AD 2003-09-09

[Federal Register Volume 68, Number 84 (Thursday, May 1, 2003)]
[Rules and Regulations]
[Pages 23186-23189]
From the Federal Register Online via the Government Publishing Office [<a href="http://www.gpo.gov">www.gpo.gov</a>]
[FR Doc No: 03-10509]


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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. 2002-CE-18-AD; Amendment 39-13138; AD 2003-09-09]
RIN 2120-AA64


Airworthiness Directives; Cessna Aircraft Company Models 441 and 
F406 Airplanes

AGENCY: Federal Aviation Administration, DOT.

ACTION: Final rule.

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SUMMARY: This amendment supersedes Airworthiness Directive (AD) 2002-
09-13, which currently requires a one-time inspection of the fuel boost 
pump wiring inside and outside the boost pump reservoir and repair or 
replacement of the wiring as necessary on certain Cessna Aircraft 
Company (Cessna) Model 441 airplanes. AD 2002-09-13 resulted from 
several reports of chafing and/or arcing of the fuel boost pump wiring 
inside and outside the fuel pump reservoir. This AD retains the actions 
required in AD 2002-09-13, makes the one-time inspection repetitive, 
requires the inspection and possible replacement of the wire harness, 
lead wires and fuel boost pump on Model F406 airplanes, and requires 
eventual installation of an improved design wire harness and fuel boost 
pump as terminating action for the repetitive inspections. The actions 
specified by this AD are intended to detect, correct, and prevent 
chafing and/or arcing fuel boost pump wiring, which could result in 
arcing within the wing fuel storage system. Such a condition could lead 
to ignition of explosive vapor within the fuel storage system.

DATES: This AD becomes effective on June 24, 2003.
    The Director of the Federal Register approved the incorporation by 
reference of certain publications listed in the regulations as of June 
24, 2003.

ADDRESSES: You may get the service information referenced in this AD 
from Cessna Aircraft Company, Product Support, P.O. Box 7706, Wichita, 
Kansas 67277; telephone: (316) 517-5800; facsimile: (316) 942-9006. You 
may view this information at the Federal Aviation Administration (FAA), 
Central Region, Office of the Regional Counsel, Attention: Rules Docket 
No. 2002-CE-18-AD, 901 Locust, Room 506, Kansas City, Missouri 64106; 
or at the Office of the Federal Register, 800 North Capitol Street, 
NW., suite 700, Washington, DC.

FOR FURTHER INFORMATION CONTACT: Robert Adamson, Aerospace Engineer, 
FAA, Wichita Aircraft Certification Office, 1801 Airport Road, Room 
100, Wichita, Kansas 67209; telephone: 316-946-4145; facsimile: 316-
946-4107.

SUPPLEMENTARY INFORMATION:

Discussion

    What events have caused this AD? Reports of chafing and/or arcing 
of the fuel boost pump wiring inside the fuel pump reservoir that 
supplies fuel to each engine on Cessna Model 441 airplanes caused us to 
issue AD 2002-09-13, Amendment 39-12746 (67 FR 31117, May 9, 2002). AD 
2002-09-13 requires you to: (1) do a one-time inspection of the 
electrical wiring going to the fuel boost pump reservoir and the boost 
pump wiring inside the reservoir for chafing or damage, and (2) repair 
or replace the wiring as necessary.
    These actions are required in accordance with Cessna Conquest 
Service Bulletin No.: CQB02-1R1, Revision 1, dated April 22, 2002.
    What has happened since AD 2002-09-13 to initiate this action? 
Further analysis of this situation reveals that:

--The actions required by AD 2002-09-13 should also apply to Model F406 
airplanes;
--The inspection should be repetitive; and
--Improved design wire harnesses and fuel boost pumps should eventually 
be installed as terminating action for the repetitive inspections.

