{"id":"F2009L03773","name":"AD/PMC/53 - Cracked Propeller Blades","slug":"ad-pmc-53-cracked-propeller-blades","collection":"legislative_instrument","jurisdiction":"commonwealth","status":"in_force","isInForce":true,"actNumber":null,"makingDate":null,"administeringDepartment":null,"currentVersion":{"id":141662,"registerId":"commonwealth-F2009L03773-current","compilationNumber":null,"startDate":"2026-04-03","status":"InForce","reasons":null,"registeredAt":null},"sections":[{"sectionNumber":"Propellers - Variable Pitch - McCauley","sectionType":"division","heading":"Propellers - Variable Pitch - McCauley","content":"### Propellers - Variable Pitch - McCauley\n\n| AD/PMC/53 | Cracked Propeller Blades | 12/2009 DM |\n| --------- | ------------------------ | ---------- |\n\n```html\n

Applicability:

McCauley Propeller Systems propeller models B5JFR36C1101/114GCA-0, C5JFR36C1102/L114GCA-0, B5JFR36C1103/ 114HCA-0 and C5JFR36C1104/L114HCA-0.

Note 1: These propellers are known to be installed on, but not limited to, BAE Systems (Operations) Limited Jetstream Model 4100 and 4101 series aeroplanes (Jetstream 41).

Requirement:

1. For propeller blades with more than 10,000 operating hours time-since-new (TSN) on the effective date of this Directive, unless previously accomplished in accordance with AD/PMC/52, remove the propeller blades from service.

2. For propeller blades with more than 3,000 operating hours TSN on the effective date of this Directive, remove the propeller blades from service.

3. For propeller blades with 3,000 or fewer operating hours TSN on the effective date of this Directive, remove the propeller blades from service.

Propeller blades removed in accordance with Requirements 1 through 3 are prohibited from installation in any configuration on any airframe.

4. Remove the propeller blades and the hubs listed in Table 1 of this Directive from service. The propeller blades and hubs listed in Table 1 are prohibited from installation in any configuration on any airframe.

Table 1 - Serial Numbers of Propeller Blade and Hub
Required to be Removed from Service

Hub Serial Number

Blade Serial Number

023062
040296
041016
051193
040282
051204
051194

XH31043, XH31131, XE31002, XH31025, XI31014
YA31058, YA31055, YB31084, YB31088, YB31090
XB31009, XA31073, XA31071, XA31063, WK31013
XH31018, XH31077, XH31081, XL31008, XL31043
XG31015, XG31016, XH31113, XH31117, XI31017
XI31049, XH31140, XH31129, XH31084, XH31074
WF31010, WD31032, WF31002, WF31029, WF31078

\n```\n\n| | 5. Remove from service any propeller blades and hubs found or documented to have been installed in any propeller assembly that has had one or more cracked propeller blades at any time. Propeller blades and the propeller hub of a propeller assembly that has had one or more cracked propeller blades are prohibited from installation in any configuration on any airframe. |\n| --- | --------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------- |\n| | 6. Perform a fluorescent penetrant inspection and eddy current inspection of the propeller blades, together with a visual inspection for a \"step condition'' of the blade shank. Use the Equipment Required and Accomplishment Instructions of McCauley Propellers Alert Service Bulletin (ASB) ASB255A dated6 October 2008. |\n| | Note 2: If there is any question as to the acceptability of a blade shank \"step condition'', the ability to accurately measure 0.005-inch wear or the acceptability of any other wear present, the Civil Aviation Safety Authority recommends that you contact McCauley Product Support at McCauley Propeller Systems, 5800 E. Pawnee, Wichita, KS 67218, telephone 0011 1 316 831 4021 for guidance. |\n| | 7. If, as a result of the Requirement 6 fluorescent penetrant inspection, one or more propeller blades are found cracked on a propeller assembly remove from service all of the propeller blades and the propeller hub. Propeller blades and the propeller hub of a propeller assembly that has had one or more cracked propeller blades are prohibited from installation in any configuration on any airframe. |\n| | 8. If, as a result of the Requirement 6 visual inspection for a \"step condition'' of the blade shank, remove from service all propeller blades that exhibit a blade shank \"step condition'' of 0.005-inch or greater. Blades removed from service are prohibited from installation in any configuration on any airframe. |\n| | 9. Remove from service all C-5963 split retainers at the time of blade inspection specified in Requirement 6. C-5963 split retainers removed from service are prohibited from installation in any configuration on any airframe. |\n| | 10. Propeller assemblies with C-5963 split retainers may not be installed on any airframe. |\n\n```html\n

11. Report all inspection findings, using the Reporting Form in McCauley ASB255A, including any photograph and any other information related to the means of detection of the crack, together with the history of the propeller and blades, to:

Manager, Continuing Airworthiness
Airworthiness Engineering Branch
Civil Aviation Safety Authority
GPO Box 2005
CANBERRA ACT 2600

Facsimile (02) 6217 1914

Note 3: FAA AD 2009-19-04 Amdt 39-16021 refers.

