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

336

bald eagle watching over three eggs

JULY

2006

 


CONTENTS

AIRPLANES

BEECH......................................................................................................................................... 1

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

ENGINES

LYCOMING................................................................................................................................ 3

CONTINENTAL......................................................................................................................... 4

PRATT & WHITNEY.................................................................................................................. 4

ROLLS ROYCE........................................................................................................................... 6

PROPELLERS

MC CAULEY.............................................................................................................................. 8

ACCESSORIES

ELECT. WIRE.............................................................................................................................. 9

ELECTROSYSTEMS................................................................................................................ 10

KELLY AEROSPACE............................................................................................................... 10

LAMAR TECHNOLOGY.......................................................................................................... 11

AIR NOTES

ELECTRONIC VERSION OF FAA FORM 8010-4, MALFUNCTION OR
DEFECT REPORT..................................................................................................................... 11

PAPER COPY OF FAA FORM 8010-4, MALFUNCTION OR DEFECT REPORT............... 11

INTERNET SERVICE DIFFICULTY REPORTING (iSDR) WEB SITE................................... 12

IF YOU WANT TO CONTACT US......................................................................................... 13

AVIATION SERVICE DIFFICULTY REPORTS...................................................................... 13

 


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

BEECH

Beech (Raytheon): A36; Fuel Tank Bladder Contamination; ATA 2810

A repair station technician states, “A customer reported ‘white particles’ coming from the (aircraft’s) quick drains.” Two fuel bladders were removed and inspected: evidence of the white powder was found in various places in both tanks. They were replaced with new units from the original manufacturer who was made aware of the problem. (Part numbers provided are 2121-9-1 and 2121-10-2.)

Part Total Time: 9.7 hours.

 

Beech (Raytheon): E55; Failed Nose Gear Retraction Rod-End; ATA 3230

“After takeoff,” states this repair station technician, “the landing gear was retracted and a banging noise was heard by the pilot. It became apparent the nose gear retract mechanism had broken and that the nose gear did not retract properly. The aircraft was flown to its destination airport where the nose gear collapsed on landing—as expected. Investigation of the mechanism revealed a broken and spread rod-end (Beech P/N HMXL6FG) located under the landing gear transmission. (It is) connected to the nose landing gear push-pull tube (Beech P/N 36-820011-9). The probable cause (of this defect) is suspected to be an out-of-rig condition that eventually caused failure. No evidence of foreign objects was evident. Special inspections of rigging at regular intervals is recommended to avoid recurrence of this incident.”

Part Total Time: (unknown).

 

Beech (Raytheon): E90; Cracked Main Gear Torque Plate; ATA 3242

A mechanic states, “During a phase 1 and 2 inspection a crack was found in this Cleveland part attached to the R/H gear assembly. The crack is on the torque plate upper forward brake cylinder pin attach hole. A bushing installed in this hole has no sign of damage. Probable cause of cracking would be stress related.” (Torque plate P/N 075-15500.)


Closeup of a crack in a brake torque plate.

 

Part Total Time: 8,273.7 hours.

 

Beech (Raytheon): 200; Broken Chain Link in Gear Extension: 3230

“The link in the landing gear extension chain was found broken and in the belly of the aircraft,” says this submitter. “This breakage prevented the extension of the nose gear.” (Connecting link P/N 131378-25-CL.)

Part Total Time: (unknown).

 

Beech (Raytheon): A200; Sheared Cabin Door Bolt; ATA 5210

(Not shown here are reference page copies that were included with this report: Beech C-12 Internal Parts Catalog 52-10-02 item 68 and Beech A200 52-10-02 item 122.)


A mechanic states, “During routine maintenance to replace the cabin door hardware (as required by the maintenance manual) a bolt was found sheared inside the (latch) bracket. (Bolt P/N NAS 1103-21D; Bracket P/N 50-430062-19.) There have been multiple SDRS (Service Difficulty Reports) of cabin doors opening in flight due to failure of similar hardware. We recommend replacement of the door latch mechanism (and its) pins and bolts at 5,000 cycles rather than the manufacturer’s recommended 10,000 cycles.”

Part Total Time: (unknown).

 

Beech (Raytheon): B200; Loose Elevator Torque-Tube Rivets; ATA 2730

The mechanic writing this report describes finding free play in the L/H elevator. “(I) found the L/H elevator torque tube (P/N 101-610019-5) mounting flange—from the tube assembly (itself) to the elevator (structure)—with its rivets working loose. This allowed the elevator to have 1.5 inches of play. This (defect) was found during a 400 hour lubrication inspection. The recommendation to prevent reoccurrence is (for the manufacturer) to use solid rivets, not blind rivets.”

Part Total Time: 3,808.4 hours.

 

CESSNA

Cessna: 210; Cracked Hydraulic Line; ATA 2910

A landing gear hydraulic line described as the (door open line) failed, resulting in the aircraft landing with the main landing gear up. The submitting mechanic states, “The ferule on the nose landing gear door open line cracked along stress risers created by a flaring tool vice. (This) resulted in loss of hydraulic fluid to operate the landing gear.” (The part number for this line was not provided. This defect is yet another example of little things creating great consequences. SDRS data reflects at least three similar failures.)

Part Total Time: (unknown).

 

Cessna: 560XL; Arcing Fuel Level Switch; ATA 2842

A submitter describes the following difficulty with a fuel level switch. “The right low fuel level system was inoperative. (I) removed the switch and found signs of arcing on the top side of the switch. (I) troubleshot further and found the PC (printed circuit) board was defective. It is not known if the switch damaged the PC board. This is not the first time we have seen a defective float switch with signs of arcing. However, it is the first time that a damaged PC board was associated with it. It was noted when the float switch is in the ‘high fuel level’ position the contact surfaces are aligned. When the switch is in the ‘low fuel level’ the contacts are (almost) completely misaligned.” (Part number for this switch is 99144272.)

Part Total Time: 2,291.0 hours.

 

ENGINES

LYCOMING

Lycoming: O-320-E3D; Premature Camshaft Wear; ATA 8520

“During an annual inspection, ferrous metal flakes were found in the oil filter,” states the submitter. “Several pieces (were also) found in the finger strainer. (All of these pieces) were sent to Textron Lycoming for analysis. It was reported by them that the ferrous metal came from the camshaft and tappet bodies. The engine was removed


for overhaul. Time since overhaul is 2,092.9 hours. The camshaft was replaced at 1,164.4 hours since overhaul. Total time on the Camshaft is 928.5. The average oil change interval since overhaul is 91 hours. (I) recommend the 50 hour oil change interval recommended by Textron Lycoming be strictly adhered to.” (The camshaft P/N LW-18837 returns five additional entries from SDRS data.)

Part Total Time: 928.5 hours.

 

Lycoming: O360 A4M; Premature Camshaft Wear; ATA 8520

Quite similar to the previous report, another mechanic writes, “At annual inspection, metal was found in the oil filter. The engine was torn down and the camshaft and lifter bodies were found to be damaged. (These parts) were purchased from Superior Air Parts...and installed in accordance with TBO (time between overhaul). Failure occurred at TSO (time since overhaul—800.0 hours indicated). It appears the failure was caused by manufacturing defect.” (Provided part numbers: Camshaft--SL18840; Lifter Bodies--SL72877. SDRS returns five additional entries for each part number.)

Part Total Time: 800.0 hours.

 

CONTINENTAL

Continental: IO520E; Cracked Crankshaft; ATA 8520

This engine’s crankshaft is described by a mechanic as having developed a crack “...behind the prop flange—(approximately ˝ the circumference of the shaft) while in flight....” (Crankshaft P/N 633620 returns four additional from SDRS data.)

Part Total Time: 591.2 hours.

 

PRATT & WITNEY

Pratt & Whitney: PT6A-20; Broken Turbine Shaft Housing ; ATA 7250

The submitting repair station technician and an attending FAA field inspector provided the following description and documentation of a cracked and broken turbine shaft housing (P/N 3104279-01). “I assisted in the investigation of an occurrence of an in-flight engine shut-down. The investigation consisted of witnessing an engine disassembly and determining why the engine failed. Investigation revealed the engine failure was caused by an over-speed condition of the engine as result of a power turbine shaft housing failure. (Disassembly of the engine)...revealed the housing assembly for the power turbine shaft had failed at the flange (at the base of the housing), allowing the power turbine shaft to uncouple from the gear case. This allowed the engine to over-speed, leading to the power turbine blade failures. Inspection of the housing revealed a crack was present for some time prior to the engine failure.”


Picture of a failed turbine housing and its mounting flange beside a new unit.

 

Picture of the failed housing mount flange beside the turbine housing.


Picture of the turbine housing mount.

Part Total Time: (unknown).

 

ROLLS ROYCE

Rolls Royce: TAY 611-8; Fuel Pump Contamination; ATA 7310

A Gulfstream GIV was “input” to a repair station due to an intermittent fuel quantity indication. The submitter states, “...it was also elected to have the terminating action of AD 2005-03-06 complied with by incorporating Tay Service Bulletin 73-1592: ‘Replacement of Fuel Tubes (P/N JR33021A).’ When (the repair station) removed the tubes for replacement they discovered substantial amounts of metal shavings had accumulated against the inlet screens on the high pressure fuel pumps on both engines. All findings were immediately forwarded to Rolls Royce for guidance. (The repair station sent) a sample of the metal to an independent testing lab to have the metal analyzed to help make a judgment as to what it was and where it came from. The findings from the lab indicated the metal was consistent with airframe metals. Rolls Royce came back with recommendations to have the fuel system components of both engines downstream of the low-pressure fuel filters inspected and or repaired as necessary. Both engines were removed and forwarded (to a specializing facility) for repairs and test cell evaluations.” (Later, these engines were reinstalled and the aircraft was returned to service.) “We have failed to explain where the metal came from and how it got there.” (Twenty-one digital photographs were included with this submission—three are shown here. The visual implications are quite dramatic.)


Closeup of fuel pump on engine, line removed, debris visible inside pump.

 

Picture same as (a), with fingers removing debris.


Closeup of machined metal shavings extracted from pump.

 

Part Total Time: (unknown).

 

PROPELLERS

MC CAULEY

McCauley: 3AF32C528-A; Improper Assembly; ATA 6111

A technician states, “This propeller came into our shop for an STC (supplemental type certificate) blade angle change on a new propeller. On our first check of the blade angle we got four degrees and knew something was wrong, so we pulled the dome—the piston snap ring had not been installed from the factory.” (Snap ring P/N A-1636-16.)

Part Total Time: 0.0 hours.

 


ACCESSORIES

ELECT. WIRE

Elect. Wire: Fluoropolymer Insulation (Typical W-22759/43); ATA 2400

(The following safety article is published as received from the Fort Worth Rotorcraft Directorate. Contact information can be found at the article’s end.)

Concerns

Electrical wire with cross-linked fluoropolymer insulation has been identified as an influence in causing corrosion of electrical components. This type of insulation is common in several dash number configurations of Mil Std. W-22759 wire, and there may be other wire that also uses this type of insulation.

Data indicates wire with cross-linked fluoropolymer insulation will emit trace amounts of fluorine and contribute to the creation of hydrofluoric acid (a corrosive agent that reacts with moisture). If proper controls are in place during manufacture and storage, the occurrence of corrosion can be minimized. This corrosion is red in color and has been referred to as “Red Plague”. There have been verified cases of this type of corrosion on helicopters and space shuttle program applications. This type of corrosion can compromise electrical wiring by the same factors associated with other types of corrosion.

Background

An FAA safety recommendation was issued to the FAA Rotorcraft Directorate Fort Worth, Texas. This safety recommendation addressed two malfunction/ defect reports, one from a repair station and another from a helicopter operator. These reports addressed the existence of copper oxidation in 10 and 16 gage wires, for two Sikorsky S-76C helicopters. Additional investigation, by the reporting sources, revealed the same oxidation in other circuits. An FAA investigation discovered NASA had issued an advisory about the same type of corrosion, associated with the same type of wire insulation. Given the information gained by the NASA advisory and an accompanying white paper, there are concerns associated with the use of this type of wiring insulation in any helicopters. 

Recommendations:

·                  Pre-wired Harness Assemblies

·                  Pre-wired and stored wiring harnesses should be inspected for the appearance of “Red Plague” (a darkening of otherwise shiny metal surfaces, and/or evidence of reddish corrosion).

·                  Manufactured or Modified/Repaired Aircraft

·                Aircraft that have been manufactured or modified/repaired during the last six months using wire with cross-linked fluoropolymer insulation should be inspected for evidence of “Red Plague” corrosion.

·                  Storing of Wiring Harness Assemblies

·                  Pre-wired harness assemblies should be removed from sealed bags and stored in  packages that will allow any trace amounts of fluorine to escape. Wiring assemblies should be stored in a controlled humidity environment. The preferred environment would be a dry nitrogen atmosphere.

·                  Awareness of Manufacturing Processes

·                  The manufacturing process of wire that uses cross-linked fluoropolymer insulation can affect the escaping rate of trace amounts of fluorine. The preferred method for cooling the insulation extrusion during manufacture is to use dry nitrogen.

For Further Information Contact

Robert McCallister, Safety engineer, FAA Fort Worth Rotorcraft Directorate Standards Staff, Fort Worth, TX 76137; Phone (817) 222-5121; fax (817) 222-5961; email: Robert.r.mccallister@faa.gov

 


(These last entries on Electrosystems, Kelly, and Lamar will clear the “starter” pile from my desk. Kelly constitutes the largest part of the stack—I suspect they also produce the greatest number of these units! Readers are reminded no correlation necessarily exists between reporting frequency and brand quality for any of these Alert articles—Ed.)

ELECTROSYSTEMS

Electrosystems: Starter: MHB 4016; Sheared Splines; ATA 8011

“The pilot reported grinding noise from the engine compartment when the starter was engaged,” states a mechanic. “The starter was removed. The armature was found with two splines sheared off and the intermediate gear was missing two teeth. The cause is unknown. This is the third armature (failure) within the past six months having the same defect.” (Armature P/N MHB 2399S. Not clarified in the last sentence is whether or not this third failure is with the same model starter. SDRS records four additional items relating to the MHB 4016 starter.)

Part Total Time: 40.0 hours.

 

KELLY AEROSPACE

Kelly Aerospace: Starter: MHB 6016; Failed Bendix; ATA 8011

...part one...

The mechanic states, “(I) installed a factory overhauled engine onto this aircraft (Cessna 182 with Lycoming 540L3C5D). The Kelly Aerospace starter bendix was engaged when the engine was installed. After first start the starter would spin, but the bendix would not re-engage the starter ring gear on the engine. This starter (S/N E111092) was replaced with (another) overhauled Kelly Aerospace starter (S/N E123085).” (SDRS records four additional items relating to the MH 6016 starter. A generic “starter” data base query returns almost 300 entries from which to study.)

Part Total Time: 0.0 hours.

...part two...

(Our mechanic continues here with the same aircraft on the same day—with the same problem. Another part generates another defect report.)

(I had previously removed...) the defective Kelly Aerospace starter (S/N E11092) from the engine. (I) installed Kelly Aerospace overhauled starter (S/N E123085) on to the aircraft with the bendix engaged. After the first start the starter would spin but not re-engage the starter bendix into the ring gear on the engine. (I) installed a Prestolite starter MHB 4016 (S/N 6120763). Operation and ground run checked good.” (So...if you think this mechanic is experiencing frustration with starters, read the next submission for “streamlined frustration.”)

Part Total Time: 0.0 hours.

 

Kelly Aerospace: Starter: ES646275-1; Locked Starters; ATA 8011

(The following is a composite of nine separate reports on the same model starter from the same submitting repair station. Generally excluded from an Alert article, serial numbers listed here help demonstrate earnest intent of the submitter.)


A technician describes these nine Kelly starter defects as, “Starter does not turn freely by hand (1 ea.); unable to turn starter by hand (5 ea.); or new starter does not turn freely by hand (3 ea.).” Serial numbers listed are: F050672, F050674, F050665, F050666, F050681, F050682, F050684, F080941, and F061641. (This particular part number returns 12 entries from the SDRS base.)

Part(s) Total Time: 0.0 hours.

 

LAMAR TECHNOLOGY

Lamar Technology: Starter: PM2401; Failed Bendix; ATA 8011

An operator of an air taxi writes, “We operate three Cessna 172 model (aircraft) and have replaced seven of these (Lamar) starters already, including unit S/N 85681216 which was overhauled by the manufacturer. (All of these units failed) with barely 100 hours of flying (time). The main problem with this starter is that servicing can be accomplished only by the manufacturer, which on this particular unit amounted to $407.35. The other units were replaced by Cessna under new aircraft warranty claims. Only one failure occurred at the home base, leaving our aircraft stranded at other airports, including international locations. Every time we have replaced these units (it has been with) new or factory overhauled components, which confirms there is a quality/materials problem.” (The above serial number is a “best guess” of hand-written material. Not mentioned in the narration, this report indicates the bendix was “cracked or split” by entry of the same in the “part condition” block. As with the previous report, this particular part number also returns 12 entries from the SDRS base.)

Part Total Time: 100.0 hours.

 

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

AU510001474

 

 

HONEYWELL

LIGHT

OPEN

12/12/2005

 

 

 

40023344

INDICATOR

(AUS) ATTITUDE INDICATOR PANEL LAMPS ON BEZEL BLOWN. FOUND DURING INSPECTION IAW AD/RAD/043.(AD/SB DESC: AD/RAD/O43 ) (CASA# 510001474)

AU510001968

 

 

 

HUB  

DAMAGED

12/12/2005

 

 

 

D65591

PROPELLER

CHECK OF PROPELLER HUB BEFORE FITMENT TO AIRCRAFT FOUND UNACCEPTABLE DAMAGE IN BLADE/HUB SOCKET RADIUS. THIS IS A CRITICAL AREA AND THE MANUFACTURER ADVISED THAT THE HUB BE SCRAPPED.

2006FA0000554

 

 

 

STARTER

INOPERATIVE

5/23/2006

 

 

 

ES6462382

ENGINE

STARTER IS DIFFICULT TO TURN. (K)

2006FA0000557

 

 

 

STARTER

INOPERATIVE

5/17/2006

 

 

 

MZ6222

ENGINE

WHINNING STARTER, WOULD NOT ENGAGE. (K)

2006FA0000558

 

 

 

DIAPHRAGM

WORN

5/9/2006

 

 

 

 

FUEL PUMP

DURING DISASSEMBLY FOR OVERHAUL, OVER THE PAST FEW MONTHS, HAVE NOTED THAT THE STEEL WASHER ON TOP OF THE DIAPHRAGM STEM IS LOOSE ON THE STEM AND IN SOME CASES IS PARTIALLY EATEN THROUGH OR WORN AWAY BY HAMMERING AGAINST UPSET END OF DIAPHRAGM STEM. IF WASHER COMES COMPLETELY OFF, FUEL PUMP WILL BE INOPERABLE. SOME WASHERS HAVE BEEN OBSERVED TO BE WORN 60-80 PERCENT THROUGH THEIR THICKNESS. SB NR 548A IS APPLICABLE TO THIS ISSUE. HOWEVER, MANY OF THE PUMPS WITH WORN/LOOSE WASHERS ARE OUTSIDE DATE CODES COVERED BY SB. THIS HAS BEEN OBSERVED IN MODELS 15472 AND 15473. AT THE SAME TIME, A MODEL 16775 WAS DISCOVERED TO HAVE A WORN/LOOSE WASHER. THIS MODEL NR WAS NOT IN THE SB. (K)

CA060220003

 

 

BOMBDR

SCREEN

DAMAGED

2/16/2006

 

 

 

MDL15R2001

APU INLET

A COMPRESSOR INLET SCREEN MODIFICATION, AWI RECEIVED INFORMATION FROM STANDARD AERO LATE ON FEB 16,2006 THAT THREE OR FOUR OF THE SCREENS HAD RUPTURED IN SERVICE AND THERE WAS A POSSIBILITY THAT FOD TO THE ENGINE HAD OCCURRED. THE PARTS WERE SHIPPED TO AWI AND RECEIVED FEB. 17, 2006, THERE ARE SOME SCREENS THAT HAVE BEEN PERFORATED. BUT, THE INLET SCREENS DO NOT APPEAR TO HAVE BEEN IN SERVICE. THE RUBBER AROUND THE INLET SCREENS IS NOT BURNED FROM ENGINE HEAT AND THE SCREENS ARE NOT BLACKENED. AEROSPACE WELDING TAKES THIS MATTER VERY SERIOUSLY AND A MATERIAL REVIEW BOARD MEETING HAS BEEN CALLED FOR MONDAY AFTERNOON FEB 20,2006 TO REVIEW AND RESOLVE THIS MATTER AS SOON AS POSSIBLE.

AU510001707

 

 

HONEYWELL

CONVERTER

OUT OF TOLERANCE

12/8/2005

 

 

 

4040831901

DADC 

DIGITAL AIR DATA COMPUTER (DADC) PRESSURE CONVERTER PS AND PT SENSORS OUT OF TOLERANCE. FOUND DURING INSPECTION IAW AD/RAD/43 AMDT5 PART1.

AU510001875

 

 

HONEYWELL

SENSOR

OUT OF LIMITS

12/12/2005

 

 

AZ810

4040831901

DADC 

DIGITAL AIR DATA COMPUTER (DADC) PRESSURE CONVERTER (PS AND PT SENSOR) OUT OF TOLERANCE.

CA060111001

 

 

 

CIRCUIT BREAKER

BURNED

1/3/2006

 

 

 

 

 

AIRCRAFT HAD NR 1 AC GENERATOR INOPERATIVE (GOES OFFLINE AFTER 20 SECONDS). INITIALLY, THE GENERATOR HAD BEEN REPLACED, HOWEVER, THE DISCREPANCY REMAINED. SUBSEQUENTLY, CIRCUIT BREAKER, P/N 2TC2-5 FOUND WITH HOLE BURNT IN THE SIDE. FOR RECTIFICATION PURPOSES, CONTACTOR RELAY 2421-K1 REPLACED. RING CONNECTORS TO CB3 AND CB5 REPLACED, P/N HC-AJN022 (CONTACTOR RELAY), P/N 2TC2-5 (CB3) & (CB5).

CA060330002

 

 

 

VALVE

DAMAGED

3/30/2006

 

 

 

AVZ4B11198

FUEL SYSTEM

ELECTRIC MOTOR SECTION OF PUMP ASSY WAS FOUND DURING INSPECTION TO MISSING A "C" CLIP AND PLUG. REPLACED WITH SERVICABLE UNIT.

CA060110006

 

 

 

CABLE

DAMAGED

1/10/2006

 

 

 

82700561003

ELEVATOR

DURING CHECK , 2 CHAIN CABLE ASSY`S, P/N 82700561-003, TITLED "ELEV TRIM AND ELEV GUST LOCK CONTROL" INSPECT OF CHAINS, REF AD CF-2005-38, WAS FOUND INCORRECTLY ASSEMBLED AND SUPPLIED BY SPARES. ASSY FOUND INCORRECTLY BUILT WHEN ATTEMPTING TO INSTALL AS PER AMM 27-36-01, PARA B, STEP 3. SPECIFIES THAT CHAIN PLATE IS REQ`D TO BE ON INBD SIDE OF SPROCKET. THIS CAN'T BE ACCOMP WITH NEW CHAIN ASSY IN ITS PRESENT CONFIG (DWG 82700561 SHOWS THE DIMENSIONS AND CORRECT ORIENTATION OF ASSY). TECH HELP DESK E-MAILED, ADVISED OF ISSUE & REQUESTED TO PULL THEIR DRAWINGS TO CONFIRM OUR FINDINGS. REQUESTED INSPECT EXISTING INVENTORY TO CONFIRM IF THEIR SPARES WERE ALSO AFFECTED. REPLACEMENT CHAIN CABLE ASSY`S ORDERED AOG AND REQUEST ALSO MADE TO MODIFY EXISTING ASSY`S FOR INSTALLATION.

CA060616004

 

 

 

WHEEL

MISMANUFACTURED

5/24/2006

 

 

 

40289

MLG 

PURCHASED EIGHT CLEVELAND 40-289 WHEEL ASSEMBLIES NEW FROM FACTORY, RETURNED FIVE ASSEMBLIES DUE TO WHEELS INSPECTED BY EDDY CURRENT AND FOUND SEVERAL CASTING FLAWS (VOIDS) IN BEAD AREAS. WHEEL ASSEMBLIES RETURNED TO FACTORY FOR INVESTIGATION BY THEIR QA DEPARTMENT, HAVE NOT RECEIVED ANY RESPONSE FROM PARKER AEROSPACE AS OF JUNE 9/06. TWO WHEEL ASSEMBLIES RETURNED THROUGH KADEX AERO SUPPLY, NO SERIAL NUMBERS LISTED. THREE WHEEL ASSEMBLIES RETURNED THROUGH AVIALL (CALGARY), SERIAL NUMBERS AS FOLLOWS: 4553/4578, 4581/4554, 4575/NSN.

CA060526005

 

 

SKRSKY

FREEWHEEL UNIT

DAMAGED

5/9/2006

 

 

 

6107435000060

M/R GEARBOX

LT P/N 61074-35000-061 S/N C144-00286 RT P/N 61074-35000-060 S/N C144-00279 THESE UNITS WERE CHANGED UPON REQUEST OF THE CUSTOMER AFTER A SUSPECTED FREEWHEEL SLIP. SEE ATTACHED REPORT AND DIGITAL PICTURES FOR DETAILS. UNABLE TO ATTACH FILES, WILL E-MAIL THEM. THESE UNITS HAVE BEEN SENT TO WALDRON AND COMPANY FOR ANALYSIS.

CA060112006

 

ALLSN

 

TURBINE BLADES

BROKEN

1/5/2006

 

250C*

 

6886407

ENGINE

TURBINE RECEIVED AT ESSENTIAL TURBINES IN A DISASSEMBLE STATE. LOG CARDS REFLECT THAT THE TURBINE HAD BEEN INVOLVED IN A HARD LANDING. IT HAD BEEN INSPECTED AND SENT TO MAC-V AVIATION WHO RE-ASSEMBLED THE ENGINE. MAC-V STATED VIA A PHONE CALL THAT THE HARDWARE WAS MIXED IN THE COMBUSTION SECTION AND COULD NOT FIND ALL OF THE NUTS, BOLTS ETC. OUR INVESTIGATION LEADS US TO BELIEVE THAT THE HARD LANDING WAS NOT A FACTOR. THE FAILED TURBINE WHEEL WILL BE FORWARDED TO THE SAFETY BOARD TO EVALUATE THE REASON FOR FAILURE, POSSIBLY DUE TO FOD FROM ITEM MISSED DURING RE-ASSEMBLY.

CA051206005

 

ALLSN

 

COUPLING

DAMAGED

12/1/2005

 

250C20

 

6870832

TURBINE ASSY

DURING A CONVERSATION BETWEEN ESSENTIAL TURBINES INC (ETI) PROCUREMENT MANAGER, AND CENTRAL ROMANA CORPORATION LTD., LA ROMANA, DOMINICAN REPUBLIC (T.809-723-1372, 809-523-8232, 809-813-9350 FAX 305-574-7873), A QUERY WAS ABOUT PARTS THAT (ETI) WAS ASSUMED TO HAVE SUPPLIED. ETI REQUESTED THE CERTIFICATION COPIES AND RECEIVED FAA 8130.3 WITH ESSENTIAL TURBINES INC ON IT AND AMO18-09 DATED 11/10/2005. CERTIFICATES ARE IDENTIFIED WITH 68708324 & 6898977-H PN RESPECTIVELY. ETI, Q.A. MANAGER HAS SENT ETI TRANSPORT CANADA AMO37-94 & EASA 145.7117 CERTS TO THE COMPLAINANT.

CA060227005

 

ALLSN

 

SUPPORT

CRACKED

2/24/2006

 

250C28B

 

6898806

ENGINE

ON REMOVAL OF TURBINE SECTION FROM ENGINE ASSY ONE OF THE FWD SUPPORT STUTS WAS FOUND TO BE CRACKED. TURBINE ASSY SENT FOR REPAIR. RECOMMEND BETTER VISUAL INSPECTIONS ON SCHEDUELED INSPECTIONS AND POSSIBLY VIBRATION CHECKS.

CA051209003

 

ALLSN

ALLSN

ENGINE

MALFUNCTIONED

12/3/2005

 

AE3007A

 

 

LEFT 

(CAN) A/C WAS IN ROUTE TO DESTINATION, WHEN 20 MINUTES INTO THE FLIGHT, THE CAPTAIN NOTICED THAT EICAS INDICATIONS FLICKERED OFF THEN ON. LT ENGINE THEN SHUTDOWN UNCOMMANDED AND CREW RECEIVED NUMEROUS EICAS MESSAGES. (TC NR 20051209003)

AU510002167

 

GARRTT

 

BULL GEAR

BROKEN

7/11/2005

 

TPE33110

 

8937396

ENGINE

CHIP LIGHT ON IN FLIGHT. STRIP INSPECTION FOUND THAT THE ENGINE BULL GEAR HAD BROKEN TEETH.

CA060104006

 

GE  

 

MANIFOLD

FAILED

12/28/2005

 

CF650E2

 

9196M44G01

SUMP 

OPERATOR REPORTED N1 VIBRATION AND METAL CONTAMINATION OF A SUMP SCAVENGE SCREEN AND MASTER CHIP DETECTOR. THE ENGINE WAS REMOVED FOR FURTHER INVESTIGATION. DURING INITIAL TROUBLESHOOTING, LOOSE MATERIAL WAS HEARD TUMBLING IN THE SPINNER CONE AND EVIDENCE OF OIL LEAKAGE FROM UNDER THE SPINNER WAS OBSERVED. THE SPINNER CONE WAS REMOVED FOR INVESTIGATION. OBSERVED CATASTROPHIC FAILURE OF THE A SUMP MANIFOLD ASSEMBLY. SIX OF THE TEN MOUNTING BOLTS WERE FOUND SHEARED. ENG HAS BEEN SCHEDULED FOR DISASSEMBLY AND FURTHER INVESTIGATION IN EARLY JANUARY. THE OEM WILL BE ADVISED AND WILL ASSIST WITH THE INVESTIGATION. FURTHER DETAILS WILL BE FORWARDED TO THE TCCA WHEN AVAILABLE.

CA060413004

 

GE  

 

WIRE HARNESS

MISMANUFACTURED

2/21/2002

 

CT581401

 

5003T78P04

ENGINE

SIX NEW HARNESSES WERE SENT TO COLUMBIA HELICOPTERS FOR JET CAL TEST. ALL SIX FAILED. THIS WAS THE RESULT OF AN ENGINE NOT PASSING TEST ON THE TEST STAND AND THE FAULT WAS FOUND TO BE A NEW T5 HARNESS. AFTER THAT WE HAVE BEEN SENDING ALL NEW T5 HARNESS OUT FOR JET CAL BEFORE BEING INSTALLED ON AN ENGINE.

AU510002155

 

LYC  

 

CRANKSHAFT

BROKEN

9/11/2005

 

IO540E1B5

 

75038

ENGINE

CRANKSHAFT BROKEN COMPLETELY THROUGH AT NR 1 CRANKPIN JOURNAL.

AU510002033

 

LYC  

LYC  

TUBE

LOOSE

12/12/2005

 

O360A1F6

 

68484

CRANKSHAFT

OIL TRANSFER TUBE LOOSE IN CRANKSHAFT. SUSPECT POOR QUALITY OF FLARING. INVESTIGATION FOUND TWO OTHER CRANKSHAFTS WITH THE SAME PROBLEM.

AU510001908

 

LYC  

 

CAM FOLLOWER

FAILED

12/12/2005

 

TIO540J2BD

 

72877R

ENGINE

(AUS) ECI PNO 72877R CAM FOLLOWERS FAULTY. LIFTERS ARE BADLY WORN AND CAMSHAFT LOBES DAMAGED. ENGINES FITTED WITH THIS PN LIFTERS INCLUDE MFG TIO540J2BD AND O320D2J MODELS. (MATERIAL - ORGANIZATIONAL ) (CASA NR 510001908)

CA051221004

 

LYC  

 

CRANKSHAFT

SEPARATED

12/6/2005

 

TIO540R2AD

 

13F17760

ENGINE

CRANKSHAFT FAILED AT THROW BETWEEN NR 2 MAIN JOURNAL (AS NUMBERED BACK TO FRONT) AND NR 4 CRANK PIN. CRACK STARTED AT RADIUS OF MAIN JOURNAL AND PROPAGATED APPROX 70% THROUGH THROW BEFORE SEPARATING. AFTER SEPARATION, THROW BETWEEN NR 3 ROD AND NR 3 MAIN FRACTURED THROUGH FROM OVERLOAD. APPEARS TO HAVE BEEN INITIATED BY STRESS RISER CREATED BY SLIGHT STEP IN RADIUS. (POSSIBLY CREATED FROM BEING TOUCHED ACCIDENTALLY BY GRINDING WHEEL WHEN CRANKSHAFT WAS REWORKED.) CRANKSHAFT WAS (TC# 20051221004).

CA060110005

 

PWA  

 

SHROUD

DISTORTED

1/4/2006

 

PT6A114A

 

311074102

COMPRESSOR

DURING A RECTIFICATION INSPECTION OF RENTAL ENGINE, CT SHROUD SEGMENT RETAINING RING OF POST SB 1627 CONFIG FOUND LOOSE AND MINOR SHIFTING OF CT SHROUD SEGMENT WAS NOTED. CT SHROUD SEGMENT-RETAINING RING WAS OF POST SB 1627 CONFIG AND CT SHROUD SEGMENTS (P/N 3053094) WERE PER SB 1628. QTY 6-RUB SPOTS WERE NOTED ON CT SHROUD SEGMENTS WITH MINOR RUB ON CT BLADES. CT SHROUD SEGMENT-RETAINING RING WAS FOUND DISTORTED AND PARTIALLY DISENGAGED FROM RETAINING GROOVE OF CT SHROUD HOUSING. NO OVER HEATING/BURNING OF HOT SECTION PARTS NOTED. INSPECT OF CT SHROUD HOUSING WAS DONE AND ROUNDNESS OF ALL CRITICAL DIAMETERS NOTED WITHIN O/H MANUAL LIMIT. SHIFTING OF CT SHROUD SEGMENTS WAS DUE TO PARTIAL DISENGAGEMENT OF CT SHROUD SEGMENTS RETAINING RING FROM CT SHROUD HOUSING RETENTION GROOVE.

CA060531023

 

PWA  

 

ENGINE

MAKING METAL

5/24/2006

 

PT6A27

 

 

 

DURING CRUISE, ENGINE OIL PRESSURE WAS REPORTED TO DECREASE ACCOMPANIED BY AN UNCOMMANDED REDUCTION IN POWER. THE ENGINE WAS SHUT DOWN IN FLIGHT. SUBSEQUENT INSPECTION REVEALED METALLIC DEBRIS ON THE ENGINE CHIP DETECTOR AND AN INABILITY TO ROTATE. P&WC WILL INVESTIGATE THE EVENT AND ADVISE OF ROOT CAUSE ONCE ESTABLISHED.

