MSB 00-5A TECHNICAL PORTIONS FAA APPROVED

Transcription

1 TELEDYNE CONTINENTL IRCRFT ENGINE MNDTORY SERVICE BULLETIN The Subject Matter Of This Service Bulletin Is Incorporated In Whole Or In Part In n F irworthiness Directive CTEGORY 1 MSB 00-5 TECHNICL PORTIONS F PPROVED SUBJECT: CRNKSHFT MTERIL INSPECTION BCKGROUND: Teledyne Continental Motors (TCM) has identified the cause of 11 crankshaft fractures which have occurred in the connecting rod journals on straight drive engines manufactured in 1998 and The cause of the fractures has been identified as composition and processing deficiencies during several discrete periods of steel production and/or forming operations by suppliers. The fractures have occurred in new, rebuilt and field overhauled engines with operational times varying from 15 to 1257 hours. TCM is working closely with its suppliers to insure future production integrity. TCM has developed an inspection process to identify and replace any other crankshafts potentially affected by this problem. This will be accomplished by means of a metallurgical inspection of two small core samples removed from the crankshaft propeller flange. Review of Teledyne Continental Motors manufacturing processes, nitride characteristics, and dimensional characteristics have not identified any other contributing causes. PURPOSE: To provide instructions for the removal of crankshaft core samples for metallurgical evaluation. WRNING The inspection required by this service bulletin is intended to detect metallurgical anomalies which if present and left uncorrected can result in engine failure. This inspection requires the removal of the aircraft spinner, propeller and spinner bulkhead to provide access to the crankshaft propeller flange. Two equally sized core samples will be taken from the propeller flange 180 degrees from each other using a customized tool provided by Teledyne Continental Motors. The removed core samples will be placed into a plastic, zip closure bag and identified by engine model, engine serial number and crankshaft serial number. These core samples must be returned to Teledyne Continental Motors for evaluation. ISSUED REVISED PGE NO REVISION MO DY YER MO DY YER CONTINENTL MOTORS 1 of TELEDYNE TECHNOLOGIES, INC.

2 COMPLINCE: For affected engines or crankshafts this inspection must be performed within the next 10 hours of operation. Uninstalled service spare crankshafts of the affected serial number range must be inspected prior to installation in any engine. ENGINES and/or CRNKSHFTS FFECTED: IO-360, TSIO-360, LTSIO-360, O-470, IO-470, TSIO-470, IO-520, TSIO- 520, LTSIO-520, IO-550, TSIO-550 and TSIOL-550 series new and rebuilt direct drive engines assembled utilizing a crankshaft that was manufactured from pril 1, 1998 through March 31, ffected engine serial numbers are specified below. ny of the preceding series engines that have had a replacement crankshaft installed during field overhaul or repair. ffected replacement crankshaft serial numbers are specified below. Refer to the Crankshaft Serial Number Identification below for identification of affected crankshafts. Note: If your engine has recently had a crankshaft installed that may have been manufactured from pril 1, 1998, through March 31, 2000, the crankshaft serial number must be examined to determine if this inspection procedure applies. Visit TCM s website at to determine if your engine or crankshaft is affected by this service bulletin. If you do not have access to the TCM website, you may contact TCM service department at For International customers who do not have access to the Internet and TCM s website, you may contact TCM s Service Department via one of the International toll free numbers listed below or by dialing our direct number extension Country Phone number USTRLI VNTEL VNTEL VNTEL VENTEL BHMS BELGIUM BRZIL CHIN COLOMBI COST RIC CTC DENMRK DOM REPUBLIC Country Phone number FINLND FRNCE GERMNY GOLDEN GREECE HONG KONG HUNGRY INDONESI IRELND ITLY JPN KORE-TELE LUXEMBOURG MLYSI ISSUED REVISED PGE NO REVISION MO DY YER MO DY YER CONTINENTL MOTORS 2 of 26

3 Country Phone number MEXICO MEXICO MEXICO MEXICO NETHERLND NEW ZELND NICRGU PLDT PHILI PORTUGL Country Phone number SINGPORE SPIN SWEDEN SWITZERLND TIWN THILND TURKEY UNITED URUGUY VENEZUEL CRNKSHFT SERIL NUMBER IDENTIFICTION Each crankshaft is identified by a serial number steel stamped on the O.D. of the propeller flange that reflects its manufacturing date. Crankshafts produced prior to December 31, 1999 may be identified as follows: Month ➀ Day Year Sequence Denotes Crankshaft XX98XXN Crankshafts produced beginning January 1, 2000 may be identified as follows: Denotes Crankshaft Year Month➁ Serial Number N 00 XX XXX ➀ To determine month of manufacture use the following alpha code: = January G= July B= February H= ugust C= March I= September D= pril J = October E= May K= November F= June L= December ➁ To determine month of manufacturer use the following alpha code: (X)- is a production alpha code for internal use. (X)= January G(X)= July B(X)= February H(X)= ugust C(X)= March I(X) = September D(X)= pril J(X) = October E(X)= May K(X) = November F(X)= June L(X) = December ISSUED REVISED PGE NO REVISION MO DY YER MO DY YER CONTINENTL MOTORS 3 of 26

