Product Support; telephone (513) 778-4388, fax (513) 
778-4321. This information may be examined at the Federal Aviation 
Administration (FAA), New England Region, Office of the Assistant Chief 
Counsel, 12 New England Executive Park, Burlington, MA; or at the 
Office of the Federal Register, 800 North Capitol Street, NW., suite 
700, Washington, DC.

FOR FURTHER INFORMATION CONTACT: Tomaso DiPaolo, Aerospace Engineer, 
Chicago Aircraft Certification Office, FAA, Small Airplane Directorate, 
2300 East Devon Ave., Des Plaines, IL 60018; telephone (847) 294-7031, 
fax (847) 294-7834.

SUPPLEMENTARY INFORMATION: A proposal to amend part 39 of the Federal 
Aviation Regulations (14 CFR part 39) to include an airworthiness 
directive (AD) that is applicable to Hartzell Propeller Inc. (Hartzell) 
HC-A3V, HC-B3M, HC-B3T, HC-B4M, HC-B4T, and HC-B5M series propellers 
was published in the Federal Register on April 26, 1996 (61 FR 18520). 
That action proposed to require over a 10-year time period, propeller 
hub replacement with a concurrent blade and blade clamp inspection for 
Hartzell Propeller Inc. Models HC-A3VF-7(), HC-B3TF-7(), HC-B3MN-3(), 
HC-B3TN-2(), HC-B3TN-3(), HC-B3TN-5(), HC-B4MN-5(), HC-B4MP-3(), HC-
B4TN-3(), HC-B4TN-5(), HC-B5MA-3(), HC-B5MP-3(), HC-B5MP-5(), HC-B3MN-
5(), HC-B3TN-4(), HC-B4MP-4(), and HC-B5MN-3() propellers.
    Interested persons have been afforded an opportunity to participate 
in the making of this amendment. Due consideration has been given to 
the comments received.
    Commenters state that the AD should be modified to limit the 
affected propellers to those installed on engine types similar to those 
in Mitsubishi MU-2 aircraft. The commenters also state that their 
service history has shown that this engine type has more problems and 
that the NPRM documents that only propellers on the Mitsubishi MU-2 
aircraft have been found with cracked hubs. The FAA does not concur. 
Regardless of engine types, the 3, 4, and 5-bladed hubs have similar 
loading and load paths to the failed propellers and, in addition, could 
contain characteristics that the FAA has determined can cause a 
reduction in hub fatigue strength. The NTSB has also recommended 
addressing the same hub fatigue strength characteristics for the 3, 4, 
and 5-bladed hubs. This hub replacement program will provide the 
following hub fatigue strength improvements: (1) Improved hub 
metallurgy; (2) Elimination of any surface decarburization in the pilot 
tube bore; (3) Introduction of compressive residual stress in the pilot 
tube bore; (4) Improved corrosion protection in the pilot tube bore; 
and (5) Improved surface finish in the pilot tube bore.
    Additionally, the commenters state that the cost of complying with 
the proposed AD is severely understated and will increase overhaul 
costs. Therefore, they imply that the proposed AD should be withdrawn 
or limited in scope. The FAA does not concur. The costs documented in 
the AD are weighted average costs. For example, individual operators 
with five-bladed propellers will have costs that run higher than the 
weighted average costs. Therefore, the costs stated in the AD

[[Page 47810]]

