AD 2000-05-14

[Federal Register Volume 65, Number 57 (Thursday, March 23, 2000)]
[Rules and Regulations]
[Pages 15531-15534]
From the Federal Register Online via the Government Publishing Office [<a href="http://www.gpo.gov">www.gpo.gov</a>]
[FR Doc No: 00-6033]


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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. 96-ANE-36-AD; Amendment 39-11624; AD 2000-05-14]
RIN 2120-AA64


Airworthiness Directives; AlliedSignal Inc. ALF502 and LF507 
Series Turbofan Engines

AGENCY: Federal Aviation Administration, DOT.

ACTION: Final rule.

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SUMMARY: This amendment supersedes two existing airworthiness 
directives (AD's), applicable to AlliedSignal Inc. ALF502 and LF507 
series turbofan engines, that require rework or replacement of No. 4 
and 5 bearing oil system hardware, initial and repetitive inspections 
of the oil system, optional installation of an improved oil filter 
bypass valve, and repetitive inspection of No. 4 and 5 bearing oil 
inlet tube, to ensure the integrity of the reduction gear system and 
overspeed protection system. This action would require replacement of 
the existing power turbine bearing housing assembly with a new, 
improved power turbine bearing housing assembly, and installation of a 
reworked or modified fourth turbine rotor disk assembly as a part of a 
design change to the new No. 4 bearing configuration that eliminates 
the requirement for repetitive inspections of oil system and No. 4 and 
5 bearing oil inlet tube assembly. This amendment is prompted by one 
report of a contained power turbine rotor shaft separation forward of 
the Stage 4 low pressure turbine (LPT) rotor on an AlliedSignal Inc. 
ALF502R-5 engine. The LPT failure was caused by improper inspection of 
the engine oil system required by AD 97-05-11 R1.
    The actions specified by this AD are intended to prevent a No. 4 
and 5 duplex bearing failure, which can result in a Stage 4 LPT rotor 
failure, an uncontained engine failure, and damage to the airplane.

DATES: Effective date April 27, 2000.
    The incorporation by reference of SB ALF 502R-72-0160, revision 2, 
dated May 26, 1987; ALF 502R-72-0160, revision 1, dated March 23, 1987; 
SB ALF502R 79-9 revision 1, dated November 27, 1996; SB ALF502L 79-
0171, revision 1, dated November 27, 1996; SB ALF502R-79-0162, revision 
2, dated September 8, 1987; SB ALF502R-79-0162, revision 1, dated May 
26,1987; SB ALF502R-79-0162, dated March 23,1987; SB LF507-1F-79-5, 
revision 1, dated November 27, 1996; and SB LF507-1H 79-5, revision 1, 
dated November 27, 1996, was previously approved by the Director of the 
Federal Register in accordance with 5 U.S.C. 552(a) and 1 CFR part 51 
as of April 16, 1997 (62 FR 15378).
    The incorporation by reference of certain publications listed in 
the regulations is approved by the Director of the Federal Register as 
of April 27, 2000.

ADDRESSES: The service information referenced in this AD may be 
obtained from AlliedSignal Aerospace, Attn: Data Distribution, M/S 64-
3/2101-201, P.O. Box 29003, Phoenix, AZ 85038-9003; telephone (602) 
365-2493, fax (602) 365-5577. This information may be examined at the 
Federal Aviation Administration (FAA), New England Region, Office of 
the Regional Counsel, 12 New England Executive Park, Burlington, MA; or 
at the Office of the Federal Register, 800 North Capitol Street, NW, 
suite 700, Washington, DC.

FOR FURTHER INFORMATION CONTACT: Robert Baitoo, Aerospace Engineer, Los 
Angeles Aircraft Certification Office, FAA, Transport Airplane 
Directorate,

[[Page 15532]]

3960 Paramount Blvd., Lakewood, CA 90712-4137; telephone 562-627-5245; 
fax 562-627-5210.

SUPPLEMENTARY INFORMATION: A proposal to amend part 39 of the Federal 
Aviation Regulations (14 CFR part 39) by superseding AD 80-22-53, 
Amendment 39-3995 (45 FR 83202, December 18, 1980) and AD 97-05-11 R1, 
Amendment 39-10091 (62 FR 41262, August 1, 1997) which are applicable 
to AlliedSignal Inc. ALF502 and LF507 series turbofan engines was 
published in the Federal Register on October 14, 1998 (63 FR 55056). 
That action proposed to require rework or replacement of No. 4 and 5 
bearing oil system hardware, initial and repetitive inspections of the 
oil system, optional installation of an improved oil filter bypass 
valve, a more stringent oil system inspection of the full flow chip 
detector, oil filter impending bypass button, oil acid number, oil 
color, and oil quantity.

