United States Department of Transportation / Federal Aviation Administration logo

AFS-600 Regulatory Support Division logo

 

ADVISORY CIRCULAR

43-16A

 

 

AVIATION MAINTENANCE ALERTS

 

 

flag of the United States of America

 

ALERT

NUMBER

329

bald eagle watching over three eggs

DECEMBER

2005

 


CONTENTS

AIRPLANES

AERONCA.................................................................................................................................. 1

BEECHCRAFT............................................................................................................................ 1

BOEING...................................................................................................................................... 1

CESSNA...................................................................................................................................... 3

DASSAULT................................................................................................................................. 7

ISRAEL AIRCRAFT.................................................................................................................... 8

PIPER........................................................................................................................................... 8

RAYTHEON................................................................................................................................ 9

ZENAIR..................................................................................................................................... 10

HELICOPTERS

AUGUSTA................................................................................................................................. 15

BELL.......................................................................................................................................... 18

AIR NOTES

ELECTRONIC VERSION OF FAA FORM 8010-4, MALFUNCTION OR
DEFECT REPORT..................................................................................................................... 18

PAPER COPY OF FAA FORM 8010-4, MALFUNCTION OR DEFECT REPORT............... 18

INTERNET SERVICE DIFFICULTY REPORTING (iSDR) WEB SITE................................... 18

IF YOU WANT TO CONTACT US......................................................................................... 19

AVIATION SERVICE DIFFICULTY REPORTS...................................................................... 20

 


U.S. DEPARTMENT OF TRANSPORTATION
FEDERAL AVIATION ADMINISTRATION
WASHINGTON, DC 20590

AVIATION MAINTENANCE ALERTS

The Aviation Maintenance Alerts provide a common communication channel through which the aviation community can economically interchange service experience, cooperating in the improvement of aeronautical product durability, reliability, and safety. This publication is prepared from information submitted by those who operate and maintain civil aeronautical products. The contents include items that have been reported as significant, but have not been evaluated fully by the time the material went to press. As additional facts such as cause and corrective action are identified, the data will be published in subsequent issues of the Alerts. This procedure gives Alerts’ readers prompt notice of conditions reported via a Mechanical Reliability Report (MRR), a Malfunction or Defect Report (M or D), or a Service Difficulty Report (SDR). Your comments and suggestions for improvement are always welcome. Send to: FAA; ATTN: Aviation Data Systems Branch (AFS-620); P.O. Box 25082; Oklahoma City, OK 73125-5029.

(Editor’s notes are provided for editorial clarification and enhancement within an article. They will always be recognized as italicized words bordered by parentheses.)

 

AIRPLANES

AERONCA

Aeronca: 7AC; Cracked Wing Spar; ATA 5711

The submitter states, “The aft R/H spar has a longitudinal crack on the lower end. The crack is located at the strut attach point. (This) spar also shows signs of rotting—inboard of the crack area.” (No description of this crack or dimensions was provided, nor was there an included part number for the spar.)

Part Total Time: 4,138.1 hours.

 

BEECHCRAFT

Beechcraft: A-36; Imploded Tip-Tank; ATA 2810

(This aircraft’s...) R/H Osborne Inc. auxiliary fuel tip tank imploded,” states the technician (P/N 55000-105). “(It has been...) determined the probable cause was a plugged vent. Guidance suggests: (1) when parked, keep the vent capped with a pitot-like cover, (2) during preflight...open the gas cap, connect a tube to the ¼ inch vent tube and blow, (verifying) the vent is  not plugged.” Obviously, a restricted vent should be cleared before flight. (The SDRS data base reflects one specific entry of insects clogging this vent.)

Part Total Time: unknown.

 

BOEING

Boeing: 747 SP-21; Broken Aileron Power Control Rod; ATA 2710

“On August 5th, during the flight control rigging operation, the L/H aileron power control unit’s rod-end was found broken,” states the submitter. “This rod-end is part of the Bendix PCU (P/N 317012-1) assembly. Evidence of corrosion is apparent at the cracked location. See the attached photo’s of the PCU rod end....” (The part’s total time and/or time since last overhaul was not provided. The attached photographs are low resolution, but clearly show the consequences of undetected corrosion.)


 

This is a black and white picture showing a broken control rod: the first is a close view of the rod's cross section.

 

This is a black and white photo showing a broken control rod. This is an overview of the rod with the connecting end.

Part Total Time: unknown.

 


CESSNA

Cessna: 152; Sinking Carburetor-Floats; ATA 7322

This respondent describes practicing touch-and-go landings. He had reduced power and turned base when the engine suddenly quit. “An uneventful landing was made, and after climbing out of the aircraft, fuel could be seen coming out of the cowling. Further investigation found one of the fuel bowl floats to be ¾ full of fuel, and the other was ¼ full. This caused the float to sink and fuel/air mixture to be rich at reduced power settings. (These two events...) caused the engine to flood out and quit on the approach to land.” (Carburetor listed as a Precision. No part numbers were provided. The SDRS data base records three other float related defects.)

Part Total Time: 509.5 hours.

 

Cessna: 172 RG; Cracked Landing Gear Actuators; ATA 3233

(The following is a composite of three separate defect reports from the same technician on the same model—but different aircraft.)

The first submission states, “The pilot (for this aircraft) reported a side load  on landing. On a subsequent take-off the R/H main landing gear would not fully retract. (Inspection...) found the R/H actuator (P/N 9882015-2) cracked at the forward bolt hole.” Another aircraft produced a similar defect during a 100-hour inspection for the L/H retraction actuator (same part number): it was not only cracked but the upper forward bolt was found sheared. The third defect report again describes failure of another 172 aircraft’s L/H main gear to retract...and the same “...actuator cracked at the forward bolt hole...” as the above discrepancy. (The reported part times on each aircraft’s failed actuator were 2,893.6, unknown, and 1,407.2 hours, respectively. The SDRS data base  records 28 entries related to this ATA code since 1995.)

Part Total (averaged) Time: 2,150.4 hours.

 

Cessna: 172RG; Frayed Elevator Cables; ATA 2730

(The following is a composite of three separate defect reports from the same technician on the same model—but different aircraft.)

During the months of April, May, and July of this year a technician at a repair station finds and reports the exact same defect on the same type aircraft; all in the same location; all within the same approximate (part) time frames. A 100-hour inspection on each aircraft found broken elevator cable strands approximately two feet from the aft end. The elevator cable part number listed is 0510105-391. Part times ranged 694.2 -- 886.1 hours. No anecdotal observations as to cause were provided.

Part Total Time (averaged): 822.1 hours.

 

Cessna: U206F; Corroded Fuselage Skins; ATA 5330

This aircraft was undergoing extensive avionics upgrade installations. During some of the antenna installations “...a technician noticed corrosion under factory installed dampening/installation material,” writes the submitter. This corrosion was found on the lower fuselage skins only beneath those pieces of insulating material that were apparently coming loose. He describes removing the minor corrosion and treating the affected areas. (I) suggest close inspection of this area in all aircraft. (This) problem is more than likely caused by age and moisture accumulation.” (There are two additional internal skin corrosion reports in the SDRS data base.)


 

Corrosion found on the top side of belly skins as viewed down from inside the aircraft with the flooring material removed.


 

Picture depicting corrosion found on the top side of belly skins as viewed down from inside the aircraft with the flooring material removed.

Part Total Time: 5,757.0 hours.

 

Cessna: 401A; Main Gear: Torque-Link Attach Points Cracked; ATA 3222

The submitter states, “The left and right main landing gear had cracks on the boss area where the torque links attach. These cracks were about ¼ inch long and located next to where the boss connects to the tube (strut housing).” (Main landing gear part number as provided: 509410.)

Part Total Time: 8,875.0 hours.

 


Cessna: 550; Cracked Seat Frames; ATA 2510

(The following combines two submissions from the same repair station describing identical discrepancies on two different Cessna 550 aircraft. Ten photographs were included, two of which are duplicated here.)

“The upper chair base assembly(s) are cracked at the chair back attach points.” These discrepancies include notations that these assemblies both show previous, inappropriate repairs. The technician references Aviation Fabricators STC (supplemental type certificate) ST01042WI structural seat repair as proper guidance. Part numbers for the left and right assemblies were noted as 5519015-13 and -14. (See also the Alerts for July, September, and November for almost identical reports. From 2002 to the present, the SDRS data base records 19 reports related to this ATA code, 15 of which specifically reference cracks.)

 

Tubular cracks of these seat frames, found after upholstery removal.

 

Tubular cracks of these seat frames, found after upholstery removal.

Part Total Times: unknown.

 


Cessna: 650; Broken Wheel Bolts; ATA 3246

This respondent describes conducting a weekly inspection of the aircraft, during which one broken through-bolt was discovered in the L/H main landing gear’s number one wheel, and two broken through-bolts in the number two wheel (for the same gear). He indicates these bolts have been retained for further investigation, but does not offer speculation as to cause of their failure. The main wheel part number provided as 3-1399-6.

Part Total Time: unknown.

 

DASSAULT

Dassault: 900B; Bleed Air Temperature Probe Support Cracked; ATA 7500

A mechanic’s investigation into a problem with an oil pressure transmitter for this aircraft’s number one engine led to the discovery of a hot air leak from the supporting pylon. Further observation revealed a large crack in a bleed-air duct around a temperature probe. No secondary damage was found as result of the cracked duct, or speculation offered for its cause. (One of two photographs is shown below.)

 

Picture depicts a stainless steel duct (about 2.5 inches in diameter) with a torn temperature mount.

Part Total Time: 3,844.4 hours

 


ISRAEL AIRCRAFT

Israel Aircraft: 1124; Failed Hydraulic O-Ring; ATA 2910

A mechanic describes troubleshooting the cause for this aircraft’s emptied hydraulic system. A hydraulic line “...was found to have a defective o-ring just aft of the hydraulic reservoir at a T-fitting location. The defective o-ring depleted the hydraulic reservoir—running the hydraulic system out of fluid. This caused the R/H engine driven hydraulic pump to cavitate, which damaged the pump internally. The o-ring was replaced with a new o-ring (P/N NAS 1612-4), and the engine driven hydraulic pump was also replaced. The system was serviced and operationally function and leak checked with no other discrepancies noted.” “At this time I have no recommendations to prevent recurrence, except for maintenance care when working with hydraulic o-rings. I suspect this o-ring failure was due to normal deterioration and or improper installation at the time of the last maintenance function performed to that fitting.” (The SDRS data base references two additional hydraulic O-ring failures.)

Part Total Time: unknown.

 

PIPER

Piper: PA-24-180; Failed Landing Gear Extension; ATA 3230

The submitter states, “The landing gear retraction system would not extend the gear to a down and locked position. Several attempts to cycle the gear popped the gear motor circuit breaker. The transmission de-coupler released when the emergency gear extension was attempted, however, the gear would not go to the down and locked position. The pilot’s attempt to recycle the gear to the retracted position, and then back to the extended position--after the emergency gear extension was actuated--more than likely exacerbated the problem....” “(The) transmission de-coupler was now in direct contact with the gear through-bolt, making extension improbable.” The writer suggest a flight manual supplement or a revised emergency gear extension placard advising pilots against normal gear retraction after an emergency extension attempt. (The transmission assembly part number listed is Piper 25720-00.)

Part Total Time: unknown.

 

Piper: PA 28-181; Chaffed Battery Cable; ATA 2432

Routine maintenance found this aircraft’s positive battery cable (P/N 78140-39) progressively chaffed by a control cable’s turnbuckle. “This sawing motion of the turnbuckle almost wore through the battery cable insulation jacket,” says a mechanic. “This battery cable was repositioned during the last 100 hour inspection for the same reason. Apparently the cable has taken a ‘set’—it keeps returning to its original bend configuration. (My) recommendation is to shorten the cable and to crimp the terminal ends 90 degrees to the lay of the cable.”


Drawing showing the relation of a control cable to a battery main wire.

 

Part Total Time: 1794.8 hours.

 

RAYTHEON

Raytheon: B36TC; Failed Alternator; ATA 2421

A mechanic describes a sequence of events resulting from a failed alternator. This aircraft was in flight, engine running, and the alternator switch “on.” At some point the alternator’s red annunciator fail light illuminated, followed by the load meter registering zero. As battery voltage began to drop below 24 volts, so too oil temperature and pressure indications. In preparation for landing, gear and flaps were selected to the down position, but they failed to respond due to the low battery voltage and the dead alternator. He states the aircraft was forced to land gear-up. (The Continental alternator part number given is TCM 649304.)

Part Total Time: 709.4 hours.

 


ZENAIR

Zenair: CH-701; Cracked Warp Drive Propeller Hub; ATA 6114

“During an inspection,” states the submitter, “it was noted the Warp Drive, 2 bladed propeller (WD-2B-68) had a crack in the hub (extending) from the base of the blade to one of the outer flange bolts. This is the flange that lashes (mates) up to the reduction gear box hub on the Rotax 582 installed on this aircraft.” (At the time of this writing, requisite permissions have not yet been extended for other source references. More on this propeller issue will hopefully follow next month. Relevant discussions may be read at the “www.ultralightnews.ca” website. Look under “advisories”, and then “Warp Drive”.)

 

The propeller hub has a 1/2 inch crack. Shown in three pictures.


 

Propeller hub has a 1/2 inch crack, shown in three pictures.


 

Propeller hub has a 1/2 inch crack, shown in three pictures.

Part Total Time: unknown.

 


Zenair: CH-701; Cracked Elevator Hinge Bracket; ATA 5552

The submitter describes finding the elevator’s forward hinge attach bracket “...cracked at the aft bend in the radius near the aft attach rivet. The owner stated this was a common occurrence on these model aircraft and that...(he knew of two other planes having the same defect).” No part numbers were provided with this report.

 

Picture shows a minor crack approximately 1/8 inch in an elevator support bracket.


 

Picture shows a minor crack approximately 1/8 inch in an elevator support bracket.

 

Part Total Time: unknown.

 

Zenair: CH-701; Loose Rudder Hinge Fitting; ATA 5554

The same submitter from the preceding report found another significant structural defect on the same aircraft and during the same inspection. The rudder lower hinge attach fitting’s aft two attach rivets were found pulling free from the reinforcing channels. “It should be noted the rudder is also the vertical fin on this aircraft. (I) recommend these pop-rivet type fastener be removed and aircraft hardware be installed, either bolts or MS screws. Aircraft owners should also consider installing doubler channels on the bottom side of this attach point.” No part numbers were provided with this report.


 

Picture shows rivets pulling loose in a rudder support brace.

 

Part Total Time: unknown.

 

HELICOPTERS

AUGUSTA

Augusta: A109E; Flawed Antenna Placement; ATA 3454

A technician describes having difficulties with the placement of this aircraft’s navigation antennas. “Over the past 24 months this aircraft has had four sets of navigation antennas installed. The failure mode of the antenna is ‘right hand element becomes extremely weak’, which causes navigation indicator display errors of up to 5 degrees. Visual inspection indicates the R/H antenna element is exposed to a much higher temperature than the L/H element. A recent flight performed with temperature strips affixed to the aircraft proved this as fact. The temperature strips on the R/H side of the aircraft indicate an ‘in flight’ temperature in excess of 199 degrees F. The design limit for this antenna is 185 degrees F (according to) the manufacturer. (My) recommendations include either using an antenna suitable for higher temperature exposure or re-locating the antennas (to fuselage positions) away from the exhaust. (Antenna part number is DMN48-1.)


 

Helicopter antenna's relative navigation antenna mount position on the empennage.


 

Picture L and R combined picture of temperature indicating strips: the left side clearly showing temperature approaching 200 degrees F.

Part Total Time: unknown.

 


BELL

Bell: 206L-1; Broken Throttle Cable; ATA 7321

A technician states, “Upon landing for cargo transport, the throttle was reduced to flight idle but the engine RPM stayed the same. The throttle was opened and closed several times with no effect on engine RPM. Finally the pilot shut the engine off by turning the main fuel shut-off...(then he) notified maintenance. The mechanic discovered the inner cable was severed two feet (back) from the throttle (mechanism) in the cockpit. He removed and replaced the cable and the aircraft was returned to service after completion of function checks in accordance with the maintenance manual.” (Throttle cable part number is given as 04638C80Z38-2. No speculation as to cause was provided.)

Part Total Time: unknown.

 

AIR NOTES

ELECTRONIC VERSION OF FAA FORM 8010-4, MALFUNCTION OR DEFECT REPORT

One of the recent improvements to the Flight Standards Service Aviation Information Internet web site is the inclusion of FAA Form 8010-4, Malfunction or Defect Report. This web site is still under construction and further changes will be made; however, the site is now active, usable, and contains a great deal of information.

Various electronic versions of this form have been used in the past; however, this new electronic version is more user friendly and replaces all other versions. You can complete the form online and submit the information electronically. The form is used for all aircraft except certificated air carriers who are provided a different electronic form. The Internet address is: http://forms.faa.gov/forms/faa8010-4.pdf

When the page opens, select “M or D Submission Form” and, when complete, use the “Add Service Difficulty Report” button at the top left to send the form. Many of you have inquired about this service. It is now available, and we encourage everyone to use this format when submitting aviation, service-related information.

 

PAPER COPY OF FAA FORM 8010-4, MALFUNCTION OR DEFECT REPORT

In the past, the last two pages of the Alerts contained a paper copy of FAA Form 8010-4, Malfunction or Defect Report. To meet the requirements of *Section 508, this form will no longer be published in the Alerts; however, the form is available on the Internet at: http://forms.faa.gov/forms/faa8010-4.pdf . You can still download and complete the form as you have in the past.

*Section 508 was enacted to eliminate barriers in information technology, to make available new opportunities for people with disabilities, and to encourage development of technologies that will help achieve these goals.

 

INTERNET SERVICE DIFFICULTY REPORTING (iSDR) WEB SITE

The Federal Aviation Administration (FAA) Internet Service Difficulty Reporting (iSDR) web site is the front-end for the Service Difficulty Reporting System (SDRS) data base that is maintained by the Aviation Data Systems Branch, AFS-620, in Oklahoma City, Oklahoma. The iSDR web site supports the Flight Standards Service (AFS), Service Difficulty Program by providing the aviation community with a voluntary and electronic means to conveniently submit in-service reports of failures, malfunctions, or defects on aeronautical products. The objective of the Service Difficulty Program is to achieve prompt correction of conditions adversely affecting continued airworthiness of aeronautical products. To accomplish this, Mechanical Reliability Reports (MRRs),


Malfunction or Defect Reports (M or Ds), or Service Difficulty Reports (SDRs) as they are commonly called, are collected, converted into a common SDR format, stored, and made available to the appropriate segments of the FAA, the aviation community, and the general public for review and analysis. SDR data is accessible through the “Query SDR data” feature on the iSDR web site at: http://av-info.faa.gov/SDRX/ .

A report should be filed whenever a system, component, or part of an aircraft, powerplant, propeller, or appliance fails to function in a normal or usual manner. In addition, if a system, component, or part of an aircraft, powerplant, propeller, or appliance has a flaw or imperfection, which impairs or may impair its future function, it is considered defective and should be reported under the Service Difficulty Program.

The collection, collation, analysis of data, and the rapid dissemination of mechanical discrepancies, alerts, and trend information to the appropriate segments of the FAA and the aviation community provides an effective and economical method of ensuring future aviation safety.

The FAA analyzes SDR data for safety implications and reviews the data to identify possible trends that may not be apparent regionally or to individual operators. As a result, the FAA may disseminate safety information to a particular section of the aviation community. The FAA also may adopt new regulations or issue airworthiness directives (ADs) to address a specific problem.

The iSDR web site provides an electronic means for the general aviation community to voluntarily submit reports, and may serve as an alternative means for operators and air agencies to comply with the reporting requirements of 14 Title of the Code of Federal Regulations (CFR) Section 121.703, 125.409, 135.415, and 145.221, if accepted by their certificate-holding district office. FAA Aviation Safety Inspectors may also report service difficulty information when they conduct routine aircraft maintenance surveillance as well as accident and incident investigations.

The SDRS data base contains records dating back to 1974. At the current time, we are receiving approximately 40,000 records per year. Reports may be submitted to the iSDR web site on active data entry form or submitted hardcopy to the address below.

The SDRS and iSDR web site point of contact is:

John Jackson
Service Difficulty Reporting System, Program Manager
Aviation Data Systems Branch, AFS-620
P.O. Box 25082
Oklahoma City, OK 73125
Telephone: (405) 954-6486
SDRS Program Manager e-mail address: 9-AMC-SDR-ProgMgr@faa.gov

 

IF YOU WANT TO CONTACT US

We welcome your comments, suggestions, and questions. You may use any of the following means of communication to submit reports concerning aviation-related occurrences.

Editor:  Daniel Roller (405) 954-3646
FAX:    (405) 954-4570 or (405) 954-4655

E-mail address:   Daniel.Roller@faa.gov

Mailing address: FAA, ATTN: AFS-620 ALERTS, P.O. Box 25082 , Oklahoma City, OK 73125-5029

You can access current and back issues of this publication from the internet at:
http://av-info.faa.gov/ . Select the General Aviation Airworthiness Alerts heading.

 


AVIATION SERVICE DIFFICULTY REPORTS

The following are abbreviated reports submitted for the previous month, which have been entered into the FAA Service Difficulty Reporting (SDR) System data base. This is not an all-inclusive listing of Service Difficulty Reports. For more information, contact the FAA, Regulatory Support Division, Aviation Data Systems Branch, AFS-620, located in Oklahoma City, Oklahoma. The mailing address is:

FAA
Aviation Data Systems Branch, AFS-620
PO Box 25082
Oklahoma City, OK 73125

To retrieve the complete report, click on the Control Number located in each report. These reports contain raw data that has not been edited. Also, because these reports contain raw data, the pages containing the raw data are not numbered.

If you require further detail please contact AFS-620 at the address above.


Federal Aviation Administration

Service Difficulty Report Data

 

Sorted by aircraft make and model then engine make and model. This report derives from unverified information submitted by the aviation community without FAA review for accuracy.

