O-540Lycoming O-540

Parts most often named Magneto (38) · Bearing (14) · Impulse Coupling (13) · Gear (7)

RECENTLY INSTALLED ELECTROAIR ELECTRONIC IGNITION SYSTEM EIS-61000-5M AND EIS-61000-5C. WHILE TROUBLE SHOOTING ERRONEOUS RPM INDICATIONS WE OPENED THE COVER OF THE MAGNETO TIMING HOUSING (MTH) AND FOUND SIGNIFICANT SHAVINGS IN THE CASE. BORESCOPE INSPECTION SHOWED DAMAGE TO BOTH PLASTIC GEARS INSIDE THE MTH. THE MTH HAS LESS THAN 3 HOURS TIME SINCE NEW.

MAGNETO TIMING REPORT AFTER EACH FLIGHT. (TWO CONSECUTIVE FLIGHTS WITH THE SAME REPORT) - DISTRIBUTOR BLOCK CRACKS FOUND AT MAGNETO INSPECTION.

PILOT PERFORMED PRE FLIGHT MAGNETO CHECK. THE LH MAG WAS INOPERATIVE. FURTHER INSPECTION BY MX PERSONNEL DISCOVERED THE LH MAGNETO DRIVE GEAR WAS MISSING 3 TEETH; MAKING THE MAGNETO NOT FUNCTIONAL.

Parts most often named Spring (8) · Cylinder (8) · Intake Valve (8) · Cylinder Head (6)

ABOUT 30 MINUTES INTO A TOUR, PILOT HEARD A SOUND AND EXPERIENCED LOSS OF POWER AND HIGH MANIFOLD PRESSURE. INITIATED POWER ON LANDING ON AN ADJACENT OPEN FIELD. VISUAL INSPECTION REVEALED OIL LEAK NEAR CYLINDER # 6. UPON REMOVAL OF VALVE COVER A BROKEN OFF VALVE STEM TIP WAS IDENTIFIED. NEW STYLE ROTATOR CUP INTAKE VALVE PN 17A29467 INSTALLED.

PILOT IDENTIFIED HIGH MANIFOLD PRESSURE REQUIRED AFTER TAKE OFF AND PERFORMED A PRE CAUTIONARY LANDING OFF AIRPORT. INSPECTION REVEALED A WET SPARK PLUG ON CYLINDER # 6. AFTER REMOVAL OF THE VALVE COVER, A BROKEN INTAKE VALVE TIP WAS DISCOVERED. NEW STYLE ROTATOR CAP INTAKE VALVES ARE INSTALLED PER LYCOMING SI1280D.

LOW CYLINDER COMPRESSIONS WERE NOTED AT ANNUAL FOR AN ENGINE THAT WAS REPAIRED BY LYCOMING ONLY 180 HRS PRIOR TO CURRENT INSPECTION. BORESCOPE REVEALED BURNED INTAKE VALVES. CRANKSHAFT EXPANSION PLUG HAD A SUNSTANTIAL OIL LEAK AND CRANKSHAFT SEAL WAS LOOSE IN THE CASE CAUSING A SECOND OIL LEAK. ENGINE WAS REMOVED AND SHIPPED TO TRIAD AVIATION FOR REPAIR. REPLACED ALL EXHAUST GUIDES, INTAKE VALVES, HONED CYLINDERS, RESURFACED VALVE SEATS AND INSTALLED ROTATING INTAKE VALVES AS PER LYCOMING SI 1280D.

Parts most often named Crankshaft (8) · Crankcase (7) · Bearing (4) · Tappet (3)

ENGINE RECEIVED FOR O/H DUE TO HIGH METAL. DURING DISASSEMBLY, IT WAS DISCOVERED THAT A PIECE OF THE CHEEK ON THE CRANKSHAFT HAD BROKEN OFF ALLOWING THE COUNTERWEIGHT TO IMPACT CONNECTING RODS AND THE CRANKSHAFT. THE COUNTERWEIGHT PINS WERE UNDAMAGED. THE CRANKSHAFT COUNTERWEIGHT BUSHING WAS BROKEN.

WHILE TROUBLESHOOTING ROUGH RUNNING ENGINE ON MORNING RUNUP, ENGINE CASE FOUND WITH LARGE CRACK UNDER THE NR 2 CYLINDER, ENGINE REMOVED FROM [S/N removed].

PILOT REPORTED THAT ON DOWNWIND IN THE TRAFFIC PATTERN AT THE DESTINATION AIRPORT, HEARD A LOUD "POP", AND AND EXPERIENCED A POWER LOSS ON LT ENGINE. NOTICED OIL AND SMOKE COMING OUT OF LT ENGINE COWL. SHUTDOWN ENGINE AND FEATHERED PROPELLER IAW THE ENGINE FAILURE CHECKLIST AND LANDED NORMALLY. VISUAL INSPECTION OF ENGINE REVEALED A QUARTER SIZED HOLE IN THE LT ENGINE CASE NEAR THE FWD ENGINE HOIST RING.