should not be construed as understated. Concerning the increase in 
overhaul costs comment, the FAA has determined that the required 
actions are necessary to address an unsafe condition. While those 
required actions may increase maintenance costs, those increased costs 
are balanced by achieving a level of safety that protects against 
further failures. However, if the operator complies with the proposed 
AD at overhaul, the cost is lower than accomplishing the AD action by 
itself.
    Since issuance of the NPRM, the FAA has determined that relief can 
be given to the compliance schedule. Therefore, the dates for hub 
replacement and inspections are shifted three months for all affected 
propellers. Table 1 now reflects the denoted three month calendar 
shift.
    After careful review of the available data, including the comments 
noted above, the FAA has determined that air safety and the public 
interest require the adoption of the rule as proposed with the changes 
described previously. The FAA has determined that these changes will 
neither increase the economic burden on any operator nor increase the 
scope of the AD.
    There are approximately 24,320 propellers of the affected design in 
the worldwide fleet. The FAA estimates that 50% of the subject 
propellers are installed on aircraft of U.S. registry and that 75% will 
have the work done during normally scheduled propeller maintenance. For 
those who accomplish the AD action during normal propeller maintenance, 
the parts cost will average $1,955 with no additional labor. For those 
who accomplish the AD action by itself, the parts cost will average 
$2,174, plus approximately 27 work hours per propeller at an average 
labor rate of $60 per work hour. Based on these figures, the total cost 
impact of the AD on U.S. operators is estimated to be $29,363,360. The 
cost will vary between the 3, 4, and 5-bladed propeller configurations 
and the above data represents an average cost.
    The regulations adopted herein will not have substantial direct 
effects on the States, on the relationship between the national 
government and the States, or on the distribution of power and 
responsibilities among the various levels of government. Therefore, in 
accordance with Executive Order 12612, it is determined that this final 
rule does not have sufficient federalism implications to warrant the 
preparation of a Federalism Assessment.
    For the reasons discussed above, I certify that this action (1) Is 
not a ``significant regulatory action'' under Executive Order 12866; 
(2) is not a ``significant rule'' under DOT Regulatory Policies and 
Procedures (44 FR 11034, February 26, 1979); and (3) will not have a 
significant economic impact, positive or negative, on a substantial 
number of small entities under the criteria of the Regulatory 
Flexibility Act. A final evaluation has been prepared for this action 
and it is contained in the Rules Docket. A copy of it may be obtained 
from the Rules Docket at the location provided under the caption 
ADDRESSES.

List of Subjects in 14 CFR Part 39

    Air Transportation, Aircraft, Aviation safety, Incorporation by 
reference, Safety.

Adoption of the Amendment

    Accordingly, pursuant to the authority delegated to me by the 
Administrator, the Federal Aviation Administration amends part 39 of 
the Federal Aviation Regulations (14 CFR part 39) as follows:

PART 39--AIRWORTHINESS DIRECTIVES

    1. The authority citation for part 39 continues to read as follows:

    Authority: 49 USC 106(g), 40113, 44701.


Sec. 39.13  [Amended]

    2. Section 39.13 is amended by adding the following new 
airworthiness directive:

96-18-14 Hartzell Propeller Inc.: Amendment 39-9738. Docket 95-ANE-
30.

    Applicability: Hartzell Propeller Inc. (Hartzell) Models HC-
A3VF-7( ), HC-B3TF-7( ), HC-B3MN-3( ), HC-B3TN-2( ), HC-B3TN-3( ), 
HC-B3TN-5 ( ), HC-B4MN-5( ), HC-B4MP-3( ), HC-B4TN-3( ), HC-B4TN-5( 
), HC-B5MA-3( ), HC-B5MP-3( ), HC-B5MP-5( ), HC-B3MN-5( ), HC-B3TN-
4( ), HC-B4MP-4( ), and HC-B5MN-3( ) propellers. These propellers 
are installed on but not limited to the following aircraft:

