SR20Cirrus

Parts most often named Magneto (24) · Brushes (3) · Distributor Blk (3) · Spring (2)

PILOT REPORTED NO START. MAINTENANCE CONFIRMED NO START. CHECKED POWER TO SLICK START, OKAY. CHECKED MAGNETO TO ENGINE TIMING, FOUND LEFT MAGNETO POINTS NOT OPENING. FOUND FACTORY PUTTY BROKEN ON LEFT MAGNETO.

REBUILT T WAS DETERMINED TO BE FAULTY OUT OF THE BOX BY THE SHOP TECHNICIAN PERFORMING INSTALL OF MAGNETO TO THE AIRCRAFT. TECHNICIAN TESTED AND VERIFIED REBUILT MAGNETO WAS FAULTY OUT OF THE BOX. TECHNICIAN REMOVED FAULTY OUT OF THE BOX MAGNETO FROM THE AIRCRAFT AFTER INSTALL AND TESTING AND INSTALLED A PROPER WORKING MAGNETO APPLICABLE TO THE AIRCRAFT WITH SUCCESSFUL OUTCOME OF NEW MAG BEING INSTALLED.

DURING 500 HOUR MAGNETO INSPECTION IT WAS NOTED THE IMPULSE COUPLING ON MAGNETO WAS NOT FUNCTIONING PROPERLY. UPON REMOVAL OF IMPULSE COUPLING IT WAS NOTED THAT THE DRIVE KEY WAS NOT INSTALLED IN DRIVE SHAFT PROPERLY AND WAS PROTRUDING AND JAMMING THE PROPER OPERATION OF THE IMPULSE COUPLING. 1 PROPERLY INSTALLED, IMPULSE COUPLING OPERATION WAS NORMAL. NO DAMAGE WAS NOTED TO IMPULSE COUPLING, 469 HOURS SINCE FACTORY REBUILD.

Parts most often named Pump (36) · Bellows (1)

MECHANICAL ENGINE DRIVEN FUEL PUMP FAILED IMMEDIATELY AFTER ENGINE WAS OVERHAULED. WE HAVE FOUND INTERNAL COMPONENTS OF THIS ITEM FAIL WITHIN A FEW HOURS OF [S/N removed].

(B-9749) WHEN CHECKED, THE FUNCTION BOOST AND PRIME OF THE ENGINE DRIVEN FUEL PUMP, THERE WAS A LITTLE FUEL LEAKING FROM MIXTURE SEAT.

PILOT REPORTED LOW FUEL FLOW ON CLIMB OUT IN THE RANGE OF 13.4 TO 13.6 GALLON PER HOUR. WE HAVE ESTABLISHED AN OPERATIONAL MINIMUM FUEL FLOW OF 16.0 GALLONS PER HOUR DUE TO OUR EXPERIENCE WITH THESE ENGINE DRIVEN FUEL PUMP ANEROID FAILURES. WHEN THE ALTITUDE COMPENSATING ANEROID FAILS IN THE FUEL PUMP, THE FUEL FLOW WILL DROP FROM THE NORMAL 16.5 TO 17.5 GALLONS PER HOUR TO THE 12 TO 14 GALLONS PER HOUR RANGE. EXTENDED OPERATIONS WITH LOW FUEL FLOW CAN LEAD TO ENGINE DAMAGE BASED ON OUR OPERATING EXPERIENCE.

Parts most often named Crankcase (17) · Case (3) · Piston (1) · Gear (1)

DURING 100 HR INSPECTION, A GEAR TOOTH WAS FOUND IN OIL SUMP. AFTER FURTHER INSPECTION IT WAS FOUND TO BE A TOOTH FROM THE TIMING GEAR ON THE CRANKSHAFT.

OIL ON WINDSCREEN. ON CLEANING ENGINE, A CRACK WAS FOUND ABOUT 4 INCHES IN LENGTH FROM THE ALTERNATOR BRACKET ACROSS THE RT UPPER SECTION OF THE CASE.

DURING AN OIL CHANGE, ENGINE WAS NOTED TO HAVE LARGE AMOUNT OF OIL IN THE COWLING AND ON THE ENGINE. AFTER CLEANING ENGINE, A CRACK WAS FOUND ABOUT 3 INCHES IN LENGTH FROM THE ALTERNATOR BRACKET ACROSS THE RT UPPER SECTION OF THE CASE.

Parts most often named Exhaust Valve (7) · Tube (3) · Valve (2) · Bolt (1)

LOSS OF POWER DUE #3-CYLINDER EXHAUST PUSH ROD BEING BENT. PILOT LOST POWER TO THE #-3 CYLINDER DURING FLIGHT. UPON REMOVAL OF THE # 3 CYLINDER, IT WAS FOUND THAT THE EXHAUST PUSH ROD WAS GALLED AND BENT. THE PUSH ROD TUBE WAS ALSO BENT.

