O-200Continental O-200

Parts most often named Cylinder (45) · Exhaust Valve (24) · Valve (13) · Cylinder Head (7)

AFER TAKING ON FUEL AT BAF, THE AIRCRAFT DEPARTED FOR 47N. WHILE CLIMBING OUT THROUGH 2500 MSL, THE AIRCRAFT ENGINE SUFFERED CATASTROPHIC FAILURE OF CYLINDER NUMBER 4. THE UPPER SECTION OF THE CYLINDER BARREL SEPERATED FROM THE LOWER SECTION APPROXIMATELY FOUR INCHES ABOVE THE CYLINDER FLANGE.

ENGINE ROUGH RUNNING DURING TAKE OFF RUN UP. COMPRESSION TEST FOUND #4 CYLINDER LOW. REMOVED CYLINDER FOUND EXHAUST VALVE STUCK OPEN. REMOVED VALVE, CLEANED GUIDE OF CARBON BUILDUP, RE-ASSEMBLED, RE-INSTALLED, OPERATES SATISFACTORY.

ENGINE ROUGH RUNNING DURING PRE-TAKE OFF RUN UP. COMPRESSION TEST FINDS NONE IN #4 CYLINDER. DISASSEMBLED, FOUND EXHAUST VALVE STUCK DUE CARBON BUILD UP IN VALVE GUIDE. CLEANED VALVE AND GUIDE, RE-ASSEMBLED, RE-INSTALLED, OPERATION SATIFACTORY

Parts most often named Carburetor (10) · Float (3) · Venturi (3) · Nozzle Assembly (2)

(CAN) DURING INVESTIGATION OF AN UNRELATED ENG SNAG, THE THROTTLE SHAFT WAS FOUND TO BE SLIGHTLY BENT ON THE THROTTLE CONTROL ATTACH SIDE, JUST OUTSIDE THE THROTTLE BODY ASSEMBLY. THE CARBURETOR WAS REPLACED WITH A [S/N removed] UNIT.

(CAN) ENGINE EXPERIENCED BEFORE FIRE WHICH MELTED INDUCTION FILTER. FIRE EXTINGUISHING PROCEDURE UTILIZED CONTAMINATED INDUCTION SYS, INDUCTION SYS PULLED, CLEANED AND INSPECTED CORRECT. CARBURETOR REPLACED WITH [S/N removed] UNIT AS A PRECAUTIONARY. ALL REASSEMBLED AND ENGINE GROUND RUN CORRECT. NO PRIME WAS REQUIRED ON START TO GET ENGINE GOING. ENGINE WAS PRIMED PRIOR TO ATTEMPTED START PRIOR TO THE FIRE, SUSPECT OVER PRIMING.

ENGINE STOPPAGE ON FINAL DUE TO CARBURATOR FLOODING, SUSPECT STUCK FLOAT. REMOVED UNIT AND SENT BACK TO MANUFACTURE FOR INSPECTION. THIS CARBURETOR WAS (FACTORY REBUILT) 1 YEAR EARLIER AND HAD LESS THAN 55 HOURS TT. FUEL WAS FOUND SPILLING OUT OF COWLING WHEN EXITING THE AIRCRAFT, SHUT FUEL VALVE OFF. (K)

Parts most often named Crankshaft (7) · Crankcase (3) · Piston (3) · Camshaft (2)

AIRCRAFT IN FOR ANNUAL INSPECTION, REMOVED SPINNER TO CHECK PROP HUB, S/N, MODEL. NOTICED CRANKSHAFT OIL PLUG MISSING, LOOKED INSIDE CRANKSHAFT BORED HOLE I NOTICE A 1/2" CRACK AT BOTTOM OF BORED HOLE CRACK STARTS AT CENTER OF CRANKSHAFT AND RADIATES OUTWARD.

(CAN) WHILE PERFORMING 100 HRS INSPECTION, POST OPENING INSPECTION OF OIL FILTER REVEALED ALUMINUM CHIPS IN FILTER. AFTER CONSULTING WITH APPROVED REPAIR SHOP, NR 2 & NR 4 CYLINDERS WERE REMOVED AND PISTON PIN ENDS WERE FOUND WITH METAL MISSING. CYLINDER WALLS INSPECTION REVEALED NO FAULTS. REMAINING CYLINDERS NR 1 & NR 4 WALLS WERE CHECKED WITH BOROSCOPE THROUGH SPARK PLUG HOLE AND REVEALED NO TRACES OF SCORING/SCRATCHING. NEW PINS WERE INSTALLED. GROUND RUN C/OUT AND ACFT RETURNED TO [S/N removed].

