2008-09-10: Aluminum spar caps

2008-09-10 Air Tractor, Inc.: Amendment 39-15491; Docket No. FAA- 2008-0476; Directorate Identifier 2008-CE-018-AD. \n\nEffective Date \n\n\t(a) This AD becomes effective on May 8, 2008. \n\nAffected ADs \n\n\t(b) This AD supersedes AD 2003-06-01, Amendment 39-13088. \n\nApplicability \n\n\t(c) This AD applies to the following airplanes that are certificated in any category: \n\t(1) Models AT-300, AT-301, AT-302, and AT-400A airplanes, all serial numbers, that have aluminum spar caps; \n\t(2) Models AT-400 airplanes, serial numbers 400-0244 through 400-0415, that have aluminum spar caps; and \n\t(3) Models AT-300 and AT-301 airplanes, all serial numbers that have aluminum spar caps and are or have been converted to turbine power. \n\nUnsafe Condition \n\n\t(d) This AD is the result of service reports and analysis done on wing lower spar caps of Air Tractor, Inc. airplanes. The actions specified by this AD are intended to prevent fatigue cracks from occurring in the wing lower spar cap before the established safe life is reached. Fatigue cracks in the wing lower spar cap, if not detected and corrected, could result in failure of the spar cap and lead to wing separation and loss of control. \n\nCompliance \n\n\t(e) To address this problem, you must do the following, unless already done: \n\t(1) For all affected airplanes without steel web plates, part numbers (P/N) 20990-1 or 20990-2, or steel spar caps installed, eddy-current inspect the left and right wing spar lower cap outboard holes for cracks following Snow Engineering Co. Process Specification 197, revised June 4, 2002. Do the inspections at the following compliance times: \n\n\nAffected airplanes \nInitial compliance time \nRepetitive compliance time \n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n(i) For all airplanes\nInitially inspect upon reaching 3,500 total \nhours time-in-service (TIS) on the wing spar lower cap or within the next 10 hours TIS after May 8, 2008 (the effective date of this AD), whichever occurs later. \nRepetitively inspect thereafter at intervals not to exceed 450 hours TIS until the wing spar center splice joint modification or the required wing spar lower cap replacement. After each replacement, initially inspect upon reaching 3,500 total hours TIS on either wing spar lower cap, and repetitively \ninspect thereafter at intervals not to exceed 450 hours TIS until the wing spar center splice joint modification or the required wing spar lower cap replacement. \n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n(ii) Airplanes that have had an eddy-current inspection done on the wing spar lower cap within the last 450 hours TIS before the effective date of this AD. \nYou may take credit for that inspection. Continue with the required repetitive inspection intervals. \nRepetitively inspect thereafter at intervals not-to-exceed 450 hours TIS from the time of the last inspection until the wing spar center splice joint modification or the required wing spar lower cap replacement. After each replacement, initially inspect upon reaching 3,500 total hours TIS on either wing spar lower cap, and repetitively inspect there-\nafter at intervals not to exceed 450 hours TIS until the wing spar center splice joint modification or the required wing spar lower cap replacement. \n\n\n\t(2) For all affected Models AT-300 and AT-301 airplanes with reciprocating engines, the 450-hour repetitive inspections required in this AD are terminated after the wing spar center splice joint modification is incorporated in accordance with paragraph (g) of this AD or when the wing lower spar caps are replaced. The replacement specified in paragraph (f)(2) of this AD is still applicable. \n\t(3) If cracks are found during any inspection required in paragraphs (e)(1)(i), (e)(1)(ii), or (g)(2) of this AD, replace the wing lower spar cap before further flight. \n\t(f) Replace each wing lower spar cap in accordance with the applicable maintenance manual, as follows:Affected airplanes \nInitial replacement compliance time \nRepetitive replacement/inspection compliance time \n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n(1) For all affected Models AT-300 and AT-301 \nairplanes with reciprocating engines and that do not incorporate the wing spar center splice joint modification. \nUpon reaching 5,000 total hours TIS on either wing spar lower cap or within the next 25 hours TIS after April 4, 2003 (the effective date of AD 2003-06-01), whichever occurs later. \nReplace each time the safe life limit of 5,000 total hours TIS on either wing spar lower cap is reached. After each replacement, inspect as specified in paragraph (e)(1) of this AD until the wing spar center splice joint modification or the required wing spar \nlower cap replacement. \n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n(2) For all affected Models AT-300 and AT-301 \nairplanes with reciprocating engines that do incorporate the wing spar center splice joint \nmodification done in accordance paragraph (g) of this AD. \nUpon reaching the safe life limit of 7,000 total hours TIS on either wing spar lower cap or within the next 25 hours TIS after April 4, 2003 (the effective date of AD 2003-06-01), whichever occurs later. \nReplace each time the safe life limit of 7,000 total hours TIS on either wing spar lower cap is reached. After each replacement, inspect as specified in paragraph (e)(1) of this AD until the wing spar center splice joint modification or the required wing spar \nlower cap replacement. \n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n(3) For all affected AT-302, AT-400, and AT-400A airplanes with aluminum spar caps; and all affected