Control Number

Aircraft Make

Engine Make

Component Make

Part Name

Part Condition

Difficulty Date

Aircraft Model

Engine Model

Component Model

Part Number

Part Location

MDR02BO2005

 

 

 

NUT  

CRACKED

1/10/2005

 

 

 

10514104119

MAIN ROTOR HEAD

UPON INSPECTION AND MAINTENANCE OF MAIN ROTOR HEAD ASSY, SUBCOMPONENT (UPPER QUAD NUT) WAS SENT TO VENDOR FOR MAG PARTICLE INSPECTION AND SUBSEQUENTLY WAS REJECTED. THIS CONDITION HAS BEEN REPORTED TO MFG FOR INVESTIGATION AND ANALYSIS OF CAUSE. (K)

2005FA0001492

 

 

 

BEARING

CORRODED

11/1/2005

 

 

 

3661RSP5

HORIZ STAB ACT

TAILPLANE ACTUATOR EXCEEDED SCREW/CASING END PLAY LIMIT OF 0.25 MM AS LISTED IN MM. DISASSEMBLED UNIT AND FOUND PRESENCE OF WATER CONTAMINATION AND INTERNAL BALL BEARINGS RUSTED. DATE DISCOVERED 17 AUG 2005. UNIT SHOULD BE CHECKED INTERNALLY FOR CONDITION OF BALL BEARINGS AND PROPER LUBRICATION. AT PRESENT MM PROVIDES NO SCHEDULED INTERVALS TO MONITOR BEARING CONDITIONS. (K)

2005FA0001491

 

 

AMD  

BEARING

CORRODED

9/1/2005

 

 

 

EX405RC

HORIZONTAL STAB

TAILPLANE ACTUATOR EXCEEDED SCREW CASING END PLAY LIMIT OF 0.25 MM AS LISTED IN MM. DISASSEMBLED UNIT AND FOUND PRESENCE OF WATER CONTAMINATION AND INTERNAL BALL BEARINGS RUSTED. DATE DISCOVERED 17 AUG 2005. UNIT SHOULD BE CHECKED INTERNALLY FOR CONDITION OF BALL BEARINGS AND PROPER LUBRICATION. AT PRESENT, MFG MM PROVIDE NO SCHECULED INTERVALS TO MONITOR BEARING CONDITIONS. (K)

CA051007002

 

 

 

MANUAL

INACCURATE

9/30/2005

 

 

 

 

MAINTENANCE

AFTER REVIEWING PRODUCTION FLT TEST PROCEDURE, IT WAS FOUND THAT NO MENTION OF PROP BOLTS TQ CHECK AFTER FIRST FLT AS RECOMMENDED BY MT PROPELLER DOCUMENT. AFTER REVIEWING MM , IT WAS FOUND THAT PROP BOLTS TQ CHECK AFTER FIRST 25HRS OF OP AS RECOMMENDED BY MT PROPELLER WAS MISSING IN SPECIAL INSPECT SECTION. AS PRECAUTIONARY MEASURE OWNERS OF MDL SA160 S/N S-0001, S-0002, S-0003,S-0004S-0005, S-0006 WERE CONTACTED BY PHONE AND ADVISED TO CARRY OUT PROP BOLTS TQ CHECK AS PER MT PROP, BEFORE NEXT FLT IF A/C HAD ACCUMULATED LESS THAN 100 HRS ON TACH IND SINCE DELIVERY, FOR A/C THAT HAD ACCUMULATED MORE THAN 100 HRS, RE-TQ SHOULD HAVE BEEN CARRIED OUT AS PER ANNUAL/100 HRS INSPECTION AS INCORPORATED IN MM INSPECTION PROGRAM.

CA051017010

 

ALLSN

ALLSN

IDLER GEAR

FRACTURED

9/29/2005

 

250C20B

 

6845867

SCAVENGE PUMP

AIRCRAFT NOTED AS SMOKING ON TAXI BY TOWER. TAKEOFF WAS ABORTED AND INSUFFICIENT OIL PUMP SCAVENGE NOTED AS SOURCE OF TURBINE SMOKING PROBLEM. WHEN DISMANTLED FOR REPAIR AND INSPECTION, FOUND ONE SCAVENGE ELEMENT GEAR HAD A BROKEN TOOTH. PART IS 3812.7 HOURS SINCE LAST NDT INSPECTION. OEM NOTIFIED OF PROBLEM AND PROVIDED PICTURES OF NONCONFORMANCE.

2005FA0001396

 

CONT

 

CYLINDER HEAD

CRACKED

7/5/2005

 

IO520BA

 

1691111

ENGINE

CYLINDER 16911-11 BLEW A HOLE IN THE SIDE. CYLINDER 16757-25 CRACKED. TSN 71.2 ACA CYLINDERS. (K)

2005FA0001389

 

PWA  

 

COMPRESSOR WHEEL

CORRODED

10/3/2005

 

JT12*

 

725008

ENGINE

THESE PARTS WERE REMOVED FROM SERVICE AT ENGINE TSO OF 2824.2 HOURS. THE FOLLOWING PARTS (COMPRESSOR DISKS) WERE DEEMED SCRAP DUE TO NOT BEING ABLE TO READ PN AND/OR SN BECAUSE OF CORROSION. WE SUSPECT THAT THE CAUSE OF EXCESSIVE CORROSION IS THE WINDAGE TABS NOT BEING ADEQUATELY COATED. (NOTE: DUE TO PN AND SN OF PARTS BEING NOT LEGIBLE, THE PN AND SN WERE OBTAINED FROM PREVIOUS RECORDS/DISK SHEETS). (K)

2005FA0001390

 

PWA  

 

COMPRESSOR WHEEL

CORRODED

10/3/2005

 

JT12*

 

701409

ENGINE

THESE PARTS WERE REMOVED FROM SERVICE AT ENGINE TSO OF 2824.2 HOURS. THE FOLLOWING PARTS (COMPRESSOR DISK) WERE DEEMED SCRAP DUE TO NOT BEING ABLE TO READ PN AND/OR SN BECAUSE OF CORROSION. WE SUSPECT THAT THE CAUSE OF EXCESSIVE CORROSION IS THE WINDAGE TABS NOT BEING ADEQUATELY COATED. (NOTE: DUE TO PN AND SN OF PARTS BEING NOT LEGIBLE, THE PN AND SN WERE OBTAINED FROM PREVIOUS RECORDS/DISK SHEETS). (K)

2005FA0001391

 

PWA  

 

COMPRESSOR WHEEL

CORRODED

10/3/2005

 

JT12*

 

725008

ENGINE

THESE PARTS WERE REMOVED FROM SERVICE AT ENGINE TSO OF 160.5 HOURS (PRIOR TO THE ENGINE TBO OF 3000 HOURS). THE FOLLOWING PARTS (COMPRESSOR DISK) WERE DEEMED SCRAP DUE TO NOT BEING ABLE TO READ PN AND/OR SN BECAUSE OF CORROSION. SUSPECT THAT THE CAUSE OF EXCESSIVE CORROSION IS THE WINDAGE TABS NOT BEING ADEQUATELY COATED. (NOTE: DUE TO PN AND SN OF PARTS BEING NOT LEGIBLE, THE PN AND SN WERE OBTAINED FROM PREVIOUS RECORDS/DISK SHEETS). (K)

2005FA0001388

 

PWA  

 

COMPRESSOR WHEEL

CORRODED

10/3/2005

 

JT12*

 

496706

ENGINE

THESE PARTS WERE REMOVED FROM SERVICE AT ENGINE TSO OF 2824.2 HOURS. THE FOLLOWING PARTS (COMPRESSOR DISK) WERE DEEMED SCRAP DUE TO NOT BEING ABLE TO READ PN AND/OR SN BECAUSE OF CORROSION. SUSPECT THAT THE CAUSE OF EXCESSIVE CORROSION IS THE WINDAGE TABS NOT BEING ADEQUATELY COATED. (NOTE: DUE TO PN AND SN OF PARTS BE NOT LEGIBLE, THE PN AND SN WERE OBTAINED FROM PREVIOUS RECORDS/DISK SHEETS). (K)

2005FA0001383

 

PWA  

 

COMPRESSOR WHEEL

CORRODED

10/3/2005

 

JT12*

 

701106E

ENGINE

THESE PARTS WERE REMOVED FROM SERVICE AT ENGINE TSO OF 1493.7 HOURS (PRIOR TO THE ENGINE TBO OF 3000 HOURS). THE FOLLOWING PARTS (COMPRESSOR DISKS) WERE DEEMED SCRAP DUE TO NOT BEING ABLE TO READ PN AND/OR SN BECAUSE OF CORROSION. WE SUSPECT THAT THE CAUSE OF EXCESSIVE CORROSION IS THE WINDAGE TABS NOT BEING ADEQUATELY COATED. (NOTE: DUE TO PN AND SN OF PARTS BEING NOT LEGIBLE, THE PN AND SN WERE OBTAINED FROM PREVIOUS RECORDS/DISK SHEETS). (K)

2005FA0001384

 

PWA  

 

COMPRESSOR WHEEL

CORRODED

10/3/2005

 

JT12*

 

725008F

ENGINE

THESE PARTS WERE REMOVED FROM SERVICE AT ENGINE TSO OF 1493.7 HOURS (PRIOR TO THE ENGINE TBO OF 3000 HOURS). THE FOLLOWING PARTS (COMPRESSOR DISK) WERE DEEMED SCRAP DUE TO NOT BEING ABLE TO READ PN AND/OR SN BECAUSE OF CORROSION. WE SUSPECT THAT THE CAUSE OF EXCESSIVE CORROSION IS THE WINDAGE TABS NOT BEING ADEQUATELY COATED. (NOTE: DUE TO PN AND SN OF PARTS BEING NOT LEGIBLE, THE PN AND SN WERE OBTAINED FROM PREVIOUS RECORDS/DISK SHEETS). (K)

2005FA0001450

 

PWA  

 

SEAL

WRONG PART

10/12/2005

 

JT8D15

 

 

FUEL NOZZLE

INCORRECT SEAL INSTALLED ON PRE-ASB6169 FUEL NOZZLES, PT NR 809137-01, SEAL NR 814352 INSTALLED, CORRECT SEAL FOR PRE ASB6169 IS NR 775723. (K)

CA051017001

AEROSP

PWA  

 

SENSOR

MALFUNCTIONED

10/11/2005

ATR42300

PW120

 

1030032

HALL EFFECT

THE NR 2 DC GENERATING SYSTEM WENT OFF LINE AFTER DEPARTING YFB. THE AIRCAFT RETURNED TO POINT OF DEPARTURE WHERE MAINTENANCE DETERMINED THE NR 2 HALL EFFECT SENSOR HAD FAILED. THE SENSOR WAS REPLACED AND THE AIRCRAFT RETURNED TO SERVICE.

CA051005003

AEROSP

PWA  

 

GENERATOR

MALFUNCTIONED

10/3/2005

ATR42300

PW120

 

200322

NR 2 A/C SYSTEM

(CAN) APPROXIMATELY 30 MINUTES ENROUTE THE AIRCRAFT HAD NR 2 AC WILD FAULT INDICATION. THE AIRCRAFT RETURNED WHERE MAINTENANCE REPLACED THE UNIT AND RETURNED THE AIRCRAFT TO SERVICE.

CA051005005

AEROSP

PWA  

 

GENERATOR

INOPERATIVE

10/3/2005

ATR42300

PW120

 

200322

NR 2 A/C

(CAN) APPROXIMATELY 30 MINUTES AFTER DEPARTING THE AIRCRAFT HAD A NR 2 AC WILD FAULT INDICATION. THE CREW RETURNED THE AIRCRAFT, WHERE MAINTENANCE REPLACED THE NR 2 AC GENERATOR AND RETURNED THE AIRCRAFT TO SERVICE.

CA051006012

AEROSP

PWA  

 

TSCU

UNSERVICEABLE

9/19/2005

ATR42300

PW121

 

30005000044

ENGINE

(CAN) FOLLOWING TAKE-OFF, THE ENGINE EXPERIENCED AN UNCOMMANDED TORQUE REDUCTION ACCOMPANIED BY A REDUCTION IN PROPELLER SPEED. THE ENGINE WAS SHUT DOWN IN FLIGHT AND THE AIRCRAFT DIVERTED TO POINT OF DEPARTURE. SUBSEQUENT INSPECTION REVEALED AN UNSERVICEABLE TORQUE SIGNAL CONTROL UNIT (TSCU).

CA051006002

AEROSP

PWA  

 

COMPRESSOR

LEAKING

9/7/2005

ATR42300

PW121

 

 

ENGINE

(CAN) DURING CLIMB, SMOKE BECAME EVIDENT IN THE CABIN AIR ACCOMPANIED BY AN DECREASE IN ENGINE OIL PRESSURE AND AN INCREASE IN TEMPERATURE. THE ENGINE WAS SHUTDOWN IN FLIGHT AND THE AIRCRAFT DIVERTED TO POINT OF DEPARTURE. SUBSEQUENT INSPECTION REVEALED SEIZURE OF THE PROP SHAFT AND OIL LEAKING FROM THE COMPRESSOR SECTION. MFG WILL MONITOR INVESTIGATION OF THE INCIDENT AND ADVISE OF ROOT CAUSE ONCE ESTABISHED.

CA051005010

AEROSP

PWA  

 

ENGINE

MALFUNCTIONED

9/3/2005

ATR42320

PW121

 

 

 

(CAN) IN DESCENT THE ENGINE EXPERIENCED AN UNCOMMANDED POWER ROLL-BACK. THE ENGINE WAS SHUT DOWN IN FLIGHT AND A SINGLE ENGINE LANDING ACCOMPLISHED AT POINT OF DESTINATION. THE ENGINE FUEL CONTROL WAS SUBSEQUENTY REPLACED. MFG WILL MONITOR INVESTIGATION OF THE EVENT AND ADVISE OF ROOT CAUSE ONCE DETERMINED.

2005FA0001462

AEROSP

 

 

PIPE

CRACKED

10/11/2005

ATR72

 

 

S7811200000200

ENGINE

JET PIPE, CRACK IN BASE METAL PARALLEL TO ATTACH FLANGE, FROM VIBRATION. (K)

CA051006004

AEROSP

PWA  

 

ENGINE

POWER LOSS

9/7/2005

ATR72

PW124B

 

 

 

(CAN) DURING CLIMB, THE ENGINE EXPERIENCED AN UNCOMMANDED DECREASE IN TORQUE ACCOMPANIED BY AN INCREASE IN TEMPERATURE. THE ENGINE WAS REPORTED TO EMIT A LOUD NOISE. THE AIRCRAFT DIVERTED TO POINT OF DEPARTURE. MFG WILL MONITOR INVESTIGATION OF THE EVENT AND WILL ADVISE OF ROOT CAUSE ONCE DETERMINED.

2005FA0001485

AEROSP

 

 

FEEDER CABLE

CHAFED

9/23/2005

ATR72202

 

 

 

RT CABIN AREA

DURING INDUCTION INSPECTION FOR PASSENGER TO FREIGHTER CONVERSION MODIFICATION, INSPECTION REVEALED 2 AREAS OF SEVERE CHAFING RESULTING IN EXPOSURE OF CONDUCTOR WIRES FOR AC WILD FEEDERS AT RT SIDE CABIN AREA BETWEEN FRAMES 15-17 APPROXIMATELY STRINGER 5R. (K)

2005FA0001486

AEROSP

 

 

FEEDER CABLE

CHAFED

9/23/2005

ATR72212

 

 

 

RT CABIN AREA

DURING INDUCTION INSPECTION FOR PASSENGER TO FREIGHTER CONVERSION MODIFICATION, INSPECTION REVEALED 2 AREAS OF SEVERE CHAFING RESULTING IN EXPOSURE OF CONDUCTOR WIRES FOR AC WILD FEEDERS AT RT SIDE CABIN AREA BETWEEN FRAMES 15-17 APPROXIMATELY STINGER 5R. (SW17200603842) (K)

2005FA0001515

AEROSP

TMECA

 

FLOOR PANEL

CORRODED

10/18/2005

SA365N1

ARRIEL1

 

3652100590501

COCKPIT

DURING A PRE-BUY INSPECTION, THE LONCOIN RUBBER MATS WERE PULLED UP FROM THE COCKPIT FLOORS. UNDER THE PILOTS SIDE OF THE MATS, MAJOR CORROSION ACCUMULATION WAS DISCOVERED. THESE MATS WERE STILL DAMP UNDERNEATH WHICH SHOWED WHY THIS CORROSION EXISTED. SUSPECT THAT SALT LADEN WATER FROM THE PILOTS FEET DURING WINTER OPERATIONAS CONTRIBUTED TO THIS CORROSION. THE RUBBER MATS ALLOWED THE MOISTURE TO PENETRATE BUT WOULD NOT LET IT DRY. THIS FLOOR PANEL IS COMPLETELY DESTROYED AND MUST BE REPLACED. MORE STRIGENT CLEANING AND INSPECTION PRACTICES MUST BE PRACTICED IN ENVIROMENTS SUCH AS THIS. (K)

2005FA0001493

AIRTRC

PWA  

 

SPAR

SEPARATED

10/20/2005

AT402

PT6A15AG

 

450001

WING 

THE MAIN SPARS (PN 4500-01 AND 4500-02, RT AND LT) WERE BROKEN AWAY FROM THE WINGLET. WINGLETS AND SPAR ARE PART OF STC INSTALLATION. SPAR IS ATTACHED TO INSIDE WINGLET WITH FIBERGLASS CLOTH. CLOTH WAS TORN AND DELAMINATED. SPAR WAS COMPLETELY SEPARATED FROM WINGLET ON RT SIDE AND MOSTLY SEPARATED ON THE LT SIDE. DISCOVERED DURING INSPECTION.

CA050909004

AIRTRC

PWA  

 

ATTACH BRACKET

CRACKED

9/8/2005

AT802A

PT6A67A

 

 

FUSELAGE

(CAN) DURING ACCOMPLISHMENT OF A 200 HOUR INSPECTION, A CRACK WAS OBSERVED IN THE ATTACH BRACKET WELD THAT SECURED THE RT UPPER AUX FINLET TO THE HORIZONTAL STABILIZER. THE FINLET WAS REMOVED FROM THE AIRCRAFT FOR REPAIR. UPON COMPLETION OF THE REPAIR THE FINLET WILL BE RE-INSTALLED ON THE AIRCRAFT.

2005FA0001484

AMTR

LYC  

 

NEEDLE VALVE

FAILED

10/19/2005

GLASTAR

O320*

 

 

CARBURETOR

DURING CRUISE FLIGHT ENGINE QUIT SUDDENLY. PILOT APPLIED CARBURETOR HEAT, CHECKED HIS FUEL GAUGE, WHICH SHOWED 5 PSI AND TURNED ON THE ELECTRIC FUEL PUMP AND SWITCHED TO ANOTHER FUEL TANK. ALL HAD NO EFFECT. PILOT WAS ABLE TO MAINTAIN 2000 RPM ON ENGINE BY PUMPING THE PRIMER HANDLE IN AND OUT. PILOT LANDED THE AIRCRAFT AND WAS UNABLE TO STOP THE AIRCRAFT, IT FLIPPED OVER. CARBURETOR WAS DISASSEMBLED AND THE FLOAT ACTUATED AND RELEASED, NEEDLE VALVE STUCK IN THE CLOSED POSITION. BLACK PARTICLES WERE FOUND IN THE FLOAT BOWL. ACTUATION OF THE NEEDLE SEVERAL TIMES APPEARED TO CORRECT THE PROBLEM. IT IS STILL A LITTLE STICKY BUT DOES NOT REMAIN CLOSED WHEN THE FLOAT IS RELEASED. (K)

CA051006003

AYRES

PWA  

 

ENGINE

FLAMED OUT

9/5/2005

S2RT660

PT6A65AG

 

 

 

(CAN) THE ENGINE WAS REPORTED TO HAVE FLAMED OUT ON FINAL APPROACH RESULTING IN THE AIRCRAFT LANDING SHORT OF THE RUNWAY. MFG WILL INVESTIGATE THE INCIDENT AND ADVISE OF ROOT CAUSE ONCE DETERMINED.

CA051006010

BAG  

PWA  

 

COOLER

DAMAGED

9/12/2005

ATP  

PW126A

 

 

FUEL/OIL

(CAN) THE ENGINE LOW OIL PRESSURE WARNING ANNUNCIATED AND THE ENGINE WAS SHUTDOWN IN FLIGHT. SUBSEQUENT INSPECTION REVEALED THE PRESENCE OF FUEL IN THE ENGINE OIL TANK. THE ENGINE FCOC WAS REPLACED AND THE AIRCRAFT RETURNED TO SERVICE.

CA051011005

BAG  

GARRTT

 

GENERATOR

SEPARATED

9/21/2005

JETSTM3212

TPE33110UG

 

230790069

DC SYSTEM

(CAN) GENERATOR WENT OFF LINE IN CLIMB OUT. AIRCRAFT RETURNED TO BASE. GENERATOR REPLACED WITH OVERHAULED UNIT. SYSTEM TESTED SATISFACTORY.

CA051003009

BAG  

GARRTT

LUCAS

BRUSHES

FRAYED

9/11/2005

JETSTM3212

TPE33110UG

23079009

230791281

STARTER GEN

(CAN) FOUND WIRES NOT FASTENED TO STARTER GENERATOR BRUSHES, DUE TO RIVET BEING LOOSE,WHICH THEN CAUSED ARCING OF WIRE AND RIVET TO CAUSE THE TEMPOR OUT OF THE RIVET .

CA050927002

BBAVIA

LYC  

 

CONTROL CABLE

FRAYED

9/27/2005

8GCBC

O360C2E

 

31072

ELEVATOR

(CAN) ELEVATOR UP CONTROL CABLED FRAYED AT AFT PULLEY.

CA050922005

BEECH

PWA  

 

SKIN

DAMAGED

9/12/2005

1900C

PT6A65B

 

 

ELEVATOR

(CAN) DURING INSPECTION OF THE ELEVATOR IAW AD 2005-18-21 AND COMMUNIQUE NO. 261, SMOKING RIVETS WERE DISCOVERED IN THE LOWER SKIN OF BOTH ELEVATORS (2 IN THE LT, 4 IN THE RT). REQUIRED REPAIRS WERE CARRIED OUT.

CA050926003

BEECH

PWA  

 

GOVERNOR

FAULTY

9/20/2005

1900C

PT6A65B

 

8210212E

PROPELLER

(CAN) DURING CRUISE, THE RT PROPELLER RPM OCCASIONALLY FLUCTUATED 100 RPM WITH NO INPUT FROM THE CREW. THE DEFECT WAS CONFIRMED ON THE GROUND BY MAINTENANCE AND THE PROPELLER GOVERNOR WAS REPLACED.

CA051005008

BEECH

PWA  

 

ENGINE

MALFUNCTIONED

9/1/2005

1900D

PT6A67D

 

 

 

(CAN) DURING FLIGHT, SMOKE CONTAMINATED CABIN AIR AND MAIN OIL PRESSURE DECREASED TO UNACCEPTABLE LEVELS. THE ENGINE WAS SHUTDOWN IN FLIGHT AND A SINGLE ENGINE LANDING CARRIED OUT. WILL MONITOR INVESTIGATION OF THE EVENT AND WILL ADVISE OF ROOT CAUSE ONCE ESTABLISHED. (SEE ALSO: US #2005090900013)

CA051005002

BEECH

PWA  

 

WINDSHIELD

FAILED

10/2/2005

200BEECH

PT6A41

 

10138402521

COCKPIT

(CAN) ENROUTE, WHEN THE AC EXPERIENCED A CRACKED WINDSHIELD AND THE CREW REQUESTED IMMEDIATE DESCENT TO COMPLY WITH INSTRUCTIONS IN THE PILOTS HANDBOOK P/N101-590010-5, PAGE 3-16. SITUATION DID NOT REQUIRE THE DECLARATION OF AN EMERGENCY. UPON ARRIVAL OF AIRCRAFT, MAINTENANCE PERSONNEL INSPECTED THE WINDOW AND FOUND THE INSIDE PANE OF THE LT WINDSHIELD TO BE BROKEN. THE WINDOW WAS FOUND TO BE INSTALLED CORRECTLY USING THE CORRECT PARTS. ALSO NOTED WAS THAT THE WINDSHIELD HEAT WAS WORKING CORRECTLY AT THE TIME OF THIS INCIDENT. THE WINDSHIELD WAS TH EN REPLACED IAW THE MFG MM. THE PN REMOVED WAS 101-384025-21.