Aerospace Technologies of Australia PTY LTD N22B, N24A, N22S;
Air Tractor, Inc. AT-301, AT-302, AT-400, AT-400A, AT-401, AT-402, 
AT-502, AT-503, AT-802;
Agusta S.p.A. SF600, F.260;
Ayres Corporation S-2R, S2R-T11, S2R-T15, S2R-T34, S2R-T56, S2RHG-
T65;
Beech A36, 65-90, 65-90A, C90, B90, E90, C90A, F90, 100, 200, 200C, 
A200C, B200, B200C, 200T, 200CT, A200CT, B200T, B200CT, 65-80, 65-
A90-1, 65-A90-2, 65-A90-4, 99, 99A, A99A, B99, A200, C99, H90, 300, 
300LW, B300, B300C, 1900, 1900C, T34C, T34C-1;
Cessna 208, 208A, 208B, 421, 425, 441, 402, P210N;
Construcciones Aeronauticas, S.A. (CASA) C-212-CB, -CC, -CE, -CF;
deHavilland Aircraft Co., Ltd. D.H.114;
deHavilland Inc. DHC-2, DHC-3, DHC-4; DHC-6, 1, 100, 200, 300;
Empresa Brasileira de Aeronautica S/A Embraer EMB-110P1, EMB-110P2;
Fairchild Aircraft, Inc. SA26-AT, -T; SA226-AT, -TB;
Frakes Aviation (Gulfstream American ) G-73;
Great Lakes Aircraft Co. 2T-1A;
Helio HST-550, HST-550A;
Industrie Aeronautiche e Meccaniche Piaggio P.166DL3;
Israel Aircraft Industries, Ltd. Arava 101, 101B;
McDonnell Douglas DC-3 series;
McKinnon Enterprises, Inc. (Grumman) G-21E, G21-G;
Mitsubishi MU-2B series;
Pacific Aerospace Corporation, Ltd. FU24-954, FU2A-954;
Partenavia Costruzioni Aeronautiche S.p.A. AP68TP 300, AP68TP 600;
Pilatus Aircraft Ltd. PC-6/A-H2, /B1-H2, /B-H2, /B2-H2, /B2-H4, PC-
7;
Piper Aircraft Corporation PA31-T1, -T2, -T3; PA31P; PA42, -42-720, 
-42-720R;
Prop-Jets, Inc., Interceptor (Aero Commander) (Meyers) 400;
Schweizer Aircraft Corp. (Grumman) G-164A, G-164B, G-164B-34T, -15T, 
G-164D;
Short Bros. Limited & Harland Ltd. SC-7 series, SD3 series;
Twin Commander Aircraft Corp. 680T, V, 681, 690A, 690B, 690C, 695, 
695A;
Weatherly Aviation Company 620TP.

    Note 1: The parenthesis that appear in the propeller models 
indicate the presence or absence of additional letter(s) which vary 
the basic propeller hub model designation. This airworthiness 
directive (AD) is applicable regardless of whether these letters are 
present or absent on the propeller hub model designation.
    Note 2: The above is not a complete list of aircraft which may 
contain the affected Hartzell Propeller Inc. Models HC-A3VF-7( ), 
HC-B3TF-7( ), HC-B3MN-3( ), HC-B3TN-2( ), HC-B3TN-3( ), HC-B3TN-5( 
), HC-B4MN-5( ), HC-B4MP-3( ), HC-B4TN-3( ), HC-B4TN-5( ), HC-B5MA-
3( ), HC-B5MP-3( ), HC-B5MP-5( ), HC-B3MN-5( ), HC-B3TN-4( ), HC-
B4MP-4( ), and HC-B5MN-3( ) propellers because of installation 
approvals made by, for example, Supplemental Type Certificate or 
field approval under FAA Form 337 ``Major Repair and Alteration.'' 
It is the responsibility of the owner, operator, and person 
returning the aircraft to service to determine if an aircraft has an 
affected propeller.
    Note 3: This AD applies to each propeller identified in the 
preceding applicability provision, regardless of whether it has been 
modified, altered, or repaired in the area subject to the 
requirements of this AD. For propellers that have been modified, 
altered, or repaired so that the performance of the requirements of 
this AD is affected, the owner/operator must use the authority 
provided in paragraph (h) to request approval from the Federal 
Aviation Administration (FAA). This approval may address either no 
action, if the current configuration eliminates the unsafe 
condition, or different actions necessary to address the unsafe 
condition

