Airworthiness Directives; Engine Components Incorporated (ECi) Reciprocating Engine Cylinders

[Federal Register Volume 69, Number 76 (Tuesday, April 20, 2004)]
[Rules and Regulations]
[Pages 21049-21053]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 04-8877]


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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. 2004-NE-07-AD; Amendment 39-13579; AD 2004-08-10]
RIN 2120-AA64


Airworthiness Directives; Engine Components Incorporated (ECi) 
Reciprocating Engine Cylinders

AGENCY: Federal Aviation Administration (FAA), DOT.

ACTION: Final rule; request for comments.

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SUMMARY: The FAA is adopting a new airworthiness directive (AD) for 
Teledyne Continental Motors (TCM) models 520 and 550 series engines 
with certain ECi cylinders installed. This AD requires replacing 
certain serial-numbered (SN) cylinders supplied by ECi before further 
flight. This AD results from reports of 34 failures of cylinder heads 
marketed by ECi. We are issuing this AD to prevent loss of engine power 
due to cracks in the cylinder head and possible engine failure caused 
by separation of a cylinder head.

DATES: This AD becomes effective May 5, 2004.
    We must receive any comments on this AD by June 21, 2004.

ADDRESSES: Use one of the following addresses to submit comments on 
this AD:
    <bullet<ls-thn-eq> By mail: The Federal Aviation Administration 
(FAA), New England Region, Office of the Regional Counsel, Attention: 
Rules Docket No. 2004-NE-07-AD, 12 New England Executive Park, 
Burlington, MA 01803-5299.
    <bullet<ls-thn-eq> By fax: (781) 238-7055.
    <bullet<ls-thn-eq> By e-mail: [email protected]. 
    You can get the service information referenced in this AD from 
Engine Components, Inc., 9503 Middlex, San Antonio, TX 78217; Phone 
(210) 820-8100; fax (210) 820-3103.
    You may examine the AD docket at the FAA, New England Region, 
Office of the Regional Counsel, 12 New England Executive Park, 
Burlington, MA.

FOR FURTHER INFORMATION CONTACT: Fred Stellar, Branch Manager, Special 
Certification Office, FAA, Rotorcraft Directorate, 2601 Meacham Blvd., 
Fort Worth, TX 76193; telephone (817) 222-5199; fax (817) 222-5785.

SUPPLEMENTARY INFORMATION: On February 1, 2003, we received a report of 
an ECi cylinder head, part number (P/N) AEC65385, that separated from 
the barrel at the head-to-barrel junction. Since that report, we have 
received reports of 27 additional ECi cylinder heads that had the same 
condition. We also received reports of six cylinder heads that had a 
crack between the 9th and 10th head fin from the head-to-barrel 
junction. All of the reported separations and cracks were located 
between the ninth and tenth head fin from the head-to-barrel junction. 
All of the cracks started on the exhaust side of the head. The ECi 
cylinder head, P/N AEC65385, is part of ECi cylinder, P/N AEC631397. 
RAM Series III, IV, and VII reciprocating engines are the primary users 
of these cylinders. The RAM series engines are TCM TSIO-520-NB, -VB, 
and -WB engines that are modified by supplemental type certificate 
(STC) SE4327SW, STC SE09104SC, or STC SE09261SC for operation at 325 HP 
or greater. In addition, we approved the engine cylinders, ECi P/N 
AEC631397 for use on TCM models 520 and 550 series reciprocating 
engines under a Parts Manufacturer Approval (PMA). The Airmotive Engine 
Division of ECi holds the PMA. ECi markets the parts as ECi parts.

Results of Manufacturer's Investigation

    An investigation by ECi revealed that cylinder heads, P/N AEC65385, 
manufactured between September 1, 2002, and May 12, 2003, SNs 1044 
through 7708, are susceptible to an over-hardened condition, which 
reduces the fatigue strength of the cylinder. It also increases the 
chance that the cylinder will crack.

Relevant Service Information

    We reviewed and approved the technical contents of RAM Aircraft 
Mandatory Service Bulletin (MSB) MSB2003-02, dated August 8, 2003, and 
ECi MSB S.I. No. 04-1, Revision 1, dated March 11, 2004, that describe 
procedures for identifying, inspecting, and replacing affected 
cylinders.