CA051013009

BEECH

PWA  

 

ACTUATOR

LEAKING

10/11/2005

200BEECH

PT6A41

 

ADI79990033

MLG 

ON DESCENT, CREW WAS UNABLE TO GET THE NOSE GEAR DOWN INDICATION. EMERGENCY EXTENSION WAS COMPLETED AND A/C LANDED SAFELY. FERRY PERMIT WAS ISSUED AND A/C RETURNED TO YYC MAINTENANCE BASE WITH GEAR DOWN. RT MAIN GEAR ACTUATOR FOUND TO HAVE THE SEAL FOR THE PISTON ROD FAIL, CAUSING THE LOSS OF HYDRAULIC FLUID.

CA051009001

BEECH

PWA  

PPG  

WINDSHIELD

BROKEN

10/2/2005

300BEECH

PT6A60A

1013840252

1013840252

COCKPIT

(CAN) ON CLIMB OUT, THE CREW HEARD A LOUD BANG AND THE PILOTS WINDSHIELD INNER PANE HAD BROKEN. THE CREW RETURNED WITHOUT A PROBLEM.

2005FA0001457

BEECH

PWA  

 

TRANSMITTER

OUT OF ADJUST

10/10/2005

400A

JT15D1

 

 

TE FLAPS

FLAP ASYMMETRY ANNUNCIATOR ILLUMINATED DURING APPROACH. FOUND MIDBOARD ASYMMETRY DETECTOR READING 5.7 VOLTS. FOUND IB ASYMMETRY DETECTOR READING 7.8 VOLTS. ADJUSTED LT AND RT FLAP POSITION TRANSMITTERS AS REQUIRED IAW MM TO BRING VOLTAGES TO 5.8 VOLTS 0.2 VOLTS. FLAP SYSTEM FUNCTIONAL CHECKS SATISFACTORY, NO ASYMMETRY FAULTS INDICATED AFTER 20 CYCLES. (K)

2005FA0001482

BEECH

CONT

 

CRANKSHAFT

CRACKED

10/14/2005

50  

IO470*

 

633620

ENGINE

CRANKSHAFT DEVELOPED CRACK BEHIND PROP FLANGE .3333 - .5 AROUND SHAFT IN FLIGHT, LEAKED OIL STEADY ON GROUND RUN. (EA21200603317) (K)

2005FA0001480

BEECH

CONT

 

CLAMP

LOOSE

10/18/2005

58P  

TSIO520WB

 

 

INTERCOOLER DUCT

IN CRUISE FLIGHT, 2500 RPM, 35 HG, PILOT NOTED L/ENGINE LOST POWER. PILOT FEATHERED PROPELLER AND POWERED ENGINE. MAINT NOTED INTERCOOLER DUCT, PN 102-389003-3 LOOSE AT DUCT SERV CLAMP WAS LOOSE, DUCT WAS PARTIALLY DETACHED. REPLACED DUCT, RUNUP OK. (K)

CA051013007

BEECH

PWA  

 

BULKHEAD

CRACKED

10/12/2005

A100

PT6A28

 

 

FUSELAGE

DURING A SPECIAL INSPECTION AFTER FINDING DAMAGE ON TWO OTHER AIRCRAFT, (SDR 20050829003 AND 20050928001) AFT PRESSURE BULKHEAD WAS FOUND CHAFFED BY THE CENTER INTERCOSTALS ADJACENT TO THE TAIL ACCESS DOOR. NDT WAS COMPLETED AND A CRACK FOUND.

CA050928001

BEECH

PWA  

 

BULKHEAD

CRACKED

9/23/2005

A100

PT6A28

 

 

FUSELAGE

(CAN) DURING A SPECIAL INSPECTION AFTER FINDING DAMAGE ON ANOTHER AIRCRAFT, (SDR 20050829003) THE SAME TWO AREAS OF THE AFT PRESSURE BULKHEAD WERE FOUND CHAFED BY THE TWO INTERCOSTALS ADJACENT TO THE TAIL ACCESS DOOR. NDT WAS COMPLETED AND THERE WERE NO CRACKS FOUND. THE INTERCOSTALS WERE TRIMMED BACK TO MAINTAIN A CLEARANCE WHEN THE AIRCRAFT IS PRESSURIZED AND PREVENT FURTHER CHAFING AND POSSIBLE CRACKING. WE HAVE SET UP A FLEET CAMPAIGN TO INSPECT ALL OF OUR AIRCRAFT AS THEY COME DUE FOR THEIR NEXT PHASE INSPECTION.

CA050912001

BEECH

PWA  

BEECH

SUPPORT

CRACKED

9/9/2005

A100

PT6A28

 

1156100151

TORQUE TUBE

(CAN) DURING ACCOMPLISHMENT OF SB 2145 CRACK WAS DETECTED ON TORQUE TUBE ASSEMBLIES (P/N 115-610015-325). FOUND AT IB SUPPORT (P/N 115-610015-1). TORQUE TUBE REPLACED.

CA051019004

BEECH

 

BEECH

TRIM TAB

DEBONDED

10/17/2005

B100

 

 

96630000335

RUDDER

(CAN) DURING COMPLIANCE WITH RAYTHEON S/B 55-2365 REV.2 ISS. OCT 2005 MAINTENANCE FOUND THE RUDDER TAB DISBONDED ON LOWER END. MAINTENANCE REPLACED THE RUDDER TAB AND RELEASED THE AIRCRAFT. RESEARCH ON THIS AIRCRAFT DISCOVERED THAT RAYTHEON S/B 2 365R1 (A/D 92-07-05) HAD BEEN COMPLIED WITH IN 1992. THIS AREA IS CALLED UP IN THE MAINTENANCE SCHEDULE TO BE INSPECTED EVERY PHASE 2 AND 4. SUGGEST ALL OPERATORS INSPECT THIS AREA CLOSELY FOR DISBONDING NOT JUST THE DRAIN HOLE ITSELF.

CA050921001

BEECH

GARRTT

 

DOOR FRAME

CRACKED

9/16/2005

B100

TPE3316252B

 

50430043BG5

FUSELAGE

(CAN) DURING A DAILY INSPECTION 2 CRACKS WERE DETECTED ON EACH SIDE OF THE UPPER ATTACHMENT FOR THE REAR DOOR. THE PART WAS REPLACED.

CA051004006

BEECH

GARRTT

 

FIRE DETECTOR

FAILED

9/26/2005

B100

TPE3316252B

 

30215B

ENGINE BAY

(CAN) AFTER TAKE OFF AN (ENGINE FIRE) INDICATION FOR THE RT ENGINE ILLUMINATED. PILOT SHUT DOWN THE ENGINE AND LANDED ON ONE ENGINE. AFTER INSPECTION OF THE SYSTEM, NO FAULT FOUND, SYSTEM NORMAL. AIRCRAFT RETURNED TO SERVICE.

2005FA0001409

BEECH

PWA  

 

TORQUE TUBE

FAILED

10/5/2005

B200

PT6*

 

1016100195

LT ELEVATOR

FOUND LT ELEVATOR TORQUE TUBE MOUNTING FLANGE FROM TUBE ASSY TO ELEVATOR RIVETS WORKING LOOSE, ALLOWING THE LT ELEVATOR TO HAVE 1.5 INCHES OF PLAY. THIS WAS FOUND DURING A 400 HOUR LUBRICATION AND INSPECTION. RECOMMENDATION TO PREVENT RECURRENCE, USE SOLID RIVET NOT BLIND RIVET. (K)

CA051003007

BEECH

PWA  

 

MOTOR

FAILED

9/13/2005

B200

PT6A42

 

481 

MLG 

(CAN) UPON SELECTION OF GEAR DOWN, PILOT NOTICED THAT GEAR WOULD NOT EXTEND AND THAT THE CIRCUIT BREAKER HAD POPPED. HE RESET IT AND SELECTED GEAR DOWN AGAIN WITHOUT ANY SUCCESS. PILOT USED EMERGENCY EXTENSION AND LANDED WITHOUT INCIDENT. UPON INSPECTION OF LANDING GEARPOWER PACK MOTOR BY ENGINEER, IT WAS FOUND TO BE SHORTED OUT. MOTOR WAS REPLACED AND EXTENSION/RETRACTION SYSTEM FUNCTIONALLY CHECKED SERVICEABLE.

CA050912006

BEECH

PWA  

 

PRESSURE VALVE

WORN

9/8/2005

B200

PT6A42

 

5038017027

CABIN PRESSURE

(CAN) REMOVED LT PNEUMATIC CHECK VALVE TO INSPECT INTERNAL HINGE OPERATIONS. FOUND HINGE PIN DISLODGED (WORKED) TO ONE SIDE, RESULTING IN OFFSET FLAPPER DOOR MOVEMENT, WEAR AND POOR OPERATION. A LONGER HINGE PIN OR STAKING THE ORIGINAL PIN MAY PREVENT THIS TYPE OF MALFUNCTION.

CA051003002

BEECH

PWA  

 

WINDSHIELD

FRACTURED

9/29/2005

B300B350C

PT6A60A

 

10138402515

COCKPIT

(CAN) WHILE ON ROUTE, AT 23,000 FEET AT 12 NOON, OAT -25 C, WINDSHIELD HEAT ON. THE PILOTS (LT) INNER LAYER OF WINDSHIELD FRACTURED WITHOUT WARNING DURING FLIGHT. NO LOSS OF CABIN PRESSURE OR OTHER EFFECTS FROM WINDSHIELD DELAMINATING. EMERGENCY WAS DECLARED AND THE AC WAS LANDED WITH OUT FURTHER INCIDENT.

CA051005011

BEECH

PWA  

 

ENGINE

FAILED

8/29/2005

C90  

PT6A21

 

 

 

(CAN) DURING CRUISE THE ENGINE EXPERIENCED AN UNCOMMANDED INCREASE IN TORQUE AND TEMPERATURE AND WAS SHUTDOWN IN FLIGHT. A SUBSEQUENT RESTART ATTEMPT WAS UNSUCCESSFUL AND A SINGLE ENGINE LANDING WAS ACCOMPLISHED AT POINT OF DESTINATION. WILL MONITOR INVESTIGATION OF THE EVENT AND WILL ADVISE OF ROOT CAUSE ONCE ESTABLISHED.

CA050915004

BEECH

PWA  

 

BOLT

BROKEN

9/15/2005

C90A

PT6A21

 

AN3H32A

VANE 

(CAN) CREW ENTERED DEFECT IN JOURNEY LOGBOOK, (RT ANTI-ICE LIGHT ON. VISUAL INSPECTION INDICATES BY-PASS DOOR FULLY DOWN, DEFLECTOR DOOR HALF WAY DOWN). MAINTENANCE CREW FOUND A BOKEN BOLT IN LINKAGE P/N AN3H-32A. (REFER TO IPC 30-20-02 PAGE 0 ITEM 35) RT ENGINE COMPRESSOR CHECKED FOR FOD DAMAGE. NO DEFECTS FOUND. THE BOLT WAS REPLACED, SYSTEM CHECKED AND AIRCRAFT RETURNED TO SERVICE.

2005FA0001440

BEECH

CONT

 

RELAY

INTERFERENCE

10/6/2005

F33A

IO520*

 

SM50D7

DYNAMIC BREAKER

PILOT REPORTED AFTER PUTTING THE GEAR SELECTOR IN THE DOWN POSITION, THE GEAR WOULD NOT EXTEND, AFTER CYCLING GEAR SELECTOR GEAR WENT DOWN, AC RETURNED TO BASE. ON TROUBLESHOOTING, THE MECHANIC SELECTED DOWN AND IT FAILED TO EXTEND, AFTER TAPPING ON TOP OF RELAY THE GEAR WENT DOWN. PROBABLE CAUSE AT THIS TIME IS UNKNOWN. INSTALLED NEW AND IMPROVED RELAY IAW DATE CODE. (K)

CA051001001

BELL

LYC  

 

CROSSTUBE

CRACKED

9/30/2005

205A1

T5313B

 

212321103

MLG 

(CAN) HIGH SKID GEAR. UPON LANDING THE FRONT CROSS TUBE CRACKED IN THE MIDDLE OF THE TUBE, BETWEEN THE MOUNTING SADDLES. FROM THE INFORMATION WE HAVE AT THIS TIME, THE AIRCRAFT WAS NOT HARD LANDED.

CA050916003

BELL

ALLSN

 

FILTER

INCORRECT

9/14/2005

206B

250C20

 

500751

ENGINE OIL

(CAN) A PHYSICAL DIFFERENCE WAS NOTICED ON FILTERS 50-075-1. A SCREEN HOLE PATTERN WAS FOUND TO BE OUT OF SPECIFICATION.

CA050912002

BELL

ALLSN

 

BUSHING

CRACKED

8/31/2005

206B

250C20

 

C4264145

TRUNNION

(CAN) AFTER DISASSEMBLY THIS ITEM WAS SENT FOR NDT AND WAS RETURNED WITH CRACK INDICATIONS.

CA050914003

BELL

ALLSN

BELL

BEARING RACE

BRINELLED

9/14/2005

206B

250C20

 

047641175001

T/R HUB

(CAN) TAIL ROTOR HUB ASSY WAS REMOVED TO REPLACE TX BLADES. TO ALLOW A PROPER STATIC BALANCE THE YOKE WAS TAKEN APART AND CLEANED. ONE INNER RACE ON THE YOKE WAS SERVICEABLE, THE OTHER RACE WAS FOUND BADLY BRINELLED. THE ASSEMBLY LOOKED TO BE PROPERLY GREASED AT TIME OF DISASSEMBLY, HOWEVER THE GREASE ON THE BRINELLED SIDE WAS SLIGHTLY REDDISH BROWN. NO SIGN OF CORROSION IN THE ASSEMBLY. BOTH INNER RACES WERE REPLACED AT THIS TIME.

CA050919003

BELL

ALLSN

 

GOVERNOR

MALFUNCTIONED

8/19/2005

206B

250C20

 

25491701

ENGINE

(CAN) DROOPING NR, AND WOULD NOT RECOVER. GOVERNOR REPLACED, NO FURTHER DEFECTS.

CA050919005

BELL

ALLSN

 

SERVO

LEAKING

8/18/2005

206B

250C20

 

41103750017

MAIN ROTOR

(CAN) HYDRAULIC LEAK WAS NOTED DURING MAINTENANCE. SERVO REPLACED, NO FURTHER DEFECTES NOTED.

CA051017007

BELL

ALLSN

 

GOVERNOR

UNSERVICEABLE

9/1/2005

206B

250C20

 

252476914

ENGINE

NR WAS REPORTED AS SURGING WITH EVERY COLLECTIVE MOVEMENT. LINEAR ACTUATOR DISCONNECTED FROM GOVERNOR LEVER AND LEVER WAS FOUND TO BE VERY DIFFICULT TO ROTATE. WHEN FORCED TO ROTATE THE ARM WOULD RELEASE AND BIND INTERMITTENTLY. GOVERNOR REPLACED AND A/C RETURNED TO SERVICE.

CA051017008

BELL

ALLSN

BELL

FITTING

UNSERVICEABLE

8/30/2005

206B

250C20

 

 

STABILIZER

RT HORIZONTAL STABILIZER MOUNT FITTING FOUND CRACKED. THE STABILIZER SPAR WAS FOUND DAMAGED AS A RESULT OF THE FITTING DAMAGE AND WAS REPLACED ALONG WITH THE STABILIZER.

CA051003008

BELL

ALLSN

ALLSN

LABYRINTH SEAL

LEAKING

5/27/2005

206B

250C20B

250C20B

23038241

RT EXHAUST

(CAN) SUBJECT ENGINE WAS REMOVED FROM A/C FOR EXCESSIVE OIL VENTING FROM EXHAUST. THE DIFFUSER VENT ORIFICE HAD BEEN PREVIOUSLY ADJUSTED TO REDUCE VENTING, BUT WAS UNSUCCESSFUL. THE ENGINE WAS SENT BACK TO ENGINE SHOP FOR REPAIR. THE TURBINE WAS DISMANTLED BY THE ENGINE SHOP, AND THE POWER TURBINE LABYRINTH SEALS WERE ADJUSTED AS REQUIRED. THEY ALSO REPAIRED CRACKS FOUND IN COMBUSTION SECTION, TO ALLEVIATE EXCESS VENTING. THE ENGINE WAS INSTALLED IN THE TEST CELL AND RUN UP. THE ENGINE SHOP REPORTED NO OIL VENTING FOUND DURING THE RUNUP. THE ENGINE WAS RETURNED AND REINSTALLED IN THE AIRCRAFT. THE AIRCRAFT WAS RUNUP AND RETURNED TO SERVICE.

CA051012007

BELL

ALLSN

 

HINGE

BROKEN

9/27/2005

206L

250C20R2

 

206033111023

BATTERY DOOR

ON APPROACH WITH A SLING LOAD THE BATTERY DOOR OPEN AT A SPEED OF 60 MPH AND THE DOOR HINGE BROKE. THE DOOR STAYED ATTACH TO THE AIRCRAFT BY THE SPRING P/N 206-031-155-005. NO OTHER DAMAGES HAVE BEEN FOUND ON THE AIRCRAFT. AFTER INVESTIGATION, THE HINGE P/N 206-033-111-023 HAVE BEEN FOUND THAT IT WAS PARTIALLY BROKEN BEFORE THE INCIDENT. ALSO, THE D2U5 FASTENER USED TO KEEP THE DOOR IN CLOSE POSITION WHERE A DASH TOO LONG WITH THE RESULT THAT YOU COULD CLOSE THEM TO FAR OUT OF THE LOCK POSITION IN A WAY THAT IT NEEDED JUST A WEAK FORCE TO MOVE THEM IN THE OPEN POSITION. AFTER HINGE REPLACEMENT THE USE OF PROPER D2U5 LENGTH ALONG WITH RED LINE FOR LOCK POSITION FOR PREVENTION.

CA051018006

BELL

ALLSN

BELL

RESTRAINT

DELAMINATED

10/12/2005

206L1

250C28

 

206033506101

XMSN MOUNT

DELAMINATION FOUND ON AFT TRANSMISSIN MOUNT ELASTOMERIC. MOUNT CHANGED.

CA051004004

BELL

ALLSN

 

CONTACTOR

BURNED

9/6/2005

206L1

250C28

 

SM20ACD200A21

BATTERY

(CAN) DURING CRUISE PORTION OF A SHORT (15 MIN) CREW TRANSFER FLIGHT, THE PILOT AND 2 PASSENGERS ABOARD SMELLED/SAW FUMES/SMOKE IN COCKPIT. ELECTRICAL SYSTEMS WERE SHUTDOWN AND AN UNEVENTFUL LANDING WAS CARRIED OUT NEAR CAMP SITE. UPON INVESTIGATI ON, IT WAS DISCOVERED THAT THE FORWARD BODY RETENTION SCREW AND INSERT HAD BECOME DISBONDED AND WORKED UP INTO CONTACTS SHORTING THE POSITIVE TERMINAL TO GROUND, VAPOURIZING THE INSERT AND PORTION OF SCREW AND BURNING THE SURROUNDING AREA. BETTER INTERNAL BONDING AND/OR COVERING OF THE INSERT COULD HAVE PREVENTED SAID MALFUNCTION.

CA051003003

BELL

ALLSN

 

BLEED VALVE

MALFUNCTIONED

9/11/2005

206L1

250C28B

 

23005367

COMPRESSOR

(CAN) TOT RUNNING TO WARM. BLEED VALVE STICKING OPEN. BLEED VALVE CHANGE PROBLEM GOES AWAY.

CA051005004

BELL

ALLSN

 

FITTING

CRACKED

10/4/2005

206L1

250C28B

 

206031403005

TAILBOOM

(CAN) CRACKED FITTING ON TAILBOOM PN 206-033-004-045 AFMA FITTING P/N 206-031-403-005

CA050920005

BELL

ALLSN

 

PUMP

WORN

9/15/2005

206L1

250C30

 

206076050

HYDRAULIC SYS

(CAN) PUMP SPLINES INSPECTED DURING ROUTINE 1200 HOUR INSPECTION AND FOUND SPLINE TEETH WORN. THERE IS NO SET INSPECTION TIME CALLED UP IN THE MFG MM AND REPORTS FROM OTHER OPERATORS INDICATE THAT THIS SPLINE SHOULD BE INSPECTED APROX. EVERY 600 HOURS.

CA050916004

BELL

 

 

FILTER

IMPROPER PART

9/14/2005

206L4

 

 

500751

TRANSMISSION

(CAN) A PHYSICAL DIFFERENCE WAS NOTICED ON FILTERS 50-075-1. A SCREEN HOLE PATTERN WAS FOUND TO BE OUT OF SPECIFICATION. ATTACHED PICTURE SHOWING DIFFERENCES BETWEEN ACCEPTABLE AND NON-CONFORMING PARTS.

CA051006011

BELL

PWA  

BELL

PANEL

DEBONDED

10/4/2005

212  

PT6T3

212030100067

205032813041

TAILBOOM

(CAN) DEBONDED BEYOND LIMITS ON LT SIDE BETWEEN STATION 241.22 AND 324.51.

CA051017009

BELL

PWA  

 

FUEL HEATER

UNSERVICEABLE

9/9/2005

212  

PT6T3

 

10544E

NR 2 ENGINE

NR 2 ENGINE FUEL HEATER FOUND TOO HOT TO TOUCH FOLLOWING SHUTDOWN. HEATER REPLACED AND A/C RETURNED TO SERVICE.

MDR01KH2005

BELL

 

 

BOLT

SHEARED

10/10/2005

222  

 

 

200571045D

M/R CONTROLS

UPON INSPECTION AND MAINTENANCE OF MAIN ROTOR CONTROLS, INSPECTION REVEALED SHEARED BOLT (PN 20-057-10-45D) AT BOLT HEAD AT THE M/R SWASH PLATE COLLECTIVE LEVER IDLER LINK. (ATTACH BOLTS) MFG A- NR 28 BOLT, MFG U-NR 28 BOLT. THIS CONDITION HAS BEEN REPORTED TO MFG FOR INVESTIGATION ADN ANALYSIS OF CAUSE. ALL REMAINING COMPANY HELICOPTERS HAVE BEEN INSPECTED FOR LIKE CONDITION AND FOUND AIRWORTHY. (K)

CA050919002

BELL

 

 

FILTER

WRONG PART

9/14/2005

407  

 

 

500751

TRANSMISSION

(CAN) A PHYSICAL DIFFERENCE WAS NOTICED ON FILTERS 50-075-1. A SCREEN HOLE PATTERN WAS FOUND TO BE OUT OF SPECIFICATION. PICTURE SHOWING DIFFERENCES BETWEEN ACCEPTABLE AND NON-CONFORMING PARTS.

CA050913007

BELL

ALLSN

 

BEARING

SHEARED

9/9/2005

407  

250C47B

 

407310101101

CENTER SUPPORT

(CAN) BEARING SHEARED FROM THE CENTER SUPPORT.

CA051004007

BELL

ALLSN

 

BLADE

DAMAGED

9/8/2005

407  

250C47B

 

23053299

TURBINE WHEEL

(CAN) AIRCRAFT LIFTED OFF STAGING AREA WITH SLING LOAD. LOUD NOISE HEARD 2 MINUTES INTO FLIGHT. NO CAUTION LIGHTS OR OTHER INDICATION OF PROBLEM OTHER THAN LOUD AND HIGH-PITCHED NOISE. AIRCRAFT TURNED BACK AND MADE A NORMAL LANDING AND SHUT-DOWN. TURBINE WAS REMOVED AND SENT FOR INSPECTION. ONE BLADE FOUND MISSING FROM FIRST STAGE TURBINE WHEEL. SUSPECT CAUSED BY TIP RUB. INFORMATION AND PHOTOS FORWARDED TO MFG.

