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AVStar Fuel Systems, Inc.
1365 Park Lane South Jupiter, FL 33458
www.avstardirect.com
MANDATORY SERVICE BULLETIN DOCUMENT: AFS-SB6 REVISION: 2
THE FRACTURE OF A FUEL DIAPHRAGM STUD
IN FUEL SERVOS ISSUED: APRIL 6, 2011 PAGE: 1 OF 13 Engineering aspects of this Bulletin are FAA approved.
Any questions regarding Service Bulletin are to be directed to AVStar Fuel Systems, Inc. at www.avstardirect.com, or call (561) 575-1560
1. APPLICABILITY
This Service Bulletin applies to RSA-5AB1, RSA-5AD1, RSA-10AD1, RSA-10DB1, RSA- 10DB2, RSA-10ED1 and RSA-10ED2 fuel servos overhauled or manufactured by AVStar Fuel Systems (AVStar) between May 21, 2010 and October 19, 2010. It also applies to fuel servos of any make (AVStar, Bendix, Precision, etc.) overhauled by others using AVStar Value Kits (P/N’s AVK-5AB1, AVK-5AD1, AVK-10AD1, AVK-10ED1 and AVK-10ED2) and/or Fuel Diaphragms (P/Ns AV2541801 and AV2541803) purchased from AVStar between May 21, 2010 and October 19, 2010. A list of serial numbers of servos and lot numbers of the diaphragm assemblies affected by this Bulletin are included as Attachments A and B and further can be found on our website at www.avstardirect.com.
2. REASON FOR PUBLICATION
There has been a report of a possible failure after 19 hours of an RSA-10ED1 fuel servo overhauled by AVStar that may involve the fuel diaphragm assembly. This report involved an aircraft that lost power and crashed. The fuel diaphragm assemblies being investigated are limited to those AVStar fuel diaphragm assemblies manufactured between May 21, 2010 and October 19, 2010 and further limited to the lot numbers and/or servo serial numbers shown in Attachments A and B.
3. SAFETY FIRST
AVStar is committed to its customer’s safety through technical innovation. AVStar has no authority to compel owners to act responsibly and take prudent action to insure their and others safety, but the company believes compliance with this MANDATORY SERVICE BULLETIN is important and will insure a safer product.
AVStar Fuel Systems, Inc.
1365 Park Lane South Jupiter, FL 33458
www.avstardirect.com
MANDATORY SERVICE BULLETIN DOCUMENT: AFS-SB6 REVISION: 2
THE FRACTURE OF A FUEL DIAPHRAGM STUD
IN FUEL SERVOS ISSUED: APRIL 6, 2011 PAGE: 2 OF 13 Engineering aspects of this Bulletin are FAA approved.
Any questions regarding Service Bulletin are to be directed to AVStar Fuel Systems, Inc. at www.avstardirect.com, or call (561) 575-1560
4. COMPLIANCE
THE POSSIBILITY EXISTS OF SERVO FAILURE WITHOUT WARNING WITH THE POTENTIAL OF A TOTAL LOSS OF POWER. IT IS RECOMMENDED THAT FLIGHTS BE LIMITED TO DELIVERING THE AIRCRAFT TO A SERVICE FACILITY.
If the fuel servo is an affected unit that was overhauled by AVStar, or if it contains an affected AVStar fuel diaphragm assembly installed by another facility, the servo is to be removed from the aircraft and returned to AVStar for immediate inspection and repair.
5. EVIDENCE OF COMPLIANCE
After replacement of the affected fuel diaphragm assembly, compliance with this service bulletin will be noted on the servo data tag by adding the mark SB6 as shown in Figs 3 and 4 below.
Fig 3 Fig 4
AVStar Fuel Systems, Inc.
1365 Park Lane South Jupiter, FL 33458
www.avstardirect.com
MANDATORY SERVICE BULLETIN DOCUMENT: AFS-SB6 REVISION: 2
THE FRACTURE OF A FUEL DIAPHRAGM STUD
IN FUEL SERVOS ISSUED: APRIL 6, 2011 PAGE: 3 OF 13 Engineering aspects of this Bulletin are FAA approved.
