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

404

bald eagle watching over three eggs

MARCH

2012

 


CONTENTS

AIRPLANES

CESSNA...................................................................................................................................... 1

DE HAVILLAND......................................................................................................................... 3

PIPER........................................................................................................................................... 6

POWERPLANTS

AEC PISTON............................................................................................................................ 11

CONTINENTAL....................................................................................................................... 13

ACCESSORIES

CONTINENTAL MAGNETO................................................................................................... 15

AIR NOTES

INTERNET SERVICE DIFFICULTY REPORTING (iSDR) WEB SITE................................... 19

IF YOU WANT TO CONTACT US......................................................................................... 21

AVIATION SERVICE DIFFICULTY REPORTS...................................................................... 21

 


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

AVIATION MAINTENANCE ALERTS

The Aviation Maintenance Alerts provides the aviation community with an economical means to exchange service experiences and to assist the FAA in improving aeronautical product durability, reliability, and safety.  We prepare this publication from information operators and maintenance personnel who maintain civil aeronautical products pertaining to significant events or items of interest.  At the time we prepared this document, we have not fully evaluated the material.  As we identify additional facts such as cause and corrective action, we may publish additional data in subsequent issues of the Alerts.  This procedure gives Alerts’ readers prompt notice of conditions reported to the FAA Service Difficulty Reporting System (SDRS).  We welcome your participation, comments, and suggestions for improvement.  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

Cessna:  208B; Cracked Bulkhead; ATA 5312

This submitter states, "The aft canted bulkhead (P/N 2612060-5) at station 474.40 has two cracks, each approximately 1.5 inches in length.  During removal of this part, other damage was found.  Both vertical stabilizer webs (P/N's 2631021-15 and 2631022-2) were replaced because of significant fretting, (so too) the aft bulkhead assembly (P/N 2612059-1)."

CRACKED FRAME.


 

CRACKED FRAME.

Part Total Time:  18,405.0 hours

 

Cessna:  750; Bent Speed Brake Push Pushrod; ATA 2701

"When deploying speed brakes, the handle must be continuously held in position or the air load will stow the panels," says a corporate defect report.  "A visual inspection revealed the speed brake pushrod to be installed upside down and bent—causing it to rub against the thrust reverser solenoid and preventing full travel of the speed brake handle.  It was confirmed with Cessna Engineering that the pushrod should be installed with adjustable end up—and the rod should be straight, not bent.  The pushrod was replaced with new (P/N 6760270-36).  Operational checks were satisfactory."


 

BENT CONTROL ROD.

 

BENT CONTROL ROD.

 

Part Total Time:  (unknown)

 

de Havilland:  DHC8103; Corroded Aileron Control Shaft; ATA 2710

An air carrier operation writes, "Roll control was very stiff.  (We checked) the tension of the aileron fuselage cables and lubricated the aileron quadrant bearings externally for (initial) troubleshooting."  "We replaced the L/H and R/H bearings in the aileron quadrant IAW Mod Kit 8MK0930-001 instructions and the AMM 27-12-31.  The control cable tensions (and their safeties) were not disturbed.  The L/H aileron control shaft (P/N 82740083-101) was replaced due to corrosion."


 

CORRODED AILERON CONTROL SHAFT.

 

CORRODED AILERON CONTROL SHAFT.


 

CORRODED AILERON CONTROL SHAFT.

 

CORRODED AILERON CONTROL SHAFT.


CORRODED AILERON CONTROL SHAFT.

Part Total Time:  50,244.0 hours

 

Piper:  PA28-180; Worn Fuel-select Valve; ATA 2823

A general aviation mechanic writes, "When the fuel tank selector valve (P/N 756645) was rotated it was stiff to move, and the detents could not be felt at each position.  A teardown showed the valve was very dirty inside, and the detent ring was worn.  A review of Airworthiness Directives (AD's) and Service Bulletins (SB's) revealed two bulletins that directly involve problems with this valve.  This defect (worn and dirty) led to improper fuel selection (position), greatly reducing fuel flow and causing stoppage of the engine.

      "1.  SB 0355:  Fuel Selector Valve Lubrication.  I was unable to locate a sign-off in the maintenance records of (compliance) with this bulletin.

      "2.  SB 0840:  Fuel Selector Valve Cover Replacement.  I was unable to locate a sign-off in the maintenance records of (compliance) with this bulletin.  This bulletin deals directly with preventing the pilot from inadvertently moving the valve to the 'off' position.  Piper considers this SB to be mandatory.  No AD was found."


 

FUEL SELECTOR VALVE COVER.


 

FUEL SELECTOR VALVE OPENED.


FUEL SELECTOR VALVE PARTS EXPOSED.

(Note:  the last photo was stretched horizontally to fit the page—and my sense of "symmetry"—Ed.)

Part Total Time: 6,961.0 hours

 

Piper:  PA31-350; Cracked Main Gear Fittings; ATA  3211

(A technician for an air carrier operation provides the following report. His reference can be found at:  http://www.niar.twsu.edu/researchlabs/aa_overview.asp.)

"(Topic:)  Cracks in the Aft Main Gear Side Brace Fitting Assembly (P/N 40294-00).  The Aging Aircraft Lab at the National Institute for Aviation Research (NIAR) in Wichita, Kansas recently produced a report titled, 'The Aging Airplane Study:  Piper Navajo Chieftain.'  Based on their findings, we initiated a dye penetrant inspection program on the forward and aft main gear Side Brace fitting assemblies on our Piper Chieftain Navajo fleet.  The inspection of our aircraft revealed several of the aft fitting assemblies on both the left and right landing gear have cracks located in the lower inboard web of the Side Brace (Piper P/N 40294-00).  As a result of finding these cracks, we have added a 1,000 hour Special Inspection to our PA31-350 AAIP (Aging Airplane Inspection Program) to monitor and replace any assemblies exhibiting the cracking found in the fitting assemblies.  It is interesting to note these cracks have only been found in the aft assemblies on our aircraft."


TWO SIDE BRACE FITTINGS AND POSITIONS OF CRACKS SHOWN.

 

(Thanks for sharing this "heads-up"—and appreciation for NIAR at Wichita State—Ed.)

Part Total Time:  (unknown)

 


Piper:  PA34-200T; Frozen Aileron/gap Seals; ATA 2710

A general aviation pilot says, "I recently had the 'Knots 2U' aileron gap seals (Supplemental Type Certificate SA729GL) installed on my PA34.  In February I departed (my airport) and climbed through moderate to heavy precipitation for 10 to 15 minutes, leveling off at 9,000 feet.  This altitude was below freezing.  I set my autopilot for straight and level flight, (but) after ten minutes I noticed the airplane was veering off heading and beginning to enter a slight bank.  I shut off the autopilot and leveled the airplane, noticing the aileron control seemed very stiff.  I then pulled the circuit breaker for the autopilot and the electric trim to ensure they were disengaged.  After four to five more minutes in level flight the ailerons went from being very stiff to completely frozen.  I was forced to control the airplane with only rudder and elevator inputs.  Later in the flight I descended to above freezing temperatures and the aileron control slowly returned.  Subsequent inspection on the ground revealed no aileron control abnormalities.  I believe the precipitation encountered during the climb froze the ailerons to the gap seals when the airplane entered below freezing temperatures.  I called the STC holder to discuss this issue...."  "This safety hazard could easily lead to a complete loss of aircraft control (and fatalities) if not addressed (in) the STC or by an AD (Airworthiness Directive)."

Part Total Time:  50.0 hours

 

POWERPLANTS

AEC Piston:  AEC646263; Blown Piston; ATA 8530

An engine mechanic states, "(After) approximately 300 hours of (operation) the number five cylinder on this Continental O-470R engine experienced piston failure—appearing at first impression to be caused by detonation.  However, (I) believe this piston (P/N AEC646263) to have failed due to a flaw in its manufacture—or (it may have) experienced damage (such as a fall to the floor) prior to installation in the engine.  It is my belief this failure occurred over a period of several hours by combustion gasses slowly eroding the edge of the piston...."


 

DIRTY AND BURNED PISTON.


 

DIRTY AND BURNED PISTON.

 

(Very nice photos of a very ugly piston.  Thanks for your submission—Ed.)

Part Total Time:  300.0 hours (approximate)

 

Continental:  GTSIO520L; Broken Camshaft Gear; ATA 8520

"(I) was complying with AD 07-05-15 and performing an Annual Inspection," states this submitter, "when I found one broken tooth on the camshaft gear.  No other indications were found of related defects or damage, internally or externally, after the engine was disassembled.  And no metal (or the gear tooth) was found in the oil filter or internal to the engine.  (Note:)  The camshaft gear P/N 656914 supersedes P/N 537432."


BROKEN CAMSHAFT GEAR.

 

BROKEN CAMSHAFT GEAR.


 

BROKEN CAMSHAFT GEAR.

 

(Nice camera—even better eyeballs; thank-you for the effort—Ed.)

Part Total Time:  1,828.0 hours

 

ACCESSORIES

Continental Magneto:  S6RSC-25P; Failed Distributor Gear; ATA 7414

(This report—and the following report—comes to us from Hungary by way of the European Aviation Safety Agency.  Both reports reference the same Cirrus SR22 airplane and Continental IO550N engine, but different magnetos.)

A mechanic writes, "The crew reported severe engine vibration and raised EGT (exhaust gas temperature) at the same time in cylinder number three.  A quick inspection on the ground revealed the R/H magneto to be inoperative.  The operator decided to replace the magneto (P/N 10-500556-101) with a brand new one.  After replacement was accomplished, further investigations followed:  cylinder differential compression check; spark plug check.  During this additional (inspection) we also found the ceramic on the upper spark plug of number three cylinder to be broken.  It was replaced, and a test flight conducted.  We climbed to 18,000 feet—everything reported normal.

"During disassembly of the magneto, the distributor gear (was found to have failed).  This (defect) might have caused an engine in-flight shut down that could lead to a loss of control.  This magneto was replaced...."


 

STRIPPED MAGNETO DISTRIBUTOR GEAR.


 

GEAR TEETH CAPTURED IN HOUSING.

 

(Thank-you for this report and its photos.  Readers should note the next report, especially the magneto service times—Ed.)

Part Total Time:  673.0 hours

 

Continental Magneto:  S6RSC-25P; Failed Distributor Gear; ATA 7414

(Please note the preamble in the previous report.  This report is "scene two"—less than two hours later....)

Again our mechanic says, " The crew reported severe engine vibration during takeoff.  Quick inspection on the ground revealed the L/H magneto was inoperative.  (As before...) the operator decided to replace the magneto with a brand new one.  Disassembly of the magneto (P/N 10-500556-101) found the distributor gear to have failed."

"We (note) the magneto overhaul manual does not include mandatory replacement of the distributor gear.  We would highly recommend this (suggestion) to the manufacturer...."


 

MAGNETO DATA PLATE.


STRIPPED DISTRIBUTOR GEAR--SEEN THROUGH HOUSING INSPECTION PORT.

Part Total Time:  674.0 hours

 

AIR NOTES

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) database 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, 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/Query.aspx.


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.

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 database 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 following address.

The SDRS and iSDR web site point of contact is:

Pennie Thompson
Service Difficulty Reporting System, Program Manager
Aviation Data Systems Branch, AFS-620
P.O. Box 25082
Oklahoma City, OK 73125
Telephone: (405) 954-5313
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 processed for the previous month, which have been entered into the FAA Service Difficulty Reporting System (SDRS) database. 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

2011FA0000747

 

 

 

TIRE

MISMANUFACTURED

11/17/2011

 

 

 

 

MLG  

MIXED RUBBER COMPOUND WITH POOR SULPHUR DISPERSION WAS DETECTED BY MFG DURING PRODUCTION.

2011FA0000753

 

 

 

INDICATOR

FAILED

11/9/2011

 

 

 

5473032101

LOX  

LOX INDICATOR FAILED INSPECTION IAW APPROVED ICA. THESE INDICATORS ARE NOT INSTALLED ON AN ACFT. PROBABLE CAUSE IS EXCEEDED ITS LIFE LIMIT BEFORE TESTING. REPAIR STATION IS IN CONTACT WITH THE MFG TO DETERMINE ROOT CAUSE.

2011FA0000754

 

 

 

WIRE

DAMAGED

11/2/2011

 

 

 

 

CONTACTOR

DURING DISASSEMBLY OF THE GENERATOR, ON THE START CONTACTOR REPAIR EVALUATION, FOUND THE 2 RED WIRES CONNECTING THE FRONT AUXILLIARY SWITCH TO TERMINAL POSTS 13 AND 14 HAD BLACK SHRINK TUBING INSTALLED. WHEN THE SHRINK TUBING WAS REMOVED FOR INSPECTION, THE CONDITION OF THE WIRES WERE FOUND TO BE UNACCEPTABLE. THE INSULATION WAS MELTED AND THE WIRES WERE HARD TEMPERED FROM EXCESSIVE HEAT AND CURRENT.

2011FA0000756

 

 

 

O-RING

WRONG PART

11/21/2011

 

 

 

M202331

FIRE EXTING

THE PART IS A FAA-PMA APPROVED PART USED ON WATER PORTABLE SOLUTION FIRE EXTINGUISHER, PN 892480, CMM 26-20-2O. O-RING PN M202331 IS USED TO CREATE A SEAL BETWEEN THE CO2 CARTRIDGE AND IT'S PIERCING ASSY, THE O-RING IS SEATED IN AN INTERNAL GROOVE ON THE PIERCER ASSY. THE O-RING IS NOT THE CORRECT SIZE, IN BEING IT IS TOO LARGE, THE PART CREATES A SEAL. WHEN YOU TURN THE ACTUATION HANDLE, WHICH IN TURN BY MEANS OF A SPRING PROVIDES PRESSURE AGAINST THE C02 CARTRIDGE AS THE HANDLE IS TURNED TOWARDS THE CHARGING POSITION AND IS PIERCED BY A SMALL HOLLOW PIN, THIS ALLOWS THE CO2 TO CHARGE THE EXTINGUISHER READY FOR USE. THE EXTINGUISHER IS FIRED BY DEPRESSING THE OPERATING TRIGGER. THE O-RING HELPS TO CREATE A SEAL TO ALLOW THE ENTIRE CONTENTS OF THE CO2 CARTRIDGE TO EMPTY INTO THE EXTINGUISHER CYLINDER.

Z2KR2011FA0000761

 

 

 

COFFEEMAKER

SHORTED

11/28/2011

 

 

 

400179402

ZONE 900

REPAIR STATION HAS RECEIVED A LIMITED NUMBER OF COMPLAINTS OF 400-1794-02 BREWERS CAUSING ELECTRICAL SHOCK TO F/A. IN-HOUSE GROUND TESTING OF THE POWERED BREWER SITTING ON A METAL SURFACE, WITH A STEADY STREAM OF WATER DIRECTLY ONTO THE POWER SWITCH INDICATED THAT THE WET COFFEE BREWER SWITCH CAN CAUSE ELECTRICAL SHOCK TO THE OPERATOR. IF THE BREWER IS OPERATED IAW STANDARD OPERATING PROCEDURES, THERE ARE NO HAZARDS.

2012FA0000090

 

 

 

CONNECTOR

MISMARKED

1/27/2012

 

 

 

R015S10GEX

 

RECEIVED A CONNECTOR IN A KIT FOR A QUICK DISCONNECT TO BE USED IN A SATELLITE PHONE SYS IN THE CABIN. ALL CONNECTIONS WERE MADE ACCORDING TO THE PRINT. SYS CHECK OUT WAS STARTED AND FOUND THAT 1 OF THE NEWLY INSTALLED CABIN PHONES DID NOT WORK. DURING TROUBLESHOOTING, FOUND THE PIN HOLE NUMBERING SYS DIFFERENT WHEN COMPARING THE 2 DIFFERENT SIDES. BECAUSE OF THIS MIS-NUMBERING, IT CAUSED THE PHONE TO BECOME INTERNALLY DAMAGED AND UNUSUABLE. TO PREVENT THIS INCIDENT FROM HAPPENING AGAIN, ALL" IN STOCK" SPAR CONNECTORS WERE VERIFIED FOR PROPER NUMBERING AND 4 ADDITIONAL CONNECTORS WERE FOUND PURCHASED FROM A DIFFERENT VENDOR. THESE 4 CONNECTORS WERE PURGED FROM STOCK.

2012FA0000096

 

 

 

LIFE VEST

FAILED

2/6/2012

 

 

 

PO723E105P

 

LIFE VEST FAILED CELL PSI TEST.

2012FA0000097

 

 

 

LIFE VEST

NO TEST

2/6/2012

 

 

 

PO723103W

 

LIFE VEST FAILED CELL PRESSURE TEST.

2012FA0000069

 

 

CONT

CAPACITOR

FAILED

1/26/2012

 

 

 

AB51676

MAGNETO

INSTALLED NEW CAPACITOR AS PART ON 500 HR INSPECTION ON 1/20/2012. ON FIST FLIGHT DATE 1/21/2012 CUSTOMER SAID HE HAD LOSS OF POWER WITH LOOPING RPM APPROXIMATELY 45 MINUTES INTO FLIGHT. THIS RESULTED IN UNSCHEDULED LANDING. INVESTIGATION FOUND THAT THE NYLON POINT’S FOLLOWER WAS MELTED TO THE STEEL ARM. THIS IS THE SECOND CAPACITOR WITH THE SAME BATCH NUMBER / DATE CODE OF 11-20 THAT HAS FAILED WITHIN THE LAST WEEK THE FIRST FAILED DURING FINAL TEST INSPECTION.

2012FA0000084

 

 

 

LIFE VEST

FAILED

2/2/2012

 

 

 

PO201105

 

DEVICE FAILED THE CELL PRESURE TEST.

2012FA0000085

 

 

 

LIFE VEST

FAILED

2/2/2012

 

 

 

PO201105

 

DEVICE FAILED THE CELL PRESSURE TEST.

2012FA0000087

 

 

 

LIFE VEST

FAILED

2/2/2012

 

 

 

S213506300

 

LIFE PRESERVER FAILED CELL PRESSURE TEST.

2011FA0000788

 

CONT

CONT

DIAPHRAGM

DETERIORATED

12/12/2011

 

IO550B

 

 

FLOW DIVIDER

ENGINE LOST POWER IN FLIGHT, MADE A PRECAUTIONARY LANDING AND COULD NOT BE RESTARTED. PROBLEM WAS AN EXTREMELY HARDENED DIAPHRAGM IN THE ENGINE'S FLOW DIVIDER. THE DIAPHRAGM WAS SO INFLEXIBLE THAT THE FLOW DIVIDER CLOSED AND COULD NOT BE OPENED NO MATTER HOW MUCH FUEL PRESSURE WAS APPLIED TO THE INLET OF THE FLOW DIVIDER. THE DATE CODE ON THE DIAPHRAGM WAS FROM 2007. UNKNOWN CAUSE FOR THE PROBLEM BUT A POSSIBLE FUEL CONTAMINATION OR ADDITIVE CAUSING A REACTION THAT CAUSED THE DIAPHRAGM TO HARDEN IS SUSPECT.

DT1R2012020500002

AGUSTA

 

 

SEAL

DISCOVERED

2/5/2012

A119

 

 

109036001185

PAX DOOR WINDOW

PILOT AND CO-PILOT DOOR WINDOW SEALS FOUND NOT TO HAVE ADHEASIVE/SEALANT APPLIED. APPLIED SEALANT RTV 732 TO COCKPIT DOOR WINDOWS IAW TEMPORARY MAINTENANCE INSTRUCTION NR 109-244.

DT1R2012020800003

AGUSTA

 

 

SEAL

MISINSTALLED

2/8/2012

A119

 

 

109036001185

ZONE 800

PILOT AND CO-PILOT DOOR WINDOW SEALS FOUND NOT TO HAVE ADHEASIVE/SEALANT APPLIED. APPLIED SEALANT RTV 732 TO COCKPIT DOOR WINDOWS IAW TEMPORARY MAINTENANCE INSTRUCTION NR 109-244.

2011FA0000759

AGUSTA

 

RFDAVIATION

TUBE

MISSING

11/26/2011

AW139

 

 

 

LIFE RAFT

DURING FIRST SCHEDULED INSPECTION SINCE MFG OF LIFERAFT, FOUND THAT SURVIVAL KIT CONTAINED AN INCORRECT MANUAL INFLATION PUMP. CORRECT PUMP HAS AN INTEGRAL HOSE. INSTALLED PUMP HAD NO HOSE, A FITTING INCOMPATIBLE WITH THE TOP BUOYANCY TUBE MANUAL INFLATION RECEPTACLE AND UNABLE TO REACH THE LOWER MANUAL INFLATION RECEPTACLE. IF LIFERAFT NEEDED TO BE DEPLOYED, THE INSTALLED MANUAL INFLATION PUMP COULD NOT BE USED.

2012FA0000006

AMD   

 

 

CONNECTOR

SHORTED

12/13/2011

FALCON

 

 

 

LIGHT

LIGHT ASSY, UNIT SUPPLIES 28VDC AISLE MARKER LIGHTING AND 6VDC AISLE PATH EMERGENCY LIGHTING. THE LIGHT ASSY ON THIS ACFT WAS MOUNTED AT THE INBD BOTTOM CUT OUT OF THE AFT RT DIVAN ARM REST. THE ARM REST HAD 2 MARKED AREAS, 1 ON FWD FACE OF ARM REST NEAR LIGHT ASSY, AND 1 NEAR CTR TOP FWD EDGE. BOTH MARKED AREAS WERE AT LOCATIONS OF INSERTS. TECHS PERFORMED A CONTINUITY ON THE REMOVED LIGHT ASSY AND NOTED THE ASSY CASE HAD CONTINUITY TO PIN "1" OF THE CONNECTOR. PIN "1" IS THE 28VDC SUPPLY INTO THE ASSY. THE CABINET HAS BEEN REPAIRED AND THE LIGHT ASSY WAS REPLACED WITH A NEW UNIT.

2012FA0000041

AMD   

 

 

HOSE

OBSTRUCTED

1/19/2012

FALCON10

 

 

FAL1007

ZONE 500

POST FLIGHT INSP REVELED ICE BUILD UP ON LT OTBD WING SLAT. PERFORMED ACFT RUN-UP TO TEST THE SLAT ANTI-ICE SYS AND USING A TEMPERATURE GUN FOUND THE SLAT TEMPERATURE ON THE OTBD SECTION TO BE HALF OF THE OTHER 3 SECTIONS. INSPECTION FOUND THAT THE HOT AIR SUPPLY HOSE TO THE OTBD SLAT WAS PARTIALLY BLOCKED BECAUSE OF A SEPARATION OF THE INNER LINER OF THE HOSE WHEN IT GETS WARM. WE REPLACED THE HOSE AND LEAK CHECKED THE SYS AND RETURNED THE ACFT TO SERVICE. NO FURTHER ISSUES.

DXTR20120207001

AMD   

 

 

RETAINING CLIP

MISSING

2/7/2012

FALCON2000

 

 

 

SEAT BELT

PASSENGER SEAT BELT ) FOUND WITH RETAINING CLIP MISSING. R & R SEAT BELT.

2012FA0000000

AMRGEN

 

 

STRUT

DEBONDED

8/18/2011

AA5A

 

 

 

NLG  

NOSE STRUT DISBONDED AT NOSE FORK BEARING SPINDLE. SPINDLE AND STRUT ARE BONDED VIA A HOT BOND AGENT WHILE IN AUTOCLAVE. SUSPECT DISBONDING OCCURED DUE TO UNREPORTED HARD LANDINGS AND EXTREME STRESS DUE TO IMPROPER GROUND HANDLING.