4 FFECTED ENGINE MODELS BY ENGINE SERIL NUMBER ND CRNKSHFT SERIL NUMBER ENGINE ENGINE CRNKSHFT I0-360-C J059805N I0-360-D J029809N J059804N J059801N I0-360-DB I259805N K109817N I249807N K049817N K109802N I0-360-ES I259804N I299804N I249806N I0-360-G J059808N J029808N I0-360-KB I249801N I259808N I259806N K099801N K109807N LTSI0-360-EB I239802N J019810N J019814N J019811N J019816N K059812N J019815N K079803N K059808N K069803N LTSI0-360-KB K059815N J019817N I239804N J019812N J019808N I259809N K059814N K069811N K069805N K069808N K069810N ENGINE ENGINE CRNKSHFT LTSI0-360-KB K069802N LTSI0-360-RB J019813N J019807N I309802N I259810N J019809N K069809N K069806N K079802N K069807N TSI0-360-B K109805N K109815N TSI0-360-C J029805N TSI0-360-CB K109812N K109801N TSI0-360-D J029810N TSI0-360-EB I259803N I249805N K069813N K109803N K109814N TSI0-360-FB I299803N J019804N I259807N K049813N K069816N K109813N K109810N K109808N TSI0-360-KB K069812N J019802N K099808N I259811N K049818N K099809N K109816N K099810N K109811N K109804N K109806N ISSUED REVISED PGE NO REVISION MO DY YER MO DY YER CONTINENTL MOTORS 4 of 26

5 FFECTED ENGINE MODELS (CONTINUED) ENGINE ENGINE CRNKSHFT TSI0-360-LB I259802N K099802N TSIO-360-LB K099811N K099804N TSI0-360-MB I249809N K099807N TSIO-360-MB K069815N TSI0-360-RB I299802N I249808N I309805N K049815N K059802N I299806N K099803N K099805N K099806N K109809N K059804N GCI H249809N J H139808N K B199910N D129904N D139901N D129901N L F049806N H129807N N H149805N E199926N N N B189912N D139904N B189911N R B189909N E199919N F209804N F209812N F199803N F239808N ENGINE ENGINE CRNKSHFT O-470-R H139803N H139814N H139816N H139807N H139811N H139804N E199917N H139812N H129811N D129911N H139806N H139805N E199915N L029811N N N B199904N B199907N B199911N C159917N C179905N C169906N C169903N C159911N C169905N C169907N C169911N D129903N C159916N C169908N C169904N E199923N H139801N F199804N S F209810N F199802N H129810N N N C169901N ISSUED REVISED PGE NO REVISION MO DY YER MO DY YER CONTINENTL MOTORS 5 of 26

6 FFECTED ENGINE MODELS (CONTINUED) ENGINE ENGINE CRNKSHFT O-470-S B199906N C169910N F259917N U N F049801N H149801N H149806N H149802N N N C159915N D139903N D129908N D129907N C159912N E199921N I0-470-C E079819N F249811N F259803N C189903N I0-470-D F179805N I0-470-F F109815N C159918N E199909N I0-470-K E059810N F289908N H249816N I0-470-L E079807N E079813N E059811N E079820N E079815N E079821N E079810N E069805N E059807N E059812N E079816N E079817N F249806N ENGINE ENGINE CRNKSHFT IO-470-L F249810N F259802N H259802N H249813N H259812N H249810N H249808N H259806N F249813N H259816N H259807N H259815N F249809N F249807N H259809N H259813N H249814N L089804N C189906N C189902N C189909N C189904N E079803N E079808N E079818N E059808N E079823N E079812N I0-470-N E079809N E069804N E069810N E059809N E069802N F249815N E079825N E079814N E069808N F249808N F249814N F249816N ISSUED REVISED PGE NO REVISION MO DY YER MO DY YER CONTINENTL MOTORS 6 of 26

7 FFECTED ENGINE MODELS (CONTINUED) ENGINE ENGINE CRNKSHFT IO-470-N H259814N H259817N C189901N I0-470-S E019915N I0-470-V/VO C159905N D099907N E019914N E019917N E039904N E049917N E049913N E039910N F109816N I F159811N B179901N D089909N F109812N E069905N IO G149915N I0-520-B J109803N J119802N J119805N J099802N K259809N K309806N L019807N L029805N B109911N N B099915N B119918N D069905N L019810N I0-520-BB B159903N C089905N I169814N I169816N K139803N N N ENGINE ENGINE CRNKSHFT IO-520-BB B019910N B029902N C089901N C109907N C279901N B129910N D149902N D149913N D309904N D149912N D309902N K129806N I0-520-C D059908N D059905N J119808N K309805N K309807N K259801N K259811N L029807N L019801N L029810N N N B099913N B119909N B119915N D069909N D059912N D019910N D079904N D059906N J099806N B099914N I0-520-CB K169812N K169805N K179811N K169806N N ISSUED REVISED PGE NO REVISION MO DY YER MO DY YER CONTINENTL MOTORS 7 of 26

