2000-11-16 AYRES CORPORATION: Docket No. 98-CE-56-AD, Amendment 39-11764; Supersedes AD 97-17-03, Amendment 39-10105.
(a) What airplanes are affected by this AD? Airplanes with the following model and serial number (S/N) designations with or without a -DC or -X suffix, certificated in any category:
Group 1 Airplanes
Model
Serial Numbers
S-2R
5000R through 5099R, except 5010R, 5031R, 5038R, 5047R, and 5085R.
S2R-R1820
R1820-001 through R1820-035.
S2R-T34
6000R through 6049R, T34-001 through T34-143, T34-145, T34-147 through T34-167, T34-171, T34-180, and T34-181*.
S2R-T15
T15-001 through T15-033**.
S2R-G1
G1-101 through G1-106.
* The serial numbers of the Model S2R-T34 airplanes could incorporate 34-xxx, T36-xxx, T41-xxx, or T42-xxx. This AD applies to all of these serial number designations as they are all Model S2R-T34 airplanes.
** The serial numbers of the Model S2R-T15 airplanes could incorporate T15-xxx and T27-xxx. This AD applies to both of these serial number designations as they are both Model S2R-T15 airplanes.
Group 2 Airplanes
Model
Serial Numbers
S2R-R1820
R1820-036.
S2R-T65
T65-001 through T65-017.
S2RHG-T65
T65-002 through T65-017.
S2R-T34
T34-144, T34-146, T34-168, T34-169, T34-172 through T34-179, and T34-189 through T34-232. And T34-234.*
S2R-T45
T45-001 through T45-014.
S2R-G6
G6-101 through G6-147.
S2R-G10
G10-101 through G10-136, G10-138, G10-140, and G10-141.
S2R-G5
G5-101 through G5-105.
* The serial numbers of the Model S2R-T34 airplanes could incorporate T34-xxx, T36-xxx, T41-xxx, or T42-xxx. This AD applies to all of these serial number designations as they are all Model S2R-T34 airplanes.
Group 3 Airplanes*
Model
Serial Numbers
600 S2D
All serial numbers beginning with 600-1311D.
S-2R
1380R and 1416R through 4999R.
S2R-R1340
R1340-001 through R1340-035.
S2R-R3S
R3S-001 through R3S-011.
S2R-T11
T11-001 through T11-005.
* Any Group 3 airplane that has been modified with a hopper of a capacity over 410 gallons, a piston engine greater than 600 horsepower, or any gas turbine engine, makes the airplane a Group 1 airplane for the purposes of this AD. The owner/operator must inspect the airplane at the Group 1 compliance time specified in this AD.
Group 4 Airplanes
Model
Serial Numbers
S2R-T34
T34-225, T34-236, T34-237, and T34-238.*
S2R-G1
G1-107, G1-108, and G1-109.
S2R-G10
G10-137, G10-139, and G10-142.
* The serial numbers of the Model S2R-T34 airplanes could incorporate T34-xxx, T36-xxx, T41-xxx, or T42-xxx. This AD applies to all of these serial number designations as they are all Model S2R-T34 airplanes.
Group 5 Airplanes
Model
Serial Numbers
S2R-T34
T34-239 through T34-266.*
S2RHG-T34
T34HG-102.
S2R-T15
T15-034 through T15-040.**
S2R-T45
T45-015.
S2R-G1
G1-110 through G1-114.
S2R-G6
G6-148 through G6-151.
S2R-G10
G10-143 through G10-160.
* The serial numbers of the Model S2R-T34 airplanes could incorporate T34-xxx, T36-xxx, T41-xxx, or T42-xxx. This AD applies to all of these serial number designations as they are all Model S2R-T34 airplanes.
** The serial numbers of the Model S2R-T15 airplanes could incorporate T15-xxx and T27-xxx. This AD applies to both of these serial designations as they are both Model S2R-T15 airplanes.
Group 6 Airplanes
Model
Serial Numbers
S2R
5010R, 5031R, 5038R, 5047R, and 5085R.
(b) Who must comply with this AD? Anyone who wishes to operate any of the above airplanes on the U.S. Register.
(c) What problem does this AD address? The actions specified by this AD are intended to detect and correct fatigue cracking of the lower spar caps. This could result in the wing separating from the airplane with consequent loss of control of the airplane.
(d) What actions must I accomplish to address this problem? To address this problem, you must accomplish the following:
(1) Repetitively inspect, using magnetic particle, ultrasonic, or eddy current procedures, the 1/4-inch and 5/16-inch bolt hole areas on each lower spar cap for fatigue cracking. Reference paragraph (e)(3) and (e)(4) of this AD (including all subparagraphs) to obtain the initial and repetitive inspection compliance times.
(i) The cracks may emanate from the bolt hole on the face of the spar cap or they may occur in the shaft of the hole.
(ii) You must inspect both of these areas.