Manufacturer Service Information

    The FAA has reviewed and approved the technical contents of the 
accomplishment instruction paragraphs of AlliedSignal Inc. Service 
Bulletin (SB) No. ALF/LF 72-1030, Revision 2, dated December 14, 1998, 
and AlliedSignal Inc. SB No. ALF/LF 72-1040, Revision 1, dated December 
14, 1998, that describe procedures for installation of a reworked or 
modified fourth turbine rotor disk assembly, and that describes 
procedures for replacement of the existing power turbine bearing 
housing assembly with a new, improved power turbine bearing housing 
assembly.

Requirements of This AD

    Since an unsafe condition has been identified that is likely to 
exist or develop on other products of this same type design, this AD 
supersedes AD's 80-22-53 and 97-05-11 R1 to require replacement of the 
existing power turbine bearing housing assembly with a new, improved 
power turbine bearing housing assembly, and installation of a reworked 
or modified fourth turbine rotor disk assembly as a part of design 
change to the new No. 4 bearing configuration, that eliminates the 
requirements for repetitive inspections of oil system and No. 4 and 5 
bearing oil inlet tube assembly.

Correction to Note 2

    Reference to Avco Lycoming Textron SB No. ALF 502R-72-0160, 
Revision 2, dated May 26, 1987, which was inadvertently omitted from 
the NPRM and has been added to Note 2. Revision 2 to SB No. ALF 502R-
72-0160, dated May 26, 1987, was an editorial change to the SB and does 
not affect the technical content of the SB.
    Interested persons have been afforded an opportunity to participate 
in the making of this amendment. No comments were received on the 
proposal or the FAA's determination of the cost to the public. The FAA 
has determined that air safety and the public interest require the 
adoption of the rule with the changes described previously.

Economic Cost Analysis

    There are approximately 1,500 AlliedSignal Inc. ALF502 and LF507 
series turbofan engines of the affected design in the worldwide fleet. 
The FAA estimates that 300 engines installed on airplanes of U.S. 
registry will be affected by this AD, that it will take approximately 
20 work hours per engine to accomplish the required actions, and that 
the average labor rate is $60 per work hour. Required parts will cost 
approximately $30,000 per engine. Based on these figures, the total 
cost impact of the AD on U.S. operators is estimated to be $9,540,000.

Regulatory Impact

    This final rule does not have federalism implications, as defined 
in Executive Order 13132, because it does not have a substantial direct 
effect on the States, on the relationship between the national 
government and the States, or on the distribution of power and 
responsibilities among the various levels of government. Accordingly, 
the FAA has not consulted with state authorities prior to publication 
of this final rule.
    For the reasons discussed above, I certify that this action (1) is 
not a ``significant regulatory action'' under Executive Order 12866; 
(2) is not a ``significant rule'' under DOT Regulatory Policies and 
Procedures (44 FR 11034, February 26, 1979); and (3) will not have a 
significant economic impact, positive or negative, on a substantial 
number of small entities under the criteria of the Regulatory 
Flexibility Act. A final evaluation has been prepared for this action 
and it is contained in the Rules Docket. A copy of it may be obtained 
from the Rules Docket at the location provided under the caption 
ADDRESSES.

List of Subjects in 14 CFR Part 39

    Air Transportation, Aircraft, Aviation safety, Incorporation by 
reference, Safety.

Adoption of the Amendment

    Accordingly, pursuant to the authority delegated to me by the 
Administrator, the Federal Aviation Administration amends part 39 of 
the Federal Aviation Regulations (14 CFR part 39) as follows:

PART 39--AIRWORTHINESS DIRECTIVES

    1. The authority citation for part 39 continues to read as follows:

    Authority: 49 U.S.C. 106(g), 40113, 44701.


Sec. 39.13  [Amended]

    2. Section 39.13 is amended by removing Amendment 39-3995 (45 FR 
83202, December 18, 1980), and Amendment 39-10091 (62 FR 41262, August 
1, 1997) and by adding a new airworthiness directive to read as 
follows:

2000-05-14  AlliedSignal Inc.: Amendment 39-11624. Docket 96-ANE-36-
AD Supersedes AD 80-22-53, Amendment 39-3995, and AD 97-05-11 R1, 
Amendment 39-10091.

    Applicability: Allied Signal Inc. (formerly Textron
    Lycoming and Avco Lycoming) ALF502 and LF507 series turbofan 
engines, installed on but not limited to British Aerospace BAe 146-
100A, BAe 146-200A, BAe 146-300A, AVRO 146-RJ70A,
    AVRO 146-RJ85A, AVRO 146-RJ100A, and Canadair Model CL-600-1A11 
series airplanes.

