Airworthiness Directives; Teledyne Continental Motors GTSIO-520 Series Reciprocating Engines, 17366-17368 [05-6775]

Agencies

• Federal Aviation Administration
• DEPARTMENT OF TRANSPORTATION

[Federal Register Volume 70, Number 65 (Wednesday, April 6, 2005)]
[Proposed Rules]
[Pages 17366-17368]
From the Federal Register Online via the Government Printing Office [www.gpo.gov]
[FR Doc No: 05-6775]


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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. FAA-2005-20850; Directorate Identifier 2005-NE-05-AD]
RIN 2120-AA64


Airworthiness Directives; Teledyne Continental Motors GTSIO-520 
Series Reciprocating Engines

AGENCY: Federal Aviation Administration (FAA), DOT.

ACTION: Notice of proposed rulemaking (NPRM).

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SUMMARY: The FAA proposes to adopt a new airworthiness directive (AD) 
for Teledyne Continental Motors (TCM) GTSIO-520 series reciprocating 
engines. This proposed AD would require initial and repetitive visual 
inspections of the starter adapter assembly and crankshaft gear. This 
proposed AD would also require unscheduled visual inspections of the 
starter adapter assembly and crankshaft gear due to a rough-running 
engine. This proposed AD would also require replacement of the starter 
adapter shaft gear needle bearing with a certain bushing. Also, this 
proposed AD would require installation of a certain TCM service kit at 
the next engine overhaul, or at the next starter adapter replacement, 
whichever occurs first. Also, this proposed AD would require adding a 
certain placard to the instrument panel before further flight. This 
proposed AD results from six service difficulty reports and one fatal 
accident report received related to failed starter adapter assemblies. 
We are proposing this AD to prevent failure of the starter adapter 
assembly and or crankshaft gear, resulting in failure of the engine and 
possible forced landing.

DATES: We must receive any comments on this proposed AD by June 6, 
2005.

ADDRESSES: Use one of the following addresses to comment on this 
proposed AD.
     DOT Docket Web site: Go to https://dms.dot.gov and follow 
the instructions for sending your comments electronically.
     Government-wide rulemaking Web site: Go to https://
www.regulations.gov and follow the instructions for sending your 
comments electronically.
     Mail: Docket Management Facility; U.S. Department of 
Transportation, 400
    Seventh Street, SW., Nassif Building, Room PL-401, Washington, DC 
20590-001.
     Fax: (202) 493-2251.
     Hand Delivery: Room PL-401 on the plaza level of the 
Nassif Building, 400 Seventh Street, SW., Washington, DC, between 9 
a.m. and 5 p.m., Monday through Friday, except Federal holidays.
    You can get the service information identified in this proposed AD 
from Teledyne Continental Motors, Inc., PO Box 90, Mobile, AL 36601; 
telephone (251) 438-3411.
    You may examine the comments on this proposed AD in the AD docket 
on the Internet at https://dms.dot.gov.

FOR FURTHER INFORMATION CONTACT: Jerry Robinette, Senior Engineer, 
Propulsion, Atlanta Aircraft Certification Office, FAA, Small Airplane 
Directorate, One Crown Center, 1895 Phoenix Blvd., Suite 450, Atlanta, 
GA 30349; telephone: (770) 703-6096, fax: (770) 703-6097.

SUPPLEMENTARY INFORMATION:

Comments Invited

    We invite you to send us any written relevant data, views, or 
arguments regarding this proposal. Send your comments to an address 
listed under ADDRESSES. Include ``Docket No. FAA-2005-20850; 
Directorate Identifier 2005-NE-05-AD'' in the subject line of your 
comments. We specifically invite comments on the overall regulatory, 
economic, environmental, and energy aspects of the proposed AD. We will 
consider all comments received by the closing date and may amend the 
proposed AD in light of those comments.
    We will post all comments we receive, without change, to https://
dms.dot.gov, including any personal information you provide. We will 
also post a report summarizing each substantive verbal contact with FAA 
personnel concerning this proposed AD. Using the search function of the 
DMS Web site, anyone can find and read the comments in any of our 
dockets, including the name of the individual who sent the comment (or 
signed the comment on behalf of an association, business, labor union, 
etc.). You may review the DOT's complete Privacy Act Statement in the 
Federal Register published on April 11, 2000 (65 FR 19477-78) or you 
may visit https://dms.dot.gov.