(2) If any cracking is found during any inspection required by this AD, you must accomplish the following:
(i) Use the cold work process to ream out small cracks as defined in Ayres Service Bulletin No. SB-AG-39, dated September 17, 1996; or replace the affected spar cap in accordance with the maintenance manual; or ream the 1/4-inch bolt holes to 5/16 inches diameter as defined in Part I of Ayres Custom Kit No. CK-AG-29, dated December 23, 1997; and
(ii) Submit a report of inspection findings to the Manager, Atlanta ACO, One Crown Center, 1895 Phoenix Boulevard, Suite 450, Atlanta, Georgia 30349; facsimile: (770) 703-6097. You must include the airplane serial number and engine model number; the total number of flight hours on the lower spar cap that is cracked; time on the spar cap since last inspection, if applicable; and the type of inspection used for the last inspection. Indicate if cold working has been accomplished or modifications incorporated such as installation of big butterfly plates. Include the time on the spar cap when the cold working or modifications were accomplished. Indicate which bolt hole is cracked and the length of the crack. Information collection requirements contained in this regulation have been approved by the Office of Management and Budget (OMB) under the provisions of the Paperwork Reduction Act of 1980 (44 U.S.C. 3501 et seq.) and have been assigned OMB Control Number 2120-0056.
(e) What is the compliance time of this AD? The compliance times for each ofthe actions of this AD are as follows:
(1) Any required repair or replacement: Prior to further flight after the inspection where the crack(s) was/were found.
(2) Reporting requirement:
(i) Submit the report within 10 days after finding any crack(s) during any inspection required by this AD.
(ii) For airplanes where cracking was found during any inspection accomplished in accordance with AD 97-17-03, which is superseded by this AD; or by AD 97-13-11, which was superseded by AD 97-17-03, submit the report within 10 days after the effective date of this AD, unless already accomplished.
(3) Initial Inspection: The following is for the initial inspections required by this AD. The affected airplanes are categorized into six different groups.
(i) Group 1 Airplanes: Required upon the accumulation of 2,000 hours time-in-service (TIS) on each lower spar cap or within 50 flight hours after the effective date of this AD, whichever occurs later, unless already accomplished (compliance with AD 97-17-03 or AD 97-13-11).
(ii) Group 2 Airplanes: Required upon the accumulation of 2,200 hours TIS on each lower spar cap or within 50 flight hours after the effective date of this AD, whichever occur later, unless already accomplished (compliance with AD 97-17-03 or AD 97-13-11).
(iii) Group 3 Airplanes: Required upon the accumulation of 6,400 hours TIS on each lower spar cap or within 50 flight hours after the effective date of this AD, whichever occurs later, unless already accomplished (compliance with AD 97-17-03 or AD 97-13-11).
(iv) Group 4 Airplanes: Required upon the accumulation of 2,500 hours TIS on each lower spar cap or within 50 flight hours after the effective date of this AD, whichever occurs later, unless already accomplished (compliance with AD 97-17-03 or AD 97-13-11).
(v) Group 5 Airplanes: Required upon the accumulation of 6,200 hours TIS on each lower spar cap or within 50 flight hours after theeffective date of this AD, whichever occurs later, unless already accomplished (compliance with AD 97-17-03 or AD 97-13-11).
(vi) Group 6 Airplanes: As presented below.
(A) For S/N 5010R: Required upon the accumulation of 5,530 hours TIS on each lower spar cap or within the next 50 hours TIS after the effective date of this AD, whichever occurs later.
(B) For S/N 5038R: Required upon the accumulation of 5,900 hours TIS on each lower spar cap or within the next 50 hours TIS after the effective date of this AD, whichever occurs later.
(C) For S/N's 5031R and 5047R: Required upon the accumulation of 6,400 hours TIS on each lower spar cap or within the next 50 hours TIS after the effective date of this AD, whichever occurs later.
(D) For S/N 5085R: Required upon the accumulation of 6,290 hours TIS on each lower spar cap or within the next 50 hours TIS after the effective date of this AD, whichever occurs later.
(4) Repetitive Inspections:The following chart gives the required repetitive inspection intervals based on the work performed and the method of inspection utilized. Each time is hours TIS intervals after the last inspection:
Work Previously Performed
Magnetic Particle
Ultrasonic
Eddy Current
(i) No cracks found previously on wing spar and no optional cold work or bolt hole reaming accomplished.
500 hours TIS
550 hours TIS
700 hours TIS
(ii) One of the following where the airplane does not have butterfly plates, part number (P/N) 20211-09 and P/N 20211-11, installed per CK-AG 29, Part II* * *.
(A) Small cracks repaired through cold work (or done as an option if never cracked) accomplished per SB-AG-39; OR
(B) Small cracks repaired through 1/4-inch bolt hole reamed to 5/16 inches diameter (or done as an option if never cracked) per CK-AG-29, Part I; OR
(C) Small cracks repaired through previous Alternative Methods of Compliance. * *
500 hours TIS
550 hours TIS
700 hours TIS
(iii) One of the following where the airplane has butterfly plates, part number (P/N) 20211-09 and P/N 20211-11, installed per CK-AG-29, Part II* * *.