CA060405002

 

PWA  

 

ENGINE

MAKING METAL

4/5/2006

 

PT6A50

 

 

 

ENGINE OIL METAL CONTAMINATION WAS REPORTED AND ENGINE SENT TO APPROVED ENGINE FACULITY.

CA060307004

 

PWA  

PWA  

BOLT

FAILED

3/3/2006

 

PT6A65AR

PT6A65AR

MS949034

GEARBOX

(CAN) THE POWER SECTION OF ENGINE S/N PCE-PS 97533 WAS REMOVED DUE TO SEIZED CONDITION. THE REASON FOR REMOVAL AS DESCRIBED BY THE OPERATOR WAS FAILURE ON START-UP. THE POWER SECTION ROTATION HUNG ON LIGHT UP, RELEASED AND HUNG UP AGAIN. START ABORTED. POWER SECTION BINDS UP DURING MANUAL ROTATION. (TC NR 20060307004)

CA051129008

 

PWA  

 

ENGINE

FIRE

11/2/2005

 

PT6A68

 

 

 

DURING AEROBATIC MANEUVERS (RAYTHEON T-6A) SMOKE AND FUMES BECAME EVIDENT IN THE COCKPIT. P&WC WILL MONITOR INVESTIGATION OF THE INCIDENT AND WILL ADVISE OF ROOT CAUSE ONCE ESTABLISHED.

CA051223006

 

PWA  

 

WARNING LIGHT

ILLUMINATED

11/30/2005

 

PT6A68

 

 

ENGINE

DURING SPIN RECOVERY MANEUVERS THE ENGINE CHIP DETECTOR WARNING ANNUNCIATED ACCOMPANIED BY VIBRATION. THE AIRCRAFT DIVERTED FOR AN UNSCHEDULED LANDING. P&WC WILL INVESTIGATE THE EVENT AND ADVISE OF ROOT CAUSE ONCE ESTABLISHED.

CA060306006

 

PWA  

 

TURBINE BLADES

DAMAGED

3/6/2006

 

PT6T3

 

311532101

POWER SECTION

(CAN) POWER SECTION WAS RECEIVED FROM THE OPERATOR FOR REPAIR DUE TO HIGH VIBRATION LEVELS. INSPECTION REVEALED THAT THE COMPRESSOR TURBINE BLADES HAD SUFFERED EXTENSIVE DAMAGE. 12 CT BLADES WERE FOUND DAMAGED TO VARYING DEGREES OF THE BLADE SURFACE MISSING. ANOTHER 12 BLADES EXHIBITED FATIGUE CRACKING EMANATING FROM THE TRAILING EDGE OF THE BLADE. (TC NR 20060306006)

CA060410006

 

PWA  

MESSIER

CYLINDER

CORRODED

4/6/2006

 

PW126A

 

 

MLG 

AT DISASSEMBLY BY FIRST AIR MAINTENANCE SERVICES (EASA APPROVAL NR 145-7030) THE OUTER CYLINDER WAS FOUND TO HAVE SEVERE CORROSION, VIRTUALLY PERFORATED AND ASSESSED AS INELIGIBLE FOR RETURN TO SERVICE. THE RECORDS INDICATE THE LANDING GEAR ASSEMBLY WAS REMOVED FROM AIRCRAFT SE-LGX (WEST AIR SWEEDEN).

CA051205006

 

PWC  

 

MANIFOLD

MISSING

11/7/2005

 

PW150A

 

AS3209010012

FUEL SYSTEM

SEVERAL PACKINGS P/N AS3209-010 AND AS3209-012 WERE NOT INSTALLED DURING ASSY OF FUEL MANIFOLDS TO FLOW DIVIDER. ASSEMBLER SUBSEQUENTLY REALIZED OMITTED ONE OF TWO O-RINGS AT FUEL MANIFOLD LOCATION OF ONE ENG. ENG TECH MADE RESEARCHES TO TRACK ENG SERIAL NUMBER. P&WC REQUESTED THAT THE CUSTOMER LANDS HIS A/C TO CHECK ENGINE AND CONFIRM THE MISSING O-RING. PREVENTIVE ACTION WAS ALSO REQUESTED TO PREVENT ANY FUTURE OCCURRENCE. ASSEMBLY INSTRUCTION WAS AMENDED TO CLEARLY SHOW WERE THE TWO PARALLEL O-RINGS MUST BE INSTALLED PRIOR TO SLIDING THE FUEL MANIFOLD INTO THE FLOW DIVIDER. THE INVESTIGATION SHOWED THAT THIS WAS AN ISOLATED CASE.

CA060614001

 

RROYCE

RROYCE

OIL COOLER

UNSERVICEABLE

6/14/2006

 

TAYMK6118

JR28548A

JR28548A

FUEL OIL

5 FUEL COOL OIL COOLERS (FCOC) RE-CALLED FROM SOUTHWEST COOLER SERVICE INC, APPROVED SUPPLIER FOR ROLLS-ROYCE CANADA) DUE TO FAA UNAPPROVED PART NOTIFICATION NR 2005-00187. ROLLS-ROYCE CANADA HAVE RE-ROUTED 5 SUSPECT UNAPPROVED FCOCS TO SERCK AVIATION (OEM APPROVED SUPPLIER) FOR RE-OVERHAUL. SERCK AVIATION HAS REPORTED FCOC WITH MISSING; THERMO ADAPTOR, NUTS AND WASHERS FROM END COVERS AND ALSO ONE FCOC MATRIX (CORE) THAT FAILED PRESSURE TEST DUE TO 11 TUBES JOINT (FERRULE) LEAKS. THE FCOC WERE PREVIOUSLY DECLARED OVERHAULED CONDITION BY SOUTHWEST COOLER SERVICE INC UNDER RRC PURCHASE ORDER. RRC ENGINEERING AND ROLLS-ROYCE OEM ARE EVALUATING IN SERVICE COOLERS OVERHAULED BY SOUTHWEST COOLER INC.

CA060615006

 

WRIGHT

 

ROD END

BROKEN

6/14/2006

 

982C9HE2

 

M4612BFG

 

DURING GROUND OPERATION THE PILOT FELT A "CLUNK" IN THE RUDDER SYSTEM WHILE OPERATING THE SERA SYSTEM. MAINTENANCE CREWS INVESTIGATED AND FOUND THE SERA LOCK ACTUATOR ROD END HAD BROKEN. THE ROD END WAS REPLACED, THE SYSTEM WAS FUNCTION CHECKED SERVICEABLE AND THE AIRCRAFT WAS RETURNED TO SERVICE.

CA060531017

AEROSP

PWA  

 

ENGINE

MALFUNCTIONED

5/21/2006

ATR42*

PW120

 

 

 

(CAN) ON APPROACH, ENGINE TORQUE WAS REPORTED TO FLUCTUATE AND THE ENGINE WAS SUBSEQUENTLY SHUTDOWN IN FLIGHT. MFG WILL INVESTIGATE THE EVENT AND ADVISE OF ROOT CAUSE ONCE ESTABLISHED.

CA060425006

AEROSP

PWA  

 

TOWERSHAFT

DAMAGED

4/5/2006

ATR42*

PW121

 

 

AGB 

DURING CRUISE, THE ENGINE EXPERIENCED AN UNCOMMANDED SHUT DOWN. SUBSEQUENT INSPECTION REVEALED A DISTRESSED ACCESSORY DRIVE TOWER SHAFT.

CA060419001

AEROSP

PWA  

 

PITOT HEAD

OBSTRUCTED

4/18/2006

ATR42300

PW120

 

 

 

DURING TAKEOFF ROLL, THE CREW OBSERVED A 20 KT DIFFERENTIAL BETWEEN ASIS. THE TAKEOFF WAS REJECTED AND THE AIRCRAFT RETURNED TO RAMP. MAINTENANCE CLEARED DEBRIS FROM THE CAPT'S PITOT PROBE AND CONDUCTED A SYSTEM LEAK CHECK. THE AIRCRAFT WAS RETURNED TO SERVICE.

CA051129009

AEROSP

PWA  

 

TOWERSHAFT

FRACTURED

11/8/2005

ATR42300

PW120

 

 

ENGINE

THE ENGINE FLAMED OUT DURING CLIMB. AN EMERGENCY WAS DECLARED AND THE FLIGHT DIVERTED. SUBSEQUENT INVESTIGATION REVEALED A FRACTURED TOWERSHAFT. P&WC WILL INVESTIGATE THE INCIDENT AND ADVISE OF ROOT CAUSE ONCE ESTABLISHED.

CA051129015

AEROSP

PWA  

 

CONNECTOR

CONTAMINATED

11/13/2005

ATR42300

PW120

 

 

TORQUE SENSOR

ON APPROACH, ENGINE TORQUE COULD NOT BE REDUCED BELOW 40 PERCENT. THE ENGINE WAS SHUT DOWN IN FLIGHT. SUBSEQUENT INVESTIGATION REVEALED A CONTAMINATED TORQUE SENSOR CONNECTOR.

CA060605009

AEROSP

PWA  

 

WIRE

CHAFED

6/3/2006

ATR42300

PW120

 

 

AC GEN

(CAN) WE HAD BEEN HAVING TROUBLES WITH NR 2 AC GENERATOR FAULTS IN FLIGHT. AFTER READING SDR NR 20050427005, WE CHECKED OUR ATR AND DISCOVERED NR 2 AC GEN WIRING CHAFING AND ARCING ON NR 2 STARTER GENERATOR COOLING DUCT. WIRING REPAIRED AND INSULATED AS REQUIRED. WIRING SECURED TO PREVENT FUTURE CHAFING. (TC NR 20060605009)

CA060606006

AEROSP

PWA  

 

FILTER

CLOGGED

6/5/2006

ATR42300

PW120

 

 

FUEL SYS

(CAN) IN CRUISE FLIGHT CREW NOTICED NR 1 ENGINE FUEL FILTER CLOG LIGHT ON. AIRCRAFT RETURNED TO BASE. MAINTENANCE REMOVED NR 1 ENGINE LP AND HP FUEL FILTERS FOR INSPECTION. LARGE AMOUNTS OF CONTAMINENTS FOUND IN LP. FILTERS WERE REPLACED. GROUND RUN CARRIED OUT. THIS IS THE SECOND OCCURANCE OF FUEL CLOG WARNING. 1ST AFTER 25 HRS FOLLOWING C-CHECK INSP. THE SECOND 1000HRS FOLLOWING C-CHECK. (TC NR 20060606006)

CA060612001

AEROSP

PWA  

 

WIRE HARNESS

INOPERATIVE

6/6/2006

ATR42300

PW120

 

 

LT MLG

DURING DEPARTURE, THE LANDING GEAR WOULD NOT RETRACT. THE AIRCRAFT RETURNED TO POINT OF DEPATURE AND LANDED WITHOUT INCIDENT. MAINTENANCE REPLACED THE UPPER WIRING HARNESS ON THE LT MAIN LANDING GEAR AND THE AIRCRAFT WAS RETURNED TO SERVICE.

CA060227012

AEROSP

PWA  

 

PACKING

CUT  

2/1/2006

ATR42320

PW121

 

 

RGB OIL SYS

THE ENGINE LOW OIL PRESSURE WARNING ANNUNCIATED AND THE ENGINE WAS SHUT DOWN IN FLIGHT. SUBSEQUENT INSPECTION REVEALED A CUT O-RING PACKING AT THE PROPELLER CONTROL UNIT ADAPTER INTERFACE TRANSFER TUBE.

CA051129014

AEROSP

PWA  

 

HOUSING

LEAKING

11/2/2005

ATR42500

PW127

 

 

OIL FILLER

DURING CRUISE, THE ENGINE LOW OIL PRESSURE WARNING ANNUNCIATED AND THE ENGINE WAS SHUT DOWN IN FLIGHT. SUBSEQUENT INSPECTION REVEALED THE OIL TANK OIL FILTER HOUSING TO BE LEAKING.

CA060403018

AEROSP

PWA  

PWC  

OIL SYSTEM

LOW PRESSURE

3/29/2006

ATR42500

PW127

PW127E

 

ENGINE

DURING CLIMB, ENGINE OIL PRESSURE WAS OBSERVED TO FLUCTUATE FOLLOWED BY A LOSS OF OIL PRESSURE. THE ENGINE WAS SHUT DOWN IN FLIGHT. P&WC WILL INVESTIGATE THE EVENT AND WILL ADVISE OF ROOT CAUSE ONCE DETERMINED.

CA060425012

AEROSP

PWA  

 

ENGINE

LEAKING

4/16/2006

ATR72

PW127

 

 

OIL SYS

DURING CLIMB, ENGINE LOW OIL PRESSURE WARNING ACTIVATED. ENGINE SUBSEQUENTLY EMITTED A NOISE AND EXPERIENCED AN UNCOMMANDED POWER REDUCTION. POST-FLIGHT INSPECTION REVEALED NO OIL REMAINING IN THE ENGINE AND SEIZURE OF THE HIGH PRESSURE ROTOR. MFG WILL INVESTIGATE THE EVENT AND WILL ADVISE OF ROOT CAUSE ONCE DETERMINED.

CA060227009

AEROSP

PWA  

 

WARNING LIGHT

ILLUMINATED

2/3/2006

ATR72

PW127

 

 

ENGINE OIL SYS

DURING CRUISE, THE ENGINE LOW OIL PRESSURE WARNING ANNUNCIATED. THE ENGINE WAS SHUT DOWN IN FLIGHT. SUBSEQUENT GROUND TESTING WAS UNABLE TO DUPLICATE THE EVENT. THE OIL PRESSURE TRANSMITTER AND LOW OIL PRESSURE SWITCH WERE REPLACED AND THE AIRCRAFT RETURNED TO SERVICE.

CA060227008

AEROSP

PWA  

 

ENGINE

MALFUNCTIONED

1/29/2006

ATR72

PW127

 

 

 

IN CRUISE, THE ENGINE EXPERIENCED AN UNCOMMANDED POWER REDUCTION ACCOMPANIED BY AN UNCOMMANDED INCREASE IN PROP SPEED. THE ENGINE WAS SHUT DOWN IN FLIGHT. GROUND INSPECTION WAS UNABLE TO DUPLICATE THE PROBLEM. THE ENGINE FUEL CONTROL UNIT, FUEL PUMP, FADEC, ELECTRICAL HARNESS AND TORQUE SENSOR WERE SUBSEQUENTLY REPLACED. P&WC WILL MONITOR INVESTIGATION OF THE INCIDENT AND WILL ADVISE OF ROOT CAUSE ONCE ESTABLISHED.

CA060228016

AEROSP

PWA  

 

ENGINE

FLAMED OUT

2/22/2006

ATR72

PW127

 

 

 

ON DESCENT, THE ENGINE FLAMED OUT AND THE PROPELLER FEATHERED. A RE-LIGHT ATTEMPT WAS UNSUCCESSFUL. P&WC WILL INVESTIGATE THE INCIDENT AND ADVISE OF ROOT CAUSE ONCE ESTABLISHED.

CA060129002

AEROSP

PWA  

 

PUMP

FAULTY

1/15/2006

ATR72

PW127

 

50099820

FUEL BOOST

(CAN) DURING CRUISE, THE ENGINE LOST POWER AND WAS SHUTDOWN INFLIGHT. SUBSEQUENT INVESTIGATION DETERMINED THE HYDROMECHANICAL FUEL CONTROL TO BE FAULTY. FUEL CONTROL AND FUEL PUMP WERE REPLACED. (TC NR 20060129002)

CA060531021

AEROSP

PWA  

 

TURBINE BLADES

FAILED

5/23/2006

ATR72212

PW127

 

 

TURBINE SECTION

(CAN) DURING TAKEOFF CLIMB, THE ENGINE EMITTED A LOUD NOISE ACCOMPANIED BY AN UNCOMMANDED POWER REDUCTION AND A FIRE WARNING. THE ENGINE WAS SHUTDOWN IN FLIGHT, AT WHICH POINT THE FIRE WARNING DEACTIVATED. THE AIRCRAFT DIVERTED TO POINT OF DEPARTURE. SUBSEQUENT INSPECTION REVEALED FRACTURED POWER TURBINE BLADES. MFG WILL INVESTIGATE THE EVENT AND ADVISE OF ROOT CAUSE ONCE ESTABLISHED. (TC NR 20060531021)

CA060425017

AEROSP

PWA  

 

ENGINE

MALFUNCTIONED

4/20/2006

ATR72212

PW127

 

 

 

ON TAKEOFF AND CLIMB, THE ENGINE WAS REPORTED TO EXHIBIT PARTIAL POWER LOSS AND WAS SHUTDOWN IN FLIGHT. POST-FLIGHT INSPECTION REVEALED NO ANOMALIES. MFG WILL INVESTIGATE THE EVENT AND ADVISE OF ROOT CAUSE ONCE ESTABLISHED.

CA051129007

AEROSP

PWA  

 

ENGINE

FLAMED OUT

10/28/2005

ATR72212A

PW127

 

 

 

DURING CLIMB, THE ENGINE FLAMED OUT. THE AIRCRAFT DIVERTED TO POINT OF DEPARTURE. P&WC WILL MONITOR INVESTIGATION OF THE INCIDENT AND WILL ADVISE OF ROOT CAUSE ONCE DETERMINED.

CA051223008

AEROSP

PWA  

 

CIRCUIT BOARD

CRACKED

10/30/2005

ATR72212A

PW127

 

 

AUTOFEATHER

DURING CLIMB, THE ENGINE EXPERIENCED UNCOMMANDED TORQUE FLUCTUATIONS AND THE ENGINE WAS SHUT DOWN IN FLIGHT. SUBSEQUENT INSPECTION REVEALED AN INTERMITTENTLY FAULTY AUTOFEATHER UNIT DUE TO A CRACKED INTERNAL CIRCUIT BOARD.

CA060601004

AEROSP

PWA  

 

PRESSURE VALVE

INOPERATIVE

5/30/2006

ATR72212A

PW127

 

 

OIL SYSTEM

(CAN) IN TAKE-OFF CLIMB, THE ENGINE LOW OIL PRESSURE WARNING ACTIVATED AND THE ENGINE WAS SHUTDOWN IN FLIGHT. THE AIRCRAFT RETURNED TO POINT OF DEPARTURE. THE ENGINE OIL PRESSURE REGULATING VALVE WAS REPLACED. (TC NR 20060601004)

AACSDR061006B

AGUSTA

 

AIRCOM

LINE

MAINT ERROR

6/10/2006

A119

 

 

 

AIR CONDITIONER

AIR CONDITIONING SYSTEM STC NR SR00463DE UTILIZES RIGID FREON LINES RUNNING FORE AND AFT ON THE ENGINE DECK. AT THE FORWARD END, THESE LINES CONNECT TO FLEX LINES. AT THIS CONNECTION THE LINES WERE SWAPPED. THE CONNECTIONS ARE LOCATED RIGHT NEXT TO EACH OTHER AND THE LINES RUN PARALLEL, MAKING THIS A VERY EASY MISTAKE. THESE LINES SHOULD UTILIZE DIFFERENT FITTINGS TO PREVENT THIS FROM HAPPENING.

CA060220001

AIRBUS

GE  

 

WIRE HARNESS

BURNED

2/14/2006

A310

CF680C2*

 

E0266QF20EO261

TOILET

AIRCRAFT ARRIVED AT STATION WITH A DEFECT LOG REPORT OF THE FORWARD LAVATORY NOT FLUSHING. TROUBLESHOOTING FOUND THAT 4 WIRES BETWEEN THE FLUSH MOTOR AND THE TIMER UNIT WERE BROKEN. IT WAS NOTED THAT MINOR ARCH/BURNING OF THE WIRES HAD OCCURRED. ALL 4 WIRES AND PINS WERE REPLACED AND SYSTEM WAS TESTED SERVICEABLE.

CA030115009

AIRBUS

GE  

 

PANEL

MISSING

12/9/2002

A310300

CF680C2*

 

A5247007020200

 

UPON A/C ARRIVAL FROM FLIGHT, FOUND ON WALK AROUND 3 MISSING PANELS (PANELS 134ER; P/N A5247007020600, 134CR; P/N A5247007020200, 134DR; P/N A5247007020400). HOLDING BRACKETS THOSE PANELS WERE ALSO FOUND TO BE DAMAGED. NEW HOLDING BRACKETS WERE FABRICATED IAW SRM 51-72-10 AND PANELS INSTALLED IAW AMM 53-13-00. THESE PANELS ARE OFTEN HIT BY CARGO LOADING EQUIPMENT OR STEPPED ON BY THE CARGO HANDLERS.

CA060228003

AIRBUS

GE  

 

PICKUP

CONTAMINATED

2/26/2006

A310300

CF680C2*

 

9028A000201

TE FLAPS

AIRCRAFT LANDED WITH FULL SLATS AND NO FLAPS. UNABLE TO EXTEND FLAPS ON LANDING. SYSTEM TORQUE LIMITERS AND SCREW JACKS LIMITER INSPECTED AND NO FAULT FOUND. DURING TROUBLESHOOTING, THE LT AND RT POWER PICK UP UNITS WERE FOUND CONTAMINATED WITH SKYDROL AND READOUTS NOT MEETING THE MM LIMITS. BOTH UNITS REPLACED AND SYSTEM TESTED SERVICEABLE.

CA051130001

AIRBUS

GE  

 

FLAP SYSTEM

MALFUNCTIONED

11/28/2005

A310304

CF680C2*

 

 

TE FLAPS

DURING APPROACH, ECAM MESSAGE CAME ON FLAP SYSTEM 1 AND 2 FAULT AT POSITION 15/20. RETURNED FLAP TO 0 THE SAME THING HAPPENED ON SECOND ATTEMPT. DURING INSPECTION, FOUND THE RIGHT TORQUE LIMITER FLAP GEAR BOX NR 1 INDICATOR TRIPPED. INDICATOR RESET AND OIL LEVEL CHECKED ON NR 1, 2 AND 3 GEARBOXES. ALL FOUND NORMAL. SYSTEM OPERATED SEVERAL TIMES. UNABLE TO DUPLICATE PROBLEM. AD F2005-174 COMPLETED AND SYSTEM FOUND SERVICEABLE.

CA060502003

AIRBUS

GE  

 

WIRE

BURNED

4/22/2006

A310304

CF680C2A5

 

 

NAV LIGHT

(CAN) DURING AIRCRAFT TOWING, THE NAV 2 POSITION LIGHT CB POPPED. UNABLE TO RESET. DURING INVESTIGATION, FOUND THE 4 WIRES FROM THE LIGHT UNIT ASSY (7LA) BURNED ABOUT 8 INCHES LONG. WIRING WAS REPLACED AND LIGHT ASSEMBLY AND RELAY WERE REPLACED AS PRECAUTIONARY MEASURE. SB 30-0627-33-SB01 WILL BE INCORPORATED IN ALL AIRCRAFT TO UPGRADE THE NAVIGATIONAL LIGHT SYSTEM AND PREVENT THIS TYPE OF PROBLEM. (TC NR 20060502003)

CA060502002

AIRBUS

GE  

 

WIRE

BURNED

4/27/2006

A310304

CF680C2A5

 

 

 

(CAN) DURING ROUTINE INSPECTION, FOUND THE ELECTRICAL OUTLET WIRE FIN 8ME CHAFED ON FRAME 17 BETWEEN STR 28 AND 29 RT SIDE. THE GROMMET PROTECTION HAD FALLEN OFF FROM THE FRAME AND WIRE WAS HANGING ON THE FRAME WITH THE RESULT OF ARCING AND FRAME DAMAGE. THE WIRING AND FRAME WAS REPAIRED. A FLEET CAMPAIGN HAS BEEN INITIATED TO INSPECT THIS AREA ON ALL A-310. (TC NR 20060502002)

CA060307007

AIRBUS

CFMINT

 

BLEED AIR SYS

INOPERATIVE

3/2/2006

A319112

CFM565B6

 

26361090018

NR 2 

(CAN) DISPATCHED WITH BLEED NR 2 OFF IAW MEL. LT WING LEAK IN CRUISE EMERGENCY DESCENT COMPLETED. REMOVED ACCESS PANELS FOR ZONE 521 BLEED DUCT FROM THE ENG NR 1 PYLON TO THE FUSELAGE. REMOVED ACCESS DOORS TO AIR CONDITIONING UNITS (191+192). REMOVED BELLY FAIRINGS FOR ACCESS TO BLEED DUCT FWD OF THE AIR CONDITIONING UNITS. (TC NR 20060307007)

CA051206002

AIRBUS

 

 

FAN  

ODOR

12/6/2005

A319114

 

 

EVT3454H

AVIONICS BAY  

VENT EXTRACT FAULT. BURNING ODOR NOTICED PRIOR TO MESSAGE. EXTRACT FAN SET TO OVRD. ODOR DISAPPEARED. EXTRACT BLOWER REPLACED AS PER AMM 21-26-51. OPERATIONAL TEST C/O THROUGH CFDS, NO FAULT.

CA060117001

AIRBUS

GE  

 

ENGINE

INOPERATIVE

1/17/2006

A319114

CFM565A

 

 

NR 1 

ECAM MSG ENG 1 LOW OIL PRESS ON APPROACH/AGAIN ON GRD DROPPED TO 13 PSI ENG SHUTDOWN. TSM 79-00-00 PG 1, FOUND OVER 2 GAL OF OIL IN AGB-OIL DRAINED AND CKD SUPPLY FILTER/SCAVENGE FILTER AND MAG PLUGS. ALL OK, CK AGB SCAVENGE LINE, CLEAR, CK OIL TANK STRAINER, CLEAR. GRD RUN AT T/O POWER AND LEAK CK OK.

CA060104008

AIRBUS

GE  

 

REDUCER

SHEARED

1/4/2006

A319114

CFM565A

 

0CFM565A5

P3 LINE

IN CLIMB THRU FL185, ENG NR 2 PWR REDUCED TO 74.5 N1/1200 KGH FF. ENG PARAMETERS NORMAL WHEN PWR REDUCED TO LOWER SETTINGS. ENG NR 1 NORMAL THROUGHOUT. FOUND PS3 LINE REDUCER SHEARED AS PER TSM 77-00-00-810-833. REDUCER REPLACED AS PER AIRBUS STANDARD PRACTICES. GROUND RUN CHKD SERV.

CA060110007

AIRBUS

GE  

 

OVEN

SHORTED

1/10/2006

A319114

CFM565A

 

8201170000

AFT GALLEY

OVEN NR 02-02-17535 OVEN NR 3 IN AFT GALLEY EMITTED AN ELECTRIC SHOCK TO F/A UPON TOUCHING IT. MEL ERASED IN CCS AND CB PULLED AND COLLARED BY FLIGHT CREW. REPLACED NR 3 OVEN CONTROLLER FUNCTION CHECK SATISFACTORY.

CA060104007

AIRBUS

CFMINT

 

UPLOCK

DAMAGED

1/4/2006

A320211

CFM565A1

 

201122006

MLG 

AFTER T/O ECAM L/G DOORS NOT CLOSED. CYCLED LDG GEAR. ECAM RE-APPEARED. LT MAIN GEAR DOOR SHOWED PARTIALLY OPEN IN AMBER. GEAR DOORS SHOW CLOSED WHEN GEAR DOWN. LT GEAR DOOR UPLOCK ASSY REPLACED AS PER TASK, 32-31-33-400-002.

CA031224001

AIRBUS

CFMINT

 

WIRE HARNESS

CHAFED

12/16/2003

A320211

CFM565A1

 

 

SMOKE DETECTOR

F/A NOTICED SPARK FROM OXYGEN PNL. A/C REMAINED IN SERV SEVERAL DAYS. UPON INSPECT, WIRE BUNDLE DIRECTLY ABOVE LAV "E" SMOKE DETECT FOUND CHAFFED ON SMOKE DETECT. INSPECT FOUND ROUTING OF WIRE BUNDLE WITH LITTLE CLEARANCE BETWEEN BUNDLE AND DETECTOR AND REPEAT OF INCIDENT WITH MORE SERIOUS CONSEQUENCES COULD BE LIKELY. WIRED BUNDLE RECEIVES IT'S POWER FROM 2000 C/B PANEL AND SUPPLIES PWR TO AFT CARGO LOADING SYS, AFT DRAIN MAST AND VARIOUS RIBBON HEATERS, ETC. FEW A/C WERE INSPECTED 401, 408, 410, 219, 224 HERE. NO A/C HAD WIRE BUNDLE TOUCHING SMOKE DETECTOR. HOWEVER, DISTANCE BETWEEN BUNDLE AND SMOKE DETECTOR IS NEVER SAME. NOTICED FLEXIBLE EXTRACT DUCT IS NEVER INSTALLED SAME WAY.

CA060307008

AIRBUS

CFMINT

 

VANE

CHAFED

3/6/2006

A320211

CFM565A1

 

 

3RD STAGE VSV

(CAN) NR 1 ENG STALL, ENG 1 SHUTDOWN AND LANDED. BORESCOPE CARRIED OUT IAW AMM 72-00-00-200-003 AND 72-31-00-290-001 FOUND 3 RD STAGE VSV VANES RUBBING ON IB END MAKEING A GROOVE WITH DISPLACED METAL AT BOTH ENDS OF VANE TRAVEL. (TC NR 20060307008)

CA030117006

AIRBUS

IAE  

 

HOSE

CHAFED

1/16/2003

A320231

V2500A1

 

AE707910

HYD SYSTEM

HYDRAULIC HOSE FOUND CHAFFED THROUGH ON ENGINE 1 GREEN HYDRAULIC SYSTEM PUMP PRESSURE TRANSDUCER. REF. 29-11-49-80A TUBES INSTL-HYDRAULIC, V2500, ENGINE 1, ZONE 400/ITEM 310.

AU510002220

AIRBUS

IAE  

 

VALVE

FAULTY

12/12/2005

A320232

V2527A5

 

6730010000

PNEUMATIC SYS

NR 2 ENGINE BLEED SYSTEM FAN AIR VALVE SUSPECT FAULTY.

AU510001766

AIRBUS

IAE  

 

HINGE PIN

LOOSE

12/12/2005

A320232

V2527A5

 

D9251015520000

BATTERY BOX 

(AUS) 103VU PANEL HINGE PIN LOOSE. NO CONTACT WITH ADJACENT ELECTRICAL HARNESS. FOUND DURING INSPECTION IAW AD/A320/175.(AD/SB DESC: AD/A320/175 ) (CASA NR 510001766)

CA060404002

AIRBUS

 

 

DISK

RUPTURED

3/29/2006

A321211

 

 

L95F50603

CENTER TANK

FUEL AUTO TRANSFER FAULT ECAM IN CLIMB. SELECTED MAN AS PER ECAM. REALIZED NR 1 TANK WAS FEEDING BOTH ENG AND UNBALANCE INCREASED. UNABLE TO GET FUEL FROM CENTER OR RIGHT TANK. RETURNED TO YYZ. RECTIFICATION: TSM TASK 28-12-00-810-801 CARRIED OUT. OVERPRESSURE PROTECTOR DISK 96QM RUPTURED. REMOVED TASK 28-12-41-000-003 AND INSTALLED TASK 28-12-41-400-003 MM TASK 28-25-00-869-001 FUEL TRANSFER AND PANEL LEAK CHECK CARRIED OUT SERVICEABLE.

CA060221003

AIRBUS

GE  

 

HMU  

MALFUNCTIONED

2/20/2006

A321211

CFM56*

 

8061532

NR 2 ENGINE

AFTER T/O YOW EN ROUTE YVR ENG 2 COMPRESSOR VANE MSG SEVERAL TIMES DURING FLIGHT. CREW ELECTED TO DIVERT TO YUL. ACFT ROUTED TO BASE FOR INVEST. HMU REPLACED AS PER T/S.

AU510001470

AIRBUS

 

 

SOLENOID VALVE

SHORTED

12/6/2005

A330*

 

 

CH251040

SLAT CONTROL

(AUS) RH SLAT SOLENOID (34CW) SHORT CIRCUITING TO CHASSIS. (OTHER CAUSE: MATERIAL ) (CASA# 510001470)

AU510001651

AIRBUS

GE  

 

DISPLAY

FAILED

5/7/2005

A330*

CF680

 

 

NAVIGATION

CAPTAIN`S LT AND FIRST OFFICER`S DISPLAY UNITS READ `DATA INVALID` FOR APPROXIMATELY 20 SECONDS AND THEN RETURNED TO NORMAL DISPLAY.

AU510001666

AIRBUS

GE  

 

TIRE

LOW PRESSURE

12/12/2005

A330*

CF680

 

 

NLG 

LEFT NOSE WHEEL TIRE LOW PRESSURE. NOSE SHIMMY ALSO EVIDENT.

AU510001522

AIRBUS

GE  

 

PROXIMITY SENSOR

FALSE INDICATION

12/12/2005

A330*

CF680

 

893301

CARGO DOOR

AFT CARGO DOOR OPEN INDICATION. INSPECTION FOUND THE DOOR SECURE. SUSPECT FAULTY SENSOR.

AU510001537

AIRBUS

GE  

 

PROXIMITY SENSOR

FAULTY

12/12/2005

A330*

CF680

 

893301

CARGO DOOR

AFT CARGO DOOR WARNING. INVESTIGATION FOUND THE DOOR CLOSED AND LOCKING MECHANISM SERVICEABLE. SUSPECT CAUSED BY FAULTY SENSOR.

AU510001562

AIRBUS

GE  

 

COMPUTER

FAILED

12/12/2005

A330*

CF680

 

LA2K2B100D80000

FLT CONTROL

FLIGHT CONTROL PRIMARY COMPUTER (FCPC) FAILED. FCPC REMOVED AND SENT FOR TEST AND REPAIR. INVESTIGATION FOUND THE POWER SUPPLY FAULTY.

AU510001899

AIRBUS

GE  

 

LIGHT

FAILED

12/12/2005

A330*

CF680

 

 

COCKPIT

FO READING LIGHT FAILED. SMOKE AND FUMES IN COCKPIT. INVESTIGATION FOUND SWARF MATERIAL IN THE LENS ASSEMBLY FOLLOWING REMOVAL OF THE COVER.

