Airworthiness Directive · Amendment 39-15471 · Kelly Aerospace Power Systems Turbochargers
Kelly Aerospace Power Systems Turbochargers
This AD applies to the turbochargers referenced in paragraphs (c)(1) through (c)(15)(vi) of this AD:
(1) Kelly Aerospace Power Systems (KAPS) turbochargers, part number (P/N) 409170-0001 (Lycoming P/N LW-12463), installed on Lycoming Engines (L)TIO-540-J2B and (L)TIO-540-J2BD engines:
(i) With the engine serial numbers (SNs) listed in Table 1 of Lycoming Engines Mandatory Service Bulletin (MSB) No. 580, dated February 15, 2008; and
(ii) With the turbocharger SNs listed in KAPS MSB No. 029, dated February 1, 2008.
(iii) Lycoming Engines (L)TIO-540-J2B and (L)TIO-540-J2BD engines are installed on, but not limited to, Piper PA31-350 Navajo Chieftain, Piper T1020 airplanes, and Colemill Panther conversion airplanes using a 350 horsepower engine.
(2) KAPS turbochargers, P/N 465930-0003 (Teledyne Continental Motors (TCM) P/N 641672-3), installed on TCM GTSIO-520-L and GTSIO-520-N engines, with the turbocharger SNs listed in KAPS MSB No. 030, Revision A, dated April 1, 2008.
(3) KAPS turbochargers, P/N 466412-0003 (TCM P/N 652964), installed on TCM TSIOL-550-A and TSIOL-550-C engines, with the turbocharger SNs listed in KAPS MSB No. 030, Revision A, dated April 1, 2008.
(4) KAPS turbochargers, P/N 466412-0004, installed on RAM modifications only, with the turbocharger SNs listed in KAPS MSB No. 030, Revision A, dated April 1, 2008.
(5) KAPS turbochargers, P/N 466412-0003 (TCM P/N 652964), installed on Cessna 414 airplanes with a TCM TSIOL-550-A or TSIOL-550-C engine (Supplemental Type Certificate (STC) SA7633SW), with the turbocharger SNs listed in KAPS MSB No. 030, Revision A, dated April 1, 2008.
(6) KAPS turbochargers, P/N 465930-0003 (TCM P/N 641672-3), installed on Cessna 421 Golden Eagle airplanes with a TCM GTSIO-520-L or GTSIO-52-N engine with the turbocharger SNs listed in KAPS MSB No. 030, Revision A, dated April 1, 2008.
(7) KAPS turbochargers, P/N 465680-0004 (Cessna P/N C295001-0202), installed on TCM TSIO-520-AF or TSIO-520-P engines, with the turbocharger SNs listed in KAPS MSB No. 030, Revision A, dated April 1, 2008.
(8) KAPS turbochargers, P/N 465930-0002 (TCM P/N 641672-2), installed on TCM GTSIO-520-M engines, with the turbocharger SNs listed in KAPS MSB No. 030, Revision A, dated April 1, 2008.
(9) KAPS turbochargers, P/N 465680-0004 (Cessna P/N C295001-0202), installed on Cessna P210 Pressurized Centurion airplanes with a TCM TSIO-520-AF or TSIO-520-P engine, with the turbocharger SNs listed in KAPS MSB No. 030, Revision A, dated April 1, 2008.
(10) KAPS turbochargers, P/N 465930-0002 (TCM P/N 641672-2), installed on Cessna 404 Titan airplanes with a TCM GTSIO-520-M engine, with the turbocharger SNs listed in KAPS MSB No. 030, Revision A, dated April 1, 2008.
(11) KAPS overhauled turbochargers, P/N 465930-9003, installed on TCM GTSIO-520-L or GTSIO-520-N engines, with the turbocharger SNs listed in KAPS MSB No. 031, dated February 28, 2008.
(12) KAPS overhauled turbochargers, P/N 409170-9001, installed on Lycoming Engines TIO-540-J2B; TIO-540-J2BD; TIO-540-N2BD, and LTIO-540-N2BD engines, with the turbocharger SNs listed in KAPS MSB No. 031, dated February 28, 2008.
(13) KAPS overhauled turbochargers, P/N 465680-9005, installed on Lycoming Engines TIO-540-V2AD and TIO-540-W2A engines, with the turbocharger SNs listed in KAPS MSB No. 031, dated February 28, 2008.
(14) KAPS overhauled turbochargers, P/N 465930-9002, installed on TCM GTSIO-520-M engines, with the turbocharger SNs listed in KAPS MSB No. 031, dated February 28, 2008.
(15) Also, the following KAPS turbochargers might have been overhauled or repaired by other than KAPS, that used a P/N 441977-0023S or P/N 441977-0025S turbine housing sold as a spare part, through the Aviall Company. These turbine housings have the date code of 1006 and might have been installed between October 2006 and January 25, 2008. The turbocharger data plates might include manufacturer's information other than KAPS information, such as, Garrett:
(i) P/N 409170-0001; installed on Lycoming Engines TIO-540-J2B; TIO-540-J2BD; TIO-540-N2BD; and LTIO versions of the noted engine models.
(ii) P/N 465680-0004; installed on TCM TSIO-520-AF and TSIO-520P engines.
(iii) P/N 465680-0005; installed on Lycoming Engines TIO-540-V2AD and TIO-540-W2A engines.
(iv) P/N 465930-0002; installed on TCM GTSIO-520-M engines.
(v) P/N 465930-0003; installed on TCM GTSIO-520-L and GTSIO-520-N engines.
(vi) P/N 465448-0004; installed on TCM TSIO-520-CE engines.
(vii) P/N 466412-0003; installed on TCM TSIOL-550-A and TSIOL-550-C engines. (viii) P/N 466412-0004; installed on engines modified by RAM.
The FAA is adopting a new airworthiness directive (AD) for certain Kelly Aerospace Power Systems turbochargers. This AD requires a onetime visual inspection of suspect turbochargers for an excessive gap between the turbocharger turbine housing flange and the exhaust tube flange, and replacement of turbochargers that fail the gap inspection. This AD results from two reports of exhaust leakage occurring between the turbocharger turbine housing flange and the exhaust tube flange due to machining defects of the turbocharger turbine housing flange. We are issuing this AD to prevent hazardous amounts of carbon monoxide from entering the cabin, an increase in under-cowl temperatures hampering engine and accessory function, and loss of tailpipe retention, which could lead to an in-flight fire and loss of control of the airplane.
You are responsible for having the actions required by this AD performed within 10 hours time-in-service or at the next regular inspection interval, whichever occurs first, unless the actions have already been done.
Carefully remove the “V” band clamp from around the turbocharger turbine housing at the turbocharger exhaust outlet, taking care not to move the exhaust tube and tailpipe assembly.
(g) Visually inspect the area that was captured by the “V” band clamp. Use a feeler gauge at the split line between the turbine housing flange and the exhaust tube flange all around the circumference.
(h) The maximum gap must not exceed 0.005 inch.
(i) Before further flight, replace any turbocharger that exceeds the 0.005 inch maximum gap, with a serviceable turbocharger.
(j) If the maximum gap is not exceeded, metal stamp a 1/8″ upper case “I” on the side of the turbocharger discharge flange. Information on the stamping location can be found in the MSBs referenced in this AD.
For the purpose of this AD, a serviceable turbocharger is one that is not listed in the suspect SN lists of the Lycoming Engines MSB or KAPS MSBs referenced in this AD, or one that passes the visual inspection in this AD.
The aircraft, engines and makers this AD names, by the model designations in its text. A model listed here may still be outside the AD's serial ranges.
