ALERT SERVICE

BULLETIN
October 6, 2008 ASB255A

TITLE

JETSTREAM 4100/4101 BLADE LIFE LIMITS AND ADDED BLADE INSPECTIONS

TO:

FAA-Approved Propeller Repair Stations, Aircraft Manufacturers, Owners, and Operators

MODELS AFFECTED

B5JFR36C1101/114GCA-0, C5JFR36C1102/L114GCA-0, B5JFR36C1103/114HCA-0 and

C5JFR36C1104/L114HCA-0

AIRCRAFT AFFECTED

BAE Jetstream 4100/4101 Series

PUBLICATIONS AFFECTED

SB137[X]
ASB246C
ASB252
C1100 Series Overhaul Manual - MPC1100
Component Maintenance Manual C1101 - 1104 Series, CMM1100

REASON FOR REVISION

• All 114GCA-0, L114GCA-0, 114HCA-0, and L114HCA-0 propeller blades are now life limited to 3,500
hours total time in service.
• Revise the Compliance, Inspection Requirement statement.
• Remove the Repetitive Inspection Requirements statement.
• Require the removal from service of the propeller hub and all propeller blades in the propeller assembly in
the event that any blade in the propeller assembly is rejected as a result of a crack that is detected during
the accomplishment of this inspection.
• Added an inspection for a step condition in the blade shank area.
• Require the installation of a new part number C-7870 Split Retainer for each propeller blade. These
split retainers incorporate an improved finish to provide a better contact surface between the propeller
retention area and the retainer. The new retainers must be installed in a specific "clocked" position
when the propeller blades are installed.

Original Issue: January 8, 2007 Page 1 of 14

TO OBTAIN SATISFACTORY RESULTS, PROCEDURES SPECIFIED IN THIS SERVICE INFORMATION MUST BE ACCOMPLISHED IN
ACCORDANCE WITH ACCEPTED METHODS AND PREVAILING GOVERNMENT REGULATIONS. MCCAULEY PROPELLER SYSTEMS
CANNOT BE RESPONSIBLE FOR THE QUALITY OF WORK PERFORMED IN ACCOMPLISHING THIS SERVICE INFORMATION.
McCauley Propeller Systems
PO Box 7704
Wichita, Kansas 67277-7704
COPYRIGHT © 2007 McCauley Propeller Systems
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REASON

McCauley has received additional reports of blade cracks on its C1100 series propellers that are installed on
BAE Jetstream 4100/4101 aircraft. The cracks were all found in the blade retention groove near the "ledge"
where the split retainers seat, on or near the shot peened surface. The blade cracks are caused by operation
in the restricted and placarded regions. These restrictions may be found in the aircraft Type Certificate Data
Sheet.

DESCRIPTION

Alert Service Bulletin 255A establishes instructions for expanded fluorescent dye penetrant inspection and
eddy current inspections and establishes new life limits for the propeller blades. This Service Bulletin also
retires ASB252, ASB246C, and the original issue of ASB255.

COMPLIANCE

MANDATORY. All inspection and replacement requirements must be accomplished at the compliance times
and intervals listed below.
1. Blade Life Limit Change:
A. All 114GCA-0, L114GCA-0, 114HCA-0, and L114HCA-0 propeller blades with less than 3,000
hours Total Time In Service (TTIS) must be retired and removed from service upon reaching 3,500
hours TTIS.
B. All 114GCA-0, L114GCA-0, 114HCA-0, and L114HCA-0 propeller blades with more than 3,000 hours
TTIS must be retired and removed from service within the next 500 hours Time In Service (TIS).
2. Inspection Requirements:
A. For propeller blades with less than 2,400 hours TTIS:
(1) Inspect propeller blades upon reaching 2,500 hours TTIS.
B. For propeller blades with more than 2,400 hours TTIS:
(1) If the propeller blades have been inspected in accordance with McCauley Alert Service Bulletin
ASB255 within the past 2,400 hours TIS:
(a) Inspect the propeller blades upon reaching 2,500 hours TIS since last inspection.
(2) If the propeller blades have not been inspected in accordance with McCauley Alert Service
Bulletin ASB255 within the past 2,400 hours TIS:
(a) Inspect the propeller blades within the next 100 hours TIS.
NOTE: In the event that any blade in the propeller assembly is rejected as a result of a crack that is
detected during the accomplishment of this inspection, all propeller blades in the propeller
assembly and the propeller hub must be retired and removed from service.

