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Hartzell Bantam 3A2 Series Overhaul Manual

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Manual No. 402
61-10-02
Original
June 2024
3A2 Series
Overhaul Manual
"Bantam" Models with Composite Blades
3A2-( )( )( )
Hartzell Propeller LLC
One Propeller Place
Piqua, Ohio 45356-2634 U.S.A.
Phone: 937.778.4200
Fax: 937.778.4215

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  • Page 1 Manual No. 402 61-10-02 Original June 2024 3A2 Series Overhaul Manual "Bantam" Models with Composite Blades 3A2-( )( )( ) Hartzell Propeller LLC One Propeller Place Piqua, Ohio 45356-2634 U.S.A. Phone: 937.778.4200 Fax: 937.778.4215...
  • Page 2 HARTZELL PROPELLER OVERHAUL MANUAL © 2024 - Hartzell Propeller LLC - All rights reserved 61-10-02 Inside Cover COVER Jun/24...
  • Page 3 HARTZELL PROPELLER OVERHAUL MANUAL REVISION HIGHLIGHTS • Original issue, manual issued in its entirety 61-10-02 Page 1 REVISION HIGHLIGHTS Jun/24...
  • Page 4 HARTZELL PROPELLER OVERHAUL MANUAL REVISION 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.
  • Page 5 HARTZELL PROPELLER OVERHAUL MANUAL RECORD OF REVISIONS This is a record of revisions inserted into this manual. Revision Number Issue Date Date Inserted Inserted By Jun/24 Hartzell Orig Jun/24 61-10-02 Page 1 RECORD OF REVISIONS Jun/24...
  • Page 6 HARTZELL PROPELLER OVERHAUL MANUAL (This page is intentionally blank.) 61-10-02 Page 2 RECORD OF REVISIONS Jun/24...
  • Page 7 HARTZELL PROPELLER OVERHAUL MANUAL 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 Removed 61-10-02 Page 1 RECORD OF TEMPORARY REVISIONS...
  • Page 8 HARTZELL PROPELLER OVERHAUL MANUAL 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 Removed 61-10-02 Page 2 RECORD OF TEMPORARY REVISIONS...
  • Page 9 HARTZELL PROPELLER OVERHAUL MANUAL SERVICE DOCUMENT LIST CAUTION 1: DO NOT USE OBSOLETE OR OUTDATED INFORMATION.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.
  • Page 10 HARTZELL PROPELLER OVERHAUL MANUAL SERVICE DOCUMENT LIST Service Document Incorporation Service Document Incorporation Number Rev./Date Number Rev./Date 61-10-02 Page 2 SERVICE DOCUMENT LIST Jun/24...
  • Page 11 AIRWORTHINESS LIMITATIONS 1. Airworthiness Limitations A. Life Limits (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) For airworthiness limitations information, refer to Hartzell Propeller Owner's Manual 411. 61-10-02 Page 1 AIRWORTHINESS LIMITATIONS Jun/24...
  • Page 12 HARTZELL PROPELLER OVERHAUL MANUAL (This page is intentionally blank.) 61-10-02 Page 2 AIRWORTHINESS LIMITATIONS Jun/24...
  • Page 13 HARTZELL PROPELLER OVERHAUL MANUAL LIST OF EFFECTIVE PAGES Chapter Page Rev. Level Date Cover Cover and Inside Cover Orig. Jun/24 Revision Highlights 1 and 2 Orig. Jun/24 Record of Revisions 1 and 2 Orig. Jun/24 Record of Temporary Revisions 1 and 2 Orig.
  • Page 14 HARTZELL PROPELLER OVERHAUL MANUAL (This page is intentionally blank.) 61-10-02 Page 2 LIST OF EFFECTIVE PAGES Jun/24...
  • Page 15 HARTZELL PROPELLER OVERHAUL MANUAL 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 ........................
  • Page 16 HARTZELL PROPELLER OVERHAUL MANUAL (This page is intentionally blank.) 61-10-02 Page 2 TABLE OF CONTENTS Jun/24...

  • Page 17: Table Of Contents

    9. Propeller Critical Parts ....................11 A. Propeller Critical Parts..................11 10. Warranty Service ......................11 A. Warranty Claims ....................11 11. Hartzell Propeller Contact Information ..............12 A. Product Support Department................12 B. Technical Publications Department ..............12 C. Recommended Facilities ..................12 12.
  • Page 18 HARTZELL PROPELLER OVERHAUL MANUAL LIST OF FIGURES "Video" Icon/QR Code ..............Figure 1 .....13 61-10-02 Page 2 INTRODUCTION Jun/24...

  • Page 19: General

    Letters, Service Advisories, and Service Instructions for information that may have not yet been incorporated into the latest revision of this manual. (4) This manual makes reference to other Hartzell Propeller manuals that provide important details for procedures such as anodizing, penetrant inspection, and overhaul procedures for hub units.

  • Page 20: Item References

    HARTZELL PROPELLER OVERHAUL MANUAL B. Item References (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.

  • Page 21: Reference Publications

    Advisories, and Service Instructions for information that may have not yet been incorporated into the latest revision of this manual. (2) Some manuals are available on the Hartzell Propeller website at www.hartzellprop.com. The complete Hartzell Propeller Technical Library is available by subscription.

  • Page 22: Personnel Requirements

    (Rev. 2) A. Special Tooling (1) Special tooling may be required for procedures in this manual. For further tooling information, refer to Hartzell Propeller Illustrated Tool and Equipment Manual 165A (61-00-65). (a) Tooling reference numbers appear with the prefix “TE” directly following the tool name to which they apply. For example, a template that is reference number 133 will appear as: template TE133.

  • Page 23: Safe Handling Of Paints And Chemicals

    (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 Standard Practices Manual 202A (61-01-02). 61-10-02 Page 7 INTRODUCTION...

  • Page 24: Component Life And Overhaul

    (a) It is a regulatory requirement that a record of the Time Since New (TSN) be maintained for all life limited parts. (b) Refer to the Airworthiness Limitations chapter in the applicable Hartzell Propeller Owner's Manual for a list of life limited components.

  • Page 25: Overhaul

    Hartzell Propeller component maintenance manual. (b) Parts that must be replaced at overhaul are identified by a "Y" in the O/H column of the Illustrated Parts List in the applicable Hartzell Propeller component maintenance manual. (4) The information in this manual supersedes data in all previously published revisions of this manual.

  • Page 26: Damage/Repair Types

    B. Minor/Major Repair (1) Minor Repair (a) Minor repair is that which may be done safely in the field by a certified aircraft mechanic. For serviceable limits and repair criteria for Hartzell propeller components, refer to the applicable Hartzell Propeller component maintenance manual. (2) Major Repair (a) Major repair cannot be done by elementary operations.

  • Page 27: Propeller Critical Parts

    (Rev. 2) A. Warranty Claims (1) If you believe you have a warranty claim, contact the Hartzell Propeller Product Support Department to request a Warranty Application form. Complete this form and return it to Hartzell Propeller Product Support for evaluation before proceeding with repair or inspection work.

  • Page 28: Hartzell Propeller Contact Information

    Hartzell propeller assemblies or components. (2) Information about the Hartzell Propeller LLC worldwide network of aftermarket distributors and approved repair facilities is available on the Hartzell website at www.hartzellprop.com. 61-10-02 Page 12...

  • Page 29: Video" Icon/Qr Code

    HARTZELL PROPELLER OVERHAUL MANUAL 12. "Video" Icon/QR Code A. Instructions for Use (1) The "Video" icon/QR code (refer to Figure 1) that appears in this manual allows you to access a video or animated demonstration of the applicable procedure. CAUTION: THESE VIDEOS/ANIMATIONS ARE INTENDED TO SUPPLEMENT THE APPLICABLE INSTRUCTIONS.

