Date: 201408
Local time of day: 0601-1200
Location: ZZZ.Airport, US
Light: Daylight
Aircraft: Regional Jet 900 (CRJ900)
Operator: Air Carrier
Operating under: Part 121
Flight phase: Parked
Aircraft component: Engine Air Starter
Component problem: Design; Malfunctioning
Reporter organization: Air Carrier
Reporter function: Technician
Reporter qualification: Maintenance Airframe; Maintenance Powerplant
Human factors: Communication Breakdown; Confusion
Anomaly: Aircraft Equipment Problem Less Severe
Detector: Person Flight Crew; Person Maintenance
When detected: Aircraft In Service At Gate
Result: General Flight Cancelled / Delayed; General Maintenance Action
Contributing factors: Human Factors; Aircraft
Primary problem: Aircraft

Narrative: Serviced Right (RH) Engine Starter with Turbo 2380 [synthetic] oil to replace Aeroshell 500. Secured all ports on starter. Issue that happened is common and needs addressed. Can happen without error from anyone. Port can often times come open without being commanded. I was also not the last person to look at the starter. I performed work; but wrote up a separate Leak Check to be performed at a later time by a different Mechanic. Starter failed; causing the engine not to start. Event occurred because starter could no longer perform duty; due to supposed oil starvation from port being left open. Starter was replaced and plane made a late departure.[Recommend] starter be designed to where the port cannot come open as easily. Starter failure.

Callback: Reporter stated he was performing an 'Entry into Service' Job Card on a new CRJ-900 aircraft his Air Carrier had just received. Part of the Servicing requires draining the existing oil from the Starter. There are two; One-Quarter (1/4) turn plugs on the bottom of the starter that are used for different reasons. One for completely draining the oil and the other during a 'Fill and Spill' procedure; where the other one-quarter turn (1/4) 'Overflow' plug is removed. Oil is then poured into the Starter through an upper fill opening that also uses a 1/4-turn plug. Once oil reaches a certain height inside the starter; an internal Standpipe will allow excess oil to drain out of the starter through the (1/4) one quarter turn Overflow plug. He believes the Standpipe should keep a certain amount of oil in the starter even with the Overflow plug not reinstalled.  Starter oil is replaced every 500 Flight Hours on the GE CF34-8C Engines. Reporter stated the one-quarter turn plugs have been a problem because they are not very secure. No safety wire is used to secure the spring loaded plugs which looks like a pin with an O-ring and two small ears for locking. When he was told the starter had later failed; due to oil starvation; because he had alledgedly left the Overflow plug hanging from a lanyard on the starter; he questioned how oil loss could have occurred even with the Overflow plug not installed; since the purpose of the internal Standpipe was to maintain a set level of oil in the starter.  Problems with loss of starter oil that later require starter replacements; have also occurred on CRJ-700 aircraft. The same GE CF34-8C Engines and Honeywell starters are used on both CRJ-700 and -900 aircraft. The CRJ-200 use CF34-3 Engines with a completely different designed starter utilizing crush washers on the plugs and safety wire. When he mentioned the issue to other mechanics; many have said they were very familar with the same problem. Reporter stated that just because a new aircraft arrives; does not mean that all the engine components are new. The engines are built up using parts that may have sat on a Parts shelf for two years with time still remaining before overhaul is required. He wants to see the Starter Manufacturer improve the locking feature of the One Quarter turn plugs.



Synopsis: A Line Aircraft Maintenance Technician (AMT) reports about the inadequate locking design of One-Quarter turn oil plugs used on GE CF34-8C Engine Starters that have resulted in oil starvation and starter failures. The engine and starters are used on CRJ-700 and -900 aircraft.