APPROVAL

FAA approval has been obtained on technical data in this publication that affects product type design.

REFERENCES

McCauley Component Maintenance Manual C1101 - 1104 Series, CMM1100

McCauley C1100 Series Overhaul Manual, MPC1100
McCauley Blade Overhaul Manual, BOM100
McCauley Standard Practices Manual, SPM100
BAE Systems Jetstream 4100/4101 Aircraft Maintenance Manual

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EQUIPMENT REQUIRED

NOTE: Equivalent substitutes may be used for the listed equipment

NAME NUMBER MANUFACTURER USE

Penetrant Type I, Level 3 Magnaflux Penetrant inspection
Sensitivity 3624 West Lake Avenue
Glenview, IL 60026
www.magnaflux.com
Radiometer DSE 2000A Spectronics Corp. Measure light intensity
956 Brush Hollow Rd.
Westbury, NY 11590
http://www.spectroline.com
Blacklight ZB-100F Magnaflux To do penetrant
inspection
Eddy Current Unit NDT-19E Staveley Corp. To inspect blade shank
with X-Y Storage 421 N. Quay
Oscilloscope Kennewick, WA 98444
Surface Pencil MP905-50 NDT Engineering Corporation To inspect blade shank
Probe 1/8 inch 19620 Russell Road
diameter capable Kent, WA 98032
of operating at 200 Email: [email protected]
kHz
Aluminum SRS-0812A NDT Engineering Corporation To test system
Reference calibration.
Standard Note

NOTE: Any reference standard that has an 0.020 inch deep EDM notch. The dimensional accuracy of EDM
notches shall be documented and traceable to the National Institute of Standards and Technology
(NIST) or international equivalent.

1. Additional Eddy Current Instrument Requirements

A. The instrument shall demonstrate a repeatable signal response that has a signal-to-noise ratio of
greater than 3 to 1 for this inspection.

B. Functional performance of the eddy current instrumentation shall be verified at an interval of no

more than one year.

2. Probe Requirements

A. The probe may have an absolute or differential coil arrangement.

(1) The probe may be shielded or unshielded.

(2) A shielded probe is recommended.

B. The probe shall be capable of operating at a frequency of 200 kHz.

C. A coil diameter of 1/8 inch is normally used for surface crack detection.

(1) A ferrite core in the coil is recommended.

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MATERIAL INFORMATION

NOTE: The following parts are required to reassemble the propeller after the inspection in this service bulletin
is performed. These parts cover installation for one propeller.

NEW P/N QUANTITY KEY WORD OLD P/N INSTRUCTIONS/

DISPOSITION
A-1633-55 3 O-ring, piston rod to piston; Same Discard
piston rod to support plate;
piston rod to rear hub
bushing
A-1633-56 5 Blade O-ring Same Discard
A-1633-57 1 Beta tube to piston rod. Same Discard
O-ring
A-1633-98 1 Mounting O-ring Same Discard
A-1633-99 5 Blade Plug O-ring Same Discard
A-1633-108 1 Support plate to cylinder Same Discard
O-ring
A-1633-112 1 Hub to support plate O-ring Same Discard
A-1633-122 1 Piston to cylinder O-ring Same Discard
A-1635-117 3 Piston index plate screw Same Discard
A-1635-119 4 Spring housing attachment Same Discard
screw
A-1635-141 4 Support plate to hub screw Same Discard
A-1635-142 14 Cylinder attachment screw Same Discard
A-1635-160 20 Actuating pin screw (short) Same Discard
A-1635-161 10 Actuating pin screw (long) Same Discard
A-1636-39 5 Retaining ring, actuating Same Discard
pin to link
A-1639-4 5 Link assembly to piston rod Same Discard
nut
A-1639-32 12 Mounting nut Same Discard

A-1750-6 2 Dynaseal, oil fill Same Discard

C-7870 5 Retainer - Split C-5963 Discard

ACCOMPLISHMENT INSTRUCTIONS
NOTE: Read all instructions thoroughly prior to performing work in accordance with this service bulletin.