AU510001917

AIRBUS

GE  

 

SLIDE

FAILED

12/12/2005

A330*

CF680

 

 

L1 DOOR

(AUS) DURING EMER EVAC FOR FIRE WARNING, DOOR 1L SLIDE FAILED TO DEPLOY. DOOR OPENING HANDLE HAD BEEN MOVED TO FULL UP POSITION, DOOR WAS FOUND TO HAVE OPENED APPROX 3 INCHES, JAMMED IN THAT POSITION. DOOR ARMING HANDLE HAD BEEN MOVED FROM ARMED POSITION TO DISARMED POSITION. SLIDE GIRT BAR WAS STILL ATTACHED TO DOOR FRAME FLOOR FITTINGS, SLIDE WAS STILL WITHIN DOOR COVER. FILLING VALVE NUT ON DOOR ASSIST ACT WAS LOOSENED TO RELEASE REMAINING PRESS IN ACT. AFTER SLIGHT RELEASE OF PRESS, DOOR OPENED AUTOMATICALLY, SLIDE DEPLOYED NORMALLY. DETERMINED DOOR HAD BECOME JAMMED BECAUSE PRESS FROM DOOR ASSIST ACT FORCED DOOR AGAINST DOOR FRAME, PREVENTED DOOR FROM BEING MOVED TO CLOSED POSITION. (CASA NR 510001917)

CA051205005

AIRBUS

RROYCE

 

ENGINE

MAKING METAL

12/5/2005

A330*

RB211*

 

 

NR 1 

PRELIMINARY INVESTIGATION AND TROUBLESHOOTING HAS NOTED UNUSUALLY HIGH N3 INDICATION DURING A GROUND START ATTEMPT, WHICH SUGGESTS THAT THE ACCESSORY GEARBOX MAY HAVE LOST COUPLING TO THE N3 ROTOR. AS FURTHER SUPPORTING EVIDENCE, THE MASTER CHIP DETECTOR WAS FOUND WITH SIGNIFICANT CONTAMINATION. THE TROUBLESHOOTING FINDINGS ARE CONSISTENT WITH OTHER INDUSTRY OCCURRENCES THAT ARE CURRENTLY UNDER INVESTIGATION BY ROLLS ROYCE, WHERE THE ACCESSORY GEARBOX LOST MECHANICAL DRIVE FROM N3 ROTOR. REFERENCE ROLLS ROYCE WORLD WIDE COMMUNICATION WW10379/1 AND WW10345. WILL BE REQUESTING A FULL INVESTIGATION AT ENGINE TEAR DOWN.

CA060104005

AIRBUS

RROYCE

 

OVEN

SHORTED

1/4/2006

A330*

RB211*

 

820317000

FWD GALLEY

FWD GALLEY OVEN FIRE EXTINGUISHED WITH 2 FIRE EXT BOTTLES ACTION. FWD GALLEY NR1/NR 2 OVENS REPLACED. FUNCT CHKD SERV NR 1 OFF HK76R5 NR 2 OFF 8203-17-000 S/N 9403-6150. NR 1 ON 8203-17-000, S/N 96-11-7934 NR 2 ON 568K81.

CA060405005

AIRBUS

RROYCE

 

CANISTER

BROKEN

2/13/2006

A330*

RB211*

 

FRH280002

BOOST PUMP

FOB 5100 KG WING CROSSFEED SELECTED ON AS PER ATB 376. FUEL IS 2500KG IN EACH TANK. NO FUEL IN OUTERS AND TRIM. ON SHORT FINAL "L TANK LOW FUEL" ON ECAMLTANK INDICATED 1200 KG AND RIGHT TANK 3500 KG REF SNAG 4205167. FOUND RT WING NR 1 MAIN BOOST PUMP CANNISTER DELIVERY ELBOW BROKEN AT FLANGE CONNECTION TO FUEL FEED MANIFOLD. NEW ELBOW INSTALLED WITH NEW SEALS. OPERATION CHECK OF FEED SYSTEM COMPLETED. CHECKS SERVICEABLE.

CA051208001

AIRBUS

RROYCE

MESSIER

TIRE

BLOWN

12/8/2005

A330*

RB211*

 

300828

MLG 

AFTER T/O FROM YYC, A LARGE PIECE OF TIRE RUBBER WAS FOUND ON RUNWAY, NO UNUSUAL INDICATIONS IN COCKPIT. LANDED IN LHR WITH EMERG SERVICES IN STANDBY, TIRE IS SHREDDED. ACCOMPLISHED INSPECTION AFTER TIRE BLOWN AS PER AMM 05-51-12, REF L4044129 FOR FINDINGS. REPLACED NR 6 TIRE DUE BLOWN AND MATING TIRE NR 5 AS PER AMM 32-41-11-400-801.

CA051202005

AIRBUS

RROYCE

 

STEERING SYS

MALFUNCTIONED

11/29/2005

A330243

RB211*

 

C24780003

NLG 

DURING LEVELING A/C FOR WEIGHT AND BALANCE PURPOSES, GREEN SYS ELECT HYD PUMP WAS TURNED ON TO POSITION HORIZ STAB, A/C WAS BEING LEVELED USING 5 LANDING GEAR AXLE JACK POINTS, N/G STEERING SWITCH WAS SELECTED OFF AND N/G STEERING BY-PASS PIN INSTALLED. AT THE MOMENT OF SYSTEM PRESSURIZATION NOSE LANDING IMMEDIATELY SWUNG 90 DEG. T/S CARRIED OUT USING BITE INFO; AIRBUS INDUSTRIES WAS ALSO SOLICITED FOR ASSIST. AN EXISTING TFU 32.51.00.020 DETAILS A SIMILAR PROBLEM. A RECOMMENDATION WAS RECEIVED FROM AIRBUS TO REPLACE THE SELECTOR VALVE (FIN 5113GC) PRIOR TO NEXT FLT, WHICH WAS ACCOMP AND SENT UNIT OUT FOR ANALYSIS. ADDITIONAL T/S RELATED TO A CLASS 3 FAULT THAT MAY BE RELATED REMAINS TO BE INVESTIGATED.

AU510001752

AIRBUS

GE  

 

CONTROL UNIT

FAULTY

12/12/2005

A330300

CF680

 

RAI2811M0103

SMOKE DETECTOR

(AUS) CARGO COMPARTMENT SMOKE WARNINGS. FORWARD CARGO FIRE BOTTLES DISCHARGED. EMERGENCY LANDING CARRIED OUT. LOCAL AUTHORITIES REPORTED A (WHITE POWDER) IN THE WHEEL WELL AREA. DURING EMERGENCY EVACUATION, DOOR 1L ESCAPE SLIDE FAILED TO DEPLOY. ALL OTHER SLIDES DEPLOYED SUCCESSFULLY. INVESTIGATION FOUND THE FALSE SMOKE WARNING WAS CAUSED BY A DESIGN DEFICIENCY IN THE SMOKE DETECTOR CONTROL UNIT (SDCU). NOTE: FAILURE OF THE SLIDERAFT TO DEPLOY IS COVERED BY SDR 510001917. (CASA NR 510001752)

CA060404003

AIRBUS

CFMINT

 

VIDEO DISPLAY

BURNED

3/29/2006

A340313

CFM565C4

 

845438421

CABIN

4H VIDEO MACHINE GOT REALLY HOT AND SMELLED BURNED AT THE END OF FLIGHT. THICK WHITE SMOKE CAME FROM PTV. FOUND PTV OPERATION SERV. FOUND SEAT PWR SUPPLY U/S AND ODOR OF SMOKE. DEACTIVATED BY PULLING AND COLLERING C/B.

CA060531008

AIRTRC

PWA  

 

ENGINE

FAILED

4/28/2006

AT502

PT6A15AG

 

 

 

(CAN) THE ENGINE WAS REPORTED TO HAVE LOST POWER IN FLIGHT LEADING TO A FORCED LANDING AND RESULTANT AIRFRAME DAMAGE. MFG WILL INVESTIGATE THE INCIDENT AND ADVISE OF ROOT CAUSE ONCE ESTABLISHED. (TC NR 20060531008)

CA060606004

AIRTRC

PWA  

CLEVELAND  

LINE

CRACKED

6/5/2006

AT502B

PT6A34AG

3098C

20700600

BRAKE ASSY

(CAN) PILOT REPORTED RT BRAKE ALWAYS GOES SOFT WHILE TAXING. AFTER INSPECTING ENTIRE BRAKE INSTALLATION FOR LEAKS, FOUND THE FWD AND AFT BRAKE CALIPER INTERCONNECT HOSE, FWD FITTING CRACKED. THIS CRACK WAS ONLY APPARENT WHEN THE BRAKES HEAT UP AND THE CRACK OPENED AS IT EXPANDED, CAUSE FLUID TO LEAK. THE HOSE WAS REPLACED WITH NEW UNIT AND BRAKES BLED WITH NO FURTHER FAULTS. (TC NR 20060606004)

CA060407006

AIRTRC

PWA  

 

PUMP

LEAKING

4/3/2006

AT802

PT6A67A

 

510767

FUEL SYSTEM

DURING DE-INHIBITING INSPECTION, A FUEL LEAK WAS DETECTED AT THE REAR OF THE FUEL PUMP ASSEMBLY.

CA060303010

AIRTRC

PWA  

 

HOSE

CHAFED

3/3/2006

AT802A

PT6A67A

 

 

BRAKE

WHILE PERFORMING A GEAR SWING DURING THE ANNUAL INSPECTION, IT WAS DISCOVERED THAT THE MLG BRAKE HOSES WERE ROUTED SO THAT THEY WERE RUBBING DIRECTLY ON THE TREAD PORTION OF THE TIRES. THE STRAIGHT BULKHEAD FITTINGS P/N AN832-4D (4 OF) WERE REPLACED WITH 45 DEGREE BULKHEAD FITTINGS AND BRAKE HOSES WERE CHECKED FOR CLEARANCE ON A SUBSEQUENT GEAR SWING WITH NO RUBBING NOTED. BRAKE SYSTEM WAS BLED. THE OTHER AIRCRAFT IN THE FLEET WILL BE INSPECTED.

CA060124005

AMBLP

ROTAX

ROTAX

ARM  

CRACKED

1/18/2006

A150

ROTAX912F3

 

 

AIRBOX

(CAN) ENGINE RECIEVED FOR OVERHAUL WITH AIRBOX INSTALLED. THE CARB DRIP TRAYS ARE CONNECTED TO THE AIRBOX BY A SUPPORT ARM WITH TWO SCREWS HOLDING THE TRAYS ONTO THE SUPPORT ARM. THE DRIP TRAY SUPPORT ARM WAS FOUND CRACKED AT THE HOLES FOR THE SCREWS. (TC 20060124005)

CA051209004

AMD  

GARRTT

 

PUMP

MALFUNCTIONED

11/30/2005

FALCON10

TFE7312

 

4005303

HYDRAULIC SYS

HYD NR 1 ANNUNCIATOR ILLUMINATED AFTER TAKEOFF. HYDRAULIC PRESSURE WAS LOST ON SYSTEM 1. QUANTITY WAS SUFFICIENT AND STANDBY SYSTEM WORKED NORMALLY. HYD NR 1 SYSTEM PRESSURE PUMP HAS BEEN REPLACED, P/N 40053-03, S/NOFF AH-16041A, S/NON AH-16086A. FILTER INSPECTED AND GROUND TEST CARRIED OUT OK.

THMN4113SQ118

AMD  

 

 

COWLING

CRACKED

5/8/2006

FALCON20

 

 

MY20552302

RT ENGINE

RT UPPER ENGINE COWL SKIN CRACKED AT FWD SEAL BRACKET. MADE AIRWORTHY REPAIR IAW SRM 54-20-43.

CA051129011

AMD  

PWA  

 

ENGINE

MALFUNCTIONED

11/8/2005

FALCON2000

PW306B

 

 

 

DURING CLIMB, THE ENGINE EMITTED A LOUD NOISE AND SHUT DOWN UNCOMMANDED. SUBSEQUENT INSPECTION REVEALED DAMAGE TO THE TURBOMACHINE. P&WC WILL INVESTIGATE THE INCIDENT AND ADVISE OF ROOT CAUSE ONCE DETERMINED.

CA060129014

AMD  

PWA  

 

ENGINE

ODOR

1/4/2006

FALCON2000

PW306B

PW308C

 

 

(CAN) THE ENGINE WAS REPORTED TO EXHIBIT OIL SMELL IN CABIN AIR ACCOMPANIED BY HIGH OIL CONSUMPTION. MFG WILL INVESTIGATE THE EVENT AND ADVISE OF ROOT CAUSE ONCE DETERMINED. (TC NR 20060129014)

2006FA0000619

AMD  

 

 

CONTROL PANEL

FAILED

6/23/2006

FALCON50MYST

 

 

7503611

FIRE DETECTION

FIRE CONTROL PANEL FAILED.

CA060410003

AMD  

GARRTT

 

DOOR

DAMAGED

3/21/2006

FALCON50MYST

TFE73131C

 

F50B258707

S DUCT

DURING TAKEOFF, THE NR 2 ENGINE "FAIL" LIGHT ILLUMINATED. THE TAKEOFF WAS REJECTED AND THE AIRCRAFT RETURNED TO THE RAMP. MAINTENANCE WAS CONTACTED AND UPON INVESTIGATION IT WAS DISCOVERED THAT NR 2 ENGINE S DUCT DOOR AFT LATCH HAD NOT BEEN COMPLETELY ENGAGED WITH THE HOOK. BOTH THE FRONT AND REAR LATCHES WERE RE-ENGAGED AND THE DOOR WAS CHECKED FOR PROPER SECURITY. THE CREW RESUMED THE FLIGHT AND A NORMAL TAKEOFF WAS CONDUCTED.

CA060615002

AMD  

GARRTT

 

GUIDE

BENT

6/4/2006

FALCON50MYST

TFE73131C

 

F50B381003111

HORIZONTAL STAB

GUIDE PLATE SEPARATED FROM HORIZONTAL STAB FILLET, WAS FOUND LYING BETWEEN VERTICAL STABILIZER AND HORIZONTAL STABILIZER. UNIT HAD BEEN CRUSHED BETWEEN HORIZONTAL STAB AND VERTICAL STAB AS STAB WAS TRIMMED POTENTIAL THAT GUIDE PLATE COULD HAVE MOVED AFT AND JAMMED ELEVATOR LINKAGE. UNIT WAS REMOVED STRAIGHTENED AND REATTACHED TO HORIZONTAL STAB FILLET ASSEMBLY PER MANUFACTURERS INSTRUCTIONS "SRM SI-20-05, S0-10-04, HORIZONTAL STAB WAS TRIMMED THROUGHOUT ITS ENTIRE RANGE AND NO DISCREPANCIES FOUND.

CA060116005

AMD  

 

 

COOLING FAN

SEIZED

1/3/2006

FALCON900B

 

 

TVT10728H3

 

WHILE ON THE GROUND WITH THE APU RUNNING, SMOKE WAS OBSERVED IN THE CABIN. THE CREW IMMEDIATELY SHUT DOWN THE APU. THE TURBO COOLING FAN WAS FOUND SEIZED.

2006FA0000618

AMD  

 

 

CONTROL PANEL

FAILED

6/23/2006

STCFALC50

 

 

7503611

FIRE DETECTION

FIRE CONTROL PANEL FAILED.

2006FA0000544

AMTR

AMTR

 

DRIVE GEAR

DAMAGED

5/26/2006

AVIDFLYER

CUYUNA430

 

 

ENGINE

ACCIDENT INVESTIGATION. ON CLIMB-OUT ENGINE RPM INCREASED AND PROPELLER RPM DECREASED. THE GRD-2000 GEAR REDUCTION UNIT WAS DISASSEMBLED AND THE DRIVE GEAR WAS FOUND TO DAMAGED. (TEETH GONE)

AU510002168

AMTR

 

 

BEARING

MISMANUFACTURED

2/11/2005

LC41550FG

 

 

13889

WHEEL

NEW WHEEL BEARING HAD TWO ROLLERS MISSING. FAULTY MFG.

AU510001680

AMTR

 

 

PUMP

FAILED

4/8/2005

LC41550FG

 

 

216CWRWIP

VACUUM SYS

EXCESSIVE AMOUNT OF VACUUM PUMPS FAILING EITHER ON FITMENT OR SHORTLY AFTER. THESE PUMPS ARE PURCHASED FROM AERO ACCESSORIES INC.

AU510001765

AMTR

 

 

PUMP

FAILED

4/8/2005

LC41550FG

 

 

216CWWIP

VACUUM SYS

(AUS) VACUUM PUMPS FAILED. (OTHER CAUSE: MATERIAL - DEBRIS REMAINING AFTER FAILURE ) (CASA NR 510001765)

AU510001912

AMTR

LYC  

 

TIRE

DISINTEGRATED

12/12/2005

LC41550FG

IO540N1A5

 

252752

NLG 

(AUS) NOSE WHEEL TYRE DISINTEGRATED CIRCUMFERENTIALLY. INVESTIGATION FOUND EXCESSIVELY LONG NOSEWHEEL SPAT ATTACHMENT SCREWS WHICH CUT INTO THE TYRE AS IT ROTATED. INCORRECT PART. (CASA NR 510001912)

AU510001855

AYRES

PWA  

 

ROD END

BROKEN

6/9/2005

S2RT15RESTD

PT6A15AG

 

40024T008

HORIZONTAL STAB

LT HORIZONTAL STABILIZER ATTACHMENT BOLT BROKEN AT TOP OF THREADED AREA UNDER CLEVIS. FOUND WHEN STABILIZER REMOVED FOR PAINTING. INSPECTION FOUND ALL OTHER ATTACHMENT BOLTS RUSTED AND PITTED IN THE SAME AREA.

CA060425015

AYRES

PWA  

 

TURBINE BLADES

FRACTURED

4/5/2006

S2RT34NORMAL

PT6A34AG

 

 

ENGINE

ON TAKEOFF, THE ENGINE WAS SEEN TO EMIT SMOKE AND SPARKS FROM THE EXHAUST. SUBSEQUENT INVESTIGATION REVEALED FRACTURED COMPRESSOR TURBINE BLADES. PWC WILL INVESTIGATE THE EVENT AND WILL ADVISE OF ROOT CAUSE ONCE DETERMINED.

AU510001464

BAC  

LYC  

 

PIN  

INSTALLED

9/6/2005

146100A

ALF502R5

 

201138002

NLG 

(AUS) NOSE LANDING GEAR FAILED TO RETRACT. INVESTIGATION FOUND NLG PIN STILL INSTALLED. PERSONNEL/MAINTENANCE ERROR. (CASA# 510001464)

AU510001836

BAC  

LYC  

 

O-RING

FAILED

10/9/2005

146200A

ALF502R5

 

 

HYDRAULIC SYS

LOSS OF HYDRAULIC FLUID. INVESTIGATION FOUND A FAILED O-RING SEAL AT THE PIPE CONNECTOR ON NR 2 HIGH PRESSURE MANIFOLD. THIS PIPE SUPPLIES GREEN SYSTEM HIGH PRESSURE FLUID THROUGH THE STANDBY GENERATOR ISOLATION VALVE.

AU510001710

BAG  

LYC  

 

FRAME

CRACKED

10/8/2005

BAE146100A

ALF502R5

 

 

FUSELAGE

FUSELAGE FRAME 15 AND FRAME 41 CRACKED. FOUND DURING INSPECTION IAW AD/BAE146/116.

AU510001880

BAG  

LYC  

 

FRAME

CRACKED

5/9/2005

BAE146100A

ALF502R5

 

 

FUSELAGE

FUSELAGE FRAMES 15 AND 18 CRACKED, FOUND DURING INSPECTION IAW AD/BAE146/116.

AU510001709

BAG  

 

 

WIRE

SHORTED

10/8/2005

BAE146300A

 

 

 

FUEL SYSTEM

RT INNER FUEL BOOST PUMP PRESSURE SWITCH TO PRINTED CIRCUIT BOARD WIRE SHORT CIRCUITED.

AU510001495

BAG  

 

 

SELECTOR

FAILED

12/12/2005

BAE146300A

 

 

643500100

MLG 

LANDING GEAR SELECTOR LEVER WOULD NOT MOVE TO THE `UP` POSITION.

AU510001750

BAG  

LYC  

 

INDICATOR

DAMAGED

12/12/2005

BAE146300A

ALF502*

 

 

TAIL STRIKE

(AUS) AIRCRAFT EXPERIENCED A HIGH SINK RATE DURING LANDING. INVESTIGATION FOUND THAT THE MAIN LANDING GEAR AND TAILSKID CONTACTED THE GROUND CAUSING DAMAGE TO THE TAIL STRIKE INDICATOR. (CASA NR 510001750)

AU510001967

BAG  

LYC  

 

BOLT

SHEARED

6/10/2005

BAE146300A

ALF502R5

 

HLT912AP109

WING SPAR

CENTER FUEL TANK WING SPAR ATTACHMENT BOLTS (4OFF) HAD SHEAR BOLT HEADS. FUEL LEAKING FROM CENTER TANK AT RT FRONT CORNER ABOVE THE WING TO FUSELAGE ATTACHMENT LINK AT FRAME 26 RIB 2.

AU510001664

BAG  

LYC  

 

HINGE

CORRODED

2/8/2005

BAE146300A

ALF502R5

 

HC528B0039002

RT MLG DOOR

RT MAIN LANDING GEAR DOOR HINGE FITTINGS CORRODED IN BORES. BEARING HOUSINGS ALSO CONTAINED PITTING AND RUST DEPOSITS ON THE OUTER SURFACES. FOUND DURING INSPECTION IAW BAE SYSTEMS ISB 52-113 REV 1 AND AAES AD ER BA6-32-10-43B AND UK CAA AD G-2005-0017.

AU510001532

BAG  

GARRTT

 

PLATE

CRACKED

12/12/2005

JETSTM3107

TPE33110U

 

 

BS 223

PASSENGER CUTOUT INTERCOSTAL UPPER JOINT PLATE LOCATED AT FS 223 LT CRACKED. FOUND DURING INSPECTION IAW AD/JETSTREAM/98 AND SB51-JA030544 R1.

CA060529004

BAG  

GARRTT

 

FLANGE

SPLIT  

4/28/2006

JETSTM3212

TPE33110UG

 

8210263C

PROP GOVERNOR

FOUND OIL DRIPPING UNDER RIGHT ENGINE AFTER SHUT DOWN, ENGINE CLEANED AND CASE NEGATIVE PRESSURE CHECKED, FOUND SERVICEABLE. ENGINE GROUND RUN/MAX POWER CARRIED OUT. OIL FOUND TO BE LEAKING FROM THE PROP GOVERNOR. PROP GOVERNOR REPLACED WITH SERVICEABLE UNIT P/N 8210-263C, S/N 1812067. GROUND RUN CARRIED OUT SATISFACTORY.

CA060525003

BAG  

GARRTT

 

ENGINE

MALFUNCTIONED

5/25/2006

JETSTM3212

TPE33110UG

 

 

RIGHT

IN CRUISE, RT ENGINE TORQUE INCREASED TO 104.5%, WHEN TTL TURNED OFF WENT TO 120%. FUEL FLOW ON RT ENG DROPPED TO 200LBS.

CA060104004

BAG  

GARRTT

 

WINDSCREEN

CRACKED

1/2/2006

JETSTM3212

TPE33110UG

 

01379377C405

COCKPIT

AT CRUISE ALT 20,000 FT, NOTICED CRACK AND SUBSEQUENT FLAME WITHIN LAYERS OF LT WINDSHIELD. FLAME SELF EXTINGUISHED WITH DE-SELECTION OF WINDSHIELD HEAT. DURING DESCENT ADDITIONAL CRACKING. DIVERTED TO CYMM. MX DISPATCHED, REPLACED WINDSHIELD. UPON MX REVIEW FOLLOWING WAS DETERMINED; THE PART WAS IN SERVICE ON THIS A/C ON REGISTER SINCE 2003 JANUARY AND PRIOR. NO ABNORMALITIES OBSERVED DURING REMOVAL REGARDING INSTALLATION, EXCEPT FOR PRC APPLIED OVER EXT SCREW HEADS. AIRFRAME VOLTAGE AND CURRENT OUTPUT TO LT WINDOW HEAT SYS FOUND NORMAL. NO EVIDENCE OF MISTORQUE OF SECURING SCREWS OBSERVED. MX PRELIMINARY CONCLUSION, MALFUNCTION LEADING TO A SHORT CIRCUIT OF INTERNAL HEAT FILAMENTS OF WINDSHIELD.

CA060116001

BAG  

GARRTT

 

VALVE

CRACKED

1/12/2006

JETSTM3212

TPE33110UG

 

HTE400005

RT HYD SYSTEM

ON APPROACH, UPON FLAP SELECTION, NO SYSTEM HYD PRESSURE. EMERG GEAR SELECTION USED TO EXTEND L/G, AND TO OBTAIN 10 DEGREES FLAP. A/C LANDED W/O INCIDENT, DUE TO LOSS OF SYS HYD PRESSURE, N/W STEERING INOP AND MAIN BRAKING WAS LIMITED. TOWED TO HANGAR. MX FOUND PN HTE400005 CHECK VALVE CRACKED, WHICH RESULTED IN LOSS OF SYS HYD FLUID. CHECK VALVE WAS REPLACED, SYS WAS REPLENISHED AND BLED, OPS CHECKED SERVICEABLE. COMPANY ISSUED FLEET INSP TO DETERMINE IF A COMMON PROBLEM WITH FACTORY INSTALLATION. FOUND MULTIPLE A/C WITH THESE NRV'S CRACKED IN RADIUS. (FPI, 10X MAG. GLASS REQUIRED TO DETECT.) VALVE'S REPLACED AS REQ`D AND MFG TO BE CONTACTED. DEFECTIVE VALVES TAGGED AND ON FILE FOR FURTHER INSPECT.

CA051214001

BAG  

GARRTT

 

GENERATOR

FAILED

12/13/2005

JETSTM3212

TPE33110UG

 

51539002B

AC REGULATOR

(CAN) IAW AMM 24-30-00 501 DC GENERATION-ADJUSTMENT/TEST. GENERATOR VOLTAGE MUST BE WITHIN 0.3 VOLTS OF EACH OTHER. WHEN REPLACING COMPONENTS IN THE GENERATOR SYSTEM, A CHECK OF THE GCU'S VOLTAGE IS RECOMMENDED AS NUMEROUS HOURS OF TROUBLESHOOTING AND PARTS REPLACEMENT WILL OCCUR. (TC NR 20051214001)

2006FA0000577

BBAVIA

CONT

 

GAUGE

STUCK

5/21/2006

7CCM

C90*

 

2731 

COCKPIT

AIRCRAFT LOST POWER AND LANDED IN A HAYFIELD UP ON ITS NOSE. PILOT STATED HE CHECKED THE FUEL GAUGE PRIOR TO THE FLIGHT AND IT READ (HALF FULL). HE DID NOT VISUALLY CHECK THE QUANTITY. INVESTIGATION REVEALED FUEL TANK TO BE EMPTY AND GAUGE STUCK IN THE (HALF FULL) POSITION. (K)

2006FA0000595

BBAVIA

LYC  

 

SPAR

CRACKED

6/2/2006

7ECA

O235C1

 

5271L

LT WING

REQUIRED INSPECTION OF WOODEN WING SPARS IN ACCORDANCE WITH AD. REVEALED A COMPRESSION CRACK IN THE LT WING FWD SPAR AT THE TOP OB OF WING STRUT ATTACH DOUBLER PLATE. (K)

CA060424005

BBAVIA

LYC  

 

FRAME

CRACKED

4/12/2006

8GCBC

O360C1E

 

21949

FUSELAGE

DURING THE COMPANY STRUCTURAL INSPECTION AND REPAIR PROGRAM (SIRP), THE RIGHT SIDE OF THE FUSELAGE FRAME WAS FOUND CRACKED IN THE AREA WHERE THE RIGHT MAIN GEAR LEG RESTS AGAINST THE AIRFRAME. THE CRACK WAS LONGITUDINAL AND WAS ABOUT 1 1/8" LONG.

CA060424006

BBAVIA

LYC  

 

SPAR

DAMAGED

4/24/2006

8GCBC

O360C2E

 

5428L

LT WING TE FLAP

2 HOLES FOR MOUNTING INBD FLAP HINGE BRACKET LWR ATTACH AND INBD BOLT FOR SHIM PLATE BOTH FOUND CRUDELY DRILLED AND VERY OVAL.

CA060421020

BBAVIA

LYC  

 

CRANKSHAFT

CORRODED

3/23/2006

8GCBC

O360C2E

 

74968

ENGINE

CORROSION FOUND UNDER PID AT FWD ID.

CA060421021

BBAVIA

LYC  

 

CRANKSHAFT

CORRODED

3/23/2006

8GCBC

O360C2E

 

74968

ENGINE

CORROSION FOUND UNDER PID FWD ID.

CA060421019

BBAVIA

LYC  

 

CRANKSHAFT

CORRODED

3/23/2006

8GCBC

O360C2E

 

74968

ENGINE

(CAN) FWD INNER DIA CRANKSHAFT CORRODED BEYOND LIMITS IAW AWD 98-02-08. (TC NR 20060421019)

CA060116006

BBAVIA

LYC  

 

CRANKSHAFT

CORRODED

1/11/2006

8GCBC

O360C2E

 

74968

ENGINE

THE CRANKSHAFT A/C WAS INSPECTED DUE TO A FAILURE OF A CRANKSHAFT ON ANOTHER AIRCRAFT IN THE FLEET (INTERNAL CORROSION). UPON REMOVAL OF THE FRONT CRANK PLUG AND CLEANING OF THE CRANKSHAFT, IT DISCOVERED THAT URETHABOND COATING WAS BLISTERING. URETHABOND REMOVED AND CORROSION WAS FOUND WITHIN FIRST INCH OF CRANK. ENGINE WAS A FACTORY EXCHANGE OVERHAUL (21 APR 2002) AND THE CRANK HAD BEEN RE-WORKED. THE CRANKSHAFT WAS AT MAX ID THEREFORE PITTING FROM CORROSION COULD NOT BE COMPLETLY REMOVED. CRANK WAS INSPECTED BY AN APPROVED AMO(NDT) AS PER LYC SB 505B AND NO FAILING INDICATION WERE FOUND. CRANK WAS MARKED PID AND DID NOT REQURIE ANY INTERNAL INSPECTIONS UNTIL 2000-HRS.

2006FA0000591

BBAVIA

LYC  

 

SLEEVE

BROKEN

6/8/2006

8KCAB

AEIO360*

 

714145

FUEL LINE

CREW REPORTED STRONG ODOR OF FUEL IN CABIN.MX INSPECTED FOUND FUEL LEAKING ONTO CARPET ON THE FWD LEFT SIDE OF CABIN. TRACED LEAK TO THE VENT LINE HEADER TANK ATTACH FITTING. FITTING FOUND TO BE TIGHT BUT LINE CRACKED AT COMPRESSION SLEEVE CONNECTOR. LINE AND CONNECTOR REPLACED NO LEAKS NOTED.

2006FA0000590

BBAVIA

LYC  

 

VENT LINE

CRACKED

6/8/2006

8KCAB

AEIO360*

 

714145

FUEL CELL

CREW REPORTED STRONG SMELL OF FUEL IN CABIN. MX INSPECTED FOUND FUEL LEAKING ONTO CARPET ON THE FWD LT SIDE OF CABIN. TRACED LEAK TO THE VENT LINE HEADER TANK ATTACH FITTING. FITTING FOUND TO BE TIGHT BUT LINE CRACKED AT COMPRESSION SLEEVE CONNECTOR. LINE AND CONNECTOR REPLACED NO LEAKS NOTED.

CA051109004

BEECH

PWA  

 

TORQUE LINK

CRACKED

7/13/2002

100BEECH

PT6A28

 

508103237

MLG 

UPON INSPECTION DISCOVERED MLG TORQUE LINKS CRACKED AT CENTER BOLT ATTACH POINTS. TORQUE LINKS SUBSEQUENTLY REPLACED.

CA051202001

BEECH

PWA  

 

WIRE

LOOSE

11/24/2005

100BEECH

PT6A28

 

G13A22

MLG 

WIRE G13A22 CAME OFF AT V3-1 EMERGENCY EXTENSION HANDLE SAFETY SWITCH. THIS CAUSED THE GEAR TO NOT RETRACT WHEN SELECTED TO THE UP POSITION. POSSIBLE CAUSE OF LOOSE WIRE, MAY BE THAT THE WIRE WAS MOVED DURING FUSELAGE INSPECTION, WHICH MAY HAVE LOOSENED ATTACHING HARDWARE.

CA060219001

BEECH

PWA  

 

SEAL

CUT  

1/17/2006

100BEECH

PT6A28

 

1158100714

TORQUE SHAFT

RUBBER SEAL DETERIORATED ALLOWING METAL SPRING TO CUT A LARGE GROOVE IN THE TORQUE SHAFT.

CA060502000

BEECH

PWA  

 

SKIN

CRACKED

4/24/2006

100BEECH

PT6A28

 

5012016318

WING 

(CAN) SKIN CRACKED AT HILOC FASTENERS ATTACHING SKIN TO AFT FLANGE OF WING ATTACH FITTING. CONDITION EVIDENT ON BOTH LT AND RT SKINS OF WING CENTER SECTION. MFG HAS A FIELD REPAIR TO DEAL WITH THESE CRACKS. CRACKS FOUND VISUALLY WITH WING BOLT COVERS REMOVED. (TC NR 20060502000)

CA060402001

BEECH

PWA  

 

SKIN

CRACKED

3/27/2006

100BEECH

PT6A28

 

11564000098

VERTICLE STAB TE

TRAILING EDGE SKIN, RT SIDE CRACKED APPROX 1 INCH AT MAIN SPAR STATION. CRACK STARTS AT ONE JO BOLT FASTENER LOCATION AND GOES DOWN TO EDGE OF SKIN. MOST OF THE CRACK WAS HIDDEN BY THE LOWER RIGHT STABILIZER ATTACH/FAIRING ANGLE P/N 97-440025-14.

CA060125004

BEECH

PWA  

 

CAM  

BROKEN

1/24/2006

1900C

PT6A65B

 

50910276BSC

 

HEARD A BANG DURING APPROACH, FOUND RT UPPER FWD COWL INNER PORTION HAD LIFTED FROM NORM POSITION. FOUND CAM BOLT FAILED THAT PROVIDES TENSION TO LWR COWL ASSY. OVER CTR COWL FASTENERS ON THESE A/C (4) INSTILL CONSIDERABLE FORCE AND HAVE A HISTORY ON ALL SIMILAR INSTALLATIONS WITH VARIOUS FAILURE MODES. AS A RESULT, INSTALLED A BACKUP SYS OF PROVIDING HARDPOINTS TO ALLOW .032 LOCKWIRE TO BE INSTALLED BETWEEN TWO COWL HALVES, SHOULD ANY OF CAM POINTS FAIL. LOCKWIRE ON INBD POINTS ALSO FAILED BUT OUTER POINTS HELD THRU CONCLUSION OF FLT. COWL SUSTAINED SOME DAMAGE REQUIRING REPLACEMENT. NOW LOOKING AT DEVELOPING AN STC TO REMOVE ORIG CAM SYS ENTIRELY AND GOING WITH AN OVERLAP ARRANGEMENT AND SEVERAL CAMLOCKS INSTEAD.