Compliance:

For Requirement 1 - Before further flight after the effective date of this Directive.

For Requirement 2 - Within the next 500 operating hours, not to exceed 10,000 operating hours TSN.

For Requirement 3 - At or before reaching 3,500 operating hours TSN.

For Requirements 4 and 5 - Before further flight after the effective date of this Directive.

For Requirement 6 - In accordance with Table 2 of this Directive.

Table 2 - Compliance Schedule

If on the Effective Date of this Directive, the Propeller Blade:

Then Inspect the Propeller Blade:

Has more than 2,400 operating hours TSN, time-since-last inspection (TSLI) or time-since-overhaul (TSO) and has been inspected using AD/PMC/52 (FAA AD 2008-08-01) or McCauley Propellers ASB255, dated 8 January 2007, within the past 2,400 operating hours.

Upon reaching 2,500 operating hours TSLI. (For the purpose of this Directive, TSLI refers only to inspections performed using AD/PMC/52 or ASB255.)

Has more than 2,400 operating hours TSN, TSLI or TSO and has not been inspected using AD/PMC/52 or ASB255 within the past 2,400 operating hours.

Within the next 100 operating hours time-in-service.

\n```\n\n```html\n

Has 2,400 or fewer operating hours TSN, TSLI or TSO.

Upon reaching 2,500 operating hours TSN, TSLI or TSO.

For Requirements 7, 8 and 9 - Before further flight after the Requirement 6 inspection(s).

For Requirement 10 - As of the effective date of this Directive.

For Requirement 11 - Within ten calendar days of completing the inspection(s).

This Airworthiness Directive becomes effective on 27 October 2009.

Background:

This Directive supersedes AD/PMC/52 which will be cancelled. That Directive required initial and repetitive fluorescent penetrant inspections together with eddy current inspections of propeller blades for cracks. That Directive required the removal from service of propeller blades if any crack indications were found, the Directive also mandated a life limit for the blades.

This Directive requires the same inspections, adds a visual inspection and mandates a new propeller blade life limit. This Directive also requires removing propeller blades with more than 10,000 operating hours TSN. This Directive also requires removal from service of all the propeller blades and the propeller hub if one or more propeller blades have been found cracked on a propeller assembly. Additionally, this Directive requires removing from service all C-5963 split retainers.

This Directive results from the United States Federal Aviation Administration receiving eight reports of propeller blades found cracked since May 2006. The Directive is issued to detect cracks in the propeller blade that could cause failure and separation of the propeller blade and loss of control of the aeroplane.