Examining the AD Docket

    You may examine the docket that contains the proposal, any comments 
received and, any final disposition in person at the DMS Docket Offices 
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

[[Page 17367]]

ADDRESSES. Comments will be available in the AD docket shortly after 
the DMS receives them.

Discussion

    Between January 1980 and January 2001, we received one loss of 
airplane report and 34 service difficulty reports related to failure of 
the starter adapter assembly or crankshaft gear or both, on TCM GTSIO-
520 series reciprocating engines. On March 2, 2001, we issued Special 
Airworthiness Information Bulletin (SAIB) No. NE-01-17. That SAIB 
states the following:
     Engine failure may occur if the starter adapter viscous 
damper becomes inoperative, due to overheating, or other causes.
     Continued operation of an engine with an overheated 
viscous damper may lead to failure of the starter adapter assembly and 
or crankshaft gear.
     Overheating of the viscous damper may be caused by exhaust 
gas leakage in the nacelle area, and in particular, the engine 
accessory section of the engine nacelle.
     A rough-running engine such as one with a misfiring 
ignition system, will cause overheating of the viscous damper.
     Recommendation to perform visual inspections and parts 
replacement as necessary, as described in TCM Critical Service Bulletin 
(CSB) No. CSB94-4D.
    After we issued that SAIB, we received six service difficulty 
reports and one fatal accident report related to failed starter adapter 
assemblies. The fatal accident event indicates that the airplane may 
not have been in compliance with TCM CSB No. CSB94-4D. This condition, 
if not corrected, could result in failure of the starter adapter 
assembly and or crankshaft gear, resulting in failure of the engine, 
and possible forced landing.

Relevant Service Information

    We have reviewed and approved the technical contents of TCM 
Mandatory Service Bulletin (MSB) No. MSB94-4E, dated January 24, 2005, 
that describes procedures for visual inspections of the starter adapter 
assembly and crankshaft gear and replacement of components as 
necessary. That MSB also describes procedures for replacement of the 
starter adapter shaft gear needle bearing with a bushing. That MSB also 
describes procedures for installation of TCM service kit, part number 
(P/N) EQ6642R, at next engine overhaul, or next starter adapter 
replacement, whichever occurs first.

Differences Between the Proposed AD and the Manufacturer's Service 
Information

    Although TCM MSB No. MSB94-4E, dated January 24, 2005, is 
applicable to GIO-550 and GTSIO-520 series reciprocating engines, this 
proposed AD is only applicable to GTSIO-520 series reciprocating 
engines. Also, although that MSB mandates in Part 1, that magnetos must 
be overhauled and periodically inspected at specified times, this 
proposed AD does not mandate those actions.

FAA's Determination and Requirements of the Proposed AD

    We have evaluated all pertinent information and identified an 
unsafe condition that is likely to exist or develop on other products 
of this same type design. We are proposing this AD, which would 
require:
     Before further flight, adding a placard to the instrument 
panel within view of the pilot that states, in \1/4\ inch-high or 
higher characters, ``In accordance with AD (number to be provided), the 
pilot must report a rough-running engine that cannot be cleared by 
adjustment of the engine controls; particularly the fuel mixture 
setting, to maintenance personnel, immediately after landing.''
     Initial and repetitive visual inspections of the starter 
adapter assembly and crankshaft gear, and replacement of components as 
necessary.
     Unscheduled visual inspections of the starter adapter 
assembly and crankshaft gear due to a rough-running engine, and 
replacement of components as necessary.
     Replacement of the starter adapter shaft gear needle 
bearing, P/N 537721 with bushing, P/N 654472.
     Installation of TCM service kit, P/N EQ6642R, at next 
engine overhaul, or at next starter adapter replacement, whichever 
occurs first.