STUCK EXHAUST VALVE IN THE OPEN POSITION HAS CAUSED THE NR 5 CYLINDER PISTON TO PUSH IT CLOSED AND BENDING THE PUSHROD IN THE PROCESS. CYL ASSY'S NR 3, 5 & 6 DID THE SAME SHORTLY AFTER. CMI WAS CONTACTED & PARTS WERE COVEREND UNDER WARRANTY. REASON THIS WAS FOUND IS CYLINDERS HOT FIRING & ENGINE RUNNING ROUGH RICH AFTER START UP. ACFT HAS ENGINE ANALYZER INSTALLED.

ACFT EXPERIENCED ENGINE OIL LOSS DURING CLIMB OUT, ACFT ALSO EXPERIENCED LOSS OF ENGINE OIL PRESSURE. ACFT LANDED SAFELY. UPON INSPECTION BY MAINTENANCE THE NR 5 CYLINDER HEAD WAS FOUND TO BE SEPARATED FROM THE CYLINDER BASE.

Parts most often named Exhaust Header (6) · Exhaust Pipe (5) · Collector (2) · Nut (1)

EXHAUST COLLECTOR SLIP JOINTS LEAKING AND CAUSED LOWER RIGHT ENGINE COWLING TO BE BURNED. EXCESSIVE GAPS FOUND BETWEEN #1 AND #3 EXHAUST HEADER TO COLLECTOR JOINTS. DAMAGE WAS CAUGHT BEFORE ANY IN-FLIGHT EMERGENCY.

EXHAUST COLLECTOR SLIP JOINTS LEAKING CAUSING BURNS TO LOWER RIGHT COWLING. #1 HEADER TO COLLECTOR HAD EXCESSIVE GAP. NO IN-FLIGHT EMERGENCIES, BUT COWLING STRUCTURE WAS CHARRED AND SLIGHTLY WARPED FROM HEAT.

(CAN) SOUND OF BACK FIRE WAS HEARD ON LANDING APPROACH. INSPECTION FOUND NR 2 CYLINDER EXHAUST HEADER PIPE HAD DROPS DOWN .1875 DUE TO MISSING EXHAUST NUTS.

Parts most often named Alternator (5) · Bracket (3) · Bolt (3) · Drive Coupling (1)

GEAR PORTION OF COUPLER SLIPS INSIDE METAL/RUBBER HOUSING, CAUSING ALTERNATOR #2 TO REMAIN OFFLINE. A SECOND ALTERNATOR EXISTS WITHIN THE SYSTEM, SO NO INITIAL SAFETY OF FLIGHT ISSUES WITH LOSS OF POWER IF LANDING IS ACCOMPLISHED IN A TIMELY MANNER. THIS IS THE 14TH COUPLER TO FAIL IN A YEAR'S TIME ACROSS THE FLEET OF 24 AIRCRAFT MAINTAINED AT THE USAFA. THIS SPECIFIC PART HAS BECOME A HIGH FAILURE ITEM AS MOST FAILED AT OR NEAR 200 HOURS OF RUN TIME.

DURING A PHASE 2 INSPECTION, TECH NOTED A BROKEN ALTERNATOR CASE BOLT. THE CASE HALVES HAD NOT LOOSENED UP AND NO FURTHER DAMAGE TO ALTERNATOR WAS NOTED. ALL THE CASE BOLTS WERE REPLACED WITH NEW. ALTERNATOR ES-4024LP.

DURING A PHASE 2 INSPECTION, THE TECH NOTED A BROKEN ALTERNATOR CASE BOLT. THE CASE HALVES HAD NOT LOOSENED UP AND NO FURTHER DAMAGE TO ALTERNATOR WAS NOTED. ALL THE CASE BOLTS WERE REPLACED WITH NEW. ALTERNATOR ES-4024LP.

Parts most often named Spindle (3) · Bracket (3) · Landing Gear (2) · Bumper Block (2)

CRACKS DISCOVERED ADJACENT TO WELD ON NOSE LANDING GEAR. REFERENCE SB SB2X-32-22R1 THIS IS A CHRONIC PROBLEM DISCOVERED ON A FLEET OF SR20S (T-53) OPERATED BY THE USAF. 22 OUT OF 24 AIRCRAFT WERE DISCOVERED WITH CRACKS.

