Service difficulty report · Spring · Robsin R44

Difficulty date
August 17, 2009
Submitted
October 23, 2009
Operation
General aviation
Make and model
Robsin R44
Aircraft time
5,936 hours
Engine
Lyc O540F1B5
Part
Spring
Part number
LW16475
Condition
Broken
Location
Exhaust Valve
Component
Cylinder Assy · Lyc
Component part number
LW13870
Stage of operation
TX
How discovered
O
Nature of condition
R, E
Precautionary procedure
E

As reported to the FAA. Reports are unverified, and codes are left as the FAA publishes them.

What was found

DURING A POST MX GROUND RUN, THE ENG WAS FOUND TO BE RUNNING ROUGH AND VIBRATING EXCESSIVELY. POST-SHUTDOWN, A CHECK FOR COMPRESSION WAS CARRIED OUT, BUT THERE WAS NONE FOUND ON THE NR 4 CYL. REMOVAL OF THE ROCKER COVER REVEALED THE EXHAUST VALVE WAS SPRUNG OUT AGAINST THE ROCKER BOX COVER, AND SMALL METALIC PIECES FELL OUT WITH THE OIL. THE PIECES WERE LATER IDENTIFIED TO BE THE INNER PORTION OF SEAT PN LW-16475. DUE TO THE FAILURE OF THIS PIECE, THE EXHUAST VALVE BENT, FORCING THE VALVE GUIDE (PN 74230) TO BECOME DISLODGED FROM THE CYL ASSY, AND BENDING THE PUSH-ROD AND PUSH ROD TUBE. A NEW CYL ASSY WAS INSTALLED WITH NEW PISTON AND PUSHRODS. A SATISFACTORY GROUND RUN AND TEST FLIGHT WERE CARRIED OUT AND THE ACFT WAS RETURNED TO SERVICE.