8 FFECTED ENGINE MODELS (CONTINUED) ENGINE ENGINE CRNKSHFT IO-520-CB B049906N B129908N D079907N D079909N D079910N D149903N D149904N I0-520-D F179811N F099816N F189805N E059915N F169801N H039801N H099809N H119801N H099802N D109912N H279818N H129806N G149908N B169914N B169906N C119903N D089905N C159923N C159901N C159904N C159902N C159922N D099904N D099909N D099908N D269905N E059902N E019918N E059906N E049904N E059904N E059901N E189921N ENGINE ENGINE CRNKSHFT IO-520-D E189902N F179808N F179817N D249906N E039912N G159902N I0-520-E F269901N C129917N E199908N I0-520-F F169813N F109817N B189904N G149906N D239809N F049807N F189801N F169812N F179803N F179818N E049907N F059810N E189926N F109814N F089809N F119805N F179816N F169805N E199911N F109810N H099821N D109903N E199910N B169902N B169915N B169917N B189905N B179905N B179907N C119909N C119913N ISSUED REVISED PGE NO REVISION MO DY YER MO DY YER CONTINENTL MOTORS 8 of 26

9 FFECTED ENGINE MODELS (CONTINUED) ENGINE ENGINE CRNKSHFT IO-520-F C119907N B189906N C129904N C119911N C119905N C129911N C129912N C139901N C159920N C159919N D109911N D109901N D089917N D099903N D239912N D239907N D269917N D249904N E059905N E039903N E039917N E049908N E189920N E189911N E189905N E199914N E199913N F169817N E059910N D109905N D239905N E059903N I0-520-L F059807N F169806N E189917N F109809N E039905N E189925N E059913N E189915N ENGINE ENGINE CRNKSHFT IO-520-L C159903N D089911N D109906N D089907N D239908N D269908N E039901N E059917N E199904N E199906N D109907N F119804N F269913N I0-520-M J099809N B109912N D019912N D019906N D019903N D019907N I0-520-MB K189801N I229809N K139801N C279902N D149907N LTSI0-520-E G159915N G159918N TSI0-520-E G169904N G169903N TSI0-520-F F169815N TSI0-520-B L029808N J099810N N B119914N K309801N TSI0-520-BB K169801N C089904N C089903N TSI0-520-C F179813N B169911N E039908N ISSUED REVISED PGE NO REVISION MO DY YER MO DY YER CONTINENTL MOTORS 9 of 26

10 FFECTED ENGINE MODELS (CONTINUED) ENGINE ENGINE CRNKSHFT TSI0-520-CE C039919N TSI0-520-E J109806N J089809N J109804N I109810N K309803N K309808N L029804N K259813N K259810N K259807N N N L029803N N B099910N D019905N D019911N TSI0-520-EB F169808N C089906N C269906N D149915N TSI0-520-G E039906N TSI0-520-H F109808N E189928N B169904N D109908N E189918N F269905N F129806N TSI0-520-J B099917N TSI0-520-JB N TSI0-520-L N N TSI0-520-LB B049904N TSI0-520-M F109803N E199912N F119806N F049809N H279804N ENGINE ENGINE CRNKSHFT TSIO-520-M C119906N E049910N B169908N B179906N B179916N B169905N C139908N D099905N D089913N D099906N D269906N C119902N E019912N E189910N E189903N E069901N F179814N TSI0-520-NB K139802N N N B159911N B159908N C109914N D079911N D079908N D299907N C109912N TSI0-520-P E059912N F129803N E039915N E069904N E189914N E199907N E039913N TSI0-520-R E069906N F049808N F089805N F179804N F169816N ISSUED REVISED PGE NO REVISION MO DY YER MO DY YER CONTINENTL MOTORS 10 of 26

11 FFECTED ENGINE MODELS (CONTINUED) ENGINE ENGINE CRNKSHFT TSIO-520-R B169907N B189903N C119901N B169903N E019919N E059918N E189922N E189904N E189924N D099902N D099911N F269902N E039918N TSI0-520-T B189902N C129910N C129916N D089908N TSI0-520-UB I189807N D149905N N B159902N TSI0-520-VB I189801N K199804N K149802N K179805N N N N B019915N B159912N B159904N C279905N C269909N D149910N D149906N D149914N TSI0-520-WB C279912N I J269804N J239810N J279805N ENGINE ENGINE CRNKSHFT I0-550-B I229805N I219802N J259804N J259805N J269801N J269812N J279810N J259812N N N N B059901N B039916N B059908N C249909N C259902N C299910N J259811N J269808N J269811N B039913N N N B039915N B039907N B039910N C239917N C259903N C259904N C259909N C319910N B059920N C069905N I0-550-C I229806N J279804N N B049910N ISSUED REVISED PGE NO REVISION MO DY YER MO DY YER CONTINENTL MOTORS 11 of 26