Any questions regarding Service Bulletin are to be directed to AVStar Fuel Systems, Inc. at www.avstardirect.com, or call (561) 575-1560
6. WARRANTY STATEMENT
Affected units must be returned directly to AVStar for repair or replacement at AVStar’s discretion upon validation and approval of Claim Form AFS-900-F98 and the assignment of a Return Material Authorization (RMA) number (See Claim Process below). In the event that a Value Kit or a separately purchased fuel diaphragm assembly from the affected lots was used to overhaul a fuel servo, AVStar will also repair or replace the servo as described above. There will be no charge to the customer for repair of the diaphragm assembly or replacement of the affected unit. However, in the event that AVStar elects to repair the diaphragm assembly rather than to replace the unit and evaluation of the unit indicates that additional repairs above and beyond those to the diaphragm assembly are required in order to insure airworthiness, the customer will be contacted and standard rates will apply.
Unused fuel diaphragms included in Value Kits from the affected lots will be replaced at no charge.
AVStar Fuel Systems, Inc.
1365 Park Lane South Jupiter, FL 33458
www.avstardirect.com
MANDATORY SERVICE BULLETIN DOCUMENT: AFS-SB6 REVISION: 2
THE FRACTURE OF A FUEL DIAPHRAGM STUD
IN FUEL SERVOS ISSUED: APRIL 6, 2011 PAGE: 4 OF 13 Engineering aspects of this Bulletin are FAA approved.
Any questions regarding Service Bulletin are to be directed to AVStar Fuel Systems, Inc. at www.avstardirect.com, or call (561) 575-1560
The Customer has the following options for reimbursement of removal and installation labor:
OPTION 1: AVStar will offer a removal and installation labor allowance in accordance with the following table at a maximum of $75 USD per hour. No other claims for financial compensation will be reimbursed. Customers selecting this option do so instead of the reimbursement under Options 2 or 3.
Allowance Normally Aspirated Turbo TIO & TGIO-541 Heli Normally Aspirated Heli Turbo S/charged IO-360 IO-540 TIO-540 4 Cyl 6 Cyl 8 Cyl 4 Cyl 6 Cyl 4 Cyl 6 Cyl L2A AB1A5 AC1A5 AF1B AH1A AJ1A AE2A (Hr) 2.5 2.5 1.5 2.5 2.5 2.0 2.5 2.5 2.5 2.5 2.0 2.0 2.0 2.5 3.0 2.0 8.0
OPTION 2: AVStar will offer a renewed Limited Warranty for each affected unit. The renewed Warranty shall be for 48 months or 900 engine hours from the date the repaired unit is returned (based on shipping date). This is a not a 48 month addition to the standard Limited Warranty. Customers selecting this option do so instead of the reimbursement under Options 1 or 3.
OPTION 3: AVStar will offer a $300 credit towards the customer’s next servo overhaul. The credit will be valid for a 10 year period from the date the repaired unit is returned (based on shipping date). Customers selecting this option do so instead of the reimbursement under Options 1 or 2.
The customer must select the desired Option on Claim Form AFS-900-F98 before signing and returning it to AVStar.
AVStar Fuel Systems, Inc.
1365 Park Lane South Jupiter, FL 33458
www.avstardirect.com
MANDATORY SERVICE BULLETIN DOCUMENT: AFS-SB6 REVISION: 2
THE FRACTURE OF A FUEL DIAPHRAGM STUD
IN FUEL SERVOS ISSUED: APRIL 6, 2011 PAGE: 5 OF 13 Engineering aspects of this Bulletin are FAA approved.
Any questions regarding Service Bulletin are to be directed to AVStar Fuel Systems, Inc. at www.avstardirect.com, or call (561) 575-1560
CLAIM PROCESS:
1. Complete Claim Form AFS-900-F98 (see Attachment C).
2. Submit to – AVStar Fuel Systems, Inc.
1365 Park Lane South Jupiter, FL 33458 Tel: (561) 575-1560 Fax: (561) 575-0795 Email: sb@avstardirect.com
3. Return the affected unit or fuel diaphragm assembly under the assigned RMA. The unit must be returned according to the packing and shipping instructions in the RMA.