2011FA0000803

BEECH

 

 

MOUNT

CRACKED

12/7/2011

400A

 

 

45A34361005

LT ENGINE

DURING THE REMOVAL OF THE LT ENGINE, IT WAS NOTICED THAT THE LT ENGINE MOUNT HAD A LARGE CRACK.

2012F00030

BEECH

PWC   

 

ROLL SERVO

BINDING

12/26/2011

400A

JT15D5D

 

6225027002

ZONE 100

UPON LANDING YOKE WOULD NOT TURN TO THE RIGHT. HAD NO CONTROL.

2012FA0000104

BEECH

WILINT

 

SHUTOFF VALVE

FAILED

1/18/2012

400A

FJ443A

 

5915001

BLEED AIR SYS

DURING FLIGHT, LEFT HIGH FLOW PRESSURE RELIEF/SHUTOFF VALVE FAILED TO REGULATE LT ENGINE BLEED AIR RESULTING IN DOWN STREAM OVER PRESSURE CONDITION CAUSING THE OVER PRESSURE RELIEF VALVE TO OPEN PREVENTING WHICH FURTHER DAMAGED TO DOWN STREAM COMPONENTS. FAILING VALVE WAS RETURNED TO MFG ON 17 JAN 2012 FOR EVALUATION. MFG FAILURE ANALYSIS DETERMINED THE PISTON RETURN SPRING FRACTURED.

2011FA0000804

BEECH

WILINT

 

BEARING

FAILED

12/9/2011

400A

FJ443A

 

 

RT ENGINE

WHILE PERFORMING A 200 HR A INSPECTION ON THE RT ENGINE OF ACFT, THE MAGNETIC CHIP COLLECTORS WERE REMOVED FROM THE GEAR BOX AND OIL TANK. METAL PARTICLES WERE FOUND ON BOTH COLLECTORS. OIL SOAP SAMPLES WERE SENT TO FOR EVALUATION. THE OIL FILTER ANALYSIS REPORT SHOWS HIGH IRON DEBRIS CONTENT. THE MAJOR SOURCES OF THE IRON ARE FROM M50 AND SAE 52100. THIS INDICATES BEARING ISSUES HAVE DEVELOPED WHICH REQUIRE THE ENGINE TO BE REMOVED AND RETURNED TO REPAIR STATION.

2012FA0000008

BEECH

 

 

SCREW

MISINSTALLED

1/5/2012

58   

 

 

MS27039109

ZONE 600

DURING ANNUAL INSPECTION FOR IMPORTATION TO US, THE RT AILERON WAS OBSERVED TO BE MISALIGNED WITH THE WING. INSPECTION REVEALED BOTH UPPER OTBD AILERON MOUNTING SCREWS WERE NOT ENGAGING HINGE NUTPLATES. THIS ALLOWED THE AILERON TO MOVE AFT AND DOWN WITH POTENTIAL FOR INFLIGHT SEPARATION. AILERON WAS REMOVED, INSPECTED AND REINSTALLED IAW THE MM USING NEW HARDWARE. ACFT HAS 1 HR FLIGHT TIME SINCE ANNUAL INSPECTION WAS COMPLETED.

2012FA0000009

BEECH

 

 

HANDLE

WORN

1/5/2012

58   

 

 

364200151

ZONE 800

DURING ANNUAL INSPECTION FOR IMPORT TO US, THE INTERIOR CABIN DOOR HANDLE WAS FOUND SEVERELY WORN. THE HANDLE COULD BE RELEASED WITHOUT PUSHING THE LOCKING BUTTON WITH THE POTENTIAL FOR ACCIDENTAL OPENING OF THE CABIN DOOR. AD 97-14-16 AND SB 2693 ADDRESSES THIS ISSUE AND HAD BEEN COMPLIED LONG AGO. THE AD AND & SB ONLY REQUIRES REINSPECTION IF DOOR HANDLE IS REMOVED. RECOMMEND THE AD BE REVISED TO INSPECT AT 100 HR/ANNUAL INSPECTIONS. A NEW REVISED DESIGN HANDLE WAS INSTALLED. NOTE, ACFT HAS 1 HR SINCE ANNUAL INSPECTION WAS COMPLETED.

FCPR20121121001

BEECH

 

 

BRACKET

CRACKED

11/21/2011

58   

 

 

969100501

ZONE 400

WHILE PERFORMING OTHER MX, FOUND RT ENGINE FUEL FLOW TRANSDUCER BRACKET CRACKED. REPLACED BRACKET WITH NEW.

W59R2011112930999

BEECH

CONT

MCAULY

HUB   

CRACKED

11/29/2011

58   

IO520C

 

 

PROPELLER

PROPELLER SUBMITTED FOR INSPECTION FOR THE CAUSE OF RED OIL LEAK IAW AD 91-15-04. PROPELLER WAS DISASSEMBLED AND BLADE RETENTION THREADS OF THE HUB SN 723369 WERE EDDY CURRENT INSPECTED. THE HUB WAS FOUND CRACKED IN THE RETENTION THREADS. THE BLADE COUNTERWEIGHTS WERE ALSO FOUND UNDERTORQUED AND 1 HAD ROTATED OUT OF PROPER ALIGNMENT WHICH WAS FOUND TO BE CONTRIBUTING TO A LOW STATIC RPM CONDITION.

2012FA0000107

BEECH

CONT

 

ARM   

FAILED

1/27/2012

58   

IO550C

 

9581001723

NLG  

LANDING GEAR ACTUATOR ARM, FOR THE NLG RETRACTION FAILED, ALLOWING THE NLG TO COLLAPSE UPON LANDING.

2012FA0000102

BEECH

CONT

 

CYLINDER

CRACKED

2/9/2012

58P   

TSIO520WB

 

 

ENGINE

LT ENGINE CYLINDER FOUND TO BE CRACKED AT FUEL INJECTOR NOZZLE HOLE. NEW CYLINDERS WERE INSTALLED AT ENGINE O/H.

2012FA0000046

BEECH

 

 

HINGE FITTING

CRACKED

1/13/2012

77   

 

 

 

CREW DOOR

DURING AN ANNUAL, DISCOVERED A WELDED REPAIR TO A CRACK ON THE PILOT-SIDE DOOR ON THE INNER SKIN BELOW THE RIVETS THAT FASTEN THE LOWER HINGE TO THE DOOR. WHILE THIS DOOR IS SERVICEABLE, THE SAME CRACK EXISTED ON ANOTHER ACFT SERVICED EARLIER. THE CRACK WAS APPROX 3-4" LONG AND THE PREVIOUS MECHANIC HAD TRIED TO (UNSUCCESSFULLY) DRILL-STOP IT. IT IS UNCLEAR HOW FAR THE CRACK EXTENDED. THIS CRACK DID NOT EXIST ON THE CO-PILOT DOOR ON EITHER AIRPLANE, LIKELY DUE TO HEAVIER WEAR ON THE PILOT SIDE. PROBABLE CAUSE IS LIKELY BOTH THE OPERATOR USING EXCESSIVE FORCE AND INADEQUATE REINFORCEMENT FOR THE DOOR HINGE. A REPAIR CAN LIKELY BE MADE WITH MULTIPLE METHODS IAW 43.13-1B CHG 1?OpenDocument')">AC 43.13-1B, CHAP 4, SEC 4. RECOMMEND THAT THE AFFECTED AREA OF THE DOOR BE INSPECTED EVERY 100 HRS OR DURING ANNUAL, WHICHEVER COMES FIRST. UNCLEAR AT THIS TIME IF DRILL-STOPPING DURING THE EARLY DEVELOPMENT OF A CRACK WILL BE SUCCESSFUL.

2011FA0000787

BEECH

PWA   

 

PITOT TUBE

MISMARKED

12/9/2011

A200

PT6A41

 

PH5023

ZONE 100

DURING ALTIMETER AND PITOT STATIC SYSTEM RE-CERTIFICATION, THE TECH OBSERVED THAT THE LT PITOT TUBE WAS INCORRECT AND WAS ACTUALLY A RT PITOT TUBE. UPON FURTHER INVESTIGATION, THE PN WAS MIS-IDENTIFIED AS A LT PITOT TUBE PN PH502-3 WHEN ACTUALLY THE DRAIN HOLE AND IMBOSSED "TOP" MARK WERE CONSISTENT WITH A RT PITOT TUBE PN PH502-5. THESE PARTS ARE ALSO SOLD UNDER THE PN 50-384040-3 (LT) AND 50-384040-5 (RT).

2012FA0000005

BEECH

CONT

 

ADAPTER

BROKEN

12/7/2011

A36   

IO550R

 

 

STARTER

ENGINE FAILS TO START, PROP WAS LOCKED SOLID. STARTER ADAPTER REMOVED TO FIND 2 GEAR TEETH MISSING. EMERGENCY AD 2011-25-51 SEEMS TO BE RELEVANT TO THIS FAILURE BUT DOES NOT COVER THIS ENGINE TYPE AND STARTER PN. UNABLE TO ASCERTAIN ENGINE HOURS, BUT BELIEVE THEM TO BE IN THE REGION OF 100-200 HOURS.

2012FA0000098

BEECH

GARRTT

 

BEARING

FAILED

2/7/2012

B100

TPE3315

 

31080981

TURBINE SECTION

PILOT REPORTED DURING CLIMB OUT OF FL200 FOR FL210 NOTICED THE RT ENGINE EGT RISING. FELT A VIBRATION AND NOTICED THE OIL PRESSURE INDICATOR FLUCTUATING FROM GREEN TO YELLOW AND NOTICED THE TORQUE INDICATOR FLUCTUATING IN 400 FT/LBS INCREMENTS. CONDUCTED AN ENGINE SHUTDOWN, DECLARED AN EMERGENCY, RAN THE APPROPRIATE PRECAUTIONARY ENGINE SHUTDOWN CHECKLIST, AND RETURNED TO DEPARTURE. DURING ENGINE TEARDOWN, FOUND THE REAR TURBINE BEARING APPEARED TO HAVE FAILED, WHICH CAUSED INTERNAL TURBINE AND COMPRESSOR SHIFT AND RUB.

HSRR2011122800001

BEECH

 

 

STRUCTURE

CRACKED

12/28/2011

B200

 

 

 

PAX DOOR

CRACKS INSIDE DOOR STRUCTURE FOUND.

J8UR20111219001

BEECH

 

 

CONNECTOR

CHAFED

12/19/2011

B300C

 

 

MS3456L16S

ZONE 400

RT FUEL SHUT-OFF VALVE ELECTRICAL CONNECTOR IS COMING IN CONTACT WITH ACCESS PANEL NUTPLATE ON RT NACELLE (PANEL NR 5RH). THE CLOSE PROXIMITY OF THE FIREWALL ELECTRICAL CONNECTOR AND THE ACCESS PANEL NUTPLATE CAUSED WIRING TO BECOME CHAFED. NUTPLATE PROTRUDES INTO ELECTRICAL CONNECTOR AND BACKSHELL CAUSING INTERMITTENT SHORTING IN TURN CAUSING RT FIREWALL SHUT-OFF VALVE CAUTION LIGHT TO FLICKER IN-FLIGHT.

J8UR20120118001

BEECH

PWA   

 

PRESSURE SWITCH

FAILED

1/18/2012

B300C

PT6A60A

 

5038912129

AUTOFEATHER SYS

PROPELLER AUTO-FEATHER DOES NOT TEST DURING GROUND AND PRE-FLIGHT ENGINE RUNS. GROUND IDLE SOLENOID FAILS TO OPERATE PROPERLY.

VJ3S2011FA0000766

BEECH

CONT

 

CIRCUIT BREAKER

FAILED

12/1/2011

F33A

IO520*

 

35380132203

ZONE 100

PILOT REPORTED LANDING LIGHT INOPERATIVE. ON TROUBLESHOOTING TECH FOUND CIRCUIR BREAKER TO BE AT FAULT. CIRCUIT BREAKER HAD BEEN REPLACED, 1303 FLIGHT HOURS PRIOR AND ESTIMATED CYCLES 5212. NOTIFIED NEW CIRCUIT BREAKER MANUFACTURER.

VJ3R2012FA0000028

BEECH

CONT

 

CIRCUIT BREAKER

BROKEN

1/13/2012

F33A

IO520*

 

35380132101

TAXI LIGHTS

PILOT REPORTED TAXI LIGHT INOPERATIVE. ON TROUBLESHOOTING THE TECH FOUND THE CIRCUIT BREAKER AT FAULT. INSTALLED NEW CIRCUIT BREAKER. OPS CHECKED OK. SWITCH THAT FAILED WAS INSTALLED TO COMPLY WITH AD 2008-13-17. THIS ACFT HAS HAD 4 OF THE IMPROVED CIRCUIT BREAKERS FAIL IN THE LAST 830 HRS OF OPERATION.

VJ3R2012FA0000027

BEECH

CONT

 

CIRCUIT BREAKER

BROKEN

1/13/2012

F33A

IO520BB

 

35380132101

NAVIGATION LIGHT

PILOT REPORTED NAVIGATION LIGHTS INOPERATIVE. ON TROUBLESHOOTING, FOUND THE CIRCUIT BREAKER AT FAULT. INSTALLED NEW CIRCUIT BREAKER. OPS CHECKED OK. SWITCH THAT FAILED WAS INSTALLED TO COMPLY WITH AD 2008-13-17. THIS ACFT HAS HAD 6 OF THE IMPROVED CIRCUIT BREAKERS FAIL IN THE LAST 1400HRS OF OPERATION.

2012FA0000014

BEECH

CONT

 

CIRCUIT BREAKER

FAILED

1/8/2012

F33A

IO520BB

 

35380132103

LANDING LIGHT

PILOT REPORTED LANDING LIGHT INOPERATIVE. ON TROUBLESHOOTING, FOUND THE LANDING LIGHT CIRCUIT BREAKER AT FAULT. INSTALLED NEW LANDING LIGHT CIRCUIT BREAKER. OPS CHECKED OK.

2012FA0000015

BEECH

CONT

 

CIRCUIT BREAKER

FAILED

1/8/2012

F33A

IO520BB

 

35380132103

BEACON

PILOT REPORTED BEACON LIGHT INOPERATIVE. ON TROUBLESHOOTING, THE TECH FOUND THE BEACON LIGHT CIRCUIT BREAKER AT FAULT. INSTALLED NEW BEACON LIGHT CIRCUIT BREAKER. OPS CHECKED OK.

2012FA0000016

BEECH

CONT

 

CIRCUIT BREAKER

FAILED

1/8/2012

F33A

IO520BB

 

35380132103

BEACON

PILOT REPORTED BEACON LIGHT INOP. ON TROUBLESHOOTING THE TECH FOUND THE BEACON LIGHT CIRCUIT BREAKER AT FAULT. INSTALLED NEW BEACON LIGHT CIRCUIT BREAKER. OPS CHECKED OK.

2012FA0000095

BEECH

CONT

 

CIRCUIT BREAKER

FAILED

2/3/2012

F33A

IO520BB

 

3538013263

PITOT HEAT

PILOT REPORTED PITOT HEAT SWITCH WOULD NOT STAY IN THE ON POSITION. ON TROUBLESHOOTING TECH FOUND CIRCUIT BREAKER/SWITCH TO BE AT FAULT. AD 2008-13-17 HAD BEEN COMPLETED 2427 FLIGHT HOURS PRIOR. RECOMMEND MFG DEVELOP A MORE DURABLE CIRCUIT BREAKER OR ACFT MFG LOOK FOR A DIFFERENT MANUFACTURER FOR ITS CIRCUIT BREAKERS.

2011FA0000801

BEECH

CONT

 

CIRCUIT BREAKER

FAILED

12/24/2011

F33A

IO520BB

 

35380132101

NAVAGATION LIGHT

PILOT REPORTED NAVAGATION LIGHTS INOPERATIVE. ON TROUBLESHOOTING, TECH FOUND CIRCUIT BREAKER TO BE AT FAULT, AD 2008-13-17 HAD BEEN COMPLETED, 2160 FLIGHT HOURS PRIOR AND ESTIMATED CYCLES 8640.

2011FA0000751

BEECH

CONT

 

CIRCUIT BREAKER

UNSERVICEABLE

11/17/2011

F33A

IO520BB

 

35380132103

TAXI LIGHT

PILOT REPORTED TAXI LIGHT INOPERATIVE. FOUND THE CIRCUIT BREAKER AT FAULT. INSTALLED NEW CIRCUIT BREAKER. OPS CHECKED OK. CIRCUIT BREAKERS ARE A POOR DESIGN AND REQUIRE FREQUENT REPLACMENT.

2011FA0000783

BEECH

CONT

 

CIRCUIT BREAKER

FAILED

12/9/2011

F33A

IO520BB

 

35380132101

NAVAGATION LIGHT

PILOT REPORTED NAV LIGHTS INOPERATIVE. ON TROUBLESHOOTING, TECH FOUND CIRCUIT BREAKER TO BE AT FAULT AD 2008-13-17 HAD BEEN COMPLETED.

2011FA0000785

BEECH

CONT

 

CIRCUIT BREAKER

FAILED

12/10/2011

F33A

IO520BB

 

3538013263

PITOT HEAT

PILOT REPORTED THAT THE PITOT HEAT STAYED ON WHILE THE SWITCH WAS IN THE OFF POSITION. DURING TROUBLESHOOTING, TECH FOUND THAT THE PITOT CIRCUIT BREAKER WAS AT FAULT. THE PITOT CIRCUIT BREAKER WAS REPLACED.

2012FA0000040

BEECH

CONT

 

CIRCUIT BREAKER

FAILED

1/19/2012

F33A

IO520BB

 

35380132103

ZONE 100

PILOT REPORTED TAXI LIGHT INOP. ON TROUBLESHOOTING, TECH FOUND CIRCUIT BREAKER TO BE AT FAULT. AD 2008-13-17 HAD BEEN COMPLETED 2593 FLIGHT HOURS PRIOR AND ESTIMATED CYCLES 10372. RECOMMEND MFG IMPROVE DESIGN FOR A MORE DURABLE CIRCUIT BREAKER OR ACFT MFG SEARCH FOR A MFG WITH A MORE DURABLE CIRCUIT BREAKER.

2012FA0000082

BEECH

CONT

 

SWITCH

BROKEN

2/1/2012

F33A

IO520BB

 

3538013273

STROBE

PILOT REPORTED STROBE LIGHT SWITCH INOP. ON TROUBLESHOOTING, THE TECH FOUND THE CIRCUIT BREAKER/SWITCH AT FAULT. INSTALLED NEW CIRCUIT BREAKER/SWITCH. OPS CHECK OK. SWITCH THAT FAILED WAS INSTALLED TO COMPLY WITH AD 2008-13-17. THIS ACFT HAS HAD 6 OF THE IMPROVED SWITCHES FAIL IN THE LAST 2000 OF OPERATION.

2012FA0000083

BEECH

CONT

 

SWITCH

BROKEN

2/1/2012

F33A

IO520BB

 

3538013273

ALTERNATOR

PILOT REPORTED ALTERNATOR SWITCH INOPERATIVE. ON TROUBLESHOOTING, THE TECH FOUND THE CIRCUIT BREAKER/SWITCH AT FAULT. INSTALLED NEW CIRCUIT BREAKER/SWITCH. OPS CHECK OK. SWITCH THAT FAILED WAS INSTALLED TO COMPLY WITH AD 2008-13-17. THIS ACFT HAS HAD 6 OF THE IMPROVED SWITCHES FAIL IN THE LAST 2000 OF OPERATION.

VJ3R2011FA0000777

BEECH

CONT

 

SWITCH

FAILED

12/7/2011

F33C

IO520BB

 

35380132103

BEACON LIGHT

PILOT REPORTED THE BEACON LIGHT INOP. DURING TROUBLESHOOTING, TECH FOUND BEACON LIGHT BREAKER/SWITCH TO BE AT FAULT. THE BEACON BREAKER/SWITCH WAS LAST REPLACED 1074.8 FLIGHT HOURS PRIOR WITH AN ESTIMATED 4299.2 CYCLES. EARLY FAILURE REASON IS UNKNOWN NO RECOMMENDATIONS AT THIS TIME.

VJ3S2011FA0000767

BEECH

CONT

 

MOTOR

FAILED

12/1/2011

F33C

IO520BB

 

583800901

MLG  

PILOT REPORTED LANDING GEAR WOULDN’T EXTEND WHEN GEAR WAS SELECTED IN THE DOWN POSITION, PILOT MANUALLY EXTENDED THE GEAR AND RETURNED TO BASE. NO PROBABLE CAUSE OR RECOMMENDATIONS AT THIS TIME.

ZD4R20111201001

BELL  

ALLSN

 

BEARING CAGE

LOOSE

11/28/2011

407   

250C47B

 

23035272

GEARBOX

DURING INSPECTION OF GEARBOX FOR METAL IN OIL, IT WAS NOTED THAT 5 OF THE 6 STUDS THAT SECURE THE 2.5 BEARING CAGE TO THE GEARBOX COVER ASSY HAD BACKED OUT ALLOWING MOVEMENT OF THE CAGE INSIDE THE GEARBOX. WHILE LOOSENING HARD WEAR THAT RETAINS THE BEARING CAGE IN THE COVER ASSY, THE STUDS BACKED OUT OF THE COVER INSTEAD OF THE NUTS BACKING OFF OF THE STUDS.

HN6R201201250001

BOEING

 

 

SCREW

DISLODGED

1/25/2012

737   

 

 

 

LIGHT TRANFORMER

FOUND ONE TRANSFORMER MOUNTING SCREW DISLODGED AND FLOATING LOOSE IN UNIT CAUSING SHORT TO GROUND. SOCKET WORN. REFLECTOR FINISH WORN.

DU4R20111119020

BOEING

 

 

FLOORBEAM

CORRODED

11/19/2011

737524

 

 

 

BS 344

DURING SCHEDULED INSPECTION, FOUND CORROSION ON FLOORBEAM AT BS 344, RBL 12, LBL-11.

DU4R2011019

BOEING

 

 

SKIN

DENTED

11/24/2011

737524

 

 

 

CARGO DOOR

DENT/GOUGE AFT CARGO DOOR AT BS 820.5 AND 2.5" ABOVE STR 23R.

DU4R2011021

BOEING

 

 

FLOORBEAM

CORRODED

11/20/2011

737524

 

 

 

BS 986

DURING SCHEDULED INSPECTION, FOUND CORROSION ON AFT CABIN FLOORBEAM AT BS 986, LBL 27 - 46.

2012FA0000007

BOEING

 

 

COIL COLLAR

FAILED

7/12/2011

747400

 

 

 

CATHODE RAY TUBE

DURING MX, A NEW CATHODE RAY TUBE (CRT) HAD BEEN FITTED TO A DISPLAY UNIT. UNDER TEST, THE UNIT FAILED (DISPLAY WENT BLANK). THE FAILURE MODE WAS THAT THE POWER SUPPLY FAILED HALF WAY THROUGH THE TEST. THE NEW CRT WAS FOUND TO BE THE CAUSE. IT FOUND THAT THE DEFLECTION COIL COLLAR SECURING BOLT ON THE CTR HAD PIERCED AN ADJACENT BLACK PROTECTIVE SLEEVE AND SHORTED TO THE DEFLECTION COIL WIRES CAUSING THE POWER SUPPLY TO TRIP.

2011FA0000758

BOEING

 

 

AUTOBRAKE SYS

INTERMITTENT

11/22/2011

747SP31

 

 

26700011

MLG  

DURING LANDING, AUTO BRAKE WAS SELECTED. UPON TOUCHDOWN ALL SIXTEEN (16) MLG WHEELS WERE LOCKED, CAUSING ELEVEN (11) MAIN TIRES TO BLOW. THE CAPTAIN IMMEDIATELY DE-SELECTED AUTO BRAKE UPON RECOGNITION OF FAILURE.