12 FFECTED ENGINE MODELS (CONTINUED) ENGINE ENGINE CRNKSHFT IO-550-C B039906N B049907N B049908N B089901N B059918N B059922N B059917N C239914N C259910N D279904N B089910N C259907N C259905N I219804N J239807N J269803N N B099904N B059916N N B089907N C069909N C069903N B059903N C259906N B059910N B059913N I0-550-D D179916N N N N B019904N B019905N N N D179915N G169910N N I0-550-E B019906N I0-550-F D179907N N ENGINE ENGINE CRNKSHFT IO-550-F N B019903N B019901N D179911N D179908N I0-550-G I229801N J269807N J269802N N B039909N IO-550-G B039911N B059914N B059902N B089902N B059921N B059911N B089909N B059905N I219805N C069906N C069907N B089906N C299907N C319908N C319901N J269809N I0-550-L D199908N I0-550-N B089908N C269902N TSI0-550-C J259803N I219803N J279811N B059907N TSI0-550-E C319905N B059915N B089903N B059906N B059912N B059904N I219801N ISSUED REVISED PGE NO REVISION MO DY YER MO DY YER CONTINENTL MOTORS 12 of 26

13 ENGINE ENGINE CRNKSHFT TSIO-550-E N N B049911N B089905N C249905N TSI0L I219806N FFECTED ENGINE MODELS (CONTINUED) FFECTED CRNKSHFTS BY CRNKSHFT PRT NUMBER ND SERIL NUMBER CRNKSHFT CRNKSHFT PRT NUMBER SERIL NUMBER N N D179904N D089912N B119903N B179904N B179909N B179910N B179918N B189901N C129902N C129905N C129906N C129907N C129909N C129915N C139904N C139906N C139909N C139910N C139911N D089903N D089915N D099901N D099910N D109904N CRNKSHFT CRNKSHFT PRT NUMBER SERIL NUMBER D109909N D239901N D239902N D239903N D239904N D239906N D239909N D239910N D239911N D249910N D249915N D249916N D249918N D269901N D269903N D269904N D269907N D269910N D269911N D269912N D269913N D269914N D269915N D269916N D269918N E039902N ISSUED REVISED PGE NO REVISION MO DY YER MO DY YER CONTINENTL MOTORS 13 of 26

14 FFECTED CRNKSHFTS (Continued) BY CRNKSHFT PRT NUMBER ND SERIL NUMBER CRNKSHFT CRNKSHFT PRT NUMBER SERIL NUMBER E039907N E039909N E039911N E039914N E049901N E049902N E049906N E059908N E059914N E059916N E059919N E059920N E189913N E189923N E199902N E199903N E199905N F099810N F109804N F109811N F109818N F119801N F119802N F119803N F119807N F119808N F119809N F119810N F119811N F119812N F129801N F129805N F129811N F159807N F159809N F169802N F169814N F179802N F179812N F179815N F189802N F189803N CRNKSHFT CRNKSHFT PRT NUMBER SERIL NUMBER F199801N F269912N G149909N G149910N G149911N G149912N G149913N G149916N G159901N G159905N G159906N H099818N H109803N H109804N F109813N B189910N B199902N B199905N C169902N D129912N D139900N E199924N H149803N H149804N B189907N B189908N B199901N B199909N C159907N C179906N D129905N E199918N E199920N E199922N F049805N F209801N F209802N F209803N H139809N H139810N H139815N G159917N ISSUED REVISED PGE NO REVISION MO DY YER MO DY YER CONTINENTL MOTORS 14 of 26

15 FFECTED CRNKSHFTS (Continued) BY CRNKSHFT PRT NUMBER ND SERIL NUMBER CRNKSHFT CRNKSHFT PRT NUMBER SERIL NUMBER N N N N N B099909N B099912N B099918N B109901N B109917N B109918N B109922N B119904N B119906N B119907N B119908N B119917N D019901N D019902N D019908N D019909N D059902N D059907N D059909N D069902N D069904N D069906N D079903N I109811N I119811N I119812N J089810N J099801N J099804N J099807N J099808N J099811N J099812N J099815N J119801N J119804N J319805N CRNKSHFT CRNKSHFT PRT NUMBER SERIL NUMBER K249801N K259803N K259805N K309802N L019803N L019805N L019806N L019809N L029801N L029802N L029806N L029809N L309808N N B099908N B109905N B109914N D019904N D059901N D079902N J109802N J119803N K309804N K309809N K309810N L019802N N N N N N N B049901N B049903N C099901N C099902N C099904N C099905N C099906N C109901N C109903N C109904N ISSUED REVISED PGE NO REVISION MO DY YER MO DY YER CONTINENTL MOTORS 15 of 26

