COMMONWEALTH OF AUSTRALIA (Civil Aviation Regulations 1998), PART 39 - 106 CIVIL AVIATION SAFETY AUTHORITY
SCHEDULE OF AIRWORTHINESS DIRECTIVES
Lycoming Piston Engines
AD/LYC/101
Amdt 1
Superior Cylinders 3/97
Applicability: All Lycoming TIO/LTIO-540-A2C, -J2B, -F2BD, -J2BD, -N2BD, -R2AD, -S1AD
and IO-540-M1B5D engines fitted with Superior Air Parts Inc. cylinders part number (P/N) SL54000-A1, SL54000-A2, SL54000-A2P, SL54000-A20P and SL54000-
A21P with serials numbers 001 through 650.
Requirement: 1. To prevent the possible loss of a cylinder head, the subsequent loss of engine power and a possible engine fire, carry out:
- A visual inspection of applicable cylinder assemblies for evidence of combustion leaks and/or cracking in the area adjacent to the location of the inlet valve seat as detailed in Figure 1, and
b. An 80psi pressure “wet” leak check of the cylinder assemblies paying particular attention to the area detailed in Figure 1.
Remove from service before further flight, any cylinder showing either combustion gas leakage or cracks.
2. Remove applicable cylinders from service.
Note 1: For the purpose of Requirement 1.(B), a wet leak check may be carried out by using soapy water or a commercial leak detector product such as “Sherlock Leak Detector”.
Note 2: FAA Airworthiness Directive 97-01-04 refers.
COMMONWEALTH OF AUSTRALIA (Civil Aviation Regulations 1998), PART 39 - 106 CIVIL AVIATION SAFETY AUTHORITY
SCHEDULE OF AIRWORTHINESS DIRECTIVES
Compliance: 1. Cylinders with a time in service greater than 250 hours; within 5 hours time in service from the effective date of this directive and thereafter at intervals not to exceed 25 hours time in service.
Cylinders with a time in service less than 250 hours; prior to exceeding 250 hours time in service and thereafter at intervals not to exceed 25 hours time in service.
2. Prior to exceeding 300 hours cylinder time in service. This Amendment becomes effective on 27 February 1997.
Background: This directive was originally issued to require the inspection of certain cylinder assemblies. The requirement follows the CASA investigation of a PA31-350 cylinder head failure in service. This amendment reflects the issue of an FAA airworthiness directive based on the results on the CASA investigation and the subsequent revision to the cylinder manufacturer’s published requirements.
FAA Airworthiness Directive 97-01-04 increases the engine models applicable, reduces the compliance threshold and adds a terminating action by replacement of affected cylinders.
The original issue of this Airworthiness Directive became effective on 27 November 1996.
Overview
The Civil Aviation Regulations 1998, as amended by the Civil Aviation Safety Authority (CASA) through Schedule of Airworthiness Directives, address the issue of potential safety risks associated with specific Lycoming piston engines. This legislation was enacted to ensure that certain Lycoming TIO/LTIO-540 engines fitted with specific Superior Air Parts cylinders undergo regular inspections and maintenance to prevent possible cylinder head failures, engine power loss, and potential engine fires. The policy objective behind this directive is to maintain the highest standards of aviation safety through proactive measures and regular monitoring of critical engine components. The directive mandates visual inspections and pressure leak checks of the cylinders to detect any signs of combustion leaks or cracks, with specific requirements for compliance based on the engine's time in service. This directive reflects CASA's commitment to aligning with international safety standards and recommendations, as evidenced by its reference to the Federal Aviation Administration's (FAA) Airworthiness Directive 97-01-04.
Scope and Application
The Civil Aviation Regulations 1998, specifically Part 39 - 106, applies to the Civil Aviation Safety Authority (CASA) Schedule of Airworthiness Directives concerning Lycoming Piston Engines. This legislation is targeted at all Lycoming TIO/LTIO-540-A2C, -J2B, -F2BD, -J2BD, -N2BD, -R2AD, -S1AD and IO-540-M1B5D engines that are fitted with Superior Air Parts Inc. cylinders meeting particular part numbers and serial ranges. The directive mandates visual and pressure inspections of cylinder assemblies to prevent potential cylinder head loss, engine power loss, and possible engine fires. The inspections must be carried out within specified intervals based on the time in service of the cylinders, with additional removal actions stipulated for cylinders exhibiting defects. This Act is nationally applicable within Australia and is overseen by CASA, reflecting the findings from investigations into engine failures and aligned with the Federal Aviation Administration’s (FAA) airworthiness directives. The directive became effective on 27 February 1997, with amendments made to broaden the scope of engine models and lower compliance thresholds, further aligning with FAA standards.
Key Provisions
The Civil Aviation Safety Authority (CASA) issued a directive under the Civil Aviation Regulations 1998, specifically targeting Lycoming TIO/LTIO-540 series engines that have been fitted with certain Superior Air Parts Inc. cylinders (Part 39 - 106). This directive, AD/LYC/101 Amendment 1, applies to engines with specific part numbers and serial ranges (s.1). The primary requirement of this directive is to mitigate the risk of cylinder head loss, which could lead to reduced engine power and potentially an engine fire. This is achieved through two main actions. Firstly, operators must visually inspect the cylinder assemblies for any signs of combustion leaks or cracking near the inlet valve seat area, as illustrated in Figure 1 (s.1(a)). Secondly, an 80 psi pressure "wet" leak check must be performed on the cylinder assemblies, focusing on the same area (s.1(b)). Any cylinder exhibiting signs of combustion gas leakage or cracks must be removed from service before further flight.
In addition to the visual and leak checks, the directive mandates the removal of the affected cylinders from service prior to exceeding 300 hours of time in service (s.2). For cylinders already in service, inspections must occur within specific timeframes: within five hours of the directive's effective date and subsequently at intervals not exceeding 25 hours of time in service for those with more than 250 hours in service, and before exceeding 250 hours of time in service and then at the same intervals for those with less than 250 hours in service (s.2). These inspections are crucial for ensuring the ongoing airworthiness of the affected engines.
Failure to comply with the requirements set forth in this directive can result in severe consequences. The primary risk is the potential for in-flight engine failure, which could endanger the aircraft and its occupants. Additionally, non-compliance with CASA directives is a breach of the Civil Aviation Act 1988, which could lead to enforcement actions. Such actions might include fines, enforcement notices, or even prosecution for criminal offences under the Act, depending on the severity and circumstances of the breach. The exact penalties can vary but may include substantial fines for corporations and, in serious cases, imprisonment for individuals found guilty of non-compliance.