ABXR2011122200053

BOEING

 

 

STRINGER

CRACKED

4/18/2011

767200

 

 

146T3001178

ZONE 100

STRINGER 33RT HAS APPROX 2" CRACK AT BS 1081 IN AFT LOWER CARGO. REPAIRED STRINGER 33RT AT STA 1081 IAW SRM 53-00-03.

ABXR2011122200054

BOEING

 

 

ANGLE

CORRODED

4/21/2011

767200

 

 

146T005126

ZONE 100

LARGE AREA OF CORROSION BENEATH R2 DOOR THRESHOLD DRAIN CHANNEL. REPLACED ANGLE IAW SRM 51-40-02.

ABXR2011122200052

BOEING

GE   

 

MOUNT

CORRODED

4/16/2011

767200

CF680C2B4

 

310U20202

NR 2 ENGINE

NR 2 ENGINE AFT MOUNT CORRODED. INSTALLED NEW MOUNT IAW AMM 71-21-02.

ABXR2012020400019

BOEING

 

 

STRUCTURE

CRACKED

2/4/2012

767231

 

 

141T293816

ZONE 100

DURING INSPECTION, FOUND RT VERICAL STRUCTURE AT STA 287, WL 159 CRACKED. REPAIRED STRUCTURE IAW SRM.

ABXR2012020400020

BOEING

 

 

CHANNEL

CRACKED

2/4/2012

767231

 

 

313T3380459

ZONE 400

DURING INSPECTION, FOUND LT AND RT CHANNELS CRACKED ON T/E OF NR 2 PYLON. REPAIRED IAW SRM.

ABXR2012020400021

BOEING

 

 

SKIN

GOUGED

2/4/2012

767231

 

 

112T41022

ZONE 600

DURING INSPECTION, FOUND RT WING FUEL PANEL CUTOUT AT WS 520 GOUGED. REPAIRED IAW REA 657-59643-MR.

ABXR2012020400022

BOEING

 

 

SKIN

CRACKED

2/4/2012

767231

 

 

148T73212

ZONE 100

DURING INSPECTION, FOUND RT FUSELAGE SKIN CRACKED AT STA 1730, S20R. R & R FUSELAGE SKIN AT STA 1730 S20R IAW SRM.

ABXR2012020400023

BOEING

 

 

SKIN

CHAFED

2/4/2012

767231

 

 

148T73214

ZONE 100

DURING INSPECTION, FOUND RT FUSELAGE SKIN AT STA 1730 CHAFED. REPLACED SKIN IAW SRM.

ABXR2012020400024

BOEING

 

 

WIRE

SHORTED

2/4/2012

767231

 

 

 

EXTERIOR LIGHT

DURING INSPECTION, FOUND WING ANTI-COLLISION LIGHTS POPS CIRCUIT BREAKER. REPAIRED SHORTED WIRING AND REPLACED SWITCH IAW SWPM.

ABXR2012020400026

BOEING

 

 

ACCESS PANEL

CRACKED

2/4/2012

767231

 

 

311T157085

ZONE 400

DURING INSPECTION, FOUND NR 2 PYLON ACCESS PANEL 446 BL CRACKED AROUND NUT PLATES. REPAIRED IAW REA B564-59630 AND SRM.

ABXR2012020400025

BOEING

 

 

SKIN

CRACKED

2/4/2012

767231

 

 

311T345021

ZONE 400

DURING INSPECTION, FOUND NR2 PYLON ACCESS PANEL 446AL FLANGE CRACKED AT NUTPLATE HOLE. REPAIRED PANEL ATTACH FLANGE IAW REA B654-59629.

ABXR2011122200581

BOEING

 

 

STIFFENER

CORRODED

6/6/2011

76725D

 

 

14T831317

ZONE 200

PANEL MARKED FWD R1 SCUFF, LOWER STIFFENER CORRODED. R & R LOWER STIFFENER ON R1 SCUFF PLATE IAW SRM 51-40-02.

ABXR2011122200058

BOEING

 

 

ACOUSTIC LINER

CORRODED

6/7/2011

76725D

 

 

2242101543

ZONE 400

NR 1 ENGINE INLET COWL INNER BARREL ACOUSTIC LINER CORRODED AT 4 O'CLOCK POSITION. REPAIRED INNER ACOUSTIC BARREL PANEL ON CWO 23052-0001 IAW ROHR MM 71-11-16, REPAIR NR 15, REV 40, FEB 1/11.

ABXR2011122200055

BOEING

 

 

STIFFENER

CORRODED

4/19/2011

76725D

 

 

143T820019

ZONE 200

STIFFENER ON WEB HAS CORROSION AT STA 610, STRINGER 16 RT. R & R STIFFENER IAW SRM 51-40-02.

ABXR2011122200056

BOEING

 

 

WIRE

CHAFED

4/21/2011

76725D

 

 

 

EMERGENCY LIGHT

WIRING FOR R2 ENTRY DOOR EMERGENCY LIGHT, DAMAGED AT FWD UPPER DOOR TRACK. REPAIRED WIRING ON R2 ENTRY DOOR EMERGENCY LIGHT L309.

2012F00021

BOEING

 

 

POWER SUPPLY

FAULTY

12/2/2011

767300

 

 

PAC5005

ZONE 200

OVERWING EMERGENCY EXIT SIGNS 4EA AND SEAT MOUNTED EMERGENCY MARKERS WOULDN'T TEST. FOUND POWER SUPPLY FAULTY.

FWTA2011FA0000792

BOEING

 

 

DRAIN LINE

LEAKING

12/13/2011

767316F

 

 

 

FUEL SYSTEM

DURING REFUELING OPERATION, FUEL LEAK DISCOVERED AT LEFT TANK CANISTER DRAIN TUBE HOUSING. PERFORMED TEMPORARY REPAIR OF DRAIN TUBE, SLAT TRACK HSG NR2.

2012FA0000063

BOMBDR

 

 

TIRE

BULGED

1/5/2012

BD1001A10

 

 

269K432

ZONE 700

BULGE ON NR 2 TIRE (PN 269K43-2) OUTER SIDEWALL CONSISTANT WITH PREVIOUS BULGES FOUND ON PN 269K43-1 TIRES. TIRE IS BEING SENT TO MFG FOR EVALUATION.

LC1R201202011501

CESSNA

 

CESSNA

SKIN

CORRODED

2/1/2012

150G

 

 

0432001550432001

HORIZONTAL STAB

DURING A PRE-PURCHASE INSPECTION, HEAVY CORROSION WAS FOUND AT THE JOINT BETWEEN THE LT STABILIZER SKIN, PN 0432001-55 AND THE RT STABILIZER SKIN, PN 0432001-54 AT THE LOWER CENTER RIVET LINE WHICH HAD EATEN AWAY NUMEROUS RIVETS, LOOSENED THE SKIN JOINT AND BEGAN TO EAT AWAY THE SKIN. THIS WILL REQUIRE REMOVAL OF THE SURFACE, A THOROUGH INSP FOR ADDITIONAL CORROSION AND PROBABLE REPLACEMENT OF BOTH SKINS.

2012FA0000012

CESSNA

LYC   

SLICK

ROTOR

LOOSE

1/6/2012

152   

O235N2C

 

K3008

DISTRIBUTOR GEAR

FOUND DURING A 500HR MAG AND IMPULSE COUPLING INSPECTION, A DEFECTIVE DISTRIBUTOR GEAR FINGER. THIS FINGER HAD WORKED LOOSE FROM ITS PLASTIC SEAT ALLOWING SOME MOVEMENT BOTH SIDE TO SIDE AS WELL AS UP AND DOWN THE SHAFT. PARTS WERE STILL FUNCTIONING WHEN DISCOVERED. THIS WAS A PROBLEM FOR BOTH THE LT AND RT MAGS OF THE SAME ENGINE.

2012FA0000067

CESSNA

 

 

ATTACH BOLT

CORRODED

1/15/2012

170B

 

 

 

ZONE 200

DURING INSPECTION OF THE WING ATTACH BOLTS, THE HEADS AND NUTS WERE FOUND CORRODED. INSTALLED NEW BOLTS AND FOUND THAT THE REMOVED BOLTS HAD SOME CORROSION ON THE SHANK. 3 OF THESE BOLTS WERE SEVERELY CORRODED WITH MAJOR PITTING ON THE SHANKS. THESE BOLTS APPEAR TO BE ORIGINAL. INSPECTED THE HOLES FOR CORROSION WITH BORESCOPE, FOUND OK.

FK8R201110240001

CESSNA

 

 

BULKHEAD

CRACKED

10/24/2011

172M

 

 

055032110

SPINNER

AFT SPINNER BULKHEAD CRACKED.

FK8R201107190004

CESSNA

LYC   

 

SUPPORT BRACKET

CRACKED

7/19/2011

172M

O320*

 

055521616

AIR BOX

AIRBOX FRONT SUPPORT BRACKET WAS FOUND CRACKED AT THE STARTER. THIS PART WAS REPLACED AT THE ANNUAL INSPECTION IN 2010.

2011FA0000776

CESSNA

LYC   

 

BATTERY  

EXPLODED

12/6/2011

172P

O320*

 

G243  

ZONE 100

ON ENGINE START-UP A LOUD POP WAS HEARD FROM UNDER THE COWL. INVESTIGATION SHOWED THAT THE BATTERY, A 24 VOLT, MODEL 243 INSTALLED IN 2007, HAD EXPLODED UPWARD. THIS BATTERY IS EQUIPPED WITH A CAST ALUMINUM SEALING COVER THAT IS HELD IN PLACE OVER THE CELLS BY THE BATTERY HOLD DOWN BOLTS. THE ALUMINUM SEALING COVER WAS DEFORMED UPWARD AND THE 2 LUGS ON ITS SIDES WERE BROKEN AWAY FROM THEIR POSITIONS. 1 CELL VENT CAP WAS FOUND BROKEN. THERE HAD OBVIOUSLY BEEN A HYDROGEN EXPLOSION WITHIN THE UPPER VENT AREA OF THE BATTERY. THE BATTERY VENT SYSTEM WAS FOUND PROPERLY CONNECTED AND OPEN. THE MAIN POST CONNECTIONS AND ALL SURROUNDING CONNECTIONS WERE FOUND TIGHT. THERE WAS MINOR DEFORMATION OF THE RIVETED SHEET ALUMINUM BATTERY HOLD DOWN CLAMP, WITH NO DAMAGE TO THE BATTERY TRAY OR SURROUNDING EQUIPMENT.

FK8R201110050002

CESSNA

LYC   

 

BEARING RACE

WORN

10/5/2011

172P

O320D2J

 

 

NLG WHEEL

NOSE WHEEL BEARING RACE WAS FOUND SPINNING INSIDE WHEEL ASSEMBLY.

FK8R201112110006

CESSNA

LYC   

 

CYLINDER

INFLT SEPARATION

12/11/2011

172P

O320D2J

 

AEL65102

ENGINE

PARTIAL POWER LOSS AND VIOLENT VIBRATION REPORTED BY PILOT DURING CLIMB, EMERGENCY LANDING WAS PERFORMED. COMPLETED VISUAL INSP OF ENGINE, FOUND NR 3 CYLINDER HEAD SEPARATED FROM CYLINDER BARREL. CYLINDER WAS O/H 87.4 HOURS BEFORE THE SEPARATION. THIS IS THE CYLINDER ASSY PN AEL65102.

2011FA0000750

CESSNA

LYC   

 

SHAFT

BROKEN

11/8/2011

172RG

O360F1A6

 

24411001

MLG ACTUATOR

RIGHT MAIN GEAR WAS DOWN BUT NOT LOCKED. PILOT PERFORMED GEAR UP LANDING. ON INSPECTION, THE RT PIVOT ASSY WAS PROTRUDING APPROX .5" OUT OF ACTUATOR. AFTER RAISING ACFT ON JACKS, HYD APPEARED TO BE WORKING PROPERLY AND POWER PACK WAS FULL OF FLUID. REMOVED RT ACTUATOR AND PIVOT ASSY. SHAFT WAS FOUND TO BE BROKEN IN 2 PIECES

2012FA0000043

CESSNA

LYC   

 

ARM   

DETACHED

1/20/2012

172S

IO360L2A

 

 

FUEL PUMP

LOST FUEL PRESSURE IN FLIGHT. FOUND FUEL PUMP ARM DETACHED FROM PUMP DIAPHRAGM.

2012FA0000080

CESSNA

 

 

CONTROL CABLE

BROKEN

1/27/2012

177   

 

 

S488567

TE FLAPS

FLAPS, 10 SELECTED AND FLAPS WENT TO FULL DOWN. FOUND CONTROL WIRE BROKEN.

2012FA0000025

CESSNA

CONT

 

CYLINDER

PEELING

1/5/2012

182L

O520*

 

 

NR 5  

METAL PARTICLES WERE FOUND IN OIL FILTER DURING OIL CHANGES, APPROX 100 HRS AFTER MAJOR O/H. ALL CYLINDERS WERE REMOVED AND INSPECTED. FOUND NR 5 CYLINDER NICKLE PLATING PEELING AT THE BASE OF THE CYLINDER. PISTON AND RINGS WERE SCUFFING THE PEELING AREA CREATING PARTICLES IN THE OIL. ENGINE HAS BEEN REMOVED FROM SERVICE AND DISASSEMBLED FOR CONTAMINATION INSP.

2012FA0000124

CESSNA

CONT

 

PISTON

FAILED

2/20/2012

182M

O470R

 

AEC646263

NR 5 CYLINDER

NUMBER 5 CYLINDER ON O-470 ENGINE WITH APPROXIMATELY 300 HOURS EXPERIENCED PISTON FAILURE DUE TO WHAT APPEARS AT FIRST IMPRESSION DETONATION. HOWEVER, PISTON IS BELIEVE TO HAVE FAILED DUE TO FLAW IN MANUFACTURE OR EXPERIENCE DAMAGE SUCH AS DROPPING PRIOR TO INSTALLATION IN ENGINE. IT IS MY BELIEF THAT THIS FAILURE OCCURED OVER A PERIOD OF SEVERAL HOURS BY COMBUSTION GASES SLOWLY ERRODING EDGE OF PISTON TO THE POINT OF FAILURE OF PISTON TO OPERATE NORMALLY WITHOUT PASSING OIL AND GASOLINE INTO INDUCTION SYSTEM THEREBY AFFECTING OTHER CYLINDERS.

RJWR20111130003

CESSNA

 

 

BUNGEE

SEIZED

11/30/2011

208   

 

 

26430651

NLG STEERING

DURING PREFLIGHT PILOT WAS UNABLE TO MOVE RUDDER, FOUND NOSE STEERING BUNGEE/SPRING ASSY SEIZED. REPLACED ASSY AND FUNCTIONAL CHECKED GOOD.

2011FA0000806

CESSNA

 

ARTEX

G SWITCH

NO TEST

4/15/2011

208B

 

 

 

ELT  

ELT G-SWITCH FAILED TEST.

2011FA0000807

CESSNA

PWA   

ARTEX

G SWITCH

NO TEST

12/27/2011

208B

PT6A114A

 

 

ELT  

ELT FAILED G-SWITCH TEST.

2011FA0000808

CESSNA

PWA   

ARTEX

G SWITCH

NO TEST

12/27/2011

208B

PT6A114A

 

 

ELT  

ELT FAILED G-SWITCH TEST.

2011FA0000809

CESSNA

PWA   

ARTEX

G SWITCH

INOPERATIVE

12/27/2011

208B

PT6A114A

 

 

ELT  

ELT FAILED G-SWITCH TEST.

2012FA0000079

CESSNA

 

 

PUMP

MISREPAIRED

1/27/2012

340A

 

 

A8150B

FUEL BOOST

FOLLOWING INSTALLATION OF A FRESHLY OVERHAULED AUX PUMP INTO THE AIRCRAFT, A FUNCTIONAL AND PRESSURE TEST WAS PERFORMED. THE PUMP WOULD RUN PUT ONLY PUT OUT 3 PSI. REQUIRED PSI IS 5. FURTHER TROUBLESHOOTING PERFORMED AND THEN PUMP WOULD ONLY PUT OUT 0.5 PSI. WHEN THE PUMP WAS REMOVED FOR INSPECTION 2 SCEWS FELL OUT OF THE PUMP INLET FITTING, AND A 1 WAS LOOSE INSIDE. THE FOURTH SCEW OF THE SET WAS THE ONLY SCEW STILL INSTALLED. THE PUMP WAS A A8150-B SN 63853. 8130-3 FORM TRACKING NR 15535. THE PUMP HAD ZERO RUN TIME ON IT, ONLY WAS FUNCTION CHECKED FOLLOWING INSTALLATION AND FOUND THAT IT APPEARED TO HAVE NOT BEEN ASSEMBLED PROPERLY.

2011FA0000790

CESSNA

CONT

 

CYLINDER

CRACKED

11/29/2011

414A

TSIO520NB

 

SA52006A1

ZONE 400

THE CYLINDER HEAD SEPARATED FROM THE BARREL ONE COOLING FIN BELOW THE CYLINDER HEAD.

2012FA0000113

CESSNA

CONT

 

GEAR

BROKEN

2/2/2012

421C

GTSIO520L

 

656914

CAMSHAFT

DURING ANNUAL INSPECTION, WHILE COMPLYING WITH AD-07-05-15 (DATED 04/16/07), STARTER ADAPTER 400-HOUR INSPECTION IAW MSB 94-4G, FOUND ONE BROKEN TOOTH ON CAMSHAFT GEAR. ENGINE DISASSEMBLED WITH NO OTHER INDICATIONS FOUND OF RELATED DEFECTS OR DAMAGE INTERNALLY OR EXTERNALLY. NO METAL FOUND IN OIL FILTER OR INTERNAL TO THE ENGINE. BROKEN TOOTH NOT FOUND. CAMSHAFT GEAR PN 656914 SUPERCEDES PN 537432.

2012FA0000045

CESSNA

 

 

TUBE

CHAFED

1/9/2012

525   

 

 

631700353

HYD SYSTEM

DURING INSPECTION, FOUND 2 HYD PRESSURE LINES RUBBING AND WORN 50 TO 80 PERCENT THROUGH. PRESSURE LINES WERE LOCATED AT THE FWD SIDE OF THE AFT ENGINE CARR THRU BEAM BETWEEN THE LT AND RT HYD PRESSURE FILTERS. IMPROPER INSTALLATION OF 90 DEGREE FITTIN IN LEFT FILTER ASSY. ASSURE PROPER INSTALLATION OF ALL FITTINGS AND RIGID LINE CLEARANCE.

2012FA0000010

CESSNA

WILINT

 

COMPUTER

FAILED

1/5/2012

525   

FJ44

 

8221137001

IAPS  

FLIGHT INSTRUMENT COMPARATOR WARNING INDICATOR ILLUMINATED. ACFT LANDED WITHOUT INCIDENT. REPLACED IAPS. SYSTEM TESTED WITH NEW PART INSTALLED CONFIRMED SYS NOW FUNCTIONS CORRECTLY.

AMCR201201180002

CESSNA

 

 

COAX

MISINSTALLED

1/18/2012

525C

 

 

5001688105

TCAS  

CREW REPORTED THAT THE TCAS DISPLAY WAS INCORRECTLY PAINTING TARGETS AT 45 DEG TO THE LT OF WHERE IT SHOULD HAVE BEEN, BASED ON VISUAL AND ATC VERIFICATION. CREW EXPERIENCED SIMILAR PROBLEM ON AN EARLIER SN ACFT (0049, 19 HRS TT) A FEW MONTHS PRIOR. MX FOUND THE TWO COAX CABLES THAT CONNECT THE BELLY ANTENNA TO THE FUSELAGE BULKHEAD WERE INCORRECTLY INSTALLED. THE YELLOW (PY1001B) AND THE BLACK (PY1002B) CABLES WERE SWAPPED. THERE WERE NO COLOR MARKINGS ON THE BULKHEAD. SINCE THESE TWO ACFT ARE NEW AND THE FLOOR PANELS HAVE NEVER BEEN REMOVED, IT'S APPARENT THIS CAME FROM THE MFG IN THIS CONDITIONS, AND WERE NOTIFIED OF THE PROBLEM.

2012FA0000002

CESSNA

CONT

 

THROTTLE ARM

SEIZED

12/20/2011

550   

TSIO550C

 

6567852

POWERPLANT

PILOT REPORTED THROTTLE VERY HARD TO MOVE. UPON INSPECTION, THE THROTTLE ARM WAS FOUND TO BE SEIZED AFTER THE THROTTLE CONTROL WAS REMOVED. THROTTLE ASSY WAS REMOVED FROM THE ENGINE AND THE THROTTLE AREM COULD NOT BE MOVED. NO VISIBLE SIGNS OF ANY OTHER DAMAGE TO UNIT. THE ADDITION OF LUBRICATION TO THROTTLE SHAFT MADE NO DIFFERENCE.

2012FA0000011

CESSNA

PWA   

 

STATOR

CRACKED

12/21/2011

550   

JT15D4

 

1338932

MLG BRAKE DISK

ON LANDING ROLLOUT, LT MAIN GEAR BRAKE LOCKED UP. UPON DISASSEMBLY AND INSP OF MALFUNCTIONING BRAKE BY MECHANIC, IT WAS DISCOVERED THAT THE STATOR DISK (1 OF THE 2 ON THE BRAKE ASSY) CLOSEST TO THE INBD SIDE HAD CRACKED AND SHATTERED INTO 4 LARGE SEGMENT PIECES. THE BROKEN PIECES OF THE DISK HAD JAMMED UP AND PREVENTED THE WHEEL FROM TURNING. SUSPECT FATIGUE OR THERMAL SHOCK COULD BE THE CAUSE OF FAILURE.

DXTR20120117003

CESSNA

 

 

FUEL LINE

CHAFED

1/17/2012

560CESSNA

 

 

65264404

ZONE 100

RT REFUEL/DEFUEL FLOW TUBE ASSY IS CHAFED BEYOND LIMITS.

DXTR20120131010

CESSNA

 

 

AXLE

CORRODED

1/31/2012

560CESSNA

 

 

 

ZONE 700

CORROSION FOUND ON LT MLG WHEEL AXLE.

VIB82012020700001

CESSNA

 

 

CONTROL CABLE

MISROUTED

2/7/2012

560CESSNA

 

 

 

ZONE 200

LEFT ELEVATOR TRIM TAB CABLE, SAWING INTO BULKHEAD AT FS 448.5. CABLE ROUTED INCORRECTLY ON SIDE OF PULLEY.

DXTR20120124008

CESSNA

 

 

LINE

CHAFED

1/24/2012

560CESSNA

 

 

652640061

FUEL TRANSFER

FUEL TRANSFER LINE, PN 6526400-61, IS CHAFING THE FUSELAGE UNDER PANEL 161AB.

DXTR2012009

CESSNA

PWA   

 

INLET

CRACKED

1/31/2012

560CESSNA

JT15D1

 

65528001

ZONE 400

LT ENGINE INLET FAN FLANGE CRACKED APPROX AT 9 OCLOCK POSITION, CRACK IS 4" IN LENGTH.

DXTR20120206001

CESSNA

 

 

RIB   

CRACKED

2/6/2012

560XL

 

 

652206544

RT WING

RT WING T/E RIB CRACKED AT WS 167.07. R & R RT T/E RIB.

DXTR20120125008

CESSNA

 

 

PIVOT ASSY

LOOSE

1/25/2012

560XL

 

 

663110215

ZONE 300

AFT HORIZONTAL PIVOT FITTING, LOOSE (HAND TURN) ATTACH LOCK FASTENERS AND LOOSE ATTACH BOLTS.