16 FFECTED CRNKSHFTS (Continued) BY CRNKSHFT PRT NUMBER ND SERIL NUMBER CRNKSHFT CRNKSHFT PRT NUMBER SERIL NUMBER C109906N C109911N D149909N I139813N I169813N I169815N I189808N K149801N K149805N K169802N K169814N K179804N K189804N L189808N N N B059909N C259901N C269901N C269904N C319907N C319909N J239811N K229807N E079801N E079822N F259801N F259804N H259803N H259805N H259811N E069801N E069806N E069807N E069809N E079802N E079805N H249807N H249811N H249815N H249817N H249818N CRNKSHFT CRNKSHFT PRT NUMBER SERIL NUMBER H259801N H259804N H259808N H259818N B189914N C189907N C189908N E069803N E079804N E079806N E079811N E079824N H249812N F049803N I249803N I249804N I249810N I259801N I309803N I309804N J019801N J019803N J019805N K059803N K069804N K069814N I239801N I239803N I239805N I239806N I239807N I239808N I239810N I239811N K059809N K059811N K079804N K079810N J029802N J029803N J029804N J029807N ISSUED REVISED PGE NO REVISION MO DY YER MO DY YER CONTINENTL MOTORS 16 of 26

17 FFECTED CRNKSHFTS (Continued) BY CRNKSHFT PRT NUMBER ND SERIL NUMBER CRNKSHFT CRNKSHFT PRT NUMBER SERIL NUMBER J059802N J059803N J059807N J059809N J059810N J059811N J059812N N N N C299906N I229804N ISSUED REVISED PGE NO REVISION MO DY YER MO DY YER CONTINENTL MOTORS 17 of 26

18 . GENERL INFORMTION: Teledyne Continental Motors will provide the following specialized tools and equipment required to perform the procedure detailed in this service bulletin: MSB 00-5 Tool Kit Contents 1. 1 each-crankshaft Boring Tool & dapter 2. 1 each Instructional Video 3. 1 each-positive Stop Depth Rod 4. 1 each.025 Feeler Gage 5. 1 each-end Mill 6. 2 each-coring Bit (Rotobroach) 7. 1 each-de-burring Tool (1 spare blade) each-core Sample Bags and Labels. One crankshaft (2) core samples per bag. The following supplies must be obtained locally. 1. Zinc Chromate Primer- non aerosol 2. cid brushes or cotton swabs 3. LPS-1 Spray Lubricant- non-silicon/non- Teflon based. 4. Dye Check Kit 5. Dial Type Torque Wrench; inch lbs. 6. Spark plug gaskets. 7. Propeller hub O-ring. WRNING Do not use silicon or Teflon based coolants or lubricants during any part of this procedure. Silicon and/or Teflon based products will affect the reliability of the dye check procedure. B. PRE-CORING PROCEDURE: Verify that engine model and serial number, or replacement crankshaft serial number, is listed as affected by this service bulletin. Service spare crankshafts affected by this service bulletin which have not been installed in an engine must be inspected prior to being installed. In accordance with the aircraft manufacturer s maintenance manual: 1. Remove engine cowling to gain access to the upper spark plugs and propeller mounting hardware. Remove upper spark plug ignition leads and spark plugs. 2. Remove propeller spinner, spinner bulkhead and propeller. If the aircraft is equipped with propeller de-ice or anti-ice, follow the aircraft manufacturer s instructions for removal of this equipment, if required for propeller removal. 3. Using a clean shop towel, clean the propeller flange. 4. Record engine model and serial number, crankshaft serial number and total engine time on shop repair work order and on the labels provided by TCM. C. MOUNTING TOOLING: Before installing the crankshaft boring tool and crankshaft flange adapter, insure that the adapter face and counter bore are clean and free of any debris. Insure that the mounting studs are secure in the propeller flange adapter mounting plate. 1. Plug the crankshaft opening with a clean shop towel to prevent any debris from entering the crankshaft oil transfer area. 2. Using a piece of plastic, fabricate a protective cover for the engine and nacelle area. In the approximate center of the piece of plastic, cut a slit 6 inches long. Slip the crankshaft propeller flange through the slit, drape the upper part of the plastic over the top of the engine and drape ffected engines installed in aircraft must be inspected within the next 10 hours of operation. For engines installed in aircraft proceed as follows. ISSUED REVISED PGE NO REVISION MO DY YER MO DY YER CONTINENTL MOTORS 18 of 26