Differences Between This AD and the Service Information

    RAM Aircraft MSB MSB2003-02, dated August 8, 2003, requires 
replacing only the No. 6 cylinder, ECi P/N AEC631397, on RAM Series 
III, IV, and VII engines. ECi MSB S.I. No. 04-1, Revision 1, dated 
March 11, 2004, requires identifying the suspect cylinders on TCM 
models 520 and 550 engines and inspecting them for cracks. This AD 
requires replacing all cylinders, ECi P/N AEC631397, on all RAM Series 
III, IV, and VII engines; a\nd all TCM model 520, and 550 series 
engines.

FAA's Determination and Requirements of This AD

    The unsafe condition described previously is likely to exist or 
develop on other RAM Series III, IV, and VII engines; and TCM model 
520, and 550 series engines of the same type design. We are issuing 
this AD to prevent loss of engine power due to cracks in the cylinder 
head and possible engine failure caused by separation of a cylinder 
head. This AD requires:
    <bullet<ls-thn-eq> Performing a check to identify cylinders, ECi P/
N AEC631397, S/Ns 1044 through 7708, within 50 hours time-in-service 
after the effective date of this AD. and
    <bullet<ls-thn-eq> If a cylinder has an affected P/N and SN, 
replacing the cylinder before further flight if it was not inspected at 
ECi.

FAA's Determination of the Effective Date

    Since an unsafe condition exists that requires the immediate 
adoption of this AD, we have found that notice and opportunity for 
public comment before issuing this AD are impracticable, and that good 
cause exists for making this amendment effective in less than 30 days.

Comments Invited

    This AD is a final rule that involves requirements affecting flight 
safety and was not preceded by notice and an opportunity for public 
comment; however, we invite you to submit any written relevant data, 
views, or arguments regarding this AD. Send your comments to an address 
listed under ADDRESSES. Include ``AD Docket No. 2004-NE-07-AD'' in the 
subject line of your comments. If you want us to acknowledge receipt of 
your mailed comments, send us a self-addressed, stamped postcard with 
the docket

[[Page 21050]]

number written on it; we will date-stamp your postcard and mail it back 
to you. We specifically invite comments on the overall regulatory, 
economic, environmental, and energy aspects of the rule that might 
suggest a need to modify it. If a person contacts us verbally, and that 
contact relates to a substantive part of this AD, we will summarize the 
contact and place the summary in the docket. We will consider all 
comments received by the closing date and may amend the AD in light of 
those comments.
    We are reviewing the writing style we currently use in regulatory 
documents. We are interested in your comments on whether the style of 
this document is clear, and your suggestions to improve the clarity of 
our communications with you. You can get more information about plain 
language at http://www.faa.gov/language and http://www.plainlanguage.gov.

Examining the AD Docket

    You may examine the AD Docket (including any comments and service 
information), by appointment, between 8:00 a.m. and 4:30 p.m., Monday 
through Friday, except Federal holidays. See ADDRESSES for the 
location.

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 the 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. 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 by 
sending a request to us at the address listed under ADDRESSES. Include 
``AD Docket No. 2004-NE-07-AD'' in your request.

List of Subjects in 14 CFR Part 39

    Air transportation, Aircraft, Aviation safety, Safety.

Adoption of the Amendment

0
Accordingly, under the authority delegated to me by the Administrator, 
the Federal Aviation Administration amends part 39 of the Federal 
Aviation Regulations (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:

2004-08-10 Engine Components Incorporated (ECi): Amendment 39-13579. 
Docket No. 2004-NE-07-AD.

Effective Date

    (a) This airworthiness directive (AD) becomes effective May 5, 
2004.

Affected ADs

    (b) None.

Applicability

    (c) This AD applies to Teledyne Continental Motors (TCM) TSIO-
520-NB, -VB, and -WB engines that are modified by supplemental type 
certificate (STC) SE4327SW, STC SE09104SC, or STC SE09261SC for 
operation at 325 HP or greater, (the so-called RAM TSIO-520-NB, -VB, 
or -WB Series III, IV, and VII reciprocating engines; and Teledyne 
Continental Motors (TCM) model 520 and 550 series reciprocating 
engines with certain ECi reciprocating engine cylinders, part number 
(P/N) AEC631397, installed. These engines are installed on, but not 
limited to the airplanes listed in the following Table 1:

        Table 1.--List of Airplanes That Use the Affected Engines
------------------------------------------------------------------------
    Airplane manufacturer and model                Engine model
------------------------------------------------------------------------
AERFER/AERMECCHI AM, 3.................  GTSIO-520-C
AERO COMMANDER:
  200D.................................  IO-520-A
  500A COLEMILL CONVERSION.............  IO-520-E
  685..................................  GTSIO-520-K
AISA: F20, PEGASO......................  IO-520-K
AMBROSIN MF-151........................  IO-520-F
AVIONES PIHAO..........................  IO-520-D
BEAGLE (U.K.): B206S...................  GTSIO-520-C
BEECHCRAFT BARON:
  C55..................................  IO-520-CB, -C
  D55..................................  IO-520-CB, -C
  E55..................................  IO-520-CB, -C
  58...................................  IO-520-CB
  58P..................................  TSIO-520-LB
  58P..................................  TSIO-520-L
  58P..................................  TSIO-520-WB
  58TC.................................  TSIO-520-LB
  58TC.................................  TSIO-520-L
  58TC.................................  TSIO-520-WB
BEECHCRAFT BONANZA:
  A36..................................  IO-550-B
  E33A.................................  IO-520-BA
  E33A.................................  IO-520-BB
  E33B.................................  IO-520-B
  F33..................................  IO-520-BB
  F33A.................................  IO-520-B
  F33A.................................  IO-520-BA
  F33A.................................  IO-520-BB
  S35..................................  IO-520-B
  ST35.................................  TSIO-520-D
  V35..................................  IO-520-BB
  V35A.................................  IO-520-B
  V35A-TC..............................  TSIO-520-D
  V35B.................................  IO-520-B
  V35B.................................  IO-520-BA
  V35B.................................  IO-520-BB
  A36..................................  IO-520-B
  A36..................................  IO-520-BA
  A36..................................  IO-520-BB
  A36-TC...............................  TSIO-520-UB
BEECHCRAFT DEBONAIR: C33A..............  IO-520-B
VIKING 300.............................  IO-520-A
                                         IO-520-D
                                         IO-520-K
BONNAIRE 185...........................  IO-520-D
BONNAIRE 188 CONVERSION................  IO-520-D
BURNS BA42.............................  IO-520-D
CESSNA:
  SUPER SKYLANE A, B, C, D, E..........  IO-520-A
  TURBO SUPER SKYLANE..................  TSIO-520-C
  SKYWAGON A185 E,F....................  IO-520-D
  SKYWAGON A185FII.....................  IO-520-D
  AG SPRAYER 188-300...................  IO-520-D
  A188-230.............................  IO-520-D
  AG TRUCK (A 188B) -300...............  IO-520-D
  AG HUSKEY (A 188C) -310..............  TSIO-520-T
  AG WAGON (A 188B)....................  IO-520-D
  SUPER SKYWAGON U206, A...............  IO-520-A
  U206B, C, D, E, F....................  IO-520-F
  TURBO SKYWAGON TU206 A...............  IO-520-C
  TU206B, C, D, E, F...................  TSIO-520-C
  STATIONAIR U206......................  IO-520-F
  TU206................................  TIOS-520-C
  U206FII-300..........................  IO-520-F
  U206G-300............................  IO-520-F
  U206GII-300..........................  IO-520-L
  TU206G-310...........................  TSIO-520-M
  SUPER SKYLANE P206A..................  IO-520-A
  P206B, C, D, E.......................  IO-520-A
  TURBO P 206 A, B, C, D, E............  TSIO-520-C
  SKYWAGON 207.........................  IO-520-F
  TURBO 207............................  TSIO-520-G
  STATIONAIR 207A, 207AII..............  IO-520-F
  STATIONAIR 8, 811....................  IO-520-F
  T-STATIONAIR 811.....................  TSIO-520-M

[[Page 21051]]