DXTR20120209001

CESSNA

 

 

BOLT

LOOSE

2/9/2012

560XL

 

 

 

VERTICAL STAB

FOUR VERTICAL ATTACH BOLTS ARE LOOSE AT THE VERTICAL STAB AFT SPAR ASSY TO WEB/RIB ASSY FS 588 - WL161.5. RETORQUED TO STANDARD PRACTICES.

DXTR2012004

CESSNA

 

 

RIB   

CRACKED

1/19/2012

560XL

 

 

 

LT WING

LEFT WING FLAPWELL T/E RIB AT WS 64.0 IS CRACKED.

DXTR20120119005

CESSNA

 

 

RIB   

CRACKED

1/19/2012

560XL

 

 

 

RT WING

RIGHT WING FLAPWELL T/E RIB AT WS 88.63 IS CRACKED.

DXTR20120119006

CESSNA

 

 

RIB   

CRACKED

1/19/2012

560XL

 

 

 

RT WING

RIGHT WING FLAPWELL T/E RIB AT WS 143.07 IS CRACKED.

DXTR20120119007

CESSNA

 

 

BRACKET

CRACKED

1/19/2012

560XL

 

 

66611542

ZONE 100

RUDDER AUTOPILOT CABLE BRACKET IS CRACKED AT AFT CANTED BULKHEAD.

DXTR2011121400000

CESSNA

 

 

HYDRAULIC LINE

CHAFED

12/14/2011

560XL

 

 

66171092

ZONE 100

COPILOTS RT RUDDER PEDAL IS CHAFING ON LT HYDRAULIC BRAKE LINE AT FORWARD BULKHEAD.

DXTR20111214401

CESSNA

 

 

ATTACH FITTING

WORN

12/14/2011

560XL

 

 

 

HORIZONTAL STAB

THE FWD AND AFT HORIZONTAL STAB ATTACH POINTS ARE WORN, ALLOWING HORIZONTAL STAB MOVEMENT BOTH RADIALLY AND UP AND DOWN. THIS MOVEMENT HAS PLAY IN THE HORIZONTAL, SEEMS TO HAVE STARTED TO LOOSEN UP ANOTHER AREA. THE LT SIDE OF THE AFT VERTICAL SPAR HAS AN AREA THAT IS GAPPING BETWEEN THE SPAR AND THAT FRAME STATION. THE GAP IS AROUND 0.002" WHEN PRESSURE IS BEING PLACED ON THE UPPER OTBD SIDE OF THE HORIZONTAL. THE GAP IS CLOSED IN THE STATIC POSITION OR WHEN PRESSURE IS APPLIED ON THE LOWER SIDE OF THE STAB.

2011FA0000778

CESSNA

 

 

BRACKET

CRACKED

12/8/2011

560XL

 

 

6661152

ZONE 200

DURING A ROUTINE PHASE A/B INSPECTION, TECHS DISCOVERED THAT THE AUTOPILOT RUDDER CABLE BRACKET LOCATED AFT OF THE CANTED BULKHEAD HAS A 1" CRACK AT THE BASE OF THE BRACKET PASSING THROUGH THE TOP MOUNT HOLE.

JEMA2012FA0000029

CESSNA

PWA   

 

MOUNT

DAMAGED

1/16/2012

560XL

PW545A

 

99124802

RT ENGINE

RT ENGINE AFT MOUNT ASSY FOUND TO BE DAMAGED. CENTER BOLT BENT. DEEP CHECK CUTS IN ENDS OF RUBBER INSERT MATERIAL. ATTACHING ARMS SIEZED TOGETHER AT CENTER BEARING, PN 6651602-4. PART REPLACEMENT RECOMMENDED AT SECOND ENGINE CHANGE (APPROX 10,000 HRS).

WAIA2012FA0000030

CESSNA

 

 

CURRENT LIMITER

FAILED

1/12/2012

650   

 

 

 

TE FLAPS SYSTEM

AFTER TAKEOFF, SELECTED "FLAPS UP", FLAPS RETRACTED AS INDICATED. NOTICED "FLAP INOP" ANNUNCIATOR ILLUMINATED. FOLLOWED CHECKLIST TO RESET FLAP SYS BUT COULD NOT RESET THE FLAPS. RETURNED AND PERFORMED A ZERO FLAP LANDING. MX INSPECTED FLAP CONTROLLER BITE INDICATIONS, CONTROLLER INDICATED BITE NR 5. IAW THE MM, MAIN J-BOX WAS OPENED AND FOUND THE FL23 CURRENT LIMITER TO BE BLOWN. INSTALLED A NEW CURRENT LIMITER AND PERFORMED OPS CHECK OF THE FLAP SYS. OPS CHECKED GOOD, ACFT WAS RELEASED BACK TO SERVICE.

CF4R20120213001

CESSNA

 

 

FITTING

CUT   

2/13/2012

A185F

 

 

AN8334D

FUEL LINE

IN PREPARING FOR A ENGINE CHANGE THE INSPECTOR WAS CHECKING ALL FITTINGS LOCATED ON THE FIREWALL. THE FUEL CONTROL, FUEL RETURN LINE BULKHEAD FITTING AN833-4D WAS NOTED TO BE LOOSE. WHEN THE FITTING WAS REMOVED IT WAS DISCOVERED TO BE CUT ALMOST IN HALF, DUE TO THE STAINLESS MATERIAL OF THE FIREWALL CUTTING INTO THE FITTING WHILE THE FITTING WAS LOOSE.

2012FA0000099

CESSNA

PWA   

 

BEARING

CRACKED

2/7/2012

STC500CESSNA

JT15D4

 

ADL16

ZONE 600

GEAR WAS REMOVED FOR OTHER MX AND RT FORWARD MAIN LANDING TRUNNION PIN WING FITTING BEARING ASSY WAS REMOVED DUE TO PHENOLIC LINING DAMAGE. TECH WAS INSPECTING BEARING AND FOUND BEARING CRACKED.

2011FA0000797

CESSNA

 

CESSNA

HOUSING

WORN

12/8/2011

T210M

 

 

171400033

COCKPIT SEAT

COPILOT SEAT ROLLER HOUSING TANG LENGTH WORN BELOW LIMIT OF AD 2011-10-09.

2012FA0000068

CESSNA

CONT

 

GOVERNOR

DISINTEGRATED

1/25/2012

TU206G

TSIO520M

 

C290D4KT2

 

PROP GOVERNOR BEARING IN THE IDLER PART OF THE OIL PUMP DISINTEGRATED.

2012FA0000024

CESSNA

CONT

 

HOUSING

GALLED

1/2/2012

U206F

IO520F

 

 

FUEL PUMP

ENGINE DIED ON INITIAL RUN-UP DUE TO FUEL STARVATION. FOUND GALLING BETWEEN FUEL PUMP DRIVE GEAR AND HOUSING. CAUSE UNDETERMINED. SENT BOTH PARTS OUT FOR O/H.

ODAR201112220011

CIRRUS

 

 

CABLE

BINDING

12/12/2011

SR20

 

 

 

RT MLG BRAKE

SHORTLY AFTER THE ANNUAL INSP, THE OWNER REPORTED THAT OCCASIONALLY AFTER APPLYING RUDDER DURING TAXI, THE RT WHEEL BRAKE WOULD BE APPLIED, CAUSING THE ACFT TO STEER IN THAT DIRECTION BECAUSE OF THE CASTER TYPE NOSE WHEEL. UPON INVESTIGATION BY MX, IT WAS DISCOVERED THAT THE PARK BRAKE CABLE WAS ROUTED NEAR THE RUDDER PEDAL RETURN SPRING. WHEN RUDDDER WAS APPLIED, THE SPRING STRETCHED, ALLOWING A GAP FOR THE PARK BRAKE CABLE TO FALL INTO. WHEN THE RUDDER WAS RELEASED, THE SPRING CAPTURED THE PARK BRAKE CABLE WHICH ESSENTIALLY APPLIED THE BRAKE TO THAT SIDE. THERE WAS NO INCIDENT OR ACCIDENT INVOLVED WITH THIS EVENT. MX REPORTED THAT THIS CABLE, SPRING AND PANEL HAD NOT BEEN DISTURBED DURING THE ANNUAL INSPECTION.

2012FA0000033

CIRRUS

CONT

 

EXHAUST VALVE

BINDING

11/8/2011

SR20

IO360ES

 

655866

NR 2  

DURING A ROUTINE PRE-INSPECTION ENGINE RUN-UP, THE MX TECH DISCOVERED THAT THE ENGINE WAS RUNNING ROUGH AND WAS UNABLE TO REACH STATIC RPM. THE TECH ALSO NOTED LOW EGT ON CYLINDER NR 2. THE CYLINDER NR 2 EXHAUST VALVE ROCKER COVER AND EXHAUST VALVE SPRING WERE REMOVED, AT WHICH POINT IT WAS DISCOVERED THAT THE NR 2 EXHAUST VALVE WAS SEIZED AND COULD NOT BE MOVED BY HAND. A BORESCOPE INSP WAS PERFORMED ON CYLINDER NR 2 AND NO EVIDENCE OF CONTACT BETWEEN THE EXHAUST VALVE AND PISTON WAS FOUND. AFTER PERFORMING A BORESCOPE INSP ON THE REMAINING CYLINDERS, IT WAS DISCOVERED THAT THE EDGE OF THE CYLINDER NR 6 EXHAUST VALVE HAD CONTACTED THE TOP OF THE PISTON, LEAVING A SHALLOW EYEBROW SHAPED MARK. NO EVIDENCE OF CONTACT BETWEEN THE EXHAUST VALVE AND PISTON WAS FOUND ON THE REMAINING CYLINDERS. THE CYLINDER NR 6 EXHAUST VALVE ROCKER COVER AND EXHAUST VALVE SPRING WERE REMOVED AND IT WAS DISCOVERED THAT THE NR 6 EXHAUST VALVE WAS BINDING AND COULD NOT BE MOVED FREELY BY HAND. THE EXHAUST VALVE ROCKER COVERS AND EXHAUST VALVE SPRINGS WERE REMOVED FROM THE REMAINING CYLINDERS AND ALL OF THE REMAINING EXHAUST VALVES MOVED FREELY. IAW TECH SUPPORT INSTRUCTIONS, CYLINDER NR 2 (S/N: AC10BA845) AND NR 6 (S/N: AC10BA893) WERE REMOVED AND SENT TO AUTHORIZED SERVICE CENTER FOR WARRANTY REPAIR. SERVICEABLE REPAIRED REPLACEMENT CYLINDER ASSEMBLIES AND NEW CYLINDER NR 6 PISTON WERE SUBSEQUENTLY INSTALLED.

2012FA0000036

CIRRUS

CONT

CONT

EXHAUST VALVE

BINDING

9/29/2011

SR20

IO360ES

 

655866

 

DURING A ROUTINE PRE-INSPECTION ENGINE RUN-UP, THE MX TECH DISCOVERED THAT THE ENGINE WAS RUNNING ROUGH AND WAS UNABLE TO REACH STATIC RPM. THE TECH ALSO NOTED LOW EGT ON CYLINDERS NR 1 AND NR 5. THE CYLINDER NR 1 AND NR 5 EXHAUST VALVE ROCKER COVERS AND EXHAUST VALVE SPRINGS WERE REMOVED, AT WHICH POINT IT WAS DISCOVERED THAT THE NR 1 AND NR 5 EXHAUST VALVES WERE BINDING AND COULD NOT BE MOVED FREELY BY HAND. A BORESCOPE INSP WAS PERFORMED ON CYLINDERS NR 1 AND NR 5 AND NO EVIDENCE OF CONTACT BETWEEN THE EXHAUST VALVE AND PISTON WAS FOUND. A BORESCOPE INSP WAS THEN PERFORMED ON THE REMAINING CYLINDERS AND NO FURTHER EVIDENCE OF CONTACT BETWEEN THE EXHAUST VALVES AND PISTONS WERE FOUND. THE EXHAUST VALVE ROCKER COVERS AND EXHAUST VALVE SPRINGS WERE REMOVED FROM THE REMAINING CYLINDERS AND ALL OF THE REMAINING EXHAUST VALVES MOVED FREELY. IAW TECH SUPPORT INSTRUCTIONS, CYLINDER NR 1 (S/N: AC10EA128) AND NR 5 (S/N: AC10EA124) WERE REMOVED, SENT TO AN AUTHORIZED SERVICE CENTER FOR WARRANTY REPAIR, AND REINSTALLED.

2012FA0000037

CIRRUS

CONT

CONT

EXHAUST VALVE

BINDING

10/18/2011

SR20

IO360ES

 

655866

 

DURING A ROUTINE PRE-INSPECTION ENGINE RUN-UP, THE MX TECH DISCOVERED THAT THE ENGINE WAS RUNNING ROUGH AND WAS UNABLE TO REACH STATIC RPM. THE TECH ALSO NOTED LOW EGT ON CYLINDER NR 5. THE CYLINDER NR 5 EXHAUST VALVE ROCKER COVER AND EXHAUST VALVE SPRING WERE REMOVED, AT WHICH POINT IT WAS DISCOVERED THAT THE NR 5 EXHAUST VALVE WAS BINDING AND COULD NOT BE MOVED FREELY BY HAND. AFTER PERFORMING A BORESCOPE INSPECTION ON CYLINDER NR 5, IT WAS DISCOVERED THAT THE EDGE OF THE EXHAUST VALVE HAD CONTACTED THE TOP OF THE PISTON, LEAVING A SHALLOW EYEBROW SHAPED MARK. A BORESCOPE INSP WAS THEN PERFORMED ON THE REMAINING CYLINDERS AND NO FURTHER EVIDENCE OF CONTACT BETWEEN THE EXHAUST VALVES AND PISTONS WERE FOUND. AFTER REMOVING THE EXHAUST VALVE ROCKER COVERS AND EXHAUST VALVE SPRINGS FROM THE REMAINING CYLINDERS, IT WAS DISCOVERED THAT THE CYLINDER NR 3 EXHAUST VALVE WAS ALSO BINDING AND COULD NOT BE MOVED FREELY BY HAND. ALL OF THE REMAINING EXHAUST VALVES COULD BE MOVED FREELY BY HAND. IAW TECHNICAL SUPPORT INSTRUCTIONS, CYLINDER NR 3 (S/N: AC10EA236) AND NR 5 (S/N: AC10EA503) WERE REMOVED AND SENT TO AN AUTHORIZED SERVICE CENTER FOR WARRANTY REPAIR. NEW REPLACEMENT CYLINDER ASSEMBLIES AND NEW CYLINDER NR 5 PISTON WERE SUBSEQUENTLY INSTALLED.

2012FA0000038

CIRRUS

CONT

CONT

EXHAUST VALVE

BINDING

10/31/2011

SR20

IO360ES

 

655866

 

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

2012FA0000039

CIRRUS

CONT

CONT

EXHAUST VALVE

BINDING

11/30/2011

SR20

IO360ES

 

655866

 

AFTER NOTICING THAT THE ENGINE RAN ROUGH DURING TAXI PRIOR TO TAKEOFF, THE PILOT RETURNED TO THE RAMP AND REPORTED THE PROBLEM TO A MX TECH. THE MX TECH VERIFIED THAT THE ENGINE WAS RUNNING ROUGH AND WAS UNABLE TO MAKE TAKEOFF POWER. THE TECH ALSO NOTED LOW EGT ON CYLINDER NR 4. THE CYLINDER NR 4 EXHAUST VALVE ROCKER COVER AND EXHAUST VALVE SPRING WERE REMOVED, AT WHICH POINT IT WAS DISCOVERED THAT THE NR 4 EXHAUST VALVE WAS BINDING AND COULD NOT BE MOVED FREELY BY HAND. AFTER PERFORMING A BORESCOPE INSP ON CYLINDER NR 4, IT WAS DISCOVERED THAT THE EDGE OF THE EXHAUST VALVE HAD CONTACTED THE TOP OF THE PISTON, LEAVING A SHALLOW EYEBROW SHAPED MARK. THE EXHAUST VALVE ROCKER COVERS AND EXHAUST VALVE SPRINGS WERE REMOVED FROM THE REMAINING CYLINDERS AND IT WAS DISCOVERED THAT THE EXHAUST VALVES ON CYLINDERS NR 1, NR 3, AND NR 5 WERE ALSO BINDING. AFTER PERFORMING A BORESCOPE INSPECTION ON THE REMAINING CYLINDERS, IT WAS DISCOVERED THAT THE EDGE OF THE CYLINDER NR 3 EXHAUST VALVE HAD ALSO MADE CONTACT WITH THE PISTON, LEAVING A SHALLOW EYEBROW SHAPED MARK. NO EVIDENCE OF EXHAUST VALVE CONTACT WAS FOUND ON THE REMAINING CYLINDERS. IAW TECH SUPPORT INSTRUCTIONS, CYLINDER NR 1 (S/N: AC10FA220), NR 3 (S/N: AC10FA240), NR 4 (S/N: AC10FA217), AND NR 5 (S/N: AC10FA446) WERE REMOVED AND SENT TO AN AUTHORIZED SERVICE CENTER FOR WARRANTY REPAIR. NEW REPLACEMENT CYLINDER ASSEMBLIES AND NEW CYLINDER NR 3 AND NR 4 PISTONS WERE SUBSEQUENTLY INSTALLED.

2012FA0000072

CIRRUS

 

 

TUBE

FAILED

12/22/2011

SR22

 

 

G156006

MAIN TIRE

MAIN TIRE BLOWOUT ON RUNWAY DURING A TURN. MX REPLACED THE TIRE AND TUBE STATED, REPLACED A FEW OF THESE TYPES (BUTYL RUBBER) TUBES IN THE PAST DUE TO HOLES IN VARIOUS PLACES FOR NO APPARENT REASONS.

2012FA0000108

CIRRUS

 

 

ADAPTER

FAILED

1/30/2012

SR22

 

 

642083A2

STARTER

REMOVED STARTER ADAPTER, INSTALLED REBUILT STARTER ADAPTER, REBUILT STARTER ADAPTER FAILED ON INITIAL STARTUP. REMOVED STARTER ADAPTER. PERFORMED 500 HR INSPECTION ON MAGNETOS, FINDING OIL SEAL FROM MAGNETO HAD PREVENTED THE IMPULSE COUPLING PAWLS FROM ENGAGING THE IMPULSE COUPLING. INSTALLED REPLACEMENT REBUILT STARTER ADAPTER, OPS CHECK PERFORMED WITH NO DISCREPANCIES NOTED.

LC1R2011120700001

CIRRUS

 

 

AIR FILTER

SPLIT  

12/7/2011

SR22

 

 

BA24  

ENGINE

DURING AN ANNUAL INSPECTION, THE AIR FILTER WAS DISCOVERED TO BE SPLIT OPEN AT THE SEAM. THIS SAME CONDITION HAS BEEN FOUND ON SEVERAL OTHER AIR FILTERS OF THE SAME PN. WHILE NOT AN IMMEDIATE SAFTEY OF FLIGHT ISSUE, THIS CONDITION ALLOWS UNFILTERED AIR TO ENTER THE INDUCTION SYSTEM WHICH IF ALLOWED TO CONTINUE FOR ANY GREAT LENGTH OF TIME CAN CAUSE PREMATURE WEAR AND POSSIBLE EARLY FAILURE OF THE ENGINE.

2012FA0000106

CIRRUS

CONT

 

WASHER

LOOSE

1/31/2012

SR22

IO550*

 

 

MAG OIL SEAL

DURING A 500 HR INSPECTION, IT WAS DISCOVERED THAT THE OIL SEAL WASHER IN A MAGNETO HAD MOVED OUT ON THE SHAFT AND WAS HOLDING THE IMPULSE COUPLING PAWLS IN RUNNING POSITION, CAUSING ADVANCED TIMING FOR START. AT 15 HRS AFTER 500 HR INSPECTION, CONDITION OCCURRED AGAIN. MAGNETO REPAIR SHOP SAYS THIS IS THE 8TH OCCURRENCE OF THIS CONDITION THEY HAVE SEEN IN THE LAST 12 MONTHS.

2012FA0000100

CIRRUS

CONT

BENDIX

DISTRIBUTOR GEAR

FAILED

1/24/2012

SR22

IO550N

 

 

RT MAGNETO

CREW REPORTED SEVERE ENGINE VIBRATION DURING TAKEOFF. QUICK INSPECTION ON GROUND REVEALED THAT LT WAS INOPERATIVE. OPERATOR DECIDED TO REPLACE MAGNETO WITH A BRAND NEW ONE. DURING THE DISASSEMBLING OF THE MAGNETO THE DISTRIBUTOR GEAR`S FAILURE WERE FOUND . IT MIGHT CAUSE AN ENGINE IN-FLIGHT SHUTDOWN, WHICH COULD LEAD TO A LOSS OF CONTROL. MAGNETO DEFECT. MAGNETO REPLACED.

2012FA0000101

CIRRUS

CONT

 

DISTRIBUTOR GEAR

FAILED

1/23/2012

SR22

IO550N

 

 

MAGNETO

CREW REPORTED SEVERE ENGINE VIBRATION AND EGT RAISED AT THE SAME TIME IN CYLINDER NR 3. QUICK INSPECTION ON GROUND REVEALED THAT RT MAGNETO IS INOPERATIVE. OPERATOR DECIDED TO REPLACE MAGNETO WITH A BRAND NEW ONE. AFTER REPLACEMENT WAS ACCOMPLISHED, PERFORMED A CYLINDERS DIFFERENTIAL COMPRESSION CHECK, & SPARK PLUG CHECK. DURING THIS ADDITIONAL INVESTIGATION, FOUND CYLINDER NR 3 UPPER SPARK PLUG`S CERAMIC WAS BROKEN & IT WAS REPLACED. DURING TEST-FLIGHT, CLIMBED TO FL180, EVERYTHING REPORTED NORMAL. DURING THE DISASSEMBLY OF THE MAGNETO, FOUND DISTRIBUTOR GEAR FAILED. MAGNETO REPLACED, SPARK PLUGS REPLACED TO MASSIVE TYPE.

FCPR20121214002

CIRRUS

CONT

 

HOUSING

LEAKING

12/14/2011

SR22

IO550N

 

ETISR22212

FUEL PUMP

WHILE PERFORMING AN OIL CHANGE, FOUND ENGINE DRIVEN FUEL PUMP LEAKING FUEL AT ANEROID HOUSING FLANGE. REMOVED FUEL PUMP AND SENT TO MFG FOR REPAIRS.

FCPR20121223003

CIRRUS

CONT

 

HOUSING

LEAKING

12/23/2011

SR22

IO550N

 

ETISR22212

FUEL PUMP

WHILE PERFORMING A 100 HR INSPECTION, FOUND ENGINE DRIVEN FUEL PUMP LEAKING FUEL AT ANDROID HOUSING FLANGE. REMOVED FUEL PUMP AND SENT TO MFG FOR REPAIRS.

2012FA0000076

CNDAIR

 

 

HANDLE

CRACKED

1/10/2012

CL6002B16

 

 

600318873

MAIN CABIN DOOR

THE PASSENGER DOOR INNER LOCKING HANDLE IS CRACKED AT THE TOP OF THE HANDLE, FROM THE KNOB EXTENDING DOWN THE HANDLE, ALL THE WAY THROUGH. SUSPECT CAUSE IS DUE TO FLEXING OF HANDLE AT KNOB AREA WHERE THE MATERIAL IS TRIMMED OUT. SUGGEST OEM REVISE DESIGN OF HANDLE TO IMPROVE STRENGTH.