[[Page 47811]]

described in this AD. Such a request should include an assessment of 
the effect of the changed configuration on the unsafe condition 
addressed by this AD. In no case does the presence of any 
modification, alteration, or repair remove any propeller from the 
applicability of this AD.
    Compliance: Required as indicated, unless accomplished 
previously.
    To prevent propeller hub, blade, or blade clamp failure, which 
can result in loss of aircraft control, accomplish the following:
    (a) This AD requires no action for operators with Hartzell 
propeller models HC-B4TN-5(D,G,J)L/LT10282(B,K)-5.3R, HC-B4TN-
5(D,G,J)L/LT10282N(B,K)-5.3R, and HC-B4TN-5(D,G,J)L/LT10282NS(B,K)-
5.3R installed on Mitsubishi MU-2B-26A, -36A, -40, -60; MU-2B-30 
modified by Supplemental Type Certificate (STC) SA336GL-D & SA339GL-
D; MU-2B-36 Modified by STC SA2413SW and any other MU-2 Series 
aircraft which have the referenced propeller models installed. These 
operators must, however, comply with AD 95-01-02.
    (b) This AD requires no action for operators with Hartzell 
propeller models HC-B4TN-3/T10173F(N)(B,K)-12.5 and HC-B4TN-3A/
T10173F(N)(B,K)-12.5 installed on Beech A100 and A100A aircraft. 
These operators must, however, comply with AD 95-03-03.
    (c) Disassemble the propeller in accordance with Hartzell 
Propeller Inc. Service Manual 118F, Revision 2, dated May 1992, 
pages 15 to 19, for 3- and 4-bladed hub models, and Service Manual 
132A, Revision 2, dated June 1992, pages IV-5 to IV-11, for 5-bladed 
hub models, remove the hub from service, and replace the hub with a 
serviceable hub in accordance with the compliance schedule in Table 
1 of this AD.
    (1) Utilize Table 1 of this AD in accordance with the following 
example: Model HC-B3TN-3( ) series propellers, starting with serial 
numbers (S/N's) BU1 through BU377, require replacement before the 
end of March of calendar year 1997. Serial numbers BU378 through 
BU754 require hub replacement before the end of September of 
calendar year 1997, and so forth.
    (2) The affected hubs can only be replaced with serviceable hubs 
having a S/N not listed in Table 1 of this AD for that propeller 
model, or serviceable hubs having a S/N for which replacement is not 
yet required in accordance with Table 1 of this AD.
    (3) Some existing propeller hub S/N's include a suffix letter, 
such as an ``A.'' The presence or absence of this letter has no 
significance in determining compliance.
    (4) Since a hub may be used in various propeller models, the S/N 
and the model number shown in Table 1 of this AD may not coincide. 
Precedence is given to the hub S/N in determining compliance 
requirements. The hub model is only given as a reference.
    (5) Hub replacement must be accomplished by the end of the 
calendar month indicated at the top of the appropriate column in 
Table 1 of this AD. The S/N ranges in this table identify the 
propeller hubs that require replacement by the end of that month.

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[[Page 47812]]

Table 1
[GRAPHIC] [TIFF OMITTED] TR11SE96.002

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[[Page 47813]]

    (d) Perform a fluorescent penetrant inspection of blades for 
cracks in accordance with Hartzell Propeller Inc. Service Bulletin 
136H, dated March 12, 1993, prior to installing a serviceable hub.
    (e) Perform magnetic particle inspection of blade clamps for 
cracks in accordance with Hartzell Service Manual 202A, dated March 
1993, pages 201 to 215, prior to installing a serviceable hub.
    (f) If cracks are found in either the blade or the blade clamps, 
prior to further flight replace with serviceable blade or blade 
clamps.
    (g) Reassemble the propeller in accordance with Hartzell 
Propeller Inc. Service Manual 118F, Revision 2, dated May 1992, 
pages 57 to 96, for 3- and 4-bladed hub models, and Service Manual 
132A, Revision 2, dated June 1992, pages VII-1 to VII-46, for 5-
blade hub models.
    (h) An alternative method of compliance or adjustment of the 
compliance time that provides an acceptable level of safety may be 
used if approved by the Manager, Chicago Aircraft Certification 
Office. The request should be forwarded through an appropriate FAA 
Principal Maintenance Inspector, who may add comments and then send 
it to the Manager, Chicago Aircraft Certification Office.