(CAN) DURING AN INTERNAL INSPECTION OF THE ENGINE, WHEN THE PISTONS WERE REMOVED FROM THE CYLINDERS, EACH OF THE FACES OF THE TOP PISTON RINGS HAD STRIPS OF CHROME PLATING MISSING BETWEEN THE TOP AND THE BOTTOM OF THE RING AROUND APPROXIMATELY 70 PERCENT OF THE RING.

Parts most often named Magneto (10) · Coil (4) · Drive Gear (2) · Gear (2)

LARGE MAG DROP ON RUNUP THAT WAS SIGNIFICANT ENOUGH TO ALMOST SHUT DOWN THE ENGINE. MAGNETO HAD 568.9 HOURS SINCE INSTALLATION ON THE ENGINE, AND WAS INSTALLED 10 MONTHS AGO.

REMOVED DEFECTIVE RT MAGNET, OWNER REPORTED DEAD MAG ON RUN UP. REMOVED COVER, BREAKING FACTORY TORQUE SEAL. APRON INSPECTION FOUND THE ROTATING MAGNET CRACKED AND THAT THE SHAFT HAD SLIPPED ON THE SHAFT 6 TEETH FROM ALINEMENT WITH KEY WAY.

BOTH MAGNETOS HAD INTERNAL DAMAGE. BOTH MAGNETOS REQUIRED NEW ROTORS, LT MAGNETO REQUIRED NEW ROTOR AND HOUSING DUE TO ROTOR BREAKING AND DAMAGING HOUSING.

Parts most often named Muffler (12) · Flame Tube (1)

(CAN) DURING CF-90-03, INSPECTION A CRACK WAS FOUND AT FORWARD FLANGE. CRACK IS APPROXIMATELY 75 PERCENT AROUND THE CIRCUMFERENCE. THERE IS SEPERATION ALONG THE CRACK. EXHAUST TRAILS ARE FOUND INSIDE SHROUD AND WELL DOWN INTO HOT AIR DUCTING. MUFFLER IDENTIFIED AS HAVING 3 SMALL PIN HOLES IN 2008. HEAT SYSTEM INCAPACITAED AT THAT TIME FOR SAFETY REASONS, MUFFLER REMAINED IN [S/N removed].

DURING DESCENT TO LANDING THE PILOT EXPERIENCED A HIGH OIL TEMPERATURE FOLLOWED BY A HOT SMELL AND SMOKE ENTERING THE COCKPIT. ENGINE LOST POWER AS A RESULT OF THE (P) LEAD WIRE SHIELDING MELTING TO THE RT MAGNETO AND GROUNDING OUT.

RT MUFFLER P/N 0450400-26 WAS REMOVED FOR CYLINDER REPLACEMENT, INSP REVEALED DETERIORATED FLAME TUBES IN OUTLET PIPE AND NR1 INLET PIPE. OUTLET PIPE FLAME TUBE IS NOT READILY VISIBLE LOOKING UP TAIL PIPE. NO ENTRIES IN LOGBOOK INDICATING REPLACEMENT OF EITHER MUFFLER.

Parts most often named Starter (3) · Clutch (2) · Motor (1) · Contactor (1)

(CAN) UPON START UP OF ENGINE, STARTER FAILED ON FIRST ATTEMPT. STARTER FAILURE TROUBLESHOT TO DETERMINE THE CAUSE AND PROBLEM OF FAILURE. FAILURE FOUND TO BE STARTER ITS SELF. STARTER REMOVED FROM ENGINE AND REPLACED NEW, WITH NEW STARTER, NEW STARTER FUCNTION CHECKED [S/N removed] NO MORE PROBLEMS FOUND ALL PARAMETER FOUND NORMAL.

(CAN) STARTER DRIVE ENGAGES ON TEETH ON GEAR. STARTER WAS SLIPPING, TOOK APART TO EXAMINE AND FOUND 3 BROKEN TEETH. STARTER IS LIGHT WEIGHT. REPLACE STARTER SOLENOID 19 HOURS EARLIER AND BELIEVE FAULTY SOLENOID CAUSE OF PROBLEM. (TC NR 20071126006)

(AUS) ENGINE STARTER MOTOR HAD NO DRAIN HOLE DRILLED. THIS ALLOWED OIL TO ACCUMULATE IN THE PINION AREA AND LEAK PAST THE ADAPTER PLATE GASKET.

