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Proposed Rule
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We must receive any comments on this proposed AD by March 13, 2006.
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AGENCY:
Federal Aviation Administration (FAA), Department of Transportation (DOT).
ACTION:
Notice of proposed rulemaking (NPRM).
SUMMARY:
The FAA proposes to supersede an existing airworthiness directive (AD) for Lycoming Engines (formerly Textron Lycoming) models 320, 360, and 540 series, “Parallel Valve” reciprocating engines, with certain Engine Components Inc. (ECi) cylinder assemblies, part number (P/N) AEL65102 series “Classic Cast”, installed. That AD currently requires replacing these ECi cylinder assemblies. This proposed AD would require the same actions, but would replace the “Engine Models” Table 1 and “Engines Installed On, But Not Limited To” Table 2 with corrected tables. Also, this proposed AD would correct a casting part number. This proposed AD results from reports of applicability errors found in AD 2005-26-10. We are proposing this AD to prevent loss of engine power due to cracks in the cylinder assemblies and possible engine failure caused by separation of a cylinder head.
DATES:
We must receive any comments on this proposed AD by March 13, 2006.
ADDRESSES:
Use one of the following addresses to comment on this proposed AD.
DOT Docket Web site: Go tohttp://dms.dot.gov
and follow the instructions for sending your comments electronically.
Government-wide rulemaking Web site: Go tohttp://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 20590-0001.
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.
FOR FURTHER INFORMATION CONTACT:
Peter Hakala, Aerospace Engineer, Special Certification Office, FAA, Rotorcraft Directorate, 2601 Meacham Blvd., Fort Worth, TX 76193; telephone (817) 222-5145; fax (817) 222-5785.
SUPPLEMENTARY INFORMATION:
Comments Invited
We invite you to send any written relevant data, views, or arguments regarding this proposal. Send your comments to an address listed under
ADDRESSES
. Include “Docket No. FAA-2005-22358; Directorate Identifier 2005-NE-20-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
http://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
http://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 Office 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.
Discussion
On December 19, 2005, we issued AD 2005-26-10, Amendment 39-14431 (70 FR 76385, December 27, 2005). That AD requires replacing ECi cylinder assemblies P/N AEL65102 series “Classic Cast”, having casting P/N AEL65099 and SN 1 through 9879. That AD was the result of reports of about 30 failures of the subject cylinder assemblies marketed by ECi. That condition, if not corrected, could result in loss of engine power due to cracks in the cylinder assemblies and possible engine failure caused by separation of a cylinder head.
Actions Since AD 2005-26-10 was Issued
Since AD 2005-26-10 was issued, we received reports of errors in the “Engine Models” Table 1, and “Engines Installed On, But Not Limited To” Table 2. Also, we discovered an incorrect part number in paragraph (h)(3).
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. For that reason, we are proposing this AD to ensure that operators are provided with the correct applicability, which would require:
Replacing ECi cylinder assemblies P/N AEL65102 series “Classic Cast”, having casting P/N AEL65099 and SN 1 through 9879 (sold from January 1997 to September 2001); (same as AD 2005-26-10);
Replacing the “Engine Models” Table 1 with a corrected Table 1, to ensure that operators are provided with the correct applicability; and
Replacing the “Engines Installed On, But Not Limited To” Table 2 with a corrected Table 2; and
Replacing casting P/N AEL85009 with P/N AEL85099 in paragraph (h)(3),
( printed page 9481)
“Definition of a Replacement Cylinder Assembly”.
Costs of Compliance
There were 9,879 ECi cylinder assemblies produced of the affected design available to the worldwide fleet. ECi reported that about fifteen percent of their cylinder assemblies go to foreign countries. We estimate ten percent of the remaining cylinders were never installed or are already removed from service, leaving 7,557 cylinder assemblies in service in the United States. We estimate that 1,574 Lycoming engines are in the United States with the subject cylinder assemblies installed. We estimate that it would take about two work hours per engine to perform the proposed aircraft inspections of the cylinder assemblies for applicability, and that the average labor rate is $65 per work hour. From the Lycoming Engines “Removal and Installation Labor Allowance Guidebook”, dated May 2000, the complete cylinder replacement for a four cylinder engine takes 12 hours, while the complete cylinder replacement for a six cylinder engine takes 16 hours. Required parts would cost about $1,000 per cylinder assembly. Based on these figures, we estimate that the total cost of the proposed AD to U.S. operators to be $9,152,140. ECi indicated that they might give operators and repair stations credit for returned cylinder assemblies toward the purchase of new ECi cylinder assemblies.
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:
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.
We prepared a regulatory evaluation of the estimated costs to comply with this proposed AD. See the
ADDRESSES
section for a location to examine the regulatory evaluation.
(a) The Federal Aviation Administration (FAA) must receive comments on this airworthiness directive (AD) action by March 13, 2006.
Affected ADs
(b) This AD supersedes AD 2005-26-10, Amendment 39-14431.
Applicability
(c) This AD applies to Lycoming Engines (formerly Textron Lycoming) models 320, 360, and 540 series, parallel valve, reciprocating engines specified in Table 1 of this AD, with Engine Components Inc. (ECi) cylinder assemblies, part number (P/N) AEL65102 series “Classic Cast”, having casting P/N AEL65099 and serial numbers (SNs) 1 through 9879, (sold from January 1997 to September 2001) installed.
Maule: Star Rocket (MX-7-235), Super Rocket (M-6-235), Super Std. Rocket (M-7-235).
O-540-J3A5
Robin: R-3000/235.
O-540-J3A5D
Piper Aircraft: Dakota (PA-28-236).
O-540-J3C5D
Cessna Aircraft: Skylane RG.