No warranty consideration will be made until the customer has complied with the above claim process. However, requested special arrangements (made in writing) may be made for international customers. All other terms and conditions of AVStar’s Limited Warranty Policy shall apply.
7. ATTACHMENTS A. Model, Part Number and Serial Number of affected servos B. Lot numbers of affected fuel diaphragm assemblies C. Claim Form AFS-900-F98
AVStar Fuel Systems, Inc.
1365 Park Lane South Jupiter, FL 33458
www.avstardirect.com
MANDATORY SERVICE BULLETIN DOCUMENT: AFS-SB6 REVISION: 2
THE FRACTURE OF A FUEL DIAPHRAGM STUD
IN FUEL SERVOS ISSUED: APRIL 6, 2011 PAGE: 6 OF 13 Engineering aspects of this Bulletin are FAA approved.
Any questions regarding Service Bulletin are to be directed to AVStar Fuel Systems, Inc. at www.avstardirect.com, or call (561) 575-1560
ATTACHMENT A: Model, Part Number and Serial Number of affected servos
Model Part Number Serial Number RSA-5AD1 2524054-10 4143 RSA-5AD1 2524243-11 10121 RSA-5AD1 2524450-9 10926 RSA-5AD1 2524450-8 11710 RSA-5AD1 2524145-12 13011 RSA-10ED1 2524556-9 15517 RSA-5AD1 2524054-11 17640 RSA-5AD1 2524550-8 18653 RSA-5AD1 2524145-12 18970 RSA-5AD1 2524297-10 19758 RSA-10AD1 2524163-15 20748 RSA-5AD1 2524590-7 23147 RSA-10AD1 2524163-13 24367 RSA-5AD1 2524450-9 27299 RSA-5AD1 2524450-9 27312 RSA-5AD1 2524590-8 27890 RSA-10AD1 2524163-13 31853 RSA-10ED1 2524273-12 34763 RSA-5AD1 2524213-10 35210 RSA-5AD1 2524054-10 35862 RSA-10ED1 2524273-12 36004 RSA-5AD1 2524590-7 36039 RSA-10ED1 2524273-12 37244 RSA-5AD1 2524590-8 37694 RSA-5AD1 2524590-8 38283 RSA-5AD1 2524450-9 40315 RSA-5AD1 2524590-8 43301 RSA-5AD1 2524550-8 45341 RSA-5AD1 2524590-8 47100 RSA-5AD1 2524147-13 47391 RSA-5AD1 2524905-2 49636 RSA-5AD1 2524054-11 51728 RSA-5AD1 2524054-10 54841 RSA-10ED1 2524582-8 55878
AVStar Fuel Systems, Inc.
1365 Park Lane South Jupiter, FL 33458
www.avstardirect.com
MANDATORY SERVICE BULLETIN DOCUMENT: AFS-SB6 REVISION: 2
THE FRACTURE OF A FUEL DIAPHRAGM STUD
IN FUEL SERVOS ISSUED: APRIL 6, 2011 PAGE: 7 OF 13 Engineering aspects of this Bulletin are FAA approved.