2012FA0000088

CNDAIR

 

 

LINE

CHAFED

2/2/2012

CL6002B16

 

 

604752383

HYDRAULIC SYS

CAUTION MESSAGE HYD 1 HI TEMP, LOW FLUID INDICATION, LOW PRESSURE INDICATION, CHECKLIST FOLLOWED, UNSCHEDULED LANDING WITHOUT INCIDENT. MX EVALUATION FOUND NR1 HYD SYSTEM PRESSURE LINE IN AFT ACCESSORY COMPARTMENT CHAFED THROUGH BY SUPPORTING CLAMP. HYD TUBE ASSY AND CLAMP REPLACED WITH NEW.

JR2R2011122900690

CNDAIR

 

 

FLOORBEAM

CORRODED

12/29/2011

CL6002C10

 

 

CC67033292135

ZONE 100

FLOOR PANEL SUPPORT ANGLE ON THE FWD SIDE OF THE 280 CROSSBEAM CORRODED. REPLACED ANGLE IAW SRM 51-42-06 AND 51-42-21.

JR2R2011122900691

CNDAIR

 

 

FLOORBEAM

CORRODED

12/29/2011

CL6002C10

 

 

CC670341757

ZONE 100

LEFT SIDE OF THE FS 280 CROSSBEAM CORRODED. REPLACED CROSSBEAM IAW RO CRJ7-53-0490.

JR2R2011122900693

CNDAIR

 

 

STEP

CRACKED

12/29/2011

CL6002C10

 

 

 

PAX DOOR

PAX DOOR TOP STEP CRACKED. REPAIRED IAW RO CRJ7-52-0265.

JR2R2011122900694

CNDAIR

 

 

SKIN

CHAFED

12/29/2011

CL6002C10

 

 

CC670392511

ZONE 100

AFT FUSELAGE CHAFED AT CENTERLINE AND FS 970. REMOVED CHAFE AND COMPLETED MOD SUM IS670538200021IAW RO CRJ7-53-0492.

JR2R2011123100695

CNDAIR

 

 

STRINGER

CORRODED

12/31/2011

CL6002D24

 

 

 

ZONE 100

STRINGER 23R CORRODED FROM FS 280 TO 333. REPLACED STRINGER IAW SRM 51-42-06 AND 51-41- 21.

JR2R2011123100696

CNDAIR

 

 

STRINGER

CORRODED

12/31/2011

CL6002D24

 

 

SH670312102

ZONE 100

STRINGER 22R CORRODED FROM FS 280 TO 333. REPLACED STRINGER IAW SRM 51-42-06 AND 51-41- 21.

JR2R2011123100697

CNDAIR

 

 

STRINGER

CORRODED

12/31/2011

CL6002D24

 

 

SH670313831

ZONE 100

STRINGER 21R CORRODED FROM FS 280 TO 333. REPLACED STRINGER IAW SRM 51-42-06 AND 51-41-21.

JR2R2011123100698

CNDAIR

 

 

STRINGER

CORRODED

12/31/2011

CL6002D24

 

 

SH670313801

ZONE 100

STRINGER 23R CORRODED FROM FS 349 TO 379. REPLACED STRINGER IAW SRM 51-42-06 AND 51-41- 21.

JR2R2011123100699

CNDAIR

 

 

STRINGER

CORRODED

12/31/2011

CL6002D24

 

 

SH670313801

ZONE 100

STRINGER 18R CORRODED FROM FS 280 TO 310. REPLACED STRINGER IAW SRM 51-42-06 AND 51-41- 21.

JR2R2011123100700

CNDAIR

 

 

STRINGER

CORRODED

12/31/2011

CL6002D24

 

 

SH670313801

ZONE 100

STRINGER 19R CORRODED FROM FS 295 TO 310. REPLACED STRINGER IAW SRM 51-42-06 AND 51-41- 21.

JR2R2011123100701

CNDAIR

 

 

STRINGER

CORRODED

12/31/2011

CL6002D24

 

 

SH670312081

ZONE 100

STRINGER 20R CORRODED FROM FS 280 TO 295. REPLACED STRINGER IAW SRM 51-42-06 AND 51-41- 21.

JR2R2011123100702

CNDAIR

 

 

STRINGER

CORRODED

12/31/2011

CL6002D24

 

 

SH670316361

ZONE 100

STRINGER 21R CORRODED FROM FS 280 TO 333. REPLACED STRINGER IAW SRM 51-42-06 AND 51-41- 21.

JR2R2011122100654

CNDAIR

 

 

FLOORBEAM

CORRODED

12/21/2011

CL6002D24

 

 

CC670341757

ZONE 100

LEFT SIDE OF 280 FLOORBEAM CORRODED NEAR THE INBD DRIP TRAY. REPLACED LT SIDE OF 280 FLOORBEAM IAW RO CRJ 9-53-0889.

JR2R2011122100655

CNDAIR

 

 

FLOORBEAM

CORRODED

12/21/2011

CL6002D24

 

 

CC670341757

ZONE 100

RIGHT SIDE OF 280 FLOORBEAM CORRODED. REPLACED RT SIDE OF 280 FLOORBEAM IAW RO CRJ9-53-0890.

JR2R2011122100653

CNDAIR

 

 

SKIN

CORRODED

12/21/2011

CL6002D24

 

 

SH69037142

ZONE 100

CENTER FUSELAGE SKIN CHAFED AT FS 920. BLENDED CHAFE TO .030 WITH IN LIMITS IAW RO CRJ9-53-0897.

JR2R2011122200656

CNDAIR

 

 

FITTING

CHAFED

12/22/2011

CL6002D24

 

 

AV67023120

ZONE 300

HORIZ STAB LT AND RT ANTI-ROTATION FITTINGS DAMAGED. TEMP REPAIRED LT AND RT FITTINGS IAW RO CRJ9-55-0152.

JR2R2011122200657

CNDAIR

 

 

SEAT TRACK

CORRODED

12/22/2011

CL6002D24

 

 

SH690334041

ZONE 100

RIGHT FLOOR SEAT TRACK STICK NR 3 CORRODED OUT OD LIMITS. REPLACED SEAT TRACK IAW MM 53-00-49.

JR2R2011122200658

CNDAIR

 

 

SEAT TRACK

CORRODED

12/22/2011

CL6002D24

 

 

SH690334041

ZONE 100

RIGHT FLOOR SEAT TRACK STICK NR 1 CORRODED OUT OD LIMITS. REPLACED SEAT TRACK IAW MM 53-00-50.

JR2R2011122200659

CNDAIR

 

 

STRINGER

CORRODED

12/22/2011

CL6002D24

 

 

SH670322333

ZONE 100

STRINGER 26R CORRODED BETWEEN FS 280 TO 333. REPLACED STRINGER IAW SRM 51-42-06 AND 51-42-21.

JR2R2011122200660

CNDAIR

 

 

STRINGER

CORRODED

12/22/2011

CL6002D24

 

 

SH670313724

ZONE 100

STRINGER 26R CORRODED BETWEEN FS 333 TO 349. REPLACED STRINGER IAW SRM 51-42-06 AND 51-42-21.

JR2R2011122200661

CNDAIR

 

 

STRINGER SPLICE

CORRODED

12/22/2011

CL6002D24

 

 

SH670324293

ZONE 100

STRINGER SPLICE 26R CORRODED AT FS 333. REPLACED STRINGER SPLICE IAW SRM 51-42-06 AND 51-42-11.

JR2R2011122200662

CNDAIR

 

 

FLOORBEAM

CORRODED

12/22/2011

CL6002D24

 

 

CC67033292135

ZONE 100

FLIGHT DECK FLOOR LANDING AT 280 FLOORBEAM CORRODED. REPLACED FLOORBEAM LANDING IAW SRM 51-42-06 AND 51-42-10.

JR2R2011122300663

CNDAIR

 

 

STRINGER

CORRODED

12/23/2011

CL6002D24

 

 

SH670316341

ZONE 100

STRINGER 26L CORRODED BEWEEN FS 319 AND 333. REPLACED STRINGER FROM 280 TO 333 IAW SRM 51-42-06 AND 51-42-21.

JR2R2011122300664

CNDAIR

 

 

STRINGER

CORRODED

12/23/2011

CL6002D24

 

 

SH670316341

ZONE 100

STRINGER 25L CORRODED BEWEEN FS 319 AND 333. REPLACED STRINGER FROM 280 TO 333 IAW SRM 51-42-06 AND 51-42-21.

JR2R2011122300665

CNDAIR

 

 

BULKHEAD WEB

CORRODED

12/23/2011

CL6002D24

 

 

CC670341706

ZONE 100

FS 280 LOWER RT BULKHEAD CORRODED. REPLACED WEB IAW SRM 51-42-06, 51-42-10, AND 51-42-21.

JR2R2011122300666

CNDAIR

 

 

BULKHEAD WEB

CORRODED

12/23/2011

CL6002D24

 

 

CC670341703

ZONE 100

FS 280 LOWER LT BULKHEAD CORRODED. REPLACED WEB IAW SRM 51-42-06, 51-42-10, AND 51-42-21.

JR2R2011122300667

CNDAIR

 

 

SKIN

CORRODED

12/23/2011

CL6002D24

 

 

SH690313513

ZONE 100

LIGHTNING STRIKE DAMAGE NEXT TO POTABLE WATER SERVICE DOOR. REPAIRED IAW SRM 53-00-00.

JR2R2011122300668

CNDAIR

 

 

SKIN

CORRODED

12/23/2011

CL6002D24

 

 

SH690313513

ZONE 100

LIGHTNING STRIKE DAMAGE AT LWR FWD CORNER OF FORWARD TOILET SERVICE DOOR. REPAIRED IAW SRM 53-00-00.

JR2R2011122300669

CNDAIR

 

 

SKIN

DAMAGED

12/23/2011

CL6002D24

 

 

SH670331061

ZONE 100

LIGHTNING STRIKE DAMAGE AT LT SIDE OF NOSE RADOME FS 202. REPAIRED IAW SRM 53-00-00.

JR2R2011122300670

CNDAIR

 

 

SKIN

DAMAGED

12/23/2011

CL6002D24

 

 

SH670331031

ZONE 100

LIGHTNING STRIKE DAMAGE AT AFT EDGE OF RT NLG DOOR CUTOUT. REPAIRED IAW SRM 53-00-00.

JR2R2011122300671

CNDAIR

 

 

CHANNEL

CORRODED

12/23/2011

CL6002D24

 

 

SH670323647

ZONE 100

TCAS ANTENNA INTERNAL CHANNEL CORRODED. REMOVED CORROSION REMAINING MATERIAL IS .048 WITH IN LIMITS IAW SRM 51-21-06.

JR2R2011122300673

CNDAIR

 

 

SKIN

DAMAGED

12/23/2011

CL6002D24

 

 

SH690313513

ZONE 100

LIGHTING STRIKE DAMAGE ON RIVETS BETWEEN FS 409 AND 442 BETWEEN STRINGER 22R AND 23R. REPLACED RIVETS IAW SRM.

JR2R2011122300674

CNDAIR

 

 

SKIN

DAMAGED

12/23/2011

CL6002D24

 

 

SH690316337

ZONE 100

LIGHTING STRIKE DAMAGE ON RIVETS BETWEEN FS 312 AND 318 BETWEEN STRINGER 22R AND 23R. REPLACED RIVETS IAW SRM.

JR2R2011122300675

CNDAIR

 

 

SKIN

DAMAGED

12/23/2011

CL6002D24

 

 

CC670381573

ZONE 100

GALLEY SERVICE DOOR HAS 1 EA RIVET WITH LIGHTNING DAMAGE. REPLACED RIVET IAW SRM.

JR2R2011122700676

CNDAIR

 

 

SEAT TRACK

CORRODED

12/27/2011

CL6002D24

 

 

SH690334071

ZONE 100

RIGHT FLOOR SEAT TRACK NR 2 CORRODED OUT OF LIMITS. REPLACED SEAT TRACK IAW AMM 53-00-49.

JR2R2011122700677

CNDAIR

 

 

SEAT TRACK

CORRODED

12/27/2011

CL6002D24

 

 

SH690334071

ZONE 100

LEFT FLOOR SEAT TRACK NR 2 CORRODED OUT OF LIMITS. REPLACED SEAT TRACK IAW AMM 53-00-49.

JR2R2011122700678

CNDAIR

 

 

SEAT TRACK

CORRODED

12/27/2011

CL6002D24

 

 

SH690362821

ZONE 100

RIGHT SIDEWALL SEAT TRACK NR 2 CORRODED OUT OF LIMITS. REPLACED SEAT TRACK IAW AMM 53-00-49.

JR2R2011122800679

CNDAIR

 

 

LUG   

DAMAGED

12/28/2011

CL6002D24

 

 

521005

NLG TORQUE LINK

NLG LOWER TORQUE LINK ATTACHMENT LUGS DAMMAGED FROM ROTATING BUSHINGS. REMOVED DAMAGE AND REBUSHED LUGS IAW RO CRJ9-32-0099.

JR2R2011122800680

CNDAIR

 

 

SILL

CORRODED

12/28/2011

CL6002D24

 

 

 

ZONE 100

AFT CARGO DOOR SILL CORRODED BETWEEN FS 1015 AND 1031. REPAIRED IAW RO CRJ9-53-0918.

JR2R2011122800681

CNDAIR

 

 

WEB   

CORRODED

12/28/2011

CL6002D24

 

 

MM67035340001

ZONE 100

RIGHT SIDE AFT CARGO BAY , WEB CORRODED AT FS 1098 -1092. REPAIRED IAW RO CRJ9-53-0922.

JR2R2011122800682

CNDAIR

 

 

HINGE FITTING

GOUGED

12/28/2011

CL6002D24

 

 

CC67013013

ZONE 500

LEFT AILERON INBD AND OTBD INNER LUGS (HINGE FITTING) GOUGED. REPAIRED LUGS IAW RO CRJ9-57-0351.

JR2R2011122800683

CNDAIR

 

 

SUPPORT FITTING

DAMAGED

12/28/2011

CL6002D24

 

 

SH670340653

ZONE 100

FS 453 BETWEEN STRINGER 22L AND 23L BULKHEAD SUPPORT FITTING HAS DOUBLE DRILLED HOLE. REPLACED FITTING IAW SRM 51-42-20.

JR2R2011122800684

CNDAIR

 

 

SILL

CORRODED

12/28/2011

CL6002D24

 

 

SH670315181

ZONE 100

AFT CARGO RT FLOOR SILL CORRODED BETWEEN 969 AND 985. REPAIRED IAW RO CRJ9-53-0920.

JR2R2011122800685

CNDAIR

 

 

SILL

CORRODED

12/28/2011

CL6002D24

 

 

MM67035401001

ZONE 100

AFT CARGO RT FLOOR SILL CORRODED BETWEEN 985 AND 1000. REPAIRED IAW RO CRJ9-53-0919.

JR2R2011122800686

CNDAIR

 

 

SILL

CORRODED

12/28/2011

CL6002D24

 

 

MM67035402001

ZONE 100

AFT CARGO RT FLOOR SILL CORRODED BETWEEN 1000 AND 1015. REPAIRED IAW RO CRJ9-53-0917.

JR2R2011122900688

CNDAIR

 

 

SKIN

DAMAGED

12/29/2011

CL6002D24

 

 

CC670331051

ZONE 200

2 EA LIGHTNING STRIKES AT LT FWD FUSELAGE FS 212 AND 236. REPAIRED IAW RO CRJ9-53-0923.

JR2R2011122900689

CNDAIR

 

 

INTERCOSTAL

CORRODED

12/29/2011

CL6002D24

 

 

SH670335985

ZONE 100

INTERCOSTAL AT STRINGER 24R CORRODED FS 645 TO 661. REPLACED INTERCOSTAL IAW SRM 51-42-06 AND 51-42-21.

2011FA0000794

COLUMB

CONT

 

SPARK PLUG

DEFECTIVE

12/16/2011

LC40550FG300

TSIO550C

 

RHB32S

CYLINDER

PILOT REPORTED HIGH MAGNETO DROP DURING PRE-RUN CHECK. NR 3 CYLINDER BOTTOM SPARK PLUG WAS FOUND TO HAVE ENTIRE CERAMIC MISSING. BORESCOPE OF CYLINDER REVEALED NO INTERNAL DAMAGE.

UE5R201202020012

DHAV

 

 

PLANETARY GEAR

MISALIGNED

2/2/2012

DHC6

 

PT6A27

E310145502

REDUCTION GEAR

IN THE PROCESS OF REPLACING 1ST STAGE SUN GEAR AND PLANETARY GEAR SET, A DEFECT IN THE BEARINGS INSTALLED IN ALL 3 PLANET GEARS WAS FOUND. THE BRONZE SLEEVE PORTION OF THE BEARING HAD ROTATED CAUSING MISALIGNMENT OF BEARING SCALLOPS. THE BRONZE SLEEVE SHOULD NOT MOVE DURING A TYPICAL SERVICE LIFE OF 1ST STAGE PLANET GEAR. SUN GEAR AND PLANET GEAR SET WERE BEING REPLACED TO COMPLY WITH AD2011-25-12. REF SB-804, REV B. THIS IS THE 4TH INSTANCE OF BRONZE SLEEVE ROTATION WE HAVE SEEN FOR THIS PART.

UE5R201201030012

DHAV

PWA   

 

GEAR SET

MISALIGNED

1/3/2012

DHC6

PT6A27

PT6A27

E310145502Q

REDUCTION GEAR

IN THE PROCESS OF REPLACING 1ST STAGE SUNGEAR AND PLANET GEAR SET, A DEFECT IN THE BEARINGS INSTALLED IN ALL 3 PLANET GEARS WERE FOUND. THE BRONZE SLEEVE PORTION OF THE BEARING HAD ROTATED CAUSING MISALIGNMENT OF BEARING SCALLOPS. THE BRONZE SLEEVE SHOULD NOT MOVE DURING A TYPICAL SERVICE LIFE OF 1ST STAGE PLANET GEAR. SUNGEAR AND PLANET GEAR SET WERE BEING REPLACED TO COMPLY WITH AD2011-25-12. REF SB-804, REV B. THIS IS THE SECOND INSTANCE OF BRONZE SLEEVE ROTATION WE HAVE SEEN FOR THIS PART.

UE5R201201170001

DHAV

PWA   

 

GEAR SET

MISALIGNED

1/17/2012

DHC6*

PT6A27

 

E310145502

REDUCTION G/B

WHILE REPLACING THE 1ST STAGE SUN GEAR AND PLANET GEAR SET TO COMPLY WITH AD 2011-25-12 AND SB-804 REV B, A DEFECT WAS FOUND IN THE BEARINGS INSTALLED IN THE REMOVED PLANET GEARS. THE BRONZE SLEEVE OF THE BEARINGS HAD ROTATED AND ALSO STARTED TO MOVE OUT OF THE GEAR. IN ONE OF THE GEAR BEARINGS, THE BRONZE SLEEVE HAD MOVED OUT APPROX .1250". THE BRONZE SLEEVE OF THE BEARING SHOULD NOT MOVE DURING A TYPICAL SERVICE LIFE OF A FIRST STAGE PLANET GEAR.

LC1R2011120900002

DIAMON

 

 

PUMP

NOISY

12/9/2011

DA40

 

 

5100009

FUEL SYSTEM

PILOTS HAVE BEEN COMPLAINING ABOUT EXCESSIVE NOISE IN THE HEADSETS GENERATED BY THE ELECTRIC FUEL PUMP. AT 104.8 HOURS OF OPERATION PER RECOMMENDATIONS FROM TECH SUPPORT, THE GROUNDS WERE CHECKED AND CLEANED AND A NEW PUMP WAS INSTALLED. THIS SOLVED THE PROBLEM BUT 147 HOURS LATER, THE SAME PROBLEM RE-OCCURED. AGAIN AT THE RECOMMENDATION OF TECH SUPPORT, THE SAME ACTIONS WERE TAKEN, GROUNDS CLEANED AND NEW PUMP INSTALLED. THIS, AS BEFORE, SOLVED THE PROBLEM BUT 60.8 HOURS LATER THE PROBLEM OCCURED AGAIN. ONCE AGAIN, THE GROUNDS WERE CLEANED AND A NEW PUMP WAS INSTALLED. THIS ONE LASTED FOR 194 HOURS AND ONCE AGAIN AT THE RECOMMENDATION OF TECH SUPPORT A OVERHAULED PUMP WAS INSTALLED AND THE GROUNDS WERE CLEANED. DURING TROUBLESHOOTING, A FERRITE BEAD WAS INSTALLED OVER THE POWER WIRE AND THE NOISE WAS ELIMINATED BUT SINCE THIS WAS NOT AN APPROVED, INSTALLATION WAS REMOVED. TECH SUPPORT WAS INFORMED OF THIS PROPOSED FIX BUT WOULD/COULD NOT APPROVE THIS. WE CAN ONLY SPECULATE THAT IN TIME, THIS HEADSET NOISE WILL RETURN.

2012FA0000094

DIAMON

 

 

LINE

COLLAPSED

2/3/2012

DA42

 

 

 

STATIC

PILOT REPORTED THAT ON TAKEOFF AIRSPEED, ALTITUDE AND ROC SECTION OF G1000 X'D OUT. TAKEOFF ABORTED WITH NO PROBLEMS. ON INVESTIGATION OF THE STATIC LINE FROM INSTRUMENT PANEL TO THE AIR DATA COMPUTER (ADC) HAD COLLAPSED. THE STATIC LINE WAS COLLAPSED DUE TO CONTACT WITH DEFROST HOSE. STATIC LINE REPLACED, SYSTEM OPERATED NORMALLY.

FOTR2118614580

DOUG

 

 

VANE

CORRODED

11/14/2011

DC982

 

 

 

RT WING TE FLAP

RIGHT WING OTBD FLAP OTBD FIXED VANE HAS SURFACE CORROSION ON VANE SUPPORT LWR SURFACE. REPAIRED ON FASI WO 21186, NR 14580.

FOTR2118615227

DOUG

 

 

CUSP WEB

CORRODED

11/14/2011

DC982

 

 

 

BS 655-674

RIGHT MAIN DECK CUSP WEB EXFOLIATED FS 655-674. REPAIRED ON FASI WO 21186, NR 15227.

FOTR2118614935

DOUG

 

 

WEB   

CHAFED

11/14/2011

DC982

 

 

 

ZONE 200

LEFT MAIN DECK FLOOR WEB CHAFED, LBL 44-52, FS 864. REPAIRED ON FASI WO 21186, NR 14935.

FOTR2118615292

DOUG

 

 

SHEAR TIE

CORRODED

11/17/2011

DC982

 

 

 

ZONE 100

BS 1174 AT LONGERON 29R SHEAR TIE IS CORRODED ON FWD AND AFT SIDE. REPAIRED ON FASI WO21182, NR15292.

FOTR2118615084

DOUG

 

 

LONGERON

CORRODED

11/16/2011

DC982

 

 

 

ZONE 100

CORROSION AFT CARGO PIT BILGE AREA STA 1297 IN LONGERON CHANNEL AT LONGERON 28L. REPAIRED ON FASI WO21182, NR15084.

FOTR2118615372

DOUG

 

 

FLOORBOARD

DAMAGED

11/17/2011

DC982

 

 

 

ZONE 100

BS 875, RBL 44, FLOORBOARD COVERING CENTER FUEL TANK ACCESS PANEL IS DAMAGED. REPAIRED ON FASI WO21186, NR15372.

FOTR2118614938

DOUG

 

 

FLOORBOARD

CRACKED

11/18/2011

DC982

 

 

 

ZONE 200

LEFT MAIN DECK METAL FLOORBOARD LOWER SURFACE SUPPORTS CRACKED AND DISBONDING, LBL 44-52, FS 927-1003. REPAIRED ON FASI WO21186, NR 14938.