19 the lower part in such a manner that the plastic protects the lower portion of the engine and the nacelle area. FIGURE 1 PROTECTIVE PLSTIC COVER 3. Place a drip pan under the plastic to catch cooling/lubricating fluid and metal shavings. 4. On the propeller flange, identify, and using a red magic marker, mark the location from which the core samples will be taken. See Figure Locate the two crankshaft flange holes that will be used to mount the adapter and boring tool. See Figure 2. plate does not contact any portion of the engine surrounding the propeller flange or the aircraft cowling. 7. Position the boring tool propeller flange adapter plate mounting studs to align with selected propeller flange holes and slide the adapter studs through the propeller flange holes. Secure the coring tool flange to the propeller flange with the two nuts provided with the tooling. Tighten nuts to 150 inch lbs. 8. The red mark made on the propeller flange must be visible through the boring tool adapter plate hole. If the red mark is not visible, remove the boring tool from the propeller flange and repeat the above steps 5,6 and 7. MRK CORE SMPLE LOCTION WITH RED MRKER DPTER STUD MOUNT HOLE FIGURE 3 VERIFICTION OF CORING SMPLE LOCTION & TOOL LIGNMENT D. REMOVL OF NITRIDE LYER: DPTER STUD MOUNT HOLE FIGURE 2 FLNGE CORE SMPLE RE MRKED 6. Rotate the crankshaft so that the crankshaft flange holes to be used to mount the adapter plate and boring tool (identified in step 4) are positioned so that, when installed, the adapter Removal of the nitride layer from the forward face of the crankshaft flange will require spot facing an area.025 inches deep for each core sample. To remove the nitride layer proceed as follows: 1. With the boring tool and adapter plate correctly positioned and mounted, install the end mill provided with the tool kit into the boring chuck. Insure that the flats machined on the shank of the end mill align with the allen set screw in the chuck. Tighten the set ISSUED REVISED PGE NO REVISION MO DY YER MO DY YER CONTINENTL MOTORS 19 of 26

20 screws with the allen wrench provided in the tool kit. See FIGURES 4 and To set the correct depth of the spot face, position a.025 feeler gage so that it is captured between the mounting adapter surface and the end on the positive stop rod as the rod is moved forward. Lock the positive stop rod in place using the thumb screw or set screw on top of the rod adapter. See Figure FEELER GGE FIGURE 4 END MILL FOR SPOT FCING PROPELLER FLNGE FRONT FCE THUMB SCREW OR SET SCREW POSITIVE STOP ROD FIGURE 6 POSITIVE STOP ROD SET-UP FOR.025 SPOT FCE 6. Back the end mill away from the front surface of the propeller flange and remove the feeler gage. FIGURE 5 INSTLLING END MILL 2. Install a dial type inch pound torque wrench into the square drive on the side of the boring tool. Ensure that the range of motion is sufficient to allow the end mill to contact the work. 3. Install the positive stop rod provided into the holder mounted on the top of the boring tool motor. 4. dvance the end mill toward the front face of the crankshaft flange until the end mill contacts the flange. CUTION Eye protection must be worn during the machining processes. Steel shavings will be made during this procedure. 7. Turn the boring tool on using the switch provided on the tool. 8. Slowly advance the end mill toward the front face of the crankshaft flange by applying pressure to the handle of the dial type torque wrench. 9. Spray generous amounts of coolant/lubrication (LPS-1) onto the work and end mill during the spot facing operation. 10. Maintain a constant pressure on the torque wrench during the spot facing operation, but do not exceed 110 inch lbs. See Figure 7. ISSUED REVISED PGE NO REVISION MO DY YER MO DY YER CONTINENTL MOTORS 20 of 26

21 1. Mount the coring rotobroach into the boring tool chuck. Ensure that the rotobroach is positioned so that a portion of the set screw flat protrudes from the end of the chuck. Secure the rotobroach by tightening the allen set screw in the chuck. See FIGURE 5 and 8. FIGURE 7 USING TORQUE WRENCH TO MINTIN CONSISTENT FEED RTE 11. Spot face the front face of the propeller flange until the positive stop rod contacts the adapter plate surface. dditionally, as the nitrided surface is penetrated an audible sound change will occur and the feed rate of the end mill will increase as the end mill cuts into the non-nitrided steel. 12. Back the end mill away from the propeller flange front face and turn OFF the boring tool. 13. Loosen the thumb screw or set screw securing the positive stop rod in place and sliding the rod aft remove it from the holder. 14. Remove the end mill from the boring tool chuck. Clean the machining debris from the boring tool and adapter flange. E. PROPELLER FLNGE CORING SMPLE PROCEDURE: With the boring tool and adapter plate mounted to the propeller flange, proceed as follows: FIGURE 8 ROTOBROCH CORING BIT 2. Ensure that the torque wrench has sufficient travel for the rotobroach to drill through the propeller flange. 3. Turn the boring tool on and advance the rotobroach toward the propeller flange by applying pressure to the handle of the torque wrench. Spray generous amounts of coolant/lubricant (LPS-1) onto the propeller flange and rotobroach as it contacts and bores into the propeller flange. 4. pply consistent pressure of 100 to 110 inch lbs. to the torque wrench to control boring tool feed rate pressure during the initial stages of the coring operation. pply generous amounts of coolant/lubricant (LPS-1) to the work surface and rotobroach throughout the machining operation. Occasionally back the rotobroach away form the work surface to clear the cutting flutes of machining debris. See Figure 9. ISSUED REVISED PGE NO REVISION MO DY YER MO DY YER CONTINENTL MOTORS 21 of 26