    Note 1: This airworthiness directive (AD) applies to each engine 
identified in the preceding applicability provision, regardless of 
whether it has been modified, altered, or repaired in the area 
subject to the requirements of this AD. For engines that have been 
modified, altered, or repaired so that the performance of the 
requirements of this AD is affected, the owner/operator must request 
approval for an alternative method of compliance in accordance with 
paragraph (h) of this AD. The request should include an assessment 
of the effect of the modification, alteration, or repair on the 
unsafe condition addressed by this AD; and, if the unsafe condition 
has not been eliminated, the request should include specific 
proposed actions to address it.

    Compliance: Required as indicated, unless accomplished 
previously. To prevent a No. 4 and 5 duplex bearing failure, which 
can result in a Stage 4 low pressure turbine (LPT) rotor failure, an 
uncontained engine failure, and damage to the airplane, accomplish 
the following:

Replacement or Rework of the No. 4 and 5 Bearing Inlet Assembly

    (a) For AlliedSignal Inc. (formerly Textron Lycoming and Avco 
Lycoming) ALF502L and ALF502L2 series engines, prior to further 
flight, rework or replace the following parts and reassemble in 
accordance with Avco Lycoming Service Bulletin (SB) No. ALF502-72-
0008, Revision 1, dated October 14, 1980,

[[Page 15533]]

and SB No. ALF502-72-0010, dated October 14, 1980:
    (1) Remove No. 4 and 5 bearing inlet tube assembly, part number 
(PN) 2-141-380-07/-08/-11/-12 and replace with PN 2-141-380-13/-14.
    (2) Remove adapter assembly, PN 2-141-640-01 and replace with PN 
2-141-640-02.
    (3) If not previously incorporated, install Bracket, PN 2-143-
049-01, spacer PN 2-143-051-01, two bolts PN STD3061-11, Clamp PN 
TA1501H05, Bolt PN MS9565-06, Nut PN STD3073-3, and Washer PN 
STD3035C2.
    (4) Rework fourth stage turbine nozzle, PN 2-141-150-38, to PN 
2-141-150-42, or PN 2-141-150-39 to PN 2-141-150-41 in accordance 
with SB No. ALF502-72-0010.
    (5) Rework upper half of fire shield, PN 2-163-990-04 to 2-163-
990-07, or PN 2-163-990-05 to 2-163-990-08 in accordance with SB No. 
ALF502-72-0010.
    (6) Install: Washer, PN 2-163-585-01, and Spring PN 2-163-586-
01, and Retainer PN 2-163-584-01.
    (7) Remove oil feed line, PN 2-173-240-02 and replace with PN 2-
303-377-01.
    (8) Remove jam nut, PN R44118P05W. (The function of the jam nut 
is accomplished by the parts in paragraphs (a)(6) and (a)(7) of this 
AD.)
    (9) Remove oil inlet support bracket, PN 2-141-335-02 and 
replace with PN 2-141-335-03.
    (b) After replacement of the No. 4 and 5 bearing oil inlet tube 
and associated hardware in accordance with paragraph (a) of this AD, 
inspect the No. 4 and 5 bearing oil inlet tube at intervals not to 
exceed 100 hours time in service (TIS) since last inspection for 
chafing, in accordance with Avco Lycoming SB No. ALF502-72-0008, 
Revision 1, dated October 14, 1980. Prior to further flight, replace 
oil inlet tubes that exhibit chafing in excess of 0.010 inch deep 
with serviceable parts.

Inspection of Oil Filter Bypass Valve

    (c) For ALF502R series engines equipped with oil filter bypass 
valve, PN 2-303-432-01, accomplish the following:
    (1) Inspect the engine oil filter bypass valve for leakage 
within the next 25 hours TIS or 25 flights in service, whichever 
occurs first, from the effective date of this AD, in accordance with 
Avco Lycoming Textron SB No. ALF 502R-79-0162, Original, dated March 
23, 1987, or Revision 1, dated May 26, 1987. Prior to further 
flight, remove from service oil filters exhibiting any leakage and 
replace with serviceable parts.
    (2) Thereafter, inspect the oil filter bypass valve for any 
leakage in accordance with Avco Lycoming Textron SB No. ALF 502R-79-
0162, Original, dated March 23, 1987, or Revision 1, dated May 26, 
1987, at intervals not to exceed 50 hours TIS or 50 flights in 
service since last inspection, whichever occurs first, and at the 
same time accomplish the following:
    (i) Visually inspect the following engine chip detectors for 
metal contamination:
    (A) For engines with a full flow chip detector installed, 
inspect the full flow chip detector.
    (B) For engines without a full flow chip detector installed, 
inspect the chip detectors located in the accessory gearbox, Number 
2 bearing scavenge line, and No. 4 and 5 bearing scavenge line.
    (ii) For engines with engine chip detectors exhibiting Condition 
3, or Condition 2, or Condition 1 where the oil filter bypass 
indicator is extended, prior to further flight, remove oil filter 
bypass valves exhibiting any leakage and replace with a serviceable 
part.