Parts most often named Blade (9)

(CAN) PROPELLER RECEIVED FOR CORROSION INSPECTION. STONE DAMAGE WAS FOUND. SUBMITTER STATES THE PROPELLER WAS NOT MAINTAINED PER THE MCCAULEY MAINTENANCE INSTRUCTIONS.

(AUS) SECTION OF PROPELLER BLADE SEPARATED - APPROXIMATELY 279.4MM(11IN) OF BLADE TIP SEPARATED - AIRCRAFT IS USED FOR CATTLE MUSTERING FROM UNSEALED STRIPS - EVIDENCE OF STONE DAMAGE ON BLADES

(CAN) PROPELLER WAS SENT FOR 5 YEAR INSPECTION. CORROSION WAS FOUND PAINTED OVER. PROP HAD NOT BEEN INSPECTED SINCE 1970.

Parts most often named Mount (8)

(CAN) ENGINE MOUNT TUBE CRACKED AT NOSE GEAR OLEO UPPER ATTACH POINT- RT SIDE DIAGONAL TUBE FROM RT LOWER ENGINE MOUNT, TOO UPPER NOSE GEAR ATTACH POINT, AND LT LOWER DIAGONAL TUBE FROM LOWER LT FIRE WALL ATTACH POINT TO LOWER NOSE GEAR ATTACH POINT. (CRACKED IS AT NOSE GEAR ATTACH POINT).

100 HOUR INSPECTION, RT LOWER ENGINE MOUNT TUBE CRACKED. CRACK LOCATED WITHIN 1 INCH OF NOSE WHEEL STRUT SUPPORT CRACK, .7500 INCH IN LENGTH AROUND CIRCUMFERENCE OF TUBE. REPLACED MOUNT. (K)

(CAN) LEFT TUBE MEMBER AT THE LOWER NOSE GEAR STRUT ATTACH POINT FOUND CRACKED. WHEN REPAIRING, THE TUBE WAS FOUND CORRODED.

Parts most often named Valve (1) · Housing (1) · Drain (1) · Quick Drain (1)

(CAN) DURING UNSCHEDULED MAINTENANCE, AN OIL LEAK WAS DISCOVERED AT THE OIL SCREEN HOUSING. UPON REMOVAL OF THE HOUSING, A CRACK WAS FOUND FROM ONE SIDE TO THE OTHER OF ONE OF THE MOUNTING EARS. THE HOUSING WAS REPLACED WITH AN INSPECTED USED [S/N removed] HOUSING. THE ENGINE WAS GROUND RUN AND NO FURTHER LEAK WAS FOUND. THE TOTAL TIME IN [S/N removed] OF THE CRACKED HOUSING IS UNKNOWN.

(CAN) IFSD RT ENGINE OIL PRESSURE INDICATION DROPPED TO THE YELLOW AREA. PILOT REDUCED POWER AND IT CONTINUED TOWARDS THE RED. THE PILOT SHUTDOWN ENGINE AND LANDED WITHOUT INCIDENT. TROUBLESHOOTING IS ONGOING.

INSTALLED QUICK DRAIN VALVE (OIL) ON NEW AIRCRAFT/ ENGINE. AIRCRAFT FLEW APPROX 1 HR , INITIAL FLIGHT TEST. VERY MINUTE OIL LEAK WAS NOTED FROM OIL QUICK DRAIN VALVE. REMOVED VALVE TO FIND VALVE SNAP RING IN OIL DRAINED FROM ENGINE, ALSO FOUND O-RING SPLIT. NOTE: NO DAMAGE TO ENGINE OCCURRED. (K)

Parts most often named Bulkhead (4) · Spinner (2)

(CAN) ON PILOT WALK AROUND THE SPINNER ASSY WAS NOTED TO BE LOOSE. UPON INSPECTION IT WAS OBSERVED THAT THE FWD SPINNER BULKHEAD WAS CRACKED. THIS WAS MOST LIKELY CAUSED BY PILOTS PUSHING ON THE SPINNER WHEN GROUND HANDLING THE AIRCRAFT. (TC NR 20061017007)