Aircraft
Certification Service Washington, DC U.S. Department of Transportation Federal Aviation Administration
NE-10-09
November 20, 2009
This is information only. Recommendations
aren’t mandatory.
Introduction
This Special Airworthiness Information Bulletin (SAIB) alerts you,
owners, operators, certificated repair facilities, and flight standards
district offices, of Teledyne Continental Motors (TCM) 240, 360, 470,
520, and 550 series reciprocating engines and Rolls-Royce Motors, Ltd.
(R-RM) 240 and 360 series reciprocating engines hydraulic lifter
failures. These TCM hydraulic lifters, part numbers (P/Ns) 657913,
657915, and 657916 have experienced rapid wear on the surface of the
hydraulic lifter assemblies both in new and rebuilt engines. Hydraulic
lifter failures have occurred at very low time-in-service (i.e.,
between 5 and 38 hours). When a hydraulic lifter fails, it no longer
opens the associated valve, which makes the associated cylinder
ineffective. As a result, the engine runs rough with a loss of power
potentially leading to a safety of flight issue.
Background
Teledyne Continental Motors has identified a service issue with certain
TCM hydraulic lifters. TCM has verified and documented occurrences of
rapid wear on the surface of the hydraulic lifter assemblies, both in
new and rebuilt engines and hydraulic lifter assemblies sold as spares
beginning on 19 June 2009. All TCM 240, 360, 470, 520, and 550 series
reciprocating engine models and R-RM 240 and 360 series reciprocating
engines are affected. In June 2009, TCM released for production new
part number lifters made from casting from a different foundry. To
distinguish the change in the casting source, these parts were assigned
new part numbers. Hydraulic lifters manufactured using castings from
the new source were designated by part numbers 657913, 657915, and
657916.
TCM has issued Mandatory Service Bulletin (MSB) No. MSB09-8, dated
November 3, 2009. MSB09-8 details inspection procedures to prevent an
engine cylinder failure. The FAA issued emergency airworthiness
directive (AD) 2009-24-52, dated November 18, 2009, to mandate
inspection and replacement of these hydraulic lifters. The inspections
are to be accomplished before further flight of any airplane with an
affected engine model installed. The MSB lists those engine models and
serial numbers that had the affected hydraulic lifters installed at the
factory. Engines that had the affected hydraulic lifters installed
during field repair or maintenance should also be inspected.
Replacement hydraulic lifters should be part numbers 628488, 646277,
653877, 653888, or 653906.
Hydraulic lifters, part numbers 653877, 653888, and 653906, are not
affected by the MSB or AD 2009-24-52. The FAA has approved the
installation of TCM factory-rebuilt hydraulic lifters in affected
engine models. These hydraulic lifters have accumulated previous hours
time-in-service, but have been inspected, reconditioned, and
functionally tested.
Recommendations
The FAA recommends that you replace TCM hydraulic lifters, P/Ns 657913,
657915, and 657916. The FAA has approved the installation of TCM
factory rebuilt hydraulic lifters, P/Ns 628488, 646277, 653877, 653888,
or 653906, during assembly of the affected engines (new, overhauled,
rebuilt, or repaired). These TCM factory rebuilt hydraulic lifters have
accumulated previous time in service. However, these TCM factory
rebuilt hydraulic lifters are 1) inspected and reconditioned to comply
with new print limits, 2) comply with approved oversize/undersize
tolerances, and 3) functionally tested. The FAA approved the
installation of these TCM factory rebuilt hydraulic lifters during
assembly of the affected engines (new, overhauled, rebuilt, or
repaired) due to shortage of replacement parts only from November 16,
2009 through May 16, 2010.
For Further Information Contact
Anthony Holton, Aerospace Engineer, Atlanta Aircraft Certification
Office, FAA, Small Airplane Directorate, 1701 Columbia Avenue, College
Park, GA 30337; e-mail: anthony.holton@faa.gov; phone (404) 474-5567;
fax (404) 474-5506.
For Related Service Information Contact
Teledyne Continental Motors, 2039 Broad Street, Mobile, AL 36615;
mailing address: P.O. Box 90, Mobile, AL 36601; phone (888) 826-5465;
or go to: www.genuinecontinental.com.