Models AT-300 and AT-301 airplanes with aluminum spar caps that are or have ever been converted to turbine power. \nUpon reaching 4,450 total hours TIS on either wing spar lower cap or within the next 25 hours TIS after April 4, 2003 (the effective date of AD 2003-06-01), whichever occurs later. \nReplace each time the safe life limit of 4,450 totalhours TIS on the wing spar lower cap is reached. After each replacement inspect as specified in paragraph (e)(1) of this AD until the required wing spar lower cap replacement. \n\n\t(g) For airplanes specified in paragraph (f)(1) of this AD, you may extend the safe life limit of the wing spar lower cap to 7,000 hours TIS by incorporating the wing spar center splice joint modification following the procedures in Snow Engineering Co. Service Letter 55, revised October 23, 2002; or Snow Engineering Co. Service Letter 55, revised October 4, 2004, with the following requirements: \n\t(1) This modification must be done no earlier than 4,600 total hours TIS on the wing spar lower cap and no later than 5,000 total hours TIS on the wing spar lower cap. \n\t(2) Immediately before incorporating the modification, you must do an eddy-current inspection for cracks following Snow Engineering Co. Process Specification 197, revised June 4, 2002. \n\t(3) After each replacement, inspect as specified in paragraph (e)(1) of this AD until the wing spar center splice joint modification or the required wing spar lower cap replacement. \n\t(h) Eddy-current inspections required by this AD must be done by one of the following: \n\t(1) A level 2 or 3 inspector certified in eddy-current inspection using the guidelines established by the American Society for Nondestructive Testing or NAS 410; or \n\t(2) A person authorized to perform AD maintenance work and who has completed and passed the Air Tractor, Inc. training course on eddy-current inspection on wing lower spar caps. \n\n\tNote 1: We are not retaining from AD 2003-06-01 the provision to allow a limited time of continued operation beyond the safe life limit provided parts are ordered, the replacement is scheduled, and repetitive inspections reveal no cracks. That provision was put in AD 2003-06-01 to prevent airplanes from being inadvertently grounded if parts were not available. If parts availability were to ever become a problem in the future,the owner/operator could request an alternative method of compliance following the procedures in 14 CFR 39.19 and this AD. \n\n\t(i) Report the results of any inspection required by this AD where cracks are found to the FAA. \n\t(1) Submit this report within 10 days after the inspection. \n\t(2) Use the form (Figure 1 of this AD) and submit it to FAA, Fort Worth Airplane Certification Office (ACO), 2601 Meacham Boulevard, Fort Worth, Texas 76193-0150; telephone: (817) 222-5156; facsimile: (817) 222-5960. \n\t(3) The Office of Management and Budget (OMB) approved the information collection requirements contained in this regulation under the provisions of the Paperwork Reduction Act of 1980 (44 U.S.C. 3501 et seq.) and assigned OMB Control Number 2120-0056. \n\n\n\nAlternative Methods of Compliance (AMOCs) \n\n\t(j) The Manager, Fort Worth ACO, FAA, has the authority to approve AMOCs for this AD, if requested using the procedures found in 14 CFR 39.19. Send information to ATTN: Rob Romero, Aerospace Engineer, FAA, Fort Worth ACO, 2601 Meacham Boulevard, Fort Worth, Texas 76193-0150; telephone: (817) 222-5102; facsimile: (817) 222- 5960; or Andrew McAnaul, Aerospace Engineer, ASW-150 (c/o MIDO-43), 10100 Reunion Place, Suite 650, San Antonio, Texas 78216; telephone: (210) 308-3365; facsimile: (210) 308-3370. Before using any approved AMOC on any airplane to which the AMOC applies, notify your appropriate principal inspector (PI) in the FAA Flight Standards District Office (FSDO), or lacking a PI, your local FSDO. \n\n\t(k) AMOCs approved for AD 2003-06-01 are approved for this AD. \n\nSpecial Flight Permit \n\n\t(l) Under 14 CFR part 39.23, we are limiting the special flight permits for this AD by the following conditions: \n\t(1) Operate only in day visual flight rules (VFR). \n\t(2) Ensure that the hopper is empty. \n\t(3) Limit airspeed to 135 miles per hour (mph) indicated airspeed (IAS). \n\t(4) Avoid any unnecessary g-forces. \n\t(5) Avoid areas of turbulence. \n\t(6) Plan the flight to follow the most direct route. \n\nMaterial Incorporated by Reference \n\n\t(m) You must use Snow Engineering Co. Service Letter 55, revised October 23, 2002; Snow Engineering Co. Service Letter 55, revised October 4, 2004; and Snow Engineering Co. Process Specification Number 197, revised June 4, 2002, to do the actions required by this AD, unless the AD specifies otherwise. \n\t(1) The Director of the Federal Register approved the incorporation by reference of Snow Engineering Co. Service Letter 55, revised October 4, 2004, under 5 U.S.C. 552(a) and 1 CFR part 51. \n\t(2) On April 4, 2003, (68 FR 13221, March 19, 2003), the Director of the Federal Register approved the incorporation by reference of Snow Engineering Co. Service Letter 55, revised October 23, 2002, and Snow Engineering Process Specification Number 197, revised June 4, 2002. \n\t(3) For service information identified in this AD, contact Tractor, Inc., P.O. Box 485, Olney, Texas 76374. \n\t(4) You may review copiesat the FAA, Central Region, Office of the Regional Counsel, 901 Locust, Kansas City, Missouri 64106; or at the National Archives and Records Administration (NARA). For information on the availability of this material at NARA, call 202- 741-6030, or go to: http://www.archives.gov/federal_register/code_ of_federal_regulations/ibr_locations.html.