  • Page 30: Definitions

    HARTZELL PROPELLER OVERHAUL MANUAL 13. Definitions (Rev. 5) A basic understanding of the following terms will assist in maintaining and operating Hartzell propeller systems. Term Definition 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...
  • Page 31 HARTZELL PROPELLER OVERHAUL MANUAL Term Definition 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.
  • Page 32 HARTZELL PROPELLER OVERHAUL MANUAL Term Definition 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).
  • Page 33 HARTZELL PROPELLER OVERHAUL MANUAL Term Definition Distortion Alteration of the original shape or size of a component 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...
  • Page 34 HARTZELL PROPELLER OVERHAUL MANUAL Term Definition Laminate To unite composite material by using a bonding material, usually with pressure and heat 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...
  • Page 35 HARTZELL PROPELLER OVERHAUL MANUAL 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...
  • Page 36 HARTZELL PROPELLER OVERHAUL MANUAL Term Definition Station Line See "Blade Station" 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...

  • Page 37: Abbreviations

    HARTZELL PROPELLER OVERHAUL MANUAL 14. Abbreviations (Rev. 2) Abbreviation Term Airworthiness Directives Aircraft Maintenance Manual Aircraft on Ground As Required Air Transport Association Constant Speed Unit Federal Aviation Administration Flight Hour Flight Manual Flight Manual Supplement Ft-Lb Foot-Pound Human Machine Interface...
  • Page 38 HARTZELL PROPELLER OVERHAUL MANUAL Abbreviation Term Not Applicable National Aerospace Standards NASM National Aerospace Standards, Military Nondestructive Testing NIST National Institute of Standards and Technology N•m Newton-Meters Outside Diameter Optional Production Certificate Propeller Critical Part Programmable Logic Controller Plastic Media Blasting (Cleaning) Pilot’s Operating Handbook...
  • Page 39 HARTZELL PROPELLER OVERHAUL MANUAL DESCRIPTION AND OPERATION - CONTENTS 1. General ........................3 A. Propeller/Blade Model Designation ............... 3 2. Operation ........................3 A. Bantam Series Constant Speed, Feathering Propellers with Composite Blade ..3 61-10-02 Page 1 DESCRIPTION AND OPERATION...
  • Page 40 HARTZELL PROPELLER OVERHAUL MANUAL (This page intentionally left blank.) 61-10-02 Page 2 DESCRIPTION AND OPERATION Jun/24...
  • Page 41 1. General (Rev. 3) A. Propeller/Blade Model Designation (1) Hartzell Propeller LLC uses a model number designation system to identify specific propeller and blade assemblies. The propeller model number and blade model number are separated by a slash ( / ).
  • Page 42 HARTZELL PROPELLER OVERHAUL MANUAL (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, which stores a supply of oil under pressure.
  • Page 43 HARTZELL PROPELLER OVERHAUL MANUAL 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. Blades Not Tracking ................... 1-4 E. End-Play Movement of the Blade............... 1-4 F. In-and-Out Movement of the Blade ..............1-4 G. Fore-and-Aft Movement of the Blade ..............

  • Page 44: Testing And Fault Isolation - Contents

    HARTZELL PROPELLER OVERHAUL MANUAL (This page is intentionally blank.) 61-10-02 Page 1-2 TESTING AND FAULT ISOLATION Jun/24...

  • Page 45: Troubleshooting Guide

    HARTZELL PROPELLER OVERHAUL MANUAL 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 chapter is to isolate probable causes and suggest remedies for 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 Excessive friction in moving Refer to problem, "Friction" in this parts.

  • Page 46: Abnormal Propeller Vibration

    HARTZELL PROPELLER OVERHAUL MANUAL Problem Probable Cause Remedy C. Abnormal Propeller Bent, cracked, or damaged Refer to Hartzell Propeller Vibration blade. Composite Blade Overhaul Manual 135F (61-13-35). or Cracked or damaged hub. Refer to the Aluminum Hub Overhaul chapter of Hartzell Propeller Standard Practices Manual 202A (61-01-02). or Incorrect balance of the propeller. Refer to the Static and Dynamic Balance chapter of Hartzell Propeller Standard Practices Manual 202A (61-01-02). D. Blades Not Tracking Foreign object strike damage.

  • Page 47: Radial Play In The Blade

    HARTZELL PROPELLER OVERHAUL MANUAL Problem Probable Cause Remedy H. Radial Play in the Blade. Pitch change fork is worn. Disassemble the propeller. Inspect and replace parts, as required. Refer to Figure 1-2 Pitch change block is worn. and the section, "Blade Disassemble the propeller. Inspect Tolerances" in the Fits and replace parts, as required. and Clearances chapter of this manual. Oil Leakage Faulty O-ring seal between the Remove the propeller from the engine flange and the propeller engine and inspect the O-ring and mounting flange.

  • Page 48: Lightning Strike On Hub Or Blade

    HARTZELL PROPELLER OVERHAUL MANUAL 2. Lightning Strike on Hub or Blade (Rev. 3) A. Before Further Flight (1) In the event of a propeller lightning strike, an inspection is required before further flight. (a) A lightning strike on the propeller usually leaves arcing damage on the hub or blade, as evidence of where it entered or left the propeller. (b) Refer to the Special Inspections chapter of Hartzell Propeller Standard Practices Manual 202A (61-01-02) for lightning strike inspection criteria. 61-10-02 Page 1-6 TESTING AND FAULT ISOLATION Jun/24...
  • Page 49 HARTZELL PROPELLER OVERHAUL MANUAL AUTOMATIC TEST REQUIREMENTS (NOT APPLICABLE) (Rev. 2) 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 models included in this manual. 61-10-02 Page 2-1 AUTOMATIC TEST REQUIREMENTS Jun/24...
  • Page 50 HARTZELL PROPELLER OVERHAUL MANUAL (This page is intentionally blank.) 61-10-02 Page 2-2 AUTOMATIC TEST REQUIREMENTS Jun/24...
  • Page 51 HARTZELL PROPELLER OVERHAUL MANUAL DISASSEMBLY - CONTENTS 1. Important Information ....................3-3 A. Removing the Propeller ..................3-3 B. Record Serial Numbers/Blade Location Before Disassembly ......3-3 C. Ice Protection System (if applicable) ..............3-4 2. Three Blade Propeller Disassembly ................3-5 A. Hub Balance Weight Removal ................3-5 B.
  • Page 52 HARTZELL PROPELLER OVERHAUL MANUAL (This page is intentionally blank.) 61-10-02 Page 3-2 DISASSEMBLY Jun/24...

  • Page 53: Important Information

    (a) For the location of the serial number on the hub, refer to the Parts Identification and Marking chapter of Hartzell Propeller Standard Practices Manual 202A (61-01-02). 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.

  • Page 54: Ice Protection System (If Applicable)

    HARTZELL PROPELLER OVERHAUL MANUAL C. Ice Protection System (if applicable) (1) If the propeller is equipped with an ice protection system supplied by Hartzell, refer to Hartzell Propeller Ice Protection System Manual 180 (30-61-80) for technical information about the applicable ice protection system.

  • Page 55: Three Blade Propeller Disassembly

    (570), and washer (590). (2) Remove the balance weights (600). B. Counterweight Removal (1) Composite Blade Counterweight Removal (a) For removal instructions, refer to the Overhaul chapter of Hartzell Propeller Composite Blade Overhaul Manual 135F (61-13-35). 61-10-02 Page 3-5...
  • Page 56 HARTZELL PROPELLER OVERHAUL MANUAL VIDEO Cap/Cylinder/Piston Removal: 3A2 Propellers Figure 3-1 61-10-02 Page 3-6 DISASSEMBLY Jun/24...