Any questions regarding Service Bulletin are to be directed to AVStar Fuel Systems, Inc. at www.avstardirect.com, or call (561) 575-1560
Model Part Number Serial Number RSA-5AD1 2524054-11 55976 RSA-5AD1 2524054-11 56017 RSA-5AD1 2524054-11 56869 RSA-10ED1 2524273-12 56963 RSA-10ED1 2524273-12 58153 RSA-5AD1 2524054-11 58950 RSA-5AD1 2524450-9 59779 RSA-10ED1 2524500-9 61438 RSA-5AD1 2524054-11 62352 RSA-10AD1 2524163-15 62439 RSA-10ED1 2524273-12 63114 RSA-5AD1 2524054-10 63834 RSA-5AD1 2524450-9 65906 RSA-5AD1 2524450-9 65951 RSA-5AD1 2524682-8 66456 RSA-5AD1 2524450-9 67459 RSA-10ED1 2524273-12 68116 RSA-10ED2 2524791-6 69673 RSA-5AD1 2524213-10 69915 RSA-10ED1 2524500-9 70706 RSA-5AD1 2524054-10 71201 RSA-10ED1 2524500-8 72078 RSA-10ED1 2524500-8 77459 RSA-10ED1 2524500-9 77528 RSA-5AD1 2524213-11 77945 RSA-5AD1 2524450-9 78337 RSA-10ED1 2524273-12 78829 RSA-10ED1 2524273-11 79040 RSA-10AD1 2524163-15 81485 RSA-10AD1 2524163-15 81493 RSA-10AD1 2524163-15 81504 RSA-5AD1 2524054-11 82235 RSA-5AD1 2524213-11 997411 RSA-10ED1 2524500-9 70017104 RSA-10AD1 2524757-7 70022001 RSA-10ED1 2524500-9 70027507 RSA-5AD1 2524054-11 70050502
AVStar Fuel Systems, Inc.
1365 Park Lane South Jupiter, FL 33458
www.avstardirect.com
MANDATORY SERVICE BULLETIN DOCUMENT: AFS-SB6 REVISION: 2
THE FRACTURE OF A FUEL DIAPHRAGM STUD
IN FUEL SERVOS ISSUED: APRIL 6, 2011 PAGE: 8 OF 13 Engineering aspects of this Bulletin are FAA approved.
Any questions regarding Service Bulletin are to be directed to AVStar Fuel Systems, Inc. at www.avstardirect.com, or call (561) 575-1560
Model Part Number Serial Number RSA-5AD1 2524450-9 70054102 RSA-5AD1 2549050-1 70080709 RSA-10ED1 2524500-9 70090105 RSA-10ED1 2524273-12 70091005 RSA-5AD1 2524054-11 70122706 RSA-5AD1 2524054-11 70129709 RSA-5AD1 2576536-2 70134206 RSA-5AD1 2576536-2 70141008 RSA-5AD1 2576536-2 70144804 RSA-5AD1 2524752-7 70147603 RSA-10ED1 2524273-12 70155003 RSA-5AD1 2576536-2 70156707 RSA-10ED1 2524500-9 70157203 RSA-5AD1 2524054-11 70162308 RSA-10ED1 2524500-9 70166004 RSA-5AD1 2576536-2 70176203 RSA-5AD1 2576536-2 70181608 RSA-5AD1 2524054-11 70185408 RSA-5AD1 2576536-2 70191803 RSA-10ED1 2576562-1 70193507 RSA-10ED1 2576554-1 70193607 RSA-5AD1 2576544-2 70194101 RSA-5AD1 2576536-2 70198302 RSA-5AD1 2524054-11 70204204 RSA-10ED1 2524273-12 70210808 RSA-10ED1 2524273-12 70216501 RSA-10ED1 2576554-2 70223303 RSA-10ED1 2576546-1 70225006 RSA-5AD1 2576544-3 70227101 RSA-5AD1 2576536-2 70229809 RSA-5AD1 2524297-10 70233107 RSA-5AD1 2576524-2 70233501 RSA-5AD1 2576536-2 70237609 RSA-5AD1 2576536-2 70245107 RSA-5AD1 2576536-2 70245509 RSA-5AD1 2576536-2 70248507 RSA-5AD1 2576536-2 70258309
AVStar Fuel Systems, Inc.
1365 Park Lane South Jupiter, FL 33458
www.avstardirect.com
MANDATORY SERVICE BULLETIN DOCUMENT: AFS-SB6 REVISION: 2
THE FRACTURE OF A FUEL DIAPHRAGM STUD
IN FUEL SERVOS ISSUED: APRIL 6, 2011 PAGE: 9 OF 13 Engineering aspects of this Bulletin are FAA approved.