DURING GROUND OPERATION, THE AIRCRAFT EXPERIENCED AN EXTREME SHIMMY. INSPECTION LED TO THE DISCOVERY OF A BROKEN SPINDLE CUP ON THE NLG

NOSE WHEEL PANT BRACKETS, QTY2, FOUND WITH ELONGATED MOUNTING HOLES UNDER NORMAL USE. AIRCRAFT HAS BEEN OPERATED BY A SINGLE INDIVIDUAL WITH MINIMAL TAKEOFFS AND LANDING IN APPROXIMATELY ONE YEARS TIME. FURTHERMORE, THE MOUNTING HOLES IN THE NEW REPLACEMENT PART ARE APPRECIABLY LARGER THAN THE AN3 BOLT THAT IS SPECIFIED TO SECURE IT TO THE FORK ASSEMBLY. THE HOLE IS LARGER THANT .1875 OF INCH BUT SMALLER THAN .2500 OF AN INCH.

Parts most often named Pump (11)

FUEL BOOST PUMP NOISY. CONDUCTED A FUNCTIONAL TEST. ELECTRIC FUEL PUMP LEAK CHECK IAW AMM TEMP REVISION 28-20-01, PAGE 10 ITEM (3). FAILED TEST FUEL LEAKED INTO COLLECTION CONTAINER DURING TESTING.

WHILE WORKING TO COMPLETE A FUEL SYSTEM ADJUSTMENT, FOUND THAT THE METERED FUEL PRESSURE WOULD NOT OUTPUT ABOVE 10 PSI AT WIDE OPEN THROTTLE, AFTER ADJUSTMENT ([S/N removed] INFORMATION DIRECTIVE 97-3 CALLS FOR 13.8 -15.5 PSI).

Parts most often named Cooling Fan (3) · Keyway (2) · Mount Bracket (1) · Brushes (1)

FLIGHT CREW REPORTED ALTERNATOR 2 FAILURE FOLLOWED BY STRONG BURNING SMELL IN CABIN. ALTERNATE AIRPORT WAS USED WITH AN EMERGENCY LANDING DECLARED. THE ROOT CAUSE OF THE PROBLEM WAS INTERNAL FAILURE OF ALTERNATOR 2 BEARING CAUSING COMPLETE SEIZURE OF ROTATION. ALTERNATOR 2 DRIVE BELT SLIPPED ALONG DRIVE PULLEY CAUSING EXTREME HEAT BUILDUP WHICH RESULTED IN BELT AND PULLEY FAILURE. BURNING ODOR IN CABIN WAS CAUSED FROM EXCESSIVE FRICTION ALONG BELT AND PULLEY.

DURING AN ACFT PROGRESSIVE 50 HOUR INSPECTION, DISCOVERED ALTERNATOR NR 2 COOLING FAN LOOSE ON ALTERNATOR SHAFT. THE FAN IS PART OF ALTERNATOR. THE KEY WAY OF THE FAN HUB WEARS PREMATURELY ALLOWING ROTATIONAL MOVEMENT OF THE FAN ON THE SHAFT. WE HAVE SEEN THIS CONDITION ON SEVERAL OF THESE ALTERNATORS RECENTLY.

DURING A PROGRESSIVE INSPECTION PROGRAM, PHASE 2 INSPECTION DISCOVERED ALTERNATOR NR 2 COOLING FAN LOOSE ON ALTERNATOR SHAFT. FAN PN: ES4137 IS PART OF ALTERNATOR PN: 653344. THE KEY WAY OF THE FAN HUB WEARS PREMATURELY ALLOWING ROTATIONAL MOVEMENT OF THE FAN ON THE SHAFT.

Parts most often named Starter (3) · Adapter (1) · Commutator (1) · Spring (1)

DISCOVERED FERROUS METAL FLAKES IN OIL FILTER. DURING INVESTIGATION DETERMINED SOURCE WAS THE DRIVE SHAFT WITHIN THE STARTER ADAPTER. APPEARS THE DRIVE CLUTCH SPRING WAS DRAGGING ON THE DRUM AREA OF THE SHAFT REMOVING METAL FLAKES.

PILOT REPORTED DURING ATTEMPTED ENGINE START, A GRINDING NOISE WAS HEARD AND PROPELLER DIDN'T TURN. DISCOVERED CLUTCH SPRING IN STARTER ADAPTER HAD BROKEN.

AFTER A 1.5 HOURS FLIGHT, CREW SHUTDOWN AIRCRAFT AND NOTICED OIL LEAKING FROM UNDER ENGINE COWLING. DISCOVERED STARTER HAD SEPARATED FROM ADAPTER BUT HAD NOT LEFT THE ENGINE COMPARTMENT. DID NOT HEAR ANY STRANGE SOUNDS DURING THE START OR THROUGH OUT FLIGHT. SEARCHING THE PARKING SPOT WHERE THE FLIGHT HAD ORIGINATED STARTER PARTS WHERE FOUND.