  • Page 57: Pre-Disassembly

    HARTZELL PROPELLER OVERHAUL MANUAL C. Pre-Disassembly (1) To simplify the assembly process make a record of the location and orientation (where applicable) of each part in the propeller hub assembly. CAUTION: TO PREVENT DAMAGE TO THE PITCH CHANGE ROD (430),...
  • Page 58 HARTZELL PROPELLER OVERHAUL MANUAL (14) Remove the flyweight plate (130). WARNING: WHEN COMPRESSED, THE CYLINDER SPRING ASSEMBLY IS LOADED TO APPROXIMATELY 750 POUNDS (341 KG) FORCE. MAKE SURE OF THE SAFETY OF PERSONNEL IN THE VICINITY DURING DISASSEMBLY PROCEDURES. (15) Put the assembling tool TE9 in a vise with the flattened part of the threaded rod between the jaws of the vise, and tighten the vise.
  • Page 59 HARTZELL PROPELLER OVERHAUL MANUAL Set Screw Drilled Washer Cylinder (180) Threaded Rod Hex Nut Positioning the Cylinder on the Assembly Tool Figure 3-3 61-10-02 Page 3-9 DISASSEMBLY Jun/24...

  • Page 60: Propeller Internal Pitch Change Parts Disassembly

    HARTZELL PROPELLER OVERHAUL MANUAL (23) Remove the outer spring sleeve (210). (24) Remove the feather compression spring (200) on the cylinder spring seat (190) in the cylinder (180). (25) Remove the cylinder spring seat (190) in the cylinder (180). (26) Remove and discard the internal spiral retaining ring (240).
  • Page 61 HARTZELL PROPELLER OVERHAUL MANUAL (7) Remove the blades from the hub (340). (a) Remove blade number one from the hub (340). (b) Remove the pitch change block unit (490). Remove and discard the fork bumpers (460). (d) Remove the shim(s) (470).
  • Page 62 HARTZELL PROPELLER OVERHAUL MANUAL Blade Disassembly Figure 3-5 61-10-02 Page 3-12 DISASSEMBLY Jun/24...

  • Page 63: Hub Disassembly

    A. All Propeller Models (1) Remove components of the hub unit/assembly (340) in accordance with Appendix C in the Aluminum Hub Overhaul chapter of Hartzell Propeller Standard Practices Manual 202A (61-01-02). (a) The inspection criteria for hub assembly components is located in Appendix C in the Aluminum Hub Overhaul chapter of Hartzell Propeller Standard Practices Manual 202A (61-01-02).
  • Page 64 HARTZELL PROPELLER OVERHAUL MANUAL (This page is intentionally blank.) 61-10-02 Page 3-14 DISASSEMBLY Jun/24...
  • Page 65 HARTZELL PROPELLER OVERHAUL MANUAL CLEANING - CONTENTS 1. Cleaning Procedures ....................4-3 A. General Cleaning ....................4-3 B. Cleaning Steel Parts for Magnetic Particle Inspection ........4-3 C. Cleaning Steel Parts for Cadmium Replating Procedures ......... 4-3 D. Cleaning Aluminum Parts for Penetrant Inspection ..........4-3 E.
  • Page 66 HARTZELL PROPELLER OVERHAUL MANUAL (This page intentionally left blank.) 61-10-02 Page 4-2 CLEANING Jun/24...
  • Page 67 (1) Refer to the Cleaning chapter of Hartzell Propeller Standard Practices Manual 202A (61-01-02). B. Cleaning Steel Parts for Magnetic Particle Inspection (1) Refer to the Magnetic Particle Inspection chapter of Hartzell Propeller Standard Practices Manual 202A (61-01-02). C. Cleaning Steel Parts for Cadmium Replating Procedures (1) Refer to the Cadmium Replating chapter of Hartzell Propeller Standard Practices Manual 202A (61-01-02).
  • Page 68 HARTZELL PROPELLER OVERHAUL MANUAL (This page is intentionally blank.) 61-10-02 Page 4-4 CLEANING Jun/24...
  • Page 69 HARTZELL PROPELLER OVERHAUL MANUAL CHECK - CONTENTS 1. Inspection Interval Requirements ................5-3 A. General....................... 5-3 2. Dimensional Inspection.................... 5-3 A. Diameter Measurements ..................5-3 B. Decimal Places....................5-3 3. Inspection Criteria/Procedures ................5-4 A. Propeller Components (Except for those listed separately in this section) ..5-4 B.
  • Page 70 HARTZELL PROPELLER OVERHAUL MANUAL LIST OF FIGURES Low Pitch Stop Set Screws ..............Figure 5-1 ..... 5-6 A-2499-( ) Stop Sleeve ................. Figure 5-2 ... 5-10 B-317 Start Lock Flyweights ..............Figure 5-3 ... 5-12 Flyweight Plate ..................Figure 5-4 ..5-14 Cylinder ....................

  • Page 71: Inspection Interval Requirements

    (1) For information about life limited components and mandatory inspections, refer to the Airworthiness Limitations chapter of the applicable Hartzell Propeller owner's manual. (2) For overhaul periods of Hartzell propellers, refer to Hartzell Propeller Service Letter HC-SL-61-61Y. 2. Dimensional Inspection (Rev.

  • Page 72: Inspection Criteria/Procedures

    (1) For ice protection systems supplied by Hartzell, refer to Hartzell Propeller Ice Protection System Manual 180 (30-61-80). (2) For ice protection systems not supplied by Hartzell, refer to the applicable TC or STC holder’s Instructions for Continued Airworthiness (ICA).

  • Page 73: Propeller Component Checks

    HARTZELL PROPELLER OVERHAUL MANUAL 4. Propeller Component 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.

  • Page 74: Screw, Set, 5/8-18, Drilled (Item 20)

    HARTZELL PROPELLER OVERHAUL MANUAL Component Inspection Criteria Table 5-1 Inspect Serviceable Limits Corrective Action SCREW, SET, 5/8-18, DRILLED (Item 20) Refer to Figure 5-1. (1) Visually examine the Slight damage is permitted. If the damage is greater than pitch change rod screw...

  • Page 75: Cap (Item 40)

    HARTZELL PROPELLER OVERHAUL MANUAL Component Inspection Criteria Table 5-1 Inspect Serviceable Limits Corrective Action (Item 40) (1) Visually examine the cap Corrosion product is not permitted. If there is corrosion product, for corrosion product. replace the cap. (2) Visually examine the...

  • Page 76: Feather Stop (Item 60)

    HARTZELL PROPELLER OVERHAUL MANUAL Component Inspection Criteria Table 5-1 Inspect Serviceable Limits Corrective Action FEATHER STOP (Item 60) (1) Visually examine Corrosion product is not permitted. Remove corrosion product the feather stop for using glass bead cleaning in corrosion product and Slight damage is permitted.
  • Page 77 HARTZELL PROPELLER OVERHAUL MANUAL (This page intentionally left blank.) 61-10-02 Page 5-9 CHECK Jun/24...

  • Page 78: A-2499-( ) Stop Sleeve

    HARTZELL PROPELLER OVERHAUL MANUAL Corner "A" A-2499-( )Stop Sleeve Figure 5-2 61-10-02 Page 5-10 CHECK Jun/24...

  • Page 79: Stop, Sleeve (Item 80)

    HARTZELL PROPELLER OVERHAUL MANUAL Component Inspection Criteria Table 5-1 Inspect Serviceable Limits Corrective Action STOP, SLEEVE (Item 80) Refer to Figure 5-2. (1) Visually examine the OD The maximum permitted depth of Polish out the damaged area. If of the stop sleeve for damage is 0.005 inch (0.12 mm).

  • Page 80: Start Lock Flyweights

    HARTZELL PROPELLER OVERHAUL MANUAL 0.363 ± 0.005 inch Areas of (9.22 ± 0.13 mm) permitted wear. B-317 Start Lock Flyweights Figure 5-3 61-10-02 Page 5-12 CHECK Jun/24...

  • Page 81: Flyweight, Start Lock (Item 110)

    HARTZELL PROPELLER OVERHAUL MANUAL Component Inspection Criteria Table 5-1 Inspect Serviceable Limits Corrective Action FLYWEIGHT, START LOCK (Item 110) Refer to Figure 5-3. (1) Visually examine the Corrosion product is not If there is corrosion product, start lock flyweight for permitted.

  • Page 82: Plate, Flyweight (Item 130)

    HARTZELL PROPELLER OVERHAUL MANUAL Component Inspection Criteria Table 5-1 Inspect Serviceable Limits Corrective Action PLATE, FLYWEIGHT (Item 130) (Refer to Figure 5-4) (1) Visually examine the Corrosion product, wear, or If there is corrosion product, wear, flyweight plate for damage is not permitted.

  • Page 83: Balance Ring (Item 170)

    HARTZELL PROPELLER OVERHAUL MANUAL Component Inspection Criteria Table 5-1 Inspect Serviceable Limits Corrective Action BALANCE RING (Item 170) (1) Visually examine Corrosion product is not permitted. Remove corrosion product using the balance ring for glass bead cleaning in accordance corrosion product, wear, with the Cleaning chapter of or damage.

  • Page 84: Cylinder (Item 180)

    HARTZELL PROPELLER OVERHAUL MANUAL Area Around Attachment Holes Flyweight Plate Attachment Hole Threads Area A Cap Attachment Hole Threads O-ring Groove Cylinder Figure 5-5 61-10-02 Page 5-16 CHECK Jun/24...
  • Page 85 0.5 inch (12.7 mm). apply a chemical conversion coat in accordance with the Chromic Raised material is not permitted. Acid Anodizing chapter of Hartzell Propeller Standard Practices Manual 202A (61-01-02). If damage is greater than the permitted serviceable limits, replace the cylinder.
  • Page 86 HARTZELL PROPELLER OVERHAUL MANUAL Component Inspection Criteria Table 5-1 Inspect Serviceable Limits Corrective Action CYLINDER, Continued (Item 180) Refer to Figure 5-5. (5) Visually examine the If wear is present, measure the If the wear is less than the O-ring groove for wear.

  • Page 87: Spring Seat, Cylinder (Item 190)

    HARTZELL PROPELLER OVERHAUL MANUAL Component Inspection Criteria Table 5-1 Inspect Serviceable Limits Corrective Action SPRING SEAT, CYLINDER (Item 190) (1) Visually examine the If damage is present, measure If the damage is greater than spring seat for damage. the depth of the damage. The...

  • Page 88: Spring, Compression, Feather (Item 200)

    If there is corrosion product, glass bead cleaning. Refer to spring for corrosion remove it in accordance with the the Cleaning chapter of Hartzell product and pitting. corrective action repair limits. Propeller Standard Practices The maximum permitted depth of Manual 202A (61-01-02).

  • Page 89: Spring Sleeve, Outer (Item 210)

    HARTZELL PROPELLER OVERHAUL MANUAL Component Inspection Criteria Table 5-1 Inspect Serviceable Limits Corrective Action SPRING SLEEVE, OUTER (Item 210) (1) Visually examine the The maximum permitted depth of If damage or wear is greater than the permitted serviceable limits, outer spring sleeve for damage and wear is damage and wear.

  • Page 90: Spring Sleeve, Inner (Item 220)

    HARTZELL PROPELLER OVERHAUL MANUAL Component Inspection Criteria Table 5-1 Inspect Serviceable Limits Corrective Action SPRING SLEEVE, INNER (Item 220) (1) Visually examine the Corrosion product is not permitted. Remove corrosion product using inner spring sleeve glass bead cleaning in accordance...
  • Page 91 HARTZELL PROPELLER OVERHAUL MANUAL (This page intentionally left blank.) 61-10-02 Page 5-23 CHECK Jun/24...

  • Page 92: Piston (Item 250)

    HARTZELL PROPELLER OVERHAUL MANUAL "A" "B" "C" "D" Piston Part Maximum Maximum Minimum Minimum Number Diameter Width Diameter Diameter 0.486 inch 0.292 inch 2.628 inch 2.986 inch 106929 (12.34 mm) (7.41 mm) (66.76 mm) (75.85 mm) Piston Figure 5-6 61-10-02...
  • Page 93 HARTZELL PROPELLER OVERHAUL MANUAL Component Inspection Criteria Table 5-1 Inspect Serviceable Limits Corrective Action PISTON (Item 260) Refer to figure 5-6. (1) Measure the diameter of Refer to Figure 5-6 for the If the diameter is greater than area "A" of the piston.

  • Page 94: Hex Head Bolt

    HARTZELL PROPELLER OVERHAUL MANUAL AREA "A" Threads Fillet AREA "A" Fillet Hex Head Hex Head Bolt Figure 5-7 61-10-02 Page 5-26 CHECK Jun/24...

  • Page 95: Bolt, 3/8-24, Hex Head (Item 290)

    HARTZELL PROPELLER OVERHAUL MANUAL Component Inspection Criteria Table 5-1 Inspect Serviceable Limits Corrective Action BOLT, 3/8-24, HEX HEAD (Item 290) Refer to Figure 5-7. (1) Visually examine the hex Corrosion product is not permitted. Remove corrosion product using head bolt for corrosion glass bead cleaning in accordance product and pitting.

  • Page 96: A-2043-1 Nut Modification

    HARTZELL PROPELLER OVERHAUL MANUAL 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. Metal Housing Plastic Locking Element Nut may be machined to remove the plastic...
  • Page 97 HARTZELL PROPELLER OVERHAUL MANUAL Component Inspection Criteria Table 5-1 Inspect Serviceable Limits Corrective Action BOLT, 3/8-24, HEX HEAD, continued (Item 290) Refer to Figure 5-7 and Figure 5-8. (5) Visually examine the A maximum total accumulation of Limited thread file repair is...

  • Page 98: Pitch Change Rod

    HARTZELL PROPELLER OVERHAUL MANUAL Threads (inside rod) Pitch Change Rod Figure 5-9 61-10-02 Page 5-30 CHECK Jun/24...

  • Page 99: Rod, Pitch Change (Item 430)

    HARTZELL PROPELLER OVERHAUL MANUAL Component Inspection Criteria Table 5-1 Inspect Serviceable Limits Corrective Action ROD, PITCH CHANGE (Item 430) Refer to Figure 5-9. (1) Visually examine the Damage below the chrome plating If the damage is greater than the chrome plating of the is not permitted.
  • Page 100 HARTZELL PROPELLER OVERHAUL MANUAL Component Inspection Criteria Table 5-1 Inspect Serviceable Limits Corrective Action ROD, PITCH CHANGE, continued (Item 430) Refer to Figure 5-9. Visually examine all Minor wear on corners and If the cadmium plating coverage surfaces, except "A" and...

  • Page 101: Shim, Stainless Steel (Item 470)

    HARTZELL PROPELLER OVERHAUL MANUAL Component Inspection Criteria Table 5-1 Inspect Serviceable Limits Corrective Action SHIM, STAINLESS STEEL (Item 470) (1) Visually examine the A torn, bent, or damaged stainless If a torn, bent, or damaged shim stainless steel shim steel shim is not permitted.
  • Page 102 HARTZELL PROPELLER OVERHAUL MANUAL Fork Figure 5-10 61-10-02 Page 5-34 CHECK Jun/24...

  • Page 103: Fork, Three Blade (Item 480)

    HARTZELL PROPELLER OVERHAUL MANUAL Component Inspection Criteria Table 5-1 Inspect Serviceable Limits Corrective Action FORK, THREE BLADE (Item 480) Refer to Figure 5-10. (1) Visually examine the fork Corrosion product is not permitted. Using an abrasive pad CM47 or for corrosion product, equivalent, polish to a maximum wear, or damage.

  • Page 104: Pitch Change Block Unit (Item 490)

    HARTZELL PROPELLER OVERHAUL MANUAL Component Inspection Criteria Table 5-1 Inspect Serviceable Limits Corrective Action PITCH CHANGE BLOCK UNIT (Item 490) Refer to Figure 5-11. (Includes pitch change block [500] and bushing [510].) (1) Visually examine the If there is damage, measure the...
  • Page 105 HARTZELL PROPELLER OVERHAUL MANUAL (This page intentionally left blank.) 61-10-02 Page 5-37 CHECK Jun/24...

  • Page 106: Bearing Races

    HARTZELL PROPELLER OVERHAUL MANUAL Hub Contact Surface Hub-side Race Radial Ball Bearing Groove (dashed lines) Blade-side Race Outer Diameter Blade Contact Surface Cracks Chips Race Mating Surface Chips Bearing Races Figure 5-12 61-10-02 Page 5-38 CHECK Jun/24...

  • Page 107: Bearing Race (Items 530 And 560)

    HARTZELL PROPELLER OVERHAUL MANUAL Component Inspection Criteria Table 5-1 Inspect Serviceable Limits Corrective Action BEARING RACE (Items 530 and 560) Refer to Figure 5-12. (1) Visually examine the Corrosion product is not Remove corrosion product ball bearing groove in permitted. If there is corrosion using glass bead cleaning.
  • Page 108 HARTZELL PROPELLER OVERHAUL MANUAL Component Inspection Criteria Table 5-1 Inspect Serviceable Limits Corrective Action BEARING RACE, continued (Items 530 and 560) Refer to Figure 5-12. (3) Except for the ball Corrosion product is not Remove corrosion product bearing groove, visually permitted.
  • Page 109 HARTZELL PROPELLER OVERHAUL MANUAL Component Inspection Criteria Table 5-1 Inspect Serviceable Limits Corrective Action BEARING RACE, continued (Items 530 and 560) Refer to Figure 5-12. (6) Magnetic particle A relevant indication is not If there is a relevant indication, inspect each bearing permitted.

  • Page 110: Balance Weight (Item 600)

    Remove corrosion product in glass bead cleaning. Refer to corrosion product. accordance with the corrective the Cleaning chapter of Hartzell action instructions. Propeller Standard Practices Manual 202A (61-01-02). If the corrosion product cannot be removed, replace the balance weight.
  • Page 111 HARTZELL PROPELLER OVERHAUL MANUAL REPAIR - CONTENTS 1. General Repair Requirements ................. 6-3 A. Shot Peening ...................... 6-3 B. Aluminum and Steel Parts .................. 6-4 2. Repair/Modification Procedures................6-5 A. Propeller Components..................6-5 B. Hubs ........................6-5 C. Blades ........................ 6-5 D.
  • Page 112 HARTZELL PROPELLER OVERHAUL MANUAL (This page is intentionally blank.) 61-10-02 Page 6-2 REPAIR Jun/24...
  • Page 113 HARTZELL PROPELLER OVERHAUL MANUAL WARNING 1: DO NOT ATTEMPT IN THE FIELD ANY REPAIR, REPLACEMENT, REPLATING, RE-ANODIZING, OR RE-SHOT PEENING PROCEDURE NOT SPECIFICALLY AUTHORIZED BY HARTZELL PROPELLER LLC OR NOT SPECIFICALLY REFERRED TO IN HARTZELL PROPELLER MANUALS. CONTACT HARTZELL PROPELLER LLC FOR GUIDANCE ABOUT THE AIRWORTHINESS OF ANY PART WITH UNUSUAL WEAR OR DAMAGE.
  • Page 114 HARTZELL PROPELLER OVERHAUL MANUAL 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.
  • Page 115 HARTZELL PROPELLER OVERHAUL MANUAL 2. Repair/Modification Procedures (Rev. 4) A. Propeller Components (Except for those listed separately in this section) (1) For repair and modification procedures of propeller components (except for those listed separately in this section), refer to the applicable section in this chapter. B. Hubs (1) Aluminum Hubs: Refer to the Aluminum Hub Overhaul chapter of Hartzell Propeller Standard Practices Manual 202A (61-01-02). C. Blades (1) Composite Blades: Refer to Hartzell Propeller Composite Blade Overhaul Manual 135F (61-13-35). E. Spinner Assemblies (1) Metal Spinners: Refer to Hartzell Propeller Metal Spinner Maintenance Manual 127 (61-16-27). (2) Composite Spinners: Refer to Hartzell Propeller Composite Spinner Maintenance Manual 148 (61-16-48). F. Ice Protection Systems (1) For ice protection systems supplied by Hartzell, refer to Hartzell Propeller Ice Protection System Manual 180 (30-61-80). (2) For ice protection systems not supplied by Hartzell, refer to the applicable TC or STC holder’s Instructions for Continued Airworthiness (ICA).
  • Page 116 HARTZELL PROPELLER OVERHAUL MANUAL (This page is intentionally blank.) 61-10-02 Page 6-6 REPAIR Jun/24...
  • Page 117 HARTZELL PROPELLER OVERHAUL MANUAL ASSEMBLY - CONTENTS 1. General ........................7-3 A. Important Information ..................7-3 B. Ice Protection Systems..................7-4 C. O-rings ........................ 7-4 D. Blade Bore Plug/Bearing Installation ..............7-4 E. Blade Angle Information ..................7-4 2. Three Blade Assembly Procedures ................. 7-5 A.
  • Page 118 HARTZELL PROPELLER OVERHAUL MANUAL LIST OF FIGURES Installation of the Fork Assembly on the Pitch Change Rod ....Figure 7-1 ..... 7-6 Three Blade Bantam Propeller - Installation of the Fork, Pitch Change Rod, and Pitch Change Block Unit in the Hub ..Figure 7-2 ..... 7-8 Installation of Balls, Spacers, and Races on Blade ......

  • Page 119: General

    HARTZELL PROPELLER OVERHAUL MANUAL 1. General (Rev. 7) WARNING 1: ANY PART IDENTIFIED IN THIS MANUAL AS AN EXPERIMENTAL OR NON-AVIATION PART MUST NOT BE USED IN AN FAA OR INTERNATIONAL EQUIVALENT TYPE CERTIFICATED PROPELLER. A PART IDENTIFIED AS EXPERIMENTAL OR...

  • Page 120: Ice Protection Systems

    B. Ice Protection Systems (1) If installing an ice protection system supplied by Hartzell, refer to Hartzell Propeller Ice Protection System Manual 180 (30-61-80). (2) If installing an ice protection system not supplied by Hartzell, refer to the applicable TC or STC holder’s Instructions for Continued Airworthiness (ICA). C. O-rings (1) Unless specified differently, lubricate all O-rings with lubricant CM12 before installing them in the propeller assembly.

  • Page 121: Three Blade Assembly Procedures

    (2) Install the propeller assembly on the rotatable fixture TE125 on the assembly table TE129 using hub flange spindle TE536. (3) Use protractor TE96, TE97, or equivalent when measuring a blade angle. B. Hub Assembly (1) Install components of the hub unit (340) in accordance with Appendix C in the Aluminum Hub Overhaul chapter of Hartzell Propeller Standard Practices Manual 202A (61-01-02). (a) The inspection criteria for hub assembly components is located in Appendix C in the Aluminum Hub Overhaul chapter of Hartzell Propeller Standard Practices Manual 202A (61-01-02).

  • Page 122: Fork

    HARTZELL PROPELLER OVERHAUL MANUAL Fork (480) External Spiral Retaining Ring (450) O-ring (440) Unthreaded End of the Pitch Change Rod (430) O-ring (440) Fork (480) Pitch Change Rod (430) External Spiral Retaining Ring (450) NOTE: Three Blade Fork Shown for Reference Installation of the Fork Assembly on the Pitch Change Rod...

  • Page 123: Pitch Change Rod (430) And Fork (480) Assembly

    HARTZELL PROPELLER OVERHAUL MANUAL C. Pitch Change Rod (430) and Fork (480) Assembly (1) Using a clean cloth dampened with solvent acetone CM173, MEK CM106, or MPK CM219, clean the pitch change rod (430) and fork (480). (2) Permit the solvent acetone CM173, MEK CM106, or MPK CM219 to dry. (3) Apply thread locking compound CM74 to the pitch change rod (430) and push the unthreaded end of the pitch change rod through the fork (480).
  • Page 124 HARTZELL PROPELLER OVERHAUL MANUAL Pitch Change Rod (430) Pitch Change Block Unit (490) Fork Bumper Marking (460) Pitch Change Block Unit (490) Guide Hub Bushing (380) Socket "Spacer" Engine-Side Hub Half (340) Three Blade Bantam Propeller - Installation of the Fork, Pitch Change Rod,...

  • Page 125: Pitch Change Component Installation

    HARTZELL PROPELLER OVERHAUL MANUAL D. Pitch Change Component Installation (1) Using grease CM12, lightly lubricate O-ring (330). (2) Install the O-ring (330) in the engine-side hub bushing (360). (3) Apply a thin layer of grease CM12 to the unthreaded end of the pitch change rod (430).
  • Page 126 HARTZELL PROPELLER OVERHAUL MANUAL Bearing Assembly Blade O-Ring Clamp TE505 (520) Blade Side Bearing Race (530) Teflon Bearing Assembly Tool TE504 Ball Spacer (550) Bearing Ball (540) Installation of Balls, Spacers, and Races on Blade Figure 7-3 61-10-02 Page 7-10...

  • Page 127: Installation Of The Blade Bearing Race And Balls

    ALL THE BEARING BALLS (540) IN A SINGLE BEARING MUST BE OF THE SAME SIZE AND GAUGE. ALL BEARING BALLS SUPPLIED BY HARTZELL PROPELLER LLC ARE THE SAME GAUGE. (d) Alternate the bearing balls (540) and the ball spacers (550) on the hub-side race (560).
  • Page 128 HARTZELL PROPELLER OVERHAUL MANUAL Blade O-Ring (520) Bearing Ball (540) Hub-Side Bearing Race (560) Ball Spacer (550) Blade Teflon Strip Blade-Side Bearing Race (530) Blade Hub (340) Installation of the Blade in the Hub Figure 7-4 61-10-02 Page 7-12 ASSEMBLY Jun/24...
  • Page 129 HARTZELL PROPELLER OVERHAUL MANUAL (e) Put the blade-side bearing race (530) on the bearing balls (540). (f) Put the blade O-ring (520) on the blade teflon. CAUTION: MAKE SURE TO REMOVE THE "SOCKET/SPACER" BETWEEN THE FORK (480) AND THE HUB (340) BEFORE INSTALLING THE LAST BLADE. (g) Install the number one blade assembly into the socket of the engine-side hub half.

  • Page 130: Shimming Of The Fork Bumpers

    HARTZELL PROPELLER OVERHAUL MANUAL F. Shimming of the Fork Bumpers (1) Position the fork (480) in the center of the hub parting line. (2) Using grease CM12, lightly lubricate O-ring (320). (3) Install the O-ring (320) in the cylinder-side hub bushing (360).

  • Page 131: Piston

    HARTZELL PROPELLER OVERHAUL MANUAL G. Piston Installation Refer to Figure 7-5. (1) Using grease CM12, lightly lubricate the ID piston O-ring (440). (2) Install the ID piston O-ring (440) in the pitch change rod (430) O-ring groove. (3) Using grease CM12, lightly lubricate the OD piston O-ring (270).

  • Page 132: Cylinder

    HARTZELL PROPELLER OVERHAUL MANUAL Assembling Tool TE319 Set Screw Drilled Washer Cylinder (180) Threaded Rod Assembling Tool TE9 Hex Nut Vise Positioning the Cylinder on the Assembly Tool Figure 7-6 61-10-02 Page 7-16 ASSEMBLY Jun/24...

  • Page 133: Cylinder Installation

    HARTZELL PROPELLER OVERHAUL MANUAL H. Cylinder Installation (1) Put the cylinder spring seat (190) in the cylinder (180). (2) Put the feather compression spring (200) on the cylinder spring seat (190) in the cylinder (180). (3) Using spring compressor TE9 and TE319, compress the outer spring sleeve (210) on the feather compression spring (200) in the cylinder (180).
  • Page 134 HARTZELL PROPELLER OVERHAUL MANUAL (13) Install O-ring (310) on the OD of the cylinder (180). (14) Put the cylinder assembly (180) on the hub (430). (15) Install the balance ring (170) to the cylinder (180) and the cylinder-side hub half.

  • Page 135: Setting The Blade Angles

    HARTZELL PROPELLER OVERHAUL MANUAL I. Setting the Blade Angles NOTE 1: Grease CM12 may be used between the washers (70) and the feathering stop (60) 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-3851-0432 or A-2435-1 washer equals 1.5 degree (1) Remove the start lock flyweights (110) from the cylinder (180). (2) Install washers (70) and the feathering stop (60) on top of the high pitch stop sleeve (80) using a temporary screw. NOTE: The total number of washers, both inside and outside the sleeve, sets the feather angle.
  • Page 136 HARTZELL PROPELLER OVERHAUL MANUAL (d) Check the feather blade angle at the reference blade radius previously marked. (e) Repeat steps (3) through (4)(d) of this section until feather angle is correct. (5) When the feather angle is correct, apply air pressure to move the propeller into high pitch position, with the temporary screw still installed.
  • Page 137 HARTZELL PROPELLER OVERHAUL MANUAL CAUTION: AFTER THE FEATHER ANGLE HAS BEEN SET, THE TOTAL NUMBER OF WASHERS (70, 90) MUST BE MAINTAINED. CHANGING THE POSITIONS OF THE WASHERS TO ACHIEVE HIGH PITCH WILL NOT EFFECT THE FEATHER ANGLE. ADDING OR REMOVING...
  • Page 138 HARTZELL PROPELLER OVERHAUL MANUAL NOTE: Three Blade Hub Shown for Reference Allen Wrench Washer (60) Pitch Stop Screw (50) Sleeve Stop (80) Flyweight Start Lock (110) Cylinder (180) Balance Ring (170) Propeller Balance Figure 7-9 61-10-02 Page 7-22 ASSEMBLY Jun/24...
  • Page 139 HARTZELL PROPELLER OVERHAUL MANUAL (c) Using a 3/16 inch allen wrench, install the stop screw (50) through the top of the feather stop (60) into the pitch change rod (430), making sure that the washers (70) are still in position on top of the pitch change rod. Refer to Figure 7-9. (d) Tighten the pitch stop screw (50) with a 3/16 inch allen wrench. Maintain a minimum stop screw engagement of seven threads. (e) Torque the pitch stop screw (50) in accordance with Table 8-1, Torque Values in the Fits and Clearances chapter in this manual. (f) Release the air pressure to allow the start lock flyweight (110) to hold the propeller at high pitch.

  • Page 140: Cap Installation

    HARTZELL PROPELLER OVERHAUL MANUAL NOTE: Three Blade Hub Shown for Reference Low Pitch Stop Set Self-locking Nut (10) Screw (20) Cap (40) Cylinder (180) Balance Ring (170) Cap Screw (140) Cap Installation Figure 7-10 61-10-02 Page 7-24 ASSEMBLY Jun/24...

  • Page 141: Blade Angle Check

    K. Blade Angle Check (1) Apply air pressure to turn the blades to the low pitch position and set the propeller pitch in accordance with the aircraft Type Certificate Data Sheet. (2) Adjust the low pitch blade angle with the set screw (20). NOTE: To increase pitch, turn the low pitch stop set screw (20) clockwise. To decrease pitch, turn the low pitch stop set screw counterclockwise. (3) When the correct blade angle is set, torque the set screw (20) in accordance with Table 8-1, Torque Values in the Fits and Clearances chapter of this manual. L. Propeller Balance (1) Apply an index mark on the cylinder (180), balance ring (170), and hub (340). (2) Perform static balance of the propeller in accordance with the Static and Dynamic Balance chapter of Hartzell Propeller Standard Practices Manual 202A (61-01-02). 61-10-02 Page 7-25 ASSEMBLY Jun/24...
  • Page 142 HARTZELL PROPELLER OVERHAUL MANUAL Sealant CM257 Cylinder Side Hub Application of Sealant on the Cylinder-Side Hub Half Figure 7-11 61-10-02 Page 7-26 ASSEMBLY Jun/24...

  • Page 143: Hub Sealing Procedure

    HARTZELL PROPELLER OVERHAUL MANUAL M. Hub Sealing Procedure (1) Remove the screws (30) that attach the cap (40) to the cylinder (180). (2) Remove the cap (40). CAUTION: BE SURE AIR PRESSURE IS APPLIED BEFORE REMOVING THE STOP SCREW (280) (3) Apply air pressure. (4) Remove the temporary set screw (50). (5) Remove the feather stop (60).
  • Page 144 HARTZELL PROPELLER OVERHAUL MANUAL CAUTION: SEALANT CM257 HAS A TACK TIME OF SIX (6) MINUTES. Apply sealant CM257 to the cylinder-side and engine-side hub mating surfaces. Spread the sealant CM257 to achieve complete coverage of the cylinder-side and engine-side hub mating surfaces.

  • Page 145: Leak Check The Hub

    HARTZELL PROPELLER OVERHAUL MANUAL N. Leak Check the Hub (1) Install the cylinder (180) on the cylinder-side hub half (340). (2) Install the balance ring (170) on the cylinder (180). (3) Install the screws (140) that attach the balance ring (170) and cylinder (180) to the cylinder-side hub half (340). (4) Install two oil level check screws (150) and O-rings (160). (5) Install the leak check manifold TE644 with adapter to the cylinder (180) as shown in Figure 7-12.

  • Page 146: Oil Installation

    HARTZELL PROPELLER OVERHAUL MANUAL O. Oil Installation (1) The Bantam propeller is an oil-filled design. The propeller hub contains a red-dyed oil. (2) Remove the oil level check screws (150) and O-rings (160) from the cylinder (180). (3) Remove screws (140) in the blind holes that attach the balance ring (170) and cylinder (180) to the hub (340). (4) Remove the cylinder (180). (5) Pour, pump, or use syringe CM3 to add red-dyed oil equally through the three threaded cylinder mounting holes in the cylinder-side hub half.

  • Page 147: Disassembling A Propeller For Shipping

    HARTZELL PROPELLER OVERHAUL MANUAL 3. Disassembling a Propeller for Shipping 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, inspected, and statically balanced before blade removal and shipping. (2) A propeller disassembled for shipping does not need the oil installation procedure performed.
  • Page 148 (b) Reassemble the propeller without the blade assemblies. Refer to the Assembly section in this chapter. (7) Packing the Propeller and Blades for Shipping (a) Refer to the Packaging and Storage chapter of Hartzell Propeller Standard Practices Manual 202A (61-01-02), for packing the propeller and blades for shipping. (b) Pack the propeller without blades for shipping.

  • Page 149: Reassembly Of A Propeller Disassembled For Shipping

    (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. (b) If damage is found on a blade, refer to Hartzell Propeller Composite Blade Manual 135F (61-13-35). 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.
  • Page 150 HARTZELL PROPELLER OVERHAUL MANUAL (This page is intentionally blank.) 61-10-02 Page 7-34 ASSEMBLY Jun/24...
  • Page 151 HARTZELL PROPELLER OVERHAUL MANUAL FITS AND CLEARANCES -CONTENTS 1. Torque Values ......................8-4 A. Important Information ..................8-4 2. Blade Tolerances ..................... 8-7 A. Blade Play ......................8-7 B. Blade Track ......................8-7 C. Blade Pitch Tolerance ..................8-7 LIST OF FIGURES Calculating Torque When Using a Torque Wrench Adapter ....
  • Page 152 HARTZELL PROPELLER OVERHAUL MANUAL (This page is intentionally blank.) 61-10-02 Page 8-2 FITS AND CLEARANCES Jun/24...
  • Page 153 HARTZELL PROPELLER OVERHAUL MANUAL Torquing Adapter Standard Torque Wrench 1.00 foot 0.50 foot (304.8 mm) (152.4 mm) torque wrench reading (actual torque required) x (torque wrench length) to achieve required (torque wrench length) + (length of adapter) actual torque EXAMPLE:...
  • Page 154 (2) Use accurate wrenches and professional procedures to make sure of correct tensioning. (3) For the torque values to use when assembling a Hartzell propeller, refer to Table 8-1, "Torque Values" in this chapter. (4) When an adapter is used with a torque wrench, use the equation in Figure 8-1 to determine the correct torque value.
  • Page 155 HARTZELL PROPELLER OVERHAUL MANUAL 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. NOTE: Torque tolerance is ±10 percent unless otherwise noted.
  • Page 156 HARTZELL PROPELLER OVERHAUL MANUAL In-and-Out Play Radial Play End Play Leading Edge-to-Trailing Edge Fore-to-Aft Blade Play Figure 8-2 61-10-02 Page 8-6 FITS AND CLEARANCES Jun/24...
  • Page 157 HARTZELL PROPELLER OVERHAUL MANUAL 2. Blade Tolerances (Rev. 4) A. Blade Play Limits for blade play are specified below. Refer to Figure 8-2. (a) End Play: Leading Edge-to-Trailing Edge ± 0.0625 inch (1.58 mm) Total: 0.125 inch (3.17 mm) Fore-to-Aft (face to camber) ±...
  • Page 158 HARTZELL PROPELLER OVERHAUL MANUAL (This page is intentionally blank.) 61-10-02 Page 8-8 FITS AND CLEARANCES Jun/24...
  • Page 159 HARTZELL PROPELLER OVERHAUL MANUAL SPECIAL TOOLS, FIXTURES, AND EQUIPMENT - CONTENTS 1. Tooling and Facility Requirements ................9-3 A. Standard Tooling ....................9-3 B. Special Tooling ....................9-3 C. Facilities ......................9-3 61-10-02 Page 9-1 SPECIAL TOOLING, FIXTURES, AND EQUIPMENT...
  • Page 160 HARTZELL PROPELLER OVERHAUL MANUAL (This page intentionally blank.) 61-10-02 Page 9-2 SPECIAL TOOLING, FIXTURES, AND EQUIPMENT Jun/24...
  • Page 161 HARTZELL PROPELLER OVERHAUL MANUAL 1. Tooling and Facility Requirements (Rev. 2) A. Standard Tooling (1) Propeller repair stations certified by the FAA or international equivalent to overhaul Hartzell Propeller LLC 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. Special Tooling (1) Special tooling may be required for procedures in this manual. For further tooling information, refer to Hartzell Propeller Illustrated Tool and Equipment Manual 165A (61-00-65). (a) Tooling reference numbers appear with the prefix “TE” directly following the tool name to which they apply. For example, a template that is...
  • Page 162 HARTZELL PROPELLER OVERHAUL MANUAL (This page intentionally blank.) 61-10-02 Page 9-4 SPECIAL TOOLING, FIXTURES, AND EQUIPMENT Jun/24...
  • Page 163 HARTZELL PROPELLER OVERHAUL MANUAL ILLUSTRATED PARTS LIST - CONTENTS 1. Introduction .......................10-3 A. General......................10-3 B. Counterweights/Slugs/Mounting Hardware ..........10-3 C. Spinner Assemblies/Mounting Hardware ............10-3 D. Ice Protection System Components ............10-4 2. Description of Columns..................10-4 A. Fig./Item Number ..................10-4 B. Part Number ....................10-4 C.
  • Page 164 HARTZELL PROPELLER OVERHAUL MANUAL PROPELLER PARTS LISTS and FIGURES 3A2-Q( )450( ): Propeller Parts..........Figure 10-1 ....10-8 Parts List ........................10-9 SUB-ASSEMBLY PARTS LISTS and FIGURES Blade Retention Parts.............. Figure 10A-1 ... 10A-2 Parts List ......................10A-3 106837: Hub Unit..............Figure 10A-2 ... 10A-4 Parts List ......................10A-5...

  • Page 165: Introduction

    HARTZELL PROPELLER OVERHAUL MANUAL 1. Introduction (Rev. 2) WARNING: ANY PART IDENTIFIED AS AN EXPERIMENTAL OR NON-AVIATION PART MUST NOT BE USED IN AN FAA OR INTERNATIONAL EQUIVALENT TYPE CERTIFICATED PROPELLER. A PART IDENTIFIED AS EXPERIMENTAL OR NON-AVIATION DOES NOT HAVE FAA OR INTERNATIONAL EQUIVALENT APPROVAL EVEN THOUGH IT MAY STILL SHOW AN AVIATION TC OR PC NUMBER STAMP.

  • Page 166: Ice Protection System Components

    HARTZELL PROPELLER OVERHAUL MANUAL D. Ice Protection System Components (1) Ice protection systems are application specific. Refer to Hartzell Propeller Application Guide Manual 159 (61-02-59). (a) For components of ice protection systems supplied by Hartzell, refer to Hartzell Propeller Ice Protection System Manual 180 (30-61-80). (b) For components of ice protection systems not supplied by Hartzell, refer to the applicable TC or STC holder’s Instructions for Continued Airworthiness (ICA). 2. Description of Columns (Rev. 2) A. Fig./Item Number (1) Figure Number refers to the illustration where items appear. Item Numbers refer to the specific part callout in the applicable illustration. (a) Item Numbers that are listed but not shown in the illustration are identified by a dash to the left of the item number. (example: "-800")

  • Page 167: Description

    HARTZELL PROPELLER OVERHAUL MANUAL C. Description (1) This column provides the Hartzell Propeller description of the part. (2) Bullets and indentations are used to indicate parts that are components of a sub-assembly. (a) For example, a Fork Assembly that is part of a HC-C2YR-1 propeller assembly will have one bullet ( • ) before the description. This indicates that the Fork Assembly is part of the propeller assembly. A Fork Bumper that is part of the Fork Assembly will appear directly below the Fork Assembly with two bullets ( • • ) before the description. This indicates that the Fork Bumper is part of the Fork Assembly - that is part of the Propeller Assembly.

  • Page 168: Overhaul (O/H)

    HARTZELL PROPELLER OVERHAUL MANUAL F. 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. G. Propeller Critical Part (PCP) (1) This column identifies the Propeller Critical Parts (PCP) that are contained in each propeller model. (a) Refer to the Introduction chapter of this manual for the definition of Propeller Critical Parts (PCP). 3. Description of Terms (Rev. 1) A. Alternate (1) Alternate parts are identified by the term "ALTERNATE" in the Description...

  • Page 169: Vendor Supplied Hardware

    4. Vendor Supplied Hardware (Rev. 2) A. Important Information (1) Many O-rings, fasteners, and other vendor supplied hardware listed in Hartzell Propeller LLC manuals have previously been specified with AN, MS, NAS, or vendor part number. To provide internal controls and procurement flexibility, Hartzell part numbers have been assigned to all O-rings, fasteners, and hardware. Part shipments from Hartzell Propeller LLC will specify only the Hartzell 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 products without additional standards imposed by Hartzell. (a) For a listing of part number interchangeability, refer to the Vendor Cross Reference chapter of Hartzell Propeller Standard Practices Manual 202A (61-01-02). (b) Where permitted, both the Hartzell part number item and AN, MS, NAS, and other specified vendor number items can be used interchangeably. (c) The Hartzell part number must be used when ordering these parts from Hartzell Propeller LLC. 61-10-02 Page 10-7...
  • Page 170 HARTZELL PROPELLER OVERHAUL MANUAL 140 150 920 910 3A2-Q( )450( ): Propeller Parts Figure 10-1 61-10-02 Page 10-8 ILLUSTRATED PARTS LIST Jun/24...
  • Page 171 HARTZELL PROPELLER OVERHAUL MANUAL FIG./ITEM PART DESCRIPTION UPA O/H PCP NUMBER NUMBER CODE 3A2-Q( )450( ) 10-1 PROPELLER PARTS B-3807 • NUT, 5/8-18, HEX, SELF-LOCKING A-4257 • SCREW, SET, 5/8-18, DRILLED A-2626-2 • SCREW, 10-32, CAP 107665 • CAP A-2038-12 • SCREW, 1/4-28 CAP 106994 • FEATHER STOP B-3851-0432 • WASHER A-2499-2 • STOP, SLEEVE A-2435-1 • WASHER, 5/16 INCH 100 A-1595-1 • SCREW, SHOULDER, 1/4 INCH...
  • Page 172 HARTZELL PROPELLER OVERHAUL MANUAL FIG./ITEM PART DESCRIPTION UPA O/H PCP NUMBER NUMBER CODE 3A2-Q( )450( ) 10-1 PROPELLER PARTS, CONTINUED 106837 • PCP:HUB UNIT, 3A2-QP450-A( ) (REFER TO “106837 HUB UNIT” IN THIS CHAPTER FOR EXPLODED VIEW/PARTS LIST) 430 106840 • PCP: ROD, PITCH CHANGE 440 C-3317-012 • O-RING 450 105113-55 • RING, RETAINING, EXTERNAL SPIRAL 460 104763-( ) • BUMPER, FORK 470 104940-( ) • SHIM, STAINLESS STEEL 480 105023 • FORK, THREE BLADE...
  • Page 173 REFER TO HARTZELL PROPELLER APPLICATION GUIDE MANUAL 159 (61-02-59) AND THE APPLICABLE HARTZELL PROPELLER SPINNER MAINTENANCE MANUAL: MANUAL 127 (61-16-27) - METAL SPINNER ASSEMBLIES MANUAL 148 (61-16-48) - COMPOSITE SPINNER ASSEMBLIES EFF CODE INFORMATION MOUNTING STUDS ARE APPLICATION SPECIFIC. REFER TO HARTZELL PROPELLER APPLICATION GUIDE MANUAL 159 (61-02-59) FOR SPECIFIC MOUNTING STUD PART NUMBERS. - ITEM NOT ILLUSTRATED 3A2-Q( )450( ) 61-10-02 61-10-02 Page 10-11 ILLUSTRATED PARTS LIST...
  • Page 174 HARTZELL PROPELLER OVERHAUL MANUAL (This page is intentionally left blank.) 61-10-02 Page 10-12 ILLUSTRATED PARTS LIST Jun/24...
  • Page 175 HARTZELL PROPELLER OVERHAUL MANUAL SUB-ASSEMBLY PARTS LISTS and FIGURES 61-10-02 Page 10A-1 ILLUSTRATED PARTS LIST Jun/24...
  • Page 176 HARTZELL PROPELLER OVERHAUL MANUAL Blade Retention Parts Figure 10A-1 61-10-02 Page 10A-2 ILLUSTRATED PARTS LIST Jun/24...
  • Page 177 HARTZELL PROPELLER OVERHAUL MANUAL FIG./ITEM PART DESCRIPTION UPA O/H PCP NUMBER NUMBER CODE 10A-1 BLADE RETENTION PARTS C-3317-337-8 O-RING 520A C-3317-338-8 O-RING, ALTERNATE FOR ITEM 520 105444 RACE, BEARING, BLADE SIDE 540 B-6144-1 BALL, BEARING, 3/8" DIA 104949 BALL SPACER 105421 RACE, HUB SIDE...
  • Page 178 HARTZELL PROPELLER OVERHAUL MANUAL 106837: Hub Unit Figure 10A-2 61-10-02 Page 10A-4 ILLUSTRATED PARTS LIST Jun/24...
  • Page 179 HARTZELL PROPELLER OVERHAUL MANUAL FIG./ITEM PART DESCRIPTION UPA O/H PCP NUMBER NUMBER CODE 10A-2 106837 HUB UNIT PARTS 106837 PCP: HUB UNIT, 3A2-QP450-A( ) 350 C-3317-021-1 • O-RING, HUB BUSHING ROD OD, ENGINE-SIDE 360 105233 • HUB BUSHING, ROD ENGINE-SIDE 370 A-6153-81 • RING, RETAINING, EXTERNAL SPIRAL 380 A-2249 • HUB BUSHING, GUIDE 390 105017 • HUB BUSHING, ROD CYLINDER-SIDE 400 A-6153-81 • RING, RETAINING, EXTERNAL SPIRAL -410 B-6142 • INSERT, 1/4-28, CRES, COILED...
  • Page 180 HARTZELL PROPELLER OVERHAUL MANUAL (This page is intentionally blank.) 61-10-02 Page 10A-6 ILLUSTRATED PARTS LIST Jun/24...

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