\n```\n\n![](image.001.png) \nDavid Villiers \nDelegate of the Civil Aviation Safety Authority\n\n25 September 2009","sortOrder":0},{"sectionNumber":"AD/PMC/53","sectionType":"part","heading":"AD/PMC/53","content":"## AD/PMC/53","sortOrder":1},{"sectionNumber":"Cracked Propeller Blades","sectionType":"part","heading":"Cracked Propeller Blades","content":"## Cracked Propeller Blades","sortOrder":2},{"sectionNumber":"12/2009 DM","sectionType":"part","heading":"12/2009 DM","content":"## 12/2009 DM","sortOrder":3}],"analysis":{"flash_summary_failed":{"failed":true,"reason":"A positive credit balance is required for all requests, including BYOK, so fallback providers remain available. Add credits at https://vercel.com/d?to=%2F%5Bteam%5D%2F%7E%2Fai%3Fmodal%3Dtop-up to continue.","source":"analysis-cron"},"kimi_summary":{"content_quality":"ok","complexity_score":6,"scope_assessment":{"changed":true,"description":"This directive significantly expanded beyond its predecessor AD/PMC/52. The original directive required inspections and removal of cracked blades with life limits. This version adds: (1) immediate removal of all blades over 10,000 hours regardless of condition, (2) mandatory hub removal when any blade in an assembly is cracked, (3) new visual inspection for 'step condition' wear, (4) specific serial number mandates, (5) ban on C-5963 split retainers, and (6) enhanced reporting requirements. The scope shifted from 'inspect and remove if cracked' to a comprehensive grounding and replacement program with multiple permanent prohibitions."},"complexity_factors":["Multiple overlapping compliance deadlines based on operating hours (TSN, TSLI, TSO) creating a matrix of conditions","10 distinct requirements with different compliance timeframes (immediate, within 100/500 hours, at specific hour thresholds)","Cross-references to external documents: McCauley ASB255A, previous AD/PMC/52, and FAA AD 2009-19-04","Nested conditional logic: Requirements 7-9 depend on findings from Requirement 6 inspections","Specific serial number tracking required (Table 1 with 7 hub serial numbers and 35 blade serial numbers)","Technical aviation terminology requiring specialised knowledge (fluorescent penetrant inspection, eddy current, 'step condition', split retainers)","Prohibition language with broad scope ('any configuration on any airframe') repeated across multiple requirements"],"plain_english_summary":"This CASA Airworthiness Directive orders immediate grounding of certain McCauley variable-pitch propeller blades, mandates fluorescent-penetrant, eddy-current and visual inspections, prohibits reinstallation of removed parts, and requires reporting of findings. It applies to operators and maintenance organisations using specified McCauley blade models (notably on Jetstream 41 aircraft). The AD responds to multiple cracked-blade reports that risk catastrophic failure and tightens requirements and life limits from the earlier AD."},"flash_summary":{"complexity_score":6,"scope_assessment":{"changed":true,"description":"This Directive expands scope relative to the prior AD/PMC/52 by adding a mandatory visual 'step' inspection, a new blade life limit (including immediate removal of blades over 10,000 TSN), mandatory removal of entire propeller assemblies (hub and all blades) if any blade was cracked, and removal/prohibition of C‑5963 split retainers. It retains the prior inspection methods but increases mandatory removals, reporting and part prohibitions."},"complexity_factors":["Multiple, tiered time‑in‑service thresholds (e.g. >10,000 TSN, >3,000 TSN, ≤3,000 TSN) with different removal deadlines, increasing operational bookkeeping and tracking complexity.","Detailed compliance schedule tied to prior inspection history (TSLI/TSO) and specific hour triggers (2,400 / 2,500 hours), requiring record checks against past AD/ASB inspections.","Specific serial‑number table listing hubs and blade serials required to be removed, necessitating parts-level traceability across fleets.","Multiple inspection techniques mandated (fluorescent penetrant, eddy current, and visual measurement of a 0.005‑inch 'step' condition), raising equipment, skill and measurement‑accuracy issues.","Immediate prohibitions on reinstallation of removed blades, hubs and C‑5963 split retainers, creating replacement procurement and logistics burdens.","Assembly‑level rule: if any blade in an assembly is cracked, the entire hub and all blades must be removed, expanding potential removals beyond individually affected blades.","Reporting requirement to CASA within ten days, adding administrative compliance tasks and potential scrutiny.","Cross‑reference to McCauley ASB255A and FAA AD introduces reliance on external service documentation and potential interpretation variance.","Measurement ambiguity acknowledged (difficulty measuring 0.005‑inch wear) creates implementation risk and need for manufacturer guidance."],"plain_english_summary":"This Airworthiness Directive requires operators of aircraft fitted with specified McCauley variable‑pitch propellers to remove blades or hubs that meet listed serial numbers or exceed time‑in‑service limits, perform fluorescent‑penetrant, eddy‑current and visual “step” inspections, remove all C‑5963 split retainers, and report findings to CASA. Removed parts must not be reinstalled. Aircraft owners/operators bear the cost of inspections, removals and replacements; the Civil Aviation Safety Authority (Delegate) sets compliance deadlines and bans reuse of affected components."}},"importantCases":[],"_links":{"self":"/api/acts/ad-pmc-53-cracked-propeller-blades","history":"/api/acts/ad-pmc-53-cracked-propeller-blades/history","analysis":"/api/acts/ad-pmc-53-cracked-propeller-blades/analysis","conflicts":"/api/acts/ad-pmc-53-cracked-propeller-blades/conflicts","importantCases":"/api/acts/ad-pmc-53-cracked-propeller-blades/important-cases","documents":"/api/acts/ad-pmc-53-cracked-propeller-blades/documents"}}