2005FA0001504

BELL

ALLSN

 

SKIN

DEBONDED

11/2/2005

407  

250C47B

 

206020113223

VERTICIAL FIN

LESS THAN 10 HOURS FLIGHT TIME AFTER REPAIR FOR LEADING EEDGE DISBONDING THE BONDING FAILED AND TAIL ROTOR WASH DISPLACED THE LEADING EDGE. (K)

CA050927001

BELL

 

BELL

PACKING

FAILED

9/22/2005

412EP

 

212076007003

MS28775212

ACCUMULATOR

(CAN) DURING FTP'S, MS28775-212 PACKING FAILED CAUSING LOSS OF HYDRAULIC FLUID FROM ACCUMULATOR ASSY, 212-076-007-003.

2005FA0001531

BELL

 

 

SOLENOID

STUCK

10/12/2005

430  

 

 

3136171

DIVERTER VALVE

SOLENOID FAILED IN ENERGIZED POSITION. THIS UNIT IS IN THE DUCTING DIVERTER VALVE MAKING IT SUBJECT TO MOISTURE. THIS CORRODES THE UNIT OVER TIME. IT FAILED ON, THUS DIVERTING AIR IN THE WRONG DIRECTION. HEAT WILL COME OUT OF OVERHEAD CABIN DUCTS.

CA051007003

BOEING

CFMINT

 

BELLCRANK

CORRODED

10/4/2005

737500*

CFM563C

 

65C308461

TE FLAPS

(CAN) DURING A ROUTINE DAILY CHECK,IT WAS NOTED THAT THE LT OB T/E FLAP HAD EXCESSIVE PLAY WHEN HAND FORCE WAS APPLIED TO THE TRAILING EDGE FLAP. UPON FURTHER INVESTIGATION IT WAS DISCOVERED THAT THE CLEVIS BOLT AND THE BELLCRANK WERE WORN AND CORRODED. BELLCRANK AND CLEVIS REPLACED.

CA051003001

BOEING

CFMINT

 

SCREW

DAMAGED

10/1/2005

737522

CFM563C1

 

BACB30NN4K12

RT WING

(CAN) AFTER LANDING, AFTER THE AIRCRAFT WAS REFUELED, FUEL WAS OBSERVED COMING FROM THE RIGHT WING FORWARD OF THE IB FLAP TRACK. THE FUEL ACCESS PANEL DIRECTLY AFT OF THE RT WING NACELLE WAS FOUND LEAKING. ON INVESTIGATION SEVERAL SCREWS WERE FOUND TO BE STRIPPED AND LOOSE. AFTER RESEALING THE ANCHOR NUTS AND REPLACING THE SCREWS, THE TANK WAS LEAK CHECKED SERVICEABLE. THE ACCESS PANEL HAD LAST BEEN REMOVED, DURING A PRE-LEASE C-CHECK.

CA051007006

BOEING

CFMINT

BOEING

DISPLAY

FAILED

10/6/2005

7377CG

CFM567B22

 

50401100003

SEAT 13B, VDU

(CAN) A/C WAS ON THE GROUND WHEN A BURNING ELECTRICAL SMELL WAS NOTICED AT ROW 13. SEAT 13B WAS DEACTIVATED. MAINTENANCE REPLACED THE VDU AND THE SYSTEM WAS TESTED SERVICEABLE. THIS COMPONENT WILL BE RETURNED TO THE MANUFACTURER AND A COMPLETE TEAR DOWN REPORT WILL BE REQUESTED. THIS SDR WILL BE UPDATED ONCE THAT INFORMATION IS AVAILABLE.

2005FA0001479

BOEING

GE  

 

WIRE

CROSSED

10/26/2005

737800*

CFM56*

 

 

CONTROL VALVE

DURING TROUBLESHOOTING FOLLOWING PTU TEST FIRE, THE PTU CONTROL VALUE AS FOUND FAILED IN CLOSED POSITION WITH 28 VDC ON PIN: 2 OF VALVE CONNECTOR. AN INVESTIGATION REVEALED WIRES WERE CROSSED AT MFG. WIRING REMADE IAW WDM2911 AND NEW VALVE FIT. (SW15200606366) (K)

CA051006009

BOMBDR

PWC  

PWC  

FADAC

MALFUNCTIONED

9/14/2005

DHC8400

PW150A

PW150A

 

ENGINE

(CAN) AFTER TAKE-OFF THE ENGINE (FADEC FAIL) WARNING ANNUNCIATED. THE ENGINE WAS SHUTDOWN IN FLIGHT AND THE AIRCRAFT DIVERTED TO POINT OF DEPARTURE. INSPECTION REVEALED FAULT CODES ON BOTH FADEC CHANNELS. THE FADEC, FUEL CONTROL UNIT AND BLEED VALVES WERE SUBSEQUENTLY REMOVED FOR INVESTIGATION. MFG WILL INVESTIGATE THE INCIDENT AND ADVISE OF ROOT CAUSE, ONCE ESTABLISHED.

CA051017002

BOMBDR

PWC  

 

PRESSURE SWITCH

DEFECTIVE

10/7/2005

DHC8400

PW150A

312242902

1030032

NR 2 ENGINE OIL

IN-FLIGHT SHUTDOWN OF THE NR 2 ENGINE DUE TO LOW OIL PRESSURE CAUTION LIGHT, OIL PRESSURE INDICATION WAS NORMAL. PILOTS INITIATED CHECKLIST AND PERFORMED SHUTDOWN AND RETURNED TO BASE. ENGINE IS A MODIFIED CIS ENGINE. THE PROBLEM WAS FOUND TO BE A DEFECTIVE LOW OIL PRESSURE SWITCH. THE OIL WAS A NORMAL COLOR AND PROPER QUANTITY, THE FILTERS WERE CLEAR. LOW OIL PRESSURE SWITCH REPLACED, SYSTEMS CHECKED, A/C RETURNED TO SERVICE.

CA051011011

BOMBDR

PWC  

PARKERHANFIN

SHAFT

SHEARED

10/7/2005

DHC8400

PW150A

 

6617302

NR 2 OIL PUMP

AIRCRAFT SUFFERED A NR 2 EDP FAILURE DURING APPROACH. ON INVESTIGATION, THE QUILL DRIVE WAS FOUND SHEARED AND THE CASE DRAIN DPI HAD ACTIVATED, THE FILTER WAS FULL OF BRASS. NR 2 EDP REPLACED.

2005FA0001481

BRAERO

PWA  

 

DRAIN

CHAFED

10/4/2005

BAE1251000A

PW305

 

259SF3325

HYD PUMP

RT HYDRAULIC PUMP CASE DRAIN HYDRAULIC LINE RUPTURED IN FLIGHT, DRAINING HYDRAULIC FLUID FROM THE AIRCRAFT SYSTEM. FOUND RT HYDRAULIC PUMP CASE DRAIN LINE CRACKED WHERE LINE HAS BEEN CHAFING. INSPECTED AIRCRAFT AND FOUND SIMULAR CHAFE IN SAME LINE IN SAME LOCATION IN AFT EQUIPMENT BAY. THIS APPEARS TO BE A COMMON PROBLEM IN THE 1000 SERIES AIRCRAFT WITH THE PROXIMITY OF THE AFT BAY HYDRAULIC LINE RUNS. (K)

2005FA0001474

BRAERO

GARRTT

 

BULB

IMPROPER PART

10/12/2005

BAE125800A

TFE731*

 

6335110

CABIN LIGHTING

A SELA FLORESCENT BULB WAS FOUND IN THE CABIN LIGHTING SYSTEM. THIS SYSTEM IS AN ALC SYSTEM. THE SELA BULB HAD IMPROPER CONNECTORS ON IT AS WELL. WE CHANGED OUT THE SELA BULB WITH AN ALC BULB AND USED THE PROPER CONNECTORS WHEN INSTALLING IAW AD 95-22-01 AND IB 90-001. (K)

2005FA0001528

BRAERO

PWA  

 

EXTINGUISHER

INCORRECT

11/8/2005

HAWKER1000

PW305

 

C352TS

COCKPIT

REMOVING HAND HELD FIRE EXTINGUISHER FROM THE COCKPIT FOR ROUTINE INSPECTION IT WAS NOTED THAT THE HANDLE DID NOT APPEAR TO BE CORRECT. FURTHER INSPECTION SHOWED THAT THERE ARE TABS ON THE LOWER HANDLE THAT WOULD HAVE PREVENTED THE EXTINGUISHER FROM DISCHARGING. NUMEROUS ATTEMPTS AT DISCHARGING FAILED. IT APPEARS THAT AN INCORRECT HEAD WAS INSTALLED. SUBJECT FIRE EXTINGUISHER WAS REMOVED FROM SERVICE. (K)

CA051006008

BRAERO

PWA  

 

ENGINE

LEAKING

9/13/2005

HS125700A

PW305B

 

 

 

(CAN) DURING CLIMB, THE CABIN AIR BECAME CONTAMINATED WITH SMOKE. ECS WAS SELECTED OFF AND AN EMERGENCY DECLARED. SUBSEQUENT INSPECTION FOUND EXTERNAL ENGINE OIL LEAKAGE. MFG WILL INVESTIGATE THE INCIDENT AND ADVISE OF ROOT CAUSE, ONCE DETERMINED.

2005FA0001494

CESSNA

 

CESSNA

SCREW

CORRODED

10/21/2005

 

 

 

AN5158R26

TRIM TAB

THERE ARE 4 SCREWS WHICH HOLD THE ELEVATOR TRIM TAB HORN TO THE TRIM TAB. HAVE STARTED TO REMOVE THESE SCREWS ON EVERY ANNUAL WE DO ON 300/400 SERIES. HAVE FOUND NUMEROUS SCREWS CORRODED ALMOST IN HALF. THERE IS NOT A WAY TO INSPECT THESE SCREWS WITHOUT REMOVAL. DUE TO THE CRITICAL NATURE OF THESE SCREWS AND THE AGEING FLEET. RECOMMEND MANDITORY REMOVAL AND INSPECTION AT EACH ANNUAL INSPECTION. (K)

CA050926002

CESSNA

CONT

 

ROCKER BOSS

FAILED

9/26/2005

150M

O200A

 

 

CYLINDER

(CAN) ON INSPECTION, BRASS AND ALUMINUM PARTICLES FOUND IN FILTER. ROCKER BOSSES AND BUSHINGS FOUND WORN. THIS SHOWS UP AT ABOUT 200 HRS IN SERVICE AND HAS HAPPENED TO ALL CYLINDERS THAT ARE FACTORY NEW IN THE LAST COUPLE OF YEARS. ACCORDING TO THE FACTORY WE ARE THE ONLY OPERATOR THAT THIS HAS HAPPENED TO, THEIR FIX IS TO BUSH THE BOSSES WHICH THEY WILL DO UNDER WARRANTY BUT THEY WILL NOT DO IT RT FROM THE FACTORY WHICH CAUSES A GREAT DEAL OF DOWN TIME COST.

2005FA0001520

CESSNA

LYC  

 

FLOORBOARD

CRACKED

11/1/2005

152  

O235L2C

 

 

FUSELAGE

FOUND FLOORBOARD SKIN ABOVE THE LT AND RT GEAR BOXES, CRACKED AT THE INSPECTION HOLES. CRACKS RAN FROM THE EDGE OF THE HOLE TO THE SCREW HOLE FOR THE INSPECTION PLATE. INSTALLED A REINFORCEMENT UNDER THE DOUBLER AND STOP DRILLED THE CRACKS. (K)

CA051011007

CESSNA

LYC  

 

SKIN

CRACKED

10/4/2005

172L

O320E2D

 

052300710

TE FLAP

SEVERAL CRACKS IN SKIN THROUGH RIVET HOLES IN TRAILING EDGE. THIS SKIN IS IN THE FLAP BAY. SUSPECT FAILURE IS DUE TO FLEXING OF TRAILING EDGE, CAUSED BY TURBULENCE IN SLOW FLIGHT WITH FLAPS LOWERED. AIRCRAFT IS USED SOLELY FOR FLIGHT TRAINING.

05308

CESSNA

LYC  

LYC  

SEAL

LEAKING

11/4/2005

172M

O320E2D

 

STD-2217

VAC PUMP DR ASSY

DURING 100 HOUR INSPECTION, FOUND ENGINE VACUUM PUMP DRIVE LEAKING OIL AND CONTAMINATING VACUUM PUMP. REMOVED VACUUM PUMP AND ENGINE VACUUM PUMP ADAPTOR DRIVE ASSEMBLY. FOUND SEAL P/N STD-1774 NOT FULLY INSTALLED IN DRIVE ASSY. REPLACED SEAL AND VACUUM PUMP, OPERATIONAL AND LEAK CHECK SAT. ENGINE HAS 168.7 HOURS SINCE OVERHAUL BY MFG. THIS IS THE SECOND OVERHAULED ENGINE WITH THIS DISCREPANCY.

CA051004005

CESSNA

LYC  

 

MOUNT

BROKEN

9/23/2005

172M

O320E2D

 

05510171

ENGINE

(CAN) DURING A 200 HOUR INSPECTION, DISCOVERED THIS TUBE WAS BROKEN. A REPLACEMENT MOUNT WAS INSTALLED.

CA051003004

CESSNA

LYC  

 

CYLINDER

CRACKED

9/29/2005

172N

O320D2J

 

05K21100

ENGINE

(CAN) CYLINDER HEAD SEPARATED FROM CYLINDER BARREL WHILE IN FLIGHT.

053006

CESSNA

LYC  

ELECTROSYS

DRIVE ASSY

FAILED

11/2/2005

172P

O320D2J

 

480379 01 C1

STARTER

ON ENGINE START, STARTER DRIVE DID NOT DISENGAGE AND THE DRIVE GEARS SHEARED OFF, DAMAGING THE ENGINE RING GEAR. THE PILOT DID NOT DETECT THE FAILURE UNTIL LANDING AND TRYING TO RESTART THE ENGINE.

2005FA0001519

CESSNA

LYC  

LAMAR

COMMUTATOR

DESTROYED

11/1/2005

172R

IO320*

 

 

STARTER

A SEGMENT OF THE COMMUTATOR CAME OFF DURING STARTING, COMPLETELY DISTROYING THE BRUSES AND THE INSIDE OF THE STARTER. (K)

2005FA0001496

CESSNA

LYC  

 

ACTUATOR

CRACKED

10/20/2005

172RG

O360*

 

98820152

MLG DOOR

COMPLYING WITH SB, FOUND BFE BORE CRACKED IAW ILLUSTRATION OF ACCOMPLISHEMENT OF INSTRUCTION OF SEB. (K)

2005FA0001395

CESSNA

CONT

 

CYLINDER

FAILED

8/22/2005

175  

GO300A

 

654004

EXHAUST VALVE

CYLINDER WAS REBUILT 5/12/05 USING CURRENT PRODUCTION MFG EXHAUST VALVE AND GUIDE. THE EXHAUST VALVE STRUCK (17 HOURS IN SERVICE) RESULTING IN A BROKEN EXHAUST ROCKER ARM, AS A RESULT AN EMERGENCY LANDING WAS SUCCESSFULLY MADE. (K)

2005FA0001514

CESSNA

LYC  

 

BULKHEAD

CRACKED

11/8/2005

177RG

IO360A1B

 

17121042

ZONE 200

BULKHEAD CRACKED AROUND BOTH VERTICAL FIN FORWARD ATTACH BOLTS.

2005FA0001513

CESSNA

LYC  

 

BULKHEAD

CRACKED

11/8/2005

177RG

IO360A1B6

 

17121042

BS 263

BULKHEAD CRACKED AROUND BOTH VERTICAL FIN FORWARD ATTACH BOLTS.

2005FA0001477

CESSNA

CONT

 

SUPPORT BRACKET

CRACKED

10/10/2005

182P

O470*

 

 

BEND RADIUS

WING T/E SKIN SUPPT BRKT CRACKED CAUSED FLAP INTERFERENCE AND FAILURE. BRKT IS ATTACHED TO EACH FLAP TRACK RIB INSIDE T/E OF WING, SUPPT T/E WING SKIN IN FLAP BAY. PART CRACKED, ALLOWED FLAP SUPPT TO GET CAUGHT DURING FLAP RETRACTION, BINDING FLAP. FLAP STRUCTURE FAILED BEFORE FLAP MOTOR CAUSED CB TO TRIP. RESULTING CONFIGURATION OF FLAP CAUSED YAW IN FLT. VERY LITTLE CLEARANCE BTWN THESE BRKTS AND/OR CRACKED WING SKINS AT BRKT ATTACH POINT, FLAP SUPPT RAILS BY DESIGN. BRKTS REST FIRMLY AGAINST UPPER PORTION OF FLAP SUPPT RAILS WHEN FLAPS ARE FULLY RETRACTED, PROPERLY RIGGED. BRKT APPEARS TO BE A SUB-PART OF WHOLE RIB ASSY. IRREGULARITY OF RIVET HOLES IN BRKTS, FLAP TRACK RIB, HAND DRILLED AT FACTORY.

2005FA0001429

CESSNA

LYC  

 

WIRE

CHAFED

7/6/2005

182T

IO540*

 

 

TRANSPONDER

TRANSPONDER CIRCUIT BREAKER POPPED AND PILOTS NOTED SMOKE IN CABIN. FLIGHT WAS DISCONTINUED AND DISCREPENCY WAS NOTED. AFTER INSPECTION, CHAFFED WIRE WAS FOUND NEAR THE AVIONICS RACK THAT HAD SHORTED ON THE AIRFRAME. THE WIRES WERE REPAIRED IAW MFG RECOMMENDATION. MFG ALSO RECOMMENDED ANTI-CHAFE BE INSTALLED ON AIRFRAME AT THE LOCATION OF CHAFFING. (WP13200510948) (K)

CA050926005

CESSNA

PWA  

 

CONNECTOR

MELTED

9/26/2005

208B

PT6A114A

 

2601048200

PROP HEAT

(CAN) APPROXIMATELY 5 TO 10 MIN BEFORE LANDING THE PILOT NOTICED A FAINT SMELL OF SMOKE OR SOMETHING BURNING. EVERYTHING WAS OPERATING NORMALLY AND HE LANDED WITHOUT MISHAP. UPON INSPECTION, THE PROP HEAT WIRE CONNECTOR BETWEEN THE CIRCUIT BREAKER AND PROP DE-ICE TIMER WAS FOUND TO BE MELTED AND BURNED. THE WIRE TERMINAL ENDS AND CONNECTOR WERE REPLACED AND THE PROP HEAT SYSTEM FUNCTION CHECKED SERVICEABLE. THE CONNECTOR IS LOCATED ON THE LT SIDE OF THE COCKPIT JUST IN FRONT OF THE CIRCUIT BREAKER PANEL.

CA051027005

CESSNA

CONT

BENDIX

IGNITION LEAD

DETERIORATED

10/14/2005

337G

IO360G

S6LSG25T

IO8216743

MAGNETO CAP

(CAN) ON GROUND RUN, LT MAGNETO ON FRONT ENGINE HAD A 200 RPM DROP. DURING TROUBLESHOOTING FOUND NR 4 CYLINDER TOP LEAD SHORTING FROM INNER COIL THROUGH INSULATOR TO CAP. LEAD REPAIRED, AIRCRAFT RELEASED INTO SERVICE. AFTER A FEW HOURS OF FLIGHT, THE PROBLEM RE-OCCURRED ON RT MAGNETO FRONT ENGINE. REPLACED IGNITION HARNESSES WITH NEW. MAGNETO RT PN S6LSG-25T, SN D03GA258R, LT P/N S6LSG-25, SN D03GA179R.

CA051014003

CESSNA

CONT

 

WASHER

MISSING

10/13/2005

414  

TSIO520N

 

S14505H12063

MLG SCISSORS

AFTER LANDING, THE A/C SUDDENLY VEERED OFF THE RUNWAY. THE RT MAIN LANDING GEAR SCISSORS CAME APART AT THE CENTER. THE WHEEL THEN TURNED AND PULLED THE AIRCRAFT OFF THE RUNWAY. ON EACH SIDE OF THE CENTER BOLT HOLDING THE SCISSORS TOGETHER TWO P/N S1450-5H12-063 WASHERS WERE MISSING. AN WASHERS WERE USED IN THEIR PLACE. THE PROPER WASHERS WERE INSTALLED AND THE AIRCRAFT WAS RETURNED TO SERVICE.

2005FA0001357

CESSNA

CONT

 

MOTOR

MALFUNCTIONED

9/23/2005

414A

TSIO520*

 

HE812933

BLOWER

RT AIR CONDITIONER BLOWER MOTOR LOCATED UNDER CO-PILOTS SEAT MALFUNCTIONED AND PRODUCED SMOKE WHICH WAS DRAWN THROUGH THE RT SIDE VENTILATION DUCTS. PILOT FOLLOWED EMERGENCY PROCEDURES AND LANDED SAFELY. (EA09200505819) (K)

CA051006013

CESSNA

PWA  

 

GEARBOX

SEIZED

9/23/2005

425  

PT6A112

 

 

ACCESSORY

(CAN) DURING CRUISE, THE ENGINE EMITTED A LOUD NOISE ACCOMPANIED BY FLAMES FROM THE EXHAUST AND VIBRATION. THE ENGINE WAS SHUTDOWN IN FLIGHT. SUBSEQUENT INSPECTION REVEALED THE ACCESSORY GEARBOX TO BE SEIZED. MFG WILL INVESTIGATE THE INCIDENT AND WILL ADVISE OF ROOT CAUSE, ONCE ESTABLISHED.

2005FA0001400

CESSNA

GARRTT

 

RIB  

CRACKED

9/13/2005

441  

TPE331*

 

57222061

WINGS

WHILE ACCOMPLISHING MFG CQB 03-1 EDDY CURRENT INSPECTION THE CANTED RIB CAPS WERE FOUND CRACKED ON THE LT AND RT WINGS. THE AIRCRAFT WILL REQUIRE SERVICE KIT SK441-110-1 REPAIR KIT IAW CQB 03-1 BEFORE FURTHER FLIGHT. (K)

CA051011008

CESSNA

PWA  

 

SUPPORT BRACKET

CRACKED

10/7/2005

550  

JT15D4

 

 

RUDDER

PILOT REPORTED THAT WHEN BRAKES WERE APPLIED FROM CAPTS POSITION, THE CO-PILOTS INSTRUMENTS LIGHTS WOULD GO OUT. MAINTENANCE WAS ABLE TO DUPLICATE THE SNAG. INVESTIGATION REVEALED CAPTS RUDDER SUPPORT BRACKET CRACKED AND BROKEN AT TOP AND BOTTOM ATTACH CHANNELS. THREE CHANNELS BEING REPLACED (P/N'S 5565609-6, 5565609-7, 5565609-14). CO-PILOTS LIGHTS AFFECTED DUE TO THE POSITIONING OF A RHEOSTAT LOCATED IMMEDIATELY ABOVE RUDDER SUPPORT. WHEN BRAKES WERE APPLIED, FLEXING IN THE SUPPORT ALLOWED IT TO COME INTO CONTACT WITH THE RHEOSTAT. A FLEET WIDE CAMPAIGN WAS CARRIED OUT WITH NO OTHER DEFECTS OF THIS TYPE NOTED

CA051011010

CESSNA

PWA  

 

LONGERON

CRACKED

10/6/2005

550  

JT15D4

 

202001551

THRUST REVERSER

DURING SCHEDULED INSPECTION, MAINTENANCE FOUND A CRACK ON THE LT THRUST REVERSER LT INNER UPPER LONGERON TAB. THE CRACK STARTED IN FASTENER HOLE AND PROPAGATED TO THE EDGE OF THE TAB. THE CRACK WAS REPAIRED BY FABRICATING AND INSTALLING REPAIR DOUBLER IAW NORDAM STANDARD REPAIR PROCEDURE. MAJOR MOD/REPAIR REPORT FILED WITH T.C.