22 5. s the rotobroach contacts the nitrided back wall of the propeller flange, the feed rate will decrease. It may be necessary to increase the feed rate pressure to 140 to 180 inch lbs. Do not apply more than 200 inch lbs. of force to the rotobroach. If the rotobroach stops cutting, install new rotobroach and continue coring operation. NOTE: Rotobroach will require replacement after coring 2 to 3 crankshafts. Tool life is dependent on maintaining the proper feed rate pressure and providing a continuous and generous flow of lubricant/coolant (LPS-1) during the coring operation. 10. Supporting the boring tool and propeller flange adapter plate loosen and remove the two nuts on the aft side of the propeller flange that secured the boring tool and adapter plate to the propeller flange. 11. Remove the boring tool and adapter plate from the propeller flange. FIGURE 9 ROTOBROCH TKING CORE SMPLE 6. Once the rotobroach has cut through the back wall of the propeller flange, release the pressure on the torque wrench and pull the rotobroach out of the machined hole in the propeller flange and clear of the boring tool adapter plate. 7. Loosen the allen set screw and remove the rotobroach and propeller flange core sample from the boring tool chuck. 8. Remove the core sample from the rotobroach and place it in the self sealing plastic bag provided. See Figure Fill out the label on the front of the selfsealing plastic bag in its entirety. FIGURE 10 PROPELLER FLNGE CORE SMPLES (One crankshaft set (2) per sample bag) 12. Clean the machining debris from the boring tool adapter plate and from the propeller flange. 13. Position the boring tool and adapter plate 180 degrees from its previous position to machine the second core sample. 14. Mount and seat the boring tool and adapter plate onto the propeller flange and secure in place by installing the two nuts onto the studs protruding from the back side of the propeller flange. 15. Ensure that the red mark identifying the desired machining area of the propeller flange is visible through the adapter plate boring hole. See FIGURE To obtain the second propeller flange core sample repeat PRT D steps 1 through 14 and PRT E steps 1 through 12. ISSUED REVISED PGE NO REVISION MO DY YER MO DY YER CONTINENTL MOTORS 22 of 26

23 F. CLENING ND CHMFERING CORE SMPLE HOLES: fter removing the boring tool and adapter plate from the propeller flange, clean and chamfer the core sample hole as follows: 1. Ensure that the front and aft face of the propeller flange is clean and free of any machining debris. FIGURE 12 CORE SMPLE HOLE FTER CHMFERING FIGURE 11 CHMFERING CORE SMPLE HOLE NOTE: The chamfering tool has a spring loaded cutting blade. To chamfer the aft side of the core sample hole, apply enough pressure to the chamfering tool to cause the blade to retract sufficiently to allow the tool to pass through the core sample hole. 2. Using the chamfering tool provided in the tool kit, chamfer the core sample hole I.D. on the front and aft faces of the propeller flange. See Figure pply a light even pressure to the tool during the chamfering process. 4. Using 180 crocus cloth or emery paper polish the core sample hole I.D. 5. Clean the core sample holes and propeller flange using a lint free shop towel dampened with cetone. 6. Measure edge distance of core sample hole to propeller flange O.D. Minimum edge distance is.080 inches. If edge distance is less than.080 inches, contact TCM at for removal and replacement of crankshaft. MINIMUM EDGE DISTNCE.080 INCHES FIGURE 13 CORE SMPLE HOLE MINIMUM EDGE DISTNCE 7. Visually inspect core sample holes for sharp edges and burrs. Remove any sharp edges or burrs prior to proceeding. See Figure 12. ISSUED REVISED PGE NO REVISION MO DY YER MO DY YER CONTINENTL MOTORS 23 of 26

24 G. DYE CHECK OF CORE SMPLE HOLES: to cure completely prior to installation of the propeller. See Figure 14. In accordance with S E 1417 perform a complete Dye Check Inspection of the core sample holes and the adjacent front and aft flange surfaces ¼ inches around the holes. 1. Brush red visible dye check penetrant in the core sample holes and the surrounding area on the front and aft flange faces. 2. Brush red visible dye check penetrant in the core sample holes and the surrounding area on the front and aft flange faces. 3. llow penetrant to dwell for a minimum of 20 minutes. 4. Clean off residual penetrant with a clean lint free shop towel dampened with penetrant remover. 5. pply removable dye check developer by spraying a light, uniform coating to cover the core sample hole I.D. and the surrounding area. 6. llow developer to dwell for 15 minutes. 7. Visually inspect affected area surrounding the core sample holes on the front and aft face of the propeller flange for crack indications. If no crack indications are noted, proceed to Part H. 8. If crack indications are noted, contact Teledyne Continental Motors Service Representative at H. PINTING CORE SMPLE HOLES: 1. Clean all dye check residue from the core sample holes and surrounding area with penetrant remover or acetone. 2. Using an acid brush or cotton swab, apply zinc chromate primer to core sample holes and chamfered areas on the front and aft faces of propeller flange. llow the primer FIGURE 14 CORE SMPLE HOLE FTER PPLICTION OF ZINC CHROMTE PRIMER I. MILING SMPLE: Ensure that the label on the plastic bag containing the core samples is completed in its entirety. Place plastic core sample bag in an overnight envelope and mail to: Teledyne Continental Motors 2039 Broad Street Mobile, labama TTN: MSB 00-5 J. RETURNING IRCRFT ND ENGINE TO SERVICE: In accordance with the aircraft manufacturer s maintenance manual and Teledyne Continental Motors engine maintenance manual or overhaul manual perform the following: 1. Remove protective plastic covering from around the crankshaft propeller flange and engine. 2. Remove the shop towel or other protective device that was used to protect the interior of ISSUED REVISED PGE NO REVISION MO DY YER MO DY YER CONTINENTL MOTORS 24 of 26