    Has FAA taken any action to this point? We issued a proposal to 
amend part 39 of the Federal Aviation Regulations (14 CFR part 39) to 
include an AD that would apply to certain Cessna Models 441 and F406 
airplanes. This proposal was published in the Federal Register as a 
notice of proposed rulemaking (NPRM) on October 21, 2002 (67 FR 64568). 
The NPRM proposed to supersede AD 2002-09-13 with a new AD that would 
require repetitive inspections of the Models 441 and F406 airplanes 
fuel boost pump wiring inside and outside the boost pump reservoir for 
chafing or damage and replacement of the wiring and fuel boost pump, as 
necessary, and require eventual installation of an improved design wire 
harness and fuel boost pump as terminating action for the repetitive 
inspections.
    How will this action relate to the FAA's aging commuter-class 
aircraft policy? The FAA's aging commuter aircraft policy briefly 
states that when a modification exists that could eliminate or reduce 
the number of required critical inspections, the modification should be 
incorporated. This policy is based on the FAA's determination that 
reliance on critical repetitive inspections on airplanes utilized in 
commuter service carries an unnecessary safety risk when a design 
change exists that could eliminate or, in certain instances, reduce the 
number of those critical inspections. In determining what inspections 
are critical, the FAA considers (1) the safety consequences of the 
airplane if the known problem is not detected by the inspection; (2) 
the reliability of the inspection.
    What is the potential impact if FAA took no action? This condition, 
if not detected and corrected, could result in arcing within the wing 
fuel storage system. Such a condition could lead to ignition of 
explosive vapor within the fuel storage system.
    Was the public invited to comment? The FAA encouraged interested 
persons to participate in the making of this amendment. The following 
presents the comments received on the proposal and FAA's response to 
each comment:

[[Page 23187]]

Comment Issue No. 1: Remove Warnings Following Compliance to the 
Proposed AD

    What is the commenter's concern? The commenter, for clarity and 
completeness, requests that the AD call out removing the warning 
placards after compliance with Cessna Conquest Service Bulletin No.: 
CQB02-1, Revision 2, dated October 7, 2002.
    What is FAA's response to the concern? We concur with the commenter 
and for clarity and completeness will change the final rule AD action 
to incorporate this change.

Comment Issue No. 2: Validity of the 200-Hour Time-in-Service (TIS) 
Recurrent Inspection Requirement

    What is the commenter's concern? The commenter states that the 200-
hour TIS recurrent inspection is not necessary because the commenter's 
specific aircraft is 24 years old and has more than 7,900 hours TIS and 
inspection finds only minor chafing of one wire. Further, the commenter 
states that the 200-hour TIS recurrent inspection increases the 
likelihood of creating fuel leaks because of the constant reopening and 
resealing of the fuel boost pump panels. The commenter disagrees with 
the 200-hour TIS recurrent inspection requirement. Because the 
commenter did not request an alternative time, we infer that the 
commenter wants the repetitive inspection deleted from the AD.
    What is FAA's response to the concern? We do not concur. Initial 
investigation revealed harnesses and fuel boost pump leads with 
virtually no chafing, some with minor chafing, and several with 
excessive chafing that appeared to have been arcing. Additionally, all 
of the above conditions were found on aircraft with relatively low TIS 
to high TIS. The 200-hour TIS recurrent inspection is necessary to 
assure continued airworthiness of repaired wire harnesses.
    We are not changing the final rule AD action as a result of this 
comment.

Comment Issue No. 3: Allow the Aircraft To Be Operated With Greater 
Than 80 Pounds or 12 Gallons of Fuel in Either Wing Tank Instead of 
Replacing the Wire Harnesses and Fuel Boost Pumps

    What is the commenter's concern? The commenter states that the wire 
harness is submerged in fuel when 80 pounds or 12 gallons of fuel 
remain in each wing tank. The commenter requests that the proposed AD 
allow the aircraft to be flown with greater than 80 pounds or 12 
gallons of fuel remaining in either wing tank instead of replacing the 
wire harnesses and fuel boost pumps that exhibit chafing of the wire 
harness.
    What is FAA's response to the concern? We do not concur. There are 
two wire harnesses in each wing tank, each with the potential for 
chafing and subsequent arcing if not corrected. The potential for 
arcing within the fuel tank continues to exist until replacing or 
repairing both sources of possible arcing. The request to allow 
operation with 80 pounds of fuel remaining in either tank only assures 
the fuel boost pump lead wires to remain covered with fuel. Engineering 
evaluation has determined that safe operation without repaired or 
replaced wire harnesses requires approximately 300 pounds to assure 
both wire harnesses are submerged in fuel.
    We are not changing the final rule AD action as a result of this 
comment.

Comment Issue No. 4: Replace the Fuel Boost Pumps

    What is the commenter's concern? The commenter states that the fuel 
boost pump wire harness is the reason for the AD action and the fuel 
boost pumps remain in an acceptable operating condition. The commenter 
disagrees with replacing the fuel boost pumps. The commenter states 
that the problem is with the fuel boost pump wire harnesses and 
replacement of the fuel pumps is an undue and unnecessary burden on the 
operators.
    What is FAA's response to the concern? We do not concur. Chafing 
has been found to occur on both the fuel boost pump lead wires and the 
wire harness extending from the fuel boost pump housing to wing 
structure on several aircraft with varying times-in-service.
    We are not changing the final rule AD action as a result of this 
comment.

Comment Issue No. 5: Correct Cost Estimate for Replacing the Wire 
Harnesses and Fuel Boost Pumps

    What is the commenter's concern? The commenter disagrees with the 
estimated cost of replacing the wire harnesses and fuel boost pumps. 
The commenter justifies disagreement with cost data from one service 
center.
    What is FAA's response to the concern? We do not concur. The cost 
estimate associated with the cost impact with the proposed AD has been 
coordinated with Cessna, and found to be valid.
    We are not changing the final rule AD action as a result of this 
comment.

Comment Issue No. 6: Adequacy of the 1,200-Hour TIS Phase 11 Inspection

    What is the commenter's concern? The commenter requests that, once 
the wire harnesses have been replaced and the fuel boost pumps have 
been replaced or repaired, the inspection criteria on the 1,200-hour 
TIS Phase 11 inspection include specific instructions to inspect the 
wire harnesses and fuel boost pump leads for chafing and security. The 
commenter further states that including specific instructions to 
inspect the wire harnesses and fuel boost pump leads would assure 
continued airworthiness of the harnesses and boost pump leads.
    What is FAA's response to the concern? We do not concur. The Model 
441 Maintenance Manual was revised on July 1, 2002, with specific 
instructions to visually inspect all wire bundles/electrical components 
in the fuel storage area. Cessna and FAA agreed that inspection of 
these areas would occur every 600 hours TIS or 24 calendar months, 
whichever occurs first, to coincide with the general electrical wiring 
and component inspection interval. The FAA will monitor the service 
history and take further rulemaking action if it shows that normal 
maintenance practices are not eliminating the problem.
    We are not changing the final rule AD action as a result of this 
comment.

FAA's Determination

    What is FAA's final determination on this issue? We carefully 
reviewed all available information related to the subject presented 
above and determined that air safety and the public interest require 
the adoption of the rule as proposed except for the changes discussed 
above and minor editorial questions. We have determined that these 
changes and minor corrections:

--Provide the intent that was proposed in the NPRM for correcting the 
unsafe condition; and
--Do not add any additional burden upon the public than was already 
proposed in the NPRM.

Cost Impact

    How many airplanes does this AD impact? We estimate that this AD 
affects 370 airplanes in the U.S. registry.
    What is the cost impact of this AD on owners/operators of the 
affected airplanes? We estimate the following costs to accomplish the 
inspection:

[[Page 23188]]



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                                                         Total cost per
           Labor cost                   Parts cost          airplane           Total cost on U.S. operators
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8 workhours x $60 per hour =      None.................           $480   $480 x 370 = $177,600
 $480.
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    For Model 441 airplanes, we estimate the following costs to 
accomplish the replacements:

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                Labor cost                      Parts cost                  Total cost per airplane
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8 workhours x $60 per hour = $480.........           $13,101   $480 + $13,101 = $13,581
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    For Model F406 airplanes, we estimate the following costs to 
accomplish the replacements:

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                Labor cost                      Parts cost                  Total cost per airplane
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8 workhours x $60 per hour = $480.........            $7,558   $480 + $7,558 = $8,038
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Regulatory Impact

    Does this AD impact various entities? The regulations adopted 
herein will 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. Therefore, it is determined that this final rule does not 
have federalism implications under Executive Order 13132.
    Does this AD involve a significant rule or regulatory action? 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 copy 
of the final evaluation prepared for this action is contained in the 
Rules Docket. A copy of it may be obtained by contacting 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

0
Accordingly, under 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

0
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]

0
2. FAA amends Sec.  39.13 by adding a new AD to read as follows:

2003-09-09 Cessna Aircraft Company: Amendment 39-13138; Docket No. 
2002-CE-18-AD; Supersedes AD 2002-09-13, Amendment 39-12746.

    (a) What airplanes are affected by this AD? This AD affects the 
following airplane models and serial numbers that are certificated 
in any category:

------------------------------------------------------------------------
              Model                           Serial numbers
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441.............................  0001 through 0362 and 698.
F406............................  0001 through 0089.
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    (b) Who must comply with this AD? Anyone who wishes to operate 
any of the airplanes identified in paragraph (a) of this AD must 
comply with this AD.
    (c) What problem does this AD address? The actions specified by 
this AD are intended to detect, correct, and prevent chafing and/or 
arcing fuel boost pump wiring, which could result in arcing within 
the wing fuel system. Such a condition could lead to ignition of 
explosive vapor within the fuel storage system.
    (d) What actions must I accomplish to address this problem? To 
address this problem, you must accomplish the following:

------------------------------------------------------------------------
           Actions                 Compliance            Procedures
------------------------------------------------------------------------
(1) For Model 441 airplanes:  Initially at          In accordance with
 Inspect the part number (P/   whichever occurs      Cessna Conquest
 N) 5718106-1 wire harness     first, unless         Service Bulletin
 and fuel boost pump lead      already               No.: CQB02-1,
 wires for chafing or          accomplished:         Revision 2, dated
 damage.                       Within the next 25    October 7, 2002.
                               hours time-in-
                               service (TIS) or 60
                               days after May 31,
                               2002 (the effective
                               date of AD 2002-09-
                               13): Repetitively
                               thereafter at
                               intervals not to
                               exceed 200 hours
                               TIS.
(2) For Model F406            Initially at          In accordance with
 airplanes: Inspect the P/N    whichever occurs      Reims/Cessna
 5718106-4 wire harness and    first, unless         Caravan Service
 fuel boost pump lead wires    already               Bulletin No.: CAB02-
 for chafing or damage.        accomplished:         8, dated June 3,
                               Within the next 25    2002.
                               hours TIS after
                               June 24, 2003 (the
                               effective date of
                               this AD) or 60 days
                               after June 24, 2003
                               (the effective date
                               of this AD):
                               Repetitively
                               thereafter at
                               intervals not to
                               exceed 200 hours
                               TIS.

[[Page 23189]]

 
(3) If chafing or damage is   Before further        For the Model 441
 found during any inspection   flight after any      airplanes: In
 required in paragraph         inspection required   accordance with
 (d)(1) or (d)(2) of this      in paragraphs         Cessna Conquest
 AD:                           (d)(1) and (d)(2)     Service Bulletin
(i) For the Model 441          of this AD in which   No.: CQB02-1,
 airplanes, replace the wire   damage is found. If   Revision 2, dated
 harnesses, repair fuel        improved design       October 7, 2002.
 boost pump lead wires, or     wire harnesses and    For the Model F406
 replace the fuel boost        fuel boost pumps      airplanes: In
 pump, as applicable..         are not installed,    accordance with
(ii) For the Model F406        continue to inspect   Reims/Cessna
 airplanes, repair or          as specified in       Caravan Service
 replace the wire harnesses    paragraph (d)(1) or   Bulletin No.: CAB02-
 or lead wires, or fuel        (d)(2) of this AD     8, dated June 3,
 boost pump, as applicable..   until these           2002.
                               improved design
                               parts are installed.
(4) Perform the following     Within the next 400   For the Model 441
 installations:                hours TIS after       airplanes: In
(i) For the Model 441          June 24, 2003 (the    accordance with
 airplanes: Install improved   effective date of     Cessna Conquest
 design fuel boost pump (P/N   this AD), unless      Service Bulletin
 1C12-17 or FAA-approved       already               No.: CQB02-1,
 equivalent P/N) and           accomplished.         Revision 2, dated
 improved design wire                                October 7, 2002.
 harness (P/N 5718106-6 or                           For the Model F406
 FAA-approved equivalent P/                          airplanes: In
 N). Installing both                                 accordance with
 improved part numbers in                            Reims/Cessna
 each wing tank terminates                           Caravan Service
 the repetitive inspection                           Bulletin No.: CAB02-
 requirements of paragraph                           8, dated June 3,
 (d)(1) of this AD..                                 2002.
(ii) For the Model F406
 airplanes: Install improved
 design fuel boost pump (P/N
 1C12-17 or FAA-approved
 equivalent P/N) and
 improved design wire
 harness (P/N 406 28 01 or
 FAA-approved equivalent P/
 N). Installing both
 improved part numbers in
 each wing tank terminates
 the repetitive inspection
 requirements of paragraph
 (d)(2) of this AD.
(5) Remove the following      As of June 24, 2003   Not applicable.
 warnings for the Model 441    (the effective date
 airplanes after compliance    of this AD).
 with Cessna Conquest
 Service Bulletin No.: CQB02-
 1, Revision 2, dated
 October 7, 2002:
(i) ``PRIOR TO THE INITIAL
 INSPECTION: THE AIRPLANE
 SHOULD NOT BE OPERATED WITH
 LESS THAN 300 POUNDS OF
 FUEL IN EACH WING.''
(ii) ``AFTER THE INITIAL
 INSPECTION: THE AIRPLANE
 SHOULD NOT BE OPERATED
 WHENEVER THE LEFT OR RIGHT
 LOW FUEL ANNUNCIATOR IS
 ILLUMINATED.''
(6) Only install improved     As of June 24, 2003   Not applicable.
 design wire harnesses and     (the effective date
 fuel boost pumps as           of this AD).
 specified in paragraphs
 (d)(4)(i) and (d)(4)(ii) of
 this AD.
------------------------------------------------------------------------