FOTR2118615052

DOUG

 

 

SHEAR TIE

CORRODED

11/18/2011

DC982

 

 

 

ZONE 100

CORROSION AFT CARGO PIT BILGE SHEAR TIE FWD AND AFT SIDE STA 1250, RBL 3 BETWEEN LONGERON 30 AND LONGERON 29R. REPAIRED ON FASI WO21186, NR 15052.

FOTR2118614968

DOUG

 

 

CARGO TRACK

DAMAGED

11/19/2011

DC982

 

 

 

ZONE 100

AFT CARGO PIT RT FLOOR TRACK HAS A DOUBLE DRILLED HOLE AT STA 1195, RBL 17. REPAIRED ON FASI WO 21186, NR 14968.

FOTR2118615312

DOUG

 

 

WEB   

CORRODED

10/25/2011

DC982

 

 

 

ZONE 200

SUPPORT WEB BENEATH FLOOR FS207, LBL-44-45 HAS LARGE AREA OF EXFOLIATION AND A HOLE WHERE IT MEETS SEAT TRACK. REPAIRED ON FASI WO 21186 MR15312.

FOTR2118615234

DOUG

 

 

CUSP WEB

CORRODED

11/11/2011

DC982

 

 

 

ZONE 200

RIGHT MAIN DECK CUSP WEB SHOWS CORROSION ON TOP OF SURFACE FS 1287-1309. REPAIRED ON FASI WO21186, NR15234.

FOTR2118615251

DOUG

 

 

CUSP WEB

CORRODED

11/11/2011

DC982

 

 

 

ZONE 200

LEFT MAIN DECK CUSP WEB SHOWS MULTIPLE AREAS OF CORROSION AT LIGHTNING HOLE AND AIR GRILL ATTACH ANGLE FS 541-560. REPAIRED ON FASI WO21186, NR15251.

FOTR2118614774

DOUG

 

 

SKIN

DENTED

11/13/2011

DC982

 

 

 

ZONE 100

DEEP CREASE IN LOWER FUSELAGE SKIN- AFT OF AFT CARGO DOOR- STA 1256 BETWEEN LONGERONS 28R-27R. REPAIRED ON FASI WO 21186, NR 14774.

FOTR2118614934

DOUG

 

 

WEB   

CORRODED

11/8/2011

DC982

 

 

 

ZONE 100

LEFT MAIN DECK WEB CHAFED IN MULTIPLE LOCATIONS ON UPPER SURFACE LBL-44 TO LBL-52, FS 807-845. REPAIRED ON FASI WO 21186, NR 14934.

FOTR2011112315020

DOUG

 

 

SPAR

CORRODED

11/23/2011

DC982

 

 

 

ZONE 500

LT WING T/E LOWER AFT SPAR CAP CORRODED OTBD OF AILERON. REPAIRED ON FASI WO 21186, NR 15020.

FOTR2011110821186

DOUG

 

 

WEB   

CORRODED

11/8/2011

DC982

 

 

 

ZONE 200

LEFT MAIN DECK WEB CHAFED IN MULTIPLE LOCATIONS ON UPPER SURFACE LBL 44 TO LBL 52, FS 807 - 845. REPAIRED ON FASI WO 21186 AT 14934.

FOTR2011111815056

DOUG

 

 

FRAME

CORRODED

11/18/2011

DC982

 

 

 

ZONE 100

CORROSION AND BARE METAL AFT CARGO PIT BILGE AREA ON LWR AFT SIDE OF FRAME STA 1250 BETWEEN LONGERON 28L AND 29R. REPAIRED ON FASI WO21186, NR15056.

FOTR2011111814871

DOUG

 

 

CARGO TRACK

DAMAGED

11/18/2011

DC982

 

 

 

ZONE 100

AFT CARGO PIT LEFT CARGO TRACK HAS BLOWN OUT HOLES WITH NO EDGE DISTANCE DRILLED IN THE INBD SIDE OF SCALLOP LBL 15 BETWEEN STA 1098 AND 1117. REPAIRED ON FASI WO 21186, NR 14871.

FOTR2011111715314

DOUG

 

 

FLOORBOARD

CRACKED

11/17/2011

DC982

 

 

 

ZONE 200

FWD ENTRY MAIN DECK FLOORBOARD IS CRACKED FS 157-200, LBL 12-LBL 50. REPAIRED ON FASI WO 21186, NR 15314.

FOTR2011111915243

DOUG

 

 

FLOORBOARD

DELAMINATED

11/19/2011

DC982

 

 

 

ZONE 200

MAIN CABIN FLOORBOARD IS VERY SPONGEY AND APPEARS DELAMINATED, FS 1022-1041, LBL 22 TO RBL 22. REPAIRED ON FASI WO 21186, NR 15243.

FOTR2011111915313

DOUG

 

 

FLOORBOARD

CRACKED

11/19/2011

DC982

 

 

 

ZONE 200

FWD ENTRY, MAIN DECK FLOORBOARD IS CRACKED FS 120-148, BL0 TO LBL24.5. REPAIRED ON FASI WO 21186, NR 15313.

FOTR2011111915315

DOUG

 

 

FLOORBOARD

CRACKED

11/19/2011

DC982

 

 

 

ZONE 200

FWD ENTRY MAIN DECK FLOORBOARD IS CRACKED FS 120-148, RBL48 TO RBL 62.5. REPAIRED ON FASI WO 21186, NR 15315.

FOTR2011111815077

DOUG

 

 

FRAME

CORRODED

11/18/2011

DC982

 

 

 

ZONE 100

CORROSION AFT CARGO PIT BILGE AREA LWR AND AFT SURFACE OF FRAME 1309 FROM LONGERON 29L TO 28R. REPAIRED ON FASI WO21186, NR 15077.

FOTR2011111814760

DOUG

 

 

TORQUE BOX

CORRODED

11/18/2011

DC982

 

 

 

ZONE 100

AFT CARGO DOOR CUTOUT LOWER TORQUE BOX INTERNAL CHORD APPROX FS 1207 HAS MULTIPLE TOOLING MARKS AND AREAS OF CORROSION. REPAIRED ON FASI WO 21186, NR14760.

FOTR2011112015030

DOUG

 

 

FLOORBOARD

DAMAGED

11/20/2011

DC982

 

 

 

ZONE 200

MAIN DECK METAL FLOORBOARD LOWER SURFACE SUPPORTS ARE CRUSHED IN MULTIPLE AREAS RBL 44-52, FS 927-1003. REPAIRED ON FASI WO 21186, NR 15030.

FOTR2011112014801

DOUG

 

 

SUPPORT

GOUGED

11/20/2011

DC982

 

 

 

ZONE 100

FWD E & E DOOR CUTOUT SUPPORT HAS A GOUGE ON FWD SIDE. REPAIRED ON FASI WO21186, NR14801.

FOTR2011111915351

DOUG

 

 

FLOOR PANEL

DAMAGED

11/19/2011

DC982

 

 

 

ZONE 200

MAIN CABIN FLOOR PANEL CENTER SECTION FROM FS 1338-1039 IS DAMAGED. REPAIRED ON FASI WO 21186, NR 15351.

FOTR2011111915013

DOUG

 

 

FLOOR PANEL

DAMAGED

11/19/2011

DC982

 

 

 

ZONE 200

SCREW EMBEDDED IN LOWER SURFACE OF CABIN FLOOR PANEL STA656 LBL30. REPAIRED ON FASI WO 21186, NR 15013.

FOTR2011112015007

DOUG

 

 

FLOORBOARD

PUNCTURED

11/20/2011

DC982

 

 

 

ZONE 200

MAIN CABIN FLOORBOARD HAS MULTIPLE PUNCTURES AND DAMAGED INSERTS ON UPPER AND LOWER SURFACE FS 769-807, RBL54 TO LBL 62. REPAIRED ON FASI WO 21186, NR 15007.

FOTR2011112315114

DOUG

 

 

SPAR

CORRODED

11/23/2011

DC982

 

 

 

ZONE 500

LT WING STA XRS 454 APPROX REAR SPAR LOWER SPAR CHORD HAS CORROSION. REPAIRED ON FASI WO 21186, NR15114.

FOTR2118614933

DOUG

 

 

FLOOR SKIN

CRACKED

11/13/2011

DC983

 

 

 

ZONE 200

LEFT MAIN DECK FLOOR DOUBLER CRACKED ALL THE WAY THRU AT LIGHTNING HOLE, INBD SIDE, LBL 44-52 BETWEEN FS 788-807. REPAIRED ON FASI WO 21186, NR 14933.

FOTR2118615371

DOUG

 

 

FLOORBOARD

DAMAGED

11/17/2011

DC983

 

 

 

ZONE 100

BS 875, LBL 44, FLOORBOARD COVERING CENTER FUEL TANK ACCESS PANEL IS DAMAGED. REPAIRED ON FASI WO21186, NR15371.

2012FA0000019

EMB   

 

 

SKIN

CRACKED

1/12/2012

EMB500

 

 

50011540406

ZONE 600

THE RT WING LOWER WING SKIN, AFT OF THE RT MLG, WAS FOUND CRACKED AT THE FORWARD RIVET HOLE FOR THE SKIN ATTACHMENT TO THE MIDDLE RIB DURING A VISUAL INSPECTION.

2012FA0000017

EMB   

 

 

PITOT TUBE

ERODED

1/12/2012

EMB500

 

 

0851LP

ZONE 100

EROSION OF THE "PLATING MATERIAL" ON THE FACE/INLET OF THE TUBE WHICH THEN PROCEEDS TO MIGRATE DOWN THE BARREL OF THE TUBE. PITOT TUBE HAS THEN BEEN INSTALLED AND THE CORRESPONDING RECONNECT/LEAK AND CERTIFICATION CHECKS HAVE BEEN PERFORMED TO RETURN THE ACFT TO SERVICE.

2011FA0000772

GULSTM

PWC   

 

STRUCTURE

CRACKED

11/7/2011

200   

PW306A

 

 

LT AILERON

DURING A POST FLIGHT INSPECTION, FOUND LT AILERON CRACKED AND DELAMINATED AT THE INBD END CAP OF AILERON. LT AILERON WAS R & R WITH NEW AILERON.

2011FA0000773

GULSTM

PWC   

 

STRUCTURE

CRACKED

11/7/2011

200   

PW306A

 

 

RT AILERON

DURING A POST FLIGHT INSPECTION FOUND LT AILERON CRACKED AND DELAMINATED AT THE INBD END CAP OF AILERON. LT AILERON WAS R & R WITH NEW AILERON.

GR4D20120125012

GULSTM

 

VOUGHT

WINGLET

CORRODED

1/25/2012

GIV   

 

 

1159W407015

ZONE 500

LT WINGLET CORRODED.

ZI3R025M012720121

GULSTM

RROYCE

 

SWIRLER

MISSING

1/24/2012

GVSPG550

BR700710A110

 

6934408

FUEL NOZZLE TIP

ZI3R RECEIVED 3 EA, BR710 FUEL NOZZLES FROM MFG. ONE (1) OF THE THREE (3) NOZZLES HAD A MISSING COMPONENT; THE INNER AIR SWIRLER. THE MISSING COMPONENT WAS DISCOVERED DURING AN CUSTOMER REQUIRED X-RAY INSPECTION PERFORMED BY OEM, AND THE MISSING PART WAS VERIFIED AT REPAIR STATION DURING THE RECEIVING INSPECTION. THE PO THAT WAS RECEIVED WITH THE PARTS DID NOT INDICATE ANY ISSUE WITH THE NOZZLES OR WITH THE ENGINE THAT THEY WERE REMOVED FROM. THE CUSTOMER INDICATED IN A FOLLOWING EMAIL: "THIS ENGINE WAS SUBJECT TO OIL CONTAMINATION WHICH APPEARS TO HAVE FROM HEAVY FRETTAGE AND FAILURE IN THE INTERMEDIATE CASE MODULE." THERE IS NO PREVIOUS RECORD OF THIS SN FOR MX; EITHER THE NOZZLE HAS BEEN IN SERVICE SINCE NEW, OR THE NOZZLE HAS BEEN SERVICED BY OTHER REPAIR STATIONS.

2012FA0000070

HUGHES

LYC   

 

PISTON

FAILED

1/14/2012

269C1

HIO360G1A

 

 

NR 4 CYLINDER

NORMAL TAKEOFF, HOVER, AND STEADY LEVEL FLIGHT. 30 MINUTES ENROUTE, SUDDEN VIBRATIONS FOLLOWED BY LOW RPM WARNING LIGHT & HORN. VERIFIED DROPPING NEEDLES AND LOWERED COLLECTIVE FOR AUTOROTATION. CHECKING AIRSPEED GAUGE AT 40KTS, ADJUSTED FORWARD CYCLIC FOR MORE AIRSPEED. VIBRATIONS STOPPED AND ENGINE QUIT. ESTABLISHED AUTOROTATION, LOOKED FOR LANDING SPOT, AIRSPEED 60-70KTS, FLARED AND LANDED. UPON VISUAL INSPECTION OF ENGINE, CATASTROPHIC FAILURE OF NR 4 CYLINDER, PISTON.

2011FA0000802

ISRAEL  

GARRTT

 

SHAFT

SEPARATED

12/7/2011

ASTRASPX

TFE731*

 

30603663

HP COMPRESSOR

ENGINE REMOVED FOR SCHEDULED 2500 HR, MAJOR PERIODIC INSPECTION AND 5000 HR COMPRESSOR ZONE INSPECTION. DISASSEMBLY FINDINGS REVEALED SEPARATION OF THE SHAFT ADJACENT TO THE HIGH PRESSURE COMPRESSOR AFT CURVIC TEETH.

2012FA0000103

LANCAR

CONT

 

SPARK PLUG

CRACKED

2/9/2012

LC41550FG

TSIO550C

 

RHB32S

ENGINE

RT B32S SPARK PLUGS HAVE CRACKED PORCELAIN, QTY 6 OUT OF 12, FOUND DURING ANNUAL INSPECTION.

JKIR2012010619587

LEAR

 

 

LINE

CORRODED

1/6/2012

35A   

 

 

2307003

HYDRAULIC SYS

NLG EXTEND ALUMINUM HYD LINE AT FRAME 9L, STRINGER 19, RUPTURED DUE TO INTERNAL CORROSION. THIS CAUSED ACFT TO LOSE HYD PRESSURE IN-FLIGHT. ACFT LANDED WITHOUT INCIDENT.

2011FA0000798

LEAR

 

 

CONTROL VALVE

INOPERATIVE

12/8/2011

45LEAR

 

 

32912221

COCKPIT HEAT

FOLLOWING INITIAL DESCENT FROM FL430 AND WHEN PASSING THROUGH FL400 THE FLIGHT CREW NOTICED FUMES AND SMOKE ACCUMULATING IN THE COCKPIT AND CABIN. AN EMERGENCY DESCENT WAS INITIATED AND AFTER PASSING THROUGH FL200 THE SMOKE AND FUMES RAPIDLY DISSIPATED. A NORMAL LANDING WAS MADE. MX PERSONNEL FOUND THE COCKPIT HEAT TEMP EXCESSIVELY HIGH WHEN RUNNING IN MANUAL MODE. FURTHER TROUBLESHOOTING FOUND THE COCKPIT HEAT CONTROL VALVE NOT RESPONDING TO INPUTS IN MANUAL OR AUTO MODE. THE COCKPIT HEAT TEMP CONTROL VALVE ALONG WITH THE ECS TEMP CONTROLLER WAS REPLACED AND OPS CHECKS WERE SATISFACTORY.

UVVR2012012000020

LEAR

 

 

CHECK VALVE

FOD   

1/20/2012

45LEAR

 

 

HTE460072

RT WING

WHEN ACFT PARKED ON UNLEVEL SURFACE FUEL WOULD MIGRATE FROM RT WING TO LT WING. FOD WAS FOUND LODGED IN THE RT WING FUELING TRANSFER CHECK VALVE. REPLACED RT TRANSFER CHECK VALVE ASSY. REMOVED LT TRANSFER CHECK VALVE ASSY, INSPECTED, AND REINSTALLED WITH NO DEFECTS NOTED. REFUELED ACFT AND PERFORMED SATISFACTORY LEAK AND OPS CHECK. FOD SAMPLE APPEARED TO BE FUEL TANK SEALANT MATERIAL.

2011FA0000799

LEAR

GARRTT

 

MUFFLER

CRACKED

12/16/2011

45LEAR

TFE731*

 

12945096001

COCKPIT AIR

CREW REPORTED LOW AIRFLOW TO THE COCKPIT. INSPECTION FOUND INSULATION MATERIAL BLOWN FROM THE COCKPIT ESC MUFFLER. VISUAL INSP OF THE MUFFLER REVEALED 3.5 INCH CRACK AT THE LOWER WELD SEAM. THE DEFECT WAS REPORTED TO FIELD SERVICE AND THE MUFFLER WAS REPLACED WITH A NEW UNIT.

2012FA0000086

LET   

 

 

CONTROL CABLE

FRAYED

2/2/2012

L23SUPERBLAN

 

 

A740255N

RUDDER

FRAYED RUDDER CABLE FOUND DURING 500 HOUR. CHRONIC PROBLEM.

NI6R20120131002

LKHEED

 

 

SPAR

BROKEN

1/27/2012

SP2H

 

 

 

ZONE 500

AT WING STATION 40, LT SIDE, A CRACK JUST OTBD OF THE FUSELAGE SKIN APPROX 20-24 INCHES LONG WAS DISCOVERED DURING PSE EDDY CURRENT INSPECTION. THE BREAK STARTS AT THE FRONT SPAR NR 22 RUNNING AFT ALONG WITH THE NEXT STRINGER NR 21 AFT OF THE SPAR, WHICH HAD NOT COMPLETELY SEVERED. THE FORWARD SPAR WEB IS ALSO CRACKED FROM THE TOP OF THE SPAR RUNNING UPWARDS AND EVENTUALLY DISAPPEARING BEHIND AN EXISTING DOUBLER APPROX 18 INCHES IN LENGTH.

FK8R201010080005

MOONEY

LYC   

 

BRACKET

CRACKED

10/8/2010

M20C

O360A1D

 

650017000

OIL COOLER

OIL COOLER MOUNTING BRACKET WAS FOUND CRACKED.

2012FA0000003

MOONEY

LYC   

 

SPINNER

CRACKED

12/14/2011

M20F

IO360A1A

 

103937P

PROPELLER

INSTALLED A NEW STC PROPELLER WITH A NEW SPINNER AND ADAPTER PLATE SUPPLIED IAW STC SA02414CH-D. AFTER 30 HOURS OF OPERATION, WHILE DOING A WALK AROUND INSPECTION, NOTICED THE SPINNER WAS CRACKED AT A SCREW HOLE. REMOVED SPINNER AND FOUND ADAPTER PLATE CRACKED. THE PILOT FELT NO UNUSUAL VIBRATIONS AND OPERATED. THE ENGINE & PROPELLER IAW FLIGHT MANUAL AND STC INSTRUCTIONS. CAUSE OF CRACKING IS UNDETERMNED. MFG HAS FOUND THAT THERE HAVE BEEN A HIGH NUMBER OF SPINNER CRACKING WHICH IS STILL UNDER INVESTIGATION, MFG HAS OBSERVED THAT IT CAN BE UNPREDICTABLE, WITH CUSTOMERS PREVIOUSLY EXPERIENCING THIS CRACKING PARTICULARLY SUSCEPTIBLE TO ADDITIONAL CRACKING INCIDENTS ON LONGER METAL SPINNERS.

2012FA0000004

MOONEY

LYC   

 

ADAPTER

CRACKED

12/14/2011

M20F

IO360A1A

 

1101186

PROP SPINNER

INSTALLED A NEW STC PROPELLER WITH A NEW SPINNER AND ADAPTER PLATE SUPPLIED IAW STC SA02414CH-D. AFTER 30 HOURS OF OPERATION, WHILE DOING A WALK AROUND INSP, NOTICED THE SPINNER WAS CRACKED AT A SCREW HOLE. REMOVED SPINNER AND FOUND ADAPTER PLATE CRACKED. THE OWNER/PILOT STATED HE FELT NO UNUSUAL VIBRATIONS AND OPERATED THE ENGINE/PROP IAW FLIGHT MANUAL AND STC INSTRUCTIONS. CAUSE OF CRACKING IS UNDETERMNED. MFG HAS FOUND THAT THERE HAVE BEEN A HIGH NUMBER OF SPINNER CRACKING WHICH IS STILL UNDER INVESTIGATION, MFG HAS OBSERVED THAT IT CAN BE UNPREDICTABLE, WITH CUSTOMERS PREVIOUSLY EXPERIENCING THIS CRACKING PARTICULARLY SUSCEPTIBLE TO ADDITIONAL CRACKING INCIDENTS ON LONGER METAL SPINNERS. RECOMMEND MECHANICS AND OPERATORS INSPECT SPINNER AND ADAPTER PLATE MORE FREQUENTLY. RECOMMEND A CLOSER INSP BEFORE AND AFTER EACH FLIGHT.

FK8R201104210003

MOONEY

LYC   

 

PANEL

CRACKED

4/21/2011

M20J

IO360A3B6D

 

 

SEAT BACK

PILOT SEAT BACK REAR PANEL WAS FOUND CRACKED ON BOTH SIDES.

2012F00029

PIAGIO

 

 

HYDRAULIC SYSTEM

MALFUNCTIONED

12/22/2011

P180

 

 

 

 

HYDRAULIC PRESSURE READS 0 AFTER LOWERING GEAR, HYD PRESSURE READS 0 DURING GEAR EXTENSION AND RETRACTION, NO HYD PRESSURE LIGHT.

2012F00010

PIAGIO

PWA   

 

ENGINE

OVERSPEED

11/16/2011

P180

PT6A66

 

 

NR 1  

NR 1 ENGINE EXPERIENCED OVERSPEED CONDITION, ENGINE SECURED.

2011FA0000810

PIAGIO

PWA   

 

AUTOFEATHER SYS

MALFUNCTIONED

12/27/2011

P180

PT6A66

 

 

 

UNCOMMANDED AUTOFEATHER IN FLIGHT/APPROACH.

LF1R2011082300001

PILATS

 

HONEYWELL

PIN   

UNSECURE

8/23/2011

PC1245

 

 

 

TERMINAL BLOCK

ACFT OPERATOR TAXIED TO RUN UP AREA AND PERFORMED PREFLIGHT CHECKS. NOTED AUTOPILOT WOULD NOT PASS PREFLIGHT TEST. RETURNED ACFT TO SERVICE HANGAR. DURING TROUBLESHOOTING PROCESS, FOUND THAT PIN F AT TERMINAL BLOCK 290-02 WAS NOT FULLY SEATED. THIS CAUSED AN OPEN CIRCUIT FOR AUTOPILOT DISCONNECT LINE AND FAILED THE TEST. AFTER INFORMING OPERATOR, THEY MENTIONED THAT THEY HAVE HAD SOME INSTANCES OF CLEAR AIR AUTOPILOT DISCONNECTS AS WELL PREVIOUSLY. RESEATED THIS PIN AND AUTOPILOT PASSED PREFLIGHT TEST SATISFACTORILY. WE HAVE FOUND INSTANCES OF LOOSE PINS IN TERMINAL BLOCKS ( VARIOUS SYS) OCCASIONALLY ON OTHER ACFT. THIS AREA SHOULD BE CHECKED CLOSELY WHEN TROUBLESHOOTING HARD TO FIND PROBLEMS.