25 the crankshaft during the sample coring process. 3. Insure that propeller flange is clean and free of any debris that would interfere with correct seating and installation of the aircraft propeller. 4. In accordance with the aircraft manufacturer s maintenance manual install propeller, propeller spinner bulkhead and spinner. Torque attaching hardware to values specified in the aircraft manufacturer s maintenance manual. 5. Install upper sparkplugs using new gaskets and torque to 300 to 360 inch lbs. 6. Install ignition leads and torque B nuts to inch lbs. 7. Install engine cowling. 8. Perform a complete engine ground run up in accordance with the aircraft manufacturer s maintenance manual. Teledyne Continental Motors will notify the FBO via Internet , FX or telephone upon completing the testing on the core samples. Evaluation of core samples should be completed in 24 to 48 hours after the samples are received by Teledyne Continental Motors. Engines with crankshaft core samples meeting the acceptance criteria may be returned to service. Teledyne Continental Motors will provide a logbook attachment indicating the core samples from the specified engine are acceptable and that the engine may be returned to service. Make an engine logbook entry stating compliance with TCM MSB Make an aircraft logbook entry referring to removal and installation of the propeller, propeller spinner and spinner bulkhead to facilitate compliance with TCM MSB K. WRRNTY The labor and material required to comply with this service bulletin will be covered by Teledyne Continental Motors New, Rebuilt or Gold Medallion Warranty policy as applicable to the affected engine. Labor hours approved to comply with this service bulletin will not exceed 3 ½ manhours per affected engine. Reimbursement for compliance with the inspection specified in this service bulletin will be processed using the Crankshaft Material Inspection Reimbursement Form on the last page of the service bulletin. To ensure prompt processing of you reimbursement, complete the form in its entirety and attach a copy of the repair work order and customer invoice. Mail reimbursement form to: Teledyne Continental Motors 2039 Broad Street Mobile, labama TTN: WRRNTY DMINISTRTION If crankshaft replacement is required, the following labor allowances will apply: 1. Removing and reinstalling engine. Non turbocharged : 29 manhours Tubrocharged: 36 manhours If field replacement of the crankshaft is authorized by Teledyne Continental Motors, the following labor allowances will apply: 1. Engine disassembly to facilitate crankshaft replacement only and reassembly after replacement crankshaft installation: Non turbocharged: 35 manhours Turbocharged: 37 manhours NOTE: Claims submitted that include labor and material charges not related to crankshaft replacement will be denied and returned to the submitter. Do not separate pistons from ISSUED REVISED PGE NO REVISION MO DY YER MO DY YER CONTINENTL MOTORS 25 of 26

26 cylinders, Remove cylinder sufficiently to remove the piston pin only. If a varnish layer has formed on the piston pin between the piston pin bosses and the connecting rod bushing, lightly spray the effected area with carburetor cleaner to soften the varnish and aid in piston pin removal. Do not use tools that may damage the aluminum end plugs of the piston pin. Engine test run after crankshaft replacement: 1. In an engine test cell: 16 man hours 2. In the aircraft: 4 man hours ISSUED REVISED PGE NO REVISION MO DY YER MO DY YER CONTINENTL MOTORS 26 of 26

27 CONTINENTL MOTORS CRNKSHFT MTERIL INSPECTION REIMBURSEMENT FORM For Compliance of MSB 00-5 ttach a copy of the shop work order and invoice to this form. Complete the following information: DTE: ENGINE MODEL: ENGINE SERIL NUMBER: ENGINE TOTL TIME: CRNKSHFT SERIL NUMBER: IRCRFT MODEL: IRCRFT REG. NUMBER: OWNER NME: DDRESS: CITY: STTE: ZIP: COUNTRY: PHONE: FX: E-MIL DDRESS: MOUNT of Reimbursement Requested. MKE REIMBURSEMENT CHECK PYBLE TO: OWNER: or FBO: FBO NME: DDRESS: CITY: STTE: ZIP: COUNTRY: PHONE: FX: E-MIL DDRESS: MIL COMPLETED FORM TO: TELEDYNE CONTINENTL MOTORS P.O. BOX 90 MOBILE, L TTN: WRRNTY DMINISTRTION TCM USE ONLY DTE: PPROVED SIGNTURE: MOUNT: CCOUNTING VERIFICTION: CHECK NUMBER: