9 June – 16 July 2018

603

PISTON

LYCOMING IO540 E1B5–ATA 8520 RECIPROCATING ENGINE POWER SECTION–CRANKCASE–CRACKED. DR 611852060
Visual inspection revealed cracked crankcase. Repaired.

LYCOMING O320D3G–ATA 8520 RECIPROCATING ENGINE POWER SECTION–TAPPET–DAMAGED. DR 611852110
Pilot reported lack of engine power during climb after take-off. Number 2-cylinder intake valve hydraulic tappet body failure. Intake valve would not actuate resulting in a 25% power reduction and vibration. Number 2 cylinder removed, visual inspection revealed #2 intake valve hydraulic cam follower contact platen missing from hydraulic body. Moreover, opposing hydraulic body platen on #1-cylinder intake valve has lost 50% of its contact face.

LYCOMING TIO540 J2BD–ATA 7810 ENGINE COLLECTOR/TAILPIPE/NOZZLE–Exhaust flange–CRACKED. DR 611852125
Cracked exhaust flange on tube connecting to turbocharger collector. Exhaust segment replaced.

LYCOMING TIO540 AJ1A–ATA 8520 RECIPROCATING ENGINE POWER SECTION–COUNTERWEIGHT–INCORRECT ASSY.
LYCOMING TIO540 AJ1A–ATA 8520 RECIPROCATING ENGINE POWER SECTION–COUNTERWEIGHT–INCORRECT ASSY.
LYCOMING TIO540 AJ1A–ATA 8520 RECIPROCATING ENGINE POWER SECTION–COUNTERWEIGHT–INCORRECT ASSY.
LYCOMING TIO540 AJ1A–ATA 8520 RECIPROCATING ENGINE POWER SECTION–COUNTERWEIGHT–INCORRECT ASSY.

LYCOMING TIO540 AJ1A–ATA 8520 RECIPROCATING ENGINE POWER SECTION–COUNTERWEIGHT–INCORRECT ASSY. DR 611852138 (images above)
While investigating metal in filters, engine removed and forwarded to approved overhaul facility for detailed examination. During dismantling, it was found that the counterweight bush P/N 7380 had not been installed in the crankshaft, allowing excessive movement of the counterweight. It must be noted that the engine is a first life unit from Lycoming factory.

LYCOMING IO540 E1B5–ATA 8520 RECIPROCATING ENGINE POWER SECTION–CRANKCASE–CRACKED. DR 611852156
During periodic inspection, crack located below cylinder # 1 on engine crankcase. Engine replaced.

LYCOMING O540 F1B5–ATA 8520 RECIPROCATING ENGINE POWER SECTION–EXHAUST VALVE–LEAKING. DR 611852158
While engine cylinder leak check, IAW Lycoming service bulletin1191A, 5 out of 6 cylinders were found to be unserviceable due to leaking exhaust valves. Disassembly of cylinder assemblies found leakage between exhaust valve & seat. Leakage was caused by valve guide wearing excessively. Moreover, evidence of ‘tuliping’ found on all exhaust valves removed from cylinders. Exhaust valves & guides replaced with new items, valve seats re-cut. Cylinders re-installed on engine & returned to service.

LYCOMING O540 F1B5–ATA 8520 RECIPROCATING ENGINE POWER SECTION–EXHAUST VALVE–LEAKING. DR 611852166
During inspection, exhaust valves found to be leaking in cylinder 4 & 6. Disassembly & further inspection found 5/6 valves & associated valve guides to be unserviceable as well. Pitting and erosion of the valve faces is evident when inspected visually with 10X magnification. This type of damage may be associated with reduced levels of Tetraethyl Lead in Avgas currently being used, in addition to subsequent elevated exhaust gas temperatures. Exhaust valves & guides are currently being replaced as required.

LYCOMING O360 J2A–ATA 8520 RECIPROCATING ENGINE POWER SECTION–EXHAUST VALVE–LEAKING. DR 611852168
Exhaust valve in #3 cylinder found leaking. Inspection of cylinder found exhaust valve guide was worn and elongated, causing associated exhaust valve to not seat properly & leak. Cylinder to be returned to engine overhaul facility for warranty claim. New cylinder fitted to aircraft.

LYCOMING O540 F1B5–ATA 8520 RECIPROCATING ENGINE POWER SECTION–ENGINE CYLINDER–LOW COMPRESSION. DR 611852175
Low compression detected on cylinders 1 and 2. Moreover, inlet valve seats and faces found burnt. Cylinder assemblies replaced with overhauled items.

LYCOMING O540 F1B5–ATA 8520 RECIPROCATING ENGINE POWER SECTION–INLET VALVE–ERODED. DR 611852185
Number 2 cylinder failed compression check at the 100-hr inspection. Valve contact face eroded.

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