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1. Lighting Equipment/Environment
A. The penetrant inspection must be done in a darkened environment where the ambient white light
intensity does not exceed 2 fc (foot candles). In order for Type I penetrant materials to fluoresce,
they must be exposed to ultraviolet light with a wavelength of 320 to 380 nanometers.
WARNING: PERSONNEL MUST NOT WEAR LIGHT SENSITIVE
(PHOTOCHROMIC) LENSES DURING THE INTERPRETATION/
EVALUATION OF PARTS.
(1) The black light must produce a minimum light intensity of 1200 µW/cm2 at the part surface
or 1000 µW/cm2 at a distance of 15 inches. Let the black light warm up for a minimum of 10
minutes before use.
(2) Both the ultraviolet light and ambient light intensities must be measured with a calibrated
light meter before each inspection.
NOTE: It is recommended that the inspector allow 3 minutes for the eyes to adapt to the dark
before the interpretation/evaluation of parts.

2. Blade Disassembly
A. Remove propeller from the airplane. (Refer to BAE Systems Jetstream 4100/4101 Aircraft
Maintenance Manual.)
B. Remove the propeller blades from the propeller assembly. (Refer to McCauley C1100 Series
Overhaul Manual, MPC1100, Disassembly.)
CAUTION: DO NOT CLEAN WITH A STEEL BRUSH, OTHER METAL BRUSH, HARD BRISTLE
BRUSH, SCOTCHBRITE PADS, OR TOOL OF ANY TYPE NOT SPECIFIED.
CAUTION: DO NOT USE PLASTIC MEDIA BLAST TO CLEAN.
CAUTION: YOU MUST NEVER SMOOTH THE SHOT PEENED AREA OF THE BLADE SHANK
WITH ANY ABRASIVE.
C. Remove and discard part number C-5963 Split Retainers.
D. Remove thick or packed-on grease or dirt with a soft brush.
E. Clean the blade shank with a cloth dampened with methyl propyl ketone or acetone.
NOTE: It is critical that all turbine oil be removed from the blade shank in the inspection area
shown in Figure 3.

NOTE: Do not polish the area indicated on Figure 3 until all inspections have been completed
and no cracks have been found.

(1) When you think all dirt and oil has been removed, use a clean cloth dampened with methyl
propyl ketone or acetone to carefully wipe the area to be inspected.
(2) Immediately wipe the cleaned surface with a clean dry cloth.
(3) If there is any stain transferred to the drying cloth, repeat the cleaning and wiping procedure
until there is no stain on the dry cloth.
F. Do the Fluorescent Dye Penetrant Inspection on all blades.
3. Blade Fluorescent Dye Penetrant Inspection
A. Personnel must be certified to a minimum of Level II per the recommended requirements of National
Aerospace Standard’s NAS 410, ASNT’s SNT-TC-1A, or equivalent national/international standard.
B. Inspection is performed in accordance with standard ASTM E 1417, Standard Practice for Liquid
Penetrant Examination, or international equivalent, except for dwell time.