    (e) Can I comply with this AD in any other way?
    (1) You may use an alternative method of compliance or adjust 
the compliance time if:
    (i) Your alternative method of compliance provides an equivalent 
level of safety; and
    (ii) The Manager, Wichita Aircraft Certification Office (ACO), 
approves your alternative. Submit your request through an FAA 
Principal Maintenance Inspector, who may add comments and then send 
it to the Manager, Wichita ACO.
    (2) Alternative methods of compliance approved in accordance 
with AD 2002-09-13, which is superseded by this AD, are approved as 
alternative methods of compliance for all inspection requirements of 
this AD. Regardless, you still must comply with the replacement 
requirements of this AD.

    Note: This AD applies to each airplane identified in paragraph 
(a) of this AD, regardless of whether it has been modified, altered, 
or repaired in the area subject to the requirements of this AD. For 
airplanes 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 (e) 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 you have not eliminated the unsafe condition, specific 
actions you propose to address it.

    (f) Where can I get information about any already-approved 
alternative methods of compliance? Contact Robert Adamson, Aerospace 
Engineer, FAA, Wichita Aircraft Certification Office, 1801 Airport 
Road, Room 100, Wichita, Kansas 67209; telephone: 316-946-4145; 
facsimile: 316-946-4107.
    (g) What if I need to fly the airplane to another location to 
comply with this AD? The FAA can issue a special flight permit under 
Sec. Sec.  21.197 and 21.199 of the Federal Aviation Regulations (14 
CFR 21.197 and 21.199) to operate your airplane to a location where 
you can accomplish the requirements of this AD.
    (h) Are any service bulletins incorporated into this AD by 
reference? Actions required by this AD must be done in accordance 
with Cessna Conquest Service Bulletin No.: CQB02-1, Revision 2, 
dated October 7, 2002; and Reims/Cessna Caravan Service Bulletin 
No.: CAB02-8, dated June 3, 2002. The Director of the Federal 
Register approved this incorporation by reference under 5 U.S.C. 
552(a) and 1 CFR part 51. You may get copies from Cessna Aircraft 
Company, Product Support, P.O. Box 7706, Wichita, Kansas 67277; 
telephone: (316) 517-5800; facsimile: (316) 942-9006. You may view 
copies at the FAA, Central Region, Office of the Regional Counsel, 
901 Locust, Room 506, Kansas City, Missouri, or at the Office of the 
Federal Register, 800 North Capitol Street, NW, suite 700, 
Washington, DC.
    (i) Does this AD action affect any existing AD actions? This 
amendment supersedes AD 2002-09-13, Amendment 39-12746.
    (j) When does this amendment become effective? This amendment 
becomes effective on June 24, 2003.

    Issued in Kansas City, Missouri, on April 22, 2003.
Dorenda D. Baker,
Acting Manager, Small Airplane Directorate, Aircraft Certification 
Service.
[FR Doc. 03-10509 Filed 4-30-03; 8:45 am]
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