CA051206009

BEECH

PWA  

LUCAS

BEARING

WRONG PART

11/23/2005

1900C

PT6A65B

 

03600923

STARTER GEN

STARTER-GEN SUFFERED A BEARING FAILURE THAT TOOK THE GENERATOR OFF-LINE. THE ANTI-DRIVE END (ADE) BEARING FAILED, CAUSING THE ARMATURE TO DESTROY ITSELF BY RUBBING ON THE STATOR POLES. ON DISASSEMBLY BY OVERHAUL SHOP, THE BEARING WAS FOUND TO BE P/N 03-6009-23, WHICH IS NOT APPROVED IN THE 23085-001 ST-GEN. THE CORRECT BEARING IS P/N 03-6009-18.

CA060518004

BEECH

PWA  

 

WINDSCREEN

FAILED

5/8/2006

1900C

PT6A65B

 

10138402523

COCKPIT

WINDSCREEN INSIDE PANE SHATTERED IN FLIGHT.

CA060526001

BEECH

PWA  

 

SHROUD

LOOSE

5/25/2006

1900C

PT6A65B

 

3037347

ENGINE

DURING TAKEOFF ROLL IT WAS NOTED, RT ENG ITT WAS AT RED LINE AND ENG TQ WAS BELOW REQUIRED T/O VALUE. T/O WAS ABORTED AND A/C RETURNED TO RAMP. DURING MX INVESTIGATION, LARGE INCREASES IN ITT READINGS COULD BE SEEN WHEN SELECTING BLEED AIR ON OR ACCELERATING ENG. ENGINE WAS SPLIT AT THE C FLANGE AND THE CT VANE SHROUD SEGMENTS WERE FOUND TO BE LOOSE AND CONTACTING THE CT DISC BLADES. PART OF ONE SEGMENT WAS MISSING AND THERE WAS IMPACT DAMAGE NOTED ON THE PT TURBINE WITH METAL IN THE EXHAUST STACKS. ENGINE IS BEING REPLACED AND SENT FOR INVESTIGATION AND REPAIR TO AN APPROVED ENGINE OVERHAUL FACILITY. THE ENGINE HAS COMPLETED 90 HOURS SINCE THE LAST HOT SECTION REPAIR.

CA060615003

BEECH

PWA  

 

ENGINE

SURGES

6/15/2006

1900C

PT6A65B

 

 

LEFT 

ON CLIMB-OUT, THE AIRCRAFT EXPERIENCED A LEFT ENGINE SURGE WITH HIGH ITT AND LOW OIL PRESSURE INDICATIONS. THE CREW SHUT DOWN THE ENGINE IN FLIGHT AND RETURNED FOR AN UNEVENTFUL LANDING. MAINTENANCE PERSONNEL REPORTED DEBRIS IN THE EXHAUST AND OIL LEAKING FROM THE ENGINE. THERE IS ALSO AN UNUSUAL NOISE WHEN THE PROPELLER IS ROTATED BY HAND. THE ENGINE WILL BE REMOVED TO AN APPROVED OVERHAUL FACILITY FOR INVESTIGATION.

CA060218001

BEECH

PWA  

 

MOTOR

BURNED

2/14/2006

1900D

PT6A67D

 

571302

MLG 

AFTER TAKEOFF, AIRCRAFTS LANDING GEAR WOULD NOT RETRACT. CREW CONTACTED MX AND CREW AND MX DECIDED TO LEAVE THE LANDING GEAR DOWN AND CONTINUE THE 30 MINUTE FLIGHT TO THE MAIN BASE. ALL INDICATIONS SHOWED THAT THE LANDING GEAR WAS DOWN AND LOCKED. THE AIRCRAFT LANDED AND DEPLANED THE PASSENGERS AND RETURNED TO THE HANGAR. WHEN MAINTENANCE TROUBLESHOT THE LANDING GEAR SYSTEM THE FAULT WAS FOUND WITH THE MOTOR. MOTOR WAS REPLACED AND GEAR SWINGS CARRIED OUT SATISFACTORY. THE PCB WAS ALSO REPLACED DUE TO THE TIME DELAY BUT THIS HAD NOTHING TO DO WITH THIS FAULT. AIRCRAFT THEN RETURNED TO SERVICE.

CA060205001

BEECH

PWA  

 

WIRE

BURNED

2/2/2006

1900D

PT6A67D

 

10936102247

DC POWER

ON START, THE CREW ATTEMPTED TO START THE RIGHT ENGINE. BUT NO LUCK STARTING THE ENGINE. AIRCRAFT BROUGHT TO HANGAR AND MAINTENANCE DISPATCHED. UPON ARRIVAL, MAINTENANCE ATTEMPTED TO START THIS ENGINE. NO JOY. THE STARTING ONLY HAD APPROX 300 HOURS REMAINING TIL OVERHAUL THEREFORE MAINTENANCE REPLACED THE STARTER THINKING THIS WOULD BE THE FAULT. THE STARTER GENERATOR WAS NOT THE FAULT. INSPECTION REVEALED THAT THE STARTER CABLE FEED THRU WAS BURNT UP ALONG WITH THE DC POWER PANEL. THE STARTER LUG. REPLACED THE FEED THRU CABLE AND THE POWER PANEL AND ENGINE START AND RUNS CARRIED OUT. NOW CHECKING SERVICEABLE.

CA051213009

BEECH

PWA  

 

UPLOCK SWITCH

MALFUNCTIONED

12/9/2005

1900D

PT6A67D

 

1003810061

NLG 

A/C SCHEDULED DEPARTURE AND DESTINATION. AFTER T/O CREW SELECTED GEAR UP AND THEY HAD THE INTRANSIT LIGHT STAY ON (GEAR HANDLE LIGHT). CREW CALLED MX FROM THE AIR AND CYCLED GEAR. CYCLING OF GEAR DID NOT MATTER. MX AND CREW DECIDED IT WOULD BE BEST TO RETURN TO ITS MAIN MX BASE. CREW DID HAVE ALL THREE GREEN WITH GEAR DOWN THEREFORE KNEW IT WAS NOT A PROBLEM WITH AN UNSAFE LANDING. CREW OFF LOADED PAX`S AND RETURNED A/C TO HANGAR. MX JACKED A/C AND T/S SYSTEM. T/S REVEALED THAT CONTACTS WITHIN THE UPLOCK SWITCH WERE CLOSED RESULTING IN THE IN TRANSIT LIGHT STAYING ON. MX REPLACED N/G UPLOCK SWITCH AND CARRIED OUT OP CHECKS. ALL CHECKED OK. A/C WAS RETURNED TO SERVICE.

AU510001493

BEECH

PWA  

 

ENGINE

LOW PRESSURE

12/12/2005

1900D

PT6A67D

 

 

OIL SYSTEM

RT ENGINE LOST OIL PRESSURE. ENGINE SHUT DOWN WHEN OIL PRESSURE DROPPED TO 60 PSI.

CA051207005

BEECH

PWA  

 

UPLOCK SWITCH

INTERMITTENT

12/6/2005

1900D

PT6A67D

 

H111541

LG RETRACT SYS

ON CLIMB WHEN GEAR WAS SELECTED UP, THE INTRANSIT LIGHT IN GEAR HANDLE STAYED ILLUMINATED. PILOT CYCLED GEAR AND DOWNLOCK GREEN LIGHTS GOOD BUT HANDLE ALWAYS RED IN GEAR UP POSITION. ELECTED TO RETURN TO MAINTENANCE BASE. THE GEAR WAS GOOD IN THE DOWN AND LOCKED POSITION, EMERG SERVICES WHERE ON STANDBY AND AN UNEVENTFUL LANDING WAS DONE. MAINTENANCE FOUND THAT THE LT LANDING GEAR UPLOCK SWITCH WAS INTERMITTENT AND WAS REPLACED.

CA051129002

BEECH

PWA  

 

SPRING

FRACTURED

11/14/2005

1900D

PT6A67D

 

1295240051

AILERONS

DURING TAXI, THE FLIGHT CREW NOTICED A FULL LEFT BIAS DEFLECTION IN THE AILERON SYSTEM. MAINTENANCE FOUND ONE OF THE AILERON INTERCONNECT SPRINGS HAD FRACTURED AT THE END RING THAT PROVIDES CONNECTION TO THE BRIDLE. IT IS FELT THAT THE ISSUE MAY HAVE BEEN INDUCED DURING PHASE INSPECTION REQUIREMENTS TO REMOVE THE SPRINGS DURING TENSIONING PROCEDURES AND THAT TOOL MARKS FROM PLIERS OR OTHER MECHANICAL MEANS MAY HAVE SCORED THE SPRING PROVIDING AREAS FOR STRESS RISERS TO DEVELOP. A COMPANY SUPPLEMENTAL INSPECTION HAS BEEN INSERTED INTO OUR PROCESS CONTROL FOR THIS ISSUE.

CA051130008

BEECH

PWA  

 

STARTER GEN

FAILED

11/30/2005

1900D

PT6A67D

 

23078019

ENGINE

ATTEMPTED TO START THE LEFT ENGINE BUT NO SUCCESS. MAINTENANCE WAS NOTIFIED AND AIRCRAFT BROUGHT BACK INTO HANGAR. SYSTEM INSPECTED AND FOUND THAT STARTER GENERATOR AT FAULT. REPLACED STARTER GENERATOR AND ENGINE RUN PERFORMED. SYSTEM CHECKED SATISFACTORY AND NO LEAKS PRESENT. AIRCRAFT RETURNED TO SERVICE.

CA060106003

BEECH

PWA  

 

WIRE

DAMAGED

1/5/2006

1900D

PT6A67D

 

 

UPLOCK SWITCH

UPON ARRIVAL, THE GEAR WAS SELECTED DOWN BUT NO DOWN AND LOCKED ANNUNCIATORS ILLUMINATED. THE IN TRANSIT LIGHT WAS ALSO NOT ILLUMINATED SO THE PILOT DID A FLY BY OF TOWER TO CONFIRM GEAR POSITION, THEY ALSO HAD EMERGENCY SERVICES ON STANDBY. AN UNEVENTFUL LANDING WAS COMPLETED. AS THE AIRCRAFT WAS BEING SHUTDOWN THE CREW NOTICED THAT THE CB FOR THE ANNUNCIATORS WAS POPPED. RESET THE CB AND ALL THE ANNUNCIATORS ILLUMINATED AS REQUIRED. A SPECIAL FERRY PERMIT WAS ISSUED TO RETURN THE AIRCRAFT TO A MAINTENANCE BASE. MAINTENANCE FOUND A CHAFED WIRE ON THE HARNESS FOR THE RT UPLOCK MICROSWITCH. GEAR SWUNG AND AIRCRAFT RETURNED TO SERVICE.

CA060106004

BEECH

PWA  

 

WINDSHIELD

CRACKED

1/5/2006

1900D

PT6A67D

 

10138402523

COCKPIT

DEPARTING AIRPORT THE LT HEATED WINDSHIELD CRACKED. TURNED AROUND AND MADE AN UNEVENTFUL LANDING. THE AIRCRAFT WAS SENT TO MAINTENANCE WHO REPLACED THE WINDSHIELD.

CA060418003

BEECH

PWA  

 

WIRE

CHAFED

4/7/2006

1900D

PT6A67D

 

 

MLG 

CREW REPORTED LEFT MAIN GEAR NOT INDICATING GREEN BUT WAS DOWN AND LOCKED. MAINTENANCE FOUND WIRE IN WHEEL WELL AREA CHAFFED TO ACTUATOR DOWNLOCK. WIRE REPAIRED AND PROTECTED.

CA060503004

BEECH

PWA  

LEARSIEGLER

SHAFT

SHEARED

5/1/2006

1900D

PT6A67D

 

 

STARTER GEN

IN CRUISE, LT GEN FAIL LIGHT ILLUMINATED. ATTEMPTED TO RESET GEN BUT IT STILL WOULD NOT COME ON LINE. SHORTLY AFTER GEN FAILURE, LT ENG FIRE WARNING IND ALSO CAME ON. LT ENG WAS SHUTDOWN AND ENG FIRE BOTTLE WAS DISCHARGED. MX INSPECTED A/C. FOUND LT STARTER GEN HAD FAILED INTERNALLY AND PAINT ON UNIT WAS BLISTERED INDICATING IT HAD DRASTICALLY OVERHEATED. ALSO REVEALED STARTER GEN DRIVE SPLINE HAD SHEARED. INSP CARRIED OUT IAW MM. STARTER GEN, FIRE BOTTLE WERE REPLACED, AND A/C RETURNED TO SERV. NOTED FIRE WIRE IS LOCATED IN CLOSE PROX TO STARTER/GEN. STARTER/GEN WAS INSTALLED PREVIOUS DAY IN A REPAIRED CONDITION, AT TIME OF FAILURE STARTER/GEN HAD ONLY ACCUMULATED 1.6 HRS SINCE REPAIR.

CA060531009

BEECH

PWA  

 

ENGINE

MALFUNCTIONED

5/8/2006

1900D

PT6A67D

 

 

 

(CAN) DURING TAKE-OFF ROLL THE ENGINE WAS REPORTED TO EMIT A LOUD NOISE ACCOMPANIED BY SEIZURE OF THE POWER SECTION. SUBSEQUENT INSPECTION REVEALED DAMAGED POWER TURBINE BLADES. MFG WILL INVESTIGATE THE INCIDENT AND ADVISE OF ROOT CAUSE ONCE ESTABLISHED. (TC NR 20060531009)

CA060525004

BEECH

PWA  

 

BRACKET

CRACKED

5/24/2006

1900D

PT6A67D

 

35165050271

ACTUATOR

(CAN) DURING A BASE INSPECTION THE RT OB FLAP ACTUATOR BRACKET WAS FOUND CRACKED. WHEN THE BRACKET WAS REMOVED FROM THE SKIN, IT WAS DISCOVERED THAT THE SKIN WAS ALSO CRACKED. FURTHER INSPECTION REVEALED THAT THE RIB UNBER THE SKIN WAS ALSO DAMAGED. THE FLAP WILL BE REPLACED. (TC NR 20060525004)

CA060126008

BEECH

PWA  

BEECH

BEARING

WORN

1/24/2006

1900D

PT6A67D

1306300001

MS289135

RUDDER

(CAN) DURING A GENERAL WALKAROUND THE RUDDER WAS MOVED BY HAND. NOTICING THAT THE RUDDER SEEMED TO MOVE UP AND DOWN AND APPEARED TO RUB AGAINST THE TAIL CONE. RUDDER ATTATCHMENT INSPECTED. INVESTIGATION REVEALED THAT ALL THREE BEARINGS HAVING SOME PLAY. THE LOWER BEARING SEEMED TO CAUSE THE RUDDER TO DROP. THIS INTURN WORE THE CLEVIS BRACKETS. REPLACED ALL THREE BEARINGS AND BOTH CLEVIS BRACKETS. RUDDER REINSTALLED AND TRAVEL CHECKED OK. AIRCRAFT RETURNED TO SERVICE. (TC NR 20060126008)

CA060531015

BEECH

PWA  

 

ENGINE

MAKING METAL

5/21/2006

1900D

PT6A67D

 

 

 

(CAN) DURING DESCENT THE ENGINE WAS REPORTED TO LOSE POWER ACCOMPANIED BY A FIRE. THE CREW DEPLOYED FIRE EXTINGUISHERS AND SHUT THE ENGINE DOWN IN FLIGHT. SUBSEQUENT INSPECTION REVEALED METAL IN THE ENGINE EXHAUST. MFG WILL INVESTIGATE THE EVENT AND ADVISE OF ROOT CAUSE ONCE ESTABLISHED.

CA060531016

BEECH

PWA  

 

BLADE

FAILED

5/30/2006

1900D

PT6A67D

 

 

ENGINE

(CAN) UPON APPLYING TAKEOFF POWER FOR DEPARTURE, THE PILOT HEARD A LOUD BANG. HE THEN INITIATED A SUCCESSFULL REJECTED TAKEOFF. UPON STOPPING, A PASSENGER CAME FORWARD AND STATED THAT HE THOUGHT SOMETHING FELL OFF THE RT WING. THE RT ENGINE WAS SECURED. THE AIRCRAFT TAXIED BACK TO THE GATE AND PASSENGERS DISEMBARKED. UPON INVESTIGATION BY MAINTENANCE THE RT ENGINE SEEMS TO HAVE SUFFERED A POWER TURBINE BLADE FAILURE. THE DEBRIS FROM THE BLADES IS WHAT THE PASSENGERS WOULD HAVE SEEN. ENGINE WILL BE FORWARDED TO THE MFG FOR INVESTIGATION. SDR WILL BE LEFT OPEN AND UPDATED WITH INVESTIGATION FINDINGS. (TC NR20060531016)

CA060601005

BEECH

PWA  

 

TURBINE BLADES

FRACTURED

5/31/2006

1900D

PT6A67D

 

 

ENGINE

(CAN) DURING TAKE-OFF ROLL THE ENGINE EMITTED A LOUD NOISE AND TAKE-OFF WAS ABORTED. SUBSEQUENT INSPECTION REVEALED FRACTURED POWER TURBINE BLADES AND RESULTS, EXHAUST STUB DAMAGE. MFG WILL INVESTIGATE THE INCIDENT AND ADVISE OF ROOT CAUSE ONCE ESTABLISHED. (TC NR 20060601005)

CA060531024

BEECH

PWA  

 

TURBINE BLADES

DAMAGED

4/29/2006

1900D

PT6A67D

 

 

ENGINE

(CAN) DURING TAKEOFF ROLL, THE ENGINE WAS REPORTED TO VIBRATE ACCOMPANIED BY AN UNCOMMANDED REDUCTION IN POWER. TAKEOFF WAS ABORTED. SUBSEQUENT INSPECTION REVEALED DAMAGED POWER TURBINE BLADES. MFG WILL MONITOR INVESTIGATION OF THE EVENT AND REPORT ON ROOT CAUSE ONCE DETERMINED. (TC NR 20060531024)

CA060606008

BEECH

PWA  

 

RELAY

DAMAGED

5/27/2006

1900D

PT6A67D

 

MS24166D1

LOW HEAT

(CAN) WHEN GROUND POWER WAS APPLIED TO THE AIRCRAFT IT WAS NOTICED THAT THE LT HEATED WINDSHIELD WAS WARM AND ANTI-ICE SWITCH WAS OFF. POWER TO WINDSHIELD, LIMITER IN LT NACELLE, WAS PULLED. INSP OF THE LT WINDSHIELD ANTI-ICE HI/LO RELAYS, BEHIND INSTRUMENT PANEL, REVEALED THAT TERMINAL A2 OF LO HEAT RELAY HAD HEAT DAMAGE AND WAS NO LONGER ATTACHED TO RELAY, IT WAS STILL ATTACHED TO WIRE H16A8, WIRE WAS NO LONGER ATTACHED TO RELAY AND ABOUT ONE INCH OF THE INSULATION FROM WIRE END WAS MISSING. RELAY INTERNAL CONTACTS A1 TO A2 SHOW EXCESSIVE PITTING AND ARCING. RELAY MS24166-D1 WAS REPLACED AND WIRE H16A8 WAS ALSO REPLACED. (TC NR 20060606008)

CA060129012

BEECH

PWA  

 

ENGINE

LOW PRESSURE

1/2/2006

1900D

PT6A67D

 

PT6A6D

 

(CAN) DURING TAKE-OFF ROLL, THE ENGINE LOW PRESSURE WARNING ANNUNCIATED AND THE TAKE-OFF WAS ABORTED. MFG WILL MONITOR INVESTIGATION OF THE EVENT AND WILL ADVISE OF ROOT CAUSE ONCE ESTABLISHED. (TC NR 20060129012)

CA060614005

BEECH

PWA  

 

CASE

LEAKING

6/9/2006

1900D

PT6A67D

 

 

ENGINE

APPROX 20 MIN INTO CRUISE FLIGHT, THE LT LOW OIL PRESSURE LIGHT CAME ON . THE ENGINE WAS SHUT DOWN AS IT REACHED 50 PSI. ELECTED TO RETURN TO PLACE OF DEPARTURE AND A SUCCESSFUL LANDING WAS MADE. UPON STOPPING A LARGE QUANTITY OF OIL WAS FOUND UNDERNEATH LT ENGINE COWL. MAINTENANCE WAS DISPATCHED AND A COMPLETE REPORT WILL FOLLOW WITH FURTHER FINDINGS.

CA060309005

BEECH

PWA  

BEECH

RIVET

LOOSE

3/7/2006

200BEECH

PT642A

 

1016100197

TORQUE TUBE

(CAN) PHASE INSPECTION REVEALED SLIGHT MOVEMENT BETWEEN THE TORQUE TUBE AND THE ACTUATING ARM. THE ASSEMBLY IS SECURED BY 8 CHERRY LOCK RIVETS THAT WERE BEGINNING TO WORK, ALLOWING SUBTLE PLAY IN THE ASSEMBLED JOINT. TORQUE TUBE ASSEMBLY DETERMINED TO BE NON-REPAIRABLE AND WILL BE REPLACED. (TC NR 20060309005)

CA060501006

BEECH

PWA  

 

VANE

CRACKED

4/17/2006

200BEECH

PT642A

 

1019100203

INTAKE

(CAN) VANE FOUND SEVERELY CRACKED ON VISUAL INSPECTION. CRACK APPEARS TO HAVE STARTED AT LEADING EDGE OF VANE FROM THE HINGE AREA. HINGE WAS FOUND CRACKED ALSO. DAMAGE POSSIBLY ACCELERATED DUE TO FLUTTER OF THE DAMAGED VANE. (TC NR 20060501006)

AU510002161

BEECH

PWA  

 

SEAL

DAMAGED

12/12/2005

200BEECH

PT642A

 

 

FUEL FILTER

LT ENGINE FUEL FILTER BOWL SEAL DISPLACED AND FUEL LEAKING. FILTER BOWL WAS CORRECTLY LOCKWIRED.

CA060427000

BEECH

PWA  

 

MOUNT

LOOSE

4/3/2006

200BEECH

PT642A

 

50980002185

ENGINE

(CAN) BOTH LOWER ENGINE MOUNT FITTINGS P/N 50-980002-185 CONTAINING THE ENGINE MOUNT BARREL NUTS WERE FOUND LOOSE BY LIFTING ON THE NON ENGINE MOUNT AND OBSERVING THE LOWER LEGS OF THE MOUNT IN RELATION TO THE FIREWALL. THE OB FITTING HAD MORE MOVEMENT THAN THE IB. AN ENGINE MOUNT WOULD TAKE A HARDER LIFT TO SHOW MOVEMENT. THE FASTENERS ARE VISIBLE THROUGH THE NACELLE SIDE HATCHES. IF LOOSE THEY COULD EXHIBIT HEAVY SMOKING AND A BLACK GREASE LIKE BUILDUP AT EACH FASTENER. (TC NR 20060427000)

CA060403013

BEECH

PWA  

PWC  

ENGINE

POWER LOSS

3/15/2006

200BEECH

PT642A

PT6A42

 

ENGINE

(CAN) DURING CRUISE THE ENGINE EXPERIENCED AN UNCOMMANDED SHUT DOWN. THE AIRCRAFT DIVERTED TO POINT OF DEPARTURE. P&WC WILL MONITOR INVESTIGATION OF THE EVENT AND WILL ADVISE OF ROOT CAUSE ONCE ESTABLISHED.

AU510001997

BEECH

PWA  

 

BULKHEAD

CRACKED

12/12/2005

200BEECH

PT642A

 

 

FUSELAGE

REAR PRESSURE BULKHEAD EXTENDER NR 7 CLEAT CRACKED.

AU510001701

BEECH

PWA  

 

CONNECTOR

DAMAGED

10/7/2005

200BEECH

PT642A

 

MS3450KT3685

FIRE DETECTION

LT ENGINE SUFFERED FROM FALSE FIRE WARNING INDICATIONS. INVESTIGATION FOUND LOW INSULATING RESISTANCE IN FIREWALL CONNECTOR J102. CONNECTOR WAS SECTIONIZED AND EVIDENCE OF INTERNAL CRACKING AND TRACKING WAS FOUND.

CA051223012

BEECH

PWA  

 

ENGINE

VIBRATION

12/16/2005

200BEECH

PT642A

 

 

 

ON DESCENT, THE ENGINE WAS REPORTED TO VIBRATE ACCOMPANIED BY AN UNCOMMANDED POWER ROLL-BACK AND SHUT DOWN. A SUCCESSFUL IN-FLIGHT RELIGHT WAS ACCOMPLISHED. P&WC WILL INVESTIGATE THE EVENT AND ADVISE OF ROOT CAUSE ONCE ESTABLISHED.

AU510002003

BEECH

PWA  

 

INVERTER

FAILED

6/10/2005

200BEECH

PT642A

 

334977E14

CABIN LIGHTS

FLUORESCENT CABIN LIGHTING SYSTEM COLD CATHODE INVERTER FAILED INTERNALLY.

CA060403007

BEECH

PWA  

 

PUMP

UNSERVICEABLE

2/20/2006

200BEECH

PT642A

 

 

FUEL SYS

ON DESCENT, THE ENGINE EXPERIENCED AN UNCOMMANDED SHUTDOWN. THE FUEL CONTROL UNIT AND FUEL PUMP WERE SUBSEQUENTLY REPLACED AND THE AIRCRAFT RETURNED TO SERVICE.

CA060531020

BEECH

PWA  

 

ENGINE

MALFUNCTIONED

5/15/2006

200BEECH

PT6A21

 

 

 

(CAN) DURING CLIMB THE ENGINE WAS REPORTED TO EMIT A NOISE AND WAS SHUT DOWN IN FLIGHT. AN EMERGENCY WAS DECLARED AND THE AIRCRAFT DIVERTED. THE AIRFRAME WAS DAMAGED IN THE SUBSEQUENT LANDING (OVERSHOOT). MFG WILL INVESTIGATE THE EVENT AND ADVISE OF ROOT CAUSE ONCE ESTABLISHED. (TC NR 20060531020)

CA060606011

BEECH

PWA  

 

LINE

LEAKING

6/5/2006

200BEECH

PT6A41

 

130F0014S0314

OIL 

(CAN) WHILE APPLYING TAKEOFF POWER THE PILOTS NOTICED SMOKE IN THE CABIN AND ABORTED THE TAKEOFF WITHOUT INCIDENT. DURING INVESTIGATION MAINTENANCE DISCOVERVED THAT A RECENTLY REPLACED OIL PRESSURE LINE TO THE TORQUE TRANSMITTER MANIFOLD WAS LEAKING AT THE FLARE FITTING. THE HOSE WAS REPLACED AND THE AIRCRAFT RETURNED TO SERVICE. (TC NR 20060606011)

CA060129005

BEECH

PWA  

 

ENGINE

FIRE

1/20/2006

200BEECH

PT6A41

 

 

 

(CAN) THE ENGINE WAS REPORTED TO EMIT A LOUD NOISE ACCOMPANIED BY A LOSS IN POWER AND FLAMES EMINATING FROM THE EXHAUST. THE ENGINE WAS SHUT DOWN IN FLIGHT. MFG WILL MONITOR INVESTIGATION OF THE EVENT AND WILL ADVISE OF ROOT CAUSE ONCE DETERMINED. (TC NR 20060129005)

CA060129013

BEECH

PWA  

 

COMPRESSOR

DAMAGED

1/2/2006

200BEECH

PT6A41

 

 

ENGINE

(CAN) DURING DESCENT, THE ENGINE EXPERIENCED AN UNCOMMANDED POWER REDUCTION, ACCOMPANIED BY NOISE AND FLAMES EMANATING FROM THE EXHAUST. THE ENGINE WAS SHUT DOWN IN FLIGHT, AN EMERGENCY DECLARED AND THE AIRCRAFT DIVERTED TO POINT OF DEPARTURE. SUBSEQUENT INSPECTION REVEALED COMPRESSOR SECTION DAMAGE. MFG WILL MONITOR INVESTIGATION OF THE EVENT AND WILL ADVISE OF ROOT CAUSE ONCE ESTABLISHED. (TC NR 20060129013)

CA051109006

BEECH

PWA  

 

WINDSHIELD

FAILED

10/11/2005

200BEECH

PT6A41

 

10138402521

COCKPIT

DURING CLIMB-OUT, THE PILOT NOTICED THAT SUDDENLY THE INNER PLY OF THE CAPTAINS HEATED WINDSHIELD SHATTERED. THERE WAS NO INDICATION OF IMPACT, OR ANY OTHER APPARENT REASON, THAT MAY HAVE CAUSED THIS. THE AIRCRAFT RETURNED TO THE DEPARTURE AERODROME WITHOUT FURTHER INCIDENT WHERE MAINTENANCE PERSONNEL INSPECTED THE WINDSHIELD. A FERRY PERMIT WAS OBTAINED TO FERRY THE AEROPLANE TO THE COMPANY'S MAINTENANCE BASE WHERE THE WINDSHIELD WAS REPLACED. DURING THE REPLACEMENT PROCESS NOTHING WAS FOUND THAT MAY HAVE EXPLAINED WHY THE WINDSHIELD SHATTERED IN THE FIRST PLACE.

CA060501003

BEECH

PWA  

 

FUEL CONTROL

FAILED

4/7/2006

200BEECH

PT6A41

 

324475520

ENGINE

(CAN) DURING CRUISE THE ENGINE EXPERIENCED AN UNCOMMANDED POWER ROLL-BACK. THE ENGINE WAS SHUTDOWN IN FLIGHT. THE FUEL CONTROL UNIT WAS SUBSEQUENTLY REPLACED. (TC NR 20060501003)

CA060529009

BEECH

PWA  

 

PUMP

FAILED

5/18/2006

200BEECH

PT6A41

 

HP3001

HYDRAULIC SYS

(CAN) MAINTENANCE INSPECTED THE AIRCRAFT, FOUND MAIN 60A CB TRIPPED RESET CB AND SYSTEM APPEARED TO FUNCTION NORMAL FURTHER INVESTIGATION FOUND HYDRAULIC PUMP WOULD INTERMITTENTLY (ONLY OCCUR ON FIRST SYSTEM POWER UP) INTERNALLY BYPASS CAUSING LOW PRESSURE OUTPUT AND PUMP RUN-ON UNTIL CB WOULD TRIP INVESTIGATION OF THE SYSTEM FOUND WIRE (SPRING MATERIAL) IN FIRST CHECK VALVE OFF PUMP AND MAIN FILTER HYDRAULIC PUMP REPLACED, SYSTEM FLUSHED AND FUNCTION CHECKED. (TC NR 20060529009)

CA060531005

BEECH

PWA  

 

FUEL CONTROL

INOPERATIVE

4/7/2006

200BEECH

PT6A41

 

324475520

ENGINE

(CAN) DURING CRUISE THE ENGINE EXPERIENCED AN UNCOMMANDED POWER REDUCTION. THE ENGINE WAS SHUT DOWN IN FLIGHT AND THE AIRCRAFT DIVERTED. THE FUEL CONTROL WAS SUBSEQUENTLY REPLACED. MFG WILL INVESTIGATE THE EVENT AND ADVISE OF ROOT CAUSE ONCE DETERMINED. (TC NR 20060531005)

CA060224004

BEECH

PWA  

 

WINDSHIELD

FAILED

2/22/2006

200BEECH

PT6A41

 

10138402522

COCKPIT

WHILE IN CRUISE FLT AT FL 270, APPROXIMATELY 250 MILES INTO THE MIDDAY FLT, FLIGHT CREW REPORTED HEARING A MILDLY LOUD BANG WITHIN THE CABIN. THEY THEN NOTICE SMALL SHARDS OF GLASS FALLING ONTO THE LAP OF THE FIRST OFFICER. THE INNER PANE OF THE RIGHT WINDSHIELD HAD SHATTERED. THE CREW INITIATED THE STANDARD PROCEDURE FOR A CRACKED WINDSHIELD IAW THE POH BY REDUCING THEIR CRUISE SPEED, DESCENDED TO 14000 FEET AND REDUCE CABIN DIFFERENTIAL TO 4.0 PSI. THE FIRST OFFICER DONED HIS GOGGLES AND THEY RETURNED SAFELY. THE WINDSHIELD WAS REPLACED AND THE AIRCRAFT WILL BE RETURNED TO SERVICE UPON COMPLETING THE CURE TIME FOR THE SEALANT. NOTE THAT THE OAT AT THE TIME OF THE FLIGHT AT 270 WAS -47'C.

CA060223002

BEECH

PWA  

 

TUBE

SPLIT  

2/22/2006

200BEECH

PT6A41

 

302039402

TIRE 

A NORMAL LAND UP UNTIL, SENSED WHAT FELT LIKE DRAGGING BRAKE ON RT M/G. ONCE SAFELY STOPPED, AND ENG`S SHUT DOWN, CREW EXITED A/C, DISCOVERED RT O/B WHEEL ASSY FLAT TIRE. RETURNED TO A/C TO FIND TWO OTHER TIRES FLATTENED. THESE WERE BOTH RT AND LT INBDS TIRES. PLANE RETURNED TO BASE. ONCE THE WHEEL ASSEMBLIES WERE TAKEN APART FOR TIRE/TUBE REPLACEMENT, DISCOVERED INNER TUBES HAD SPLIT IN A RADIAL DIRECTION ACROSS TUBE. THE FOLLOWING MORNING, MX FOUND 4TH MAIN WHEEL, THE ONE NOT PREVIOUSLY REPLACED, ALSO LOST IT'S AIR OVERNIGHT. A SIMILAR SPLIT WAS FOUND IN INNER TUBE. ALL 4 WHEELS WERE NEW JUDGING FROM CONDITION. A/C FLEW DURATION OF FLT IN EXTREME COLD CONDITIONS (-40'C) AT FL 230.

CA060103001

BEECH

PWA  

 

ENGINE

FAILED

1/2/2006

200BEECH

PT6A41

 

 

RIGHT

AT APPROXIMATELY 09:30 THIS MORNING, THE RT ENGINE OF KING AIR 200 HAD AN IN-FLIGHT TORQUE ROLL BACK TO APPROX 200 FT LBS, WITH A RISE IN ITT TO APPROX 680 DEG C, WITH A POPPING NOISE AND CORRESPONDING FLAMES FROM THE RT ENGINE EXHAUST. THE CREW INITIATED THE ENGINE SHUTDOWN.

CA051220008

BEECH

PWA  

 

TUBE

CUT  

12/20/2005

200BEECH

PT6A41

 

302039402

MLG TIRE

WHEEL ASSY P/N 101-8002-3 ASSEMBLED USING GOODYEAR TIRE P/N 301-392-641 AND TUBE P/N 302-039-402. AFTER 34 HRS TO 250 HRS OF OPERATION, TUBES WOULD FAIL. PERIODIC AIR PRESSURE TESTING WOULD REVEAL A TIRE PRESSURE LOSS OF 10 LBS. THE TUBE WAS REMOVED AND CUTS WERE EVIDENT. THIS IS THE 7TH TIME THIS HAS HAPPENED IN 6 WEEKS PRIOR. THE AREA THAT THE TUBES ARE CUT ARE ADJACENT TO A MANUFACTURES STICKER ON THE INSIDE OF THE TIRE.