CA051007005

CESSNA

PWA  

CESSNA

SEGMENT

COLLAPSED

10/6/2005

560CESSNA

JT15D5

651532636

651532629

COOLING SYSTEM

(CAN) DURING CLIMBOUT THE PILOTS HEARD A POP AND THE CABIN ALTITUDE BEGAN TO CLIMB BECAUSE OF LOSS OF PRESSURIZATION. THEY COMMENCED AN EMERGENCY DESCENT AND LANDED SAFELY. ON INVESTIGATION, FOUND THAT THE INLET END OF THE WYE ASSEMBLY OF THE FLOOD COOLING SYSTEM HAD DETERIORATED OVER TIME AND HAD COLLAPSED ENOUGH TO ALL OW THE END TO BE BLOWN OUT OF THE CLAMP. THE WYE ASSEMBLY WAS REPAIRED AND THE SYSTEM REASSEMBLED. THE AIRCRAFT WAS TEST FLOWN AND FUNCTION PERFECTLY.

2005FA0001402

CESSNA

PWA  

 

CONTROL VALVE

SHORTED

1/24/2005

560CESSNA

PW535A

 

OA553191

HYD SYSTEM

FLAP CONTROL VALVE PN 2710970 TO BE MAKING CONTACT WITH DUMP VALVE PN OA55319-1 CAUSING WAS SUBSTIALLY DAMAGE. BY SHORTING THE STAND OFF ON THE BOTTOM SIDE OF THE DUMP VALVE BY APROX .1250 OF AN INCH A CLEARANCE OF APROX .0625 OF AN INCH WAS OBTAINED. (K)

CA051018001

CESSNA

GARRTT

 

TURNBUCKLE

CHAFED

10/17/2005

650  

TFE7313C

 

MS21251B5S

AILERON CONTROL

DURING PHASE 1-5 INSPECTION ON AIRCRAFT, TECHNICIANS DISCOVERED THAT THE LT AND RT AILERON CABLES WERE FOULING. THE RESULT WAS THAT THE LT TURNBUCKLE WAS CHAFED AND THE RT SIDE THE SAFETY CLIP WAS GONE AND THE TURNBUCKLE WAS ALSO CHAFED.

2005FA0001522

CESSNA

ALLSN

 

HINGE BRACKET

CORRODED

10/24/2005

750  

AE3007C

 

67240204

OB AILERON

DURING RECENT INSPECTION CORRODED HARDWARE WAS FOUND ON AILERON. AFTER AILERON WAS REMOVED HEAVY GALLING WAS FOUND ON OUTBOARD HINGE SUPPORT AND AILERON FITTING. SEVERAL OTHER AIRCRAFT WERE INSPECTED AND 3 OTHERS AND IDENTICAL GALLING. MFG WAS NOTIFIED AND REPAIRS MADE,, INCLUDING BLENDING AND NDT. AILERON ARE NOT REMOVED DURALAY INSPECTIONS. BUT CLOSE VISUAL INSPECTIONS SHOULD FIND DEFECTS. AIRCRAFT ARE DAMAGE TOLERANT AND PART IS CONSIDERED. PSE. (K)

2005FA0001498

CESSNA

 

 

ENCODER

FAILED

10/20/2005

A185F

 

 

 

ALTITUDE

FOLLOWING INSTALLATION OF A NEW GNS480, DURING INITIAL POWER CHECKS, FOUND THE FOLLOWING FAILURE FLAGS DISPLAYED: COM COMUNICATION FAILURE, NAV COMMUNICATION FAILURE, ALTITUDE ENCODER COMMUNICATION FAILURE. INSTALLATION OF ANOTHER UNIT RESOLVED THE PROBLEMS. (K)

2005FA0001527

CESSNA

LYC  

SLICK

CAPACITOR

INOPERATIVE

11/3/2005

A188B

TIO540A1A

 

M3984

MAGNETO

OPENED PRESSURIZED MAGNETO TO INSPECT FOR CORROSION DURING ANNUAL INSPECTION. DETECTED A LARGE AMOUNT OF OIL IN AFT CASE OF MAGNETO. FURTHER INVESTIGATION REVEALED THAT IT IS DIELECTRIC FLUID FROM CAPACITOR. TESTED CAPACITOR WITH A SIMPSON METER AND WAS FOUND TO HAVE FAILED. SUBMITTER FEELS THAT MAGNETO FAILURE WAS EMINENT DUE TO OIL CONTAMINATION TO POINTS AND DISTRIBUTOR. SUBMITTER SUGGESTS INSPECTION OF ALL MAGNETOS CONTAINING THS PN CONDENSOR BEFORE FURTHER FLIGHT. (K)

2005FA0001499

CESSNA

CONT

 

MOUNT

CRACKED

10/5/2005

U206F

IO520*

 

 

FUEL TRANSDUCER

DURING A ROUTINE INSPECTION FOUND THE FUEL FLOW TRANSDUCER MOUNT BRACKET CRACKED. (K)

CA051007008

CESSNA

CONT

MCAULY

HUB  

LEAKING

10/6/2005

U206F

IO520F

 

 

PROPELLER

(CAN) DURING AN ROUTINE INSPECTION, THE PROPELLER WAS FOUND LEAKING. PART OF THE INSPECTION CALLS OUT TO ENSURE THERE IS NO RED DYE LEAKING FROM THE PROP HUB ASSEMBLY. THE PROP HAS BEEN REMOVED FROM THE AIRCRAFT AND SENT TO THE OVERHAUL FACILITY. THIS IS THE SECOND TIME THE PROPELLER HAS LEAKED. HAVE ASKED FOR THE HUB ASSEMBLY TO BE NDT TO ENSURE THERE IS NO CRACKS. INSTALLED A LOANED PROP AND THE AIRCRAFT RETURNED TO THE FLIGHT LINE.

2005FA0001398

CESSNA

CONT

 

ATTACH BRACKET

CRACKED

4/16/2005

U206G

IO520*

 

12346251

LT ELEVATOR

DURING AN ANNUAL INSPECTION, THE LT ELEVATOR OB ATTACH HINGE WAS FOUND TO BE CRACKED AT WELD. UPON FURTHER INSPECTION, IT WAS NOTED THAT WELD WAS IN FACT ONLY A SPOT WELD. THIS PART IS SUPPOSED TO BE WELDED THE FULL LENGTH OF THE HINGE. PART APPEARS TO BE THE ORIGINAL FACTORY INSTALLED PART. (K)

CA051003016

CIRRUS

CONT

 

EXHAUST HEADER

CRACKED

10/29/2004

SR20

IO360ES

 

10351002

ENGINE

(CAN) NR5 EXHAUST HEADER FOUND CRACKED 75 PERCENT OF THE WAY AROUND JUST BELOW FLANGE WELD.

CA051003017

CIRRUS

CONT

CIRRUS

NUT  

MISSING

10/3/2005

SR20

IO360ES

10353002

22022

EXHAUST HEADER

(CAN) SOUND OF BACK FIRE WAS HEARD ON LANDING APPROACH. INSPECTION FOUND NR 2 CYLINDER EXHAUST HEADER PIPE HAD DROPS DOWN .1875 DUE TO MISSING EXHAUST NUTS.

2005FA0001507

CIRRUS

CONT

 

EXHAUST HEADER

CRACKED

10/19/2005

SR22

IO550N

 

15070001

NR 5 

NR 5 EXHAUST HEADER CRACKED AT CYLINDER FLANGE JUST BELOW WELD UNDER NORMAL USE. HEADER NEEDS REDESIGN OR SOME SORT OF SUPPORT. IT IS OVER CANTILEVERED FOR STRESSES IMPOSED ON IT. AIRFRAME AND EXHAUST HOURS.

2005FA0001508

CIRRUS

CONT

 

EXHAUST HEADER

CRACKED

10/19/2005

SR22

IO550N

 

15070001

ENGINE

NR 5 EXHAUST HEADER CRACKED AT CYLINDER FLANGE JUST BELOW WELD UNDER NORMAL USE. HEADER NEEDS REDESIGN OR SOME SORT OF SUPPORT. IT IS OVER CANTILEVERED FOR STRESSES IMPOSED ON IT. AIRFRAME ADN EXHAUST HOURS: 33.7

2005FA0001505

CIRRUS

CONT

 

EXHAUST HEADER

CRACKED

10/19/2005

SR22

IO550N

 

15074001

ENGINE

NR 5 EXHAUST HEADER CRACKED AT CYLINDER JUST BELOW FLANGE ONE HALF THE WAY AROUND HEADER UNDER NORMAL USE. HEADER NEEDS REDESIGN OR SOME SORT OF SUPPORT. IT IS OVER CANTILEVERED FOR STRESSES IMPOSED ON IT. NR 6 HEADER CRACKED THRU THE FLANGE FOR A DISTANCE OF ABOUT 1.5 INCHES RADIUSING OUT ALONG THE FLANGE WELD. AIRFRAME AND EXHAUST HOURS: 25.6 (K)

2005FA0001506

CIRRUS

CONT

 

EXHAUST HEADER

CRACKED

10/19/2005

SR22

IO550N

 

15070001

NR 5 

NR 5 EXHAUST HEADER CRACKED AT CYLINDER JUST BELOW FLANGE HALF THE WAY AROUND HEADER UNDER NORMAL USE. HEADER NEEDS REDESIGN OR SOME SORT OF SUPPORT. IT IS OVER CANTILEVERED FOR STRESSES IMPOSED ON IT. NR 6 EXHAUST HEADER CRACKED THRU THE FLANGE FOR A DISTANCE OF ABOUT 1.5 INCHES RADIUSING OUT ALONG THE FLANGE WELD. (K)

CA051004009

CNDAIR

PWA  

 

ANGLE

CRACKED

9/30/2005

CL2151A10

CA3  

 

2153003126

WING 

(CAN) LT AND RT ANGLES FOUND CRACKED WHEN DOING SB 215-454R3 PART B.

CA050920004

CNDAIR

GE  

 

WIRE

OVERHEATED

9/13/2005

CL6002B16

CF343A

 

 

IDG 

(CAN) POST FLIGHT INSPECTION REVEALED EVIDENCE OF OVERHEAT CONDITION FOUND AT 6 O'CLOCK POSITION AT THE COMBUSTOR SECTION FWD FRAME WHEN COWLINGS OPENED TO INVESTIGATE IDG FAILURE. MAINTENANCE PERSONNEL FOUND LOCALIZED AREA WITH OVERHEATED WIRE AND FUEL MANIFOLD INSULATION. NO DAMAGE TO COWLINGS. ENGINE BEING REMOVED AND SENT FOR INVESTIGATION TO OVERHAUL FACILITY.

CA051012006

CNDAIR

GE  

 

CONTROL CABLE

SEVERED

10/10/2005

CL6002B19

CF343A1

 

1600980005

THROTTLE

WHEN BOTH ENGINES WERE REMOVED FOR INSPECTION ACCESS DURING A HEAVY MAINTENANCE VISIT, THE LT ENGINE AUTO THROTTLE RETARD CABLE (ITEM 220 IN FIGURE 2 ON CANADAIR IPC CHAPTER 76-10-00) WAS FOUND SEVERED BETWEEN THE DRILLED JAM NUT (ITEM 125) AND NUT (ITEM 165) AFT OF THE BELLCRANK (ITEM 85).

CA051013001

CNDAIR

GE  

 

BULKHEAD

CRACKED

10/13/2005

CL6002B19

CF343A1

 

 

BS 621

FOUND NUMEROUS CRACKS AT PRESSURE BULKHEAD MARKED BY BLACK MARKING REF 53-61-153 PAGE 9. PRESSURE BULKHEAD CRACKS AT STN 621 REPAIRED IAW REO 601R53-61-1230 AND PROD PERM CRJ-53-21664.

CA051013002

CNDAIR

GE  

 

BULKHEAD

CRACKED

10/13/2005

CL6002B19

CF343A1

 

 

BS 621

REAR PRESS BULKHEAD CRACKED AT LBL 27.5, WL97.5, FS 621.11. REPAIRED PER: REO 601R-53-61-1285. INTEL FITTING, REPAIRED PER REO 601R-53-61-1230 UPPER OF TRACK: AS PER REO 601R-53-61-1458.

CA051013003

CNDAIR

GE  

 

BOLT

SHEARED

10/12/2005

CL6002B19

CF343A1

 

NAS6204L11

RT PYLON

WHILE CARRYING OUT CANADAIR SB601R-53-061 PART C, BOLT P/N NAS6204L11ON THE RT SIDE ENGINE PYLON WAS FOUND SEPARATED IN TWO PARTS. FRACTURE OCCURRED UNDER THE HEAD OF BOLT. BOTH THE HEAD AND SHANK OF THE BOLT LOCATED ARE IN OUR POSSESSION. WILL BE DOING A DETAILED INSPECTION OF THE AREA USING NDT METHOD, SB 601R-54 -005 WHICH WAS NOT PREVIOUSLY DONE WILL BE INCORPORATED IN CONJUNCTION WITH SB601R-53-061. THE ENGINE PYLON BOLTS WILL BE REPLACED.

CA051019000

CNDAIR

GE  

 

EXHAUST PIPE

DETACHED

10/17/2005

CL6002B19

CF343B1

 

2285018124

ENGINE

EN ROUTE LOST THE LT ENGINE EXHAUST NOZZLE DURING CRUISE. THE FLIGHT CREW REPORTED A SLIGHT YAW WHEN THE EXHAUST NOZZLE DETACHED, AND THE FLIGHT ATTENDANT REPORTED A CHANGE IN ENGINE NOISE. THE EXHAUST NOZZLE HAS NOT BEEN RECOVERED. SHORTS BROTHERS SERVICE BULLETIN CF34-78-NAC-024 IS APPLICABLE TO THIS AIRCRAFT/ENGINE, NO EVIDENCE WHERE FOUND THAT SHOWED THAT THE SHORTS SB HAD BEEN PERFORMED.

CA050923001

CNDAIR

GE  

MESSIER

SELECTOR VALVE

FAILED

7/9/2005

CL6002B19

CF343B1

555405

555405

ACTUATOR

(CAN) ON APPROACH THE 3A AND 3B HYD PUMPS WERE TURNED ON. SHORTLY THEREAFTER THE SYSTEM 3 HIGH TEMP MSG CAME ON. QRH FOLLOWED AND TURNED OFF 3A PUMP TO ISOLATE PROBLEM. THE HIGH TEMP WENT OUT. ON SHORT FINAL THE CREW PUT GEAR DOWN, THE GEAR DISAGREE MSG CAME ON ASSOCIATED WITH THE NOSE GEAR. THE CREW FOLLOWED QRH AND PULLED THE LANDING GEAR MANUAL RELEASE, THE NOSE GEAR CAME DOWN FINE. MX REPLACED THE ACTUATOR AND THE SELECTOR VALVE, SWING CHECKS GOOD. PARTS REMOVED: ACTUATOR, P/N 16520-101, VENDOR: MESSIER-DOWTY. SELECTOR VALVE, P/N 55540-5, VENDOR: VICKERS.

CA050923002

CNDAIR

GE  

 

ENGINE

OVERHEATED

5/25/2005

CL6002B19

CF343B1

 

6089T11G01

NR 2 

(CAN) MFG HAS RECEIVED A REPORT WHICH WE FEEL IS A REPORTABLE EVENT. THE FLIGHT CREW REJECTED TAKE-OFF WHEN THEY NOTICED THE AIRCRAFT VEERING TO THE RT ASSOCIATED WITH ENGINE NR 2 OIL PRESSURE AND ITT ABNORMALITIES. TAKE-OFF WAS ABORTED AT APPROXIMATELY 100 KNOTS. RT ENGINE REPLACED.

CA050923003

CNDAIR

GE  

 

PIN  

BROKEN

8/4/2005

CL6002B19

CF343B1

 

BLC3BC09SL5C

COWL 

(CAN) FLIGHT CREW HAD TO SHUT DOWN THE LT ENGINE ON FINAL AS THE LT THROTTLE WOULD NOT RETARD BELOW 93 PERCENT. THE THROTTLE WAS ABLE TO ADVANCE TO PROVIDE MORE POWER, BUT WOULD NOT RETARD BELOW 93 PERCENT. FOUND THAT THE UPPER COWL PIN HOLDING THE ROD HAD BROKEN WHICH LET UPPER CORE COWL SUPPORT ROD POSITION ITSELF AT THE THROTTLE MAIN FUEL CONTROL CONNECTION FROM THE THROTTLE CONTROL BOX. THE PIN ITSELF WAS INTACT, BUT THE TWO SPRING LOADED BALLS AT THE END OF THE PIN HAD COME APART ALLOWING THE PIN TO COME OUT. CODE: V84256.(SEE ALSO: US 2005081600047)

CA051011003

CNDAIR

GE  

MESSIER

LANDING GEAR

MALFUNCTIONED

8/8/2005

CL6002B19

CF343B1

16040

 

NOSE 

(CAN) UPON SELECTING THE LDG DOWN, THE NLG DID NOT COME DOWN AND A (GEAR DISAGREE) MESSAGE FOLLOWED. QRH FOLLOWED, NLG FINALLY EXTENDED. AN UNEVENTFUL LANDING FOLLOWED. NUMEROUS TROUBLESHOOTING STEPS WERE PERFORMED DURING THE TROUBLESHOOTING PERIOD THAT FOLLOWED, HOWEVER THE FINAL FINDINGS HAVE STILL NOT BEEN DETERMINED. STILL INVESTIGATING/ANALYSING THE EVENT.

CA051011001

CNDAIR

GE  

HARTMAN

RELAY

MELTED

10/7/2005

CL6002B19

CF343B1

D7GRZ

 

RELAY/CONTACTOR

(CAN) THE FLIGHT CREW WAS ON THE GROUND WITH THE APU ON (NO PASSENGERS ON BOARD). JUST AFTER TRANSFERING FROM APU TO EXTERNAL POWER, SMOKE STARTED TO FILL THE COCKPIT. POWER WAS REMOVED FROM THE AIRCRAFT. THE MECHANICS DETERMINED THAT THE SOURCE OF THE SMOKE WAS THE AVIONICS BAY. THE MECHANICS FOUND THAT RELAY (AC SERVICE CONTACTOR) HAD MELTED. IT IS ALSO REPORTED THAT SOME WIRES HAVE SUSTAINED HEAT DAMAGE. THERE WAS NO EVIDENCE OF A WATER LEAK IN THE AREA.

CA051011002

CNDAIR

GE  

 

WINDOW

CRACKED

10/5/2005

CL6002C10

CF348C1

 

NP1393226

COCKPIT

(CAN) RT COCKPIT SIDE WINDOW CRACKED ON APPROACH. WINDOW REPLACED IAW AMM, AIRCRAFT RETURNED TO SERVICE.

CA051003018

CNDAIR

GE  

BOMBDR

DOOR

MISSING

10/3/2005

CL6002C10

CF348C1

 

 

LT MLG

(CAN) DURING INSPECTION OF THE AC DURING TRANSIT STOP THE LT MLG DOOR HAS BEEN FOUND MISSING. REMAINS OF THE BOTH DOOR HINGE FITTINGS AND THE CONNECTING LINK ARE STILL PRESENT ON THE AC. PILOT REPORTED THAT THEY HAD STRONG TURBULENCE IN FLIGHT. THE SB HAS BEEN PERFORMED ON THE AIRCRAFT ON 03-DEC-2003. BOTH LT AND RT DOORS HAVE BEEN INSPECTED IAW TC AD CF-2003-23R1 ON 26-SEP-2005 WITH NO FAULT FOUND. MLG DOOR P/N CC670-10520-951A NEW DOOR WILL BE INSTALLED.

CA051002001

CNDAIR

GE  

 

WINDSHIELD

CRACKED

9/23/2005

CL6002C10

CF348C1

 

601R33033177

COCKPIT

(CAN) AT FLT LEVEL 370 CAPT WINDSHIELD CRAKED. THE AIRCRAFT DIVERTED AND LANDED WITHOUT INCIDENT.

CA051005001

CNDAIR

GE  

 

WINDOW

CRACKED

10/3/2005

CL6002C10

CF348C1

 

NP1393225

COCKPIT

(CAN) LT WINDOW CRACKED AT FL410. NO PRESSURE PROBLEM. DIVERTED FLIGH. LT SIDE WINDOW REPLACED ACCORDING AMM. THERE IS NO POST/PRE SB FOR WINDOWS.

CA051019001

CNDAIR

GE  

 

MCU  

MALFUNCTIONED

10/7/2005

CL6002C10

CF348C1

 

70744

HORIZONTAL STAB

IN CRUISE FLIGHT 36000 FT, THE MASTER CAUTION ALERT CAME ON WITH STAB TRIM AND MACH TRIM MESSAGES. FOLLOWED QRH AND DECLARED AN EMERGENCY. LANDED WITHOUT INCIDENT. ACCOMPLISHED TROUBLESHOOTING AND REPLACED THE HORIZONTAL STABILIZER MOTOR CONTROL UNIT. THE VENDOR OF THE HORIZ STAB MCU IS SAGEM, VENDOR CODE: VF6151. NOTE 2: AS STATED IN BOMBARDIER AOM 254. AIRCRAFT EQUIPPED WITH SPOILER STAB CONTROL UNIT (SSCU) P/N C13045BA03 ARE MORE SUSCEPTIBLE TO STAB TRIM CAUTION MESSAGES IN CERTAIN CONDITIONS. THIS AIRCRAFT WAS EQUIPPED WITH SSCU P/N C13045BA03 AT THE TIME OF THE EVENT. VENDOR OF THE SSCU IS THALES AVIONICS, VENDOR CODE: VF9111.

CA051017004

CNDAIR

GE  

 

THERMAL BARRIER

FAILED

10/17/2005

CL604

CF34*

 

 

BATTERY

DURING FINAL TOP CHARGE CELL NR 19 WENT INTO THERMAL BARRIER BREAKDOWN. HIGH TEMPERATURE LIMIT WAS REACHED AND THE CELL HOUSING MELTED.

CA051005006

CNDAIR

GE  

 

PIN  

BROKEN

10/5/2005

CL604

CF343A1

 

200811620

NLG UPLOCK

(CAN) DURING A WALK AROUND THE NLG UPLOCK ROLLER PIN WAS FOUND BROKEN AT THE COTTER PIN HOLE.

CA050920002

CNDAIR

GE  

 

OXYGEN SYSTEM

FAILED

9/20/2005

CL604

CF343B1

 

60144101

PAX 

(CAN) DURING SCHEDULED MM DEPLOYMENT OF THE PASSENGER OXYGEN MASKS WAS ATTEMPTED. THE CONTROLLER WAS SWITCHED TO THE OVERRIDE POSITION BUT ALL OF THE PASSENGER OXYGEN MASKS FAILED TO DEPLOY. UPON FURTHER INVESTIGATION IT WAS DISCOVERED THAT THERE WAS INSUFICIENT PRESSURE AT THE PASSENGER OXYGEN BOX SOLENOIDS TO DEPLOY THE MASKS. THE OXYGEN CONTROLLER WAS REPLACED AND THE SYSTEM WAS TESTED SERVICEABLE.