(A) Small cracks repaired through cold work (or done as an option if no cracks found) accomplished per SB-AG-39; OR
(B) Small cracks repaired through 1/4-inch bolt hole reamed to 5/16 inches diameter (or done as an option if no cracks found) per CK-AG-29, Part I; OR
(C) Small cracks repaired through previous Alternative Methods of Compliance.* *
900 hours TIS
950 hours TIS
1,250 hours TIS
(iv) Cracked wing spar found during previous inspection with wing spar replacement.
Time for initial and repetitive inspection intervals start over when wing spar is replaced.
Time for initial and repetitive inspection intervals start over when wing spar is replaced.
Time for initial and repetitive inspection intervals start over when wing spar is replaced.
* Aircraft S/N s T45-007DC and T45-10DC had modified splice block assemblies installed at Ayres (Ayres/Kaplan Assembly No. 88-251) and must still follow the repetitive inspection intervals listed here.
* * If a crack is found, the reaming associated with the cold work process may remove a crack if it is small enough. Some aircraft owners/operators were issued alternative methods of compliance with AD 97-17-03 to ream the 1/4-inch bolt hole to 5/16 inches diameter to remove small cracks. Ayres CK-AG-29, Part I, also provides procedures to ream the 1/4-inch bolt hole to 5/16 inches diameter. If you use either of these two methods to remove cracks and the airplane is reinspected immediately with no cracks found, you may continue to follow the repetitive inspection intervals listed above.
* * * Group 4 and Group 5 airplanes had the butterfly plates installed at the factory and may follow this repetitive inspection interval.
(f) What procedures must I use to accomplish the actions required in this AD?
(1) Inspections:
(i) For the magnetic particle inspection, utilize the procedures contained in Ayres Service Bulletin No. SB-AG-39, dated September 17, 1996. Use only sections titled "Inspection Accomplishment Instructions" and "Lower Splice Fitting Removal and Installation Instructions." You must follow American Society for Testing Materials (ASTM) E1444-94A, using wet particles meeting the requirements of the Society for Automotive Engineers (SAE) AMS 3046. CAUTION: You must firmly support the wings during the inspection to prevent movement of the spar caps when the splice blocks are removed. This will allow easier realignment of the splice block holes and the holes in the spar cap for bolt insertion.
(ii) The FAA must approve ultrasonic or eddy current inspection procedures. To obtain FAA approval, you must send your proposed procedure to the Manager, Atlanta Aircraft Certification (ACO), One Crown Center, 1895 Phoenix Boulevard, Suite 450, Atlanta, Georgia 30349. You are not required to remove the splice blockfor either the ultrasonic or eddy current inspections, unless corrosion is visible.
(iii) All inspections required by this AD must be accomplished by a Level 2 or Level 3 inspector certified for that inspection method using the guidelines established by the American Society for Nondestructive Testing or MIL-STD-410.
(2) Repair: Utilize the procedures contained in Ayres Service Bulletin No. SB-AG-39, dated September 17, 1996; or in Part I of Ayres Custom Kit No. CK-AG-29, dated December 23, 1997 if necessary to remove small cracks. You must then immediately re-inspect and continue to accomplish the repetitive inspections.
(3) Replacement: Utilize the procedures contained in the maintenance manual.
(g) 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, Atlanta Aircraft Certification Office, approves your alternative. Submit your request through an FAA Principal Maintenance Inspector, who may add comments and then send it to the Manager.
(2) This AD applies to each airplane 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 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 (g)(1) 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.
(3) Alternative methods of compliance approved in accordance with AD 97-17-03, which is superseded bythis AD; or in accordance with AD 97-13-11, which was superseded by AD 97-17-03, are approved as alternative methods of compliance with this AD, unless otherwise noted in this AD.
(h) Where can I get information about any already-approved alternative methods of compliance? Contact the Atlanta ACO, One Crown Center, 1895 Phoenix Boulevard, Suite 450, Atlanta, Georgia 303496; telephone: (770) 703-6082; facsimile: (770) 703-6097.
(i) 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 sections 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, provided that:
(1) The hopper is empty.
(2) Vne is reduced to 126 miles per hour (109 knots) indicated airspeed (IAS).
(3) Flight into known turbulence is prohibited.
(j) Are any service bulletins incorporated into this AD by reference? You must accomplish the actions required by this AD in accordance with Ayres Service Bulletin No. SB-AG-39, dated September 17, 1996, and Ayres Custom Kit No. CK-AG-29, dated December 23, 1997. The Director of the Federal Register approved this incorporation by reference under 5 U.S.C. 552(a) and 1 CFR part 51. You can get copies from the Ayres Corporation, P.O. Box 3090, One Rockwell Avenue, Albany, Georgia 31706-3090. You can look at copies at 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.
(k) Does this AD affect any other AD actions? This amendment supersedes AD 97-17-03, Amendment 39-10105.
(l) When does this amendment become effective? This amendment becomes effective on July 25, 2000.