CA051208008

BEECH

PWA  

 

BULKHEAD

CRACKED

12/2/2005

200BEECH

PT6A41

 

 

FUSELAGE

WHILE TROUBLESHOOTING A PRESSURIZATION SNAG ON THE AIRCRAFT UNDERGOING MAINTENANCE AT OUR FACILITY, DISCOVERED AN APPROXIMATELY 3.5 LONG CRACK IN A SECTION OF THE BULKHEAD LOWER FLANGE ATTACHED AT THE REAR SPAR AT FS 227. THE CRACK WAS CAUSING A MAJOR PRESSURIZATION LEAK THAT COULD BE FELT OUTSIDE OF THE AFT SPAR BOX ON THE EXTERIOR OF THE AIRCRAFT. NO SPECIFIC REPAIR INSTRUCTIONS ARE PROVIDED IN THE MAINTENANCE MANUAL FOR THIS DAMAGE. A CANADIAN DAR WAS CONTRACTED TO PROVIDE A REPAIR DESIGN FOR THE ABOVE AND REPAIRS WERE COMPLETED AS PER APPROVAL. UPON COMPLETION OF REPAIRS A PRESSURIZATION TEST WAS COMPLETED.

AU510001673

BEECH

PWA  

 

STRINGER

CRACKED

12/12/2005

200BEECH

PT6A41

 

 

BS 190

FUSELAGE CLEATS AND STRINGERS CRACKED AND CORRODED IN THE FOLLOWING AREAS, CLEAT AT LOWER LONGERON LT SIDE CRACKED AT FRAME ATTACHMENT FS 216.125 2 LT SIDE STRINGER CORRODED ON END AT FS 190.6 3. CLEAT AT STRINGER 6 LT HAS RIVETS MISSING AT FS 227.

CA051209001

BEECH

PWA  

BEECH

WINDOW

CRACKED

12/8/2005

200BEECH

PT6A41

 

1014301833

EMERGENCY DOOR

LEVELING OFF AT 19000 FT, CREW HEARD FAINT CRUNCH SOUND WITHIN CABIN. PAX SITTING AT EMERG EXIT NOTIFIED FLT CREW OF LOUD GUNSHOT TYPE NOISE. THEN NOTICED OUTER WINDOW PANE FOR EMERG EXIT CRACKED. CREW PROMPTLY REDUCED THEIR ALT TO 11000 FT AND DIALED CABIN UP TO OBTAIN CABIN PRESS DIFF OF APPROX 1.0 PSI. SAFELY CONTINUED TO DESTINATION. RETURN FLT WAS CONDUCTED UNPRESSURIZED. MX INSPECTED OUTER SURFACE OF WINDOW AND FOUND IT DELAMINATED AND THE CRACK IN A MOON SHAPE FROM TOP TO BOTTOM FACING FWD. CRACKED PORTION PROTRUDING SLIGHTLY OUTWARDS. ONCE REMOVED, INNER SURFACE OF WINDOW FOUND TO BE INTACT. NO DAMAGE FOUND ON OUTER SURFACE OF WINDOW THAT MIGHT INDICATE WHERE CRACK MIGHT HAVE ORIGINATED.

CA060217001

BEECH

PWA  

 

DIODE

FAILED

2/14/2006

200BEECH

PT6A41

 

70H10A

COCKPIT

CREW REPORTS THAT MULTIPLE SYSTEMS AND ANNUNCIATORS UNSERVICEABLE. MAINTENANCE PERSONAL DISPATCHED AND FOUND THAT NR 1 DUAL FED ELECTRICAL BUS HAD FAILED BOTH MAIN FEED DIODES (P/N 70H10A). DIODES REPLACED AND FUNCTION CHECKED SERVICEABLE. COMPANY HAS NOW IMPLEMENTED A MONTHLY REPETITIVE CHECK OF THE BUS SYSTEM DUE TO THE DORMANT FAILURE RISK OF THESE DIODES.

CA060403019

BEECH

PWA  

 

ENGINE

FAILED

4/29/2006

200BEECH

PT6A41

 

 

 

THE ENGINE WAS REPORTED TO HAVE EXPERIENCED AN INFLIGHT SHUTDOWN. SUBSEQUENT INSPECTION REVEALED METAL DEBRIS ON THE ENGINE CHIP DETECTOR. P&WC WILL INVESTIGATE THE EVENT AND ADVISE OF ROOT CAUSE ONCE ESTABLISHED.

CA051114007

BEECH

PWA  

 

LINK

BROKEN

10/19/2005

200BEECH

PT6A41

 

9981004311

MLG 

AFTER SELECTION OF GEAR UP ON DEPART, GEAR STOPPED PART WAY THROUGH ITS TRAVEL AND HAD TO BE EXTENDED BY MEANS OF ALT EXTENSION SYSTEM. A/C LANDED UNEVENTFUL WITH 3 GREEN, DOWN AND LOCKED. INSPECTION OF A/C INITIALLY INDICATED A BROKEN LT INBOARD MAIN GEAR DOOR SWIVEL LINK. THE GEAR CONTROL C/B WAS ALSO TRIPPED. AFTER RESETTING BREAKER, GEAR WAS CYCLED FOR INVESTIGATION AND IT WAS NOTED THAT LEFT MAIN GEAR ACT EXHIBITED AN ABNORMAL NOISE DURING CYCLE AND APPEARED SLOWER. ACTUATOR REMOVED FOR INSPECTION AND FOUND TO HAVE AN AREA OF TRAVEL WHICH WAS ROUGH AND STIFF TO EXTEND AND RETRACT WHEN ROTATED BY HAND. ACTUATOR WAS REPLACED ALONG WITH THE SWIVEL LINK AND GEAR DOOR BRACKETS. ALL GEAR DOOR LINKAGES WERE INSPECTED FOR CONDITION AND GEAR FUNCTION CHECKS CARRIED OUT. ALL KING AIR 200 AIRCRAFT IN THE FLEET WERE INSPECTED FOR CONDITION OF THE GEAR DOOR LINKS AND BRACKETS WITH NO DEFECTS DISCOVERED.

CA060117005

BEECH

PWA  

 

WINDSHIELD

BROKEN

1/14/2006

200BEECH

PT6A41

 

10138402522

COCKPIT

DURING CRUISE AT 19,000 FT ALTITUDE, CABIN DIFF OF 5.8 PSI, THE INNER PANE OF THE CO-PILOT'S WINDSHIELD SHATTERED. THE CREW LANDED THE AIRCRAFT SAFELY AT IT'S DESTINATION.

CA060419004

BEECH

PWA  

 

LIMIT SWITCH

FAILED

4/7/2006

200BEECH

PT6A41

 

BZ2RQ181A2

MLG 

A NEW LANDING GEAR GEARBOX WAS INSTALLED IN THE AIRCRAFT. SEVERAL DAYS LATER THE CREW WERE UNABLE TO SELECT THE GEAR UP AFTER TAKEOFF. THE AIRCRAFT RETURNED AND LANDED NORMALLY. THE UP LIMIT SWITCH WAS FOUND TO BE DAMAGED WHERE THE INTERNAL CONTACTS WERE NOT MAKING AND NOT ALLOWING THE GEAR TO BE POWERED FOR A GEAR UP SELECTION. IT IS NOT KNOWN WHEN THE SWITCH WAS DAMAGED AS IT WAS REPLACED AT THE TIME THE GEARBOX WAS REPLACED. THE SWITCH IS IN AN AREA THAT IS DIFFICULT TO REACH THEREFORE MAKING THE RIGGING ALSO DIFFICULT.

CA051003005

BEECH

PWA  

 

PRESSURE SWITCH

NO INDICATION

8/13/2005

200BEECH

PT6A65B

 

10038901819

FUEL SYSTEM

FUEL WARNING LIGHT WOULD NOT INDICATE WHEN A/C WAS SHUT DOWN, IT IS SUPPOSE TO UNDER NORMAL PROCEDURES. SWITCH WAS REPLACED WITH SAME PART NUMBER AND CORRECT AS PER IPC. NEW SWITCH ALSO WOULD NOT WORK. A SECOND NEW SWITCH WAS TRIED, IT ALSO DID NOT WORK. AFTER CONVERSATIONS WITH BEECHCRAFT TECHNICAL REP, IT WAS DISCOVERED SWITCH HAS A VENT HOLE SHOULD BE OPEN TO ATMOSPHERE. FAILING SWITCHES HAD METAL TAG THAT COVERED THE VENT HOLE. SUSPECT SWITCHES HAD TAG REMOVED AND THE SWITCHES WERE TESTED AND FOUND SERVICEABLE. INFORMATION WAS FORWARDED TO BEECHCRAFT AND THEY ARE INFORMING THE VENDOR OF THIS ERROR.

AU510002002

BEECH

PWA  

 

FUEL CONTROL

FAILED

12/10/2005

200CBEECH

PT642A

 

324476812

ENGINE

ENGINE FUEL CONTROL UNIT FAILED. FORWARD BEARING COLLAPSED. BEARING WAS OLD PRE-MOD TYPE.

AU510001509

BEECH

PWA  

 

CABLE

FAULTY

12/12/2005

200CBEECH

PT642A

 

1015240895

RUDDER TAB

RUDDER TAB CONTROL CABLE OVERRAN RUDDER TAB ACTUATOR CABLE DRUM. INVESTIGATION FOUND THE CABLE RIGGING WAS OUT OF ADJUSTMENT.

CA051208009

BEECH

PWA  

 

STRUCTURE

PULLED

12/2/2005

200CBEECH

PT6A41

 

 

 

AFT STRAKES RIVETS PULLED THROUGH ON THE TAIL TO FUSELAGE JOINT. ADVISED ENGINEERING AND GAINED INSTRUCTIONS FOR REPAIR AND COMPLETED, AIRCRAFT RETURNED TO SERVICE. CAUSE OF THE RIVETS PULLING THROUGH IS UNKNOWN AT THIS TIME.

AU510001892

BEECH

PWA  

 

SQUAT SWITCH

OUT OF ADJUST

12/12/2005

200CBEECH

PT6A41

 

444EN496

MLG 

RT MAIN LANDING GEAR SQUAT SWITCH ADJUSTED TO MINIMUM TOLERANCE PREVENTING RETRACTION OF THE LANDING GEAR. SWITCH ADJUSTED AND LANDING GEAR RETRACTION WAS NORMAL.

CA051107002

BEECH

PWA  

 

LINK

BROKEN

11/4/2005

200CBEECH

PT6A41

 

50820189

NLG STEERING SYS

ONCE LANDED , FLT CREW PROCEEDED TO STEER A/C OFF RUNWAY, WERE UNABLE. BY APPLYING THE BRAKES AND DIFFERENTIAL ENGINE POWER SETTINGS, ABLE TO MANEUVER A/C OFF RUNWAY AND OVER TO MX HANGAR. MX PERSONNEL FOUND STEERING LINK SEVERED IN HALF APPROX MID SPAN AND HANGING DOWN. UPON FURTHER INVESTIGATION, FOUND STEERING BUNGEE (P/N 50-820034-3) WAS JAMMED NOT ALLOWING SPRING TO COMPRESS IN ONE DIRECTION. THIS JAMMED BUNGEE CAUSED STEERING LINK TO BREAK ONCE STEERING PRESSURE WAS APPLIED TO RUDDER PEDALS. WHEN MX PERSONNEL DISASSEMBLED THE BUNGEE MECHANISM, FOUND THREE LARGE INTERNAL WASHERS BENT OVER AND CRUMPLED WITHIN MECHANISM. THE REASON FOR THIS TYPE OF FAILURE IS UNKNOWN.

CA060317011

BEECH

PWA  

 

HYDRAULIC SYSTEM

LEAKING

3/14/2006

200CBEECH

PT6A41

 

 

 

ON INVESTIGATING A HYDRAULIC LEAK IN THE NR 1 GEAR WELL AREA, CRACKS WERE NOTED IN THE CHANNELS P/N 101-120025-57 AND P/N 101-120025-55 AS WELL AS THE ANGLE'S P/N 101-120025-67 AND 101-120025-68. THE A/C HAD A HYDRAULIC GEAR INSTALLED IN 1988 (REPLACING THE MECHANICAL GEAR ACTUATORS), AND AT THAT TIME HAD 2403.9 HOURS ON THE AIRFRAME. THE NR 2 GEAR WELL WAS INSPECTED FOR SIMILAR DAMAGE AND NONE WAS NOTED. THE AFFECTED PARTS WERE REPLACED GEAR SWINGS ACCOMPLISHED AND THE A/C RETURNED TO SERVICE.

AU510001890

BEECH

PWA  

 

SCREW

LOOSE

12/12/2005

300BEECH

PT6A60A

 

NAS22112

WING FITTING

OUTER WING FORWARD UPPER BATHTUB FITTING TO UPPER SKIN PANEL ATTACHMENT SCREWS LOOSE. SUSPECT SCREWS INCORRECTLY TORQUED DURING MANUFACTURE.

AU510001884

BEECH

PWA  

 

SCREW

LOOSE

12/12/2005

300BEECH

PT6A60A

 

NAS22112

WING SKIN

OUTER WING FORWARD UPPER BATHTUB FITTING TO UPPER SKIN PANEL ATTACHMENT SCREWS LOOSE. SUSPECT SCREWS INCORRECTLY TORQUED DURING MANUFACTURE.

AU510001876

BEECH

CONT

 

PISTON

BROKEN

12/12/2005

3533

IO470J

 

 

ENGINE

NR 6 CYLINDER PISTON BROKEN AT GUDGEON. CONNECTING ROD BIG END CAP BROKEN OFF.

CA060303002

BEECH

PWA  

 

SPAR

CRACKED

2/1/2006

3TM  

R985AN14B

 

18144L

WING 

CENTER SECTION FUSELAGE REAR WING CARRY-THRU SPAR CRACKED 3/4" FROM TOP OF SPAR RUNNING DOWNWARD AT EDGE OF REINFORCEMENT INSIDE FUSELAGE AT REAR LT FLOAT FITTING STATION NR 199.5 BULKHEAD NR 8.

2006FA0000602

BEECH

 

 

CIRCUIT CARD

INTERMITTENT

5/30/2006

400A

 

 

6227410302

FCC 

FLIGHT CREW REPORTED AUTOPILOT PITCH TRIM FAILURE ANNUNCIATION CAME ON DURING CLIMB WITH AUTO PILOT DISCONNECTED. AIRCRAFT REPPORTED TO HAVE PITCH-UP MOVEMENT. FOUND NR 1 FCC-850 CARD INTERMITTENTLY NOT CROSS-TALKING TO NR 2 FCC-850 CARD. REPLACED NR 1 FCC 850 CARD WITH OVERHAULED UNIT. GROUND/FLIGHT CHECKS SATISFACTORY. (K)

2006FA0000601

BEECH

 

 

FUSE

FAILED

6/1/2006

400A

 

 

251005

EMER BUSS

FLIGHT CREW REPORTED NO BATTERY VOLTAGE INDICATION ON VOLTMETER WITH ALL DC BUSSES POWERED. TROUBLESHOOTING FOUND AIRCRAFT WOULD NOT GO INTO EMERGENCY POWER OR PERFORMED FEEDER FAULT TEST. FOUND 5A MICROFUSE F105 CONNECTED TO K005 EMERGENCY BUSS POWER RELAY OPEN. REPLACED F105 FUSE, ALL DC POWER FUNCTIONS NORMAL, NO FAULTS NOTED. (K)

2006FA0000603

BEECH

 

 

SERVO

INTERMITTENT

5/30/2006

400A

 

 

6226717004

YAW DAMPER

FLIGHT CREW REPORTED PILOTS CONTROL WHEEL TRIM INTERRUPT/AUTOPILOT DISENGAGE SWITCH NOT DISCONNECTING YAW DAMPER ON FINAL APPROACH. FOUND CONTROL WHEEL SWITCH OPERATIONS NORMAL. REPLACED SVO-85C YAW DAMPER SERVO WITH OVERHAULED UNIT. ALSO, REPLACED NR 1 FCC-850 CARD WITH OVERHAULED UNIT TO CORRECT ADDITIONAL AUTOPILOT INTERMITTENT PITCH TRIM FAILURE FAULT. GROUND AND FLIGHT TESTS SATISFACTORY. (K)

0MKR20064

BEECH

 

BEECH

RIB  

CRACKED

5/25/2006

400A

 

 

45A21104641

HORIZ STAB

LT IB ROLLER SUPPORT RIB FOUND CRACKED. P/N 45A21104-641 WAS REMOVED AND REPLACED WITH NEW. DUE TO THE NUMBER OF THESE WE ARE SEEING, IT IS LIKELY THE ENTIRE 400A FLEET HAS A PROBLEM IN THIS AREA.

CA051223001

BEECH

PWA  

 

ENGINE

FLAMED OUT

11/28/2005

400A

JT15D5

 

 

 

DURING CRUISE AT 38K FEET, BOTH ENGINES FLAMED-OUT. IN-FLIGHT RELIGHT ATTEMPTS WERE UNSUCCESSFUL AND THE AIRCRAFT DIVERTED FOR A DEAD-STICK LANDING. P&WC WILL PARTICIPATE IN THE INVESTIGATION OF THIS INCIDENT AND WILL ADVISE OF ROOT CAUSE ONCE ESTABLISHED.

AU510002007

BEECH

CONT

 

DRIVE SHAFT

FAILED

12/12/2005

58  

IO520C

 

 

CSU 

CSU DRIVE ASSEMBLY FAILED. INVESTIGATION CONTINUING.

AU510001670

BEECH

CONT

 

ARM  

SHEARED

12/12/2005

58  

IO520C

 

5052432651

RUDDER CONTROL

PILOT`S LT RUDDER PEDAL ARM SHEARED.

AU510001435

BEECH

CONT

 

FITTING

CRACKED

2/6/2005

58  

IO520C

 

24300259

WING SPAR

(AUS) UPPER LH REAR SPAR FITTING CRACKED. (OTHER CAUSE: MATERIAL ) (CASA# 510001435)

AU510001580

BEECH

CONT

 

FRAME

CRACKED

12/7/2005

58  

IO520C

 

P1756021

FUSELAGE

(AUS) FUSELAGE FRAMES PN P1756-02/1 AND PN P1756-01/1 LOCATED IN WING FORWARD SPAR CARRY THROUGH SECTION CRACKED. FOUND DURING INSPECTION IAW AD. (CASA NR 510001580)

AU510001440

BEECH

CONT

 

RELAY

FAILED

7/6/2005

58  

IO550*

 

SM50D7

DYNAMIC RELAY

(AUS) LANDING GEAR RETRACTION SYSTEM DYNAMIC RELAY FAULTY.(OTHER CAUSE: HIGH HOURS ) (CASA# 510001440)

AU510001653

BEECH

CONT

 

VENT LINE

LEAKING

12/12/2005

58  

IO550*

 

6017001079

RT FUEL VENT

RT FUEL VENT LEAKING. INVESTIGATION FOUND THAT THE SEALANT AROUND THE VENT TUBE IN THE RT WET WING FUEL TANK HAD DETERIORATED ALLOWING FUEL TO LEAK INTO THE VENT LINE.

2006FA0000580

BEECH

CONT

 

CONNECTING ROD

UNKNOWN

5/8/2006

58  

IO550*

 

 

LT ENGINE

50 MILES OUT OF HOME BASE, PILOT HEARD A (POP) CAME FROM LEFT ENGINE, THEN NOTICED OIL PRESSURE START THE FALL. FEATHERED PROP AND SECURED ENGINE. MADE A UNEVENTFUL LANDING. INSP FOUND NR 4 CYLINDER ON L/E DDEPARTED FROM ENGINE AND NR 4 ROD BROKEN. SUSPECT EITHER ROD BOLTS FAILED OR IMPROPERLY TORQUED, OR CYLINDER IMPROPERLY TORQUED. ENGINE COMPLETE LOSS. (K)

AU510001900

BEECH

CONT

 

COUPLING

SHEARED

12/12/2005

58  

IO550B

216CW

 

VACUUM PUMP

RT VACUUM PUMP FAILED. INVESTIGATION FOUND THE PUMP JAMMED AND FULL OF CARBON VANE DEBRIS. DRIVE SHAFT FAILED AT SHEAR POINT. PUMP IS OUTSIDE OF THE SN RANGE AS INDICATED IN TEMPEST SB-003.

AU510001656

BEECH

CONT

 

LINE

LEAKING

12/12/2005

58  

IO550C

 

292000017

FUEL SYSTEM

MAIN FUEL LINE LOCATED IN RT NACELLE LEAKING IN AREA ABOVE THE ELECTRIC FUEL PUMP. INVESTIGATION FOUND LINE CORRODED.

0079965A

BEECH

 

 

HUB  

CORRODED

4/4/2006

58P  

 

 

E71693

PROPELLER

PROPELLER HUB HAS INTERNAL AND EXTERNAL CORROSION

AU510001469

BEECH

 

 

BRACKET

CRACKED

12/12/2005

76  

 

 

1051300001

AILERON

(AUS) LH AND RH AILERONS PNO 105-130000-1 (LH) AND PNO 105-130000-2 (RH) SPARS AND DOUBLER BRACKETS CRACKED AT PUSHROD SUPPORT BRACKETS. (CASA# 510001469)

AU510001482

BEECH

 

 

SPAR

CRACKED

12/12/2005

76  

 

 

1051300002

AILERON

(AUS) RT AILERON UPPER DOUBLER AND SPAR CRACKED. CRACK LENGTHS 10MM (0.39IN) IN DOUBLER AND 5MM (0.196IN) IN SPAR. (CASA# 510001482)

AU510001458

BEECH

 

BEECH

STRUCTURE

CRACKED

12/12/2005

76  

 

 

 

AILERONS

(AUS) LT AND RT AILERONS PNO 105-130000-1 (LT) AND PN 105-130000-2 (RT) SPARS AND DOUBLER BRACKETS CRACKED AT PUSHROD SUPPORT BRACKETS. FLEET INSPECTION FOUND SIMILAR CRACKING ON FOUR OF SEVEN AIRCRAFT. (CASA# 510001458)

2006FA0000612

BEECH

 

 

FRAME

CRACKED

6/21/2006

76  

 

 

1054200116

RT WINGFEATHERIN

CRACK IN RT FORWARD WING BOLT ATTACH FRAME, P/N: 105-420011-6.

2006FA0000613

BEECH

 

 

FRAME

CRACKED

6/21/2006

76  

 

 

1054200116

RT WING

CRACK IN RT FWD WING BOLT ATTACH FRAME, P/N: 105-420011-6.

2006FA0000614

BEECH

 

 

FRAME

CRACKED

6/21/2006

76  

 

 

1054200116

ZONE 100

CRACK IN RT FWD WING BOLT ATTACH FRAME, P/N: 105-420011-6.

2006FA0000615

BEECH

 

 

FRAME

CRACKED

6/21/2006

76  

 

 

1054200116

ZONE 100

CRACK IN RT FWD WING BOLT ATTACH FRAME, P/N: 105-420011-6.

2006FA0000616

BEECH

 

 

FRAME

CRACKED

6/21/2006

76  

 

 

1054200116

ZONE 100

CRACK IN RT FWD WING BOLT ATTACH FRAME, P/N: 105-420011-6.

2006FA0000617

BEECH

 

 

FRAME

CRACKED

6/21/2006

76  

 

 

1054200116

ZONE 100

CRACK IN RT FWD WING BOLT ATTACH FRAME, P/N: 105-420011-6.

AU510001460

BEECH

 

 

SPAR

CRACKED

12/12/2005

76  

 

 

 

AILERON

(AUS) LT AND RT AILERONS PNO 105-130000-1 (LT) AND PN 105-130000-2 (RT) SPARS AND DOUBLER BRACKETS CRACKED AT PUSHROD SUPPORT BRACKETS. (CASA# 510001460)

AU510001510

BEECH

LYC  

 

BRACKET

CRACKED

12/12/2005

76  

O360A1G

 

10598000023

RT NACELLE

RT ENGINE FIREWALL BRACKET CRACKED ON BOTH SIDES OF ANCHOR NUT. FOUND DURING INSPECTION IAW AD/BEECH76/10-2.

CA060410009

BEECH

LYC  

 

CHANNEL

CRACKED

4/1/2006

76  

O360A1G6D

 

10541000057

NLG ACTUATOR

DISCOVERED DURING INSPECTION. NLG ACTUATOR ATTACH BRACKET WAS FOUND CRACKED FROM THE EDGE OF THE BRACKET, THROUGH A LIGHTENING HOLE AND OUT THE OTHER SIDE. THE AREA IS DIFFICULT TO INSPECT. THIS IS THE SUPPORT CHANNEL THAT THE UPPER END OF THE NLG ACTUATOR ATTACHES TO.

AU510001756

BEECH

LYC  

 

PISTON RING

DETERIORATED

12/12/2005

76  

O360A1G6D

 

AEL74241PL

ENGINE

(AUS) ENGINE OIL FOUND TO BE VERY BLACK. INSPECTION FOUND THE PLASMA COATING ON THE TOP PISTON RINGS ON ALL FOUR CYLINDERS FRACTURED. (CASA NR 510001756)

CA060516003

BEECH

PWA  

 

ACTUATOR

CRACKED

5/15/2006

99  

PT6A27

 

505211984

RT OB FLAP

ROUTINE VISUAL INSPECTION OF THE FLAP ACTUATORS INDICATED THAT THE OUTBOARD ATTACHMENT FLANGE OF THE RT OUTBOARD FLAP ACTUATOR WAS CRACKED. THERE WAS NO EVIDENCE OF THE ACTUATOR BEING DROPPED OR OTHERWISE ABUSED. THE FLANGE WAS BENT SLIGHTLY INBOARD AND THERE WAS EVIDENCE OF THE ACTUATOR CHAFFING ON THE MOUNTING FRAME DURING ITS NORMAL OPERATING CYCLE.

CA060425019

BEECH

PWA  

 

SKIN

CRACKED

4/25/2006

99  

PT6A27

 

999800007

LT NACELLE

VISUAL INSPECTION INDICATED A CRACK ON LT ENGINE NACELLE IB SKIN JUST FORWARD OF WING LEADING EDGE. CRACK RAN VERTICALLY JUST AFT OF IB NACELLE INSPECTION PANEL. A RIVET THAT ATTACHES THE NACELLE FILLET STRIP TO THE WING WAS INCLUDED IN THE CRACK. THERE WAS NO REPORT OF A HARD LANDING AND NO ADJACENT STRUCTURE IS DAMAGED.

CA051122001

BEECH

PWA  

 

NUT  

MISMANUFACTURED

11/21/2005

99  

PT6A28

 

817911018

WING 

THE CREW WENT TO INSTALL A WING BOLT RETAINING NUT ON THE AIRCRAFT. IT WAS NOTICED THAT THE NUT WAS MISSING ONE OF THE TWO PLASTIC LOCKING DEVICES. IT APPEARS THE PLASTIC WAS NEVER INSTALLED IN ONE HOLE. THIS IS THE SECOND NUT THAT WAS FOUND WITH PROBLEMS. PREVIOUSLY ANOTHER NUT HAD BAD THREADS IN IT EVEN THOUGH IT WAS NEW.

CA060124001

BEECH

PWA  

BEECH

PINION GEAR

BROKEN

1/21/2006

99  

PT6A28

 

1158100283

ACTUATOR

(CAN) THE GEAR ACTUATOR WAS REMOVED FROM THE AIRCRAFT FOR A RELUBE AND END PLAY CHECK IAW AD72-10-04R2 PART B AND C. WHEN IT WAS CLEANED UP THE MECHANIC NOTICED THAT SEVERAL OF THE TEETH ON THE PINION GEAR WERE BROKEN OFF. THERE WAS NO OBVIOUS REASON FOR FAILURE OF THE TEETH. THIS WAS THE FIRST INSPECITON SINCE THE ACTUATOR WAS INSTALLED AFTER OVERHAUL. THE ACTUATOR ALSO FAILED THE END PLAY CHECK BY .003 THOUSANDS OF AN INCH. (TC NR 20060124001)

CA060126001

BEECH

PWA  

BEECH

TORQUE TUBE

CRACKED

1/25/2006

99  

PT6A28

115610010341

115610010325

ELEVATOR

(CAN) DURING THE 100 HR INSPECTION THE TAIL CONE WAS REMOVED TO INSPECT THE TORQUE TUBES IAW INSPECTION PACKAGE. THE LT TORQUE TUBE WAS FOUND CRACKED AROUND HALF THE TUBE BRACE. IT HAD BEEN 100 HRS SINCE THE LAST INSPECTION. THE PN OF THE BRACKET IS 115-610018-1 (TC NR 20060126001)

CA060531012

BEECH

PWA  

 

ENGINE

MAKING METAL

5/27/2006

99  

PT6A28

 

 

POWER SECTION

(CAN) IN CRUISE, THE CHIP LIGHT ACTIVATED ON THE LT ENGINE. THE ENGINE WAS SHUTDOWN AS A PRECAUTION AND THE AIRCRAFT DIVERTED TO NEAREST FIELD FOR NORMAL LANDING. CFR WAS REQUESTED TO BE ON STANBY. THERE WAS NO OTHER INDICATIONS OF ENGINE PROBLEMS. THE CHIP PLUG WAS REMOVED AND CLEANED. THE OIL SYSTEM WAS FLUSHED AND CHECKED AGAIN FOR CONTAMINATION. AS A PRECAUTION THE AIRCRAFT WAS FLOWN TO AN ENGINE OVERHAUL FACILITY WHERE THE ENGINE WAS REMOVED. DETAILS OF THE OVERHAUL FINDINGS WILL BE FORWARDED WHEN AVAILABLE. (TC NR 20060531012)

CA060228015

BEECH

PWA  

 

MOUNT

DAMAGED

1/19/2006

99AFACH

PT6A27

 

9998000060463

RT ENGINE

DURING A SCHEDULED DETAILED NR 3 INSPECTION, OBSERVED THE RT ENGINE MOUNT ASSY HAD SEPARATED APPROX 1/4 OF AN INCH FROM RT NACELLE. LIFTING OF ENG WITH CRANE CONFIRMED MOVEMENT. VISUAL INSPECTION REVEALED 2 OF THE 4 UPPER INBD BOTTOM ENGINE MOUNT CASTING RIVITS SHEARED. THIS AREA IS DIFFICULT TO INSPECT. REMOVAL OF THE INBD AND OUTBD NACELLE SKINS IS THE ONLY WAY TO GAIN ACCESS TO THE UPPER CASTINGS FOR INSPECTION WHICH WERE FOUND WITH SIGNS OF RIVET FAILURE. THE RT ENGINE, PROPELLER, COWLINGS, AND FUSELAGE SUFFERED SUDDEN STOPPAGE DAMAGE BY A DEER STRIKE 125 HOURS PRIOR TO THESE OBSERVATIONS WHICH MAY HAVE ATTRIBUTED IN THIS FAILURE. REPAIRS C/O BY R.D.C.

CA051122003

BEECH

PWA  

 

INVERTER

FAILED

11/19/2005

A100

PT6A28

 

 

AC SYSTEM

THE PILOT IN COMMAND REPORTED THE NR 2 INVERTER CIRCUIT BREAKER POPPED. ON INVESTIGATION, THE NR 2 INVERTER AND ASSOCIATED RELAY WIRING SHOWED SIGNS OF OVERHEATING. THE WIRING FOR THE RELAY OVERHEATED TO THE POINT THAT ONE OF THE WIRES SEPARATED FROM THE POLE OF THE RELAY.

CA051107004

BEECH

PWA  

BENDIX

RESISTOR

OPEN

11/1/2005

A100

PT6A28

 

EA85098

VOLT REGULATOR

LT GEN FAIL ANNUNCIATOR LIGHT ILLUMINATED IN CRUISE. ATTEMPED RESET BY SWITCHING LT GEN OFF, WAITED 10 SECONDS, THEN SWITCHED BACK ON. RESULT WAS BRIEF SMALL PUFF OF SMOKE FROM INSTRUMENT PANEL, SUBSEQUENTLY FOUND TO BE BURN OF GPS ANNUNCIATOR BRT/DIM/TEST MODULE P/N 3423-P14 C/B, THEN PILOT SIDE ALT C/B TRIPPED. ATC WAS ADVISED AND IMMEDIATE RETURN TO AERODROME OF DEPARTURE REQUESTED. LANDED WITHOUT FURTHER INCIDENT. AMO INVESTIGATION REVEALED LT GENERATOR HAD FAILED DUE TO AN OPEN CIRCUIT RESISTOR IN THE VOLTAGE REGULATOR, AND THAT RESETTING CAUSED A VOLTAGE SPIKE WHICH BURNED OUT GPS MODULE C/B DESCRIBED ABOVE, AND ALSO DAMAGED ALT SELECTOR P/N 065-0053-00 AND TRIPPED PILOT SIDE ALT C/B.

CA060217002

BEECH

PWA  

 

ACTUATOR

DAMAGED

2/7/2006

A100

PT6A28

 

79990022A

NLG 

NOSE LANDING GEAR WOULD NOT RETRACT AFTER TAKEOFF. MAINTEANCE DID MULTIPLE GEAR SWINGS BUT COULD NOT DUPLICATE THE PROBLEM. THE ACTUATOR WAS REMOVED AND PUT IN A TEST STAND WHERE IT FINALLY FAILED STAYING IN THE LOCKED POSITION. A OVERHAULED ACTUATOR WAS INSTALLED AND THERE HAS BEEN NO MORE PROBLEMS REPORTED.

CA060601002

BEECH

PWA  

 

DUCT

CRACKED

5/31/2006

A100

PT6A28

 

 

ENGINE

(CAN) CRACK DEVELOPED IN THE DOMED PORTION OF THE SMALL EXIT DUCT BESIDE THE WELD. FOUND DURING THE BOROSCOPE INSPECTION. (TC NR 20060601002)

CA051206004

BEECH

PWA  

 

INTERCOSTAL

CRACKED

12/1/2005

A100

PT6A28

 

 

BULKHEAD

DURING A SPECIAL INSPECTION AFTER FINDING DAMAGE ON OTHER AIRCRAFT, THE AFT PRESSURE BULKHEAD WAS FOUND CHAFED BY BOTH THE CENTER INTERCOSTAL AND THE OUTBOARD INTERCOSTAL ADJACENT TO THE TAIL ACCESS DOOR. NDT WAS COMPLETED AND A CRACK FOUND AT THE OUTBOARD LOCATION.