CA051006001

CVAC

ALLSN

 

FITTING

CRACKED

10/27/2004

440  

501D13D

 

MS2190512D

HYD LINE

(CAN) AIRCRAFT RETURN TO BLOCK AFTER LOSS OF HYDRAULIC FLUID. AFTER INVESTIGATION MAINTENANCE FOUND FROM LT ENGINE DRIVE HYDRAULIC PUMP PRESSURE LINE AND AC HYDRAULIC PUMP, T-FITTING AT FS 319 CRACKED. THE FITTING WAS REPLACED, SYSTEM REPLENISHED AND LEAK CHECK SERVICEABLE. AIRCRAFT RETURN TO SERVICE.

2005FA0001500

DHAV

 

 

MOUNT

CRACKED

10/1/2005

DHC2*

 

 

612826

ADC 

DURING ANNUAL INSPECTION FOUND THE ADC TRAY CRACKED COMPLETELY ACROSS ONE END. (K)

CA051017005

DHAV

PWA  

 

SERVO

CRACKED

10/14/2005

DHC3

PT6A34

 

AA112911002

ELEVATOR TAB

RIGHT ELEVATOR SERVO TAB FOUND CRACKED DURING ROUTINE INSPECTION.

CA051018003

DHAV

PWA  

 

FRAME

CRACKED

10/10/2005

DHC6100

PT6A20

 

C6FSM2528S12

FUSELAGE

DURING SCHEDULED INSPECTION FOR SB 6/521 AND CF 95-12, A SINGLE CRACK WAS SUSPECTED IN THE WEB AREA OF THE AFT SECTION OF THE RT SIDE FRAME. AN EDDY CURRENT INSPECTION CONFIRMED THE CRACK AS WELL AS SMALLER CRACKS EMANATING FROM THREE ADJACENT RIVETS. THE LARGER CRACK WAS ESTIMATED AT 3/8 INCH IN LENGTH AND ORIGINATED FROM A RIVET HOLE. THERE IS NO RECORD OF THIS PARTICULAR SECTION OF THE SIDE FRAME HAVING BEEN CHANGED PREVOUSLY. THE A/C REMAINS GROUNDED PENDING DELIVERY OF A SIDEFRAME FROM THE MANUFACTURER.

CA051012005

DHAV

 

DHAV

SKIN

DEBONDED

10/6/2005

DHC6300

 

 

 

WING BOX

FOUND LT AND RT WING DISBONDING OF THE UPPER WING SKIN, INBOARD AND OUTBOARD OF NACELLES FROM YW 60 TP YW 150. BOMBARDIER IS IN THE PROCESS OF ISSUING A SB TO COVER INSPECTION OF THE UPPER WING SKINS. DARK AREAS ON THE SKETCHES INDICATE DISBONDING. MODEL P/N C6W1001-25 L/H, S/N 250082, L/H P/N C6W1001-27 R/H, S/N 270083 R/H.

CA050928002

DHAV

PWA  

 

LONGERON

CRACKED

9/27/2005

DHC6300

PT6A27

 

C6WM1712

RT NACELLE

(CAN) WHILE CARRYING OUT THE LOWER LONGERON INSPECTION IAW AD CF 81-07R4 AND SB 6/509, THE LT IB LONGERON ON THE RT NACELLE WAS FOUND CRACKED LATERALLY ACROSS THE WEB. THE CRACK WAS JUST AFT OF THE ENGINE MOUNT.

CA051013005

DHAV

PWA  

 

BRACKET

CRACKED

10/12/2005

DHC6300

PT6A34

 

3012525

THRUST REVERSER

UPON VISUAL INSPECTION, TOP PLATE OF AFT REVERSING TELEFLEX BRACKET WAS FOUND CRACKED 70 PERCENT THROUGH. TOTAL FAILURE OF THIS BRACKET WOULD ALLOW THE REVERSING TELEFLEX TO MOVE FORE AND AFT CAUSING DIFFICULTIES IN ENGINE CONTROL DURING REVERSE OPERATIONS. DEFECTIVE PART WAS REPLACED AND AIRCRAFT RETURNED TO SERVICE.

CA051006006

DHAV

PWA  

 

COMPRESSOR

DAMAGED

9/8/2005

DHC7*

PT6A50

 

 

ENGINE

(CAN) THE ENGINE EXPERIENCED AN UNCOMMANDED POWER ROLL-BACK TO IDLE IN CRUISE, AND WAS SHUTDOWN IN FLIGHT. SUBSEQUENT INSPECTION REVEALED DAMAGE TO THE 1ST STAGE COMPRESSOR BLADES. WILL MONITOR INVESTIGATION OF THE INCIDENT AND ADVISE OF ROOT CAUSE, ONCE ESTABLISHED.

CA050928003

DHAV

PWA  

BFGOODRICH

BEARING RACE

CRACKED

9/27/2005

DHC71

PT6A50

 

L814710

MAIN WHEEL

(CAN) DURING A ROUTINE VISUAL INSPECTION THE INNER BEARING RACE OF THE NR 4 MAIN WHEEL ASSY WAS FOUND CRACKED.

2005FA0001475

DHAV

PWA  

 

ENGINE

SEIZED

10/25/2005

DHC7102

PT6A50

 

 

 

ENGINE INSTALLED ON AIRCRAFT AFTER RETURN FROM REPAIR FACILITY. DURING INITIAL GROUND RUN OF ENGINE THE POWER LEVER SEIZED AND VERY HARD TO MOVE. ENGINE TEMPERATURE AND PRESSURE WERE NORMAL. FEATHERED THE PROPELLER AND SHUTDOWN ENGINE. POST INSPECTION SHOWED NO LEAKS WITH THE PROPELLER VERY HARD TO TURN AND BETA REVERSING LEVER SEIZED. (K)

CA051012001

DHAV

PWA  

 

TIRE

FAILED

10/4/2005

DHC8*

PW121

 

314353

MLG 

DURING TAXI FOR TAKEOFF, A LOUD NOISE CAME FROM THE LEFT SIDE. THE AIRCRAFT STOPPED AND AFTER INSPECTION THE LEFT MAIN TIRE WAS FOUND DEFLATED. MAINTENANCE INSPECTION FOUND THE LT MLG INNER TIRE FOUND DEFLATED AND DAMAGED. ALSO FROM INNER SIDE A LARGE METAL PIECE OF WHEEL WAS FOUND MISSING. AFTER DV, INSPECTION OF MLG NOTHING ABNORMAL OBSERVED. THE MLG WHEELS ASSY'S REPLACED BY SERVICEABLE ONES.

CA050929001

DHAV

PWA  

DHAV

SHAFT

BROKEN

9/28/2005

DHC8301

PW123

 

87620130101

SPRING STRUT

(CAN) DURING POST ENGINE CHANGE RIGGING NR 1 ENGINE SPRING STRUT ASSEMBLY WAS REMOVED DUE TO EXCESSIVE PLAY (SLOPPY AT LOOSE). AFTER DISASSEMBLY AND INSPECTION SHAFT P/N87620130 WAS BROKEN AT POINT RIVET P/N MS204170AD3. THE SIZE OF THE RIVET LEAVES MINIMAL MATERIAL AROUND THE HOLE IN THE SHAFT.

2005FA0001444

DIAMON

CONT

 

CANOPY

SEPARATED

10/5/2005

DA20C1

IO240A

 

2056000101

COCKPIT

GLASS SEPARATING FROM FRAME. (EA07200505548) (K)

2005FA0001521

DIAMON

CONT

 

FUEL TANK

CRACKED

11/4/2005

DA20C1

IO240A

 

2228610000

 

DURING OUTER MAINTENANCE FOUND FUEL TANK CRACKED IN NP SURFACE AT CENTERAL APT SPOT WELD FOR INTERNAL BAFFEL. INSTALLED NEW FUEL TANK TO CORRECT PROBLEM. (K)

2005FA0001483

DIAMON

CONT

 

HINGE

FAILED

10/5/2005

DA40

IO360*

 

 

AFT CABIN DOOR

UPON INSTALLATION OF A NEW AFT CABIN DOOR SUPPORT STRUT, THE DOOR WAS CLOSED, AND THE AFT CABIN DOOR HINGE FAILED. UPON FURTHER INSPECTION, THE DOOR HINGE WAS FOUND TO HAVE BEEN DELAMINATED WHICH COULD NOT WITHSTAND THE PRESSURE OF THE NEW SUPPORT STUT. THE DOOR HINGE IS BONDED TO THE DOOR ASSY, AND IS NOT REPLACEABLE IN THE FIELD. (SW05200512642) (K)

CA051013008

DORNER

GARRTT

 

ENGINE

POWER LOSS

10/12/2005

DO228202

TPE33125D

 

 

RIGHT

RT ENGINE WAS REMOVED FOR LOW TORQUE INDICATION AND SENT OUT FOR REPAIR AFTER TESTING PROVED AN INTERNAL PROBLEM. THE ENGINE WAS RE-INSTALLED FROM REPAIR WITH A NEW TORSION SHAFT SN 05P15649 AND TORQUE SENSOR P/N 3101726 AND NTS TEST FLIGHT WAS CARRIED OUT AND FUNCTIONED NORMALLY. THE AIRCRAFT ACCUMULATED LESS THAN 8 HOURS TIS AND SHOWED SIGNS OF TORQUE LOSS. GROUND TESTS WERE CARRIED OUT AND SYSTEMS WERE FUNCTIONING NORMAL, AND NTS TEST FLIGHT WAS THEN CARRIED OUT AND FAILED. ENGINE HAS SINCE BEEN REMOVED AND WILL BE SENT BACK TO THE OVERHAUL SHOP FOR RE-EVALUATION.

CA050901005

DORNER

PWA  

 

WIRE HARNESS

SHORTED

8/29/2005

DO328100

PW119C

 

 

PROPELLER SYNC

A/C DEPARTED YYC, DURING CLIMB-OUT LIGHTS FLICKERED LT GEN KICKED OFFLINE AND CREW LOST FMS SCREEN AND PROP SYNC CB POPPED. AS DEPARTING MX BASES, ELECTED TO RETURN TO YYC. PAX`S WHERE DISEMBARKED AND A/C RETURNED TO HANGAR. GENERATOR CAME ON LINE DURING STARTUP AND TAXI BACK TO HANGAR ALTHOUGH FMS SCREEN AND PROP SYNC REMAINED INOP. VISUAL CHECK OF START/GEN COMPLETED AND GROUND RUN AND FLT TEST COULD NOT DUPLICATE ANY ELECTRICAL FAULT IN GENERATOR. FMS AND PROP SYNC WHERE DEFERRED AND FLIGHT CONTINUED. ELECTRICAL SHORT OF PROP SYNC SYSTEM SUSPECTED OF INTERFERRING WITH START/GEN AND HARMING FMS SCREEN. TROUBLESHOOTING OF PROP SYNC SHORT ONGOING. WILL REPORT FINDINGS.

CA051011006

EMB  

PWA  

 

DRIVE ASSY

SHEARED

10/5/2005

EMB110P1

PT6A34

 

02532310103

EDP 

IN CRUISE FLT AT 7000 FEET, NR 1 ENGINE LOST POWER. FLT CREW SECURED NR 1 ENGINE IAW APPLICABLE FLT MANUAL PROCEDURES AND LANDED A/C AT NEAREST AIRPORT. UPON INVESTIGATION, MX FOUND THAT CAUSE OF ENG FAILURE WAS DUE TO ENG DRIVEN FUEL PUMP. WHEN FUEL PUMP WAS REMOVED IT WAS FOUND THAT SPLINES HAD SHEARED OFF OF DRIVE AS A RESULT OF INTERNAL PUMP FAILURE. THE ACCESSORY DRIVE SECTION, ON THE ENGINE, WAS INSPECTED AND FOUND TO BE DEFECT FREE. THE ENGINE DRIVEN FUEL PUMP ALONG WITH THE FUEL CONTROL UNIT WERE BOTH REPLACED AND THE ENGINE WAS GROUND RUN WHERE ALL PARAMETERS WERE FOUND TO BE NORMAL. THE AIRCRAFT WAS THEN RETURNED TO SERVICE. THE FUEL PUMP HAS BEEN SENT OUT FOR TEAR DOWN AND A STRIP REPORT.

2005FA0001464

EMB  

 

 

TIRE

LEAKING

10/12/2005

EMB135BJ

 

 

304K632

MLG 

DURING LEAK CHECK OF A NEW TIRE, IT WAS DISCOVERED THAT THE SIDEWALL WEEP HOLES WERE LEAKING, THIS CONDITION WAS NOTICED AFTER THE TIRE HAD COMPLETED A 12 HOUR LEAK CHECK. (K)

2005FA0001530

EMB  

 

 

TIRE

LEAKING

11/2/2005

EMB135BJ

 

 

304K632

MLG 

AFTER COMPLETING THE SPECIFIED LEAK CHECK TIME, THE WEEP HOLES IN THE SIDE WALL OF THE TIRE WERE STILL BUBBLING WHEN CHECKED WITH LEAK DETECTOR FLUID.

EAHR200500003

ENSTRM

ALLSN

 

GCU  

MALFUNCTIONED

11/1/2005

480/TH28

250C20

 

VR152811B

DC SYSTEM

GENERATOR CONTROL UNIT CAUSES GENERATOR RELAY TO CYCLE ON AND OFF.

CA051006005

FOKKER

PWA  

 

PACKING

FAILED

9/1/2005

F27MK50

PW125B

 

 

N1 PROBE

(CAN) ON TAXI, CABIN AIR BECAME CONTAMINATED WITH SMOKE. SUBSEQUENT INSPECTION REVEALED A HARDENED AND BROKEN N1 PROBE O-RING PACKING.

CA051012009

FOKKER

RROYCE

 

SKIN

CRACKED

10/2/2005

F28MK1000

SPEY55515

 

 

EMERGENCY DOOR

DURING SERVICE CHECK, 13 INCH CRACK DISCOVERED ON EXTERNAL SKIN OF FWD SERVICE/EMERGENCY DOOR. NO REPLACEMENT DOOR WAS IN STOCK. REPAIRS WERE COMPLETED AS PER STRUCTURAL REPAIR MANUAL. THIS AREA IS COVERED BY STRUCTURAL INSPECT PROGRAM WHICH IS COMPLETED EVERY 2000 CYCLES AND WAS DUE WITHIN 70 CYCLES. FOKKER SERVICES HAVE BEEN CONTACTED FOR THEIR RECOMMENDATION REGARDING INSPECTION LVL AND FREQ. ALL INITIAL FINDINGS ON SIP-1 ITEM 52-40-01 ARE FOUND WELL ABOVE INITIAL INSPECT AT 18700 CYCLES. IN MAJORITY OF FINDINGS, CRACK SIZE IS IN BETWEEN 8 AND 11 INCH. CRACK GROWTH CALCULATIONS (50 MM - 250 MM) DO SHOW A RAPID GROWTH. HOWEVER, TAKING INTO ACCOUNT A SCATTER FACTOR OF 3, 3200 CYCLE INTERVAL SHOULD COVER THIS GROWTH. THERE IS NO REASON TO REVISE SIP ITEM SINCE AREA IS DAMAGE TOLERANT AND IS ABLE TO SUSTAIN THESE CRACK LENGTHS W/O HAVING AN ADVERSE EFFECT ON AIRWORTHINESS OF A/C.

CA051027001

FRCHLD

GARRTT

GARRTT

LINE

CRACKED

10/13/2005

SA227DC

TPE33112UHR

TPE33112UHR

3108081

NR 1 ENGINE

(CAN) ENROUTE, FLIGHT CREW OBSERVED A LOW OIL PRESSURE INDICATION ON NR 1 ENG. CONFIRMED LOW OIL PRESS ON GAUGE AND CONDUCTED AN IN-FLIGHT SHUTDOWN PROCEDURE. SINGLE ENG FLIGHT CONTINUED TO DESTINATION. CREW CARRIED OUT LANDING, WITH ERS STANDING BY, WITHOUT FURTHER INCIDENT. MAINT INSPECT FOUND CRACK ON RIGID OIL LINE, APPROX 0.125 INCHES AFT OF ONE FLARED END AND CONTINUING HALF WAY AROUND DIAMETER OF LINE. LINE WAS REPLACED WITH NEW LINE, 5.5 QUARTS OF OIL WAS ADDED, MAG PLUG INSPECTED, FOUND TO BE CLEAN, OIL FILTER INSPECTED, NO METAL PARTICLES NOTED. AC WAS GROUND RUN FOR LEAK CHECKS AND TAKE OFF PERFORMANCE VERIFIED, AC WAS RETURNED TO BASE, SPECTRO-GRAPHIC OIL ANALYSIS SAMPLES (S.O.A.P.) WASTAKEN.

2005FA0001497

GULSTM

LYC  

 

SPAR

DAMAGED

9/15/2005

112A

TO360A1A6

 

 

FUSELAGE

FOUND LT AND RT MAIN SPAR WEBS DAMAGED FROM STATION 50 TO 63. EACH WEB HAD DIAGONAL WRINKLES FROM TOP OF SPAR, JUST IB OF LANDING GEAR ATTACH AREA, DOWN AND IB TO JUST OB OF DRAG BRACE BRACKET AND REINFORCEMENTS. AIRCRAFT HAS BEEN FOUND TO BE IN COMPLIANCE WITH AD. BY REINFORCEMENT KIT INSTALLED IAW SB. NO CRACKS DETECTED ATH THIS DATE. (K)

CA051014002

GULSTM

RROYCE

 

BLADES

DAMAGED

10/12/2005

G1159

SPEY5118

 

 

ENGINE

GII SERIAL 236 IN NR 1 POSITION HAS EXPERIENCED FOD DAMAGE. THE DAMAGE HAS BEEN FOUND TO THE LPC5 BLADES AND HPC1 BLADES. THE REST OF THE HP COMPRESSOR HAS YET TO BE INSPECTED. THE DAMAGE HAS BEEN CAUSED BY THE RELEASE OF ONE LP OGV INNER BOLT WASHER AND NUT.

2005FA0001476

GULSTM

RROYCE

 

O-RING

LEAKING

9/11/2005

GIV  

SPEY5118

 

NAS161210A

HYD SHUTOFF VLVE

HYD LINE WAS REPLACED DUE TO CRACK IN FLARE AT TEE FITTING. REPLACEMENT OF LINE REQUIRED INSTALL OF NEW O-RING, WHERE TEE FITTING ATTACHES TO FLIGHT CTRL HYD SHUT OFF VALVE. AFTER INSTALL OF HYD LINE AND O-RING, A LEAK CHECK WAS PERFORMED. NO LEAKS WERE NOTED. AC WAS APPROVED FOR RETURN TO SERVICE. AFTER 2.6 HOURS, O-RING FAILED CAUSING LEAKAGE OF HYD FLUID FROM COMBINED HYD SYS. AC MADE PRECAUTIONARY LANDING. MAINT REPLACED DEFECTIVE O-RING AND SERVICED HYDR SYS. LEAK CHECK WAS PERFORMED AND NO DEFECTS WERE NOTED. DEFECTIVE O-RING WAS INSPECTED AND FOUND TO BE CUT. DETERMINATION ALSO COULD NOT BE MADE AS TO WHY O-RING FAILED 2.6 HOURS AFTER INSTALLATION, INITIAL LEAK CHECK SHOWED NO DEFECTS.

2005FA0001501

GULSTM

RROYCE

 

CONNECTOR

DISCONNECTED

10/26/2005

GULFSTREAMGV

BR700710A110

 

394A1J1

CABIN LIGHTS

DURING SCHEDULED MAINTENANCE, CREW NOTED SEVERAL CABIN LIGHTS WENT INOPERATIVE. WIRE PX601A8 AT CONNECTOR 394A1J1/369A1P1 BEHIND AUX CB PANEL AT RT RADIO RACK WAS FOUND WITH EVIDENCE OF OVERHEATING AND ARCING. SOLDERED CONNECTION TO CORRESPONDING PIN HAD FAILED. CB DID NOT TRIP. REPLACED CONNECTOR, TRIMMED DAMAGED WIRE, INSTALLED NEW PIN. REPLACED 50 AMP CB. INTERNALLY INSPECTED POWER DISTRIBUTION BOX FOR EVIDENCE OF OVERHEATING. TESTED REPAIRED CIRCUIT. (K)

2005FA0001502

GULSTM

RROYCE

 

CONNECTOR

DISCONNECTED

10/26/2005

GULFSTREAMGV

BR700710A110

 

394A1P1

CABIN LIGHTS

DURING SCHEDULED MAINTENANCE, CREW NOTED SEVERAL CABIN LIGHTS WENT INOPERATIVE. WIRE PX601A8 AT CONNECTORS 394A1J1/394A1P1 BEHIND AUX CB PANEL AT RT RADIO RACK WAS FOUND WITH EVIDENCE OF OVERHEATING AND ARCING. SOLDERED CONNECTION TO CORRESPONDING PIN HAD FAILED. CB DID NOT TRIP. REPLACED CONNECTOR 394A1J1/394A1P1, TRIMMED DAMAGED WIRE, INSTALLED NEW PIN. REPLACED 50 AMP CB. INTERNALLY INSPECTED POWER DISTRIBUTION BOX FOR EVIDENCE OF OVERHEATING. TESTED REPAIRED CIRCUIT. (K)

CA051003015

HUGHES

LYC  

 

TUBE

CRACKED

9/22/2005

269C1

HO360C1A

 

269A21725

MAST 

(CAN) 1) TUBE ASSEMBLY IS CRACKED ON THE MAST SIDE. 2) REPLACED TUBE ASSEMBLY, P/N 269A2172-5.

CA051007004

HUGHES

LYC  

 

CARBURETOR

FAILED

9/28/2005

269C1

HO360C1A

 

1060301

ENGINE

(CAN) AIRCRAFT HAVE LOW POWER IN FLIGHT. REPLACED CARBURATOR.