5APR0201210377103

PILATS

PWA   

 

DISPLAY

FAULTY

1/3/2012

PC1245

PT6A67B

 

066031252500

EFIS  

THE COPILOTS EADI WAS REPORTED AS INOPERATIVE. THE COPILOTS EAD, WAS R & R USING A SERVICEABLE UNIT IAW AMM 12-A-34-26-03-00A-920A-A. THE SYS OPERATIONALLY CHECKED GOOD IAW AMM 12-A-34-26-00-00A-903A-A.

5APR20120117105

PILATS

PWA   

 

CONTROLLER

FAULTY

1/17/2012

PC1245

PT6A67B

 

065000860017

AUTO PILOT

THE FLIGHT CREW REPORTED THE AUTO PILOT SYSTEM AS BEING INOP. THE AUTO PILOT MODE CONTROLLER, PN 065-00086-0017 WAS FOUND TO BE FAULTY. IT WAS R & R USING A SERVICEABLE UNIT OF THE SAME PN IAW AMM 12-A-22-10-05-00A-920A-A. THE SYS OPERATIONALLY TESTED GOOD IAW AMM 12-A-22-10-00-00A-903A-A.

5APR20120119106

PILATS

PWA   

 

EADI

FAILED

1/19/2012

PC1245

PT6A67B

 

066031252500

NR 2  

THE NR 2 EADI WAS FOUND TO BE BLOOMING DURING OTHER MX AND NEEDING REPLACEMENT. THE NR 2 EADI PN 066-03125-2500 WAS R & R USING A SERVICEABLE UNIT OF THE SAME PN 066-03125-2500 IAW AMM 12-A-34-26-03-00A-920A-A, OPS CHECKED GOOD IAW AMM 12-A-34-26-00-00A-903A-A.

5APR20120120107

PILATS

PWA   

 

DISPLAY

FAULTY

1/20/2012

PC1245

PT6A67B

 

066031252500

EHSI  

THE EHSI WAS REPORTED AS INOPERATIVE. THE EHSI DISPLAY WAS FOUND TO BE FAULTY. THE EHSI DISPLAY WAS R & R USING A SERVICEABLE UNIT OF THE SAME PN IAW AMM12-A-34-26-02-00A-920A-A. THE SYS OPERATIONALLY CHECKED GOOD IAW AMM 12-A-34-26-00-00A-903A-A.

K5SR2012012823151

PILATS

 

 

COMPUTER

MALFUNCTIONED

1/28/2012

PC1247

 

 

9754423104

STICK PUSHER

ACFT WAS ENROUTE WHEN AT FL200 WITH AN OAT OF -18, THE COMPUTER WAS PUSHER CAUTION LIGHT ILLUMINATED 5 TO 10 SECONDS AFTER THE INITIAL SEPARATOR AND PROP DE-ICE WAS TURNED ON DUE TO ICE. THE ACFT RETURNED TO DEPARTURE FOR REPAIRS. PERFORMED TROUBLESHOOTING OF THE STICK PUSHER SYS. FOUND STICK PUSHER COMPUTER PN 975.44.23.104, SN 9368 FAILED PUSHER CHECK IAW PC12 AMM 12-A-22-20-00-00A-903A-A. INSTALLED INSPECTED STICK PUSHER COMPUTER WITH SATISFACTORY RESULTS. ACFT WAS RETURNED TO SERVICE.

5APR20120208108

PILATS

PWA   

 

ROTOR

CRACKED

2/5/2012

PC1247

PT6A67

 

244759C

BRAKE ASSY

THE LEFT BRAKE ASSY WAS INSPECTED DURING A LINE CHECK AND FOUND TO HAVE A CRACKED ROTOR. THE LT BRAKE ASSY R & R IAW MM 12-B-32-40-03-00A-920A-A.

5APR2012010577104

PILATS

PWA   

 

RELAY

FAULTY

1/5/2012

PC1247

PT6A67

 

9742001221

PITCH TRIM

THE CREW REPORTED THAT THE PITCH TRIM CB FOUND POPPED UPON LANDING. THE STAB TRIM RELAY K161E2 WAS FOUND TO BE INOPERATIVE. REMOVED BOTH STAB TRIM RELAYS K161E2 AND K161D2, AND INSTALLED NEW RELAYS. THE HORIZONTAL PITCH TRIM SYS OPERATIONALLY CHECKED GOOD. ALL WORK ACCONPLISHED IAW AMM 12-B-27-40-00-00A-903A-A AND WDM 91-10-01.

5APR2012010177102

PILATS

PWA   

 

RELAY

FAULTY

1/1/2012

PC1247

PT6A67B

 

9742001212

STAB TRIM

PILOTS REPORTED ENROUTE: STAB TRIM FAILURE WHEN MANUALLY TRIMMING UP FROM THE CAPTAINS SEAT AN AURAL WARNING FOLLOWED BY RUNAWAY TRIM. THE STABILIZER TRIM RELAY K022, PN 974.20.01.212 WAS FOUND FAULTY. IT WAS R & R USING A SERVICEABLE RELAY OF THE SAME PN. THE SYSTEM OPS CHECKED GOOD IAW AMM 12-A-27-40-00-00A-903A-A.

5APR2011122877100

PILATS

PWA   

 

FITTING

OUT OF ALIGNMENT

12/28/2011

PC1247

PT6A67B

 

5551012150

ZONE 300

THE HORIZONTAL STABILIZER ATTACHMENT FITTING, WHERE THE PITCH TRIM ACTUATOR IS SECURED TO THE STABILIZER. LUGS ARE SEPARATING. THE GAP WAS MEASURED WITH A FEELER GUAGE, AND FOUND TO BE .635MM. THERE IS NO EVIDENCE OF DAMAGE TO THE STABILIZER.

5APR2011122977101

PILATS

PWA   

 

RELAY

FAULTY

12/29/2011

PC1247

PT6A67B

 

9742001212

STAB TRIM

CREW REPORTED STAB TRIM FAILURE, RUNAWAY NOSE DOWN ENROUTE TO GMU, THE ACFT LANDED SAFELY. THE STAB TRIM DOWN RELAY WAS FOUND FAULTY, R & R USING A NEW RELAY IAW WDM 27-40-00. THE SYS OPERATIONALLY TESTED GOOD IAW AMM 12-A-27-40-00-00A-903A-A.

5APR2011121557799

PILATS

PWA   

 

SKIN

DAMAGED

12/15/2011

PC1247

PT6A67B

 

5570512131

LT WING

THE ACFT LEFT WING L/E WAS DAMAGED BY A BIRDSTRIKE. THE DAMAGE WAS OUTSIDE THE GUIDANCE OF THE SRM FOR "ALLOWABLE DAMAGE". TECHNICAL SUPPORT WAS CONTACTED, AN ENGINERING REPAIR MEMO AND "STATEMENT OF APPROVED DESIGN DATA" ECC-12-RM-11-249 WAS ISSED. THE ACFT WAS REPAIRED USING THOSE INSTRUCTIONS, UTILIZING A FLUSH PATCH AND DOUBLERS FOR THE REPAIR OF THE EXISTING L/E SKIN AND RIBS. AN FAA FORM 337 DATED 12-15-2011 WAS SUBMITTED.

5APR2011111557797

PILATS

PWA   

 

DISPLAY

FAULTY

11/15/2011

PC1247

PT6A67B

 

066031252500

EFIS  

DURING AHRS SWING CHECKS THE NR 2 EHSI WAS FOUND FUZZY AND NEEDING REPLACEMENT. THE NR 2 EHSI WAS R & R WITH A SERVICEABLE UNIT OF THE SAME PN 066-03125-2500 IAW AMM 12-A-34-26-02-00A-920A-A AND TESTED SATISFACTORY IAW AMM 12-A-34-26-00-00A-903A-A.

5APR2011120557798

PILATS

PWA   

 

DISPLAY

FAULTY

12/5/2011

PC1247

PT6A67B

 

066031252500

EADI  

PILOT REPORTED THAT THE PILOTS SIDE EADI, IS FUZZY AND FLICKERS OFF WHEN COLD. PILOTS SIDE EADI WAS R & R USING A SERVICEABLE UNIT IAW AMM 12-A-34-26-03-00A-920A-A AND OPS CHECKED GOOD IAW AMM 12-A-34-26-00-00A-903A-A.

2012FA0000110

PIPER

 

PIPER

AXLE

CORRODED

2/10/2012

J3C65

 

 

314721

RT MLG

DURING CLEANING IN PREPARATION FOR RECOVERING OF THE RT LANDING GEAR IT WAS NOTED THAT WOOD PLUG, PN 30941, WAS MISSING. SEVERE CORROSION WAS NOTICED INSIDE LOWER RADIUS OF THE AXLE TUBE. ESTIMATE THE LOWER PORTION OF TUBE WAS CORRODED MORE THEN 50 PERCENT OF WALL THICKNESS. NORMALLY 10 PERCENT IS CONSDERED EXCESSIVE LIMIT. IT APPEARS WATER SAT IN AXLE TUBE. THIS ACFT HAS BEEN OUT OF SERVICE FOR SOME TIME & IN NEED OF RECOVERING. CORROSION PROTECTION WITH PREVENTATIVE COMPOUND WOULD HELP PREVENT THIS CONDITION. THIS LANDING GEAR ASSY WAS REPLACED.

BQVR20120204

PIPER

 

 

BRAKE

LOCKED

2/4/2012

PA22150

 

 

 

LEFT  

AT THE BEGINNING OF THE TAKEOFF ROLL, THE NOSE OF THE ACFT SUDDENLY LOWERED AND THE PROPELLER MADE CONTACT WITH THE GROUND. MX ARRIVED AT THE ACFT AND DISCOVERED THE LT BRAKE LOCKED AND THE LT WHEEL UNABLE TO ROLL. THE RT WHEEL WAS FREE TO MOVE. THE LT BRAKE GRADUALLY FREED UP BUT NOT COMPLETELY WITH REPEATED APPLICATION AND RELEASE OF THE BRAKE. THE ACFT HAD BEEN STORED IN AN UNHEATED HANGER THE NIGHT BEFORE. TEMPERATURE APPARENTLY WAS AT OR BELOW FREEZING WHEN THE PROBLEM OCCURRED. ACFT WAS MOVED INTO A HEATED MX HANGER AND AFTER A WHILE, NORMAL BRAKE RELEASE WAS OBSERVED.

2011FA0000812

PIPER

 

 

LINK ASSY

FAILED

12/9/2011

PA23160

 

 

1904300

LT MLG

DURING ROLLOUT, AFTER LANDING, ACFT STARTED TO LEAN TO THE LEFT. PILOTS USED RT RUDDER AND BRAKES TO MAINTAIN CONTROL OF THE ACFT ON THE RUNWAY. ACFT CAME TO COMPLETE STOP ON RUNWAY. FURTHER INVESTIGATION, NOTED THAT THE LT MLG TO PASS CENTER AND FALL AFT. LINK ASSY HAD FAILED AT A DRILLED BOLT HOLE BY THE MFG. SLIGHT RUST WAS NOTED INSIDE THE TUBE. THE WELD ON THE LINK TUBE, FOR THE ROD END, ENDS AT THE POINT WHERE THE MFG DRILLS A HOLE TO MOUNT THE LOCK. HEAT TREATING OF THIS AREA MIGHT BE AN ISSUE. WATER/MOISTURE CAN GET INTO THIS TUBE THROUGH THE BOLT HOLE. LINK COULD BE MADE FROM A BETTER MATERIAL AND POSSIBLE CORROSION TREATMENT INTERNALLY IN THE TUBE TO PREVENT CORROSION.

2012FA0000001

PIPER

LYC   

 

KEY   

BROKEN

12/9/2011

PA28151

O320D3G

 

 

ENGINE

WHILE TROUBLESHOOTING A ROUGH RUNNING ENGINE, DISCOVERED A DEFORMED ROCKER COVER. WHEN THE COVER WAS REMOVED THE SPRING SEAT LOOSE ON FLANGE PIECES AND THE VALVE KEYS WERE FOUND IN THE ROCKER COVER.

2012FA0000109

PIPER

LYC   

BENDIX

DISTRIBUTOR GEAR

DAMAGED

2/6/2012

PA28151

O320E3D

 

 

RT MAGNETO

PILOT REPORTED A NORMAL RUN-UP BEFORE TAKEOFF. DURING CLIMB-OUT POWER LOSS WAS EXPERIENCED. ON LANDING ANOTHER RUN UP SHOWED THE RT MAGNETO WAS INOPERATIVE. REMOVED THE RT MAGNETO AND FOUND THE PLASTIC DISTRIBUTOR GEAR WAS MISSING TEETH .2500 OF THE WAY AROUND THE GEAR.

2011FA0000811

PIPER

LYC   

PIPER

AXLE

CRACKED

12/12/2011

PA28161

O320B2B

 

78738003

MLG  

CRACK FOUND IN EAR OF RT AXLE STUB DURING ANNUAL INSPECTION. UNKNOWN IF IT HAS EVER BEEN CHANGED BEFORE. UNKNOWN IF CRACK IS RESULT OF HARD LANDING OR FATIGUE (OR BOTH). ACFT IS INVOLVED IN A FLIGHT SCHOOL OPERATION. R & R PART, RESEALED STRUT. ACFT RELEASED FOR SERVICE.

C41R201112130107

PIPER

 

 

CONTACTOR

CORRODED

12/12/2011

PA28181

 

 

455151

ELECTRICAL

PILOT REPORTED BATTERY WOULD LOOSE CHARGE RAPIDLY. ALSO, RANDOMLY HAD STARTING PROBLEMS. TROUBLESHOT ELECTRICAL AND STARTING SYSTEM. FOUND MASTER CONTACTOR TO HAVE EXCESS RESISTANCE INTERNALLY CAUSING EXCESS AMPERAGE TO BE DRAWN DURING ENGINE START. 149 AMPS DC - SHOULD BE 12-18 AMPS. REPLACED MASTER CONTACTOR AND ALL SYS, OPS CHECKED NORMAL.

2012FA0000031

PIPER

LYC   

LYC   

PLUG

DISINTEGRATED

1/18/2012

PA28181

O360A4M

 

LW12892

ROCKER SHAFT

ON RECENT REPLACEMENT OF VALVE COVER GASKETS, DISCOVERED THE ROCKER SHAFT PLUGS HAVE BROKEN INTO SMALL PIECES. IT APPEARS THAT DUE TO THE HIGH INTERNAL HEAT ASSOCIATED WITH THIS PART OF THE ENGINE, THAT THE PLUGS HAVE LIKELY SEIZED INTO PLACE AND OR BECOME SO BRITTLE THAT WHEN THEY DO SEIZE INTO PLACE THEY BREAK. DO NOT BELIEVE ANY PLASTIC WITH THIS PART HAS CAUSED ANY DAMAGE AND THE OIL FILTER SHOULD STOP ANY PROBLEMS, HOWEVER WE HAVE SEEN SO MANY OF THESE PROBLEMS RECENTLY I WOULD QUESTION THE MATERIAL BEING USED IN THE DESIGN OF THE PART.

2012FA0000065

PIPER

LYC   

HOOF

O-RING

TORN

1/23/2012

PA28R200

AEIO360*

 

MS28775006

ZONE 100

A DEFECTIVE EMERGENCY LANDING GEAR EXTENSION VALVE. SPECIFICALLY THE INTERNAL O-RING SEALS WERE FOUND TORN AND DAMAGED. THIS CONDITION WAS DETERMINED TO BE CAUSING THE LANDING GEAR EMERGENCY EXTEND LEVER FROM PROPERLY FUNCTIONING, AS WELL, IT CAUSES THE LANDING GEAR PUMP HYD PRESSURE TO BYPASS IN THE RETRACT FUNCTION. THIS CONDITION ALONG WITH AN INOPERATIVE ALTERNATOR/ELECTRICAL FAILURE IN FLIGHT, CAUSED A GEAR UP LANDING.

2011FA0000793

PIPER

 

 

ATTACH FITTING

CHAFED

12/16/2011

PA28R201

 

 

63900174

FLAP CONTROL

UPON INSPECTION OF FLAP CONTROL CABLE TO FLAP HANDLE ATTACHMENT FOUND BUSHING (PN 63900-174) CLEVIS BOLT (PN AN23-11), AND FLAP HANDLE (PN 63781-008) HAD BEEN "SAWING" THROUGH EACH OTHER. THIS CONDITION WAS ADDRESSED ON OLDER MODEL ACFT BY AD96-10-03 "FLAP LEVER HANDLE AND BOLT". THIS IS A TRAINING FLEET ACFT. FOUND THE PROBLEM TO BE THAT THE BUSHING WAS NOT FREE TO ROTATE DUE TO EITHER EXCESSIVE LENTH OR BEING TIGHTENED DOWN TOO MUCH AT THE FACTORY.

MV1R2011121400000

PIPER

 

 

PUMP

FAILED

12/14/2011

PA31350

 

 

1213HBG310

HYD SYSTEM

DURING TRAINING FLIGHT, AFTER 2ND TOUCH & GO LANDING, GEAR UNSAFE LIGHT STAYED ON AFTER THE GEAR WAS RETRACTED. LANDING GEAR TOOK MUCH LONGER TO EXTEND & LOCK THAN NORMAL. ACFT LANDED WITHOUT INCIDENT. UPON INSPECTION, MX FOUND HYD FLUID ON THE LT FLAP AREA. THE HYD RESERVIOR WAS EMPTY & HYD FLUID DRIPPING FROM THE LT HYD PUMP DRAIN. HYD FILTERS WERE CHECKED AND THE LT FILTER HAD PIECES OF SEAL MATERIAL IN IT. REPLACED FILTER, SERVICED & BLED HYD SYS IAW MM. OPS CHECK WITH RUNING ENGINES SHOWED LT PUMP FAILED PRESSURE CHECK AND HYD FLIUD COMING OUT OF LT PUMP DRAIN. PUMP TO BE REPLACED.

2012FA0000111

PIPER

 

 

CONNECTOR

BURNED

2/14/2012

PA31350

 

 

 

 

DURING INSPECTION FOR COMPLIANCE WITH SB1004 THE E303 CONNECTOR WAS FOUND TO BE BADLY BURNED. THE CONNECTION WAS REPAIRED IAW THE SB. INSPECTOR NOTES THAT THE INITIAL INSP OF EVERY ACFT HAS SHOWN NO COMPLIANCE WITH THIS SB AND ALL SHOW THE SAME BURNING OF THE CONNECTOR.

2012F00031

PIPER

LYC   

 

LIFTER

BROKEN

12/19/2011

PA31350

TIO540J2B

 

15B26064

EXHAUST VALVE

DURING ANNUAL INSP, A PIECE OF METAL (APP .2500" SQUARE) WAS FOUND IN THE SUCTION SCREEN. INSPECTION REVEALED NR 6 EXHAUST LIFTER BODY WAS MISSING A PIECE WHERE THE HYD TAPPET PLUNGER ASSY INSERTS INTO THE LIFTER BODY. NO REPORTS OF LOSS IN ENGINE PERFORMANCE.

2011FA0000774

PIPER

LYC   

LYC   

B-NUT

BACKED OUT

12/2/2011

PA32260

O540E4B5

 

 

NR 4 CYLINDER

PILOT REPORTED SMOKE IN THE COCKPIT AFTER LANDING. AFTER AN INSPECTION OF THE ENGINE, IT WAS FOUND THAT NR4 CYLINDER HEAD OIL RETURN LINE "B" NUT HAD BACKED OFF CAUSING OIL TO DRIP ONTO THE EXHAUST STACK WHICH CAUSED THE SMOKE IN THE COCKPIT. THE MECHANIC INSTALLED AND TIGHTENED THE LOOSE "B" NUT AND INSPECTED ALL OTHER CYLINDERS FOR ANY OTHER LOOSE "B" NUTS. NO OTHER LOOSE OIL RETURN "B" NUTS WERE FOUND TO BE LOOSE. THE ACFT WAS RETURNED TO SERVICE AND THE PROPER PAPERWORK WAS COMPLETED.

1SMA2012FA0000032

PIPER

LYC   

 

TIRE

DEFECTIVE

1/18/2012

PA32300

IO540K1A5

 

60066RTM

ZONE 700

WHILE SECURING ACFT AFTER FLIGHT, PILOT REPORTED RT MAIN TIRE WAS FLAT. INVESTIGATION REVEALED THAT ONE COMPLETE SECTION OF TREAD HAD DEBONDED AND COME OFF OF TIRE AND WRAPPED AROUND MAIN WHEEL FAIRING SUPPORT CAP ON AXLE END, CAUSING DAMAGE TO THE TUBE VALVE STEM RESULTING IN THE FLAT TIRE. THE PILOT INDICATED THAT THERE WAS NO INDICATION OF THE TIRE BEING FLAT DURING LANDING AND SUBSEQUENT TAXI AND BELIEVES THAT IT DEFLATED AFTER PARKING. THERE IS NO INDICATION OF DAMAGE TO THE ACFT. TIRE WAS A MONSTER RETREAD AND HAD APPROX 20 LANDINGS SINCE INSTALLATION. REPORT INCLUDING PICTURES HAS BEEN EMAILED TO THE MFG TO SEE IF OTHER SIMILAR REPORTS HAVE BEEN MADE.

C41R201112290108

PIPER

LYC   

 

TRANSDUCER

CONTAMINATED

12/28/2011

PA32301T

TIO540*

 

84522003

FUEL PRESSURE

PILOT REPORTED NO FUEL PRESSURE INDICATION ON DISPLAY. FOUND FUEL PRESSURE TRANSDUCER MOUNTED UNDER LT MAGNETO WITH WIRING FACING UP. INSPECTION REVEALED UNIT TO BE OIL-SOAKED DUE TO PRIOR MAGNETO REPLACEMENT. SUSPECT OIL MIGRATED INTO WIRING AND SHORTING OUT UNIT. REPLACED TRANDUCER WITH NEW AND OPS CK GOOD. NEW UNIT WIRING EXTERNALLY SEALED WITH RTV TO PREVENT FUTURE PROBLEMS.

2012FA0000089

PIPER

CONT

 

SEAL

FROZEN

2/1/2012

PA34200T

TSIO360EB

 

 

AILERONS GAP

DEPARTED AND CLIMBED THROUGH MODERATE TO HEAVY PARTICIPATION FOR 10-15 MINUTES, LEVELED OFF AT 9,000 FT WHICH WAS AN ALTITUDE THAT WAS BELOW FREEZING. SET AUTOPILOT FOR STRAIGHT AND LEVEL FLIGHT AND AFTER ABOUT 10 MINUTES, NOTICED THAT THE AIRPLANE WAS VEERING OFF THE HEADING AND BEGINNING TO ENTER A SLIGHT BANK. SHUT OFF THE AUTOPILOT AND LEVELED THE PLANE BUT NOTICED THAT THE AILERON CONTROL SEEM VERY STIFF. PULLED THE CIRCUIT BREAKER FOR THE AUTOPILOT AND ELECTRIC TRIM TO ENSURE THAT THEY WERE DISENGAGED. AFTER ABOUT 4 TO 5 MORE MINUTES IN LEVEL FLIGHT THE AILERONS WENT FROM BEING VERY STIFF TO COMPLETELY FROZEN. FORCED TO CONTROL THE AIRPLANE WITH RUDDER AND ELEVATOR INPUTS ONLY. LATER IN THE FLIGHT, DURING DESCENT TO ABOVE FREEZING TEMPERATURES THE AILERON CONTROLS SLOWLY RETURNED AND A SUBSEQUENT INSPECTION ON THE GROUND REVEALED NO AILERON CONTROL ABNORMALITIES. BELIEVE THAT THE PRECIPITATION ENCOUNTERED DURING THE CLIMB FROZE THE AILERON TO THE GAP SEALS WHEN THE AIRPLANE ENTERED BELOW FREEZING TEMPERATURES. CALLED THE STC HOLDER TO DISCUSS THIS ISSUE AND THEY ACKNOWLEDGED NOTIFICATION OF THE SAME PROBLEM WITH THEIR GAP SEALS UNDER RAIN AND FREEZING CONDITIONS. THIS SAFETY HAZARD COULD EASILY LEAD TO A COMPLETE LOSS OF ACFT CONTROL AND FATALITIES IF NOT ADDRESSED WITH THE STC HOLDER OR IN AN AD.