    Note 2: Chip detector conditions are described in Figures 1, 2 
and 3 of Avco Lycoming Textron SB No. ALF 502R-72-0160, Revision 1, 
dated March 23, 1987, or Revision 2, dated May 26, 1987.

    (3) At the next engine shop visit, or within 2,500 hours TIS 
after the effective date of this AD, whichever occurs first, conduct 
the oil filter bypass valve spring compression force check, in 
accordance with Avco Lycoming Textron SB No. ALF 502R-79-0162, 
Original, dated March 23, 1987. Oil filter bypass valves that do not 
comply with the spring compression force limits contained in Avco 
Lycoming Textron SB No. ALF502R-79-0162, Original, dated March 23, 
1987, must be removed and replaced with oil filter bypass valve, PN 
2-303-432-02. Replacement of oil filter bypass valve, PN 2-303-432-
01, with the improved oil filter bypass valve, PN 2-303-432-02, 
constitutes terminating action for the inspection requirements of 
paragraphs (c)(1) and (c)(2) of this AD.

Definition of a Shop Visit

    (4) For the purpose of this AD, an engine shop visit is defined 
as engine maintenance that entails any of the following:
    (i) Separation of a major engine flange (lettered or numbered) 
other than flanges mating with major sections of the nacelle 
reverser. Separation of flanges purely for purposes of shipment, 
without subsequent internal maintenance, is not a ``shop visit.''
    (ii) Removal of a disk, hub, or spool.
    (iii) Removal of the fuel nozzles.
    (d) For ALF502R, ALF502L, LF507-1F, and LF507-1H series engines, 
equipped with the No. 4 and 5 duplex bearing assembly numbers 2-141-
930-01, 2-141-930-02, or 2-141-930-03, perform the repetitive oil 
system maintenance and inspections in accordance with the intervals 
and procedures described in the Accomplishment Instructions 
paragraphs of the applicable AlliedSignal Inc. SBs referenced in 
paragraphs (d)(1), (d)(2), (d)(3), and (d)(4) of this AD, within the 
next 25 hours TIS or 25 flights in service, whichever occurs first, 
from the effective date of this AD.
    (1) For ALF502R series engines, in accordance with AlliedSignal 
Inc. SB No. ALF502R 79-9, Revision 1, dated November 27, 1996.
    (2) For ALF502L series engines, in accordance with AlliedSignal 
Inc. SB No. ALF502L 79-0171, Revision 1, dated November 27, 1996.
    (3) For LF507-1F series engines, in accordance with AlliedSignal 
Inc. SB No. LF507-1F-79-5, Revision 1, dated November 27, 1996.
    (4) For LF507-1H series engines, in accordance with AlliedSignal 
SB No. LF507-1H-79-5, Revision 1, dated November 27, 1996.

Modification of the No. 4 and 5 Duplex Bearing Assembly

    (e) Modify the fourth turbine rotor disk assembly at the next 
access to the No. 4 and 5 duplex bearing assembly during the engine 
shop visit not to exceed 6,000 cycles in service (CIS) or 6,000 
hours TIS, whichever occurs first, from the effective date of this 
AD, in accordance with the accomplishment instructions paragraph of 
AlliedSignal Inc. SB No. ALF/LF 72-1030, Revision 2, dated December 
14, 1998.
    (f) Modify the power turbine bearing housing assembly at the 
next access to the No. 4 and 5 duplex bearing assembly during the 
engine shop visit not to exceed 6,000 CIS or 6,000 hours TIS, 
whichever occurs first, from the effective date of this AD, in 
accordance with the accomplishment instructions paragraph of 
AlliedSignal Inc. SB No. ALF/LF 72-1040, Revision 1, dated December 
14, 1998.
    (g) Performance of the modifications described in paragraphs (e) 
and (f) of this AD constitutes terminating action to the rework and 
replacement requirements of paragraph (a), and the repetitive 
inspection requirements of paragraphs (b), (c), and (d) of this AD.