    The proposed AD would require you to use the service information 
described previously to perform the inspections and replacements.

Costs of Compliance

    There are about 5,300 TCM GTSIO-520 series reciprocating engines of 
the affected design in the worldwide fleet. We estimate that 4,240 
engines installed on airplanes of U.S. registry would be affected by 
this proposed AD. We also estimate that it would take about one work 
hour per engine to perform one of the proposed inspections, and about 
one work hour per engine to perform the proposed bushing installation. 
We also estimate that it will take about six work hours per engine to 
install TCM service kit, P/N EQ6642R. The average labor rate is $65 per 
work hour. We estimate that about 25% (1,060) of the engines will 
require an unscheduled (rough-running engine) inspection. We also 
estimate that each engine will have eight 100-hour inspections per 
year, and two 400-hour inspections per year. We also estimate that 
about 50% (2,120) of the engines will require the bushing installed and 
TCM service kit, P/N EQ6642R installed. Required bushings would cost 
about $16 per engine and required service kits would cost about $800 
per engine. Based on these figures, we estimate the total cost of the 
proposed AD to U.S. operators to be $5,518,932.

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 proposed AD would not have federalism 
implications under Executive Order 13132. This proposed AD would 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 the proposed 
regulation:
    1. Is not a ``significant regulatory action'' under Executive Order 
12866;
    2. Is not a ``significant rule'' under the DOT Regulatory Policies 
and Procedures (44 FR 11034, February 26, 1979); and
    3. Would not have a significant economic impact, positive or 
negative, on a substantial number of small entities under the criteria 
of the Regulatory Flexibility Act.

[[Page 17368]]

    We prepared a summary of the costs to comply with this proposal 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, Safety.

The Proposed Amendment

    Under the authority delegated to me by the Administrator, the 
Federal Aviation Administration proposes to amend 14 CFR part 39 as 
follows:

PART 39--AIRWORTHINESS DIRECTIVES

    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]

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

Teledyne Continental Motors: Docket No. FAA-2005-20850; Directorate 
Identifier 2005-NE-05-AD.

Comments Due Date

    (a) The Federal Aviation Administration (FAA) must receive 
comments on this airworthiness directive (AD) action by June 6, 
2005.

Affected ADs

    (b) None.

Applicability

    (c) This AD applies to Teledyne Continental Motors (TCM) GTSIO-
520 series reciprocating engines. These engines are installed on, 
but not limited to, Twin Commander (formerly Aero Commander) model 
685, Cessna model 404, 411 series, and 421 series, British 
Aerospace, Aircraft Group, Scottish Division model B.206 series 2 
and Aeronautica Macchi, model AM-3 airplanes.

Unsafe Condition

    (d) This AD results from six service difficulty reports and one 
fatal accident report received related to failed starter adapter 
assemblies. We are issuing this AD to prevent failure of the starter 
adapter assembly and or crankshaft gear, resulting in failure of the 
engine and possible forced landing.

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.

Aircraft Placard Installation and Compliance

    (f) Before further flight, install a placard to the instrument 
panel in \1/4\ inch-high or higher characters, within plain view of 
the pilot that states: ``In accordance with AD (number to be 
provided), the pilot must report a rough-running engine that cannot 
be cleared by adjustment of the engine controls; particularly the 
fuel mixture setting, to maintenance personnel, immediately after 
landing.''