2012FA0000053

PIPER

 

 

ANGLE

CRACKED

1/4/2012

PA44180

 

 

 

RT NACELLE

DURING A SCHEDULED INSPECTION, A CRACK WAS FOUND IN THE NACELLE ANGLE. UPON FURTHER INVESTIGATION, IT WAS FOUND THAT THE CRACK WAS BETWEEN THE 2 RIVETS THAT EXTENDED THRU THE WING SKIN INTO CAP (P/N 67097-002 OR -003 DEPENDENT ON SIDE) WHICH IS ATTACHED TO A WEB (PN 67079-000 OR 001 DEPENDENT ON SIDE) THAT THE MAIN GEAR AFT ATTACH POINT IS MOUNTED. IT IS SUSPECTED THAT THIS IS A FAILURE DUE TO FATIGUE.

2012FA0000056

PIPER

 

 

ANGLE

CRACKED

1/4/2012

PA44180

 

 

 

RT NACELLE

DURING A SCHEDULED INSPECTION, A CRACK WAS FOUND IN THE NACELLE ANGLE. UPON FURTHER INVESTIGATION, IT WAS FOUND THAT THE CRACK WAS BETWEEN THE 2 RIVETS THAT EXTENDED THRU THE WING SKIN INTO CAP (P/N 67097-002 OR -003 DEPENDENT ON SIDE) WHICH IS ATTACHED TO A WEB (PN 67079-000 OR 001 DEPENDENT ON SIDE) THAT THE MAIN GEAR AFT ATTACH POINT IS MOUNTED. IT IS SUSPECTED THAT THIS IS A FAILURE DUE TO FATIGUE.

2012FA0000057

PIPER

 

 

ANGLE

CRACKED

1/4/2012

PA44180

 

 

86331003

LT NACELLE

DURING A SCHEDULED INSPECTION, A CRACK WAS FOUND IN THE NACELLE ANGLE. UPON FURTHER INVESTIGATION, IT WAS FOUND THAT THE CRACK WAS BETWEEN THE 2 RIVETS THAT EXTENDED THRU THE WING SKIN INTO CAP (P/N 67097-002 OR -003 DEPENDENT ON SIDE) WHICH IS ATTACHED TO A WEB (PN 67079-000 OR 001 DEPENDENT ON SIDE) THAT THE MAIN GEAR AFT ATTACH POINT IS MOUNTED. IT IS SUSPECTED THAT THIS IS A FAILURE DUE TO FATIGUE.

2012FA0000058

PIPER

 

 

ANGLE

CRACKED

1/4/2012

PA44180

 

 

86331003

LT NACELLE

DURING A SCHEDULED INSPECTION, A CRACK WAS FOUND IN THE NACELLE ANGLE. UPON FURTHER INVESTIGATION, IT WAS FOUND THAT THE CRACK WAS BETWEEN THE 2 RIVETS THAT EXTENDED THRU THE WING SKIN INTO CAP (P/N 67097-002 OR -003 DEPENDENT ON SIDE) WHICH IS ATTACHED TO A WEB (PN 67079-000 OR 001 DEPENDENT ON SIDE) THAT THE MAIN GEAR AFT ATTACH POINT IS MOUNTED. IT IS SUSPECTED THAT THIS IS A FAILURE DUE TO FATIGUE.

2012FA0000059

PIPER

 

 

ANGLE

CRACKED

1/4/2012

PA44180

 

 

86331002

RT NACELLE

DURING A SCHEDULED INSPECTION, A CRACK WAS FOUND IN THE NACELLE ANGLE. UPON FURTHER INVESTIGATION, IT WAS FOUND THAT THE CRACK WAS BETWEEN THE 2 RIVETS THAT EXTENDED THRU THE WING SKIN INTO CAP (P/N 67097-002 OR -003 DEPENDENT ON SIDE) WHICH IS ATTACHED TO A WEB (PN 67079-000 OR 001 DEPENDENT ON SIDE) THAT THE MAIN GEAR AFT ATTACH POINT IS MOUNTED. IT IS SUSPECTED THAT THIS IS A FAILURE DUE TO FATIGUE.

2012FA0000048

PIPER

 

 

ANGLE

CRACKED

1/4/2012

PA44180

 

 

 

RT NACELLE

DURING A SCHEDULED INSPECTION, A CRACK WAS FOUND IN THE NACELLE ANGLE. UPON FURTHER INVESTIGATION, IT WAS FOUND THAT THE CRACK WAS BETWEEN THE 2 RIVETS THAT EXTENDED THRU THE WING SKIN INTO CAP (P/N 67097-002 OR -003 DEPENDENT ON SIDE) WHICH IS ATTACHED TO A WEB (PN 67079-000 OR 001 DEPENDENT ON SIDE) THAT THE MAIN GEAR AFT ATTACH POINT IS MOUNTED. IT IS SUSPECTED THAT THIS IS A FAILURE DUE TO FATIGUE.

2012FA0000049

PIPER

 

 

ANGLE

CRACKED

1/4/2012

PA44180

 

 

 

RT NACELLE

DURING A SCHEDULED INSPECTION, A CRACK WAS FOUND IN THE NACELLE ANGLE. UPON FURTHER INVESTIGATION, IT WAS FOUND THAT THE CRACK WAS BETWEEN THE 2 RIVETS THAT EXTENDED THRU THE WING SKIN INTO CAP (P/N 67097-002 OR -003 DEPENDENT ON SIDE) WHICH IS ATTACHED TO A WEB (PN 67079-000 OR 001 DEPENDENT ON SIDE) THAT THE MAIN GEAR AFT ATTACH POINT IS MOUNTED. IT IS SUSPECTED THAT THIS IS A FAILURE DUE TO FATIGUE.

2012FA0000050

PIPER

 

 

ANGLE

CRACKED

1/4/2012

PA44180

 

 

 

LT NACELLE

DURING A SCHEDULED INSPECTION, A CRACK WAS FOUND IN THE NACELLE ANGLE. UPON FURTHER INVESTIGATION, IT WAS FOUND THAT THE CRACK WAS BETWEEN THE 2 RIVETS THAT EXTENDED THRU THE WING SKIN INTO CAP (P/N 67097-002 OR -003 DEPENDENT ON SIDE) WHICH IS ATTACHED TO A WEB (PN 67079-000 OR 001 DEPENDENT ON SIDE) THAT THE MAIN GEAR AFT ATTACH POINT IS MOUNTED. IT IS SUSPECTED THAT THIS IS A FAILURE DUE TO FATIGUE.

2012FA0000051

PIPER

 

 

ANGLE

CRACKED

1/4/2012

PA44180

 

 

 

RT NACELLE

DURING A SCHEDULED INSPECTION, A CRACK WAS FOUND IN THE NACELLE ANGLE. UPON FURTHER INVESTIGATION, IT WAS FOUND THAT THE CRACK WAS BETWEEN THE 2 RIVETS THAT EXTENDED THRU THE WING SKIN INTO CAP (P/N 67097-002 OR -003 DEPENDENT ON SIDE) WHICH IS ATTACHED TO A WEB (PN 67079-000 OR 001 DEPENDENT ON SIDE) THAT THE MAIN GEAR AFT ATTACH POINT IS MOUNTED. IT IS SUSPECTED THAT THIS IS A FAILURE DUE TO FATIGUE.

2012FA0000052

PIPER

 

 

ANGLE

CRACKED

1/4/2012

PA44180

 

 

 

LT NACELLE

DURING A SCHEDULED INSPECTION, A CRACK WAS FOUND IN THE NACELLE ANGLE. UPON FURTHER INVESTIGATION, IT WAS FOUND THAT THE CRACK WAS BETWEEN THE 2 RIVETS THAT EXTENDED THRU THE WING SKIN INTO CAP (P/N 67097-002 OR -003 DEPENDENT ON SIDE) WHICH IS ATTACHED TO A WEB (PN 67079-000 OR 001 DEPENDENT ON SIDE) THAT THE MAIN GEAR AFT ATTACH POINT IS MOUNTED. IT IS SUSPECTED THAT THIS IS A FAILURE DUE TO FATIGUE.

C41R201201240101

PIPER

CONT

 

MASTER CYLINDER

DAMAGED

1/23/2012

PA46310P

TSIO520*

 

82805002

BRAKES

ON LANDING ROLLOUT, PILOT HAD NO LT BRAKE. MX REMOVED LT MASTER CYLINDER AND DISCOVERED MASTER CYLINDER END GLAND HAD UNSCREWED ALL BUT 2 THREADS CAUSING FLUID AND PRESSURE LOSS FROM MASTER CYLINDER. REPLACED INTERNAL SEALS AND REASSEMBLED. REINSTALLED AND OPS CHECKED OK.

2012FA0000071

PIPER

 

 

CONNECTOR

CORRODED

1/22/2012

PA46500TP

 

 

 

ELT  

WATER IN ELT CONNECTOR CAUSING CORROSION BETWEEN PINS, CAUSING ELT TO TURN ON, COULD NOT RESET.

E81R2012011700001

RAYTHN

 

 

KEELBEAM

CORRODED

1/17/2012

390   

 

 

3904200700001

COCKPIT

DURING SCHEDULED "A" AND "B" INSPECTIONS, VISUAL INSPECTION OF COCKPIT UNDERFLOOR AREA SHOWED FLUID SPILLAGE. FURTHER INVESTIGATION FOUND SURFACE CORROSION AND DEEP CORROSION PITS ON LBL 8.10 KEEL BEAM CAP FROM FS 121.2 TO FS 148.4 AREA. AFFECTED STRUCTURAL MEMBER ATTACHES LT SIDE OF LOWER FWD FUSELAGE KEEL BEAM UNDER PEDESTAL TO FUSELAGE EXTERIOR, FROM AFT OF FORWARD PRESSURE BULKHEAD TO AFT END OF PEDESTAL AREA. DAMAGE REQUIRED REPLACEMENT OF KEEL CAP IAW MFG REPAIR DESIGN OFFICE. OPERATOR REPORTS NO KNOWN FLUID SPILLAGE. LEAK CHECKS OF FLIGHT COMPARTMENT RELIEF TUBE AND PLUMBING SATISFACTORY. RECOMMEND MFG CONSIDER ADDING A RECURRING 12-MONTH INTERVAL VISUAL INSP OF UNDERFLOOR AREAS IN ZONES WHERE CORROSIVE FLUID SPILLAGE OR COLLECTION POSSIBLE.

2011FA0000748

RAYTHN

WILINT

 

ENGINE

FAILED

11/13/2011

390   

FJ44

 

FJ44  

ZONE 400

DURING CRUISE AT 25,000 FEET, DETECTED SMOKE IN THE COCKPIT. SHORTLY AFTER THE LEFT ENGINE INDICATORS SHOWED LOW OIL PRESSURE (IN THE RED) AND THE LOW OIL PRESSURE ANNUNCIATOR. SHUTDOWN ENGINE, AND DIVERTED TO THE NEAREST MAJOR AIRPORT. ON LANDING, OBSERVED A LOT OF BLACK OIL ON THE EXTERIOR UNDERSIDE OF THE LT ENGINE COWLING.

2012FA0000105

RAYTHN

 

 

SNAP RING

MISSING

1/30/2012

C90GT

 

 

 

HYD POWERPACK

DURING APPROACH, SELECTED MLG DOWN & IT FAILED TO RESPOND. TRIED SEVERAL TIME TO EXTEND GEAR WITH NO RESULTS. PROCEEDED TO PUMP GEAR DOWN & RECEIVED 3 DOWN & LOCK LIGHTS WITHOUT FURTHER INCIDENT. FOUND 60 AMP CIRCUIT TRIPPED. NO OTHER DEFECTS NOTICED ON INITIAL INSPECTION. A RETRACTION WAS PERFORMED IAW MANUAL & GEAR RETRACTED WITH NO DEFECTS NOTED. WHEN GEAR DOWN SELECTED, RETRACT MOTOR BOGGED DOWN & TRIPPED THE 60 AMP CIRCUIT BREAKER. ON CLOSER INSPECTION, HYD FLUID OBSERVED LEAKING FROM AREA WHERE RETRACT MOTOR CONNECTS TO HYD POWER PACK. REMOVED HYD POWER PACK & RETRACT MOTOR ASSY. SOURCE OF HYD LEAK FOUND TO BE HYD POWER PACK GARLOCK SEAL OR SHAFT SEAL. SNAP RING TO RETAIN THE GARLOCK SEAL WAS MISSING. RETAINING SNAP RING PREVENTS GARLOCK SEAL FROM MOVING AND ALLOWING HYD FLUID TO LEAK INTO RETRACT MOTOR.

2012FA0000077

RAYTHN

 

 

SEAL

LEAKING

1/12/2012

HAWKER800XP

 

 

 

WING FITTING

SEVERE CORROSION FOUND IN CASTING LUG DURING WING TO FUSELAGE ATTACHMENT LINKS, BRACKETS & BOLT INSPECTION AT LT LOWER WING TO FUSELAGE LINK AND BEARING JUNCTION. EXPOSURE TO CONSTANT MOISTURE DUE TO IMPROPER FUSELAGE-TO WING FAIRING SEALING PRACTICES THAT MAY HAVE LET TO SYS LEAKS. PROPER SEALING METHODS USED WHEN ATTACHING WING-TO-FUSELAGE FAIRINGS; PROPER PLUMBING PRACTICES WHEN PERFORMING MX ON WING ANTI-ICING SYSTEMS.

2011FA0000762

RAYTHN

 

 

SPIGOT

BROKEN

11/28/2011

HAWKER800XP

 

 

25FC6244A

ZONE 800

DURING MX PRE-FLIGHT INSPECTION, TECH NOTICED THAT UPPER AFT DOOR ALIGNMENT SPIGOT WAS CRACKED AROUND THE FULL CIRCUMFERENCE OF THE BASE. THE SPIGOT BROKE COMPLETELY OFF WITH A VERY LIGHT TOUCH. IT IS SPECULATED THAT SPIGOT MAY HAVE AT ONE TIME BEEN HIT TO CAUSE CRACK AND THEN SUBSEQUENT DOOR CLOSINGS PROPAGATED THE CRACK AS SPIGOT PENETRATED DOOR ALIGNMENT CHANNEL.

2012FA0000092

RAYTHN

 

 

LEVER

CORRODED

1/26/2012

HAWKER800XP

 

 

25UM1080A

MLG  

NOTED DEFECTS IN 2 LOCATIONS. BOTH DEFECTS HAVE BEEN PREVIOUSLY NOTED BY TECHS AT OTHER TIME ON OTHER ACFT. 1 DEFECT, CORROSION FOUND AROUND THE PERIMETER OF THE BOSS CONNECTION POINT OF THE LEVER ASSY TO THE CHANNEL SUPPORT. THE INSTALLATION CALLS FOR A THRUST WASHER (DUA7) ON 1 SIDE AND ANOTHER WASHER (SP125D) ON THE OTHER SIDE. THERE IS SOME EVIDENCE OF CORROSION ON THE STEEL WASHERS AND OBVIOUS CORROSION IS THE RESULT OF BOTH DRYNESS AND DISSIMILAR METAL CONTACT. SUGGEST MORE FREQUENT LUBRICATION OR LUBRICATION SUBSTITUTION FROM THE MFG. ANOTHER NOTED DEFECT PERTAINS TO THE GOUGING ON THE CORNER OF 1 ARM OF THE LEVER. IT IS SUSPECTED THAT THE DEFECT MAY BE A RESULT OF USING PRY BARS ON THE ARM WHEN PERFORMING MX REQUIRING THE ARMS TO BE MOVED FOR GEAR OVER-CENTERING AND ADJUSTMENT PURPOSES. SUGGEST USING A COMPOSITE PRY BAR IF OVER CENTER IS REQUIRED.

2012FA0000093

RAYTHN

 

 

SEAT

UNLOCKED

1/24/2012

HAWKER800XP

 

 

3037081CS

CABIN

FOUND NR 1 AND NR 2 LT SEAT DID NOT HAVE "SPRING-LOADED TRACK FITTING" PROPERLY ENGAGED INTO THE SEAT TRACK. THIS IS THE 2ND ACFT FOUND TO HAVE THIS CONDITION. DUPLICATE PROBLEMS SUGGEST THE DESIGN OF THE SAFETY LOCKING DEVICE THAT SHOULD PREVENT THE SEAT FROM DISENGAGING FROM THE SEAT TRACK SYS IN CASE THE OTHER 4 FITTINGS (FEET) HAPPEN TO ALIGN WITH THE SEAT TRACK OPENINGS. MM STATES THAT INSTALLING TECH NEEDS TO "ACCESS THE SPRING LOADED CHAIR FITTING IN THE CHAIR INBD BASE. ROTATE THE FITTING DOWN AND EXTEND WITH A SCREWDRIVER TO ENGAGE THE TRACKS. THEMM ADDS TO THE FOLLOWING CHECK: " TRACK THE SEAT FORE AND AFT TO CHECK THE OPERATION", WHICH WITH ENSURE PROPER OPERATION BUT THE ADDITIONAL RECOMMENDATION WOULD BE TO DO AN ADDITIONAL VISUAL INSPECTION FOR VERIFICATION OF PROPER FITTING ENGAGEMENT.

2012FA0000042

ROBSIN

LYC   

 

RADIO

SMOKE

1/16/2012

R44   

O540F1B5

 

064105360

COCKPIT

SMOKE EMITTED FROM COMMUNICATIONS RADIO IN FLIGHT, RESULTING IN PRECAUTIONARY LANDING.

2012FA0000078

SNIAS

 

 

CONNECTOR

MISINSTALLED

1/19/2012

AS350B3

 

 

14803190

EXTERIOR LIGHT

LIGHT FOUND TO BE INOPERATIVE. FOUND PINS AT CONNECTOR TO NOT BE CRIMPED AND WIRES LOOSE. RECOMMEND IMPROVEMENT IN QC DURING INSTALLATION.

2012FA0000075

SNIAS

 

 

LIGHT

MISINSTALLED

1/19/2012

AS350B3

 

 

14803180

HORIZONTAL STAB

LIGHT FOUND TO BE INOPERATIVE. FOUND PINS AT CONNECTOR TO NOT BE CRIMPED AND WIRES LOOSE. RECOMMEND IMPROVEMENT IN QC DURING INSTALLATION.

QMLD201201180821

SNIAS

 

 

STRUCTURE

CHAFED

1/18/2012

AS350B3

 

 

 

TAIL BOOM

THE NEGATIVE BATTERY CABLE WAS FOUND TO HAVE RUBBED THE (INSIDE) TAIL BOOM BEYOND LIMITS.

2012FA0000073

SNIAS

TMECA

 

MAGNETIC SEAL

LEAKING

1/19/2012

AS350B3

ARRIEL2B1

 

9560134100

FREEWHEEL SHAFT

OIL FOUND ON ENGINE DECK DURING ALF CHECK. LEAK WAS DETERMINED TO COME FROM THE FRONT MAGNETIC SEAL OF THE FREEWHEEL SHAFT. LEAK RATE WAS MEASURED AT 11.94 ML/H. MAX LEAK RATE ALLOWED IS 10 ML/H AS SPECIFIED IN MFG TROUBLESHOOTING BOOK 71-00-06-816-804-B01. SUSPECT CAUSE TO BE INCORRECT INSTALLATION DURING ASSY OR DEFECT IN THE MAGNETIC SEAL. RECOMMEND MONITORING INSTALLATION PRACTICES AND MAKING NECESSARY CHANGES OR A DESIGN CHANGE TO THE SEAL FOR IMPROVED SEALING CHARACTERISTICS.

2012FA0000074

SNIAS

TMECA

 

GROUND WIRE

BROKEN

1/19/2012

AS350B3

ARRIEL2B1

 

TB1N  

CAUTION PANEL

PITOT LIGHT ON CAUTION PANEL NOT FUNCTIONING. FOUND GROUND WIRE FOR THE PITOT LIGHT CIRCUIT TO BE BROKEN. WIRE DID NOT HAVE THE SLACK REQUIRED WHEN INSTALLED, PLACING A STRAIN ON THE WIRE WHICH BROKE DURING OPERATION OF THE ACFT. RECOMMEDN IMPROVEMENTS IN QC OF ELECTRONICS INSTALLATIONS AND FOLLOWING RECOMMENDATIONS OF MFG AND AC43.13-1B/2B CHANGE 1.

LC1R2012020292GT

SOCATA

LYC   

 

CLAMP

WORN

2/2/2012

TB21

TIO540AB1A

 

66M19385

MAGNETO

DURING AN ANNUAL INSP, THE DUAL MAGNETO WAS REMOVED TO FACILITATE REPLACEMENT OF A LEAKY MOUNTING GASKET. WHEN REMOVED IT WAS NOTICED THAT THE UPPER MOUNTING CLAMP, HAD WORN INTO THE UPPER MAG BASE FLANGE BY GREATER THAN .020". THE NUT SECURING THE MOUNTING CLAMP WAS FOUND TO BE TIGHT. THIS MAG HAD BEEN O/H 377 HOURS AGO AND WAS REMOVED FOR AN UNKNOWN REPAIR 198 HOURS AGO. THE FLANGE UNDER THE LOWER CLAMP WAS HEAVILY MARKED BUT NOT WORN TO ANY GREAT DEGREE.

2012FA0000081

SOCATA

PWA   

 

FUEL CONTROL

FAILED

1/31/2012

TBM700

PT6A64

 

8063055REVNEW

ENGINE

DURING RUNUP, PROP FEATHER CHECK CONDUCTED NORMALLY. WHEN ADVANCING POWER LEVER TO DO A PROP OVERSPEED TEST, COULD NOT REACH 1900 RPM WITH POWER LEVER FORWARD. HIGHEST RPM ACHIEVED WAS 1700. SHUTDOWN AND RESTART. DURING THE START, AT LOW IDLE, FLAMES SHOT OUT OF THE EXHAUST. SHUTDOWN AND MOTORED STARTER FOR A MINUTE. ON A SUBSEQUENT START UP, FLAMES SHOT OUT AGAIN. A NEW FCU WAS INSTALLED. ENGINE PERFORMED NORMALLY. ENG MFG IS EXAMINING THE FAILED FCU IN THEIR LAB.

HKGR20120207442

SWRNGN

 

 

WIRE

BURNED

2/7/2012

SA227AC

 

 

 

STARTER

DURING ENGINE START, 4/0 WIRES FROM NR 1 START CONTROL RELAY TO NR 1 START/GEN OVERHEATED AND SEPARATED COMPLETELY. 1 WIRE WAS SPLICED IAW MM AT BL0. THE SPLICE APPEARS TO HAVE FAILED VIOLENTLY, AND THE WIRE THAT WAS NOT SPLICED OVERHEATED AND PARTED. POST INCIDENT INSPECTION CANNOT DETERMINE WHICH WIRE FAILED FIRST, BUT THE OTHER CONDUCTOR WAS NOT ABLE TO CARRY THE ENTIRE INRUSH LOAD. REPLACE CABLES ENTIRELY FROM START CONTROL TO STARTER GENERATOR, NO SPLICES USED.