O-540-L3C5D
Cessna Aircraft: TR-182, Turbo Skylane RG.
IO-540-C1B5
Piper Aircraft: Aztec B (PA-23 “250”), Comanche (PA-24 “250”).
IO-540-C1C5
Riley Aircraft: Turbo-Rocket.
IO-540-C4B5
Piper Aircraft: Aztec C (PA-23 “250”), Aztec F.
Wassmer: (WA4-21).
Avions Pierre Robin: (HR100/250).
Bellanca Aircraft: Aries T-250.
Aerofab: Renegade 250.
IO-540-C4D5
S.O.C.A.T.A.: TB-20.
IO-540-C4D5D
S.O.C.A.T.A.: Trinidad TB-20.
IO-540-D4A5
Piper Aircraft: Comanche (PA-24 “260”).
Siai-Marchetti: (SF-260).
IO-540-D4B5
Cerva: (CE-43 Guepard).
IO-540-J4A5
Piper Aircraft: Aztec (PA-23 “250”).
IO-540-R1A5
Piper Aircraft: Comanche (PA-24).
IO-540-T4A5D
General Aviation: Model 114.
IO-540-T4B5
Commander: 114B.
IO-540-T4B5D
Rockwell: 114.
IO-540-T4C5D
Lake Aircraft: Seawolf.
IO-540-V4A5
Maule: MT-7-260, M-7-260.
Aircraft Manufacturing Factory.
IO-540-V4A5D
Brooklands: Scoutmaster.
IO-540-W1A5
Maule: MX-7-235, MT-7-235, M7-235.
IO-540-W1A5D
Maule: Star Rocket (MX-7-235), Super Rocket (M-6-235), Super Std. Rocket (M-7-235).
IO-540-W3A5D
Schweizer: Power Glider.
AEIO-540-D4A5
Christen: Pitts (S-2S), S-2B).
Siai-Marchetti: SF-260.
H.A.L.: HPT-32.
Slingsby: Firefly T3A.
AEIO-540-D4B5
Moravan: Zlin-50L.
H.A.L.: HPT-32.
AEIO-540-D4D5
Burkhart Grob: Grob G, 115T Aero.
TIO-540-C1A
Piper Aircraft: Turbo Aztec (PA-23-250).
TIO-540-K1AD
Piper Aircraft.
TIO-540-AA1AD
Aerofab Inc.: Turbo Renegade (270).
TIO-540-AB1AD
S.O.C.A.T.A.: Trinidad TC TB-21.
TIO-540-AB1BD
Schweizer.
TIO-540-AF1A
Mooney Aircraft: “TLS” M20M.
TIO-540-AG1A
Commander Aircraft: 114TC.
( printed page 9487)
TIO-540-AK1A
Cessna Aircraft: Turbo Skylane T182T.
LTIO-540-K1AD
Piper Aircraft.
Unsafe Condition
(d) This AD results from reports of applicability errors found in AD 2005-26-10. We are issuing this AD to prevent loss of engine power due to cracks in the cylinder assemblies 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.
Engines Not Overhauled or Repaired Since New
(f) If your engine has not been overhauled or had any major repair since new, no further action is required.
Engines Overhauled or Repaired Since New
(g) If your engine was overhauled or repaired since new, do the following:
(1) Determine if ECi cylinder assemblies, P/N AEL65102 series “Classic Cast”, having casting P/N AEL65099 and SNs 1 through 9879 are installed on your engine, as follows:
(i) Inspect the engine log books and maintenance records for reference to the subject ECi cylinder assemblies.
(ii) If the engine log books and maintenance records did not record the P/N and SN of the cylinder assemblies, visually inspect the cylinder assemblies and verify the P/N and SN of the cylinder assemblies.
(2) If the cylinder assemblies are not ECi, P/N AEL65102 series “Classic Cast”, having casting P/N AEL65099, no further action is required.
(3) If any cylinder assembly is an ECi P/N AEL65102 series “Classic Cast”, having casting P/N AEL65099 and a SN 1 through 9879, do the following:
(i) If the cylinder assembly has fewer than 800 operating hours-in-service (HIS) on the effective date of this AD, replace the cylinder assembly at no later than 800 operating HIS. No action is required until the operating HIS reaches 800 hours.
(ii) If the cylinder assembly has 800 operating HIS or more on the effective date of this AD, replace the cylinder assembly within 60 operating HIS after the effective date of this AD.
Definition of a Replacement Cylinder Assembly
(h) For the purpose of this AD, a replacement cylinder assembly is defined as follows:
(1) A serviceable cylinder assembly made by Lycoming Engines.
(2) A serviceable FAA-approved, Parts Manufacturer Approval cylinder assembly from another manufacturer.
(3) A serviceable ECi cylinder assembly, P/N AEL65102 series, “Titan”, having casting P/N AEL85099.
(4) A serviceable ECi cylinder assembly, P/N AEL65102 series, having casting P/N AEL65099, that has a SN 9880 or higher.
Prohibition of Cylinder Assemblies, P/N AEL65102 Series “Classic Cast”, Having Casting P/N AEL65099, and SNs 1 Through 9879
(i) After the effective date of this AD, do not install any ECi cylinder assembly, P/N AEL65102, having casting P/N AEL65099 that has a SN 1 through 9879, onto any engine.
Alternative Methods of Compliance
(j) 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.
Related Information
(k) ECi Service Bulletin No. 05-08, Revision 1, dated December 29, 2005, pertains to the subject of this AD.
Issued in Burlington, Massachusetts, on February 15, 2006.
Ann C. Mollica,
Acting Manager, Engine and Propeller Directorate, Aircraft Certification Service.