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C. Material and Equipment used to perform inspection are in accordance with QPL-AMS-2644-1,
Qualified Products of Inspection Material, Penetrant, or international equivalent.
CAUTION: ALL MATERIALS USED IN A PROCESS MUST BE FROM THE SAME FAMILY
GROUP.
D. Penetrants used must be Type I, Fluorescent dye, Level 3 sensitivity - high. Recommended
processes are:
Type I, Level 3 Sensitivity, Method A, Form C or D
Type I, Level 3 Sensitivity, Method C, Form D
Type I, Level 3 Sensitivity, Method D, Form C or D
CAUTION: DO NOT ETCH THE BLADE SHANK PRIOR TO INSPECTION
CAUTION: THE USE OF VISIBLE DYE PENETRANT ON MCCAULEY PROPELLER
COMPONENTS IS FORBIDDEN.
E. (Refer to Figure 3.) Fluorescent dye penetrant inspect the indicated areas of the blade shank area.
Pay careful attention to blade retention area. (Refer to McCauley Standard Practices Manual,
SPM100, 60-00-03, Fluorescent Dye Penetrant Examination.)
NOTE: There is a high definition color photograph (Figure 2 is a low resolution black and white
version of the photograph) of a blade with very small crack indications on the McCauley
website. http://www.mccauley.textron.com/pro-sup/J41.html. The photo contained in this
Service Bulletin is of poor quality because it was made under black light and has very low
contrast.
NOTE: The website photo has dark lines that circle the crack indications. These are marks that
were placed on the blade after the crack indications were located. The bright lines are
the fluorescent crack indications.
(1) It is not necessary to strip paint from the blade to do this fluorescent dye penetrant check.
(2) The standard dwell time and viewing conditions specifics of ASTM E 1417 are modified as
follows:
(a) The fluorescent dye penetrant dwell time must be a minimum of 45 minutes.
(b) Examine the inspection area under black light with a 10x minimum magnifier to make
sure that any small crack indications are detected.
F. If a crack is confirmed on a blade by the fluorescent dye penetrant inspection, make the appropriate
notation on the reporting form. Prepare the blade for shipment to McCauley.
NOTE: In the event that any blade in the propeller assembly is rejected as a result of a crack that is
detected during the accomplishment of this inspection, all propeller blades in the propeller
assembly and the propeller hub must be retired and removed from service.
G. If no cracks are found by the fluorescent dye penetrant check, clean and prepare the blade for the
Surface Eddy Current Inspection. Refer to the Surface Eddy Current Inspection procedure for
specific requirements.
H. Do the Surface Eddy Current Inspection on all blades which passed the Fluorescent Dye Penetrant
Inspection.
4. Surface Eddy Current Inspection
A. Personnel must be certified to a minimum of Level II per the recommended requirements of National
Aerospace Standard’s NAS 410, ASNT’s SNT-TC-1A, or equivalent national/international standard.
B. Apply a layer of Teflon tape to the probe tip to prevent the probe from scratching the blade.
NOTE: Tape must be applied before you calibrate the probe.

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C. (Refer to Figure 4) Adjust the instrument to achieve a signal-to-noise ratio of greater than 3 to 1
between the null/balance point on the reference standard and the 0.020 inch deep EDM notch.
D. Carefully examine the area defined in Figure 3 sheet 1.
NOTE: The entire circumference of the blade shank in indicated inspection area must be inspected.
(1) Scan the inspection area at index increments with 50 percent overlap of each pass of the
width of the eddy current probe coil.
(2) The part edge can be scanned if the response from edge effect does not mask the calibration
notch response.
(a) Areas where edge effect is greater than the calibration notch signal shall not be inspected
using eddy current.
(3) Whenever possible, a fillet or radius should be scanned both transverse and parallel to the
axis of the radius.
WARNING: THE OTHER COMPONENTS IN A PROPELLER ASSEMBLY WITH
A SUSPECT BLADE MAY NOT BE RETURNED TO SERVICE
UNTIL RELEASE AUTHORIZATION IS GRANTED BY MCCAULEY
PRODUCT SUPPORT OR ENGINEERING.
E. Report ALL findings (even no cracks found) to McCauley on the Reporting Form in this service
bulletin.
NOTE: In the event that any blade in the propeller assembly is rejected as a result of a crack that is
detected during the accomplishment of this inspection, all propeller blades in the propeller
assembly and the propeller hub must be retired and removed from service.
F. Life Limit Stamping
(1) Examine the stamping on the blade butt of blades with no crack indications.
(a) Make sure the letter L is impression stamped under the TC number on the blade butt.
(2) If the stamping is not present, use a round bottom steel stamp to correctly stamp the blades
similar to the following example.

Example of Life Limit Stamping Blade

T.C. P15NE
L

G. Do the Visual Inspection For Step Condition on all blades which passed the Surface Eddy Current
Inspection.
5. Visual Inspection For Step Condition
A. (Refer to Figure 1.) Examine the propeller blade shank in the blade retention area for a "Step" type
feature in the "B" to "C" region as defined in Figure 1. If a step of 0.005 inch (0.13 mm) or greater is
present, the blade must be removed from service and retired.
NOTE: In the event that any blade in the propeller assembly is rejected as a result of a step being
detected during the accomplishment of this inspection, replacement of the other propeller
blades in the propeller assembly and the propeller hub is not required.
B. If a step of 0.005 inch (0.13 mm) or greater is confirmed in the propeller blade retention area, make
the appropriate notation on the reporting form.
C. If no step of 0.005 inch (0.13 mm) or greater is found, clean and prepare the propeller blade for
reassembly. Blades with less than 0.005 inch (0.13 mm) step indications may be reinstalled in
the propeller assembly and returned to service.