    Note 3: Installation of a reworked or modified fourth turbine 
rotor disk assembly as a part of a design change to the new No. 4 
bearing configuration that eliminates the requirements for 
repetitive inspections of oil system does not relieve the operators 
from accomplishment of the engine oil system inspection in 
accordance with the engine manufacturer's applicable maintenance 
documents.

Alternative Method of Compliance

    (h) An alternative method of compliance or adjustment of the 
compliance time that provides an acceptable level of safety may be 
used if approved by the Manager, Los Angeles Aircraft Certification 
Office. Operators shall submit their requests through an appropriate 
FAA Principal Maintenance Inspector, who may add comments and then 
send it to the Manager, Los Angeles Aircraft Certification Office.

    Note 4: Information concerning the existence of approved 
alternative methods of compliance with this airworthiness directive, 
if any, may be obtained from the Los Angeles Aircraft Certification 
Office.

Special Flight Permits

    (i) Special flight permits may be issued in accordance with 
Secs. 21.197 and 21.199 of the Federal Aviation Regulations (14 CFR 
21.197 and 21.199) to operate the airplane to a location where the 
requirements of this AD can be accomplished.

Manufacturer Service Bulletins

    (j)(1) The inspections, modifications, and rework shall be done 
in accordance with the following AlliedSignal Inc. (formerly Textron 
Lycoming and Avco Lycoming) service bulletins:

[[Page 15534]]



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           Document No.                    Pages               Revision                      Date;
----------------------------------------------------------------------------------------------------------------
ALF502-72-0008...................  All.................  1...................  October 14, 1980.
Total Pages: 6
ALF502-72-0010...................  All.................  Original............  October 14, 1980.
Total Pages: 8
ALF/LF 72-1030...................  1-2.................  2...................  December 14, 1998.
                                   3...................  1...................  February 23, 1998.
                                   4...................  2...................  December 14, 1998.
                                   5...................  1...................  February 23, 1998.
                                   6-7.................  2...................  December 14, 1998.
                                   8-9.................  1...................  February 23, 1998.
                                   10..................  2...................  December 14, 1998.
                                   11-14...............  1...................  February 23, 1998.
                                   15..................  2...................  December 14, 1998.
                                   16-17...............  1...................  February 23, 1998.
                                   18-55...............  2...................  December 14, 1998.
                                   56 (blank)..........  ....................  .................................
Total pages: 56
ALF/LF 72-1040...................  1-3.................  1...................  December 14, 1998.
                                   4-13................  Original............  October 20, 1997.
                                   14-46...............  1...................  December 14, 1998.
Total pages: 46
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    (2) The incorporation by reference of AlliedSignal Inc. 
(formerly Textron Lycoming and Avco Lycoming) service bulletins 
listed in paragraph (j)(1) of this AD was approved by the Director 
of the Federal Register in accordance with 5 U.S.C. 552(a) and 1 CFR 
part 51.
    (k) The incorporation by reference of SB ALF 502R-72-0160, 
revision 2, dated May 26, 1987; ALF 502R-72-0160, revision 1, dated 
March 23, 1987; SB ALF502R 79-9 revision 1, dated November 27, 1996; 
SB ALF502L 79-0171, revision 1, dated November 27, 1996; SB ALF502R-
79-0162, revision 2, dated September 8, 1987; SB ALF502R-79-0162, 
revision 1, dated May 26,1987; SB ALF502R-79-0162, dated March 
23,1987; SB LF507-1F-79-5, revision 1, dated November 27, 1996; SB 
LF507-1H 79-5, revision 1, dated November 27, 1996, was previously 
approved by the Director of the Federal Register in accordance with 
5 U.S.C. 552(a) and 1 CFR part 51 as of April 16, 1997 (62 FR 
15378).

Address for Obtaining Referenced Service Bulletins

    (l) Copies may be obtained from AlliedSignal Aerospace, Attn: 
Data Distribution, M/S 64-3/2101-201, P.O. Box 29003, Phoenix, AZ 
85038-9003; telephone (602) 365-2493, fax (602) 365-5577. Copies may 
be inspected at the Federal Aviation Administration (FAA), New 
England Region, Office of the Regional Counsel, 12 New England 
Executive Park, Burlington, MA; or at the Office of the Federal 
Register, 800 North Capitol Street, NW., suite 700, Washington, DC.
    (m) This amendment becomes effective on April 27, 2000.


    Issued in Burlington, Massachusetts, on March 6, 2000.
David A. Downey,
Assistant Manager, Engine and Propeller Directorate, Aircraft 
Certification Service.
[FR Doc. 00-6033 Filed 3-22-00; 8:45 am]
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