AD 2007-08-04

[Federal Register Volume 72, Number 70 (Thursday, April 12, 2007)]
[Rules and Regulations]
[Pages 18377-18380]
From the Federal Register Online via the Government Publishing Office [<a href="http://www.gpo.gov">www.gpo.gov</a>]
[FR Doc No: E7-6831]


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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. FAA-2005-22898; Directorate Identifier 2005-NE-10-AD; 
Amendment 39-15021; AD 2007-08-04]
RIN 2120-AA64


Airworthiness Directives; McCauley Propeller Systems Models 
3A32C406/82NDB-X and D3A32C409/82NDB-X Propellers

AGENCY: Federal Aviation Administration (FAA), Department of 
Transportation (DOT).

ACTION: Final rule.

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SUMMARY: The FAA is adopting a new airworthiness directive (AD) for 
McCauley Propeller Systems models 3A32C406/82NDB-X and D3A32C409/82NDB-
X propellers, installed on Teledyne Continental Motors (TCM) IO-520, 
TSIO-520, or IO-550 reciprocating engines. These propellers are herein 
referred to as C406 and C409 propellers, respectively. This AD requires 
adding an operational revolutions per minute (RPM) restriction on the 
C406 and C409 propellers, and installing an RPM restriction placard in 
the cockpit. This AD also adds a 10,000-hour total time-in-service 
(TIS) life limit for these propellers. This AD also removes from

[[Page 18378]]

service any propeller that has 10,000 hours or more total TIS, or that 
has an unknown total TIS. Also, this AD requires initial and repetitive 
propeller blade inspections for damage, and repair if necessary. This 
AD results from testing by the manufacturer that identified stress 
conditions that affect the fatigue life and damage tolerance of C406 
and C409 propellers, when installed on TCM IO-520, TSIO-520, or IO-550 
reciprocating engines. We are issuing this AD to prevent blade or hub 
failure that could result in separation of a propeller blade and loss 
of control of the airplane.

DATES: This AD becomes effective May 17, 2007. The Director of the 
Federal Register approved the incorporation by reference of certain 
publications listed in the regulations as of May 17, 2007.

ADDRESSES: You can get the service information identified in this AD 
from McCauley Propeller Systems, P.O. Box 7704, Wichita, KS 67277-7704; 
telephone (800) 621-7767.
    You may examine the AD docket on the Internet at <a href="http://dms.dot.gov">http://dms.dot.gov</a> 
or in Room PL-401 on the plaza level of the Nassif Building, 400 
Seventh Street, SW., Washington, DC.

FOR FURTHER INFORMATION CONTACT: Jeff D. Janusz, Aerospace Engineer, 
Wichita Aircraft Certification Office, Small Airplane Directorate, 1801 
Airport Road, Room 100, Wichita, KS 67209, telephone: 316-946-4148, 
fax: 316-946-4107.

SUPPLEMENTARY INFORMATION: The FAA proposed to amend 14 CFR part 39 
with a proposed AD. The proposed AD applies to McCauley Propeller 
Systems C406 and C409 propellers, installed on TCM IO-520, TSIO-520, or 
IO-550 reciprocating engines. We published the proposed AD in the 
Federal Register on Nov. 16, 2005 (70 FR 69472). That action proposed 
to require adding an operational RPM restriction on the C406 and C409 
propellers, and installing an RPM restriction placard in the cockpit. 
We coordinated the proposed placard placement with the responsible 
Aircraft Certification Offices within the Small Airplane Directorate, 
and all proposed installations include a manifold pressure gauge. That 
action also proposed to add a 10,000-hour total time-in-service (TIS) 
life limit for these propellers. That action also proposed to remove 
from service any propeller that has 10,000 hours or more total TIS, or 
that has an unknown total TIS. Finally, that action proposed to require 
initial and repetitive propeller blade inspections for damage, and 
repair if necessary.

Examining the AD Docket

    You may examine the docket that contains the AD, any comments 
received, and any final disposition in person at the Docket Management 
Facility between 9 a.m. and 5 p.m., Monday through Friday, except 
Federal holidays. The Docket Office (telephone (800) 647-5227) is 
located on the plaza level of the Department of Transportation Nassif 
Building at the street address stated in ADDRESSES. Comments will be 
available in the AD docket shortly after the DMS receives them.

Comments

    We provided the public the opportunity to participate in the 
development of this AD. We have considered the comments received.

Financial Burden and Potential Unsafe Condition

    One commenter states that this AD will impose a financial burden on 
owners and operators of airplanes with this propeller installation 
because of the increased number of inspections and additional wear on 
the propeller system increasing the probability of the propeller system 
failing. The commenter also suggests that stamping a letter on the 
propeller model to designate a life-limited propeller could create a 
potentially unsafe condition because the stamping can create stress 
risers and if improperly treated after stamping, could contribute to 
corrosion. The commenter also notes that the airplane model 
designations are incorrect and we omitted one model from the airplane 
model listing. Finally, the commenter asks why we did not immediately 
ground the fleet using this propeller because of the described severity 
of the unsafe condition. We partially agree with the comments. Each is 
addressed in turn. The increased inspections required by this AD are 
necessary to resolve the unsafe condition. Owner operators must 
maintain their aircraft in an airworthy condition, which includes 
paying for maintenance. We considered that cost and discussed it in the 
cost section below. We did not change the AD.
    This AD will not result in additional wear and tear on the 
propellers, or in increased failures. This AD resolves an unsafe 
condition. All actions required are either performed with the propeller 
installed, or coincident with the next overhaul or major disassembly. 
An experienced, appropriately rated mechanic can do the inspection and 
rework without removing the propeller. We did not change the AD.
    The manufacturer carefully considered where to stamp the life limit 
indication to minimize any stress riser. We have no indications that 
his choice was wrong. We did not change the AD.
    We agree that this AD should include additional models. We changed 
the AD to include the Beech 35-A33 and 35-B33. The Beech 35-A33 and 35-
B33 are now included in Applicability paragraph (c) Table (1).
    Grounding the fleet that has the suspect propellers installed is 
not required. The unsafe condition identified is due to material 
fatigue. The actions required by this AD adequately address the unsafe 
condition. We did not change the AD.

Eliminate the Repetitive Inspections of This AD

    Another commenter states that the AD does not include a terminating 
action to eliminate the recurring inspections necessary to comply with 
it. Even if an operator replaces the existing propeller with a new 
propeller, the recurring inspections are necessary as long as the 
replacement propeller is one of same models identified in the 
airworthiness directive. Additionally, the commenter notes that 
aircraft performance is also a consideration. This AD will require 
operating the engine and propeller combination in a less than full 
engine power regime, which could compromise safety in particular 
situations associated with departures, arrivals and clearing obstacles. 
We partially agree.
    This AD imposes the RPM and life limit to correct an unsafe 
condition. The recurring inspections are required to enhance safety. 
The RPM restriction, imposed propeller life limit, and periodic 
propeller blade inspection/rework provide a cost effective means to 
correct the unsafe condition without prematurely retiring the 
propeller. The RPM restriction does not affect the engine full power 
ratings. Takeoff, climb, and descent values remain unchanged. 
Therefore, this AD does not compromise safety during departures, 
arrivals, and in clearing obstacles. We did not change the AD.

Recall Impacted Propellers

    Another commenter believes that the FAA should require a recall of 
all propeller models listed in the AD so the manufacturer will be 
responsible for the cost of repair and replacement. We do not agree.
    The FAA cannot dictate commercial business decisions related to AD 
actions. We identified the unsafe condition and are imposing 
appropriate corrective action. We did not change the AD.

[[Page 18379]]

Extend the Comment Period

    Two commenters asked that we extend the comment period for the 
proposed rule to give the general aviation community added time to 
review non-proprietary data used to substantiate the proposed action 
and to make additional comments. We agree, and extended the comment 
period to give the aviation community time to respond. The comments 
that we responded to above include any additional comments that came 
in.

Correct Date of Service Bulletin

    The proposed rule referenced McCauley Propeller Systems Alert 
Service Bulletin (ASB) No. ASB248, dated January 17, 2005. The correct 
date is April 19, 2005. We changed the AD to indicate the correct date 
of the service bulletin.