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6. Propeller Assembly
A. Propeller blades may be reinstalled in the propeller assembly and returned to service, if no step
indications of 0.005 inch (0.13 mm) or greater was found and no propeller blades within the propeller
assembly exhibited any crack indications.
(1) Reassemble the propeller. (Refer to McCauley C1100 Series Overhaul Manual MPC1100,
Assembly.) The following are changes to the assembly instructions currently provided in the
McCauley C1100 Series Overhaul Manual:
NOTE: All parts to be assembled must be kept clean, during the propeller assembly process,
parts that are observed to have dirt, grit or other foreign material must be removed and
cleaned again in accordance with the SPM100, Standard Practices Manual, Section
60-00-01, Cleaning Procedures.

(a) Blade Assembly

1 Before the propeller blade is assembled, liberally lubricate area of blade shank and
hub socket, blade O-ring and groove, shims, shim carrier, retaining ring, and split
retainer with Orelube (A-1637-4) lubricant.
CAUTION: DURING THE ASSEMBLY OF EACH PROPELLER BLADE, DO NOT
MAR OR SCRATCH THE PROPELLER BLADE SHANK, O-RING, OR
HUB SOCKET. DO NOT COAT BLADE BUTT END WITH LUBRICANT.
REMOVE EXCESS LUBRICANT AFTER THE SHIMMING OPERATION.
(b) Blade Installation
CAUTION: IT IS VERY IMPORTANT THAT ONLY PART NUMBER C-7870
SPLIT RETAINER HALVES WITH MATCHING SERIAL NUMBERS
ARE USED TO ASSEMBLE EACH PROPELLER BLADE.
1 Prior to lowering the propeller blade and the C-7870 split retainer halves engaging
the bearing inner race, locate the split retainer ends such that they are clocked 90
degrees +10 or -10 degrees from the counterweight hole when they are installed in
the hub and fully seated on the blade shank.
B. Reinstall propeller assembly on airplane. (Refer to BAE Systems Jetstream 4100/4101 Aircraft
Maintenance Manual.)
C. Make propeller logbook entry stating: "Compliance with ASB255A", Fluorescent Dye Penetrant
and Eddy Current Inspection.
7. Findings
A. All findings must be reported back to McCauley on the reporting form attached to this Service Bulletin.

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REPORTING FORM FOR SERVICE BULLETIN 255A
This form must be completed following all dye-penetrant and eddy current inspections of blades required
for compliance with this service bulletin.
NOTE: Information requested on this form is vital. Regardless of findings, this form must be completed and
returned to McCauley following dye-penentrant and eddy current inspections.
This completed form must be either mailed or faxed to McCauley at the following:
McCauley Propeller Systems
PO Box 7704
Wichita, KS 67277-7704
U.S.A
Phone: 316-831-4021
Fax: 316-831-3858
Section 1 - Operator/Propeller Information
Aircraft Operator:
Aircraft Operator Primary Contact Person:
Telephone:
Aircraft N-number:
Aircraft S/N:
Date of Compliance with "A" version of ASB255A:
Propeller S/N:
Propeller Total
Time:
Propeller T.S.O:

Propeller Model Number:

Blade Model Number:
Section 2 - Blade Inspection Findings
Facility that did the inspection
Telephone number of inspection facility

Total Time Since

New: 0.005 Inch or
(Blade Total Time, Blade Total Time Since Greater Step
Blade: NOT Hub/Propeller) Overhaul: Crack Found: Found:
#1 S/N: Y/N Y/N
#2 S/N: Y/N Y/N
#3 S/N: Y/N Y/N
#4 S/N: Y/N Y/N
#5 S/N: Y/N Y/N
Submit photographs, preferably digital, of any crack indictions and tell McCauley how
the cracks were found or confirmed. For example visual, penetrant or eddy current.

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Figure 1. Step Inspection on Propeller Blade Retention Area (Sheet 1)

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Figure 2. 4100/4101 Propeller Blade With Crack Indications Under Black Light (Sheet 1)

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Figure 3. Blade Retention Inspection Area (Sheet 1)

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Figure 3. Blade Retention Inspection Area (Sheet 2)

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Figure 4. Calibration of Eddy Current Crack Detection (Sheet 1)

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