Parts most often named Carburetor (15) · Float (6) · Valve (2) · Venturi (2)

(CAN) CARBURATOR FLOAT FILLED WITH AVGAS THIS IS THE SECOND TIME IT HAPPEN ON ARE FLEET WITH THIS PART (REF SDR#20170503018) (TC# 20190621006)

THE ENGINE HAD A VERY ROUGH IDLE, SHUTDOWN ATTEMPT WITH IDLE CUTOFF FAILED TO ACHIEVE SHUTDOWN. ENGINE SHUTOFF WITH IGNITION AND AS EXITING THE ACFT, NOTED FUEL DRAINING FROM CARBURETOR AIR BOX. REMOVED CARBURETOR AND FOUND FLOAT FULL OF FUEL AND NO LONGER FUNCTIONAL AS MEANS OF OPERATING NEEDLE VALVE.

(CAN) DURING TAKEOFF AND REDUCING POWER TO CRUISE, APPROXIMATELY 25" TO 22", THE ACFT SUDDENLY YAWED LT AND THEN STRAIGHTENED OUT. THIS WAS REPEATABLE. THE CARB WAS CHANGED AND THE ACFT RETURNED TO [S/N removed].

Parts most often named Engine (18) · Governor (2) · Crankcase (2) · None (1)

PILOT REPORTED THAT DURING CRUISE FLIGHT FROM TJIG TO TJCP LEFT ENGINE OIL PRESSURE STARTED DROPPING AND AFTER A FEW SECONDS PROPELLER FETHERED BY ITSELF AND ENGINE SHUT DOWN. PILOT PERFORMED ENGINE FAILURE PROCEDURE AS PER FLIGHT MANUAL AND DIVERTED TO TJRV AIRPORT, LANDING SAFELY WITHOUT ANY OTHER ISSUES. ENGINE WAS INSPECTED AND FOUND A DAMAGED REAR CRANKSHAFT IDLER GEAR. ENGINE WAS REMOVED AND ANOTHER ENGINE INSTALLED, GROUND RUN UP AND LEAK CHECK PERFORMED, NO DISCREPANCIES FOUND, ALL INDICATION NORMAL.

THE SCORED CONDITIONS HAVE BEEN FOUND AFTER REPORTS OF: HIGH OIL TEMPERATURE, LOSS OF POWER AND HIGH OIL CONSUMPTION ON THE O-540-J3A5D THE PLUNGER ASSEMBLY INSTALLED SHOWS DIFFERENT LENGTHS

AFTER LANDING IN CULEBRA, RIGHT ENGINE QUIT ON TAXI TO THE RAMP. ENGINE WAS INSPECTED AND THE ENGINE CRANKSHAFT IDLE GEAR FOUND BROKEN. ENGINE WAS REMOVED AND REPLACED.

Parts most often named Gauge (20) · Line (1)

(CAN) MANIFOLD PRESSURE STOCK AT 23 INC WHILE REDUCING FOR CRUISE SETTING, PILOT RETURN TO BASE. INSPECTION REVEAL DIRT IN MANIFOLD PRESSURE LINE AND INSTRUMENT ORIFICE. INSTRUMENT SENT TO APPROVED SHOP FOR REPAIR.

Parts most often named Starter (12) · Drive Gear (2) · Bendix Drive (1) · Gear (1)

BENDIX ON STARTER OF RT ENGINE FAILED TO DISENGAGE AFTER STARTUP. R & R STARTER WITH NEW. NO FURTHER DISCREPANCIES NOTED.

REMOVED THIS STARTER FROM SAME AIRCRAFT FOR THE 3RD TIME WITH 62.3 HRS SINCE OVERHAUL. STARTER BENDIX WOULD NOT ENGAGE ANYMORE DURING START UP. NO PROBLEM COULD BE FOUND WITH AIRCRAFT ELECTRICAL SYSTEM. (K)

REMOVED THIS STARTER WITH 3.3 HOURS SINCE OVERHAUL. STARTER BENDIX STAYED ENGAGED DURING START UP. NO PROBLEM COULD BE FOUND WITH AIRCRAFT ELECTRICAL SYSTEM. (K)

Parts most often named Gasket (3) · Drain Tube (2) · Oil Filter (1) · B-Nut (1)

(CAN) AIRCRAFT IS AN AMATEUR BUILT, ENGINE AND SUBJECT OIL FILTER ADAPTER ARE USED ON MANY CERTIFIED ACFT. DURING ANNUAL INSPECTION SUBSTANTIAL OIL LEAK WAS NOTED ON BACK OF ENGINE. TROUBLESHOOTING SOURCED OIL LEAK TO CRACK ON OIL FILTER ADAPTER EAR. CRACK COULD NOT BE SEEN WITHOUT SOME NDT PROCESS. NEW PART INSTALLED, OIL LEAK WAS FIXED.