Conclusion

    We have carefully reviewed the available data, including the 
comments received, and determined that air safety and the public 
interest require adopting the AD with the changes described previously. 
We have determined that these changes will neither increase the 
economic burden on any operator nor increase the scope of the AD.

Costs of Compliance

    This AD will affect about 2,350 C406 and C409 propellers installed 
on airplanes of U.S. registry. We estimate it will take three work-
hours per propeller to perform the proposed inspections and repairs. We 
also estimate it will take about 0.5 work-hour to install the proposed 
cockpit placard, and about 950 airplanes will require the placard. The 
average labor rate is $80 per work-hour. A replacement propeller blade 
set will cost about $5,200. We estimate 500 propellers in the fleet (or 
about 21 percent) would require propeller blade set replacement. Based 
on these figures, we estimate the total cost of the AD to U.S. 
operators to be $3,202,000.

Authority for This Rulemaking

    Title 49 of the United States Code specifies the FAA's authority to 
issue rules on aviation safety. Subtitle I, Section 106, describes the 
authority of the FAA Administrator. Subtitle VII, Aviation Programs, 
describes in more detail the scope of the Agency's authority.
    We are issuing this rulemaking under the authority described in 
Subtitle VII, Part A, Subpart III, Section 44701, ``General 
requirements.'' Under that section, Congress charges the FAA with 
promoting safe flight of civil aircraft in air commerce by prescribing 
regulations for practices, methods, and procedures the Administrator 
finds necessary for safety in air commerce. This regulation is within 
the scope of that authority because it addresses an unsafe condition 
that is likely to exist or develop on products identified in this 
rulemaking action.

Regulatory Findings

    We have determined that this AD will not have federalism 
implications under Executive Order 13132. This AD will not have a 
substantial direct effect 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.
    For the reasons discussed above, I certify that this AD:
    (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.
    We prepared a summary of the costs to comply with this AD and 
placed it in the AD Docket. You may get a copy of this summary at the 
address listed under ADDRESSES.

List of Subjects in 14 CFR Part 39

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

Adoption of the Amendment

0
Accordingly, under the authority delegated to me by the Administrator, 
the Federal Aviation Administration amends 14 CFR part 39 as follows:

PART 39--AIRWORTHINESS DIRECTIVES

0
1. The authority citation for part 39 continues to read as follows:

    Authority: 49 U.S.C. 106(g), 40113, 44701.


Sec.  39.13  [Amended]

0
2. The FAA amends Sec.  39.13 by adding the following new airworthiness 
directive:

 2007-08-04 McCauley Propeller Systems: Amendment 39-15021. Docket 
No. FAA-2005-22898; Directorate Identifier 2005-NE-10-AD.

Effective Date

    (a) This airworthiness directive (AD) becomes effective May 17, 
2007.

Affected ADs

    (b) None.

Applicability

    (c) This AD applies to McCauley Propeller Systems models 
3A32C406/82NDB-X and D3A32C409/82NDB-X propellers, herein referred 
to as C406 and C409 propellers, respectively. These propellers are 
installed on, but not limited to, the airplanes in the following 
Table 1:

Table 1.--Airplanes That Propellers Are Installed On, But Not Limited To
------------------------------------------------------------------------
            Airplane models                     With engine model
------------------------------------------------------------------------
Beech:
    A35, B35, C35, D35, E35, F35, G35,   Teledyne Continental Motors
     H35, J35, K35, M35, N35, P35, S35,   (TCM) IO-520 series and IO-550
     V35, V35A, V35B, 35-33, 35-A33, 35-  series reciprocating engines.
     B33, 35-C33, 35-C33A, E33, E33A,
     E33C, F33, F33A, F33C, 36, A36,
     A45, and D45.
Beech:
    A36TC, B36TC, S35, V35A, V35B......  TCM TSIO-520 series
                                          reciprocating engines.
Navion:
    A (L-17B, C), B, D, E, F, G, and H.  TCM IO-550 and TSIO-520 series
                                          reciprocating engines.
------------------------------------------------------------------------

Unsafe Condition

    (d) This AD results from testing by the manufacturer that 
identified stress conditions that affect the fatigue life and damage 
tolerance of C406 and C409 propellers, when installed on TCM IO-520, 
TSIO-520, or IO-550 reciprocating engines. We are issuing this AD to 
prevent blade or hub failure that could result in separation of a 
propeller blade and loss of control of the airplane.