CA060320003

BEECH

PWA  

BEECH

SUPPORT BRACKET

CRACKED

3/9/2006

A100

PT6A28

 

1156100153

 

(CAN) CRACK FOUND ON IB SUPPORT BRACKET WHILE CARRYING OUT REPETITVE INSPECTION MSB 2145. TORQUE TUBE REPLACED WITH NEW. (TC NR 20060320003)

CA060307003

BEECH

PWA  

BEECH

ACCUMULATOR

FAILED

1/25/2006

A100

PT6A28

 

11538011119

HORIZONTAL STAB

(CAN) THE ABOVE P/N FAILED SENT FOR REPAIR THEN FAILED AGAIN WITH IN 5.3 HRS. SERVICEABLE ACTUATOR INSTALLED WITH NO MORE PROBLEMS. (TC NR 20060307003)

CA060127002

BEECH

PWA  

 

ELT  

INTERMITTENT

1/23/2006

A100

PT6A28

 

ELT10

CABIN

(CAN) ELT FAILED THE ACTIVATION TEST DURING THE ROUTINE INSPECTION. THE UNIT HAD THE BATTERY REPLACED AND RECERTIFIED 21 DAYS EARLIER. AVIONICS SHOP FOUND THE PROBLEM TO BE A INTERMITTENT ON/OFF SWITCH. (TC NR 20060127002)

CA060127004

BEECH

PWA  

 

SWITCH

UNSERVICEABLE

1/26/2006

A100

PT6A28

 

10038900161

FUEL DRAIN

(CAN) FLOAT SWITCH FAILED INTERNALLY CAUSING THE EPA CAN TO DRAIN OVERBOARD ON SHUTDOWN. (TC NR 20060127004)

CA060406003

BEECH

PWA  

 

DUCT

DISCONNECTED

3/30/2006

A100

PT6A28

 

9755501115

HEAT DUCT

DURING A ROUTINE INSPECTION OF THE CABIN HEATING DUCTS THE HOT AIR DUCT ASSEMBLY P/N 97-555011-15 ITEM NR 22 IN PICTURE NR 1 WAS FOUND DISCONNECTED AT THE AFT END. 2 DUCTS FURTHER FWD WERE FOUND CRACKED ALLOWING THEM TO MOVE FWD AND ALLOWING THIS DUCT TO DISCONNECT FROM ITEM NR 23. ONCE THE DUCT HAD DISCONNECTED THE CABIN HEAT WAS FLOWING INTO THE FLOOR AND ONTO THE DE-ICE PRESSURE TUBE P/N 50-970101-143 ITEM 81 IN PICTURE NR 2. THE HEAT ALLOWED A 15 INCH SECTION OF THE DE-ICE TUBE DEFORM AND COLLAPSE RESTRICTING THE AIRFLOW TO THE TAIL PART OF THE DE-ICE SYSTEM. IT IS UNCLEAR WHETHER OR NOT THE TAIL DE-ICE SYSTEM WAS SERVICEABLE.

CA060613004

BEECH

PWA  

 

BEARING

MISINSTALLED

6/12/2006

A100

PT6A28

 

50380043

MLG ACTUATOR

DURING ACT ENDPLAY CHECK AND LUBE OF N/G ACT 50-820208-5, NOTICED THRUST BEARING IMPROPERLY INSTALLED. INSTRUCTIONS IN COMPONENT MM ARE TO INSTALL BEARING WITH P/N AWAY FROM GEAR, THIS BEARING HAD BEARING MANUF P/N AND WORD THRUST ON ONE SIDE AND RAYTHEON P/N ON OTHER, ALLOWING YOU TO FOLLOW INSTRUCTIONS AND HAVING A 50% CHANCE OF GETTING IT RIGHT. THIS BEARING WAS INSTALLED BACKWARDS WITH RAYTHEON P/N AWAY FROM GEARS PUTTING ACTUAL THRUST SIDE TOWARDS GEARS OPPOSITE TO THRUST LOADS. ACT WAS FURTHER INSPECTED AND SMALL AMT OF SPALLING FOUND ON GEARS. ACT IS BEING RETURNED TO OVERHAUL FACILITY WERE BEARING AND GEARS WILL BE REPLACED. THIS ACT WAS REMOVED FOR IT FIRST ENDPLAY CHECK SINCE LAST OVERHAUL WITH A TSO OF 1041 LANDING. RAYTHEON WAS CONTACTED AND ARE INVESTIGATING THE MATTER IN ORDER TO CORRECT.

CA060227024

BEECH

PWA  

 

MOUNT

DETACHED

1/16/2006

A100A

PT6A27

 

509800891

RT ENGINE

UPPER INBOARD ENGINE MOUNT FITTING RT NACELLE UNDER SKIN FOUND DETACHED. SUBSEQUENT INSPECTION OF OTHER FITTINGS ON SAME AIRCRAFT (THERE ARE 4) FOUND ALL WITH ATTACHING FASTENER DEFECTS SUCH AS LOOSE OR SHEARED. AREA IS ALMOST UN-INSPECTABLE. SUGGEST BOROSCOPE INSPECTION OR REMOVING A PORTION OF NACELLE SKIN IF ENGINE MOUNT MOVEMENT IS DETECTED IN FITTING AREA.

AU510001736

BEECH

CONT

 

CONTROL CABLE

FRAYED

4/8/2005

A36  

IO520BA

 

3652400023

ELEVATOR

(AUS) ELEVATOR CONTROL CABLE FRAYED. INSPECTION FOUND AT LEAST 4 STRANDS BROKEN INTERNALLY. (CASA NR 510001736)

2006FA0000586

BEECH

GARRTT

 

STARTER GEN

SEIZED

5/18/2006

B100

TPE3316

 

230790001

 

RT ENGINE WOULD NOT START. TROUBLESHOT AND FOUND RT STARTER GENERATOR SEIZED DUE TO BRUSHES WORN BEYOND LIMITS AND PIGTAILS ARCHING TO ARMATURE. (K)

CA051202003

BEECH

GARRTT

 

CONTROL PANEL

BURNED

11/25/2005

B100

TPE3316252B

 

 

TRIM INDICATOR

A BURNT ODOR WAS NOTICED FOLLOWED BY SMOKE IN THE COCKPIT, COMING FROM THE TRIM INDICATOR LIGHT PANEL. THE PILOT CLOSED THE RHEOSTAT AND RETURNED TO BASE. AFTER INSPECTION OF THE LIGHT PANEL, HUMIDITY WAS FOUND UNDER THE PANEL, WHICH CAUSED A SHORT CIRCUIT. THE PANEL WAS REPLACED AND AIRCRAFT RETURNED TO SERVICE.

CA051109002

BEECH

GARRTT

 

STRINGER

CRACKED

11/7/2005

B100

TPE3316252B

 

 

NR 10

DURING AN INSPECTION OF THE ELEVATOR CABLES, AFT OF THE REAR PRESSURE BULKHEAD, THE ENGINEER DISCOVERED A CRACK IN THE NR 10 STRINGER OF THE AFT PRESSURE BULKHEAD. THIS AIRCRAFT HAS A CVR INSTALLED IAW STC 'SA-02-26' AND THE MOUNTING TRAY FOR THE CVR TIES INTO THE NR 10 STRINGER. THE CRACK IS APPROX 2" LONG AND LOCATED ON THE LT OUTBOARD SIDE.

CA060405003

BEECH

GARRTT

 

ADAPTER

CRACKED

3/16/2006

B100

TPE3316252B

 

B441172

OIL FILTER

DURING AN INSPECTION OF THE "OIL FILTER ADAPTER", IT WAS FOUND CRACKED IN TWO PLACES. A SMALL OIL LEAK WAS EVIDENT. THE PART WAS REPLACED.

CA060406002

BEECH

GARRTT

 

TORQUE TUBE

CORRODED

4/3/2006

B100

TPE3316252B

 

 

ELEVATOR

DURING AN INSPECTION OF THE ELEVATOR TORQUE TUBE, THE PRIMARY ELEVATOR TORQUE TUBE WAS FOUND CORRODED. THE PART WAS REPLACED.

CA060405008

BEECH

PWA  

 

SEAL

FAILED

1/19/2006

B200

PT642A

 

3022375

FCU/FUEL PUMP

AIRCRAFT DEPARTED AND ON CLIMB THE PILOT REPORTED A LOW OIL PRESSURE INDICATION ON THE LEFT HAND ENGINE. THE AIRCRAFT RETURNED TO BASE. A TECHNICIAN WAS CALLED IN, AND FOUND THAT THE FCU/FUEL PUMP DRIVE SEAL HAD MIGRATED, AND WAS LEAKING. A NEW SEAL P/N:3022375 AND SEAL CARRIER P/N:3004085 WERE INSTALLED. ENGINE GROUND RUNS COMPLETED SATISFACTORY, AIRCRAFT RETURNED TO SERVICE.

CA060329001

BEECH

PWA  

 

MOTOR

FAILED

3/21/2006

B200

PT642A

 

 

MLG 

AFTER TAKEOFF, EN ROUTE TO DESTINATION, GEAR WARNING LIGHT CAME ON. PILOT TRIED EXTENDING THE GEAR AND NO EXTENSION WAS NOTED. AIRCRAFT RETURNED TO BASE AND GEAR WAS EXTENDED USING MANUAL EXTENSION. AIRCRAFT PUT ON LOCKS. GEAR MOTOR CIRCUIT BREAKER WAS FOUND POPPED AND ACCUMULATOR WAS FOUND TO BE LOW IN PRESSURE. CIRCUIT BREAKER WAS RESET AND ACCUMULATOR CHARGED TO PROPER PRESSURE. GEAR SWUNG SEVERAL TIMES WITH NO ABNORMAL RESULTS. AIRCRAFT RETURNED TO SERVICE.

CA051206010

BEECH

PWA  

 

DOWNLOCK SWITCH

FAILED

12/1/2005

B200

PT642A

 

 

NLG 

ON APPROACH, CREW DID NOT GET A NOSE GEAR DOWN INDICATION ON SELECTION. EMERG PROCEDURES COMPLETED WITH NO INDICATION. FLY BY VISUAL SHOWED NOSE GEAR DOWN, INDICATION ILLUMINATED ON TOUCH DOWN. MAINTENANCE FOUND NOSE GEAR ACTUATOR INTERNAL DOWN LOCK SWITCH TO BE INTERMITTENT. ACTUATOR REPLACED.

CA060419007

BEECH

PWA  

BEECH

BOLT

FAILED

4/12/2006

B200

PT642A

504300377

504300377

PAX DOOR

WHILE CLIMBING THROUGH 10000 FT, A LOUD BANG WAS HEARD FOLLOWED BY A CONSTANT HISSING SOUND. THE FLIGHT RETURNED UNEVENTFULLY AND MAINT FOUND THE UPPER FWD DRAW BOLT ROLLER HAD FAILED CAUSING THAT PORTION OF THE DOOR TO SHIFT SLIGHTLY. BOTH UPPER DRAW BOLT ROLLERS WERE REPLACED AND DOOR INSPECTED FOR FURTHER DAMAGE. NONE WAS FOUND AND GROUND CHECKS WERE C/O SERVICEABLE.

CA060531013

BEECH

PWA  

 

ENGINE

SURGES

4/27/2006

B200

PT642A

 

 

 

(CAN) DURING CRUISE THE ENGINE WAS REPORTED TO SURGE AND SUBSEQUENTLY FLAME OUT. MFG WILL INVESTIGATE THE EVENT AND WILL ADVISEOF ROOT CAUSE ONCE ESTABLISHED. (TC NR 20060531013)

CA060410004

BEECH

PWA  

 

PUMP

UNSERVICEABLE

4/9/2006

B200

PT642A

 

02532330003

RT ENGINE

ON TAKEOFF, THE CREWS ROTATED AND HAD RT ENGINE POWER ROLL BACK. CREWS FEATHERED AND SHUT DOWN THE ENGINE AND TURNED AROUND AND LANDED. MAINTENANCE FOUND FUEL LEAKING FROM RT ENGINE DRIVEN HIGH PRESSURE FUEL PUMP P/N 025323-300-03. PUMP ASSY REPLACED AND GROUND RUN, FLIGHT TEST SERVICEABLE.

CA060403015

BEECH

PWA  

PWC  

FUEL SYS

FLUCTUATES

3/16/2006

B200

PT642A

PT6A42

 

ENGINE

DURING INITIAL DESCENT, ENGINE FUEL FLOW WAS OBSERVED TO FLUCTUATE. THROTTLE INPUT RESULTED IN EXCESSIVE INTERTURBINE TEMPERATURE INCREASE AND THE ENGINE WAS SHUT DOWN IN FLIGHT. P&WC WILL MONITOR INVESTIGATION OF THE EVENT AND WILL ADVISE OF ROOT CAUSE ONCE ESTABLISHED.

CA051116003

BEECH

PWA  

 

BOOT

TORN

11/13/2005

B200

PT642A

 

SMR504108

DE-ICE SYS

IN CRUISE FLIGHT, A THUMPING NOISE WAS DETECTED ON THE RIGHT SIDE OF AIRCRAFT. AFTER LANDING IT WAS FOUND THAT A NEWLY INSTALLED RIGHT INBOARD WING BOOT LOWER HALF HAD TORE LOOSE FROM THE GLUE, AND WAS TRAILING BEHIND THE AIRCRAFT ABOUT 8 FEET HITTING THE LOWER PORTION OF THE WING AND THE RIGHT SIDE OF THE BAGGAGE POD. IT APPEARS THE GLUE UNDER THE BOOT DID NOT HOLD, MAY BE DUE TO THE GLUE FREEZING DURING SHIPPING.

CA060422009

BEECH

PWA  

BEECH

LOCK NUT

MISSING

4/21/2006

B200

PT6A41

 

130909B40130909

MLG ACTUATOR

DURING L/G EXT IN FLT, LT MAIN AND NOSE GEAR DOWN AND LOCKED IND PRESENT, WITH NO RT IND AND LOUD BANGING SOUND FROM RT SIDE OF A/C. C/O FLY-BY TO VISUALLY VERIFY ALL THREE LANDING GEARS WERE DOWN. A/C LANDED SAFELY, VERIFIED ALL 3 L/G WERE DOWN AND LOCKED BEFORE TAXING A/C OFF RUNWAY. DURING INSPECTION ACT TQ TUBE TO ACT DRIVE BOLT FOUND MISSING. TQ TUBE END AND ACT DRIVE INSPECTED FOR DAMAGE/CRACKS WITH 10X MAGNIFYING GLASS. NO DAMAGE EVIDENT. INNER TQ TUBE SPACER REPLACED DUE TO SOME SCORING OF INNER BORE. A NEW DRIVE BOLT AND LOCK NUT WAS INSTALLED ON LT AND RT ACT. LANDING GEAR SYSTEM INSPECTION/RIGGING C/O: GOOD IAW KA200 MM NR 101-590010-19B9 CHAPTER 32-30-00. FIVE FAULT FREE GEAR SWINGS C/O.

CA060317010

BEECH

PWA  

BEECH

ACTUATOR

SEIZED

3/11/2006

B200

PT6A64

 

50820285

NLG 

NOSE LANDING GEAR ACTUATOR SEIZED AND OVER-LOADED MLG MOTOR BREAKER.

AU510001575

BEECH

PWA  

 

SERVO

FAULTY

12/12/2005

B200C

PT642A

 

7002260903

YAW DAMPER

RUDDER AUTOPILOT SERVO/YAW DAMPER FAULTY, OTHER CAUSE: FAILURE OF INTERNAL MECHANISM.

CA051215001

BEECH

PWA  

 

ACTUATOR

FAILED

12/6/2005

B200C

PT642A

 

99810057651

MLG 

AFTER T/O, GEAR WAS SELECTED UP AND CLUNK WAS HEARD, T/O CONTINUED TO SAFE ALT AND WAS VISUALLY CONFIRMED THAT RT GEAR HAD NOT RETRACTED. THE GEAR WAS RECYCLED DOWN 3 GREEN LIGHTS CONFIRMED ALL GEAR DOWN AND LOCKED. A/C RETURNED TO AIRPORT AND LANDED W/O FURTHER INCIDENT. FURTHER INVESTIGATION BY MX REVEALED THAT RT GEAR ACTUATOR HAD FAILED INTERNALLY. ACTUATOR WAS REPLACED AND A/C RETURNED TO SERVICE. FAILED ACTUATOR IS BEING RETURNED TO THE OVERHAUL FACILITY FOR FURTHER INVESTIGATION, AT OUR REQUEST, THE FAA WILL BE SUPERVISING THE DISASSEMBLY OF THE ACTUATOR. THIS ACTUATOR HAD 2339 LANDING SINCE OVERHAUL.

CA051222004

BEECH

PWA  

 

SPAR

CORRODED

12/9/2005

B300

PT6A60A

 

10111007315

LT WING

A/C IN FOR 5 YR WING BOLT REPLACEMENT AND MAIN SPAR LWR FITTING VISUAL INSPECT. LWR FWD LT WING BOLT DIFFICULT TO REMOVE AND UPON REMOVAL MODERATE CORROSION WAS OBSERVED IN BOLT BORES. LOOKING AT BOLT BORES FROM FRONT, GREATEST CORROSION APPEARED TO BE AFT AIRFRAME LUG AND AFT WING LUG. MILD CORROSION NOTED IN FWD AIRFRAME LUG. NDT WAS CARRIED OUT ON LUG W/NO CRACKS FOUND. ALL OTHER BOLTS WERE SERVICEABLE. RAYTHEON WAS CONTACTED FOR ASSESSMENT OF DAMAGE FOUND AND FOLLOWING SEVERAL DELAYS APPROVED A/C FOR LIMITED RETURN TO SERV UNDER REPAIR ORDER NUMBER FR-KA-01836 REV 1. THIS TEMP REPAIR WAS APPROVED FOR 250 HRS OR NINE WEEKS AT WHICH POINT A PERMANENT REPAIR MUST BE CARRIED OUT. PERMANENT REPAIR ENTAILS INSTALLING BUSHINGS IN THE WING LUGS. RT WING HAD BUSHINGS INSTALLED ABOUT 4 YRS AGO AFTER EXCESSIVE PLAY WAS FOUND IN LWR FWD FITTING. ALL WING BOLTS ON BOTH SIDES WERE REPLACED AT TIME AND COATED WITH CORROSION PREVENTIVE.

CA051213006

BEECH

PWA  

 

HOSE

BURST

12/13/2005

B300

PT6A60A

 

1013800159

LT BRAKE DEICE

DURING DAILY INSPECTION, THE AME FOUND THE LT BRAKE DEICE HOSE (P/N 101-380015-9) BURST NEAR UNION (P/N 832-12D).

CA060301007

BEECH

PWA  

BEECH

NUT PLATE

DAMAGED

2/24/2006

B300

PT6A60A

1018200351

K10004

MLG 

AIRCRAFT WAS ON APPROACH. POSITIVE NOSE GEAR DOWN LOCK WAS NOT INDICATING USING THE NORMAL SYSTEM. EMERGENCY GEAR DOWN WAS REQUIRED TO HAVE POSITIVE DOWN AND LOCK INDICATION. NOSE LANDING GEAR INSPECTION WAS CARRIED OUT OF THE GREEN LIGHT INDICATOR SWITCHES ON THE ACTUATOR AND DRAG BRACE. THE SWITCH STOP WAS BACKED OFF INTO THE ANCHOR NUT. STOP WAS RERIGGED AND SECURED. LANDING GEAR SWING CARRIED OUT AS PER B300 MM AND CHECKED SERVICEABLE.

CA051202008

BEECH

PWA  

 

ANGLE

CRACKED

11/9/2005

B300

PT6A60A

 

504300431329

CABIN DOOR

WHEN COMPLYING WITH SPECIAL INSPECTION ON CABIN DOOR, DISCOVERED CRACKED CABIN DOOR SILL ANGLE AT TOP OF DOOR. ADVISED TO HAVE A SPARE PART ON HAND BEFORE DOING INSPECTION. PART WAS CRACKED ALONG WIDTH OF THE ANGLE RUNNING FORE AND AFT FROM AFT END OF THE DOOR. APPROX LENGTH WAS 8" ALONG THE ATTACHMENT RIVETS. THIS A/C IS CONTRACTED TO DO AIR AMBULANCE 7 DAYS/WEEK AND HAD ACCRUED APPROX 2000 HOURS IN THIS TYPE OF USE BY TWO OPERATORS. PREVIOUS INSPECTION DETECTED NO PROBLEM 1000 CYCLES PREVIOUS. THE PART WAS ALSO INADVERTENTLY THROWN OUT AFTERWARDS SO IT IS NOT AVAILABLE. INCREASED OUR INSPECTION FREQUENCY IN THIS AREA DUE TO HEAVY USE IT IS SUBJECTED TO.

2006FA0000584

BEECH

PWA  

 

TRIM TAB

MISMANUFACTURED

6/2/2006

C90  

PT6A11

 

96630000335

RUDDER TRIM

WHEN INSPECTED IAW SB, THIS AC WAS IDENTIFIED AS MISSING THE DRAIN PROVISIONS. C/A WAS TAKEN IAW SB. DURING OUR RESEARCH INTO THIS MATTER IT WAS IDENTIFIED THAT THE CCORRELATING AD TO THIS ISSUE. THIS IS A NEARLY NEW AC. (K)

CA060216003

BEECH

PWA  

 

FRAME

CRACKED

2/15/2006

C90  

PT6A28

 

 

WING 

UPON BEGINNING A PHASE 3 INSPECTION, A TECHNICIAN DISCOVERED A SMALL CRACK ON THE RIGHT FORWARD LOWER SPAR HINGE CAP. THE CRACK WAS OUT FROM THE FOURTH FASTENER FORWARD TOWARD THE HINGE EDGE. A SMALL AREA OF PAINT HAD BEEN FLAKED AWAY IN THIS AREA. MORE PAINT WAS REMOVED IN THIS AREA IN AID TO FURTHER INVESTIGATE THE DISCREPANCY. IT WAS CLEARLY VISIBLE TO SEE WITHOUT ANY NDT INSPECTION METHODS REQUIRED. THE AIRCRAFT WAS REMOVED FROM SERVICE. IT WAS NOTED THE PREVIOUS EDDY CURRENT INSPECTION (AS REQUIRED IAW THE RAYTHEON SIRM) WAS CONDUCTED IN THIS AREA IN JANUARY 2005, 754.8 HOURS AGO.

2006FA0000471

BEECH

 

BFGOODRICH

WHEEL HALF

CRACKED

4/12/2006

C90A

 

 

300257

LT MLG

LEFT MAIN WHEEL (INBOARD HALF) FOUND CRACKED. PROBLEM SHOWED ITSELF DUE TO WHEEL/TIRE ASSY SUFFERING A SLOW LEAK OF AIR PRESSURE. THIS IS NOT THE SAME PROBLEM REPORTED FOR THIS AIRCRAFT ON 4/27/2006. THIS IS A PREVIOUS OCCURRENCE ON THE OTHER SIDE. BOTH MAIN WHEELS HAVE NOW BEEN CHANGED.

2006FA0000567

BEECH

PWA  

 

BEARING

FAILED

6/1/2006

C90A

PT6*

 

 

FCU 

THE BEARING IN FUEL CONTROL UNIT FAILED CAUSING THE LT ENGINE TO SURGE AND EXCEED THE N1, ITT AND TORQUE LIMITS. THE ITT EXCEEDED 1000 C AND THE TORQUE EXCEEDED 1500 FT POUNDS FOR 5-10 SECONDS. SHORTLY AFTER TAKEOFF, PILOTS REPORTED PLANE HAD YAWED TO THE RT AND FIRST CORRECTED FOR THE YAW BEFORE NOTICING ITT AND TORQUE ABOVE RED LINE. PILOTS THEN REDUCED POWER AND RETURNED TO AIRPORT. ENGINE WAS REMOVED FOR REPAIR AND ALL ROTATING PARTS WERE FOUND TO BE IN NEED OF REPLACEMENT. IN-SITU TEST HAD BEEN DONE REGULARLY AND NO INDICATION OF BEARING INSPECTION BUT IT IS AT THE END OF THE NOTES UNDER THE FUEL SYSTEM INSPECTION. BEARINGS ARE CALLED OUT FOR INSP/ REPLACEMT AT MID TBO OR 6 YEARS.

CA060403014

BEECH

PWA  

 

SEAL

LEAKING

3/16/2006

C90A

PT6A21

 

 

PROPELLER

DURING FLIGHT, AN ENGINE OIL LEAK WAS OBSERVED AND THE ENGINE WAS SHUTDOWN IN FLIGHT. SUBSEQUENT INSPECTION REVEALED A LEAKING PROPELLER SHAFT SEAL AND A LOOSE BETA VALVE RETAINING NUT.

CA051216003

BEECH

PWA  

 

RESISTOR

OVERHEATED

12/15/2005

C90A

PT6A21

 

2K40D10

CABIN LIGHTS

DURING ROUTINE INSPECTION, FOUND RESISTOR R145 (ATA 33-21-01 PAGE 4) OVERHEATED. INSULATION ABOVE THE RESISTOR WAS SCORCHED AND BURNED.

CA051222006

BEECH

PWA  

 

RESISTOR

OVERHEATED

12/20/2005

C90A

PT6A21

 

2K40D10

LIGHTS

WHILE CARRYING OUT COMPANY CAMPAIGN 681-33-21-018, RESISTOR R145 FOR FLUORESCENT LIGHT CIRCUIT FOUND SHOWING SIGNS OF OVERHEATING. SYSTEM DISABLED AND DEFERRED.

CA051222007

BEECH

PWA  

 

RESISTOR

OVERHEATED

12/20/2005

C90A

PT6A21

 

2K40D10

CABIN LIGHTS

RESISTOR R145 FOR FLUORESCENT LIGHT CIRCUIT FOUND SHOWING SIGNS OF OVERHEATING WHILE CARRYING OUT COMPANY CAMPAIGN 681-33-21-018. SYSTEM DISABLED AND DEFFERED.

CA051222009

BEECH

PWA  

 

RESISTOR

OVERHEATED

12/22/2005

C90A

PT6A21

 

2K40D10

CABIN LIGHTS

VISUAL INSPECTION CARRIED OUT AS PER CAMPAIGN NOTICE 681-33-21-018. RESISTOR VISUAL INSPECTED OKAY. SCORCHING FOUND ON INSULATION BLANKET. SYSTEM CB PULLED AND PLACARDED.

CA060425009

BEECH

PWA  

 

ENGINE

MALFUNCTIONED

4/9/2006

C90A

PT6A21

 

 

 

ON APPROACH, ENGINE TORQUE AND FUEL FLOW WERE SEEN TO FLUCTUATE. THE ENGINE WAS SUBSEQUENTLY SHUT DOWN IN FLIGHT. P&WC WILL INVESTIGATE THE EVENT AND WILL ADVISE OF ROOT CAUSE ONCE ESTABLISHED.

CA060106002

BEECH

PWA  

 

ENGINE

FAILED

12/20/2005

C90A

PT6A21

 

 

LEFT 

WHILE IN FINAL DESCENT, THE FLIGHT CREW DISCOVERED THAT THEY DID NOT HAVE FULL AUTHORITY OVER THE LEFT ENGINE. THE LEFT ENGINE COULD NOT BE REDUCED BELOW 800 LBS TORQUE. ENGINE CONTROL WAS STILL AVAILABLE IN A RANGE FROM 800 LBS TO MAX TORQUE. FLIGHT CREW OPTED TO SECURE LEFT ENGINE AND CARRY OUT A SINGLE ENGINE LANDING IN FREDERICTON WITH CFR STANDBY. ENGINE SHUTDOWN AND FEATHERING OF PROP WAS NORMAL. INITIAL INSPECTION SHOWS ALL LINKAGE NORMAL. FURTHER DIAGNOSIS BEING CONDUCTED.

CA060110001

BEECH

PWA  

 

RESISTOR

OVERHEATED

1/6/2006

C90A

PT6A21

 

2K40D10

PANEL LIGHT

DURING SPECIAL INSPECTION AS PER CAMPAIGN 681-33-21-018, FOUND RESISTOR R145 (ATA 33-21-01 PAGE 4) OVERHEATED. INSULATION ABOVE THE RESISTOR WAS SCORCHED AND BURNED. THE SYSTEM WAS DEACTIVATED AND DEFERRED.

CA060110003

BEECH

PWA  

 

RESISTOR

OVERHEATED

1/6/2006

C90A

PT6A21

 

2K40D10

PANEL LIGHTS

DURING SPECIAL INSPECTION AS PER CAMPAIGN 681-33-21-018, FOUND RESISTOR R145 (ATA 33-21-01 PAGE 4) OVERHEATED. INSULATION ABOVE THE RESISTOR WAS SCORCHED AND BURNED. THE SYSTEM WAS DEACTIVATED AND DEFERRED.

CA060320001

BEECH

PWA  

 

SEAL

DAMAGED

3/16/2006

C90A

PT6A21

 

311466001

PROPELLER

IN CRUISE 16,000 FT, NOTICED OIL LEAK ON TOP RT FWD ENG COWL. LEAK PROGRESSIVELY GOT WORSE, PILOTS ELECTED TO RETURN TO BASE. EVEN THOUGH ENG OIL TEMP AND PRESS NORM, PILOTS SHUTDOWN RT ENG. CREW DECLARED EMERG. BECAUSE QTY OF OIL LOST, PROP SHAFT SEAL SHOULD BE LOOKED AT. RT PROP SEAL HAD BEEN REPLACED 2 DAYS EARLIER DUE TO OIL LEAKAGE IN NOSE CASE AREA. MX FOUND FAULTY PROP SEAL WAS WRONG P/N. BY TIME OF DISCOVERY OUR P & W FSR WAS ON SITE, WENT BACK TO OUR STORES AND PULLED THE REMAINING SEAL IN STOCK STAMPED 3114661-01, AND IT TO WAS WRONG PART INSIDE, (3114660-01). WITNESSED BY FSR. SEALS CAME FROM CPWA, PACKAGED ON 02/2000. BECAUSE OF LOSS OF OIL/AIR PRESSURE IN THE RGB, OIL WAS ALLOWED TO MIGRATE PAST NR 3 AND 4 BEARING AND INTO EXHAUST AREA, P & W ADVISED TO SPLIT ENG AND REPLACE INSULATION BLANKET IN PWR SECTION DUE TO OIL CONTAM. THIS IS CURRENTLY BEING DONE. SEALS AND PACKAGES ARE BEING RETAINED AND ARE AVAILABLE UPON REQUEST.

CA060317008

BEECH

PWA  

 

PUMP

LEAKING

3/15/2006

C90A

PT6A21

 

3034794

FUEL SYS

VISUAL INSPECTION CARRIED OUT IAW SERVICEABILITY CHECK. PRE-DISPATCH CHECK NOTICED FUEL UNDER THE RT ENGINE. INSPECT FUEL FILTER AND DRAINS WITH THE BOOST PUMP ON AND NO LEAKAGE WAS FOUND. REMOVED FUEL PUMP DRAIN HOSE AND A LARGE AMOUNT OF FUEL WAS EXPELLED FROM THE FUEL PUMP DRAIN. THE FUEL PUMP/FUEL CONTROL ASSEMBLY WAS REMOVED FROM SERVICE DUE TO SUSPECTED INTERNAL BEARING WASHOUT DUE TO SEAL FAILURE.

CA060317009

BEECH

PWA  

LEARSIEGLER

BEARING

FAILED

3/17/2006

C90A

PT6A21

 

 

STARTER GEN

VISUAL INSPECTION CARRIED OUT IAW OPERATION FOUR. NOTICED METAL DUST ON BACK OF THE ACCESSORY GEARBOX AND FOUND IT TO BE MAGNETIC. REMOVED STARTER GENERATOR AND FOUND THE QUILL SHAFT BEARING HAD FAILED. UNIT WAS REMOVED FROM SERVICE.

CA060530008

BEECH

PWA  

 

LINE

CRACKED

5/30/2006

C90A

PT6A21

 

3027039

FUEL CONTROL

(CAN) AIRCRAFT HAD TAXIED TO RUN-UP AREA PRIOR TO TAKEOFF. WHILE COMMENCING ENGINE RUN-UP NOTICED THAT THERE WAS NO THROTTLE RESPONSE ON THE RT ENGINE. CREW CONTACTED MAINTENANCE AND REQUESTED A TOW BACK TO THE HANGER. MAINTENANCE FOUND THAT THE FUEL FEED LINE FROM THE FCU TO THE FUEL FLOW DIVIDER WAS CRACKED AND SPRAYING FUEL INSIDE THE ENGINE NACELLE. CRACK WAS AT THE FCU END OF THE FUEL LINE, CRACK RAN PARALLEL WITH THE SWAGGED FERRULE. FUEL LINE REPLACED AND AIRCRAFT RETURNED TO SERVICE. (TC NR 20060530008)

CA060125006

BEECH

PWA  

 

SHAFT SEAL

LEAKING

1/13/2006

C90A

PT6A21

 

 

FUEL PUMP

(CAN) WHILE DOING A GROUND RUN TO VERIFY THE COMPASS SYSTEM, TECH NOTICED UNCOMMANDED ACCELERATION AND DECELERATION OF THE RT ENGINE. VISUAL INSPECTION IDENTIFIED BLUE DYE WASHOUT FROM THE FUEL PUMP TO FUEL CONTROL UNIT SEAL AREA AND CONFIRMED A FAULT. THE FUEL CONTROL UNIT AND FUEL PUMP ASSEMBLY WERE REMOVED AND REPLACED WITH SERVICEABLE UNITS. (TC NR 20060125006)

CA051213004

BEECH

PWA  

 

CYLINDER

SEPARATED

7/15/2005

D18S

R985AN14B

 

126741

ENGINE

ON DAILY INSPECTION, FOUND OIL SPATTERING ON SIDE OF NR 5 CYLINDER AND EXCESSIVE STAINING AT BARREL TO SLEEVE JUNCTION OF NR 6 CYLINDER. NOTICED EXCESSIVE CLEARANCE BETWEEN COOLING FIN ON BARREL AND CYLINDER HEAD OF NR 6 CYLINDER, INDICATING THAT CYLINDER HEAD WAS SEPARATING FROM THE BARREL. REMOVED NR 6 CYLINDER AND INSTALLED SERVICEABLE REPLACEMENT CYLINDER. CYLINDER S/N 25997 RETURNED TO O/H AGENCY, AWAITING REPORT.

AU510002160

BEECH

CONT

 

CABLE

FAILED

1/11/2005

D55  

IO520C

 

5038901219

POWER LEVER

LH ENGINE THROTTLE CABLE FAILED IN AREA UNDER SHEATH.

AU510001901

BEECH

CONT

AERO

DRIVE SHAFT

SHEARED

12/12/2005

F33A

IO520B

 

 

VACUUM PUMP

(AUS) VACUUM PUMP FAILED. INVESTIGATION FOUND THE PUMP JAMMED AND FULL OF CARBON VANE DEBRIS. DRIVE SHAFT FAILED AT SPLINED SECTION AND NOT AT SHEAR POINT AS DESIGNED. PUMP IS OUTSIDE OF THE SN RANGE AS INDICATED IN TEMPEST SB-003. (AD/SB DESC: TEMPEST SB-003 ) (OTHER CAUSE: MATERIAL ) (CASA NR 510001901)

CA060227023

BEECH

PWA  

 

MOTOR

UNSERVICEABLE

2/24/2006

F90  

PT6A135

 

M710501

NLG 

NOSE GEAR FAILED TO EXTEND CORRECTLY AS INDICATED BY GEAR IN TRANSIT. GEAR EXTENDED MANUALLY AND LANDED WITHOUT INCIDENT. CAUSE UNDER INVESTIGATION AT THIS TIME.