2005FA0001337

HUGHES

ALLSN

 

MOTOR

INOPERATIVE

8/13/2005

369A

250C20B

 

369A717111

FLIGHT CONTROLS

ON APPROACH TO LANDING THE LONG TRIM MOTOR QUIT WORKING. REPLACED UNIT. (K)

2005FA0001524

HUGHES

 

 

SKID

CRACKED

9/4/2005

369D

 

 

369D2921143

MLG 

UPON LANDING THE MECHANIC SAW THE FORWARD LT SKID TUBE WAS ANGLED UP SEVERAL DEGREES. IT WAS DISCOVERED THAT THE TUBE WAS CRACKED UNDER THE FORWARD FOOT AND SKID PLATE. REPLACED UNIT. (K)

2005FA0001525

HUGHES

 

 

BRACKET

MISMANUFACTURED

10/2/2005

369D

 

 

369D256273

FUSELAGE

RECEIVED A BLOWN BRACKET FROM THE VENDOR AND FOUND IT IS NOT BUILT TO THE LATEST SPECS, IT WAS BUILT IN 2002 AND REQUIRES MODIFICATIONS CALLED OUT IN AN SB. (K)

2005FA0001339

HUGHES

ALLSN

 

HUB  

DAMAGED

8/7/2005

369D

250C20

 

369D21200501

MAIN ROTOR

FOUND THE UPPER M/R P/C LINK BEARING HAD WORN INTO THE ATTACH HUB OF THE PITCH HOUSING ABOUT .130 INCH UNTIL THE SPHERICAL PART OF THE BEARING CONTACTED, PREVENTING FURTHER PROGRESSION. (K)

2005FA0001338

HUGHES

ALLSN

 

MOTOR

INOPERATIVE

8/9/2005

369D

250C20B

 

369A20023

GOVERNOR TRIM

PILOT BEEPED THE N2 UP AND WAS UNABLE TO BEAP DOWN, THEN LATER GOT IT DOWN WITH NUMEROUS ATTEMPTS AND FLEW IT BACK. UNIT WAS CHANGED. (K)

2005FA0001336

HUGHES

ALLSN

 

GOVERNOR

STIFF

8/15/2005

369D

250C20B

 

252476914

ENGINE

ON INSPECTION THE GOV LOOKED TO BE OUT OF RIG. WHEN THE ARM WAS REMOVED IT WAS DISCOVERED THAT THE SHAFT WAS EXTREMELY STIFF. REPLACED GOVERNOR. (K)

2005FA0001523

HUGHES

ALLSN

 

STUD

BROKEN

9/26/2005

369D

250C20B

 

 

COMPRESSOR

FOUND THE LOWER RT COMPRESSOR STUD BROKEN OFF. DURING INSPECTION PROCESS FOR COMPRESSOR CASE HALVES. IT WAS NOTICED THAT THE RT LOWER COMPRESSOR STUD WAS MISSING (THAT IS THE NUT AND STUD WERE NOT VISABLE ON THE COMPRESSOR FLANGE). REPLACED UNIT. (K)

CA050929002

ISRAEL

GARRTT

 

CAP  

LOOSE

9/23/2005

ASTRASPX

TFE73140

 

30607493

OIL TANK

(CAN) AFTER TAKEOFF,LOSS OF LT ENGINE OIL PRESSURE. SHUT DOWN LT ENGINE, DECLARED EMERGENCY AND RETURNED TO BASE. ENGINE SHOWED SIGNS OF OIL LEAK ON LT COWL. INVESTIGATED OIL LEAK AND FOUND THE OB OIL CAP LOOSE. INSPECTED OIL CAP/DIP STICK O-RING AND LOCKING ASSY SERVICEABLE. CLEAN DOWN ENGINE OIL SPILLAGE AND SERVICED ENGINE WITH MOBIL 254. C/O GND RUNS AND ENGINE PERFORMED SERVICEABLE. NO APPARENT LEAKS ON ENGINE. AIRCRAFT RELEASED FOR RETURN TO SERVICE.

2005FA0001490

LEAR

GARRTT

 

CONNECTOR

LOOSE

9/29/2005

35LEAR

TFE731*

 

 

ADC 

THE PILOTS ALTIMETER FLAGGED WHILE ENROUTE. THE FLIGHT CREW NOTIFIED ATC. SEVERAL MINUTES LATER THE ALTIMETER BEGAN WORKING NORMALLY. THE CONNECTIONS WERE CHECKED AND A BITE TEST WAS PERFORMED ON THE ADC WITH NO DEFECTS NOTED. AC WAS RETURNED TO SERVICE AND CONTINUED FLIGHT. WHILE ON THE GROUND, THE ALTIMETER AND ADC CONNECTIONS WERE RECHECKED. BOTH PRIMARY ALTIMETERY SYSTEMS WERE RUN TO ALTITUDE USING A DPS 500 AND NO DEFECTS WERE NOTED. THERE HAVE BEEN NO PRIOR REPORTS OF ALTIMETERY ERRORS ON THE AIRCRAFT. (K)

CA051002002

LEAR

GARRTT

 

GIMBAL JOINT

DAMAGED

9/22/2005

45LEAR

TFE7312

 

1457711

FLAP ACTUATOR

(CAN) FOUND LEADING EDGE OF LOWER PANEL COVERING OB FLAP ACTUATOR ON BOTH LT AND RT FLAPS DAMAGED. INVESTIGATION FOUND LOWER PIN P/N 145680-1 AND SNAP RING P/N 9-INI7437A2-70 HAD COME OUT OF THE BOTTOM OF GIMBAL ASSY. P/N 145771-1. PART OF ACTUATOR P/N 6627503000-011. WHEN THE ABOVE PIN CAME LOOSE IF ALSO GOUGED THE LEADING EDGE OF THE FLAP ACTUATOR CUTOUT FRAME. THE ACTUATOR HOUSING ALSO CONTACTED THE LEADING EDGE OF THE COVER PANEL. THE DAMAGED AREAS WERE BLENDED OUT AND TREATED IAW MFG ENGINEERING AND BOTH FLAP ACTUATORS REPLACED.

2005FA0001469

LET  

 

 

DAMPER

CRACKED

10/27/2005

L23  

 

 

A751305N

MLG 

UPPER HINGE ARM OF GEAR STRUT CRACKED AT WELDS.

CA050920006

MAULE

 

 

CONTROL CABLE

SEPARATED

8/18/2005

M7235B

 

 

36320500

CARB HEAT

(CAN) PILOT ACTUATED CARB HEAT AND HANDLE CAME UNSWAGED FROM CABLE. AIRCRAFT HAD TO COME BACK TO BASE PREMATURELY.

CA050920007

MAULE

 

 

MUFFLER

BURNED

8/31/2005

M7235B

 

 

M7235B

ENGINE

(CAN) PILOT COMPLAINED OF ABNORMAL CARB HEAT OPERATION IN FLIGHT AND BACK AT BASE ON GROUND. COWLS REMOVED ONLY TO DISCOVER LARGE FIST SIZE BURN HOLE THROUGH LT MUFFLER AND HEAT MUFF SHROUD. CARB HEAT HOSE WAS TOTALLY BURNED OFF AND INDUCTION AIR BOX SUSTAINED MINOR DAMAGE BUT NOT TO AIR VALVE OR SEAL. CAUSE WAS DETERMINED TO BE THAT THE INTERNAL BAFFLE HAD BROKEN AWAY AT THE TOP TACK WELDS AND FALLEN DOWN CAUSING A HEAT SINK ON THE MUFFLER BOTTOM AND BURNING THROUGH. NEW PARTS WHERE INSTALLED AND REPAIRS TO LOWER COWL CARRIED OUT AND AIRCRAFT RELEASED FOR RETURN TO SERVICE.

2005FA0001361

MOONEY

LYC  

 

COUPLING

FAILED

5/28/2005

M20E

IO360A1A

 

 

MLG 

SUFFERED A GEAR UP LANDING DUE TO A FAILURE OF THE COUPLING BETWEEN THE ACTUATOR AND GEARBOX. (K)

2005FA0001431

MTSBSI

GARRTT

 

DUCT

LOOSE

9/15/2005

MU2B40

TPE331*

 

31018303

ENGINE

ENGINE WAS TORN DOWN, BY AN APPROVED ENGINE SERVICE CENTER, FOR AN AUDIT OF ITS SB AND TBO CONFIGURATION, DUE TO CROSSOVER DUCT/DIFFUSER FAILURE OF ITS SISTER ENGINE ON THE SAME AIRCRAFT. IT WAS FOUND THE MAINTENANCE RECORDS CONCERNING SB STATUS AND TBO STATUS WERE IN ERROR ON THIS ENGINE ALSO AND INSPECTION OF THE CROSSOVER DUCT ASSY IN THIS ENGINE WAS FOUND VERY LOOSE, BUT NOT YET FAILED. FAILURE OF THIS PART WAS IMINENTNENT AND SEALS IN THIS DUCT WERE MOSTLY FAILED, AFFECTING COMPRESSOR AND ENGINE POWER. COMPRESSOR CROSSOVER DUCT/ DIFFUSER POOR CONDITION FOR ENGINE. (K)

2005FA0001430

MTSBSI

GARRTT

 

DUCT

FAILED

9/15/2005

MU2B40

TPE33110

 

31018303

ENGINE

ENGINE EGT SUDDENLY ROSE IN FLIGHT AND POWER HAD TO BE REDUCED. SAFE LANDING ACCOMPLISHED AT HOME BASE. TROUBLESHOOTING REVEALED THE COMPRESSOR CROSSOVER DUCT (DIFFUSER) HAD FAILED, CAUSING LOW COMPRESSOR PERFORMANCE. A VANE HAD BROKEN OFF AND LODGED, PREVENTING CATASTROPHIC FAILURE OF COMPONENTS DOWNSTREAM. INVESTIGATION REVEALED THIS PART WAS REQUIRED TO BE REPLACED WITH AN UPGRADED DUCT LESS PRONE TO FAILURE AT THE ENTINE TBO EXTENSION, WHICHC WAS RECORDED IN MAINTENANCE RECORDS AS HAVING BEEN ACCOMPLISHED AT AN EARLIER TIME, AND THE ENGINE CERTIFIED TO MEET THE 5400 HOUR TBO. (K)

CA051006015

PILATS

PWA  

WOODWARD

FCU  

FAILED

9/21/2005

PC12

PT6A67B

806304101

806304101

ENGINE

(CAN) IN FLIGHT, THE CREW REPORTED A LOUD NOISE ACCOMPANIED BY AN ENGINE SURGE. ENGINE POWER ROLLED BACK AND RECOVERED WITHOUT PILOT INPUT. THE AIRCRAFT DIVERTED FOR AN UNSCHEDULED LANDING. THE FUEL CONTROL UNIT WAS SUBSEQUENTLY REMOVED FOR INVESTIGATION. MFG WILL MONITOR INVESTIGATION OF THE INCIDENT AND WILL ADVISE OF ROOT CAUSE, ONCE DETERMINED.

CA050922001

PILATS

PWA  

 

EXCITER

FAILED

9/21/2005

PC1245

PT6A67B

 

103815504

IGNITION

(CAN) ENGINE FAILED TO LIGHT AT REMOTE COMMUNITY AIRPORT. IGNITION EXCITER BOX FOUND TO BE AT FAULT. FAILED UNIT HAD BEEN REPLACED AT ENGINE CHANGE, 17.4 HRS PREVIOUS.

CA050922002

PILATS

PWA  

 

STRUCTURE

CRACKED

9/15/2005

PC1245

PT6A67B

 

5302412151

INTAKE

(CAN) TRACES OF EXHAUST EMISSIONS WERE NOTICED COMING OUT OF EDGE OF INTAKE LIP. PART WAS REMOVED FROM COWL AND WITH THE TAPE AND INSULATION REMOVED, AN 8 INCH CRACK WAS REVEALED ON THE AFT SIDE OF THE EXHAUST CHAMBER PASSAGE. NEW INTAKE LIP KIT WAS FITTED, RETURNED TO SERVICE.

CA050922003

PILATS

PWA  

 

ACTUATOR

INOPERATIVE

9/15/2005

PC1245

PT6A67B

 

978731530

PARTICAL SEPARA

(CAN) PARTICLE SEPARATOR ACTUATOR FAILED TO OPERATE. UNIT REPLACED WITH SERVICEABLE UNIT, TESTS SATISFACTORY.

CA050923005

PILATS

PWA  

PILATS

BUSHING

WORN

8/24/2005

PC1245

PT6A67B

 

9411412107

RUDDER

(CAN) DURING AN INSPECTION THE TOP RUDDER BUSHING WAS FOUND TO BE WORN BEYOND LIMITS. RUDDER WAS REMOVED AND RUDDER WAS REPAIRED IAW MFG TECH MEMO ECE -12-TM-02-327. RUDDER REINSTALLED AND CHECKED FOR TRAVEL IAW MM.

CA050930001

PILATS

PWA  

 

TERMINAL BLOCK

MELTED

9/20/2005

PC1245

PT6A67B

 

9714231705

WINDSHIELD HEAT

(CAN) THE WINDSHIELDS DE-ICE SYSTEM WAS SNAGGED AS DEFECTIVE BY THE PILOTS. AFTER INSPECTION OF THE SYSTEM 3 TERMINAL BLOCKS LOCATED IN THE COCKPIT ROOF PORTION WERE FOUND TO HAVE OVERHEATED. ALL (3) TERMINAL BLOCKS AND BOTH WINDSHIELDS HAVE BEEN REPLACED. SYSTEM WAS TESTED AND FOUND SERVICEABLE.

CA050919004

PILATS

PWA  

 

RADIO

ODOR

9/16/2005

PC1245

PT6A67B

 

069010320101

VHF 

(CAN) 15 MINUTES INTO CLIMB TO ALTITUDE, PILOTS SAW AND SMELLED SMOKE EMANATING FROM LOWER PORTION OF COPILOT'S WINDSHIELD. AIRCRAFT RETURNED TO BASE OF DEPARTURE, MEANWHILE CIRCUIT BREAKERS FOR WHAT APPEARED TO BE CAUSE OF SMOKE WERE PULLED. WINDSHIELD HEAT BREAKERS WERE PULLED. INVESTIGATION ON GROUND REVEALED STRONG BURNED SMELL EMANATING FROM NR 1 VHF NAV/COMM ONCE REMOVED FROM INSTALLATION RACK. BACK OF NAV/COMM IS LOCATED BELOW COPILOT'S WINDSHIELD AND THIS IS WHY SMOKE WAS COMING FROM LOWER PORTION OF WINDSHIELD. NAV/COMM REPLACED WITH SERVICEABLE UNIT.

CA051011004

PILATS

PWA  

 

WIRE HARNESS

CHAFED

9/29/2005

PC1245

PT6A67B

 

 

NAVIGATION SYS

THE MODE C FUNCTION OF ENCODING ALTIMETER FAILED, AS WELL THERE WERE INTERMITTENT FAULTS OF THE RADAR ALTIMETER AND OTHER AVIONICS SYSTEMS. DURING TROUBLESHOOTING, THE MAIN WIRE BUNDLE ATTACHED TO THE FORWARD FIREWALL/PRESSURE BULKHEAD BEHIND THE INSTRUMENT PANEL WAS FOUND TO BE CHAFED THROUGH BY THE COOLING/BLAST TUBE FOR THE KLN 90B GPS. BOTH THE WIRE BUNDLE AND BLAST TUBE WERE WELL SECURED BUT IN THE AREA OF THE DAMAGE THERE WAS CONTACT BETWEEN THE TWO. THE DAMAGED WIRING WAS REPAIRED AND SPIRAL WRAP WAS APPLIED TO THE WIRE BUNDLE TO PREVENT FURTHER DAMAGE BY THE COOLING HOSE.

CA051006014

PILATS

PWA  

 

BLEED VALVE

OUT OF LIMITS

9/22/2005

PC7  

PT6A25

 

 

COMPRESSOR

(CAN) ON TAKE-OFF ROLL, THE ENGINE SURGED, ACCOMPANIED BY FLAMES EMITTED FROM THE EXHAUST. SUBSEQUENT INVESTIGATION DETERMINED THE COMPRESSOR BLEED VALVE CLOSING POINT TO BE OUT OF LIMITS. THE BOV WAS REPLACED.

2005FA0001470

PIPER

LYC  

 

P-LEAD

DETERIORATED

10/28/2005

PA22150

O320*

 

 

LT MAGNETO

DURING RUNUP AFTER ANNUAL INSPECTION, LT MAG WAS NOT WORKING. FOUND INSULATION ON P-LEAD WIRE WAS DETERIORATING AND SHORTING TO SHIELDING CAUSING MAG TO BE CONTINUOUSLY GROUNDED NO MATTER WHAT SWITCH POSITION WAS. REPLACED SECTION OF P-LEAD AS REQUIRED. THIS WIRING IS DIRECTLY ABOVE EXHAUST AND DETERIORATION WAS PROBABLY CAUSED BY HEAT OF EXHAUST SYSTEM OVER TIME.

2005FA0001471

PIPER

LYC  

 

P-LEAD

DETERIORATED

10/28/2005

PA22150

O320*

 

 

MAGNETO

DURING RUNUP AFTER ANNUAL INSPECTION, LT MAG WAS NOT WORKING. FOUND INSULATION ON P-LEAD WIRE WAS DETERIORATING AND SHORTING TO SHIELDING CAUSING MAG TO BE CONTINUOUSLY GROUNDED NO MATTER WHAT SWITCH POSITION WAS. REPLACED SECTION OF P-LEAD AS REQUIRED. THIS WIRING IS DIRECTLY ABOVE EXHAUST AND DETERIORATION WAS PROBABLY CAUSED BY HEAT OF EXHAUST SYSTEM OVER TIME.

2005FA0001472

PIPER

LYC  

 

P-LEAD

DETERIORATED

10/28/2005

PA22150

O320*

 

 

MAGNETO

DURING RUNUP AFTER ANNUAL INSPECTION, LEFT MAG WAS NOT WORKING. FOUND INSULATION ON P-LEAD WIRE WAS DETERIORATING AND SHORTING TO SHIELDING CAUSING MAG TO BE CONTINUOUSLY GROUNDED NO MATTER WHAT SWITCH POSITION WAS. REPLACED SECTION OF P-LEAD AS REQUIRED. THIS WIRING IS DIRECTLY ABOVE EXHAUST AND DETERIORATION WAS PROBABLY CAUSED BY HEAT OF EXHAUST SYSTEM OVER TIME.

2005FA0001473

PIPER

LYC  

 

P-LEAD

DETERIORATED

10/28/2005

PA22150

O320*

 

 

MAGNETO

DURING RUNUP AFTER ANNUAL INSPECTION, LEFT MAG WAS NOT WORKING. FOUND INSULATION ON P-LEAD WIRE WAS DETERIORATING AND SHORTING TO SHIELDING CAUSING MAG TO BE CONTINUOUSLY GROUNDED NO MATTER WHAT SWITCH POSITION WAS. REPLACED SECTION OF P-LEAD AS REQUIRED. THIS WIRING IS DIRECTLY ABOVE EXHAUST AND DETERIORATION WAS PROBABLY CAUSED BY HEAT OF EXHAUST SYSTEM OVER TIME.

2005FA0001438

PIPER

LYC  

 

GEAR

BROKEN

6/22/2005

PA23250

IO540*

 

 

STARTER

ON RESTART IN THE AIR THE STARTER DRIVE GEAR BROKE. THE PILOT WAS UNABLE TO START THE ENGINE. THE GEAR ALSO DAMAGED THE RING GEAR ON THE ENGINE. (K)

CA051006016

PIPER

LYC  

PIPER

SUPPORT

CRACKED

6/24/2005

PA28160

O320*

66600

62102000

AILERON

(CAN) AILERON BELLCRANK SUPPORT ASSEMBLY WAS CRACKED AT THE FORWARD ATTACH BOLT HOLE. THE CRACKS WERE APP 1 INCH LONG. PART HAS NOW BEEN REPLACED NEW.

2005FA0001405

PIPER

GE  

 

SKIN

CRACKED

9/22/2005

PA28161

CFM567B24

 

62061002

WING 

WING WALK STIFFENER PANEL CRACKED UNDER UPPER WING SKIN, YEARS OF WALKING ON PANEL. STIFFENER PANEL SHOULD BE HEAVER GAUGE METAL. (K)

2005FA0001509

PIPER

LYC  

 

SKIN

CRACKED

10/25/2005

PA28161

O320*

 

62061002

WING 

FORWARD WING WALK DOUBLER CRACKED. DOUBLER SHOULD BE HEAVIER GAUGE METAL. (K)

2005FA0001489

PIPER

LYC  

 

THROTTLE CABLE

BROKEN

10/6/2005

PA28161

O320D3G

 

455350

ENGINE

THE THROTTLE CABLE BROKE IN HALF, INSIDE THE THROTTLE CABLE HOUSING. WHEN THE THROTTLE CABLE BROKE, IT CREATED FREYED ENDS THAT CAUGHT IN THE CABLE HOUSING WHICH RESULTED IN THE THROTTLE BECOMING (STUCK) IN THE FULL POSITION WHICH ENDED IN THE PILOT PULLING THE MIXTURE TO FULL LEAN POSITION AND LANDING (DEAD STICK) AT OTIS ANG BASE. (NE01200505868) (K)

2005FA0001403

PIPER

LYC  

 

CYLINDER HEAD

FAILED

9/20/2005

PA28180

O360A4A

 

 

ENGINE

NR 3 CYLINDER PRODUCED CRACK FROM LOWER SPARK PLUG TO EXHAUST PORT, ENGINE LOST POWER DURING CLIMB OUT AT APPROX 700 FT ATTEMPT TO RETURN FOR LANDING WAS UNSUCESSFUL, FAILED. CYCLINDER INSTALLED 1/12/00 RECONDITION CYLINDER TIME UNKNOWN - TIME IN SERVICE, APPROX 1300. (K)

2005FA0001360

PIPER

LYC  

 

SKIN

CRACKED

9/14/2005

PA28R200

IO360A1A

 

62061002

FUSELAGE

AT CABIN ENTRANCE, WING WALK, FOUND SUPPORT PANEL UNDER WING WALK CRACKED. FAILURE DUE TO REPEATED WALKING ON. IF FACTORY STAMPED SUPPORT OUT OF HEAVIER, THICKER PANEL, MAY HELP PROLONG FAILURE. (EA21200507814) (K)

2005FA0001512

PIPER

 

 

LIGHT

MISINSTALLED

11/4/2005

PA28R201

 

 

 

MLG INDCATOR

DURING TRAINING FLIGHT IN APPROACH, PILOT NOTICED, THAT LT LANDING GEAR GREEN LIGHT WAS NOT ON, RED LANDING GEAR UNSAFE LIGHT WAS ON HYD PUMP WAS RUNNING CONSTANTLY. PROBLEM CONTINUED EVEN AFTER EMERGENCY EXTENSION. AFTER FLYBY, ABOVE CONTROL TOWER, GROUND CONTROL SAW LANDING GEAR WAS DOWN, PILOT PROCEEDED WITH SAFE LANDING. TROUBLESHOOTING WAS PERFORMED WITH FOLLOWING RESULTS: THE MLG WARNING LIGHTS WHERE INVERTED. LT MAIN GEAR MICROSWITCH OPERATED RT MAIN GEAR GREEN LIGHT, RT MAIN GEAR MICROSWITCH OPERATED LT MAIN GEAR GREEN LIGHT. RT MAIN GEAR MICROSWITCH POSITION WAS ADJUSTED IAW MM, WIRES WERE INSTALLED CORRECT WAY. GEAR SWING WAS PERFORMED WITH SATISFACTORY RESULT.

2005FA0001495

PIPER

LYC  

 

MOUNT

BROKEN

10/18/2005

PA28R201

IO360C1C6

 

6711957

ENGINE

DURING ROUTING SCHEDULED MAINTENANCE INSPECTION NOTED ENG MOUNT WAS CRACKED JUST ABOVE WELD ON RT LOWER SIDE OF ENGINE MOUNT. JUST ABOVE AFT DRAGLINK MOUNT POINT. ALSO, UPON FURTHER INSPECTION THE LOWER HORIZONTAL TUBE MOST OB WAS ALSO BENT. MOS NOTED TOWARD THE FRONT PART OF THE MOUNT BY THE LANDING GEAR ATTACH POINT. NO HARD LANDING HAD BEEN REPORTED. (K)

CA051005012

PIPER

LYC  

 

CYLINDER

CRACKED

10/4/2005

PA31

TIO540A2B

 

LW13447

LT ENGINE

(CAN) LT ENGINE SPRUNG HUGE OIL LEAK, WAS SHUTDOWN IN FLIGHT. ENGINE FEATHERED. A/C WAS EN-ROUTE. A/C MAINTAINED ALTITUDE, CONTINUED AND LANDED SAFELY. LT ENGINE NR 6 CYLINDER WAS PULLED AND FOUND HAVE ALMOST CRACKED IN HALF AROUND BASE OF CYLINDER. CYLINDER WAS REPLACED WITH NEW CYLINDER.