Compliance

    (e) You are responsible for having the actions required by this 
AD performed within the compliance times specified unless the 
actions have already been done.

[[Page 18380]]

Installation of Cockpit Placard for RPM Restriction

    (f) Within 10 hours time-in-service (TIS) after the effective 
date of this AD, install a placard on the instrument panel as close 
to the tachometer as possible, that states, in \1/8\ inch-high or 
higher characters, ``Continuous operation between 2,350-2,450 RPM at 
or above 24'' manifold pressure is prohibited''.
    The placard shall have red letters, on a white contrasting 
background with a red border. For example:

------------------------------------------------------------------------
 
---------------------------------------------------------------------------
                          Continuous operation
                         between 2,350-2,450 RPM
                        at or above 24'' manifold
                         pressure is prohibited
------------------------------------------------------------------------

Propellers With Unknown Total Hours TIS, or 10,000 or More Hours Total 
TIS on the Effective Date of This AD

    (g) For propellers that the total TIS is unknown, or that have 
10,000 or more hours total TIS on the effective date of this AD, 
remove the propeller from service within 50 hours TIS after the 
effective date of this AD.

Propellers With Fewer Than 10,000 Hours Total TIS on the Effective Date 
of This AD

    (h) For propellers with fewer than 10,000 total hours TIS on the 
effective date of this AD, do the following:
    (1) Perform an inspection of the propeller blades and repair if 
necessary, within 100 hours after the effective date of this AD, 
using paragraphs 2.B. through 2.F. of Accomplishment Instructions of 
McCauley Propeller Systems Alert Service Bulletin (ASB) No. ASB248, 
dated April 19, 2005.
    (2) At the next propeller overhaul or next major propeller 
disassembly, life-limit-stamp the letter ``L'' on the propeller hub 
and blades, using paragraph 3 of Accomplishment Instructions of 
McCauley Propeller Systems ASB No. ASB248, dated April 19, 2005.
    (3) Thereafter, within every 100 hours TIS or at next annual 
inspection, whichever occurs first, inspect, and repair if 
necessary, the propeller blades using paragraphs 2.B. through 2.F. 
of Accomplishment Instructions of McCauley Propeller Systems ASB No. 
ASB248, dated April 19, 2005.
    (4) Remove the propeller from service upon reaching the life 
limit of 10,000 hours total TIS.

Alternative Methods of Compliance

    (i) The Manager, Wichita Aircraft Certification Office, has the 
authority to approve alternative methods of compliance for this AD 
if requested using the procedures found in 14 CFR 39.19.

Related Information

    (j) Contact Jeff D. Janusz, Aerospace Engineer, Wichita Aircraft 
Certification Office, Small Airplane Directorate, 1801 Airport Road, 
Room 100, Wichita, KS 67209; telephone: 316-946-4148, fax: 316-946-
4107, for more information about this AD.

Material Incorporated by Reference

    (k) You must use McCauley Propeller Systems Alert Service 
Bulletin No. ASB248, dated April 19, 2005, to perform the actions 
required by this AD. The Director of the Federal Register approved 
the incorporation by reference of this service bulletin in 
accordance with 5 U.S.C. 552(a) and 1 CFR part 51. Contact McCauley 
Propeller Systems, P.O. Box 7704, Wichita, Kansas; telephone (800) 
621-7767, for a copy of this service information. You may review 
copies at the FAA, New England Region, Office of the Regional 
Counsel, 12 New England Executive Park, Burlington, MA; or the 
National Archives and Records Administration (NARA). For information 
on the availability of this material at NARA, call 202-741-6030, or 
go to: <a href="http://www.archives.gov/federal-register/cfr/ibr-locations.html">http://www.archives.gov/federal-register/cfr/ibr-locations.html</a>.

    Issued in Burlington, Massachusetts, on April 4, 2007.
Peter A. White,
Acting Manager, Engine and Propeller Directorate, Aircraft 
Certification Service.
[FR Doc. E7-6831 Filed 4-11-07; 8:45 am]
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