    Note: Information concerning the existence of approved 
alternative methods of compliance with this airworthiness directive, 
if any, may be obtained from the Chicago Aircraft Certification 
Office.

    (i) Special flight permits may be issued in accordance with 
sections 21.197 and 21.199 of the Federal Aviation Regulations (14 
CFR 21.197 and 21.199) to operate the aircraft to a location where 
the requirements of this AD can be accomplished.
    (j) The actions required by this AD shall be done in accordance 
with the following service documents:

----------------------------------------------------------------------------------------------------------------
              Document No.                             Pages                                Date                
----------------------------------------------------------------------------------------------------------------
Hartzell Propeller Inc., SB No. 136H...  1-18                               March 12, 1993.                     
Total Pages: 18.                                                                                                
Hartzell Propeller Inc., Service Manual  201-215                            March 1993.                         
 No. 202A.                                                                                                      
Total Pages: 15.                                                                                                
TRW Hartzell Propeller Overhaul Manual,  57, 58                             April 1985.                         
 No. 118-E.                                                                                                     
Hartzell Propeller Inc., Manual No.      59, 60                             May 1992.                           
 118F, Revision 2.                                                                                              
TRW Hartzell Propeller Overhaul Manual   61-83                              April 1985.                         
 No. 119-E.                                                                                                     
Hartzell Propeller Inc., Manual No.      84, 84a, 84b                       May 1992.                           
 118F, Revision 2.                                                                                              
TRW Hartzell Propeller Overhaul Manual   85, 86                             April 1985.                         
 No. 118-E.                                                                                                     
Hartzell Propeller Inc., Manual No.      87, 88, 88a, 88b                   April 1985, May 1992.               
 118F, Revision 2.                                                                                              
TRW Hartzell Propeller, Overhaul Manual  89-96                              April 1985.                         
 No. 118-E.                                                                                                     
Total Pages: 44.                                                                                                
Hartzell Propeller, Products Division,   VII-1-VII-30                       Sept. 1, 1985.                      
 Instruction Manual No. 132-A.                                                                                  
Hartzell Propeller Inc., Instruction     VII-31                             Sept. 1, 1985.                      
 Manual No. 132-A.                                                                                              
Hartzell Propeller Inc., Manual No.      VII-32                             No Date.                            
 132A.                                                                                                          
Hartzell Propeller, Products Division,   VII-33-VII-40                      Sept. 1, 1985.                      
 Instruction Manual No. 132-A.                                                                                  
Hartzell Propeller Inc., Instruction     VII-41                             Sept. 1, 1985.                      
 Manual No. 132-A.                                                                                              
Hartzell Propeller Inc., Manual No.      VII-42, VII-43                     April 1990.                         
 132A, Revision #1.                                                                                             
Hartzell Propeller Inc., Instruction     VII-44                             Sept. 1, 1985.                      
 Manual No. 132-A.                                                                                              
Hartzell Propeller Inc., Manual No.      VII-45, VII-46                     April 1990.                         
 132A, Revision #1.                                                                                             
Total Pages: 46........................                                                                         
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    This incorporation by reference was approved by the Director of 
the Federal Register in accordance with 5 U.S.C. 552(a) and 1 CFR 
part 51. Copies may be obtained from Hartzell Propeller Inc., One 
Propeller Place, Piqua, OH 45356-2634, ATTN: Product Support; 
telephone (513) 778-4388, fax (513) 778-4321. Copies may be 
inspected at the FAA, New England Region, Office of the Assistant 
Chief Counsel, 12 New England Executive Park, Burlington, MA; or at 
the Office of the Federal Register, 800 North Capitol Street NW., 
suite 700, Washington, DC.
    (k) This amendment becomes effective on October 16, 1996.

    Issued in Burlington, Massachusetts, on August 26, 1996.
Jay J. Pardee,
Manager, Engine and Propeller Directorate, Aircraft Certification 
Service.
[FR Doc. 96-22770 Filed 9-10-96; 8:45 am]
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