CA060127003

BEECH

PWA  

 

INDICATOR

FAILED

1/19/2006

F90  

PT6A135

 

903800097

FUEL FLOW

(CAN) FUEL FLOW INDICATIONS WENT INTERMITTENT THEN FAILED IN FLIGHT. FOUND TRANSMITTER TO HAVE FAILED INTERNALLY. TIME ON UNIT APROX.5000 HRS. (TC NR 20060127003)

CA060403008

BEECH

PWA  

 

SPLINE

WORN

1/12/2006

T34C

PT6A25

 

 

FUEL PUMP

THE ENGINE EXPERIENCED AN UNCOMMANDED POWER REDUCTION WHICH RESULTED IN THE AIRCRAFT CRASHING. INVESTIGATION DETERMINED THE FUEL PUMP SPLINE TO BE SUFFICIENTLY WORN TO RESULT IN THE LOSS OF ENGINE FUEL FLOW.

CA060425011

BEECH

PWA  

 

TURBINE BLADES

DAMAGED

4/7/2006

T34C1

PT6A25

 

 

ENGINE

DURING A TRAINING FLIGHT, THE ENGINE WAS REPORTED TO EMIT NOISES AND SMOKE FOLLOWED BY AN UNCOMMANDED POWER REDUCTION AND FLAME OUT. SUBSEQUENT INSPECTION REVEALED FRACTURED POWER TURBINE BLADES. P&WC WILL INVESTIGATE THE EVENT AND WILL ADVISE OF ROOT CAUSE ONCE ESTABLISHED.

CA060605010

BELL  

LYC  

 

TRANSMISSION

MAKING METAL

5/13/2006

204B

T5313B

 

204040009061

MAIN ROTOR

(CAN) METAL PARTICLES FOUND IN TRANSMISSION INTERNAL FILTER AFTER ROUTINE INSPECTION. NO CHIP LIGHT INDICATION. OIL DRAINED WITH NEW FILTER INSTALLED, AIRCRAFT RUN FOR ONE HOUR ON GROUND WITH METAL PARTICLES FOUND IN INTERNAL AND INLINE FILTER ASSY. NO CHIP LIGHT INDICATION. TRANSMISSION WAS REMOVED WITH T.S.N. 6631.1 T.S.O. 472.3 (TC NR 20060605010)

CA060602004

BELL  

LYC  

 

DRAG BRACE

CRACKED

5/29/2006

205A1

T5317A

 

204011179003

MAIN ROTOR

(CAN) THE DRAG BRACE WAS IN THE COMPONENT SHOP GETTING ITS 1200 HR INSPECTION/24 MONTH INSPECTION. THE DRAG BRACE ASSEMBLY WAS PREPARED FOR NDT MAGNETIC PARTICLE INSPECTION. THE NDT SHOP FOUND THIS FITTING WAS CRACKED ON THE IB CURVE. (TC NR 20060602004)

CA060331005

BELL  

LYC  

 

SADDLE

CRACKED

3/27/2006

205A1

T5317A

 

 

SKID TUBE

CRACK WAS FOUND ON SKID TUBE AT FORWARD CROSSTUBE MOUNTING SADDLE. THERE WAS NO REPORT OF A HARD LANDING WITH THIS AIRCRAFT AT THIS TIME. TIMES FOR THESE SKID TUBES WERE NOT AVAILABLE.

CA060524001

BELL  

LYC  

 

FITTING

CRACKED

5/19/2006

205A1

T5317A

 

212030154101

 

AIRCRAFT WAS ON SEISMIC DRILL MOVE JOB. THE ENGINEER WAS DOING HIS DAILY INSPECTION WHEN NOTICED THAT ONE EAR OF THE LIFT LINK FITTING WAS APPEARED CRACKED. A CLOSER VISUAL LOOK CONFIRMED IT WAS CRACKED. INVESTIGATING IF THE BUSHING WAS WRONG FOR THIS INSTALLATION. THE BELL 205 PARTS MANUAL AND TB 205-91-88 ARE NOT TO CLEAR OF THE DIFFERENT BUSHINGS NEEDED.

CA060222001

BELL  

 

 

LINE

CRACKED

2/17/2006

206B

 

 

206061677001

FUEL SYSTEM

ON REINSTALLATION OF FUEL LINES IN FUEL VALVE COMPARTMENT TUBE ASSY WAS TORQUED AND FERRULE WAS FOUND TO BE CRACKED. TUBE ASSY WAS SUSPECTED TO BE CRACKED ON REMOVAL BUT NO LEAKS DETECTED. LINE REMOVED FROM SERVICE. RECOMMEND BETTER VISUAL INSPECTION OF ALUMINUM LINES AND PROPER TORQUE PROCEDURES.

CA051220011

BELL  

 

 

BLADE

LOOSE

12/13/2005

206B

 

 

206016201131

TAIL ROTOR

AS THE ENGINEER WAS CONDUCTING A DAILY CHECK WITH THE PILOTS, IT WAS NOTED UNUSUAL AMOUNT OF MOVEMENT OF THE T/R BLADE TO THE HUB ASSEMBLY. FURTHER INVESTIGATION IT WAS REVEALED THAT THE STAKED SLEEVE ONTO THE T/R BLADE AND THE SPHERICAL FEATHERING BEARING WAS LOOSE. THE LOOSENESS WAS BETWEEN THE SLEEVE AND THE T/R BLADE. THE SPHERICAL BEARING WAS A OLDER P/N BEARING THE BLADE WAS SENT AWAY FOR REPAIR.

CA051211001

BELL  

ALLSN

 

FUEL CONTROL

MALFUNCTIONED

11/22/2005

206B

250C20

 

23034702

ENGINE

PILOT LANDED ON REMOTE LEASE SITE AND UPON LOWERING THE COLLECTIVE THE ENGINE DID AN UNCOMMANDED DECEL TO 75 PERCENT. PILOT ROLLED THROTTLE BACK TO IDLE AND TRIED TO ROLL THROTTLE BACK TO 100 PERCENT. ENGINE WOULD NOT RETURN PAST 75 PERCENT. MAINTENANCE WAS CALLED AND FUEL CONTROL WAS REPLACED.

CA060117006

BELL  

ALLSN

 

PIN  

UNSERVICEABLE

11/22/2005

206B

250C20

 

206928110

TAIL ROTOR

THREADED PORTION OF EXPANDABLE PIN FOUND SHEARED OFF, REPLACED WITH SERVICEABLE ASSEMBLY. ASSEMBLY WAS FOUND TO BE BROKEN DURING A GROUND RUN. THIS PIN IS PART OF THE QUICK DISCONNECT PEDAL SYSTEM.

CA051205008

BELL  

ALLSN

BELL  

STOP

CRACKED

12/5/2005

206B

250C20

 

206011160101

M/R HUB

DURING OVERHAUL OF MAIN ROTOR HUB, NDT OF THE STATIC STOPS FOUND CRACKS IN CORNERS. THE ASSEMBLY HAS TWO STOPS, AND BOTH WERE CRACKED.

CA060306015

BELL  

ALLSN

 

VOLT REGULATOR

FAILED

10/21/2005

206B

250C20

 

15891F

 

(CAN) NO CHARGE. REPLACED VOLTAGE REGULATOR. (TC NR 20060306015)

CA060306016

BELL  

ALLSN

 

TACHOMETER

FAILED

10/28/2005

206B

250C20

 

D22A690

MAIN ROTOR

(CAN) NO ROTOR TACH INDICATION. REPLACED TACH. (TC NR 20060306016)

CA060605005

BELL  

ALLSN

 

SKID

CORRODED

6/1/2006

206B

250C20B

 

206020110005

MLG 

(CAN) DURING A ROUTINE 300 HR INSP OF THE AC, IT WAS NOTED THAT A SMALL PIECE OF PAINT HAD FALLEN OFF OF THE LOWER AFT END OF THE TAIL SKID ASSY, AT THE LOWER WELD BEAD JOINT. UPON FURTHER INVESTIGATION, IT WAS NOTED THAT A SMALL HOLE (APPROX .1875) WAS PRESENT. WHEN THE WELD AREA WAS INSPECTED ON THE OPPOSITE SIDE, A SMALL AREA OF CORROSION WAS ALSO NOTED, BUBBLING UNDER THE PAINT. THE CORROSION WAS REMOVED WHICH REVEALED ANOTHER SMALL HOLE (APPROX .1875). THIS AREA OF THE TAIL SKID ASSY IS ALSO THE LOWEST POINT, WHERE WATER AND CONDENSATION CAN BE TRAPPED. A NEW TAIL SKID ASSY WAS PURCHASED AND INSTALLED ON THE AIRCRAFT. (TC NR 20060605005)

CA060605006

BELL  

ALLSN

 

WEB  

CRACKED

5/31/2006

206B

250C20B

 

206031121023

FUSELAGE

(CAN) DURING A ROUTINE 300 INSP ON THE AIRFRAME, A CRACK WAS NOTED ON UPPER AFT SECTION OF THE SEAT WEB ASSY. THIS AREA IS PRONE TO STRESS AND CRACKS WHEN THE SEAT PANEL (THAT IS ATTACHED TO IT) IS REMOVED, AND NO SUPPORT IS ADDED TO THE TOP OF THIS WEB ASSY. PEOPLE TEND TO LEAN OVER THIS AREA, PUTTING THEIR HANDS ON THE TOP OF THE WEB AND THE WEB ENDS UP SUPPORTED THE PERSONS WEIGHT. THIS IS THE PROBABLE CAUSE OF THE CRACK, WHICH CAN HAPPEN OVER TIME. THE WEB ASSY WAS REPLACED WITH A NEW PIECE, AND THE AIRCRAFT WAS RETURNED TO SERVICE. (TC NR 20060605006)

CA060605008

BELL  

ALLSN

 

LONGERON

CRACKED

5/31/2006

206B

250C20B

 

206031123059

FUSELAGE

(CAN) DURING A ROUTINE 300 HR INSP, A CRACK WAS FOUND ON THE LONGERON ABOVE THE LT REAR PASSENGER DOOR, AT THE FWD ATTACHMENT TO THE ROLLOVER BULKHEAD. THE CRACK ORIGINATED AT THE ATTACHING RIVETS. THE LONGERON WAS REPLACED WITH A NEW PIECE, AND THE AIRCRAFT WAS RETURNED TO SERVICE. (TC NR 20060605008)

CA060606009

BELL  

ALLSN

 

CONTROL CABLE

BROKEN

5/29/2006

206B

250C20B

 

412B0220

THROTTLE

(CAN) CABLE BROKE APPROXIMATELY 9.5 FROM END. (TC NR 20060606009)

CA060303017

BELL  

ALLSN

 

IGNITER

FAILED

6/4/2005

206L

250C20R

 

CH34168

ENGINE

NO IGNITION. REPLACED IGNITER.

CA060303018

BELL  

ALLSN

 

VOLT REGULATOR

FAILED

7/19/2005

206L

250C20R

 

206075447007

 

AT START UP NO CHARGE. REPLACED VOLTAGE REGULATOR.

CA051202002

BELL  

ALLSN

 

TAIL BOOM

CRACKED

11/23/2005

206L

250C20R

 

206033001003

BS 45

DURING THE CLEANING OF THE TAIL BOOM, A CRACK WAS FOUND AT BOOM STATION 45". THE CRACK ORIGINATED FROM A RIVET THE TOP LEFT SLIP (FOR THE CAMLOC FITTING). THE CRACK MEASURED 3.5" AND RUNS ON AN 80 DEGREES ANGLE.

CA060227002

BELL  

ALLSN

 

STIFFENER

CRACKED

2/23/2006

206L

250C20R

 

206032319023

FUSELAGE

AFTER REMOVAL OF AFT FUSELAGE FAIRING FOR REPAIR. VISUAL INSPECTION AND CLEANING OF AFT FUSELAGE A STIFFENER FOUND CRACKED. STIFFENER REPLACED NEW.

CA060403010

BELL  

ALLSN

RROYCE

TUBE

BROKEN

3/26/2006

206L1

250C28B

6896024CP

 

ENGINE

PILOT HEARD A BIG "BANG" FROM ENGINE AND LOST POWER. THE PILOT LANDED IN THE BUSH WITHOUT DAMAGING THE A/C. AFTER THE INSPECTION OF THE COMPRESSOR BY THE MECHANIC, FOUND THE COMPRESSOR IN BAD SHAPE, CONFIRMED FOD WAS IN TO THE COMPRESSOR. MECHANIC CHECKED AND FOUND SOME LITTLE METAL PIECES IN THE INTAKE BEHIND THE INLET SCREEN, FINALLY FOUND THE INJECTOR TUBE BROKEN ON THE WELDING POINT.

CA060120002

BELL  

ALLSN

 

BEARING RACE

CORRODED

1/17/2006

206L1

250C28B

 

206011111003

M/R TRUNNION

(CAN) ON A SCHEDULED 1200 HR M/R CORROSION INSPECTION THE INNER RACE OF THE M/R TRUNNION BEARING WAS FOUND TO BE SEVERLY CORRODED TO THE POINT THAT THE INNER RACE WAS CRACKED. THIS BEARING RACE IS THERMALLY PRESS FIT AND THE TIGHT TOLLERANCE, SEVERE CORROSION AND FLIGHT LOADS CAUSED THIS RACE TO CRACK (TC NR 20060120002)

CA060105003

BELL  

ALLSN

 

MAST

MAKING METAL

12/8/2005

206L1

250C28B

 

206040014105

MAIN ROTOR

M/R MAST WAS REPLACED 4 HOURS PREVIOUSLY. PILOT HAD A TRANSMISSION CHIP LIGHT AND NOTIFIED TOWER OF LANDING DUE TO A MX PROBLEM. ENGINEER INSPECTED F/W, TRANSMISSION, AND MAST CHIP DETECTORS. FOUND HAIR LIKE SLIVER ON THE UPPER MAST BRG CHIP DETECTOR AND ON THE TRANSMISSION OIL MONITOR, AS PER BELL 206L-1 CHIP DETECTOR GUIDE C/O INSPECTION AS REQUIRED, C/O OPERATIONAL CHECK AND 20 MIN GROUND RUN AS PER BELL 206L-1 MM. CHECK CHIP DETECTORS, OIL REPLACED, FILTER INSPECTED AND REPLACED AND ANOTHER OPERATIONAL CHECK C/O. SLIVERS MAY HAVE BEEN FROM MAST INSPECTION OR OIL CANS? SOURCE UNKNOWN. AIRCRAFT RETURNED TO SERVICE WITH A SATISFACTORY TEST FLIGHT.

CA060420002

BELL  

ALLSN

 

BULKHEAD

CRACKED

4/7/2006

206L1

250C30

 

206032308003

TAILBOOM

WHILE PERFORMING 100 HR INSPECTION OF THE ATTACHMENT HOLES FOR TAILBOOM FOUND A CRACK ORIGINATING FROM UPPER RIGHT HOLE. CRACK WAS 1 INCH IN LENGTH. BULKHEAD WAS REPLACED.

CA051122002

BELL  

ALLSN

 

WEB  

CRACKED

10/26/2005

206L1

250C30

 

206333110

FUSELAGE

WHILE PERFORMING A 1200 HR INSPECTION ON THE VERTICAL TUNNEL AND BOXBEAM A CRACK WAS NOTICED ON THE RIGHT VERTICAL WEB\SKIN AND THE VERTICAL ANGLE STIFFENER INSIDE THE TUNNEL. THIS AREA HAD BEEN REPAIRED PREVIOUSLY IN 1996 BY ANOTHER REPAIR STATION. THIS AREA IS KNOWN FOR CRACKS AND IS ALREADY ADDRESSED IN THE STRUCTURAL REPAIR MANUAL.

CA060224003

BELL  

ALLSN

 

FUEL CONTROL

FAILED

2/22/2006

206L1

250C30

 

84250077

ENGINE

ON A TWO MINUTE COOL DOWN AFTER ONE HOUR FLIGHT, THE ENGINE STARTED TO SURGE, THE PILOT SHUTDOWN THE ENGINE AND AFTER A MOMENT TRIED A RESTART BUT IT WOULD NOT LIGHT-OFF. THE ENGINEER FOUND NO FUEL WOULD COME OUT OF FCU. FCU WAS REPLACED.

CA060413005

BELL  

ALLSN

 

FUEL CONTROL

BROKEN

4/12/2006

206L1

250C30P

 

23070613

ENGINE

ONE OF THE FUEL CONTROL BYPASS COVER SCREWS BROKE CAUSING FUEL TO LEAK INTO THE ENGINE BAY. THIS IS TO BE INSPECTED EVERY 100 HOURS IAW ALLISON 250 C30 CEB A-73-3075R1 WHICH IT WAS.

CA060424009

BELL  

 

 

YOKE

OBSTRUCTED

3/27/2006

206L3

 

 

 

COCKPIT

WITH THE COLLECTIVE IN THE MID TO FULL DOWN POSITION AND THE CYCLIC FULL FORWARD AND LEFT THE RT CONTROL YOKE CONTACTS THE WINDSCREEN DEFROST HEATER PIPE.

CA051220003

BELL  

 

 

SKIN

DAMAGED

12/16/2005

206L4

 

 

 

VERTICAL STAB

DURING A SCHEDULED DESTRUCTIVE TEST, FOUND SOME STABILIZER SKINS DAMAGED WITH TOOL MARKS AT SOME INSERT HOLES.

CA030124002

BELL  

ALLSN

 

UNION  

OBSTRUCTED

1/22/2003

206L4

250C30P

 

 

GOVERNOR

DIFFICULTY TO START ENGINE. UNION FITTING OBSTRUCTED WITH METALLIC PARTICLES.

CA051124003

BELL  

 

 

BEARING

UNSERVICEABLE

9/20/2005

212  

 

 

RSS9 

 

NEW SPHERICAL BEARING RECEIVED WITH EXCESSIVE AXIAL PLAY. AXIAL PLAY OF THE INNER RACE TO OUTER RACE WAS MEASURES AT 0.032" THE BHT-ALL-SPM LIMIT FOR A USED BEARING IS 0.030". THE BEARING HAS BEEN RETURNED TO BHT FOR WARRANTY WITH A BHT MMIR.

CA051104019

BELL  

PWA  

 

BLEED VALVE

STUCK

8/3/2005

212  

PT6T3

 

 

ENGINE

COMPRESSOR STALL CAUSED OSCILLATIONS IN AIRFRAME. ENGINE POWER REDUCED TO IDLE. A SINGLE ENGINE LANDING CARRIED OUT IN NEAR BY FIELD. ENGINE REPLACED WITH SERVICEABLE UNIT. IT WAS FOUND TO BE A STUCK CLOSED, BLEEDVALVE AND 3RD STAGE COMPRESSOR BLADE DAMAGE.

CA060104009

BELL  

PWA  

BELL  

SHAFT

CRACKED

1/4/2006

212  

PT6T3

 

2660163501

BLOWER

PERFORMED MAGNETIC PARTICLE INSPECTION IAW BHT-ALL-SPM, SHAFT P/N 2660-1635-01 WAS FOUND TO BE CRACKED IN KEY WAY, PART HAS BEEN SUBSEQUENTLY SCRAPED. BELL HELICOPTER HAS BEEN NOTIFIED FOR INTEREST AND INFORMATION ONLY.

CA060605012

BELL  

PWA  

 

BLADE

CRACKED

5/25/2006

212  

PT6T3

 

212015501115

MAIN ROTOR

(CAN) MAIN ROTOR BLADE SMALL DEBOND FOUND ON LOWER SURFACE APPROX 81.5 INCHES FROM BUTT END JUST AFT OF THE STAINLESS STEEL LEADING EDGE STRIP ON DISASSEMBLY. (APRIL 07 2006) BLADE WILL BE INSPECTED WHEN ARRIVING BACK FOR REPAIR EVALUATION. PAINT REMOVED FROM DEBOND AREA WITH A SMALL CRACK FOUND CHORD WISE APPROX .7500 OF AN INCH LONG.(MAY 25 2006) (TC NR 20060605012)

CA060601006

BELL  

PWA  

 

DETECTOR

FAILED

3/27/2006

212  

PT6T3

 

2090753261

RPM LIMIT

(CAN) ENGINE OUT LIGHT STAYS ON AFTER ENGINES STARTED. RPM LIGHT INTERMITTENT WITH RPM IN NORMAL OPERATING RANGE.THE RELIABILITY OF THESE UNITS ARE NOT GOOD.IN OUR FLEET OF 4 BELL 212'S WE GO THROUGH 6 RPM BOXES IN 1 SUMMER (TC NR 20060601006)

CA060524007

BELL  

PWA  

 

CONTROL UNIT

MALFUNCTIONED

5/19/2006

212  

PT6T3

 

51509002

FUEL QTY IND

(CAN) TROUBLESHOOTING A FUEL QUANTITY INDICATING A/C SYSTEM DEFECT. WITH BOTH POWER SECTIONS RUNNING THE FUEL QUANTITY INDICATION WOULD CHANGE WITH NO FUEL ADDED. FUEL QUANTITY SELECTOR WOULD BE POSITIONED TO LT TANK AND VERY SLOWLY THE INDICATOR WOULD SHOW THE CORRECT QUANTITY. THEN MOVE THE SELECTOR TO RT TANK AND THE FUEL QUANTITY WOULD REACT VERY SLOWLY THE FUEL INDICATOR WOULD READ THE CORRECT QUANTITY. THEN MOVE THE SELECTOR BACK TO THE LEFT TANK AND THE READING WOULD BE DIFFERENT THAN THE ORIGINAL FUEL INDICATION. WHAT WAS FOUND THE LEFT DC CONTROL UNIT WAS AFFECTING THE A/C FUEL QUANTITY INDICATING SYSTEM. UNIT REPLACED, FUNCTIONAL/ OPERATIONAL TEST, A/C RETURNED TO SERVICE. (TC NR 20060524007)

CA060329003

BELL  

PWA  

BELL  

CASE

BROKEN

7/30/2005

212  

PT6T3

212040001123

204040353023

TRANSMISSION

WHILE IN CRUISE, A LOUD BANG WAS HEARD AND AC SHUDDERED. AC SETTLED OUT AND CREW DIVERTED TO AIRPORT. INSPECTION OF AC REVEALED MAIN TRANSMISSIOM SUPPORT CASE BROKEN AT DRAG LINK ATTACHMENT POINT. AC GROUNDED AND MAIN TRANSMISSION REPLACED. AC RELEASED BACK TO SERVICE.

CA060329005

BELL  

PWA  

 

ENGINE

FAILED

8/1/2005

212  

PT6T3

 

 

NR 2 

WHILE IN CRUISE, A LOUD BANG WAS HEARD FOLLOWED BY AIRFRAME SHUDDER. AN EMERGENCY WAS DECLARED AND AIRCRAFT STARTED LANDING PROCEDURES. NR 2 ENGINE INDICATING FAILURE AND ROLLED BACK. AIRCRAFT SUCCESSFULLY LANDED IN A FIELD. POWER RECOVERY OF NR 2 ENGINE ABORTED DUE TO COMPRESSOR STALL. AC WAS SHUTDOWN AND GROUNDED UNTIL POWER SECTION COULD BE REPLACED.

CA060129016

BELL  

PWA  

 

CASE

FRACTURED

12/13/2005

212  

PT6T3B

 

 

COMPRESSOR

(CAN) DURING APPROACH, THE ENGINE EXPERIENCED AN UNCOMMANDED POWER REDUCTION ACCOMPANIED BY NOISE AND VIBRATION. THE ENGINE WAS SHUT DOWN IN FLIGHT. SUBSEQUENT ISPECTION REVEALED A FRACTURED INLET CASE STRUT. (TC NR 20060129016)

CA060531010

BELL  

PWA  

 

ROTOR

MALFUNCTIONED

4/4/2006

212  

PT6T3B

 

 

MAIN ROTOR

(CAN) FOLOWING CLIMB THE MAIN ROTOR SPEED DECREASED UNCOMMANDED AND THE LOW ROTOR RPM WARNING ACTIVATED. AN EMERGENCY LANDING WAS CARRIED OUT RESULTING IN AIRFRAME DAMAGE. NR WILL INVESTIGATE THE EVENT AND WILL ADVISE OF ROOT CAUSE ONCE ESTABLISHED. (TC NR20060531010)

CA060118002

BELL  

PWA  

 

ENGINE

MALFUNCTIONED

1/16/2006

212  

PT6T3B

 

 

NR 1 

(CAN) HELI-SKING: AC DROPPED SKIERS AT TOP, HAD LIFTED OFF MOUNTAIN TO GO TO SKIER PICK UP PAD. AC WAS ON A DESCENDING, SLIDE SLIPPING, PILOT CARRIED OUT A SCAN OF INDICATORS, NOTICE NR AT 99 PERCENT, DESCENDING TO 98 PERCENT, WAS EXPECTING A 101 PERCENT FOR HIM TO BEEP DWN TO 100 PERCENT. ENG OUT LIGHT NR1 ENG CAME ON AS WELL AS OTHER LIGHTS. NG, ITT WERE DECREASING ON NR 1 ENG. CREEPED NR BACK UP TO 100 PERCENT. ALSO CONFIRMED THAT THROTTLE WAS FULL OPEN. LEVEL OUT AC, ISOLATED DEAD PWR SEC AND RETURNED TO HANGAR. NORMAL SHUTDOWN ON NR 2 PWR SEC. MAINT BOTH PWR SEC WERE STARTED UP ON GROUND, BOTH PWR SEC STARTED NML, OPS CHECK APPEARED TO BE NML. AC GROUNDED TO TROUBLESHOOT THE DEFECT. (TC NR 20060118002)

CA051223005

BELL  

PWA  

 

COMPRESSOR

DAMAGED

11/14/2005

212  

PT6T3B

 

 

ENGINE

DURING A MAINTENANCE CHECK FLIGHT, THE ENGINE EMITTED A LOUND NOISE ACCOMPANIED BY AN UNCOMMANDED POWER REDUCTION. THE ENGINE WAS SHUT DOWN IN FLIGHT. SUBSEQUENT INSPECTION REVEALED DAMAGE TO THE COMPRESSOR AND INLET AREA. P&WC WILL INVESTIGATE THE EVENT AND ADVISE OF ROOT CAUSE ONCE ESTABLISHED.

AU510001454

BELL  

PWA  

 

GEARBOX

MAKING METAL

4/6/2005

212  

PT6T3B

 

PT6T3B6

COMBINING

(AUS) COMBINING GEARBOX METAL CONTAMINATION. (CASA# 510001454)

CA060524008

BELL  

LYC  

 

SPINDLE

BROKEN

5/24/2006

214B

T5508D

 

214030606005

TRANSMISSION

DONT HAVE ANY OTHER INFO AT THIS TIME, AS THIS INCIDENT JUST OCCURRED THIS MORNING. WILL ADD INFORMATION AS IT COMES IN. THIS INCIDENT SEEMS VERY SIMILAR TO ONE 16 OCT 1996 NTSB REPORT NUMBER A96P0231. WITH ONE GOOD DIFFERENCE, NO LOSS IN FLIGHT CONTROL AND SAFE LANDING. PART WAS NOTED AND X-RAYED AT TIME OF OVERHAUL.

CA060317007

BELL  

 

BELL  

HORN

CRACKED

2/13/2006

214B1

 

 

214001920101

ELEVATOR

CRACK FOUND ON ELEVATOR HORN ASSY ON REGULAR INSPECTION. REMOVED FROM SERVICE AND REPLACED WITH NEW ASSEMBLY. PART HAS A RETIREMENT LIFE OF 2500 HOURS.

CA051223002

BELL  

 

 

SEAL

DISLODGED

11/15/2005

407  

 

 

209340265103

FREEWHEEL UNIT

THE AFT SEAL OF THE FREEWHEEL UNIT CAME OUT FROM THE AFT CAP WHILE THE ENGINE WAS RUNNING.

CA051220002

BELL  

 

 

SKIN

DAMAGED

12/16/2005

407  

 

407023801109

 

VERTICAL STAB

DURING A SCHEDULED DESTRUCTIVE TEST, FOUND SOME STABILIZER SKINS DAMAGED WITH TOOL MARKS AT SOME INSERT HOLES.

CA051223004

BELL  

ALLSN

 

CLUTCH

CRACKED

12/12/2005

407  

250C47B

 

406040506101

FREEWHEELING

4 FATIGUE CRACKS WERE FOUND AROUND TWO LOWER ENGINE ATTACHMENT BOLT HOLES.

CA051208006

BELL  

ALLSN

BELL  

SKIN

CRACKED

11/28/2005

407  

250C47B

BELL407

206033003161

FUSELAGE

SKIN FOUND TO BE CRACKED DURING ROUTINE INSPECTION.

CA060123003

BELL  

ALLSN

 

TURBINE WHEEL

DAMAGED

1/21/2006

407  

250C47B

 

6898663

ENGINE

(CAN) PILOT HEARD LOUD SQUEALING NOISE FOLLOWED BY VIBRATION WHILE IN CRUISE FLIGHT WITH PASSENGERS. ELECTED TO LAND IMMEDIATELY. NORMAL LANDING AWAY FROM BASE CARRIED OUT. INSPECTION FOUND DAMAGE TO ENGINE TURBINE SECTION, SUSPECT 3RD STAGE TURBINE WHEEL PROBLEM. ENGINE REMOVED AND REPLACED. TURBINE WILL BE SENT FOR INSPECTION. (TC NR 20060123003)

AU510001984

BELL  

PWA  

 

NUT  

CRACKED

12/12/2005

412  

PT6T3

 

 

FUEL HOSE

FUEL SYSTEM HOSE ASSEMBLY NUT CRACKED ON FLARE FITTING. FUEL LEAKING.

CA060129008

BELL  

PWA  

 

FUEL CONTROL

FAULTY

1/10/2006

412  

PT6T3B

 

 

ENGINE

(CAN) DURING FLIGHT, THE ENGINE LOST POWER FOLLOWED BY (ENGINE OUT) AND (LOW ROTOR SPEED) WARNING ANNUNCIATIONS. A SINGLE-ENGINE UNSCHEDULED LANDING WAS CARRIED OUT. SUBESQUENT INSPECTION REVEALLED A FAULTY AUTOMATIC FUEL CONTROL UNIT. MFG WILL INVESTIGATE THE EVENT AND ADVISE OF ROOT CAUSE ONCE DETERMINED. (TC NR 20060129008)

CA060116008

BELL  

 

 

PANEL

MISMANUFACTURED

1/13/2006

412EP

 

 

205032814103

TAILBOOM

MFG WAS ADVISED BY A SUPPLIER THAT PANELS WERE PROCESSED UNDER A DIFFERENT CURE CYCLE THAN THE ONE PRESCRIBED BY THE MFG PROCESS SPECIFICATION.

CA060116009

BELL  

 

 

PANEL

MISMANUFACTURED

1/13/2006

412EP

 

 

 

TAILBOOM

MFG WAS ADVISED BY A SUPPLIER THAT PANELS WERE PROCESSED UNDER A DIFFERENT CURE CYCLE THAN THE ONE PRESCRIBED BY THE MFG PROCESS SPECIFICATION.

CA060224002

BELL  

 

 

CYCLIC CONTROL

OBSTRUCTED

2/17/2006

427  

 

 

 

COCKPIT

CYCLIC STICK FWD MOVEMENT RESTRICTED BY T/R PEDAL STOP MECHANISM CABLE. T/R PEDAL STOP MECHANISM CABLE BRACKET 427-001-296-103 FOUND MISLOCATED.

CA060608004

BELL  

 

 

BOLT

LOOSE

5/11/2006

427  

 

 

 

TAIL BOOM

THE VERTICAL FIN WAS FOUND LOOSE DURING A SCHEDULE INSPECTION. ONE ATTACHMENT BOLT WAS SHANKED-OUT. ANOTHER BOLT WAS LOOSE BUT NOT SHANKED. NO OTHER DAMAGE WAS REPORTED.

CA060403002

BELL  

PWC  

 

WIRE STRIKE

DAMAGED

3/30/2006

427  

PW207D

 

STC 

 

DURING COOL DOWN AT IDLE RPM CYCLIC CONTROL STICK WAS MOVED FORWARD AND MAIN ROTOR BLADE (QTY 2) CONTACTED THE UPPER CUTTER OF THE WIRE STIKE PROTECTION SYSTEM.

CA051125002

BELL  

ALLSN

 

CONTROL TUBE

CHAFED

11/9/2005

430  

250C40B

 

430001007101

TAIL ROTOR

T/R CONTROL TUBE 430-001-007-101, FOUND WITH CHAFING MARKS. TUBE WAS REPLACED WITH NEW -105.

CA051125003

BELL  

ALLSN

 

CONTROL TUBE

CHAFED

11/9/2005

430  

250C40B

 

 

TAIL ROTOR

T/R CONTROL TUBE 430-001-007-101 FOUND WITH CHAFING MARKS. TUBE WAS REPLACED WITH NEW -105.

AU510002143

BELL  

 

 

BLADE

CORRODED

12/12/2005

47  

 

 

47642117105

TAIL ROTOR

TAIL ROTOR BLADE CORRODED AND DELAMINATED. DELAMINATION IS LOCATED AT THE OUTBOARD TIP OF THE LEADING EDGE ABRASION STRIP.

AU510002174

BELL  

 

 

BLADE

CORRODED

12/12/2005

47  

 

 

47642117105

TAIL ROTOR

(AUS) TAIL ROTOR BLADE CORRODED AND DELAMINATED IN AREA UNDER OB TIP OF ABRASION STRIP. (CASA NR 510002174)

AU510002119

BELL  

LYC  

 

SHAFT

CRACKED

8/11/2005

47G2

VO435A1F

 

477271611

THROTTLE

THROTTLE/COLLECTIVE CONTROL SHAFT CRACKED IN AREA HIDDEN BY GEAR.

AU510001577

BELL  

LYC  

 

SHAFT

WRONG PART

8/6/2005

47G3B1

TVO435B1A

 

476452051

TAIL ROTOR

TAIL ROTOR GEARBOX PINION SHAFT WORN AND INCORRECT PART. BELL 47 SI 428 CALLED FOR REPLACEMENT OF P/N 47-645-205-1 WITH P/N 47-645-205-3 SHAFT.

CA060417001

BELL  

LYC  

 

ENGINE

SHUTDOWN

4/14/2006

47G4

VO540B1B3

 

 

 

HELICOPTER WAS FLYING ALONG AND ENGINE QUIT, SUCCESSFUL AUTOROTATION WAS ACCOMPLISHED. UPON INVESTIGATION OF ENGINE, IT WAS FOUND THAT NONE OF THE VALVES WERE OPENING OR CLOSING AND THEREFORE SUGGESTS THAT CAM SHAFT IS NOT TURNING OR HAS BROKEN, ENGINE IS BEING SENT FOR TEARDOWN INSPECTION AT THIS TIME.

