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Maintenance Error Leads to Power Loss in Cirrus SR22T

Maintenance Error Causes Power Loss in Cirrus SR22T During Takeoff
A Cirrus SR22T experienced a significant power loss shortly after takeoff from Boerne, Texas, resulting in a runway overrun and extensive wing damage. The incident was traced to a maintenance error that led to excessive fuel flow, raising concerns about maintenance protocols and operational safety within the general aviation community.
Incident Details and Technical Findings
The flight instructor reported that both the preflight inspection and engine run-up appeared normal. However, approximately 20 to 30 feet above the runway, a cockpit alert indicated abnormal fuel flow. The engine began to sputter and failed to provide sufficient power for a safe climb. Despite the instructor’s attempt to abort the takeoff and land on the remaining runway, the aircraft was unable to stop in time and collided with a fence.
Data retrieved from the aircraft’s onboard systems showed fuel flow peaking at around 45 gallons per hour (gph) during the flight, surpassing the 42 gph limit specified in Cirrus’s mandatory service bulletin and the SR22T Pilot’s Operating Handbook. Both documents caution that fuel flow above this threshold can lead to engine power loss or failure and require immediate maintenance action.
Post-accident engine testing confirmed the excessive fuel flow, with readings again reaching 44 gph. This condition caused rough engine operation and black smoke emissions from the exhaust. No other mechanical faults were identified during the examination.
Maintenance and Operational Concerns
The aircraft had undergone a 100-hour inspection just 15 flight hours prior to the accident. While the mechanic documented the engine setup as compliant with Cirrus and Continental Motors manuals, the required operational check data—specifically unmetered fuel pressure and fuel flow at 2,500 rpm—were not recorded. This omission raises questions about the thoroughness and completeness of the inspection process.
Further analysis of the aircraft’s remote data module revealed that fuel flow had exceeded the 42 gph threshold on multiple previous flights. A flight instructor who had flown the aircraft before reported receiving fuel flow anomaly alerts on all four of his flights, describing high fuel flow as a known issue with this model. However, the instructor on the accident flight was not informed of any prior anomalies, highlighting a breakdown in communication.
Broader Implications for Cirrus Design Corporation
This incident occurs amid a challenging period for Cirrus Design Corporation. The company is under increased scrutiny from aviation safety authorities, with potential regulatory actions that could lead to higher insurance costs for operators. Additionally, the U.S. Department of Defense has designated Cirrus as a "Chinese Military Company," a classification that may restrict government contracts and affect the company’s financial outlook. Competitors are reportedly leveraging these developments to promote their aircraft as safer alternatives, potentially eroding Cirrus’s market share.
As investigations proceed, the case emphasizes the vital importance of meticulous maintenance documentation and clear communication among flight crews—issues that are increasingly critical across the general aviation sector.

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