 
  210 CENTURION D, E, F, G, H..........  IO-520-A
  210 CENTURION J......................  IO-520-J
  210 CENTURION K, L, M, N, R..........  IO-520-L
  210 CENTURION TURBO..................  TSIO-520-C
  210 CENTURION TURBO..................  TSIO-520-H
  210 CENTURION TURBO K, L.............  TSIO-520-H
  TURBO 210 J, K, L....................  TSIO-520-H
  TURBO 210 MII, NII...................  TSIO-520-R
  TURBO 210R...........................  TSIO-520-R
  PRESSURIZED CENTURION P210N..........  TSIO-520-P
  PRESSURIZED CENTURION P210NII........  TSIO-520-AF
  PRESSURIZED CENTURION P210R..........  TSIO-520-CE
  T303 CRUSADER........................  TSIO-520-AE
  T303 CRUSADER........................  LTSIO-520-AE
  310R.................................  IO-520-MB
  310R.................................  IO-520-M
  TURBO 310 P, Q.......................  TSIO-520-B
  TURBO 310 R..........................  TSIO-520-BB
  TURBO 310 R..........................  TSIO-520-B
  EXECUTIVE SKYNIGHT D, E, F...........  TSIO-520-B
  335..................................  TSIO-520-EB
  340..................................  TSIO-520-K
  340A.................................  TSIO-520-NB, -N
  401 A, 401 B.........................  TSIO-520-E
  402 A, 402 B.........................  TSIO-520-E
  402C.................................  TSIO-520-VB
  404 TITAN............................  GTSIO-520-M
  411, 411A............................  GTSIO-520-C
  414..................................  TSIO-520-J
  414, 414 A...........................  TSIO-520-NB, -N
  421A.................................  GTSIO-520-D
  421B.................................  GTSIO-520-H
  421C.................................  GTSIO-520-L
  421C.................................  GTSIO-520-N
JANOX JAVILON..........................  IO-520-B
NAVION:
  RANGEMASTER MODEL H..................  IO-520-B
  RANGEMASTER MODEL H..................  IO-520-BA
PIPER: MALIBU..........................  TSIO-520-BE
PRINAIR:
  DE HAVILLAND HERON...................  IO-520-E
  WINDECKER EAGLE......................  IO-520-C
------------------------------------------------------------------------

Unsafe Condition

    (d) This AD results from reports of 34 failures of ECi cylinder 
head. We are issuing this AD to prevent loss of engine power due to 
cracks in the cylinder head and possible engine failure caused by 
separation of a cylinder head.

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.

Identifying Suspect Cylinders

    (f) Within 50 hours time-in-service (TIS) after the effective 
date of this AD, identify, and if necessary replace cylinders, ECi 
P/N AEC631397 as follows:
    (1) Identify the cylinder serial number (SN) as follows:
    (i) Determine the SN of the cylinder by looking in the engine 
records or by inspecting the cylinder for a SN on the intake port 
boss (see Figure 1) or on the flat area next to the head to barrel 
junction (see Figure 2). Disregard any dash numbers that might 
follow the four digit SN.
[GRAPHIC] [TIFF OMITTED] TR20AP04.002


[[Page 21052]]


[GRAPHIC] [TIFF OMITTED] TR20AP04.003

    (ii) If the SN is 1043 or lower, or if it is 7709 or higher, no 
further action is required.
    (2) If the cylinder SN is 1044 through 7708, do the following:
    (i) Remove the rocker box cover from the cylinder.
    (ii) Look at the left-front cylinder casting.
    (iii) If the casting has AEC65385, and an ``O'' under the ECi 
logo, the cylinder is P/N AEC631397. See Figure 3.
[GRAPHIC] [TIFF OMITTED] TR20AP04.004

    (iv) If the cylinder is not ECi P/N AEC631397, no further action 
is required.
    (3) If the cylinder is ECi P/N AEC631397, do the following:
    (i) Look at the flange of the rocker box.

[[Page 21053]]

    (ii) If there is a letter ``A,'' ``B,'' or ``X'' stamped on the 
flange of the rocker box, no further action is required. See Figure 
4.
[GRAPHIC] [TIFF OMITTED] TR20AP04.005

    (iii) If there is no letter ``A,'' ``B,'' or ``X'' stamped on 
the flange of the rocker box, replace the cylinder before further 
flight.

Alternative Methods of Compliance

    (g) The Manager, Special 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.

Material Incorporated by Reference

    (h) None.

Related Information

    (i) ECi Mandatory Service Bulletin S.I. No. 04-1, revision 1, 
dated March 11, 2004, also pertains to this subject of this AD.

    Issued in Burlington, Massachusetts, on April 9, 2004.
Francis A. Favara,
Acting Manager, Engine and Propeller Directorate, Aircraft 
Certification Service.
[FR Doc. 04-8877 Filed 4-19-04; 8:45 am]
BILLING CODE 4910-13-P

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