Airworthiness Directive

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Federal Aviation Administration

14 CFR Part 39

Amendment 39-4515; AD 82-27-03

Airworthiness Directives; ROTO-MASTER, INC. (RAJAY INDUSTRIES, INC.): Rajay Model 325E10 and 3AT6EE10J2 Turbochargers
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AGENCY: Federal Aviation Administration, DOT

DATES: Effective December 30, 1982.

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82-27-03 ROTO-MASTER, INC. (RAJAY INDUSTRIES, INC.): Amendment 39-4515. Applies to Rajay Model 325E10 and 3AT6EE10J2 turbochargers, installed on but not limited to: Continental Engine Models TSIO-360, 0-470, IO-470, IO-520, TIO-520; Lycoming Engine Models O-320, IO-320, LIO-320, 0-360, IO-360, TO-360, 0-540, IO-540, TIO-540. These engines are installed on, but not limited to the following aircraft: Piper PA-28R-201T, PA-28-RT-201T, PA-28-201T series; PA-34-200, PA-34-200T, series; PA-30 and -39 series; Mooney M-20 A thru K series; Lake LA-4, LA-4A, and LA-200 Series.

Compliance is required as indicated, unless already accomplished.

To prevent the possibility of a fire in the powerplant nacelle and/or heat damage to the powerplant installation caused by the engine exhaust gases escaping through a cracked turbocharger turbine housing, accomplish the following:

(a) Within 50 hours of time in service after the effective date of this AD inspect the engine turbocharger exhaust systems and determine whether or not the turbine housing Rajay P/N TC-60-11 or Rajay P/N 600510, 600510-01, 600510-02 or TCM P/N 643930 or turbocharger model 325E10 or 3AT6EE10J2 is installed. If any of these part numbers are installed, or if the turbine housing part number cannot be determined, before further flight, and thereafter at intervals not to exceed 200 hours time in service from the last inspection, comply with paragraph (b) through (g) of this AD.

(b) Remove the turbocharger turbine housing exhaust coupling V-Band and tailpipes (see Figure 1).

(c) Visually inspect the turbocharger turbine housing for cracks using a dye penetrant inspection method. (NOTE: The suspect area can be viewed through the exhaust port to ascertain possible presence of cracks penetrating through the outer wall as shown in Fig. 2.)

(d) Inspect coupling V-Band clamp for cracks by spreading the band segments and checking for failed spot welds and for indication of exhaust flanges bottoming in coupling V-Band (see Figure 1) and clamp bolt for bending, overstress, thread damage, and cracks (see Figure 1).

(e) Inspect turbochargers and tailpipe flanges for cracks and distortion (see Figure 1). Remove all carbon deposits from mating flanges before reassembly.

(f) Inspect mating area of turbocharger exhaust flange to exhaust tailpipe connection for proper mating of surfaces.

(g) Inspect engine mount for indication of overheat, warpage, and corrosion, or rust. Repair as required.

(h) If during inspection required by paragraph (c), an internal crack is found that either exceeds the limit shown in Figure 2, View 1 or 2, or a crack penetrates the outer wall of a turbine housing as shown in Figure 2, View 3, the existing turbine housing must be removed from service and replaced with a serviceable turbine housing prior to the next flight.

(i) If during the inspections required by paragraphs (d) through (g), cracked, distorted, or otherwise damaged parts, components, or assemblies are found, before further flight repair or replace with serviceable parts, components, and assemblies of the same part number.

(j) The inspections required by this AD may be discontinued when the turbine housing is replaced with a Roto-Master part number 600510-04 (TCM P/N 643931).

(k) Special flight permits may be issued in accordance with FAR 21.197 and 21.199 to operate aircraft to a base for the accomplishment of inspections required by this AD.

(l) Alternative inspections, modifications or other actions which provide an equivalent level of safety may be used when approved by the Manager, Western Aircraft Certification Field Office, FAA Northwest Mountain Region, Hawthorne, California.

NOTE: Roto-Master, Inc. Service Letter Number 27, Rev. A dated September 24, 1982, refers to the above procedures.

This amendment becomes effective December 30, 1982.