Any questions regarding Service Bulletin are to be directed to AVStar Fuel Systems, Inc. at www.avstardirect.com, or call (561) 575-1560
Model Part Number Serial Number RSA-5AD1 2576536-2 70258401 RSA-5AD1 2524450-9 70261505 RSA-5AD1 2576536-2 70262409 RSA-5AD1 2576568-1 70267804 RSA-5AD1 2576536-2 70268006 RSA-10ED1 2524273-12 70271904 RSA-10ED1 2576554-2 70276607 RSA-5AD1 2576536-2 70277808 RSA-5AD1 2576536-2 70278709 RSA-5AD1 2576536-2 70280708 RSA-5AD1 2576536-2 70283304 RSA-5AD1 2576536-2 70283305 RSA-5AD1 2576536-2 70285102 RSA-5AD1 2576536-2 70285309 RSA-5AD1 2576536-2 70288203 RSA-5AD1 2576536-2 70288703 RSA-10AD1 2576630-4 70369801 RSA-10AD1 2576630-4 70382005 RSA-10AD1 2576630-4 70382107 RSA-10ED1 2576554-2 70392806 RSA-10ED1 2524273-12 70427704 RSA-5AD1 2576536-2 70523707 RSA-5AD1 2576536-2 70523709 RSA-10AD1 2576630-4 70664609 RSA-5AD1 2576536-2 70692709 RSA-5AD1 2576536-2 70709802 RSA-5AD1 2524054-11 70741105 RSA-5AD1 2576536-2 70742402 RSA-10ED1 2576546-3 70744606 RSA-5AD1 2576536-2 70773203 RSA-5AD1 2576586-1 70773909 RSA-10ED1 2524500-9 70784109 RSA-5AD1 2576536-2 70821407 RSA-10ED1 2576562-4 70879504 RSA-5AD1 2576586-1 70882910 RSA-10AD1 2576630-4 70885610 RSA-5AD1 2576586-1 70949408
AVStar Fuel Systems, Inc.
1365 Park Lane South Jupiter, FL 33458
www.avstardirect.com
MANDATORY SERVICE BULLETIN DOCUMENT: AFS-SB6 REVISION: 2
THE FRACTURE OF A FUEL DIAPHRAGM STUD
IN FUEL SERVOS ISSUED: APRIL 6, 2011 PAGE: 10 OF 13 Engineering aspects of this Bulletin are FAA approved.
Any questions regarding Service Bulletin are to be directed to AVStar Fuel Systems, Inc. at www.avstardirect.com, or call (561) 575-1560
Model Part Number Serial Number RSA-10AD1 2576630-4 70949509 RSA-5AD1 2576536-2 70979007 RSA-10ED1 2524500-9 87171200 RSA-10AD1 2524757-7 87361603 RSA-10ED1 2576562-4 770268101 RSA-5AD1 2576536-2 70A89708 RSA-10ED1 2576546-3 70AA0406 RSA-5AD1 2576536-2 70AJ4906 RSA-10ED1 2576546-3 70AM0309 RSA-10ED1 2576562-4 70AU0208 RSA-5AD1 2576536-2 70AU7110 RSA-5AD1 2576536-2 70AW2608 RSA-10ED1 2524273-12 70B08310 RSA-5AD1 2576544-3 70BM3207 RSA-10ED1 2524500-9 70CE4106 RSA-5AD1 2576536-2 70CJ8106 RSA-5AD1 2576586-1 70CM2106 AVX-5VA1 AVX3015006-1 AV014090 AVX-5VA1 AVX3015006-1 AV014091 AVX-5VA1 AVX3015006-1 AV014092 AVX-5VA1 AVX3015006-1 AV014103 AVX-5VA1 AVX3015008-1 AV014224 RSA-10ED1 61M26612-Y AV101358 RSA-10ED1 AV2576554-3 AV106683 RSA-10ED1 AV2576554-3 AV106684 RSA-5AD1 AV2576536-2 AV117671 RSA-5AD1 AV2576544-3 AV1176716 RSA-5AD1 AV2576544-3 AV1176717 RSA-5AD1 AV2576544-3 AV1176718 RSA-5AD1 AV2576544-3 AV1176719 RSA-5AD1 AV2576536-2 AV117672 RSA-5AD1 AV2576544-3 AV1176720 RSA-5AD1 AV2524450-9 AV1176721 RSA-5AD1 AV2524450-9 AV1176722 RSA-5AD1 AV2524450-9 AV1176723 RSA-5AD1 AV2524450-9 AV1176724 RSA-5AD1 AV2524450-9 AV1176725
AVStar Fuel Systems, Inc.