(CAN) DURING ENGINE TROUBLESHOOTING, NOTED ENGINE CRANKCASE BREATHER RUBBER COUPLING KINKED AND RESTRICTING VENTING ALONG WITH BREATHER ALTERNATE AIR OUTLET COVERED BY NO APPROVED SCREEN. ENGINE CRANKCASE BREATHER TUBE COUPLING REPLACED AND FREEDOM VERIFIED. CRANKCASE BREATHER ALTERNATE AIR HOLE UNCOVERED AS REQUIRED. NO FURTHER FAULTS FOUND.

PILOT REPORTED SMOKE IN THE COCKPIT AFTER LANDING. AFTER AN INSPECTION OF THE ENGINE, IT WAS FOUND THAT NR4 CYLINDER HEAD OIL RETURN LINE "B" NUT HAD BACKED OFF CAUSING OIL TO DRIP ONTO THE EXHAUST STACK WHICH CAUSED THE SMOKE IN THE COCKPIT. THE MECHANIC INSTALLED AND TIGHTENED THE LOOSE "B" NUT AND INSPECTED ALL OTHER CYLINDERS FOR ANY OTHER LOOSE "B" NUTS. NO OTHER LOOSE OIL RETURN "B" NUTS WERE FOUND TO BE LOOSE. THE ACFT WAS RETURNED TO [S/N removed] AND THE PROPER PAPERWORK WAS COMPLETED.

Parts most often named Air Filter (3) · Hinge (2) · Valve (1) · Sleeve (1)

(CAN) AIR FILTER FOUND DETERIORATED AT 50 HRS INSPECTION WITH DIFFERENT DATE CODE LISTED. HELICOPTER MFG SB-85. PN C177-1 WITH DATE CODE OL1912AY2 FOUND DETERIORATED.

DURING FLIGHT, POWER LOSS FROM ENGINE. SUCCESSFUL OFF FIELD LANDING WAS MADE. INSPECTION REVEALED A BAFFLE INSIDE THE CARBURETOR AIR BOX, CAME LOOSE STARTVING THE CARB OF AIR CAUSING ENGINE TO LOOSE POWER.

(CAN) UPON INSPECTION PULLED THE AIR FILTER OUT TO REPLACE IT AND IT WAS FOUND TO BE DETERIORATED AROUND THE RIM OF THE FILTER AND PARTS OF THE RUBBER MOLDING , WHICH HOLDS THE WIRE MESH IN PLACE, WERE FOUND INSIDE THE AIRBOX. FOUND 3 OTHER DETERIORATING FILTERS ON DIFFERENT HELICOPTERS WITH HOURS RANGING FROM 60 TO 90 ON THEM. SENT THE FILTERS TO MFG FOR THEIR INSPECTION. RECOMMEND LOOKING AT THESE FILTERS BEFORE 50 HRS TO SEE IF YOU HAVE ANY DETERIORATING. SB85 HAS BEEN ISSUED.

Parts most often named Shaft (5) · Pin (2) · Governor (1) · Valve Seat (1)

AT LANDING IN VIEQUES AIRPORT RIGHT ENGINE PRESENTED EXESIVE VIBRATION, PILOT PERFORMED PREVENTIVE SHUTDOWN. ENGINE WAS INSPECTED AND FOUND THE PROPELLER GOVERNOR SHAFT BROKEN. PROPELLER GOVERNOR WAS REMOVED AND OVERHAULED PROPELLER GOVERNOR INSTALLED. OPERATIONAL CHECK PERFORMED FOUND NO OTHER DISCREPANCIES.

AT LANDING IN VIEQUES AIRPORT RIGHT ENGINE PRESENTED EXCESSIVE VIBRATION SO PILOT PERFORMED PREVENTIVE SHUTDOWN. ENGINE WAS INSPECTED AND FOUND THE PROPELLER GOVERNOR SHAFT BROKEN. PROPELLER GOVERNOR WAS REMOVED AND AN OVERHAULED PROPELLER GOVERNOR INSTALLED. OPERATIONAL CHECK WAS PERFORMED AND NO OTHER DISCREPANCIES FOUND AT THIS TIME.

(CAN) STOP PIN WAS NOTICED MISSING. THE PIN HAD BROKEN OFF FLUSH OF THE PROP GOVERNOR CONTROL LEVER ASSY. THE PILOT FIRST NOTICED AND REPORTED THAT THE ENGINE RPM WAS REACHING AND EXCEEDING THE RED LINE. THE STOP PIN ALLOWS THE CONTROL LEVER ASSY TO CONTACT THE ADJUSTABLE STOP FOR MAXIMUM RPM SETTING AND ALSO IS THE ATTACH POINT FOR SPRING PRESSURE TO MOVE THE CONTROL ARM FINE PITCH IN THE EVENT OF FAILURE TO PROP CONTROLS.