AU510001896

BNORM

LYC  

BNORM

SPACER

WORN

12/12/2005

BN2B26

O540E4B5

EQUIPMENT

NB31B133

ELEVATOR

LT OB ELEVATOR SPACER (DISTANCE PIECE) WORN BEYOND LIMITS. AS A RESULT THE ELEVATOR SUPPORT STRUCTURE WAS CRACKED TO THE POINT OF NEAR SEPARATION.

CA030120005

BOEING

PWA  

 

CONTROL PANEL

FLUCTUATES

1/9/2003

727223

JT8D15A

 

80053258

CABIN PRESSURE

AT FLIGHT LEVEL 25,000 FT, IT WAS OBSERVED CABIN PRESSURE WAS CLIMBING 1,000 FT - 2,000 FT PER MINUTE. AIRCRAFT RETURNED TO BASE WITHOUT INCIDENT. CABIN PRESSURE CONTROL PANEL REPLACED AND CHECKED SERVICEABLE IAW WITH MM 21-30-00. NO FURTHER INCIDENT DURING SUBSEQUENT FLIGHT.

CA060403028

BOEING

PWA  

 

FUEL CONTROL

MALFUNCTIONED

4/1/2006

727225

JT8D9A

 

7436024

NR 2 ENGINE

AT CRUISE ALTITUDE(FL350), THE NR 2 ENGINE WAS SURGING AND DROPPING POWER. ENGINE ANTI ICE AND FUEL HEAT CHECK C/W, NO CHANGE, ENGINE FAILURE- SHUTDOWN CHECK LIST C/W, NR 2 ENGINE SHUTDOWN INFLIGHT. MAINTENANCE INSPECTED AIRCRAFT IAW PW MM 72-00-00 PAGE 531. ENGINE FUEL PUMP/FCU PACKAGE REPLACED AND AIRCRAFT RETURNED TO SERVICE.

CA060119003

BOEING

PWA  

 

ACTUATOR

LEAKING

1/17/2006

727231

JT8D15A

 

65C3575816

UPLOCK

(CAN) ON APPROACH, NLG FAILED TO EXTEND NORMALLY. SUSPECT POSSIBLE FREEZING IN UPLOCK MECHANISM AND/OR BUNGEE LINK. MANUAL EXTENSION USED, NLG EXTENDED AND LOCKED. AIRCRAFT LANDED WITHOUT INCIDENT. UPON INSPECTION BY MAINTENANCE SUSPECTED ACTUATOR BYPASSING INTERNALLY. ACTUATOR REPLACED. (TC NR 20060119003)

CA060119004

BOEING

PWA  

 

ACTUATOR

FROZEN

1/17/2006

727231

JT8D15A

 

69141001

MLG 

(CAN) ON APPROACH, NLG FAILED TO EXTEND NORMALLY. SUSPECT POSSIBLE FREEZING IN UPLOCK MECHANISM AND/OR BUNGEE LINK. MANUAL EXTENSION USED. NLG EXTENDED AND LOCKED. AIRCRAFT LANDED WITHOUT INCIDENT. UPON INSPECTION BY MAINTENANCE SUSPECTED BUNGEE ACTUATOR FROZEN. BUNGEE LINK REPLACED. (TC NR 20060119004)

CA060427004

BOEING

PWA  

 

SHUTOFF VALVE

MALFUNCTIONED

4/25/2006

727233

JT8D15

 

 

CABIN PRESSURE

(CAN) CLIMBING THROUGH FL20 THE F/E ADVISED OF PRESSURIZATION PROBLEMS. AFTER REDUCING TO 10,000 FT. CABIN INDICATED 10,000 WITH 3 PSI DIFF.WHEN THRUST REDUCED THE DIFF WAS 0. THE AIRCRAFT RETURNED TO POINT OF DEPARTURE. MAINTENANCE REPLACED THE PRESSURIZATION CONTROL PANEL AND THE PRESSURE CONTROL MODULATING SOV. THE SYSTEM WAS FUNCTION CHECKED AND THE AIRCRAFT RETURNED TO SERVICE. (TC NR 020060427004)

CA060608001

BOEING

PWA  

 

SWITCH

MALFUNCTIONED

6/4/2006

727233

JT8D15

 

 

CARGO DOOR

AFTER DEPARTURE ON AN ACCEPTANCE FLIGHT AFTER HEAVY MAINTENANCE, THE CREW OBSERVED A NR 1 CARGO DOOR UNSAFE INDICATION. THE WARNING LIGHT EXTINGUISHED AT 7.2 PSID AFTER REDUCING ALTITUDE TO 11K FT. THE AIRCRAFT RETURNED TO POINT OF DEPARTURE WHERE THE SWITCH WAS ADJUSTED AND THE AIRCRAFT RELEASED FOR RETURN TO SERVICE.

CA060216006

BOEING

PWA  

 

PUMP

UNKNOWN

2/16/2006

727247

JT8D15

 

3823002

NR 2 FUEL TANK

ON CLIMB, NR 2 RT AFT FUEL BOOST PUMP CB RELEASED FOLLOWED BY NR 2 LT AFT CB RELEASING APPROX 3 MIN LATER, NR 2 RT FWD CB RELEASED AND NR 2 LT FWD BOOST PUMP LOW PRESS LIGHT ILLUMINATED INTERMITTENTLY. A/C RETURNED TO DEPARTURE. MX INSPECTED ALL EFFECTED PUMPS, CONNECTORS, BREAKERS AND SWITCHES, NO FAULTS FOUND. BREAKERS WERE RESET, PUMPS WERE RUN FOR AN HOUR. DURING THIS TIME PUMPS WERE SELECTED OFF AND ON NUMEROUS TIMES. A/C RETURNED TO SERV & OPERATED WITH NO INCIDENT. MX REINSPECTED ALL OF ABOVE ALONG WITH CHECKING NR 2 TANK FOR FUEL CONTAMINATION. NOTHING FOUND. DUE TO UNUSUAL CIRCUMSTANCES MAINT HAS DECIDED TO REPLACE THREE EFFECTED BOOST PUMPS, BREAKERS AND SWITCHES.

AU510001461

BOEING

PWA  

 

LINE

DAMAGED

10/6/2005

727277

JT8D15

 

651784961

HYDRAULIC SYS

(AUS) HYDRAULIC PIPES PNO 65-17849-61 AND PNO 65-17849-4014 RUBBING TOGETHER CAUSING ONE PIPE TO BE HOLED. LOSS OF HYDRAULIC FLUID. INVESTIGATION FOUND A FAILED `P` CLIP ON ONE OF THE PIPES WHICH ALLOWED THE PIPES TO RUB TOGETHER.(OTHER CAUSE: AGE ) (CASA# 510001461)

AU510001965

BOEING

PWA  

 

ENGINE

BIRD INGESTION

4/10/2005

727277

JT8D15

 

JT8D15

 

NR 1 ENGINE BIRDSTRIKE. INVESTIGATION FOUND THE REMAINS OF THREE FLYING FOXES. THOROUGH INSPECTION OF THE ENGINE FOUND NO OBVIOUS DEFECTS. A WATER WASH WAS CARRIED OUT AND THE AIRCRAFT RELEASED TO SERVICE.

AU510001985

BOEING

PWA  

BOEING

SPAR

CRACKED

12/12/2005

727277

JT8D15

657278411

651693541

LT ELEVATOR

LT ELEVATOR REAR SPAR CRACKED. FOUND DURING INSPECTION IAW AD/B727/100.

AU510001660

BOEING

PWA  

BOEING

SKIN

CRACKED

12/12/2005

727277

JT8D15

B727200GROUP

 

BS 480-720B

FUSELAGE SKIN LAP JOINTS CRACKED. JOINTS WERE LOCATED AT STRINGER 4R BETWEEN BS 480 AND BS 720B AND AT STRINGER 26L BETWEEN STN 560 AND STN 580. FOUND DURING MEDIUM FREQUENCY EDDY CURRENT (MFEC) INSPECTION IAW AD/B727/160 AND SB727-53AO222.

AU510001519

BOEING

PWA  

 

DOOR FRAME

CRACKED

12/12/2005

727277

JT8D15

 

 

FUSELAGE

NR 3 CARGO DOOR LOWER FORWARD FRAME RADIUS AND `T` FRAME CRACKED THROUGH THREE FASTENER HOLES. FOUND DURING INSPECTION IAW SB 727-52-0149.

AU510001526

BOEING

PWA  

BFGOODRICH

WHEEL

CRACKED

12/12/2005

727277

JT8D15

 

101376

MLG 

MAIN WHEEL INNER HUB CRACKED APPROXIMATELY 35MM (1.377IN) BELOW THE MATING FACE AND EXTENDING THROUGH TO THE OUTSIDE OF THE HUB AT THE TIE BOLT HOLE SEAT RADIUS. CRACK LENGTH 18MM (0.708IN). CRACK IS LOCATED OUTSIDE OF AREAS LAID DOWN IN THE MAINTENANCE MANUAL. FOUND USING EDDY CURRENT INSPECTION.

AU510001545

BOEING

PWA  

 

DUCT

BROKEN

4/7/2005

727277

JT8D15

 

65222723

NR 2 ENGINE

NR 2 ENGINE INLET ANTI-ICE DUCT FLANGE COUPLING LIP FRACTURED AND SEPARATED. EVIDENCE OF A PRE-EXISTING CRACK.

AU510001874

BOEING

PWA  

 

SUPPORT FITTING

CRACKED

12/7/2005

727277

JT8D15

 

 

ENGINE

LT AND RT ENGINE FORWARD SUPPORT FITTING ASSEMBLIES CRACKED. LT PYLON FITTING CRACKED AT HOLE `F`. RT PYLON FITTING CRACKED AT HOLE `P`. FOUND DURING INSPECTION IAW AD/B727/151 AND BOEING SB 727-54A0010.

CA060309003

BOEING

PWA  

 

TURBINE BLADES

FAILED

2/19/2006

727281

JT8D17

 

 

ENGINE

(CAN) ON START UP THE CREW WAS UNABLE TO SUCCESSFULLY START THE NR 2 ENGINE. LARGE PIECES OF TURBINE BLADES WERE DISCOVERED LAYING IN THE TAILPIPE AREA. THE ENGINE WAS REPLACED AND A/C RETURNED TO SERVICE. (TC NR 20060309003)

AU510001744

BOEING

PWA  

 

BEARING

COLLAPSED

10/8/2005

7272J4

JT8D17

 

 

DRAG CONTROL

GROUND SPOILER QUADRANT UPPER AND LOWER BEARINGS COLLAPSED. SPOILER DIFFERENTIAL MIXER P/N 10-60841-8 ROUGH IN OPERATION.

AU510001527

BOEING

PWA  

 

PRESSURE PANEL

CORRODED

12/12/2005

7272J4

JT8D17

 

 

FUSELAGE

FUSELAGE STRUCTURE PRESSURE WEB CORRODED. WEB IS LOCATED AT FS 46 IN THE MAIN LANDING GEAR WHEEL WELL.

AU510001528

BOEING

PWA  

 

BEAR STRAP

CORRODED

12/12/2005

7272J4

JT8D17

 

 

NR 3 CARGO DOOR

NR 3 CARGO DOOR BEAR STRAP INNER SURFACE CORRODED.

AU510001492

BOEING

PWA  

 

SKIN

CORRODED

12/12/2005

7272J4

JT8D17

 

 

BS 822

CABIN WING CENTER SECTION UPPER SKIN PANEL CORRODED. PANEL IS LOCATED AT FS 822 RBL12.

AU510001894

BOEING

 

 

ODOR

DETECTED

10/9/2005

737  

 

 

 

COCKPIT

BURNING SMELL ON FLIGHT DECK. SMELL TRACED TO FAULTY P5-9 PANEL. AIRCRAFT IS FOREIGN REGISTERED.

AU510002166

BOEING

 

 

INSULATION

DAMAGED

12/12/2005

737*

 

 

 

HOT WATER LINE

HEATED POTABLE HOT WATER PIPE INSULATION AND ATTACHING CLAMPS HEAT DAMAGED. SUSPECT WATER IN PIPE IS NOT THERMOSTATICALLY CONTROLLED. PIPE SUPPLIES HOT WATER TO VIP SUITE. AIRCRAFT IS RAAF VIP.

AU510001745

BOEING

 

 

ADC  

FAILED

9/8/2005

737*

 

 

 

 

AIR DATA COMPUTER FAILED. AIRCRAFT IS FOREIGN REGISTERED.

CA051124009

BOEING

CFMINT

HONEYWELL

TURBINE BLADES

DAMAGED

11/22/2005

737*

CFM567B22

 

38403031

APU 

ITEM/ISSUE IS NON SDR REPORTABLE REQUIREMENT. PMI REQUESTED ITEM TO BE FILED TO BRING VISIBILITY TO ISSUE. APU INOP DUE TO AUTOSHUT DOWN, TURBINE SCAVENGE RETURN LINE BROKEN RESOLUTION NOTES: DUE BROKEN OIL SCAVENGE RETURN LINE. TURBINE AREA INSPECTED AS PER HONEYWELL SIL APU-91. NO BLADE SHIFT NOTED (NO RUBBING OR TIP CURL). APU CENTER BODY CAP APPEARS TO BE CRACKED BETWEEN UPPER SUPPORT STRUTS, SOME OIL STAINING NOTED ON BOTTOM OF BODYCAP.

CA060104010

BOEING

CFMINT

 

VIDEO DISPLAY

ODOR

1/1/2006

737*

CFM567B22

 

50401100003

SEAT 20E

A/C WAS ON DESCENT WHEN A BURNING SMELL WAS NOTICED COMING FROM SEAT 20E VDU. THE IFE SYSTEM 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.

CA060105001

BOEING

CFMINT

 

VIDEO DISPLAY

SMOKE

1/3/2006

737*

CFM567B22

 

50401100003

SEAT 6D

A/C WAS IN CRUISE WHEN SMOKE WAS OBSERVED COMING FROM SEAT 6D VDU. THE IFE SYSTEM 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.

CA051213008

BOEING

CFMINT

 

VALVE

MALFUNCTIONED

12/13/2005

737*

CFM567B22

 

38805

GND SPOILER

A/C HAD AN AIR TURNBACK AFTER TAKEOFF FROM YYZ. PIREP A43921 READS "LANDING GEAR DOES NOT RETRACT WHEN LANDING GEAR LEVER MOVED TO UP POSITION". MAINTENANCE FOUND THE GROUND SPOILER INTERLOCK VALVE RIGGED TO IT'S FAR LIMIT. THE INTERLOCK VALVE WAS RIGGED IAW AMM 26-62-61, GEAR SWINGS WERE CARRIED OUT WITH NO FAULTS FOUND AND THE AIRCRAFT WAS RETURNED TO SERVICE.

CA060608008

BOEING

CFMINT

 

EXTINGUISHER

LEAKING

6/6/2006

737*

CFM567B22

 

898052

COCKPIT

THE A/C WAS AT CRUISE WHEN A HISSING SOUND WAS HEARD. IT WAS DETERMINED TO BE LEAKAGE FROM THE PORTABLE FIRE EXTINGUISHER IN THE FLIGHT DECK. THE HISS CHANGED TO A LOUD WHISTLE AS IT INCREASED. THE CAPTAIN GRABBED THE TOP OF THE EXTINGUISHER AND TWISTED IT AND THE LEAK STOPPED. THE EXTINGUISHER HAS BEEN RETRIEVED AND IS BEING SENT TO THE VENDOR FOR COMPLETE INVESTIGATION AND ANALYSIS. ONCE THOSE RESULTS HAVE BEEN RECEIVED THEY WILL BE ADDED TO THIS POSTING.

CA060126005

BOEING

CFMINT

 

VIDEO DISPLAY

SMOKE

1/23/2006

737*

CFM567B22

 

50401100003

SEAT 11B

(CAN) ON JANUARY 23, 2006 A/C WAS IN CRUISE WHEN SMOKE WAS OBSERVED COMING FROM SEAT 11B VDU. THE IFE SYSTEM WAS DEACTIVATED. MAINTENANCE REPLACED THE VDU AND THE SYSTEM WAS TESTED SERVICEABLE. THIS COMPONENT WILL BE RETURNED TO THE MANUFACTURER AND A COMPLETE TEARDOWN REPORT WILL BE REQUESTED. THIS SDR WILL BE UPDATED ONCE THAT INFORMATION IS AVAILABLE. (TC NR 20060126005)

AU510001846

BOEING

GE  

 

EEC  

FAULTY

12/9/2005

737*

CFM56*

 

2042M67P02

NR 1 ENGINE

NR 1 ENGINE ELECTRONIC CONTROL (EEC) FAULTY.

AU510001848

BOEING

GE  

HONEYWELL

TIRE

DELAMINATED

12/9/2005

737*

CFM56*

 

 

MLG 

NR 4 MAIN WHEEL TIRE TREAD DELAMINATED AT INBOARD SIDEWALL. TIRE HAS A RETREAD DATE R1 505.

AU510001570

BOEING

GE  

 

CONTROLLER

FAILED

6/6/2005

737*

CFM567B24

 

285A178010

INTERPHONE

(AUS) FLIGHT ATTENDANT HANDSET CONTROLLER FAILED. (CASA NR 510001570)

AU510002044

BOEING

PWA  

 

PIPE

LEAKING

12/12/2005

737200

JT8D7

 

65445101378

HYDRAULIC SYS

HYDRAULIC PIPE LOCATED IN NR 2 ENGINE NACELLE LEAKING.

SROM200600010

BOEING

PWA  

 

CASE

CRACKED

5/23/2006

737201

JT8D15

 

648031

NR 2 ENGINE

DURING HEAVY MAINTENANCE INSPECTION FOUND CRACKED OUT SECTION IN REAR EXHAUST CASE OF NR 2 ENGINE. REPLACED WITH OVERHAULED UNIT.

CA060609004

BOEING

PWA  

 

ANTI-ICE VALVE

INOPERATIVE

6/7/2006

737201

JT8D9A

 

320115

 

IN CLIMB, THE PORT ENGINE COWL ANTI-ICE LITE ILLUMINATED BRIGHT. THE AIRCRAFT RETURNED TO BASE. THE PORT ANTI-ICE VALVE WAS REPLACED, CHECKED SERVICEABLE AND AIRCRAFT RETURNED TO SERVICE.

2006FA0000588

BOEING

PWA  

 

CAP  

INOPERATIVE

6/7/2006

737205

JT8D17A

 

 

CHECK VALVE

AFTER COMPLETING 2 FLIGHTS, (A) HYDRAULIC SYSTEM BECAME INOPERATIVE. A LARGE AMOUNT OF FLUID WAS NOTED ON THE GROUND UNDER THE LT WHEEL. UPON FURTHER INVESTIGATION IT WAS NOTED THAT THE RT (A) SYSTEM MODULE CHECK VALVE INSTALLATION CAP HAD SHEARED IN THE MODULE CHECK VALVE INSTALLATION CAP HAD SHEARED IN THE MODULE PACKAGE, ALLOWING A LARGE QUANTITY OF HYDRAULIC FLUID TO BE LOST. DO NOT HAVE A PROBABLE CAUSE OR ANY RECOMMENDATIONS. (K)

CA060220002

BOEING

PWA  

 

SKIN

CRACKED

2/16/2006

737242C

JT8D9A

 

737200C

FUSELAGE

DURING THE PREFLIGHT INSPECTION 2 CRACKS WERE OBSERVED IN THE FUSELAGE SKIN. BOTH DEFECTS WERE APPROXIMATELY 2 INCHES IN LENGTH. THE LOCATION IS ESTIMATED TO BE BS 750 STR 19/20. THE AIRCRAFT IS CURRENTLY OUT OF SERVICE FOR REPAIR.

CA060424007

BOEING

PWA  

GARRTT

FIRE LOOP

FAULTY

4/22/2006

737248C

JT8D9A

GTCP85129

 

APU 

AFTER ARRIVAL AT DESTINATION AND DURING TAXI, A FIRE INDICATION WAS OBSERVED WHEN APU WAS STARTED. FIRE DRILL CARRIED OUT, EMERGENCY CREW FOUND NO EVIDENCE OF FIRE AND THE AIRCRAFT WAS TOWED TO GATE FOR PASSENGERS DEPLANE. AIRCRAFT RELEASED ON MEL, APU INOP.

CA060525005

BOEING

 

 

SKIN

GOUGED

5/25/2006

7372Q8C

 

 

 

BS 245

FOUND SKIN GOUGE AT BS 245 2" INBD OF STR 25L. REPAIRED IAW CUSTOMER EA.

CA060525006

BOEING

 

 

SKIN

DAMAGED

5/25/2006

7372Q8C

 

 

 

BS 1016-1028

EXISTING REPAIR AT BS 1016 AND 1028 FROM STR 15L TO 12L DAMAGED BEYOND LIMITS (DENTED) AND REPAIR IAW CUSTOMER EA.

CA060525007

BOEING

 

 

FRAME

CRACKED

5/25/2006

7372Q8C

 

 

 

BS 490 S24R

FWD PIT DOOR WAY AFT FRAME BS 490 STR 24R CRACKED AND REPAIRED IAW CUSTOMER EA.

AU510001456

BOEING

 

 

ACTUATOR

FAILED

12/12/2005

737300

 

 

550030017

AILERONS

(AUS) RT OUTBOARD AILERON LOCKOUT ACTUATOR FAILED IN PARTLY EXTENDED POSITION. WORKSHOP INVESTIGATION OF THE ACTUATOR FOUND INTERNAL CORROSION. SEE ATTACHMENT FOR INVESTIGATION DETAILS. (OTHER CAUSE: MATERIAL - AGE - ENVIRONMENT ) (CASA# 510001456)

PIDR2006001

BOEING

 

 

ATTACH FITTING

DAMAGED

6/8/2006

73735B

 

 

 

HORIZ STAB

DURING AN A-CHECK/BRIDGING CHECK FOR RETURN TO SERVICE FROM STORAGE, MAINTENANCE DISCOVERED A TIME LIMITED BLENDOUT REPAIR TO THE AFT FACE OF THE LEFT HORIZONTAL STABILIZER LOWER FORWARD ATTACH LUG. REWORKED AFT FACE OF LOWER FORWARD ATTACH LUG PER DELTA ENGINEERING REPAIR/AUTHORIZATION 089066-14 REVISION D DATED 5/10/06 WITH FAA 8100-9 APPROVAL DATED 5/30/2006.

AU510001746

BOEING

GE  

 

GIRT BAR

FAULTY

12/12/2005

737376

CFM563B1

 

737M25651013

SLIDE

(AUS) DOOR R1 ESCAPE SLIDE GIRT BAR CONTACTING DOOR FRAME.

PIDR2006008

BOEING

 

 

SKIN

DENTED

6/13/2006

7373L9

 

 

 

FUSELAGE

DURING A-CHECK/BRIDGING CHECK FOR RETURN TO SERVICE FROM STORAGE, INSPECTION NOTED A DENT IN THE FUSELAGE SKIN BEYOND ALLOWABLE LIMITS AT BS 887 STR 22 LT. REPAIRED PER SRM 53-00-01.

PIDR2006009

BOEING

 

 

SKIN

DAMAGED

6/6/2006

7373L9

 

 

 

HORIZ STAB

DURING A-CHECK/BRIDGING CHECK FOR RETURN TO SERVICE FROM STORAGE, DAMAGE NOTED ON THE RIGHT HORIZONTAL STABILIZER APPROXIMATELY 8 FEET FROM THE INBOARD END. REPAIRED PER SRM 55-10-01.

PIDR2006007

BOEING

 

 

SKIN

DENTED

6/19/2006

7373L9

 

 

 

BS 887-907

DURING A-CHECK/BRIDGING CHECK FOR RETURN TO SERVICE FROM STORAGE, INSPECTION NOTED DENTS BEYOND ALLOWABLE LIMITS IN FUSELAGE SKIN FROM BS887 TO BS907 BETWEEN STR20RT AND STR22RT. REPAIRED IAW SRM 53-00-01.

AU510001850

BOEING

CFMINT

 

CONTROL PANEL

FAILED

11/9/2005

737400

CFM563C

 

4051601937

AUTOPILOT

AUTOPILOT MODE CONTROL PANEL (MCP) FAILED.

AU510001524

BOEING

CFMINT

 

GCU  

FAILED

12/12/2005

737476

CFM563C

 

948F4583

AC SYSTEM

NR 1 GENERATOR CONTROL UNIT (GCU) FAILED.

AU510001687

BOEING

CFMINT

 

OUTFLOW VALVE

FAILED

12/12/2005

737476

CFM563C

 

7110033

CABIN PRESSURE

PRESSURIZATION SYSTEM AFT OUTFLOW VALVE FAILED TO OPEN. INVESTIGATION FOUND A DEFECTIVE AC MOTOR AND AC POTENTIOMETER.

AU510002009

BOEING

CFMINT

 

SYMBOL GENERATOR

FAILED

6/10/2005

737476

CFM563C

 

6229436100

ATTITUDE

CAPTAIN`S SYMBOL GENERATOR FAILED.

AU510002014

BOEING

CFMINT

 

IRU  

FAILED

12/12/2005

737476

CFM563C

 

HG1050AD04

ATTITUDE GYRO

NR 1 INERTIAL REFERENCE UNIT (IRU) FAILED.

AU510001672

BOEING

CFMINT

 

BEARING

FAILED

12/12/2005

737476

CFM563C

 

1060779124A

LE SLAT

LT WING OUTBOARD KRUGER FLAP NOSE LINK EYE END SHEARED.

AU510001457

BOEING

CFMINT

 

SERVO

FAILED

10/6/2005

737476

CFM563C

 

AR6460M2

AUTOPILOT TRIM

(AUS) AUTOPILOT STABILISER TRIM SERVO FAILED. WORKSHOP INVESTIGATION FOUND ROTOR GEAR STRIPPED AND ROTOR BEARING JOURNAL WORN. (OTHER CAUSE: AGE ) (CASA# 510001457)

AU510001496

BOEING

CFMINT

 

SENSOR

FAULTY

12/12/2005

737476

CFM563C

 

189929

SLATS

NR 3 LEADING EDGE FLAP RETRACTION SENSOR FAULTY.

AU510001468

BOEING

CFMINT

 

ACTUATOR

FAILED

11/6/2005

737476

CFM563C

 

AR7077M3

STAB 

(AUS) STABILISER ELECTRIC TRIM ACTUATOR FAILED. CAUSED BY WORN AND STICKING CLUTCH. (OTHER CAUSE: STICKING CLUTCH PLATES ) (CASA# 510001468)

AU510002104

BOEING

CFMINT

 

TIRE

DEBONDED

12/12/2005

737476

CFM563C

 

 

MLG 

NR 3 MAIN WHEEL TIRE TREAD DEBONDED.

AU510002105

BOEING

CFMINT

 

ACTUATOR

FAULTY

12/12/2005

737476

CFM563C

 

654492532

MLG 

LT MAIN LANDING GEAR ACTUATOR FAULTY. LT MAIN LANDING GEAR NOT FULLY RETRACTED.

AU510001907

BOEING

CFMINT

 

INDICATOR

FAULTY

12/12/2005

737476

CFM563C

 

2061141

TE FLAPS

(AUS) TRAILING EDGE FLAP ASSYMETRY. FLAPS RECYCLED AND OPERATED NORMALLY. INVESTIGATION CONTINUING. (CASA NR 510001907)

AU510001571

BOEING

CFMINT

 

SLIDE

FAULTY

5/7/2005

737476

CFM563C

 

D31591478

 

DOOR L1 ESCAPE SLIDE PRESSURE OUTSIDE OF OPERATING RANGE.

AU510002047

BOEING

CFMINT

 

ADAPTER

FAULTY

12/12/2005

737476

CFM563C

 

DG1035AB03

DAA 

RT INERTIAL REFERENCE SYSTEM (IRS) FAILED. CAUSED BY FAULTY RT DIGITAL ANALOGUE ADAPTER (DAA).

AU510002038

BOEING

CFMINT

 

DOOR

MISREPAIRED

12/12/2005

737476

CFM563C

 

 

LAVATORY

PAPER AND LINEN WASTE RECEPTACLE DOORS IN TOILETS NOT SEALING. INVESTIGATION FOUND LAV A (FWD) TO BE LATCHING SECURELY BUT NOT SEALING. INVESTIGATION REVEALED EXTRA STRIKER PLATE BONDED OVER EXISTING STRIKER PLATE CAUSING DOOR TO SIT OUT FURTHER THAN REQUIRED. EXTRA PLATE REMOVED. DOOR IS NOW SEALING. LAV B (MID) HINGE REQUIRED TO BE ADJUSTED IN SO THAT THE WASTE COMPARTMENT INNER DOOR COULD SEAL ADEQUATELY. PAINT REMOVED FROM STRIKER PLATE TO ENSURE MAGNETIC LATCH OPERATION. WASTE CONTAINER OUTER DOOR FOULS INNER DOOR HINGE AREA WHEN CLOSED CAUSING A SLIGHTLY PRE-LOADED CONDITION ON THE OUTER DOOR LATCH ASSEMBLY. FOUND DURING INSPECTION IAW AD/GENERAL/48 AND EI 734-25-2R9.

AU510001727

BOEING

CFMINT

 

WINDOW

DAMAGED

12/8/2005

737476

CFM563C

 

5893543135

COCKPIT

CAPTAIN`S NR 1 WINDOW CRACKED DUE TO ARCING.

AU510001728

BOEING

CFMINT

 

SLIDE

NO TEST

12/8/2005

737476

CFM563C

 

737M25651013

R1 DOOR

DOOR 1R ESCAPE SLIDE FAILED TO DEPLOY NORMALLY DURING TEST. SLIDE CONTACTED EDGE OF DOOR DURING OPENING CAUSING IT TO TWIST SIDEWAYS.

AU510002152

BOEING

CFMINT

 

SPRING

FAILED

12/12/2005

737476

CFM563C

 

6933691

ELEVATOR

ELEVATOR FEEL SPRING BROKEN.

AU510002153

BOEING

CFMINT

 

IRU  

FAILED

12/12/2005

737476

CFM563C

 

HG1050AD04

LEFT 

LT INERTIAL REFERENCE UNIT (IRU) FAILED.

AU510002177

BOEING

CFMINT

 

FRAME

CRACKED

11/11/2005

737476

CFM563C

 

 

FUSELAGE

FUSELAGE FRAMES (21OFF) CRACKED AT PASSENGER SERVICE UNIT (PSU) ATTACHMENT POINTS. FOUND DURING EDDY CURRENT INSPECTION IAW EI 737-53-68R3 AND NDT TECHNIQUES E-13 AND E-18.

AU510001552

BOEING

CFMINT

 

COUPLER

FAULTY

3/7/2005

737476

CFM563C

 

 

HF RADIO

NR 2 HF SYSTEM FAILED. NEW TRANSMITTER FITTED BUT PROBLEM REMAINED. SUSPECT FAULTY COUPLER.

AU510002148

BOEING

CFMINT

 

PANEL

MISINSTALLED

12/11/2005

737476

CFM563C

 

 

VERTICAL STAB

VERTICAL STABILIZER RT LOWER PANEL INCORRECTLY FITTED BETWEEN FORWARD AND AFT ATTACHMENT POINTS.

AU510001547

BOEING

CFMINT

 

ACTUATOR

FAILED

1/7/2005

737476

CFM563C

 

AR6460M2

AUTOPILOT

AUTOPILOT STABILIZER TRIM ACTUATOR FAILED DUE TO STRIPPED ROTOR GEAR AND WORN ROTOR BEARING JOURNAL.

AU510001584

BOEING

CFMINT

 

WIRE

BURNED

8/7/2005

737476

CFM563C

 

 

 

(AUS) WIRE LOCATED ON THE BACK OF PLUG D4001P LOCATED BEHIND THE E I RACK BURNED DUE TO CONTACT WITH TRAY DISCONNECT BRACKET. (OTHER CAUSE: MATERIAL ) (CASA NR 510001584)

AU510001913

BOEING

CFMINT

 

TRANSMITTER

FAULTY

12/12/2005

737476

CFM563C

 

1817389

TE FLAPS

(AUS) LT FLAP POSITION TRANSMITTER FAULTY. (CASA NR 510001913)

CA060309004

BOEING

 

 

SKIN

CHAFED

3/8/2006

737490

 

 

65C32362

BS 871-883

(CAN) FUSELAGE SKIN CHAFFING BS 871 TO 883 AT STR 1-2 L REPAIRED IAW EA 5330-02065 (TC NR 20060309004).

CA060228008

BOEING

CFMINT

 

LINE

CHAFED

2/27/2006

737522

CFM563C

 

65C265101024

HYD SYSTEM

FLUID LEAK ON RT GEAR "UP" HYDRAULIC RETURN LINE NOTICED DURING OVERNIGHT CHECK. LINE WAS CHAFED THROUGH DUE TO RUBBING ON A BRACKET. LINE REPLACED,GEAR SWING CARRIED OUT AND AIRCRAFT RETURNED TO SERVICE. TT-37255:17 TC-22887.

CA060418004

BOEING

CFMINT

 

COVER

SCORED

4/17/2006

737522

CFM563C1

 

301350238

OIL INLET

MAINTENANCE WAS CARRYING OUT A 7 DAY CHECK ON AIRCRAFT WHEN NOTICED SIGNS OF OIL LEAKING IN THE AFT SECTION OF THE NR 2 ENGINE. ON INVESTIGATION, THE OIL WAS FOUND TO BE LEAKING PAST THE OIL INLET COVER FOR THE NR 5 BEARING AREA. THE COVER WAS FOUND TO HAVE SCORING ON THE INTERIOR SMALL RADIUS. THE COVER WAS REPLACED WITH A SERVICEABLE UNIT. THIS SAME ITEM WAS REPLACED FOR A SIMILAR PROBLEM IN JULY 2005.

CA060531001

BOEING

CFMINT

 

WINDOW

FAILED

5/30/2006

737522

CFM563C1

 

58935734

COCKPIT

ON APPROACH, THE F/O'S NR 4 EYEBROW WINDOW SHATTERED. APPROACH CONTINUED AND AN UNEVENTFUL LANDING FOLLOWED. WINDOW REPLACED.

CA060111002

BOEING

CFMINT

 

BRACKET

SPLIT  

1/11/2006

737522

CFM563C1

 

69215313

FUSELAGE

ON LANDING IN YYZ,FORWARD ATTENDANTS SEAT BELT CAME FREE OF THE ATTACH BRACKET. UPON INVESTIGATION IT WAS FOUND THAT A WASHER WAS MISSING FROM THE RETAINING BOLT. THIS MISSING WASHER WAS LEFT OFF THE BOLT AT INSTALLATION BY A PREVIOUS OPERATOR.

CA060425013

BOEING

CFMINT