1365 Park Lane South Jupiter, FL 33458
www.avstardirect.com
MANDATORY SERVICE BULLETIN DOCUMENT: AFS-SB6 REVISION: 2
THE FRACTURE OF A FUEL DIAPHRAGM STUD
IN FUEL SERVOS ISSUED: APRIL 6, 2011 PAGE: 11 OF 13 Engineering aspects of this Bulletin are FAA approved.
Any questions regarding Service Bulletin are to be directed to AVStar Fuel Systems, Inc. at www.avstardirect.com, or call (561) 575-1560
Model Part Number Serial Number RSA-5AD1 AV2576536-2 AV117673 RSA-5AD1 AV2576536-2 AV117674 RSA-5AD1 AV2576536-2 AV117675 RSA-5AD1 AV2576536-2 AV119661 RSA-5AD1 AV2576544-3 AV1196616 RSA-5AD1 AV2576544-3 AV1196617 RSA-5AD1 AV2576544-3 AV1196618 RSA-5AD1 AV2576544-3 AV1196619 RSA-5AD1 AV2576536-2 AV119662 RSA-5AD1 AV2576544-3 AV1196620 RSA-5AD1 AV2524450-9 AV1196621 RSA-5AD1 AV2524450-9 AV1196622 RSA-5AD1 AV2524450-9 AV1196623 RSA-5AD1 AV2524450-9 AV1196624 RSA-5AD1 AV2524450-9 AV1196625 RSA-5AD1 AV2576536-2 AV119663 RSA-5AD1 AV2576536-2 AV119664 RSA-5AD1 AV2576536-2 AV119665
AVStar Fuel Systems, Inc.
1365 Park Lane South Jupiter, FL 33458
www.avstardirect.com
MANDATORY SERVICE BULLETIN DOCUMENT: AFS-SB6 REVISION: 2
THE FRACTURE OF A FUEL DIAPHRAGM STUD
IN FUEL SERVOS ISSUED: APRIL 6, 2011 PAGE: 12 OF 13 Engineering aspects of this Bulletin are FAA approved.
Any questions regarding Service Bulletin are to be directed to AVStar Fuel Systems, Inc. at www.avstardirect.com, or call (561) 575-1560
ATTACHMENT B: Lot numbers of affected Fuel Diaphragms and Value Kits
Name Part Number Lot Number Diaphragm AV2541801 L100515 Diaphragm AV2541803 L100515 Diaphragm AV2541801 L100672 Diaphragm AV2541803 L100672 Diaphragm AV2541801 L100758 Diaphragm AV2541803 L100758
Name Part Number Qty Lot Number Value Kit AVK-10AD1 1 011975 Value Kit AVK-10AD1 1 014298 Value Kit AVK-10AD1 1 014698 Value Kit AVK-10ED1 4 013757 Value Kit AVK-10ED1 4 014413 Value Kit AVK-10ED1 4 014685 Value Kit AVK-10ED2 1 014405 Value Kit AVK-5AD1 18 013859 Value Kit AVK-5AD1 6 014078 Value Kit AVK-5AD1 6 014208 Value Kit AVK-5AD1 2 014450 Value Kit AVK-5AD1 5 014461 Value Kit AVK-5AD1 1 014638 Value Kit AVK-5AD1 5 014744 Value Kit AVK-5AD1 5 014798 Value Kit AVK-5AD1 2 014802