CA051003012

PIPER

LYC  

 

TURBOCHARGER

FAILED

9/16/2005

PA31

TIO540A2C

LW12689

 

ENGINE

(CAN) SAW SMOKE DURING FLIGHT. RETURN TO BASE.

CA050913006

PIPER

LYC  

 

HOSE

RUPTURED

8/31/2005

PA31325

LTIO540F2BD

 

1776602

HYD SYSTEM

(CAN) PILOT NOTICE HYDRAULIC FLUID LEAKING FROM RT LOWER FUSELAGE TO WING FAIRING AFT MAIN SPAR. AP ON INSPECTION, FOUND LANDING GEAR HOSE RUPTURED. REPAIRED HOSE ASSY P/N 17766-02 BY REPLACING HOSE.

77866

PIPER

 

 

FORK

CRACKED

11/2/2005

PA31350

 

 

C4503L

PITCH CHANGE

PITCH CHANGE FORK CRACK FOUND DURING MAG-PARTICLE CHECK AT OVERHAUL (OH).

CA051011009

PIPER

LYC  

 

BOLT

SHEARED

9/29/2005

PA31350

TIO540J2BD

 

AN37A

NLG STEERING SYS

(CAN) PILOT COMPLAINED OF NO NOSE WHEEL STEERING WITH RUDDER INPUT. MX FOUND 2 OF 3 BOLTS SHEARED ON STEERING LINKAGE ON TOP OF NLG TRUNNION. MX DRY ASSEMBLED STEERING LINKAGE AND DISCOVERED BOLT GRIP LENGTH INSUFFICIENT. FOUND THAT 12 LENGTH WAS CORRECT LENGTH FOR THE 7 BOLT INDICATED IN IPC. BOLTS WERE FOUND SHEARED WHERE GRIP MEETS THE THREADS. ALL THREE BOLTS REPLACED WITH NEW HARDWARE.

CA050923006

PIPER

LYC  

 

DOWNLOCK SWITCH

STUCK

9/12/2005

PA31350

TIO540J2BD

 

487862

RT MLG

(CAN) ON APPROACH THE GEAR WAS LOWERED FOR LANDING AND THE RT GEAR DID NOT INDICATE DOWN AND LOCKED. FIGHT CREW NOTIFIED FLIGHT SERVICES THAT THEY WOULD DO A FLY PASS SO MAINTENANCE CREWS COULD CHECK TO SEE IF THE GEAR WAS EXTENDED. THE GEAR WAS DOWN AND APPEARED TO BE LOCKED SO THE AIRCRAFT LANDED WITH NO PROBLEM. THE AIRCRAFT WAS TAKEN TO MAINTENANCE AND PLACED ON JACKS GEAR OPERATION WAS CHECKED AND IT WAS FOUND THE THE RT DOWN SWITCH WAS DIRTY AND STUCK. ALL SWITCHES WERE CLEANED AND THE GEAR OPERATION CHECKED FOR 5 CYCLES. MAINTENANCE/FLIGHT CREWS WERE INFORMED OF THE PROBLEM.

CA051007007

PIPER

LYC  

 

SHAFT

SHEARED

10/6/2005

PA31350

TIO540J2BD

 

 

PROP GOVERNOR

(CAN) LT ENGINE LOSS OF FUEL PRESSURE IN FLIGHT. ENGINE SHUTDOWN AND FEATHER COMPLETED. IN CRUISE, ENGINE HAD PARTIAL POWER LOSS. ENGINE WAS FEATHERED AND A/C LANDED SAFELY. TRIED GROUND START, ENGINE WOULD NOT COME OUT OF FEATHER. ENGINEER FOUND FAILED PROP GOVERNOR. ENGINE DID WHAT IT SHOULD GOING TO FEATHER. SERVICEABLE PROP GOVERNOR INSTALLED. ENGINE IS NOW BACK TO SERVICE.

CA051012002

PIPER

PWA  

 

PUMP

DAMAGED

10/6/2005

PA31T

PT6A28

 

8000420

HYD SYSTEM

THE FLIGHT CREW REPORTED THAT THE LANDING GEAR WAS SLOW TO RETRACT/EXTEND. UPON INSPECTION, A RETURN (SUCTION) LINE FOR THE LEFT HYDRAULIC PUMP WAS FOUND CHAFED AND PIERCED INSIDE THE LEFT WING LEADING EDGE. THE HOLE IN THE LINE WAS CAUSED BY THE VOLTAGE REGULATOR WIRE (PF16A), WHICH WAS BARE AND ARCING AGAINST THE PIPE.

CA051012003

PIPER

PWA  

 

CABLE

JAMMED

10/8/2005

PA31T

PT6A28

 

 

ELEVATOR TAB

THE FLIGHT CREW REPORTED THAT THE ELEVATOR TRIM WAS JAMMED IN THE FORWARD POSITION. UPON INSPECTION, A LOOSE RIVET TAIL WAS FOUND LODGED ON TOP OF THE LEFT ELEVATOR TRIM DRUM AT THE CABLE STOP BOLT.

CA051012004

PIPER

PWA  

 

ARM  

CRACKED

10/11/2005

PA31T2

PT6A135

 

42042002

MLG 

WHILE COMPLYING WITH PIPER SL1092, INSPECTION/REPLACEMENT OF MAIN LANDING GEAR RETRACTION ARMS, THE LEFT ARM WAS FOUND CRACKED AT THE INSIDE RADIUS.

2005FA0001503

PIPER

LYC  

 

WINDOW

CRACKED

10/19/2005

PA32RT300

IO540*

 

6971203

COCKPIT

LT FORWARD SIDE WINDOW. CRACKED AND BROKEN 2 PLACES AROUND SIDE VENT WINDOW CAUSING LARGE SECTION TO BECOME LOOSE. (K)

2005FA0001478

PIPER

LYC  

 

FITTING

UNSERVICEABLE

10/10/2005

PA34200

IO360A1A

 

67040012

MLG 

MLG PIVOT CASTING (FWD TRUNNION FITTING ASSY) ATTACH HARDWARE CONTINUALLY COMES LOOSE ALLOWING CHAFFING BETWEEN CASTING, WING SPAR, ENLARGING ATTACH BOLT HOLES IN CASTING AND SPAR. AFFECTED LT CASTING HAD BEEN PREVIOUSLY REMOVED, INSPECTED AND INSTALLED IAW MM FOR THIS REASON ONLY 100 HRS PRIOR TO THIS REOCCURENCE. CONDITION HAD BEEN NOTED ON RT CASTING AT SAME INSPECTION HAD BEEN CORRECTED BY REPLACING CASTING WITH NEW, REAMING ATTACH HOLES IN CASTING, SPAR (UTILIZING APPROVED DATA) TO ACCEPT BOLTS. NUTPLATES ON THE FWD SIDE OF WING SPAR, NOT ADEQUATE TO ACCEPT STRESSES IMPOSED ON THEM, LEADING FACTOR IN CONTINUAL LOOSENING OF FWD PIVOT CASTING ATTACH HARDWARE.

CA050913008

PIPER

CONT

PIPER

O-RING

WORN

9/1/2005

PA34200T

TSIO360EB

 

484706

ACTUATOR

(CAN) PILOT REPORTED THAT LANDING GEAR FAILED TO RETRACT. AIRCRAFT PLACED ON JACKS, LANDING GEAR SWUNG, FOUND NOSE GEAR ACTUATOR FAILED TO COMPLETELY RETRACT. REMOVED NOSE GEAR ACTUATOR, DISASSEMBLED, FOUND PISTON ORING EXCESSIVELY WORN. INSTALLED NEW ORINGS P/N 484-706 AND BACK UP RING P/N 758-053 AND RE-ASSEMBLED. RE-INSTALLED NOSE GEAR ACTUATOR, SWUNG GEAR WITH NO FAULT FOUND.

2005FA0001488

RAYTHN

 

 

ACTUATOR

FAILED

10/25/2005

390  

 

 

3903814020018

TE FLAP

INSTALLED .0 TIME SINCE FACTORY, MODIFIED NR 1L FLAP ACTUATOR AS PART OF COMPLIANCE WITH MFG MSB. (FLAP FAIL) ANNUNCIATOR ILLUMINATED AFTER INSTALLATION. FLAP SYSTEM TROUBLESHOOTING SHOWED FAULT CODES 2,8 AND THEN 1,2, 8. ANNUNCIATOR NOT ILLUMINATED AFTER REINSTALLING ORIGINAL ACTUATOR. REPLACED ACTUATOR WITH MODIFIED ACTUATOR, NO ADDITIONAL (FLAP FAIL) ANNUNCIATOR INDICATIONS NOTED. (K)

2005FA0001487

RAYTHN

 

 

ACTUATOR

FAILED

10/25/2005

390  

 

 

3903814020020

TE FLAPS

INSTALLED .0 TIME SINCE FACTORY MODIFIED NR 2R FLAP ACTUATOR AS PART OF COMPLIANCE WITH MFG MSB. (FLAP FAIL) ANNUNCIATOR ILLUMINATED AFTER INSTALLATION. FLAP SYSTEM TROUBLESHOOTING SHOWED FAULT CODES 3, 8 AND THEN 1,3, 8. ANNUNCIATOR NOT ILLUMINATED AFTER REINSTALLING ORIGINAL ACTUATOR. REPLACED ACTUATOR WITH MODIFIED ACTUATOR, NO ADDITIONAL (FLAP FAIL) ANNUNCIATOR INDICATIONS NOTED. (K)

2005FA0001511

RAYTHN

GARRTT

 

NUT  

BACKED OUT

8/18/2005

HAWKER800XP

TFE731*

 

A103TGS

MLG DOOR

RT OB GEAR DOOR. FOUND THE DOOR TO GEAR STRUT ATTACHMENT BOLT BACKING OUT AND LOOSE. AFTER REMOVING COVER WAS FOUND THAT NUT WAS TO SECURE THE BOLT WAS NOT SAFETIED AND HAD BACKED OFF ABOUT 3 TURNS. THIS HAD COM OFF THE DOOR AND WOULD HAVE DROPPED INTO THE SLIP STREAM. (K)

CA050929003

ROBSIN

LYC  

 

BOLT

CRACKED

9/26/2005

R44  

O540F1B5

 

A6502

XMSN MOUNT

(CAN) TRANSMISSION MOUNTING BOLT WAS REMOVED FOR 2200 HR AIRCRAFT OVERHAUL. CRACK UNDER HEAD WAS FOUND DURING NDT. THE CRACK CAN NOT BE SEEN WITH VISUAL INSPECTION. THE BOLT HAS ATLEAST 2200 HR. AIRCRAFT HAS 6366.9 HRS.

CA050913009

ROBSIN

LYC  

 

RESERVOIR

INOPERATIVE

9/1/2005

R44  

O540F1B5

 

D2111

HYDRAULIC SYS

(CAN) HYDRAULIC FLUID FOUND VENTING FROM CAP. ALL FITTINGS AND LINES OF HYDRAULIC SYSTEM CHECKED. NO DEFECTS FOUND. GROUND RUN LEAK CHECK, AND STILL VENTING FROM CAP. HYDRAULIC RESERVOIR ASSEMBLY REPLACED. GROUND RUN AND LEAK CHECK, NO DEFECTS FOUND.

CA051004008

ROBSIN

 

 

DRIVE GEAR

CHIPPED

10/4/2005

R44RAVENII

 

BC3151004

BC3151004

STARTER

(CAN) AIRCRAFT HAD BEEN HARD TO START. UPON INVESTIGATION THE STARTER BENDIX DRIVE GEAR FOUND TO HAVE A CHIPPED TOOTH. NO PROBLEMS NOTED WITH THE INSTALLATION OF THE STARTER.THERE IS NO SHIMMING PROCEDURE, OR ANY OTHER KIND OF ADJUSTMENT WITH THIS INSTALLATION.

CA051018002

ROBSIN

 

POINTER

G SWITCH

WEAK

10/16/2005

R44RAVENII

 

 

PS400010

ELT 

DURING CRUISE FLIGHT PAST AIRPORT, THE ELT WENT OFF IN FLIGHT. NO UNUSUAL FLIGHT CONDITIONS AT THE TIME OF THE INCIDENT. FSS WAS CONTACTED.

CA050919001

ROBSIN

LYC  

POINTER

G SWITCH

FAILED

9/14/2005

R44RAVENII

IO540*

 

 

ELT 

(CAN) ELT WENT OFF DURING GROUND HANDLING. THE ELT WAS REMOVED FOR FURTHER INVESTIGATION. SUSPECT G-SWITCH.

CA050916001

ROBSIN

LYC  

 

MAGNETO

FAILED

9/15/2005

R44RAVENII

IO540*

 

BL6006163

ENGINE

(CAN) THE MAGNETO WAS REMOVED DUE TO FAILURE (NOT WORKING) UPON DISASSEMBLY THE BRUSH WAS BROKEN AND THE SPARK WAS NOT MAKING IT OUT OF THE COIL TO THE DISTRIBUTOR. ALSO, FOUND COIL CLAMP BROKEN THIS WILL BE REPAIRED HERE ALONG WITH A FRESH 500 HR INSP. DURING THE 500 HR INSPECTION THE COIL FAILED INTERNAL RESISTANCE CHECK. THE COIL IS ALSO BEING REPLACED.

CA050916002

ROBSIN

LYC  

CONT

BEARING

DAMAGED

9/15/2005

R44RAVENII

IO540*

 

1081806

MAGNETO

(CAN) MAGNETO WAS REMOVED FOR SCHEDULED 500 HOUR INSPECTION. THE LOWER BEARING LOOKS AS THOUGH IT HAD BEEN SPINNING ON THE SHAFT. THE SPACER WAS ALSO DAMAGED.

CA050923010

ROBSIN

LYC  

 

STARTER GEN

FAILED

9/21/2005

R44RAVENII

IO540*

 

BC3151004

ENGINE

(CAN) DURING START UP, THE STARTER WOULD NOT ENGAGE. THE STARTER WAS REMOVED AND REPLACED WITH ANOTHER UNIT AND THE PROBLEM NO LONGER WAS EVIDENT. WE HAVE HAD SEVERAL STARTER PROBLEMS AND ROBINSON ARE TRYING TO SOLVE THE ISSUE.

CA051004003

ROBSIN

LYC  

 

PUMP

LEAKING

10/1/2005

R44RAVENII

IO540AE2A

 

LW15473

FUEL SYS

(CAN) ENGINE DRIVEN FUEL PUMP REPLACED BECAUSE OF OIL LEAK. SB548A HAD BEEN COMPLIED WITH.

CA050930002

SKRSKY

GE  

 

BLADE

UNSERVICEABLE

9/21/2005

S61N

CT581401

 

6117020221067

MAIN ROTOR

(CAN) COCKPIT BIM INDICATOR ILLUMINATED ON TAKEOFF. AIRCRAFT RETURNED TO RAMP. VISUAL INDICATION REVELED (BLUE) MAIN ROTOR BLADE BIM INDICATOR IN THE BLACK. MAIN ROTOR BLADE REPLACED.

CA051004002

SKRSKY

ALLSN

 

BLADE

FRACTURED

9/27/2005

S76A

250C30S

 

 

TURBINE SECTION

(CAN) DURING IN-CRUISE POWER CHECK OF NR 1 ENGINE, NO 2 ENGINE (CHIP LIGHT) CAME ON, SHORTLY FOLLOWED BY (ENGINE OUT) HORN. THE ENGINE WAS BROUGHT BACK TO FLIGHT IDLE AND EMERGENCY LANDING WAS ACCOMPLISHED. ENGINE WAS SHUTDOWN. UPON PRELIMINARY INSPECTION IT WAS FOUND THAT N1 SYSTEM ROTATED NORMALLY. N2 SYSTEM WAS SEIZED AND PIECES OF 3RD STAGE TURBINE WHEEL SHROUD WERE FOUND IN THE EXHAUST COLLECTOR. DAMAGE TO THE 4TH STAGE TURBINE WHEEL AND EXHAUST COLLECTOR WAS ALSO EVIDENT. ENGINE WAS REPLACED AND A/C RETURNED TO SERVICE.

2005FA0001510

SKRSKY

TMECA

 

WIRE

CORRODED

8/10/2005

S76C

ARRIEL1

 

 

STARTER GEN

THE TERMINALS ON THE GENERATOR ARE DESIGNATED A8 TERMINAL D WHICH HAS 2 WIRES. WIRE NR P257A16 GOES TO P708 PIN -3 AND THIS WIRE WAS FOUND TO HAVE BUBBLED UP INSULATION CAUSED BY WIRE CORROSION AND HEAT. THE OTHER WIRE ON TERMINAL D IS P256A16 WHICH GOES TO P708 PIN 4 WHICH THAT WAS PULLED AND IT ALSO WAS FOUND TO HAVE RED CORROSION STARTING ON WIRE SURFACE. THIS WIRE AS WELL AS THE OTHERS SHOWED STARTING SIGNS OF CORROSION. MAINTENANCE HAS REPLACED ALL THE ABOVE CORRODED WIRES. (EA17200603551) (K)

CA050919007

SNIAS

TMECA

UROCOP

SHOCK ABSORBER

CRACKED

9/14/2005

AS350B

ARRIEL1B

 

350A31033KIT2

M/R HUB

(CAN) REMOVED FROM AIRCRAFT FOR MANUFACTURER 2500 HOUR INSPECTION AND 2 COILS OF THE SAME PN WERE FOUND TO BE CRACKED.

CA051003006

SNIAS

TMECA

 

TURBINE BLADES

FAILED

9/13/2005

AS350B2

ARRIEL1D1

 

0292803080

ENGINE

(CAN) WHILE CARRYING OUT THE ALF INSPECTION, THE ENGINEER NOTICED THAT A PORTION OF A TURBINE BLADE WAS MISSING. A THOROUGH INSPECTION WAS CARRIED OUT UPSTREAM OF THE MO4 UTILIZING A BORESCOPE, NO ANOMALIES WHERE NOTED. ANOTHER S/N MO4 WAS INSTALLED WITH NO FURTHER INDICATION OF PROBLEMS.

CA051017006

SNIAS

TMECA

 

PUMP

UNSERVICEABLE

9/18/2005

AS350B2

ARRIEL1D1

 

350A35013100

HYDRAULIC SYS

WHILE REPLACING THE PUMP DRIVE ASSEMBLY FOR THE 1200 HOUR INSPECTION, FOUND THE SPLINES ON THE DRIVE WORN OUT.

CA051018005

SNIAS

TMECA

 

SERVO

LEAKING

10/17/2005

AS350B3

ARRIEL2B

 

SC5083

HYDRAULIC SYS

SERVO WAS REMOVED FROM AIRCRAFT TO REPAIR A LEAK. THE PART WAS SHIPPED TO EUROCOPTER FOR REPAIR. EUROCOPTER HAS CONTACTED US SAYING THAT THE PISTON HAD BEEN PREVIOUSLY DRESSED FOR DAMAGE, AND WAS FOUND TO BE BENT APPROX 0.032

CA051012011

SNIAS

TMECA

 

SWITCH

INTERMITTENT

10/6/2005

AS350BA

ARRIEL1B

 

MS2771923

ON COLLECTIVE

PILOT WAS CARRYING OUT THE HYDRAULIC TEST OF THE ACCUMULATORS AND THE HORN WOULD NOT ACTIVATE. THE A/C WAS SHUT DOWN AND AN ENGINEER STARTED TO TROUBLESHOOT. IT WAS DISCOVERED THAT THE HYDRAULIC CUT-OFF SWITCH WAS OPERATING INTERMITTENTLY. DUE TO HYDRAULIC PROBLEMS IN THE AS350 WORLD A/C GROUNDED UNTIL SERVICEABLE PART ARRIVED.

CA051019002

SNIAS

TMECA

 

IGNITER

LOOSE

9/2/2005

AS350BA

ARRIEL1B

 

CH34745

ENGINE

(CAN) LOOSE CENTER ELECTRODE, REMOVED FOR FEAR OF FODDING ENGINE.

CA051019003

SNIAS

TMECA

 

IGNITER

LOOSE

9/2/2005

AS350BA

ARRIEL1B

 

CH34745

ENGINE

(CAN) LOOSE CENTER ELECTRODE, REMOVED FOR FEAR OF FODDING ENGINE.

CA050914002

SNIAS

TMECA

 

PUMP

INTERMITTENT

9/3/2005

AS350BA

ARRIEL1B

 

P94B12209

FUEL BOOST

(CAN) FUEL BOOST PUMP WAS INTERMITTENT DURING PRE-START CHECKS. PUMP WAS REPLACED WITH AN OVERHUALED UNIT. NO FURTHER DEFECTS. PUMP INSTALLED 35.3 HOURS.

CA051003013

SNIAS

TMECA

 

BLADE

CRACKED

9/10/2005

AS350BA

ARRIEL1B

 

355A12004008

TAIL ROTOR

(CAN) TAILING EDGE CRACKED. BLADES WHERE DESTROYED, ONLY HAD 125 HOURS REMAINING ON THEM. INSTALLED A NEW SET OF BLADES SAME PART NUMBER.

CA051003014

SNIAS

TMECA

 

SPHERICAL STOP

DELAMINATED

9/9/2005

AS350BA

ARRIEL1B

 

704A33633208

MAIN ROTOR

(CAN) FOUND DELAMINATION ON 2 SPHERICAL BEARINGS, OUT OF LIMITS. REPLACED BY 2 NEW ONES.

CA051013006

SWRNGN

GARRTT

 

COOLING TURBINE

LEAKING

10/4/2005

SA227AC

TPE33111U

 

20475546

WING ROOT

CREW COMPLAINED OF A SLIGHT OIL SMELL IN CABIN IN ALL FLIGHT STAGES. MAINTENANCE REPLACED LT COOLING TURBINE AND RELEASED AIRCRAFT TO SERVICE. DURING MAINTENANCE GROUND RUN PRIOR TO REPLACEMENT COOLING TURBINE FAILED AND FILLED CABIN WITH SMOKE AND A STRONG SMELL OF OIL.

2005FA0001461

UROCOP

 

 

FIREWALL

CRACKED

10/5/2005

EC135P1

 

 

L713M2072104

FUSELAGE

FIREWALL, CRACK IN BASE METAL DUE TO ENGINE VIBRATION. (K)


 

CA050913004

UROCOP

 

 

TUBE

CRACKED

9/8/2005

EC155B

 

 

365A75814012

HYD SYSTEM

(CAN) DURING A POST FLIGHT WALK AROUND PILOT NOTICED HYDRAULIC FLUID DRIPPING FROM LT WHEEL WELL. FURTHER INVESTIAGTION FOUND FLUID ACTUALLY DRIPPING FROM ABOVE IN THE FORWARD LT BAGGAGE AREA WHERE THE HYDRAULIC SYSTEM PIPING RUNS. A SINGLE PIPE GOING INTO A MANIFOLD WAS FOUND CRACKED ABOUT .5 INCH FROM THE FITTING. FURTHER VISUAL INSPECTION FOUND A FLAT SPOT ON THE PIPE WHERE THE CRACK WAS LOCATED. WHEN REMOVED IT WAS FOUND THAT THE PIPE WAS LOADED SLIGHTLY. A NEW PIPE WAS INSTALLED AND NO FURTHER PROBLEMS NOTED. PIPE HAS BEEN RETURNED TO FOR FURTHER INVESTIGATION.

 

END OF REPORTS