Starter Adapter Shaft Gear Needle Bearing Replacement

    (g) If, during an inspection required by paragraph (h), (i), 
(j), or (k) of this AD, you find needle bearing, part number (P/N) 
537721, installed in the crankcase, replace it with bushing, P/N 
654472, before reassembling components. Use the bushing installation 
procedure specified in Part 4 of TCM Mandatory Service Bulletin 
(MSB) No. MSB94-4E, dated January 24, 2005.

Unscheduled Inspections for Rough-Running Engines

    (h) For any engine that experiences rough running conditions 
regardless of time-in-service (TIS), do the following:
    (1) Before further flight, perform the inspection procedures 
specified in Part 1 and Part 3 of TCM MSB No. MSB94-4E, dated 
January 24, 2005, and replace components as necessary.
    (2) An engine is considered rough-running if there is a sudden 
increase in the perceived vibration levels that cannot be cleared by 
adjustment of the engine controls; particularly the fuel mixture 
setting. Information on a rough running engine can be found in the 
aircraft manufacturer's Airplane Flight Manual, Pilot's Operating 
Handbook, or Aircraft Owners Manual.

100-Hour and Annual Inspections

    (i) For any engine, at the next 100-hour or annual inspection, 
whichever occurs first, do the following:
    (1) Perform the inspection procedures specified in Part 2 of TCM 
MSB No. MSB94-4E, dated January 24, 2005, and replace components as 
necessary.
    (2) Thereafter, at each 100-hour inspection, (plus or minus 10 
hours), and annual inspection, perform repetitive inspections and 
component replacements as specified in paragraph (h)(1) of this AD.

Starter Adapters With 400 Hours or More Time-In-Service (TIS) or 
Unknown TIS

    (j) For any starter adapter with 400 hours or more TIS or 
unknown TIS on the effective date of this AD, do the following:
    (1) Within 25 hours TIS, perform the inspection procedures 
specified in Part 3 of TCM MSB No. MSB94-4E, dated January 24, 2005, 
and replace components as necessary.
    (2) Thereafter, at 400-hour TIS intervals, (plus or minus 10 
hours), perform repetitive inspections and component replacements as 
specified in Part 3 of TCM MSB No. MSB94-4E, dated January 24, 2005, 
and replace components as necessary.

Starter Adapters With Fewer Than 400 Hours TIS

    (k) For any starter adapter with fewer than 400 hours TIS on the 
effective date of this AD, do the following:
    (1) Upon accumulation of 400 hours TIS, (plus or minus 10 
hours), perform the inspection procedures specified in Part 3 of TCM 
MSB No. MSB94-4E, dated January 24, 2005, and replace components as 
necessary.
    (2) Thereafter, at 400-hour TIS intervals, (plus or minus 10 
hours), perform repetitive inspections and component replacements, 
as specified in Part 3 of TCM MSB No. MSB94-4E, dated January 24, 
2005, and replace components as necessary.

Installation of TCM Service Kit, EQ6642R

    (l) At the next engine overhaul or starter adapter replacement 
after the effective date of this AD, whichever occurs first, do the 
following:
    (1) Install TCM service kit, P/N EQ6642R. Use the service kit 
installation procedures specified in Part 5 of TCM MSB No. MSB94-4E, 
dated January 24, 2005.
    (2) Continue performing the inspections and component 
replacements specified in paragraphs (i), (j), and (k) of this AD.

Prohibition of Special Flight Permits for Rough-Running Engines

    (m) Special flight permits are prohibited for rough-running 
engines described in paragraph (h)(2) of this AD.

Alternative Methods of Compliance

    (n) The Manager, Atlanta 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

    (o) European Aviation Safety Agency AD 2004-0006, dated December 
15, 2004, also addresses the subject of this AD.

    Issued in Burlington, Massachusetts, on March 30, 2005.
Diane Cook,
Acting Manager, Engine and Propeller Directorate, Aircraft 
Certification Service.
[FR Doc. 05-6775 Filed 4-5-05; 8:45 am]
BILLING CODE 4910-13-P